Dear JCB Customer

Even if you have operated this type of equipment before, Your Local JCB Dealer is:
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 has not yet been completed with you.

OPERATOR MANUAL
THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE
LIGHTING TOWER LT9

ENGLISH - 9811/5050 - ISSUE 4 - JULY 2013

Copyright © 2004 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.

A4-6-Range - Printed In England

Notes:

0 9811/5050 0
 Contents Page No.
Safety Notices
Important Information .................................................................................... 1
The Operator Manual ............................................................................... 1
Safety Warnings ....................................................................................... 1

Introduction
About This Manual ......................................................................................... 3
Machine Model and Serial Number .......................................................... 3
Using this Manual ..................................................................................... 3
Cross References ..................................................................................... 3
Machine Description ...................................................................................... 4
Intended Use ............................................................................................ 4
Component Location ................................................................................ 4
Safety Check List ........................................................................................... 5
Safety - Yours and Others ........................................................................ 5
Introduction ............................................................................................... 5
General Safety ......................................................................................... 7
Operating Safety ...................................................................................... 8
Maintenance Safety .................................................................................. 9
Safety Label ................................................................................................ 12
Introduction ............................................................................................. 12
Safety Label Identification ...................................................................... 13
Component Identification ............................................................................. 14
Data Plate ............................................................................................... 14

Operation
General Specification .................................................................................. 15
Introduction ............................................................................................. 15
Dimensions ............................................................................................. 15
Towing Safety .............................................................................................. 16
Control Panel ............................................................................................... 17
Components - KS1 ................................................................................. 17
Control Panel - KS1 ................................................................................ 18
Components - KS2 ................................................................................. 21
Control Panel - KS2 ................................................................................ 22
System Setup .............................................................................................. 28
Introduction ............................................................................................. 28
General Precautions ............................................................................... 28
Initial Setup ............................................................................................. 28
Start the Engine/Generator ..................................................................... 30
Turn the Floodlights On .......................................................................... 30
Turn the Floodlights Off .......................................................................... 30
Stop the Engine/Generator ..................................................................... 30
Fault Conditions ..................................................................................... 30
Auxiliary Power ....................................................................................... 30
Program Timer Type 1 (Option fitted to KS1) ......................................... 31
Program Timer Type 2 (Option - Fitted in the KS2 controller) ................ 33
Fault Finding ................................................................................................ 35
LT9 LED Version .................................................................................... 36

Routine Maintenance
Service Requirements ................................................................................. 37
Health and Safety ........................................................................................ 38
Lubricants ............................................................................................... 38
Battery .................................................................................................... 40

i i
 Contents

Contents Page No.

Service Schedules ....................................................................................... 42
Introduction ............................................................................................. 42
How to Use the Service Schedules ........................................................ 42
Service Schedule Checklist .................................................................... 43
Pre-Start Checks ......................................................................................... 44
Checks After Running .................................................................................. 45
Cleaning ...................................................................................................... 46
General ................................................................................................... 46
Cleaning the Radiator ............................................................................. 46
Battery ......................................................................................................... 47
Connection and Disconnection ............................................................... 47
Charging the Battery .............................................................................. 47
Battery Maintenance .............................................................................. 47
Battery Life ............................................................................................. 47
Engine ......................................................................................................... 48
Component Identification ........................................................................ 48
Location of Labels .................................................................................. 49
97/68/EC Directive Certified Engines ..................................................... 49
Engine Family ......................................................................................... 49
Oil and Filter ........................................................................................... 50
Check and Adjust the Fan Belt ............................................................... 54
Cooling System ...................................................................................... 55
Coolant Mixtures .................................................................................... 56
Fuel System ........................................................................................... 57
Inlet and Exhaust System ....................................................................... 62
Technical Information ............................................................................. 63
Alternator ..................................................................................................... 65
Safety Precautions ................................................................................. 65
Installation .............................................................................................. 66
General Information ................................................................................ 67
Fault Finding ................................................................................................ 70
Introduction ............................................................................................. 70
Fault Finding Charts ............................................................................... 71
A Charts - Engine ................................................................................... 72
B Charts - Fuel ....................................................................................... 76
C Charts - Lubricating Oil ....................................................................... 77
D Charts - Coolant .................................................................................. 78

Connection and Wiring Diagrams

Intentionally Blank ....................................................................................... 81
Control Panel - LT9 to 1650482 - Linz Alternator ........................................ 82
Control Panel - LT9 (Mark 5) from 1650483 to 1696109 Sincro Alternator . 93
Control Panel - LT9 with KS2 from 1696110 ............................................. 110
LT9 LED With KS2 From 16501695 .......................................................... 126

Warranty
Warranty Information ................................................................................. 131
Introduction ........................................................................................... 131
Installation Access ................................................................................ 131
Downtime Support ................................................................................ 131
Terms and Conditions ........................................................................... 131
JCB Technical Service ............................................................................... 132

ii ii
 Safety Notices
Important Information
T1-042

The Operator Manual Safety Warnings

!MWARNING This safety alert system identifies

You and others can be killed or seriously injured if you
operate or maintain the machine without first studying
the Operator Manual. You must understand and follow
the instructions in the Operator Manual. If you do not
understand anything, ask your employer or JCB
dealer to explain it.
INT-1-4-2
Do not operate the machine without an Operator Manual,
or if there is anything on the machine you do not
understand.
Treat the Operator Manual as part of the machine. Keep it
clean and in good condition. Replace the Operator Manual
immediately if it is lost, damaged or becomes unreadable.
important safety messages in this
manual. When you see this symbol, be
alert, your safety is involved, carefully
read the message that follows, and inform
other operators.
In this publication and on the machine, there are safety
notices. Each notice starts with a signal word. The signal
word meanings are given below.
!MDANGER
Denotes an extreme hazard exists. If proper
precautions are not taken, it is highly probable that the
operator (or others) could be killed or seriously
injured.
INT-1-2-1

!MWARNING
Denotes a hazard exists. If proper precautions are not
taken, the operator (or others) could be killed or
seriously injured.
INT-1-2-2

!MCAUTION
Denotes a reminder of safety practices. Failure to
follow these safety practices could result in injury to
the operator (or others) and possible damage to the
machine.
INT-1-2-3

1 9811/5050-4 1
 Safety Notices
Important Information

Page left intentionally blank

2 9811/5050-4 2
 Introduction
About This Manual

Introduction
About This Manual

Machine Model and Serial Number Cross References

T1-004_2

This manual provides information for the following In this publication, page cross references are made by
model(s) in the JCB machine range: presenting the subject title printed in bold, italic and
underlined. It is preceeded by the 'go to' symbol. The
– LT9 serial numbers 1695000 to 1699999. number of the page upon which the subject begins, is
indicated within the brackets. For example: K Cross
Using this Manual References ( T 3).
T1-044

This manual is arranged to give you a good understanding

of the machine and its safe operation. It also contains
maintenance information and specification data. Read this
manual from front to back before using the machine for the
first time. 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
distributor or employer. Do not guess, you or others could
be killed or seriously injured.

General warnings in this chapter are repeated throughout

the book, as well as specific warnings. 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 differ, the text and or the illustration
will specify.

This manual contains original instructions, verified by the

manufacturer (or their authorised representative).

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 publication.

All optional equipment included in this manual may not be

available in all territories.

3 9811/5050-4 3
 Introduction
Machine Description

Machine Description

Intended Use Component Location

The machine is intended to be used under normal Note: The illustration(s) show a typical machine model;
conditions for the applications described in this manual. If your machine may look different from the model shown.
the machine is used for other purposes or in dangerous
environments, for example in a flammable atmosphere or
in areas with dust containing asbestos, special safety
regulations must be followed and the machine must be
equipped for use in these environments.
A

B C H

F
G
T063510-2C101280
Fig 1.
A Lamp
B Mast
C Main control panel
D Auxiliary power sockets (x2)
E Auxiliary external mains power source input plug
F Front jack/stabilizer legs
G Rear stabilizer legs
H Emergency stop button

4 9811/5050-4 4

Safety Check List
Safety - Yours and Others
INT-1-3-1_3
All machinery can be hazardous. When a machine is
correctly operated and properly maintained, it is a safe
machine to work with. But 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. Read and understand them. They tell you of
potential hazards and how to avoid them. If you do not fully
understand the warning messages, ask your employer or
JCB distributor to explain them.
But 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 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 job until you are sure that you and those
around you will be safe.
If you are unsure of anything, about the machine or the job,
ask someone who knows. Do not assume anything.
Remember
BE CAREFUL
BE ALERT
BE SAFE
5 9811/5050-4
Introduction
Safety Check List
Introduction
You must also refer to the local regulations in the country
your machine will be used. Some of the information may be
repeated in the following warnings and cautions pages and
in the main text.
– Operate the machine in accordance with the
recommendations made in the Operator Manual.
– Never do a maintenance task (for example oil/filter
changes, a clean) unless all of the electrical
components are shut down and the engine is
stopped.
– Never allow water to collect around the base of the
light tower. If water is found, do not do a maintenance
task.
– Never service the electrical components if your
clothing or skin is wet. If the machine is stored
outside, check the engine and the generator for any
moisture and dry the machine before use.
– Never clean the machine with a power washer or a
high pressure hose.
– Do not change the application or a specification of the
machine.
– Do not work under a raised machine unless it is
supported correctly with axle stands or the equivalent
equipment.
– Open the main circuit breaker before the battery
cables are disconnected.
– Do not lift heavy objects on your own, use lifting
equipment or get the help of an assistant.
– Do not do a procedure that need the help of several
people if you are alone, especially when moving or
operating any components. For example switches,
section switches, fuses and/or any other live devices.
– Periodically make sure that the bolts that attach
electrical connections are secure.
– Do not smoke when you add fuel to the tank or work
in the engine bay area.
– Always clean up any spilt fluids. Dispose of the fluids,
contaminated material etc, in accordance with the
local regulations. Do not pollute the drains or the
ground.
– Use the correct tools for the job.
– The electrical control panels as all electrical devices,
are vulnerable to damp and dust. Make sure that the
5
 Introduction
Safety Check List
anti-condensation heaters if available, are in good unconsciousness, or death if inhaled. Use these
working order and that the air ventilation intakes are items in well ventilated areas.
clean. – Get medical advice immediately if your skin contacts
– Always make the equipment safe before you do a high pressure fuel.
maintenance task. For example disconnect the – Make sure the machine is operated by a person who
battery so that the engine cannot be started. is in the correct position at the controls.
– Before the electrical panel is opened, approved – Do not operate the machine at high speeds with no-
personnel must stop the generator, set the electrical load applied.
panel to the LOCK position, disconnect the batteries
– Make sure you have enough fire fighting equipment in
from the generator set and disconnect the power
your workshop or repair area. Contact your local fire
input.
prevention officer for advice.
– Allow the components to cool for 20-25 minutes
– The turbocharger impeller blades operate at very high
before you do any maintenance tasks. The
revolutions and the turbocharger becomes very hot.
components for example the exhaust, light bulbs and
Let the turbocharger cool before you do a
fittings can become very hot.
maintenance task. Keep all tools and objects away
– Do not adjust the engine or add fuel oil while it is from the impeller when the unit is operating.
running, unless the procedures in this manual instruct
– Use only JCB recommended parts. These parts are
you to do so.
designed to give the engine its optimum performance.
– Never start the engine if the governor is If spurious parts are used, it may affect the integrity of
disassembled. the engine.
– Do not operate the machine if the fuel cap is loose or
missing.
– Do not siphon fluids by mouth.
– Operate the engine in well ventilated areas. If the
machine is used indoors, then a purpose designed
exhaust fume extraction unit may be needed.
– Keep the area around the exhaust pipes and the air
ducts free of debris to decrease the risk of an
accidental fire.
– Wear hearing protection when you work around a
running engine. Do not operate the machine without
a functional exhaust system.
– Keep other people at a safe distance when you
operate the engine or equipment.
– Do not operate the engine if the safety guard (when
applicable) is removed.
– The vapours from solvents, thinners and adhesives
can be highly flammable. In addition to the fire risk,
they can be toxic and in certain conditions cause

6 9811/5050-4 6
 Introduction
Safety Check List

General Safety

!MWARNING
Care and Alertness
All the time you are working with or on the machine,
take care and stay alert. Always be careful. Always be
alert for hazards.
INT-1-3-5

!MWARNING
Clothing
You can be injured if you do not wear the proper
clothing. Loose clothing can get caught in the
machinery. Wear protective clothing to suit the job.
Examples of protective clothing are: a hard hat, safety
shoes, safety glasses, a well fitting overall, ear-
protectors and industrial gloves. Keep cuffs fastened.
Do not wear a necktie or scarf. Keep long hair
restrained. Remove rings, watches and personal
jewellery.
INT-1-3-6_2

!MWARNING
Raised Attachments
Raised attachments can fall and injure you. Do not
walk or work under raised attachments unless they are
safely blocked.
INT-1-3-8

!MWARNING
Lifting Equipment
You can be injured if you use incorrect or faulty lifting
equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
equipment is in good condition and complies with all
local regulations.
INT-1-3-7_2

!MWARNING
Machine Modifications
This machine is manufactured in compliance with
legislative and other requirements. It should not be
altered in any way which could affect or invalidate any
of these requirements. For advice consult your JCB
Distributor.
INT-1-3-10_2

7 9811/5050-4 7

Operating Safety
!MWARNING
Machine Condition
A defective machine can injure you or others. Do not
operate a machine which is defective or has missing
parts. Make sure the maintenance procedures in this
manual are completed before using the machine.
INT-2-1-2_2
!MWARNING
Machine Limits
Operating the machine beyond its design limits can
damage the machine, it can also be dangerous. Do not
operate the machine outside its limits. Do not try to
upgrade the machine performance with unapproved
modifications.
INT-2-1-4
!MWARNING
Engine/Steering Failure
If the engine or steering fails, stop the machine as
quickly as possible. Do not operate the machine until
the fault has been corrected.
INT-2-1-5
!MWARNING
The engine has exposed rotating parts. Switch OFF the
engine before working in the engine compartment. Do
not use the machine with the engine cover open.
5-2-6-5
!MWARNING
Exhaust Gases
Breathing the machine exhaust gases can harm and
possibly kill you. Do not operate the machine in closed
spaces without making sure there is good ventilation.
If possible, fit an exhaust extension. If you begin to
feel drowsy, stop the machine at once and get into
fresh air.
INT-2-1-10_2
8 9811/5050-4
Introduction
Safety Check List
!MWARNING
Communications
Bad communications can cause accidents. If two or
more people are working on the machine, make sure
each is aware of what the others are doing. Before
starting the engine make sure the others are clear of
the danger areas; examples of danger areas are: the
rotating blades and belt on the engine, the
attachments and linkages, and anywhere beneath or
behind the machine. People can be killed or injured if
these precautions are not taken.
INT-3-1-5
!MWARNING
Communications
Bad communications can cause accidents. Keep
people around you informed of what you will be doing.
If you will be working with other people, make sure any
hand signals that may be used are understood by
everybody. Work sites can be noisy, do not rely on
spoken commands.
INT-2-2-3
!MDANGER
Sparks
Explosions and fire can be caused by sparks from the
exhaust or the electrical system. Do not use the
machine in closed areas where there is flammable
material, vapour or dust.
INT-2-2-10
!MWARNING
Alcohol and Drugs
It is extremely dangerous to operate machinery when
under the influence of alcohol or drugs. Do not
consume alcoholic drinks or take drugs before or
while operating the machine or attachments. Be aware
of medicines which can cause drowsiness.
INT-1-3-9_2
8
 Introduction
Safety Check List

Maintenance Safety !MWARNING

!MWARNING If you try to charge a frozen battery, or jump start and
run the engine, the battery could explode. Do not use
This machine can auto-start. You must Isolate the a battery if its electrolyte is frozen. To prevent the
engine start circuit before you start service or battery electrolyte from freezing, keep the battery at
maintenance procedures. full charge.
ENG-8-7_1 0125

!MWARNING
Repairs
If your machine does not function correctly in any way,
get it repaired straight away. Neglect of necessary
repairs could result in an accident or affect your
health. Do not try to do repairs or any other type of
maintenance work you do not understand. To avoid
injury and/or damage get the work done by a specialist
engineer.
GEN-1-5_2
!MWARNING
Battery Gases
Batteries give off explosive gases. Keep flames and
sparks away from the battery. Do not smoke close to
the battery. Make sure there is good ventilation in
closed areas where batteries are being used or
charged. Do not check the battery charge by shorting
the terminals with metal; use an approved battery
tester.
INT-3-1-8_2

!MWARNING !MWARNING
Metal Splinters Battery Terminals
You can be injured by flying metal splinters when The machine is negatively earthed. Always connect
driving metal pins in or out. Use a soft faced hammer the negative pole of the battery to earth.
or copper pin to remove and fit metal pins. Always
wear safety glasses. When connecting the battery, connect the earth (-) lead
INT-3-1-3_2
last.

!MWARNING When disconnecting the battery, disconnect the earth

(-) lead first.
Electrical Circuits INT-3-1-9
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong
connection can cause injury and/or damage.
!MWARNING
Fuel
INT-3-1-4
Fuel is flammable; keep naked flames away from the

!MWARNING fuel system. Stop the engine immediately if a fuel leak

Petrol
Do not use petrol in this machine. Do not mix petrol
with the diesel fuel; in storage tanks the petrol will rise
to the top and form flammable vapours.
INT-3-1-6
is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the
engine running. Completely wipe off any spilt fuel
which could cause a fire. There could be a fire and
injury if you do not follow these precautions.
INT-3-2-2_3

!MWARNING
Do not open the high pressure fuel system with the
engine running. Engine operation causes high fuel
pressure. High pressure fuel spray can cause serious
injury or death.
13-3-2-16

9 9811/5050-4 9

!MWARNING
Oil
Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
contains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves to
prevent skin contact. Wash skin contaminated with oil
thoroughly in warm soapy water. Do not use petrol,
diesel fuel or paraffin to clean your skin.
INT-3-2-3
!MWARNING
Soft Ground
A machine can sink into soft ground. Never work
under a machine on soft ground.
INT-3-2-4
!MWARNING
The cooling system is pressurised when the coolant is
hot. When you remove the cap, hot coolant can spray
out and burn you. Make sure that the engine is cool
before you work on the cooling system.
9-3-3-1_2
!MWARNING
Always wear safety glasses when dismantling
assemblies containing components under pressure
from springs. This will protect against eye injury from
components accidentally flying out.
GEN-6-2
!MCAUTION
Cleaning
Cleaning metal parts with incorrect solvents can cause
corrosion. Use only recommended cleaning agents
and solvents.
INT-3-2-11
!MCAUTION
'O' rings, Seals and Gaskets
Badly fitted, damaged or rotted 'O' rings, seals and
gaskets can cause leakages and possible accidents.
Renew whenever disturbed unless otherwise
instructed. Do not use Triochloroethane or paint
thinners near 'O' rings and seals.
INT-3-2-12
10 9811/5050-4
Introduction
Safety Check List
!MWARNING
Fires
If your machine is equipped with a fire extinguisher,
make sure it is checked regularly. Keep it in the correct
machine location until you need to use it.
Do not use water to put out a machine fire, you could
spread an oil fire or get a shock from an electrical fire.
Use carbon dioxide, dry chemical or foam
extinguishers. Contact your nearest fire department as
quickly as possible. Firefighters should use self-
contained breathing apparatus.
INT-3-2-7_2
!MWARNING
Beware of the hot exhaust system even with the
engine stopped.
ENG-4-3
!MWARNING
To avoid burning, wear protective gloves when
handling hot components. To protect your eyes, wear
goggles when using a brush to clean components.
HYD-1-3_2
!MWARNING
Certain seals and gaskets (e.g. crankshaft oil seal) on
JCB machines contain fluoroelastomeric materials
such as Viton®, FluorelTM and Technoflon®.
Fluoroelastomeric materials subjected to high
temperatures can produce highly corrosive
hydrofluoric acid. THIS ACID CAN SEVERELY BURN.
New fluoroelastomeric components at ambient
temperature require no special safety precautions.
Used fluoroelastomeric components whose
temperatures have not exceeded 300°C (572°F) require
no special safety precautions. If evidence of
decomposition (e.g. charring) is found, refer to the
next paragraph for safety instructions DO NOT TOUCH
COMPONENT OR SURROUNDING AREA.
Used fluoroelastomeric components subjected to
temperatures greater than 300°C (572°F) (e.g. engine
fire) must be treated using the following safety
procedure. Make sure that heavy duty gloves and
special safety glasses are worn:
10

1 Thoroughly wash contaminated area with 10%
calcium hydroxide or other suitable alkali
solution, if necessary use wire wool to remove
burnt remains.
2 Thoroughly wash contaminated area with
detergent and water.
3 Contain all removed material, gloves etc. used in
this operation in sealed plastic bags and dispose
of in accordance with Local Authority
Regulations.
DO NOT BURN FLUOROELASTOMERIC MATERIALS.
INT-3-3-5_4
!MCAUTION
Damaged or spent batteries and any residue from fires
or spillage should be put in a closed acid proof
receptacle and must be disposed of in accordance
with local environmental waste regulations.
INT-3-1-12
!MCAUTION
Do not disconnect the battery while the engine is
running, otherwise the electrical circuits may be
damaged.
INT-3-1-14
!MDANGER
Electrolyte
Battery electrolyte is toxic and corrosive. Do not
breathe the gases given off by the battery. Keep the
electrolyte away from your clothes, skin, mouth and
eyes. Wear safety glasses.
INT-3-2-1_3
!MWARNING
Compressed air is dangerous. Wear suitable eye
protection and gloves. Never point a compressed air
jet at yourself or others.
0147_1
11 9811/5050-4
Introduction
Safety Check List
!MWARNING
Machinery utilizing the engine must be correctly
parked and prepared, for example safety strut fitted,
prior to completing maintenance tasks on the engine.
Maintenance must be completed by suitably qualified
personnel.
You or others could be killed or seriously injured if the
machine is not correctly prepared and maintained.
ENG-1-5
!MCAUTION
Do not allow dirt to enter the fuel system. Before
disconnecting any part of the fuel system, thoroughly
clean around the connection. When a component has
been disconnected, for example a fuel pipe, always fit
protective caps and plugs to prevent dirt ingress.
Failure to follow these instructions will lead to dirt
entering the fuel system. Dirt in the fuel system will
seriously damage the fuel injection equipment and
could be expensive to repair.
ENG-1-7
!MCAUTION
It is illegal to pollute drains, sewers or the ground.
Clean up all spilt fluids and/or lubricants.
Used fluids and/or lubricants, filters and contaminated
materials must be disposed of in accordance with
local regulations. Use authorised waste disposal sites.
INT-3-2-14
11
 Introduction
Safety Label

Safety Label

Introduction
T1-014_2

!MWARNING
Safety Labels
Safety labels on the machine warn you of particular
hazards. You can be injured if you do not obey the
safety instructions shown.
INT-1-3-11

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 place 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.

Note: The illustration(s) show a typical machine model.

Your machine may look different from the model shown.

Keep all safety labels clean and readable. Replace lost or

damaged safety labels. Make sure replacement parts
include 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 distributor.

12 9811/5050-4 12
 Introduction
Safety Label

Safety Label Identification Description: Location of emergency stop

button.
Description: Warning. Keep away from Location: Near the emergency stop
moving belts or shafts. button, on the back of the trailer.
Location: Near alternator or transmission
shafts. C101200

Description: Warning. Electric shock

hazard
C101150
Location: On control panel.

Description: Warning. Do not touch while

machine is in operation or shortly after C101210.

having stopped.
Location: On parts of the machine which
heat up during operation. Description: Warning. Do not manipulate
the generator set when the switch is on.
Location: On thermal-magnetic switches.

C101160

C101220
Description: Warning. Do not open when
hot.
Location: On coolant tank cap.

C101170

Description: Warning. Earth must be

secure, suitable and sufficient to protect
against electric shock.
Location: Near earth point.
C101180

Description: Location of switches that

provide protection against possible
overloading.
C101190
Location: Near thermal-magnetic
switches.

13 9811/5050-4 13
 Introduction
Component Identification

Component Identification

Data Plate
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:

Generator Set identification nomenclature:

T039250
Fig 2.

A Manufacturer (JCB Power Products Ltd.)

B Model name
C Machine serial number
D Rated power (KVA)
E Rated power (KW)
F Rated power factor (Cos f)
G Current (A)
H Manufacture date
J Weight (wet) (kg)
K Dimensions (m)
L Maximum site altitude above sea level (1000m)
M Temperature of ref. (25 deg C)

14 9811/5050-4 14
 Operation
General Specification

Introduction It consists of a trailer with a diesel powered 7kVA 50/60Hz

generator and a 9 metre (30 feet) cable actuated tower
The lighting tower provides mobile trailer mounted with four 1000 watt floodlight lamps.
floodlighting for night time maintenance, construction,
mining and emergency work. The LT9 LED version is fitted with six 240 Watt lamps.

Dimensions

Travel position length 2220 mm (87 in)

Travel position width 1260 mm (50 in)
Travel position height 2200 mm (87 in)
Working position length 2200 mm (87 in)
Working position width 2450 mm (96 in)
Working position maximum height 9000 mm (354 in)
Dry weight 911 kg (2008 lb)
Sound power level 87 Lwa (64 dB)

!MCAUTION
Allow the machine to stand for a minimum of 15
minutes to enable any electrical stored charge to
dissipate before starting maintenance work on the
electrical power circuit to the lamps.
GEN-9-21

15 9811/5050-4 15
 Operation
Towing Safety

Towing Safety

Towing a trailer requires care, both the trailer and vehicle

must be in good condition and securely fastened to each
other to reduce the possibility of an accident.

Also, some territories require that large trailers be

registered and licensed. Contact your local authorities to
check on license requirements for your particular unit.

Check that the hitch and coupling on the towing vehicle are
rated equal to, or greater than, the trailer's "gross vehicle
weight rating" (GVWR).

Check the tyres on the trailer for tread wear, inflation and
condition.

Inspect the hitch and coupling for wear or damage. Do not

tow a trailer with defective parts. Make sure the trailer hitch
and the coupling are compatible. Make sure the coupling
is securely fastened to the vehicle.

Make sure any directional and brake lights on the trailer

are connected and working properly.

Check that all the lug nuts holding wheels on are tight and
that none are missing.

Check the local requirements on the towing speed.

When towing, maintain extra space between vehicles and

avoid soft shoulders, kerbs and sudden lane changes. If
you have not pulled a trailer before, practice turning,
stopping, and backing up in an area away from heavy
traffic.

A film of grease on the coupler will extend coupler life and

eliminate squeaking. Wipe the coupler clean and apply
fresh grease each time the trailer is towed.

16 9811/5050-4 16
 Operation
Control Panel

Control Panel

Components - KS1

T063450-2a
Fig 1. Sheet 2
F1 Main panel fuse - 20A
F2 U phase fuse - 2A
1a Push button - Mast Up
1b Push button - Mast down
2 Fuel level gauge
3 Frequency meter
4 Voltmeter
5 Hour counter - 230V
6 KS1 control panel
8 Alarm HO1
9 Two position switch, switches between generator
power and mains input power
10 Socket circuit breakers
11 Lamp circuit breakers
12 RCD 25A 2P 30mA

17 9811/5050-4 17
 Operation
Control Panel

Control Panel - KS1 a Advanced programming of the controller.

Features b Internal tour-counter reading.

The KS1 control panel allows the engine to be started in c Alarm history files.
Manual or Automatic modes (by means of a voltage-free
contact) and protects it against possible breakdowns. d PC communication.

The management is via an electronic circuit based on a

micro controller which is located inside the controller.

1 Power supply voltage 12V.

2 Free-voltage contact start (LT).

3 Engine protections:

a Fuel reserve

b Battery charger failure

c High engine coolant temperature

d Low oil pressure

4 Over frequency (overspeed):

a By generator

b By Pick-Up

5 Auxiliary Input with alarm LED

6 All outputs are short-circuit sensitive

7 Quick connection terminals

8 Programming by micro-switches of the following

parameters:

a Overspeed programming and activation

b Reading of frequency by generator or Pick-up

c Pre-heating time

d Cooling time

e Action after fuel reserve alarm

f Engine running detection through D+

9 Port RJ11, which allows:

18 9811/5050-4 18
 Operation
Control Panel
Components

2 9
A
3 10
4 11
5 B 12
6 13
7 14
1
8 15

T038070
Fig 2.

Modes 7 Contact LED of activated LT contactor (green). This

signal activates when you close the voltage-free
A - Off/On switch (12V DC) contact and it stops when you open this contact.

B - Mode selection key (MAN, STOP, AUTO).
Alarms
1 Reset button. Press to reset the control panel.
2 Fuel reserve LED (yellow). Indicates low fuel level in
the tank.
3 Battery charger failure LED (D+) (yellow). Indicates
that the alternator is not charging the battery.
4 Auxiliary alarm LED (AUX) (yellow). Indicates that the
alarm condition established in the auxiliary input of
the controller has been detected. This LED remains lit
during the time that we have this alarm condition.
5 Pre-heating LED (yellow). This LED starts blinking in
1 second intervals approx. during the pre-heating
cycle carried out before every attempt to start the
engine.
6 Cooling stop LED (COOL STOP) (yellow). This LED
starts blinking in 1 second intervals (approx.) when
the controller orders a stop cycle and continues to
blink until this cycle comes to an end.
8 Engine running LED (M) (green). Indicates that the
engine is working.
9 Emergency stop LED (red). This LED comes on when
you push the emergency stop button. It will only go off
once you release the emergency stop button and
reset the controller.
10 Over speed LED (red). This LED becomes active
depending on two conditions:
a During the over speed programming to indicate
that the programming was successful and
b When the internal over speed protection device
trips. In this case the controller starts a
programmable stop cycle and the optical warning
will continue until you reset the controller.
11 Low oil pressure LED (BPA) (red). Indicates that the
engine pressure switch has detected an anomaly.
This condition activates a programmable stop cycle.
The LED will remain lit until this alarm condition is
reset.
12 High water temperature LED (HWT) (red). Indicates
that the engine temperature switch has detected an
anomaly. This condition activates a programmable

19 9811/5050-4 19

stop cycle. The LED will remain lit until this alarm
condition is reset.
13 Unintended stop. LED (red). Indicates that the engine
has stopped without any order from the controller.
14 Fail to start LED (red). Indicates that the controller
completed 5 attempts to start the engine but the
generator set did not start.
15 Power supply LED (ON) (green). This optical signal
indicates that the controller is ON.
Operation Modes
Operation
Control Panel
Automatic Mode
In the AUTO position, the controller will remain in
automatic mode.
In this mode, the engine start sequence is activated when
the voltage-free contact is closed. When this contact is
closed, the controller tries to start the engine (up to five
times) if there is no engine running detection signal. Each
try is 5 seconds long and the time between tries is 10
seconds.
When the voltage-free contact opens, the controller stops
the engine and returns to stand-by mode.

Introduction Note: The generator set will stop if the controller is

disconnected, resets or the DC power supply fails. In the
Before the control panel is switched ON, make sure that automatic mode with the voltage-free contact closed, the
the power supply terminals are connected correctly and generator set will restart automatically when the
the mode selection key B is set to STOP. connection is restored.

Set the off/on switch A to ON to start the control panel. The Data
control panel will do an internal diagnostic check and
check the function of the LEDs. The control panel
Programmed Variables Time -
operations will stay on hold when the mode selection key
seconds
is set to STOP.
Pre-heating time - max 15
Turn the key to the left to select manual mode (MAN). Cool down time - max 60
Heating time (input contactor) 20
Turn the key to the right to select automatic mode (AUTO).
Maximum cranking time 5
Stop Mode Time between cranking attempts 10

In the STOP position, the controller will stop the engine. Maximum number of cranking attempts 5
Stopped time (for excitation) 10
Important: You cannot stop the engine by turning the BPA (Low oil pressure) alarm delay 15
control panel OFF or by pressing the RESET button. To
stop the engine you must turn by the key to STOP. ATA (High coolant temperature) Checkup 15
delay
Manual Mode AUX alarm delay 15

In the MAN position the control panel will start the engine
(One try to start). (It will do a warm-up cycle for a preset
time).

The engine protection systems are active at all times. The

load connection (generator set contactor closes), is done
automatically after 20 seconds to stabilize the generator
set. The contactor will remain in the same position until the
engine is stopped or any related alarm is activated.

if the engine stops, you must activate the STOP mode

before you try to restart in the MAN mode.

20 9811/5050-4 20
 Operation
Control Panel

Components - KS2

2 3 4 5

1a

1b

9 8 7 6
T068780-2.eps
Fig 3.

1a Push button - Mast Up

1b Push button - Mast Down
2 Buzzer and alarm
3 Light head tilt control (if fitted)
4 Solar sensor on/off (if fitted)
5 KS2 control panel
6 RCD 25A 2P 30mA
7 Lamp circuit breakers
8 Socket circuit breakers
9 Two position generator/external switch

21 9811/5050-4 21
 Operation
Control Panel

Control Panel - KS2 Engine warning digital input:

– Fuel reserve.
A – Oil pressure.
B – High coolant temperature.
– Coolant level.
KS2 C – Emergency stop.

D Engine warning analog input:

– Fuel level.
E – Pressure
– Coolant temperature.
MAN
0
AUTO
F – Battery charger alternator voltage.
– Battery voltage.
START STOP
Automatic external start; The KS2 provides a digital input
in order to start the generator set (only in AUTO mode).

Counters:
J G H
– Working time.
P033460-90
Fig 4. – Succeeded starts.
– Failed starts.
A Back lit display
– Total energy.
B Warning LED – Indicates an active alarm
C Up button – moves along the selection displays The KS2 has 2 passwords levels of four digits to avoid non-
and maintenance menus, also increases authorised access. The different access levels are:
programmed values
D Down button – Moves back in the selection – User level (default password: 1111). The user level
display and maintenance menus, also reduces allows access to KS2 main menu.
the programmed values – Maintenance level (default password: 1911). The
E Confirmation button – Allows access to menu, maintenance level allows the user to configure the
validates and stores the entered data unit.

F Cancellation button – Goes back in the menu and The KS2 passwords can be changed by the user in the
cancels the entered data main menu. The user can change the passwords in the
G Start engine button (manual mode only) – One user access level, as well as in lower access levels.
press will start the engine
The status of the inputs and outputs of the KS2 can be
H Stop engine button (manual mode only) – Press
seen using the maintenance menu.
once a cooling phase begins followed by engine
stop, press twice engine stops immediately
J Key control – ‘Man’ for direct control via buttons G
and H. ‘Auto’ for control via light sensor, timer or
remote start options

Features

The KS2 provides the following electrical supply

measurements:

– Phase voltage.
– Phase current.
– Frequency.

The KS2 provides the following engine signals:

22 9811/5050-4 22
 Operation
Control Panel

Emergency stop

Presets Inputs

The KS2 controller has 5 digital inputs, whose working

process is already preset.

External start signal - This function only

works in automatic mode.

High temperature - Digital signal reporting

to the controller that the thermostat of the
engine has detected a high temperature
P033460-73 and sets on an alarm.
Fig 5.
A Output Low oil pressure - Digital signal reporting
B Input to the controller that the engine pressure
switch has detected a low pressure and
sets on an alarm.
The following Icons are used for active inputs:

Coolant level - Digital signal reporting to

Fuel reserve the controller that an alarm triggered due
to low coolant level.

Emergency stop - Digital signal reporting

Low oil pressure to the controller that an immediate stop
without cooling must be done.

High temperature Fuel reserve - Digital signal reporting to

the controller that an alarm has been
generated due to a failure in the fuel
reserve.
Coolant level
Fuel level (N/C) - The fuel level analog
input indicates the amount of fuel that left
in the tank. A minimum fuel-in tank
threshold can be fixed, and it will raise an
engine warning when the fuel level is
External start detected under such limits.
Oil pressure (P)- The oil pressure analog
input allows supervising the engine oil
pressure.

