Standard for: Variant

SAU Long type trailer brake lines

Department / Group Position Takt time (s)

MZEPF 583861
Order of procedure

Issued by Date Reg.nr /

Issue

SNLVOJ 2018.01.1 1
Element nr.

Element time

Element time

Element time

Element time

Element time

Element time
Important / to remember / Safety

Acc. Time

Acc. Time

Acc. Time

Acc. Time

Acc. Time

Acc. Time
Activity / Element name
alternatively, Tool symbol

1 2477297 Dismantling
2 2477297 Dismantling
3 2477297 Fitting stickers and valves
4 2477297 Fitting spiral hoses
5 2477297 Fitting bracket and finishing
6 2477297 Platform preparation
7 2477297 Fitting bracket
8 2477297 Fitting spiral hoses on catwalk
9 2477297 Testing
10 2477297 Securing couplings
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
SV Approval TL Approval Sum. of Required Protective Equipment: Sum. Sum. Sum. Sum. Sum. Sum.

The variant proportion of the total volume (%):

Work that is incidentally done on the position

What: How: Why: When: Frequency:
Eng Approval

Purpose of Standard: Base for training and follow-up. The basis for improvement. How: Shows what happens at the position including variants, in what order and the right time

583861_2477297_SAU_Long_type_trailer_brake_lines_2018.01.1 TD - SPS Industrial Development 2012-11-14

 Element name - task headline Dismantling MECO/Proj nr.
Variant/Type ECO nr. 583861
Task nr. 1 Issued by SNLVOJ Tools Global Elt nr. 2477297
Task location on product Element nr. 2477297 Date 12-12-17 Issuer SNLVOJ
Issue 1 Page 1/10 Protection equipments required:
Global eng. SNLVOJ
Element time 0,0 s Date 12-12-17

Picture Nr What How Why

1 Follow the correct standard for Use standard 3637 for tightening Quality Assurance
assembly torques and standard 4251 for line
marking unless otherwise stated

2 Check whether button A is Press it to check. It is located under No air pressure in the trailer
depressed. the parking brake lever. circuit

3 Dismantle the couplings Remove couplings (B) on the The plugs are needed to keep
bracket. Do not remove lines. Fit the trailer circuit airtight.
the plugs

4 Dismantle the couplings Dismantle couplings (C) on the Nuts and washers will be used
bracket. Save couplings, nuts and again
washers.

5 Disconnect connectors (D) Remove 4x M8 nut. Save nuts They will be used again

Approval by each shift, name & date

Legal
Supervisor requirement
s / Safety
TL
Equipment
Process engineer Product engineer

583861_2477297_SAU_Long_type_trailer_brake_lines_2018.01.1 TD - SPS Industrial Development 2012-08-31

 Element name - task headline Dismantling MECO/Proj nr.
Variant/Type ECO nr. 583861
Task nr. 2 Issued by SNLVOJ Tools Global Elt nr. 2477297
Task location on product Element nr. 2477297 Date 12-12-17 Issuer SNLVOJ
Issue 1 Page 2/10 Protection equipments required:
Global eng. SNLVOJ
Element time 0,0 s Date 12-12-17

Picture Nr What How Why

1 Remove the heat shield (A), if Remove 2x M8 nut. Save nuts They will be used again
present.

2 Remove the bracket (B) Remove 4x M10 nut. Save nuts and Nuts and spacer bushes will
spacer bushes be used again

Approval by each shift, name & date

Legal
Supervisor requirement
s / Safety
TL
Equipment
Process engineer Product engineer

583861_2477297_SAU_Long_type_trailer_brake_lines_2018.01.1 TD - SPS Industrial Development 2012-08-31

 Element name - task headline Fitting stickers and valves MECO/Proj nr.
Variant/Type ECO nr. 583861
Task nr. 3 Issued by SNLVOJ Tools Global Elt nr. 2477297
Task location on product Element nr. 2477297 Date 12-12-17 Issuer SNLVOJ
Issue 1 Page 3/10 Protection equipments required:
Global eng. SNLVOJ
Element time 0,0 s Date 12-12-17

Picture Nr What How Why

1 Affix the stickers to the See picture. First degrease surface To ensure good adhesion of
bracket the stickers

2 Fit the couplings in the shut-off Use the parts and order shown in
valves the picture.

3 Fit the shut-off valves to the Use the parts, sequence and
bracket. position shown in the picture.

4 Fit the plugs in the shut-off Fit the 45° couplings and the plugs
valves.

Approval by each shift, name & date

Legal
Supervisor requirement
s / Safety
TL
Equipment
Process engineer Product engineer

