JASO-F204-1999.pdf

japan automobile standard jas0 f204: 1999 shape main body lug wire automotive parts - spring action hose clamps dimensions attached table 1 1. scope this standard specifies hose clamps with spring action (herein referred to as clamps) used to connect hoses to joints or pipes, in automobile systems including cooling, intake, fuel, lubricating, and air conditioning single i bridge 2. applicable publications the following publications from a part of this standard to the extent specified herein. the latest issue of all publications shall apply. jis do201 jis g3311 jis g3521 jis g3522 piano wires jis g4802 jis h8502 jis 22244 jis 22371 automobile parts - general rules of electriplating cold rolled special steel strip hard drawn steel wire cold-rolled steel strips for springs methods of corrosion resistance test for metallic coatings vickers hardness test - test method methods of neutral salt spray testing attached table 2 3. classification clamps are classified according to shape as specified in table 1. double 1 sedarate attached table 3 i hardness vickers hardness plate thickness zinc electroplating zinc chromic acid mm compound coatings 0.4 - 0.7 0.8 - 1.9 420 - 520hv1 o 420 - 520 hv50 420 - 550hv1 o 420 - 550 hv50 plate bridge 4. quality 4.1 appearance the clamp surface shall be smooth and free of flaws that may impede service, including fins, burrs, scratches, cracks, rust, etc. types 2 and 3, particularly, must be free of fins and burrs on inner diameter surfaces. 4.2 hardness types 2 and 3, when tested as specified in 8.1, shall conform to table 2. 1 jaso f204: 1999 surface treatment zinc electroplating zinc chromic acid compound coatings 5. shapes and dimensions conform to attached tables 1-3 specifications ep-fe/an5c of jis d 0201, or equivalent coating weight 20g/m2mimimum 6. material conform to table 3. surface treatment zinc electroplating zinc chromic acid compound coatings table 3 clamp material material applicable test method conform to jis h8502 conform to jis 22371 or swp-a or jis g3522 or sk5m or jis g4802 7. surface treatment conform to table 4 for rust prevention. any other surface treatments, if required, shall be subject to agreement between the parties concerned. zinc electroplating used for the clamps must conform to jis d0201, 5.4 corrosion resistance, table 12. zinc chromic acid compound coatings require testing as specified in 8.2, with a 480-hour rust-free limit. table 4 surface treatment specifications 8. test methods 8.1 hardness conform to jis 22244. 8.2 corrosion conform to table 5. table 5 corrosion test 9. inspection quality, shape, dimensions, material and surface treatment must meet the requirements of 4 - 7. io. product designation designate products by standard number or name, type, nominal size, and surface treatment code or name. example jaso f204 type2 080 ep-feiznsc spring action hose clamp type2 080 zinc chromic acid compound (type) (nominal) surface treatment code or name 2 -,-,- jas0 f204: 1999 attached table 1 type 1 wire type hose clamp approx. 60“ straight pipe bulge - il i f standard size tolerance d() standard size 0.8 0.9 1 .o 1.6 2.0 2.6 3.2 tolerance k0.02 k0.03 k0.04 section sect i on /pipe 1/clamp hose reference drawing unit: mm reference dia. 9.0 10.1 10.5 notes: (i) dimension d indicates initial free diameter, showing direction at right angle to lug () tolerance of d indicates that of wire diameter before forming. (3) d, indicates hose outer diameter, straight pipe section, when inserted into pipe. (4) d2 indicates clamp inner diameter when lugs are in contact with each other. 3 -,-,- jas0 f204: 1999 nominal attached table 2 type 2 single plate clamp d(1) standard i tole- approx. 70“ 138 13.8 14.5 150 15.0 15.5 170 17.0 178 17 8 f 0.4 * 0.5 38.5 40.7 430 43.0 t standard size 0.4 0.5 0.6 0.7 0.8 0.9 1 .o 1.2 1.3 1.4 1.5 1.6 1.9 tole- rance 10.025 f0.03 f 0.04 10.05 i0.055 i standard size 6.0 8.0 10.0 12.0 15.0 18.0 tole- rance f 0.25 straight pipe bulge section section /pipe i/ciamps hose reference drawing unit: mm 45.8 18.0 45.6 48.4 48.2 51.2 notes: for (i), ( 3 ) , and (4), see notes for attached table i. (5) tolerance off indicates that of plate thickness before forming. 