MAY 2000

NIGHT-LITE

NIGHT-LITE PRO
SERIES
OPERATOR’S MANUAL
ALLMAND BROS. INC
P.O. BOX 888
HOLDREGE, NE 68949

PHONE: 308/995-4495, 1-800/562-1373

ALLMAND FAX: 308/995-5887
ALLMAND PARTS FAX: 308/995-4883

NIGHT-LITE SERIES

For Parts and Updates visit Allmand on the Web at www.allmand.com

1
 INSPECTION CHECK LIST
FOR PREPARING THE NIGHT-LITE PRO FOR DELIVERY OR RENTAL

The NIGHT-LITE PRO requires service as well as proper operation in order to provide the
performance and safety it has been designed for. Never deliver or put a machine into service
with known defects or missing instructions or decals. Always instruct the customer in the
proper operation and safety procedures as described in the operator’s manual. Always
provide the manual with the equipment for proper and safe operation.

CHECK LIST:
ƒ Visually inspect the equipment to ensure that all instructions and decals are in place and
legible.
ƒ Inspect the tower latch and knob assembly which locks the tower in the vertical position for
proper operation
ƒ Check the hitch assembly and safety tow chains
ƒ Check the outriggers and jacks to make sure they operate properly
ƒ Inspect the light assemblies for damage and test for proper operation
ƒ Inspect the electrical wiring for signs of damage
ƒ Check the ground rod cable and the ground lug. Make sure they are clean, undamaged,
and functional.
ƒ Inspect the tires to ensure good condition and proper inflation
ƒ Check oil, fuel, coolant levels, and hydraulic fluid levels.
ƒ Check to make sure the operator’s manual is with the equipment.
ƒ Inspect the machine physically for damage and repair if necessary.

NOTE: See appropriate section of manual for scheduled maintenance intervals.

After completing the inspection check list, operate the tower through a complete
operation cycle, following the operating instructions in the operator’s manual.

! WARNING
NEVER ALLOW ANYONE TO OPERATE THE EQUIPMENT WITHOUT
PROPER TRAINING!
ALWAYS READ THE INSTRUCTIONS FIRST!

2
 TABLE OF CONTENTS

INSPECTION CHECK LIST ..................................................................................................... 2

TABLE OF CONTENTS ........................................................................................................... 3

INTRODUCTION ...................................................................................................................... 4

SAFETY SYMBOL INFORMATION .......................................................................................... 4

SAFETY AND WARNING DECALS ...................................................................................... 5-7

MANUAL WINCH MAST OPERATION .................................................................................. 8-9

ELECTRIC WINCH MAST OPERATION ............................................................................10-11

SPECIFICATIONS ............................................................................................................. 12-14

STARTING INSTRUCTIONS ............................................................................................. 15-16

SERIAL NUMBER LOCATIONS ....................................................................................... 17-18

CONTROLS AND COMPONENTS ................................................................................... 19-25

ROUTINE MAINTENANCE SCHEDULE ............................................................................... 26

KUBOTA D905, D1105, PERKINS 103-10, and LOMBARDINI LDW 903

TROUBLESHOOTING ........................................................................................................... 27

ASSEMBLY PARTS AND ACCESSORIES ........................................................................... 28

3
 INTRODUCTION

ƒ This manual provides the information necessary for the safe operation of the Allmand
Bros., Inc., NIGHT-LITE PRO light tower.

ƒ The NIGHT-LITE PRO standard tower configuration is operated with two manual crank
winches or single electric winch used to erect, extend, and lower the tower.

ƒ Specific operating instructions and specifications are contained in this publication to

familiarize the operator and maintenance personnel with the correct and safe procedures
necessary to maintain and operate the equipment.

Take time to read this book thoroughly. If you are uncertain about any of the information
presented in the manual, contact the factory or your dealer for clarification before operation.

SAFETY SYMBOLS
The purpose of the SAFETY INFORMATION SYMBOL shown below is to attract your special
attention to safety related information contained in the text.

! DANGER

! WARNING

! CAUTION

FAILURE TO UNDERSTAND AND COMPLY WITH SAFETY RELATED INFORMATIONAL

INSTRUCTIONS MAY RESULT IN INJURY TO OPERATOR OR OTHERS. IF YOU DO NOT
UNDERSTAND ANY PART OF THIS INFORMATION CONTACT YOUR DEALER FOR
CLARIFICATION PRIOR TO OPERATING EQUIPMENT.

NOTE
The word NOTE is used to bring your attention to supplementary information in relation to
various aspects of proper operation and maintenance.

NOTE: Keep this manual accessible during operation to provide convenient reference.

NOTE: Any reference in this manual to LEFT or RIGHT shall be determined by looking at
the trailer from the rear.

