TP 116 04

TP-116-04
April 22, 2005
U.S. DEPARTMENT OF TRANSPORTATION
NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION
LABORATORY TEST PROCEDURE
FOR
FMVSS 116
Motor Vehicle Brake Fluids
ENFORCEMENT
Office of Vehicle Safety Compliance
Room 6115, NVS-222
400 Seventh Street, SW
Washington, DC 20590
OVSC LABORATORY TEST PROCEDURE NO. 116

TABLE OF CONTENTS
PAGE
1. PURPOSE AND APPLICATION....................................................................... 1
2. GENERAL REQUIREMENTS........................................................................... 1
3. SECURITY ....................................................................................................... 2
4. GOOD HOUSEKEEPING ................................................................................. 2
5. TEST SCHEDULING AND MONITORING ....................................................... 3
6. TEST DATA DISPOSITION.............................................................................. 3
7. GOVERNMENT FURNISHED PROPERTY (GFP)........................................... 3
8. CALIBRATION OF TEST INSTRUMENTS....................................................... 3
9. PHOTOGRAPHIC DOCUMENTATION ............................................................ 4
10. DEFINITIONS................................................................................................... 5
11. PRETEST REQUIREMENTS ........................................................................... 6
12. COMPLIANCE TEST EXECUTION.................................................................. 7
13. POST TEST REQUIREMENTS........................................................................ 35
14. REPORTS ........................................................................................................ 35
14.1. MONTHLY STATUS REPORTS............................................................ 35
14.2. APPARENT TEST FAILURE ................................................................. 35
14.3. FINAL TEST REPORTS........................................................................ 35
14.3.1. COPIES ........................................................................... 35
14.3.2. REQUIREMENTS............................................................ 36
14.3.3. FIRST THREE PAGES.................................................... 36
14.3.4. TABLE OF CONTENTS................................................... 42
15. DATA SHEETS................................................................................................. 43
16. FORMS ............................................................................................................ 50
REVISION CONTROL LOG

FOR OVSC LABORATORY
TEST PROCEDURES
TP-116
Motor Vehicle Brake Fluids
TEST PROCEDURE FMVSS 116
REV. DATE AMENDMENT EFFECTIVE DESCRIPTION

No. DATE
00 Original Issue
01
02
03
04 April 22, 69 FR 67654 Jan. 18, 2005 Deletion of evaporation test.

2005
Nov. 21, 2005 Modification of corrosion test.
05
06
07
08
09
10
1
1. PURPOSE AND APPLICATION
The Office of Vehicle Safety Compliance (OVSC) provides contracted laboratories with
Laboratory Test Procedures (TPs) which serve as guidelines for obtaining compliance
test data. The data are used to determine if a specific vehicle or item of motor vehicle
equipment meets the minimum performance requirements of the subject Federal Motor
Vehicle Safety Standard (FMVSS). The purpose of the OVSC Laboratory Test
Procedures is to present a uniform testing and data recording format, and provide
suggestions for the use of specific equipment and procedures. Any contractor
interpreting any part of an OVSC Laboratory Test Procedure to be in conflict with a
Federal Motor Vehicle Safety Standard or observing any deficiencies in a Laboratory
Test Procedure is required to advise the Contracting Officer's Technical Representative
(COTR) and resolve the discrepancy prior to the start of compliance testing.
Contractors are required to submit a detailed test procedure to the COTR before
initiating the compliance test program. The procedure must include a step-by-step
description of the methodology to be used.
The OVSC Laboratory Test Procedures are not intended to limit or restrain a contractor
from developing or utilizing any testing techniques or equipment which will assist in
procuring the required compliance test data.
NOTE:
The OVSC Laboratory Test Procedures, prepared for use by independent

laboratories under contract to conduct compliance tests for the OVSC, are not
intended to limit the requirements of the applicable FMVSS(s). In some cases, the
OVSC Laboratory Test Procedures do not include all of the various FMVSS
minimum performance requirements. Sometimes, recognizing applicable test
tolerances, the Test Procedures specify test conditions which are less severe
than the minimum requirements of the standards themselves. Therefore,
compliance of a vehicle or item of motor vehicle equipment is not necessarily
guaranteed if the manufacturer limits certification tests to those described in the
OVSC Laboratory Test Procedures.
2. GENERAL REQUIREMENTS
FMVSS 116 specifies requirements for fluids for use in hydraulic brake systems of
motor vehicles, containers for these fluids, and labeling of the containers.
The purpose of FMVSS 116 is to reduce failures in the hydraulic braking systems of
motor vehicles which may occur because of the manufacture or use of improper or
contaminated fluid.
The standard applies to all fluid for use in hydraulic brake systems of passenger cars,
multipurpose passenger vehicles, trucks, buses, trailers, and motorcycles which are
equipped with a hydraulic brake system. The fluid for use in the
2
2. GENERAL REQUIREMENTS....Continued
referenced vehicle shall have been manufactured and packaged in conformity with the
requirements of FMVSS 116. The tests which are contained within this test procedure
are used to determine compliance with the specified requirements. These tests are as
follows:
A. Equilibrium Reflux Boiling Point (ERBP)

B. Wet ERBP
C. Kinematic Viscosity
D. Ph Value
E. Fluid Stability
F. Corrosion
G. Fluidity and Appearance (Low Temperature)
H. Water Tolerance
I. Compatibility
J. Resistance to Oxidation
K. Effect on SBR Cups
L. Stroking Properties (This test is only conducted when specifically specified in the
contract)
M. Container Information
3. SECURITY
The contractor shall provide appropriate security measures to protect the OVSC test
equipment from unauthorized personnel during the entire compliance testing program.
The contractor is financially responsible for any acts of theft and/or vandalism which
occur during the storage of test equipment. Any security problems which arise shall be
reported by telephone to the Industrial Property Manager (IPM), Office of Contracts and
Procurement, within two working days after the incident. A letter containing specific
details of the security problem will be sent to the IPM (with copy to the COTR) within 48
hours.
The contractor shall protect and segregate the data that evolves from compliance
testing before and after each test. No information concerning the safety compliance
testing program shall be released to anyone except the COTR, unless specifically
authorized by the COTR, the COTR's Branch or Division Chief, or by the Contracting
Officer.
NO INDIVIDUALS, OTHER THAN CONTRACTOR PERSONNEL, SHALL BE

ALLOWED TO WITNESS ANY COMPLIANCE TEST UNLESS SPECIFICALLY
AUTHORIZED BY THE COTR.
4. GOOD HOUSEKEEPING
Contractors shall maintain the entire equipment compliance testing area, test fixtures
and instrumentation in a neat and clean condition with test instruments arranged in an
orderly manner consistent with good test laboratory housekeeping
3
4. GOOD HOUSEKEEPING....Continued
practices.
5. TEST SCHEDULING AND MONITORING
The contractor shall submit a test schedule to the COTR prior to testing. Tests shall be
completed as required in the contract. All testing shall be coordinated to allow
monitoring by the COTR.
6. TEST DATA DISPOSITION
The contractor shall make all equipment preliminary compliance test data available to
the COTR on location within four hours after the test. Final test data, including digital
printouts and computer generated plots (if applicable), shall be furnished to the COTR in
accordance with the contract schedule.
All backup data sheets, strip charts, recordings, plots, technicians notes, etc., shall be
retained by the contractor for a minimum of five years after conclusion of each delivery
order, purchase order, etc. The COTR shall direct final disposition at that time.
7. GOVERNMENT FURNISHED PROPERTY (GFP) AND TEST SAMPLES
TEST SAMPLE IDENTIFICATION AND STORAGE
Upon receipt at the laboratory, the items to be tested shall be assigned laboratory serial
numbers.
EXAMPLE:
Brand X Heavy Duty Brake Fluid; Lab Group #00X
An inventory shall be made of the number, name and condition of samples received.
The test samples shall be stored in a dry and clean area specifically designated by the
Laboratory Project Manager.
8. CALIBRATION OF TEST INSTRUMENTS
Before the contractor initiates the safety compliance test program, a test instrumentation
calibration system will be implemented and maintained in accordance with established
calibration practices. Guidelines for setting up and maintaining such calibration systems
are described in MIL-C-45662A, "Calibration System Requirements". The calibration
system shall be set up and maintained as follows:
4
8. CALIBRATION....Continued
A. Standards for calibrating the measuring and test equipment will be stored and
used under appropriate environmental conditions to assure their accuracy and
stability.
B. All measuring instruments and standards shall be calibrated by the contractor, or

a commercial facility, against a higher order standard at periodic intervals NOT
TO EXCEED TWELVE (12) MONTHS except for static types of measuring
devices such as rulers, weights, etc., which shall be calibrated at periodic
intervals not to exceed two years. Records, showing the calibration traceability
to the National Institute of Standards and Technology (NIST), shall be maintained
for all measuring and test equipment.
C. All measuring and test equipment and measuring standards will be labeled with
the following information:
(1) Date of calibration

(2) Date of next scheduled calibration
D. A written calibration procedure shall be provided by the contractor

which includes as a minimum the following information for all measurement and
test equipment unless the calibration is performed by a licensed commercial
facility.
(1) Type of equipment, manufacturer, model number, etc.

(2) Measurement range
(3) Accuracy
(4) Calibration interval
(5) Type of standard used to calibrate the equipment (calibration traceability
of the standard must be evident)
E. Records of calibration for all test instrumentation shall be kept by the contractor
in a manner which assures the maintenance of established calibration schedules.
All such records shall be readily available for inspection when requested by the
COTR. The calibration system will need the acceptance of the COTR before the
test program commences.
9. PHOTOGRAPHIC DOCUMENTATION
Each final test report shall include glossy photographs (minimum size 4 x 6 inches) of
the test setup used for each phase of testing. One set of original photographs shall be
included in the final test report which will be used for optical scanning by the OVSC.
Other copies of the final test report may contain multilith or other suitable photographic
copies of the original photographs.
5
10. DEFINITIONS
BLISTER
Cavity or sac on the surface of a brake cup.
BRAKE FLUID
Liquid designed for use in a motor vehicle hydraulic brake system in which it will contact
elastomeric components made of styrene and butadiene rubber (SBR), ethylene and
propylene rubber (EPR), polychloroprene (CR) brake hose inner tube stock or natural
rubber (NR).
CHIPPING
Condition in which small pieces are missing from the outer surface of a brake cup.
DUPLICATE SAMPLES
Two samples of brake fluid taken from a single packaged lot and tested simultaneously.
HYDRAULIC SYSTEM MINERAL OIL
Mineral-oil-based fluid designed for use in motor vehicle hydraulic brake systems in
which the fluid is not in contact with components made of SBR, EPR or NR.
PACKAGED LOT
That quantity of brake fluid shipped by the manufacturer to the packager in a single
container, or that quantity of brake fluid manufactured by a single plant run of 24 hours
or less, through the same processing equipment and with no change in ingredients.
PACKAGER
Person who fills containers with brake fluid that are distributed for retail sale.
SCUFFING
Visible erosion of a portion of the outer surface of a brake cup.
SILICONE BASE BRAKE FLUID (SBBF)
A brake fluid which consists of not less than 70 percent by weight of a diorgano
polysiloxane.
6
10. DEFINITIONS....Continued
SLOUGHING
Degradation of a brake cup as evidenced by the presence of carbon black loosely held
on the brake cup surface, such that a visible black streak is produced when the
cup, with a 500 ∀ 10 gram dead weight on it, is drawn base down over a sheet of white
bond paper placed on a firm flat surface.
STICKINESS
Condition on the surface of a brake cup such that fibers will be pulled from a wad of
U.S.P. absorbent cotton when it is drawn across the surface.
11. PRETEST REQUIREMENTS
IN-HOUSE TEST PROCEDURE
Prior to conducting any compliance test, contractors are required to submit a detailed
in-house compliance test procedure to the COTR which includes a step-by-step
description of the methodology to be used. Written approval must be obtained from the
COTR before initiating the compliance test program so that all parties are in agreement.
TEST DATA LOSS
A compliance test is not to be conducted unless all of the various test conditions
specified in the applicable OVSC Laboratory Test Procedure have been met. Failure of
a contractor to obtain the required test data and to maintain acceptable limits on test
parameters in the manner outlined in the applicable OVSC Laboratory Test Procedure
may require a retest at the expense of the contractor. The retest costs will include the
cost of the replacement brake fluid and all costs associated with conducting the retest.
The Contracting Officer of NHTSA is the only NHTSA official authorized to notify the
contractor that a retest is required. The retest shall be completed within two (2) weeks
after receipt of notification by the Contracting Officer that a retest is required. If a retest
is conducted, no test report is required for the original test.
TEST CONDITIONS
Unless otherwise specified, all tests and measurements shall be conducted under the
following environmental conditions:
A. Temperature 75ΕF ∀ 15ΕF

