Yanmar LB446HB-1 H-1 Operation & Maintenance Manual - PDF DOWNLOAD

Never attempt to operate or service this Lighting Tower until you have first read and understood all of the applicable Safety Instructions that are set forth in this Manual.

The failure to comply with all relevant Safety Instructions could result in bodily injury.

To assure that this Manual will be conveniently available to future users, store this manual carefully after use.

Published:04/06/2007 p/n°:LGBBOY-00000

LB446HB-1 S/N E1000001 & Above LB446H-1 S/N E0900001 & Above

Read this manual carefully to learn how to operate and service your machine correctly.

Failure to do so could result in personal injury or equipment damage This manual should be considered a permanent part of your machine and should remain with the machine when you sell it.

This machine is of metric design, and consequently the measurements in this manual are also metric.

Use only metric hardware and tools as specified.

Warranty is provided as a part of Yanmar's product support program for customers who operate and maintain their equipment as described in this manual. Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements under warranty may be denied.

Setting fuel delivery above specifications or otherwise overpowering machines will result in such action.

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

REFERENCE INFORMATION Write the correct information for your YANMAR Lighting tower in the spaces bellow.

Always use these numbers when referring to your YANMAR Lighting tower.

Model name

:

Serial Number (Lighting tower)

:

Serial Number (Generator)

:

Your YANMAR

Dealer

:

Address

:

Phone

: General

1. Introduction • This Operation & Maintenance Manual for the YANMAR Lighting tower and air cooled diesel generator are designed to provide you with important information and suggestions necessary for using the machine with safety and efficiency. Please be sure to read through the manual before using the machine, to make yourself familiar with the procedures and instructions for operating, inspecting and servicing.

Keep in mind that failure to observe the precautions given in the manual or using any procedures not prescribed in the manual may cause a serious accident.

• Do not attempt to operate the machine before making yourself familiar with the contents of the manual.

• Personnel responsible for using the machine must keep the manual at hand and review it periodically.

• If the manual should be lost or damaged, promptly order a new copy from the dealer.

• When you transfer the machine to another user, always transfer the manual as well.

• We at YANMAR provide customers with products in compliance with all applicable your country’s regulations and industrial standards. If you are using a YANMAR machine purchased abroad, the machine may lack some safety devices. Please consult your dealer to confirm whether or not that machine is in compliance with all applicable your country’s regulations and industrial standards.

• Some machine specifications may differ from those that are described in this manual because of improvements in its design and performance. If you have any questions about the contents of the manual, don’t hesitate to contact your dealer.

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2. Safety Information • The YANMAR lighting tower is designed to give safe and dependable service provided that it is operated according to instructions.

Read and understand the Operation & Maintenance Manual before operating the lighting tower. Failure to do so could result in personal injury or equipment damage.

• The following signal words have been used in this manual and on the safety signs to indicate the seriousness of the hazards that could be encountered by failing to comply with the applicable product warnings, as follows: Could result in death or catastrophic bodily injury.

Could result in bodily injury.

Could result in property damage.

The signal word "IMPORTANT" has been utilized in this manual to denote those user directions that must be followed to assure the safe operation and maintenance of the lighting tower.

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3. Contents General 1. Introduction ......................................................................................................................................0-1 2. Safety Information ............................................................................................................................0-2 3. Contents ...........................................................................................................................................0-3 SAFETY 4. Basic Precautions ............................................................................................................................1-2 5. Operating Precautions .....................................................................................................................1-4 5-1. Precautions before starting the engine ....................................................................................1-4 5-2. Precautions starting the engine, working and parking .............................................................1-5 5-3. Precautions for transportation..................................................................................................1-7 5-4. Precautions for electric shock, short circuit, and battery..........................................................1-9 6. Precautions for Servicing ...............................................................................................................1-10 7. Location of Warning Labels............................................................................................................1-13 7-1. Warning labels and location...................................................................................................1-13 SPECIFICATIONS 8. Lighting tower ...................................................................................................................................2-2 OPERATION 9. Lighting tower ...................................................................................................................................3-2 9-1. Product overview .....................................................................................................................3-2 9-2. Loading generator....................................................................................................................3-3 9-3. Replacing balloon and lighting units ........................................................................................3-6 9-4. Replacing consumable parts....................................................................................................3-9 9-5. Operating each part ...............................................................................................................3-14 MAINTENANCE 10. Lighting tower .................................................................................................................................4-2 10-1. Periodic checks, maintenance and storage ...........................................................................4-2 10-2. Unclear points or problems ....................................................................................................4-4 TROUBLESHOOTING 11. Lighting tower .................................................................................................................................5-2 ORDERING REPLACEMENT PARTS AND SERVICE CALL 12. Ordering Replacement Parts and Service Call...............................................................................6-2 NOTES 13. Maintenance Log............................................................................................................................7-2 14. Notes ..............................................................................................................................................7-5 0-3

MEMO

0-4

SAFETY

Never attempt to operate or service this lighting tower until you have first read and understood all of the applicable Safety Instructions that are set forth in this Manual.

The failure to comply with all relevant Safety Instructions could result in bodily injury.

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4. Basic Precautions Read operation and maintenance manual • Do not attempt to operate or service the machine before making yourself familiar with the contents of the manual.

• Know how to stop the generator quickly and understand how to operate all of the controls. Never permit anyone to operate the generator without proper instruction.

Wear proper clothing and safety items • Do not wear loose clothing or jewelry that can be caught on the handle, bar and other machine parts. Also avoid wearing working clothes stained with oil as they can ignite.

• Be sure to wear a helmet, safety goggles, safety shoes, a mask, gloves and other protective items, as appropriate.

Take particular precautions when generating metal debris, when striking metal objects with a hammer or when cleaning components with compressed air.

Also make sure there are no persons near the machine.

Alcohol • Never operate the machine after consuming alcoholic beverages, or while you are under the influence of alcohol or if you feel ill or unwell, as that could result in accidental bodily injury to yourself or others.

