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Copyright ©2002 Society of Automotive Engineers, Inc.
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SAE J2044 Revised SEP2002
6.4.3
6.4.4
6.5
6.5.1
6.5.2
6.6
6.6.1
6.6.2
7.
7.1
7.1.1
7.1.2
7.2
7.2.1
7.2.2
7.3
7.3.1
7.3.2
7.3.3
7.4
7.4.1
7.4.2
7.4.3
7.4.4
7.5
7.5.1
7.5.2
7.5.3
7.5.4
7.5.5
7.5.6
7.5.7
7.5.8
7.5.9
7.6
7.7
7.7.1
7.7.2
8.
9.
9.1
Test Requirement (Side Load Fracture Test)...........................................................................................9
9
Resistance to 10
.10
.10
10
.10
.10
Design Verification/.11
11
.11
.11
Zinc 11
.11
.11
External Chemical and 11
.11
Fluid 12
.12
12
.12
12
12
.12
13
.13
.13
13
13
13
Fluid Flow (Liquid Fuel Quick Connectors Only).....................................................................................13
13
14
.15
16
Elevated 16
.16
.17
Design Verification/Validation and In-Process 17
17
.17
Appendix AMating Tube End .18
-2-
SAE J2044 Revised SEP2002
—This SAE Recommended Practice defines standard tube end form dimensions so as to guarantee
interchangeability between all connector designs of the same size and the standard end form. This document
also defines the minimum functional requirements for quick connect couplings between flexible tubing or hose
and rigid tubing or tubular fittings used in supply, return, and vapor/emissions in fuel systems. This document
applies to automotive and light truck applications under the following conditions:
a.
b.
c.
d.
Gasoline and diesel fuel delivery systems or their vapor venting or evaporative emission control
systems.
Operating pressure up to 500 kPa, 5 bar, (72 psig).
Operating vacuum down to –50 kPa, –0.5 bar (–7.2 psi).
Operating temperatures from –40 °C (–40 °F) to 115 °C (239 °F).
Quick connect couplings function by joining the connector to a mating tube end form then pulling back to
assure a complete connection. The requirements stated in this document apply to new connectors in assembly
operations unless otherwise indicated. For service operations, the mating tube should be lubricated with SAE
30-weight oil before re-connecting.
NOTE—New connector designs using the same materials as previously tested connectors may use the
original results as surrogate data for 7.1, 7.2, 7.3, and 7.4.
Vehicle OEM fuel system specifications may impose additional requirements beyond the scope of this general
SAE document. In those cases, the OEM specification takes precedence over this document.
2.
2.1
References
Applicable Publications—The following publications form a part of this specification to the extent specified
herein. Unless otherwise specified, the latest issue of SAE publications shall apply.
SAE P
UBLICATIONS
—Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.
SAE J1645—Fuel System—Electrostatic Charge
SAE J1681—Gasoline, Alcohol, and Diesel Fuel Surrogates for Materials Testing
SAEJ1737—Test Procedure to Determine the Hydrocarbon Losses from Fuel Tubes, Hoses, Fittings, and
Fuel Line Assemblies by Recirculation
SAE J2045—Performance Requirements for Fuel System Tubing Assemblies
2.1.2ASTM P
UBLICATION
—Available from ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959.
ASTM B 117—Method of Salt Spray (Fog) Testing
2.2Related Publication—The following publication is provided for information purposes only and is not a required
part of this specification.
SAE P
UBLICATION
—Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.
SAE J30—Fuel and Oil Hoses
3.
3.1
3.2
Definitions
Unexposed coupling—One that has not been used or deteriorated since manufacture.
Lot—A group of couplings that can be traced to a single assembly set-up or material lot. No more than one
week production in a lot.
2.1.1
2.2.1
-3-
SAE J2044 Revised SEP2002
Designation—The following system of size designations apply to the tube end and connector portions of
quick connect couplings. The connector size designation consists of two numbers. The first number
designates the OD of the mating tube end. The second number designates the tubing size suited for the stem.
EXAMPLE—9.5 mm x 8 mm connector fits a 9.5 mm male and 8 mm flexible tubing or hose. The mating tube
end size designations refers to the nominal OD of the sealing surface. Refer to Figure 1 for an
illustration of this Coupling Nomenclature.
FIGURE 1—CONNECTOR NOMENCLATURE
Details for standard coupling sizes and dimensions for standard tube end forms are shown on Figure 2.
