NAVISTAR MPAPS P-9567-2014 Evacuation and Fill Process for Clutch Fluid.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. 2014 by Navistar, Inc. OCTOBER 2014 Page 1 of 4 NAVISTAR, INC. Material, Parts, and Process Specificatio

2、ns (MPAPS) NUMBER: MPAPS P-9567 Former Designation: N/A TITLE: Evacuation and Fill Process for Clutch Fluid CURRENT REV No.: 1410 DATE: Oct. 2014 WRITTEN/EDITED BY: Transmission Engineering APPROVED BY: Materials Engineering SUPERSED Rev. 1406- June 2014 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIF

3、IED FOR CURRENT REVISION 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 app

4、licability of regulatory limits prior to use. Change Notice: Removed Section 4.3.3 and renumbered following sections; revised Section 4.3.4 (now Section 4.3.3); editorial changes. 1.0 APPLICATION This specification covers the requirements within vehicle assembly plants for the process to remove air

5、from the clutch system (reservoir, master and slave cylinders, tubing) known as EVAC, and the subsequent process to fill the system with appropriate Hydraulic Fluid (typically DOT 3 or 4). 2.0 SCOPE This specification includes requirements on vehicle manufacturing processes, to protect various vehic

6、le components from damage during the EVAC and FILL of the Clutch system. 2.1 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. 3.0 REFERENCE DOCUMENTS Unless othe

7、rwise specified, the latest issue of all referenced standards shall apply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 CFR Title 29, Part 1910 NAVISTAR MPAPS B-50 Manufacturing Standard MS-D-13 4.0 REQUIR

8、EMENTS 4.1 General The clutch system is made up of metal parts (cylinders, tubing) and some plastic or rubber parts (reservoir, seals, gaskets). It has been found that excessive vacuum or fill pressure can damage some of these components. This can be apparent at the plant (such as the bursting or le

9、ak in the reservoir) or may not show up until the vehicle is in the hands of the customer (e.g., slow leaks). Hydraulic fluid is generally detrimental to paint and many plastics. Avoiding the mess associated with a burst reservoir is important. Therefore it is required to control these vacuum and fi

10、ll pressure settings. NUMBER: MPAPS P-9567 TITLE: Evacuation and Fill Process for Clutch Fluid REVISION: 1410 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 liabil

11、ity. 2014 by Navistar, Inc. OCTOBER 2014 Page 2 of 4 4.2 EVAC and Fill Process Overview A “top fill” procedure in the vehicle plant station is to avoid the inconvenience of bleeding of lines. The process uses an evacuation pump to remove air from the system, and follows by filling with fluid. The st

12、ation has a dedicated hose for the process, that screws onto the reservoir cap location, which is mounted high in the engine compartment near the meeting of the hood and the bulkhead, just forward of the driver. This hose is partially supported by a cable, and the operator must also insert a tempora

13、ry brace under the reservoir, so the considerable weight of the hose/fill cap do not unduly stress the plastic part. This is critical to maintaining the mechanical integrity of the system. 4.3 EVAC Step 4.3.1 The system, all components collectively, has a volume on the order of one liter. Removal of

14、 all air is not practical, but sufficient quantity must be removed to reduce any bubbles once the remaining space is filled with fluid. 4.3.2 The station hose is attached to the system at the cap, and evacuation begins. 4.3.3 Note that full evacuation is not a requirement. The plant should perform s

15、ome tests with their equipment, and aim to fill the system within station cycle time, with as little evacuation as possible. The clutch hydraulic system is self-bleeding. The only requirement is that the pedal can develop pressure (may require a few pumps) such that the pedal does not hit the floor.

16、 This step is performed at the end of the fill cycle. Failure to develop this pressure (caused by the slave cylinder reaching the clutch brake stop) is considered indicative of a leak somewhere, requiring the vehicle to be “off lined” and repaired. 4.4 Fill Step 4.4.1 The same hose used for EVAC sha

17、ll deliver fluid at a pressure not to exceed 20 psi. It is suggested that a setting of 18 psi will be satisfactory regarding cycle time. 4.4.2 It is desirable that the filling system be able to monitor the volume of fluid delivered, and cease pumping if the volume exceeds some set value, on the assu

18、mption there is some leak in the system. This condition would be recorded as a failure. 4.4.3 It is desirable that the filling system halt the process if it fails to deliver at least some minimum amount of fluid within a set time limit the system shall stop pumping, on the assumption there is some b

