STD00017 Issue 19 Corrosion Prevention (18-10-2017)

STD00017
GROUP STANDARD ISSUE: 19

TITLE: Corrosion preventive zinc-based coatings PAGE: 1 OF 28
THIS DOCUMENT IS THE PROPERTY OF J C BAMFORD EXCAVATORS LTD. IT MUST NOT BE COPIED, REPRODUCED OR TRANSMITTED WITHOUT PRIOR WRITTEN CONSENT
Always consult electronic master. Paper copies are uncontrolled.
Contents
Contents ............................................................................................................................................................................................. 1
Foreword ........................................................................................................................................................................................... 2
Introduction ....................................................................................................................................................................................... 2
1.0 Scope ..................................................................................................................................................................................... 3
1.1 General .....................................................................................................................................................................3
1.2 Not in scope ...........................................................................................................................................................3
2.0 Alternatives to superseded/obsolete/phase out coatings ......................................................................................... 4
3.0 Concessions ......................................................................................................................................................................... 4
4.0 Corrosion protection theory .......................................................................................................................................... 5
5.0 Mixing of various coatings on assemblies...................................................................................................................... 5
6.0 Supply condition.................................................................................................................................................................. 5
7.0 Considerations in choosing a coating ............................................................................................................................ 6
7.1 General .....................................................................................................................................................................6
7.2 Thread-forming screws into plastic components...........................................................................................6
7.3 Acceptance trials....................................................................................................................................................6
8.0 Stress relief........................................................................................................................................................................... 7
8.1 For fasteners ...........................................................................................................................................................7
8.1.1 Grade 8.8 .................................................................................................................................................................7
8.1.2 Grade 10.9 or higher ............................................................................................................................................7
8.2 For other than fasteners ......................................................................................................................................7
8.2.1 Stress relief prior to electroplating ...................................................................................................................7
8.2.2 Hydrogen embrittlement stress relief ..............................................................................................................7
9.0 Coating attributes............................................................................................................................................................... 8
9.1 Colour ......................................................................................................................................................................8
9.2 Conversion coatings (passivation) .....................................................................................................................8
9.3 Sealing (top coat) ...................................................................................................................................................8
9.4 Painting or other supplementary coatings .......................................................................................................8
9.5 Damage resistance .................................................................................................................................................8
10.0 APPROVED COATING TYPES ...................................................................................................................................... 9
11.0 Coating physical requirements ...................................................................................................................................... 14
11.1 Adhesion ............................................................................................................................................................... 14
11.2 Temperature resistance .................................................................................................................................... 14
11.3 Thickness .............................................................................................................................................................. 14
11.4 Corrosion performance requirements .......................................................................................................... 15
11.5 Friction coefficient .............................................................................................................................................. 15
12.0 Thread inspection ............................................................................................................................................................. 16
13.0 Corrosion test methods ................................................................................................................................................. 16
13.1 Neutral salt spray................................................................................................................................................ 16
13.2 Corrosion visual inspection.............................................................................................................................. 16
13.2.1 General .................................................................................................................................................................. 16
13.2.2 Components other than threaded fasteners................................................................................................ 16
14.0 Drawing call-out / identification .................................................................................................................................... 17
Prepared by: Kim Spence

Date: 18/010/2017 Amended by: P Smallman Approved by: P Smallman
STD00017
14.1 Hydraulic components....................................................................................................................................... 17

14.2 Fasteners ............................................................................................................................................................... 17
14.3 Other than the above ........................................................................................................................................ 17
15.0 Coatings to be phased out ............................................................................................................................................. 18

15.1 Types...................................................................................................................................................................... 18
15.2 Salt spray performance ...................................................................................................................................... 19
16.0 Tooling limitations ............................................................................................................................................................ 20
16.1 Torque control .................................................................................................................................................... 20
16.2 Coating damage ................................................................................................................................................... 20
16.3 Tooling choice ..................................................................................................................................................... 20
Annex A - HYDRAULIC COMPONENTS: coating requirements .................................................................................... 21
Annex B - THREADED FASTENERS ........................................................................................................................................ 23
Annex C – JCB Design, Production, PLM/CAD team advice .............................................................................................. 25
Annex Y – Change history archive ............................................................................................................................................ 26
Annex Z - Terms, definitions, references and related documents ................................................................................... 28
Foreword
This standard has been prepared under the authority of the JCB Standards and Legislation department
(Standards department).
This standard is intended solely for use in connection with the business requirements of J C Bamford Excavators
Ltd. (JCB) and is for use by appropriately qualified and competent people.
Contractual and legal considerations are not part of the scope of this standard. This standard does not
relinquish any responsibility, regulatory requirements, or duty of care.
Introduction
JCB GLOBAL REQUIREMENT IS TO PROHIBIT THE USE OF COATINGS WHICH CONTAIN
HEXAVALENT CHROME (Cr6) IN LINE WITH REACH LEGISLATION.
FOR JCB, THIS MEANS SPECIFICALLY TYPE 3 & 4 - ZINC AND YELLOW, WHICH IS TO BE PHASED OUT
ON BUILT PRODUCTS BY 01 JAN 2018.
CHANGES HAVE BEEN MADE TO THE DEFAULT RULES FOR FASTENERS IN ZINC AND YELLOW, AS
STIPULATED IN SECTION 2.0.

