Yanmar LB446HB H LIGHT BOY Service Manual – PDF DOWWNLOAD
YANMAR LB446HB H LIGHT BOY SERVICE MANUAL:
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Yanmar LB446HB H LIGHT BOY Service ManualYanmar LB446HB H LIGHT BOY Service Manual
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Yanmar LB446HB H LIGHT BOY Service Manual – PDF DOWWNLOAD
This service manual is intended for service engineers who maintain the YANMAR construction machinery, and describes the specifications, maintenance procedures of individual machine sections, and operational precautions.
Read this manual carefully and become familiar with your YANMAR machinery so that you will be able to quickly and accurately maintain and keep it in perfect working order throughout its life.
The dimensions and other values referred to in this manual are for your reference in servicing, and should not be considered as the values stipulated in the Inspection Standard.
This manual represents the most up-to-date information at the time of publication and is subject to change without notice to reflect specification changes for performance improvement or technological advancement, and/or correction of typographical errors.
If you find any discrepancies between your machine and the information in this manual, obtain the most up-to-date information from our Customer Service Group.
You will be informed of major improvements and specification changes by delivery of the revised version of this manual.
TABLE OF CONTENTS:
Yanmar LB446HB H LIGHT BOY Service Manual – PDF DOWWNLOAD
COVER............................................................................... 1
Floodlight Projector................................................................ 2
COVER........................................................................... 2
FOREWORD........................................................................ 3
CONTENTS........................................................................ 4
Safety.......................................................................... 7
1. Safety....................................................................... 8
1-1. Warning Symbols........................................................ 8
1-2. Loading generator...................................................... 9
1-2-1. Service Shop (Location).......................................... 9
1-2-2. Working Wear..................................................... 9
1-2-3. Tools to Be Used................................................. 10
1-2-4. Parts............................................................ 10
1-2-5. Bolt Tightening Torque........................................... 10
1-2-6. Product Handling................................................. 10
1-2-7. Installation..................................................... 11
1-2-8. Transport........................................................ 11
1-2-9. Warning Labels................................................... 12
Outline of Floodlight Projector................................................. 13
2. Outline of Floodlight Projector.............................................. 14
2-1. Specifications......................................................... 14
2-2. External View and Components of Floodlight Projector................... 15
Structure of Floodlight Projector............................................... 17
3. Structure of Floodlight Projector............................................ 18
3-1. Outline of Structure................................................... 18
3-2. Electrical Group....................................................... 18
3-2-1. Balloon Unit..................................................... 19
3-2-2. Lamp Stand Unit.................................................. 21
3-2-3. Power Cable Unit................................................. 22
3-3. Mast Group............................................................. 23
3-4. Outrigger group........................................................ 24
3-5. Base Plate Group....................................................... 25
3-5-1. Base Plate Unit.................................................. 25
3-5-2. Steering Unit.................................................... 26
3-5-3. Brake Unit....................................................... 26
Disassembly and Assembly........................................................ 27
4. Disassembly and Assembly..................................................... 28
4-1. Before Starting Operation.............................................. 28
4-1-1. Grasp of Service History......................................... 28
4-1-2. Preparing the Necessary Tools, Parts and Materials............... 28
4-2. Disassembly and Assembly Procedures.................................... 28
4-2-1. General Instructions............................................. 28
4-2-2. Disassembly Procedure of Each Assembly /Unit /Group.............. 29
4-2-3. Disconnection of Couplers........................................ 30
4-2-4. Removal of Balloon Assembly...................................... 32
4-2-5. Removal of Lighting Unit Assembly................................ 33
4-2-6. Removal of Pin (Socket) Contact.................................. 34
4-2-7. Removal of Stand Assembly........................................ 35
4-2-8. Removal of Lamp Stand Assembly................................... 35
4-2-9. Unloading of Generator........................................... 36
4-2-10. Removal of Mast Group........................................... 37
4-2-11. Removal of Outrigger Group...................................... 37
4-2-12. Disassembly of Balloon Assembly................................. 38
4-2-13. Disassembly of Stand Assembly................................... 40
4-2-14. Disassembly of Lighting Unit Assembly........................... 40
4-2-15. Disassembly of Lamp Stand Assembly.............................. 41
4-2-16. Disassembly of Power Cable Unit................................. 41
4-2-17. Disassembly of Mast Group....................................... 42
4-2-18. Disassembly of Outrigger Group.................................. 43
4-2-19. Disassembly of Base Plate Unit.................................. 44
4-2-20. Disassembly of Steering Unit.................................... 45
4-2-21. Disassembly of Brake Unit....................................... 46
Inspection and Maintenance...................................................... 47
5. Inspection and Maintenance................................................... 48