19、lockage in the system. This condition would be recorded as a failure. 4.5 Hose Removal The hose shall have the vacuum port such that it extends into the reservoir to the depth between the MIN and MAX fill lines. This is so the vacuum will suck up any liquid above the desired level as the cap is bein

20、g removed, and also catch any drips. Vacuum will be maintained until the operator has hung the hose on a hook or otherwise signaled the control system the step is complete. This vacuum need not be strong to be effective. It is suggested (as a starting point) that 360 mm Hg (1/2 Atmosphere) is suffic

21、ient to accomplish the goal (leave just the right amount of fluid in the reservoir, and capture drips). It is not suggested to use the same setting for the EVAC step- in fact, such a strong vacuum is not recommended. Use a setting reliably sufficient for the goal, not stronger. In this context the g

22、oal is completing the process within station cycle time. NUMBER: MPAPS P-9567 TITLE: Evacuation and Fill Process for Clutch Fluid REVISION: 1410 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are r

23、equired to assume all patent liability. 2014 by Navistar, Inc. OCTOBER 2014 Page 3 of 4 4.6 Control System 4.6.1. The proper operation of the station requires monitoring and control of valves. It shall monitor sensors to keep pressure/vacuum within specified limits. 4.6.2. It shall record the name o

24、r ID of the operator, VIN, time of process begin and end, the time required to achieve specified vacuum, the time required to deliver the fluid, the lowest vacuum and peak fill pressure reached anywhere in the cycle. A success/fail indication shall be part of this record. Also desired, to support 4.

25、4.2 and 4.4.3, is to monitor and record the net volume of fluid delivered. 4.6.3 There should be a means to allow the operator to enter notations on any unusual circumstances that may have occurred, and to indicate if it was specific to the VIN in the station or a general problem. These notations wo

26、uld be recorded in a file with date, time and operator ID. 4.6.4 The system should calculate the average fill volume and the range. This can be used to adaptively control the limits for overfill/under-fill, as described in 4.4.2 and 4.4.3. The calculations could use the portion of the VIN that codes

27、 model and engine type to cluster the calculations into groups, should it be found that volumes vary wildly from model to model. 4.6.5 There shall be a means for the operator to immediately stop the process at any time (Emergency or E-stop). 4.7 Cap Fill The system connects at the same location that

28、 a service technician would normally pour liquid at atmospheric pressure, i.e., the reservoir. The system nozzle includes a seal, while a normal cap is vented. It shall include a tube to remove any overfill and be designed to capture any drips. 4.8 Seal The Fill Station Cap used to connect the vacuu

29、m and fill hose to the tank shall include some sort of seal (typically an O-ring), and this must be of a material unaffected by hydraulic fluid. It must be easily replaced, and should be replaced after some number of fill cycles or calendar time. The values for this PM are at the discretion of the p

30、lant. 4.9 Handling of fluid captured at Cap removal DOT 3/4 fluid from the post-fill-vacuuming will be collected in a drum adjacent to the fill station or returned to the source tank. It is up to the plant to dispose of this material in accordance with regulations for environment and safety or to re

31、use if it is determined to be of an acceptable quality by the plant Quality Control department. 5.0 SOURCE APPROVAL AND QUALITY CONTROL 5.1 Supplier Requirements All suppliers to NAVISTAR are required to be registered to ISO 9001 Quality System Requirements. NAVISTAR will also accept TS-16949 regist

32、ration as long as the supplier can also fulfill all AIAG PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must NUMBER: MPAPS P-9567 TITLE: Evacuation and Fill Process for Clutch Fluid REVISION: 1410 This document is restricted and may not be sent outside Nav

33、istar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. OCTOBER 2014 Page 4 of 4 maintain their certification with an accredited registrar and must furnish copies of registration certificates to th

34、eir Corporate Buyer upon request. 5.2 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 formulation or processing practices are permitted without approval. In

35、 the event that changes in material, properties, processing practices, construction, color, or labeling 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 req

36、uirements 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. 5.3 Process Control The supplier shall either perform and report results of tests on specific

37、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 and the quality control manager of the using NAVISTAR pla

38、nt may determine testing and reporting requirements on specific products. 6.0 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

39、. 7.0 DESIGNATION ON DRAWINGS Reference to MPAPS P-9567 will be made on drawings, DRDs, and other documents as applicable. 8.0 TECHNICAL INFORMATION 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:/