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. 2017 by Navistar, Inc. APRIL 2017 Page 1 of 5 NAVISTAR, INC. Material, Parts, and Process Specifications
2、 (MPAPS) NUMBER: MPAPS P-9545 Former Designation: TMS-9545 TITLE: Cab Leakage Testing Requirements CURRENT REV No.: 1704 DATE: Apr. 2017 WRITTEN/EDITED BY: J. Goldschmidt APPROVED BY: R. Goluch SUPERSEDES: Rev. 1304 April 2013 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION Thi
3、s specification may involve 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 lim
4、its prior to use. 1.0 APPLICATION This specification describes engineering requirements for the performance of air and water leakage testing of finished cabs assembled onto chassis. 2.0 SCOPE This specification covers equipment and general testing procedures, repair procedures, and reporting of test
5、s results. 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
6、shall apply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 NAVISTAR MPAPS B-50 CFR Title 29, Part 1910 NAVISTAR MPAPS P-9543 4.0 REQUIREMENTS Many methods of body leak detection are available. Two commonly
7、used at Navistar facilities are listed below. All test methods suffer from various levels of test errors. Air leak methods have a tendency to have a high false-positive rate shows more leaks than would be noticeable in use. And water leak methods suffer high false-negatives does not show leaks that
8、can occur in the field. It is important that leaks are thoroughly investigated during development and corrected. It is also important that production processes are regularly tested and monitored and that leaks identified are quickly communicated to parties responsible for correcting them. 4.1 Air Le
9、ak Test Method 4.1.1 Equipment 4.1.1.1 Blower motor calibrated on a flow bench, certified by Navistar Engineering, with an air flow rate vs voltage calibration curve at 0.25 kPa (1.0 inch water) pressure. NUMBER: MPAPS P-9545 TITLE: Cab Leakage Testing Requirements REVISION: 1704 This document is re
10、stricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2017 by Navistar, Inc. APRIL 2017 Page 2 of 5 4.1.1.2 A window mounting plug suitable for the body being tested. It shall ha
11、ve a sealed mounting for the blower scroll and a pressure port. 4.1.1.3 A variable voltage, DC power source. 4.1.1.4 A digital voltmeter, accurate to 0.01 volts in the range of 1 - 20 volts. 4.1.1.5 A pressure transducer with a digital readout, accurate to 0.0025 kPa (0.01 inches of water) at 0.25 k
12、Pa (1.0 inches) of water. 4.1.1.6 A solution of water and liquid detergent of approximately 20:1. 4.1.1.7 A suitable liquid spray apparatus. 4.1.1.8 A vehicle diagram or picture for that cab model tested, showing exterior surfaces with seams and joints. 4.1.1.9 Masking tape. 4.1.1.10 A camera. 4.1.2
13、 Procedure 4.1.2.1 Mount plug, blower and pressure transducer into door window opening. 4.1.2.2 Seal the mounting with the masking tape. 4.1.2.3 Close the fresh air duct and check all other windows and vents to be sure that they are closed. 4.1.2.4 Turn on blower and adjust voltage to obtain a stabl
14、e 0.25 kPa (1.0 inch of water) pressure. 4.1.2.5 Measure and record the voltage (initial) applied to the blower (measure at the blower). 4.1.2.6 Spray exterior seams and joints with the water and detergent solution. 4.1.2.7 Record on the vehicle diagram areas where bubbles are generated and document
15、 with photograph. 4.1.2.8 Based on the rate of bubble generation, note whether each leak is minor, significant, or major. 4.1.2.9 Repair significant and major leak points to the extent practical and readjust blower voltage to obtain a stable reading of 0.25 kPa (1.0 inch of water) pressure and recor
16、d voltage. (Use tape for test purposes and after test is complete, make permanent repairs.) 4.1.2.10 Report results of testing. Acceptant Criteria = Reference applicable DRD for acceptance criteria. 4.1.3 Air Leak - Test Report A report will be prepared, following the format described in MPAPS P-954
17、3, and submitted to engineering for inclusion in the engineering tracking system. (See Test Report Section). 4.2 Water Leak Test Method The water leak test should be performed on a regular basis to ensure that changes to the sealing processes do not create water leaks which may not be readily detect
18、ed by the air leak test. It should also be used on units and/or in cases that require more extensive repair work as identified by the air leak test. 4.2.1 Equipment 4.2.1.1 Water test facility - The test facility may be set up differently at each assembly plant. The facility must be capable of apply
19、ing large quantities of water over the entire exterior surface of the cab. The facility must be capable of directing the water flow to provide adequate testing of special areas such as the windshield, roof, etc. The test facility and water spray/application methods will be approved on a plant-by-pla
20、nt basis by Engineering and Reliability. 4.2.1.2 Light source for cab inspection. 4.2.1.3 Finished cab/unit with as much trim removed as possible. NUMBER: MPAPS P-9545 TITLE: Cab Leakage Testing Requirements REVISION: 1704 This document is restricted and may not be sent outside Navistar, Inc. or rep
21、roduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2017 by Navistar, Inc. APRIL 2017 Page 3 of 5 4.2.1.4 A vehicle diagram for that cab model being tested, showing exterior surfaces with seams and joints. 4.2.1.5 A camera. 4.2.2 Proc