NOTE—On metal or nonmetallic tubing, the OD is used to designate size and on flexible hose and tubing, the
ID is used to designate size.
Temperatures—Unless otherwise specified, all tests will be performed at room temperature 23 °C ± 2 °C
(73.4 °F ± 4 °F).
Functional Requirements—This section defines the minimum functional requirements for quick connector
couplings used in flexible tubing fuel systems.
Leak Test—In order to provide a production compatible process, all leak testing should be performed using
compressed air in a manner that insures the connectors will not leak liquid fuel or vapor.
T
EST
P
ROCEDURE
(L
OW
P
RESSURE
)
a.
b.
Insert leak test pin, shown in Figure 3, into the connector.
Pressurize between the seals with suitable air leak test equipment to 69 kPa ± 7 kPa, 0.69 bar ±
0.07bar (10 psig ± 1 psig).
6.
6.1
6.1.1
NOTE—For single seal connectors, the stem must be capped or sealed.
6.1.2
6.1.3
A
CCEPTANCE
C
RITERIA
(L
OW
P
RESSURE
)—Maximum leak rate 2 cc/min at stabilization.
T
EST
P
ROCEDURE
(H
IGH
P
RESSURE
)
a.
b.
c.
Insert leak test pin, shown in Figure 3, into the connector.
For liquid fuel quick connector couplings, pressurize between the seals with suitable air leak test
equipment to 1034 kPa ± 35 kPa, 10.34 bar ± 0.35 bar (150 psig ± 5 psig).
For vapor/emission quick connector couplings, pressurize between the seals with suitable air leak test
equipment to 138 kPa ± 10 kPa, 1.38 bar ± 0.10 bar (20 psig ± 2 psig).
-4-
SAE J2044 Revised SEP2002
FIGURE 2—MATING TUBE FORM
-5-
SAE J2044 Revised SEP2002
6.1.4A
CCEPTANCE
C
RITERIA
(H
IGH
P
RESSURE
)—Maximum leak rate 5 cc/min at stabilization.
NOTE 1—For single seal connectors, the stem must be capped or sealed.
NOTE 2—Appropriate safety precautions should be taken when testing with high-pressure air.
6.1.5T
EST
P
ROCEDURE
(V
ACUUM
)
a.
b.
6.1.6
Insert leak test pin shown in Figure 3 into connector.
Apply a vacuum of 7 kPa with suitable vacuum leak test equipment.
A
CCEPTANCE
C
RITERIA
(V
ACUUM
)—Maximum leak rate 2 cc/min at stabilization.
FIGURE 3—LEAK TEST PIN
6.2Assembly Effort—Quick connect coupling assembly effort is the peak force required to fully assemble (latch
or retain) the mating tube end into the connector. Use a suitable tensile/compression tester to verify
conformance to this document.
T
EST
P
ROCEDURE
(N
EW
P
ARTS
)
a.
b.
c.
d.
e.
Test a minimum of 10 couplings.
Test the quick connect coupling as supplied. Do not add additional lubrication to the quick connect
coupling or test pin.
Attach quick connect coupling to a suitable test fixture.
Wipe the test pins, before each test, with a clean lint-free cloth to prevent an accumulation of
lubrication.
Insert assembly test pin, shown in Figure 4, into the quick connect coupling at a rate of 51 mm/min ± 5
mm/min (2 in/min ± 0.2 in/min) and measure assembly effort. (Simulated maximum tube end form)
6.2.1
-6-
SAE J2044 Revised SEP2002
6.2.2T
EST
P
ROCEDURE
—Connectors after Section 7 exposure.
a.
b.
c.
Allow samples to dry 48 h before insertion testing.
Lubricate test pin with SAE 30-weight oil by dipping the end in oil up to the retaining bead.
Insert assembly test pin, shown in Figure 4, into the quick connector at a rate of 51 mm/min ± 5 mm/
min (2 in/min ± 0.2 in/min) and measure assembly effort.
6.2.3A
CCEPTANCE
C
RITERIA
a.
b.
Maximum first time assembly effort must not exceed 67 N (15 lb) for sizes <11 mm male tubes, and
111 N (25 lb) for sizes ≥11 mm male tubes.
Maximum assembly effort after Section 7 exposures must not exceed 111 N (25 lb) for <11 mm male
tubes and 156 N (35 lb) for ≥11 mm male tubes.
