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Iveco Daily Euro 4. Manual - part 204

32795

HYDRO-PNEUMATIC SYSTEM - BRAKES

AILY

URO

DESCRIPTION

SYMBOL

SINGLE CYLINDER HYDRAULIC BRAKE

TWIN CYLINDER HYDRAULIC BRAKE

DUAL SERVO HYDRAULIC BRAKE

DUAL SERVO HYDRAULIC BRAKE
WITH PARKING BRAKE

SINGLE CAM OPERATED BRAKE

TWIN DUAL CAM OPERATED BRAKE

The pipes in the braking systems of commercial vehicles are
currently of two types:

- Flexible nylon hose with single or two-ply structure and in

the following diameters (

∅ 6-8-10-12-16 mm) supplied as

spares in metre lengths.

- Rigid metal pipes of the following diameters (

∅

4.75-6.35-8-10-12 mm). Pipes from

∅ 4.75 to ∅ 10 mm

are supplied as spares in straight lengths of 4, 5 and 6 m,
while those which are over 10 mm diam. are supplied as
spares ready cut, bent and flared.

Figure 1

TYPES OF RE-FLANGING OF RIGID PIPES

A Type re-flanging

General

Deburr pipe (1), insert union fitting (2) on this and position it
between blocks (3) bearing against pin (5). Lock pipe (1) with
screw (4).

31971

31974

31973

Move pin (4) to neutral position. Tighten screw (1) until matrix
die (2) comes up against blocks (3), thus forming the end of
the pipe (5).

31972

31975

Position of press 99386523 (3) the blocks (1) so that the
stamped numbers indicating the diameter of the pipes to be
worked are facing towards the due (2). The choice of the
matrix die (2) depends on the diameter of the pipe to be
re-flanged. Additionally, the diameter of the pipe that can be
re-flanged is stamped on the matrix die.

Fix matrix die (2) to press 99386523 (1).
For re-flanging follow the instructions given above for A Type
re-flanging.

Re-flanging rigid pipes

B Type re-flanging

Figure 2

Figure 3

Figure 4

Figure 5

HYDRO-PNEUMATIC SYSTEM - BRAKES

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PIPES AND COUPLINGS

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

HYDRO-PNEUMATIC SYSTEM - BRAKES

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- 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.

When the hose is incorrectly fitted, do not reuse the
hose once the bush and support ring have been
removed.

Replacing

flexible

hoses

with

threaded

couplings

Twin-layer

- 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);

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;

1. Reinforcement bush - 2. Pressure ring - 3. Nut -

4. Union fitting - 5. Hose - h. Distance between bush edge

and ring edge (see table)

After having cut the pipe, deburr and shape the ends as
described previously.

ASSEMBLY OF REINFORCEMENT BUSH

A = CORRECT ASSEMBLY

B = INCORRECT ASSEMBLY

Hose

Distance between

bush edge and ring

edge mm (*)

Fitting pressure

(N/mm

)

6 x 1

8 x 1

10 x 1,5

12 x 1,6

16 x 2,34

0,040

0,050

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, Fig. 14

Figure 12

Figure 13

Figure 14

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.

da 1 a 1,5

da 2 a 2,5

da 3 a 3,5

NOTE

HYDRO-PNEUMATIC SYSTEM - BRAKES

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