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1.0 Scope
1.1 General
The main body of this standard contains specifications for approved zinc-based coatings (‘zinc coatings’), applied
either by electrolytic or by mechanical processes (e.g. dip-spin) which may be used for corrosion protection and
/ or cosmetic purposes on JCB machines.
For application-specific requirements:

Hydraulic components - see Annex A
Fasteners - see Annex B
General hardware - see main body
Designers must first check within JCB standards whether a coating(s) requirement specific to the component
already exists, before specifying a coating from this standard.
JCB Power Systems shall independantly manage their transition away from zinc and yellow.
1.2 Not in scope

- certain proprietary components:
- where specified elsewhere in JCB standards (e.g. worm drive clips)
- where the component is not controlled by a JCB standard and the coating is the common finish
offered by the component manufacturer (e.g. rivet nuts, brake calipers)
- load-bearing components
- paint or coatings which remain in a fluid or wax state
- other coating types such as chrome
- any components where finish requirements are controlled by independent JCB standards
ssue Date Change history Super-
session
19 As footer Alternative to Types 3&4 specified. -
Deadline dictated by REACH regulations has been relaxed; standard amended accordingly.
Rules for zinc and yellow fastener part supply amended (see 2.0).
18 26/07/2017 -
Type 5 status for fasteners elevated to ‘acceptable’.
Suffix letter assigned for Type 7 standard fasteners.
17 10/05/2017 Caveat for regions where procurement of specified coatings is unworkable (see ‘Concessions’). -
PREPARATION FOR FUTURE CHANGES:
MERGED 9994/0800 iss. 08 ‘Corrosion protection for hydraulic components’ into Annex A of this
9994
16 28/03/2017 standard, thus rendering 9994/0800 obsolete. TECHNICAL DETAIL from the two standards IS
UNCHANGED. /0800
Fastener-specific detail has been moved out of the main body into Annex B.
Title amended.
Archived change history can be found in Annex Y.

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2.0 Alternatives to superseded/obsolete/phase out coatings

Type JCB name Comments / alternatives
Prohibited.
Type 9 is recommended instead - except for threads smaller than M6, where Type
2 Zinc and black
8 should be selected.
On phase out for built products.
Type 5 should be specified as the alternative to Type 3&4, unless a BU elects to

use another coating from this standard for their specific requirements.
3&4 Zinc and yellow

JCB will revise relevant drawings and Bills of Materials to replace any reference to
Type 3&4 zinc and yellow with an alternative coating from this standard.
Suppliers are to supply to drawing.
Zinc and heavy Prohibited

trivalent passivate
6
with leach seal,
silver
Black: Wherever these are specified on drawings, use Type 9 instead, or Type 8 where
Legacy drawings ‘Polyseal’, appropriate.
specifying: ‘E Cote Polyseal’
‘Legacy black’
or similar
3.0 Concessions
In the case of a failure to conform to the requirements of this standard:
- where the procurement of specified coatings is unworkable due only to their non-availability, alternatives from
this standard may be specified by JCB (except for hydraulic components)
otherwise
- a documented concession should be generated following the requirements given in GRP-023. Suppliers should
contact their JCB purchasing contact to obtain a copy of the standard operating procedure covering concessions
(GRP-023).

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4.0 Corrosion protection theory

Corrosion protection offered by the coatings within this standard are all based on the fundamental metallurgical
principle that corrosion occurs in anodic (positively charged) areas and is facilitated by cathodic (negatively
charged) areas. The zinc base of the corrosion protection coating is naturally more anodic and therefore more
active than steel, which is more passive (noble), according to the galvanic table. This galvanic relationship makes
the steel into the more passive cathode whenever coupled to zinc which becomes the active anode. The zinc is
known as the sacrificial anode. The corrosion of zinc produces white, powdery zinc oxide (white rust) and only
once the majority of the zinc has corroded will the steel begin corroding, indicated by the presence of red rust
(iron oxide).
5.0 Mixing of various coatings on assemblies

In order to control the appearance of finished JCB products, external adjacent parts should be of the same finish
colour wherever possible.
Certain coatings react with one another causing premature corrosion (see Annex C).
6.0 Supply condition

Parts shall be:
- completely coated, except for the bores of pipework and unless otherwise stated on the drawing
- clean
- smooth and free from visual defects
- in the dry to touch condition – as specified in BS 7371-2
The coating system shall be such that it is not susceptible to handling damage during the normal logistics of
supply.
Any products supplied in accordance with this standard shall satisfy all of the requirements of this standard at
the point of use.
Coating systems shall not compromise the health, safety or welfare of personnel in the ‘as applied’ condition but
shall satisfy all applicable mandatory, regulatory and legislative requirements for the JCB application.
Handling of the components without the use of protective clothing shall not represent a risk to personnel.
Coating shall not create an odour in the ‘as delivered’ condition.
Hydraulic components:
Cleanliness and packaging shall conform to 9993/0003.
The finishing process shall provide protection against ‘flash rust’ on un-coated areas. Under normal storage
conditions (e.g. shop floor) these areas shall remain free of rust for a minimum of two weeks.
All parts shall be rust and damage free at the point of use.

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7.0 Considerations in choosing a coating

7.1 General
Considerations to define the choice of coating include:
- colour - silver or grey or black (clause 9.1)
- longevity of corrosion protection (clause 13.1)
- effect of tooling damage to coating / reduction in corrosion protection (see clause 9.5)
- colour-matching to other components (clause 5.0)
- whether over-painting is a requirement (clause 9.4)
- risk caused by hydrogen embrittlement (electroplated coatings only – clause 8.2.2)
- cost (beyond the scope of this standard, but cost vs. quality must be considered)
- fastener grade and size (clause 8.0)
- thread-forming screws into plastic require special consideration (see clause 7.2)
The table in clause 13.1 specifies the minimum corrosion resistance requirements for each coating.
7.2 Thread-forming screws into plastic components

Certain coating attributes may have a detrimental effect (such as embrittlement) on the plastic component into
which the thread is formed by the fastener; the table in clause 10.0 advises further.
7.3 Acceptance trials

Individual BUs must conduct acceptance trials to determine suitability before an approved coating from this
standard is introduced onto their product:
- fasteners must not be interchanged without due consideration of the proposed coating attributes (in
particular, those with differing friction coefficients)
- friction co-efficient, tooling type/speed and torque must guarantee that a bolted joint will be secure
- effects of tooling or handling damage must be investigated (a coating chosen for its [theoretically] superior
corrosion resistance but with inferior damage resistance may prove to be undesireable)
Fastener suppliers are usually willing to assist with or conduct lineside or laboratory trials, or otherwise offer
assistance and recommendations for a particular application.
Fastener torque values and associated formulae can be found in STD00019.

