Doosan LIGHTSOURCE V9 Operation And Maintenance Manual Download Page 14

SAFETY

10

LIGHTSOURCE V9

Materials

The following substances 

may

 be produced during the operation of

this machine:

. brake lining dust

. engine exhaust fumes

AVOID INHALATION

Ensure that adequate ventilation of the cooling system and exhaust

gases is maintained at all times.

The following substances are used in the manufacture of this

machine and 

may

 be hazardous to health if used incorrectly:

. engine lubricant

. preservative grease

. rust preventative

. diesel fuel

. battery electrolyte

AVOID INGESTION, SKIN CONTACT AND INHALATION OF

FUMES

Safety data sheets for engine lubricants should be obtained from the

lubricant supplier.

Never operate the engine of this machine inside a building without

adequate ventilation. Avoid breathing exhaust fumes when working on

or near the machine.

This machine may include such materials as oil, diesel fuel,

antifreeze, brake fluid, oil/air filters and batteries which may require

proper disposal when performing maintenance and service tasks.

Contact local authorities for proper disposal of these materials.

When recycling or disposing of any electrical components, light

bulbs etc., do not mix with general waste.

There is a separate collection system for used electronic products

in accordance with legislation that requires proper treatment, recovery

and recycling.

Please contact your local authorities for the correct method of

disposal or recycling.

Battery

A battery contains sulphuric acid and can give off gases which are

corrosive and potentially explosive. Avoid contact with skin, eyes and

clothing. In case of contact, flush area immediately with water.

DO NOT ATTEMPT TO SLAVE START A FROZEN BATTERY

SINCE THIS MAY CAUSE IT TO EXPLODE.

Exercise extreme caution when using booster battery. To jump

battery, connect ends of one booster cable to the positive (+) terminal

of each battery. Connect one end of other cable to the negative (

)

terminal of the booster battery and other end to a ground connection

away from dead battery (to avoid a spark occurring near any explosive

gases that may be present). After starting unit, always disconnect

cables in reverse order.

Radiator

Hot engine coolant and steam can cause injury. Ensure that the

radiator filler cap is removed with due care and attention.

Do not remove the pressure cap from a HOT radiator. Allow radiator

to cool down before removing pressure cap.

Generator sets

The generator set is designed for safety in use. However, the

responsibility for safe operation rests with those who install, use and

maintain it. The following safety precautions are offered as a guide,

which, if conscientiously followed, will minimise the possibility of

accidents throughout the useful life of this equipment.

Emergency Stop Controls

Important Note:

 In addition to the key operated emergency stop

control on the main control panel, a second control is provided at the

socket control panel in the event of electrical hazards associated with

generator operation. Use this second control to immediately isolate all

electrical power to all sockets, then use the key control to stop the

engine.

Operation of the generator must be in accordance with recognised

electrical codes and local health and safety codes.

The generator set should be operated by those who have been

trained in its use and delegated to do so, and who have read and

understand the operator’s manual. 

Failure to follow the instructions,

procedures and safety precautions in the manual may increase the

possibility of accidents and injuries.

Do not start the generator set unless it is safe to do so. Do not

attempt to operate the generator set with a known unsafe condition. Fit

a danger notice to the generator set and render it inoperative by

disconnecting the battery and disconnecting all ungrounded

conductors so others who may not know of the unsafe condition will not

attempt to operate it until the condition is corrected.

An earth point is provided beneath the socket outlets.

The generator set should only be used with the earth point

connected directly to the general earth/ground mass. An earth spike kit

is available as an optional extra for this purpose (refer to the 

parts

catalogue

).

WARNING: DO NOT OPERATE THE MACHINE UNLESS IT HAS

BEEN SUITABLY EARTHED.

Generator sets must be connected to the load only by trained and

qualified electricians who have been delegated to do so, and when

required by applicable regulations, their work should be inspected, and

accepted by the inspection agency having authority, prior to attempting

to operate the generator set.

Do not make contact with electrically energised parts of the

generator set and/or interconnecting cables or conductors with any

part of the body or with any non

insulated conductive object.

Make sure the generator set is effectively grounded in accordance

with all applicable Regulations prior to attempting to make or break load

connections and prior to attempting operation.

