Part of the Yanmar Repair Manuals.
The generator is humming, the mast is up, and all four metal halide lamps stay dark. That is the moment this Yanmar Light Boy service manual earns its keep: the Troubleshooting section walks the fault through the system in order, so you are testing instead of guessing.
It covers the LB446HB-1 and LB446H-1 lighting towers across 81 pages: full specifications for both models, the structure of the balloon and lamp stand units, step-by-step disassembly and assembly procedures, inspection and maintenance for the electrical, mast, outrigger and base plate groups, the electrical circuit, and tightening torques for the major bolts and nuts.
It is a PDF, so it downloads in minutes and prints clean. Run off the circuit diagram and the torque table, carry them out to the tower, and let those pages get dirty while the file stays safe on your drive.
What's Inside This Yanmar LIGHT BOY LB446HB-1, LB446H-1 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 7 | Warning Symbols (Service Shop, Working Wear), Loading Generator (Tools to Be Used, Parts, Bolt Tightening Torque, Product Handling, Installation, Transport, Warning Labels) |
| Safety | 8-12 | Warning Symbols (Service Shop, Working Wear), Loading Generator (Tools to Be Used, Parts, Bolt Tightening Torque, Product Handling, Installation, Transport, Warning Labels) |
| Outline of Lighting Tower | 13 | Specifications, External View and Components of Lighting Tower |
| Outline of Lighting Tower | 14-15 | Specifications, External View and Components of Lighting Tower |
| Structure of Lighting Tower | 17 | Outline of Structure, Electrical Group (Balloon Unit, Balloon Assembly, Stand Assembly, Lamp Stand Unit, Lighting Unit Assembly, Lamp Stand Assembly, Power Cable Unit) |
| Structure of Lighting Tower | 18-26 | Outline of Structure, Electrical Group (Balloon Unit, Balloon Assembly, Stand Assembly, Lamp Stand Unit, Lighting Unit Assembly, Lamp Stand Assembly, Power Cable Unit) |
| Disassembly and Assembly | 28-46 | Before Starting Operation, Disassembly and Assembly Procedures |
| Inspection and Maintenance | 47 | Electrical Group, Mast Group, Base Plate Group, Outrigger Group, Grounding |
| Inspection and Maintenance | 48-59 | Electrical Group, Mast Group, Outrigger Group, Base Plate Group, Grounding |
| Periodic Inspection Items | 61 | Lamp, Balloon, Mast, Cart, Electric |
| Periodic Inspection Items | 62-62 | Inspection Items and Intervals |
| Circuit | 66-68 | Electrical Circuit |
| Tools, Instruments and Other Materials for Inspection and Maintenance | 69 | Machines, Tools and Instruments, General Tools, Special Tool, Measuring Instrument, Materials Required |
| Tools, Instruments and Other Materials for Inspection and Maintenance | 70-71 | Machines, Tools and Instruments |
| Bolts and Nuts Tightening Torques | 73 | General Instructions, Base Plate Components, Mast and Lamp Components, Steering Components, Outrigger Components, Brake Components |
| Bolts and Nuts Tightening Torques | 74-75 | General Instructions, Major Bolts and Nuts |
| Troubleshooting | 78-79 | Troubleshooting Procedures |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Lamp Type | Metal Halide Lamp type S | p. 14 |
| Lamp Model | HIE400W/C/U/EURO/4K | p. 14 |
| Grounding Cable Thickness | appropriate to the load carrying capacity according to your countryís regulation and industrial standards | p. 59 |
| Ground Rod Resistor | 10 ohms or less | p. 59 |
| Rated voltage | 130 V | p. 14 |
| Rated life (lamps) | 20000 h | p. 14 |
| LB446HB-1 | ||
| Balloon diameter | 3'9" (1150 mm) | p. 14 |
| Mast min. & max. height, LB446HB-1 | 8' to 14'8" (2440 to 4470 mm) | p. 14 |
| Dry weight (w/o generator), LB446HB-1 | 214 (97) lbs.(kg) | p. 14 |
| LB446H-1 | ||
| Mast min. & max. height, LB446H-1 | 6'9" to 13'8" (2060 to 4160 mm) | p. 14 |
| Dry weight (w/o generator), LB446H-1 | 231(105) lbs.(kg) | p. 14 |
Yanmar LIGHT BOY LB446HB-1, LB446H-1 Common Problems This Manual Covers
Lamps stay dark with generator running
Power is available but nothing lights, which usually traces to a breaker, a damaged cable, or a failed lamp assembly. The troubleshooting procedures step through the lighting circuit in a fixed order so you find the open point instead of swapping parts.
