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. 2009 by Navistar, Inc. DECEMBER 2009 Page 1 of 27 NAVISTAR, INC. TMS (TRUCK MATERIAL SPECIFICATION) NUMBE
2、R: TMS-6021 TITLE: Hose, Air Conditioning CURRENT REV No.: 0912 DATE: December 2009 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES Rev No.: 0908 August 2009 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may involve ha
3、zardous 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 Notic
4、e: Revised Sections 4.3.1.1 and 4.3.2 related to finish requirements; added Section 7.2 for I.D. marking of end fittings; editorial changes. Reference: File 20-3 Keywords: Hose, Air Conditioning 1.0 APPLICATION This specification covers reinforced hose assemblies with permanently attached fittings s
5、uitable for conducting liquid or gaseous refrigerant and refrigerant oils within the temperature range of -29C (-20F) to 120C (250F) and a maximum recommended working pressure of 500 psi (3.5 MPa). 1.1 Type I, II, III and IV OBSOLETE - Do not use in new designs Contact Materials Engineering for furt
6、her information. 1.2 Type V FOR USE WITH R-134a REFRIGERANTS Meets the requirements of SAE J2064 Type C (except dimensions) and is approved for systems using tetrafluoroethane (HFC134a, B-41) refrigerant and polyalkylene glycol lubricants (TMS-6818). 2.0 SCOPE This specification covers the general r
7、equirements, property and performance requirements, qualification, KCC and quality control, dimensional tolerances, requirements for fittings, and hose assemblies purchased with permanently attached end fittings and used as a flexible connector in automotive air conditioning systems. 2.1 Restricted
8、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. The following S
9、pecifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 NAVISTAR CEMS G-20 ASTM D 1680 NAVISTAR Mfg Std. MS-D-13 NAVISTAR CEMS C-3 SAE J51 NAVISTAR Eng. Design Std A-16 NAVISTAR TMS-6818 SAE J517 CFR Title 29, Part 1910 NAVISTAR CE
10、MS A-6, Part I SAE J2064 NAVISTAR CEMS A-45, Part I NAVISTAR CEMS C-10 AWS A5.8 NAVISTAR Eng. Drawing PT16053776 NAVISTAR CEMS B-50 SAE J343 NAVISTAR Eng. Drawing PT16044276 ASME Y14.5M-1994 (1994 version reqd) ASTM D 380 NAVISTAR TMS-9543 ASTM D 471 MIL-PRF-2104H NAVISTAR CEMS A-0, Part II ASTM B 8
11、41 ASTM D 2000 Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TMS-6021 TITLE: Hose, Air Conditioning REVISION: 0912 This document is restricted and may not be sent outsid
12、e Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. DECEMBER 2009 Page 2 of 27 4.0 GENERAL REQUIREMENTS 4.1 Construction 4.1.1 Type V: The hose shall consist of a seamless smooth bore inne
13、r tube of a layered rubber/nylon/rubber, reinforced with a high tensile ply or plies of polyester fabric bonded to the inner tube, and a chloro-butyl rubber, weather resistant outer cover which is perforated (pin pricked). 4.2 Dimensional Tolerances 4.2.1 Hose: Hose I.D., O.D., and concentricity lim
14、its are shown in Table 1 for Type V hose. Dimensions and tolerances shown are for hoses with crimped ends. TABLE 1. TYPE V HOSE DIMENSIONAL TOLERANCES HOSE SIZE NOMINAL SIZE INSIDE DIAMETER OUTSIDE DIAMETER CONCENTRICITY TIR BEND RADIUS, MIN mm inches mm mm mm mm min max min max 8.0 5/16 7.62 8.38 1
15、4.22 15.24 0.76 38 10.0 13/32 10.16 11.17 16.76 17.78 50.8 13.0 1/2 12.44 13.46 18.92 19.94 63.5 16.0 5/8 15.62 16.63 23.11 24.13 90 19.0 3/4 18.92 19.94 26.92 27.94 127 4.2.2 Hose assemblies: Assembly length tolerances are shown below. Under 30.5 cm (12 in) 3.2 mm ( 1/8 in) 30.5 to 45.7 cm (12 to 1
16、8 in) 4.8 mm ( 3/16 in) 45.7 to 91.4 cm (18 to 36 in) 6.4 mm ( 1/4 in) Over 91.4 cm (36 in) 1% 4.2.3 C-Plate Fittings: All dimensioning and tolerances pertaining to fittings are in accordance with ASME Y14.5M-1994 (conformance to the 1994 version of ASME Y14.5M is required). 4.2.4 Steel Tubing: Dime
17、nsional tolerances for steel tubing will conform to the tolerances as given in CEMS A-45, Part I. 4.3 Coupling Hardware 4.3.1 Tubing Tubing will be made from low carbon electric resistance welded steel tubing conforming to Grade 6, CEMS A-45, Part I. After forming, out-of-roundness of tubing shall n
