Yanmar Light Boy LB446H Operation & Maintenance Manual - PDF DOWNLOAD

LGBLB446H0 Never attempt to operate or service this Floodlight Projector 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.

S/N E10001 & 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 Floodlight projector in the spaces bellow.

Always use these numbers when referring to your YANMAR Floodlight projector.

Model name

:

Serial Number (Floodlight Projector)

:

Serial Number (Generator)

:

Your YANMAR

Dealer

:

Address

:

Phone

:

1. Introduction • This Operation & Maintenance Manual for the YANMAR floodlight projector 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 floodlight projector 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 floodlight projector.

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 floodlight projector.

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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..........................................................1-8 6. Precautions for Servicing .................................................................................................................1-9 7. Location of Warning Labels............................................................................................................1-11 7-1. Warning labels and location...................................................................................................1-11 SPECIFICATIONS 8. Floodlight Projector ..........................................................................................................................2-2 9. Generator .........................................................................................................................................2-3 OPERATION 10. Floodlight Projector ........................................................................................................................3-2 10-1. Product overview ...................................................................................................................3-2 10-2. Loading generator..................................................................................................................3-3 10-3. Replacing lamp ......................................................................................................................3-6 10-4. Operating each part ...............................................................................................................3-7 11. Generator .....................................................................................................................................3-15 11-1. Product overview .................................................................................................................3-15 11-2. Grounding ............................................................................................................................3-20 11-3. Installation............................................................................................................................3-21 11-4. Operation instructions ..........................................................................................................3-23 MAINTENANCE 12. Floodlight Projector ........................................................................................................................4-2 12-1. Periodic checks, maintenance and storage ...........................................................................4-2 12-2. Unclear points or problems ....................................................................................................4-4 13. Generator .......................................................................................................................................4-5 13-1. Precautions for inspection......................................................................................................4-5 13-2. List of periodic inspections.....................................................................................................4-7 13-3. Periodic inspection items .......................................................................................................4-8 0-3

3. Contents TROUBLESHOOTING 14. Floodlight Projector ........................................................................................................................5-2 15. Generator .......................................................................................................................................5-3 ELECTRICAL DIAGRAM 16. Electrical Diagram ..........................................................................................................................6-2 ORDERING REPIACEMENT PARTS AND SERVICE CALL 17. Ordering Replacement Parts and Service Call...............................................................................7-2 NOTES 18. Maintenance Log............................................................................................................................8-2 19. Notes ..............................................................................................................................................8-5

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SAFETY

Never attempt to operate or service this Floodlight projector 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 • Lower the position of lamps when using in a strong wind, to prevents floodlight projector from overturning.

• Set the floodlight projector 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 floodlight projector from overturning.

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

• If no generator is loaded, put the weight (about 100 kg) to prevent the floodlight projector from over turning.

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

For the procedure of grounding the cable, refer to Section "10-4-5. Grounding cable".

Tires • Set the air pressure in the tires for 2.0 to 2.5 kgf/cm2 (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 [m]

100/200 or less

2 or more

6600 or less

2 or more

22000 or less

3 or more

66000 or less

4 or more

154000 or less

5 or more

275000 or less

7 or more

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5. Operating Precautions

5-3. Precautions for transportation

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

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

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

• Be sure to lift the floodlight projector sideways when lifting it with a forklift.

Insert forks of the forklift between the cart and the link shaft and stabilize the floodlight projector on the forks, to prevent it from falling or being damaged.

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

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

• Lower the mast and fold the lamp stand to prevent the floodlight projector from bumping into a tunnel or the like when transporting it by a truck.

Model

Height in storage Style

LB446H

1780 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 floodlight projector in a place exposed to rain, snow or water sprays.

• Never touch the plugs and the electric terminals when the floodlight projector is in operation 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 to turn the lamp switches (for floodlight projector) 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.

• The generator should be grounded to prevent electric shocks from faulty appliance.

For the procedure of grounding, refer to Section "11-2. Grounding".

• 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.

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 generator before replacing the lamp with a new one. Failure to stop the generator could result in electric shocks.

• 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.

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6. Precautions for Servicing

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.

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.

7-1-1. Location of warning labels

1

2 1-11

7. Location of Warning Labels 7-1-2. Warning labels

Caution: Exhaust gas, Burns and Flammables (183797-07720)

Emergency stop (183797-07220)

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7. Location of Warning Labels

Shock hazard 1-7510069-30

Shock hazard 1-7510064-30

Genuine lamp 1-7510071-30

Burn hazard 1-7510063-30

Handling of lamp stand 1-7510067-30

Operation of winch 1-7510070-30

Lifting point 1-7510065-30 Direction of winch 1-7510073-30

Forklift lifting 1-7510072-30

Ground cable 1-7510066-30

Setup of outrigger 1-7510060-30

Precautions for use 1-7510062-30 Commonness (Warning,Danger) 1-7510061-30

Tire air pressure 1-7510068-30

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MEMO

1-14

SPECIFICATIONS

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8. Floodlight Projector Type

High-frequency floodlight projector

Model

LB446H Rated voltage

V

Type!Number of lamp Lamp

Total luminous flux

Metal Halide Lamp Type S M400 SC/BU!4 lm

Projection angle Floodlight projector

Telescopic 4 stage mast

Mast operation

Manual winch

Min. & max. height

mm

In operation (L!W!H)

mm

1690!2110!2180~5630

In storage (L!W!H)

mm

1040!920!1780

kg

246

Mass Model Rated output

YDG25HSS-EX kVA

Starting system Generator

2180 to 5630 4 tired wheels (Ø300 mm)

Wheel Dimension

160000 Variable

Type of mast Mast

130

Fuel oil/Tank capacity

Electric starting L

Continuous operation without re-supplying fuel oil

1.7

hrs

Emergency stop system

Diesel fuel/15 18* Engine stop device by low level oil sensor

Generator dry mass

kg

130

Cart dry mass

kg

116

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

• The total luminous flux is the value when lamps irradiate the 45 degrees direction downward from the level.

