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Allmand MAXI-LITE AS3000 Operator's Manual

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MAXI-LITE®
AS3000
AUSTRALIAN STANDARD
OPERATOR'S
MANUAL
ALLMAND BROTHERS INC.
P.O. BOX 888
HOLDREGE, NE 68949
PHONE: (308) 995- 4495, 1- 800- 562- 1373
ALLMAND FAX: (308) 995– 5887
ALLMAND PARTS DEPT. FAX : (308) 995– 4883
allmand.com
WWW.
PART NO. 103565 REVISED: JANUARY 2012

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  • Page 1 OPERATOR’S MANUAL ALLMAND BROTHERS INC. P.O. BOX 888 HOLDREGE, NE 68949 PHONE: (308) 995- 4495, 1- 800- 562- 1373 ALLMAND FAX: (308) 995– 5887 ALLMAND PARTS DEPT. FAX : (308) 995– 4883 allmand.com WWW. PART NO. 103565 REVISED: JANUARY 2012...
  • Page 2 RECORD IMPORTANT INFORMATION 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:...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ABOUT THIS MANUAL 7-11 SAFETY SAFETY DEFINITIONS SAFETY PRECAUTIONS SAFETY LABELS 12-19 TRAILERING, TRANSPORTING AND LIFTING PREPARING THE UNIT FOR DELIVERY OR RENTAL CHECK LIST BEFORE TRAILERING/ TRANSPORTING SHUTDOWN-PREPARE FOR TRAILERING TOWER LIGHTS-STOWAGE FOR TRAILERING—VERTICAL TOWER LIGHTS-STOWAGE FOR TRAILERING—LAYDOWN TOWER LIGHTS-REMOVAL FOR TRAILERING/TRANSPORTING (OPTIONAL) TRAILER/TOWING TRAILER COMPONENT IDENTIFICATION...
  • Page 4 TABLE OF CONTENTS TOWER LIGHTS GENERATOR CAT C1.1 OPTIONAL ACCESSORY EQUIPMENT 28-38 OPERATION PRE-OPERATION SETUP WORK SITE CONSIDERATIONS PRE-OPERATION CHECK LIST LEVELING AND STABILIZING THE TRAILER INSTALLING THE GROUND ROD ENGINE OPERATION PRE-START CHECKS ENGINE CONTROL PANELS STARTING THE ENGINE STOPPING THE ENGINE EMERGENCY STOP SWITCH BATTERY DISCONNECT SWITCH...
  • Page 5 TABLE OF CONTENTS ENGINE CHANGING AND ADDING ENGINE OIL ENGINE FILTERS ELECTRICAL SYSTEM BALLAST PANEL 39-40 HYDRAULIC PUMP HYDRAULIC OIL SPECIFICATIONS ADDING HYDRAULIC OIL PRIMING THE HYDRAULIC PUMP LIGHT TOWER AND LAMPS CHANGING LAMPS TRAILER FRAME GREASE POINTS TRAILER WHEELS AND TIRES WHEEL BREARINGS 42-43 TRAILER LIGHTING...

  • Page 6: Introduction

    TAKE TIME TO READ THIS MANUAL THOROUGHLY This instruction manual provides necessary instructions for the MAXI-LITE AS3000 light tower. The information found in this manual is in effect at the time of printing. Allmand Bros Inc. may change contents without notice and without incurring obligation.

  • Page 7: Safety

    Indicates a hazardous situation which, if not avoided, will result in death or serious injury. If you are uncertain about any of the information in the manual, contact Allmand service depart- ment at 1-800-562-1373, for clarification. Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
  • Page 8 SAFETY MODIFICATION HAZARD  Never modify the equipment without written The safety statements that follow have DANGER level hazards. consent of the manufacturer. Any modification can effect the safe operation of ELECTROCUTION HAZARD the equipment.  Always check overhead wires EXPOSURE HAZARD and obstructions before raising ...
  • Page 9 SAFETY ENTANGLEMENT / SEVER FIRE AND EXPLOSION HAZARD  Diesel fuel is flammable and explosive HAZARD under certain conditions.  Always stop the engine before be-  Never use a shop rag to catch the fuel. ginning service.  Wipe up all spills immediately. ...
  • Page 10 SAFETY FLYING OBJECT HAZARD  Always wear eye protection when The safety statements that follow have NOTICE level . cleaning the equipment with compressed air or high pressure  Any part which is found defective as a result water. Dust, flying debris, of inspection or any part whose measured compressed air, pressurized value does not satisfy the standard or limit...

  • Page 11: Safety Labels

    SAFETY SAFETY LABELS Refer to these representations of the safety warning decals used on the MAXI-LITE AS3000 light tower to insure correct ordering if replacement becomes necessary.

