18-1600 en
18-1600 en
18-1600 en
18-1600
Standard PARTS COMPOSING AN INDUSTRIAL VEHICLE Page 1/13
SPECIFICATION Date 12.05.2015
All rights reserved. This standard must not be reproduced or in any way utilized by other parties without the written consent of IVECO.
ANY HARD COPY IN YOUR POSSESSION SHOULD BE CONSIDERED NOT UP-TO-DATE. SEE RELEVANT WEB SITE FOR UP-TO-DATE DOCUMENT
1 PURPOSE
To define metallic materials protection classes depending on their location on the vehicle and
quality, appearance and protection requirements (see Table IV).
Define the general minimum protection cycles for each class according to the following types:
a) Parts and painted sub-assemblies.
b) Threaded fasteners or unpainted metal parts.
c) Aluminum parts.
17-1600 "Paint cycles for metal parts to be installed on chassis and body".
17-1600-A001 "Protection cycle for rear axles, front axles and front suspensions".
17-1600-A002 "Protection cycle for uncoated sheet steel fuel tanks and aluminium coated
sheet steel fuel tanks".
17-1600-A003 "Coating procedure for the protection of iron transmissions and associated
flange for connection to propeller shaft".
17-1600-A004 "Coating procedure for the protection of propeller shafts and associated
coupling flange (Transmission-to-Axle)".
10-4152 "Protection classes for vehicle metal parts".
Component drawings and associated IVECO STDs shall specify for the components made of
precoated (galvanized, etc.) sheet:
2.1 SURFACE PROTECTION as per IVECO STD. 181600 CLASS ... (A , B , B1, B2, B3, B4, C, D)
2.2 BREAK CORNERS as per Table II of IVECO STD. 18-1600 and SURFACE PROTECTION as per
IVECO STD. 18-1600 CLASS ... (A , B , B1, B2, B3, B4, C, D)
In addition to the above, where frame cross member interface sealing is required, the following
shall be specified:
2.3 SEAL CROSS MEMBER INTERFACES SHOWN ON DWG, AS SPECIFIED IN PARA. 8 OF IVECO
STD. 18-1600.
NOTE : For chassis frame protection designation shall be called up on all drawings of individual
components (side members, cross members).
TABLE I
NOTE: The sub-classes S1B - S2A -S2B - S2C have been suppressed. For transcoding refer to
corresponding classes B, A, B, C as shown in Table I above.
[1] Parts must only be supplied with cataphoretic coating (e-coat) or rustproofed (Table III). Top
coat shall be applied during the chassis finishing process. On cast iron components (or with
high superficial rugosity) must be prescribed the class B4, the class B3 must be applied only
on the machined surfaces.
[2] Threads must be supplied only with cataphoretic coating (e-coat), instead have to be masked
if the diameter is ≤ M6.
3.2.2 Light alloy parts can be not protected (it depends if the aluminum alloys has corrosion resistance
properties). Otherwise protection should be required, specify it on the drawing (following the
indications of Table IV).
Protection is not required on brass or copper parts.
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IVECO S t a n d a r d
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18-1600 Date 12.05.2015
4 CORNER BREAKING
In order to obtain the corrosion resistance also foreseen for sheared surfaces, the operation
shown in the Table II must be required. It must be indicated on the drawing for chassis
components in view.
TABLE II
Classes
Description of cycle phase
A B [3] B1 [4] B2 B3 B4 C D
TABLE III
Classes
Description of cycle phase B1
A B [3] B2 B3 B4 C D
[4]
[3] For ferrous sheet metal or precoated fuel tanks refer to para. 6.
[4] Only rear axles and front axles.
[5] To be performed when burring or swarf left by cutting or welding, oxidisation or surfaces cut
by laser are present.
[6] Pretreatment cycles that do not contain zinc or iron phosphates should not be used, for parts
in classes A, B, B1, B2, B3 and B4.
[7] Alternative products and cycles for the same phase must be compatible with the part.
[8] Specific phosphate pretreatments must be used for aluminium or galvanised sheet metal.
[9] Two coat cycle for bodyshell.
[10] Three coat cycle for bodyshell.
[11] Excluding parts unsuitable for dipping in pretreatment or paint bath to maintain serviceability
(e.g.: mechanical components), these components shall be treated with rustproof primer.
