Disclosure to Promote the Right To Information

Whereas the Parliament of India has set out to provide a practical regime of right to information for citizens to secure access to information under the control of public authorities, in order to promote transparency and accountability in the working of every public authority, and whereas the attached publication of the Bureau of Indian Standards is of particular interest to the public, particularly disadvantaged communities and those engaged in the pursuit of education and knowledge, the attached public safety standard is made available to promote the timely dissemination of this information in an accurate manner to the public.

इंटरनेट मानक

“!ान $ एक न' भारत का +नम-ण”Satyanarayan Gangaram Pitroda

“Invent a New India Using Knowledge”

“प0रा1 को छोड न' 5 तरफ”Jawaharlal Nehru

“Step Out From the Old to the New”

“जान1 का अ+धकार, जी1 का अ+धकार”Mazdoor Kisan Shakti Sangathan

“The Right to Information, The Right to Live”

“!ान एक ऐसा खजाना > जो कभी च0राया नहB जा सकता है”Bhartṛhari—Nītiśatakam

“Knowledge is such a treasure which cannot be stolen”

“Invent a New India Using Knowledge”

है”ह”ह

IS 8654 (2001): Automotive Hydraulic Brake Fluid, HeavyDuty [PCD 3: Petroleum, Lubricants and their RelatedProducts]

IS 8654:2001

Indian Standard

AUTOMOTIVE HYDRAULIC BRAKE FLUID,HEAVY DUTY— SPECIFICATION

(Second Revision )

ICS 75.100

0 BIS 2001

BUREAU OF INDIAN STANDARDSMANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG

NEW DELHI 110002

May 2001 Price Group 8

.-

Lubricants and Related Products Sectional Committee, PCD 4

FOREWORD

This Indian standard (Second Revision) was adopted by the Bureau of Indian Standards, after the draft finalizedby the Lubricants and Related Products Sectional Committee had been approved by the Petroleum, Coal andRelated Products Division Council.

Earlier there were two Indian Standards on hydraulic brake fluids, namelyIS317 :1970 for moderate duty andIS ‘8654 :1977 for heavy duty. To ensure better safety of vehicles in the increased traffic.density areas, committeedecided to withdraw IS 317 and promote-the use of heavy duty brake fluid.

This Indian Standard was originally prepared in 1977 based on SAE J 1703(J) ‘Motor vehicle brake fluids’,published by the Society of Automotive Engineers, USA. In the first revision this standard was updated andaligned with the requirements stipulated in Federal Motor Vehicle Safety Standard (FMVSS) No. 116, DOT-3.In this revision two more types of super heavy duty automotive brake fluids have been incorporated as Type IIand Type 111corresponding to DOT-4 and DOT-5.1 of FMVSS No. 116 October 1998 and SAE J 1703 January1995 in addition to the existing DOT-3 brake fluid as Type I. These super heavy duty automotive brake fluidshave higher equilibrium reflux boiling points and wet equilibrium reflux boiling points to cope up with thesevere conditions existing in the recently introduced newer models of automobiles. The superior boiling propertiesof these new automotive hydraulic brake fluids will provide smoother and safer stoppage of these vehicles.DOT-5 type automotive hydraulic brake fluids which are based on silicone chemistry are not covered by thisstandard. These silicone fluids are not compatible with glycol/glycol ether based fluids.

For the purpose of deciding whether a particular requirement of this standard is complied with, the final value,observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance withIS 2: 1960 ‘Rules for rounding of numerical values (revised)’. The number of significant piaces retained in therounded off value should be the same as that of the specified-value in this standard.

IS 8654:2001

Indian Standard

AUTOMOTIVE HYDRAULIC BRAKE FLUID,HEAVY IXJTY — SPECIFICATION

(Second Revision )

1 SCOPE

This standard prescribes the requirements and methodsof sampling and test for non-petroleum type heavyduty automotive hydraulic brake fluid for use inhydraulic brake systems fitted with drum, disc or eithertype of brakes at wide ambient temperatures. Thesefluids are designed for use in braking systems fittedwith rubber cups and seal made from nitrile rubber(NR), styrene butadiene rubber (SBR) or a terpolymerof ethylene, propylene and a diene (EPDM) robber.

2 NORMATIVE REFERENCES

The following Indian Standards contain provisionswhich, through reference in this text, constituteprovisions of this standard. At the time of publicationthe editions indicated were valid. All standards aresubject to revision, and parties to agreements baaedon this standard are encouraged to investigate thepossibility of applying the most recent editions of thestandards indicated below:

IS No.323:1959410:1977

737:1986

1070:19921447(Part 1): 2000

1448

[P: 25] :1976

[P: 41] :1992

1570: i961

1972:1989

2362:1973

2631:19763355:1974

TitleRectified spirit (revised)Cold rolled brass sheet, strip and foil(~hird revision)Wrought aluminium and ahuniniumalloy sheet and stxipfor general engi-neering purposes (tlzird revision)Reagent grade water (third revision)Petroleum and its products —Methods of sampling Part 1Manualsampling (& revision)Methods of test for petroleum andits productsDetermination of kinematic anddynamic viscosity (@ revzkion)Water and sediment in crude oils andfuel oils by centrifuge (secondrevision)Schedules for wrought steel forgeneral engineering purposesCopper plate, sheet and strip forindustrial purposes (second revision)Determination of water by KarlFisher method @st revision)iso-Propyl alcohol (fzrst revision)Grey iron castings for elevatedtemperatures for non pressurecontaining parts (@W revision)

3400 Methods of test for vulcanized(Par 2): 1995 rubbers: Part 2 Hardness

(second revision)

3 TYPES

The material shall be of three types depending uponequilibrium reflux boiling points:

a) Type I;

b) Type II; and

c) Type III.

4 REQUIREMENTS

4.1 Appearance

The material shall be clear homogeneous liquid, freefrom water, dirt, suspended matter and other visibleimpurities.

4.2 Colour

The brake fluid defined under Type I, II and III shallbe dyed red for identifying the leakage easily.However, undyed product may also be supplied ifagreed to between the supplier and the user. As DOT-3, DOT-4 and DOT-5.1 brake fluids are based onglycols/glycol ethem, they are mutually compatible andhence, there is no need of dyeing them differently.

4.3 The material shall also meet the requirementsprescribed in Table 1 when tested in accordance withthe methods given inCO16 and 7 of Table 1.

5 PACKING AND MARKING

5.1 Packing

The material shall be securely closed and packed incontainers of metal or any suitable material as agreedto between the purchaser and the supplier.

5.2 Marking

Material shall be marked with the followinginformation.

a)

b)

c)

d)

1

Name and type of material;

Manufacturer’s name, initials or trade-mark,if any;

Net mass of material; and

Identification in code or otherwise to enablethe lot of consignment or manufacture to betraced back from records.

IS 8654:2001

5.2.1 BISCertification A4arking

The container-may also be marked with the StandardMark.

5.2.2.1 The use of “Standard Mark is governed by theprovisions of the Bureau ofIndian Standards Act, 1986and the Rules and Regulations made thereunder. Thedetails of conditions under which the licence for theuse of the Standard Mark may be granted to

manufacturers or producers maybe obtained from theBureau of Indian Standards.

