jcb G20 Operator'S Manual Download Page 8

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Introduction

About this Manual

9831/0650-3

Introduction

About this Manual

Model and Serial Number

This manual provides information for the following model(s) in the JCB machine range:

Model

From:

To:

G20

2288985

2298985

G20QS

2288985

2298985

G20S

2288985

2298985

G27

2288985

2298985

G27QS

2288985

2298985

G27S

2288985

2298985

G33

2288985

2298985

G33QS

2288985

2298985

G33S

2288985

2298985

G34QS

2288985

2298985

G40

2288985

2298985

G40QS

2288985

2298985

G40S

2288985

2298985

G41QS

2288985

2298985

G45

2288985

2298985

G45QS

2288985

2298985

G45S

2288985

2298985

Using the Manual

This operator's manual is arranged to give you a good understanding of the machine and its safe operation.

It also contains maintenance and technical data.

Read this manual from the front to the back before you use the machine for the first time, even if you have used

machines of a similar/same type before as the technical specification, systems and controls of the machine

may have changed. Particular attention must be given to all the safety aspects of operating and maintaining

the machine.

If there is anything you are not sure about, ask your JCB dealer or employer. Do not guess, you or others could

be killed or seriously injured.

The general and specific warnings in this section are repeated throughout the manual. Read all the safety

statements regularly, so you do not forget them. Remember that the best operators are the safest operators.

The illustrations in this manual are for guidance only. Where the machines are different, the text and or the

illustration will specify.

The manufacturer's policy is one of continuous improvement. The right to change the specification of the

machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur

between specifications of the machine and the descriptions contained in this manual.

All of the optional equipment included in this manual may not be available in all territories

Left-Hand Side, Right-Hand Side

References to the left side and right side of the engine are when view from the flywheel end of the engine.

Summary of Contents for G20

Page 1: ...OPERATOR S MANUAL GENERATOR G20 G20QS G20S G27 G27QS G27S G33 G33QS G33S G34QS G40 G40QS G40S G41QS G45 G45QS G45S EN 9831 0650 ISSUE 3 11 2017 THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE...

Page 2: ...the instructions in the Operator s Manual If you do not understand anything ask your employer or JCB dealer to explain it Do not operate the machine without an Operator s Manual or if there is anythin...

Page 3: ...9831 0650 3 Notes...

Page 4: ...liance 5 Description Main Component Locations 6 Product and Component Identification General 10 Engine 10 Safety Labels General 12 Safety Label Identification 13 Installation and Removal Installation...

Page 5: ...l 103 Dust Valve 104 Fuel System General 105 Engine Fuel Filter 106 Water Separator 106 Cooling System Coolant 108 Cooling Pack 108 Electrical System General 110 Battery 110 Fault Finding General 119...

Page 6: ...e Ventilation ECM Engine Control Module ECU Electronic Control Unit FEAD Front End Accessory Drive HPV High Pressure Valve LCD Liquid Crystal Display LED Light Emitting Diode PIN Product Identificatio...

Page 7: ...Notes iv 9831 0650 3 iv...

Page 8: ...he machine may have changed Particular attention must be given to all the safety aspects of operating and maintaining the machine If there is anything you are not sure about ask your JCB dealer or emp...

Page 9: ...ross References In this manual cross references are made by presenting the subject title in blue electronic copy only The number of the page upon which the subject begins is indicated within the brack...

Page 10: ...Remember Be careful Be alert Be safe Safety Warnings In this manual there are safety notices Each notice starts with a signal word The signal word meanings are given below The signal word DANGER indic...

Page 11: ...ng indoors then a purpose designed exhaust fume extraction unit may be needed Keep other people at a safe distance when operating the engine or equipment Do not operate an engine if the safety guard w...

Page 12: ...Conformity These marking s and documents are relevant only for the country region in which the product was first sold to the extent that the laws and regulations required them Re sales and import exp...

Page 13: ...6 Description Main Component Locations Figure 2 A B C D E F A Access door for the control panel B Access door for engine and radiator C Access panel for exhaust muffler D Access door for alternator E...

Page 14: ...N G E F C P B A A Fuel tank B Control panel C Emergency stop D Fuel filter water separator E Fuel tank filler neck F Engine oil filter G Water separator H Exhaust silencer J Radiator cap K Radiator L...