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4. Basic Precautions

Keep fuel and oil away from sources of ignition • Open flames can ignite fuel or oil, which are flammable and dangerous.

Special attention must be paid to the following matters.

• Keep flammable materials away from lighted cigarettes or matches, or any other sources of ignition.

• Never refuel while the engine is running. Smoking during refueling must be strictly prohibited.

• Firmly tighten the caps on the fuel.

• Store fuel and oil in a cool and well-ventilated place where they are not subjected to direct sunlight.

• Fuel and oil must be stored in a place which meets all applicable safety regulations. Unauthorized persons should not be allowed entry.

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5. Operating Precautions 5-1. Precautions before starting the engine

Ensure the safety of your workplace • Before starting the machine, check to see if there are any hazards in your working area.

Prevent fire • Wood chips, dead leaves, trash and other flammable materials in proximity to the engine are hazardous as they may cause fire.

Always check and keep your machine clear of these flammable materials.

• Check for any leaks from fuel or lube oil lines. Repair faults and clean spilled oil as necessary.

• Check to see where fire extinguishers are located and know how to use them.

• To prevent fire hazards and to provide adequate ventilation, keep the generator at least 1meter away from buildings and other equipment during operation.

• Make sure there are no flammables in the direction of the exhaust opening to prevent the flames from igniting them.

Provide adequate ventilation when working in an enclosed area • Engine exhaust gas is harmful to the human body and its inhalation is extremely hazardous. When starting the engine in an enclosed area, open the windows and doors for ventilation.

• When using the generator indoors or inside tunnels, check for any gas from the exhaust gas pipe line extended to the outdoors before initial start up for the day.

Repair faults to prevent exhaust gas poisoning.

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5. Operating Precautions

5-2. Precautions starting the engine, working and parking

Precautions for set up • Never use the lighting tower in a wind of 22 mph (10 m/s) or more, to prevent it from overturning.

• [For balloon type] Lower the mast when using the lighting tower in such a strong wind as deforms the balloon, to prevent it from overturning.

• Set the lighting tower on the stable and flat ground, to prevent it from overturning. Never use it on a slant of 5 degrees or more.

• Use the outrigger to prevent the lighting tower from overturning.

• Apply the parking brake and also provide stoppers using blocks for the wheels so that the lighting tower will not move.

• If no generator is loaded, put the weight about 220lbs.(100kg) to prevent the lighting tower from over turning.

• The overturning risk varies according to the setting situation. For extra safety, use a rope and blocks to steady the lighting tower.

• To prevent electric shocks, always connect to the ground.

Tires • Set the air pressure in the tires for 28.4 to 35.5 psi (196 to 245 kPa).

• The air pressure lower than the above spec. could be dangerous as the brake power is weakened.

Precautions for adjusting height of mast • Be careful not get your fingers caught in the mast when raising and lowering the mast.

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5. Operating Precautions

Keep away from electric power lines • Working in the vicinity of overhead electric power lines presents a very serious hazard and special precautions must be taken. For purposes of this manual you are considered to be working in the vicinity of overhead power lines when the mast can reach to within the minimum safe distances shown below.

• To determine the transmission voltage at the working site, contact the electric utility concerned.

Power distribution

Transmission line

Transmission voltage (V)

Minimum safe distance [ft.(m)]

100/200 or less

6.6 (2) or more

6600 or less

6.6 (2) or more

22000 or less

9.8 (3) or more

66000 or less

13.1 (4) or more

154000 or less

16.4 (5) or more

275000 or less

23.0 (7) or more

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5. Operating Precautions

5-3. Precautions for transportation

Precautions for loading and unloading the lighting tower • Be sure to use crane when lifting the lighting tower by the hanger.

• Never lift up the lighting tower at any points except the specified one. Using the other point could result in personal injuries.

• The lighting tower can be lifted in a well-balanced posture at the specified point when the generator is mounted and the mast is completely lowered.

• Lower the mast fully when moving or lifting the lighting tower. Failure to do so could cause the wire to be come off or the lighting tower to be overturned and result in personal injuries.

• Make sure that the generator is loaded when conveying lighting tower by forklift. Failure to do so could cause the lighting tower to fall down and result in bodily injuries.

• Be sure to insert forks at marked position exactly under pipe frame of the base plate.

• Be careful not to make a sudden stop or a short turn when conveying lighting tower by forklift, to prevent it from falling down.

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Pipe frame

5. Operating Precautions

Precautions for transporting • The lamps or the generator could be damaged if the lighting tower gets a shock.

• Apply the parking brake as well as tie the lighting tower up with a rope when transporting it by a truck.

• Always tighten the adjust lever and the bolt firmly and make sure that the balloon or the lamp stand is fixed to the mast before transporting the lighting tower, to prevent it from falling down or being damaged in transport.

• Always lower the mast fully and lag down the balloon or fold the lamp stand before transporting the lighting tower, to prevent the balloon or the lighting units from bumping into a tunnel or against a guard during transport in a truck.

• [For balloon type]Be sure to cover the balloon with the cover and close the cover tightly with the buckle, to prevent it from blowing off in transport.

Model

Height in storage style

Balloon type

5.7ft. (1750 mm)

Spotlight type

5.6ft. (1700 mm)

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5. Operating Precautions

5-4. Precautions for electric shock, short circuit, and battery

Precautions for electric shock and short circuit • To prevent electric shocks or electric leaks, never use or left lighting tower during storm or lighting.

• Never touch the plugs and the electric terminals when the lighting tower is in operation to prevent electric shocks.

• Make sure to keep control panel and switches dry to prevent electric shocks.

• Take great care when handling the generator in the rain or at the humid place.

This may cause short circuits and electric shocks during operation.

• Before starting the engine, make sure of no cut or damage on power cord.

• Before starting the engine, make sure to turn the lamp switches (for lighting tower) to their "OFF" position on the control panel.

If the switches are not "OFF", the sudden load of the lamps when the generator is started could cause electric shocks.

