MAN Truck & Bus AG WORKS STANDARD July 2012

Coating systems for the series version

of standard trucks as well as for M 3300-1
bus components and attachments
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 Designation of coating systems and information in drawings
3 General coating information
4 Released coating systems;
overview, selection
5 Temporary corrosion protection
6 Coating thickness inspection
7 Adhesion test
8 Degree of gloss and colour inspection
9 Repair of the top coating

1 Scope and purpose

This standard defines the released coating systems and coating materials for standard coatings (corro-
sion protection level B) of components, assemblies and large assemblies of standard trucks. It applies for
all production locations of MAN Truck & Bus AG worldwide, including MAN Force Trucks Pvt. Ltd., India.
The coating systems as per this standard also apply to the coating of bus components, attachments and
small parts and can also be used for the coating for parts of outside origin and parts of outside manufac-
ture.
Additional temporary corrosion protection or tropical preservation as per table 6 can be agreed for trans-
portation and use under particular climatic conditions (e.g. sea transport and/or operation in the tropics)
and also for longer storage periods.
Corrosion protection and the coatings of purchased parts (parts of outside origin and parts of outside
manufacture) are governed by the provisions in M 3018.
If MN own parts with the drawing information "Coating: primed or top coated as per table 1; M 3300" are
sourced as coated purchased parts, their coatings are governed by the requirements as per M 3018 and
corrosion protection class 2 - or for components (small parts) in the splashwater-protected interior, also
zinc electroplating A4C as per DIN EN ISO 4042 - unless otherwise specified in the drawing.
For customer-specific special versions, the coating systems are governed by M 3300-2, for military ver-
sions M 3311-1.
The coating of large assemblies of buses is governed by M 3312.

Continued on Page 2 to 24
Co-sponsors of the standard: EMTAC

Prepared by: Kluger, Release: EAS Replaces: M 3300-1: 2008-05 Material group no.:
Gary 2012-08, englisch

MAN Truck & Bus Aktiengesellschaft, Munich works - Dept. Standardization (EAS)  All rights reserved according to ISO 16016.
Distribution and use of the contents are not allowed without written permission from MAN Truck & Bus Aktiengesellschaft.
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M 3300-1 : 2012-07

2 Designation of coating systems and information in drawings

2.1 Designation of coating systems in technical documents

Coating M 3300 – xxx – x – xxx – x – RAL xxxx – x

 Version ID
(XXK = CDP)
- Components with general use
from various materials as per Table 2
- Components of the large assembly Chassis (FG)
as per Table 3
Large assembly Cab (FH)
as per Table 4
Large assembly Attachments and body structures (AU)
as per Table 5
- Bus components,
attachments and other removable small parts
which are used in Salzgitter, as per Table 6

 Treatment level
(Preferable, final or top coating (D) )

 Type of final or top coating

1K1  Top coat -1K M 3031 Type 1
1K2  Top coat - 1K M 3031 Type 2
1K3  Top coat - 1K M 3031 Type 3
2K3  Top coat - 2K M 3094 Type 3
2K7  Top coat - 2K M 3094 Type 7, water-dilutable
KTL  Cathodic dip primer (CDP) M 3078 Type 2

 Degree of gloss in acc. with DIN 67 530

g = gloss for cabs (FH) Angle of incidence 20 °
as well as attachments and body structures (AU) Reflectometer
and chassis (FG) value range 80 ± 5
h = semi-gloss Angle of incidence 60°
Reflectometer
value range 70 ± 5
m = matt for Angle of incidence 85°
military versions Reflectometer
value range 20 – 30
s = dull matt for Angle of incidence 85° or 60°
military versions Reflectometer
value range 8 or 2

 Colour as per RAL or MN colour chart

(preferred as per RAL colour chart RAL 840 HR or RAL F9)

 where appropriate surface texture (if smooth version not permissible)

as per Standex standard
(e.g. powder coatings or non-standardised textured paints).
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2.2 Information on coating in drawings

2.2.1 Normal case: The work preparation department of the respective MN plant must refer to Tables 2 to 6
– in line with Table 1 – in order to select the suitable coating system.
Specification in the drawing:
- Normal case: for final or top coated components
1)
e.g..: MN drawings Third-party drawings1)
SURFACE TREATMENT CORROSION PROTECTION M 3018 - - -
TYPE OR VERSION STANDARD CORROSION PROTECTION CLASS
IN-HOUSE COMPONENT: FINAL COATING (E) *
DEGREE OF GLOSS *
Top coating M 3300 COLOUR *
Tab.1-g-black-RAL 9011 * ONLY IF REQUIRED
PURCHASED PART: Corr. protec- M 3018
tion Sect. 3.3
1-E-g-black-RAL 9011

- Special case: for primed components

SURFACE TREATMENT CORROSION PROTECTION M 3018 - - -
TYPE OR VERSION STANDARD CORROSION PROTECTION CLASS
FINAL COATING (E) *
IN-HOUSE COMPONENT: primed
DEGREE OF GLOSS *
as per Table 1 M 3300 COLOUR *
* ONLY IF REQUIRED
PURCHASED PART: Corr. protec- M 3018
tion 3 Sect. 3.1
1) Use sticker as per M 3056-2

2.2.2 Components/ assemblies subject to by a standardised function-specific coating system (without version
ID in Tables 3 to 6).
Specification in the drawing:
e.g. For compressed air tank, interior: Coating MAN 272,
For interior fittings: Powder coating M 3166-1-h-RAL 9011.

2.2.3 Components/assemblies for which a specific coating system from Tables 2 to 6 must be prescribed in
special cases.
Specification in the drawing: as per Section 2.1.

