2009/08/31 A New Alternator Is Available for the Tier III 631G and the Tier III 637GWheel Tractor-Scraper Tractor Engines {1405} Caterpillar

Wheel Tractor-Scraper:

631G (S/N: DFA1-UP)

637G (S/N: DFJ1-UP)

Service Magazine SEPD1001, 07 July 2009, "A New Alternator is Available for the Tier III 631G and the Tier III 637G Wheel Tractor-Scraper Tractor Engines". The information in this article has changed. Disregard this article. The correct information follows:

Description of Change: A new alternator is available for the 631G and the 637G Wheel Tractor-Scraper models that are listed above. An 80 ampere alternator is replacing the current 74 ampere alternator. The new alternator provides superior reliability and increased performance over the present alternator. A new grounding cable has been added for improved grounding of the alternator.

Adaptable To: The 200-2232 Charging Alternator Gp is being replaced by 235-7133 Charging Alternator Gp. A new 338-1678 Cable As is being used for improved grounding of the alternator.

Note: In order to replace the existing alternator with the new 235-7133 Charging Alternator Gp, perform the instructions that follow.

Table 1

Parts List
Quantity	Part Number	Description
4	132-5789	Clip
2	200-6345	Mount
1	235-7133	Charging Alternator Gp
1	289-9520	Bracket As
1	338-1678	Cable As
1	5M-3062	Bolt
8	7K-1181	Cable Strap
2	8T-4121	Hard Washer
1	8T-4137	Bolt
1	8T-4191	Bolt
1	8T-4896	Hard Washer
1	9G-0028	Boss As

1. Move the machine to a safe area and secure the machine. Lower the bowl to the ground. Set the brakes. Chock the wheels. Shut off the master disconnect switch.

2. Remove the stand for the air filter. Set the stand aside.

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Illustration 1	g01954937
9G-0028 Boss As location

3. Attach the new 9G-0028 Boss As (1) for ground. Locate the boss on the inside of the frame rail on the right hand side. The boss should be lined up with the junction block support for the battery cable and 50.8 mm (2 inch) from the top of the frame rail. Remove paint from the area. Weld the boss into position with a 3 mm (0.12 inch) fillet weld.

4. Remove the old alternator.

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Illustration 2	g01963186
(A) 136.7 mm (5.4 inch) (B) 154.9 mm (6.1 inch)

5. Install new 235-7133 Charging Alternator Gp. Assemble one 132-5789 Clip (2) onto the top rear mounting bolt.

   Note: Some machines will require holes to be drilled and tapped into the bracket assembly. Refer to Illustration 2. The hole sizes should be M10X1.5.

6. Reconnect the leads for the harness.

7. Install one 132-5789 Clip (2) onto the engine block that is located behind the compressor for the air conditioner. Assemble the clip with the clip for the lead of the air inlet for the engine with one 8T-4191 Bolt and one 8T-4121 Hard Washer .

8. Assemble one 132-5789 Clip (2) onto the top bolt of the compressor for the air conditioner.

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Illustration 3	g01954940
132-5789 Clip location

9. Secure the leads of the harness to the clips with three 7K-1181 .

10. Reinstall the belt guard. Assemble one 289-9520 Bracket As (3) to the bottom hole in the guard. Reuse the original hardware.

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Illustration 4	g01954941
289-9520 Bracket As location

11. Assemble one 132-5789 Clip (2) to 289-9520 Bracket As (3) with one 8T-4137 Bolt and one 8T-4121 Hard Washer .

12. Assemble one 338-1678 Cable As to the terminal on the alternator to the new ground boss with one 5M-3062 Bolt and one 8T-4896 Hard Washer .

    Note: Tighten the terminal on the alternator to 4.4 N·m (3.3 lb ft).

13. Secure cable to the clip with one 7K-1181 Cable Strap .

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Illustration 5	g01954942
200-6345 Mount location

14. Secure harness to air conditioner hose and heater hose with four 7K-1181 Cable Strap and two 200-6345 Mounts (4) .

    Note: Use caution. Do not squeeze the heater hose.

15. Install the stand for the air filter.

16. Return the machine to service.

The new alternator and grounding cable are adaptable to the following machines:

• 631G (S/N: DFA1-364)

• 637G (S/N: DFJ1-399)

The new alternator and grounding cable are effective in production on the following machines:

• 631G (S/N: DFA365-UP)

• 637G (S/N: DFJ400-UP)