4
 SAFETY AND WARNING DECALS
! SAFETY WARNING
ALWAYS REPLACE ANY SAFETY AND INSTRUC-
TION DECALS THAT BECOME DAMAGED, PAINTED,
OR OTHERWISE ILLEGIBLE.
PART NO. D-249
Location: Inside left hand
door panel of Kubota engine
units.
5
Refer to these representations of the safety
warning decals used on the NIGHT-LITE to
insure correct ordering if replacing be-
comes necessary.
PART NO. D-264
Location: Inside left hand
door panel.
SAFETY AND WARNING DECALS

6
SAFETY AND WARNING DECALS

7
 MANUAL WINCH MAST OPERATION
DESCRIPTION OF OPERATION
The Allmand NIGHT-LITE tower assembly
consists of a three section telescoping
mast which can be raised and extended by
operating two hand crank winches. One
winch, mounted with the handle extending
through the side of the trailer frame, raises
and lowers the mast from the horizontal
towing position, the vertical position, and
back. The second winch mounted on the
tower extends the telescopic sections.
The three section mast assembly can be
rotated from the ground by loosening a
knob and rotating the entire assembly 360°
to aim the lights as necessary.
! SAFETY WARNING
ƒ ALWAYS CHECK FOR OVERHEAD
OBSTRUCTIONS BEFORE RAISING
AND LOWERING MAST. ALLOW 35'
CLEARANCE. AVOID ALL OVERHEAD
ELECTRICAL WIRES.
ƒ TO PREVENT INSTABILITY AND HELP
ENSURE SAFE OPERATION, ALWAYS
PROVIDE PROPER GROUND SUP-
PORT BEFORE RAISING MAST.
ƒ BEFORE RAISING MAST, VISUALLY
INSPECT EQUIPMENT FOR DAMAGE
OR WEAR. FAMILIARIZE YOURSELF
WITH THE LOCATION AND FUNCTION
OF ALL OPERATING PARTS BY STUDY-
ING THIS MANUAL. OBSERVE ALL
CAUTION DECALS LOCATED ON
EQUIPMENT
NOTE: The latch locks the mast in the
vertical position and disengages the
sections allowing the tower assembly
to be rotated to position the lights.
8
TO ERECT MAST AND RAISE
LIGHTS
1. Extend both side outrigger jacks, rear jack
and tongue jack to stabilize and level the
trailer.
NOTE: Jacks should be placed only on
firm footing.
!
SAFETY WARNING
ƒ WHEN EXTENDING REAR JACK, WATCH
TO ENSURE YOU ARE CLEAR OF THE
OVERHANGING ENDS OF THE MAST
BEFORE YOU STAND UP.
ƒTHE SUPPLEMENTAL GROUND ROD IS A
SAFETY DEVICE THAT MAY REDUCE
THE CHANCE OF PERSONAL INJURY
FROM STRAY ELECTRICAL CURRENT.
Therefore, Allmand recommends using
the ground rod. However, it is the user’s
responsibility to determine the require-
ments and/or applicability of local, state,
or national electrical code which governs
the use of the ground rod.
2. Attach the ground rod to the grounding lug,
and drive the ground rod fully for adequate
electrical ground, as required by local,
state, or national code.
3. Release the pin that secures the mast to
the rear mast support.
4. Operate the hand crank on the side of the
trailer to raise the mast from horizontal to
vertical.
5. Turn black knob counterclockwise and
engage latch in strike plate. Retighten black
knob.
6. Operate the hand crank winch on the tower
clockwise to raise the lights vertically.
7. To rotate the lights, release the black knob
and turn the tower assembly with the
handles provided.
8. To turn on lights, flip the breaker switches to
the up position. (SEE FIG. 1)
 MANUAL WINCH MAST OPERATION
! SAFETY WARNING 6. Operate the hand crank on the side of the
trailer counterclockwise to fold the mast
ƒ IF THE TOWER CANNOT BE ROTATED
down into the towing position.
AFTER LOOSENING THE BLACK KNOB,
CHECK TO ASSURE THE LOWER
NOTE: Sufficient load (75 lb. min ) must
LATCH IS ENGAGED IN THE STRIKE
be applied to the cable to overcome
PLATE. THIS DOUBLE LATCH FEATURE
internal resistance and operate the
PREVENTS THE TOWER FROM BEING
brake properly. Insufficient load will not
ROTATED IF THE LATCH IS NOT EN-
turn the reel thus continual turning
GAGED. without sufficient load will remove the
winch handle from the shaft.
! SAFETY WARNING 7. Secure light cords into hook on the rear
tower support for towing.
VISUALLY INSPECT EQUIPMENT FOR 8. Secure pin locking mast to rear tower
DAMAGE BEFORE OPERATING. ALLOW support.
ADEQUATE CLEARANCE AROUND 9. Remove ground rod from earth. Discon-
TRAILER FOR TOWER AND INSURE THAT nect wire from ground lug and secure in
NO PERSONS ARE STANDING IN FRONT trailer
OF OR BEHIND UNIT WHEN LOWERING. 10. Raise jacks and rear stand, retract
outriggers and secure for towing
TO LOWER MAST AND LIGHTS
NOTE: Ensure the detent pins are
properly engaged in the outriggers
1. Turn off lights.
before towing.
2. Release black knob and rotate tower until
winch handle points to the front of the trailer
and retighten knob.
3. Operate hand crank winch on tower counter-
clockwise to lower the lights to the lowest
vertical position
4. Operate hand crank winch on side of trailer
clockwise to take up any cable slack.
5. Turn the black knob counterclockwise and lift to
release the latch from the strike plate. Re-
tighten the knob with the latch disengaged from
the strike plate.