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

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

2-2

9. Generator

Model Item

YDG25HSS

Applicable floodlight projector

4-lamp high frequency floodlight projector (400W, 4 lamps)

Generator Type

Permanent magnet revolving field type synchronous generator

Phase

Single

Number of poles

18

Frequency

Hz

540 (3600 rpm)

Rated output

kVA

1.7

Rated (on load) voltage

V

130

Current x Number of coils

A

3.3 x 4

Power factor

1.0

Rated revolution speed

rpm

3600

Insulation

Type E

Engine Model

L48AD EGYSS6H

Type

Vertical air-cooled 4 cycle diesel engine

No. of cylinders - bore x stroke Displacement Continuous rated output

mm

1 - 70 x 55

L

0.211

kW (PS)/rpm

3.1 / (4.2) / 3600

Cooling system

Forced air-cooled system

Lubricating system

Forced lubrication

Starting system Electrical equipment

Electric starting Starter capacity

V-kW

12 - 0.8

Charge system Battery capacity

Flywheel dynamo V-Ah

12 - 18 (12N18-3)

Fuel oil

Diesel fuel oil (light oil)

Lube oil

CC class (10W-30)

Fuel tank capacity

L

15

Lube oil capacity

Upper limit

L

0.8

(Oil pan)

Lower limit

L

0.55

Replenishing interval

Fuel

hrs

18

(Reference period in rated output)

Lube oil

hrs

100

Engine protect device

Low oil level

Automatic stop device

Gen. Set Overall length x width x height Dry mass

mm

713 x 595 x 688

kg

130

2-3

MEMO

2-4

OPERATION

3-1

10. Floodlight Projector 10-1. Product overview 10-1-1. Running condition Ambient temperature -5 to 40 °C 10-1-2. Parts name Lighting unit

Fold lever Lamp stand Lamp Direction adjust lever

Mast

Cable Generator

Winch

Hanger

Handle bar

Winch handle

Generator holder

Wheel stopper (for Generator)

Lamp switch

Connector cover

Cart

Brake pedal Parking brake Outrigger

3-2

Wheel

10. Floodlight Projector

10-2. Loading generator • Read this section when loading the generator.

• If the generator has been loaded and ready for use, refer to Section “10-4. Operating each part”.

10-2-1. Loading of generator 1) Apply the brake to prevent the cart from moving. (Refer Wheel stopper

to Section “10-4-2. Operating 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.

Brake pedal

Stopper bolt (M12)

3) Lift up the rear side of the generator (the opposite side of the exhaust outlet) to put the rear wheels onto the cart.

4) Hold the front and push it in.

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

Guide square pipe

3-3

10. Floodlight Projector 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 : 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

Shackle

Tightening torque : 38 to 51 N•m 10-2-2. 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.)

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Coupler

10. Floodlight Projector 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

10-2-3. Unloading of generator When unloading the generator, first follow the reverse order of the procedure of Section "10-2-2. Connection of generator power cable", and then the reverse order of the procedure of Section "10-2-1. Loading of generator".

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10. Floodlight Projector

10-3. Replacing lamp 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 type S M400•SC/BU

1-3010006-10

10-3-1. Installation of lamp

Socket

1) Screw the lamp into the socket.

• Be sure to stop the generator before replacing the lamp with a new one to prevent electric Lamp

shocks.

Socket

Never screw the lamp by force to prevent breakCable

age.

Reflex mirror

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.

Cable

Make sure that the cables are not upside down.

Cable

3) Fix all three latches in order to stabilize the reflex mirror to the socket. the lamp in the reverse order of the procedure ( • Remove ) of the “Installation of lamp” 3) 2) 1) when replacing it.

• 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.

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Latch

10. Floodlight Projector

10-4. Operating each part 10-4-1. Handle operation 1) Forward and reverse travel Pushing the handle bar forward makes the floodlight projector 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.

10-4-2. Operating 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 floodlight projector could move and cause accidents or injuries.

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10. Floodlight Projector 10-4-3. Outrigger 1) Setup (1) Turn out the upper outrigger received in the side of the cart. The outrigger is automatically locked.

In operation

In storage Outrigger

(2) Turn out the lower outrigger backward. Go ahead to the next procedure before it is turned down.

(3) Turn the outrigger 90 degrees forward horizontally.

90 degrees

(4) Adjust the outrigger to the catcher indicated by lower right arrow and turn it down on the ground. The outrigger is automatically locked.

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

Use the outrigger to prevent the floodlight projector from overturning when using it in a strong wind or without loading a generator. In order to increase safety, fix it with a rope and blocks as well.

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10. Floodlight Projector 2) Storage (1) Strongly step on the places indicated by arrows to set

Weight

up the weights.

(2) Holding the weight as shown in the right figure, turn the sideward outrigger to a diagonally upper position.

Weight

(3) Turn the outrigger 90 degrees backward horizontally and store it in the cart.

90 degrees

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

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10. Floodlight Projector 10-4-4. Operating lighting unit 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 direction adjust lever and turn the lamp stand to any direction.

Always tighten the direction adjust lever firmly except when changing direction of lamp stand to pre-

Direction adjust lever

vent 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

3-10

10. Floodlight Projector 4) How to adjust the angle of the lights (1) 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.

(2) Be sure to set a metal halide lamp (M400 SC/BU) to the lighting direction between the level and 90 degrees downward when using it.

Horizontal

The lighting unit is hot while lamps are on and right

90 degrees

after they are turned off. Take great care in the operation.

Vertical

If turning on the standard equipped lamp beyond the direction range, the lamp could be damaged.

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.

3-11

10. Floodlight Projector 10-4-5. Grounding cable 1) Be sure to ground a ground cable.

Grounding cable

2) Choose a cable whose thickness is appropriate to the load carrying capacity according to your country’s regulations and industrial standards. Use a ground rod

Ground rod

whose ground resistor is 10 Ω or less.

Ground terminal

To prevent electric shocks, always connect to the ground.

10-4-6. 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.

1) Turning light on • Check the engine oil, battery fluid and fuel oil (diesel fuel)

YDG25HSS-EX

of the generator.

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

(2) Start the engine.

Starter key

For starting the engine, refer to Section "11-4-5. (1) Starting generator".

• 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.

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Lamp switch

10. Floodlight Projector 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 lighting units are hot while lamps are on and immediately after they are turned off.

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

10-4-7. Storage of lighting unit (1) Set the lighting unit 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.

3-13

Fold lever

10. Floodlight Projector (4) After completely pressing down the lighting unit, push down the fold lever to lock the lamp stand.

3-14

11. Generator 11-1. Product overview 11-1-1. Intended uses and conditions This generator has been developed as a dedicated generator for a floodlight projector to meet its quality requirements and is featured as follows.

(1) Features of generator • A higher quality of lighting provided owing to the developed high frequency generator (540 Hz, 18 poles), which solved the flickering and alternate lighting (like the glow of a firefly) of lamps.

• Economical generator with smaller fuel consumption owing to the dedicated generator developed for a floodlight projector, which adopts a smaller engine than a conventional one.)

• Environment friendly generator with a hood and frames developed to realize lower noises and vibrations.

• User-friendly generator with a side panel on which a startup operation, a switching operation of fuel cock, and the daily checks and maintenance of the oil and battery can be performed.

• No choice of frequency between 50 Hz and 60 Hz currently available. This generator deals with any frequency level and provides universal functions and performance.

(2) Running conditions • Fuel: Diesel fuel oil [ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No.45 minimum)] • Engine lube oil : API service classification, class CC SAE viscosity 10W30 • Ambient temperature : -5 to 40°C • Altitude : 300 m or lower • Relative humidity : 40 to 85% • For safety reasons, the operation and servicing of this generator is restricted to the persons who have good expertise and skills.

