Conversion Guideline Opel Movano [ X62 ]

Transcription

Conversion Guideline
Opel Movano [ X62 ]
Part 3 - Chapter 53-79 and 142-148
Edition:
September 2014
GME Engineering
Special Vehicle Development / Light Commercial Vehicles
Rüsselsheim / Germany
OPEL MOVANO (X62)
CONTENTS
Conversion Guideline - Part 3
CHAPTER
DESCRIPTION:
PAGE
53
FOLDING PARKING BRAKE
3
56
ROOF RACKS AND ROOF BARS
4
TRAILER HITCH
7
57.1
*
57.2
INTEGRATED STEP IN REAR BUMPER
15
58
TACHOGRAPH
17
59
SUNROOF AND EMERGENCY EXIT
18
60
REAR AND FRONT SUSPENSION
20
63.1
POWER TAKE-OFF, FRONT WHEEL DRIVE
24
63.2
POWER TAKE-OFF, REAR WHEEL DRIVE
28
63.3
POWER TAKE-OFF ON GEARBOX, REAR WHEEL DRIVE
32
65
PREPARING FOR COLD COUNTRIES
37
67
FUEL SUPPLY SYSTEM
38
68
EXHAUST SYSTEM
43
69
BRAKE SYSTEM
47
78
TRANSLATION OF THE FUEL TANK FILLER PIPE
54
79
MAXIMUM AUTHORIZED LOAD PER AXLE
56
142
AERIAL WORK PLATFORM (CHERRY PICKER) ON PANEL VAN
57
143
PROHIBITED CONVERSION TYPES
58
146
LIFT TAILGATE
59
148
DETERMINING THE CENTRE OF GRAVITY
60
* = This chapter is new or was modified after the last edition of September 2014.
Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines).
OPEL MOVANO (X62)
53 – FOLDING PARKING BRAKE
The platform cab and chassis cab versions specific to campervans may be fitted with a folding parking
brake as an option.
The parking brake on all vehicles can be replaced by a folding model. The folding parking brake reference
for ordering from the Opel dealer network is 8200727562. Upon replacement, the main cable must also be
changed.
FOLDING PARKING BRAKE
1
2
1:
Parking brake
2:
Main cable (under body)
Operating the folding parking brake:
-
To engage: pull the lever up and then release. It goes back down into horizontal position.
-
To release: while holding down the push button, pull the lever up before returning it to a horizontal
position.
up-to-date data on body guidelines (online body guidelines). Data status June 2009
3
OPEL MOVANO (X62)
56 – ROOF RACKS AND ROOF BARS
Fixing points for roof rack systems
Movano vehicles are prepared for the fitting of a roof rack, except on models with an H3 high roof. The use
of roof rack fixing points requires an inside connection and reinforcement plate between the roof and roof
strut reinforcement.
For safety reasons and to avoid damage to the roof, the vehicle approved roof rack system is
recommended. Follow the installation instructions and remove the roof rack when not in use. Driving with a
roof load increases the sensitivity of the vehicle to cross-winds and has a detrimental effect on vehicle
handling due to the vehicle's higher centre of gravity. Distribute the load evenly and secure it properly with
retaining straps. Adjust the tyre pressure and vehicle speed according to the load conditions.
N.B:
For passenger transport vehicles fitted with emergency exits in the roof, it is forbidden to block or
even partially obstruct these openings when installing roof racks or roof bars.
The following specified fixing points must be used.
L1H1 / L1H2
1- 2
3- 4
5- 6
1- 2
3- 4
5- 6
L1H2
Y (+/-)
Z
600
2177
X
1557
1617.5
2480
2540
3330
3390
4135.5
4196
L2H2
1
2
3
4
5
6
7
8
X
1557
1617.5
2397
2458
3635.5
3696
---
L1H1
Y (+/-)
Z
660.5
1979
X
1557
1617.5
2397
2458
3635.5
3696
---
7- 8
L2H2
Y (+/-)
Z
600
2177
N.B: The values are in mm and start from the axis of the front axle for the dimensions along X.
up-to-date data on body guidelines (online body guidelines). Data status January 2012
4
OPEL MOVANO (X62)
1- 2
3- 4
5- 6
7- 8
1- 2
3- 4
5- 6
7- 8
9-10
L3H2
L4H2
1
2
3
4
5
6
7
8
9
10
11
12
X
1557
1617.5
2480
2540.
3330
3390
3938
3999
4785.5
4846
---
L3H2
Y (+/-)
Z
600
2177
X
1557
1617.5
2480
2540
3330
3390
3938
3999
4785.5
4846
5435.5
5496
9-10
11-12
L4H2
Y (+/-)
Z
600
2177
N.B: The values are in mm and start from the axis of the front axle for the dimensions along X.
5
OPEL MOVANO (X62)
Roof bars
VEHICLE TYPE
L1H1
L1H2
MAX. NUMBER
OF BARS
3
L2H2
4
L3H2
5
L4H2
6
LENGTH *
MASS OF ONE
BAR *
approx. 1650 mm
approx. 2.4 kg
approx. 1530 mm
approx. 2.3 kg
MAX. PERMISSIBLE LOAD
ON THE ROOF
(All fixing points must be used)
150 kg
200 kg
*= Weight and length may vary depending on version.
ATENTION:
-
The maximum permissible mass per bar on the roof is 50kg.
-
The maximum permissible mass on the roof is 150kg for a
Van L1H1 and L1H2.
-
The maximum permissible mass on the roof is 200kg for a
Van L2H2, L3H2 and L4H2.
-
The H3-roof is made of plastic. This roof is not intended for
attaching a roof rack
Example of roof bars
Roof rack
VEHICLE TYPE
L1H1
L1H2
NUMBER OF
MOUNTINGS
2x3
MASS OF
THE ROOF RACK *
MAX. PERMISSIBLE LOAD ON
THE ROOF
(All fixing points must be used)
approx. 22,7 kg
200 kg
approx. 22,0 kg
L2H2
2x4
approx. 30,5 kg
L3H2
2x5
approx. 34,5 kg
L4H2
2x6
approx. 43,0 kg
200 kg
*= Weight may vary depending on version.
Example of roof rack
6
OPEL MOVANO (X62)
57.1 – TRAILER HITCH
A trailer hitch is available as an option for the panel van, combi models und chassis cabs; a tow bar can also
be obtained as an accessory from your Opel dealer (all models, including chassis cab).
The fitted tow bar must comply with European standard 94/20.
The permissible maximum towable, unless otherwise noted:
of a braked trailer is
2500 kg,
