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jcb G20 - User Manual

jcb G20
177 pages
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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

Table of Contents

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jcb G20 Specifications

General IconGeneral
Brandjcb
ModelG20
CategoryPortable Generator
LanguageEnglish

Summary

Introduction

About this Manual

Provides guidance on using the operator's manual effectively.

Cross References

Explains how to navigate references within the manual.

Safety

Safety - Yours and Others

Emphasizes personal safety and awareness of hazards.

Safety Warnings

Explains signal words and safety alert symbols used in the manual.

General Safety

Provides a checklist of safety procedures and practices.

About the Product

Introduction

Introduces the product and manufacturer details.

Product Compliance

Discusses compliance with laws and regulations for the product.

Description

Main Component Locations

Identifies key components of the generator set with visual aids.

Product and Component Identification

General

Details information found on the generator's data plate.

Engine

Describes the location of engine data labels on the cylinder block.

Safety Labels

General

Explains the purpose and placement of safety labels on the machine.

Safety Label Identification

Illustrates and identifies specific safety labels and their meanings.

Installation and Removal

Installation

Provides guidelines for the proper installation of the generating set.

Site Installation

Covers foundation requirements and lifting procedures for the generating set.

Remote Fuel Tank Installation

Details considerations for installing a remote fuel tank for the generator.

Outdoor Installations

Discusses best practices for installing generators outdoors for optimal performance.

Indoor Installations

Outlines requirements for installing a generator set in a dedicated room.

Recommended Room Dimensions

Shows recommended room dimensions for soundproof generator sets.

Basic Elements to be Considered

Lists key elements to consider during installation.

Foundations

Specifies requirements for generator set foundations.

Exhaust Installation

Provides guidance on safe and effective exhaust system installation.

Ventilation

Explains the importance of adequate ventilation for generator set operation.

Heating

Discusses heating requirements for generator sets in cold climates.

Fuel Supply System

Details the generator's integral and optional fuel supply systems.

Electrical Connections

Refers to electrical schematics for correct cable connections.

Grounding

Highlights the need for proper grounding of metal parts.

Operating Generators in Extreme Cold Climates

Provides guidance on operating generators in very cold ambient temperatures.

Cold Start

Details procedures and requirements for starting the generator in cold conditions.

Cold Running

Covers operating guidelines for the generator in low temperatures.

Important Notes

Lists potential issues and consequences of operating in cold climates without precautions.

Operation

Operating Safety

Outlines essential safety practices and precautions for operating the generator.

General Operating Precautions

Covers general safety including alertness, clothing, lifting, and training.

Fuel

Details safety precautions related to fuel handling and refueling.

Machine Condition

Emphasizes the importance of maintaining the machine in good working order.

Machine Limits

Warns against operating the machine beyond its design specifications.

Exhaust Gases

Highlights the dangers of inhaling exhaust gases and the need for ventilation.

Hazardous Atmospheres

Advises against operating in potentially explosive environments.

Regulations

Stresses adherence to local laws and regulations.

Hot Components

Warns about hot surfaces and the need for cooling before servicing.

Alcohol and Drugs

Advises against operating machinery under the influence of alcohol or drugs.

Battery Isolator

General

Explains the function of the battery isolator switch.

Disconnect

Provides step-by-step instructions for disconnecting the battery.

Connect

Details the procedure for connecting the battery isolator.

Before Starting the Engine

General

Outlines essential pre-start checks for the generating set.

Checks After Running

Lists checks to perform after the engine has stopped running.

Instruments

Instrument Panel

Introduces the instrument panel and its components.

Operation

Guides through the steps for starting and operating the generator.

Digital Controller

Explains the functionality and operation of the digital controller module.

Emergency Stop Button

Describes the function and use of the emergency stop button.

Control Push-Buttons

Details the function of various control push-buttons on the module.

Module Display

Explains the module's display and navigation.

Instrumentation Icons

Lists and describes icons used on the instrumentation pages.

Active Configuration

Explains how active configuration is indicated.

