IVECO INLET COUPLING WITH PIPES/SLEEVES

10-4302
Standard
All rights reserved. This standard must not be reproduced or in any way utilized by other parties without the written consent of IVECO.

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DESIGN STANDARD Date 06.06.2018

Supervisor: IVECO STD. 19-0201

Manager: IVECO STD. 19-0201

IMPORTANT NOTE
This Standard is valid for IVECO designs.
For new FPT Industrial designs, use Standard FPI9.ENG005.
In case of dispute the only valid reference is the original Italian/English edition.

Edition Date Description of modifications Group

1 12.12.1998 New.

5 15.09.1993 Points 1.1, 1.2, 1.2.1, 1.3, 1.4.1, 2.2 and 2.3 modified for: the
redefinition of range of diameters of use, change to parameters for
sizing of inlet Ø and sleeve Ø, change to coupling interference
values, increase of tolerance on permitted defects.
6 27.03.1998 Points 3.1, 3.2 and Tables I, II, III, IV modified. Editing carried out.
7 20.11.1998 Table I: addition of inlet nominal d Ø 10, 18, 22, 48, and corre­
sponding values for Nominal D Ø Pipe/sleeve. Addition of note and
correction of diameter D deviation (previously 0 - 0.60). Table III
addition of Nominal Ø 10, 18, 22, 48.
8 30.03.2001 Addition at point 1 of the NOTE and the new points 4.3.1 and 4.3.2.
at page 9. Editing carried out.
9 01.09.2010 Updated indication of Supervisor, Manager and Reference Stan­ TFO
dards.
10 29.09.2014 Values of dimensions S modified in Table V.
11 09.06.2016 Modified Note to Table IV.
12 06.06.2018 Added “Important note” on page 1.

IN CASE OF PRINTING THE COPY IS TO BE CONSIDERED AS NON-CONTROLLED, THEREFORE IT IS NECESSARY TO CHECK THE UPDATE ON THE WEBSITE

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1 PURPOSE

Provide the designer with the indications for the drawing definition of the inlet unions for interfer­
ence coupling with the flexible sleeves/pipes, envisaged by IVECO STD. 18-0398, 18-0399 and
18-0400.

NOTE: If cast inlets, which ensure tightness (for example: connection of turbocharging pipes; pres­
ence of recirculated “blow-by”) require subsequent mechanical processing, this must be speci­
fied on the drawing, in accordance with indications provided at point 4.3.

2 SUMMARY

- Inlet dimensions;
- Inlet acceptance limits;
- Collar position;
- Indications to be provided on the drawing.

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3 SIZING

3.1 Relation between inlet Ø and sleeve Ø

The specifications provided below are valid for inlets obtained from sheet metal pipe and for
inlets obtained from casting or plastic moulds which couple with sleeves whose elastic elonga­
tion is ≥ 3%.

S
ØD
Ød

Figure 1

For oil/coolant conduction sleeves (for diameters up to 70 mm), the dimensions of the inlets and
the sleeves are considered with the deviations provided in Table I. Table II provides the dimen­
sions of the air conduction inlets and sleeves (for diameters from 71 to 120 mm, with the corre­
sponding deviations).

TABLEI

INLET PIPE/SLEEVE

Nominal diameter (D) Wall thickness (S)

Ø Nominal d Deviation [mm] [mm]
[mm][1] [mm]
Ø Deviation S Deviation
8 7
10 ±0.20 9
12 11
16 14.5 3.5 ±0.35
18 16.5
20 18.5
±0.25
22 20.5
25 23.5
30 28.5 - 0,60
35 33 - 0,60
40 38 4.0 ±0,40
45 43
48 ±0.30 46
50 48
55 53
60 58
4.5 ±0.50
65 62.5
±0.35
70 67.5

[1] The most commonly used values are indicated; the deviations, diameters D and thickness S
obtained by deduction for intermediate values are valid.
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TABLEII

Ø Nominal (d)
from 71 to 89 from 90 to 119 from 120 to 180
[mm]
Inlet

- 0,60 - 0,70
Deviation ±0.70
+ 0,40 + 0,50

d - 1,5 d - 1,8 d - 2,1

Ø Nominal (D)
Sleeve

[2] d - 1,1 [2] d - 1,3 [2] d - 1,4

Deviation ±0.50 ±0.60 ±0.70

[2] Values to be considered for the sleeves, wound with fabric layers whose elastic elongation at
a load of 40 N is ≤ 3%. (Test: standard “butterfly” test 25x150 mm - torquemeter at 500 N
scale limit - load applied at speed of mm 50/min). During sampling, the Supplier must report
this particular type of method to the plant quality department.

3.2 Coupling interference

Tables III and IV indicated the minimum and maximum nominal interferences for inlet/sleeve
coupling listed in Tables I and II.

