JASO-F402-2001.pdf

japanese automobile standard jaso f402:2001 automotive parts - flare fittings introduction this standard is a revision of jaso f402-90 specifying flared pipe fittings. the specifications herein reflect current conditions, and all descriptions relating to double-flared parts are adjusted to those specified in is0 13486-1, first edition, 1999. 1. scope this standard specifies pipe fittings used for flared metal pipes() for automobile pipings (hereafter referred to as pipe fittings), and shapes and dimensions of flared parts. note: ( i ) the metal pipes for automobile pipings are those specified in jaso m101. remarks: 1. single-flared pipe fittings (is0 type) for hydraulic brakes conform to jaso f412. 2. this standard is related to the following international standard: i s 0 13486-1, road vehicles - hydraulic braking systems - part i: double- flared pipes, tapped holes, male fittings and tube seats 2. applicable publications the following publications form a part of this standard to the extent specified herein. the latest edition of all publications shall apply. jis b 0203 jis b 0207 jis b 0211 jis b 1071 jis d 0201 jis g 0301 jis g 3123 jis g 3539 jis g 4051 jis g 4804 jis g 5501 jis h 3250 jis h 5202 jis h 8601 jaso f404 jaso f412 jaso mi01 is0 13486-1 taper pipe threads metric fine screw threads limits of sizes and tolerances for metric fine screw threads method of verification for size and geometry of threaded fasteners automobile parts - general rules of electroplating rolled steels for general structure cold finished carbon and alloy steel bars carbon steel wires for cold heading and cold forging carbon steels for machine structural use free cutting carbon steels grey iron castings copper and copper alloy rods and bars aluminum alloy castings anodic oxide coatings on aluminium and aluminium alloys o-rings for automobiles single-flared pipe fitting for hydraulic brakes metal pipes for automobile tubing road vehicles - hydraulic braking systems - part i: double-flared pipes, tapped holes, male fittings and tube seats 3. pipes 3.1 pipe shapes and dimensions shapes and dimensions of duplex winding steel pipes used for hydraulic brakes, simplex winding steel pipes used primarily for fuel oil and lubricating oil, carbon steel pipes for machine structure purposes, and copper and copper alloy seamless pipes shall conform to jaso f412, table 1 (shapes and dimensions of pipes) and jaso m101, item 5.1 (nominal diameter and dimensions of pipes). 1 jaso f402:2001 type flared o-ring flared 3.2 flare types requirements are as specified in table 1. table 1 type of flare name symbol applicable table double flare idf attached table 1 single flare (jaso type) jsf - o-ring flare jof - 3.4 appearance requirements are as specified in jaso m101, 3.5 physical properties requirements are as specified in jaso m101, pressure and burst pressure). 3.6 surface treatment and corrosion resistance requirements are as specified in jaso m101, resistance of duplex winding steel pipes may be in 3.7 inspection requirements are as specified in jaso m101, item 3.1 (appearance). items 3.3 (mechanical properties) and 3.5 (proof item 3.4 (surface treatment). however, corrosion accordance with jaso f412, item 3.c. item 7 (inspection) 4. pipe fittings 4.1 pipe fitting types the three types of pipe fittings shown below shall be used depending on coupling method 4.1.1 flared female pipe fittings (attached tables 2 - 5) 4.1.2 flared male pipe fittings (attached table 8) 4.1.3 o-ring flared pipe fittings (attached table 9) remarks: tube seats used for flared female pipe fittings shall be as specified in attached table 6. 4.2 pipe fitting names and symbols requirements are as specified in table 2. table 2 pipe fitting names and symbols i flared female pipe fittings c pipe fittings flared male pipe fittings o-ring flared fuel oil system lubricating system steering system steering system remarks: tapped holes a i and b i seats are formed by machining and a2 and 82 seats are fitted by driving 2 jaso f402:2001 type flared female pipe fitting flared male pipe fitting o-ring flared pipe fitting 4.3 combination requirements are specified in table 3. table 3 pipe fitting combinations combination 1 2 flared part shape fittings o-rings nuts - an as 1 as2 bsi bs2 cs - cn ds dr dn o-ring flare double flare, single flare (jaso bn type) - fitting type flared female pipe