B. Relative Humidity 50% ∀ 10%
C. Atmospheric Pressure 28 to 32 inches of mercury
7
11. PRETEST....Continued
Continuous recording of environmental temperature and relative humidity of the testing

area shall be available during all tests. Test samples, unless otherwise specified, shall
be stabilized at test room conditions for a period of at least 24 hours immediately prior
to testing.
TEST PERSONNEL PERFORMANCE
Personnel supervising and/or performing the compliance test program shall be

thoroughly familiar with the requirements, test conditions, equipment for the test to be
conducted, and safety requirements.
RECORDING OF TEST DATA
Environmental data and test data shall be recorded on permanent strip charts, circular
recording charts, or other acceptable print-out media. Where permanent trace
recording is not required, data will be recorded on standard report forms. Changes or
corrections shall be made by drawing a line through the original entry, which must still
remain legible, and adding the change alongside.
Test data will be submitted on the standard form Test Data Sheets specified for use in
the final test report and shown in Section 15. Data will be typed before the sheets are
submitted. If stroking test is conducted, Data Sheet No. 3 shall be used.
12. COMPLIANCE TEST EXECUTION
TEST QUANTITIES
The amount of brake fluid required for one complete test group is shown below:
TEST QUANT.
6.1 Equilibrium Reflux Boiling Point (ERBP) 125 ml
6.2 Wet ERBP 205 ml
6.3 Kinematic Viscosity 120 ml
6.4 pH Value 55 ml
6.5 Fluid Stability 125 ml
6.6 Corrosion 1520 ml
6.7 Fluidity & Appearance (Low Temp.) 205 ml
6.8 Water Tolerance 105 ml
6.9 Compatibility 55 ml
6.10 Resistance to Oxidation 65 ml
6.11 Effect on SBR Cups 150 ml
6.12 Stroking Properties 3785 ml
6.13 Container Information 348 ml
Reserve 2850 ml
TOTAL 9713 ml (328 oz)
8
12. COMPLIANCE....Continued
TEST REQUIREMENTS
The fluid samples shall meet specific requirements when tested in accordance with the
procedures in FMVSS 116.
6.1 Equilibrium reflux boiling point. Determine the ERBP of a brake fluid by running
duplicate samples according to the following procedure and averaging the results.
6.1.1 Summary of procedure. Sixty milliliters (ml.) of brake fluid are boiled under
specified equilibrium conditions (reflux) at atmospheric pressure in a 100-ml. flask. The
average temperature of the boiling fluid at the end of the reflux period, corrected for
variations in barometric pressure if necessary, is the ERBP.
6.1.2 Apparatus. (See Figure 1) The test apparatus shall consist of— (a) Flask. (See
Figure 2) A 100-ml. round-bottom, short-neck heat-resistant glass flask having a neck
with a 19.38 standard taper, female groundglass joint and a side-entering tube, with an
outside diameter of 10 millimeters (mm.), which centers the thermometer bulb in the
flask 6.5 mm. from the bottom; (b) Condenser. A water-cooled, reflux, glass-tube type,
condenser having a jacket 200 mm. in length, the bottom end of which has a 19.38
standard-taper, drip-tip, male ground-glass joint; (c) Boiling stones. Three clean, unused
silicon carbide grains (approximately 2 mm. (0.08 inch) in diameter, grit No. 8); (d)
Thermometer. Standardized calibrated partial immersion (76 mm.), solid stem,
thermometers conforming to the requirements for an ASTM 2C or 2F, and an ASTM 3C
or 3F thermometer; and (e) Heat source. Variable autotransformer-controlled heating
mantle designed to fit the flask, or an electric heater with rheostat heat control.
6.1.3 Preparation of apparatus. (a) Thoroughly clean and dry all glassware. (b) Insert
thermometer through the side tube until the tip of the bulb is 6.5 mm. (1.4 inch) from the
bottom center of the flask. Seal with a short piece of natural rubber, EPDM, SBR, or
butyl tubing. (c) Place 60±1 ml. of brake fluid and the silicon carbide grains into the
flask. (d) Attach the flask to the condenser. When using a heating mantle, place the
mantle under the flask and support it with a ring-clamp and laboratory-type stand,
holding the entire assembly in place by a clamp. When using a rheostat- controlled
heater, center a standard porcelain or hard asbestos refractory, having a diameter
opening 32 to 38 mm., over the heating element and mount the flask so that direct heat
is applied only through the opening in the refractory. Place the assembly in an area free
from drafts or other types of sudden temperature changes. Connect the cooling water
inlet and outlet tubes to the condenser. Turn on the cooling water. The water supply
temperature shall not exceed 28 °C. (82.4 °F.) and the temperature rise through the
condenser shall not exceed 2 °C. (3.6 °F.).
9
FIG. 1. BOILING POINT TEST APPARATUS
FIG. 2. DETAIL OF 100 ML SHORT-NECK FLASK

10
6.1.4 Procedure. Apply heat to the flask so that within 10±2 minutes the fluid is refluxing
in excess of 1 drop per second. The reflux rate shall not exceed 5 drops per second at
any time. Immediately adjust the heating rate to obtain an equilibrium reflux rate of 1 to
2 drops per second over the next 5±2 minutes. Maintain this rate for an additional 2
minutes, taking four temperature readings at 30–second intervals. Record the average
of these as the observed ERBP. If no reflux is evident when the fluid temperature
reaches 260 °C (500 °F), discontinue heating and report ERBP as in excess of 260 °C
(500 °F).
6.1.5 Calculation. (a) Thermometer inaccuracy. Correct the observed ERBP by applying
any correction factor obtained in standardizing the thermometer. (b) Variation from
standard barometric pressure. Apply the factor shown in Table I to calculate the
barometric pressure correction to the ERBP.
(c) If the two corrected observed ERBP’s agree within 2 °C. (4 °C. for brake fluids
having an ERBP over 230 °C./446 °F.) average the duplicate runs as the ERBP;
otherwise, repeat the entire test, averaging the four corrected observed values to
determine the original ERBP.
Table I – Correction for Barometric Pressure

Correction per 1mm difference in
Observed ERBP corrected for thermometer pressurea
inaccuracy
°C. °F.
100 °C. (212 °F.) to 190 °C. (374 °F.) 0.039 (0.07)
Over 190 °C. (374 °F.) 0.04 (0.08)
a
To be added in case barometric pressure is below 760 mm.; to be subtracted in
case barometric pressure is above 670 mm.
6.1.6 Pass/Fail Criteria. The ERBP shall not be less than the following value for the
grade indicated: (a) DOT 3: 205 °C. (401 °F.). (b) DOT 4: 230 °C. (446 °F.). (c) DOT 5:
260 °C. (500 °F.).
6.2 Wet ERBP. Determine the wet ERBP of a brake fluid by running duplicate samples
according to the following procedure.
6.2.1. Summary of procedure. A 350 ml. sample of the brake fluid is humidified under
controlled conditions; 350 ml. of SAE triethylene glycol monomethyl ether, brake fluid
grade, referee material (TEGME) as described in appendix E of SAE Standard J1703
Nov. 83, ‘‘Motor Vehicle Brake Fluid,’’ November 1983, is used to establish the end
point for humidification. After humidification, the water content and ERBP of the brake
fluid are determined.
6.2.2 Apparatus for humidification. (See Figure 3). Test apparatus shall consist of— (a)
Glass jars. Four SAE RM–49 corrosion test jars or equivalent screwtop, straight-sided,
round glass jars each having a capacity of about 475 ml. and approximate inner
dimensions of 100 mm. in height by 75 mm. in diameter, with matching lids having new,
clean inserts providing water-vapor-proof seals; (b) Desiccator and cover. Two bowlform
glass desiccators, 250-mm. inside diameter, having matching tubulated
11
covers fitted with No. 8 rubber stoppers; and (c) Desiccator plate. Two 230-mm.
diameter, perforated porcelain desiccator plates, without feet, glazed on one side.
6.2.3 Reagents and materials. (a) Distilled water, see S7.1. (b) SAE TEGME referee
material.
6.2.4 Preparation of apparatus. Lubricate the ground-glass joint of the desiccator. Pour
450±10 ml. of distilled water into each desiccator and insert perforated porcelain
desiccator plates. Place the desiccators in an oven with temperature controlled at 50±1
°C. (122±1.8 °F.) throughout the humidification procedure.
6.2.5 Procedure. Pour 350±5 ml. of brake fluid into an open corrosion test jar. Prepare
in the same manner a duplicate test fluid sample and two duplicate specimens of the
SAE TEGME referee material (350±5 ml. of TEGME in each jar). The water content of
the SAE TEGME fluid is adjusted to 0.50±0.05 percent by weight at the start of the test
in accordance with S7.2. Place one sample each of the test brake fluid and the
prepared TEGME sample into the same desiccator. Repeat for the second sample of
test brake fluid and TEGME in a second desiccator. Place the desiccators in the 50 °C.
(122 °F.) controlled oven and replace desiccator covers. At intervals, during oven
humidification, remove the rubber stoppers in the tops of desiccators. Using a long
needled hypodermic syringe, take a sample of not more than 2 ml. from each TEGME
sample and determine its water content. Remove no more than 10 ml. of fluid from each
SAE TEGME sample during the humidification procedure. When the water content of
the SAE fluid reaches 3.70±0.05 percent by weight (average of the duplicates). remove
the two test fluid specimens from their desiccators and promptly cap each jar tightly.
Allow the sealed jars to cool for 60 to 90 minutes at 23°±5 °C. (73.4°±9 °F.). Measure
the water contents of the test fluid specimens in accordance
12
with S7.2 and determine their ERBP’s in accordance with S6.1. If the two ERBPs agree
within 4 °C. (8 °F.), average them to determine the wet ERBP; otherwise repeat and
average the four individual ERBPs as the wet ERBP of the brake fluid.
6.2.6 Pass/Fail Criteria. The wet ERBP shall not be less than the following value for the
grade indicated: (a) DOT 3: 140 °C. (284 °F.). (b) DOT 4: 155 °C. (311 °F.). (c) DOT 5:
1 180 °C. (356 °F.).
6.3 Kinematic viscosities. Determine the kinematic viscosity of a brake fluid in mm2/s by
the following procedure. Run duplicate samples at each of the specified temperatures,
making two timed runs on each sample.
6.3.1 Summary of the procedure. The time is measured for a fixed volume of the brake
fluid to flow through a calibrated glass capillary viscometer under an accurately
reproducible head and at a closely controlled temperature. The kinematic viscosity is
then calculated from the measured flow time and the calibration constant of the
viscometer.
6.3.2 Apparatus. (a) Viscometers. Calibrated glass capillary- type viscometers, ASTM
D2515– 66, ‘‘Standard Specification for Kinematic Glass Viscometers,’’ measuring
viscosity within the precision limits of S6.4.7. Use suspended level viscometers for
viscosity measurements at low temperatures. Use Cannon-Fenske Routine or other
modified Ostwald viscometers at ambient temperatures and above. (b) Viscometer
holders and frames. Mount a viscometer in the constanttemperature bath so that the
mounting tube is held within 1°of the vertical. (c) Viscometer bath. A transparent liquid
bath of sufficient depth such that at no time during the measurement will any portion of
the sample in the viscometer be less than 2 cm. below the surface or less than 2 cm.
above the bottom. The bath shall be cylindrical in shape, with turbulent agitation
sufficient to meet the temperature control requirements. For measurements within 15°to
100 °C. (60°to 212 °F.) the temperature of the bath medium shall not vary by more than
0.01 °C. (0.02 °F.) over the length of the viscometers, or between the positions of the
viscometers, or at the locations of the thermometers. Outside this range, the variation
shall not exceed 0.03 °C. (0.05 °F.). (d) Thermometers. Liquid-in-Glass Kinematic
Viscosity Test Thermometers, covering the range of test temperatures indicated in
Table II and conforming to ASTM E1–68, ‘‘Specifications for ASTM Thermometers,’’ and
in the IP requirements for IP Standard Thermometers. Standardize before use (see
S6.3.3(b)). Use two standardized thermometers in the bath.
Table II – Kinematic Viscocity Thermometers

For tests at Subdivisions Thermometer Number
°C. °F. °C. °F. °C. °F. ASTM IP
Minus 55.3 to Minus 67.5 to minus
Minus 55 Minus 67 0.05 0.1 74 F 69 F. or C.
minus 52.5 62.5
Minus 41.4 to Minus 42.5 to minus
Minus 40 Minus 40 0.05 0.1 73 F 68 F. or C.
minus 38.6 37.5
98.6 to 101.4 207.5 to 212.5 100 212 0.05 0.1 30 F 32 F. or C.
13
(e) Timing device. Stop watch or other timing device graduated in divisions representing
not more than 0.2 second, with an accuracy of at least ±0.05 percent when tested over
intervals of 15 minutes. Electrical timing devices may be used when the current
frequency is controlled to an accuracy of 0.01 percent or better.
6.3.3 Standardization. (a) Viscometers. Use viscometers calibrated in accordance with

