Yanmar Lghting Tower LB446HB-1 H-1 LIGHT BOY Service Manual

FOREWORD This manual explains the service procedure for Yanmar lighting tower model LB446HB-1 & LB446H-1.

Please use this manual for correct, quick, safe servicing of the lighting tower.

Please be advised that the contents of this manual may be different from actual lighting tower because of any later modification of parts or specifications for improving the quality.

CONTENTS 1.Safety.................................................................................................................... 1-2 1-1. Warning Symbols.......................................................................................... 1-2 1-2-1. Service Shop (Location) .................................................................... 1-3 1-2-2. Working Wear ................................................................................... 1-3 1-2. Loading generator.......................................................................................... 1-3 1-2-3. Tools to Be Used............................................................................... 1-4 1-2-4. Parts .................................................................................................. 1-4 1-2-5. Bolt Tightening Torque ...................................................................... 1-4 1-2-6. Product Handling............................................................................... 1-4 1-2-7. Installation ......................................................................................... 1-5 1-2-8. Transport ........................................................................................... 1-5 1-2-9. Warning Labels ................................................................................. 1-6 2.Outline of Lighting Tower................................................................................... 2-2 2-1. Specifications................................................................................................ 2-2 2-2. External View and Components of Lighting Tower........................................ 2-3 3.Structure of Lighting Tower ............................................................................... 3-2 3-1. Outline of Structure....................................................................................... 3-2 3-2. Electrical Group ........................................................................................... 3-2 3-2-1. Balloon Unit ....................................................................................... 3-3 1) Balloon assembly ........................................................................ 3-3 2) Stand assembly............................................................................ 3-4 3-2-2. Lamp Stand Unit ............................................................................... 3-5 1) Lighting unit assembly.................................................................. 3-5 2) Lamp stand assembly .................................................................. 3-5 3-2-3. Power Cable Unit .............................................................................. 3-6 3-3. Mast Group .................................................................................................... 3-7 3-4. Outrigger group.............................................................................................. 3-8 3-5-1. Base Plate Unit ................................................................................. 3-9 3-5. Base Plate Group .......................................................................................... 3-9 3-5-2. Steering Unit ................................................................................... 3-10 3-5-3. Brake Unit ....................................................................................... 3-10 4.Disassembly and Assembly ............................................................................... 4-2 4-1. Before Starting Operation ............................................................................ 4-2 4-1-1. Grasp of Service History ................................................................... 4-2 4-1-2. Preparing the Necessary Tools, Parts and Materials ........................ 4-2

4-2. Disassembly and Assembly Procedures ..................................................... 4-2 4-2-1. General Instructions .......................................................................... 4-2 1) Disassembly ................................................................................. 4-2 2) Reassembly.................................................................................. 4-2 4-2-2. Disassembly Procedure of Each Assembly /Unit /Group .................. 4-3 4-2-3. Disconnection of Couplers ................................................................ 4-4 1) Removal of connector covers....................................................... 4-4 2) Disconnection of coupler .............................................................. 4-5 4-2-4. Removal of Balloon Assembly .......................................................... 4-6 4-2-5. Removal of Lighting Unit Assembly .................................................. 4-7 4-2-6. Removal of Pin (Socket) Contact ...................................................... 4-8 4-2-7. Removal of Stand Assembly ............................................................. 4-9 4-2-8. Removal of Lamp Stand Assembly ................................................... 4-9 4-2-9. Unloading of Generator ................................................................... 4-10 4-2-10. Removal of Mast Group ................................................................ 4-11 4-2-11. Removal of Outrigger Group ......................................................... 4-11 4-2-12. Disassembly of Balloon Assembly ................................................ 4-12 4-2-13. Disassembly of Stand Assembly................................................... 4-14 4-2-14. Disassembly of Lighting Unit Assembly ........................................ 4-14 4-2-15. Disassembly of Lamp Stand Assembly ......................................... 4-15 4-2-16. Disassembly of Power Cable Unit ................................................. 4-15 4-2-17. Disassembly of Mast Group .......................................................... 4-16 4-2-18. Disassembly of Outrigger Group................................................... 4-17 4-2-19. Disassembly of Base Plate Unit .................................................... 4-18 4-2-20. Disassembly of Steering Unit ........................................................ 4-19 4-2-21. Disassembly of Brake Unit ............................................................ 4-20 5.Inspection and Maintenance .............................................................................. 5-2 5-1. Electrical Group ............................................................................................. 5-2 5-1-1. Balloon Unit ....................................................................................... 5-2 1) Balloon assembly ......................................................................... 5-2 5-1-2. Lamp Stand Unit ............................................................................... 5-4 1) Lighting unit assembly.................................................................. 5-4 2) Lamp stand assembly .................................................................. 5-5 5-1-3. Replacement of Balloon Unit and Lamp Stand Unit .......................... 5-6 1) Replacement ................................................................................ 5-6 2) Storage of removed balloon unit and lamp stand unit .................. 5-6

5-1-4. Power Cable Unit .............................................................................. 5-6 1) Connection of power cable.......................................................... 5-6 2) Voltage check............................................................................... 5-7 3) Replacement of lamp cable.......................................................... 5-8 5-2-1. Mast Group ....................................................................................... 5-9 1) Shaft of mast ................................................................................ 5-9 2) Sliding surface of mast ................................................................. 5-9 3) Winch ........................................................................................... 5-9 5-2. Mast Group .................................................................................................... 5-9 4) Wire ............................................................................................ 5-10 5-4. Base Plate Group ........................................................................................ 5-12 5-4-1. Base Plate Unit ............................................................................... 5-12 5-4-2. Steering Unit ................................................................................... 5-12 5-3. Outrigger Group........................................................................................... 5-12 5-4-3. Brake Unit ....................................................................................... 5-13 5-5. Grounding .................................................................................................... 5-13 6.Periodic Inspection Items................................................................................... 6-2 6-1. Inspection Items and Intervals ....................................................................... 6-2 7.Circuit ................................................................................................................... 7-2 7-1. Electrical Circuit ............................................................................................. 7-2 7-1-1. How to Read Electrical Circuit Diagram ............................................ 7-2 7-1-2. Electrical Circuit Diagram .................................................................. 7-2 8.Tools, Instruments and Other Materials for Inspection and Maintenance ................................................................................. 8-2 8-1. Machines, Tools and Instruments.................................................................. 8-2 8-1-1. General Tools.................................................................................... 8-2 8-1-2. Special Tool ...................................................................................... 8-3 8-1-3. Measuring Instrument ....................................................................... 8-3 8-1-4. Materials Required ............................................................................ 8-3 9.Bolts and Nuts Tightening Torques .................................................................. 9-2 9-1. General Instructions....................................................................................... 9-2 9-2. Major Bolts and Nuts ..................................................................................... 9-3 10.Troubleshooting .............................................................................................. 10-2 10-1. Troubleshooting Procedures...................................................................... 10-2

Safety

1-1

1. Safety

1. Safety 1-1. Warning Symbols zMost accidents are caused by negligence of basic safety rules and precautions.

Avoiding possible cause is important for accident prevention. Be sure to read this manual carefully for full understanding of safety precautions and appropriate service/inspection procedures before starting actual repair or service jobs. Repair or service jobs without sufficient knowledge may lead to unexpected accidents. zIt is not possible to cover all possible accidents in repair or service in the manual.

It is, therefore, necessary to pay sufficient attention to safety in various jobs not indicated with the following warning symbols. Especially for the safety in conducting various jobs not covered herein, receive instructions from a knowledgeable leader. zThe warning symbols used in this manual and their meanings are as follows: DANGER- Indicates an imminently hazardous job which, if not conducted correctly, will result in death or serious injury.

CAUTION- Indicates a potentially hazardous job which, if not conducted correctly, may result in minor or moderate injury.

zThe notice sign used in this manual and its meaning are as follows:

[NOTICE]

NOTICE- Indicates an important point in service operation which, if not observed, the product performance and quality may not be guaranteed.

1-2

1. Safety

1-2. Loading generator zAlways observe the following instructions for safe repair and maintenance jobs: 1-2-1. Service Shop (Location) Well-ventilated location zSelect a well-ventilated location for conducting lighting tower operation, parts welding or polishing the paint with sandpaper.

[Non-observance] Very dangerous for human health since inhalation of poisonous gas or dust is possible.

Sufficiently wide, flat location zThe floor of the service shop (area) for inspection and service shall be sufficiently wide and flat without any hole.

[Non-observance] Dangerous since unexpected accidents such as a violent fall may occur.

Cleaned location arranged in good order zThe floor surface shall be free from dust, dirt or oil without any flammable substance or parts on it.

[Non-observance] Unexpected accidents may arise.

Brightly and safely illuminated location zThe working area shall be illuminated in a safe manner with sufficient brightness. When operating in a dark place involving poor visibility, use a safe, portable flashlight. The bulb shall be covered with wire cage.

[Non-observance] Accidental breaking of the bulb may cause ignition of leaking oil.

Location with fire-extinguishing equipment zAlways work in the neighborhood of a first aid kit and fire extinguisher in preparation for an accidental fire.

1-2-2. Working Wear Wear for safe operation zWear protective items such as a cap, safety shoes and working wear matching the job to be done. Especially select a working wear fitting your body.

[Non-observance] Critical accidents such as trapping in a machine may arise.

1-3

1. Safety 1-2-3. Tools to Be Used Proper supporting and lifting zNever operate when the product is supported with blocks or wooden pieces or only with a jack. Always use a crane with sufficient allowance in limit load or with rigid jack(s) for lifting and supporting the product.

[Non-observance] Severe accidents may arise.

Use of appropriate tools zUse appropriate tools for individual jobs. Use a correct-size tool when loosening or tightening a nut or bolt.

[Non-observance] A severe injury or damage to a machine or part may arise.

1-2-4. Parts

[NOTICE]

Always use genuine items [Non-observance] Shortening of the machine life or unexpected accidents may arise.

1-2-5. Bolt Tightening Torque Always tighten to torque specified in the manual, if any [Non-observance] Loosening or falling will arise to damage the machine or parts or cause injuries.

1-2-6. Product Handling Pay attention to hot parts zThe lamps, balloon and the lighting units are hot while lamps are on and right after they are turned off. Take great care in handling them.

[Non-observance] Scald may occur.

Keep clear of pinch-point zKeep clear of pinch-point of the mast and the lamp stand when handling them.

[Non-observance] An injury may be caused by unexpected entrapping.

