jcb RENTAL Series User manual

RENTAL SERIES
STAGE V DIESEL GENERATOR
G40RS V
Quick Start Guide

INDEX
Disclaimer
Dimensions & Volumes
Key Components
General Checks
Control Panel
Battery Isolator
Fuel Connections
Positioning
Lifting
Refuelling
Emergency Stops
Maintenance Schedule
Service Checks
3
4
5
10
12
18
19
20
21
22
23
24
25
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Please consult your manual for full information or consult your local dealer

> This Quick Reference Guide is to provide quick and simple information to the
Operator and does not include any health and safety aspects. In addition, because of
our continual development of machines, features described in this Quick Reference
Guide may differ from those on your machine. No errors and emissions be entirely
ruled out.
> This Quick Reference Guide DOES NOT replace the Operators Manual. You MUST
read ALL the disclaimers and safety and other instructions in the Operators Manual
before initially operating this product. Accordingly, no legal claims can be entertained
on the basis of the data, illustrations or descriptions in this Quick Reference Guide.
This machine should not be operated by any person who isn’t appropriately qualified or
had the appropriate training.
Operation of this machine without periodic maintenance could cause it to malfunction.
For more information please contact your JCB Dealer.
DISCLAIMER
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Please consult your manual for full information or consult your local dealer

DIMENSIONS & VOLUMES
Fuel –EN590 & EN15940
Lube Oil –API CJ4
* - wet weight
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MODEL G40RS V
3 PHASE –400V –kW/kVA (Prime Power) 40
3 PHASE –400V –A58
DIMENSIONS –mm
L2265 x W1050
x H1574
WEIGHT (OPERATING) –kg 1400
AFTERTREATMENT DOC/DPF
FUEL TANK CAPACITY –L176
FUEL CONSUMPTION @ 75% PRP –L/h 7.4
FUEL AUTONOMY - Hrs 24
NOISE LEVEL (7m @ 75% LOAD) 67

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BForklift Pockets
DCoolant Fill Access
ALeft Door
CExhaust Rain Cap
ELift Hook
KEY COMPONENTS - ENCLOSURE

KEY COMPONENTS - GENERATOR
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A Socket box
B Control panel
C Primary Fuel Filter
D Dipstick
E Oil drain pump
FBattery
GAlternator
HEngine
J Exhaust
K Resistive Elements
L Aftertreatment Canister
M LiveLink

KEY COMPONENTS - ENGINE
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A Rocker Cover
B Lifting Eye (engine only)
C Fuel injectors
D Radiator cap
E Radiator
F Oil filler cap
G High Pressure Pump
H Oil Filter
J Secondary Fuel Filter

KEY COMPONENTS - SKID
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A Alternator cross member
B Fuel tank inspection hatch
C Engine cross member
D Base frame
E Anti-vibration mounts
FCanopy protection block
F

KEY COMPONENTS - CONTROL PANEL
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A
DC Control Section
B
Digital Controller
C
AC Power Section
D
Bus Live Indicator
E
Frequency Selection Switch
F
Hour Counter (Optional)
G
Basic Operator Instruction
H
MCCB
E
D
A
B
G
H
C
F

GENERAL CHECKS
After correct installation of the unit and the wiring, the generating set must be fully checked
over before first starting can be attempted. Points to check include:
•Make sure that the battery isolator is at 'off' position before carrying out any checks.
•Check all belts, guards and panel covers are firmly secured.
•Check the installed wiring to ensure all connections are firmly installed in the correct
position, and that wires are in good condition.
•Make sure that the battery connections are secure and polarity of connections are correct.
•Ensure that there is fuel in the fuel tank.
•If the machine has not been run previously, if it has run out of fuel or if the fuel supply has
been reconnected then the fuel system must be primed prior to starting. Check for fuel
leaks during this process.
•Check level of coolant in machine radiator, and top-up if low.
•Check hoses for damage or loose clamps.
•Check level of engine oil using dipstick.
•Check fuel filter/water separator for presence of water or contaminants.
•Check the position of the 3-way valve to correct fuel source. Do not run the generator
with the 3-way valve set to the 'off' position (if applicable).
•Visually inspect the engine and alternator for any signs of damage, water, oil or fuel leaks.
•Make sure that all supplied documents are kept in the document holder case.
•Ensure that machine intake and outlet air vents and grills are not obstructed or blocked in
any way to allow good airflow through the machine.
•Check that the engine intake air filter is correctly fitted, and that there are no obstructions
to the incoming air.
•Make sure that the that the alternator windings and assembly are not damp, or dirty.
Failure to do so could result in damage to the alternator windings. If windings are observed
to be damp/dirty contact your JCB Dealer.
•Make sure that all the engine access doors are closed and secured.
•With the exception of emergency power generators, the engine should be warmed up with
a reduced load before applying the full load.
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Please consult your manual for full information or consult your local dealer
Before Starting the Engine

