MAN Nutzfahrzeuge AG WORKS STANDARD August 2008

Corrosion Protection and Coating Systems

for purchased parts M 3018
Technical Delivery Conditions
Dimensions in mm

This English version is a translation. In case of doubt or conflict the valid German-language original will govern.

Contents
1 Scope and purpose
2 Release conditions
3 Designation of the corrosion protection and coating systems
4 Corrosion protection classes, selection
5 Coating systems, selection
6 Requirements and test samples
7 Corrosion resistance
8 Adhesive strength and basic characteristics of the coating system
9 Coverability
10 Resistance to other media
11 Identity test

1 Scope and purpose

This Standard applies for the corrosion protection and coating of purchased parts 1), for which none of
the assembly group and function-specific MAN coating systems as defined by M 3300-1 2), Table 2 have
to be applied.
This Standard is also applicable in cases where manufacturer-specific data on the coating have already
been included on external drawings.
Galvanic and chemical coverings must be documented in accordance with DIN 50960, DIN EN ISO 4042
or the applicable MAN Plant Standards.
The purpose of this Standard is to stipulate, for purchased parts in the normal cases, the
- corrosion resistance necessary for application using the corrosion resistance class required in the
designation (in accordance with 3.1-3.4),
as well as
- adhesive strength on the component and
- coverability with MAN top coatings,
thus enabling the component supplier/manufacturer to select a suitable, preferably commercially
available coating system, which is binding for all consignments following release by MAN
- and likewise, via the examples of proven and commercially available MAN coating systems, offer
those suppliers that have no proprietary, commercially available system for the required corrosion
protection class, a decision-making aid, through which the time required for release by MAN can be
significantly reduced (information and advice from MTWV Dept, Nuremberg Plant).
For purchased parts, which are no longer final coated by MAN, the selected coating systems must
include the top coat required in line with Section 3.3 or 3.4 and must fulfil the additional requirements
according to Section 7 to Section 11.2.
For proprietary parts bearing the designation "Coating: primed in accordance with Table 1; M 3300",
which are procured as purchased parts, the stipulations in accordance with Section 3.1 and optionally
corrosion protection classes 2 or 3.
1) Externally-produced parts in accordance with MAN documentation, as well as commercially available or special external parts in
accordance with external documentation.
2) Also coating systems in accordance with M 3300-2 and M 3311-1.

Co-responsibility for the standard: Dept. MTWV, Continued on Pages 2 to 16

Nuremberg

Prepared by: Jürgens, TDN Release TDN Replaces: 2008-02 Material group No.:
Gary, MTWV 2008-09, englisch
MAN Nutzfahrzeuge Aktiengesellschaft, Munich Plant - Standards Department (TDN) xAll rights reserved in accordance with ISO 16016.
Distribution and use of the content without the written approval of MAN Nutzfahrzeuge Aktiengesellschaft is strictly prohibited.
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2 Release conditions
For release in accordance with this Standard, the following additional conditions apply as well as the general
supply conditions for purchased parts, release conditions and procedures in accordance with MAN 239 et seq:
The coating system selected by the supplier/manufacturer for the required corrosion protection must be
presented to MAN for release in due time (MTWV Dept., Nürnberg Plant).
In addition to the initial sample test report, a precise description of the coating system, including details of the
condition of the component surfaces (e.g. bare, blasted) prior to coating and also the applied treatment stages
(cleaning, pre-treatment, priming and where necessary interim priming and top coat) with their coating
procedures, coating substances and layer thicknesses must be presented and appropriate test samples
provided.
The MAN weathering simulation test in accordance with MAN 365 (see Table 5) is conducted by MAN, MTWV
Dept., Nürnberg Plant.
As release is issued by MAN, the supplier undertakes to apply the approved coating system in its unchanged
form for all consignments and confirm compliance with same by means of Plant Certificate 2.2 in accordance
with DIN EN 10204 (previously DIN 50049 ) (example shown in Annex).
Any change to the coating system and/or coating substances and procedures will necessitate a new release by
MAN.

3 Designation of the corrosion protection and coating systems

The corrosion protection required in accordance with this Standard is specified and/or must be defined on both
MAN and external drawings, as well as in MAN master data via the following designations in accordance with
3.1 to 3.4:
Labels (in TDN and in the CAD library) are available for the data on drawings.
The word "corrosion protection" is not required for details in the master data.
The coating data in the component drawings always include the final state of the coating, which the
component at the finished vehicle must have.
If applicable, supply conditions deviating from the final condition, due to the production process (pre-coatings)
on individual components (if applicable only for an individual locations and or temporarily) will be notified by the
applicable operative units of the GE, Process Planning and Material Management, to the responsible MAN
buyer. The latter reaches agreement with the supplier and documents the result in the contractual records.
There will be no additional specification in the component drawing. For this reason, the information from the
applicable pilot sample test department must be ensured using the deviating supply condition.
In these cases, if no overpainting occurs with the large assembly, the further coating to the final condition
specified in the component drawing must be controlled by the operative units of the GE, Material Management
and Process Planning, using the work plan.
The corrosion protection class required in the designation determines the corrosion resistance to be
satisfied in accordance with Tables 5 and 6.. The design engineer selects the corrosion protection class for
each individual component in accordance with Table 2 (see also Section 4).

