NAVISTAR MPAPS F-30-2017 Coolant Hose (Former Designation CEMS D-30).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. 2017 by Navistar, Inc. APRIL 2017 Page 1 of 22 NAVISTAR, INC. Material, Parts, and Process Specifications

2、 (MPAPS) NUMBER: MPAPS F-30 Former Designation: CEMS D-30 TITLE: Coolant Hose CURRENT REV No.: 1704 DATE: Apr. 2017 WRITTEN/EDITED BY: M. Ghaddar APPROVED BY: R. Goluch SUPERSEDES: 1504 April 2015 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may involve ha

3、zardous 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 limits prior to use. 1.0 APPLICAT

4、ION This specification covers general requirements, property and performance requirements, identification, quality, packing and shipping, and source approval and quality control requirements for coolant hoses used on Navistar vehicles as assembled in Navistar plants and for field service application

5、s. 2.0 SCOPE This specification covers requirements of straight and preformed hose intended for use as radiator hose, heater hose and other flexible conduits for engine cooling systems. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this spe

6、cification must comply with the requirements of the MPAPS B-50 specification. 2.2 Hose Connections Effective April 2012 on all releases subsequent to this date, hose dimensions and tolerances shall meet MPAPS F-1. 3.0 CONTENTS PAGE REFERENCE DOCUMENTS 2 CLASSIFICATION AND CONSTRUCTION 2 CONVERSION O

7、F PREVIOUS SPECIFICATIONS 3 GENERAL REQUIREMENTS 4 QUALITY 5 METHODS OF TEST 9 SOURCE APPROVAL AND QUALITY CONTROL 12 DESIGNATION ON DRAWINGS 13 PACKING, SHIPPING, AND IDENTIFICATION 13 TECHNICAL INFORMATION 14 TABLES 15-20 NUMBER: MPAPS F-30 TITLE: Coolant Hose REVISION: 1704 This document is restr

8、icted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2017 by Navistar, Inc. APRIL 2017 Page 2 of 22 4.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all refe

9、renced standards shall apply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 NAVISTAR TMS-6018 ASTM D 412 NAVISTAR Supplier Packing and Shipping Std. D-13 NAVISTAR TMS-6025 ASTM D 413 NAVISTAR Engineering De

10、sign Std. A-16 NAVISTAR TMS-6026 ASTM D 471 CFR Title 29, Part 1910 NAVISTAR MPAPS-6032 ASTM D 573 ASME/ANSI Y 14.5M-1994* NAVISTAR MPAPS-6036 ASTM D 624 NAVISTAR MPAPS A-9 ASTM A 764 ASTM D 1171 NAVISTAR MPAPS A-37 ASTM B 117 ASTM D 1193 NAVISTAR MPAPS B-1 ASTM D 380 ASTM D 2240 NAVISTAR MPAPS DT-9

11、 ASTM D 395 SAE J20 NAVISTAR TMS-6017 NAVISTAR MPAPS B-50 SAE J1684 NAVISTAR MPAPS P-9543 NAVISTAR MPAPS F-2 ASTM D 1418 NAVISTARMPAPS F-1058 NAVISTAR MPAPS C-1059 ASTM D 5827 ASTM D 3321 ASTM D 1287 ASTM D 6130 NAVISTAR MPAPS F-1 *Conformance to the 1994 version of ASME Y14.5M is required. 5.0 CLAS

12、SIFICATION AND CONSTRUCTION Grade designations are used to specify the tube and cover stocks. Suffix designations are used to specify the manufacturing method used to make the hose and the reinforcement fibers allowed. Note: New hoses released to this specification shall be limited to 1A, 1BF, 1BDF

13、2A, 2BF and 2BDF. Alternate constructions shown below are not allowed. 1BF and 2BF can be supplied as a substitution to 1A and 2A respectively with engineering approval as documented by an SREA (Supplier Request for Engineering Approval). 5.1 Grades 5.1.1 Grade 1 This grade covers a premium, long li

14、fe hose used in engine coolant systems (including heater) and clean air supply lines. This hose is not recommended for use in fuel, oil, or hydraulic fluid applications. The tube and cover stocks shall be made from an EPDM (a terpolymer of ethylene, propylene and diene, see ASTM D 1418 for naming co

15、nventions), similar to SAE J20 Type EC Class D-1. It is generally preferred that peroxide cured compounds are used, especially for 1B constructions, but it is not required at this time. The tube shall be zinc free and the cover shall be non-blooming. 5.1.2 Grade 2 This grade covers a silicone based

16、hose used in engine coolant systems (including heater) and clean air supply lines. This hose may be used where extreme temperature conditions exist that justify its high cost or where a customer requires its use. This hose is not recommended for use in fuel, oil, or hydraulic fluid applications. The