2.3 Item designation for parts that are top coated from pre-coated parts
using special parts lists

Example: 81.32002-6052 Gearbox M 3300-61 D - 2K2 - S - RAL 6031 81.32001-6760

Item number of the

top coated part

Designation of the
top coated part
(maximum 9 places)

Designation of the coating system

as per Section 2.1 (max. 25 places)

Item number of the pre-coated part

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3 General coating information

- The coating specifications in the component drawings always contain the final condition of the coating
which the component must have on the finished vehicle.
Any supply conditions (pre-coatings) for individual components deviating from the final condition due to the
production process (if applicable only for an individual location and/or temporarily) will be notified by the
operational units Process Planning and Material Management of the business unit to the responsible MAN
buyer. The latter is responsible for reaching agreement with the supplier and will document the result in the
contractual records.
There will be no additional specification in the component drawing. For this reason, forwarding of informa-
tion from the respective initial sample inspection department about the deviating supply condition must be
ensured.
In these cases, if recoating does not take place automatically with the large assembly, further coating to
the final condition specified in the component drawing must be controlled by the respective operational
units Material Management and Process Planning of the business unit by means of the work plan.
- Truck frame parts, reinforcements and attachments made from flat material should be top coated before
assembly with 1K stoving top coat, M 3031-Type 3.
- The overall coating thickness before assembly must not exceed 60 µm on joining surfaces and head bear-
ing surfaces (settlement risk on screw connections). In these areas, it is possible in exceptional cases to
deviate from the required corrosion protection.
- Cast and forged attachments on the frame (supports) may only be coated with maximum 35 µm on the joi-
ning surfaces. This restriction shall be stated in the drawing.
- For end or top coated cab and chassis attachments, the degree of gloss "gloss (g)" and the colour black
RAL 9011 always apply in normal cases. Deviations shall be stated in the drawing.
- Powder-coated surfaces may only be permanently recoated with 1K top coats if they have first been trea-
ted with intermediate primer using a 2K primer as per M 3162, Type A or Type C. A 2K top coat does not
require any intermediate primer.
- Welded areas on pre-coated components must be linished and coated with 2K primer as per M 3162, Ty-
pe C as intermediate primer.
- Elastomer parts may only be coated in special cases.
- A new vehicle must not to be polished until it has cooled to room temperature.
- Application of a cathodic dip coating according to M 3078 Type 2 as a thick cathodic dip coating
(25 - 35 m) for attachments on chassis, cab and bus is possible subject to manufacturer specification.

4 Released coating systems; overview, selection

In the case of drawing specification as per Section 2.2.1, the Work Preparation department of the respective
plant must select in accordance with table 1, on the basis of the large assembly to which the component be-
longs, the suitable coating system in the corresponding Table 3 - 6 and the treatment stage stipulated in the
drawing (primed (G) ) or end- or top-coated (D) ) from the coating systems prescribed for the assembly.
For components of general use that cannot be assigned to any of the assemblies in Tables 3 to 5, the suitable
coating system is to be selected based on the component material in Table 2.
Replaced coating systems are listed in Tables 2 to 6 for a transitional period.
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Table 1: Overview for selection of coating systems

Coating systems for: see

Components for general use, made of various materials, without specified assembly- Table 2
specific coating systems in Tables 3 to 5
Components or assemblies with specified assembly- or function-specific coating systems:
- large assembly Chassis (FG)
- large assembly Cab (FH) Table 3
- large assembly Attachments and body structures (AU) Table 4
Table 5

Coating systems for bus components, attachments and other removable small parts that Table 6
are coated in Salzgitter.
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Table 2 Coating systems for components without specified assembly-specific coating systems

Type of Version Corro- Treatment levels Application information

component ID sion (the preceding levels are always included in the stated level)
protec-
tion R V G Z D Total coating
class Cleaning Pre-treatment Primer coat Intermediate Top coating thickness
to 1) primer 2
(µm) )
M 3018
Components of 01K 2 Coating --- Phosphating --- --- Cathodic dip Black cab interior parts
steel and galva- Material M 3161 M 3098-2 primer without exposure to hand
nised steel M 3078-2 sweat or salt water
20 - 25
Coating thick- --- ---
ness (µm) 20 - 25
02K 1 Coating --- Phosphating Cathodic dip 2K primer Top coat Chassis parts
Material M 3161 M 3098-2 primer M 3162-A 2K-M 3094-3/ 7
M 3078-2 85 – 110
Coating thick- 20 – 35 40 – 50
ness (µm) --- --- 20 – 25

03 Replaced by System 03K

03K 1 Coating --- Phosphating Cathodic dip --- Top coat Cast and forged parts and
Material M 3161 M 3098-2 primer 1K-M 3031-2 other supports that have to
M 3078-2 be assembled in primed
2K-M 3094-3/ 7 65 – 85 condition
Coating thick- --- --- 40 - 50 also see Table 3, Page 8
ness (µm) 25 – 35
Chassis parts with 2K top
coat
Cab parts, interior
05 3 Coating --- --- 1K primer --- Top coat Chassis parts,
Material M 3161 M 3086-A/ B 2K-M 3094-3/ 7 avoid where possible
65 – 85
Coating thick- --- 25 – 35 40 – 50
ness (µm)
--- 1 Powder coating --- --- --- --- --- Interior parts and small parts
M 3166-1 --- under front panel,
small parts for chassis

08 1 Powder coating --- --- 2K primer --- Top coat Chassis parts
M 3166-1 M 3162-A 2K-M 3094-3/ 7
Coating thick- 65 – 85
ness (µm) 25 – 35 40 – 50
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Table 2 Coating systems for components without specified assembly-specific coating systems

Type of Version Corro- Treatment levels Application information

component ID sion (the preceding levels are always included in the stated level)
protec-
tion R V G Z D Total coating
class Cleaning Pre-treatment Primer coat Intermediate Top coating thickness
to 1) primer 2
(µm) )
M 3018
09 1 Powder coating --- --- --- --- Top coat Chassis parts
M 3166-1 2K-M 3094-3/ 7
Coating thick- 40 – 50
ness (µm) 40 – 50