fitting swchior, swch12r sg d400- d flared nut b bn sioc, s12c, s15c s45c, swchior swch12r, sg d400- d tapped hole as1 ss400, sioc, s12c a i s15c. c3604. flared male pipe fitting tapped hole bsi tadded hole as2 b i o-ring flared pipe fitting fc250 sum22 ss400. sioc. s12c name i symbol i material nut i flared nut a i an i sioc, s12c, s15c nut fitting i i a2 fc250, c3604, 82 ac2b, adc12, tapped hole bs2 ac2a ac4c ac4d, sum24l,sum43 flared nut c cn sioc, s12c, s15c sum22, swchior, swch12r, sg d400- d fitting c cs ss400, sioc, s i 2 c , s15c, c3604, fc250, sum22 nut i o-ring flared i sioc, s12c, s15c fitting nut o-ring flared fitting ds swchior, swch12r sg d400- d ss400, sioc, s i 2 c , s15c, fc250, sum22, c3604 i o-ring i dr i nbr jis g 3101. jis g 4051 for sioc, s12c, s15c, s20c and s45c. jis g 3539 for swchior and swch12. jis g 4804 for sum22, sum24l and sum43. jis h 3250 for c3604. jis g 5501 for fc250. jis h 5202 for ac2a, ac2b, ac4c, ac4d and adci 2. jis g 3123 for jaso f404 for nbr. sg d400- d. remarks: use of any material other than those shown in table 4, shall be determined by the parties concerned. 4.5 shapes, dimensions and geometric tolerance requirements are specified in attached tables 2 - 9. for flared nuts a and b, marking in accordance with attached table 7 is preferred. 4.6 appearance pipe fitting surface shall be smooth and be free of harmful defects such as cracks, burrs, scars and rust which may impede practical application. the interior of the pipe fittings shall be kept clean and protected from foreign substances. 3 jaso f402:2001 screw thread type 4.7 surface treatment pipe fitting surfaces made of steel or aluminium shall be treated as follows or shall conform to the requirements specified in jaso f412, item 5.c. 4.7.1 surface treatment of steel pipe fittings either of the following surface treatments shall be used for the surface treatment of pipe fittings made of steel. a) ep-fe/zn 5c or ep-fe/zn 8c as specified in jis d 0201 (general rules of electroplating for automobile parts). pipe fitting parts treated by electric zinc plating shall be subjected to removal of hydrogen b) for treatment with zinc chromate film, the coating mass shall exceed 160 mg/dm2. embrittlement as necessary. clogging may occur with pipe fittings treated with zinc chromate film due to peeling of the coated film therefore, the use of zinc chromate shall be determined by the parties concerned. 4.7.2 surface treatment of aluminum pipe fittings the requirements specified in jis h 8601 shall be met as necessary. the film thickness of anodic oxide coating shall be determined by the parties concerned. 4.8 screw thread type and accuracy requirements are as specified in table 5. however, accuracy after surface treatment shall not be applied to zinc chromate coating parts. table 5 pipe fitting screw thread types accuracy male female male female as specified in jis b 0211 before surface treatment i after surface treatment metric fine pitch thread pipe thread within specified tolerance (6h) upper limit: jis b 0207 maximum 6g 6h allowable dimensions. (4h) as specified in jis b 0203 jis b 0203 nominal size less than 6.35 8-10 over 12 4.10 inspections 4.10.1 shapes, dimensions and geometric tolerance inspections shall be performed as follows and shall meet the requirements specified in item 4.5. a) shape and dimension inspection direct measurement of shape and dimensions shall be performed by a limiting gauge or an equivalent method. geometric tolerance shall be measured as specified in jis b 1071 or an equivalent method. b) surface roughness inspection measurement shall be performed as specified in jis b 1071 or an equivalent method. 4.10.2 appearance inspection requirements for visual inspection are as specified in item 4.6. water pressure 34.3 24.5 24.5 19.6 14.7 - flared type o-ring flared type 4 -,-,- jaso f402:2001 4.10.3 surface treatment inspection inspections shall be performed as follows and shall meet the requirements specified in item 4.7. however, thread parts are not required to be inspected. a) electric zinc plated parts b) zinc chromate coated parts requirements are as specified in jis d 0201. surface film shall be dissolved in caustic soda and the difference in mass before and after dissolving shall be divided by the sample surface area to obtain the adhered mass per unit area. c) anodic oxidation coated parts inspection requirements shall be determined by the parties concerned. 