GENLYON- KINGKAN BODYBUILDERS INSTRUCTIONS SAIC-IVECO HONGYAN ISSUE2013 IVECO S.p.A. Technical Application Strada delle Cascinette, 424/34 10156 Torino (TO) - Italy www.iveco.com Printed 603.95.640 -1st ed. 09/2013 GENLYON - KINGKAN Bodybuilders instructions Printed 603.95.640 - 1st ed. Base - 09/2013 UPDATE DATA Section Paragraph Description Revision date Update data Printed 603.95.640 Base - 09/2013 Update data Base - 09/2013 Printed 603.95.640 Notes This document is compiled from technical data for Hongyan Genlyon and Hongyan Kingkan products from SAIC-IVECO HONGYAN Commercial Vehicle Company (hereinafter referred to as ’our company’); national regulations and standards for motor vehicles; the IVECO STRALIS and IVECO TRAKKER refitting guides; and the ’Hongyan STEYR Guide to Refitting (2005)’. This document provides specific guidance for refitting factories on how to refit a Hongyan Genlyon or Hongyan Kingkan, methods for measuring key dimensions, and relevant parameters for chassis and assemblies for certain vehicle models. In addition to this docu- ment, readers should also refer to the latest versions of compulsory national standards such as GB 7258 ”Safety specifications for power-driven vehicles operating on roads” and GB1589 ”Limits of dimensions, axle load and masses for road vehicles” in designing arefit. This document contains parameters relevant to refitting our mainstream chassis. However, due to the fact that Genlyon products are constantly being improved, some information contained herein may not be up to date. Should you require more specific technical parameters during the refitting design or manufacturing process, please contact your local sales representative or technical staff from our Sales Division or R&D Centre. Please note that our company is happy to provide information on how to refit our products as required, and also to give guidance on refits that are not covered in this document. If you have any suggestions regarding this document,pleasefeelfreetocontactthe relevant department of our company. Warning signs If you have any suggestions regarding this document,pleasefeelfreetocontactthe relevant department of our company. Warning! ! Ignoring or not fully complying with these instructions may cause severe damage to the vehicle the loss of entitlement to warranty services (repair, replacement, and return), and also injury to yourself. Notes Printed 603.95.640 Base - 09/2013 Notes Base - 09/2013 Printed 603.95.640 TABLE OF CONTENTS Section General Rules Chassis Parameters 1 Parameter Settings 2 Refitting the Chassis 3 Structure and Installation of the Body 4 Refitting Special Vehicles 5 Power take-off 6 Points for Attention during the Refitting of China IV Emissions Standards Vehicles 7 Appendix A - Relevant special vehicle standards A Table of contents Printed 603.95.640 Base - 09/2013 Table of contents Base - 09/2013 Printed 603.95.640 I GENLYON - KINGKAN GENERAL RULES SECTION General Rules Page 1 Basic refitting principles III 2 GB 1589-2004 body refit regulations (see Standard for more details) VII 3 Product coding rules IX 4 Selecting the chassis XII Printed 603.95.640 Base - 09/2013 II GENERAL RULES GENLYON - KINGKAN Base - 09/2013 Printed 603.95.640 III GENLYON - KINGKAN GENERAL RULES This document provides guidance on how to build a special vehicle using chassis made by our company, such as the Hongyan Genlyon or Hongyan Kingkan chassis.Intended for skilled personnel from refitting factories, it provides the necessary technical data and relevant principles for certain refittings.Read this document carefully before refitting a vehicle, and strictly comply with the rules herein in the course of refitting a vehicle.In the case that the rules do not apply to a specific vehicle, please contact our staff before taking any action. The refitting factory shall be responsible for the complete vehicle that it designs and refits. Purpose of this document:This document aims to guide refitting factories in the refitting of vehicles and the design, manufacture, and installation of bodies, while ensuring that the performance of refit vehicles and various systems are not affected, and while ensuring the safety and reliability of complete vehicles. Basic refitting principles 1 Basic refitting principles 1. Approval principles To build a special vehicle, one usually needs to refit the chassis by modifying some of the assemblies and relocating some parts, unless the chassis is specialized or specially designed and made for a user. Such modifications are broad in scope and may involve:changing the speed limiter;increasing or decreasing the wheel base;relocating the beam, pipelines, batteries, and fuel tanks;strengthening the frame;or mounting devices such as power take-offs, where necessary. Before making the aforementioned modifications or when undertaking refitting work not covered in this document, please first provide the necessary explanations or technical documents to our R&D Centre, so as to enable us to evaluate whether the refit is appropriate. The refitting factory should never modify our products without receiving formal approval from our company. ! If, during a refit without our approval, a chassis is damaged due to the unsuitability of the body, the refitting factory shall be responsible for all damage caused by the refit (including losses by end users). Meanwhile, our company shall not undertake any economic or legal responsibilities for such losses. 