NAVISTAR TMS 9547-2013 Quality Requirements For Mufflers and Exhaust Aftertreatment Modules.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. 2013 by Navistar, Inc. DECEMBER 2013 Page 1 of 19 NAVISTAR, INC. TMS (TRUCK MATERIAL SPECIFICATION) NUMBE

2、R: TMS-9547 TITLE: Quality Requirements For Mufflers and Exhaust Aftertreatment Modules CURRENT REV. No: 1312 DATE: December 2013 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: Rev 1104 April 2011 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: Revised Section 4.3.1 related to rate of draining the water trap; added chart in Section 4.3.1 for drain rate; editorial changes. Reference: File 650-8 Keywords: Exhaust Quality, Mufflers, Noise Emissions, Aftertreatment 1.0 APPLICATION This specification

5、is divided into two sections as follows: Part I Quality Requirements for Mufflers and Muffler Assemblies Part II Quality Requirements for Exhaust Aftertreatment Modules Application of TMS-9547 Specification Based on Emissions Regulations EURO 0 EURO I-VI US EPA pre-04 US EPA 2004 US EPA 2007 US EPA

6、2010 Mufflers or 10 years or 485,000 miles in service or for 22,000 engine hours, whichever occurs first, for heavy duty diesel engines as per 40 CFR 86.004-2. 4.2 Back Pressure The aftertreatment exhaust modules, when tested in combination with the rest of the exhaust piping, must not exceed the ma

7、x exhaust back pressure allowance determined by the engine manufacturer. 4.3 Leakage Testing 4 3.1 Water Ingestion The catalyst and filter substrates used in the aftertreatment modules are mounted to their stainless steel housings using a ceramic fiber mat. This ceramic material must be protected fr

8、om contact with water. Vertically mounted modules must include a water trap that prevents water from entering the substrate section(s) or equivalent drainage provision to ensure the fiber mat is not wetted. Horizontally mounted modules should include vertically aligned ( 10) drain holes in the outle

9、t section or equivalent drainage method to ensure the fiber mat will not be wetted. Drainage holes must not be covered by mounting straps or otherwise become plugged. The module shall be capable of storing a minimum quantity of one (1) gallon of water without leakage into the catalyst and filter. Th

10、e module shall also be capable of draining the water trap at a rate as shown in the chart below. See Appendix A for test procedure. 4 3.2 Exhaust Gas Leakage Maximum allowable leakage rate in the aftertreatment module is one (1) standard cubic foot of air per minute 4 psig. Maximum allowable leakage

11、 of the exhaust piping between the turbocharger and inlet to the DOC is limited to a maximum of one (1) standard cubic foot of air per minute 4 psig. 4.4 Noise Requirement 4.4.1 Pass-By Noise Requirement The aftertreatment exhaust module is a part of the truck noise control system which enables a ve

12、hicle to comply with the 80 dB(A) requirement of the Federal Noise Regulation (CFR Title 40, Part 205, Subpart B). The equivalent NAVISTAR test lab procedure is VA-PR-001. NUMBER: TMS-9547 TITLE: Quality Requirements For Mufflers and Exhaust Aftertreatment Modules REVISION: 1312 This document is res

13、tricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2013 by Navistar, Inc. DECEMBER 2013 Page 5 of 19 PART II. EXHAUST AFTERTREATMENT MODULES (contd) All vehicles for sale/use i

14、n the global market shall meet the E.C.E. Regulation (ECE 51-02). All aftertreatment exhaust modules used on Navistar trucks require approval for noise compliance by NAVISTAR for each truck model and engine combination. In general, total noise contribution from the tailpipe outlet(s) and the aftertr

15、eatment exhaust module shell body/bodies is limited to 70 dB(A). Deviations from this limit are not acceptable without prior approval from the NAVISTAR Vehicle Acoustics Group. After review and approval of supplier test data (and final vehicle validation, if applicable), noise control may not be mod

