SAE J 2593-2015 Information Report for the Installation of Fluid Conductors and Connectors.pdf

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1、 SURFACE VEHICLE INFORMATION REPORTJ2593 FEB2015 Issued 2004-10 Revised 2015-02 Superseding J2593 JAN2009 Information Report for the Installation of Fluid Conductors and ConnectorsRATIONALE On page 21 in Figure 7 the pictorials were replaced with figures from ISO 11686 to better represent correct as

2、sembly procedure for adjustable port fittings, removed SAE J2244 (this standard has been canceled), added SAE J1926-4 and ISO 6149-4 for external and internal hex plug torques, replaced SAE J518 with SAE J518/1 and SAE J518/2 and editorial changes were made. To help eliminate confusion and improve t

3、he connection, a minimum class 10.9 metric (SAE grade 8 or better) screws are now required. On page 20 removed Table 1 which was showing 8.8 metric or SAE grade 5 screws and then renumbered all of the subsequent tables respectfully. Updated dated ORFS and straight thread o-ring port tables with addi

4、tional sizes. Replaced inch size hex sizes and wrenches with metric sizes where appropriate. Converts the document to metric hex standard in accordance with FCCTC resolution on metric hex conversion. The resolution provides rationale for converting to metric hex and not using inch hex for new design

5、s as follows: “In an effort to standardize within a global market and ensuring that companies can remain competitive in an international market, it is the intent to convert to metric hex sizes which will: x lead to one global standard x guide users to a preferred system x reduce complexity x elimina

6、te duplication x reduce confusion” Ballot comments have been addressed as follows: 1. In 6.1.1 - Added, J518 -1 and J518-2 are technically identical to ISO 6162-1 and ISO 6162-2. 2. In 6.1.1.4 - Added, Note: If for use with only metric screws parts are stamped with an “M“. Many can be used with both

7、 inch and metric screws and are not marked. 3. In 6.1.1.2 Table 1 - Changed the following Metric assembly torques; 24 32; 50 70; 92130; 210 295 4. In 6.1.3.3 Table 2 - Changed Maximum Working Pressure from 40 to 42 MPa. Also in Tables 1 and 2, ISO 4017 was added to metric wrench size column and the

8、following sizes changed; 17 to 16 and 19 to 18, to comply with ISO 4017 which is applicable to SAE J518. _ 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

9、its applicability and suitability for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your

10、written comments and suggestions. Copyright 2014 SAE International All rights reserved. No part of this publication may 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 pe

11、rmission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970 (outside USA) Fax: 724-776-0790 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.

12、org/technical/standards/J2593_201502 SAE INTERNATIONAL J2593 Revised FEB2015 Page 2 of 34 TABLE OF CONTENTS 1. SCOPE 4 2. REFERENCES 4 2.2 Related Publications . 7 3. EXPLANATION OF TERMS AND TERMINOLOGY . 10 4. FLUID CONDUCTOR AND CONNECTOR SERVICE LIFE . 10 4.1 Leak Classifications 10 4.2 Common C

13、auses of Leaks with Fluid Conductors and Connectors . 11 5. HYDRAULIC FLUID CONDUCTOR AND CONNECTOR INSTALLATION 12 5.1 Typical Tightening Sequence 12 5.2 Typical Multiple Tube Installation Tightening Sequence . 12 5.3 Proper Joint Closure . 13 5.4 Improper Joint Closure 14 5.5 Proper Wrench Usage .

14、 14 5.6 Using the Torque Wrench Correctly 14 5.7 Co-efficient of Friction . 15 5.8 Component Materials 15 5.9 SAE Dash Size 15 5.10 Metric Size 15 5.11 Connector Identification 15 5.12 Hydraulic System Cleanliness 15 6. ASSEMBLY PROCEDURES AND TORQUE LEVELS FOR FLUID CONDUCTOR AND CONNECTORS 17 6.1

15、ISO 6162-1, ISO 6162-2/SAE J518-1 and SAE J518-2 Flange Connections 17 6.2 ISO6149-2/ISO 6149-3/SAE J1926-2/SAE J1926-3 Straight Thread O-Ring Port Connectors Recommended Assembly Procedures, see Figure 7. 20 6.3 SAE J2337-2 High Pressure Connections and SAE J2337-3 High Pressure Plugs Recommended A

16、ssembly Procedures, see Figure 8. 23 6.4 ISO 8434-3/SAE J1453 O-Ring Face Seal Connections Recommended Assembly Procedures, see Figure 9. . 24 6.5 ISO 8434-2/SAE J514 - Flared Connections Recommended Assembly Procedures, see Figure 10. . 25 6.6 ISO 8434-3 and SAE J1453 ORFS Threaded Connectors Recom