• Check the insulation resistance of the generator periodically to prevent short circuits and electric shock.

(Contact your Yanmar dealer for measurement.)

Precautions for battery • The battery electrolyte contains dilute sulfuric acid, which can severely burn the eyes or skin. Always wear safety goggles and protective clothing when servicing the battery. If contact with the eyes or skin should occur, flush with a large amount of water and obtain prompt medical treatment.

• Because flammable hydrogen gas is produced by the battery, ignition and explosion may occur.

Keep flames and sparks away from the battery.

• If you swallow battery electrolyte by mistake, drink a large amount of water, milk, or fresh eggs, and obtain medical treatment immediately.

• Before checking or handling the battery, be sure to stop the engine and turn the starter switch to the "OFF" position.

• Be careful not to cause a short circuit by placing a tool across the terminals of the battery.

• If a terminal connection is loose, sparks may be generated due to contact failure, causing possible ignition and explosion. Be sure to connect the terminals securely.

• Do not use the machine with the battery which is short of battery electrolyte. The shortage of battery electrolyte not only will reduce the life of the battery but also could cause an explosion.

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6. Precautions for Servicing Use appropriate tools • Using damaged or worn tools or using tools inappropriate for the required application is very dangerous, and may also cause damage to the machine. Make sure to use the tools that are appropriate for the specific job.

• To prevent electric shocks, never maintain/service in rain or wet condition.

Keep unauthorized persons away • Never admit any persons into the work area who are not taking part in the work. Be conscious of the safety of other persons.

Be especially careful when grinding, welding, or using a large hammer.

Precautions for fueling and oiling • Be sure to stop and to cool the engine before refueling.

• Do not overfill the fuel tank to prevent fuel from spilling out due to expansion.

• Spilled fuel and oil could cause a fire and they are dangerously slippery. Wipe up spills immediately.

• Close the fuel cap and oil cap securely.

• Never use fuel for cleaning.

• Provide good ventilation when replenishing fuel or oil.

Precautions for handling the lamp • Be sure to stop the engine before replacing the lamp with a new one. Failure to stop the engine could result in electric shocks.

• The lamps are hot when they are on or right after they are turned off. Never touch the lamp until it gets cold to prevent burns • Be sure to replace any damaged or broken lamp with a YANMAR genuine lamp. Failure to do so could cause the lamp to burst, resulting in bodily injury.

• Keep the operator and the balloon dry when replacing the lamps so that the lamps should not get wet or dirty.

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6. Precautions for Servicing

Precautions for handling the balloon (for balloon type) • Never touch or unzip the balloon when the lamps are on, to prevent burns.

• Keep the envelope away from the fire and do not touch it with a sharp-edged tool, to prevent damage to it.

• A damaged envelope will not be inflated enough, and cause foreign matter to get into the balloon and moisture to sit on the surfaces of the lamps, which might not light.

• The lamps are very hot right after turned off. Never touch them right after they are turned off, to prevent burns.

• Do not house the balloon until lamps get cold, to prevent the envelope from damage.

• Cover the balloon with the cover after use, to prevent the envelope from degrading.

Disconnect battery cable • Disconnect battery cables before performing any maintenance.

If battery cables are connected, the generator may suddenly start and result in injuries.

Precaution for lifting up the generator • Never lift up the generator at anything but the specified lifting eye. This may cause a hazardous fall of the generator and result in personnel injuries.

Prevent burns • Never touch the muffler, muffler cover or engine body while the engine is running or hot.

• Never perform inspections and maintenance while the engine is hot.

• Never check, refill or change the lube oil, and never replace the lube oil filter while the engine is running or hot after it had been running..

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6. Precautions for Servicing

Processing wastes • Do not dispose of waste oil in the sanitary sewer system.

• Always drain the oil from the engine into a secure container and never directly to the ground.

• When disposing of toxic wastes such as fuel, oil, solvent, filters and spent batteries, comply with all applicable disposal regulation.

Neglecting these may cause environmental pollution.

Modification not authorized Never modify this product or release the limit devices (which limit engine speed, fuel injection quantity, etc.).

Such modification or release will impair the safety and performance of the product and functions and result in shorter engine life.

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7. Location of Warning Labels

• There are a number of warning labels on the machine. Full descriptions of all warning labels and their locations are reviewed in this section. Periodically confirm whether all warning labels are still mounted in their correct locations and can be easily read.

• If a warning label is missing, damaged or cannot be read, it must be promptly replaced. Also, if a warning label was mounted on a part that is replaced, a new warning label must be installed on the replaced part.

• Contact your dealer to obtain new labels. The part code number is shown on each warning label as well as on the reproductions in this manual.

7-1. Warning labels and location To insure safe operation, the warning labels have been affixed. Their locations are shown below. Periodically confirm whether the warning labels are still affixed on their locations and can be easily read.

If a warning label is missing, damaged or can not be read, it must be promptly replaced, ordering it in the same way as for the service parts. Also, if a warning label was affixed on a part which is replaced, a new warning label must be affixed on the replaced part.

Contact your dealer to obtain new labels. The part code number is shown on each warning label shown on next page.

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7. Location of Warning Labels 7-1-1. Location of warning labels

UP (FOR SPOTLIGHT TYPE)

Direction of winch 1-7510073-30

Always tighten adjust lever firmly except when changing direction of lamp stand, to prevent lamp stand and lamps from falling down or being damaged in transport.

DOWN 1-7510073-30

Keep clear of pinch-point when raising lamp stand, to prevent bodily injury.

Never use Lighting Tower in a strong wind of 10 m/s or more, to avoid overturning. [for balloon type] Lower the mast when using the Lighting Tower in such a strong wind as deforms the balloon, to prevent it from overturning.

Never use Lighting Tower on a slant of 5 deg. or more, to prevent any accident resulting from overturning or drifting of Lighting Tower.

Always apply parking brake. Place blocks to prevent wheels from moving.

ELECTRICAL SHOCK HAZARD Always pay attention to obstacles overhead, such as power lines, when raising mast.

