SAE J1402 2005

9E lnternational'SURFACE VEHICLE RECOMMENDED PRACTICE atEfr, J1402 REV. JAN2OO5 lssued 1942-01 Revised 2005-01 Superseding J'1402 JUN1985 (R) Automolive Air Brake Hose and Hose Assemblies l. Scope This recommended praciice covers minimum requirements for air brake hose assemblies made from reinforced elastomeric hose and suitable fittings for use in automotive air brake systems including Ilexible connections from frame to axle, tractor to trailer, trailer to trailer and other unshielded air lines with air pressures up to 1 MPa, that are exposed to potential pull or impact. This hose is not to be used where temperatures, extemal or intemal, fall outside the range of -40 "C to +100 'C. '1.1 Rationale This document is the long overdue update of SAE J 1402. Major additions, deletions and changes include lhe following: Fationalizing all units to the preferred Sl (metric) units as directed by SAE. The maximum working pressure for air brake hose assemblies was defined in the Scope as 1 MPa. Relerence to applicable publications was added to this update. This update turther defines the ditferences between Types A, Al and All hoses in both constructions and dimensions. Permanent and field attachable (previously known as reusable) fittings used with Type A hoses are not interchangeable with permanent and Jield attachable fittings used with Types Al and Al hoses due to construction and dimensional differences of the listed hoses. Tables A, Al and All were combined into a single Table 1. All other Tables were renumbered accordingly. The hose layline was increased to 600 mm in order to accommodate all the labeling requirements of this standard as well as those from the applicable govemment regulations. A note was added allowing for the labeling of hose contorming to this recommended practice with the lractional nominal inch size until JanuaN 1,2007. s,qE Tednical S_tandads Boad Rules povije that This repon is published by SAE to adlanca th€ sbte of l€dnical and engin€sring sdenc€s. The use of this report is entir€|yvoluntar'anditsapp|icabi|itygndsuihbi|ityf �oranypartidjaruse'indudinganypateftiniiingemenlarisingthere|iom'istheso|ere�ns|bi!rofthgusgr'' SAE rwieuA €adr ted|nical report at least ev€ry fNe years at whidr lime it may be reaffrmed, revised, or cancellod. SAE invites your sritten comm€nb and sugg€stions. Copyrisht @ 2005 SAE Int€rnalional A||rightsres€rv€d.Nopartofthispub|ica|ionmayberepmduced'storedinarelrievalsystemorl.ansnitted'inanyfolmolbya|tymeans'e|e(foniqmed�ni€|'pMo6p'ng' recording, or otherv/is€, without the pnor Miten permission of SAE. TOPLACEADOCUiIE TORDER: Tel: 8z{06-7?3 (iGida UsA.nd Canada) Tel: 72+2649?0 (outside USA) Fax: 72+n6479O ETail: cusbYc@ae.org cry{fi1 s^E |nffid ----^^. :;t\.|d by rHs ue!re6 sAEt: ntbJ rvwsae.org No rsErtucfd a Br'ftridno pdhir.rr not &. R..ae SAE J1402 Revised JAN2005 The table listing the radius for high temperature resistance test was deleted. All tests will use the radius listed in Table 1. ASTM No. 3 oil was changed to ASTM IRM 903 oil. 2. References 2.1 ApplicablePublications The following publications form a part of this specification to the extent specified herein. The latest issue of the publications shall apply. 2.1.'I SAEPUBLICATIoNS Available from SAE, 400 Commonwealth Drive, Warrendale, PA |5096-0001. SAE J51 7-Hydraulic Hose SAE J1401-Road Vehicle-Hydraulic Brake Hose Assemblies for Use with Nonpetroleum-Base Hydraulic Fluids, Appendix A, Table A1, Hose Manutacturers ldentification Code--Colored Yarn Assignments 2.1.2 ASTM PUBLIoATIoN Available from ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959. ASTM B | 17-Standard Test Method ol Salt Spray (Fog) Testing ASTM D 38o-Standard Test Methods for Flubber Hose ASTM D 413-Test Methods for Rubber Property-Adhesion to Flexible Substrate 3. Hose Constuctions and Dimensions There are three distincl hose constructions used for air brake hose assemblies made from