1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there
2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2009 SAE International All rights reserved. No part of this publication m
3、ay be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: 724-776-4970 (outside USA)
4、 Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSURFACEVEHICLESTANDARDJ560 FEB2009 Issued 1951-07 Revised 2009-02Superseding J560 APR2004 Primary and Auxiliary Seven Conductor Electrical Connector for Truck-Trailer Jumper Cable RATIONALE This revision of SAE J560 s
5、eeks to correct some small items that have caused some confusion, make the document more user friendly by rearranging the Test sections, and to make the test sequences more practical by changing the sequence of the testing. The following list is a detail of the changes made to this document. Correct
6、ed Titles to SAE J2222 and SAE J2394. Added the word publications after titles in Sections 2.1.4 and 2.1.5. Moved Test Sequence section to 6.1 for better clarity all Section 6 sections were bumped. Added verbiage to the now 6.2.3.2 Vibration clarifying when the transition from displacement to accele
7、ration occurs. Created Section 6.5 Additional tests. Moved Section 6.3.4 to Section 6.5.1 and removed it from test sequence. It wasnt practical to have this in the sequence this way. Since Ultraviolet effects testing is most typically farmed out to test houses, it made sense to have it as its own te
8、st item and remove it from the test sequence. Moved Section 7.4 to 7.1 to match move of 6.4 to 6.1 all Section 7 sections were bumped. Added Section 7.5 Additional Tests. Moved Section 7.3.4 to 7.5.1 to reflect changes in Section 6. Adjusted all references to align with new section numbers. 1. SCOPE
9、 This SAE Standard provides the minimum requirements for Primary and Auxiliary jumper cable plug and receptacle for the truck-trailer and converter dolly jumper cable systems. It includes the test procedures, design, and performance requirements. 2. REFERENCES 2.1 Applicable Publications The followi
10、ng publications form a part of this specification to the extent specified herein. Unless otherwise indicated, the latest issue of the publications shall apply. Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from
11、 IHS-,-,-SAE J560 Revised FEB2009 Page 2 of 172.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org.SAE J2222 Coiled Electrical CableTruck and Bus SAE J2394 Seve
12、n Conductor Cable for ABS PowerTruck and Bus 2.1.2 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org ASTM B 117-94 Standard Method of Salt Spray (Fog) Testing ASTM G 153 Standard Practice for O
13、perating Enclosed Carbon Arc Light Apparatus for Exposure of Nonmetallic Materials ASTM G 154 Standard Practice for Operating Fluorescent Light Apparatus for UV Exposure of Nonmetallic Materials 2.1.3 ISO Publications Available from ANSI, 25 West 43rd Street, New York, NY 10036-8002, Tel: 212-642-49
14、00, www.ansi.org.ISO 1185:1997 Electrical connections between towing and towed vehicles with 24 V systems7 pole connector type 24 N (normal). ISO 1724:1997 Electrical connections between towing and towed vehicles with 12 V systems7 pole connector type 12 N (normal). ISO 3731:1997 Road VehiclesElectr
15、ical connections between towing and towed vehicles with 24 V systems7 pole connector type 24 S (supplementary). ISO 3732:1997 Road VehiclesElectrical connections between towing and towed vehicles with 12 V systems7 pole connector type 12 S (supplementary). 2.1.4 Truck Trailer Manufacturers Associati
16、on (TTMA) Publications Available from Truck Trailer Manufacturers Association, 1020 Princess Street, Alexandria, VA 22314-2247, 703-549-3010, www.ttmanet.org.TTMA Technical Bulletin #65 Wiring Diagram for Truck Trailers TTMA Technical Bulletin #119 Electrical Interface for Truck-Trailer Interconnect
17、ion 2.1.5 FMVSS Publications Available from the Superintendent of Documents, U.S. Government Printing Office, Mail Stop: SSOP, Washington, DC 20402-9320. Code of Federal Regulations Title 49 Part 571.108 Lamps, Reflective devices, and Associated Equipment Code of Federal Regulations Title 49 Part .1
18、21 Air Brake Systems Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J560 Revised FEB2009 Page 3 of 172.2 Related Publications The following publications are provided for information purposes and