Table III

Nominal Ø of inlets INTERFERENCE [mm]

[mm] Nominal Min. Max.
8
10 1.00 0.80 1.80
12
16
18
20
1.50 1.25 2.35
22
25
30
35
40
45
48 2.00 1.70 2.90
50
55
60
65
2.50 2.15 3.45
70

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TABLEIV

INLET Ø d from 71 to 89 from 90 to 119 from 120 to 180

INTERFERENCE min. 0.40 min. 0.50 min. 70

[mm] max. 2.40 max. 2.90 max. 3.50

INTERFERENCE[3] min. 0 min. 0 min. 0

[mm] max. 2 max. 2.40 max. 2.80

[3] Interference relating to the coupling with the sleeves [2] as indicated in Table II.

NOTE: To make sleeve fitting easier, it is advisable, where possible, that “PARAFLU” is used as the
lubricant diluted 50% with water.

Alternatively, use the lubricant “HELLERLINE” (100%).

3.2.1 Fitting force

The sleeve Suppliers must be able to ensure the sleeve can be fitted onto the relative inlet in
maximum interference conditions.

3.2.2 Reference inlet

The reference inlet is still defined as follows:

- Execution of the fusion;

- external Ø of maximum ogive of the Ø d class to which it belongs.
- Roughness at maximum tolerance.

3.3 Ogive shape and size

Tolerances for values without tolerance indication, according to IVECO STD. 10-2311: D grade
linear values, B grade angular values.

3.3.1 Inlets from sheet metal pipes

Alternative ogive
H
end
S

α
Ød

Internal pipe Ø

R
RS
Radius or bevel at 45°

Figure 2

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Table V

+0.5
Ød H RS S R +0 α

+0 min. 0.4
from 6 to 19 6.0 -0.2 0.8 8°
0.5 max. 0.55
+0 min. 0.6
from 20 to 29 6.5 -0.2 1.0 10°
0.5 max. 0.75
+0 min. 0.8
from 30 to 39 7.0 -0.2 1.2 12°
0.5 max. 1
+0 min. 1
from 40 to 89 7.5 -0.2 1.5 14°
1.0 max. 1.2
+0 min. 1
from 90 to 119 8.5 -0.2 1.8 17°
1.0 max. 1.2
+0 min. 1
from 120 to 180 9.5 -0.2 2.0 20°
1.5 max. 1.2

3.3.2 Inlets from plastic mould or casting

H
R1
S

α
Ød

R2

Figure 3

Table VI

+0.5 +0.5
Ød H S R1 +0 R2 +0 α

from 6 to 19 5 0.4 2 1.8 15°

from 20 to 29 6 0.6 2 2.0 20°

from 30 to 39 6.5 0.8 2 2.2 22°

from 40 to 89 7 1.0 2.2 2.4 30°

from 90 to 119 8 1.0 2.5 2.6 30°

from 120 to 180 9 1.0 2.5 2.8 30°

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3.4 Stop shoulder for fitting sleeve

The stop shoulder must be included for each end of the sleeve. Where there are assembly or
disassembly difficulties, it is possible to use only one.
Below are the indications for the shoulder dimensions and relative fitting depths.

3.4.1 Inlets from sheet metal pipes

centre R
2 min.

R see
Table V

Ød

1.5 max.
a

Useful fitting length of the sleeve sub­

ject to tolerance X.

Figure 4

Table VII
L = Fitting depth

Ød L min. Deviation X a

from 6 to 19 24 0.20 7

from 20 to 39 30 0.30 8
±1
from 40 to 89 32[4] 0.40 9

from 90 to 180 34[4] 0.50 10.5

[4] Extend “L min” by 4 mm when using 20 mm collars and by 10 mm when using 25 mm collars.
(See IVECO STD. 11-4540)

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3.4.2 Inlets from plastic mould or casting

L
centre R1
2 min. R1 see
Table VI

Ød

Section at tolerance X as per point 3.4.1

Figure 5

Table VIII

Ød L min. Deviation

from 6 to 19 24

from 20 to 39 30
±1
from 40 to 89 32[5]

from 90 to 180 34[5]

[5] Extend “L min” by 4 mm when using 20 mm collars and by 10 mm when using 25 mm collars.
(See IVECO STD. 11-4540)

3.4.3 Reinforcement for plastic inlets

For plastic inlets, there must be a metal insert for strengthening purposes, as indicated in Fig­
ure 6.

Metal insert

Figure 6

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- The length of the reinforcement inserts must be no less than the minimum length L indicated
at point 3.4.2.
- The thickness of the inserts must be such that permanent distortion of the inlets during the
collar closing action is avoided.
- The metal inserts must have a chemical composition or have a suitable covering which
makes them resistant to attacks by fluids circulating in the sleeves and atmospheric agents.
- The insert locking system must be such that they do not slide or move under the action of
the flow.
- The inserts must in any case have an expected life equal to that of the assembly onto which
they are applied.

