624H Repower Work Instructions
Contents
1. 18 Proure 24 S pportkibraeketrBasgusu u uu Susu pupuna cuu s 19 Fise 29 COV Dube 19 Figure 26 Muffler Support Bracket Modification for CCV 20 27 Muttler SupDOEPD s at ec u u Du a S tn ceed aa a ec 20 Figure 27 2I pin Deutsch Instrument Panel COnDector 23 Figure 29 21 pin Deutsch Instrument Panel and Controls 23 sure 0 Winne llin e nuyu un ym A E CI E CI 24 1 Parts Table 1 Parts List CATEGORY PART QTY DESCRIPTION KIT 6068HF285 624H J vipat EXHAUSTCLAMP RADIATOR T181335 RADIATOR HOSE T181336 RADIATOR HOSE TY22472 RADIATOR HOSE CLAMP INSTRUMENT PANEL 32120 AT832191 2122 AIR CLEANER AT225535B H88782 AIR CLEANER KIT AIR CLEANER ELBOW HOSE LF i i wRPAFT40DA01 1 4 ODX16 AIRFLOWTUBE REez44 O Oo O O OSOS O O 88Hi981 _ 4 SPACER 7175358 1 INTAKE RAINCAP ARe4937 2 SUPPORTBAND L d _ 1675 202 135501 10825 R120467 1 45DEGREECCVELBOWFITTNG 1174316 BELT Due to differences in configurations you may need to supply miscellaneous mounting hardware 2 Removing Old Engine e Remove old engine according to the 624H S2. talk to a Western Power Products engineer at 888 ENG POWR or 661 397 9155 They will help you develop a more complete picture of the scope of your repower project Table of Contents MAH ReDOWOE Work LODS r u uu Su uu uu su su ua uuu usu 1 4 1 MEN cuo ec 4 2 5 ICO 5 Tostalhnp NSwW EBPIIO toca se 5 6 6 COrnttols usu Su uuu s ceri ee eine iota 10 02 MC 14 _ ModE AON RENE TOEIC 15 TE Arar Cleaner Mounino T accesses care ac toe etra hie dum 16 T2 Exhaust Moun M z uy u u makna Ion editi oun LOL UE LSU Rd 17 Appendix A 6068HF285 Engine 2 Appendix 5 act aus ssh EON ese ea 23 Figures and Tables Radiator Removal o sopa a u ID eae 5 Froure 2 New Eng me Ii stall ati ii uu aes etapa eects 5 Jou o CAC Tube hoga 6 Wire Harness ROU uuu decocto suu Duka dea tente added 6 Figure 5 Rear Left Wiring Harness RoOuting ccccccssseececcccecceececeaaaesesssssesee
3. 2201 2395 2499 2699 28AV 2957 3041 3142 35ED 3614 3999 4002 4199 4399 4434 5204 5399 5569 5603 5722 5902 6099 6277 6387 6438 65RM 6730 6901 72MC 7499 7899 8171 83DR 8453 Appendix A 6068HF285 Engine Specification Table 2 Engine Option Codes Product PE 6068HF285 Diesel Engine 2684F Specification Name 6068HF285 624H Final Specification Number S022139 Create Date 09Dec2009 Build Number 2 Customer Name Description 09Dec2009 PE 6068HF285 Diesel Engine 2684F Rocker Arm Cover Rear Fill w John Deere Nameplate Oil Filler RH for use w Remote Mounted ECU Crankshaft Pulley 168mm 6 6 Standard Duty Damper for Taper Nose Crank Flywheel Housing SAE 3 LH 3 Bolt Type 1 Starter Mount Front Access for Torque Converter Magnetic PU Flywheel for SAE 3 11 5 OCC 129 Tooth 8 10 Pitch Ring Gear Fuel System Denso HPCR w ECU 1000cc Flow Injector Industrial 116kW 155hp thru149kW 200hp and Gen Set 147kW 197hp amp 177kW 237hp at 1800RPM Air Intake Vertical Intake Oil Pan Aluminum Deep Center Sump 45 Int amp 20 Cont Off Level 19L Thermostat Cover Vertical Outlet Single Thermostat Two Sensor Ports Thermostat Single No Fan Housing w Fan Mount Capability No Fan Belt No Engine Cylinder Block Heater Exhaust Manifold High Mount Turbocharger Vent System 90 Elbow w o Clamp 1100mm 43 Vent Hose Clamped to Right Side of Flywheel Housing 24V Denso 10 HP
