MAN Nutzfahrzeuge AG WORKS STANDARD January 2004

Vehicle coatings
Coating systems M 3300-2
for customised, special versions
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 General principles
3 Designation of the coating systems
4 Documentation of the coating system
5 Coating systems for general use
6 Coating systems for component-dependent application
7 Specification for customer-specific final coating
8 Temporary corrosion protection for finished products
9 Layer thickness test
10 Adhesion test
11 Gloss level and colour tone inspection
12 Repair of the top coating

1 Scope and purpose

This standard specifies the coating systems for customer-specific special versions of vehicle coatings,
dependent on the customer-required
- quality of the top coat
and/or
- quality of the corrosion protection
deviating from the regular versions as per M 3300-1.
The purpose of this standard is to specify uniform coating systems for these special versions as well
1
- for typical series pre-coating ) of components or assemblies per M 3300-1
- that fulfil customer-specific requirements through one economical final coating adapted to UBN
production processes.
This standard does not apply to customer-specific top coatings that differ only in colour and gloss level
from the regular versions per M 3300-1.

1
) Commercially available corrosion protection per M 3018 or primed per Table 1

Co-sponsors of standard: MTWV, Nuremburg Plant Continued on Page 2 to 14

Prepared by: Jürgens, TDN Release TDN: Replaces: 1986-01 Material Group No.:
Schwarz, MTWV 2008-09, englisch
MAN Nutzfahrzeuge Aktiengesellschaft, Munich works – Dept. Normung (TDN) x All rights reserved according to ISO 16016.
Distribution and use of the contents are not allowed without written permission from MAN Nutzfahrzeuge Aktiengesellschaft.
Page 2
M 3300-2 : 2004-01

2 General principles

2.1 Scope of customer-specific coating

For vehicles with customer-specific special design, the coating according to this standard shall be agreed upon
when creating the customer order to decide which components or assemblies (house and purchased parts)
can be designed
- with coating systems for regular versions as per M 3300-1
- and in the in the customer-neutral colour specified for the typical series vehicles (normally black)
(e.g. parts attached to the cab, foot lever, radiator).
Those coating systems in question here are recorded in Table 2 and 4.

2.2 Coating for in-house components and purchased parts

- Coating for in-house parts is performed using the coating systems in Table 1 and 3 of this standard,
or if agreed upon per Section 2.1, per M 3300-1
- For purchased parts, the coating is performed:
- using the coating systems according to this standard as much as possible (e.g. components
manufactured by 3rd party) and if necessary per M 3300-1.)
- to the extent required for commercial reasons (e.g. commercially-available externally procured parts)
using the specifications of required corrosion protection per M 3018.

2.3 Coating structure

The coating structure contains the following treatment levels
- Cleaning (R) typical series pre-coating irrespective of customer
- Preliminary treatment (V) typical series pre-coating irrespective of customer
- Priming (G) typical series pre-coating irrespective of customer
- Intermediate primer (Z) customer-specific final coating (S)
- Top coating (D) customer-specific final coating (S)
The customer-specific final coating (S) is specified according to Section 7 and normally occurs after assembly
of the large assembly (chassis, cab, superstructure).

2.4 Other
- Components or assemblies that were stocked in the warehouse shall be cleaned before the customer-
specific final coating as per M 3161.
- Parts made from elastomers must not be coated.
- Corrosion protection for longer storage and/or transport under special climatic conditions can also be
agreed upon per M 3300-1 (see Section 8.2).
 Page 3
M 3300-2 : 2004-01

3 Designation of the coating systems

Regular versions according to Section 2.1 are to be designated as per M 3300-1.

