Every system on your lighting tower gets broken down in this 81-page Yanmar LB446HB-1, LB446H-1 service manual PDF. You get full electrical circuits, step-by-step teardown procedures for the mast and balloon assemblies, and dedicated troubleshooting charts to track down power failures quickly. Open to the maintenance section to find exact inspection intervals paired with page after page of exploded views covering the entire lamp stand, base plate, and outrigger units. Verify the ground rod resistor reads 10 ohms or less, and confirm you are installing the correct HIE400W/C/U/EURO/4K metal halide lamps before sending the rig back out to the job site. Stop burning billable hours searching for accurate electrical data on the internet. Save this bookmarked file directly to your phone, walk right up to the tower, and get the lights back on.
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 | ||
| General Instructions for Tightening Torques | Refer to Section "9-2. Major Bolts and Nuts" for specified torque values. | p. 28 |
| 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 | 8' to 14'8" (2440 to 4470 mm) | p. 14 |
| Dry weight (w/o generator) | 214 (97) lbs.(kg) | p. 14 |
| LB446H-1 | ||
| Mast min. & max. height | 6'9" to 13'8" (2060 to 4160 mm) | p. 14 |
| Dry weight (w/o generator) | 231(105) lbs.(kg) | p. 14 |
Yanmar LIGHT BOY LB446HB-1, LB446H-1 Common Problems This Manual Covers
Yanmar Light BOY LB446HB-1 engine starts and runs smoothly but the lamps will not light up. p. 78
Check the cable connections and measure the non-load voltage at the plug housings. Verify the output is between AC 230 to 250 V as shown on page 53. Inspect the lamp assemblies and replace any faulty bulbs using part number 1-3010010-10. Wait for hot lamps to cool before resetting breakers.
Manual Section: 10. TroubleshootingWinch binds during operation and the mast cannot be raised or lowered. p. 33
Inspect the mast sliding surface and winch winding mechanism. Check wire ropes for damage and verify the safety stopper function. If removing the lighting unit during repairs, torque the M16 assembly nut to 115 to 155 N-m (11.5 to 16 kgf-m) as specified on page 33.
Manual Section: 4. Disassembly and AssemblyFan motor fails to run and the envelope remains flat so the balloon is not inflated. p. 78
Check the zipper status and inspect the envelope for tears. Verify the fan motor cable connections are secure. Measure the fan motor supply to ensure it receives the rated 12V as listed on page 14. If the motor is defective, replace the unit to restore proper inflation.
Manual Section: 10. TroubleshootingUnit wanders during transport or exhibits poor handling due to underinflated tires. p. 58
Inspect the outrigger movement and steering unit linkages for excessive wear. Check the tires and inflate them to the specified air pressure of 245 and 294 kPa as shown on page 58. Inspect the brake pedal wear and adjust the brake linkages if travel is excessive.
Manual Section: 5. Inspection and MaintenanceFrequently Asked Questions
What are the torque specifications for the mast group bolts on the YANMAR LB446HB-1 and LB446H-1 lighting towers?
The bolt and washer (M10X25) used for the mast group should be tightened to a torque of 25 to 34 N-m (2.6 to 3.5 kgf-m). Additionally, the bolt (M12X40) for the first mast and hanger requires a tightening torque of 44 to 61 N-m (4.5 to 6.2 kgf-m).
What are the replacement specifications and part number for the lamps used in the YANMAR LB446HB-1 and LB446H-1 lighting towers?
The lamps are Metal Halide Lamp type S, model HIE400W/C/U/EURO/4K, with a rated life of 20,000 hours and a total luminous flux of 160,000 lm. The Yanmar Genuine Lamp 400W has a part number of 1-3010010-10.
What are the periodic inspection intervals for the YANMAR LB446HB-1 and LB446H-1 lighting towers?
Daily checks are recommended for items like the fan motor, frame pipe, lamp brace, and lamp. Inspections for items like the mast sliding surface, wire rope, and winch are recommended every 20 hours. More extensive checks, such as for the mast sliding surface and wire rope, are suggested every 100 hours, while some items like the safety stopper are checked every 500 hours.
What is the recommended tire pressure for the YANMAR LB446HB-1 and LB446H-1 lighting towers?
The recommended air pressure for the tires is between 245 and 294 kPa (28.4 and 35.5 psi). It is important to maintain this pressure, as insufficient air pressure can affect the proper functioning of the brake.
What do I get after purchasing this Yanmar LB446HB-1, LB446H-1 manual?
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 this Yanmar LB446HB-1, LB446H-1 Service Manual printable?
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?
Included. The Yanmar LB446HB-1, LB446H-1 Service Manual covers complete wiring harness diagrams, electrical circuits, and connector pinouts.
Document Quality
This document is a scanned PDF with an OCR layer, allowing you to search and copy text throughout. The text quality is generally crisp and readable, although some original elements show minor blurriness typical of scanned material. Diagrams and illustrations are raster images, which means they may pixelate when significantly zoomed, but their labels are clear at standard viewing sizes. Pages are clean with no significant scan artifacts, stains, or heavy skewing. You will find several blank pages marked 'MEMO' or as the back of title pages, which are part of the original document structure.
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