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. OCTOBER 2009 Page 1 of 8 NAVISTAR, INC. TMS (TRUCK MATERIAL SPECIFICATION) NUMBER
2、: TMS-9555 TITLE Quality Requirements For Fuel Tanks CURRENT REV. No: 0910 DATE: OCTOBER 2009 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: 0904 April 2009 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: Modified 4.4 for label requirements; editorial changes. Reference: File 15 Keywords: Fuel Tanks, Welded Fuel tanks, Diesel Fuel Tanks. 1.0 APPLICATION This specification covers Engineering quality requirements for purchased fuel tanks used on Navistar trucks as assembled in Navistar plants, and
5、to such components as may be provided for field service applications. 2.0 SCOPE The fuel tank consists of a center section with end-caps, fill-pipe, and flanges or spuds suitable for the installation of all fittings. The center section, end-caps, fill-pipe, and flanges are all suitably welded to pro
6、vide a single unit for assembly or service. This specification covers the material and performance requirements of aluminized steel and aluminum tanks, including requirements of the Process Verification Plan and Report, the manufacturing quality plan, quality control and source approval, suppliers c
7、ompliance reports, painting, appearance criteria, and shipping and identification 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 REFERENCE
8、 DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following specifications, standards, and regulations are referenced in this specification: Quality System Standard ISO 9001 or TS-16949 NAVISTAR CEMS A-6, Part I FMCSR 393.65 CFR Title 23, Part 658 N
9、AVISTAR CEMS A-6, Part II FMCSR 393.67 CFR Title 29, Part 1910 NAVISTAR CEMS B-32 Alum. Assn AA 45 NAVISTAR Manufacturing Std MS-D-13 NAVISTAR CEMS C-10 TMS-9009 NAVISTAR RQ-COM-0032-WI NAVISTAR TMS-4513 TMS-9605 NAVISTAR TEM-PR-7.03 ASME Y14.5M-1994* NAVISTAR TMS-9511 NAVISTAR TMS-9512 CEMS G-7 TMS
10、-6929 NAVISTAR CEMS B-50 NAVISTAR TMS-9543 EPS-145 *Conformance to the 1994 version of ASME Y14.5M is required. Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TMS-9555 TI
11、TLE: Quality Requirements For Fuel Tanks REVISION: 0910 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. OCTOBER 2009 Page 2 of 8 4
12、.0 GENERAL REQUIREMENTS 4.1 Design Guidelines 4.1.1 GD&T GD&T is required on all new fuel tank drawings. GD&T will be applied to drawings per ASME Y14.5-1994 and TDS-SD-10. TDTC Chassis Engineering will review and approve all GD&T drawings. 4.1.2 CAD Requirements - Supplier shall submit a drawing (a
13、nd/or solid model) to Navistar for each tank. All drawings and solid models will be in UNIGRAPHICS per CAD/CAM Supplier Data Design Requirements per TEM-PR-7.03. 4.2 Construction The fuel tank consists of a center section with end-caps, fill-pipe, and flanges or spuds suitable for the installation o
14、f all fittings. The fuel tank shall be constructed in accordance with requirements described in FMCSR 393.67(c). All welds must meet the requirements of TMS-9511 (for aluminum) or TMS-9512 (for steel). 4.2.1 Material Suppliers are responsible for meeting all specified material requirements. The cont
15、rolling Engineering Design Responsible group at TDTC must approve pre-production requests for material deviations. Post-production requests for material deviations must be submitted to the plant metallurgist and/or the quality control manager of the using Navistar plant for approval in accordance wi
16、th NAVISTAR RQ-COM-0032-WI. 4.2.1.1 Aluminized Steel Tanks 4.2.1.1.1 Tank Material: Aluminized steel, Grade 1A, Class T1-75, per CEMS A-6, Part II 4.2.1.1.2 Tank Finish: Exterior - Paint per TMS-9009, Class IIA Interior - See Section 5.0 for interior fogging requirements. 4.2.1.1.3 Fuel Filler Necks
17、 for Painted Steel Tanks: Interior surfaces of filler necks will be coated with paint meeting the requirements of TMS-9009, Class II, as well as the long-term fuel immersion test referenced in Section 4.2.1.1.3.1. See Section 10.0 for approved coating(s). 4.2.1.1.3.1 Fuel immersion test: Coated fill
