Allmand Maxi-Lite II Bedienungsanleitung

en Installation Instructions

Three Phase 725 Relays

Replacement for Zettler Relay

Service Kit for Maxi-Lite II

Part No.: 114148

Revision: A

es Instrucciones de instalación

Kit para servicio de repuesto

de relés Zettler por relés 725

trifásicos para Maxi-Lite II

fr Instructions d’installation

Relais triphasé de la série 725

Remplacement pour relais Zettler

Ensemble d’entretien pour Maxi-Lite II

Not for

Reproduction

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 rst 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.

2. Disconnect the battery, black negative (-) cable rst,

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.

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 identied

Zettler relay for service kit instructions.

Not for

Reproduction

3. Look in to the component box to determine a

convenient back side location near the existing Zettler

light relays (C, Figure 3a) to install one 725 light relay

(D, Figure 2, Ref. 1) from the kit contents or use the

suggested layout for installing the relays as shown in

Figure 3a. Using the slots as guides on the 725 relays,

drill 1/8” holes into the back side of the component

box. Install the new relay in the box by securing it with

the #8 x 5/8 hex washer head screws (Ref. 10). Add

RTV sealant to the screws if necessary. Install the

relays with the DC posts facing up and the AC posts

down for more accessible wire connections.

4. The DC and AC detail congurations of the new 725

light relay and the existing Zettler light relays are

shown in Figures 3b and 3c. Refer to these gures for

relay disconnection and connection points.

English

DC Post 2DC Post 1

AC Post 2AC Post 1

DC Ground SpadeDC Power Spade

725 Relay Detail

Zettler Relay Detail

AC Light Switch Spade

AC Distribution

Block Spade

Zettler Relay 1

Suggested 725 Relay Layout

Zettler Relay 2

Zettler Relay 3

725 Relay

5. Note: The 725 light relays shown in these installation

instruction gures are for replacing damaged Zettler

light relay 2. Zettler light relay 1 replacement will

be similar; the dierences will be mentioned in the

instructions and not shown.

6. On Zettler light relay 2 disconnect the existing 12 AWG

wire (E, Figure 4a-b) from the AC distribution block

spade. This wire should be leading from distribution

block 2. On Zettler relay 1 disconnect the wire leading

distribution block 1 from the same spade, and on

Zettler relay 3 disconnect the wire leading distribution

block 3 from the same spade.

Distribution Block 1

Distribution Block 3

Distribution Block 2

Not for

Reproduction

Zettler Relay

Disconnection Detail

7. Cut o and discard the female spade terminal from

the wire that was connected to the Zettler relay. Strip

o the appropriate amount of wire insulation and crimp

a yellow fork terminal (F, Figure 5, Ref. 8) onto the

wire.

8. Loosen the screw on AC post 1 of 725 light relay 1 and

connect the new fork terminal on the wire (G, Figure

6a-b) removed from either Zettler relay 1 or 2 into the

post. Tighten down the screw onto the fork terminal.

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 recongured on the light switch 3.

On Zettler relay 1, disconnect the wire leading from

light switch 1 from the same spade.

10. Cut o and discard the female spade terminal from

the wire that was connected to the Zettler relay. Strip

o the appropriate amount of wire insulation and crimp

a yellow fork terminal (I, Figure 7, Ref. 8) onto the wire.

4 www.allmand.com

Zettler Relay 2

Relay Connection

and Disconnection Detail

725 Relay

Zettler Relay 2

Not for

Reproduction

11. Loosen the screw on AC post 2 of 725 light relay 2 and

connect the fork terminal on the wire (J, Figure 8a-b)

that is leading from either light switch 2 or 4 into the

post. Tighten down the screw onto the fork terminal.

12. On Zettler light relay 2 disconnect the existing 16 AWG

black wire (K, Figure 8a-b) from the DC ground spade.

This wire should be leading from the divider panel of

the component block. On Zettler relay 1 disconnect

the 16 AWG black wire from the same spade.

13. Cut o and discard the female spade terminal from

the wire that was connected to the Zettler relay. Strip

o 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 the kit contents.

English

14. From the kit contents, locate and select the black

16 AWG wire (N, Figure 10, Ref. 2). Cut the black

16 AWG wire in half. Keep one half of the wire, and

discard the other half of the wire. Strip the ends of the

cut wire, and crimp a blue fork terminal (O, Figure 10,

Ref. 9) on one of the ends.

725 Relay

Zettler Relay 2

3 Pin Lever

Lock Connection Detail

10 NO

Relay Connection

and Disconnection Detail

Not for

Reproduction

15. Install the fork terminal end of the black wire (P, Figure

11a-b) on DC post 1 of the 725 light relay. Then, install

the bare wire end of the black wire into one of the

open ports of the 3 port lever lock (Q, Figure 19a-b)

that was installed in Step 20.

16. On Zettler light relay 2 disconnect the remaining

16 AWG wire (R, Figure 19a&c) from the DC power

spade. This wire should be leading from the divider

panel of the component block. On Zettler relay 1

disconnect the 16 AWG wire from the same spade.

17. Cut o and discard the female spade terminal from

the wire that was connected to the Zettler relay. Strip

o the appropriate amount of wire insulation and install

wire (S, Figure 21) into a 3 pin lever lock (T, Figure 21,

Ref. 10) from the kit contents.

6 www.allmand.com

11a

725 Relay

Connection Detail

11b Q

725 Relay

11c

725 RelayZettler Relay 2

Zettler Relay 2

Zettler Relay

Disconnection Detail

Not for

Reproduction

18. From the kit contents, locate and select the yellow

16 AWG wire (U, Figure 18, Ref. 2). Cut the yellow

16 AWG wire in half. Keep one half of the wire, and

discard the other half of the wire. Strip the ends of the

cut wire, and crimp a blue fork terminal (V, Figure 18,

Ref. 8) on one of the ends.

