Allmand MAXI LITE ML FCS Series User manual

MAXI LITE®
ML FCS SERIES
OPERATOR’S
MANUAL
ALLMAND BROTHERS INC.
P.O. BOX 888
HOLDREGE, NE 68949
PHONE: [phone]
ALLMAND FAX: [phone]
ALLMAND PARTS DEPT. FAX : [phone]
WWW.allmand.com
PART NO. 103408 REVISED: APRIL 2012
Not for Reproduction

RECORD IMPORTANT INFORMATION
2
Recording the equipment information will help, when placing an order for replacement parts and/ or
decals.
Company Equipment No:
Unit model No:
Unit Vin:
Engine Model No: Serial No:
Generator Model No: Serial No:
Accessories:
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3
INTRODUCTION 7
ABOUT THIS MANUAL 7
SAFETY 8-13
SAFETY DEFINITIONS 8
SAFETY PRECAUTIONS 8
SAFETY LABELS 11-13
TRAILERING, TRANSPORTING AND LIFTING 14-21
PREPARING THE UNIT FOR DELIVERY OR RENTAL 14
CHECK LIST 14
BEFORE TRAILERING/ TRANSPORTING 15
SHUTDOWN-PREPARE FOR TRAILERING 15
TOWER LIGHTS-STOWAGE FOR TRAILERING—VERTICAL 16
TOWER LIGHTS-STOWAGE FOR TRAILERING—LAYDOWN 17
TOWER LIGHTS-REMOVAL FOR TRAILERING/TRANSPORTING (OPTIONAL) 18
TRAILER/TOWING 18
TRAILER COMPONENT IDENTIFICATION 18
TOWING VEHICLE AND HITCH CONSIDERATIONS 19
LIFTING THE LIGHT TOWER 20
TRANSPORTING ON A TRAILER 21
GENERAL SERVICE INFORMATION 22-34
EQUIPMENT IDENTIFICATION-VERTICAL 22
EQUIPMENT IDENTIFICATION-LAYDOWN 23
MODELS AND SERIAL NUMBERS 24-25
TRAILER 24
TABLE OF CONTENTS
GENERATOR 24
ENGINE 24-25
OVERALL DIMENSIONS 26
SPECIFICATIONS (STANDARD AND OPTIONAL) 26
TRAILER 28
LIGHT TOWER-VERTICAL 28
LIGHT TOWER-LAYDOWN 28
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TOWER LIGHTS 29
GENERATOR-STANDARD 29
GENERATOR–AS3000 29
ENGINES 30-33
ISUZU 4LE1 30
CAT C1.1 31
CAT C2.2 32
OPTIONAL ACCESSORY EQUIPMENT 34
OPERATION 34-46
PRE-OPERATION SETUP 34
WORK SITE CONSIDERATIONS 34
PRE-OPERATION CHECK LIST 34-35
LEVELING AND STABILIZING THE TRAILER 35-36
INSTALLING THE GROUND ROD 36
ENGINE OPERATION 37
PRE-START CHECKS 37
ENGINE CONTROL PANELS 37-38
STARTING THE ENGINE 38
STOPPING THE ENGINE 39
AUTOMATIC ENGINE SHUTDOWN SYSTEM 39
TOWER AND LIGHT OPERATION-VERTICAL 39
TOWER AND LIGHT OPERATION-LAYDOWN 39-40
LIGHTBAR AND LIGHT FIXTURE ADJUSTMENT-VERTICAL 40
LIGHTBAR AND LIGHT FIXTURE ADJUSTMENT-LAYDOWN 41
RAISING AND LOWERING THE LIGHT TOWER-VERTICAL 41-42
RAISING AND LOWERING THE LIGHT TOWER-MANUAL LAYDOWN 42-43
RAISING AND LOWERING THE LIGHT TOWER-ELECRIC LAYDOWN 43-44
ELECTRIC WINCH AUXILLARY HANDLE 44
LIGHT CONTROL PANEL 45
SHUTDOWN PROCEDURE 45
TABLE OF CONTENTS
KUBOTA D1105BG 33
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TABLE OF CONTENTS
SHUTDOWN-SHORT PERIOD 45
SHUTDOWN-LONG TERM OR PREPARE FOR TRAILERING 45
AUXILLARY AC OUTLET OPERATION 45-46
MAINTENANCE 46-52
ENGINE 46
