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 41 NAVISTAR, INC. Material, Parts, and Process Specifications
2、 (MPAPS) NUMBER: MPAPS F-6021 Former Designation: TMS-6021 TITLE: Hose added Eaton GH001/GH134 Hose in Table I; revised wall thickness column in Table 4; added Section 4.6.5; added Test Conditions in Sec. 4.7.13; added Approved Product in Section 9.1; editorial changes. 1.0 APPLICATION This specific
3、ation covers reinforced hose assemblies with permanently attached fittings suitable 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). 2.0 SCOPE This specificati
4、on covers the general requirements, 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 s
5、ystems. 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 MPAPS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards sha
6、ll apply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 NAVISTAR MPAPS H-1 SAE J51 NAVISTAR Mfg Std. MS-D-13 NAVISTAR MPAPS G-20 SAE J517 NAVISTAR Eng. Design Std A-16 NAVISTAR CEMS C-3 SAE J2064 CFR Title
7、29, Part 1910 NAVISTAR CEMS FT-1 SAE J343 NAVISTAR Eng. Drawing PT16053776 NAVISTAR MPAPS A-6, Part I ASTM D 1680 NAVISTAR Eng. Drawing PT16044276 NAVISTAR MPAPS C-10 ASTM D 380 NAVISTAR MPAPS P-9543 NAVISTAR MPAPS F-2 ASTM B 841 NAVISTAR TMS-6818 NAVISTAR MPAPS B-50 ASTM D 2000 NAVISTAR MPAPS A-0,
8、Part II MIL-PRF-2104H ASTM D 471 NAVISTAR CEMS A-45, Part I ASME Y14.5M-1994 (1994 version reqd) NAVISTAR MPAPS F-01 AWS A5.8 NAVISTAR MPAPS F-1058 NUMBER: MPAPS F-6021 TITLE: Hose other types of coatings may be used with prior approval from Engineering. Use of hexavalent chromate conversion coating
9、s is prohibited, however trivalent chromate or chrome-free conversion coatings are allowed. Plating of internal surfaces is optional. (Refer to Section 4.7.3 for corrosion requirements of hose assemblies.) NUMBER: MPAPS F-6021 TITLE: Hose variation from these radii must be approved by Navistar Engin
10、eering. Minimum recommended dimensions from bend tangent points to various features used in A/C plumbing are illustrated in Figures 17 through 25. In cases where the dimension is shown as a range, the larger number is preferred for ease of manufacture and cost, but the smaller number may be used whe
11、n design constraints require its use. Table 3: Standard Sizes and Bend Radii for Steel Tubing Size Outer Diameter Wall Thickness Preferred Centerline Bend Radii Allowable with Special Tooling 9.50 mm (3/8 inch) 0.89 mm (.035 inch) 19.05 mm (0.75 inch) N/A 9.50 mm (3/8 inch) 1.25 mm (.049 inch) 19.05
12、 mm (0.75 inch) N/A 12.70 mm (1/2 inch) 0.89 mm (.035 inch) 31.80 mm (1.25 inch) 19.05 mm (0.75 inch) 25.40 mm ( 1.00 inch) 12.70 mm (1/2 inch) 1.25 mm (.049 inch) 31.80 mm (1.25 inch) 19.05 mm (0.75 inch) 25.40 mm ( 1.00 inch) 15.90 mm (5/8 inch) 1.25 mm (.049 inch) 31.80 mm (1.25 inch) 25.40 mm (
13、1.00 inch) 19.00 mm (3/4 inch) 1.25 mm (.049 inch) 38.10 mm (1.50 inch) 31.80 mm (1.25 inch) NUMBER: MPAPS F-6021 TITLE: Hose SAE J2064, R134a Refrigerant Automotive Air-Conditioning Hose; and ASTM D 380, Standard Test Methods for Rubber Hose. Whenever possible, test samples shall be taken from fini
14、shed hose. Sample size for testing must be 6 to 10 pieces. 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 fractures and leak test. 4.
