The Copyright of the Companies VOSS and Daimler...

Specification 2016-04

Class: Executing guidelines Class No.:62

Tapped holes for push-in connections JED

system Voss Company 388

Previous Edition Abbreviated Title

2005-05 Tapped h.push-in con. Voss 852 003 880 4

Compiler Approved Product Group: 4961

Olaf Hilla Stephan Eisfelder

Doc. Code Language Rev.

008 - en - E

The Copyright of the Companies VOSS and Daimler Chrysler has to be respected!

1 Scope ................................................................................................................. 3

2 General............................................................................................................... 3

3 Dimensions of the connection contours ......................................................... 5

3.1 Threaded port according to Voss, System 230 for metal housings ............................. 5

3.1.1 JED-388-0-M16x1.5 (from DC A 930 00 93 99-ZGS 001) ...................................... 5

3.1.2 JED-388-0-M22x1.5 (from DC A 930 000 92 99-ZGS 001) .................................... 6

3.2 Threaded port according to Voss, System 203 / NG 4 and NG 6 ............................... 7

3.2.1 JED-388-1-M8x1 .................................................................................................... 7

3.2.2 JED-388-1-M10x1 .................................................................................................. 8

3.3 Threaded port according to Voss, System 230 / NG 4 to NG 12 for plastic housings .. 9

3.3.1 JED-388-2-V8x1 .................................................................................................... 9

3.3.2 JED-388-2-V10x1 ................................................................................................ 10

3.3.3 JED-388-2-V16x1.5 (from DC A 930 000 95 99-ZGS 001) ................................... 11

3.3.4 JED-388-2-V22x1.5 (from DC A 930 000 94 99-ZGS 001) ................................... 12

3.4 Threaded port according to Voss, System 232 for through-hole ............................... 13

3.4.1 JED-388-3-M16x1.5 (from DC A 930 00 93 99-ZGS 001) .................................... 13

3.4.2 JED-388-3-M22x1.5 (from DC A 930 000 92 99-ZGS 003) .................................. 14

3.5 Threaded port according to Voss, System 232 for metal housing ............................. 15



4 Representation on drawings .......................................................................... 17

4.1 Representation on the Outline Drawing, Document Code 005/053 ........................... 17

4.2 Representation on the Sectional Drawing, Document Code 006/052 and Component Drawing, Document Code 007/051 ........................................................................... 18

4.3 Special Characteristics ............................................................................................. 18

JED-388 : 2016-04

Specification

4.3.1 Indication of Special Characteristics on drawings ................................................. 18

4.3.2 Verification of Special Characteristics for PPAP, process release and after tool change ................................................................................................................. 19

4.3.3 Serial inspection of Special Characteristics .......................................................... 19

5 Minimum center spacing of tapped holes .................................................... 20

6 Tightening torques ......................................................................................... 20

6.1 Maximum permissible tightening torque for the tapped holes .................................... 20

6.2 Maximum permissible tightening torques for the coupling ......................................... 20

Annex 1 Coupling system ............................................................................................. 20 Annex 2 Comparison VOSS 232 versus VOSS 230 ..................................................... 22

JED-388 : 2016-04

Specification

1 Scope This specification defines the dimensions of tapped holes and shows the representation of dimensioning in the Component, Blank and Outline Drawings. Tapped holes, as defined in this specification, are designed for couplings of the Company Voss GmbH, Wipperfürth, Germany. They shall be applied at customer’s request: JED-388-0 System 230 for metal housings; JED-388-1 System 203 JED-388-2 System 203/230 for plastic housings JED-388-3 System 232 for metal housings, for through-holes, e.g. air reservoirs JED-388-4 System 232 for metal housings, shall, in coordination with the Customer Team, be

used for new projects instead of JED-388-0. If JED-388 is indicated in the drawing, JED-388-0 shall be applied.

2 General Except for JED-388-2, the dimensions apply to machining. The manufacturing plants have to produce the threaded ports in accordance with the drawing indication as specified in the present JED document. The roughness requirements stated in the Voss drawings are based on the old version of ISO 1302: 1992. The incomplete thread run-out has to be removed on all pneumatic port threads. It is required in order to avoid thin burrs that may lead to failure of the device. The removal of maximum one pitch is allowed. In the thread pores and blowholes with the maximum size of 1xP (pitch) are acceptable. Therefore, the following roughness requirements, differing from those indicated in the

Voss drawings, apply to WABCO: Surfaces

Voss WABCO surface requirement

No sealing function Rz 40; Rz 25 Rmax 25

Ra 25; Rmax 25

Sealing function

Rmax 20 Ra 3.2 and Rmax 16

Sealing function, circular pattern*

Rz 25; Rmax 25 Ra 6.3c and Rmax 25c

Front face and O-ring sealing surface (10° chamfer), circular pattern*

Rmax 16 or Rmax 25 or Rz 25

Ra 3.2c and Rmax 16c

*according to ISO 1302 No deviations, such as additional grooves or undercuts, are permitted on the contours.

