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MAXI-LITE
HYDRAULIC TOWER
683, 695, 883, 895, and 895XL
OPERATOR’S MANUAL
ALLMAND BROS. INC
P.O. BOX 888
HOLDREGE, NE 68949
PHONE: 308/995-4495, 1-800/562-1373
ALLMAND FAX: 308/995-5887
ALLMAND PARTS FAX: 308/995-4883
MAXI-LITE SERIES
For Parts and Updates visit Allmand on the Web at www.allmand.com
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INSPECTION CHECK LIST
FOR PREPARING THE MAXI LITE FOR DELIVERY OR RENTAL
The MAXI LITE requires service as well as proper operation in order to provide the perfor-
mance and safety it has been designed for. Never deliver or put a machine into service with
known defects or missing instructions or decals. Always instruct the customer in the proper
operation and safety procedures as described in the operator’s manual. Always provide the
manual with the equipment for proper and safe operation.
CHECK LIST:
Visually inspect the equipment to ensure that all instructions and decals are in place and
legible.
Inspect the tower latch and knob assembly which locks the tower in the vertical position for
proper operation.
Check the hitch assembly and safety tow chains.
Check the outriggers and jacks to make sure they operate properly.
Inspect the light assemblies for damage and test for proper operation.
Inspect the electrical wiring for signs of damage.
Check the ground rod cable and the ground lug. Make sure they are clean, undamaged,
and functional.
Inspect the tires to ensure good condition and proper inflation.
Check oil, fuel, coolant levels, and hydraulic fluid levels.
Check to make sure the operator’s manual is with the equipment.
Inspect the machine physically for damage and repair if necessary.
NOTE: See appropriate section of manual for scheduled maintenance intervals.
After completing the inspection check list, operate the tower through a complete
operation cycle, following the operating instructions in the operator’s manual.
!
WARNING
NEVER ALLOW ANYONE TO OPERATE THE EQUIPMENT WITHOUT
PROPER TRAINING!
ALWAYS READ THE INSTRUCTIONS FIRST!
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TABLE OF CONTENTS
INSPECTION CHECK LIST ..................................................................................................... 2
TABLE OF CONTENTS ........................................................................................................... 3
INTRODUCTION ...................................................................................................................... 4
SAFETY SYMBOL INFORMATION .......................................................................................... 4
SAFETY AND WARNING DECALS ...................................................................................... 5-7
HYDRAULIC MAST OPERATION ......................................................................................... 8-9
MODEL AND SERIAL NUMBERING SYSTEM ..................................................................... 10
SPECIFICATIONS ..............................................................................................................11-15
CONTROLS AND COMPONENTS ................................................................................... 16-23
ROUTINE MAINTENANCE SCHEDULE ............................................................................... 24
KUBOTA D905, D1105 AND PERKINS 103-10
TROUBLESHOOTING ........................................................................................................... 25
ASSEMBLY PARTS AND ACCESSORIES ........................................................................... 26
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INTRODUCTION
This manual provides the information necessary for the safe operation of the Allmand
Bros., Inc., MAXI-LITE light tower.
The MAXI-LITE standard tower configuration is operated by a two cylinder hydraulic sys-
tem used to erect, extend, and lower the tower.
Specific operating instructions and specifications are contained in this publication to
familiarize the operator and maintenance personnel with the correct and safe procedures
necessary to maintain and operate the equipment.
Take time to read this book thoroughly. If you are uncertain about any of the information
presented in the manual, contact the factory or your dealer for clarification before operation.
SAFETY SYMBOLS
The purpose of the SAFETY INFORMATION SYMBOL shown below is to attract your special
attention to safety related information contained in the text.
!
DANGER
!
WARNING
!
CAUTION
FAILURE TO UNDERSTAND AND COMPLY WITH SAFETY RELATED INFORMATIONAL
INSTRUCTIONS MAY RESULT IN INJURY TO OPERATOR OR OTHERS. IF YOU DO NOT
UNDERSTAND ANY PART OF THIS INFORMATION CONTACT YOUR DEALER FOR
CLARIFICATION PRIOR TO OPERATING EQUIPMENT.