Front Panel Editor (FPE);Auto Run Icon

Describes icons related to front panel configuration and auto-run.

Mode Icon

Details icons indicating the controller's current operating mode.

Load Switching Icon

Explains icons showing the status of generator and mains breakers.

Backlight

Describes the behavior of the LED backlight.

Alarm Icons (Protections)

Explains how alarm icons are displayed on the controller.

Warning Alarm Icons

Lists and describes warning icons, their faults, and meanings.

Electrical Trip Alarm Icons

Details icons and procedures for electrical trip alarms.

Shutdown Alarm Icons

Explains icons related to shutdown alarms and reset procedures.

Viewing The Instrument Pages

Guides on how to view instrument pages and navigate through them.

Navigation Menu

Explains how to enter and use the navigation menu.

Navigation Menu Icons

Lists icons used in the navigation menu for different information screens.

General Navigation

Provides instructions for navigating through the controller's display screens.

Home

Describes the default display screen showing generator and mains voltage.

Generator

Details electrical values related to the generator's voltage and frequency.

Mains

Provides electrical values related to the mains supply voltage and frequency.

Load

Displays electrical values related to the generator's load.

Engine

Shows engine parameters such as speed, runtime, and oil pressure.

Info

Contains information about the controller's settings and version.

Engine DTC (ECU Alarms)

Explains how active Diagnostic Trouble Codes (DTC) from the ECU are displayed.

Viewing Active Engine DTC

Guides on how to view active DTC alarms on the controller.

Event Log

Describes the module's event log containing trip and shutdown events.

Viewing The Event Log

Details how to access and view the event log entries.

Quickstart Guide

Offers a concise guide for quick operation of the module.

Starting The Engine

Explains the procedure for starting the engine using the manual/start button.

Stopping The Engine

Details how to stop the generator using the STOP/RESET mode.

Stop;Reset Mode

Explains the function and activation of the STOP/RESET mode.

Automatic Mode

Describes the AUTO mode for automatic generator operation.

Waiting In Auto Mode

Explains the state when the generator is waiting for an auto start request.

Starting Sequence

Outlines the sequence of events for starting the generator in AUTO mode.

Engine Running

Describes what happens once the engine is running and placed on load.

Stopping Sequence

Details the process of stopping the generator after it has run off-load.

Manual;Start Mode

Explains the Manual/Start mode and its operation.

Waiting In Manual Mode

Describes the state when waiting for a manual start in MANUAL/START mode.

Starting Sequence

Details the starting sequence in Manual/Start mode.

Engine Running

Describes engine running status in Manual mode.

Manual;Start Mode

Continues explanation of Manual/Start mode.

Stopping Sequence

Explains how to stop the generator in Manual/Start mode.

Maintenance Alarm

Discusses the occurrence and configuration of maintenance alarms.

Scheduler

Explains the function of the built-in exercise run scheduler.

Stop Mode

States that scheduled runs do not occur in STOP/RESET mode.

Manual;Start Mode

States that scheduled runs do not occur waiting for manual start.

Auto Mode

Explains when scheduled runs operate in AUTO mode.

Front Panel Configuration

Describes how to configure the module using the front panel editor.

Accessing the Front Panel Configuration Editor

Provides step-by-step instructions to enter the configuration editor.

Commissioning

Operating Environment

General

Introduces factors affecting the generator's operating environment.

Power De-rating

Explains how temperature and altitude affect power output.

Derate Table

Provides tables for applying power derating based on temperature and altitude.

Attachments

Working with Attachments

Introduces the section on attachments for the machine.

Bunding Tank

Details the bunding tank attachment for environmental protection.

Fork Pockets

Describes the fork pockets attachment for lifting and handling.

Transportation Bracket

Explains the temporary transportation bracket and its removal.

Oil Drain Valve;Pump Assembly

Details the oil drain valve and pump assembly for oil changes.

Oil Pressure Sensor

Identifies the oil pressure sensor and its connection.

Water Jacket Heater

Describes the water jacket heater for cold starts.

Battery Isolator

Shows the location and components of the battery isolator.

