What is included in a lighting tower 250-hour service?

A 250-hour lighting tower service is a minor service that includes draining and replacing engine oil (typically 10W-30 or 15W-40), replacing the engine oil filter, inspecting the air filter, draining the fuel/water separator, checking coolant level and condition, inspecting the mast mechanism (winch cable or hydraulic cylinder), checking mast extension, rotation and locking, inspecting light heads and lamps or LEDs for damage, checking ballast or LED driver operation, testing the auto-start system (if fitted), checking fuel tank level, inspecting trailer frame and wheels, greasing mast pivot points and winch, checking earthing connections, testing the emergency stop, and inspecting enclosure panels and latches. It takes approximately 1 to 1.5 hours.

How often should a lighting tower be serviced?

Lighting towers follow a tiered service schedule based on engine hours. A 250-hour (minor) service covers oil, filters, mast inspection, light checks and basic trailer inspections. A 500-hour or annual (major) service adds fuel filter and air filter replacement, drive belt replacement, full electrical testing, lux meter output checks, battery load test, trailer brake check, winch or hydraulic service and fuel system service. Daily pre-start checks are performed by the operator before each shift. Always refer to the manufacturer service manual for your specific make and model.

What oil does a lighting tower engine use?

Most lighting tower engines use 10W-30 or 15W-40 diesel engine oil. Typical engine oil capacity for a trailer-mounted diesel lighting tower is 3 to 8 litres depending on the engine size. Some manufacturers specify different grades for extreme cold or hot conditions. Always check the service manual for your specific make and model.

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Yes. Download and use the lighting tower 250-hour service procedure for free. Open the file and use your browser's Print, then Save as PDF. No MapTrack account required. If you later want digital service procedures linked to each asset with scheduling by hours, cost tracking and alerts, we would be happy to show you MapTrack.

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Free lighting tower 250-hour service checklist

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A step-by-step 250-hour (minor) service procedure for trailer-mounted diesel lighting towers. Covers engine oil and filter change, air filter inspection, mast mechanism and light head checks, auto-start and emergency stop testing, trailer frame and wheel inspection, and greasing pivot points. Includes fluid specifications, parts list and technician sign-off. This page explains what the service involves, how to perform it, and offers a free PDF-ready form you can download straight away.

Last updated: 2026-03-26 · MapTrack

Jarrod Milford

Commercial Director

Updated 26 March 2026

How to use: Fill equipment details and hour reading, then work through each service action. Tick Done as each task is completed. Record fluid quantities and part numbers used. Set the next service due hours and sign off.

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What is a lighting tower 250-hour service?

A 250-hour service is the first tier of scheduled preventive maintenance for a diesel lighting tower. It is performed every 250 engine hours and is classified as a minor service. The procedure covers engine oil and filter replacement, air filter inspection, fuel system checks, mast mechanism inspection (winch cable or hydraulic cylinder), light head and lamp checks, electrical testing (auto-start, emergency stop, earthing), trailer frame and wheel inspection, greasing mast pivot points, and enclosure panel checks. Unlike a daily pre-start check (which confirms the unit is safe to operate), the 250-hour service involves actual maintenance actions: draining and replacing fluids, replacing filters, and testing mechanical and electrical systems. It is typically performed by a qualified mechanic or electrician.

Benefits of scheduled lighting tower servicing

Reduced breakdowns: regular oil, filter and coolant changes prevent engine failures that leave your site in the dark during night shifts.
Extended component life: clean oil and correct lubrication reduce wear on the engine, mast mechanism and light heads.
Lower repair costs: a 250-hour service costs a fraction of an emergency callout to fix a failed lighting tower on a remote site.
Site safety: inspecting light output, mast locking, emergency stops and earthing connections at regular intervals ensures safe illumination for workers.
Compliance: documented service records demonstrate that equipment is maintained to WHS standards, supporting insurance and regulatory obligations.
Resale value: a complete service history increases the unit's value at trade-in or auction.

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Build conditional logic (show or hide questions based on answers).
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Restrict permissions (who can view, complete or approve).
Build forms with AI (describe what you need and MapTrack suggests the form).

Book a demo to see digital service procedures and hour-based scheduling in MapTrack.

Service actions included in the 250-hour procedure

This service procedure covers 17 service actions across 5 system areas:

Engine: drain and replace engine oil (10W-30 or 15W-40), replace oil filter, inspect air filter, drain fuel/water separator, check coolant level, check fuel tank.
Mast and lights: inspect mast mechanism, check mast extension, rotation and locking, inspect light heads and lamps/LEDs, check ballast or LED driver.
Electrical: test auto-start system, check earthing connections and stake, test emergency stop.
Lubrication: grease mast pivot points and winch.
Trailer and enclosure: inspect trailer frame, wheels and jockey wheel, inspect enclosure panels and latches, check hour meter reading.

Fluid specifications

General fluid specifications for diesel lighting towers. Capacities vary by engine and unit size.

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. Always refer to the manufacturer's service manual for your specific make and model.

Parts and consumables

Have the following parts and consumables ready before starting the 250-hour service:

Engine oil (10W-30 or 15W-40) - 3-8 litres
Engine oil filter - 1
Fuel/water separator element - 1
EP2 grease cartridges - 1-2
Coolant (pre-mixed or concentrate) - as required for top-up
Replacement lamps/globes (if needed)
Rags, drip tray and waste oil container

Look up part numbers in the manufacturer's parts manual for your specific make and model before ordering.

How to perform a lighting tower 250-hour service

Shut down the lighting tower and allow the engine to cool. Lower the mast fully and ensure the unit is on stable, level ground.
Record the equipment details and current hour meter reading at the top of the service procedure form.
Start with the engine section: drain the old engine oil, replace the oil filter, fill with new oil to the correct level, then inspect the air filter, drain the fuel/water separator and check coolant level and fuel tank.
Inspect the mast mechanism (winch cable or hydraulic cylinder). Check mast extension, rotation and locking. Grease mast pivot points and winch.
Inspect all light heads, lamps or LEDs for damage. Check ballast or LED driver operation.
Test the auto-start system (if fitted), check earthing connections and stake, and test the emergency stop.
Inspect the trailer frame, wheels, jockey wheel, enclosure panels and latches.
Start the engine and raise the mast. Check for leaks, abnormal noises or warning lights. Test all lights at full output. Record any defects or recommendations in the notes section.
Set the next service due hours (next 250-hour and next 500-hour intervals). Sign off and update the unit's maintenance log.

In MapTrack, you can schedule services based on hour meter readings, get automatic reminders, complete service procedures on mobile and link every record to the asset. Book a demo to see how.

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Lighting tower service interval hierarchy

Lighting tower maintenance follows a tiered schedule where each level includes all tasks from the level below. This is called carry-forward or cumulative servicing.

250 hours - Minor service (you are here)

Engine oil and filter, mast and light inspection, electrical tests, trailer checks, greasing. Estimated 1-1.5 hours.

500 hours / annual - Major service

All 250-hour tasks plus fuel filter, air filter and drive belt replacement, full electrical test, lux meter check, battery load test, trailer brake check, winch service. Estimated 2-3 hours.

In MapTrack, you can configure service schedules by engine hours and receive automatic alerts when each interval is due.

Frequently asked questions

What is included in a lighting tower 250-hour service?: A 250-hour lighting tower service is a minor service that includes draining and replacing engine oil (typically 10W-30 or 15W-40), replacing the engine oil filter, inspecting the air filter, draining the fuel/water separator, checking coolant level and condition, inspecting the mast mechanism (winch cable or hydraulic cylinder), checking mast extension, rotation and locking, inspecting light heads and lamps or LEDs for damage, checking ballast or LED driver operation, testing the auto-start system (if fitted), checking fuel tank level, inspecting trailer frame and wheels, greasing mast pivot points and winch, checking earthing connections, testing the emergency stop, and inspecting enclosure panels and latches. It takes approximately 1 to 1.5 hours.
How often should a lighting tower be serviced?: Lighting towers follow a tiered service schedule based on engine hours. A 250-hour (minor) service covers oil, filters, mast inspection, light checks and basic trailer inspections. A 500-hour or annual (major) service adds fuel filter and air filter replacement, drive belt replacement, full electrical testing, lux meter output checks, battery load test, trailer brake check, winch or hydraulic service and fuel system service. Daily pre-start checks are performed by the operator before each shift. Always refer to the manufacturer service manual for your specific make and model.
What oil does a lighting tower engine use?: Most lighting tower engines use 10W-30 or 15W-40 diesel engine oil. Typical engine oil capacity for a trailer-mounted diesel lighting tower is 3 to 8 litres depending on the engine size. Some manufacturers specify different grades for extreme cold or hot conditions. Always check the service manual for your specific make and model.
Is the template free to use without MapTrack?: Yes. Download and use the lighting tower 250-hour service procedure for free. Open the file and use your browser's Print, then Save as PDF. No MapTrack account required. If you later want digital service procedures linked to each asset with scheduling by hours, cost tracking and alerts, we would be happy to show you MapTrack.

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Register every lighting tower in MapTrack. Set up 250 and 500-hour service schedules, complete procedures on mobile, track parts and costs, and get automatic alerts when the next service is due.

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