JCB G130RX to G220QX Operator Manual 9811-4650

Description

• Model List:
  • G130RX, G144X, G144QX, G160RX, G175X, G175QX, G200RX, G220X, G220QX

• 1. Introduction
• 2. Machine Model and Serial Number ………………………………………………………1
• 3. About This Manual ……………………………………………………………………………..2
• 4. Cross References ………………………………………………………………………….2
• 5. Component Identification …………………………………………………………………….3
• 6. Data plate …………………………………………………………………………………….4
• 7. Important Information …………………………………………………………………………5
• 8. The Operator Manual …………………………………………………………………….5
• 9. Safety Warnings ……………………………………………………………………………5
• 10. Safety, Yours and Others …………………………………………………………………….6
• 11. Checklists …………………………………………………………………………………………7
• 12. General Safety ……………………………………………………………………………..7
• 13. Operating Safety …………………………………………………………………………..8
• 14. Maintenance Safety ……………………………………………………………………….9
• 15. Installation
• 16. Unpacking ……………………………………………………………………………………….13
• 17. Site Installation ………………………………………………………………………………..14
• 18. Outdoor Installations. ………………………………………………………………………..15
• 19. Indoor installations ……………………………………………………………………………16
• 20. Generator Set Room ……………………………………………………………………16
• 21. Basic Elements to be considered …………………………………………………..21
• 22. Routine Maintenance
• 23. Service Requirements ………………………………………………………………………22
• 24. Health and Safety …………………………………………………………………………….23
• 25. Lubricants …………………………………………………………………………………..23
• 26. Service Schedules ……………………………………………………………………………25
• 27. Introduction …………………………………………………………………………………25
• 28. How to Use the Service Schedules ………………………………………………..25
• 29. Service Schedule Checklist …………………………………………………………..26
• 30. Battery ……………………………………………………………………………………………28
• 31. Connection and Disconnection (battery arrangement) ………………………28
• 32. Charging the Battery ……………………………………………………………………28
• 33. Battery Maintenance ……………………………………………………………………28
• 34. Battery Life …………………………………………………………………………………28
• 35. Cooling System ……………………………………………………………………………….29
• 36. Checking and Adding Coolant ……………………………………………………….29
• 37. Coolant Mixtures …………………………………………………………………………29
• 38. Cleaning the Radiator …………………………………………………………………..30
• 39. Pre Start Checks ………………………………………………………………………………31
• 40. Checks After Running ……………………………………………………………………….32
• 41. Cleaning …………………………………………………………………………………………33
• 42. CP1 and CP2 Digital Control Panels
• 43. Introduction ……………………………………………………………………………………..34
• 44. The panel provides the following readings of the electric mains supply: 34
• 45. The panel provides the following engine features information: …………..34
• 46. The panel controls the following functions of the engine: …………………..34
• 47. Password ……………………………………………………………………………………35
• 48. Control Panel Front Views …………………………………………………………………36
• 49. CP1 …………………………………………………………………………………………..36
• 50. CP2 …………………………………………………………………………………………..37
• 51. Control Panel Push Buttons ………………………………………………………………38
• 52. Operating mode buttons ……………………………………………………………….38
• 53. Command buttons ……………………………………………………………………….38
• 54. Display Buttons …………………………………………………………………………..39
• 55. Contactors Buttons (CP2 only) ………………………………………………………39
• 56. Data LEDs ………………………………………………………………………………………40
• 57. Engine Status LEDs …………………………………………………………………….40
• 58. Alarm LEDs ………………………………………………………………………………..40
• 59. Electric Power Status LEDs …………………………………………………………..41
• 60. Starting and Stopping – Manual Mode …………………………………………………42
• 61. Starting ………………………………………………………………………………………42
• 62. Stopping …………………………………………………………………………………….42
• 63. Starting and Stopping – Automatic Mode ……………………………………………..43
• 64. Operational Modes …………………………………………………………………………..44
• 65. Test Mode (CP2 only) …………………………………………………………………..44
• 66. Block Mode (CP1 only) …………………………………………………………………44
• 67. Block Mode (CP2 only) …………………………………………………………………44
• 68. Activation of Contactors (CP2 only) ……………………………………………….45
• 69. Linking Generators and Transfer Panels …………………………………………45
• 70. Alarms ……………………………………………………………………………………………46
• 71. Engine Alarms …………………………………………………………………………….46
• 72. Generator Set Alarms …………………………………………………………………..47
• 73. Mains Alarms (CP2 only) ………………………………………………………………47
• 74. Transfer Fuel Pump (Optional) …………………………………………………………..48
• 75. ATP1 Digital Control Panel (option)
• 76. Introduction ……………………………………………………………………………………..49
• 77. The automatic transfer panel provides the following readings of the electric
• 78. mains supply: ……………………………………………………………………………..49
• 79. Outputs to allow Monitoring of Controller Operating Conditions …………49
• 80. Control Panel Front View …………………………………………………………………..50
• 81. Control Panel Push Buttons ………………………………………………………………51
• 82. Operating mode buttons ……………………………………………………………….51
• 83. Command buttons ……………………………………………………………………….52