3.1 For components pre-coated for neutral colour (Special case),

which are final-coated by MAN with the large-scale assembly.

Designation: Corrosion protection M 3018 - X

Corrosion protection class (see Table 2, 5 & 6)

The manufacturer is at liberty to select the applied treatment stages (with either primer or top coat), gloss level
(normal case: semi-gloss) and colour (normal case: reddish brown or black).
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3.2 For colour-specific pre-coated components (special case),

which are final-coated by MAN with the large-scale assembly, although the colour must be consistent with that
of the final coat.
Designation: Corrosion protection M 3018 - X - RAL XXXX
Corrosion protection class (see Table 2, 5 & 6)
Colour according to RAL
(use preferred colours according to colour index RAL 840 HR - civil vehicles -
and/ RAL F9 - military vehicles)

The manufacturer is at liberty to select the applied treatment phases (with either base coat or top coat) and
gloss level (normal case: semi-gloss).

3.3 For order-independent final coated components (normal case),

which are not final-coated by MAN with the large assembly and for which an order-independent top coat must
be procured.

Designation: Corrosion protection M 3018 - X - E - g - RAL 9011

Corrosion protection class (see Table 2, 5 & 6)

Treatment stage E = with final coating
(Normal case : 2K top coats)

Gloss level in accordance with Table 1

(Normal case : g = gloss)

Colour
(preferred colour in accordance with colour index RAL 840;
Normal case: black, RAL 9011)

The manufacturer is at liberty to select the applied treatment stages (with the exception of the final coat).

3.4 For order-specific final-coated components (normal case)

which are not final-coated by MAN with the large assembly and for which an order-dependent top coat must be
procured (military vehicles).

Designation: Corrosion protection M 3018 - X - E - 2K - S - RAL 6031

Corrosion protection class (see Table 2, 5 & 6)

Treatment stage E = with final coating
(1K or 2K top coat)

Paint system where applicable*)

(Data required only for 2K =two component top coat)

Gloss level in accordance with Table 1 *)

(Normal case : s = dull matt)

Colour in accordance with RAL *)

(use preferred colours according to colour index RAL 840 HR - civil vehicles -
and/ RAL F9 for military vehicles)

*) In special cases, the item number for the customer-specific top layer can be indicated instead of this data.

The manufacturer is at liberty to select the applied treatment stages (with the exception of the final coat).
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Table 1 Gloss levels

Letter Reflectometer value Angle of irradiation

Name As per DIN 67 530 As per DIN 67 530

dull matt ≤8 85°

s
(for military vehicles) ≤2 60°
matt
m (for military vehicles) 20 - 30 85°

semi-gloss
h (Chassis up to F2000, M2000, 70 ±5 60°
L2000)
gloss
g (for cab and chassis from TG in 85 ±10 20°
commercially available design)

4 Corrosion protection classes, selection for design engineer

The corrosion protection of purchased parts is governed by the corrosion protection classes in accordance
with Table 2 (see Page 5), which are specified depending on the use of components on the vehicle and thus
the requirements for corrosion resistance (in accordance with Tables 5 and 6), as well as appearance as
defined in Section 3.

To make selection easier for the design engineer, Table 2 already contains an assignment of the corrosion
protection classes required in MN for the most important assemblies. The required corrosion protected class
can be specified likewise for non-stated assemblies.

In principle, the assignments in Table 2 also apply for the corrosion protection of external parts defined on
external component drawings.
The additional requirements in M 3297 apply for the corrosion protection of external bodywork.

5 Coating systems, selection for the supplier

In principle, the component supplier is at liberty to select a proprietary or commercially available coating
system that satisfies the requirements indicated on the drawing in accordance with Section 3 of this Standard,
via the indicated corrosion class, for corrosion protection.

Coating specifications in Section 7 of this standard and restricting layer thicknesses required in drawings must
be observed.

For pre-coated components with corrosion protection without final coating (in accordance with Sections 3.1
and 3.2), the selected coating system, as the final treatment stage, may include either a primer or top coat.

For suppliers with no established coating system for the required corrosion protection, the defined, proven
MAN coating systems assigned to the MAN corrosion classes in Table 3, which serve as decision-making aids,
or can be directly applied and therefore significantly reduce the time required for the MAN release procedure.