Components of 19 Replaced by System 19K

steel and galva- 19K K2 Coating --- Phosphating Cathodic dip Top coat Top coat Chassis parts, normal case,
nised steel primer in splashwater zone
Material M 3161 M 3098-2 1K-M 3031-3 2K-M 3094-3/ 7
M 3078-2 85 - 110
Coating thick-
ness (µm) --- --- 20 – 25 25 – 35 40 – 50
29K 1 Coating --- Phosphating Cathodic dip --- Powder paint
Material M 3161 M 3098-2 primer M 3166-1
M 3078-2 90 - 125
Coating thick-
ness --- --- 20 - 25 70 - 100
Components made 20 2 Coating --- --- 2K primer --- Top coat
of stainless steel Material M 3161 M 3162-A 2K-M 3094-3/ 7
80 - 100
Coating thick- --- 40 - 50 40 - 50
ness (µm)
Components made 03K 1 Coating --- Phosphating Cathodic dip --- Top coat
from aluminium Material M 3161 M 3098-2 primer 1K-M 3031-2
M 3078-2 2K-M 3094-3/ 7 60 - 75
Coating thick-
ness (µm) --- --- 20 – 25 40 – 50
30 1 Coating Start- --- 2K primer --- Top coat
Material grinding M 3162-C 2K-M 3094-3/ 7
or pickling 65 - 85
Coating thick- M 3161 25 - 35 40 - 50
ness (µm)
1
) Drawing specification where appropriate: Pre-treatment of welding contact surfaces with paint: as per M 3158-F, coating thickness 15-30 µm
2
) The total coating thickness may increase by 10 µm as a result of use of cathodic dip paint in accordance with M 3078 Type 2 as a thick cathodic dip coating (25 - 35 µm).
 Page 8
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Table 3 Coating systems for large assembly Chassis (FG)

Type of Version Corro- Treatment levels Application information

component ID sion (the preceding levels are always included in the stated level)
protec-
tion R V G Z D Total coating
class Cleaning Pre-treatment Primer coat Intermediate Top coating thickness
to 1) primer 2
(µm) )
M 3018
Axles, 05 System not applicable
driven and non- 21 System not applicable
driven,
with and without 20 2 Coating --- --- 2K primer --- Top coat
primer to M 3018-3 Material M 3161 M 3162-A 2K-M 3094-3/ 7
80 - 100
Coating thickness --- 40 - 50 40 – 50
(µm)
Exhaust system --- 3 Coating system --- --- --- --- --- Sourced as purchased part
MAN 247 with final coating
20 – 30
Battery case and 02K 1 Coating --- Phosphating Cathodic dip 2K primer Top coat
storage box Material M 3161 M 3098-2 primer M 3162-A 2K-M 3094-3/ 7
M 3078-2 85 - 110
Coating thickness
(µm) --- --- 20 - 25 25 - 35 40 – 50
03K 1 Coating --- Phosphating Cathodic dip --- Top coat
Material M 3161 M 3098-2 primer 2K-M 3094-3/ 7
M 3078-2 60 – 75
Coating thickness
(µm) --- --- 20 – 25 40 – 50
 Page 9
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Table 3 Coating systems for large assembly Chassis (FG)

Type of Version Corro- Treatment levels Application information

component ID sion (the preceding levels are always included in the stated level)
protec-
tion R V G Z D Total coating
class Cleaning Pre-treatment Primer coat Intermediate Top coating thickness
to 1) primer 2
(µm) )
M 3018
Battery case, lower --- 1 Powder coating --- --- --- --- --- ---
part
M 3166-1

09 1 Powder coating --- --- --- --- Top coat

M 3166-1 2K-M 3094-3/ 7
Coating thickness 40 – 50 40 – 50
(µm)
19K K2 Coating --- Phosphating Cathodic dip Top coat Top coat
Material M 3161 M 3098-2 primer 1K-M 3031-3 2K-M 3094-3/ 7
M 3078-2
Coating thickness --- --- 20 – 25 25 – 35 40 – 50 85 - 110
(µm)
Compressed air --- 3 Coating --- --- --- --- --- Sourced as purchased part
tank interior, system with interior coating
steel
MAN 272 50 – 60
Compressed air 20 2 Coating --- --- 2K primer --- Top coat Sourced as purchased part
tank exterior, Material M 3161 M 3162-A 2K-M 3094-3/ 7 with primed exterior
steel
80 - 100
Primed M 3018-3
Coating thickness --- 40 - 50 40 – 50
(m)
21 1 Coating --- --- 2K primer --- Top coat
Material M 3161 M 3162-C 2K-M 3094-3/ 7

Coating thickness --- 25 - 35 40 – 50 65 - 85

(m)
Propshafts, 20 2 Coating --- --- 2K primer --- Top coat Joints sourced as primed
in-house produc- Material M 3161 M 3162-A 2K-M 3094-3/ 7 purchased parts
tion,
with articulated
joints, Coating thickness --- 40 - 50 40 – 50 80 – 100
primed M 3018-4 (m)
 Page 10
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Table 3 Coating systems for large assembly Chassis (FG)

Type of Version Corro- Treatment levels Application information

component ID sion (the preceding levels are always included in the stated level)
protec-
tion R V G Z D Total coating
class Cleaning Pre-treatment Primer coat Intermediate Top coating thickness
to 1) primer 2
(µm) )
M 3018
Cast and forged 03K 1 Coating --- Phosphating Cathodic dip --- Top coat Must be sourced as pur-
parts Material M 3161 M 3098-2 primer 2K-M 3094-3/ 7 chased parts bright/oiled if
(supports) M 3078-2 the cathodic dip coating
that have to be 65 – 85 thickness 35 µm an the
assembled in Coating thickness --- --- 25 – 35 40 – 50 joint surfaces cannot be
primed state (m) guaranteed
Steering arm, 20 2 Coating --- --- 2K primer --- Top coat Uncoated blanks sourced
steering knuckle Material M 3161 M 3162-A 2K-M 3094-3/ 7 as purchased parts
arm
80 – 100
Coating thickness --- 40 - 50 40 – 50
(m)
Air intake pipes, Replaced by System 01K
raw air, not pickled
01K 2 Coating --- Phosphating --- --- Cathodic dip
Material M 3161 M 3098-2 primer
Coating thickness M 3078-2 20 – 25
(m) --- --- 20 – 25
Air intake pipes, 27K 1 Coating --- Phosphating Cathodic dip --- Top coat
clean air, pickled Material M 3161 M 3098-2 primer 1K-M 3031-3
M 3161-2.5 M 3078-2
Coating thickness 45 – 60
(m) --- --- 20 – 25 25 – 35
Water pipes 03K 1 Coating --- Phosphating Cathodic dip --- Top coat
Material M 3161 M 3098-2 primer 2K-M 3094-3/ 7
Coating thickness M 3078-2 50 - 70
(µm) --- --- 20 – 25 30 -45
29K 1 Coating --- Phosphating Cathodic dip --- Powder paint
Material M 3161 M 3098-2 primer M 3166-1
M 3078-2 30 - 45 50 - 70
Coating thickness --- --- 20 - 25

