Allmand MAXI-LITE V Series User manual

Not for

Reproduction

Part No.: 114132USCN

Revision: A

Installation Instructions

Metal Halide to Conssin LED

Light Conversion Kit for

Maxi-Lite V-Series: 4 Light

es Instrucciones de instalación

Kit de conversión de haluro

metálico a luz LED Conssin para

la serie Maxi-Lite V: 4 luces

fr Instructions d’installation

Trousse de conversion d’éclairage

d’halogénure métallisé vers DEL Conssin

pour Maxi-Lite série V : 4 lumières

Not for

Reproduction

Model 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 V-Series

Kit Contents

Allmand Parts & Service

Locate and identify the kit contents using the table below.

Ref Description Qty

1. 1/2-13 nyloc hex nut 4

2. 1/2-13 x 1-1/4 hex head bolt 4

3. 1/2 at washer 4

4. Conssin LED light 4

5. Conssin 4-LED drivers panel assembly 1

6. LED light CSA stop bracket 4

7. LED driver input cord 2

8. LED driver output cord 2

9. 2 wire lever locks 8

10. 8” cable tie 8

2 www.allmand.com

These kit instructions cover the conversion of metal halide

SHO lights to Conssin LED lights for Maxi-Lite V-Series.

Kit Instructions Description

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. 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.

3. Maxi-Lite II unit must be equipped with 725 light relays

prior to Conssin LED light conversion kit installation.

If 725 light relays are not present on unit, contact

Allmand Parts & Service for more information.

Kit Installation: Subassembly

1. Conssin LED light subassembly. Steps for assembling

the LED light CSA stop bracket to the Conssin LED

light are as follows:

a. From the kit contents install the LED light CSA stop

bracket (A, Figure 1, Ref. 6) onto the Conssin LED

light yoke bracket (B, Figure 1, Ref. 4) using the 1/2-

13 nyloc hex nut, 1/2-13 x 1-1/4 hex head bolt, and

1/2 at washer (C, Figure 1, Ref. 1, 2, & 3).

b. Repeat step on another Conssin LED light. On the

other two repeat the same step, but on the opposite

side of the light yoke bracket.

2. Locate the Conssin 4-LED drivers panel assembly

(D,Figure 2a, Ref. 5) from the kit contents. The LED

drivers on the panel are numbered #1 through #4 as

shown in Figure 2a. Remove the hardware (E, Figure

2b) securing the LED driver junction box (F, Figure 2b)

to the LED driver panel. Set hardware aside as it will

be used in step 7. Open junction box.

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Reproduction

English

2b E

Output

Input 1 & 2

Input 3 & 4

3. LED Output driver cord subassembly. Steps for

assembling the LED driver output cord to the Conssin

4-LED drivers panel assembly are as follows:

a. Loosen the Output cord grip (G, Figure 3). From the

kit contents, run one end of the LED driver output

cord (H, Figure 3, Ref. 8) through the cord grip.

b. Locate the lever locks that are coming from the

outputs of the LED drivers. Connect the LED driver

output cord wires with the lever locks. Connect the

black wire (I, Figure 3) of the LED output cord to the

brown wire coming from LED driver #1. Connect the

white wire (J, Figure 3) to the blue wire coming from

LED driver #1. Connect the green wire (K, Figure

3) to the blue wire coming from LED driver #2.

Connect the red wire (L, Figure 3) to the brown wire

coming from LED driver #2. Connect the blue wire

(M, Figure 3) to the brown wire coming from LED

driver #3. Connect the orange wire (N, Figure 3) to

the blue wire coming from LED driver #3. Connect

the white with black stripe wire (O, Figure 3) to the

blue wire coming from LED driver #4. Connect the

red with black stripe wire (P, Figure 3) to the brown

wire coming from LED driver #4.

Driver 2

Driver 4

Driver 1

Driver 3

Front of Driver Panel

Back of Driver Panel

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Reproduction

www.allmand.com

5. LED Input 3 & 4 driver cord subassembly. Steps for

assembling the LED driver output cord to the Conssin

4-LED drivers panel assembly are as follows:

a. Loosen the Input 3 & 4 cord grip (W, Figure 5).

From the kit contents, run the cord end without ring

terminals of the remaining of the LED driver input

cord (X, Figure 5, Ref. 7) through the cord grip.

b. Locate the lever locks that are coming from the

inputs of the LED drivers. Connect the LED driver

input cord wires with the lever locks. Connect the

green wire (Y, Figure 5) of the LED Input cord to

the green with yellow stripe wire coming from LED

drivers #3 and #4. Connect the black wire (Z, Figure

5) to the brown wire coming from LED driver #3.

Connect the red wire (AA, Figure 5) to the brown

wire coming from LED driver #4. Connect the white

wire (BB, Figure 5) to the blue wire coming from

LED drivers #3 and #4.

