Dbl7391ing 0406

Die DBL 7391 wird Teilweise (fr PKW-Aggregate und Anbauteile wie Rder Zierleisten etc.
)
durch die DBL 7381 ersetzt. Gltig nur fr Neukonstruktionen !
April 2006
Supply Specification
Coating / Painting for Parts with
High Corrosive Stress
Mercedes-Benz
DBL 7391
BQF available
Additional DaimlerChrysler Standards required:

DBL 7399, 7390, 7392, 8585, 6714 and MB Special Terms. In addition, Directive 2000/53/EC of the European
Parliament and Council of 2000-09-18 regarding end-of-life vehicles (ELV) shall be observed.
Supersedes
edition: 01/2005
Product versions (PV) and application examples

General:
Finish coat (top coat) for components subject to high corrosive stress, and - if applicable - also mechanical stress.
This DBL applies to coatings on the outer side and underside of vehicles and in the engine compartment.
Corrosive stress
high
Specific additional
requirements
Type of coating
Application examples
Operating fluids in the

engine compartment
Air or force-dried single or multi-coat finishes
as for PV 00
Air or force-dried single-coat finishes
Components in engine compartment, brackets,

struts, engine shock absorbers, radiators,
signaling horns
Cast iron parts such as engine, transmission
and steering gear housings, clutch and brake
cylinders, forged parts
Metal-rubber parts such as engine and chassis
mounts, vibration dampers/absorbers on
crankshafts and propshafts
as for PV 01
00*
long
term
high
50
01*
02*
52
Compatibility during product as for PV 00/50

manufacturing
03*
53
as for PV 00
04
54
10*
60
Run-free painting
high corrosion protection
(non decorative,
non weather resistant,
not stone chip resistant)
Stone-impact resistant
coating
20*
30
80
31*
40*
90
as for PV 00
High-build coating
Single-coat finish from hot-set electrophoretic
paints (anaphoretic/cataphoretic dip coating)
Stone-impact resistant air or force-dried single

or multi-coat finishes
Coating suitable for spot

welding
High mechanical resistance
Single-coat finish from air-dried one- or twocomponent paints

Powder coating or equivalent high-build coating
as for PV 30/80
Decorative appearance,
weather resistant
as for PV 30/80
Single/multi-coat finish,
predominantly from baked paints
Steel sheet drawn/pressed parts, steel disk

wheels, air filters, pulleys, brake units
Vehicle underside, chassis/axle parts, shock

absorbers, coil springs, torsion bars, tie rods
and drag links, longitudinal and cross members
of commercial vehicle chassis,
brake/compressed air reservoirs
Bus substructure sheet stiffening, Unimog frame
and attachment parts
Passenger car underside/engine compartment,
bus seat frames and interior parts up to
waistrail height, bus underfloor coating,
attachment parts, engine blocks, oil pans,
cylinder head covers, brake/compressed air
reservoirs
Interior fittings for buses above waistrail height
Body and/or attachment parts, Al disk wheels,
mirror frame, ventilation window frame, air inlet
grille, door handles, wiper arms/blades
Not for new design
Abbreviated designation:
For drawings in the block for surface protection
e.g.: DBL 7391.00
On the underfloor, PVs "long term/high" shall be used

PV 04/ 30 only for the engine compartment area
Replacement remarks:
For PV 01
PV 03 / 53
For PV 20
DBL 7390.20 or DBL 7390.21
For PV 31
DBL 7392.40
Continued on pages 2 to 15
Issued by:
DaimlerChrysler AG
70546 Stuttgart
Standards (EP/QIN)
Technical responsibility (Name): Petra
Emmert
Plant: 050
Department: PWT/VBT
Telephone: +49(0) 7031 903775 HPC: E430
Technical coordination by PWT / Materials and Process Engineering

Plant 050, Department PWT/VBT: Dr.Rolf Specht
HPC: B 515
Telephone: +49(0)70 31 90-53 26
Confidential! All rights reserved. Distribution or duplication in part or in whole without prior written approval of DaimlerChrysler AG is not permitted.
In case of doubt, the German language original should be consulted as the authoritative text.
Uncontrolled copy when printed (I+D: Ribas Sandra, 2008-01-15)
Die DBL 7391 wird Teilweise (fr PKW-Aggregate und Anbauteile wie Rder Zierleisten etc.)
Page 2
DBL 7391 : April 2006
Field of application, general requirements
1.1
Product versions with light alloys as base material
1.1.1 Aluminum alloys