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8.0 Stress relief

8.1 For fasteners
8.1.1 Grade 8.8

Fasteners in grade 8.8 material (ISO 898-1) may have any of the coatings herein applied.
8.1.2 Grade 10.9 or higher

Electroplating of fasteners in grade 10.9 or above should be avoided due to the increased risk of hydrogen
embrittlement. Where this is unavoidable, embrittlement shall be investigated in accordance with ISO 4042.
8.2 For other than fasteners
8.2.1 Stress relief prior to electroplating

Steel parts with an ultimate tensile strength ≥1000MPa which contain tensile stresses caused by machining,
grinding, straightening or cold forming operations should be given a stress relief heat treatment prior to cleaning
and electroplating.
8.2.2 Hydrogen embrittlement stress relief

All steel components subjected to electroplating treatments may absorb hydrogen evolved during this process
which can cause premature failure well below their normal failure level if the component is made from higher
tensile steel, particularly if used in tension (most embrittlement failures occur in a relatively short time after
assembly, typically between a few minutes and up to 24 hours).
Steel parts with an ultimate tensile strength ≥1000MPa as well as surface hardened parts shall receive hydrogen-
embrittlement-relief, in accordance with ISO 2081, but note that susceptible parts can never be guaranteed to
be completely free from embrittlement even after extensive heat treatments.
Where hydrogen embrittlement is identified as a risk then zinc flake should be used.

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9.0 Coating attributes

9.1 Colour
A zinc coating, without colour modifiers, results in a silver or grey finish.

The phase out of Type 3&4 (zinc and yellow) will mean that a yellow coating will no longer be available and
there is no alternative yellow coating approved for use on JCB products.
Note: Colour attributes for approved coatings can be found in clause 10.0.
9.2 Conversion coatings (passivation)

Solutions containing trivalent, or those free from chromium salts may be applied to further enhance the
corrosion properties of the zinc base layer and achieve various colour finishes.
9.3 Sealing (top coat)
Conversion coatings can be post-treated with sealing agents in order to enhance the corrosion protection
further and to enhance the resistance of the conversion coating at higher temperatures.
Note 1: The addition of a sealing coat is usually to modify the frictional coefficent required e.g. for fastener torque characteristics .
Note 2: The addition of a sealing coat usually makes the component unsuitable for overpainting.
9.4 Painting or other supplementary coatings

Where supplementary treatments are required over the coating, such as painting, powder coating, waxing or
the application of grease, oil or other lubricants then these may be applied over the zinc base coat in place of
the conversion coatings.
9.5 Damage resistance
Tooling or other damage can significantly shorten the corrosion resistance of a coating (in particular, impact
tools and bi-hex sockets, worn bits and sockets) and improved tooling may be required (see section 16.0 for
tooling advice and its limitations).

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10.0 APPROVED COATING TYPES

Note: coatings being phased out can now be found in section 15.0.
Coatings in this standard are allocated a type number for the purpose of simplification and are listed chronologically in this clause.
Column ‘Coating suffix for fasteners’ indicates the suffix to use in fastener part numbers (only) to denote a particular coating, where relevant (example of part numbers
incorporating the suffix letter can be found in Annex B.
Type Description Colour Image Attributes Limitations
Mechanically applied, usually via spray or Damaged by poor handling processes and impact/percussive
dip-spin. tools which will cause significant reduction of corrosion
resistance - it is recommended that trials be conducted
Can offer superior corrosion resistance prior to introduction.
White
Zinc aluminium for thinner coatings compared with May collect in recesses, thread roots, hex. sockets, etc.
Avoid use for threaded components smaller than M6, or
1 flake - (silver-
grey).
conventional coating methods.
No hydrogen-embrittlement; those with a thread pitch less than 1mm- Type 7 is
silver Dull. recommended for fasteners. suggested as an alternative. May cause sticking and/or
Self-repairing. marking of washers smaller than M10.
Usually electrically conductive.
Beneficial in removal/refit applications. KL100 with VH302 top coat contains silicate and may
Water or solvent based options. impede overpainting.
Note 1: Type 1 Zinc Flake - coatings approved for use (licence holder):
- Geomet 500A (NOF)
- Delta Protekt KL100 + VH302 friction control coating (Doerken)
- Delta Protekt KL105 - enhanced control of friction co-efficient where this is required e.g. for bolted joints (Doerken)
- Magni 565 or Magni 560 (Magni)
The licencing and application of the above is strictly quality controlled to provide reliable and controlled coatings.
Silver approved coatings are licenced. Licencing and application is strictly quality controlled to provide reliable and controlled coatings.
Note 2: According to BS EN ISO 10683 the description for the appearance of zinc flake is silver-grey. This and other JCB standards specify the appearance as ‘white aluminium’;
this description is retained here for clarity and continuity.

