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NAVISTAR, INC.

CEMS NUMBER:

(CORPORATE ENGINEERING MATERIAL SPECIFICATION) CEMS G-5, Part IA


TITLE: CURRENT ISSUE DATE:
Paint – Part IA , Product Finishing Requirements June 2008
WRITTEN/REVIEWED BY: APPROVED BY: SUPERSEDES ISSUE OF:
Materials Engineering Materials Engineering October 2006

PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION


This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of
the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine
the applicability of regulatory limits prior to use.
Change Notice: Correction to Table I salt spray requirements for Class B; replaced “International Truck and
Engine Corporation” with “Navistar, Inc.” per corporate directive; editorial changes.

1.0 SCOPE
The intent of this specification is to establish acceptable durability and quality levels for the finish on
Navistar products and to define requirements and physical properties of the various materials used in the
painting operation.

1.1 Restricted Chemical Substances


Effective January 1, 2007, all product supplied to the requirements of this specification must comply
with the requirements of the CEMS B-50 specification.
2.0 INTRODUCTION
CEMS G-5 is divided into eight parts as follows:
Part IA - Product Finishing Requirements Part V - Primers
Part IB - Paint Material Requirements Part VI - Paints for Repair and Service
Part II - Topcoats Part VII - Deleted
Part III - Chassis, and Miscellaneous Paints Part VIII - Engine Paints
Part IV - Casting Sealers

Part IA - Outlines classes of finish for Navistar parts, components, and products.
It defines requirements and describes physical properties, which govern durability,
corrosion protection, and overall appearance quality.
Part IB - Outlines the procedure for specifying paint materials covered in the CEMS G-5
specification.
Parts II thru VIII - Details specific liquid properties and dry film requirements for all paint
materials used by the Company. The dry film requirements described in these seven
sections apply to painted test panels evaluated under laboratory conditions.

This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards.
Suppliers are required to assume all patent liability. ©2008 by Navistar, Inc.

JUNE 2008 --``,``,`,`,,`,`,,```,,`,```,`,-`-`,,`,,`,`,,`---


Page 1 of 5
Copyright Navistar International Corporation
Provided by IHS under license with INTERN Licensee=Core Molding Tech/5946063001
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NUMBER: TITLE: CURRENT ISSUE DATE:
CEMS G-5, Part IA Paint - Product Finishing Requirements June 2008

PART IA - PRODUCT FINISHING REQUIREMENTS


3.0 CONTENTS PAGE
REFERENCE DOCUMENTS 2
GENERAL REQUIREMENTS 2
QUALITY 4
METHODS OF TEST 4
SOURCE APPROVAL AND QUALITY CONTROL 4
DESIGNATION ON DRAWINGS AND PURCHASE ORDERS 5

4.0 REFERENCE DOCUMENTS


Unless otherwise specified, the latest issue of all referenced standards shall apply. The following
standards, specifications and regulations are referenced in this specification.

Quality System Standard ISO 9001 or TS-16949 NAVISTAR CEMS GT-6B ASTM D 4138
NAVISTAR Manufacturing Standard MS-D-13 NAVISTAR CEMS GT-7D ASTM D 1729
CFR Title 29, Part 1910 NAVISTAR CEMS GT-7E SAE J2334
NAVISTAR CEMS B-50 NAVISTAR CEMS GT-23 SSPC-VIS-2
NAVISTAR CEMS GT-4D NAVISTAR CEMS GT-29
NAVISTAR CEMS GT-5A ASTM D 1186

5.0 CLASSIFICATION
Paint grades are classified by chemical composition, durability and application.
5.1 Class of Finish
The Class of finish for specific products will be established by appropriate design engineering personnel
in conjunction with the Industrial Design and Materials Engineering Groups. This specification will
form the basis for uniform inspection standards for both manufactured and purchased parts. All
materials utilized must conform to the requirements for the appropriate Class and Grade for the finish
specified. All deviations from this specification must be approved by the appropriate Materials
Engineering Department.