For pre-coated components (treatment stage G) with corrosion protection without final coating (in accordance
with Section 3.1 and 3.2), the corrosion resistance required by the corrosion protection class in accordance
with Table 5 can be checked in consultation with MAN and where applicable in the final-coated condition, i.e.
with MAN top coat in accordance with Table 3, Treatment Stage D. See also Section 8.

After processes such as laser cutting, laser welding, and resistance welding in oxygen atmospheres (without
special protective/inert gas), as well as welding in protective gas atmospheres and hot alignment where there are
thermally induced surface soiling (oxidation coatings and tarnishing) clean the components/assemblies analogous
to M 3161.
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5.1 Corrosion protection classes, selection and assignment
The assignment always applies for the final coated condition in line with Section 3.3. Deviating supply
conditions (pre-coatings) are assigned to the appropriate corrosion protection classes in Table 2 with the
symbol (G)=primed or (A)=supply condition primed.
Table 2 Corrosion protection classes, selection and assignment for the design engineer For footnotes, see next page
Corrosion protection class K1 / K2 0 1 2 3 4
Corrosion Very high Higher Higher High Normal Adequate
1
resistance )
(see Table 5)
2
Re- Appearance Very Very High High ) / Normal Sub-
quire- (visual high high Normal standard
ments impression)
3 3 3
Applicability Exterior ) Exterior ) Exterior ) Interior and Interior and Interior and
3 4 4
exterior ) exterior ) exterior )
Cab - Cab - Wiper - Window - Small parts
components - Fender - Radiator frame, below
exterior trim - Horn engine hood
- Headlight - Door handle - Auxiliary
--- - Mirror bracket - Lock heater ---
- Cab
suspension
- Air intake
pipe
- Step
- Bumper
- Roof light
- Spare wheel
hoist - MIL
- Camouflage
net bracket
Cab - Display - Cab - Small parts
components instruments bodywork - Small
internal - Instrument - Pedal cluster electrical parts
--- --- --- panel - Gear shift - Rubber/
- Dash panel lever metallic
insert - Bracket bearings
- Glove box
cover
- Bed
Application Chassis - Frame - - Battery and - Underride - Small parts in
for components MIL storage box guard brake system
- frame - Civil - Stabiliser - Exhaust
6
- Fuel - Brake cylinder system )
tank - Frame - Brackets
- Steel bodywork (G) - Small parts
- Stainless - Radiator (e.g. valves)
5
--- steel - Air filter - Engine )
- Alu - Axle - Cast and
- Compressed - Axle parts forged ---
air tank - Steering parts (A)
- Shock ab components - Drive shaft
sorbers - Cast and (G)
- Wheels forged parts - Transmission
- Frame - Compressed - Trailer,
bodywork air tank (G) Fifth wheel
- Drive shaft coupling
- Springs
Add-ons and - Closed - Tipper
bodywork bodywork - Tarpaulin
--- (e.g. tropics) frame --- ---
- External - Flatbed ---
bodywork frame,
- Tailboards
- Crane
- Slot-in frame
from alu
- External
bodywork
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1) Highly corrosive components
2) Visible interior cab parts
3) Heavy impact by spray water and stones and/or mechanical abrasion (components fitted in unprotected positions)
4) Less severe or indirect impact with spray water and occasional stone impact and mechanical abrasion
(components fitted in protected positions)
5) In the case of engines with Common Rail injection system (e.g. type D 20 ), no organic coating materials may be used in the direct
vicinity of the injection nozzles. This protects the injection systems from contamination during a service event.
6) Temperature resistance shall be demonstrated up to 650 °C
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Table 3 Examples of released pre-coated and final-coated MAN coating systems (see Section 5)
Corro- coating system / Treatment stages
sion Component surface V G Z D
protection Initial condition
class Pre-treatment Priming Intermediate coat Top coat