6 SAMPLING

Representative samples of material shall be drawn asprescribed in IS 1447.

7 TEST METHODS

Tests shall be conducted according to the methodprescribed inCO16 and 7 of Table 1.

Table 1 Requirements for Automotive Hydraulic Brake Fluid, Heavy Duty

(Clauses 4.3 and 7)

SI Characteristics Requirements Method of Test, Ref toNo. ~~

Type I T~ 11 Type tI1 1S 1448

(1) (2) (3) (4) (5) (6) (7)

i)

ii)

iii)

iv)

v)

vi)

vii)

Equilibrium reflux boiling point (ERBP), “C, Min 205 230 260 A —

Wet equilibrium reflux boiling point,” C, &fin

Kinematic viscosity, cSCa) at -40”C, Max

b) at 10O°C,Min

pH value

Brake tluid stability:

a) High temperature stability, change inERBP, “C,Max

b) Chemical stabtlity, change in ERBP ofmixture, ‘C, Max

Corrosion test at 100& 2°C for 120+2 h

O

b)

c)d)

e)

o

g)

Mass change, mg/cm2,MUXTinned Iron

steel

Absminium

Cast IronBrass

CopperCondition of test metal stripsAppearance of test fluid in the jar at 23 * 5°CCrystalline deposit on the walls oftest jar testmetal strips

Sediments, percent by volume, Mar

pH oftest fluidEffect on rubber cup (SBR)l) Appearance

2) Hardness decrease (IRHD), Mm

3) Base diameter increase in mm, Mux

Fluidity and appearance at low temperatures:a) at-40*2 ‘C for 144* 4hiJ

1) Sludging, sedimentation crystallization, orstratification

2) Bubble flow time (seconds), Max

b) at-50* 2°C for6 + 0.2 h

.1) Shrdging, sedimentation crystallization, orstratification

2) Bubble flow time (seconds), Mar

140 155 180 B .

[P: 25]I 500 I 800 900

1.5 1.5 1.5

~ 7.0to11.5~ —

4-

4-

3.0 + ().05 for each ~

degree above 225°C

3.0 +0.05 for each ~degree above 225°C

No disintegration as evidenced byblisters or sloughing

~15~1.4 1.4 1.4

c

D

E

F

—

—

—

1)Test at SJNo. vii a) should be t~ken as type test.

2

Is 86s4 :2001

Table 1 (Concluded)

SI Characteristics Requirements Method of Tes~ Ref to

No. ~~Type I Type U Type 111 Annex IS 1448

(1) (2) (3) (4) (5) (6) (7)

viii) Evaporation test at 100 + 2°C: G —

a) Loss in mass, percent, Max ~80~b) Abrasiveness or grittiness ~Norre ~c) Pour point of residue, “C, Mu ~5~

ix) Water tolerance test:

a) at +0 *2°C for 120*2 h

1) Clarity

2) Sludging, sedimentation, crystallizationor strat ification

3) Bubble flow time (seconds), Mar

b) at60*2°Cfor24+2h

I) Stratification

2) .Sedimenta, percent by volume, Max

x) Compatibility test:

a) at+O+2°Cfor24+2h

I) Clarity

2) Sludging, sedimentation, crystallization orstratification

b) at60*2°Cfor24+2h

1) Stratification

2) Sediments, percent by volume, Max

xi) Resistance to oxidation:

a) Change in mass<’mg/cm2),Max

I) Aluminium

2) Cast Iron

b) Condition ofmetal strips

xii) Effects on robber cups (SBR):

a) at70+2° Cfor70*2h

1) Base diameter irtwease, mm

2) Hardness decrease, IRHD, Max

3) Appearance

b) at 120 *2°C for 7.0+2h

1) BS.Wdiameter increase, mm2) Hardness deerease, IRHD, Max

3) Appearance

H

~ 0-05 ~

~ 0.30 ~No visible pitting oretchirrg

and no gummy deposits

~ 0.17 to 1.6->

~ lo~No dkintegration as evidenced

by blistersor slougbhg andstickiness.

<—0.17 to 1.6->

~15~No disintegration is evidenced bybliirs or sloughing and stickiness

J

K

L

—

—

—

xiii) Simulated performance test ~ Shall pass the teat ~ M —

(stroking properties)

3

IS 8654:2001

ANNEX A

fTable 1, S1No. (i)]

EQUILIBRIUM REF.LUX BOILING POINT (ERBP)

A-1 GENERAL

Determine the ERBP of the brake fluid by runningduplicate samples according to the following procdureand averaging the results.

A-2 OUTLINE OF METHOD

60 ml of brake fluid is boiled under specifiedequilibrium conditions (reflux) at atmosphericpressure in 100-ml flask. The average temperature ofthe boiling fluid at the end of the reflux period,corrected for variations in barometric pressure ifnecessary, is the ERBP.

A-3 APPARATUS

The test apparatus shall consist of the following (seeFig. l):

a) Flask (see Fig, 2) —A 100-ml round botto~short-neck heat resistant glass flask having

THERMOMETER

WAT[RINLET

RUBBCRTUBING

A

PIECES OFPOROUS PMTC

ASBESTOS-CfNTREDWIRE GAUZE 6.5

. m

kBUNSENBuRNER

Alldimensionsin millimteres.FIG. 1 ASSEMBLYOFAPPARATUSFORDETERMINATION

OF EQUILIBRIUMREFL{JX BOILING POINT AND

TEST FORSTABILITY

WATEROUTLST

r

UE81C •~CONDENSER

GR0u!40CLASS JOINT

r

t

b)

c)

d)

e)

a neck with a 19/38 standard taper, femaleground glass joint and a side-entering tubewith an outside diameter of 10 mm whichcentres the thermometer bulb in the flask 6.5mm from the bottom;

Condenser — A water-cooled, retlux, glasstube type condenser having a jacket 200 mmin length, the bottom end of which have a19/38 standard-taper, drip-tip, male groundglass joint

Boiling Stones — Three clean, unused siliconcarbide grains (approximately 2 mm indiameter, grit No. 8);

Thermometer — Standardized calibratedpartial emission (76 mm) solid stem,thermometers conforming to therequirements of ASTM 2C or ASTM 3C; and

Heat Source — Variable autotransformercontrolled heating mantle desi~ed to fit theflask, or an electric heater with rheostat heatcontrol.

A-4 PREPARATION OF APPARATUS

a)

b)

c)

d)

Thoroughly clean and dry all glassware.

Insert thermometer through the side tube untilthe tip of the bulb is 6.5 mm from the bottomcentre of the flask. Seal with a short piece ofnatural rubber, SBR or butyl tubing.

Place 60* 1 ml of brake fluid and the siliconcarbide grains into the flask.