3.1 Designation of customer-specific coating systems

Coating M 3300 - xx - x - 81.99113-xxxx
System as per Table 1 and 3
Treatment level as per Table 1 and 3
S = customer-specific final coating
Item number of specification for customer-specific final coating (S)
(see Section 7)

4 Documentation of the coating systems

4.1 Documentation in drawings

The pre-coated condition (as per M 3018 or "primed as per Table 1") irrespective of customer shall be
documented according to M 3300-1 for series and commercially available components or assemblies in the
drawings to the extent possible.
Components or assemblies that are only used for that customer-specific special design and can or must be
final-coated before assembly of large assemblies, shall be documented in drawings in customer-specific final-
coated condition by specifying the coating systems as per Section 3.1.
In-house components and purchased parts which can contain a top coating suitable for all cases including
colour, regular versions per Section 2.1, shall be documented in drawings in top coated condition irrespective
of customer according to M 3300-1.

4.2 Verbal documentation via item designation

Components or assemblies, which must be customer-specific final-coated before assembly of large assemblies
or during procurement, but were documented in un-coated or pre-coated condition according to Section 4.1 for
typical series stock, shall be documented as follows using item designation verbally in customer-specific final-
coated condition and recorded in a special parts list for each customer order.
Example: 81.32002-xxxx Gearbox M 3300 - 65 - S - 81.99113-xxxx 81.32001-6760
Item number of the customer-specific
final-coated part
Name of the part (maximum 10 characters)
Description of customer-specific coating system
(according to Section 3.1)
Item number of stocked for pre-coated part regardless of customer order

4.3 Documentation via customer design regulation or assembly order

The documentation of the coating systems via customer design regulation or the assembly order is performed
for all components or assemblies that are final coated specific to customer after assembly of large assemblies.
Page 4
M 3300-2 : 2004-01

5 Coating systems for general use

Applicable to all cases where special standards for coating systems have not been specified.

Table 1 Coating systems with customer-specific final coating

Treatment levels
Pre-coating not specific to customer
Customer-specific final coating
Type of Normal case: "primed (G) according
Sys- S
compo- to Table 1"
tem
nent
R V G Z D Total layer
Preliminary Intermediate thickness
Cleaning Priming Top coat (µm)
treatment 1) coat
Varnished
Designation --- Phosphating by electric
immersion 2)
11
Material standard 3161 M 3098-1/2 M 3078-1/2
Coating thickness
--- --- 15 – 30
(µm)
Designation --- --- 1K
Steel
12 parts M 3086 ww.
Material standard M 3161 ---
3
) M 3018-3 3)
Coating thickness
--- --- 25 – 35
(µm)
Designation --- Phosphating Powder coating

13 Material standard M 3161 M 3098-2 M 3166-1

Coating thickness
--- --- 80 – 100
(µm)
Varnished
Designation --- Phosphating by electric
immersion 2)
11 Parts Material standard M 3161 M 3098-1/2 M 3078-1/2 See applicable customer-specific
made Coating thickness
of steel, --- --- 15 – 30
(µm) Specification 81.99113-xxxx
stainless
2K
steel, Designation --- --- (according to Section 7)
Primer
Zinc die-
25 casting Material standard M 3161 --- M 3162-B
and Coating thickness
galva- --- --- 25 – 35
(µm)
nised Designation --- --- ---
parts
26 Material standard M 3161 --- ---
8
)
Coating thickness
--- --- ---
(µm)
Grinding, cleaning,
Designation --- 2K
Parts or pickling
50 made Material standard M 3161 --- M 3162-B
from
alumi- Coating thickness
--- --- 25 - 35
nium (µm)
Varnished
Designation --- Phosphating by electric
immersion 2)
51
Material standard M 3161 M 3098-1/2 M 3078-1/2
Coating thickness
--- --- 15 – 30
(µm)
 Page 5
M 3300-2 : 2004-01