• 84. Display Buttons …………………………………………………………………………..52
• 85. Contactors Buttons ………………………………………………………………………52
• 86. Data LEDs ………………………………………………………………………………………53
• 87. Starting and Stopping – Manual Mode …………………………………………………54
• 88. Starting ………………………………………………………………………………………54
• 89. Stopping …………………………………………………………………………………….54
• 90. Starting and Stopping – Automatic Mode ……………………………………………..55
• 91. Introduction …………………………………………………………………………………55
• 92. Starting ………………………………………………………………………………………55
• 93. Stopping …………………………………………………………………………………….55
• 94. Operational Modes …………………………………………………………………………..56
• 95. Integrated Generator Set Mode ……………………………………………………..56
• 96. Test Mode …………………………………………………………………………………..56
• 97. Block Mode …………………………………………………………………………………56
• 98. Activation of Contactors ……………………………………………………………….56
• 99. Inputs and Outputs …………………………………………………………………………..57
• 100. Digital Input (Non Programmable) ………………………………………………….57
• 101. Programmable Inputs …………………………………………………………………..57
• 102. Digital Outputs …………………………………………………………………………….57
• 103. Alarms ……………………………………………………………………………………………58
• 104. Electrical Characteristics …………………………………………………………………..62
• 105. Wiring Diagrams ………………………………………………………………………….63
• 106. Alternator
• 107. Introduction ……………………………………………………………………………………..64
• 108. Safety Precautions ………………………………………………………………………64
• 109. Designation ………………………………………………………………………………..64
• 110. Installation ………………………………………………………………………………………65
• 111. Lifting …………………………………………………………………………………………65
• 112. AVR Settings and Type ………………………………………………………………..66
• 113. Protection …………………………………………………………………………………..69
• 114. Alternator Terminal Connections ………………………………………………………..70
• 115. Series Star ………………………………………………………………………………….70
• 116. Parallel Star ………………………………………………………………………………..70
• 117. Series Delta ………………………………………………………………………………..71
• 118. Double Delta ……………………………………………………………………………….71
• 119. Parallel Zig-Zag …………………………………………………………………………..72
• 120. Fault Finding ……………………………………………………………………………………73
• 121. Service and Maintenance ………………………………………………………………….76
• 122. Winding Condition ……………………………………………………………………….76
• 123. Winding Condition Assessment ……………………………………………………..76
• 124. Spares and After Sales Service ………………………………………………………….77
• 125. Ordering Parts …………………………………………………………………………….77
• 126. Engine Maintenance
• 127. Introduction ……………………………………………………………………………………..78
• 128. Component Identification (N67 TE2A) …………………………………………….78
• 129. Component Identification (NEF 67 TM) …………………………………………..79
• 130. Warning Signs …………………………………………………………………………….80
• 131. Electrical Precautions …………………………………………………………………..80
• 132. Engine Electrics ……………………………………………………………………………….81
• 133. Electrical Interconnection Unit – N 67 only ………………………………………81
• 134. Failure Code Decoding – N 67 Only ……………………………………………….82
• 135. Engine Oil and Filter …………………………………………………………………………84
• 136. Recommended Oils ……………………………………………………………………..84
• 137. Engine Oil Capacity ……………………………………………………………………..84
• 138. Checking the Oil Level …………………………………………………………………85
• 139. Changing the Oil and Filter ……………………………………………………………86
• 140. Changing the Oil Vapour Filter (N 67 TE2 Engine) …………………………..87
• 141. Cooling System ……………………………………………………………………………….88
• 142. Checking and Adjusting Drive Belt with Automatic Tensioning (NE 67 TE2
• 143. Engine) ………………………………………………………………………………………88
• 144. Checking and Adjusting Drive Belt (NEF 67 Engine) ………………………..89
• 145. Drain and Refill the Coolant ………………………………………………………….90
• 146. Fuel System …………………………………………………………………………………….91
• 147. Diesel Fuel …………………………………………………………………………………91
• 148. Priming the Fuel System ………………………………………………………………91
• 149. To Drain the Filters or Pre-filter ……………………………………………………..93
• 150. To Renew the Fuel Filter ………………………………………………………………94
• 151. To Renew the Fuel Pre-filter ………………………………………………………….94
• 152. Inlet and Exhaust System ………………………………………………………………….95
• 153. To Renew the Air Cleaner Outer Element ……………………………………….95
• 154. Engine Removal and Replacement …………………………………………………….96
• 155. Technical Data – N67 TE2A ……………………………………………………………….97
• 156. Technical Data – NEF 67, TM2/TM3 ……………………………………………………98
• 157. Connection and Wiring Diagrams
• 158. Introduction ……………………………………………………………………………………..99
• 159. CP1 and CP2 Wiring Diagrams ………………………………………………………..100
• 160. ATP1 Wiring Diagrams …………………………………………………………………… 114
• 161. Socket Wiring – Rental Specification Only ………………………………………….120
• 162. Warranty
• 163. Warranty Information ………………………………………………………………………121
• 164. Installation Access ……………………………………………………………………..121
• 165. Downtime Support ……………………………………………………………………..121
• 166. Terms and Conditions …………………………………………………………………121
• 167. JCB Technical Service …………………………………………………………………….122