Iveco Daily. Manual — part 318
Fit union fitting (2) and tighten so that ring (3, Figure 6) is locked
over the pipe (1).
Bending rigid pipes
C type re-flanging
31979
Fit nut (2) and ring (3) over the pipe (1).
Position pipe (1) in tool (3) and bend the pipe by acting on lever
(2).
31976
31977
31980
To remove the pipe (2) from the tool (3) use lever (1).
31978
31981
Fit tool (1) 99386523 and select components (2) and (3)
according to the diameter of the pipe to be bent.
Position pipe (2) in tool (3) 99386523 and tighten screw (1).
By holding the pipe (2) still, rotate the tool (3) until the pipe
has been completely cut.
Cutting rigid pipes
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
18
HYDRO-PNEUMATIC SYSTEM - BRAKES
D
AILY
Base - May 2004
When the hose is incorrectly fitted, do not reuse the
hose once the bush and support ring have been
removed.
- Re-flange the support ring when fitted on the vehicle or
at the test bench on a union fitting.
- The pressure and the final distance of the pressure ring
front edge from the reinforcement bush should be in
accordance with those shown in the table below.
- 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
°, with respect the to axis, to the required
length by means of pipe-cutter pliers 99387050;
Fit the following in the specified order over the hose:
- nut (3), pressure ring (2) (the thickest part should be facing
the nut (3)) and the reinforcement bush (1);
- the bush must be in perfect condition (it must be free from
deformation or hammer dents).
Replacing
flexible
hoses
with
threaded
couplings
By turning tool (3) around the pipe (2), screw (1)
becomes loose. To completely cut the pipe, you must
tighten the screw (1) as soon as it becomes loose.
1. Reinforcement bush - 2. Pressure ring - 3. Nut -
4. Union fitting - 5. Hose - h. Distance between bush edge
and ring edge (see table)
Twin-layer
Carefully follow the instructions below:
10397
10398
10399
- Fit the reinforcement bush with tool 99372219 ensuring
contact between its flange and end of the hose.
- Make sure that the end of the hose penetrates into the
rake throat of the flange.
After having cut the pipe, deburr and shape the ends as
described previously.
ASSEMBLY OF REINFORCEMENT BUSH
A = CORRECT ASSEMBLY
B = INCORRECT ASSEMBLY
Hose
mm
Distance between
bush edge and ring
edge mm (*)
Fitting
pressure
(N/mm
2
)
6 x 1
8 x 1
10 x 1.5
12 x 1.6
16 x 2.34
0.040
0.050
0.050
0.060
0.060
Introduce the end of the prepared hose into the union fitting
until the reinforcement bush flange rests in the appropriate
seat:
- to lock the nut on the union fitting, tighten this up by hand
and then by means of a box wrench and dynamometric
wrench; this must tightened up to the required driving
torque.
Single layer
(*) See reference h, Figure 14.
Figure 12
Figure 13
Figure 14
da 1 a 1.5
da 2 a 2.5
da 2 a 2.5
da 2 a 2.5
da 3 a 3.5
NOTE
NOTE
HYDRO-PNEUMATIC SYSTEM - BRAKES
19
D
AILY
Base - May 2004
- 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.
For greater safety and convenience in working, it is
advisable to remove the hoses during these
operations.
- 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.
- 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.
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;
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.
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.
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.
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
!
!
1
20
HYDRO-PNEUMATIC SYSTEM - BRAKES
D
AILY
Base - May 2004
Whenever a hose is removed from a quick release
coupling, the coupling itself must be replaced. Spare
quick release couplings are supplied complete.
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).
- 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.
- 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;
When removing couplings (1) on pneumatic components, check
the condition of the seal ring (2) and, if necessary, replace.
- 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.
D
(mm)
33977
33978
6
8
12
16
Figure 18
Figure 19
Figure 20
33976
A
A = Mark to identify end of tube travel
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
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
-
!
!
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
HYDRO-PNEUMATIC SYSTEM - BRAKES
21
D
AILY
Base - May 2004
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