JIS JAPANESE INDUSTRIAL STANDARD Translated and Published by Japanese Standards Association JIS D 2604» Automotive parts — Hydraulic brake wheel cylinders for hydraulic brake systems using a non-petroleum base brake fluid ICS 43,060.40 Descriptors ; road vehicles, private cars, cere, Ys systems, hydraulical- ly-operated devices, wheels, hydraulic cylinders Reference number : JIS D 2604 : 1998 (E)D 2604 :1998 Foreword ‘This translation has been made based on the original Japanese Industrial Standard revised by the Minister of International Trade and Industry through deliberations at Japanese Industrial Standards Committee in accordance with the Industrial Standardization Law. Consequently JIS D 2604 : 1989 is replaced with JIS D 2604 : 1998. ‘No International Standard corresponds to this Standard. Date of Establishment: 1961-09-01 Date of Revision: 1998-07-20 Date of Public Notice in Official Gazette: 1998-07-21 Investigated by: Japanese Industrial Standards Committee Divisional Couneil on Aircraft and Automobiles JIS D 2604:1998, First English edition published in 1999-06 Translated and published by: Japanese Standards Association 41-24, Akasaka, Minato-ku, Tokyo, 107-8440 JAPAN In the event of any doubts arising as to the contents, the original JIS is to be the final authority. © JS 1999) All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying and microfilm, ‘without permission in writing from the publisher Printed in Japan,JAPANESE INDUSTRIAL STANDARD JIS D 2604 ; 1998 Automotive parts — Hydraulic brake wheel cylinders for hydraulic brake systems using a non-petroleum base brake fl Introduction This Standard has been established in 1961 and extended through several revisions. In this revision the provision for waterproof property, which is presently deleted from JIS D_ 2608 in the revision to conform with the corresponding International Standard, is added for necessity on the products function. 1 Scope This Japanese Industrial Standard specifies hydraulic brake wheel cylinders for hydraulic brake systems of automobiles using a non-petroleum base brake fluid (hereafter referred to as “wheel cylinder”). 2 Normative references The following standards contain provisions which, through reference in this text, constitute provisions of this Standard. The most recent editions (including amendments) of the standards shall be applied. JIS B 0209 Limits of sizes and tolerances for metric coarse screw threads JIS B 0211 Limits of sizes and tolerances for metric fine screw threads IS B 0401-2 1SO system of limits and fits— Part 2: Tables of standard tolerance grades and limit deviations for holes and shafis JIS B 0601 Surface roughness — Definitions and designation JIS B 2707 Cold formed helical compression springs JIS D 2605 Rubber cups for hydraulic cylinders for automotive hydraulic brake systems using a non-petroleum base hydraulic brake fluid JIS D 2608 Rubber boots for automotive hydraulic brake wheel cylinders using a non-petroleum base hydraulic brake fluid JIS G 3101 Rolled steels for general structure JIS G 3141 Cold-reduced carbon steel sheets and strip JIS G 3521 Hard drawn steel wires JIS G 3522 Piano wires JIS G 4051 Carbon steels for machine structural use JIS G 4401 Carbon tool steels JIS G 4801 Spring steels JIS G 5501 Grey iron castings JIS H 4040 Aluminium and aluminium alloy rods, bars and wires JIS H_ 5202 Aluminium alloy castings JIS K 2233 Non-petroleum base motor vehicle brake fluids2 D 2604 : 1998 3° Classification Wheel cylinders shall be classified as given in Table 1 Table 1 Classification Class: Application Class 1_| Suitable for operation at an ordinary temperature Class 2 _| Suitable for operation ata high temperature Class 3 | Suitable for operation at an extra high temperature 4 Maximum service pressure _The maximum service pressure of wheel cylinders shall be graded into four steps of 10 MPa, 15 MPa, 20 MPa and 25 MPa. 5 Performances 5.1 Performance of components The performances of wheel cylinder main components shall be as follows: ) Cups shall meet the performance requirements specified in JIS D 2605, b) Boots shall mect the performance requirements specified in JIS D 2608, ©) Piston springs shall pass the inspections specified in JIS B 2707. 