Specification

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1 Previous Edition Specification Class: Executing guidelines Class No.:62 Tapped holes for push-in connections JED system Voss Company 388 Abbreviated Title Tapped h.push-in con. Voss The Copyright of the Company VOSS has to be respected! 1 Scope General Dimensions of the connection contours Threaded port according to Voss, System 230 for metal housings JED M16x JED M22x Threaded port according to Voss, System 203 / NG 4 and NG JED M8x JED M10x Threaded port according to Voss, System 230 / NG 4 to NG 12 for plastic housings JED V8x JED V10x JED V16x JED V22x Threaded port according to Voss, System 232 for through-hole JED M16x JED M22x Threaded port according to Voss, System 232 for metal housing JED M16x JED M22x Representation on drawings Representation on the Outline Drawing, Document Code 005/ Representation on the Sectional Drawing, Document Code 006/052 and Component Drawing, Document Code 007/ Special Characteristics Compiler Approved Product Group: 4961 Olaf Hilla Andrzej Kozłowski Stephan Eisfelder Doc. Code Language Rev en - F

2 JED-388 : Page Indication of Special Characteristics on drawings Verification of Special Characteristics for PPAP, process release and after tool change Serial inspection of Special Characteristics Minimum center spacing of tapped holes Tightening torques Maximum permissible tightening torque for the tapped holes Maximum permissible tightening torques for the coupling Annex 1 Coupling system Annex 2 Comparison VOSS 232 versus VOSS

3 JED-388 : Page 3 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 System 230 for metal housings; JED System 203 JED JED JED System 203/230 for plastic housings System 232 for metal housings, for through-holes, e.g. air reservoirs System 232 for metal housings, shall, in coordination with the Customer Team, be used for new projects instead of JED If JED-388 is indicated in the drawing, JED 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: 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 Ra 25; Rmax 25 Rmax 25 Sealing function Rmax 20 Ra 3.2 and Rmax 16 Sealing function, circular pattern* Front face and O-ring sealing surface (10 chamfer), circular pattern* *according to ISO 1302 Rz 25; Rmax 25 Rmax 16 or Rmax 25 or Rz 25 Ra 6.3c and Rmax 25c Ra 3.2c and Rmax 16c No deviations, such as additional grooves or undercuts, are permitted on the contours.

4 JED-388 : Page 4 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: and ), provided that the male fitting has the profile defined in ISO : issue 1998, ISO : issue or DIN Form A: issue The installation and maintenance instructions provided by the manufacturer have to be observed: VOSS Automotive GmbH Leiersmühle 2-6 D Wipperfürth Telefon: /63-0 Telefax: / automotive@voss.de Internet:

5 JED-388 : Page 5 3 Dimensions of the connection contours 3.1 Threaded port according to Voss, System 230 for metal housings JED M16x1.5 * Optional R

6 JED-388 : Page JED M22x1.5 * Optional R ** 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

7 JED-388 : Page Threaded port according to Voss, System 203 / NG 4 and NG JED M8x1 See drawing , Doc. Code 007, page 1

8 JED-388 : Page JED M10x1 See drawing , Doc. Code 007, page 2

9 JED-388 : Page Threaded port according to Voss, System 230 / NG 4 to NG 12 for plastic housings JED V8x1 See drawing , Doc. Code 007, page 1

10 JED-388 : Page JED V10x1 See drawing , Doc. Code 007, page 2

11 JED-388 : Page JED V16x1.5 See drawing , Doc. Code 007, page 3 * optional R 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 b) thread angle 65 c) pitch diameter /-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.:

12 JED-388 : Page JED V22x1.5 See drawing , Doc. Code 007, page 4 * optional R 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 b) thread angle 65 c) pitch diameter /-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.:

13 JED-388 : Page Threaded port according to Voss, System 232 for through-hole JED M16x1.5 See drawing , Doc. Code 007, page 1 Free space for the connector system No mechanical forces shall act on the free space for the connector system (application example: air reservoir).

14 JED-388 : Page JED M22x1.5 See drawing , Doc. Code 007, page 2 Free space for the connector system No mechanical forces shall act on the free space for the connector system (application example: air reservoir).

15 JED-388 : Page Threaded port according to Voss, System 232 for metal housing JED M16x1.5 See drawing , Doc. Code 007, page 1 acc. to flow requirements ** * optional Alternative design without step * Optional R ** 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.

16 JED-388 : Page JED M22x1.5 See drawing , Doc. Code 007, page 2 Ø acc. to flow requirements ** * optional Alternative design without step ** The passage cross-section shall be selected in accordance with the desired nominal width.

17 JED-388 : Page 17 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

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

19 JED-388 : Page 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 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.

20 JED-388 : Page 20 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 D 1 Hole spacing L Usual widths Recommended Minimum sizes across flats sizes M10 x M12 x M14 x M16 x M22 x 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 B VOSS 230 B VOSS 232 B

21 JED-388 : Page 21 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 can be used. But the connectors and thrust screws belonging to the systems 230 and 232 are not interchangeable! 2. VOSS System 230 / JED Tapped hole with assembled connector 230 and PA pipe on insert profile according to DIN 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

22 JED-388 : Page VOSS System 232 / JED Tapped hole with thrust screw, system 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.

23 JED-388 : Page 23 Annex 2 Comparison VOSS 232 versus VOSS 230 (only for information) 1. Tapped hole M16x1.5

24 JED-388 : Page Tapped hole M22x1.5

Specification Tapped holes f. coupl Scope Allocation of the JED Numbers General...

Specification Tapped holes f. coupl Scope Allocation of the JED Numbers General... WABCO Specification 2003-07 Class: Engineering Guidelines Class No.:62 Tapped Holes for Couplings JED according to ISO 4039-2 464 Previous Edition Abbreviated Title 1985-11 Tapped holes f. coupl. 852 004