17、mended Assembly Procedures for Bulkhead Fastening Jam Nuts, see Figure 11. 26 6.6.1 ISO 8434-3 and SAE J1453 ORFS Bulkhead Fastening Jam Nuts Recommended Torque Levels, see Table 10. 27 6.7 ISO 8434-2 and SAE J514 Threaded Connectors Recommended Assembly Procedures for Bulkhead Fastening Jam Nuts, s

18、ee Figure 12. 27 6.8 ISO 8434-1/SAE J514 24 Cone Flareless Tube Connectors Recommended Assembly Procedures. . 28 6.9 ISO 6149-4/SAE J1926-4 Metric/Inch Hex Drive and Recess Drive Plugs Recommended Assembly Procedures, see Figure 13. . 29 6.10 SAE J530 Automotive Tapered Pipe Thread Port Connections

19、and SAE J531 Filler and Drain Plug Recommended Assembly Procedures, see Figure 14. . 31 6.11 SAE J514 30 Swivel Pipe Adapters Recommended Assembly Procedures, see Figure 15. 32 6.12 SAE J532 Automotive Straight Threaded Filler and Drain Plugs Recommended Assembly Procedures, see Figure 16. . 33 7. N

20、OTES 34 7.1 Marginal Indicia . 34 SAE INTERNATIONAL J2593 Revised FEB2015 Page 3 of 34 FIGURE 1 TYPICAL HYDRAULIC FLUID CONDUCTOR AND CONNECTOR INSTALLATION . 12 FIGURE 2 MULTIPLE TUBE INSTALLATION TIGHTENING SEQUENCE. 13 FIGURE 3 PROPERLY CLOSED JOINT . 13 FIGURE 4 IMPROPERLY CLOSED JOINT . 14 FIGU

21、RE 5 TYPICAL COMBINATIONS OF PROPER USE OF TORQUE WRENCH AND BACK-UP WRENCH FOR THREADED CONNECTIONS . 14 FIGURE 6 ISO 6162 -1, ISO 6162 -2, SAE J518-1 AND SAE J518-2 FOUR-BOLT SPLIT FLANGE TIGHTENING SEQUENCE BEFORE PROCEEDING, REFER TO ASSEMBLY INSTRUCTIONS IN PARAGRAPHS 6.1.1 THROUGH 6.1.3.1, THE

22、N TORQUE SCREWS IN DIAGONAL SEQUENCE IN SMALL INCREMENTS TO THE APPROPRIATE TORQUE LEVELS LISTED IN TABLE 1 OR 2 . 18 FIGURE 7 ISO6149-2/ISO 6149-3 AND SAE J1926-2/SAE J1926-3 STRAIGHT THREAD O-RING PORT CONNECTORS RECOMMENDED ASSEMBLY PROCEDURES . 20 FIGURE 8 SAE J2337-2 CONNECTORS AND SAE J2337-3

23、PLUGS ASSEMBLY PROCEDURES . 23 FIGURE 9 ISO 8434-3/SAE J1453 O-RING FACE SEAL CONNECTORS RECOMMENDED ASSEMBLY PROCEDURES TO TUBE ASSEMBLIES, HOSE ASSEMBLIES AND OTHER ORFS CONNECTORS 24 FIGURE 10 ISO 8434-2/SAE J514 FLARED CONNECTORS RECOMMENDED ASSEMBLY PROCEDURES FOR TUBE ASSEMBLIES, HOSE ASSEMBLI

24、ES AND OTHER FLARED CONNECTORS 25 FIGURE 11 ISO 8434-3 AND SAE J1453 ORFS CONNECTORS RECOMMENDED ASSEMBLY PROCEDURES FOR BULKHEAD FASTENING JAM NUTS . 26 FIGURE 12 ISO 8434-2 AND SAE J514 FLARED CONNECTORS RECOMMENDED ASSEMBLY PROCEDURES FOR BULKHEAD FASTENING JAM NUTS . 27 FIGURE 13 ISO 6149-4/SAE

25、J1926-4 METRIC/INCH HEX DRIVE AND RECESS DRIVE PLUGS RECOMMENDED ASSEMBLY PROCEDURE. 29 FIGURE 14 SAE J530 TAPERED PIPE THREADED PORT CONNECTIONS AND SAE J531 FILTER AND DRAIN PLUG RECOMMENDED ASSEMBLY PROCEDURES 31 FIGURE 15 SAE J514 30 SWIVEL PIPE ADAPTERS RECOMMENDED ASSEMBLY PROCEDURES 32 FIGURE

