JCB EcoMAX Engine Installation Manual
© JCB Power Systems Ltd. 320/A9164-1 Page 59 of 64
- D.C tools are used to ensure the correct torque and the correct numbers of fasteners are
torqued. Where snug torques are required, these are controlled in the same way.
- Different joints within a similar operation may be controlled by variation in bolt head size,
and the d.c. tool station monitors for the correct tool and provides an indication as to which
tool is required when.
- Sub assemblies are pressure tested before a component label is installed, i.e. the part
cannot be labelled unless it has passed a pressure test.
- Engine labelling and flashing are completed at the same station to ensure engine is flashed
before being labelled. Controls then relate to the label to ensure engines do not leave the
facility unless the correct software is on the ECU.
- Upon completion of the assembled engine, coolant circuit is pressure tested for integrity
prior to hot test.
- Hot test uses oil and coolant which are doped to reflect different colours under UV light.
Upon completion of hot test the engine is subjected to a UV assessment prior to final lacquer
application.
- Until lacquer is complete, the transport label is not attached, preventing unfinished product
being accidentally shipped.
The above is considered current best practise, and is subject to continual improvement. JCB
appreciate that it is not practicable to provide computer controlled assembly to a large proportion of
the world’s off highway equipment. However the above points should be considered when planning
assembly of a new machine.
18.8 Attachment of OEM equipment to engine (Other than PTO)
JCB engines are assembled on a no-faults forward basis, with d.c. tooling to both provide correct
torque and record that the torque was achieved on each fastener. Hot test and UV checks are used to
assure the quality of the engine as shipped from the Dove Valley or Ballhabgar plants.
To maintain this through to the finished machine, removal and reassembly of any existing bolted joints
are discouraged and must be agreed with JCB as part of the Application Sign Off process. In any case
where a bolted joint is disturbed a suitable control method is required to ensure the correct fastener
torque is applied and the action either marked on the bolt or otherwise recorded. For larger
manufacturers it is anticipated that this would be achieved by a similar d.c. tool to that used in the
original assembly.
Details of the assembly equipment used by JCB Power Systems may be requested, although the
company is unable to provide specific advice.
Under no circumstances should items such as remote oil drain or cast iron components be attached to
the engine without agreement from JCB on the detailed assembly process.
18.9 Coolant Hoses
Coolant connections should be designed to have a small interference under all
circumstances in accordance with DIN standards. As such there may be some difficulty for
some personnel in assembling hoses to the spigot. JCB use and have good experience with
P-80 THIX Rubber Lubricant Gel, which may be used safely as a lubricant to aid assembly
without risking hose blow-off. As with all lubricants, the material should be used in as small a
quantity as possible. It is the responsibility of the engine installer to verify that this material is
compatible with their selected hose materials, and that it meets with relevant safety
legislation. An MSDS is attached in Appendix 2.
Suitable clips are required to secure hoses to spigots. Care should be taken to ensure these
are suitably positioned along the parallel part of the spigot and not twisted. The clip should
typically be not less than 3-5mm from the end of the hose, depending upon diameter.
Where SAE quick connections are used, ensure that the retaining tabs are properly secured
upon installation.
Where possible, a vacuum fill technique is recommended for coolant filling.
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