saej398v002

SURFACEVEHICLERECOMMENDEDPRACTICE(R)Rated(Advertised)FuelCapacity—PassengerCar,Multi-PurposePassengerVehicles,andLightDutyTrucksSAETechnicalStandardsBoardRulesprovidethat:“ThisreportispublishedbySAEtoadvancethestateoftechnicalandengineeringsciences.Theuseofthisreportisentirelyvoluntary,anditsapplicabilityandsuitabilityforanyparticularuse,includinganypatentinfringementarisingtherefrom,isthesoleresponsibilityoftheuser.”SAEreviewseachtechnicalreportatleasteveryfiveyearsatwhichtimeitmaybereaffirmed,revised,orcancelled.SAEinvitesyourwrittencommentsandsuggestions.Copyright©2005SAEInternationalAllrightsreserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystemortransmitted,inanyformorbyanymeans,electronic,mechanical,photocopying,recording,orotherwise,withoutthepriorwrittenpermissionofSAE.TOPLACEADOCUMENTORDER:Tel:877-606-7323(insideUSAandCanada)Tel:724-776-4970(outsideUSA)Fax:724-776-0790Email:custsvc@sae.orgSAEWEBADDRESS:http://www.sae.orgIssued1969-06Revised2005-03SupersedingJ398JUL1995®J398REV.MAR20051.ScopeThisrecommendedpracticeprovidesamethodforestablishingtheratedoradvertisedfuelcapacityforavehicleutilizingliquidfuelatatmosphericpressure.Itappliestopassengercars,multi-purposepassengervehiclesandlightdutytrucks(10000lb(4536kg)maximumGVW),(Ref.SAEJ1100).Italsoincludesastandardizedprocedureforcreatingafulltankwhenanothertestrequiresthatconditionasastartingpoint.Itisintendedasaguidetowardstandardpracticeandissubjecttochangetokeeppacewithexperienceandtechnicaladvances.1.1RationaleThisdocumentwasdevelopedtorefinetheprocedureusedtodefineratedcapacityofafueltank.Inaddition,manyotherfueltankquantitiesthatareincommonusebuthadnopreviousformaldefinitionarenowincludedinthisdocument.Thesestandardizeddefinitionsapplytoemissionstesting,OBDconsiderationsaswellasCustomerInformationrelatedtoAdvertisedCapacity.Thislevelofdefinitionhasnotbeenavailabletotheindustrypriortothis.2.References2.1ApplicablePublicationsThefollowingpublicationsformapartofthisspecificationtotheextentspecifiedherein.ThelatestissueofSAEpublicationsshallapply.2.1.1SAEPUBLICATIONSAvailablefromSAE,400CommonwealthDrive,Warrendale,PA15096-0001.SAEJ285—GasolineDispenserNozzleSpoutsSAEJ703—FuelSystems—TruckandTruckTractorsSAEJ1100—MotorVehicleDimensionsSAEJ1140—FillerPipesandOpeningsofMotorVehicleFuelTanksSAEJ398RevisedMAR2005-2-2.1.2ULPUBLICATIONAvailablefromUnderwriter’sLaboratories,Inc.,333PfingstenRoad,Northbrook,Il60062-2096UL842—StandardforValvesforFlammableFluids2.1.3ISOPUBLICATIONAvailablefromInternationalOrganizationforStandardization,Casepostale56–CH-1211,Geneva20,SwitzerlandISO/DIS13331—Roadvehicles—Fillerpipesandopeningsofmotorvehiclefueltanks—Vaporrecoverysystems3.DefinitionsandSymbolsIncludedasAppendicestothisdocument,are:AppendixA—Alistingofstandardizedtermstobeusedtodescribevariousfuelvolumesandfuelgageindications.AppendixB—Agraphicalillustrationtoaidinunderstandingtheterms.4.TechnicalRequirements—FuelSystemDesignGuidelines4.1Forallvehicles,designedinaccordancewithISO/DIS13331(Ref.obsoleteSAEJ1140).Thedesignshouldprovidevehiclebodyopeningsthatpermitsuitableengagementoftheretentionfeatureofthefillnozzleinthefillerpipe.Whensoengaged,thenozzleshutoffsensingdevicewillberetainedbelowthefillerpipeopeningandbelowanyrestrictoropening(ifpresent),duringunattendedoperation.4.2Indesigningforconsistentandrepeatabletankcapacity,includeconsiderationofallvehicledesignandfuel-relatedsourcesofvariation,includingthefollowing:•Tankproportions(length,width,height,otherunusualfeatures).•OffsetofshutofffeaturetovolumetriccenteroffuelatFulllevel.•OffsetofshutofffeaturetolevelsensorlocationatFulllevel.•SpecificGravityoffuelsvs.levelsensorfloatifused.•Tankstraptension.•Foaminginthefillpipe.4.3ServiceStationConditionsInattemptingtoconsistentlyachieveaFulltankconditionandtoavoidliquidlossesduringfueling,thedesignershouldrecognizethefollowingservicestationconditions:4.3.1FORECOURTGRADEVehiclesmaybeparkedinanydirectionongradesupto6%.SAEJ398RevisedMAR2005-3-4.3.2DISPENSERNOZZLESAutomaticnozzlesapprovedunderUL842,StandardforValvesforFlammableFluids,maybeused.•Considernozzle-to-nozzleshutoffvariability4.3.2.1NozzlespoutsforgasolinedesignedinaccordancewithSAEJ285.4.3.2.2NozzlespoutsfordieselfuelmayhaveanominalO.D.upto30mm(13/16in)andaminimumO.D.of23.8mm(15/16in).4.3.3DELIVERYRATESFuelmaybedispensedatflowratesupto:•53L/min(14gal/min)forgasoline.RefertoSAEJ703forfueltanksof95L(25gal).•76L/min(20gal/min)fordieselfuel.Considernozzle-to-nozzleflowratevariability.5.TechnicalRequirements—TestConditions5.1Thesurfaceonwhichthevehicleisparkedshallbelevel(within0.5%grade).5.2Thetankshallbepositionedinnominalvehicleinstalledconfigurationatmanufacturer'sdesigncurbweightattituderelativetothetirepatches.5.3Forteststomeasureratedcapacity,theresidual"Unusable"fuelinthetankatteststartshallberepresentativeofthemanufacturer’sdesignintentatarun-out-of-fuelcondition.5.4Ifthevehicleisequippedwithaplasticfueltank,itisrecommendedthatthetestvehicleorrigbe“conditioned”byhavingthefueltankexposedtofueluntildeflectionstabilizes,butatleastonemonth)priortotestingtobetterassurearepresentativein-usecondition.5.5ThegasolineshallhaveaReidVaporPressure(RVP)between48Kpaand62Kpa(7.0psiand9.0psi)forboththedispensedandresidual(unusable)components.5.6Number2dieselfuelistobeusedfortestingdieselfuelapplications.5.7Thedispensedfueltemperatureshallbe22°C±2°C(72°F±3°F).5.8Theresidualfueltemperatureshallbewithin2°C(3°F)ofthedispensedfueltemperature.5.9Thefillnozzleusedforthistestingshallhaveanautomaticshut-offfeatureandbecommerciallyavailable,withasignificantmarketshareofactualservicestationusage.Verifythatthefillnozzleautomaticshut-offfunctionisoperationalpriortotestingbythefollowingmethod.5.9.1Whileholdingthenozzleoveranelectricallygrounded,openvesselandengagingtheoperatinglever,dispensefueluntilatleast6inchesofdepthhasaccumulated,thendunkthenozzlespoutintotheliquidtooccludetheshutoffport(s)andobserveforinstantshutoff.Repairorreplacenozzleifitfailstoshutoffcorrectly.SAEJ398RevisedMAR2005-4-5.10Setthedesiredflowrateofthefueldispensingequipmentbydischargingfuelintoanothercontainerorintoawastefueldisposalsystem.Thesettingistobemadewiththenozzlelatchedinitshighestflowposition.Thesettingsare:•38L/min±0.8L/min(10.0gal/min±0.2gal/min)forgasoline.