Page 15: ...8 9831 0650 3 8 Figure 4 D E B C A F G J H K A Rocker cover B Lifting eye C Fuel injectors D Radiator cap E Radiator F Oil filler cap G High pressure pump H ECU Electronic Control Unit J Fuel filter...

Page 16: ...he Product Description 9 9831 0650 3 9 Figure 5 A H G C B D E F A Oil filter cap B Air filter C Oil pressure sensor D Starter motor assembly E Fly wheel housing F Oil drain plug sump G Oil sump H Alte...

Page 17: ...formation The data plate is normally located on the right hand side of the alternator terminal box looking at the alternator end of the generator The generator model designation can be used to determi...

Page 18: ...About the Product Product and Component Identification 11 9831 0650 3 11 Figure 8 A A A Engine data label...

Page 19: ...r reading make sure you wear them when reading the safety labels Do not over stretch or put yourself in dangerous positions to read the safety labels If you do not understand the hazard shown on the s...

Page 20: ...About the Product Safety Labels 13 9831 0650 3 13 Safety Label Identification Figure 9 D E 817 7000 5 C 817 7003 2 A B 817 70021 2 C 817 70032 2...

Page 21: ...key and refer to the operator s manual and service manual 2 B 817 70021 Noise warning Wear ear protection 2 C 335 D7145 Risk of electrocution Read the operator s manual before you operate the machine...

Page 22: ...eturn system and overload the fuel injection equipment this may cause significant damage to the engine fuel system Care must be taken when connecting a remote tank All connections must be securely att...

Page 23: ...ng the generator set using the available means of transport The door through which the generator set is brought in must be central so that the set remains centred once it is inside and there is no nee...

Page 24: ...on and Removal 17 9831 0650 3 17 Recommended Room Dimensions Figure 11 Static Soundproof Generator Set Side View D A B C E A Generator set B Access door C Concrete base D Exhaust and hot air outlet du...

Page 25: ...831 0650 3 18 Figure 12 Static Soundproof Generator Set Plan View B F D B C E A G H A Generator set B Air inlet grill C Exhaust and hot air outlet duct D Cable Conduit E Access door F Concrete base G...

Page 26: ...F G E J A Access door B Exhaust pipe C Exhaust silencer D Hot air outlet ducts E Control panel F Concrete base G Generator set H Generator length 200mm J Alternator The above figure shows a typical e...

Page 27: ...About the Product Installation and Removal 20 9831 0650 3 20 Figure 14 Open Generator Set Side View A B C D A Control panel B Concrete base C Generator set D Generator over all length...

Page 28: ...lation Electrical connections Grounding Heating Foundations Foundations must prevent the transmission of vibrations and noise to other parts of the building The surface on which the set will be placed...

Page 29: ...onditions a separate fuel tank may be required This must be connected to the engine using suitable pipework to ensure that the fuel injection pump can draw fuel correctly Electrical Connections The ge...

Page 30: ...ndard 10w40 oil For generators and engines operating in temperatures between 15 C 59 0 F to 25 C 77 0 F an appropriate oil grade such as 5x40 and a coolant mixture of minimum 40 anti freeze must be us...

Page 31: ...mbient temperature and subsequent air flow wind speed reduce the temperature around the components to a level that the condensate freezes Moderating the airflow using actuated louvers on the air intak...

Page 32: ...mmediately if a fuel leak is suspected Do not smoke while refuelling or working on the fuel system Do not refuel with the engine running Completely wipe off any spilt fuel which could cause a fire The...

Page 33: ...ine and machine components will be hot after the unit has been running Allow the engine and components to cool before servicing the unit Alcohol and Drugs It is extremely dangerous to operate machiner...

Page 34: ...Engine Control Module to shutdown correctly The time period starts when you turn the ignition off Check the isolator switch label and the operators manual for the correct time period In the event of a...

Page 35: ...he engine and alternator for any signs of damage water oil or fuel leaks Ensure that machine intake and outlet air vents and grills are not obstructed or blocked in any way to allow good airflow throu...

Page 36: ...e power on LED Light Emitting Diode is illuminated on earth leakage trip and there is no trip active 4 Make sure that the main power supply MCCB is switched off 5 Check that the emergency stop button...

Page 37: ...e with STOP RESET mode AUTO mode and MANUAL START mode functions For normal operation these are the only controls which need to be operated The module may instruct an engine start event due to externa...

Page 38: ...erating in this mode a start will not occur Auto Auto This button places the module into its AUTO MODE This mode allows the module to control the function of the generator automatically The module wil...