Lower mast fully when moving or lifting Lighting Tower, to prevent it from overturning or wire from coming off.

Be sure to use hanger when lifting Lighting Tower with crane.

1-7510067-31

Handling of lamp stand 1-7510067-31

Always use outrigger when raising mast, to avoid overturning.

DEPLOYMENT OF OUTRIGGER A Setting

Light Boy logo 1-7510004-30

B Release

TIRE AIR PRESSURE 28.4 to 35.5 psi (245 to 294 kPa)

SETTING : Deploy outrigger and push downward on A lightly if necessary.

RELEASE : To unlock outrigger, push downward on B. Grab hold of outrigger and place in stow position.

1-7510068-32

* The figure is showing deployed position.

Tire air pressure 1-7510068-32

Ground 1-7510100-30

Read and understand Operation & Maintenance Manual before using Lighting Tower.

Carry out periodic checks listed in Operation & Maintenance Manual before using Lighting Tower.

Follow the instruction in Operation & Maintenance Manual when storing Lighting Tower.

Never maintain/service in rain or wet conditions.

Never use during storm or lightning.

Turn off power before checking or servicing, unless power is required.

Lighting tower should only be used in temperatures between 23-104 degrees Fahrenheit (-5 to 40 degrees Celsius).

BURN HAZARD Lamps and lighting units are hot while lamps are on and right after they are turned off. Never touch them to prevent skin burns.

PRECAUTIONS FOR USE

Make sure that generator is loaded when conveying Lighting Tower by forklift.

Be sure to insert forks at marked position exactly under pipe frame of base plate.

A-4001164-00

Forklift A-4001164-00 (Base plate : front,rear,right and left side)

Be sure not to give lamps a high impact when moving or transporting Lighting Tower, to prevent lamps from damage or breakage.

Lower mast completely to slacken the stretched wire rope when storing Lighting Tower.

Replace wire rope immediately if there is corrosion or loose threads on it.

Once lamps are turned off, they will take about 20 minutes to light again.

Wait until lamps cool down, and then switch them on.

Start or stop generator after turning off lamps.

A-4001061-00

Commonness A-4001061-00

Yanmar logo A-4000828-00 (Mast : left side)

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7. Location of Warning Labels

Be sure to use YANMAR genuine lamp.

Parts NO. :1-3010010-10 Name : Lamp HIE400W/C/U/EURO/4K 1-7510089-31

Genuine lamp 1-7510089-31

ELECTRICAL SHOCK HAZARD Always stop generator before replacing lamps, to prevent electric shock.

Never touch any terminals by wet hand during operation, to prevent electric shocks.

A-4001063-00

Electrical shock hazard A-4001063-00

BURN HAZARD Lamps and lighting units are hot while lamps are on and right after they are turned off. Never touch them to prevent skin burns.

Make sure to remove both cover and primary cover from balloon when turning lights on to prevent cloth envelope from damage.

If covers are on balloon, an alarm buzzer will sound.

1-7510110-32

A-4000850-00

Burn hazard/lamp A-4000850-00

Alarm buzzer 1-7510110-32

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MEMO

1-16

SPECIFICATIONS

2-1

8. Lighting tower Type

High-frequency lighting tower

Model

Balloon type(LB446HB-1) Rated voltage

V

130

Type¯Number of lamp Lamp

Total luminous flux

Metal Halide Lamp (HIE400W/C/U/EURO/4K¯4) lm

160000

Projection angle Balloon

Diameter

Variable ft.in.(mm)

3’9" (1150)

Type of mast Lighting

Mast

tower

Manual winch ft.in.(mm)

8’ to 14’7" (2440 to 4470)

In operation

ft.in.

5’1"¯5’2"¯8’¯14’7"

5’1"¯5’2"¯6’8"¯13’6"

(L¯W¯H)

(mm)

(1550¯1600¯2440 to 4470)

(1550¯1600¯2060 to 4160)

In storage

ft.in.

3’1"¯2’8"¯5’7"

3’4"¯3’4"(2’8")¯5’6"

(L¯W¯H)

(mm)

(945¯800¯1750)

(1040¯920¯1700)

lbs.(kg)

214 (97)

231(105)

Cart dry mass Model

YDG25HSS-EXB

Rated output Engine & Generator

6’8" to 13’6" (2060 to 4160)

4 tired wheels Ø12" (Ø300mm)

Wheel

Dimension

-

Telescopic 3 stage mast

Mast operation Min. & max. height

Spotlight type(LB446H-1)

kVA

1.7

Starting system

Electric starting

Fuel oil/Tank capacity Continuous operation without re-supplying fuel oil

gal.(L)

Diesel fuel/4.0 (15)

hrs

18*

Emergency stop system Dry mass

Engine stop device by low level oil sensor lbs.(kg)

Mass

287 (130)

lbs.(kg)

501(227)

518 (235)

*Note : The operating time of a generator is measured continuously using a lighting tower in the condition of the generator fitted after breaking in.

Type

Fan motor

Model

DC fan motor

Rated voltage

12V

Ampere

1.08A

Pressure

152Pa

• The specifications could be changed without notice because of the improvements.

• An actual article could differ from the figure in this manual.

2-2

OPERATION

3-1

9. Lighting tower 9-1. Product overview 9-1-1. Parts name Primary cover Zipper

Envelope

Mast

Buckle Generator Cable

Hanger

Winch

Cover holder

Generator holder

Winch handle

Wheel stopper (for Generator)

Handle bar Weight (for Outrigger)

Wheel (of Generator) Outrigger

Parking brake Cart Brake pedal

Wheel

Lamp Lamp guard Lighting unit Frame pipe

Lamp brace

Fan motor

Lamp stand

Adjust lever

Cover

Adjust lever

3-2

Lamp

9. Lighting tower

9-2. Loading generator • Read this section when loading the generator.

• If the generator has been loaded and ready for use, refer to Section "9-4. Replacing consumable parts" .