vehicles with a GVW of 3500kg and single wheels only.
The maximum nose weight is 100kg (vertical force
allowable on the ball/towing system).
3000 kg,
vehicles with a GWV of 4500kg, RWD and twin wheels only.
The maximum nose weight is 120kg (vertical force
3500 kg,
chassis cab with a GWV of 3500kg, RWD and twin wheels
only. The maximum nose weight is 140kg (vertical force
of an unbraked trailer is 750kg
The permissible trailer loads are specified in the vehicle documents. In general, they are valid
for gradients up to max. 12 %.
GVW = gross vehicle weight; RWD = rear wheel drive
Mounting points and fabrication tolerances are given as follows; it is essential that all these mounting
points are used.
Note:
Vehicles from MY2015 are usually equipped with a trailer stability function ( = TSF ).
This system helps improve vehicle stability when it is towing a trailer or caravan. The system
detects the oscillation being a trailer and rear brake works by alternating left / right to cancel
the oscillations.
The TSF-function is deactivated in vehicles without tow bar. When retrofitting a trailer hitch, this
function can be activated by your Opel/ Vauxhall-Service. With the diagnostic tool [GDS2] under
the option item "Trailer Brake Control" it is possible to activate this function.
In the case of a change in the rear overhang, reinforcing brackets must be added if a trailer hitch is
fitted. These reinforcing brackets will ensure the soundness of the vehicle's side member when
towing.
It may be necessary to check compliance with the regulations.
The wiring diagram for this trailer hitch is given in chapter 132.
up-to-date data on body guidelines (online body guidelines). Data status September 2014
7
OPEL MOVANO (X62)
1. Trailer hitch on panel vans
1
4
2
3
5
6
View from the bottom assembly, left side.
1:
2:
3:
4:
5:
6:
Rear left suspension
SCREW: HM12X175-55
Rear section of the rear left sidemember
Rear crossmember and skirt
trailer hitch
support trailer hitch
8
OPEL MOVANO (X62)
1.1. Front wheel drive version (Towing weight 2,5 t)
2
1
3
1:
2:
3:
trailer hitch
support left side
support right side
1.2. Single wheel rear drive version (Towing weight 2,5 t)
outside
2
1
1:
2:
3:
3
trailer hitch
support left side
support right side
9
OPEL MOVANO (X62)
1.3.
Twin wheel rear drive version (Towing weight 3 t and 3,5 t)
inside
2
1
1:
2:
3:
3
trailer hitch
support left side
support right side
10
OPEL MOVANO (X62)
2. Tow bars on chassis cabs and chassis double cabs
3
1
2
4
5
View from the bottom assembly, left side.
1:
2:
3:
4:
5:
Rear left suspension
Rear section of the rear left sidemember
Extreme rear crossmember
Support trailer hitch
Trailer hitch
11
OPEL MOVANO (X62)
2.1. Front wheel drive version single wheel (Towing weight 2,5 t)
S1 single wheel
S2 single wheel
12
OPEL MOVANO (X62)
2.2. Twin wheel rear drive version twin wheels (Towing weight 3 t and 3,5 t)
S1 twin wheels
S2 twin wheels
S1 twin wheels
S2 twin wheels
Note:
< S1 single wheel
< S2 single wheel
The short overhang chassis cab version is not compatible with the coupling devices described
above.
It may be necessary to check compliance with the regulations.
13
OPEL MOVANO (X62)
3. Dimensions trailer hitch ball
trailer hitch ball type approved at
2.5t for vehicles with a maximum permissible laden mass of 3.5t GVW.
3.0t and 3,5t for vehicles with a maximum permissible laden mass of 3,5 and 4.5t GVW
(Only for RWD with twin wheels).
3.1. Version 2,5 t
oder
oder
3.2. Version 3 t and 3,5 t
min = minimum
14
OPEL MOVANO (X62)
57.2 – INTEGRATED STEP IN REAR BUMPER
Integrated step in rear bumper for panel vans are available as an option or in after-sales.
They are compatible with tow bars.
Parts A, B and C must be installed for versions without tow bars.
1.1. Front wheel drive version
A
1.2. Rrear drive version
B - Single wheel
C - Twin wheel
up-to-date data on body guidelines (online body guidelines). Data status Mai 2011
15
OPEL MOVANO (X62)
57.2 – INTEGRATED STEP IN REAR BUMPER
Van
overall length in mm
Vehicle
length
wheelbase
drive
without
integrated step
with
integrated step
L1
3182
FWD
5048
5095
L2
3682
FWD
5548
5595
4332
FWD
6198
6245
3682
RWD
6198
6311
4332
RWD
6848
6961
L3
L4
Example for integrated step in rear bumper for rear wheel drive version (the rear parking
distance sensors are available as an option)
up-to-date data on body guidelines (online body guidelines). Data status Mai 2011
16
OPEL MOVANO (X62)
58 – DIGITAL TACHOGRAPH
Depending on the type of vehicle and the country where it is sold, the vehicle may be fitted with a digital
tachograph as standard.
It is also possible, on a vehicle not fitted with a tachograph as standard and depending on what the vehicle
will be used for, to order the tachograph as an option.
This is particularly the case in Europe for goods vehicles with a gross train weight of more than 3.5 t. It is
therefore highly recommended to offer the chronotacygraph option for vehicles ordered with the trailer
coupling option.
If the customer is exempt from the use of a tachograph , it is prudent to get him to mention this on the order
stating that he is lawfully exempt from tachograph use.
A vehicle fitted with a digital tachygraph (standard or optional) is also fitted with an CAN BUS- Interface