4 jas0 f204: 1999 nominal attached table 3 type 3 double plate clamp d(1) standard i tole- approx. 70“ i . . reference pari (7 11.3 12 o k0.3 1 o7 10 7 dia. (4) 12.0 12 7 11.9 12.5 13.1 137 13.7 12.5 13.0 13.3 14.0 14.7 15.3 16.0 16.8 17.4 163 16.3 13.3 13.8 14.2 14.9 15.6 16.3 17.0 17.9 18.4 k 0.4 18.3 t( standard 19.4 size 0.6 0.7 0.9 1 .i 1.2 1.3 e ii p 4 tole- rance f 0.03 * 0.04 f 0.05 type 3-a type 3-b b standard size 10.0 12.0 15.0 to i e- rance k 0.25 straight pipe bulge section section 7 7 t i : : - , i /pipe e l a m p s hose reference drawing unit: mm 8.0 9.0 10.0 notes: for (i), (3), and (4), see notes for attached table 1. (6) plate thickness f shall be the same for both inner and outer plates. tolerance oft indicates that of plate thickness before forming 5 jas0 f204: 1999 annex 1 (reference) performance test this annex 1 (reference) describes performance tests and does not form a part of the provisions. 1. objective the objective of this annex is to facilitate selection and use of spring action hose clamps by providing standardized test methods and performance criteria regarding settling that can affect hose performance by interfering with anti-leak pressure. 2. clamp performance to confirm clamp performance, it is necessary to evaluate leak pressure when mounted on a hose. leak pressure depends on the clamping force of the clamp, which varies by clamp type and settling, hose type and dimensions, pipe shape and dimensions, and other operating conditions. of these conditions, only hose type and dimensions have not been standardized. therefore, results of leak pressure tests for various combinations of clamps, hoses and pipes and the results of permanent set tests are shown below for reference. 3. leak pressure test since the following summary of results were taken at the time of establishment if this standard and subsequent revisions, results for nominal sizes no longer included in the main text are included. type 1 includes 3 types with nominal sizes 095, 180, and 400. type 2 includes 6 types with nominal sizes 090, 110, 170, 180, 280, and 370. type 3 includes 3 types with nominal sizes 105, 164, and 270. test results of anti-leak pressure (including hose slip-off pressure) are shown below. these values can vary by hose material/type, pipe shape/dimensions, and operating conditions. 3.1 test procedures refer to annex fig. 1. p ure gauge fixing clamp , - i liquefiec nitrogen gas * l 30 h i/ annex fig. 1 test procedures 6 -,-,- jas0 f204: 1999 3 - 932 - - 6.35 7.00 5.6 x 11.7 - 785 - - 12.00 13.50 11.6 x 20.0 24.0 x 31.7 - 755 - - 25.00 26.55 (1 05) (164) 270 remarks: 1. each value is the average for all three types 2. the 9.4 x 17.5 hose is double layer construction; outer layer coating 0.2mm thick. other hoses include splicing yarns between inner and outer layers. 3. hose rubber hardness conforms to annex table 2 and is indicated in jis spring action type hardness 4. hardness for types 2 and 3 clamps are shown in annex table 3. 5. the clamp has been fitted by passing through the bulge section after installation of a hose 6. relations between the nominal sizes and part dimensions for the sample clamps are shown in annex table 4. 7. the nominal sizes not included in the main text of this standard are given in parentheses inner dia. x outer dia. mm 5.0 x 9.2 5.6 x 11.7 9.4 x 17.5 11.6 x 20.0 24.0 x 31.7 30.0 x 39.0 32.5 x 41.9 hardness hs 80 63 70 60 62 57 59 annex table 3 clamp hardness 370 500 7 -,-,- jaso f204: 1999 51 (095) annex table 4 clamp dimensions 9.5 x 1.2 d jaso f204-83 6 1 8 400 110 11.0 x 0.7t x 8.0 b jaso f204-93 180 x 2.0 40 x 2.6 1 7 4. permanent set tests the following data are extracted from results of tests at the time of establishment of this standard and subsequent revisions. clamp settling can affect pressure resistance and can vary by operating conditions other than clamp dimensions and hardness. annex figs. 2 - 4 show measuring procedures and results for number of setting repetitions (expanding inner diameter