5-1. Electrical Group....................................................... 48
5-1-1. Balloon Unit..................................................... 48
5-1-2. Lamp Stand Unit.................................................. 50
5-1-3. Replacement of Balloon Unit and Lamp Stand Unit.................. 52
5-1-4. Power Cable Unit................................................. 52
5-2. Mast Group............................................................. 55
5-2-1. Mast Group....................................................... 55
5-3. Outrigger Group........................................................ 58
5-4. Base Plate Group....................................................... 58
5-4-1. Base Plate Unit.................................................. 58
5-4-2. Steering Unit.................................................... 58
5-4-3. Brake Unit....................................................... 59
5-5. Grounding.............................................................. 59
Periodic Inspection Items....................................................... 61
6. Periodic Inspection Items.................................................... 62
6-1. Inspection Items and Intervals......................................... 62
Circuit......................................................................... 65
7. Circuit...................................................................... 66
7-1. Electrical Circuit..................................................... 66
7-1-1. How to Read Electrical Circuit Diagram........................... 66
7-1-2. Electrical Circuit Diagram....................................... 66
Tools, Instruments and Other Materials for Inspection and Maintenance........... 69
8. Tools, Instruments and Other Materials for Inspection and Maintenance........ 70
8-1. Machines, Tools and Instruments........................................ 70
8-1-1. General Tools.................................................... 70
8-1-2. Special Tool..................................................... 71
8-1-3. Measuring Instrument............................................. 71
8-1-4. Materials Required............................................... 71
Bolts and Nuts Tightening Torques............................................... 73
9. Bolts and Nuts Tightening Torques............................................ 74
9-1. General Instructions................................................... 74
9-2. Major Bolts and Nuts................................................... 75
Troubleshooting................................................................. 77
10. Troubleshooting............................................................. 78
10-1. Troubleshooting Procedures............................................ 78
BACKCOVER....................................................................... 81
Generator........................................................................... 82
COVER........................................................................... 82
Introduction.................................................................... 83
Contents........................................................................ 84
1. FOR SAFE OPERATION........................................................... 87
1.1. Warning Symbols........................................................ 87
1.2. Safety Precautions..................................................... 88
1.2.1. General Precautions for Operation and Maintenance................ 88
1.2.2. Preventing Fires................................................. 89
1.2.3. Preventing Exhaust Gas Inhalation................................ 89
1.2.4. Preventing Burns................................................. 89
1.2.5. Electric Shock, Short Circuits and Batteries..................... 90
1.2.6. Processing Wastes................................................ 90
1.2.7. Modification not authorized...................................... 90
1.2.8. Installation..................................................... 90
1.2.9. Do not use the floodlight projector on a slope................... 91
1.2.10. Use an outrigger to prevent the floodlight projector from ov.... 91
1.2.11. Confirm the ground cable connection............................. 91
1.2.12. Transport....................................................... 91
1.2.13. Lamp............................................................ 92
1.2.14. Generator....................................................... 92
1.2.15. When Lamps are On............................................... 92
1.2.16. Adjusting Height of Mast........................................ 93
1.2.17. Others.......................................................... 93
1.3. Location of Warning Labels............................................. 94
2. PRODUCT OVERVIEW............................................................. 97
2.1. Intended Uses and Conditions........................................... 97
2.1.1. Features of Generator............................................ 97
2.1.2. Running Conditions............................................... 97
2.1.3. Mounting of Generator............................................ 97
2.1.4. Description of Model Name........................................ 97
2.2. Specifications......................................................... 98
2.3. Performance............................................................ 99
2.4. Applicable fuel and Lube Oil...........................................100
2.4.1. Fuel.............................................................100
2.4.2. Lube oil.........................................................100
2.5. Out view and Part names................................................101
2.6. Control Panel..........................................................103
2.6.1. Control Apparatus................................................104
2.6.2. Protective Device................................................105
2.7. Compornent of Generator................................................106
2.8. Electric Wiring Diagram................................................107
2.9. Precaution for Installation............................................110
2.10. How to Operate Generator..............................................111
2.10.1. Checking Before Start-up........................................111
2.10.2. How to Start Generator..........................................112