JED-388 : 2016-04

Specification

Tapped holes according to this specification are also suited for pipe couplings with flat gasket (e.g. DIN 7603) or WABCO pressure ring and O-ring (e.g. M22x1.5: 893 030 040 4 and 897 780 400 4), provided that the male fitting has the profile defined in ISO 4039-2: issue 1998, ISO 6149-2: issue 1993-11 or DIN 3852-1 - Form A: issue 2002-05. The installation and maintenance instructions provided by the manufacturer have to be observed:

VOSS Automotive GmbH Leiersmühle 2-6 D-51688 Wipperfürth Telefon: +49 22 67/63-0 Telefax: +49 22 67/63-59 82 E-Mail: [email protected] Internet: www.voss.de

JED-388 : 2016-04

Specification

3 Dimensions of the connection contours

3.1 Threaded port according to Voss, System 230 for metal housings

3.1.1 JED-388-0-M16x1.5 (from DC A 930 00 93 99-ZGS 001)

* Optional R0.3 - 0.2

JED-388 : 2016-04

Specification


* Optional R 0.3 - 0.2 ** Max. Dia 10: The passage cross-section shall be selected in accordance with the desired

nominal width; for ABS and EBS it is also the minimum required diameter

JED-388 : 2016-04

Specification

3.2 Threaded port according to Voss, System 203 / NG 4 and NG 6

3.2.1 JED-388-1-M8x1

See drawing 852 003 881 4, Doc. Code 007, page 1

JED-388 : 2016-04

Specification

3.2.2 JED-388-1-M10x1


JED-388 : 2016-04

Specification

3.3 Threaded port according to Voss, System 230 / NG 4 to NG 12 for plastic housings

3.3.1 JED-388-2-V8x1


JED-388 : 2016-04

Specification

3.3.2 JED-388-2-V10x1


JED-388 : 2016-04

Specification

3.3.3 JED-388-2-V16x1.5 (from DC A 930 000 95 99-ZGS 001)


* optional R0.3 1. The two initial turns of the thread (length 5.5 ± 0.2) are the same as M16x1.5 – 6H. 2. In the area **, the outer diameter, thread angle and pitch diameter values are:

a) outer diameter 15.72 –0.15 b) thread angle 65° c) pitch diameter 15 +0.16/-0.02

The core diameter and pitch are the same as for M16x1.5-6H.

Test of the V-thread in the series production possible by means of thread plug gauge, Voss No.: 9 7 68 08 17 40.

JED-388 : 2016-04

Specification

3.3.4 JED-388-2-V22x1.5 (from DC A 930 000 94 99-ZGS 001)


* optional R0.3 3. The two initial turns of the thread (length 5.5 ± 0.2) are the same as M22x1.5 – 6H. 4. In the area **, the outer diameter, thread angle and pitch diameter values are:

a) outer diameter 21.72 –0.15 b) thread angle 65° c) pitch diameter 21 +0.16/-0.02

The core diameter and pitch are the same as for M22x1.5-6H.

Test of the V-thread in the series production possible by means of thread plug gauge, Voss No.: 9 7 68 08 17 42.

JED-388 : 2016-04

Specification

3.4 Threaded port according to Voss, System 232 for through-hole



No mechanical forces shall act on the free space for the connector system (application example: air reservoir).

Free space for the connector system

JED-388 : 2016-04

Specification



No mechanical forces shall act on the free space for the connector system (application example: air reservoir).

Free space for the connector system

JED-388 : 2016-04

Specification

3.5 Threaded port according to Voss, System 232 for metal housing



* Optional R 0.3-0.2 ** The passage cross-section shall be selected in accordance with the desired nominal width; for

ABS and EBS it is also the minimum required diameter.

acc. to flow requirements **

Alternative design without step * optional

JED-388 : 2016-04

Specification



** The passage cross-section shall be selected in accordance with the desired nominal width.

Ø acc. to flow requirements **

Alternative design without step

* optional

JED-388 : 2016-04

Specification

4 Representation on drawings

4.1 Representation on the Outline Drawing, Document Code 005/053 The threaded ports shall be indicated in the Outline Drawing, giving only the nominal diameter and reference to JED-388-X. For instance: M22x1.5 / JED-388-0.

JED-388 : 2016-04

Specification

4.2 Representation on the Sectional Drawing, Document Code 006/052 and Component Drawing, Document Code 007/051

Threaded ports shall be represented in the Sectional and Component drawings, giving the contour, nominal diameter and reference to JED-388-x, for instance: M22x1.5 / JED-388-0 (see 4.1). The single dimensions must not be shown in the cross section views.

