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. 2014 by Navistar, Inc. February 2014 Page 1 of 8 NAVISTAR, INC. Material, Parts, and Process Specificati
2、ons (MPAPS) NUMBER: MPAPS P-9563 Former Designation: TMS-9563 TITLE: Quality Requirements for Diesel Exhaust Fluid Tanks CURRENT REV No.: 1402 DATE: Feb. 2014 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: TMS-9563 - August 2013 PRINTED COPIES OF THIS DOCUMEN
3、T MUST BE VERIFIED FOR CURRENT REVISION This 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 de
4、termine the applicability of regulatory limits prior to use. Change Notice: Modified Section 4.4.3.5 (Extraction in DEF); modified Section 4.4.3.6 (Tank Media Resistance to DEF); editorial changes. 1.0 APPLICATION This specification covers engineering quality and functional requirements for purchase
5、d Diesel Exhaust Fluid (DEF) tanks used on Navistar vehicles as assembled in Navistar plants and for field service applications. 2.0 SCOPE This specification covers the material and performance requirements of DEF tanks, including requirements of the Process Verification Plan and Report, the manufac
6、turing quality plan, quality control and source approval, suppliers compliance reports, painting, appearance criteria, and shipping and identification requirements. DEF tanks can be made of plastic or stainless steel and generally come as an assembly complete with a shell, fill pipe, flanges, connec
7、tors, and fittings. 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 s
8、tandards shall apply. The following specifications, standards, and regulations are referenced in this specification: Quality System Standard ISO 9001 or TS-16949 NAVISTAR CEMS A-37 FMCSR 393.67 CFR Title 23, Part 658 NAVISTAR CEMS F-2 DIN 70070 CFR Title 29, Part 1910 NAVISTAR MPAPS D-28 ISO 2241-1
9、NAVISTAR Manufacturing Std MS-D-13 NAVISTAR TMS-4117 ASTM 5420 NAVISTAR RQ-COM-0032-WI NAVISTAR CEMS G-7 EPS-145 NAVISTAR TEM-PR-7.03 ASME Y14.5M-1994* ARM Low Temperature Impact Test NAVISTAR TMS-6929 NAVISTAR MPAPS GT-31 SAE J1926 NAVISTAR MPAPS B-50 AWS D1.6 AWS D1.1 AWS D1.3 ASTM D 543 *Conforma
10、nce to the 1994 version of ASMY14.5M is required. NUMBER: MPAPS P-9563 TITLE: Quality Requirements for Diesel Exhaust Fluid Tanks REVISION: 1402 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are r
11、equired to assume all patent liability. 2014 by Navistar, Inc. February 2014 Page 2 of 8 4.0 GENERAL REQUIREMENTS 4.1 Design Guidelines 4.1.1 GD no post-molded inserts are allowed in the tank. Stainless Steel DEF tanks consist of a center section with end-caps, fill-pipe, fluid connector fittings, a
12、nd flanges or spuds for fittings. The center section, end-caps, fill-pipe, and flanges shall be suitably welded to provide a single unit for assembly or service. All welds on stainless steel DEF tanks must meet the requirements of TMS-9512 and AWS D1.1/1.3. All materials that contact DEF fluid must
13、be made from either High Density Polyethylene material per MPAPS D-28; Stainless Steel, grade 304, per CEMS A-37, and passivated per TMS-4117 Type 5; or other approved materials designated by Navistar Materials Engineering. 4.2.1 Tank Material and Finish Requirements Suppliers are responsible for me
14、eting all specified material requirements. The controlling Engineering Design Responsible group must approve pre-production requests for material deviations. Navistar Industrial Design will designate the tank exterior finish. Post-production requests for material deviations must be submitted to the
15、quality control manager of the using Navistar plant for approval in accordance with NAVISTAR RQ-COM-0032-WI. 4.2.2 Plastic Tanks 4.3.2.1 Plastic Materials: Medium or High Density Polyethylene that meets or exceeds the properties of PE, A46A66C0DF940K17M6SA55YB3600AC1Z1, material per MPAPS D-28. Z1:
16、F0 1000 hours in 100% Igepal per ASTM D1693. 4.3.2.2 Plastic material will be tested to MPAPS GT-31, Method B, for 3600 kJ for long term outdoor exposure. 4.2.3 Stainless Steel Tanks 4.2.3.1 Tank Material: Stainless Steel, grade 304, per CEMS A-37; passivated per TMS-4117 Type 5. 4.2.3.2 DEF Filler
17、Neck Materials: may be made from Medium-High Density Polyethylene per MPAPS D-28, or Stainless Steel, grade 304, per CEMS A-37 and passivated per TMS-4117 Type 5. 4.2.4 Fittings Table 1 provides the assembly torque requirements for straight threaded O-ring tank fittings used in the supply and return
