Excavator lighting: how do you ensure optimum work light?

Not everyone realises it, but on an excavator, additional work lights, signalling lights and driving lights can make the job a great deal more pleasant. TRALERT® specialises in work lights and helps businesses optimise their work lighting.

The main lighting options for an excavator are:

• work lights at the front, sides and rear;ip
• work lights on the boom, arm and bucket;
• reversing lights;
• an LED bar or light bar;
• rotating flashing beacons and LED warning lights;
• cab, interior and step lighting;
• Approved headlights and running lights.

The most suitable combination depends on the size of the machine, the type of work and the environment. Below, you can read about the options available for each working area. We also cover technical considerations such as light image, on-board voltage, IP protection, vibrations and EMC.

Overview of lighting options for an excavator

This table shows the types of excavator lighting available, their functions and where they are typically fitted.

Type of lighting	Primary function	Typical position
Flood work light	Lighting up a wide working area	Cab, sides and rear
Work light	Illuminating a specific or more distant area	Front, boom or arm
LED bar	Creating extra width and/or range	Cab roof or machine frame
Reversing lights	Visibility when reversing	Back cover
Flashing light or LED warning light	Making the machine visible	High visibility from all angles
Cab lighting	Improving operability and working comfort	Inside the cab
Step lighting	Safe entry and exit	Steps and handrails
Headlight or driving lights	Visibility whilst on the move	Front

During the hours of darkness, additional lighting can bring significant benefits by making the working area larger and more comfortable. This ensures better working conditions for the driver.

Front and round the cab

From the cab, the direction of travel and the immediate working area in front of the machine are illuminated. Several well-positioned LED work lights generally provide a more even result here than a single, very powerful light. This minimises harsh shadows and glare and improves visibility of the excavation area, obstacles and people around the machine.

Boom, arm and bucket

The moving boom makes lighting this area more challenging. A light that illuminates the working area well in one position may be obscured or shine towards the cab in another. Light can also be reflected off the boom, bucket or paintwork of the machine.

There is therefore no fixed rule stating that a spotlight must always be fitted to the boom. The correct light image depends on the distance to the work area, the mounting position and the type of work. There is therefore no fixed rule stating that a spotlight must always be fitted to the boom. The correct light image depends on the distance to the work area, the mounting position and the type of work. Switch on the lighting after installation and check, at various boom and bucket positions, that the beam follows the work zone properly, is not obscured and does not cause any annoying reflections in the cab.

Sides and blind spots

Additional work lights on the sides improve visibility alongside the tracks or wheels and around the counterweight. This is particularly useful on busy construction sites, when working close to obstacles and when people are working around the machine. Position the lights so that the light source is not directly visible from the cab.

Rear and reversing lights

Various functions are at work at the rear. Rear work lights illuminate the working area behind the machine. Reversing lights provide specific visibility whilst reversing. In addition, warning signals can be used to alert people in the vicinity.

These functions are not automatically interchangeable. Select a suitable light for each function and, when using the vehicle on public roads, check that the lighting for the relevant function is approved.

When is an LED bar suitable for an excavator?

An LED bar may be suitable if you wish to illuminate a wide working area or require extra reach. However, multiple individual work lights sometimes provide better light distribution, particularly around the cab and along the sides of the machine.

When fitting an LED bar, please note:

• the mounting height and available space;
• reflectors on the boom, bucket and cab;
• damage caused by branches, debris or moving parts;
• glare affecting people round the machine;
• the required width and range of the beam;
• the distinction between work lights and driving lights.

An LED bar used as a work light is not automatically permitted as a driving light on public roads. You can find more information about models, light images and applications in the LED bar selection guide.

Flashing beacons and LED warning lights

Flashing beacons and LED warning lights make the excavator more visible to staff, other machines and road users. When selecting and mounting these, factors such as all-round visibility of the machine, product approval, the working situation and the difference between a worksite and the public highway all play a role.

For special warning lights, ECE R65 is an important type approval. Whether and when flashing beacons or LED warning lights may or must be used also depends on national regulations and the working situation. An ECE R65 approval therefore does not automatically mean that the light may always be used.

Cab, interior and step lighting

Cab lighting helps drivers to read controls and documents. Step lighting makes steps and handrails visible and helps with getting in and out safely. Targeted lighting can also be useful during maintenance and checks in or around the cab.

