Caterpillar Product Information

Salesgram
June 2006

Introducing
High Intensity
Discharge (HID)
Lights for Cat
Mining Trucks

Caterpillar is pleased to announce the availability of high intensity

gas discharge (HID) lights for Cat 785C, 789C, 793C, 793D and
797B Mining Trucks. HID lights are designed to improve lighting
during night operations and increase machine and operator
productivity in high hour mining applications. Compared with
halogen lights, HID lights provide four times more light, which
means greater visibility on the haul roads. They also are more
resistant to shock and vibration, for significantly longer bulb life.
Premium line of 35 watt HID lights available from Caterpillar:
1) 793D attachment option
2) 797B and new C-series trucks factory install custom package
3) Existing 797B and C-series trucks retrofit custom package
HID lighting package:
35 watt flood light high and low beam patterns
24 volt vertical and suspended mounts
Deutsch connectors

For Dealer Sales Personnel

www.cat.com

High Intensity Gas

Discharge (HID) Lights

The 35 Watt high intensity gas discharge (HID) light produces

3,200 lumens of light. The light produced is whiter than halogen
lights, providing an additional feeling of more light. HID lights
are approximately 70% efficient compared with 20-25% efficiency
for halogen lights because more energy is released as light instead
of as heat.
HID lights do not have a filament. High intensity gas discharge lights
create light from an electrical discharge between two electrodes in
a microenvironment of gas and metal halide salts sealed in a quartz
capsule. An electronically energized gas caused by an arc between
the two electrodes emits light. The arc requires an operating voltage
of 90 volts with a short burst at 25,000 volts when the lamp is turned
on. Once the arc is stabilized, the voltage is reduced to 90 volts.
Since there are no filaments present, the HID gas lamp has a life
expectancy of up to 6,000 hours.

Benefits

Longer life. 6-10 times the life of halogen lamps.

More light. 35 watt HID lights provide 2-times more lighting
than 65 watt halogen lamps.
Self-contained. No filament or external high voltage parts.
Greater visibility. Bluish color light is closer to true daylight.
Penetrates dust and fog better than halogen lamps.
Gradual power loss. Gradual reduction in light power versus
sudden burnout in halogen lamps.
Low current draw. 1.7 amps at start-up for 35 watt HID lights
versus 2.4 amps for halogen.
Environmentally sealed. Designed to resist dust and water in harsh
weather conditions. Meets IP68 standard.
Reliable. Proven for 8,500-hours+ without failure on off-highway
test vehicle.
Durable. Corrosion resistant hardware for long life and hardened
glass lens for improved thermal and abrasion performance.
Shock resistant. 5
5 lights designed with a rubber bezel to
cushion the lens, reflector and bulb from machine vibration.
More resistant to vibration than halogen lamps.
Vibration resistant. Passes Caterpillar design specification test
for vibration resistance by 12 times the average or 12 Grms.
Grms is an average (mean) force over a range of frequencies.
1G = normal force of gravity 12G = 12 times and 20G = 20 times
the normal force of gravity.

Field reports indicate a positive reaction by customers to HID lighting

on off-highway trucks in mining applications. Operators and other
personnel are impressed by the improved visibility resulting from
the brighter lights. Since operating hauling equipment in a mine
at night presents challenges to efficiency, lighting improvements
can make a dramatic difference to enhancing operator visibility
and improving efficiency of hauling, maneuvering and dumping
operations at night. However, some sites choose to operate with
HID lights on during the day as well. In this case, the bright lights
provide a warning of the trucks presence and movement.
The difference between halogen and HID lights is significant
over distance and width. Customers and tests indicate that standard
halogen lights, at the yellow end of the spectrum, are relatively dim
when compared to High Intensity Discharge lights. HID lights, at
the blue-white end of the spectrum, provide a brighter light and
project light further from the source, providing superior light on
the haul roads.
The graph below compares Halogen light output with HID lights
and shows how Halogen lighting falls off towards the edge of the
road at a faster rate than the HID lighting.
Halogen vs HID Light Output
12
10
8
Lux

Field Report

6
4

5 lux
3 lux

2
0

0 lux

1 lux
-7.5

-2.5

2.5

7.5

12.5

17.5

Angle (degrees)
Lux Halogen

Lux HID

Conclusion

While HID lights are more costly than our shock resistant halogen
lights, they provide 4-6 times the life and 2-times more light to
the work site than a standard 65 watt halogen light. Caterpillars
premium 35 watt High Intensity Gas Discharge (HID) lights
provide long life, reduced downtime and low maintenance cost.
They are designed to Caterpillar specifications in order to meet
the demanding vibration levels of large mining trucks.