Page 39: ...instrumentation event log and configuration screens Module Display Depending upon the module s configuration some display screens may be disabled Instrumentation Icons When viewing instrumentation pa...

Page 40: ...displayed in the Active Config section to indicate the active configuration within the currently selected within the controller Table 5 Icons Description 1 Appears when the main configuration is selec...

Page 41: ...SB Universal Serial Bus connec tion is made to the controller Appears if either the configuration file or engine file becomes corrupted Load Switching Icon Additional features for optional DSE4520 mai...

Page 42: ...ler In the event of a warning alarm the LCD Liquid Crystal Display only displays the alarm icon In the event of an electrical trip or shutdown alarm the module displays the alarm icon and the stop res...

Page 43: ...at indicates that the en gine is running when it has been instructed to stop Fail to Stop could indicate a faulty oil pressure sensor If engine is at rest check oil sensor wiring and configuration Cha...

Page 44: ...ondition the module de energises all the Delayed Load Output and the Close Gen Output outputs to remove the load from the generator Once this has occurred the module starts the Cooling timer and allow...

Page 45: ...ET Mode button on the module The alarm condition must be rectified before a reset will take place If the alarm condition remains it is not be possible to reset the unit The exception to this is the Lo...

Page 46: ...pre set alarm setting after the Safety On timer has expired HZ Generator Over Frequency The generator output frequency has risen above the pre set alarm setting A Delayed Over Current The measured cu...

Page 47: ...o enter the navigation menu press both the UP and DOWN buttons simultaneously Figure 22 To select the required icon press the UP button to cycle right or the DOWN button to cycle left until the desire...

Page 48: ...hrough the display to view different pages of information by repeatedly operating the up or down navigation buttons and so on until the last page is reached A further press of the navigation down butt...

Page 49: ...ph ph Mains Voltage ph N ph ph Figure 25 2 230V 230V 230V 230V 230V 230V L1N L2N L3N A B A Mains voltage B Generator voltage Generator These pages contain electrical values of the generator measured...

Page 50: ...rh Figure 28 2 20 kW 20 kW 20 kW L1 L2 L3 Engine These pages contain instrumentation gathered about the engine measured or derived from the module s inputs some of which may be obtained from the engin...

Page 51: ...enu is then displayed Once entered cycle to the DTC section and enter To view the active DTC alarms repeatedly press the UP or DOWN buttons until the LCD screen displays the alarm Continuing to press...

Page 52: ...ed that the engine s DC supply has fallen below or risen above its configured alarm level Event Log This module s event log contains a list of the last 15 record electrical trip or shutdown events and...

Page 53: ...as been recorded E Number of event displayed out Operation The following descriptions detail the sequences followed by a module containing the standard factory configuration Always refer to your confi...

Page 54: ...is possible to send configuration files to the module from DSE configuration suite PC software and to enter the front panel editor to change parameters Any latched alarms that have been cleared are re...

Page 55: ...f all start requests are removed the stopping sequence will begin Stopping Sequence The return delay timer operates to ensure that the starting request has been permanently removed and isn t just a sh...

Page 56: ...a number of sources Activation of an auxiliary input that has been configured to Remote Start On Load or Auxiliary Mains Fail Activation of the inbuilt exercise scheduler if configured for on load run...

Page 57: ...e type of maintenance alarm air fuel or oil Pressing the maintenance reset button in the DSE Configuration Suite Maintenance section Pressing and holding the STOP RESET mode button for ten seconds on...

Page 58: ...5 hours then start at 13 30 on Tuesday and run for 30 minutes Stop Mode Scheduled runs do not occur when the module is in STOP RESET mode Manual Start Mode Scheduled runs do not occur when the module...

Page 59: ...ion Editor 1 Press the STOP RESET and AUTO buttons together to enter the editor mode 2 Press the UP or DOWN navigation buttons to cycle through the front panel editor to select the required page in th...

Page 60: ...fuel solenoid 9 Press the MANUAL START mode button 9 1 This time the engine should start and the starter motor should disengage automatically If not then check that the engine is fully operational fu...

Page 61: ...operating air temperature above 25 degrees Celsius 2 0 2 4 6 8 10 12 25 30 35 40 45 50 55 Y X X Power de rating Y Air temperature Celsius Figure 41 Power de rating depending on operating altitude hig...