CHANGING AND ADDING ENGINE OIL 46
ENGINE FILTERS 46
ELECTRICAL SYSTEM 47
BALLAST PANEL 47
HYDRAULIC PUMP 47-48
HYDRAULIC OIL SPECIFICATIONS 47
ADDING HYDRAULIC OIL 48
PRIMING THE HYDRAULIC PUMP 48
LIGHT TOWER AND LAMPS 48-49
CHANGING LAMPS 48-49
TOWER CORNER GUIDE BLOCK ADJUSTMENT-7 SECTION VERT. TOWER 49
TRAILER 49-51
FRAME 49-50
GREASE POINTS 50
TRAILER WHEELS AND TIRES 50
WHEEL BREARINGS 50-51
TRAILER LIGHTING 51
LONG-TERM STORAGE 51
CLEANING 52
CLEANING AND DRAINING THE TRAILER BILGE 52
TROUBLESHOOTING 53
TROUBLESHOOTING CHART 53
MAINTENANCE RECORD 54
WIRE SCHEMATICS 55-79
ISUZU 4LE ENGINE 55
TABLE OF CONTENTS
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TABLE OF CONTENTSTABLE OF CONTENTS
CAT 2.2 ENGINE 57
MARATHON GENERATOR 61
MARATHON GENERATOR 4-LEAD SINGLE PHASE 62
240V 3-PHASE GENERATOR HIGH DELTA 63
HYDRAULIC PUMP 64
HYDRAULIC PUMP WITH RELAYS 65
4-LIGHT BALLAST 66
6-LIGHT BALLAST CSA (OPTION) 67
4-LIGHT BALLAST/LAMP SOCKET 68
ELECTRIC WINCH (OPTION) 69
TAIL LIGHTS/MARKER LIGHTS CSA 70
240V 3-PHASE ELECTRIC WINCH 4 LIGHT 71
240V 3-PHASE ELECTRIC WINCH 6-LIGHT 72
240V SINGLE PHASE REAR OUTLET PANEL 73
240V 3-PHASE ELECTRIC WINCH LIGHT BAR 6-LIGHT 74
208V 3-PHASE REAR OUTLET PANEL 75
208V 3-PHASE MANUAL WINCH BALLAST PANEL 76
4-LIGHT FIXTURE LIGHT BAR 1000W HID 77
208V 3-PHASE 6-LIGHT MANUAL WINCH BALLAST PANEL 78
CAT 1.1 ENGINE 56
6-LIGHT FIXTURE LIGHT BAR 1000W HID 79
WARRANTY 80-81
PARTS BOOK
KUBOTA KEYED SWITCH 58
KUBOTA KEYED SWITCH WITH E-STOP 59
KUBOTA D1105 WITH DEEP SEA PANEL & E-STOP 60
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INTRODUCTION
Congratulations on the purchase of your new
Allmand MAXI-LITE ML FCS SERIES light
tower and welcome to the Allmand Family of
equipment owners.
The Allmand MAXI-LITE ML FCS SERIES light
tower offers many advantages to make
operation safer, more convenient and more cost
effective. The MAXI-LITE ML FCS SERIES
light tower will provide you with high quality
performance and durability which translates into
more productivity on the job site.
ABOUT THIS MANUAL
Take time to read this manual thoroughly.
This Operator’s Manual provides information
necessary for the safe operation of the Allmand
Bros. inc. MAXI-LITE ML FCS SERIES light
tower.
The graphics and text in this manual generally
describe the Allmand MAXI-LITE ML FCS
SERIES light tower. Allmand light towers differ
by model and optionally installed equipment.
Your Allmand light tower may not exactly match
the graphics and /or text descriptions in this
manual.
If you are uncertain about any of the information
in the manual, contact Allmand Service Depart-
ment at 1-800-562-1373 or your Allmand dealer
for clarification before operation.
