Procedure to Install LED Lights on AD30 Underground Articulated Trucks{1429, 1434} Caterpillar


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Procedure to Install LED Lights on AD30 Underground Articulated Trucks{1429, 1434} [REHS9512]
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:
AD30 (S/N: DXR1-UP; GXR1-UP)

Introduction

This special instruction covers the procedure to install LED lights on the above AD30 S/N:DXR and AD30 S/N:GXR 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, RENR6919, "AD30 Underground Articulated Truck Machine Systems".

ReferenceDisassembly and Assembly, UENR4812, "AD30 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    
4     3D-9871     Plug Button    
9     460-2514     Bracket As    
1     471-6594     Harness As    
27     8T-4121     Hard Washer    
9     8T-4136     Bolt    

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 2g03743449

    Head lamp assembly

    (2) 2Y-5829 Nut

    (3) 8T-4121 Hard Washer

    (4) 160-8492 Bolt

    (5) 460-2514 Bracket As

    (6) 386-1717 Head Lamp

  1. Assemble two head lamps. Refer to Illustration 2.



    Illustration 3g03743446

    (7) 471-6594 Harness As

  1. Connect 471-6594 Harness As (7) to one head lamp assembled in Step 2.

LED Light (Front) - Install




    Illustration 4g03718737

    View of the front of the machine

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



    Illustration 5g03718741

    View of the right side front of the machine

    (3) 12 mm (0.45 inch)

    (A) 45 mm (1.75 inch)

  1. Drill two holes (3). Refer to Illustration 5.

  1. Repeat Step 2 for the left side of the machine.

  1. Install four 3D-9871 Plug Buttons into the holes where head lamps (1) and flood lamps (2) were removed. Refer to Illustration 4.



    Illustration 6g03718760

    View of the front of the machine

    (4) 8T-4136 Bolt

    (5) 8T-4121 Hard Washer

    (6) 386-1717 Head Lamp

    (7) 383-8634 Flood Lamp

  1. Install two 386-1717 Head Lamps (6) and two 383-8634 Flood Lamps (7), using Item (4) and Item (5) .

    Note: Install the 386-1717 Head Lamp with the 471-6594 Harness As connected, to the right side of the machine.

LED Light (Rear) - Install




    Illustration 7g03719502

    View of the rear of the machine

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



    Illustration 8g03719503

    Rear lamp mount

    (2) 12 mm (0.50 inch)

    (A) 45 mm (1.75 inch)

  1. Drill two holes (2). Refer to Illustration 8.



    Illustration 9g03719504

    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) .

    Note: Connect the harness to each lamp.

LED Light (Operators Station) - Install




    Illustration 10g03718115

    View of the rear of the operators station

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



    Illustration 11g03718120

    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) .

    Note: Connect the harness to each lamp.

LED Light (Right Side) - Install




    Illustration 12g03719512

    View of the right side of the machine

  1. Remove and discard flood lamp (1) .



    Illustration 13g03719514

    View of the right side of the machine

    (2) 383-8634 Flood Lamp

    (3) 8T-4136 Bolt

    (4) 8T-4121 Hard Washer

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

    Note: Connect the harness to the lamp.

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