Treatment levels
Pre-coating not specific to customer
Customer-specific final coating
Type of Normal case: "primed (G) according
Sys- S
compo- to Table 1"
tem
nent
R V G Z D
Total layer
Preliminary Intermediate thickness
Cleaning 1 Priming Top coat (µm)
treatment ) coat
52 Designation --- Phosphating Powder coating See applicable customer-specific
Material standard M 3161 M 3098-2 M 3166-1 Specification 81.99113-xxxx
Coating thickness
--- --- 80 – 100 (according to Section 7)
(µm)
Designation --- --- --- ---
Parts 6)
45 made of Material standard M 3161 --- --- ---
plastic Coating thickness
--- --- --- ---
(µm)
Assem- Designation --- --- ---
blies
Material standard M 3161 --- ---
from
parts
with
65
different Coating thickness
coating (µm) --- --- ---
condi-
tion
7
)
1
) Drawing specification: Pre-treatment of the weld contact surfaces with paint: as per M 3158-F, coating thickness 15 – 30 µm
2
) For anodic dip primer ETL M 3078-1: Preliminary treatment according to M 3098-1
For cathodic dip primer ETL M 3078-2: Preliminary treatment according to M 3098-2
3
) This coating system also applies alternatively to purchased parts coated as per M 3018-3 documented in the drawings
or obtained.
6
) Only applies to exterior cab parts that have not been already delivered coloured.
7
) The individual parts must at least fulfil the corrosion protection requirement of corrosion protection type 4 as per
M 3018, if other specifications in the drawings did not apply.
8
) Customer-specific final coating (S) before assembly of the large assembly.
Page 6
M 3300-2 : 2004-01

Table 2 Coating systems, regular versions according to M 3300-1 (see Section 2.1)

Treatment levels Total

Type of layer
Sys- R V G Z D
compo- thickness
tem
nent Preliminary Intermediate (µm)
Cleaning Priming Top coat
treatment 1) coat
Designation --- Phosphating --- --- Varnished
by electric
immersion
2 4
01 ) ) 15 - 30
Material standard M 3161 M 3098-1/2 --- --- M 3078-1/2

Steel Coating thickness --- --- --- --- 15 - 30

parts (µm)
Designation --- Phosphating --- --- Powder
coating 4)
07 Material standard M 3161 M 3098-2 --- --- M 3166-1/2 80 – 100
Coating thickness --- --- --- --- 80 – 100
(µm)
Parts Designation --- Phosphating --- --- Powder 80 – 100
made coating 4)
Material standard M 3161 M 3098-2 --- --- M 3166-1/2
39 of
alumi- Coating thickness --- --- --- --- 80 – 100
nium (µm)
1
) Drawing specification: Pre-treatment of the weld contact surfaces with paint: as per M 3158-F, coating thickness 15 – 30 µm
2
) For anodic dip primer ETL M 3078-1: Preliminary treatment according to M 3098-1
For cathodic dip primer ETL M 3078-2: Preliminary treatment according to M 3098-2
4
) The normal colour is black. Other colours and surface structures shall be agreed upon with the customer.
 Page 7
M 3300-2 : 2004-01

6 Coating systems for component-dependent application

The coating systems per Table 1 or standards for special coating systems are shown in this section for a few
important components or assemblies.

6.1 Chassis

Table 3 Coating systems with customer-specific final coating

Treatment levels
Pre-coating not specific to customer
Customer-specific final coating
Type Normal case: "primed (G) according
S
of to Table 1"
System
compo- Total
nents R V G Z D
layer
Preliminary Intermediate thickness
Cleaning Priming Top coat
treatment 1) coat (µm)
Designation --- --- 1K
12 Frame, M 3086 ww.
3 Material standard M 3161 ---
) axles, M 3018-3
See applicable customer-specific
outer Coating thickness
--- --- 25 – 35
fuel (µm)
specification 81.99113-xxxx
tank, 2K
outer Designation --- ---
Primer (according to Section 7)
pressure
25 tank Material standard M 3161 --- M 3162-B
Coating thickness
--- --- 25 – 35
(µm)
Corrosion
Axles, --- --- --- ---
protection system
exter-
14 nally M 3018-3 M 3161 --- --- ---
procured
parts --- --- --- --- ---
Corrosion
--- --- ---
protection system
12 Rims M 3018-3 M 3161 --- ---