Specific operating instructions and specifica-
tions are contained in this publication to famil-
iarize the operator and maintenance personnel
with the correct and safe procedures necessary
to maintain and operate the equipment.
Engine - specific operating instructions and
specifications are contained in the engine
owner’s manual provided in your owners kit.
Always refer to the engine owner’s manual for
operation and maintenance procedures.
NOTE: On the MAXI-LITE ML FCS SERIES
Light Tower Trailer there are two styles of
Vertical Tower mast: a 7-section Tower (older
model) or a 6-section Tower (newer model) and
there are two options of the Laydown Tower
mast: a Manual Winch or an Electric Winch.
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8
SAFETY
The safety messages that follow have
DANGER level hazards.
 Always check overhead wires
and obstructions before raising
or lowering the light tower.
Allow 35 feet (10.6 m) of
clearance.
ELECTROCUTION HAZARD
SAFETY DEFINITIONS
Safety statements are one of the primary ways
to call your attention to potential hazards. Fol-
low the precautions listed throughout the man-
ual before operation, during operation and dur-
ing periodic maintenance procedures for your
safety, the safety of others and to protect the
performance of equipment. Keep the decals
from becoming dirty or torn and replace them if
they are lost or damaged. Also, if a part needs
to be replaced that has a decal attached to it,
make sure to order the new part and decal at
the same time.
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not
avoided, could result in minor or serious injury.
This safety alert symbol appears
with most safety statements. It
means attention,
become alert, your safety is in-
volved! Read and abide by the mes-
sage that follows the safety alert
symbol.
Indicates a situation which can cause damage
to the equipment, personal property and/or the
environment, or cause the equipment to oper-
ate improperly.
NOTE: provides key information to make pro-
cedures easier or clearer.
SAFETY PRECAUTIONS
There is no substitute for common sense and
careful practices. This information contains gen-
eral safety precautions and guidelines that must
be followed to reduce risk to personal safety.
Special safety precautions are listed in specific
procedures. Read and understand all of the
safety precautions before operating or perform-
ing repairs or maintenance. This safety section
cannot cover every situation that may occur that
is incidental to the use of the equipment.
If you are uncertain about any of the information
in the manual, contact Allmand service depart-
ment at 1-800-562-1373, for clarification.
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SAFETY
The safety messages that follow have
WARNING level hazards.
 High voltage is present when engine is
running. Never attempt to service electrical
components while engine is running.
 Do not operate the light tower if the
insulation on the electrical cord or other
electrical wiring is cut or worn or if bare
wires are exposed. Repair or replace
damaged wiring before starting the engine.
 Read and understand this Operator’s
Manual, the Engine Operator’s Manual
before operating or servicing the light tower
to ensure that safe operating practices and
maintenance procedures are followed.
UNSAFE OPERATION HAZARD
 Never carry riders on the equipment
FALL HAZARD
MODIFICATION HAZARD
 Never modify the equipment without written
consent of the manufacturer. Any
modification can effect the safe operation of
the equipment.
EXPOSURE HAZARD
 Always wear personal protec-
tive equipment, including
appropriate clothing, gloves,
work shoes, and eye and
hearing protection, as required
by the task at hand.
ROLLOVER HAZARD
 Do not raise, lower or use light tower unless
all outriggers and jacks are positioned on
firm ground.
 Never move or reposition the light tower
while the light tower is extended in the
vertical position.
EXPLOSION HAZARD
 While the engine is running or
the battery is charging,
hydrogen gas is being
produced and can be easily
Ignited. Keep the area around
the battery well ventilated and
keep sparks, open flame and
any other form of ignition out
of the area.
 Always disconnect the negative (-) battery
cable before servicing equipment.
 Only use the starting procedure as
described in the Engine Operator’s Manual
to start the engine.
 Never charge a frozen battery. Always
slowly warm the battery to room
temperature before charging.
FIRE AND EXPLOSION HAZARD
 Diesel fuel is flammable and explosive
under certain conditions.
 Never use a shop rag to catch the fuel.
 Wipe up all spills immediately.
 Never refuel with the engine running.
 Store any containers containing fuel in a
well ventilated area, away from any
combustibles or sources of ignition.
 Never permit anyone to install or operate the
equipment without proper training.