583861_2477297_SAU_Long_type_trailer_brake_lines_2018.01.1 TD - SPS Industrial Development 2012-08-31

 Element name - task headline Fitting spiral hoses MECO/Proj nr.
Variant/Type ECO nr. 583861
Task nr. 4 Issued by SNLVOJ Tools Global Elt nr. 2477297
Task location on product Element nr. 2477297 Date 12-12-17 Issuer SNLVOJ
Issue 1 Page 4/10 Protection equipments required:
Global eng. SNLVOJ
Element time 0,0 s Date 12-12-17

Picture Nr What How Why

1 Fit the spiral hoses on the Place the adapter in a vice with Easy assembly without
adapters (A) protective jaws. Use Loctite 542. damage
Tighten to 30 Nm

2 Fit the spiral hoses to the See picture. Reuse washers and
bracket (B) nuts

3 Cut air lines Make a connection between the

4 Fit the air lines
shut-off valve and the spiral hose.
Cut lines to size during the work.
Apply marking according to
standard
See picture

Approval by each shift, name & date

Legal
Supervisor requirement
s / Safety
TL
Equipment
Process engineer Product engineer

583861_2477297_SAU_Long_type_trailer_brake_lines_2018.01.1 TD - SPS Industrial Development 2012-08-31

 Element name - task headline Fitting bracket and finishing MECO/Proj nr.
Variant/Type ECO nr. 583861
Task nr. 5 Issued by SNLVOJ Tools Global Elt nr. 2477297
Task location on product Element nr. 2477297 Date 12-12-17 Issuer SNLVOJ
Issue 1 Page 5/10 Protection equipments required:
Global eng. SNLVOJ
Element time 0,0 s Date 12-12-17

Picture Nr What How Why

1 Fit the bracket (A) Reuse 4x M10 nut and spacer
bushes

2 Fit connectors C and D Use 4x M8X20 and reuse 4x M8 nut

3 Strap the air lines Place the air lines along the cables
and strap them with heat-resistant
straps

4 Route the cables and lines at Where possible, use the original
your own discretion and strap positions and routing. Use heat
them in place resistant straps. Avoid sharp edges

5 Fit the heat shield (B) Reuse 4x M8 nut, if previously

removed

Approval by each shift, name & date

Legal
Supervisor requirement
s / Safety
TL
Equipment
Process engineer Product engineer

583861_2477297_SAU_Long_type_trailer_brake_lines_2018.01.1 TD - SPS Industrial Development 2012-08-31

 Element name - task headline Platform preparation MECO/Proj nr.
Variant/Type ECO nr. 583861
Task nr. 6 Issued by SNLVOJ Tools Global Elt nr. 2477297
Task location on product Element nr. 2477297 Date 12-12-17 Issuer SNLVOJ
Issue 1 Page 6/10 Protection equipments required:
Global eng. SNLVOJ
Element time 0,0 s Date 12-12-17

Picture Nr What How Why

1 Fit the studs in the threaded 10 Nm. Short end into the threaded
sleeves. sleeve.

2 Dismantle the first catwalk Loosen 4x M8 bolt several turns to

release the clamps

3 Fit the threaded sleeves to the At the indicated positions (A) with
catwalk 6x M8 flange lock nut

4 Fit the plate (B) On the catwalk with 6x M8x14

flange screw

5 Drill a hole (C) Use 12 mm drill bit to drill through Finish to remove sharp edges
the plate in the catwalk. Finish with
a countersink bit

Approval by each shift, name & date

Legal
Supervisor requirement
s / Safety
TL
Equipment
Process engineer Product engineer

583861_2477297_SAU_Long_type_trailer_brake_lines_2018.01.1 TD - SPS Industrial Development 2012-08-31

 Element name - task headline Fitting bracket MECO/Proj nr.
Variant/Type ECO nr. 583861
Task nr. 7 Issued by SNLVOJ Tools Global Elt nr. 2477297
Task location on product Element nr. 2477297 Date 12-12-17 Issuer SNLVOJ
Issue 1 Page 7/10 Protection equipments required:
Global eng. SNLVOJ
Element time 0,0 s Date 12-12-17

Picture Nr What How Why

1 Remove the plate (A).

2 Fit the bracket (B) on the plate 40 Nm. Note: the nut is an imperial
with the pipe clamp (C) turned size.
to the right (driver's side)

3 Fit the assembly on the 1st Reuse 6x M8x14 flange screw

catwalk.