NOTE: Visually inspect the flood light mounting yokes for loose hardware. This could pre-
vent a broken fixture during towing.

9
 STRONG ARM ELECTRIC WINCH MAST OPERATION
DESCRIPTION OF OPERATION
The Allmand NIGHT-LITE tower assembly
consists of a three section telescoping mast
which can be raised and extended by operat-
ing a single electric winch mounted inside the
enclosure. A single three position toggle switch
mounted on the control panel is used to raise
and lower the mast. The winch and cable are
protected by an integral clutch and a circuit
breaker. The clutch is designed to slip when
the mast reaches full extension. The circuit
breaker is a safeguard for the clutch. If the
clutch is misadjusted or inoperative the circuit
breaker should trip to protect the system from
overload. The electric winch operates off the
120 volt circuit breaker along with 120 volt
receptacle thus requiring that the 120 volt
circuit breaker switch must be on to oper-
ate the winch.
The three section mast assembly can be
rotated from the ground by loosening a knob
and rotating the entire assembly 360° to aim
the lights as necessary.
! SAFETY WARNING!
ƒ ALWAYS CHECK FOR OVERHEAD OB-
STRUCTIONS BEFORE RAISING AND
LOWERING MAST. ALLOW 35' CLEAR-
ANCE. AVOID ALL OVERHEAD ELECTRI-
CAL WIRES.
ƒ TO PREVENT INSTABILITY AND HELP
ENSURE SAFE OPERATION, ALWAYS
PROVIDE PROPER GROUND SUPPORT
BEFORE RAISING MAST.
NOTE: The latch locks the mast in the
vertical position and disengages the
sections allowing the tower assembly to
be rotated to position the lights
10
BEFORE RAISING MAST, VISUALLY INSPECT
EQUIPMENT FOR DAMAGE OR WEAR. FA-
MILIARIZE YOURSELF WITH THE LOCATION
AND FUNCTION OF ALL OPERATING PARTS
BY STUDYING THIS
MANUAL. OBSERVE ALL CAUTION DECALS
LOCATED ON EQUIPMENT
TO ERECT MAST AND RAISE
LIGHTS
1. Extend both side outrigger jacks, rear jack
and tongue jack to stabilize and level the
trailer.
NOTE: Jacks should be placed only on
firm footing.
! SAFETY WARNING!
WHEN EXTENDING REAR JACK, WATCH
TO ENSURE YOU ARE CLEAR OF THE
OVERHANGING ENDS OF THE MAST
BEFORE YOU STAND UP.
THE SUPPLEMENTAL GROUND ROD IS A
SAFETY DEVICE THAT MAY REDUCE THE
CHANCE OF PERSONAL INJURY FROM
STRAY ELECTRICAL CURRENT. There-
fore, Allmand recommends using the
ground rod. However, it is the user’s
responsibility to determine the require-
ments and/or applicability of local, state, or
national electrical code which governs the
use of the ground rod.
2. Attach the ground rod to the grounding lug,
and drive the ground rod fully for adequate
electrical ground, as required by local, state,
or national code.
3. Start engine and switch the 120 volt circuit
breaker switch to the ON position.
4. Release the pin that secures the mast to the
rear mast support.
5. Push the toggle switch in the up position to
raise the mast from horizontal to vertical.
 STRONG ARM ELECTRIC WINCH MAST OPERATION
6. Turn black knob counterclockwise and
engage latch in strike plate. Retighten
knob.
7. Release the latch by squeezing the
handle and push the toggle switch to the
UP position to raise lights
8. To rotate the lights, release the black
knob and turn the tower assembly with
the handles provided
! SAFETY WARNING!
IF THE TOWER CANNOT BE ROTATED
AFTER LOOSENING THE BLACK KNOB,
CHECK TO ASSURE THE LOWER LATCH
IS ENGAGED IN THE STRIKE PLATE.
THIS DOUBLE LATCH FEATURE PRE-
VENTS THE TOWER FROM BEING RO-
TATED IF THE LATCH IS NOT ENGAGED.
! SAFETY WARNING!
VISUALLY INSPECT EQUIPMENT FOR
DAMAGE BEFORE OPERATING. ALLOW
ADEQUATE CLEARANCE AROUND
TRAILER FOR TOWER AND INSURE THAT
NO PERSONS ARE STANDING IN FRONT
OF OR BEHIND UNIT WHEN LOWERING.
TO LOWER MAST AND LIGHTS
1. Turn off lights.
2. Release black knob and rotate tower
until winch handle points to the front
of the trailer and retighten knob.
3. Operate electric winch toggle switch
in the down position to lower the
lights to the lowest vertical position
until the latch clicks.
4. Operate electric winch in the UP
position to take up any cable slack.
5. Turn the black knob counterclock-
wise and lift to release the latch from
the strike plate. Retighten the knob
with the latch disengaged from the
strike plate.
11
6. Operate the electric winch toggle switch
DOWN to fold the mast down into the
towing position.
7. Stop engine.
8. Secure light cords into hook on the rear
tower support for towing.
9. Secure pin locking mast to rear tower
10. Remove ground rod from earth. Discon-
nect wire from ground lug and secure in
trailer
11. Raise jacks and rear stand, retract
outriggers and secure for towing
NOTE: Ensure the detent pins are properly
engaged in the outriggers before towing.
AUXILIARY HANDLE
An emergency crank handle is provided
for use in the event of a power failure.
1. Remove the electrical power from the
winch
2. Insert the handle so that it completely
engages with the driveshaft. The
handle can be cranked in either
direction with the clutch in the en-
gaged position.
3. Always remove the handle from the
winch after use.
! SAFETY WARNING!
NEVER OPERATE THE WINCH
ELECTRICALLY WITH THE EMER-
GENCY HANDLE IN POSITION.
 SPECIFICATIONS

