VOSS 232 Bedienungsanleitung

B 232 Assembly instructions

VOSS quick connect system 232

Experience plus ideas

These assembly instructions

are intended for qualified fit-

ters of pneumatic systems in

commercial vehicles.

1. Introduction

Nylon tube lines are in general

use today in pneumatic brak-

ing systems in commercial

vehicles. Nylon tubes are in-

sensitive to corrosion, vibrati-

on and torsional stress in

vehicle bodywork.

The following factors are

essential for their functional

reliability:

- Correct material and proper

handling

- Appropriate connection fit-

tings

- Correct assembly

As a connecting element

between nylon tubing and

components, the VOSS quick

connect system 232 permits

rapid and safe connection.

2. Nylon tubing

The properties of nylon tubing

and details of its use in com-

mercial vehicles are defined in

the following standards:

DIN 73 378

Polyamide tubing for motor

vehicles

DIN 74 324, Part 1

Air braking systems - thermo-

plastic tubing; part 1: require-

ments and tests

DIN 74 324, Part 2

Air braking systems - thermo-

plastic tubing; part 2: guide

for assembling

Only nylon tubing which con-

forms to DIN 74324 part 1

and made of polyamide 11 or

polyamide 12 may be used.

VOSS quick connect system 232 for pneumatic systems in commercial vehicles

VOSS quick connect system 232

Plug:

1Plug body Brass or PA11 – GF30

2 Dirt-protection and NBR 60

pretension o-ring

3 O-ring seal EPDM 60

Coupling element:

4 Male nut Brass

5 Thread-sealing o-ring NBR 70

6 Fixing ring POM

Retaining element:

7 Retaining clips Spring steel

8 Retaining ring POM

Other:

9 Nylon tubing

10 Component

3.2 Individual

components/materials

The VOSS quick connection

system 232 consists of two

main assemblies: the plug

with its fir-tree and the cou-

pling element.

Plug

The plug has a broad retaining

groove, the reverse flank of

which is inclined at 45°. This

protects the clips which snap

into place during assembly

from being subject to excess

tension.

There are two additional

grooves, both for o-rings. The

first o-ring (3) functions as a

seal against the medium being

transported.

The second, exterior o-ring

prevents contamination from

penetrating the connection.

In addition, the specially

designed groove geometry

exerts an axial pre-tensioning

force on the plug, when the

clips have snapped into place.

The reduced plug diameter

above the exterior o-ring (2)

acts as a stabilising factor on

the coupling element and at

the same time provides opti-

cal assistance during assem-

bly.

Coupling element

The coupling element is

screwed tightly into the com-

ponent. An o-ring acts as a

seal in the threaded port (5).

The two-step retaining ele-

ment is clipped to the male

nut (4) by means of a fixing

ring (6). The retaining element

contains the retaining ring (8)

and two metal clips (7) which

lock into place in the retaining

groove once the plug has

been pressed into the end

position.

3. VOSS quick connect

system 232

The VOSS quick connect sys-

tem 232 permits rapid assem-

bling of nylon tubes to com-

ponents. The only tool re-

quired for disconnection is a

wrench (for width across flats,

see section 4.3).

The connecting fittings are

made from brass, die-cast alu-

minium, die-cast zinc, alumini-

um or nylon, depending

on the general conditions. In

their standard design, the

plugs are available in brass.

Individual plug variants are

also available in nylon (PA 11 –

GF30). Nylon and brass plugs

are mutually replaceable. The

dimensions of nylon plugs dif-

fer from those of brass plugs

(see table in section 4.2.2

page 6).

The drawings and tables of

dimensions contained in

these assembly instructions

refer to the brass plug model.

When inserting the nylon plug

into the tube, due considera-

tion has to be given to the

greater length of the fir-tree

compared to the brass model

(see section 4.2.2).

3.1 Range of application

The individual components in

the VOSS quick connect sys-

tem 232 are designed for a

working temperature range of

between -40°C and +100°C.

Their rated operating pres-

sure is 15,5 bar and is limited

by the compressive strength

of the nylon tubing used.

Possible applications for other

service conditions are avail-

able on request.

Individual components of VOSS quick connect system 232

CAUTION!

Due to the different material properties, particular

attention should be paid to the instructions for

nylon plugs contained in section 6.

CAUTION!

The chart obtains only for metallic housings.

For nylon housings the VOSS V-thread

has to be used.