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Silver Electroplated zinc coating with heavy Not suitable for over-painting due to
Zinc and heavy trivalent trivalent chromium iridescent passivate. the silicone content of the seal.
5 passivate with seal Bright Seal coating with integral friction Process causes hydrogen
iridescent modifier.
Acceptable for fasteners embrittlement (clause 8.0 and 8.2.2).

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Electroplated / clear passivated zinc-

nickel.
Zinc Nickel Process may cause hydrogen embrittlement
7 - silver/grey
Dark, dull Where higher corrosion (clause 8.0 and 8.2.2).
silver grey performance required.
Approved for use (licence holder):

- Zinclad 1000 with Torque & Tension 15 top coat (MacDermid).

STD00017

Process may cause hydrogen
Electrolytic zinc-nickel plate, black trivalent chromate and clear sealer,
embrittlement (clause 8.0 and 8.2.2).
integral torque control lubricant.
8 Excellent corrosion resistance and good wear characteristics.
Not suitable for thread-forming
Good resistance to mechanical damage.
screws into plastic components, see
Best suited for CAB roofs and fenders (high corrosion resistance).
Type 8P or Type 9P.
Zinc Black,
Nickel - chalky
black texture
Resistance to tooling damage: as Type 8.
As Type 8, but WITHOUT the torque control lubricant.
8P Suitable for use on thread-forming screws into plastics
Only to be specified for thread-forming
(hence ‘P’ in 8P).
fasteners into plastic components.
Type 8:
- Zinclad 1000B with Torque & Tension 15 top coat (MacDermid).
Type 8P:
- Zinclad 1000 with no top coat (MacDermid).

STD00017

Damaged by poor handling processes and impact/percussive tools which will cause
Mechanically applied usually significant reduction of corrosion resistance - it is recommended that trials be
via spray or dip-spin. conducted prior to introduction.
No hydrogen-embrittlement
issues. May cause infil to heads e.g. hex. sockets and collect in recesses and thread roots.
Self-repairing. Where possible avoid use on threads smaller than M6, or of less than 1mm pitch.
9 Usually electrically
conductive.
May casue sticking and/or marking of washers smaller than M10. For these
reasons, Type 8 is recommended instead.
Zinc Black, Beneficial in removal/refit
flake - slight applications. BU’s must assess and approve for their own use.
gloss Torque control lubricant
black intergrated within base coat
Not suitable for thread-forming screws into plastic components -
or top coat.
choose Type 8P or 9P.
As Type 9, but WITHOUT
the torque control lubricant. As Type 9.
9P Suitable for use on thread-
forming screws into plastics Only to be specified for thread-forming fasteners into plastic components.
(hence ‘P’ in 9P).
Type 9:
MKS Delta Protekt KL100 with Delta Seal GZ Black top coat (Doerken).
Type 9P:
MKS Delta Protekt KL100 with Delta Seal (Black) top coat (Doerken).

STD00017
11.0 Coating physical requirements

11.1 Adhesion
For electrogalvanic coatings:

- adhesion is to be checked by a thermal shock test in accordance with DIN EN ISO 2819
For zinc flake coatings:

- adhesion is to be checked by a Tape Test. Textile adhesive strip with an adhesive force of
7±1N per 25 mm of width is pressed onto the coating firmly by hand and subsequently torn off
abruptly. Coatings shall not allow themselves to be torn off, but a slight adhering of the coating
material to the adhesive strip is tolerated.
11.2 Temperature resistance

After heating the coated part for 3 hrs at 150 °C (component temperature) the corrosion
protection requirements as specified within this standard shall be met (see clause 11.4).
11.3 Thickness
Typical coating thickness is 10±5 microns (info).

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11.4 Corrosion performance requirements

Neutral salt spray requirements

Coating type Required minimum corrosion protection
duration / Minimum NSS test duration for
corrosion to appear
(for an undamaged coating*)
Type Approved coatings Coating Base metal (red rust)
1 Zinc flake - silver 720
(but may return significantly inferior
240 performance if coating is damaged
e.g. by installation tooling)
96 360
5 Zinc and heavy trivalent with seal
(subject to improvement)
7 Zinc Nickel - silver 240 720
8 Zinc Nickel - black 240
8P Zinc Nickel – black 168** 720

(Type 8 but without torque (240
control lubricant) preferred)
9 Zinc flake - black 720
(but may return significantly inferior
9P Zinc flake – black 240 performance if coating is damaged e.g. by
(Type 9 but without torque installation tooling)
control lubricant)
Note*: Alternative / improved tooling may help reduce damage to coatings (see also clause 9.5 and 16.0).
Note**: Realigned with industry standard supply and demand; this applies to ‘coating white corrosion’
(required duration for base metal to red corrosion is not affected). 240hrs is preferred where available, but
168hrs will be accepted if (and only if) 240 cannot be achieved through manufacturing constraints.
Note 1: Type 8/8P and Type 9/9P are capable of achieving 1000hrs+; the table above specifies minimum
requirements.
11.5 Friction coefficient

Friction
Coating Type
Coefficient
1 0.15 ± 0.03
5 0.15 ± 0.03
7 0.15 ± 0.03
8 0.15 ± 0.03
8P N/A
9 0.15 ± 0.03
9P N/A
Note: Type 5 is non-preferred for fasteners.