reintorced elastomeric hose. All dimensions are in accordance with Table 1. Type A consists of an elastomeric tube, a fiber reinforcement and an elastomeric cover. Type Al consists ot an elastomeric tube, a wire or fiber reinforcement and a iiber braid cover. Type All consists oi an elastomeric tube, a wire or fiber reinforcement and a fiber braid or elastomeric cover. This hose is dimensionallv identical to SAE J517 100R5 hose. ceiqh saE hEnddd PFvr&d t rtts 'rn* fidr yirr s E No noi.drdon a normid4 F.nrtu *lrBr fre nm tr]s A, AI AND AII Type Type A A I o.D. o.D. ax Min 12.0 16.7 13.6 18.3 15.1 19.8 18.1 21.4 23.O 20.5 27.4 23.7 SAE J1402 Revised JAN2005 OUTSIDE DIAMETERS FOR TYPE Type Type Type Al Type Al Type A A and All andAll A t.o. t.o- t.D. t.D. o.D- in Max Min Max llin 4.4 5.5 5.8 6.9 6.4 7.2 15.1 7 .3 8.5 7 .9 4.7 16.7 8.9 10.1 18.3 10 .3 11 .1 10 .3 11 .9 19 .6 11.9 13.5 21.4 12.7 13.7 '15.1 16.7 15.9 17.0 26.2 TABLE I-INSIDE AND SAE SAE Type Inch Typ€ A Al and All Size Dashsize Dash SiE (Ref) (Reo (Re0 316 -4 1 t4 -4 -5 5 /16 -5 -6 13132. - 8 7 t16 -7 1,2 SP -8 1t2 -10 Type Atl o.D. l/lax 't3.7 15.3 17.6 20.0 24.0 2A.O HOSES Typ6 TyFe AI AII o.D. o.D. llax in 13.O 12.7 14.6 14.3 16.2 16.7 19.3 18.9 21.7 22.8 24.9 26.4 llelric Sizg 6.3 8 1 0 1 1 12.5 SP 12.5 1 6 NOTE-The sizes 3i/8, 7hG and'll2 SP of Type A hose can be assembled with field attachable fittings il desired. These field attachable fittings are not the same as used with Types AI and All hoses. 4. Fittings 4.1 For Permanently Attached Fittings When the hose is assembled with permanently attached fittings, the hose portion of the hose assembly shall conform to the dimensional requirements of Type A, Al or All hose in Table 1. 4.2 For Field Attachable Fittings When the hose is assembled with field attachable fittings, the hose portion of the hose assembly shall conform to the dimensional requirements for all sizes of Type Al or All hose in Table 1 or shall conform to the dimensional requirements ol U8, 7h6 and 1/2 SP Type A hose from Table 1. The field attachable fiftings for Type A hose are not the same as used with Types Al and All hoses. NOTE-The sizes 3V8 and 1/2 SP of Type A hose can be assembled with field aftachable fittings it desired. These field attachable fittings are not the same as used with Types Al and All hoses. cdn:o|'r saE hsd$iand _:l- Pr*i,t6d b [lS undn Id* |l$ sAE NoE+rodrofd dngrdrdnoF.i .d |{dt R..J. , SAE J1/t{r2 Revised JAN2005 .: 5. Minimum Bend Radius Table 2 contains the minimum bend radii recommended for vehicle installations. TABLE 2_RECOMMENDED MINIMUM BEND RADIUS Minimum B€nd Radiu6 To et ic Slze Inch Slze (ReD Inside ol Bend (mm) 5 3/16 50 6.3 8 1 0 1 1 114 t16 98 1St32 65 75 90 90 100 100 100 1 1 5 11.5 7t16 12.5 SP 1/2 SP '12.5 ln 16 S8 6. ldentilication 6.1 Hose Each hose manutacturer shall incorporate into the hose construction an identification yam as assigned by the RMA and as shown in Appendix A, Table Al of SAE J1401. Each air brake hose shall also be labeled in a color contrasting to that of the hose and labeling shall be repeated every 600 mm or less along the entire length of hose in legible block capital letters at least 3 mm high with the following minimum information in the order listed: a. The hose manufactureis identification XXXXX b. The words "AlR BRAKE" to identify specific hose application c. The hose metric size, such as I mm (') d. SAE J1402 Example: XXXXX AIR BRAKE 8mm SAEJ1402 In addition, each air brake hose shall be labeled with either an A, Al or All, identifying whether lhe hose has been manufactured to the dimensions of A, Al or All hose as shown in Table 1. Thls additional labeling need not appear on the same layline as the above (a), (b), (c) and (d) information, but shall have the same minimum requirements ol color contrast, spacing and letter height. (') NOTE-The fractional inch size may be used until January 1,2007. 