Swift Group Bolero 712SB / E572 Tech Handbook

Swift Group
Dunswell Road
Cottingham
East Yorkshire HU16 4JX
Tel 01482 875740
Fax 01482 840082
email [email protected]
Bolero / E500
Tech Handbook
For more information visit
www.swiftgroup.co.uk
Issued July 2012
1401809
Contents
Standard Specifications .............................................................. 2
Optional Specifications ............................................................... 4
Capacities .................................................................................... 7
Towing Capabilities ..................................................................... 8
Jacking ...................................................................................... 10
Wiring Diagrams ........................................................................ 11
Bulb Chart.................................................................................. 17
Bulb Replacement....................................................................... 18
1
Standard Specifications
Model
Bolero 630EW / E540
Bolero 630PR / E520
Bolero 682FB / E562
Bolero 684FB / E564
Bolero 712SB / E572
Bolero 722FB / E582
Bolero 724FB / E584
Low Profile
Low Profile
Low Profile
Low Profile
Low Profile
Low Profile
Low Profile
Engine
130 MJT
130 MJT
130 MJT
130 MJT
150 MJT
150 MJT
150 MJT
Engine Capacity
2287cc
2287cc
2287cc
2287cc
2287cc
2287cc
2287cc
96kW @ 3600rpm
96kW @ 3600rpm
96kW @ 3600rpm
96kW @ 3600rpm
109kW @ 3600rpm
109kW @ 3600rpm
109kW @ 3600rpm
Roof Profile
Engine Power
Torque
320Nm @ 1800rpm
320Nm @ 1800rpm
320Nm @ 1800rpm
320Nm @ 1800rpm
350Nm @ 1500rpm
350Nm @ 1500rpm
350Nm @ 1500rpm
Chassis
Fiat AL-KO low line
Fiat AL-KO low line
Fiat AL-KO low line
Fiat AL-KO low line
Fiat AL-KO low line
Fiat AL-KO low line
Fiat AL-KO low line
Wheel base
4.04m/13'3"
4.04m/13'3"
4.04m/13'3"
4.04m/13'3"
4.40m/14'5"
4.40m/14'5"
4.40m/14'5"
Designated Passenger Seats
1
1
1
3
1
1
3
Berths (sleeping positions)
2
2
4
4
4
4
4
Overall Length (no ladder)*
7.04m/23'1"
7.04m/23'1"
7.04m/23'1"
7.04m/23'1"
7.71m/25'3"
7.71m/25'3"
7.71m/25'3"
Overall Width (mirrors folded)
2.35m/7'9"
2.35m/7'9"
2.35m/7'9"
2.35m/7'9"
2.35m/7'9"
2.35m/7'9"
2.35m/7'9"
Overall Height
2.77m/9'1"
2.77m/9'1"
2.77m/9'1"
2.77m/9'1"
2.77m/9'1"
2.77m/9'1"
2.77m/9'1"
Maximum Technical Permissible
Laden Mass (A)
3500kg
3500kg
3500kg
3700kg
4250kg
4250kg
4250kg
Mass in Running Order (B)†
3130kg
3190kg
3150kg
3222kg
3315kg
3280kg
3345kg
Maximum User Payload (A-B)
370kg
310kg
350kg
478kg
935kg
970kg
905kg
Unladen Weight
2874kg
2934kg
2894kg
2966kg
3059kg
3024kg
3089kg
Essential Habitation Equipment
Thermal Insulation Grade
8kg
8kg
8kg
8kg
8kg
8kg
8kg
THREE
THREE
THREE
THREE
THREE
THREE
THREE
2.08m x 1.05m / 6'10" x 3'5"
2.08m x 1.20m/1.05m /