NOTE
The word NOTE is used to bring your attention to supplementary information in relation to
various aspects of proper operation and maintenance.
NOTE: Keep this manual accessible during operation to provide convenient reference.
NOTE: Any reference in this manual to LEFT or RIGHT shall be determined by looking at
the trailer from the rear.
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!
SAFETY WARNING
SAFETY AND WARNING DECALS
ALWAYS REPLACE ANY SAFETY AND INSTRUC-
TION DECALS THAT BECOME DAMAGED, PAINTED,
OR OTHERWISE ILLEGIBLE.
PART NO. D-151
Location: Inside left hand door
panel of Lister Petter engine units.
PART NO. D-249
Location: Inside left hand door
panel of Kubota engine units.
Refer to these representations of the safety
warning decals used on the MAXI-LITE to
insure correct ordering if replacing becomes necessary.
PART NO. D-264
Location: Inside left hand door panel.
PART NO. D-325
Location: Inside left hand door panel.
(Hydraulic tower model only.)
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SAFETY AND WARNING DECALS
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SAFETY AND WARNING DECALS
PART NO. D-160
Location: On pintle hitch
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HYDRAULIC MAST OPERATION
DESCRIPTION OF OPERATION
The Allmand MAXI-LITE tower assembly
consists of a three section telescoping
mast that can be raised and extended by
operating two toggle switches mounted on
the D.C. Control Panel. The lift cylinder
toggle switch operates a solenoid on a
hydraulic pump that pressurizes a cylinder
to raise the mast from the horizontal towing
position to the vertical position. The extend
cylinder toggle switch operates a solenoid
on the same hydraulic pump that pressurizes a cylinder that extends the telescoping
sections.
The three section mast assembly can be
rotated from the ground by loosening a knob
and rotating the entire assembly 360° to aim
the lights as necessary.
!
SAFETY WARNING
ALWAYS CHECK FOR OVERHEAD
OBSTRUCTIONS BEFORE RAISING
AND LOWERING MAST. ALLOW 35'
CLEARANCE. AVOID ALL OVERHEAD
ELECTRICAL WIRES
.
TO ERECT MAST AND RAISE
LIGHTS
1. Extend both side outrigger jacks, rear jack
and tongue jack to stabilize and level the
trailer.
NOTE: Jacks should be placed only on
firm footing.
!
SAFETY WARNING
WHEN EXTENDING REAR JACK, WATCH
TO ENSURE YOU ARE CLEAR OF THE
OVERHANGING ENDS OF THE MAST.
THE SUPPLEMENTAL GROUND ROD IS A
SAFETY DEVICE THAT MAY REDUCE
THE CHANCE OF PERSONAL INJURY
FROM STRAY ELECTRICAL CURRENT
Therefore, Allmand recommends using
the ground rod. However, it is the user’s
responsibility to determine the requirements and/or applicability of local, state,
or national electrical code which governs
the use of the ground rod.
.
TO PREVENT INSTABILITY AND HELP
ENSURE SAFE OPERATION, ALWAYS
PROVIDE PROPER GROUND SUPPORT BEFORE RAISING MAST.
BEFORE RAISING MAST, VISUALLY
INSPECT EQUIPMENT FOR DAMAGE
OR WEAR. FAMILIARIZE YOURSELF
WITH THE LOCATION AND FUNCTION
OF ALL OPERATING PARTS BY STUDYING THIS MANUAL. OBSERVE ALL
CAUTION DECALS LOCATED ON
EQUIPMENT.
NOTE: The latch locks the mast in the
vertical position and disengages the
sections allowing the tower assembly
to be rotated to position the lights.
8
2. Attach the ground rod to the grounding lug,
and drive the ground rod fully for adequate
electrical ground, as required by local,
state, or national code.