The approval-relevant corrosion test for aluminum parts is the CASS test (refer to Section 4.24 of this DBL).
For mirror turned aluminum wheels, the filiform corrosion test (refer to Section 4.27 of this DBL) shall be performed.
1.1.2 Magnesium die-casting alloy
The alternating corrosion test shall be used as the approval-relevant corrosion test for magnesium die-casting alloys.
To check the coverage of the whole surface, the CASS test can be used as accelerated test.
(This test is performed without scratching the surface)
1.1.3 Other substrates
Approval-relevant corrosion tests shall be agreed with the responsible department.
General properties of the materials, raw materials and supply condition
2.1 All product versions

The materials (cleaning and phosphating agents) used for pretreatment before coating, the binder types and pigments used for
the paintwork structure as well as the coating methods and the drying type shall be disclosed to the receiving MB plant for
initial samples and in the event of changes. This stipulation is intended to facilitate, in particular within the framework of
development processes, the general material assessment and compliance with any necessary technical and/or personal
protective measures for the processing of painted components (e.g. grinding, welding).
The pretreatments and coatings shall be free of heavy metals and their compounds such as arsenic, cadmium, mercury,
chromium-VI compounds or lead. In addition, DBL 7399, Section 1.2.1, DBL 8585 and DBL 6714 as well as directive
2000/53/EC of the European Parliament and Council of 2000-09-18 regarding end-of-life vehicles (ELV) or the latest version
of the ELV directive shall be observed.
Exception:
The requirements regarding "Chromium-VI compounds and lead-free" refer to new designs or new samples.
Production parts shall be adapted within the statutory transitional periods following agreement with the responsible
department.
Pretreatment, coating material and coating processes shall be selected by the part supplier so as to fulfill the requirements of
this DBL. Residues which could promote corrosion and/or impair adhesion of the coating (flux, scale, organic contamination
residues from assembly or other processing steps) shall be removed chemically or mechanically, in particular from weld seams
or on laser-cut edges.
Edges, corners, overlaps and points accessible only with difficulty which are subject to the risk of corrosion shall be treated
particularly carefully.
The surface shall be free of any visible roughness, craters, dust inclusions etc.
2.1.1 Initial sampling
The corrosion-relevant documents of the initial sample inspection report (ISIR) to PWT/VBT or the receiving MB plant shall
include the following information:
Pretreatment materials, product name, supplier
Coating material, product name, supplier
Process description (flow chart)
Process parameters, test frequency
Layer thickness, layer thickness measuring points (illustrated documentation), test frequency
Object stoving temperature (target value, minimum, maximum), object temperature curve (at full load)
Object temperature measuring points (illustrated documentation), test frequency
Corrosion test report (illustrated)
Requalification measures, test frequency (at least acc. to MB Special Terms No. 14) Corrosion tests, technicalmechanical properties in analogy with Section 6.2 of this DBL
Page 3
DBL 7391 : April 2006
2.1.2 Changes (material, process)

Any changes shall be notified to the MB receiving plant in good time according to VDA volume 2 and MB Special Terms No. 13
and initial sampled and approved before production application.
2.1.3 MAG weld seams / heat-affected zone
MAG weld seams shall be pretreated so that silicate and slag residues are removed to an extent that allows proper
phosphating/coating. The heat-affected zone shall be treated in the same way, if it is accessible.
Possibilities: ceramic blasting, barrel finishing etc. In individual cases, an additional coating on the weld seams is also possible.
It depends on the component which of these possibilities mentioned makes sense, and it should therefore be selected
following discussions with the responsible department.
2.1.4 Punched and cut edges
Punched and cut edges shall be designed such that compliance with the edge protection required in the relevant PV is reliably
ensured. The following rework possibilities are available for edge protection: grinding, brushing, barrel finishing, shot peening
etc. If the parts are laser cut, an oxygen-free cut shall be chosen. Where this is not possible, the edges shall be finished as
described above.
2.1.5 Cavity coating
The minimum layer thickness of the cataphoretic dip coating in cavities shall be 12 m. A complete flow through the parts
shall be ensured. If air bubbles cannot be avoided for design reasons, these air bubbles shall be shifted to areas which are
non-critical with regard to corrosion and functionality by suspending the parts appropriately.
If required, additional measures such (waxing etc.) shall be taken.
2.1.6 Cataphoretic dip coating material and pretreatment
The supplier shall ensure that the phosphate content in the cataphoretic dip coating bath does not exceed 100 ppm as
corrosion protection deteriorates significantly with increasing phosphate content. PWT/VBT and the relevant MB receiving
plant shall be notified in writing if the cataphoretic dip coating materials are changed following sampling with regard to binder
/ solids ratio, or if measures are taken which might impact on the flow.
2.1.7 Overpaintability
The coating shall be capable of being repaired using state-of-the-art touch-up paints without disturbing surface changes such
as crinkling. The paints to be used shall be agreed with the receiving plant and shall be matched to the relevant paint
structure. Also refer to Section 4.20 of this DBL in this respect.
2.1.8 Assemblies
Note that this DBL applies to the testing of individual components. If these components are installed with other components
which might have an influence on the overall corrosion result after stressing (e.g. conductive rubber components, material
combinations which run the risk of contact corrosion creation etc.), relevant corrosion tests in the corresponding assembly
condition shall be agreed.
Dimensions and tolerances / Form of supply
In accordance with drawing and approved sample.
Page 4
DBL 7391 : April 2006
Technical data
Preliminary remark:
Since in addition to the quality of the coating material itself, the material, the pretreatment and the shape of the parts to be
coated may also be crucial to compliance with the following requirements, the tests shall be conducted, wherever possible, on
finished parts.
All values indicated are maximum values.
FPT=Focal point test according to Section 6.2 of this DBL
Requirements
Properties
00
02
Product versions
04
10
03
01
50
30
40
20
52
53
54
60
Test method
31
80
90
4.1
Color
Deviation with respect to standard panel not greater than degree of deviation 3-4
4.2
Gloss
In accordance with drawing or approved sample.