6'10" x 3'11"/3'5"
1.88m x 1.33m / 6'2" x 4'4"
1.88m x 1.33m / 6'2" x 4'4"
Bed Sizes
Front Double
2.08m x 1.81m/1.33m / 6'10" x
5'11"/4'4"
Front Nearside Single
1.93m x 0.71m / 6'4" x 2'4"
Front Offside Single
1.81m x 0.71m / 5'11" x 2'4"
Rear Double
2.08m x 1.23m/1.05m / 6'10" x 4'0"/3'5"
2.08m x 1.78m / 6'10" x 5'10"
1.90m x 1.30m / 6'3" x 4'3"
2.08m x 1.20m/1.05m / 6'10" x 3'11"/3'5" 2.08m x 1.23m/1.05m / 6'10" x 4'0"/3'5"
1.90m x 1.30m / 6'3" x 4'3"
Rear Nearside Single
1.86m x 0.71m / 6'1" x 2'4"
1.89m x 0.71m / 6'2" x 2'4"
Rear Offside Single
1.78m x 0.71m / 5'10" x 2'4"
1.89m x 0.71m / 6'2" x 2'4"
NOTE: 1. The Maximum User Payload includes:
a) the conventional load (this is the allowance for
passengers)
b) essential habitation equipment (items and
fluids required for safe and proper functioning of
habitation equipment)
c) optional equipment (items available from
the manufacturer over and above the standard
specification)
d) personal effects (those items not covered by
the above)
2
2. The Mass in Running Order is the mass of the
unladen vehicle including a 75kg allowance for the
driver plus engine coolants and 90% of the fuel tank,
water tank and gas capacity.
4.WARNING - UNDER NO CIRCUMSTANCES
SHOULD THE MAXIMUM TECHNICAL PERMISSIBLE
LADEN MASS OF THIS MOTOR CARAVAN BE
EXCEEDED.
* For optional roof ladder (add 100mm).
3. PLEASE TAKE CARE TO ENSURE THAT YOU HAVE
ALLOWED FOR THE MASSES OF ALL ITEMS YOU
INTEND TO CARRY IN THE MOTOR CARAVAN,
e.g. passengers, optional equipment, essential
habitation equipment and personal effects, such
as clothing, food, pets, bicycles, sailboards, sports
equipment etc.
3
Optional Specifications
Model
Bolero 630EW / E540
Bolero 630PR / E520
Bolero 682FB / E562
Bolero 684FB / E564
Low Profile
Low Profile
Low Profile
Low Profile
Roof Profile
Engine
130 MJT Auto
Engine Capacity
150 MJT Auto
2287cc
109kW @ 3600rpm
130 MJT Auto
150 MJT Auto
2287cc
96kW @ 3600rpm
130 MJT Auto
150 MJT Auto
2287cc
130 MJT Auto
150 MJT Auto
2287cc
109kW @ 3600rpm
Bolero 684FB / E564 Optional MTPLM
Low Profile
130 MJT Auto
Low Profile
150 MJT Auto
130 MJT Auto
2287cc
96kW @ 3600rpm
150 MJT Auto
2287cc
Engine Power
96kW @ 3600rpm
109kW @ 3600rpm
96kW @ 3600rpm
109kW @ 3600rpm
96kW @ 3600rpm
Torque
320Nm @ 1800rpm 350Nm @ 1500rpm 320Nm @ 1800rpm 350Nm @ 1500rpm
320Nm @ 1800rpm
350Nm @ 1500rpm
320Nm @ 1800rpm 350Nm @ 1500rpm 320Nm @ 1800rpm 350Nm @ 1500rpm 320Nm @ 1800rpm 350Nm @ 1500rpm
109kW @ 3600rpm
96kW @ 3600rpm
109kW @ 3600rpm
Fiat AL-KO low line
Fiat AL-KO low line
Fiat AL-KO low line
4.04m/13'3"
4.04m/13'3"
4.04m/13'3"
Designated Passenger Seats
1
1
1
3
2
Berths (sleeping positions)
2
2
4
4
4
Overall Length (no ladder)*
7.04m/23'1"
7.04m/23'1"
7.04m/23'1"
7.04m/23'1"
Overall Width (mirrors folded)
2.35m/7'9"
2.35m/7'9"