(3) Description of model name.

YDG 25 H SS - EX Product identified designation Soundproof type High frequency generator (540Hz) Capacity class of generator (25=1.7kVA) Denotation of Yanmar air-cooled diesel generator

3-15

11. Generator 11-1-2. Part names Inspection window "C" (for air cleaner) Lifting eye Fuel gauge Fuel filler cap Muffler

Cooling air outlet Air intake port Fuel drain plug

Muffler drain plug

Inspection window "A" (for battery, fuel cock, fuel filter and emergency stop lever) Lube oil drain plug Grounding terminal Control panel

Inspection window "B" (for lube oil filter)

3-16

11. Generator 11-1-3. Control panel (1) Control apparatus

OIL ALERT LAMP 3

1

2

OFF

ON START

STARTER SWITCH

ON

4

OFF

LAMP SWITCH

No.

Name

1

Starter switch

2

Oil alert lamp

3

Hour meter

4

Upper lamp switch

5

Lower lamp switch

3-17

5

11. Generator (2) Operating apparatus 1. Starter switch This is a control switch for starting, running and stopping OFF

the engine

ON

1) OFF The engine is stopped, all the power is cut off, and the key is allowed in and out.

START

STARTER SWITCH

Be sure to pull out the key and maintain it in a proper place to prevent accidents when the generator is not in use.

2) ON Operating position. Leave the key in this position while operating the generator.

3) START Engine starting position.

Turn the starter switch key to "START" to start the engine. Release the starter switch key after the engine is started and it will return to the "ON" position.

2. Oil alert lamp If the lube oil pressure falls during operation, the lamp lights and the engine is automatically stopped for protection.

Before starting the engine, the lamp lights when the starter switch is turned to the "ON" position, and the lamp goes off when the lube oil pressure rises.

If the lamp lights and the engine is stopped, check the oil level and for any oil leak immediately.

3. Hour meter Hour meter digitizes the integrated service hour of generator. Refer to it for a standard of periodic checks.

3-18

11. Generator 4. Upper lamp switch Upper lamp switch switches ON and OFF two lamps in the upper raw of the floodlight projector.

Be sure to turn the lamp switch to the OFF position before starting the engine.

Be sure to turn OFF the lamp switches and stop the engine when checking the lamps of the floodlight projector.

5. Lower lamp switch Lower lamp switch switches ON and OFF two lamps in the lower raw of the floodlight projector.

Be sure to turn the lamp switch to the OFF position before starting the engine.

Be sure to turn OFF the lamp switches and stop the engine when checking the lamps of the floodlight projector.

(3) Protective device The generator has a protect device, which works to stop the engine automatically when any troubles occur, to prevent the engine from damaging.

Trouble

Automatic engine stop

Oil alert lamp ON

Low lube oil pressure

"

"

The DC circuit for engine control has a 20A fuse to prevent a burn-out of electrical circuit and fire hazard when short circuit occurs. The fuse is installed in the hidden side of the control panel. (Refer to Section "16. Electrical Diagram") When the starter motor does not rotate, though no abnormality exists in the battery, terminal connection and starter switch in result of the inspections, check if the fuse has blown out.

IMPORTANT If any troubles occur, immediately stop using, check and repair the generator to remove the abnormality. To prevent accidents, never use it before removing the abnormality.

3-19

11. Generator

11-2. Grounding

Failure to ground the generator could cause electric shocks. The grounding terminal for its enclosure is installed in the output coupler. [Refer to Section Connecting complex and Section "16.

Electrical Diagram".)]

Connecting the coupler with that of the floodlight projector allows both of the generator and the floodlight projector to be grounded.

11-2-1. Grounding generator IMPORTANT Use the grounding terminal for the floodlight projector to ground the generator.

The grounding terminal for the enclosure of the generator is installed in the output coupler. [Refer to Section Connecting complex] (Refer to the Section "16. Electrical Diagram".)

Connecting the coupler with that of the floodlight projector allows both of the generator and the floodlight projector to be grounded.

11-2-2. Precautions for grounding work 1) Drive the ground rod into a shadowy and highly humid ground until its upper end completely is buried.

2) In a busy place, securely clamp the lead wire to prevent people from getting caught.

3) To extend the lead wire, connect the lead wires as follow.

• Securely connect the lead wires by soldering or sleeve, and then wind an insulating tape onto the connecting portion.

• Don not bury the connecting portion of the lead wires in the ground 4) Do not lay the ground cables underground within 2 meters of the place where a lightening rod is grounded.

5) Do not share the grounding cable with telephones.

3-20

11. Generator

11-3. Installation 11-3-1. Precaution for lifting up

• Use the lifting eye on the top of the hood to lift up the generator. Lifting it up with a rope or 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.

Handle bar (Never hang here)

3-21

11. Generator 11-3-2. Precaution for installation

Poor ventilation could result in exhaust fumes poisoning.

• Never use in a poorly ventilated location such as behind a building or a covered place, which is easily filled with the exhaust gas.

• Never use the generator in poorly ventilated locations such as indoors and inside tunnels.

• When using indoors or inside tunnels by necessity, take the following measures.

1) Extend the muffler to the outside or a well ven-

Note) To prevent the drain from remaining in the pipe, lay the pipe so that they have no concavity.

tilated place.

2) Extend the muffler drain pipe to the outside or a well ventilated place. Some amount of exhaust gas is discharged from the muffler drain pipe, which is always opened because the generator automatically evacuates a drain from the muffler.

3) Ventilate well using a ventilating fan or the like.

• Do not put the muffler and the muffler drain pipe with their exhaust outlets toward passersby or houses.

IMPORTANT Take the following precautions for installing the generator.

• Install the generator at least 1 meter away from buildings and other equipment.

• Do not operate the generator in a humid place to avoid short circuits and electric shocks.

• Unload the generator smoothly with special care not to giving it a shock. The generator could be seriously damaged with a shock.

• Refer to Section "10-2. Loading generator" for the procedures of removal and reinstallation of generator from and to the floodlight projector.

3-22

11. Generator

11-4. Operation instructions 11-4-1. Applicable fuel and lube oil # Fuel IMPORTANT Only use the recommended fuel to obtain the best engine performance and prevent damage of parts.

(1) Selection of fuel Use the following diesel fuels for best engine performance.

• ISO 8217 DMA • BS 2869 A1 or A2 [Fuels equivalent to Japanese Industrial standard, JIS. No. K2204-2] Cetane fuel number should be 45 or greater.

(2) Handling of fuel • Water and dust in the fuel oil can cause operation failure.

Use containers which are clean inside to store fuel oil.

Store the containers away from rain water and dust.