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12.0 Thread inspection

Hydraulic components - see Annex A.
Threaded fasteners - see Annex B.
13.0 Corrosion test methods

13.1 Neutral salt spray
Neutral Salt Spray (NSS) corrosion testing according to ISO 9227:2007 / ASTM B117 shall be used
to indicate the likely service life of the coating and the resultant protection given to the base
component for the durations specified in this standard (clause 11.4).
Time taken for the development of corrosion will vary from one coating system to another, as will
the type, appearance and severity of the corrosion.
Corrosion testing to the cited standards above is normally performed on goods ‘as produced’.
Where a BU wishes to investigate the effects of screwthread tightening and untightening on the
durability of the corrosion preventive coating this should be performed after an initial assembly and
disassembly. It should be noted that the corrosion resistance of certain coatings will be adversly
affected if damaged by tooling or rough handling during this test. The following conditions are
suggested. Assembly prior to corrosion testing shall be by use of:
- tooling of the correct size (e.g. hexagonal chrome vanadium socket)
- calibrated manual torque wrench
- torque tightening to 75% of theoretical yield
- nut shall travel over a minimum of 2d thread engagement (where d is nominal diameter)
Parts shall be disassembled prior to corrosion testing.
Where hydraulic joints occur, or parts thereof, these shall be assembled and manually tightened
using the correct tooling to 100% of specification. The tightening method described for ‘sealing face
characteristics’ in Annex A shall be used where this is applicable to the joint design. Parts shall then
be disassembled prior to corrosion testing.
13.2 Corrosion visual inspection
13.2.1 General
For the purposes of assessment, the presence of white corrosive product indicates corrosion of the
coating (‘white rust’) and the presence of red corrosive product indicates corrosion of the base
metal (‘red rust’).
Fastener-specific requirements can be found in Annex B.
13.2.2 Components other than threaded fasteners

Following the test duration required for the coating, there may be, at most, slight corrosion of the
coating on all surfaces (according to ISO 10289:2001). Black or grey staining or spotting should not

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constitute a failure.
There shall be no corrosion of the base metal.
Following the test duration required for the base metal there may be, at most, slight corrosion of
the base metal on all surfaces (according to ISO 10289:2001).
14.0 Drawing call-out / identification

14.1 Hydraulic components
Where a zinc coating is required the drawing shall include:
- “CORROSION PROTECTION TO JCB STD00017”
(the coating ‘Type’ should not be included on the drawing; STD00017 contains the recommended
coating type(s) for hydraulic components, see annex A, such that a basic referral to STD00017 is
sufficient).
14.2 Fasteners
Drawings shall include:
- the statement “CORROSION PROTECTION TO JCB STANDARD STD00017”
- the coating type number (e.g. Type 9)
- the finish colour (e.g. Black)
(see Note below)
14.3 Other than the above

Drawings shall include:
- “CORROSION PROTECTION TO JCB STD00017”
- the coating type number (e.g. Type 9)
- the finish colour (e.g. Black)
(see Note below)
NOTE:
Coating suffix letter (e.g. 1315/1234D)
Only common, standard fastener parts, as specified and listed in JCB Standards, carry a final suffix letter (tabulated in
Annex B); these letters are not to be used for non-standard parts.

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15.0 Coatings to be phased out

Coatings listed below are to be phased out by JCB BU’s.
15.1 Types
Type Description Colour Attributes Limitations Coating
suffix for
fasteners
2 Zinc and Black

Colour shall be
Electroplated
zinc with
Non-preferred.
Inferior to Type 9 (and Type 8) coating.
No suffix
allocated
black visually assessed heavy Head selection and torque tightening of
against RAL 9005 hexavalent black fasteners is particularly critical, as
colour swatch. chromium any assembly damage is more obvious.
Colour match shall black Discipline of assembly operations and
be a minimum of 4 in passivated. correct tooling is thus of paramount
accordance with ISO importance.
105-A02 grey scale Process causes hydrogen embrittlement
for assessing colour (clause 8.0 and 8.2.2).
change. Arbiters
shall be the JCB
Industrial Design
department.
Note: Legacy black ‘Polyseal’, ‘E Cote Polyseal’, or similar (as specified on some JCB drawings) is no longer available.
Type 8 or Type 9 should be used instead.

suffix for
fasteners
3 Zinc and Yellow

iridescent
Electroplated zinc
coating with heavy
Process causes hydrogen
embrittlement (clause 8.0 and 8.2.2). Z
and yellow hexavalent chromium
4 yellow passivate.
Note 1: Types 3 and 4 were originally specified from differing British standards which are now obsolete. The coating specification for
Types 3 and 4 is now identical. Each of the type numbers 3 and 4 are retained within this document for clarity and continuity.
Note 2: Types 3 and 4 contain hexavalent chromium (Cr6) which is known to be environmentally harmful. This coating will become
increasingly difficult to source with impending legislative requirements to reduce its usage and with an expected gradual increase in cost.
However, Types 3 and 4 are currently the only approved choices where a yellow finish is a specific design requirement.

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suffix for
fasteners
6 Zinc and Bright

silver/iridescent
Electroplated zinc
coating with heavy
Non-preferred.
Legacy coating.
No suffix
allocated
heavy trivalent chromium Not suitable for over-painting
trivalent iridescent passivate due to the silicone content of
and leach sealant top
passivate coat.
the seal.
with leach Process causes hydrogen
embrittlement (clause 8.0 and
seal 8.2.2).
15.2 Salt spray performance

Coating type Colour Minimum corrosion protection duration / Minimum NSS test
duration for corrosion to appear (hours)
[for an undamaged coating]
Coating Base metal
2 Zinc and black black 96 168
3 Zinc and yellow yellow 96 168

and
4
6 Zinc and heavy trivalent silver 96 500
with leach seal

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16.0 Tooling limitations

16.1 Torque control
Considerations:
- the ability of the chosen tooling to repeatedly apply a pre-set calibrated torque value
- paint infill will affect torque tightness
- coating frictional coefficient will affect torque tightness
16.2 Coating damage

