To the top of the site > To the list of this category

The name was changed due to legal amendments on July 1, 2019. Except for the preface, please read "Japanese Industrial Standards" as "Japanese Industrial Standards" throughout th

D 2604: 2012

table of contents

page

Preface 1
1 Scope of application 1
2 References.................................................................................................................................. 1
3 Terms and definitions 2
4 Types 2
5 Maximum operating pressure 2
6 Performance ................................................................................................................. 2
6.1 Performance of components .................................................................................................. 2
6.2 Performance of the Assembly 2
6.3 Low temperature operation....................................................................................................2
6.4 Operational durability 2
6.5 Storage Corrosion.................................................................................................... 3
6.6 Water Resistance....................................................................................................3
7 Structure.................................................................................................................................. 3
8 Main dimensions 3
8.1 Cylinder body 3
8.2 Pistons.................................................................................................................. 3
8.3 Screws .......................................................................................................................... 3
9 Appearance....................................................................................................................3
10 Names and materials of major parts 4
10.1 Parts Names.................................................................................................................. 4
10.2 Materials 4
11 Water immersion resistance test method 4
11.1 Test equipment 4
11.2 Test conditions 4
11.3 Test procedure ................................................................................................................. 5

(1)
The name was changed due to legal amendments on July 1, 2019. Except for the preface, please read "Japanese Industrial Standards" as "Japanese Industrial Standards" throughout th

D 2604: 2012

Introduction

This Standard has been prepared by the Japan Industrial Standardization Association in accordance with the provisions of Article 12, Paragraph 1,
The Japan Auto Parts Industries Association (JAPIA) and the Japanese Standards Association (JSA) have submitted the draft industrial standard to th
The Japanese Industrial Standards Committee deliberated on the matter, and the Minister of Economy, Trade and Industry revised it.
It is.
This revised JIS D 2604:1998 and replaced it with this standard.
This Standard is a work protected by copyright law.
Please note that parts of this standard may infringe on patent rights, patent applications after publication, or utility model rights.
The Minister of Economy, Trade and Industry and the Japanese Industrial Standards Committee call attention to the above.
We are not responsible for verifying patent rights.

(2)

The name was changed due to legal amendments on July 1, 2019. Except for the preface, please read "Japanese Industrial Standards" as "Japanese Industrial Standards" throughout th

Japanese Industrial Standards JIS

D 2604: 2012
 Automotive parts -
Non-mineral oil hydraulic brake wheel cylinder
Automotive parts-Hydraulic brake wheel cylinders
for hydraulic brake systems using a non-petroleum base brake fluid

preface
This standard was established in 1961 and has since been revised six times. The last revision was in 1998.
However, it was later revised to reflect technological advances.
At present, no corresponding international standards have been established.

1 Scope of application
This standard applies to wheel cylinders for drum brakes (hereinafter referred to as wheel cylinders) that use non-mineral oil brake fluid in automo
This standard specifies the type of pressure cylinders used.

2 Normative References
The following standards, through their reference in this Standard, constitute part of the provisions of this Standard.
The latest editions of the standards cited (including amendments) shall apply.
JIS B 0209-3 General Metric Screw Threads - Tolerances - Part 3: Dimensional Tolerances for Structural Screw Threads
JIS B 0401-2 Dimensional Tolerances and Fit Methods - Part 2: Tolerance Classes and Dimensional Tolerances for Holes and Shafts
JIS B 0601 Geometric Product Specifications (GPS) - Surface Texture: Profile Method - Terms, Definitions and Surface Texture Parameters
Data
JIS B 2704-1 Coil springs - Part 1: Basic calculation methods for compression and tension coil springs
JIS D 0107 Automobiles - Brake terminology - Parts
JIS D 2605 Automotive parts - Rubber cups for non-mineral oil hydraulic brake cylinders
JIS D 2608 Automotive parts - Rubber boots for non-mineral oil hydraulic brake wheel cylinders
JIS G 3101 General structural rolled steel
JIS G 3141 Cold-rolled steel sheets and strips
JIS G 3521 Hard steel wire
JIS G 3522 Piano wire
JIS G 4051 Carbon steel for machine structure
JIS G 4401 Carbon tool steel
JIS G 4801 Spring steel
JIS G 5501 Gray iron castings
JIS H 4040 Aluminum and aluminum alloy rods and wires
The name was changed due to legal amendments on July 1, 2019. Except for the preface, please read "Japanese Industrial Standards" as "Japanese Industrial Standards" throughout th

2
D 2604: 2012

JIS H 5202 Aluminum alloy castings

JIS K 2233 Non-mineral oil brake fluid for automobiles

3 Terms and Definitions

The main terms and definitions used in this Standard are from JIS D 0107.