module (refer to chapter105- CAN BUS- INTERFACE MODULE) for reduncancy of vehicle speed information.
N.B.:
Fitting after manufacture is not possible.
TACHOGRAPH POSITION IN THE ROOF CONSOLE
up-to-date data on body guidelines (online body guidelines). Data status October 2012
17
OPEL MOVANO (X62)
59 – SUNROOF AND EMERGENCY EXIT
The roofs of some bodywork versions are marked out for cutting out and installing a sunroof and/or an
emergency exit.
SUNROOF
(Panel vans L1H1)
(L2H2 Chassis double cab)
SUNROOF AND EMERGENCY EXIT
(Panel vans L2H2, L3H2 and L4H2)
Sunroof
Emergency Exit
18
OPEL MOVANO (X62)
59 – SUNROOF AND EMERGENCY EXIT
DIMENSIONS
(Sunroof cut-out)
396
816
27
(Emergency exit cut-out)
522
33
N.B:
756
For passenger transport vehicles fitted
with emergency exits in the roof, it is
forbidden to block or even partially
obstruct these openings when installing
roof racks or roof bars.
19
OPEL MOVANO (X62)
60 – REAR AND FRONT SUSPENSION
1. Rear suspension
The vehicle’s rear suspension is created by leaf springs coupled to hydraulic shock absorbers. All rear
wheel drive vehicles and some front wheel drive versions also have an anti-roll bar.
The definition of the leaf springs varies depending on the type of vehicle and the gross vehicle weight
(GVW).
Regardless of the suspension type, it is prohibited to add an additional air cushion in the bump stop
area and between the side members.
A host structure, sized to withstand the cushion / body interface forces, must be used.
Regardless of the vehicle, do not touch the original bump stops, which are suspension parts with two
functions:
-
bump stop
-
suspension function
2
1:
2:
3:
1
3
2
Bump stop of the vehicle
air bellows
frame longitudinal member
N.B.:
The polyurethane bump stops are in constant contact with the axle and therefore contribute to the
stiffness of the rear suspension.
up-to-date data on body guidelines (online body guidelines). Data status August 2013
20
OPEL MOVANO (X62)
2. Front wheel drive vehicles
All front wheel drive vehicles are fitted with one single steel leaf spring.
2.1. Rear axle for panel van and chassis cabs
The rate of the single spring, flanged in the centre and with no articulation, is 71.7 N/mm
2.2. Rear axle for camper vans (with normal and widened tracks)
Special campervan versions with widened tracks for which the rate is 100.9 N/mm.
Note: The widened track is strictly reserved for camper vans. It is prohibited to fit this axle to any
other conversion.
2.3. Rear Axle with Pneumatic suspension
It is available for panel vans and chassis
21
OPEL MOVANO (X62)
3. Rear wheel drive vehicles
3.1. Rear axle with single wheels
All single wheel rear drive vehicles are fitted with two steel leaf springs.
The rate of the single spring flanged in the centre and with no articulation, is 89.08 N/mm for a
deflection of 0 to 80 mm and 121.14 N/mm for a deflection of 80 to 180 mm. The origin of the travel
corresponds to the spring in free state.
3.2. Rear axle with twin wheels
All twin wheel rear drive vehicles are fitted with three steel leaf springs.
The rate of the single spring flanged in the centre and with no articulation, is 72.25 N/mm for a
deflection of 0 to 100 mm and 166.22 N/mm for a deflection of 100 to 200 mm. The origin of the
travel corresponds to the spring in free state.
4. Front suspension
The front suspension is a McPherson strut type suspension.
All rear wheel drive vehicles and some front wheel drive versions also have an anti-roll bar.
The coil spring rate is 56 N/mm.
FRONT AXLE
22
OPEL MOVANO (X62)
5. If the anti-roll bar is absent
5.1. Front axle
MOVANO [X62] WITHOUT ANTI-ROLL BAR ON REAR AXLE
Front wheel
drive
Rear wheel
drive
Wheelbase
[mm]
Roof
height
H1, H2
PANEL VAN
X
3182
PANEL VAN
X
3182
Twinwheels
ESP
No
GVW
[kg]
2800
2800
5.2. Rear axle
MOVANO [X62] WITHOUT ANTI-ROLL BAR ON REAR AXLE
Front wheel
drive
PANEL VAN
Rear wheel
drive
X
X
PANEL VAN
Wheelbase
[mm]
Roof
height
Twinwheels
3182
H1
No
3682
H2, H3
No
ESP
GVW
[kg]
2800
3300
3500
X
3500
PANEL VAN
X
3182
H2
No
PANEL VAN
X
3682
H2
No
3300
COMBI
X
3682
H2
No
3300
COMBI
X
3182
H1
No
X
2800
23
OPEL MOVANO (X62)
63.1 – POWER TAKE-OFF, FRONT WHEEL DRIVE
1. Option V66
Power take-off is available as an option on front wheel drive versions. The option consists mainly of a free
pulley attached to a support in place of the air-conditioning compressor and an automatic idler pulley.
Power take-off on rear wheel drive see also chapter 63.2 and 63.3
The power take-off option is incompatible with the robotized gearbox.
The power take-off option is incompatible with air conditioning.
If a piece of equipment is not installed in place of the free pulley immediately, the free pulley can be left as
it is. Its operation has been validated for normal use of the vehicle with no change to the belt changing
frequencies.
N.B.:
It is not possible to fit power take-off to the vehicle at a later stage. However, a space is provided at the
top of the engine to fit an additional piece of equipment driven by a second belt.
FREE PULLEY
6
1
5
2
4
3
1: Alternator
2: Accessory belt
3: Free pulley
4: Crankshaft damper pulley
5: Water pump
6: Power-assisted steering pump
24
OPEL MOVANO (X62)