4.10.4 screw thread accuracy inspection inspection shall be performed as specified in jis b 1071 or an equivalent method, and requirements specified in item 4.8 shall be met. 4.10.5 pressure resistance inspection inspection shall be performed by applying water pressure, and the requirements specified in item 4.9 shall be met. remarks: 4.11 designation 4.11.1 pipe fitting designation fastening torque shall be determined by the parties concerned. pipe fittings shall be designated by standard number, standard title and type. example: jaso f402 automobile parts - flared pipe fitting flared female pipe fitting ii ii ii standard number standard title type 4.11.2 pipe fitting part designation pipe fitting parts shall be designated by standard number, name or symbol of pipe fittings, nominal diameter of applicable pipe or diameter of thread. if necessary, designation of the material and surface treatment shall be added to the diameter of thread as follows: example: jaso f402 flared nut a 4.75 mio x 1 s i 5c e p-fe/zn5c ii ii ii ii ii ii standard no. name nominal diameter diameter of thread material surface treatment jaso f402 an 4.75 mio x 1 s i 5c e p- f e/z n 5c ii ii ii ii ii ii standard no. symbol nominal diameter diameter of thread material surface treatment related standards jis z 2371 jaso f 403 jaso z 202 is0 4038 methods of neutral salt spray testing flareless type tube fittings for automobiles glossary of terms relating to pipe fittings for automobiles hydraulic braking system - single flare pipes, tapped holes, male fittings and hose end fittings sae j512 automotive tube fittings sae j514 hydraulic tube fittings 5 -,-,- jas0 f402:2001 15 attached table 1 shape and dimensions of double flared (idf) parts unit: mm - i 1.0 i 2.0 i 1.6 - i 18.45 i 13.05 i 21 note: () b3 shows minimum seal length 18 - i 1.0 i 2.0 i 1.6 - i 21.85 i 16.05 i 21 6 -,-,- jas0 f402:2001 12 12.7 30“_ 25.4. 25.4 o 0.35 23.29 m20x1.5 14.8 16.4 15.5 8 12.5 22 12.99 m20x1.5 15.2 16.4 15.5 8 12.5 22 attached table 2 flared nut a (an) unit : mm roughness u m note: (3) undercutting at portion (a) depends on manufacturing method. s 7 -,-,- jas0 f402:2001 attached table 3 tapped hole a i , a2 (asi, as2) tapped hole a i (asi) unit: mm roughness u m unit: mm tapped hole a2 (as2) l * l i - tube seat remarks: l. nominal size denotes the nominal diameter of the pipe to be applied 2. refer to attached table 6 for the tube seat 8 -,-,- jas0 f402:2001 attached table 4 flared nut b (bn) unit: mm roughness u m 30”, s i notes: flared nut b is not addlied to nominal size 8. 10. 12 and 12.7. remarks: nominal size denotes the nominal diameter of the pipe to be applied 9 -,-,- jas0 f402:2001 attached table 5 tapped hole b i , b2 (bsi, bs2) tapped hole b i (bsi) tapped hole b2 (bs2) tube seat unit: mm roughness pm unit: mm remarks: 1. nominal size denotes the nominal diameter of the pipe to be applied. 2. refer to attached table 6 for tube seat shown in the figure 10 jas0 f402:2001 da di(”) nominal size attached table 6 tube seat d i o di i d i 2 0 1 3 0 1 4 d i o lii(”) k0.3 k0.05 k0.2 k0.05 k0.2 k o . 1 unit: mm rniirihness pm 10 7.5k0.2 8.8 9.7 13.5 10.5 9.5 10 7.5 5.7 4.75 i 3.2k0.1 i 3.8 i 5.2 i 7.5 i 6.2 i 5 i 7.5 i 3.2 i 4.6 6.35 i 4.5k0.2 i 5.3 i 6.6 i 9.5 i 7.7 i 6.4 i 8 i 4.5 i 4.6 8 i 5.5ko.2 i 6.8 i 7.8 i 11.8 i 9.2 i 7.6 i 8.8 i 5.5 i 5.3 remarks: nominal size denotes the nominal diameter of the pipe to be applied 11 -,-,- jas0 f402:2001 di nominal size 4.75 6 6.35 8 10 attached table 7 marking marking of pipe fitting manufactured by forging d i 5 d i 6 maximum minimum 10 7 w h + 0.5 + 0.2 o o 12 9 0.5 0.3 14 10.5 17 12.5 1 o da di nominal size 120“ l4 o 0.2 unit: mm marking of pipe fitting manufactured by a lathe unit: mm i 4.75 i 9 i 0.7 i 8 i 13 i i 10 i 16 i remarks: nominal size denotes the nominal diameter of the pipe to be applied 12 -,-,- jas0 f402:2001 nominal size 4.76 6.35 12 mm d cn cs s e rn di d2 d3 k s i l di di d3 li 12 13 basic toler- (apprx.) basic toler- (min.) size ance size ance 13.9 9 4.9 +0.2 l2 7.5 5.5 18 32 3.8 7.5 3.2 10 12 16.2 14 12 m l o x l 14 m12x1 17 -o,25 o 19.6 1 1 6 . 