Installation of Factory Ordered High Intensity Discharge Lights{1429, 1434} Caterpillar

Track-Type Tractor:

D10R (S/N: AKT1-UP)

D11R (S/N: AAF1-UP; 7PZ1-UP)

Introduction

This Special Instruction provides the procedures to install the High Intensity Discharge lights (HID). The lights are optional on a new tractor. HID lamps produce a light intensity that is equal to four 65 watt halogen lamps. Also, HID lamps are more efficient than halogen lamps. Refer to Special Instruction, REHS1248 for information about electrical requirements and service repair.

Note: The detailed location of cable straps is covered at the end of this Special Instruction.

Illustration 1	g00994637
Two HID lamps are mounted to the lift cylinders. Two halogen lamps are also mounted to the lift cylinders.

Illustration 2	g00994645
Three HID lamps are mounted to the ROPS.

After the installation procedure is complete, prepare the machine for operation. Refer to your machine's Operation and Maintenance Manual for instructions.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

Required Parts

The following parts will be shipped with your tractor.

Installation Procedures

Note: All torques that are not specified are standard torques.

Note: The harness should be secured with cable straps in order to prevent damage to the harness.

Lights on the Lift Cylinders

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Illustration 3	g01274204
(A) Existing light harness on the cylinder

1. Install spray shields (2) with two bolts (3) and two washers (4) on each shield. Refer to Illustration 3. Do not torque the bolts at this time.

2. Install harnesses (A) through grommet (5) on each shield.

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Illustration 4	g01274289

3. Lift spray shields (2) into position on the lift cylinders and install the remaining two bolts (3) and washers (4) on each shield. Tighten four bolts on each shield to the standard torque.

4. Follow Steps 4.a through 4.d in order to install the HID lamps on the lift cylinders. The HID lamps are mounted to the side of the spray shield that faces away from the centerline of the tractor.
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   Illustration 5	g01274474
   HID light guard on the left lift cylinder

   1. Install the following components on the left spray shield:
      • Guard (9)

      • Four rubber mounts (6)

      • Eight washers (7)

      • Eight nuts (8)

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   Illustration 6	g01274478
   HID light on the left lift cylinder (A) Existing light harness on the cylinder

   2. Install lamp assembly (10) to the top of guard (9) with one bolt (11) and one washer (4) .

   3. Connect harness (A) to the lamp assembly. Secure the harness with cable straps (1) .

   4. Repeat Steps 4.a through 4.c for the right spray shield.

5. Install support bracket (12) with four bolts (13), four nuts (8), and eight washers (7) on each spray shield. Refer to Illustration 6.

Lights on the ROPS

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Illustration 7	g01274480
View from the rear of the tractor

1. Install harness (14) on the ROPS. Harness (15) will already be installed on the machine. Route harness (14) through grommets (16) .

2. Secure the harnesses with cable straps (1). Install plate (17) on the left ROPS post with two bolts (18) and two washers (19) .

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Illustration 8	g01274482

3. Install the following components on the top of the ROPS:
   • Bracket (20)

   • four bolts (21)

   • four nuts (8)

   • eight washers (7)

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Illustration 9	g01274649

5. Install two brackets (26) on bracket (20) with four bolts (23) and four washers (7) .

6. Install guard (9) on brackets (26) with four rubber mounts (6), eight washers (7), and eight nuts (8) .

7. Install lamp assembly (10) to the top of guard (9) with one bolt (11) and one washer (4) .

8. Connect harness (14). Secure the harness with cable ties (1) .

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Illustration 10	g01274522

9. Install two mounting brackets (22) on the sides of the ROPS. Use four bolts (23) and four washers (7) on each bracket.

   Note: These lights will be facing forward to the outside edges of the blade.

10. Install left glare shield (24) and right glare shield (25) on mounting brackets (22). Use four bolts (23) and four washers (7) on each glare shield.

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Illustration 11	g01274542

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Illustration 12	g01385546
The location of the four hole bolt patterns.

11. Install the light guard (9) to the left hand side of the tractor with the following components to (22) mounting bracket:
    • four rubber mounts (6)

    • eight washers (7)

    • eight nuts (8)

12. Install lamp assemblies (10) to the top of guards (9) with one bolt (11) and one washer (4) on each light.

13. Secure the harnesses with cable straps (1) .

14. Repeat steps 11 through 12 for the right hand side.

15. Connect harness (14). Use cable straps (1) in order to secure the harness.

Installation of the Cable Straps

The cable straps (1) will be applied to the following locations during the installation of the lights.

• Right side Lift Cylinder

• Left side Lift Cylinder

• Bottom of the frame for the ROPS

• Rear of the cab attached to the frame for the ROPS.

• Left side Vertical frame of the ROPS

• Left side rear bracket for the light

• Right side rear bracket for the light

Illustration 13	g01409540
The Top view of the left lift hydraulic cylinder. Typical location of the cable strap

Illustration 14	g01409542
The top view of the right lift hydraulic cylinder. Typical location of the cable straps

Illustration 15	g01409590
Left side view of the right lift hydraulic cylinder. Typical locations of the cable straps

Illustration 16	g01409591

Illustration 17	g01409625
Typical location of the cable strap on the bottom of the ROPS

Illustration 18	g01409628
Typical location of the cable strap on the vertical left hand side of the ROPS

Illustration 19	g01417138
The connection between the main wiring harness and the wiring harness for the ROPS

Illustration 20	g01440866
Close up view of the connections

Illustration 21	g01409631
The location of the rear light. Typical location of cable straps

Illustration 22	g01416681
Right side bottom of the ROPS

Illustration 23	g01397529
The light is mounted forward on the left side of the cab. Typical locations for the cable straps

Illustration 24	g01386941
The light is mounted forward on the right side of the cab. Typical locations for the cable straps