6. Tighten up all the cord grips on the open junction box.

7. Close up the junction box on the back of the LED

drivers panel assembly. Be careful not to pinch any

of the wires. Use the hardware removed in Step 2 to

secure the junction box in place.

4. LED Input 1 & 2 driver cord subassembly. Steps for

assembling the LED driver output cord to the Conssin

4-LED drivers panel assembly are as follows:

a. Loosen the Input 1 & 2 cord grip (Q, Figure 4).

From the kit contents, run the cord end without ring

terminals of one of the LED driver input cords (R,

Figure 4, Ref. 7) through the cord grip.

b. Locate the lever locks that are coming from the

inputs of the LED drivers. Connect the LED driver

input cord wires with the lever locks. Connect the

green wire (S, Figure 4) of the LED Input cord to

the green with yellow stripe wire coming from LED

drivers #1 and #2. Connect the black wire (T, Figure

4) to the brown wire coming from LED driver #1.

Connect the red wire (U, Figure 4) to the brown

wire coming from LED driver #2. Connect the white

wire (V, Figure 4) to the blue wire coming from LED

drivers #1 and #2.

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Reproduction

English

2. Junction box disassembly. Steps for disconnecting

wiring in control box are as follows:

a. Locate where the ballast cords (B,Figure 2a) and

the tower cord (C,Figure 2a) connect to the junction

box.

b. Locate the neutral isolator (D,Figure 2a-b) and

remove nut holding wires in place. Set nut aside

as it will be used in Assembly Step 4-a. From each

ballast cord remove each white wire. From the tower

cord remove the white wire and the white with black

stripe wire. Leave all other wires on isolator.

c. Locate the ground bolt (E,Figure 2a-b) and remove

nut holding wires in place. Set nut aside as it will

be used in Assembly Step 4-b. From each ballast

cord remove each green wire with ring terminal end.

From the tower cord remove the green wire and

orange wire. Leave all other wires on ground bolt.

d. Locate the 2-port lever locks (F,Figure 2b) that are

connected to black and red wires leading from the

ballast cords. Remove the lever locks connecting

ballast cord wires to tower cord and junction cord

wires.The ballast black wire connections are black

to black, black to red with black stripe, black to red,

and black to blue. The ballast red wire connections

are red to black, red to red with black stripe, red to

red, and red to blue. Set lever locks aside as they

will be used in Assembly Step 5-b.

e. Loosen cord grips (G,Figure 2b) and completely

remove the four ballast cords from the junction box.

1. Open the driver’s side door of the light tower. Remove

hardware (A,Figure 1) securing the junction box into

the closed postion, and set hardware aside as they will

be re-installed in Step 6. Open junction box.

Kit Installation: Disassembly

Tower

Ballast 1

Ballast 2

Ballast 3

Ballast 4

Not for

Reproduction

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5a MN

4. Remove the hardware (H,Figure 4) securing both

ballast box assemblies in place. Set the hardware of

one ballast box aside as it will be used in Assembly

Step 2. Remove both ballast box assemblies with

attached ballast cords (I,Figure 4).

3. Remove the hardware (H,Figure 3a-b) and front vents

with covers (I,Figure 3a-b) from the front of the Maxi-

Lite II unit. Set the hardware and vents with covers

aside as they will be used in Assembly Step 7.

I H

5. Tower lamp disassembly. Steps for disconnecting

lamps and wiring are as follows:

a. Remove light bar cover (J, Figure 5a) and hardware

on top side of the light bar. Set the hardware and

cover aside as they will be re-installed in Assembly

Step 1-d.

b. Cut and remove any zip ties holding wires together.

Use caution as not to cut or damage any wires.

c. Locate all lever locks inside the light bar, and

remove the lever locks (K, Figure 5b) from the lamp

and tower wires. Set aside the four 2-port lever

locks as they will be used in Assembly Step 1-c.

Discard the remaining lever locks.

d. Loosen the cord grips and nuts (L, Figure 5b) in the

light bar and remove all lamp cords.

e. Remove the hardware (M,Figure 5a) securing lamp

xtures in place. Set hardware aside as it will be

used in Assembly Step 1-a. Remove all four lamp

xtures (N,Figure 5a).