Certain tooling will damage corrosion preventive coatings leading to premature corrosion of the
fastener.
Damage limitation (elimination) is desired by using tooling that will prevent damage (e.g. specialised
tooling, replacement of worn tools, tooling used in the correct way, etc.).
Rotary tooling must be stationary when engaged with the fastener (unless the fastener is designed
specifically to accept a rotating tool – rare).
Any tooling must be selected and proven to be suitable for the type of fastener, coating and torque,
such that damage to coating/fastener is minimised/does not cause premature corrosion and that the
desired torque is repeatably achieved.
Fasteners and coating specifications must be sympathetic to the tooling proposed.
16.3 Tooling choice

Table is offered for general advice only.
BU’s are responsible for their own product and hence for any damage caused to fastener coatings.
Tooling Control of torque Damage occasioned to coating
DC tooling excellent none / minimal
Electric clutch type excellent none / minimal
Manual good (so long as they are used none / minimal
correctly e.g. torque bars
Proprietary ‘TorqueControl’* generally poor generally poor (depends on user)
Impact/percussive** poor very poor and not suitable for
zinc flake coatings Type 1 and
Type 9.
Note: The above assumes a non-worn, correctly sized bit or socket.
Note*: The terms ‘Torque Control’ etc. advertised on or by a tool may not necessarily mean accuracy, also read as ‘auto
shut-off at an approximate torque’! e.g. rechargeable drill driver
Note**: Will generally continue to tighten with the trigger held open.

STD00017
Annex A - HYDRAULIC COMPONENTS: coating requirements
This standard (at issue 16) incorporated requirements for zinc coatings on hydraulic components
(transferred from JCB standard 9994/0800 issue 08).
Coatings for hydraulic components

Preferred zinc coating (Type 5)
The preferred zinc coating was reflected from issue 5 of STD00017; coating Type 5.
Zinc and yellow coating (Type 3 and 4)

Where a ‘yellow’ zinc electroplated coating is required this has to be by using hexavalent-chromium
as there is currently no alternative. Phase out should be in line with the date stipulated at the head
of this standard.
Exceptions
Where a drawing calls up a superior performance coating, the drawing shall take precedence,
provided that the coating is not listed in section 2.0.
Finish selection guidance

NOTE: This table was transferred from 9994/0800 issue 08. JCB accepts that paint, referred to in the table below, is not
part of the scope of STD00017, but is retained here for continuity of data.
Coating permitted
Component Zinc coating Paint
Accumulators no yes
Adaptors (loose) yes no
Auxiliary valves, manifolds preferred permissible
Cylinder tubes (including welded pipework) permissible yes
Filter bodies yes no
Heat exchangers permissible yes
Hose end fittings yes no
Quick release hydraulic couplings yes no
Main control valves permissible preferred: 4200/0000, jet black, ref 0002
Motors yes yes
Pipe or tube assemblies see 1000/0007 see 1000/0007
Pumps permissible preferred: 4200/0000, jet black, ref 0002
Steer valves (orbitrols) permissible preferred: 4200/0000, jet black, ref 0002
Strainers yes no
Test points yes no
NOTE: Hydraulic components not included in the above table have their own JCB standard to which the user should refer.

STD00017
Threads
After the application of a zinc coating, all hydraulic component threads shall conform to the relevant
JCB standard.
Sealing joint mechanical characteristic requirements

Hydraulic joints must be capable of being torque tightened to an appropriate level to achieve zero
leakage.
It is the responsibility of the component supplier to ensure that, following the coating process,
adequate sealing-face mechanical characteristics are achieved, as described in Figure 1.
With the applied force (F1) removed and a force applied to F2 causing the pipe or hose fitting to
tend to rotate, the following relationship applies; F2 x Y >= 50% x F1 x X
i.e. the torque applied to the pipe before any movement occurs must not be less than 50% of the
applied tightening torque. Any movement of the pipe or hose fitting must not cause the swivel nut
torque to move.

STD00017
Annex B - THREADED FASTENERS
Creation of new threaded fasteners

Rules
Where a part would ordinarily fit into a part family / part number table in a JCB
standard (e.g. fasteners, clips) the user must first contact JCB S&L for advice.
Engineers may create special fasteners or other items, the specifications of which are
not detailed in JCB standards, by using a generic 'off the clock' part number with a
comprehensive specification (drawing).
Note: JCB utilise an intelligent part numbering sytem for standard bolts, set screws, nuts, washers and the like and a letter
as the final digit of the part number identifies the coating type. Parts are grouped into ‘part families’ for the designer to call
up.
Coating suffix for standard fasteners

Standard fasteners are specified and listed in JCB Standards using intelligent part numbers of the
form xxxx/yyyy. Where a coated standard fastener is required, the intelligent part number is
appended with a letter corresponding to the coating type in this standard, according to the below
table.
These should only be used for standard fasteners, under the control and direction of JCB S&L.
Specials / non-standard fasteners not listed in JCB Standards should take an ‘off the clock’ number
and should not include the letter.
e.g. 1315/3208D:
Coating type Fastener final digit
no coating no digit
1 D
5 V
7 G
8 N
8P not assigned
9 B
9P not assigned
Fastener mechanical inspection
Coating thickness
Coating thickness measurement methods for fasteners is defined within BS EN ISO 10683 for
mechanically-applied zinc flake and in BS EN ISO 2081 for electroplated coatings.
Threads
Requirements have been relocated to fastener standards JCB STD00004 and STD00007.
STD00017
Lubrication and torque tightening

