STD00045

GROUP STANDARD ISSUE: 04

TITLE: Pivot pin coating PAGE: 1 OF 18
THIS DOCUMENT IS THE PROPERTY OF J C BAMFORD EXCAVATORS LTD. IT MUST NOT BE COPIED, REPRODUCED OR TRANSMITTED WITHOUT PRIOR WRITTEN CONSENT

Contents

Contents ............................................................................................................................................................................................ 1
Foreword ........................................................................................................................................................................................... 3
Introduction ..................................................................................................................................................................................... 3
1.0 Scope .................................................................................................................................................................................... 3
2.0 Definitions........................................................................................................................................................................... 3
3.0 References .......................................................................................................................................................................... 4
4.0 Concessions........................................................................................................................................................................ 4
5.0 Pin coatings – background information .................................................................................................................. 4
6.0 Approval .............................................................................................................................................................................. 5
7.0 Functional requirements – Standard Duty coatings ........................................................................................... 5
7.1 Mechanical ......................................................................................................................................................... 5
7.1.1 Coating thickness ............................................................................................................................................ 5
7.1.2 Scratch resistance ............................................................................................................................................ 5
7.1.3 Impact performance ....................................................................................................................................... 5
7.1.4 Coating hardness ............................................................................................................................................. 5
7.1.5 Wear performance .......................................................................................................................................... 6
7.1.6 Endurance performance (optional at discretion of end-user) ........................................................ 6
7.1.7 Pin hardness ...................................................................................................................................................... 6
7.1.8 Hydrogen embrittlement .............................................................................................................................. 6
7.2 Corrosion and chemical resistance ........................................................................................................... 6
7.2.1 Salt spray............................................................................................................................................................. 6
7.2.2 Oil immersion .................................................................................................................................................... 7
7.2.3 Detergent immersion ..................................................................................................................................... 7
7.3 Appearance ........................................................................................................................................................ 7
7.3.1 Colour................................................................................................................................................................... 7
7.3.2 Uniformity of coating ..................................................................................................................................... 7
7.3.3 Surface defects ................................................................................................................................................. 8
8.0 Functional requirements – Heavy Duty coatings ................................................................................................. 8
8.1 Wear performance .......................................................................................................................................... 8
8.2 Endurance testing (optional at discretion of end-user) .................................................................... 8
9.0 General requirements..................................................................................................................................................... 8
9.1.1 Shipping and delivered condition ............................................................................................................. 8
9.1.2 Touch-up............................................................................................................................................................. 8
9.1.3 Process control ................................................................................................................................................. 8
10.0 Standard pin sample for functional testing ........................................................................................................... 9
11.0 Drawing requirements ................................................................................................................................................... 9

Prepared by: D Panni

Date 20/08/2010 Amended by: M Leeming Approved by: M Ireland
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GROUP STANDARD ISSUE: 04
TITLE: Pivot pin coating PAGE: 2 OF 18
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Annex A – Approved coatings ................................................................................................................................................ 10

Annex B – Declaration form – Standard Duty coating................................................................................................... 11
Annex C – Declaration form – Heavy Duty coating ........................................................................................................ 13

Prepared by: D Panni

Date 20/08/2010 Amended by: M Leeming Approved by: M Ireland
 STD00045
GROUP STANDARD ISSUE: 04
TITLE: Pivot pin coating PAGE: 3 OF 18
THIS DOCUMENT IS THE PROPERTY OF J C BAMFORD EXCAVATORS LTD. IT MUST NOT BE COPIED, REPRODUCED OR TRANSMITTED WITHOUT PRIOR WRITTEN CONSENT

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.

This is the fourth issue of this standard, to add E-Coat as an approved coating.

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

This standard has been introduced to ensure all relevant suppliers comply with the pin-coating
requirements of JCB. These requirements are detailed below, and Annexes A and B are forms to be
completed and signed by the supplier to demonstrate compliance with this standard.

The forms must be signed by both the supplier and JCB before approval to supply may be given.

1.0 Scope

This standard specifies the requirements for the coating of pivot pins supplied to JCB. This standard
incorporates pin coating detailed in 9994/0500 - Coating of Pivot Pins with Rocol 1PX1, which is now
withdrawn and the coating defined herein as Heavy Duty coating.

This document covers both Standard Duty and Heavy Duty coatings of similar performance but where
the latter has an additional requirement for superior wear and lubrication.

Pins meeting this standard are approved for use in metallic bearings only.

