NAVISTAR, INC.

NUMBER:
Material, Parts, and Process Specifications
MPAPS G-9005
(MPAPS) Former Designation: TMS-9005

TITLE: CURRENT REV No.: DATE:

Prepaint Treatment, Plastic Parts 1406 JUNE 2014

WRITTEN/EDITED BY: APPROVED BY: SUPERSEDES:

Materials Engineering Materials Engineering TMS-9005 - August 2013
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: Changed to new MPAPS format; editorial changes.

1.0 APPLICATION
This specification covers the prepaint treatment required for open or closed mold fiberglass reinforced
thermosetting plastic parts, or thermoplastic parts that are injection molded or thermoformed, which are
to be subsequently finish painted in NAVISTAR facilities. Typical parts are hood and fender assemblies,
headlight panels, radiator grilles, window panel inserts, engine covers, and similar exterior and interior
applications.

2.0 SCOPE
This specification covers surface appearance and dry film property requirements of the primer,
inspection, KCC, quality control and source approval, repair of primed surfaces, and handling required
for prime painted FRP or thermoplastic parts prior to shipment to the using NAVISTAR plant. Parts
receiving heat cured topcoats and parts that specify air dry topcoat finish are covered by this
specification.

2.1 Restricted Chemical Substances

Effective January 1, 2007, all product supplied to the requirements of this specification must comply
with the requirements of the MPAPS B-50 specification.

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3.0 REFERENCE DOCUMENTS
Unless otherwise specified, the latest issue of all referenced standards shall apply. The following
specifications, standards, and regulations are referenced herein.

Quality System Standard ISO 9001 or TS-16949 NAVISTAR CEMS GT-5A,5B, 5C

NAVISTAR Manufacturing Std. MS-D-13 NAVISTAR CEMS GT-6B
NAVISTAR Engineering Design Std A-16 NAVISTAR CEMS GT-7E
CFR Title 29, Part 1910 NAVISTAR CEMS GT-14A
NAVISTAR MPAPS B-50 NAVISTAR CEMS GT-18
NAVISTAR CEMS G-5, Part V NAVISTAR CEMS GT-28
NAVISTAR CEMS GT-4D ASTM D 4138
NAVISTAR MPAPS G-9012 SAE J400
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Suppliers are required to assume all patent liability. 2014 by Navistar, Inc.
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MPAPS G-9005 Prepaint Treatment, Plastic Parts 1406

4.0 GENERAL REQUIREMENTS

This specification is not intended to limit or to specify the exact process and materials to be used in
providing plastic parts ready for topcoating in NAVISTAR painting operations. The control of the
primer quality and its application shall be the responsibility of the part supplier. All primed parts
supplied shall be compatible with the finish painting operations employed by the using NAVISTAR
plant.

4.1 Material/Process Approvals

The primers used by the supplier must be approved by NAVISTAR Materials Engineering to meet the
dry film requirements of Grade -52 and/or Grade -52HS as per CEMS G-5, Part V, prior to their first use
in production. In addition, parts primed with the materials and application processes/methods to be used
by the supplier shall be approved by Materials Engineering and, after approval, no deviation in materials
and/or manufacturing processes shall be permitted without written approval by Materials Engineering.

4.1.1 A typical preparation and priming procedure is shown in the General Information Section. This
procedure has provided acceptable parts when used with good substrate and the proper materials.

4.2 In-Mold-Coating
Priming of FRP parts which use in-mold-coating (IMC) as a sealer to seal the part requires special
treatment. In cases where coverage of the part with IMC is essentially complete, if needed, the use of
spot primer will be satisfactory. In cases where coverage of the part with IMC is less than complete, the
use of a 1.0-2.0 mil dry film primer-sealer (with oven bake after application of the primer-sealer) will be
required to seal the substrate. If the incompletely covered area is less than 2 inches in diameter, no
priming may be necessary if the area does not show through the topcoat and does not promote surface
defects (e.g., pitting and porosity). Spot priming (and rebake) of these areas is acceptable if there is no
show-through of primer boundaries after topcoat . If show-through occurs, the entire part must be primed
and oven baked prior to topcoating.

4.3 Surface Quality

It is recognized that certain defects, such as substrate porosity, may not be detectable in a primed part
until after topcoating. Isolated instances of porosity, as defined in Table 1, shall not be considered cause
for rejection. Chronic cases of porosity requiring significant rework shall be cause for rejection and the
responsibility of the vendor to correct. The supplier has the responsibility to provide quality primed parts
which will not cause delayed defects after finishing in the using plant. Parts supplied shall be free of dirt,
oils, molding flash, sharp edges or other potential contaminants that could cause in-plant rework and
negatively impact overall quality. This will require close cooperation with the paint facility at the using
plant and with Materials Engineering.