3. Release the pin that secures the mast to
the rear mast support.
4. Operate the LIFT CYLINDER toggle switch
UP to raise the mast from horizontal to
vertical.
5. Turn black knob counterclockwise and
engage latch in strike plate. Retighten black
knob.
6. Operate the EXTEND CYLINDER toggle
switch UP to raise the lights vertically.
7. To rotate the lights, loosen the black knob
on mast and turn the tower assembly with
the handles provided. Retighten knob.
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!
SAFETY WARNING
IF THE TOWER CANNOT BE ROTATED
AFTER LOOSENING THE BLACK KNOB,
CHECK TO ASSURE THE LOWER
LATCH IS ENGAGED IN THE STRIKE
PLATE. THIS DOUBLE LATCH FEATURE
PREVENTS THE TOWER FROM BEING
ROTATED IF THE LATCH IS NOT ENGAGED.
HYDRAULIC MAST OPERATION
NOTE: The tower has to be positioned
with the winch handle pointing directly
forward before the latch can be released.
This aligns the tower correctly with the
pin in the rear tower support, preventing
tower extension during towing.
!
SAFETY WARNING
VISUALLY INSPECT EQUIPMENT FOR
DAMAGE BEFORE OPERATING. ALLOW
ADEQUATE CLEARANCE AROUND
TRAILER FOR TOWER AND INSURE THAT
NO PERSONS ARE STANDING IN FRONT
OF, OR BEHIND UNIT WHEN LOWERING.
TO LOWER MAST AND LIGHTS
1. Turn off lights.
2. Loosen black knob and rotate tower until
the black triangles are aligned and retighten knob.
3. Operate the extend cylinder toggle switch
DOWN to lower the lights to the lowest
vertical position.
6. Secure pin locking mast to rear tower
support.
7. Remove ground rod from earth.
Disconnect wire from ground lug and
secure in trailer.
8. Raise jacks and rear stand, retract
outriggers and secure for towing.
NOTE: Ensure the detent pins are
properly engaged in the outriggers
before towing.
4. Turn the black knob counterclockwise and
lift to release the latch from the strike plate.
Retighten the knob with the latch disengaged from the strike plate.
5. Operate the lift cylinder toggle switch down
to lower the mast from vertical to horizontal
into the towing position.
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MODEL AND SERIAL NUMBERING SYSTEM
MODEL NUMBERING SYSTEM
EXAMPLE: ML683HCKFMX
MAXI-LITE trailer, 6KW generator (standard),
1000 Watt Ballast Capacitors, Hydraulic tower,
Coiled Cord w/Tunnel, Kubota water cooled engine,
Marathon Generator, Metal Halide Lamps, and Light
Package
ML-MAXI-LITE trailer
683 - 6KW Gen., standard 1000 watt Ballast Cap.
695 - 6KW Gen., Special Capacity 28 UF
883 - 8KW Gen., standard 1000 watt Ballast Cap.
895 - 8KW Gen.k, Special Cap. 28 UF
XL - 6-Light Option
E - Electric Winch 120V
R - Cord Reel
I - Straight Cord
C - Coiled Cord
P – Perkins 103-10 Water Cooled Engine
W - Lister Petter LPW-3 Water Cooled Engine
K - Kubota Water Cooled Engine
F - Marathon Pancake Generator
P - T & J Pow r Gard Generator
O - Allmand 6KW Generator
M - Metal Halide, 1000 Watt Multi-Vapor Lamps
H - High pressure sodium 1000 Watt
(Power-lite Fixtures)
X - Indicates stop, turn and tail lights
V - Visor Package
S - Sound Attenuation
NOTE: 50 following a generator letter indicates
50 hertz.
SERIAL NUMBERING SYSTEM
EXAMPLE: 00 03 ML 11
00 - Year of manufacture
03 - Month of manufacture
ML - MAXI-LITE
11 - Allmand code indicating this unit was
the 11th produced that month.
