Manual de Operacion LEK 1.4 LED 46693831

OPERATION and MAINTENANCE
MANUAL
LIGHT TOWER MODEL
LSCK4, LSCK4 PLUS AND LEK1.4
Doosan Bobcat India Pvt Ltd

6th Floor, HTC Towers,
No. 41, Mount Road, Guindy,
Chennai - 600032, India.
Toll Free : 1 800 103 2869
www.doosanportablepower.com/in/en
P/N: 46693831 (MAY 2022) Rev J

TABLE OF CONTENTS
Operations & Maintenance Manual
TITLE PAGE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General Light Tower Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Electrical Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Before Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Winch Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Flammable Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GENERAL LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Operation Set-Up (Prior to Raising Tower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Raise Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Extending Tower In Upright Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Lowering Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Stand Aside While . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Stand Aside While . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Check the following . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Lifting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Owner’s Manual and Parts List for Winch Model KR15000301 . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1500lb. (680 kg) Maximum Rated Line Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Assembly Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Cable Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
357 3 5
Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3
TABLE OF CONTENTS
Operations, Maintenance and Parts Manual
TITLE PAGE
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Wire Routing Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Electrical Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Wiring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Fuel/Water Separator (If provided) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Air Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Air Filter Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Tower Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Tower Locking Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Tower Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Engine Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Engine Protection Shut Down System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Control Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Running Gear/Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cleaning Instructions (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Exterior Finish Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Light Tower Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Control Box Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
MATERIAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Material Safety Data Sheet for Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Lamp Material Information Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Material Safety Data Sheet (MSDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Information and Applicability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Lamp Materials and Hazardous Ingredients . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Phosphor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Arc Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Health Concerns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Mercury Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Ultraviolet (UV) Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Disposal Concerns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
TCLP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Material Safety Data Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Hazardous Ingredients . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Fire and Explosion Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Reactivity Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4
TABLE OF CONTENTS
TITLE PAGE
Health Hazard Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Precautions for Safe Handling and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Control Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Regulatory Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
GENERAL TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Action Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Trouble Shooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Short Air Cleaner Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Engine RPM Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Excessive Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Unit Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Unit Fails To Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Won’t Start/Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
No Generator Voltage Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
High/Low Generator Voltage Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
High/Low Generator Frequency Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
TROUBLE SHOOTING HIGH INTENSITY DISCHARGE LAMP BALLASTS . . . . . . . . 65
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Operating Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
HID Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Lamp Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Mercury and Metal Halide Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
High Pressure Sodium Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Low Pressure Sodium Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Lamp Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Ballasts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Ballast Design Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Core and Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Ballast Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Lamp Regulation Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Constant Wattage Autotransformer (CWA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Oil Filled Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Capacitor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Single Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Capacitor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Visual Inspection Check List Normal End of Lamp Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Quick Fix for Restoring Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Flow Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Open Circuit Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Open Circuit Voltage Test Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
When Circuit Voltage Tests Results Into Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Capacitor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5
TABLE OF CONTENTS
TITLE PAGE
Ballast Continuity Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Short Circuit Lamp Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Short Circuit Lamp Current Test Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
When Short Circuit Lamp Current Test Results in High, Low or No Reading . . . . . . . . . . . . . . 83
Further Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
PARTS ORDERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Markings and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
How to Use Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
How to Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6
Foreword
7
Light Source - LSCK4 / LSCK4 PLUS Foreword
Foreword
Nothing contained in this document is in Light Source - LSCK4 / LSCK4 PLUS to extend
any promise, warranty or representation, expressed or implied, regarding the Doosan
Bobcat products described here in. Any such warranties or other terms and conditions of
sale of products shall be inaccordance with the standard terms and conditions of sale for
such products, which are available upon request.
This manual contains instructions and technical data to cover all routine operation and
scheduled maintenance tasks by operation and maintenance staff. Major overhauls are
outside the scope of this manual and should be referred to an authorized Doosan Bobcat
service department. Details of approved equipment are available from Doosan Bobcat
Service departments.
The use of repair parts other than those included within the Doosan Bobcat approved parts
list may create hazardous conditions over which Doosan Bobcat has no control. Therefore,
Doosan Bobcat cannot be held responsible for equipment in which non-approved repair
parts are installed.
Doosan Bobcat reserves the right to make changes and improvements to products without
notice and without incurring any obligation to make such changes or add such improvements
to products sold previously.
This company accepts no responsibility for errors in translation of this manual from the original
English version.
6
8
Safety Precautions
9
Safety Precautions Light Source - LSCK4 / LSCK4 PLUS
Safety Precautions
General Light Tower Information

Ensure that the operator reads and understands the decals and consults the manuals before
maintenance or operation.
Ensure that the operation and Maintenance manual is available to the operator and
maintenance personnel.
Ensure that maintenance personnel are adequately trained are competent and have read the
manuals.
This machine is not designed for operating life sustaining equipment. It is equipped with a
safety shutdown system that will cause the machine to stop operating whenever a shutdown
condition is present.
Hot Pressurized Fluid - Remove cap slowly to relieve PRESSURE from HOT radiator. Protect
skin and eyes. HOT water or steam and chemical additives can cause serious personal injury.
Electrical shock hazard will cause severe injury or death. DO NOT position light tower under
electric power lines.
Improper operation of this machine can result in severe injury or death.
Hazardous Voltage can cause serious injury or death.
Never inspect or service unit without first disconnecting battery cable(s) to prevent accidental
starting.
Wear eye protection while cleaning unit with compressed air, to prevent debris from injuring
eyes.
Do not open and probe into the ballast box while engine is running. Do not steam clean ballast
box. Capacitor/Ballast can cause severe injury.
Do not operate lights with broken or missing lens or broken glass bulb. Ultra violet radiation
can cause serious skin burn and eye inflammation.
Do not extend, retract or use tower unless it is in a VERTICAL position with latch and lock pin
securely in place.
Do not place hand in tower recess while tower is being lowered or raised. Pinch point can
cause severe injury.
Ground equipment in accordance with applicable codes. (Consult local electrician)
10
Light Source - LSCK4 / LSCK4 PLUS Safety Precautions
Electrical Shock
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) is present
unless the battery cables have been disconnected. Higher voltage (potentially 500 volts) is
present at all times when the engine is running.
Always treat electrical circuits as if they are energized.
Before attempting any repair service, disconnect all leads to electrical power loads
DO NOT connect or disconnect lamps while engine is running.
DO NOT climb on tower. Perform repairs and adjustments with the tower in the down/
horizontal (transport) position.
Before using the Light Tower as a power unit, verify the electrical requirements of the power
tools, etc., and do not exceed the rated output shown in General Data Section.
General Information
Make sure that all protective covers are in place and that the canopy doors are closed during
operation.
Never operate the engine of this machine inside a building without adequate ventilation. Avoid
breathing exhaust fumes when working on or near the machine. Do not alter or modify this
machine.
The battery contains sulphuric acid and can give off gases which are corrosive and explosive.
Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with
water.
Exercise extreme caution when using booster battery. To jump battery connect ends of one
booster cable to the positive (+) terminal of each battery.
Never operate unit without first observing all safety warnings and carefully reading the
operation and maintenance manual shipped from the factory with this machine.
This machine may include such materials as oil, diesel fuel, antifreeze, 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.
Never inspect or service unit without first disconnecting battery cable(s) to prevent accidental
starting.
Make sure wheels, tires and tow bar connectors are in safe operating condition and tow bar is
properly connected before towing.
11
Before Towing
Store the rear jack and secure the handle by wrapping the jack positioning pin chain around
the handle to keep it from being damaged during towing.
Towing
Do not tow this unit with a vehicle whose towing capacity is less than shipping weight shown
in general data
Welding
Prior to any welding, disconnect alternator relays, voltage regulator, meters, circuit breakers
and battery cables. Open all circuit breakers, and remove any external connections. Connect
the welding ground as close as possible to the area being welded.
Winch Operation
Before and during all winch operation, ensure the area around each winch is clear of persons
and obstructions over a 2 meter radius.
Lamps
Inspect lamps and replace broken or missing lamp lens or punctured glass bulb. DO NOT
operate lights with broken or missing lens or broken glass bulb.
12
Light Source - LSCK4 / LSCK4 PLUS Safety Precautions
Flammable Fuels
Do not fill fuel tank when engine is running.
Do not smoke or use an open flame in the vicinity of the generator or fuel tank.
Do not permit smoking, or open flame, or sparks to occur near the battery, fuel, cleaning
solvents or other flammable substances and explosive gases.
Thoroughly clean up any fuel spills occurring inside this unit.
Safety Labels
Safety labels are used to warn or identify hazards, consequences of ignoring the warning and
explains how to avoid the hazard. The labels are located near where the hazard exists.
! DANGER
Indicates the presence of a hazard which WILL cause serious injury or
death if ignored.
! WARNING
Indicates the presence of a hazard which CAN cause serious injury or
death if ignored.
! CAUTION
Indicates the presence of a hazard which WILL or CAN cause injury or
property damage if ignored.
NOTICE
Indicates important set-up, operating or maintenance information.
Do not store or transport hazardous (combustible, etc.) material in or on

this unit.
Do not suspend this machine with other equipment hanging from the
running gear (undercarriage).
13
**Always use Doosan Replacement parts!**
14
General Data
15
General Data Light Source - LSCK4 / LSCK4 PLUS
General Data
LIGHT SOURCE DETAILS LSCK4 LSCK4 PLUS LEK1.4

