JCB G306X to G726X-QX Operator Manual 9821-9650

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JCB G306X to G726X-QX Operator Manual 9821-9650

$20.00

Type Of Manual: Operator Manual
ManualID: 9821-9650
Number of Pages: 216
Size: 18.0MB
Format: PDF

Category: JCB Operator Manual PDF

Model List:
- G306X, G306QX, G336X, G336QX, G406X, G406QX, G446X, G446QX, G506X, G506QX, G556X, G556QX, G656X, G656QX, G726X, G726QX

1. Introduction
2. Machine Model and Serial Number ………………………………………………………1
3. Product Compliance ………………………………………………………………………1
4. About This Manual ……………………………………………………………………………..2
5. Cross References ………………………………………………………………………….2
6. Component Identification …………………………………………………………………….3
7. MTU 6 Cylinder …………………………………………………………………………….3
8. MTU V8 ……………………………………………………………………………………….4
9. MTU V10 ……………………………………………………………………………………..5
10. MTU V12 1600 10-20F …………………………………………………………………..6
11. MTU V12 1600 10S-20S ………………………………………………………………..7
12. Canopy’s ……………………………………………………………………………………..8
13. Data plate …………………………………………………………………………………..10
14. Important Information ………………………………………………………………………. 11
15. The Operator Manual ………………………………………………………………….. 11
16. Safety Warnings …………………………………………………………………………. 11
17. Safety, Yours and Others …………………………………………………………………..12
18. Checklists ……………………………………………………………………………………….13
19. General Safety ……………………………………………………………………………13
20. Operating Safety …………………………………………………………………………14
21. Maintenance Safety ……………………………………………………………………..15
22. Installation
23. Unpacking ……………………………………………………………………………………….19
24. Site Installation ………………………………………………………………………………..20
25. Outdoor Installations. ………………………………………………………………………..21
26. Indoor installations ……………………………………………………………………………22
27. Generator Set Room ……………………………………………………………………22
28. Recommended Room Dimensions ………………………………………………23
29. Basic Elements to be considered …………………………………………………..27
30. Foundations ……………………………………………………………………………..27
31. Exhaust Installation ……………………………………………………………………27
32. Ventilation ………………………………………………………………………………..27
33. Heating ……………………………………………………………………………………27
34. Fuel Supply System …………………………………………………………………..27
35. Electrical Connections ……………………………………………………………….27
36. Grounding ………………………………………………………………………………..27
37. Operating Conditions ………………………………………………………………………..28
38. Rating Definitions ………………………………………………………………………..28
39. Emergency Standby Power (ESP) …………………………………………………28
40. Prime Power (PRP) ……………………………………………………………………..28
41. Continuous Power (COP) ……………………………………………………………..28
42. Limited Time Running Power (LTP) ………………………………………………..28
43. Derate Table ……………………………………………………………………………….29
44. Routine Maintenance
45. Service Requirements ………………………………………………………………………31
46. Health and Safety …………………………………………………………………………….32
47. Lubricants …………………………………………………………………………………..32
48. Introduction ………………………………………………………………………………32
49. Hygiene ……………………………………………………………………………………32
50. Storage ……………………………………………………………………………………32
51. Waste Disposal …………………………………………………………………………32
52. Handling …………………………………………………………………………………..32
53. First Aid – Oil …………………………………………………………………………….33
54. Spillage ……………………………………………………………………………………33
55. Fires ………………………………………………………………………………………..33
56. Service Schedules ……………………………………………………………………………34
57. Introduction …………………………………………………………………………………34
58. How to Use the Service Schedules ………………………………………………..35
59. Service Schedule Checklist – Stand-by Applications Only ………………….36
60. Battery ……………………………………………………………………………………………38
61. Connection and Disconnection (battery arrangement) ………………………38
62. Activating Dry Batteries ………………………………………………………………..38
63. Charging the Battery ……………………………………………………………………38
64. Battery Maintenance ……………………………………………………………………38
65. Battery Life …………………………………………………………………………………39
66. Cooling System ……………………………………………………………………………….40
67. Checking and Adding Coolant ……………………………………………………….40
68. Coolant Mixtures …………………………………………………………………………40
69. Cleaning the Radiator …………………………………………………………………..41
70. Pre Start Checks ………………………………………………………………………………42
71. Cleaning …………………………………………………………………………………………43
72. CP1 and CP2 Digital Control Panels