1-4

1. Safety Carefully avoid shock hazard zNever touch the plugs and the electric terminals when the lighting tower is in operation.

[Non-observance] An electric shock may be caused by a leaking current.

1-2-7. Installation Use in a strong wind zNever use the lighting tower in a wind of 22 mph (10m/s) or more.

[Non-observance] Accidents may occur due to unexpected overturning.

Lower mast in a strong wind [ For balloon type (LB446HB-1)] zLower the mast when using the lighting tower in a strong wind as deforms the balloon.

[Non-observance] Accidents may occur due to sudden overturning of the lamps.

Avoid a slant zSet the lighting tower on the stable and flat ground avoiding a slant or weak ground.

[Non-observance] Accidents may occur due to unexpected overturning.

Use of outriggers zUse the outrigger when raising the mast.

[Non-observance] An injury may be caused by unexpected overturning.

1-2-8. Transport Tie up lighting tower zApply the parking brake as well as tie up the lighting tower with a rope when transporting it by a truck. Also, be sure to tighten the adjust lever and the bolt firmly to fix the balloon or the lamp stand to the mast.

[Non-observance] Dangerous since unexpected accidents such as a violent fall may occur.

1-5

1. Safety Attention to height zLower the mast fully and lay down the balloon or fold the lamp stand when transporting it by a truck.

[Non-observance] Accidents such as bumping into a tunnel or the like may occur.

Balloon cover [For balloon type (LB446HB-1)] zBe sure to cover with the cover and close the cover tightly with the buckle when transporting it by a truck.

[Non-observance] Accidents may occur due to sudden blowing of the envelope.

Lifting point zBe sure to use crane and use the specified lifting point when lifting the lighting tower by the hanger.

[Non-observance] Using another point may result in a personnel injury.

Lower mast when lifting zLower the mast fully when moving or lifting the lighting tower.

[Non-observance] Dangerous since the wire may come off or the lighting tower may be overturned.

Conveying lighting tower zBe sure that the gererator is loaded when conveying lighting tower by forklift and insert forks at marked position exactly under pipe frame of the pipe plate.Be careful not to make a sudden stop or a short turn when conveying lighting tower by forklift.

[Non-observance] A personnel injury or damage to a machine may arise by falling.

Use vehicle on steep slope zBe sure to use a vehicle, such as a truck, to move the lighting tower on a steep slope.

[Non-observance] Dangerous because it could run out of control.

1-2-9. Warning Labels

[NOTICE]

Confirm warning labels zIf 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.

1-6

Outline of Lighting Tower

2-1

2. Outline of Lighting Tower

2. Outline of Lighting Tower 2-1. Specifications Type

High-frequency lighting tower

Model

Unit

Rated voltage

V

Current

A

Balloon type (LB446HB-1)

Spotlight type (LB446H-1) 130 3.3 x 4

Type of lamp

Metal Halide Lamp type S

Model of lamp

HIE400W/C/U/EURO/4K

No. of lamps Lamp

Balloon

4

Total luminous flux

lm

160000

Outside temperature

℃

- 5 to 40

Rated life

h

20000

Burning position

Universal

Projection angle

Variable

Diameter

ft.in. (mm)

3'9" (1150)

Type of mast

Telescopic 3 stage mast

Mast operation

Mast

Min. & max. height

Manual winch ft.in. (mm)

8' to 14'8" (2440 to 4470)

Type of wheel Wheel

4 tired wheels

Diameter

in. (mm)

In operation (L x W x H)

ft.in. (mm)

In storage (L x W x H)

ft.in. (mm)

Dry weight (w/o generator)

lbs.(kg)

Dimension

6'9" to 13'8" (2060 to 4160)

Ø12" (Ø300mm) 5’1"¯5’2"¯8’¯14’7"

5’1"¯5’2"¯6’8"¯13’6"

(1550¯1600¯2440 to 4470)

(1550¯1600¯2060 to 4160)

3’1"¯2’8"¯5’7" (945¯800¯1750)

3’4"¯3’¯5’6" (1040¯920¯1700)

214 (97)

231(105)

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

Fan motor Type Rated voltage

DC fan motor 12V

Ampere

1.08A

Pressure

152Pa

zThe specifications could be changed without notice because of the improvements. zAn actual article could differ from the figure in this manual.

2-2

2. Outline of Lighting Tower

2-2. External View and Components of Lighting Tower

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

2-3

Lamp

MEMO

2-4

Structure of Lighting Tower

3-1

3. Structure of Lighting Tower

3. Structure of Lighting Tower 3-1. Outline of Structure The lighting tower consists of four groups, electrical group, mast group, outrigger group and base plate group.

The outrigger group and the mast group are mounted on the base plate group.

The balloon unit for the balloon type (LB446HB-1) or the lamp stand unit for the spotlight type (LB446H1) of the electrical group are mounted on the mast group and they are replaceable each other.

Table 3.1 Structure of lighting tower Balloon Type (LB446HB-1) Electrical Group

Spotlight Type (LB446H-1) 3.2

Balloon Unit

Electrical Group

3.2.1

3.2

Lamp Stand Unit

3.2.2

Balloon assembly

3.2.1-1)

Lighting unit assembly

3.2.2-1)

Stand assembly

3.2.1-2)

Lamp stand assembly

3.2.2-2)

Power Cable unit Mast Group

3.2.3 3.3

Power Cable unit Mast Group

3.2.3 3.3

Outrigger Group

3.4

Outrigger Group

3.4

Base Plate Group

3.5

Base Plate Group

3.5

Base Plate Unit

3.5.1

Base Plate Unit

3.5.1

Steering Unit

3.5.2

Steering Unit

3.5.2

Brake Unit

3.5.3

Brake Unit

3.5.3

3-2. Electrical Group The electrical group of the balloon type (LB446HB-1) consists of the balloon unit and the power cable unit.

The cable from the balloon unit is connected with the power cable unit on the bottom of the balloon unit through the coupler.

The electrical group of the spotlight type (LB446H-1) consists of the lamp stand unit and the power cable unit.

The cables from the lamp stand unit are connected with the power cable unit at the top of the lamp stand through the coupler.

3-2

3. Structure of Lighting Tower 3-2-1. Balloon Unit The balloon unit consists of the balloon assembly and the stand assembly.

1) Balloon assembly The balloon assembly is mainly divided into the frame part, two lamp parts and envelope. (Fig.3.2.1-1) The frame part mainly consists of the flange, four frame pipes and various plates, seals, sheets located at the top and bottom of the frame pipes.

The flange is installed to the stand assembly with the set screw (M10X20).

The fan motor is installed on the flange and covered with the motor cover 1,2 and the vessel.

The primary cover is installed on the top of the frame part.

The lamp part mainly consists of the two lamps and plate (lamp) and the lamps are installed on the plate (lamp) together with their sockets, lamp holders and lamp guards.

The two lamp parts are installed opposite each other to the frame pipe between the plate (top) and motor cover 2 of the frame part.

The envelope is installed to the sheet of the frame part.

Envelope

Primary cover Motor cover 1

Plate (Cap)

Motor cover 2 Vessel

Seal (Packing)

Plate (Lamp)

Microswitch

Buzzer

Sheet (Top) Seal (Normal) Fan motor

Flange

Lamp guard Lamp holder

Seal (Normal) Sheet (Bottom)

Socket (E40)

Set screw (M8X10)

Seal (Packing) Lamp Plate (Bottom) FilterǾ200 Plate (Air)

Plate (Lamp)

Frame pipe Fig. 3.2.1-1 Balloon assembly

3-3

Plate (Top)

3. Structure of Lighting Tower 2) Stand assembly The stand assembly consists of the stand, shaft, two springs, covers, grip shaft and spacer.

(Fig. 3.2.1-2) It is installed on the mast group with the washer and the spacer(stand) and fixed with the button screw (M8X10).

Cover (Spring) Spring (Stand) L

Stand Shaft (Stand)

Button screw (8X10)

Spring (Stand) R Cover (Spring)

Grip shaft

Button screw & washer (M8X25) Washer

Spacer (Stand)

Fig. 3.2.1-2 Stand assembly

3-4

3. Structure of Lighting Tower 3-2-2. Lamp Stand Unit The lamp stand unit consists of four lighting unit assemblies and the lamp stand assembly.

The lighting unit assemblies are installed on the lamp stand assembly.

1) Lighting unit assembly The light source tube is installed to the reflex mirror together with the lamp. (Fig. 3.2.2-1) The arm of the lighting unit assembly is installed between two spacers on the lamp stand.

The cables from the lighting unit assemblies are concentrated in the receptacle housing.

Lighting unit assy.

Pin contact

Light source tube Lamp

Nut (M16) Spring

Reflex mirror Receptacle housing

Spacer (Lamp) Arm (Lighting unit)

Fig. 3.2.2-1 Lighting unit assembly

2) Lamp stand assembly The lamp stand unit consist of the lamp stand, connector cover, clamp, two springs, adjust lever, two caps and bolt (8X20) which adjust the folding lever. (Fig. 3.3.2-2) The lamp stand is installed on the mast group and fixed with the adjust lever.

Spring (Lamp stand) L Cap bolt (8X20)

Connector cover

Lamp stand Cap

Adjust lever (Lamp stand)

Spring (Lamp stand) R Fig. 3.3.2-2 Lamp stand unit

3-5

Clamp

3. Structure of Lighting Tower 3-2-3. Power Cable Unit The power cable unit consists of the lamp cable, cable (ground), plug housings and receptacle housing.

(Fig. 3.2.3) The plug housing is connected with the receptacle housing of the balloon unit on the bottom of the balloon assembly or the lighting unit at the top of the lamp stand assembly.

The receptacle housing which is located on the side of the first mast is connected with the plug housing of the generator.

The power cable unit is coiled on the side of the mast group.

Socket contact Tube Plug housing

Lamp cable

Cable (Ground)

Pin contact

Receptacle housing

Fig. 3.2.3 Power cable unit

3-6

3. Structure of Lighting Tower

3-3. Mast Group The mast group mainly consists of the first mast made of steel, the second and third masts made of stainless steel, the wire, winch, hanger and connector cover. (Fig. 3.3) Each mast is telescoped into its lower mast and connected with each other by the wire.

The winch is mounted on the side of the first mast and connected with the tip of the wire.

On the opposite side is the hanger to connect with the generator.

Second mast Bracket (Pulley) 2

First mast

Hanger Winch HM-G103

Eye bolt

Shackle

Bolt (M12X40)

Bolt & washer (M10X25)

Connector cover

Third mast

Fig. 3.3 Mast group

3-7

3. Structure of Lighting Tower

3-4. Outrigger group The outrigger group mainly consists of two outriggers(L,R) on either side. (Fig. 3.4) Each outrigger has the bracket and weight.