OVERALL DIMENSIONS

ƒ Weight 1600 LBS

ƒ Length 13' 6" (4.04 m)
ƒ Height lowered 6' 1" (1.85 m)
ƒ Height extended 30' (9.14 m)
ƒ Width ( outriggers retracted ) 4' 1 1/2" (1.26 m)
ƒ Width ( outriggers extended ) 7' 9 1/2" (2.37 m)
ƒ Trailer steel frame, leaf spring axle
ƒ Wheels and tires 13"

72mm
ENGINE SPECIFICATIONS
MODEL KUBOTA D905-EBG1 ISUZU 3LB1 ISUZU 3LD1
LOMBARDINI LDW 903 PERKINS 103-10
Water cooled 4-cycle Water cooled 4-cycle Water cooled 4-cycle Water cooled 4-cycle
TYPE
diesel diesel diesel diesel
BORE 2.83” (72 mm) 77.4 mm 83.1mm
72 mm 75 mm

STROKE 2.90” (73.6 mm) 79.7 mm 92 mm

75 mm 72 mm
DISPLACEMENT 54.9 cu. in. (898 cc) 69 cu. in (1124 cc) 91 cu. in
56 in.(1496 cc)
(916 cc) 58.3 cu. in.(954 cc)
POWER @ 1800
10.5 HP (8.8kw) 16 HP (11.9 kw) 21 HP
10.8 HP(15.7 kw)
(8.1kw) 10.7 HP (8.0 kw)
RPM
3% per 1000 ft above 360 3% per 1000 ft. above 3% per 1000 ft. above 3% per 1000 ft. above
POWER OUTPUT
ft 360 ft. 360 ft. 360 ft.
DERATING
1% per 10 ° above 77°F. 1% per 10 ° above 77°F. 1% per 10 ° above 77°F. 1% per 10 ° above 77°F.
Cassette type fuel
FUEL SYSTEM Indirect injected diesel Indirect injected diesel Indirect injected diesel
injected diesel
STARTING
12 volt DC 12 volt DC 12 volt DC 12 volt DC
SYSTEM
COMPRESSION
22:1 22:1 22:1
22.8:1 22:1
RATIO
WEIGHT 205 lbs (93 kg) 249 lb (115 kg) 188 lbs(132
291lb (85 kg)
kg) 183 lb (83 kg)

OIL CAPACITY 5.4 qt. (5.1 L) 5.4 qt. (5.1 L) 7.2 qt. (6.8
2.5 (2.4 L) Fill to correct level
Forced lubrication by Forced lubrication by Forced lubrication by
LUBRICATION Forced lubrication by pump
pump pump pump
OIL FILTRATION Cartridge type Cartridge type Cartridge type Cartridge type
COOLANT 1.8 qt. (1.7 L) (Engine
.82 gal. (3.1 L) 2.3 qt. (2.2 L) 2.6 qt. (2.5
5.1 (4.9 L)
CAPACITY Only)
Pressurized radiatior, Pressurized radiatior, Pressurized radiatior, Pressurized radiatior,
COOLING
forced circulation with forced circulation with forced circulation with forced circulation with
SYSTEM
water pump water pump water pump water pump

ƒ Low oil pressure and high engine temperature shut-downs are standard equipment. Both
The Kubota, Perkins, Isuzu, and Lombardini diesel are equipped with glow plug cold start
assist as standard equipment.

NOTE: See the appropriate section of this manual for cold weather starting instructions
or consult the Operators Manual for your particular engine application.

Horsepower ratings are established in accordance with Society of Automotive Engineers

Small Engine Test Code- J1349 GROSS.

12
 SPECIFICATIONS

GENERATOR

ƒ Make Marathon electric

ƒ Model 332RSA1020
ƒ Construction Capacitor excitation
ƒ Speed: 60HZ 1850 RPM at no load
1800 RPM at full load
ƒ Air cooled
ƒ Max. ambient temp. 104 deg. F (40 deg. C)
ƒ Insulation Class “F”
ƒ Voltage response 0.1 sec.

