INSTRUCTION PACKET TIER 3 ENGINE REPOWER KIT 762B SCRAPER

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Sarah Holmes
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1 PLEASE READ ALL INSTRUCTIONS THOROUGHLY BEFORE STARTING REPOWER INSTRUCTION PACKET TIER 3 ENGINE REPOWER KIT 762B SCRAPER

2 Engine Prep 762B 1. Install (1) BELL1033 engine f/w adapter ring using (8) 19H3093 ⅜ x 1 ¾ allen head bolts. 2. Install (1) RE oil filler neck, (1) R gasket and (1) RE filler cap using (2) RE67239 bolts on the r/h side of the block. 3. Drain the engine oil and install (1) metric adapter with (1) R375R O-ring, (1) NPT elbow, (1) AU40997 hose, and (1) 15H3 ½ NPT pipe cap. (NOTE: The hose and 90 elbow must face the back of the engine.) (see photo # 762B054) 4. Remove the existing oil filter adapter and tubes. Remove and reinstall the filter head using (1) R bracket, (1) R spacer, (1) R adapter, and (2) RE tubes with clamps using (1) 19M7784 M10x20 flange bolt, (1) 19M7804 M10x40 flange bolt and (1) 19M7805 M10x45 flange bolt. (NOTE: Re-use all but the (2) M8890 bolts on the filter adapter use the (2) 19M7802 M8x65 bolts supplied.) (See attached parts breakdown.) (see photo # 762B052) 5. Remove and replace the exhaust manifold and turbo drain line with (1) R manifold and (1) RE line. Turn the turbo to rear exhaust and re-install it re-indexing the center and compressor housing as necessary. Use (9) R M10x35 bolts supplied (see photo # 762B048). 6. Remove the primary fuel filter. Remove the primary fuel filter to transfer pump fuel line and discard them. Install (1) R primary fuel filter bracket using (2) 19M7785 M10x25 flange bolts (see parts breakdown) to the top of the cylinder head. Re-install the primary filter and connect it to the transfer pump with (1) RE fuel line. 7. Remove the large water plug located in the right hand side of the block below the fuel transfer pump and install (1) R adapter, (1) U13639 O-ring, and (1) M18- ⅜ NPT adapter. Remove the M18 plug from the water-pump and install (1) fitting and (1) ⅜ NPT 45 fitting. (NOTE: The 45 fitting should face forward.) Remove the heater connection fittings from the original engine and install them on to the new engine. 8. Remove the fan pulley and fan drive support. Set them aside. Remove the hub from the new RE fan drive support and press (1) RE hub in its place. Replace the (1) R66077 plug. Install fan support on engine using (4) 19M7805 M10x45 bolts maintaining 16.5 center line from fan to crank. Install (1) R right hand support bracket along with (1) BELL1095 upper CAC tube support using (1) 19M7835 M10x35 bolt and (1) 19M7789 M12x30 bolt. Install the (1) R left hand support bracket using (1) 19M7835 M10x35 bolt, (2) H98792 spacers, and (1) 19M8112 M10x55 flange bolt. Install (1) T fan pulley, (1) AT fan, and (1) R fan spacer using (6) 19M9168 M10x180 flange bolts. Install (1) RE idler pulley and (1) R sleeve using (1) 19M8320 M10x45 flange bolt. Install (1) R fan belt (see photos # 762B052, 762B058, 762B058B, & 762B058C). INST762B 2