Luminiries 4000 W 4000 W 1400 W
Number of bulbs 4 nos, 1000W each 4 nos, 1000W each 4 nos, 350 W each
Type of bulbs Metal Halide Metal Halide LED
Tower height 9 meter 9 meter 9 meter
Fuel tank capacity 102 Ltrs 102 Ltrs 105 Ltrs
Ambient Temp (Max) 52 deg C 52 deg C 52 deg C
Ambient Temp (Min) (-) 5 deg C (-) 5 deg C (-) 5 deg C
ENGINE DETAILS
Make Kubota Kubota Kubota
Model D1105-BG2-LTE-1 D1105-BG2-LTE-1 D1105-BG2-LTE-1
Engine Rating 11 HP @ 1500 RPM 11 HP @ 1500 RPM 11 HP @ 1500 RPM
Strokes/Number of cylinder 4 Stroke, 3 Cylinder 4 Stroke, 3 Cylinder 4 Stroke, 3 Cylinder
Rated speed 1500 RPM 1500 RPM 1500 RPM
System oil capacity 5.1 Ltrs 5.1 Ltrs 5.1 Ltrs
Electric system 12 V, -ve ground 12 V, -ve ground 12 V, -ve ground
Battery 700 CCA @ 85AH 700 CCA @ 85AH 700 CCA @ 85AH
GENERATOR DETAILS
Make MeccAlte MeccAlte MeccAlte
Model LT3-130/4 (4 pole, single phase) LT3-100/2 (4 pole, single phase) LT3-130/4 (4 pole, single phase)
Rating 6 kVA 7kVA 6 kVA
Frequency 50 Hz 50 Hz 50 Hz
OPTIONS
Power IN Not Applicable 230 V, 50 Hz Not Applicable
Power IN MCB rating Not Applicable 25A Not Applicable
Power OUT Not Applicable 4.5kVA Not Applicable
Power OUT MCB rating Not Applicable 20A Not Applicable
Socket power inlet/outlet Rating Not Applicable 3 pole, 32 A, 200-250 V Not Applicable
INSTRUMENTATION
Hour meter Yes Yes Yes
Main MCB 3 pole, 25 A, 250 V max. 3 pole, 25 A, 250 V max. 3 pole, 25 A, 250 V max.
Key switch ( with pre heat) Yes Yes Yes
SAFRETY
Low engine oil pressure shutdown 6.52 psig 6.52 psig 6.52 psig
High engine water temp shutdown 110 +/- 3 dec C 110 +/- 3 dec C 110 +/- 3 dec C
DIMENSIONS (mm)
Overall length (including drawbar) 4500 4500 4500
Overall width (fender to fender) 1430 1430 1430
Overall Height (Winch on tower) 1730 1730 1730
Net weight (less fuel) 700 Kgs 700 Kgs 700 Kgs
RUNNING GEAR
Tyre size and loading rating 185/70-R14 185/70-R14 185/70-R14
Tyre inﬂation pressure (cold) 35 psig 35 psig 35 psig
Track width 1100 mm 1100 mm 1100 mm
Max Hub/Axle rating 2400 kgs 2400 kgs 2400 kgs
Max tyre rating 560 kgs 560 kgs 560 kgs
Max towing speed 40 km/hr 40 km/hr 40 km/hr
Max spring rating 1626 kg 1626 kg 1626 kg
Towing brakes No No No
4
16
Light Source - LSCK4 / LSCK4 PLUS General Data
! WARNING
Modification or alteration of this machine can result in severe injury or
death. Do not modify or alter without the express written consent of
Doosan Bobcat Company.
17
18
General Layout
17
19
1717171
Light Source - LSCK4 / LSCK4 PLUS General Layout
GENERAL LAYOUT
GENERAL LAYOUT FOR LIGHT SOURCE LSCK4
1816.6
187.0
447.7
4500
95.0
1658.0
505.9
1729.5
1774.9
2202.4
20
General Layout Light Source - LSCK4 / LSCK4 PLUS
1430
656.8
1374.5
2X 669
2163.9
2X 721
21
Light Source - LSCK4 / LSCK4 PLUS General Layout
1337. 4
1730
76.9
454.6 103.6
911.1
22
General Layout Light Source - LSCK4 / LSCK4 PLUS
GENERAL LAYOUT
GENERAL LAYOUT FOR LIGHT SOURCE LSCK4 PLUS
1316
422
4500
1279
352
1729.5
1816.7
2200.4
23
General Data Light Source - LSCK4 & LSCK4 PLUS
1430
1332
526
414
747
1289
1442
24
836
1549 1727
748
911
1289
1 337
25
Light Source LSCM4 / LSCM1.6 GENERAL LAYOUT
GENERAL LAYOUT FOR LIGHT SOURCE LEM1.4 BEFORE CAISLEK060
889.00
1731.68
1583.53
428.40
1252.5
3895.11
4398.57
EXHAUST OUTLET
1235.15 1056.62
85.02
158.07
842.47 886.53
1291.33
562.87
20 26
GENERAL LAYOUT
GENERAL LAYOUT FOR LIGHT SOURCE LEK1.4

CAISLEK060 ONWARDS (CN108192)
1724.4
891.0
1579.5
421.3
1252.5
3895.2
4322.9
1236.4 905.1
85.3
EXHAUST OUTLET
842.2
1336.9 885.4
159.2
564.0
1187.1
20
Operating Instructions
27
Light Source - LSCK4 / LSCK4 PLUS Operating Instructions
Operating Instructions
Control Panel
1
28
Operating Instruction Light Source - LSCK4 / LSCK4 PLUS
Operation Set-Up (Prior to Raising Tower)

1. Inspect cables.
2. Ensure no obstruction is overhead within 40 feet.
3. Mount lamps on cross bar and aim as desired.
4. Extend all outriggers fully and insert locking pins fully. Ensure drawbar jack and
all outrigger and jacks are firmly in contact with ground.
5. Level unit using jacks and bubble level indicator on drawbar.
6. Jacks must support entire unit weight (tires off the ground).
7. Remove pin “D”.
8. Remove pin “C”.
Raise Tower
1. Operate winch “A”, to raise tower to vertical, upright position.
2. Insert and lock pin “C” to secure tower in upright position.
Extending Tower In Upright Condition

1. With tower in upright position, operate winch “B” to extend tower to desired
height. DO NOT extend mast unless vertical and lock pin is secure. DO NOT
extend past upright mark on tower (T).
2. Loosen screw “E” to rotate tower. Tighten screw “E” after rotating tower.
Lowering Tower
1. Rotate tower to line up arrows.
2. Tighten screw “E”.
3. Operate winch “B” to lower tower.
4. Remove lock pin and pin “C”. Do not remove pin or tilt tower down until fully
retracted.
5. Operate winch “A” to lower tower to horizontal position, insert and lock pin “D”
before moving or lifting.
1
29
Towing
NOTE: Assure tow vehicle has towing capacity for weight of this unit as
stated as General Data Decal.
• Chock wheels.
• Check pintle eyes bolts for any looseness or wear. Tighten or replace as required.
• Position tow vehicle to align hitch with pintle eye.
Stand Aside While
• Operating jack to seat pintle eye onto hitch.

• Securing hitch.
• Removing wheel chocks.
Disconnect
• Chock wheels.
Stand Aside While
• Operating jack to raise pintle eye from hitch.

• Moving tow vehicle.
• Levelling machine.
20
30
Before Starting
Check the following
1. Engine oil level. Add as required.

2. Engine coolant level. Add as required.
3. Air cleaner service indicator. Service when showing “RED”.
4. Fuel level in tank - Fill, using CLEAN DIESEL fuel, at the end of the day to
minimize condensation.
5. Battery - Keep terminals clean and lightly greased.
6. Engine belts and hoses - Check for proper fit and/or damage. Service as
required.
7. Air Vents/Grilles - Check for obstructions (Leaves, paper, etc.) in both engine
radiator and generator cooling air vents.
8. Visual inspection - Check for excessive fluid leaks, evidence of arcing around
control panel, loose wire-routing clamps, etc.
! CAUTION
Call qualified personnel to make electrical repairs.
Starting
1. All external loads shall be turned “OFF” or unplugged at the receptacles.

2. Main circuit breaker and Lamp switches shall be “OFF”.
3. Turn ignition switch for starting.
! WARNING
Electrical power is present upon cranking engine.
NOTE: DO NOT crank for more than 15 seconds without allowing starter
to cool for 30 seconds. If engine does not start after a few attempts, refer
to “General Trouble Shooting” on page 50.
21
31
4. Release Ignition switch after engine continues to run.

