JCB G50R, G80R, G55X, G55QX, G66X, G66QX, G88X, G88QX, G110X, G110QX, G120X, G120QX Operator Manual 9811-1870

Description

• Model List:
  • G50R, G80R, G55X, G55QX, G66X, G66QX, G88X, G88QX, G110X, G110QX, G120X, G120QX

• 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 …………………………………………………………………………………..46
• 69. Parts List …………………………………………………………………………………………47
• 70. Alternator Terminal Connections ………………………………………………………..49
• 71. Series Star ………………………………………………………………………………….49
• 72. Parallel Star ………………………………………………………………………………..49
• 73. Series Delta ………………………………………………………………………………..50
• 74. Double Delta ……………………………………………………………………………….50
• 75. Parallel Zig-Zag …………………………………………………………………………..51
• 76. Fault Finding ……………………………………………………………………………………52
• 77. Service and Maintenance ………………………………………………………………….55
• 78. Winding Condition ……………………………………………………………………….55
• 79. Winding Condition Assessment ……………………………………………………..55
• 80. Spares and After Sales Service ………………………………………………………….56
• 81. Ordering Parts …………………………………………………………………………….56
• 82. Engine – Care and Safety
• 83. Important Information ……………………………………………………………………….58
• 84. The Operator Manual …………………………………………………………………..58
• 85. Safety Warnings ………………………………………………………………………….58
• 86. Safety, Yours and Others …………………………………………………………………..59
• 87. Checklists ……………………………………………………………………………………….60
• 88. General Safety ……………………………………………………………………………60
• 89. Operating Safety …………………………………………………………………………61
• 90. Maintenance Safety ……………………………………………………………………..62
• 91. Engine – General Information
• 92. Introduction ……………………………………………………………………………………..68
• 93. Left Side, Right Side …………………………………………………………………….68
• 94. Units of Measurement ………………………………………………………………….68
• 95. Machine – Equipment Related Data ………………………………………………..68
• 96. Acronyms and Abbreviations …………………………………………………………69
• 97. Engine – Identifying the Engine
• 98. Engine Identification Plate …………………………………………………………………70
• 99. Typical Engine Identification Number ……………………………………………..70
• 100. Component Labels ………………………………………………………………………71
• 101. Engine Component Identification ………………………………………………………..72
• 102. Engine – Fluids, Lubricants and Capacities
• 103. Engine Lubricating Oil ………………………………………………………………………77
• 104. Recommended Oils ……………………………………………………………………..77
• 105. Engine Oil Capacity ……………………………………………………………………..77
• 106. Coolant …………………………………………………………………………………………..78
• 107. Coolant Mixtures ………………………………………………………………………………79
• 108. Coolant Mixtures …………………………………………………………………………79
• 109. Fuel ……………………………………………………………………………………………….80
• 110. Acceptable and Unacceptable Fuels ………………………………………………80
• 111. Fuel Types ………………………………………………………………………………….82
• 112. Usage and Effects of Fuels …………………………………………………………..83
• 113. Sulphur Content ………………………………………………………………………….84
• 114. Effects of Fuel Contaminates ………………………………………………………..85
• 115. Engine – Routine Maintenance
• 116. Introduction ……………………………………………………………………………………..87
• 117. Cleaning the Engine …………………………………………………………………………88
• 118. High Pressure Cleaning ……………………………………………………………….88
• 119. Lubricants – Health and Safety …………………………………………………………..89
• 120. Hygiene ……………………………………………………………………………………..89
• 121. Storage ………………………………………………………………………………………89
• 122. Waste Disposal ……………………………………………………………………………89
• 123. Handling …………………………………………………………………………………….89
• 124. First Aid – Oil ……………………………………………………………………………….90
• 125. Spillage ………………………………………………………………………………………90
• 126. Fires ………………………………………………………………………………………….90
• 127. Engine Oil and Filter …………………………………………………………………………91
• 128. Checking the Oil Level …………………………………………………………………91
• 129. Changing the Oil and Filter ……………………………………………………………92
• 130. Engine Cooling System …………………………………………………………………….93
• 131. Checking the Coolant Level ………………………………………………………….93
• 132. Changing the Coolant …………………………………………………………………..93
• 133. Front End Accessory Drive (FEAD) Belt …………………………………………94
• 134. Engine Fuel System …………………………………………………………………………95
• 135. Draining the Water Separator and Fuel Filter …………………………………..95
• 136. Changing the Filter Element ………………………………………………………….96
• 137. Changing the Water Seperator Pre- Filter ……………………………………….97
• 138. Bleeding the Fuel System …………………………………………………………….98
• 139. Air Intake System …………………………………………………………………………….99
• 140. Air Cleaners ………………………………………………………………………………..99
• 141. Engine Breather …………………………………………………………………………….100
• 142. Cleaning the Engine Breather Gauze ……………………………………………100
• 143. Valve Clearances and Adjustment …………………………………………………….101
• 144. Before Adjustment ……………………………………………………………………..101
• 145. Adjustment ……………………………………………………………………………….101
• 146. After Adjustment ………………………………………………………………………..102
• 147. Engine Lifting Information ………………………………………………………………..103
• 148. Engine – Fault Finding
• 149. Introduction ……………………………………………………………………………………105
• 150. Fault Finding Charts …………………………………………………………………..106
• 151. A Charts – Engine …………………………………………………………………………..107
• 152. B Charts – Fuel ………………………………………………………………………………123
• 153. C Charts – Lubricating Oil ………………………………………………………………..125
• 154. D Charts – Coolant ………………………………………………………………………….129
• 155. Engine – Storage and Preservation
• 156. Storage …………………………………………………………………………………………133
• 157. Preservation ………………………………………………………………………………….134
• 158. Capping Engine Openings ………………………………………………………….134
• 159. Hot Test Description …………………………………………………………………..135
• 160. Engine – Technical Data and Specifications
• 161. Basic Engine Data ………………………………………………………………………….137
• 162. Torque + Angle Explanation …………………………………………………………….139
• 163. Torque + Angle Tightening Procedure ……………………………………………….140
• 164. Engine Torque Figures ……………………………………………………………………141
• 165. Connection and Wiring Diagrams
• 166. Generator Schematic Woodward Panel – ATP2 ………………………………….149
• 167. AC Wiring ……………………………………………………………………………………..151
• 168. DC Wiring ……………………………………………………………………………………..154
• 169. JCB G50-G80 Rental Specification – AC Wiring ………………………………….159
• 170. JCB G50-G80 Rental Specification – DC Wiring ………………………………….163
• 171. Automatic Transfer Panel 2 ……………………………………………………………..166
• 172. Automatic Transfer Panel 7 ……………………………………………………………..168
• 173. Warranty
• 174. Warranty Information ………………………………………………………………………171
• 175. Installation Access ……………………………………………………………………..171
• 176. Downtime Support ……………………………………………………………………..171
• 177. Terms and Conditions …………………………………………………………………171
• 178. JCB Technical Service …………………………………………………………………….172