5 9.5 17 8 6 22 4.5 5.3 9 3.2 10.5 12.5 8 28 5.5 6.8 11 4 13.5 16.5 11 17 12 19 12 8.2 m14x 17 l3 15 22 219 14 10.2 m16x 19 m20x 24 27.7 16 24 13 l6 12.2 o 1.5 19 21.9 1.5 22 25.4 12.5 9.5 32 7.5 8.8 13 4 15 18 10 40 9 10.5 17 5 16.5 19.5 illustrated example of type c combination +0.15 17 27 16 24 13 10 40 1.5 unit: mm 9.7 11.2 17 5 16.5 19.5 remarks: nominal size denotes the nominal diameter of the pipe to be applied 13 jas0 f402:2001 nominal attached table 9 o-ring flared nut (dn), o-ring pipe fitting part (ds) and o-ring (dr) pipe fitting part (ds) unit: mm flared nut (dn) d d d4 basic i toler- i basic i toler- illustrated example of o-ring flared pipe fitting o-ring (dr) 8 i m 1 4 x 1 . 5 i 6.2 10 i m 1 6 x 1 . 5 i 7.6 i i i u k i ko.1 i i:; i o ; 7 i i size i ance i size i ance 6.35 i m12x1 1 6 . 2 i i 1.6 i remarks: nominal size denotes the nominal diameter of the pipe to be applied 14 jaso f402:2001 explanatory notes on automotive parts - flare fittings these explanatory notes explain matters specified in the main text and related matters, and do not constitute a part of the standard. 1. purpose of revision this revision is intended to facilitate the use of jaso standards and to establish a level of efficacy equivalent to the and international standard, consideration is given to commonly used parts to be procured in domestic and overseas markets. 2. deliberated items with the current revision, types and shapes are reviewed to provide easy to use jaso standards which reflect actual conditions, and efforts are made to maintain good compliance with the corresponding international standard (is0 13486-1). in trying to adjust the jaso standard to the i s 0 standard, it was discovered that the applicable scope differs in the previous standard and jaso m101. the i s 0 standard specifies shapes and dimensions of pipes, double-flare units, and pipe fittings while the previous jaso standard specifies pipe fittings, and jaso mi01 specifies pipes (including flared shapes). application of the i s 0 standard is intended for hydraulic brakes while the previous standard and jaso mi01 are intended for metal pipes used in automobile piping for brakes, fuel oil, steering systems (the previous standard includes lubricating systems). it was decided that the specifications of the i s 0 standard should be combined with those of the previous standard that cover a wider application range, and that jaso mi01 should be used for pipes that are not covered by the previous standard but are covered by the i s 0 standard to avoid duplicated specifications. it was also decided that adjustment of shapes and dimensions of the double-flare to the international standard be given priority even though problems of duplicated specifications and non-conformance are generated. in future, revision of jaso mi01 will be proposed. work is in progress regarding the format of the standard sheet, considering conformity with the i s 0 standard. the following explanations address the details of each item. 2.1 scope (item 1. of the main text) jaso mi01 is mainly cited for pipe shapes and dimensions of the double-flare, and pipe fittings for hydraulic brakes which are defined in the i s 0 standard, and applications are specified for metal pipes for automobile piping in a wider range than in the previous standard. 2.2 pipes (item 3 of the main text) jaso mi01 was designated for primary use, based on the quality of the jaso specifications related to pipes and to avoid redundancy. however, nonconformity between jaso mi01 and the i s 0 standard was noticed, particularly for pipe shapes and dimensions where there are differences in the outside and nominal diameters (4.76 and 4.75), and the outside diameter and thickness tolerance (i0.08, i o . l and i0.07). it was consequently decided to use both jaso f412 and jaso m101. the standard conforms to the i s 0 standard for items related to the shape of the double-flare and a study of actual conditions showed no particular problems from a manufacturing perspective. 15 -,-,- jaso f402:2001 jaso mi01 was designated for items related to physical properties, because of differences in tensile strength ( 2 2 9 4 mps and 2290 mps), and yield point ( 2 176 mpa and 2200 mpa). jaso mi01 was designated for items related to surface treatment and corrosion resistance, because the contents of the i s 0 standard were considered inadequate. however, the specifications for corrosion resistance of duplex winding steel pipes contained in jaso f412 may be used. furthermore, the single-flare (jaso type), shape of o-ring flare, appearance and inspection specified in jaso mi01 are