SAE J 1241-1999 Fuel and Lubricant Tanks for Motorcycles《摩托车的燃料和润滑油箱》.pdf

1、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 entirelyvoluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefro

2、m, is the sole responsibility of the user.”SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions.TO PLACE A DOCUMENT ORDER: (724) 776-4970 FAX: (724) 776-0790SAE WEB ADDRESS http:/www.s

3、ae.orgCopyright 1999 Society of Automotive Engineers, Inc.All rights reserved. Printed in U.S.A.SURFACEVEHICLE400 Commonwealth Drive, Warrendale, PA 15096-0001RECOMMENDEDPRACTICESubmitted for recognition as an American National StandardJ1241REV.NOV1999Issued 1978-09Revised 1999-11Superseding J1241 S

4、EP1978(R) Fuel and Lubricant Tanks for Motorcycles1. ScopeThis SAE Recommended Practice is applicable to two- or three-wheel motorcycles intended forhighway use. Unless noted, requirements apply to both metallic and nonmetallic tanks. Accessory oraftermarket tanks as well as original equipment tanks

5、 are covered.1.1 PurposeThis document establishes test procedures and performance criteria for the integrity of tanks,associated fittings, filler caps, and plumbing separate from the engine and transmission, used to supply fuel orengine lubricant to a motorcycle.2. References2.1 Applicable Publicati

6、onsThe following publications form a part of this specification to the extent specifiedherein. Unless otherwise specified, the latest issue of SAE publications shall apply.2.1.1 SAE PUBLICATIONSAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.SAE J30Fuel and Oil HosesSAE J826Dev

7、ices for Use in Defining and Measuring Vehicle Seating Accommodation2.1.2 ASTM PUBLICATIONAvailable from ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959.ASTM D 1435-75Outdoor Weathering of PlasticsASTM E 437Standard Specification for Industrial Wire Cloth and Screens2.1.3 ISO PUBLICATI

8、ONAvailable from ANSI, 11 West 42nd Street, New York, NY 10036-8002.ISO4639-1Rubber tubing and hoses for fuel circuits for internal combustion enginesPart 1:Conventional liquid fuels2.2 Related PublicationsThe following publications are provided for information purposes only and are not arequired pa

9、rt of this document.2.2.1 SAE PUBLICATIONAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.SAE J905Fuel Filter Test MethodsCOPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J1241 Revised NOV1999-2-2.2.2 DOT PUBLICATIONAvailable from the N

10、HTSA, web site: www.nhtsa.dot.gov.Motorcycle Safety Improvement, Volume II-Technical Report, July 1976, DOT-HS-5-01181, NationalHighway Safety Administration3. Definitions3.1 Rated Fuel CapacityThe volumetric capacity of the tank after subtracting the expansion and ventingvolumes. A fill tube instal

11、led in the fuel tank filler opening is a typical method by which rated capacity fuel levelis indicated (Figure 1). The rated fuel capacity is the volume of fuel required to bring the fluid level to the loweredge of the fill tube, when filling from an initially empty tank with the motorcycle in a lev

12、el unladen condition.FIGURE 1TYPICAL FUEL TANK FILL TUBE INSTALLATION3.2 Pressure Relief Set PointThe pressure at which the pressure relief vent first opens.3.3 Automatic Fuel Shutoff ValveA device that prevents fuel flow from the fuel tank to the fuel delivery system,except when the motorcycle engi

13、ne is running.3.4 Normally Installed PositionThe attitude of the fuel tank when installed on a motorcycle which is loadedwith a 75 kg 5 kg (165 lb 10 lb) rider. Suspension components shall be set to the manufacturersrecommended settings for the stated load. If no recommendations for suspension adjus

14、tment are provided bythe manufacturer, the suspension shall be set at the midpoint, or if adjustment increments do not include amidpoint, at the next lower spring preload setting.3.5 Conventionally Located Fuel TankConventionally located fuel tanks (Figure 2), satisfy all of the followingconditions:

15、a. The tank is mounted between the seat and the steering head.b. The major portion of the tank is not enclosed by the structure of the motorcycle.c. The tank is positioned such that the operators knee is located within the region formed by projectingthe tank outline in a horizontal direction perpend

16、icular to the motorcycles vertical plane of symmetry.COPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J1241 Revised NOV1999-3-FIGURE 2REFERENCE AXES4. Design and Construction4.1 General4.1.1 Tanks shall pass the tests specified in Section 5. Any failure enc

17、ountered during operational testing must beconsidered significant.4.1.2 Fuel tanks should be sized such that actual volume exceeds rated volume (rated fuel capacity) by an amountcalculated to provide for:a. Expansion of the contents due to a temperature increase appropriate for the intended useb. Th

18、e inclusion of venting above the liquid level4.1.3 All fuel valves, caps, tank badge attachments, hoses, fuel quantity sending units, evaporative control systemcomponents (excluding remotely located evaporative canisters, pipes, and valves not directly mounted to thetank), and any other component at