6.0 GENERAL REQUIREMENTS


This specification is not intended to limit or specify the metal pretreatment or painting process but note
that iron phosphate is not recommended for zinc or aluminum coated substrates. When a chemical
surface pretreatment is required, any process such as zinc or iron phosphate, acid wash prime or
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conversion coating applied by spray, immersion, or steam cleaning which results in finished parts
meeting the requirements of this specification will be approved. However, all systems from new vendors
or deviations to this specification or changes in currently approved systems must be approved by
Materials Engineering.
6.1 Finish Requirements
All parts, whether painted by Navistar or purchased, will be finished with paints which meet all dry film
requirements of the CEMS G-5 grade specified unless otherwise designated on the part drawing or
purchase order. The resultant coating must match the appropriate Navistar color standard as well as meet
all of the requirements for the appropriate finish classification as shown in Table I.

This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards.
Suppliers are required to assume all patent liability. ©2008 by Navistar, Inc.

JUNE 2008 Page 2 of 5


Copyright Navistar International Corporation
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NUMBER: TITLE: CURRENT ISSUE DATE:
CEMS G-5, Part IA Paint - Product Finishing Requirements June 2008

TABLE I - FINISH CLASSIFICATION(1) AND REQUIREMENTS FOR PAINTED PARTS


Class A(C(2) ) Class B Class D Class E Class F Class G
Part/Finish Nondecorative Frame
Classification Engine Castings
Decorative and Interior and (4 ) (4)
Small Part Chassis
SURFACE PREPARATION
Zinc Phosphate (Immersion or Spray) System, Shot or grit
Coating Type Solvent Wipe
or Conversion Coating Blast
Metal

Coating Weight, 200-400 for Zinc Immersion Systems


Ferrous - -
mg/ft2 170-250 for Zinc Spray Systems
Non Coating Weight, 150-250 for Zinc Immersion Systems
- -
Ferrous mg/ft2 75-150 for Zinc Spray Systems
Preparation per accepted industry standards
Nonmetal -

PRIMER
Film Thickness, µm 20 (3) 20 (3) 20 (3) 15 25 25
Ferrous
min 0.8(3) 0.8 (3) 0.8 (3)
Metal

mil 0.6 1.0 1.0


Non Film Thickness, µm 15 (3) 15 (3 15 (3 15 25 25
Ferrous min mil 0.6 (3) 0.6 (3) 0.6 (3) 0.6 1.0 1.0
Film Thickness, µm 25 - - - - -
Nonmetal
min mil 1.0 - - - - -
Hours 500 250 - 250 100 100 (9)
Salt
Spray Corrosion mm 0.8 1.5 - 1.5 1.5
Creepage, max inch 0.03 0.06 - 0.06 0.06 -
Humidity, Hours, Pass 500 250 100 250 100 100
Cycles 60 30
Cyclic
Corrosion mm 0.8 1.5 - - - -
Corrosion
Creepage, max inch 0.03 0.06
Orange Peel, Min (5 ) 7 - - - - -
Gloss - - - - 5-25 5-25
Adhesion, % 90 90 90 90 90 90
Hardness HB HB HB HB H B
TOP COATS
Film Thickness, min. unless 1.7-9.5 (43-241)
(6 ) (7 ) 1.5 (38) 1.0 (25) 1.0 (25) -
specified as a range, mil (µm)
Initial Gloss @ 20º, min unless otherwise As
80 -
specified Specified
Hardness, min HB HB B B -
Adhesion, % min 90 90 90 90 -
Salt Hours 500 - 250 100 -
Spray Corrosion mm 0.8 - 1.5 1.5 -
Exposure Creepage, max inch 0.03 - 0.06 0.06 -
Humidity, Hours, Pass 500 100 250 100 -
Cyclic Cycles 60
Corrosion Corrosion mm 0.8 - - - -
Exposure Creepage, max
inch 0.03
Color Match International Standard
Orange Peel Reflected Light, Min (8) 6.0 - - - -
Humidity, Hours, Pass 500 100 - - -

(footnotes next page)

(1)
See Appendix - General Information for cross reference to TMS-9009 Finish Classification.