NOTE: Operate the generator at 60 hertz, 1800 RPM only.

Consult the factory if an operating speed of less than the rated speed is required.

FUEL REQUIREMENTS
Use a clean No. 2 Diesel fuel oil (SAE J313 JUN87) according to ASTM D975. Do not use
alternative fuel, because its quality is unknown or it may be inferior in quality,and kerosene,
which is very low in cetane rating, adversely effects the engine. Refer to the Kubota,
Perkins, or Isuzu Operators Manual for more detailed fuel requirements.

ENGINE OIL REQUIREMENTS

Use a high quality engine oil of API (American Petroleum Institute)
service class CC/CD/CE Refer to the Kubota, Perkins, Lombardinior Isuzu
Operator’s Manual for more detailed engine oil requirements.
KUBOTA LUBRICATION CHART ISUZU LUBRICATION CHART

LOMBARDINI LUBRICATION CHART

PERKINS LUBRICATION CHART

13
 SPECIFICATIONS

TRAILER
The complete generator is housed in a lockable enclosure with the frame fabricated from
heavy gauge steel mounted on a two - wheel, leaf spring axle.
The design enables the trailer to contain the outriggers in a simple, compact position.

When the mast is in the operating position it is located in the middle of a three point
outrigger system for optimum balance and stability. This system was engineered to allow
the light tower to remain operational in sustained winds of 65 MPH with the mast extended
to full height and the outriggers in position.

MAST
The mast consists of a three section steel tube that extends to 30 feet.
The mast is extended with two manual winches.The mast includes self lubricating nylon
guide pads and a 360 degree rotatable light bar .

STABILIZERS
The three point outrigger design consists of two retractable side outriggers and a tongue
jack.

FLOOD LIGHT ASSEMBLY

The flood light assembly consists of four 1000 watt lamp fixtures sealed for all weather use.
SHO 1000 fixture - BT - 37 lamp, Metal Halide
Laboratory rated life is 12,000 hours.

ƒ Lumen rating: 110,000

ƒ Warm up time: 2-4 minutes
ƒ Restart time: 10-15 minutes

TOWING INSTRUCTIONS
Before towing the Night-Lite Pro the trailer should be inspected visually to insure that the
following operations have been completed:

1. Hitch is securely attached to the towing vehicle (safety chains securely attached
2. All outriggers and jacks are retracted and secured.
3. Rear tower support pin is in the locked position.
4. Light fixtures are positioned for transport.
5. Doors are closed and secure.
6. Check for adequate tire pressure.
7. Tail lights are connected and operational.
8. Ground rod is removed from ground and secured in trailer.

14
 STARTING INSTRUCTIONS
BEFORE STARTING:

1. Fill the engine with the right grade of lubricating oil (refer to the proper page of this manual or the Kubota,
Perkins, or Isuzu diesel operators manual for oil specifications)
2. Ensure there is an adequate supply of diesel fuel.
3. Ensure that the air cleaner is firmly attached and air cleaner seals and hose clamps are
properly sealed. Air cleaner element should be checked and replaced if necessary.

STARTING ENGINE

NOTE: The Kubota D905, Perkins 103-10, Lombardini LDW 903 and the Isuzu 3LD diesel engines include a
glow plug cold start system controlled by the ignition switch on the control panel. Glow plugs are not needed on
a warm engine or if the ambient temperature is above 50 degrees F.

COLD WEATHER STARTING: KUBOTA D905, LOMBARDINI LDW 903 (for temperatures below 32° F/ 0° C)
1. Turn the key switch to the PREHEAT position, hold until the glow plug indicator lamp goes out,
then release switch.
2.Turn the key switch to the START position and the engine should start. Release the key
immediately when the engine starts. If engine fails to start it may be necessary
to cycle the glow plugs again (see chart below)
COLD WEATHER STARTING: KUBOTA D905 Power Unit
1. Turn the key switch to the PREHEAT position, hold for 5 seconds, then release switch.
2. Depress the START ASSIST button and turn the key switch to the START position and the engine
should start. Release the key immediately when the engine starts. Hold the START ASSIST button for
five seconds after the engine starts then release. If engine fails to start it may be necessary to cycle
the glow plugs again (see chart below).

IF ENGINE HAS RUN OUT OF FUEL:

1. Hold the START ASSIST button for 10 seconds and then release. This will allow the fuel system to
re-prime itself.
2. Follow normal starting procedures.
PREHEATING TIME
AMBIENT TEMPERATURE Ordinary heat type With glow plug timer
Above 50°F (10°C) NO NEED Automatic preheating is
50°F (10°C) to 23°F (-5°C) Approx. 5 seconds made for about 6 seconds
Below 23°F (-5°C) Approx. 10 seconds when starter switch key is
turned to preheating
Limit of continuous use 20 seconds
position

NOTE: Do not operate starter for more than 10 seconds without allowing 30 seconds
to pass between starting attempts. Possible starter damage could result from
excessive heat caused by cranking too long.