9-2-1. Loading of generator 1) Apply the brake to prevent the cart from moving. (Refer

Wheel stopper

to Section “"9-5-2. Operation of parking brake"” for the instruction of applying brake.)

2) Remove the stopper bolts to remove the wheel stoppers on both sides at front of the cart.

Stopper bolt (M12)

Brake pedal

3) Use a rope to lift the generator up with a crane.

Rope

• Use the lifting eye on the top of the hood to lift up the generator. Lifting it up with a rope at the handle bar could damage or drop off the generator.

• Be sure to keep away from the area beneath the generator which is lifted up.

4) Put the generator on the cart slowly.

Rope

5) When setting the generator, the inner surface of the wheel below the generator’s control panel should be in contact with the rail as shown in the right figure.

Rail

3-3

9. Lighting tower 6) Fix the handle bar at the rear side of the generator to the generator holder in order to completely put the genera-

Generator holder

tor on the cart.

Handle bar

7) Install the wheel stoppers, which have been removed, and tighten up the both sides with the stopper bolts (M12) to secure the wheels.

Tightening torque : 28 to 38 ft•lbf (38 to 51 N•m) Stopper bolt (M12)

8) Loosen the bolt (M12) for the hanger and connect the eyebolt of the generator to the shackle.

Bolt (M12)

Hanger

9) Lift the hanger upward so that there is no room in connection between the shackle and the lifting eye of the generator, and then tighten the bolt (M12).

Lifting eye

Tightening torque : 28 to 38 ft•lbf (38 to 51 N•m) 9-2-2. Connection of generator power cable 1) Remove the connector cover at the side of the mast.

(Remove the 3 screws.)

Connector cover

2) Securely plug the coupler of the generator power cable as shown in the right figure. (Disconnect the coupler pressing the part indicated by arrow as the coupler has a lock.)

3-4

Shackle

9. Lighting tower 3) Install the connector cover. (Securely tighten the 3 screws.)

Connector cover

4) Fix the cable with a wire band as shown in the right figure.

Wire band

9-2-3. Unloading of generator When unloading the generator, first follow the reverse order of the procedure of Section ""9-2-2. Connection of generator power cable"", and then the reverse order of the procedure of Section ""9-2-1. Loading of generator"".

3-5

9. Lighting tower

9-3. Replacing balloon and lighting units

Do not replace the balloon or the lighting units immediately after the lamps are turned off to prevent burns because the lamps are hot.

9-3-1. Removal of balloon (for balloon type) 1) Rise the balloon vertically by operating the adjust lever and tighten the adjust lever.

2) Remove the connector cover at the bottom of the balloon.

(Remove the 2 screws.)

3) Disconnect the coupler pressing the part indicated by arrow as the coupler has a lock.

4) Loosen the setscrew and lift off the balloon from the mast.

3-6

9. Lighting tower 9-3-2. Reinstallation of balloon (for balloon type) Reinstall the balloon in the reverse order of the rimoval procedure.

Tightening torque: 24 to 33 ft.lbf (33 to 45 N.m)

Be sure to tighten the bolt completely. Failure to do so could cause the balloon to fall down and result in personnel injuries.

9-3-3. Removal of lighting units (for spotlight type) 1) Remove the connector cover at the lamp stand.

(Remove the 2 screws)

2) Cut the wire band and remove the clamp.

(Remove the 2 screws)

3) Disconnect the coupler pressing the part indicated by arrow as the coupler has a lock.

4) Loosen the adjust lever and lift off the lamp stand from the mast.

3-7

9. Lighting tower 9-3-4. Reinstallation of lighting units (for spotlight type) Reinstall the lighting units in the reverce order of the removal Tightening torque: 24 to 33 ft.lbf (33 to 45 N.m)

Be sure to tighten the adjust lever completely. Failure to do so could cause the lamp stand to fall down and result in personnel injuries.

Be careful not to lose removed screws and connector covers.

9-3-5. .Storage of removed balloon and lighting units [Balloon] zWipe off mud and dirt. zCover the balloon with the cover. zAvoid a place exposed to rain or with high humidity to store the balloon.

[Lighting units] zWipe off mud and dirt, supply grease and grease up. zCover the lighting units with the cloth not to gather dust. zAvoid a place exposed to rain or with high humidity to store the lighting units.

3-8

9. Lighting tower

9-4. Replacing consumable parts Make sure that the lamp should be replaced with a YANMAR genuine lamp. Other types of lamp could not light or provide their performance.

YANMAR genuine lamp 400 W

Name

Parts No.

Metal halide lamp HIE400W/C/U/EURO/4K

1-3010010-10

Make sure that the lamp should be replaced with a YANMAR genuine lamp. Failure to do so could cause the lamp to explode and result in bodily injury.

9-4-1. Balloon type 1) Replacement of lamp

Be sure to stop the engine before replacing the lamp with a new one to prevent electric shocks.

• Do not replace the lamps immediately after the lamps are turned off to prevent burns because the lamps are hot.

• Replace the lamps after cooling them sufficiently.

Remove the balloon from the mast when changing broken lamps to prevent bodily injury.

(1) Lay down the balloon flatly with the adjust lever. (For lay-down of the balloon, refer to Section ""9-5-6. Storage of balloon and lighting units"".)

(2) Open the zipper at the bottom of the balloon and roll up the envelope of the balloon.

Tighten the adjust lever after laying down the balloon.

If you unzip the balloon by forced, the envelope is broken and become unusable.

3-9

9. Lighting tower (3) Loosen each cramp of 4 frame pipes.

Loosen downside cramps only.

(4) Extend the frame about 12in. (30cm) long, and tighten cramps.

Never extend frame longer than necessary to prevent the frame from damage and overturning.

(5) Expand the head of the lamp guard, then turn the lamp counterclockwise to remove the lamp.

(6) Screw a new lamp into the socket, then close the head of the lamp guard.

Never screw the lamp by force to prevent breakage.

(7) Loosen each cramp of four frame pipes and shorten the frame completely.