4 Fit the catwalk on the chassis. In the original location

Approval by each shift, name & date

Legal
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s / Safety
TL
Equipment
Process engineer Product engineer

583861_2477297_SAU_Long_type_trailer_brake_lines_2018.01.1 TD - SPS Industrial Development 2012-08-31

 Element name - task headline Fitting spiral hoses on catwalk MECO/Proj nr.
Variant/Type ECO nr. 583861
Task nr. 8 Issued by SNLVOJ Tools Global Elt nr. 2477297
Task location on product Element nr. 2477297 Date 12-12-17 Issuer SNLVOJ
Issue 1 Page 8/10 Protection equipments required:
Global eng. SNLVOJ
Element time 0,0 s Date 12-12-17

Picture Nr What How Why

1 Unscrew the bolt (1) from the
plastic clamp.

2 Fit the spiral hoses in the
clamp on the bracket
3 Fit the bolt (1) back into the
clamp on the bracket
Place the clamp immediately after
the metal spring. Red right, blue
left. The spiral hoses must not cross
each other. Middle position remains
open.
3 Nm MAX.

Approval by each shift, name & date

Legal
Supervisor requirement
s / Safety
TL
Equipment
Process engineer Product engineer

583861_2477297_SAU_Long_type_trailer_brake_lines_2018.01.1 TD - SPS Industrial Development 2012-08-31

 Element name - task headline Testing MECO/Proj nr.
Variant/Type ECO nr. 583861
Task nr. 9 Issued by SNLVOJ Tools Global Elt nr. 2477297
Task location on product Element nr. 2477297 Date 12-12-17 Issuer SNLVOJ
Issue 1 Page 9/10 Protection equipments required:
Global eng. SNLVOJ
Element time 0,0 s Date 12-12-17

Picture Nr What How Why

1 Supply air pressure to the Pull out knob B on the dashboard To supply air pressure to the
trailer circuit trailer circuit.

2 Check that there are no air Spray leak detection spray on the In the event of air leakage,
leaks in the installation plugs (see page 1, point B) visible air bubbles are created

3 After checking for air leaks, The trailer circuit is now

push button A. pressure-free

Approval by each shift, name & date

Legal
Supervisor requirement
s / Safety
TL
Equipment
Process engineer Product engineer

583861_2477297_SAU_Long_type_trailer_brake_lines_2018.01.1 TD - SPS Industrial Development 2012-08-31

 Element name - task headline Securing couplings MECO/Proj nr.
Variant/Type ECO nr. 583861
Task nr. 10 Issued by SNLVOJ Tools Global Elt nr. 2477297
Task location on product Element nr. 2477297 Date 12-12-17 Issuer SNLVOJ
Issue 1 Page 10/10 Protection equipments required: Global eng. SNLVOJ
Element time 0,0 s Date 12-12-17

Picture Nr What How Why

1 Strap the spiral hoses to the See picture. Place a protection To prevent damage
bracket rubber around the bracket

Approval by each shift, name & date

Legal
Supervisor requirement
s / Safety
TL
Equipment
Process engineer Product engineer

583861_2477297_SAU_Long_type_trailer_brake_lines_2018.01.1 TD - SPS Industrial Development 2012-08-31

 ECO nr. / FPC code: 583861
Partlist Valid from p. period: 2018.01.1

Issue: 1
Description of adaptation: SAU Long type trailer brake lines
Date: 12-12-2017
Disc. parts Intro. parts
Part nr: QTY Part nr: QTY Description Conditions Remarks
2477297 Mounting instruction
2662757 1 LABEL "SERVICE"
2662758 1 LABEL "EMERGENCY"
2601258 1 TRAILER CONNECTION BRACKET ASS
1424404 2 SWITCH CONTROL VALVE
2058225 2 STRAIGHT JOINT UNION REG M22
1374839 2 SEAL
1762305 2 ADAPTER UNION 22-16
1349129 2 UNION
803007 4 WASHER 19X34
814577 2 HEXAGON NUT M18X1,5
1369865 2 INSERT CONNECTION
2058417 2 ELBOW JOINT UNION 45 DEG REG
2246502 2 PLUG
1765856 2 TRAILER COUPLING ASSY
2452475 1 COILED HOSE RED COLOURED
2452476 1 COILED HOSE BLUE COLOURED
2443494 450 PLASTIC PIPE 12X1,5
2443494 550 PLASTIC PIPE 12X1,5
805977 4 PAN HEAD SCREW M8X20
800045 6 STUD M8X35
1724974 6 NUT
377647 6 FLANGE LOCK NUT
812514 6 FLANGE SCREW M8X14
2333068 1 MOUNTING PLATE
2295557 1 TRAILER CONNECTION ARM
1314199 1 PROTECTION HOSE
2575051 1 HEAT SHIELD ASSY 142D or 142H
815132 4 HEXAGON NUT WITH FLANGE M8 142D or 142H