Avoid unnecessarily bright lighting in the cab. Interior light that is too bright can reflect off the windows and reduce visibility out of the cab. Dimmable lighting or fittings that are directed downwards help to minimise this nuisance.

Additional headlights and driving lights for excavators

Work lights and driving lights serve different purposes. A work light or LED bar is not automatically approved for use as low beam, high beam or supplementary high-beam function. If the excavator is being moved on public roads, check that the headlights used are approved for their specific driving light function.

Use work lights only to illuminate the work area and avoid dazzling other road users or staff.

Which light pattern is best suited to an excavator?

When it comes to additional work lights, a number of factors are important. More lumen do not automatically mean better visibility. The light distribution, beam width, mounting angle and distance to the work area are just as important. A powerful light that is incorrectly positioned can actually cause glare, cast harsh shadows or be reflected off the machine. You can choose from:

• Flood: for a wide working area at short to medium distances.
• Spotlight: for a narrower area at a greater distance.
• Combo: when both width and extra reach are required.

The mounting position and application remain key factors. Read more about this consideration in the article on the correct light image for work lights.

Plug-and-play lighting for mini-excavators

TRALERT® has developed a ready-to-fit, plug lighting set specifically for mini-excavators. Ideal if you’re looking for greater convenience and excellent lighting that, of course, meets all certifications. The kit includes compact front and rear lights with integrated indicators, licence plate light, a central junction box and a pre-programmed control unit.

Technical requirements for excavator lighting

It is not just the type of light that determines whether the lighting functions properly. The on-board voltage, connection, IP rating, vibration resistance and electromagnetic compatibility are also important.

Vehicle voltage and connection

Not every excavator operates on 24V. Many larger machines use a 24V system, whilst compact excavators can also operate on 12V. You should therefore always check:

• the nominal on-board voltage;
• the permitted voltage range of the light;
• potential voltage spikes;
• the total power requirement;
• the required cable diameter and fuse;
• the use of a relay or controller;
• the sealing of cables and connectors.

A multi-voltage work light may be suitable for both 12V and 24V systems, but always check the specified voltage range for the product in question.

IP protection and high-pressure cleaning

The IP rating indicates the degree to which a housing provides protection against dust and water. However, the different codes correspond to different tests:

• IP67: protection against temporary immersion in accordance with the relevant truck conditions;
• IP68: protection against prolonged immersion under conditions specified for the product;
• IP6K9K: dust-tight and tested in accordance with ISO 20653 for protection against the effects of high-pressure and steam jet cleaning.

An IP67 or IP68 rating does not automatically guarantee protection against high-pressure washing. If you regularly clean your excavator with a high-pressure washer, you should preferably choose lighting that has been demonstrably tested for this purpose. Do not direct the jet at seals, cable entries and connectors for an unnecessarily long time or from a very short distance.

You can find further details in the comprehensive guide to IP values and on the information page about IP69K.

Vibrations, shocks and physical stress

Excavators place high demands on lights, mounting brackets, cables and connectors. The lighting is subjected to prolonged vibrations, impacts during excavation and demolition work, stone chips, mud, corrosion and potential contact with rubble or moving parts.

Materials such as cast aluminium, polycarbonate and stainless steel can contribute to a robust design, but are no guarantee of quality in themselves. The design, material thickness, sealing, mounting and substantiated truck results are also decisive factors.

So please check for:

• specified shock and vibration tests;
• sturdy and suitable mounting brackets;
• securing bolts and fasteners;
• strain relief at cable entry points;
• protected cable routes;
• waterproof and suitable connectors.

EMC, radio and GNSS machine control

LED lighting can produce electromagnetic emissions. If not adequately shielded, these emissions may interfere with radio and communication systems. For excavators fitted with GNSS or GPS machine control systems, it is advisable to also take into account sensitive satellite reception and correction signals.

Whether interference actually occurs depends not only on the light, but also on the cabling, mounting and the machine’s overall configuration. A CE marking is not an independent quality mark and, on its own, says little about the extent to which a light may interfere with radio or GNSS signals. An ECE R10 approval demonstrates that the product has been assessed in accordance with established EMC requirements, but does not guarantee that completely interference-free operation is possible in every machine configuration.

