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Plug-In Couplings For Steering Hydraulic System

IMPORTANT:
  • The principle of the plug-in couplings for the pressure and return lines is the same. It is the diameter of the plug-in coupling and of the pipelines that differ (return line = large diameter / pressure line = small diameter).
  • Plug-in couplings are components that permit simple, fast and precise connection of pipelines.
  • These precision components must be handled carefully during repairs. Excess force during assembly work, damage to the sealing surface and soiling can cause leakage.
  • Perform preparations carefully when handling plug-in couplings - e.g. cleaning and fitting the plugs - as repairs are possible only by replacing the affected line in most cases. Only the threaded part A (with fitted O-rings) and the holder C are available as individual parts for the plug-in coupling (see Plug-in couplings for pipelines  ).
Fig 1: Identifying Plug-In Coupling Tool
G03103491Courtesy of PORSCHE OF NORTH AMERICA, INC.
PLUG-IN COUPLING TOOL EXPLANATION

No. Designation Special tool Explanation
A in Fig 1 Testing tool for plug-in couplings 9623 Used to check whether the plug-in couplings are seated properly.
 
Suitable for pressure and return lines (nominal diameter 6 and nominal diameter 10)
NOTE:
  • Pressure and return lines have different dimensions. Pressure line = nominal diameter 6, return line = nominal diameter 10.
  • The plug-in coupling is opened by unscrewing. It is joined by plugging together.
  • Join the plug-in connection only in a straight line. Never use excess force.
  • After separating the plug and socket piece, carefully protect them against dirt and scratches with caps.
  • Pull slightly to make sure the connection is locked properly. Use special tool 9623 for this purpose.
STEERING HYDRAULIC SYSTEM PROCEDURE

No. Procedure Instructions
1 Open plug-in coupling. Turn at threaded part A to open the plug-in coupling. When doing so, counter at plug-in coupling B.
  Open corresponding retainers on the body. Carefully disengage clip and fold down.
2 Remove holder C. Tilt holder C on one side and simultaneously pull to disengage.
3 Pull threaded part A from the plug. Detach threaded part A by pulling it off the plug.
4 Screw together plug-in coupling. Close holder C (arrow / dovetail system). Screw threaded part A with fitted holder C into plug-in coupling B and tighten. Counter when tightening.
 
Replace holder C and threaded part A if necessary in order ensure that the plug-in connection functions properly (holding function and tightness).
5 Join plug-in coupling. Insert the plug (line with plug) into the plug-in coupling in a straight line.
The plug must audibly engage in the holder.
6 Use special tool 9263 to check whether the plug-in coupling was engaged properly. Insert special tool 9263 into the groove (arrow) and apply slight pressure on the special tool to check whether the connection is securely locked (holder is seated properly). The plug must not slide out.
 
If the special tool cannot be inserted in the groove of the plug, shift the plug in the plug-in coupling (pull on plug without using excess force).
 
Note:
The plug-in connection is designed so that the plug can be shifted in the plug-in coupling by approx. 1 mm in axial direction by slightly pulling or pressing.
7 Close corresponding retainers on the body. Carefully fold the clip up and engage.
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