The tolerance quality is „medium“ according to ISO 965-1, i.e. 6H. Any deviating tolerance qualities for processing steps shall be indicated in the drawing, e.g. M22x1.5 – 6E / JED-388-x.

4.3 Special Characteristics

4.3.1 Indication of Special Characteristics on drawings

To evoke e.g. a Significant Characteristic on JED-388, indicate the symbol “<2>” at the JED.

Example for evoking a Special Characteristic for JED-388-4

If a Special Characteristic is evoked for JED-388, then the marked dimensions have to be verified as described in 4.3.2 and 4.3.3 (example for Special Characteristics on a M16x1.5 port):

JED-388 : 2016-04

Specification

4.3.2 Verification of Special Characteristics for PPAP, process release and after tool change

For the verification of Special Characteristics for PPAP, process release and after tool change, the Control Plan of the manufacturer has to define the measurement of all dimensions and the statistical analysis of:

- Thread pitch diameter measurements

- Thread depth measurements

- Bore depth measurements

- Chamfer A x 10° (contour) measurements

4.3.3 Serial inspection of Special Characteristics

For the serial inspection of Special Characteristics, the Control Plan of the manufacturer has to define:

- Thread inspection by means of gauge

- Measurement of the thread depth

- Measurement of the bore depth

- Visual inspection of the chamfer A x 10° (visually inspect parts for damages and completeness

and tool for breakouts)

WABCO Quality recommends to use a combined tool for the manufacturing. If the bore, the plane

surface and the chamfer are not manufactured at once with a combined tool, align the Control Plan with

WABCO Quality.

JED-388 : 2016-04

Specification

5 Minimum center spacing of tapped holes The indications of minimum center spacing L refer to straight male stud couplings and double-end flat flare nut wrenches according to DIN 3118.

D1 Hole spacing L Usual widths

Recommended sizes

Minimum sizes across flats

M10 x 1 27 24 16 M12 x 1.5 29 26 18 M14 x 1.5 32 28 20 M16 x 1.5 35 30 22 M22 x 1.5 43 36 28

If due to space requirements smaller minimum sizes have to be made, the sequence of tightening of the connectors has to be defined.

6 Tightening torques

6.1 Maximum permissible tightening torque for the tapped holes On the Outline Drawings, the maximum permissible tightening torque of the tapped holes (without fittings) applies as defined in JED-366. Deviating values (which might be due to lower material strength of the housing, for instance plastic material) have to be indicated.

6.2 Maximum permissible tightening torques for the coupling On the Outline Drawings and Sectional Drawings, the tightening torque and the tolerance as defined by the Voss Company have to be indicated at all tapped holes shown with the fitting. Deviating tightening torque values have to be agreed with the customer, and the responsible product engineer has to check the deviation and enter it into the drawings.

Manufacturer’s installation instruction:

Installation instruction WABCO Id. No. Doc.Code

VOSS 203 B203 851 020 070 4 008 VOSS 230 B23 851 020 062 4 008 VOSS 232 B232 852 003 884 4 035

JED-388 : 2016-04

Specification

Annex 1 Coupling system

(only for information)

1. Interchange/combination of VOSS System 230 and 232

For complete push-in fittings of the system 232, tapped holes according to JED-388-0 can be used.

But the connectors and thrust screws belonging to the systems 230 and 232 are not interchangeable! 2. VOSS System 230 / JED-388-0

Tapped hole with assembled connector 230 and PA pipe on insert profile according to DIN 73377

1 PA pipe 6 O-ring 2 Insert profile 7 Housing 3 O-ring 8 Retaining ring 4 Thrust screw 9 Sealing ring 5 O-ring

JED-388 : 2016-04

Specification

3. VOSS System 232 / JED-388-4

4. Tapped hole with thrust screw, system 232

1 Thrust screw 2 O-ring 3 Fastening ring 4 Holding element 5. VOSS System 203 The VOSS push-in coupling 203 is a push-in system without insert for quick and safe assembly of plastic pipes having small diameters in pneumatic and fuel systems. Applications, for instance engine-independant heating system At WABCO, the push-in connections of the Legris Company shall be preferred for plastic pipes having diameter 4mm, 6mm or 10mm.

JED-388 : 2016-04

Specification

Annex 2 Comparison VOSS 232 versus VOSS 230 (only for information) 1. Tapped hole M16x1.5 (DC A 930 00 93 99 Bl.2-ZGS 001)

JED-388 : 2016-04

Specification

2. Tapped hole M22x1.5 (DC A 930 00 92 99 Bl.2-ZGS 001)

The Copyright of the Companies VOSS and Daimler...

Documents

Transcript of The Copyright of the Companies VOSS and Daimler...