2.35m/7'9"
2.35m/7'9"
Overall Height
2.77m/9'1"
2.77m/9'1"
2.77m/9'1"
Maximum Technical Permissible
Laden Mass (A)
3500kg
3500kg
3500kg
3700kg
Mass in Running Order (B)†
3147kg
3207kg
3167kg
3239kg
3222kg
Maximum User Payload (A-B)
353kg
293kg
333kg
461kg
278kg
261kg
Unladen Weight
2891kg
2951kg
2911kg
2983kg
2966kg
2983kg
Chassis
Wheel base
Essential Habitation Equipment
Thermal Insulation Grade
Fiat AL-KO low line
4.04m/13'3"
2.77m/9'1"
3500kg
8kg
8kg
8kg
8kg
THREE
THREE
THREE
THREE
2.08m x 1.23m/1.05m / 6'10" x 4'0"/3'5"
2.08m x 1.20m/1.05m / 6'10" x 3'11"/3'5"
1.90m x 1.30m / 6'3" x 4'3"
1.90m x 1.30m / 6'3" x 4'3"
3239kg
Bed Sizes
Front Double
2.08m x 1.81m/1.33m / 6'10" x 5'11"/4'4"
Front Nearside Single
1.93m x 0.71m / 6'4" x 2'4"
Front Offside Single
1.81m x 0.71m / 5'11" x 2'4"
Rear Double
2.08m x 1.78m / 6'10" x 5'10"
Rear Nearside Single
1.86m x 0.71m / 6'1" x 2'4"
Rear Offside Single
1.78m x 0.71m / 5'10" x 2'4"
NOTE: 1. The Maximum User Payload includes:
a) the conventional load (this is the allowance for
passengers)
b) essential habitation equipment (items and
fluids required for safe and proper functioning of
habitation equipment)
c) optional equipment (items available from
the manufacturer over and above the standard
specification)
d) personal effects (those items not covered by
the above)
4
2. The Mass in Running Order is the mass of the
unladen vehicle including a 75kg allowance for the
driver plus engine coolants and 90% of the fuel tank,
water tank and gas capacity.
4. WARNING - UNDER NO CIRCUMSTANCES
SHOULD THE MAXIMUM TECHNICAL PERMISSIBLE
LADEN MASS OF THIS MOTOR CARAVAN BE
EXCEEDED.
* For optional roof ladder (add 100mm).
3.PLEASE TAKE CARE TO ENSURE THAT YOU HAVE
ALLOWED FOR THE MASSES OF ALL ITEMS YOU
INTEND TO CARRY IN THE MOTOR CARAVAN,
e.g. passengers, optional equipment, essential
habitation equipment and personal effects, such
as clothing, food, pets, bicycles, sailboards, sports
equipment etc.
5
Optional Specifications
Model
Roof Profile
Engine
Engine Capacity
Capacities
Bolero 712SB / E572
Bolero 722FB / E582
Bolero 724FB / E584
Low Profile
Low Profile
Low Profile
150 MJT Auto
150 MJT Auto
150 MJT Auto
2287cc
2287cc
2287cc
Engine Power
109kW @ 3600rpm
109kW @ 3600rpm
109kW @ 3600rpm
Torque
350Nm @ 1500rpm
350Nm @ 1500rpm
350Nm @ 1500rpm
Chassis
Fiat AL-KO low line
Fiat AL-KO low line
Fiat AL-KO low line
4.40m/14'5"
4.40m/14'5"
4.40m/14'5"
1
1
3
Wheel base
Designated Passenger Seats
Berths (sleeping positions)
4
4
4
Overall Length (no ladder)*
7.71m/25'3"
7.71m/25'3"
7.71m/25'3"
Overall Width (mirrors folded)
2.35m/7'9"
2.35m/7'9"
2.35m/7'9"
Overall Height
2.77m/9'1"
2.77m/9'1"
2.77m/9'1"
Maximum Technical Permissible
Laden Mass (A)
4250kg
4250kg
4250kg
Mass in Running Order (B)†
3332kg
3297kg
