NAVISTAR TMS 9502-2010 Cleanliness Of Radiator Assemblies.pdf

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. 2010 by Navistar, Inc. DECEMBER 2010 Page 1 of 5 NAVISTAR, INC. TMS (TRUCK MATERIAL SPECIFICATION) NUMBER

2、: TMS-9502 TITLE: Cleanliness Of Radiator Assemblies CURRENT REV No.: 1012 DATE: DEC. 2010 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: Rev. D-1 August 2001 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may involve

3、 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 limits prior to use. Change No

4、tice: Replaced “International Truck and Engine Corp.” with “Navistar, Inc.” per corporate directive; added CEMS B-50 requirement; added Table I; added Section 9.0; editorial changes. directive; added CEMS B-50 requirement; Reference: File 09-1 Keywords: Radiator Cleanliness 1.0 APPLICATION This spec

5、ification covers cleanliness requirements for all radiator assemblies containing soldered, brazed, and welded joints. 2.0 SCOPE This specification covers requirements for cleanliness, freedom from contaminants, methods of test, certification, receiving plant inspection, and designation on drawings.

6、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 CEMS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply.

7、 The following standards, specifications and regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 CEMS B-50 NAVISTAR Manufacturing Standard MS-D-13 ASTM D 857 CFR Title 29, Part 1910 ASTM D 1179 ASTM D 512 ASTM D 1246 ASTM D 4192 4.0 REQUIREMENTS The radiato

8、rs shall be manufactured so that all surfaces, both inside and outside, are free from contaminating chemical elements, particularly from flux or flux residues, which are or might be corrosive to any material in the radiator, engine assembly, or other parts in the coolant passages. Chemical testing i

9、s described in section 4.3.2. The concentration of chlorides, bromides, or other corrosive chemicals shall not exceed 75 parts per million (ppm) for testing performed according to Method A. Refer to Table I for concentration limits for Method B. 4.1 In addition, radiators purchased to this specifica

10、tion shall be free from visible residues, powders, dirt, paste, or other foreign materials that might tend to clog the passages of the radiator or engine. NUMBER: TMS-9502 TITLE: Cleanliness Of Radiator Assemblies REVISION: 1012 This document is restricted and may not be sent outside Navistar, Inc.

11、or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2010 by Navistar, Inc. DECEMBER 2010 Page 2 of 5 4.2 The radiator manufacturer shall protect the radiator interior by securely sealing all openings to prevent powder, dirt, moi

12、sture, corrosive vapors, or sprays from entering the radiator prior to assembly on the vehicle, unless this requirement is specifically waived by Navistar. 4.3 Methods Of Test 4.3.1 Visual Examination Inspect visually the external and internal surfaces to determine if visual residues, powder, dirt,

13、paste, or other foreign materials are present. It may be necessary to remove paint with chemical paint removers or to disassemble bolted assemblies to facilitate inspection. Reassemble per radiator assembly drawings. 4.3.2 Chemical Testing 4.3.2.1 Method A: Soldered Radiator When the radiator is at

14、ambient room temperature, fill with warm water at a temperature of 49-60C (120-140F), noting the amount of water added. Retain a sample of the water used for filling. Place the radiator in the normal operating position, and after thirty minutes, invert the radiator to an upside-down position. After

15、an additional thirty minutes, place the radiator back to the normal operating position. Withdraw 4 liters (1.05 gallons) of water from a bottom drain plug into a clean vessel. When the radiator is filled with water, there should be no water leaking from openings. Mix the solution with a glass stir r

16、od to suspend any sediment. Analyze the sample of filler water and the 4 liter (1.05 gallon) sample withdrawn from the radiator by the method described in Table I or a method mutually agreed upon between the radiator manufacturer and Navistar Materials Engineering. The content of chlorides and bromi

17、des in the filler water sample shall be subtracted from the content in the withdrawn sample. The difference, which should be zero or a positive value, shall not exceed the limits stated above. If the difference is a negative value, then the test must be repeated on a different radiator. Also, there

