Body Installation and Chassis Modification Guideline
Contents
1. One longitudinal section on each side of the vehicle is used for vehicles fitted with 215 75R17 5 225 75R17 5 a 245 70R17 5 tyres Two longitudinal sections are used on each side of the vehicle for vehicles fitted with 9 5R17 5 245 70R19 5 a 265 70R19 5 tyres The body manufacturer must also observe the instructions provided in Section 9 4 hereof When a different lateral protective device is used the manufacturer must apply for new homologation according to the applicable international regulation The following institutions are authorised to award homologation in accordance with the above mentioned regulations in the Czech Republic T V SUD Auto CZ s r o DEKRA Automobil a s Legislativn divize Novodvorsk 994 T rkova 1001 142 21 Prague 4 149 00 Prague 4 Tel 420 239 046 911 Tel 420 267 288 111 6 Dimensions and Weight The applicable national and international regulations prevail over the technically permissible dimensions and weight if they restrict such dimensions and weight The documents of AALM specify the dimensions the weight the position of the centre of gravity for the payload and body the minimum and maximum position of the centre of gravity of the body of a stock vehicle These data may differ depending on the technical scope of the supply of the vehicle The key factor is the actual structural condition of the vehicle supplied In order to achieve an optimum payload it is fundamental to weigh the supplied2. under no load of the vehicle exceed the maximum permissible axle load while not exceeding the total weight specified in Table 2 es Pee Pe po pe pe pes peo pro pmo pro 5 990 16 490 6 990 7 490 7 990 8490 19 000 9 990 10990 11990 Total weight kg Permissible F A kg 3 400 3 400 3 400 3 400 3 400 3 400 3 400 13 500 4 000 4 200 load R A kg 4 100 14 450 4 800 5 200 5 200 15 800 16 200 6 600 17 400 8 200 Table 6 2 Kerb Weight Distribution for Chassis with a Cabin Table 3 Kerb weight distribution k Type Kerb weight kg 5 kg 3374 1 m 1 343 2247 1180 D60 75 80 D85 90 100 D110 120 Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 6 3 Maximum Permissible Height of the Centre of Gravity see Table 4 K 150m 155m 155m 155m_ ON 160m 160m 160m L60m iem iem 160m 160m 6 17m 17m 160m 160m Table 4 ATTENTION When installing a type of body enabling the use of the maximum permissible axle load or the maximum permissible height of the vehicle s centre of gravity the manufacturer of the body must inform the party operating the vehicle about the changed driving properties of the vehicle when these extreme values are reached The instantaneous weight of the vehicle must be so distributed as to prevent a drop of the front axle load under 30 of the instantaneous weight of the vehicle 6 4 Axle Overloa
3. QU AVIA ASHOK LEYLAND Body Installation and Chassis Modification Guideline for the D60 D120 Euro5 Vehicles TABLE OF CONTENTS de Applicability of the Body Installer Guideline 3 1 1 Vehicle Designation 3 1 2 Engine Designation Table 1 3 2 Responsibility 3 3 Quality Assurance 4 4 Body or Chassis Modification Approval Procedure 4 5 Homologation of D60 D120 Euro5 Vehicles Finalised By Body Installer 5 5 1 Mandatory Equipment by Body Manufacturer 5 5 2 Changes in Equipment Made by Body Manufacturer 6 6 Dimensions and Weight 8 6 1 Maximum Permissible Axle Load 8 6 2 Kerb Weight Distribution for Chassis with a Cabin 9 6 3 Maximum Permissible Height of the Centre of Gravity 10 6 4 Axle Overload Single Side Load 10 6 5 Minimum Axle Load 10 6 6 Permissible Overhang 11 6 7 Axle Load Calculation 11 7 Body Installation 12 7 1 Basic Body Specifications 12 7 2 Mainframe 14 8 General Instructions for Chassis Modification 15 8 1 Drilling of Openings in the Mainframe 16 8 2 Welding on the Mainframe 16 8 3 Change in Mainframe Overhang 17 8 4 Welding up of Openings Drilled into the Mainframe 17 8 5 Bolted Connections 17 8 6 Subframe 18 9 Attachment of Various Types of Bodies and Eguipment to the Mainframe 19 9 1 Attachment with Side Brackets 19 9 2 Attachment with External Metal Sheets 19 9 3 Rear Underrun Protective Device 21 9 4 Lateral Underrun Protective Device 22 9 5 Tow Coupling 23 9 6 Rear Emergenc
4. The inspection procedure and the procedure for determining the relevant adjustment values are described in the workshop manual for the D60 D120 series of vehicles 16 Permitted Exceptions Upon the written request AALM may grant an exception from the permitted parameters provided that they are compatible with the functional road and operational safety requirements This applies but is not limited to gt permitted axle loads gt permitted total weight gt modifications of installed component additional installation of power units dimension changes Restricting conditions may be added to these exemptions e g a maximum operating speed limit restrictions regarding operation on public roads etc Exemptions awarded by AALM are not of a binding nature for any competent authorities which are in charge of approvals AALM has not impact on the granting of exemptions by the competent bodies If any of the relevant measures do not meet the roadworthiness requirements an approval of the exemption must first be obtained from the Ministry of Transport of the Czech Republic The most common cases of technical exemptions include the following change of tyres increase in the permitted total weight of the trailer increased permitted axle loads increase in the permitted total weight Bodybuilders Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 17 Annexes 17 1 Basic Dimensions of the Chassis e 00 lt Q
5. Upln pod ln k bo n ochrany PLASTOV KONCOVKA 2 TITGEMEYER 518595 PLASTOVA KONCOVKA TITGEMEYER 518582 v kresu Obr 23 Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 ge 140 S2490 c88t 61 LO geri 6l a o x st OEZ L 8 ci 3 O E A X oza 001 090 wu TY uuu 9 d o S 3 1 ad sy 6 5 N y cud sye xezag ajpizoa Bu sy rupaud Araj Yezig d O I E S gt C y oe M E IE f 4 z L a ID bL A ff TT i c am arn T a ara B S E e Lh EN y JELI iT e aA 8 m O P E e TL a 09 En E e a ES O S 6L 2104 AugJu2o 1U3OC NYBZIp Zeug f lt lt gt 8 lt e A m 5 uon oo aa L lt Ya Gor DW IP E N D JOAZOJ oid 5 aznod ojiznog m B E ap E D feu Brow ALEMAN A00 nwezin FEINN 2 O gt o m Montaz vyztuhy pro zaves Installation of the Ringfeder drawbar in the rear overhang 9 SROUB M12x20 S JISTENIM SELF LOCKINGG BOLT M12x20 2 MATICE S JISTENIM M12 15201 168 4 SELF LOCKING NUT M12 esr PRICKA ZADNI UPLNA REAR CROS MEMBER 17557 170 VYZTUHA UPLNA BRACE ASM 17558 437 KS NAZEV ROZMER CISLO VYKRESU POZ Obr 29 Add a Spacer 2mm on each Side at Frame Thickness Horizontal Row 1 4x M16x50 each Side from Bolt Kit 14990468 Horizontal Row 2 4x M16x50 each Side from Bol
6. 9 1 2 Flexible coupling For flexible coupling which enables a certain degree of movement of the subframe a rubber element a coil spring or a disc spring can be used as the suspension element Bodybuilders Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 9 2 Attachment with External Metal Sheets This method of attachment is complementary to the attachment of the body frame using the brackets in order to absorb the longitudinal as well as lateral forces It is mainly used to attach the rear part of the body We recommend to place these external metal sheets close to the rear axle spring housing so as not to compromise the flexible mounting of the body in the front part of the vehicle The external metal sheet is mostly welded onto the subframe of the body and bolted to the underframe The use of these external metal sheets is necessary on vehicles with the S and G wheelbases if the subframe side members with a section of below 160x60x5 mm have been used For the attachment to the frame we recommend to use the two openings according to Fig 14 Rear axle axis Fig 14 A INSTALLATION OF PLATFORM TYPE BODIES A fixed coupling using the side brackets according to Section 9 1 1 will be used for the installation of platform bodies with the grid flooring also forming the subframe Lateral support is provided by the support plates on the frame The front part of the tarp must be secured against bellying in order to preve