Manual Section: 10. Troubleshooting p. 78Burned out metal halide lamp
The four metal halide lamps are rated for 20000 hours, but rough handling and vibration shorten that. The electrical group maintenance pages cover lamp inspection and replacement and list the replacement lamp part number 1-3010010-10.
Manual Section: 5. Inspection and Maintenance p. 48Balloon damage or dead fan motor
On the balloon-equipped LB446HB-1, a torn balloon or a failed 12V fan motor takes the whole light out of service. The disassembly and assembly procedures show how the balloon unit and stand assembly come apart and go back together.
Manual Section: 4. Disassembly and Assembly p. 28Mast binds or will not extend
Grit and neglected lubrication make the telescoping mast stick or hang up partway. The periodic inspection tables set out what to check on the mast, cart, and lamp hardware and at what intervals, before it seizes on you.
Manual Section: 6. Periodic Inspection Items p. 62Flickering lights or intermittent operation
Flicker, tripping, or only some lamps working typically points to chafed wiring or a loose connection somewhere between the power cable unit and the lamp stand. The electrical circuit diagram lets you trace each leg with a meter instead of guessing.
Manual Section: 7. Circuit p. 66Fasteners loosen from towing vibration
Base plate, mast, steering, outrigger, and brake hardware all work loose over time on a towed unit. The torque tables give the correct tightening values for the major bolts and nuts so nothing gets left finger-tight or stretched.
Manual Section: 9. Bolts and Nuts Tightening Torques p. 74Frequently Asked Questions
Which models does this manual cover?
Both Yanmar Light Boy variants: the LB446HB-1 and the LB446H-1. The specifications section gives separate values where they differ, such as mast height range and dry weight, and the rest of the 81-page manual applies to both machines.
Does it include torque specifications?
Yes. The Bolts and Nuts Tightening Torques section covers base plate, mast and lamp, steering, outrigger and brake components. Worked examples from the book: the M10x25 bolt and washer at 25 to 34 N-m and the M12x40 bolt at 44 to 61 N-m (page 75), the grounding bolt M6x10 at 5.9 to 7.8 N-m (page 59), and the fold lever adjusting bolt M8x20 at 14 to 19 N-m (page 51). p. 74
What lamps does it use, and is replacement covered?
It uses four type S metal halide lamps, model HIE400W/C/U/EURO/4K, rated for 20000 hours. The Inspection and Maintenance section covers lamp checks and replacement and lists the replacement lamp part number, 1-3010010-10. p. 48
My lights will not come on. Will this manual help?
That is exactly what the Troubleshooting section is for: it works through the fault step by step. Pair it with the electrical circuit diagram in the Circuit section to test breakers, cables, and lamp assemblies with a meter. p. 78
How quickly can I access this Yanmar Light BOY LB446HB-1 manual after buying?
You get a 81-page searchable PDF that downloads instantly after checkout. Open it on your laptop, tablet, or phone, and bring it right to the shop floor.
Is printing allowed for this Yanmar Light BOY LB446HB-1 Service Manual?
The PDF is DRM-free. Print whatever sections you need to take out to the shop. Standard letter or A4 paper works.
Are electrical wiring diagrams included in this Yanmar LB446HB-1?
Yes. The Circuit section carries the electrical circuit diagram for the tower, covering the lamp, fan motor and generator connections, and the Inspection and Maintenance section adds the electrical group checks - including the note that voltage must be measured with a 600 WV-0.1 microfarad capacitor in parallel with the tester (page 53).
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