appendix 1 of ASTM D445–65, ‘‘Viscosity of Transparent and Opaque Liquids
(Kinematic and Dynamic Viscosities).’’ The calibration constant, C, is dependent upon
the gravitational acceleration at the place of calibration. This must, therefore, be
supplied by the standardization laboratory together with the instrument constant. Where
the acceleration of gravity, g, in the two locations differs by more than 0.1 percent,
correct the calibration constant as follows:
C2=(g2/g1)*C1
where the subscripts 1 and 2 indicate respectively the standardization laboratory and
the testing laboratory. (b) Thermometers. Check liquid-inglass thermometers to the
nearest 0.01 °C. (0.02 °F.) by direct comparison with a standardized thermometer.
Kinematic Viscosity Test Thermometers shall be standardized at ‘‘total immersion.’’ The
ice point of standardized thermometers shall be determined before use and the official
corrections shall be adjusted to conform to the changes in ice points. (See ASTM E77–
66, ‘‘Verification and Calibration of Liquid-in-Glass Thermometers.’’) (c) Timers. Time
signals are broadcast by the National Bureau of Standards, Station WWV, Washington,
DC at 2.5, 5, 10, 15, 20, 25, 30, and 35 Mc/sec (MHz). Time signals are also broadcast
by Station CHU from Ottawa, Canada, at 3.330, 7.335, and 14.670 Mc/sec, and Station
MSF at Rugby, United Kingdom, at 2.5, 5, and 10 Mc/sec.
6.3.4 Procedure. (a) Set and maintain the bath at the appropriate test temperature (see
S5.1.3) within the limits specified in S6.3.2(c). Apply the necessary corrections, if any, to
all thermometer readings. (b) Select a clean, dry, calibrated viscometer giving a flow
time not less than its specified minimum, or 200 seconds, whichever is the greater. (c)
Charge the viscometer in the manner used when the instrument was calibrated. Do not
filter or dry the brake fluid, but protect it from contamination by dirt and moisture during
filling and measurements. (1) Charge the suspended level viscometers by tilting about
30°from the vertical and pouring sufficient brake fluid through the fill tube into the lower
reservoir so that when the viscometer is returned to vertical position the meniscus is
between the fill marks. For measurements below 0 °C. (32 °F.), before placing the filled
viscometer into the constant temperature bath, draw the sample into the working
capillary and timing bulb and insert small rubber stoppers to suspend the fluid in this
position, to prevent accumulation of water condensate on the walls of the critical
portions of the viscometer. Alternatively, fit loosely packed drying tubes into the open
ends of the viscometer to prevent water condensation, but do not restrict the flow of the
sample under test by the pressures created in the instrument. (2) If a Cannon-Fenske
Routine viscometer is used, charge by inverting and immersing the smaller arm into the
brake fluid and applying vacuum to the larger arm. Fill the tube to the upper timing
mark, and return the viscometer to an upright position. (d) Mount the viscometer in the
bath in a true vertical position (see S6.3.2(b)). (e) The viscometer shall remain in the
bath until it reaches the test temperature. (f) At temperatures below 0 °C. (32 °F.)
14
conduct an untimed preliminary run by allowing the brake fluid to drain through the
capillary into the lower reservoir after the test temperature has been established. (g)
Adjust the head level of the brake fluid to a position in the capillary arm about 5 mm.
above the first timing mark. (h) With brake fluid flowing freely measure to within 0.2
second the time required for the meniscus to pass from the first timing mark to the
second. If this flow time is less than the minimum specified for the viscometer, or 200
seconds, whichever is greater, repeat using a viscometer with a capillary of smaller
diameter. (i) Repeat S6.3.4 (g) and (h). If the two timed runs do not agree within 0.2
percent, reject and repeat using a fresh sample of brake fluid.
6.3.5 Cleaning the viscometers. (a) Periodically clean the instrument with chromic acid
to remove organic deposits. Rinse thoroughly with distilled water and acetone, and dry
with clean dry air. (b) Between successive samples rinse the viscometer with ethanol
(isopropanol when testing DOT 5 fluids) followed by an acetone or ether rinse. Pass a
slow stream of filtered dry air through the viscometer until the last trace of solvent is
removed.
6.3.6 Calculation. (a) The following viscometers have a fixed volume charged at
ambient temperature, and as a consequence C varies with test temperature: Cannon-
Fenske Routine, Pinkevitch, Cannon-Manning Semi- Micro, and Cannon Fenske
Opaque. To calculate C at test temperatures other than the calibration temperature for
these viscometers, see ASTM D2515–66, ‘‘Kinematic Glass Viscometers’’ or follow
instructions given on the manufacturer’s certificate of calibration. (b) Average the four
timed runs on the duplicate samples to determine the kinematic viscosities.
6.3.7 Precision (at 95 percent confidence level). (a) Repeatability. If results on duplicate
samples by the same operator differ by more than 1 percent of their mean, repeat the
tests.
6.3.8. Pass/Fail Criteria. The kinematic viscosities in square millimeters per second at
stated temperatures shall be neither less than 1.5 mm2/s at 100 °C. (212 °F.) nor more
than the following maximum value for the grade indicated: (a) DOT 3: 1,500 mm2/s at
minus 40 °C. (minus 40 °F.). (b) DOT 4: 1,800 mm2/s at minus 40 °C. (minus 40 °F.).
(c) DOT 5: 900 mm2/s at minus 40 °C. (minus 40 °F.).
6.4 pH value. Determine the pH value of a brake fluid by running one sample according
to the following procedure.
6.4.1 Summary of the procedure. Brake fluid is diluted with an equal volume of an
ethanol-water solution. The pH of the resultant mixture is measured with a prescribed
pH meter assembly at 23 °C. (73.4 °F.).
6.4.2 Apparatus. The pH assembly consists of the pH meter, glass electrode, and
calomel electrode, as specified in Appendices A1.1, A1.2, and A1.3 of ASTM D 1121–
67, ‘‘Standard Method of Test for Reserve Alkalinity of Engine Antifreezes and
Antirusts.’’ The glass electrode is a full range type (pH 0–14), with low sodium error.
6.4.3 Reagents. Reagent grade chemicals conforming to the specifications of the

15
Committee on Analytical Reagents of the American Chemical Society. (a) Distilled

water. Distilled water (S7.1) shall be boiled for about 15 minutes to remove carbon
dioxide, and protected with a soda-lime tube or its equivalent while cooling and in
storage. (Take precautions to prevent contamination by the materials used for
protection against carbon dioxide.) The pH of the boiled distilled water shall be between
6.2 and 7.2 at 25 °C. (77 °F.). (b) Standard buffer solutions. Prepare buffer solutions for
calibrating the pH meter and electrode pair from salts sold specifically for use, either
singly or in combination, as pH standards. Dry salts for 1 hour at 110 °C. (230 °F.)
before use except for borax which shall be used as the decahydrate. Store solutions
with pH less than 9.5 in bottles of chemically resistant glass or polyethylene. Store the
alkaline phosphate solution in a glass bottle coated inside with paraffin. Do not use a
standard with an age exceeding three months. (1) Potassium hydrogen phthalate buffer
solution (0.05 M, pH=4.01 at 25 °C. (77 °F.)). Dissolve 10.21 g. of potassium hydrogen
phthalate (KHC8 H4 O4) in distilled water. Dilute to 1 liter. (2) Neutral phosphate buffer
solution (0.025 M with respect to each phosphate salt, pH=6.86 at 25 °C. (77 °F.)).
Dissolve 3.40 g. of potassium dihydrogen phosphate (KH2 PO4) and 3.55 g. of
anhydrous disodium hydrogen phosphate (Na2 HPO4) in distilled water. (3) Borax
buffer solution (0.01 M, pH=9.18 at 25 °C. (77 °F.)). Dissolve 3.81 g. of disodium
tetraborate decahydrate (Na2 B4 O7°10H2 O) in distilled water, and dilute to 1 liter.
Stopper the bottle except when actually in use. (4) Alkaline phosphate buffer solution
(0.01 M trisodium phosphate, pH=11.72 at 25 °C. (77 °F.)). Dissolve 1.42 g. of
anhydrous disodium hydrogen phosphate (Na2 HPO4) in 100 ml. of a 0.1 M carbonate-
free solution of sodium hydroxide. Dilute to 1 liter with distilled water. (5) Potassium
chloride electrolyte. Prepare a saturated solution of potassium chloride (KCl) in distilled
water. (c) Ethanol-water mixture. To 80 parts by volume of ethanol (S7.3) add 20 parts
by volume of distilled water. Adjust the pH of the mixture to 7±0.1 using 0.1 N sodium
hydroxide (NaOH) solution. If more than 4 ml. of NaOH solution per liter of mixture is
required for neutralization, discard the mixture.
6.4.4 Preparation of electrode system. (a) Maintenance of electrodes. Clean the glass
electrode before using by immersing in cold chromic-acid cleaning solution. Drain the
calomel electrode and fill with KCl electrolyte, keeping level above that of the mixture at
all times. When not in use, immerse the lower halves of the electrodes in distilled water,
and do not immerse in the mixture for any appreciable period of time between
determinations. (b) Preparation of electrodes. Condition new glass electrodes and those
that have been stored dry as recommended by the manufacturer. Before and after
using, wipe the glass electrode thoroughly with a clean cloth, or a soft absorbent tissue,
and rinse with distilled water. Before each pH determination, soak the prepared
electrode in distilled water for at least 2 minutes. Immediately before use, remove any
excess water from the tips of the electrode.
6.4.5 Standardization of the pH assembly and testing of the electrodes. (a) Immediately
before use, standardize the pH assembly with a standard buffer solution. Then use a
second standard buffer solution to check the linearity of the response of the electrodes
at different pH values, and to detect a faulty glass electrode or incorrect temperature
compensation. The two buffer solutions bracket the anticipated pH value of the test
brake fluid. (b) Allow instrument to warm up, and adjust according to the manufacturer’s
instructions. Immerse the tips of the electrodes in a standard buffer solution and allow
16
the temperature of the buffer solution and the electrodes to equalize. Set the
temperature knob at the temperature of the buffer solution. Adjust the standardization or
asymmetry potential control until the meter registers a scale reading, in pH units, equal
to the known pH of the standardizing buffer solution. (c) Rinse the electrodes with
distilled water and remove excess water from the tips. Immerse the electrodes in a
second standard buffer solution. The reading of the meter shall agree with the known
pH of the second standard buffer solution within ±0.05 unit without changing the setting
of the standardization of asymmetry potential control. (d) A faulty electrode is indicated
by failure to obtain a correct value for the pH of the second standard buffer solution after
the meter has been standardized with the first.
6.4.6 Procedure. To 50±1 ml. of the test brake fluid add 50±1 ml. of the ethanol- water
(6.4.3(c)) and mix thoroughly. Immerse the electrodes in the mixture. Allow the system
to come to equilibrium, readjust the temperature compensation if necessary, and take
the pH reading.
6.4.6 Pass/Fail Criteria. The pH value shall not be less than 7.0 nor more than 11.5
(except DOT 5 SBBF).
6.5 Fluid stability. Evaluate the heat and chemical stability of a brake fluid by the
following procedure, running duplicate samples for each test and averaging the results.
6.5.1 Summary of the procedure. The degradation of the brake fluid at elevated
temperature, alone or in a mixture with a reference fluid, is evaluated by determining the
change in boiling point after a period of heating under reflux conditions.
6.5.2 Apparatus. Use the apparatus and preparation specified in S6.1.2 and S6.1.3.
6.5.3 High temperature stability.
6.5.3.1 Procedure. (a) Heat a new 60±1 ml. sample of the brake fluid to 185°±2 °C.
(365°±3.6 °F.). Hold at this temperature for 120±5 minutes. Bring to a reflux rate in
excess of 1 drop per second within 5 minutes. The reflux rate should not exceed 5
drops per second at any time. Over the next 5±2 minutes adjust the heating rate to
obtain an equilibrium reflux rate of 1 to 2 drops per second. Maintain this rate for an
additional 2 minutes, taking four temperature readings at 30–second intervals. Average
these as the observed ERBP. If no reflux is evident when the fluid temperature reaches
260 °C. (500 °F), discontinue heating and report ERBP as in excess of 260 °C. (500
°F.).
6.5.3.2 Calculation. Correct the observed ERBP for thermometer and barometric
pressure factors according to S6.1.5 (a) and (b). Average the corrected ERBP’s of the
duplicate samples. The difference between this average and the original ERBP obtained
in S6.1 is the change in ERBP of the fluid.
6.5.4 Chemical stability.
6.5.4.1 Materials. SAE RM–66–04 Compatibility Fluid as described in appendix B of

17
SAE Standard J1703 JAN 1995, ‘‘Motor Vehicle Brake Fluid.’’ (SAE RM–66–03
Compatibility Fluid as described in appendix A of SAE Standard J1703 Nov83, ‘‘Motor
Vehicle Brake Fluid,’’ November 1983, may be used in place of SAE RM–66–04 until
January 1, 1995.)
6.5.4.2 Procedure. (a) Mix 30 ±1 ml. of the brake fluid with 30 ±1 ml. of SAE RM–66–04
Compatibility Fluid in a boiling point flask (S6.1.2(a)). Determine the initial ERBP of the
mixture by applying heat to the flask so that the fluid is refluxing in 10 ±2 minutes at a
rate in excess of 1 drop per second, but not more than 5 drops per second. Note the
maximum fluid temperature observed during the first minute after the fluid begins
refluxing at a rate in excess of 1 drop per second. Over the next 15 ±1 minutes, adjust
and maintain the reflux rate at 1 to 2 drops per second. Maintain this rate for an
additional 2 minutes, recording the average value of four temperature readings taken at
30 second intervals as the final ERBP. (b) Thermometer and barometric corrections are
not required.
6.5.4.3 Calculation. The difference between the initial ERBP and the final average
temperature is the change in temperature of the refluxing mixture. Average the results
of the duplicates to the nearest 0.5 °C (1.0 °F).
6.5.5 Pass/Fail Criteria.
6.5.5.1 High-temperature stability. When brake fluid is tested according to S6.5.3 the
ERBP shall not change by more than 3 °C. (5.4 °F.) plus 0.05°for each degree that the
ERBP of the fluid exceeds 225 °C. (437 °F.).
6.5.5.2 Chemical stability. When brake fluid, except DOT 5 SBBF, is tested according to
S6.5.4, the change in temperature of the refluxing fluid mixture shall not exceed 3.0 °C
(5.4 °F.) plus 0.05°for each degree that the ERBP of the fluid exceeds 225 °C (437 °F.).
6.6 Corrosion. Evaluate the corrosiveness of a brake fluid by running duplicate samples
according to the following procedure.
6.6.1 Summary of the procedure. Six specified metal corrosion test strips are polished,
cleaned, and weighed, then assembled as described. Assembly is placed on a standard
wheel cylinder cup in a corrosion test jar, immersed in the water-wet brake fluid, capped
and placed in an oven at 100 °C. (212 °F.) for 120 hours. Upon removal and cooling, the
strips, fluid, and cups are examined and tested.
6.6.2 Equipment. (a) Balance. An analytical balance having a minimum capacity of 50