Care must be taken to comply with the following points for assembly minimizing the impact on engine
reliability.
-
The weight of the equipment to be fitted in place of the free pulley must not exceed 7.5 kg.
-
The equipment must use the existing fastening points on the accessory support.
-
The pitch diameter of the equipment’s drive pulley must be the same as that of the original pulley.
The pitch diameter of the engine’s free pulley is between 119.88 mm and 120.68 mm.
-
The position of the equipment’s drive pulley must match the spatial coordinates of the free pulley.
-
The alignment of the belt’s grooves must be the same as they were to start with.
-
The maximum power absorbed by the equipment replacing the engine’s free pulley should not
exceed 6 kW.
-
Characteristics of the original belt:
Type Poly-V to 7 V, width: 21.36 0.5 mm, length: 1,970 4 mm
These criteria allow the use of the original accessory belt. The belt replacement frequency must be reassessed according to the vehicle's use cycle and may differ from that stated in the vehicle maintenance
log book.
Driving a piece of equipment may call for the use of the accelerated idle.
2. After-sales assembly
This allows equipment to be fitted to a vehicle with air conditioning or to a vehicle without the power takeoff option.
An additional pulley (Kat.-No. 44 21 741) can be fitted to the crankshaft damper pulley to operate an
additional belt. Assembly of the additional crankshaft damper pulley means the original strut needs to be
removed and a new fastening screw used (Kat.-No. 44 31 161). The tightening torque is 50 Nm, plus angular
tightening of 85 6°.
The additional belt can vary from 5 to 7 V and may be elastic for which a dynamic tensioner need not be
used. Check that the additional belt is correctly lined up. The changing frequency for the additional belt
should be assessed and the user notified.
A space at the top of the engine is provided for fitting additional equipment. The fastenings for the
additional equipment support should take into account its weight. The maximum power absorbed by the
additional equipment should not exceed 6 kW.
This type of assembly is incompatible with the robotised gearbox.
25
OPEL MOVANO (X62)
ADDITIONAL CRANKSHAFT DAMPER PULLEY ASSEMBLY
9
1
8
7
2
6
3
5
4
1:
Alternator
2:
Accessory belt
3: Air-conditioning compressor
4:
Strut (to be removed)
5: Additional crankshaft damper pulley
6:
Mounting bolt
7: Crankshaft damper pulley
8:
Water pump
9:
Power-assisted steering pump
26
OPEL MOVANO (X62)
ASSEMBLY EXAMPLE
5
1
4
2
3
1 : Additional equipment
2 : Additional belt
3 : Additional crankshaft damper pulley
4:
Idler roller
5 : Additional equipment support
27
OPEL MOVANO (X62)
63.2 – POWER TAKE-OFF, REAR WHEEL DRIVE
1. Option V66
Power take-off is available as an option on rear wheel drive versions. The option is comprised only of an
additional pulley attached to the crankshaft pulley. Power take-off on front wheel drive see also chapter
63.1 and 63.2.
The power take-off option is incompatible with the robotised gearbox.
Assembly of the additional crankshaft pulley is independent of the equipment fitted to the accessory face.
The additional crankshaft pulley may be left as it is without any particular effect.
ASSEMBLY EXAMPLE
1
2
3
6
4
5
1: Crankshaft pulley
2:
Additional crankshaft pulley
3: Mounting bolt
4:
Additional belt
5: Cooling compressor
6:
Support
28
OPEL MOVANO (X62)
Care must be taken to comply with the following points for assembly minimising the impact on engine
reliability.
-
The weight of the equipment must not exceed 7.5 kg.
-
The equipment must use the existing mounting points on the engine block.
-
The equipment pulley and the additional crankshaft pulley must be aligned.
-
The maximum power absorbed by the equipment should not exceed 6 kW.
-
The additional belt can vary from 5 to 7 V and may be elastic for which a dynamic tensioner need
not be used.
-
Check that the additional belt is correctly lined up.
-
The changing frequency for the additional belt should be assessed and the user notified.
With this type of assembly, the whole equipment and support should be tested for vibratory resistance and
the additional belt for slippage, jump and longevity.
N.B.: There is no free pulley on rear wheel drive versions.
DETAIL OF THE ADDITIONAL CRANKSHAFT PULLEY
29
OPEL MOVANO (X62)
POSITION OF THE ADDITIONAL CRANKSHAFT PULLEY
IN RELATION TO THE SUPPORT’S MOUNTING POINTS
30
OPEL MOVANO (X62)
N.B.:
The three holes are threaded to a depth of 19 mm; M8 x 1.25 tapping
2. After-sales assembly
The additional crankshaft pulley (Kat.-No. 44 21 741) can be fitted post-process. Assembly of the additional
crankshaft pulley means the original strut needs to be removed and a new mounting bolt used (Kat.-No.
44 31 161). The tightening torque is 50 Nm, plus angular tightening of 85 6°.
31
OPEL MOVANO (X62)
63.3 – POWER TAKE-OFF ON GEARBOX, REAR WHEEL DRIVE
1. Power take-off (PTO) on gearbox option is available on rear wheel drive vehicles only.
The option consists of the power take-off, assembled on the gearbox, an activation button on the
instrument panel and an ECU.
The power take-off on gearbox option is incompatible with the robotized gearbox.
POWER TAKE-OFF ON GEARBOX
