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. JUNE 2009 Page 1 of 6 NAVISTAR, INC. TMS (TRUCK MATERIAL SPECIFICATION) NUMBER: TM
2、S-6042 srr TITLE: Brake Hose, Low Pressure, Hydraulic CURRENT REV No: 0906 DATE: June 2009 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES ISSUE OF: June 2003 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may involve h
3、azardous 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 Noti
4、ce: Replaced “International Truck and Engine Corporation” with “Navistar, Inc.” per corporate directive; changed plating requirements in 4.2.2; corrected 4.4.9.; changed pressure in 4.4.3; editorial changes. Reference: File 20-3 Key Words: Hose; Low Pressure; Brake 1.0 APPLICATION This specification
5、 covers low-pressure hydraulic brake hose suitable for use with DOT 3 brake fluid using clamped or fitted connections. 2.0 SCOPE This specification covers the general requirements, identification, property and performance requirements, and source approval and quality control. 2.1 Restricted Chemical
6、 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 specifica
7、tions, standards, and regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 NAVISTAR TMS-9528 ASTM B 117 NAVISTAR Manufacturing Std. MS-D-13 NAVISTAR TMS-9543 ASTM D 380 NAVISTAR CEMS C-3 CFR Title 29, Part 1910 ASTM D 471 NAVISTAR CEMS A-0, Part I and II SAE
8、 J30 ASTM D 622 NAVISTAR CEMS G-20 SAE J526 ASTM D 3884 CEMS B-50 SAE J1019 ASTM G 154 SAE J1873 4.0 GENERAL REQUIREMENTS 4.1 Hose Construction This hose shall consist of a smooth-bore tube of non-plasticized EPDM reinforced with one ply of braided, knit, or woven rayon yarn or two-ply counter direc
9、tional helically wound rayon yarn and covered by an outside layer of non-plasticized EPDM. This hose is available as either bulk, straight hose or as formed (curved) hose and may be assembled with either clamps or with crimped fittings. 4.2 Fittings The hose fittings shall be permanently attached en
10、ds of brass or coated steel. Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TMS-6042 TITLE: Brake Hose, Low Pressure, Hydraulic REVISION: 0906 This document is restricted
11、 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. JUNE 2009 Page 2 of 6 4.2.1 Brass: Shall be C36000 (half hard), C34500, C35000 for bar or extruded stock or C
12、37700 for forgings as per CEMS C-3. 4.2.2 Steel: Shall meet the requirements of Code 0-115 per CEMS A-0, Part II. Flareless type ferrules shall be made from steel meeting the requirements of Code 0-100 or Code 0-115 as per CEMS A-0, Part II and will be zinc plated per CEMS G-20, Class 6A. Tubing sha
13、ll be per SAE J526 and will have a corrosion resistant coating viable for 500 hours salt spray per ASTM B117. 4.3 Dimensions and Tolerances Unless otherwise specified, hose shall meet the dimension and tolerance requirements shown in Table 1. TABLE 1. DIMENSIONS AND TOLERANCES Nominal ID Inside Diam
14、eter Outside Diameter inches in. (mm) in. (mm) 5/16 .315 .020 (8.0 .5) .630 .020 (16.0 .5) 3/8 .394 .020 (10.0 .5) .709 .024 (18.0 .6) 5/8 .594 .024 (15.1 .6) .909 .024 (23.1 .6) 4.4 Property and Performance Requirements All tests shall be in accordance with ASTM D380 or ASTM D622 as appropriate unl
15、ess otherwise specified. 4.4.1 Original Properties Tensile Tube and Cover 8.0 MPa (1160 psi) minimum Elongation Tube and Cover 250% minimum Adhesion All Plies 2.0N/mm (11.4 lbf/in) width minimum Burst Strength All Sizes 2.0 MPa (290 psi) minimum Assembly Tensile Strength All Sizes 1.45 kN (325 LB) m
16、inimum crimp only 4.4.2 Cold Flexibility 4.4.2.1 Method Perform test on unaged hose, and on brake fluid aged hose 70 hours 125 2C (257 5F); perform Cold Flexibility test per SAE J30 method for SAE30R7 hose. 4.4.2.2 Required The hose shall not show any cracks, checks, or breaks in the tube or cover.
