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006
This document is to provide manufacturing procedures that all Moffett Engineering Ltd.
suppliers must follow to obtain a commonality and high level of quality across our product
range. The sections contained herein are deemed critical and any deviation from the
specification must come with written approval of the Moffett Engineering Quality
Department and Moffett Engineering Department. Any suggested deviation from a
material specification must be supplied with mechanical and chemical properties before
being considered for substitution.
In the event of a revision the date and details of the effected section will be updated to
reflect the change and the new document. Suppliers must discard the previous revision
and replace with the new. If any parts of this document, or subsequent revisions, are not
clear, you must contact Moffett Engineering Quality Department or Moffett Engineering
department.
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Document: TS.006
Contents
5) Painting ....................................................................................................................... 16
a. Preferred Powder Coating Method ........................................................................................... 16
b. Alternative Powder Coating Method ......................................................................................... 17
c. OEM Wet Painted Parts ............................................................................................................ 18
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Document: TS.006
1) Material Specifications:
Materials are specified on the drawing title block. Any deviation from the material
specification must be approved by Moffett Engineering. This can be requested as
follows:
• At RFQ stage as part of RTS document, this may result in a drawing revision.
• By submitting a MDA form, this will not require a drawing revision.
• Any temporary changes to material should be requested via CRF process.
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Document: TS.006
Details Tolerance
i) Tolerances for machined holes and shafts are according to ISO 286-2, the most
commonly used are summarised below:
Hole
Nominal (mm) Tolerance Shaft Tolerance (µm)
(µm)
Up to and
Above H7 e9 f6 f7 h6 p6
including
+18 -32 -16 -16 0 +29
10 18
0 -75 -27 -34 -11 +18
+21 -40 -20 -20 0 +35
18 30
0 -92 -33 -41 -13 +22
+25 -50 -25 -25 0 +42
30 50
0 -112 -41 -50 -16 +26
+30 -60 -30 -30 0 +51
50 80
0 -134 -49 -60 -19 +32
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Document: TS.006
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Document: TS.006
i) The dimensional tolerances of the cut part shall comply with Class 1 as per EN ISO
9013, and outlined in the table below:
All dimensions in mm
Nominal Dimensions
Work
≥10 ≥35 ≥125 ≥315 ≥1000 ≥2000
Piece >0 <3 ≥3 <10
<35 <125 <315 <1000 <2000 <4000
Thickness
Limit deviations
>1 ≤3.15 ±0.1 ±0.2 ±0.2 ±0.3 ±0.3 ±0.4 ±0.4 ±0.4
>3.15 ≤6.3 ±0.3 ±0.3 ±0.4 ±0.4 ±0.5 ±0.5 ±0.5 ±0.6
>6.3 ≤10 - ±0.5 ±0.6 ±0.6 ±0.7 ±0.7 ±0.7 ±0.8
>10 ≤50 - ±0.6 ±0.7 ±0.7 ±0.8 ±1 ±1.6 ±2.5
ii) The perpendicular or angularity tolerance of the cut edge shall comply with range 2
as per EN ISO 9013.
iii) The mean height of the profile of the cut edge shall comply with range 2 as per EN
ISO 9013.
iv) All plates 3mm and less must be laser cut using nitrogen as a shield gas, unless
otherwise agreed with Moffett Engineering Department.
v) Minimum plate thickness for flame cutting of 20mm unless otherwise specified.
vi) All cuts must start with a lead in cut and end with a lead out cut and should be placed
on a corner where possible.
vii) All kerfs to be perpendicular to cutting surface
viii) All sharp edges on finished parts must be removed. Specification of rounded edge to
be agreed with Moffett Engineering quality department at QAP stage using reference
parts.
ix) Excluding laser cut parts all holes marked as tapped must be drilled.
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Document: TS.006
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Figure 1
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b. Weld Symbols
i. All weld symbols follow ISO 2553 unless otherwise stated. The charts below detail the
description of the symbols used.
ii. Additional to ISO 2553 the symbol shown in Figure 2 below is used to indicate double run
weld with a v-butt weld capped with a fillet weld.
Figure 2
iii. For fillet weld dimensions, if no letter is shown (i.e. “a” or “z”) this dimension must be
taken as the leg length (see chart 4).
iv. Indication of welding process (i.e. ‘131’ or ‘135’) follows ISO 4063.