5. Allow the engine to warm-up for 3-5 minutes.
6. Turn on main circuit breaker.
7. Lamp switches may be switched on and Receptacles may now be used.
! WARNING
Keep side doors closed for optimum cooling and safety of unit while
running.
Stopping
1. Turn Lamps “OFF”.

2. Turn main breaker “OFF”.
3. Disconnect any devices plugged into external power receptacles.
4. Turn ignition key to the “OFF” position.
NOTE: If lights are turned off, a fifteen minute cool down is required
before they will restrike.
Lifting Instructions
LIFTING POINTS FOR :

FORK LIFT
LIFTING EYE
22
32
Before Lifting ensure:
Tower hold down pin at point “D” is fully inserted through both sides of tower rest and
lock pin “D” is installed.
No loose objects shall be stored inside or on top of machine.
No additional equipment is to be hung onto or under machine.
Any device used for lifting shall be rated at a minimum of 2 ton working capacity.
No personnel should be on or under machine at any time during lifting.
! WARNING
Damaged cables may break during tower operation allowing the tower to
fall. Do not operate tower with damaged cables. Replace damaged cables.
NOTICE
Hazards may exist on the job site should this unit shutdown
automatically and all lamps extinguished. Personnel should be advised
of this and have additional lighting.
The engine in this unit is protected with sensors for high coolant temperature and low oil
pressure. Should either of these conditions occur, the engine will automatically stop causing
a loss of power to all lamps (except on control panel) and receptacles. Before restarting the
unit, check the fuel level and engine/radiator thoroughly and correct the problem. The lamps
should not be restarted for approximately fifteen minutes (15 minutes).
23
33
Owner’s Manual and Parts List for Winch Model KR15000301
1500lb. (680 kg) Maximum Rated Line Pull
! WARNING
THIS EQUIPMENT SHOULD NOT BE INSTALLED, OPERATED OR
MAINTAINED BY ANY INDIVIDUAL WHO HAS NOT READ ALL THE
CONTENTS OF THIS OWNER’S OPERATING MANUAL.
FAILURE TO READ AND APPLY THE INSTRUCTIONS AND WARNINGS

CONTAINED HEREIN CAN RESULT IN SUDDEN FAILURE ON
EQUIPMENT, PROPERLY DAMAGE AND SERIOUS INJURY.
Assembly Instructions
1. HANDLE: Insert handle (Item 6, Figure 1) on threaded brake assembly shaft.

Thread handle to point of engagement (touching) of brake pad.
2. HANDLE RETAINER ASSEMBLY: Insert bolt (Item 1, Figure 1) through lock
washer (Item 2, Figure 1), flat washer (Item 3, Figure 1), spacer
(Item 4, Figure 1) and spring (Item 4, Figure 1) and spring (Item 5, Figure 1 -
spring will fit over spacer). Recheck Figure 1 to ensure proper order of
assembly.
Insert bolt containing assembled retainer parts (Figure 1). Into threaded end of
brake shaft and tighten bolt securely.
24
34
Figure 1 : Handle Retainer Assembly
NOTE: Proper Installation is important for maximum braking

performance. Handle retainer assembly permits free action of brake and
handle. No backing handle off shaft. No locking of handle away from
brake. RECHECK ASSEMBLY BEFORE USE.
Cable Assembly Instructions
1. CABLE ATTACHMENT: Winch model KR15000301 is designed for up to 95 ft of 1/4”

diameter, 7 x 19 galvanized aircraft - quality cable.
a. Feed cable onto top of drum (Item 7, figure 3). From inside drum, thread the
cable through one round hole in the drum side, until it extends 1-1/2” past
two square holes.
b. Clamp the cable to the outside of the drum with keeper parts (Items 8, 9, 10
Figure 3). Be sure that carriage bolt heads are on the inside of winch drum.
25
35
Figure 2 : Cable Installation
! CAUTION
1. Always be sure cable is strong enough to support the load to be lifted.
2. Always inspect cable and attachment hook before each use to insure they are
not damaged.
3. Replace cable if worn, frayed or kinked. If cable or hook breaks, the cable can
act like a whip and inflict serious injury to anyone in the path of its movement.
4. Never stand alongside winch cable, or guide the cable with your hands.
5. Never fully extend cable and ALWAYS keep three (3) complete wraps of cable
around drum.
6. Always be sure cable is pulling straight off winch-not at an angle. This will
prevent cable from rubbing against winch drum, avoiding cable damage.
Operating Procedure
1. TO REEL IN OR LIFT LOAD: This winch is designed to lift a load (reel in) by
turning the hand crank in a clockwise direction. This action will produce a
clicking sound inside the winch mechanism. To lock the load at any desired
position, release handle slowly.
2. TO REEL OUT OR LOWER LOAD: To lower load (reel out), turn the hand
crank in a counter - clockwise direction. To Lock load in any desired position,
turn handle crank clockwise until at least two (2) clicks (approximately 8”
movement of handle) are heard inside the winch mechanism before releasing
handle.
26
36
Operating Instructions Light Source - LSCK4 / LSCK4 PLUS
! CAUTION
If hand slips off handle while turning counter clockwise, the brake will
prevent the handle from spinning rapidly backwards.
NOTE: The brake is not fully locked until the handle is turned clockwise
far enough to hear two (2) clicks of the ratchet.
! WARNING
Sufficient load must be applied to the cable to overcome internal
resistance and operate brake properly. NEVER CONTINUE TURNING THE
HANDLE COUNTER-CLOCKWISE IF THE CABLE DOES NOT KEEP
MOVING OUT. This will disengage the brake mechanism and create an
unsafe or hazardous condition. MINIMUM OPERATING LOAD
REQUIREMENTS - Model KR15000301 - 100 lbs.
The brake mechanism under continuous long periods of lift and lower
movement will get hot. DO NOT TOUCH BRAKE MECHANISM UNDER
THESE CONDITIONS.
Maintenance Instructions
1. LUBRICATION: All gears, shafts, bushings and ratchet parts must be clean
and wet with oil (auto-type 10W-30) to ensure proper and safe operation.
2. BRAKE DISC: Brake disc wear can be inspected by removing handle retainer
assembly, handle and brake disc cover. Brake discs should be replaced if the
thickness is less than 1/16” cracked or broken. DO NOT USE OIL OR GREASE
ON FIBRE BRAKE FACES.
! WARNING
If brake disc mechanism operates intermittently or erratically, brake disc
inspection should be accomplished.
3. BRAKE RATCHET MECHANISM: Check ratchet operation by listening for

“clicking sound” when cable is reeled in (turn handle clockwise). Also, when the
cable is reeled out, there will NOT be a clicking sound of the ratchet. Brake
ratchet parts can be inspected for worn parts and unsafe conditions by
removing handle retainer assembly, handle and disc cover.
27
37
! CAUTION
CARE MUST BE TAKEN DURING REASSEMBLY TO ENSURE THAT ALL
PARTS ARE INSTALLED CORRECTLY FOR PROPER OPERATION.
28
38
Maintenance
39
Light Source - LSCK4 / LSCK4 PLUS Maintenance
Maintenance
! CAUTION
Any unauthorized modification or failure to maintain this equipment may
make it unsafe and out of factory warranty.
! WARNING
Before attempting any repair service, disconnect engine battery cables
and all leads to electrical power requirements. Failures to do so can result
in severe personal injury, death or damage to the equipment.
General
In addition to periodic inspections, many of the components in this unit requires periodic
servicing to provide maximum output and performance. Servicing may consist of pre-operation
procedures to be performed by the operating or the maintenance personnel. The primary
function of preventive maintenance is to prevent failure, and consequently, the need for repair.
Preventive maintenance is the easiest and the least expensive type of maintenance.
Maintaining your unit and keeping it clean at all times will facilitate servicing.
Scheduled Maintenance
The maintenance schedule is based on normal operation of the unit. In the event unusual
environmental operating conditions exist, the schedule should be adjusted accordingly.
Wire Routing Clamps

Daily check for loose wire routing clamps. Clamps must be secure and properly mounted. Also
check wiring for wear, deterioration and vibration abrasion.
Electrical Terminals
Check daily for evidence of arcing around the electrical terminals.
30
40
Maintenance Light Source - LSC K4 / LSCK4 PLUS
Hoses
Each month it is recommended that the intake hoses from the Air Cleaner and all flexible
hoses used for water and fuel be inspected for the following:
1. All rubber hose joints and the screw type hose clamps must be tight and the
hoses should be showing no signs of wear, abrasion or deterioration.
2. All flexible hoses must be free of wear, deterioration and vibration abrasion.
Routing clamps must be secure and properly mounted.
Wiring Installation
Daily check for loose, or frayed wiring insulation or sleeving.
Fuel/Water Separator (If provided)

Daily check for water in the fuel filter/water separator unit. Some engines have a translucent
bowl for visual indication, and others have a drain valve below the primary element.
Every six months or 500 hours, or less if fuel is of poor quality or contaminated, replace the
bowl element(s).
Air Vents
Daily clean the air vents of any obstructions or debris.
Air Filter Elements

The air filters should be inspected and maintained only when the clog indicator shows red.
Dust collector boxes should be cleaned daily; this will become more frequent in dusty
operating conditions.
Dust collector boxes must not be allowed to become more than half full.
Replace air filter element every 500 hours or every six months whichever comes first.
It is recommended that air filter elements be replaced by new Doosan Bobcat elements.
Inspection
1. Check for cracks, holes or any other damage to the element by holding it up
against a light or by passing a lamp inside.
2. Check the seal at the end of the cartridge and replace, if any sign of damage is
evident.
3. Renew safety element if inspection reveals damage to main element.
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41
! CAUTION
NEVER USE AN ELEMENT WHICH IS DEFECTIVE OR PUNCTURED
Replacement
1. Assemble the new element.

