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jcb EcoMAX Installation Manual

jcb EcoMAX Installation Manual

Engine tier 4/stage iv industrial power unit
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JCB EcoMAX Engine Installation Manual
JCB Tier 4/Stage IV Industrial
Power Unit
Installation Manual
©
JCB Power Systems Ltd.
320/A9164-1
Page 1 of 64

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Summary of Contents for jcb EcoMAX

  • Page 1 JCB EcoMAX Engine Installation Manual JCB Tier 4/Stage IV Industrial Power Unit Installation Manual © JCB Power Systems Ltd. 320/A9164-1 Page 1 of 64...
  • Page 2 This manual contains original instructions, verified by the manufacturer (or their authorised representative). The original language is British English. Copyright 2016 © JCB Power Systems Ltd. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB Power Systems Ltd.

  • Page 3: Table Of Contents

    JCB EcoMAX Engine Installation Manual Contents Safety ..........................7 Safety Notices ...................... 7 General Safety ..................... 8 Lifting Safety ......................9 Installation ........................11 Engine Model ..................... 11 Application ......................11 Using this Installation Manual ................11 Emissions Related Installation Instructions ............12 Cooling System ......................
  • Page 4 JCB EcoMAX Engine Installation Manual Front End Accessory Drive (FEAD) ..............28 9.3.1 Torsional Vibration ................28 Fluids and Ambient Temperature: Fuel, Lubricant and Coolant ......29 10.1 Overview 29 10.2 Fuel 10.3 Lubricant 29 10.4 Dipsticks 30 10.5 Coolant 30 Hostile Environment Precautions ................
  • Page 5 JCB EcoMAX Engine Installation Manual 13.6.1 Operator Interface & Warnings ............38 13.7 Engine Control Devices ..................40 13.7.1 Engine Throttles ................. 40 13.7.2 Engine Fixed Speed Control (EFSC) ..........42 13.7.3 Low Fuel Level Switch ................ 43 13.7.4 Electric Lift Pump ................43 13.7.5...
  • Page 6 JCB EcoMAX Engine Installation Manual 18.9.2 CCV hoses ..................60 18.10 Fluids 18.11 Remote Oil Filter Options .................. 60 18.12 Wiring & Sensors ....................61 18.13 FEAD Including Fan Drive ................. 61 18.14 Machine Variant Coding ..................61 18.15 Engine Finish / Paint ..................62 18.16 Engine First Start ....................

  • Page 7: Safety

    JCB EcoMAX Engine Installation Manual Safety Safety Notices There are safety notices in this manual. Each notice starts with a signal word. The meanings of the signal words are given below. The safety alert system also helps to identify important safety messages in this manual and on the engine.

  • Page 8: General Safety

    JCB EcoMAX Engine Installation Manual General Safety Clothing You can be injured if you do not wear the correct clothing. Loose clothing can get caught in the machinery. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and personal jewelry.

  • Page 9: Lifting Safety

    JCB EcoMAX Engine Installation Manual Lifting Safety WARNING Severe injury can occur if faulty or incorrect lifting equipment is used. Lifting equipment used must be in good condition and suitably rated for the lift. Make sure that the lifting tackle complies with the local regulations.
  • Page 10 JCB EcoMAX Engine Installation Manual Small Cooling Pack IPU Spreader Bar Required (Distance between chains): 895mm Lifting Eye Horizontal Height Variation: 120.8mm © Page 10 of 64 320/A9164-1 JCB Power Systems Ltd.

  • Page 11: Installation

    Using this Installation Manual This manual is arranged to give a good understanding of the JCB EcoMAX Industrial Power Unit and guidance on its safe integration into equipment. The main purpose of the manual is to help engineers and designers specialising in installing JCB EcoMAX engines into equipment.

  • Page 12: Emissions Related Installation Instructions

    JCB EcoMAX Engine Installation Manual Emissions Related Installation Instructions Failing to follow these instructions when installing a certified engine in a piece of non-road equipment violates federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act If you install the engine in a way that makes the engine’s emission control information label...

  • Page 13: Cooling System

    Fans are a significant source of Off-Highway equipment noise. Introduction With an IPU the JCB EcoMAX engine is cooled using the supplied liquid cooling system to maintain the correct operating temperature. The engine installer must ensure the cooling performance of the unit is maintained when installed in the finished equipment. There are maximum limits for coolant and lubricating oil temperature which must not be exceeded.

  • Page 14: Fan Design

    IPU products however fitting a puller fan will increase the temperature around the engine bay and aftertreatment components and could risk causing temperature limits for such components to be exceeded. For further advice and guidance consult your JCB EcoMAX dealer, or JCB Power Systems Applications department.