K1 Galvanised and/or hot- Zinc-phosphated KTL M 3078-2 Filler M 3079 1K M 3031-2

galvanised (if required) or or
2K M 3162-C 2K M 3094
3) Zinc-phosphated KTL M 3078-2 Filler M 3079
K2 Bare metallic
(if required) or
2K M 3162-C 1K M 3031-2
3) Zinc-phosphated KTL M 3078-2 1K M 3031-3 or
Bare metallic
Blasted --- M 3037 2K M 3162-C 2K M 3094
3) Zinc-phosphated KTL M 3078-2 Powder-coated
Bare metallic
M 3166-1
0 Galvanised and/or hot- Zinc-phosphated KTL M 3078-2 --- 1K M 3031
galvanised or
2K M 3094
3) Zinc-phosphated KTL M 3078-2 ---
Bare metallic
Galvanised and/or hot- --- 2K M 3162-C 1K M 3031
galvanised 1)
1 or
or galvanised / chromatised 2K M 3162-C --- 2K M 3094
or zinc-phosphated or
blasted
3) Zinc-phosphated KTL M 3078-2 --- Powder-coated
Bare metallic
M 3166-1
3) Zinc-phosphated --- --- Powder-coated
Bare metallic
M 3166-1
Galvanised and/or hot- Zinc-phosphated 2) --- ---
KTL M 3078-2
galvanised
3) Zinc-phosphated
Bare metallic
Galvanised and/or hot- ---
2 galvanised 1K M 3086-B
or galvanised / chromatised or --- ---
or zinc-phosphated or 2K M 3162-C
blasted
3) --- 2K M 3162-C --- ---
Bare-metallic , degreased
Zinc phosphated or --- 1K M 3086-A ---
Fe thick-layer phosphated or 2K M 3094
or blasted 2K M 3162-A
3) Zinc-phosphated --- --- Powder-coated
Bare metallic
M 3166-2
3) --- 1K M 3086-B --- 1K M3031
Bare-metallic , degreased
or or
2K M 3162-C 2K M 3094
3) --- 1K M 3086-A 2K M 3162-C ---
Bare-metallic , degreased
3) --- 1K M 3086-A --- 1K M 3031
Bare-metallic , degreased
or
2K M 3094
Engine L. N 680-A --- Engines L. N 680-B
partially
3 Zinc phosphated or --- 1K M 3086-A --- ---
Fe thick-layer phosphated or
or blasted 2K M 3162-A
3) --- 1K M 3086-A --- ---
Bare-metallic , degreased
Engines L. N 680-A/ B --- ---
Bare aluminium --- --- --- ---
Zn DIN 50976 --- --- --- 1K M 3031
or A3C, A4C or A3R or
DIN ISO 4042 (DIN 267-9) 2K M 3094
Bare metallic --- Standard commercial singlelayer coatings / coverings
4 Zn DIN 50976 --- --- --- ---
or A3C, A4C or A3R
DIN ISO 4042 (DIN 267)
1) Only for military, matt and dull matt top coats or as bonding agent for customised top coats
2) For interior cab parts only, if no demand by hand sweat or salt water is existent
3) According to M 3161
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6 Requirements and test samples

6.1 Based on the data in the designation (Section 3.1-3.4), the following requirements apply
in principle for:
- Coating requirements in acc. with Section 7

- corrosion resistance, for the corrosion protection class required in the designation
(Section 3.1-3.4) in acc. with Section 8
- Adhesive strength on the component and basic properties in acc. with Section 9
- Ability to be covered with MAN top coat materials in acc. with Section 10
- Temperature resistance in acc. with Section 11.1
and for coating systems with final coating (letter E in designation) also the requirements for
- colour and gloss level (designation example 3.3) and where applicable also the type of film formation
(2K = twocomponent top layer) or composition (customer-specific) of the top coatingmateria (designation
example 3.4)
- resistance to other media in accordance with Section 11.2.

6.2 The test panels shown in Table 4 must be coated under standard production conditions in
accordance with the coating system selected by the supplier for the required corrosion protection
class (see Sectio 2).
The coating is applied on the burred side of the test panels, including the edge areas.

Table 4 Test sheets in accordance with DIN EN ISO 1514

Test Dimension
Sheet quality and surface Edge type
sheet (mm)
no.

1 Pickled, deep-drawn sheet ST 1405 m using standard tool 200 x 100 x 1

in acc. with DIN 1623 / DC04B in acc. Punched
with DIN EN 10130

2 Pickled, deep-drawn sheet ST 1405 m min. 2 edges 190 x 65 x 1

1)
in acc. with DIN 1623 / DC04B in acc. with burr
with DIN EN 10130

3 Pickled, deep-drawn sheet ST 1405 m (without deburring) 300 x 150 x 1

2)
in acc. with DIN 1623 / DC04B in acc.
with DIN EN 10130

4 Finished parts and/or sections with dimensions indicated under test sheets 1 to 3 (as per
agreement)
3)
5 Pickled, deep-drawn sheet ST 1405 m using standard tool 95 x 65 x 1
in acc. with DIN 1623 / DC04B in acc.
Punched
with DIN EN 10130
1
) Only for MAN weathering simulation test in acc. with MAN 365
2
) Only for release weathering test in acc. with ISO 2810-1974
3
) Only for UV weathering in acc. with DIN EN ISO 11341

- Storage and regeneration times

Unless otherwise specified in individual cases, the test samples must be stored after coating and before
starting the tests for 7 days at room temperature (RT) and, after the test loads and before determining the
requirements (analyses) subject to a regeneration time of 1 hour at RT.
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6.3 Layer thickness test

The layer thicknesses specified in the investigation report from MTWV, in the pilot sample test report or in the
plant certificate according to DIN EN 10204 (dry layer thicknesses) are target layer thicknesses for the
released coating system in line with DIN EN ISO 12944-5. This coating system, and thus also the layer
thicknesses entered in the investigation report, are to be met on all deliveries from the supplier. The target
layer thickness is considered to have been achieved, if a maximum of 5 % of the measurement values are no
more than 20 % below the required target value.
The maximum layer thickness (DIN EN ISO 12944-5) of the overall system (final condition) must not exceed
200 µm. If the maximum layer thickness is slightly exceeded, the clearance of the coating may only occur in
agreement with MTWV.
Exceeding the target layer thickness, but still lower than the maximum layer thickness (DIN EN ISO 12944-5)
of the overall system, is permissible. Restricting layer thicknesses required in the drawings must be observed.

