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jcb G40QS User Manual

jcb G40QS
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 G40QS Specifications

General IconGeneral
ModelG40QS
Rated Power Output3.2kW
Voltage230V
Frequency50Hz
Fuel TypePetrol
Maximum Power Output3.5kW
Engine Type4-Stroke, OHV, Air Cooled
Starting SystemRecoil

Summary

Foreword

Introduction

Safety

Safety - Yours and Others

Emphasizes the hazardous nature of machinery and the importance of safe operation.

Safety Warnings

Explains signal words (DANGER, WARNING, CAUTION, Notice) and safety symbols.

General Safety

Introduces a safety checklist and responsibility for procedures.

Description

Product and Component Identification

Safety Labels

Installation and Removal

Indoor Installations

Ventilation

Fuel Supply System

Grounding

Operation

Operating Safety

Stresses constant vigilance and alertness for hazards during operation.

Starting The Engine

Provides instructions on how to start the engine using the manual/start button.

Training

Emphasizes the need for adequate training and confidence for safe operation.

Fuel

Provides safety precautions regarding fuel handling, flammability, and refueling.

Machine Condition

Warns against operating a defective or incomplete machine.

Hot Components

Alcohol and Drugs

Battery Isolator

Disconnect

Details the procedure for disconnecting the battery, including ECM shutdown wait time.

Connect

Outlines the procedure for reconnecting the battery isolator.

Before Starting the Engine

Instruments

Instrument Panel

Introduces the instrument panel layout and its components.

Operation

Details the step-by-step procedure for starting the generator in manual mode.

Digital Controller

Emergency Stop Button

Alarm Icons (Protections)

Warning Alarm Icons

Electrical Trip Alarm Icons

Shutdown Alarm Icons

Viewing The Instrument Pages

Engine

Engine DTC (ECU Alarms)

Viewing Active Engine DTC

Explains how to view active Diagnostic Trouble Codes (DTCs) from the engine ECU.

Event Log

Stopping The Engine

Stop/Reset Mode

Automatic Mode

Manual/Start Mode

Maintenance Alarm

Scheduler

Front Panel Configuration

Accessing the Front Panel Configuration Editor

Commissioning

Power De-rating

Power De-rating depending on operating altitude

Derate Table

Preservation and Storage

Maintenance

Maintenance Safety

Hot Components

Advises caution with hot engine and machine components before servicing.

Fires

Fluids and Lubricants

Used Oil

First Aid - Oil

Battery

Battery electrolyte handling precautions.

Disposal

First Aid - Electrolyte

Maintenance Schedules

How to Use the Maintenance Schedules

Explains how to use the schedules, considering hourly intervals or calendar equivalents.

Pre-start Cold Checks, Service Points and Fluid Levels

Details pre-start checks and service points based on operating hours (Table 19).

Engine

Drive Belt

Alternator

Safety Requirement

Electrical Connections

Windings Connection

DSR Digital Regulator

Connection

Regulator Setup

Trimmers

Excitation Overcurrent

Alarms

Regulators

Protections

Explains underspeed and overload protections of the DSR regulator.

Starting and Stopping The Operations

Routine maintenance operations

Internal and External Cleaning of the Generator

Air Filter

Remove

Outlines the procedure for removing the air filter elements (Figure 83).

Install

Describes the procedure for installing the air filter, reversing removal steps.

Fuel System

Bleed

Provides instructions for bleeding the fuel system to remove air and prevent dirt ingress.

Engine Fuel Filter

Water Separator

Cooling System

Replace

Outlines the procedure for replacing the coolant, including draining and flushing.

Electrical System

Battery

Details how to safely clean battery terminals and posts.

Clean

Details how to safely clean battery terminals and posts.

Connect

Battery Cable Installation

Check (Electrolyte Level)

Charging the Battery

Check (Charge Level)

Precautions before Charging

Lists precautions to prevent damage to the alternator and battery before charging.

Battery Test

Specific Gravity Test

Fault-Finding

General

Explains fault-finding procedures using flow charts and systematic checks.

Engine - Will Not Start or Difficult to Start (No Exhaust Smoke)

Provides troubleshooting steps for engine start issues without exhaust smoke.

Engine - Will Not Start or Difficult to Start (Exhaust Smoke)

Provides troubleshooting steps for engine start issues with exhaust smoke.

Engine - Will Not Crank or Cranks Slowly

Engine - Starts then Stops

Engine - Poor Running

Engine - Poor Running at Idle

Engine - Reduced Power Output

Engine - Will Not Reach Maximum RPM

Engine - Exhaust Smoke Excessive (Black Smoke)

Engine - Exhaust Smoke Excessive (White/Blue Smoke)

Engine - Will Not Shut Off

Fuel - Consumption Excessive

Lubricating Oil - Consumption Excessive

Lubricating Oil - Contaminated

Lubricating Oil - Pressure Low

Coolant - Loss

Coolant - Over Temperature

General Fuel System Faults

General Sensor Fault

Injector Calibration

Open Circuit Injector

Injection Bank

Short Circuit Injector

Engine Low on Power

Battery Voltage

Crankshaft Position Sensor

Camshaft Position Sensor

High Pressure Diagnostics

Alternator does not excite

Low voltage at no load

High voltage at no load

At load conditions, voltage lower than rated voltage

At load conditions, voltage higher than rated voltage

Unstable voltage

Unit is inoperative. Read/Write configuration does not operate

Unit shuts down

Low oil pressure fault operates after engine has fired

High engine temperature fault operates after engine has fired

Shutdown fault operates

Electrical Trip fault operates

Warning fault operates

CAN ECU warningCAN ECU shutdown

CAN data fail

Incorrect reading on engine gauges

Fail to stop alarm when engine is at rest

Inaccurate generator measurements on controller display

Fuel

Coolant

Schematic Circuit

Warranty Information

General

States that maintenance must follow handbook requirements and use genuine JCB parts.

Terms and Conditions

Lists warranty terms: 18 months despatch/12 months service, no cross-hire/consequential damage.

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