22、edure 4.2.2.1 Drive truck into water testing booth. Apply flow and direction of water spray as defined below in the test parameters. (Alternate test A and test B when water testing trucks.) Test Parameters: A. Truck Wash - Pressure Spray Test Flow Rate = 3.5 to 6 GPM (794.9 to 1362.7 liters/hour) Pr
23、essure = 1500 PSI (10.34 MPa) Angle of Impingement on Window = Perpendicular to Window, Parallel to margin Nozzle Distance = 2 to 4 inches from target surface (Fanning back and forth on tested component) Duration = 2 minutes (120 sec) on each tested component Nozzle Fan Angle = 25 Water Temperature
24、= 115 to 120F (46 to 49C) Ambient Temperature = Room Temperature 68 to 77F (20 to 25C) Number of Test Washes Required = 1 wash for each component tested Acceptant Criteria = Reference applicable DRD for acceptance criteria. B. Truck Wash - Rain Simulation Test Flow Rate = 0.133 GPM (30.3 liters/hour
25、) Pressure = 29 PSI (0.2 MPa) Angle/Location = Any angle at any location Nozzle Distance = 24 to 40 inches from target surface; Spray should spread uniformly over the targeted surface. Duration = 10 minutes (600 sec) on each tested component Nozzle Type = Shower type Water Temperature = 115 to 120F
26、(46 to 49C) Ambient Temperature = Room Temperature 68 to 77F (20 to 25C) Number of Test Washes Required = 1 wash for each component tested Acceptant Criteria = Reference applicable DRD for acceptance criteria 4.2.2.2 Inspect cab for leaks, removing interior trim as necessary to facilitate complete i
27、nspection. 4.2.2.3 Record leakage points on the vehicle diagram and document with photograph. 4.2.2.4 Repair all water leaks to the extent practical and repeat the test procedure. 4.2.2.5 Report results of testing. 4.2.3 Water Leak - Test Report A report will be prepared, following the format descri
28、bed in MPAPS P-9543, and submitted to engineering for inclusion in the engineering tracking system. (See Test Report Section). NUMBER: MPAPS P-9545 TITLE: Cab Leakage Testing Requirements REVISION: 1704 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without perm
29、ission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2017 by Navistar, Inc. APRIL 2017 Page 4 of 5 4.3 Repair 4.3.1 Repair Actions 4.3.1.1 Repair all areas that could result in damaging water leaks. 4.3.1.2 Repair major and significant air leak points unt
30、il unit is within flow rate specification for that model. 4.3.1.3 Report significant/major leaks indicative of deficient sealing to responsible manufacturing and plant engineering groups immediately. 4.3.1.4 Record repetitive repair requirements and recommend changes to the sealing process. 4.3.2 Re
31、pair Methods All sealers and adhesives used to effect repairs shall be approved by Materials Engineering. In all cases, repairs made to exterior, glamour surfaces shall be repainted with approved paint repair systems (Clear sealers are NOT acceptable for repairs on glamour surfaces without being rep
32、ainted.). 4.4 Leakage - Test Report A report will be prepared, using the MPAPS P-9543 format, for inclusion in the engineering report tracking system. The following information will be included in appropriate sections of the report: 4.4.1 Cab model tested, including body configuration (for each test
33、 method). 4.4.2 Line set number(s) of unit(s) tested (for each test method). 4.4.3 Number of units tested of each body type (for each test method) 4.4.4 Initial voltage, measured at 0.25 kPa (1.0 inch of water) pressure (Air Leak Test). 4.4.5 Initial flow rate, from calibration curve (Air Leak Test)
34、. 4.4.6 Water temperature, flow rates, pressures, time of water flow (Water Leak Methods). 4.4.7 Leakage points recorded on the vehicle diagram (for each test method) and documented with a photograph. 4.4.8 Number of leaks and leakage severity levels (for each test method). 4.4.9 Flow rate improveme
35、nts after repair of leakage points (Air Leak Test). 4.4.10 Voltage, measured at 0.25 kPa (1 inch of water) pressure, after repair of leaks (Air Leak Test). 4.4.11 Average leakage (difference between initial and after repair - flow rates) by body type (Air Leak Test). 4.4.12 Summary and running trend
36、 (12 month trends) of leakage rates (for each test method). 4.4.13 Actions taken to improve cab sealing process (all tests). 4.4.14 Recommendations for improvements/changes to the engineering cab sealing diagrams (all tests). 5.0 TECHNICAL INFORMATION For further information related to the technical
37、 content of this specification, contact: Suppliers may purchase controlled copies of this specification by contacting: Materials Engineering and Technology Dept. 10400 W. North Avenue Melrose Park, IL 60160 E-mail: MaterialsEngineeringN IHS Markit Inc. 15 Inverness Way East Englewood CO 80112-5776 P
38、hone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/ NUMBER: MPAPS P-9545 TITLE: Cab Leakage Testing Requirements REVISION: 1704 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are require
39、d to assume all patent liability. 2017 by Navistar, Inc. APRIL 2017 Page 5 of 5 REVISION HISTORY Revision Level Change Approved by Date Approved 1704 Update to MPAPS format; correct test parameter A flow conversion error in 4.2.2.1. Update acceptance criteria to all read “Reference applicable DRD for acceptance criteria”. Remove 4.4.15 (monthly report distribution). R. Goluch 4/28/2017