grams and capable of weighing to the nearest 0.1 mg. (b) Desiccators. Desiccators
containing silica gel or other suitable desiccant. (c) Oven. Gravity convection oven
capable of maintaining the desired set point within 2 °C. (3.6 °F.). (d) Micrometer. A
machinist’s micrometer 25 to 50 mm. (1 to 2 inches) capacity, or an optical comparator,
capable of measuring the diameter of the SBR wheel cylinder (WC) cups to the nearest
0.02 mm. (0.001 inch).
6.6.3 Materials. (a) Corrosion test strips. Two sets of strips from each of the metals
18
listed in appendix C of SAE Standard J1703b. Each strip shall be approximately 8 cm.
long, 1.3 cm. wide, not more than 0.6 cm. thick, and have a surface area of 25±5 sq.
cm. and a hole 4 to 5 mm. (0.16 to 0.20 inch) in diameter on the centerline about 6 mm.
from one end. The hole shall be clean and free from burrs. Tinned iron strips shall be
unused. Other strips, if used, shall not be employed if they cannot be polished to a high
finish. (b) SBR cups. Two unused standard SAE SBR wheel cylinder (WC) cups, as
specified in S7.6. (c) Corrosion test jars and lids. Two screw-top straight-sided round
glass jars, each having a capacity of approximately 475 ml. and inner dimensions of
approximately 100 mm. in height and 75 mm. in diameter, and a tinned steel lid (no
insert or organic coating) vented with a hole 0.8±0.1 mm. (0.031±0.004 inch) in
diameter (No. 68 drill). (d) Machine screws and nuts. Clean, rust and oil-free, uncoated
mild steel round or fillister head machine screws, size 6 or 8–32 UNC–Class 2A,
fiveeighths or three-fourths inch long (or equivalent metric sizes), and matching
uncoated nuts. (e) Supplies for polishing strips. Waterproof silicon carbide paper, grit
No. 320 A and grit 1200; lint-free polishing cloth. (f) Distilled water as specified in S7.1.
(g) Ethanol as specified in S7.3. (h) Isopropanol as specified in S7.7.
6.6.4 Preparation. (a) Corrosion test strips. Except for the tinned iron strips, abrade
corrosion test strips on all surface areas with 320A silicon carbide paper wet with
ethanol (isopropanol when testing DOT 5 SBBF fluids) until all surface scratches, cuts
and pits visible to an observer having corrected visual acuity of 20/40 (Snellen ratio) at a
distance of 300 mm (11.8 inches) are removed. Use a new piece of paper for each
different type of metal. Except for the tinned iron strips, further abrade the test strips on
all surface areas with 1200 silicon carbide paper wet with ethanol (isopropanol when
testing DOT 5 SBBF fluids), again using a new piece of paper for each different type of
metal. Wash all strips, including the tinned iron and the assembly hardware, with
ethanol (isopropanol when testing DOT 5 SBBF fluids); dry the strips and assembly
hardware with a clean lint free cloth or use filtered compressed air and place the strips
and hardware in a desiccator containing silica gel or other suitable desiccant and
maintained at 23°±5 °C. (73.4°±9 °F.), for at least 1 hour. Handle the strips with forceps
after polishing. Weigh and record the weight of each strip to the nearest 0.1 mg.
Assemble the strips on a clean dry machine screw, with matching plain nut, in the order
of tinned iron, steel, aluminum, cast iron, brass, and copper. Bend the strips, other than
the cast iron, so that there is a separation of 3±1.2 mm. (1.8±1.64 inch) between
adjacent strips for a distance of about 5 cm. (2 inches) from the free end of the strips.
(See Figure 4.) Tighten the screw on each test strip assembly so that the strips are in
electrolytic contact, and can be lifted by either of the outer strips (tinned iron or copper)
without any of the strips moving relative to the others when held horizontally. Immerse
the strip assemblies in 90 percent ethyl alcohol. Dry with dried filtered compressed air,
then desiccate at least 1 hour before use.
(b) SBR WC cups. Measure the base diameters of the two standard SBR cups, using an
optical comparator or micrometer, to the nearest 0.02 mm. (0.001 inch) along the
centerline of the SAE and rubber-type identifications and at right angles to this
centerline. Take the measurements at least 0.4 mm. (0.015 inch) above the bottom
edge and parallel to the base of the cup. Discard any cup if the two measured diameters
differ by more than 0.08 mm. (0.003 inch). Average the two readings on each cup.
Determine the hardness of the cups according to S7.4.
19
FIG. 4 CORROSION STRIP ASSEMBLY
6.6.5 Procedure. Rinse the cups in ethanol (isopropanol when testing DOT 5 SBBF
fluids) for not more than 30 seconds and wipe dry with a clean lintfree cloth. Place one
cup with lip edge facing up, in each jar. Insert a metal strip assembly inside each cup
with the fastened end down and the free end extending upward. (See Figure 5.) When
testing brake fluids, except DOT 5 SBBF, mix 760 ml. of brake fluid with 40 ml. of
distilled water. When testing DOT 5 SBBF’s, humidify 800 ml. of brake fluid in
accordance with S6.2, eliminating determination of the ERBP. Using this water-wet
mixture, cover each strip assembly to a minimum depth of 10 mm. above the tops of the
strips. Tighten the lids and place the jars for 120±2 hours in an oven maintained at
100°±2 °C. (212°±3.6 °F.). Allow the jars to cool at 23°±5 °C. (73.4°±9 °F.) for 60 to 90
minutes. Immediately remove the strips from the jars using forceps, agitating the strip
assembly in the fluid to remove loose adhering sediment. Examine the test strips and
jars for adhering crystalline deposits. Disassemble the metal strips, and remove
adhering fluid by flushing with water; clean each strip by wiping with a clean cloth wetted
with ethanol (isopropanol when testing DOT 5 fluids). Examine the strips for evidence of
corrosion and pitting. Disregard staining or discoloration. Place the strips in a desiccator
containing silica gel or other suitable desiccant, maintained at 23°±5 °C. (73.4°±9 °F.),
for at least 1 hour. Weigh each strip to the nearest 0.1 mg. Determine the change in
weight of each metal strip. Average the results for the two strips of each type of metal.
Immediately following the cooling period, remove the cups from the jars with forceps.
Remove loose adhering sediment by agitation of the cups in the mixture. Rinse the cups
in ethanol (isopropanol when testing DOT 5 fluids) and air-dry. Examine the cups for
evidence of sloughing, blisters, and other forms of disintegration. Measure the base
diameter and hardness of each cup within 15 minutes after removal from the mixture.
Examine the mixture for gelling. Agitate the mixture to suspend and uniformly disperse
sediment. From each jar, transfer a 100 ml. portion of the mixture to an ASTM cone-
shaped centrifuge tube. Determine the percent sediment after centrifuging as described
in S7.5. Measure the pH value of the corrosion text fluid according to S6.4.6. Measure
the pH value of the test mixture according to S6.4.6.
6.6.6 Calculation. (a) Measure the area of each type of test strip to the nearest square
20
centimeter. Divide the average change in mass for each type by the area of that type.
(b) Note other data and evaluations indicating compliance with S5.1.6. In the event of a
marginal pass on inspection by attributes, or of a failure in one of the duplicates, run
another set of duplicate samples. Both repeat samples shall meet all requirements of
S5.1.6.
6.6.7 Pass/Fail Criteria. (a) The metal test strips shall not show weight changes
exceeding the limits stated in Table III below;
Table III - Weight Change Limits

Test Strip Material Maximum permissible weight change, mg./sq.cm. of surface
Steel, tinned iron, cast iron 0.2
Aluminum 0.1
Brass, copper 0.4
(b) Excluding the area of contact (13±1 mm. (1.2±1.32 inch) measured from the bolt
hole end of the test strip), the metal test strips shall not show pitting or etching to an
extent discernible without magnification; (c) The water-wet brake fluid at the end of the
test shall show no jelling at 23±5 °C (73.4±9 °F.); (d) No crystalline deposit shall form
and adhere to either the glass jar walls or the surface of the metal strips; (e) At the end
of the test, sedimentation of the water-wet brake fluid shall not exceed 0.10 percent by
volume; (f) The pH value of water-wet brake fluid, except DOT 5 SBBF, at the end of the
test shall not be less than 7.0 nor more than 11.5; (g) The cups at the end of the test
shall show no disintegration, as evidenced by blisters or sloughing; (h) The hardness of
the cup shall not decrease by more than 15 International Rubber Hardness Degrees
(IRHD); and (i) The base diameter of the cups shall not increase by more than 1.4 mm.
(0.055 inch).
FIG. 5 CORROSION TEST APPARATUS

21
6.7 Fluidity and appearance at low temperatures. Determine the fluidity and appearance
of a sample of brake fluid at each of two selected temperatures by the following
procedure.
6.7.1 Summary of procedure. Brake fluid is chilled to expected minimum exposure

temperatures and observed for clarity, gellation, sediment, separation of components,
excessive viscosity or thixotropy.
6.7.2 Apparatus. (a) Oil sample bottle. Two clear flint glass 4–ounce bottles made
especially for sampling oil and other liquids, with a capacity of approximately 125 ml., an
outside diameter of 37±0.05 mm. and an overall height of 165±2.5 mm. (b) Cold
chamber. An air bath cold chamber capable of maintaining storage temperatures down
to minus 55 °C. (minus 67 °F.) with an accuracy of ±2 °C. (3.6 °F.). (c) Timing device. A
timing device in accordance with S6.3.2(e).
6.7.3 Procedure. (a) Place 100±1 ml. of brake fluid at room temperature in an oil sample
bottle. Stopper the bottle with an unused cork and place in the cold chamber at the
higher storage temperature specified in Table II (S5.1.7(c)). After 144±4 hours remove
the bottle from the chamber, quickly wipe it with a clean, lint-free cloth, saturated with
ethanol (isopropanol when testing DOT 5 fluids) or acetone. Examine the fluid for
evidence of sludging, sedimentation, crystallization, or stratification. Invert the bottle and
determine the number of seconds required for the air bubble to travel to the top of the
fluid. Let sample warm to room temperature and examine. (b) Repeat 6.7.3(a),
substituting the lower cold chamber temperature specified in Table II, and a storage
period of 6 hours ±12 minutes. NOTE: Test specimens from either storage temperature
may be used for the other only after warming up to room temperature.
6.7.4 Pass/Fail Criteria. At the storage temperature and for the storage times given in
Table II— (a) The fluid shall show no sludging, sedimentation, crystallization, or
stratification; (b) Upon inversion of the sample bottle, the time required for the air bubble
to travel to the top of the fluid shall not exceed the bubble flow times shown in Table IV;
and (c) On warming to room temperature, the fluid shall resume the appearance and
fluidity that it had before chilling.
Table IV - Fluidity and Appearance at Low Temperatures