 Safety signs and decals are additional
reminders for safe operating and
maintenance techniques.
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SAFETY
The safety messages that follow have
WARNING level hazards.
EXHAUST HAZARD
 All internal combustion engines
create carbon monoxide gas
during operation and special
precautions are required to avoid
carbon monoxide poisoning.
 Never block windows, vents or other means
of ventilation if the equipment is operating in
an enclosed area.
 Always ensure that all connections are
tightened to specifications after repair is
made to the exhaust system.
ENTANGLEMENT / SEVER
HAZARD
 Always stop the engine before be-
ginning service.
 If the engine must be service while it is
operating, remove all jewelry, tie back long
hair and keep hands, other body parts and
clothing away from moving/rotating parts.
 Verify that all guards and covers are
attached properly to the equipment before
starting the engine. Do not start the engine if
any guards are or covers are not properly
installed on the equipment.
 Attach a “Do Not Operate” tag near the key
switch while performing maintenance on the
equipment.
ALCOHOL AND DRUG HAZARD
 Never operate the light tower while
under the influence of alcohol or
drugs, or when ill.
PIERCING HAZARD
 Avoid skin contact with high
pressure hydraulic fluid or
diesel fuel spray caused by a
hydraulic or fuel system leak
such as a broken hydraulic
hose or fuel injection line. High
pressure hydraulic fluid or fuel
can penetrate your skin and
result in serious injury. If you
are exposed to high pressure
hydraulic fluid or fuel spray,
obtain prompt medical
treatment.
 Never check for a hydraulic fluid or fuel leak
with your hands. Always use a piece of
wood or cardboard.
FLYING OBJECT HAZARD
 Always wear eye protection when
cleaning the equipment with
compressed air or high pressure
water. Dust, flying debris,
compressed air, pressurized
water or steam may injure your
eyes.
COOLANT HAZARD
 Wear eye protection and rubber
gloves when handling engine
coolant. If contact with the eyes or
skin should occur, flush eyes and
wash immediately with clean
water.
BURN HAZARD
 light fixtures and some of the
engine surfaces become very hot
during operation and shortly after
shutdown.
 Keep hands and other body parts away from
hot engine surfaces.
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11
SAFETY
Refer to These representations of the safety
warning decals used on the MAXI-LITE ML
FCS SERIES light tower. To insure correct
ordering if replacing becomes necessary.
The safety messages that follow have
WARNING level hazards.
BURN HAZARD
 Handle hot components, such as light
fixtures, with heat resistant gloves.
The safety messages that follow have
CAUTION level hazards.
TOOL HAZARD
 Always use tools appropriate for the task at
hand and use the correct size tool for
loosening or tightening equipment parts.
SLIP HAZARD
 Immediately clean up any spilled liquid on
the shop floor.
 Clean up accumulated dirt and debris on the
shop floor at the end of each shift.
The safety messages that follow have
NOTICE level hazards.
 Any part which is found defective as a result
of inspection or any part whose measured
value does not satisfy the standard or limit
MUST be replaced.
 Always tighten components to the specified
torque. Loose parts can cause equipment
damage or cause it to operate improperly.
 Only use replacement parts specified.
Other replacement parts may effect
warranty coverage.
 Clean all accumulated dirt and debris away
from the body of the equipment and is
components before you inspect the
equipment or perform preventative
maintenance procedures or repairs. Oper-
ating equipment with accumulated dirt and
debris will cause premature wear of
equipment components. Accumulated dirt
and debris also hinders effective equipment
inspection.
 Never dispose of hazardous materials by
dumping them into a sewer, on the ground,
or into groundwater or waterways.
 Retrieve any tools or parts that may have
dropped inside of the equipment to avoid
improper equipment operation.
 If any alert indicator illuminates during
equipment operation, stop the engine
immediately. Determine the cause and re-
pair the problem before continuing to oper-
ate the equipment.
 Follow the guidelines of the EPA
or other governmental agencies
for the proper disposal of
hazardous materials such as
engine oil, diesel fuel and engine
coolant. Consult the local
authorities or reclamation facility.