Outrigger L Bolt (M16X90) Outrigger R

Weight (Out,R) L

Bracket (Out,R) 2 R Bolt (M12X30)

Bracket (Out,R) L

Weight (Out,R) R Selflock nut(M10) Rubber Bolt & washer (M10X25)

Fig. 3.4 Outrigger group

3-8

3. Structure of Lighting Tower

3-5. Base Plate Group Base plate group consists of the base plate unit, steering unit and brake unit.

3-5-1. Base Plate Unit The base plate unit consists of the base plate made of steel, four tire assemblies and two stoppers which hold the wheels of the generator. (Fig. 3.5.1) The two tire assemblies are installed to the rear shaft of the base plate.

The other two tire assemblies are installed to the right and left front shaft of the steering unit.

The two rails are installed to the right and left of the top of the base plate.

The rail (E/G oil) CP is installed to the right side of the rail R. The two side guards are installed to the right and left sides of the base plate.

Stopper (Generator) L

Stopper (Generator) R Bolt & washer (M12X25)

Rail L Base plate

Rail R

Tire assy.

Rail (E/G oil) CP Rear shaft Side guard

Snap ring (20)

Fig. 3.5.1 Base plate unit

3-9

3. Structure of Lighting Tower 3-5-2. Steering Unit The steering unit consists of the handle, front shaft(L,R), link (handle), link (front shaft) and steering link.

(Fig. 3.5.2) Steering of the handle installed to the handle link together with the base plate is transmitted through the steering link and front shaft link and is connected with the right and left front shaft.

Handle Link (Front shaft)

Front shaft (L)

Front shaft (R)

Link (Handle)

Link (Steering)

Selflock nut (M8)

Bolt & washer (M12X25) Fig. 3.5.2 Steering unit

3-5-3. Brake Unit The brake unit consists of the brake pedal, two brakes and brake shaft. (Fig. 3.5.3) The two brakes connected with the brake pedal through the brake shaft apply the brakes to the right and left rear tire assemblies.

Bolt (M12X75) left screw Brake Brake shaft

Spring (Brake) Brake Bolt (M12X75) right screw Brake pedal Bolt (M8X30) Fig. 3.5.3 Brake Unit

3-10

Disassembly and Assembly

4-1

4. Disassembly and Assembly

4. Disassembly and Assembly 4-1. Before Starting Operation Sufficient knowledge related safety is needed for servicing and for ensuring safe quality of the generator.

Be sure to carefully read Section 1, Safety, and the following notes before beginning the work.

4-1-1. Grasp of Service History Understand the history of the services on the lighting tower prior to the work by the records, in order to ensure efficient and correct work. zReasons for and contents of previous services. zDate of previous services. zPeriod and operating hours from previous services. zParts which would require replacement during the work.

4-1-2. Preparing the Necessary Tools, Parts and Materials zPrepare the necessary general tools, special tools and measuring instruments. zPrepare a case for storing disassembled parts. Locate it at appropriate place. zPrepare the materials necessary at inspection and reassembly such as the grease. zMake sure that all parts prepared are genuine ones.

4-2. Disassembly and Assembly Procedures This manual mainly gives the disassembly procedures. Reassembly of each unit is fundamentally in reverse order of the disassembly procedure.

4-2-1. General Instructions 1) Disassembly zBegin disassembly after the lamps are cool down sufficiently. If a lighting toweris disassembled immediately after operation, a burning accident may occur. zBe sure to stop the engne and generator before disassembly. Failure to stop them could result in electric shocks.

2) Reassembly zThoroughly clean parts before beginning reassembly. zMake sure to tighten nuts and bolts to the specified torque, wherever the tightening torque is instructed. Refer to Section "9-2. Major Bolts and Nuts". zMake sure to connect the terminals of the electrical circuits securely. Incomplete reassembly will result in a larger electrical resistance, resulting in poor electrical connection or possible melting of terminals.

4-2

4. Disassembly and Assembly 4-2-2. Disassembly Procedure of Each Assembly /Unit /Group Disassembly of each assembly /unit /group has to be done through required processes in proper order.

The figure below is the flowchart shows the required processes and the order to disassemble each assembly /unit /group. Numerals in the flowchart indicate the sections to refer to.

Table 4.2.2 Flowchart of disassembly procedure

Base plate group

Electrical group Required process

Balloon unit Balloon assy.

Stand assy.

Lamp stand unit Power cable unit Lighting unit Lamp stand assy. assy.

Disconection of Couplers

Mast group

Outrigger group

Brake unit Steering unit Brake unit

4.2.3

Removal of Balloon Assy.

4.2.3

4.2.4

Removal of Lighting Unit Assy.

4.2.5

Removal of Pin (Socket) Contact

4.2.6

Removal of Stand Assy.

4.2.6

4.2.7 4.2.7 or 4.2.8

Removal of Lamp Stand Assy.

4.2.7 or 4.2.8

4.2.8

Unloading of Generator

4.2.9

Removal of Mast Group

4.2.10

Removal of Outrigger Group

Disassembly of Each Assy. /Unit /Group

4.2.10

4.2.11

4.2.12

4.2.13

4.2.14

4.2.15

4.2.16

4-3

4.2.17

4.2.18 4.2.16

4.2.11

4.2.19 4.2.17

4.2.20

4.2.21

4. Disassembly and Assembly 4-2-3. Disconnection of Couplers 1) Removal of connector covers zConnections of couplers (connections of the plug

Screw & washer

housing and the receptacle housing) are located on the mast group and balloon assembly for balloon

Connector cover

type (LB446HB-1) and on the mast group and lamp stand assembly for spotlight type (LB446H-1).

Mast

Loosen the screw & washers, and then remove the connector covers when disconnecting couplers.

(Fig. 4.2.3-1)

[Spotlight type (LB446H-1)] Balloon assy.

Screw & washer

Connector cover

[Balloon type (LB446HB-1)] Screw & washer Connector cover

Lamp stand assy.

4-4

4. Disassembly and Assembly 2) Disconnection of coupler

Receptacle housing

zThe coupler between the lamp cable of the power cable unit and the generator is located on the side

Plug housing (generator)

of the mast unit. When disconnecting the coupler, remove the plug housing (generator) from the re-

a

ceptacle housing pressing the part indicated by ar-

Lamp cable

row a in Fig. 4.2.3-2 as the coupler has a lock.

Fig. 4.2.3-2 Disconnecting coupler 1

(1) For balloon type (LB446HB-1) zThe coupler between the balloon unit and the lamp cable of the power cable unit is located on the bot-

Clamp

tom of the balloon assembly.

When disconnecting the coupler, remove the clamp

b

by loosening the button screw (M10X35), and then remove the plug housing (lamp cable) from the receptacle housing pressing the part indicated by ar-

Plug housing (lamp cable)

row b in Fig.4.2.3-3 as the coupler has a lock.

Note: Tighten the button screw (M10X35) securely

Button screw (M10X35)

when connection the coupler.

Fig. 4.2.3-3 Dis

Tightening torque: 25 to 34 N-m (2.6 to 3.5 kgf-m) (2) For spotlight type (LB446H-1) zThe coupler between the lamp stand unit and the lamp cable of the power cable unit is located on the lamp stand assembly. When disconnecting the coupler, remove the clamp by loosening two screw & washers, and then remove the plug housing (lamp

Screw & Washer Plug housing (lamp cable)

Clamp

c

cable) from the receptacle housing pressing the part indicated by arrow c in Fig. 4.2.3-4 as the coupler has a lock.

Note: When connecting the coupler, plug the plug housing securely until it clicks.

Receptacle housing Fig. 4.2.3-4 Disconnecting coupler 3

4-5

4. Disassembly and Assembly 4-2-4. Removal of Balloon Assembly zDisconnect the coupler between the balloon unit and the lamp cable of the power cable unit before

Balloon assembly

removing the balloon assembly. Refer to Section "4-2-3. Disconnection of Couplers". zRemoval procedure of the balloon assembly is as follows. (Fig.4.2.4) 1. Loosen the set screw (M10X20) in the flange of the balloon assembly.

Set screw (M10X20)

2. Lift off the balloon assembly from the stand assemStand assembly

bly.

Note: When installing the balloon assembly, put the balloon assembly on the stand assembly and tighten the set screw (M10X20) securely.

Fig. 4.2.4 Removing balloon assembly

Tightening torque: 25 to 34 N-m (2.6 to 3.5 kgf-m)

4-6

4. Disassembly and Assembly 4-2-5. Removal of Lighting Unit Assembly zDisconnect the coupler between the lamp stand assembly and the lamp cable of the power cable unit

Receptacle housing

before removing the lighting unit assembly. Refer to Section "4-2-3. Disconnection of Couplers". zRemoval procedure of the lighting unit is as follows.

(Fig. 4.2.5-1) 1. Remove the receptacle housing of the lighting unit assemblies from the lamp stand assembly.

2. Loosen the nuts (M16) and remove each lighting unit assembly with the washer, spring and two spacers from the shaft of the lamp stand unit.

Note: When installing lighting unit assembly, put the arm of the lighting unit assembly between slip-

Nut (M16)

pery sides (black sides) of the spacers on the shaft of the lamp stand assembly. And set oth-

Lighting unit assy.

er parts in order of the spring, washer and nut (M16) as show in Fig.4.2.5-2, and then tighten

Lamp stand unit

up the nut (M16) securely. After installing four lighting unit assemblies, install the receptacle housing to the lamp stand unit.

Tightening torque:

Fig. 4.2.5-1 Removing lighting unit assembly

115 to 155 N-m(11.5 to 16kgf-m) Nut (M16) Washer

Spacer

Spring

Arm

Fig. 4.2.5-2 Installing ighting unit assembly

4-7

4. Disassembly and Assembly 4-2-6. Removal of Pin (Socket) Contact zWhen disconnecting the cable from the plug (re-

Contact remover

ceptacle) housing such as replacing the lighting unit assembly, disconnect the coupler first. Refer to Section "4-2-3. Disconnection of Couplers" for disconnection of the coupler. And remove the pin (socket) contact by using a special tool, contact remover, as shown in Fig. 4.2.6-1. Refer to Section "8.1.2 Special Tool" for the contact remover.