Page 62: ...cted by temperature and altitude The following derate should be applied to take this into account Table 14 Altitude Ambient Temperature 30 C 86 0 F 25 C 77 0 F 20 C 68 0 F 15 C 59 0 F 10 C 50 0 F 5 C...

Page 63: ...15 20 21 5 000 13 16 16 18 18 23 24 Table 16 Altitude Ambient Temperature 35 C 95 0 F 40 C 103 9 F 45 C 112 9 F 50 C 121 9 F 55 C 130 9 F 60 C 139 9 F Sea Level 4 7 9 11 500 M 4 7 9 11 1 000 4 7 9 11...

Page 64: ...ts 57 9831 0650 3 57 Attachments Working with Attachments Attachments for your Machine Bunding Tank Figure 43 B C A D E A Alternator mounting plate B Fuel bunding tank C Engine mounting plate D Bundin...

Page 65: ...Attachments Working with Attachments 58 9831 0650 3 58 Fork Pockets Figure 44 A A Fork pocket...

Page 66: ...B Bolts Transportation brackets is a temporary installation and must be removed after transportation Loosen the bolts to remove all the four transportation bracket from the generator base Refer to Fi...

Page 67: ...Attachments Working with Attachments 60 9831 0650 3 60 Figure 47 D A Drain pump mounting bracket B Drain pump C Hose D Drain valve...

Page 68: ...Attachments Working with Attachments 61 9831 0650 3 61 Oil Pressure Sensor Figure 48 A B A Bonded seal B Pressure transducer...

Page 69: ...Attachments Working with Attachments 62 9831 0650 3 62 Water Jacket Heater Figure 49 A A Block heater thermostat...

Page 70: ...G20QS Only A B C D A Isolator switch B Cable Battery negative to isolator C Battery isolator mounting bracket D Cable Isolator to starter motor Figure 51 B C A D A Isolator switch B Battery isolator m...

Page 71: ...ne return to 3WFV B Forward line 3WFV to lift pump inlet C 3 way fuel valve D Return line 3WFV outlet to fuel tank E Forward line Fuel tank suction to 3WFV Always refer to the direction label for the...

Page 72: ...Attachments Working with Attachments 65 9831 0650 3 65 Canopy Delete Z0 Figure 54 Typical Generator A D B A Electrical installation B Skid installation D Fuel system installation...

Page 73: ...Attachments Working with Attachments 66 9831 0650 3 66 CE Hot Guards Figure 55 Typical Hot Guard Plate A B A Mounting bracket B CE hot guard...

Page 74: ...trol panel box B Monitoring relay C MCB stopper D Mechanical Interlock E Indicator LED yellow F Indicator LED red G Power busbar terminal H AC contactor J Voltage surge suppressor K PVC duct Figure 57...

Page 75: ...Attachments Working with Attachments 68 9831 0650 3 68 Door Stop Arrangement Figure 58 A C D B A Position 1 B Position 2 C Door retainer bracket D Door retainer link...

Page 76: ...Attachments Working with Attachments 69 9831 0650 3 69 Canopy Protection Kit Figure 59 A A Canopy protection block...

Page 77: ...Working with Attachments 70 9831 0650 3 70 Open Set Dedicated Design Figure 60 For G20QS Only F E B C D A A KDI B Battery installation C Fuel system installation D Generator installation E Generator F...

Page 78: ...rking with Attachments 71 9831 0650 3 71 Figure 61 For G27QS Only F B C E D A A Electrical installation B Generator installation C Fuel system installation D G drive installation E Battery installatio...

Page 79: ...ts Working with Attachments 72 9831 0650 3 72 Figure 62 For G40QS Only F D C E B A A Electrical installation B Alternator C Battery installation D Fuel system installation E Generator installation F B...

Page 80: ...chments Working with Attachments 73 9831 0650 3 73 Figure 63 For G45QS Only C B A D E F A KDI B Electrical installation C Base frame D Generator installation E G drive installation F Battery installat...

Page 81: ...Attachments Working with Attachments 74 9831 0650 3 74 Socket Box Figure 64 A A Socket box...

Page 82: ...Attachments Working with Attachments 75 9831 0650 3 75 Lifting Frame Single Point Figure 65 A B A Lifting hook B Lifting frame...

Page 83: ...Attachments Working with Attachments 76 9831 0650 3 76 Four Point Lifting Kit Figure 66 A A Lifting hook...

