1、 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. JUNE 2016 Page 1 of 10 NAVISTAR, INC. Material, Parts, and Process Specifications
2、 (MPAPS) NUMBER: MPAPS F-6012 Former Designation: TMS-6012 TITLE: Power Steering High Pressure Hose CURRENT REV No.: 1606 DATE: June 2016 WRITTEN/EDITED BY: J. Goldschmidt APPROVED BY: R. Goluch SUPERSEDES: Rev. 1210 October 2012 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION
3、This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applicability of regulatory
4、limits prior to use. 1.0 APPLICATION This specification outlines the minimum requirements for a hose reinforced with a wire braid which is used in power steering pressure systems or equivalent hydraulic systems. The operating temperature shall be -40 to +150C (-40 to +302F). 2.0 SCOPE This specifica
5、tion covers the general, property and performance, quality, source approval and quality control requirements for a hose purchased with end fittings and used as a flexible connector in power steering systems requiring hose with 1/2“ or smaller ID (-8 dash size and smaller). The hose shall be classifi
6、ed according to the maximum working pressure of the hydraulic system, as follows: Nominal Type Maximum Working Pressure Bend Radius ID MPa psi cm in (-4) in III 34.5 5000 7.6 3.0 I 17.2 2600 12.7 5.0 (-8) 1/2 in II Obsolete (See Note) III 21.0 3000 12.7 5.0 I 18.0 2600 12.5 4.9 (-6) 3/8 in II Obsole
7、te (See Note) III 21.0 3000 6.5 2.6 I 25.0 2600 9.0 3.5 (-3) 3/16 in II Obsolete (See Note) III 21.0 3000 4.5 1.8 Note Do not use Type II in new designs. For existing drawings that specify Type II, Type I or III may be substituted. 2.1 Restricted Chemical Substances Effective January 1, 2007, all pr
8、oduct supplied to the requirements of this specification must comply with the requirements of the MPAPS B-50 specification. NUMBER: MPAPS F-6012 TITLE: Power Steering High Pressure Hose REVISION: 1606 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permis
9、sion from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. JUNE 2016 Page 2 of 10 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following Specifications, Standards, and Reg
10、ulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 NAVISTAR MPAPS F-2 ASTM D471 CFR Title 29, Part 1910 NAVISTAR MPAPS G-20 ASTM D865 NAVISTAR Manufacturing Std. MS-D-13 NAVISTAR MPAPS G-22 ASTM D1418 NAVISTAR Engineering Design Std A-16 NAVISTAR MPAPS G-9009
11、 ASTM D2240 NAVISTAR MPAPS A-0 Part II NAVISTAR MPAPS P-9543 ISO 8033 NAVISTAR MPAPS A-45 ASTM B117 MIL-L-2104 NAVISTAR MPAPS B-21 ASTM D380 SAE J343 NAVISTAR MPAPS B-50 ASTM D395 SAE J517 NAVISTAR MPAPS B-6810 ASTM D412 4.0 REQUIREMENTS 4.1 Hose Construction The hose shall be constructed with a smo
12、oth bore inner tube of suitable synthetic rubber reinforced with plies of braided fabric and/or steel and covered with a black (unless otherwise specified) oil and weather resistant synthetic rubber or textile cover. 4.2 Fittings 4.2.1 Material Fittings shall be made from steel, Code 0-115, per MPAP
13、S A-0, Part II, and meet the dimensional requirements shown on the engineering drawing. 4.2.2 Finish Unless otherwise specified: a) Zinc plating, Class 6A, per MPAPS G-20 b) Zinc-nickel plating, Class ZNi-C2 or ZNi-C3, per MPAPS G-22 For crimped socket products, use the corrosion requirements from s