2. Ensure that the seal seats properly on the bottom of the housing.
3. Secure the element in housing by hand tightening the nut.
4. Assemble the dust collector box parts ensuring they are correctly positioned
with the lug interlocked with the slot in the cover rim.
5. Ensure the arrow and “TOP” marking on the collector box is correctly
positioned.
6. Reset restriction indicator by depressing the rubber diaphragm.
7. Before starting the machine check whether all clamps are tight.
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42
Tires
Weekly check the condition of the tires, and gauge the air pressure. Tires that have cuts or
cracks or little tread should be repaired or replaced.
Tower Cables
Each week the tower lifting cables should be inspected to ensure the ends are attached
securely. The cables should be checked for fraying or other damage and replaced if damaged.
Also the pulleys should be checked for unusual wear or damage and replaced if worn
excessively or damaged.
Tower Locking Pins

All tower locking pins should be checked weekly. Replace any missing or damaged pins before
lifting the unit or raising the tower.
Tower Guides
Every month inspect all of the tower guides for proper operation. Clean and lubricate sliding
surfaces. Replace any missing or damaged parts before raising the tower.
! WARNING
Remove cap slowly to relieve pressure from HOT radiator. Protect skin
and eyes. Hot water or steam and chemical additives can cause serious
personal injury.
It is recommended to test the freezing protection of the coolant every six months or prior to
freezing temperatures. Replenish with a fresh mixture every twelve months.
Each month, inspect the radiator exterior for obstructions, dirt and debris. If present, blow
water or compressed air containing a non-flammable solvent between the fins in a direction
opposite the normal air flow. Should the radiator be clogged internally, reverse flushing, using
a commercial product and the supplier’s recommended procedure, may correct the problem.
Engine Radiator
Check the coolant level, in the radiator. the coolant must cover the tubes in the top tank
(approximately 1 inch high on a clean measuring rod, stuck down filler neck).
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43
Maintenance Light Source - LSCK4 / LSCK4 PLUS
Engine Protection Shut Down System

The operation of the engine protection shutdown system should be checked every month
(scheduled maintenance). The two switches involved in this protective shut down system are
the engine coolant high temperature switch and the engine oil pressure switch.
The engine oil pressure switch which prevents the engine from operating with low oil pressure.
Once a month, remove a wire from the engine oil pressure switch and check the shutdown
system for proper operation.
Test the engine oil pressure switch by removing it and connecting it to a source of controlled
pressure while monitoring an ohm meter should show a lack of continuity through the contacts.
Replace a defective switch before continuing to operate the unit. Once a year, the temperature
actuated switch should be tested by removing it from the unit and placing it in a bath of heated
oil. The engine coolant high temperature switch will require a temperature of approximately
(110°C) to actuate.
NOTE: The engine temperature switch does NOT offer protection when
no coolant is present.
! CAUTION
Never operate the unit with a defective safety shutdown switch or
by-passing a switch.
Control Compartment
Every six months or 500 hours with the unit "OFF", perform visual inspection for loose
connections, dirt, arcing and damage to electrical components.
Fuel Tank
In order to minimize condensation inside the fuel tank, refill as soon as possible after every
use or at the end of each work day. Use only clean, DIESEL fuel. When using a funnel, ensure
that it is clean and free from dust.
Battery
Keep the battery posts and cable connections clean and lightly coated with vaseline/petroleum
jelly.
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44
Fasteners
Monthly spot check several cap screws and nuts for proper torque. If any are found loose, a
more thorough inspection must be made and deficiencies corrected.
Running Gear/Wheels
Check the wheel nut torque 20 miles (30 kilo metres) after refitting the wheels.
Lifting jacks should only be used under the axle.
The bolts securing the running gear to the chassis should be checked periodically for tightness
(refer to the SERVICE/MAINTENANCE CHART for frequency) and re-tightened where
necessary.
Instruments
Inspect the gauges and switches prior to start-up and during operation to ensure proper
functioning. Refer to Instrument and Control Panel for normal readings.
Cleaning Instructions (General)

Keeping the generator set clean of any oil and dirt is recommended for both appearance and
maximum service life of the equipment. The frequency of cleaning will be dependent on local
conditions and the severity and frequency of operation.
NOTE: Do not use high pressure water, steam or solvent on the exterior
finish of the unit housing.
Exterior Finish Care

This unit was painted and heat cured at the factory with a high quality, thermoset polyester
powder coating. The following care will ensure the longest possible life from this finish.
1. If necessary to remove dust, pollen, etc., from housing, wash with water and
soap or dish washing liquid detergent. Do not scrub with a rough cloth, pad, etc.
2. If grease removal is needed, a fast evaporating alcohol or chlorinated solvent
can be used.
NOTE: This may cause some dulling of the paint finish.
3. If the paint has faded or chalked, the use of a commercial grade, non-abrasive
car wax may partially re-store the color and gloss.
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Light Tower Interior

The light tower may be cleaned internally following the below listed procedure.
1. Start and operate the engine unloaded.

2. Use dry compressed air (25 psi maximum) to blow loose dirt and debris from
the interior of the generator.
! WARNING
Wear eye protection to prevent debris from injuring eye(s). Do not allow
the blow gun tip to come into contact with rotating or moving parts.
Personal injury or equipment damage may result.
Control Box Interior

The light tower control box is partially sealed to minimize the entrance of dust and other
contaminants and should require little cleaning. If cleaning is required, the following procedure
is recommended.
1. Disconnect the battery cables.

2. Open the top and/or front of the generator control box and vacuum out the
interior.
! CAUTION
The following should only be performed in a a well ventilated area.
3. Spray all switch contacts with a quality commercial electrical contact cleaner.
Cycle the switches through all possible positions, spraying at each position.
Leave control box door open until completely dry.
The cleaner must have an evaporative carrier agent which leaves no residue after application.
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Preventive Maintenance Schedule

If operating in extreme environments (very hot, cold, dusty or wet), these time periods should
be reduced.
3 Month 6 Month 12 Month

Daily Weekly Month
250 hrs 500 hrs 1000 hrs
Evidence of Arcing Around Elect. Terminals C
Loose Wire Routing Clamps C
Engine Oil and Coolant Level C
Proper Grounding Circuit C
Engine Oil R R R
Engine Oil Filter R R R
Instruments C
Frayed/Loose Fan Belts, Hoses, Wiring Insulation C
Obstructions in Air Vents C
Fuel/Water Separator Drain
Tires C
Battery Connections C
Battery Electrolyte C
Engine Radiator (Exterior) C
Air intake Hoses and Flexible Hoses C
Fasteners (tighten) C
Emergency Stop Switch Operation C
Engine protection Shutdown System C
Air Cleaner Housing C
Control Compartment (Interior) C
Fuel Tank (III at end of each day) Drain
Fuel/Water Separator Element R
Wheel Bearings & Grease Seals Repack
Engine Shutdown System Switches (setting) C
Exterior Finish -As Needed
Engine - Refer to Engine Operator Manual
Decals - Replace decals if removed, damaged or missing
C = Check (and adjust or replace if necessary). WI = OR when indicated. R= Replace
Unit:
Hours:
Date:
Servicemen:
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47
Maintenance Schedule
37
Material Data
49
Light Source - LSCK4 / LSCK4 PLUS Material Data
Material Data
Material Safety Data Sheet for Battery
MATERIAL SAFETY DATA SHEET

HAZARDOUS COMPONENT
COMPONENT %WEIGHT TLV LD50 LD50 LD50
ORAL INHALATION CONTACT
Lead (Pb, PbO2, PbsO4) about 70% (500) mg/kg
Sulfuric Acid about 20% 1mg/m³ (2,140) mg/kg
PHYSICAL DATA
COMPONENT DENSITY MELTING SOLUBILITY ORDER APPEARANCE
POINT
(Boiling)
Lead 11.34 327.4° C In Water None Silver-Gray Metal
Lead Sulfate 6.2 1070° C 40 mg/l (15C) None White Powder
Lead Dioxide 9.4 290° C None None Brown Powder
Sulfuric Acid about 1.3 about 114° C 100% Acidic Clear Colorless liquid
FLAMABILITY DATA
COMPONENT FLASH POINT EXPLOSIVE LIMIT COMMENTS
Lead None None
Sulfuric Acid None None
Hydrogen 4% - 74.2% Sealed Batteries can emit
hydrogen only if over

charged
(float voltage > 2.40 VPC)
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50
Material Data Light Source - LSCK4 / LSCK4 PLUS

