1994/11/14 Caterpillar

New 24 Volt Halogen Lamp Groups And Lamp Guards Available{1429}

Usage:

D4H (8PB4000-UP, 9DB4000-UP, 2AC4000-UP, 3AC4000-UP, 8PJ, 9GJ, 4NK),
D5H (7NC4000-UP, 8RC4000-UP, 9HC4000-UP, 1DD4000-UP, 1YD4000-UP, 2SD4000-UP, 3MD4000-UP, 4KD4000-UP, 8RJ),
D6H (4RC5500-UP, 6FC5500-UP, 8FC5500-UP, 1KD5500-UP, 2KD5500-UP, 3ED5500-UP, 3ZF5500-UP, 4YF5500-UP, 5HF5500-UP, 6CF5500-UP, 2TG5500-UP, 3YG5500-UP, 4GG5500-UP, 4LG5500-UP, 1FJ5500-UP, 2DK5500-UP, 8ZJ, 9KJ, 5KK, 6CK, 7ZK, 8KK, 8SK, 9LK, 9RK, 1YL, 2BL, 2TL),
D7H (4AB4000-UP, 5WB4000-UP, 5BF4000-UP, 2RG4000-UP, 3XG4000-UP, 4FG4000-UP, 79Z4000-UP, 80Z4000-UP),
D8N (5TJ, 7TK),
D9N (6XJ),
D10N (3SK),
D11N (4HK) Track-Type Tractors;
D4H (7PK),
D5H (7EG) Track Skidders

SUPPLEMENT: 05/01/95

Service Magazine; November 14, 1994; Page 8; "New 24 Volt Halogen Lamp Groups And Lamp Guards Available" for D4H, D5H, D6H, D7H, D8H, D9N, D10N, D11N Track-Type Tractors; D4H, D5H Track Skidders.

The new lamp groups and lamp guards are effective with D4H (8PB6171, 2AC5598, 8PJ774, 9GJ1240, 4NK175), D5H (8RC5930, 1DD5943, 1YD5524, 2SD5572, 3MD5622, 4KD5623, 8RJ4293), D6H (4RC5706, 6FC5578, 1KD5617, 2KD5643, 3ZF6028, 4YF5590, 5HF5548, 6CF5552, 3YG5996, 4GG5667,4LG5589, 8ZJ329, 9KJ724, 5KK345, 6CK386, 7ZK354, 8SK379, 9RK316, 2TL349), D7H (4AB5547, 5WB5588, 5BF5828, 2RG5637, 3XG5522, 4FG5604, 79Z5759, 80Z5521), D8N (5TJ2025, 7TK439), D9N (6XJ904), D10N (3SK693), D11N (4HK499) Track-Type Tractors; D4H (7PK167), D5H (7EG1136) Track Skidders.

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Description of Change: New 24 volt halogen lamp groups are now available for the machines listed above.

Adaptable To: Improvements have been made to provide a lamp with more light output and increased bulb life. Also, the lamp mounts have been improved to lower the vibration input to the lamps. This decreased exposure to vibration leads to improved service life of the lamps.

Either improvement can be used to to improve the overall life of the lamps on Track-Type Tractors; however, maximum bulb-life is achieved when both improvements are implemented. The lamp mounting improvements can be accomplished by either modifying existing parts or by installing new parts.

NOTE: Anytime halogen lamps with replaceable bulbs are adjusted or repaired; make sure that the lamp case has ample room [12.7 mm - 19.1 mm (.5 in - .75 in)] between the lamp and lamp guard when the lamps are re-installed. This spacing allows the lamps to flex without being damaged.

When installing new bulbs, be sure NOT to touch the glass of the bulb. Oils naturally present on your hands cause hot spots and possible early failure of the bulb. If the bulb glass has been touched, use a soft cloth and alcohol to clean the oil from the glass, before installation.

New Lamp Groups (D4H-D11N)

Illustration 1. 106-8964 Lamp Group-Flood Supended Mount (top), 107-6689 Lamp Group-Flood Vertical Mount (bottom). Tighten to 1.1 ± 0.2 N·m (.81 ± .11 lb ft) (1) Tighten to 1.7 ± 0.2 N·m (1.26 ± .18 lb ft) (6)

New 24 volt lamp groups are available to replace the previous lamp groups used on 24 volt track-type tractors. The new lamp groups are 106-8964 Lamp Group-Flood for the suspended mount (mounting bracket on top) and 107-6689 Lamp Group-Flood for the vertical mount (mounting bracket on the bottom). Both lamp groups are the same lamp except for the bezel orientation. Each part number is serviced separately so the lamp does not have to be disassembled to change the bezel orientation. The new lamp groups DO NOT include mounting hardware. The hardware is serviced separately to eliminate wasted hardware when ordering replacement lamps. See Illustrations 2 and 3 for hardware. These new lamp groups replace the previous 9X-1439, 9X-6774, 9X-6775, and 9X-4381 Lamp Group-Flood and the 9X-7169, 9X-6874, 9X-7165, and 9X-7167 Lamp Group-Head in current track-type tractor applications.

