Are you in need of replacing the cabin and boom lights on your Komatsu PC200LC Excavator? Look no further! We have prepared a comprehensive guide that will walk you through each step of the installation process for new LED lights on both the cabin and the excavator boom. LED lights offer increased durability and energy efficiency, ensuring that you get the most value for your investment.

 

 

Fitting The Cabin Lights

Step 1: Verify Voltage Compatibility

Before proceeding, it is crucial to ensure that the LED lights you have selected are compatible with the voltage requirements of your excavator. It is worth noting that most boom lights available in the market operate at 12V, which is insufficient for the Komatsu PC200LC Excavator. For optimal performance, the boom lights need to be 24V and preferably low profile. This is due to the presence of a rollover protection system (ROPS) on the machine, which can obstruct the light. Additionally, a taller boom light may not fit properly due to the ROPS.

 

Step 2: Check for Power Supply

Head to the cabin and conduct a power supply test on the cables. Always exercise caution when working with electricity and ensure that you are wearing the appropriate safety gear to protect yourself.

To begin, turn on the lights and use a multimeter to measure the voltage. Verify that all connectors receive power at the plug-in points. Each connector should display a minimum reading of 25V. If all connectors have voltage, there is no need to check the fuses for power supply. You can proceed directly to mounting the brackets for the boom lights.

 

Step 3: Fabricate or Acquire Brackets

There are two options when it comes to brackets: you can either fabricate your own or purchase them from manufacturers. Keep in mind that ordering brackets may take a week or two for delivery, so consider your timeline when making a decision.

Fabricating your own brackets is not only cost-effective but also time-saving. To create brackets, you can modify an adapter plate by bending, twisting, and drilling holes to accommodate the bolts. 

When fabricating customized brackets, start by determining the optimal placement for both lights. Ensure that the lights fit securely within the square of the ROPS, allowing the light to shine through the screen.

Once you have determined the ideal placement, continue bending and twisting the bracket until you achieve a 90-degree angle. This will allow the bracket to sit flat on the designated placement point.

Drill two mounting holes in the brackets, ensuring that they are large enough for the bolts to fit properly. One hole will be used to mount the bracket to the cabin, while the other will secure the lights. When opting for DIY brackets, be prepared to make adjustments as needed until they fit perfectly.

 

Step 4: Testing the Lights

Now that the brackets have been securely mounted to the cab, it's time to test-fit the lights and ensure they are positioned optimally for excellent aim. This step is crucial to guarantee proper functionality and visibility. 

Begin by mounting the lights in an upright position. If it appears that the lights are positioned too high, there is a good chance that they will hit the bar. In this case, carefully unscrew the lights from the brackets and mount them upside down instead. This adjustment will help ensure proper clearance and avoid any potential damage to the bar or lights. 

During the test fitting process, it's important to take the time to retwist and re-bend the brackets as needed to achieve the perfect positioning for the lights. However, exercise caution to avoid damaging the brackets during these adjustments.

 

Wiring The Cabin Lights

Poke A Hole Through The Grommets

Next, it's time to address the wiring. Begin by taking the grommets that were previously installed and create a small hole in the center to allow the wires to pass through. These grommets serve a dual purpose: they keep the wires secure and prevent water from leaking into the wiring system, protecting it from potential damage.

 You may notice that there are multiple wires coming from the power source. Don't worry, this is normal. However, you will only be using one of these wires for the installation. Allow the remaining wires to rest inside the cab behind the grommet.

 Take the wire connected to the light and carefully thread it through the hole you created in the grommet. This will ensure that the light is properly connected to the power source.

 

Connect The Wires

Begin by cutting out the connector from the power wires and also trim the light wires to a suitable length.

To join the wires from the light to the wires from the cab, make use of the red sealed butt connectors. These connectors have a special feature - they contain internal sealant or glue. When heat is applied, this sealant activates and ensures a secure, watertight connection. It is crucial to use these sealed butt connectors instead of regular ones to prevent moisture from reaching the wires and causing potential short circuits due to corrosion.

Once the wires are connected using the red sealed butt connectors, give them a gentle tug to ensure they are securely joined and won't accidentally disconnect.

 

Test the light

Turn on the lights and verify that they are illuminating as expected. If any issues arise, such as the lights not working, it will be necessary to double-check the connection and potentially redo it. However, if the lights are working properly, you can confidently proceed to the next step of the installation process.

 

Heat Shrink The Connectors

To ensure a secure and weather-resistant connection, follow these steps to properly heat shrink the connectors:

1. Begin by using a butane torch. Hold the flame at a moderate distance and start heating the connectors from the middle, gradually working your way outwards. If the shrinking process seems to be taking longer than expected, you can adjust the torch to a higher setting.

2. While heating the connector, it's important to gently move it around. This helps the sealant to melt evenly and allows any trapped oxygen to escape. By eliminating oxygen, you can effectively prevent corrosion, especially during the winter months or in humid conditions.

3. Continue heating the connector until it has completely shrunk and sealed. The sealed connectors should appear clear, allowing you to see through to the wires inside. When tugging on the wires, there should be no movement or slippage, indicating a secure connection.

4. For added protection, consider constructing a cable harness to encase the connected wires. This will provide an extra layer of safeguarding against potential damage and ensure long-lasting durability. To complete the wiring process, follow these additional steps:

5. Begin by fixing the grommets back into their original positions.

6. Move to the other side and repeat the following steps:

• Slip the grommet through the designated hole 

• Strip the wires that supply power to the lights and twist the ends to insert a butt connector for each wire.

• Crimp the connectors securely and double-check their snugness.

• Connect the LED light wires, matching positive to positive and negative to negative.

• Finally, apply heat shrink tubing to seal the connectors, ensuring a watertight connection. Once done, fix the grommet back into place to seal the hole where the power wires pass through.

 

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FAB Heavy Parts Can Help With Your Needs

Welcome to Fab Heavy Parts' online catalog, where you can explore a delightful array of lights for yor Komatsu excavator.  We have a diverse selection to cater to your needs. Our knowledgeable parts team is at your disposal, ready to assist you every step of the way.