• Before supplying fuel, let the fuel container rest for sev-

Pump up only fuel above the down haif, leaving dreg accumulated on the bottom.

eral hours so that water and dust in the fuel are deposited on the bottom. Pump up only the clean fuel. # Lube oil IMPORTANT Use of non-recommended lube oil significantly increases the risk of seizure or wear of the inner parts, and your generator’s life may be seriously shortened.

(1) Selection of lube oil Use the following lube oil: • API Classification CC (Standards of America Petroleum Institute) • SAE Viscosity10W30 (Standards of Society of Automotive Engineering) (2) Handling of lube oil • Store and handle the lube oil with care not to allow any contamination or dust to be mixed in the lube oil. When filling the oil, take meticulous care such as cleaning around the oil filler port.

• Never mix up the different kinds of oil, which could lower an efficiency of lubrication.

3-23

11. Generator 11-4-2. Handling of 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.

• Batteries generate hydrogen gas, which can be highly explosive.

Do not smoke or allow flames or sparks near a battery.

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

• Charge the battery in a fully ventilated location.

• Keep the battery away from lighted cigarettes or matches or any other sources of ignition.

• To disconnect the battery cables, begin with the negative begin with the positive

terminal, and connect them,

terminal. Otherwise, if a tool simultaneously touches unexpect-

edly the positive terminal and the generator, potentially hazardous sparks may be generated and may damage the electric parts due to the short circuit.

• Do not connect the booster cables to the terminals in reverse polarity, if start the engine using booster cables. # Inspection of battery (1) Checking battery fluid level

Cap

Remove the cap from the each cell of the battery to see the

[Upper limit]

fluid level. If the fluid level has dropped to the lower mark (10 to 12 mm above the pole plate), supply the distilled water up to the upper mark.

[Lower limit]

(2) Checking specific gravity of electrolyte

Battery fluid level

When there is a possibility that the battery is discharged due to the failure of engine start-up, measure the specific gravity of the electrolyte. Charge the battery if the remaining charge is less than 75% Low

3-24

Normal

Too high

11. Generator • Measurement with gravimeter When using a gravimeter, a measured specific gravity should be corrected for temperature.

Based on the temperature at 20°C, the specific gravity of battery electrolyte is increased or decreased by 0.0007 as

Float

the temperature changes by 1°C. Therefore, a measured specific gravity can be converted into the specific gravity for 20°C using the following equation.

S20 = St + 0.0007(t-20) Fluid temperature at measurement

(Inspection of electric charge in battery with gravimeter)

Specific gravity of electrolyte at measurement Corrected specific gravity of electrolyte for 20 C

Rubber bulb Glass tube

Float

Gravimeter and Remaining electric charge of battery Gravity 20°C

Electric discharge %

Remaining electric charge %

1.260 (1.280)

0

100

1.210 (1.260)

25

75

1.160 (1.240)

50

50

1.110 (1.230)

75

25

(Structure of gravimeter)

(3) Checking terminal Clean the terminal if corroded or dirty.

(4) Checking clamp Repair or replace the clamp if corroded.

Tighten it if loosened.

(How to read gravimeter)

(5) External inspection of battery Exchange the battery if cracked or distorted.

Clean it with water if dirty.

3-25

11. Generator # Precautions for charging battery

• Charge the battery in a fully ventilated location removing the battery from battery mounting.

• To disconnect the battery cables, begin with the negative begin with the positive

terminal, and connect them,

terminal.

Otherwise, if a tool simultaneously touches unexpectedly the positive terminal and the generator, potentially hazardous spanks may be generated and may damage the electric parts due to the short circuit.

• Keep flames and sparks away from the battery while charging the battery because of producing the hydrogen gas. Ignition and explosion may occur.

• While charging the battery, remove all caps to release the gases generated by charging.

• If the battery overheats (the temperature of the electrolyte exceeds 45°C), interrupt charging. After charging, be sure to turn off the battery charger before disconnecting the cables.

If the battery charger is on, sparks may be generated and cause ignition or explosion.

IMPORTANT • Check the specific gravity of the battery electrolyte to prevent overcharge. Overcharging could shorten the battery life.

• Do not reverse polarity of the battery cable connected to the battery (i.e., the negative to the positive, or the positive to the negative). Reversing the polarity in the connection will cause the charging dynamo and etc. to be damaged.

3-26

11. Generator 11-4-3. Connecting and disconnecting booster battery cables

• When you start the engine using booster battery cables, wear safety goggles.

• If you start the engine by taking electric power from another machine, do not allow contact between your machine and the other machine.

• To connect the booster battery cables, begin with the positive terminal, and to disconnect them, begin with the negative terminal (ground side).

• If a tool touches the positive terminal and the machine at the same time, hazardous sparks may be generated.

• Do not connect the booster battery cables to terminals of the reverse polarity. That is, never connect the negative terminal on one machine to the positive terminal on the other machine.

• As the last step, connect the negative booster battery cables to the upperstructure. At this time, sparks will be generated. Connect the terminal to a point as far away from the battery as possible.

To start the engine using booster battery cables, do the follows. # Connecting booster cables 1) Connect the clip of the booster battery cables A (normally red) to the positive terminal on the machine in trouble.

2) Connect the other clip of the booster battery cables A

A

Battery on normal machine

2)

Battery on machine in trouble

1)

3)

to the positive terminal on the normal machine.

3) Connect the clip of the booster battery cables B (normally black) to the negative terminal on the normal machine.

4) Connect the other clip of the booster battery cables B to the engine block of the generator in trouble.

3-27

B

Engine of trouble block machine

4)

11. Generator # Disconnecting booster cables 1) Remove the clip of the booster battery cables B from the engine block on the machine in trouble.

2) Remove the clip of the booster battery cables B from

Battery on normal machine

3)

Battery on machine in trouble

4)

2)

the negative terminal on the normal machine.

3) Remove the clip of the booster battery cables A from

1)

the positive terminal on the normal machine.

4) Remove the clip of the booster battery cables A from

Engine of trouble block machine

the positive terminal on the machine in trouble. # Precautions for handling booster battery cables 1) The booster battery cables capacity and the clip size should be suitable for the battery size.

2) The battery of the normal machine should be the same capacity as that of the machine in trouble.

3) Securely connect the clips.

4) Do not connect the booster battery cables to terminals of the reverse polarity. That is, never connect the negative terminal on one machine to the positive terminal on the other machine.

11-4-4. Before operating new generator Before operating you new generator for the first time, make precautions as follows. # Preparing battery The battery equipped with the generator includes no electrolyte. Fill the battery with the provided electrolyte following the procedure below. (Read the attached "Operation and Maintenance Manual of Car Battery" as well.)

The battery is installed behind the inspection window "A" for battery. (Refer to Section "11-1-2. Part names") Be sure to take the battery out of the battery mounting when supplying the battery electrolyte.

• 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.

