Retrofit Procedure to Install LED Lights on Certain 630G and 650G Wheel Tractor Scrapers {1429, 1431, 1434} Caterpillar

Wheel Tractor-Scraper

631G (S/N: DFA1-UP; DXE1-UP; AWK1-UP; CLR1-UP; M1W1-UP)

637G (S/N: CEH1-UP; DFJ1-UP; AXT1-UP)

657G (S/N: W1B1-UP; W1C1-UP; W1E1-UP; W1F1-UP; A4G1-UP; DXG1-UP; GER1-UP; GRS1-UP)

Introduction

This Special Instruction provides the information for installing 544-0470 Lighting Kit in 631G Wheel Tractor Scrapers and 544-0471 Lighting Kit in 657G Wheel Tractor Scrapers.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

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Do not operate this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Before service work is begun, park the machine on a hard level surface. Block the wheels of the machine so unexpected movement will not occur. Unexpected movement of the machine can cause personal injury or death.

1. Park the machine on a hard level surface

2. Apply parking brake.

3. Turn the engine key to the OFF position.

4. Isolate the electrical system by turning the battery disconnect switch to the OFF position.

5. Perform lock out tag out procedure to operator controls in the machine cab.

Installation Procedure for 544-0470 Lighting Kit in 630G Series Machines

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Illustration 1	g06229022
Front of the Machine (A) Electrical Harness

1. Remove the electrical harness (A) from the back of each lamp.
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   Illustration 2	g06229023
   View from rear of left-front lamp assemblies (B) Flood Lamp (C) Head Lamp (D) Head Lamp

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   Illustration 3	g06229043
   View from rear of right-front lamp assemblies (B) Flood Lamp (C) Head Lamp (D) Head Lamp

2. Undo the lamp mounting hardware from bracket assembly. Remove and discard lamp (B), lamp (C), and lamp (D) on both the left and right side of the machine.
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   Illustration 4	g06229025
   View from rear of left-front lamp assemblies (B) Flood Lamp (C) Head Lamp (D) Head Lamp

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   Illustration 5	g06229026
   View from rear of right-front lamp assemblies (1) 449-9219 Flood Lamp Gp (2) 091-9035 Spacer (3) 474-4633 Head Lamp Gp (4) 505-8918 Head Lamp Gp

3. Install flood lamp group (1), head lamp group (3), head lamp group (4) and two spacers (2) on both the left and right side of the machine as shown in Illustration 4 and Illustration 5. Tighten all lamp mounting bolts to 55 ± 10 N·m (41 ± 7 lb ft).

4. Connect electrical harness (A) into the back of each of flood lamp group (1), head lamp group (3), and head lamp group (4). Check all lamps for proper operation.
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   Illustration 6	g06229028
   (E) Flood Lamp Group (F) Electrical Harness

5. Disconnect the electrical harness (F) and undo the mounting hardware from the bracket assembly. Remove and discard flood lamp group (E) from the machine.
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   Illustration 7	g06229032
   (F) Electrical Harness (1) 449-9219 Flood Lamp Gp

6. Install new flood lamp group (1) as shown in Illustration 7. Tighten lamp mounting bolt to 55 ± 10 N·m (41 ± 7 lb ft). Connect electrical harness (F) into the back of flood lamp group (1) and check for proper operation.
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   Illustration 8	g06229031
   (G) Electrical Harness (H) Flood Lamp Group

7. Disconnect the electrical harness (G) and undo the mounting hardware from the bracket assembly. Remove and discard flood lamp group (H) from the machine.
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   Illustration 9	g06229034
   (G) Electrical Harness (1) 449-9219 Flood Lamp Gp

8. Install new flood lamp group (1) as shown in Illustration 9. Tighten lamp mounting bolt to 55 ± 10 N·m (41 ± 7 lb ft). Connect electrical harness (G) into the back of flood lamp group (1) and check for proper operation.

Installation Procedure for 544-0471 Lighting Kit in 650G Series Machines

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Illustration 10	g06228595
Front of machine with lamp locations

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Illustration 11	g06228597
View from rear of left-front lamp assemblies (J) Flood Lamp Group (K) Head and Signal Lamp Group (L) Electrical Harness

1. Disconnect the electrical harness (L) from the back of flood lamp group (J) and head and signal lamp group (K).
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   Illustration 12	g06228599
   View from rear of left-front lamp assemblies (J) Flood Lamp Group (K) Head and Signal Lamp Group

2. Undo the mounting hardware from the bracket assembly. Remove and discard flood lamp group (J) and head and signal lamp group (K) as shown in Illustration 12.
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   Illustration 13	g06228600
   View from rear of right-front lamp assemblies (J) Flood Lamp Group (K) Head and Signal Lamp Group (L) Electrical Harness

3. Disconnect the electrical harness (L) from the back of flood lamp group (J) and head and signal lamp group (K).
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   Illustration 14	g06228601
   View from rear of right-front lamp assemblies (J) Flood Lamp Group (K) Head and Signal Lamp Group

4. Undo the mounting hardware from the bracket assembly. Remove and discard flood lamp group (J) and head and signal lamp group (K) as shown in Illustration 14.
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   Illustration 15	g06295885
   (L) Electrical Harness (1) 449-9219 Flood Lamp Gp (2) 457-6743 Head and Signal Lamp Gp (3) 457-6744 Head and Signal Lamp Gp (4) 491-6705 Lighting Harness As

5. Install flood lamp group (1) on both sides of the machine. Install head and signal lamp group (2) and head and signal lamp group (3) with two lighting harness assemblies (4) on both the left and right side of the machine as shown in Illustration 15. Tighten the mounting bolts for flood lamp groups (1) to 55 ± 10 N·m (41 ± 7 lb ft). Tighten the mounting bolts for head and signal lamp group (2) and head and signal lamp group (3) to 50 ± 5 N·m (37 ± 3.6 lb ft).

6. Connect the electrical harness (L) into the back of flood lamp group (1) and the two lighting harness assemblies (4). Check all the lamps for proper operation.
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   Illustration 16	g06228585
   Rear of machine with lamp location

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   Illustration 17	g06228622
   (M) Electrical Harness (N) Flood Lamp Group

7. Disconnect the electrical harness (N) and undo the mounting hardware from the bracket assembly. Remove and discard flood lamp group (M) from the machine.
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   Illustration 18	g06228623
   (N) Electrical Harness (1) 449-9219 Flood Lamp Gp

8. Install new flood lamp group (1) as shown in Illustration 18. Tighten lamp mounting bolt to 55 ± 10 N·m (41 ± 7 lb ft). Connect electrical harness (N) into the back of flood lamp group (1) and check for proper operation.