 Prior to attempting to make or break electrical connections at the

generator set, stop the engine, disconnect the battery and disconnect

and lock out the ungrounded conductors at the load end.

Keep all parts of the body and any hand

held tools or other

conductive objects, away from exposed live parts of the generator set

engine electrical system. Maintain dry footing, stand on insulating

surfaces and do not contact any other portion of the generator set when

making adjustments or repairs to exposed live parts of the generator

set engine electrical system.

Replace the generator set terminal compartment cover as soon as

connections have been made or broken. Do not operate the generator

set without the terminal cover secured firmly in place.

Summary of Contents for LIGHTSOURCE V9

Page 1: ...11 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...

Page 2: ...hat 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...

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Page 5: ...serial number Up to Serial No From Serial No Not illustrated Option AR As required HA High ambient machine F H R G Fixed height running gear V H R G Variable height running gear bg Bulgarian cs Czech...

Page 6: ...conditions over which the company has no control Therefore the company cannot be held responsible for equipment in which non approved repair parts are installed The company reserves the right to make...

Page 7: ...4 000 hours of operation by the initial user D Spare Parts Six 6 months from date of shipment to the initial user The company will provide a new part or repaired part at its sole discretion in place...

Page 8: ...NTHS 4 000 HRS FOR LIGHTSOURCE INTRODUCED 8 16 99 ENGINE SEE BELOW ENGINES MONTHS HOURS COMMENTS KUBOTA 7 20 24 4 000 EXTENDED WARRANTY OF 60 MONTHS 10 000 HRS WHEN USING GENUINE DOOSAN FLUIDS AND PAR...

Page 9: ...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 Dr ve Richelle 167 1410 Waterloo Belgium Fax 32 2 371 69...

Page 10: ...Corrosion risk WARNING Air gas flow or Air discharge WARNING Pressurised vessel WARNING Hot and harmful exhaust gas WARNING Flammable liquid X XBAR 0 C WARNING Maintain correct tyre pressure Refer to...

Page 11: ...ING Corrosion risk Do not remove the Operating and Maintenance manual and manual holder from this machine Do not stack Do not operate the machine without the guard being fitted XX km h Do not exceed t...

Page 12: ...us skin burn and eye inflammation Do not operate lights with missing or broken lens Do not operate if glass bulb is broken or punctured Electrical ground earth FREE SAFETY DECALS Safety Decals are ava...

Page 13: ...sult local electrician Do not operate electrical equipment while standing in water on wet ground with wet hands or shoes Use extreme caution when working on electrical components Battery voltage 12V i...

Page 14: ...In addition to the key operated emergency stop control on the main control panel a second control is provided at the socket control panel in the event of electrical hazards associated with generator...

Page 15: ...t of the drawbar To ensure full braking efficiency the front towing eye section must always be set level When adjusting variable height running gear Ensure front towing eye section is set level When r...

Page 16: ...to the area being welded Mast Operation Before and during all mast operation ensure that the area is clear of persons and obstructions over a 2m radius When the mast has completedits normal travel or...

Page 17: ...ional 10 When fitted with bund the machine must only be operated when levelled Drains for engine water engine oil and fuel tank are located at the rear right corner of the machine Draining of contamin...

Page 18: ...GENERAL INFORMATION 14 LIGHTSOURCE V9 FIXED HEIGHT RUNNING GEAR VARIABLE HEIGHT RUNNING GEAR...

Page 19: ...r 30 amps 12 Volts GENERATOR Type Mecc Alte LT3 130 4 Voltage 230 V Frequency 50 Hz Power 6 kVA Voltage stability 6 Standard socket outlet 2 x 16 Amps Max total 26 Amps 230 Volts INFORMATION ON AIRBOR...

Page 20: ...y specified minimum dimensions to walls floors etc Adequate clearance needs to be allowed around and above the machine to permit safe access for specified maintenance tasks Ensure that the machine is...

Page 21: ...ast control unit Operates the mast to raise and lower the lamps 5 Main circuit breaker Protects all lamp circuits 6 Socket circuit breaker 7 Lamp switch Controls individual lamps Reference Description...