This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards.
Suppliers are required to assume all patent liability. ©2008 by Navistar, Inc.

JUNE 2008 --``,``,`,`,,`,`,,```,,`,```,`,-`-`,,`,,`,`,,`--- Page 3 of 5


Copyright Navistar International Corporation
Provided by IHS under license with INTERN Licensee=Core Molding Tech/5946063001
No reproduction or networking permitted without license from IHS Not for Resale, 10/30/2008 15:17:04 MDT
NUMBER: TITLE: CURRENT ISSUE DATE:
CEMS G-5, Part IA Paint - Product Finishing Requirements June 2008
(2)
Class C is obsolete. Parts, such as bumpers, wheels, hubcaps, etc., formerly designated as Truck Group Class C finish, and all existing drawings,
blueprints, purchase orders, etc., which specify Class C finish will meet the requirements of Class A finish. Class C finish will not be used on new
drawings and/or part releases.
(3)
Minimum film thickness for cathodic E-Coat primer, is 0.8 mils (20µm) for steel, 0.6 mils (15µm) for aluminum.
(4)
Class F - Primers used for Class F and Class G must be compatible for recoating with Grades -81H and/or -81W engine topcoats.
(5)
Comparison test: Orange peel comparison standards are available from Advanced Coatings Technologies, Inc., P.O. Box 401, 273 Industrial Drive,
Hillsdale, MI 49242
(6)
Minimum film thickness requirements for BC/CC are: Base Coat 0.8 mils (20 µm); clear coat 1.5 mils (38 µm). Basecoat must pass black/gray
Morest hiding.
(7)
For painted wheels - top coat film thickness will not exceed 2.3 mils (58 µm).
(8)
See International CEMS GT-29.
(9)
Test on as-cast parts prior to machining. Castings are not to be scribed and will be rated visually per SSPC-VIS- 2, controlled by the Society for
Protective Coatings, to assign the appropriate "Rust Grade and Distribution". A minimum rating of Grade 7 is required.

7.0 QUALITY
All painted surfaces will be free from sags, runs, dirt, seediness, orange peel, dry spray, dents, scratches,
pits, gouges, and weld spatter when viewed with the unaided eye. The supplier should be capable of
providing statistical evidence that products supplied to the requirements of this specification have been
produced using manufacturing processes which are in statistical control and are competent to meet the
requirements of this specification. The purchaser may request results of the supplier’s quality control
tests on each shipment.

8.0 METHODS OF TESTS


Unless otherwise specified, tests will be run in accordance with the following test procedures except the
finished part or sections of the finished part, are to be used in place of the test panels.

Test Procedure*
Hardness CEMS GT-4D
Gloss CEMS GT-6B
Orange Peel, Reflected Light CEMS GT-29
Salt Spray CEMS GT-7D/ASTM B117
Cyclic Corrosion CEMS GT-7D/SAE J2334
Humidity CEMS GT-7E
Adhesion CEMS GT-5A
Color ASTM D 1729
Phosphate Coating Wt. CEMS GT-23
Non-Destructive ASTM D 1186
Film Thickness
Destructive ASTM D 4138

*Copies of Navistar CEMS GT test methods must be purchased from Information Handling
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Services (IHS), 15 Inverness Way East, Englewood, CO 80112 (1-800-854-7179; or internet


http://www.ihs.com ).
ASTM Test Methods are available from American Society for Testing and Materials,
1916 Race Street, Philadelphia, PA 19103 (or http://www.astm.org)

This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards.
Suppliers are required to assume all patent liability. ©2008 by Navistar, Inc.