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Document: TS.006
v. Specification of the “Weld all around” symbol, in section 3 in tables below, indicates that a
joint should be welded completely. The weld may, but does not need to, start and end at
the same point.
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4) Anti-Corrosion Treatment
a. Zinc Plating and Passivate Coating
i. Unless otherwise requested all parts must follow the specification below.
ii. All zinc plating and passivate coatings to ISO 2081:2008.
iii. A corrosion resistance rating to ISO 9227:2006 or equivalent with a minimum of
72 hours neutral salt spray. Unless otherwise stated or agreed
b. Nitrotec Treatment
i. All parts must be free of weld spatter and dust prior to plating.
ii. Parts must be acid pickle dipped after welding to remove any scale.
iii. Nitrotec treatment specification is NQ 40.
iv. All surfaces must be coated with a film of oil (P3 / Gerocore or equivalent).
v. A corrosion resistance rating to ISO 9227:2006 or equivalent with a minimum of
250 hours neutral salt spray.
c. Dacromet LC500A
d. Geomet
i. Chains are to be double coated, (before assembly and again after assembly), in a
chrome 6 free coating, similar to Geomet.
ii. A corrosion resistance rating to ISO 9227:2006 or equivalent with a minimum of
500 hours neutral salt spray.
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5) Painting
a. Preferred Powder Coating Method
All painted must be powder coated by Moffett Engineering Ltd. unless otherwise
requested.
If parts are being powder coated externally then the following guidelines should be
adhered to:
i. All parts shall be H(high) C(carbon) Steel shot blasted before paint, for the removing of
all surface rust, millscale and improve paint key.
ii. After blasting the part shall be made free from shot and debris.
iii. All sharp edges must be removed prior to painting to improve edge retention of paint.
iv. All bearing surfaces, steering trunions, bearing /cylinder stub, mast tilt brackets and
tapped holes must be bunged prior to paint.
v. Cleaning & degreasing:
• Components should then be thoroughly cleaned and degreased.
• Components should then be rinsed with water and subjected to a Zinc
Phosphate Rinse(1.5-2g/m2)
• Components should then be rinsed again with water and subjected to a
Passivation Rinse.
• After the application of the Passivation Rinse components should be rinsed
again with clean water and dried in an oven prior to painting.
• Only Moffett Engineering approved chemicals should be used.
vi. Treated and dried components are then to be painted using Moffett Engineering
specified paint.
vii. After the components have been suitably covered with powder, the component needs to
be cured. Curing should take place in a temperature controlled oven and the process
should meet the specifications of the Moffett Engineering Paint.
viii. All powder coated components must have a paint thickness of greater than 50µm and
suppliers should typically aim for a thickness of 80µm - 100µm.
ix. Visually the components should be free of run marks and surface imperfections, the
surface finish should be smooth and free from “orange peel” effect. Edge coverage must
be good with special attention to sharp edges.
x. Components will be subject to Neutral Salt Spray testing carried out by Moffett
Engineering Quality Assurance Department to ISO 9227:2006 and must offer a sufficient
level of protection, with a minimum of 1000hrs, and a maximum peel back of 2mm.
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Document: TS.006
Any parts supplied to Moffett Engineering Ltd. must be powder coated to this
specification.
Any alternative must first be approved and tested by Moffett Engineering Engineering.
i. All parts shall be H(high) C(carbon) Steel shot blasted before paint, for the removing of
all surface rust, millscale and improve paint key.
ii. After blasting the part shall be made free from shot and debris.
iii. All sharp edges must be removed prior to painting to improve edge retention of paint.
iv. All bearing surfaces, steering trunion’s, bearing /cylinder stub, mast tilt brackets and
tapped holes must be bunged prior to paint.
v. A layer of zinc epoxy primer shall be applied electro-statically to Interpon PZ 660 or
equivalent.
vi. Powder in the ordered colour shall be applied electro-statically to Interpon D36 Gloss
(85) or equivalent.
vii. The polymerization process shall be in a chamber furnace at approx. 200°C.
viii. After cooling down the polyester-layer on the part is finished, and the part is ready for
assembly.
ix. Components will be subject to Neutral Salt Spray testing carried out by Moffett
Engineering Quality Assurance Department to ISO 9227:2006 and must offer a sufficient
level of protection, with a minimum of 1000hrs, and a maximum peel back of 2mm.