3.5 Sleeve orientation notch

If using pre-shaped sleeves which need to be secured during assembly, there must be a refer­
ence notch on inlets with a diameter ≥ 20 mm.
This notch also serves as a stop when fitting the sleeve in place of the shoulder indicated at the
previous point.
The sleeve must have a seat which engages with the reference notch of the inlet or a permanent
marking; for the latter, the length of the sleeve must be reduced by the distance z (See Figure
7)
L + R1
L see point 3.4
n

R1 see Table VI

Sleeve

ØZ

Sleeve
R

Figure 7

Height ”h” must be equal to the nominal thickness of the sleeve (3.5 - 6 mm; See the IVECO
STD. mentioned at point 1).
Distance “Z” varies as a function of the diameter of the inlet (See Table IX).

Table IX

Ød
from 6 to 19 from 20 to 39 from 40 to 59 from 60 to 89 from 90 to 180
Inlet

Z - 5 6 7 8

For inlets from sheet metal pipes, the reference notch may consist of a brazed pin.
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4 Inlet acceptance limits

4.1 Defects not permitted

Concave irregulari­ Longitudinal scoring

ties

Figure 8

Brands, acronyms, highlighted references, injection points, ingates, etc., must not be present in
the section of length ”L” usable for fitting the sleeve.

4.2 Permitted defects

The defects illustrated below, after any necessary crimping interventions, must be within the lim­
its indicated in the Figure 9.

Longitudinal scoring

PLATES RELIEFS
X

Z
Mould figure displacement Burrs

Figure 9

X = 0.1 for diameters ≤ 60 mm, 0.2 for diameters > 60 mm.

Y = 0.1 max. Z = 0.3 max. Q = 0.1 max.

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NOTE: For inlets in sheet metal or casting, if the fabrication process is not able to keep the defects to
within the limits indicated above, then operations must be used which require mechanical pro­
cessing, to be agreed upon on a case by case basis with IVECO Purchasing Management.
This processing must be limited to length ”L” usable for fitting the sleeve.
Processing is only permitted in the radial direction.

4.2.1 Permitted grinding interventions

Some grinding interventions are permitted providing they are circular, with a radius r between 1 -
1.5 times the theoretical radius of the inlet. In order to facilitate these interventions, the entry
profile (ogive) on the junction line can be eliminated (Figure 10).

d +2S [6]
d

R = 1/2 d
[6] For the S values, see the indications given in Table VI.

Figure 10

4.3 State of the inlet surfaces

4.3.1 With inlets obtained from sheet metal pipes or casting without any further mechanical process­
ing, the roughness of the surfaces must be within:

Ra max. = 12 for diameters ≤ 75 mm;

16 for diameters ≤ 75 mm

On the drawing, reference to IVECO STD. 10-4302 is sufficient.

4.3.2 With inlets obtained by casting, for which subsequent mechanical processing is required in order
to ensure tightness (example: connection of turbocharging pipes; presence of recirculated “blow-
by”), the roughness of the surfaces must be within:

Ra max. = 6.8

On the drawing, IVECO STD. 10-4302 mechanical processing must be specified.

Alternatively, it is possible to indicate the tolerance on the inlet diameter, which automatically
leads to the request for mechanical processing.

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4.4 Max. misalignment permitted

Δ
d

Ød
DS min = 1 +
2

Figure 11

Table X

Ød
from 6 to 19 from 20 to 39 from 40 to 59 from 60 to 89 from 90 to 180
Inlet

Δ max. 1 1.2 1.5 2 3

5 COLLAR POSITION

b b

5 5+Z

Figure 12
The collar fitted onto the sleeve must be positioned according to the indications provided in Ta­
ble X.
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For dimension Z, see point 3.5.

For sleeve material and thickness, see the IVECO STD. mentioned at point 1.
In order to make positioning of the collar easier, there must be permanent markings on the
pipes/sleeves (paint or serigraph silicone in a colour that stands out: white or black) in the posi­
tion and of the size indicated in the Size 13:

3
2-4

Painted markings

Z+ 3

b+4

Figure 13

NOTE: If the sleeve geometry does not allow painted markings to be applied on the entire circumfer­
ence as indicated in the Figure (example: curvature near the ends), the Supplier may negotiate
with the Quality department of the plant suggesting an alternative solution.
For the distance b (band width), at equal sleeve diameter, consider the greatest nominal value
specified by IVECO STANDARDS 11-4543 and 11-4544.
The use of collars according to IVECO STD. 11-4540 must be noted on the sleeve drawing.

5.1 Collar closing torque

After the operational test, the plants must carry out a retightening of the collar tightening torques
according to the IVECO STD mentioned at point 1 and IVECO STD. 11-4543.

6 INDICATIONS TO BE PROVIDED ON THE DRAWINGS

INLETS: - Reference to this standard for the geometry;

- Nominal external diameter of the inlet.
ASSEMBLIES: - Reference to this standard for collar position.
PIPES/SLEEVES: - For the internal diameter of the sleeve, reference to the nominal external
diameter of the inlet to be coupled, according to this standard;
- If using collars according to IVECO STD. 11-4540, specify the width of
the band to allow the positioning notches to be made.

REFERENCE STANDARDS

IVECO STD.: 10-2311, 11-4540, 11-4543, 11-4544, 18-0398, 18-0399, 18-0400, 19-0201.

SDBI: FPI9.ENG005.
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