Deviation with respect to standard panel not greater than degree of deviation 2-3
4.3
Layer thickness
(FPT)
4.4
Cross-cut
(FPT)
4.5
Adhesion test
(Scratch test)
(FPT)
4.5.2
Adhesive tape
method
not applicable
4.5.3
Temperature
resistance
Only for parts lying within area exposed to temperature.

The coating shall attain the characteristic values of Section 4.4, 4.5.1 following exposure to
temperature
4.6
Stone impact
resistance
4.6.1
Single impact
Ball impact
4.7
Multiple impact
test
4.7.1
Original condition
DBL 7399,
Section 6.1
DBL 7399,
Section 6.1
According to drawing or approved sample with the tolerances typical of the material,
as documented in the ISIR
DBL 7399
Section 2.4.1
Characteristic value 1
K2
DIN EN ISO
2409
K3
K2
K2
DBL 7399
Section 5.1
not applicable
24h, 130C
not applicable
not applicable
not applicable
DBL 7399,
Section 5.3.4
Only PV 40/90 coated body/parts

Chipping area rating 2
Degree of rusting 0,5
DIN 55996-1
method B,
Refer to Section 4.18.2 of this DBL
4.7.1.1
Steam-jet
4.7.2
With salt spray fog
PVs 10/ 30/ 80: exposure time 48 h (passenger cars + commercial vehicles)
DIN 55996-1
method C
PV 60: exposure time 72 h (passenger cars + commercial vehicles)

PVs 40/ 90: exposure time 48h (commercial vehicles)
4.7.2.2
Requirement
PV 10/30/80/60

Degree of rusting 1
4.7.2.3
Requirement
PV 40/90

Degree of rusting 0,5
DIN 55996-1
method C
Page 5
DBL 7391 : April 2006
Requirements
Test method
Properties
00
02
Product versions
04
10
03
30
01
50
4.8
Salt spray test

Steel substrate
(FPT) *
4.8.1
Surface rust
4.8.2
Edge rust
96
40
20
52
96
96
240
53
96
240
54
240
240
60
80
96
504
Ri 1
31
240
240
240
Ri 0
90
96
504
Ri 1
DBL 7399,
Section 7.1
240
504
DBL 7399,
Section 7.4.2
Ri 0
KR 1
KR2
KR 1
KR 1
DBL 7399
Section 7.4.4
KR2
0
4.8.3
Blistering
<2 (S2)
0
<2 (S2)
DIN EN ISO 4628-2

0
0
<2 (S2)
<2 (S2)
1
4.8.4
Infiltration at crack
U/2 in mm
DBL 7399
Section 7.4.1
1
2
4.8.5
Adhesion test
K2
120
4.9
Exposure to
constant
condensed water
climate
in h
K3
60 minutes after removal from the test apparatus on the undamaged surface
120
120
240
120
240
120
240
96
240
240
240
360
240
DBL 7399
Section 5.1
K2
240
360
DIN EN ISO 6270-2

Assessment 1h and
24h after removal from
360 test apparatus
4.9.1
Blistering/
Degree of
blistering
4.9.2
Adhesion test
Process and
operating fluid tests
2 (S2)
<2 (S2)
2 (S2)
K2
<2 (S2)
K3
K2
DIN EN ISO 4628-2
DBL 7399
Section 5.1
With the exception of PVs 20 and 31

