SFN-20240102D Replace Halogen headlights with LED

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TICO Document #: SFN-20240102D (formerly TES 215)

Description of Procedure: There is a manufacturer defect in the headlight’s ability to cool itself. Replace the initially supplied halogen headlights with Weldex LED headlights.

Units Affected: N/A

Parts Required: KIT - HALOGEN TO LED HEADLIGHT CONVERSION 970028 (QTY 1)

  • HEADLIGHT-LH, LED HI/LOW, TURN, SADDLE MNT, 910741 (QTY 1)

  • HEADLIGHT-RH, LED HI/LOW, TURN, SADDLE MNT, 910742 (QTY 1)

  • HARNESS, WIRE JUMPER, HEADLIGHT 621126 (QTY 2)

  • CABLE TIE, 8” LONG, NYLON 420437 (QTY 8)

Planned Labor: 1 hour

The headlight will have to be realigned per FMVSS 571.108 /CMVSS 571.108.

Instructions:

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

  2. The halogen headlight will look like the light seen in Figure #1.

  3. Disconnect the headlight connection at the back of the headlight.

  4. Locate the headlight mounting nut and remove it. See Figure #2. Be sure to support the headlight as it is removed from the headlight mounting bracket.

  1. Install the LED headlight, see Figure #3, in the same mounting hole as the previous headlight.

  2. When the lights are handed, be sure to mount the turn signal portion of the light toward the outside of the truck. See Figure #3.

  1. Using the provided hardware, mount the headlight to the headlight bracket. See Figure #4. Make sure the headlight mounting nut is more than hand-tight but not at its full torque for final installation.

  2. Install the provided electrical harness jumper to connect the headlight connector to the chassis harness. See Figures #5a & 5b.

  1. Repeat the procedure for the other side headlight.

  2. Turn the tractor’s ignition switch to the accessory position to check for the headlight functions. The functions are low beam, high beam, turn signal & flasher.

  3. Headlights need to be aimed per FMVSS 571.108 /CMVSS 571.108; see next step.

Headlight Aiming Procedure

  1. Select an area that is flat and has a vertical flat wall to use in aiming lights. The area needs to be the full length of the truck plus 25 feet.

  2. Measure the bumper and mark the center with a piece of masking tape. The bumper is 90 inches in length, and the center will be at 45”. If you have a newly formed bumper with the “T” in the face, that is in the center. This will be the line labeled “V” (vehicle centerline).

  3. Measure the distance up from the ground to the center of the light. Record that measurement. This line will be labeled as “H”(the horizontal centerline of the lights).

  4. Measure the distance between the headlights and the centers of the light it should be approximately 52” or 26” from the center of the vehicle. This line will be labeled as “C”( vertical centerline of lights).

  5. Drive the vehicle up to the wall and mark the wall as follows; see Figure #7.

    16A. Mark the vertical centerline of the vehicle, the line labeled “V”.

    16B. Mark a vertical line on the wall for the center of each headlight, the lines labeled “C”.

    16C. Mark a horizontal line on the wall for the height of the headlights, the line labeled “H”.

    16D. Mark a position on the vertical lines labeled “C”, 3” below the horizontal line labeled “H”. e. This is the aiming spot for the headlights.

  1. Drive the vehicle directly backward and park it so the front of the headlights are 25ft [7.5m] from the wall. Turn on lights, and some trucks require the dash to be on along with key switch.

  2. The tires should be cold and inflated to the correct inflation pressure (both front and rear tires).

  3. Aim both headlights with the horizontal portion of the beam, just below the aiming spot. The upper tail of the beam should be to the right of the aiming spot. The low-beam pattern of a visually-amiable headlight has a distinct horizontal cut-off. Below the cutoff is a bright light. Above the cutoff is dark. The headlight aim is determined by measuring and adjusting the height of the cutoff relative to the lines marked on the wall.

  4. For the vertical aiming, the cutoff is at the top left of the beam pattern and should align with the ”B” line for both left and right headlights.

  5. There is a standard method for horizontal alignment. Refer to the beam patterns as shown in Figure #8.

  1. A correctly aimed low-beam headlight pattern is shown in Figure #8.

  2. After adjusting the low beam pattern, no further adjustment is required for the high beam pattern. The high beam pattern is addressed in the design of the headlight itself.

Headlight Aiming Procedure Completed

  1. After aiming lights, tighten the M12 mounting bolt to 25 ft-lbs. See Figure #4.

  2. Use the provided cable ties to secure the headlight jumper harnesses to the existing chassis harnesses to ensure the harness does not interfere with the operation of the tractor.

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

  1. Return vehicle to service.