JCB EcoMAX Engine Installation Manual
© JCB Power Systems Ltd. 320/A9164-1 Page 21 of 64
7.2 Installation of the Fuel System
7.2.1 Fuel Tank
The OEM must install the fuel tank in a position between 0.7 m above the engine and 0.7 m
below the engine (defined as the fuel outlet position in the tank to the fuel inlet position on
the engine). The fuel tank must also incorporate a drain plug to allow draining and flushing of
the tank to remove sediment and water that typically build up in the fuel tanks of off-highway
equipment.
Install the fuel feed to the engine pipe centrally inside the fuel tank, at a height above the
bottom of the tank so that 5% of the tank’s volume lies below the bottom of the suction pipe
with the machine on a flat and level surface. This makes sure that the fuel feed pipe does not
become blocked and water ingress is reduced to the fuel filter and sedimenter.
Fuel tanks must ideally be of 1:1 aspect ratio. If possible, avoid shallow tanks. If a shallow
tank is unavoidable, the risk of fuel starvation when the machine is inclined can be reduced
by fitting baffles in the tank.
Install the return pipe to avoid the return fuel being directly drawn back into the fuel feed pipe
by separating the two by approximately 300 mm and by baffling.
Vent the tank to prevent the formation of a vacuum as fuel is used up. The vent must not
allow ingress of dirt or water to the fuel tank. A vented fuel tank caps can be used.
Install the fuel tank so that any relative movement of the mounting locations is not
transmitted into the tank structure and that stresses in the tank are within the material’s
capabilities when the full tank is subjected to operating loads.
Install a label permanently stating: “ULTRA LOW SULFUR FUEL ONLY” in a clearly visible
location near to the fuel filler cap by the machine manufacturer on all series built equipment
that is to enter the US Commerce. (40 CFR 1039.135(e))
7.2.2 Fuel Feed Pipe (Suction Pipe)
Fuel feed pipe material must be resistant to fuel oil and from materials that can operate
safely up to 100ºC and tolerate the inlet depression for the engine.
Connection to the engine is made using quick release connectors as described in SAE
standard J2044.
Use an internal hose diameter of 8 mm to allow for a fuel flow rate of up to 100 L/hour.
The hose and pipework must give a smooth flow to the engine without any sharp bends or
rising loops. You need to clip the hose and pipework at intervals to prevent chafing and to
avoid fatigue failures due to resonant vibration.
7.2.3 Injector Leak Off Return to Fuel Tank
Connection from the engine is made using a quick release connector, as described in SAE
Standard J2044.
This pipe must conform to the requirements of the fuel feed pipe. With exception that the fuel
return hose must have an internal diameter of at least 6.0 mm and must follow the most
direct route back to tank, avoiding sharp bends and restrictive adaptors. Avoid close
proximity of fuel pipes and hoses to hot surfaces such as exhaust pipes.
The return line must feed back into the tank a minimum of 300 mm away (Ref 7.2.1) from the
fuel supply outlet and under the level of the fuel. See the Technical Data Sheet for the
maximum pressure that can be seen in the fuel return line.
To Next Page
Loading...