GENERAL CHECKS
Ensure that the electrical load is switched OFF before stopping the engine.
• Check that battery isolator is at 'off' position.
• Fill the fuel tank. Make sure that the filler cap and the area round the filler opening are
clean to avoid contamination of the fuel.
• Make sure that all the engine access doors are closed and secured.
• If there is a risk of freezing, the cooling system must contain the correct antifreeze.
• At temperatures below 0°C: Prepare for the next start by connecting the engine
heater.
Coolant should be topped up when the engine is stopped. Make sure that enough time is
allowed for the engine/coolant to cool before the radiator cap is removed
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Please consult your manual for full information or consult your local dealer
Checks After Running

CONTROL PANEL –DSE 7310
AModule display
BFour configurable status LED (Light Emitting Diode)
CTransfer to generator - manual mode only (not used)
DGenerator available LED
EStart button
FAlarm mute and lamp test
GGenerator breaker LED (not used)
HAuto mode
JTest mode (not used)
KMains breaker LED (not used)
LManual mode
MStop/reset button
NSelected mode indication LED
PMains available LED (not used)
QTransfer to mains - manual mode only (not used)
RModule display navigation button
This button places the module into its STOP/RESET mode. This will clear any alarm conditions for which the
triggering criteria have been removed. If the engine is running and the module is put into STOP/RESET mode,
the module will automatically instruct the generator to unload ('Close Generator output' becomes inactive. In
STOP/RESET mode the generator remains at
rest.
This button places the module into its MANUAL mode. Once in MANUAL mode, the module responds to the
start button to start the generator and run it off load. The MCCB need to be closed manually.
This button places the module into its AUTO MODE. This mode allows the module to control the function of
the generator automatically. The module monitors numerous start requests via digital input, PLC and MSC link
and when one has been made, the set is automatically started. Once the generator is available, the module
automatically instructs the generator to synchronise and once in sync, to be place the generator on load (‘Close
Generator Output’ becomes active). Upon removal of the starting signal, the module starts the Return Delay
Timer and once expired, the load is automatically ramped off the generator and then it is taken off load (‘Close
Generator Output’ becomes inactive). The generator then continues to run for the duration of the Cooling
Timer until it stops. The module then waits for the next start event.
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Please consult your manual for full information or consult your local dealer

CONTROL PANEL –DSE 7310
This button is only active in the STOP/RESET mode, MANUAL mode. Pressing the Start button in Stop/Reset
Mode powers up the engine’s ECU but does not start the engine. This can be used to check the status of the
CAN communication and to prime the fuel system
Used for navigating the instrumentation, event log and configuration screens.
Used to silences the audible alarm in the controller, de-activates the audible alarm output (if configured) and
illuminates all of the LED on the module’s facia as a lamp test function.
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Please consult your manual for full information or consult your local dealer