7. CN o O e CN Wheelbase A K 2 950 N 3 400 L 3 900 E 4 500 S 5 100 D75 major chassis dimensions mm R 1 849 F 1 736 Wheelbase A K 2 950 N 3 400 L 3 900 E 4 500 S 5 100 R 1 849 F 1 736 Wheelbase A 2 950 3 400 3 900 4 500 5 100 5 600 K N L E S G E the maximum dimension of the body applies to the regular day cabin R 1 845 F 1 740 B C D 1415 5590 2280 1415 6040 2730 1670 6795 3230 2070 7795 3830 2470 8795 4430 D90 major chassis dimensions mm B C D 1415 5590 2280 1415 6040 2730 1670 6795 3230 2070 7795 3830 2470 8795 4430 D120 major chassis dimensions mm B C D 1415 5590 2280 1415 6040 2730 1670 6795 3230 2070 7795 3830 2470 8795 4430 2520 9345 4930 Bodybuilders Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 D 700 E max 1 580 5 780 2 030 6 230 2 530 6 730 3 130 7 330 3 730 7 930 D 700 Emax 1 580 5 780 2 030 6 230 2 530 6 730 3 130 7 330 3 730 7 930 D 700 Emax 1 580 5 780 2 030 6 230 2 530 6 730 3 130 7 330 3 730 7 930 4 230 8 430 17 2 Position of the Lateral Protective Devices Basic dimensions 17 5 wheels ME YANA AN A Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 17 3 Position of the Rear Underrun Protective Device SrA TUE 210842 2217 2300 ACCORDING TO TYRES Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5
8. 550 mm above the ground the distance between the rear underrun protective device and the furthest lower edge of the body or auxiliary equipment must not exceed 350 mm see Fig 15 Rear edge of the body or auxiliary equipment Fig 15 This value is based on the result of the homologation tests It is to ensure that the distance of 400 mm from the furthest rear edge of the body is not exceeded upon the deformation of the rear underrun protective device by the specified force Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 If the rear underrun protective device is to be modified or ifa new one is to be installed such protection must comply with the reguirements of UN ECE Regulation 58 01 and must be approved by an authorised testing institution 9 4 Lateral Protection The stock chassis eguipped with lateral underrun protective devices are homologated according to UN ECE Regulation No 73 00 The limit distance must be observed in the installation of the body see Fig 16 If itis impossible to meet the limit values the body manufacturer must use a different compliant lateral underrun protective device and apply for homologation by an authorised testing institution Fig 16 A max 120 Lid Outer surface marking the greatest width of the vehicle excl rear view mirrors The upper edge of the lateral underrun protective device must not be more than 350 mm below that part of the structure of the
9. ASHOK LEYLAND MOTORS EURO 4 amp 5 7 1 Basic Body Specifications The recommended length of the bodies for chassis with a day cabin is shown in Table 6 4 250 mm 5 100 mm 6 100 mm 7 100mm 250 mm 5 100 mm 6 100 mm 7 100 mm D100 120 4 150 mm 4 900 mm 5 900 mm 6 900 mm 7 700 mm The height between the lower plane of the body and the upper plane of the chassis frame over the rear axle wheels wheel arch must be at least 140 mm and sufficient space must be kept for the wheel suspension see Fig 1 Space for the whee compression jc pine R outside radius of the wheel depending on the tyre used for the 225 75R17 5 tyre R 366 1 mm Fig 1 gt Depending on the chassis version which are provided with different rear view mirror holders and the position of the side direction indicator lamps the maximum outer width of the body is 2 350 mm but not less than 2 150 mm and 2 550 2 600 mm for isothermal bodies but not less than 2 350 mm respectively Without the replacement of the parts specified above the chassis versions do not enable the installation bodies of a width different from that for which it is intended gt In the case of a requirement to use a different body width the chassis manufacturer must be consulted gt The recommended maximum outer height of the body with regard to lateral stability is 2 200 mm gt The total length of the body must be so sele
10. applies to vehicles which are currently in operation but are subject to additional work 1 1 Vehicle Designation The designation of the vehicles consists of the designation of the type D 2 3 characters to describe the maximum permissible total weight of the vehicle figure x 100 kg and a dash followed by the designation of the engine HP For example D60 160 D75 185 D90 160 D120 170 D120 185 1 2 Engine Designation Table 1 TUN ISB4 5E5 160 160hp 117kW Euro 5 ISB4 5E5 185 Cummins 185hp 136kW ISB4 5E5 207 207hp 152kW 2 Responsibility The responsibility for the design manufacture and installation of bodies and for the modification of the chassis is always entirely with the company which manufactures and installs the body or performs any modifications thereof manufacturer warranty This will also apply if AALM expressly approves such body or modifications The written approval of the body or conversion by AALM does not exempt the body manufacturer for its responsibility for the product Should the company performing the operation discover as early as during planning or upon examining the intention of the customer user the company s personnel or manufacturer of the vehicle any error the company must notify the relevant person The company is also responsible for compliance with the applicable laws and regulations regarding the assemblies to be modified or added The company must also ensure that the
11. base in the slots on the side of the fuse board lead the wires under the instrument panel to the connection points Install the button switches on the body and connect them to the wires 2 Connection of the remote control wires to the wiring vehicle wiring system a Next to the ignition box find wire no 302AB and connect to it the wire marked IGNITION BOX WIRE No 302AB on the diagram Connect according to TI 395 b Next to the connector on the front panel marked CTOACI a vertical 50 pin connector find wire 050B leading from outlet 6 and connect to it the wire marked HAND BRAKE TELL TALE WIRE No 050B on the diagram Connect according to TI 395 c Next to the connector on the front panel marked CTOAC3 a horizontal 50 pin connector find wire 017N leading from outlet 30 Cut the wire Connect the wire marked C B WIRE No 17N on the diagram to the end leading from the harness to circuit breaker connect the wire marked ENGINE ECU WIRE No 017N on the diagram to the end leading to the connector Connect according to TI 395 d Remove the PLUS and MINUS switches for engine speed control from the instrument panel find wires 445NN 429N and 430N and connect them to the wires marked as PLUS SWITCH and MINUS SWITCH on the diagram Connect according to TI 395 e Connect the wire marked as GND WIRE No 9xx on the diagram gray to any gray wire marked 9xx On vehicles with an E4 engine it i
12. body cut or contacted by plane R Outer surface of the lateral protection R 7 a plane contacting the surface of the tyres lt excluding any bulging close to the ground 9 5 Tow Coupling ATTENTION Until the relevant homologation certificates are issued the maximum weight of any trailer towed is 3 500 kg The information in the following paragraphs is provided with regard to this figure This Guideline will be amended following the issue of the relevant certificates When installing the tow coupling the maximum distance of 300 mm between the axis of the pin and the furthest part of the body must be observed according to Directive 94 20 EC It is necessary to maintain the recommended free space around the coupling device for easy handling Each tow coupling is provided with a name plate containing the key data with the value of the reduced pulling force on the towbar of the trailer D being of great importance D 9 81 x Gv x Gt Gv Gt kN Gv total weight of the vehicle t Gp total weight of the trailer t The reduced forces D on the towbar for the trailers used and approved for AVIA vehicles are shown in Table 10 Mireal 1540V 30 kN Ringfeder 30 kN The installation of the coupling must be performed in accordance with the installation manual supplied by the manufacturer Before the installation the rear crossbar of the frame must be reinforced with a brace Bodybuilder s Guideline AVIA ASHOK LEYLAN