REACTIVITY DATA
COMPONENT STABILITY DECOMPOSITION PRODUCTS
Sulfuric Acid Stable at all temperature Sulfuric dioxide, trioxide, hydrogen sulfide,
hydrogen
INCOMPATIBILITY POLYMERIZATION
Reactive metals, strong bases, most organic compounds Will not polymerize
CONDITIONS TO Prohibit smoking, sparks, flames, etc. from battery charging area. Avoid mixing acid with
AVOID: other chemicals.
HEALTH HAZARD DATA
LEAD
The toxic effects of lead are cumulative and slow to appear. It affects the kidneys, reproductive organs and central
nervous system. The symptoms of lead overexposure are anemia, vomiting, headaches, stomach pains (lead
colic), dizziness, loss of appetite, muscle and joint pain. Exposure to lead from a battery most often occurs during
lead reclamation operations through the breathing or ingestion of lead dust and/or fumes.
***This sheet must be passed to any scrap dealer or smelter when the battery is resold.
SULFURIC ACID
Sulfuric acid is highly corrosive. Contact can cause severe burns in the skin and eyes. Ingestion of sulfuric acid
will cause GI track burns. Exposure to sulfuric acid may occur if the battery case has been damaged or the vents
have been tampered with.
SPILL OR LEAD PROCEDURES
STEPS TO TAKE IN CASE OF LEAK OR SPILL
If sulfuric acid is spilled from a battery, neutralize the acid with sodium bicarbonate (baking soda), sodium
carbonate (soda ash), or calcium oxide (lime). Flush the area with water and it is acceptable to discard the
neutralized acid in the sewage system.
***Do not allow un neutralized acid in to the sewage system.
WASTE DISPOSAL METHOD
Neutralized acid may be discarded in the sewage system. Spent batteries must be treated as hazardous waste
and disposed of in accordance with Local, State, and Federal regulations.
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51

SAFETY DATA
ELECTRICAL
Due to the battery's low internal resistance and high power density, high levels of short circuit current can develop
across the battery terminals. Do not rest tools or cables on the battery. Use insulated tools only. Follow all
installation instructions and diagrams when installing or maintaining a battery system.
CONDITION TO AVOID
Prohibit smoking, sparks, flames, etc., from battery charging area. Avoid mixing acid with other chemicals.
PROTECTION
EXPOSURE SITE PROTECTION COMMENTS
Skin Rubber gloves, Apron Protective equipment must be worn if the

battery is cracked or otherwise
Respiratory Respirator (for lead) damaged. A respirator should be worn
during lead reclamation operations if the
Eyes Safety goggles, Face shield
TLV is exceeded.
FIRST AID
SULFURIC ACID
SKIN CONTACT Flush with water. See a physician if the contact area is large or if blister occur.
EYE CONTACT Call a physician immediately. Flush with water until medical help arrives.
INGESTION Call a physician immediately. If patient is conscious, flush mouth with water, have the
patient drink milk or sodium bicarbonate solution.
***Do not give anything to an unconscious person.
REGULATORY INFORMATION
SCHEDULE: II LIST: II CLASS: 8 PACKING GROUP: III
DESCRIPTION: BATTERIES, Fluid Acid,
DOT REGULATION: Class 60
DESCRIPTION: BATTERIES, NON-HAZARDOUS, NON-SPILLABLE
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52
Lamp Material Information Sheet
Material Safety Data Sheet (MSDS)
Information and Applicability

The Material Safety Data Sheet (MSDS) requirements of the Occupational Safety and Health
Administration (OSHA) for chemicals are not applicable to manufactured articles such as
lamps. No material contained in a lamp is released during normal use and operation.
The following information is provided as a service to our customers. The following Lamp
Material Information Sheet contains applicable Material Safety Data Sheet information.
Lamp Materials and Hazardous Ingredients
Glass
These lamps consist of an inner quartz arc tube enclosed in an outer envelope of heat-
resistant glass. Depending on the lamp type, the envelope is either clear of coated with one of
two different materials. The “MVR” and “MVT” lamps are coated with a phosphor material while
the “MXR” lamps are coated with a diffusing material.
Phosphor
The phosphor used on the outer envelope of the coated lamps consists of yttrium vanadium
phosphate. This material, like most vanadium compounds, is relatively insoluble, and appears
to have a much lower toxicity than vanadium pentoxide but may elicit some similar symptoms
at high exposure levels. Excessive inhalation exposure to vanadium Pentecost may result in
irritation of the nasal passages and respiratory tract, cough, difficulty in breathing, and
bronchitis. However, the yttrium vanadium phosphate from the breakage of one or a small
number of lamps should not result in a significant exposure.
The material used as a diffuser in the “MXR” lamps is a specially prepared kaolin clay that
contains no crystalline silica or asbestos as impurities. These types of clays are generally
considered to be toxicologically relatively inert materials.
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53
Arc Tube
The quartz arc tube contains a small amount of mercury, ranging from 5 milligrams in a 32 watt
lamp up to 165 mg in a 1500 watt lamp. The arc tube contains a small amount of inert gas
argon used as a fill gas. It also contains a small amount of other materials, used as an
emission mix on the electrodes, but there would be no significant exposure from lamp
breakage.
Also contained in the arc tube are small amounts of sodium and scandium iodide, and in some
cases thorium iodide. None of these materials are expected to be a hazard in the small
quantities present in the arc tube. The coating on the end(s) of the arc tube is aluminum oxide,
a material generally considered to have a low order of toxicity.
Metals
Internally, the support wires used in the lamp construction are made from nickel-coated iron
or stainless steel while the electrodes are tungsten. Many of the metal halide types will use a
brass base and have lead-soldered connections to that base.
Health Concerns
Mercury Exposure
The air concentration of mercury resulting from the breakage of one or a small number of
lamps should result in no significant exposure to the individual. However, if breaking a large
number of lamps for disposal, appropriate monitoring, controls and equipment should be
implemented to control airborne mercury and dust levels or surface contamination. Such work
should be done in a well ventilated area, and local exhaust ventilation or personal protective
equipment may be needed.
Ultraviolet (UV) Radiation

The quartz arc tube, when operating, generates a considerable amount of ultraviolet
radiation.The UV is filtered to acceptable levels by the glass outer envelope during normal use.
However, if the outer envelope is broken, the UV filtering is lost. Lamps having ordering codes
beginning with the letters “MVR” or “MXR” have the following warning notice required under
Federal Regulation 21CFR 1040.30:
! WARNING
This lamp can cause serious skin burn and eye inflammation from
shortwave ultraviolet radiation if outer envelope of the lamp is broken or
punctured, and the arc tube continues to operate. Do not use where
people will remain for more than a few minutes unless adequate shielding
or other safety precautions are used. General Electric Company has
commercially available SAF-T-GARD Mercury and Multi-Vapor lamps that
will automatically extinguish when the outer envelope is broken.
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54
The self-extinguishing metal halide lamps referred to above have order codes beginning with
the letters “MVT”. If the outer glass envelope of a SAF-T-GARD lamp is broken, although the
arc tube will have self-extinguished, its support structure will still be electrically connected and
could present an electrical shock hazard. Therefore, regardless of the type, if the outer
envelope of the lamp is broken, turn the power off before replacing the lamps.
Disposal Concerns
TCLP
A Toxicity Characteristic Leaching Procedure (TCLP) test conducted on the lamp for lead or
mercury could cause the lamp to be classified as a hazardous waste. Metal Halide lamps use
leads older on the lamp base and mercury in the arc tube. The lead solder or mercury vapor
should pose little risk of exposure under normal use and handling. While small numbers of
these lamps placed in the ordinary trash should not appreciably effect the nature or method of
disposal of the trash in most states, under some circumstances disposal of large quantities
may be regulated. You should review your waste handling practices to assure that you dispose
of waste lamps properly. Please check with state environmental departments regarding
individual state disposal requirements.
Lighting
Material Safety Data Sheet

PRODUCT: METAL HALIDE FAMILY
Hazardous Ingredients
OSHA (PEL) ACGIH (TLV)

% by Wt.
mg/m3 mg/m3
Mercury (7439-97-6) 0.1 Ceiling 0.025 8 hr. Less than 0.03%

TWA
Iodine (7553-56-2) 1.0 mg/m3 1.0 mg/m3 Less than 0.02%
(0.1 ppm (0.1 ppm ceiling)
ceiling)
Sodium Iodide (NaI) (7681-82-5) None Less than 0.02%
Established
Inert ingredients ingredients Approximately
(Glass, Quartz, Metal) 97.9% by weight
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Physical Data
This item is a light bulb. Chemical characteristics are not applicable.
Fire and Explosion Data

This item is a light bulb; it has no fire data. Under extreme heat, outer envelope might melt or
crack.
Reactivity Data
Stability: Lamp is stable.
Incompatibility: Glass will react with hydrofluoric acid.
Polymerization: Will not occur.
Health Hazard Data