Page 84: ...Attachments Working with Attachments 77 9831 0650 3 77 Battery Charger 27 45kVA Figure 67 B A A Lead acid battery charger B 230V AC 16A 1P44 plug...

Page 85: ...Attachments Working with Attachments 78 9831 0650 3 78 20kVA Figure 68 A B A Lead acid battery charger B 230V AC 16A 1P44 plug...

Page 86: ...Attachments Working with Attachments 79 9831 0650 3 79 EFR Figure 69 D B C E A A Current transducer B Earth leakage relay C Din rail D MCB Stopper E Earth leakage bracket...

Page 87: ...Notes 80 9831 0650 3 80...

Page 88: ...nd the generator is made safe by disconnecting at the breaker turning off the machine and activating the emergency stop switch 3 Make sure that all electrical connectors are correctly coupled If conne...

Page 89: ...ose connections contamination debris etc in addition to the recommended maintenance tasks If the generator is not being sufficiently loaded on a regular basis it may cause coking of the engine and exh...

Page 90: ...unit Chemicals Certain seals and gaskets e g crankshaft oil seal on JCB machines contain fluoroelastomeric materials such as Viton FluorelTM and Technoflon Fluoroelastomeric materials subjected to hi...

Page 91: ...ap when the engine is running Antifreeze is toxic If accidentally swallowed medical advice must be sought Immediately Antifreeze is corrosive to the skin If accidentally spilled on to skin it must be...

Page 92: ...oroughly with soap and water Using a nail brush will help Use special hand cleansers to help clean dirty hands Never use petrol diesel fuel or paraffin for washing Avoid skin contact with oil soaked c...

Page 93: ...d the electrical circuit before connecting or disconnecting an electrical component A wrong connection can cause injury and or damage Notice Do not disconnect the battery while the engine is running o...

Page 94: ...Machine users that cannot find a suitable battery recycling facility should contact their JCB dealer for assistance First Aid Electrolyte Eyes In the case of eye contact flush with water for 15min al...

Page 95: ...the regular maintenance checks are rectified immediately How to Use the Maintenance Schedules The schedules show the service tasks which must be done and their intervals The services must be done at e...

Page 96: ...s Machine earth connec tions Check condi tion Engine and controller harness Check condi tion and con nections Load Test Load Test 75 of maxi mum load Engine Oil Level Check Engine oil 3 Change Coolant...

Page 97: ...ace if there is any sign of wear 3 In case of low use 12 months 4 The period of time that must elapse before checking the filter element depends on the environment in which the engine operates The air...

Page 98: ...air intake exhaust and breather system 5 Make sure that the oil filler caps and dipstick are correctly installed 6 Use a low pressure water jet and brush to soak off caked mud or dirt 7 Apply an appro...

Page 99: ...l WARNING Hot oil and engine components can burn you Make sure the engine is cool before doing this job Used engine crankcase lubricants contain harmful contaminants In laboratory tests it was shown t...

Page 100: ...TG 2 The tension must be between the values specified Weight Force 200 230N 5 2 If necessary adjust the tension Adjustment 1 Loosen the alternator mount bolts Do not remove them 2 Pull the alternator...

Page 101: ...and disconnected from the power supply When stopping the generator ensure the compliance with the procedures for stopping the prime mover Electrical Connections Windings Connection All alternators fea...

Page 102: ...o control many different types of generators it must be appropriately configured to obtain the best performance Most of the settings are stored in a non volatile integrated memory EEPROM The first tim...

Page 103: ...he regulator operation time starting from revision 11 of the Firmware RS232 and RS485 serial communications interface with optional DI1 module Operation of the DSR is not specified below 12Hz Installa...

Page 104: ...turning on the power Terminals The connections must be made using cables having a minimum diameter For power cables on terminals 1 2 3 and 9 Exc Aux exc Aux 1 5 mm For signal cables 0 5mm For the conn...

Page 105: ...ration Menu at 50Hz the threshold can be calibrated from 40Hz to 50Hz at 60 Hz the threshold can be calibrated from 48Hz to 60Hz The Amp trimmer adjusts the excitation overcurrent protection intervent...

Page 106: ...tor light mounted on the board flashes every two seconds It flashes differently in the event of intervention or alarm Figure 78 A B C D E F Y G L L M H J K X A Stop B Amp and Hz or O S C Hz or O S D A...

