jcb EcoMAX - Wiring & Sensors; FEAD Including Fan Drive; Machine Variant Coding

JCB EcoMAX Engine Installation Manual
© JCB Power Systems Ltd. 320/A9164-1 Page 61 of 64
 Correct orientation of filter housing and any additional equipment to support oil
filter drain.
NOTE: Priming of any remote oil filter circuit needs to be considered as part of the PFMEA process,
and appropriate controls put in place. In practise, this will likely mean an additional 10s period of “dead
crank” prior to starting the engine. Please see section 21.2.
18.12 Wiring & Sensors
In order to achieve the ever more stringent emissions requirements, modern engines must be fitted
with complex control systems to ensure that they are able to meet the legal requirements for the
duration of their lives. In most cases these are controlled via electrical actuators and monitored via
sensors, all linked together by a harness or harnesses. The terminals on these harnesses are often
quite sensitive to vibration, dust and water ingress and as such it is important that they are installed
correctly.
 Incoming materials should be properly checked to ensure no pins are bent or misplaced.
 Harnesses should be properly clipped or retained as per the design specification, with no
excess tension applied to any connection.
 ECU and interconnect harness should be correctly installed and fully locked on.
 Drip loops should be correctly installed to protect from water seeping into connectors.
 Any heat shielding should be correctly located and oriented
 Engine harness, if disturbed, should be moved back into the correct position
18.13 FEAD Including Fan Drive
Assembly of the belt drive is necessary to ensure the engine water pump, as a minimum, is driven. As
noted previously in this document, JCB engines are assembled in such a way as to provide maximum
flexibility at the engine customer’s assembly location. Thus items such as alternator, air conditioning
compressor and fan are required to be installed to suit the machine being built.
Assembly of the FEAD and optionally fan drive to the engine should consider the following:
 Ensure the correct components are installed to the engine to suit the machine.
 Assembly process should be suitably controlled to confirm that the correct fasteners are used
and the correct tightening torques used.
 A.C compressor connections should remain capped until the system can be connected to the
machine, and at that point the correct quantity of lubricating oil added.
NOTE: For EU sales, it should be noted that the engine as shipped is classified as “partially completed
machinery” and it is the responsibility of the engine installer to ensure that any FEAD or fan guards,
along with heat shields etc. are correctly installed. Design and assembly should be controlled in such
a way as to demonstrate safe operation for the end user and associated Service personnel.
18.14 Machine Variant Coding
In the case of electronic engines, the engine ECU is pre-programmed at the factory for parameters
such as rating, max fuelling and a large number of performance and emissions related functions.
Variant Coding is applied for all machines with common rail engines to ensure the machine has:
 Correct throttle input
 Correct interface to any machine CAN controls
 Machine serial number and other security details
The variant coding is correctly flashed prior to despatch to the OE customer. It is important that the
correct engine be installed in the correct machine type, as otherwise it will not operate as required.