SERIAL NUMBER LOCATION
Trailer: All MAXI-LITE models have a serial
number plate located just below the rear tower
support on the rear panel.
Generator: Plate attached to the side of the
generator housing
Engine: Plate attached to the engine
KUBOTA D905-BG and D1105-BG:
Left side, between manifold and starter
PERKINS 103-10:
Upper right front corner behind injector pump
DESCRIPTION OF MODELS AND OPTIONS
The MAXI-LITE hydraulic light tower uses four 1000 Watt Metal Halide or High Pressure Sodium lamps with the
exclusive Allmand SHO lighting system to produce a total of 334,204 lumens (83,551 lumens per fixture). Optional
reflective visors and 6-light units are available. The lights are mounted on a hydraulically operated tower. The tower
is operated by two hydraulic cylinders powered by an electrically driven hydraulic pump. One cylinder, mounted on
the trailer frame, erects the mast from the horizontal towing position to vertical. The second cylinder, mounted
inside the tower, extends the mast vertically to the desired height. The hydraulic cylinders both erect the mast
from horizontal to vertical and extend the mast vertically to the desired height. Inside fixture storage is offered for
the 4-light option.
The heavy duty trailer shell has 12 gauge doors and roof panels. The shell houses the 15” wheels and tires
inside the side panels. The front panels are rust proof ABS plastic. The MAXI-LITE light tower is powered by
either one of two Kubota water cooled engines, 10.5 hp or 13.6 hp., or a Perkins water cooled 10.7 hp diesel
engine. Each engine mounts to either the 6KW or 8KW generator. The trailer houses a 50 gallon poly fuel tank
and an optional sound attenuation package.
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SPECIFICATIONS
KUBOTA D905, D1105, AND PERKINS 103.10
FUEL AND LUBRICATING OIL REQUIREMENTS
See the KUBOTA 905 EBG1 or 1105 EBG1 Engine Operators Handbook or
the PERKINS 103-10 Engine Operators Handbook for information on
oil and fuel requirements.
TOWING INSTRUCTIONS
Before towing the MAXI-LITE the trailer should be inspected visually to insure that
the following operations have been completed.
1. Hitch is securely attached to towing vehicle (safety chain secure).
2. All outriggers and jacks are retracted and secured.
3. Tower is lowered and the rear tower support pin is in place.
4. Light fixtures are positioned for transport.
5.
Doors are closed and secure.
Check for adequate tire pressure.
6.
7. Taillights are connected and operating (if equipped).
8. Ground rod is removed from ground and secured in the trailer.
GROUND ROD INSTRUCTIONS
1. Remove ground rod stowed inside the left door (attached to the lower frame).
2. Unroll the electrical wire lead from the ground rod.
3. Attach the ground rod lead to the grounding lug located near the ballast compartment.
4. Drive the ground rod a minimum of 2 1/2 FT into the earth for adequate electrical grounding. If
this is not possible consult your local qualified electrician.
5. After shutdown of engine: Remove the ground rod from the earth, remove lead from the trailer
ground lug and store ground rod inside left door.
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SPECIFICATIONS
BEFORE STARTING
1. Fill the engine with the right grade of lubricating oil
and to correct level (check dipstick).
2. Ensure there is an adequate supply of fuel.
3. Ensure that the air cleaner is firmly attached, the
air canister seals and the hose clamps are properly sealed. Air cleaner element should be
checked and replaced if necessary.
4. Install the ground rod.
DESCRIPTION OF OPERATION
By depressing the start assist switch, the fuel solenoid
is energized. The solenoid plunger is drawn into the
coil and activates the fuel control linkage to RUN
position. When the engine starts, adequate engine oil
pressure at the oil pressure switch will maintain the
solenoid in the energized position. The start assist
switch can be released as soon as the engine starts.
A 10A inline fuse protects the solenoid from electrical
damage.
LOW OIL PRESSURE SHUTOFF SYSTEM
Should a low oil pressure condition occur (less than 5
PSI) the pressure sending unit breaks the circuit
between the battery and the fuel solenoid, allowing the
spring load to immediately move the fuel control to the
shutoff position.
