SAE J 560-2016 Primary and Auxiliary Seven Conductor Electrical Connector for Truck-Trailer Jumper Cable.pdf

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1、 _ 6$(7HFKQLFDO6WDQGDUGV%RDUG5XOHVSURYLGHWKDW7KLVUHSRUWLVSX EOLVKHGE6$(WRDGYDQFHWKHVWDWHRIWHFKQLFDO 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 therefrom, LVWKHVROHUHVS

2、RQVLELOLWRIWKHXVHU SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2016 SAE International All rights reserved. No part of this publication may be reproduced

3、, 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: +1 724-776-4970 (outside USA) Fax: 724-776

4、-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/J560_201604 SURFACE VEHICLE STANDARD J560 APR2016 Issued 1951-07 Revised 2016-04 Superseding J560 FEB2009 Pri

5、mary and Auxiliary Seven Conductor Electrical Connector for Truck-Trailer Jumper Cable RATIONALE Section 2 - SAE Editors made corrections and updated to SAE document standard. Section 2.1/2.2 Moved reference for SAE J2222 to related publications from referenced publications as it does not appear in

6、the document. Section 2.1.3 Moved all existing references to 2.2.3 as they are not referenced in the document and removed year references since they are for information only. Added reference for ISO 22241-1. Section 2.1.4 Moved all references to 2.2.4 as they are not referenced in the document. Sect

7、ion 2.1.5 Moved all references to 2.2.5 as they are not referenced in the document. Section 6.1 corrected all section references in Table 1. Section 6.4.1 Fluid resistance added DEF. Added 6.4.1.1 When using the Diesel Exhaust Fluid the solution can be washed off with deionized or distilled water af

8、ter the 20 h exposure. Section 8.4 - removed reference to SAE J2394 as it was unnecessary. These wiring circuit colors are required for SAE J560 regardless of what they are in SAE J2394. Section 8.5 added the following For Auxiliary Connector per table 4 use figures 4 and 5. Section 8.6 added the fo

9、llowing - For Auxiliary Connector per table 4 use figure 6. 1. SCOPE 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

10、 requirements. SAE INTERNATIONAL J560 APR2016 Page 2 of 18 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this specification to the extent specified herein. Unless otherwise indicated, the latest issue of the publications shall apply. 2.1.1 SAE Publications Availabl

11、e from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org. SAE J2394 Seven Conductor Cable for ABS Power - Truck and Bus 2.1.2 ASTM Publications Available from ASTM International, 100 Barr Harb

12、or 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 Operating Enclosed Carbon Arc Light Apparatus for Exposure of Nonmetallic Materials ASTM G 154 Standard Practice for O

13、perating Fluorescent Light Apparatus for UV Exposure of Nonmetallic Materials 2.1.3 ISO Publications ISO 22241-1 Diesel engines NOx reduction agent AUS 32 Part 1: Quality requirements - First Edition;:2005 2.2 Related Publications The following publications are provided for information purposes only

14、 and are not a required part of this SAE Technical Report. 2.2.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org. SAE J2222 Coiled Electrical Cable - Truck an

15、d Bus 2.2.2 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, http:/tmc.trucking.org. TMC RP-107C Seven Conductor Truck-Trailer/Convertor Dolly Jumper

16、Cable and Connector Selection TMC RP-137C 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 SAE INTERNATIONAL J560 APR2016 P

17、age 3 of 18 2.2.3 ISO Publications Available from American National Standards Institute, 25 West 43rd Street, New York, NY 10036-8002, Tel: 212-642-4900, www.ansi.org. ISO 1185 Electrical connections between towing and towed vehicles with 24 V systems - 7 pole connector type 24 N (normal). ISO 1724

18、Electrical connections between towing and towed vehicles with 12 V systems - 7 pole connector type 12 N (normal). ISO 3731 Road Vehicles - Electrical connections between towing and towed vehicles with 24 V systems - 7 pole connector type 24 S (supplementary). ISO 3732 Road Vehicles - Electrical conn

19、ections between towing and towed vehicles with 12 V systems - 7 pole connector type 12 S (supplementary). 2.2.4 Truck Trailer Manufacturers Association (TTMA) Publications Available from Truck Trailer Manufacturers Association, 7001 Heritage Village Plaza, Suite 220, Gainesville, VA 20155, 703-549-3

20、010, www.ttmanet.org. TTMA Technical Bulletin #65 Wiring Diagram for Truck Trailers TTMA Technical Bulletin #119 Electrical Interface for Truck-Trailer Interconnection 2.2.5 FMVSS Publications Available from the Superintendent of Documents, U.S. Government Printing Office, Mail Stop: SSOP, Washingto

21、n, 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 .121 Air Brake Systems 3. DEFINITIONS 3.1 AUXILIARY CONNECTOR As used in this standard refers to the receptacle and cable plug that provid

22、es 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 plug is part of the jumper cable assembly. 3.3 COUPLING CYCLE Coupling and uncoupling the plug and

