SAE J 1725-1995 Structural Modification for Personally Licensed Vehicles to Meet the Transportation Needs of Persons with Disabilities.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 15096-0001INFORMATIONREPORTSubmitted for recognition as an American National StandardJ1725REAF.NOV1999Issued 1995-06Reaffirmed 1999-11Superseding J1725

4、 JUN1995Structural Modification for Personally Licensed Vehicles to Meetthe Transportation Needs of Persons with DisabilitiesForewordA variety of adaptations to vehicles are necessary in order to meet the transportation needs of peoplewith disabilities. Structural modifications allow entry of occupi

5、ed wheelchairs into vans. Modifications to floors,roofs, or both can create the head clearance necessary for entry or egress, and for proper eye position to enabledrivers and passengers in wheelchairs to see outside of the vehicle.Because of this need, a specialized industry has evolved to provide t

6、hese modifications for the disabled consumer.However, the industry is without the benefit of uniform standards.This SAE Information Report provides recommended state-of-the-art practices in the vehicle modification field,and suggests minimum acceptable design requirements and performance criteria. I

7、ts goal is to promote areasonable level of performance and vehicle reliability after modification.With the realization that the field of vehicle structural modification is ever changing, it is intended that thisdocument provide a general framework by which future revisions and additions can be incor

8、porated.The document was drafted by a working group of the Society of Automotive Engineers (SAEs) Adaptive DevicesStandards Committee, and reviewed by a committee made up of the following:a. Individuals from companies that manufacture and/or install adaptive equipment,b. Third party contributors to

9、funds for adaptive equipmentc. Driver Rehabilitation Specialistsd. Researcherse. Engineers with Original Vehicle Manufacturer experiencef. Users of adaptive devicesSAE J1725 Reaffirmed NOV1999-2-TABLE OF CONTENTS1. Scope31.1 Purpose 32. References .32.1 Applicable Publications.33. Definitions .54. V

10、ehicle Preparation and Precautions .84.1 Preparation for Modification85. General Practice .85.1 Fasteners85.2 Materials .85.3 Cutting 85.4 Welding.85.5 Sealing95.6 Body Finish .95.7 Corrosion 95.8 Gross Vehicle Weight .95.9 Flammability95.10 Performance .96. General Vehicle Modification Process 96.1

11、 Scope96.2 Vehicle Preparation 96.3 Temporary Reinforcement 96.4 Permanent Removal of OEM Structure, Components or Material106.5 ModificationAltering an OEM Structure or Component .106.6 FabricationComponents Wholly Fabricated by Modifier106.7 Installation of Components .106.8 Removal and Reinstalla

12、tionUnaltered OEM Components 116.9 Sealing, Finish, Corrosion Protection .116.10 Labels .116.11 Inspection .116.12 Testing 126.13 Applicable Standards126.14 Documentation127. Specific Vehicle Modification Process 127.1 Power Pan Well 127.2 Lowered Floors .147.3 Powerplant and Transmission Relocation

13、 177.4 OEM Powerplant Compartment Alterations187.5 Drive Shaft 197.6 Entrance Modifications .207.7 Raised Roofs and Structural Reinforcement 227.8 Raised Body .257.9 Fuel System277.10 Brake System .287.11 Exhaust System297.12 Electrical System 31SAE J1725 Reaffirmed NOV1999-3-7.13 OEM Occupant Restr

14、aint and Seatbase Anchorages and Anchor Points 327.14 Wheelchair Flooring331. ScopeThe recommendations in this SAE Information Report apply to structural integrity, performance,driveability, and serviceability of personally licensed vehicles not exceeding 10 000 lb GVWR. While many ofthese recommend

15、ations may have application to other vehicles, such as those used in paratransit operations,the contents of this document are not directed at these types of vehicles.1.1 PurposeThe purpose of this document is to:a. Provide engineering direction to vehicle modifiers that does not limit innovation.b.

16、Suggest minimum acceptable performance criteria that maintain OEM design intent, allowingconsumers and third party payers the ability to obtain equipment that meets or exceeds theseminimum acceptable performance criteria.c. Provides general recommendations on the vehicle modification process and rec

17、ommendations onspecific vehicle modifications.2. References2.1 Applicable PublicationsThe following publications form a part of this specification to the extent specifiedherein. Unless otherwise indicated, the latest issue of these publications shall apply.2.1.1 SAE PUBLICATIONSAvailable from SAE, 4

18、00 Commonwealth Drive, Warrendale, PA 15096-0001.SAE TSB 002Preparation of SAE Technical ReportsSAE HS-131Vehicle Occupant Restraint Systems and Components, November, 1985SAE J140aSeat Belt Hardware Test Procedure (4.33.01)SAE J1411Seat Belt Hardware Performance Requirements (4.33.03)SAE J201In-serv

19、ice Brake Performance Test (2.22.69)SAE J1551Service Brake System Performance RequirementsLight Duty TruckSAE J229Brake System Structural Integrity Test (2.22.110)SAE J299Stopping Distance Test (2.22.133)SAE J367Passenger Car Door System Crush Test (4.34.227)SAE J369Flammability of Automotive Interi