13. d BOSLI II connector bw mide marker lamps Position 1 Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 The connectors BOSL I BOSL II left side BOSP I BOSP II right or the connector in the box in the rear part of the frame are intended for the side and end outline marker lamps Option 1 distribution from the front double pole connectors The connectors are situated in the corners above the transmission crossing through the frame from left to right and on the frame cross member above the rear axle Diagram The respective lengths of sections A B and C must be determined depending on the specific type of body Side marker lamps VALEO FE94PDK 194010 or FES94PDK 194020 or FET94PDK 194030 wire material FLYY85 2x0 5 pair wire or equivalent or separate FLRY wires covered with a Schlemmer NW4 5 non slit tube The AMP 1 965 421 1 connectors and the relevant accessories are a part of the delivery Option 2 distribution from the rear 16 pole connector The connector is situated in the box on the left side member in front of the rear end of the frame Diagram Fight side Ground point m battery compartment TIT 4 PTET TIT ort ttt tt tee Fig 20 Left side The length of the individual sections must be determined depending on the specific type of body End outline marker lamps lamps for two wire connection from any manufacturer homologated as an end o
14. device This data sheet is required for the inclusion of the towing device in the Certificate of Roadworthiness 9 8 Towing Devices over 3 500 kg AVIA only permits the installation of towing devices over 3 500 kg if the company which installs the towing device has obtained the prior approval of such modifications from the Ministry of Transport When installing a drawbar in the rear overhang or a low mounted towing device the installer must under any circumstances observe the requirements of this body installer guideline The recommended drawbar is for example the Ringfeder DB35V for installation in the rear overhang and the low mounted towing device kit containing this drawbar 10 Transmissions and Auxiliary Drives The drives on the vehicle may be used for a range of equipment placed in the body when certain types of bodies are installed on the chassis In order to achieve this the auxiliary drives installed on the transmissions must be used see Table 12 The detailed data regarding the position and type of the auxiliary drives will be provided by the sales technical support staff The auxiliary drives are driven by the gear countershaft for the ZF 65850 transmission the auxiliary drives are installed on the rear cover These drives can only be controlled while the vehicle is stationary the clutch is off and the engine is running The running speed while the auxiliary drive is on can only be adjusted by a Cummins authorised centre
15. safety of operation safety of transport maintainability and driving properties of the vehicle are not affected by the body installed or by the chassis modifications performed Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 3 Ouality Assurance In order to meet the high guality reguirements of our customers and the international legislation concerning product warranty it is necessary to monitor quality while performing conversions or manufacturing or installing bodies This assumes the existence of a functional quality assurance system 3 We therefore recommend that the body manufacturers put in place and provide evidence of the existence of a quality management system complying with general requirements and recognised rules e g one according to the ISO 9000 The evidence of such a qualification may be provided for example by submitting the relevant certificate If AALM is the customer of the body or modification order it requires that the implementing company submit the ISO 9001 2000 certificate 4 Body or Chassis Modification Approval Procedure Before commencing any work the suitable chassis must be selected for the desired body based on the implementor s own experience or upon consulting the chassis manufacturer This Guideline must be read and followed in order to select the suitable chassis Any and all modifications must be performed in accordance with this Guideline In addition the requireme
16. D MOTORS EURO 4 amp 5 Part No 442 17558 437 7 according to assembly drawing no 442 18950 131 7 in Fig 29 The brace will be supplied as a part of the 1540V coupling If other brands of coupling devices are to be used e g Rockinger Ringfeder the device must have a pin diameter of 40 mm and must be approved for the reduced pulling force D which depends on the weight of the vehicle and of the trailer and the flange must have the same bolt spacing as the rear cross member on the chassis In such a case the brace must be purchased as a spare part from AALM and the reinforcement must be performed in accordance with assembly drawing no 442 18950 131 7 in Fig 29 9 6 Rear Emergency Tow Points Manufacturer Pin diameter Mireal Michalovce Rockinger 30B35000 Type SK 30 1 2 9 7 Towing Device with an ISO 50 Coupling Ball The requirements of Directive 94 20 EC or UN ECE Regulation No 55 must be observed when installing a towing device with an ISO 50 coupling ball Only such a towing device may be used as has been approved for installation on the AVIA D60 120 vehicles Each towing device must be provided with a plate indicating the key data based on the durability test according to the prescribed regulation and the towing device approval number An installation manual must be supplied by the manufacturer with each towing device and must be adhered to A data sheet containing the approval must be supplied with each towing
17. Installation 24N main socket connection to the RAM NAST I connector position box in the frame GP7 auxiliary grounding in the box Socket position 1 GND RAM NAST I position 1 Socket position 2 left end outline marker lamp RAM NAST I position 2 Socket position 3 left direction indicator lamp RAM NAST I position 3 Socket position 4 stop lamp RAM NAST I position 4 Socket position 5 right direction indicator lamp RAM NAST I position 5 Socket position 6 right end outline marker lamp RAM NAST I position 13 Socket position 7 trailer brake failure tell tale 24S main socket connection to the RAM NAST I connector position box in the frame GP7 auxiliary grounding in the box Socket position 1 GND Socket position 2 spare RAM NAST I position 6 Socket position 3 reversing lamps RAM NAST I position 8 Socket position 4 permanent power by battery terminal 30 Socket position 5 spare RAM NAST I position 9 Socket position 6 ignition box power terminal 15 RAM NAST I position 7 Socket position 7 rear fog lamps Bodybuilders Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 ABS connection socket 5 pole ISO 7638 ABS socket connected to the CLUS 4 connector on the cabin harness CLUS 4 position 1 Socket position 1 Solenoid valve power CLUS 4 position 2 Socket position 2 ABS electronic circuit power CLUS 4 position 3 Socket position 3 ABS electr