2.0 Definitions

Standard Duty coatings are typically used on mid-range machines (i.e. BHL and Loadall) where the
function of the coating is to provide corrosion protection only.

Heavy Duty coatings are specified where superior wear and lubrication performance are required.

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Date 20/08/2010 Amended by: M Leeming Approved by: M Ireland
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3.0 References

This standard incorporates provisions from other standards / procedures. These references are cited at
the appropriate places within the text and are listed hereafter. For undated references, the latest edition
applies.
- BS EN ISO 2409: 1995 Paint and varnishes – cross-cut test
- BS EN ISO 1514: 1997 Paint and varnishes – standard panels for testing
- ASTM B 117: 2003 Standard practise for operating salt spray (fog) apparatus
- ASTM D 3359: 2002 Standard test methods for measuring adhesion by tape test
- ASTM D 3363: 2000 Standard test method for film hardness by pencil test
- ISO 9227: 2006 Corrosion tests in artificial atmospheres - Salt spray tests

4.0 Concessions

In the case of a failure to conform to the requirements of this standard, 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).

A digital copy of the concession shall be filed with JCB Standards department (concessions by e-mail
shall be accepted).

5.0 Pin coatings – background information

Various pin coating technologies may meet this standard. However, the general requirements of a pin
coating are as follows.

The coating shall:

- exhibit adequate toughness under standard JCB assembly practices
- provide adequate long-term corrosion protection
The coating shall not:
- mechanically degrade the performance or the strength of the pin
- degrade the wear characteristics of the pin/bearing system in which the pin is installed
Coatings may be organic or metallic.

Coating processes typically consist of a pre-treatment and a final coating. The final coating typically
falls into one of the following categories:
- Electrocoating (also referred to as electro deposition, electrophoretic deposition or electro
painting), is an organic finishing process that uniformly applies thin-film primers and one-coat
finishes to metallic substrates. Electro coating utilises an electrical current to deposit a

Prepared by: D Panni

Date 20/08/2010 Amended by: M Leeming Approved by: M Ireland
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waterborne paint onto the substrate. The process comprises of four main process steps; pre-
treating, electro coating, rinsing and baking.
- Plating is a metallic finishing process that can be either Chemical-Plating or Electro-plating.
- Spray (with or without electric charge). The coating is sprayed onto the substrate and then
cured at an elevated temperature.

6.0 Approval

Where a coating has been tested, meets the functional requirements of the standard and has a
completed Declaration Form (See Annexes B and C) then the coating will be approved for use.

Declaration forms for new coatings are to be reviewed, approved and stored by the receiving quality
department. The approving quality department should send a copy to the Standards and Legislation
department to enable the standard to be updated with new approved coatings.

Coatings which have not been qualified against this standard but for which there is sufficient field
evidence (historical use) to support their inclusion may be accepted in the list of approved coatings as a
‘non-preferred’ coating.

7.0 Functional requirements – Standard Duty coatings

7.1 Mechanical

7.1.1 Coating thickness

The surface coating thickness shall not be greater than 20μm.

7.1.2 Scratch resistance

Scratch testing shall be performed on both flat ends of the standard sample pin (clause 10.0) in
accordance with BS EN ISO 2409. 1mm spacing shall be used. Class ‘0’ is required for pass criteria, with
0% removed.

7.1.3 Impact performance

The pin flat face shall undergo three off aggressive impacts with a 10lb copper hammer, swung at an
angle of 90° to the horizontal. A testing frame for this purpose is available with JCB Research. There
shall be no visible delamination or penetration of the coating.

7.1.4 Coating hardness

The pencil hardness of the coating on the standard test pin (clause 10.0) shall be ascertained in

Prepared by: D Panni

Date 20/08/2010 Amended by: M Leeming Approved by: M Ireland
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accordance with ASTM D 3363. The scratch hardness shall be a minimum of 2B.

7.1.5 Wear performance

The coating on the standard test pin (clause 10.0) shall withstand six rubs with a force of 50N, using
P400 emery paper. This shall not penetrate the coating to the substrate.

Degradation of the coating in service shall not produce wear debris which can accelerate wear of the
pivot bearing or the pin.

7.1.6 Endurance performance (optional at discretion of end-user)

A full set of pins shall complete a 1000 hour endurance test on a BHL (3CX, 4CX or equivalent). The pin
shall be greased at the service intervals stated in the operator handbook. On completion of the test the
pin and bearing shall be inspected. There shall be no signs of excessive wear, corrosion or other
degradation.

