JCB EcoMAX Engine Installation Manual
Page 60 of 64 320/A9164-1 © JCB Power Systems Ltd.
18.9.1 Hoses relating to Tier4Final / Stage 4 engines (SCR system heating/cooling)
The routing of SCR lines including connection from one line to another is critical, both to ensure that
the correct parts are controlled as required but also to avoid risk of air locks impacting system
performance. In some cases the ECU diagnostics can take many hours to find issues, so it is essential
to ensure the correct assembly.
Ideally coolant lines will be poka-yoke by design. However this is not always practicable. In such
cases fixtures, care points and SoP should be constructed in such a manner as to prevent errors in
machine build.
18.9.2 CCV hoses
In most cases the CCV system is installed on the engine by JCB, although by exception the engine
may be shipped with fittings to support a chassis mounted CCV filter. In most cases the outlet pipe
from the CCV system must be installed at the OEM in order to ensure optimal outlet from a machine
perspective.
Assembly of the hose must consider the following:
- Pipe routing should be a continuous fall with no kinks or restrictions.
- Outlet must not be obstructed by other components; any retaining chassis clips should be properly
positioned and securely fastened.
- Hose clamps must be correctly positioned along the parallel section of the CCV hose spigot, not
twisted, and correctly torqued.
18.10 Fluids
Fluids used should be as per the specification defined in the installation manual. Fluids should be
stored and handled in such a way as to minimise water or build-up of debris. Tanks should be
maintained and regularly inspected, and regular sampling is recommended to monitor and maintain
the quality of fluids being put into the engine. It should be noted that coolant and particularly Diesel
Exhaust Fluid (DEF) have shelf lives. A suitable FIFO system is required to ensure that the machine
can reach at least first service (or DEF refill) before these fluids reach their expiry date.
Diesel fuel should pass through a filter (rating not greater than 100 microns) and water separator prior
to being used for machine first fire.
Diesel fuel types and limitations vary by engine type and are available from the respective Service
Manual. Care is required at machine assembly to ensure that fuel is of the correct type for the territory
to which the machine will be despatched. For example, low temperature fuel may be required if the
next stop for the machine is the US mid-west in winter.
DEF / Ad blue must be kept in the temperature range as recommended by the manufacturer (typically
between 5°C and 30°C) so as to maintain its shelf life..
NOTE: Under no circumstances should fuel be poured into a new filter; it is likely that dirty fuel will fall
into the clean side of the filter. This will increase opportunity for engine damage and risk early life
failures.
18.11 Remote Oil Filter Options
Is most common for the engine oil filter to be engine mounted, although options may exist for remote
mount for installations where side access is impractical. In such cases, hydraulic hoses and a remote
filter assembly will be either supplied by JCB, or designed by the engine customer in liaison with the
JCB Applications Engineer.
Incorrect assembly of these parts can lead to issues ranging from poor serviceability to a delay or
even failure to build oil pressure. The latter would lead to early engine failure. Thus it is important that
the remote oil circuit be correctly installed.
Hoses fitted to agreed specification and routing, with no twists or kinks.
Hose clamping in appropriate location and to agreed standard.
Tightening torques observed and any gaskets correctly installed.
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