16、ified on production units without prior consideration by the Vehicle Acoustics Group. . 4.4.2 Deceleration Noise Requirement The aftertreatment exhaust module is a part of the truck noise control system enabling a vehicle to comply with Federal Noise Regulations. All aftertreatment exhaust modules u

17、sed on Navistar trucks require approval for noise compliance by NAVISTAR for each truck model and engine combination. The noise level contributed by the aftertreatment exhaust module during a deceleration pass-by test shall not exceed 78 dBA when used on an engine with an engine compression brake. T

18、he engine compression brake shall be full on. The test method shall be the deceleration portion of SAE J366. This requirement does not apply if the application of the aftertreatment exhaust module is on an engine that does not offer an engine compression brake. 4.4.3 Interior Noise Requirement The a

19、ftertreatment exhaust module is a part of the truck noise control system enabling a vehicle to comply with Federal Noise Regulations. All aftertreatment exhaust modules used on Navistar trucks require approval for noise compliance by NAVISTAR for each truck model and engine combination. The exhaust

20、outlet noise shall be measured for all aftertreatment exhaust modules and engine combinations. For vertical tailpipe systems, position the microphone at 2 feet from the center of the tailpipe outlet and 110 degrees down from the axis of the vertical tailpipe outlet. For horizontal tailpipe systems,

21、position the microphone at the 2 foot radius from the center of the tailpipe outlet, meter laterally from the DPF in the direction where the centerline of the truck would be, and vertically at the same height from the floor as the DPF centerline. The microphone shall be pointed at the tailpipe outle

22、t. Measure overall and 1/3 octave band sound pressure levels in dBA, fast response versus engine speed. The engine speed shall sweep the full range, at full load, up to maximum governed engine speed, under quasi-steady state conditions. Add the 1/3 octave bands of 50 through 250 hertz center frequen

23、cy together to obtain a band-pass sound pressure level. The band-pass sound pressure level shall be plotted versus engine speed. The maximum band-pass sound pressure level over the engine speed range shall not exceed 85 dBA for a vertical tailpipe or 88 dBA for a horizontal tailpipe. 4.4.4 Interior

24、Noise during Regeneration The aftertreatment exhaust module is a part of the truck noise control system enabling a vehicle to comply with Federal Noise Regulations. All aftertreatment exhaust modules used on Navistar trucks require approval for noise compliance by NAVISTAR for each truck model and e

25、ngine combination. The sound quality of the noise from the aftertreatment exhaust system shall not be objectionable at the side of the truck or at the drivers location in the cab during a regeneration cycle. The sound quality of the regeneration noise can be evaluated using the 1 to 10 rating scale

26、in SAE J1060. The average rating must be 7 or above to be acceptable. NUMBER: TMS-9547 TITLE: Quality Requirements For Mufflers and Exhaust Aftertreatment Modules REVISION: 1312 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Tec

27、hnical Standards. Suppliers are required to assume all patent liability. 2013 by Navistar, Inc. DECEMBER 2013 Page 6 of 19 PART II. EXHAUST AFTERTREATMENT MODULES (contd) 4.5 Structural Integrity Exhaust aftertreatment modules shall be capable of withstanding the normal static and dynamic loading an

28、ticipated in service. When requested by NAVISTAR, the supplier shall provide test data indicating capability of the module to withstand the defined load conditions. 4.6 Test Reports When the supplier is assigned responsibility to provide test data in support of NAVISTAR engineering design programs,

29、test reports submitted will follow the format described in TMS-9543. The use of this format enables test reports to be filed and permanently stored in the NAVISTAR Project Tracking, Reporting, and Retrieval System. 4.7 Aftertreatment Module Tracking and Identification Requirements Federal EPA tracki

30、ng and identification requirements for aftertreatment components/modules are described in the ADDENDUM to this specification. The ADDENDUM is a part of this specification and requirements shown in the ADDENDUM are a part of the Engineering requirements of this specification. The first part of the ad

