NAVISTAR MPAPS P-9556-2015 Quality Requirements For Air Brake Reservoirs.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. 2015 by Navistar, Inc. DECEMBER 2015 Page 1 of 6 NAVISTAR, INC. Material, Parts, and Process Specificati

2、ons (MPAPS) NUMBER: MPAPS P-9556 Former Designation: TMS -9556 TITLE: Quality Requirements For Air Brake Reservoirs CURRENT REV No.: 1512 DATE: Dec. 2015 WRITTEN/EDITED BY: W. Cook APPROVED BY: R. Goluch SUPERSEDES: Rev. New October 2007 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT R

3、EVISION 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 reg

4、ulatory limits prior to use. Change Notice: Changed rated working pressure notation from 150 psig(1034 kPa) to “Governor Cutout Pressure; adopted MPAPS format; added qualification section; editorial changes 1.0 APPLICATION Air brake reservoirs covered by this specification are tanks used for the pur

5、pose of storing compressed air in connection with air brake systems. This specification covers engineering quality requirements for purchased air brake reservoirs/tanks supplied to Navistar, Inc. for use on Navistar products with air brake systems, and to such components as may be provided for field

6、 service applications. 2.0 SCOPE This specification covers the material and performance and quality requirements of metallic air tanks, including quality control and source approval, suppliers compliance reports, painting, appearance criteria, and shipping and identification requirements. 2.1 Restri

7、cted 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. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The foll

8、owing Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 Navistar MPAPS C-10 NAVISTAR Manufacturing Std. MS-D-13 Navistar MPAPS G-9009 NAVISTAR Engineering Design Std A-16 Navistar TMS 4513 NAVISTAR MPAPS B-50 FMVSS -121 Alum

9、inum Association AA45 CFR Title 29, Part 1910 ASTM B-117 Navistar MPAPS A-6 Part I Navistar CSE-SP-0012 SAE J10 AWS A2.4 4.0 GENERAL REQUIREMENTS All air reservoirs supplied under this specification shall conform to the requirements of FMVSS-121, SAE J10, and CSE-SP-0012. NUMBER: MPAPS P-9556 TITLE:

10、 Quality Requirements For Air Brake Reservoirs REVISION: 1512 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. 2015 by Navistar, Inc. DECEMBER 2015 Page 2

11、 of 6 4.1 Material The supplied parts will meet the material requirements of this specification depending on the type of base material specified on the tank drawing or purchase order. 4.1.1 Steel Tanks 4.1.1.1 Material Specification: Steel, Grade 1 or 2, per MPAPS A-6, Part I (or other grade as agre

12、ed upon between supplier and purchaser) 4.1.1.2 Material Finish 4.1.1.2.1 Exterior Surface: Paint per MPAPS G-9009, Class IIA (unless otherwise specified on drawing or purchase order); color to be specified on drawing or purchase order. 4.1.1.2.2 Interior Surface: Suitable coating must be applied in

13、 order to meet minimum corrosion requirements specified in SAE J10. 4.1.2 Aluminum Tanks 4.1.2.1 Material Specification: 5052-H34 or 5052-H32 aluminum per MPAPS C-10 4.1.2.2 Material Finish 4.1.2.2.1 Non-Polished/Painted aluminum: mill finish Class AA-M10 per Aluminum Association document 45; paint

14、per MPAPS G-9009, Class IIA (unless otherwise specified or ordered). Paint color to be specified on drawing or purchase order. 4.1.2.2.2 Polished aluminum: will have a buffed finish Class AA-M22 per AA Document 45. The polished/buffed surface will be coated with a protective coating per TMS-4513 or

15、other protective wrap prior to shipping. (If a specific type of protective coating is desired, it will be defined on the drawing or purchase order.) 4.1.3 Material Thickness Tank material thickness will be selected by the supplier based on what is needed to meet the burst pressure and minimum volume

16、 requirements. 4.2 Welding All welds on air tanks must be in conformance to applicable American Welding Society (AWS) standards. Required weld locations and parameters (weld length, size, etc.) may be specified on the engineering drawings with standard welding symbols per AWS A2.4. However, if such

17、parameters are not specified, welding procedures and parameters will be selected by the supplier so as to meet applicable requirements of FMVSS 121, SAE J10, and CSE-SP-0012. 4.3. Performance Requirements 4.3.1 Proof Tests Prior to a production run or lot (defined as a single part number manufacture

18、d for a one-year period or for 200 pieces, whichever occurs sooner), the first reservoir shall be subjected to proof testing per FMVSS-121, Section 5.1.2.2. The rated working pressure for purposes of this specification shall be defined as the Governor Cutout Pressure. 4.3.2 Leakage Tests Each air ta

19、nk supplied to this specification shall be subjected to twice the rated working pressure when tested per SAE J10; leakage shall not exceed 20 std cm3/m. 4.3.3 Painted Tanks For tanks required to be painted, all outside surfaces (including weld area) will be clean and free from rust, oxidation, exces

20、sive weld spatter, flux, scale, oils, and other debris prior to painting. Exterior NUMBER: MPAPS P-9556 TITLE: Quality Requirements For Air Brake Reservoirs REVISION: 1512 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical

21、 Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. DECEMBER 2015 Page 3 of 6 surfaces will meet the performance requirements specified for Class IIA per MPAPS G-9009 (or as otherwise specified). In addition, tanks subjected to ASTM B 117 salt spray testing shal

22、l not exhibit any pits or evidence of red rust (including weld areas) when visually inspected. Tanks with interior coatings will meet the salt spray requirements of SAE J10; specimen preparation and evaluation will be performed in accordance with SAE J10. 4.4 Certification Certification of complianc