FIGURE 4—ASSEMBLY TEST PIN
6.3Pull-Apart Effort—Quick connect coupling pull-apart effort is the peak force required to pull the mating tube
end out of the quick connect coupling. Use a suitable tensile tester to verify conformance to this document.
For hose pull-off, see SAE J2045.
T
EST
P
ROCEDURE
a.
b.
c.
Attach the quick connector body stem to a fixture suitable for pulling axially through the centerline of
the quick connector.
Use the pull-apart test pin shown in Figure 5. (Simulated minimum mating end form)
Apply a tensile load, at a rate of 51 mm/min ± 5 mm/min (2 in/min ± 0.2 in/min), until complete
separation occurs.
6.3.1
-7-
SAE J2044 Revised SEP2002
6.3.2A
CCEPTANCE
C
RITERIA
m Force P required to separate the test pin from the fuel quick connector should be, P = 56d up
to a maximum of 600 N (135 lb) or for unexposed connectors and P = 37d up to a maximum of 400 N
(90 lb) after Section 7 exposure where P = Force in Newtons and d = Nominal Tube Diameter in
millimeters.
Minimum Force P required to separate the test pin from the vapor/emissions quick connector should
be P = 16d up to a maximum of 400 N (90 lb) for unexposed connectors, P = 12d up to a maximum of
300 N (67 lb) after Section 7 exposure.
b.
FIGURE 5—PULL APART PIN
6.4Side Load Capability—Quick connect couplings must be able to withstand side loads typical of what might be
imposed by hose routing in a vehicle application as well as from having the hose pushed aside to reach other
objects on the vehicle during service procedures. The connector side load capability is measured using a side
load leak test and a side load fracture test. All connector designs and all tube end forms on metal or plastic
molded parts must meet the requirements of this procedure.
-8-
SAE J2044 Revised SEP2002
6.4.1T
EST
P
ROCEDURE
a.
b.
c.
d.
e.
f.
Insert quick connector into a length of design intent flexible tubing or hose with the opposite end
sealed.
Attach the quick connector to a suitable side load leak fixture or the plastic molded part, shown in
Figure 6. (Simulated minimum end form)
For liquid fuel quick connect couplings, pressurize the assembly with 1034 kPa ± 35 kPa, 10.34 bar ±
0.35 bar (150 psig ± 5 psig) air pressure.
For vapor/emission quick connect couplings, pressurize the assembly with 69 kPa ± 14 kPa, 0.69 bar
± 0.14 bar (10 psig ± 2 psig) air pressure.
Side load the hose or tube center point with the required load specified and perform the leak test.
Mount a sample in the fracture fixture or plastic molded part, side load quick connector, at a rate of
12.7 mm/min ± 5 mm/min (0.5 in/min ± 0.2 in/min), until the specified force is applied or fracture of the
quick connector occurs. Kinking of design intent hose is permitted.
6.4.2A
CCEPTANCE
C
RITERIA
(S
IDE
L
OAD
L
EAK
T
EST
)
leaks, fracture, or rupture of the quick connector or its components or the plastic molded tube end
permitted below the minimum F = 19d up to maximum of 225 N (50 lb), where F = Side Load in
Newtons and d = nominal tube diameter in millimeters.
Maximum leak rate is 8 cc/min at stabilization with 10.34 bar ± 0.34 bar (150 psig ± 5 psig) applied
pressure for liquid connectors or 69 kPa ± 14 kPa, 0.69 bar ± 0.14 bar (10 psig ± 2 psig) applied
pressure for vapor connectors.
b.
6.4.3
6.4.4
T
EST
R
EQUIREMENT
(S
IDE
L
OAD
F
RACTURE
T
EST
)—Push above the end of the stem.
A
CCEPTANCE
C
RITERIA
—No fracture, rupture, or yield of the quick connector or its components or the plastic
molded tube end permitted, below the minimum of F = 28d up to a maximum of 400 N (90 lb), where F = Side
Load in Newtons and d = nominal tube diameter in millimeters
FIGURE 6—SIDE LOAD TEST FIXTURE
-9-
SAE J2044 Revised SEP2002
6.5Resistance to Evaporative Emissions—Fuel line couplings are an integral part of the fuel system barrier to
evaporative emissions. They are viewed as potential leak sites in the system. This method is to be used to
determine hydrocarbon losses from permeation or micro leaks that are characteristic of each connector
design.
T
EST
P
ROCEDURE
e the losses from a single coupling are normally too small to measure accurately, it is
recommended that a test specimen be created consisting of 10 couplings. The value measured is
then divided by the number of connectors in the test specimen to arrive at the per connector value.