NOTE: If the engine develops sufficient speed to disengage the starter but does not keep
running (a false start), the engine rotation must be allowed to come to a complete stop
before attempting to restart the engine. If starter is engaged while the flywheel is rotating,
the starter pinion and flywheel ring gear may clash, resulting in damage to the starter or
flywheel ring gear.

NOTE: If the starter does not turn the engine over, stop cranking immediately. Do not make
further attempts to start the engine until the condition is corrected. See your local
Kubota Engine Service Dealer for trouble analysis
15
 STARTING INSTRUCTIONS

COLD WEATHER STARTING ISUZU 3LD and PERKINS 103-10 (for tem-
peratures below 32° F/ 0° C)
1. If the engine is cold, turn the key switch counterclockwise to the “preheat” position until
the glow plug indicator turns red. CAUTION: Never heat glow plugs more than 5
seconds or damage to the glow plugs may occur.
2. Turn the key switch to the “start” position and start the engine immediately once the
indicator turns red. Release the key immediately when the engine starts. (If engine fails
to start, repeat steps 1 and 2.)

NOTE: Do not operate starter for more than 10 seconds without allowing 30 seconds to pass
between starting attempts. Possible starter damage could result from excessive heat
caused by cranking too long.

NOTE: If the engine develops sufficient speed to disengage the starter but does not keep
running (a false start), the engine rotation must be allowed to come to a complete stop
before attempting to restart the engine. If starter is engaged while the flywheel is rotating,
the starter pinion and flywheel ring gear may clash, resulting in damage to the starter or
flywheel ring gear.

NOTE:If the starter does not turn the engine over, stop cranking immediately. Do not make
further attempts to start the engine until the condition is corrected. See your local ISUZU
Engine Service Dealer for trouble analysis.

FOR A WARM ENGINE (Kubota, Perkins, Isuzu, and Lombardini engines)

ƒ Follow the same procedure as described for cold weather starting, skipping step 1.
Use of the glow plugs is not recommended when engine is warm.

LOW OIL PRESSURE SHUT-OFF SYSTEM

Should a low oil pressure condition occur, the oil pressure sending unit breaks the circuit
between the battery and the fuel solenoid, allowing the spring load to immediately move the
fuel control to the shut-off position.

HIGH COOLANT TEMPERATURE SHUT-OFF SYSTEM

Should a high coolant temperature condition occur, the temperature sending unit breaks
the circuit between the battery and the fuel solenoid, allowing the spring load to immedi-
ately move the fuel control to the shut-off position.

STOPPING THE ENGINE

To stop the engine turn the ignition switch to the off position, this breaks the circuit between
the battery and the fuel solenoid, allowing the spring load to immediately move the fuel
control to the shut-off position

16
 SERIAL NUMBER LOCATIONS

SERIAL NUMBER LOCATION

Trailer: All NIGHT-LITE PRO se-
ries trailers have a serial number
plate attached to the rear tower
support below the tower lock.
(See illustration)

TRAILER SERIAL NUMBER

LOCATION

17
 SERIAL NUMBER LOCATIONS

SERIAL NUMBER LOCATION

Generator: The generator has a plate attached

to the side of the housing.

Engine: The KUBOTA engine has the serial

number stamped on the engine block just below
the exhaust manifold. (see illustration below )

The ISUZU and PERKINS engines have the

serial number stamped on the right side of the
engine block just ahead of the first cylinder. (see
illustration below)

The LOMBARDINI engine has the serial number

tag located on the right side of the engine block.
(see illustration below)

PERKINS engine
serial number
KUBOTA engine
serial number

ISUZU engine serial

number
LOMBARDINI engine
serial number

18
 CONTROLS AND COMPONENTS

NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.

FIG. 1. A.C./D.C.CONTROL PANEL (Kubota)

FIG. 1a. A.C./D.C.CONTROL PANEL (Isuzu

and Perkins)

1. Breaker Switch Fig. 1 (Kubota)

Controls lights 1 and 2
2. Breaker Switch
Controls lights 3 and 4
3. Hour Meter
Shows the total elapsed hours of engine
operation.
4. Glow Plug Lamp
5. Key Switch
Turn key counter-clockwise to activate the
glow plugs.

NOTE: Release key as soon as the engine fires.

FIG. 1a (Isuzu and Perkins)

19
 CONTROLS AND COMPONENTS

NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.

FIG. 1b. A.C./D.C.CONTROL PANEL

(Lombardini)
5
1. Breaker Switch
Controls lights 1 and 2
2. Breaker Switch 1
Controls lights 3 and 4
3. Hour Meter 4
Shows the total elapsed hours of engine
operation.
2
4. Key Switch
Turn key clockwise one click to activate the
3
glow plugs.
5. Glow Plug Lamp

NOTE: Release key as soon as the engine fires.