Screw-in thread Nominal size Fir-tree for tubes

NS O.D. x wall thickness

M 16 x 1.5 8 6 x 1

8 x 1/9 x 1.5

10 x 1,25

10 x 1/11 x 1.5

12 x 1.5

M 22 x 1.5 12 6 x 1

8 x 1/9 x 1.5

10 x 1.25

10 x 1/11 x 1.5

12 x 1.5/14 x 2.5

12,5 x 1.25/14 x 2

16 x 2

VOSS quick connect system 232, functional diagram

Retention of the plug in the

first snap-in stage thus solves

the safety problem of faulty

insertion, leading to sudden

failure of the connection and

subsequent breakdown of the

entire system. Compensation

for the minor leakage is

topped up by the compressor.

3.4 Product range

The VOSS quick connect

system is available in nominal

sizes 8 and 12.

Please refer to the table below

for possible combinations of

plug size and nylon tubing

dimensions.

The entire range of parts and

accessories for the VOSS

quick connect system 232 is

contained in catalogue 232.

3.3 Functional description

The coupling element forms

the connection to the compo-

nent. Connection is made by

screwing the coupling element

into an appropriate port.

Suitable ports are the industri-

ally standard moulded port for

the VOSS quick connect sys-

tem 230 and special port

shapes agreed with VOSS for

the application in question.

On request, we will be

pleased to supply design

specifications for the appropri-

ate port.

The connection between a

nylon tube and a component

is made by sliding the plug

into the coupling element.

When this is done the plug is

kept in place by a two-stage

retaining element which, once

it has reached its second

snap-in location, is automati-

cally shifted from the push-in

to the locking position by

means of axial compression

and the pressure of the com-

pressed air.

Should the second snap-in

stage not be reached due to

insufficient insertion force or

other unfavourable circum-

stances, the plug is safe from

disconnection as soon as the

retaining element has snap-

ped into the first stage.

It is possible to push the

retaining element into this first

snap-in stage by applying very

little force. In this retention

position, the connection has

an intended leakage path.

Incomplete connections may

be noticed by an acoustic

warning signal and a drop in

pressure.

Possible combinations

of thread size, nominal size and tube dimensions

First snap-in

stage Second snap-in

stage

Axial

compression

Acoustic warning

signal through

leakage path

CAUTION!

The connection between nylon tubing and fir-tree

must under no circumstances be secured by

hose clips or by clamping sleeves.

Nylon tube pliers

4 Assembly instructions

4.1 Cutting nylon tubing to

length

The nylon tube must be cut

off square. A saw may not be

used for this purpose as the

possible formation of burrs will

jeopardise the sealing capabi-

lity of the connection. For cut-

ting nylon tubing to the cor-

rect length, we recommend

the use of the VOSS cutting

pliers shown on the right,

which ensure that the tubing

is cut squarely and cleanly.

Subsequent treatment of the

cut surface such as deburring

is no longer necessary then.

4.2 Insertion of the fir-tree

in nylon tubing

The following has to be

observed when pressing the

fir-tree into the nylon tube:

-Insertion procedure must be

carried out at room tempera-

ture

-Nylon tube may not be

heated

-Fir-tree must be undamaged

as the connection to the

nylon tubing will otherwise

not be tight

-Fir-tree must be clean and

free of any grease

4.2.1 Insertion of the

fir-tree with the nylon

tube collet

Insert the nylon tube into the

opened pliers in such a way

that the end of the tube

extends approx. 2 mm for

brass plugs and approx.

6 mm for nylon plugs from

the side of the pliers without

serration. Fix the nylon tube

into place with the grip

mechanism. The clamping

force exerted may be varied

by means of the adjusting

screw.

Press the fir-tree as far as

possible into the end of the

tube manually. Then drive the

plug into the polyamide tube

with the aid of a plastic ham-

mer until the fir-tree is fully

covered by the tube. The plug

has to be protected by a plas-

tic cap.

Nylon tube collet

Insertion of the fir-tree with nylon tube collet

VOSS

68 10 12 16

approx. 2mm

for brass plugs

aprox. 6mm

for nylon plugs

NS d1Tube d3d4a (mm)

(mm) O.D. x wall thickness (mm) (mm)

(brass/nylon)

NS 8 9.7 6 x 1 4.6 4.0 16

8 x 1/9 x 1.5 6.9 6.0 16

10 x 1.25 8.1 7.5 22

10 x 1/11 x 1.5 9.0 8.0 22

12 x 1.5 10.3 9.0 22

NS 12 15.2 6 x 1 4.6 4.0 16

8 x 1/9 x 1.5 6.9 6.0 16

10 x 1.25 8.1 7.5 22

10 x 1/11 x 1.5 9.0 8.0 22

12 x 1.5/14 x 2.5 10.3 9.0 22/26

12,5 x 1.25/14 x 2 11.2 10.0 22

16 x 2 13.6 12.0 25

Manual assembly tool

4.2.3 Protective cap

All plugs are supplied with a

protective cap to protect the

neck of the plug and the o-

rings from damage and dirt.