--- --- --- ---

Varnished
Battery Designation --- Phosphating by electric
and immersion 2)
11 storage
Material standard M 3161 M 3098-1/2 M 3078-1/2
box,
outer Coating thickness
--- --- 15 – 30
(µm)
1
) Drawing specification: Pre-treatment of the weld contact surfaces with paint: as per M 3158-F, coating thickness 15 – 30 µm
2
) For anodic dip primer ETL M 3078-1: Preliminary treatment according to M 3098-1
For cathodic dip primer ETL M 3078-2: Preliminary treatment according to M 3098-2
3
) This coating system also applies alternatively to purchased parts coated as per M 3018-3 documented in the drawings
or obtained.
.
Page 8
M 3300-2 : 2004-01

Table 4 Coating systems, regular versions according to M 3300-1 (see Section 2.1)

Treatment levels Total

Type of layer
Sys- R V G Z D
compo- thickness
tem
nent Preliminary Intermediate (µm)
Cleaning Priming Top coat
treatment 1) coat
Varnished
Battery Special
Designation --- Phosphating by electric ---
coating
and immersion 2)
75 storage 115 - 150
box, Material standard M 3161 M 3098-1/2 M 3078-1/2 --- M 3008
inner Coating thickness
--- --- 15 – 30 --- 100 - 120
(µm)
Coating
--- --- --- --- ---
system
--- Engine N 680-B --- --- --- --- --- 35 – 40
Black similar
to RAL 9005 --- --- --- --- ---
Com- Coating
--- --- --- --- ---
pressed system
--- air MAN 272 --- --- --- --- --- min. 70
container
(inner) --- --- --- --- --- ---
Coating
system
--- MAN 247

Commercially
Exhaust
--- available fire-
system
5 aluminium coated
)

Commercially
--- available
enamelled

Special Coating
--- --- --- --- ---
pur- system
--- chased M 3018-1/2/3 --- --- --- --- --- ---
parts
4
) --- --- --- --- --- ---
1
) Drawing specification: Pre-treatment of the weld contact surfaces with paint: as per M 3158-F, coating thickness 15 – 30 µm
2
) For anodic dip primer ETL M 3078-1: Preliminary treatment according to M 3098-1
For cathodic dip primer ETL M 3078-2: Preliminary treatment according to M 3098-2
4
) The normal colour is black. Other colours and surface structures shall be agreed upon with the customer.
5
) The desired design for pipes and exhaust muffler shall be agreed upon with the customer.
 Page 9
M 3300-2 : 2004-01

6.2 Cab

Table 5 Coating systems with customer-specific final coating

System 70
Material
Treat- standard or
Coating
ment Operation/process customer- Comments
thickness
level specific
specification
Pre-treatment for spot-welded M 3158-F ww
A connections of the cab shell M 3158-P ww 15 µm - 30 µm
(as per work plan) M 3158-B
B Clean cab shell M 3161-2 --- ---
Preparation for dip priming
- Degreasing M 3161-0
C --- ---
- Zinc phosphating M 3098-2
including passivation
Interior
10 µm - 15 µm
Filling as needed afterwards
D Stove cataphoresic dip primer M 3078-2
Filler M 3032-1
External area
15 µm - 20 µm
PVC underseal
E M 3068 min. 1 mm ---
(as per work plan)
Sealing spot welding
M 3065-1 3 mm - 4 mm
F folds, joints and edges ---
M 3065-2 1 mm - 2 mm
(as per work plan)
Insert insulation mats (internal)
in doors, back panel, M 3041 2 mm - 3 mm
G ---
side panel and floor M 3105 2 mm - 3 mm
(as per work plan)
Stone impact coating
H M 3191 15 µm - 25 µm In areas subject to stone impacts
(as per work plan)
Interior
Only roof and visible surfaces
20 µm - 30 µm
J Inject filler M 3079
External area
Complete; outer PVC-coated areas
25 µm - 35 µm
Top coat (D) Interior area: all visible surfaces
Interior area
according including door cavity
35 µm - 45 µm
to customer-
K Top coating
specific Exterior area: complete; including
Exterior 9)
specification surface behind radiator flap and
n x 35 - 45 µm
81.99113-xxxx side parts
L Cavity sealing M 3082-3 20 µm - 50 µm as per plan
Top coat (D)
according
Top coat Interior 65 µm - 90 µm
to customer- Total layer 10)
M (only if damage has External area 75 µm - 145 µm
specific thickness:
to be repaired) Maximum 200 µm
specification
81.99113-xxxx
9
) n = number of layers according to customer-specific specification 81.99113-xxxx
10
) depending on the number of layers of top coating (treatment level K)
Page 10
M 3300-2 : 2004-01

