jcb G20 User manual

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

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 contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2017 © JCB SERVICE
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow 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 anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Machine Delivery and Installation
Even if you have operated this type of equipment
before, it is very important that your new machines
operations and functions are explained to you by
a JCB Dealer Representative following delivery of
your new machine.
Following the installation you will know how to gain
maximum productivity and performance from your
new product.
Please contact your local JCB dealer if the
Installation Form (included in this manual) has not
yet been completed with you.
Your local JCB Dealer is

9831/0650-3
Notes:

Table of Contents
i 9831/0650-3 i
Contents Page No.
Acronyms Glossary ......................................................................................................................................... iii
Introduction
About this Manual
Model and Serial Number ..................................................................................................................... 1
Using the Manual .................................................................................................................................. 1
Left-Hand Side, Right-Hand Side ......................................................................................................... 1
Cross References ................................................................................................................................. 2
Safety
Safety - Yours and Others .................................................................................................................... 3
Safety Warnings .................................................................................................................................... 3
General Safety ...................................................................................................................................... 3
About the Product
Introduction
Name and Address of the Manufacturer .............................................................................................. 5
Product Compliance .............................................................................................................................. 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 ........................................................................................................................................... 15
Operation
Operating Safety
General ................................................................................................................................................ 25
Battery Isolator
General ................................................................................................................................................ 27
Before Starting the Engine
General ................................................................................................................................................ 28
Instruments
Instrument Panel ................................................................................................................................. 29
Operating Environment
General ................................................................................................................................................ 54
Attachments
Working with Attachments
Attachments for your Machine ............................................................................................................ 57
Preservation and Storage
Cleaning
General ................................................................................................................................................ 81
Maintenance
Introduction
General ................................................................................................................................................ 82
Maintenance Safety
General ................................................................................................................................................ 83

Table of Contents
ii 9831/0650-3 ii
Fluids and Lubricants ......................................................................................................................... 84
Maintenance Schedules
General ................................................................................................................................................ 88
How to Use the Maintenance Schedules ........................................................................................... 88
Maintenance Intervals ......................................................................................................................... 88
Pre-start Cold Checks, Service Points and Fluid Levels .................................................................... 88
Engine
General ............................................................................................................................................... 91
Oil ........................................................................................................................................................ 91
Drive Belt ............................................................................................................................................ 93
Alternator ............................................................................................................................................ 93
Air Filter
General ............................................................................................................................................. 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
Technical Data
Introduction
General .............................................................................................................................................. 141
Static Dimensions
Dimensions ........................................................................................................................................ 142
Weights ............................................................................................................................................. 142
Noise Emissions
Noise Data ........................................................................................................................................ 143
Fluids, Lubricants and Capacities
General .............................................................................................................................................. 144
Fuel ................................................................................................................................................... 145
Coolant .............................................................................................................................................. 146
Electrical System
General .............................................................................................................................................. 147
Schematic Circuit .............................................................................................................................. 148
Engine
General .............................................................................................................................................. 168
Warranty Information
General .............................................................................................................................................. 170

Table of Contents
iii 9831/0650-3 iii
Acronyms Glossary
CAN Controller Area Network
CCV Crankcase 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 Identification Number
RPM Revolutions Per Minute
SAE Society of Automotive Engineers
USB Universal Serial Bus

Notes:
iv 9831/0650-3 iv

Introduction
About this Manual
1 9831/0650-3 1
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.

Introduction
About this Manual
2 9831/0650-3 2
Cross 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 brackets. For example: Refer to:
Cross References (Page 2).

Introduction
Safety
3 9831/0650-3 3
Safety
Safety - Yours and Others
All machinery can be hazardous. When a machine is correctly operated and maintained, it is a safe machine
to work with. When it is carelessly operated or poorly maintained it can become a danger to you (the operator)
and others.
In this manual and on the machine you will find warning messages, you must read and understand them. They
inform you of potential hazards and how to avoid them. If you do not fully understand the warning messages,
ask your employer or JCB dealer to explain them.
Safety is not just a matter of responding to the warnings. All the time you are working on or with the machine
you must be thinking of what hazards there might be and how to avoid them.
Do not work with the machine until you are sure that you can control it.
Do not start any work until you are sure that you and those around you will be safe.
If you are not sure of anything, about the machine or the work, ask someone who knows. Do not assume
anything.
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' indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
The signal word 'WARNING' indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
The signal word 'CAUTION' indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
The signal word 'Notice' indicates a hazardous situation which, if not avoided, could result in machine damage.
The safety alert system symbol (shown) also helps to identify important safety messages in this manual. When
you see this symbol your safety is involved, carefully read the message that follows.
Figure 1. The safety alert system symbol
General Safety
The following safety checklist is intended to help remind you of safety procedures and practices.
Safety is Your Responsibility
You must also refer to local regulations in the country your equipment is being used in. Some of the information
may be repeated in the following warnings and cautions pages and in the main text.