[12] Only for parts for installation on engine.
[13] The rustproof primer is in alternative to the ecoat, where the ecoat can’t be applied.
[14] As an alternative to single or two component top coat for bodyshell parts only (wipers, rear
view mirrors, etc.).
[15] Application necessary only if colour, as per I.C., is defined on the drawing.
[16] The coating film thickness must be sufficient to fulfill the requirements indicated on Table V.
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IVECO S t a n d a r d
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18-1600 Date 12.05.2015
TABLE IV
Corrosion
resistance Protection
Protection Drawing require Friction
type ment Characteristics coefficient (hours - fer class
rous corro Table I
sion)
Fe/Zn 7 V (olive
green) High corrosion resistance. 192
Their appearance may show hues 0,12-0,30 C, D
GALVANIZING TREATMENT FOR IRON PARTS
required.
Without hexavalent chrome
[19] Galvanizing with a greater thickness (12 mm) is to be used on those parts installed in areas of
the vehicle which are more subject to corrosion (e.g. chassis).
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6 PROTECTIVE CHARACTERISTICS OF PAINTED METAL PARTS
Protection features of metal parts paint coated according to cycles as per Table III are described in Table V.
TABLE V
Class
Characteristics Test Method Limits
A B B4 B1 B2 B3 C D
Non-protected surfaces not permitted.
Visual inspection (▲) - Serious surface defects not permitted. Yes
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I.S. 15-0457
Colour gloss (angle 60o) (ISO 2813) 90 - 95 gloss unless otherwise stated. Yes NOTE 1 - NOTE 1 Yes
18-1600
Covered surface Wave scan - side members, -
- Horizontal sur cross mem
faces:
bers:
GMT 12-16
GMT ≥ 5
I.S. 15-6021
Hardness (PERSOZ) (ISO 1522) ≥ 200 full oscillations. Yes -
Date
Page
I.S. 15-0454 - ≥ 4 mm for two-layer cycle
Drawing Method A Yes -
- ≥ 2.5 mm for three-layer cycle
Resistance to solvents I.S. 15-0473
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[20] Method B Surface changes not permitted. Yes
For notes (▲), [20], [21] and NOTE 1 see page 10.
(continued ⇒ ⇒ )
( ⇒ ⇒ continued Table V)
IVECO S t a n d a r d
Class
Characteristics Test Method Limits
A B B4 B1 B2 B3 C D
External surfaces
Not acceptable:
- the onset of corrosion on edges, joints
and surfaces in general;
- blistering, separation;
- sub-surface corrosion > 2 mm.
Resistance to salt spray I.S. 16-0135 Yes
A1/B1 Boxed section surfaces Yes Yes Yes Yes (300 h) Yes Yes
(▲) (only for non zinc Not acceptable: (1000 h) (300 h) (500 h) (200 h) (500 h) (96 h)
plated ferrous sheet) (ISO 7253) [23]
- ferrous corrosion spots on walls
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Acceptable:
- minor ferrous corrosion spots on spot
welds
- minor ferrous corrosion spots at stiffener
coupling to walls [22]
Water resistance I.S. 15-0470 Surface defects and changes in adhesion
(24 h at 60 oC) (ISO 1521) are not permitted Yes - Yes -
External surfaces
Not acceptable:
- the onset of corrosion on edges, joints
and surfaces in general;
- blistering, separation;
18-1600
- sub-surface corrosion > 6 mm.
Yes Yes
Resistance to Boxed section surfaces (1000 h) Yes Yes (300 h) Yes
“Scab Corrosion" I.S. 15-6035 (300 h) (500 h) - (500 h) -
Not acceptable: [25] [23]
- ferrous corrosion spots on walls
Acceptable:
- minor ferrous corrosion spots on spot
welds
- minor ferrous corrosion spots at stiffener
coupling to walls [22]
Date
Page
Not acceptable:
Resistance to copper - the onset of corrosion on edges, joints
saline acetic mist (only I.S. 16-0135 and surfaces in general; Yes Yes Yes
- - -
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aluminium) A3/B1 (168 h) (168 h) (120 h)
- blistering, separation;
- sub-surface corrosion > 4 mm.