Page 22: ...y now be used WARNING Keep side doors closed for optimum cooling and safety of unit while running NOTE The engine in this unit is protected with sensors for high coolant temperature and low oil pressu...

Page 23: ...to rotate tower Release the pin after rotating the tower to the desired position Lowering the tower 1 Start the engine 2 Switch the lamps off 3 Lift the pin 2 to rotate tower Release the pin after ro...

Page 24: ...out the following checks 1 No loose objects are stored inside or on top of the machine 2 No additional equipment is hung onto or under the machine 3 Any device used for lifting is rated at a minimum...

Page 25: ...g Nuts C Hoses Oil Air Intake etc C Automatic Shutdown System C Air Cleaner System C Engine Rad Oil Cooler Exterior C Fasteners Guards C Air Cleaner Elements R WI Fuel Water Separator Element R Engine...

Page 26: ...oper Grounding Circuit C Wiring Insulation C Obstructions in Air Vents C Control Compartment Interior C Engine Shutdown System Switches setting C Exterior Finish As needed Engine Refer to Engine Opera...

Page 27: ...seen Upon completion of maintenance tasks and prior to returning the machine into service ensure that the machine is suitably tested all guards and safety protection devices are refitted all panels a...

Page 28: ...rminals As pressure is applied slowly from the controlled source the switch should close at 12 psi 84 kPa and show continuity through the contacts As the pressure is slowly decreased to 10 psi 70 kPa...

Page 29: ...s manual ENGINE OIL FILTER ELEMENT The engine oil filter element should be changed at the engine manufacturer s recommended intervals Refer to the Engine section of this manual TYRES TYRE PRESSURE See...

Page 30: ...axle tube 4 Brake linkage adjustment Adjust the brake linkage 7 lengthways without pre tension Readjustment Engage the handbrake lever 1 forcefully a number of times to set the brake Check the alignme...

Page 31: ...ings on the transmission system cables brake equalisationsystem and linkage Apply the handbrake while rolling the machine forward travel of the handbrake lever up to 2 3 of maximum is allowed Check th...

Page 32: ...d clamp on hose 106 133 143 180 Wheel nuts 50 80 67 109 USE VALUES FROM TABLE 2 IF NOT SPECIFIED IN TABLE 1 TABLE 2 METRIC FASTENERS NOMINAL DESIGN TORQUE PROPERTY GRADE 8 8 HEAD MARKING PROPERTY GRAD...

Page 33: ...MAINTENANCE 29 LIGHTSOURCE V9...

Page 34: ...ELECTRICAL SYSTEM 30 LIGHTSOURCE V9 SCHEMATIC DIAGRAM FOR AC ELECTRICAL HARNESS...

Page 35: ...ELECTRICAL SYSTEM 31 LIGHTSOURCE V9 SCHEMATIC DIAGRAM FOR AC ELECTRICAL HARNESS...

Page 36: ...ELECTRICAL SYSTEM 32 LIGHTSOURCE V9 SCHEMATIC DIAGRAM FOR AC ELECTRICAL HARNESS...

Page 37: ...B9 Breaker RCD option DS1 4 Lamp G1 Generator IG1 4 Ignitor light KM1 Contactors KM2 Contactors option KM3 Overcurrent monitoring relay option R1 Resistor R2 Resistor option R3 Resistor option S3 Swit...

Page 38: ...ELECTRICAL SYSTEM 34 LIGHTSOURCE V9 SCHEMATIC DIAGRAM FOR DC ELECTRICAL HARNESS...

Page 39: ...M2 Contactors Mains AC option M1 Starter motor M2 Hourmeter M3 Tilting actuator option M4 Motor hydraulic pump PS1 Engine oil pressure switch S1 Key switch S3 Switch emergency stop S4 Switch Mains Gen...

Page 40: ...ht left hand IL RH Indicator light right hand FL Fog light RL Reverse light SL LH Stop light left hand SL RH Stop light right hand TL LH Tail light left hand TL RH Tail light right hand E Earth RPL Re...

Page 41: ...run or engine shuts down prematurely Low engine oil pressure Check the oil level and oil filter s prematurely Safety shut down system in operation Check the safety shut down switches Fuel starvation...