14、ection 4.7.8.2. 4.3 Tubing 4.3.1 Material Tubing will be steel tubing, single-wall, electric-resistance welded (ERW) low carbon steel, Grade F, per MPAPS A-45 Part II with flash height controlled to 380 m (0.015 inch) max. 4.3.2 Tubing Finish 4.3.2.1 Paint Steel tubing will be painted per MPAPS G-90
15、09, Class II_ (NAV 0001 BLK). 4.3.2.2 Optional finish Unless otherwise specified: a) Zinc plating, Class 8A, MPAPS G-20 b) Zinc-nickel plating, Class ZNi-C2 or ZNi-C3, per MPAPS G-22 4.3.3 Interior Surfaces: Plating on the inside of tubes and fittings is not required. NUMBER: MPAPS F-6012 TITLE: Pow
16、er Steering High Pressure Hose REVISION: 1606 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. JUNE 2016 Page 3 of 10 4.3.4 Tube De
17、sign Steering tube designs are dependent upon the space available in the engine compartment, the proximity of the parts to be connected, and need to avoid interference with other engine compartment components and connectors. Tube design uses the XYZ-Tube program in the Unigraphic Grip Program System
18、. All radii are specified to the centerline of the tube and all dimensions are given from the centerline and intersecting points. Three sizes of steel tubing are used (see Table 1 for tube size, wall thickness and bend radii). Terminology and Design Factors for Tube Bending are indicated in Figures
19、1 and 2. Recommended Centerline Bend Radii are identified in Table 1; variation from these radii must be approved by Navistar Engineering. In cases where the dimension is shown as a range, the larger number is preferred for ease of manufacture and cost, but the smaller number may be used when design
20、 constraints require its use. TABLE 1. STANDARD SIZES AND BEND RADII FOR STEEL TUBING Size Outer Diameter Wall Thickness Centerline Bend Radii 6.35 mm (1/4 inch) 0.89 mm (.035 inch) 12.70 mm (0.50 inch) 12.70 mm (1/2 inch) 1.24 mm (.049 inch) 25.40 mm (1.00 inch) 12.70 mm (1/2 inch) 2.08 mm (.082 in
21、ch) 25.40 mm (1.00 inch) Figure 1. Tube Bending Terminology Figure 2. Design Factors for Tube Bending NUMBER: MPAPS F-6012 TITLE: Power Steering High Pressure Hose REVISION: 1606 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Te
22、chnical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. JUNE 2016 Page 4 of 10 4.4 Brazing BCu (Copper), BAg (Silver), BCuZn (Brass) at the producers option. 4.5 Dimensions Hose shall meet the dimensional requirements of SAE 100R1, SAE 100R2, SAE 100R16 or SA
23、E 100R17 as outlined in SAE J517 (Hydraulic Hose Standard). If SAE requirements for wire reinforcement cannot be met, wire reinforcement diameter shall be 17.78 mm. 4.6 Property And Performance Requirements Unless otherwise specified, all tests will be performed per SAE J343 and indicated ASTM Test
24、Methods. See Table 2 for material property requirements of the tube and cover. NUMBER: MPAPS F-6012 TITLE: Power Steering High Pressure Hose REVISION: 1606 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Supp
25、liers are required to assume all patent liability. 2016 by Navistar, Inc. JUNE 2016 Page 5 of 10 TABLE 2 PROPERTIES OF TUBE AND COVER PROPERTIES OF TUBE AND COVER TEST METHOD (ASTM) TUBE Type I COVER* Type I TUBE Type III TUBE Type III Alt. Material COVER* Type III COVER* Type III Alt. Material POLY
26、MER D1418 CM (CPE) CM (CPE) CM (CPE) ORIGINAL PROPERTIES: HARDNESS, DUROMETER, SHORE A D2240 60-75 65-75 55-75 80-90 65-70 75-80 TENSILE STRENGTH, MPA (PSI) D412, DIE C 7.0(1015) 10(1450) 6.0(870) 6.0(870) 7.0(1015) 7.0(1015) ELONGATION, PERCENT MIN D412, DIE C 250 250 250 130 175 450 100% MODULUS,