18、 lines. For stainless steel fittings, use the upper limit of the torque range in Table 1. NUMBER: MPAPS P-9563 TITLE: Quality Requirements for Diesel Exhaust Fluid Tanks REVISION: 1402 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corpor
19、ate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. February 2014 Page 3 of 8 TABLE 1: SAE STRAIGHT THREAD PORT ASSEMBLY (SAE J1926) 4.2.5 Weight The weight of the DEF tank as delivered to the Navistar Plant assembly line will be reported. In additi
20、on, the weight of separate and individual parts included will be reported. All parts having a 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 DEF tank shall be ca
21、pable of meeting all performance requirements specified herein as well as conforming to the applicable Navistar DRD(s). 4.3.1 Design Service Life The DEF tank shall be capable of providing the normal performance expected of a commercial vehicle (within the anticipated design environment) for the ser
22、vice life designated for that truck application. 4.4 Testing 4.4.1 Functional Tests These tests should be conducted prior to any tanks being shipped to the assembly plants. Additionally these tests are to be used to test tank assemblies at the conclusion of all Validation Testing unless otherwise sp
23、ecified. All DEF tanks must pass the functional tanks to be utilized by Navistar. If a stainless steel tank fails the functional tests, the steel may be recycled. If a plastic DEF tank fails the functional tests, the plastic may not be recycled or re-enter the manufacturing stream. 4.4.1.1 DEF Tank
24、Leakage Test: 4.4.1.1.1 Preferred Method The preferred testing shall use a pressure decay tester while the tank is subjected to a minimum internal pressure of 3 0.5 psig and allowed to equilibrate for a period of at least 30 seconds. A NUMBER: MPAPS P-9563 TITLE: Quality Requirements for Diesel Exha
25、ust Fluid Tanks REVISION: 1402 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. 2014 by Navistar, Inc. February 2014 Page 4 of 8 pressure decay tester sha
26、ll be used to measure any change of internal pressure within the tank over a one minute period. The maximum allowable pressure over this period is 0.5 psig. 4.4.1.1.2 Alternative Method: To only be performed with prior approval from the design responsible engineering group. The DEF tank shall be pre
27、ssurized with air to a minimum internal pressure of 3 0.5 psig and allowed to equilibrate for a minimum of 30 seconds. The tank shall then be submerged in a water bath at room temperature for a minimum of 5 minutes. No bubbles or evidence of gas leakage is allowed during the test. 4.4.1.2 Inspection
28、: The DEF tank, fill-pipe, fluid connector fittings, metallic inserts, and flanges shall be visually inspected for any form of deformity or loss of functionality. 4.4.2 Validation Testing These tests are to be used to validate DEF tanks and assemblies prior to production. Section 4.4.2 Functional Te
29、sts should be run at the conclusion of all tests unless otherwise specified. 4.4.2.1 Burst Test 4.4.2.1.1 Method: Three tanks must be capable of withstanding 150% of the leak test pressure used in the DEF Tank Leakage Test. 4.4.2.2 Tank Drop Test 4.4.2.2.1 Method: Three empty tank to be dropped from
30、 a height of one meter following FMCSR 393.67(e)(1). 4.4.2.3 Cold Impact 4.4.2.3.1 Method: Condition specimens taken from DEF tank walls, at -40 o C for a minimum of 4 hours, and test specimens per ASTM D5628. The use of the ARM Low Temperature Impact Test, Method B is also acceptable. 4.4.2.3.2 Req
31、uired: A minimum 50% failure level of 40 ft lbf. 4.4.3.5 Extraction in DEF (Plastic Materials Only) 4.4.3.5.1 Method: Store ten tensile bars, with dimensions per ASTM D638 Type I, or bars of equivalent surface area, for each material in contact with DEF (i.e. both the DEF tank and quick filler neck
32、material, if different) in 1 kg of DEF for 500 hours at a fluid temperature of 23o 3o C in polyethylene Nalgene or glass containers. Following the 500 hour exposure, the tensile bar samples shall be removed from solution and discarded, and the DEF solution drained. The DEF solution shall be filtered
33、 with a general purpose paper filter and 250 ml of DEF solution retained in a polyethylene Nalgene or glass sample bottle. The general appearance, odor, turbidity, and foaminess of the solution shall be reported and recorded as well as any indicators of DEF tank material degradation including amount