Page 107: ...ection with an intervention threshold which can be adjusted by the potentiometer marked Hz This protection intervenes instantaneously by reducing the alternator voltage to a safe value when frequency...

Page 108: ...rn automatically to its nominal value as soon as the fault is removed For further details on regulators please see the specific manual Starting and Stopping The Operations All the instrumentation for...

Page 109: ...vibrations Mechanical inspections on all fastening bolts and in particular on electric connections External cleaning of generator Internal and External Cleaning of the Generator For the external clean...

Page 110: ...safe 2 Depress the clips on the cover and lift off the cover 3 Remove the outer element Take care not to tap or knock the element 4 If the inner element is to be changed lift up pull and remove the i...

Page 111: ...31 0650 3 104 Dust Valve Check Condition Check the dust valve for rips tears Check there are no obstructions Check that the dust valve is free of dirt and dust Check that the dust valve securely attac...

Page 112: ...ould be expensive to repair 1 Make the machine safe 2 Get access to the fuel filter 3 Make sure there is sufficient fuel in the tank 4 Loosen the bleed screw on the fuel filter 5 Turn on the ignition...

Page 113: ...t Lubricate the gasket of the new cartridge Do not fill the new cartridge with fuel 6 Refit the sensor housing 7 Bleed the fuel system 8 Close the engine cover Figure 85 A B A Filter element B Sensor...

Page 114: ...Maintenance Fuel System 107 9831 0650 3 107 Figure 86 B A A Tap B Bowl Figure 87 C B A A Water separator B Maximum level red line C Drain plug...

Page 115: ...leaks and re check the fluid level Replace CAUTION The cooling system is pressurised when the coolant is hot When you remove the cap hot coolant can spray out and burn you Make sure that the engine is...

Page 116: ...109 9831 0650 3 109 3 Get access to the radiator 4 Check the condition of the coolant hoses 5 Check the radiator and intercooler surfaces for signs of damage 6 If necessary contact your JCB dealer fo...

Page 117: ...may become sulphated hardened this condition makes recharging the battery very difficult Extra precautions must be taken when bench charging maintenance free batteries they are more prone to damage b...

Page 118: ...ing the twin batteries to the machine first connect the link lead or leads then the positive terminal and finally the negative terminal If the machine has a battery isolator move the switch to the on...

Page 119: ...D Handle E Cable 2 F Clamp 1 Make the machine safe 2 Use the handles to put the battery into its compartment 3 Connect the cable 1 and the cable 2 4 Install the cover if removed 5 Install the clamp 6...

Page 120: ...ing method and device Notice Before you install a pair of batteries to a machine make sure you know the machines voltage Some machines require two batteries but have a 12 V electrical system This mean...

Page 121: ...94 Twin Battery 12V Machines Parallel Connection Example B A A C D A Battery B Positive lead C Battery link lead D Negative lead Figure 95 24 Volt Machines Series Connection Example _ _ B C D A A Bat...

Page 122: ...e battery lead and put it away from the batteries Refer to Figure 94 and Refer to Figure 95 6 Disconnect and remove the battery link lead or leads Refer to Figure 94 and Refer to Figure 95 7 Remove th...

Page 123: ...ine cranking speed is so low that the engine does not start charging is required If the generating set has an on board battery charger this will take care of charging when connected to the auxiliary m...

Page 124: ...output cables are always in active state of current flow even when the engine is not in operation If the alternator connector is removed do not earth the moulded plug 5 When you do arc welding on the...

Page 125: ...Readings should be taken using a hydrometer when the electrolyte temperature is 15 C 60 F If the battery has recently been on charge wait approximately one hour or slightly discharge the battery to d...

Page 126: ...edy No fuel in supply tank Check the level in the fuel tank use sight gauge or dipstick Replenish as required Starter switch or starter electrical system failure Check the operation of the starter swi...

Page 127: ...ces Engine compression low in one or more cylinders Check the engine compression Cranking speed too slow Refer to Table 24 Electrical sensor fault Check the electrical connections at the sensors Table...

Page 128: ...he neces sary components and install new ones Fuel injection lines leaking WARNING Fine jets of fluid at high pressure can penetrate the skin Keep face and hands well clear of pressurised fluid and we...

Page 129: ...er s Check fuel lines for restriction Stop the engine Replace the fuel filters Operate the engine with a temporary supply of the correct grade of clean fuel Fuel is contaminated or incorrect grade die...

