JCB G144, G144Q, G175, G175Q, G220, G220Q, G130R, G160R, G200R Operator Manual 9811-2850

Description

• Model List:
  • G144, G144Q, G175, G175Q, G220, G220Q, G130R, G160R, G200R

• 1. Introduction
• 2. About This Manual ……………………………………………………………………………..1
• 3. Cross References ………………………………………………………………………….1
• 4. Component Identification …………………………………………………………………….2
• 5. Dataplate ……………………………………………………………………………………..3
• 6. Installation
• 7. Unpacking …………………………………………………………………………………………5
• 8. Site Installation ………………………………………………………………………………….6
• 9. Routine Maintenance
• 10. Service Requirements ………………………………………………………………………..8
• 11. Health and Safety ………………………………………………………………………………9
• 12. Lubricants …………………………………………………………………………………….9
• 13. Battery ………………………………………………………………………………………. 11
• 14. First Aid – Electrolyte …………………………………………………………………… 11
• 15. Service Schedules ……………………………………………………………………………13
• 16. Introduction …………………………………………………………………………………13
• 17. How to Use the Service Schedules ………………………………………………..13
• 18. Service Schedule Checklist …………………………………………………………..14
• 19. Battery ……………………………………………………………………………………………15
• 20. Connection and Disconnection (battery arrangement) ………………………15
• 21. Activating Dry Batteries ………………………………………………………………..15
• 22. Charging the Battery ……………………………………………………………………15
• 23. Battery Maintenance ……………………………………………………………………16
• 24. Battery Life …………………………………………………………………………………16
• 25. Coolant …………………………………………………………………………………………..17
• 26. Checking and Adding Coolant ……………………………………………………….17
• 27. Engine Oil ……………………………………………………………………………………….18
• 28. Pre Start Checks ………………………………………………………………………………19
• 29. Cleaning …………………………………………………………………………………………20
• 30. JCB Digital Control Panel
• 31. Introduction ……………………………………………………………………………………..21
• 32. Top Level Screen ……………………………………………………………………………..22
• 33. Application Modes ……………………………………………………………………………23
• 34. Standard Operation ……………………………………………………………………..23
• 35. ATP7 Operation …………………………………………………………………………..23
• 36. Start and Stop the Machine ……………………………………………………………….24
• 37. Manual Mode ………………………………………………………………………………24
• 38. Manual ATP7 Operation (when configured for MCB-GCB application) ..25
• 39. Automatic Mode ………………………………………………………………………….26
• 40. Alarm List ………………………………………………………………………………………..27
• 41. Accessing List …………………………………………………………………………….27
• 42. Changing Method of Voltage Calculations ……………………………………………28
• 43. Information Screens …………………………………………………………………………29
• 44. Top Level Screen …………………………………………………………………………29
• 45. Mains Overview Screen (only when enabled) ………………………………….29
• 46. Generating Set Overview Screen …………………………………………………..29
• 47. Mains Value Details ……………………………………………………………………..30
• 48. Generator Peak Currents ……………………………………………………………..30
• 49. Analogue Inputs ………………………………………………………………………….30
• 50. Digitial Inputs and Outputs ……………………………………………………………30
• 51. Real Time Clock ………………………………………………………………………….31
• 52. Counters …………………………………………………………………………………….31
• 53. Maintenance Call …………………………………………………………………………31
• 54. Main Menu ………………………………………………………………………………………32
• 55. Basic Main Menu …………………………………………………………………………32
• 56. Basic Main Menu List …………………………………………………………………..32
• 57. Setting the Clock ……………………………………………………………………………..34
• 58. Earth Leakage Relay (Option) ……………………………………………………………35
• 59. Possible Alarms ……………………………………………………………………………….36
• 60. Status Messages ……………………………………………………………………………..38
• 61. Alternator
• 62. Safety Precautions …………………………………………………………………………..40
• 63. Introduction ……………………………………………………………………………………..41
• 64. Designation ………………………………………………………………………………..41
• 65. Installation ………………………………………………………………………………………42
• 66. Lifting …………………………………………………………………………………………42
• 67. AVR Settings And Type ………………………………………………………………..43
• 68. Protection …………………………………………………………………………………..47
• 69. Parts List …………………………………………………………………………………………48
• 70. Alternator Terminal Connections ………………………………………………………..50
• 71. Series Star ………………………………………………………………………………….50
• 72. Parallel Star ………………………………………………………………………………..50
• 73. Series Delta ………………………………………………………………………………..51
• 74. Double Delta ……………………………………………………………………………….51
• 75. Parallel Zig-Zag …………………………………………………………………………..52
• 76. Fault Finding ……………………………………………………………………………………53
• 77. Service and Maintenance ………………………………………………………………….56
• 78. Winding Condition ……………………………………………………………………….56
• 79. Winding Condition Assessment ……………………………………………………..56
• 80. Spares and After Sales Service ………………………………………………………….57
• 81. Ordering Parts …………………………………………………………………………….57
• 82. Engine – Care and Safety
• 83. Important Information ……………………………………………………………………….59
• 84. The Operator Manual …………………………………………………………………..59
• 85. Safety Warnings ………………………………………………………………………….59
• 86. Safety, Yours and Others …………………………………………………………………..60
• 87. Checklists ……………………………………………………………………………………….61
• 88. General Safety ……………………………………………………………………………61
• 89. Operating Safety …………………………………………………………………………62