Four kinds
Wheel cylinder types are classified according to their operating conditions as shown in Table 1.

Table 1 - Types
kinds Classification
1 type Can be used under normal temperature operating conditions
2 types Can be used under high temperature operating conditions
3 types Can be used under special high temperature operating conditions

Five Maximum Operating Pressure

The maximum operating pressure of the wheel cylinder is four types: 10 MPa, 15 MPa, 20 MPa, and 25 MPa.

6 Performance
6.1 Component Performance
The performance of the main components of the wheel cylinder shall be as follows:
a) The performance of the rubber cup shall satisfy the requirements of JIS D 2605.
b) The performance of the rubber boot shall satisfy the requirements of JIS D 2608.
c) The performance of the piston spring shall satisfy the requirements of JIS B 2704-1.
6.2 Assembly performance
The performance of the wheel cylinder assembly shall be as follows:
The test liquid shall conform to JIS K 2233.
a) With the bleeder hole closed, the wheel cylinder is supplied with 100 kPa of air pressure from the joint hole into the cylinder body.
When the piston is gently moved back and forth several times, the piston operates smoothly and there is no air leakage from any part.
In addition, when the bleeder hole is opened, air must be able to escape.
b) When hydraulic pressure is applied to the cylinder body from the joint hole, the piston operates and the required
It has to generate force.
c) The wheel cylinder is filled with test fluid in the cylinder body, and 130 % of the maximum operating pressure is applied to the cylinder body.
When a hydraulic pressure of 10 ...
6.3 Low temperature operation
The low-temperature operation of the wheel cylinder is tested according to the provisions of JIS D 2605, 6.7 (cold leakage test).
There should be no leakage from the cup.
6.4 Operational Durability
The operational durability of the wheel cylinder was tested according to the provisions of JIS D 2605, 6.8 (operational durability test).
The operating durability specified in 4.2 (performance) of JIS D 2605 shall be satisfied.
There must be no harmful deformation, wear, defects, etc.
The name was changed due to legal amendments on July 1, 2019. Except for the preface, please read "Japanese Industrial Standards" as "Japanese Industrial Standards" throughout th

3
D 2604: 2012

6.5 Storage corrosion resistance

The storage corrosion test of the wheel cylinder was conducted in accordance with the provisions of JIS D 2605, 6.9 (storage corrosion test).
After the test, the piston shall operate smoothly. In addition, the warranty specified in 4.2 (performance) of JIS D 2605 shall be satisfied.
The corrosion resistance must be satisfied.
6.6 Water Resistant
The water ingress resistance of the wheel cylinder shall be such that, when tested in accordance with the provisions of Clause 11, no water ingress
There shall be no gaps, except in boot grooves.

7 structure
The structure of the wheel cylinder must be such that the joint hole and the bleeder hole are connected to the inside of the cylinder body.

8 Main dimensions
8.1 Cylinder body
The main dimensions of the cylinder body shall be as follows:
a) The standard dimensions of the cylinder body bore diameter shall be in accordance with Table 2.