Attach the flask to the condenser. When usinga heating mantle, place the mantle under theflask and support it with a ring-clap andlaboratory type stand, holding the entireassembly in place by a clamp. When using arheostat-controlled heater, centre a standardporcelain or hard asbestos refractory, havinga diameter opening 32 to 38 mm over theheating element and mount the flask so thatthe direct heat is applied only threugh theopening in the refractory. Place the assemblyin an area free from dratls or other types ofsudden temperature changes. Connect thecooling water inlet and outlet tubes to thecondenser. Turn on the cooling water. Thewater supply temperature shall not exceed28°C and temperature rise through thecondensor shall not exceed 28°C.

4

<S 8654:2001

1’

A-5 -PROCEDURE

T ‘-”----”””----1

I

-+

) 15(3U >IAPJU13KU

/TAPER,GROUNDGLASS JOINT

5

, #

/

~

I

25$s0

/

~60tz 00 SPHERE—

All dimensionsin nrillimterea.

FIG. 2 DETAILSOF 100-ml SHORT-NECKFLASK

Apply heat to the flask so that within 10+2 minutesthe fluid is refluxing in excess of 1 drop per second.The reflux rate shdll not exceed 5 drops per second atany time. Immediately adjust the heating rate to obtainan equilibrium reilux mte of 1 to 2 dro~s per secondover the next 5 * 2 minutes. Maintain this rate for anadditional 2 minutes, taking four temperature readingsat 30-second-intervals. Record the average of these asthe observed ERBP. If no reflux is evident when thefluid temperature reaches 260”C, discontinue heatingand observe the ERBP as in excess of 260”C. Recordthe barometric pressure.

A-6 CALCULATION AND REPORTFNG

A-6.1 Variation from Standard BarometricPressure

Apply to factor shown in Table 2 to calctilate the

barometric pressure correction to the ERBP.

Table 2 Correction for Barometric Pressure

(Clause A-6.1)

S1 Observed ERBP, Correction perl mmNo. “C Difference in Pressure’), “C(1) (2) (3)

i) 100to 190”C 0.039

ii) Over190”C 0.04

lTo be added in case barometric pressure is below 760 rmwtobesubtracted in case barometric pressure is above 760 mm.

A-6.2 If the two corrected observed ERBP’s agreewithin 2.O”C (4.0°C for brake fluids having an ERDPover 230°C) average the duplicate runs as the ERBP;otherwise, repeat the entire test, averaging the fourcorrected observed values to determine the originalERBP.

5

Is 8654:2001

ANNEX B

[Table 1, S1No. (ii)]

WET EQUILIBRIUM REFLUX BOILING POINT (ERBP)

-B-1 GENERAL

Determine the wet ERBP of brake fluid by runningduplicate samples according to the following procedureand averaging the results.

B-2 OUTLINE OF THE METHOD

A 350 ml sampleof the brake fluid is hurnidif~d undercontrolled conditions, 350 ml of SAE TEGME(triethylene glycol monomethyl ether), brake fluidgrade, fluid is used to establish the end point forhumidification. After humidification the water contentand ERBP of the brake fluid are determined.

B-3 APPARATUS FOR HUMIDIFICATION

Test apparatus shall consist of the following (see

a)

b)

Fig. 3):

Glass Jars — Four SAE RM-49 corrosiontest jars or equivalent screw top, straight-sided, round glass jars each having a capacityof about 475 ml and approximate innerdimensions of 100 mm in height by 75 mmin diameter, with matching lids having new,clean inserts providing water-vapour-proofscales;

Desiccator and Cover — TWO bowl formglass desiccators, 250 mm inside diameter,

c)

having matching tubulated covers fitted withsuitable robber stoppers; and

Desiccator Plate — Four 230 mm diameter,perforated porcelain desiccator plates, with-out feet, glazed on one side.

B-4 REAGENTS AND MATERIALS

a) Distilled Water — see IS 1070.

b) TEGME1) (Triethylene Glycol MonomethylEther) — Brake fluid grade.

B-5 PREPARATION OF APPARATUS

Lubricate the ground glass joint of the desiccator. Pour450 & 10 ml of the distilled water into each desiccatorand insert perforated porcelain desiccator plate. Placethe desiccator in an oven with temperature controlledat 50* 2°C throughout the humidification procedure.

B-6 PROCEDURE

Pour 350 * 5 ml of the brake fluid into and opencorrosion test jar. Prepare in same manner a duplicatetest fluid sample, and two duplicate specimens of theSAE TEGME referee material. The water content of

1)obtainable from Society of Automotive Engineers, Inc. mcommonweatthDrive, Warrendate,PA 15(B6,USA or fmm any othersuitable source.

VER

2

&—-----2lotlo 10—0

AU dimensionsin mittimteres.

‘FIG.3 HUMIDIFICATIONAPPARATUS

6

IS 8654:2001

the SAE TEGME fluid is adjusted to 0.50+0.05percent by mass at the start of the test in accordancewith IS 2362. Place one kmple each of the test brakefluid and the prepared TEGME sample into the samedesiccator. Repeat for the second sample of test brakefluid and TEGME in a second desiccator. Place thededicators in the 50”C , controlled oven and replacedesiccator covers. At intervals during ovenhumidification remove the rubber stopper in the topof each desiccator. Using a long needled hypodermicsyringe, take a sample of not more than 2 ml fromeach TEGME sample and determine water content.Remove no more than 10 ml of the fluid from each

SAE TEGME sample during the humidificationprocedure. When the water content of the SAETEGME fluid reaches 3.70 + 0.05 percent by mass(average of the duplicates), remove the two test fluidspecimens from their desiccators and promptly capeach jar tightly. Allow the sealed jars to cool for 60 to90 minutes at 23 * 5“C. Measure the water contentsof the test fluid specimens in accordance with IS 2362and determine their ERBP’s in accordance with A-1.If the two ERBP’s agree within 4“C, average them todetermine the wet ERB~ otherwise repeat and averagethe four individual ERBP’s as the wet ERBP of thebrake fluid.

ANNEX C

[Table 1,SIIVo.(iv)]

pH VAI.AJE

C-1 PROCEDURE (see IS 1070). The mixture of rectified spirit and water

Tests shall be carried out on material as received asshall be adjusted to a pH of 7.0 before mixing it withthe material. Determine the pH of the final mixture

well as on the material as obtained after corrosion test(see Annex E).

at 23”C.

C-1.l Mix an equal volume of the material and mixtureC-1.2 The pH may be-determined by either electro-

(80:20 v/v) of rectified spirit (see IS 323)andmetric method or indicator method. In case of disputethe electrometric method shall be adopted.

ANNEX D

[Tabfe 1,S1No. (v)]

FLUID STABILITY

D-1 SUMMARY OF THE METHOD

The degradation of brake fluid at elevated temperaturealone or in a mixture with a reference fluid is evaluatedby determining the change in ERBP afler a period ofheating under reflux conditions.

D-2 APPARATUS

Same as specified in Annex A.