Does the excavator use sensitive electronics, communication equipment or GNSS machine control systems? If so, ask for demonstrable EMC performance. In the case of a claim based on CISPR 25, factors such as the truck method used, the frequency ranges tested and the emission class achieved are important. Read more about EMC interference suppression and CISPR 25 in vehicle lighting.

Do you experience static, crackling or a loss of reception as soon as you switch on the lighting? Find out how to investigate and resolve radio interference caused by LED lighting.

CAN-bus and lamp monitoring

Not every excavator monitors the load on its lighting system. Furthermore, additional work lights are often connected via a separate, fused circuit and a relay or controller . On some modern machines, replacing monitored halogen lighting with LEDs can cause an error message, flashing indicators or a failure.

You should therefore check whether the relevant circuit uses lamp monitoring and whether a suitable interface, control box or other modification is required. Individual resistances are not automatically the best solution. You can find further explanation in the article on CAN bus issues with LED lighting.

Common mistakes with excavator lighting

• Don’t just look at the number of lumen ;
• using a single very powerful light instead of distributing the light effectively;
• choosing the wrong light image for the distance and work area;
• position the lights so that the light reflects off the boom, bucket or cab;
• failing to take sufficient account of moving machine parts;
• Do not confuse IP67 with protection against high-pressure washing;
• Ignoring EMC performance in relation to radio, communication or GNSS machine control;
• using mounting brackets that are too light or not securely fastened;
• running cables unprotected alongside moving parts;
• do not monitor the on-board voltage, current draw or lamp status;
• Do not confuse work lights with approved road lights.

Checklist for selection and fitting

Before selecting and fitting the lighting, please check the following points:

• Determine which function the light should fulfil for each work zone.
• Check the on-board voltage and the voltage range of the light.
• Calculate the total current requirement and select the fuse and cable diameter accordingly.
• Choose the light image based on the width and distance of the work area.
• Select the IP rating based on the operating and cleaning conditions.
• Check the available information on shock and vibration testing.
• Use sturdy, suitable and securely fastened mounting brackets.
• Install cables in a protected manner and use strain relief and suitable connectors.
• Check the EMC performance when using radio, communication or GNSS.
• Check whether the circuit has a bulb monitoring function and whether an interface is required.
• Keep work lights and approved driving lights separate.
• Check the mounting position for reflections and moving parts.

Frequently asked questions about excavator lighting

What lighting is essential on an excavator?

A complete lighting plan may consist of work lights at the front, sides, boom and rear, supplemented by reversing lights, signalling lights, cab lighting and approved driving lights. The combination required depends on the machine, the work being carried out and the working environment.

Is an excavator always 24 Volts?

No. Many larger excavators operate on 24 V, but compact excavators may also have a 12V system. Always check the nominal on-board voltage and the permitted voltage range of the light. Multi-voltage LED work lights may be suitable for both systems.

Which work light is suitable for mounting on the boom?

This depends on the distance to the work area, the mounting position and the type of work. A flood work light is suitable for a wider area at a shorter distance. A focused beam can be useful for a more distant or specific work area. Always check that the light does not cause glare or reflections when the boom is in different positions.

Which IP value is suitable for high-pressure cleaning?

If you regularly clean the machine with a high-pressure washer, you should preferably choose lighting that has been demonstrably tested against high-pressure and steam jet cleaning, such as IP6K9K in accordance with ISO 20653. IP67 and IP68 relate to other forms of water exposure and do not automatically guarantee this level of protection.

Can LED lighting interfere with GPS machine control systems?

Inadequately shielded LED lighting can cause electromagnetic emissions that interfere with radio, communication or GNSS signals. Whether this occurs depends on the light and the entire installation. For sensitive machine control systems, choose lighting with proven EMC performance and carefully check ECE R10 and any CISPR 25 claims.

Can halogen lighting be replaced directly with LED lighting?

This is often possible, but not always without additional checks. Pay attention to the on-board voltage, connections, mounting and light distribution. In a monitored lighting circuit, the lower load of LEDs can also cause an error message, flashing or failure. In such cases, a suitable interface or control box may be required.

Help with choosing excavator lighting

Not sure which combination of work lights, signalling lights and driving lights suits your machine and your operations? TRALERT® is happy to advise you on matters such as the light image, on-board voltage, EMC, connections and mounting.

Browse our range of professional LED work lights, discover the Apex Series or read more about our lighting for specialised vehicles and machinery. For a complete solution, please request a no-obligation consultation.