- Underground Articulated Truck:
- AD55 (S/N: DNW1-UP)
- AD55B (S/N: JNW1-UP)
- AD60 (S/N: KNW1-UP)
- AD55B (S/N: JNW1-UP)
Introduction
This special instruction covers the procedure to install LED lights on the above AD55, AD55B, and AD60 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.
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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. |
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ReferenceDisassembly and Assembly, RENR8512, "AD55 Underground Articulated Truck Machine Systems"
ReferenceDisassembly and Assembly, KENR6709, "AD55B Underground Articulated Truck Machine Systems"
ReferenceDisassembly and Assembly, UENR2741, "AD60 Underground Articulated Truck Machine Systems"
Parts Required
| Parts Required | ||
| Qty | Part Number | Part Description |
| 2 | 102-8802 | Receptacle Kit |
| 2 | 130-5300 | Clip |
| 9 | 160-8492 | Bolt |
| 11 | 2Y-5829 | Nut |
| 7 | 383-8634 | Flood Lamp Gp |
| 2 | 386-1717 | Head Lamp Gp |
| 9 | 460-2514 | Bracket As |
| 1 | 461-0955 (1) | Cover As |
| 1 | 462-2139 (2) | Cover As |
| 3 | 471-6594 | Wiring Harness |
| 33 | 8T-4121 | Hard Washer |
| 13 | 8T-4136 | Bolt |
| 4 | 8T-8737 | Seal Plug |
| ( 1 ) | S/N:JNW and ; S/N:KNW Machines only |
| ( 2 ) | S/N:DNW Machines only |
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.
- Move the machine to a hard level surface away from operating machines and away from personnel.
- Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.
- Stop the engine.
- Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".
- 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
- Assemble seven flood lamps. Refer to Illustration 1.
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| Illustration 1 | g03715729 |
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 | |
- Assemble two head lamps. Refer to Illustration 2.
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| Illustration 2 | g03743449 |
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 | |
- Connect two 471-6594 Harness As (7) to the two head lamp assemblies and to one flood lamp assembly.
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| Illustration 3 | g03743446 |
(7) 471-6594 Harness As | |
LED Light (Front) - Install
- Remove and discard two head lamps (1) and two flood lamps (2) .
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| Illustration 4 | g03719538 |
- Drill two holes (3). Refer to Illustration 5.
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| Illustration 5 | g03719541 |
View of the right side front of the machine (3) 12 mm (0.45 inch) (A) 60 mm (2.40 inch) | |
- Repeat Step 2 for the left side of the machine.
- Cut four notches (4). Refer to Illustration 6 and Illustration 7.
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| Illustration 6 | g03721505 |
View of the right inside radiator guard (B) 15 mm (0.60 inch) (C) Radius 5 mm (0.20 inch) (D) 245 mm (9.60 inch) (E) 195 mm (7.70 inch) (F) 75 mm (2.95 inch) (G) 25 mm (1.0 inch) | |
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| Illustration 7 | g03721506 |
View of the left inside radiator guard (H) 15 mm (0.60 inch) (J) 370 mm (14.50 inch) (K) 320 mm (12.60 inch) (L) 195 mm (7.70 inch) (M) 145 mm (5.70 inch) (N) Radius 5 mm (0.20 inch) | |
- Install two 386-1717 Head Lamps (5) and two 383-8634 Flood Lamps (8), using Item (6) and Item (7) .
Note: Ensure two 386-1717 Head Lamps (5) are fitted with two 471-6594 Harness As . Refer to Illustration 3.
Note: Connect the machine harness to each lamp.
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| Illustration 8 | g03719543 |
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 | |
LED Light (Rear) - Install (Dump Body)
- Remove and discard four rear flood lamps (1) .
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| Illustration 9 | g03720276 |
View of the rear of a dump body machine | |
- Drill two holes (2). Refer to Illustration 10.