Connector stem is to be inserted into the design intent flexible tubing or hose and a design intent tube
end inserted into the connector. The flexible tubing or hose should have its permeation properties
measured independently using the same test fluid, preconditioning time and temperature, test
temperature and measurement technique. The value measure in this test is then corrected by
subtracting the permeation contribution from the flexible tubing.
For the purpose of making the correction described in b. (previously) measure the length of flexible
tubing in the test specimen that will be exposed to fuel during the test. For each section of flexible
tubing this should be measured from a point half way up the stem on one connector to the same point
on the next connector in line.
Precondition the test specimen per SAE J1737 until steady state permeation/leak measurements are
obtained. Use Test Fluid C per SAE J1681. Precondition at 40 °C and 60 °C for separate tests at
each of those temperatures.
Measure the hydrocarbon losses using a suitable SAE test method (i.e., SAE J1737, Mini-SHED,
weight loss, etc) providing it is sufficiently accurate and the flexible tubing has been permeation tested
using the same method. Test at steady state temperatures of 40 °C and 60 °C.
Correct the measured value for the multi-coupling test specimen by first subtracting the permeation
value attributed to the flexible tubing then dividing that value by the number of couplings in the test
specimen.
6.5.1
b.
c.
d.
e.
f.
6.5.2
6.6
A
CCEPTANCE
C
RITERIA
—None. Report value for each size and material combination only.
Electrical Resistance—If required by the OEM, all connectors used in fuel system applications involving
flowing liquid fuel must be sufficiently conductive and capable of creating an electrical connection with the
flexible tubing into which they are inserted and with the tube end form that is inserted into them in order to
prevent the buildup of harmful electrostatic charges.
T
EST
P
ROCEDURE
Test specimen is to consist of a coupling representative of the design as it will be installed in a vehicle
application. The coupling is to be in the middle of the specimen. The length of both the flexible tubing
or hose and rigid tubing must be 250 mm.
the specimens in accordance with 7.4 of this document then dry the exterior thoroughly.
e electrical resistance per SAE J1645 between the inner surfaces at each end of the specimen.
CAUTION—Measurement device may produce hazardous electrical charge, handle components with
insulated means.
the measurement system in place and recording, using insulated tongs or grasping device, move
the connector both axially and tangentially with respect to the installed tube end.
a.
6.6.1
6.6.2A
CCEPTANCE
C
RITERIA
a.
b.
c.
Measured resistance must be less than 10
6
Ω (at 500 V).
Electrical continuity must be maintained in all orientations of the connector relative to the tube end.
Maintain material certification log to show in-process capability.
-10-
SAE J2044 Revised SEP2002
7.
7.1
Design Verification/Validation Testing
Corrosion—The corrosion test is performed to assure that the quick connector components will meet the
functional requirements of the fuel system after exposure to the corrosion test.
T
EST
P
ROCEDURE
a.
b.
c.
7.1.2
Insert design intent mating tube ends, shown in Figure 2, into the quick connect couplings.
Cap the mating tube ends and the stem ends of the quick connect couplings, so internal surfaces
remain free of water and corrosion.
Perform salt spray test per ASTM B 117.
7.1.1
A
CCEPTANCE
C
RITERIA
—The quick connect couplings shall be capable of meeting the functional
requirements of 6.1, 6.2, and 6.3 after 500 h salt spray. Appearance is not a functional requirement.
Zinc Chloride Resistance—Zinc chloride is an environmental stress-cracking agent to which some
hygroscopic polymers are sensitive. This test is performed to assure that the quick connect couplings meets
their functional requirements after exposure to zinc chloride.
T
EST
P
ROCEDURE
a.
b.
c.
Insert mating tube ends, shown in Figure 2, into the quick connect couplings.
Cap the mating tube ends and stem ends of the quick connect couplings, so internal surfaces remain
free of water and corrosion.
Immerse the couplings in a 50% aqueous solution (by weight) of zinc chloride for 200 h at 23°C (room
temperature). Cover or cap the container to prevent the solution from changing concentration
significantly during the exposure. When in doubt, measure the concentration of ZnCl at the completion
of the test.
When the exposure is complete, remove the quick connect couplings from the zinc chloride solution,
do not rinse or clean.
The quick connect couplings must then be held at room temperature for 24 h.
Quick connect couplings are to be inspected after each exposure sequence for any evidence of
cracking.
