program product improvement - iveco link

1 03 October 2016 CNHi internal user EN

Product ImprovementProgram

BINDER: TRUCK PAGE:1 / 11

FILE UNDER: Daily DATE: 03 October 2016

ISSUE NUMBER: ISSUED BY: Quality & Product Support

REPLACES: BULLETIN NUMBER: 2016 - 027 TRUCK M PIP

SERIES: Daily MY 2016 Minibus - Daily MY 2016 - Daily MY 2014Minibus - Daily MY 2014 - Daily MY 2016 Natural Power -Daily MY 2014 E.E. Euro III - Euro 4 - Daily MY 2014 CNG- Daily MY 2014 Minibus EIII - Daily MY 2016 MinibusNatural Power

GROUP - SUBGROUP -DEFECT:

50 27 22

SUBJECT: CHECK SECONDARY HAND BRAKE CABLES

PROGRAM TYPE PROGRAM CODE TERMINATION DATE

MANDATORY SAFETY 5T6 31 October 2017

SPECIAL INSTRUCTIONS

The instructions contained in this bulletin are identical to those of bulletin for the PIP 5T7 with the only difference thatthis one is aimed at vehicles with mechanical gearbox.

This bulletin includes the Customer letter template to distribute in accordance to the local market procedures.

OVERVIEW

IVECO announces this Product Improvement Program to improve operative performances of the parking brake

For the information on how to perform this Product Improvement Program update, see the service instructions at theend of this bulletin.

Carry out this Product Improvement Program on all affected vehicles as a priority.

ACTION

Production

The new secondary hand brake cable with Steel terminals is effective from product identification number: VIN Suzzara5119783 VIN Valladolid D572545 .

Vehicles involved

Find your list of affected vehicles for this Product Improvement Program in SAP dealer portal.


You can search for a Product Improvement Program and see the details in the SAP dealer portal “REPAIR” menu.Details on the Product Improvement Program contain two "sub-folders":

• The sub-folder “Position”: This sub-folder shows the reference information of the work (material and/or workunits) for the searched Product Improvement Program in the “Repair” search item.

• The sub-folder “Vehicles”: This sub-folder shows information on:

○ Chassis involved with the repairs and associated with the Dealers that are performing access

○ Information on vehicle repaired/to repair

○ Customer Information (Data taken from Vehicle Management/VELO)

○ Date that letter to customer was sent (fields that the Dealer may fill out for a personal log)

If a vehicle present on the list has obtained the updates in a previous intervention covered by a warranty, DO NOTUPGRADE the vehicle again. Contact your local service representative. Provide the vehicle details to remove thevehicle from the Product Improvement Program. These details must include the relevant warranty claim.

Identify all the units that fall under the responsibility of you own dealership. The units must include:

• All your new units in transit

• All your stock units

If any known vehicle within this Product Improvement Program becomes the responsibility of your dealership, carryout the listed rework action.

If any known vehicle within this Product Improvement Program is no longer in your area of responsibility, inform yourlocal service representative. Provide all details relative to the unit. Where possible, provide the new location of thevehicle.

PARTS INFORMATIONNOTE: Use ASIST to order the kit required for this Product Improvement Program. Click on the following link forfurther information on how to order the kit through ASIST : SERVICE BULLETIN (-H.10.A.10) .

Model/Versions Description Quantity Current PartNumber

Daily MY 2014, Daily MY 2016

, 40C / 50C

The kit consists of two handbrakecables part number 5802235434

1 MPT005T6A


, 65C / 70C


1 MPT005T6B

CLAIM FILING INSTRUCTIONS:NOTE: Only submit one warranty claim per machine for this Product Improvement Program. This claim must includeall the relevant levels of the involved rework actions.

"Failures" section:

Defect code: 0005027225T61 Warranty Type: H

"Item data" section:

Causal part: 504347504

Model/Versions Description Code LabourDaily MY 2014, Daily MY 2016,

Check type of handbrake ca-ble mounted on the vehicle. -50272A5T6 1 WU


Model/Versions Description Code Labour 40C / 50C 65C 70C

Daily MY 2014, Daily MY 2016,

40C / 50C 65C 70C

Replace the handbrake sec-ondary cables and park-

ing brake adjustment.-50272B5T6 5 WU

TERMINATION DATE

Complete the rework action of this Product Improvement Program by 31 October 2017 . All the claims for this ProductImprovement Program must comply with the standard claiming policies for your region.

DISPOSAL OF REMOVED PARTS

IVECO does not require you to return the parts. See the latest version of the Warranty Policy Manual for instructionson the period that you must keep the removed parts. Make sure that the removed parts are unusable prior to disposal.


General InstructionAPPROVED PRODUCT IMPROVEMENT PROGRAM UPDATE TIME(S)

• Checking the type of secondary handbrake cable fitted to the vehicle: 0.1 h

• Replacing secondary handbrake cables and parking brake adjustment: 0.5 h

On vehicles manufactured before the following chassis numbers ( Suzzara 5062897 and Valladolid D554487 ) thetype of handbrake cables fitted to the vehicle must be checked; if manufactured subsequently, directly replace thesecondary handbrake cables.