Fig. 4.2.6-1 Removing pin contact

zRemoval procedure of the pin (socket) contact is as follows. Be sure to stop the generator before re-

4

3

2

1

moving the pin (socket) contact to prevent electric shocks. (Fig. 4.2.6-2) 1. Insert the contact remover 1 into the receptacle (plug) housing 2 from the opposite side. Be careful of direction of the tip of the contact remover.

2. Push the contact remover to release housing lance 3 in the receptacle (plug) housing.

Fig. 4.2.6-2 Sectional view of receptacle housing

3. Pull the cable to remove the pin (socket) contact 4.

Note: Plug the pin (socket) contact securely until it clicks. Refer to Section "7-1-2. Electrical Circuit Diagram" for locations of the pin (socket) contact. After plugging, pull the cable to check whether the pin (socket) contact is certainly plugged.

4-8

4. Disassembly and Assembly 4-2-7. Removal of Stand Assembly zDisconnect the coupler between the balloon unit

Button screw (M8)

and the lamp cable of the power cable unit before removing the stand assembly. Refer to Section "42-3. Disconnection of Couplers". zRemoval procedure of the stand assembly is as follows. (Fig.4.2.7) 1. Loosen the button screw (M8X10) in the shaft of the stand assembly.

2. Lift off the stand assembly from the forth mast.

3. Remove the washer and the spacer (stand) from the fourth mast.

Washer Spacer (stand) Fig. 4.2.7 Removing stand assembly

Note: When installing the stand assembly, apply grease on the shaft of the mast group. Refer to Section "8-1-4. Materials Required" for description of the grease. After applying grease, put the stand assembly on the forth mast and tighten the button screw (M8) securely.

Tightening torque: 14 to 19 N-m (1.4 to 1.9 kgf-m)

4-2-8. Removal of Lamp Stand Assembly zDisconnect the coupler between the lamp stand unit and the lamp cable of the power cable unit before removing the lamp stand assembly. Refer to Section "4-2-3. Disconnection of Couplers".

Adjust lever

zRemoval procedure of the lamp stand assembly is as follows. (Fig.4.2.8) 1. Loosen the adjust lever.

2. Lift off the lamp stand unit from the fourth mast.

Note: When installing the lamp stand assembly, apply grease on the shaft of the mast unit. Refer

Shaft

to Section "8-1-4. Materials Required" for description of the greases.

Fig. 4.2.8 Removing lamp stand assembly

4-9

4. Disassembly and Assembly 4-2-9. Unloading of Generator zDisconnect the coupler between the lamp cable of the power cable unit and the generator before unloading the generator. Refer to Section "4-2-3. Disconnection of Couplers". zUnloading procedure of the generator is as follows.

(Fig.4.2.9) 1. Loosen the bolt (M12X40) for the hanger.

Mast unit

Note: When tightening the bolt (M12X40) in loading of the generator, lift the hanger upward so that

Bolt (M12X40)

Hanger

there is no room in connection between the

Grommet

Eyebolt

shackle and the lifting eye of the generator.

Tightening torque: 44 to 61 N-m (4.5 to 6.2 kgf-m) Shackle

Lifting eye

2. Remove the eyebolt with the grommet from the shackle by loosing it.

3. Apply the parking brake to prevent the cart from

Stopper (generator)

moving. Loosen the bolt & washers (M12X25), and then remove the stoppers (generator) from both sides of the front of the base plate unit.

Tightening torque: 44 to 61 N-m (4.5 to 6.2 kgf-m)

Bolt & washer (M12X25)

4. Lift up the front side of the generator (the side of the exhaust outlet.) to remove handle bar of the

Generator holder Handle bar

generator from the generator holder on the mast unit. Then pull back the generator and unload it from the base plate unit.

Note: 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.

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

Fig. 4.2.9 Unloading generator

4-10

Rope

4. Disassembly and Assembly 4-2-10. Removal of Mast Group zDisconnect the both couplers on the mast group

Mast unit

and on the balloon unit for the balloon type (LB446HB-1) or on the lamp stand unit for the spotlight type(LB446H-1)before removing the mast. Re-

Bolt & Washer (M10X25)

fer to Section "4-2-3. Disconnection of Couplers". zRemove the lamp stand unit before removing the mast. Refer to Section "4-2-8. Removal of Lamp Stand Assembly". zDisconnect the hanger from the generator before removing the mast. Refer to the unloading procedure of the generator 1 and 2 in Section "4-2-9. Unloading of Generator". zRemoving procedure of the mast group is as follows. (Fig.4.2.10) 1. Loosen six bolt & washers (M10X25).

2. Lift off the mast unit from the base plate.

Note: When installing the mast unit, Put the mast unit

Fig. 4.2.10 Removing mast group

on the base plate and tighten six bolt & washers (M10X25) securely.

Tightening torque: 25 to 34 N-m (2.6 to 3.5 kgf-m)

4-2-11. Removal of Outrigger Group zRemoving procedure of the outrigger group is as follows. (Fig.4.2.11)

Bolt & Washer (M10X25)

1. Loosen three bolt & washers each (M10X25) 2. Remove the right and left outriggers from the base plate unit.

Note: When installing the outrigger group, Put the right and left outriggers on the base plate and tighten three bolt & washers (M10X25) each securely.

Tightening torque: 25 to 34 N-m (2.6 to 3.5 kgf-m) Fig. 4.2.11 Removing outrigger group

4-11

4. Disassembly and Assembly 4-2-12. Disassembly of Balloon Assembly Fig.4.2.12 illustrates the scope of work and parts configurations.

1. Remove the envelope 1 from the balloon assembly by opening the zipper at the both side of the balloon assembly.

2. Loosen three screw & washers (M4X12) 2, and then remove the plate (air) 3 and the filter Ø200 4 from the flange 5.

3. Loosen four button screw & washers (M8X25) 6, and then remove the primary cover 7, plate (cap) 8, seal (packing) 9, sheet (top) 10, seal (normal) 11 and the plate (top) 12.

Tightening torque: 14 to 19 N-m (1.4 to 1.9 kgf-m) 4. Loosen the screw & washer (M4X8) 13, and then remove the joint blocks 2 14 from each frame pipe 15.

5. Disconnect four cables of two sockets (E40) 16 from four curl codes 17 coming from the top of the frame pipes 15.

Note: Connect the cables securely when reassembling. Refer to Section "7-1-2. Electrical Circuit Diagram" for reconnection of the cables.

6. Loosen two screws (M4X35) 18, and then remove the stoppers 2 19 from each stopper 1 20 on the upper and lower plates 21,22.

7. Pull out upper plate 21 from the frame pipes 15.

8. Disconnect four cables of two sockets (E40) 23 from the cable 1 (balloon) 24, and then pull out lower plate 22 from the frame pipes 15.

Note: Connect the cables securely when reassembling. Refer to Section "7-1-2. Electrical Circuit Diagram" for reconnection of the cables.

9. Loosen two screw & washers (M4X16) 25, and then remove the stoppers 1 20 from the upper and lower plates 21,22.

10. Remove the lamps 26 from each socket (E40) 16,23 by loosening them.

11. Loosen three screw & washers (M4X12) 27, and then remove two lamp guards 28 and lamp holders 29 each from the upper and lower plates 21,22.

12. Loosen two screw & washers (M4X20) 30, and then remove two sockets (E40) 23 each from the upper and lower plates 21,22.

13. Loosen three screw & washers (M4X12) 31, and then remove the motor cover 1 32 from the motor cover 2 33.

14. Loosen the screw & washer (M4X50) 34, and then remove the fan motor 35 from the flange 5.

15. Disconnect the cable (joint) 1 36 and the cable (joint) 2 37 from the cable 1 (balloon) 24, buzzer 38 and the micro switch 39.

Note: Connect the cables securely when reassembling. Refer to Section "7-1-2. Electrical Circuit Diagram" for reconnection of the cables.

16. Disconnect four curl codes 17 from the cable 1 (balloon) 24.

Note: Connect the cables securely when reassembling. Refer to Section "7-1-2. Electrical Circuit Diagram" for reconnection of the cables.

17. Cut the wire bands at each top of four curl codes 17, and then pull out them from each frame pipe 15 through the joint block 1 40.

Note: Replace new wire bands when installing the curl codes 17.

4-12

4. Disassembly and Assembly 18. Loosen the screw and washer (M4X8) 41, and then remove frame pipes 15 from each joint block 1 40.

19. Loosen four screw & washers (M4X8) 42, and then remove the bracket (contactor) 43 from the plate (bottom) 44.

20. Pull out the cable 1 (balloon) 24 and remove the free bush 45 from the plate (bottom) 44.

21. Loosen three button screws (M10X35) 46, and then remove the plate (bottom) 44, seal (packing) 47, sheet (bottom) 48 and the seal (normal) 49 from the flange 5.

Tightening torque: 25 to 34 N-m (2.6 to 3.5 kgf-m) 22. Pull out four joint block 1 40 from the motor cover 2 33, and then remove four washers (34DX21dX3.0t) 50, spacers (motor side) 51 and the vessel 52.

23. Loosen two screws (M3X6) 53, and then remove 1 the buzzer 38 from the motor cover 2 33.

24. Loosen two screw (M4X30) 54, and then remove the micro switch 39 and the micro switch cover 55 from the motor cover 2 33.

6

31 32

7 8

36 37

54

9

55

33

39

38 53 52

34

51

21

24

10

19 18 20 25

26 30

11 12

23

5

28

49

27 35

48

29

14

47 45

13

16

42 46

15

44

41 22

43

40

4

50

3 2

17 Fig. 4.2.12 Disassembling balloon unit

4-13

4. Disassembly and Assembly 4-2-13. Disassembly of Stand Assembly Fig.4.2.13 illustrates the scope of work and parts configurations.

1. Remove the grip shaft 1 from the stand 2 by loos-

3

ening it.

4

2. Loosen two button screw & washers (M8X25) 3,

6

and then remove covers (spring) 4 from the both

2

side of the stand 2.

7 5

Tightening torque: 14 to 19 N-m (1.4 to 1.9 kgf-m) 3. Remove the right and left spring (stand) 5,6 from the stand 2.

4. Remove the shaft (stand) 7 from the stand 2.

1

Fig. 4.2.13 Disassemble stand assembly

4-2-14. Disassembly of Lighting Unit Assembly zFig. 4.2.14 illustrates the scope of work and parts configurations.

1. Disconnect two pin contacts 1 from the receptacle

1

housing 2 by using a special tool.

5

Note: Refer to Section "8-1-2. Special Tool" for the

6

contact remover and Section "4-2-6. Removal of Pin (Socket) Contact" for disconnection of

4 2

the pin contact.