6.2 Fittings Each field attachable air brake hose fitting shall be permanently etched, embossed or stamped in legible block capital letters at least 1.5 mm high with the coupling manufactureCs identification, hose size and whether they are intended tor use with Type A, Al or All hose. c.pyrigrn sAE hb@iod l.loq!&dmrrohddnlldnilsd SAE J1402 Revised JAN2005 6,3 Assemblies Each air brake hose assembly shall be identified by means of a band around the hose. The band may move freely along the length of the assembly as long as it is retained by the end fitting. The band shall be permanently etched, embossed or siamped in legible block capital letters at least 3 mm high with the following information: a. The month, day and year, or the month and year the assembly nras made expressed in numerals For example, 3/1t5 means March 1, 1975 or 3175 means March 1975 b. The assembleis identilication and additional information as reouired 7. Perfomance NOTE 1-All samples sublected to one or more performance tests other than Proof Pressure and Length Change shall be destroyed and discarded after completion of the tests and their analysis. NOTE 2-Burst Strength and Assembly Tensile Strenglh tests are qualification tests and do not imply that the hose assemblies can be used under those conditions. 7.1 AcceptancePerformance Hose or hose assemblies at the time of manufacture shall conform to the followino: 7.1-1 END FrnNGs End fiftings shall be such as to permit conformance to all portions of this recommended practice. After assembly of the end fiftings to the hose, the minimum l.D. of the end fittjngs or the hose shall not be less than 66% of the minimum hose lD shown in Table 1. All hose assemblies shall pass this requirement prior to conducting any other test in this recommended practice. 7 .1.2 PRooF PRESSURE Assemblies subiected to a pressure test using 2 MPa r 0.1 MPa air or nitrogen under water tor a minimum oi 30 s shall show no leaks. 7.1.3 BURST STRENGTH There shall be no hose burst, leakage or end iitting separation below 6 MPa when hose or hose assemblies are subjected to a hydrostatic burst tesl using water. 7-1.4 ASSEMBLY TENSTLE STRENGTH 450 mm long hose assemblies including the fittings shall be subjected to a longitudinal tensile test at a steady rate of 25 mrn/min r 2.5 mrn/min until separation of the hose from the fittings or rupture ot the hose occurs. Failure of the 6.3 mm and smaller size shall occur at no less than 1100 N and laroer sizes at no less than 1450 N. - r i - SAE J1402 Revised JAN2005 7..1.5 LENGTH CHANGE Test ior length change shall be conducted in accordance wilh ASTM D 380 (Elongation and Contraction) with the original measurement made at 0.1 MPa. The change in length shall be determined at 1.5 MPa and shall be from +sYo to -7"/"- 7-1-G ADHESToN Tests for adhesion shall be conducted only on original unaged specimens as follows: 7-l-6-1 Adhesion of Fiber Reinforced Hose Test for adhesion shall be conducted in accordance with ASTM D 413 Machine Method, and the average load required to separate any adiacent layers shall be 1.4 N/mm minimum. 7.1.6.2 Adhesion of Wire Reinforced Hose The requirements and method of testing cover adhesion for Type Al and All hoses with wire reinforcement shall be as in 7.1.6.1. The integrity of the inner tube adhesion shall be tested by subjecting a length ol hose not less than 380 mm long to the following requirements: Place a steel ball of the size specified in Table 3 in the bore of the hose. One end of the hose shall be attached to a vacuum source and the other end plugged. A vacuum of 17 kPa absolute shall be applied for a period of 5 min while the hose is in an essentially straight position. At the conclusion of this period and while still under vacuum, the hose shall be bent 180'to the minimum bend radius in Table 2 in each of two dkections 180" apart. After bending and reiurning to an essentially straight position and while still under vacuum, the ball shall be rolled from end to end of the hose. Failure ot the ball to pass freely from end to end shall be indication of seoaration of the inner tube from the reinforcement laver and shall constitute failure. TABLE 3-BALL SIZE FOR TESTING ADHESION OF WIRE REINFORCED HOSE Merric si4 5 6.3 8 11 12.5 16 fnch Slze (Ref) 3y16 114 5/16 13!