  • Page 15: Intake System

    JCB Power Systems to obtain a quotation to develop a suitable calibration for an alternative induction system arrangement.

  • Page 16: Exhaust System

    If you begin to feel drowsy, stop the engine at once and get into fresh air. NOTE: Tier 4 / Stage IV engines must also refer to JCB EcoMAX Emissions Related Installation Instructions. For more advice, contact JCB Power Systems Applications department.

  • Page 17: Performance

    JCB EcoMAX Engine Installation Manual Performance The OEM must test the exhaust system to make sure it meets performance requirements for backpressure, vibration levels, turbocharger mounting loads (see Technical Data Sheet). 6.2.1 Backpressure The exhaust backpressure, measured on a straight section of pipe close to the turbocharger outlet, must be within the minimum and maximum range specified limits shown in the Technical Data Sheet for the specific engine rating.

  • Page 18: Exhaust Mounting

    The NOx sensor must not be removed from the stub pipe. Welding this stub pipe is also not approved. The JCB flange, which is supplied loose, may be welded and then bolted, with the supplied gasket, to the stub pipe.

  • Page 19: Water Protection

    JCB EcoMAX Engine Installation Manual 6.3.5 Water Protection The aftertreatment system must be protected from water ingress up the exhaust pipe as this may freeze and damage the catalyst. Protection of the NOx sensors from water and other contamination is also mandatory to avoid premature damage to the components.

  • Page 20: Fuel System

    The fuel system included on the JCB EcoMAX engine meets the required legislated emission standards. The engine needs a supply of clean fuel and a return line back to the fuel tank. The system is designed to allow high bypass fuel flow and can deliver full flow return to tank.

  • Page 21: Installation Of The Fuel System

    JCB EcoMAX Engine Installation Manual 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).

  • Page 22: Fuel Filters And Water Separators

    Water separation requirements vary depending on fuel quality. If the fuel does not comply with EN590 you may need to install an additional water separator. JCB Power Systems Applications Department can give advice on expected regional fuel conditions.
  • Page 23 JCB EcoMAX Engine Installation Manual See Figure 3 for recommended fuel filtration schematic. Figure 3: Example fuel filtration schematics for common rail fuel injection systems © JCB Power Systems Ltd. 320/A9164-1 Page 23 of 64...

  • Page 24: Fuel Temperature

    It is possible to install an electric heater adjacent to the engine mounted fuel filter for extreme temperature situations. NOTE! Refer to JCB Power Systems Applications department for more advice. 7.2.6 Fuel Lubricity Additive Dosing Filters A lubricity additive dosing filter unit is available for use with low lubricity fuels.

  • Page 25: Ipu Mounting And Noise Reduction

    JCB EcoMAX Engine Installation Manual IPU Mounting and Noise Reduction WARNING! Poor engine mount design may lead to excessive operator environment noise and vibration levels resulting in personal injury. NOTICE! Poor engine or powertrain mount design may cause engine damage.

  • Page 26: Power Take-Offs

    Operating the engine PTOs beyond their design limits may result in engine damage or personal injury. The four Power Take-Off (PTO) points are provided on the JCB EcoMAX engine, as shown in Figure 4. These PTO points and maximum loadings are as follows: PTO No.

  • Page 27: Performance Of Power Take Offs

    PTO No. 3 has been evaluated successfully with cast iron hydraulic pumps with no additional support and a calculated bending moment of up to 33 Nm. Please consult JCB Power Systems Applications department for specific information and advice. ©...

  • Page 28: Front End Accessory Drive (Fead)

    9.3.1 Torsional Vibration The JCB EcoMAX engine gives generally refined torsional vibration characteristics. The crank is exceptionally stiff giving very low levels of wind-up between the crank pulley and the flywheel. Torsional vibrations must not present a problem for transmissions (manual and torque converter) and hydrostatic pumps typically used in construction equipment and attached to PTO No.

  • Page 29: Fluids And Ambient Temperature: Fuel, Lubricant And Coolant

    You must select fluids appropriate for the engine and the climatic conditions in which the equipment is to be used. The JCB EcoMAX engine has been developed to operate using particular quality fuels, lubricants and coolant. If you use other fluids then you must consult JCB Power Systems Applications department confirm that they are acceptable.

  • Page 30: Dipsticks

    Dipsticks 10.4 The dipstick is located on the left-hand side of the JCB EcoMAX engine, as shown in Figure 6. You must make sure that the dipstick is accessible to the equipment operator. There are various dipstick options available. Please contact JCB Power Systems Applications department for more information.