STARTING THE KUBOTA AND PERKINS
ENGINES
NOTE: The Kubota and the Perkins engines
include a glow plug cold start system controlled
by the ignition switch on the control panel.
Glow plugs are not needed on a warm engine or
if the ambient temperature is above 50 F. Do not
use starting fluid or ether.
1. Turn the ignition switch to the PREHEAT posi-
tion and hold until the glow plug lamp goes out.
2. Turn the ignition switch to the Start position until
the engine starts. Release key as soon as the
engine starts.
3. If engine fails to start, it may be necessary to
cycle the glow plugs again.
NOTE: To prevent equipment damage, DO NOT
hold ignition switch for more than 10 seconds
in the start position. If the engine does not start
in 10 seconds, wait 30 seconds and try the start
sequence again. Do not run the cell motor for
more than 20 seconds continuously. Limit
engine cranking to 3 attempts with a 2 minute
cool-down between each. After 3 attempts allow
to cool to ambient temperature.
HIGH COOLANT TEMPERATURE SHUTOFF
SYSTEM
Should a high coolant temperature condition occur, the
temperature sending unit breaks the circuit between
the battery and the fuel solenoid, allowing the spring
load to immediately move the fuel control to the shutoff
position.
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STOPPING THE KUBOTA AND PERKINS
ENGINES
Turn the ignition switch to the OFF position. This breaks the circuit between the
battery and the fuel solenoid, allowing the
spring load to immediately move the fuel
control to the shutoff position.
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SPECIFICATIONS
ELECTRICAL
Hard wired electrical circuits
Componentized ballast assemblies
Ground rod
Hour meter
Voltmeter (optional)
External 120V and 240V outlets (optional)
FLOOD LIGHT ASSEMBLY
Four or six 1000 watt lamp fixtures sealed for
all weather use. Lamps can be either the SHO
1000 fixture, 1250 watt fixture or PowerLite
fixture.
SHO 1000 FIXTURE - BT-37 lamp, Metal
Halide, Laboratory rated life is 10,000 hours.
Lumen rating: 110,000
Warm-up time: 2-4 minutes
Restart time: 10-15 minutes
MAST
1. A single stage hydraulic cylinder inside
the cabinet raises the tower from the
horizontal towing position to vertical.
2. A three-stage telescopic hydraulic
cylinder supported inside a steel tube
mast extends to raise the lights to 30
feet.
3. Hydraulic power is provided by a self contained 12 volt hydraulic power unit
operated by two switches located on the
control panel.
TRAILER
The complete generator is housed in a
lockable enclosure with the frame fabricated
from heavy gauge steel mounted on a twowheel, leaf spring axle. The design enables
the trailer to contain the outriggers in a
simple compact position.
POWERLITE FIXTURE - BT-56 1000 watt
Multi-Vapor lamp, Metal Halide, Laboratory
rated life is 12,000 hours.
Lumen rating: 110,000
Warm-up time: 2-4 minutes
Restart time: 10-15 minutes
POWERLITE FIXTURE - E-25 1000 watt
High Pressure Sodium lamp (often referred to
as H.P.S), Laboratory rated life is 24,000
hours.
Lumen rating: 140,000
Warm-up time: 4-6 minutes
Restart time: 1 minute
NOTE: A trailer equipped with Metal Halide
lights and a trailer equipped with High Pres-
sure Sodium lights use different ballasts and
starters. Therefore, it is not advisable to
interchange bulb types.
When the mast is in the operating position it
is located in the middle of a four point
outrigger system for optimum balance and
stability. This system was engineered to
allow the light plant to remain operational in
sustained winds of 65 MPH with the mast
extended to full height and the outriggers in
position.
The design includes an adjustable-height reversible hitch, which includes a 2” ball and
pintle hook hitch.