27K 1 Coating --- Phosphating Cathodic dip --- Top coat

Material M 3161 M 3098-2 primer 1K-M 3031-3
M 3078-2 45 – 60
Coating thickness --- --- 20 – 25 25 – 35
(m)
 Page 11
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Table 3 Coating systems for large assembly Chassis (FG)

Type of Version Corro- Treatment levels Application information

component ID sion (the preceding levels are always included in the stated level)
protec-
tion R V G Z D Total coating
class Cleaning Pre-treatment Primer coat Intermediate Top coating thickness
to 1) primer 2
(µm) )
M 3018
Fuel tank, exterior --- 1 Powder coating --- --- --- --- --- --- Helically wound tank, in-
M 3166-1 house production, pur-
chased part, normal case
black
20 2 Coating --- --- 2K primer --- Top coat Purchased part, special
Material M 3161 M 3162-A 2K-M 3094-3/ 7 case, wet painted for spe-
cial colours
80 – 100
Coating thickness --- 40 - 50 40 – 50
(µm)
Engine --- 3 Coating system --- --- --- --- ---
N 680-B
40 – 60
Frame side member 19K K2 Coating --- Phosphating Cathodic dip Top coat Top coat See also Section 6
Material M 3161 M 3098-2 primer 1K-M 3031-3 2K-M 3094-3/ 7 60 – 75
M 3078-2 (exterior)
Coating thickness --- --- 40 – 50
(µm) 20 – 25 25 – 35 Full coverage 45 – 110
on the outside. (interior)
On the inner
side only where
technically
Inner side only
feasible.
Frame attachments 19K K2 Coating --- Phosphating Cathodic dip Top coat Top coat
for side protection Material M 3161 M 3098-2 primer 1K-M 3031-3 2K-M 3094-3/ 7 85 – 110
skirts M 3078-2
Coating thickness 25 – 35 40 – 50
(µm) --- --- 20 – 25
Frame cross mem- 05 3 Coating --- --- Primer 1K --- Top coat Avoid, being discontinued,
bers, frame rein- Material M 3161 M 3086-A/B 2K-M 3094-3/ 7 65 - 85 where appropriate partially
forcements, coated with primer
frame attachments, (90 - 120) 1K-M 3162-A (25 35)
holders Coating thickness --- 25 – 35 40 – 50
(µm)
19 Replaced by System 19K
 Page 12
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Table 3 Coating systems for large assembly Chassis (FG)

Type of Version Corro- Treatment levels Application information

component ID sion (the preceding levels are always included in the stated level)
protec-
tion R V G Z D Total coating
class Cleaning Pre-treatment Primer coat Intermediate Top coating thickness
to 1) primer 2
(µm) )
M 3018
19K K2 Coating --- Phosphating Cathodic dip Top coat Top coat Standard case, preferable
Material M 3161 M 3098-2 primer 1K-M 3031-3 2K-M 3094-3/ 7
M 3078-2 85 – 110
Coating thickness
(µm) --- --- 20 – 25 25 – 35 40 – 50
29K 1 Coating --- Phosphating Cathodic dip --- Powder paint
Material M 3161 M 3098-2 primer M 3166-1 90 - 125
M 3078-2
Coating thickness 70 - 100
--- --- 20 - 25
Disc wheels, 63 2 Coating --- --- --- --- Top coat Sourced as coated pur-
primed or top to Material M 3161 2K-M 3094-3/ 7 chased parts
coated
1 40 – 50
M 3018-1/ 2
Coating thickness --- 40 – 50
(µm)
Underride protec- 19 Replaced by System 19K
tion, in-house pro- 19K K2 Coating --- Phosphating Cathodic dip Top coat Top coat
duction primer
Material M 3161 M 3098-2 1K-M 3031-3 2K-M 3094-3/ 7 85 – 110
M 3078-2
Coating thickness
(µm) --- --- 20 – 25 25 – 35 40 – 50
Underride protec- 63 2 Coating --- --- --- --- Top coat Sourced as coated pur-
tion, purchased Material M 3161 2K-M 3094-3/ 7 40 – 50 chased parts
part, coated
M 3018-2
Coating thickness --- 40 – 50
(µm)
1
) Drawing specification where appropriate: Pre-treatment of welding contact surfaces with paint: as per M 3158-F, coating thickness 15-30 (µm)
2
) The total coating thickness may increase by 10 µm as a result of use of cathodic dip paint in accordance with M 3078 Type 2 as a thick cathodic dip coating (25 - 35 µm).
 Page 13
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Table 4 Coating systems for large assembly Cab (FH)

Type of Version Corro- Treatment levels Application information

component ID sion (the preceding levels are always included in the stated level)
protec-
tion R V G Z D Total coating
class Cleaning Pre-treatment Primer coat Intermediate Top coating thickness
to 1) primer 2
m) )
M 3018
Pedal system 01 Replaced by System 01K
01K 2 Coating --- Phosphating --- --- Cathodic dip
Material M 3161 M 3098-2 primer
M 3078-2 20 – 25
Coating thickness --- --- 20 – 25
(m)
Brackets, attachment --- 1 Powder coating --- --- --- --- --- ---
parts under the front M 3166-1
panel

