Major service - diesel lighting tower (trailer-mounted, all makes)
Estimated duration: 2 - 3 hours • Frequency: every 500 engine hours or annually
Equipment Details
| # | Service Action | Type | Done | Notes |
|---|---|---|---|---|
| Engine (additional to 250-hour) | ||||
| 1 | Replace fuel filter | REPLACE | ☐ | |
| 2 | Replace air filter element | REPLACE | ☐ | |
| 3 | Replace drive belt | REPLACE | ☐ | |
| 4 | Service fuel system (drain tank sediment, check fuel quality) | SERVICE | ☐ | |
| 5 | Check and replace vibration isolator mounts if perished | INSPECT | ☐ | |
| Mast and Lights (additional to 250-hour) | ||||
| 6 | Service mast winch (inspect cable, lubricate drum) or hydraulic cylinder (check seals, test operation) | SERVICE | ☐ | |
| 7 | Replace lamps or LED modules if degraded or below output spec | REPLACE | ☐ | |
| 8 | Test light output with lux meter (each head) | TEST | ☐ | |
| Electrical (additional to 250-hour) | ||||
| 9 | Full electrical test (insulation resistance, wiring integrity) | TEST | ☐ | |
| 10 | Inspect wiring harness for chafing or heat damage | INSPECT | ☐ | |
| 11 | Replace battery if failing load test | REPLACE | ☐ | |
| Trailer (additional to 250-hour) | ||||
| 12 | Inspect tow bar hitch, safety chain and coupling | INSPECT | ☐ | |
| 13 | Full trailer brake check (adjust or reline) | CHECK | ☐ | |
| General | ||||
| 14 | Update service sticker | CHECK | ☐ | |
Fluid Specifications (General Guide)
| System | Type / Grade | Approx. Capacity |
|---|---|---|
| Engine oil | 10W-30 or 15W-40 | 3 - 8 L |
| Coolant | 50/50 ethylene glycol | 3 - 6 L |
| Grease | EP2 lithium complex | As required |
Specifications are general guidelines for typical diesel lighting towers. Always refer to the manufacturer's service manual for your specific make and model. Capacities vary by unit size.
Parts / Consumables Required (500-hour additional items)
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Engine oil (10W-30 or 15W-40) | 3-8 L | ☐ | |
| 2 | Engine oil filter | 1 | ☐ | |
| 3 | Fuel filter | 1 | ☐ | |
| 4 | Air filter element | 1 | ☐ | |
| 5 | Drive belt | 1 | ☐ | |
| 6 | Fuel/water separator element | 1 | ☐ | |
| 7 | Replacement lamps/LEDs | As req. | ☐ | |
| 8 | Battery (if replacing) | 1 | ☐ | |
| 9 | Winch cable (if worn) | 1 | ☐ | |
| 10 | EP2 grease cartridges | 1-2 | ☐ | |
| 11 | Coolant (pre-mixed or concentrate) | As req. | ☐ | |
| 12 | Rags, drip tray, waste oil container | - | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager