JCB G8X to G45QX Operator Manual 9811-4550

Description

• Model List:
  • G8X, G8QX, G13X, G13QX, G17X, G17QX, G20RX, G22X, G22QX, G30RX, G33X, G33QX, G40RX, G45X, G45QX

• 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 ……………………………………………………………………………………………27
• 31. Connection and Disconnection (battery arrangement) ………………………27
• 32. Charging the Battery ……………………………………………………………………27
• 33. Battery Maintenance ……………………………………………………………………27
• 34. Battery Life …………………………………………………………………………………27
• 35. Cooling System ……………………………………………………………………………….28
• 36. Checking and Adding Coolant ……………………………………………………….28
• 37. Coolant Mixtures …………………………………………………………………………28
• 38. Cleaning the Radiator …………………………………………………………………..29
• 39. Pre Start Checks ………………………………………………………………………………30
• 40. Checks After Running ……………………………………………………………………….31
• 41. Cleaning …………………………………………………………………………………………32
• 42. KS1 Digital Control Panel
• 43. Introduction ……………………………………………………………………………………..33
• 44. Features …………………………………………………………………………………….33
• 45. Components ……………………………………………………………………………….34
• 46. Operation Modes …………………………………………………………………………35
• 47. Data …………………………………………………………………………………………..36
• 48. CP1 and CP2 Digital Control Panels
• 49. Introduction ……………………………………………………………………………………..37
• 50. The panel provides the following readings of the electric mains supply: 37
• 51. The panel provides the following engine features information: …………..37
• 52. The panel controls the following functions of the engine: …………………..37
• 53. Password ……………………………………………………………………………………38
• 54. Control Panel Front Views …………………………………………………………………39
• 55. CP1 …………………………………………………………………………………………..39
• 56. CP2 …………………………………………………………………………………………..40
• 57. Control Panel Push Buttons ………………………………………………………………41
• 58. Operating mode buttons ……………………………………………………………….41
• 59. Command buttons ……………………………………………………………………….41
• 60. Display Buttons …………………………………………………………………………..42
• 61. Contactors Buttons (CP2 only) ………………………………………………………42
• 62. Data LEDs ………………………………………………………………………………………43
• 63. Engine Status LEDs …………………………………………………………………….43
• 64. Alarm LEDs ………………………………………………………………………………..43
• 65. Electric Power Status LEDs …………………………………………………………..44
• 66. Starting and Stopping – Manual Mode …………………………………………………45
• 67. Starting ………………………………………………………………………………………45
• 68. Stopping …………………………………………………………………………………….45
• 69. Starting and Stopping – Automatic Mode ……………………………………………..46
• 70. Operational Modes …………………………………………………………………………..47
• 71. Test Mode (CP2 only) …………………………………………………………………..47
• 72. Block Mode (CP1 only) …………………………………………………………………47
• 73. Block Mode (CP2 only) …………………………………………………………………47
• 74. Activation of Contactors (CP2 only) ……………………………………………….48
• 75. Linking Generators and Transfer Panels …………………………………………48
• 76. Alarms ……………………………………………………………………………………………49
• 77. Engine Alarms …………………………………………………………………………….49
• 78. Generator Set Alarms …………………………………………………………………..50
• 79. Mains Alarms (CP2 only) ………………………………………………………………50
• 80. Transfer Fuel Pump (Optional) …………………………………………………………..51
• 81. ATP1 Digital Control Panel (option)
• 82. Introduction ……………………………………………………………………………………..52
• 83. The automatic transfer panel provides the following readings of the electric
• 84. mains supply: ……………………………………………………………………………..52
• 85. Outputs to allow Monitoring of Controller Operating Conditions …………52
• 86. Control Panel Front View …………………………………………………………………..53
• 87. Control Panel Push Buttons ………………………………………………………………54
• 88. Operating mode buttons ……………………………………………………………….54
• 89. Command buttons ……………………………………………………………………….55
• 90. Display Buttons …………………………………………………………………………..55
• 91. Contactors Buttons ………………………………………………………………………55
• 92. Data LEDs ………………………………………………………………………………………56
• 93. Starting and Stopping – Manual Mode …………………………………………………57
• 94. Starting ………………………………………………………………………………………57
• 95. Stopping …………………………………………………………………………………….57
• 96. Starting and Stopping – Automatic Mode ……………………………………………..58
• 97. Introduction …………………………………………………………………………………58
• 98. Starting ………………………………………………………………………………………58
• 99. Stopping …………………………………………………………………………………….58
• 100. Operational Modes …………………………………………………………………………..59
• 101. Integrated Generator Set Mode ……………………………………………………..59
• 102. Test Mode …………………………………………………………………………………..59
• 103. Block Mode …………………………………………………………………………………59
