1、NAVISTAR, INC. ENGINEERING MATERIAL SPECIFICATION NUMBER: CEMS D-30 TITLE: Coolant Hose CURRENT ISSUE DATE: October 2008 WRITTEN/REVIEWED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES ISSUE OF: June 2007 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION
2、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 regulatory
3、limits prior to use. Change Notice: Replaced “International Truck and Engine Corporation” with “Navistar, Inc.” per corporate directive; eliminated circulating fluid resistance; modified Table 1; editorial changes. 1.0 SCOPE This specification covers requirements of straight and preformed hose inten
4、ded for use as radiator hose, eater hose and other flexible conduits for engine cooling systems. h2.0 INTRODUCTION This specification covers general requirements, property and performance requirements, identification, quality, packing and shipping, and source approval and quality control requirement
5、s. 2.1 Restricted Chemical SubstancesEffective 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 CONTENTS PAGE REFERENCE DOCUMENTS 2 CLASSIFICATION AND CONSTRUCTION 2 CONVERSION OF PREVIOUS SPECIFICAT
6、IONS 3 GENERAL REQUIREMENTS 3 QUALITY 5 QUALIFICATION 6 METHODS OF TEST 7 SOURCE APPROVAL AND QUALITY CONTROL 10 DESIGNATION ON DRAWINGS AND PURCHASE ORDERS 11 PACKING, SHIPPING, AND IDENTIFICATION 11 TECHNICAL INFORMATION 12 TABLES 13 - 19 APPENDIX Green Sheets This document is restricted and may n
7、ot be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2008 by Navistar, Inc. OCTOBER 2008 Page 1 of 19 Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for
8、 ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TITLE: CURRENT ISSUE DATE: CEMS D-30 Coolant Hose October 2008 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. 4.0 REFERENCE
9、 DOCUMENTS Unless otherwise specified*, the latest issue of all referenced standards shall apply. The following tandards, specifications and regulations are referenced in this specification. sQuality System Standard ISO 9001 or TS-16949 NAVISTAR TMS-6018 ASTM D 412 NAVISTAR Manufacturing Standard MS
10、-D-13 NAVISTAR TMS-6025 ASTM D 413 NAVISTAR Engineering Design Std. A-16 NAVISTAR TMS-6026 ASTM D 471 CFR Title 29, Part 1910 NAVISTAR TMS-6032 ASTM D 573 ASME/ANSI Y 14.5M-1994* NAVISTAR TMS-6036 ASTM D 624 NAVISTAR CEMS A-9 ASTM A 764 ASTM D 1171 NAVISTAR CEMS A-37 ASTM B 117 ASTM D 1193 NAVISTAR
11、CEMS B-1 ASTM D 380 ASTM D 2240 NAVISTAR CEMS DT-9 ASTM D 395 SAE J20 NAVISTAR TMS-6017 NAVISTAR CEMS B-50 SAE J1684 NAVISTAR TMS-9543 NAVISTAR TMS-9528 ASTM D 1418 NAVISTAR TMS-1058 NAVISTAR TMS-1059 ASTM D 573 ASTM D 3321 ASTM D 1287 ASTM D 5827 ASTM D 6130 *Conformance to the 1994 version of ASME
12、 Y14.5M is required. 5.0 CLASSIFICATION AND CONSTRUCTIONGrade 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. 5.1 Grades5.1.1 Grade 1 This grade covers a premium,
13、long life 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 na
14、ming conventions), 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 cover shall be non-blooming. 5.1.2 Grade 2 This grade covers a silicone based hose used in engine coola
15、nt 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 tube and cover stocks sh
16、all 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 medium duty trucks and b
17、uses. This shall not be used in heavy duty or severe service application requiring or advertising long life. 5.2 Suffix Letters5.2.1 Suffix A bulk, straight hose through 25.4 mm (1.0 inch) ID suitably reinforced with ply or plies of spiraled, knitted or braided aramid yarn. Grade 3 hoses may be cons
18、tructed from lower cost reinforcements, such as Rayon, with prior Materials Engineering approval. 5.2.2 Suffix B Preformed hose over 12.7 mm (1/2 inch) ID reinforced with ply or plies of knitted or spiraled aramid yarn. Grade 3 hoses may be constructed from lower cost reinforcements, such as Rayon,
19、with prior Materials Engineering approval. Suppliers are required to assume all patent liability. 2008 by Navistar, Inc. OCTOBER 2008 Page 2 of 19 Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without licen
20、se from IHS-,-,-NUMBER: TITLE: CURRENT ISSUE DATE: CEMS D-30 Coolant Hose October 2008 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. 5.2.3 Suffix C Straight hose over 25.4 mm (1 inch) ID reinforced with wra
21、pped 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 shall not be supplied. 5.2.5 Suffix X This is an additional requirement that may be added to Suffix B constru
22、ction to limit the amount of swell allowed. The use of this requirement may limit design flexibility further than described in the Appendix and should be thoroughly reviewed with the supplier prior to release. 5.2.6 Suffix Y This is a similar requirement to Suffix X except it limits the swell even f
23、urther and restricts constructions to lock stitch or other non-expanding types of reinforcement. This should be thoroughly reviewed with the supplier prior to release. 5.2.7 Suffix Z This is an additional requirement for high impulse and torsion applications. Typically, this is required for large bo