7 Coating requirements

- The overall layer thickness before assembly must not exceed 60 µm, for powder coatings 80+10 µm,
on joint surfaces and top support surfaces (settlement risk on screw connections). In these areas,
it is possible in exceptional cases to deviate from the required corrosion protection class. Where the
position of the joint and top support surfaces is unclear, the supplier must make contact with the operative
unit (Process Planning) at MAN.
- Cast and forged attached parts on the frame (supports) may only be coated with maximum 35 µm on the
joint surfaces. This restriction is to be stated in the drawing.
- For final or top coated lorry cab and chassis attached parts, gloss level (g) and the colour tone black
RAL 9011 are always to be applied. The gloss level and the colour are to be stated in the drawing.
- Elastomer parts may only be coated in special cases following agreement with the responsible MAN
specialist department.
- The use of a cathodic dip primer according to M 3078 Type 2 as thick coat CDP (25 - 35 μm) for attached
parts on chassis, cab and bus is possible if specified by the manufacturer.
- Frame parts, frame side members, strengtheners and attached parts made from flats must be top coated
before assembly.
Exception: On a lorry frame side member, the top coat is not required on the outside. The corrosion
resistance here before assembly must correspond to at least corrosion protection class 2. The lorry frame
side member will, in this case, be top coated after assembly of the attached parts as part of the chassis
coating.
- There can be very high temperatures in exhaust systems, intake, and charge air cooling in the engine
area. Coatings on these components shall be verified to have temperature resistance up to 650 °C
by suppliers.
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8 Corrosion resistance
The preliminary test with test loads a, b and c is a key criterion for the release.
Tests d and e apply only for corrosion resistance with final-coating (letter E in corrosion protection
designation).
If the MAN coating systems as shown in Table 3 are applied, Tests d and e are omitted.
Cast and forged parts must generally be tested for their final coats.
Test samples: Coating system on test sheets shown in Table 4 with following preparation
of coated- test sheets with letters a, b, c and d:

Preparation: The coating is treated down to the sheet subsurface with a 0.5
mm wide diamond milling cutter (see diagram)

Table 5 Corrosion resistance, test load

Test requirement for the
Test sheet
Letter Test load corrosion protection class required in the designation (Section 3.1-3.4) acc. to
K1 K2 0 1 2 3 4 Table 4

a Salt spray fog test

--- 1 000 h 720 h 480 h 240 h 120 h 72 h 1
DIN 50021 - SS (h)
b Condensed water - Constant climate
720 h 480 h 360 h 240 h 240 h 120 h 72 h 1
in acc. with DIN 50017 - KK
c MAN weathering simulation test
9 cycles 9 cycles 6 cycles 6 cycles 3 cycles --- --- 2
in acc. with MAN 365
1) 36 24 12 12 6
d Open-air weathering
--- --- 3
in acc. with ISO 2810 - 1974 Months Months Months Months Months
2) 600 h (DB 1K M 3031)
e Weathering in devices
4
in acc. with DIN EN ISO 11341 1200 h (DB 2K M 3094)

1) Open-air weathering from MTWV

Tests on finished component: letters and b only, letter c on agreement
2) For test conditions, see applicable Plant Standard (M 3031 and/or M 3094)

Table 6 Corrosion resistance, requirements

Properties Test load Analysis Requirements for the corrosion protection class specified
3
as per table 5 in the designation (Section 3.1-3.4) )
Test in accordance with 1)
(Letter) K1 K2 0 1 2 3 4
Degree of bubbling a; b; c; d Surface, cut max. m1 / g1
in acc. with DIN EN ISO 4628-2 and edges
Degree of rusting a; b; c; d Surface and Ref. value 0 Max. ref. value Ref. value 0
in acc. with DIN EN ISO 4628-3 edges 1
2
Rust creep ) a; b; d Cut ≤2 ≤3
in acc. with DIN EN ISO 7253
c ≤3 ≤4
(mm)
Crosscut a; b; c max. GT 2 max. GT 1
in acc. with DIN EN ISO 2409
Adhesive strength (scratching a; b; c max. K 2
test)
in acc. with MAN 277 Surface
Colour (colour difference) e max. ΔE* from ≤3 ---
in acc. with DIN 6174
max. ΔH* from 0 to 0.5
1) For test loads a and b, the analysis is conducted after a regeneration time of 6 h at RT
2) Assessment under the microscope with 10-times magnification
3) In the case of uncoated aluminium components, only the degree of rust is to be assessed; the maximum achievable degree of rusting is
ref. value 3; no other significant surface abrasion or pitting is permitted
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9 Adhesive strength and basic characteristics of the coating system

