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 V-SERIES requires service as well as proper operation in order to provide
the performance 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, undam-
aged, and functional.
Inspect the tires to ensure good condition and proper ination
Check oil, fuel, coolant levels, and hydraulic uid levels.
Check to make sure the operator’s manual is with the equipment.
Inspect the machine physically for damage and repair if necessary.
Inspect the light bar and latch in transport position.
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
This manual provides the information necessary for the safe operation of the Allmand
Bros., Inc., MAXI-LITEV-SERIES light tower.
The MAXI-LITE V-SERIES standard tower is operated with a 12 VDC hydraulic pump
and hydraulic cylinder.
Specic operating instructions and specications are contained in this publication to fa-
miliarize 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 clarication before operation.
SAFETY SYMBOLS
The purpose of the SAFETY INFORMATION SYMBOL shown below is to attract your spe-
cial 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 INSTRUCTION DECALS THAT BECOME DAMAGED, PAINTED, OR OTHERWISE ILLEGIBLE.
PART NO. 090249
Location: Inside left hand
door panel.
Refer to these representations of the safety
warning decals used on the MAXI-LITE to
insure correct ordering if replacing becomes necessary.
PART NO. 101925
Location: Inside left hand door panel.
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SAFETY AND WARNING DECALS
PART NO. 090158
Location: AC control panel
PART NO. 090165
Location: Inside left hand
door panel
PART NO. 090166
Location: Inside left hand
door panel
PART NO. 090084
Location: AC control panel
PART NO. 090163
Location: On left side
wheel well
PART NO. 090162
Location: On left front
enclosure panel
PART NO. 090133
Location: On left side panel below
ground lug
PART NO. 090034
Location: On left inner fender
adjacent to fuel tank ller neck
PART NO. 090159
PART NO. 090226
Location: Left front
panel.
Location: On right hand
wheel well
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PART NO. 090002
Location: On light bar
assembly
SAFETY AND WARNING DECALS
PART NO. 090005
Location: Inside left door panel
PART NO. 090160
Location: On trailer drawbar near
revsible hitch assembly.
PART NO. 100247
Location: Inside left door panel.
PART NO. 090179
Location: On fuel tank near ller neck.
PART NO. 101404
Location: On either side of mast assembly
immediately above roof panel .
PART NO. 101057
Location: On fuel tank near ller neck.
PART NO. 090306
Location: On DC
control panel
7
PART NO. 090465
Location: Inside left door panel.
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HYDRAULIC LIFT VERTICAL MAST OPERATION
DESCRIPTION OF OPERATION
The Allmand MAXI-LITE V Series hydraulic
lift tower assembly consists of a seven section telescoping mast which can be extended
by operating a single hydraulic cylinder.
The light bar assembly can be rotated into
position by releasing the light bar park pin.
To release the park pin, pull the ring and turn
it 90 degrees so that the pin remains in the
retracted position. The light bar is designed
to rotate with enough resistance so that the
bar will stay in the desired position once the
operator has directed the lights on the work
zone. if the light bar rotates too easily or does
not stay in position, remove the cap plug from
the center of the light bar cover and tighten
the nut to achieve the desired resistance and
replace the cap plug.
SAFETY WARNING!
TO SET UP TOWER 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
rm footing.
SAFETY WARNING!
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.
.
ALWAYS CHECK FOR OVERHEAD OB-
STRUCTIONS BEFORE RAISING AND
LOWERING MAST. ALLOW 35' CLEARANCE. AVOID ALL OVERHEAD ELECTRICAL WIRES
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
.
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. Start engine.(NOTE: Tower may be raised
and lowered as needed without engine running.)
4. While the tower is still in the down position,
position the light bar and lamps so they are
aimed at the work zone and tilted at the approximate angle to get maximum coverage
once the tower is raised.
5. Stand clear of the tower when raising and
lowering the lights.
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HYDRAULIC LIFT VERTICAL MAST OPERATION
6. Operate the hydraulic lift switch to the
“up” position to raise tower to the desired height.
7. If lights need to be adjusted for better
lighting of the work zone after raising the
tower, lower the tower using the “down”
switch position and make desired adjust-
ments to the light bar and light xtures.