CONTROL PANEL –DSE 8610
A Module display
B Four configurable status LED
C Close generator
D Generator available LED
E Start button
F Alarm mute and lamp test
G Auto mode
H Generator breaker LED
J Manual mode
K Stop/reset button
L Selected mode indication LED
M Open generator (manual mode only)
N Module display Menu navigation buttons
This button places the module into its STOP/RESET mode. This will clear any alarm conditions for which the
triggering criteria have been removed. If the engine is running and the module is put into STOP/RESET mode,
the module will automatically instruct the generator to unload ('Close Generator output' becomes inactive. In
STOP/RESET mode the generator remains at
rest.
This button places the module into its MANUAL mode. Once in MANUAL mode, the module responds to the
start button to start the generator and run it off load. To place the generator on load, use the 'Transfer to
Generator‘ button. The module automatically instructs the generator to synchronise and once in sync, to be
place the generator on load (‘Close Generator Output’ becomes active). To place the generator off load, use
the 'Open Generator‘ button. The module automatically ramps the load off the generator and then takes it off
load (‘Close Generator Output’ becomes inactive). Additional digital inputs are available to perform these
functions. If the generator is running off-load in MANUAL mode and on load signal becomes active, the module
automatically instructs the generator to synchronise and once in sync, to be place the generator on load (‘Close
Generator Output’ becomes active). Upon removal of the on load signal, the generator remains on load until
either selection of the 'STOP/RESET' mode or 'AUTO' mode.
This button places the module into its AUTO MODE. This mode allows the module to control the function of
the generator automatically. The module monitors numerous start requests via digital input, PLC and MSC link
and when one has been made, the set is automatically started. Once the generator is available, the module
automatically instructs the generator to synchronise and once in sync, to be place the generator on load (‘Close
Generator Output’ becomes active). Upon removal of the starting signal, the module starts the Return Delay
Timer and once expired, the load is automatically ramped off the generator and then it is taken off load (‘Close
Generator Output’ becomes inactive). The generator then continues to run for the duration of the Cooling
Timer until it stops. The module then waits for the next start event.
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Please consult your manual for full information or consult your local dealer

CONTROL PANEL –DSE 8610
This button is only active in the STOP/RESET mode, MANUAL mode. Pressing the Start button in Stop/Reset
Mode powers up the engine’s ECU but does not start the engine. This can be used to check the status of the
CAN communication and to prime the fuel system
Used for navigating the instrumentation, event log and configuration screens.
Used to silences the audible alarm in the controller, de-activates the audible alarm output (if configured) and
illuminates all of the LED on the module’s facia as a lamp test function.
Close Generator- The Close Generator button controls the operation of the generator load switch and is only
active in the Manual Mode once the generator is available. Pressing the Close Generator button when the
generator is available and off load automatically instructs the generator to synchronise and once in sync, to be
place the generator on load (‘Close Generator Output’ becomes active). If the generator bus is dead (has not
supply on it) the generator is placed on load immediately. Further presses of the Close Generator button have
no effect.
Open Generator- The Open Generator button is only active in the Manual Mode and allows the operator to
open the generator load switch. Pressing the Open Generator button when the Generator is on load,
automatically ramps the load off the generator and then takes it off load (‘Close Generator Output’ becomes
inactive). Further presses of the Open Generator button have no effect.
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Please consult your manual for full information or consult your local dealer

CONTROL PANEL - DSE
Operation
Single generator, controlled manually through its genset controller. Load is monitored
by the operator.
Starting Procedure
Perform all the pre-start checks before starting the generator.
Turn ON battery isolator
1. Make sure ALL power output supply MCCB’s are switched off.
2. Check that the emergency stop button is fully out, if necessary twist to reset the
button.
3. Complete all pre-start, system and engine checks.
4. Turn on the Digital Controller (DC) switch to power the DSE Controller.
5. Wait for few seconds, to allow the controller to power up and display to stabilise.
6. Make sure that the power on LED (Light Emitting Diode) is illuminated on earth
leakage trip and there is no trip active where required.
7. Press the stop/reset button on DSE to clear any elapsed alarms
8. When ready “Press the Manual mode button” on DSE controller.
9. When ready “Press Start button” and the machine will start
10. The Generator will attempt three start cycles before registering a fault / alarm
11. The engine will run up to speed and stabilise.
12. Check that the machine operation is correct using the screen information.
13. Make sure the power on LED is illuminated on earth leakage trip and there is no
trip active.
14. Manually turn on the main power supply MCCB.
15. Turn on any socket MCCB’s that may be fitted and required .
16. The generator can now be loaded.
17. If the earth leakage relay trips at this point consult the site electrical installation
engineer.
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Please consult your manual for full information or consult your local dealer
For synchronising instructions using the DSE8610 controller,
please consult the operators manual or contact your local
dealer.