UNIT PREPARATION

NOTE: The left side, right side, front, and back of the vehicle are referenced as standing behind the vehicle facinga normal direction of travel.


Service InstructionsPARTS INFORMATION

Model/Versions Description Quantity Current PartNumber


, 40C / 50C


1 MPT005T6A


, 65C / 70C


1 MPT005T6B

Procedure for checking the type of hand brake sec-ondary cable fitted to the vehicle.

On the vehicle can be mounted different types of sec-ondary brake cables:

1. Handbrake cables with Zinc / Aluminium alloy termi-nals, identifiable by bellows (1) and heat-shrink (2)present on the cable in the secondary hand brake ca-ble area connecting to the main cable.

BAIL16PIP0868AA 1

2. Handbrake cables with steel terminals, without bellowsand heat-shrink and in the area of the secondary handbrake cable connection to the main cable.

BAIL16PIP0869AA 2


Place the vehicle on a bridge crane and check (in thearea of the secondary handbrake connection cableswith the primary hand brake cable) the type of ropes fit-ted onto the vehicle by comparing them with the photospreviously attached.

BAIL16PIP0870AA 3

If the vehicle is fitted with handbrake cables with steelterminals, no type of operation is necessary.

If instead, handbrake cables are present with Zinc /Aluminium alloy terminals, replace the two secondaryhandbrake cables with those in KIT, as follows.

Secondary handbrake cables replacement procedure:

Remove the two retaining seeger (3) secondary brakecables from the designated housing positioned on thechassis cross member and save them for subsequentuse.

BAIL16PIP0956AA 4

Loosen lock nut (4) to allow the removal of the termi-nals of the secondary brake cables (5) of tensioner (6) .

BAIL16PIP0872AA 5


Remove from the hooking seat for rear left brake cable,the protection plug (7) and save for subsequent use

BAIL16PIP0873AA 6

Disconnect eyelet (8) of the handbrake cable on lefthand brake lever and remove the left side secondarybrake cable from the vehicle.

BAIL16PIP0874AA 7

Use a handbrake cable ordered with the specific kit andinsert it in the rear axle seat (9) ; Connect hand brakecable eyelet on left brake lever.

BAIL16PIP0867AA 8

Use the previously removed plug and place it into itsseat.

Move to the right of the vehicle for:

Removing from the hooking seat for the rear right brakecable, the protection plug and storing it for subsequentuse.

Disconnect handbrake cable eyelet cable on right handbrake lever and remove the right side secondary brakecable from the vehicle.

Take the second handbrake cable ordered with the spe-cific kit and insert in the seat of the rear axle; Connecthand brake cable eyelet on the right brake lever.


Use the previously removed plug and place it into itsseat.

Position the two handbrake cables in the appropriateretaining housing present on chassis cross memberand secure it with the two retaining seeger ring (10)previously removed.

BAIL16PIP0956AA 9

Insert the terminals of the secondary brake cables(11) in tensioner (12) and adjust the parking brake.Clearance compensation is not automatic, therefore,for slight lever stroke extensions (corresponding to ap-proximately 2 notches beyond the normal lever strokewhich is of 7 notches) adjustment is possible by meansof the tensioner as described below

BAIL16PIP0872AA 10

Lift the rear of the vehicle, resting the chassis frame onthe specific support stands.Loosen lock nut (13) .Set the parking brake lever in the cab onto its thirdcatch.Tighten tensioner screw (14) until resistance is felt inturning the rear wheels by hand.Operate for three / four times the lever in the cab to set-tle the parts, then check whether the stroke is approx.of 6 steps.Tighten lock nut (13) . The tightening torque to be ap-plied is of 18.0 - 22.0 N·m ( 13.3 - 16.2 lb ft ) .

BAIL16PIP0955AA 11

Lower the vehicle .

FAQ - RECALL to control the secondary cable of the parking brake.

• Which vehicles are involved?

Daily MY 2014 40C / 50C / 65C / 70C and Daily MY 2016 40C / 50C / 65C / 70C. Produced from September 2015to July 2016.


• How do I know if my vehicle is subject to the recall campaign?

The owners of the vehicles involved in the campaign will be notified by registered post with proof of receipt. However,it is possible to contact any IVECO authorised dealer or workshop to check whether the vehicle is involved in thecampaign.

• Why are these models subject to the recall campaign? What is the problem?

It is possible that the eyelet of the secondary cable of the parking brake may break.

• Are there any risks?

Hi-Matic gearboxes: The eyelet breakage of the secondary cable of the parking brake does not compromise the brakefunction thanks to the presence of an internal locking device.

Mechanical gearboxes: Can it affect correct operation of the parking brake.


• Is it safe to drive the vehicle?

Hi-Matic gearboxes: The vehicle can be driven safely but it is important that it is checked if it is part of the campaign.If there are abnormal conditions when using the handbrake, contact any IVECO authorised dealer or workshop.