3 9. Remove the 2 bolts from the water pump inlet. Install (1) BELL1096 CAC tube support bracket using (2) 19M8039 M8x80 bolts, (1) 28H3405 7/16 spacer, (1) 28H spacer. Install (1) BELL1064 CAC tube to the air inlet using (1) T190408, 2-2½ 90 hose (1) CT250 and (1) CT300 clamps. Secure the tube to the upper CAC tube support using (1) AQ19033 cable and (2) 19M7786 M10x30 bolt to secure cable to the tube. (NOTE: Bolt will bottom out at tube to leave slack in cable eyelet.) Do not over tighten. Pass the other bolt through the other eyelet and thread (1) 14M7296 nut (reverse) onto the bolt leaving space enough for the cable to be in a slack position. Secure the cable to the upper support with (1) 14M7296 M10 nut. Jam the nuts to the support. Secure the CAC tube to the (1) BELL1096 bracket using (1) F1451R tube clamp, (1) 19M7786 M10X30 bolt and (1) 14M7296 flange nut. (see photos # 762B053 &762B053B) 10. Assemble (2) RE isolators onto the (1) BELL1102 ECU bracket using (4) 19M7867 M8 x 25 fl. bolts and (4) 14M7298 M8 flange nuts. Bolt the ECU onto the isolators with (2) 19M8319 M8 x 50 fl. bolts. Install the 19M7868 M8 x 30 flange bolt into the hole at the top of the ECU bracket using (2) 14M7298 flange nuts creating an anchor point for the throttle return spring (see photo # 762B061). 11. Remove (3) bolts from the right side of the oil pan (see photo # 762B060) and install the ECU and mounting bracket. Plug the loose engine harness to the ECU. 12. Bolt (1) BELL1090L left and (1) BELL1090R right front mounts onto the engine using (6) 19M7790 M12x35 bolts, (2) 19M7843 M16x35 flange bolts, (2) 19M7826 M16x70 flange bolts and (2) 14M7291 M16 flange nuts. NOTE: Bolt the Bell #1373 throttle assembly along with the right front leg (see photo # 762B061). 13. Bolt (1) BELL1091L left and (1) BELL1091R right rear mounts onto the flywheel housing using (8) 19M7790 M12x35 flange bolts. 14. Bolt (1) BELL1099 muffler support to the rear engine mounts, using (2) 19M7791 M12x40 flange bolts and (2) 14M7299 M12 flange nuts. Bolt the original muffler support to the BELL1099 with (2) 19M7793 M16x40 bolts and 14M7291 nuts (see photo # 762B063). (Do no tighten the bolts until muffler has been modified and installed.) 15. Transfer the original engine wiring harness to the new engine. Transfer the engine water temperature sender. (Not the head temperature sensor). Transfer the engine oil sensor to the left hand side of the engine. The sender wire will have to be lengthened approximately 28 INST762B 3

4 Machine Prep 1. Remove the original throttle pedal and cable. Install (1) AT pedal with (1) T gasket and (1) BELL1102 throttle pedal harness. 2. Drill a 2 ⅛ hole in the dash above the steering column for the PV101A and a ½ hole just below it for the HKP fuse holder (see photo # 762B028). Drill another ¾ hole in the side of the cab next to the Deutsch connector (see photo # 762B030) and pass the BELL726 wiring harness through it. Install the PV101A and fuse holder into the dash and make the necessary connections from the harness to PV101A and fuse holder. 3. Take the radiator isolator pan measure 8 ¼ into the center from the right and 6 ½ up and remove a 4 ½ wide mouse hole for the CAC lower connection(see photo # 762B042). 4. Cut the headlight assembly mounting brackets flush at their mounting points in the hood and weld them centered on the (2) 2 x 2 x2 x ¼ tubing(see photos # 762B026, 762B035, 762B035B, & 762B035C). Measure 5 ¾ back from the front of the hood to the tubing and 3 ½ over from the side of the hood to the side of the light assembly bracket and tack weld them. Check for clearance for the CAC. Finish welding them in place. 5. Take the coolant recovery bottle mount and support brackets and slot the mounting holes (see photos # 762B023 & 762B024). Measure 5 ½ over and 5 deep and remove a portion of the recover bottle mount (see photos # 762B022 & 762B023). 6. Mount (1) CAC to the radiator utilizing the same bolts and nuts as the air conditioner condenser (see photo # 762B021). 7. Install the engine and radiator package. Install the (1) BELL1097 upper radiator hose using (1) 7415, 1 ¾ x 2 hose, (1) x2 ½ hose, (2) HC832, (1) HC828, and (1) HC840 clamps. Install (1) BELL1098 lower coolant pipe using (1) hose, (1) T x 3 hose, (2) HC832, (1) CT250L, and (1) CT350L clamps (see photos # 762B039 & 762B049). 8. Connect (1) BELL1094 tube on the engine to the CAC using (1) T168123, 2 ½ str. hose (1) P ½ 90 hose and (1) BELL1093 CAC tube, (4) CT300L clamps (1) F1451R support clamp, (1) 28H ¾ long bushing, (1) 19M7807 M10x60 bolt, and (1)14M7296 M10 nut. 9. Install (1) BELL1092 upper CAC tube from the turbo to CAC using (1) T hose, (1) T x2 ½ 90 hose, (3) CT250L, and (1) CT300L clamps. Use (1) T tube clamp, (1) 19M7786 M10x30 bolt, (1) 14M7296 M10 nut and secure (1) BELL1093 tube to the BELL1095 support. Close and check clearance between the CAC tube and hood. Modify if necessary (see photos # 762B038, 762B038B, 762B038C, & 762B038D). 10. Cut and remove a 1 long piece of the muffler flange and secure it to the turbo (see photo # 762B036), cut the remaining portion of the pipe left on the muffler flush with the weld install and locate the muffler onto the muffler support. Take the 6 piece of 3 ½ exhaust pipe and tack weld it to the muffler and flange. Remove the muffler and finish welding it, reinstall the INST762B 4