17、Shall pass a proof test hold 1.0 MPa (145 psi) pressure for 30 seconds without leakage or failure. 4.4.3 Vacuum Collapse 4.4.3.1 Method 4.4.3.1.1 Install a 45 cm (18 in) length of hose on a test fixture. The test fixture shall hold both ends rigidly with the hose suspended between the ends. 4.4.3.1.
18、2 Measure the OD at several locations and mark these locations. 4.4.3.1.3 Heat soak hose and fixture in a forced convection oven for 4 hours at 125 2C (257 5F). 4.4.3.1.4. While still at temperature in the oven, apply a vacuum to an absolute pressure of 3 millibars (maximum pressure) all sizes. 4.4.
19、3.1.5 Measure the OD at the marked locations while under vacuum. Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TMS-6042 TITLE: Brake Hose, Low Pressure, Hydraulic REVISI
20、ON: 0906 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. JUNE 2009 Page 3 of 6 4.4.3.2 Required: Diameter shall not decrease by mo
21、re than 20% during application of a vacuum. 4.4.4 Aged Properties 4.4.4.1 Method - 1 Expose hose sample for 600 hours at 125 2C (255 5F), while wrapped 180 over a mandrel with a diameter of 10X the nominal OD. After exposure, remove and slowly straighten (taking 4 to 8 seconds). 4.4.4.1.1 Required:
22、Sample shall show no cracks, charring or disintegration externally or internally. 4.4.4.2 Method - 2 Expose samples for 70 hours at 1252C (2555F) 4.4.4.2.1 Required 4.4.4.2.1.1 Tube and cover: Tensile change = -20% max 4.4.4.2.1.2 Tube and cover: Elongation change = -60% max 4.4.4.2.1.3 Tube and cov
23、er: Hardness change = -5, +20 pts 4.4.5 Kink Resistance - Bulk Hose Only Same as SAE J30 for SAE30R7 hose, except as indicated in Table 2 TABLE 2 Nominal Hose ID. In. (mm) Hose Inside Diameter In. Hole Center Distance In. (mm) Hole Diameter In. (mm) Hose Length (per D-30) 5/16 (8.0) .312 1.00 (25.4)
24、 .625 (15.9) 11.8 (300) 3/8 (10.0) .375 3.00 (76.2) .750 (19.0) 11.8 (300) 5/8 (15.1) .625 5.90 (150) 1.14 (29.0) 12.0 (304.8) 4.4.6 Fluid Resistance 4.4.6.1 Method Per ASTM D471 except immerse samples 168 hours in DOT 3 brake fluid at 125 2C (255 5F). 4.4.6.2 Required 4.4.6.2.1 Tube & Cover: Hardne
25、ss Change = 15 pts 4.4.6.2.2 Tube & Cover: Tensile strength reduction = 30% maximum 4.4.6.2.3 Tube & Cover: Elongation reduction = 45% maximum 4.4.6.2.4 Tube & Cover: Volume change = -5 to +15% 4.4.7 Ozone Resistance 4.4.7.1 Method Three test specimens will be mounted on a mandrel 7X OD. After mount
26、ing, the specimens will be aged 168 hours 125C then exposed in the ozone chamber for 168 hours 100 pphm. 4.4.7.2 Required After cooling on the mandrel, inspection of the specimens shall not reveal signs of cracking under 7X magnification. 4.4.8 Moisture Ingression 4.4.8.1 Method Per SAE J1873 using
27、DOT 3 Brake Fluid 4.4.8.2 Required Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TMS-6042 TITLE: Brake Hose, Low Pressure, Hydraulic REVISION: 0906 This document is rest
28、ricted 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. JUNE 2009 Page 4 of 6 The brake fluid within the hose assemblies shall contain no more than 5.0% water.
