jcb G220RS User manual

1
RS T4F Diesel Generator
G220RS
Quick Start Guide
EN - XXXX/XXXX ISSUE A 09/2020

2Please 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

RS T4F Diesel Generator | G220RS 3
Disclaimer ..........................................................................................................................................2
Dimensions & volumes .......................................................................................................................4
Key components .................................................................................................................................5
General checks ...................................................................................................................................9
Control panel ...................................................................................................................................12
Battery isolator .................................................................................................................................19
Multi voltage selection ......................................................................................................................20
Fuel connections ...............................................................................................................................21
Positioning ........................................................................................................................................22
Lifting ...............................................................................................................................................23
Emergency stops ..............................................................................................................................24
Maintenance schedule.......................................................................................................................25
Service checks ..................................................................................................................................26
Your notes ........................................................................................................................................29
Index

4Please consult your manual for full information or consult your local dealer.
Dimensions and volumes
Model G220RS
3 Phase – 480V – kW (prime power) 175
3 Phase – 480V – A 263
3 Phase – 208V – kW 175
Single phase – 240V – kW 85
Dimensions – inches (LxWxH) 156 x 61 x 89
Weight (operating) – lbs 11000
Dimensions (with trailer) - inches (LxWxH) 222 x 88 x 114
Weight (operating) with trailer – lbs 12720
Aftertreatment SCR
Fuel tank capacity – US gallon 245
Fuel consumption @ 75% PRP – US gallon 10.2
Fuel autonomy – hours 24
DEF tank capacity – US gallon 18
DEF consumption @75% PRP – US gallon 0.71
DEF autonomy– hours 25
Noise level (23ft @ 75% load) 67
Fuel – EN590 Diesel fuel types - Auto/C0/C1/C2/C3/C4 BS2869 Class A2
Lube Oil – API CH4-SAE 10W40
Coolant – ASTM D6210
* wet weight without fuel

RS T4F Diesel Generator | G220RS 5
Key components – enclosure
A Right front door
B Right centre door
C Rear rear door
D Rear door
E Front door
F Left front door
G Left rear door
Fig 1
G
F
A
B
C
D
E
G
F
A
B
C
D
E

6Please consult your manual for full information or consult your local dealer.
Key components – generator
A Air filter
B Control panel
C Power cable exit
D Cam lock connections
E Engine
F Main fuel filter
Fig 2
A Bulk head
B Skid
C Battery
D Fuel tank filler
E DEF (Diesel Exhaust Fluid)
tank filler
F Alternator
G Voltage control rotary switch
H Exhaust system
J 'SCR (Selective
Catalytic Reduction)
K Radiator
F
J
K
G
D
E
H
A
C
B
F
C
A
B
E
D

RS T4F Diesel Generator | G220RS 7
Key components – engine
A Flywheel housing
B Fuel pre-filters
C Engine oil dipstick
D Main fuel filter
E Engine oil filler cap
F Oil filter
G Fuses
Fig 3
B
F
A
G
C
E
D
D
G
C
E
BA
F
A Expansion tank
B Coolant filler cap
C Air filter
D Air filter indicator
E Turbocharger
F Oil sump
G Radiator

8Please consult your manual for full information or consult your local dealer.
Key components – control panel
A DIN rail terminal
B Toroid
C Self latching cable cover with padlock
D Automatic circuit breaker
E AVR (Alternator Voltage Regulator)
F Test point
A Auxiliary indicator lamps
B Audible alarm
C Hour meter
D Lockable door
E Coolant heater and battery charger sockets
F GFCI 120V Small power
G USB (Universal Serial Bus) port
H Voltage alarm
J End of line synch switches
K Digital synch connections
L Analogue load share connection point
M 3x50A Shore power – 120V/240V
Fig 4
A
D
B
C
H
J
K
L
M
G
F
E
G
C
F
E
B
D
A
A
D
B
C
H
J
K
L
M
G
F
E
G
C
F
E
B
D
A