19、 are not a required part of this document. 2.2.1 Technology and Maintenance Council Available for the Technology and Maintenance Council, American Trucking Associations, 950 North Glebe Road, Suite 210, Arlington, VA 22203-4181, Tel: 703-838-1763, .TMC RP-107C Seven Conductor Truck-Trailer/Convertor
20、 Dolly Jumper Cable and Connector Selection TMC RP-137 Antilock Electrical Supply from Tractors through the SAE J560 Seven Pin Connector TMC RP-141 Trailer ABS Power Supply Requirements TMC RP-147 SAE J560 Plug and Receptacle Wire-To-Wire Terminal Interface Performance Guidelines 3. DEFINITIONS 3.1
21、Auxiliary Connector As used in this standard refers to the receptacle and cable plug that provides power to the auxiliary devices on the trailer, but does not provide power to safety lighting and the Antilock Braking System (ABS) as required by FMVSS 108 and/or FMVSS 121. 3.2 Cable Plug The cable pl
22、ug is part of the jumper cable assembly. 3.3 Coupling Cycle Coupling and uncoupling the plug and receptacle is one coupling cycle. 3.4 Primary Connector As used in this standard refers to the receptacle and cable plug that provides power to safety lighting and the ABS as required by FMVSS 108 and FM
23、VSS 121. 3.5 Receptacle The receptacle consists of the connector socket, its housing, and a cover which latches the cable plug in place. 3.6 Serviceable A serviceable part is one that can be removed with reasonable force and reinstalled without visible damage. 4. IDENTIFICATION CODE DESIGNATION 4.1
24、Manufacturer Identification Devices conforming to this document shall be identified with the manufacturers identification. The device may include the model or part number. 4.2 SAE Designation Devices conforming to this document shall be visually differentiated by connector type, Copyright SAE Intern
25、ational Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J560 Revised FEB2009 Page 4 of 174.2.1 SAE J560 Primary connectors are used to supply power to devices regulated by FMVSS 108 and FMVSS 121. See Table 4 for wiring fun
26、ctions. 4.2.2 SAE J560 AUX Auxiliary connectors are used to supply power and control to auxiliary devices (i.e. lift gates, refrigeration power units, dome lamps, etc.). The connector shall be identified either by the color yellow and/or permanently marked with “AUX”. See Table 4 for wiring function
27、s 4.3 The revision (month and year) of the document to which the device conforms. 4.4 Example XYZ Corp. SAE J560 Mo/Yr5. TEST EQUIPMENT AND INSTRUMENTATION 5.1 The Power Supply The power supply shall be capable of supplying the continuous current required to perform all tests. 5.2 Voltmeter A direct
28、 current (DC) voltmeter with an input resistance greater than 1000 /V and with a resolution of 0.1 V shall be used. To achieve this resolution, the full-scale deflection shall be appropriate to the voltage rating of the system being tested. A digital meter having at least a 3-1/2-digit readout with
29、an accuracy of 1% plus one digit is recommended for millivolt readings. 5.3 Ammeter A DC ammeter shall be used for current measurements. The meter range resolution shall be 0.1 A. 5.4 Milliammeter A DC ammeter shall be used for current measurements. The meter range resolution shall be 1.0 mA. 5.5 Hi
30、pot Capable of detecting leakage currents of 0.5 mA at 500 VAC. 6. TEST PROCEDURES 6.1 Test Sequences The tests in 6.2, 6.3, and 6.4 are to be tested in the order listed in Table 1. Each test sequence is to be performed on six different production level connector assemblies. No supplemental lubricat
31、ion or other cleaning of the terminal pins prior or during the test sequence is permitted. Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J560 Revised FEB2009 Page 5 of 17TABLE 1 - TEST SEQUENCE
32、S Test Order Durability Test Mechanical Test Environmental Test 1 Voltage Drop 6.1.1 Voltage Drop 6.1.1 Voltage Drop 6.1.1 2 Isolation Resistance 6.1.2 Isolation Resistance 6.1.2 Isolation Resistance 6.1.2 3 Thermal Shock 6.3.3 Thermal Shock 6.3.3 Thermal Shock 6.3.3 4 Coupling Force 6.2.1 Vibration
33、 6.1.3 Salt Spray 6.3.2 5 Uncoupling Force 6.2.2 Straight Pull 6.2.4 Fluid Resistance 6.3.1 6 Angular Pull Force 6.2.3 Terminal Retention Force 6.3.6 Voltage Drop 6.1.1 7 Cycle Cover Spring 6.2.7 Voltage Drop 6.1.1 Isolation Resistance 6.1.2 8 Coupling Cycle Test 6.2.8 Isolation Resistance 6.1.2 9 V