This protective cap should not

be removed until immediately

before final assembly.

4.2.2 Insertion of the

fir-tree with manual

assembly tool

The tube clamping jaws

should be turned in the cor-

rect position until they match

the outer diameter of the tube

to be mounted. A tool insert

corresponding to the plug to

be fitted (NS 8 or NS 12,

straight or shaped plug)

should then be placed into

the fixture.

The diameter d3 of the fir-tree

should match the internal

diameter of the nylon tube

(see table). This ensures that

the required pretension pres-

sure of tube onto the fir-tree

is reached.

Next place the nylon tube in

the jaws, allowing it to pro-

trude by the length L (see

fig.), and firmly secure the

nylon tube by tightening the

vicegrip. The clamping force

exerted may be varied by

means of the adjusting screw.

The plug to be fitted should

then be placed in the tool

insert with a protective cap

and the transport bar pressed

manually towards the nylon

tubing until the fir-tree is pre-

centred in the tube end.

Now the nylon tube can be

pressed onto the plug as far

as the end of the fir-tree by

using the insert lever.

Outline of tube and plug dimensions

Possible combinations

of tube dimensions and fir-tree dimensions

L ≥a+2 mm

tection and pretension o-ring

while being pressed into the

coupling element, until both

clips snap into place in the

groove of the plug.

The first clip snaps into place

when only very little force is

applied. In this initial retention

position, the connection is

already secured against unin-

tentional loosening, but it is

not yet leak-tight. The con-

nection ist not fully sealed until

the second clip snaps into

Thread sizes Nominal size Across flats Tightening

torque

NS Nm

M 16 x 1.5 8 19 10 - 17

M 22 x 1.5 12 24 10 - 17

Coupling element:

1 Male nut Brass

2 Thread-sealing o-ring NBR 70

3 Fixing ring POM

4 Retaining element Spring steel/POM

4.3 Assembly of the

coupling element

In order to achieve safe func-

tioning, the connecting port

should be cleaned before fit-

ting the coupling element.

In particular, any residue of

paint still attached to the

region of the sealing lip should

be removed. Care is also be

taken to ensure that the

thread of the component is at

right angles to the contact

surface of the coupling ele-

ment.

The coupling element consists

of a male nut (1) with greased

thread-sealing o-ring (2) and

retaining element (4) clipped

into place with a fixing ring (3).

It is available from the factory

with or without paint protec-

tion stickers. If there is a paint

protection sticker on the front

of the coupling unit, it should

not be removed. The coupling

unit is screwed hand-tight

into the connecting port.

When the coupling element is

inserted into the thread, the

fixing ring acts to pre-align

the coupling element, thus

facilitating the assembly.

Now the coupling element

should be tightened with a

torque wrench. For this pur-

pose, the flap of the paint

protection sticker should be

folded upward. The recom-

mended tightening torques

are listed in table on the right.

The values quoted are valid

both for metal (die-cast alumi-

nium, die-cast zinc) and for

nylon casings (PA-GF30) with

VOSS V-thread.

Automatic VOSS assembly

tools are available on request

for high volume assembly.

4.4 Connecting line to

component

Now the protective cap can

be removed from the plug

(see section 4.2.3) and the

paint protection sticker can be

removed from the coupling

element (see section 4.3).

Slide plug with nylon tube fit-

ted to fir-tree into the port of

the coupling element. The

plug must overcome the axial

force exerted by the dirt-pro-

place. To conclude the inser-

tion process, check the clips

have snapped into place cor-

rectly by pulling in the oppo-

site direction from that used

for insertion. Always ensure

that the connector does not

sit at a false angle in the port.

It should not be possible to

pull back the connector when

checking whether it has been

correctly fitted.

The connection has been cor-

rectly made, if after pulling

back the plug the shoulder of

the plug above the exterior

(dirt-protection and preten-

sion) o-ring is located below

the top face end of the cou-

pling element and thus the o-

ring is not visible.

Incorrect connections, i.e.

plug connectors in the first

stop position, can be

reconnected to the second

stop position, also if the

system is pressurized (< 7

bar). This will not result in

damage. Whether

reconnection is possible also

depends on the possible

insertion force at the

installation location.

Tightening torque of VOSS quick connect system 232

Individual components of the coupling element

CAUTION!

Connections which have not snapped into place

can impair braking performance and may even

lead to failure of the entire pneumatic system.

4.5 Disconnecting and

reassembling

The pneumatic line connected

must be free of any pressure

before it is detached. If the

plug is detached while the line

is pressurised, it can cause

personal injury and damage to

connecting components or to

the pneumatic unit. These

damaged components must

then be replaced. All individual

components must be cleaned

before reassembly.