3-28

11. Generator (1) Supplying battery electrolyte 1) Put the battery on a level place. Remove a sealing for

Fig.1

Sealing for fluid supply port

fluid supply ports. (See the Fig.1) 2) Open the provided electrolyte container and pull out a rubber hose.

3) Cut the tip of the rubber hose and gradually fill the six cells of battery with the electrolyte up to the UPPER limit mark. (See the Fig.2) The level of electrolyte goes down as the electrolyte infiltrates into pole plates. After

Fig.2

leaving it stand for about 20 min., add the same kind of electrolyte until its level comes up to the UPPER limit mark again. (If the battery is filled with electrolyte beyond the UPPER level mark, take the excess electrolyte Electrolyte

out with a poppet or the like.)

4) Firmly tighten the provided six caps on the fluid supply ports of the battery.

(2) Connecting battery cables After filling the battery with the electrolyte, reinstall the battery to the generator.

When connecting the battery cables, first fasten the positive terminal onto the battery, and then the negative terminal.

3-29

11. Generator # Refueling

• Never fill gasoline into the fuel tank by mistake. Recheck the type of fuel is correct before refueling.

• Never refuel while the engine is running.

• Overfilling is dangerous. Do not fill the tank beyond the top of the red plug inside the fuel tank filter.

• Wipe away all fuel spills with a clean cloth.

Fuel tank capacity is as follows.

Fuel tank capacity (L)

Fuel supply port 15

Cap

Red plug

3-30

11. Generator # Checking and replenishing lube oil IMPORTANT • When checking and replenishing the lube oil, place the generator so that the engine is set on a level.

• Check the lube oil level with the oil filler cap unscrewed.

1) Be sure to check the lube oil level before starting engine.

• Open the inspection window "A" (Refer to Section "11-12. Part names") to check and replenish the lube oil.

• Check the lube oil level is between the upper and lower limits of the oil level gauge of the oil filler cap. If any oil is spilled, wipe it away with a clean cloth.

• Be sure to firmly tighten the oil filler cap after inspection.

2) Replenish the lube oil up to the upper limit of the oil level gauge of the oil filler cap.

After replenishing, wipe all the spilled oil away and firmly tighten the oil filler cap by hand.

Upper limit Lower limit

3) The lube oil capacity is as follows ; Lube oil capacity (L)

Put the oil level gauge into the filler port and check the oil level with the oil filler cap unscrewed

0.8

# Cranking (Idling) After a long time storage, the sliding part of the engine has not lubricated. Therefore, the engine may be seized if it is run without lubricating. When you start the engine for the first time after purchase or a long term storage, crank up and idle the engine.

1) Turn off the lamp switches.

2) Insert the key into the starter switch and turn it to the "START" position, and the engine starts. Check for abnormal noise while idling the engine for about 5 minutes.

3) Turn the key back to the "OFF" position, and the engine stops.

3-31

11. Generator # Rechecking lube oil level When the lube oil is supplied or changed, recheck the lube oil level after a test run for about 5 minutes.

After the engine runs, the lube oil level goes down as the lube oil is supplied to the clearances of each part. Therefor, rechecking and replenishing the lube oil is required.

How to replenish the lube oil : Refer to Section "11-4-4. Before operating new generator". # Connecting coupler Connect the coupler of the generator with that of the floodlight projector. Be sure to install the coupler cover after connecting the couplers.

To coupler of floodlight projector Coupler

11-4-5. How to operate generator

There are some heat built-up parts such as cylinders or exhaust muffler and hazardous high voltage sections inside the generator during operation.

• Be sure to close all the inspection windows during operation.

• Be sure to stop the engine before performing inspection and servicing. # Checking Before Start-up Check the items described here before starting the engine first in a day.

1) Check that there are no dust deposits or combustibles around the muffler or the engine. If there are any, remove them.

Check that there are no litter or sheets covering the intake port or the muffler. If there are any, remove them.

2) Checking the inside of generator (through the inspection window.)

Check for the followings.

• Oil leak from the engine • Fuel leak from the fuel system • Breaking or short circuit of electric wiring and loose terminal • Looseness or lack of bolts If there is any abnormality, be sure to repair it before the next use.

3-32

11. Generator 3) Checking the fuel level in the fuel tank and refueling Check the fuel level in the fuel tank and refill the fuel tank with the recommended fuel.

Refer to Section "11-4-4. Before operating new generator" for the refueling procedure.

4) Checking and replenishing the lube oil • Check the lube oil level with the oil level gauge.

• When the lube oil is running short, replenish the recommended lube oil from the oil filler port. Fill the lube oil up to the upper level, checking with the oil level gauge. Refer to Section "11-4-4. Before operating new generator" for the checking and replenishing procedure.

5) Checking ground connection Confirm the generator and the floodlight projector are securely grounded. # How to start generator

Never start the engine when the lamp switches of the generator are in the "ON" position. This causes a sudden supply of the electricity to the floodlight projector and may cause electric shocks.

(1) Starting generator 1) Open the inspection window "A" (Refer to Section "111-2. Part names") to open the fuel cock full.

OFF ON

2) Make sure the lamp switches of the generator are in the "OFF" position.

Take your hand off the key after start-up START

Turn the key to the "START" position, and the engine starts.

3) Remove your hand from the key after the engine starts,

(Starter switch)

and the key returns to the "ON" position by itself.

IMPORTANT If the engine is started with insufficient lube oil, the low oil pressure warning system could work to stop

Close

the engine immediately. Check the lube oil level and Open

refill before restarting.

(Fuel cock)

3-33

11. Generator (2) Restarting after failure in start-up If the engine fails to start, be sure to check the engine has completely stopped before restarting through operating the starter switch.

Never attempt to turn the starter switch on while the engine is still running.

This may cause the breakage of the gear tooth of the starter motor or ring gear.

IMPORTANT • Do not hold the starter switch on for more than 15 seconds at a time. If the engine does not start the first time, wait for about 15 seconds before trying again.

• If the engine continuously fails to start three times, wait for about 2 minutes, and try again.

• After the engine starts, leave the key in the "ON" position and never turn it off. The generator can not be operated with the key in the "OFF" position.

(3) After starting the engine After starting the engine, warm it up by idling for about 5 minutes. (Warm up the engine to supply every part of it with the lube oil.)

(4) Checking before use of the floodlight projector 1) Check the lube oil pressure alarm lamp. (OIL ALERT LAMP) Check the oil alert lamp on the control panel is off.

2) Check around the engine.

• Check the exhaust gas color for abnormality.

Colorless or pale blue : normal Black: malfunction (imperfect combustion or overload) White: malfunction (lube oil burning) • Check for abnormal noise, difficulty in rotation and abnormal vibration.

• Check for fuel oil leak and lube oil leak.

(5) Loaded operation Turn on the lamp switches of the generator.

