Allmand NIGHT-LITE PRO II Manuel utilisateur

en Installation Instructions

725 Relays Replacement for

Zettler Relay Service Kit

for Night-Lite Pro II

Part No.: 114142

Revision: A

es Instrucciones de instalación

Kit para servicio de repuesto de

relés Zettler por relés 725

para Night-Lite Pro II

fr Instructions d’installation

725 Remplacement de relais pour

l’ensemble d’entretien de relais

Zettler pour Night-Lite Pro 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

• Night-Lite Pro II - V-Series

• Night-Lite Pro II - LD-Series

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. #8 ring terminal 1

7. #8 yellow fork terminal 4

8. #8 blue fork terminal 4

9. #8 x 5/8 hex washer head screw 4

10. 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. Open the doors on the Night-Lite Pro II unit. Remove

hardware securing the AC front panel (A, Figure 1) to

the component box and lay open the panel. Set the

hardware aside as they will be re-installed in Step 27.

Kit Installation

2. Look into the component box to determine a

convenient back side location near the existing Zettler

light relays (B, Figure 2a) to install the two 725 light

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

use the suggested layout for installing the relays as

shown in Figure 2a. 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 (Not Included) to

the screws if necessary. Install the relays with the

DC posts facing up and the AC posts down for more

accessible wire connections.

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

light relays and the existing Zettler light relays are

shown in Figures 2b and 2c. Refer to these gures for

relay disconnection and connection points.

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

Night-Lite Pro II unit.

Kit Instructions Description

Not for

Reproduction

English

DC Post 2DC Post 1

AC Post 2AC Post 1

DC Ground Spade

725 Relay Detail

Zettler Relay Detail

AC Light Switch Spade

AC Main Breaker

Spade

Suggested 725 Relay Layout

725 Relay 1

725 Relay 2

4. 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.

Main Breaker

Zettler Relay 2

DC Power Spade

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

wire (D, Figure 3a-b) from the AC main breaker spade.

This wire should be leading from the main breaker. On

Zettler relay 1, disconnect the wire leading from the

main breaker from the same spade.

Zettler Relay

Disconnection Detail

Zettler Relay 2

Zettler Relay 1

Zettler Relay 2

Zettler Relay 1

6. 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 (E, Figure 4, Ref. 7) onto the wire.

Not for

Reproduction

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

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

5a-b) removed from either Zettler relay 1 or 2 into the

post. Tighten down the screw onto the fork terminal.

8. From the kit contents, locate and select either the

black 10 AWG wire (G, Figure 6, Ref. 5) that matches

the color of the wiring from Zettler relay 2 or the red 10

AWG wire (Ref. 4) that matches the color of the wiring

from Zettler relay 1. 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 (H, Figure 6, Ref. 7)

on one of the ends. Set aside the other cut wire as it

will be used in Step 15.

9. Install the stripped end of the black wire (I, Figure 7a)

with the new fork terminal into the screw down port

of main breaker (J, Figure 7a-b) with the black wires

leading into it. If wire is red, install wire into the screw

down port with the red wires leading into it. To install

in the breaker, 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 main breaker.

4 www.allmand.com

725 Relay

Connection Detail

725 Relay 1

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

and connect the fork terminal of the installed wire (K,

Figure 8a-b) into the post. Tighten down the screw

onto the fork terminal.

Main Breaker

Detail

Black Wire Port

Red Wire Port

Not for

Reproduction

English

725 Relay

Connection Detail

725 Relay 2

Light Switches Detail

Light Switch 3

Light Switch

Connection Detail

9b Light Switch 3

Light Switch 4

Light Switch 2Light Switch 1

11. If replacing Zettler relay 2, locate the 12 AWG wire

(L, Figure 9a-b) that is leading from the relay to light

switches 3 and 4. If working from Zettler relay 1 locate

wire from light switches 1 and 2. Remove the two

screws (M, Figure 9a), the 12 AWG wire, and buss bar

(N, Figure 9a) from the top of the switches. Discard

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

be used in Step 16. Depending on Zettler relay, re-

install the wire and screw onto light switch 1 or 3.

12. On Zettler light relay 2, disconnect the 12 AWG wire

(O, Figure 10) 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.

Zettler Relay

Disconnection Detail

Zettler Relay 2

Not for

Reproduction

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 crimp

a yellow fork terminal (P, Figure 11, Ref. 7) onto the

wire.

6 www.allmand.com

12 725 Relay 1

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

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

12) removed from either Zettler relay 1 or 2 into the

post. Tighten down the screw onto the fork terminal.

15. Take the cut 10 AWG wire (R, Figure 13) that was set

aside in Step 8 and crimp a yellow fork terminal (S,

Figure 13, Ref. 7) on one of the ends. On the other

end, crimp on the terminal ring (T, Figure 13, Ref. 6).

Light Switch 3 Light Switch 4

Light Switch 2

Light Switch 1

16. If working from Zettler relay 2, install the terminal ring

end of the new assembled 10 AWG wire (U, Figure 14)

onto the top of light switch 4 by using the screw that

was removed in Step 11. If working from Zettler relay

1, install wire onto light switch 3 (Not Shown). Make

sure screw is tightened down on the ring terminal.

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

connect the fork terminal on the wire (U, Figure 14)

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

post. Tighten down the screw onto the fork terminal.

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

black wire (V, Figure 15) 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.

Zettler Relay

Disconnection Detail

Zettler Relay 2

725 Relay 2

Not for

Reproduction

English

16a

19. 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 (W, Figure 16a-b) into a 3 pin lever lock (X, Figure

16a-b, Ref. 10) from the kit contents.