18. acturer has been homologated according to UN ECE Regulation No 58 01 The body manufacturer must observe all the instructions provided in Section 9 3 of this Guideline When a different rear underrun protective device is used its manufacturer must apply for homologation according to the applicable international regulation Lateral Underrun Protection If a chassis without a body has been supplied without homologated lateral protective devices such lateral protective devices must be installed by the manufacturer of the body unless the nature of the body permits operation without the lateral protective devices Such equipment homologated in the Czech Republic according to UN ECE Regulation No 73 00 can be additionally ordered from AALM The basic dimensions of this equipment are shown in Fig The equipment consists of the parts shown in Figures 23 25 Number of holders K N wheelbase 2 pieces on each side of the vehicle L E S G wheelbase 3 pieces on each side of the vehicle ATTENTION the first holder on left side member is according to Fig 25 the other holders are according to Fig 26 Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 The openings for the attachment of such holders have been pre drilled in the frame side members The use of the longitudinal sections of the lateral protective devices differs according to the disc wheels or tyres used as follows see Fig 22
19. ange For that reason the calculation must be made prior to commencing any work When extending the overhang the section which is being welded on must be made from a material of a quality identical with or similar to that of the original side member of the underframe see Table 7 Extending the overhang using multiple sections is not permitted If the extension has been performed the side member of the underframe must be shortened to the original length and it must extended by inserting a new section having the required length The cross member between the rear housings of the laminated springs of the rear axle must always be kept in its place The end crossbar of the frame must also be kept installed on the frame After the extension of the overhang is completed the load on the towing device cannot be higher than the standard load If the overhang is shortened the maximum technically permissible load on the towing device is permitted 8 4 Welding up of the Openings Drilled in the Underframe If a new opening is to be drilled in the underframe and if it interfered with an old opening such an old opening must be welded up as follows a Bevel the edges of the opening b Attach a copper plate on the inside of the opening and weld the opening up c For large openings an insert may be used and welded into the opening d Dress the opening and apply a primer and then a top coat 8 5 Bolted Connections Class 8G and higher bolts clamps an
20. chassis of the D60 D120 Euro4 or Euro5 truck or if the Body Installation Guideline has not been observed AALM shall not be responsible for any failures of the chassis caused by the body in particular by its function attachment weight distribution over the axles quality of manufacture and installation etc unless the body manufacturer has submitted the vehicle with the body for verification by the chassis manufacturer and unless the chassis manufacturer has issued an evaluation report ATTENTION The passing lamps must be readjusted on each completed vehicle e the chassis with the cabin to the basic value 1 ATTENTION The manufacturer of any body whose tailgate when folded covers the rear combined lamps must attach the following label to a place visible from the driver s seat THE DRIVER MUST PLACE A WARNING TRIANGLE BEHIND THE VEHICLE WHEN THE TAILGATE IS FOLDED IN REDUCED VISIBILITY CONDITIONS ATTENTION After the installation of the body and its accessories is completed vehicle must be weighed in order to obtain the operating weight of the vehicle and the weight must be entered in the Certificate of Roadworthiness After the installation of the body the body manufacturer must check and complete the automatic load sensing valve adjustment label If a change in the operating weight of the vehicle has changed the manufacturer will complete line 2 If the total weight has changed line 4 must be completed
21. chassis prior to the commencement of the installation of the body Calculations can then be used to determine the most favourable position of the centre of gravity for the payload and for the body and the optimum length of the body The permissible deviation of the weight of a stock vehicle is 5 depending on the manufacturing tolerances All the deviations from the stock condition affect the dimensions and weight to a certain degree AALM takes the permitted tolerances into consideration Deviations in the dimensions and weight may appear following a change in the eguipment in particular in the case of the change of the tyres resulting also in the change in the permissible load values Dimensional variations from the stock dimensions e g a change in the centre of gravity of the payload may affect the axle load and payload values The following instructions must be followed for each body gt The permissible axle load values must never be exceeded see Section 6 1 gt The sufficient value of the minimum front axle load must be achieved see Section 6 5 gt The centre of gravity and the load must not be one sided see Section 6 4 gt The permissible rear overhang of the vehicle must not be exceeded see Section 6 6 Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 6 1 Maximum Permissible Axle Load When designing the body it is necessary to consider that the load on the individual axles must never e
22. cted that if the load is equally distributed over the body the requirements specified in Sections 6 1 to 6 5 are met including the recommended distribution of the load over the individual axles and that the rear overhang of the body complies with the requirements of Section 6 6 gt For regular cabins the distance of the front edge of the body from the front axle must be at least X 670 mm for extended sleeper cabins it must be at least X 1 370 mm see Fig 2 The gap between the body and the cabin fitted with noise reduction shields must be at least 20 mm gt On vehicles fitted with CUMMINS engines and a ZF six speed gearbox free space must be kept inside the frame at the distance of 650 mm to 820 mm from axis of the front axle and in height between 50 mm above the upper flange plate and 170 mm from the left side member web and between 820 mm to 1 000 mm from the axis of the front axle and in height between 80 mm above the upper flange plate and 195 mm from the left side member web gt The structure of the body in the place of the fuel tank neck must be such as to prevent obstruction during refuelling Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 gt In addition to the fuel tank neck access must also be preserved to the other components installed on the frame e g the spare wheel battery casing For reference we state the following The following modifications must be per
23. ction Two side direction indicator lamps on the body for chassis for the body width of 2 550 mm 2600 mm for chassis intended for this maximum width there is no side direction indicator lamp on the cabin door Lighting equipment and its positioning on the vehicle End outline marker lamps Any lamp homologated as an end outline marker lamp under the most recent version of UN ECE Regulation No 7 or EU Regulation No 76 758 Positioning in width as close to and no less than from 400 mm from the extreme outer edge of the vehicle jn height at the greatest height compatible with the required width design and operation requirements for the vehicle and symmetry of the lamps 200 mm from the end outline marker lamps geometric visibility horizontal angle 809 outward vertical angle 5 above and 20 below the horizontal See the requirements of UN ECE Regulation No 48 02 Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 Side markers combined with retro reflectors Lamps of a type homologated according to the UN ECE or EU combined with retro reflectors must be used AALM recommends the following manufacturer FER Fahrzeugfabrik GMBH type 4204 colour orange category SMI lamp IA retro reflector homologation marks E1 00401 and E1 02401 or VIGNAL type FE 94DK colour orange category SMI lamp IA retro reflector homologation marks E2 4093 The positioning on the vehic