19、tached directly to or installed within the tank shall be considered part ofthe tank. However, failure of a purely cosmetic tank component, e.g., a tank badge, shall not constitutefailure of any test. Fuel delivery system components (carburetors, fuel injection systems, etc.) andassociated fittings,

20、external to the fuel tank, are excluded from this document.COPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J1241 Revised NOV1999-4-4.1.4 The filler opening shall be of such size and be so located that the tank can be filled conveniently. All otheropenings

21、shall be provided with closures or fittings that are liquid-tight and will not pass fuel or lubricantexcept as intended. Straight threads may be used on fittings with integral flanges and sealing gaskets orsealing surfaces. Threads on all other fittings shall be of the dry seal tapered pipe thread t

22、ype.4.1.5 All fuel tank filler caps should present a smooth contour, or shall be covered by a rear hinged access coverthat presents such a contour. Hinged fuel tank filler caps shall be hinged at the rear.4.1.6 All hoses shall meet the applicable performance requirements of SAE J30 DEC93 or ISO 4639

23、-1.4.1.7 If fitted, fuel strainers should have openings not larger than 600 m. ASTM E 437 provides standardspecifications for Industrial Wire Cloth and Screens.4.1.8 Manually operated valves shall have a positive indication of each position, e.g., open, closed, and reserve, ifapplicable.4.2 Material

24、sMaterials used in the construction of tanks and tank fittings shall be appropriate for the functionintended at temperatures ranging from 20 to +60 C (4 to +140 F).4.2.1 Materials shall be chemically resistant to and compatible with commercial grades of fuel or lubricants, asappropriate and commerci

25、al fuel and lubricant additives, in the concentrations normally encountered.4.3 VentingAir pressure equalization vents shall be provided on every fuel tank to maintain fuel flow from thetank as the fuel is consumed by the engine. Air vents may be mounted separately or combined with thepressure relie

26、f vent or filler cap. If pressure equalization is combined with pressure relief, vents shall allow noescape of vapor until the pressure relief set point pressure is reached (see 4.4).4.4 Pressure ReliefFuel tanks shall be provided with appropriate devices for automatically releasing excessinternal p

27、ressure. Tanks shall not be fitted with fusible plugs. Pressure relief vents shall be self-sealing afterthe pressure has dropped 10% below the pressure relief set point.4.5 Fuel Valves/PumpsAll motorcycles shall be equipped with a means of positively shutting off the fuel flow tothe fuel delivery sy

28、stem. Fuel valves may be manual or automatic in operation, and may be either attacheddirectly to the tank, or remotely located. Remotely located fuel valves and the hoses/tubing connecting them tothe tank shall be included as a part of the tank assembly being tested.5. Tests5.1 General5.1.1 At least

29、 three randomly selected samples of each specific model fuel tank shall pass all applicable tests ofSection 5. Tanks subjected to and passing tests of 5.2 to 5.6, as applicable, may be utilized for tests of 5.7(nonmetallic tanks only) and 5.8. Tests of 5.8 are considered destructive tests; each samp

30、le fuel tank shallbe subject to testing only once (a minimum of three sample fuel tanks are required for 5.8.4 and threeadditional tanks for 5.8.5). Nonmetallic fuel tanks shall be aged as specified in 5.7 prior to being submitted tothe tests of 5.8.5.1.2 At least three randomly selected samples of

31、each specific engine lubricant tank shall be submitted to andpass appropriate tests of 5.2 to 5.4, and 5.7.5.1.3 All fittings as described in 4.1.3, shall be included for each test. Tests are to be conducted at a temperatureof 21 C 6 C (70 F 10 F) unless otherwise specified.COPYRIGHT Society of Auto

32、motive Engineers, Inc.Licensed by Information Handling ServicesSAE J1241 Revised NOV1999-5-5.1.4 REFERENCE AXESLongitudinal motion (refer to Figure 2) is along the X-axis and lateral motion is along theY-axis of the motorcycle. The X-Z plane is the vertical plane of symmetry.5.2 Low Temperature Test

33、5.2.1 PREPARATIONFill the tank to 50% of rated capacity with commercial gasoline, or with a nonflammablesolvent with a specific gravity similar to that of commercial gasoline (fuel tanks) or recommended lubricant(lubricant tanks).5.2.2 TESTSoak at 20 C 5 C (4 F 9 F) for at least 120 h. At the end of

34、 the storage period, soak the tankand the contents at 21 C 6 C (70 F 10 F) for at least 4 h. Rotate the tank about its longitudinal axis topositions 90 degrees, 180 degrees (inverted), and 270 degrees from the normally installed position. Allow tostand for 5 min at each position.5.2.3 FAILURE CRITER