18、shall not be a pH change greater than 1 between the withdrawn sample and filler water sample. 4.3.2.2 Method B: CAB Radiator The CAB radiator outlet port needs to be plugged before adding water to the radiator core. Be sure to clean the rubber stopper with deionized water prior to plugging the outle

19、t port. Once the rubber stopper is plugged in the outlet port fill the radiator half full with deionized water from the tap with no temperature added. Tip the radiator back and forth to work any air out of the inlet port. Continue to add DI water until radiator is full. Note the volume of water used

20、 to completely fill the radiator core and tank assembly. Once the radiator is full, plug the inlet port with a clean rubber stopper. Let the radiator stand at room temperature for 8 hours. At the conclusion of eight hours, the radiator should be drained into a clean vessel large enough to hold the v

21、olume of solution. Mix the solution with a glass stir rod to suspend any sediment. After mixing fill a clean sample bottle with the solution from the vessel for analysis. Analyze the sample for aluminum, fluoride, and potassium concentrations using a method described in Table I. The concentration of

22、 aluminum, fluoride, and potassium should not exceed those outlined in Table I. NUMBER: TMS-9502 TITLE: Cleanliness Of Radiator Assemblies REVISION: 1012 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppli

23、ers are required to assume all patent liability. 2010 by Navistar, Inc. DECEMBER 2010 Page 3 of 5 4.4 Certification The radiator manufacturer shall submit quarterly certification stating that all radiators shipped during each quarter fully comply with this specification. This certification is not me

24、ant to state or imply that every radiator has been tested, but that manufacturing process controls assure that the desired level of quality can be expected in every radiator shipped. In addition, the radiator manufacturer shall provide inspection records, test methods, and results to Navistar person

25、nel upon request. 4.5 Receiving Plant Quality Assurance The receiving Navistar plant shall periodically inspect radiators received from the radiator manufacturer. If a tested radiator from a certified shipment does not fully comply with this specification, the entire shipment shall be returned to th

26、e radiator manufacturer for cleaning and reinspection. 5.0 QUALITY All product supplied shall be clean and free from dirt, oils, sharp edges, or defects harmful to product performance. 6.0 SOURCE APPROVAL AND QUALITY CONTROL 6.1 Supplier Requirements All suppliers to NAVISTAR are required to be regi

27、stered to ISO 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

28、and must furnish copies of registration certificates to their Corporate Buyer upon request. 6.2 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

29、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 chang

30、e(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. 6.3 Process Control The supplier shall either

31、 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 and the

32、plant metallurgist and/or the quality control manager of the using Navistar plant may determine testing and reporting requirements on specific products. 7.0 SHIPPING, PACKING AND IDENTIFICATION Loading, packing and identification shall be in accordance with Manufacturing Std. MS-D-13. NUMBER: TMS-95

33、02 TITLE: Cleanliness Of Radiator Assemblies REVISION: 1012 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. 2010 by Navistar, Inc. DECEMBER 2010 Page 4 o

34、f 5 8.0 DESIGNATION ON DRAWINGS “Cleanliness shall meet requirements of TMS-9502.” 9.0 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 an

35、d Technology Dept. Truck Development and Technology Center (TDTC) 2911 Meyer Road Fort Wayne, IN 46803 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:/ NUMBER: TMS-9502 TITLE: Cleanliness Of Ra

36、diator Assemblies REVISION: 1012 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. 2010 by Navistar, Inc. DECEMBER 2010 Page 5 of 5 TABLE I RESIDUAL FLUX L

37、IMITS Contaminants, ppm Test Method Concentration Limits Aluminum AA for use at 309.3 nm per ASTM D 857 8.4 Fluoride ISE per ASTM D1179-04 46 Potassium AA for use at 766.5 nm per ASTM D 4192-08 60 These test methods listed are recommendations. Some methods may be appropriate for tests other than the one listed depending on labs skill and capability. Employ an appropriate method agreed upon by the manufacturer and Navistar. Definitions: AAAtomic Absorption Spectroscopy ISEIon Selective Electrode