Service Life can be Increased with the Installation of LED Lights{1429} Caterpillar

Articulated Truck:

D350E (PIN: 9LR1-UP)

D400E (PIN: 2YR1-UP)

Introduction

Reference: Service Welding Guide, SEBD0512

Reference: Parts Manual, SEBP2535 D350E Articulated Truck

Reference: Parts Manual, SEBP2455 D400E Articulated Truck

LED lights for the turn and the stop/tail lamps can be installed on the above machines. The LED lights increase the service life of the lamps.

This article details the removal of the existing rear lamp group from the machine and the fabrication and installation of LED light assemblies. It is necessary to extend the rear frame lugs in order to mount the brackets for the LED lights.

The following parts are required to carry out the modification.

Welding on Machines and Engines with Electronic Controls

Proper welding procedures are necessary in order to avoid damage to the electronic controls and to the bearings. The following steps should be followed in order to weld on a machine or an engine with electronic controls.

1. Turn off the engine.

2. Turn the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.

3. Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. Make sure that the electrical path from the ground cable to the component does not go through any bearing. Use this procedure in order to reduce the possibility of damage to the following components:
   • Bearings of the drive train

   • Hydraulic components

   • Electrical components

   • Other components of the machine

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NOTICE
Do NOT use electrical components (ECM or ECM sensors) or electronic component grounding points for grounding the welder.

4. Protect any wiring harnesses from the debris which is created from welding. Protect any wiring harnesses from the splatter which is created from welding.

5. Use standard welding procedures in order to weld the materials together.

Fabrication Of Brackets and Mounting Assemblies For LED Lights

Use a suitable steel with a yield stress of 450 ± 50 MPa (65267 ± 7250 psi) to fabricate the following items.

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Illustration 1	g00735933
Extension plate

1. Fabricate two extension plates in order to extend the rear frame lugs. The extension plates will allow the mounting of the lamp brackets. Use a 20 mm (0.79 inch) steel plate. Refer to Illustration 1 and Table 1.
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   Table 1

   Dimensions For Extension Plate
   Item	Dimension
   A	215 ± 1 mm (8.465 ± 0.04 inch)
   B	212.5 mm (8.366 inch)
   C	270 mm (10.63 inch)
   D	98 ± 1 mm (3.858 ± 0.04 inch)
   E	8 ± 1 mm (0.3150 ± 0.04 inch)
   F	37° ± 1°
   G	20 mm (0.787 inch)
   H	31 ± 1 mm (1.22 ± 0.04 inch)
   J	171 ± 1 mm (6.732 ± 0.04 inch)
   K	10 ± 1 mm (0.394 ± 0.04 inch) Radius (4 places)

2. Fabricate the following components for the lamp brackets.
   • (a) Two Plates

   • (b) Two Brackets

   • (c) Two Plates (Mountings for LED Lights)

   • (d) Two Bracket Plates

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   Illustration 2	g00735934
   Plate

   1. Fabricate two plates. Use a 5 mm (0.197 inch) steel plate. Refer to Illustration 2 and Table 2.
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      Table 2

      Dimensions For Plates
      Item	Dimension
      A	37 ± 1 mm (1.457 ± 0.04 inch)
      B	265 ± 1 mm (10.433 ± 0.04 inch)
      C	305 ± 1 mm (12.008 ± 0.04 inch)
      D	11 ± 1 mm (0.433 ± 0.04 inch) Diameter (4 places)
      E	156 ± 1 mm (6.142 ± 0.04 inch)
      F	205 ± 1 mm (8.071 ± 0.04 inch)
      G	5 mm (0.197 inch)
      H	20 ± 1 mm (0.7874 ± 0.04 inch)
      J	20 ± 1 mm (0.7874 ± 0.04 inch)
      K	150 ± 1 mm (5.906 ± 0.04 inch)
      L	206.7 ± 1 mm (8.138 ± 0.04 inch)
      M	154 ± 1 mm (6.063 ± 0.04 inch)
      N	10 ± 1 mm (0.394 ± 0.04 inch) Radius