Power take-off (PTO) for M9T engines is a production option which must be specified by the converter
when the vehicle is ordered.
2. Power take-off production option assembly
PTO requires a ZF4*001 type gearbox and cannot be ordered with a robotized gearbox (Easytronic).
32
OPEL MOVANO (X62)
3. Power take-off/Unit interface
1:
Power take-off on ZF4 gearbox
2:
Kit to mount a unit to the power take-off.
A
B
E
2
1
C
3.1. Assembly flowchart
D
Clean mating surface (1)
Screw the studs (A) to the power take-off
Tighten to a torque of 20 ± 3 N.m
Put the sleeve into place (B)
Put into place the joint (C), unit (pump, etc.), washers (D) and nuts (E) M10x150
Tighten the nuts (E)
Torque of 50 ± 8 N.m
3.2. Mechanical properties
Maximum resulting torque
PTO weight
Drive/Engine rotation speed ratio
Max. permissible power at idle
150 N.m between 1,000 and 2,000 rpm
7,4 kg
1.091
22 kW
33
OPEL MOVANO (X62)
4. Positioning of the PTO on vehicle (±2mm).
Distance Description
(mm)
D
PTO mounting face / front axle
369,5
E
PTO mounting face / partition wall of the Panel van
1482
F
PTO mounting face / rear panel of the Chassis Cab
1615
G
PTO mounting face / rear panel of the Chassis Crew Cab
2366
Part
Description
Part
Description
1
left front side member
5
partition wall of the Panel van
2
motor
6
rear panel of the Chassis Cab
3
gearbox
7
rear panel of the Chassis Crew Cab
4
Power take-off
1
3
2
D
4
5
6
7
E
F
G
34
OPEL MOVANO (X62)
Distance Description
(mm)
A
Middle axle shaft PTO / vehicle longitudinal axis (X- axis)
B
Middle axle shaft PTO / left front side members
285,5
C
Middle axle shaft PTO / left front side members
61,5
Part
176
Description
1
left front side member
3
gearbox
4
Power take-off
3
A
1
C
B
4
PTO mounting face
Middle axle shaft PTO
35
OPEL MOVANO (X62)
5. Position from the PTO and its control unit
2
3
Part
1
Description
1
Power take-off
2
control unit (ECU) of Power take-off
3
engine interconnections unit (= BIM can be found to the left of the
engine compartment)
36
OPEL MOVANO (X62)
65 – PREPARING FOR COLD REGIONS
The vehicle is adapted to extreme cold configuration by modifying or adding the following elements:
- Coolant
- Windscreen wash
- Addition of protective parts
Engine coolant
Drain the circuit and refill with a mixture of 5.5 litres of coolant and 5.5 litres of demineralised water.
Windscreen wash
Vehicles manufactured between April 1 and July 31 are delivered with a screen wash composed of
20% washer liquid and 80% demineralised water.
Outside of these dates, the vehicles are delivered in extreme cold (-20°C) configuration (45%
Antifreeze & clear view liquid and 55% demineralised water).
Front brake disc protection
Front brake disc protection must be added for extreme cold vehicles:
Front left:
Front right:
The addition of disc protection also protects the steering ball joint cover.
up-to-date data on body guidelines (online body guidelines). Data status November 2009
37
OPEL MOVANO (X62)
67 – FUEL SUPPLY SYSTEM
1. Fuel tank capacity
The mass production vehicle is delivered with an 80 litre fuel tank. A fuel tank with a capacity of 100
litres is available as an option. From the outside, the two tanks are identical. It is not possible to
modify the capacity of the fuel tank.
Any modification to the fuel tank will require the converter to apply for a new type approval.
Precaution
If disassembling and re-assembling the fuel tank, it is essential to maintain the assembly order of the
fuel tank straps on the front zone.
The vertical strap must be positioned above the strap that holds the fuel tank in place.
Retaining straps
Vertical strap
up-to-date data on body guidelines (online body guidelines). Data status December 2010
38
OPEL MOVANO (X62)
100 and 80 litre fuel tank - REAR WHEEL DRIVE - Left-hand drive
2
4
6
3
1
5
100 and 80 litre fuel tank - REAR WHEEL DRIVE - Right-hand drive
2
6
3
4
1
5
1: Filler pipe
2: Tank
3: Engine supply pipe
4: Diesel filter
5: Vapour absorber pipe
6: Intake assembly
39
OPEL MOVANO (X62)
100 and 80 litre fuel tank - FRONT WHEEL DRIVE - Left-hand drive
2
4
6
3
1
5
100 and 80 litre fuel tank - FRONT WHEEL DRIVE - Right-hand drive
2
6
3
4
1
5
1: Filler pipe
2: Tank
3: Engine supply pipe
4: Diesel filter
5: Vapour absorber pipe
6: Intake assembly
40
OPEL MOVANO (X62)
2.
Precautions for assembly and disassembly
2-1 Fuel tank
If disassembling and re-assembling the fuel tank, it is essential to maintain the assembly order of
the fuel tank straps on the front zone.
The vertical strap (1) must be positioned above the strap (2) that holds the fuel tank in place.
3
1
2
1
2
1: Vertical strap
2: Front support strap
3: Rear support strap
41
OPEL MOVANO (X62)
2-2 Regulatory tank guard
This protective guard around the tank is subject to Regulation ECE 34 and
concerns the fire resistance of the fuel circuit.
Any modification or removal of this guard must comply with this directive.
For information:
On all the CHASSIS CAB vehicles (except the double cab), carry-over of the fuel tank guard element.
This measure is identical for TRACTION HEADS when the standard fuel tank is carried over onto a specific
chassis developed by a coach-builder.
Fuel tank guard
42
OPEL MOVANO (X62)
68 – EXHAUST SYSTEM
