SFN-20231018E_Install a New DRL Headlight Kit

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TICO Document #: SFN-20231018E (formerly TES-246)

Description of Procedure: Remove existing headlights and install a new DRL headlight kit

Reason: Customer wants to increase driver/pedestrian awareness, visibility, and safety

Units Affected: TICO Cabs built from March 2016 - May 2017, see Figure 7

Parts Required: KIT 970057 (QTY 1)

Planned Labor: 3 hour

Tools Required:

  • Adjustable Crescent Wrench

  • Cordless Drill

  • 1/8” Hex Bit

  • 3/4” Rachet Wrench

  • Pin Punch

  • Hammer

  • Fish Tape

  • Flexible Impact Bit Holder (Optional)

DRL installation layout:

Instructions:

  1. Park the vehicle on a flat surface, apply a parking brake, and chock wheels. If your company utilizes a “Lock Out, Tag Out” policy, you should employ it during this procedure.

  • Warning: To avoid electrical shock to personnel and/or damaging equipment, remove the battery power on the truck by disconnecting the negative side of the battery.

  1. Remove the (13) screws from the dash panel; see Figure 8.

  1. Remove the installation nut on each air valve using an adjustable crescent wrench. See Figures 9 and 10.

  1. Disconnect the transmission shift pad and boom control connectors, then remove the panel and set it to the side. See Figures 11 and 12.

  1. Locate the pass-through that leads underneath the cab. See Figures 13 and 14.

  1. Run the fish tape down the pass-through until it reaches out the other end. See Figures 15 and 16.

  1. Wrap electrical tape around the end of the fish tape under the cab and the 2-way connector labeled “LIGHTS” on the harness p/n: 910384. Pull this end of the harness up and pass through until it reaches inside the dash. See Figures 17 and 18.

  1. On the left side of the dash, locate the (3) dash harness connectors labeled “J15”, “J14”, and “J8”. See Figures 19 and 20.

  1. Connect the (3) corresponding connectors on the new harness p/n: 621420 to the (3) connectors found on the existing dash harness. See Figures 21 and 22.

  1. Slide the remaining portion of the harness toward the bottom section of the dash and out of the way so that the dash panel lays flat when put back down. See Figures 23 and 24.

  1. Connect the remaining 2-way connector on harness p/n: 621420 labeled “LIGHTS” to the 2-way connector on harness p/n: 910384 labeled “LIGHTS”. See Figures 25 and 26.

  1. Disconnect and replace the left-side headlight jumper harness that connects the headlight to the chassis harness with the new headlight jumper harness p/n: 621163. See Figure 27. Discard the old harness.

  1. Remove and discard the left headlight and associated mounting hardware. See Figure 28.

  1. Repeat the same steps to remove the right-side headlight. See Figures 29 and 30.

  1. Install the new Weldex DRL Headlights mounting using the hardware included with the light. Torque to 25 ft-lbs.

  1. Connect the Weldex DRL jumper harness P/N: 621163 to the headlights and its corresponding connection to the chassis harness that was previously disconnected.

  1. Complete an operational checkout out of the DRL headlights before re-installing the dash panels.

  1. Reconnect the negative side of the battery.

  2. DRL Test Operation: Turn the ignition key switch to ON. 191.

    19A Press the headlight switch to the “down” position. See Figure 32. ̶ DRL’s ON, Marker Lights OFF, Headlights OFF.

    19B Press the headlight switch to the “center” position. See Figure 33. ̶ DRL’s ON, Marker Lights ON, Headlights OFF.

    19C Press the headlight switch to the “down” position. See Figure 34. ̶ DRL’s OFF, Marker Lights ON, Headlights ON.

  1. Re-install the 13 hex screws back into the dash panels. See Figure 35.

  1. Re-install the air valve installation nuts and tighten until snug. See Figures 36 and 37.

  1. Re-install the retaining pins to the air valve handles using a hammer and pin punch. See Figure 38.

  1. Remove “Lock Out, Tag Out” plaque.

  1. Return vehicle to service.