Not applicable to intact lamp.
! WARNING
These lamps can cause serious skin burn and eye inflammation from
short wave ultraviolet radiation if outer envelope of the lamp is broken or
punctured. Do not use where people will remain for more than a few
minutes when envelope is broken unless adequate shielding or other
safety precautions are used.
The inner envelope is composed of quartz. Breakage of this envelope may result in some
exposure to elemental mercury vapor or iodine compound vapors. No adverse effects are
expected from occasional exposure to broken lamps. As a matter of good practice breakage
should be avoided prolonged or frequent exposure to broken envelopes should be avoided
through the use of adequate ventilation during disposal of large quantities of lamps.
EMERGENCY FIRST AID: NORMAL FIRST AID PROCEDURE FOR GLASS CUTS IF SUCH
OCCUR THROUGH LAMP BREAKAGE.
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Precautions for Safe Handling and Use

Normal precautions should be taken for collection of broken glass.
WASTE DISPOSAL METHOD: The arc tube contains a small amount of mercury. A toxic
characteristic leachate test conducted on based HID lamps for lead and/or mercury will cause
the lamp to be classified as a hazardous waste for mercury and lead. These lamps will come
under the Universal Waste Rule published by EPA on July 6, 1999. State regulations will vary.
Check with local and state authorities. Philips Lighting Company recommends recycling of
spent Metal Halide lamps. The lead used in the solder should pose little risk of exposure under
normal use and handling.
Control Measures
Respiratory Protection: Appropriate dust mask should be used if large volumes of lamps are
broken for disposal.
Ventilation: Avoid inhalation of any airborne dust. Provide local exhaust when disposing large
quantities of lamps.
Hand and Eye Protection: Appropriate hand and eye protection should be worn when
disposing of large quantities of lamps or handling broken lamps.
Regulatory Information
For Air Shipment: This lamp will require a manifest of dangerous goods if it is a 400W or
higher.
47
57
58
General Trouble
Shooting
59
Light Source - LSCK4 / LSCK4 PLUS General Trouble Shooting
General Trouble Shooting
Introduction
Trouble shooting for a portable light tower is an organized study of a particular problem or
series of problems and a planned method of procedure for investigation and correction. The
trouble shooting chart that follows includes some of the problems that an operator may
encounter during the operation of a portable generator.
The chart does not attempt to list all of the troubles that may occur, nor does it attempt to give
all of the answers for correction of the problems. The chart does give those problems that are
most apt to occur. To use the trouble shooting chart:
1. Find the "complaint" depicted as a bold heading.

2. Follow down that column to find the potential cause or causes.
Action Plan
A. Think Before Acting
Study the problem thoroughly and ask yourself these questions:
a. What were the warning signals that preceded the trouble?

b. Has a similar trouble occurred before?
c. What previous maintenance work has been done?
d. If the generator will still operate, is it safe to continue operating it to make
further checks?
B. Do the Simplest Things First
Most troubles are simple and easily corrected.
Always check the easiest and most obvious things first; following this simple
rule will save time and trouble.
NOTE: For trouble shooting electrical problems, refer to the Wiring

Diagram Schematic.
C. The source of most troubles can be traced not to one component alone, but to
the relationship of one component with another. Too often, a machine can be
partially disassembled in search of the cause of a certain trouble and all
evidence is destroyed during disassembly. Check again to be sure an easy
solution to the problem has not been overlooked.
D. After a mechanical failure has been corrected, be sure to locate and correct the
cause of the trouble so the same failure will not be repeated. A complaint of
"premature breakdown" may be corrected by repairing any improper wiring
connections, but something caused the defective wiring. The cause may be
excessive vibration.
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60
Trouble Shooting Chart

Bold Headings depict the COMPLAINT - Subheadings depict the CAUSE.
NOTE: Subheadings suggest order to follow in cause of troubleshooting.
Short Air Cleaner Life

Dirty Operating Conditions
Inadequate Element Cleaning
Defective Service Indicator
Wrong Air Filter Element
Engine RPM Low

Clogged Fuel Filter
lncorrect Engine Speed Adjustment
Dirty Air Filter
Electrical Output Overload
Engine Malfunctioning
Generator Malfunctioning
Excessive Vibration
Low Engine RPM
Rubber Mounts Damaged
Out of Balance Fan
Generator Malfunctioning
Unit Shutdown
Out of Fuel
Engine Oil Pressure Too Low
Engine Temperature Too High
Broken Engine Fan Belt
Loose Wire Connection
Defective Switches
Defective Fuel Solenoid
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Malfunctioning Relay
Blown Fuse
Unit Fails To Shutdown

Defective Switches
Defective Engine Start Switch
Won’t Start/Run
Low Battery Voltage
Blown Fuse
Malfunctioning Engine Start Switch
Clogged Fuel Filters
Out of Fuel
Engine Water Temp. Too High
Engine Oil Pressure Too Low
Loose Wire Connection
Defective Switches
No Generator Voltage Output

Main Circuit Breaker "OFF"
Panel Circuit Breaker "OFF”
Loose or Intermittent Wire
Low Engine Power
Incorrect Electrical Connection
Defective capacitor
Defective Generator
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62
General Trouble Shooting Light Source - LSCK4 / LSCK4 PLUS
High/Low Generator Voltage Output

lncorrect Electrical Connection
lncorrect Engine Speed Adjustment
Unstable Engine Speed (oscillation)
Unstable Electrical Requirements
Low Engine Power
Loose or lntermittent Wire Connection (s)
Defective Capacitor
Clogged Air Fuel Filter (s)
High/Low Generator Frequency Output

Incorrect Engine Speed Adjustment
Incorrect Electrical Connection
Low Engine Power
Unstable Engine Speed (Oscillation)
Unstable Electrical Connection
Loose or Termittent Wire Connections
Clogged Air/Fuel Filter(s)
53
63
64
Trouble Shooting High Intensity
Discharge Lamp Ballasts
65
Light Source - LSCK4 / LSCK4 PLUS Trouble Shooting High Intensity Discharge
Trouble Shooting High Intensity Discharge Lamp

Ballasts
Foreword
Operating Characteristics
High Intensity Discharge Lamps (from left) Mercury, Metal Halide, High Pressure Sodium and
low Pressure Sodium.
Advance HID lamp ballasts are available to operate a wide variety of Mercury, Metal Halide,
High-pressure Sodium and Low Pressure Sodium lamps available in today’s marketplace.
All are electric discharge lamps. Light is produced by an arc discharge between two electrodes
located at opposite ends of an arc tube within the lamp.
The purpose of the ballast is to provide the proper starting and operating voltage and current
to initiate and sustain this arc.
HID Lamps
Lamp Starting
Mercury and Metal Halide Lamps

Mercury and most Metal Halide lamps have an additional electrode located at one end of the
arc tube to assist in lamp starting. These types of lamps require an Open Circuit Voltage
(O.C.V.) approximately two times the lamp voltage to initiate and sustain the arc.
High Pressure Sodium Lamps

High Pressure Sodium and some of the newer Metal Halide lamps, however, have no starting
electrodes. In addition to an O.C.V. of approximately two times the lamp voltage, these lamps
are started by a high voltage starting pulse, provided by an ignitor, applied across the arc tube.
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66
Trouble Shooting High Intensity Discharge Light Source - LSCK4 / LSCK4 PLUS
Low Pressure Sodium Lamps

Because they have neither a starting electrode or an ignitor, Low Pressure Sodium Lamps
require an open circuit voltage of approximately three to seven times the lamp voltage to start
and sustain the lamp.
Lamp Operation
Electric discharge lamps have a negative resistance characteristic, which would cause them
to draw excessive current leading to instant lamp destruction if operated directly from this
voltage. The ballast is therefore utilized to limit this current to the correct level for proper
operation of the lamp.
HID lamps will take several minutes to warm up and reach full lumen output. An interruption in
the power supply, or a sudden voltage may cause the arc to extinguish. A lamp that is still hot
will not restart immediately.
Before the lamp will relight, it must cool sufficiently to reduce the vapor pressure within the arc
tube to a point where the arc will restrike. The approximate warm-up and restriking times of
the HID lamp groups are as follows:
LIGHT SOURCE WARM-UP TIME RESTRIKE TIME
Mercury Vapor 5 - 7 minutes 3 - 6 minutes
Metal Halide 2 - 5 minutes 10 - 20 minutes
High Pressure Sodium 3 - 4 minutes 1/2 - 1 minute
Low Pressure Sodium 7 - 10 minutes 3 - 12 minutes
Ballasts
Ballast Design Applications