D-3 PROCEDURE FOR HIGH TEMPERATURESTABILITY

D-3.1 Heat a new 60 + 1 ml sample of the brake fluid

7

to 185 + 2°C. Hold at this temperature for 120 + 5minutes. Bring to a reflux rate in excess of one dropper second within 5 minutes. The reflux rate shouldnot exceed five drop per second at any time. Over thenext 5 * 2 minutes adjust the heating rate to obtain anequilibrium reflux rate of 1 to 2 drops per second.Maintain this rate for an additional two minutes taking4 temperature reading at 30 seconds intervals. Averagethese as the observed ERBP. If no reflux is evidentwhen the fluid temperature reaches 260°C, discontinueheating and observe the ERBP as in excess of 260”C.Record the barometric pressure.

1s 8654:2061

D-3.2 Calculation and Reporting

Correct the observed ERBP for barometric pressureftictors in accordance with Table 2. Average thecorrected ERBP’s of the duplicate samples. Thedifference between this average and the original ERBPcMaincdinA-1 isthechangein ERBP of the fluid.

I&4 PROC-EDURE FOR CHEMICAL STABILITY

D-4.1 ,Mix 30 + 1 ml sample of the brake fhtid with30 + I ml of SAE compatibility fluidl) in a boilingpoint flask (see Annex A). Determine the initial ERBPof the mixture by applying heat to the flask so that thetluid is rethxing in 10 + 2 minutes at a rate in excessof one drop per second, but not more than five drops

per second. Note the maximum fluid temperatureobserved during the first minute afier the fluid beginsrefluxing at a rate in excess of one drop per second.Over the next 15 + 1 minutes adjust and maintain thereflux rate at 1 to 2 drops per second. Maintain thisrate for an additional two minutes recording theaverage value of four temperature readings taken at30 second intetvals as the final ERBP.

D-4.2 Calculation and Reporting

The difference between the initial ERBP and the finalaverage temperature is the change in temperature ofthe refluxing mixture. Average the results of theduplicates to the nearest 0.5”C.

ANNEX E

[Table 1,S1No. (vi)]

CORROSION TEST

E-1 OKJTLINK OF THE METHOD

Six specified metal corrosion test strips are polished,cleaned and weighed then assembled as described..4ssernbly is placed on a standard wheel cylinder cupin corrosion test jar immersed in the water-wet brakefluid, capped and placed in an oven at 100”C for 120 h.Upon removal and cooling the strips, fluid and cupsare examined and tested.

E-2 EQUIPMENT

E-2.1 Balance

An analytical balance having a minimum capacity of50 g and capable of weighing to the nearest 0.1 mg.

E-2.2 Desiccators

Desiccators containing silica gel or other suitabledesiccant.

E-2.3 Oven

Gravity convection oven capable of maintaining thedesired set point within 2“C.