73. Introduction ……………………………………………………………………………………..45
74. The panel provides the following readings of the electric mains supply: 45
75. The panel provides the following engine features information: …………..45
76. Engine alarm inputs: ………………………………………………………………….45
77. Analog engine inputs …………………………………………………………………45
78. Configurable inputs; …………………………………………………………………..45
79. Engine statistics: ……………………………………………………………………….45
80. The panel controls the following functions of the engine: …………………..45
81. Password ……………………………………………………………………………………46
82. Control Panel Front Views …………………………………………………………………47
83. CP1 …………………………………………………………………………………………..47
84. CP2 …………………………………………………………………………………………..48
85. Control Panel Push Buttons ………………………………………………………………49
86. Operating mode buttons ……………………………………………………………….49
87. Command buttons ……………………………………………………………………….49
88. Display Buttons …………………………………………………………………………..50
89. Contactors Buttons (CP2 only) ………………………………………………………50
90. Data LEDs ………………………………………………………………………………………51
91. Engine Status LEDs …………………………………………………………………….51
92. Alarm LEDs ………………………………………………………………………………..51
93. Electric Power Status LEDs …………………………………………………………..52
94. Starting and Stopping – Manual Mode …………………………………………………53
95. Starting ………………………………………………………………………………………53
96. Stopping …………………………………………………………………………………….53
97. Starting and Stopping – Automatic Mode ……………………………………………..54
98. Operational Modes …………………………………………………………………………..55
99. Test Mode (CP2 only) …………………………………………………………………..55
100. Block Mode (CP1 only) …………………………………………………………………55
101. Block Mode (CP2 only) …………………………………………………………………55
102. Activation of Contactors (CP2 only) ……………………………………………….56
103. Linking Generators and Transfer Panels …………………………………………56
104. Alarms ……………………………………………………………………………………………57
105. Engine Alarms …………………………………………………………………………….57
106. Generator Set Alarms …………………………………………………………………..58
107. Mains Alarms (CP2 only) ………………………………………………………………58
108. Transfer Fuel Pump (Optional) …………………………………………………………..59
109. ATP1 Digital Control Panel (option)
110. Introduction ……………………………………………………………………………………..61
111. The automatic transfer panel provides the following readings of the electric
112. mains supply: ……………………………………………………………………………..61
113. Outputs to allow Monitoring of Controller Operating Conditions …………61
114. Control Panel Front View …………………………………………………………………..62
115. Control Panel Push Buttons ………………………………………………………………63
116. Operating mode buttons ……………………………………………………………….63
117. Command buttons ……………………………………………………………………….64
118. Display Buttons …………………………………………………………………………..64
119. Contactors Buttons ………………………………………………………………………64
120. Data LEDs ………………………………………………………………………………………65
121. Starting and Stopping – Manual Mode …………………………………………………66
122. Starting ………………………………………………………………………………………66
123. Stopping …………………………………………………………………………………….66
124. Starting and Stopping – Automatic Mode ……………………………………………..67
125. Introduction …………………………………………………………………………………67
126. Starting ………………………………………………………………………………………67
127. Stopping …………………………………………………………………………………….67
128. Operational Modes …………………………………………………………………………..68
129. Integrated Generator Set Mode ……………………………………………………..68
130. Test Mode …………………………………………………………………………………..68
131. Block Mode …………………………………………………………………………………68
132. Activation of Contactors ……………………………………………………………….68
133. Inputs and Outputs …………………………………………………………………………..69
134. Digital Input (Non Programmable) ………………………………………………….69
135. Programmable Inputs …………………………………………………………………..69
136. Digital Outputs …………………………………………………………………………….69
137. Generator Set Start-up ……………………………………………………………….69
138. Alarms ……………………………………………………………………………………………70
139. Electrical Characteristics …………………………………………………………………..74
140. Wiring Diagrams ………………………………………………………………………….75
141. Alternator
142. Machine Description …………………………………………………………………………77
143. Introduction ……………………………………………………………………………………..78
144. Altitude Derations …………………………………………………………………………….79
145. Temperature and Altitude ……………………………………………………………..79
146. Environmental Concerns ………………………………………………………………79
147. Humidity and Moisture ………………………………………………………………….79