Storage temperature Storage time (hours) Maximum bubble flow time
(seconds)
Minus 40±2 °C. (minus 40±3.6 °F.) 144±4.0 10
Minus 50±2 °C. (minus 58±3.6 °F.) 6±0.2 20
6.8 Water tolerance. Evaluate the water tolerance characteristics of a brake fluid by
running one test specimen according to the following procedure.
6.8.1 Summary of the procedure. Brake fluid, except DOT 5 SBBF, is diluted with 3.5
percent water (DOT 5 SBBF is humidified), then stored at minus 40 °C. (minus 40 °F.)
for 120 hours. The cold, water-wet fluid is first examined for clarity, stratification, and
sedimentation, then placed in an oven at 60 °C. (140 °F.) for 24 hours. On removal, it is
22
again examined for stratification, and the volume percent of sediment determined by
centrifuging.
6.8.2 Apparatus. (a) Centrifuge tube. See S7.5.1(a). (b) Centrifuge. See S7.5.1(b). (c)
Cold chamber. See S6.7.2(b). (d) Oven. Gravity or forced convection oven. (e) Timing
device. See S6.3.2(e). S6.9.3 Procedure. (a) At low temperature. Humidify 100±1 ml. of
DOT 5 SBBF brake fluid in accordance with S6.2 eliminating determination of the
ERBP. When testing brake fluids except DOT 5 SBBF, mix 3.5±0.1 ml. of distilled water
with 100±1 ml. of the brake fluid; pour into a centrifuge tube. Stopper the tube with a
clean cork and place in the cold chamber maintained at minus 40±2 °C. (minus 40±3.6
°F.). After 120 hours±2 hours remove the tube, quickly wipe with clean lint-free cloth
saturated with ethanol or acetone and examine the fluid for evidence of sludging,
sedimentation, crystallization, or stratification. Invert the tube and determine the number
of seconds required for the air bubble to travel to the top of the fluid. (The air bubble is
considered to have reached the top of the fluid when the top of the bubble reaches the 2
ml. graduation of the centrifuge tube.) If the wet fluid has become cloudy, warm to 23±5
°C. (73.4±9 °F.) and note appearance and fluidity. (b) At 60 °C. (140 °F.). Place tube
and brake fluid from
6.8.3(a) in an oven maintained at 60°±2 °C. (140°±3.6 °F.) for 24±2 hours. Remove the
tube and immediately examine the contents for evidence of stratification. Determine the
percent sediment by centrifuging as described in S7.5.
6.8.4 Pass/Fail Criteria. (a) At low temperature. (1) The fluid shall show no sludging,
sedimentation, crystallization, or stratification; (2) Upon inversion of the centrifuge tube,
the air bubble shall travel to the top of the fluid in not more than 10 seconds; (3) If
cloudiness has developed, the wet fluid shall regain its original clarity and fluidity when
warmed to room temperature; and (b) At 60 °C. (140 °F.). At At 60 °C. (140 °F.) (1) The
fluid shall show no stratification; and (2) Sedimentation shall not exceed 0.15 percent by
volume after centrifuging.
6.9 Compatibility. The compatibility of a brake fluid with other brake fluids shall be
evaluated by running one test sample according to the following procedure.
6.9.1 Summary of the procedure. Brake fluid is mixed with an equal volume of SAE
RM–66–04 Compatibility Fluid, then tested in the same way as for water tolerance
(S6.9) except that the bubble flow time is not measured. This test is an indication of the
compatibility of the test fluid with other motor vehicle brake fluids at both high and low
temperatures.
6.9.2 Apparatus and materials. (a) Centrifuge tube. See S7.5.1(a). (b) Centrifuge. See
S7.5.1(b). (c) Cold Chamber. See S6.7.2(b) (d) Oven. See S6.9.2(d) (e) SAE RM–66–
04 Compatibility Fluid. As described in appendix B of SAE Standard J1703 JAN 1995
‘‘Motor Vehicle Brake Fluid.’’ (SAE RM–66–03 Compatibility Fluid as described in
appendix A of SAE Standard J1703 NOV83, ‘‘Motor Vehicle Brake Fluid,’’ November
1983, may be used in place of SAE RM–66–04 until January 1, 1995.)
6.9.3 Procedure. (a) At low temperature. Mix 50±0.5 mL of brake fluid with 50±0.5 mL
23
of SAE RM–66–04 Compatibility Fluid. Pour this mixture into a centrifuge tube and
stopper with a clean dry cork. Place tube in the cold chamber maintained at minus
40°±2 °C. (minus 40°±4 °F). After 24±2 hours, remove tube, quickly wipe with a clean
lint-free cloth saturated with ethanol (isopropanol when testing DOT 5 fluids) or acetone.
Examine the test specimen for evidence of slugging, sedimentation, or crystallization.
Test fluids, except DOT 5 SBBF, shall be examined for stratification.
6.9.4 Pass/Fail Criteria. (a) At low temperature. When brake fluid is tested according to
S6.10.3(a), the test specimen shall show no sludging, sedimentation, or crystallization.
In addition, fluids, except DOT 5 SBBF, shall show no stratification. (b) At 60 °C. (140
°F.). When brake fluid is tested according to S6.10.3(b)— (1) Sedimentation shall not
exceed 0.05 percent by volume after centrifuging; and (2) Fluids, except DOT 5 SBBF,
shall show no stratification.
6.10 Resistance to oxidation. The stability of a brake fluid under oxidative conditions
shall be evaluated by running duplicate samples according to the following procedure.
6.10.1 Summary of procedure. Brake fluids, except DOT 5 SBBF, are activated with a
mixture of approximately 0.2 percent benzoyl peroxide and 5 percent water. DOT 5
SBBF is humidified in accordance with S6.2 eliminating determination of the ERBP, and
then approximately 0.2 percent benzoyl peroxide is added. A corrosion test strip
assembly consisting of cast iron and an aluminum strip separated by tinfoil squares at
each end is then rested on a piece of SBR WC cup positioned so that the test strip is
half immersed in the fluid and oven aged at 70 °C. (158 °F.) for 168 hours. At the end of
this period, the metal strips are examined for pitting, etching, and loss of mass.
6.10.2 Equipment. (a) Balance. See S6.6.2(a). (b) Desiccators. See S6.6.2(b). (c) Oven.
See S6.6.2(c). (d) Three glass test tubes approximately 22 mm. outside diameter by
175 mm. in length.
6.10.3 Reagents and materials. (a) Benzoyl peroxide, reagent grade, 96 percent.
(Benzoyl peroxide that is brownish, or dusty, or has less than 90 percent purity, must be
discarded.) Reagent strength may be evaluated by ASTM E298–68, ‘‘Standard Methods
for Assay of Organic Peroxides.’’ (b) Corrosion test strips. Two sets of cast iron and
aluminum metal test strips as described in appendix C of SAE Standard J1703b. (c)
Tinfoil. Four unused pieces of tinfoil approximately 12 mm. (1.2 inch) square and
between 0.02 and 0.06 mm. (0.0008 and 0.0024 inch) in thickness. The foil shall be at
least 99.9 percent tin and contain not more than 0.025 percent lead. (d) SBR cups. Two
unused, approximately one-eighth sections of a standard SAE SBR WC cup (as
described in S7.6). (e) Machine screw and nut. Two clean oil-free, No. 6 or 8–32 3.8¥
or 1.2–inch long (or equivalent metric size), round or fillister head, uncoated mild steel
machine screws, with matching plain nuts.
6.10.4 Preparation. (a) Corrosion test strips. Prepare two sets of aluminum and cast iron
test strips according to S6.6.4(a) except for assembly. Weigh each strip to the nearest
0.1 mg. and assemble a strip of each metal on a machine screw, separating the strips at
each end with a piece of tinfoil. Tighten the nut enough to hold both pieces of foil firmly
in place. (b) Test mixture.Place 30±1 ml. of the brake fluid under test in a 22
24
by 175 mm. test tube. For all fluids except DOT 5 SBBF, add 0.060±.002 grams of
benzoyl peroxide, and 1.50±0.05 ml. of distilled water. For DOT 5 SBBF, use test fluid
humidified in accordance with S6.2, and add only the benzoyl peroxide. Stopper the
tube loosely with a clean dry cork, shake, and place in an oven for 2 hours at 70°±2 °C.
(158°±3.6 °F.). Shake every 15 minutes to effect solution of the peroxide, but do not wet
cork. Remove the tube from the oven and allow to cool to 23°±5 °C. (73.4°±9 °F.) Begin
testing according to paragraph S6.11.5 not later than 24 hours after removal of tube
from oven.
6.10.5 Procedure. Place a one-eighth SBR cup section in the bottom of each tube. Add
10 ml. of prepared test mixture to each test tube. Place a metalstrip assembly in each,
the end of the strip without the screw resting on the rubber, and the solution covering
about one-half the length of the strips. Stopper the tubes with clean dry corks and store
upright for 70±2 hours at 23°±5 °C. (73.4°±9 °F.). Loosen the corks and place the tubes
for 168±2 hours in an oven maintained at 70°±2 °C. (158°±3.6 °F.). Afterwards remove
and disassemble strips. Examine the strips and note any gum deposits. Wipe the strips
with a clean cloth wet with ethanol (isopropanol when testing DOT 5 fluids) and note
any pitting, etching or roughening of surface disregarding stain or discoloration. Place
the strips in a desiccator over silica gel or other suitable desiccant, at 23°±5 °C.
(73.4°±9 °F.) for at least 1 hour. Again weigh each strip to the nearest 0.1 mg.
6.10.6 Calculation. Determine corrosion loss by dividing the change in mass of each
metal strip by the total surface area of each strip measured in square millimeters (mm2),
to the nearest square millimeter (mm2). Average the results for the two strips of each
type of metal, rounding to the nearest 0.05 mg. per 100 square millimeter (mm2). If only
one of the duplicates fails for any reason, run a second set of duplicate samples. Both
repeat samples shall meet all requirements of S5.1.11.
6.10.7 Pass/Fail Criteria. (a) The metal test strips outside the areas in contact with the
tinfoil shall not show pitting or etching to an extent discernible without magnification; (b)
No more than a trace of gum shall be deposited on the test strips outside the areas in
contact with the tinfoil; (c) The aluminum strips shall not change in weight by more than
0.05 mg./sq. cm.; and (d) The cast iron strips shall not change in weight by more than
0.3 mg./ sq. cm.
6.11 Effect on SBR cups. The effects of a brake fluid in swelling, softening, and
otherwise affecting standard SBR WC cups shall be evaluated by the following
procedure.
6.11.1 Summary of the procedure. Four standard SAE SBR WC cups are measured
and their hardnesses determined. The cups, two to a jar, are immersed in the test brake
fluid. One jar is heated for 70 hours at 70 °C. (158 °F), and the other for 70 hours at 120
°C (248 °F). Afterwards, the cups are washed, examined for disintegration, remeasured
and their hardnesses redetermined.
6.11.2 Equipment and supplies. (a) Oven. See S6.6.2(c). (b) Glass jars and lids. Two
screw-top, straight-sided round glass jars, each having a capacity of approximately 250
ml. and inner dimensions of approximately 125 mm. in height and 50 mm. in diameter,
25
and a tinned steel lid (no insert or organic coating). (c) SBR cups. See S7.6.
6.11.3 Preparation. Measure the base diameters of the SBR cups as described in
6.6.4(b), and the hardness of each as described in 7.4.
6.11.4 Procedure. Wash the cups in 90 percent ethanol (isopropanol when testing DOT
5 fluids) (see S7.3), for not longer than 30 seconds and quickly dry with a clean, lint-free
cloth. Using forceps, place two cups into each of the two jars; add 75 ml. of brake fluid
to each jar and cap tightly. Place one jar in an oven held at 70°±2 °C. (158±3.6 °F.) for
70±2 hours. Place the other jar in an oven held at 120°±2 °C. (248°±3.6 °F.) for 70±2
hours. Allow each jar to cool for 60 to 90 minutes at 23°±5 °C. (73.4°±9 °F.). Remove
cups, wash with ethanol (isopropanol when testing DOT 5 fluids) for not longer than 30
seconds, and quickly dry. Examine the cups for disintegration as evidenced by
stickiness, blisters, or sloughing. Measure the base diameter and hardness of each cup
within 15 minutes after removal from the fluid.
6.11.5 Calculation. (a) Calculate the change in base diameter for each cup. If the two
values, at each temperature, do not differ by more than 0.10 mm. (0.004 inch) average
them to the nearest 0.02 mm. (0.001 inch). If the two values differ by more than 0.10
mm., repeat the test at the appropriate temperature and average the four values as the
change in base diameter. (b) Calculate the change in hardness for each cup. The
average of the two values for each pair is the change in hardness. (c) Note
disintegration as evidenced by stickiness, blisters, or sloughing.
6.11.6 Pass/Fail Criteria. (a) The increase in the diameter of the base of the cups shall
be not less than 0.15 mm. (0.006 inch) or more than 1.40 mm. (0.055 inch); (b) The
decrease in hardness of the cups shall be not more than 10 IRHD at 70 °C. (158 °F.) or
more than 15 IRHD at 120 °C. (248 °F.), and there shall be no increase in hardness of
the cups; and (c) The cups shall show no disintegration as evidenced by stickiness,
blisters, or sloughing.
6.12 Stroking properties. Evaluate the lubricating properties, component compatibility,