  • Page 31: 11. Hostile Environment Precautions

    JCB EcoMAX Engine Installation Manual 11. Hostile Environment Precautions The JCB EcoMAX engine has been designed for use in a wide range of conditions. Normal environments are described as temperate and tropical, and are defined in terms of the following: Temperate - Ambient temperatures between -20ºC and +40ºC...

  • Page 32: 12. Electrical System

    12 V system, all components must be capable of safe operation at voltages up to 18 V. For a 24 V system the limit is 36 V. (See JCB standard 00140, section 12). A minimum of 6.5 V must be seen at the ECU to avoid ECU brown out.

  • Page 33: Electromagnetic Compatibility

    JCB EcoMAX Engine Installation Manual Electromagnetic Compatibility 12.4 Electromagnetic emissions for the electrical system of the machine must be tested when it is applicable to the application. NOTE: It is the manufacturers’ responsibility to make sure that the machine conforms to the overall EMC limit.

  • Page 34: Battery Isolators

    NOTE: The battery isolator must not be used to shut down the machine. Starter Motor 12.7 The geared motor on the JCB EcoMAX engine is rated at 4.2 kW for the 12 V and 24 V systems. The starter motor’s cranking speed varies depending on a range of different conditions such as ambient temperature, parasitic loads and available battery charge.

  • Page 35: Electrical Load

    12.10 All wiring in the engine bay must have insulation that can withstand temperatures up to 150°C (Class D wiring to ISO Standard 6722, JCB Standard 7000/3400). The wiring must also be resistant to Diesel, moisture and lubricating oil. Battery cables must be as short as possible. The minimum recommended cross-section is...

  • Page 36: 13. Electrical Control & System Integration

    13.1 A Delphi DCM Common Rail Engine Control Unit (ECU) has been installed onto the JCB EcoMAX engine to manage the combustion process in line with the requirements of Stage 4 / Tier 4 emissions regulations. The ECU has two connectors:...

  • Page 37: Control Unit Power Strategy

    The ECU requires a 6 V to 16 V supply. It must not be connected to a 24 V equipment supply. A 24 V to 12 V converter is available from JCB Power Systems Ltd for use on equipment with a 24 V electrical system.

  • Page 38: Required Operator Warnings

    CAN Bus, you need to make a ‘splice’ into the harness as close to the ECU as possible to accommodate the CAN termination resistor. CAN terminating resistors are available from JCB Power Systems in either 2 way; JCB part no. 7212/0059 or 3 way; JCB part no.727/00002 or 727/00003.
  • Page 39 JCB EcoMAX Engine Installation Manual Figure 7: Tier 4 Final Inducement DEF Availability Figure 8: Tier 4 Final Inducement Strategy Other © JCB Power Systems Ltd. 320/A9164-1 Page 39 of 64...

  • Page 40: Engine Control Devices

    CAN enabled dash controller or by a TSC1 pedal which sends the speed request. Further details can be seen in the electronic integration manual 320/A9059. Please contact your JCB EcoMAX Dealer, or JCB Power Systems Applications department, for more information and advice.
  • Page 41 JCB EcoMAX Engine Installation Manual Figure 10: Electronic throttle pin-outs © JCB Power Systems Ltd. 320/A9164-1 Page 41 of 64...

  • Page 42: Engine Fixed Speed Control (Efsc)

    This system needs electrical switches to be connected to three pins on the engine ECU. This feature cannot be used in conjunction with two twin track control devices. Please contact your JCB Power Systems Applications department for more information and advice. ©...

  • Page 43: Low Fuel Level Switch

    13.7.4 Electric Lift Pump The JCB EcoMAX Common Rail engine uses an electric lift pump and fuel pre filter supplied loose with the engine. This unit must not be installed on the engine but to the machine chassis as close as possible to the engine and away from significant sources of vibration.

  • Page 44: 14. Accessibility

    JCB EcoMAX Engine Installation Manual 14. Accessibility WARNING! You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job.
  • Page 45 JCB EcoMAX Engine Installation Manual Figure 12: Position of regularly accessed items on the IPU Figure 13 shows the aftertreatment components mounted to the tank module that need to have suitable access for servicing. Particular attention must be given to the removal of the filter from the supply module, DEF tank drain and the tank breather filter on the end of the breather pipe.

  • Page 46: 15. Installation Approval Limits

    Fuel return backpressure Battery voltage when cranking ECU temperature Alternator temperature The limits listed are shown in the appropriate JCB EcoMAX Technical Data Sheet. Exhaust After treatment Installation and Operation Limits 15.2 Stub pipe length and weight Diesel exhaust fluid (DEF) bulk temperature Vibration (as yet undefined) The limits listed are shown in the appropriate JCB EcoMAX Technical Data Sheet.

