Doosan LIGHTSOURCE V9 Operation And Maintenance Manual
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Doosan LIGHTSOURCE V9 Operation And Maintenance Manual

Doosan LIGHTSOURCE V9 Operation And Maintenance Manual

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LIGHTSOURCE V9
OPERATION AND MAINTENANCE MANUAL
Original Instruction
This manual contains
important safety information
and must be made available to
personnel who operate and
maintain this machine.
46500039_en_C_11/11
SERIAL No : 368000 −>

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  • Page 1 LIGHTSOURCE V9 OPERATION AND MAINTENANCE MANUAL Original Instruction This manual contains important safety information and must be made available to personnel who operate and maintain this machine. SERIAL No : 368000 −> 46500039_en_C_11/11...
  • Page 2 Machine models represented in this manual may be used in various locations world−wide. Machines sold and shipped into European Union Territories require that the machine display the CE Mark and conform to various directives. In such cases, the design specification of this machine has been certified as complying with EC directives. Any modification to any part is absolutely prohibited and would result in the CE Certification and marking being rendered invalid.

  • Page 5: Table Of Contents

    V.H.R.G. Variable height running gear Bulgarian MAINTENANCE Czech Danish MACHINE SYSTEMS German Greek English FAULT FINDING Spanish Estonian ENGINE INSTRUCTION MANUAL Finnish French Hungarian Italian Lithuanian Latvian, Lettish Maltese Dutch Norwegian Polish Portuguese Romanian Russian Slovak Slovenian Swedish Chinese LIGHTSOURCE V9...

  • Page 6: Foreword

    The intended uses of this machine are outlined below and examples of unapproved usage are also given, however the company cannot anticipate every application or work situation that may arise. IF IN DOUBT CONSULT SUPERVISION LIGHTSOURCE V9...

  • Page 7: Warranty

    Light Source model only, the earlier PURPOSE. of twenty−four (24) months from shipment to or the accumulation of 4,000 hours of operation by the initial user. Spare Parts − Six (6) months from date of shipment to the initial user. LIGHTSOURCE V9...
  • Page 8 SEE BELOW ENGINES MONTHS HOURS COMMENTS KUBOTA 4,000 EXTENDED WARRANTY OF 60 MONTHS / 10,000 HRS. (7/20) WHEN USING GENUINE DOOSAN FLUIDS AND PARTS ON MAJOR COMPONENTS. PARTS MONTHS HOURS COMMENTS DOOSAN UNLIMITED PARTS ONLY AVAILABLE FROM THE COMPANY NETWORK.
  • Page 9 To initiate the machine warranty, fill out the ”Warranty Registration” form 83242 11/99 supplied as part of the machine documentation, keep a copy for your records and mail the original to: Doosan Warranty Team Doosan BENELUX S.A. Drève Richelle 167 1410 Waterloo −...
  • Page 10 WARNING − Before connecting the tow bar WARNING − For operating temperature (Refer to the GENERAL INFORMATION or commencing to tow consult the below 0_C, consult the operation and section of this manual). operation and maintenance manual. maintenance manual. LIGHTSOURCE V9...

  • Page 11: Decals

    Do not operate with the doors or enclosure Do not exceed the trailer speed limit. Do not use fork lift truck from this side. open. Use fork lift truck from this side only. Emergency stop. Tie down point Lifting point. On (power). Off (power). LIGHTSOURCE V9...
  • Page 12 Decal part numbers are on the bottom of each decal and are also listed in the parts manual of the machine. Submit orders for Safety Decals to the Doosan Portable Power EMEA Aftermarket Department. The no charge order should contain only Safety Decals.

  • Page 13: Safety

    Do not place hand in tower recess while tower is being lowered or raised. Pinch point can cause severe injury. Do not alter or modify this machine. LIGHTSOURCE V9...
  • Page 14 Do not remove the pressure cap from a HOT radiator. Allow radiator connections have been made or broken. Do not operate the generator to cool down before removing pressure cap. set without the terminal cover secured firmly in place. LIGHTSOURCE V9...
  • Page 15 When raising towing eye, set rear joint first, then front joint. When lowering towing eye, set front joint first, then rear joint. After setting, fully tighten each joint by hand and then tighten further to the next pin. Refit the pin. LIGHTSOURCE V9...
  • Page 16 Do not operate tower with damaged cables. Replace damaged cables. Lamps Inspect lamps and replace broken or missing lamp lens or punctured glass bulbs. Do NOT operate lights with broken or missing lens or broken glass bulb. LIGHTSOURCE V9...
  • Page 17 During maintenance operations, drain machine fluids using the drain ports indicated. WARNING: Major leakages or spillages must be drained before the machine is towed. Disposal of contaminated fluids from bund Contaminated fluids removed from bund, must be disposed of to designated containers only. LIGHTSOURCE V9...
  • Page 18 GENERAL INFORMATION FIXED HEIGHT RUNNING GEAR VARIABLE HEIGHT RUNNING GEAR LIGHTSOURCE V9...

  • Page 19: General Information

    − The A−weighted emission sound pressure level 70 dB(A), uncertainty 1 dB(A) − The A−weighted emission sound power level 86 dB(A), uncertainty 1 dB(A) The operating conditions of the machinery are in compliance with ISO 3744:1995 and EN ISO 2151:2004 LIGHTSOURCE V9...
  • Page 20 Attach the battery cables to the battery(s) ensuring that they are CAUTION: Call a qualified person to make electrical repairs. tightened securely Attach the negative cable before attaching the positive cable. LIGHTSOURCE V9...

  • Page 21: Operating Instructions

    Records engine operating Hour meter hours for maintenance purposes. Low fuel lamp Operates the mast to raise Mast control unit and lower the lamps. Main circuit breaker Protects all lamp circuits. Socket circuit breaker. Lamp switch Controls individual lamps. LIGHTSOURCE V9...
  • Page 22 Turn the Ignition Switch “OFF”. The Lamp Switches may now be used. NOTE: If the lights are turned off, they should not be restarted for 15 minutes. WARNING: Keep side doors closed for optimum cooling and safety of unit while running. LIGHTSOURCE V9...
  • Page 23 [1] around the lamp bodies. Lowering the tower WARNING: The lamp bodies may be HOT. Start the engine. Switch the lamps off. Lift the pin [2] to rotate tower. Release the pin after rotating the tower to the desired position. LIGHTSOURCE V9...
  • Page 24 No loose objects are stored inside or on top of the machine. No additional equipment is hung onto or under the machine. Any device used for lifting is rated at a minimum of 2000kg. No personnel should be on or under the machine at any time during lifting. LIGHTSOURCE V9...

  • Page 25: Maintenance

    (2) or as defined by local or national legislation =Replace = Check (adjust, clean or replace as necessary) = Test =check before towing. =or when indicated if earlier. = Check and report Refer to specific sections of the operator’s manual for more information. LIGHTSOURCE V9...
  • Page 26 = Check before towing. information. = Check and report Do not tow this unit with a vehicle that has a towing capacity that is = Drain less than the unit gross weight shown in General Data. = Grease LIGHTSOURCE V9...
  • Page 27 Daily check for loose wire routing clamps. Clamps must be secure and properly mounted. Also check wiring for wear, deterioration and all panels are replaced, canopy and doors closed. vibration abrasion. hazardous materials are effectively contained and disposed of. LIGHTSOURCE V9...
  • Page 28 The engine coolant high temperature switch will require a temperature of The fan belt(s) should be checked regularly for wear and correct approximately 220_F (104_C) to actuate. tensioning. LIGHTSOURCE V9...
  • Page 29 The brake actuators must not be pre−tensioned − if necessary loosen the wheels. Refer to the TORQUE SETTING TABLE later in this the brake linkage [7] on the brake equalisation assembly [8]. section. Check that brake actuators and cables [11] operate smoothly. LIGHTSOURCE V9...
  • Page 30 Excessive operation of the handbrake lever, which may have been When the brake has been adjusted accurately the actuating distance caused by worn brake linings, must not be corrected by re−adjusting is approximately 5−8mm on the cable [11] (shortening) the brake linkage [7] LIGHTSOURCE V9...
  • Page 31 NOTE: Do not use high pressure water, steam or solvent on the exterior Apply the handbrake while rolling the machine forward, travel of the finish of the unit housing. handbrake lever up to 2/3 of maximum is allowed. LIGHTSOURCE V9...
  • Page 32 THREAD SIZE AND PITCH TYPICAL SQUARE TORQUE PATTERN (Nm.) (FT−LBF) (Nm.) (FT−LBF) (Nm.) (FT−LBF) M6 X 1.0 M8 X 1.25 M10 X 1.5 M12 X 1.75 M14 X 2 TYPICAL CIRCULAR TORQUE M16 X 2 PATTERN M20 X 2.5 LIGHTSOURCE V9...
  • Page 33 MAINTENANCE LIGHTSOURCE V9...
  • Page 34 ELECTRICAL SYSTEM SCHEMATIC DIAGRAM FOR AC ELECTRICAL HARNESS LIGHTSOURCE V9...
  • Page 35 ELECTRICAL SYSTEM SCHEMATIC DIAGRAM FOR AC ELECTRICAL HARNESS LIGHTSOURCE V9...
  • Page 36 ELECTRICAL SYSTEM SCHEMATIC DIAGRAM FOR AC ELECTRICAL HARNESS LIGHTSOURCE V9...
  • Page 37 Contactors (option) Overcurrent monitoring relay (option) Resistor Resistor (option) Resistor (option) Switch, emergency stop SK1−4 Connector, light Socket 16A/230V (option) Socket 16A/230V (option) Inlet socket (option) Socket 16/110V (option) Socket 16/110V (option) T1−4 Ballast, light Current transformer 110V (option) LIGHTSOURCE V9...
  • Page 38 ELECTRICAL SYSTEM SCHEMATIC DIAGRAM FOR DC ELECTRICAL HARNESS LIGHTSOURCE V9...
  • Page 39 Motor, hydraulic pump Engine oil pressure switch Key−switch Switch, emergency stop Switch, Mains/Gen switch (option) Inductive sensor −mast position down Switch, tilting (option) Switch, low fuel level Solenoid, fuel Solenoid, mast lowering Solenoid, hydraulic pump High water temperature switch (engine) LIGHTSOURCE V9...
  • Page 40 SL LH Stop light − left hand Orange SL RH Stop light − right hand Purple TL LH Tail light − left hand TL RH Tail light − right hand Grey Earth Blue Registration plate lights White Yellow LIGHTSOURCE V9...

  • Page 41: Fault Finding

    Blocked fuel filter. Check and replace if necessary. Blocked air filter. Check and replace the element if necessary. Excessive vibration. Engine speed too low. See ”Engine speed too low” Refer also to the engine section of this manual. LIGHTSOURCE V9...
  • Page 42 The mast is raised while machine not levelled properly. The hose burst valve in cylinder is damaged or blocked. Damaged sliding pads stop the mast from coming down. Mast falls down. Mast falls down suddenly and very Cable failed. fast fast. Pulley failed. LIGHTSOURCE V9...
  • Page 43 Fuel Lubricant Coolant OPERATION Check before operation Check and operation after start− up Operation and care of a new engine MAINTENANCE SCHEDULE PERIODICAL INSPECTION AND MAINTENANCE Lubricating system Cooling system Fuel system Air intake system Routine maintenance TROUBLESHOOTING LIGHTSOURCE V9...

  • Page 44: Foreword

    All information, illustrations, and specifications contained in this Manual are based on the latest product information available at the time of publication. The company reserves the right to make changes in this Manual at any time without prior notice. LIGHTSOURCE V9...

  • Page 45: External View

    4. Fuel injection pump 15.Oil pressure switch 5. Fuel feed pump 16.Flywheel 6. Cooling fan 17.Drain plug (engine oil) 7. Fan drive pulley 18.Oil pan 8. Engine oil filter 19.Lifting eye 9. Water drain cock 10.Filler port (engine oil) LIGHTSOURCE V9...

  • Page 46: General Information

    Please feel free to contact your dealer for periodical inspection and maintenance. Doosan Genuine Parts Genuine Doosan parts are identical with those used in the engine production, and accordingly, they are warranted. Genuine Doosan parts are supplied by your branch or distributor.

  • Page 47: Fuel, Lubricant, And Coolant

    Engine failure or malfunction resulting from use of such authorized dealer for advice on using biocides in your area and for improper fuel will not be warranted by Doosan. recommendations on which biocides you should use. To help avoid fuel system or engine damage, please read the following: Smoke Suppressants Do not use diesel fuel which has been contaminated with engine oil.

  • Page 48: Lubricant

    • Replace the cooling water every once a year CAUTION: When handling Long Life Coolant Antifreeze, wear protective rubber gloves not to contact with it. If contact with the eyes or skin should occur, wash with clean water LIGHTSOURCE V9...

  • Page 49: Operation

    CAUTION: When adding oil, take care not to spill it. If you spill oil on the engine or equipment, wipe it properly, to prevent the risk of fire and personal injury and/or equipment damage. LIGHTSOURCE V9...
  • Page 50 When disconnecting the terminals, start with “−” terminal. When connecting them, connect the “−” terminal last. A. “IDLE” B. “OPERATION” C. “START” D. “STOP” E. Speed control lever F. Engine stop lever LIGHTSOURCE V9...

  • Page 51: Operation And Care Of A New Engine

    Doosan branch or dealer. remove the cap. Overcooling...
  • Page 52 S Do not drain the cooling water S Clean dust or oil from the engine extension S Either fill completely or drain the fuel tank S Grease accelerator joints and electrical connections S Disconnect the negative battery terminal LIGHTSOURCE V9...

  • Page 53: Maintenance Schedule

    Check Fuel Valve Nozzle and clean Adjust, cleaning and repair of fuel injection Pump and fuel valve nozzle kW x 130 1500 hours of use and at 1500−hour intervals 3000 hours of use and at 3000−hour intervals thereafter thereafter LIGHTSOURCE V9...
  • Page 54 Air filter element Change element at 400 hrs or sooner if the restriction indicator shows red. replacement Cylinder compression Consult your dealer or distributor pressure Valve clearance check Check and adjust every 1000 hours. Consult your dealer or distributor LIGHTSOURCE V9...
  • Page 55 9) Stop the engine after warming up and leave it stopping for about 10 B. Drain plug minute to recheck the engine oil level with dipstick and replenish the engine oil. If any oil is spilled, wipe it away with a clean cloth. C. Engine oil filter LIGHTSOURCE V9...
  • Page 56 C. Adjusting bracket Use of genuine Doosan fan belt Always use genuine Doosan fan belts as they provide high driving ability and long operating durability. Use of non−Doosan fan belts could result in premature belt wear or belt elongation leading to engine overheating or excessive belt noise.

  • Page 57: Periodical Inspection And Maintenance

    −15_C or less. And store the battery 4) After cleaning, reinstall the fuel filter, keeping out of dust and dirt. in a warm place until the next use the unit to start the engine easily at 5) Air−bleed the injection pump. low ambient temperature. LIGHTSOURCE V9...
  • Page 58 As the governor is precisely adjusted, most of the controls are sealed, please do not break them. Should any adjustment be necessary, contact your local Doosan branch or distributor. (3) Replacing the engine oil and engine oil filter (2nd time and after) Replace the engine oil every 200 hours operation from 2nd time and on.

  • Page 59: Cooling System

    1) Remove the header tank cap. (4) Checking and adjusting the fuel injection timing 2) Remove the radiator drain plug of the radiator and drain the cooling As this maintenance requires specialized knowledge and skill, consult water. your dealer. LIGHTSOURCE V9...
  • Page 60 Faulty air heater. Fuel is injected but engine does not Incorrect injection timing. fire. cylinder compression pressure. Engine stop solenoid not fully returned. Engine fires but stalls immediately. Air in the fuel system. Incorrect low idle speed adjustment. LIGHTSOURCE V9...

  • Page 61: Troubleshooting

    Restricted coolant flow (high concentration of antifreeze, etc.) Low oil pressure Lack of oil Oil leakage High oil consumption Wrong oil Wrong type and viscosity. High coolant temperature. Over heat. Clogged filter and strainer. Worn bearings and oil pump. Faulty relief valve. LIGHTSOURCE V9...
  • Page 62 Faulty valve stem seal. Damaged seal / Damaged turbocharger seal Oil leakage Loose joints/gaskets. Improper installation of filter and piping. Fuel leakage Damaged seals. Excessive fuel consumption Improper component installation or tightening. Excessive injection volume. Injection pump defective. Excessive mechanical loads LIGHTSOURCE V9...
  • Page 63 Low coolant temperature Faulty turbocharger Battery over discharge Low electrolyte level Crack in battery body. Natural consumption. Charging failure Loose or damaged belt. Faulty alternator. Damaged wiring or contact failure. Excessive electrical loads Insufficient battery capacity for the application. LIGHTSOURCE V9...

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