resistance to leakage, and related qualities of a brake fluid by running one sample
according to the following procedures.
6.12.1 Summary of the procedure. Brake fluid is stroked under controlled conditions at
an elevated temperature in a simulated motor vehicle hydraulic braking system
consisting of three slave wheel cylinders and an actuating master cylinder connected by
steel tubing. Referee standard parts are used. All parts are carefully cleaned, examined,
and certain measurements made immediately prior to assembly for test. During the test,
temperature, rate of pressure rise, maximum pressure, and rate of stroking are specified
and controlled. The system is examined periodically during stroking to assure that
excessive leakage of fluid is not occurring. Afterwards, the system is torn down. Metal
parts and SBR cups are examined and remeasured. The brake fluid and any resultant
sludge and debris are collected, examined, and tested.
6.12.2 Apparatus and equipment. Either the drum and shoe type of stroking apparatus
26
(see Figure 1 of SAE Standard J1703b) except using only three sets of drum and shoe
assemblies, or the stroking fixture type apparatus as shown in Figure 2 of SAE
J1703Nov83, with the components arranged as shown in Figure 1 of SAE J1703Nov83.
The following components are required. (a) Brake assemblies. With the drum and shoe
apparatus: three drum and shoe assembly units (SAE RM–29a) consisting of three
forward brake shoes and three reverse brake shoes with linings and three front wheel
brake drum assemblies with assembly component parts. With stroking fixture type
apparatus: three fixture units including appropriate adapter mounting plates to hold
brake wheel cylinder assemblies. (b) Braking pressure actuation mechanism. An
actuating mechanism for applying a force to the master cylinder pushrod without side
thrust. The amount of force applied by the actuating mechanism shall be adjustable and
capable of applying sufficient thrust to the master cylinder to create a pressure of at
least 6895 kPa (1,000 p.s.i.) in the simulated brake system. A hydraulic gage or
pressure recorder, having a range of at least 0 to 6895 kPa (0 to 1,000 p.s.i), shall be
installed between the master cylinder and the brake assemblies and shall be provided
with a shutoff valve and with a bleeding valve for removing air from the connecting
tubing. The actuating mechanism shall be designed to permit adjustable stroking rates
of approximately 1,000 strokes per hour. Use a mechanical or electrical counter to
record the total number of strokes. (c) Heated air bath cabinet. An insulated cabinet or
oven having sufficient capacity to house the three mounted brake assemblies or
stroking fixture assemblies, master cylinder, and necessary connections. A
thermostatically controlled heating system is required to maintain a temperature of
70°±5 °C (158°±9 °F) or 120°±5 °C (248°±9 °F). Heaters shall be shielded to prevent
direct radiation to wheel or master cylinder. (d) Master cylinder (MC) assembly (SAE
RM–15a). One cast iron housing hydraulic brake system cylinder having a diameter of
approximately 28 mm. (11.8 inch) and fitted for a filler cap and standpipe (see
S6.13.2(e)). The MC piston shall be made from SAE CA360 copperbase alloy (half
hard). A new MC assembly is required for each test. (e) Filler cap and standpipe. MC
filler cap provided with a glass or uncoated steel standpipe. Standpipe must provide
adequate volume for thermal expansion, yet permit measurement and adjustment of the
fluid level in the system to ±3 ml. Cap and standpipe may be cleaned and reused. (f)
Wheel cylinder (WC) assemblies (SAE RM–14a). Three unused cast iron housing
straight bore hydraulic brake WC assemblies having diameters of approximately 28 mm
(11.8 inch) for each test. Pistons shall be made from unanodized SAE AA 2024
aluminum alloy. (g) Micrometer. Same as S6.6.2(d).
6.12.3 Materials. (a) Standard SBR brake cups. Six standard SAE SBR wheel cylinder
test cups, one primary MC test cup, and one secondary MC test cup, all as described in
S7.6, for each test. (b) Steel tubing. Double wall steel tubing meeting SAE specification
J527. A complete replacement of tubing is essential when visual inspection indicates
any corrosion or deposits on inner surface of tubing. Tubing from master cylinder to one
wheel cylinder shall be replaced for each test (minimum length .9 m.) Uniformity in
tubing size is required between master cylinder and wheel cylinder. The standard
master cylinder has two outlets for tubing, both of which must be used.
6.12.4 Preparation of test apparatus. (a) Wheel cylinder assemblies. Use unused wheel
cylinder assemblies. Disassemble cylinders and discard cups. Clean all metal parts with
ethanol (isopropanol when testing DOT 5 fluids). Inspect the working surfaces of all
27
metal parts for scoring, galling, or pitting and cylinder bore roughness, and discard all
defective parts. Remove any stains on cylinder walls with crocus cloth and ethanol
(isopropanol when testing DOT 5 fluids). If stains cannot be removed, discard the
cylinder. Measure the internal diameter of each cylinder at a location approximately 19
mm. (0.75 inch) from each end of the cylinder bore, taking measurements in line with
the hydraulic inlet opening and at right angles to this centerline. Discard the cylinder if
any of these four readings exceeds the maximum or minimum limits of 28.66 to 28.60
mm. (1.128 to 1.126 inch). Measure the outside diameter of each piston at two points
approximately 90°apart. Discard any piston if either reading exceeds the maximum or
minimum limits of 28.55 to 28.52 mm. (1.124 to 1.123 inch). Select parts to insure that
the clearance between each piston and mating cylinder is within 0.08 to 0.13 mm.
(0.003 to 0.005 inch). Use unused SBR cups. To remove dirt and debris, rinse the cups
in 90 percent ethyl alcohol for not more than 30 seconds and wipe dry with a clean lint-
free cloth. Discard any cups showing defects such as cuts, molding flaws, or blisters.
Measure the lip and base diameters of all cups with an optical comparator or
micrometer to the nearest 0.02 mm. (0.001 inch) along the centerline of the SAE and
rubber-type identifications and at right angles to this centerline. Determine base
diameter measurements at least 0.4 mm. (0.015 inch) above the bottom edge and
parallel to the base of the cup. Discard any cup if the two measured lip or base
diameters differ by more than 0.08 mm. (0.003 inch). Average the lip and base
diameters of each cup. Determine the hardness of all cups according to S7.4. Dip the
rubber and metal parts of wheel cylinders, except housing and rubber boots, in the fluid
to be tested and install them in accordance with the manufacturer’s instructions.
Manually stroke the cylinders to insure that they operate easily. Install cylinders in the
simulated brake system. (b) Master cylinder assembly. Use an unused master cylinder
and unused standard SBR primary and secondary MC cups which have been
inspected, measured and cleaned in the manner specified in S6.13.4(a), omitting
hardness of the secondary MC cup. However, prior to determining the lip and base
diameters of the secondary cup, dip the cup in test brake fluid, assemble on the MC
piston, and maintain the assembly in a vertical position at 23°±5 °C. (73.4°±9 °F.) for at
least 12 hours. Inspect the relief and supply ports of the master cylinder; discard the
cylinder if ports have burrs or wire edges. Measure the internal diameter of the cylinder
at two locations (approximately midway between the relief and supply ports and
approximately 19 mm. (0.75 inch) beyond the relief port toward the bottom or discharge
end of the bore), taking measurements at each location on the vertical and horizontal
centerline of the bore. Discard the cylinder if any reading exceeds the maximum or
minimum limits of 28.65 to 28.57 mm. (1.128 to 1.125 inch). Measure the outside
diameter of each end of the master cylinder piston at two points approximately 90°apart.
Discard the piston if any of these four readings exceed the maximum or minimum limits
of 28.55 to 28.52 mm. (1.124 to 1.123 inch). Dip the rubber and metal parts of the
master cylinder, except the housing and push rod-boot assembly, in the brake fluid and
install in accordance with manufacturer’s instructions. Manually stroke the master
cylinder to insure that it operates easily. Install the master cylinder in the simulated
brake system. (c) Assembly and adjustment of test apparatus. (1) When using a shoe
and drum type apparatus, adjust the brake shoe toe clearances to 1.0±0.1 mm
(0.040±0.004 inch). Fill the system with brake fluid, bleeding all wheel cylinders and the
pressure gage to remove entrapped air. Operate the actuator manually to apply a
pressure greater than the required operating pressure and inspect the system for leaks.
28
Adjust the actuator and/or pressure relief valve to obtain a pressure of 6895 kPa±345
kPa (1,000±50 p.s.i.). A smooth pressure stroke pattern is required when using a shoe
and drum type apparatus. The pressure is relatively low during the first part of the stroke
and then builds up smoothly to the maximum stroking pressure at the end of the stroke,
to permit the primary cup to pass the compensating hole at a relatively low pressure.
Using stroking fixtures, adjust the actuator and/or pressure relief valve to obtain a
pressure of 6895 kPa±345 kPa (1,000±50 p.s.i.). (2) Adjust the stroking rate to
1,000±100 strokes per hour. Record the fluid level in the master cylinder standpipe.
6.12.5 Procedure. Operate the system for 16,000±1,000 cycles at 23°±5 °C. (73.4°±9
°F.). Repair any leakage, readjust the brake shoe clearances, and add fluid to the
master cylinder standpipe to bring to the level originally recorded, if necessary. Start the
test again and raise the temperature of the cabinet within 6±2 hours to 120°±5 °C.
(248°±9 °F.). During the test observe operation of wheel cylinders for improper
functioning and record the amount of fluid required to replenish any loss, at intervals of
24,000 strokes. Stop the test at the end of 85,000 total recorded strokes. These totals
shall include the number of strokes during operation at 23°±5 °C. (73.4°±9 °F.) and the
number of strokes required to bring the system to the operating temperature. Allow
equipment to cool to room temperature. Examine the wheel cylinders for leakage.
Stroke the assembly an additional 100 strokes, examine wheel cylinders for leakage
and record volume loss of fluid. Within 16 hours after stopping the test, remove the
master and wheel cylinders from the system, retaining the fluid in the cylinders by
immediately capping or plugging the ports. Disassemble the cylinders, collecting the
fluid from the master cylinder and wheel cylinders in a glass jar. When collecting the
stroked fluid, remove all residue which has deposited on rubber and metal internal parts
by rinsing and agitating such parts in the stroked fluid and using a soft brush to assure
that all loose adhering sediment is collected. Clean SBR cups in ethanol (isopropanol
when testing DOT 5 fluids) and dry. Inspect the cups for stickiness, scuffing, blistering,
cracking, chipping, and change in shape from original appearance. Within 1 hour after
disassembly, measure the lip and base diameters of each cylinder cup by the
procedures specified in S6.13.4 (a) and (b) with the exception that lip or base diameters
of cups may now differ by more than 0.08 mm. (0.003 inch). Determine the hardness of
each cup according to S7.4. Note any sludge or gel present in the test fluid. Within 1
hour after draining the cylinders, agitate the fluid in a glass jar to suspend and uniformly
disperse sediment and transfer a 100 ml. portion of this fluid to a centrifuge tube and
determine percent sediment as described in S7.5. Allow the tube and fluid to stand for
24 hours, recentrifuge and record any additional sediment recovered. Inspect cylinder
parts, note any gumming or any pitting on pistons and cylinder walls. Disregard staining
or discoloration. Rub any deposits adhering to cylinder walls with a clean soft cloth
wetted with ethanol (isopropanol when testing DOT 5 fluids) to determine abrasiveness
and removability. Clean cylinder parts in ethanol (isopropanol when testing DOT 5
fluids) and dry. Measure and record diameters of pistons and cylinders according to
S6.13.4(a) and (b). Repeat the test if mechanical failure occurs that may affect the
evaluation of the brake fluid.
6.12.6 Calculation. (a) Calculate the changes in diameters of cylinders and pistons (see
S5.1.13(b)). (b) Calculate the average decrease in hardness of the seven cups tested,
as well as the individual values (see S5.1.13(c)). (c) Calculate the increases in base
29
diameters of the eight cups (see S5.1.13(e)). (d) Calculate the lip diameter interference
set for each of the eight cups by the following formula and average the eight values (see
S5.1.13(f)).
[(D1¥D2)/(D1¥D3)]*100=PERCENTAGE LIP DIAMETER INTERFERENCE SET
where: D1=Original lip diameter.

D2=Final lip diameter.
D3=Original cylinder bore diameter.
6.12.7 Pass/Fail Criteria. (a) Metal parts of the test system shall show no pitting or
etching to an extent discernible without magnification; (b) The change in diameter of any
cylinder or piston shall not exceed 0.13 mm. (0.005 inch); (c) The average decrease in
hardness of seven of the eight cups tested (six wheel cylinder and one master cylinder
primary) shall not exceed 15 IRHD. Not more than one of the seven cups shall have a
decrease in hardness greater than 17 IRHD; (d) None of the eight cups shall be in an
unsatisfactory operating condition as evidenced by stickiness, scuffing, blisters,
cracking, chipping, or other change in shape from its original appearance; (e) None of
the eight cups shall show an increase in base diameter greater than 0.90 mm (0.035
inch); (f) The average lip diameter set of the eight cups shall not be greater than 65
percent. (g) During any period of 24,000 strokes, the volume loss of fluid shall not
exceed 36 milliliters; (h) The cylinder pistons shall not freeze or function improperly
throughout the test; (i) The total loss of fluid during the 100 strokes at the end of the test
shall not exceed 36 milliliters; (j) The fluid at the end of the test shall show no formation
of gels; (k) At the end of the test the amount of sediment shall not exceed 1.5 percent
by volume; and (l) Brake cylinders shall be free of deposits that are abrasive or that
cannot be removed when rubbed moderately with a nonabrasive cloth wetted with
ethanol.
6.13 Container information. Each container with information marked directly on the
container surface or on a label (labels) affixed to the container pursuant to S5.2.2.2 or
S5.2.2.3 is subjected to the following procedure: (a) If the container has a label affixed
to it, make a single vertical cut all the way through the label with the container in the
vertical position. (b) Immerse the container in the same brake fluid or hydraulic system
mineral oil contained therein for 15 minutes at room temperature (23±5 °C; 73.4±9 °F).
(c) Within 5 minutes after removing the container from the fluid or oil, remove excess
liquid from the surface of the container by wiping with a clean dry cloth.
6.13.1 Pass/Fail Criteria . The information required by this section shall be legible to an
observer having corrected visual acuity of 20/40 (Snellen ratio) at a distance of 305 mm,
and any label affixed to the container in compliance with this section shall not be
removable without its being destroyed or defaced.
6.14. Marking and Labeling Inspection.
6.14.1 Each packager of brake fluid shall furnish the information specified in paragraphs
(a) through (g) by clearly marking it on each brake fluid container or on a label (labels)
permanently affixed to the container, in any location except a removable
30
part such as a lid. (a) Certification that the brake fluid conforms to § 571.116. (b) The
name of the packager of the brake fluid, which may be in code form. (c) The name and
complete mailing address of the distributor. (d) A serial number identifying the packaged
lot and date of packaging. (e) Designation of the contents as ‘‘DOT—MOTOR VEHICLE
BRAKE FLUID’’ (Fill in DOT 3, DOT 4, DOT 5 SILICONE BASE, or DOT 5.1 NON-
SILICONE BASE as applicable). (f) The minimum wet boiling point in Fahrenheit of the
DOT brake fluid in the container. (g) The following safety warnings in capital and lower
case letters as indicated: (1) FOLLOW VEHICLE MANUFACTURER’S
RECOMMENDATIONS WHEN ADDING BRAKE FLUID. (2) KEEP BRAKE FLUID
CLEAN AND DRY. Contamination with dirt, water, petroleum products or other
materials may result in brake failure or costly repairs. (3) STORE BRAKE FLUID ONLY
IN ITS ORIGINAL CONTAINER. KEEP CONTAINER CLEAN AND TIGHTLY CLOSED
TO PREVENT ABSORPTION OF MOISTURE. (4) CAUTION: DO NOT REFILL
CONTAINER, AND DO NOT USE FOR OTHER LIQUIDS. (Not required for containers
with a capacity in excess of 19 L.)
6.14.2 Each packager of hydraulic system mineral oil shall furnish the information
specified in paragraphs (a) through (e) by clearly marking it on each brake fluid
container or on a label (labels) permanently affixed to the container, in any location
except a removable part such as a lid. (a) The name of the packager of the hydraulic
system mineral oil, which may be in code form. (b) The name and complete mailing
address of the distributor. (c) A serial number identifying the packaged lot and date of
packaging. (d) Designation of the contents as ‘‘HYDRAULIC SYSTEM MINERAL OIL’’
in capital letters at least 3 mm high. (e) The following safety warnings in capital and
lower case letters as indicated: (1) FOLLOW VEHICLE MANUFACTURER’S
RECOMMENDATIONS WHEN ADDING HYDRAULIC SYSTEM MINERAL OIL. (2)
Hydraulic System Mineral Oil is NOT COMPATIBLE with the rubber components of
brake systems designed for use with DOT brake fluids. (3) KEEP HYDRAULIC
SYSTEM MINERAL OIL CLEAN. Contamination with dust or other materials may result
in brake failure or costly repair. (4) CAUTION: STORE HYDRAULIC SYSTEM
MINERAL OIL ONLY IN ITS ORIGINAL CONTAINER. KEEP CONTAINER CLEAN
AND TIGHTLY CLOSED. DO NOT REFILL CONTAINER OR USE OTHER LIQUIDS.
(The last sentence is not required for containers with a capacity in excess of 19 L.)
6.14.3 If a container for brake fluid or hydraulic system mineral oil is not normally visible
but designed to be protected by an outer container or carton during use, the outer
container or carton rather than the inner container shall meet the labeling requirements
of 6.14.2 or 6.14.3, as appropriate.
S7. Auxiliary test methods and reagent standards. S7.1 Distilled water. Nonreferee
reagent water as specified in ASTM D1193– 70, ‘‘Standard Specifications for Reagent
Water,’’ or water of equal purity.
S7.2 Water content of motor vehicle brake fluids. Use analytical methods based on
ASTM D1123–59, ‘‘Standard Method of Test for Water in Concentrated Engine
Antifreezes by the Iodine Reagent Method,’’ for determining the water content of brake
fluids, or other methods of analysis yielding comparable results. To be for use, such
other method must measure the weight of water added to samples of the SAE RM–66–
31
04 and TEGME Compatibility Fluids within ±15 percent of the water added for additions
up to 0.8 percent by weight, and within ±5 percent of the water added for additions
greater than 0.8 percent by weight. The SAE RM–66–04 Compatibility Fluid used to
prepare the samples must have an original ERBP of not less than 205 °C (401 °F) when
tested in accordance with S6.1. The SAE TEGME fluid used to prepare the samples
must have an original ERBP of not less than 240 °C (464 °F) when tested in accordance
with S6.1.
S7.3 Ethanol. 95 percent (190 proof) ethyl alcohol, USP or ACS, or Formula 3–A
Specially Denatured Alcohol of the same concentration (as specified at 27 CFR 21.35).
For pretest washings of equipment, use approximately 90 percent ethyl alcohol,
obtained by adding 5 parts of distilled water to 95 parts of ethanol.
S7.4 Measuring the hardness of SBR brake cups. Hardness measurements on SBR
wheel cylinder cups and master cylinder primary cups shall be made by using the
following apparatus and the following procedure.
S7.4.1 Apparatus. (a) Anvil. A rubber anvil having a flat circular top 20±1 mm.
(13.16±1.16 inch) in diameter, a thickness of at least 9 mm. (3.8 inch) and a hardness
within 5 IRHDs of the SBR test cup. (b) Hardness tester. A hardness tester meeting the
requirements for the standard instrument as described in ASTM D1415–68, ‘‘Standard
Method of Test for International Hardness of Vulcanized Natural and Synthetic
Rubbers,’’ and graduated directly in IRHD units.
S7.4.2 Procedure. Make hardness measurements at 23°±2 °C. (73.4°±4 °F.).