E-2.4 Micrometer

A machinist’s micrometer 25’ to 50 mm capacity, oran optical comparator, capable of measuring thediameter of the SBR wheel cylinder (WC) cups to thenearest 0.02 mm.

~~~&~i~a~\Cfromsocietyof Automotive Engineers. Im. 400 Com-rnonweakh Drive. Warrendale, PA 15096, LISAor from anyothersuitabIe source.

E-3 MATERIALS

E-3.1 Corrosion Test Strips

Test strips shall be 80 mm long, 13 mm wide, and notmore than 6 mm thick with a hole of 4-5 mm diameterdrilled at about 6 mm from one end of the strip. Themetal strips shall be of tinned iron steel, aluminium,cast iron, brass and copper conforming to the followingdescription and specifications:

a)

b)

c)

d)

Tinned Iron — The strip shall be free fromlaminations, blisters, slives, rolled-in-scale,pits, ragged edges, holes turn down comers,black or white edges, scruffy.metrd, uncoatedspots or other defects. The mass of tin coating,both sides taken together shall not be less than27 glm’.

Steel — The strips shall be made from alloysteel sheet (cold roiled), which shall be freefrom seams, laminations, blisters, excessivedetachable scales and other defects. The steelshall conform to designation Cl 10 of 1S 1570and with the phosphoms (as P) and sulphur(as S) limited to 0.04 percent and0.050 percent maximum, respectively.

Aluminium Alloy — The strip shall be madefrom annealed aluminium alloy sheet whichshall be uniform in quality and condition,sound, smooth, flat, free from buckles andother defects. The alloy shall conform tograde H14 of IS 737.

Cast iron — The strip shall be made fromgrey cast iron conforming to Grade 1 of

8

1S 3355 or from a brake cylinder of knownmake.

e) Brass — The strip shall be made from brasssheet conforming to grade Cu, Zn 30 ofIS 410. The sheet shall be clean, smooth flatand free from temper. The sheet shall alsobe free from foreign material, pipes, laps,s\ives cracks, scales, buckles and otherdefects.

0 Copper --- The strip shall be made from thelight cold rolled copper sheet. The coppercontent shall not be less than 99.9 percent(see IS 1972), silver, if any, being taken ascopper.

E-3.2 SBR Ctlp~*)

Two unused standard 32 mm dia wheel cylinder (WC)cups.

E-3.3 Corrosion Test Jars and Lids

Two screw top straight sided round glass jars, eachhaving a capacity of approximately 475 ml and innerdimensions of approximately 100 mm in height and75 mm in diameter and a tinned steel lid (no insert ororganic coating) vented with a hole 0.8 +.0.1 mm indiameter.

E-3.4 Machine Screws and Nuts

Clean, rust rmd oil-free uncoated mild steel round orfillister head machine screw of approximately 18 mmlength and matching uncoated nuts.

E-3.5 Supplies for Polishing Strips

Waterproof silicon carbide paper, grit No. 320,grade 00 steel wool, lint-free polishing cloth.

E-3.6 Distilled Water — See IS 1070.

E-3.7 lso-propanol — See IS 2631.

E-4 PROCEDURE

E-4.-1 Except for the tinned iron strips, abradecorrosion test strips on all surface areas with siliconcarbide paper wet with iso-propanol until all surfacescratches, cuts and pits are removed. Use a new pieceof paper for each different type of metal. polish thestrips with the 00 grade steel wool. Wash all’strips,including the tinned iron and the assembly hardware,with iso-propanol; dry the strips and assemblyhardware with a clean lint-free cloth or use filteredcompressed air and place the strips and hardware in adesiccator containing silica gel or other suitabledesiccant and maintained at 23 * 5°C for at least one

:)Part h’o. B1Girling 64674047 manufactured by M/s Wakes IndiaLtd. Padi. Madras 600050.

IS 8654:2001

hour. Handle the strips with forceps after polishing.Weigh and record the mass of each strip to the nearest0.1 mg. Assemble the strips on a clean dry machinescrew, with matching plain nut, in the order of tinnediron, steel, aluminium, cast iron, brass and copper.Bend the strips, other than the cast iron, so that thereis a separation of 3 + 1/2 mm between adjacent stripsfor a distance of about 5 cm from the free end of thestrips (see Fig. 4). Tighten the screw on each test stripassembly so that the strips are in electrolytic contactand can be lifted by either of the outer strips (timediron or copper) without any of the strips movingrelative to the others when held horizontally. Immersethe strip assemblies in i.so-propanol. Dry with driedfiltered compressed air, then desiccate at least one hourbefore use.

- 3mm( TYPICM SPACINGBETWEEN STRIPS)

FIG. 4 CORROSIONSTRIPSASSEMBLY

E4.2 Measure the base diameters of the 2 standardSBR cups using an optical comparator or micrometerto the nearest 0.02 mm along the centerline of theSAE and rubber-type identifications and at rightangles to this centerline. Take the measurements atleast 0.4 mm above the bottom edge and parallel tothe base of the cup. Discard any cup if the twomeasured diameters differ by more than 0.08 mm.Average the two readings on each cup. Determine thehardness of the cups by the method given inIS 3400 (Part 2).

E-4.3 Rinse the cups in iso-propanol for not morethan 30 seconds and wipe dry with a clean lint-freecloth. Place one cup with lip edge facing up in eachjar. Insert a metal strip assembly inside each cup withthe fastened end down and the free end extendingupward (see Fig. 5). Mix 760 ml of brake fluid with

9

Is 8654:2001

40 ml of distilled water. Using this water wet mixture,cover each strip assembly to a minimum depth of 10mm above the tops of the strips. Tighten the lids andplace the jars for 120 & 2 h in an oven maintained at100 * 2“C. Allow the jars to cool at 23 * 5°C for 60 to90 minutes. Immediately remove the strips from thejars using forceps, agitating the strip assembly in thefluid to remove adhering sediment. Examine the teststrips jars for adhering crystalline deposits.Disassemble the metal strips and remove adheringfluid by flushing with water, clean each strip by wipingwith a clean cloth wetted with isopropanol. Examinethe strips for evidence of corrosion and pitting.

E-4.4 Disregard staining or discoloration. Place thestrips in a desiccator maintained .at 23 & 5°C for atleast 1 h. Weigh each strip to the nearest 0.1 mg.Determine the change in mass of each metal strip.Average the results for the two strips of each type ofmetal. Immediately following the cooling periodremove the cups from the jars with forceps. Removeloose adhering sediment by agitation of the cups inthe mixture. rinse -the cups in iso-propanol and air-

dry. Examine the ‘cups for evidence of sloughing,blisters, and other forms of disintegration. Measurethe base diameter and hardness of each cup within 15minutes after removal from the mixture. Examine themixture for gelling. Agitate ‘the mixture to suspendand uniformly disperse, sediment. ‘From each jar,transfer a 100 ml portion of the mixture to a cone-shaped centrifuge tube and determine the percentsediment by the method given in IS 1448 [P: 41].Further measure the pH value of the test mixtureaccording to Annex C.

E-5 CALCULATION AND REPORTING

E-5.1 Measure the area of each type of test strip tothe nearest square centimetre. Divide the averagechange in mass for each type by the area of that type.

E-5.2 Note other data and evaluations indicatingcompliance with S1No. (vi) of Table 1. In the event ofa marginal pass on inspection by attributes, or of afailure in one of the duplicate, run another set ofduplicate samples. Both repeat samples shall meet all-requirements given in Table 1.

f-? 0.8:0.I VENT

TINNEDSTEEL LID

I, IMMERSION I

;I1

10 0 I

II

;I

SBR CUPIIII

~----//

\,_/

~—-* 751nin_+

Atl dimensionsin mittimtcms.

FIG. 5 CORROSIONTEST APPARATUS

10

IS S6!%-: 20Q1

ANNEX F

[Table 1,SINO.(J@]

FLUIDITY AND APPEARANCE AT LOW TEMPERATURES

F-1 OUTLINE OF THE METHOD

Brake fluid is chilled to the expected minimumexposure temperatures and observed for clarity,gellation, sediment, separation of components,excessive viscosity or thixotropy.

F-2 APPARATUS

F-2.1 Oil Sample Bottle

Two clear flint glass bottles of approximately 125 mlcapacity, an outside diameter of 37.0 ● 0.05 mm andan overall height of 165 + 2.5 mm.

