The Kirloskar mobile lighting tower pairs a 7.5 kVA genset with a 9 m rotating mast and four adjustable 300 W LED floodlights for temporary illumination at outdoor worksites.
7.5 kVA
9 m
4 × 300 W
Up to 5,000 m²
26 L
360°
1.1 L/h
3,000 rpm
230 V
158 lm/W
IP66
50,000 hours
Hot-dipped galvanized
Leaf-spring
4 mechanical stay jacks
Technical specifications for the Kirloskar 7.5 kVA mobile lighting tower variant
Daily pre-start checks · hour-based service schedule · warning actions · fluids and care.
About 10–15 minutes. Engine stopped and cool, lights off, mast fully lowered, unit on firm, level ground. Do the trailer and mast checks before raising the mast.
Firm, level ground, away from trench edges. Look up: the raised 9 m mast must be clear of power lines.
Act if: ground is soft or sloping, move the unit. Power line within reach, do not raise; electrocution risk.
Lower all four on firm ground (base plate or timber on soft soil) and lock. Push the trailer: it must not rock.
Act if: a jack is bent or will not lock, or the trailer rocks. Do not raise; the tower can tip.
Look for cracks, bends and loose bolts. Keep the wheels chocked when parked.
Act if: there is a crack or loose bolt. Do not tow.
No cuts, bulges or low pressure. All nuts present; a rust trail around a nut means it is loose.
Act if: a tyre is damaged or a nut is missing or loose. Do not tow.
Look under both sides for broken or shifted leaves and loose U-bolts.
Act if: a leaf is broken or a U-bolt is loose. Do not tow; the axle can shift.
With the mast lowered, look along each section for dents, bends and cracked welds.
Act if: a section is bent or cracked. Do not raise; it can jam or fold.
Check the rope on the drum and at end fittings for broken wires, kinks, crushing and rust.
Act if: any of these are found. Do not raise; rope failure drops the mast.
Turn the handle a little. It must run smoothly and hold position when released.
Act if: it slips back. Do not use; the mast can come down.
Upright lock and rotation lock engage fully. Turn the mast by hand: smooth, no grinding.
Act if: a lock will not engage, do not raise. Grinding: report it.
No cuts, crushing or pinch points. The cable must pay out freely as the mast rises.
Act if: insulation is cut. Do not switch on the lights; shock risk.
Wipe lenses. Check for cracks, water inside, missing cable glands, loose bolts and correct aim.
Act if: a lens is cracked or has water inside, report it. Loose bolt: tighten; a light can fall from 9 m.
Unit level, engine stopped a few minutes. Dipstick at the “H” mark. Top up with K-Oil Super SAE 15W-40 only.
Act if: oil is milky (water) or the level rises with a diesel smell (fuel in oil). Do not start; report it.
Read the fuel gauge. Fill with clean diesel to IS 1460, engine stopped only. Keep the filler area clean.
Act if: the tank is near empty. Refuel first; running dry lets air into the fuel line.
Canopy grilles, fan and cooling fins free of dust, leaves and plastic. Nothing stacked against the canopy.
Act if: the path is blocked. Clean before starting; an air-cooled engine overheats fast.
Housing closed and clamped. On dusty sites, check the element.
Act if: the housing is open or the element is missing. Do not run; dust wears the engine.
Look inside the canopy and under the trailer for fuel or oil drips.
Act if: fuel is leaking. Do not start; fire risk near the hot exhaust.
No cracks or soot marks at exhaust joints; outlet pointing away from people. Canopy doors latch.
Act if: exhaust leaks inside the canopy. Do not run; fumes and fire risk.
Terminals tight and clean, correct polarity, clamp firm, case not cracked.
Act if: the battery is weak. Charge it first; do not keep cranking.
Switch on: display on, no alarm. Record hours, fuel added, oil added, voltage and frequency.
Act if: an alarm is showing. Find the cause first (see Warning Actions).
Breaker OFF before starting. No burn marks on the socket; cables not under jacks or wheels.
Act if: the socket is burnt or melted. Do not use; fire risk.
Earth lead (8 SWG copper) connected and clamp tight before starting.
Act if: it is not connected. Do not switch on the lights; the frame can become live.
Fitted as standard. It is a backup; the daily dipstick check is still needed.
Act if: the engine stopped on a trip. Check oil and find the cause before restarting.
The four lights use 1,200 W. Add up any extra equipment; keep the total within 6 kW / 7.5 kVA.
Act if: the overload warning shows. Switch off extra load.
Use the genset hour meter. Select an interval and complete earlier recurring tasks where due.
Engine oil
Check level; top up to the “H” mark.
Air cleaner
Housing closed; check the element on dusty sites.
Fuel tank (26 L)
Check level; refuel only with the engine stopped.
Fuel and oil leaks
Inside the canopy and under the trailer.
Cooling fins, cylinder head, fan, air ducts
Free of dust and debris.
Exhaust and silencer
No leaks or cracks.
Engine and genset mounting bolts
Check by sight.
Starting battery
Terminals, polarity, clamp.
Controller and log book
Hours, fuel, oil, V, A, Hz.
AC breaker, socket, cables
No burn marks; cables clear of wheels and jacks.
Earth connection (8 SWG copper)
Connected and tight.
Lenses and housings
Clean lenses; check for cracks and water.