SAFETY LABELS
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SAFETY
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13
SAFETY
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14
TRAILERING, TRANSPORTING AND LIFTING
PREPARING THE UNIT FOR
DELIVERY OR RENTAL
The MAXI-LITE ML FCS SERIES light tower
requires service as well as proper operation in
order to provide the performance and safety it
has been designed for. Never deliver or put
machine into service with known defects or
missing instructions or decals. Always instruct
the customer in proper operation and safety
procedures as described in this 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 light tower locking bar latch
assembly which locks the light tower in the
vertical position for proper operation.
 Check the hitch assembly and safety 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 ground rod cable and the ground lug.
Make sure they are clean, undamaged and
functional.
 Inspect tires to insure good condition and
proper inflation.
 Check engine oil, fuel, engine coolant levels
and hydraulic fluid levels, if equipped.
 Check to make sure the Light Tower
Operator’s Manual and Generator
Operator’s Manual are with the equipment.
 Inspect the machine physically for damage
and repair if necessary.
ALWAYS READ AND
UNDERSTAND THE
INSTRUCTIONS FIRST.
After completing the pre-operation check list,
operate the tower through a complete operation
cycle, following the operating instructions in the
MAXI-LITE ML FCS SERIES Operator’s
Manual.
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15
TRAILERING, TRANSPORTING AND LIFTING
Before trailering, transporting or lifting, read
Safety on page 8.
The complete engine and generator set is
housed in a lockable enclosure with the frame
fabricated from heavy gauge steel mounted on
a two-wheel, leaf spring axle.
BEFORE TRAILERING OR TRANS-
PORTING
Perform the following before trailering /
transporting:
 Lower the light tower and shut down the
tower lights and the engine; See Shutdown-
prepare for trailering on page 15.
 Visually inspect the trailer and equipment for
damage. Repair or replace any components
as needed before trailering.
 Check the trailer lights for proper operation
 Inspect the tires to insure good condition
and proper inflation.
 Inspect trailer springs and undercarriage for
damage or loose parts.
 Check the hitch assembly and safety chains.
 Ensure the outriggers and jacks are properly
stowed.
 Ensure the ground rod and cable are
disconnected and properly stowed.
 Clean any spills from inside the trailer bilge
area around the outside of the trailer; they
may have occurred during operation.
 Ensure all compartment doors are closed
and securely locked.
SHUTDOWN - Prepare for trailering
1. With the tower lights off, lower the light
tower to the full DOWN position; See
Raising and lowering the light tower on page
38-41.
2. Turn the engine off . Refer to your Engine
Operator’s Manual for stopping procedure.
3. Adjust the light bar and light fixtures for
trailering; See Tower Lights-Stowage for
trailering on page 16-17.
7. Raise each outrigger stabilizer jack and
rotate into trailering position (horizontal with
outrigger bar).
4. Secure the light cords into the hook on the
rear tower support.(Laydown Tower Only)
5. Disconnect the ground rod cable rod the
ground lug. Remove the ground rod from the
earth and clean and secure the ground rod
and cable in the trailer.
6. Close, secure and lock all compartment
doors.
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16
TRAILERING, TRANSPORTING AND LIFTING
8. Retract each outrigger bar and secure in the
stowed position with latch pin.
VERTICAL TOWER LIGHTS - Stowage
for Trailering
The light bar and fixtures must be stowed
before trailering or transporting.
1. Ensure lights are off and tower is lowered to
the full DOWN position; See Raising and
Lowering the Light Tower on page 38-41.
2. Release the light bar park pin by pulling the
ring and turning it 90° so that the pin
remains in the retracted position.
3. Rotate the light bar into the trailering/
transporting park position (inline with the
trailer) and engage the park pin by twisting
the park pin ring until the plunger is released
and the pin engages and locks into the hole
in the light bar.
4. Reposition the light fixtures for trailering/
transporting by pulling them down into the
lowest position and face the fixtures toward
the center of the trailer. (See Right )
NOTE: If lights are to be removed for
trailering/ transporting, See Tower Lights -
Removal for Trailering/ Transporting on page
18.
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TRAILERING, TRANSPORTING AND LIFTING
LAYDOWN TOWER LIGHTS - Stowage
for Trailering
The light bar and fixtures must be stowed
before trailering or transporting.