  • Page 12: Trailering, Transporting And Lifting

    PREPARING THE UNIT FOR Make sure they are clean, undamaged and DELIVERY OR RENTAL functional. The MAXI-LITE AS3000 light tower should be  Inspect tires to insure good condition and operated properly and maintained properly for proper inflation. maximum service life. Never deliver or put ma- ...

  • Page 13: Before Trailering/ Transporting

    TRAILERING, TRANSPORTING AND LIFTING BEFORE TRAILERING OR TRANS- SHUTDOWN - Prepare for trailering PORTING 1. With the tower lights off, lower the light tower to the full DOWN position; See Before trailering, transporting or lifting, read Raising and lowering the light tower on page Safety on page 7.

  • Page 14: Tower Lights-Stowage For Trailering-Vertical

    TRAILERING, TRANSPORTING AND LIFTING 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 34-37.

  • Page 15: Tower Lights-Stowage For Trailering-Laydown

    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 34-37.

  • Page 16: Tower Lights-Removal For Trailering/Transporting (Optional)

    TRAILERING, TRANSPORTING AND LIFTING TRAILERING / TOWING TOWER LIGHTS - Removal for Trailer- ing/ Transporting (optional) Before trailering / towing the light tower trailer, read Before Trailering / Transporting on page Your light tower may be equipped with lights 13 and read Safety on page 7. that can be removed for trailering/ transporting or for theft protection.

  • Page 17: Towing Vehicle And Hitch Considerations

    TRAILERING, TRANSPORTING AND LIFTING Towing Vehicle and Hitch Considera- Hitch and Coupler tions PARK BRAKE The towing vehicle must be able to safely pull TRAILER the full trailer load. Never pull a trailer load that COUPLER exceeds the vehicle’s towing capacity. The ve- SOCKET hicle must have a towing hitch that is capable of safely handling the trailer load and tongue...

  • Page 18: Lifting The Light Tower

    Vertical tower - 1,271.4 kg (2,803lbs) Laydown tower - 1,173.9 kg (2,588 lbs) The MAXI-LITE AS3000 light tower is equipped with top forklift pockets and a lifting eye for lift- ing or hoisting. 7-pin Trailer Light...

  • Page 19: Transporting On A Trailer

    TRAILERING, TRANSPORTING AND LIFTING LIFTING ATTACHMENT POINTS - Laydown Tower LIFTING EYE LIFTING ATTACHMENT POINTS - Vertical Tower LIFTING EYE FORKLIFT POCKETS TRANSPORTING ON A TRAILER When transporting the light tower trailer on a truck or a trailer, always secure the unit using properly rated tie-down chains or straps con- necting the light tower frame using tie-down loops to the towing trailer.

  • Page 20: General Service Information

    GENERAL SERVICE INFORMATION EQUIPMENT IDENTIFICATION– VERTICAL TOWER LIGHT BAR LIFTING BAR LAMP ASSEMBLY LEFT FUEL TANK AND CONTROL ACCESS DOOR BATTERY DISCONNECT SWITCH HYDRAULIC LIGHT TOWER STEP PLATE (Hydraulic Only) PARK BRAKE COUPLER FRONT STABI- FRONT OUTRIGGER LIZER JACK EMERGENCY STOP BUTTON BALLAST ACCESS COVER PANEL SAFTEY CHAINS TRAILER TONGUE JACK...

  • Page 21: Equipment Identification-Laydown

    GENERAL SERVICE INFORMATION EQUIPMENT IDENTIFICATION– LAYDOWN TOWER LAMP ASSEMBLY LIFTING EYE LAYDOWN LIGHT TOWER BATTERY DISCONNECT CORD REEL SWITCH FORKLIFT POCKETS PARK BRAKE LEFT FUEL TANK AND CONTROL ACCESS DOOR COUPLER FRONT STABILIZER FRONT OUTRIGGER JACK EMERGENCY STOP BUTTON SAFETY CHAINS BALLAST ACCESS PANEL TRAILER TONGUE JACK...

  • Page 22: Models And Serial Numbers

    Trailer All MAXI-LITE AS3000 light tower trailers have SERIAL PLATE a serial number plate attached to the rear panel . TRAILER SERIAL PLATE CAT ENGINE C1.1...

  • Page 23: Overall Dimensions

    GENERAL SERVICE INFORMATION Overall Dimensions Hydraulic Tower Laydown Tower Height Light Tower Lowered 2.34 m (7 Ft 8 in.) 1.7 m (5 ft. 7in.) Height Light Tower Raised 7.8 m (25 ft 6in.) 9.14 m (30 ft.) Width (outriggers retracted) 1.9 m (74 in.) 1.95 m (76 ft.