26、 16 SAE J532 AUTOMOTIVE STRAIGHT THREADED FILLER AND DRAIN PLUGS 33 TABLE 1 ISO 6162 - 1 AND SAE J518-1 SCREW TORQUE AND MAXIMUM WORKING PRESSURES FOR MEDIUM PRESSURE (CODE 61) FLANGED PORT ASSEMBLIES WHEN USING HIGH STRENGTH SCREWS, PROPERTY CLASS 10.9 METRIC SCREWS OR GRADE 8 INCH SCREWS . 19 TABL

27、E 2 ISO 6162 - 2 AND SAE J518-2 SCREW TORQUE AND MAXIMUM WORKING PRESSURES FOR HIGH PRESSURE (CODE 62) FLANGED PORT ASSEMBLIES WHEN USING HIGH STRENGTH SCREWS, PROPERTY CLASS 10.9 METRIC SCREWS OR GRADE 8 INCH SCREWS . 19 TABLE 3 ISO 6149-3 METRIC STRAIGHT THREAD O-RING PORT CONNECTOR RECOMMENDED TO

28、RQUE LEVELS FOR USE WITH ISO 8434-3/SAE J1453 ORFS AND/OR ISO8434-2/SAE J514 FLARED CONNECTORS IN LIGHT-DUTY APPLICATIONS 21 TABLE 4 ISO 6149-2 METRIC STRAIGHT THREAD O-RING PORT CONNECTOR RECOMMENDED TORQUE LEVELS FOR USE WITH ISO 8434-3/SAE J1453 ORFS CONNECTORS IN HEAVY-DUTY APPLICATIONS 21 TABLE

29、 5 SAE J1926-3 INCH STRAIGHT THREAD O-RING PORT CONNECTOR RECOMMENDED TORQUE LEVELS FOR USE WITH ISO 8434-1 FLARELESS CONNECTORS AND ISO 8434-2/ SAE J514 FLARED CONNECTORS IN LIGHT DUTY APPLICATIONS 22 TABLE 6 SAE J1926-2 INCH STRAIGHT THREAD O-RING PORT CONNECTOR RECOMMENDED TORQUE LEVELS FOR USE W

30、ITH ISO 8434-3/SAE J1453 ORFS CONNECTORS 23 TABLE 7 SAE J2337-2 HIGH PRESSURE CONNECTORS AND SAE J2337-3 HIGH PRESSURE PLUGS RECOMMENDED TORQUE LEVELS TO TUBE ASSEMBLIES, HOSE ASSEMBLIES, OTHER HIGH PRESSURE CONNECTORS AND COMPONENTS 24 TABLE 8 ISO 8434-3/SAE J1453 O-RING FACE SEAL CONNECTORS RECOMM

31、ENDED TORQUE LEVELS TO TUBE ASSEMBLIES, HOSE ASSEMBLIES AND OTHER ORFS CONNECTORS 25 TABLE 9 ISO 8434-2/SAE J514 FLARED CONNECTORS RECOMMENDED TORQUE LEVELS TO TUBE ASSEMBLIES, HOSE ASSEMBLIES AND OTHER FLARED CONNECTORS . 26 TABLE 10 ISO 8434-3 AND SAE J1453 RECOMMENDED ASSEMBLY TORQUE LEVELS OR OR

32、FS CONNECTOR BULKHEAD FASTENING JAM NUTS 27 TABLE 11 ISO 8434-2 AND SAE J514 RECOMMENDED ASSEMBLY TORQUE LEVELS FOR FLARED CONNECTOR BULKHEAD FASTENING JAM NUTS 28 SAE INTERNATIONAL J2593 Revised FEB2015 Page 4 of 34 TABLE 12 ISO 6149-4 METRIC EXTERNAL HEX DRIVE PLUG RECOMMENDED TORQUE LEVELS 29 TAB

33、LE 13 ISO 6149-4 METRIC INTERNAL DRIVE PLUGS RECOMMENDED TORQUE LEVELS . 30 TABLE 14 SAE J1926-4 INCH EXTERNAL HEX DRIVE PLUGS RECOMMENDED TORQUE LEVELS 30 TABLE 15 SAE J1926-4 INCH INTERNAL HEX DRIVE PLUGS RECOMMENDED TORQUE LEVELS . 31 TABLE 16 SAE J514, SAE J530 AUTOMOTIVE TAPERED PIPE THREAD POR

34、T CONNECTOR AND SAE J531 FILLER AND DRAIN PLUG RECOMMENDED TORQUE LEVELS . 32 TABLE 17 SAE J514 30 SWIVEL PIPE ADAPTERS RECOMMENDED TORQUE LEVELS 33 TABLE 18 SAE J532 AUTOMOTIVE STRAIGHT THREAD FILLER AND DRAIN PLUGS RECOMMENDED TORQUE LEVELS 34 1. SCOPE This information report provides general info