15、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. Expose the hose for 70 ho
16、urs 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 constituent shall be oily or so
17、ft, greasy in nature, and not harmful to the refrigerant system. 4.6.5 Temperature Range: Hose material is to be able to withstand a temperature range of -40oC to +125oC (-40oF to +275oF) NUMBER: MPAPS F-6021 TITLE: Hose SAE J2064, R134a Refrigerant Automotive Air-Conditioning Hose; and ASTM D 380,
18、Standard Test Methods for Rubber Hose. Sample size for testing must be 6 to 10 pieces. 4.7.1 Leak Testing Leak test all assemblies before and after performing the indicated tests as listed. 4.7.1.1 Method Validation: Pressurize assembly to 3.4 MPa with the appropriate refrigerant. Perform the leak t
19、est 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 Method Quality Control:
20、Pressurize assembly to 150 psi with 100% Helium. Perform the leak test at room temperature. Use a Helium Leak Detector calibrated to alarm at 7.0 gm/yr (0.015 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“
21、from, and normal to, the surface. 4.7.1.3 Acceptance Criteria: Assemblies must pass the leak test as per Section 4.7.1 at the completion of this test. 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 sho
22、w any evidence of charring, cracking, leaking or disintegration. Capped hose 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. 4.7.2.1 Acceptance Criteria: Assemblies must pass the
23、leak test as per Section 4.7.1 at the completion of this test. 4.7.3 Corrosion Resistance 4.7.3.1 Method: Connect male/female end form fittings per Section 4.5.1. Deadhead open ends of test parts. Expose assembled parts to 480 hours salt spray per ASTM B 117. 4.7.3.2 Acceptance Criteria: End form fi
24、tting assembly must pass leak test per Section 4.7.1. No permanent corrosion damage that would result in not being able to service the assembly (i.e., must be able to disassemble the fitting) is allowed. 4.7.4 Refrigerant Permeation Test procedure per SAE J2064 except as indicated below. Coupled hos
25、e assemblies with a minimum of 762 mm of free hose shall not permit the permeation of R-134a at a rate greater than shown below. The assemblies shall be subjected to the leak test before and after the permeation test. HOSE I.D. 24 hr TOTAL LOSS LOSS RATE AT 100C SIZE mm GRAMS Kg/m/yr 7.9 20 24.4 10.
26、3 26 24.4 12.7 32 24.4 15.9 40 24.4 19.0 40 24.4 NUMBER: MPAPS F-6021 TITLE: Hose & Tube Assemblies for Air Conditioning 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 t
27、o assume all patent liability. 2015 by Navistar, Inc. APRIL 2015 Page 11 of 41 4.7.4.1 Three test assemblies shall be connected to canisters having internal volumes of 510 cm and loaded to 0.61 g/cm of total volume with Refrigerant. 4.7.4.2 This test shall be conducted by sealing the refrigerant wit
28、hin the hose assemblies and placing them in an air oven at 100 C for 96 hours. Calculation of refrigerant permeation is to be made from accurate weight loss measurements. Weight measurements shall be made at approximately the same time each day until the test is completed. 4.7.4.3 One uncharged unca
29、pped assembly shall be included in the test. Loss in weight of the uncharged assembly shall be considered as “tare weight loss,“ which shall be deducted from the total weight loss of the charged assemblies. 4.7.4.4 The first 24 hours will be regarded as a “preconditioning period,“ and weight loss du
30、ring this period will not be considered in the final calculation. The maximum weight loss for this period shall not exceed the values shown above. 4.7.4.5 Acceptance Criteria: Assemblies must pass the leak test as per Section 4.7.1 at the completion of this test. 4.7.5 Moisture Ingression 4.7.5.1 Me
31、thod: Test per SAE J2064 4.7.5.2 Required: Hose shall not have a moisture ingression rate greater than 0.039 g/cm/yr (0.25 g/in/yr), Class I per SAE J2064 4.7.5.3 Acceptance Criteria: Assemblies must pass the leak test as per Section 4.7.1 at the completion of this test. 4.7.6 Vacuum Test Test per S
32、AE J2064. The collapse of the outside diameter shall not exceed 20% of the original O.D. when tested as specified. 4.7.7 Length Change Test per SAE J2064. Hose shall not contract in length more than 4% nor elongate more than 2% when tested under a pressure of 2.75 MPa (399 psi). 4.7.8 Proof Test (As
33、sembly) Test per SAE J2064. Hose shall satisfactorily withstand a test using hydraulic pressure equivalent to 50% of the specified minimum burst pressure for a period of not less than one minute nor more than five minutes. After proof, continue to burst strength. 4.7.9 Burst Strength (Assembly) Type