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Document: TS.006
i) In the case of A class steel components, parts should be stamped or etched with a
unique serial number. The markings should be between 0.5mm and 1mm deep, and 8-
10mm in height. Method of marking should be agreed with Moffett Engineering to
ensure it is visible after paint. The format for the serial number is as follows:
MANUFACTURERS WEEK
YEAR SEQUENTIAL
INITIALS NUMBER
NUMBER
IN 11 25 0001
XXX.XXX.XXXX YY
xi) In the case of machined steel components, bunging of parts should be agreed with
Moffett Engineering sourcing department at RFQ stage. The bunging specification will
not be specified on the drawing, but by another document as approved by Moffett
Quality department.
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Document: TS.006
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2. Tolerance Class: This is the tolerance classification of the part and will be one of the
following;
3. For machining, cutting, profiling, tolerance must be Fine, Medium, Coarse or Very
Coarse, reference section 1 of this document
4. For welded structures; tolerance must be A or B, section 3 of this document.
5. Part Status: The details the current status of the part. This will either be WIP (Work
in Progress), Prototype or Production. (NB: Parts must not be manufactured if at
WIP status unless otherwise directed)
6. Part Revision: This displays the revision level of the drawing. If in doubt the supplier
should contact Moffett Engineering Ltd. to obtain the latest revision level.
7. Finish: This details the finish of the part. The specification of the finish must be
referenced to this document (e.g. Zinc Plating- reference TS.006.04)
9. Sheet Number: This displays the drawing sheet number and total of drawing sheets
for this part.
10. Part Change information: This shows a summary of the recent changes made to
the part and includes the change number (AR Action Request No), Description, Date
and Changed By.
11. Revision symbol below indicates the change on the drawing that relates to the
revision number in the symbol.
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Document: TS.006
8) Hydraulic Cleanliness
a. Steel Hydraulic/Diesel Tanks
i. All external faces of tanks to be free from surface defects i.e. pitting, scale and
rust.
ii. All visible welds to be finished/ linished smooth where specified by drawing or
sample (if provided).
iii. All weld spatter removed from all surfaces and threads.
iv. All tank assemblies to be leak tested at a pressure of between 0.2 and 0.6 bar and
checked for leaks. The pressure used should be the maximum possible without
distorting the tank. Any pressure outside of this range should be agreed with
Moffett Engineering.
v. All completed tanks to be washed internally with anti-corrosion treatment as
agreed with Moffett Engineering.
vii. In the case that gravimetric analysis is not available, a fluid cleanliness can be
stated, with agreement from Moffett Engineering. Fluid cleanliness must meet
ISO4406 18/16/13 (NAS1638 Class 7)
viii. All tanks to be transported with ports capped or blocked to prevent contamination
ingress.
ix. All steel tanks to must be made from cold rolled EN10130 DC01A unless
otherwise stated.
b. Hydraulic Hoses
i. The preferred method to determining hose cleanliness is using gravimetric
methods, as per ISO 4405. The allowable mass and particle size as per table
below.
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Document: TS.006
ii. In the case that gravimetric analysis is not available, a fluid cleanliness can be
stated, with agreement from Moffett Engineering. Fluid cleanliness must meet
ISO4406 18/16/13 (NAS1638 Class 7)
iii. All hoses must be capped and sealed before packaging.
iv. All hoses to be carefully packaged ensuring no contamination or damage will
occur during transport.
c. Hydraulic Components
i. The preferred method to determining component cleanliness is using gravimetric
methods, as per ISO 4405. The allowable mass is relative to the wetted area of
the component as below:
ii. In the case that gravimetric analysis is not available, a fluid cleanliness can be
stated, with agreement from Moffett Engineering. Fluid cleanliness must meet
ISO4406 18/16/13 (NAS1638 Class 7)
iii. All components flushed must have all ports capped and sealed before packaging.
iv. All components to be carefully packaged ensuring no contamination or damage
will occur during transport.
d. Complete Machine
i. Component cleanliness levels, in conjunction with Moffett assembly procedures,
should result in a fully assembled machine cleanliness level of ISO4406 20/18/15
(NAS1638 Class 9).
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Document: TS.006
9) Casting/Forging
All castings or forgings which replace fabricated parts must first be approved by
Moffett Engineering Ltd., engineering department for design, material spec and
casting/forging processes involved.
a. Casting of Components
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• Chassis
• Mast
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• Boom
• Mast Carriage
• Fork Carriage
Preferred Position
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• Overhead Guard
• Swivels
• Rear Arms
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• Stabiliser Legs
• Pantograph
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