IMPORTANT When the engine is new, never stop it suddenly or operate it with overload before its service hour exceeds 20 hours. # During operation Checking during operation

3-34

11. Generator Note : If any abnormality is found in the generator, immediately stop using, check and repair the generator to remove the abnormality. To prevent accidents, never use it before removing the abnormality.

Check the generator for abnormality about the following items during operation irregularly.

1) Check the engine oil pressure alarm lamp. (OIL ALERT LAMP) Check the oil alert lamp is off.

2) Check the exhaust gas color for abnormality.

Colorless or pale blue : normal Black : malfunction (imperfect combustion or overload) White : malfunction (oil burning) 3) Check for abnormal noise and abnormal vibration.

4) Check for fuel leak and oil leak.

5) Check the sufficient fuel is left in the fuel tank.

Refuel in early stage to prevent the fuel from running out during operation. # How to stop generator Stop the generator following the procedure below.

1) Turn the lamp switches to the "OFF" position.

2) Cool down the engine by idling for about 5 minutes.

IMPORTANT Do not stop the engine suddenly after loaded operation because this may rapidly heat up each part of the engine and cause the engine failure such as seizure.

3) Turn the key of the starter switch to the "OFF" position, and the engine stops.

IMPORTANT If the engine keeps on running even after the starter switch is turned off, stop the engine as follows.

• Open the inspection window "A". Pull the stop lever and hold it until the engine stops.

Note : Take this measure only when the starter switch does not work to stop the engine.

Emergency stop lever

• Some problems in the electrical system (e.g. damaged stop solenoid, defective electric wiring, or low battery voltage) may exist. Ask the nearest dealer for check and service.

Pull

3-35

11. Generator 4) Pull out the key and keep it with care.

5) Close the fuel cock full.

6) When storing the generator for a long period, disconnect the battery cable from the negative terminal of the battery.

Note : If the battery cables are left connected to the battery during a long term storage, the battery could go flat.

3-36

11. Generator # Flow chart of operation method

Start-up inspection

Lamp switches of generator [OFF]

Starter switch [START] Engine starts.

Starter switch [ON] After starting, remove your hand, and key returns to [ON] position by itself.

Generation of electricity starts.

Stop operation Lamp switches of

Warm up run

generator [OFF]

(for 5 min.)

Idle engine Check before using Check oil alert lamp

floodlight projector

Cool down engine for 5 min.

Starter switch [OFF]

Generator is applied load and starts power supply.

Lamp switches of generator [ON] Engine stops.

Check exhaust gas color, vibration, and noise for abnormality.

Check oil alert lamp

Lamp goes on.

(Full brightness

Pull out key of

provided in 5 min.)

starter switch

Close fuel cock

Complete operation

3-37

11. Generator 11-4-6. Long term storage When storing the generator for a long period (for 3 months or more), do the followings for the next use.

1) Wipe off mud, dust and oil or grease adhering to the outside of the generator.

2) Complete the periodic checks, whose next checkup is not far away, before storage.

3) To prevent fires, drain the fuel tank.

4) Disconnect the battery cable from the negative terminal of the battery.

5) Put a vinyl cover over the silencer or the electrical equipment to prevent water or dust from covering or getting into them.

6) Store the generator in a well ventilated place free from moisture and dust.

7) To refill self discharge from the battery, charge the battery at least once a month during storage

3-38

MAINTENANCE

4-1

12. Floodlight Projector 12-1. Periodic checks, maintenance and storage 12-1-1. Periodic checks and maintenance Figure

Lamp

Mast

Part

Electric

Service item

L1

Lamp (Base)

Check if it is not loosened.

Screw in securely.

L2

Pin contact

Check if it is not disconnected or loosened.

Connect securely.

L3

Nut

Check if it is not too loose.

Tighten properly.

L4

Hinge for lamp stand

Check if it moves smoothly.

Supply grease.

$

L5

Pivot for lamp stand

Check if it turns smoothly.

Apply grease.

$

Check if bulb is not burned out or lamp is bro-

L6

Lamp

L7

Front glass

Check if it is not dirty.

Wipe off dirt.

L8

Reflex mirror

Check if it is not too dirty or broken.

Wipe off dirt or replace.

M1

Fold lever

Check if it locks and releases properly.

Repair.

M2

Mast sliding surface

Check if mast slides smoothly.

Apply grease.

ken.

"

Replace.

M3

Wire rope

Check if it not damaged.

Apply grease or replace.

M4

Wire rope end

Check if end is not damaged caulking.

Replace.

$

M5

Winch

Check if brake works well.

Repair.

M6

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.

$

Check if it is not loose linking.

Tighten securely

" "

C3

Cart

Check item

Link of handle and wheels

C4

Bolt for handle

Check if it is not loosened.

Tighten securely

C5

Brake pedal

Check if linking part moves smoothly.

Spray grease.

C5

Brake pedal

Check if notch is not worn.

Replace.

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

C10

Link for front shaft

Check if air pressure in tire is between 245 and 294 kPa. Check linkage moves smoothly.

Adjust.

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. $...Every 100 hrs. !...Every 500 hrs.

!...Every 1000 hrs.

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

4-2

12. Floodlight Projector • Inspection points (Correspond to the left list) L4 M1

L1

L6 L3 L7 L2 L8 L5 M2 C6 E1 M3 M4 M5

E3

M6 C7 E2 C8

C2

C1

C9 C3 C4

C10 C5

C11

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.

• Fold the lamp stand to store the lighting unit.

• 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 floodlight projector.

4-3

12. Floodlight Projector

12-2. Unclear points or problems If any instructions are unclear or if problems occur during operation of your floodlight projector, complete the followings form and contact your YANMAR dealer.

1) Model and serial number of floodlight projector 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

13. Generator 13-1. Precautions for inspection Be sure to perform periodic checks.

The engine deterioration and degradation proceed in proportion to its service conditions and service hours. Leaving deterioration and degradation may cause an unexpected malfunction which interferes with your work an increase in consumption of the fuel and lube oil, or an increase in exhaust gas problems or noise, and result in shortening the life of the engine. Perform routine periodic checks and maintenance to prevent accidents from occurring. Also, check the electric system periodically to prevent electric shocks.

Never fail to start-up inspection.

Routine periodic checks are based on start-up inspections. Make a habit of performing the start-up inspections before initial start up for the day.

For the procedure of start-up inspection, refer to Section "11-4-5. How to operate generator".

Keep a record of daily operation to perform the periodic checks.

Keep a record of daily operation and the results of maintenance work. Periodic check intervals are established every 20, 100, 500 and 1000 service hours. Be sure to perform a periodic check after each setup interval.

Only use Yanmar genuine parts.

Only use Yanmar genuine parts when replacing consumables. The use of replacement parts which are not genuine may degrade the engine performance or shorten its life.

Have a set of maintenance tool always ready.

Have a set of maintenance tool always ready for checking the machinery.

Ask for our help with periodic checks and maintenance work.

