Allmand Maxi-Lite II Installation Instructions Manual Download Page 2

B

Models This Instruction Covers

If uncertain about any of the information in this instruction, 

or if questions or problems arise, contact the Allmand 

service department at 1-800-562-1373, or contact through 

the Allmand website, www.allmand.com

•  Maxi-Lite II

•  Mine Spec

•  Rig Spec

Kit Contents

Allmand Parts & Service

Locate and identify the kit contents using the table below.

Ref  Description

Qty

1.

 725 light relays

2

2.

 12” black 16 AWG wire

1

3.

 12” yellow 16 AWG wire

1

4.

 60” red 10 AWG wire

1

5.

 60” black 10 AWG wire

1

6.

 60” blue 10 AWG wire

1

7.

 #8 ring terminal

1

8.

 #8 yellow fork terminal

4

9.

 #8 blue fork terminal

4

10.

 #8 x 5/8 hex washer head screw

4

11.

 3 pin lever lock

2

1.  Shut down the unit and allow ample time for engine 

and lamps to cool.  Refer to operator’s manual.

Before Kit Installation

DANGER

Electrocution Hazard

• 

Attempting to install the kit without first shutting down 

the unit will result in death or serious injury. Shut down 

the unit before installing the kit.

WARNING

Burn Hazard

•  Contact with hot surfaces of the engine and lamps 

could result in death or serious injury.  Always keep 

clear of the engine, lamps and other hot areas of the 

light tower.

2

www.allmand.com

1.  Locate and remove the rear door panel (

A

, Figure 

1) from the unit.  Set the door panel, bolts nuts, and 

washers aside as they will be re-installed in Step 22.

Kit Installation: 4-Light Replacement 

725 Relay for Zettler Relay 1 or 2

2.  Remove hardware from the AC front panel (

B

, Figure 

2) of the component box and lay open the panel.  Set 

the hardware aside as they will be re-installed in Step 

21.

1

2. 

Disconnect the battery, black negative (-) cable first, 

followed by red positive (+) cable.  Refer to operator’s 

manual.

DANGER

Electrocution Hazard

•  Attempting to install the kit without disconnecting the 

battery will result in death or serious injury. Disconnect 

the battery before installing the kit.

2

A

These kit instructions cover the installation of the 725 

relays to replace a damaged Zettler relay along side the 

functioning Zettler relay into the component box of the 

Maxi-Lite II unit.

Kit Instructions Description

3.  Identify the number of lights and the damaged Zettler 

relay number on the Maxi-Lite II trailer model, and 

choose the section that corresponds with the identified 

Zettler relay for service kit instructions.

Not for  

Reproduction

Summary of Contents for Maxi-Lite II

Page 1: ...ege NE USA All rights reserved Part No 114148 Revision A es Instrucciones de instalaci n Kit para servicio de repuesto de rel s Zettler por rel s 725 trif sicos para Maxi Lite II fr Instructions d ins...

Page 2: ...or serious injury Always keep clear of the engine lamps and other hot areas of the light tower 2 www allmand com 1 Locate and remove the rear door panel A Figure 1 from the unit Set the door panel bol...

Page 3: ...ction and connection points 3a 3b 3 en English 3c DC Post 2 DC Post 1 AC Post 2 AC Post 1 DC Ground Spade DC Power Spade 725 Relay Detail Zettler Relay Detail AC Light Switch Spade AC Distribution Blo...

Page 4: ...rminal 9 On Zettler light relay 2 disconnect the 12 AWG wire H Figure 6a b from the AC light switch spade and this wire was just reconfigured on the light switch 3 On Zettler relay 1 disconnect the wi...

Page 5: ...de terminal from the wire that was connected to the Zettler relay Strip off the appropriate amount of wire insulation and install wire L Figure 9a b into a 3 pin lever lock M Figure 9a b Ref 11 from t...

Page 6: ...e leading from the divider panel of the component block On Zettler relay 1 disconnect the 16 AWG wire from the same spade 17 Cut off and discard the female spade terminal from the wire that was connec...

Page 7: ...tened 21 The wiring is now complete Close the AC front panel reconnect the battery start the engine and turn on the lights to make sure all are operating correctly 22 Once the unit is verified to be o...

Page 8: ...25 Relay Detail Suggested 725 Relay Layout 3c DC Ground Spade DC Power Spade Zettler Relay Detail AC Light Switch Spade AC Distribution Block Spade 5 Note The 725 light relays shown in these installat...

