Procedure to Install LED Lights on AD45B Underground Articulated Trucks{1429, 1434} Caterpillar


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Procedure to Install LED Lights on AD45B Underground Articulated Trucks{1429, 1434} [REHS9511]
ELECTRICAL AND STARTING SYSTEM
LIGHTING GP
1.1. Introduction
2.1. Safety Section
3.1. Parts Required
4.1. Machine Preparation
5.1. Procedure
6.2. LED Light - Assemble
7.2. LED Light (Front) - Install
8.2. LED Light (Rear) - Install
9.2. LED Light (Operators Station) - Install
10.2. LED Light (Right Side) - Install
Underground Articulated Truck:
AD45B (S/N: CXM1-UP)

Introduction

This special instruction covers the procedure to install LED lights on the above AD45B S/N:CXM Underground Articulated Trucks. This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.

Read the entire Special Instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.

Safety Section

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. AVSpare cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by AVSpare. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

------ WARNING! ------

Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock between the front and rear frames before working on the machine.

Before operating the machine, place the steering frame lock in the stored position.

Failure to place the steering frame lock into the stored position before operating can result in loss of steering.

----------------------

ReferenceDisassembly and Assembly, RENR8576, "AD45B Underground Articulated Truck Machine Systems"

Parts Required

Table 1
Parts Required    
Qty     Part Number     Part Description    
9     160-8492     Bolt    
9     2Y-5829     Nut    
7     383-8634     Flood Lamp Gp    
2     386-1717     Head Lamp Gp    
9     460-2514     Bracket As    
1     462-2139     Cover As    
5     471-6594 (1) (2)     Harness As    
29     8T-4121     Hard Washer    
11     8T-4136     Bolt    
( 1 ) Five required if the machine is fitted with the Truck Payload Measurement System (TPMS)
( 2 ) Four required if the machine is not fitted with the Truck Payload Measurement System (TPMS)

Machine Preparation

Note: Cleanliness is an important factor. Before the removal procedure, clean the exterior of the component thoroughly. Cleaning the exterior will help to prevent dirt from entering the internal mechanism.

  1. Move the machine to a hard level surface away from operating machines and away from personnel.

  1. Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.

  1. Stop the engine.

  1. Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".

  1. Turn the key start switch and the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.

Procedure

LED Light - Assemble




    Illustration 1g03715729

    Flood lamp assembly

    (1) 383-8634 Flood Lamp

    (2) 2Y-5829 Nut

    (3) 8T-4121 Hard Washer

    (4) 160-8492 Bolt

    (5) 460-2514 Bracket As

  1. Assemble seven flood lamps. Refer to Illustration 1.



    Illustration 2g03731576

    (6) 471-6594 Harness As

  1. For machines fitted with the Truck Payload Measurement System (TPMS), connect three 471-6594 Harness As (6) to three flood lamp assemblies.

    Note: For machines not fitted with the Truck Payload Measurement System (TPMS), connect two 471-6594 Harness As (6) to two flood lamp assemblies.




    Illustration 3g03715731

    Head lamp assembly

    (2) 2Y-5829 Nut

    (3) 8T-4121 Hard Washer

    (4) 160-8492 Bolt

    (5) 460-2514 Bracket As

    (7) 386-1717 Head Lamp

  1. Assemble two head lamps. Refer to Illustration 3.

  1. Connect two 471-6594 Harness As (6) to two head lamp assemblies. Refer to Illustration 2.

LED Light (Front) - Install




    Illustration 4g03715733

    View of the front of the machine

  1. Remove and discard two head lamps (1) and two flood lamps (2) .



    Illustration 5g03715736

    View of the right side front of the machine

    (3) 10.5 mm (0.40 inch)

    (A) 45 mm (1.75 inch)




    Illustration 6g03715737

    View of the left side front of the machine

    (3) 10.5 mm (0.40 inch)

    (A) 45 mm (1.75 inch)

  1. Drill four holes (3). Refer to Illustration 5 and Illustration 6.



    Illustration 7g03715756

    View of the right side front of the machine

    (B) 15.0 mm (0.60 inch)

    (C) 35 mm (1.40 inch)

    (D) 90 mm (3.50 inch)

    (E) 90 mm (3.50 inch)

    (F) 30 mm (1.20 inch)

    (G) Radius 5 mm (0.20 inch)




    Illustration 8g03715766

    View of the left side front of the machine

    (G) Radius 5 mm (0.20 inch)

    (H) 345 mm (13.50 inch)

    (J) 290 mm (11.40 inch)

    (K) 175 mm (6.90 inch)

    (L) 120 mm (4.70 inch)

    (M) 15 mm (0.60 inch)

  1. Cut four notches (4). Refer to Illustration 7 and Illustration 8.



    Illustration 9g03715773

    View of the front of the machine

    (5) 386-1717 Head Lamp

    (6) 8T-4136 Bolt

    (7) 8T-4121 Hard Washer

    (8) 383-8634 Flood Lamp

  1. Install two 386-1717 Head Lamps (5) and two 383-8634 Flood Lamps (8), using Item (6) and Item (7) .

    Note: Use lamps with the 471-6594 Harness As installed. Refer to Illustration 2.

LED Light (Rear) - Install




    Illustration 10g03716939

    View of the rear of the machine

  1. Remove and discard two rear flood lamps (1) .



    Illustration 11g03716942

    Rear lamp mount

    (2) 12 mm (0.50 inch)

    (A) 45 mm (1.75 inch)

  1. Drill two holes (2). Refer to Illustration 11.



    Illustration 12g03716948

    View of the rear of the machine

    (3) 383-8634 Flood Lamp

    (4) 8T-4136 Bolt

    (5) 8T-4121 Hard Washer

  1. Install two 383-8634 Flood Lamps (3), using Item (4) and Item (5) .

LED Light (Operators Station) - Install




    Illustration 13g03718115

    View of the rear of the operators station

  1. Remove and discard two flood lamps (1) .



    Illustration 14g03718120

    View of the rear of the operators station

    (2) 8T-4136 Bolt

    (3) 8T-4121 Hard Washer

    (4) 383-8634 Flood Lamp

  1. Install two 383-8634 Flood Lamps (4), using Item (2) and Item (3) .

LED Light (Right Side) - Install




    Illustration 15g03718128

    View of the right side of the machine

  1. Remove and discard flood lamp (1) and cover assembly (2) .



    Illustration 16g03718130

    View of the right side of the machine

    (3) 383-8634 Flood Lamp

    (4) 8T-4136 Bolt

    (5) 8T-4121 Hard Washer

    (6) 462-2139 Cover As

  1. Install 383-8634 Flood Lamp (3) and 462-2139 Cover As (6), using Item (4) and Item (5) .

    Note: If the machine is fitted with the Truck Payload Measurement System (TPMS), use a lamp with the 471-6594 Harness As installed. Refer to Illustration 2.

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