7.2
7.2.1
d.
e.
f.
7.2.2A
CCEPTANCE
C
RITERIA
a.
b.
No cracks or fractures of the quick connector or its components permitted.
The quick connect couplings shall be capable of meeting the functional requirements of 6.1, 6.2, and
6.3 after exposure to zinc chloride.
7.3External Chemical and Environmental Resistance—Quick connect couplings may be exposed to a range of
chemicals typical of the automotive environment. This chemical resistance test is performed to assure that the
quick connect couplings will meet their functional after exposure to typical automotive fluids.
T
EST
P
ROCEDURE
a.
b.
c.
d.
Insert mating tube ends, shown in Figure 2, into the quick connect couplings.
Cap mating tube ends and stem ends of the quick connect couplings.
Submerge the quick connect coupling assemblies completely.
At the end of 60 days, dry connectors at room temperature for 48 h.
7.3.1
-11-
SAE J2044 Revised SEP2002
7.3.2
7.3.3
F
LUID
OR
M
EDIUM
—See Table 1.
A
CCEPTANCE
C
RITERIA
—The quick connect couplings shall be capable of meeting the functional
requirements of 6.1, 6.2, and 6.3 upon completion of the external chemical and environmental testing.
NOTE—New connector sizes using the same materials and architectural design as previously tested
connectors may use the original results as surrogate data.
TABLE 1—FLUID OR MEDIUM
(1)
Fluid or Medium
Automatic Transmission Fluid
Motor Oil
Brake Fluid (Dot 3)
Ethylene Glycol (50% Water)
Propylene Glycol (50% Water)
Diesel Fuel
Engine Degreaser
1.
Exposure Time
60 Days
60 Days
60 Days
60 Days
60 Days
60 Days
60 Days
Procedure
Soak @ room temp
Soak @ room temp
Soak @ room temp
Soak @ room temp
Soak @ room temp
Soak @ room temp
Soak @ room temp
The fluids in Table 2 shall be considered generic or those that are common to the industry.
7.4Fuel Compatibility—The fuel compatibility test is performed to assure that the quick connector will meet the
functional requirements of the fuel system after exposure to specific fuel blends.
NOTE—The intention of the document is that all couplings be fully interchangeable. As such couplings must
be qualified to operate with all available fuels. Connectors made of materials that are not suitable for
use in some fuels must be clearly labeled to identify their limitations.
7.4.1T
EST
P
ROCEDURE
a.
b.
c.
d.
Insert mating tube ends, shown in Figure 2, into the connectors.
The samples shall have fuel contact surfaces exposed to the fuels specified in 7.4.2, see Table 2.
Replace the fuel every 7 days.
New samples must be used for each test.
7.4.2
7.4.3
T
EST
F
UELS
—Reference SAE J1681 and Table 2.
T
EST
R
EQUIREMENT
—One-half the samples shall be tested immediately after removal from the test fuel and
the remaining samples shall be tested after a 48-h dry-out period.
A
CCEPTANCE
C
RITERIA
—The quick connect coupling shall meet the functional requirements of 6.1, 6.2, and
6.3 after the completion of the fuel compatibility test.
NOTE—New connector sizes using the same materials and architectural design as previously tested
connectors may use the original results as surrogate data.
TABLE 2—TEST FLUIDS
Test Fluid (Per SAE J1681)
ASTM Reference Fuel C
SAE CE10 (Fuel C Plus 10% Ethyl Alcohol)
SAE CM30 (Fuel C Plus 30% Methyl Alcohol)
SAE CME15 (Fuel C Plus 15% MTBE)
SAE CP (Auto-Oxidized Fuel)
Exposure Time
60 Days
60 Days
60 Days
60 Days
60 Days
Procedure
Soak @ 40 °C
Soak @ 40 °C
Soak @ 40 °C
Soak @ 40 °C
Soak @ 40 °C
7.4.4
-12-
SAE J2044 Revised SEP2002
7.5Life Cycle—The life cycle test is performed to assure that the quick connector will meet the functional
requirements of the fuel system when exposed to pressure, vibration, and temperature cycles typical of severe
duty in automotive applications.
T
EST
P
ROCEDURE
a.
b.
c.
d.
e.
Insert a connector in each end of a 500 mm (19.69 in) length of suitable flexible tubing.
Leak test the assembly per 6.1, except use mating tube end shown in Figure 2.
Connect the assembly to a test fixture, shown in Figure 7 using production intent tubes.