FIG. 2a. A.C./D.C.CONTROL PANEL (Electric

Winch Model)

1a. Breaker Switches

Controls lights 1 through 4 1a 2a
2a. Hour Meter
Shows the total elapsed hours of engine 3a
operation.
3a. Glow Plug Lamp 4a
4a. Key Switch 6a
Turn key counter-clockwise to activate the
glow plugs. 5a

5a. Electric Winch On/Off Switch

6a. Electric Winch Up/Down Switch FIG. 2a (Electric Winch Model)
NOTE: Release key as soon as the engine fires.

20
 CONTROLS AND COMPONENTS

NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.

7
6

FIG. 3. BALLAST PANEL

6. Transformer (lights 1 thru 4)

7. Capacitors (lights 1 thru 4)

FIG. 3

FIG. 4. CONVENIENCE PANEL

8. Grounding Lug (not shown)
Attach ground rod lead here
9. 15 Amp Pop-up Circuit Breaker
10. 120 volt Outlet Receptacle

FIG. 4

11
FIG. 5. GROUND ROD
11. Ground rod should be attached to
grounding lug with wire provided
and ground rod and then driven fully
into the earth for adequate electri-
cal ground, as required by local,
state, or national electrical code.

FIG. 5

21
 CONTROLS AND COMPONENTS

NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.

FIG. 6A ENGINE COMPONENT IDENTIFI- 13

CATION (KUBOTA and PERKINS)
12. Water temp switch
13. Alternator
14. Starter 15

15. Air cleaner

14
12

FIG. 6A

FIG. 6B ENGINE COMPONENT IDENTIFI-

CATION (ISUZU)
16. Water temp switch
17. Alternator
18. Starter
19. Air cleaner (not shown)
17 16 18

FIG. 6B

16c
FIG. 6C ENGINE COMPONENT IDENTIFI-
CATION (LOMBARDINI)
16c. Muffler
17c. Alternator
18c. Oil Filter
19c. Air cleaner (not shown)

19c 18c
17c

FIG. 6C

22
 20

21
FIG. 7A. ENGINE COMPONENT IDENTI-
FICATION (KUBOTA and PERKINS
cont’d)
22
20. Oil fill
21. Glow plugs 23
22. Fuel solenoid
23. Fuel lift pump 24 25
24. Fuel filter
25. Oil filter FIG. 7A

28 26

FIG. 7B. ENGINE COMPONENT IDENTI- 30

27
FICATION (ISUZU cont’d)
26. Oil fill
27. Glow plugs
28. Fuel solenoid 31
29. Fuel lift pump (not shown)
30. Fuel filter
31. Oil filter

FIG. 7B

FIG. 7C. ENGINE COMPONENT IDENTI- 31c

FICATION (LOMBARDINI cont’d)

26c. Air Cleaner 29c
27c. Starter
28c. Fuel solenoid
29c. Fuel pump
30c. Fuel filter
31c. Cooling Fan
26c

27c
30c

FIG. 7C

23
 CONTROLS AND COMPONENTS

NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.

35 32

FIG. 8 TOWING COMPONENT IDEN-

34 33
TIFICATION
32. Tongue jack
33. Safety chains
34. Taillight wiring harness
35. Hitch (2” ball)

FIG. 8

FIG. 9. REAR OUTRIGGERS

36. Jack Handle
Crank handle to raise or lower foot
of jack to level trailer
37. Jack Pin
Pull to allow jack to rotate
38. Outrigger Lock Stud

SAFETY WARNING
Be sure outrigger jack is securely latched FIG. 9
on the outrigger lock stud before towing.

FIG. 10. REAR TOWER SUPPORT

39. Pin
Locks tower into the rear tower support
40. Tower Interlocking Pin
Keeps tower from extending during towing
41. Cord Hanger
Holds lamp cords up during towing

FIG. 10

24
 CONTROLS AND COMPONENTS
NOTE: COMPONENTS SHOWN ARE STANDARD.
PICTURES MAY VARY WITH DIFFERENT OPTIONS.

FIG. 11 POSITIVE DOOR LATCH

42. Positive door latch
Locks door in the open position

42

FIG. 11

43
FIG. 12. MANUAL WINCH HANDLE
43. Manual Winch
Crank handle to raise or lower foot of jack 44
to level trailer
44. Manual Winch Handle
Used to raise and fold mast

FIG. 12

FIG. 13. MANUAL WINCH

45
45. Manual Winch
Extends and lowers mast
46. Mast Handle 47 46
Used to rotate tower and lights
47. Swivel Lock Knob
Locks tower in position

FIG. 13
FIG. 13a ELECTRIC WINCH 45a
45a. Strong Arm Winch—Used to raise and
extend, lower and fold mast.
46a. Slack Limit Switch-(Located below winch
on ballast panel) -Shuts off winch when
cable slack is sensed by sensor arm. 46a

NOTE: See pages 10-11, Strong Arm Electric

Winch Mast Operation, for correct operating
procedures.

25 FIG. 13a
 CONTROLS AND COMPONENTS

NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.