5.2 Performance of assembly The performance of wheel cylinder assemblies shall be as follows. ‘The test fluid shall be the brake fluid conforming to JIS K 2233, or that agreed between the parties concerned with delivery. a) The wheel cylinder, when, closing the bleeder hole, a pneumatic pressure of 100 kPa is applied onto the cylinder body inside through the joining port to reciprocate the piston for several cycles, shall stroke the piston smoothly, and free from leakage at any part. Furthermore, the air shall flow out at opening the bleeder. b) The wheel cylinder, when a hydraulic pressure is applied onto the cylinder body inside through the joining port, shall stroke the piston to generate the force required. ©) The wheel cylinder, when the cylinder body inside is filled with the test fluid to be subjected to a pressure of 130% of the maximum service pressure and maintained for 5's, shall be free from leakage or other abnormalities on any part. 5.3 Low temperature stroking For the low temperature stroking performance of wheel cylinders, when tested by the specification of 6.7 of JIS D 2605, there shall be no leakage of the cup, 5.4 Stroking durability The stroking durability of wheel cylinders, when tested by the specification of 6.8 of JIS D 2605, shall mect the requirements of 4.2 of that standard. Further, each component shall be free from harmful deformations, deteriorations and other defects,3 D 2604 : 1998 5.5 Storage corrosion For the storage corrosion of wheel cylinders, when tested by the specification of 6.9 of JIS D 2605, the piston shall function smoothly after testing. Further- more, the wheel cylinder shall meet the requirements for storage corrosion specified in 4.2 of JIS D 2605. $.6 Waterproof For the waterproof property of wheel cylinders, when tested by the methods described in clause 10, there shall not be penetration of moisture into the boot inside, excluding at the boot groove. 6 Construction Wheel cylinders shall be so constructed that the joining port and the bleeder hole shall be interconnected to the cylinder body inside, 7 Mi ensions 7.1 Cylinder body The main jensions of cylinder bodies shall be as follows a) The basic dimension of the inside diameter of cylinder bodies shall be as given in Table 2. ‘Table 2 Basic dimension of inside diameter of cylinder body Unit mm Nominal size | Basic dimension [| Nominal size | Basic dimension 9716 1429 Ls 31.75 38 1587 138 3493 16 1746 mn 3651 34 1905 || tie 38.10 136 mse |e 41.30 7s 2a iim a5 IS/6 23.81 116 47.62 1 25.40, I 2 5080 | 1s 26.99 26 35.56 ie B57 2an8 3874 b) For the permissible deviation of the inside diameter of cylinder bodies, unless otherw' indicated particularly, H9 of JIS B 0401-2 shall be applied to the basic dimensions given in Table 2. ©) The surface roughness of the cylinder body interior shall be 2 pmRe according to JIS B 0601. 7.2, Piston For the dimensional tolerance of the outside diameter of piston sliding sur- faces, unless otherwise indicated particularly, ITS of JIS B 0401-2 shall be applied to the basic dimensions given in Table 2. 7.3. Screw threads The accuracy of the screw threads used in the hydraulic passage shall be 6H according to JIS B 0209 or JIS B 02114 D 2604 : 1998 8 Appearance The appearance of the main components of wheel cylinders shall be as follows: a) The metal parts, if recognized the functional necessity, shall be subjected to a rust prevention by means of suitable treatment b) There shall not be adhering any dust, machined chip, sand or the like on the cylinder body inside. ©) The cup sliding surface of cylinder bodies shall be free from harmful flaws, casting porosities, pinholes, rust and the like. d) The piston sliding surface shall be free from harmful flaws, burrs, casting porosities, pinholes, rust and the like. ©) The bleeder seat surface shall be free from harmful flaws, burrs, etc. 9 Name and materials of main components 9.1 Name of component The name of the main components of wheel cylinders shall be as given in Attached Tables 1 to 4. 9.2 Material The material of the main components of wheel cylinders shall be as given in Attached Tables 1 to 4. 10 Waterproof test The waterproof test shall be as follows 10.1 Apparatus The apparatus shall be as follows: a) Actuating device ‘The actuating device shall be of such conception as illustrated in Fig. 1 b) Wheel cylinder fixture |The wheel cylinder fixture shall be according to 6.7.2 of JIS D 2605. c) Thermostat It shall be a thermostatic chamber capable of maintaining a wheel cyl- inder, which is installed in the fixture of b), at the test temperature given in Table 3. Pressure gauge ‘Wheel cylinder Relief valve Water. iE \ Master cylinder [)- Fig. 1 Waterproof test apparatus (example) 10.2 Test conditions The test conditions shall be as followsg D 2604: 1998 ) Heat exposure conditioning Specimens shall be conditioned with the heat exposure as given in Table 3. Table 3 Heat exposure condition = Heat exposure Temperature °C | Duration h Class 1 ozs | 22 Class 2 120= | ‘Chass 3 150: b) Test condition The waterproof test conditions shall be as given in Table 4. Table 4 Waterproof test condition Underwater stroking, Class Depth mm | Water temperature] Strokes | Number of stroking | Stroke(') mm Chass 1 ] Ordinary Class2 | 300430 | operant 00 | 2 Class 3 i Note (‘) If particularly required, it shall be agreed between the parties concerned with delivery Remarks: The fluid used for actuating shall be the fluid conforming to JIS K 2233, or that agreed between the parties concerned with delivery. 