18、er neck samples must pass a 14-week fuel immersion test in ULSD and soy-based biodiesel (B-20). At the conclusion of the test, there shall be no evidence of softening, deterioration, major discoloration, or other changes to the coating. Suppliers wanting to use a coating other than the approved coat
19、ing in Sec. 10.0, must submit test results, including actual test samples, to Materials Engineering for approval. Contact Materials Engineering (TDTC) for detailed test procedure. 4.2.1.2 Aluminum Tanks 4.2.1.2.1 Tank Material: 5052-H34 or 5052-H32 aluminum per CEMS C-10 4.2.1.2.2 Tank Finish: Non-p
20、olished aluminum tanks will have a bright-etched finish. Polished aluminum tanks will have a buffed finish AA-M22 per Aluminum Association Document 45. The polished/buffed surface will be protected with a sprayed coating per TMS-4513 or other protective wrap prior to shipping. 4.2.1.3 Weight The wei
21、ght of the fuel tank as delivered to the Navistar Plant assembly line will be reported. In addition, the weight of separate and individual parts included will be reported. All parts having a Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reprod
22、uction or networking permitted without license from IHS-,-,-NUMBER: TMS-9555 TITLE: Quality Requirements For Fuel Tanks REVISION: 0910 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to
23、 assume all patent liability. 2009 by Navistar, Inc. OCTOBER 2009 Page 3 of 8 separate and distinct Navistar Part Number will have their weight reported by part number. Refer to TMS-9605 for preferred units and precision of measurement. 4.3 Design Performance The fuel tank shall be capable of meetin
24、g all performance requirements specified herein. The controlling Engineering Design Responsible group at TDTC must approve any deviation from the specified performance requirements. 4.3.1 Design Service Life The fuel tank shall be capable of providing the normal performance expected of a commercial
25、vehicle (within the anticipated design environment) for the service life designated for that truck application. 4.3.2 Testing 4.3.2.1 Manufacturing Tests Each tank shall be tested for joint and fitting leakage prior to painting. Testing will be performed by application of a soap solution to all join
26、ts and fittings, or by submersion, or by an equivalent means of leak detection, while the tank is subjected to a minimum internal pressure of 10 psi. Any discernible leakage shall be repaired using the same methods as were used in the fabrication of the tank. Refer to Section 6.3, Process Control. 4
27、.3.2.2 Liquid Fuel Tank Tests 4.3.2.2.1 Safety Venting System Test test to be performed per requirements of FMCSR 393.67(d)(1) 4.3.2.2.2 Leakage Test - test to be performed per requirements of FMCSR 393.67(d)(2) with the additional requirement that neither the tank nor any fitting shall show any dis
28、cernible leakage in any position the tank may assume during this test. 4.3.2.3 Side Mounted Liquid Fuel Tank Tests 4.3.2.3.1 Drop Test - test to be performed per requirements of FMCSR 393.67(e)(1) 4.3.2.3.2 Fill-pipe Test - test to be performed per requirements of FMCSR 393.67(e)(2) 4.4 Certificatio
29、n and Label Requirements Each liquid fuel tank shall be permanently and legibly marked in accordance with requirements of FMCSR 393.67. Welded labels are not acceptable. Labels shall be etched, engraved or embossed anodized aluminum per CEMS G-7 PSF-8CY8. The adhesive shall be acrylic foam a minimum
30、 of 0.50 mm thick and shall meet the requirements of CEMS G-7 PSF-8CY8 and TMS-6929. See TMS-6929 Part 2 for Design Guidelines, Process Considerations, and Validation. Alternately, the information may be etched, engraved or embossed directly to the tank with prior engineering approval. See Engineeri
31、ng Procedural Standard EPS-145 for guidelines on the color and composition of graphics. Prior to production, proposed layout of product graphic shall be approved by Corporate Technical Standards Department and Industrial Design at TDTC, Truck Design and Technology Center, 2911 Meyer Rd, Fort Wayne,