CONTROL PANEL - DSE
Operation
Single generator, controlled manually through its genset controller. Load is monitored
by the operator.
Stopping Procedure
Perform the procedure below to stop the generator:
1. To stop the generator, remove any electrical loads.
2. Turn the main power supply MCCB to off position.
3. Press the stop button the generator will now stop after a cool down period .
4. Turn Off the Digital Controller (DC) switch
5. Turn Off battery isolator after a short time period
6. Ensure generator is secured and all doors are locked
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Please consult your manual for full information or consult your local dealer
IMPORTANT
Before Stopping
1. Check with other personnel on the job site and let them know that
power is being turned off.
2. Make sure that the power shutdown will not create any hazards by
turning off site critical or life safety devices that may need to be kept
on.

BATTERY ISOLATOR
The battery isolator switch is used to disconnect the battery from the machine electrics. The switch
must be turned to the off position if any maintenance work is to be performed on the machine.
Some machine systems perform shut down cycles after the engine stops. Wait until shut down cycles are
complete before setting the battery isolator switch to the off position.
At the end of a working cycle or if the machine is being left unattended and the lights are not required,
the battery must be isolated.
Disconnect
If the machine has an electronically controlled engine, you must wait a period of time before you isolate
the battery. This is to allow the ECM (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 an emergency, remove the isolator key without waiting.
1. Wait for the specified duration after the engine is turned off before you isolate the battery (60 s).
2. Make the machine safe.
3. Turn the ignition to the off position.
4. Wait for the engine ECM to shutdown correctly (if installed).
5. Get access to the isolator key.
6. Turn the battery isolator key in the indicated direction and remove.
Connect
Before you start the engine or use the machine electrics, the battery isolator key must be installed and
switched on.
1. Make sure the ignition is set to off.
2. Insert the battery isolator key and turn in the indicated direction.
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Please consult your manual for full information or consult your local dealer
Battery Isolator (where fitted)
A. Off Position
B. On Position

FUEL CONNECTIONS (WHERE FITTED)
The optional 3-Way Fuel Valve allows the generator to be connected to feed and return
to a remote bulk tank.
The selection lever dictates if the engine will feed from either the base tank or bulk tank.
This selection lever should be fully engaged in the chosen position.
Please consult the manual for details of maximum distances and acceptable elevation of
bulk fuel tanks.
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Please consult your manual for full information or consult your local dealer
FForward line (3 way valve to lift pump inlet)
GReturn line (engine return to 3 way valve)
Hdirection lever
J Forward line (External fuel tank suction to 3
way valve)
KReturn line (3 way valve outlet to external fuel
tank)
A External tank
BBase tank
C Forward line (fuel tank suction to 3 way valve)
DReturn line (3 way valve outlet to fuel tank
E3 way fuel valve

LIFTING
The generating set should only be lifted using the designated lifting points or the fork
pockets where provided.
Do not lift the unit by the alternator or engine lifting eyes. These are designed only to
carry the weight of the specific unit (engine or alternator) and not for the weight of the
fully assembled generating set.
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Please consult your manual for full information or consult your local dealer
IMPORTANT
Always ensure that lifting equipment is rated to lift the load. Weights are
shown on the generator rating plate on the side of the control panel. These
weights exclude fuel, and while both the fork pockets and lifting frame are
rated to allow lifting including fuel, the operator needs to ensure that they
have adequate lifting capacity.
ALifting Eye
B Fork Pockets.
C Lifting Point Decal
For movement on site the optional fork pockets enable the generating set to be lifted and
shifted by forklift or telescopic handler. The fork pockets are sized and spaced to allow lifting
by equipment with a standard fork carriage.