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| Illustration 10 | g03720277 |
Rear lamp mount (2) 12 mm (0.50 inch) (A) 65 mm (2.60 inch) (B) 167 mm (6.60 inch) | |
- Install two 383-8634 Flood Lamps (3), using Item (4) and Item (5) .
Note: Connect one of the machine harness connectors to each lamp.
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| Illustration 11 | g03720278 |
View of the rear of the machine (3) 383-8634 Flood Lamp (4) 8T-4136 Bolt (5) 8T-4121 Hard Washer | |
- Install Item (8) through Item (11) .
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| Illustration 12 | g03722308 |
View of the right side rear flood lamp (6) 102-8802 Receptacle Kit (7) 8T-8737 Seal Plug (8) 130-5300 Clip (9) 8T-4136 Bolt (10) 8T-4121 Hard Washer (11) 2Y-5829 Nut | |
- Install Item (6) and Item (7) to the second harness connector, and install the connector to 130-5300 Clip (8) .
- Repeat Step 4 and Step 5 for the left side of the machine.
LED Light (Rear) - Install (Ejector Body)
- Remove and discard four rear flood lamps (1) .
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| Illustration 13 | g03722301 |
View of the rear of an ejector body machine | |
- Drill one hole (2). Refer to Illustration 14.
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| Illustration 14 | g03722302 |
View of the right side rear lamp mount (2) 12 mm (0.50 inch) (A) 50 mm (2.0 inch) | |
- Repeat Step 2 for the left side rear lamp mount.
- Install 383-8634 Flood Lamp (3), using Item (4) and Item (5) .
Note: Connect one of the machine harness connectors to the lamp.
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| Illustration 15 | g03722306 |
View of the right side rear of the machine (3) 383-8634 Flood Lamp (4) 8T-4136 Bolt (5) 8T-4121 Hard Washer | |
- Repeat Step 4 for the left side of the machine.
- Install one 130-5300 Clip (8) .
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| Illustration 16 | g03722307 |
View of the right side rear of the machine (6) 102-8802 Receptacle Kit (7) 8T-8737 Seal Plug (8) 130-5300 Clip | |
- Install Item (6) and Item (7) to the second harness connector, and install the connector to 130-5300 Clip (8) .
- Repeat Step 6 and Step 7 for the left side of the machine.
LED Light (Operators Station) - Install
- Remove and discard flood lamp (1) and flood lamp (2). Refer to Illustration 17 and Illustration 18.
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| Illustration 17 | g03720279 |
View of the left side of the operators station | |
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| Illustration 18 | g03720280 |
Typical example View of the right side of the operators station | |
- Install two 383-8634 Flood Lamps (3), using Item (4) and Item (5). Refer to Illustration 19 and Illustration 20.
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| Illustration 19 | g03721094 |
View of the left side of the operators station (3) 383-8634 Flood Lamp (4) 8T-4136 Bolt (5) 8T-4121 Hard Washer | |
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| Illustration 20 | g03721095 |
Typical example View of the right side of the operators station (3) 383-8634 Flood Lamp (4) 8T-4136 Bolt (5) 8T-4121 Hard Washer | |
LED Light (Right Side) - Install
- Remove and discard flood lamp (1) and cover assembly (2) .
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| Illustration 21 | g03719544 |
View of the right side of the machine | |
- Install 383-8634 Flood Lamp (3) and cover assembly (4), using Item (5) and Item (6) .
Note: Install 383-8634 Flood Lamp (3) with the 471-6594 Harness As installed.
Note: Ensure the correct cover assembly (4) is installed.
Note: Connect the machine harness to the lamp.
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| Illustration 22 | g03719545 |
View of the right side of the machine (3) 383-8634 Flood Lamp (4) 461-0955 Cover As (S/N:JNW and ; S/N:KNW Machines) (4) 462-2139 Cover As (S/N:DNW Machines) (5) 8T-4136 Bolt (6) 8T-4121 Hard Washer | |