3362kg
Maximum User Payload (A-B)
918kg
953kg
888kg
Unladen Weight
3076kg
3041kg
3106kg
Essential Habitation Equipment
Thermal Insulation Grade
8kg
8kg
8kg
THREE
THREE
THREE
2.08m x 1.23m/1.05m / 6'10" x 4'0"/3'5"
2.08m x 1.05m / 6'10" x 3'5"
2.08m x 1.20m/1.05m /
6'10" x 3'11"/3'5"
1.88m x 1.33m / 6'2" x 4'4"
1.88m x 1.33m / 6'2" x 4'4"
Water Tank Capacities
Bolero / E500
Fresh Water Tank
Waste Water
Tank
Water Heater
90 litre
95 litre
8.5 litre
Gas Capacities
Capacity
Bolero / E500
2 x 7kg
The above are recommended gas bottle sizes
NOTICE : For technical data on the base vehicle please refer to
manufacturer’s handbook
Bed Sizes
Front Double
Front Nearside Single
Front Offside Single
Rear Double
Rear Nearside Single
1.89m x 0.71m / 6'2" x 2'4"
Rear Offside Single
1.89m x 0.71m / 6'2" x 2'4"
6
7
Towing Capabilities
Bolero / E500 Series Towing Capabilities
Engine / Chassis
MTPLM
Permissible
Front Axle Load
Permissible
Rear Axle Load
Bolero 630EW / E540
130MJT (2.3L)
3500kg
1850kg
2000kg
Recommended
Maximum Trailer
Weight
2000kg
Bolero 630EW / E540
150MJT (2.3L) AUTO
3500kg
1850kg
2000kg
2000kg
Model
Gross Train Weight
5500kg
5500kg
Bolero 630PR / E520
130MJT (2.3L)
3500kg
1850kg
2000kg
2000kg
5500kg
Bolero 630PR / E520
150MJT (2.3L) AUTO
3500kg
1850kg
2000kg
2000kg
5500kg
Bolero 682FB / E562
130MJT (2.3L)
3500kg
1850kg
2000kg
2000kg
5500kg
Bolero 682FB / E562
150MJT (2.3L) AUTO
3500kg
1850kg
2000kg
2000kg
5500kg
Bolero 684FB / E564
130MJT (2.3L)
3700kg
1850kg
2000kg
2000kg
5500kg
Bolero 684FB / E564
150MJT (2.3L) AUTO
3700kg
1850kg
2000kg
2000kg
5500kg
Bolero 684FB / E564
130MJT (2.3L)
3500kg
1850kg
2000kg
2000kg
5500kg
Bolero 684FB / E564
150MJT (2.3L) AUTO
3500kg
1850kg
2000kg
2000kg
5500kg
Bolero 712SB / E572
150MJT (2.3L)
4250kg
2100kg
2400kg
2000kg
6000kg*
Bolero 712SB / E572
150MJT (2.3L) AUTO
4250kg
2100kg
2400kg
2000kg
6000kg*
Bolero 722FB / E582
150MJT (2.3L)
4250kg
2100kg
2400kg
2000kg
6000kg*
Bolero 722FB / E582
150MJT (2.3L) AUTO
4250kg
2100kg
2400kg
2000kg
6000kg*
Bolero 724FB / E584
150MJT (2.3L)
4250kg
2100kg
2400kg
2000kg
6000kg*
Bolero 724FB / E584
150MJT (2.3L) AUTO
4250kg
2100kg
2400kg
2000kg
6000kg*
The maximum trailer weight is limited by the Gross Train
Weight which must not be exceeded. For example, if
the vehicle is at the maximum MTPLM of 4250kg, then the
maximum trailer weight possible is 1250kg. Reducing the
weight of the vehicle by removing payload, will allow you to
increase the trailer weight up to a maximum of 2000kg.
To ensure adequate road holding, the load on the front axle,
under all conditions, must not be less than 40% or more
than 70% of the total weight.
Care must be taken when distributing loads. The loadings and weights above are maximums and must not be
exceeded under any circumstances.