4.4 Appearance Requirements

Specific appearance requirements are given in Table 1. Appearance requirements are specified for the
following zones or locations on the vehicle:

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. 2014 by Navistar, Inc.
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MPAPS G-9005 Prepaint Treatment, Plastic Parts 1406

ZONE DESCRIPTION
I Primary, exterior, glamour surfaces, such as: hood and fender exteriors, including visible
edges; grilles, cab fronts, sides, doors, corners, and lower aerodynamic fairings.
II Secondary, exterior, glamour surfaces, such as: cab tops, cab backs (between corner
radii) and upper aerodynamic fairings. Also, primary, interior, low gloss painted
surfaces, such as: engine covers and instrument panels.
III Recessed exterior or interior surfaces, such as: door openings, door ends, and painted
grab handles.
IV Hidden areas, such as those covered in assembly and backsides, if primed.

4.4.1 Inspection Conditions

Parts shall be inspected for appearance requirements at a distance of 2 feet under a light intensity of 100
foot-candles minimum at the part surface. Samples illustrating acceptable appearance and unacceptable
appearance defects shall be prepared and displayed in the inspection area.

4.5 Primer-Dry Film Requirements

Dry film property requirements for the primer are given in Table 2. These requirements apply to each
individual coating of the primer where multi-coat primers are used with baking and/or drying between
coats. For spot primes, dry film thickness may be less, but no less than 0.5 mils and as close to 1.0 mils
as the process will allow.

4.6 Bake Temperatures (For Primers Requiring Oven Bake)

Primers shall be oven-cured within the minimum and maximum schedules for time and temperature
prescribed by the primer supplier. However, the substrate temperature shall reach a minimum of 200 F
in at least one oven.

4.7 Test Procedures

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

TEST PROCEDURE TEST PROCEDURE

Gloss CEMS GT-6B Intercoat Adhesion CEMS GT-5B

Hardness CEMS GT-4D Humidity* CEMS GT-7E
Adhesion CEMS GT-5A Conductivity CEMS GT-18
Xylene Rub CEMS GT-14A Gravelometer* SAE J400 & GT-28
Accelerated Adhesion* CEMS GT-5 Film Thickness * ASTM D 4138
* Tested on sections from primed part which have been topcoated and cured with materials
and processing representing production.

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. 2014 by Navistar, Inc.
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MPAPS G-9005 Prepaint Treatment, Plastic Parts 1406

4.8 Repriming Of Surface Repairs

4.8.1 Parts With In-Mold Coating (IMC) to Receive Oven-Baked Topcoat (ref. MPAPS G-9012)
1. Sand-throughs of the IMC, or incompletely covered areas greater than 2 inches in diameter, must
be reprimed with primer (sealer) and rebaked. Spot priming of these areas is acceptable if it can be
demonstrated that the repair area is sufficiently sealed and no show through of the area can be seen
after topcoating. Spot priming without rebake is acceptable on exposed substrate areas less than 2
inches in diameter or no priming may be necessary if the transition area between the substrate and
IMC cannot be read after topcoat and no surface defects result. If the surface demonstrates that it
cannot be adequately sealed, as defined in Table 1, the area in question must be reprimed.
2. Repair areas in the primer, which expose the substrate greater than 2 inches in diameter, must
receive a flash coat of primer and rebaked prior to applying the topcoat. Spot priming without rebake
is acceptable on exposed substrate areas less than 2 inches in diameter or no priming may be required
if the transition area between the substrate and primer cannot be read after topcoat and no surface
defects result.
3. Surface repairs, which do not expose the substrate and which are less than 2 inch diameter, may
require only the application of an air-dry repair primer approved by Materials Engineering. Primer
will not be required if the repair does not show through the topcoat and does not promote surface
defects. If the total area of these small repairs exceeds 5% of the part surface, the procedure in (2)
above shall be followed.

4.8.2 Parts Without IMC to Receive Oven-Baked Topcoat

1. Repair areas in the primer require repriming with the primer and rebaking prior to applying the
topcoat.
2. Repairs greater than 2 inch diameter after priming shall be reprimed as in paragraph 2 of the
preceding section.
3. Repairs less than 2 inch diameter after priming shall be treated as in paragraph 3 of the preceding
section.

4.8.3 Parts to Receive Air Dry Topcoat

1. Repair areas in the primer shall receive a flash coat of the same primer if it is an air-dry system. If a
baking-type primer is used, the procedure for parts to receive an oven-baked topcoat shall be
followed.

5.0 QUALITY PLAN

A quality plan will be established by mutual agreement between NAVISTAR and the supplier to
establish compliance to the requirements listed in Tables 1 and 2.

5.1 Location and Number of Tests

Hoods: Test three locations on each hood; the hold down area on each side and the emblem area.
Other Parts: Other parts shall be tested in at least two locations which will be covered in assembly
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. 2014 by Navistar, Inc.
June 2014
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MPAPS G-9005 Prepaint Treatment, Plastic Parts 1406

5.2 Frequency of Testing

Until such time as mutually satisfactory statistical evidence demonstrating process capability has been
presented, three randomly selected parts/components from each lot shall be tested for adhesion per
CEMS GT-5A.

5.2.1 Definition Of Lot

A lot consists of all similar/like parts produced in a continuous production run in a period of 24 hours or
less.

5.3 Retest Provisions

If any one test location on a part/component fails to meet the minimum adhesion requirements as per
CEMS G-5, Part V, Grade -52 or -52HS, three additional parts/components shall be tested and each
location on all three parts must pass or the lot shall be subject to rejection.

6.0 SOURCE APPROVAL AND QUALITY CONTROL

6.1 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.

6.2 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 and Purchasing and Supplier Quality 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.

6.3 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 quality control manager of the using NAVISTAR plant may determine testing and
reporting requirements on specific products.

7.0 SHIPPING, PACKING AND IDENTIFICATION

Parts shall be packaged and shipped in such a manner as to protect the surface finish in transit. Packing
and identification will be in accordance with requirements of NAVISTAR Mfg. Standard MS-D-13.

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. 2014 by Navistar, Inc.
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MPAPS G-9005 Prepaint Treatment, Plastic Parts 1406

8.0 DESIGNATION ON DRAWINGS

Example: Prime paint per MPAPS G-9005.
The drawing may utilize the KCC symbol with a note that completed assemblies will comply with
requirements of MPAPS G-9005.

9.0 TECHNICAL INFORMATION

For further information related to the technical Suppliers may purchase controlled copies of
content of this specification, contact: this specification by contacting:
Materials Engineering and Technology Dept. IHS Global Inc.
10400 W. North Avenue 15 Inverness Way East
Melrose Park, IL 60160 Englewood CO 80112-5776
E-mail: MaterialsEngineering@Navistar.com Phone: 1-800-854-7179
E-mail: Automotive@IHS.com
Website: http://global.ihs.com

GENERAL INFORMATION (Not a Requirement)

The following methods of preparation and priming are typical of those providing acceptable parts:

Surface Finishing And Prime Painting Of Parts Receiving Heat Cured Topcoats
1. Repair all structural defects by properly reinforcing the defect and cosmetically repairing it.
2. Putty fill all surface imperfections with a 2-part putty. Allow to set, then sand smooth.
3. Scuff sand entire repaired area surface with 280 grit paper.
4. Clean all significant surfaces.
5. Prime with a primer-sealer, approved to Grade -52 per CEMS G-5 Part V by Materials Engineering.
6. Bake in accordance with paint supplier's recommendations.

A minimum conductivity reading of 110 on the Ransburg Model 236 sprayability meter shall be
obtained on the primed surface after it returns to room temperature.

Surface Finishing And Painting Of Parts Receiving Air Dry Prime Or Topcoat
1. Repair all structural defects by properly reinforcing the defect and cosmetically repairing it.
2. Putty fill all surface imperfections. Allow to set, then sand smooth.
3. Scuff sand entire repaired area surface with 280 grit paper.
4. Clean all significant surfaces.
5. Prime with a primer approved for air-dry use by Materials Engineering to a dry film thickness of 0.025
mm (1.0. mil) minimum.
6. Allow two to six hours drying time, depending on film thickness, before applying topcoat, unless
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otherwise recommended by the paint supplier.

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. 2014 by Navistar, Inc.
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MPAPS G-9005 Prepaint Treatment, Plastic Parts 1406

TABLE 1 APPEARANCE REQUIREMENTS

ZONE
REQUIREMENT
I II III IV

Orange Peel, min

4.5 4.5 3.5
(Test per CEMS GT-29)** --
7 7 6
Or ACT comparison test ***

Craters, including porosity,

1 2 2 3
greater than 1 mm dia. max. no.
per square foot
2 Max Per Unit
4
3 6
Dirt particles, max. no.* per @ 1.5 mm max.
@ 1.5mm max @1.5 mm max. unlimited
square foot
10 Max per Unit
Fine Craters, including
porosity, less than 1mm dia., 3 3 3 unlimited
max. no. per square foot
2 Max Per Unit

Solvent Pop None None None acceptable

Overspray Discernible by
None None None acceptable
Touch

Sags and Runs, max. no. per

None None None Unlimited
square foot

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Acceptable if
Scratches Discernible by Touch None None None Substrate Not
exposed

* Dirt particles may be removed using 320-400 grit sand paper.

** Orange Peel test per CEMS GT-29
*** Orange Peel comparison Test Panels are available from:
Advanced Coatings Technology, PO Box 401, Industrial Dr., Hillsdale MI 49242
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MPAPS G-9005 Prepaint Treatment, Plastic Parts 1406

TABLE 2 DRY FILM PROPERTIES*

DRY FILM PROPERTY REQUIREMENT*

ALL ZONES

Hardness, min./max. (a) B/2H

Adhesion, % min. (a) 90

Xylene Rub (a) PASS

Accelerated Adhesion, % min. 90

Intercoat Adhesion, % min. 90

500 hr. humidity, blisters None

Adhesion % in. 90

Conductivity, min. (a) (b) 110

Gravelometer Test Requirement 4B per CEMS GT-28

Film thickness, mils, min. (a) (c) (d) 1.0

* Requirements shown apply to each individual coating of the primer where multi-coat primers
are used with baking and/or drying between coats.

(a) Most suitable for acceptance testing.

(b) Conductivity requirement applies only to the final primer coating.

(c) Max film thickness is 4.0 mils; no more than 2 recoats of prime are permitted.

(d) Target for spot primes: 0.5 mils minimum

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