STABILIZERS
Four (4) point outrigger design with tower
center mounted between two (2) retractable
side outriggers, tongue and rear jack.
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SPECIFICATIONS
MAXI-LITE DIMENSIONS
Height lowered: 6’0" (1.84 m)
Height extended: 30’ (9.14 m)
Length: 14’9” (4.49 m)
Width: 6’4” (1.93 m)
Outrigger width: 11’6” (3.5 m)
Trailer: Structural steel frame
Leaf spring axle
Wheels & tires: 15"
DOMESTIC SHIPPING WEIGHT
Fixtures: 15 Ibs. ea. = 60 Ibs.
Trailer with mast: 2,180 Ibs. (902.7 kg)
Total weight: 2,240 Ibs. (1016 kg)
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SPECIFICATIONS
KUBOTA D905-EBG1 ENGINE
Kubota D905-EBG1, Indirect injection 3 Cylinder
Displacement: 54.80 cu. in.(898 cm)
Bore: 2.83 in. (72 mm)
Stroke: 2.90 in. (73.6 mm)
Power output: 10.5 BHP@ 1800 rpm
Power output derating: 3.0% for every1000 ft.
altitude (305 m) above sea level
Ambient temp: 1% per 10° F (5.6°C) above 77°F (25°C)
Fuel: Diesel
Fuel consumption: 0.63 US gal (2.39 L/hr)
Starting: Glow plugs needed below 45° F. 12V electric
Oil sump capacity (excluding filter) 5.4 US qt. (5.14L)
Low oil pressure shutdown, high engine
temp. shutdown, and glow plug cold start
assist are standard.
KUBOTA D 1105-EBG1 ENGINE
Kubota D1105-EBG1, Indirect injection 3 Cylinder
Displacement: 68.53 cu. (1.1 cm)
Bore: 3.07 in. (78 mm)
Stroke: 3.09 in. (78.4 mm)
Power output: 13.6 BHP@ 1800 rpm
Power output derating: 3.0% for every1000 ft.
altitude (305 m) above sea level
Ambient temp: 1% per 10°F (5.6°C) above 77°F (25°C)
Fuel: Diesel
Fuel consumption: 0.63 gal (2.39 L/hr)
Starting: Glow plugs needed below 45° F. 12\/ electric
Oil sump capacity (excluding filter): 5.4 US qt. (5.14 L)
Low oil pressure shutdown, high engine
temp. shutdown, and glow plug cold start
assist are standard.
PERKINS 103.10 ENGINE
Perkins 103.10, Indirect injection 3 Cylinder
Displacement: 58.3 cu. in. (954 cc)
Bore: 75 mm
Stroke: 72 mm
Power output: 10.7 BHP@ 1800 RPM
Power output derating: 3.5% for every 1000 ft
altitude (305 m) above sea level
Air Inlet Temp:
Fuel: Diesel
Oil sump capacity: Fill to correct level
Starting: 12 volt electric
Low oil pressure shutdown, high engine
temp. shutdown, and glow plug cold start
1% per 10°F (5.6°C) above 77° F (25°C)
assist are standard.
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CONTROLS AND COMPONENTS
NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.
FIG. 1. A.C. CONTROL PANEL
1. Switch, Circuit Breaker (Lights 1 through 4)
2. Switch, Circuit Breaker (240V Receptacle)
3. Switch, Circuit Breaker (120V Receptacles)
!
SAFETY WARNING
FAILURE TO UNDERSTAND AND COMPLY
WITH SAFETY RELATED INFORMATION
AND INSTRUCTIONS MAY RESULT IN
INJURY TO THE OPERATOR OR OTHERS.
IF YOU DO NOT UNDERSTAND ANY PART
OF THIS CONTACT YOUR DEALER FOR
CLARIFICATION PRIOR TO OPERATING
EQUIPMENT.