• 90. Maintenance Safety ……………………………………………………………………..63
• 91. Engine – General Information
• 92. Introduction ……………………………………………………………………………………..69
• 93. Safety Instructions ……………………………………………………………………………70
• 94. Engine – Identifying the Engine
• 95. Typical Engine Identification Number ………………………………………………….71
• 96. Typical Injection Pump Identification Number ……………………………………….72
• 97. Component Identification …………………………………………………………………..73
• 98. 620 – 634 DS Engine – Viewed from the Left ……………………………………73
• 99. 620 – 634 DS Engine – Viewed from the right …………………………………..74
• 100. Engine – Operation
• 101. Basic Operation ……………………………………………………………………………….75
• 102. General ………………………………………………………………………………………75
• 103. Air Intake System ………………………………………………………………………..75
• 104. Fuel System ……………………………………………………………………………….77
• 105. Lubrication System ………………………………………………………………………80
• 106. Cooling System …………………………………………………………………………..82
• 107. Electrical System …………………………………………………………………………83
• 108. Operation ………………………………………………………………………………………..84
• 109. Daily Pre-start Check …………………………………………………………………..84
• 110. Starting ………………………………………………………………………………………84
• 111. Cold Start ……………………………………………………………………………………84
• 112. Warming up the engine ………………………………………………………………..85
• 113. Attention during operation …………………………………………………………….85
• 114. Stopping …………………………………………………………………………………….85
• 115. The Engine Stops When Running ………………………………………………….85
• 116. Coupling Additional Equipment to the Engine ………………………………….86
• 117. Lifting The Engine …………………………………………………………………………….87
• 118. Engine – Routine Maintenance
• 119. Periodical maintenance …………………………………………………………………….88
• 120. Putting Engine into Operation …………………………………………………………….89
• 121. Services to be made daily or at 10 hours intervals ………………………………..90
• 122. Check engine oil level ………………………………………………………………….90
• 123. Check coolant level ……………………………………………………………………..90
• 124. Check for leakages (fuel, oil and coolant) ……………………………………….91
• 125. Clean air filter cyclone ………………………………………………………………….91
• 126. Services to be made weekly or at 50 hours intervals …………………………….92
• 127. Check the water trap ……………………………………………………………………92
• 128. Clean-change the air filter …………………………………………………………….93
• 129. Clean the cooling system ……………………………………………………………..93
• 130. Services to be made at 500 hours intervals …………………………………………94
• 131. Change the engine oil and filter ……………………………………………………..94
• 132. Check fan belt tension ………………………………………………………………….95
• 133. Check battery fluid level ……………………………………………………………….96
• 134. Change fuel filter – Bosch ……………………………………………………………..96
• 135. Change fuel filter – CAV ………………………………………………………………..97
• 136. Change pre-filter – Stanadyne ……………………………………………………….98
• 137. Drain fuel tank …………………………………………………………………………….98
• 138. Grease coolant pump …………………………………………………………………..98
• 139. Services to be made at 1000 hours intervals ……………………………………….99
• 140. Adjust valve clearances ………………………………………………………………..99
• 141. Services to be made at 2000 hours intervals ……………………………………..100
• 142. Check and clean injectors …………………………………………………………..100
• 143. Service to be made at 4800 hours intervlas ……………………………………….101
• 144. Check turbocharger play and check that the intercooler cell is clean ..102
• 145. Services to be made every 1 year …………………………………………………….103
• 146. Change coolant …………………………………………………………………………103
• 147. Additional service and adjusting instruction ………………………………………..104
• 148. Bleed fuel system ………………………………………………………………………104
• 149. Check and adjust injection timing …………………………………………………105
• 150. Adjust low idling speed ……………………………………………………………….106
• 151. Fit cylinder Head ……………………………………………………………………….107
• 152. Check of the rubber element vibration damper ………………………………108
• 153. Before the cold season ……………………………………………………………………109
• 154. Tightening Torques ………………………………………………………………………… 110
• 155. Lubricating oil quality requirements ………………………………………………….. 111
• 156. Coolant quality requirements …………………………………………………………… 112
• 157. Fuel quality requirements ……………………………………………………………….. 113
• 158. Biodiesel Fuel …………………………………………………………………………… 114
• 159. Troubleshooting …………………………………………………………………………….. 115
• 160. Storing the engine …………………………………………………………………………. 118
• 161. After storage attention ……………………………………………………………………. 119
• 162. Engine – Technical Data and Specifications
• 163. Technical Data ……………………………………………………………………………….120
• 164. Connection and Wiring Diagrams
• 165. AC Wiring ……………………………………………………………………………………..121
• 166. DC Wiring ……………………………………………………………………………………..124
• 167. Automatic Transfer Panel 2 ……………………………………………………………..127
• 168. Automatic Transfer Panel 7 ……………………………………………………………..129
• 169. Warranty
• 170. Warranty Information ………………………………………………………………………132
• 171. Installation Access ……………………………………………………………………..132
• 172. Downtime Support ……………………………………………………………………..132
• 173. Terms and Conditions …………………………………………………………………132
• 174. JCB Technical Service …………………………………………………………………….133