Page 9: ...6a b removed from either Zettler relay 1 2 or 3 into the post Tighten down the screw onto the fork terminal 9 From the kit contents locate and select the blue 10 AWG wire H Figure 7 Ref 5 that matches...

Page 10: ...725 Relay Connection Detail 9b K 725 Relay 2 725 Relay 2 12 If replacing Zettler relay 2 locate the 12 AWG wire L Figure 10a b that is leading from the relay to light switches 1 and 2 If working from...

Page 11: ...the female spade terminal from the wire that was connected to the Zettler relay Strip off the appropriate amount of wire insulation and crimp a yellow fork terminal P Figure 12 Ref 7 onto the wire 15...

Page 12: ...ght Switch 5 Light Switch Connection Detail 15b Light Switch 2 U 16a V 725 Relay 2 18 Loosen the screw on AC post 2 of 725 light relay 2 and connect the fork terminal onto the post from the wire V Fig...

Page 13: ...rminal AA Figure 18 Ref 8 on one of the ends 22 Install the fork terminal end of each black wire BB Figure 19a b on DC post 1 of 725 light relay 1 and 2 Then install the bare wire ends of the two blac...

Page 14: ...contents locate and select they yellow 16 AWG wire GG Figure 22 Ref 3 Cut the yellow 16 AWG wire in half and strip the ends of the cut wires On each of the cut wires crimp a blue fork terminal HH Fig...

Page 15: ...tions are secure and tightened 28 The wiring is now complete Close the AC front panel reconnect the battery start the engine and turn on the lights to make sure all are operating correctly 29 Once the...

Page 16: ...las superficies calientes del motor y de las l mparas podr a provocar la muerte o lesiones graves Siempre al jese del motor de las l mparas y de otras reas calientes de la torre de iluminaci n 2 www...

Page 17: ...n de los rel s 3a 3b 3 es Espa ol de Am rica Latina 3c Borne de CC 2 Borne de CC 1 Borne de CA 2 Borne de CA 1 Pala de conexi n a tierra de CC Pala de alimentaci n de CC Detalle del rel 725 Detalle d...

Page 18: ...illa 9 En el rel Zettler de luces 2 desconecte el cable de 12 AWG H Figura 6a b de la pala del interruptor de luz de CA este cable se reconfigur reci n en el interruptor de luz 3 En el rel Zettler 1 d...

Page 19: ...que estaba conectado al rel Zettler y des chelo Pele la cantidad adecuada de aislamiento del cable e instale el cable L Figura 9a b en un conector de palanca de 3 clavijas M Figura 9a b Ref 11 del co...

Page 20: ...n de CC Este cable deber a provenir del panel divisor del bloque de componentes En el rel Zettler 1 desconecte el cable de 16 AWG de la misma pala 17 Corte el terminal de pala hembra del cable que es...

Page 21: ...e apretadas 21 El cableado ahora est completo Cierre el panel frontal de CA vuelva a conectar la bater a arranque el motor y encienda las luces para asegurarse de que todas funcionen correctamente 22...

Page 22: ...etalle del rel 725 Disposici n sugerida para el rel 725 3c Pala de conexi n a tierra de CC Pala de ali mentaci n de CC Detalle del rel Zettler Pala del interruptor de luz de CA Pala del bloque de dist...

Page 23: ...l Zettler 1 2 o 3 al borne Ajuste el tornillo hacia abajo sobre el terminal de horquilla 9 Del contenido del kit ubique y seleccione el cable azul de 10 AWG H Figura 7 Ref 5 que coincide con el color...

Page 24: ...2 12 Si reemplaza el rel Zettler 2 ubique el cable de 12 AWG L Figura 10a b que va del rel a los interruptores de luz 1 y 2 Si trabaja desde el rel Zettler 1 ubique el cable de los interruptores de l...

Page 25: ...ces de la misma pala 14 Corte el terminal de pala hembra del cable que estaba conectado al rel Zettler y des chelo Pele la cantidad adecuada de aislamiento del cable y encaje un terminal de horquilla...

Page 26: ...luz 6 Interruptor de luz 1 Interruptor de luz 5 Interruptor de luz Detalle de conexi n 15b Interruptor de luz 2 U 16a V Rel 725 2 18 Afloje el tornillo en el borne de CA 2 del rel 725 de luces 2 y co...

