1、This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2013 by Navistar Inc. APRIL 2013 Page 1 of 5 NAVISTAR INC. TMS (TRUCK MATERIA
2、L SPECIFICATION) NUMBER: TMS-9545 TITLE: Cab Leakage Testing Requirements CURRENT REV No.: 1304 DATE: APRIL 2013 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: August 2007 REV. C PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This speci
3、fication 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 limits pri
4、or to use. Change Notice: Water Leak Test Parameters Reference: File 30-1 Keywords: Leakage Requirements; Cab Leakage 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 spe
5、cification covers equipment and general testing procedures, repair procedures, and reporting of tests 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 CEMS B-50 specification
6、. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 NAVISTAR TMS-9543 NAVISTAR CEMS B-50 CFR Title 29
7、, Part 1910 NAVISTAR Manufacturing Standard D-13 4.0 GENERAL REQUIREMENTS Many methods of body leak detection are available. Two commonly 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-po
8、sitive rate shows more leaks than would be noticeable in use. And water leak methods suffer high false-negatives does not show leaks that can occur in the field. It is important that leaks are thoroughly investigated during development and corrected. It is also important that production processes ar
9、e regularly tested and monitored and that leaks identified are quickly communicated to parties responsible for correcting them. NUMBER: TMS-9545 TITLE: Cab Leakage Testing Requirements REVISION: 1304 This document is restricted and may not be sent outside International Truck and Engine Corporation o
10、r reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2013 by Navistar Inc. APRIL 2013 Page 2 of 5 4.1 Air Leak Test Method 4.1.1 Equipment 4.1.1.1 Blower motor calibrated on a flow bench, certified by Navistar Engineering, with an
11、 air flow rate vs voltage calibration curve at 0.25 kPa (1.0 inch water) pressure. 4.1.1.2 A window mounting plug suitable for the body being tested. It shall have 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, a
12、ccurate 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 kPa (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
13、. 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 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.
14、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 stable 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.
15、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 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 si
16、gnificant 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 record voltage. (Use tape for test purposes and after test is complete, make permanent repairs.) 4.1.2.10 Report results of testing. Acceptant C
17、riteria = Reference applicable DRD for acceptance criteria. NUMBER: TMS-9545 TITLE: Cab Leakage Testing Requirements REVISION: 1304 This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards.
18、Suppliers are required to assume all patent liability. 2013 by Navistar Inc. APRIL 2013 Page 3 of 5 4.1.3 Air Leak - Test Report A report will be prepared, following the format described in TMS-9543, and submitted to engineering for inclusion in the engineering tracking system. (See Test Report Sect
19、ion). 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 detected by the air leak test. It should also be used on units and/or in cases that require more extensive re
20、pair 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 applying large quantities of water over the entire exterior surface of the cab. The facility must be capable
21、 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-plant basis by Engineering and Reliability. 4.2.1.2 Light source for cab inspection. 4.2.1.3 Finished cab/
22、unit with as much trim removed as possible. 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 Procedure 4.2.2.1 Drive truck into water testing booth. Apply flow and direction of water spray as defined below in the test
23、 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 (1135.6 to 1362.7 liters/hour) Pressure = 1500 PSI (10.34 MPa) Angle of Impingement on Window = Perpendicular to Window, Parallel to margin Nozzle Dista
24、nce = 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 = 115 to 120F (46 to 49C) Ambient Temperature = Room Temperature 68 to 77F (20 to 25C) Number of Test Washes Required =
25、 1 wash for each component tested Acceptant Criteria = No leaking, breaking, dropping-off or any other failures. B. Truck Wash - Rain Simulation Test Flow Rate = 0.133 GPM (30.3 liters/hour) NUMBER: TMS-9545 TITLE: Cab Leakage Testing Requirements REVISION: 1304 This document is restricted and may n
26、ot be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2013 by Navistar Inc. APRIL 2013 Page 4 of 5 Pressure = 29 PSI (0.2 MPa) Angle/Location = Any angle at any locatio
27、n 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 (46 to 49C) Ambient Temperature = Room Temperature 68 to 77F (20 to 25C
28、) Number of Test Washes Required = 1 wash for each component tested Acceptant Criteria = No leaking, breaking, dropping-off or any other failures. 4.2.2.2 Inspect cab for leaks, removing interior trim as necessary to facilitate complete inspection. 4.2.2.3 Record leakage points on the vehicle diagra
29、m 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 described in TMS-9543, and submitted to engineering for inclusion in
30、 the engineering tracking system. (See Test Report Section). 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 until unit is within flow rate specification for that model. 4.3.1.3 Report significan
31、t/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 Repair Methods All sealers and adhesives used to effect repairs shall be approved by
32、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 repainted.). 4.4 Leakage - Test Report A report will be prepared, using the TMS-9543 f
33、ormat, 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 method). 4.4.2 Line set number(s) of unit(s) tested (for each test method). 4.4.3 Numb
34、er of units tested of each body type (for each test method) NUMBER: TMS-9545 TITLE: Cab Leakage Testing Requirements REVISION: 1304 This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards.
35、Suppliers are required to assume all patent liability. 2013 by Navistar Inc. APRIL 2013 Page 5 of 5 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). 4.4.6 Water temperature, flow rates, pressure
36、s, 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 improvements after repair of leakage points (Air Leak Te
37、st). 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 (12 month trends) of leakage rates (for each t
38、est 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). 4.4.15 Issue reports on a monthly basis with electronic notification to the following individuals: 5.0 TECHNICAL INFORMAT
39、ION For further information related to the technical content of this specification, contact: Suppliers may obtain controlled copies of this specification by contacting: Materials Engineering and Technology Dept. 10400 W. North Avenue Melrose Park, IL 6016 E-mail: MaterialsEngineeringN Information Ha
40、ndling Service (IHS) 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/ CIW Body Engineer (for that model tested) Paint Facility Quality Materials Engineer Body Plant Manager HVAC Engineer Body Plant Area Supervisor Assembly Plant Trim Line
41、Supervisor (for that model tested) Body Plant Quality Manager Assembly Plant Quality Manager Body Plant Resident Engineer Assembly Plant Resident Engineer Director Technical Development Assembly Plant Manager Manager of Body Engineering Paint Facility Manager Platform Engineering Manager Paint Facility Seal Line Supervisor
