Doosan LIGHTSOURCE V9 Operation And Maintenance Manual Download Page 63

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ENGINE TROUBLESHOOTING

LIGHTSOURCE V9

Improper exhaust

Clogged air cleaner.

Damaged injector nozzle.

Excessive black smoke

Wrong injector nozzle.

Injection timing incorrect.

Excessive injection volume.

Incorrect 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 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.

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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