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. 2015 by Navistar, Inc. APRIL 2015 Page 1 of 21 NAVISTAR, INC. Material, Parts, and Process Specifications
2、 (MPAPS) NUMBER: MPAPS F-30 Former Designation: CEMS D-30 TITLE: Coolant Hose CURRENT REV No.: 1504 DATE: Apr. 2015 WRITTEN/EDITED BY: D. Daley APPROVED BY: K. Chapman SUPERSEDES: 1402 - February 2014 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may involv
3、e 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 limits prior to use. Change N
4、otice: Revised 7.6 and 7.7, added 7.9. Clarified 5.0, 10.0 and 8.16 1.0 APPLICATION This specification covers general requirements, property and performance requirements, identification, quality, packing and shipping, and source approval and quality control requirements for coolant hoses used on Nav
5、istar vehicles as assembled in Navistar plants and for field service applications. 2.0 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. 2.1 Restricted Chemical Substances
6、 Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the MPAPS B-50 specification. 2.2 Hose Connections Effective April 2012 on all releases subsequent to this date, hose dimensions and tolerances shall meet CEMS F-1. 3.0 CON
7、TENTS PAGE REFERENCE DOCUMENTS 2 CLASSIFICATION AND CONSTRUCTION 2 CONVERSION OF PREVIOUS SPECIFICATIONS 3 GENERAL REQUIREMENTS 4 QUALITY 5 METHODS OF TEST 8 SOURCE APPROVAL AND QUALITY CONTROL 10 DESIGNATION ON DRAWINGS 11 PACKING, SHIPPING, AND IDENTIFICATION 11 TECHNICAL INFORMATION 12 TABLES 13-
8、20 NUMBER: MPAPS F-30 TITLE: Coolant Hose REVISION: 1504 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. 2015 by Navistar, Inc. APRIL 2015 Page 2 of 21 4
9、.0 REFERENCE 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 TMS-6018 ASTM D 412 NAVISTAR Manufacturing
10、 Standard MS-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 11
11、93 NAVISTAR MPAPS B-1 ASTM D 380 ASTM D 2240 NAVISTAR CEMS DT-9 ASTM D 395 SAE J20 NAVISTAR TMS-6017 NAVISTAR MPAPS B-50 SAE J1684 NAVISTAR TMS-9543 NAVISTAR CEMS F-2 ASTM D 1418 NAVISTAR TMS-1058 NAVISTAR TMS-1059 ASTM D 5827 ASTM D 3321 ASTM D 1287 ASTM D 6130 NAVISTAR MPAPS F-1 *Conformance to th
12、e 1994 version of ASME Y14.5M is required. 5.0 CLASSIFICATION 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. Note: New hoses released to th
13、is specification shall be limited to 1A, 1BF, 1BDF 2A, 2BF and 2BDF. Alternate constructions shown below are not allowed. 1BF and 2BF can be supplied as a substitution to 1A and 2A respectively with engineering approval as documented by an SREA (Supplier Request for Engineering Approval). 5.1 Grades
14、 5.1.1 Grade 1 This grade covers a premium, 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,
15、 propylene and diene, see ASTM D 1418 for naming 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 tube shall be zinc free and the cover shall be non-blooming
16、. 5.1.2 Grade 2 This grade covers a silicone based hose used in engine coolant 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
17、 in fuel, oil, or hydraulic fluid applications. The tube and cover stocks shall 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 h
18、eater hoses or lower (cold-side) radiator hoses for medium duty trucks and buses. This shall not be used in heavy duty or severe service application requiring or advertising long life. NUMBER: MPAPS F-30 TITLE: Coolant Hose REVISION: 1504 This document is restricted and may not be sent outside Navis
19、tar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. APRIL 2015 Page 3 of 21 5.2 Suffix Letters 5.2.1 Suffix A bulk, straight hose through 38 mm (1 inch) ID suitably reinforced with ply or plies o
20、f spiraled, knitted or braided aramid yarn. Grade 3 hoses may be constructed from lower cost reinforcements, such as Rayon, with prior Materials Engineering approval. 5.2.2 Suffix B Preformed hose reinforced with ply or plies of knitted or spiraled aramid yarn. Grade 3 hoses may be constructed from
21、lower cost reinforcements, such as Rayon, with prior Materials Engineering approval. 5.2.3 Suffix C Straight hose over 25.4 mm (1 inch) ID reinforced with wrapped 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 s
22、uffix is not designated on the drawing, a spring shall not be supplied. 5.2.5 Suffix X No longer used, all notes referring to Suffix X shall meet Suffix Y requirements. 5.2.6 Suffix Y This is an additional requirement that may be added to Suffix B construction to limit the amount of swell allowed an
23、d requires a lock stitch knit to be used when using a knitted reinforcement or other non-expanding types of reinforcement. The use of this requirement may limit design flexibility further than described in MPAPS F-1 and should be thoroughly reviewed with the supplier prior to release. 5.2.7 Suffix Z