Raise the tower into position. Repeat
this step if necessary.
SAFETY WARNING!
VISUALLY INSPECT EQUIPMENT FOR
DAMAGE BEFORE OPERATING. ALLOW
ADEQUATE CLEARANCE AROUND TRAILER FOR TOWER AND INSURE THAT NO
PERSONS ARE STANDING IN UNDER THE
LIGHTS WHEN LOWERING.
5. Reposition the lamp xtures for transport
by pulling them down into the lowest position and face the
xtures toward the center of the trailer.
6. Remove ground rod from earth. Disconnect wire from ground lug and secure in
trailer
7. Raise jacks and rear stand, retract outriggers and secure for towing
NOTE: Ensure the detent pins are prop-
erly engaged in the outriggers before
towing.
TO LOWER TOWER AND LIGHTS
1. Turn off lights.
2. Operate the hydraulic lift switch in the down
position to lower the lights to the lowest
vertical position. When tower reaches
the bottom, run switch for three additional
seconds to ensure that the tower is at it’s
lowest possible position.
3. Stop engine.
4. Rotate the light bar into the transport park
position (in line with trailer) and engage the
park pin by twisting on the park pin ring until
the plunger is released and the pin engages
the hole in the light bar.
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HYDRAULIC T OWER POWER UNIT
GENERAL START UP INSTRUCTIONS
NOTE: The ports are marked on the casing UP
and DN. When facing the power unit with the
motor up, plug the right hand, or DN port Jog
the motor until the oil flows from the left hand,
or up port. If oil does not flow from the UP port,
reverse the wire leads on the motor, and repeat. The pump is now primed. Connect the
hose (or tubing) to the UP port and tighten.
Connect the other hose end to the blind end of
a fully retracted hydraulic cylinder.
With the hose fitting loose, operate the power
unit until oil (and no air) bleeds from the fitting.
Tighten the fitting. Refill the reservoir.
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TOWING AND STARTING INSTRUCTIONS
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 chains secure).
2. All outriggers and jacks are retracted and secured.
3. Tower is lowered.
4. Light xtures are positioned for transport.
5. Doors are closed and secure.
6. Check tires for adequate air
pressure
7. Taillights are connected and operating (if equipped).
8. Ground rod is removed from ground and secured in the trailer
GROUND ROD INSTRUCTIONS (If so equipped)
1. Remove optional ground rod stowed just 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 qualied 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.
BEFORE STARTING
1. Fill the engine with the right grade of lubricating oil (see pg. 19) and to correct level (check
dipstick).
2. Ensure there is an adequate supply of fuel.
3. Ensure that the air cleaner is rmly 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 fue! 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.
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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STARTING INSTRUCTIONS
STARTING THE ENGINE
NOTE: The Isuzu engine includes 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 uid or ether!
1. Turn the ignition switch to the PREHEAT position
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 sec-
onds 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 continu-
ously. Limit engine cranking to 3 attempts with a 2 minute cooi-down between each. After 3
attempts allow to cool to ambient temperature.
STOPPING THE ENGINE
1. 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.
2. Disconnect the ground rod (if so equipped).
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Trailer: All MAXI-LITE ML 15/ML
20 V-SERIES models have a serial
number plate located on the lower left
corner of the rear panel.
SERIAL NUMBER LOCATIONS
Engine: ISUZU 4LE1 - Plate
attached to the engine right side,
near the fuel lter.
Generator: Label attached to the
side of the generator housing.
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SPECIFICATIONS
MAXI-LITE DIMENSIONS
Height lowered: 7’8” (2.34 m)
Height extended: 25’6”’ (7.8 m)
Length: 10’4” (3.25 m)
Width: 6’4” (1.92 m)
Outrigger width: 12’10” (3.5 m)
Trailer: Structural steel frame
Leaf spring axle
Wheels & tires: 15”
DOMESTIC SHIPPING WEIGHT
Fixtures: 15 Ibs. ea. = 60 Ibs.