RS T4F Diesel Generator | G220RS 9
General checks
Before Starting the Engine
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.
Check the DEF (Diesel Exhaust Fluid). The
system will only check DEF level at key on.
> 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.
> Visually inspect the engine and alternator for
any signs of damage, water, oil or fuel leaks.
A
B
K
J
H
E
G
F
C
D
Fig 5
A External tank
B Base tank
C Forward line (Fuel tank suction to 3-Way
fuel valve)
D Return line (3-Way fuel valve outlet to fuel
tank)
E 3-Way fuel valve
F Forward line (3-Way fuel valve to lift pump
inlet)
G Return line (Engine return to 3-Way fuel
valve)
H Direction lever
J Forward line (External fuel tank suction to
3-Way fuel valve)
K Return line (3-Way fuel valve outlet to
external fuel tank)

10 Please consult your manual for full information or consult your local dealer.
> 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 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.
> Check the multi-voltage section switch and
configuration of breakers for your application.
General checks

RS T4F Diesel Generator | G220RS 11
General checks
Multi-voltage Selection
IMPORTANT NOTE: Operation of
the rotary switch must only be
carried out with the generator in
stop mode and electrically isolated
to prevent personal injury and
damage to the equipment. Changes
to the alternator voltage must be
completed by a suitably trained and
competent person. Please refer to
the operator manual for detailed
instructions including breaker
protection settings.
۱
۲
۳
A
A
D
Fig 6
A Voltage control rotary switch
1 480/277V Three Phase
2 208/120V Three Phase
3 240/120V Single Phase
D Padlock
NOTICE: A padlock must be
installed to prevent accidental
rotation of the multi voltage switch
whilst the generator is running,
otherwise damage will be caused to
the alternator.
Checks after running
Ensure that the electrical load is switched off
before stopping the engine.
> Check that battery isolator is in the ‘off’ position.
> Fill the fuel and DEF tanks. Make sure that the
filler caps and the area round the filler
openings are clean to avoid contamination of
the fuel and DEF.
> Make sure that all the engine access doors are
closed and secured.
> Check the condition of the cooling system
antifreeze.
> If necessary, prepare for the next start by
connecting the cold climate equipment.
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.

12 Please consult your manual for full information or consult your local dealer.
H
G
E
D
B
L
C
F
A
N
P
MK J
Control panel – DEIF TDU107
Fig 7
Item Function
A DEF (Diesel Exhaust Fluid)
percentage
Shows the percentage of DEF
B Breaker Control Closes the breaker
C Date and Time Shows the controller data and time
D EAT (Exhaust After
Treatment) dashboard
Opens EAT dashboard (shortcut)
EAlarm Opens Alarms (shortcut)
FLanguage Opens Language (shortcut)
GMenu Opens the Menu page
H Scroll Page Scroll up or down
J Mode Change Manual/Semi/Auto/Test modes
Touchscreen

RS T4F Diesel Generator | G220RS 13
Item Function
KAOP Opens Additional Operator Panel (shortcut)
L Breaker Control Opens Breaker
M Generator Control Starts Generator
N Generator Control Stops Generator
PInstrument Values Shows instrument values

14 Please consult your manual for full information or consult your local dealer.
Control panel – DEIF TDU107
Operation – Manual Mode
Starting Procedure
Perform all the pre-start checks before starting
the generator.
1. Turn the battery isolator to the ‘on’ position.
Controller will power up.
2. Use the alarm shortcut to reset any alarms
that may be displayed on the controller.
Check for any standing alarms and investigate
as necessary before proceeding with start.
3. The machine can be run in manual or semi
auto dependent on the application. For
remote start function the controller must be
set to semi auto mode by pressing the mode
change button.
4. Press the start button. The generator
controller will display the start-up sequence.
5. Engine will now crank and start to run.
6. Generator will now display engine and
alternator status. It will change from red
to a solid green to show that it is ready
with no faults.
7. Check voltage and frequency on the
controller.
8. Close breaker via breaker control pushbutton.
AUTO AND LOAD SHARING
OPERATION: Remote start and
synchronizing multiple sets must
only be set up by a suitably trained
and competent person. Please refer
to the operator manual for more
detailed instructions.
B
C D A
Fig 8
A Mode change
B Alarm shortcut
C Stop button
D Start button