@ 1/2 tB Bafl Ske 3.5 4.5 6.0 7.5 9.5 12.0 7.2 QualificationPertormance For initial qualification under this specification all of the requirements Qualification Performance and Flexure Test shall be met. Minimum including the specified sequential test procedure. under Acceptance Perf ormance, sampling shall be per Table 4, c.pyn€r sAEffi'Erdrd _ ti _Prdl&d t' |16 ui'r,c rd* $[l s E NoE rdddan€nEtcnspdtr{!.drilhrrfrefrmrr|s Nor6.R..a. SAE J1402 Revised JAN2005 TABLE 4_MINIMUM SAMPLING AND SEOUENTI,AL TEST PROCEDURE Sample No. Subi€cted to Folloued by 1 3 4 5 6 7 8 7.1.i $ 7.1.1, ' , 7.2.2.1 7.1.1n' 7.2.2.3 7 .1 .1 ! ' 7 .1 .1 ( ) 7.1.6 7 .1 .1 ( ) 7 .2.1 .1 Ihetl 7 .1 .2 7 .2.1 .2lhen 7 .'l .2 7 .2.2.21hen 7 .'l .4 7 .2.2.4 lhen 7 .1 .3 7.1.5 then 7.1.2 and 7.1.3 (r) Couple hos€ before staning tests or aging 7.2.1 TEMPERATURERESISTANCE 7-2.1-1 HighTemperaturc Resistance The hose portion of a hose assembly shall show no cracks, chaning or disintegration extemally or intemally when straightened after being bent over a form for a period ot 70 h + 2 h while in an air oven at 100 "C t 2 'C. The radius of the test form shall be in accordance with Table 2. The extemal surface of fiber braid covered hoses shall be exempt from inspection for cracks as visual inspection is not practical. After completion of this test, the hose assembly shall be tested in accordance with 7.1.2 Proof Pressure. 7.2.1.2 Low Temperature Resistance The hose shall show no cracks extemally or internally when bent 180" over a form having the radius shown in Table 2 after hose and form have been exposed for a period ot 70 h *. 2 h in an air circulating chamber at --40 'C r 2 "C and while still at this temperature. The hose and form shall be supported by a non-metallic surface during the entire period. The bend shall be completed in a period of 3 to 5 s. The external surface of liber braid covered hoses shall be exemDt from insoection for cracks as visual inspection is not practical. 7-2-2 REsrsrANcE ro ENVTRoNMENT 7.2.2.1 oil Specimens prepared from the inner tube and the cover shall show a volume increase when measured after removal from ASTM IRM 903 oil in which it has been immersed tot 70 h ! 2 h at 100 'C *.2 "C ol not more lhan 100%. 7-2-2.2 Water Condition hose assembly by immersion in distilled water at room temperature for a period ol 168 h r 2 h while bent over a form having the minimum bend radius shown in Table 2. Ends shall be completely capped during immersion. After completion of this test, the hose assembly shall be tested in accordance with 7.1.4 Assembly Tensile Strength. F ai&d by |trs undq [d* Yi[t SAE SAE JlrO2 Revised JAN20O5 7.2.2.3 Ozone Atter being exposed for 7O h * 2 h in an ozone test cabinet with an atrnosphere comprised of air anc ozone with an ozone partial pressure of 100 mPa (100 parts of ozone per i00 million parts of air) at standard atmospheric conditions at an ambient temperature of 40 "C r 2 "C and while bent over a form having the radius shown in Table 2, the hose shall show no cracking under 7X magnification. This tesl only applies to elastomeric covered hoses. 7.2.2.4 Salt Sptay Test A hose assembly, while supported or suspended between '15 and 30 degrees from vertical, shatl withstand 24 h r t h exposure to salt spray when tested in accordance with ASTM B 117, Method of Salt Spray (Fog) Testing. After this exposure, finings shall show no base metal corrosion except red rust is acceptable in areas of identification stamping and crimp distortions. White corrosion products are acceptable. After completion of this test, the hose assembly shall be tested in accordance with 7.1.3 Burst Strength. 