Iveco Daily Euro 4. Manual — part 200
2
HYDRO-PNEUMATIC SYSTEM - BRAKES
D
AILY
E
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4
- Outline diagram for vehicles 35C with ESP 8
29
. .
- Outline diagram for vehicles 40C - 45C - 50C - 60C -
65C with ABS 8
30
. . . . . . . . . . . . . . . . . . . . . . . .
- Outline diagram for vehicles 35C with ESP 8
31
. .
- Braking system main components layout
32
. . . . .
- Location of the main brake system components on
vehicles with ABS
34
. . . . . . . . . . . . . . . . . . . . . . .
-
Location of the main brake system components on
vehicles with ESP
36
. . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION
37
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Service brake
37
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Emergency brake
37
. . . . . . . . . . . . . . . . . . . . . . .
- Parking brake
37
. . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKES
37
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Front and Rear disc brakes
37
. . . . . . . . . . . . . . . .
FAULT DIAGNOSIS
38
. . . . . . . . . . . . . . . . . . . . . .
- Diagnosis Instruments
38
. . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES
46
. . . . . . . . . . . . . . . . . .
TOOLS
48
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS AND DATA - HYDRAULIC
SYSTEM
51
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS AND DATA - BRAKES
52
. . . . . .
CHECKS
54
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Functional check of vacuum brake system
54
. . . .
BRAKING SYSTEM MAIN COMPONENTS
55
. . . .
- Vacuum pump
55
. . . . . . . . . . . . . . . . . . . . . . . . .
- Vacuum servo brake
55
. . . . . . . . . . . . . . . . . . . . .
- Bleeding air from the hydraulic circuit (vehicles not
equipped with ABS)
56
. . . . . . . . . . . . . . . . . . . . .
- Bleeding air from the hydraulic circuit with deaerator
device (vehicles not equipped with ABS)
56
. . . . .
Page
- Air bleeding from the ABS/ESP system hydraulic
circuit
57
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- ABS 8/ESP 8 system bleeding procedure sequence
58
- Mechanically controlled load sensing valve (vehicles
35C)
59
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Regulation of load proportioning valve on vehicle
59
.
- Dual mechanically controlled load sensing valve
(vehicles 29L - 35S)
60
. . . . . . . . . . . . . . . . . . . . .
- Adjusting the load sensing valve
60
. . . . . . . . . . . .
STABILITY CONTROL AND ANTI-SKID DEVICES
61
. . .
ABS SYSTEM FUNCTIONS
61
. . . . . . . . . . . . . . . . .
- Antilock braking system (ABS)
61
. . . . . . . . . . . . .
- Electronic braking distribution device (EBD)
61
. . .
- Electronic Stability Program (ESP) - Option
61
. . .
FUNCTIONS INCLUDED IN THE ESP SYSTEM ONLY 61
- Acceleration drive control device (ASR)
61
. . . . .
- Engine braking torque control (MSR)
61
. . . . . . . .
- Hill holder control (HHC)
61
. . . . . . . . . . . . . . . .
- Hydraulic Brake Assistant (HBA)
61
. . . . . . . . . . .
- Electro-hydraulic modulator/control unit for 29L -
35S vehicles )
62
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Electro-hydraulic modulator/control unit for 29L -
35S vehicles )
63
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Rev sensor
64
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Phonic wheels
64
. . . . . . . . . . . . . . . . . . . . . . . . .
ESP SYSTEM SENSORS
64
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HYDRO-PNEUMATIC SYSTEM - BRAKES
3
D
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- Yaw sensor with built-in side acceleration sensor
64
. .
- Longitudinal acceleration sensor
64
. . . . . . . . . . . .
- Steering angle sensor
64
. . . . . . . . . . . . . . . . . . . .
BRAKE REPAIR OPERATIONS
65
. . . . . . . . . . . . . .
- Front brakes
65
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacing brake linings
65
. . . . . . . . . . . . . . . . . . .
- Checks
66
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal/Re-fitting of brake calipers
67
. . . . . . . . .
REAR BRAKES
68
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal/Refitting of brake calipers
68
. . . . . . . . . .
- Checks
69
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal/Refitting brake calipers
70
. . . . . . . . . . . .
OVERHAUL OF BRAKE CALIPERS
70
. . . . . . . . . . .
- 2x44 - 2x48 - 2x60 Brembo brake calipers
70
. . .
- 1x52 - 1x60 Brembo brake calipers
71
. . . . . . . . .
OVERHAUL OF BRAKE DISCS
72
. . . . . . . . . . . . . .
MACHINING AND GRINDING OF DISC BRAKES
72
. . .
OVERHAULING PARKING BRAKE
73
. . . . . . . . . . .
WHEEL NUT TIGHTENING SEQUENCE
73
. . . . .
- Assembly
75
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Adjusting parking brake
75
. . . . . . . . . . . . . . . . . .
STEERING ANGLE SENSOR
76
. . . . . . . . . . . . . . . .
Page
- Replacing
76
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE ESP COMPONENTS
76
. . . . . . .
- Calibration
76
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
LONGITUDINAL ACCELERATION SENSOR
77
. .
- Removal
77
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting
77
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Calibration
77
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
YAW SENSOR
78
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal
78
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting
78
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Calibration
78
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTROHYDRAULIC MODULATOR/CONTROL
UNIT
79
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal
79
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting
78
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Programming
79
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Calibration
79
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Bench overhauling
80
. . . . . . . . . . . . . . . . . . . . . .
- Disassembly
80
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembly
80
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
HYDRO-PNEUMATIC SYSTEM - BRAKES
D
AILY
E
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4
32780
HYDRO-PNEUMATIC SYSTEM - BRAKES
5
D
AILY
E
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4
GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(MISCELLANEOUS AND GENERATORS)
DESCRIPTION
SYMBOL
HYDRAULIC FLOW
AIR FLOW
ELECTRICAL LINE
ABLE TO ROTATE
CROSSOVER OF CONNECTED LINES
PRESSURE TEST POINT
QUICK-RELEASE COUPLING
COCK
COCK WITH OUTLET
1
2
SILENCER
COMPRESSOR
0
2
ENERGY SAVING COMPRESSOR
0
2
4
VACUUM PUMP
3
2
HYDRAULIC PUMP
0
2
HYDRAULIC HAND PUMP
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