Test fluid (liquid fuel quick connect couplings)—Mobil Arctic 155 refrigerant oil or equivalent.
Test fluid (vapor/emission quick connect couplings)—Air.
7.5.1
NOTE—Use of flammable materials is not recommended. However, tests in fuel or fuel surrogates can
produce better results at low temperatures.
7.5.2
7.5.3
V
IBRATION
F
REQUENCY
—Continuously sweep the frequency from 7 Hz to 200 Hz, with 3 sweeps per hour.
A
CCELERATION
—See Table 3.
TABLE 3—ACCELERATION
(1)
Maintain Acceleration Load
18 m/s
2
(2 G)
90 (10 G)
182 (20 G)
163 (18 G)
145 (16 G)
127 (14 G)
109 (12 G)
90 (10 G)
1.
From
7 Hz
25
50
75
100
125
150
175
To
25 Hz
50
75
100
125
150
175
200
This test may be interrupted or shut down for weekends at the end of any
section.
7.5.4
7.5.5
V
IBRATION
D
URATION
—Maintain vibration as specified in 7.5.8 (Test Cycles).
F
LUID
P
RESSURE
liquid fuel quick connect couplings during pressure portions of the test, alternate pressure between
0 and 1034 kPa ± 35 kPa, 10.34 bar ± 0.35 bar (150 psig ± 5 psig). Alternate pressure one time per
minute (i.e., 1 min at each pressure).
For vapor/emission quick connect couplings during pressure portions of the test, alternate pressure
between 0 and 69 kPa ± 2 kPa, 0.69 bar ± 0.02 bar (10 psig ± 0.3 psig). Alternate pressure one time
minute (i.e., 1 min at each pressure).
b.
NOTE—Pressure transition rate is to be as close to a square wave as practical but not so abrupt that
pressure overshoot occurs. This may require up to 3 s.
7.5.6F
LUID
F
LOW
(L
IQUID
F
UEL
Q
UICK
C
ONNECT
C
OUPLINGS
O
NLY
)—Flow rate during the specified test cycle is
1.33 Lpm ± 0.2 Lpm (0.46 gpm ± 0.07 gpm) through each quick connect coupling.
T
EST
D
URATION
—336 h (14 test cycles) (14 days)7.5.7
-13-
SAE J2044 Revised SEP2002
7.5.8T
EST
C
YCLES
—The test cycle consists of five sections to simulate hot operation, hot soak, hot operation after
hot soak, cold soak, and cold operation. See Table 4.
NOTE—Included at the beginning of the hot and cold test sections are temperature transitions times of 1h
maximum.
7.5.8.1Hot Operation Test
a.
b.
c.
d.
e.
f.
7.5.8.2
Length of Time—7 h
Chamber Temperature—125 °C ± 5 °C (257 °F ± 9 °F)
Fluid Temperature (liquid fuel quick connect couplings only)—66 °C ± 5 °C (151 °F ± 9 °F)
Fluid Pressure—yes
Fluid Flow—yes
Vibration—yes
Hot Soak
a.
b.
c.
d.
e.
f.
Length of Time—2 h
Chamber Temperature—125 °C ± 5 °C (257 °F ± 9 °F)
Fluid Temperature (liquid fuel quick connect couplings only)—Heat to chamber temperature
Fluid Pressure—yes
Fluid Flow—no
Vibration—no
7.5.8.3Hot Operation after Hot Soak
a.
b.
c.
d.
e.
f.
Length of Time—7 h
Chamber Temperature—125 °C ± 5 °C (25 7°F ± 9 °F)
Fluid Temperature (liquid fuel quick connect couplings only)—66 °C ± 5 °C (151 °F ± 9 °F)
Fluid Pressure—yes
Fluid Flow—yes
Vibration—yes
7.5.8.4Cold Soak
a.
b.
c.
d.
e.
f.
Length of Time—7 h
Chamber Temperature— –40 °C (-40 °F)
Fluid Temperature (liquid fuel quick connect couplings only)—Cool to chamber temperature
Fluid Pressure—yes
Fluid Flow—no
Vibration—no
7.5.8.5Cold Operation
a.
b.
c.
d.
e.
f.
Length of Time—1 h
Chamber Temperature— –40 °C (–40 °F)
Fluid Temperature (liquid fuel quick connect couplings only)—Cool to chamber temperature
Fluid Pressure—yes
Fluid Flow—yes
Vibration—yes
-14-
SAE J2044 Revised SEP2002
7.5.9A
CCEPTANCE
C
RITERIA
a.
b.
c.