Proof of compliance with these requirements by the paint supplier shall be sufficient (test results
are part of ISIR)
4.10
Hydraulic fluids
The coating shall not demonstrate any changes
4.11
Standard gasoline
Temporary softening is still permitted provided that the adhesion test requirements in accordance VDA test sheet 621with Section 4.5.1. are fulfilled again after a regeneration time of 16 hours
412 Section 4.1.1
Exposure time
10 min at 23C 2C
4.12
Preservatives
After an exposure time of 60 minutes at (23 2) C, wipe off the preservative with standard
gasoline in accordance with DIN 51 604 Part 1. The coating shall neither be swollen nor
discolored.
4.13
Cold cleaning
solvent
412 Section 4.2.3
Exposure time
10 min at 23C 2C
4.14
Brake fluid
412 Section 4.2.1
Exposure time
10 min at 23C 2C
4.15
Sensitivity to tar
not applicable
VDA test sheet 621412 Section 4.1.4

Exposure time
4 h at 50 C
VDA test sheet 621412 Section 4.2.4
DBL 7399,
Section 8.4
* For commercial vehicles, this test is also permitted for zinc-coated components. Values shall be specified with the relevant commercial vehicle receiving
plant.
Page 6
DBL 7391 : April 2006
Requirements
Properties
00
02
Product versions
04
10
03
01
50
30
52
53
54
60
Test method
40
20
31
80
90
Execution
according to
PBODC 371
4.16
Resistance to
chemicals
4.16.1
Resistance to oil
black
not applicable
4.16.2
Sulfuric acid
No discoloration, no change in surface with regard to gloss and adhesion
4.16.3
Hydrochloric acid
not applicable
not applicable
4.16.4
Ammonia
not applicable
not applicable
4.16.5
Tree pitch
4.16.6
Pancreatin
4.16.7
Water
4.16.8
Caustic soda
solution
4.17
Cold resistance
Only for PVs 40 and 90:

No cracks
1 hour at
-40C
4.18
Steam-jet
Testing
Only for PVs 40 and 90:
4.18.1
on St Andrews
cross
Execution
according to
PBODC 361
Section 5.4
Only PVs 40 / 90
Proof of compliance with these requirements by the paint supplier shall be sufficient (test results
are part of ISIR)
not applicable
No loss of adhesion on St Andrew's cross

D1, minor wash-out of existing damage
4.18.2
on multi-impact
stone
chipping
Execution
according to
PBODC 371
Section 5.2.4 A
Execution
according to
PBODC 371
Section 5.2.4 A
Execution
according to
PBODC 371
Section 5.2.4 A
Execution
according to
PBODC 371
Section 5.2.4 A
Execution
according to
PBODC 371
Section 5.2.4 A
Refer to Section
5.5 of this DBL
4.19
Weathering
4.19.1
Central European
climate
4.19.2
Florida test
Change in color and gloss compared to unexposed reference sample not

greater than assessment figure color 3-4 / gloss 2-3. No cracks, no chalking. Proof of compliance
with this requirement by the paint supplier shall be sufficient. (reference sample)
DBL 7399,
Section 7.5.2 under
5 South
Exposure time at
least 3 years
4.19.3
Artificial
weathering
(not for Al wheels)

Change in color and gloss compared to unexposed reference sample not
greater than assessment figure 3-4 / 2-3. No cracks, no chalking. Proof of compliance with this
requirement by the paint supplier shall be sufficient. (reference sample)
DIN EN ISO 4892-2
The coating shall be capable of being repaired using state-of-the-art touch-up paints without
disturbing surface changes such as crinkling. The paints to be used shall be agreed with the
receiving plant and shall be matched to the relevant paint structure.
DBL 7399
Section 4.4.1
4.20
Overpaintability
only PV 40/90
Proof of compliance with this requirement by the paint supplier shall be sufficient (reference
sample part of ISIR)
not applicable
3000 hours
Page 7
DBL 7391 : April 2006
4.21
Weldability
Refer to DBL 7390.20/.21
Page 8
DBL 7391 : April 2006
Requirements
Properties
00
02
Product versions
04
10
03
01
50
4.22
Corrosion
cycle test
Steel substrate
(FPT)
Exposure time in
cycles
4.22.1
Surface rust (red

rust)
4.22.2
Edge rust (red

rust)
52
Blistering/
Degree of
blistering
4.22.4
Infiltration
U/2 in mm
4.22.5
4.22.5.1
Adhesion test
Scratch test
4.22.5.2
Adhesive tape
method at fold
4.23
Corrosion
cycle test
zinc-coated
substrates (FPT)
Product version
Exposure time in
cycles
4.23.1
Surface rust (white

rust)
4.23.2
Edge rust (white

rust)
none
6 req.
Ri 2
Blistering/
Degree of
blistering
4.23.4
Infiltration
U/2 in mm
4.23.5
4.23.5.1
Adhesion test
Scratch test
4.23.5.2
Adhesive tape
method at fold
54
60
Ri 2
80
KR 3
2 (S2)
Ri 0
Ri 1
KR 2
KR 3*
KR 2
KR 3
-
none
6 req.
10
Ri 2
KR 2
90
2 (S2)
none
10 req.
Ri 1
6
10
Ri 0
KR 2
<2 (S2)
DBL 7399,
Section 7.4.2
KR 1
KR 3*
2 (S2)
KR 2
<2 (S2)
2 (S2)
<2 (S2)
DBL 7399,
Section 7.4.4
DIN ISO 4628-2
No accumulations, no clusters
5
K2
K3
K2
1,5
DBL 7399,
Section 7.4.1
K2
DBL 7399,
Section 5.1
not applicable
This test shall be carried out in principle on try-out and initial samples of new coatings and parts. * DBL 7399,
The compliance with this test is a condition for the delivery of parts. In the receiving MB plants, the Section 7.6
corrosion cycle tests shall be used to assess the corrosion resistance of production parts. No saltspray test can be performed on zinc-coated substrates.
00
02
03
04
10
30
40
01
20
31
50
52
53
54
60
80
90
3
none
6 req.
Ri 2
KR 3
4.23.3
53
Test method
40
31
This test shall be carried out in principle on try-out and initial samples of new coatings and parts.* DBL 7399,
The compliance with this test is a condition for the delivery of parts. In the receiving MB plants, the Section 7.6
corrosion cycle tests shall be used to assess the corrosion resistance of production parts. To get a
quick assessment of running series with steel substrates, the supplier may use the salt spray test
(DIN 50021-SS), Section 4.8.
KR 2
4.22.3
30
20
5
Ri 2
Ri 2
KR 3
2 (S2)
KR 4
-
none
6 req.
10
Ri 0
Ri 1
KR 3
KR 4*
KR 3
KR 4
2 (S2)
Ri 1
6
10
Ri 0
DBL 7399,
Section 7.4.2
KR 3
DBL 7399,
Section 7.4.4
<2 (S2)
<2 (S2)
KR 2
KR 4*
2 (S2)
none
10 req.
KR 3
<2 (S2)
2 (S2)
DIN EN ISO 4628-2
8
K2
K3
not applicable
* For commercial vehicles, the agreement with the relevant commercial vehicle receiving plant shall apply
K2
K2
DBL 7399,
Section 7.4.1
DBL 7399,
Section 5.1
Page 9
DBL 7391 : April 2006
Requirements
Properties
00
02
Product versions
04
10
03
30
01
50
4.24
CASS test
Al substrate
(FPT)
52
4.24.1
Surface rust
4.24.2
Edge rust
54
31
60
80
90
DBL 7399,
Section 7.1.1
For body components in accordance with DBL 7391.54/ .90, the test shall be performed on
unground and ground (current body-in-white grinding method) Al substrate,
for production parts the requirements for ground Al apply.
For all other components, the requirements for unground Al apply.
96
Exposure time in
hours
53
Test method
40
20
96
96
168
96
168
96
240
240
168
168
168
Ri1
240
96
168
Ri 0
DBL 7399,
240 Section 7.1
240
Ri 1
Ri 0
DBL 7399,
Section 7.4.2
KR1
KR2
KR1
DBL 7399
Section 7.4.4
KR2
0
4.24.3
Blistering
Degree of
blistering (S)
0)
DIN EN ISO 4628-2
<2 (S2)
<2 (S2)
<2 (S2)
<2 (S2)
4.24.4
Infiltration
U/2 in mm
2
4
DBL 7399
Section 7.4.1
4
4.24.4.1
unground
4.24.4.2
ground
4.24.5
Adhesion test
K2
K3
K2
DBL 7399
Section 5.1
60 minutes after removal from the test apparatus on the undamaged surface
4.25
Only for PVs 54 / 90

Body only
Severe outdoor
weathering
DBL 7399,
Section 7.8
Product version
54
90
Exposure time
12 months with light protection
12 months
Ri 0
Ri 0
DBL 7399,
Section 7.4.2
4.25.1
Surface rust
4.25.2
Edge rust
KR 2,5
KR 2,5
DBL 7399,
Section 7.4.4
4.25.3
Blistering/
Degree of
blistering
<2 (S2)
<2 (S2)
DIN EN ISO 4628-2
4.25.4
Infiltration
U/2 in mm
4.25.4.1
Steel
4.25.4.2
Zn
4.25.4.3
Al unground
4.25.4.4
Al ground
4.25.4.5
Al production
DBL 7399,
Section 7.4.1
Page 10
DBL 7391 : April 2006
4.25
Only for PVs 54 / 90

Body only
Severe outdoor
weathering
DBL 7399,
Section 7.8
Product version
54
90
Exposure time
12 months with light protection
12 months
4.25.5
4.25.5.1
4.25.5.2
4.25.5.3
Filiform corrosion
Max. filament
length
in mm (singlesided)
Al unground
Al ground
Al production
Section 5.4
of this DBL
2
4
4
2
4
4
Requirements
Properties
00
02
Product versions
04
10
03
01
50
4.26
Corrosion
cycle test
Magnesium
substrate
Exposure time in
cycles
30
52
53
54
Test method
40
20
31
60
80
90
only PV 80/90
DBL 7399,
This test shall be carried out in principle on try-out and initial samples of new coatings and parts. Section 7.6
In the receiving MB plants, the corrosion cycle tests shall be used to assess the corrosion
resistance of production parts.
No test criterion
10
10
4.26.1
Infiltration
U/2 in mm
1,5
1,5
DBL 7399,
Section 7.4.1
4.26.2
Surface rust
Ri 0
Ri 0
DBL 7399,
Section 7.4.2
4.26.3
Edge rust
DBL 7399,
KR 2 Section 7.4.4
KR 2
4.26.4
Blistering
Degree of
blistering (S)
4.26.5
Adhesion test
4.27
CASS test
Magnesium
substrate
4.27.1
Surface rust
<2 (S2)
<2 (S2)
DIN EN ISO 4628-2
K2
K2
In principle, this test is only intended to check the complete coverage of the surface.
(Testing is performed without scratching the surface.)
Only to be used as comparative test.

Surface rust, edge rust and blistering shall comply with the values of the alternating VDA test.
The values of the original sample from the CASS test are then a constituent part of the ISIR.
DBL 7399
Section 7.1.1
DBL 7399,
Section 7.4.2
4.27.2
Edge rust
DBL 7399,
Section 7.4.4
4.27.3
Blistering/
Degree of
blistering
DIN EN ISO 4628-2
Page 11
DBL 7391 : April 2006
Requirements
Properties
00
02
Product versions
04
10
03
01
50
4.28
4.28.1
4.28.1.1
Filiform corrosion
Mirror-turned
aluminum wheels
Infiltration
U/2 in mm
30
52
53
54
60
Test method
40
20
31
80
90
Mirror-turned aluminum wheels only
PPAP3002_
Filiform corrosion
This test shall be performed for mirror-turned aluminum wheels instead of the CASS test.
2
No test criterion
Max. filament
length
in mm
DBL 7399,
Section 7.4.1
4.28.2
Surface rust
No test criterion
Ri 0
DBL 7399,
Section 7.4.2
4.28.3
Edge rust
No test criterion
KR0
DBL 7399,
Section 7.4.4
4.28.4
Blistering/
Degree of
blistering
No test criterion
Adhesion test
No test criterion
4.2785
DIN EN ISO 4628-2

0
K2
Page 12
DBL 7391 : April 2006
Test methods
5.1 Adhesion test Section 4.5.2

not applicable
5.2 Combined steam-jet/weathering test
not applicable
5.3
N/A
Adhesive tape method at fold (adhesive tape method)
5.4 Filiform corrosion Section 4.25.5

Following the end of the test, the longest filament shall not exceed the specified value.
5.5 Steam-jet test Section 4.18
The steam-jet test can be performed optionally on the St Andrews cross or on the multi-impact stone-chipping,
whereby the multi-impact stone-chipping shall be preferred.
Duties of the supplier
This DBL as well as all other required DaimlerChrysler standards shall be provided to all sub-suppliers in order to ensure DBLcompliant products.
6.1 Tests before delivery
Refer to DBL 7399, Section 1.5.
The parts to be sampled shall be tested by the supplier in accordance with the specifications before initial sampling. For the
corrosion tests, photographic documentation of the intermediate and final assessment is required.
6.2 Scope of focal point testing (FPT)
A reduced test scope in accordance with the following sections of this DBL may be conducted for supplies:
All substrates:
Steel substrates:
Zinc-coated substrates:
Aluminum substrates:
Magnesium substrates:
4.3/4.4/4.5/4.9.(layer thickness, cross cut, scratch test, constant condensed water

climate)
4.8 (4.22 preferred) (salt spray test, VDA alternating test)
4.23 (VDA alternating test for zinc)
4.24 (CASS test)
4.26 (VDA alternating test for magnesium)
6.3 Requalification
Refer to MB Special Terms No. 14.
6.4 Functional tests of test equipment (VDA alternating test and outdoor weathering)
Functional tests are required In order to check the reproducibility of the test results of test equipment or the comparability of
test results from different test equipment. The following
procedure must be followed:
Page 13
DBL 7391 : April 2006
6.4.1 Specimens for functional tests