to lug angle o“) and inner diameter settling by type 170 17.0 x 0.9 t x 12.0 b 280 28.0 x 1.2 t x 15. ob (090) 9.0 x 0.6 t x 8.0 b jaso f204-83 (1 80) 18.0 x 1.0 t x 12.0 b (370) 37.0 x 1.6 t x 15. ob (1 05) 10.7 x 0.6 t x 10.0 b jaso f204-93 (1 64) 16.4 x 0.8 t x 12.0 b 270 26.8 x 1.3 t x 15. ob lug angle a = ( 6 x + 6 v ) i2 where 6 : settling of inner diameter (mm), average value x a x : settling of inner diameter in x-axis direction (mm) 6 : settling of inner diameter in x-axis direction (mm) . i y setting -o type 1 nominal 400 0 type 1 nominal 180 1 .o o- 0.9 *-o 0 type 1 nominal 095 e 0.7 - - , - x - type 2 nominal 280 type 3 nominal 270 a type 3 nominal 164 type 2 nominal 170 type 3 nominal 105 type 2 nominal 110 0-0 0.8 - 0.6 v 0.5 -c. 0.4 (r) 0.3 c .- - -w a l 0.2 0.1 o o 1 2 3 4 5 no. of setting repetitions annex fig. 2 relation between setting repetitions and settling -,-,- jas0 f204: 1999 1.2 1 o .8 e e 0.6 - q v p 0.4 ._ - c ci a l c o 0.2 u o 1 o0 200 300 400 500 nominal size annex fig. 3 relation between nominal size and settling (1st setting) 1.2 i 0.8 e e - 0.6 q m e 0.4 (o v c ._ t . 095 21.0 - 210 22.1 - 221 in the previous standard, the inner diameters did not correspond to the nominal designation for type 3 double clamps. the current revision eliminated this inconsistency and adopted tenfold values of d dimension for all clamps. 6.3.2 lug shapes although four kinds of lug shapes are actually in use for type 1 wire clamps, only type b of the provious standard was included because of its greater use. regarding lug shapes for type 2 single clamps, both a (separate) and b (bridge) of the previous standard are still in actual use , but only the more commonly used type b was retained in the standard in order to reduce the number of types covered. as for type 3 double clamps, which have only recently been standardized, it cannot yet be determined whether type a or b will eventually predominate and therefore both were retained in the standard. 6.3.3 clamps with holders types 2 and 3 plate clamps are sometimes equipped with holders. a common shape is shown in explanatory fig. 1 for reference. there are various holder shapes other than the one shown below. explanatory fig. 1 11 -,-,- jas0 f204: 1999 6.3.4 clamp shapes clamps are available in various shapes in order to facilitate roundness when being mounted. 6.3.5 inner diameter (d) tolerance has been determined for each d dimension in consideration of actual use. for spring action clamps, the initial free diameter has been set as the inner diameter because the inner diameter varies according to the number of settings. the measuring direction has been set at right angles to the lugs. 6.3.6 wire diameter (d), plate thickness (t) type 1 wire clamps adopt the tolerance specified in jis g3521 (hard drawn steel wires), while types 2 and 3 plate clamps adopt grade a tolerances as specified in jis g3311 (cold roller special steel strip). these tolerances must be taken prior to forming since bending or other treatment may alter the tolerance conditions. 6.3.7 plate width (b) plate widths and tolerances for types 2 and 3 plate clamps have been set according to the data on actual use. 6.3.8 lug length the length of many lugs now on the market do not conform to the previous standard. as the wide variety of lengths in use make it impractical to determine standard dimensions only the upper limit value was specified in the current revision. 6.3.9 minimum diameter at fitted pari (d,) based on investigations of actual usage, the expansion rate at fitting (min. diameter at fitted parffinner diameter at free) was generally from 1.08 to 1.21 regardless of nominal size. the dimension multiplied by 1.12 was adopted throughout this standard as it is most common. 6.3.10 maximum expanded diameter (d,) the maximum expanded diameter (d2 dimension in the attached table) serves as a criteria to judge whether or not the clamp passes through the bulge section. the maximum expanded diameter is the clamp inner diameter when the lug angle (60“ or 70“) reaches o and has been calculated assuming complete roundnes