2. Release three latches 3 of the mirror 4 and remove

3

the light source tube 5 from the mirror 4.

3. Turn the lamp 6 counterclockwise to remove it from the light source tube 5.

4. Disassemble other three lighting unit assemblies in the same order of this procedure 1 to 3.

Note: Connect the socket contacts and pin contacts securely when reassembling.

4-14

Fig. 4.2.14 Disassembling lighting unit assembly

4. Disassembly and Assembly 4-2-15. Disassembly of Lamp Stand Assembly zFig. 4.2.15 illustrates the scope of work and parts configurations.

Note: Apply spray grease (

) or grease (

)at the places where indicated by arrows when reassem-

bling. Refer to Section "8-1-4. Materials Required" for description of the greases.

1. Remove the right and left springs (lamp stand) 1, 2

7

and spring (lever) 3 from the lamp stand 4.

4 6

2. Remove the adjust lever 5 from the lamp stand 4 2

by loosing it.

3. Loosen the bolt (M8X20) 6.

7

Tightening torque:

3

14 to 19 N-m (1.4 to 1.9 kgf-m) 4. Remove two caps 7 from both side of the lamp

5

stand 4.

1

Fig. 4.2.15 Disassembling lamp stand assembly

4-2-16. Disassembly of Power Cable Unit zFig. 4.2.16 illustrates the scope of work and parts configurations.

1. Remove eight socket contacts 1 from the plug

2

housing 2 with the tube 3 by using a special tool,

1

contact remover.

Note: Refer to Section "8-1-2. Special Tool" for the

3

contact remover and Section "4-2-6. Removal of Pin (Socket) Contact" for disconnection of the pin (socket) contact 2. Remove the tube 3 from the lamp cable 4.

3. Remove receptacle housing 5 from the mast unit.

4. Remove eight pin contacts 6 from the receptacle housing 5 by using the contact remover.

4

5. Remove the earth cable 7 from the receptacle housing 5 by using the contact remover.

Note: Connect the socket contacts and pin contacts securely when reassembling.

6. Cut the wire bands at the mast group, and then remove the lamp cable 4.

7

Note: Replace new wire bands when installing the lamp cable 4 .

6

5

Fig. 4.2.16 Disassembling power cable unit

4-15

4. Disassembly and Assembly 4-2-17. Disassembly of Mast Group zFig. 4.2.17-1 illustrates the scope of work and parts configurations.

Note: Apply spray grease (

) or grease (

)at the places where indicated by arrows when reassem-

bling. Refer to Section "8-1-4. Materials Required" for description of the greases.

1. Loosen four screw & washers 1 and then remove the winch cover 2.

4

2

2. Disconnect the tip of the wire 3 from the winch 4.

3. Loosen three bolt & washers (M10X25) 5 and then

8

remove the winch 4 from the first mast 6.

7

Tightening torque: 25 to 34 N-m (2.6 to 3.5 kgf-m) 1

11

5

14

6

4. Loosen the bolt (M12X40) 7, and then remove the hanger 8 from the first mast 6.

Tightening torque: 44 to 61 N-m (4.5 to 6.2 kgf-m)

3

5. Pull out the second mast 9 together with the third

13

mast 10 from the first mast 6 pulling wire 11 to release the safety stopper of the pulley (second mast) 12.

6. Disconnecting the wire 11 from the third mast 10 by pulling it.

7. Loosen six screws 13, and then remove the bracket (pulley) 14 from the second mast 9.

8. Pass a length of rope through the pulley 15 as

10

9

shown in Fig. 4.2.17-2, and then pull out the third mast 10 from the second mast 9 pulling the rope to release safety stopper of the pulley (third mast) 15.

15

12

Fig. 4.2.17-1 Disassembling mast group

Rope

Pulley (third mast)

Third mast

Second mast

Fig. 4.2.17-2 Removing third mast

4-16

4. Disassembly and Assembly 4-2-18. Disassembly of Outrigger Group zFig. 4.2.18 illustrates the scope of work and parts configurations.

Note: Apply spray grease (

) or grease (

)at the places where indicated by arrows when reassem-

bling. Refer to Section "8-1-4. Materials Required" for description of the greases.

1. Remove the rubbers 1.

2. Loosen the bolts (M16 x 90) 2, and then remove the outrigger R 3 with spacers (out,r) 4 from the bracket (out,r)R 5.

Tightening torque:

4

115 to 155 N-m (11.5 to 16.0 kgf-m) 3. Loosen the selflock nuts (M10) 6 and

3

remove the weights (out,r) R 7 with the

10

spacers 8 from the bracket (out,r) R 5.

5

Tightening torque:

2

25 to 34 N-m (2.6 to 3.5 kgf-m) 4. Disassemble the left outrigger in the

7 6

9

same order of this procedure 1 to 3.

1

8

Fig. 4.2.18 Disassembling outrigger group

4-17

4. Disassembly and Assembly 4-2-19. Disassembly of Base Plate Unit zFig. 4.2.19 illustrates the scope of work and parts configurations.

1. Remove the snap rings 1 from the shaft of the base plate 2 and the front shaft of the steering unit 3.

2. Remove the front tire assembly 4 and the rear tire assembly 5 from the shaft of the base plate 2 and the front shaft of the steering unit 3.

3. Remove the snap rings 6 from the shafts.

4. Remove the tire assemblies on the other side in the same order of this procedure 1 to 3.

5. Loosen four bolt & washers (M8x15) 7 and remove two side guards 8 from the base plate 16.

6. Loosen four bolt & washers (M10x25) 9 and remove the catchers 10 from the base plate 16.

7. Loosen four bolt & washers (M12x25) 11 and remove the rail (R) 12 and the rail (L) 13 from the base plate 16.

8. Loosen two bolts (M6x15) 14 and remove the rails(E/G oil)CP 15 from the rail R 12.

11

13

15

12

9

14 3

16

4 2

10 1

6 8 7

5

Fig. 4.2.19 Disassembling base plate

4-18

4. Disassembly and Assembly 4-2-20. Disassembly of Steering Unit zFig. 4.2.19 illustrates the scope of work and parts configurations.

Note: Apply spray grease (

) or grease (

)at the places where indicated by arrows when reassem-

bling. Refer to Section "8-1-4. Materials Required" for description of the greases.

1. Loosen the bolt & washer (M12X25) 1 from the handle 2, and then remove the handle 2 from the base plate unit 3 and

3

the link (handle) 4.

Tightening torque: 7

44 to 61 N-m (4.5 to 6.2 kgf-m)

2

2. Remove two sleeve bearings 5 from the base plate unit 3.

13

3. Remove the snap ring 6 and the right

6

and left handle grips 7 from the handle

11

2.

4. Loosen the selflock nut (M8) 8 and then

5

12

remove the link (handle) 4 from the link (steering) 9.

4 9

Tightening torque: 14 to 19 N-m (1.4 to 1.9 kgf-m)

8

10

12

1

5. Remove the push nut 10 and then remove the link (steering) 9 from the front

Fig. 4.2.20 Disassembling of steering unit

shaft (L) 11.

6. Remove the push nuts 12, and then remove the link (front shaft) 13 from the front shaft(R) 14 and the front shaft(L) 11.

Replace new push nuts when reassembling 9 and 13.

7. Remove the front shaft (R) 14 and the front shaft (L) 11 from the base plate unit 3 by loosening them.

Note: Before removing the front shaft (R)14 and the front shaft (L) 11 from the base plate unit 3, remove the front tires of the base plate unit. Refer to Section "4-2-19. Disassembly of Base Plate Unit" for removal of the tire.

4-19

14

4. Disassembly and Assembly 4-2-21. Disassembly of Brake Unit zFig. 4.2.21 illustrates the scope of work and parts configurations.

Note: Apply spray grease (

) or grease at the places where indicated by arrows when reassembling.

Refer to Section "8-1-4. Materials Required" for description of the grease.

1. Loosen the nuts (M8) 1 and remove the 8

bolt (M8X30) 2 from the brake pedal 3

9

and the brake shaft 4.

Note: When reassembling, securely tight-

10

en two nuts (M8) 1 with each other 1

in a position which the brake pedal 3 can move freely on the bolt

5 4

(M8X30) 2.

7

2. Remove the spring (brake) 5 from the 6

base plate unit 6 and the brake shaft 3.

3. Loosen the through bolts (M12X75) 7

3

and 8, and then remove the right and

2

left brakes 9 from the brake shaft 3.

Fig. 4.2.21 Disassembling brake unit

Tightening torque: 44 to 61 N-m (4.5 to 6.2 kgf-m) Note: The bolt (M12X75) 8 is a left-hand screw.

4. Remove the left and right sleeve bearings 10 from the base plate unit 6.

5. Remove the brake shaft 3 from the base plate 6.

4-20

Inspection and Maintenance

5-1

5. Inspection and Maintenance

5. Inspection and Maintenance This section gives part of daily maintenance procedures as well as the inspection procedure.

Unlike the maintenance inspection, overhaul inspection generally require disassembly and reassembly.

Thoroughly read and understand Section "4. Disassembly and Assembly" before beginning the work.

5-1. Electrical Group 5-1-1. Balloon Unit 1) Balloon assembly (1) Replacement of lamp zCheck if the lamp is not loosened. if it is, screw it securely.

Note: Never force the lamp into the socket to prevent breakage. zIf the lamp dose not light up properly although a new lamp lights properly, the lamp Is burned out or broken. Replace the lamp with a new one. Replacement procedure is as follows.

(Fig. 5.1.1-1, Fig.5.1.1-2) Note: 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.

Name

Parts No.

Yanmar Genuine Lamp

Metal Halide Lamp Type S

400W

HIE400W/C/U/EURO/4K

1-3010010-10

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

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

1. Lay down the balloon flatly with the adjust lever.

Adjust lever

2. Open the zipper at the bottom of the balloon and

Envelope

roll up the envelope of the balloon.

Note: Tighten the adjust lever after laying down the balloon.

Note: If you unzip the balloon by force, the envelope is broken and become unusable.

Zipper

3. Loosen each cramp of four frame pipes.

Note: Loosen downside cramp only.

Downside cramp

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

12 in.

Frame pipe Fig. 5.1.1-1 Replacing lamp (balloon) 1

5-2

5. Inspection and Maintenance Note: Never extend frame longer than necessary to prevent the frame from damage and overturn-

Lamp

ing.

Lamp guard

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.

Note: Never screw the lamp by force to prevent Cramp

breakage.

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

8. Tighten the cramps.

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

Fig. 5.1.1-2 Replacing lamp (balloon) 2

(2) Replacement of envelope zCheck if the envelope is not broken or dirty. If it is, replace the envelope with a new one. Replacement procedure of the envelope is as follows. (5.1.1-3) Note: Common dirt such as mud will come off with washing machines. Remove the envelope from the balloon and put it in a laundry bag. Natural detergent is available. In case of greasy dirt, wipe off the dirt using grease and oil cleaning sprays and wash it with washing machines.

1. Lay down the balloon flatly with the adjust lever.

Envelope

2. Open the zipper at the 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.

Zipper

Frame pipe

Grommet Fig. 5.1.1-3 Replacing envelope

(3) Fan motor zCheck if the fan motor is working right. If the balloon is not inflated properly because the fan motor malfunctions, replace the fan motor with a new one. Refer to Section "4-2-2. Disassembly Procedure of Each Assembly /Unit /Group" for replacement of the fan motor.

5-3

5. Inspection and Maintenance 5-1-2. Lamp Stand Unit 1) Lighting unit assembly (1) Replacement of lamp zCheck if the lamp is not loosen. If it is, screw it securely.

Note: Never force the lamp into the socket to prevent breakage. zIf the lamp dose not light up properly although a new lamp lights properly, the lamp is burned out or broken. Replace the lamp with a new one. Refer to Section "4-2-14. Disassembly of Lighting Unit Assembly" for disassembly of the lighting unit assembly. It is not necessary to remove the lighting unit assembly from the lamp stand unit when replacing the lamp. Installation procedure of lamp is as follows. (Fig. 5.1.2-1) Note: 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.

Name

Parts No.

Yanmar Genuine Lamp

Metal Halide Lamp Type S

400W

HIE400W/C/U/EURO/4K

1-3010010-10

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

Note: 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.

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

1. Turn the lamp clockwise to install it into the light source tube.

Light source tube

Lamp

Note: Never screw the lamp by force to prevent breakage.

2. Fit the reflex mirror and the light source tube together.

3. Fix all three latches in order to stabilize the mirror

Reflex mirror

to the light source tube.

Note: The lamps are hot when they are on or right after they are turned off. Replace the lamp after it gets cold to prevent burns.

Note: Be sure to stop the generator before replacing the lamp to prevent electric shocks.

Note: Make sure that the lamp should be replaced with a YANMAR genuine lamp. Other types of lamp could not light or provide their perfor-

Latch

mance.

Fig. 5.1.2-1 Replacing lamp (spotlight)

5-4

5. Inspection and Maintenance Note: Be sure to set the light source tubes to the reflex mirrors so that the cables of the two upper lighting unit assemblies should come downward and the cables of the two lower lighting unit

assemblies

should

come

upward.

(Fig.5.1.2-2)

Cable

Fig. 5.1.2-2 Setting light source tube

(2) Replacement of lighting unit assembly zCheck if the front glass and the reflex mirror are not dirty. If they are, wipe off dirt. If the lamp does not light properly because the lighting unit assembly malfunctions, replace the lighting unit assembly with a new one. Refer to Section "4-2-5. Removal of Lighting Unit Assembly" and "4-2-6. Removal of Pin (Socket) Contact" for replacement of the lighting unit assembly.

2) Lamp stand assembly (1) Greasing of lamp stand

Fold lever

zCheck if the hinge of the lamp stand and fold lever moves smoothly. If they donít, apply spray grease at the place indicated by arrows in Fig. 5.1.2-3.

Hinge Fig. 5.1.2-3 Greasing lamp stand

(2) Adjustment of fold lever

Bolt (M8X20) Fold lever

zCheck if the fold lever locks and releases properly.

If it is not, adjust the fold lever by turning the bolt

Nut (M8)

(M8X20) as shown in Fig. 5.1.2-4, so that force needed for operating the fold lever will be 35 lbs.

(16kg). If turned the bolt clockwise, the force will be decreased. If turned the bolt counterclockwise, the force will be increased. And then tighten the nut (M8) securely to lock the position of the bolt.

Tightening torque: Fig. 5.1.2-4 Adjusting fold lever

14 to 19 N-m (1.4 to 1.9 kgf-m) 5-5

5. Inspection and Maintenance 5-1-3. Replacement of Balloon Unit and Lamp Stand Unit 1) Replacement zThe balloon unit for the balloon type (LB446HB-1) and the lamp stand unit for the spotlight type (LB446H-1) are replaceable each other. Refer to Section "4-2-7. Removal of Stand Assembly" for removal of the balloon unit and Section "4-2-8. Removal of Lamp Stand Assembly" for removal of the lamp stand unit. And Install the balloon unit and the lamp stand unit in the reverse order of the removal procedure.

Note: Note: Be sure to tighten the button screw or adjust lever completely. Failure to do so could cause the balloon unit or the lamp stand unit to fall down and result in personnel injuries.

Note: Note: Be careful not to lose removed screws and connector covers.

2) Storage of removed balloon unit and lamp stand unit (1) Balloon unit zWipe off mud and dirt zCover the balloon unit with the cover. zAvoid a place exposed to rain or with high humidity to store the balloon unit.

(2) Lamp stand unit zWipe off mud and dirt, supply grease and grease up. zCover the lamp stand unit with the cloth not to gather dust. zAvoid a place exposed to rain or with high humidity to store the lamp stand unit.

5-1-4. Power Cable Unit 1) Connection of power cable zRemove the connector covers on the mast group and on the balloon assembly for the balloon type (LB446HB-1) or on the lamp stand assembly for the spotlight type (LB446H-1), and check if the couplers (plug housing and receptacle housing), pin contacts and socket contacts are connected securely. Refer to Section "4-2-3. Disconnection of Couplers" for removal of the connector covers. If there is any connection loosened or disconnected, connect it securely until it clicks.

5-6

5. Inspection and Maintenance 2) Voltage check zCheck if the standard voltage is outputted from the generator. Measure voltage at the plug housings (generator) and the plug housing (lamp cable) by using a circuit tester as shown in Fig. 5.1.4-1. Observe the following procedures for measuring non-load voltage.

1. Disconnect the couplers on the mast group and on the balloon assembly for the balloon type (LB446HB-1) or on the lamp stand assembly for the spotlight type (LB446H-1). Refer to section "4-2-3. Disconnection of Couplers" for removal of the couplers.

Plug housing

2. Start the engine and confirm the speed is 3700 to 3750 rpm.

Note: When the starter key is at the "ON" position, the power for the fan motor is generated.

3. Turn on lamp switches of the generator.

4. Confirm locations of measuring points and measure each voltage. Locations of measuring points in the each plug housing and corresponding lamps and fan motor to those

Fig. 5.1.4-1 Voltage check

points are shown in Table 5.1.4.

Table 5.1.4 Locations of measure voltage

Plug housing (lamp cable)

A B C D E F G H I J Lamp 1 Lamp 2 Lamp 3 Lamp 4 Fan motor

B-F A-E C-I D-J G-H

Plug housing (generator)

Balloon type (LB446HB-1)

Spotlight type (LB446H-1)

K L M N O P Q R S T O-T N-S M-R L-Q K-P

Non-load Voltage: AC 230 to 250 V (Lamp) DC 12 V (Fan motor)

Pulse

1 min.

Pulse

Note: Voltage for the lamps differs between when the pulse is generated and when it is not as shown in Fig. 5.1.4-2.

Read off voltage when the pulse is not generated.

2000V 230V to 250V

Note: High voltage pulse at over 2000V is generated. Take great care not to get electric shocks when measuring

Fig. 5.1.4-2 Interval of generated pulse

voltage.

Note: When measuring voltage, connect a capacitor in parallel

Capacitor

Circuit tester

with the circuit tester as shown in Fig. 5.1.4-3.

Specification of Capacitor: 600 WV-0.1 microF Fig. 5.1.4-3 Connecting capacitor

5-7

5. Inspection and Maintenance 3) Replacement of lamp cable zCheck if the lamp cable is not bared or broken. If it is, replace the lamp cable with a new one. Refer to section "10-1. Troubleshooting Procedures" for

Plug housing Receptacle housing

Wire band T50RSF

check for the lamp cable. zObserve the following procedure for replacing the lamp cable. (Fig. 5.1.4-4).

1. Disconnect the couplers on the mast group and on the balloon assembly for the balloon type (LB446HB-1) or on the lamp stand assembly for the spotlight type (LB446H-1). Refer to Section "42-3. Disconnection of Couplers" for removal of the couplers.

2. Cut the wire bands at the mast unit, and then remove the lamp cable.

3. Set the mark on new lamp cable to the right hole of each mast as shown in Fig.5.1.4-5 and install the lamp cable to the first, second and third mast with two wire bands T50RSF each.

Note: Start installing the lamp cable to each mast

Wire band SKB-2M

Receptacle housing

with the wire bands in order of the first mast, Plug housing

the second mast and the third mast.

4. Bind the lamp cable and the first mast with the wire band SKB-2M.

Generator

5. Cut off extra part of the wire bands.

Fig. 5.1.4-4 Replacing lamp cable

Mark

Third mast Second mast First mast

Fig. 5.1.4-5 Installing lamp cable

5-8

5. Inspection and Maintenance

5-2. Mast Group 5-2-1. Mast Group 1) Shaft of mast zCheck if the lamp stand turns smoothly. If they donít, remove the balloon unit for the balloon type (LB446HB-1) or the lamp stand unit for the spotlight type (LB446H-1) from the mast group and apply grease lightly on the shaft of the fourth mast. Refer to Section "4-2-7. Removal of Stand Assembly" for removal of the balloon unit and Section "4-2-8. Removal of Lamp Stand Assembly" for removal of the lamp stand unit and Section "8-1-4. Materials Required" for description of the grease.

2) Sliding surface of mast zCheck if the mast is raised and lowered smoothly.

If the sliding surface of the mast is not smooth, clean the surface of the mast or apply spray grease at the place indicated by the arrows in Fig. 5.2.2-1.

Refer to Section "8-1-4. Materials Required" for description of the grease.

Fig. 5.2.1-1 Greasing mast

3) Winch zCheck if the end of the wire is connected with the winch securely. If the wire is disconnected or loosened, remove the winch cover and securely tighten the screw indicated by arrow in Fig. 5.3.2-5.

If the winch malfunctions such as the brake dose not work well, replace the winch with a new one.

Refer to section "4-2-13. Disassembly of Stand Assembly" for removal of the winch.