Lighting Packages

The table below specifies the lighting packages for each Cat Mining
Truck. Due to the power of the HID lights to oncoming traffic, it is
desirable to easily turn the bright lights off. Therefore, HIDs are
not installed in low beam positions.

Model
785C, 789C,
793C, 797B
793D

Lighting
Configuration
Standard
HID*
Standard
HID**

Bumper/
Fenders/
Lower Grill
Upper Grill
4 Halogen
4 Halogen
4 Halogen
2 Halogen, 2 HID
4 Halogen
4 Halogen
2 Halogen, 2 HID 2 Halogen, 2 HID

Rear/Reverse
2 Halogen
2 Halogen
2 Halogen
2 HID

Total
10 Halogen
2 HID, 8 Halogen
10 Halogen
6 HID, 4 Halogen

* Because the 797B and C-series trucks were designed before the HID customized package, HID lights are only available
in the high beam positions.
** Design changes from the 797B and C-series trucks to the 793D allow HIDs to be installed in the fog lamp and rear/reverse
lamp as well as the high beam positions for the 793D only.
Lighting Locations
1. High Beams/Upper Low Beams (793D, 797)
2. High Beams/Upper Low Beams (785C,
789C, 793C) Lower Low Beams and Fog
Lamps (785C, 789C)
3. Lower Low Beams/Fog Lamps (793C,
793D, 797)
4. High Beams/Upper Low Beams (785C,
789C, 793C) Lower Low Beams/Fog
Lamps (785C, 789C)
5. High Beams/Upper Low Beams
(793D, 797)
6. Backup Lights

Specifications

Size
Light Output
Power
Connectors

Service Repair Parts

Ordering Information

5
5 in (127
127 mm)

35 watt (3,200 lumens) flood light
with flood, high or low beam
24 volt with vertical or
suspended mounts
Integral (mounted in housing) DT
(Deutsch) connector for ease of
installation. (Information on servicing
Deutsch HD & DT style connectors
can be found in SEHS9615-03)
Lens Reflector Assembly:
229-9969 (Flood)
229-9971 (High Beam)
229-9970 (Low Beam)
Bracket Assembly:
229-9972 (Lamp)
209-6638 (HID 35 watt DS2)

HID lights are available as a factory install on Cat 785C, 789C,

793C, 793D and 797B Mining Trucks as a Mandatory Attachment
on the Price List, with the choice between standard lighting and
HID lighting. HID lights are also available as an ex-factory Custom
Product as a retrofit. Field installed lighting groups must be ordered
via a Miscellaneous MSO.

Installation Information

Please refer to Special Instruction REHS1504 for complete details

on installing and retrofitting HID lights on Cat Mining Trucks.
The above-mentioned field reports indicate it is important to properly
aim HID lights at the time of installation to optimize performance
and operator satisfaction.

Model

Part #
4Z-7078

785C, 789C
4Z-7081
793C

4Z-7012

793D

240-4775*
4Z-7082

797B
4Z-7083

Description
Lighting GP
HID (upper)
Lighting GP
HID (upper)
Lighting GP
HID (upper)
Lighting, HID
Lighting GP
HID (upper)
Lighting GP
HID (upper)

Installed

Includes

factory

2 HID, 2 Halogen

field

2 HID, 2 Halogen

field

2 HID, 2 Halogen

factory

6 HID, 4 Halogen

factory

2 HID, 2 Halogen

field

2 HID, 2 Halogen

* 240-4775 is an attachment option. All others listed are customized packages.

The information contained herein is intended for circulation only to Caterpillar and dealer employees whose duties require knowledge of such reports and
is intended exclusively for their information and training. It may contain unverified analysis and facts observed by various Caterpillar or dealer employees.
However, effort has been made to provide reliable results regarding any information comparing Caterpillar built and competitive machines. Effort has been
made to use the latest available spec sheet and other material in the full understanding that these are subject to change without notice. Any reproduction
of this release without the foregoing explanation is prohibited.
CAT, CATERPILLAR, their respective logos and Caterpillar Yellow, as well as corporate and product identity used herein, are trademarks of Caterpillar
and may not be used without permission.

TEKQ0240-01
June 2006
www.cat.com
2006 Caterpillar
All Rights Reserved
Printed in U.S.A.