20、or Materials Test (1.11.152)SAE J374Vehicle Roof Strength Test (4.34.226)SAE J383Seat Belt Anchorages Design Requirements (4.33.06)SAE J384Seat Belt Anchorages Test Procedure (4.33.08)SAE J3851Seat Belt Anchorages Performance Requirements (4.33.09)SAE J3981Fuel Tank Filler Conditions (3.24.415)SAE J

21、4291Requirements for Externally Threaded Fasteners (1.4.01)SAE J5141Hydraulic Tube Fittings (2.19.51)SAE J5161Hydraulic Hose Fittings (2.19.85)SAE J6151Engine Mountings (3.24.220)SAE J6891Curb Clearance Approach, Departure, and Ramp Breakover Angles (4.32.03)SAE J800Motor Vehicle Seat Belt Assembly

22、InstallationsSAE J843dBrake System Road Test (2.22.90)SAE J937b1Service Brake System Performance Requirements-Passenger CarSAE J9411Motor Vehicle Drivers Eye Range (4.34.104)SAE J10301Maximum Sound Level for Passenger Car (3.26.17)SAE J10471Brake System Hydraulic Tubing (2.22.139)SAE J1050a1Drivers

23、Ellipse (4.34.157)SAE J11001Motor Vehicle Dimensions (4.34.85)1. Denotes performance requirements.SAE J1725 Reaffirmed NOV1999-4-SAE J1827Unibody Weld Quality Testing (4.42.22)SAE J18282Dimensional Guidelines for Unibody Vehicles (4.42.27)SAE J11402Filler Pipes of Automobile Fuel Tanks (3.24.412)SAE

24、 J11472Welding, Brazing and Soldering Materials and Practices (1.9.07)SAE J12142Tire to Body Clearance Check for Recreational Vehicles (4.35.04)SAE J12922Wiring Automotive (2.20.110)SAE J15172Driver Selected Seat Position (4.34.190)SAE J1554Identifying and Repairing High Strength Steel Vehicle Compo

25、nentsSAEJ15552Design Guidelines for Optimizing Automobile Collision Damage resistance, Repairability,and Serviceability (4.42.19)SAE J19592Corrosion Preventative Compounds Underbody (1.3.53)SAE J19762Outdoor Weathering of Exterior Materials (1.11.234)2.1.2 AWS PUBLICATIONSAvailable from the American

26、 Welding Society, 2501 Northwest 7th Street, Miami, FL33125.AWS 1.3-81 Sheet SteelAWS D1.1-88 Structural WeldingAWS D8.4-61 Automotive Welding DesignAWS D8.5-66 Automotive Portable Gun Resistance Spot WeldingAWS D8.7-78 Auto Weld Quality Resistance Spot WeldingAWS D8.8-79 Auto Frame Weld Quality Arc

27、 Welding Specification2.1.3 NFPA PUBLICATIONSAvailable from The National Fire Prevention Association, Battery Park, Quincy, MA02269-9990.NEC 2.240Overcurrent ProtectionNEC3.300Wiring MethodsNEC5.551Recreational VehiclesNEC6.620Wheelchair Lifts2.1.4 NHTSA REGULATIONSPromulgated by the National Highwa

28、y Traffic Safety Administration (NHTSA), U.S.Department of Transportation (DOT), 400 7th Street, S.W., Washington, DC 20590. Available from theSuperintendent of Documents, Government Printing Office, Washington, DC 20402. Tel. (202) 783-3238.2.1.4.1 Code of Federal Regulations (CFR), Title 49Transpo

29、rtation, Part 571Federal Motor Vehicle SafetyStandards (FMVSS).FMVS Standard No. 105Hydraulic Brake SystemsFMVS Standard No. 106Brake HosesFMVS Standard No. 116Motor Vehicle Brake FluidsFMVS Standard No. 204Steering Control Rearward DisplacementFMVS Standard No. 206Door Locks Date of alteration6.10.

30、3 Any OEM label that has been affected by vehicle structural modification should be replaced by a label thatcontains the same information and is located as close as possible to the original location.6.11 Inspection6.11.1 Each Inspection section in 7.1 through 7.14 provides guidance on inspection pro

31、cedures to be followed aftercompletion of the vehicle modification.6.11.2 Each structurally modified vehicle, within the scope of this document, should be inspected. Inspectionsshould verify the use of fasteners, materials, welding, sealing, finishing, and installation procedures asspecified by this

32、 document. Inspections should also verify the adherence to good engineering practices andcompliance with all applicable FMVSS, and should verify adherence to all applicable AWS, NEC, and SAEstandards.6.11.3 Inspections should be documented.SAE J1725 Reaffirmed NOV1999-12-6.12 Testing6.12.1 Each Test