F-2.2 Cold Chamber

An air bath cold chamber capable of maintainingstorage temperatures, down to –55°C with an accuracyof+ 2“C.

F-2.3 Timing Device

A suitabletiming device.

F-3 PROCEDURE

F-3.1 Place 100 * 1 ml of brake fluid at roomtemperature in an oil sample bottle. Stoppper the bottlewith an unused cork and place in-the cold chambermaintained at -40°C. Afler 144*4 h remove the bottlefrom the chamber, quickly wipe it with a clean, “lint-free cloth, saturated with iso-propanol. Examine theflu”id for evidence of sludging, sedimentation,crystallization, or stratification. Invert the bottle anddetermine the number of seconds required for the airbubble to travel to the top of the fluid. Let samplewarm up to room temperature and examine.

F-3.2 Repeat the above procedure with the coldchamber maintanied at -50”C for a period of 6 h + 12minutes.

F-3.3 Test specimens from either storage temperaturemay be used for the other only or afier warming up toroom temperature.

ANNEX G

[Table 1, SINO. (viii)]

EVAPORATION TEST

G-1 OUTLINE OF THE METHOD

The volatile diluent portion of a brake fluid isevaporated in an oven at 100”C. The non-volatilelubricant portion (evaporation residue) is measuredand examined for grittiness, the residues are thencombined and checked to assess fluidity at –5°C.

G-2 APPARATUS

G-2.1 Petri Dishes

Four covered glass petri dishes approximately 100 mmin diameter and 15 mm in height.

G-2.2 Oven

A top vented gravity convection oven capable of

maintaining a temperature of 100+ 2°C.

G-2.3 Balance

A balance having a capacity of at least 100 g capableof weighing to the nearest 0.01 g and suitable forweighing petri dishes.

G-2.4 Oil Sample Bottle

A glass sample bottle as described in E-2.1.

G-2.5 Cold Chamber

Air bath cold chamber capable of maintaining atemperature of –5 + l“C.

G-2.6 Timing Device

A suitable timing device.

11

1S 8654:2001

G-3 PROCEDURE

Obtain the tare mass of each of the four covered petridishes to the nearest 0.01 g. Place 25 + 1 ml of brakefluid in each dish, replace proper covers and reweigh.Determine the mass of each brake fluid test specimenby the difference. Place the four dishes, each insideits inverted cover, in the oven at 100 + 2°C for 46 &2 b (see Note). Remove the dishes from the oven, allowto cool to 23 * 5°C and weigh. Return to the oven foran additional 24 * 2h. If at the end of 72 * 4 h theaverage loss by evaporation is less than 60 percent,discontinue the evaporation procedure and proceedwith examination of residue. Otherwise, continue thisprocedure either until equilibrium is reached asevidenced by an incremental mass loss of less than0.25 g in 24 h on all individual dishes or for amaximum of 7-days. During the heating and weighingoperation, if it is necessary to remove the dishes fromthe oven for a period of longer than 1 h, the dishes

shall be stored in a desiccator as soon as cooled toroom temperature. Calculate the percentage of fluidevaporated from each dish. Examine the residue inthe dishes at the end of 1 h at 23 * 5°C, Rub anysediment with the finger tip to determine grittiness orabrasiveness. Combine the residues from all fourdishes in a 125-ml sample bottle and store verticallyin cold chamber at –5 + 1‘C for 60 * 10 minutes.Quickly remove the bottle and place in the horizontalposition. The residue shall flow at least 5 mm alongthe tube within 5 seconds.

NOTE — Do not simultaneously heat more than one fluid in thesame oven.

G-4 CALCULATION AND REPORTING

G-4.1 The average of the-percentage evaporated fromall four dishes is the loss on evaporation.

G-4.2 Also report the other requirements given inTable 1 at S1No. (viii).

ANNEX H

[Table 1,SINO.(ix)]

WATER TOLERANCE TEST

H-1 OUTLINE OF THE METHOD

Brake fluid is diluted with 3.5 percent water and thenstored at -40°C for 120 h. The cold water wet fluid isfirst examined for clarity, stratification andsedimentation, then placed in an oven at 60”C for 24 h.On removal, it is again examined for stratification. .,ldthe volume percent of sediment determined bycentrifuging.

H-2 PROCEDURE

H-2.1 At – 40°C — Mix 3.5 + 0.1 ml of distilledwater with 100 * 1 ml of the brake fluid and pour intoa centrifuge tube. Stopper the tube with a clean corkand place in the cold chamber maintained at -40 +2°C. After 120 * 2 h remove the tube, quickly wipewith clean lint-free cloth saturated with iso-propanol

and examine the fluid, for evidence of sludging,sedimentation, crystallization or stratification. Invertthe tube and determine the number of seconds requiredfor the air bubble to travel to the top of the fluid. Theair bubble is considered to have reached the top of thefluid when the top of the bubble reaches the 2-mlgraduation of the centrit%ge tube. If the wet fluid hasbecome cloudy, warm to 23 + 5°C and note appearanceand fluidity.

H-2.2 At 60”C — Place tube and brake fluidfrom H-2.1 in an oven maintained at 60 + 2°C for 24+ 2 h. Remove the tube and immediately examine thecontents for evidence of stratification. Determine thepercent sediment by centrifuging by the method givenin IS 1448 [P : 41].

12

Is 8654:2001

ANNExJ[Table 1, S1No. (x)]

COMPATIBILITY TEST

J-1 OUTLINE OF THE METHOD

Brake fluid is mixed with an equal volume of SAEcompatibility fluid, then tested in the same way as forwater tolerance test (see Annex H) except that thebubble flow time is not measured. This test is anindication of the compatibility of the test fluid withother motor vehicle brake fluids at both high and lowtemperatures.

J-2 PROCEDURE

J-2.1 At – 40”C — Mix 50+ 0.5 ml of brake fluidwith 50 + 0.5 ml of SAE compatibility fluidl). Pour

this mixture into a centrifuge tube and stopper with aclean dry cork. Place tube in the cold chambermaintained at 40 &2“C. After 24 ● 2h, remove tube,quickly wipe with a clean lint-free cloth saturated withiso-propanol. Examine the fluid-mixture for evidenceof sludging, sedimentation, crystallization orstratification.

J-2.2 At 60°C — Place tube and test fluid from J-2.1for 24+ 2 h in an oven maintained at 60 * 2“C. Removetube and immediately, examine the fluid mixture forevidence of stratification. Determine percent sedimentby centrifuging by the method given inIS 1448 [P : 41].

ANNEX K

[Table 1,S2N0. (xi)]

RESISTANCE TO OXIDATION

K-1 OUTLINE OF THE METHOD

Brake fluid is activated with a mixture ofapproximately 0.2 percent benzoyl peroxide and5 percent water. A corrosion test strip assemblyconsisting of a cast iron and an aluminium stripseparated by tin foil squares at each end is then restedon a piece of SBR WC cup positioned so that the teststrip is half immersed in the fluid and oven aged at70°C for 168 h. At the end of this period the metalstrips are examined for pitting, etching and mass loss.

K-2 REAGENTS AND MATERIALS

K-2.1 Benzoyl Peroxide — Reagent grade 96 percentpurity.

K-2.2 Corrosion Test Strips — Two sets of cast ironand aluminium metal test strips as described inAnnex E.

K-2.3 Tinfoil — Four unused pieces of tinfoilapproximately 12 mm square and between 0.02 and

1)Obtained from Society of Automotive Engineera, he. 400Commonwealth Drive, Warrendale,PA 15096USA orfiom anyotbersuitable source.

0.06 mm in thickness. The foil shall be at least 99.9percent tin and should not contain more than 0.025percent lead.

K-2.4 SBR CUPS — Two, unused, approximately one-eighth sections of a standard SBR WC cup (seeAnnex E).

K-2.5 Machine Screw and Nut — Two, clean, oilfree, 12 mm long round or fillister head, uncoatedmild steel machine screws, with matching plain nuts.

K-3 PROCEDURE

K-3.1 Prepare two sets of aluminium -andcast iron teststrips according to Annex E except for assembly. Weigheach strip to the nearest 0.1 mg and assemble a strip ofeach metal on a machine screw, separating the strips ateach end with apiece of tinfoil. Tighten the nut enoughto hold both pieces of foil fumly in place.

K-3.2 Place 30+ 1 ml of the brake fluid under test in22x 175 mm test tube. Add 0.060*0.002 g of benzoylperoxide and 1.50 +0.05 ml of distilled water. Stopperthe tube loosely with a clean dry cork shake and placein an oven for 2 h at 70 * 2°C.-Shake every 15 minutesto effeet solution of the peroxide. Remove the tubefrom the oven and allow to cool at 23 ● 5°C. Begin