Page 130: ...e fuel system for loose con nections and possible air ingress points Rectify and bleed the fuel system STOP THE ENGINE Replace the fuel filters Operate the engine with a temporary supply of the correc...

Page 131: ...ces set incorrectly Set the valve clearances to the recommended clear ances Worn or malfunctioning fuel injection pump Do all the necessary fault finding checks before re moval of the fuel injection p...

Page 132: ...ing smoothly misfiring Refer to Table 27 Oil level over full Check oil level Fan damaged or accessories faulty Check replace the vibrating component Fan hub faulty Inspect replace the fan hub Refer to...

Page 133: ...olant temperature too low over cooling light blue or white high speed light load Refer to Table 45 Electrical sensor fault Check the electrical connections at the sensors One or more engine injector w...

Page 134: ...oning Check the electrical connections at the injectors Lubricating Oil Table 39 Lubricating Oil Consumption Excessive Cause Remedy Oil leaks Inspect the engine for visible signs of leaks Pay par ticu...

Page 135: ...e more frequently Lubricating oil filter drain down valve not fitted Change lubricating oil filter Suction pump pressure relief valve stuck open Check replace seal Oil pump pressure relief valve stuck...

Page 136: ...t Make sure the fill rate is not exceeded and the cor rect vented thermostat is installed Air or combustion gases in the cooling system If aeration continued check for a compression leak through the h...

Page 137: ...tart If the rail pressure is OK and backleak is within limits raise Techweb Helpdesk Call Table 48 General Sensor Fault Step Trouble Action Remedy Disconnect the sensor check sensor voltage supply at...

Page 138: ...necessary 1 Wiring fault If no faults is found proceed to Step 3 Check the network and CAN resistors repair as necessary 2 Network and CAN Controller Area Network resistors faulty If no fault is found...

Page 139: ...r connection fault If no fault is found proceed to step 2 Check all the injectors individually Replace the injector and re calibrate the ECU with the trim file of the new injector 2 Injector faulty If...

Page 140: ...injector calibration codes read then write in correct position to reset learned parameters 1 Sensor connection fault If no fault is found proceed to step 2 Check the grounding of knock sensors repair...

Page 141: ...e the sensor 1 Sensor supply voltage fault If sensor supply voltage is OK proceed to Step 2 Check the condition of sensor to harness connection make sure the seals are in place check for signs of corr...

Page 142: ...ed to Step 4 Check the sensor resistance see relevant help file page If sensor is out of specification replace 4 Sensor failure If no faults is found proceed to Step 5 Check the harness continuity and...

Page 143: ...12 V battery voltage with a 30 resistor in series respecting the polarities After being excited alternator does not excite Check connection cables as per attached drawings Reset voltage potentiometer...

Page 144: ...uration then set will not start if oil pres sure is not low Check the wiring to engine heater plugs Check the battery supply Check the battery supply is present on the Pre heat output of module Pre he...

Page 145: ...e configuration of input Check the relevant switch and wiring of fault indicat ed on LCD display Warning fault operates Check the configuration of input CAN ECU warningCAN ECU shutdown This indicates...

Page 146: ...w er specified digital multimeters Accuracy of the controller is better than 1 of full scale Generator voltage full scale is 415V ph N ac curacy is 4 15V 1 of 415V Miscellaneous Table 72 Symptom Possi...

Page 147: ...Notes 140 9831 0650 3 140...

Page 148: ...KDI 2504M From 2288985 to 2298985 G33 33 kVA KDI 2504TM From 2288985 to 2298985 G33S 33 kVA KDI 2504TM From 2288985 to 2298985 G33QS 33 kVA KDI 2504TM From 2288985 to 2298985 G34QS 33 kVA KDI 2504TM...

Page 149: ...33 2 250mm 800mm 1 350mm 2 43m G33S 2 075mm 670mm 1 250mm 1 75m G33QS G34QS 2 250mm 840mm 1 350mm 2 55m G40 2 250mm 800mm 1 350mm 2 43m G40S 2 075mm 670mm 1 250mm 1 75m G40QS 41QS 2 250mm 840mm 1 350m...

Page 150: ...chnical Data Noise Emissions 143 9831 0650 3 143 Noise Emissions Noise Data Table 76 Description G20QS G27QS G33QS G34QS G40QS G41QS G45QS LpA 7m 60 dB A 62 dB A 62 dB A 62 dB A 62 dB A 62 dB A 62 dB...