33、ing section in 7.1 through 7.14 provides guidance on testing to be performed on the modifiedvehicle or components other than testing necessary to certify compliance with standards referenced by thisdocument. Some of the tests listed in 7.1 through 7.14 are required to be performed on each vehiclemod

34、ified. Others are only required on an example of each modification design.6.13 Applicable Standards6.13.1 Each Applicable Standards section in 7.1 through 7.14 provides a list of FMVSS possibly affected by thealteration. A list of AWS, NEC, and SAE standards is also provided as a guide to important

35、considerations inperforming a vehicle modification and in assessing the completed modification. The list is not necessarily allinclusive. Some of the SAE standards referenced are test procedures rather than performance standards.These are provided to assist the modifier in testing the vehicle and af

36、fected components.6.14 DocumentationEach Documentation section in 7.1 through 7.14 provides guidance on the appropriatedocumentation to accompany the modified vehicle6.14.1 OWNERS MANUALAll structurally modified vehicles should be furnished with an owners manual whichprovides at least the following

37、information.a. Intended UsersThis section should describe the basis for alterations with regard to the client.b. WarningsA list of any warnings concerning the operation, limits on performance or hazards.Particular attention should be given to alterations affecting the dynamic characteristics of the

38、vehicle.c. MaintenanceA description of all required periodic maintenance of any new components should beincluded.d. Operating InstructionsWhere applicable, a description of the guidelines for operation.e. The modifier should provide documentation that all the requirements outlined in this document h

39、avebeen met.7. Specific Vehicle Modification Process7.1 Power Pan Well7.1.1 SCOPEThis section addresses alterations to the OEM structure in preparation for the installation of thepower pan system. It does not cover the power pan system itself.7.1.2 VEHICLE PREPARATION7.1.2.1 Remove gas, brake, elect

40、rical, and exhaust system components as necessary. Secure remaining fuelsystem from liquid and vapor leaks. Remove undercoating as required. Layout the area of the floorintended for alteration. Protect all interior components from welding, cutting, and grinding procedures.7.1.2.2 See 6.2.7.1.3 TEMPO

41、RARY REINFORCEMENTSee 6.3.7.1.4 PERMANENT REMOVAL OF OEM STRUCTURE, COMPONENTS, OR MATERIAL7.1.4.1 If temporary structural reinforcement is not used, the replacement frame structure should be installed priorto removal of any OEM frame structure or material.7.1.4.2 See 6.4.SAE J1725 Reaffirmed NOV199

42、9-13-7.1.5 MODIFICATIONALTERING AN OEM STRUCTURE OR COMPONENT7.1.5.1 Frame AlterationsAny offset frame structure should be gussetted, triangulated, and/or braced. Anyalteration required to install a power pan should not compromise the integrity of the vehicle frame includingcross-members. The OEM en

43、ergy-absorbing crush zones should be maintained.7.1.5.2 Cross-membersAny alteration of a cross-member should not compromise the function, number, andmethod of attachment. All detachable cross-members should remain detachable.7.1.5.3 Body MountsBody mounts removed or modified should be reinstalled or

44、 replaced to maintain form, fit,and function of the OEM component. Non-integrated body/frame vibration isolation should be maintained.The body should not be welded or otherwise rigidly attached to the frame at any point. If body mounts arerelocated, they should be positioned as close as possible to

45、the original location. Additional supportingstructure may be required to maintain the OEM design intent. Minimum body to frame clearance should be6.4 mm (0.25 in). Flexible and weatherproof isolating material should be placed between body and framein appropriate locations.7.1.5.4 Wheel WellsAlterati

46、on should provide clearance for full jounce and rebound with steering position lock-to-lock.7.1.5.5 Engine Cover7.1.5.5.1 The flammability of materials used in any alteration, fabrication, or reinstallation of the OEM enginecover, should not exceed that of the OEM engine cover components. Any engine

47、 cover alteration shouldnot compromise OEM barriers to moisture, fumes, and temperature.7.1.5.5.2 See 5.5 and 7.4.7.1.5.6 Fuel SystemFasteners should not protrude in such a way as to increase the likelihood of puncturing anycomponent of the fuel system.7.1.5.7 Exhaust SystemHeat shielding should be

48、provided both above and below the system to maintain OEMdesign intent and performance. The modified vehicle exhaust system should also meet or exceed theOEM performance with respect to heat dissipation. Gaseous emissions and noise level should be belowthe limits set by the jurisdiction in which the

49、vehicle is registered.7.1.5.8 See 6.5.7.1.6 FABRICATIONCOMPONENTS WHOLLY FABRICATED BY MODIFIER7.1.6.1 Welding ProcedureAll joints should have continuous welds. Care should be taken to minimize distortionto the vehicle.7.1.7 INSTALLATION OF COMPONENTSThe installation should not compromise the serviceability of OEMtransmission and exhaust systems. Power pan wells should be installed to power pan manufacturersspecifications.7.1.8 REMOVAL AND REINSTALLATIONUNALTERED OEM COMPONENTSBody mounts