3 Way Fuel Valve (WFV)

Details the 3-way fuel valve and its connections for fuel supply.

Canopy Delete Z0

Illustrates a typical generator without a canopy.

CE Hot Guards

Shows the CE hot guard plate for safety.

ATP Panel

Describes the ATP panel and its electrical components.

Door Stop Arrangement

Illustrates the door stop mechanism for securing access doors.

Canopy Protection Kit

Details the canopy protection kit components.

Open Set Dedicated Design

Shows the layout of an open set generator design.

Preservation and Storage

Cleaning

Provides instructions for cleaning the generator set.

General

Outlines general steps for safely cleaning the machine.

Maintenance

Introduction

Introduces the importance of regular maintenance for preserving the generator's life.

General

Emphasizes safety and the need for qualified personnel for maintenance.

Maintenance Safety

Covers critical safety procedures and precautions during maintenance.

General Safety Precautions

Covers safety for exhaust, communication, modifications, repairs, and components.

Chemicals

Warns about hazards associated with fluoroelastomeric materials and hydrofluoric acid.

Oil

Provides safety information regarding oil toxicity and handling.

Fuel

Details safety precautions for handling flammable fuel.

Fires

Offers guidance on extinguishing machine fires and the use of appropriate extinguishers.

Fluids and Lubricants

Covers safety aspects of oil, fuel, antifreeze, hygiene, and waste disposal.

Battery

Highlights battery safety, including explosive gas hazards.

Warning Symbols

Illustrates common warning symbols found on batteries.

Disposal

Advises on the proper disposal and recycling of used batteries.

First Aid - Electrolyte

Provides first aid measures for electrolyte exposure.

Maintenance Schedules

General

Stresses the importance of regular maintenance for safe operation.

How to Use the Maintenance Schedules

Explains how to interpret and follow the maintenance schedules.

Maintenance Intervals

Lists the calendar equivalents for machine maintenance intervals.

Pre-start Cold Checks, Service Points and Fluid Levels

Details critical checks to perform before starting the engine.

Engine

General

Introduces engine maintenance procedures and safety warnings.

Clean

Provides detailed steps for cleaning the engine before maintenance.

Oil

Covers checking and maintaining the engine oil level.

Replace

Details the procedure for replacing engine oil and filter.

Drive Belt

Explains how to check and adjust the drive belt tension.

Alternator

Describes the general characteristics of the alternators used.

Safety Requirement

Emphasizes safety precautions before performing maintenance on the generator.

Electrical Connections

Discusses alternator winding connections and voltage regulator adjustments.

Windings Connection

Explains star and delta connection options for alternators.

DSR Digital Regulator

Provides information on the operation and use of the DSR digital regulator.

Installation

Guides on the proper installation of the digital regulator.

Connection

Details the digital regulator's connections to the excitation system.

Regulator Setup

Explains how to set up the regulator using trimmers and jumpers.

Trimmers

Describes the function of the volt, stab, and amp trimmers.

Excitation Overcurrent

Details the excitation overcurrent protection and its temperature estimator.

Alarms

Explains how alarms are indicated during normal operation and events.

Regulators

Discusses voltage regulation and protections provided by the DSR regulator.

Starting and Stopping The Operations

Guides on starting, running, and stopping the system safely.

Maintenance

Emphasizes the long maintenance-free life of the alternators.

Internal and External Cleaning of the Generator

Provides methods for cleaning the generator externally and internally.

Extraordinary maintenance operations

Lists major maintenance tasks beyond routine checks.

Air Filter

General

Introduces the air filter system.

Check (Condition)

Details how to check the condition of the air filter and hoses.

Replace

Explains that air filter elements must be renewed, not cleaned.

Remove

Provides steps for removing the air filter elements.

Install

Outlines the procedure for installing the air filter.

Dust Valve

Check (Condition)

Specifies checks for the dust valve's condition and attachment.

Fuel System

General

Introduces the fuel system and safety precautions.

Bleed

Details the procedure for bleeding the fuel system to remove air.

Check (Leaks)

Guides on checking the fuel system for any leaks.