JUNE 2008 Page 4 of 5


Copyright Navistar International Corporation
Provided by IHS under license with INTERN Licensee=Core Molding Tech/5946063001
No reproduction or networking permitted without license from IHS Not for Resale, 10/30/2008 15:17:04 MDT
NUMBER: TITLE: CURRENT ISSUE DATE:
CEMS G-5, Part IA Paint - Product Finishing Requirements June 2008

9.0 SOURCE APPROVAL AND QUALITY CONTROL


9.1 Supplier Requirements
All suppliers to NAVISTAR are required to be registered to ISO 9001 Quality System Requirements.
NAVISTAR will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG
PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must
maintain their certification with an accredited registrar and must furnish copies of registration
certificates to their Corporate Buyer upon request.
9.2 Approval
Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all
respects to those samples, which were approved by the purchaser. No changes in formulation or
processing practices are permitted without approval. In the event that changes in material, properties,
processing practices, construction, color, or labeling of the product are required, the supplier shall
notify Materials Engineering, Truck Development and Technology Center and Purchasing and
Supplier Development of the proposed change(s). Test data indicating conformance to all
requirements of this specification, test samples, and new or amended or updated Material Safety Data
Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for
change.
9.3 Process Control
The supplier shall either perform and report results of tests on specific lots of parts produced using
ISO 9001 or TS-16949 guidelines, or provide statistical evidence of the lot having been produced in a
state of statistical control and with a process capable of providing all required properties. The part
supplier and the plant metallurgist and/or the quality control manager of the using International plant
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may determine testing and reporting requirements on specific products.

10.0 DESIGNATION OF DRAWINGS AND PURCHASE ORDERS


Finishing requirements on drawings and purchase orders will include color and finish class.
Examples: FINISH: NAV 0311 Orange, Class B, CEMS G-5, Part IA.
FINISH: NAV 0001 Black, Class F, CEMS G-5, Part IA.

11.0 TECHNICAL INFORMATION

For further information related to the technical content Suppliers may purchase controlled copies of this
of this specification, contact: specification by contacting:
Materials Engineering and Technology Dept. Information Handling Service (IHS)
Truck Development and Technology Center 15 Inverness Way East
2911 Meyer Road Englewood CO 80112-5776
Fort Wayne, IN 46803 Phone: 1-800-854-7179
E-mail: MaterialsEngineering@Navistar.com E-mail: Automotive@IHS.com
Website: http://global.ihs.com

This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards.
Suppliers are required to assume all patent liability. ©2008 by Navistar, Inc.

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NAVISTAR, INC.
CEMS NUMBER: CEMS G-5, PART I
(CORPORATE ENGINEERING MATERIAL SPECIFICATION) APPENDIX
TITLE: CURRENT ISSUE DATE:
Paint - Part I Appendix June 2008
WRITTEN/REVIEWED BY: APPROVED BY: SUPERSEDES ISSUE OF:
Materials Engineering Materials Engineering February 2002

PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION


This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of
the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine
the applicability of regulatory limits prior to use.
Change Notice: Replaced “International Truck and Engine Corporation” with “Navistar, Inc.” per corporate
directive; editorial changes