34、oltage Drop 6.1.1 Terminal Wire Retention 6.3.5 10 Isolation Resistance 6.1.2 6.2 Electrical 6.2.1 Voltage Drop The test is to be conducted in a draft-free room maintained at an ambient temperature of 25 C 5 C. Test sample to comprise of a mated SAE J560 assembly consisting of a receptacle and plug
35、each with their terminals terminated to a 1000 to 2000 mm length of SAE J2394 cable 6.2.1.1 Connect a 1000 to 2000 mm long SAE J2394 type cable to the receptacle terminals and another 1000 to 2000 mm long SAE J2394 type cable to the cable plug terminals. 6.2.1.2 Mate the cable plug and receptacle. 6
36、.2.1.3 Connect a power supply to the two cable ends in such a way that it applies 35 A to each circuit having a 4.75 mm diameter terminal and 70 A to the circuit having a 6.35 mm diameter terminal. 6.2.1.4 Turn on power supply and wait 5 min for the circuits to stabilize. 6.2.1.5 Measure the voltage
37、 drop across each circuit of the assembly at a convenient point on the wire at least 25 mm from the terminal. 6.2.1.6 Connectors with active or passive electrical components may be tested by installing low-resistance shunts across the device. 6.2.2 Isolation Resistance This test is to be performed w
38、ith the connectors unmated with a hi-pot tester at 500 VAC with a leakage current setting of 0.5 mA. Connect the tester from terminal “x” to all the other terminals in parallel for one minute and observe for failure (breakdown). Perform this test for the following terminal combinations: #1 terminal
39、to all other terminals #2 terminal to all other terminals #3 terminal to all other terminals #4 terminal to all other terminals #5 terminal to all other terminals #6 terminal to all other terminals #7 terminal to all other terminals #8 Shell to all other terminals If applicable, this test should be
40、performed after salt residue has been washed off and the parts have been dried. Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J560 Revised FEB2009 Page 6 of 176.2.3 Vibration 6.2.3.1 Mounting C
41、onnectors (Cable plug and receptacle mated) under test are to be mounted to the vibrating plane with the SAE J2394 wire harness end fixed to a stationary object no closer than 100 mm and not farther than 300 mm from the rear of the connector. Connectors under test shall be wired in series and connec
42、ted to a DC power supply source, with a current flow of 10 A in each terminal. 6.2.3.2 Vibration Test Characteristics Connectors under test shall be subjected to a sine motion sweep having an initial displacement of 1.78 mm double amplitude. The frequency shall be varied between limits of 15 to 2000
43、 Hz. The entire frequency range (15 to 2000 back to 15 Hz) shall be traversed in 15 min. (Acceleration levels not to exceed 20 Gs the transition from displacement to acceleration occurs at 75 Hz). 6.2.3.3 Test Duration Test to last a total of 12 h. The connector shall be tested in each axis (X, Y an
44、d Z) for 4 h. Monitor for discontinuity in excess of 100 ms at 100 mA during the last hour of vibration in each axis. 6.3 Mechanical 6.3.1 Coupling Force Mount the assembled cable plug and receptacle on a suitable fixture. Measure and record the peak force to fully mate the receptacle and cable plug
45、 until the receptacles cover latch feature has engaged. 6.3.2 Uncoupling Force Mount the assembled cable plug and receptacle on a suitable fixture. The force in the following tests shall be applied parallel to the axis of the connector. 6.3.2.1 Unlatched Measure and record the peak force to disconne
46、ct the cable plug after manually disengaging the receptacles cover latch feature. 6.3.2.2 Latched Measure and record the peak force to disconnect the cable plug with the cover latch engaged. 6.3.3 Angular Pull Force Mount the cable plug and SAE J2394 cable assembly and receptacle on a suitable fixtu
47、re. A pull force of 667 N shall be exerted on the cable at an angle 60, on the plugs horizontal axis, for a duration of 24 h at 25 5 C. Continuity of the wiring circuits shall be monitored during the test. 6.3.4 Straight Pull (Cable Plug) A cable plug and SAE J2394 cable assembly shall be securely m
48、ounted in a suitable fixture. A pull force of 667 N shall be exerted on the cable along the axis of the cable plug for a duration of 24 h at 25 5 C. Continuity of the wiring circuits should be measured before and after completion of the 24 h duration. Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J560 Revised FEB2009 Page 7 of 176.3.5 Terminal Wire Retention This test pertains to the mechanical connection betwe