Test sample: Coating system on test sheet no. 1

Table 7 Adhesive strength, basic properties, requirements

Properties Tests after Requirements

DIN 6174 in acc. with RAL colour index

Colour (colour difference)
or MAN specification
Gloss level DIN 67 530 in acc. with Section 3

Crosscut DIN EN ISO 2409 max. GT 1

Adhesive strength (scratching test) MAN 277 Max. K2

Resistance to steam jet See Section 10.3 No signs of separation:

to be presented by supplier
4)
Carwash resistance DIN 55 668 Max. 50% drop in gloss level after
10 runs;
to be presented by supplier
Cupping
1) DIN EN ISO 1520
2)
≥4

Stone impact resistance (performance

M 3171 max. K2 / A
value)
(only on request)
1
) Determined on test sheet no. 1, coated only with top layer where applicable
2
) Assessed under microscope with 10 x magnification
3
) Only with top coat for military vehicles (RAL colour index F9)
4
) Only for final-coated purchased parts

10 Coverability
Must be capable of being covered with MAN top coat materials in acc. with M 3031 or M 3094.
Test sample: Coating system on test sheet no. 1, covered with coating materials in acc. with M 3031
or M 3094, layer thickness 40 - 50 µm

Table 8 Coverability, test load and requirements

Properties and requirements

Test load Test requirement Crosscut Adhesive strength Degree of bubbling
(Scratching test)
DIN EN ISO 2409 MAN 277 DIN EN ISO 4628-2

Thermal aging 3 h at 105°C Max. GT 1 Max. K2 m0 / g0

in acc. with
DIN EN ISO 2409

Condensed water -
1) 1) 1)
Constant climate 240 h Max. Gt 1 max. K2 m0 / g0
in acc. with
DIN 50017 - KK
1
) Analysis after regeneration time of 6 h at RT
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11 Resistance to other media
11.1 Temperature resistance
Test sample: Coating system on test sheet no. 1
Table 9 Temperature resistance, test load, requirements

Properties and requirements

Test load Test requirement Crosscut Adhesive strength Cupping
(Scratching test) (mm)
DIN EN ISO 2409 MAN 277 DIN ISO 1520

Thermal aging 48 h at 80°C Max. GT 2 Max. K2 ≥2

1)
in acc. with
DIN EN ISO 2409
1
) Assessed under microscope with 10 x magnification

11.2 Resistance to operating fluids and chemicals

These requirements apply only for corrosion protection with final coating
(letter E in description)
Test sample: Coating system on test sheet no. 1, coated on all sides for test media 1 and 2

Table 10 Media resistance, test load, requirements

Test Properties and requirements (all systems)

requirements
No. Test requirement Test method Colour Gloss Degree off Cross Adhesive
and other level bubbling cut strength
changes (Scratchin
DIN 67 530 DIN EN ISO DIN EN ISO g
4628-2 2409 test)
MAN 277

1. ASTM-Öl 2 24h at 50°C --- m0 / g0 Max. GT 1 Max. K2

in acc. with MAN 352-B
ASTM D 471
2. Diesel fuel B 24h at 50°C none m0 / g0 Gt 1 to Gt 2 Max. K2
in acc. with MAN 352-B Change
DIN 51604
3. Bio-diesel 24h at 50°C none m0/g0 Gt 1 to Gt 2 Max. K2
(RME/ FAME) in acc. MAN 352-B
with DIN EN 14214 Change

4. De-waxing 24h at 23°C none

agent MAN 352-A Change m0 / g0 Gt 1 to Gt 2 Max. K2
in acc. with M 3082 None visible
to naked eye
5. Paint protection 48h at 23°C none
1) m0 / g0 Gt 1 to Gt 2 Max. K2
wax A MAN 352-A Change
in acc. with M 3082
6. Insect- 24h at 23°C none
removing agent, MAN 352-A Change m0 / g0 Gt 1 to Gt 2 Max. K2
standard commercial
7. Oil black none
in acc. with --- Change m0 / g0 Gt 1 to Gt 2 Max. K2
VDA 621408
Section 6.2
8. Stain-
removability in acc. --- No visible change to surface
with M 3007
1
) Removal with test benzene in washing process
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M 3018 : 2008-08

11.3 Resistance to steam jets

Test sample: Coating system on test sheet no. 1
Test medium: water vapour with 3 - 5 % detergent Erwa 2000 at 100 bar
Test temperature and test duration: 5 min. steam jet / 90°C at a nozzle distance of 10 cm
Requirements: no signs of separation with all types
The steam jet test is to be performed only on purchased parts to which a final coat has been applied)
(Treatment stage E, see Item 3.3). The supplier must submit the results hereby achieved when presenting the
purchased part.