5 muffler and secure it and the support bolts (see photos # 762B036B & 762B036C). 11. Connect the small 3 pole harness with the red and black wires to the original injection pump shut-off Packard connector located in the original harness. Run the harness along with the throttle pedal and PV101A harness toward the battery box and plug the wires into the (1) HDP Deutsch connector (see schematic # 700-B ), secure the 21Pin connector to the (1) BELL552 plug mount using (1) nut and (1) washer. Remove 2 bolts from the fender and install the BELL552 (see photo # 762B051). Coil the remaining harness up and neatly wrap them together and place them behind the BELL552 (see photo #762B059). 12. Secure (1) R low or ultralow sulfur fuel sticker in a visible place next to the fuel tank filler neck. 13. Secure the grill to the hood using (6) 28H long spacers and (6) 19H3727 ⅜ x 2 flange bolts. 14. Top-off all fluids, charge the air conditioning system. 15. Connect (1) AR fuel return line and fitting to the high pressure pump. Connect the fuel feed line to the primary filter. 16. Use (1) T battery terminal boot to protect the positive battery post on the starter. 17. Machine is ready to start. INST762B 5

6 Picture # 762B021 Picture # 762B022 INST762B 6

7 Picture # 762B023 Picture # 762B024 INST762B 7

8 Picture # 762B028 Picture # 762B030 INST762B 8

9 Photo # 762B035 Photo # 762B035B INST762B 9

10 Picture # 762B035C Picture # 762B036 INST762B 10

11 Picture # 762B036B Picture # 762B036C INST762B 11

12 Picture # 762B038 Picture # 762B038B INST762B 12

13 Picture # 762B038C Picture # 762B038D INST762B 13

14 Picture # 762B039 Picture # 762B042 INST762B 14

15 Picture # 762B048 Picture # 762B049 INST762B 15

16 Picture # 762B052 Picture # 762B053 INST762B 16

17 Picture # 762B054 Picture # 762B058 INST762B 17

18 Picture # 762B058B Picture # 762B058C INST762B 18

19 Picture # 762B060 Picture # 762B061 INST762B 19

20 Picture # 762B063 INST762B 20

21 INST762B 21

22 Product: PE 6068HF285 Diesel Engine (2684F) Specification Name: 762B Specification Number: S Create Date: 16Jul2012 Build Number: 1 Customer Name: Code Description As Of Date 16Jul2012 Base PE 6068HF285 Diesel Engine (2684F) 1158 Rocker Arm Cover, Front Fill, w/o John Deere Nameplate 1295 No Oil Filler, w/ ECU Mounting Bracket, for use w/ Engine Mounted ECU 1324 Crankshaft Pulley, 168mm (6.6 in.), Standard Duty Damper, for Taper Nose Crank 1405 Flywheel Housing, SAE #3, LH, 3 Bolt Type 1 Starter Mount 1503 Flywheel for SAE #3, 11.5" OCC, 129 Tooth 8/10 Pitch Ring Gear 16A6 Fuel System, Denso HPCR w/ecu, 1000cc Flow Injector, Industrial - 116kW (155hp) thru149kw (200hp) and Gen-Set - 147kW (197hp) & 177kW (237hp) at 1800RPM 1783 Air Intake, Vertical Intake 1907 Oil Pan, Aluminum, Center Sump, 35 Off Level, 19L 2158 Thermostat Cover, Vertical Outlet, Single