In order to replace compo-

nents, loosen the male nut

and remove the connection.

The nylon tube with plug and

coupling element with o-ring

need not to be separated.

Check the port on the new

unit is clean. Then re-grease

the thread-sealing o-ring,

screw in coupling element

with plug, fitted with nylon

tube and tighten male nut.

(For tightening torque, see

section 4.3).

Final assembly:

Inserting plug and subsequently pulling back to check

correct fitting

Final assembly:

Incomplete connection at first snap-in stage; the dirt-protection

and pretension o-ring is visible after pulling back the plug.

4.6 Assembly tools

The following tools are avail-

able from VOSS for assem-

bling quick connect system

232:

Series assembly

- VOSS type 56 assembly

machine for inserting fir-trees

into nylon tubing

Small series or individual

assembly

- Manual assembly tool

- Nylon tube collet

- Nylon tube pliers

Service case 1:

- 1 nylon tube collet for

external tube diam.

6, 8, 10, 12, 16

- 1 plastic hammer

- 1 nylon tube pliers

- 1 wrench 24/19 width

across flats

Service case 2:

-1 manual assembly tool with

tube clamping jaws for

external tube diam. 6, 8, 10,

and 12 and for external

diam. 11, 12, 14 and 16

- 1 tool insert for straight

connectors NS 8

- 1 tool insert for straight

connectors NS 12

- 1 tool insert for right-angle

connectors NS 8 with tubing

6 x 1, 8 x 1 and 9 x 1.5

- 1 tool insert for right-angle

connectors NS 12 with tub-

ing 6 x 1, 8 x 1 and 9 x 1.5

- 1 tool insert for right-angle

connectors NS 12 with tub-

ing 10 x 1.25 and 12 x 1.5

- 1 tool insert for right-angle

connectors NS 12 with tub-

ing 16 x 2

- 1 nylon tube pliers

- 1 wrench 24/19 width

across flats

Operating instructions and

product descriptions are avail-

able for the assembly tools

mentioned above; we will be

pleased to send you these on

request.

VOSS type 56 assembly machine

CAUTION!

Always use a new coupling element for reassem-

bling whenever male nut and plug have been dis-

connected.

Removing clips

5. Repairs

The components of VOSS

quick connect system 232 do

not wear or tear as a result of

operation.

Should any of the compo-

nents be damaged as a result

of inappropriate handling,

these may be replaced as

required.

5.1 Replacing the thread-

sealing o-ring

The old o-ring can be re-

moved when the system is

disconnected from the com-

ponent (see section 4.5).

Clean the groove in the cou-

pling element carefully and

check that it is not damaged.

The coupling element must be

replaced if there are any signs

of damage (see section 5.2).

Then replace the old o-ring

with a new one which has

been greased. All damage,

excess stretching or twisting

of the o-ring is to be avoided

when fitting.

5.2 Disconnecting coupling

element

Break the connection (see

section 4.5) and lever off the

fixing ring using a suitable tool

(see fig. 1). Take care that the

plug is not damaged in this

process.

Then pull the clips sideways

out of the retaining ring. This

can be done by inserting a

pointed tool through the slot

in the cage behind the clips

(see fig. 2).

Once the two clips and the

retaining ring have been

removed, the plug may be

pulled out of the male nut.

A suitable disassembly tool is

available on request.

1. Slide disassembly

tool onto fixing ring

3. Insert disassembly

hook from below

and pull out first clip

sideways

To reassemble, always use a

new coupling element when-

ever the plug has been

removed from the male nut. In

addition, the o-rings for the

plug must be checked,

replaced if necessary and re-

greased.

5.3 Replacing plug o-rings

The damaged o-ring can be

removed after disconnection

(see section 5.2). Clean the

groove carefully, and then

replace the old o-ring with a

new one which has been

greased. All damage, excess

stretching or twisting of the o-

ring is to be avoided when

refitting. This applies both to

the sealing o-ring and to the

dirt-protection and pretension

o-ring.

5.4 Lubrication of the

o-rings

In order to ensure the functio-

nal reliability of the o-rings,

use only grease that has

been tested and approved by

VOSS.

Approved lubricating greases

are:

- Bechen – Berulub

Hydrohaf 2

- Bechen – Berulub

Hydrohaf GR

- Klüber – SYNTHESO

GLEP 1

Levering off fixing ring

VOSS Part No. 5 9 94 47 10 00 Fig. 3

Disassembly tool for the coupling element

2. Remove fixing ring

by levering

Fig. 1

4. Insert disassembly

hook from above and

pull out second clip

sideways

Fig. 2

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