34、 of filtrate separated from solution. Photographs of the filtrate shall be submitted and if an excess of filtrate is observed, indicating material degradation, samples shall be submitted to Navistar Materials Engineering for approval. ICP-OES or ICP-AES may be required on the retained, filtered DEF
35、by Navistar Materials Engineering. 4.4.3.5.2 Required: The metal concentrations in the DEF shall be within the Limit Value after Storage column shown in Table 2. Values shall be reported to the appropriate Navistar Design Engineer. Metal concentrations in excess of those shown in Table 2 will result
36、 in failure. NUMBER: MPAPS P-9563 TITLE: Quality Requirements for Diesel Exhaust Fluid Tanks REVISION: 1402 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 liabilit
37、y. 2014 by Navistar, Inc. February 2014 Page 5 of 8 TABLE 2: EXTRACTION LIMITS Element Unit Limit Value after Storage (Maximum) Calcium mg/kg DEF 2 Iron mg/kg DEF 0.5 Copper mg/kg DEF 0.5 Zinc mg/kg DEF 0.2 Chrome mg/kg DEF 0.5 Nickel mg/kg DEF 0.2 Aluminum mg/kg DEF 0.5 Magnesium mg/kg DEF 0.5 Sodi
38、um mg/kg DEF 2 Potassium mg/kg DEF 0.5 4.4.3.6 Tank Media Resistance to DEF 4.4.3.6.1 Method: Fill five DEF tanks with DEF, cap and store at 23o 3o C for 1000 hours. Every seven days, the tanks shall be drained of DEF, stored, and replaced with fresh DEF. The drained DEF solution shall be filtered w
39、ith a general purpose paper filter and 250 ml of DEF solution retained in a polyethylene Nalgene or glass sample bottle. The general appearance, odor, turbidity, and foaminess of the solution shall be reported and recorded as well as any indicators of DEF tank material degradation including the amou
40、nt of filtrate separated from solution. Photographs of the filtrate shall be submitted and if an excess of filtrate is observed, indicating material degradation, samples shall be submitted to appropriate Navistar Design Engineer for approval. For stainless steel DEF tanks, the filtered solutions fol
41、lowing weeks one, six, and 12 shall be submitted for elemental analysis. For plastic DEF tanks, if there is an excess of filtrate indicating degradation of the plastic tank materials, samples shall be analyzed with ATR and GCMS for evidence of plastic degradation. 4.4.3.6.2 Required: For stainless s
42、teel tanks, the metal concentrations in the DEF shall be within the Limit Value after Storage column shown in Table 2. Values shall be reported to the appropriate Navistar Design Engineer. Metal concentrations in excess of those shown in Table 2 will result in failure. For plastic tanks if an excess
43、 of filtrate is found, the analytical results shall be submitted to Navistar Design Engineering. There shall be no corrosion products or products of plastic degradation evident and tanks must pass 4.4.2 Functional Tests upon completion. 4.5 Certification and Label Requirements Each liquid DEF tank s
44、hall be permanently and legibly marked with “DEF ONLY”, the part number, and the useable volume in gallons and liters. The word “Diesel” is impermissible for labeling. The label position must be approved with Navistar Industrial Design. It is preferred that this information is molded directly or emb
45、ossed into plastic tanks but etching is also permitted with engineering approval. New stainless steel DEF tank labels shall be etched or engraved. Welded labels are not acceptable. Prior to production, proposed layout of product graphic shall be approved by Navistar Corporate Technical Standards Dep
46、artment and Industrial Design. 4.6 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 requirements of this specification as is described in Section 6.0 of this specification. NUMBER: MPAPS P
47、-9563 TITLE: Quality Requirements for Diesel Exhaust Fluid Tanks REVISION: 1402 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. 2014 by Navistar, Inc. Fe
48、bruary 2014 Page 6 of 8 5.0 QUALITY All DEF tanks shall be supplied in a clean and dry condition. No assembly or test fluids/DEFs may remain and/or leave a residue in the DEF tank. Tanks shall be free of rust at the point of application at the assembly plant. The use of paper or cloth towels to clea
49、n components is prohibited to prevent contamination of the tanks with fibers and fluffs. All tank assemblies should be capped for shipment to prevent contaminants from entering the tanks. Finished stainless steel DEF tanks must meet the Surface Appearance Acceptance Criteria as described in Table 3. 5.1 Qualification Material and processes submitted for approval to this specification shall include the following: 5.1.1 Report: A detailed and signed test rep