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Kit Installation: Assembly

1. Tower LED lamp assembly. Steps for connecting LED

lamps and wiring are as follows:

a. Using the hardware (A,Figure 1a) removed in

Disassembly Step 4-e attach and secure LED lamp

xtures (B,Figure 1a) on to the light bar. Pay close

attention to the postion of the CSA stop bracket

when attaching the lamps to the light bar.

b. Take cords leading from the LED lamp xtures and

run them through their designated and numbered

cord grips (C,Figure 1b) on the light bar. The

numbering of the light bar can be found on the

bottom side in the style of dice pips (dots). Install

the cords into the cord grip until the outer insulation

is ush with the top of the cord grip inside the light

bar. Hand tighten cord grips on cords plus 1/4 turn,

and do not over tighten.

c. Using the four 2-port lever locks that were removed

in Disassembly Step 4-c and four of the 2-port lever

locks (Ref. 9) from kit contents connect the LED

lamp cord wires to the tower cord wires in the light

bar. LED lamp #1 connections (D,Figure 1b) are

blue to white and brown to black. LED lamp #2

connections (E,Figure 1b) are blue to green and

brown to red. LED lamp #3 connections (F,Figure

1b) are blue to orange and brown to blue. LED lamp

#4 connections (G,Figure 1b) are black to white

with a black stripe and white to red with a black

stripe. Secure wires together with zip ties (Ref. 10).

d. Re-install light bar cover (H,Figure 1a) on light

bar with existing hardware that was removed in

Disassembly Step 4-a. Make sure not to pinch wires

when re-installing light bar cover.

LED 3

LED 4

LED 1

LED 2

G E

English

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4. Junction box input 1 & 2 cord and input 3 & 4 cord

wiring connections. Steps for connecting input wiring

are as follows:

a. Locate the neutral isolator (N,Figure 4) and connect

the white wire with a ring terminal from each input

cord. Secure the wires to the isolator by using the

nut that was removed in Disassembly Step 2-b.

b. Locate the ground bolt (O,Figure 4) and connect the

green wire with a ring terminal from each input cord.

Secure the wires to the ground bolt by using the nut

that was removed in Disassembly Step 2-c.

c. Locate the loose wires leading from the junction

cord. Using four of the 2-port lever locks (Ref. 9)

from kit contents connect the input cord wires to the

junction cord wires in the junction box. Connect the

black wire from the input 1 & 2 cord (Q,Figure 4)

to the lever lock and the orange wire from junction

cord. Connect the red wire from the input 1 & 2 cord

(R,Figure 4) to the lever lock and the yellow wire

from junction cord. Connect the black wire from the

input 3 & 4 cord (S,Figure 4) to the lever lock and

the red wire from junction cord. Connect the red

wire from the input 3 & 4 cord (T,Figure 4) to the

lever lock and the black wire from junction cord.

d. Secure wires with zip ties (Ref. 10).

2. Install the driver assembly (I, Figure 2, Ref. 1) into

the Maxi-Lite II unit using the hardware (J, Figure 2)

removed in Disassembly Step 3.

Output

Input 1 & 2

Input 3 & 4

3. Take the loose end of the output cord (K, Figure 3),

input 1 & 2 cord (L, Figure 3), and input 3 & 4 cord (M,

Figure 3) and run each end through the designated

cord grip for each cord. Install the cords into the cord

grip until the outer insulation is ush with the top of the

cord grip inside the control box. Hand tighten cord

grips on cords plus 1/4 turn, and do not over tighten.

Tower

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Reproduction

Input 1 & 2

Input 3 & 4

Output

Tower

English

5. Junction box output cord and tower cord wiring

connections. Steps for connecting the ouput and tower

wiring are as follows:

a. Remove the ring terminals from the green and

orange wires from the tower cord. Strip insulation

just enough so that the bare wire can be inserted

into a lever lock.

b. Using the eight 2-port lever locks that were removed

in Disassembly Step 2-d connect the output cord

wires to the tower cord wires in the junction box.

Connect the output cord red with black stripe wire

to the lever lock and the tower cord red with black

stripe wire (T,Figure 5). Connect the white with

black stripe wire to the lever lock and the white with

black stripe wire (U,Figure 5). Connect the blue

wire to the lever lock and the blue wire (V,Figure

5). Connect the orange wire to the lever lock and

the orange wire (W,Figure 5). Connect the red

wire to the lever lock and the red wire (X,Figure

5). Connect the green wire to the lever lock and

the green wire (Y,Figure 5). Connect the black

wire to the lever lock and the black wire (Z,Figure

5). Connect the white wire to the lever lock and the

white wire (AA,Figure 5).

c. Secure wires together with zip ties (Ref. 10).

Output

Input 1 & 2

Input 3 & 4

Tower

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6. Close up the junction box, and use the hardware (BB,

Figure 6) removed in Step 1 to secure panel to box.

Be careful not to pinch wires when closing up the

junction box.

7. Using the hardware (CC, Figure 7a-b) and front vents

with covers (DD, Figure 7a-b) removed in Disassembly

Step 3, install the cover onto the Maxi-Lite II unit.

8. Reconnect the battery cables to the battery, start the

engine, and turn on the lights to make sure all are

operating correctly.

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