10.3 Procedure With the boot installed to the wheel cylinder, the waterproof test shall be performed according to the followings: a) b) °) a) °) ny 8) u Fix the wheel cylinder assembly in the fixture. Set the piston positioning at 2mm backwards from the position of 4.8mm one way stroking (’). Put it in the thermostat maintained at the temperature given in Table 3, and after consecutive heating for 70 h2+2 h leave it in a room to cool to the room temperature. Connect the fixture with the actuating device and, after bleeding air sufficiently, im- merse it into the tank filled with water and fix the cylinder axis as positioning at 300 mm +30 mm below the water surface. ‘Stroke the piston from the position returned 2 mm from 4.8 mm stroking to the position of 4.8 mm stroking ('), under the conditions given in Table 4. Take out the wheel cylinder assembly from the water tank and wipe dry the outside. Remove the boot to examine for soaking into the boot inside. Marking Wheel cylinders shall be marked with the following information on a conspicuous place by an indelible means.6 D 2604: 1998 a) The numerical value indicating the inside diameter of the cylinder body b) Manufacturer's name or abbreviation No, | Name of main component Material 1 | Cylinder body FC 200 or FC 250 of JIS G S501, or AC 2A or AC 2B of JIS H 5202 —E A Tar AC Taf SW Sorat scaing WHS G WSL JIS H 4040 3 | Cupcdish ype) Class 1,2 0F3 of JIS D 2605 4 | Piston spring That according to JIS G 3521 or JIS G 3522 5 | Boot Class 1, 20F3 of JIS D 2608 ‘ © | Bleeder S$ 400 of JIS G 3101, or that according w0 JIS G 4051 7__| Push rod $$ 400 of JIS G 3101, or that acconding to JIS G 4081 | Spring seat SPCC of JIS G 3141 Remarks 1 The construction expressed in the drawing shows an example. 2° Materials other than for cup and boot are listed as the practical examples. Attached Fig. 1 Wheel cylinder7 D 2604 : 1998 No, | Name of main component Material 1 | Cylinder body FC 200 or FC 250 of JIS G 5501, or AC 2A or AC 2B of JIS H 5202 2_| Piston ‘That according to JIS G 401 or JIS H 4040 3_| Cup (ring type) Class 1, 20r3 of JIS D 2605 4_| Piston spring ‘That according io JIS G 3521 or JIS G 3522 | Boot Class 1, 20r3 of JIS D 2608 6 | Bleeder ‘SS 400 of JIS G 3101, or that according to JIS G 4051 Remarks 1 The construction expressed in the drawing shows an example. 2. Materials other than for cup and boot ate listed for the practical examples. Attached Fig. 2 Wheel cylinder8 D 2604 : 1998 No. | Name of main component Material | Cylinder body FC 200 oF FC 250 of JIS G S501, or AC 2A or AC 2B of JIS H 5202 2 | Piston ‘That according to JIS G 4051 or JIS H 4040 3 | coming wre) Class 1, 20r3 of JIS D 2605 4 | Boot Class 1, 20r 3 of JIS D 2608 5 | Bleeder $8400 of JIS G 3101, or that acconding to JIS G 4051 6 | Adjuster whee! $8400 of JIS G 3101, orthat according to JIS G 4051 7_| Adjuster screw ‘That according 10 JIS G 4051 8 | Wheel lock spring ‘That according to JIS G 4801 or IS G 4401 Remarks 1 The construction expressed in the drawing shows an example. 2. Materials other than for cup and boot are listed for the practical examples. Attached Fig. 3 Wheel cylinder9. D 2604 : 1998 3 No. | Name of main component Material 1 | Ohlinder body FC 200 or FC 250 of JIS G S501, or AC 2A and AC 2B of JIS H 5202 elms AC2A oF AC 2B of JIS H 5202, or that according to JIS G 4051 oF JIS H 4040 3. | Cup cing ype) Class 1, 20r3 of JIS D 2605 4. | Piston spring That according to JIS G 3521 or JIS G 3522 5 | Boot Class, 20r3 of JIS D 2608 6 | Bleeder $$ 400 oF JIS G 301, or tat according © JIS G 4051 2c 7 | Push rod 'S$-400 of JIS G 3101, or that according to JIS G 4051 8 | Back-up ring Polytetrafluoroethylene resin Remarks 1 The construction expressed in the drawing shows an example. 2. Materials other than for cup and boot are listed for the practical examples, Attached Fig.4 Wheel cylinderErrata for JIS (English edition) are printed in Standardization Journal, published monthly by the Japanese Standards Association, and also provided to subseribers of JIS (English edition) in Monthly Information Errata will be provided upon request, please contact: ‘Standardization Promotion Department, Japanese Standards Association, 4-1-24, Akasaka, Minato-ku, Tokyo, 107-8440 JAPAN, TEL. 03-3583-8002 FAX. 03-3583-0462