NAVISTAR MPAPS F-2-2016 Fluid System Cleanliness Requirements.pdf

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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 7 NAVISTAR, INC. Material, Parts, and Process Specifications (

2、MPAPS) NUMBER: MPAPS F-2 Former Designation: CEMS F-2 TITLE: Fluid System Cleanliness Requirements CURRENT Rev. No.: 1606 DATE: JUNE 2016 WRITTEN/REVISED BY: J. Goldschmidt APPROVED BY: R. Goluch SUPERSEDES: 1506 - June 2015 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This

3、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 limit

4、s prior to use. 1.0 SCOPE This specification defines test procedures and cleanliness requirements of finished components ready for assembly. Components ready for assembly have been thoroughly cleaned to remove foreign debris remaining on or inside the parts after manufacture and/or parts as-received

5、 at the assembly plant. 1.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the MPAPS B-50 specification. 2.0 INTRODUCTION This specification covers general requirements, property and perfor

6、mance requirements, identification, quality, packing and shipping, and source approval and quality control requirements. 3.0 CONTENTS PAGE REFERENCE DOCUMENTS 1 REQUIREMENTS 2 QUALITY 5 SOURCE APPROVAL AND QUALITY CONTROL 5 SHIPPING AND HANDELING 6 DESIGNATION ON DRAWINGS 6 TECHNICAL INFORMATION 4.0

7、 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 CFR Title 29, Part 1910 ISO 16232-6 NAVISTAR Manufactu

8、ring Std. MS-D-13 EMD 991 ISO 16232-7 NAVISTAR Engineering Design Std A-16 ISO 4406 SAE J1726 NAVISTAR MPAPS B-50 ISO 4407 SAE J2064 AEB 21.112 ISO 16232-3 NUMBER: MPAPS F-2 TITLE: Fluid System Cleanliness Requirements REVISION: 1606 This document is restricted and may not be sent outside Navistar,

9、Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. JUNE 2016 Page 2 of 7 5.0 REQUIREMENTS 5.1 Components The five levels of component cleanliness defined below are generally specified for the followi

10、ng types of applications and components: Level I: Component surfaces in contact with high pressure fuel or oil system (EMD 991 Level AA) Level II: Component surfaces in contact with filtered lubricating oil or filtered fuel (EMD 991 Level A) Level III: Internal surfaces of Intercoolers, Intake pipin

11、g and component surfaces in contact with lubricating oil, inlet air, and exhaust gas (EMD 991 Level B) Level IV: HVAC A/C Hose Assemblies Level V: Component surfaces in contact with cooling water (EMD 991 Level C) Specified applications will appear as a noted requirement on individual part drawings.

12、 Finished components shall meet the following cleanliness requirements as shown in the table below when tested according to the procedure defined in this specification. Components containing ferrous material shall exhibit maximum residual magnetism of 0.0005 Tesla (5 Gauss). This is low enough to pr

13、eclude the adherence of fine metallic particles. Cleanliness Level Level I Level II Level III Level IV Level V Max containment weight per unit surface area 2.0 mg per 15.5 in2 (0.01 m2) up to 15 mg max per passage 2.5 mg per 15.5 in2 (0.01 m2) up to 15 mg max per passage 3.0 mg per 15.5 in2 (0.01 m2

14、) up to 25 mg max per passage 3.0 mg per 15.5 in2 (0.01 m2) up to 25 mg max per passage for 5.0 mg per 15.5 in2 (0.01 m2) up to 50 mg max per passage X 0.012 in (300 Micron) 0.048 in (1200 Micron) 0.048 in (1200 Micron) 0.048 in (1200 Micron) 0.08 in (2000 Micron) Y 0.006 in (150 Micron) 0.02 in (50

15、0 Micron) 0.048 in ( 1200 Micron) 0.048 in ( 1200 Micron) 0.08 in (2000 Micron) Z 0.006 in (150 Micron) 0.006 in (150 Micron) 0.008 in (200 Micron) 0.008 in (200 Micron) 0.008 in (200 Micron) Levels I, II III and V: Up to 4 particles* max per passage may exceed “X” dimension Level IV No particle* ma

16、y exceed any dimension shown All Levels: No particle* may exceed the Y or Z dimensions shown. TABLE 1: COMPONENT PARTICLE SIZE REQUIREMENTS * Particles for dimensional analysis include abrasive particles such as sand, scale, cleaning shot, weld slag and spatter, machining chips, or particles not eas

17、ily broken with a probe. Maximum particle size applies to length, width, or thickness. NUMBER: MPAPS F-2 TITLE: Fluid System Cleanliness Requirements REVISION: 1606 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standa

18、rds. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. JUNE 2016 Page 3 of 7 5.2 Method of Test The procedure and apparatus used are described in SAE J1726. A basic procedure based upon the SAE method is listed below and may be used for convenience. 5.2.1 Apparatus 5.2.1.