At least two specimens per week which are 30 mm wide, 100 mm long and 1,2 mm to 2 mm thick (see sketch) from sheet EN
10130 + A1-DC04-B (mill-finish)
Fig. 1: Sketch of weight removal sheets
6.4.2 Specimen preparation

Before the beginning of functional tests, degrease the specimens using white spirit or other suitable solvent (e.g. n-hexane in
combination with isopropanol) with a soft, non-linting cloth or brush, and then weigh to 10 mg. If weighing is not possible
immediately after degreasing, store the specimens in a desiccator or, in the event of prolonged interruptions, freeze at at least
-20C.
6.4.3 Exposure
Install the specimens at a distance of 10-15 mm, e.g. on a plastic panel, and place in the test chamber on edge at an angle of
60 to 75 to the horizontal line.
6.4.4 Removal of corrosion products
Remove the corrosion products on both sides at 6 bar using steel corundum AbrasitA grain 0,25 to 0,5mm.
Then store the specimens in a desiccator until weighing or, in the event of prolonged interruptions,
freeze at at least -20C.
Note: The results can only be compared with each other if the same method is applied.
6.4.5 Weighing of specimens
Weigh the specimens to 10 mg.
6.4.6 Test frequency
Each week, insert test panels and remove 10 weeks later. This allows the test chamber to be monitored continuously.
6.4.7 Evaluation of the result of the function test
Take the mean value of the mass losses determined and calculate the mass loss in % relative to the original mass. In some
cases, the value to be achieved is specified in the test specifications.
m =
Mean mass loss in % relative to the mean value of the initial mass
mA =
Mass before commencement of the test
mE =
Mass after removal of corrosion products
1,2,.n = number of specimens used (statistics)
m =
[(m A1 + m A2 + ... + m An ) (mE1 + mE 2 + ... + mEn )]x100 [%]

(m A1 + m A 2 + ... + m An )
Page 14
DBL 7391 : April 2006
Samples
Refer to MB Special Terms No. 13. Initial sampling and DBL 7399, Section 1.1
Deliveries
Refer to MB Special Terms Nos. 13 and 16 and DBL 7399, Section 1.3
Marking
Refer to MB Special Terms Nos. 4, 24 and 27 as well as notes regarding marking in MBN 33015 and VDA 260
10
Packaging
Refer to MB Special Terms No. 28 and No. 30.
11
Storability
Refer to MB Special Terms No. 28 and No. 30.
12
Special instructions
Refer to DBL 7399, Section 1.11

Beyond the characteristics specified in this DBL, running deliveries shall correspond to the approved sample in every respect.
13
Complaints
Refer to DBL 7399, Section 1.6 and "Purchase Conditions for Production Materials and Spare Parts for Motor Vehicles",
Sections 4 and 10.
14
Environmental protection regulations/Industrial safety
Refer to DBL 7399, Section 1.2, DBL 8585 and the Annex to DBL 8585 "Negative list for paints and thinners",
Purchase Conditions for Production Materials and Spare Parts for Motor Vehicles", Section 9.5.
Where a danger of microbial germ formation exists, explanations shall be given on the danger/risks which arise for the user as
a result of biocides being contained in the product. The use of biocides shall always be restricted to the minimum quantity
required for functional reasons.
In addition, directive 2000/53/EC of the European Parliament and Council of 2000-09-18 regarding end-of-life vehicles (ELV)
or the latest applicable ELV directive shall be observed.
15
Other applicable standards
DBL
DBL 5416
DBL 6714
DBL 7390
DBL 7392
DBL 7399
DBL 8585
PBO DC
371
361
MBN
33015
DIN
DIN 4628-2
DIN 50021
DIN 55996-1
DIN EN ISO 2409
DIN EN ISO 4892-2
DIN EN ISO 4892-1
DIN EN ISO 6270-2
The latest versions of the standards indicated shall apply in each case.
VDA
VDA 621-412
VDA 621-415
VDA 260
VDA volume 2
Page 15
DBL 7391 : April 2006
16
Changes as against previous edition:
PV.60
PV
Section 1
Section 1.1
Section 1.1.3
Section 2
Section 2.1.1
Section 2.1.2
Section 2.1.7
Section 2.1.8
Section 2.1.9
Section 4
Section 4
Section 4.6.1
Section 4.7
Section 4.8
Section 4.8.3
Section 4.9.1
Section 4.18
Section 4.22
Section 4.22.3
Section 4.23.3
Section 4.24
Section 4.24.3
Section 4.24.4
Section 4.25.3
Section 4.25.4
Section 4.25.5
Section 4.26
Section 4.27
Section 5
Section 5.4
Section 6
Section 6.3
Section 6.4
Section 15
No cataphoretic dip coat as sole layer