  • Page 47: 16. Delegated Assembly Approval

    For engines that are to enter the US or EU the delegated assembly must be adhered to. Deviation from the design is not permitted. The EcoMAX T4 IPU is supplied with all the delegated assembly components mounted either to the engine or the tank module. If the engine and tank module are not installed into a machine, both the engine and the tank module must be shipped on a single pallet to ensure that the delegated assembly is retained.

  • Page 48: Scr System

    JCB EcoMAX Engine Installation Manual SCR System 17.3 17.3.1 Schematic Illustration of the SCR System Figure 14: SCR system 17.3.2 Component Overview DEF Solution DEF (DIN70070) is an aqueous solution of 32.5% urea to 67.5% deionised water with a freezing point of -11°C. If stored above 30°C for prolonged periods it starts to prematurely degrade, increasing its corrosive properties.
  • Page 49 JCB EcoMAX Engine Installation Manual correct operating temperature. At start up, the sensor is operated with a low heating power to protect it from damage which could be caused by contact with condensed water droplets. Once the risk of exposure to condensed water can be ruled out, the element is fully heated and prepared for operation.

  • Page 50: Installation Configurations

    The protection against rocks, debris and splash water for each of the aftertreatment components needs to be assessed by JCB / or trained distributers in the final application. Diagram showing permissible relative position of the DEF Tank Module to the IPU is shown in Figure 15.

  • Page 51: Installation Of Hydraulic Lines And Connectors

    JCB EcoMAX Engine Installation Manual Figure 15: Relative height position of tank module feet to IPU engine feet Figure 16: Dosing module siphon requirement 17.3.5 Installation of Hydraulic Lines and Connectors Heated Lines To guarantee the functionality of the SCR system at freezing temperatures, all DEF hoses must be heated and insulated.
  • Page 52 JCB EcoMAX Engine Installation Manual For the fastest defrost times, the line connectors must be straight, heated and heavily insulated. The use of PA12 (polyamide 12) is recommended as a suitable material for DEF lines. Pressure Line (PL) The maximum height of the dosing module above the supply module is limited as shown in Figure 16.

  • Page 53: Def Tank

    JCB EcoMAX Engine Installation Manual 17.3.6 DEF Tank Tank heating and defrosting is done by a line running through the tank which is linked to the engine coolant circuit. A solenoid valve controls the coolant quantity passing through the tank.
  • Page 54 JCB EcoMAX Engine Installation Manual Figure 17: Engine side coolant connection barbs The hose barbs on the engine side of the cooling system shown in Figure 17 are suitable for the 3/8 coolant hoses supplied. The hoses should be clamped with worm drive clamps or crimp style clamps.
  • Page 55 If coolant supply is required for auxiliary equipment advice should be sought from JCB power Systems Application Engineering team. © JCB Power Systems Ltd.

  • Page 56: Oem Process

    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.

  • Page 57: Def System Handling, Control And Identification

    - Ensure that records are kept to show that engine and kits are correctly handled and installed. - Allow JCB Power Systems or their agents to periodically inspect the equipment assembly process and associated records.

  • Page 58: Fitting Engine Covers Or Installing Items To The Gear Driven Pto's

    Manufacturing Engineer. JCB’s approach is fundamentally as follows: To ensure reliability of the engine and installation it is in the interests of both JCB and the engine installer to have some common ground on assembly techniques.

  • Page 59: Attachment Of Oem Equipment To Engine (Other Than Pto)

    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.

  • Page 60: Hoses Relating To Tier4Final / Stage 4 Engines (Scr System Heating/Cooling)

    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.

  • Page 61: Wiring & Sensors

    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.

  • Page 62: Engine Finish / Paint

    Further paint processes are not preferred as a deviation from JCB’s validated procedures. If it is determined that paint is a firm requirement of the end user the following should be considered when defining the paint process: ...

  • Page 63: Final Packaging And Storage

    Dealer storage & Engine start 18.19 It is recommended that JCB equipment is restarted every 4 weeks and warmed, with all booms and rams being exercised to maintain their condition ready for sale. The engine has similar requirements, and issues may occur if the engine is left un-started for significant periods.

  • Page 64: 19. Material Specification Table

    JCB EcoMAX Engine Installation Manual 19. Material Specification Table Recommended materials Metals Highly alloyed austenitic Cr-Ni-steels and Cr-Ni-Mo-steels, for example in accordance with EN 10088-1, EN 10088-2 and EN 10088-3, or stainless steel 304, 304L, 316 and 316L in accordance with ASTM A240, ASTM A276 and ASTM A312. The outside body and baffles of the exhaust silencers/catalysts must be made from high quality steel such as DX53D + AS120.