24. d Single Side Load There must be no single side load on the wheels achieved in designing the body The permissible difference in the wheel load for additional checks must not be more than 4 For this calculation the actual axle load rather than the permissible axle load represents 100 Formula Wheel load difference AG 0 04 Gstat 6 5 Minimum Permissible Front Axle Load In order to maintain the steerability of the vehicle the specified minimum load in accordance with the table below must be applied to the front axle under any load conditions Table 5 Minimum front axle load under any load conditions expressed as the percentage of the actual weight Separate vehicle Vehicle fixed Vehicle central Vehicle series total CoU weight Lnd trailer axle trailer D60 90 30 D100 120 The values relate to the actual weight of the vehicle including any additional load in the rear part of the vehicle such as Load applied on towing device by a central axle trailer Loading crane on the rear of the vehicle Tail lifts Mobile fork lift trucks 6 6 Permissible Overhang Overhang of the vehicle including the body means the distance between the centre of the rear axle and the end of the vehicle The maximum permissible value of overhang is 65 of the wheelbase If no towing device is fitted the above mentioned value may be exceeded by 5 The main requirement is that the minimum front axle load value
25. d nuts can be used to attach the body In order for the bolted connections of the brackets and holders used for the attachment of bodies to meet its purpose they have to be tightened to the specified torque Torque for bolts and nuts 8G M B P 23 Nm M10 45 Nm ii P 75 Nm 120 Nm M14x1 5 120 Nm M16x1 5 160 Nm Special M12 self locking flange bolts in Class 10 9 as well as M12 all metal self locking nuts in Class 10 are used on the chassis The tightening torque is 120 Nm The reuse of these bolts and nuts is not recommended The bolts can be purchased as spare parts Replacement of riveted parts the rivet is replaced with the suitable locking bolt M 12x20 442 15201 168 7 M 12x25 442 15201 167 7 M 12x30 442 15201 163 7 M 12x35 442 15201 164 7 M 12x40 442 15201 165 7 M 12x45 442 15201 169 7 8 6 Subframe The subframe is used to attach a variety of body types to the chassis underframe These subframes must be designed with great care in order to perform their function and ensure that they do not contribute to any damage to the chassis or the body itself The U section is the most suitable section for the subframe The subframe must always have the same width as the chassis underframe and it must follow the outer edge of the main frame The entire surface of the subframe side member must rest on the upper flange plates of the side members of the main frame For the L E and S versions of the ve
26. e 2 hydraulic cylinders because of the low bearing capacity of one cylinder A one way throttle valve must be installed in the cabin folding hydraulic circuit before the installation of the sleeper body the operation is described in the sleeper body installation manual supplied by the manufacturer of the sleeper body 13 Electrical Equipment Welded pressed or cut through cable couplers are NOT permitted 13 1 Wiring for the Interior Lighting of the Body For the interior lighting of the body use branch line LP21 coupler from frame harness The branch line coupler is situated on the left side of the vehicle before the cross member above the transmission is connected to position 1 position 2 is connected to the central ground of the chassis See Fig 18 The AMP 967239 1 connectors are a part of the delivery NO OTHER CONNECTION of the interior lighting of the body is permitted 13 2 Side Direction Indicator Lamps only for the version with the maximum body width of 2 550 mm The connectors are located on the left and right sides next to the flywheel housing LP22 LP23 Diagram ib m Position 1 Fig 18 2 Position 2 Wire material FLYY85 2x0 5 pair wire or equivalent or separate FLRY wires covered with a Schlemmer NW4 5 non slit tube The AMP 1 965 421 1 connectors and the relevant accessories are a part of the delivery 13 3 Side and End Outline Marker Lamps Fig 19 Lt j gt
27. f the body directly onto the chassis underframe We recommend the use of shielded arc welding preferably using a mixed gas using the G4Si1 electrode according to EN 440 or the SG3 according to DIN 8559 The battery the alternator and the connectors of the ABS and ISBe control units must be disconnected before welding The master switch will stay on The cables will be disconnected from the battery and then interconnected with When reconnecting it is necessary to respect the polarity and connect the terminal first Wiring and air ducts around the point of welding must be protected from heat It is preferable to remove the wiring and air ducts No welding must be performed if the ambient temperature drops to below 59C The welding operations must be performed without notching Weld cracking is not permitted The connecting welds on the side members must be performed as multi layered V or X welds see Fig 6 Any vertical welds must be made from in the upward direction see Fig 7 At least 2 layers Weld root position WN l Y Fig 6 Fig Bodybuilders Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 8 3 Change in Underframe Overhang A change in the rear overhang will result in the shift in the centre of gravity of the payload and of the body thus also changing the load on the axles Only a calculation of the axle load can prove whether these changes are within the permitted r
28. formed in order to install a body with the maximum width of 2 550 2 600 mm on a chassis intended for the installation of bodies with the maximum width of 2 350 mm gt Remove the side direction indicator lamps from the cabin doors and cover the openings with the plug Part No 4 6423 0 005 gt Install homologated side direction indicator lamps on the front part of the body in accordance with Section 5 1 The wiring is specified in Chapter 13 gt Replace the original rear view mirror holders with those intended for bodies with the maximum width of 2 550 mm The following modifications must be performed in order to install a body with the maximum width of 2 350 mm on a chassis intended for the installation of bodies with the maximum width of 2 550 mm gt Remove the plug from the side door and install the side direction indicator lamps in the opening The lamps can be purchased from AALM as spare parts gt Replace the original rear view mirror holders with those intended for bodies with the maximum width of 2 350 mm The key document for the specification of the parts for the modification of the chassis due to body width IS AALM Guideline A 12 07 7 2 Mainframe m Table 7 Lateral body support For the lateral support of the body the mainframes are provided with side plates in the area of the cross member above the gearbox and at the place of the axis of the rear axle In the rear part of the frame the rear bumper bracket is
29. he hydraulic tailgate for versions N and L is 1 000 kg for version E it is 800 kg One of the preconditions is the reinforcement of the chassis underframe with a steel section according to Table 9 or with another element having the same rigidity The reinforcement can also be a subframe of the body connected to the underframe in accordance with Chapter 9 Hydraulic tailgate bad Vehicle type Camyng capacty WB N 3400 mm WBL3900 mm WB E 4500 mm WBS5100 mm WB G 5600 mm mainframe mainframe mainframe prose not permitted not permitted not permitted 1 000kg heavy pps viia fa 3 Waja brace 70 x 50 x 5 not permitted not permitted not permitted possible The maximum permitted standard size of the lifting arm is up to 3 5 tm Any reguirements for the installation of a larger hydraulic arm must be discussed directly with the chassis manufacturer In the case of the installation of the lifting arm the frame must be reinforced with a support inserted into the frame in the place of the fixing yokes in order to form an enclosed section 9 3 Rear Underrun Protective Device The stock chassis eguipped with rear underrun protective devices are homologated according to UN ECE Regulation No 58 01 The following points must be observed in the design of the body the maximum total permissible overhang which is 65 of the wheelbase see Section 6 6 the maximum clearance of the lower edge of the rear underrun protective device must be