12 Identity test
Density - Coating
(g/ cm³) MAN 278 to be indicated
Volume of solids
(% vol.) DIN 53219) to be indicated
Bonding agent basis coat materials ⎞ All pigments and fillers
(IR spectral analysis) N 669 produced by MTWV ⎟ used in the top
⎬ must be free of
pigment basis ⎟ corrosion-promoting
(spectral analysis of pigments) produced byMTWV ⎠ electrolytes
The required identity values are to be indicated by each coating substance used in the coating system.

Standards quoted
ASTM D 471 Standard test method for rubber property - effect of liquids
DIN 1623 Flat products from steel; cold-rolled strip and sheet; Technical Delivery Conditions
DIN 50017 Climates and their technical application; condensation water test climates
DIN 50021 Corrosion tests; spray fog tests using different sodium chloride solutions
DIN 50960 Galvanic and chemical coverings
DIN 50976 Corrosion protection; coverings applied to components by hot galvanising
DIN 51604 FAM test liquid for polymers; composition and requirements
DIN 53219 Testing of paints; determination of solid body volume
DIN 6174 Colorimetric determination of colour differences in surface colours in accordance with the
CIELAB formula
DIN 67 530 Reflectometer as an aid to gloss assessment on smooth painted and plastic surfaces
DIN EN 10 204 Certificates on material tests (previously DIN 50049)
DIN EN 10130 Strip and plate, cold-rolled, soft unalloyed steels, Technical Delivery Conditions
DIN EN 14214 Fuels for vehicles, fatty acid methyl ester (FAME) for diesel engines, requirements, test
methods
DIN EN ISO 11341 Simulated weathering and irradiation
DIN EN ISO 1514 Varnishes and paints, standard tests plates
DIN EN ISO 1520 Paints; cupping test
DIN EN ISO 2409 Varnishes and paints; crosscut test (previously DIN 53 151)
DIN EN ISO 3248 Paints; determination of effect thernal effect
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M 3018 : 2008-08
DIN EN ISO 4042 Fasteners - Electroplated coatings
DIN EN ISO 4628-2 Paints and varnishes, Evaluation of degradation of coatings, Designation of quantity and
size of defects, and of intensity of uniform changes in appearance, Assessment of
degree of blistering
DIN EN ISO 4628-3 Paints and varnishes, Evaluation of degradation of coatings, Designation of quantity and
size of defects, and of intensity of uniform changes in appearance, Assessment of
degree of rusting
DIN EN ISO 7253 Coating materials, determination of resistance to neutral salt spray fog
ISO 2810-1974 (corresponds to DIN 53166) Testing of paints and similar coating materials; open-air
weathering of paints and similar coatings, general data
M 3007 Testing stain removability on matt coatings
M 3031 Single component top coating materials 1K-coating lacquer; Technical Delivery Conditions
M 3037 Zinc dust basic coating substances, Zn base layer; Technical Delivery Conditions
M 3078 Electric immersion base coating materials, electric immersion base layer; Technical
Delivery Conditions
M 3079 Synthetic resin burn-in filler; Technical Delivery Conditions
M 3082 Corrosion protection waxes; Technical Delivery Conditions
M 3086 Basic coating substances; Technical Delivery Conditions
M 3094 Dual component top coating materials, 2K top coat; Technical Delivery Conditions
M 3162 2K wash primer for vehicle construction; Technical Delivery Conditions
M 3166 Powder coating; Technical Delivery Conditions
M 3171 Testing ofstone impact resistance (Venturi principle); test loads, test conditions
M 3297 Corrosion protection and coating systems for externally-produced bodywork
M 3300 -1 Vehicle coatings; coating systems for commercial vehicles
M 3300 -2 Coating systems for customised, special versions
M 3311 -1 Corrosion protection and coating systems for military vehicles
MAN 239-1. et. seq. General terms of delivery for purchased parts, all parts
MAN 277 Coatings, adhesion test (scratching test)
MAN 278 Surface coating; determining the density of a dry layer
MAN 352 Media resistance test
MAN 365 MAN open-air weathering simulation test; test loads, test cconditions
N 669 Pyrolyse non-metallic materials for IR spectral analysis
N 680 Coating materials for coating diesel engines; Technical Delivery Conditions
TL 8010-0002 Coating materials for armed forces equipment; top coats, industrial requirement
VDA 621-408 Testing of coatings for colour changes with simulated oil black effect