2. Technical materials for approval should contain the following information: Purpose and service condition of the vehicle General drawing of the body, including body dimensions, or dimensions of parts to be refitted and those of new devices Centre of gravity of the body and that of the payload, a list of weights of body components, indicating their centres of gravity, when necessary Rear overhang of the body and that of the complete vehicle Total length, width, and height of the complete vehicle Technical documents relating to the attachment between the chassis and the body and that between the lower edge of the body floor (considering maximum wheel jump height) and the chassis, and other structures that may affect the chassis Structure and dimensions of the subframe, and how this is mounted on the chassis Force and torque of such devices as a crane, cement mixer, winch, or concrete pump 3. Approval for technical documents only covers the technical feasibility for refitting our vehicles. The refitting factory shall be responsible for: The structure of refitted chassis and/or bodies Selecting products and their features The industrial process for making and mounting refitted chassis and/or bodies Ensuring that refitted chassis and/or bodies and relevant actions comply with regulations in our refitting guides Ensuring that refitted chassis and/or bodies and relevant actions comply with current national regulations on motor vehicles The performance, safety, reliability, and maintainability of refitted vehicles, and the effects of the refit and installation on perform- ance and technical parameters of such vehicles Basic refitting principles Printed 603.95.640 Base - 09/2013 IV GENERAL RULES GENLYON - KINGKAN 4. The refitting factory must guarantee to fully comply with technical regulations in this guide, and to design and refit vehicles to a professional standard. Our company has the right to deny warranty services on a refitted vehicle in the following instances: The refitting factory violates technical regulations, or installs devices not approved by our company; or a refit is not approved by us. The chassis does not fit the device, or is inappropriate for the intended purpose of the vehicle. Our technical specifications, standards, or notes are violated. Authentic spare parts or components specially made by our company for a refit are not used. 5. Prohibition principles The overall dimensions for refitted road vehicles should comply with relevant regulations in GB 7258 ”Safety specifications for power-driven vehicles operating on roads” and GB1589 ”Limits of dimensions, axle load and masses for road vehicles”. To ensure the safety and manoeuvrability of a vehicle, the following items are in principle not to be modified: Wheelbase of the chassis Specifications and layout of major assemblies such as the engine, driver cab, transmission, and axle Steering system of the chassis Braking system and brakes of the chassis Suspension on the chassis Suspension and tilt devices on the driver cab Electrical and electronic systems on the chassis The aforementioned items may be modified only after relevant refit plans have been signed and approved by our R&D ! Centre. 6. Refit design principles In a refit design, the kerb mass should not exceed the maximum permitted gross vehicle mass, and the following principles should be followed in setting the centre of gravity of the body: The centre of gravity should be as low as possible; the maximum tilt angle should comply with relevant regulations in GB 7258; and sufficient space should be saved for wheel jump. The load should be evenly distributed; the maximum axle load should comply with regulations in this document; and the load difference between left and right tyres should be no more than 3%. When running at a low speed and in good working conditions, a special vehicle may have a moderate extra load, though it is best to stay within the maximum axle load. Adjust the automatic load sensing valve accordingly after a refit, if the vehicle has such a valve. The axle load should not exceed the limits given in relevant regulations, and the load should be evenly distributed, rather than being concentrated on one side. Whatever the load, the front axle load is crucial to ensuring correct steering in any road condi- tions. In all events, the front axle load should be more than 20% of the current gross vehicle mass. Special attention should be paid to vehicles with weights concentrated on the rear suspension, with small wheel tracks, and with a high centre of gravity (for example, a cement mixer). For such a vehicle, the front axle load should be more than 25% of its current gross vehicle mass.