7.1.7 Pin hardness

The hardness of the pin shall be checked to ensure that the coating process does not adversely affect it.

The coating should be abrasively removed from the surface. This shall be done manually using emery
paper. Hardness of the pin shall meet the requirements defined in JCB standard 1006/0001.

7.1.8 Hydrogen embrittlement

Pins shall be free from the detrimental effects of hydrogen embrittlement, or other factors which result
in detrimental embrittlement. If cleaning or plating methods are used which could lead to hydrogen
absorption, then in-process control shall be conducted such that hydrogen embrittlement is not
detrimental.

7.2 Corrosion and chemical resistance

7.2.1 Salt spray

The standard test pin (clause 10.0) subjected to the impacts defined in 7.1.3, will undergo a 250 hour
salt spray test to ISO 9227. There shall be no additional cross-scribing or damage to the pin coating.
Zero corrosion is permitted in the two 25% zones, as shown in Figure 1.

Prepared by: D Panni

Date 20/08/2010 Amended by: M Leeming Approved by: M Ireland
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25% 50% 25%

Figure 1

7.2.2 Oil immersion

Both flat ends of the standard sample pin (clause 10.0) shall be cross-scored in accordance with BS EN
ISO 2409. The pin shall then be immersed in hydraulic oil for 2 hours at a temperature of 95°C. There
shall be no delamination or visual degradation.

7.2.3 Detergent immersion

Both flat ends of the standard sample pin (clause 10.0) shall be cross-scored in accordance with BS EN
ISO 2409. The pin shall then be immersed in a 10% detergent concentration for 24hrs. There shall be no
delamination or visual degradation.

7.3 Appearance

7.3.1 Colour
Standard Duty coatings shall be black.

Heavy Duty coatings shall be grey.

7.3.2 Uniformity of coating

The application of the coating shall be such that no external surfaces are left un-coated. It is permissible
for there to be ‘dull’ areas on the coating, resulting from supporting the pin during application of the
coating, where the coating is thinner than on the majority of the pin surface.

The ‘dull’ areas may only appear in the central 50% of the pin length, as illustrated in Figure 1.

Jigging marks shall be no greater than 3mm wide.

No touch or jigging marks shall be present on visual surfaces on the component.

Prepared by: D Panni

Date 20/08/2010 Amended by: M Leeming Approved by: M Ireland
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7.3.3 Surface defects

Coating shall not entrain any visual surface defects when inspected in light with a minimum of 1,000 lux
at 0.5m.

8.0 Functional requirements – Heavy Duty coatings

Functional requirements for the Heavy Duty coating shall be as per the Standard Duty Pin (clause 7.0)
except the following clauses shall apply:

8.1 Wear performance

The pin coating shall withstand reciprocating sliding wear testing (SRV Testing) under the following test
conditions: 20Hz, 2-4mm stroke, 150N load applied to a 10mm diameter indenter. The coating shall
demonstrate a dynamic coefficient of friction of <0.12 for a minimum of 10 minutes. The test shall be
carried out on a flat test coupon.

8.2 Endurance testing (optional at discretion of end-user)

A full set of sample pins shall complete a 1000 hour endurance test on a Heavy-Line Wheeled Loader.
The pin shall be greased at the service intervals stated in the operator handbook.

On completion of the test the pin and bearing shall be inspected. There shall be no signs of excessive
wear, corrosion or other degradation.

9.0 General requirements

9.1.1 Shipping and delivered condition

Production parts shall be shipped to JCB in a manner which prevents damage. Parts shall comply with
the requirements of this standard in the as delivered line side condition.

9.1.2 Touch-up
The coating shall be suitable for over-coating in the case of damage with an air drying paint. The
coating supplier shall advise generic painting technology which is suitable for over-coating.

9.1.3 Process control

All process stages during the processing of pins shall be controlled via statistic process control
methods, with documentation retained for a minimum period of 2 years.

Prepared by: D Panni

Date 20/08/2010 Amended by: M Leeming Approved by: M Ireland
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10.0 Standard pin sample for functional testing

Tests shall be carried out on standardised pivot pin sample JCB Part Number 332/F6803.

11.0 Drawing requirements

New and revised drawings released after issue 3 of this standard should call up a preferred coating.