27K 1 Coating --- Phosphating Cathodic dip --- Top coat

Material M 3161 M 3098-2 primer 1K-M 3031-3
M 3078-2 45 - 60
Coating thickness
(m) --- --- 20 – 25 25 – 35
Interior parts, black 01K 2 Coating --- Phosphating --- --- Cathodic dip If no exposure to hand
Material M 3161 M 3098-2 primer sweat or salt water
M 3078-2 20 – 25
Coating thickness --- ---
(m) 20 – 25
--- 1 Powder coating --- --- --- --- --- ---
M 3166-1

Plastic parts (GRP) 40 --- Coating --- --- --- --- Top coat
with primer coat Material M 3161 2K-M 3094-3
M 3022-2 40 – 50
Coating thickness --- 40 – 50
(m)
43 --- Coating --- --- 2K primer --- Top coat Observe stoving tempera-
Material M 3161 M 3162-C 1K-M 3031-1 tures
2K-M 3094-3/ 7 70 - 90
Coating thickness --- 35 - 45 35 - 45
(m)
 Page 14
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Table 4 Coating systems for large assembly Cab (FH)

Type of Version Corro- Treatment levels Application information

component ID sion (the preceding levels are always included in the stated level)
protec-
tion R V G Z D Total coating
class Cleaning Pre-treatment Primer coat Intermediate Top coating thickness
to 1) primer 2
m) )
M 3018
GRP parts IMC- 41 --- Coating --- --- 1K filler --- Top coat
coated Material M 3161 M 3079-2 1K-M 3031-2
Coating thickness --- 35 - 45 2K-M 3094-3/ 7 70 - 90
(m) 35 - 45
Cab shell 70 K2 Coating see see see see see see
to Material Table 4.1 Table 4.1 Table 4.1 Table 4.1 Table 4.1 Table 4.1
K1
Coating thickness
(m)
Bunk 01A System not applicable
16A System not applicable
29K 1 Coating --- Phosphating Cathodic dip --- Powder paint
Material M 3161 M 3098-2 primer M 3166-1
M 3078-2 90 – 125
Coating thickness 70 - 100
--- --- 20 - 25
Sliding roof 24K K2 Coating --- Phosphating Cathodic dip 1K filler Top coat On high roof only with 2K -
... Cab Material M 3161 M 3098-2 primer M 3079-2 1K-M 3031-2 top coat
... High roof M 3078-2 2K-M 3094-3/ 7 85 -110
Coating thickness
(µm) --- --- 20 – 25 25 - 35 40 – 50
1
) Drawing specification where appropriate: Pre-treatment of welding contact surfaces with paint: as per M 3158-F, coating thickness 15-30 µm
2
) The total coating thickness may increase by 10 µm as a result of use of cathodic dip paint in accordance with M 3078 Type 2 as a thick cathodic dip coating (25 - 35 µm).
 Page 15
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Table 4.1 Coating system for cab shell (galvanised M 3034 or DIN EN 10142), standard commercial
(and for military and government vehicles in standard commercial version)
Version ID 70 Corrosion protection class as per M 3018:
Galvanised parts K1, bright parts K2
Treatment Operation/process Material Coating Comments
level standard thickness
A Pre-treatment for spot-welded M 3158-F 15 – 30 µm
connections of the cab shell M 3158-F
(as per work plan)
M 3158-F
B Clean cab shell M 3161-2 --- ---
C Preparation for dip priming
- Degrease M 3161-0 --- ---
- Zinc phosphating M 3098-2
including passivation
D Stove cataphoretic M 3078-2 Interior Then fill as required with filler M 3032-2
dip primer min. 10 µm
2
Exterior )
15 – 25 µm
cavities layer-
forming
E PVC underseal M 3068 min. 1 mm ---
(as per work plan)
F Seal spot-welded connec- M 3065-1 3 - 4 mm ---
tions, folds, joints and edges M 3065-2 1 - 2 mm
(as per work plan)
G Insert insulation mats (inside) M 3041 2 - 3 mm ---
in doors, back panel, side M 3105 2 - 3 mm
panel and floor
(as per work plan)
H Replaced by level J
J Inject filler M 3079-2 Interior Only roof and visible surfaces including
min. 20 µm door cavity

