Iveco Daily Euro 4. Manual — part 205

- When hoses run through chassis members or metal parts,

make sure that the holes through which they pass are
fitted with rubber grommets, and that these are in good
condition;

- Avoid sliding the hose along sharp edges which might

cause cuts;

- When the hose has to be attached to existing pipe work,

take into account of the additional heat to which it may
be subjected (power steering pipe work). In this case the
hose must be protected with shields;

- When the hose has been connected, check that it is not

under tension between the attachment points, instead
leaving it slightly slack to take up the more substantial
variations in temperature, especially for short lengths;

- Before fitting, thoroughly clean the hoses by blowing

compressed air through them to safeguard operation of
the system.

- Protect the hoses if grinding or welding operations are

carried out on the vehicle. A notice is fitted in the cabin
indicating the precautions to be observed to avoid
damage.

Figure 15

Replacing flexible hoses with quick release
couplings

When fitting is finished, check that all seals (unions, couplings,
etc.) are completely free from leaks.

When fitting the hose to the vehicle, some important points
should be borne in mind:
- Bends must comply with minimum radii, so as to avoid

constrictions

Minimum radius of curvature

mm

Diameter of pipe

mm

13132

6 x 1

8 x 1

10 x 1,5

12 x 1,6

16 x 2,34

~ 40

~ 50

~ 60

~ 75

~ 100

Screw the coupling into the threaded seating provided on the
air valve, and tighten it to the driving torque indicated in the
table.

- Check that the seal ring (1) is in its seal;

- Tighten the coupling until the seal gasket is in contact with

the valve;

- Direct the valve correctly and, by keeping the moveable

part still, lock the hexagonal nut to the driving torque
indicated in the table.

39307

Figure 16

Figure 17

39306

Swivel couplings:

Banjo couplings:

Swivel and banjo couplings

COUPLING

DRIVING TORQUE (Nm + 10%)

THREAD

M 10 x 1,0 mm

M 12 x 1,5 mm

M 14 x 1,5 mm

M 16 x 1,5 mm

M 22 x 1,5 mm

22

24

28

35

40

!

Make sure that the hoses are not in contact with sharp
edges or with sharp metal parts or sources of heat,
but are at a minimum safe distance of 15mm from
these.

!

For greater safety and convenience in working, it is
advisable to remove the hoses during these
operations.

1

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(mm)

When removing couplings (1) on pneumatic components, check
the condition of the seal ring (2) and, if necessary, replace.

33977

33978

6

8

12

16

Figure 18

Figure 19

- Only use type approved hoses;

- Check the condition of the new hose, that must be free

from cracks, cuts or scores;

- Cut the hose at 90

°, maximum error 15°, with reference

to the axis. Use pipe-cutter pliers 99387050 to cut to the
required length.

Figure 20

33976

A

A = Mark to identify end of tube travel

- Use indelible ink to clearly mark two reference notches on

both diametrically opposite faces of the pipe at an angle
of

≥ 75°, set to distances L

1

and L

2

, to ensure correct

fitting in place.

19,8

20,5

25

27,1

17

18

22

24

22

23

28

30

L

(mm)

L

1

(mm)

L

2

(mm)

+0,5

0

+1

-0,5

+1

-0,5

Figure 21

39308

- Insert the hose (2) by hand into the coupling (1), with a

force between 30 and 120 N according to the diameter
of the hose, so that reference mark L

1

is inside the hose

while mark L

2

remains visible.

COUPLING

SEAL RING DIMENSIONS

THREAD

M 10 x 1,0

M 12 x 1,5

M 14 x 1,5

M 16 x 1,5

M 22 x 1,5

10,1 x 1,6

11,0 x 2,0

-

15,0 x 2,0

-

L

1

and L

2

vary according to the diameter of the hose

and are to be measured at the longer part of the hose
(see Figure 18).

!

Whenever a hose is removed from a quick release
coupling, the coupling itself must be replaced. Spare
quick release couplings are supplied complete.

!

Quick release and threaded couplings are not
interchangeable. This also applies to flexible hoses
used with quick release couplings and flexible hoses
used with threaded couplings.

NOTE

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52378

Figure 22

1. Pressure reducer - 2. Vacuum tank (2 litres) - 3. Servo brake - 4. Hydraulic pressure test point - 5. Dual mechanical operated

load proportioning valve (for vehicles with mechanical suspensions) - 6. Parking brake lever - 7. Rear brake caliper -

8. Rear brake disc - 9. Dual pneumatic operated load proportioning valve (for vehicles with pneumatic suspensions) -

10. Front brake disc - 11. Front brake caliper - A. From pneumatic suspension circuit.

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Outline diagram for vehicles 29L - 35S without ABS

74938

Figure 23

1. Electro-hydraulic modulator - 2. Vacuum pump - 3. Vacuum tank - 4. Servo brake - 5. Hydraulic pressure test point -

6. Parking brake lever - 7. Rear brake caliper - 8. Rear brake disc - 9. Electronic control unit -

10. Wheel revolutions sensor - 11. Phonic wheel - 12. Front brake disc - 13. Front brake caliper.

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