Outer Limits 4x4 Board

I have never seen or heard of anything like this. The 3 Prados we have at work each have a pair of Lightforce spotlights on them. They look like 170 Strikers.

The bulbs are being changed regularly, very regularly. I saw a pair of bulbs changed on one vehicle about 3 nights ago- I caused a stink because they wanted us to drive about 2 1/2 hours at 2am, and the spotlights were not working- I wont take a vehicle without working spotlights for our own safety, and make sure that all headlights and spotlights are clean. By last night, both bulbs had blown, the filiment inside the bulb had one end melted into a ball.

I was told work is having to change the bulbs rediculously regularly, rarely getting more than a week out of any one bulb. And thats across all 3 vehicles. The admin officer buys the bulbs by the dozen, and yes, they are the Phillips bulbs. The vehicles are used extensively, probably in the vacinity of 80000km a year, used night and day.

On the other hand, I have a pair of Roo lights on the front of my GU, they use the same bulbs. The previous owner put them on from new, the GU is now 6 years old and coming up to 240000km. In the 2 years and 80000km that I have had it, I have not changed one bulb, only had to spray the 2 terminals on one light once, to stop a bit of corrosion.

I suggested they apply a bit of WD40 to the terminals, as I thought there might be some corrosion in the terminals, causing the issues. Of course, they didnt listen, thinking they know best, and we are just dumb shits. I also suggested they contact Lightforce themselves, but of course, because that requires someone in authority to actually get off their arse and do something, its not likely to happen.

BundyRumandCoke wrote:The admin officer buys the bulbs by the dozen.

I love this, instead of getting the root cause of the issue fixed they will just keep buying globes and replacing them.

They are Wired wrong.

Ive had plenty of Lightforce lights and NEVER blown a globe. even after submerging them, smashing one with a rock. Warranty on them is awesome too. The one that filled with water lost the refector inside and LF sent me a replacement no questions asked.

VooDoo wrote:They are Wired wrong.

How? I am struggling to think of a way of wiring them wrong that would cause bulbs to blow.

They aren't like... 12V bulbs on a 24V system or something are they?

chimpboy wrote:

VooDoo wrote:They are Wired wrong.

How? I am struggling to think of a way of wiring them wrong that would cause bulbs to blow.

They aren't like... 12V bulbs on a 24V system or something are they?

Something as simple as a crap connector, corrosion or a short will make the bulbs blow. They either heat up too much or become a fuse in the case of a short. It could be as simple as the way that all of the fleet's lights have been wired have been done with dodgy components or in a way that causes endemic problems.

Doubt very much that it's the LF's

Could it be oil off the pesons finges from putting the bulbs in?

rockcrawler31 wrote:Something as simple as a crap connector, corrosion or a short will make the bulbs blow. They either heat up too much or become a fuse in the case of a short. It could be as simple as the way that all of the fleet's lights have been wired have been done with dodgy components or in a way that causes endemic problems.

Doubt very much that it's the LF's

I agree it could be crap components or poor connections, I guess I didn't think that counted as "wired wrong" so much as "installed poorly" or something.

It's interesting that it's across all the vehicles. I am surprised they don't think it's worth getting someone to look at the installation.

No, at least it isnt oil from fingers. I have seen, and helped the guy who changes the bulbs, and he does diligently use paper towel when fitting the new bulbs.

Am I going to look further at the problem. No, as I am not classed as an auto electrician, regardless of how much of the stuff I have done. You never know, I could do something that causes an accident further down the track- It really is stupid the way OH&S can be sometimes. I can drive, and as part of my job be required to do basic fault finding on, 10000 tonnes of train, but not look into the electrics of a simple set pf spotlights.
I would guess every vehicle is fitted out by the same mob, but who knows, if it is in house, then god knows, as some of the other in house stuff done is beyond belief.

Would fitting 24v bulbs into them cause them to blow?

No, fitting 24v bulbs into a 12v system would only cause poor light output, ie dull light. Fitting 12v bulbs to a 24v system would cause almost instant blowing. Newish (the last couple of years) Prados are not 24v.

Try getting some actual lightforce bulbs, sounds stupid, but philips and lightforce run their filiments in different directions from memory (ie: one side to side, one base to tip), sounds tupid but worth a try.

Either the vehicles are all overcharging (unlikely) or the box of bulbs are a bad batch.

Hand helds use vertical filaments, vehicle lightforce spots use horizontal.

Just re-wire the things (20 minutes if your on a mission) with a new relay, connectors and wire and that will eliminate the wiring aspect. If they are still popping then fix it for good and throw in a HID kit.

bushy555 wrote: Just re-wire the things (20 minutes if your on a mission) with a new relay, connectors and wire and that will eliminate the wiring aspect. If they are still popping then fix it for good and throw in a HID kit.

I like your thinking.
I have still killed or had fail. half of my hid kits, mostly ballasts. I have got a temperamental one that only likes being matched with its own ballast and globe. Neither will work with anything else.

Light force have there own install kit, are you using there kit, if not I would re-wire it with their kit.

Get on the phone to them and ask them?
http://www.lightforce.net.au/contact-us" onclick="window.open(this.href);return false; - has the phone number just there!

QR should be using the lightforce wiring kit anyway? so replacing it shouldnt be too hard.

Hi If the filament is balled at one end it could be due to over voltage.
http://www.invisionsales.com/lighting/p ... o_know.pdf" onclick="window.open(this.href);return false;

over heating of the bulb
Just fitted a set of 240 blitz's to the cruiser
The warning in the lightforce destucksions warns of globe overheating & failer if left on a staionary vehicle.

IE: Are you using them also as a work light on the job site as this will cause overheating and burn out the globe.
If this is the case lightforce do recomend changing to lower wattage globes.

No, they are used as ordinary spotlights on the vehicles when travelling. Occasionally, the vehicle may be stationary for 15-20 minutes, if we are doing rollbys (checking the full length of a train as it rolls slowly past) or when winding on or off wagon handbrakes. Otherwise, nothing out of the ordinary.

Am I going to bother doing anything about it, nope. I am tired of making suggestions, only to be looked down at as if I dont know what I am talking about.

Hehe, that's what rail is all about. Glad I left.

I'm not sure about the lightforce vehicle spotties, but the handhelds have or use to have some pretty crap little wiring in them. We always used to replace the wiring and the switches, just aren't big enough and always overheated a few of them to the point of melting the insulation on the wires. I think the voltage drop across the crappy wires had a lot to do with them blowing globes, but not sure why. What size are the wires in the vehicle mount lights?