30. hicle the steel side members of the grid flooring of the body must be used Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 In vehicles with the S wheelbase the side members of the subframe with the section of at least 80x50x5 mm must be used provided that the subframe is interlocked with the chassis using external metal sheets according to Section 9 2 below The front part of the subframe side members must reach as far forward as possible and the side member must be terminated as described in Fig 8 and Fig 9 Fig 8 9 Attachment of Various Types of Bodies and Equipment to the Underframe 9 1 Attachment with Side Brackets Two brackets are always used in this method of attachment One bracket is always attached to the chassis frame and the other on the subframe of the body Depending on the nature of the coupling of the brackets the fixed and the flexible types of connections are distinguished 9 1 1 Fixed Coupling Before the bolts are tightened in the fixed connection a sufficient gap must be ensured between the brackets in order for the subframe to fully rest on the chassis frame when tightened We recommend a gap of approximately 2 mm between the brackets see Fig Obr 10 Bolt M12x35 10 9 Bolt M 12x90 10 9 F i 2mm before tightening Washer part No 442 1501 372 7 Spacing tube Self locking nut M12 Class 10 e g DIN 6927 ISO 7044 EN 1664 product no 442 15251 044 7
31. le must comply with Fig 28 Side Direction Indicator Lamps The side direction indicator lamps used must be in category 6 homologated according to the most recent version of UN ECE Regulation No 6 or EU Regulation No 76 759 Positioning jn height not less than 500 mm measured from the lowest point and not more than 1 500 mm measured from the highest point in length not more than 1 800 mm from the transverse plane which marks the front outline of the vehicle If the structure of the vehicle does not permit observance of the minimum angles of visibility this distance may be up to 2 500 mm geometric visibility horizontal angle 5 towards the rear vertical angle 30 above and 5 below the horizontal See the requirements of UN ECE Regulation No 48 02 Changes in Equipment Made by Body Manufacturer Lighting and Signalling If the manufacturer of the body uses lighting and signalling equipment of a different type such equipment must be homologated according to the most recent version of the applicable regulation of the UN ECE or EU Its positioning on the vehicle must comply with the requirements of UN ECE Regulation No 48 02 or EU Directive 91 663 The manufacturer of the body must apply for the extension of the homologation awarded to the chassis and cabin through AALM Development and Design Department Rear Underrun Protective Device The equipment installed by the chassis manuf
32. nes authorised to install such compressors If another version is reguested the chassis manufacturer must be consulted Any combination of two compressors on the engine is possible subject to the following reguirements 1 The specifications of the combination must be entered in the notes section of the vehicle configurator when the order is placed 2 If installation is required to be performed on a finished vehicle the chassis manufacturer must be consulted regarding the design 11 Cabin Folding Space If a part of the body is found over the cabin e g a refrigeration unit it must be so positioned as to permit sufficient space for the folding of the cabin see Fig 15 The cabin folding angle is 55 R 2150 mm Fig 15 Bodybuilders Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 12 Cabin Modification for the Installation of a Sleeper Body The D60 D120 trucks with hydraulic cabin folding can be fitted with a sleeper body whose installation has been approved and whose installation manual has been confirmed by the chassis manufacturer The installation of the sleeper body and the modifications of the cabin and chassis must be performed in strict compliance with the installation manual supplied by the chassis manufacturer together with the sleeper body ATTENTION The same requirements must be met in the installation of a sleeper body on extended cabins with a berth In addition the cabin folding function must us
33. ng convention therefore applies Dimensions gt All the dimensions lying IN FRONT of the theoretical centre of the front axle have the MINUS sign gt All the dimensions lying AFTER of the theoretical centre of the front axle have the PLUS sign Weight values gt All the weights INCREASING THE LOAD on the vehicle has the PLUS sign gt All the weights LIGHTENING the vehicle have the MINUS sign 7 Body Installation For identification purposes each body must be provided with a name plate containing the full name of the manufacturer of the body and the serial number The data on the name plate must be permanently visible The body must not unnecessarily increase running resistance and compromise the driving properties of the vehicle The frame must not be deformed before or during the installation It is advisable to drive the vehicle forward and back several times in order to remove any torsional stress During the installation of the body the vehicle must be placed on a level assembly area and the side member flange plates should be levelled The adjustment operations on the vehicle must be repeated after the completion of the installation of the body see Chapter 17 This mainly applies to the automatic load sensing valve of the brake system the headlamps etc The key dimensions must also be checked as far as the rear underrun protective device and the lateral protection are concerned Bodybuilders Guideline AVIA
34. nt the tarp from obstructing the view from the rear view mirrors B INSTALLATION OF BOX TYPE BODIES The side brackets will be used to install box bodies Flexible mounting will be used in the front part one pair of brackets on wheelbase L or two pairs of brackets on wheelbases EL and SL according to Section 9 1 2 and the rear attachment is also made with side plates to absorb the lateral forces rear fender bracket C INSTALLATION OF OTHER BODIES When installing other bodies tipper container carrier lifting platform etc the design and structure of such bodies must be considered with regard to their rigidity The attachment can be performed in a manner similar to the installation of the platform type body fixed box type eeeeenn nnnm flexible or directly without the subframe using special flexible elements The proposed method of attachment must be submitted to the chassis manufacturer for approval D INSTALLATION OF AUXILIARY EQUIPMENT LIFTING ARM HYDRAULIC TAILGATES When installing hydraulic tailgates and hydraulic lifting arms it is necessary to know the details of the lifting capacity weight centre of gravity and attachment points The manufacturers of such equipment must obtain the approval of the installation of such equipment on the chassis from the chassis manufacturer Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 The maximum load carrying capacity of t