8. FlexurcTest 8.1 Preparalion of Test Samples 8.1.1 Prior to cutting the hose, apply a layline (of a color distinguishable from that ol the hose cover) along the length of the hose (following the natural hose curvature which results from the hose being coiled in a roll) as shown in Figure 1. MARKED WHEN PREPAHING SAMPLES FOR TEST PER 8.1.1, NOI MANUFACTURER'S LAYLINE FIGURE 1--+IOSE MARKING 8.1-2 Cut the hose to provide a hose assembly sample with a free hose length as shown in Figure 2 and Table 5. Free hose length is the outside exposed hose length between the fittings in the finished hose assembly. 8.1.3 Fittings are to be assembled on the hose in accordance with the manutactureds instructions. 4,2 Preconditioning Subject each sample hose assembly to the preconditioning specified in 8.2.1, followed by the preconditioning specified in 8.2.2. ffiff*ffi*",* -it- No 'E9ndrdd d rerurdng pni0.d ritldt rq3 t8 ri|s SAE J1402 Revised JAN2005 8-2.'l SALT SPMY CoNDmoNTNG With the ends plugged, subject the hose assembly samples to 24 h t t h exposure to sah spray testing in accordance with ASTM B 117, Method of Salt Spray (Fog) Testing. Allow no more than 168 h elapsed time between completion oi the salt spray conditioning and the stan of the high temperature aging per 8.2.2. 8-2-2 H|GH TEMPEMTURE AcrNG With each hose assembly sample in a straight position, age the samples in air at a temperature of 100 'C ! 2 "C lor a period of 70 h + 2 h. During the entire conditioning period, the hose bore of each sample is lo be exDosed to the air within the oven. Allow hose assembly to cool down to room temperature for at least 2 h but no more than 168 h elapsed time between completion of the high temperature aging and the start of the flexure test per 8.3 and 8.4. 8.3 Installation ot Samples in the Test Setup After the samples have been preconditioned, they are to be installed in the test setup in the configuration specified in Figure 2 and Table 5. The installation procedure is as follows: POStT tON '2 ' END VIEW POSITION "1" ILLUSTMTES THE'LEFT' EXTREIVE OF TMVEL POSITION '2' ILLUSTMTES THE'RIGHT EXTREME OF TRAVEL FIGURE 2_FLEXURE TEST SETUP TABLE s--+LEXURE TEST SETUP DIMENSIONS POStTTON "'1" Free Hose t ength tletric (! 2 mm) Sizes Nomlml Inch SizE A(Rof) 43 Dlmgnsions (mm) Po€ilion'l" Pocition '2" B C R A B C r 3 $ R e t r 3 r 3 € R Ref I 5 and 6.3 2AO 8, 10 and 11 316 and 1/4 Y16,38 and 1332 75 70 95 34 75 75 90 1rs 43 7s 355 11.5,12.5,12.5SPand16 7/16, 1/2, 1/2 SP and t8 75 100 125 56 75 70 95 90 115 100 125 30 ,t6 - : t - Pro/i&d l' |r|s und- i@ 16 saF SAE J1402 Revised JAN2005 8.3.1 With the movable manifold of the flex lest machine al the center of its stroke, fitting "B'is connected to the movable manifold in such a manner that the layline is located at the top-center position (See Figure 2). 8.3.2 After fitting "8" has been coupled with the movable manifold, the 'A' fitting is then connected to the stationary manitold without imparting any twist to the hose, but allowing the hose to seek its natural curvafure. 8.4 Test Procedure Flex the samples by moving fitiing B from the center stroke position io 75 mm either side of center (A dimension in Figure 2) alternating between Position "1" and 2" while simultaneously cycling the air oressure on for 60 s and off for 60 s. A.4.1 FLEXURdPRESSUBE CYoLINGTEST PARAMETERS 8-4.1-l Total Flexure Stroke 150 mm * 1.5 mm 8-4.1-2 Flexurc Stroke Frequency 1 .7 Hz r. O.'l Hz 8.4.1.3 AmbientTempenturc 2 6 " C + 6 " C 8.4-1-4 lntemal Air Pressure on Test Samples '| MPa * 0.1 MPa. The air pressure shall be alternately fully "on' for 60 s r 5 s and fully 'ofP for 60 s r 5 s 8.5 Termination of Flexure Test The failure point (number of flex stroke cycles) shall be determined by loss of air pressure through the failed sample. As the air pressure is alternately fully "on" for 60 s and tully "otf for 60 s, pressure loss shall be turther d