32、IN 46803. 4.4.1 Compliance Documentation Supplier shall submit documentation reporting results of all compliance testing performed in Section 4.3.2. The reports shall be prepared in accordance with TMS-9543. 4.4.1.1 Recipients Copies of each Compliance Report shall be sent to the following: Copyrigh
33、t Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TMS-9555 TITLE: Quality Requirements For Fuel Tanks REVISION: 0910 This document is restricted and may not be sent outside Navistar
34、, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. OCTOBER 2009 Page 4 of 8 Navistar, Inc. Navistar, Inc. Truck Development and Technology Center P. O. Box 1109 Fort Wayne, IN 46801-1109 Product Re
35、liability Center P. O. Box 10088 Fort Wayne, IN 46801-535 Attention: Manager - Technical Legislation Attention: Manager of Compliance 4.5 PVP&R Plan A manufacturing process verification plan and report will be developed to insure that the manufacturing processes employed are capable of meeting all r
36、equirements of this specification as is described in Section 6.0 of this specification. 5.0 QUALITY All fuel tanks shall be supplied in a clean and dry condition. For steel tanks which will be painted, the surface cleanliness requirements of Section 5.1 will be met. After painting, the manufacturer
37、will perform oil fogging of the interior surfaces of steel fuel tanks. Open holes will be plugged to prevent moisture entrance or fogging oil leakage. Tanks shall be free of rust at the point of application at the assembly plant. All assembly or test fluids/fuels that may remain or leave a residue i
38、n the fuel tank must be compatible with Navistar factory fill fuels and must not have a detrimental effect on the fuels ability to meet all chemical analysis requirements of the CEMS B-32 specification. Finished fuel tanks must meet the Surface Appearance Acceptance Criteria as described in Table 1.
39、 5.1 Surface Cleanliness Requirements 5.1.1 White Glove Test After cleaning and prior to application of any pretreatment and/or paint to the tank, a “white glove test” must be performed. After wiping the tank in locations representing all surface conditions with a suitable white cloth material, ther
40、e should be no visual evidence of soil or contamination of any kind. 5.1.2 Water Break Free Condition In addition to the white glove test, there must also exist a “water break free” condition over the entire exterior tank surface. This must be verified by applying an atomized mist of distilled water
41、 to the surface of the tank and examining the coverage of the water. If the water droplets coalesce into large lenses lasting for 25 seconds (without sudden flash-out), the surface is considered satisfactorily clean. If the water gathers into droplets within 25 seconds (i.e., a water-break condition
42、 exists), the surface will be considered as having failed the test. If the water mist forms a continuous film by flashing out quickly over a large area, this will be considered evidence of an impurity on the surface (e.g., free alkali, residual detergent, etc.) and the surface shall be considered as
43、 having failed the test. If more than 4 hours have passed since performing either the white-glove or water break test, tanks must be re-examined for surface corrosion, dirt, foreign matter, or oily residue and the tests must be repeated. Failure of either of the above two tests mandates that additio
44、nal cleaning procedures be performed until both tests can be passed. 6.0 SOURCE APPROVAL AND QUALITY CONTROL 6.1 Supplier Requirements All suppliers to Navistar, Inc. are required to be registered to ISO 9001 Quality System Requirements. Navistar will also accept TS-16949 registration as long as the
45、 supplier can also fulfill all AIAG PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,
46、-NUMBER: TMS-9555 TITLE: Quality Requirements For Fuel Tanks REVISION: 0910 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. OCTOBE
47、R 2009 Page 5 of 8 maintain their certification with an accredited 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 resp
48、ects to those samples that were approved by the purchaser. 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 Materials Engineering at TDTC and Purchasing and Supplier Development of the proposed change(s). Tes