17、 tube and cover stocks shall be made from polysiloxane elastomers, similar to SAE J20 Class A. 5.1.3 Grade 3 This grade covers a lower cost version of Grade 1 where long life or heat resistance is not an issue. Typical applications may include bus heater hoses or lower (cold-side) radiator hoses for

18、 medium duty trucks and buses. This shall not be used in heavy duty or severe service application requiring or advertising long life. NUMBER: MPAPS F-30 TITLE: Coolant Hose REVISION: 1704 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Cor

19、porate Technical Standards. Suppliers are required to assume all patent liability. 2017 by Navistar, Inc. APRIL 2017 Page 3 of 22 5.2 Suffix Letters 5.2.1 Suffix A bulk, straight hose through 38 mm (1 inch) ID suitably reinforced with ply or plies of spiraled, knitted or braided aramid yarn. Grade 3

20、 hoses may be constructed from lower cost reinforcements, such as Rayon, with prior Materials Engineering approval. 5.2.2 Suffix B Preformed hose reinforced with ply or plies of knitted or spiraled aramid yarn. Grade 3 hoses may be constructed from lower cost reinforcements, such as Rayon, with prio

21、r Materials Engineering approval. 5.2.3 Suffix C Straight hose over 25.4 mm (1 inch) ID reinforced with wrapped plies of woven cord nylon or aramid fabric. A Grade 3 construction is not available at this time. 5.2.4 Suffix D- Spring Required. If D suffix is not designated on the drawing, a spring sh

22、all not be supplied. 5.2.5 Suffix X No longer used, all notes referring to Suffix X shall meet Suffix Y requirements. 5.2.6 Suffix Y This is an additional requirement that may be added to Suffix B construction to limit the amount of swell allowed and requires a lock stitch knit to be used when using

23、 a knitted reinforcement or other non-expanding types of reinforcement. The use of this requirement may limit design flexibility further than described in MPAPS F-1 and should be thoroughly reviewed with the supplier prior to release. 5.2.7 Suffix Z This is an additional requirement for high impulse

24、 and torsion applications. Typically, this is required for large bore engine applications using short hose connectors with pipe. The suffix requires a meta-aramid or an approved hybrid para-meta aramid reinforcement to meet the increased requirements. 5.2.8 Suffix PG This is a place holder for the d

25、evelopment of hoses in neat propylene glycol coolant systems. Contact Materials Engineering for further information and requirements for this application. 5.2.9 Suffix E Peroxide cure only. This is recommended for big bore engines. 5.2.10 Suffix F Increased operating condition hoses for Internationa

26、l Big Bore engines. This includes the requirements of Suffix E (if required), Y and Z plus higher burst and operating pressure requirements. 5.2.11 Suffix U When a suffix U or TMS-6047 is reverenced contact Navistar Materials Engineering for requirements. 5.3 Conversion of Previous Specifications Pr

27、evious versions of CEMS/MPAPS D-30 convert to the new format as follows: Types A, B and C directly convert to suffixes A, B and C. Classes 1, 2, 4, and 5 become Grade 1 unless specified for an oil or fuel application - then see MPAPS-6032 Type 1. For Class 3 use Grade 2. TMS-6026 becomes Grade 1A. T

28、MS-6017 is Grade 1B. TMS-6025 is Grade 1C. TMS-6018 Type I is Grade 2C. TMS-6018 Type II is Grade 2B. TMS-6018 Type III is Grade 2A or 2B as appropriate. 5.4 Spring Insert (Vacuum side only) If necessary, the use of a steel spring insert shall be specified on the Engineering drawing or by use of the

29、 D suffix. Unless otherwise specified, the steel spring insert shall be formed of a wire having a minimum diameter of 1.57 mm (a larger diameter wire may be used at the suppliers discretion). The spring shall exhibit a 25 mm pitch (a pitch of up to 35 mm is acceptable with larger diameter wire) and

30、an O.D. approximately 3.0 mm less than the nominal I.D. of the hose. The length of the spring NUMBER: MPAPS F-30 TITLE: Coolant Hose REVISION: 1704 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers ar

31、e required to assume all patent liability. 2017 by Navistar, Inc. APRIL 2017 Page 4 of 22 shall be such that a minimum of 60 mm of free hose length remains on each end of the hose for ease of assembly and clamping. The wire shall be cold drawn carbon steel spring wire, Type 1 or Type 2, per MPAPS A-

32、9, mechanically-coated or electroplated with zinc after forming, or cold drawn carbon steel galvanized spring wire, Class I or Class II, per ASTM A 764. Galvanized coating weight shall be such as to withstand 96 hours salt spray test (as per ASTM B 117) without visible red rust. 5.4.1 Stainless stee