Page 42: ...ctive or missing Cable assembly is damaged Hydraulic oil level is too low The mast lowers on its own The mast has lowered when the operator returns to the machine The hydraulic hose is defective or le...

Page 43: ...identification After sales support 43 FUEL LUBRICANT AND COOLANT Fuel Lubricant Coolant 45 OPERATION Check before operation Check and operation after start up Operation and care of a new engine 50 MAI...

Page 44: ...ng and maintenance recommendations This will ensure many years of trouble free and economical engine operation Should your engine require servicing please contact your nearest branch or distributor Al...

Page 45: ...r 14 Oil level gauge 15 Oil pressure switch 16 Flywheel 17 Oil drain plug 18 Oil pan 19 Engine hook 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 Intake manifold 2 Speed control lever 3 Engine sto...

Page 46: ...rall height mm 608 7 Valve clearance cold mm 0 145 0 185 Nozzle injection pressure MPa 13 73 Injection timing B T D C at 2 5mm cam lift 16 5 ENGINE IDENTIFICATION Serial No Location A Label location B...

Page 47: ...er may cause engine damage Handling of the Fuel Any fuel containing dust particles or water might cause engine failure Therefore the following must be observed Take care to protect the fuel from ingre...

Page 48: ...uted engine oil Engine damage due to improper maintenance or using oil of the improper quality and or viscosity is not covered by the warranty Fig 12 A Single grade B Ambient Temperature C Multi grade...

Page 49: ...e oil filler to the crankcase Wait at least ten minutes before checking the oil level NOTE Take care to avoid engine oil being splashed on the fan drive belt because it causes belt slippage or slackne...

Page 50: ...used as electrolyte be careful not to contaminateyour eyes hands clothes and metals with the electrolyte If it gets in your eye wash with a large amount of water at once then seek medical advice As hi...

Page 51: ...heating take the following step Close the service valve to reduce the load Let the engine run at normal idle speed for two or three minutes If the engine coolant temperature does not start to drop tur...

Page 52: ...AGE If the equipment is to be out of operation for an extended period it should be started at least once per week and run on load for about 15 minutes after it has reached normal operating temperature...

Page 53: ...Check addition cooling Radiator fin checking cleaning Cooling water Cooling fan V belt checking adjusting replacement 1st time 2nd after Cooling water Cooling water replacement or every 1 yr Cooling w...

Page 54: ...8 Coolant level Check coolant level and add coolant if necessary 9 Coolant leakage check Replace any damaged or malfunctioning parts which could cause leakage 10 Radiator filler cap fitting condition...

Page 55: ...the drain plug after draining the engine oil 4 Turn the engine oil filter counter clockwise using a filter wrench customer procured to remove It 5 Clean the engine oil filter mounting face 6 Moisten...

Page 56: ...rnator G Deflection H Press with thumb I Crankshaft V pulley J V belt 2 If necessary adjust the V belt tension deflection To adjust the V belttension loosen the set bolt and move the alternator to tig...

Page 57: ...it If operation continues with insufficient battery fluid the battery life is shortened and the battery may overheat and explode Battery fluid tends to evaporate more quickly in the summer and the flu...

Page 58: ...fuel system for leaks 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 Replace the engine oil filter at the sam...

Page 59: ...put the drain plug back 4 Fill radiator and engine with cooling water via the header tank Beware of scalding by hot water Wait until the temperature goes down before draining the Cooling water Otherw...

Page 60: ...does not turn Bad cable connections Starter or starter switch failure Safety relay failure Engine stop solenoid malfunction No fuel in the fuel tank No fuel injection Clogged fuel filter element Air i...

Page 61: ...injection amount between cylinders Deteriorated governor spring Incorrect valve clearance adjustment Deteriorated valve spring Engine speed stuck at high idle Engine control restriction or seizure Eng...

Page 62: ...earance adjustment Cylinder compression leakage Injector nozzle misalignment Low cylinder compression pressure Cylinder bore wear Insufficient air intake volume Air cleaner clogged Restricted air flow...

Page 63: ...rrect fuel Water mixing in fuel Excessive white smoke Low compression pressure Injection timing incorrect Low coolant temperature Faulty turbocharger Battery over discharge Low electrolyte level Crack...

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