29、 4.4.9 Extractables 4.4.9.1 Method Plug one end of three 12 inch hose sections, fill with DOT 3 brake fluid, plug the other ends and place in a recirculating oven at 70C for 168 hours. Remove from oven and shake each sample vigorously for 30 seconds. Repeat oven exposure and shaking cycle twice. Aft
30、er the third cycle, remove hose sections from the oven and shake vigorously for 30 seconds and let hose sections cool to room temp. Analyze the brake fluid from each section using GC/MS and compare to fresh brake fluid. 4.4.9.2 Required Report observable differences. Perform analysis to determine th
31、e presence of oils and plasticizers. Contact Materials Engineering for appropriate methods and labs for this work. 4.4.10 Performance Requirements for Labeling These tests requirements are to assure that any labeling or marking is durable enough to last through the warranty period of the part that t
32、he labeling is being applied. 4.4.10.1 QuV Test (100 hour) 4.4.10.1.1 Method Perform test per ASTM G-154 (FS-40 bulbs) with the following test cycle: 4.4.10.1.1.1 8 hours ultraviolet light 4.4.10.1.1.2 4 hours condensing humidity 4.4.10.1.1.3 Repeat until exposure is complete 4.4.10.1.2 Required No
33、visible sign of degradation 4.4.10.2 Abrasion Resistance 4.4.10.2.1 Method Test per ASTM D3884 (RPDH). Use CS-10 wheel, 250 gram load, 100 cycles. 4.4.10.2.2 Required Labeling or marking must not smear and must remain legible as compared to the go/no-go picture described in section 7.1.1.4.1. 5.0 QU
34、ALITY All product supplied shall be clean and free from dirt, oils, sharp edges, or defects harmful to product performance. Parts and assemblies shall meet the cleanliness requirements of TMS-9528. All rubber debris from cutting and processing shall be removed. Any internal release agents shall be f
35、lushed from the inside of the hose. There shall be no fabric or flash exposed on the ID of the hose. Parts shall be free of voids and/or reinforcement splices. 5.1 Qualification Materials submitted for approval to this specification shall include the following: 5.1.1 A detailed, signed test report d
36、ocumenting testing to this specification per TMS-9543. 5.1.2 The complete procedure used for preparing and curing materials for test, especially surface preparation (when appropriate) and condition of the test materials. 5.1.3 A complete description, including engineering prints and pictures of any
37、non-standard test fixtures used. Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TMS-6042 TITLE: Brake Hose, Low Pressure, Hydraulic REVISION: 0906 This document is restri
38、cted 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. JUNE 2009 Page 5 of 6 5.1.4 Adhesive, substrate and any chemicals used for bonding where appropriate. 5.2
39、 Submission The material test report shall be submitted to: Manager of Materials Engineering NAVISTAR, Inc. PO Box 1109 Fort Wayne, IN 46801 5.3 Approval A report from Navistar will be issued approving new materials to this specification. Formal approval is not granted until this report has been pub
40、lished and the new material is listed in this specification. However, the approval report may be used as authorization for usage of that approved material/process prior to a change to this specification. 6.0 SOURCE APPROVAL AND QUALITY CONTROL 6.1 Supplier Requirements All suppliers to Navistar are
41、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 PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must maintain their certification with an ac
42、credited registrar and must furnish copies of registration certificates to their Navistar 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
43、. No changes in formulation 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 Truck Development and Technology Center and NAVISTAR Pu
44、rchasing 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 Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request fo
45、r 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 evidence of the lot having been produced in a state of statistical control and with a process capable of provid
46、ing all required properties. The part supplier and the 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 AND IDENTIFICATION Shipping and identification shall be in accordance with Navi
47、star Manufacturing Standard MS-D-13. When packaged for resale, containers, packaging and identification shall be accordance with requirements set forth by the Parts Marketing Division of the Parts Operation at Cantera in Warrenville, Illinois. 7.1 Identification Each hose shall be labeled or marked
48、on the outer cover along the entire length of the hose at intervals of not more than 380 mm (15 inches) in a color contrasting to that of the hose color, in clearly legible block capital letters not less than 3 mm (1/8 inch) high, with the following minimum information: Copyright Navistar International Corpo