APPENDIX
GENERAL INFORMATION (Not a Requirement)
Navistar Principal
Grade Description and Characteristics Navistar User
PART II - TOPCOATS
-17 A two-component isocyanate activated acrylic urethane topcoat with
excellant durability, color retention, and gloss. Truck
-17HS A high solids version of Grade –17. Truck
-18 Base Coat/Urethane Clear Coat system possessing outstanding durability
color retention, and gloss. Truck
-19 An acrylic oven drying topcoat possessing superior durability, color retention, and
gloss. Truck
-19HS This is a high solids version of Grade –19. Truck
-29 A baking topcoat used for the interior of trucks. Truck
-29HS This is a high solids version of Grade –29. Truck
-29T This is a high baking temperature version of Grade –29. Truck
-29THS This is a high solids version of Grade –29T. Truck
PART III – CHASSIS AND MISCELLANEOUS PAINTS
-32 A very fast air drying chassis paint
-32HS This is a high solids version of Grade -32.
-32HS/UR This is a high solids urethane version of Grade –32.
Truck
-32W This is a water based version of Grade –32.
-33 Heat Resistant Paint
PART IV – CASTING SEALERS
-41 A chlorinated rubber base sealer with good film building properties. It may be
stored outdoors for as long as six months. It may be applied by hand spraying,
Truck
automatic spraying, airless spraying, flow coating, or dipping.
-43 A synthetic alkyd sealer for use on extremely rough casting. It possesses
excellent exposure durability and film building properties. It is sensitive
to diesel fuel unless completely cured (approx 7 days). This sealer may be applied
Truck
by hand spraying, automatic spraying, flow coating, or dipping.
-43W An air drying, water borne solution, emulsion, or dispersion type sealer. It
possesses excellent exposure durability and film building properties. This sealer
may be applied by hand spraying, automatic spraying, flow coating, or dipping. Truck

This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards.
Suppliers are required to assume all patent liability. ©2008 by Navistar, Inc.
--``,``,`,`,,`,`,,```,,`,```,`,-`-`,,`,,`,`,,`---

JUNE 2008 Page 1 of 2


Copyright Navistar International Corporation
Provided by IHS under license with INTERN Licensee=Core Molding Tech/5946063001
No reproduction or networking permitted without license from IHS Not for Resale, 10/30/2008 15:17:04 MDT
NUMBER: TITLE: CURRENT ISSUE DATE:
CEMS G-5, Part I APPX Paint - Part I Appendix June 2008

Navistar Principal
Description and Characteristics
Grade Navistar User
PART V – PRIMERS
-50 A high quality baking primer with good corrosion resistance. This
primer is a suitable substrate for Grades –17, -18, and –19 topcoats. Truck
-52 A synthetic baking primer for use on fiberglass reinforced plastic (FRP).
-52HS This is a high solids version of Grade – 52.
Truck
-52W This is a water based primer for FRP.
-53 and An air drying or oven drying synthetic alkyd primer for use on All Groups
–53A production and service parts: suitable for heated paint application when Merchandising
specified with an A suffix and Service
-54 A synthetic flash drying primer possessing excellent adhesion, holdout,
and corrosion resistance. This primer is a suitable substrate for Grades –
Truck
18, -19, and –29 topcoats.
-55 A high quality baking primer formulated for flow coat application.
-55W Primer is a suitable substrate for Grades –18, -19, and –29 topcoats. A
Truck
water-borne solution of this primer is designated by the suffix W.
-56 A cathodic, electro-deposited primer. Truck
PART VI – PAINTS FOR REPAIR AND SERVICE
-61 A merchandising paint in a pressurized container. Merchandising
and Service
-62 An air drying paint furnished for service. Merchandising
and Service
PART VII
Deleted

PART VIII – ENGINE PAINTS


-81HS A very fast drying engine paint; no exposure requirements are specified. Engine
-81W An air drying, water borne engine paint; no exposure requirements are
specified. Engine
-82W This is a water based, air drying engine primer. Engine
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-83W This is a water based, oven bake engine primer. Engine

Finish Classification (Cross Reference to TMS-9009)


CEMS G-5, Part IA TMS-9009, Class ___
Class A Class I
Class B Class II
Class C * Class I
Class D Class III
Class E Class IV
Class F Class V
Class G Class VI
* Class C is obsolete and should not be used on new drawings. Requirements of Class C are incorporated into
Class A.

This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards.
Suppliers are required to assume all patent liability. ©2008 by Navistar, Inc.

JUNE 2008 Page 2 of 2


Copyright Navistar International Corporation
Provided by IHS under license with INTERN Licensee=Core Molding Tech/5946063001
No reproduction or networking permitted without license from IHS Not for Resale, 10/30/2008 15:17:04 MDT