16
FIG. 2. D.C. CONTROL PANEL
4. Voltmeter (optional)
Indicates charging circuit voltage
5. Hour Meter
Shows total elapsed hours of engine operation
6. Momentary Contact Switch
Lift up on 6 to raise tower
Press down on 6 to fold the tower
7. Momentary Contact Switch
Lift up on 7 to extend the tower
Press down on 7 to Iower the tower
8. Glow Plug Indicator
9. Ignition ON/OFF Switch
10. Control Panel complete
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CONTROLS AND COMPONENTS
NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.
FIG. 3 BALLAST PANEL
11. Ballast, Capacitors 1 through 4
12. Ballast, Transformers 1 through 4
!
FAILURE TO UNDERSTAND AND COMPLY
WITH SAFETY RELATED INFORMATION
AND INSTRUCTIONS MAY RESULT IN
INJURY TO THE OPERATOR OR OTHERS.
IF YOU DO NOT UNDERSTAND ANY PART
OF THIS CONTACT YOUR DEALER FOR
CLARIFICATION PRIOR TO OPERATING
EQUIPMENT
FIG. 4 CONVENIENCE PANEL
13. 120 Volt/ 15 Amp Outlet Receptacles
(Ground fault)
14. 240 Volt/ 15 Amp D.C. Outlet Receptacle
15. Power Cord Access Hole
SAFETY WARNING
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CONTROLS AND COMPONENTS
NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.
FIG. 5 GROUND ROD
16. Ground Rod
Ground rod should be attached to
grounding lug with wire provided and
ground rod and then driven fully into
the earth for adequate electrical
ground, as required by local, state,
or national electrical code.
FIG. 6 ENGINE (Left Side)
17. Air Cleaner
18. Fuel Filter
19. Fuel Lift Pump
20. Fuse (10 Amp)
21. Oil fill
22. Stop Solenoid
23. Oil Filter
FIG. 7 ENGINE (Right Side)
24. Fuel Return Line
25. Fuel Suction Line
26. Starter
27. Glow Plug
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CONTROLS AND COMPONENTS
NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.
FIG. 8 REAR JACK
28. Rear Jack
!
SAFETY WARNING
WHEN EXTENDING REAR JACK,
WATCH TO INSURE YOU ARE
CLEAR OF THE OVERHANGING
ENDS OF THE MAST BEFORE
STANDING UP.
FIG. 9 OUTRIGGER JACK
29. Pin—Retains outrigger in retracted
position for towing
30. Jack Pin—Pull to allow jack to rotate
31. Outrigger Jack
32. Jack Handle—Crank handle to raise
and lower foot of jack to level trailer.
FIG. 10 REAR TOWER SUPPORT
33. Pin—Locks tower into rear tower support
34. Rear Tower Support
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CONTROLS AND COMPONENTS
NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.
FIG. 11 TONGUE ASSEMBLY
35. Taillight Wiring Harness
36. Safety Tow Chains
37. Reversible Hitch (2” Ball and Pintle
Hitch)
FIG. 12 FORKLIFT POCKETS
38. Forklift Pockets
39. Lifting Eye
FIG. 13 DOOR PROP
40. Door Prop—Locks Door Panel in
Open Position
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CONTROLS AND COMPONENTS
NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.
FIG. 14 KICKOUT SPRING
41. Kickout Spring—Tilts mast off
center when folding mast down
FIG. 15 TOWER LOCKING BAR LATCH
42. Mast Locking Bar Latch —Locks mast in
vertical position and allows tower to
rotate.
43. Mast Locking Bar Safety Switch —
Prevents extension of mast when
locking bar is not engaged.
NOTE: Tower must be positioned with the
two black triangles on the tower assembly,
near the mast handles, pointing at each other.
Then the locking bar can be released from
the strike plate allowing the tower to rotate
toward horizontal towing position.
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CONTROLS AND COMPONENTS
NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.
FIG. 16 TOWER CONTROLS
44. Alignment arrows —Must be aligned to
unlock the tower
45. Lock Knob—Locks tower in position.
46. Mast Handles—Use to rotate tower
and lights.