34、 V 13.8 MPa (2000 psi) minimum 4.7.10 Tensile Test of Assembly Test per ASTM D 380 except pressurize the test part with 207 69 kPa (30 10 psi) nitrogen or dry air. Assembly shall withstand the tensile force listed below without a loss of pressure. Note: If the hose leaks before failure but meets the
35、 failure load, then repeat the test with just the fitting only. ID (mm) ID (in) All Types 6.4 1/4 1.11 kN (250 lbf) minimum 7.9 5/16 1.56 kN (350 lbf) minimum 9.5 3/8 2.00 kN (450 lbf) minimum 10.3 13/32 2.23 kN (500 lbf) minimum 12.7 And Up 1/2 and Up 2.45 kN (550 lbf) minimum NUMBER: MPAPS F-6021
36、TITLE: Hose & Tube Assemblies for Air Conditioning 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
37、12 of 41 4.7.11 Impulse Test 4.7.11.1 Method: Test per SAE J343 except as indicated below. Hose assembly shall be installed in an impulse test machine with a 180 bend at the minimum bend radius shown in Table 1. 1. Pressure Variation: 170 + 170 kPa (25 + 25 psi) to maximum working pressure 3.45 + .1
38、7 MPa (500 + 25 psi). 2. Test Fluid: MIL-PRF-2104H, Automatic Transmission Fluid (Dexron), Refrigerant Oil (500 SUS Mineral Oil or TMS-6818 PAG Oil) or another fluid as agreed upon by the supplier and Materials Engineering. 3. Fluid Temperature: 125 2 C. 4. Air Temperature: Ambient. 5. Impulse Cycle
39、 Rate: 30 to 40 cycles per minute. 4.7.11.2 Required: Assemblies shall withstand 200,000 impulse cycles without leakage or malfunction and shall pass the Leak Test. 4.7.11.3 Acceptance Criteria: Assemblies must pass the leak test as per Section 4.7.1 at the completion of this test. 4.7.12 Coupling I
40、ntegrity 4.7.12.1 Method 1: For connectors with hoses Test procedure per SAE J2064 except as indicated below. Charge hose and canister with lubricant such that half of the exposed hose is in contact with the lubricant. Charge with refrigerant the same as in “Refrigerant Permeation“. Expose the assem
41、bly to four cycles of the following: 1. 96 hours at 125 C (257 F) (canister pressure at 2.07 MPa 300 psi) 2. Repeat the following cycle six times attaining temperature within one hour of temperature change: a. 4 hours at -30 C (-22 F) b. 4 hours at 125 C (257 F) 3. Repeat to step one until four cycl
42、es are complete. 4. After each cycle, flex the hose assembly 15, making ten full flexes in approximately 10 seconds each. Repeat flexes in a perpendicular plane. Evaluate each fitting for leakage. Hours oC Total hours MPAPS F-6021 Full Cycle 96 125 One time Repeat Full Cycle 4 times 576 4 -30 Repeat
43、 6 times (Total 48 hrs) 4 125 Method 2: For connectors without hoses 1. Place 3-6 samples into -40 oC freezer for 72 hours. 2. Remove the samples and place them into 121oC air oven for 24 hours. 3. Remove the samples and place them into -40 oC freezer for 34 hours. 4. Repeat steps two and three 9 ti
44、mes total of 432 hours. 5. Place the samples into 121 oC air oven for 72 hours. 6. Total test time is 576 hours. Hours oC Total hours NUMBER: MPAPS F-6021 TITLE: Hose & Tube Assemblies for Air Conditioning REVISION: 1504 This document is restricted and may not be sent outside Navistar, Inc. or repro
45、duced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. APRIL 2015 Page 13 of 41 MPAPS F-6021 Step 1 72 -40 One time Full Cycle 576 Step 2 24 121 Repeat 9 times (Total 432 hrs) 24 -40 Step 3 72 121 One time 4.7.12.2 R
46、equired: There shall be no observable leakage of refrigerant or oil. Total weight loss shall not exceed 5% of the original refrigerant charge. The hose shall not exhibit any cracking, blistering or delimitation anywhere in the hose construction. Hose ends shall remain firmly secured. Maximum allowab
47、le leakage shall not exceed a loss rate of 0.04 gram per 24 hours. 4.7.12.3 Acceptance Criteria: Assemblies must pass the leak test as per Section 4.7.1 at the completion of this test. 4.7.13 Vibration Test 4.7.13.1 Test Conditions For the following vibration tests, each Peanut fitting test sample s
48、hall be 700 mm (27.5”) in length consisting of 460 mm (18”) of refrigerant hose and 240 mm (9.5”) of tubing assys with the Peanut fitting located on each end of the metal tubing. Test samples to be attached to the vibration fixture following Figure A-0. 4.7.13.1 Method: Connect assemblies and mount
49、in test fixtures per Figure A-0. Pressurize the test part with 1.0 MPa (150 psi) nitrogen or dry air. Expose parts to the following loading cycle: Hours Frequency (Hz) Displacement Equivalent mm (in) “Gs” 60 30 3.30 (0.130) 6 40 5 6.35 (0.250) 0.3 40 50 2.03 (0.080) 10 Vibration Test Samples - Dimensions in mm NUMBER: MPAPS F-6021 TITLE: Hose & Tube Assemblies for A