Abbreviated designation on drawing
Special regulation for aluminum wheels
Other substrates
Layer thickness indications with tolerances
Procedure in the event of changes to materials and processes
Overpaintability added
Stone-chipping-resistant paint added
Assemblies added
S (focus point test) replaced by SPP
Single stone impact deleted
Multi-impact stone-chipping and steam jet only for PV 40/ 90
Exceptions for commercial vehicles added
Degree of blistering according to DIN
Steam-jet test, distinction between St Andrews cross and multi-impact stone chipping
Exceptions for commercial vehicles added
Differentiation Al ground/unground
Requirements differentiated according to substrate (Al ground/unground)
Requirements for infiltration differentiated according to substrate
Filiform corrosion added for outdoor weathering
Testing of and requirements for Mg substrate during VDA alternating test added
Testing of and requirements for Mg substrate during CASS test added
Filiform corrosion added
Requalification added
Functional test of test equipment added
Other applicable standards added
Correction of various typing errors

Note: DBL 7399 is under revision at present, e.g. comparative images for evaluations, updating of standards

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Die DBL 7391 wird Teilweise (fr PKW-Aggregate und Anbauteile wie Rder Zierleisten etc.

Additional DaimlerChrysler Standards required:

Product versions (PV) and application examples

Operating fluids in the

Air or force-dried single or multi-coat finishes

Air or force-dried single-coat finishes

Components in engine compartment, brackets,

Compatibility during product as for PV 00/50

Stone-impact resistant air or force-dried single

Coating suitable for spot

Single-coat finish from air-dried one- or twocomponent paints

Steel sheet drawn/pressed parts, steel disk

Vehicle underside, chassis/axle parts, shock

Not for new design

e.g.: DBL 7391.00

On the underfloor, PVs "long term/high" shall be used

Technical responsibility (Name): Petra

Technical coordination by PWT / Materials and Process Engineering

Uncontrolled copy when printed (I+D: Ribas Sandra, 2008-01-15)

Field of application, general requirements

Product versions with light alloys as base material

1.1.1 Aluminum alloys

General properties of the materials, raw materials and supply condition

2.1 All product versions

Uncontrolled copy when printed (I+D: Ribas Sandra, 2008-01-15)

2.1.2 Changes (material, process)

Dimensions and tolerances / Form of supply

In accordance with drawing and approved sample.

Uncontrolled copy when printed (I+D: Ribas Sandra, 2008-01-15)

In accordance with drawing or approved sample.

Only for parts lying within area exposed to temperature.

Only PV 40/90 coated body/parts

Refer to Section 4.18.2 of this DBL

With salt spray fog

PV 60: exposure time 72 h (passenger cars + commercial vehicles)

Chipping area rating 2

Chipping area rating 2

Uncontrolled copy when printed (I+D: Ribas Sandra, 2008-01-15)

Salt spray test

DIN EN ISO 4628-2

DIN EN ISO 6270-2

DIN EN ISO 4628-2

With the exception of PVs 20 and 31

The coating shall not demonstrate any changes

VDA test sheet 621412 Section 4.1.4

VDA test sheet 621412 Section 4.2.4

Uncontrolled copy when printed (I+D: Ribas Sandra, 2008-01-15)

No discoloration, no change in surface with regard to gloss and adhesion

No discoloration, no change in surface with regard to gloss and adhesion

No discoloration, no change in surface with regard to gloss and adhesion

No discoloration, no change in surface with regard to gloss and adhesion

No discoloration, no change in surface with regard to gloss and adhesion

Only for PVs 40 and 90:

Only for PVs 40 and 90:

No loss of adhesion on St Andrew's cross

Change in color and gloss compared to unexposed reference sample not

(not for Al wheels)

DIN EN ISO 4892-2

Uncontrolled copy when printed (I+D: Ribas Sandra, 2008-01-15)

Refer to DBL 7390.20/.21

Uncontrolled copy when printed (I+D: Ribas Sandra, 2008-01-15)

Surface rust (red

Edge rust (red