Previous issues: M 3018 / 1979-11, 1979-12, 1980-03, 1980-04, 1981-02, 1982-02, 1982-07, 1983-02,
1983-11, 1984-01, 1984-05, 1985-04, 1990-01, 1991-06, 1995-08, 1996-11, 1997-04,
1998-05, 1998-07, 1998-09, 2000-05, 2001-05, 2002-04, 2003-04, 2003-11, 2005-08,
2006-06, 2006-11, 2007-05, 2008-02
 Page 15
M 3018 : 2008-08
Changes: This version includes the following changes since version 1997-04:
- In Section 3, 3.3, 5 and Table 3, restrictions for powder coated added
- In Table 2 for chassis components, assignment to corrosion protection classes 1-4
changed and expanded
- In Section 4, note on corrosion protection for externally-produced bodywork in acc. with
M 3297 added
This version includes the following changes since version 1998-05:
- In Table 3, corrosion protection classes 0 and 1 expanded
- Standard edited
This version includes the following changes since version 1998-07:
- In Table 3, the systems with priming KTL M 3078-2 without top coat were downgraded to
corrosion protection class 2.
This version includes the following changes since version 1998-09:
- In Table 5, weathering in devices in acc. with DIN EN ISO 11 341
- In Table 2, in acc. with TUC specification "Wheels, alu" moved from corrosion class K1/K2
to corrosion class 1
This version includes the following changes since version 2000-05:
- In Table 1: Gloss level of chassis from TG gloss
This version includes the following changes since version 2001-05:
- In Table 5, Index 1 deleted
This version includes the following changes since version 2002-04:
- The Standard for the crosscut test changed from DIN 53 151 to DIN EN ISO 2409
- In Table 3, bare aluminium basic material included in corrosion protection class 3
- In Table 4, steel designation DC04B included
- In Table 4, test sheet no. 5 included
- In Table 5, weathering in the devices, irradiation times changed
- In Table 6, Index 3 added
- In Table 7, steam jet test included
- In Table 10, required resistances to bio-diesel added
- Plant certificate changed to DIN EN 10204
- Standard edited
This version includes the following changes since version 2003-04:
- In Table 2, Index 6 added
- Section 3.4, Index 1 and Section 5: Reference to the use of powder coatings (overpaintability)
deleted.
This version includes the following changes since version 2003-11:
- Table 1: Reflectometer value for gloss level g adapted
- Sections 3.1 to 3.4: Index 1 omitted
This version includes the following changes since version 2005-08:
- Table 2: Springs moved from corrosion protection class 3 to 2
- DIN 53209 replaced by DIN EN ISO 4628-2
- DIN 53210 replaced by DIN EN ISO 4628-3
- DIN ISO 4042 replaced by DIN EN ISO 4042
This version includes the following changes since version 2006-06:
- Chapter 3: Information of coating data in component drawings added
- Chapter 3.3: Normal case for treatment stages and gloss level modified
- Table 3: Index 2 added (hand sweat and salt water)
This version includes the following changes since version 2006-11:
- Section 3: Reference to coating specifications in component drawings added
- Section 3.1: Changed from normal case to special case
- Section 5: Prior agreement with MAN for 2C coating materials deleted
- In the new Section 5.1, old Footnote 5 from Table 2 added
- Section 6.3 added
- Table 3: M 3162 Type B replaced by M 3162 Type C
This version includes the following changes since version 2007-05:
- Section 7 added
- Table 3 supplemented
This version includes the following changes since version 2008-02:
- Section 5: Note for "Thermally induced surface soiling" and cleaning added analogously
to M 3161.
- Table 2: Index 6 added
- Table 3: Index 3 added
- Section 7: Deviation from the corrosion protection class on joint surfaces and top support
surfaces.
- Section 7: Total layer thickness specified before assembly for powder coatings.
- Section 7: Proof of temperature resistance for exhaust systems, intake, and charge air cooling.
Page 16
M 3018 : 2008-08
Plant Certificate in acc. with DIN EN 10204 - 2.2

(Company header) No. Date

Delivery note:
(Recipient) No.
From:

Manufacturing plant code:

Customer: Order no.: Date

MAN Plant, Munich

Our order no.: Our dept.; Ext.:

Product format: Delivery conditions: MAN Item no.:

Material: Delivery conditions and / or official regulations:

Coating type MAN - Plant Standard M 3018

1 Condition of components surfaces prior to coating (e.g. bare, blasted)

2 Cleaning (methods, agents)

3 Pre-treatment (methods, agents, layer thicknesses)

e.g. zinc-phosphating, galvanising or hot-galvanising

4 Primer (methods, agents, layer thicknesses)

5 Top coat (methods, agents, layers, layer thicknesses)

6 Overall layer thickness

7 Coating instruction for overlaps and welds on sheet metal structures

It is confirmed that the consignment complies with the Company

agreements for the order

Signature