No fluid leaks permitted during or at completion of test, for Vapor connector couplings, air leak test per
6.1.
The connector shall meet the functional requirements of 6.1, 6.2, and 6.3 after the completion of the
life cycle test.
Perform visual inspection of connector and its components. No fractures, cracks, or unusual wear
permitted.
FIGURE 7—LIFE CYCLE TEST SET UP
-15-
SAE J2044 Revised SEP2002
TABLE 4—LIFE CYCLE TEST SCHEDULE
Section
7.5.8.1
Hour
1
2
3
4
5
6
7
7.5.8.2
7.5.8.3
8
9
10
11
12
13
14
15
16
7.5.8.417
18
19
20
21
22
23
7.5.8.5
1.
24
Chamber Temperature
125 °C
(1)
125°
125°
125°
125°
125°
125°
125°
125°
125°
125°
125°
125°
125°
125°
125°
–40 °C
(1)
–40°
–40°
–40°
–40°
–40°
–40°
–40°
Fluid Temperature
125 °C
(1)
66°
66°
66°
66°
66°
66°
125°
(1)
125°
66°
(1)
66°
66°
66°
66°
66°
66°
–40°
(1)
–40°
–40°
–40°
–40°
–40°
–40°
–40°
Fluid Pressure
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Fluid Flow
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
No
No
Yes
Vibration
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
No
No
Yes
Temperature may be in transition.
7.6
7.6.1
Flow Restriction—Quick connect couplings shall be designed to provide minimal flow restriction.
T
EST
P
ROCEDURE
a.
b.
c.
Insert connector into its intended flexible tubing.
Connect the flexible tubing to a source for controlled flow of water.
Measure the pressure required to create 120 L/h flow through each connector design.
7.6.2
7.7
A
CCEPTANCE
C
RITERIA
—None. Measure and report value.
Elevated Temperature Burst—The elevated temperature burst test is performed to assure that the quick
connect coupling will withstand the pressure requirements of the fuel system at the maximum operating
temperature. This test can be performed as part of the tube and hose assembly requirements of SAE J2045 or
as follows.
T
EST
P
ROCEDURE
a.
b.
c.
d.
e.
Insert a quick connector in each end of a 500 mm (19.69 in) length of tubing or reinforced fuel hose.
Secure each end with a hose clamp if required, to prevent failure of the stem to hose interface.
Insert male tube ends, shown in Figure 2, into the quick connect couplings.
Attach assembly to a suitable, air or hydraulic, burst pressure source.
Place the assembly in a suitable environmental chamber and soak at 115 °C (239 °F) for 1 h.
Perform burst by pressurizing the hose assembly at a rate of 3450 kPa/min (500 psig/min) until burst
or rupture occurs.
7.7.1
-16-
SAE J2044 Revised SEP2002
7.7.2A
CCEPTANCE
C
RITERIA
a.
b.
Minimum burst pressure for liquid fuel quick connect couplings 2000 kPa (290 psig).
Minimum burst pressure for vapor/emission quick connect couplings 138 kPa (20 psig).
NOTE—The burst test is for the quick connector only. Leakage or rupture of the hose is not a failure. If the
hose fails below the minimum requirement; the test must be rerun with hose capable of higher
pressure, if practical.
Verification/Validation and In-Process Testing Matrix—(See Table 5.) This section describes the
minimum requirements for quick connect couplings, mating tube ends, and attachment joints.
TABLE 5—DESIGN VERIFICATION/VALIDATION AND IN-PROCESS TESTING MATRIX
Design
Verification
Acceptance
Criteria
No Failures
< Maximum
> Minimum
> Minimum
> Minimum
Report Only
< 10
6
Ohms
No Failures
No Failures
No Failures
No Failures
No Failures
> 2000 kPa
> 138 kPa
Production
Verification
Acceptance
Criteria
No Failures
< Maximum
> Minimum
> Minimum
> Minimum
Report Only*
< 10
6
Ohms*
No Failures*
No Failures*
No Failures*
No Failures*
No Failures
> 2000 kPa
> 138 kPa
In-Process Minimum
Samples
(1)
100%
5/lot
5/lot
5/lot
10/year
N/A
N/A
10 year for metal couplings
N/A
N/A
N/A
N/A
10/year
10/year
In-Process
Acceptance
Criteria
No Failures
< Maximum
> Minimum
> Minimum
> Minimum
N/A
N/A
No Failures
N/A
N/A
N/A
N/A
> 2000 kPa
> 138 kPa
Test
Leak Test
Assembly Effort
Pull-Apart
Effort - Liquid
- Vapor/Emission
Side-Load Capability
Evaporative Emissions
Electrical Resistance
Corrosion
Zinc Chloride Resistance
External Chemical and
Environmental Resistance
Fuel Compatibility
Life Cycle
Elevated Temperature
Burst - Liquid
Vapor
1.