35、IAAny significant effect on the liquid or tank. Leakage or seepage of more than 30 cc (1 floz) of liquid from a fuel or lubricant tank (including filler cap) at each position during the test.5.3 High Temperature Test 5.3.1 PREPARATIONPrepare as per 5.2.1.5.3.2 TESTSoak at 60 C 3 C (140 F 5 F) for at

36、 least 120 h. At the end of the storage period, soak the tankand contents at 21 C 6 C (70 F 10 F) for at least 4 h. Rotate the tank about its longitudinal axis topositions 90 degrees, 180 degrees (inverted), and 270 degrees from the normally installed position. Allow tostand for 5 min at each positi

37、on.5.3.3 FAILURE CRITERIAAny significant effect on the liquid or tank. Leakage or seepage of more than 30 cc (1 fl oz)of liquid from a fuel or lubricant tank (including filler cap) at each position during the test.5.4 Internal Pressure Test5.4.1 PREPARATIONEmpty tank, seal relief valve, vents, and a

38、ll other tank openings except one. Through thisopening, install a fitting to facilitate pressurization of the tank.5.4.2 TESTFor fuel tanks, pressurize the tank to 150% of the pressure relief set point or to at least 35 kPa (5 lb/in2) gage. Use a pressure of 35 kPa (5 lb/in2) gage for lubricant tank

39、s. Immerse in water for a minimum of 30s and inspect for leaks.5.4.3 FAILURE CRITERIONAny leakage from tank.5.5 Pressure Relief Test5.5.1 EXCEPTION FOR LUBRICANT TANKSOnly fuel tanks incorporating a pressure relief system shall be submittedto this test.5.5.2 PREPARATIONEmpty tank and seal the filler

40、 opening with the normally used cap. Seal all remaining tankopenings except one. Mount tank in the normal installed position.5.5.3 TESTGradually pressurize the tank through the remaining opening up to 150% of the pressure relief setpoint or at least 35 kPa (5 lb/in2) gage. Release the pressure.5.5.4

41、 FAILURE CRITERIONFailure of the pressure relief to vent pressure in excess of the pressure relief set point.COPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J1241 Revised NOV1999-6-5.6 Cap Leakage Test5.6.1 EXCEPTION FOR LUBRICANT TANKSOnly fuel tanks shal

42、l be submitted to this test.5.6.2 PREPARATIONEmpty tank and seal all the tank openings except the filler opening. Fill the tank to ratedcapacity with commercial gasoline, or with a nonflammable solvent with a specific gravity similar to that ofcommercial gasoline. Install the normally used cap in th

43、e filler opening.5.6.3 TESTRotate the tank about its longitudinal axis to positions 90 degrees, 180 degrees (inverted), and 270degrees from the normally installed position and allow to stand for 5 min at each position.5.6.4 FAILURE CRITERIONLeakage or seepage from the cap in excess of 30 cc (1 fl oz

44、) at each position.5.7 Outdoor Exposure Test5.7.1 EXCEPTION FOR METALLIC TANKSThis test is applicable only to nonmetallic tanks.5.7.2 GENERALConduct test in accordance with ASTM D 1435-75 (or the latest revision), or equivalentaccelerated weathering procedure.5.7.3 TEST CONDITIONSFulfill the followi

45、ng specific test conditions. All condition designators are as specified inASTM D 1435-75.a. Angle of Exposure45 degrees, facing Southb. Duration of Exposure1 yearc. LocationArizona desert or equivalent5.7.4 TESTAfter exposure per 5.7.2, or equivalent accelerated weathering test, clean test tanks tho

46、roughly andexamine each tank for structural integrity. Submit tanks to the tests of 5.8, if applicable.5.7.5 FAILURE CRITERIAStructural deficiencies which impair the intended function of the tank. Failure of the testsof 5.8.5.8 Impact/Deceleration Tests5.8.1 APPLICABILITYOnly conventionally located

47、fuel tanks shall be submitted to these tests.5.8.2 TEST PLATFORM AND TANK MOUNTING REQUIREMENTSProvide a test platform with provisions for mountingthe fuel tank in the normally installed position. Install the tank so that all fittings in the actual motorcycle tankmounting system are duplicated in th

48、e test setup. These include nuts and bolts, straps, rubber bushings orpads, frame-mounted brackets, and so forth. Include the motorcycle seat if it forms part of the tank mountingsystem. Include any frame members or fairing panels that surround the tank. Provide the test platform withfittings to sim

49、ulate the fuel inlet fittings for the fuel delivery system. Locate these fittings in the same positionrelative to the fuel tank as they are on the actual motorcycle.5.8.3 PREPARATION5.8.3.1 Empty the tanks, mount on the test platform, and refill to 75% of rated capacity with a nonflammablesolvent with a specific gravity similar to commercial gasoline. Metallic tanks may be tested using anequivalent weight of water.5.8.3.2 After filling, condition metallic tanks at a temperature o