3-10

9. Lighting tower (8) Tighten all cramps.

(9) Put the envelope over the frame, and zip it up.

2) Replacement of envelope (1) Lay down the balloon flatly with the adjust lever. (For lay-down of the balloon, refer to Section ""9-5-6. Storage of balloon and lighting units"") (2) Open the zipper at both sides of the balloon.

(3) Remove the envelope of the balloon from the frame.

(4) Put a new envelope on the frame so that the grommet side of the envelope should come downward.

(5) Zip up the both side of the balloon.

3-11

9. Lighting tower 9-4-2. Spotlight type 1) Installation of lamp

• Be sure to stop the engine before replacing the lamp with a new one to prevent electric shocks.

• Do not replace the lamp immediately after the lamps are turned off to prevent burns because the lamps are hot.

• Replace the lamps after the lamps have cooled suffocatingly.

(1) Screw the lamp into the socket.

Never screw the lamp by force to prevent breakage.

(2) Fix the reflex mirror and the socket together so that the cables of the two upper lighting units should come downward and the cables of the two lower lighting units should come upward.

Make sure that the cables are not upside down.

3-12

9. Lighting tower (3) Fix all three latches in order to stabilize the reflex mirror to the socket.

2) Removal of lamp Remove the lamp in the reverse order of the procedure of the “Installation of lamp” (3) (2) (1).

3-13

9. Lighting tower

9-5. Operating each part 9-5-1. Handle operation 1) Forward and reverse travel Pushing the handle bar forward makes the lighting tower to travel forward and pulling back the handle makes it to travel reverse.

2) Right and left travel Turn the handle bar in the left (right) direction, and the front wheels turn in the right (left) direction, respectively.

The wheels are designed to turn in the opposite direction of the handle operation so that you can apply the force easier.

9-5-2. Operation of parking brake 1) Braking Step on the brake pedal and draw it toward you, so that the wheels are locked to apply the brake.

2) Releasing brake Push the brake pedal forward to release the brake lock.

When parking on a sloping road or ground, be sure to provide stoppers using stones or blocks for the wheels with as well as apply the brake lock. Without them, the lighting tower could move and cause accidents or injuries.

3-14

9. Lighting tower 9-5-3. Outrigger 1) Setup (1) Turn out the outrigger received in the side of the cart.

The outrigger is automatically locked.

(2) Lightly step on the places indicated by arrow when the weights for outrigger do not work well.

Always use the outrigger to prevent the lighting tower from overturning when raising mast. In order to increase safety, fix it with a rope and blocks as well.

2) Storage (1) Strongly step on the places indicated by arrows to set up the weights.

(2) Set up the weight of the backward outrigger and turn to store the outrigger.

3-15

9. Lighting tower 9-5-4. Operation of balloon and lighting unit [Operating balloon (for balloon type)] 1) How to detach the cover from the balloon (1) Remove three velcro straps on the cover.

(2) Remove the cover from the balloon.

(3) Fold the detached cover and buckle it up with the band Hanger

on the hanger.

Band

2) How to detach the primary cover from the balloon (1) Loosen the string of the primary cover.

(2) Roll up the cover.

(3) Fold the cover and house it in the bag, then zip it up.

3-16

9. Lighting tower 3) Function of the adjust lever Operate the adjust lever when raising and storing the balloon and adjusting the angle and direction of light.

(1) Loosening the position of the balloon Turn the adjust lever to clockwise. (A) (2) Tightening the position of the balloon Turn the adjust lever to counterclockwise. (B)

(3) Changing the angle and direction of the balloon Push down the adjust lever, and the balloon will be raised (C). Pull up the adjust lever, and the balloon will be laid down (D). Swing the adjust lever, and the balloon will turn around together (E).

4) How to raise the balloon (1) Loose the position of the balloon.

(2) Raise the balloon.

(3) Tighten the position of the balloon.

Be sure to tighten the position of the balloon completely. Failure to do so could cause the balloon to fall down and result in personnel injuries.

Keep clear of pinch-point when raising the balloon to prevent bodily injury.

Pay attention to obstacles in the direction the balloon will be raised.

3-17

9. Lighting tower 5) How to adjust the angle and direction of light (1) Loosen the position of the balloon.

(2) Change the angle and direction of the balloon.

Pay attention to obstacles in the direction the bal-

Adjust lever

loon will be laid down.

• Do not adjust the angle and direction without fixing the balloon on the mast.

• Keep clear of pinch-point when adjusting the angle and direction to prevent bodily injury.

(3) Tighten the position of the balloon.

Be sure to tighten the position of the balloon completely. Failure to do so could result in personnel injuries.

6) How to adjust the height of light Turn the winch handle to raise or lower the mast for adjusting height of light. Turning the winch handle to clockwise and counterclockwise allows the mast to be raised Winch handle

and lowered respectively.

Up

Down

Pay attention to obstacles overhead, such as electric wire, when raising the mast.

3-18

9. Lighting tower [Operating lighting units (for spotlight type)] 1) How to rise the lamp stand (1) Supporting the lighting unit with one hand, pull up the fold lever. The lever is pushed up by a spring force.

Fold lever

(2) Push up the lighting unit and pull down the fold lever to lock the lamp stand.

Keep clear of pinch-point when operating the fold lever to prevent bodily injury.

2) How to turn all the lights to the same direction.

Loosen the adjust lever and turn the lamp stand to any direction.

Always tighten the adjust lever firmly except when changing direction of lamp stand to prevent lamp stand and lamps from falling down or being damaged in transport.

3) How to turn the respective lights Turn each lighting unit holding its arm on the bolt for the lighting unit. It is not necessary to loosen the nut for the lighting unit.

Arm

3-19

9. Lighting tower 4) How to adjust the angle of the lights Hold the socket of the lighting unit to tilt the light to any direction.

As the coil springs hold the position of the lighting unit, it is not necessary to loosen a bolt when adjusting the angle.

The lighting unit is hot while lamps are on and right after they are turned off. Take great care in the operation.