13

Is 8654:2001

testing according to K-3.3 not than 24 h after removal etching or roughening of surface disregarding stainof tube from oven. or discoloration. Place the strips in a desiccator over

K-3.3 Place a one-eighth SBR cup section in thesilica gel or other suitable desiccant at 23 * 5°C for at

bottom of each test tube. Add 10 ml of prepared testleast 1 h. Again weigh each strip to the nearest 0.1 mg.

mixture to each test tube. Place a metal skp-assembly K-4 CALCULATION AND REPORTINGin each, the end of the strip with?ut the screw restingon the rubber, and the solution covering about one-half the length of the strips. Stopper the tubes wibclean dry corks and store upright for 70+ 2 hat 23 *5“C. Loosen the corks and place the tubes for 168*2 h in an oven maintained at 70 + 2°C. Afterwardsremove and disassemble the strips. Examine the stripsand note any gum deposits. Wipe the strips with aclean cloth wet with iso-propanol and note any pitting,

Determine corrosion loss by dividing the change inmass of each metal strip by the total surface area ofeach strip measured in cm2 (square centimetres) tothe nearest cm2. Average the results for two strips ofeach type of metal rounding to the nearest0.05 mg/cm2. If only one of the duplicates fails forany reason, run a second set of duplicate samples. Bothrepeat samples shall meet all the requirements givenin Table 1 at S1No. (xi).

ANNEX L

~TabIe 1,SllVo.(xii)]

EFFECT ON RUBBER CUPS (SBR)

L-1 OUTLINE OF THE METHOD

Four standard 32 mm dia SBR WC cups (Annex E)are measured and their hardness determined. The cups,two to ajar are immersed h-the test brake fluid Onejar is heated for 70 h at 70”C and the other for 70 h at120”C. Afterwards the cups are washed, examined fordisintegration, remeasured and their hardnessredetermined.

L-2 APPARM’US

L-2.1 Glass. Jars and Lids

Two screw-top, straight sided round glass jars, eachhaving a capacity of approximately 250 ml and innerdimensions of approximately 125 mm in height and50 mm in diameter and a tinned steel lid (no insert ororganic coating).

L-3 PROCEDURE

L-3.1 Measure the base diameters of the SBR cupsas described in Annex E and the hardness of each cupby the method given in IS 3400 (Part 2).

L-3.2 Wash the cups in iso-propanol for not longerthan 30 seconds and quickly dry with a clean lint-freecloth. Using forceps, place two cups into each of the

tsvojars, add75 ml of brake fluid to each jar ~nd captightly. Place one jar in oven maintained at 70 * 2°Cmaintained for 70+ 2 h. Place the other jar in an ovenmaintained at 120+ 2°C for 70 * 2 h. Allow each jarto cool for 60 to 90 minutes at 23 + 5°C. Removecups, wash with iso-propancrl for not longer than 30seconds and quickly dry. Examine the cups fordisintegration as evidenced by stickiness, blisters orsloughiig. Measure the base diameter and hardnessof each cup within 15 minutes afler removal fmm thefluid.

L-4 CALCULATION AND REPORTING

L-4.l Calculate the charge in base diameter for eachcup. If the two values at each temperature-do not differby more than 0.10 mm, average them to the nearest0.02 mm. If the two values differ by more than 0.10mm repeat the test at the appropriate temperature andaverage the four values as the change in base diameter.

L-4.2 Calculate the change in hardness for each cup.The average of the two values for each paira is thechange in hardness.

L-4.3 Note any disintegration as evidenced bystickiness, blister or sloughing.

14

Is 8654:2001

ANNEX M

[Table 1,SINO. (xiii)]

SIMULATED PERFORMANCE TEST (STROKING PRQPERTIES)lJ

M-1 OUTLINE OF THE METHOD

Brake fluid is stroked under controlled conditions atan elevated temperature in a simulated motor vehiclehydraulic braking system consisting of three slavewheel cylinders and an actuating master cylinderconnected by steel tubing. Referee standard parts areused. All parts are carefully cleaned, examined andcertain measurements made immediately prior toassembly for test. During the test, temperature, rateof pressure rise, maximum pressure and rate ofstroking are specified and controlled. The system isexamined periodically during stroking to assure thatexcessive leakage of fluid is not occurring. Afterwardsthe system is disassembled. Metai parts and SBR cupsare examined and remeasured. The brake fluid andany resultant sludge and debris are collecte~ examinedand tested.

M-2 APPARATUS AND MATERIALS

M-2.1 The stroking test apparatus shall be assembledas shown in Fig. 6 ustig the following componentsand materials:

a)

b)

c)

Master CyIinderAssemblfj — One cast ironhousing hydraulic brake master cylinderhaving a diameter of approximately 32 mmitnd fitted with an uncoated steel stand pipe.

Brake Assemblies — Three cast iron housingstraight bore hydraulic brake wheel cylinderassemblies’) having diameters of approxi-mately 32 mm. Three fixture units arerequired, including appropriate adaptermounting plates to hold the brake wheelcylinder assemblies as shown in Fig. 7.

Braking Pressure Actuating Mechanism —A suitable actuating mechanism for applyinga force to the master cylinder push rodwithout side thrust. The amount of forceapplied by the actuating mechanism shall be

1)A&ptedfrom SAE J 1703JAN 1980, and FMVSS No. 116DGT-3SpecificationofUSA.z) pan No. BI Girling 29066298 manufactured by M/sBrakes IndiaLtd, Padi, Chennai 600050.1) pati No. N Girting 64674350 manufactured by IWSBrakes IndiaLtd, Padi, Chennai 600050.

I

.

SPACE@

AIDnv uvnn. h11 ,*

N._ . .. .1000 S1

) cTEMPERATURERECORDER

(TttERMOCOUPLE1)FIG. 6 STROKINGTEST APPARATUS

15

M 8654:2001

● ✍ ✍✍✍✍✍

c

I

c 1

d)

FIG. 7 STROKINGFIXTUREAPPARATUS

adjustable and capable of supplying stilcientstroke and thrust to the master cylinder tocreate a pressure of at least 70 kgf/cm2 in thesimulated brake system. A hydraulic gaugeand pressure recorder, having a range of atleast O to 140 kgf/cm2, shall be installedbetween the master cylinder and the brakeassemblies and shall be provided with a shut-off valve and with a bleeding valve forremoving air from the connecting tubing.The actuating mechanism shall be designedto permit adjustable stroking rates of 1 000+100 strokes per hour. A -mechanical orelectrical counter shall be used to record thetotal number of strokes.

Heated Air Bath Cabinet — An insulatedcabinet or oven having sufficient capacity tohouse the three wheel cylinder fixtureassemblies, master cylinder, and necessar -connections. A suitable thermostaticallycontrolled heating system is required tomaintain a brake fluid temperature 120 +5°C. Heaters shall be shielded to preventdirect radiation to wheel or master cylinders.Fluid temperatures shall be monitored atrandom intervals during the test at the mastercylinder reservoir using a temperaturerecording device.

M-3 PREPARATION OF TEST APPAWTUS

M-3.1 Wheel Cylinder Assemblies

Use new wheel cylinder assemblies having pistonsmade from steel (see E-3. 1). Disassemble cylinders

and discard rubber cups, Clean all metal parts withiso-propanol and dry with clean compressed air.Inspect the working surfaces of all metal parts forscoring, galling or pitting and cylinder bore roughnessand discard all defective parts. Remove any stains oncylinder walls with lint-free cloth and iso-propanol.If stains are not removed, discard the cylinder,

M-3.1.1 Measure the internal diameter of eachcylinder at locations approximately 19 mm from eachend of cylinder bore, taking measurements in line withthe hydraulic inlet opening and at right angles to thecentre line, Discard the cylinder if any of these fourreadings differ by more than 0.08 mm. Measure theoutside diameter of each piston at two pointsapproximately 90 degrees apart. Discard any piston ifeither reading differ by more than 0.04 mm. Selectparts to ensure that the clearance between each pistonand mating cylinder is within 0.08 to 0.13 mm.