2 complete;
Exterior )
25 – 35 µm apart from PVC-coated surfaces and
underbody area in TG/L2000 cabs
Not required for cab underbody on TG
model range if top coat is applied
1 3
K Top coating ) ) M 3031-2 Interior Interior: all visible surfaces including
20 – 30 µm door interior
or 2
Exterior ) Exterior: complete; including surfaces
M 3094-3/ 7 30 – 40 µm behind radiator flap, side parts and
bonding points
Not required for cab underbody on TG
model range if filler is applied
L Cavity sealing M 3082-B 20 – 50 µm as per plan
M Finish coat M 3094-3/ 7 Total coating Interior: min. 50 µm
thickness 4
(only if damage has to be Exterior: min. 70 µm )
repaired) maximum: 200 µm
Page 16
M 3300-1 : 2012-07
1
) For vehicles that have to be coated with daylight fluorescent colours, more than 3 colours, or other customer-specific
special coatings, a maximum total layer thickness of max. 400 µm is permissible. A max. overall coating system thick-
ness of 200 µm is permitted at bonding locations (e.g. window bonding). In the case of higher coating thicknesses, the
bonding locations must be covered after max. 200 µm.
2
) The maximum coating thickness of the individual layers (cathodic dip primer, filler, top coat) may be exceeded in indi-
vidual locations by max. 20% (approx. 5 µm) as long as the total layer thickness remains less than 200 µm.
3
) In the colour groups yellow, orange and red, it may be necessary to have a coating thickness of up to 200 m to
achieve an adequate coverage.
A max. overall coating system thickness of 200 µm is permitted at bonding locations (e.g. window bonding). In the ca-
se of higher coating thicknesses, the bonding locations must be covered after max. 200 µm.
4
) A minimum overall coating thickness of 50 µm must be observed in the hidden, protected area behind the A-pillar trim.
 Page 17
M 3300-1 : 2012-07
Table 5 Coating systems for large assembly Attachments and body structures (AU)
Type of Version Corro- Treatment levels Application information
component ID sion (the preceding levels are always included in the stated level)
protec- R V G Z D Total coating
tion class Cleaning Pre-treatment Primer coat Intermediate Top coating thickness
to 1) primer 2
M 3018 m) )
Side board attach- 03K 1 Coating --- Phosphating Cathodic dip --- Top coat
ment parts Material M 3161 M 3098-2 primer 1K-M 3031-2
M 3078-2 2K-M 3094-3/ 7 60 - 75
Coating thickness 40 - 50
(µm) --- --- 20 – 25
Side board attach- 30 1 Coating Start-grind --- 2K primer --- Top coat Sourced as purchased
ment parts of alu- Material or pickle M 3162-C 2K-M 3094-3/ 7 parts
minium M 3161 65 – 85
Coating thickness 25 – 35 40 – 50
(µm)
Side board profiles 03K 1 Coating --- Phosphating Cathodic dip --- Top coat
of aluminium Material M 3161 M 3098-2 primer 1K-M 3031-2
M 3078-2 2K-M 3094-3/ 7 60 - 75
Coating thickness --- --- 20 – 25 40 - 50
(µm)
Side board profiles 04K K2 Coating --- Phosphating Cathodic dip 2K primer Top coat
at joint surfaces Material M 3161 M 3098-2 primer M 3162-C 1K-M 3031-2
with attachment M 3078-2 2K-M 3094-3/ 7 85 – 110
parts Coating thickness 40 - 50
(µm) --- --- 20 – 25 25 – 35
Mudguard, galva- 03 Replaced by System 03K
nised 03K 1 Coating --- Phosphating Cathodic dip --- Top coat
Material M 3161 M 3098-2 primer 1K-M 3031-2
M 3078-2 2K-M 3094-3/ 7 60 - 75
Coating thickness --- --- 40 - 50
(µm) 20 – 25
73 1 Coating --- --- 2K primer Antichip coat- Top coat
Material M 3161 M 3162-C ing 1K-M 3031-2 65 – 85
M 3191-1 2K-M 3094-3/ 7 Inside
Coating thickness inside only 40 - 50 80 - 110
(µm) --- 25 – 35 15 – 25
Loading platform, 04K K2 Coating --- Phosphating Cathodic dip 2K primer Top coat Linish welded areas and
underbody cross Material M 3161 M 3098-2 primer M 3162-C 1K-M 3031-2 coat with primer-2K
beams, individual M 3078-2 2K-M 3094-3 85 – 110 M 3162-C
parts Coating thickness 20 – 25 25 – 35 40 - 50
(µm) --- ---
29K 1 Coating --- Phosphating Cathodic dip --- Powder paint
Material M 3161 M 3098-2 primer M 3166-1
M 3078-2 90 - 125
Coating thickness --- --- 20 - 25 70 - 100
 Page 18
M 3300-1 : 2012-07
Table 5 Coating systems for large assembly Attachments and body structures (AU) (continued)
Type of Application information
Ver- Corrosion Treatment levels
component
sion ID protec- (the preceding levels are always included in the stated level)
tion class
in acc. R V G Z D Total coating
with Cleaning Pre-treatment Primer coat Intermediate Top coating thickness
M 3018 1) primer m)

Loading platform, 19K K2 Coating --- Phosphating Cathodic dip Top coat Top coat Linish welded areas and
underbody frame Material M 3161 M 3098-2 primer 1K-M 3031-3 2K-M 3094-3/ 7 coat with primer-2K
individual parts M 3078-2 85 – 110 M 3162-C
Coating thickness
(m) --- --- 20 – 25 25 – 35 40 – 50
29K 1 Coating --- Phosphating Cathodic dip --- Powder paint
Material M 3161 M 3098-2 primer M 3166-1
M 3078-2 90 - 125
Coating thickness
--- --- 20 - 25 70 - 100
Loading platform, 19K K2 Coating --- Phosphating Cathodic dip Top coat Top coat
side members, Material M 3161 M 3098-2 primer 1K-M 3031-3 2K-M 3094-3/ 7
cross members, M 3078-2 85 – 110
legs Coating thickness
(m) --- --- 20 – 25 25 – 35 40 - 50
Support frame, 19K K2 Coating --- Phosphating Cathodic dip Top coat Top coat
individual parts Material M 3161 M 3098-2 primer 1K-M 3031-3 2K-M 3094-3/ 7
M 3078-2 85 – 110
Coating thickness
(m) --- --- 20 – 25 25 – 35 40 - 50
29K 1 Coating --- Phosphating Cathodic dip --- Powder paint
Material M 3161 M 3098-2 primer M 3166-1
M 3078-2 90 - 125
Coating thickness
--- --- 20 - 25 70 - 100
Loading platforms, --- --- Impregnation --- --- --- --- --- ---
wooden floor M 3095

Tarpaulin frame 03 System replaced by 03K

03K 1 Coating --- Phosphating Cathodic dip --- Top coat
Material M 3161 M 3098-2 primer 1K-M 3031-2
M 3078-2 2K-M 3094-3/ 7
Coating thickness 60 - 75
(µm) --- --- 20 – 25 40 - 50
1) Drawing specification where appropriate: Pre-treatment of welding contact surfaces with paint: as per M 3158-F, coating thickness 15-30 µm
2
) The total coating thickness may increase by 10 µm as a result of use of cathodic dip paint in accordance with M 3078 Type 2 as a thick cathodic dip coating (25 - 35 µm).
 Page 19
M 3300-1 : 2012-07

Table 6 Preferred coating systems for Salzgitter plant (extract from M 3300-1)