Table 2 - Standard dimensions of cylinder body bore

Unit: mm
Call Reference Dimensions
Call Reference Dimensions
9/16
14.29 1 1/4 31.75
5/8
15.87 1 3/8 34.93
1 1/16 17.46 1 7/16 36.51
3/4
19.05 1 1/2 38.10
1 3/16 20.64 1 5/8 41.30
7/8 1 3/4
22.22 44.45
1 5/16 23.81 1 7/8 47.62
1 25.40 2 50.80
1 1/16 26.99 2 3/16 55.56
1 1/8 28.57 2 5/16 58.74

b) The dimensional tolerance of the cylinder body inner diameter shall be in accordance with JIS B 0401-2, unless otherwise specified, for the refere
The standard shall be H9 as specified in the above.
c) The surface roughness of the inner surface of the cylinder body shall be Rz2 as specified in JIS B 0601.
8.2 piston
The dimensional tolerance of the outside diameter of the sliding surface of the piston shall be in accordance with JIS B 0401-2, unless otherwise sp
The standard shall be IT8 as specified in .
8.3 screw
The accuracy of the threads used in the hydraulic passages shall be 6H as specified in JIS B 0209-3.

9 exterior
The appearance of the main parts of the wheel cylinder shall be as follows:
a) Metal parts that are deemed necessary for the function must be treated with an appropriate rust prevention method.
b) There must be no dirt, chips, sand, etc. inside the cylinder body.
The name was changed due to legal amendments on July 1, 2019. Except for the preface, please read "Japanese Industrial Standards" as "Japanese Industrial Standards" throughout th

Four
D 2604: 2012

c) The sliding surface of the cup of the cylinder body must be free from harmful scratches, blowholes, pinholes, rust, etc.
stomach.
d) The sliding surfaces of the pistons must be free from harmful scratches, burrs, blowholes, pinholes, rust, etc.
e) The seat surface of the bleeder must be free of harmful scratches, burrs, etc.

10. Names and materials of major parts

10.1 Parts Names
The names of the main parts of the wheel cylinder are shown in Figures 1 to 4.
10.2 Materials
The materials of the main parts of the wheel cylinder shall be as shown in Figures 1 to 4.

11 Water immersion resistance test method

11.1 Test Equipment
The test equipment is as follows:
a) Actuator The actuator shown in Figure 5 shall be used.
b) Wheel cylinder fixing device The wheel cylinder fixing device shall comply with 6.8.2 c) of JIS D 2605 (operation durability test apparatus).
(Location) as provided for in this Act.
c) Thermostatic chamber The thermostatic chamber shall be capable of maintaining the test temperature in Table 3 with the wheel cylinder fixed to th
This shall be the case.

Figure 5 - Water immersion resistance test device (example)

11.2 Test conditions

The test conditions are as follows:
a) Thermal degradation conditions The thermal degradation conditions shall be as shown in Table 3.

Table 3 - Thermal degradation conditions

kinds Thermal degradation conditions
Temperature ℃Time h
1 type 100±5 70±2
2 types 120±5
3 types 150±5
The name was changed due to legal amendments on July 1, 2019. Except for the preface, please read "Japanese Industrial Standards" as "Japanese Industrial Standards" throughout th

Five
D 2604: 2012

b) Water immersion test conditions The water immersion test conditions shall be as specified in Table 4.

Table 4 - Water immersion resistance test conditions

kinds Underwater operation
Depth water temperature
Number of trips/hoursNumber of operations
stroke
mm Times/h times mm
1 type 300±30 At normal temperature
1 000±100 500 2
2 types
3 types
The liquid used for operation shall conform to JIS K 2233.

11.3 Test Procedure

The water immersion test is carried out by assembling the boot onto the cylinder as follows.
a) Fix the wheel cylinder to the wheel cylinder fixing device.
b) Set the piston to a position 2 mm back from the 4.8 mm stroke position on one side.
c) Place in a thermostatic chamber maintained at the temperature shown in Table 3, heat continuously for 70 h ± 2 h, and then leave in the room to re
d) Attach the wheel cylinder fixing device to the actuator, bleed the air out thoroughly, and then place it in a water tank.
The fixture is immersed and fixed so that the cylinder's central axis is 300 mm ± 30 mm above the water surface.
e) Operate under the conditions shown in Table 4 from a position 2 mm back from the 4.8 mm stroke position to the 4.8 mm stroke position.
Move.
f) Remove the wheel cylinder from the water bath and carefully wipe off any moisture adhering to the outside.
g) Remove the boots and check the water level inside the boots.
The name was changed due to legal amendments on July 1, 2019. Except for the preface, please read "Japanese Industrial Standards" as "Japanese Industrial Standards" throughout th

