Installation Guide for the 35-Watt High Intensity Discharge (HID) Light{1429} Caterpillar

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Introduction

Listed below is some general information on 35-watt High Intensity Discharge (HID) lights:

• A 35-watt High Intensity Discharge (HID) light produces between 2500 lumen and 3000 lumen of light.

• HID lights do not have an filament. Since there are no filaments present, the HID light can have a life of 2000 hours to 6000 hours.

• The HID creates light from an electrical discharge between two electrodes.

• These electrodes are sealed in a quartz capsule in a microenvironment of gas and metal halide salts.

• An arc between the two electrodes causes an electronically energized gas to emit light.

• The light produced is whiter, providing a feeling of additional light.

• The HID is approximately 70% efficient compared to a 25% efficient halogen light. The HID is more efficient than the halogen light because the HID gives off more energy in the form of light (as opposed to energy given off in the form of heat).

• In order to create the arc, HID lights generate high voltage (up to 25000 volts internally). Once the arc is stabilized, the voltage is reduced to 90 volts.

Table 1 shows the six styles of HID Lights that are available.

Illustration 1	g00940083
Typical 35 watt HID light

Illustration 2	g00940278
Typical 35 watt HID light (side view)

Installation Guidelines

• Install HID Lights away from sources of extreme heat (engine, exhaust system).

• Install HID Lights on rigid and substantial surfaces (minimum 3.8 mm (0.15 inch) thick).

• Install HID Lights at an angle no greater than +/- 15 degrees from horizontal. Greater installation angles may reduce gas tube (light source) life.

• HID Lamps are designed to operate on 24 VDC (@ 2.9 amperes continuous) and are polarity sensitive. Connect Pin 1 to 24 VDC (+ battery) and Pin 2 to ground (- battery).

• Install HID Lights so that they are aimed away from oncoming machine operators. Dim HID Lights when approaching other machines.

Service

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HID lamps can store energy after power is turned off. To avoid electrical shock and personal injury, disconnect power for at least five minutes before servicing HID lamps.

1. Remove power from the lamp. Before continuing, ensure that power has been removed from the lamp for at least five minutes.

2. Remove the four bezel screws and remove the bezel.

3. Remove the lens/reflector/lamp assembly.

4. Disconnect the high voltage cable from the rear of the lamp. Remove the lamp.

5. Install a replacement lamp ( 209-6638 Lamp ) in the lens/reflector assembly. Ensure that the Caterpillar logo on the lens is oriented correctly (with respect to the lamp's mounting orientation on the machine).

6. Reinstall the bezel and the four bezel screws.

7. Check for proper operation.