Our professional engineers with good expertise and skills will help you with maintenance, inspection and servicing. Consult your Yanmar dealer.

Tightening torque for bolts and nuts Applying excessive tightening torque to a bolt or nut may loosen or damage a tightened part, and too small tightening torque may cause a oil leak from the mounting surface or a loose bolt, which leads to component failure. On essential parts, bolts and nuts should be tightened with an accurate tightening torque using a torque wrench in a correct way and correct order.

When removing parts is required for maintenance, consult your nearest Yanmar dealer.

The followings are the standard tightening torque for standard bolts and nuts.

4-5

13. Generator IMPORTANT The tightening torque described below should be applied only to the bolts with "7" on their head. (Strength classification : 7T) Apply 60% tightening torque for the bolts which do not appear here.

Apply 80% tightening torque when tightened to aluminum.

Thread size × Pitch mm Tightening torque

N•m (kgf•m)

M6×1.0

M8×1.25

M10×1.5

M12×1.75

M14×1.5

M16×1.5

10.8±1.0 (1.1±0.1)

25.5±2.9 (2.6±0.3)

49.0±4.9 (5.0±0.5)

88.3±9.8 (9.0±1.0)

137±9.8 (14.0±1.5)

226±9.8 (23.0±2.0)

4-6

13. Generator

13-2. List of periodic inspections Daily and periodic inspections are important to keep the generator in its best condition. The following is a summary of inspection and servicing items by inspection interval. Periodic inspection intervals vary depending on the use, loads, fuels and lube oils used and handling conditions, and are hard to establish definitively. The following should be treated only as a general standard.

IMPORTANT Plan for periodic checks according to service conditions and be sure to perform all the inspections. If they are failed to perform, the generator could be broken or lose the durability. Also, electric shocks could occur. Maintenance, inspections and servicing every 500 hours or later especially require expertise and skills. Consult your nearest Yanmar dealer. %:Check &:Replace $:Contact your Yanmar dealer Periodic inspection interval Section

Fuel oil

Check & service items

Start-up

At first 20 hrs.

Every 100 hrs.

Every 500 hrs.

Every 1,000 hrs.

"

&

" "

Check & supply of fuel oil to the tank Check for fuel oil leak Clean or replace of fuel oil filter

Clean Lube oil

" "

Check & supply of lube oil to the tank Check for lube oil leak Replace lube oil Clean or replace lube oil filter

Intake and exhaust systems

" Clean

&

&

Adjust intake/exhaust valve clearance

$

Piston

Replace piston ring

$ $ $ $

Check fuel injection valve pressure and adjust Check fuel injection timing and adjust Check for abnormality of fuel injection pump

$ $ $

Measure insulation resistance Check connecting part of electric circuit

" "

Check grounding of enclosure Electrical equipment

" Clean

"

Check gas color.

Lapping intake/exhaust valve seats

Generator

& 2nd time & after

Replace air cleaner element

Cylinder head Injection valve and fuel injection pump

& 1st time

Check battery fluid level

$

Measure specific gravity of electrolyte

"

Check for loose bolts and nuts

$ $

Check for abnormality of rubber hose Check for abnormality of vibroisolating rubber and sound absorption material

4-7

13. Generator

13-3. Periodic inspection items 13-3-1. At first 20 hours Replacing lube oil and cleaning lube oil filter. (1st time) • In early period of use, the lube oil gets dirty rapidly because of the initial wear of internal parts. Replace the lube oil earlier.

• Clean the lube oil filter when replacing the lube oil.

• Drain the lube oil while the oil is still warm after operation for more rapid and complete draining.

(1) Draining lube oil 1) Set a container for waste oil under the drain plug.

2) Remove the drain plug on the bottom of the generator and drain the waste oil from the oil pan.

3) After draining, be sure to firmly tighten the drain plug.

When the lube oil is hot, be careful with a splash of lube oil which may cause burns.

(2) Supplying lube oil Supply a new lube oil to the specified level. (Refer to Section "11-4-4. Before operating new generator" for the procedure of lube oil replenishment.)

(3) Cleaning lube oil filter 1) Open the inspection window "B" (Refer to Section "111-2. Part names") to pull out the lube oil filter.

2) Clean the meshes of the lube oil filter with light oil.

3) Clean the installation area of the lube oil filter.

4) Install the lube oil filter and tighten the bolt for lube oil

Lube oil filter

Inspetion window "B"

filter.

(4) Test run 1) Make a test run for about 5 minutes, while checking for oil leak carefully.

2) In 5 minutes after stopping the engine, recheck the lube oil level with a oil level gauge, and refill.

Lube oil drain plug

4-8

Waste oil container

13. Generator 13-3-2. Every 100 hours Replacing lube oil and cleaning lube oil filter. (2nd time and thereafter) Perform the 2nd and thereafter oil replacement every 100 hours.

When replacing the engine oil, clean the lube oil filter.

For the replacing and cleaning procedures, refer to Sections "11-4-4. Before operating new generator" and "13-3-1. At first 20 hours".

13-3-3. Every 500 hours Also perform the maintenance every 100 hours.

(1) Replacing air cleaner element

Cover

When the air cleaner element is clogged with dusts which have been sucked into the air cleaner, the engine output

Element

declines. Check the air cleaner element periodically and clean it.

IMPORTANT

Air cleaner case

Inspection window "C"

• Do not reuse the element washing or air blowing to clean it because of oil-soaked type and non-reusable element.

• Never run the generator without the element. This may cause rapid engine wear.

1) Open the inspection window "C".

Refer to Section "11-1-2. Part names" 2) Remove the cover of the air cleaner and pull out the element.

3) Replace the element with a new one.

4) Before installing the new element, clean trash or dusts from the inside of air cleaner case not to get them into the intake port.

Air cleaner part code No. 114250-12580

4-9

13. Generator (2) Measuring specific gravity of electrolyte Open the inspection window "A" to measure the specific gravity of the battery electrolyte.

Refer to Section "11-1-2. Part names" For the measuring procedure, refer to Section "11-4-2. Handling of battery".

(3) Inspecting insulation resistance Check the insulation resistance is 1MΩ or more using a 500V insulation-resistance tester.

The inspection work requires expertise and skills. Con-

A

B

C D

sult your nearest Yanmar dealer.

Measuring method Remove the side cover and measure the insulation resistance between each of the 4-pin couplers A, B, C and D, which is connected to a starter unit, and the frame. (Measure the insulation resistance of only one of four pins in each coupler.) If the insulation resistance is less than 1MΩ, electric shocks or fire hazard could occur.

(4) Cleaning fuel filter 1) Set a container for the fuel under the drain plug.

2) Remove the fuel drain plug to drain the fuel tank.

3) Open the inspection window "A".

Refer to Section "11-1-2. Part names" 4) Remove the battery from the battery mounting.

Refer to Section "11-4-2. Handling of battery".

5) Remove the fuel hose from the filter.