Page 27: ...illa azul AA Figura 18 Ref 8 en uno de los extremos 22 Instale el extremo del terminal de horquilla en cada cable negro BB Figura 19a b en el borne de CC 1 de los rel s 725 de luces 1 y 2 Luego instal...

Page 28: ...o de 16 AWG GG Figura 22 Ref 3 Corte el cable amarillo de 16 AWG por la mitad y pele los extremos de los cables cortados En cada uno de los cables cortados encaje un terminal de horquilla azul HH Figu...

Page 29: ...gar y firmemente apretadas 28 El cableado ahora est completo Cierre el panel frontal de CA vuelva a conectar la bater a arranque el motor y encienda las luces para asegurarse de que todas funcionen co...

Page 30: ...aves voire la mort Toujours rester loign du moteur des feux et des autres zones chaudes de la tour d clairage 2 www allmand com 1 Localisez et retirez le panneau de la porte arri re A Figure 1 de l un...

Page 31: ...ts de d connexion et de connexion du relais 3a 3b 3 fr Fran ais Canada 3c Borne CC 2 Borne CC 1 Borne CA 2 Borne CA 1 Borne de masse CC Borne d alimentation CC D tails du relais 725 D tails du relais...

Page 32: ...lumi re Zettler 2 d connectez le fil 12 AWG H Figure 6a b de la borne de l interrupteur d clairage c a et ce fils a t reconfigur sur l interrupteur d clairage 3 Sur le relais Zettler 1 d connectez le...

Page 33: ...ait connect e au relais Zettler D nudez la bonne quantit d isolant de fil et installez le fil L Figure 9a b dans une serrure de levier 3 broches M Figure 9a b R f 11 que vous trouverez dans le contenu...

Page 34: ...achemin depuis le panneau de s paration du bloc de composants Sur le relais Zettler 1 d connectez le fil 16 AWG de la m me borne 17 Coupez et jetez la cosse en fourche femelle du fil qui tait connect...

Page 35: ...Fermez le panneau CA avant rebranchez la batterie d marrez le moteur et allumez les lumi res pour vous assurer que tout fonctionne correctement 22 Une fois que l unit fonctionne correctement r instal...

Page 36: ...orne CC 1 Borne CA 2 Borne CA 1 D tails du relais 725 Disposition de relais 725 sugg r e 3c Borne de masse CC Borne d alimentation CC D tails du relais Zettler Borne d interrupteur d clairage CA Borne...

Page 37: ...du relais Zettler 1 2 ou 3 dans la borne Serrez la vis sur la cosse fourches 9 Trouvez et s lectionnez le fil 10 AWG bleu dans le contenu de l ensemble H Figure 7 R f 5 qui correspond la couleur du c...

Page 38: ...lais Zettler 2 trouvez le fil 12 AWG L Figure 10a b qui est achemin du relais aux interrupteurs d clairage 1 et 2 Si vous travaillez depuis un relais Zettler 1 trouvez le fils provenant des interrupte...

Page 39: ...irage 2 pour les appareils 4 lumi res de la m me borne 14 Coupez et jetez la cosse en fourche femelle du fil qui tait connect e au relais Zettler D nudez la bonne quantit d isolation de fil et sertiss...

Page 40: ...rage 6 Interrupteur d clairage 1 interrupteur d clairage 5 Interrupteur d clairage D tails de connexion 15b Interrupteur d clairage 2 U 16a V Relais 725 2 18 Desserrez la vis sur la borne 2 CA du rela...

Page 41: ...bleue AA Figure 18 R f 8 sur une des extr mit s 22 Installez l extr mit de la cosse fourches de chaque fil noir BB Figure 19a b sur la borne CC 1 du relais de lumi re 725 1 et 2 Ensuite installez les...

Page 42: ...et s lectionnez le fil jaune 16 AWG GG Figure 22 R f 3 Coupez en deux le fil jaune 16 AWG s lectionn et d nudez les extr mit s des fils coup s Sur chacun des fils coup s sertissez une cosse fourches...

Page 43: ...sont s res et serr es 28 Le c blage est maintenant compl t Fermez le panneau CA avant rebranchez la batterie d marrez le moteur et allumez les lumi res pour vous assurer que tout fonctionne correctem...

Page 44: ...N o t f o r R e p r o d u c t i o n...

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