Mast power cable and connectors
No cuts or crushing.
Winch wire rope
Broken wires, kinks, crushing, rust.
Gear winch
Holds position when released.
Mast sections, locks, rotation
No dents or cracked welds; locks engage.
Tyres and wheel nuts
Cuts, bulges, pressure; nuts present and tight.
Leaf springs and U-bolts
No broken leaves or loose U-bolts.
Stay jacks, tow bar and hook
No bends, cracks or loose bolts.
Engine oil (1.7 L sump)
Change the full fill with K-Oil Super SAE 15W-40; refill to the dipstick “H” mark.
Log book
Record the hour-meter reading and the oil change.
Hot, dusty or long night-duty sites
The 100 h interval is for normal conditions. Shorten it on hot, dusty or long night-duty sites.
The 100-hour interval applies to engine oil only. Filters, the air-cleaner element, winch lubrication and trailer parts have no fixed hour interval; service these by condition.
Cooling fins and cylinder head
Clean when dust builds up; method in the Fluids & Care tab.
Air cleaner on heavy-dust sites
Fit a heavy-duty air cleaner; ask the dealer.
LED fixtures
Replace on failure. Rated life 50,000 h is a rating, not a replacement interval.
Winch wire rope
Replace if broken wires, kinks or crushing are found.
Starting battery
Disconnect before any maintenance work.
Whole genset
Protect from moisture, internal corrosion and rodents.
Engine and fuel system
Preservative oil, e.g. Servo Preserve 30 or Bharat Preserve Oil 30.
Starting battery
Keep charged during storage.
Re-commissioning
Have the set checked by the dealer before running it again.
Stop immediately for red alerts; resolve amber alerts before continuing. The genset has two built-in protections: low lube-oil pressure trip and overload warning. The other alerts are conditions the crew must watch for.
Action: do not keep restarting. Check the dipstick and look for leaks. Top up and restart once; if it trips again, call the dealer.
If ignored: bearings and crankshaft run without an oil film; the engine can seize.
Action: clear everyone from under the mast and around the trailer. Lower slowly only if the winch still controls it. Tag the unit out.
If ignored: mast sections drop suddenly; lights destroyed, serious injury.
Action: lower the mast as per site rule; always lower it before a storm.
If ignored: the tower tips or the mast bends; injury and total loss of the unit.
Action: switch off the AC breaker and stop the engine without touching the frame. Call an electrician.
If ignored: electrocution.
Action: stop the engine, switch off the breaker and keep a fire extinguisher ready. Do not restart until fixed.
If ignored: fire on site.
Action: stop the engine. Check oil level, air cleaner and cooling path. Call the dealer if there is no simple cause.
If ignored: piston, cylinder or bearing damage spreads.
Action: switch off extra equipment and keep the total within 7.5 kVA / 6 kW (26.09 A at unity PF). Reset the breaker only after the load is reduced.
If ignored: inverter and alternator overheat; the breaker trips and site lights go off.
Action: stop, let it cool, clean grilles and fins, and check that nothing blocks the canopy. Do not rely on an engine-temperature alarm.
If ignored: piston scuffing and cylinder damage.
Action: crank no more than 5 seconds at a time and wait one minute between tries. Check fuel, battery and air cleaner.
If ignored: long cranking drains the battery and overheats the starter.
Action: plan refuelling before the shift runs out. Refuel only with the engine stopped.
If ignored: the engine runs dry, air enters the fuel system and the lights go out.
Action: check terminals and report a suspected 12 V charger fault.
If ignored: the unit cannot restart after a stop.
Action: switch off power and lower the mast before any work on the lights, cables or connectors.
If ignored: dark patches on site; a safety risk for night work.
Action: plan the oil change at the next stop and record it in the log book.
If ignored: oil breaks down and engine wear speeds up.
Action: note the alarm text, stop safely and call the dealer.
If ignored: a real fault is left unchecked.
Use the correct fuel and oil, and keep the air-cooled engine’s cooling path clean.
Fuel tank
High Speed Diesel to IS 1460:1995 (also DIN 51601, ASTM D975 1D / 2D). Fill only with the engine stopped; keep the filler clean.
Engine oil
K-Oil Super, SAE 15W-40. Check on the dipstick to the “H” mark.
Oil change interval
At normal temperature and pressure.
Battery charger
Built-in SMPS charger, 8 A.
Battery condition (flooded lead-acid)
Specific gravity 1.24–1.27 full; 1.20–1.24 about 70%; below 1.20 recharge. Never start on a weak battery.
Earthing
Earth before operation as per local regulations.
Blow out dust
Open the air duct; use compressed air from the side opposite the normal airflow.
No diesel or kerosene
Dust sticks again to a fuel-washed surface.
Hard deposits
Scrape, then water jet, then run the engine until dry.
Keep electricals dry
Never wash the alternator, starter, controller or wiring with water.
Cranking
No more than 5 seconds per try; wait 1 minute between tries.
Warm-up
Idle 3 minutes, then switch the load on in steps.
Shut-down
Run 3 minutes off-load before stopping.
Preservative oil
Servo Preserve 30 or Bharat Preserve Oil 30 for engine and fuel system; have the set checked before re-commissioning.
Key details about the Kirloskar 7.5 kVA Mobile Lighting Tower