18、ot exceed 10% of tubing O.D. in area of forming. 4.3.1.1 Tubing Finish The outer surfaces of steel tubing will be plated with zinc-nickel plating, Class 1, Grade 8, Type E per ASTM B 841, and must provide a minimum salt spray performance (ASTM B 117) of 120 hrs to white corrosion and 600 hr to red r
19、ust for straight tubes, and 480 hrs to red rust for post-bent tubes. Use of hexavalent chromate conversion coatings is prohibited, however trivalent chromate or chrome-free topcoats are allowed. Plating of internal surfaces is optional. (Refer to Section 4.7.3 for corrosion requirements of hose asse
20、mblies.) Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TMS-6021 TITLE: Hose, Air Conditioning REVISION: 0912 This document is restricted and may not be sent outside Navi
21、star, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. DECEMBER 2009 Page 3 of 27 4.3.2 Fittings and Hardware 4.3.2.1 Fittings 4.3.2.1.1 Material - Fittings will be made from Steel, Code 0-115 per
22、CEMS A-0, Part II. 4.3.2.1.2 Optional Fitting Material 1) Brass, UNS C36000 or UNS C37700, free cutting or forging grades, per CEMS C-3. 2) Steel, Powder Metal, Code FX-1008-50, per CEMS H-1 (minimum density of 7.50 g/cc) 3) 6061-T6 aluminum extrusion per CEMS C-10 (only when aluminum tubing is used
23、) 4.3.2.1.3 Finish for Fittings Steel fittings will be plated with zinc-nickel plating, Class 1, Grade 8, Type E per ASTM B 841. 4.3.2.2 C-Plate Seal 4.3.2.2.1 Material - The C-Plate Seal will be steel conforming to Grade 1C, CEMS A-6, Part I, with a bonded seal per 4.3.4.2. 4.3.2.2.2 Finish - The C
24、-plate seals will be zinc plated, Class 8A per CEMS G-20. 4.3.3 Fitting Construction All tubing and various A/C ports will be brazed to the endform. Optional brackets and noise reduction canisters may also be brazed onto the fitting. Braze material will meet requirements of American Welding Society
25、AWS A5.8, but specific type of filler metal may be chosen at the discretion of the supplier. (Filler metals must conform to the requirements of CEMS B-50 for restricted chemical substances.) 4.3.4 Elastomer Seals 4.3.4.1 O-rings: Shall meet ASTM D 2000 M2CH710 A25 E035 F16 Z1 Z2 Z3 Z4 Z5 Z6 Z1 Polym
26、er - HNBR Z2 - Color Orange Z3 - Compression set 70 hrs at 135oC = 55% max. Z4 - Elongation 140% min. Z5 Fluid Resistance per ASTM D 471, fluid Type III per TMS-6818 (PAG), 70 hrs at 125 C. Change in Hardness 10 points Change in tensile strength -15% max Change in elongation -30% max Change in volum
27、e 0 15% Z6 Fluid Resistance per ASTM D 471, fluid Type II per TMS-6818 (Ester), 70 hrs at 125 C. Change in Hardness 10 points Change in tensile strength -15% max Change in elongation -30% max Change in volume 0 15% F16 Low temperature resistance at -35 , pass. 4.3.4.2 C-Plate Seal: an HNBR seal bond
28、ed to steel per ASTM D 2000 M3DH710 A26 B16 E016 E036 F13 Z1 Z2 Z3 Z4 Z1 Polymer - HNBR Z2 - Rubber Adhesion per ASTM D 429 Method B 3.5 N/m minimum, R50 minimum. Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitt
29、ed without license from IHS-,-,-NUMBER: TMS-6021 TITLE: Hose, Air Conditioning REVISION: 0912 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. 2009 by Nav
30、istar, Inc. DECEMBER 2009 Page 4 of 27 Z3 Fluid Resistance per ASTM D 471, fluid Type III per TMS-6818 (PAG), 70 hrs at 125 C. Change in Hardness 10 points Change in tensile strength -15% max Change in elongation -30% max Change in volume 0 15% Change in adhesion -15% max Z4 Fluid Resistance per AST
31、M D 471, fluid Type II per TMS-6818 (Ester), 70 hrs at 125 C. Change in Hardness 10 points Change in tensile strength -15% max Change in elongation -30% max Change in volume 0 15% Change in adhesion -15% max 4.3.5 Hose Coupling Construction Shall be designed, inserted, and swaged or crimped so as to
32、 prevent hose abrasion, cuts or flaws. Sharp corners contacting the hose shall be avoided. Coupling shall be designed for low flow restriction, and design must be approved by Truck Development and Technology Center, Fort Wayne. 4.4 Fitting Design 4.4.1 Endform Design The endform will be a machined p