23 9811/5050-4 23

Engine temperature (T)- The analog
engine temperature input allows
supervising the engine coolant
temperature value.
Battery charger alternator voltage (D+) -
The analog voltage input allows
supervising the value of the voltage
generated by the genset.
Preset Outputs
The KS2 controller has 5 preset outputs (3 high power
outputs and 2 digital outputs).
Pre-heating output.(PR).Power Output.
Engine cranking output.(ARR).Power
Output.
Engine control (PC): Fuel output/Engine
stop output/Enable engine/PULL. Power
Output.
Engine control (PC): Fuel output/Engine
stop output/Enable engine/PULL. Power
Output.
Alarm output (AL). Digital output.
The alarm output (AL) is in charge of communicating the
different status of the KS2.
– External start in auto mode. The alarm output of the
device (AL) is activated before starting the generator
by external start input condition in auto mode.
– Alarm notice. Alarm output is activated if it is detected
an active failure or a failure waiting to be
acknowledged by the user. If the user presses once
the x button, the AL output is deactivated. The
24
Operation
Control Panel
generator failures that activate the AL output are
either alarms which induce the engine stop or
warnings which do not stop the engines.
KS2 Alarms
The KS2 provides a set of alarms to warn of issues with the
machine. These can be both anomalies which cause the
engine to stop (alarms) and errors which do not stop the
engine (warnings).
When an alarm or warning is detected, the controller
produces an acoustic alarm, at the same time the digital
alarm output (AL) activates and the LED flashes; Alarm
LED has 3 different states:
– Off: generator state without errors.
– Flashing: one active error active alarm.
– On: no active error alarm, but KS2 needs to be reset
to erase list of non-active error alarms.
To display the list of alarms press the x button once. The
alarm screen displays a maximum of 8 alarms at once; use
the up and down buttons to navigate between the different
alarm list screens. Pressing the tick button erases all non
active error condition alarms off of this screen.
P033460-70
A Alarm list icon:
Flashing: An alarm that forces an engine
stop condition
On: A warning that does not force an
engine stop condition
9811/5050-4 24
 Operation
Control Panel

B Alarm icon: Note: The KS2 controller alarms need to be reset by

pressing the tick button (except fuel level and fuel reserve
flashing: active error condition alarms).

on: no active error condition (press tick By default setting: oil pressure, coolant temperature and
button to reset the alarm) fuel level do not command a generator stop. low oil
pressure, high engine temperature and low coolant level
C Number of alarms commands an immediate generator stop.

Alarm List

Table 1. Engine Alarms

Code Description Icon Type Action
E01 High coolant temperature Alarm Immediate engine stop with no cooling

E02 Low oil pressure Alarm Immediate engine stop with no cooling

E03 Emergency stop Alarm Immediate engine stop with no cooling

E04 Battery charge alternator failure Warning Engine doesn’t stop

(engine running)

E05 Start failure

E06 Low coolant level Alarm Immediate engine stop with no cooling

E07 Fuel storage Warning Engine doesn’t stop

E08 Overspeed Alarm Immediate engine stop with no cooling

25 9811/5050-4 25
 Operation
Control Panel

Code Description Icon Type Action

E09 Underspeed Alarm Engine stop with cooling

E16 Low battery voltage Warning Engine doesn’t stop

E17 High coolant temperature by Warning Engine doesn’t stop

sensor

E18 Low oil pressure by sensor Warning Engine doesn’t stop

E19 Low fuel level by sensor Warning Engine doesn’t stop

E23 Unexpected shutdown

E24 Stop failure

E34 Maintenance Warning Engine doesn’t stop

Table 2. Electrical Signal Alarms

Code Description Icon Type Action
E10 Overload Alarm Engine stop with cooling

E12 Maximum genset voltage Alarm Immediate engine stop with no cooling

26 9811/5050-4 26
 Operation
Control Panel

Code Description Icon Type Action

E13 Maximum genset frequency Alarm Immediate engine stop with no cooling

E20 Short circuit Alarm Immediate engine stop with no cooling

E21 Minimum genset voltage Alarm Engine stop with cooling

E22 Minimum genset frequency Alarm Engine stop with cooling

E25 Electrical genset signal stop Alarm Engine stop with cooling

27 9811/5050-4 27

System Setup
Introduction
!MDANGER
Do not start the unit if the insulation on the electrical
cord is cut or worn through. Bare wires in contact with
the mast or frame may energize the trailer and cause
electrocution.
GEN-9-17
!MWARNING
Electrical Power Cables
You could be electrocuted or badly burned if you get
the machine or its attachments too close to electrical
power cables.
You are strongly advised to make sure that the safety
arrangements on site comply with the local laws and
regulations concerning work near electric power lines.
Before you start using the machine, check with your
electricity supplier if there are any buried power
cables on the site.
There is a minimum clearance required for working
beneath overhead power cables. You must obtain
details from your local electricity supplier.
2-2-5-4
!MWARNING
Do not move the lighting tower with the mast raised.
ENG-8-16
!MCAUTION
Overhead Clearance
A raised mast can strike overhead objects. Always
check for overhead clearance before raising the mast.
9-1-3-1
28 9811/5050-4
Operation
System Setup
General Precautions
NEVER remove a safety pin or pull the mast locking
pin when the lighting tower is up.
NEVER operate the lamps without a protective lens
cover in position or with a lens cover that is cracked
or damaged.
NEVER adjust the mast when the lighting tower is
operating.
If for any reason any part of the mast hangs up or the
winch cable becomes loose when the lighting tower is
being raised or lowered, stop immediately and get
technical help.
Initial Setup
1 Check the designated location, make sure that:
a The lighting tower will not be in a position where
those working under the light are:
i Forced to look into the light regularly.
ii Forced to work with their backs to the light
(their shadows will block the light from the
work area).
b The location has a hard, level surface which is dry,
clean and free of debris. The trailer must be level
or the lighting tower may not telescope up and
down correctly.
c The lighting tower should be on the same level or
on ground that is higher than the area being
illuminated.
d Make sure that the area above the lighting tower
is open and away from any overhead wires and
obstructions.
2 Move the trailer to designated location.
Important: Before the trailer is connected/disconnected,
refer to the towing vehicles manual for information on the
tow hitch and cable connections.
3 If necessary, disconnect any trailer cables from the
towing vehicle.
28
 Operation
System Setup

!MCAUTION a Loosen the lock-nuts F and G (one on each side

of the lamp). K Fig 7. ( T 29)
If electrical or manual braking system is not fitted,
chock the wheels instead. b Adjust the lamps, as necessary.
ENG-8-14
c Tighten the lock-nuts.
4 Engage the trailer brake system.

Note: The mast will not rise if the park brake is not F
engaged. (LT9 only).
G

J H
t063510-1
Fig 7.

E 14 Lift the lighting tower:

A
a Make sure that the trailer is on level ground, so
C that the mast is vertical. The outriggers must be
spread and remain spread while the mast is up.

b Make sure that the area around the trailer is clear

B F
D G
T063510
Fig 6.
15
5 Turn the handle on the jockey wheel clockwise to lift
the trailer tongue off the towing vehicle.
of all personnel.
c Push the UP button on the control panel to lift the
mast. Be aware, the mast can rise quickly.
If necessary, to turn the lighting tower:
a Pull out the locking-pin at the bottom of the mast.

6 Release the locking levers F, then lower the rear legs Release the locking lever J. K Fig 6. ( T 29)
G. K Fig 6. ( T 29)
b Turn the mast until the lamps face the required
7 Pull out the locking-pins A, then extend the outriggers direction.
B until the spring-loaded locking-pins snap back into
position. Apply the locking lever J.

8 Release the locking levers C. c Release the locking-pin.

9 Lower the legs D, then tighten the locking levers. 16 To lower the lighting tower, push the DOWN button on
the control panel.
10 Use the handle E to adjust the legs.
17 If the park brake is released, an alarm will sound and
11 Adjust all four of the legs until they are firmly in the mast will lower.
contact with the ground and the trailer is as level as
possible. Note: Even if the mast is lowered, an alarm will sound for
30 seconds when the park brake is released.
12 Put a grounding-rod into the earth. Make sure that it
is secure and has safe, suitable and sufficient earth
connections (in accordance with the local
regulations).

13 Before you lift the lighting tower, it may be necessary

to adjust the lamps.

29 9811/5050-4 29
 Operation
System Setup

Start the Engine/Generator Stop the Engine/Generator

1 Make sure the circuit breakers are turned OFF. 1 Remove all of the loads from the engine.

This step will prevent the engine from starting under
load and stop the electrical equipment from receiving
any incorrect voltages and frequencies.
2 Check the oil, fuel and coolant levels. If the fuel tank
is empty, it may be necessary to bleed the fuel line
after the tank is filled.
3 Start the engine, refer to KS1 Control Panel,
Operation Modes.
2 Let the engine stabilize and cool.
3 Stop the engine, refer to KS1 Control Panel,
Operation Modes.
Stop the engine, refer to KS2 Control Panel.
Important: In an emergency, push the emergency stop
button H. Turn the button to release the switch.
K Fig 6. ( T 29).

Start the engine, refer to KS2 Control Panel. Fault Conditions

Let the engine get to speed and stabilize. Stop the engine if any of the following conditions occur
during the machine operation:
4 Turn the main circuit breaker ON.
1 A noticeable change in the engine speed.
Turn the Floodlights On
2 A loss of electrical output.
1 Turn the lamp circuit breakers ON and make sure that
all of the lamps illuminate. 3 Any equipment connected to the generator
overheats.
Allow a minimum of two minutes for lamps to reach
full luminance. 4 Sparking occurs.

2 If required, adjust the positions of the lighting tower 5 The engine misfires or there is excessive engine/
and the lamps. generator noise or vibration.

Turn the Floodlights Off 6 Operating on a flammable surface.

1 Turn the lamp circuit breakers OFF. 7 The protective covers are loose or missing.

2 Turn the main circuit breaker OFF. 8 If the ambient air temperature is above 45OC.

Note: Do not stop the engine before the lamps are OFF.
3 To prevent the lamps from breaking, let the lamps
cool for a minimum of ten minutes before the lighting
tower is moved.
Auxiliary Power
1 Two 16A/230V sockets and one 32A/230V mains
input plug are provided for the auxiliary power.
2 The total auxiliary power cannot exceed the main
circuit breaker rating.

30 9811/5050-4 30
 Operation
System Setup

Program Timer Type 1 (Option fitted to c To set the date: Push and hold the button A, then
push the button D+.
KS1)
3 Set the program:
Introduction
a Set the ‘On Time’:

Push the button P to enter the setup, then push

the buttons H+M+ to set the required ‘On Time’.
ON
b Set the ‘On Date’:

i If its the same timings everyday, leave it blank.

ii Push the button D+ to select the required

P D+ H+ M+ days.

Toggle through the options to select the set

days or the unique days required. (MO-FR,
RESET MANUAL MO-SA, SA+SU, MO-WE, TH-SA, MO WE
FR, TU TH SA or unique).

A c Set the ‘Off Time’:

T065590 Push the button P, then push the buttons H+M+ to

Fig 8. Part number 333/E5624 set the required ‘Off Time’.

The Program Timer is installed in the engine compartment d Set the ‘Off Date’:
and is connected to the volt free contact through the socket
behind the control panel. K Fig 8. ( T 31). i If its the same timings everyday, leave it blank.

Lift the cover to get access to the controls. ii Push the button D+ to select the required
days.
To Program the Timer
Toggle the options to select the set days or the
1 Push the RESET button to activate the Program unique days required. (MO-FR, MO-SA,
Timer. (Use a ball point pen) SA+SU, MO-WE, TH-SA, MO WE FR, TU TH
SA or unique).
2 Set the clock:
e Event 1 is now set. The Program Timer allows up
a The default option is a 24 hour clock. to 16 different Events (on and off) to be set.

To change to the 12 hour clock, push and hold the
clock button A for 5 seconds. The display will
show ‘AM’.
To return to the 24 hour clock, push and hold the
button A for 5 seconds.
4 To set the Events 2-16, repeat the steps 3a to d for
each Event.
If no more Events are required, go to step 5.
5 Save the program:

b To set the time: Push and hold the button A, then Push the clock button A. The program is now saved.
push the buttons H+M+.

31 9811/5050-4 31
 Operation
System Setup
Note: The MANUAL button switches between the
Program Timer and Manual mode. In Manual mode, the
LT9 will run continuously.

Operation

!MCAUTION
When the machine is under timer control, it will start
automatically. Make sure that the machine is set up
correctly and is in a safe and secure area, accessed by
authorised people only. Carefully consider the timer
settings used in relation to the area occupied by the
machine. Persons in the area could be injured if the
engine starts unexpectedly.
PG-1-1-14

To operate the LT9 with the Program Timer, at the KS1

panel:

– Set the Mode Selection Key B to the AUTO position

K Fig 2. ( T 19).
– Set the main and light breakers to the on positions.
– Set the on/off switch A to the on position.
K Fig 2. ( T 19).

When the Program Timer activates the engine will start,

then 20 seconds later the lights will turn on.

When the Program Timer de-activates, the lights will turn

off, then 60 seconds later the engine will stop.

Remember, when you set the Program Timer, allow time

for the bulbs to cool before you set a re-start.

32 9811/5050-4 32
 Operation
System Setup

Program Timer Type 2 (Option - Fitted in by switching switch (2) on in the control panel, and setting
the unit to ‘AUTO’. The sensor over rides the timer so even
the KS2 controller)
if the timer is ‘ON’ the machine will not start till the light
sensor activates. The light level at which this occurs is
The timer is programmed in the menu. The events are
located inside the control box and is not adjustable by the
repeated every week. In order to program some events to
user.
be done the same day every week, select the day of the
week and press tick button.
Remotely adjustable light positioner - if installed

The actuator installed to the mast head allow the angle of

the whole light head to be altered from the control panel by
use of switch (3). This switch should be returned to the mid
position once the correct angle is reached.

KS2 controller allows the user to program the event to be

enabled only in a specific season (northern hemisphere
definition) or to be enable for all the year. The different
options for seasonal programming are:

event enable the complete year

-
P033460-74

The different events that can be programmed are (in

priority order):

event enable in December, January and

locked disable any external start of February
generator in auto mode

event enable in March, April and May

start engine start and generator
breaker activation

event enable in June, July and August

test engine start without breaker
activation (for example,
battery charge operation)
event enable in September, October and
none no event programmed. November

---
The KS2 controller allows to program up to 5 different
events per day. For each event, the user must set the time
interval, where initial hour must be previous to end hour
and both must have a value between 00:00 and 23:59.
Light sensor - if installed
A solar sensor is installed to the top of the mast to allow
uninterrupted performance of the sensor. This is activated
The user can navigate with up/down buttons and select the
day of the week pressing the tick button; in the day of the
week programming screen, the user can program type of
event and interval of each of the 5 events.
Note: To program an event from one day until the next one
(2 consecutive days) the user must program a first event
between the initial hour and 23:59 of the first day and
another event between 00:00 and the end time of the
second day.

33 9811/5050-4 33
 Operation
System Setup

A Event mode P033460-75

B Initial time A Field selection

C End time B Time

D Seasonal event C Date (dd/mm/yy)

Setting time screen (timer option only) To operate the lights using the timer the control panel key
switch must be set to ‘AUTO’. In this mode the machine will
start and stop automatically.
!MCAUTION
K Fig 4. ( T 22)
When the machine is under timer control, it will start
automatically. Make sure that the machine is set up
When the programme timer activates, the engine will start.
correctly and is in a safe and secure area, accessed by
After the engine has been running for 20 seconds, the
authorised people only. Carefully consider the timer
lights will switch on.
settings used in relation to the area occupied by the
machine. Persons in the area could be injured if the
Note: For this to happen, the lamp circuit breakers must
engine starts unexpectedly.
be set in the ON position.
PG-1-1-14

K Components - KS2 ( T 21)

Note: This must be completed prior to use of the timer.
When the programme timer de-activates, the lights will
Using up/down keys and the tick button, the user can set
switch off. The engine will then run for 60 seconds before
the time of the controller from the menu.
stopping.

34 9811/5050-4 34
 Operation
Fault Finding

Fault Finding

!MDANGER – Only use a voltmeter with two well-insulated pin

Do not open the lighting tower while the circuit breaker
is on. Allow lamp to cool before touching.
ENG-8-15
Important: A qualified technician must do all of the
maintenance and fault finding work.
Be extra careful when you work on electrical circuits.
probes rated for 400V.
– Assume all of the conductors are potentially live.
– Continue through the circuits systematically, one
section at a time.
– If all the lamps are out and all the ballasts are
receiving power, check for a defective power cable.
– Before a ballast is disconnected, turn the circuit
breaker OFF and wait 30 seconds for the capacitor to
discharge.
– For any assistance, contact your JCB Dealer.

Table 3. LT9 Fitted With 1000W Metal Halide Bulbs

Symptom Possible Cause
A lamp will not light Check the ballast status light
The lamp is loose in the socket
A defective ballast
A low voltage
An incorrect ballast
The lamp has been on. The cool
down time is insufficient
A lamp starts slowly A defective lamp
The circuit breaker trips on A short circuit
start-up
Action
1 The input lights should be on. This confirms that
power is going to the ballasts.
2 The output lights should be on. This confirms that
power is coming from the ballasts.
3 The output lights should be at their normal
brightness. If one or more of the output lights stay
extra-bright, then the lamp is not striking.
4 Use this knowledge to diagnose the problem.
Inspect the lamp base to see if there is arcing at the
centre contact button. Tighten the lamp. Check the
socket for damage. Replace if defective.
Swop the ballast plugs in the generator enclosure, if the
lamp operates, replace the ballast. Check the ballast
wiring diagram. Check the capacitors, wiring, core and
coil for signs of excessive heat.
Check the line voltage at the ballast input. The voltage
should be within 10% of the nameplate rating when it
operates with a normal load. Increase the supply voltage
or remove the external load.
A proper HID lamps will operate erratically or fail to start
with an incorrect ballast. The ballast nameplate data
should agree with the line voltage and the lamp used. An
incorrect ballast will cause the lamp to fail.
HID lamps require 4 to 8 minutes to cool before a restart.
Turn the circuit breaker OFF and let the lamp cool.
The lamp may illuminate for an extended period of time.
Check the voltage and ballast, then replace the lamp if
necessary.
Check the wiring against the diagram. Check for shorts.

35 9811/5050-4 35
 Operation
Fault Finding

Symptom Possible Cause Action

The light output of a lamp is Normal lamp wear
low A dirty lamp or canopy
A defective ballast
The wrong voltage
An incorrect ballast
The arc tube is discoloured An over-voltage from the power
or swollen supply
A short lamp life The lamp is damaged
An incorrect ballast
A new lamp
A defective lamp
A high spike ballast
Replace the lamp
Allow the lamp cool sufficiently, then clean the lamp and
canopy.
Swop the ballast plugs in the generator enclosure, if the
lamp returns to a normal light output, replace the ballast.
Check for swollen capacitors, charred wiring, core and
coil or other signs of excessive heat.
Check the voltage at the ballast input. The voltage
should be within 10% of the nameplate rating. Check the
wiring connections for voltage loss. Check the contact
point of the socket.
Check the ballast nameplate against the lamp data
Check the voltage at the ballast. Check for current or
voltage surges and for shorted capacitors, replace if
defective.
Check for cracks in the outer bulb. If air enters the outer
bulb, the arc tube may continue to burn for 100 hours
before a failure. Check for cracks where the glass
touches the base, (caused by tightening the lamp too
tightly in the socket). Look for a broken arc tube or loose
metal parts. Replace the lamp.
The ballast nameplate data should agree with the lamp
line voltage and the lamp use. If an incorrect ballast is
used, the lamp life will be shortened. A mismatch can
also cause the ballast to fail.
In certain conditions a new lamp may "cycle". Usually
after three tries to start at 30 to 60 second intervals, the
lamps will stabilize and operate normally.
Replace the lamp
The ballast produces a high spike current, measure with
an oscilloscope. Replace the ballast.

