1. Safety First
Always prioritize safety before any inspection or service. Follow lockout/tagout procedures and consult your unit's OEM manual for model-specific warnings.
Shut the unit down and allow the engine and exhaust to cool before servicing.
Disconnect the battery when working on electrical components or when doing extended service.
Work on level ground, with wheel chocks and stabilizers engaged.
Personal protective equipment (PPE): gloves, eye protection, steel-toe boots, and hearing protection when running the generator.
Handle diesel and fluids in a well-ventilated area and follow local disposal regulations.
2. Daily Checks (Start of Shift)
Quick daily inspections catch small problems before they become downtime. These should take 5–10 minutes per unit.
Fuel and Fluids
Check diesel level; refuel with clean, low-sulfur diesel. Note water or sediment at tank bottom.
Check engine oil on the dipstick; top off to the recommended level with manufacturer-specified oil grade.
Check the coolant overflow bottle; top to specified mark only when cool.
Scan for leaks under the engine, radiator, fuel lines, and hoses.
Visual Inspection
Look for damaged cables, loose bolts, cracked housings, or missing guards.
Inspect the mast for dents, corrosion, bent sections, or limit switch damage.
Confirm trailer coupler, safety chains, tires, and jack stand are secure and undamaged.
Lights and Electrical
Test all lamps and aim/position lights if needed.
Check control panel — oil pressure, temperature, hour meter, and warning lights.
Verify that circuit breakers are set correctly and that overnight charging (if present) is working.
3. Weekly Maintenance
Weekly tasks keep the engine and mechanical systems in good working order.
Air Intake & Engine Health
Inspect the air filter housing. If dusty, clean or replace the filter element per OEM schedule.
Check belts for fraying, glazing or tension. Replace belts showing significant wear.
Inspect exhaust for leaks, broken hangers, or heavy soot buildup that could indicate combustion problems.
Battery
Inspect battery terminals and cables for corrosion; clean with a baking soda solution and re-tighten.
Confirm battery voltage/resting voltage and charging behavior; top up electrolyte if applicable and serviceable.
Mast Operation
Raise and lower the mast to check for smooth movement and any binding.
Lubricate mast rails, guide rollers, and pivot points with the lubricant recommended by the manufacturer.
4. Monthly Maintenance
Monthly services reduce wear and ensure reliability during longer projects.
Oil & Filters
Change engine oil and replace the oil filter (use OEM part numbers or exact-spec replacements).
Replace fuel filter when operating in dusty or humid conditions more frequently than normal.
Electrical System
Perform a detailed wiring inspection — look for chafing, overheated insulation, or loose splices.
Test alternator output under load to confirm charging system performance.
Trailer Components
Inspect wheel bearings for play or noise; repack if required according to OEM intervals.
Check tire pressure and tread; tighten lug nuts to the manufacturer's torque spec.
5. Quarterly or 500-Hour Service
Major scheduled maintenance should follow the manufacturer’s hours-based schedule. Typical quarterly items include:
Replace primary and secondary fuel filters and drain water separators.
Flush and replace coolant if due; inspect hoses and clamps for age-related deterioration.
Clean or replace crankcase breather elements to prevent oil contamination.
Inspect hydraulic components and seals where a hydraulic mast is used.
Test safety shutdown systems (low oil pressure, high coolant temperature, overspeed protection) — simulate faults where safe to confirm correct shutdown behavior.
6. Lamp and Generator Care
Lamps
Clean lenses and reflectors; remove dirt and buildup with a soft cloth and mild detergent.
Replace burnt-out or flickering bulbs; avoid bare-hand contact with halogen-type bulbs.
Aim lamps to the required work area to reduce wasted light and glare.
Generator
Inspect brushes (if brush-type alternator), voltage regulator and slip rings.
Tighten all electrical connections and check for hot spots with an infrared gun when available.
Run the generator under load periodically to prevent wet-stacking and to verify voltage/frequency stability.
7. Storage and Long-Term Shutdown
Proper long-term storage prevents corrosion, fuel degradation, and battery failure.
Fill the fuel tank to reduce condensation and add an approved diesel stabilizer for long storage periods.
Run the engine briefly to circulate stabilizer, then shut down and store in a dry, ventilated area.
Disconnect battery or connect a maintenance trickle charger; remove battery if temperatures will drop below freezing for long periods.
Store with the mast lowered, locked, and secured. Cover sensitive electrical panels and the engine if stored outdoors.
8. Troubleshooting Tips
Quick diagnostics for the most common faults.
Engine Hard to Start
Check battery voltage and terminal condition.
Confirm there is diesel fuel and the fuel shutoff valve is open.
If fuel system was opened, bleed air from the system following the OEM sequence.
Lights Not Turning On / Dimming
Verify breakers, fuses and control switches. Check sockets and bulb condition.
Check generator/alternator output and regulator if lights dim under load.
Overheating
Check coolant level and radiator airflow. Clean debris from radiator fins.
Confirm fan belt tension and inspect for slipping or damage.
9. Record Keeping
Good records reduce repeat failures and help plan preventive service.
Log hours of operation, daily checks completed, and any faults found.
Record maintenance performed with date, hours, parts used, and technician name.
Track fuel consumption and recurring issues. Use this data to schedule predictive maintenance.
| Interval | Key Tasks |
|---|---|
| Daily | Fuel, fluids, visual check, lamp test |
| Weekly | Air filter check, battery inspection, mast lubrication |
| Monthly | Oil & filter change, alternator test, bearings |
| Quarterly / 500 hrs | Fuel system service, coolant flush, safety tests |
About YGNE
YGNE designs and manufactures diesel-powered light towers focused on durability, serviceability, and safety for construction, events, and emergency response. Our engineering emphasis is on easy field maintenance — clear service access, standardized parts, and comprehensive manuals to reduce downtime.
Final Tips & Best Practices
Use OEM or OEM-equivalent parts and follow the engine/generator manufacturer’s service intervals.
Train operators on daily checks so small symptoms are reported early.
Keep a small spare parts kit: extra bulbs, fuses, filters, belts, and fuel/water separator elements.
If you need a printable checklist, OEM-specific service intervals added for your YGNE model, or professionally formatted PDF maintenance sheets, tell us the model number and we’ll tailor the document to that unit.