FIG. 17 COIL CORD
47. Coil Cord and Coil Cord Tunnel
FIG. 18 LAMP CONNECTORS
48. Lamp Connector Lead--For quick
connecting/disconnecting of the the
lamp fixtures
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CONTROLS AND COMPONENTS
NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.
FIG. 19 HYDRAULIC PUMP ASSEMBLY
49. Hydraulic Pump Assembly with Hydraulic
Reservoir
50. Electric hydraulic pump drive motor
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ROUTINE MAINTENANCE SCHEDULE
KUBOTA D905 and D1105 and PERKINS 103-10
INSPECTION AND LUBRICATION SCHEDULE
Check hydraulic fluid level.
Lubrication grease specifications: N.G.L.I. consistency #2, high temperature anti-friction
bearing lubricating grease.
Service intervals shown below have been established for operation under normal conditions.
Where equipment is operated under severe conditions (very dusty, extreme heat or cold, etc.)
affected items should be serviced more frequently.
INTERVAL ITEM PROCEDURE
Fuel level Check and fill as necessary
Daily or 10 Hr.
100 Hr.
200 Hr.
400 Hr. Fuel Filter Replace with new.
1000 hr. or yearly
1000 hr. or yearly
Lubricating oil Check level and condition
Air Cleaner
All 10 Hr. items As above
Air Cleaner
Battery Check level of electrolyte
Engine Generator assembly
All 100 Hr. items As above
Engine lubricating oil system
Coolant Check level and condition
All 200 Hr. Items As above
Fan belt Check tension and condition500 Hr.
Radiator Clean out fins with water or air
All 500 Hr. Items As above
Engine Valves Adjust clearance
Axle wheel bearings Clean and repack
Fuel System Clean sediment from tank
Clean under very dusty
conditions.
Service as required. Service
requirements may be accelerated
Check for fuel and lubricating oil
leaks
Drain lubricating oil, flush out
system, renew filter element and
refill with correct grade and type
oil
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TROUBLESHOOTING
!
SAFETY WARNING
DANGER!
HIGH VOLTAGE! DO NOT ATTEMPT TO TEST AND REPAIR GENERATOR AND
BALLAST ELECTRICAL SYSTEMS UNLESS YOU UNDERSTAND AND ARE QUALIFIED
TO WORK ON SUCH SYSTEMS.
When one lamp does not light, TURN OFF THE GENERATOR and test the lamp by switching
leads with a lamp that
ELECTRICITY!
licensed electrician. DO NOT attempt to test generator voltage or ballast electrical systems unless
you are a qualified electrician. Consult the factory for voltage specifications and test procedures.
If the following procedures do not solve your problem, have the circuit tested by a
DOES
PROBLEM POSSIBLE CAUSE
ONE OR MORE LIGHTS
DO NOT LIGHT UP.
light.
1. Circuit breakers in the outlet box are not turned on or have tripped.
2. Lamps are not allowed time to cool after last being lit. You must
allow 15 minutes between the time the lights are shut off and the
time they are restarted.
3. The lamp or lamps are burned out or broken.
4. One or more of the lamps are not screwed in securely.
5. Plug and socket at light bar not securely pushed together and
locked.
6. The temperature of the ballast is below –20 degrees F. the
efficiency of the capacitors in the ballast is not enough to ignite the
lamps. For operations where the temperatures of the ballasts falls
below –20 degrees F. some means of warming the ballast must be
used.
7. Low electrical system voltage.
8. A loose connection in the back of the lamp socket in the lamp
holder.
9. A circuit breaker or breakers are defective.
10. A loose connection on the terminal board.
11. The engine and generator are not running up to speed (1800 RPM)
12. A wrong style replacement lamp (requiring a different ballast) has
been installed.
13. Too much power is being drawn from the auxiliary outlets.
14. Capacitor or transformer has failed.
15. Corrosion has occurred on the lamp bases.
DO NOT WEAR JEWELRY WHILE WORKING WITH
.
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