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. FEBRUARY 2010 Page 1 of 19 NAVISTAR, INC. ENGINEERING MATERIAL SPECIFICATION NUMBE
2、R: CEMS D-30 TITLE: Coolant Hose CURRENT ISSUE DATE: February 2010 WRITTEN/REVIEWED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES ISSUE OF: August 2009 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may involve hazardous materials,
3、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 Notice: Added PG suffix
4、in section 5.2.8. 1.0 SCOPE This specification covers requirements of straight and preformed hose intended for use as radiator hose, heater hose and other flexible conduits for engine cooling systems. 2.0 INTRODUCTION This specification covers general requirements, property and performance requireme
5、nts, identification, quality, packing and shipping, and source approval and quality control requirements. 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
6、 CONTENTS PAGE REFERENCE DOCUMENTS 2 CLASSIFICATION AND CONSTRUCTION 2 CONVERSION OF PREVIOUS SPECIFICATIONS 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 IDENTIFICATIO
7、N 11 TECHNICAL INFORMATION 12 TABLES 13 - 19 APPENDIX Green Sheets Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: CEMS D-30 TITLE: Coolant Hose CURRENT ISSUE DATE: FEBRUA
8、RY 2010 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. FEBRUARY 2010 Page 2 of 19 4.0 REFERENCE DOCUMENTS Unless otherwise specif
9、ied*, the latest issue of all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 NAVISTAR TMS-6018 ASTM D 412 NAVISTAR Manufacturing Standard MS-D-13 NAVISTAR TMS-6025 ASTM D 413
10、 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 CEMS B-1 ASTM D 380 ASTM D 2240 NA
11、VISTAR 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 Y14.5M is required. 5.0 CLASSIFIC
12、ATION AND CONSTRUCTION Grade 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 Grades 5.1.1 Grade 1 This grade covers a premium, long life hose used in engine co
13、olant 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 naming conventions), similar to SA
14、E 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 coolant systems (including heater) an
15、d 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 shall be made from polysiloxane el
16、astomers, 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 buses. This shall not be used in
17、heavy duty or severe service application requiring or advertising long life. 5.2 Suffix Letters 5.2.1 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 constructed from lower cost reinfor
18、cements, 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, with prior Materials Engineerin
19、g approval. Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: CEMS D-30 TITLE: Coolant Hose CURRENT ISSUE DATE: FEBRUARY 2010 This document is restricted and may not be sent
20、 outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2010 by Navistar, Inc. FEBRUARY 2010 Page 3 of 19 5.2.3 Suffix C Straight hose over 25.4 mm (1 inch) ID reinforced with wrapped plies of woven cord nylo
21、n 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 construction to limit the amount of
22、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 further and restricts construc
23、tions 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 bore engine applications using
24、short hose connectors with pipe. The suffix requires a meta-aramid or a modified para-aramid to meet the increased requirements. 5.2.8 Suffix PG This is a place holder for the development of hoses in neat propylene glycol coolant systems. Contact Materials Engineering for further information and req
25、uirements for this application. 5.3 Conversion of Previous Specifications Previous versions of CEMS D-30 convert to the new format as follows: Types A, B and C directly convert 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 TM
26、S-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-6018 Type III is Grade 2A or 2B as appropriate. 5.4 Spring Insert (Vacuum side only) If necessary, the use of a steel spring i
27、nsert 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 diameter of 1.57 mm (a larger diameter wire may be used at the suppliers discretion). The spring shall exhibit a 25 mm pitch (
28、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 steel spring wire, Type 1 or Type 2, per CEMS A-9, mechanically-coated or electroplated with zinc after forming, or cold drawn
29、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) without visible red rust. 5.4.1 Stainless steel may be used as an optional material to the galvanized steel listed above. The
30、 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 REQUIREMENTS Materials and hoses shall meet the appropriate requirements of SAE J20. Test methods are listed in section 8.0 a
31、nd 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 of the tube and cover shall conform to the requirements shown in Table I when tested in accordance with “Methods of Test”,
32、Section 8. Minimum tube thickness will be 0.06 in. (1.59 mm). Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: CEMS D-30 TITLE: Coolant Hose CURRENT ISSUE DATE: FEBRUARY 20
33、10 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. FEBRUARY 2010 Page 4 of 19 Minimum cover thickness will be 0.03 in. (0.80 mm).
34、For thin cover layers (below 0.045 in.), it is allowable to use ASTM cured sheets per ASTM procedure due to increased variability with thinner rubber test pieces. 6.2 Hose Requirements Hose purchased to this specification shall meet the following requirements when tested in accordance with “Methods
35、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 diameter will not collapse more than 25 percent. 6.2.3 Cold Flexibility Specimens will not crack, check or break. 6.2.4 Burst St
36、rength 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 visible bloom when examined with the naked eye as compared to a control sample. The sample shall remain reasonably unchang
37、ed 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 requirement is report only. When suffix “X” is specified, no more than 10%. And for suffix “Y” no more than 5%. 6.2.9 Chemical I
38、nteraction Test 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 lubricants that would be present in production hoses. No more than 8% precipitate and chemical analysis limits as shown in
39、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 are still under evaluation and development, full and complete analytical reports should be submitted for review to TDTC
40、Materials Engineering prior to committing additional work. While this work is intended primarily for qualification, re-qualification of materials to this specification should be completed periodically (per agreement with the supplier and NAVISTAR). The full interaction is not required to be complete
41、d for re-qualification; a limited test schedule may be done with agreement of NAVISTARs Materials Engineering. Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: CEMS D-30 TI
42、TLE: Coolant Hose CURRENT ISSUE DATE: FEBRUARY 2010 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. FEBRUARY 2010 Page 5 of 19 6.3
43、 Hose Assembly Requirements Hose and hose assemblies purchased to 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
44、 end/bead configurations. Contact NAVISTARs Design Responsible Engineer for assistance in identifying production parts to be used in the test assembly. Inspect, measure and report the relevant dimensions of the parts used in the test. The test assembly should represent manufacturing assembly conditi
45、ons, 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 maximum of torque. When appropriate, measure and report the residual torque of each fastener. When crimp assembly technique
46、s are used, crimp separate sets of test samples to minimum and maximum crimp diameters. 6.3.1 Cold Leakage Hoses tested with selected production fittings and clamps shall not have a greater than 3% weight change. No visible fluid leakage shall be permitted during the test. 6.3.2 Fitting Insertion-Ex
47、traction 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 under development. Hoses tested with selected production fittings and clamps shall not rupture and shall not have any
48、 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 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 rubbe