Thermostat, No Sensor Ports (provided in 3924) 2217 Thermostat, Single Sealed (use w/ 3924) 2341 Fan Housing, Nodular Iron, Heavy Duty Bearing, Fan Height 402mm (15.8"), Max 12kg Fan 2496 No Fan Belt w/ Idler Pulley (pulley required for all A/C and Fan Heights 290mm (11.4") & Below) 2699 No Engine Cylinder Block Heater 28AV Exhaust Manifold, High mount w/elbow pad, ductile iron 2909 Vent System, w/90 Degree Elbow, 1350 mm Vent Hose, LS, w/o Clamp V Denso, 10 HP (7.5 kw), LH, 3-Bolt, Type 1 Mount, Gear Reduction V, 100 Amp, Bosch 35ED 6.0", 2 Micron Final Fuel Filter, RH Side, Engine Mounted (contains port for optional low pressure fuel sensor) 3614 Front Plate, w/aux-drive, HPCR 3924 Thermostat Housing (use w/sealed Thermostat), Six Threaded Ports (A/C Bracket Compatible) 4017 Dipstick, RH Side Service, Short 4199 No Auxiliary Front Drive Pulley 4399 No Starting Aid 4434 Timing Gear Cover, Aux-Drive, w/ Fan Mount Support (High Mount Alternator) 5204 Base Engine Auxiliary Drive w/ Shipping Cover (less drive gear) 5399 No Fuel Heater 5569 Shipping Stand, Metal 5603 Industrial Yellow 5722 Water Pump Inlet, Downward Orientation w/ M18 Port 5902 Oil Cooler, 7 Plate 6099 No Auxiliary Fan Drive Pulley 6293 Alternator Mounting, 24V, 100 Amp, High Output Bosch, for Aux Drive 63AB Remote Mounted Primary Filter, High RH Rear Engine Mounted Final Filter - Air Compressor Compatible 6499 Exhaust Elbow, None 65QN Turbocharger, High Mount, Industrial, High Power & Gen-Set, RH High Oil Filter 6730 Base Engine Sensors 6901 Engine Serial Number Plate and Option Code Label 72MC 24V, 185HP, 138kW@2200, 4% PB, 31% TR V, Nippendenso Air Conditioning Compressor & Mounting Bracket 7899 No Air Compressor 8164 RH Side, Remote Mounted, 6.0", 30 Micron Primary Fuel Filter w/water Separator and W.I.F Sensor, 990mm (39") Hose Length 83DR ECU Software, John Deere Custom Performance - Industrial 138kW (185HP) thru 149kW (200HP) (500 Hour Oil Change Interval) 8438 Engine Mounted ECU, LH Side, w/wiring Harness Between Engine Sensors & ECU and hardware, Factory Installed mm (7.3") Diameter, 402mm (15.8") Fan Height 8718 Belt Tensioner, Auto, High Mount & Low Mount Alternator, for use w/aux-drive 8845 Oil Filter. RH High (not compatible with aux-drive accessories) 9114 Customer/Panel Interface Harness, Engine Mounted ECU (LH Side) to Instrument Panel, packaged & shipped w/engine (contains the 21 & 23 pin connectors, 9 pin diagnostic connector, starter relay leads, power/ground leads, TVP, Aux Power, CAN Terminato 93GP Tier 4 Flex, 138kW-149kW 2200 RPM & 2400 RPM 9499 No Software Trim

READ COMPLETELY BEFORE QUOTING REPOWER

ATTENTION READ COMPLETELY BEFORE QUOTING REPOWER As in any REPOWER, experience has shown that a piece of equipment designed for older Tier 0 or Tier model engines almost always has trade-offs and compromises