The 9X-1439 Lamp Group and the 9X-7169 Lamp Group are still used and serviced on other non-track-type tractors.

New Lamp Guards (D6H-D11N)

Two new lamp guard assemblies, a single lamp guard assembly and a double lamp guard assembly, have been designed to accommodate the new lamps for D6H through D11N Track-Type Tractors.

The new single lamp guard assembly has been designed to lower input vibration into the lamps. The 114-2368 Guard Assembly can directly replace the former 6Y-9471 Guard in all applications. The new 114-2368 Single Lamp Guard Assembly is used in the 114-5992 Light Group. See Illustration 2.

Illustration 2. 114-5992 Light Group Horizontal Mounting Design (top) Vertical Mounting Design (bottom) Tighten (2) to 20 ± 4 N·m (14.8 ± 2.9 lb ft)

The new two lamp guard assembly, 114-9363, used in the 117-1328 Lighting Group, has been designed to: accommodate the new lamps, provide a built-in angle for more lamp clearance, and also lower input vibration into the lamps. The two lamp guard assembly can directly replace two single 6Y-9471 Guards mounted next to each other horizontally or vertically. See Illustration 3.

Illustration 3. 117-1328 Lighting Group Horizontal Mounting Design (top) Vertical Mounting Design (bottom) Tighten (2) to 20 ± 4 N·m (14.8 ± 2.9 lb ft) (see chart below)

NOTE: Ensure that 9W-4361 Mounts are used when assembling either of the new groups to track-type tractors, especially at the ROPS. None of these mounts were originally used when mounting lamps to the ROPS structure.

Modification to 6Y-9471 Lamp Guards (D6H-D11N)

Existing light groups on D6H through D11N Track-Type Tractors may be strengthened by modifying the 6Y-9471 Lamp Guard. The modification to the lamp guard helps to reduce the vibration input into the lamps. Modify the lamp guard by welding a piece of mild steel measuring 101.6 mm (4.00 in) by 95.2 mm (3.75 in) by 6.4 mm (.25 in) thick to the open part of the guard to effectively close up the area between the mounting holes. See illustration 4.

NOTE: Do the welding to the lamp guard only with the guard off the machine and with the lamp removed from the guard.

Illustration 4. 6Y-9471 Lamp Guard Modification Dimensions. (A). 6.4 mm (.25 in) thick (B). 95.3 mm (3.75 in) wide (C). 101.6 mm (4.00 in) long (D). Weld mild steel to peice to steel guard here.

New Lift Cylinder Brackets (D7H-D11N)

Illustration 5. D9N-D11N Typical lighting group- lift cylinder mounted.

For D9N through D11N Track-Type Tractors with lights mounted on the lift cylinder, the new 115-1250 Bracket Assembly is used at the top of lift cylinders replacing the 7T-9821 Bracket. The new bracket is strengthened at the inside corners to reduce input vibration to the lamps.

New Lift Cylinder Bracket (D9N-D10N)

Illustration 6. 1Z-0755 Supplemental Lighting Arrangement-Lift Cylinder Mounted. D9N and D10N Waste Disposal Arrangement.

For D9N and D10N Track-Type Tractors with lights mounted on the lift cylinders, a 115-1032 Bracket Assembly and a 115-1250 Bracket Assembly are used. The new brackets replace the former brackets to reduce input vibration to the lamps.

New Lift Cylinder Bracket (D8N)

Illustration 7. 1Z-0897 Supplemental Lighting Arrangement-Cylinder Mounted. D8N Waste Disposal Arrangement.

For D8N Track-Type Tractors with lights mounted on the lift cylinders, a 115-1027 Bracket is used. The 115-1027 bracket replaces the former bracket to reduce input vibration to the lamps.

Modification of 7T-9821 Lift Cylinder Brackets

A modification is available for D8N through D11N Track-Type Tractors that can be performed on existing light groups using the 7T-9821 Bracket, (lift cylinder bracket). The modification to the lift cylinder bracket increases its strength and helps to reduce vibration input to the lamps. Modify the 7T-9821 Bracket by welding a "U"channel to each side of the bracket. Fabricate the "U" channel from mild steel (see Illustration 8).

Illustration 8. "U" channel dimensions. (A) 200.0 mm (7.87 in). (B) Radius of 3.0 mm (.12 in). (C) 3.0 mm (.12 in). (D) 15.0 mm (.59 in). (E) 30.0 mm (1.18 in).