* With this vehicle configuration it will be necessary to
reduce the payload carried inside the van when towing
a trailer at maximum trailer weight to ensure that the
Maximum Gross Train Weight and maximum axle loads are
not exceeded.
CAUTION:When fitting a towbar, it must meet certain minimum requirements as specified by Type
Approval Regulations. The bar will have marked on it the approval standard (94/20/
EC) and the maximum download, or noseweight, that it can accept. It must fit the
manufacturer’s approved mounting points and must not obscure the towing vehicle’s
number plate.
8
9
Jacking
Wiring Diagrams
Swift Bolero / E500 Series
Jacking Point: ▲
Bolero / E500 - Road lighting circuits
10
11
Wiring Diagrams
Bolero / E500 - Roof lighting circuits
12
Wiring Diagrams
Bolero / E500 - Consumer Circuits - Floor circuits
13
Wiring Diagrams
Bolero / E500 - Power circuits
14
Wiring Diagrams
Bolero / E500 - 230V circuits with combi heating
15
Bulb Chart
Wiring Diagrams
Bolero / E500 - Cable Colour Chart
Road Lights
Application
Bulb Reference
Bulb Rating
Front marker light
LED Complete lamp
12v <1W
Side marker light
W5W
12v 5W
Rear high level marker light
W5W
12v 5W
High level stop lamp
T5/13.5
12v 2.3W
Rear indicator lamp
PY21 Orange
12v 21W
Rear Stop / Tail lamp
P21/5W
12v 21w / 5W
Rear reverse lamp
P21
12v 21W
Rear fog lamp
P21
12v 21W
Number plate light
C5W
12v 5W
Interior / Other
Application
Bulb Rating
Downlighters, LED
FEM0855 Silver
12v LED
Locker spotlights, LED
FEM0854 complete lamp
12v LED
Above locker mounted fluorescent lamps
300mm fluorescent bulb
12v 8W
Above locker mounted fluorescent lamps
600mm fluorescent bulb
12v 13W
530mm complete lamp, front fixed
12v 5W CCFL
FEM0858 complete lamp
12v LED
Kitchen splashback lighting
FEM0927 150mm / FEM0928
300mm LED strip
12v LED
Kitchen worktop recessed lighting
500mm / 1000mm LED ribbon
12v LED
B-pillar map reading lamps
Complete lamp on 'swan neck'
flexible arm
12v LED
Furniture mounted cold cathode
fluorescent lamps
Ceiling lights, round, triple LED
Entrance step lamp
LED complete lamp
12v LED
Awning lamp, LED
Forge Europa LED complete unit
12v 2.2W LED
FEM0442 SPLED illuminator
12v LED
FEM0927 150mm / FEM0928
300mm LED strip
12v LED
Walkway single LED lights
Vanity unit strip lights
Note: Not all lights feature on all models within a range
16
17
Replacement instructions
Bolero / E500 Series
Road Light Bulb Access replacement instructions
Stop & Tail lamps - Replacing
Rear Indicator lamps and/or Reverse
lamps - Replacing
In addition care is needed when fitting the
replacement bulb, that the orientation of the bulb
is correct. A simple check is that the lamp when
operating as a brake light should be brighter
than when operating as a tail lamp, this check
can be undertaken before the lamp body is refitted into the rear panel.
Bulb access is from rear of lamp.
The lamp is retained into the rear panel via a
spring clip located at the bottom of the lamp
body. To release the lamp:
Carefully insert a large flat bladed screwdriver
between the top of the lamp body and the
plastic of the rear panel.
Using a lever action push the lamp body down
against the spring clip.
Once the spring clip is compressed sufficiently,
the top of the lamp body can be withdrawn
from the rear panel – with the top of the lamp
withdrawn the remainder of the lamp will follow.
At the rear of the lamp, a two part metal clip
holds the bulb holder in place. To release this:
Insert a flat bladed screwdriver between the
rear of the lamp body and the curved section of
the two part clip, and use a lever action to disengage the clip from the rear of the lamp body.