Y Z

20. From the kit contents, locate and select the black 16

AWG wire (Y, Figure 17, Ref. 2). Cut the black 16

AWG wire in half, and strip the ends of the cut wires.

On each of the cut wires crimp a blue fork terminal (Z,

Figure 17, Ref. 8) on one of the ends.

3 Pin Lever

Lock Install Detail

16b

21. Install the fork terminal end of each black wire (AA,

Figure 18a-b) on DC post 1 of 725 light relay 1 and 2.

Then, install the bare wire ends of the two black wires

into the open ports of the 3 port lever lock (BB, Figure

18a-b) that was installed in Step 19.

22. On Zettler light relay 2 disconnect the remaining 16

AWG wire (CC, Figure 18b) 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.

18a

725 Relay 2

725 Relay 1

725 Relays

Connection Detail

18b

725 Relay 2725 Relay 1

Zettler Relay 2

Not for

Reproduction

23. 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 (DD, Figure 19) into a 3 pin lever lock (EE, Figure

19, Ref. 10) from the kit contents.

8 www.allmand.com

24. From the kit contents, locate and select they yellow 16

AWG wire (FF, Figure 20, Ref. 3). Cut the yellow 16

AWG wire in half, and strip the ends of the cut wires.

On each of the cut wires crimp a blue fork terminal

(GG, Figure 20, Ref. 8) on one of the ends.

FF GG

25. Install the fork terminal end of each yellow wire (HH,

Figure 19a-b) on DC post 2 of 725 light relay 1 and 2.

Then, install the bare wire ends of the two yellow wires

into the open ports of the 3 port lever lock (II, Figure

19a-b) that was installed in Step 23.

26. Check and make sure all connections are secure and

tightened.

27. 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.

28. Once the unit is veried to be operating correctly, shut

o the unit and close up the doors.

21a

725 Relay 2

725 Relay 1

725 Relays

Connection Detail

21b

725 Relay 2725 Relay 1

Zettler Relay 2

Not for

Reproduction

English

Not for

Reproduction

Modelos que cubre esta instrucción

Si no está seguro acerca de la información de estas instruc-

ciones, o si tiene preguntas o se presentan problemas, co-

muníquese con el Departamento de Mantenimiento de Allmand

al 1-800-562-1373, o comuníquese a través del sitio web de

Allmand, www.allmand.com.

• Serie Night-Lite Pro II - V

• Serie Night-Lite Pro II - LD

Contenido del kit

Departamento de Piezas y

Mantenimiento de Allmand

Ubique e identique los contenidos del kit con la tabla que se

incluye a continuación.

Ref. Descripción Cant.

1. Relés 725 de luces 2

2. Cable de color negro de 16 AWG de 12” 1

3. Cable de color amarillo de 16 AWG de 12” 1

4. Cable de color rojo de 10 AWG de 60” 1

5. Cable de color negro de 10 AWG de 60” 1

6. Terminal de anillo n.° 8 1

7. Terminal de horquilla amarillo n.° 8 4

8. Terminal de horquilla azul n.° 8 4

9. Tornillo con arandela hexagonal n.° 8 x 5/8 4

10. Conector de palanca de 3 clavijas 2

1. Apague la unidad y deje que el motor y las luces se enfríen.

Consulte el manual del operador.

Antes de la instalación del kit

PELIGRO

Peligro de electrocución

• La instalación del kit con la unidad en funcionamiento puede

provocar la muerte o lesiones graves. Apague la unidad

antes de instalar el kit.

ADVERTENCIA

Peligro de quemaduras

• El contacto con las supercies calientes del motor y de

las lámparas podría provocar la muerte o lesiones graves.

Siempre aléjese del motor, de las lámparas y de otras áreas

calientes de la torre de iluminación.

2 www.allmand.com

1. Abra las puertas de la unidad Night-Lite Pro II. Retire las

piezas que jan el panel frontal de CA (A, Figura 1) a la caja

de componentes y abra el panel. Coloque las piezas aparte

ya que se volverán a instalar en el Paso 27.

Instalación del kit

2. Mire dentro de la caja de componentes para determinar

una ubicación conveniente en la parte posterior cerca de

los relés Zettler de luces existentes (B, Figura 2a) donde

instalar los dos relés 725 de luces (C, Figura 2a, Ref.

1) del contenido del kit o utilice la disposición sugerida

para instalar los relés como se muestra en la Figura

2a. Utilizando las ranuras como guías en los relés 725,

perfore oricios de 1/8” en la parte posterior de la caja de

componentes. Instale los nuevos relés en la caja al jarlos

con tornillos con arandela hexagonal n.° 8 x 5/8 (Ref.

9). Agregue sellador RTV (no se incluye) a los tornillos,

si es necesario. Instale los relés con los bornes de CC

hacia arriba y los bornes de CA hacia abajo para que las

conexiones de cables sean más accesibles.

3. En las Figuras 2b y 2c, se muestran en detalle las

conguraciones de CC y CA de los nuevos relés 725 de

luces y los relés Zettler de luces existentes. Consulte estas

guras para ver los puntos de conexión y desconexión de

los relés.

2. Desconecte la batería, primero el cable negativo (-) de color

negro y luego el cable positivo (+) de color rojo. Consulte el

manual del operador.

PELIGRO

Peligro de electrocución

• La instalación del kit con la batería conectada puede provo-

car la muerte o lesiones graves. Desconecte la batería antes

de instalar el kit.

Las instrucciones de este kit abarcan la instalación de los relés

725 para reemplazar un relé Zettler dañado que está junto al

relé Zettler que funciona dentro de la caja de componentes de la

unidad Night-Lite Pro II.

Descripción de las instrucciones del kit

Not for

Reproduction

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