Fig. 5.2.1-2 Connection of winch

5-9

5. Inspection and Maintenance 4) Wire zCheck if there is enough grease is at the connection of the wire end and the fourth mast. If there is not, apply spray grease to the connection. Refer to Section "8-1-4. Materials Required" for description of the grease. zCheck if wire or wire end is damaged. If it is, replace the wire with a new one.

Note: Replacing wire requires removal of the second mast from the first mast. Refer to Section "4-2-2. Disassembly Procedure of Each Assembly /Unit /Group" for disassembly of the mast group. If the wire cannot be pulled because of break of the wire itself, the safety stoppers installed in the second mast will lock automat-

Fig. 5.2.1-3 Places of safety stopper

ically at the places indicated by arrows in Fig. 5.2.1-3.

In order to release the safety stopper without pulling the wire when remove the second mast from the first mast, insert a screwdriver into a hole near the position which the latch of the stopper is caught at and press down the screwdriver to lift the pulley installed in the second mast as shown in Fig. 5.2.1-4. Remove the screwdriver lifting the second mast upward when the latch is pulled back, and then pull the second mast out of the first mast.

Fig. 5.2.1-4 Releasing safety stopper

5-10

5. Inspection and Maintenance zObserve the following procedure for replacing the

Up

wire. (Fig. 5.2.1-5) 1. Remove wire from the pipe 1 at the lower part of

4

Third mast

the third mast.

2. Pass a new wire 2 through the pipe 1 from above.

3. Pass the wire around pulley 3 on the bottom of the

1

third mast from back to front.

4. Pass the wire around pulley 4 on the top of the second mast from front to back.

5. Pass the wire around pulley 5 on the bottom of the

2

Second mast

second mast from back to front.

3

Back

Front

5

Down Fig. 5.3.1-5 Replacing wire

5-11

5. Inspection and Maintenance

5-3. Outrigger Group zCheck if the outriggers move smoothly and the weights lock outriggers properly. If there is any problem in them, apply spray grease at the place indicated by arrows in Fig.5.3 or replace them. Refer to Section "8-1-4. Materials Required" for de-

Weight

scription of the grease and "4-2-18. Disassembly of Outrigger Group" for disassembly of the outrigger

Outrigger

group.

Fig. 5.3 Greasing outriggers

5-4. Base Plate Group 5-4-1. Base Plate Unit zCheck if air pressure in the tire is enough or not excessive. If it is not proper, adjust air pressure between 245 and 294 kPa. Note: When the air pressure is not enough, the brake does not work well.

5-4-2. Steering Unit zApply spray grease at the place indicated by arrows in Fig. 5.4.2 if linkages of the shafts do not move smoothly. Refer to Section "8-1-4. Materials Required" for description of the grease.

Fig. 5.4.2 Greasing linkage

5-12

5. Inspection and Maintenance 5-4-3. Brake Unit zApply spray grease in between the brake pedal and

Brake shaft

brake shaft when brakes do not work properly. Refer to Section "8-1-4. Materials Required" for description of the grease. Check the tire air pressure, too. zCheck notch of the brake pedal is not worn. If it is, replace brake pedal. Refer to Section "4-2-2. Disassembly Procedure of Each Assembly /Unit /

Brake pedal

Group" for disassembly of the brake unit.

5-5. Grounding zThe grounding plays important roles such as prevention of electric shocks. Therefore, it is required to connect to the ground with the bolt (M6X10) when operating the floodlight projector.

Tightening torque: 5.9 to 7.8 N-m (0.6 to 0.8 kgf-m) Ground cable

zChoose a cable whose thickness is appropriate to the load carrying capacity according to your countryís regulation and industrial standards. Use a ground rod whose ground resistor is 10 ohms or less.

5-13

Ground rod

Ground terminal (M6X10)

MEMO

5-14

Periodic Inspection Items

6-1

6. Periodic Inspection Items

6. Periodic Inspection Items This section gives the minimum inspection items that should be checked in order to maintain the lighting towerat excellent operating quality.

Contents of inspection vary greatly according to the operating conditions including the total operating hours, load conditions and place of operation. Here, inspection items and intervals are described on the assumption that the lighting toweris operated at the normal condition.

Understand the floodlight projectorís maintenance history and condition by checking past records before beginning a periodic inspection in order to ensure appropriate overhaul maintenance and adjustments.

6-1. Inspection Items and Intervals Table 6.1 Periodic maintenance schedule Items and inspection intervals Figure *B L1 L2 L3

Lamp

Balloon

Mast

S L4 L5 L6

L7 L8 L9 - L10 L11 - L12 B1 B2 M1 M2 M3 M4 M5 M6 C1 C2 C3 C4 C5 C5 C6 C7

Part

Check item

Service item

Fan motor Frame pipe Lamp brace Lamp (Base) Lamp Pin contact Fold lever Nut Hinge for lamp stand Shaft for lamp stand Front glass Reflex mirror Envelope Zipper Hanger Mast sliding surface Wire rope Wire rope end Winch Safety stopper Weight Outrigger Link of handle and wheels Bolt for handle Brake pedal Brake pedal Wheel stopper Front wheel shaft

Check if it works well.

Check if it is not skew.

Check if it is not loosened.

Check if it is not loosened.

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

Check if it is not disconnected or loosened.

Check if it locks and releases by force of 35 lbs.(16kg).

Check if it is not too loose.

Check if it moves smoothly.

Check if it turns smoothly.

Check if it is not dirty.

Check if it is not too dirty or broken.

Check if it is not broken or dirty.

Check if it is not broken.

Check if installation is not loosened.

Check if mast slides smoothly.

Check if it not damaged.

Check if end is not damaged caulking.

Check if brake works well.

Slacken wire rope and check if latch sticks out.

Check if it moves smoothly.

Check if it moves smoothly.

Replace.

Replace.

Replace.

Screw in securely.

Replace.

Connect securely.

Adjust.

Tighten properly.

Supply grease.

Apply grease.

Wipe off dirt.

Wipe off dirt or replace.

Replace.

Replace.

Fasten securely.

Apply grease.

Apply grease or replace.

Replace.

Replace.

Repair.

Spray grease.

Spray grease.

◎ ◎ ◎ ◎ ◎ ○ ◎ ◎ ● ● ◎ ◎ ◎ ◎ ○ ● ◎ ◎ ◎ △ ● ●

Check if it is not loose linking.

Tighten securely

○

Check if it is not loosened.

Tighten securely Check if linking part moves smoothly.

Spray grease.

Cart Check if notch is not worn.

Replace.

Check if bolt is not loosened.

Tighten securely.

Check if it turns smoothly.

Supplying grease.

Check if air pressure in tire is between 28.4 and 35.5 C8 Tire Adjust. psi (245 and 294 kPa).

C9 Link for front shaft Check linkage moves smoothly.

Spray grease.

C10 Brake Check if it works well.

Adjust.

E1 Cable Check if wire is not bared.

Replace.

Electric E2 Coupler Check if it is not disconnected or loosened.

Connect securely.

E3 Non-load voltage Check if voltage is about 240 V. Repair. ◎ ...Daily check ○ ...Every 20 hrs. ● ...Every 100 hrs. △ ...Every 500 hrs. ▲ ...Every 1000 hrs. * B...Balloon type S...Spotlight type

6-2

○ ◎ ◎ ● ● ◎ ● ◎ ◎ ○ ▲

6. Periodic Inspection Items

B2 B1

M2 E1 M1 M3 M4 E3 M5 M6 E2

C6

C1 C7 C2

C3

C8 C9 C4

L5

L2

C10

C5 L3 L3 L4

L9 L8

L1

L11

L6 L4 L10

L7 Fig. 6.1 Inspection items Correspond to Table 6.1

6-3

L12

MEMO

6-4

Circuit

7-1

7. Circuit

7. Circuit This section describes electrical circuit. Use this section as reference for inspection, overhaul maintenance and troubleshooting of the lighting tower.

7-1. Electrical Circuit 7-1-1. How to Read Electrical Circuit Diagram Locations of the pin contacts in the receptacle housings and the socket contacts in the plug housings are represented by alphabets and numerals. Refer to the detailed figure of the housings for corresponding locations to those alphabets and numerals.

7-1-2. Electrical Circuit Diagram The lamps on circuit diagram are in a position where they are seen from the front side. zBalloon type (LB446HB-1) .................................... Fig. 7.1.2-1 Electrical circuit (balloon type) zSpotlight type (LB446H-1) ..................................... Fig. 7.1.2-2 Electrical circuit (spotlight type)

7-2

7. Circuit Receptacle housing Pin contact Plug housing Socket contact Lamp

Lamp

Lamp

Lamp

Fan motor

A B C D E

A1

A3

YELLOW

C1

C3

YELLOW

PURPLE A2

A4

BROWN

C2

C4

BLACK

ORANGE B1

B3

RED

D1

D3

PURPLE

D2 F1

D4

BROWN

F3

GRAY

F2 E1

F4 E3

YELLOW

E2 A1

BLUE E4 A3 YELLOW/GREEN

GRAY

B2 C1

B4

GREEN

C3

ORANGE

C2 YELLOW D1

C4 D3

PINK

BROWN D2 BLACK F2

D4 F4

BLACK

WHITE

E4

WHITE

BLUE RED

GENERATOR GREEN

E2

BLUE GRAY

A2 GREEN B2

A4 B4

BLUE

RED GREEN Plug housing Socket contact Receptacle housing Pin cantact

Electric wire

Earth

Lamp A

Lamp D

(Located the back of Lamp D)

Lamp C

Lamp B

Detailed figure Receptacle housing B1 A1 E1 B2 A2 E2 F2 D2 C2

Fan motor E

Plug housing

C1 D1 F1

B3 A3 E1 B4 A4 E4 F4 D4 C4

Generator

C4 D4 F4

Fig. 7.1.2-1 Electrical circuit (balloon type)

7-3

It is seen from the front side

7. Circuit

Receptacle p housing g Pin contact Plug g housing g Socket contact

Lamp

Lamp

Lamp

Lamp

A B C D

A1 1

A3 3

YELLOW

C1 1

C3 3

YELLOW

PURPLE A2

A4

BROWN

C2

C4

BLACK

ORANGE B1

B3 3

RED

D1

D3 3

PURPLE

B4

GREEN

D4

BROWN

C3 3

ORANGE

D2 F1 1

F3 3

GRAY

C2 1 YELLOW D1

C4 D3 3

PINK

F2 E1 1

F4 E3 3

YELLOW

BROWN D2 F2

D4 F4

BLACK

E2 A1

BLUE E4 A3 3 Y YELLOW/GREEN EN N

E2

E4

WHITE

A2

A4 B4 4

GRAY

BLUE RED

B2 C1

GENERATOR GREEN

BLUE GRAY

BLUE

RED GREEN

Electric wire

Earth

Plug g housing g Socket contact Receptacle p housing g Pin cantact

Lamp

Lamp

Detailed figure Receptacle p housing g

Plug g housing g

B1 A1 E1 B2 E E2 D2 C2

C1 D1 F1

B3 A3 E1 B4 A4 E4 D4 C4

C4 D4 F4

Fig. 7.1.2-1 Electrical circuit (spotlight type)

7-4

It is seen from the front side

Tools, Instruments and Other Materials for Inspection and Maintenance

8-1

8. Tools, Instruments and Other Materials for Inspection and Maintenance

8. Tools, Instruments and Other Materials for Inspection and Maintenance Use of improper tools and other materials not only causes injury accidents, but also, damages to parts and failures in assembly. Make sure to use appropriate tools for ensuring excellent maintenance quality.