Engine Fuel Filter

Explains how to replace the engine fuel filter element.

Water Separator

Covers the cleaning and draining of the water separator.

Clean

Details how to drain water from the separator.

Cooling System

Coolant

Addresses checking and maintaining the coolant level.

Check (Level)

Provides instructions for checking the coolant level and adding it.

Replace

Details the procedure for replacing the coolant in the system.

Cooling Pack

Covers cleaning and checking the cooling pack.

Clean

Instructions for cleaning debris from the cooling pack.

Check (Condition)

Guides on checking the condition of the cooling pack and hoses.

Electrical System

General

Introduces the electrical system and battery maintenance.

Batteries

Covers battery maintenance, topping up electrolyte, and charging precautions.

Maintenance

Provides steps for optimal battery performance.

Quiescent Current Drain

Explains quiescent current drain and troubleshooting.

Battery

Details safety precautions and procedures for cleaning the battery.

Clean

Provides steps for cleaning battery terminals and posts.

Connect

Outlines the procedure for connecting battery leads.

Battery Cable Installation

Details the correct installation of battery cables and rubber boots.

Disconnect

Warns about handling heavy components and battery voltage.

Figure 93. Parallel and Series Connection (Example)

Illustrates parallel and series battery connection examples.

Figure 94. Twin Battery 12 V Machines - Parallel Connection (Example)

Shows an example of twin 12V battery parallel connection.

Figure 95. 24 Volt Machines - Series Connection (Example)

Shows an example of 24V battery series connection.

Check (Electrolyte Level)

Explains how to check and maintain the battery's electrolyte level.

Charging the Battery

Discusses battery charging requirements and methods.

Battery Life

Covers factors affecting battery life and the benefits of onboard chargers.

Precautions before Charging

Lists safety measures to prevent damage during charging.

Battery Test

Explains how to test the battery's electrical condition and remaining life.

Specific Gravity Test

Details how to perform a specific gravity test to assess battery charge state.

Fault-Finding

General

Introduces fault-finding procedures and basic troubleshooting steps.

Engine

Provides tables for troubleshooting engine starting and running issues.

Lubricating Oil

Covers troubleshooting for excessive or contaminated lubricating oil.

Coolant

Addresses issues related to coolant loss and contamination.

Electrical

Discusses general faults related to electrical systems and sensors.

Alternator

Details common faults and remedies related to the alternator.

Control Panel

Covers symptoms and remedies for control panel issues.

Starting

Addresses issues related to the generator's starting sequence.

Loading

Discusses symptoms and remedies when the generator runs but won't take load.

Alarms

Lists common alarms, their symptoms, and possible remedies.

Miscellaneous

Covers issues related to configuration changes and saving settings.

Technical Data

Introduction

Provides an introduction to the technical data section.

General

Lists model designations, ratings, and engine types.

Static Dimensions

Presents static dimensions (length, width, height, volume) for generator models.

Weights

Lists the weights of different generator models.

Noise Emissions

Details the noise data (sound pressure level) for different generator models.

Fluids, Lubricants and Capacities

Covers engine oil specifications, recommended oils, and capacities.

Fuel

Covers warnings about fuel types, acceptable fuels, and low-temperature considerations.

Coolant

Provides guidelines on checking coolant strength, replacement intervals, and antifreeze types.

Electrical System

Presents a table of electrical system specifications for different generator models.

Engine

Lists engine specifications including output ratings, bore, stroke, and cooling systems.

Warranty Information

Outlines general warranty terms and the importance of regular maintenance.

Installation Access

Stresses the need for unrestricted access for maintenance.

Downtime Support

Addresses the need for substitute power during maintenance.

Terms and Conditions

Details warranty periods and conditions for various applications.

Emergency Standby Power (ESP)

Specifies the warranty period for Emergency Standby Power applications.

Prime Power (PRP)

Specifies the warranty period for Prime Power applications.

Continuous Power (COP) and Limited Time Running Power (LTP)

Outlines warranty considerations for COP and LTP applications.

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