LT9 LED Version

The LED light heads have no serviceable parts and are
replaced as a whole unit. If the lamps fails to illuminate,
check the electrical supply to the lamps before changing
the LED light head.

36 9811/5050-4 36
 Routine Maintenance
Service Requirements

It is recommended that set maintenance is carried out on

a regular basis. Machine maintenance requirements
should be followed to maintain warranty validity.
K Service Schedules ( T 42)

A regular preventative maintenance schedule is highly

recommended in order to preserve the life of the
generating set.

A generating set in stand-by application and in a healthy

environment will require visual inspection approximately
once a month, while the same generating set in dusty,
damp or humid climates will require inspection and
maintenance more often than this.

Generating set preventative maintenance depends on

generating set environment, application and workload all
these factors should be taken into consideration when
planning a maintenance schedule for the machine.

Daily checks should include a MINIMUM of visual

inspections for fluid leaks, loose connections,
contamination, debris etc. in addition to the recommended
maintenance laid down in the service schedules.
K Service Schedules ( T 42)

If the generator is not being sufficiently loaded on a regular

basis it may cause coking of the engine and exhaust
system which may cause excessive smoke. To avoid this
problem ensure the load on the generator is suitable
(typically 60% or more of the generator maximum load). If
this problem does occur, then additional load will need to
be applied to rectify the problem.

Connecting a load bank (additional electrical load) should

be a routine action at normal service intervals if the
machine regularly operates at part load (less than 60%).

37 9811/5050-4 37

Health and Safety
Lubricants
T3-060_3
Introduction
It is most important that you read and understand this
information and the publications referred to. Make sure all
your colleagues who are concerned with lubricants read it
too.
Hygiene
JCB lubricants are not a health risk when used properly for
their intended purposes.
However, excessive or prolonged skin contact can remove
the natural fats from your skin, causing dryness and
irritation.
Low viscosity oils are more likely to do this, so take special
care when handling used oils, which might be diluted with
fuel contamination.
Whenever you are handling oil products you should
maintain good standards of care and personal and plant
hygiene. For details of these precautions we advise you to
read the relevant publications issued by your local health
authority, plus the following.
Storage
Always keep lubricants out of the reach of children.
Never store lubricants in open or unlabelled containers.
Waste Disposal
!MCAUTION
It is illegal to pollute drains, sewers or the ground.
Clean up all spilt fluids and/or lubricants.
Used fluids and/or lubricants, filters and contaminated
materials must be disposed of in accordance with
local regulations. Use authorised waste disposal sites.
INT-3-2-14
All waste products should be disposed of in accordance
with all the relevant regulations.
38
Routine Maintenance
Health and Safety
The collection and disposal of used oil should be in
accordance with any local regulations. Never pour used
engine oil into sewers, drains or on the ground.
Handling
!MWARNING
Oil
Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
contains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves to
prevent skin contact. Wash skin contaminated with oil
thoroughly in warm soapy water. Do not use petrol,
diesel fuel or paraffin to clean your skin.
INT-3-2-3
New Oil
There are no special precautions needed for the handling
or use of new oil, beside the normal care and hygiene
practices.
Used Oil
Used engine crankcase lubricants contain harmful
contaminants.
Here are precautions to protect your health when handling
used engine oil:
1 Avoid prolonged, excessive or repeated skin contact
with used oil.
2 Apply a barrier cream to the skin before handling
used oil. Note the following when removing engine oil
from skin:
a Wash your skin thoroughly with soap and water.
b Using a nail brush will help.
c Use special hand cleansers to help clean dirty
hands.
d Never use petrol, diesel fuel, or paraffin for
washing.
9811/5050-4 38
 Routine Maintenance
Health and Safety
3 Avoid skin contact with oil soaked clothing.

4 Don't keep oily rags in pockets.

5 Wash dirty clothing before re-use.

6 Throw away oil-soaked shoes.

First Aid - Oil

Eyes

In the case of eye contact, flush with water for 15 minutes.

If irritation persists, get medical attention.

Swallowing

If oil is swallowed do not induce vomiting. Get medical

advice.

Skin

In the case of excessive skin contact, wash with soap and

water.

Spillage

Absorb with sand or a locally approved brand of absorbent

granules. Scrape up and remove to a chemical disposal
area.

Fires

!MWARNING
Do not use water to put out an oil fire. This will only
spread it because oil floats on water.

Extinguish oil and lubricant fires with carbon dioxide,

dry chemical or foam. Fire fighters should use self
contained breathing apparatus.
7-3-1-3_1

39 9811/5050-4 39
 Routine Maintenance
Health and Safety

Battery
T3-061
!MCAUTION
!MWARNING Damaged or spent batteries and any residue from fires
or spillage should be put in a closed acid proof
Batteries give off an explosive gas. Do not smoke receptacle and must be disposed of in accordance
when handling or working on the battery. Keep the with local environmental waste regulations.
battery away from sparks and flames. INT-3-1-12

Battery electrolyte contains sulphuric acid. It can burn

you if it touches your skin or eyes. Wear goggles.
Handle the battery carefully to prevent spillage. Keep
metallic items (watches, rings, zips etc) away from the
battery terminals. Such items could short the
terminals and burn you.
Set all switches to OFF before disconnecting and
connecting the battery. When disconnecting the
battery, take off the earth (-) lead first.
Re-charge the battery away from the machine, in a well
ventilated area. Switch the charging circuit off before
connecting or disconnecting the battery. When you
have installed the battery in the machine, wait five
minutes before connecting it up.
!MWARNING
Battery Gases
Batteries give off explosive gases. Keep flames and
sparks away from the battery. Do not smoke close to
the battery. Make sure there is good ventilation in
closed areas where batteries are being used or
charged. Do not check the battery charge by shorting
the terminals with metal; use an approved battery
tester.
INT-3-1-8_2

When reconnecting, fit the positive (+) lead first.

5-3-4-12

!MCAUTION
Do not disconnect the battery while the engine is
running, otherwise the electrical circuits may be
damaged.
INT-3-1-14

!MWARNING
Electrical Circuits
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong
connection can cause injury and/or damage.
INT-3-1-4

!MDANGER
Electrolyte
Battery electrolyte is toxic and corrosive. Do not
breathe the gases given off by the battery. Keep the
electrolyte away from your clothes, skin, mouth and
eyes. Wear safety glasses.
INT-3-2-1_3

40 9811/5050-4 40
 Routine Maintenance
Health and Safety
Warning Symbols First Aid - Electrolyte

The following warning symbols may be found on the Do the following if electrolyte:
battery.
Gets into your eyes
Symbol Meaning
Immediately flush with water for 15 minutes, always get
Keep away from children. medical help.

Is swallowed
A289230-1
Do not induce vomiting. Drink large quantities of water or
Shield eyes.
milk. Then drink milk of magnesia, beaten egg or vegetable
oil. Get medical help.

A289260-1 Gets onto your skin

No smoking, no naked flames, no sparks.
Flush with water, remove affected clothing. Cover burns
with a sterile dressing then get medical help.
A289280

Explosive Gas.

A289250

Battery acid.

A289240

Note operating instructions.

A289270

41 9811/5050-4 41
 Routine Maintenance
Service Schedules

Service Schedules

Introduction How to Use the Service Schedules

T3-012_4

A poorly maintained machine is a hazard. Doing the
regular maintenance and lubrication jobs listed in these
schedules will help keep the machine in safe running
order.
!MWARNING
Maintenance must be done only by suitably qualified
and competent persons.
Before doing any maintenance make sure the machine
is safe, it should be correctly parked on level ground.
In the example shown, A shows all service requirements to
be carried out every 10 hours and B shows the
requirements to be carried out every 500 hours.
Important: Services should be carried out at either the
hourly interval or calendar interval, whichever occurs first.
Refer to Calendar Equivalents.
Important: The intervals given in the schedules must not
be exceeded. If the machine is operated under severe
conditions (high temperature, dust, water, etc.), shorten
the intervals.

To prevent anyone starting the engine, remove the

starter key. Disconnect the battery when you are not
using electrical power. If you do not take these
precautions you could be killed or injured.
8-3-1-1

Apart from the daily jobs, the schedules are based on

machine running hours. Keep a regular check on the hour
meter reading. Do not use a machine which is due for a
regular service. Rectify any defects found during regular
maintenance before clearing the machine for use.

Generators may be used in either `Prime' or `Stand-by'

applications. Minimum annual servicing is included to
cover `Stand-by' units where minimal hours will be
accumulated.

Apart from the daily jobs, the schedules are based on

machine running hours. Keep a regular check on the 795390-1
hourmeter readings to correctly gauge service intervals.
Do not use a machine which is due for a service. Make
sure any defects found during the regular maintenance
checks are rectified immediately.

Calendar equivalents:
Every 10 Hours = Daily
Every 50 Hours = Weekly
Every 500 Hours = Six Months
Every 1000 Hours = Yearly
Every 2000 Hours = 2 Years
Every 6000 Hours = 6 Years

Note: Services should be carried out at either the hourly or

calendar interval, whichever occurs first.

42 9811/5050-4 42
 Routine Maintenance
Service Schedules

Service Schedule Checklist

Table 1. Service Schedules
Interval (hrs.)
Operation 10 50 250 500 1000 1500 2000
Complete machine - Overall visual       
check
All fluids for leakage - Check       
Coolant quality and level - Check       
Fan belt(1) - Check and      
adjust
Cooling system - Drain, flush and  
Refill
Cooling and fuel system hoses - Change 
Radiator - Clean      
Oil level - Check       
Oil and Filter (1) - Change     
Water separator fuel filter(2) - Drain     
Water separator fuel filter - Clean    
Engine fuel filter - Change    
Drain fuel tank - Drain     
Air cleaner dust valve - Clean     
Air cleaner outer element - Change     
Inlet and exhaust valve seats - Lap 
Inlet and exhaust valve clearances - Check and  
adjust
Governor lever and speed control - Check and     
adjust
Injectors - Inspect, clean 
and test
Crankcase breather system - Inspect 
(3)
Lighting tower wire cables , replace if necessary (4) - Check for wear      
or damage
Alternator terminal and cable inspection, replace if - Check for wear   
necessary(4) or damage
Emergency stop operation/Earth leakage trip - Check      
Trailer lights - Check       
Tyre condition - Check       

(1) Check after first 50 hours, then every 250 hours.

(2) Check daily
(3) Check immediately in the event of possible damage due to operator error in using the winch or possible damage
caused by other equipment. Replace if damaged.
(4) Replace the cables if they show any signs of wear.

43 9811/5050-4 43
 Routine Maintenance
Pre-Start Checks

Pre-Start Checks

After the correct installation of the unit and the wiring, the cause damage to the alternator windings. If the
generating set must be fully checked before a first start is windings are damp/dirty, contact your JCB Dealer.
attempted. The points to check include: – With the exception of emergency power generators,
the engine should be warmed up with a decreased
– Make sure that all of the belts, guards and panel load before the full load is applied.
covers are installed correctly.
– Check the wiring. Make sure that all of the
connections are firmly installed in their correct
position and the wires are in good condition.
– Make sure that the machine exhaust/silencer is
installed correctly and all of the connections are
secure.
– Connect the battery cables.
– Make sure 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 was re-connected
then the fuel system must be primed before its
started. Check for fuel leaks during this procedure.
K Fuel System ( T 57).
– Make sure that if the generating set has dry batteries
they were activated and charged to the
recommended level. Make sure that the battery
connections are secure and the polarity of the
connections is correct. K Battery ( T 40)
– Check the level of coolant in the machine radiator,
and top-up if low. K Checking and Adding
Coolant ( T 55).
– Check the hoses for damage or loose clamps.
– Check the level of engine oil, use the dipstick.
K Checking and Adding Coolant ( T 55).
– Check the fuel filter/water separator for water or
contaminants.
– Inspect the engine and alternator for any signs of
damage, water, oil or fuel leaks.
– Make sure that the intake and outlet air vents and
grills are not blocked and allow a good airflow through
the machine.
– Check that the engine intake air filter is installed
correctly and there are no obstructions for the
incoming air.
– Make sure that all of the supplied documentation
packs are removed from the machine.
– Make sure that the alternator windings and the
assembly are not damp, or dirty. A failure to do so can

44 9811/5050-4 44
 Routine Maintenance
Checks After Running

Checks After Running

The points to check include:

– Check that the power is cut from the battery master

switch and that the control switch is in the 0 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.
– If there is a risk of freezing, the cooling system must
contain enough glycol.

Important: The coolant should be topped-up when the

engine is stopped after the first start.

45 9811/5050-4 45
 Routine Maintenance
Cleaning

Cleaning

General
Important: Stop the machine and let it cool for at least one
hour. Do not try to clean any part of the machine when it is
running.
1 Make sure that all of the electrical loads are
disconnected.
2 Make the generator safe:
Turn the circuit breakers OFF.
Stop the machine.
Push the emergency stop button. (On the back of the
trailer). Turn the button to release the switch).
3 Make sure that all electrical connectors are coupled
correctly. If the connectors are open, attach the
correct caps or seal them with water proof tape.
Note: Do not operate the jet nozzle closer than 600mm (24
in.) to any part of the generator.
11 When the pressure wash is completed, move the
machine away from the wash area, or alternatively,
clean away the material washed from the machine.
12 Before you work on special areas of the engine, use
a compressed air jet to remove any moisture. When
the area is dry, use a soft clean brush to remove any
sand or grit particles that remain.
13 When a component is removed, be aware of any dirt
or debris that may be exposed. Cover any open ports
and clean the deposits before you continue.
Cleaning the Radiator
1 Stop the engine,
2 Let the engine cool.

4 Cover the engine starter motor, alternator and ECU 3 Use compressed air to remove debris from the
with a plastic bag to prevent water ingress. radiator.

5 Cover the generator alternator, electrical components

and connections with plastic to prevent water ingress.

6 Seal the engine air intake, exhaust and breather

system.

7 Make sure that the oil filler caps and dipstick are
installed correctly.

8 Use a low pressure water jet and a brush to remove

any mud or dirt.
T039070
Fig 1.
!MCAUTION
4 Use a brush to remove any further debris.
The engine or certain components could be damaged
by high pressure washing systems; special
5 Inspect the radiator for damage.
precautions must be taken if the engine is to be
washed using a high pressure system.

Ensure that the alternator, starter motor and any other

electrical components are shielded and not directly
cleaned by the high pressure cleaning system.
ENG-3-3

9 Apply an approved cleaning and degreasing agent

with a brush. Obey the manufacturers instructions.

10 Use a pressure washer to remove the soft dirt and oil.

Important: Do not aim a water jet directly at oil seals or

electrical and electronic components for example the
engine Electronic Control Unit (ECU), alternator or fuel
injectors.

46 9811/5050-4 46
 Routine Maintenance
Battery

Battery

Connection and Disconnection Battery Maintenance

The machine is fitted with a sealed battery which is
+ - maintenance free.

Battery Life
+ - The control panel, remote communication (if installed) and
other stand-by functions, provide some drain on the
battery.

JCB recommend a running cycle of 1-2 hours twice weekly.

Fig 2. 12V System
The batteries leads must be connected on the initial
installation.
When you connect the batteries to the machine, always
connect the positive (+) lead first followed by the negative
(-) lead.
This exercising of the generator set recuperates the
battery utilizing the charging alternator, and allows the
machine to maintain a healthy stand-by state.
If operating where the ambient temperature could drop
below -15 degrees C (5 degrees F), remove the battery at
the end of the day and store in a warm place until required
again. This will help to start the engine easily.

When you disconnect the batteries, remove the negative

(-) lead first then the (+) positive lead.

This procedure will make sure that the battery terminals

are not shorted accidentally.

Charging the Battery

If the battery voltage is below 12.4V or the engine cranking
speed is so low that the engine does not start, charging is
required.

If the generating set has an on board battery charger this

will take care of charging when connected to the auxiliary
mains supply. If a charger is not fitted, the recommended
charging within 1/10 of the normal capacity for 5-6 hours
must be carried out by connecting an external charger.

If using the onboard battery charger the charge current will

be controlled by the unit, and reduced accordingly when
the battery is fully charged. At this point the battery charger
will switch to trickle charge, maintaining the battery in a
fully charged condition.

47 9811/5050-4 47
 Routine Maintenance
Engine

Engine

Component Identification

T038440
Fig 3. 3TNV76

1 Lifting eye (flywheel end) 14 Governor lever

2 Engine coolant pump 15 Fuel lnjection pump lntake manifold

3 Lifting eye (engine cooling fan end) 16 Air intake port (from air cleaner)

4 Engine cooling fan 17 Fuel filter

5 V-belt 18 Fuel return to fuel tank

6 Crankshaft V-pulley 19 Top filler port (engine oil)

7 Side filler port (engine oil) 20 Rocker arm cover

8 Drain plug (engine oil) 21 Flywheel

Note: Position of drain plug may differ according to 22 Starter motor

specification.
23 Exhaust manifold
9 Fuel inlet
24 Alternator
10 Mechanical fuel pump

11 Fuel priming lever

12 Dipstick (engine oil)

13 Engine oil filter

48 9811/5050-4 48
 Routine Maintenance
Engine

Location of Labels 97/68/EC Directive Certified Engines

The engines described in this manual have been certified
by the 97/68/EC Directive and carry the 97/68/EC
emission control label.

T038480 T038500
Fig 4. Fig 6.
Regulatory and Safety Labels 3TNV76
Engine Family
The EPA / ARB labels and the 97/68/EC label all have an
Engine Family field.

1 Emission control information label

2 Engine nameplate

T038510
Fig 7.
A Method of aspiration
B Number of cylinders
T038620 C Engine speed specification
Fig 5. Typical Engine Nameplate D Displacement (litres)
E Non-road/Off-road engine
F Yanmar diesel
G Model year. 5 = 2005, 6 = 2006 etc.