Mechanical gearboxes: Until the components in question have been checked (and any components have been re-placed), the vehicle can be used safely provided that when it is parked on an incline, the vehicle is left in gear and/or the wheels are positioned as indicated in the section "Start-up and driving / Parking brake use" in the "USE ANDMAINTENANCE" manual. Also make sure that all the drivers / vehicle users are notified of this procedure.

• Have any problems occurred up to now?

IVECO has not reported accidents related to the parking brake secondary cable eyelet breaking since production ofthe vehicles involved in this campaign.

• What do I have to do if my vehicle is part of this recall campaign?

Contact your IVECO authorised workshop as soon as possible to arrange for the vehicle to be inspected in order toestablish whether the parking brake secondary cable needs to be replaced.

• As of when can the repair intervention be arranged?

The repair intervention will be arranged starting from XX.XX.20XX

• Why will the intervention be arranged starting from XX.XX.20XX?

The supplier of the parking brake secondary cable is currently working on a new component made of different materialto prevent the eyelet from breaking.

• Do I have to take my vehicle to the same dealer I bought the vehicle from or can I go toanother dealer?

To carry out the intervention in this campaign you can contact any IVECO authorised dealer or workshop. Rememberthat our dealers can only intervene on your vehicle upon appointment is made starting from XX.XX.20XX.

• How long will the intervention last?

The intervention for replacing the parking brake secondary cable lasts approximately 1 hour. However, depending onthe dealer's requirements, the vehicle may need to be left longer.

• Is there a cost associated with the intervention?

No, there is no cost involved. The maintenance intervention is completely free of charge if carried out by an IVECOauthorised dealer.

• I have already arranged for this intervention to be carried out in a specialised workshop.What do I need to do?

It is important that the vehicle is checked by an IVECO authorised dealer. Remember that our dealers work on anappointment basis. The appointment can be made starting from XX.XX.20XX. Therefore, we recommend that yourvehicle is checked by an IVECO authorised workshop.

• Can I arrange for the intervention to be carried out in a specialised workshop?

Repairs carried out in a specialised workshop will not be officially recognised since the appropriate repair procedurecannot be verified therefore, IVECO will not be responsible for the quality or suitability of the service.

• My vehicle is part of the campaign and the fault has occurred. What do I need to do?

If the brake secondary cable eyelet has broken, contact an IVECO authorised dealer for assistance.

• Where can I find an IVECO authorised dealer?

To find an IVECO authorised dealer, go to: http://www.iveco.comGlobal Product Support

IVECO

c. a.

REGISTERED LETTER WITH RECEIPT OF RETURN

Subject: 5T6 Title: CHECK SECONDARY HAND BRAKE CABLES

Dear client, We hereby wish to inform you that, as a result of regular quality controls and performance testing on our vehicles, itemerged that the parking brake cable on your vehicle may require replacement. The eyelet connection of the parkingbrake secondary cable could break. Should this occur, the breakage will affect the parking brake functionality.

Please contact your authorised IVECO service centre as soon as possible for an appointment to inspect and deter-mine if your vehicle is one of the affected batch and requires replacement of the above-mentioned cable.

If this replacement is necessary, your authorised IVECO dealer will supply the spare parts necessary and will under-take the replacement FREE OF CHARGE; and in the shortest possible time.

Until such time as this important inspection and for those affected vehicles replacement of the spare parts involved,the vehicle can operate in safe mode provided that the first or reverse gear is left engaged and/or the wheels arechocked in compliance with the instructions in paragraph Use of the Parking Brake under the Starting up and Drivesection in the use and maintenance manual whenever the vehicle is parked on an incline.

Please ensure that drivers / operators of the vehicle are made aware of this operating procedure.

Should you fail to comply with this letter we reserve the right to bring it to the attention of any interested party shouldthere be a subsequent claim for personal injury or property damage.

If the vehicle has been sold or scrapped, please fill out the form on the back of this letter and return it to us.

Thank you. Kind regards,

Iveco S.p.A.Via Puglia 35

10156 Turin, Italy

Tel. +39 011 00.72111

Fax +39 011 00.74555 - 00.74905

sole shareholder

Management and Coordination as per Art. 2497 of the Italian Civil Code: Fiat Industri-

al S.p.A.

Registered office: Via Puglia 35, 10156 Torino, Italia

Fully paid-up share capital: EUR 200,000,000

C.F., VATIN and Commercial Register no. 09709770011 - REA 1074767

Subject: 5T6 Vehicle:

Please complete the section below with information regarding the new owner if the vehicle has been sold or transferredto a third party, or call the number .

Surname ________________________________ Name ____________________________

Address __________________________________ Nº _____

Post code _________ City/Loca-tion

_____________________________________________

Country __________________________________

Company name _______________________________________________________________

Tele-phone

__________________

Sold on _____ / _____ / ______

If the vehicle has been stolen or scrapped, please mark the relevant box.

Vehicle stolen Vehicle scrapped

Date _____ / _____ / ______ Signature ____________________________

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