23、 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 FMVSS 121. SAE INTERNATIONAL J560 APR2016 Page 4 of 18 3.5 RECEPTACLE The receptacle consists of t

24、he 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 Manufacturer Identification Devices conforming to th

25、is 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, 4.2.1 SAE J560 Primary connectors are used to supply power to devices re

26、gulated by FMVSS 108 and FMVSS 121. See Table 4 for wiring functions. 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

27、permanently markHGZLWK$8;6HHTable 4 for wiring functions 4.3 The revision (month and year) of the document to which the device conforms. 4.4 Example XYZ Corp. SAE J560 Mo/Yr 5. TEST EQUIPMENT AND INSTRUMENTATION 5.1 The Power Supply The power supply shall be capable of supplying the continuous curre

28、nt required to perform all tests. 5.2 Voltmeter A direct 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

29、digital meter having at least a 3-1/2-digit readout with an accuracy of r1% 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. SAE INTERNATIONAL J560 APR2016 Page 5 of 18 5.4 Milliammeter A

30、 DC ammeter shall be used for current measurements. The meter range resolution shall be 1.0 mA. 5.5 Hipot 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 sequen

31、ce is to be performed on six different production level connector assemblies. No supplemental lubrication or other cleaning of the terminal pins prior or during the test sequence is permitted. Table 1 - Test Sequences Test Order Durability Test Mechanical Test Environmental Test 1 Voltage Drop 6.2.1

32、 Voltage Drop 6.2.1 Voltage Drop 6.2.1 2 Isolation Resistance 6.2.2 Isolation Resistance 6.2.2 Isolation Resistance 6.2.2 3 Thermal Shock 6.4.3 Thermal Shock 6.4.3 Thermal Shock 6.4.3 4 Coupling Force 6.3.1 Vibration 6.2.3 Salt Spray 6.4.2 5 Uncoupling Force 6.3.2 Straight Pull 6.3.4 Fluid Resistanc

33、e 6.4.1 6 Angular Pull Force 6.3.3 Terminal Retention Force 6.3.6 Voltage Drop 6.2.1 7 Cycle Cover Spring 6.3.7 Voltage Drop 6.2.1 Isolation Resistance 6.2.2 8 Coupling Cycle Test 6.3.8 Isolation Resistance 6.2.2 9 Voltage Drop 6.2.1 Terminal Wire Retention 6.3.5 10 Isolation Resistance 6.2.2 6.2 El

34、ectrical 6.2.1 Voltage Drop The test is to be conducted in a draft-free room maintained at an ambient temperature of 25 C r 5 C. Test sample to comprise of a mated SAE J560 assembly consisting of a receptacle and plug each with their terminals terminated to a 1000 to 2000 mm length of SAE J2394 cabl

35、e 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. 6.2.1.3 Connect a power supply to the two cable ends in such a way that it applies

36、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 drop across each circuit of the assembly at a convenient point on the wire at lea

37、st 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. SAE INTERNATIONAL J560 APR2016 Page 6 of 18 6.2.2 Isolation Resistance This test is to be performed with the connectors unmated with a hi-p

38、ot tester at 500 VAC with a leakage current setting of 0.5 mA&RQQHFWWKHWHVWHUIURPWHUPLQDOWRDOOWKHRWKHUWHUPLQDOVLQSDUDOOHOIRU RQH minute and observe for failure (breakdown). Perform this test for the following terminal combinations: #1 terminal to all other terminals #2 terminal to all other terminal

39、s #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 performed after salt residue has been washed off and the

40、 parts have been dried. 6.2.3 Vibration 6.2.3.1 Mounting Connectors (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.

41、 Connectors under test shall be wired in series and connected 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.

42、The frequency shall be varied between limits of 15 to 2000 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

43、 12 h. The connector shall be tested in each axis (X, Y and 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

44、the peak force to fully mate the UHFHSWDFOHDQGFDEOHSOXJXQWLOWKHUHFHSWDFOHVFRYHUODWFKIHDWXUHKDVHQJDJHG 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

45、 0HDVXUHDQGUHFRUGWKHSHDNIRUFHWRGLVFRQQHFWWKHFDEOHSOXJDIWHUPDQXDOOGLVHQJDJL QJWKHUHFHSWDFOHVFRYHUODWFKfeature. SAE INTERNATIONAL J560 APR2016 Page 7 of 18 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 ca

46、ble plug and SAE J2394 cable assembly and receptacle on a suitable fixture. A pull force of 667 N shall be exerted on the cable at an angle 60q , on the plugs horizontal axis, for a duration of 24 h at 25 r 5 C. Continuity of the wiring circuits shall be monitored during the test. 6.3.4 Straight Pul

47、l (Cable Plug) A cable plug and SAE J2394 cable assembly shall be securely mounted 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 r 5 C. Continuity of the wiring circuits should be measured before and after completion of the 24 h duration. 6.3.5 Terminal Wire Retention This test pertains to the mechanical connection between the connector terminals and the c