RS T4F Diesel Generator | G220RS 15
Stand Alone Manual Mode Operation
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 devices such
as pumps, heaters, or lights that may need to
be kept on.
Stopping Procedure
Perform the procedure below to stop the
generator:
1. Turn off all loads to the generator.
2. Open the main circuit breaker. The power
available lamp will go off.
3 Press the ‘stop/reset’ button once. The
generator will stop after the specified cooling
time. Duration: 5min.
4. If ‘stop/reset’ button is pressed again then
generator will stop immediately.
5. Ready to load and generator available LED
indicators will go off.
6. Turn the battery isolator to ‘off’ position after
the engine has stopped.

16 Please consult your manual for full information or consult your local dealer.
Control panel – DSE 8610
Fig 9
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.
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
A
B
C
E
F
G
H
J
K
M
L
N
D

RS T4F Diesel Generator | G220RS 17
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.
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 silence 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.

18 Please consult your manual for full information or consult your local dealer.
Control panel – DSE 8610
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.
1. Turn on the digital controller switch.
2. Wait for few seconds, to allow the controller
to power up and display to stabilise.
3. Make sure that the power on LED (Light
Emitting Diode) is illuminated on earth
leakage trip and there is no trip active where
required.
4. Make sure that the main power supply
MCCB is switched off.
5. Check that the emergency stop button is fully
out, if necessary twist to reset the button.
6. Complete all pre-start, system and engine
checks.
7. Press the start button and the machine will
start in manual.
8. The engine will run up to speed and stabilise.
9. Check that the machine operation is correct
using the screen information.
10. Make sure the power on LED is illuminated on
earth leakage trip and there is no trip active.
11. Turn on the main power supply MCCB.
12. The generator can now be loaded.
13. If the earth leakage relay trips at this point
consult the site electrical installation engineer.
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 devices such
as pumps, heaters, or lights that may need to
be kept on.
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.
AUTO AND LOAD SHARING
OPERATION: Remote start and
synchronizing multiple sets must
only be set up by a suitably trained
and competent person. Please refer
to the operator manual for more
detailed instructions.

RS T4F Diesel Generator | G220RS 19
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.
The control system is designed such that if the
battery isolator is switched off then there is a 2min
time delay to de-energise the ECU (Electronic
Control Unit) to allow the DEF (Diesel Exhaust
Fluid) purge to complete its shutdown cycle.
Disconnect the Machine Electrics
1. Get access to the battery isolator.
2 Turn the battery isolator key in a
counter-clockwise direction and remove.
Connect the Machine Electrics:
1. Insert the battery isolator key and turn in a
clockwise direction.
A
Fig 10
A Battery isolator key

20 Please consult your manual for full information or consult your local dealer.
Rotary Switch
3-position voltage selector switch for safe and
quick break and make operation. Lockable with
up to 4 separate padlocks.
۱
۲
۳
A
A
D
Multi voltage selection (where fitted)
A Voltage control rotary switch
1 480/277V Three Phase
2 208/120V Three Phase
3 240/120V Single Phase
D Padlock
Fig 11
IMPORTANT NOTE: Operation of
the rotary switch must only be
carried out with the generator in
stop mode and electrically isolated
to prevent personal injury and
damage to the equipment. Changes
to the alternator voltage must be
completed by a suitably trained and
competent person. Please refer to
the operator manual for detailed
instructions including breaker
protection settings.
NOTICE: A padlock must be
installed to prevent accidental
rotation of the multi voltage switch
whilst the generator is running,
otherwise damage will be caused to
the alternator.