Total weight: 2,580 Ibs. (963 kg)
TRAILER
The engine-generator set is housed in a lockable enclosure with the frame fabricated
from heavy gauge steel mounted on a two-wheel leaf spring axle. The design enables
the trailer to contain the outriggers in a simple compact position. The design includes
an adjustable-height reversible hitch that includes a 2” ball and a 3” pintle hook hitch.
MAST
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.
The mast consists of seven fabricated steel sections that telescope to 25’ 6” (7.8m) and
UHMW plastic guide pads to provide smooth operation and reduced friction.
The mast sections are extended with either a manual or electric winch, or hydaulic
pump. The electric winch design includes limit switches that turn the winch off when the
mast reaches full extension or is fully retracted.
STABILIZERS
Four (4) point outrigger design with tower center mounted between two (2) retractable
side outriggers, tongue jack and rear jack.
FLOOD LIGHT ASSEMBLY
The ood light assembly consists of four 1250 watt metal halide, four 1000 watt metal halide
or four 1000 watt high pressure sodium (HPS) lamp xtures sealed for all weather use.
Displacement: 133 cu. in. (2179 cc)
Bore: 85 mm
Stroke: 96 mm
Power output: 34.1 BHP@ 1800 RPM
Power output derating: 3.5% for every 1000 ft
Air Inlet Temp: 1% per 10°F (5.6C) above 77° F (25°C)
Fuel: Diesel
Oil sump capacity: Fill to correct level
Starting: 12 volt electric
altitude (305 m) above sea level
Low oil pressure, high engine temperature shut-downs and a glow plug cold start assist are
standard equipment on the Isuzu 4LE1 diesel engine.
NOTE: Consult the Isuzu Operator’s Manual for cold weather starting instructions.
Horsepower ratings are established in accordance with Society of Automotive Engineers
Small Engine Test Code- J1349 GROSS.
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SPECIFICATIONS
GENERATOR
15 kW single phase and 20 kW single and three phase models available
60 hz and 50 hz models available (50 hz 15 kW only)
FUEL REQUIREMENTS
Use a clean No. 2 Diesel fuel oil (SAE J313 JUN87) according to ASTM D975. Do not
use alternative fuel, because its quality is unknown or it may be inferior in quality. Do
not use kerosene, which has a very low cetane rating, and can adversely effect the engine. Refer to the Isuzu Operators Manual for more detailed fuel requirements.
LUBRICATION REQUIREMENTS
ISUZU 4LE1 DIESEL ENGINE
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CONTROLS AND COMPONENTS
NOTE: PHOTOGRAPHS MAY SHOW NON-STANDARD EQUIPMENT AND OPTIONS
FIGURE 1
FIGURE 2
6
1
5
7
4
23
FIGURE 3
FIG. 3. ISUZU ENGINE CONTROL PANEL
4. Ignition Switch
5. Glow Plug Indicator
6. Engine Fault Warning Lamps
7. Hour Meter
FIG. 1. AC CONTROL PANEL
1. Switch, Circuit Breaker (Lights 1&2 and
lights 3&4)
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.
FIG. 2. DC CONTROL PANEL
2. Momentary Contact Switch. Lift up to raise and
extend the tower.
Press down to Iower the tower.
3. 2 AMP Circuit Breaker (Hydraulic Pump)
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CONTROLS AND COMPONENTS
NOTE: PHOTOGRAPHS MAY SHOW NON-STANDARD EQUIPMENT AND OPTIONS
11
12
11
FIGURE 3.
FIG. 4 CONVENIENCE PANEL
1. 30 Amp Breakers
2. 15 Amp Breakers
3. 50 Amp Breaker
4. 70 or 90 Amp Main Breaker
5. 120/240 volt Receptacles
6. 110/120 Volt Outlet Receptacles
(Ground fault)
FIG. 3 BALLAST PANEL
11. Ballast, Capacitors 1 through 4
12. Ballast, Transformers 1 through 4
1
1
2
2
16
5
5
6
6
FIGURE 4.
3
3
4
4
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
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CONTROLS AND COMPONENTS
NOTE: PHOTOGRAPHS MAY SHOW NON-STANDARD EQUIPMENT AND OPTIONS
FIG. 5 GROUND ROD (Optional)
16. Ground Rod
Ground Rod should be attached
to grounding lug with wire pro vided and ground rod and then
driven fully into the earth for
adequate electrical ground as
required by local, state or na tional electrical codes.
