Procedure to Install LED Lights on R1600G and R1600H Load Haul Dump Machines {1429} Caterpillar

Load Haul Dump

R1600G (S/N: 9YZ1-UP)

R1600H (S/N: 9SD1-231)

Introduction

This special instruction covers the procedure to install LED lights on the above R1600G and R1600H Load Haul Dump machines. 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 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. Caterpillar 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 Caterpillar. 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.

Reference: Disassembly and Assembly, KENR8508, "R1600G Load Haul Dump Machine Systems"

Reference: Disassembly and Assembly, UENR1457, "R1600H Load Haul Dump Machine Systems"

Parts Required

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.

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

3. Stop the engine.

4. Install the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Remove and Install".

5. 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

1. Remove and discard existing lamp assemblies.

Illustration 1	g03862978
450-4583 Harness As

Note: This harness referenced in the below procedure.

Rear LED Lamps - Install

Assemble two of the following.

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Illustration 2	g03862974
(1) 386-1717 Head Lamp Gp (2) 6V-7744 Locknut (3) 8T-4121 Hard Washer (4) 8T-4178 Bolt (5) Bracket assembly (6) 383-8634 Flood Lamp Gp (7) 484-6959 Bracket As

1. Remove and discard bracket assembly (5) from 386-1717 Head Lamp Gp (1) and 383-8634 Flood Lamp Gp (6).

2. Install 386-1717 Head Lamp Gp (1) and 383-8634 Flood Lamp Gp (6) to 484-6959 Bracket As (7) using Item (2) through Item (4).
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   Illustration 3	g03862976
   (1) 386-1717 Head Lamp Gp (3) 8T-4121 Hard Washer (6) 383-8634 Flood Lamp Gp (8) 8T-4196 Bolt

3. Install the assembled lamps from Step 2 using two 8T-4121 Hard Washers (3) and two 8T-4196 Bolts (8).

4. Connect a 450-4583 Harness As between each lamp and the machine harness. Refer to Illustration 1.

5. Repeat Step 3 and Step 4 for the other side of the machine.

Operator Station LED Lamps - Install

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Illustration 4	g03862979
(1) 386-1723 Head Lamp Gp

1. Install two 386-1723 Head Lamp Gp (1). Connect the machine harness to each lamp.
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   Illustration 5	g03862983
   R1600G only View of the operator station lower flood lamp mount (A) 40 mm (1.60 inch) (B) Diameter 11 mm (0.45 inch)

2. For the R1600G machine only, drill one hole (B) in the operator station lower flood lamp mount.

   Note: This may require drilling from inside the operator station.

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   Illustration 6	g03862985
   (2) 386-1722 Flood Lamp Gp

3. Install 386-1722 Flood Lamp Gp (2). Connect the machine harness to the lamp.

Front frame Lamp - Install

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Illustration 7	g03863530
(1) Guard assembly

1. Remove guard assembly (1). Retain the bolts and the washers for assembly purposes.
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   Illustration 8	g03863533
   View of the front frame (1) Guard assembly (2) Head lamp mount (A) 55 mm (2.25 inch) (B) Diameter 11 mm (0.45 inch)

2. Drill one hole (B) in guard assembly (1), and one hole (B) in head lamp mount (2).
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   Illustration 9	g03851808
   (3) 386-1717 Head Lamp Gp (4) Bracket assembly (5) 460-2514 Bracket As (6) 160-8492 Bolt (7) 2Y-5829 Nut (8) 8T-4121 Hard Washer

3. Remove and discard bracket assembly (4), the bolts, the washers, and the locknuts from 386-1717 Head Lamp Gp (3).

4. Install Item (5) through Item (8) to 386-1717 Head Lamp Gp (3).
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   Illustration 10	g03863538
   (1) Guard assembly (3) 386-1717 Head Lamp Gp (9) 8T-4195 Bolt (10) 8T-4121 Hard Washer

5. Install guard assembly (1) and 386-1717 Head Lamp Gp (3) using Item (9), Item (10), and the bolts and the washers retained in Step 1.

6. Connect the machine harness to 386-1717 Head Lamp Gp (3).

Lift Arm Lamps - Install

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Illustration 11	g03863540
(1) Guard assembly (2) Guard assembly

1. Remove guard assembly (1) and guard assembly (2). Retain the bolts, the washers, and the clips for assembly purposes.
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   Illustration 12	g03863544
   (A) 55 mm (2.20 inch) (B) Diameter 11 mm (0.45 inch)

2. Drill one hole (B) in each guard assembly that was removed in Step 1.
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   Illustration 13	g03851808
   (3) 383-8634 Flood Lamp Gp (4) Bracket assembly (5) 460-2514 Bracket As (6) 160-8492 Bolt (7) 2Y-5829 Nut (8) 8T-4121 Hard Washer

3. Remove and discard bracket assembly (4), the bolts, the washers, and the locknuts from 383-8634 Flood Lamp Gp (3).

4. Install Item (5) through Item (8) to 383-8634 Flood Lamp Gp (3).
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   Illustration 14	g03863559
   (1) Guard assembly (2) Guard assembly (3) 383-8634 Flood Lamp Gp (8) 8T-4121 Hard Washer (9) 8T-4137 Bolt

5. Install guard assembly (1) and guard assembly (2) using the bolts, the washers, and the clips retained in Step 1.

6. Install Item (3) through Item (9) to each guard assembly.

7. Connect a 450-4583 Harness As between each lamp and the machine harness. Refer to Illustration 1.