35、rmation for installing and tightening fluid conductors and connectors. Following these guidelines, with the consistent proper use of torque wrenches, tightening procedures and correct torque levels will result in diminishing leaks and improving service life by avoiding hose twisting, tube binding, f

36、alse torque and improper joint closures. Since many factors influence the pressure at which a hydraulic system will or will not perform satisfactorily, this report should not be used as a “standard“ nor a “specification“ and the values shown should not be construed as “guaranteed“ minimums, maximums

37、 or absolutes. This document is an information report to help users by gathering available information from the various connector standards and publishing the information in one source for easy retrieval and applied common usage. This information report is primarily intended for mobile/stationary in

38、dustrial equipment applications. Aircraft, Automotive and Aerospace applications were not considered during the preparation of this document. When assembly procedure and torque level discrepancies between this document and associated connector specifications occur, the current connector specificatio

39、ns shall take precedence. 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 SAE publications shall apply. 2.1.1 SAE Publications Available from SAE International, 400 Com

40、monwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. SAE J246 Spherical and Flanged Sleeve (Compression) Tube Fittings SAE J476a Dryseal Pipe Threads SAE J513 Refrigeration Tube Fittings - General Specifications SAE J514 Hy

41、draulic Tube Fittings SAE J516 Hydraulic Hose Fittings SAE J518-1 Hydraulic Flanged Tube, Pipe, and Hose Connections, Screw Flange Connection Part 1: 3.5 MPa to 35 MPa (Code 61) SAE J518-2 Hydraulic Flanged Tube, Pipe, and Hose Connections, 4-Screw Flange Connection Part 2: 42 MPa (Code 62) SAE J530

42、 Automotive Pipe Fittings SAE J531 Automotive Pipe, Filler, and Drain Plugs SAE INTERNATIONAL J2593 Revised FEB2015 Page 5 of 34 SAE J532 Automotive Straight Thread Filler and Drain Plugs SAE J1176 External Leakage Classifications for Hydraulic Systems SAE J1231 Formed Tube Ends for Hose Connections

43、 and Hose Fittings SAE J1273 Recommended Practices for Hydraulic Hose Assemblies SAE J1453-1 Specification for O-Ring Face Seal Connectors: Part 1 - Tube Connection Details and Common Requirements for Performance and Tests SAE J1453-2 Specification for O-Ring Face Seal Connectors: Part 2 - Requireme

44、nts, Dimensions, and Tests for Steel Unions, Bulkheads, Swivels, Braze Sleeves, Caps, and Connectors with ISO 6149-2 Metric Stud Ends SAE J1453-3 Specification for O-Ring Face Seal Connectors: Part 3 - Requirements, Dimensions, and Tests for Steel Unions, Bulkheads, Swivels, Braze Sleeves, Connector

45、s, Caps and Connectors with SAE J1926-2 Inch Stud Ends SAE J1615 Thread Sealants SAE J1926-1 Connections for General Use and Fluid Power - Ports and Stud Endgs with ASME B1.1 Threads and O-Ring Sealing - Part 1: Threaded Port with O-Ring Seal in Truncated Housing SAE J1926-2 Connections for General

46、Use and Fluid Power - Ports and Stud Ends with ASME B1.1 Threads and O-Ring Sealing - Part 2: Heavy-Duty (S Series) Stud Ends SAE J1926-3 Connections for General Use and Fluid Power - Ports and Stud Ends with ASME B1.1 Threads and O-Ring Sealing - Part 3: Light-Duty (L Series) Stud Ends SAE J 1926-4

47、 Connector Fluid Power and General Use Ports and Stud end with ASME B1.1 Threads and O-Ring Seal Part 4: External Hex and Internal Hex Inch Port Plugs Dimensions, Design, Test Methods and Requirements 2.1.2 ISO Publications Available from American National Standards Institute, 25 West 43rd Street, N

48、ew York, NY 10036-8002, Tel: 212-642-4900, www.ansi.org. ISO 7-1 Pipe threads where pressure-tight joints are made on the threads - Part 1: Dimensions, tolerances and designation ISO 7-2 Pipe threads where pressure-tight joints are made on the threads - Part 2: Verification by means of limit gauges

49、ISO 228-1 Pipe threads where pressure-tight joints are not made on the threads - Part 1: Dimensions, tolerances and designation ISO 228-2 Pipe threads where pressure-tight joints are not made on the threads - Part 2: Verification by means of limit gauges ISO 6149-1 Connections for fluid power and general use - Ports and stud ends with ISO 261 metric th