49 9811/5050-4 49
 Routine Maintenance
Engine

Oil and Filter Oil Viscosity Minimum Maximum

Temperature 0C (0F) Temperature 0C (0F)
Introduction
SAE 0W30 - 40 (-40) + 30 (86)
The generating set engine oil is pre-filled in factory. SAE 0W20 - 40 (-40) + 10 (50)
However it is important to check the level of oil in the SAE 5W20 - 30 (-22) + 10 (50)
engine before any starting can take place, and also as part
SAE 5W40 - 30 (-22) + 40 (104)
of a regular maintenance schedule.
SAE 10W30 - 20 (-4) + 40 (104)
New engines DO NOT require a running-in period. The SAE 15W40 - 15 (-5) + 50 (122)
engine/machine should be used in a normal work cycle
immediately, glazing of the piston cylinder bores, resulting
Recommended Oils
in excessive oil consumption, could occur if the engine is
gently run-in. Under no circumstances should the engine
be allowed to idle for extended periods; (e.g. warming up Engine Oil Specification
without load). JCB Extreme ACEA E5/B3/A3, API CH-4/SJ
Performance
For vehicle applications a minimum API CF-4 grade oil
must be used. Superior grade oils may be more
Choose the grade of oil to suit the temperature range as
appropriate for heavy duty applications (such as sustained
detailed.
high loads and operation at elevated temperatures).

Important: Operation of the engine with some types of Engine Oil Capacity
fuel requires use of superior grade oil. Use only the
specified oil. Other oils may affect warranty coverage, Table 2.
cause internal engine components to seize and/or shorten Item Capacity litres (UK Gal)
engine life. Engine Maximum Minimum
3TNV76 3.4 (0.75) 1.8 (0.4)
For generator set applications a minimum API CH-4 grade
oil must be used. Superior grade oils may be more
appropriate for heavy duty applications (such as sustained
high loads and operation at elevated temperatures).

The choice of lubricant viscosity should be made based on

the lowest ambient temperature at which the machine will
be started and the maximum ambient temperature at
which it will operate.

The following table provides guidance as to the

temperature range that can be accommodated by
standard oil viscosities and can be used to select an
appropriate grade.

Important: When selecting the oil viscosity grade make

sure the oil conforms with or exceeds the recommended
specification. K Recommended Oils ( T 50).

50 9811/5050-4 50
 Routine Maintenance
Engine
Checking the Oil Level

A failure to change the oil and filter at the recommended

interval can cause a serious engine failure. K Service
Schedules ( T 42).

1 Stop the engine and let it cool.

2 Make the machine safe.

3 Carefully clean the filler cap and dipstick areas to

prevent dirt and debris from contaminating the engine
oil.

4 Check that the oil level is between the marks 2 and 3

on the dipstick 1.

Note: A false level will be shown on the dipstick if the oil is

hot.

5 If necessary, add the recommended oil through one of

the filler points 4/5.

Never mix different types of engine oil. This can

adversely affect the lubricating properties of the oil.

Do not overfill as this may cause white smoke, engine

overspeed or internal damage.

T038580-B2
Fig 8. 3TN

51 9811/5050-4 51
 Routine Maintenance
Engine
Changing the Oil and Filter 2 Carefully clean the filler cap and dipstick areas to
prevent dirt and debris from contaminating the engine

!MCAUTION oil.

It is illegal to pollute drains, sewers or the ground. 3 Remove one of the filler caps A to vent the crankcase
Clean up all spilt fluids and/or lubricants. and allow the oil to drain more easily.

Used fluids and/or lubricants, filters and contaminated 4 Put a container of suitable size below the drain plug.
materials must be disposed of in accordance with
local regulations. Use authorised waste disposal sites.
INT-3-2-14

!MWARNING
Oil
Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
contains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves to
prevent skin contact. Wash skin contaminated with oil
thoroughly in warm soapy water. Do not use petrol,
diesel fuel or paraffin to clean your skin.
INT-3-2-3

Drain the oil when the engine is warm, any contaminants

held in suspension will be drained with the oil.

T038570-B1
1 Stop the engine.
Fig 10. 3TN

!MCAUTION
Oil will gush from the hole when the drain plug is
removed. Hot oil and engine components can burn
you. Keep to one side when you remove the plug.
13-3-1-15

5 Remove the drain plug 1 and let the oil drain into the
container.

6 Clean, then replace the drain plug. Torque to 54-

64Nm (40-47 lbf ft).

7 Remove the filter canister 2, use a chain wrench if

necessary.

8 Clean the seal face of the filter and its mounting.

T038560-B1 9 Apply clean engine oil to the seal on the new filter
Fig 9. 3TN canister.

52 9811/5050-4 52
 Routine Maintenance
Engine
10 Screw in the new filter canister until it touches the
mounting face, then do one additional turn.

11 Fill the engine with the recommended oil to the MAX

mark on the dipstick.

12 Remove any spilt oil.

13 Replace the filler cap and make sure it is secure.

Do not overfill as this may cause white smoke, engine

overspeed or internal damage.

14 Operate the engine until the engine is warm.

15 Check for oil leakage.

16 When the oil has cooled, check the oil level again,
and if necessary top-up with clean engine oil.

53 9811/5050-4 53
 Routine Maintenance
Engine

Check and Adjust the Fan Belt

!MWARNING
Make sure the engine cannot be started. Disconnect
the battery before doing this job.
2-3-3-5

!MWARNING
Turning the Engine
Do not try to turn the engine by pulling the fan or fan
belt. This could cause injury or premature component
failure.
0094

The belt will slip if the tension is not correct, this will T038590-B2
prevent the alternator from charging correctly. Also, the Fig 11.
engine will overheat if the coolant fan pulley slips.

Check the belt for cracks, oil or wear, replace if necessary.

Check the belt tension at position A, B or C depending on

the ease of access. The correct deflection of a used or new
belt is shown in the table.

Note: A used belt is one that has been used on a running

engine for five minutes or more.

A B C
Used belt 10 - 14 mm 7 - 10 mm 9 - 13 mm
0.4 - 0.6 in 0.3 - 0.4 in 0.35 - 0.5 in
New belt 8 - 12 mm 5 - 8 mm 7 - 11 mm
0.3 - 0.5 in 0.2 - 0.3 in 0.3 - 0.4 in
T038600-B2
Fig 12.
If necessary, to adjust the tension:

1 Loosen the bolt 1, then use a lever 3 to move the

alternator 2 to the correct position.

2 Tighten the bolt, then check the belt tension.

3 Check there is clearance Y between the belt and the

bottom of the pulley groove.

4 If there is no clearance between the belt and the

bottom of the pulley groove at X, replace the belt.
T038610
5 After the adjustment, run the engine for 5 minutes or Fig 13.
more.

6 Check the tension again, use the specifications for a

used belt.

54 9811/5050-4 54

Cooling System
Checking and Adding Coolant
!MWARNING
The cooling system is pressurised when the coolant is
hot. When you remove the cap, hot coolant can spray
out and burn you. Make sure that the engine is cool
before you work on the cooling system.
9-3-3-1_2
Normally the generating set is supplied pre-filled with
radiator coolant. K Coolant Mixtures ( T 56).
Before you start the engine, always check the level of
coolant in the radiator. Top-up the system as necessary.
To check the coolant:
1 When the generator set is completely cold, remove
the coolant cap from the top of the radiator 1.
2 Make sure that the coolant in the radiator is visible
above the radiator elements.
3 If necessary, add coolant until the radiator is full,
Make sure that cold coolant is not added to a radiator
that is warm, let the machine cool before coolant is
added.
4 When the radiator is full, replace and fully tighten the
coolant cap.
55
Routine Maintenance
Engine
Drain and Refill the Coolant
!MWARNING
The cooling system is pressurised when the coolant is
hot. When you remove the cap, hot coolant can spray
out and burn you. Make sure that the engine is cool
before you work on the cooling system.
9-3-3-1_2
When the engine coolant is contaminated with rust or
water scale, it decreases the cooling function.
Even when the engine coolant is mixed correctly, the
engine coolant becomes contaminated as its ingredients
deteriorate.
T039090
Fig 14.
1 Allow the engine and coolant to cool.
2 Remove the radiator cap 1.
3 Put a suitable container below the drain plug/drain
cock 2.
4 Remove the drain plug or open the drain cock 2.
Let the coolant drain into the container.
9811/5050-4 55

T039100
Fig 15. 3TN
5 Put a suitable container below the drain plug 3.
6 Remove the drain plug 3.
Let the coolant drain into container.
7 When the engine coolant has drained, flush the
radiator and the cylinder block with clean water to
remove any rust, scale and contaminants.
8 Install and tighten the drain plug or close the drain
cock in the radiator.
9 Install and tighten the cylinder block drain plug.
10 Fill the radiator and engine with specified coolant.
K Coolant Mixtures ( T 56).
11 Replace the radiator cap.
Coolant Mixtures
T3-009_3
Check the strength of the coolant mixture at least once a
year, preferably at the start of the cold period.
Replace the coolant mixture according to the intervals
shown in the machine's Service Schedule.
!MWARNING
Antifreeze can be harmful. Obey the manufacturer's
instructions when handling full strength or diluted
antifreeze.
7-3-4-4_1
56
Routine Maintenance
Engine
You must dilute full strength antifreeze with clean water
before use. Use clean water of no more than a moderate
hardness (pH value 8.5). If this cannot be obtained, use
de-ionized water. For further information advice on water
hardness, contact your local water authority.
The correct concentration of antifreeze protects the engine
against frost damage in winter and provides year round
protection against corrosion.
The protection provided by JCB High Performance
Antifreeze and Inhibitor is shown below.
50% Concentration (Standard)
Protects against damage down to -40 °C (-39 °F)
60% Concentration (Extreme Conditions Only)
Protects against damage down to -56 °C (-68 °F)
Important: Do not exceed a 60% concentration, as the
freezing protection provided reduces beyond this point.
If you use any other brand of antifreeze:
– Ensure that the antifreeze complies with International
Specification ASTM D6210.
– Always read and understand the manufacturer's
instructions.
– Ensure that a corrosion inhibitor is included. Serious
damage to the cooling system can occur if corrosion
inhibitors are not used.
– Ensure that the antifreeze is ethylene glycol based
and does not use Organic Acid Technology (OAT).
9811/5050-4 56
 Routine Maintenance
Engine

Fuel System Additional Technical Fuel Requirements

Fuel Specifications – The fuel cetane number should be equal to 45 or

higher.
Diesel fuel should comply with the following specifications: – The sulphur content must not exceed 0.5% by
volume. Less than 0.05% is preferred.
Fuel Specification Location
Especially in U.S.A.and Canada, low sulphur (300mg/
ASTM D975 kg sulphur content) or ultra low sulphur fuel should be
No. 1-D S15, S500 USA used.
No. 2-D S15, S500
– Bio-Diesel fuels. K Bio-Diesel Fuels ( T 58)
EN590:96 European Union – NEVER mix kerosene, used engine oil, or residual
ISO 8217 DMX International fuels with the diesel fuel.
BS 2869-A1 or A2 United Kingdom – Water and sediment in the fuel should not exceed
0.05% by volume.
JIS K2204 Grade No.2 Japan
– Keep the fuel tank and fuel-handling equipment clean
KSM-2610 Korea
at all times.
GB252 China – Poor quality fuel can reduce engine performance and
/ or cause engine damage.
– Fuel additives are not recommended. Some fuel
additives may cause poor engine performance.
Consult your JCB Dealer for more information.
– Ash content not to exceed 0.01% by volume.
– Carbon residue content not to exceed 0.35% by
volume. Less than 0.1% is preferred.
– Total aromatics content should not exceed 35% by
volume. Less than 30% is preferred.
– PAH (polycyclic aromatic hydrocarbons) content
should be below 10% by volume.
– Metal content of Na, Mg, Si, and AI should be equal
to or lower than 1 mass ppm. (Test analysis method
JPI-5S-44-95).
– Lubricity: Wear mark of WS1.4 should be Max. 0.018
in. (460 IJm) at HFRR test.

57 9811/5050-4 57

Bio-Diesel Fuels
In Europe and the United States, as well as some other
countries, non-mineral oil based fuel resources such as
RME (Rapeseed Methyl Ester) and SOME (Soybean
Methyl Ester), collectively known as FAME (Fatty Acid
Methyl Esters), are being used as extenders for mineral oil
derived diesel fuels.
Routine Maintenance
Engine
6 The use of bio-diesel fuels that do not comply with the
standards as agreed to by the diesel engine
manufacturers and the diesel fuel injection equipment
manufacturers, or bio-diesel fuels that have degraded
as per the precautions and concerns above, may
affect the warranty coverage of your engine.
Injectors

JCB approves the use of bio-diesel fuels that do not

exceed a blend of 5% (by volume) of FAME with 95% (by
volume) of approved mineral oil derived diesel fuel. Such
bio-diesel fuels are known in the marketplace as B5 diesel
fuels.
These 85 diesel fuels must meet certain requirement:
!MWARNING
Do not open the high pressure fuel system with the
engine running. Engine operation causes high fuel
pressure. High pressure fuel spray can cause serious
injury or death.
13-3-2-16

1 The bio-fuels must meet the minimum specifications
for the country in which they are used:
a In Europe, bio-diesel fuels must comply with the
European Standard EN14214.
b In the United States, bio-diesel fuels must comply
with the American Standard ASTM D-6751.
Proper operation of the fuel injectors is required to obtain
the optimum injection pattern for full engine performance.
The EPA / ARB requires that you have the injectors
inspected, cleaned and tested at the specified service
interval. K Service Schedules ( T 20) See your
authorized JCB dealer or distributor.

2 Bio-fuels should be purchased only from recognized

and authorized diesel fuel suppliers.

Use of Bio-fuels:

1 Free methanol in FAME may result in corrosion of

aluminium and zinc FIE components.

2 Free water in FAME may result in plugging of fuel

filters and increased bacterial growth.

3 High viscosity at low temperatures may result in fuel

delivery problems, injection pump seizures and poor
injection nozzle spray atomization.

4 FAME may have adverse effects on some elastomers

(seal materials) and may result in fuel leakage and
dilution of the engine lubricating oil.

5 Even bio-diesel fuels that comply with a suitable

standard as delivered, will require additional care and
attention to maintain the quality of the fuel in the
equipment or other fuel tanks. It is important to
maintain a supply of clean, fresh fuel. Regular
flushing of the fuel system, and / or fuel storage
containers, may be necessary.

58 9811/5050-4 58
 Routine Maintenance
Engine
Priming the Fuel System To Prime the Fuel System if a Mechanical Fuel Pump is
Fitted
Introduction
1 Operate the fuel priming lever 1 several times until the
fuel filter bowl 2 is filled with fuel.

2 Never use the starter motor to crank the engine in

order to prime the fuel system. This may cause the
T038450
starter motor to overheat and damage the coils,
Fig 16. pinion and / or ring gear.

!MWARNING
Fuel
Fuel is flammable; keep naked flames away from the
fuel system. Stop the engine immediately if a fuel leak
is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the
engine running. Completely wipe off any spilt fuel
which could cause a fire. There could be a fire and
injury if you do not follow these precautions.
INT-3-2-2_3

!MWARNING
Do not open the high pressure fuel system with the
engine running. Engine operation causes high fuel
pressure. High pressure fuel spray can cause serious
injury or death. T038520
Fig 17.
13-3-2-16

Prime the fuel system under the following conditions:

– Before starting the engine for the first time

– After running out of fuel and fuel has been added to
the fuel tank
– After fuel system maintenance such as changing the
fuel filter and draining the fuel filter / water separator
or replacing a fuel system component.

To Prime the Fuel System if an Electric Fuel Pump is

Fitted

1 Turn the key to the ON position for 10 to 15 seconds.

This will allow the electric fuel pump to prime the fuel
system.

2 NEVER use the starter motor to crank the engine in

order to prime the fuel system. This may cause the
starter motor to overheat and damage the coils,
pinion and / or ring gear.

59 9811/5050-4 59
 Routine Maintenance
Engine
Water Separator and Fuel Filter Drain the Water Separator

Introduction

T038450
Fig 18.

!MCAUTION
It is illegal to pollute drains, sewers or the ground.
Clean up all spilt fluids and/or lubricants.
T038630
Used fluids and/or lubricants, filters and contaminated Fig 19.
materials must be disposed of in accordance with
local regulations. Use authorised waste disposal sites. 1 Stop the engine and let it cool.
INT-3-2-14
2 Put an approved container below the bowl 1.
!MCAUTION 3 Close the fuel tap 3, (turn it to the right 2).
Do not allow dirt to enter the fuel system. Before
disconnecting any part of the fuel system, thoroughly 4 Turn the retaining-ring 4 to the left 9 and carefully
clean around the connection. When a component has remove the bowl 1.
been disconnected, for example a fuel pipe, always fit
protective caps and plugs to prevent dirt ingress. 5 Remove the retaining-spring 6 and float 7 from the
bowl.
Failure to follow these instructions will lead to dirt
entering the fuel system. Dirt in the fuel system will 6 Empty the fuel into an approved container and
seriously damage the fuel injection equipment and dispose of the waste correctly.
could be expensive to repair.
ENG-1-7 7 Hold the bottom of the bowl with a cloth to prevent the
fuel from dripping. Remove any spills immediately.
Drain the water separator/fuel filter if there are
contaminants, for example water in the bottom of the bowl. 8 Clean the inside of the bowl.
Do not wait until the scheduled maintenance interval.
9 Check the condition of the filter 10 and `O' ring 11.
The separator bowl is made from a semi-transparent Clean the filter and replace the `O' ring if necessary.
material. In the bowl is a red coloured float-ring which will
rise to the surface of the water to show how much needs 10 Install the retaining-spring 6 and float 7.
to be drained.
11 Attach the bowl to the mounting flange 8 and turn the
Some optional fuel filter/water separators have a sensor to retaining-ring 4 to the right 5 hand tight only.
sense the amount of contaminants. This sensor sends a
signal to an indicator to alert the operator. 12 Open the fuel tap 3.

13 Prime the fuel system. K Priming the Fuel

System ( T 59)

14 Check for leaks.

60 9811/5050-4 60
 Routine Maintenance
Engine
Clean the Water Separator Replace the Fuel Filter

T039040
T038630 Fig 21.
Fig 20.
1 Stop the engine and let it cool.
1 Stop the engine and let it cool.
2 Put an approved container below the bowl 1
2 Put an approved container below the bowl 1. K Fig 19. ( T 60)

3 Close the fuel tap 3, (turn it to the right 2). 3 Close the fuel tap.

4 Turn the retaining-ring 4 to the left 9 and carefully 4 Turn the retaining-ring 1 to the left 5 and carefully
remove the bowl 1. remove the bowl 3. K Fig 21. ( T 61)

5 Remove the retaining-spring 6 and float 7 from the 5 Empty the fuel into an approved container and
bowl. dispose of waste correctly.