6.3 Attachments and superstructure

Table 6 Coating systems with customer-specific final coating

Treatment levels
Pre-coating not specific to customer
Customer specific final coating
Type of Normal case: "primed (G) according
Sys- S
compo- to Table 1"
tem
nent R V G Z D Total
layer
Preliminary Intermediate thickness
Cleaning Priming Top coat
treatment 1) coat (µm)
Designation --- --- ---
26 Material standard M 3161 --- ---
8
)
Coating thickness
--- --- ---
(µm)
2K
Designation --- ---
Primer
Bridge
25 (Steel Material standard M 3161 --- M 3162-B
substruc Coating thickness
ture) --- --- 25 - 35
(µm)
Varnished
Designation --- Phosphating by electric
immersion 2)
11
Material standard M 3161 M 3098-1/2 M 3078-1/2
Coating thickness
--- --- 15 - 30
(µm)
Grinding, cleaning,
Designation --- ---
or pickling
53
8 Material standard M 3161 --- ---
) See applicable
Coating thickness --- --- ---
(µm) customer-specific
Varnished
Bridge Designation --- Phosphating by electric specification 81.99113-xxxx
(Alu- immersion 2)
51
tail- Material standard M 3161 M 3098-1/2 M 3078-1/2 (according to Section 7)
boards) Coating thickness
--- --- 15 - 30
(µm)
Grinding, cleaning,
Designation --- 2K
or pickling
50 Material standard M 3161 --- M 3162-B
Coating thickness
--- --- 25 – 35
(µm)
Varnished
Designation --- Phosphating by electric
immersion 2)
11
Material standard M 3161 M 3098-1/2 M 3078-1/2
Tarpau- Coating thickness --- --- 15 - 30
lin (µm)
frame Designation --- --- 1K

12 Material standard M 3161 --- M 3086

Coating thickness
--- --- 25 - 35
(µm)
 Page 11
M 3300-2 : 2004-01

Treatment levels
Pre-coating not specific to customer
Customer specific final coating
Type of Normal case: "primed (G) according
Sys- S
compo- to Table 1"
tem
nent R V G Z D Total
layer
Preliminary Intermediate thickness
Cleaning Priming Top coat
treatment 1) coat (µm)
11
Inner stone )
2K
Designation --- --- impact
Primer
Galva- protection See applicable
customer specific
77 nised Material standard M 3161 --- M 3162-B M 3191
specification
Wing
81.99113-xxxx
Coating thickness
--- --- 25 - 35 15 - 25 (according
(µm)
to Section 7)
Wood
Designation impregnatio --- ---
Wooden n
--- ---
floor Material standard M 3095 --- ---
Coating thickness
--- --- ---
(µm)
1
) Drawing specification: Pre-treatment of the weld contact surfaces with paint: as per M 3158-F, coating thickness 15 – 30 µm
2
) For anodic dip primer ETL M 3078-1: Preliminary treatment according to M 3098-1
For cathodic dip primer ETL M 3078-2: Preliminary treatment according to M 3098-2
8
) Customer-specific final coating (S) before assembly of the large assembly.
11
) If there is insufficient adhesion of customer-specific top coat before top coating, a primer shall be applied as under
treatment level G.