Modification of the exhaust pipe:
The exhaust lines for the MOVANO versions are designed for output below the vehicle.
The architecture of the MOVANO has been designed to maintain the vehicle's ground clearance and
to direct the exhaust gases downwards.
Any modification may result in alteration of the vehicle's type approval (engine power, noise or
exhaust emissions). The body builder is entirely responsible for carrying out this type approval.
A
B
C
A=
B=
C=
Rear attachment of the silencers
Front attachment of the silencers
Connection clamp
up-to-date data on body guidelines (online body guidelines). Data status March 2010
43
OPEL MOVANO (X62)
D
E
On the A and B attachments:
- Respect the parallelism between the 2 hooks (body and line), see reference D.
- Check that the internal clearances of the 2 flexible exhaust mounts are indeed identical, see
reference E.
Exhaust clamp:
The exhaust clamp must be changed for a new one.
Depending on the tooling used for tightening the connection clamp, apply the following procedure:
- with an automatic screw driving machine (plant type and not impact type tooling) tighten to 21 Nm
- during manual tightening, it must be carried out as linear as possible, without sudden pickup.
Tightening stops when the X clearance between the clamp ends is between 3.6 mm and 6.3 mm
(which correspond to a torque of approximately 18 Nm).
X
44
OPEL MOVANO (X62)
EXHAUST LINE ENGINE M9T 74 / 92 / 110 KW Euro 4
Front and rear wheel drive version.
45
OPEL MOVANO (X62)
EXHAUST LINE ENGINE M9T 74 / 92 / 110 KW Euro 5
Front and rear wheel drive version.
46
OPEL MOVANO (X62)
69 – BRAKE SYSTEM
Irrespective of the version, there is only one power brake system of 10 inches. The power brake system is
located on the left for left-hand drive vehicles and on the right for right-hand drive vehicles.
ESP is available as an option on front wheel drive versions.
For more information, see also Chapter 114
-
A sufficient distance must be maintained between brake lines and heat sources, sharp-edged or
moving parts.
-
If the routing of the brake hoses, lines and cables has to be altered, avoid routing across sharp
edges and through narrow cavities or near moving components
-
No other lines may be attached to brake hoses.
-
The brake cables must be routed without kinks.
-
Cover plastic lines, brake hoses and brake cables before carrying out any welding, drilling and
grinding work or before working with cutting discs. If necessary, the plastic lines, brake hoses and
brake cables should be removed.
N.B:
On no account should modifications be made to brake callipers, discs, sensors etc. Any
modifications to brake components may result in these systems not functioning correctly and
ultimately failing.
The ESP option is not compatible with large-scale bodywork modifications and prohibits any
major modifications to the vehicle's load distributions or centre of gravity.
Work carried out incorrectly on the brake hoses, lines and cables may impair their function. This
may lead to the failure of components or parts relevant to safety.
47
OPEL MOVANO (X62)
69 – BRAKE SYSTEM
LEFT-HAND FRONT WHEEL DRIVE / ABS / ESP*
1
4
2
7*
5
3
6
RIGHT-HAND FRONT WHEEL DRIVE / ABS / ESP*
7*
1
4
2
5
3
1:
2:
3:
4:
5:
6:
7:
Master cylinder and ESP/Emergency brake assist booster M/CYL 10/10 27-0
Left power brake system pipe
Primary master cylinder rigid tube - ABS
6
Secondary master cylinder rigid tube - ABS
ABS / ASR / ESP* Hydraulic Block
ABS / ASR / ESP*Hydraulic block support
ESP - sensor *
*= Vehicles with ESP only
48
OPEL MOVANO (X62)
69 – BRAKE SYSTEM
Engine cover – All types version
1: FR RH WHEEL ABS BRAKE RIGID TUBE
2: FR LH WHEEL ABS BRAKE RIGID TUBE
3: RR LH SENSOR ABS BRAKE RIGID TUBE
RR RH SENSOR ABS BRAKE RIGID TUBE
4: BRAKE RETAINER
2
1
4
3
4
Under-body circuit – Wheelbase 1, front wheel drive panel van version
4
5
1
2
5
1.
2.
3.
4.
5.
RR LH SENSOR ABS BRAKE RIGID TUBE
RR LH INTM BRAKE RIGID TUBE
RR RH INTM BRAKE RIGID TUBE
RR LH WHEEL SENSOR BRAKE RIGID TUBE
RR RH WHEEL SENSOR BRAKE RIGID TUBE
BRAKE RETAINER
3
49
OPEL MOVANO (X62)
69 – BRAKE SYSTEM
4
1
1.
2.
3.
4.
5.
BRAKE RETAINER
5
2
4
3
5
1.
2.
3.
4.
5.
BRAKE RETAINER
50
OPEL MOVANO (X62)
69 – BRAKE SYSTEM
Under-body circuit – Wheelbase 2, front wheel drive chassis cab version
4
5
2
1
5
3
1.
2.
3.
4.
5.
BRAKE RETAINER
Under-body circuit – Wheelbase 3, front wheel drive chassis cab version
4
1
2
5
5
3
1.
2.
3.
4.
5.
BRAKE RETAINER
51
OPEL MOVANO (X62)
69 – BRAKE SYSTEM
Front left-hand wheel sensor calliper – All types version
1
2
3
1: FRONT WHEEL SPEED SENSOR
2: FR BRAKE HOSE
3: FR RH BRAKE DISC DIAM 48/48 DSQ 302x28
Front right-hand wheel sensor calliper – All types version
1
3
2
1: FRONT WHEEL SPEED SENSOR
2: FR BRAKE HOSE
3: FR RH BRAKE DISC DIAM 48/48 DSQ 302x28
52
OPEL MOVANO (X62)
69 – BRAKE SYSTEM
Rear left-hand wheel sensor calliper – All types version
1: RR LH BRAKE DISC DIAM 48 DSQ 305/12
2: RR WHEEL SPEED SENSOR
3: HOSE SUPPORT LUG
4: RR BRAKE HOSE
Rear right hand wheel sensor calliper – All types version
1: RR LH BRAKE DISC DIAM 48 DSQ 305/12
2: RR WHEEL SPEED SENSOR
3: HOSE SUPPORT LUG
4: RR BRAKE HOSE
53
OPEL MOVANO (X62)
78 – TRANSLATION OF THE FUEL TANK FILLER PIPE
Some conversions require translation of the fuel tank filler pipe.