Loss of gloss of ≤ 15% is permitted. Yes [24]
Resistance to atmo Chalking is not permitted. (1500 h) Yes
spheric agents (W.O.M) I.S. 16-0180 (500 h) -
Slight discoloration is permitted. (750 h)
For notes (▲), [22], [23], [24] and [25] see page 10. (continued ⇒ ⇒ )
( ⇒ ⇒ continued Table V)
IVECO S t a n d a r d
Class
Characteristics Test Method Limits
A B B4 B1 B2 B3 C D
Extent of splintering: 6B
Stone impact resistance Stone impact on sheet metal: 7B (rust
[26] I.S. 15-6023 Yes - Yes -
spots).
Abrasion resistance [27] I.S. 15-0488 ≥ 20 Kg/mm - Yes -
Resistance to emulsifi Surface defects and separations are not
able oils [28] permitted. - Yes -
tions permitted.
Heat resistance [30] - Required by I.S. 18-1609 - Yes -
18-1600
any stone impact down to sheet metal and the sub-surface corrosion.
[27] Perform test only where specified on drawing and in area specified. The abrasion protection consists of:
− pre-treatment;
− cataphoretic coating or rustproofing;
− baking;
− application of abrasion protective coating (I.S. 18−1654);
− baking;
− applying of top coat if colour is indicated (IC), the choice between a single-component product (130 oC) or two-component product (80 oC) depends on the type of abrasion
protective coating used;
− baking.
Date
Page
Paint film thicknesses are specified in Table III.
[28] Immerse the part for 24h in a 3% solution of water and emulsifiable oil at 40 oC. Remove the part and examine it immediately when 24 h has elapsed.
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[29] Immerse the part for 15 min in a 10 % solution of sodium carbonate at 80 oC.
[30] Test to be carried out only if required on drawing.
NOTE 1: For chassis parts and assemblies (Classes B, B1, B4, C) final colour shall be as per I.C 444 (RAL 7021), 70 - 80 Gloss, unless otherwise specified.
NOTE 2: Parts of classes C and D for which IVECO requires intermediate rustproof or cataphoretic protection, i.e. no top coat, shall meet requirements shown as (▲),
depending on Class of origin.
IVECO S t a n d a r d
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18-1600 Date 12.05.2015
7.1.1 Pretreatment
Prepare sheet, after wire brushing welded areas (to remove metallic and carbon scales), as per
Table III.
As per Class B.
Coat fuel tank interior wall with (50 g/m2) of protectant as per IVECO STD. 18-1655 Type B.
7.2.1 Pretreatment
As per Class B.
The following operations are to be carried out after application of corrosion protection
(cataphoretic coating or rustproofing) for parts protected as per IVECO STD. 18-1600 class B 2
and after top coat application for parts protected as per class B.
8.1 Apply bead of black polyurethane single component sealant to all part seams specified on
drawing.
There shall be no discontinuities, especially on corners, in order to prevent the inception of
corrosion spots in the long term. Brush touching-up shall not be acceptable.
8.2 Wipe any smeared surfaces adjacent to the seams using cleaning solvent moistened cloth.
The above is the only guarantee for effective adhesion of a subsequent layer of paint.
Sealing of seams of a
cross-member as per
para. 8
Figure 1
TABLE VI
[31] Iveco reference standards 11-4540, 11-4541, 11-4542, 11-4543 and 11-4544.
[32] Collar type to be used only for uses where a resistance to salt spray between 400 - 500 hrs is
required.
[33] Class W2 has been replaced by W1 or W4 according to the salt spray resistance required.
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18-1600 Date 12.05.2015
STANDARDS QUOTED
IVECO STD.: 10-4152, 11-4540, 11-4541, 11-4542, 11-4543, 11-4544, 15-0454, 15-0457, 15-0461, 15-0470,
15-0473, 15-0488, 15-0503, 15-6021, 15-6023, 16-0135, 16-0180, 15-6035, 17-1600,
17-1600-A001, 17-1600-A002, 17-1600-A003, 17-1600-A004, 18-0506, 18-1101, 18-1102,
18-1103, 18-1148, 18-1317, 18-1318, 18-1608, 18-1609, 18-1654, 18-1655, 19-0201.
ISO: 1521; 1522; 2409; 2813, 7253.