Type of Ver- Corro- Treatment levels Application information

component sion sions (the preceding levels are always included in the stated level)
ID protec-
tion R V G Z D Total coating
class Cleaning Pre-treatment Primer coat Intermediate Top coating thickness
as per 1) primer 1
m) )
M 3018
Components made 03K K1 Coating Degrease Phosphating Cathodic dip --- 2K top coat To be preferred for all non-
from all metallic Material M 3161 M 3098-2 primer M 3094-3/ 7 scooping parts
materials M 3078-2 60 - 75
Coating thickness
(m) --- --- 20 – 25 40 - 50
Components of steel, 21E K1 Coating Degrease Fe phosphat- 2K primer --- 2K top coat especially cast and forged
galvanised steel, 1) 1) 1)
Material ing M 3162-C M 3094-3/ 7 parts in
stainless steel and
non-ferrous metals M 3161 DIN 50942 65 - 85 3-chamber washer unit
Coating thickness 25 – 35 40 – 50
(m) ---
21 1 Coating Degrease --- 2K primer --- 2K top coat only manual degreasing
Material M 3161 M 3162-C M 3094-3/ 7
65 – 85
Coating thickness --- 25 – 35 40 – 50
(m)
Components made 30E K1 Coating Degrease Fe phosphat- 2K primer --- 2K top coat 1)
1) 1)
in
from aluminium Material ing M 3162-C M 3094-3/ 7
3-chamber washer unit
M 3161 DIN 50942 65 – 85
Coating thickness 40 – 50
--- --- 25 – 35
(m)
30 1 Coating Start-grind --- 2K primer --- 2K top coat only manual degreasing
Material and de- M 3162-C M 3094-3/ 7
grease
65 – 85
M 3161
Coating thickness 40 – 50
(m) --- 25 – 35
Plastic parts with 43 --- Coating Start-grind --- 2K primer --- 2K top coat Observe temperatures in
primer M 3022-2 Material and de- M 3162-C M 3094-3/ 7 drying cubicle
grease
70 – 90
M 3161
Coating thickness
(m) --- 35 – 45 35 – 45
 Page 20
M 3300-1 : 2012-07

Table 6 Preferred coating systems for Salzgitter plant (extract from M 3300-1) (continued)
Type of Application information
Version Corro- Treatment levels
component
ID sion (the preceding levels are always included in the stated level)
protec-
tion R V G Z D Total coating
class Cleaning Pre-treatment Primer coat Intermediate Top coating thickness
as per 1) primer m)
M 3018
Bumper, 73B K1 Coating Degrease --- 2K primer Antichip coat- 2K top coat
steel or plastic Material M 3161 M 3162-C ing M 3094-3/ 7
M 3191-1 145 – 235
Coating thickness --- 25 – 35 only external 40 – 50
(m) 80 – 150
Bumper, 74K K1 Coating Degrease Phosphating Cathodic dip Antichip coat- 2K top coat
steel Material M 3161 M 3098-2 primer ing M 3094-3/ 7 140 – 225
M 3078-2 M 3191-1
Coating thickness only external 40 – 50
(m) --- --- 20 – 25 80 – 150
Grab rails --- 3–4 Powder coating --- --- --- --- --- --- Rilsan process;
(inside only) M 3166-3 colours see M 3166 or
customer build spec

Aluminium flaps on 01K 2 Coating Degrease Phosphating Cathodic dip --- --- ---
coach and regular- Material M 3161 M 3098-2 primer
service bus, M 3078-2
pre-coating
Coating thickness
(m) --- --- 20 – 25
1
) The total coating thickness may increase by 10 µm as a result of use of cathodic dip paint in accordance with M 3078 Type 2 as a thick cathodic dip coating (25 - 35 µm).
 Page 21
M 3300-1 : 2012-07

5 Temporary corrosion protection for trucks

5.1 Storing primed parts

Outdoor storage of primed parts must be avoided. The corrosion protection of primer coats as per M 3086,
M 3162-C or cathodic dip primer coats as per M 3078 is sufficient in special cases for outdoor storage not ex-
ceeding 3 months.

5.2 Temporary corrosion protection for finished products.

Table 7 External protective wax
Scope of preservation Version ID
005 006 007
Road transport, rail or Road or sea transport in Storage up to approx.
sea transport tropical countries 12 months
External area Vehicle or assembly Vehicle or assembly Vehicle or assembly
Material standard M 3082-A M 3082-A M 3082-A
Coating thickness 20 - 50 m 20 - 50 m 20 - 50 m
Removability M 3082-A M 3082-A M 3082-A
Special areas --- as per waxing plan ---
81.60000-800X
Material standard --- Two-coat wax M 3082- ---
1)
Z
Coating thickness --- 515 - 725 m ---
Removability --- may not be removed ---
Interior area --- --- Engine, axles, gearbox
Component/group etc.
Material standard --- --- M 3069
Coating thickness --- ---
Removability --- --- M 3069
1)
1st coat: Penetration wax M 3082-P, 15 - 25 m
2nd coat: Sealing wax M 3082-S, 500 - 700 m
The external protective wax may not be applied until 5 days after the final or top coat at the earliest.
Page 22
M 3300-1 : 2012-07

6 Coating thickness inspection (without powder coating and temporary corrosion protection)
The coating thicknesses stated in this standard (dry layer thicknesses) are required coating thicknesses as per
DIN EN ISO 12944-5.
The required thickness in the sense of the standard is the coating thickness which the overall system must
possess so as to offer technically sufficient and economical corrosion protection for the expected exposure.
The required coating thickness is considered to have been achieved if a maximum of 5 % of the measured val-
ues are below the required value by no more than 20 %.
The maximum total coating thickness of 200 µm may not be exceeded. For exception, see footnote in
Table 4.1.
Areas of the chassis and chassis attachment parts where full-coverage chassis coating as per M 3094 is not
technically feasible owing to undercuts must have a minimum total coating thickness of 45 µm (cathodic dip
primer + top coat).
The measurement values are determined using a measurement record in which the measurement points de-
fined that are representative for the individual coatings of the item to be tested (large components). The meas-
urement points representative for the coating must also be taken into consideration on individual parts. The av-
erage value from several individual measurements is to be taken as the measurement value.
In cases of dispute, a decision is to be reached as per DIN EN ISO 4259.