English

19. Install the fork terminal end of the yellow wire (W,

Figure 19a-b) on DC post 2 of the 725 light relay.

Then, install the bare wire end of the yellow wire into

one of the open ports of the 3 port lever lock (X, Figure

19a-b) that was installed in Step 20. 20. Check and make sure all connections are secure and

tightened.

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 veried to be operating correctly,

re-install the rear door panel.

13 UV

11a

725 Relay

Connection Detail

11b X

725 Relay

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 29.

Kit Installation: 4-Light Replacement

725 Relays for Zettler Relay 3, or

6-Light Replacement 725 Relays for

Zettler Relays 1, 2, and 3

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

28.

725 Relay

Not for

Reproduction

8 www.allmand.com

3. Look in to the component box to determine a

convenient back side location near the existing Zettler

light relays (C, Figure 3a) to install the two 725 light

relays (D, Figure 2, Ref. 1) from the kit contents or

use the suggested layout for installing the relays as

shown in Figure 3a. Using the slots as guides on

the 725 relays, drill 1/8” holes into the back side of

the component box. Install the new relays in the box

by securing them with the #8 x 5/8 hex washer head

screws (Ref. 9). Add RTV sealant to the screws if

necessary. Install the relays with the DC posts facing

up and the AC posts down for more accessible wire

connections.

4. The DC and AC detail congurations of the new 725

light relays and the existing Zettler light relays are

shown in Figures 3b and 3c. Refer to these gures for

relay disconnection and connection points.

3b DC Post 2DC Post 1

AC Post 2AC Post 1

725 Relay Detail

Suggested 725 Relay Layout

3c DC Ground SpadeDC Power Spade

Zettler Relay Detail

AC Light Switch Spade

AC Distribution

Block Spade

5. Note: The 725 light relays shown in these installation

instruction gures are for replacing damaged Zettler

light relay 2 on a Maxi-Lite II 6-light unit. Zettler light

relay 1 and 3 replacement on a Maxi-Lite II 6-light 3

phase unit and Zettler light relay 3 replacement on

a Maxi-Lite II 4-light 3 phase unit will be similar in

installation. The dierences will be mentioned in the

instructions and not shown.

6. On Zettler light relay 2 disconnect the existing 12 AWG

wire (E, Figure 4a-b) from the AC distribution block

spade. This wire should be leading from distribution

block 2. On Zettler relay 1 of a Maxi-Lite II 6-light unit

disconnect the wire leading from distribution block 1

from the same spade. On Zettler relay 3 of a Maxi-Lite

II 6-light or 4 light unit disconnect the wire leading from

distribution block 3 from the same spade.

Zettler Relay 1

Zettler Relay 2

Zettler Relay 3

725 Relay 1

Not for

Reproduction

English

Distribution Block 1

Distribution Block 3

Distribution Block 2

Zettler Relay

Disconnection Detail

Zettler Relay 2

7. Cut o and discard the female spade terminal from

the wire that was connected to the Zettler relay. Strip

o the appropriate amount of wire insulation and crimp

a yellow fork terminal (F, Figure 5, Ref. 7) onto the

wire.

8. Loosen the screw on AC post 1 of 725 light relay 1

and connect the new fork terminal on the wire (G,

Figure 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 the color

of the wiring from Zettler relay 2. For Zettler relay 1

select the red 10 AWG wire (Ref. 4), and Zettler relay

3 select the black 10 AWG wire (Ref. 6). Cut the

selected 10 AWG in half, and strip the ends of the

cut wires. On one of the cut wires crimp a yellow fork

terminal (I, Figure 7, Ref. 7) on one of the ends. Set

aside the other cut wire as it will be used in Step 16.

725 Relay

Connection Detail

725 Relay 1

725 Relay1

Not for

Reproduction

10 www.allmand.com

10. Install the stripped end of the blue wire (J, Figure

8a-b) with the new fork terminal into an open port of

Distribution block 2. If the wire is red, install wire into

Distribution block 1, and if the wire is black, install wire

into Distribution block 3. If a port is not open select a

larger port to install with another wire. To install in the

distribution block loosen the set screw for the port that

stripped end of the wire will be inserted in. Make sure

all the bare wire strands are in the port. Tighten the

set screw in the distribution block.

11. Loosen the screw on AC post 1 of 725 light relay 2 and

connect the fork terminal on the wire (K, Figure 9a-b)

leading from either Distribution block 1, 2, or 3 into the

post. Tighten down the screw onto the fork terminal.

725 Relay

Connection Detail

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 Zettler relay 1

locate wire from light switches 3 and 5. If working from

Zettler relay 3 on a 6-light unit locate wire from light

switches 4 and 6, and if working from Zettler relay on

a 4-light unit locate the. Remove the two screws (M,

Figure 10a), the 12 AWG wire, and buss bar (N, Figure

10a) from the top of the switches. Discard the buss

bar, and set one of the screws aside as it will be used

in Step 17. If replacing Zettler relay 2, re-install the

wire and screw onto light switch 1. If replacing Zettler

relay 1 go to light switch 5. If replacing Zettler relay 3,

on a 6-light unit go to light switch 4, and on a 4-light

unit go to switch 2.

Distribution Block 1

Distribution Block 3Distribution Block 2

Distribution Block

Connection Detail

Distribution Block 2

Not for

Reproduction

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