24、re engine applications using short hose connectors with pipe. The suffix requires a meta-aramid or a modified para-aramid to meet the increased requirements. 5.3 Conversion of Previous SpecificationsPrevious versions of CEMS D-30 convert to the new format as follows: Types A, B and C directly conver
25、t 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 TMS-6032 Type 1. For Class 3 use Grade 2. TMS-6026 becomes Grade 1A. TMS-6017 is Grade 1B. TMS-6025 is Grade 1C. TMS-6018 Type I is Grade 2C. TMS-6018 Type II is Grade 2B. TMS-601
26、8 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 D suffix. Unless otherwise specified, the steel spring insert shall be formed of a wire having a minimum dia
27、meter 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 an O.D. approximately 3.0 mm less than the nominal I.D. of the hose. The wire shall be cold drawn carbon stee
28、l spring wire, Type 1 or Type 2, per CEMS A-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) wi
29、thout visible red rust. 5.4.1 Stainless steel may be used as an optional material to the galvanized steel listed above. The wire shall be 300 series stainless steel, full hard, CEMS A-37. 5.4.2 Any other material must be approved by the NAVISTAR Materials Engineering Group before use. 6.0 GENERAL RE
30、QUIREMENTS Materials and hoses shall meet the appropriate 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
31、of the tube and cover shall conform to the requirements 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
32、 ASTM cured sheets per ASTM procedure due to increased variability with thinner rubber test pieces. Suppliers are required to assume all patent liability. 2008 by Navistar, Inc. OCTOBER 2008 Page 3 of 19 Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for Re
33、saleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TITLE: CURRENT ISSUE DATE: CEMS D-30 Coolant Hose October 2008 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. 6.2 Hose Require
34、ments 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 percent. 6.2.2 Vacuum Collapse (Suffix A only) Hose outside diamete
35、r 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 burst strength requirements in Tables III and IV. 6.2.5 Bloom No v
36、isible 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 1A, 1C it is currently expected to be around 15%. When no suffix requirement is given, this require
37、ment is report only. When suffix “X” is specified, no more than 10%. And for suffix “Y” no more than 5%. 6.2.9 Chemical InteractionTest by either method using each of the long-life coolants C and D listed in Table V. Test shall utilize hose from production process and include any process aids or lub
38、ricants 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 clear glass containers compared to un-aged coolant samples shall be included in the report. As these limits and requirements
39、are still under evaluation and development, full and complete analytical reports should be submitted for review to TDTC Materials Engineering prior to committing additional work. While this work is intended primarily for qualification, re-qualification of materials to this specification should be co
40、mpleted 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 be done with agreement of NAVISTARs Materials Engineering. 6.3 Hose Assembly Requirements Hose and hose assemblies purchased to
41、this 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 TMS-1058 or 1059 for guidance on pipe end/bead configurations. Contact NAVISTARs Design Responsible Eng
42、ineer for assistance in identifying production parts to be Suppliers are required to assume all patent liability. 2008 by Navistar, Inc. OCTOBER 2008 Page 4 of 19 Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitt
43、ed without license from IHS-,-,-NUMBER: TITLE: CURRENT ISSUE DATE: CEMS D-30 Coolant Hose October 2008 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. used in the test assembly. Inspect, measure and report th
44、e 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 using production clamps and torque values with one test set to the minimum torque and one test set to maxim
45、um 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 diameters. 6.3.1 Cold LeakageHoses tested with selected production fittings and clamps shall not have a g
46、reater than 3% weight change. No visible fluid leakage shall be permitted during the test. 6.3.2 Fitting Insertion-Extraction Force Report results. Limits have not yet been determined. See 6.3 for fitting information. 6.3.3 Impulse - Vibration Durability Suffix Z only This method and requirement is
47、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 retain 80% of original burst. 7.0 QUALITY All hose produced to this specification shall be clean and free
48、 of dirt, grease, and contamination. Inside surfaces of hose shall be free of any substance which could interfere with attaining a satisfactory clamping load or which could act as a lubricant resulting in unsatisfactory retention on fittings. Any internal release agents shall be flushed from the inside of the hose. All rubber debris from cutting and processing shall be removed. There shall be no fabric or flash exposed on the ID of the hose. Parts shall be free o