23、e to this specification, along with the minimum volume capacity for each air tank part number, shall be provided to TDTC, Brake Engineering Group, Fort Wayne, prior to first shipment of air reservoirs to the assembly plants. Compliance certification and the data obtained to assure compliance shall a

24、ccompany each shipment of air reservoirs delivered to International and will be delivered to the Quality Assurance Engineer or Chief Inspector of the using facility. All certifications and supporting data will be maintained for two years. 4.5 Label Requirements All air reservoirs shall be permanentl

25、y identified to show the manufacturer, SAE J10, D.O.T, the rated working pressure, and the date of manufacture. 5.0 QUALITY All air tanks shall be supplied in a clean and dry condition. All ports will be plugged before shipment to prevent entry of foreign material or moisture. Tanks shall be free of

26、 red rust/corrosion/oxidation at the point of application at the assembly plant, especially in the weld areas. All air reservoirs furnished under this specification shall contain no material that could be detrimental to the function of the air brake system. Finished air tanks must meet the Surface A

27、ppearance Acceptance Criteria as described in Table 1 below. NUMBER: MPAPS P-9556 TITLE: Quality Requirements For Air Brake Reservoirs REVISION: 1512 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers

28、are required to assume all patent liability. 2015 by Navistar, Inc. DECEMBER 2015 Page 4 of 6 TABLE 1. SURFACE APPEARANCE ACCEPTANCE CRITERIA POLISHED ALUMINUM TANKS Item Criteria VISUAL APPEARANCE Scratches None allowed Abrasions None allowed Gouges (deeper than 1 mm) None allowed Dents (in or out)

29、 None allowed Creases None allowed Blemishes None allowed Weld spatter Minimal PAINTED TANKS Item Criteria VISUAL APPEARANCE Scratches Not allowed to be felt by hand, or more than 25 mm in length nor 1 mm wide. Base metal is not allowed to be visible or showing rust or oxidation. Abrasions Multiple

30、scratches the total of which must be less than 7.5 mm in diameter and meet the other criterion of “Scratches“ Gouges (deeper than 1 mm) Not allowed. Dents (in or out) Not allowed to be greater that 0.5 mm deep nor greater than 5 mm in diameter. Base metal is not allowed to be visible or show rust or

31、 oxidation. Blemishes (in paint) Abnormalities in material finish that are apparent visually from a distance of 2 meters. Weld spatter Minimal NUMBER: MPAPS P-9556 TITLE: Quality Requirements For Air Brake Reservoirs REVISION: 1512 This document is restricted and may not be sent outside Navistar, In

32、c. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. DECEMBER 2015 Page 5 of 6 6.0 QUALIFICATION Engineering qualification of sources is required in advance of production shipments. Samples shall be acco

33、mpanied by test data certifying that all requirements of the specification have been met. 6.1 QUALITY CONTROL PLAN A Quality Control Plan for products supplied to the requirements of this specification will be established by mutual agreement between NAVISTAR and the supplier. Unless specific excepti

34、on is noted, the following characteristics, where applicable*, shall be included in the plan as features for management by statistical process control.* * Other characteristics for inclusion in the control plan may be specified on the engineering drawing and/or purchase order. * See NAVISTAR Enginee

35、ring Design Standard A-16 7.0 SOURCE APPROVAL AND QUALITY CONTROL 7.1 SUPPLIER REQUIREMENTS All suppliers to NAVISTAR are required to be registered to ISO 9001 Quality System Requirements. NAVISTAR will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG PPAP (Product

36、ion Part Approval Process) documentation and approval requirements. Suppliers must maintain their certification with an accredited registrar and must furnish copies of registration certificates to their Corporate Buyer upon request. 7.2 APPROVAL Parts supplied against contracts or purchase orders ci

37、ting this specification shall be equivalent in all respects to those samples which were approved by the purchaser. No changes in formulation or processing practices are permitted without approval. In the event that changes in material, properties, processing practices, construction, color, or labeli

38、ng of the product are required, the supplier shall notify NAVISTAR Materials Engineering and Purchasing and Supplier Development of the proposed change(s). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updated Material Safety Data She

39、et(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 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

40、lot having been produced in a state of statistical control and with a process capable of providing all required properties. The part supplier and the quality control manager of the using NAVISTAR plant may determine testing and reporting requirements on specific products. NUMBER: MPAPS P-9556 TITLE:

41、 Quality Requirements For Air Brake Reservoirs REVISION: 1512 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. 2015 by Navistar, Inc. DECEMBER 2015 Page 6

42、 of 6 8.0 SHIPPING AND HANDLING Shipping and identification shall be in accordance with NAVISTAR Manufacturing Standard MS-D-13. Parts shall be packaged so as to avoid any damage in shipment detrimental to the appearance of the part. 9.0 DESIGNATION ON DRAWINGS Type of material to be used should be

43、specified in the material block of the applicable drawing. Examples: Steel per MPAPS P-9556 Polished Aluminum per MPAPS P-9556 Painted aluminum per MPAPS P-9556 Additional note in body of drawing should read: “Must meet performance and quality requirements of MPAPS P-9556.” 10.0 TECHNICAL INFORMATIO

44、N For further information related to the technical content of this specification, contact: Suppliers may purchase controlled copies of this specification by contacting: Materials Engineering and Technology Dept. 10400 W. North Avenue Melrose Park, IL 60160 E-mail: MaterialsEngineeringN IHS Global Inc. 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/