35. nts of the act aying down the conditions for the operation of motor vehicles on roads applicable at the time and of the relevant implementing regulations applicable to the vehicle of the given category The prior approval by AALM of the body or of the chassis modification is not required if the body or modification is carried out in accordance with this Installer Guideline If the desired modifications are not contained in this document an opinion of the chassis manufacturer regarding the work must be obtained Regarding any references made in this document to the chassis manufacturer technical solutions approvals and any queries regarding the issue of chassis modification and body installation please contact AVIA ASHOK LEYLAND MOTORS s r o Technical Department Technical Documentation Unit BERANOVYCH 140 199 03 PRAGUE LETNANY Czech Republic Tel 266 142 993 Fax 266 142 058 If AALM approves the body or the chassis modification such an approval will concern in the case for bodies only the basic compatibility with the relevant chassis and the body interfaces e g in order to determine the dimensions and attachment of an auxiliary frame in the case of chassis only the basic design admissibility for the relevant chassis type of vehicle Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 5 Homologation of D60 D120 Euro4 5 Vehicles Finalised By Body Installer The chassis and cabin have been fully h
36. omologated to the extent possible in the relevant stage of manufacture of the vehicle If the body manufacturer performs any interventions on any part or assembly of the vehicle which is subject to homologation according to the regulations of the UN ECE or EEC such a manufacture must apply for an extension in the existing homologation or for a new homologation process to be performed 5 1 Mandatory Equipment by Body Manufacturer The body manufacturer must equip the vehicles as follows Vehicles with the K wheelbase End outline marker lamps Lateral protection and rear fenders if the chassis and cabin have been supplied without such devices and fenders provided that the nature of the body does not allow for the vehicle being operated otherwise e g without lateral protection Two side direction indicator lamps on the body for chassis for the body width of 2 550 mm 2600 mm for chassis intended for this maximum width there is no side direction indicator lamp on the cabin door Vehicles with the N L E S and G wheelbases End outline marker lamps Three side lamps combined with retro reflectors on each side of the vehicle if the chassis and cabin have been supplied without lateral protection Lateral protection and rear fenders if the chassis and cabin have been supplied without such devices and fenders provided that the nature of the body does not allow for the vehicle being operated otherwise e g without lateral prote
37. onic circuit GND CLUS 4 position 4 Socket position 1 Solenoid valve GND CLUS 4 position 1 Socket position 1 ABS P failure tell tale 14 3 Remote Engine Start Stop Connection and Engine Speed Control This technical instruction describes the connections for engine control from the body engine start stop and speed control Start up is controlled using the START and STOP switches engine speed is controlled using the PLUS and MINUS switches The press button switches are situated on the body The connection is made using six wires Requirements for remote engine control using switches on the body The key is turned into position I in the ignition box The CC PTO switch is ON The handbrake is activated Operating air pressure in the compressed air tanks of both brake circuits DO IE The following label must be attached next to the switches on the body CAUTION THE ENGINE CAN BE STARTED FROM THE BODY ONLY WITH THE HAND BRAKE ON AND WITH OPERATING Wiring diagram for E4 and E5 FMINUSOSWITCH PPLUSO fPLUSO ENGINE ECU C B WIRE No WIRE No 430N WIRE No 445NN WIRE No WIRE No rPLUSO SA START 30 O O O O MINUSO STOP O O 86 N 85 O O O O O E IGNITION BOX HAND BRAKE TELL GND WIRE No 302AB WIRE No 050B WIRE No 9xx Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 1 Connect the relays and control button switches according to the diagram Insert the relay
38. s 00 gt 089 1 09 os L owe S9 N oa oB sea osez S OM X waa wwa wo ws tA l OO OS A 2G me a S m IPA PA OO e m lt Lj E T Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5
39. s advisable to connect the wire to the wire leading to the 12V socket on E5 vehicles connect it to the central screw situated in the middle of the front panel of the cabin 3 Check the operation of remote engine control when the installation is completed Material used AMP 444314 1 base 3 pcs AMP 160759 4 base contacts 4 6 6 pcs AMP 925575 1 base contacts 2 5 8 6 pcs 4 8725 2 001 relay 3 pcs button switch green 1 pc button switch red 1 pc button switch black 2 pcs red DUOFLUX 830320 8 pcs FLRY A wire cross section of 0 75 mm 1 mm white and grey as needed cable ties as needed 14 5 Maximum Speed and Reverse Lock Remote Control These functions are mainly requested by the manufacturers of sanitation waste disposal vehicles The speed is limited to 30km h the contact under the foot step is engaged At the same time the reverse function of the engine is prevented by using an automatic engine stop These functions are not available in the configurator Should such functions be required they must be included as a special request in the Notes in the configurator interface AALM will supply the vehicle with these functions active and with the wiring prepared for connection anywhere on the chassis Bodybuilders Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 15 Warranty Conditions AVIA ASHOK LEYLAND MOTORS s r o will not provide any warranty for the vehicle if a non approved body has been installed on the
40. s specified in Section 6 5 and the requirements specified in Section 6 1 be observed under any operating conditions For the practical modification of overhang see Section 8 3 Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 6 7 Axle Load Calculation When optimising the vehicle and determining the correct sizing of the body the load on the axles has to be calculated The body can only be matched with the truck if the vehicle is weighed prior to commencing the installation of any body The weight determined by such weighing is then used in the axle load calculation The text below explains the axle load calculation The moment theorem is used to distribute the weight of the assemblies over the rear and front axles All the distances are referenced to the theoretical centre of the front axle For the sake of understandability the weight in the following formulas used within the meaning of mass in kg rather than within the meaning of the force of gravity in N The weight difference of the rear axle AG AG a Lt AG weight difference added weight of the body or other additional load a distance of the point of application of the load from the centre of the front axle Lt theoretical wheelbase of the chassis The weight difference of the front axle AGP AG AGz Rounding to the nearest kilogram is fully sufficient Special attention must be paid to the correct mathematical sign The followi
41. stic which can resist temperatures of 40 C to 110 For that reason the piping must protected against damage If this cannot be ensured the piping must be removed gt All the brackets and parts attached to the vehicle frame must be perfectly cleaned and primed prior to their installation gt After the completion of all the work on the chassis the top coat of all the parts must be repaired in order to maintain the corrosion resistance properties of the chassis Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 8 1 Drilling of Openings in the Underframe The following principles must be observed when drilling any openings in the underframe gt DO NOT drill any openings in the lower and upper flange plates of the side members gt Drilling in the web plate is permitted provided that the edge of the bore is at least 20 mm from the upper lower flange plate The maximum diameter of the opening drilled for wiring or air pipes must be 25 mm an opening of up to 40 mm may be made in the axis of the section see Fig 5 3m i 940 A A FLE A arte KA i E A p A yA pia el en 025 613 i a1 iA Eu E LEO 8 2 Welding on the Underframe Welding is permitted on the underframe if required for the modification work e g extending the overhang or reinforcement of the underframe tis never permitted to weld on the brackets and holders of the body or to weld the frame o
