jcb EcoMAX - OEM Process; Introduction; Engine Storage; Other Component Storage

JCB EcoMAX Engine Installation Manual
Page 56 of 64 320/A9164-1 © JCB Power Systems Ltd.
18. OEM Process
18.1 Introduction
The purpose of this section is to provide guidance to the machine manufacturing team relating to the
appropriate handling and installation of a JCB engine into a machine or vehicle. This is not intended to
replace the formal PFMEA process, rather to inform it and to provide pointers that will help avoid
potential issues.
In following the guidance in this document, the OEM installer should benefit from improved assembly
line safety, reduced risk of damage to engine or machine, and improved reliability and repeatability of
the equipment shipped to the end user.
18.2 Engine Storage
The following guidelines should be followed for the shipment and storage of completed engines:
- Engines should be stored in the as-delivered packaging, under dry conditions with relative humidity
in the range 20 to 40%.
- Capping should remain in place on all connections
- Ideally temperatures should be controlled within 10°C to 25°C, and relative humidity between 20%
and 40%.
- Wet and corrosive conditions must be avoided
- Maximum storage period should not be exceeded, typically this is six months.
If the engine is to be stored for more than 4 weeks, it should be thoroughly checked over prior to
installation to ensure that there is no tendency for engine actuators (turbo or EGR) to stick.
If stored for more than six months, the engine must be cranked over following the procedure for
engine storage as laid out in the relevant engine Service manual.
18.3 Other Component Storage
Dress items should be stored in a similar way to the engine, i.e. with caps in place and in a dry and
non-corrosive environment. Any transport packaging should remain in place. If decanting to alternative
storage, care must be taken to ensure that no damage can occur.
Care should be taken to ensure that electrical items such as ECU’s sensors are not dropped or stored
in a manner that could lead to them being crushed together. Storage and handling should ensure
components are maintained at a minimum distance of 5mm apart at all times.
Fuel system components such as filters and water separators should be handled in such a way as to
avoid damage in the form of dents or scratches as this can lead to customer complaint.
18.4 Lifting / Handling
Engine lifting eyes are specified to support the mass of the engine and reasonable engine-mounted
PTO mass (up to 50kg) and have been tested in accordance with HSE guidelines. The following
should be considered mandatory:
- Always use a spreader bar in an assembly environment, refer to figure 4.1. Length of bar should be
550mm internal length (+/-0.8mm), or otherwise be agreed with JCB Power Systems.
o For 4.4/4.8 litre engines, the JCB part number for the service lifting spreader bar is 892/01382
.
- When refitting lifting eye brackets, ensure both surfaces of the mating joint are clean and free from oil
or grease.
- Check the eye to ensure that the part is free from any defect. If in doubt replace the part.
- When fitting bolts, ensure they are clean and free from debris or damage. Fasteners may be lightly
oiled but not greased.
- Ensure the correct type, grade and length of bolt is always used.
- Tightening torque specifications must be followed.
- Engines should be kept level in their crankshaft axis during lifting.
- Engines should not be left hanging for extended periods.