16
FIGURE 5.
FIG. 6 ENGINE (Left Side)
17. Air Cleaner
18. Fuel Filter
19. Oil Filter
20. Radiator
FIG. 7 ENGINE (Right Side)
23. Starter
24 Alternator
25. Mufer
17
20
18
19
FIGURE 6.
25
24
23
FIGURE 7.
NOTE: Above photos illustrate component locations on the Isuzu 4LE1 diesel engine.
Component location on other engine models may vary from the locations indicated above.
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CONTROLS AND COMPONENTS
NOTE: PHOTOGRAPHS MAY SHOW NON-STANDARD EQUIPMENT AND OPTIONS
FIG. 8 REAR JACK
28. Rear Jack
28
FIGURE 8.
FIGURE 9.
30
29
32
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.
31
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CONTROLS AND COMPONENTS
NOTE: PHOTOGRAPHS MAY SHOW NON-STANDARD EQUIPMENT AND OPTIONS
37
36
FIGURE 11.
40
35
FIGURE 10.
38
39
FIG. 10 TONGUE ASSEMBLY
35. Taillight Wiring Harness
36. Safety Tow Chains
37. Reversible Hitch (2” Ball and 3”
Pintle Hitch)
38. Step Plate--Allows operator to
position light xtures prior to
raising tower.
FIG. 11 FORKLIFT POCKETS
39. Lifting Eye
40. Forklift Pockets
41
FIG. 12 DOOR PROP
41. Door Prop--Locks door panel
in open position.
FIGURE 12.
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NOTE: PHOTOGRAPHS MAY SHOW NON-STANDARD EQUIPMENT AND OPTIONS
Fig. 13. Hydraulic Bypass Valve
41. Bypass Valve
Allows tower to be lowered
manually in the event of a failure.
CONTROLS AND COMPONENTS
FIGURE 13.
41
43
42
FIGURE 14.
Fig 14. Hydraulic Power Unit Assembly
42. Hydraulic Pump
43. Bypass Valve
44. 12 VDC Enclosure
Houses 125A fuse and 100A solenoid
44
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CONTROLS AND COMPONENTS
NOTE: PHOTOGRAPHS MAY SHOW NON-STANDARD EQUIPMENT AND OPTIONS
45
FIG. 15 Cord Reel
45. Cord reel —Manages the mast
power cable and prevents tangling.
46
FIGURE 15
FIGURE 16.
FIG. 16 Light Bar
46. Lamp Connector Lead—Allows quick
connecting/disconnecting of the lamp
xtures
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CONTROLS AND COMPONENTS
NOTE: PHOTOGRAPHS MAY SHOW NON-STANDARD EQUIPMENT AND OPTIONS
FIG. 17 Vertical Tower
1. Seven Section Vertical Tower
2. Light Mounting Locations --Mount lights
here for use during operation
3.Light connector sockets—attach light
leads to light bar at these female receptacles
when provided
3
2
1
FIGURE 17.
FIG. 18 Light Bar and Mounting Locations
1. Light Bar
2. Light mounting locations —Mount lights here
for use during operation
1
2
FIGURE 18.
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ROUTINE MAINTENANCE
ISUZU 4LE1
INSPECTION, MAINTENANCE, AND LUBRICATION SCHEDULE
Check condition of the steel tower cables and make sure they are properly secured.
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 condi-
tions. Where equipment is operated under severe conditions (very dusty, extreme heat or
cold, etc.) affected items should be serviced more frequently.
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TROUBLESHOOTING
SAFETY WARNING
DANGER!
HIGH VOLTAGE! DO NOT ATTEMPT TO TEST AND REPAIR GENERATOR AND BAL-
LAST ELECTRICAL SYSTEMS UNLESS YOU UNDERSTAND AND ARE QUALIFIED TO
WORK ON SUCH SYSTEMS.
For engine and generator troubleshooting, see engine and generator manuals or
contact your dealer.
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