Threaded fasteners shall achieve consistent bolt tension when torque control methods for tightening
are applied.
The JCB coatings phase out programme will mean that approved finishes within are of the same
coefficient of friction, such that the nominal tightening torque for a given fastener type will be
constant whatever coating is specified.
Lubricant test methods shall conform to the requirements of BS 7371-2. Ten consecutive fasteners
randomly selected shall be tightened until 75% of theoretical yield load is achieved. The variation in
installed torque shall not deviate by more than 10% from the mean value.
Threaded fasteners
Following the test duration required for the coating, there shall be, at most, slight corrosion of the
coating on less than 5% of the significant surfaces and moderate corrosion of the coating on other
surfaces (according to ISO 10289:2001). Black or grey staining or spotting should not constitute a
failure.
There shall be no corrosion of the base metal.
Following the test duration required for the base metal there shall be, at most, slight corrosion of
the base metal on less than 5% of the significant surfaces and moderate corrosion of the base metal
on other surfaces (according to ISO 10289: 2001).
The figure below identifies and classifies significant areas of fasteners for the purposes of assessing
corrosion protection offered by the coating.
Bolt / Screw significant surfaces (A):
- External head surfaces and drive surfaces
- End of bolt
Exclusions:
A - Internal drive surfaces
- Shank and thread
- Edge of flanged head (C)
Nut significant surfaces (B):

- - External flats and drive surfaces
B - - Exposed nut seating surface
Exclusions:
- - Thread
- - Edge of nut flange (D)

STD00017
Annex C – JCB Design, Production, PLM/CAD team advice

Design
Incompatible coatings - Corrosion creep or migration
Specifying coatings with different corrosion resistance that are in contact (such as a bolt and washer)
will cause the earlier corrosion type to migrate and cause premature corrosion of the adjacent
coating.
Production Engineering
BU’s must ensure that:
- lineside operatives are adequately trained in the correct use of tooling
- there is adequate process control in place to prohibit the use of worn driver tips/sockets
- goods received with contamination within screw threads must be rejected
Note: Screw thread contamination:
It is NOT acceptable for screw threads to be contaminated by paint / foreign bodies as this will have a detrimental effect
on tightening up to a specified torque, hence joint tightness will be affected (e.g. torque clutch assembly tools can stall).
All threads are to be protected from shot blast, paint, or other material. (Paint clearing fasteners should not be required).
Group PLM / CAD Teams

Provision for informing users that relevant coatings are on phase-out and are not to be selected for
use on new product.

STD00017
Annex Y – Change history archive

Issue Date Change Supersession
Over-simplistic Section 2.2 deleted.
Section 11.5; caveat reapplied to Type 8P.

15 02/03/2017 Annex D - Approved coatings Base and Top coat trade names - deleted; trade names redistributed under -
the relevant coatings specifications in section 10; reinstated Type 1 and Type 9 trade name products
previously erroneously cited as ‘not to be used’.
14 07/02/2017 Type 5 usage relaxed to ‘non-preferred for fasteners’ to support JCB global procurement. -
13 21/12/2016 Changes have been made to: -

comply with legislation
improve corrosion performance
maintain / improve availability
improve commercial leverage (via automotive volumes)
improve machine perception
12 21/09/2015 Limited availability of certain proposed coatings has forced a relaxation of the previous requirement in -
order to support procurement and economy (previous statement ‘THESE ARE NOT TO BE USED
ON NEW PRODUCT’ has been deleted).
11 27/03/2015 Poor-performing coatings are being phased out from JCB use and are now designated as ‘not to be -
used on new product’ (JCB ref. ELF 100315).
Type 7 renamed as ‘zinc nickel – silver’ to align with other descriptive JCB names.
Type 7 added friction modifier and revised corrosion resistance.
Types 8 and 8P revised corrosion resistance (for coating to white corrosion).
Approval process deleted (with the impending rationslisation of coatings, no further coating requests
shall be required to be submitted or processed).
Coating proposal form no longer required - deleted.
10 7/01/2015 New coatings introduced for thread-forming screws (modifications to Types 8 & 9). -
09 09/05/2014 Additional suffix letters defined to denote new coating types (introduced at issue 08) when used in -
fastener part numbers.
Note: Short period between this and previous issue means that revisions in issue 08 shall carry over for
issue 09.
New Type 8 black coating introduced (JCB Landpower request-application driven). -
New Type 9 black coating introduced (to replace Type 2 and black ‘Polyseal’).
Amend ‘Type 1 zinc flake’ to become ‘zinc flake – silver’ (to distinguish it from any other zinc flake
coating).
To indicate that a black proprietary coating ‘Polyseal’, referenced on certain JCB drawings, is increasingly
difficult to source (recently capability in the UK has ceased, now approx. only two platers worldwide) and
an alternative is recommended within.
08 14/03/14 VH302 friction control coating added to the specification for Delta Protekt KL100.
‘A’ added after Geomet 500 to guarantee the minimum salt spray requirement.
Enhanced salt spray requirements reflect coating process improvements.
'Relative cost' removed from coating attributes as these may not now reflect current status.
Coating ‘Typical Thickness’ deleted.
Neutral Salt Spray: requirement of assembling and disassembling fasteners prior to subjecting components
to test has been demoted from a general requirement to a JCB business unit level option.
Visual inspection criteria deleted (formerly in Annex A).
To add a new Type 1 zinc flake coating - Delta Protekt KL 105. None
7 20/09/2012 Minor clarification of the approval process.
Cross reference superseded coatings to latest types.
Introduce Delta Protekt KL100 as an approved Type 1 zinc flake coating. The removal of a specific brand- None
6 30/08/2010 named coating from the table for Type 1 zinc flake now makes this coating type generic rather than
specific to one brand.
To correct the inspection gauge size from g to h for coated metric male threaded fasteners, to clarify the None
5 19/11/2009 scope, to elevate zinc and yellow electroplating (Types 3 and 4) from non preferred status, to reference
current standards and to make significant editorial changes to improve document flow.
To catalogue all of the coating types used regularly on JCB products in order to clarify the details None
regarding the choices available and the performance requirements for those coatings.
4 01/09/2008
The threat of future legislation will affect the use or availability of Hexavalent Chromium (Cr6) i.e. zinc
and yellow.