6) Remove three nuts to remove the fuel filter from the fuel tank.

Inspection window "A"

7) Clean the element of the fuel filter carefully with diesel fuel oil (light oil).

Container for fuel oil Fuel drain plug

8) Reinstall the fuel filter, while taking care not to drop the O-ring from the groove on the fuel filter.

Fuel tank Fuel filter O-ring Groove

4-10

13. Generator (5) Checking terminals and connections of electric circuit Check the main circuit and the auxiliary circuit for loosened terminal or coupler, corroded terminal burned wire or other abnormalities. The inspection works require expertise and skills. Consult your Yanmar dealer.

(6) Adjusting intake and exhaust valve clearances Adjust the intake and exhaust valve clearances properly to gain the best engine performance. The inspection works require expertise and skills. Consult your Yanmar dealer.

(7) Checking and adjusting fuel injection valve pressure Adjust the fuel injection pressure to its best condition to gain the best engine performance. The inspection work requires expertise and skills. Consult your Yanmar dealer.

(8) Checking fuel injection pump Adjust the fuel injection pump to gain the best engine performance. The adjustment requires expertise.

Consult your Yanmar dealer.

(9) Checking and adjusting fuel injection timing Adjust the fuel injection timing to gain the best engine performance. The adjustment requires expertise.

Consult your Yanmar dealer.

13-3-4. Every 1000 hours Also perform the maintenance every 100 and 500 hours.

(1) Replacing fuel filter Refer to Section "13-3-3. (4) Cleaning fuel filter" for the replacing procedure.

Fuel filter part code No. 183293-55320 (2) Replacing lube oil filter Refer to Section "13-3-1. (3) Cleaning lube oil filter" for the replacing procedure.

Oil filer part code No. 114250-35070 (3) Lapping intake and exhaust valve seat Perform maintenance on the intake and exhaust valve seats to maintain the airtightness of the cylinder head. The maintenance works require expertise. Consult your Yanmar dealer.

(4) Replacing piston ring Replace the piston ring to maintain the gas tightness of the cylinder. The replacing work requires expertise. Consult your Yanmar dealer.

(5) Checking rubber hoses Check the rubber hoses used in the fuel and oil systems for breakage or deterioration.

4-11

13. Generator (6) Checking vibroisolating rubber It the vibroisolating rubbers, which support the engine and the generator, are damaged or distorted by oil, consult your Yanmar dealer.

(7) Checking sound absorption material If excessive deterioration or stains such as adhesion of oil are on the sound absorption materials, consult your Yanmar dealer.

4-12

TROUBLESHOOTING

5-1

14. Floodlight Projector 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

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 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 40°C)?

Move to proper place or provide good ventilation.

Check item

Content of work

-

Mast Trouble Mast cannot be raised

Mast keeps on coming down

The mast cannot be lowered

• 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

15. Generator IMPORTANT If any abnormality is found in the generator, immediately stop using, check and repair the generator to remove the abnormality. To prevent accidents, never use it before removing the abnormality.

Consult your Yanmar dealer about the items marked "% %" Trouble

Cause

Measure

–

Discharge of battery

Check electrolyte level and specific gravity.

–

Disconnection, looseness, or corrosion of battery terminal

Clean and tighten battery terminal.

–

Defective dynamo

Repair or replace dynamo.

"

Brown out 20A fuse

Remove control panel to replace fuse installed on hidden side of panel.

"

Defective ground cable, loose terminals or breaking of wire

Repair.

–

Malfunction of starter switch

Replace starter switch.

"

Malfunction of starter

Replace starter.

"

Too high viscosity of lube oil

Check and replace lube oil.

–

Insufficient fuel

Refuel.

–

Air mixed in fuel

Release air from fuel system.

–

Clogged fuel filter

Clean or replace fuel filter.

"

Fuel cock is close.

Open fuel cock full.

–

Stop device working due to oil shortage

Check oil level in oil pan and refill. Then, restart engine.

–

In cold weather, frozen fuel

Use fuel oil for cold weather

–

In cold weather, frozen water remained in fuel system

Warm up, and remove water from fuel tank, fuel filter and fuel pipe.

–

Air mixed in fuel

Release air from fuel system.

–

Clogged air cleaner

Replace air cleaner element.

–

Clogged fuel filter

Cleaner replace fuel filter.

"

Engine does not start Starter motor does not rotate Speed of starter motor is too low

Turning on starter motor does not start engine

Engine stops Engine speed stays low

.

5-3

15. Generator

Trouble

Cause

Engine speed is abnormal (Too high, too low or irregular change)

Defective fuel valve, governor or fuel pump

Adjust or repair.

"

Engine stops while running

Stop device working due to oil shortage

Check oil level in oil pan and refill. Then, restart engine.

–

Stop device working chugged lube oil filter

Clean or replace lube oil filter, replenish oil and restart engine.

"

Malfunction of lube oil switch

Replace lube oil switch.

"

Malfunction of starter switch

Replace starter switch

"

Damaged stop solenoid or circuit

Replace or repair.

"

Blown out 20A fuse

Remove control panel to replace fuse installed on hidden side of panel.

"

Lamp switch turned "OFF"

Turn lamp switch "ON"

–

Loose connection of couplers

Securely connect couplers.

–

Loose lamp

Securely screw in lamp.

–

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

Wait until lamp gets cold enough.

–

Malfunction of starter unit

Contact dealer for repair.

"

Breaking of circuit

Contact dealer for repair.

"

Insufficient output of engine

Check fuel system or intake system.

"

Insufficient generating power of generator

Contact dealer for repair.

"

Turning starter switch to "OFF" does not stop engine

Measure

due

to

–

Floodlight projector Lamp does not go on

5-4

ELECTRICAL DIAGRAM

6-1

16. Electrical Diagram

6-2

ORDERING REPLACEMENT PARTS AND SERVICE CALL

7-1

17. 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.

Nameplate Floodlight projector)

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

YDG25HSS-EX 1.7 kW / 540 HZ L48 ADEGYSS6H 3.1 KW (4.2 PS)/3600 rpm 0.211 l

YMNMAR DIESEL GENERATOR YMNMAR CO., LTD MADE IN JAPAN

Hourmeter

Serial number plate (Generator)

Nameplate (Floodlight projector)

7-2

NOTES

8-1

18. Maintenance Log Maintenance log Date

Machine hours

Service performed

8-2

18. Maintenance Log

Date

Machine hours

Service performed

8-3

18. Maintenance Log

Date

Machine hours

Service performed

8-4

19. Notes Notes

8-5

19. Notes

8-6

19. Notes

8-7

MEMO

8-8

CONSTRUCTION EQUIPMENT DIVISION 1717-1, Kumano, Chikugo, Fukuoka, 833-0055 Japan Telephone : 0942-53-5465 Facsimile : 0942-53-5132 No.1-9900300-00