  • Page 24: Trailer

    GENERAL SERVICE INFORMATION Trailer Light Tower– Vertical Hitch Coupler Fixed height Sections 50 mm (2 in.) ball Hydraulic Cylinder Standard Max. Road Speed Vertical Optional (paved road) 60 mph (97 km/h) Max Wind Load 85.3 km/h Max. Off - road Speed 20 mph (32 km/h) (57 mph) Number of Axles...

  • Page 25: Tower Lights

    GENERAL SERVICE INFORMATION Tower Lights SHO - HD 1250W Metal Halide (lumen rating: 150,000) Standard SHO - HD 1000W Metal Halide (lumen rating: 110,000) Optional SHO - HD 1000W and 1250W Metal Halide Warm - up time: 2-4 minutes SHO - HD 1000W and 1205W Metal Halide Re - start time: 10 to 15 minutes Four Fixtures Standard (sealed for all weather use)
  • Page 26 GENERAL SERVICE INFORMATION Bore 77mm (3.03 in.) Stroke 81mm (3.19 in.) Displacement 1100cc (69 cu. In.) Power @ 1800 rpm 11.9 kW (14.3 bhp) Power Output 3% per 304.8m (1000 ft.) above 109.7m (360 ft.)  Derating 1% per 10° above 25°C (77° F) Note: Horse power ratings are established in accordance with Society of Automotive Engineers Small Engine Test Code ‐ J1349 GROSS Fuel System Cassette type fuel injected diesel Starting System 12VDC Negative Ground Electrical System 12VDC Negative Ground Battery Type Group 24 Battery Rating 550 CCA Number of Batteries Compression Ratio 22:01 Weight 87 kg (191 lbs.) Oil Capacity 3.7 L (3.9 qts.) Lubrication Forced  lubrication by Pump Oil Filteration Cartridge Type Cooling System Pressurized radiator forced circulation with water pump Low Oil Pressure Engine Shutdown High Engine...

  • Page 27: Optional Accessory Equipment

    GENERAL SERVICE INFORMATION OPTIONAL ACCESSORY EQUIPMENT  Saf -T-Visor™  Electric Winch Tower  Hydraulic Tower  LSC100™ Light Sequence Commander  Heavy Duty Battery (700 CCA)  Battery Heating Pad  Engine Block Heater  Sound Attenuation package  Four or Six Metal Halide or High Pressure Sodium Lamps (5,000, 6,000 or 7,000 Watts Total) ...

  • Page 28: Operation

    OPERATION PRE-OPERATION SETUP Pre - Operation Check list Work site safety considerations Always perform the following checks before traveling to the work site and before operation. Overhead Obstructions Repair or replace any components as required before operation. Position the light tower trailer where there are no overhead obstructions.

  • Page 29: Leveling And Stabilizing The Trailer

    Leveling and Stabilizing the Trailer 1. Position the MAXI-LITE AS3000 on an ade- quate site: See Work Site Safety Considerations on page 28. 2. Block each wheel on each side with a suitable wheel chock.

  • Page 30: Installing The Ground Rod

    The ground rod is a safety devise that may OUTRIGGER LOCK PIN reduce the chance of personal injury from stray electrical current. Allmand recommends using JACK the ground rod. However, it is the user’s re- HANDLE...

  • Page 31: Engine Operation

    Refer to your Engine tower, review Safety on page 7. Operator’s Manual for the starting procedure. The Allmand MAXI-LITE AS3000 light tower is Cold - Weather Starting powered by a diesel engine and generator unit.

  • Page 32: Emergency Stop Switch

    Emergency Stop Switch The vertical tower is raised and lowered by a hydraulic pump actuating a six section The MAXI-LITE AS3000 light tower trailer is telescoping mast. equipped with an emergency Stop switch. Which will cut the power to the engine in case of on emergency.

  • Page 33: Lightbar And Light Fixture Adjustment-Vertical

    OPERATION Light Bar and Light Fixture If the light bar rotates too easily or does not Adjustment-Vertical stay in position, remove the cap plug from the center of the light bar cover and tighten the nut Lights– Work Site Adjustment to achieve the desired resistance and replace the cap plug.

  • Page 34: Lightbar And Light Fixture Adjustment-Laydown

    OPERATION The light bar and light fixtures must be stowed Light Bar and Light Fixture properly for trailering or transporting. See Adjustment-Laydown Tower Lights– Stowage for trailering-Laydown on page 15. Lights– Work Site Adjustment Raising and Lowering the Vertical The light bar and light fixtures must be adjusted to the desired work angle before raising the Tower light tower.