7 Adhesion test
The adhesion test must be carried out as per MAN 276 or DIN EN ISO 2409 on test plates accompanying the
process. Curing times appropriate for the material in question must be taken into account.
In justified exceptional circumstances, the adhesion test can also be carried out on the object itself in liaison
with the corresponding quality assurance / 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.

8 Degree of gloss and colour inspection

Degree of gloss and colour inspections are carried out visually on the finished cab.
The required degree of gloss and colour values can be determined within the framework of the materials re-
lease.

9 Repair of the top coating

Where possible (depending on the component), damage to the finish must be repaired in spots or partially so
as to achieve the stipulated corrosion protection in the impaired area.
If partial repair impairs the visual impression of a new vehicle, the whole area in question must be reworked.
 Page 23
M 3300-1 : 2012-07

Standards quoted
DIN 50942 Phosphating of metals; principles, test methods

DIN EN ISO 2409 Paints and varnishes, cross-cut test

DIN EN ISO 4042 Fasteners, electroplated coatings
DIN EN ISO 4259 Petroleum products - Determination and application of precision data in relation to
methods of test
DIN EN ISO 12944-5 Corrosion protection of steel structures by protective paint systems

M 3018 Corrosion protection and coating systems for purchased parts; technical terms of
delivery
M 3022 Coating materials for components made of plastics; technical terms of delivery
M 3031 One-component top coating materials; 1K top coat; technical terms of delivery
M 3032 Fillers; technical terms of delivery
M 3041 Insulation of air-borne and structure-borne noise; definition of multi-layer systems;
technical terms of delivery
M 3065 Sealing pastes; technical terms of delivery
M 3068 PVC and PUR underbody protection; technical terms of delivery
M 3069 Temporary corrosion protection
M 3078 Electrophoretic dip primers, cathodic dip primer; technical terms of delivery
M 3079 One-component filler, 1K filler; technical terms of delivery
M 3082 Corrosion protection waxes; technical terms of delivery
M 3086 1K base coating materials; technical terms of delivery
M 3094 Two-component top coating materials, 2K top coat; technical terms of delivery
M 3095 Wood preservative
M 3098 Zinc phosphating for bonding coatings
M 3105 Insulation of air-borne and structure-borne noise; insulating materials; technical
terms of delivery
M 3158 Weldable materials for the corrosion protection of welded connections; technical
terms of delivery
M 3161 Cleaning metallic surfaces
M 3162 2K base coating materials, primer; technical terms of delivery
M 3166 Powder coating; technical terms of delivery
M 3191 Antichip coating materials; technical terms of delivery
M 3300-2 Coating systems for customer-specific special versions
M 3311-1 Coating systems for military vehicles

MAN 247 Heat-resistant coating materials; technical terms of delivery

MAN 272 Corrosion protection of containers and compression fittings made from steel in the
compressed air system; technical terms of delivery
MAN 276 Surface coating; adhesion test of coatings; cross-cut tear method

N 680 Coating materials for coating diesel engines; technical terms of delivery
Page 24
M 3300-1 : 2012-07

Previous issues: M 3300 / 1984-09; 1984-10

M 3300-1/ 1985-09, 1993-11, 1997-04, 1998-03, 1998-11, 2001-05, 2002-04,
2003-10, 2004-08, 2004-10, 2005-07, 2006-02, 2006-11, 2007-04, 2008-05

Changes:
Compared to issue 2004-08 the following changes have been made:
- Systems 02K, 05 and 08: top coat changed from M 3031-1 to M 3094-3/-7.
- Systems 19K, 20, 21 and 63: top coat as per M 3031-1 deleted.
- Table 3: Index 2 omitted
- Table 3: total coating thickness for frame side member (inner side) modified.
- Table 3, air intake, clean air, pickled: top coat corrected for system 27K.
- Section 6: Minimum total coating thickness (cathodic dip primer - top coat) for
undercuts modified
Compared to issue 2004-10 the following changes have been made:
- Table 3: Coating thickness adapted for version ID 20 for M 3162-A
- Total coating thickness adapted for version ID 20
Compared to issue 2005-07 the following changes have been made:
- Table 3: Axles, driven and non-driven, with primer M 3018-3 "and without
primer" added
Compared to issue 2006-02 the following changes have been made:
- Section 3: Reference to thick cathodic dip coat added
- Tables 2, 3, 4, 5: Index 2 added
- Table 6: Index 1 added
Compared to issue 2006-05 the following changes have been made:
- Section 3: Information on coating data in component drawings added
- Table 3, Component axles: Version IDs 05 and 21 deleted
- Table 4, component sliding roof: pre-treatment corrected, M 3098-2 was
M 3098-1
- Version ID 01K: corrosion protection class to M 3018 corrected
- Table 4.1: Treatment levels J and K: comment amended
- Sticker according to M 3056-2 adapted to normal case
- Editorial adaptations
Compared to issue 2006-11 the following changes have been made:
- Section 3: Information on coating data in component drawings adapted
- Table 7: Coating thicknesses adapted
Compared to issue 2007-04 the following changes have been made:
- Section 1: Application scope of standard adapted
- Section 3: Third bullet point "The overall coating thickness before assem-
bly…" adapted
- Table 4.1: Table designation adapted
- Coating thicknesses adapted for version IDs 41 and 43
Compared to issue 2008-05 the following changes have been made:
- Table 2: Type M 3094-7 added for version ID 03K
- Table 4.1: Index 1 and Index 3 extended
Index 4 added
- TDN is EAS, MTWV is EMTAC
- MAN Nutzfahrzeuge AG is now MAN Truck & Bus AG