31、dendum describes the regulatory language of EPA rule. The second part of the addendum describes the Engine manufacturers requirements and responsibility for tracking and identification. The third part of the addendum describes the Assembly plants requirements and responsibility for maintaining ident

32、ification during the assembly procedure. (THE FOLLOWING IS APPLICABLE TO BOTH PARTS I and II) 5.0 QUALITY All muffler and muffler assemblies or exhaust aftertreatment modules shall be delivered in a clean and dry condition. All inlet and outlet tubes and all electronic sensors shall be protected fro

33、m damage and/or deformation in shipping and handling. 5.1 Weld Quality 5.1.1 Weld Requirements Required welding will be specified on the applicable engineering drawings using weld symbols per American Welding Society standard ANSI/AWS A2.4. Welds will meet the requirements of AWS D1.6, Structural We

34、lding Code for Stainless Steel. Weld filler metal will be as described in CEMS A-37 Appendix, Table XV, unless otherwise agreed upon between the supplier and Navistar Engineering. 5.1.2 Weld Qualification To determine and monitor quality of welds, macroetch samples will be prepared for each weld joi

35、nt for purposes of weld setup and for PPAP. The test specimens will be prepared with a surface finish sufficient for macroetch examination. A suitable macro etchant solution (see Annex G in AWS D1.6 for suggestions) will be applied to the samples to provide a clear definition of the weld. For accept

36、ance qualification of the welds, visual examination of the test samples shall show complete fusion and absence of cracks or other weld defects. In addition, the actual weld size shall be at least equal to the specified weld size, and shall not have any concavity or convexity greater than 2 mm (1/16

37、in). 5.1.2.1 Test Frequency In addition to the required testing for weld setup and PPAP, the supplier will provide a test plan and schedule to Navistar Engineering for regular monitoring of weld quality. Supplier will provide test samples to Navistar, and must furnish records of ongoing weld quality

38、 testing to Navistar upon request. NUMBER: TMS-9547 TITLE: Quality Requirements For Mufflers and Exhaust Aftertreatment Modules REVISION: 1312 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are req

39、uired to assume all patent liability. 2013 by Navistar, Inc. DECEMBER 2013 Page 7 of 19 5.2 Quality Control Plan A Quality Control Plan for this product will be established by mutual agreement between Navistar and the supplier. The following items, where applicable*, will be included in the control

40、plan as dimensional features for management by statistical process control.* 1. Muffler Inlet Pipe: ID or OD and Ovality 2. Muffler Outlet Pipe: ID or OD and Ovality * Additional characteristics for inclusion in the control plan may be specified on the engineering drawing and/or purchase order. * Se

41、e Engineering Design Standard A-16. 6.0 SOURCE APPROVAL AND QUALITY CONTROL 6.1 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 PPA

42、P (Production 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. 6.2 Approval Parts supplied against contracts or purchase

43、 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 the event that changes in material, properties, processing practices, construction, color,

44、 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 requirements of this specification, test samples, and new or amended or updated Material Safet

45、y Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 6.3 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 eviden

46、ce 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 plant may determine testing and reporting requirements on specific products. 7.0 SHIPPING, PACKING AND

47、IDENTIFICATION Loading, packing, and identification shall be in accordance with Manufacturing Std. MS-D-13. 8.0 DESIGNATION ON DRAWINGS The drawing will utilize the KCC symbol with a note: “Completed assemblies will comply with requirements of TMS-9547.” All drawings and or Engineering documents sha

48、ll also be marked to indicate that compliance with 80 dBA Federal Noise Regulations is required. NUMBER: TMS-9547 TITLE: Quality Requirements For Mufflers and Exhaust Aftertreatment Modules REVISION: 1312 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. 2013 by Navistar, Inc. DECEMBER 2013 Page 8 of 19 9.0 TECHNICAL INFORMATION For further informati