  • Page 35: Raising And Lowering The Light Tower-Manual Laydown

    OPERATION Raising and Lowering the Manual 1. Before raising the light tower, adjust the Winch Light Tower– Laydown tower lights to the desired work position; see Light Bar and Light Fixture Adjustment- Manual Winch Light Tower Vertical on page 32. The manual winch tower can be raised and ex- 2.

  • Page 36: Raising And Lowering The Light Tower-Elecric Laydown

    OPERATION Raising 7. Secure light cords into hook on the rear mast support. Before raising the light tower, adjust the tower lights to desired position; see Light 8. Secure rear mast support release pin. Lock- Bar and Light Fixture Adjustment-Laydown ing the mast to the rear mast support for on page 34.

  • Page 37: Electric Winch Auxillary Handle

    OPERATION Raising Lowering 1. Before raising the light tower, adjust the 1. If required, start engine. Refer to your En- tower lights to the desired work position; see gine Operator’s Manual for starting proce- Light Bar and Light Fixture Adjustment- dure.

  • Page 38: Light Control Panel

    OPERATION ELECTRIC WINCH Lights On EMERGENCY CRANK HANDLE Turn the light breaker switches to the ON posi- tion. One to four lights may be used Light Control Panel Lights Off The tower light control panel consist of the Turn all light breaker switches to the OFF breaker switches.

  • Page 39: Maintenance

    For addi- Where equipment is operated under severe tional wiring information, see schematics or conditions (very dusty, extreme heat or cold, contact Allmand Bros. or your Allmand dealer. etc.), affected items should be serviced more frequently. ENGINE Refer to the Engine Operator’s Manual for all...

  • Page 40: Hydraulic Pump

    MAINTENANCE Adding Hydraulic Oil CAPACITORS Fill the reservoir with an iso viscosity grade 10 or 15 hydraulic fluid or any clean hydraulic fluid having a viscosity index that is suitable for the climate conditions in which the unit will be oper- ated.

  • Page 41: Light Tower And Lamps

    MAINTENANCE 4. Remove the silicone gasket and lens. LIGHT TOWER AND LAMPS 5. Remove the support clip screws and support Changing Lamps clip. 6. Carefully remove the old lamp and install the correct replacement lamp. 7. Clean reflector and lens. 8.

  • Page 42: Grease Points

    MAINTENANCE Grease Points INNER BEARING Use N.G.L.I. consistency #2 high-temperature WHEEL HUB anti- friction bearing lubricating grease for all GREASE SEAL trailer mechanical pivot points. COTTER PIN Trailer Wheels and Tires OUTER WASHER BEARING CASTLE NUT DUST COVER 1. Check the tires for any cracks, cuts or damage.

  • Page 43: Trailer Lighting

    MAINTENANCE  Always replace bearings and races as a set. For trailer light wiring schematic information, Never mix bearings and races. Bearing part See Tail lamp wiring schematic on page 50. numbers are sometimes found on the LONG TERM STORAGE bearing races;...

  • Page 44: Cleaning

    Cleaning and Draining the Trailer Bilge The Allmand MAXI-LITE AS3000 light tower trailers have a fuel containment tray option, de- signed to catch fuel, oil or coolant spills. Should a spill occur, position a suitable container be-...

  • Page 45: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSE 1. The lamp or lamps are burned out or broken or not screwed in securely. 2. Low electrical system voltage. Check volts and engine speed. 3. Too much power is being drawn from the auxillary outlets. 4.

  • Page 46: Maintenance Record

    MAINTENANCE RECORD DATE SERVICE DESCRIPTION SERVICED BY...

  • Page 47: Wire Schematics

    SCHEMATICS...

  • Page 48: 60Hz Ballast And Generator 16/8 Cord

    SCHEMATICS...

  • Page 49: 50Hz Ballast And Generator 16/8 Cord

    SCHEMATICS...

  • Page 50: Hydraulic Pump

    SCHEMATICS...

  • Page 51: Taillights

    SCHEMATICS...

  • Page 52: Warranty

    WARRANTY...
  • Page 53 WARRANTY...
  • Page 54 Fax 308-995-5887 / www.allmand.com LIGHTING SYSTEMS LIMITED WARRANTY ADDENDUM THIS IS AN ADDENDUM TO THE BASIC ALLMAND LIMITED WARRANTY OF TWO (2) YEARS AFTER DELIVERY TO THE ORIGINAL PURCHASER. The following manufacturers limited warranty policy warrants their components to be free from defects in material and workmanship from date of manufacture as follows (see specific manufacturer’s warranty for details):...

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