Equilibrate the tester and anvils at this temperature prior to use. Center brake cups lip
side down on an anvil of appropriate hardness. Following the manufacturer’s operating
instructions for the hardness tester, make one measurement at each of four points 6
mm from the center of the cup and spaced 90°apart. Average the four values, and
round off to the nearest IRHD.
S7.5 Sediment by centrifuging. The amount of sediment in the test fluid shall be
determined by the following procedure.
S7.5.1 Apparatus. (a) Centrifuge tube. Cone-shaped centrifuge tubes conforming to the
dimensions given in Figure 6, and made of thoroughly annealed glass. The graduations
shall be numbered as shown in Figure 6, and shall be clear and distinct. Scale-error
tolerances and smallest graduations between various calibration marks are given in
Table V and apply to calibrations made with airfree water at 20 °C. (68 °F.).
32
Table V – Calibration Tolerances for 8-Inch Centrifugue Tube

Range, ml Subdivision, ml Volume Tolerance, ml
0 to 0.1 0.05 ±0.02
Above 0.1 to 0.3 0.05 ±0.03
Above 0.3 to 0.5 0.05 ±0.05
Above 0.5 to 1 0.10 ±0.05
Above 1 to 2 0.10 ±0.10
Above 2 to 3 0.20 ±0.10
Above 3 to 5 0.5 ±0.20
Above 5 to 10 1. ±0.50
Above 10 to 25 5. ±1.00
Above 25 to 100 25. ±1.00
(b) Centrifuge. A centrifuge capable of whirling two or more filled centrifuge tubes at a
speed which can be controlled to give a relative centrifugal force (r.c.f.) between 600
and 700 at the tip of the tubes. The revolving head, trunnion rings, and trunnion cups,
including the rubber cushion, shall withstand the maximum centrifugal force capable of
being delivered by the power source. The trunnion cups and cushions shall firmly
support the tubes when the centrifuge is in motion. Calculate the speed of the rotating
head using this equation:
r.p.m. = 265[√25.4*r.c.f./d]
where: r.c.f. - Relative centrifugal force

33
d - Diameter of swing, in millimeters, measured between tips of opposing

tubes when in rotating position.
Table VI shows the relationship between diameter, swing, relative centrifugal force
(r.c.f.), and revolutions per minute.
Table VI – Rotation Speeds for Centrifugues of Various Diameters

Diameter of swing in millimetersa r.p.m. at 600 r.c.f r.p.m. at 700 r.c.f.
483 1490 1610
508 1450 1570
533 1420 1530
559 1390 1500
a
Measured in millimeters between tips of opposite tubes when in rotating position.
S7.5.2 Procedure. Balance the corked centrifuge tubes with their respective trunnion
cups in pairs by weight on a scale, according to the centrifuge manufacturer’s
instructions, and place them on opposite sides of the centrifuge head. Use a dummy
assembly when one sample is tested. Then whirl them for 10 minutes, at a rate
sufficient to produce a r.c.f. between 600 and 700 at the tips of the whirling tubes.
Repeat until the volume of sediment in each tube remains constant for three
consecutive readings.
S7.5.3 Calculation. Read the volume of the solid sediment at the bottom of the
centrifuge tube and report the percent sediment by volume. Where replicate
determinations are specified, report the average value.
S7.6 Standard styrene-butadiene rubber (SBR) brake cups. SBR brake cups for testing
motor vehicle brake fluids shall be manufactured using the following formulation:
Formulation of Rubber Compunds

Ingredient Parts by weight
SBR type 1503 100
Oil furnace black (NBS 378) 40
Zinc oxide (NBS 370) 5
Sulfur (NBS 371) 0.25
Stearic Acid (NBS 372) 1
1 n-tertiary butyl-2-benzothiazole sulfenamide (NBS 384) 1
Symmetrical dibetanaphthyl-p-phenylenediamine 1.5
Dicumyl peroxide (40 percent on precipitated CaCO3)b 4.5
Total 153.25
a
Philprene 1503 has been found suitable.
b
Use only within 90 days of manufacture and store at temperature below 27 °C. (80 °F.).
NOTE: The ingredients labeled (NBS) must have properties identical with those supplied by the
National Bureau of Standards.
Compounding, vulcanization, physical properties, size of the finished cups, and other
details shall be as specified in appendix B of SAE J1703b. The cups shall be used in
34
testing brake fluids either within 6 months from date of manufacture when stored at
room temperature below 30 °C. (86 °F.) or within 36 months from date of manufacture
when stored at temperatures below minus 15 °C. (+5 °F.). After removal of cups from
refrigeration they shall be conditioned base down on a flat surface for at least 12 hours
at room temperature in order to allow cups to reach their true configuration before
measurement.
S7.7 Isopropanol. ACS or reagent grade.
TEST PERFORMANCE
The test program shall be conducted by more than one person in the laboratory to
assure that monitoring of the program can be continuous, complete, and expeditious,
unless automated equipment is used. Test technicians shall be aware of all
requirements for each test phase which is being performed.
TEST SAMPLE IDENTIFICATION AND STORAGE
All containers of a sample used for any single test shall be identically labeled and shall
have the same lot code. Each container shall be tightly sealed after a small
quantity of fluid has been removed, to prevent changes in fluid characteristics which
might adversely affect test results.
The following data shall be recorded for each test sample. If different lot codes are
used for each test, the codes shall be recorded on the data entry for that test.
A. Name of manufacturer, distributor, packager, and the mailing address if this

information is on the container.
B. Packaged lot and date of packaging (may be in a coded form).
C. DOT grade.
All containers of test samples must be stored in a clean, dry, security storage area to
prevent deterioration of the fluids in any manner which may affect test results.
RECORDING OF DATA
Test data shall be recorded on permanent strip charts, circular recording charts, or other
acceptable printout media. Where permanent trace recording is not required, data will
be recorded on standard report forms. Changes or corrections shall be made by
drawing a line through the original entry, which must still remain legible, and adding the
change alongside.
PARTS DATA AND SUMMARY OF RESULTS
On the brake fluid information section of the Compliance Data Summary in the final
report, each space shall be filled out. Where information is not available, write "None".
35
The summary of results shall indicate pass or fail of each phase of the test program as
supported by the results tabulated on the test data sheets.
TEST DATA REPORTING FORMS
Data will be submitted on the Test Data Sheet forms specified for use in the final report.
Data will be typed before the sheets are submitted.
13. POST TEST REQUIREMENTS
The contractor shall re-verify all instrumentation and check data sheets and
photographs. Make sure that data is recorded in all applicable data blocks on every
Data Sheet.
14. REPORTS
14.1 MONTHLY STATUS REPORTS
The contractor shall submit a monthly Test Status Report and an Equipment Status
Report to the COTR. The Equipment Status Report shall be submitted until all items of
equipment are disposed of. Samples of the required Monthly Status Reports are
contained in the report forms section.
14.2 TEST FAILURE
Any indication of a test failure shall be communicated by telephone to the COTR within
1 working day with written notification mailed within 2 working days. A Notice of Test
Failure (see report forms section) with a copy of the particular compliance test data
sheet(s) and preliminary data plot(s) shall be included. In the event of a test failure, a
post test calibration check of some critically sensitive test equipment and
instrumentation may be required for verification of accuracy. The necessity for the
calibration shall be at the COTR's discretion and shall be performed without additional
costs to the OVSC.
14.3 FINAL TEST REPORTS
14.3.1 COPIES
In the case of a test failure, SEVEN copies of the Final Test Report shall be submitted
to the COTR for acceptance within three weeks of test completion. The Final Test
Report format to be used by all contractors can be found in the attachment.
Where there has been no indication of a test failure, FOUR copies of each Final Test
Report shall be submitted to the COTR within three weeks of test completion.
Payment of contractor's invoices for completed compliance tests may be withheld until
the Final Test Report is accepted by the COTR. Contractors are requested to NOT
submit invoices before the COTR is provided copies of the Final Test Report.
36
14. REPORTS....Continued
Contractors are required to submit the first Final Test Report in typed draft form within
two weeks after the compliance test is conducted. The contractor and the COTR will
then be able to discuss the details of both test conduct and report content early in the
compliance test program.
Contractors are required to PROOF READ all Final Test Reports before submittal to the
COTR. The OVSC will not act as a report quality control office for contractors. Reports
containing a significant number of errors will be returned to the contractor for correction,
and a "hold" will be placed on invoice payment for the particular test.
14.3.2 REQUIREMENTS
The Final Test Report, associated documentation (including photographs) are relied
upon as the chronicle of the compliance test. The Final Test Report will be released to
the public domain after review and acceptance by the COTR. For these reasons, each
final report must be a complete document capable of standing by itself. The contractor
should use detailed descriptions of all compliance test events. Any events that are not
directly associated with the standard but are of technical interest should also be
included. The contractor should include as much detail as possible in the report.
Instructions for the preparation of the first three pages of the final test report are
provided below for the purpose of standardization.
14.3.3 FIRST THREE PAGES
A. FRONT COVER
A heavy paperback cover (or transparency) shall be provided for the protection of
the final report. The information required on the cover is as follows:
(1) Final Report Number such as 116-ABC-XX-001
where C
116 is the FMVSS tested
ABC are the initials for the laboratory
XX is the Fiscal Year of the test program
001 is the Group Number (001 for the 1st brand,
002 for the 2nd brand, etc.)
(2) Final Report Title And Subtitle such as
SAFETY COMPLIANCE TESTING FOR FMVSS 116
Motor Vehicle Brake Fluid

****************
ACE Distributors
Little Tiger DOT 3 H.D. Brake Fluid
(3) Contractor's Name and Address such as

37
COMPLIANCE TESTING LABORATORIES, INC.

4335 West Dearborn Street
Detroit, Michigan 48090-1234
NOTE: DOT SYMBOL WILL BE PLACED BETWEEN ITEMS (3) AND (4)
(4) Date of Final Report completion
(5) The words "FINAL REPORT"
(6) The sponsoring agency's name and address as follows
U. S. DEPARTMENT OF TRANSPORTATION
National Highway Traffic Safety Administration
Enforcement
Office of Vehicle Safety Compliance
Room 6115 (NVS-222)
38
B. FIRST PAGE AFTER FRONT COVER
A disclaimer statement and an acceptance signature block for the COTR shall be
provided as follows
This publication is distributed by the U. S. Department of

Transportation, National Highway Traffic Safety Administration, in the
interest of information exchange. The opinions, findings and
conclusions expressed in this publication are those of the author(s)
and not necessarily those of the Department of Transportation or the
National Highway Traffic Safety Administration. The United States
Government assumes no liability for its contents or use thereof. If
trade or manufacturers' names or products are mentioned, it is only
because they are considered essential to the object of the publication
and should not be construed as an endorsement. The United States
Government does not endorse products or manufacturers.
Prepared By:
Approved By:
Approval Date:
FINAL REPORT ACCEPTANCE BY OVSC:
Accepted By:
Acceptance Date
39
C. SECOND PAGE AFTER FRONT COVER

A completed Technical Report Documentation Page (Form DOT F1700.7) shall
be completed for those items that are applicable with the other spaces left blank.
Sample data for the applicable block numbers of the title page follows.
Block 1 C REPORT NUMBER
116-ABC-XX-001
Block 2 C GOVERNMENT ACCESSION NUMBER
Leave blank
Block 3 C RECIPIENT'S CATALOG NUMBER
Leave blank
Block 4 C TITLE AND SUBTITLE
Final Report of FMVSS 116 Compliance Testing of Little Tiger DOT 3