42. t Kit 14994811 Horizontal Row 3 4x M16x50 each side from Bolt Kit 14990468 Horizontal Row 4 4x M16x60 each side from Bolt Kit 14994811 Bracket Kit EUP 60 21178200 or 21178278 Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 6 5mm 853mm Outside Frame Width 21019500 Set of End Plate EDS AAL 10080189 Spacer 3mm each side 21022100 Drawbeam DB35V 834mm 2009670 Tube 10069659 Tube Clamping Kit 21178400 or 21178470 Coupling Typ Ringfeder 4040G150 A 14996314 4x M20x90 8x Washer 20 from Bolt Kit 13991960 2x M16x60 each Side from Tube Clamping Kit Biechabwicklung 15 Sneat metal sprestng zeichnung Chargenzeichen und Fertigungedalurn pinzelncer od singepr gil Texth he Bem Tiela en Q 5mm Marking Batch sign and date of production laser ar stamped inl Brem Depth approx 05mm B dal Setenplatten Aus Oh rt Entdplale design Links wie gezeichnet Left according te the drawing Rechts apiegelbidich Right contrary to the drawing Geltanplatiensatz bestehend gis Endplate sel contents ot 1x Platte finke WEG 21 184900 1x plate lett AG 31 184800 1x Platte rechts BO 21 165000 1x plate right VEG 21 485000 Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 g 0988 GZ vz 08 0868 o 078 0S8 GZEZ 0015 08 8 EE 3j 383 O D s 08 og e 00v 0862 08 g
43. the speed is set at 1 000 rpm by default Pumps are installed on the auxiliary drive N850 10c NL 1c NL 4c in accordance with the coupling dimensions according to ISO 7653 Table 12 type of gear ratios transmission 1 2 3 4 5 6 R Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 Getriebe Nebenab Abtriebs Abtriebs Drehzahlfaktor Drehrichtung Antrieb durch Betriebsart bezeichnung triebstyp stelle moment Speed factor Output rotation Driven by Operation entgegen wie Motor kupplungs motor fahr Dauer 2 Kurzzeit Motor enginewise abh ngig abh ngig abh ngig betrieb betrieb Transmission PTO type Output Output designation point torque Nm counter clutch engine road driven continuous Intermittend enginewise dependet dependet operation Operation waki CZA sa 270 190 0 87 1 54 e E e NL 1 6 600 0 42 0 53 e e NL 4 6 430 0 53 0 68 e e N 36 5 400 300 0 87 1 46 e s C 560 290 0 0 1 72 S o o gt a N 850 10 D NL 1 7 600 0 42 0 53 9 e 5 D NL 4 7 430 0 53 0 68 8 1 Abtriebsdrehzahl f x Motordrehzahl Output speed f x engine speed 2 Pumpendrehzahl g x Abtriebsdrehzahl des Getriebes Pump speed g x output speed of gearbox 3 Version mit Intarder Version with Intarder 4 N 221 10 mit integriertem Lenkpumpenantrieb N221 10 with integrated steering p
44. ump drive 5 f r 16 S 2720 TO und 16 S 2730 TO wird statt N 221 10 ein N 251 10 ben tigt for 16 S 2720 TO and 16 S 2730 TO a N 251 10 is required instead of N 221 10 6 7 Installation nur m glich bei einem Durchmesser des Getriebeabtriebsflansches bis max 120 mm installation only possible with transmission output flange diameter not exceeding 120 mm 7 nicht f r 16 S 2720 TO not for 16 S 2720 TO 8 F r Dauerbetrieb muss grunds tzlich beim Ersteinbau eine Oltemperaturmessung druchgef hrt werden Wird die max zul Temperatur berschritten muss eine Zusatzk hlung eingebaut werden Initial installation for continuous operation invariably requires measurement of the oil temperature If the maximally permitted temperature is exceeded an additional cooling system must be installed 9 gleiche PTO Bezeichnung f r Sologetriebe und Getriebe mit Intarder same PTO designation for solo transmission and transmission with Intarder Standard NOTE The basic versions of the vehicle are not suitable for the integration of a three phase generator If the integration of such a generator is reguested the chassis manufacturer must be consulted ATTENTION A refrigeration compressor must be installed in compliance with AALM Guideline A 08 02 The following companies are the holders of the registered copies of the guideline PEK servis Kol n Thermo King Carrier Transicold s r o These companies are the only o
45. used for the lateral support It protrudes over the upper flange plate This bracket can also be used to attach the subframe of the body after matching holes are drilled to those provided on the bracket Lateral body support Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 The mainframes are provided with side mounting brackets which are riveted onto the frame The positioning of the brackets on the vehicle is shown in Figure 4 and Table 8 Spacing of openings on the brackets and frame width For profiles with the 200 x 60 x 5 mm section For profiles with the 203 x 62 5 x 6 5 mm section 850 2 Fig 4 Position of the side mounting brackets with regard to the axis of the front axle keare an Bracket distance from the axis of the front axle mm mm L3 D KAA IEC E CH a as pus peo p ze pao wo izo iwo a 3m ia 7 ss ms 1wo zw Table 8 m mE EM mE Note The side protection holder serves as the first bracket on the left side member 8 General Instructions for Chassis Modification The applicable occupational health and safety rules must be observed when performing any modification of the chassis The specified work may only be performed by qualified personnel Please note the following points when working on the chassis gt The air and fuel piping is made from the PA 11 and PA 12 pla
46. utline marker lamp under the most recent version of UN ECE Regulation No 7 or EU regulation Wire material FLYY85 2x0 5 pair wire or equivalent or separate FLRY wires covered with a Schlemmer NW4 5 or NW10 non slit tube The grommets on the box must be sealed Welded pressed or cut through cable couplers are NOT permitted The AMP 1 964 449 1 connector and the relevant accessories and the grommets are a part of the delivery Options 1 and 2 may be combined No other wiring for the outline marker lamps is permitted Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 14 Trailer Coupling Sockets The wiring of the trailer can be connected using the following methods 14 1 12N Socket for 24V Installation interconnection with the RAM NAST I connector position box in the frame RAM NAST I position 2 Position 1 of the left direction indicator lamp socket RAM NAST I position 7 Position 2 of the rear fog lamp socket GP7 auxiliary grounding in the box Socket position 3 GND RAM NAST I position 4 Position 4 of the right direction indicator lamp socket RAM NAST I position 5 Position 5 of the right end outline marker lamp socket RAM NAST I position 3 Position 6 of the stop lamp socket RAM NAST I position 1 Position 7 of the left end outline marker lamp socket The following label must be placed next to the socket CAUTION 24V 14 2 Double 24N and 24S Sockets for 24V
47. y Tow Points 23 9 7 Towing Device with an ISO 50 Coupling Ball 23 10 Transmissions and Auxiliary Drives 24 11 Cabin Folding Space 25 12 Cabin Modification for the Installation of a Sleeper Cabin on the Body 25 13 Electrical Equipment 25 13 1 Wiring for Interior Lighting of the Body 25 13 2 Side Direction Indicators 25 13 3 Side and End Outline Marker Lamps 26 14 Trailer Coupling Sockets 27 14 1 12N Socket for 24V Installation 27 14 2 Double 24N and 24S Sockets for 24V Installation 27 14 3 Remote Engine Start Stop Connection 27 14 4 Engine Idle Speed Remote Control 27 14 5 Maximum Speed and Reverse Lock Remote Control 27 15 Warranty Conditions 28 16 Permitted Exceptions 29 17 Annexes 30 17 1 Basic Dimensions of the Chassis 30 17 2 Position of the Lateral Protective Devices 31 17 3 Position of the Rear Underrun Protective Device 34 17 4 Position of the Side Outline Markers 35 Bodybuilder s Guideline AVIA ASHOK LEYLAND MOTORS EURO 4 amp 5 1 Applicability of the Body Installer Guideline This Body Installer Guideline is to be the manual and technical guide for companies which design and install bodies for truck chassis and the chassis This Guideline applies to the following trucks manufactured by AVIA ASHOK LEYLAND MOTORS s r o AALM AVIA series D60 D120 vehicles with Euro 4 and Euro 5 engines these vehicles use identical chassis assemblies gt The Guideline applies to new vehicles gt The Guideline
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