STD00017
To identify the two acceptable corrosion preventive zinc flake coatings that satisfies the requirements of None
3 11/2006 white aluminium (type 1) coatings specified in this standard.
2 11/2005 Update the reference to coolant - now STD00088. None

First issue - the use of different types of coating systems for fasteners have become common practice 9994/1100
within JCB and this standard has been introduced to define minimum performance requirements to STD00013
control quality and consistency. 9994/0301
Where superseded coatings are referenced on drawings etc. the following alternatives from this standard 9994/0302
should be used:
1 09/2003
Superseded standard Coating type STD00017 coating type to be used:
9994/1100 zinc flake 1(silver) or 9 (black) [or 8, black]
9994/0301 zinc and yellow 3 or 4
9994/0302 zinc and yellow 3 or 4

STD00017
Annex Z - Terms, definitions, references and related documents
Terms and definitions

NSS A means of accelerating corrosion by exposing components to a constant mist of salty water
(Neutral Salt Spray) at a slightly elevated temperature for a specified duration, after which corrosion on the
component is visually assessed against specified levels, which may be deemed to represent a
number of months or years of in-service life.
S&L JCB Standards & Legislation department
White Rust Corrosion of top coat resulting in a white ‘rust’ forming on the surface
Red Rust Corrosion of the base material resulting in a red/brown rust forming on the surface
References
This standard incorporates provisions from other standards. These references are cited at the
appropriate places within the text and are listed hereafter. For undated references, the latest edition
applies.
- STD00019 Tightening torques for plain threaded fasteners
- JCB 9993/0003 Hydraulic component cleanliness requirements
- BS 7371-2 Coatings on metal fasteners - Part 2: Specification for torque/clamping force relationship
- BS EN ISO 10683 Fasteners - Non-electrolytically applied zinc flake coatings
- BS EN ISO 2081 Metallic and other inorganic coatings - Electroplated coatings of zinc with supplementary
treatments on iron or steel
- ISO 105-A02 Tests for colour fastness
- ISO 898-1 Mechanical properties of fasteners made of carbon steel and alloy steel. Bolts, screws and studs
- ISO 4042 Fasteners – Electroplated coatings
- ISO 9227 Corrosion tests in artificial atmospheres - salt spray tests
- ISO 10289 Methods for corrosion testing of metallic and other inorganic coatings on metallic substrates
Rating of test specimens and manufactured articles subjected to corrosion tests
- ASTM B117 Standard Practice for Operating Salt Spray (Fog) Apparatus
Related documents (metric fasteners)

- STD00004 Metric nuts
- STD00020 Metric washers
- STD00007 T1 Metric male threaded fasteners - Catalogue of types, lengths and JCB part numbers


STD00017 Issue 19 Corrosion Prevention (18-10-2017)

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STD00017 Issue 19 Corrosion Prevention (18-10-2017)

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STD00017

GROUP STANDARD ISSUE: 19

Prepared by: Kim Spence

14.1 Hydraulic components....................................................................................................................................... 17

15.0 Coatings to be phased out ............................................................................................................................................. 18

Prepared by: Kim Spence

For application-specific requirements:

1.2 Not in scope

Prepared by: Kim Spence

2.0 Alternatives to superseded/obsolete/phase out coatings

On phase out for built products.

Type 5 should be specified as the alternative to Type 3&4, unless a BU elects to

3&4 Zinc and yellow

Suppliers are to supply to drawing.

Zinc and heavy Prohibited

Prepared by: Kim Spence

4.0 Corrosion protection theory

5.0 Mixing of various coatings on assemblies

6.0 Supply condition

Prepared by: Kim Spence

7.0 Considerations in choosing a coating

7.2 Thread-forming screws into plastic components

7.3 Acceptance trials

Prepared by: Kim Spence

8.0 Stress relief

8.1 For fasteners

8.1.1 Grade 8.8

8.1.2 Grade 10.9 or higher

8.2 For other than fasteners

8.2.1 Stress relief prior to electroplating

8.2.2 Hydrogen embrittlement stress relief

Prepared by: Kim Spence

9.0 Coating attributes

A zinc coating, without colour modifiers, results in a silver or grey finish.

9.2 Conversion coatings (passivation)

9.4 Painting or other supplementary coatings

Prepared by: Kim Spence

10.0 APPROVED COATING TYPES

Prepared by: Kim Spence

Type Description Colour Image Attributes Limitations

Prepared by: Kim Spence

Type Description Colour Image Attributes Limitations

Electroplated / clear passivated zinc-

Approved for use (licence holder):

Prepared by: Kim Spence

Type Description Colour Image Attributes Limitations

Approved for use (licence holder):

Prepared by: Kim Spence

Type Description Colour Image Attributes Limitations

Prepared by: Kim Spence

11.0 Coating physical requirements

For electrogalvanic coatings:

For zinc flake coatings:

11.2 Temperature resistance

Prepared by: Kim Spence

11.4 Corrosion performance requirements

Neutral salt spray requirements

8 Zinc Nickel - black 240

8P Zinc Nickel – black 168** 720

11.5 Friction coefficient

Prepared by: Kim Spence

12.0 Thread inspection

13.0 Corrosion test methods

13.2 Corrosion visual inspection