Heavy Duty Brake Fluid
Block 5 C REPORT DATE
March 1, 20XX
Block 6 C PERFORMING ORGANIZATION CODE
ABC
Block 7 C AUTHOR(S)
John Smith, Project Manager / Bill Doe, Project Engineer
Block 8 C PERFORMING ORGANIZATION REPORT NUMBER
ABC-DOT-XXX-001
Block 9 C PERFORMING ORGANIZATION NAME AND ADDRESS
ABC Laboratories
405 Main Street
Detroit, MI 48070-1234
40
Block 10 C WORK UNIT NUMBER
Leave blank
Block 11 C CONTRACT OR GRANT NUMBER
DTNH22-XX-D-12345
Block 12 C SPONSORING AGENCY NAME AND ADDRESS
US Department of Transportation
Enforcement
Office of Vehicle Safety Compliance (NVS-222)
400 Seventh Street, SW, Room 6115
Block 13 C TYPE OF REPORT AND PERIOD COVERED
Final Test Report

Feb. 15 to Mar. 15, 20XX (Start Date to Completion Date)
Block 14 C SPONSORING AGENCY CODE
NVS-222
Block 15 C SUPPLEMENTARY NOTES
Leave blank
Block 16 C ABSTRACT
Compliance tests were conducted on Little Tiger DOT 3 H.D. Brake Fluid
in accordance with the specifications of the Office of Vehicle Safety
Compliance Test Procedure No. TP-116-XX for the determination of
FMVSS 116 compliance. Test failures identified were as follows:
None
NOTE: Above wording must be shown with appropriate changes made for
a particular compliance test. Any questions should be resolved with the
COTR.
41
Block 17 C KEY WORDS
Compliance Testing
Safety Engineering
FMVSS 116
Block 18 C DISTRIBUTION STATEMENT
Copies of this report are available from C

Technical Information Services
Room PL403 (NPO-405)
Telephone No.: 202-366-2588
Block 19 C SECURITY CLASSIFICATION OF REPORT
Unclassified
Block 20 C SECURITY CLASSIFICATION OF PAGE
Unclassified
Block 21 C NUMBER OF PAGES
Add appropriate number
Block 22 C PRICE
Leave blank
42
14.3.4 TABLE OF CONTENTS
Final test report Table of Contents shall include the following:
A. Section 1 C Purpose of Compliance Test
B. Section 2 C Compliance Test Data Summary
C. Section 3 C Test Data
D. Section 4 C Test Failure Details (if applicable)
E. Appendix A CInterpretations or Deviations From FMVSS 116
F. Appendix B CTest Equipment List and Calibration Information
G. Appendix C C Photographs
43
15. DATA SHEETS
DATA SHEET 1
SUMMARY OF TEST RESULTS
GROUP NO.: ; LAB.:
BRAKE FLUID BRAND:
DISTRIBUTOR:
ADDRESS:
LOT I.D./PACKAGE CODE: ; DOT GRADE:
INDICATE P - PASS OR F - FAIL PASS FAIL
1. Boiling Point (ERBP) _____
2. Wet ERBP _
3. Viscosity at -40ΕF
Viscosity at 212ΕF
4. pH Value
5. Fluid Stability
6. Corrosion:
Weight Change, mg/cm5

Tinned Iron
Steel
Aluminum
Cast Iron
Brass
Copper
Pitting or Roughening
Jelling of Mixture
Crystalline Deposit
Sedimentation, % by volume
Disintegration of cups
pH after test
Decrease in cup hardness
Increase in cup diameter
(Continued on next page)

44
15. DATA SHEETS....Continued
7. Fluidity and Appearance at Low Temperature:

Crystallization at -40ΕF
Crystallization at -58ΕF
Sedimentation at -40ΕF
Air Bubble Rise Time at -40ΕF
8. Water Tolerance:
Stratification at -40ΕF
Stratification at 140ΕF
Sedimentation at 140ΕF
9. Compatibility:
Stratification, Crystallization
Sedimentation, Sludging
10. Resistance to Oxidation:

Weight loss, mg/cm5
Aluminum
Cast iron
Pitting and etching
Gum deposit on strips
11. Effect on SBR Cups:

Hardness increase at 158ΕF
Hardness increase at 248Ε
Hardness decrease at 158ΕF
Hardness decrease at 248Ε
Base diameter change at 158ΕF
Base diameter change at 248Ε
(Continued on next page)

45
12. Effect on SBR Cups....Continued

Disintegration at 158ΕF
Disintegration at 248Ε
13. Stroking Properties
14. Color:
Clear to Amber (DOT 3 & 4)

Purple (DOT 5)
15. Container Sealing:
Resealable
Tamper-Proof Feature
16. Certification, Marking and Labeling:
Certification - -
FMVSS 116 Statement
Marking - -
Lot I.D. Code Shown
Grade Type Shown
Minimum Wet ERBP Shown
Complete Mailing Address
Labeling - -
Safety Warning Statements
Removability
Legibility
COMMENTS:
46
DATA SHEET 2
TEST DATA
GROUP NO.: ; LAB.:
BRAKE FLUID BRAND: ; DOT-
Test Start Complete

No. Test Description Test Requirements Test Results Date Date
1* Boiling Point (ERBP) Min. = 401ΕF ΕF
2* Wet ERBP Min. = 284ΕF ΕF
3* Viscosity at -40ΕF Max. = 1500 cSt cSt
Viscosity at 212ΕF Min. = 1.5 cSt cSt
4 pH Value 7 to 11.5
5 Fluid Stability: Max. Change
High Temperature 5.4 + ∆ ΕF
Chemical 5.4 + ∆ ΕF
∆ = + 0.05ΕF/Ε that ∆=
BP is > 437ΕF ΕF
6 Corrosion:
Weight Change, mg/cm5
Tinned Iron Max. = 0.2
Steel Max. = 0.2
Aluminum Max. = 0.1
Cast Iron Max. = 0.2
Brass Max. = 0.4
Copper Max. = 0.4
Pitting/Roughening None
Jelling of mixture None
Crystalline deposits None
Sedimentation, % by vol. Max. = 0.10%
Disintegration of cups None
pH after Test 7 to 11.5
Decrease in cup hardness Max. = 15 IRHD

47
Increase in cup hardness Max. = 0.055"
Test Start Complete

7 Fluidity and Appearance at -40ΕF -58ΕF

Low Temperature:
Stratification None None
Sedimentation None None
Air Bubble Rise Time - sec. 10 max 35 max
8 Water Tolerance: -40ΕF 140ΕF
Sedimentation, % None .15 max
Air Bubble Rise Time - sec. 10 max
9 Compatibility: -40ΕF 140ΕF
Crystallization None None
Sedimentation, Sludging, % None .05 max
10 Resistance to Oxidation:
Weight Loss, mg/cm5
Aluminum Max. = 0.05
Cast Iron Max. = 0.30
Pitting/Etching None
Gum Deposits on Strips Trace
11 Effect on SBR Cups: 158ΕF 248ΕF
Hardness Increase None None
Hardness Decrease, IRHD 10 max 15 max
Base Diameter Change - in. 0.006 to 0.006 to

0.055 0.055
Disintegration None None
12 Stroking Properties N/P N/P

48
Test Start Complete

13 Color:
DOT 3 & DOT 4 Clear to Amber
DOT 5 Purple
14 Container Sealing: Resealable
Tamper-Proof Feature
15 Certification: FMVSS 116 Statement
Marking - Lot ID Code Shown
Marking - Grade Type Shown
Marking - Min Wet ERBP Shown
Marking - Mailing Address Complete
Labeling Safety Warning

Statements
Removability
Legibility
*
Values shown are for DOT-3 Brake Fluid ONLY. Values for DOT-4 and DOT-5 Brake
Fluid are shown below:
DOT-4 DOT-5
TEST 1 446ΕF 500ΕF
TEST 2 311ΕF 356ΕF
TEST 3 1800cSt 900cSt

REMARKS:
RECORDED BY: ; DATE:
APPROVED BY:
49
DATA SHEET 3
STROKING TEST DATA
GROUP NO.: ; LAB.:
BRAKE FLUID BRAND:
Test Start Complete

12 Stroking Properties: 248ΕF 248ΕF
Metal
Pitting/Etching Max. = None
Diameter Change:
Piston/Cylinder Max. = 0.005"
Cylinder/Piston Oper. Not Frozen
Cups
Hard Decrease, Average Max= 15 IRHD
Hard Decrease, One Max= 17 IRHD
Operating Condition Satisfactory
Base Diameter, Increase Max. = 0.035"
Lip Diameter, Set Average Max. = 65%
Fluid
Volume Loss/24,000 St Max. = 36 ml
Volume Loss/last 100 St Max. = 36 ml
Gel Max. = None
Sediment Volume Max. = 1.5%
Abrasive Deposits Max. = None
REMARKS:

50
APPROVED BY:
16. FORMS
LABORATORY NOTICE OF TEST FAILURE TO OVSC
FMVSS 116 TEST DATE:
LABORATORY:
CONTRACT NO.: ; DELV. ORDER NO.:
LABORATORY PROJECT ENGINEER'S NAME:
TEST SPECIMEN DESCRIPTION - -
BRAND NAME & GRADE TYPE:
MANUFACTURER OR DISTRIBUTOR:
LABEL INFO.:
PART NO.:
TEST FAILURE DESCRIPTION:
FMVSS REQUIREMENT, PARAGRAPH ' :
NOTIFICATION TO NHTSA (COTR):
DATE: BY:
REMARKS:
51
16. FORMS....Continued
MONTHLY TEST STATUS REPORT
FMVSS 116
DATE OF REPORT:
DATE FINAL
GROUP BRAKE FLUID TEST START TEST COMPLETE PASS REPORT
NO. BRAND AND GRADE DATE DATE / SUBMITTED
FAIL
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016
017
018
019
020
REMARKS:
52
16. FORMS....Continued
MONTHLY INVENTORY STATUS REPORT
FMVSS 116
DATE OF REPORT:
NO. OF
GROUP GRAD SPECIMEN CONDITION DATE
NO. BRAND NAME E S LOT NUMBERS OF RECEIVED
TYPE RECVD. SAMPLE
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016
017
018
019
020
REMARKS:
53
APPENDIX A
INTERPRETATIONS OR DEVIATIONS FROM FMVSS 116

54
APPENDIX B
EQUIPMENT LIST AND CALIBRATION SCHEDULES
TESTING LABORATORY:
NOTE: Information to be included for each item of test instrumentation is as follows:
EQUIPMENT DESCRIPTION:
EQUIPMENT MANUFACTURER:
TYPE AND/OR MODEL:
SERIAL NUMBER:
LIMITS:
ACCURACY:
FREQUENCY OF CALIBRATION:
EXPIRATION OF CALIBRATION:
USED ON TEST NUMBER:
REMARKS:
APPROVED BY:
55
APPENDIX C
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TP-116-04

April 22, 2005

U.S. DEPARTMENT OF TRANSPORTATION

NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

LABORATORY TEST PROCEDURE

Motor Vehicle Brake Fluids

OVSC LABORATORY TEST PROCEDURE NO. 116

4. GOOD HOUSEKEEPING ................................................................................. 2

5. TEST SCHEDULING AND MONITORING ....................................................... 3

6. TEST DATA DISPOSITION.............................................................................. 3

7. GOVERNMENT FURNISHED PROPERTY (GFP)........................................... 3

8. CALIBRATION OF TEST INSTRUMENTS....................................................... 3

9. PHOTOGRAPHIC DOCUMENTATION ............................................................ 4

11. PRETEST REQUIREMENTS ........................................................................... 6

12. COMPLIANCE TEST EXECUTION.................................................................. 7

13. POST TEST REQUIREMENTS........................................................................ 35

14. REPORTS ........................................................................................................ 35

14.1. MONTHLY STATUS REPORTS............................................................ 35

14.2. APPARENT TEST FAILURE ................................................................. 35

14.3. FINAL TEST REPORTS........................................................................ 35

14.3.1. COPIES ........................................................................... 35

14.3.3. FIRST THREE PAGES.................................................... 36

14.3.4. TABLE OF CONTENTS................................................... 42

15. DATA SHEETS................................................................................................. 43

16. FORMS ............................................................................................................ 50

REVISION CONTROL LOG

TEST PROCEDURE FMVSS 116

REV. DATE AMENDMENT EFFECTIVE DESCRIPTION

04 April 22, 69 FR 67654 Jan. 18, 2005 Deletion of evaporation test.

1. PURPOSE AND APPLICATION

The OVSC Laboratory Test Procedures, prepared for use by independent

A. Equilibrium Reflux Boiling Point (ERBP)

NO INDIVIDUALS, OTHER THAN CONTRACTOR PERSONNEL, SHALL BE

5. TEST SCHEDULING AND MONITORING

6. TEST DATA DISPOSITION

7. GOVERNMENT FURNISHED PROPERTY (GFP) AND TEST SAMPLES

TEST SAMPLE IDENTIFICATION AND STORAGE

Brand X Heavy Duty Brake Fluid; Lab Group #00X

8. CALIBRATION OF TEST INSTRUMENTS

B. All measuring instruments and standards shall be calibrated by the contractor, or

(1) Date of calibration

D. A written calibration procedure shall be provided by the contractor

(1) Type of equipment, manufacturer, model number, etc.

Cavity or sac on the surface of a brake cup.

HYDRAULIC SYSTEM MINERAL OIL

Visible erosion of a portion of the outer surface of a brake cup.

SILICONE BASE BRAKE FLUID (SBBF)

11. PRETEST REQUIREMENTS

IN-HOUSE TEST PROCEDURE

TEST DATA LOSS

A. Temperature 75ΕF ∀ 15ΕF

Continuous recording of environmental temperature and relative humidity of the testing

TEST PERSONNEL PERFORMANCE

Personnel supervising and/or performing the compliance test program shall be

RECORDING OF TEST DATA

12. COMPLIANCE TEST EXECUTION

FIG. 1. BOILING POINT TEST APPARATUS

FIG. 2. DETAIL OF 100 ML SHORT-NECK FLASK