148. Machine Identification ……………………………………………………………………….80
149. Safety Requirements ………………………………………………………………………..81
150. Transport and Storage ………………………………………………………………………83
151. Mechanical Coupling ………………………………………………………………………..85
152. Electrical Connections ………………………………………………………………………86
153. Windings Connection …………………………………………………………………..86
154. Alternator Terminal Connections ……………………………………………………87
155. 50Hz Connections …………………………………………………………………….87
156. 60 Hz Connections ……………………………………………………………………90
157. DSR Digital Regulator ………………………………………………………………….93
158. Introduction ………………………………………………………………………………93
159. Technical Characteristics ……………………………………………………………94
160. Technical Specifications ……………………………………………………………..95
161. Installation ………………………………………………………………………………..96
162. Excitation Overcurrent ……………………………………………………………….97
163. Alarms ……………………………………………………………………………………..97
164. Regulators ……………………………………………………………………………….98
165. DER1 Regulator ………………………………………………………………………….99
166. 50/60 Signal ……………………………………………………………………………101
167. Volt Trimmer ……………………………………………………………………………101
168. Stab Trimmer ………………………………………………………………………….101
169. Hz Trimmer …………………………………………………………………………….101
170. DER1 Connections ………………………………………………………………….101
171. Connections Based on Main Alternator Voltage …………………………..102
172. Protections ……………………………………………………………………………….103
173. Intervention of Protection Devices Causes ………………………………….103
174. Starting and Stopping The Operations ……………………………………………….104
175. Cleaning the Alternator ……………………………………………………………………105
176. Maintenance ………………………………………………………………………………….106
177. Internal and External Cleaning of the Generator …………………………….106
178. Fault Finding ………………………………………………………………………………….107
179. Engine – Care and Safety
180. Important Information ……………………………………………………………………..109
181. The Operator Manual …………………………………………………………………109
182. Safety Warnings ………………………………………………………………………..109
183. Safety, Yours and Others ………………………………………………………………… 110
184. Checklists …………………………………………………………………………………….. 111
185. General Safety …………………………………………………………………………. 111
186. Operating Safety ………………………………………………………………………. 112
187. Maintenance Safety …………………………………………………………………… 113
188. MTU Engine
189. Engine Safety ……………………………………………………………………………….. 119
190. Safety Requirements for Startup …………………………………………………. 119
191. Safety Requirements for Equipment Operation ……………………………… 119
192. Malfunctions and Emergency Stop ………………………………………………. 119
193. Operation …………………………………………………………………………………. 119
194. Operation of Electrical Equipment ……………………………………………….. 119
195. Safety Requirements Prior to Maintenance and Repair Work …………..120
196. Safety Requirements During Maintenance and Repair Work ……………120
197. Safety Requirements after Completion of Maintenance Work and Repair
198. Work ………………………………………………………………………………………..121
199. Welding Work ……………………………………………………………………………121
200. Hydraulic Installation and Removal ………………………………………………121
201. Working with Batteries ………………………………………………………………..121
202. Working on Electrical and Electronic Assemblies …………………………..121
203. Working with Laser Equipment …………………………………………………….122
204. MTU Engine
205. General Information ………………………………………………………………………..123
206. Engine Layout …………………………………………………………………………..123
207. Engine Model Designation ………………………………………………………….125
208. Engine Side and Cylinder Designations ………………………………………..126
209. Sensors and Actuators ……………………………………………………………….126
210. MTU Engine Fuels
211. Fuels – General Information ……………………………………………………………..129
212. Diesel Fuels …………………………………………………………………………………..130
213. Selection of a Suitable Diesel Fuel ……………………………………………….130
214. Limit Values for Water and Total Contamination ……………………………..130
215. Specifications for Distilate Fuels …………………………………………………..130
216. Low Sulfur Diesel Fuels ………………………………………………………………130
217. Winter Operation ……………………………………………………………………….130
218. Flow Improvers ………………………………………………………………………….131
219. Engine – Operation
220. Starting and Running ………………………………………………………………………133
221. At First Start ………………………………………………………………………………133
222. Checks Before Running ……………………………………………………………..133