6 Empty the fuel into an approved container and 6 Hold the bottom of the bowl with a cloth to prevent the
dispose of waste correctly. fuel from dripping. Remove any spills immediately.

7 Hold the bottom of the bowl with a cloth to prevent the 7 Pull the filter 4 down to remove it and replace with a
fuel from dripping. Remove any spills immediately. new one.

8 Clean the inside of the bowl. 8 Clean the inside of the bowl.

9 Pull the filter 10 down to remove it and replace with a 9 Check the condition of the `O' ring 6 and replace if
new one. necessary.

10 Check the condition of `O' ring 11 and replace if 10 Attach the bowl to the mounting flange and turn the
necessary. retaining-ring 1 to the right 2 hand tight only.

11 Install the retaining-spring 6 and float 7. 11 Open the fuel tap.

12 Attach the bowl to the mounting flange 8 and turn the 12 Prime the fuel system. K Priming the Fuel
retaining-ring 4 to the right 5 hand tight only. System ( T 59)

13 Open the fuel tap 3. 13 Check for leaks.

14 Prime the fuel system. K Priming the Fuel

System ( T 59)

15 Check for leaks.

61 9811/5050-4 61
 Routine Maintenance
Engine

Inlet and Exhaust System

Replace the Air Cleaner Outer Element

B
A
D
T039060
Fig 22. Typical Air Cleaner

The engine performance is affected when the air cleaner Valves

element is clogged with dust. Make sure you change the
air filter element at the specified service intervals.
1 Release, then remove the air cleaner cover A.
2 Remove the element B (the outer element, if there are
two elements).
3 Replace the element with a new one.
4 If the air cleaner has a double element, only remove
and replace the inner element C if the engine lacks
power or the dust indicator actuates.
Note: The inner element should not be removed when the
outer element is cleaned or replaced. The inner element is
used to prevent dust from entering the engine when the
outer element is serviced.
5 Clean inside of the air cleaner cover and dust valve D.
The correct adjustment is necessary to maintain the
correct timing for opening and closing the valves.
An incorrect adjustment will cause the engine to run noisily
and cause poor engine performance and engine damage.
See your authorized JCB Dealer or distributor to lap the
valve seats and/or adjust the inlet exhaust valve clearance
at the specified service interval.
Turbocharger (4TNV84T, 4TNV98T)
Turbocharger service is required by the EPA / ARB at the
specified service interval. Your authorized JCB dealer or
distributor will inspect and power wash the unit if
necessary. If you notice that the engine seems sluggish or
the exhaust colour is abnormal NEVER wait until the next
service interval.

6 Install the air cleaner cover, make sure you match the
arrow on the cover with the arrow on the case.

Important: Make sure that the parts are assembled

correctly, or unfiltered air could be sucked into the engine
and cause serious damage.

Crankcase Breather System

The correct operation of the crankcase breather system is

required to maintain the emission requirements of the
engine.

The EPA / ARB requires that you have the crankcase

breather system inspected at the specified service interval.
See your authorized JCB Dealer or Distributor.

62 9811/5050-4 62
 Routine Maintenance
Engine

Technical Information
Description of Model Number

4 TNV 84 T 0 000
No. of Cylinders Engine Series Cylinder Bore Turbocharged (No Rated RPM Customer Code
(mm) symbol indicates
naturally
aspirated)

General

Type Vertical In-line, Water Cooled, 4-Cycle Diesel Engine

Combustion System Direct Injection Models Direct Injection
Indirect Injection Models Swirl Chamber (Ball-Type)
Starting System Electric Starting
Cooling System Radiator
Lubricating System Forced Lubrication with Trochoid Pump
PTO Position Flywheel End
Direction of Rotation Counter clockwise Viewed from Flywheel End

Engine rating conditions are as follows (SAE J 1349, ISO

3046/1):

– Atmospheric Condition: Room temperature 25°C

(77°F) Atmospheric pressure 100kPa, 750mm Hg
(29.53 in. Hg), Relative humidity 30%
– Fuel Temperature at Fuel Injector Pump Inlet 40°C:
(104°F)
– With Cooling Fan, Air Cleaner, Exhaust silencer.
– After the Engine Break-In Period. Output Allowable
Deviation: 3%
– 1PS = 0.7355kW
– 1hp SAE (Society of Automotive Engineers) =
0.7457kW

63 9811/5050-4 63
 Routine Maintenance
Engine
Information by Engine Model

Engine Model 3TNV76 (LT9)

Version CL
Type Vertical In-line Diesel Engine
Combustion System Ball-Type Swirl Chamber
Aspiration Natural
Number of Cylinders 3
Bore x Stroke 76 x 82 mm (2.992 x 3.228 in)
Displacement 1.115 litres (68.029 in3)
RPM (minimum) 1500 1800
hp SAE 11.0 13.1
Continuous Rated Output
kW 8.2 9.8
PS 11.1 13.3
RPM (minimum) 1500 1800
hp SAE 12.1 14.3
Maximum Rated Output (Nett)
kW 9 10.7
PS 12.2 14.5
High Idling RPM (minimum) 1600+/-25 1900+/-25
Engine Weight (dry) with flywheel housing 112 kg (247.0 Ib)
PTO Position Flywheel End
Direction of Rotation Counter clockwise Viewed from Flywheel End
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Normal Oil Pressure at Rated Engine Speed 2.4 - 3.5 bar (35 - 51 lbf/in2)
Normal Oil Pressure at Low Idle Speed (minimum) 0.6 bar (8.5 lbf/in2)
Dimensions (L x W x H) without radiator 532 x 427 x 532 mm (20.59 x 16.81 x 20.94 in.)

64 9811/5050-4 64
 Routine Maintenance
Alternator

Alternator

Safety Precautions
Safe and efficient operation is only achieved if the
equipment is maintained and operated correctly.

Many accidents occur because of a failure to follow

fundamental rules and precautions.

An electrical shock can cause severe personal injury or

death.

Obey all of the WARNING/CAUTION notices.

– Make sure that the installation meets all of the

applicable safety and local electrical codes. Have all
of the installations done by a qualified electrician.
– Do not operate the generator with the protective
covers, access covers or terminal box covers
removed.
– Disable the engine start circuits before you do any
maintenance tasks.
– Disable the closing circuits and/or put warning notices
on any circuit breakers normally used for connection
to the mains or other generators to prevent accidental
closure.

Obey all of the IMPORTANT, CAUTION, WARNING, and

DANGER notices, defined as:

Important! Important refers to a hazard or dangerous

method or practice which can cause
equipment damage or related equipment
damage.

Caution! Caution refers to a hazard or dangerous

method or practice which can cause
equipment damage or personal injury.

Warning! Warning refers to a hazard or dangerous

method of practice which can cause
severe personal injury or possible death.

Danger! Danger refers to an immediate hazard

which WILL cause severe personal injury
or death.

65 9811/5050-4 65
 Routine Maintenance
Alternator

Installation
Lifting

!MWARNING
Lifting Equipment
You can be injured if you use incorrect or faulty lifting
equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
equipment is in good condition and complies with all
local regulations.
INT-1-3-7_2

Note: Minimum lifting capacity required is 750 Kg.

Two lifting lugs are provided for use with a shackle and pin
type lifting aid.

Chains of suitable length and lifting capacity must be used.

C067710
Lifting points are designed to be as close to the centre of Fig 23.
gravity of the generator as possible, but due to design
restrictions it is not possible to guarantee that the Protection
generator frame will remain horizontal while lifting.
It is the responsibility of the end user and his contractors/
Care is therefore needed to avoid personal injury or subcontractors to ensure that the overall system protection
equipment damage. meets the needs of any inspectorate, local electricity
authority or safety rules, pertaining to the site location.
The correct lifting arrangement is shown on the label
attached to the lifting lug. K Fig 23. ( T 66).
!MWARNING
A qualified electrical engineer must Install the system.
Failure can result in damage to equipment and
personnel.
ENG-8-6_1

66 9811/5050-4 66
 Routine Maintenance
Alternator

General Information
The E1C/4 Alternator

The E1C /4 series is a single-phase 4 pole brush-less

alternator with an auxiliary winding (loaded on a capacitor)
and new rotating diode system. It has been designed for
tower lights with metal halide or halogen lamps.

Class H insulating material are present both in the stators

and the rotors; the windings are tropicalised. Low-loss
lamination is used.

T043120
Fig 24. Electrical Diagram
A Main Winding
B Excitation Winding
C Rotor

Specifications

LT9 to m/c no 1650482 (Mk iv) LT9 from m/c no 1650483 (Mk v)
Manufacturer: Linz Sincro
50Hz 60Hz 50Hz 60Hz
Alternator model: E1C 13SC/4 E1C 13SC/4 SK160 XS1 SK160 XS1
KvA @ PF1.0: 8 7
Poles: 4 4
Voltage Regulator: No AVR
Insulation Class: H H
Bearings: 1 1
Coupling: SAE5-7.5" SAE5-7.5"

67 9811/5050-4 67
 Routine Maintenance
Alternator
The ECP28 XS/4 Alternator

The ECP28 4 pole alternator is a single phase brushless

alternator with AVR control allowing the use of the auxiliary
sockets immediately after bulb switch off.

Manufacturer Mecc Alte

Alternator model ECP28 XS/4
kVA @ PF1.0 7
Poles 4
Voltage regulator AVR
Insulation class H
Bearings 1
Coupling Sae5-7.5

68 9811/5050-4 68
 Routine Maintenance
Alternator
Reference Standards Operating Conditions

The E1 series alternators are manufactured pursuant to The performance data reported in the present catalogue
the provisions of the EN 60034-1, EN 50081-1, EN 50082- are valid for operation at an altitude not exceeding 1000 m
1 standards and the 73/23 CEE, EMC 89/336 CEE and 98/ a.s.l. and ambient temperature not exceeding 400C. If
037 CEE directives. operation takes place in different conditions.

Table 3.
Ambient temperature
Altitude m 250C 400C 450C 500C 550C
<1000 1.09 1.00 0.96 0.93 0.91
1000 - 1500 1.01 0.96 0.92 0.89 0.87
1500 - 2000 0.96 0.91 0.87 0.84 0.83
2000 - 3000 0.9 0.85 0.81 0.78 0.76

Winding Condition

As part of routine maintenance procedures, periodic

attention to winding condition (particularly when
generators have been idle for a long period) and bearings
is recommended.

When generators are fitted with air filters regular

inspection and filter maintenance is required.

!MWARNING
Service and fault finding procedures present hazards
which can result in severe personal injury or death.
Only personnel qualified to perform electrical and
mechanical service must do these procedures. Ensure
engine starting circuits are disabled before you start
service or maintenance procedures. Isolate the anti-
condensation heater supply.
ENG-8-9_1

Ordering Parts

When ordering parts the alternator serial number or

alternator identity number and type should be quoted,
together with the part description.

Parts are available directly from your JCB dealer.

69 9811/5050-4 69
 Routine Maintenance
Fault Finding

Fault Finding

Introduction Due to the time and effort involved in removing,

dismantling, assembling and replacing an engine, it is

!MWARNING
Machinery utilizing the engine must be correctly
isolated and prepared, for example safety strut fitted,
prior to completing maintenance tasks on the engine.
Maintenance must be completed by suitably qualified
personnel.
You or others could be killed or seriously injured if the
machine is not correctly prepared and maintained.
ENG-1-5_2
If your engine does not operate properly, refer to the fault
finding charts or consult your authorized JCB dealer or
distributor.
Supply the JCB dealer or distributor with the following
information:
– Model name and serial number of your engine
– How long the engine has been in service (the number
of engine hours or the number of calendar months)
– Operating conditions when problem occurs
– Colour of exhaust smoke
– Type of diesel fuel
– Type of engine oil
– Any abnormal noises or vibration
– Operating environment such as high altitude or
extreme ambient temperatures, etc.
– Engine maintenance history and previous problem
– Other factors that contribute to the problem
recommended that fault finding procedures are carried out
until a fault can be identified with a good degree of
certainty.
There are many reasons why an engine may malfunction,
time and effort will be saved by following basic
troubleshooting steps:
– Do not make assumptions.
– If possible, talk to the operator for a description of the
fault. Also, check if any recent maintenance or repair
has been completed on the engine.
– Start simple - for instance many starting and running
faults can be attributed to low fuel level.
– Systematically work through each of the possible
causes.
– Confirm your diagnosis before dismantling and
assembling.
– Follow the recommended repair procedures in this
manual.
Some of the tasks listed in the fault finding must only be
completed by suitably qualified and competent personnel,
for example, fuel injection pump removal and replacement.
If you are unsure, DO NOT attempt the task.

The fault finding procedures are given in the form of flow

charts. There are a number of charts, each one dedicated
to a particular fault category.

The charts are designed to identify possible causes by

performing checks and where applicable, specific tests on
the engine. Having identified a cause the suggested
remedy is given. The charts are designed to identify
causes through a process of elimination, starting with the
simplest, most easily rectified faults.

70 9811/5050-4 70
 Routine Maintenance
Fault Finding

Fault Finding Charts

A Charts
K Engine - Will Not Start or Difficult to Start (No Exhaust Smoke) ( T 72)
K Engine - Will Not Start or Difficult to Start (Exhaust Smoke) ( T 72)
K Engine - Will Not Crank or Cranks Slowly ( T 72)
K Engine - Starts then Stops ( T 73)
K Engine - Poor Running ( T 73)
K Engine - Poor Running at Idle ( T 73)
K Engine - Noise Excessive ( T 74)
K Engine - Compression Knocks ( T 74)
K Engine - Reduced Power Output ( T 74)
K Engine - RPM Surges ( T 75)
K Engine - Vibration Excessive ( T 75)
K Engine - Exhaust Smoke Excessive (Black Smoke) ( T 75)
K Engine - Exhaust Smoke Excessive (White/Blue Smoke) ( T 75)

B Charts
K Fuel - Consumption Excessive ( T 76)
K Fuel/Oil - Leaking from Exhaust Manifold ( T 76)

C Charts
K Lubricating Oil - Consumption Excessive ( T 77)
K Lubricating Oil - Contaminated ( T 77)
K Lubricating Oil - Pressure Low ( T 77)
K Lubricating Oil - Pressure High ( T 78)

D Charts
K Coolant - Loss ( T 78)
K Coolant - Over Temperature ( T 78)
K Coolant - Under Temperature ( T 79)
K Coolant - Contaminated ( T 79)

71 9811/5050-4 71
 Routine Maintenance
Fault Finding

A Charts - Engine
Table 4. Engine - Will Not Start or Difficult to Start (No Exhaust Smoke)
Cause Remedy
No fuel in supply tank Check the level in the fuel tank, use sight gauge or dipstick.
Replenish as required.
Improper starting procedure. Verify proper starting procedure.
Fuel Filter blocked with water or other contamination. Drain fuel/water separator or replace fuel filter.
Fuel is aerated. Check the fuel system for loose connections and possible
air ingress points. Rectify and bleed the fuel system.
Air intake or exhaust system blocked. Visually check the air intake and exhaust system for
blockage or obstruction - remove as required. Check the air
filter elements for signs of blocking - replace as required.

Table 5. Engine - Will Not Start or Difficult to Start (Exhaust Smoke)

Cause Remedy
Starting procedure incorrect. Verify proper starting procedure.
Air intake system blocked or restricted. Visually check the air intake for blockage or obstruction -
remove as required. Check the air filter elements for signs
of blocking - replace as required.
Fuel is aerated. Check the fuel system for loose connections and possible
air ingress points.
Fuel is contaminated or incorrect grade diesel fuel used. If the fuel is suspect, verify by operating the engine with
recommended clean fuel from a temporary tank.
Fuel filter(s) blocked, fuel supply restricted. Check/replace the fuel filter(s). K Fuel System ( T 55).
Check fuel lines for restriction.
Cranking speed too slow. Refer to K Table 6. Engine - Will Not Crank or Cranks
Slowly ( T 72) for possible low cranking speed faults.

Table 6. Engine - Will Not Crank or Cranks Slowly

Cause
Starting electrical circuit connections loose or corroded.
Battery charge low.
No electrical connection to starter solenoid.
Remedy
Clean and tighten connections.
Check battery voltage, charge the battery or replace as
required. Make sure that the alternator is functioning
correctly and charging the battery.
Check voltage to solenoid.

72 9811/5050-4 72

Table 7. Engine - Starts then Stops
Cause
No fuel in supply tank.
Engine starting under load.
Air intake or exhaust system blocked.
Fuel is aerated.
Fuel is waxing due to extremely cold weather.
Fuel is contaminated or incorrect grade diesel fuel used.
Fuel filter(s) blocked, fuel supply restricted.
Table 8. Engine - Poor Running
Cause
Condition only occurs at idle.
Fuel is aerated.
Fuel filter(s) blocked, fuel supply restricted.
Fuel is contaminated or incorrect grade diesel fuel used.
Table 9. Engine - Poor Running at Idle
Cause
Engine mounts over-tightened, damaged or loose.
Fuel is aerated.
Fuel filter(s) blocked, fuel supply restricted.
Fuel is contaminated or incorrect grade diesel fuel used.
73
Routine Maintenance
Fault Finding
Remedy
Check the level in the fuel tank, use sight gauge or dipstick.
Replenish as required.
Check generator breaker is not closed.
Visually check the air intake and exhaust system for
blockage or obstruction - remove as required. Check the air
filter elements for signs of blocking - replace as required.
Check the fuel system for loose connections and possible
air ingress points. Rectify and bleed the fuel system. K Fuel
System ( T 55).
Verify by inspecting the fuel filter. Clean the system and use
climatised fuel. K Fuel System ( T 55).
If the fuel is suspect, verify by operating the engine with
recommended clean fuel from a temporary tank. K Fuel
System ( T 55).
Check/replace the fuel filter(s). K Fuel System ( T 55).
Check fuel lines for restriction.
Remedy
Refer to K Table 9. Engine - Poor Running at Idle ( T 73)
for possible poor running at idle faults.
Check the fuel system for loose connections and possible
air ingress points. Rectify and bleed the fuel system. K Fuel
System ( T 55).
Check/replace the fuel filter(s). K Fuel System ( T 55).
Check fuel lines for restriction.
If the fuel is suspect, verify by operating the engine with
recommended clean fuel from a temporary tank. K Fuel
System ( T 55).
Remedy
Verify condition of mounts. Refer to the machine's service
manual for correct adjustment procedure.
Check the fuel system for loose connections and possible
air ingress points. Rectify and bleed the fuel system. K Fuel
System ( T 55).
Check/replace the fuel filter(s). K Fuel System ( T 55).
Check fuel lines for restriction.
If the fuel is suspect, verify by operating the engine with
recommended clean fuel from a temporary tank. K Fuel
System ( T 55).
9811/5050-4 73
 Routine Maintenance
Fault Finding
Table 10. Engine - Noise Excessive
Cause Remedy
Drive belt squeal, insufficient tension or abnormally high Check the tensioner and inspect the drive belt for loading.
loading. deterioration, Make sure water pump, tensioner pulley, fan
alternator turn freely.
Check for paint/oil or other material on pulleys.
Check the tension of accessory drive belts.
Intake air or exhaust leaks. K Table 15. Engine - Exhaust Smoke Excessive (Black
Smoke) ( T 75) and K Table 16. Engine - Exhaust Smoke
Excessive (White/Blue Smoke) ( T 75).
Fuel is contaminated or incorrect grade diesel fuel used. If the fuel is suspect, verify by operating the engine with
recommended clean fuel from a temporary tank. K Fuel
System ( T 55).