24、 This is an additional requirement for high impulse and torsion applications. Typically, this is required for large bore engine applications using short hose connectors with pipe. The suffix requires a meta-aramid or an approved hybrid para-meta aramid reinforcement to meet the increased requirement
25、s. 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 requirements for this application. 5.2.9 Suffix E Peroxide cure only. This is recommended for big bore engines. 5.2.10 Suffix F I
26、ncreased operating condition hoses for International Big Bore engines. This includes the requirements of Suffix E (if required), Y and Z plus higher burst and operating pressure requirements. 5.2.11 Suffix U When a suffix U is specified, see TMS-6047 for the specification. 5.3 Conversion of Previous
27、 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 TMS-6032 Type 1. For Class 3 use Grade 2. TMS-6026 becomes G
28、rade 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 insert shall be specified on the Engineering drawing or by
29、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 (a pitch of up to 35 mm is acceptable with larger diameter
30、wire) and an O.D. approximately 3.0 mm less than the nominal I.D. of the hose. The wire shall be cold drawn NUMBER: MPAPS F-30 TITLE: Coolant Hose REVISION: 1504 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards
31、. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. APRIL 2015 Page 4 of 21 carbon steel 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
32、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 wire shall be 18-8 stainless steel, full hard, CEMS A-37. 5.4
33、.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 and shall conform to the practices of SAE J20 and ASTM D 380 as well
34、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”, Section 8. Minimum tube thickness will be 0.06 in. (1.59 mm). Minimu
35、m cover thickness will be 0.03 in. (0.80 mm). 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 require
36、ments 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 diameter will not collapse more than 25 percent. 6.2.3 Cold Flexibility Specimens
37、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 visible bloom when examined with the naked eye as compared to a control samp
38、le. The sample shall remain reasonably unchanged in appearance throughout the cycle. 6.2.6 Electrochemical Resistance (Grades 1 it is currently expected to be around 15%. When no suffix requirement is given, this requirement is report only. When suffix “Y” is specified, no more than 8% of hot swell
39、is allowed. 6.2.9 Chemical Interaction Test by either method using each of the long-life coolants C, D and F listed in Table V. If PG is specified, then this test shall be run only using that fluid. Test shall utilize hose from production process and include any process aids or lubricants that would
40、 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 are still under ev
41、aluation and development, full and complete analytical reports should be submitted for review to NAVISTAR 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 period
42、ically (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 NAVISTAR Materials Engineering. Note: PG are required to perform this test but chemical analysis requirements have n
43、ot been determined. Submit fluids for evaluation to Navistar Materials Engineering. 6.3 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
44、 with production materials whenever possible. See MPAPS F-1 for guidance on pipe 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 use
45、d 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 maximum of torque. When appropriate, measur
46、e 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 Leakage Hoses tested with selected production fittings and clamps shall not have a greater than 3% weight change. No visi
47、ble fluid leakage shall be permitted during the test. 6.3.2 Fitting Insertion-Extraction Force Required: Less than 188N, an approved assembly lubricant may be used. See MPAPS F-1. 6.3.3 Impulse - Vibration Durability Suffix Z only This method and requirement is under development. Hoses tested with s
48、elected 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 of dirt, grease, and contamination. I
49、nside surfaces of hose shall be free of any substance which could interfere with attaining a satisfactory NUMBER: MPAPS F-30 TITLE: Coolant Hose REVISION: 1504 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. 2015 by Navistar, Inc. APRIL 2015 Page 6 of 21 clamping load or which could act as a lub