19、1 Millipore Filter Assembly 5.2.1.2 Vacuum Filtering Flask 5.2.1.3 5 micron and 0.5 micron Millipore Filter paper. 5.2.1.4 Suitable Solvent, such as n-pentane, hexane, petroleum ether, or a clean wash solution at same concentration as washer using deionized water. 5.2.1.5 Pressure tank with filter (

20、similar to Millipore Model # XX6700L05) 5.2.2 Procedure: Method 1 5.2.2.1 Wash all apparatus carefully to avoid introducing extraneous contaminants. 5.2.2.2 Clean the exterior of test components as necessary to avoid introducing extraneous contaminants. 5.2.2.3 Pre-filter the solvent to be used thro

21、ugh a 0.5 micron Millipore filter paper. Store the filtered solvent in a clean container until it is used. 5.2.2.4 Dry a 5 micron Millipore filter (with grid) in an oven at 100C (212F) for 15 minutes. Cool to room temperature and weigh to the nearest 0.1 mg. 5.2.2.5 Thoroughly flush the designated t

22、est surfaces with the filtered solvent, carefully collecting the solvent and debris into a clean beaker or container. 5.2.2.6 Pass this collected mixture through the 5 micron filter from Step 4, using the Millipore filter assembly, the vacuum filtering flask, and a vacuum source. The used solvent ma

23、y be discarded or refiltered through a 0.5 micron Millipore filter for reuse. 5.2.2.7 Remove the filter paper from the filter assembly. Dry in an oven at 100C (212F) for 15 minutes, cool in a dessicator, and reweigh to the nearest 0.1 mg to determine if the contaminant weight requirement is met. 5.2

24、.2.8 Using optical magnification equipment, examine the recovered debris to determine if the particle size limitation has been met. 5.2.3 Procedure: Method 2 (ISO 16232-3) 5.2.3.1 Equip the test liquid dispenser with one or more spray nozzle(s), suitable for the surfaces to be pressure rinsed. 5.2.3

25、.2 Adjust the pressure of the test liquid to obtain a jet of sufficient power to remove and transport the particles from the controlled surfaces without degrading or dissolving the surface material of the component. 5.2.3.3 Rinse the controlled surfaces carefully with test liquid sprayed on through

26、the nozzle, ensuring that the whole controlled surface has been swept by the jet in order to extract the particles from the component(s). Collect the extraction liquid in either a single or several sampling containers. 5.2.3.4 Collect all recovered extraction liquids and particles. Carefully rinse t

27、he collection equipment and collect all of the accumulated particles in a clean sampling container. 5.2.3.5 Analyze the extraction liquid in accordance with ISO 16232-6 (gravimetric analysis) or (particle sizing and counting) ISO 16232-7 and label the result obtained as S1. 5.2.3.6 Repeat 5.2.3.3 to

28、 5.2.3.5 twice more on the same component, using, when necessary, a different container for each extraction liquid volume and label the result obtained as S2 and S3. NOTE: The extractions should be made directly one after the other. NUMBER: MPAPS F-2 TITLE: Fluid System Cleanliness Requirements REVI

29、SION: 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 4 of 7 5.2.3.7 Validate the contamination extraction pro

30、cedure to ensure its efficiency as follows: a) For each of the three samples analyzed in 5.2.3.5 and 5.2.3.6, establish the total mass of contaminants and/or the total number of particles. For the particle count, this is applicable to the total number of particles larger than the smallest particle s

31、ize specified in the inspection document. This particle size shall be chosen to enable counting significant numbers of particles; b) Divide the result of the last sample (S3) by the sum of all the values obtained in 5.2.3.7 a); c) If the value obtained is less than or equal to 10%, the end-point is