8-1. Machines, Tools and Instruments 8-1-1. General Tools Table 8.1.1 General tools Tool name

Screwdriver

Wrench 13

19

Socket wrench 24

13

17

19

Hexagon wrench 24

5

6

Schematic drawing

Part code

Tool name

Available in the market

Screwdriver

Wrench

Socket wrench

Schematic drawing

Part code

Tool name

Available in the market

Screwdriver

Schematic drawing

Part code

Available in the market

8-2

Hexagon wrench

8. Tools, Instruments and Other Materials for Inspection and Maintenance 8-1-2. Special Tool Table 8.1.2 Special too Contact remover

Tool name

1.5 10

JST mfg co.,ltd: VLJ-20

C 0.

5

2 6.5

5 0.

C

Schematic drawing

1.5

12 14.25 20.5

50 (70.5)

Part code

1-9900201-30

8-1-3. Measuring Instrument Table 8.1.3 Measuring instrument Instrument name

Circuit tester

Schematic drawing

Part code

Available in the market

8-1-4. Materials Required Table 8.1.4 Material required Material name

Grease

Spray grease

Lithium grease NLGI grade: No.2

WD-40 company Product name: WD-40

Schematic drawing

Description Part code

Available in the market

8-3

MEMO

8-4

Bolts and Nuts Tightening Torques

9-1

9. Bolts and Nuts Tightening Torques

9. Bolts and Nuts Tightening Torques The essential requirement for ensuring high quality servicing is to use appropriate tools such as the torque wrench and special tools and observe the tightening torque requirements. Thoroughly read the following cautions for correct servicing.

9-1. General Instructions It is necessary to specify the conditions at tightening for ensuring the accurate and consistent parts holding forces or preventing loose nuts and bolts as well as protecting bolts and mating parts from damages.

As requirements are indicated under the tables, observe them carefully, in addition to the specified tightening torques.

9-2

9. Bolts and Nuts Tightening Torques

9-2. Major Bolts and Nuts Table 9.2 Standard tightening torque list For major bolts and nuts of lighting tower

Part

Name

Thread diameter x pitch

Base plate (earth)

Bolt (M6X10)

M6 x 1.0

Head surface width (mm)

Tightening torque N-m (kgf-m)

10

5.9 to 7.8 (0.6 to 0.8)

Rail (E/G oil) CP and Rail R

Bolt (M6X15)

M6 x 1.0

10

5.9 to 7.8 (0.6 to 0.8)

Lamp stand

Bolt (M8X20)

M8 x 1.25

13

14 to 19 (1.4 to 1.9)

Forth mast and shaft (stand)

Button screw (M8X10)

M8 x 1.25

*5

14 to 19 (1.4 to 1.9)

Side guard and Base plate

M8 x 1.25

13

14 to 19 (1.4 to 1.9)

M8 x 1.25

*5

14 to 19 (1.4 to 1.9)

M8 x 1.25

*5

14 to 19 (1.4 to 1.9)

Link (handle) and steering link

Bolt & washer (M8X15) Button screw & washer (M8X25) Button screw & washer (M8X25) Selflock nut (M8)

M8 x 1.25

13

14 to 19 (1.4 to 1.9)

Base plate and bracket (out,r) L

Bolt & washer (M10X25)

M10 x 1.5

17

25 to 34 (2.6 to 3.5)

Cover (spring) and stand Joint block 2 and plate (top)

Base plate and bracket (out,r) R

Bolt & washer (M10X25)

M10 x 1.5

17

25 to 34 (2.6 to 3.5)

Base plate and first mast

Bolt & washer (M10X25)

M10 x 1.5

17

25 to 34 (2.6 to 3.5)

First mast and winch HM-G 103

Bolt & washer (M10X25)

M10 x 1.5

17

25 to 34 (2.6 to 3.5)

Joint block 1 and plate (bottom)

Button screw (M10X35)

M10 x 1.5

*6

25 to 34 (2.6 to 3.5)

Bracket (out, r) L and weight (out, r) L

Selflock nut (M10)

M10 x 1.5

17

25 to 34 (2.6 to 3.5)

Bracket (out, r) R and weight (out, r) R

Selflock nut (M10)

M10 x 1.5

17

25 to 34 (2.6 to 3.5)

Flange and stand

Set screw (M10X25)

M10 x 1.5

*5

25 to 34 (2.6 to 3.5)

Catcher R and Base plate

Bolt & washer (M10X25)

M10 x 1.5

17

25 to 34 (2.6 to 3.5)

Catcher L and Base plate

Bolt & washer (M10X25)

M10 x 1.5

17

25 to 34 (2.6 to 3.5)

Base plate and stopper (gene) L

Bolt & washer (M12X25)

M12 x 1.75

19

28 to 38 (38 to 51)

Base plate and stopper (gene) R

Bolt & washer (M12X25)

M12 x 1.75

19

28 to 38 (38 to 51)

Handle and link (handle)

Bolt & washer (M12X25)

M12 x 1.75

19

28 to 38 (38 to 51)

Rail R and Base plate

Bolt & washer (M12X25)

M12 x 1.75

19

28 to 38 (38 to 51)

Rail L and Base plate

Bolt & washer (M12X25)

M12 x 1.75

19

28 to 38 (38 to 51)

First mast and hanger

Bolt (M12X40)

M12 x 1.75

19

28 to 38 (38 to 51)

Bolt (M12X75)

M12 x 1.75

19

28 to 38 (38 to 51)

Brake and brake shaft

Bolt (M12X75) left screw

M12 x 1.75

19

28 to 38 (38 to 51)

Bracket (out, r) L and outrigger L

Bolt (M16X90)

M16 x 2.0

24

86 to 117 (117 to 158)

Bracket (out, r) R and outrigger R

Bolt (M16X90)

M16 x 2.0

24

86 to 117 (117 to 158)

Lamp stand and lighting unit assy.

Nut (M16)

M16 x 2.0

24

49 to 66 (67 to 90)

* Hexagon socket head screw

9-3

MEMO

9-4

Troubleshooting

10-1

10. Troubleshooting

10. Troubleshooting When a malfunction occurs to the floodlight projector, it is necessary to isolate the part (position) causing the failure. Further, the true cause must be identified from the symptom of the part for correct recovery action under consideration of recurrence prevention.

This section gives a method for efficient troubleshooting work.

10-1. Troubleshooting Procedures If isolating the problem cause or faulty part is difficult, it is necessary to sequentially check component parts in an orderly manner. The figure below illustrates the check sequence.

First read the question in the text box and go to be next box in the direction of Y if the answer is Yes or N if the answer is No. At the end, some component parts that possibly can cause the problem are listed.

Check them and then isolate the true cause of the problem.

Table 10.1-1 Troubleshooting chart (1/4) Lamp dose not light up properly Legend : Symbols Y and N represent Yes and No, respectively.

Indication of Corrective Action column: A numeral indicates to refer the respective section of this manual.

Lighting Tower

Y

01 Is lamp switch of generator turned off?

N

Y

02 Is lamp still hot?

N

Y

03 Is lamp loosended?

N

Y

04 Dose a new lamp light up?

N

Y

05 A re any cables loosened or disconnected?

N Is voltage at plug housing of lamp cable normal?

06 Non-load voltage is about 240V. (5.1.4)

Is voltage at plug housing of power cable from

Lamp is burned out or broken.

Replace it with a new one.

(5.1.1, 5.1.2) Connect cables correctly.

(5.1.4)

Y

Lamp cable is broken.

Replace it with a new one.

(5.1.4)

N Generator mulfunctions.

Refer to generator service manual.

10-2

Screw lamp securely.

(5.1.1, 5.1.2)

Balloon or lighting unit assy is broken.

Repair it or replace it with a new one.

(4.2.12, 5.1.2)

Non-load voltage is about 240V. (5.1.4)

Generator

Wait until lamp gets cold enough.

Interval of 20 to 30 min. to light again.

Y

N 07 generator normal?

Turn on switch.

10. Troubleshooting Table 10.1-2 Troubleshooting chart (2/4) Mast can not be raised

Y

12 Is winch winded in wrong way?

N

Y

13 Is lamp cable caught in mast?

N

Y

14 Dose surface of mast slides stiff?

N

Y

15 Is end of wire disconnected from winch?

N 16

Y

Is wire broken?

N

Y

17 Winch mulfunctions.

Wind it in correct way.

Set caught cable free.

Clean sliding surface of mast and supply grease.

(5.2.1) Connect wire to winch securely.

(5.2.1) Replace wire with a new one.

(5.2.1) Replace winch with a new one.

(5.2.1)

Table 10.1-3 Troubleshooting chart (3/4) Mast can not be lowered

Y

18 Dose surface of mast slides stiff?

N 19 Dose safety stopper function because wire is

Y

broken?

N

Y

20 Mast is bent.

Clean sliding surface of mast and supply grease.

(5.2.1) Replace wire with a new one.

(5.2.1) Replace bent mast with a new one.

(4.2.2)

Table 10.1-4 Troubleshooting chart (4/4) Balloon is not inflated [for balloon type (LB446HB-1)] Y

08 Is zipper opened?

N

Y

09 Is envelope broken?

Zip it up.

Replace envelope with a new one.

(5.1.1)

N Y

Are any cables for fan motor loosened or

10 disconnected in balloon assembly?

N

Y

11 Fan motor mulfuncitons.

10-3

Connect cables correctly.

(4.2.12) Replace fan motor with a new one.

(5.1.1)