Section
6.1
6.2
6.3
Sample
Size
10
10
10
10
6.4
6.5
6.6
7.1
7.2
7.3
7.4
7.5
7.7
10
10
10
10
10
10 each
10 each
10
10
10
N/A means annual re-testing is not required. Changes in materials, production tooling or processes will require re-testing. *New
connector designs using the same materials as previously tested connectors may use the original results as surrogate data for 7.1,
7.2, 7.3, and 7.4.
9.
9.1
Notes
Marginal Indicia—The change bar (l) located in the left margin is for the convenience of the user in locating
areas where technical revisions have been made to the previous issue of the report. An (R) symbol to the left
of the document title indicates a complete revision of the report.
PREPARED BY THE SAE FUEL SYSTEMS TECHNICAL STANDARDS COMMITTEE
-17-
SAE J2044 Revised SEP2002
APPENDIX A
END FORM, 10 TIMES SCALE FOR OVERLAY USE
A.1See Figure A1.
FIGURE A1—END FORM, 10 TIMES SCALE FOR OVERLAY USE
-18-
SAE J2044 Revised SEP2002
Rationale—(Figure 2) The changes to the tube chart were in response to the ballot objections from ITT and
concern from GM. This only serves to clarify the measuring of the tube end, not the design intent.
(6.1c) The high pressure test for Vapor connectors was 50 psi but the burst pressure was only 20 psi.
This didn’t make sense so we changed the leak test to match the burst pressure
(Figures 4 and 5) These two bead diameters were changed to align with the proportions of the other tube
ends. These are new sizes for production so there was no experience when the initial numbers were
chosen.
(6.3.2b) The word “minimum” was added for clarity.
(7.2.1.c) The test temperature was changed to room temperature to agree with SAE J2260 as
recommended by Ford and GM.
(Appendix A) A scale was added to the edges for clarity.
Relationship of SAE Standard to ISO Standard—Not applicable.
Application—This SAE Recommended Practice defines standard tube end form dimensions so as to
guarantee interchangeability between all connector designs of the same size and the standard end form.
This document also defines the minimum functional requirements for quick connect couplings between
flexible tubing or hose and rigid tubing or tubular fittings used in supply, return, and vapor/emissions in
fuel systems. This document applies to automotive and light truck applications under the following
conditions:
a.
b.
c.
d.
Gasoline and diesel fuel delivery systems or their vapor venting or evaporative emission control
systems.
Operating pressure up to 500 kPa, 5 bar, (72 psig).
Operating vacuum down to –50 kPa, –0.5 bar (–7.2 psi).
Operating temperatures from –40 °C (–40 °F) to 115 °C (239 °F).
Quick connect couplings function by joining the connector to a mating tube end form then pulling back to
assure a complete connection. The requirements stated in this document apply to new connectors in
assembly operations unless otherwise indicated. For service operations, the mating tube should be
lubricated with SAE 30-weight oil before re-connecting.
NOTE—New connector designs using the same materials as previously tested connectors may use the
original results as surrogate data for 7.1, 7.2, 7.3, and 7.4.
Vehicle OEM fuel system specifications may impose additional requirements beyond the scope of this
general SAE document. In those cases, the OEM specification takes precedence over this document.
Reference Section
SAE J30—Fuel and Oil Hoses
SAE J1645—Fuel System—Electrostatic Charge
SAE J1681—Gasoline, Alcohol, and Diesel Fuel Surrogates for Materials Testing
SAEJ1737—Test Procedure to Determine the Hydrocarbon Losses from Fuel Tubes, Hoses, Fittings,
and Fuel Line Assemblies by Recirculation
SAE J2044 Revised SEP2002
SAE J2045—Performance Requirements for Fuel System Tubing Assemblies
ASTM B 117—Method of Salt Spray (Fog) Testing
Developed by the SAE Fuel Systems Technical Standards Committee
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