• 104. Activation of Contactors ……………………………………………………………….59
• 105. Inputs and Outputs …………………………………………………………………………..60
• 106. Digital Input (Non Programmable) ………………………………………………….60
• 107. Programmable Inputs …………………………………………………………………..60
• 108. Digital Outputs …………………………………………………………………………….60
• 109. Alarms ……………………………………………………………………………………………61
• 110. Electrical Characteristics …………………………………………………………………..65
• 111. Wiring Diagrams ………………………………………………………………………….66
• 112. Alternator
• 113. Introduction ……………………………………………………………………………………..67
• 114. Safety Precautions ………………………………………………………………………67
• 115. Designation ………………………………………………………………………………..67
• 116. Installation ………………………………………………………………………………………68
• 117. Lifting …………………………………………………………………………………………68
• 118. AVR Settings and Type ………………………………………………………………..69
• 119. Protection …………………………………………………………………………………..72
• 120. Alternator Terminal Connections ………………………………………………………..73
• 121. Series Star ………………………………………………………………………………….73
• 122. Parallel Star ………………………………………………………………………………..73
• 123. Series Delta ………………………………………………………………………………..74
• 124. Double Delta ……………………………………………………………………………….74
• 125. Parallel Zig-Zag …………………………………………………………………………..75
• 126. Fault Finding ……………………………………………………………………………………76
• 127. Service and Maintenance ………………………………………………………………….79
• 128. Winding Condition ……………………………………………………………………….79
• 129. Winding Condition Assessment ……………………………………………………..79
• 130. Spares and After Sales Service ………………………………………………………….80
• 131. Ordering Parts …………………………………………………………………………….80
• 132. Engine
• 133. Introduction ……………………………………………………………………………………..81
• 134. Component Identification ………………………………………………………………81
• 135. Location of Labels ……………………………………………………………………….84
• 136. 97/68/EC Directive Certified Engines ……………………………………………..85
• 137. Engine Family ……………………………………………………………………………..85
• 138. Engine Oil and Filter …………………………………………………………………………86
• 139. Recommended Oils ……………………………………………………………………..86
• 140. Engine Oil Capacity ……………………………………………………………………..86
• 141. Checking the Oil Level …………………………………………………………………87
• 142. Changing the Oil and Filter ……………………………………………………………88
• 143. Cooling System ……………………………………………………………………………….90
• 144. Check and Adjust Fan Belt ……………………………………………………………90
• 145. Drain and Refill the Coolant ………………………………………………………….92
• 146. Fuel System …………………………………………………………………………………….93
• 147. Fuel Specifications ………………………………………………………………………93
• 148. Additional Technical Fuel Requirements …………………………………………93
• 149. Bio-Diesel Fuels ………………………………………………………………………….94
• 150. Injectors ……………………………………………………………………………………..94
• 151. Priming the Fuel System – Indirect Injection …………………………………….95
• 152. Priming the Fuel System – Direct Injection ………………………………………96
• 153. Water Separator and Fuel Filter …………………………………………………….97
• 154. Inlet and Exhaust System ………………………………………………………………..101
• 155. To Renew the Air Cleaner Outer Element ……………………………………..101
• 156. Turbocharger (4TNV84T, 4TNV98T) …………………………………………….101
• 157. Crankcase Breather System ……………………………………………………….101
• 158. Valves ………………………………………………………………………………………101
• 159. Technical Data ……………………………………………………………………………….102
• 160. Description of Model Number ………………………………………………………102
• 161. General …………………………………………………………………………………….102
• 162. Data by Engine Model ………………………………………………………………..103
• 163. Engine – Fault Finding
• 164. Introduction ……………………………………………………………………………………109
• 165. Fault Finding Charts ………………………………………………………………….. 110
• 166. A Charts – Engine ………………………………………………………………………….. 111
• 167. B Charts – Fuel ……………………………………………………………………………… 115
• 168. C Charts – Lubricating Oil ……………………………………………………………….. 116
• 169. D Charts – Coolant …………………………………………………………………………. 118
• 170. Connection and Wiring Diagrams
• 171. Introduction ……………………………………………………………………………………120
• 172. CP1 and CP2 Wiring Diagrams ………………………………………………………..121
• 173. ATP1 Wiring Diagrams ……………………………………………………………………135
• 174. Socket Wiring – Rental Specification Only ………………………………………….141
• 175. KS1 Wiring Diagrams ……………………………………………………………………..143
• 176. Warranty
• 177. Warranty Information ………………………………………………………………………147
• 178. Installation Access ……………………………………………………………………..147
• 179. Downtime Support ……………………………………………………………………..147
• 180. Terms and Conditions …………………………………………………………………147
• 181. JCB Technical Service …………………………………………………………………….148