M-3.1.2 Use new hydraulic standard SBR rubber cups(see Annex E) that are free of lint and dirt. Discardany -cup showing imperfections such as cuts, toolingmarks, moulding flaws or blisters. Measure the lipand base diameter of all test cups with an opticalcomparator or a micrometer to the nearest 0.025 mmalong the centre line and at right angles to this centreline. Determine base diameter measurements within0.8 mm of the bottom edge and-parallel to the base ofthe cup. Discard any cups if the two measured lip orbase diameter differ by more than 0.08 mm. Averagethe lip and base diameters of each cup. Determine thehardness of all cups by the procedure prescribed inIS 3400 (Part 2). Clean rubber parts with iso-propanoland lint-free cloth. Dry with clean, compressed air.

I

16

IS 8654:2001

Dip the rubber and metal parts of the wheel cylinders,except h-ousings in the fluid to be tested and installthem in accordance with the manufacturersinstructions. Rubber b(jots may be retained on thecylinders if a small section is removed on the bottomto observe leakage. Manually stroke the cylinders toensure that they operate easily. Install cylinders in thesimulated brake system.

M-3.2 Master Cylinder Assembly

Use new master cylinder having a piston made fromsteel and new hydraulic SBR cupsl) which have beeninspected, measured and cleaned in manner specifiedin M-3.1. Remove ahy burrs or-wire edges from therelief and supply ports of the master cylinder. Measurethe internal diameter of the cylinder at two locations;approximately midway between the relief and supplyports and approximately 19 mm beyond the relief porttowards the bottom or discharge end on the bore, takingmeasurements at each location on the vertical andhorizontal centerlines of the bore. Discard the cylinderif any of these four readings differ by more than 0.08mm. Measure each of the outside diameter of themaster cylinder piston at two points approximately90 degrees apart. Discard any pistonif reading differsby more than 0.04 mm. Dip the robber and metal partsof the master cylinder, except housing, in the fluid tobe tested and install them in accordance withmanufacturer’s instructions. Discard boot and pushrod assembly. Manually stroke the master cylinder toensure that it operateseasily. Install the master cylinderin the simulated brake system.

M-3.3 Assembly and Adjustment of Test Apparatus

Install wheel and master cylinders. Fill the system withtest fluid, bleeding all wheel cylinders and the pressuregauge to remove entrapped air from system.

M-3.3.1 Operate the actuator manually to apply apressure more than the required operating pressureand inspect the system for leaks. Adjust the actuatorto obtain a pressure of 70 * 3.5 kgf/cm2 and a smoothpressure-stroke pattern. Adjust the rate to 1 000+ 100strokes per hour. Record the fluid level in mastercylinder stand pipe at 23 * 5°C with the mastercylinder piston in the fully returned position.

M-4 Test Procedure

M-4.1 Operate the system for 16 000+ 1000 cycles-at23+ 5°C. Repair any leakage and add fluid to mastercylinder stand pipe to bring to the level originallyrecorded at the same temperature with the piston fullyreturned.

I} pafi IQO.BI Girling 64674047 manufactured by M/a Bmkes IndiaLtd, Padi, Chennai 600050.

M-4.2 Start the test again and raise the temperatureof the fluid in the master cylinder within 6 + 2 h to120 ● 5“C. During tet%observe operation of the mastercylinder for complete piston return and wheel cylindersfor proper operation. Observe fluid level in relation tothe room temperature level at random intervals.Continue the test to 85000 total recorded strokeswhich shall include the number of strokes duringoperation at 23 + 5°C the number of strokes requiredto bring the system to the operating temperature of120 + 5°C plus the number of strokes at this operatingtemperature. Stop the test and with the master cylinderpiston in the fully returned position to relive retainedpressure in the system, allow the equipment to cool toroom temperature. Record-the amount of fluid required-to replenish any loss of fluid to the 23 * 5°C leveloriginally record. Stroke the assembly an additional100 strokes at 23 * 5°C and 70 * 3.5 kg/cm2, examinewheel cylinders for leakage, and add and recordvolume of fluid required to bring the fluid level to the23 ~ 5°C original level.

M-43 Within 16 hours remove the master and wheelcylinders from the syst~ retaining the fluid in thecylinders by immediately capping or plugging the ports.Disassemble the cylinders, collecting the fluid fbm themaster cylinder and wheel cylinder in a glassjar. Recordany sludge, jell or abrasive grit present in the test fluid.When collecting the stroked flui~ all the residue whichhas deposited on the rubber and metal internal partsshould be removed by rinsing and agitating such partsin the stroked fluid and using a sofl brush to assure thatall loose adhering sediment is collected. Clean rubbercups in iso-propanol and-dry with clean compressedair, inspect cups for tackiness, scoring, scuffing,blistering, cracking, chipping (heel abrasions) and-change in shape thm original appearance. Within 1hour after disassembly, measure the lip and basedueterof each cylinder cup bytheprocedure specifiedin M-3.2 with the exception that the lip of basediameters of cups may differ by more than 0.08 mm.Determine the hardness of each cup. Within 1 hour-after draining cylinders, agitate fluid in glass jar tosuspend and uniformly disperse sediment and transfera 100 ml portion of this fluid to an ASTM cone-shapedcentrifuge tube and determine percent sediment -asdescribed in IS 1448 [P: 41]. Inspect cylinder parts,recording any gum deposits. Rub any deposits adheringto cylinder walls with a cloth wetted with &o-propanolto determine abrasiveness and removability. Clean cylin-der parts in iso-propanol and dry with compressed air,and inspect for pitting and scoring on pistons andcylinder walls. Measure and record diametm of pis- {tons and cylinders by the procedures specified in M-3.1and M-3.2. Calculate lip diameter interference set bythe following formula:

17

IS 8654:2001

Lip diameter interference D _Dset, percent . ~xloo

D, -D,where

D, = original lip diameter,

Dz = final lipdiameter, arid

D, = original cylinder pore diameter.

Repeat the test if mechanical ftilure occurs that mayaffect the evaluation of the test fluid.

M-5 PERFORMANCE REQUIREMENTS

M-5.1 The brake fluid, when examined as prescribedin M-4.3 shall meet the following performancerequirements:

a) Metal parts shall not show corrosion asevidenced by pitting to an extent discernibleto the naked eye, but staining or discolorationshall be permitted.

b) The initial diameter of any cylinder or pistonshall not change by more than 0.13 mmduring test.

c) Rubber cups shall not decrease in hardnessby more than 15 degrees and shall not be inan unsatisfactory operating ~ondition asevidenced by excessive amounts of tackiness,scoring, scuffing, blistering, cracking,chipping (heel abrasion), or change in shapefrom original appearance.

d) The base diameter of the rubber cups shallnot increase by more than 0.9 mm.

e) The average lip diameter interference set ofthe rubber cups shall not be greater than 65percent.

f) During any periodof24000 strokes, thevolume loss of fluid shall not be more than36 ml.

g) The cylinder pistons shall neither freeze norfimction improperly throughout the test.

h) The volume loss of fluid during the 100strokes at the end of the teat shall not be morethan 36 ml.

j) The condition of the fluid at the end of testas evidenced by sludging, gelling, orgrittiness shall not be such as would be likelyto cause improper brake action in actualservice, and the sedimentation shall notexceed 1.5 percent by volume aftercentrifuging.

k) No more than a trace of gum shall bedeposited on brake cylinder walls or othermetal parts during test. Brake cylinder shallbe free of deposits which are abrasive orwhich cannot be removed with a cloth wettedwith iso-propanol.

18

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This Indian Standard has been developed from DOC : No. PCD 4 (1504).

Amendments Issued Since Publication

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