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   Illustration 3	g00741890
   Plate and Lugs For the Fabrication of the Bracket

   2. Refer to Illustration 3. Fabricate two plates and eight lugs. Use the dimensions that are given in Illustration 3 and Table 3. Use a 5 mm (0.2 inch) steel plate for the plates and use a 6 mm (0.23 inch) steel plate for the lugs. Bend the two plates to the dimensions that are given in Illustration 3 and Table 3. Weld four lugs into position. Ensure that the lugs are flat with the rear face of the bracket.
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      Table 3

      Dimensions For Brackets
      Item	Dimension
      A	346.5 ± 1 mm (13.64 ± 0.04 inch)
      B	81 ± 1 mm (3.19 ± 0.04 inch)
      C	254 ± 1 mm (10.0 ± 0.04 inch)
      D	380 ± 1 mm (14.96 ± 0.04 inch)
      E	25 ± 1 mm (0.98 ± 0.04 inch)
      F	32 mm (1.26 inch) Diameter
      G	15 ± 1 mm (0.59 ± 0.04 inch)
      H	6 mm (0.236 inch)
      J	6 mm (0.236 inch) (Metric Thread) (4 Places)
      K	195 ± 1 mm (7.68 ± 0.04 inch)
      L	3 mm (0.12 inch) Fillet Weld (4 places)
      M	5 mm (0.197 inch)
      N	15 mm (0.591 inch)
      P	50 mm (1.97 inch)
      R	55 mm (2.17 inch)
      S	5 ± 1 mm (0.197 ± 0.04 inch) Radius (2 places)
      T	90° (2 places)

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   Illustration 4	g00735936
   Plate

   3. Refer to Illustration 4 and Table 4. Fabricate two plates. Use a 5 mm (0.197 inch) steel plate.
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      Table 4

      Dimensions For Plate
      Item	Dimension
      A	340 ± 1 mm (13.386 ± 0.04 inch)
      B	154 ± 1 mm (6.063 ± 0.04 inch)
      C	100 ± 1 mm (3.937 ± 0.04 inch)
      D	10 ± 1 mm (0.394 ± 0.04 inch)
      E	45° (2 places)
      F	115 ± 1 mm (4.528 ± 0.04 inch) Diameter (2 places)
      G	6.5 ± 1 mm (0.256 ± 0.04 inch) Diameter (6 places)
      H	125 ± 1 mm (4.9213 ± 0.04 inch) Diameter (2 places)
      J	5 mm (0.197 inch)
      K	183 ± 1 mm (7.205 ± 0.04 inch)
      L	91.5 ± 1 mm (3.602 ± 0.04 inch)
      M	120° (1)

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      ( 1 )

      The six holes (G) are spaced equally.

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   Illustration 5	g00735937
   Bracket Plate

   4. Refer to Illustration 5 and Table 5. Fabricate two bracket plates. Use a 5 mm (0.197 inch) steel plate.
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      Table 5

      Dimensions For Bracket Plates
      Item	Dimension
      A	6 mm (0.236 inch)
      B	45° Chamfer (4 places)
      C	6 mm (0.236 inch)
      D	341.5 ± 1 mm (13.445 ± 0.04 inch)
      E	5 mm (0.197 inch)
      F	185 ± 1 mm (7.283 ± 0.04 inch)

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Illustration 6	g00735938
Lamp Brackets

3. Refer to Illustration 6 and Table 6. Assemble the plates that were fabricated in Step 2.c to the brackets that were fabricated in Step 2.b. Assemble one left side and one right side lamp bracket by welding these brackets to the plates (1) that were fabricated in Step 2.a. Ensure that the orientation of item (1) of the lamp bracket is correct for both the right side of the machine and for the left side of the machine.

   Note: The bracket plates that were fabricated in Step 2.d are not included at this point.