•76L/min±1.5L/min(20.0gal/min±0.4gal/min)fordieselfuel.6.TechnicalRequirements—RatedCapacityTestProcedureThefollowingshouldbeusedforestablishingtherated(advertised)fuelcapacityforavehicle.6.1Insertthedispensingnozzletomaximumpenetrationintothefuelfillinlet,thenallowittoassumeafurthestinsertedposition,latchedontheretentionfeature,representativeofunattendedoperationincustomerservice(thismayrequirebackingthespoutoutofitsfullyinsertedinitialposition.).Theplaneofthenozzleshallbeasnearlyverticalastheboundariesofthebodyopeningaroundthefuelinletpermit.6.2Setandlatchthedispensingnozzleleverinitsmaximumflowpositionandallowfueltoflowintothefueltankuntilthenozzleshutsoffautomatically.6.3After5sec.,setandlatchthedispensingnozzleinitsminimumflowratepositionandallowfuelflowuntilthenozzleshutsoffautomatically.6.4Repeat6.3.6.5Recordthetotalamountoffueldispensedtothenearest0.1galor0.1L.6.6Repeatthistestasufficientnumberoftimesonasufficientnumberofrepresentativevehiclesuntilastatisticallysignificantaveragevalueforthefueltankrated(advertised)capacitycanbeestablishedtoa90%confidencelevel.6.7Thisamountistherated(advertised)capacity.7.TechnicalRequirements—FullTankTestProcedureThefollowingprocedureshouldbeusedforobtainingafulltank,whenthatconditionisrequiredasastartingpoint.7.1Thefillprocedurecanbestartedfromanyfuellevellessthanfull.7.2Followtheproceduresinsections:5.1,5.2,5.9,5.10,6.1,6.2,6.3and6.4.SAEJ398RevisedMAR2005-5-8.Notes8.1ThedocumentwasdevelopedundertheRefuelingInterfaceSubcommitteebutthatsubcommitteeandthatcommitteestructurenolongerexists.Wehavenosubcommitteeworkingonitnow.TheTechnicalStandardCommitteeisjusttryingtopublishtheexcellentworkcompletedyearsagobythisgroup.8.2MarginalIndiciaThechangebar(l)locatedintheleftmarginisfortheconvenienceoftheuserinlocatingareaswheretechnicalrevisionshavebeenmadetothepreviousissueofthereport.An(R)symboltotheleftofthedocumenttitleindicatesacompleterevisionofthereport.PREPAREDBYTHESAEREFUELINGINTERFACESUBCOMMITTEEOFTHESAEFUELSYSTEMSTECHNICALSTANDARDSCOMMITTEESAEJ398RevisedMAR2005-6-APPENDIXAFUELTANKVOLUME/FUELGAGEINDICATIONDESCRIPTIONANDTERMSTotalTankAssemblyInternalVolume:TotalofLiquidCapacityplusVaporSpaceincludingthefuelfillerpipevolume.VaporSpace:ThevolumetricdifferencebetweenTotalTankAssemblyInternalVolumeandLiquidCapacityincludingthevaporspaceinthefillerpipe.LiquidCapacity:TheamountofdispensedfuelrequiredtoachieveaFullcondition,usingtheproceduregiveninSAEJ398fordeterminingrated(advertised)capacity,exceptstartingfromaDryTank.Rated(Advertised)FuelCapacity:TheamountofdispensedfuelrequiredtoachieveaFullcondition,usingtheproceduregiveninSAEJ398fordeterminingrated(advertised)capacity.AlsothevolumetricdifferencebetweenLiquidCapacityandtheUnusableFuelamount.IndicatedFull:Thefuellevelorquantityinthetankwhentheinstrumentpanelfuelgagepointerisatthemaximumendofthegraduatedscale(notnecessarily"pegged")or,foradigitalreadout,at"F".Full:Theendpointwhenfuelisaddedtoatank,fromanystartingconditionlessthanfull,usingtheSAEJ398procedure.FullReserve:ThevolumetricdifferencebetweentheFullandthefuelquantityselectedfordisplayasIndicatedFull.Top-Off:Thevolumetricdifferencebetweenthefirstautomaticshutoffandthesecond,additionalshutoffdescribedinSAEJ398.OBDHigh:Thetotalvolumeofliquidfuelinthetankatthepointwhere85%oftheRated(Advertised)Capacityisindicated.(ApplicabletoUS/CARBOBDregulations)OBDLow:Thetotalvolumeofliquidfuelinthetankatthepointwhere15%oftheRated(Advertised)Capacityisindicated.(ApplicabletoUS/CARBOBDregulations)IndicatedEmpty:Thetotalvolumeofliquidfuelinthetankatthepointwherethefuelgagereads"E",orthebottomofthe"Reserve"range,ifused.PerceivedCapacity(VP):ThevolumetricdifferencebetweenFullandIndicatedEmpty.LowFuelReminder:ThefuelquantityselectedtodisplayaLowFuelremindertothevehicleoperatorthattheamountoffuelremaininginthetankisapproachingempty.ThiscanbebasedoneitherapercentageoftheRated(Advertised)CapacityoranamountoffuelestimatedtoallowacertaindrivingdistancetoeitherIndicatedEmptyorEmpty(Run-Out).EmptyReserve:ThevolumetricdifferencebetweenEmptyandthefuelquantityselectedfordisplayasIndicatedEmpty.EmptyReserveshouldalwaysbeapositivenumberwhentheEmptyamountissubtractedfromtheIndicatedEmptyamount.SAEJ398RevisedMAR2005-7-Empty(Run-Out):Thefuellevelatwhichthefueldeliverysystemcannolongersupplysufficientfueltomeettherequirementsoftheengine.SeeRun-Outforadditionaldetail.UnusableFuel:ThetotalvolumeofliquidfuelremaininginafueltankatthepointofEmpty(Run-Out).Thegeneralgoalistominimizethisamount.Run-Out:Acolloquialtermfortheendconditionresultingfromthe“run-out-of-fuel”testingthatautomotivemanufacturersusetoqualifythefuelhandlingcapabilitiesofavehicle.Eachmanufacturerhasuniquetestsandacceptancecriteria,whichmayvarydependingontheintendedusageoftheparticularvehiclebeingevaluated.Someofthetypicaltestmethodsinclude:1.Static:•Drivingmethodswherethevehicleisdriveninastraightlineonalevelroad(within1deg)atpre-specifiedloadingandcontrolledtemperatureconditionsatconstantspeed.Atesttrackwithequivalentneutralsteercurvesisanacceptablealternative.Therunoutconditioncanbedefinedasfollows:•Thepointwheremisfireisfirstdetectedbyanexperiencedobserver.•Thevehiclecannolongermaintainapredeterminedspeed.•TheOBDmisfiremonitordetectsthefirstmisfire.•Labmethodwherethefuelpumpisenergizedandallowedtorununtilfuelflowand/orpressurefallbelowsomepredeterminedlimit.2.Dynamic:•Drivingmethodswherethevehicleisdriventhroughaseriesofdynamicmaneuversatpre-specifiedspeeds,loadingandcontrolledtemperatureconditions.Therunoutconditioncanbedefinedasfollows:•Thepointwheremisfireisfirstdetectedbyanexperiencedobserver.•Thevehiclecannolongermaintainapredeterminedspeed.•TheOBDmisfiremonitordetectsthefirstmisfire.SAEJ398RevisedMAR2005-8-APPENDIXBFUELTANKVOLUME/FUELGAGEINDICATIONDESCRIPTIONANDTERMSFIGUREB1—FUELTANKVOLUME/FUELGAGEINDICATIONDESCRIPTIONANDTERMS