Page 151: ...ppropriate for heavy duty applications such as sustained high loads and operation at elevated temperatures The choice of lubricant viscosity should be made based on the lowest ambient temperature at w...

Page 152: ...w Temperatures When operating the engine in ambient temperatures lower than 0 C 32 0 F use suitable low temperature fuel normally available from fuel distributors and corresponding to the specificatio...

Page 153: ...ot be obtained use de ionized water For further information advice on water hardness contact your local water authority The correct concentration of antifreeze protects the engine against frost damage...

Page 154: ...DSR DSR DSR DSR Steady State Volt age Regulation 1 00 1 00 1 00 1 00 1 00 1 00 1 00 Bearing Single bearing sealed Single bearing sealed Single bearing sealed Single bearing sealed Single bearing seale...

Page 155: ...Technical Data Electrical System 148 9831 0650 3 148 Schematic Circuit Figure 98 335 F5093 3 sheet 1 of 6...

Page 156: ...Technical Data Electrical System 149 9831 0650 3 149 Figure 99 335 F5093 3 sheet 2 of 6...

Page 157: ...Technical Data Electrical System 150 9831 0650 3 150 Figure 100 335 F5093 3 sheet 3 of 6...

Page 158: ...Technical Data Electrical System 151 9831 0650 3 151 Figure 101 335 F5093 3 sheet 4 of 6...

Page 159: ...Technical Data Electrical System 152 9831 0650 3 152 Figure 102 335 F5093 3 sheet 5 of 6...

Page 160: ...Technical Data Electrical System 153 9831 0650 3 153 Figure 103 335 F5093 3 sheet 6 of 6...

Page 161: ...Technical Data Electrical System 154 9831 0650 3 154 Figure 104 336 E4738 B sheet 1 of 7...

Page 162: ...Technical Data Electrical System 155 9831 0650 3 155 Figure 105 336 E4738 B sheet 2 of 7...

Page 163: ...Technical Data Electrical System 156 9831 0650 3 156 Figure 106 336 E4738 B sheet 3 of 7...

Page 164: ...Technical Data Electrical System 157 9831 0650 3 157 Figure 107 336 E4738 B sheet 4 of 7...

Page 165: ...Technical Data Electrical System 158 9831 0650 3 158 Figure 108 336 E4738 B sheet 5 of 7...

Page 166: ...Technical Data Electrical System 159 9831 0650 3 159 Figure 109 336 E4738 B sheet 6 of 7...

Page 167: ...Technical Data Electrical System 160 9831 0650 3 160 Figure 110 336 E4738 B sheet 7 of 7...

Page 168: ...Technical Data Electrical System 161 9831 0650 3 161 Figure 111 336 E5832 1 sheet 1 of 7...

Page 169: ...Technical Data Electrical System 162 9831 0650 3 162 Figure 112 336 E5832 1 sheet 2 of 7...

Page 170: ...Technical Data Electrical System 163 9831 0650 3 163 Figure 113 336 E5832 1 sheet 3 of 7...

Page 171: ...Technical Data Electrical System 164 9831 0650 3 164 Figure 114 336 E5832 1 sheet 4 of 7...

Page 172: ...Technical Data Electrical System 165 9831 0650 3 165 Figure 115 336 E5832 1 sheet 5 of 7...

Page 173: ...Technical Data Electrical System 166 9831 0650 3 166 Figure 116 336 E5832 1 sheet 6 of 7...

Page 174: ...Technical Data Electrical System 167 9831 0650 3 167 Figure 117 336 E5832 1 sheet 7 of 7...

Page 175: ...API CH4 SAE 10W40 API CH4 SAE 10W40 API CH4 SAE 10W40 API CH4 SAE 10W40 Compression Ra tio 11 5 1 11 5 1 11 5 1 11 5 1 11 5 1 11 5 1 11 5 1 Engine Oil Ca pacity litres 8 5L 11 3L 11 3L 11 3L 11 3L 11...

Page 176: ...ngine 169 9831 0650 3 169 Description G20 G20S G20QS G27 G27S G27QS G33 G33S G33QS G34QS G40 G40S G40QS G41QS G45 G45S G45QS Starting System V 12V 12V 12V 12V 12V 12V 12V Starter Motor kW 2kW 2kW 2kW...

Page 177: ...e to assist in sourcing a substitute generator during any periods of work Terms and Conditions The following warranty terms and conditions are applicable for further details please contact your JCB de...

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