FIG. 14 MAST LOCKING BAR LATCH

48. Mast Locking Bar Latch
Locks mast in the vertical position and allows
tower to rotate

NOTE : Tower must be positioned with the

manual winch forward before the mast locking bar
can be released from the strike plate, allowing the
tower to rotate toward the horizontal towing posi-
tion.
FIG. 14

FIG. 15. KICK-OUT SPRING

49. Kick-out spring
Tilts mast off center when folding mast down

FIG. 15

FIG. 16. LIFTING ATTACHMENT POINTS

50. Forklift Lifting Pockets
Used to lift light tower using forklift to ease loading
and unloading
51. Tower Lifting Eye
Used for lifting light tower using a crane

FIG. 16

26
 NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.

FIG. 17 Electric Mast

52. Mast Handle—Use to rotate mast.
53. Lock Handle—Pull to unlock tower
sections when raising tower. 52
53
54. Mast Locking Knob—Prevents accidental
release of lock when rotating mast.

54

FIG. 17

56

FIG. 18 Rear Tower Lock Safety Switch

55. Safety Switch—Prevents winch operation
while tower is in the down and locked position
56. Safety Switch Actuator cam—Closes
switch and allows tower operation only when in
the UNLOCKED position.
55

FIG. 18

27
 ROUTINE MAINTENANCE SCHEDULE
KUBOTA D905, D1105, PERKINS 103-10, and LOMBARDINI LDW 903

INSPECTION AND LUBRICATION SCHEDULE

Check condition of the steel cable and make sure it is properly secured. Check hydraulic fluid level.

LUBRICATION GREASE SPECIFICATIONS:

N.G.L.I. consistency #2, high temperature anti-friction bearing lubricating grease.

Service intervals shown below have been established for operation under normal conditions. Where equipment is
operated under severe conditions (very dusty, extreme heat or cold, etc.) affected items should be serviced more
frequently.
KUBOTA AND ISUZU
INTERVAL ITEM PROCEDURE
Daily or 10 Hr. Fuel Level Check and fill as necessary
Lubricating Oil Check level and condition
All 10 Hr. Items As above
Air Cleaner Service is required. Service requirements
100 Hr. may be accelerated by conditions
Battery Check level of electrolyte
Engine Generator Assembly Check for fuel and oil leaks
200 Hr. All 100 Hr. Items As above
Engine lubricating oil system Drain oil, flush out system, renew filter element
and refill with correct grade and type oil
Coolant Check level and condition
400 Hr. Fuel Filter Replace with new
All 200 Hr. Items As above
500 Hr. Fan Belt Check tension and condition
Radiator Clean out fins with water or air
All 500 Hr. Items As above
Engine Valves Adjust Clearance
Cable pulley at the bottom Remove, clean, and grease
1000 Hr. or Yearly of the front mast support Inspect for wear. Clean and lubricate
Cable pulleys on mast Remove, clean, and grease
Axle Wheel Bearings Clean and repack
Fuel System Clean sediment from tank

PERKINS ONLY LOMBARDINI ONLY

28
 TROUBLESHOOTING

! SAFETY WARNING
DANGER!
HIGH VOLTAGE! DO NOT ATTEMPT TO TEST AND REPAIR GENERATOR AND
BALLAST ELECTRICAL SYSTEMS UNLESS YOU UNDERSTAND AND ARE QUALIFIED
TO WORK ON SUCH SYSTEMS.

When one lamp does not light, TURN OFF THE GENERATOR and test the lamp by switching
leads with a lamp that DOES light. DO NOT WEAR JEWELRY WHILE WORKING WITH
ELECTRICITY! If the following procedures do not solve your problem, have the circuit tested by a
licensed electrician. DO NOT attempt to test generator voltage or ballast electrical systems unless
you are a qualified electrician. Consult the factory for voltage specifications and test procedures

PROBLEM POSSIBLE CAUSE

1. Circuit breakers in the outlet box are not turned on or have tripped.
2. Lamps are not allowed time to cool after last being lit. You must
allow 15 minutes between the time the lights are shut off and the time
they are restarted.
3. The lam or lamps are burned out or broken.
4. One or more of the lamps are not screwed in securely.
5. Plug and socket at light bar not securely pushed together and
locked.
6. The temperature of the ballast is below –20 degrees F. the efficiency
of the capacitors in the ballast is not enough to ignite the lamps. For
ONE OR MORE LIGHTS operations where the temperatures of the ballasts falls below –20
DO NOT LIGHT UP. degrees F. some means of warming the ballast must be used.
7. Low electrical system voltage.
8. A loose connection in the back of the lamp socket in the lamp holder.
9. A circuit breaker or breakers are defective.
10. A loose connection on the terminal board.
11. The engine and generator are not running up to speed (1800 RPM)
12. A wrong style replacement lamp (requiring a different ballast) has
been installed.
13. Too much power is being drawn from the auxiliary outlets.
14. Capacitor or transformer have failed.
15. Corrosion has occurred on the lamp bases.

For engine and generator troubleshooting, see engine and generator manuals or
contact your dealer.

29