27、MPa (PSI), MIN D412, DIE C Report* Report* Report* Report* Report* Report* HEAT AGING CONDITIONS AND CHANGE LIMITS HOURS EXPOSURE D865 168 168 168 168 168 168 TEMPERATURE, C (F) D865 135(275) 135(275) 150 (302) 150 (302) 150 (302) 150 (302) HARDNESS, DUROMETER, SHORE A D2240 0 to 18 0 to 20 0 to 10
28、0 to 10 0 to 10 0 to 25 TENSILE STRENGTH, % MAX D412, DIE C -35 -20 -25 -25 -20 -20 ELONGATION, % MAX D412, DIE C -65 -60 -40 -75 -40 -100 100% MODULUS, % MAX D412, DIE C Report* Report* Report* Report* Report* Report* HEAT AGING, 1000 HOURS TEMPERATURE, C (F) D865 120(248) 120(248) 150 (302) 150 (3
29、02) 150 (302) 150 (302) ELONGATION, % MIN D412, DIE C 120 120 120 120 120 120 HARDNESS, MAX D2240 85 85 85 85 85 85 PROPERTIES AFTER IMMERSION IN MPAPS B-21 15W40 Engine oil (P/N 2643576R1, Shell Rimula Premium IFF, 54267) HOURS D471 N/A 70 70 70 500 70 TEMPERATURE, C (F) D471 135(275) 135(275) 150
30、(302) 150 (302) 150 (302) 150 (302) HARDNESS, DUROMETER, SHORE A D2240 20 20 -15 -15 -15 -15 TENSILE STRENGTH, % MAX D412, DIE C -40 -40 -20 -20 -20 -20 ELONGATION, % MAX D412, DIE C -40 -40 -20 -40 -20 -79 100% MODULUS, % MAX D412, DIE C Report* Report* Report* Report* Report* Report* VOLUME CHANGE
31、, shrink/swell, % D471 -10 TO +70 -10 TO +70 -3 TO +10 -3 TO +15 -3 TO +10 -3 TO +13 PROPERTIES AFTER IMMERSION IN MPAPS B-6810 Power Steering Fluid (P/N 2643472R1, Shell 20631) HOURS D471 N/A 70 70 70 500 70 TEMPERATURE, C (F) D471 135(275) 135(275) 150 (302) 150 (302) 150 (302) 150 (302) HARDNESS,
32、 DUROMETER, SHORE A D2240 20 20 -15 -15 -15 -15 TENSILE STRENGTH, % MAX D412, DIE C -40 -40 -20 -20 -20 -20 ELONGATION, % MAX D412, DIE C -40 -40 -20 -35 -20 -70 100% MODULUS, % MAX D412, DIE C Report* Report* Report* Report* Report* Report* VOLUME CHANGE, shrink/swell, % D471 -10 TO +70 -10 TO +70
33、-3 TO +10 -3 TO +28 -3 TO +10 -3 TO +26 COMPRESSION SET HOURS 70 70 70 70 70 70 TEMPERATURE C (F) 125(257) 125(257) 150(302) 150(302) 200(302) 200(302) PERCENT MAX, PLIED D395 25 50 50 55 50 85 * Report value determined in qualification and validation testing. * - cover requirements may not be appli
34、cable to textile covered hose. N/A not applicable NUMBER: MPAPS F-6012 TITLE: Power Steering High Pressure Hose REVISION: 1606 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume
35、all patent liability. 2016 by Navistar, Inc. JUNE 2016 Page 6 of 10 4.7 Hose/Hose Assemblies Performance All hose and/or hose assemblies qualified to this specification shall meet the following requirements and shall be tested according to SAE J343 or ASTM D 380 unless otherwise indicated. 4.7.1 Pro
36、of Pressure 4.7.1.1 Method Assemblies shall be maintained at a min proof pressure equal to twice the max working pressure. Oil or water may be used. The hose assembly shall be held at the test pressure for 30-60 seconds. 4.7 1.2 Required No visible leakage. 4.7.2 Burst Pressure 4.7.2.1 Method Assemb
37、lies shall be pressurized to leakage or failure. The pressure rise shall be at a steady rate so that the minimum burst pressure of four times the maximum working pressure is reached within 15-30 seconds. 4.7.2.2 Required No leakage or other indication of failure below the min burst pressure. 4.7.3 I
38、mpulse Test 4.7.3.1 Method Test per SAE J343 except as indicated below. Hose assemblies shall be installed in an impulse test machine using a 90 or 180 bend which shall conform to the minimum bend radius. Pressure Variation: Type I, 0-.69 to 23.4 MPa (0-100 to 3400 psi) Type III, 0-.70 to 28.0 MPa (