5) How to adjust the height of lights Turn the winch handle to raise or lower the mast for adjusting height of lights. Turning the winch handle to the right (clockwise) and left allows the mast to be raised and lowered respectively.

Winch handle

Pay attention to abstracts overhead, such as electric wire, when raising the mast.

9-5-5. Turning light on, off and on again The generator is unstable just after started and in standstill condition. Never turn on the lamps until the generator becomes stable. Be sure to turn off the lamps before stopping the engine.

The generator could be broken down if the engine is stopped when the lamp switch is on.

3-20

9. Lighting tower 1) Turning light on • Check the engine oil, battery fluid and fuel oil (diesel fuel) of the generator.

YDG25HVS-EXB

• Make sure that the cover is detached.

Starter key

[For balloon type] Make sure to remove both the cover and the primary cover from the balloon when turning the lights on to prevent the cloth envelope from damage.

If the covers are on the balloon,an alarm buzzer will sound.

(1) Turn off the lamp switches of the generator.

(2) Start the engine.

For starting the engine, refer to Operation Manual of YDG25HVS-EXB. • Warm up the engine for about 3 minutes by idling.

(3) Turn on the lamp switches of the generator.

• Lamps will give a fully bright light in about 5 minutes.

2) Turning light off (1) Turn off the lamp switches of the generator.

(2) Cool down the engine for about 5 minutes by idling before stopping the generator.

• Be sure to stop the engine last of all.

3) Turning light on again (The lamp needs an interval to light again once it is turned off.)

• Confirm the lamp switches of the generator are off.

• Wait until the lamps fully get cold for about 20 minutes.

(1) Start the engine, and then turn on the lamp switches.

• The lamps and the balloon (or lighting unit) are hot while lamps are on and immediately after they are turned off.

• To prevent burns, take great care in handling them.

3-21

Lamp switch

9. Lighting tower 9-5-6. Storage of balloon and lighting units [ Storage of balloon (for balloon type)] 1) Storage of balloon

Do not house the balloon until lamps get cold, to prevent the cloth envelope from damage.

Be careful not to get burned because lamps are hot right after turning them off.

(1) Turn the adjust lever to louse the position of the bal-

Balloon

loon.

(2) Lay down the balloon flatly by operating the adjust lever slowly.

(3) Turn the adjust lever to tighten the position of the balloon.

Adjust lever

Be sure to tighten the the position of the balloon completely. Failure to do so could result in personnel injuries.

• Keep clear of pinch-point when laying down the angle to prevent bodily injury.

2) Covering of balloon with primary cover.

(1) Unzip the bag on the top of the balloon.

Zipper

(2) Stretch the inside primary cover and cover the balloon

Primary cover

with it.

• Do not cover the balloon immediately after the lamps are turned off to prevent the envelope from damage.

• Cover the balloon after the lamps have cooled sufficiently.

3-22

Bag

9. Lighting tower (3) Tighten the string of the primary cover.

Buckle

3) Covering of balloon with cover.

(1) Detach the cover from the hanger and spread it, then

Balloon cover

cover the balloon with it.

• Do not cover the balloon immediately after the lamps are turned off to prevent the cloth balloon from damage.

• Cover the balloon after the lamps have cooled sufficiently.

(2) Put two velcro straps on the cover through the loop and Loop

attach them each. Close the cover with velcro strap on the entire bottom edge of the cover.

(3) Fold the corner on the topside of the cover and put the velcro strap through the loop and attach it.

Velcro straps

3-23

Loop

9. Lighting tower [ Storage of lighting unit (for spotlight type)] (1) Set the lighting units facing the front.

(2) Holding the lighting unit with one hand, pull up the fold lever

Keep clear of pinch-point when operating the fold lever to prevent bodily injury.

(3) Push down the lighting unit. Exerting force is required to turn it down because springs are installed.

After completely pressing down the lighting unit, push down the fold lever to lock the lamp stand.

3-24

Fold lever

MAINTENANCE

4-1

10. Lighting tower 10-1. Periodic checks, maintenance and storage 10-1-1. Periodic checks and maintenance Figure * B

Cart

Electric

Service item

Frame pipe

Check if it is not skew.

Replace.

L2

Lamp brace

Check if it is not loosen.

Replace.

L3

Lamp (Base)

Check if it is not loosened.

Screw in securely.

L4

Lamp

Check if bulb is not burned out or lamp is broken.

Replace.

L5

Pin contact

Check if it is not disconnected or loosened.

Connect securely.

L6

Nut

Check if it is not too loose.

Tighten properly.

L7

Hinge for lamp stand

Check if it moves smoothly.

Supply grease.

L8

Pivot for lamp stand

Check if it turns smoothly.

Apply grease.

L9

Front glass

Check if it is not dirty.

Wipe off dirt.

L10

Reflex mirror

Check if it is not too dirty or broken.

Wipe off dirt or replace.

B1

Envelope

Check if it is not broken or dirty.

Replace.

B2

Zipper

Check if it is not broken.

Replace.

B3

Buckle

Check if it not broken.

Replace.

B4

Mast

Check item

L1

Lamp

Balloon

Part

S

Fan motor

Check if it works well.

Replace.

M1

Mast sliding surface

Check if mast slides smoothly.

Apply grease.

M2

Wire rope

Check if it not damaged.

Apply grease or replace.

M3

Wire rope end

Check if end is not damaged caulking.

Replace.

M4

Winch

Check if brake works well.

Repair.

M5

Safety stopper

Slacken wire rope and check if latch sticks out.

Repair.

C1

Weight

Check if it moves smoothly.

Spray grease.

C2

Outrigger

Check if it moves smoothly.

Spray grease.

C3

Link of handle and wheels

Check if it is not loose linking.

Tighten securely

C4

Bolt for handle

Check if it is not loosened.

Tighten securely

C5

Brake pedal

Check if linking part moves smoothly.

Spray grease.

Replace.

C5

Brake pedal

Check if notch is not worn.

