SFN-20240109B Saddle mount replacement

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TICO Document #: SFN-20240109B (formerly TES 159)

Complication: The HDI LED headlight (TICO P/N: 910377 & 910378) can not be adjusted vertically to ensure compliance with FMVSS 571.108/CMVSS 571.108.

Description of Procedure: The supplier has revised the mounting design to a saddle mount, which allows for orientation and a mounting surface to maintain the position of the headlight after it has been properly adjusted and the mounting hardware has been tightened.

Units Affected: S/N: 4660, 4652-4659 ( 9 units-CHECKER FLAG) S/N: 4708-4729 (22 units-TARGET) S/N: 4628-4647, 4608-4627, 4599-4607, 4568-4571, 4574-4675 4587-4593 (70 units FED-EX GROUND)

Parts Required: FIELD KIT, LED HEADLIGHT MOUNTING CONVERSION (QTY 1) 721466

Planned Labor: 1 hour

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.

  2. The HDI headlight assembly with existing mounting hardware is shown. Remove the light from the mounting bracket. Unplug the wire harness from the rear of the light.

  1. Discard the mounting hardware, it will not be reused

  1. Place headlight on a bench lens side up. Remove the (4) screws from the lens cover. This will allow you to remove the lamp.

  2. Removing the lamp will expose the square head 3”Lg mounting bolt. Remove this bolt and replace with a hex head ½” x 1 ½”Lg bolt.

  1. Place one rubber washer and the ½” flat metal washer on the bolt. Using a STD 1/2” nut compress this washer into the cavity of the light housing.

  2. Remove the nut and place the second rubber washer on the bolt over the metal washer Place the upper mounting bracket over the bolt and install the ½”nylock nut. The upper bracket is the one with (4) small square holes and a ½” Dia hole in the middle. Tighten the ½” nylock nut until bolt protrudes out of nut, min of 1 thread.

  1. Align the side of the bracket with the side of the light housing.

    Caution: Do not damage the potted area or wires inside of the light while tighten the nut.

  1. Place a ½” x 1 1/4Lg hex head bolt in the center hole of the lower bracket. Assemble the lower bracket to the upper using the 5/16 NC x ¾ Lg hex head bolts and nylock nuts. Tighten the 5/16 bolts snuggly leaving movement.

  1. Install the lamp cover that was removed using the (4) screws that were removed. Tighten screws securely. Now the light is ready to assemble to the on the bracket.

  2. Install the light extension brackets to the underneath side of the existing light bracket. Use (2) ½” NC x 1 ½” Lg hex head bolts with nylock nuts to mount extension plate. Install head light on extension plate and snug mount nut.

  3. Assemble light to truck with turn signal portion of the light to the outside., there are LH and RH lights. Plug harness into rear of each light. The lights are now ready to adjust, they must be adjusted in accordance with FMVSS 571.108/CMVSS 571.108.

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 new 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; the centers of the light it should be 52”, and 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 for the vertical centerline of the vehicle. The line labeled “V”. Mark a vertical line on the wall for the center of each headlight, the lines labeled “C”. Mark a horizontal line on the wall for the height of the headlights, the line labeled “H”. Mark a position on the vertical lines labeled “C”, 3” below the horizontal line labeled “H”. This is the aiming spot for the headlights.

  6. Drive the vehicle directly backward and park it so the front of the headlights are 25ft [7.5m] from the wall. Turn on the lights. Some trucks require the dash to be on along with key switch. The tires should be cold and inflated to the correct inflation pressure (both front and rear tires).

  7. 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.

  1. The low-beam pattern of a visually-amiable headlight has a distinct horizontal cutoff. Below the cutoff is a bright light. Above the cutoff is dark. The headlight aim is determined by measuring and adjusting the cutoff height relative to the lines marked on the wall.

  2. For the vertical aiming, the cutoff is at the top left of the beam pattern and should be aligned with the ”B” line for both left and right headlights. There is a standard method for horizontal alignment; refer to the beam patterns as shown in Figure 2.

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

  2. After aiming lights, tighten the ½” mounting nylock nut used to move the light side to side to 210 ft./lbs. Tighten the 5/16” nylock nuts used to aim the light up and down to 14 ft./lbs

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

  1. Return vehicle to service.