2.10.3. During Operation................................................113
2.10.4. How to Stop Generator...........................................114
2.11. How to replace light bulb.............................................115
2.11.1. Installation of lamp............................................115
3. TROUBLESHOOTING..............................................................116
4. List of Periodic Inspections.................................................118
4.1. Diesel Generator.......................................................118
4.2. Floodlight Projector...................................................119
5. Inspection and Adjustment of Engine..........................................121
5.1. Refueling..............................................................121
5.2. Cleaning fuel filter...................................................121
5.3. Bleeding air from fuel system..........................................121
5.4. Checking and Replenishing Lube Oil.....................................122
5.5. Replacing lube oil and cleaning lube oil filter. (1st time)............122
5.6. Replacing air cleaner element..........................................123
5.7. Handling of Battery....................................................123
5.8. Adjustment of Valve clearance..........................................126
5.9. Inspection of Fuel injection Valve injection pressure and sp...........127
5.10. Adjustment of fuel injection timing...................................129
5.11. Adjustments of no-load max. revolution and stopping device............130
6. Inspection of generator......................................................132
6.1. Measurement of floodlight output terminal voltage (when the ...........133
6.2. Measurement of no-load voltage.........................................133
6.3 Measurement of generator voltage (at no-load operation).................135
6.4. Measurement of insulation resistance...................................136
7. Trial running................................................................137
8. Long -term storage...........................................................137
9. Disassembly and maintenance of generator.....................................138
9.1. Precautions for the service work.......................................138
9.2. Disassembling procedure................................................140
9.3. Reassembly procedure...................................................144
10. Rotor extraction tool.......................................................144
11. Engine Service Standard.....................................................144
12. Tightening Torque...........................................................145
12.1. Major Bolts and Nuts..................................................145
12.2. Standard Bolts and Nuts...............................................146
Engine..............................................................................147
COVER...........................................................................147
INTRODUCTION....................................................................148
Service Information.............................................................149
CONTENTS........................................................................151
1. Specifications...............................................................152
1.1 Specifications........................................................152
1.2 Cross Sectional Views.................................................156
2. Service standard.............................................................159
3. Disassembly and Reassembly...................................................169
3.1 Tools, Meters and Instruments.........................................169
1. Tools...............................................................169
2. Meters, Instruments and Service Accessories.........................171
3. Instruments.........................................................173
3.2 Tightening Torque.....................................................174
3.3 Maintenace Schedule...................................................175
3.4 Disassembly Procedures................................................176
3.5 Reasembly Procedures..................................................180
3.6 Recoil Starter........................................................185
4. Checking and Servicing.......................................................188
4.1 Cylinder Head.........................................................188
4.2 Piston and Piston Pin.................................................192
4.3 Connecting Rod........................................................196
4.4 Crankshaft, Flywheel and Main Bearing.................................200
4.5 Camshaft and Tappet...................................................202
4.6 Timing Gear...........................................................203
4.7 Crankcase Cover.......................................................204
4.8 Cylinder Sleeve and Cylinder Block....................................206
4.9 Lubrication System....................................................207
4.10 Fuel System .........................................................209
4.11 Speed Control Device..................................................213
4.12 Electrical System.....................................................215
1. Wiring Diagram......................................................215
2. Starter Motor.......................................................220
3. Generator (Dynamo), Regulator and Rectifier.........................235
4. Air Heater..........................................................240
5. Battery.............................................................241
4.13 Adjustment............................................................244
5. Toroubleshooting.............................................................246
6. Test Run.....................................................................262
7. Helical Inserting Part for Repair............................................265
Appendix 1 Difference Between Parts under Spec. S and D.........................268
Appendix 2 Detail of Special Tools..............................................271
Colophon............................................................................274
Spine Title.........................................................................275
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