HID lamp ballasts are available in a variety of shapes and sizes for the most popular lighting
applications. Six basic designs are in widest use today.
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Core and Coil
The most basic of all shapes is the core & coil which may also be used by itself as a component
of a fixture, but is also used to form the nucleus to the five other ballast configurations detailed
in this section. It consists of one, two or three copper coils on a core (or “stack”) of electrical
grade steel laminations.
Ballast Circuitry
General
The ballast in an HID lighting system has generally two purposes:
1. To provide the proper starting voltage to strike and maintain the arc.
2. To provide the proper current to the lamp once the arc is established.
In addition to being designed to operate a particular type of HID lamp, a ballast design
incorporates a basic circuitry to provide specific lamp/ballast operating characteristics. As an
example, the effects of line voltage variations on resultant changes of lamp wattage are a
function of the ballast circuit design.
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Lamp Regulation Characteristics

One of the most important characteristics of each particular ballast circuit is the degree to
which it controls the lamp wattage (light output) when the input line voltage changes. The
following chart compares the relationship of the three basic circuits as the input volts are
changed.
As an example, the CWA line indicates that at 90% of line voltage, the ballast will operate the
lamp at 95% of its nominal wattage. Similarly, at 110% of line voltage, the ballast will operate
the lamp at 105% of nominal wattage.
* Reactor and High Reactance = R and HX Mercury, Metal Halide and High Pressure Sodium
lamp ballasts.
** Constant Wattage Autotransformer = CWA Mercury. Similar to regulation of CWA Metal
Halide and High Pressure Sodium lamp ballasts.
*** Constant Wattage and Regulated Lag = Premium CW Mercury and REG LAG High
Pressure Sodium lamp ballasts.
Also, like the reactor ballast, the autotransformer is inherently normal power factor (50%), but
it may be corrected to high power factor (90%) with the addition of a capacitor across the input.
Its current draw and ability to withstand voltage dips are similar to that of the reactor.
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Constant Wattage Autotransformer (CWA)
This is the most commonly used circuit because it offers the best compromise between cost
and performance. It is a high power factor devise, utilizing a capacitor in series with the lamp.
A±10% line voltage variation will result in a ±5% change in lamp wattage for Mercury, or
±10%change in wattage for Metal Halide. These regulation characteristics are greatly
improved over the reactor and the high reactance circuits.
Additionally, the ballast input current during lamp warm-up does not exceed the current when
the lamp is stabilized. The incidences of accidental lamp outages die to voltage dips is also
greatly reduced because a CWA ballast can tolerate drops in line voltage of 30-40% before
the lamp extinguishes (lamp dropout).
Capacitors
General
All Constant Wattage Autotransformer, high power factor Reactor and Hi-Reactance ballasts
require a capacitor. With core & coil units, this capacitor is a separate component and must be
properly connected electrically. In high power factor ADVANCE out door weather proof, indoor
enclosed, F-can and post line ballasts, the capacitor is already properly connected within the
assembly. Two general types of capacitors are currently in widest use: the oil-filled and the dry
type.
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Oil Filled Capacitors
Oil-filled capacitors furnished today contain a non-PCB oil and are equipped with UL
component-recognized, internal interrupters to prevent can rupture and resultant oil leakage
in the event of failure. Additionally, capacitors utilized with Mercury and Metal Halide CW and
CWA ballast circuits have a UL-required discharge resistor connected across the terminals to
discharge the capacitor after the power is extinguished for the safety of service personnel. In
High Pressure Sodium lighting applications, a discharge resistor contained within the ignitor
meets this safety requirement.
Whether furnished singly or as pairs prewired in parallel, capacitors must be properly wired in
all installations. Proper wiring methods, as well as some common miswiring methods which
must be avoided, are shown on the following page. If the capacitor is miswired, ballast or lamp
failure could result.
Capacitor Wiring
Single Capacitors
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Capacitor Failure
The older, PCB oil-filled capacitors, which have been discontinued but may still be found in
older fixtures, generally fail shorted when they fail. A shorted capacitor affects ballast types
and circuits as follows:
Mercury and Metal Halide Ballasts
A seemingly normal lamp operation, but a large increase in line current. This increased current
will usually cause the ballast primary coil to burn up in anywhere from a few minutes to a few
days.
High Pressure Sodium (HX & R) Ballasts
A direct short is created across the primary which may either open the circuit breaker or burn-
up the primary.
High Pressure Sodium (CWA & CW) Ballasts
Lamp operation continues at a very low wattage and resultant low light output with no damage
to the ballast.
Trouble Shooting
At times when an HID Lighting System becomes inoperative, a complex, thorough, trouble-
shooting procedure may prove overly time consuming. In these instances, a simple check of
the power switches, when a bank of fixtures becomes inoperative, or a visual check of the
lamp, when a singular fixture becomes inoperative, may provide the quickest response to the
problem. At other times, where individual isolated fixtures are involved, it may be necessary
to systematically isolate the problem and perform complete electrical tests in order to properly
restore the lighting.
The four basic trouble-shooting methods outlined in this booklet offer procedures which can
be applied to cover virtually all situations:
1. Visual Inspection Check List

Quick visual checks for normal end-of-lamp life and application irregularities
not requiring electrical testing.
2. Quick Fix For Restoring Lighting
Where lighting must be immediately restored
3. Troubleshooting Flow Charts
Simplified diagrams to quickly locate the problem in any given lighting fixture
based on the lamp characteristics.
a. Lamp will not start

b. Lamp cycles
c. Lamp too bright or dim
4. Electrical Tests-In-depth check of system by performing electrical tests.
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72
Visual Inspection Check List Normal End of Lamp Life

Mercury and Metal Halide Lamps
These lamps at end-of-life are characterized by low light output and/or intermittent starting.
Visual signs include blackening at the ends of the arc tube and electrode tip deterioration.
High Pressure Sodium Lamps
Aged HPS lamps will tend to cycle at end-of-life. After start-up, they will cycle off and on as the
aged lamp requires more voltage to stabilize and operate the arc than the ballast is capable
of providing.
Visual signs include a general blackening at the ends of the arc tube. The lamp may also
exhibit a brownish tinge (sodium deposit) on the outer glass envelope.
Low Pressure Sodium Lamps
At end-of-life these lamps retain their light output but starting first becomes intermittent and
then impossible. Visual signs include some blackening of the ends of the arc tube.
LAMPS
Broken arc tube or outer lamp jacket.
Lamp broken where glass meets the base.
Broken or loose components in lamp envelope.
Arc tube end blackening.
Deposits inside outer glass envelope.
Lamp type (H, M, S, or L number) and wattage must correspond to that required by ballast
label.
Lamp orientation designation (BU or BD) incorrect for application (base up, base down, etc).
LIGHTING SYSTEM COMPONENTS
Charred ballast coils.
Damaged insulation or coils on ballast.
Evidence of moisture or excessive heat.
Loose, disconnected, pinched or frayed leads.
Incorrect wiring.
Swollen or ruptured capacitor.
Damaged ignitor.
Quick Fix for Restoring Lighting

Visual Inspection
Visually inspect lamp, ballast, capacitor and ignitor (where used) for physical signs of failure,
replacing any apparently defective components.
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If either core & coil ballast or capacitor appear abnormal, replace both.
Component Replacement Where No Visual Defects appear verify that the correct fine voltage
is being supplied to the fixture.
Check power switches, circuit breakers, fuses, photo control, etc.
Replace lamp.
Replace both ballast and capacitor.
Flow Charts
A. Lamp Will Not Start (STEP 1)
(Page 68)
64
74
Lamp Will Not Start (Step 2)
(Page 68)
Lamp Will Not Start (Step 3)
65
75
B. Lamp Cycles
(Page 68)
66
76
C. Lamp Too Bright or Dim
4. Electrical Tests
NOTE: Voltage and current measurements present the possibility of

exposure to hazardous voltages and should be performed only by
qualified personnel.
The following equipment is recommended for testing HID fixtures:

RMS Voltmeter
Ranges: O-150-300-750 Volts AC
Ammeter (Clamp-on type acceptable)
Ranges: O-30 Amperes AC
Multi-meter (with voltage and current ratings as shown above).
67
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Ohm meter
Line Voltage
Measure the line voltage at input to fixture to determine if the power supply conforms to the
requirements of the lighting system. For constant wattage ballasts, the measured line voltage
should be within 10% of the name plate rating. For high reactance or reactor ballasts, the line
voltage should be within 5% of the name plate rating.
If the measured line voltage does not conform to the requirements of the lighting system, as
specified on the ballast or fixture name plate, electrical problems exist outside of the fixture
which can result in non-starting or improper lamp operation.
Check fuses, breakers and switches when line voltage readings cannot be obtained. High, low
or variable voltage readings may be due to load fluctuations on the same circuit.
Open Circuit Voltage

To determine if the ballast is supplying proper starting voltage to the lamp, an open circuit
voltage test is required. The proper test procedure is:
1. Measure input voltage (V1) to verify rated input voltage is being applied.
2. With the lamp out of the socket and the proper voltage applied to the ballast,
read the voltage (V2) between the socket pin and shell. Reading must be within
test limits shown.
As an alternative, this test may also be performed simply by screwing an adapter into the lamp
socket for easy access. Then hook up the voltmeter to this adapter. Reading must be within
test limits shown.
68
78
Open Circuit Voltage Test Limits
69
79
When Circuit Voltage Tests Results Into Reading

Further checks should be made to determine whether cause is attributable to lamp socket
short, shorted or open capacitor, inoperative ballast, improper wiring or open connection.
Simple checks may be made as follows:
Shorted Socket Check
1. Turn off power and remove lamp from socket.