33、l may be used as an optional material to the galvanized steel listed above. The wire shall be 18-8 stainless steel, full hard, MPAPS A-37. 5.4.2 Any other material must be approved by the NAVISTAR Materials Engineering Group before use. 6.0 GENERAL REQUIREMENTS Materials and hoses shall meet the app

34、ropriate requirements of SAE J20. Test methods are listed in section 8.0 and shall conform to the practices of SAE J20 and ASTM D 380 as well as good lab practices and statistical techniques as appropriate. 6.1 Properties of Tube and Cover Properties of the tube and cover shall conform to the requir

35、ements shown in Table I when tested in accordance with “Methods of Test”, Section 8. Minimum tube thickness will be 0.06 in. (1.59 mm). Minimum cover thickness will be 0.03 in. (0.80 mm). For thin cover layers (below 0.045 in.), it is allowable to use ASTM cured sheets per ASTM procedure due to incr

36、eased variability with thinner rubber test pieces. 6.2 Hose Requirements Hose purchased to this specification shall meet the following requirements when tested in accordance with “Methods of Test”, Section 8. 6.2.1 Kink Resistance (Suffix A only) Hose outside diameter will not collapse more than 25

37、percent. 6.2.2 Vacuum Collapse (Suffix A only) Hose outside diameter will not collapse more than 25 percent. 6.2.3 Cold Flexibility Specimens will not crack, check or break. 6.2.4 Burst Strength Hose tested as received and after 168 hour (see Table I for temperature) oven aging will meet the minimum

38、 burst strength requirements in Tables III and IV. 6.2.5 Bloom No visible bloom when examined with the naked eye as compared to a control sample. The sample shall remain reasonably unchanged in appearance throughout the cycle. 6.2.6 Electrochemical Resistance (Grades 1 it is currently expected to be

39、 around 15%. When no suffix requirement is given, this requirement is report only. When suffix “Y” is specified, no more than 8% of hot swell is allowed. 6.2.9 Chemical Interaction Test by either method using each of the long-life coolants C, D and F listed in Table V. If PG is specified, then this

40、test shall be run only using that fluid. Test shall utilize hose from production process and include any process aids or lubricants that would be present in production hoses. No more than 8% precipitate and chemical analysis limits as shown in Table XV. Color photography showing agitated fluids in c

41、lear glass containers compared to un-aged coolant samples shall be included in the report. As these limits and requirements are still under evaluation and development, full and complete analytical reports should be submitted for review to NAVISTAR Materials Engineering prior to committing additional

42、 work. While this work is intended primarily for qualification, re-qualification of materials to this specification should be completed periodically (per agreement with the supplier and NAVISTAR). The full interaction is not required to be completed for re-qualification; a limited test schedule may

43、be done with agreement of NAVISTAR Materials Engineering. Note: PG are required to perform this test but chemical analysis requirements have not been determined. Submit fluids for evaluation to Navistar Materials Engineering. 6.3 Hose Assembly Requirements Hose and hose assemblies purchased to this

44、specification shall meet the following requirements when tested in accordance with “Methods of Test”, Section 8. Test assemblies shall be made with production materials whenever possible. See MPAPS F-1 for guidance on pipe end/bead configurations. Contact NAVISTARs Design Responsible Engineer for as

45、sistance in identifying production parts to be used in the test assembly. Inspect, measure and report the relevant dimensions of the parts used in the test. The test assembly should represent manufacturing assembly conditions, lubricants and torque rates/values as closely as possible. Clamp hose usi

46、ng production clamps and torque values with one test set to the minimum torque and one test set to maximum of torque. When appropriate, measure and report the residual torque of each fastener. When crimp assembly techniques are used, crimp separate sets of test samples to minimum and maximum crimp d

47、iameters. 6.3.1 Cold Leakage Hoses tested with selected production fittings and clamps shall not have a greater than 3% weight change. No visible fluid leakage shall be permitted during the test. 6.3.2 Fitting Insertion-Extraction Force Required: Less than 188N, an approved assembly lubricant may be

48、 used. See MPAPS F-1. 6.3.3 Impulse - Vibration Durability Suffix Z only This method and requirement is under development. Hoses tested with selected production fittings and clamps shall not rupture and shall not have any visible fluid leakage during the test or after proof testing. The hose shall r

49、etain 80% of original burst. 7.0 QUALITY All hose produced to this specification shall be clean and free of dirt, grease, and contamination. Inside surfaces of hose shall be free of any substance which could interfere with attaining a satisfactory NUMBER: MPAPS F-30 TITLE: Coolant Hose REVISION: 1704 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are requ