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   Table 6

   Dimensions for the Lamp Brackets
   Item	Dimension
   A	68 ± 1 mm (2.677 ± 0.04 inch)
   B	32 mm (1.26 inch)
   C	30 ± 1 mm (1.18 ± 0.04 inch)
   D	45 ± 1 mm (1.772 ± 0.04 inch)
   E	3 mm (0.118 inch) Fillet Weld

Attaching the Extension Plate

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Illustration 7	g00737632
Existing Lamp Bracket Assembly (Left Side)

4. Disconnect the existing lamps and brackets from rear chassis lug (4). Remove these items. Adequately protect chassis harness (5) from future welding.

5. Remove paint from rear lug (4) in preparation for the attachment of the extension plate.

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Illustration 8	g00737634
Attachment of the Extension Plate (4) Rear chassis lug (6) Extension plate

6. Tack weld one extension plate (6) to the rear chassis lug (4) on the left side of the machine. Repeat this procedure for the right side of the machine. In case adjustment is necessary later in the procedure, use light tacks. Use a straight edge in order to ensure that the surfaces of the extension plates and the lugs are flat.

7. Remove any weld splatter from the upper surface of the fabrication.

Installation of the LED Lamp Brackets

8. Clamp the left lamp bracket onto the left extension plate and clamp the right lamp bracket onto the right extension plate.

9. Start the engine. Raise the body and lower the body of the machine in order to check that sufficient clearance exists between the lamp brackets and the body. If necessary, adjust the position of the lamp brackets.

10. Drill holes through rear chassis lug (4) and through extension plate (6) on either side of the machine for fixing. Use the holes in the base of the lamp brackets as a template. Drill the holes to a diameter of 12 mm (0.472 inch).

11. Loosen the clamps and remove the lamp brackets.

12. Once the positions of the lamp brackets have been determined, fully weld the extension plate to the rear chassis lug. Take care to ensure that flatness is maintained between the components.

13. Allow the area that has been welded to cool. Once the area is cool, grind the weld flat. Repaint the area.

Construction of the Link Harness

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Illustration 9	g00742195
Link Harness (7) 102-8808 Connector Plug (8) 102-8804 Receptacle Kit

14. Construct two link harness' in order to connect the 142-2014 LED Light and the 135-0482 LED Light to the existing harness. The wires and the parts are shown in Illustration 9. Use a suitable shrink wrap in order to insulate the wires. Refer to Table 7 for the connection of the wires to the connectors. Ensure that the length of the link harness is sufficient to allow the lamps to be mounted in the desired position.
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    Table 7

    Connections for the Link Harness
    Light	Connector	Pin	Wire
    Red	102-8808	A	Red
    		B	Black (1)
    		C	White
    Amber	102-8808	D	Brown
    		B	Black (1)

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    ( 1 )

    This is a common ground between the two lights.

    Note: Two black wires are required from pin (B) of each connector plug to the 102-8804 Receptacle Kit (5) in order to connect both lights to the chassis harness. Both wires must be inserted in to the same socket of the receptacle kit .

Installation of the Lamp Group

15. On the left side of the machine, reposition the lamp bracket onto the extension plate. Secure the lamp bracket with four 4L-9337 bolts and four 2K-4973 nuts .

16. Position the bracket plate that was fabricated in Step 2.d to the rear of the lamp bracket. Mark bolt holes on the bracket plate. These bolt holes must match the four welded bosses that are located in the lamp bracket.

17. Install the red LED light into the lower hole in the lamp bracket and install the amber LED light to the upper hole in the lamp bracket. Secure the lights in position with six 2U-2589 bolts and six 2U-2452 nuts .

18. Drill holes for the bolts in the bracket plate.

19. Refer to Illustration 6. Install 3D-6209 Grommet to hole (B) in the side of the lamp bracket. Pass the chassis harness through hole (B) .

20. Connect the LED lights to the chassis harness with the link harness. Install the bracket plate. Secure the bracket plate with four 6V-5842 Bolts and four 6V-5839 Washers .

21. Repeat Steps 15 to 20 for the right side of the machine.

22. Secure the chassis harness in position with the respective clamps.

23. Start the engine. Raise the body and lower the body of the machine in order to check that sufficient clearance still exists between the lamp brackets and the body.

24. Test the LED lights in order to ensure that the lights are working correctly.

Note: The indicator in the cab will be illuminated but the indicator will not flash.