33、art. There are six different design types. Types 1 and 2, the ” and ” Male designs (see Figures 1 and 2), have a recessed groove to retain the HNBR O-ring. Types 3 and 4, the ” and ” Female designs (see Figures 3 and 4), have a threaded hole for installation of a threaded stud. Types 5 and 6, the ”
34、and ” Female junction endform designs (see Figures 5 and 6), have two pilot holes to insert the junction block in the middle of a fitting, plus a threaded hole for installation of a threaded stud. Parts supplied shall be within the tolerances specified in Figures 1 through 6. 4.4.2 Stud Installation
35、 into Female Endform The Female endform is designed with internal threads for the installation of an M8 Grooved Drive Stud (see Figure 7). See service manual for Stud part number. Figure 7 is for reference only. The drive stud is installed into the endform as shown in Figure 8. Table 2 provides prop
36、er torque value for installing studs into endforms and other components. Table 2. Stud Torque STUD LOCATION STUD TORQUE Accumulator Bottle 12.8 1.2 N-m (113 10 in-lbs) Evaporator Core 5.0 1.0 N-m (45 9 in-lbs) Fitting Endform 12.8 1.2 N-m (113 10 in-lbs) Refrigerant Compressor 9.3 2.5 N-m (82.3 22 i
37、n-lbs) Condenser Core 8.5 1.5 N-m (75.3 13.3 in-lbs) Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TMS-6021 TITLE: Hose, Air Conditioning REVISION: 0912 This document is
38、 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. 2009 by Navistar, Inc. DECEMBER 2009 Page 5 of 27 4.4.3 O-Ring Seals Two sizes of O-ring seals are used. The 10.78 mm ID
39、is used with the ” Male endform (see Figure 9) and the 15.54 mm ID is used with the ” Male endform (see Figure 10). The O-ring seal part numbers are shown on the A/C Hose Assembly drawings. Figures 9 SAE J2064, R134a Refrigerant Automotive Air-Conditioning Hose; and ASTM D 380, Standard Test Methods
40、 for Rubber Hose. Whenever possible, test samples shall be taken from finished hose. 4.6.1 Cold Flexibility Test per SAE J2064 except at -40 C with a mandrel having a diameter equal to the minimum bend diameter as shown in Table I, which has been conditioned to -40 C. Check inner tube visually for f
41、ractures and leak test. 4.6.2 Change in Volume A section of the inner tube shall not have a volume change exceeding -5% to +20% after 70 hours immersion in TMS-6818 PAG Lubricant at 100 C (212 F). 4.6.3 Ozone Test Bend hose around a mandrel having a diameter eight times the nominal O.D. of the hose.
42、 Expose the hose for 70 hours to an atmosphere having an ozone concentration of 100 pphm at 40+2C (104+4F). The outer hose cover shall not show signs of cracking when examined under 7X magnification. 4.6.4 Extraction Test The extract shall not exceed 118 g/m of the inside tube surface, and any const
43、ituent shall be oily or soft, greasy in nature, and not harmful to the refrigerant system. 4.7 Property And Performance Requirements Hose Assemblies Unless otherwise specified, material evaluation shall be in accordance with ASTM D 1680, Methods of Testing Automotive Air Conditioning Hose; SAE J2064
44、, R134a Refrigerant Automotive Air-Conditioning Hose; and ASTM D 380, Standard Test Methods for Rubber Hose. 4.7.1 Leak Testing Leak test all assemblies before and after performing the indicated tests as listed. 4.7.1.1 Method Pressurize assembly to 3.4 MPa with the appropriate refrigerant. Perform
45、the leak test at room temperature. Use a Halogen Leak Detector calibrated to alarm at 5.9 gm/yr (0.013 lb/yr) stationary to determine if unacceptable leaks exist. Scan at a rate of no more than 1 inch per second at a distance of less than 1/4“ from, and normal to, the surface. 4.7.1.2 Required All a
46、ssemblies shall pass both before and after performing the required tests. 4.7.2 Heat Aging Resistance Test procedure per SAE J2064 except as indicated below. After heat aging for 240 hours at 125 2 C, the hose shall not show any evidence of charring, cracking, leaking or disintegration. Capped hose
47、assemblies may be charged with refrigerant or nitrogen before being subjected to heat age. Leak test 3.4 MPa and check inner tube visually for fracture after leak test. Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TMS-6021 TITLE: Hose, Air Conditioning REVISION: 0912 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are re