6
D 2604: 2012

number Name of main parts material

1 Cylinder body
2 piston
3 Cup (dish-shaped)
Four Piston spring
Five boots
6 Breeder
7 Push rod
8 Spring seat
FC200 or FC250 as specified in JIS G 5501, or AC2A,
AC2B, AC4B or AC4C as specified in JIS H 5202
AC2A or AC2B as specified in JIS H 5202, or as
specified in JIS G 4051 or JIS H 4040
Type 1, 2 or 3 as specified in JIS D 2605
Specified in JIS G 3521 or JIS G 3522
Type 1, 2 or 3 as specified in JIS D 2608
SS400 as specified in JIS G 3101 or as specified in JIS G 4051
SS400 as specified in JIS G 3101 or as specified in JIS G 4051
SPCC as specified in JIS G 3141

NOTE 1 The structure shown in the figure is an example.

NOTE 2 Materials other than the cup and boot are examples.

Figure 1 - Wheel cylinder (example 1)

The name was changed due to legal amendments on July 1, 2019. Except for the preface, please read "Japanese Industrial Standards" as "Japanese Industrial Standards" throughout th

7
D 2604: 2012

number Name of main parts material

1 Cylinder body FC200 or FC250 as specified in JIS G 5501, or AC2A,
AC2B, AC4B or AC4C as specified in JIS H 5202
2 piston Specified in JIS G 4051 or JIS H 4040
3 Cup (ring shape) Type 1, 2 or 3 as specified in JIS D 2605
Four Piston spring Specified in JIS G 3521 or JIS G 3522
Five boots Type 1, 2 or 3 as specified in JIS D 2608
6 Breeder SS400 as specified in JIS G 3101 or as specified in JIS G 4051

NOTE 1 The structure shown in the figure is an example.

NOTE 2 Materials other than the cup and boot are examples.

Figure 2 - Wheel cylinder (example 2)

The name was changed due to legal amendments on July 1, 2019. Except for the preface, please read "Japanese Industrial Standards" as "Japanese Industrial Standards" throughout th

8
D 2604: 2012

number Name of main parts material

1 Cylinder body FC200 or FC250 as specified in JIS G 5501, or AC2A,
AC2B, AC4B or AC4C as specified in JIS H 5202
2 piston Specified in JIS G 4051 or JIS H 4040
3 Cup (ring shape) Type 1, 2 or 3 as specified in JIS D 2605
Four boots Type 1, 2 or 3 as specified in JIS D 2608
Five Breeder SS400 as specified in JIS G 3101 or as specified in JIS G 4051
6 Adjust Wheel SS400 as specified in JIS G 3101 or as specified in JIS G 4051
7 Adjustment Specified in JIS G 4051
screw
8 Wheel lock Specified in JIS G 4401 or JIS G 4801
spring
NOTE 1 The structure shown in the figure is an example.
NOTE 2 Materials other than the cup and boot are examples.

Figure 3 - Wheel cylinder (example 3)

The name was changed due to legal amendments on July 1, 2019. Except for the preface, please read "Japanese Industrial Standards" as "Japanese Industrial Standards" throughout th

9
D 2604: 2012

number Name of main parts material

1 Cylinder body FC200 or FC250 as specified in JIS G 5501, or AC2A,
AC2B, AC4B or AC4C as specified in JIS H 5202
2 piston AC2A or AC2B as specified in JIS H 5202, or as
specified in JIS G 4051 or JIS H 4040
3 Cup (ring shape) Type 1, 2 or 3 as specified in JIS D 2605
Four Piston spring Specified in JIS G 3521 or JIS G 3522
Five boots Type 1, 2 or 3 as specified in JIS D 2608
6 Breeder SS400 as specified in JIS G 3101 or as specified in JIS G 4051
7 Push rod SS400 as specified in JIS G 3101 or as specified in JIS G 4051
8 Backup Ring Polytetrafluoroethylene resin

NOTE 1 The structure shown in the figure is an example.

NOTE 2 Materials other than the cup and boot are examples.

Figure 4 - Wheel cylinder (example 4)