7 Specification for customer-specific final coating

The customer-specific final coating agreed upon for each order (treatment condition S according to Table 1
and 3) shall be documented in a specification, specifying the required quality, number, and thickness of
individual layers, normally using a printed form as per Appendix 1, with its own item number.

8 Temporary corrosion protection

8.1 Storage of primed parts

Outdoor storage of primed parts is to be avoided.
With outdoor storage, evidence of corrosion may occur after a maximum of 3 months in certain climate zones
as per M 3086, M 3162-B or M 3078.

8.2 Temporary corrosion protection for finished products

Temporary corrosion protection of finished products required for longer storage and/or transport under special
climatic conditions can also be agreed upon per M 3300-1.
To do this, the requirements for M 3082 corresponding to expert dewaxing of vehicle outer surfaces without
damaging the top coating must be ensured in advance by the customer.
Page 12
M 3300-2 : 2004-01

9 Layer thickness test

The coating thicknesses stated in this standard (dry layer thicknesses) are preset thicknesses as per
DIN EN ISO 12944-5.
The target layer thickness in the sense of this standard is that layer thickness, which the overall system should
exhibit in order to offer adequate corrosion protection at the expected load level. 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 measured values at the measuring points provided in the measurement protocol are determined which are
representative for the object to be tested (large assembly).
On single parts, the measuring points representative for the coating shall be considered.
The average value from several individual measurements shall be used as the measurement value. In cases
of dispute, a decision is to be reached as per DIN EN ISO 4259.

10 Adhesion test
The adhesion test is to be carried out as per MAN 276 or DIN EN ISO 2409 on test plates carried on the
equipment. In so doing, the required hardening times must be taken into consideration.
In justified exceptional cases, it is also possible for the adhesion test to be carried out directly on the item,
in agreement with the affected Production Department. Here, areas are to be chosen that are not particularly
exposed to corrosion and are typical of the object's coating.
Following a successful test, the position is to be expertly reworked.

11 Gloss level and colour tone inspection

Gloss level and colour tone inspections are carried out visually on the finished cab or chassis.
The level of sheen and colour target values can be determined within the framework of the material clearance.

12 Repair of the top coating

Where possible (depending on the component), damage to the finish is to be repaired in spots or partially.
If partial repair impairs the visual appearance, the whole area in question must be repaired.
 Page 13
M 3300-2 : 2004-01

Standards quoted
DIN EN ISO 2409 Paints and coating materials - cross cutting test
DIN EN ISO 4259 Mineral oil products, determination and application of the values for the precision
of test procedures
DIN EN ISO 12944-5 Coating materials - corrosion protection of steel components by coating systems -
part 5: Coating systems
M 3008 Special coating material; technical supply conditions
M 3018 Corrosion protection for purchased parts; technical supply conditions
M 3022 Basic coating materials for components made from plastics; technical supply
conditions
M 3078 ET priming; technical supply conditions
M 3082 Corrosion protection waxes, good grip; technical supply conditions
M 3086 Basic coating material, technical supply conditions
M 3098 Zinc phosphatising of metals; preliminary treatment for a colour coating
M 3158 Materials capable of being welded for the corrosion protection of welding
connections; technical supply conditions
M 3161 Cleaning metallic surfaces
M 3162 2K wash primer for vehicle construction; technical supply conditions
M 3166 Powder coating; technical supply conditions
MAN 272 Surface treatment; internal coating of compressed air reservoirs
MAN 276 Surface coating; adhesion test of paints
N 680 Paint materials for coating diesel motors; technical supply conditions

Previous issue M 3300-2 / 1985-06, 1986-01

Changes: The following changes have been made to the 1986-01 issue:
- DIN EN ISO 2409 was DIN 53151
- DIN EN ISO 4259 was DIN 51848-1
- DIN EN ISO 12944-5 was DIN 55928-5
- Editorial amendments
Page 14
M 3300-2 : 2004-01

Appendix 1