223. Starting the Engine …………………………………………………………………….133
224. Starting at Low Temperatures ………………………………………………………133
225. At temperatures below 0°C: ………………………………………………………133
226. Coolant Temperature ………………………………………………………………….134
227. Oil Pressure ………………………………………………………………………………134
228. Charging Indicator Lamp …………………………………………………………….134
229. Putting the Engine Back In to Operation ……………………………………….135
230. After an Extended Period Out of Service (>3 Months) …………………..135
231. After a Scheduled Out of Service Period …………………………………….135
232. Operational Checks ……………………………………………………………………135
233. Engine Stop Test – Manual Operation ……………………………………………135
234. Stop Test Preparation ………………………………………………………………135
235. Stop Test ………………………………………………………………………………..135
236. Emergency Engine Shutdown ……………………………………………………..136
237. Emergency Engine Shutdown Test …………………………………………….136
238. After Emergency Shutdown ………………………………………………………136
239. Putting the Engine Out of Operation …………………………………………….136
240. Engine – Routine Maintenance
241. Lubricating Oil System …………………………………………………………………….137
242. Recommended Oils ……………………………………………………………………137
243. Engine Oil Capacity ……………………………………………………………………137
244. Checking the Oil Level ……………………………………………………………….138
245. Checking the Oil level Prior to Start ……………………………………………138
246. Oil Level Check after the Engine Has Stopped …………………………….138
247. Engine Oil – Change …………………………………………………………………..139
248. Draining the Oil at Drain Plug on Oil Pan ……………………………………139
249. Filling With New Oil ………………………………………………………………….139
250. Changing the Oil Filter ………………………………………………………………..140
251. Special Tools, Materials, Spare Parts ………………………………………….140
252. Engine Oil Filter – Replacement …………………………………………………140
253. Engine Cooling system ……………………………………………………………………141
254. Checking Engine Coolant Level (At Filler Neck) …………………………….141
255. Checking Engine Coolant Level (Using Level Sensor) …………………….141
256. Changing the Engine Coolant ……………………………………………………..142
257. Draining the Engine Coolant ……………………………………………………….142
258. Preparatory Steps ……………………………………………………………………142
259. Draining …………………………………………………………………………………142
260. Filling with Engine Coolant ………………………………………………………….143
261. Special Tools, Materials, Spare Parts ………………………………………….143
262. Preparatory Steps ……………………………………………………………………143
263. Filling …………………………………………………………………………………….143
264. Engine Coolant Pump – Relief Bore Check ……………………………………144
265. Air Cleaner …………………………………………………………………………………….145
266. Air Filter – Replacement ………………………………………………………………145
267. Air Filter – Removal and Installation ……………………………………………..145
268. Air Intake ………………………………………………………………………………………146
269. Service Indicator – Signal Ring Position Check ………………………………146
270. Fuel System …………………………………………………………………………………..147
271. Fuel System – Venting ………………………………………………………………..147
272. Fuel Filter …………………………………………………………………………………148
273. Special Tools, Material, Spare Parts …………………………………………..148
274. Fuel Filter – Replacement ……………………………………………………………148
275. Fuel Pre-Filter Replacement ……………………………………………………….148
276. Special Tools, Material, Spare Parts …………………………………………..148
277. Fuel Pre-Filter – Replacement ……………………………………………………148
278. Electrical system …………………………………………………………………………….149
279. Starter – Condition Check ……………………………………………………………149
280. Wiring (General) for Engine / Gearbox / Unit …………………………………149
281. Special Tools, Material, Spare Parts …………………………………………..149
282. Engine Wiring – Check ……………………………………………………………..149
283. Accessories for (Electronic) Engine Governor / Control System ……….150
284. Special Tools, Material, Spare Parts …………………………………………..150
285. Engine Governor and Connectors – Cleaning ………………………………150
286. Cleaning Severely Contaminated Connectors on the Engine Governor ..
287. 150
288. Engine Governor Plug Connections – Check ……………………………….151
289. Miscellaneous ………………………………………………………………………………..152
290. Checking Drive Belts ………………………………………………………………….152
291. Fan Drive – Adjusting the Belt Tension ………………………………………..152
292. Checking Belt Condition …………………………………………………………..152
293. Drive Belt – Tension

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