Introduction
Safety
4 9831/0650-3 4
• Do not change the application or specification of the engine. Install the engine in accordance with
recommendations made in the Engine Installation Manual. – Do not lift heavy objects on your own, use
lifting equipment or obtain the help of an assistant.
• Do not smoke when adding fuel to the tank or working in the engine bay area.
• Always clean up spilt fluids, dispose of fluids, contaminated material etc. in accordance with local
regulations. Do not pollute drains or the ground. – Use the right tools for the job. – Always make the
equipment safe before completing any maintenance tasks, for instance disconnect the battery so that the
engine can not be started.
• Allow engine components to cool before attempting any maintenance tasks, components such as the
exhaust can become extremely hot.
• Do not adjust the engine, or add fuel, oil whilst it is running unless procedures in this manual instruct
you to do so.
• Do not siphon fluids by mouth.
• Operate the engine in well ventilated areas, if using 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 (when applicable) has been removed.
• Vapours from solvents, thinners and adhesives can be high flammable. In addition to fire risk, they can
be toxic and in certain conditions cause unconsciousness, or death if inhaled. Use these items in well
ventilated areas.
• Seek medical advice immediately if your skin contacts high pressure fuel.
• Make sure the engine is operated by one person correctly positioned at the controls.
• Do not operate the engine at high speeds with no load applied.
• Make sure you have adequate fire fighting equipment in your workshop, repair area. Contact your local
fire prevention officer for advice.
• Turbocharger impeller blades operate at extremely high revolutions and the turbocharger unit becomes
very hot. Allow the unit to cool before completing any maintenance. Keep tools and objects away from
the impeller when the unit is operating.
• Use only JCB recommended parts. These parts have been designed to give the engine its optimum
performance. Using spurious parts may affect the integrity of the engine.

About the Product
Introduction
5 9831/0650-3 5
About the Product
Introduction
Name and Address of the Manufacturer
JCB Power Products Limited, 23/7, Mathura Road, Ballabgarh-121004, Haryana.
Product Compliance
Your JCB product was designed to comply with the laws and regulations applicable at the time of its manufacture
for the market in which it was first sold. In many markets, laws and regulations exist that require the owner to
maintain the product at a level of compliance relevant to the product when first produced. Even in the absence
of defined requirements for the product owner, JCB recommend that the product compliance be maintained
to ensure safety of the operator and exposed persons and to ensure the correct environmental performance.
Your product must not be altered in any way which could affect or invalidate any of these requirements. For
advice consult your JCB dealer.
For its compliance as a new product, your JCB and some of its components may bear approval numbers
and marking's, and may have been supplied with a Declaration/Certificate of 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/export of products across territories with different laws and regulations can cause new
requirements to become relevant for which the product was not originally designed or specified. In some cases,
pre owned products irrespective of their age are considered new for the purposes of compliance and may be
required to meet the latest requirements which could present an insurmountable barrier to their sale/use.
Despite the presence of any compliance related marking's on the product and components, you should not
assume that compliance in a new market will be possible. In many cases it is the person responsible for import
of a pre owned product into a market that becomes responsible for compliance and who is also considered
the manufacturer.
JCB may be unable to support any product compliance related enquiry for a product which has been moved out
of the legislative country/region where it was first sold, and in particular where a product specification change
or additional certification would have been required in order for the product to be in compliance.

About the Product
Description
6 9831/0650-3 6
Description
Main Component Locations
Figure 2.
A
B
C
D
E
F
AAccess door for the control panel BAccess door for engine and radiator
CAccess panel for exhaust muffler DAccess door for alternator
EAccess door for battery FForklift pockets

About the Product
Description
7 9831/0650-3 7
Figure 3.
D
H
J
K
L
M
N
G
E
F
C
P
B
A
AFuel tank BControl panel
CEmergency stop DFuel filter/water separator
EFuel tank filler neck FEngine oil filter
GWater separator HExhaust silencer
JRadiator cap KRadiator
LInlet manifold MAutomatic voltage regulator
NBattery PData plate

About the Product
Description
8 9831/0650-3 8
Figure 4.
D
E
BC
A
F
G
J
H
K
ARocker cover BLifting eye
CFuel injectors DRadiator cap
ERadiator FOil filler cap
GHigh pressure pump HECU (Electronic Control Unit)
JFuel filter/water separator KOil filter

About the Product
Description
9 9831/0650-3 9
Figure 5.
A
H
G
C
B
D
E
F
AOil filter cap BAir filter
COil pressure sensor DStarter motor assembly
EFly wheel housing FOil drain plug (sump)
GOil sump HAlternator

About the Product
Product and Component Identification
10 9831/0650-3 10
Product and Component Identification
General
The data plate details the model designation, rating, fuel type, weight, year of manufacture, output rating and
other generating set specific information. 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 determine the version of generating set.
Figure 6. Example Identification Plate
Figure 7. Example Identification Plate
Engine
The engine data labels are attached to the cylinder block as shown. Refer to Figure 8.
The data label includes the engine identification number.

About the Product
Product and Component Identification
11 9831/0650-3 11
Figure 8.
AA
AEngine data label

About the Product
Safety Labels
12 9831/0650-3 12
Safety Labels
General
WARNING Safety labels on the machine warn you of particular hazards. You can be injured if you do not
obey the safety instructions shown.
The safety labels are strategically placed around the machine to remind you of possible hazards.
If you need eye-glasses for 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 safety label, then refer to Safety Label Identification.
Keep all of the safety labels clean and readable. Replace a lost or damaged safety label. Make sure the
replacement parts include the safety labels where necessary. Each safety label has a part number printed on
it, use this number to order a new safety label from your JCB dealer.

About the Product
Safety Labels
13 9831/0650-3 13
Safety Label Identification
Figure 9.
DE
817 /7000 5
C
817 /7003 2
A
B
817/70021-2
C
817/70032-2