Table 11. Engine - Compression Knocks

Cause Remedy
Fuel is aerated. Check the fuel system for loose connections and possible
air ingress points. Rectify and bleed the fuel system. K Fuel
System ( T 55).
Fuel is contaminated or incorrect grade diesel fuel used. If the fuel is suspect, verify by operating the engine with
recommended clean fuel from a temporary tank. K Fuel
System ( T 55).
Coolant operating temperature incorrect. K Table 24. Coolant - Over Temperature ( T 78) and
K Table 25. Coolant - Under Temperature ( T 79).

Table 12. Engine - Reduced Power Output

Cause Remedy
No fuel in supply tank. Check the level in the fuel tank, use sight gauge or dipstick.
Replenish as required.
Oil level incorrect. Check oil level. K Checking the Oil Level ( T 51).
Engine overload. Check load on engine, disconnect electrical load from
generator.
Fuel is contaminated or incorrect grade diesel fuel used. If the fuel is suspect, verify by operating the engine with
recommended clean fuel from a temporary tank. K Fuel
System ( T 55).
Fuel filter(s) blocked, fuel supply restricted. Check/replace the fuel filter(s). K Fuel System ( T 55).
Check fuel lines for restriction.
Fuel is aerated. Check the fuel system for loose connections and possible
air ingress points. Rectify and bleed the fuel system. K Fuel
System ( T 55).
Air intake or exhaust system blocked. Visually check the air intake and exhaust system for
blockage or obstruction - remove as required. Check the air
filter elements for signs of blocking - replace as required.
Exhaust leak at the manifold or turbocharger (if applicable). Check/correct leaks in the manifold or turbocharger
gaskets. Look for a cracked manifold.

74 9811/5050-4 74
 Routine Maintenance
Fault Finding
Table 13. Engine - RPM Surges
Cause Remedy
Fuel level low. Check/fill fuel tank.
Throttle adjustment incorrectly set or binding. Check the engine maximum rpm setting is as specified in
the machine's service manual. Check the throttle linkage
and cable for binding etc.
Fuel tank cap vent/breather blocked. Inspect and rectify as required - replace cap if necessary.
Fuel is aerated. Check the fuel system for loose connections and possible
air ingress points. Rectify and bleed the fuel system. K Fuel
System ( T 55).

Table 14. Engine - Vibration Excessive

Cause Remedy
Engine not running smoothly/misfiring. K Table 9. Engine - Poor Running at Idle ( T 73).
Oil level over-full. Check oil level. K Checking the Oil Level ( T 51).
Fan damaged or accessories faulty. Check/replace the vibrating component. Refer to the
machine's service manual for correct installation and torque
figures.
Engine mounts loose or broken. Check/replace engine mounts. Refer to the machine's
service manual for correct installation and torque figures.

Table 15. Engine - Exhaust Smoke Excessive (Black Smoke)

Cause Remedy
Engine being lugged down. Check load on generator.
Air intake or exhaust system blocked. Visually check the air intake and exhaust system for
blockage or obstruction - remove as required. Check the air
filter elements for signs of blocking - replace as required.
Air leak between the turbocharger and the intake manifold Check/correct leaks in the air crossover tube, hoses, or
(Turbocharged machines only). manifold cover.
Intercooler faulty. Check for blocked cooler matrix.
Exhaust leak at the Manifold or Turbocharger Check/correct leaks in the manifold or turbocharger
(Turbocharged machines only). gaskets. Look for a cracked manifold.

Table 16. Engine - Exhaust Smoke Excessive (White/Blue Smoke)

Cause Remedy
Improper starting procedure. Verify proper starting procedure.
Fuel is contaminated or incorrect grade diesel fuel used. If the fuel is suspect, verify by operating the engine with
recommended clean fuel from a temporary tank. K Fuel
System ( T 55).
Oil level incorrect. Check oil level. K Checking the Oil Level ( T 51).
Diesel or hydraulic oil in sump. Check oil consistency. Drain, flush and fill with clean oil.
Coolant temperature too low (over-cooling) - light blue or K Table 25. Coolant - Under Temperature ( T 79).
white high speed/light load.

75 9811/5050-4 75
 Routine Maintenance
Fault Finding

B Charts - Fuel
Table 17. Fuel - Consumption Excessive
Cause Remedy
Additional load on engine. Check load on generator.
Fuel leaks. Check for external leaks and engine lubricating oil dilution.
For fuel dilution, check for internal leaks at the fuel transfer
pump and injection pump.
Inspect and correct as required leaks in the high pressure
lines, fittings injector sealing washers, or delivery valves.
WARNING: Fine jets of fluid at high pressure can penetrate
the skin. Keep face and hands well clear of pressurised fluid
and wear protective glasses. If fluid penetrates your skin,
get medical help immediately.
Fuel is contaminated or incorrect grade diesel fuel used. If the fuel is suspect, verify by operating the engine with
recommended clean fuel from a temporary tank. K Fuel
System ( T 55).
Intake air or exhaust leaks. K Table 15. Engine - Exhaust Smoke Excessive (Black
Smoke) ( T 75) and K Table 16. Engine - Exhaust Smoke
Excessive (White/Blue Smoke) ( T 75).

Table 18. Fuel/Oil - Leaking from Exhaust Manifold

Cause Remedy
Operating for extended periods under light or no load Increase load on generator.
conditions.
Intake air or exhaust leaks. K Table 15. Engine - Exhaust Smoke Excessive (Black
Smoke) ( T 75) and K Table 16. Engine - Exhaust Smoke
Excessive (White/Blue Smoke) ( T 75).
Exhaust leak at the Manifold or Turbocharger (turbocharged Check/correct leaks in the manifold or turbocharger
machines only). gaskets. Look for a cracked manifold.

76 9811/5050-4 76
 Routine Maintenance
Fault Finding

C Charts - Lubricating Oil

Table 19. Lubricating Oil - Consumption Excessive
Cause Remedy
Oil leaks. Inspect the engine for visible signs of leaks. Pay particular
attentions to seals, gaskets oil cooler and external
connections.
Oil level over-full. Check oil level. K Checking the Oil Level ( T 51).
Incorrect lubricating oil (specification of viscosity). Make sure the correct lubricating oil is being used.
K Recommended Oils ( T 50).
Look for reduced viscosity from dilution with fuel. Fuel
dilution in lubricating oil can originate from fuel injection
pump driveshaft seal or fuel transfer pump.
Review/reduce the lubricating oil change intervals.

Table 20. Lubricating Oil - Contaminated

Cause
Coolant in the lubricating oil, internal engine component
leaks.
Lubricating oil sludge excessive.
Fuel in the lubricating oil, engine operating too cold.
Remedy
K Table 23. Coolant - Loss ( T 78).
Change oil and filter. K Changing the Oil and
Filter ( T 52).
Review oil and filter change period. If operating in arduous
applications, change more frequently.
Make sure the correct lubricating oil is being used.
K Recommended Oils ( T 50).
Check load on generator and increase if necessary.
Review the operation for low load resulting in the engine
running below normal temperature.

Table 21. Lubricating Oil - Pressure Low

Cause Remedy
Oil level incorrect. Check oil level. K Checking the Oil Level ( T 51).
Incorrect lubricating oil (specification of viscosity). Make sure the correct lubricating oil is being used.
K Recommended Oils ( T 50)
Look for reduced viscosity from dilution with fuel. Fuel
dilution in lubricating oil can originate from fuel injection
pump driveshaft seal or fuel transfer pump.
Review oil and filter change period. If operating in arduous
applications, change more frequently.
Lubricating oil filter blocked. Change lubricating oil filter. K Changing the Oil and
Filter ( T 52).
Review oil and filter change period. If operating in arduous
applications, change more frequently.

77 9811/5050-4 77

Table 22. Lubricating Oil - Pressure High
Cause
Incorrect lubricating oil (specification of viscosity).
Lubricating oil sludge excessive.
Engine running too cold.
D Charts - Coolant
Table 23. Coolant - Loss
Cause
Incorrect coolant level.
Coolant leaking from engine radiator.
External engine coolant leak.
Overheating or compression gases leaking, resulting in loss K Table 24. Coolant - Over Temperature ( T 78).
through the radiator overflow.
Table 24. Coolant - Over Temperature
Cause
Incorrect coolant level (low).
External radiator matrix blocked with dirt or chaff.
Air flow to the radiator inadequate or restricted.
Coolant pump or fan drive belts loose.
Radiator hose collapsed, restricted or leaking.
Oil level over-full.
Cooling system pressure cap incorrect or faulty.
Over concentration of anti-freeze.
78
Routine Maintenance
Fault Finding
Remedy
Make sure the correct lubricating oil is being used.
K Recommended Oils ( T 50).
Review oil and filter change period. If operating in arduous
applications, change more frequently.
Change oil and filter. K Changing the Oil and
Filter ( T 52).
Review oil and filter change period. If operating in arduous
applications, change more frequently.
Make sure the correct lubricating oil is being used.
K Recommended Oils ( T 50).
Check load on generator and increase if necessary.
K Table 25. Coolant - Under Temperature ( T 79).
Remedy
Check the level. K Checking the Oil Level ( T 51).
Visually inspect the radiator heater, hoses and connection
to locate the leak.
Visually inspect the engine and components for seal, gasket
hose connection leaks. Make sure all hose clips are in good
condition and torqued to the recommended figure.
Remedy
Check the level. K Checking and Adding Coolant ( T 24).
Ensure low level is not as a result of a coolant leak,
K Table 23. Coolant - Loss ( T 78).
Clean exterior or radiator matrix.
Check/repair fan shroud, anti-recirculation sealing, shutters,
fan sensors, fan speeds as required. Refer to the machine
manufacturer's documentation for detailed information.
Check/correct belt tension.
Check/replace hose.
Check oil level. K Checking the Oil Level ( T 51).
Replace cap with the correct rating for the system.
Remove part of the coolant from cooling system and replace
with water. K Drain and Refill the Coolant ( T 54).
9811/5050-4 78
 Routine Maintenance
Fault Finding

Cause Remedy
Cooling passages in radiator, cylinder head, head gasket or Flush the system and fill with clean coolant.
block blocked.

Table 25. Coolant - Under Temperature

Cause Remedy
Air flow across the radiator excessive. Check/repair fan shroud, anti-recirculation sealing, shutters,
fan sensors, fan speeds as required. Refer to the machine
manufacturer's documentation for detailed information.

Table 26. Coolant - Contaminated

Cause Remedy
Coolant rusty, operation without correct mixture of antifreeze Drain and flush the cooling system. Fill with correct mixture
and water. of antifreeze and water.
Review the coolant change interval. Refer to the Operation
and Maintenance Manual.

79 9811/5050-4 79
 Routine Maintenance
Fault Finding

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80 9811/5050-4 80
 Connection and Wiring Diagrams
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81 9811/5050-4 81
 Connection and Wiring Diagrams
Control Panel - LT9 to 1650482 - Linz Alternator

T042310
Control Panel - LT9 to 1650482 - Linz Alternator

Fig 1. Control Panel Diagram 1

82 9811/5050-4 82
 Table 1. Key

83
Item Description
F1 Global Positive Power Fuse - 20A
F2 Chase U Fuse- 2A
1 Push Button
2 Fuel Gauge
3 Frequency Meter
4 Volt Meter
5 Hours Counter - 230V
6 Key Start Control Panel KS1
8 Horn
9 Two Position Switch, switches between
generator power and mains input power
10 Circuit Breaker B10A for Socket
11 Circuit Breaker B10A for Lamps
12 RCD 25A, 2 Pole, 30MA
13 Male Connector, 6 Pole
14 Male Connector, 16 Pole

9811/5050-4
15 Female Connector, 16 Pole
16 Female Connector, 4 Pole

83
Control Panel - LT9 to 1650482 - Linz Alternator
Connection and Wiring Diagrams
 Connection and Wiring Diagrams
Control Panel - LT9 to 1650482 - Linz Alternator

T042320
X
V
T
S
O
R
P

Fig 2. Control Panel Diagram 2

N
M
L
K
J

Y
G H
F
XT
E
D
C
B
A

84 9811/5050-4 84
 Table 2. Key

85
Item Description
A Battery Charger
B Low Oil Pressure
C High Water Temperature
D Overspeed
E Fuel Reserve
F External Start
G Emergency Stop
H Contactor Activation
J Generator Input
K Generator Input
L Battery Negative
M Battery Positive
N Stop Control
P Start Control
R Pre-heating
S Acoustic alarm

9811/5050-4
T Up Control
V Down Control
W J1 Connector
X J3 Connector
Y Fuel Gauge

85
Control Panel - LT9 to 1650482 - Linz Alternator
Connection and Wiring Diagrams
 Connection and Wiring Diagrams
Control Panel - LT9 to 1650482 - Linz Alternator

T042330
M
F
E

Fig 3. Power Circuit Diagram 1

L
G
D

K
B

J
A

86 9811/5050-4 86
 Table 3. Key

87
Item Description
A Diagram for the following voltages:
220-230-240V Single Phase
B Section of Power (External)
C Lamps
D Sockets
E Differential Protection
F Control Instruments:
Voltmeter, Frequency Meter and Hours
Counter
G External Generator Set
H J2 Connector
J Output to Ballasts
K Output to Sockets
L External Power Input
M J4 Connector

9811/5050-4
87
Control Panel - LT9 to 1650482 - Linz Alternator
Connection and Wiring Diagrams
 Connection and Wiring Diagrams
Control Panel - LT9 to 1650482 - Linz Alternator

T042340
D

Fig 4. Power Circuit Diagram 2

C
V
B
A

88 9811/5050-4 88
 Table 4. Key

89
Item Description
A Contactor Control
B Time Relay
C Relay Voltage Control
D Power Supply
K1 Contactor 20 Amp, 4 Circuits
T1 Time Delay Position Switch
V1 Relay Voltage Control

9811/5050-4
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Control Panel - LT9 to 1650482 - Linz Alternator
Connection and Wiring Diagrams
 Connection and Wiring Diagrams
Control Panel - LT9 to 1650482 - Linz Alternator

T042350
G

G
B

Fig 5. Power Circuit Diagram 3

E
C
A

Connector
E

F
D

90 9811/5050-4 90
 Table 5. Key

91
Item Description
A SI 51 Plus Igniter
B Lamp
C Output from Control Panel
D J3 Connector
E Connector X1
F Philips SI 51 Plus
G Lamp
H Connector X2

9811/5050-4
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Connection and Wiring Diagrams
 Connection and Wiring Diagrams
Control Panel - LT9 to 1650482 - Linz Alternator

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92 9811/5050-4 92
 Control Panel - LT9 (Mark 5) from 1650483 to 1696109 Sincro Alternator

93
9811/5050-4
T063460-1
Fig 6. Sheet 1

M6 control and thermal magnetic electrical protection

diagrams from 16A to 63A.