39、0-150 to 4060 psi) Test Fluid: MPAPS B-6810 Power Steering Fluid (P/N 2643472R1, Shell 20631); MPAPS B-21 15W-40 Engine oil (P/N 2643576R1, Shell Rimula Premium IFF, 54267); or approved equivalent. Fluid Temperature: Type I - 135 3C (275 5F) Type III - 150 3C (302 5F) Impulse Cycle Rate: Report plea
40、se contact Materials Engineering for prior approval. 4.7.3.2 Required Assemblies shall withstand 500,000 cycles without leakage or malfunction. 4.7.4 Low Temperature Flexibility 4.7.4.1 Method Hose assemblies shall be subjected to a temperature of -40C (-40F) for a period of 24 hours in a straight p
41、osition. While still at the specified temperature, the hose shall be evenly and uniformly bent through an angle of 180 around a mandrel whose diameter is twice the minimum bend radius. Mandrel shall be at the test temperature. Flexing shall be accomplished within four seconds for fabric reinforced h
42、ose and 8-12 seconds for wire reinforced hose. Samples shall then be returned to room temperature and proof pressure tested, and split longitudinally for inspection. 4.7.4.2 Required Hose shall not fracture or visibly show any cracks, checks or breaks in the tube or cover. 4.7.5 Tensile Test - Assem
43、bly 4.7.5.1 Required Assemblies shall withstand a minimum tensile load of 5340 N (1200 lbf) -8 size without separation of the fittings or rupturing the tube. NUMBER: MPAPS F-6012 TITLE: Power Steering High Pressure Hose REVISION: 1606 This document is restricted and may not be sent outside Navistar,
44、 Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. JUNE 2016 Page 7 of 10 4.7.6 Adhesion Test 4.7.6.1 Method Unless otherwise indicated, adhesion tests shall be conducted using the apparatus and met
45、hods in accordance with ASTM D 413, static mass method at 23C 2C (73F 3.6F). The test pieces shall be prepared in accordance with ISO 8033. 4.7.6.2 Required A force of not less than 44.5 N (10 lbf) shall be required to separate the bond between adjacent layers of a 2.5 cm (1 in) wide ring section of
46、 the hose. 4.7.7 Length Change 4.7.7.1 Method Measure length at zero and at max working pressure specified at room temperature. 4.7.7.2 Required Hose shall not change in length more than +2 or -4%. 4.7.8 Corrosion Resistance 4.7.8.1 Method Perform 480 hrs salt spray testing per ASTM B117 on hose ass
47、emblies. 4.7.8.2 Required No permanent corrosion damage that would result in not being able to service the assembly (i.e., must be able to disassemble fittings) is allowed. 5.0 QUALITY Parts and assemblies will meet the cleanliness requirements of MPAPS F-2. All hose produced to this specification w
48、ill be clean, free of dirt, grease, and contamination. All rubber debris from cutting and processing will be removed. Any internal release agents shall be flushed from the inside of the hose. Parts shall be free of voids and/or reinforcement splices. The O.D. in the area of any bend shall not be les
49、s than 85% of the nominal tubing O.D. (15% max flatness). The wall thickness of the tubing after bending shall not be less than 70% of the original dimension. The walls of the tubing (interior and exterior) in the area of the bend shall not contain surface defects which exceed 0.25 mm (0.010 in) in depth. 6.0 QUALIFICATION Material and processes submitted for app