Drawings that reference this standard shall include the following wording:

“Finish coat to STD00045 – Standard Duty”

or

“Finish coat to STD00045 – Heavy Duty”

Prepared by: D Panni

Date 20/08/2010 Amended by: M Leeming Approved by: M Ireland
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Annex A – Approved coatings

Coating name Duty Supplier Approval Status

TriChem 3800 Standard Surface Technology Meets this standard Preferred
E-Coat Standard Profin Meets this standard Preferred
Armourcote 5700 Heavy Surface Technology Meets this standard Preferred
Rocol 1PX1 Heavy EM Coatings Historic approval STD 9994/0500 refers Non-Preferred

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Date 20/08/2010 Amended by: M Leeming Approved by: M Ireland
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Annex B – Declaration form – Standard Duty coating

Note: The forms in this annex are available as templates alongside this document.

Supplier Name Address

Process trade
name
Process type
(i.e. e-coat,
e-plate, plating)
Dry film Upper
thickness limits Lower

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Date 20/08/2010 Amended by: M Leeming Approved by: M Ireland
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Operational
process

(Declaration form - Standard Duty coating, continued)

Applicable Performance requirement Acceptance criteria Result achieved Result
standard (Pass / Fail)
clause
7.1 Mechanical
7.1.1 Coating thickness <20 microns
7.1.2 Scratch resistance Class ‘0’
0% removed
7.1.3 Impact No delamination or penetration
of the coating
7.1.4 Coating hardness 2B minimum scratch hardness
7.1.5 Wear performance Std Duty - No penetration to
substrate

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Date 20/08/2010 Amended by: M Leeming Approved by: M Ireland
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7.1.6 Endurance performance 1000 hours

(optional at discretion of
end-user)

7.1.7 Pin hardness Hardness of the pin shall meet

the requirements defined in JCB
Std 1006/0001
7.1.8 Hydrogen embrittlement No adverse effects on
performance of pin
7.2 Corrosion and chemical resistance
7.2.1 Salt spray 250 hours
7.2.2 Oil immersion No delamination or visual
degradation
7.2.3 Detergent immersion No delamination or visual
degradation
7.3 Appearance
7.3.1 Colour Black
7.3.2 Uniformity of coating no external surfaces are left un-
coated
7.3.3 Surface defects No surface defects
9.0 General
9.1.1 Shipping and delivered
condition
9.1.2 Touch-up Yes/No
9.1.3 Process control Yes/No

Certified as meeting the performance requirements by:

Supplier Name: JCB
Signed Date: Signed Date:
Print Name Print Name

Annex C – Declaration form – Heavy Duty coating

Note: The forms in this annex are available as templates alongside this document.

Supplier Name Address

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Date 20/08/2010 Amended by: M Leeming Approved by: M Ireland
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Process trade
name
Process type
(i.e. e-coat,
e-plate, plating)
Dry film Upper
thickness limits Lower
Operational
process

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Date 20/08/2010 Amended by: M Leeming Approved by: M Ireland
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(Declaration form – Heavy Duty coating, continued)

Applicable Performance requirement Acceptance criteria Result achieved Result
standard (Pass / Fail)
clause
7.1 Mechanical
7.1.1 Coating thickness <20 microns
7.1.2 Scratch resistance Class ‘0’
0% removed
7.1.3 Impact No delamination or penetration
of the coating
7.1.4 Coating hardness 2B minimum scratch hardness
8.1 Wear performance Heavy Duty – SRV Test

7.1.6 Endurance performance 1000 hours

(optional at discretion of
end-user)

7.1.7 Pin hardness Hardness of the pin shall meet

the requirements defined in JCB
Std 1006/0001
7.1.8 Hydrogen embrittlement No adverse effects on
performance of pin
7.2 Corrosion and chemical resistance
7.2.1 Salt spray 250 hours
7.2.2 Oil immersion No delamination or visual
degradation
7.2.3 Detergent immersion No delamination or visual
degradation

7.3 Appearance
7.3.1 Colour Grey
7.3.2 Uniformity of coating no external surfaces are left un-
coated
7.3.3 Surface defects No surface defects
9.0 General
9.1.1 Shipping and delivered
condition
9.1.2 Touch-up Yes/No
9.1.3 Process control Yes/No
Certified as meeting the performance requirements by:

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Date 20/08/2010 Amended by: M Leeming Approved by: M Ireland
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Supplier Name: JCB

Signed Date: Signed Date:
Print Name Print Name

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Date 20/08/2010 Amended by: M Leeming Approved by: M Ireland
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Prepared by: D Panni

Date 20/08/2010 Amended by: M Leeming Approved by: M Ireland