Make sure that all of the power units are off before
starting the generator set.
Control Panel - LT9 (Mark 5) from 1650483 to 1696109 Sincro Alternator

93
Connection and Wiring Diagrams
 Connection and Wiring Diagrams
Control Panel - LT9 (Mark 5) from 1650483 to 1696109 Sincro Alternator

T063460-2
Fig 7. Sheet 2

94 9811/5050-4 94
 F1 Main panel fuse - 20A 8 Alarm HO1

95
F2 U phase fuse - 2A 9 Two position switch, switches between generator power and mains input power
1a Push button - mast up 10 Circuit breaker B10A for the base
1b Push button - mast down 11 Circuit breaker B10A for the lamps
2 Fuel level gauge 12 Earth leakage relay - 25A 2P 25mA
3 Frequency meter 13 J4 male connector, 6 pole
4 Voltmeter 14 J1 male connector, 10 pole
5 Hour counter - 230V 15 J2 female connector, 16 pole
6 Key start control panel governor w/overspeed M6 16 J3 female connector, 4 pole
7 Circuit breaker B10A for base (Option) 17 J5 female connector, 4 pole

9811/5050-4
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95
Connection and Wiring Diagrams
96
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

RC G
MA AE RC SVE ATA BPA
D+
START A B
M6
12ED+ 5BPA 4ATA 2
PICK-UP
6 RC 8 LT 9PEM 11
CONT
3 GP 1GEN 14
- BAT
15
+ BAT
18PD 16
ARR
10PR 13
AL

5 6 7 8 09 19 18 46 033 1 4 3 17

033
20 20 20 20 20

(4.13)÷
46 017

20
P1
19 K3
K3 P2
NO NC 017 017

(4.2) + 31 32
1 K1 K2
- H01

1 1 1 1 1 1

01

01 01
4
K1 K2
1
F1
F 20A 001 002
16 RNC

1 20 09 E

9811/5050-4
C 01 001 002 D 1 2 3
1 2 3 J3
5 6 7 8 9 1 2 4 3 10 CONNECTOR J5 CONNECTOR
M
J1 CONNECTOR G H
SQ
+ BATTERY

T063460-3
Fig 8. Sheet 3
Control Panel - LT9 (Mark 5) from 1650483 to 1696109 Sincro Alternator

96
Connection and Wiring Diagrams
 1 Generator input 14 Battery negative

97
2 Pickup 15 Battery positive
3 GP input 16 Start control
4 High water temperature 18 Stop control
5 Low oil pressure A Mast up control
6 Fuel reserve B Mast down control
8 External start C J1, see sheet 6 K Fig 11. ( T 102)
9 Emergency stop D J3, see sheet 8 K Fig 13. ( T 106)
10 Pre-heating E J5, see sheet 5 K Fig 10. ( T 100)
11 Contactor activation F Fuel level gauge
12 Battery charger G Mast hydraulic pump
13 Acoustic alarm H Solenoid operated check valve

9811/5050-4
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97
Connection and Wiring Diagrams
 Connection and Wiring Diagrams
Control Panel - LT9 (Mark 5) from 1650483 to 1696109 Sincro Alternator

T063460-4
Fig 9. Sheet 4

98 9811/5050-4 98
99
A Parts of power (External) E Output to ballasts
A1-A4 Lamps F Output to sockets
D1-D2 Sockets G External power input
B Differential protection H External generator set
C Control instruments: J J2, see sheet 8 K Fig 13. ( T 106)
C1 Voltmeter K J4
C2 Frequency meter L AVR 6 bornes
C3 Hour counter

9811/5050-4
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99
Connection and Wiring Diagrams
 Connection and Wiring Diagrams
Control Panel - LT9 (Mark 5) from 1650483 to 1696109 Sincro Alternator

T063460-5
Fig 10. Sheet 5

100 9811/5050-4 100

 Connection and Wiring Diagrams
Control Panel - LT9 (Mark 5) from 1650483 to 1696109 Sincro Alternator
J5, see sheet 3 K Fig 9. ( T 98)
3-position switch
C
D
Program timer
Light sensor
A
B

101 9811/5050-4 101

 Connection and Wiring Diagrams
Control Panel - LT9 (Mark 5) from 1650483 to 1696109 Sincro Alternator

T063460-6
Fig 11. Sheet 6

102 9811/5050-4 102

 A J1, (Output from the control panel) see sheet 3 K Fig 8. ( T 96) H Oil pressure measure sensor

103
B Relay board J Water temperature measure sensor
C Pre-heating K Fuel level sensor
D Electrical feed pump L Alternator (Engine)
E Fuel solenoid M Battery
F Oil pressure alarm sensor N Starter motor
G Water temperature alarm sensor

9811/5050-4
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103
Connection and Wiring Diagrams
 Connection and Wiring Diagrams
Control Panel - LT9 (Mark 5) from 1650483 to 1696109 Sincro Alternator

T063460-7
Fig 12. Sheet 7

104 9811/5050-4 104

 L1, L8 Fog light L4, L5 Stop light

105
L2 Left hand indicator L6 Right hand side tail light
L3 Left hand side tail light L7 Right hand indicator

9811/5050-4
Control Panel - LT9 (Mark 5) from 1650483 to 1696109 Sincro Alternator

105
Connection and Wiring Diagrams
 Connection and Wiring Diagrams
Control Panel - LT9 (Mark 5) from 1650483 to 1696109 Sincro Alternator

T063460-8
Fig 13. Sheet 8

106 9811/5050-4 106

 A Output from the control panel D Ballast

107
B J2, see sheet 4 K Fig 9. ( T 98) E Ignitor
C J3, see sheet 3 K Fig 8. ( T 96) F Lamp

9811/5050-4
Control Panel - LT9 (Mark 5) from 1650483 to 1696109 Sincro Alternator

107
Connection and Wiring Diagrams
 Connection and Wiring Diagrams
Control Panel - LT9 (Mark 5) from 1650483 to 1696109 Sincro Alternator

T063460-9
Fig 14. Sheet 9

108 9811/5050-4 108

 A Lamp junction box E Rectifier junction box

109
B Lamp F Rectifiers
C Oil pump for mast down G Sensor and timer
D Control panel (J2 connector)

1 Red 1 Red
2 Blue 2 Red
3 Red 3 Red
4 Blue 4 Red
5 Red 5 Black
6 Blue 6 Black
7 Red 7 Black
8 Blue 8 Black
PE Black Y/G Yellow-Green
Blue

9811/5050-4
Control Panel - LT9 (Mark 5) from 1650483 to 1696109 Sincro Alternator

109
Connection and Wiring Diagrams
 Control Panel - LT9 with KS2 from 1696110

110
A B C D E L M

9811/5050-4
J H G F
P033460-89
Fig 15. Control Panel Diagram 1
Control Panel - LT9 with KS2 from 1696110

110
Connection and Wiring Diagrams
 Table 6. Key

111
Item Description
A Push button
B Horn 12/24
C Selector 2 position thumbed switch
D Selector 3 position thumbed switch
E Key start control panel governor (KS2)
F Earth leakage relay id 25A 2p 3MA
G Circuit breaker OSMC32N1P B10A for
lamps
H Circuit breaker OSMC32N1P B10A for
base
J 2 Position switch
K Connector male 6 ports - 6 poles male
connector J4
L Connector male 10 ports - 10 poles male
connector J1
M Connector male 16 ports - 16 poles male
connector J2

9811/5050-4
N Connector female 4 poles - 4 poles
female connector J3
P Connector female 4 poles - 4 poles
female connector J5
Control Panel - LT9 with KS2 from 1696110

111
Connection and Wiring Diagrams
 10 11 12 13 14 15 16

112
A B C D E F G H J K L M N P Q R S T W
HIGH INJECTION POSITIVE INJECTION
BATTERY LOW OIL TEMPERATURE FUEL LEVEL START EMERGEN CONTACTOR GENERATOR BATTERY BATTERY BATTERY PUMP STOP PRE ACUSTIC
PUMP UP CONTROL DOWN CONTROL SALOR SWTICH
CHARGER PRESSURE WATER GAUGE EXTERNAL STOP ACTIVATION INPUT INPUT NEGATIVE POSITIVE PULL CONTROL HEATING ALARM
HOLD

1 2 3
J5 CONNECTOR
RC 1 2 N1 L
D+ G MA AE RC SVE ATA BPA
M7 START
X
8 - 36 vdc
D+ BPA ATA NC PD AE PEM CON VGN VG1 + BAT - + PC ARR PR ENT1 MC MNA

5 6 7 16 4 09 19 18 46 033 2 1 20 00 3 11 12 12 002

033
20 20 (4.10)
20
46

(4.14)
(5.2)
2 2 2 2 2
1.0 mm 19 K3 4.0 mm 4.0 mm 2.5 mm 4.0 mm
K3
1 20 20
NO NC * S1
(5.2) +
(4.2)
1 H01
- 020
017

1 1 1 1

09

01 01 01

01 01 01 01
20 1 020 09

9811/5050-4
F1 P1 P2
4A 017 001 017 002 (5.12)
017
2 2

J1 CONNECTOR
01 001 002
1 2 3
5 6 7 8 4 1 2 9 3 10 J3 CONNECTOR

+B +B
D+ M M
G RT
Y
W P T
AA NC SQ
D+ BPA ATA BT M ARR

J2 CONNECTOR
230 11
SINGLE PHASE *S1 ----OPTIONAL UNDER REQUEST

Z
T068990-2
Fig 16. Control Panel Diagram 2
Control Panel - LT9 with KS2 from 1696110

112
Connection and Wiring Diagrams
 Table 7. Key

113
Item Description
A Battery Charger
B Low Oil Pressure
C High Water Temperature
D Fuel Level Gauge
E Injection Pump Hold
F Start External
G Emergency Stop
H Contactor Activation
J Generator Input
K Positive Battery Input
L Battery Negative
M Battery Positive
N Injection Pump Pull
P Stop Control
Q Pre-heating
R Acoustic alarm

9811/5050-4
S Up Control
T Down Control
W Solar switch
X J5 Connector
Y J3 Connector
Z J2 Connector
AA J1 Connector
Control Panel - LT9 with KS2 from 1696110

113
Connection and Wiring Diagrams
 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

114
A B
DIAGRAM FOR THE FOLLOWING PART OF POWER (EXTERNAL) CONTROL INSTRUMENTS:
VOLTAGES: DIFFERENTIAL PROTECTION
LAMPS SOCKETS VOLTMETER-FRENQUENCY METER & HOUR COUNTER
C D E F
220-230-240V
SINGLE PHASE

N1 N1 N1 N1

L L L L L L L L L

K4 K3
(4.11) (3.6)
(3.16) ID 2P 30mA ( 3.1)
622

Q1 Q2 Q3 Q4 Q5 Q6 033 46

F2
2A
133 033

46 46
A1 A2 A3 A4 D1 D2
G
EXTERNALRGENSET
6 8 2 4
A1 A2 A3 A4 (5.9) AVR DSR

9811/5050-4
KM A2
5 7
1 3
K4 8 7 2 1
A1 S1 P 230V K4
33 46
N1 B1 B2 B3 B4 NO NC
(4.2)
Blue

Black
Green
Yellow

(3.12) (5.4) N2
H M
C1 C2 C3 C4
J2 CONNECTOR J4 CONNECTOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6
PE
1 4

J K L
OUTPUT TO BALLASTS 3
G
OUTPUT TO SOCKETS EXTERNAL POWER INPUT
2

T689000-1
Fig 17. Power Circuit Diagram 1
Control Panel - LT9 with KS2 from 1696110

114
Connection and Wiring Diagrams
 Table 8. Key

115
Item Description
A Diagram for the following voltages:
220-230-240V Single Phase
B Section of Power (External)
C Lamps
D Sockets
E Differential Protection
F Control Instruments:
Voltmeter, Frequency Meter and Hours Counter
G External Generator Set
H J2 Connector
J Output to Ballasts
K Output to Sockets
L External Power Input
M J4 Connector

9811/5050-4
Control Panel - LT9 with KS2 from 1696110

115
Connection and Wiring Diagrams
 10 11 12 13 14 15 16

116
A B
MOTOR SALOR SENSOR

D 020

J2 CONNECTOR
12 13

13 14

020

IN
10
13 14 13 14 11 SENSOR

* S2 09
099

20 20

9811/5050-4
20 20 20
(3.9)
C
09 020
J2 CONNECTOR 10 11
(3.8) 10

(3.15)
OPTION UNDER REQUEST

T0689010-1
Fig 18. Power Circuit Diagram 2
Control Panel - LT9 with KS2 from 1696110

116
Connection and Wiring Diagrams
 Connection and Wiring Diagrams
Control Panel - LT9 with KS2 from 1696110
Table 9. Key

J2 Connector
J2 Connector
Solar sensor
Description
Motor
Item
A
B
C
D

117 9811/5050-4 117

 10 11 12 13 14 15 16

118
RED
ELECTRICAL FEED PUMP B
BLACK

00 PULL
WHITE
A J1 HOLD
RED INJECTION PUMP C
NEGATIVE BLACK
F0
40A

POWER SUPPLY 02 +B
D+ +C
680ohm
ACTUATOR
D+ +C

02 02 POSITIVE
OIL PRESSURE
ALARM SENSOR F RT
WATER TEMPERATURE NEGATIVE
G BLACK
ALARM SENSOR
16 FUEL LEVEL
FUEL LEVEL
RED SENSOR
MEASURE SENSOR H
GREEN D

CONTROL PANEL
00 4mm

9811/5050-4
PREHEATING
10 11 4mm 11 I

STARTER SIGNAL
E
02 POSITIVET 02
START MOTOR
OPTION UNDER REQUEST

T0689020-2
Fig 19. Power Circuit Diagram 3
Control Panel - LT9 with KS2 from 1696110

118
Connection and Wiring Diagrams
 Table 10. Key

119
Item Description
A J1 Control panel
B Electrical feed pump
C Injection pump
D Fuel level sensor
E Starter motor
F Oil pressure alarm sensor
G Water temperature alarm sensor
H Fuel level measure sensor
I Pre Heating

9811/5050-4
Control Panel - LT9 with KS2 from 1696110

119
Connection and Wiring Diagrams
 10 11 12 13 14 15 16

120
13 PIN
4 4
13

11
12
13
5 3

11

4
6
1 earth

5
*OPTION UNDER REQUEST

9811/5050-4
1 4
7
2 5 8

L2 L3 L6 L7
L1 L4 L5 L8

T0689030-1
Fig 20.
Control Panel - LT9 with KS2 from 1696110

120
Connection and Wiring Diagrams
 Table 11. Key
L1 Fog light

121
L2 Left-hand indicator
L3 Left-hand side and tail light
L4, L5 Stop light
L6 Right-hand side and tail light
L7 Right-hand indicator
L8 Reversing light

9811/5050-4
Control Panel - LT9 with KS2 from 1696110

121
Connection and Wiring Diagrams
122
10 11 12 13 14 15 16

SYLVANIA RECTIFIER LAMP

SYLVANIA RECTIFIER LAMP

14
14
A OUTPUT FROM CONTROL PANEL
B 13
13
J2 CONNECTOR
10 11 12 13 11 YELLOW-GREEN
12
11 YELLOW
11
10
11
B1 B2 B3 B4 10 GREEN
10
BORNES X1S 01 01
10
LS1 YELLOW-GREEN BLACK
12
001
15
BLACK

C YELLOW-GREEN
SYLVANIA PE PE
IN
GREEN
D BLUE
YELLOW YELLOW-GREEN

9811/5050-4
OUT LAMP F
RED BROW
SYLVANIA
IN LP
GREEN E
D IGNITOR
BLUE
YELLOW YELLOW-GREEN
OUT LAMP F
RED BROW

SYLVANIA LP
IN IGNITOR E
D GREEN
BLUE
YELLOW YELLOW-GREEN
OUT LAMP F
RED BROW
SYLVANIA
IN LP
GREEN E
D BLUE IGNITOR

YELLOW YELLOW-GREEN
OUT
RED
LAMP F
BROW

LP
IGNITOR E
T689040-2
Fig 21. LT9 Metal Halide Lamps With KS2 From 1696110

For LED Lamps (With KS2 from 16501695) See

K Fig 23. ( T 126)
Control Panel - LT9 with KS2 from 1696110

122
Connection and Wiring Diagrams
 Table 12. Key
A Output from the Control panel

123
B J2 Connector
C To the Hydraulic pump
D Ballast
E Ignitor
F Lamp

9811/5050-4
Control Panel - LT9 with KS2 from 1696110

123
Connection and Wiring Diagrams
 10 11 12 13 14 15 16

124
H G
DC MOTOR Sensor C
OIL PUMP FOR
MAST DOWN

A
B
B PE 101112131415

LAMP LAMP blue blue

y/g
y/g y/g y/g

PE 10 11 12 blue blue
y/g y/g

10 11
LAMP LAMP

9811/5050-4
B B LS1

J2 CONNECTOR
10 11 12 13

CONTROL PANEL

D
SYLVANIA SYLVANIA SYLVANIA SYLVANIA
RECTIFIER RECTIFIER RECTIFIER RECTIFIER

F
T689050-1
Fig 22. LT9 Metal Halide Lamps With KS2 From 1696110

For LED Lamps (With KS2 from 16501695) See

K Fig 24. ( T 128)
Control Panel - LT9 with KS2 from 1696110

124
Connection and Wiring Diagrams
 Connection and Wiring Diagrams
Control Panel - LT9 with KS2 from 1696110
Table 13. Key
A Lamp junction box E Rectifier junction box
B Lamp F Rectifiers
C Oil pump for mast down G Sensor
D Control panel (J2 connector) H DC Motor

1 Red 1 Red
2 Blue 2 Red
3 Red 3 Red
4 Blue 4 Red
5 Red 5 Black
6 Blue 6 Black
7 Red 7 Black
8 Blue 8 Black
PE Black Y/G Yellow-Green
Blue

125 9811/5050-4 125

 LT9 LED With KS2 From 16501695

126
A B

C F

9811/5050-4
F

T689040-3
Fig 23. LT9 LED Lamps With KS2 From 16501695

For Metal Halide Lamps (With KS2 From 1696110)

See K Fig 21. ( T 122)
LT9 LED With KS2 From 16501695

126
Connection and Wiring Diagrams
 Table 14. Key
A J2 Connector

127
B Output from the Control panel
C To the Hydraulic pump
D DC Motor
E Sensor
F Lamp

9811/5050-4
LT9 LED With KS2 From 16501695

127
Connection and Wiring Diagrams
128
A A B C

H
G G

9811/5050-4
G
G

F
T689060-1
Fig 24. LT9 LED Lamps With KS2 From 16501695

For Metal Halide Lamps (With KS2 From 1696110)

See K Fig 22. ( T 124)
LT9 LED With KS2 From 16501695

128
Connection and Wiring Diagrams
 Connection and Wiring Diagrams
LT9 LED With KS2 From 16501695
Table 15.
A Lamp E Rectifier junction box
B DC Motor F Control Panel
C Sensor G Lamp
D Oil Pump For Mast Down H Lamp Junction Box

1 Red 1 Red
2 Blue 2 Red
3 Red 3 Red
4 Blue 4 Red
5 Red 5 Black
6 Blue 6 Black
7 Red 7 Black
8 Blue 8 Black
PE Black Y/G Yellow-Green
Blue

129 9811/5050-4 129

 Connection and Wiring Diagrams
LT9 LED With KS2 From 16501695

Page left intentionally blank

130 9811/5050-4 130

 Warranty
Warranty Information

Introduction – 18 months from date of despatch from JCB or 12

months from first date in service (whichever is
The machine must be maintained in accordance with the earlier).
regular maintenance requirements detailed in this – Cross-hire, consequential damage and third party
handbook. Only suitable trained personal should carry out losses are not warrantable.
the regular servicing. – Extended warranty is available for up to 2 years from
first date in service, contracts and conditions
Only Genuine JCB parts, or parts of equivalent quality applicable and administered by JCB Service.
should be used. – The engine has a limited running hours warranty of
2000 hours
Installation Access
Your JCB Generator will need to be made available for
scheduled and unscheduled maintenance work. Units
should always be sited to enable reasonable unrestricted
access for regular maintenance and repair work.
Significant extra costs incurred for gaining access to a
generator due to the installation are the responsibility of
the customer and will not be covered by warranty.

Downtime Support
If you require a substitute power source during
maintenance or repair then alternative power generation
must be arranged. JCB do not provide replacement units
under warranty, however your JCB dealer may be able to
assist in finding a substitute generator during any periods
of work.

Terms and Conditions

The following warranty terms and conditions are
applicable, for further details please contact your JCB
dealer:

131 9811/5050-4 131

 Warranty
JCB Technical Service

JCB Technical Service

JCB Service means world class support. In addition to our
JCB Engine Dealers, our worldwide Dealer network of over
930 depots ensures expert help and extensive know-how
is always close at hand. JCB Dealers can be located on the
JCB website at www.jcb.com.
It is important to note that the JCB Engine Dealer must be
the first contact in the unlikely event of a problem
developing.

132 9811/5050-4 132