2. Check for internal short in lamp socket with continuity meter across two lamp
leads.
3. Should read NO continuity.
Capacitor Check
1. Disconnect capacitor from circuit 2. 3.

2. Discharge capacitor by shorting between terminals.
3. Check capacitor with ohmmeter set at highest resistance scale.
If meter indicates a very low resistance which then gradually increases, the capacitor does not
require replacement.
If meter indicates a very high resistance which does not diminish, it is open and should be
replaced.
If meter indicates a very low resistance which does not increase, the capacitor is shorted and
should be replaced.
70
80
Ballast Continuity Check

Continuity of Primary Coil
1. Disconnect ballast from power supply and discharge the capacitor.

2. Check for continuity of ballast primary coil between input leads.
71
81
Continuity of Secondary Coil
1. Disconnect ballast from power supply and discharge the capacitor.

2. Check for continuity of ballast secondary coil between lamp and common
leads.
Short Circuit Lamp Current

To assure the ballast is delivering the proper current under lamp starting conditions, a
measurement may be taken by connecting an ammeter between the lamp socket Center pin
and the socket shell with rated input voltage applied to the ballast. If available, a socket
adapter may be used:
1. Energize ballast with proper rated input voltage.

2. Measure Current with ammeter at A1 and A2 as shown below.
3. Readings must be within test limits shown.
When using a clamp-on ammeter for this measurement, be certain the meter is not near the
magnetic field of the ballast or any steel member which might distort the magnetic field.
72
82
Short Circuit Lamp Current Test Limits
73
83
When Short Circuit Lamp Current Test Results in High, Low or No Reading
Further checks should be made to determine whether cause is attributed to improper supply
voltage, shorted or open capacitor or inoperative ballast. Checks may be made as follows.
Supply Voltage Check
1. Measure Line Voltage.

2. If ballast is multi-voltage unit such as ADVANCEÒ Quadri-Volt, make certain
input voltage connection is made to proper input voltage terminal or lead.
Capacitor Check
1. Verify capacitor rating is as required.

2. Perform Capacitor Check.
Ballast check
Perform Open Circuit Voltage test as described on page 68.
Further Checks
Probable Causes of Inoperative Ballast
1. Normal end-of-life failure.

2. Operating incorrect lamps. Use of higher or lower wattage lamps than rated for
ballast will cause premature ballast end-of-life.
3. Overheated due to heat from fixture or ambient temperature.
4. Voltage surge.
5. Miswiring or pinched wires.
6. Shorted or open capacitor.
7. Incorrect capacitor rating for ballast.
8. Capacitor miswired or wiring shorting against frame.
Probable Causes of Shorted or Open Capacitor
1. Normal end-of-life failure.

2. Overheated due to heat from fixture or ambient temperature.
3. Capacitor heat barrier inadvertently removed.
4. Incorrect voltage rating of capacitor.
5. Mechanical damage such as overtightened bracket.
74
84
Parts Ordering
75
85
Light Source - LSCK4 / LSCK4 PLUS Parts Ordering
Parts Ordering
General
This publication, which contains an illustrated parts breakdown, has been prepared as an aid
in locating those parts which may be required in the maintenance of the unit. Always insist on
genuine Doosan Bobcat Company parts.
NOTICE
Doosan Bobcat Company can bear no responsibility for injury or
damages resulting directly from the use of non-approved repair parts.
Description
The illustrated parts breakdown illustrates and lists the various assemblies, subassemblies
and detailed parts which make up this particular machine. This covers the standard models
and the more popular options that are available.
Markings and Decals
NOTICE
Do not paint over safety warnings or instructional decals. If safety
warning decals become illegible, immediately order replacements from
the factory.
Markings and Decals

Do not paint over safety warnings or instructional decals. If safety warning decals become
illegible, immediately order replacements from the factory.
Part numbers for original individual decals and their mounting locations are shown within Parts
List Section. These are available as long as a particular model is in production.
Afterwards, service sets of exterior decals and current production safety warning decals are
available.
8
86
Parts Ordering Light Source - LSCK4 / LSCK4 PLUS
How to Use Parts List

1. Locate the area in which the desired part is used and find illustration page
number.
2. Locate the desired part on illustration by visual identification and make note of
part number and description.
How to Order
The satisfactory ordering of parts by a purchaser is greatly dependent upon the proper use of
all available information. By supplying your nearest sales office, autonomous company or
authorized distributor, with complete information, you will enable them to fill your order
correctly and to avoid any unnecessary delays. In order that all avoidable errors may be
eliminated, the following instructions are offered as a guide to the purchaser when ordering
replacement parts:
1. Always specify the model number of the unit.

2. Always specify the serial number of the unit. THIS IS IMPORTANT. The serial
number of the unit will be found stamped on a plate attached to unit.
3. Always specify the quantity of parts required.
4. Always specify the part number, as well as the description of the part, or parts,
exactly as it is given on the parts list illustration.
In the event parts are being returned to your nearest sales office, autonomous company or
authorized distributor, for inspection or repair, it is important to include the serial number of the
unit from which the parts were removed.
9
87
Revision History
Rev ECN/Date Description
J CN123487 / MAY 2022 MAINTENANCE INSTRUCTION ON WINCH FOR LIGHT
TOWER UPDATED
Doosan Bobcat India Pvt Ltd
6th Floor, HTC Towers,
No. 41, Mount Road, Guindy,
Chennai - 600032, India.
Toll Free : 1 800 103 2869
www.doosanportablepower.com/in/en
© Doosan Portable Power Printed in India

Manual de Operacion LEK 1.4 LED 46693831

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OPERATION and MAINTENANCE

LIGHT TOWER MODEL

LSCK4, LSCK4 PLUS AND LEK1.4

Doosan Bobcat India Pvt Ltd

P/N: 46693831 (MAY 2022) Rev J

General Light Tower Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Material Safety Data Sheet for Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

GENERAL TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

TROUBLE SHOOTING HIGH INTENSITY DISCHARGE LAMP BALLASTS . . . . . . . . 65

General Light Tower Information

Do not store or transport hazardous (combustible, etc.) material in or on

**Always use Doosan Replacement parts!**

﻿LIGHT SOURCE DETAILS LSCK4 LSCK4 PLUS LEK1.4

**Always use Doosan Replacement parts!**

GENERAL LAYOUT FOR LIGHT SOURCE LEM1.4 BEFORE CAISLEK060

GENERAL LAYOUT FOR LIGHT SOURCE LEK1.4

Operation Set-Up (Prior to Raising Tower)

Extending Tower In Upright Condition

Stand Aside While

• Operating jack to seat pintle eye onto hitch.

Stand Aside While

• Operating jack to raise pintle eye from hitch.

Check the following

1. Engine oil level. Add as required.

1. All external loads shall be turned “OFF” or unplugged at the receptacles.

4. Release Ignition switch after engine continues to run.

1. Turn Lamps “OFF”.

LIFTING POINTS FOR :

Before Lifting ensure:

Owner’s Manual and Parts List for Winch Model KR15000301

1500lb. (680 kg) Maximum Rated Line Pull

FAILURE TO READ AND APPLY THE INSTRUCTIONS AND WARNINGS

1. HANDLE: Insert handle (Item 6, Figure 1) on threaded brake assembly shaft.

Figure 1 : Handle Retainer Assembly

NOTE: Proper Installation is important for maximum braking

Cable Assembly Instructions

1. CABLE ATTACHMENT: Winch model KR15000301 is designed for up to 95 ft of 1/4”

Figure 2 : Cable Installation

3. BRAKE RATCHET MECHANISM: Check ratchet operation by listening for

Wire Routing Clamps

Fuel/Water Separator (If provided)

Air Filter Elements

1. Assemble the new element.

Tower Locking Pins

Engine Protection Shut Down System

Cleaning Instructions (General)

Exterior Finish Care

NOTE: This may cause some dulling of the paint finish.

Light Tower Interior

1. Start and operate the engine unloaded.

Control Box Interior

1. Disconnect the battery cables.

Preventive Maintenance Schedule

3 Month 6 Month 12 Month

Material Safety Data Sheet for Battery

MATERIAL SAFETY DATA SHEET

COMPONENT %WEIGHT TLV LD50 LD50 LD50

ORAL INHALATION CONTACT

Lead (Pb, PbO2, PbsO4) about 70% (500) mg/kg

Sulfuric Acid about 20% 1mg/m³ (2,140) mg/kg

Always use Doosan Replacement parts!

LIGHT SOURCE DETAILS LSCK4 LSCK4 PLUS LEK1.4

Always use Doosan Replacement parts!

Always use Doosan Replacement parts!

Always use Doosan Replacement parts!