Continue to move the curved section of the
clip away from the lamp body, and the second
straight part will lift away from the back of the
bulb holder.
The bulb holder can now be withdrawn from the
lamp body.
Bulbs are a bayonet fitting – apply slight
pressure on bulb towards the bulb holder, and
twist to release.
Re-position the bulb holder into the lamp body
and re-engage the two part clip.
Place the lamp body back into the aperture with
the spring clip in position against the edge of
that aperture. Using a downward force compress
the spring clip until the top edge of the lamp
body can also be pushed into the aperture.
The procedure for these lamps is as for the
indicator or reverse lamps.
It is wise to avoid dis-connecting the bulb holder
from the harness, as incorrect re-connection can
cause the brake / tail operation of the bulb to be
reversed, an/or cause an bulb warning light to
illuminate on the Fiat dashboard.
Rear high level marker / position
lamps (Red lense)
Bulb access is via the front lense of each lamp
Remove the 2 screws from the front of the
light fitting, and withdraw the whole fitting from
motorhome body
The harness plugs directly into the bulb holder –
twist the bulb holder relative to the lamp body to
release, and withdraw the bulb holder and bulb.
Bulbs are push fit into bulb holder – pull bulb
directly away from holder to release
Reverse the procedure to replace the bulb in the
holder, holder in the lamp and the lamp onto the
motorhome body.
Rear fog lights
High level brake lamp
Bulb access is from rear of lamp.
This lamp is single piece and has no user
serviceable parts inside.
The light fitting can be accessed from
underneath the rear of the vehicle.
At the rear of the lamp, twist the bulb holder
relative to the lamp body to release, and
withdraw the bulb holder and bulb.
Please note: The visible rubber terminal cover is
not fixed to the bulb holder, and it may be easier
to grip the bulb holder with this removed.
Bulbs are a bayonet fitting – apply slight
pressure on bulb towards light fitting, and twist
to release
Re-position the bulb holder into the lamp and
twist to lock in place
Front high level marker / position
lamps (Clear lense)
These lamps are LED and have no user
serviceable parts inside.
Replacements should be undertaken by
your dealer, as the lamps are sealed onto the
mounting panel.
Remove the screw at both ends of lamp, and
withdraw whole fitting away from rear panel of
motorhome.
Please note: The screws which retain the lamp
also retain the reverse camera housing.
Unplug the lamp from the harness, by squeezing
the small tab on the side of the connector, and
pulling the connector away from the lamp.
Re-connect the new lamp to harness, and
secure with the original two screws.
Side marker / position lamps
Bulb access is from rear of lamp
If rear of lamp is visible from inside the vehicle:
Depending on the location, a small brown plastic
cover may be present covering the connections
to the lamp. Remove the screws in the cover to
release and access the rear of the lamp.
The harness plugs directly into the bulb holder –
twist the bulb holder relative to the lamp body to
release, and withdraw the bulb holder and bulb.
Bulbs are push fit into bulb holder – pull bulb
directly away from holder to release
Reverse the procedure to replace the bulb in the
holder, holder in the lamp and the lamp onto the
motorhome body. Replace plastic cover.
If rear of lamp is not visible from inside the
vehicle:
Remove the 2 screws from the front of the
light fitting, and withdraw the whole fitting from
motorhome body
The harness plugs directly into the bulb holder –
twist the bulb holder relative to the lamp body to
release, and withdraw the bulb holder and bulb.
Bulbs are push fit into bulb holder – pull bulb
directly away from holder to release
Reverse the procedure to replace the bulb in the
holder, holder in the lamp and the lamp onto the
motorhome body.
Lamp retaining screws are fixed into a rubber
sleeve with a threaded insert, often known
as a rawlnut. If lamp has been removed and
re-fitted several times the rubber sleeve may
need replacing, these are available through your
dealer.
Number plate lamps
Bulb access is via the front lense of each lamp
Remove the two screws in the lense of the lamp,
and remove
Lever the bulb out of retaining clips
Reverse the procedure to re-fit a new bulb and
the light lense
18
19