1. Ensure lights are off and tower is lowered to
the full DOWN position: See Raising and
Lowering the Light Tower on page 38-41.
2. Rotate the light bar into the trailering/
transporting park position (inline with the
front of the trailer) and tighten the tower lock
knob.
3. Reposition the light fixtures for trailering/
transporting by facing the fixtures toward the
mast (See right)
4. Lower the tower into the rear tower support
and engage tower lock.
NOTE: If lights are to be removed for
trailering/ transporting, See Tower Lights -
Removal for trailering/ transporting (optional) on
page 18.
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18
TRAILERING, TRANSPORTING AND LIFTING
TRAILERING / TOWING
Before trailering / towing the light tower trailer,
read Before Trailering / Transporting on page
15 and read Safety on page 8.
TOWER LIGHTS - Removal for Trailer-
ing/ Transporting (optional)
Your light tower may be equipped with lights
that can be removed for trailering/ transporting
or for theft protection.
Tongue Jack
Pintle Ring Hitch
Ball Hitch Coupler
Safety Chains
Trailer Component Identification
1. Ensure lights are off and tower is lowered to
the full DOWN position; See Raising and
Lowering the light tower on page 38-41 .
2. Disconnect the electrical cord from each
light fixture.
3. While supporting the light fixture, remove
the nut and washer for each assembly
fastening the main light fixture bracket to the
light bar.
4. Store each light fixture to avoid any damage
during transport
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TRAILERING, TRANSPORTING AND LIFTING
Towing Vehicle and Hitch Considera-
tions
The vehicle must have a towing hitch that is ca-
pable of safely handling the trailer load and
tongue weight of the trailer.
Connecting the Trailer Hitch Coupler
and Lights
The trailer is equipped with a combination trailer
coupler for a two inch ball hitch and a 3 inch
lunette ring for a pintle hitch.
The towing vehicle must be able to safely pull
the full trailer load. Never pull a trailer load that
exceeds the vehicle’s towing capacity; you risk
losing control of the trailer and/or vehicle.
Before trailering, always check your vehicle
owners manual for maximum towing/ trailering
load specifications and maximum gross vehicle
weight specifications that include the fully
loaded trailer.
LATCH AND RELEASE
LEVER
TRAILER
COUPLER
LUNETTE
RING
LATCH LEVER
SAFETY PIN
VEHICLE HITCH
Typical Lunette Ring Pintle type Hitch and
Coupler
Typical Ball Type Hitch And Coupler
LATCH AND
RELEASE
LEVER
TRAILER
COUPLER
SOCKET
COUPLER
CLAMP LATCH LEVER
SAFETY PIN
VEHICLE HITCH
AND BALL
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20
The trailer coupler must be reversed to use
either the ball or lunette hitch coupler. To
reverse the coupler, remove the two bolts and
reposition the coupler as needed.
4. Ensure there is adequate slack in the
harness to prevent binding or disconnection
when turning.
5. Before trailering, check all lights for proper
operation.
The trailer’s safety chains prevent the trailer
from completely detaching from the vehicle
when underway.
1. Connect the tow vehicle hitch to the trailer
coupler. Make sure the coupler is securely
attached to the tow vehicle’s hitch.
2. Connect the safety chains to the vehicle’s
hitch frame and crisscross the chains under
the trailer tongue to prevent the tongue from
dropping to the road if the trailer separates
from the hitch ball. Rig the chains as tight as
possible with enough slack to permit free
turning.
3. Connect the four pin light connector from the
vehicle harness to the trailer harness.
TRAILERING, TRANSPORTING AND LIFTING
4-pin Trailer Light
Harness Connector
Trailer Safety
Chains
LIFTING THE LIGHT TOWER
The approximate fully loaded weight of the light
tower and trailer is:
Vertical tower - 2,803lbs (1,271.4 kg)
Laydown tower - 2,588 lbs (1,173.9 kg)
The MAXI-LITE ML FCS SERIES light tower is
equipped with top forklift pockets and a lifting
eye for lifting or hoisting.
Not for Reproduction