32、reached and the extraction is completed. NOTE 1: This procedure enables the extraction curve to be drawn and the end-point (u 0.10) to be demonstrated (see Figure 1). NOTE 2: The cleanliness level of the component is the sum of the extractions. NOTE 3: In some cases (for example: a very low contamin

33、ation level, difficulties in extracting particles, inappropriate blank level, etc.) the extraction curve may not be of the form seen in Figure 1. If this is the case, it is ensured that all extraction parameters have been properly investigated. d) If the value obtained is 0.10, a further extraction

34、is necessary. Repeat stages 5.2.3.3 to 5.2.3.7 until the last sample (Sn) produces a result u 0.10 of the total of the whole samples ( 10100 =1 ) 5.2.3.8 If six extractions have been performed without reaching a value u 0.10, then the extraction parameters are not suitable and shall be modified. The

35、n repeat operations 5.2.3.3 to 5.2.3.7 with new parameters on a new component. 5.2.3.9 If this criterion is not fulfilled, set up a new extraction protocol and validates it according to 5.2.3 or apply another extraction method as defined in ISO 16232-2, ISO 16232-4 and ISO 16232-5. FIGURE 1: EXAMPLE

36、 OF EXTRACTION CURVE 5.3 Particle Count Method Used for Components That Contact Diesel Exhaust Fluid (DEF): All connections and lines to and from the dosing supply module must be internally clean when assembled and meet the cleanliness specifications in Table 2 using the ISO 16232 test method. Fiber

37、s and fluffs are NUMBER: MPAPS F-2 TITLE: Fluid System Cleanliness Requirements 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 Na

38、vistar, Inc. JUNE 2016 Page 5 of 7 long thin particles that can flow through filter media and plug dosing components downstream. To avoid contamination by fibers and fluffs, the use of towels, paper, or cloth to clean components is prohibited. TABLE 2: PARTICLE COUNT METHOD FOR COMPONENTS THAT CONTA

39、CT DIESEL EXHAUST FLUID 5.4 Additional Procedures; Requirements In addition to the general procedure outlined above, the following detailed procedures must be developed and maintained by the plant laboratory for each component to be tested. These procedures must include: 1. Indicate surfaces and pas

40、sages to be flushed. 2. Total area of surfaces and passages to be flushed. 3. Visual examination, if required. 4. Flushing method including quantity of solution, exposure time, and any special apparatus required. Use of solution will require additional step of establishing a standard weight for the

41、dried filter paper after soaking with solution to compensate for residue that will remain on the filter paper. 5. Specific requirements to be checked and reported for each component being evaluated, i.e., one or more of the specific requirements for maximum particle size and containment weight. 6. I

42、nformation to be included in the report. 6.0 QUALITY All product supplied shall meet the level of cleanliness specified per application as shown in section 5.1 and Table 1. 7.0 SOURCE APPROVAL AND QUALITY CONTROL 7.1 Supplier Requirements All suppliers to Navistar are required to be registered to IS

43、O 9001 Quality System Requirements. Navistar will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must maintain their certification with an accredited registrar and must fur

44、nish copies of registration certificates to their Corporate Buyer upon request. NUMBER: MPAPS F-2 TITLE: Fluid System Cleanliness Requirements REVISION: 1606 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Su

45、ppliers are required to assume all patent liability. 2016 by Navistar, Inc. JUNE 2016 Page 6 of 7 7.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all respects to those samples which were approved by the purchaser. No changes in formul

46、ation or processing practices are permitted without approval. In the event that changes in material, properties, processing practices, construction, color, or labeling of the product are required, the supplier shall notify Materials Engineering and Purchasing and Supplier Development of the proposed

47、 change(s). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updated Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 7.3 Process Control The supplier shall

48、either perform and report results of tests on specific lots of parts produced using ISO 9001 or TS-16949 guidelines, or provide statistical evidence of the lot having been produced in a state of statistical control and with a process capable of providing all required properties. The part supplier an

49、d the quality control manager of the using Navistar plant may determine testing and reporting requirements on specific products. 8.0 SHIPPING AND HANDLING Shipping and identification shall be in accordance with Navistar Manufacturing Standard MS-D-13. 9.0 DESIGNATION ON DRAWINGS Specification number Parts required to meet th