C6

Hanger

Check if installation is not loosened.

Fasten securely.

C7

Wheel stopper

Check if bolt is not loosened.

Tighten securely.

C8

Front wheel pivot

Check if it turns smoothly.

Supplying grease.

C9

Tire

Check if air pressure in tire is between 28.4 and 35.5 psi (245 and 294 kPa).

Adjust.

C10

Link for front shaft

Check linkage moves smoothly.

Spray grease.

C11

Brake

Check if it works well.

Adjust.

E1

Cable

Check if wire is not bared.

Replace.

E2

Terminal socket

Check if it is not disconnected or loosened.

Connect securely.

E3

Non-load voltage

Check if voltage is about 200 V.

Repair.

...Daily check {...Every 20 hrs. z...Every 100 hrs.

* B...Balloon type

...Every 500 hrs. S...Every 1000 hrs.

S...Spotlight type

• Refer to Section "13-2. List of periodic inspections" for the generator.

4-2

10. Lighting tower • Inspection points (Correspond to the left list)

B2

B1

B3

L1

L2 M1

L4 C6

E1

L3

M2

B4 E3

M3 M4

C7

M5

L3

C8 E2 C2

L7 L4 L6 L9 C1

C3

L5 C10

C9

C4 C5 L8

C11

L10

Checking and servicing the electrical system while the generator is running may cause short circuits. Be sure to turn off the lamp switch before checking and servicing it to avoid electric shocks.

Storage • Wipe off mud and dirt, supply grease and grease up.

• Lower the mast completely to slacken the stretched wire rope.

• Cover the balloon with the covers.

• For storage of the generator, refer to Section "11-4-6. Long term storage”.

• Apply the brake and avoid a place exposed to rain or with high humidity to store the lighting tower.

4-3

10. Lighting tower

10-2. Unclear points or problems If any instructions are unclear or if problems occur during operation of your lighting tower, complete the followings form and contact your YANMAR dealer.

1) Model and serial number of lighting tower being used Refer to Section "17. Ordering Replacement Parts and Service Call".

2) Condition At what stage of operation 3) Period of use Approximately … hours (See the hour meter of your generator.)

4) Other details of conditions at the time the problem occurred Details of conditions

4-4

TROUBLESHOOTING

5-1

11. Lighting tower Consult your YANMAR dealer about the items marked "{" Lamp Trouble

Lamp does not light

Light goes out or blinks

Lamp only lights for a short time

Balloon is not inflated (for balloon type)

Check item

Content of work

• Are couplers securely connected?

Connect power coupler correctly

-

• Is lamp switch of generator turned on?

Turn on switch.

-

• Isn’t lamp loosened?

Screw lamp securely.

-

• Are connectors correctly connected?

Connect disconnected connectors.

-

• Is voltage of generator normal? (Non-load voltage is about 200 V.)

Check connection of power cable.

Replace generator.

-

• Is model of lamp compatible?

Use YANMAR genuine lamp.

-

• Is initial pulse for lamp being outputted by generator?

Replace starter unit.

{

• Is lamp cold enough to light again?

(Interval of 20 to 30 min. is required to light again.)

Wait until lamp gets cold enough.

-

• Isn’t air cleaner element of generator clogged?

Clean element.

-

• Isn’t water collected in fuel tank of generator?

Drain water from fuel tank.

-

• Is voltage of generator normal? (Non-load voltage is about 200 V.)

Check connection of power cable.

Replace generator.

-

• Is initial pulse for lamp being outputted by generator?

Replace starter unit.

{

• Is lamp cold enough to light again?

(Interval of 20 to 30 min. is required to light again.)

Wait until lamp gets cold enough.

-

• Is voltage 115 to 135 V, and current 3.0 to 3.6 A while Repair or replace generator. operating generator?

-

• Isn’t ambient temperature too high (More than 104°F Move to proper place or provide good [40°C])? ventilation.

-

• Isn't the zipper opened?

Zip it up.

-

• Is fan motor working right?

Check or repair fan motor.

{

• Isn't the envelope broken?

Repair envelope with repairing sheet.

-

Mast Trouble Mast cannot be raised

Mast keeps on coming down

The mast cannot be lowered

Check item

Content of work

• Isn’t cable caught in mast?

Set caught cable free.

-

• Isn’t end of wire rope disconnected from winch?

Connect wire rope to winch.

-

• Does surface of mast slides smoothly?

Apply grease on sliding surface of mast.

-

• Is latch of winch effective?

Replace part if malfunction.

-

• Isn’t dram shaft on winch loosened?

Tighten dram shaft and check its operation.

-

• Does surface of mast slides smoothly?

Apply grease on sliding surface of mast.

-

• Isn’t brake disk part of winch held tight?

Holding winch handle securely, remove the latch and lower mast slowly.

(Repair.)

-

• Does safety stopper working correctly?

Winch up mast a little and lower mast by giving a load on it. (Repair.)

-

5-2

ORDERING REPLACEMENT PARTS AND SERVICE CALL

6-1

12. Ordering Replacement Parts and Service Call When ordering replacement parts or calling for service, let your dealer know the model designation and the machine serial number as well as the reading of the hourmeter.

࡮Serial number plate Generator) MODEL GEN. OUTPUT ENG. MODEL ENG. OUTPUT DISPLACEMENT SERIAL NO.

YDG25HVS-EXB 1.7 kW / 540 HZ L48 V6 3.0 KW (4.1 PS)/3600 rpm 0.219

YMNMAR DIESEL GENERATOR YMNMAR CO., LTD MADE IN JAPAN

Hourmeter

Serial number plate (Generator) Nameplate (Lighting tower)

6-2

NOTES

7-1

13. Maintenance Log Maintenance log Date

Machine hours

Service performed

7-2

13. Maintenance Log Date

Machine hours

Service performed

7-3

13. Maintenance Log Date

Machine hours

Service performed

7-4

14. Notes Notes

7-5

14. Notes

7-6

14. Notes

7-7

MEMO

7-8

-1

-1