The following recommendations can be used to offset, by up to 150 mm, the position of the filler pipe along
the Y axis. However, the position along the X and Z axes cannot be modified.
To carry out the translation, the standard connecting sleeve between the tank and the filler pipe needs to
be replaced with a special sleeve.
EXAMPLE OF SLEEVE
388 MAX
188
L
A
1
39
110
39
39
39
39
2
43.8
A
4
A-A
1:
Fuel tank side
L:
From 0 to 150 mm
2: Filler pipe side
The sleeve material must be compatible with its use.
The sleeve must be held in place on the filler pipe and on the fuel tank by elastic reserve clamps.
Assembly must comply with legislation in force, in particular Directive 70/221/EEC and Directive 2000/8/EC
for Europe: For two minutes, the fuel system (tank, pipe, sleeve) fixed as on the vehicle, must be exposed to
flame. There must be no leakage of fuel. Three tests must be carried out on three different tanks half filled
with fuel. It may be possible to thermally protect the filler sleeve to avoid the need for the flame test.
When fitted, the sleeve must not be twisted or trapped in such a way that might hinder filling.
The filler pipe must be held in place and the place where it passes through the floor must be sealed.
For translations of more than 60 mm, the body needs to be cut. After cutting, the filings or shavings must be
vacuumed and a corrosion inhibitor used; please refer to the “Specific Corrosion Guidelines”.
54
OPEL MOVANO (X62)
78 – TRANSLATION OF THE FUEL TANK FILLER PIPE
STANDARD ASSEMBLY
2
1
3
TRANSLATION OF THE FILLER PIPE
2
1
3
4
1:
Fuel tank
2: Filler pipe
3:
Sleeve
4: Area of body to be modified
55
OPEL MOVANO (X62)
79 – MAXIMUM AUTHORIZED LOAD PER AXLE
The maximum authorized load per axle depends on the version and the gross vehicle weight (GVW).
The values are given in the table.
GVW
(kg)
Front axle
(kg)
Rear axle
(kg)
Front wheel drive
2800
1550
1650
Front wheel drive
3300
1650
1900
Front wheel drive
3500
1850
2100
Single wheel rear drive
3500
1850
2300
Twin wheel rear drive
3500
1850
2800
Twin wheel rear drive
4500
1850
3200
After vehicle conversion, the weight per axle must be lower than the maximum authorised loads and the
vehicle weight must be lower than the maximum authorised laden weight.
N.B.:
The maximum authorised loads per axle and the gross vehicle weight are shown on the
manufacturer’s plate.
In order to ensure the directional stability and traction of the vehicle, Opel/Vauxhall recommends a weight
ratio (minimum weight on front axle) / (total converted vehicle weight when laden) in excess of:
- 30% for rear-wheel drive vehicles
- 40% for front-wheel drive vehicles
These conditions can be more restrictive than the maximum regulatory technical axle values in the table
above.
For more information on the compliance with the Centre of Gravity position, refer to the chapter 148 Determining the Centre of Gravity and chapter 40 - Limit of conversions with ESP.
56
OPEL MOVANO (X62)
142 – CHERRY PICKER ON PANEL VAN
With two side stabiliser jacks
During a platform conversion, the panel van vehicle may have to be fitted with two side stabiliser jacks.
The stabiliser jacks must under no circumstances be able to lift the vehicle with the wheels in suspended
position. During the stabilization and horizontal adjustment phase, the relief for the suspension system
must be limited to the minimum.
For platform conversions on FWD and RWD Chassis Cabs and Chassis Double Cabs, see Chapter 143prohibited conversion types-X62.
up-to-date data on body guidelines (online body guidelines). Data status April 2010
57
OPEL MOVANO (X62)
143 – PROHIBITED CONVERSION TYPES
The following conversions are not allowed:
1. Cherry picker conversion on FWD and RWD Chassis Cabs and Chassis Double Cabs
For conversion on panel vans, see chapter 142 - Cherry picker -X62.
2. Transformation allowing the lifting of vehicle (Unballasting of axles)
For the adaptation of type : stabilizers and jacks.
3. TRACTOR conversion on the entire range
58
OPEL MOVANO (X62)
146 – LIFT TAILGATE
The Movano can be fitted with a lift tailgate.
Fitting a tailgate precludes the fitting of a Opel/Vauxhall towing system. When installing a new coupling,
it is necessary to plan for a validation, in compliance with regulatory requirements.
Permitted masses
The maximum load + tailgate mass can vary between the vehicles in the range.
The maximum lifting capacity of the tailgate must not exceed 500kg.
It depends on the type of vehicle and the type of tailgate bearing structure.
In all cases, and particularly in the case of vehicles without an additional chassis, the loading gate
mounting system must include a structure that allows forces to be distributed over the vehicle’s chassis.
Lift tailgate maximum
lifting capacity
Panel Van
ChassisCab
Platform Cab
Lift tailgate maximum
lifting capacity
+
Tailgate mass
500 kg
700 kg
Max. load to be determined by the coachbuilder
according to the type of mounting.
Mounting on a built-on structure is advised.
Max. load to be determined by the coachbuilder
according to the type of mounting.
The absence of an upper structure (rear ring) limits the
maximum permissible load on the tailgate
NB:
The converter shall be solely responsible for any changes made.
For all versions, the converter shall ensure that the lifting tailgate does not adversely
affect the integrity or reliability of the basic vehicle.
59
OPEL MOVANO (X62)
148 – DETERMINING THE CENTRE OF GRAVITY
The vehicle's centre of gravity after conversion can be determined:
- by measurement
- by calculation.
1.
DETERMINING THE CENTRE OF GRAVITY POSITION BY MEASUREMENT
1.1. X and Y position
The x and y position of the centre of gravity is determined by measuring the mass on each
wheel and calculating the barycentre.
S
Gv1
Gh1
H
Rsc
Xv1
Xh1
ES1
S
E
v
h
H
Rsc
= centre of gravity
= Wheelbase
= Front axle
= Rear axle
= Height of centre of gravity
= Loaded radius of the tyre, axle not raised (in m)
60
OPEL MOVANO (X62)
1.2. Z position
The Z position of the centre of gravity is determined by measuring the variation in mass on one axle. The
vehicle is weighed horizontally, and then inclined at an angle .
H = Height of the centre of gravity in relation to the floor (in m)
Rsc
E
M
Mtot
= Loaded radius of the tyre, axle not raised (in m)
= Wheelbase (in m)
= Radial force variation measured on the axle (in kg)
= Total vehicle mass (in kg)
= Vehicle lift angle (in rad)
S
Gv2
Gh2
XV2
Xh2
ES2
61
OPEL MOVANO (X62)
The measurement requires the following precautions to be taken:
-
no moving fluids => tank completely empty or completely full
-
Tyres overinflated to the maximum permitted level (to minimise loaded radius variations)
-
Front and rear suspensions locked
-
the brakes (service and handbrake) MUST NOT be applied
-
in order to obtain a reliable measurement, the vehicle must be lifted at an angle of at least 20°
-
either the front or rear axle may be lifted
2. DETERMINING THE CENTRE OF GRAVITY POSITION BY CALCULATION
The converted vehicle's centre of gravity is determined by calculating the barycentre between the centre
of gravity positions of the basic and converted vehicles.
Comments on the information in the table below:
-
The centre of gravity position is given in the vehicle reference guide and in relation to the floor
where the Z dimension is concerned (indicated as ‘Z (mm)/floor' in the table)
-
The positions are given for the extremes (vehicle with no options and with all options).
It will be necessary to interpolate for an intermediate vehicle.
Glossary:
- TRS:
- PRS:
- PRJ:
- E1-3:
- P1-2:
-
H1-3:
D1-2:
EURO 5:
t:
front-wheel drive vehicle
rear-wheel drive vehicle with single-wheel
rear-wheel drive vehicle with twin-wheel
wheelbase (from 1 to 3)
E1 = 3182 mm
E2 = 3682 mm
E3 = 4332 mm
rear overhang (1 and 2)
P1* = short
P2* = long
roof height* (from 1 to 3)
Motor (1 - 2)
emissions compliance
Tons (Weight for GVW 2,8 / 3,3 / 3,5 / 4,5)
= For the corresponding values, refer to the Chapter 7
62
OPEL MOVANO (X62)
MIN. UNLADEN
(no options)
PANEL VAN
Vehicle variant
PRS-E2P2H2 EURO5 D1/D2 3,5t
PRS-E2P2H3 EURO5 D1/D2 3,5t
PRJ-E2P2H2 EURO5 D1/D2 4,5t
TRS-E1P1H1 EURO5 D1/D2 2,8t
X (mm)
Y (mm)
Z (mm) /
floor
X (mm)
Y (mm)
Z (mm) /
floor
1690
1702
1750
1758
2045
2056
1183
1179
1183
1194
1191
1195
1370
1374
1633
1651
1355
1359
-26
-26
-25
-24
-18
-18
-29
-29
-29
-29
-29
-29
-31
-30
-30
-29
-31
-31
858
881
831
852
843
867
806
805
809
833
831
835
854
858
766
877
832
836
1793
1802
1840
1846
2123
2132
1296
1293
1296
1307
1304
1307
1447
1451
1732
1744
1469
1472
-30
-30
-28
-28
-23
-23
-17
-17
-17
-17
-17
-17
-21
-21
-35
-35
-35
-35
850
867
830
847
840
858
802
801
805
826
825
829
829
833
842
853
823
827
MIN. UNLADEN
(no options)
PLATFORM CAB
Vehicle variant
TRS-E1P1H1 EURO5 D2 3,5t
MAX. UNLADEN
(all options)
X (mm)
Y (mm)
954
954
1103
1101
861
-35
-35
-35
-34
-35
Z (mm) /
floor
702
712
697
706
705
MAX. UNLADEN
(all options)
X (mm)
Y (mm)
981
980
1129
1127
886
-44
-44
-44
-44
-34
Z (mm) /
floor
697
706
693
701
700
63
OPEL MOVANO (X62)
CHASSIS CAB
MIN. UNLADEN
(no options)
Vehicle variant
X (mm)
Y (mm)
PRJ-E2P2 EURO5 D1/D2 4,5t
PRJ-E2P1 prime EURO5 D1/D2 4,5t
PRS-E2P1 EURO5 D1/D2 3,5t
TRS-E2P1 EURO5 D1/D2 3,5t
1439
1620
1395
1312
1507
1044
1179
-25
-18
-26
-29
-25
-33
-30
CHASSIS CREW CAB
Vehicle variant
MAX. UNLADEN
(all options)
Z (mm) /
floor
697
695
700
717
718
707
709
X (mm)
Y (mm)
1440
1617
1436
1318
1508
1101
1242
-33
-26
-33
-36
-33
-42
-38
MIN. UNLADEN
(no options)
Z (mm) /
floor
699
696
698
716
717
700
701
MAX. UNLADEN
(all options)
X (mm)
Y (mm)
Z (mm) /
floor
X (mm)
Y (mm)
Z (mm) /
floor
1485
1658
1409
1520
1178
1227
-24
-17
-24
-26
-27
-31
734
736
765
756
759
750
1484
1653
1409
1520
1220
1280
-31
-24
-31
-34
-35
-38
732
735
762
753
748
741
N.B.:
The floor specified in the tables is an unladen floor in running condition.
X, Y and Z refer to the fixed reference system in the vehicle, see Chapter 6
Other important measurements are in the Conversion Guideline, Part 1, Chapter 7
64

Conversion Guideline Opel Movano [ X62 ]

Transcription

Similar documents

Tactair Paris Air Show Evite 2015

VL-Whisper - Clay

2013 KX85 II Model Information

FREELINE BRAKES - Pg. 1

Heretic C SPECS.ai - ECOSSE | Moto works

compact wheel loaders

Heretic Ag SPECS.ai - ECOSSE | Moto works

Bulletin BPI-01 - Raybestos Brakes

PERSONAL TRANSPORTATION VEHICLE

VRSCDX V-Rod® 10th Anniversary Edition GASSER Wheel