4. 7 5 kW LH 3 Bolt Type 1 Mount Gear Reduction 24V 45 Amp Bosch w Wiring Harness 6 0 2 Micron Final Fuel Filter RH Side Engine Mounted contains port for optional low pressure fuel sensor Front Plate w Aux Drive HPCR No Thermostat Housing Cover Only Dipstick RH Side Service No Auxiliary Front Drive Pulley No Starting Aid Timing Gear Cover Aux Drive w Fan Mount Support High Mount Alternator Base Engine Auxiliary Drive w Shipping Cover less drive gear No Fuel Heater Shipping Stand Metal Industrial Yellow Water Pump Inlet Downward Orientation w M18 Port Oil Cooler 7 Plate No Auxiliary Fan Drive Pulley Alternator Mounting High Position Bosch 45 120 Amp for Aux Drive Engine Mounted Primary Filter High RH Rear Engine Mounted Final Filter Air Compressor Compatible Exhaust Elbow Turbocharger High Mount Industrial High Power amp Gen Set RH Low Rear Oil Filter Base Engine Sensors Serial Number Plate 24V 185HP 138kW 2200 4 PB 31 TR No Air Conditioning Compressor Bracket No Air Compressor RH Side Engine Mounted High RH Side 6 0 30 Micron Primary Fuel Filter w Water Separator and W I F Sensor ECU Software John Deere Custom Performance Industrial 138kW 185HP thru 149kW 200HP 500 Hour Oil Change Interval Remote Mounted ECU 24V w wiring harness and hardware installed ECU shipped loose Distributor OEM Installed w 10 8699 8718 8843 9109 9113 93GP 9499 foo
5. D Er 3 eral A J Paia esa Ta cde A I EET T TT EN FS ru Er A zT mu Ex r5 a sal veut yat Ew mura r m Tau5ernabr Ev 3 E Er E Lr rte Lm batt lal z Interface Alr Filer NP Rastriction Switen pu EXxzi A _ e 2 Secondary ignition or Analog c B Throttle Comman ce 4 a uoc ul al Remote amp ulce Cruicexraka lanitian Er ws zm 5 H gu E L J F JL R Ti 1 Shutdown Multi State Throttle gt Figure 30 Wiring Harness
6. support bracket will mount in the same location on the new engine Figure 23 Mocked Up Muffler Support Bracket Obtain a 22 X 3 piece of 1 4 plate Scribe a bend line 5 from one end heat with a torch and bend up 90 degrees Filet weld the support to the muffler support bracket You will need 2 gap from the right side of the bracket See Figure 23 Mocked Up Muffler Support Bracket for completed bracket Using muffler mounting bracket from previous engine mock bracket to new engine and with a pencil scribe the corner closest to the cab in a circular pattern to be ground off removed to clear valve cover oil cap Figure 25 CCV Tube Routing Remount bracket With a pencil scribe the center of the bracket where the crank case ventilation hole and valve cover come in contact Install the R120467 45 DEGREE CCV ELBOW FITTING on the engine the 90 degree fitting will not clear the exhaust support bracket Figure 26 Muffler Support Bracket Modification for CCV Remove bracket and cut a circular hole in bracket as marked to obtain crank case ventilation elbow Remount bracket Attach one AR64937 air cleaner saddle bracket to muffler Mock up the vertical section of plate to the saddle bracket and scribe mounting holes Bolt air cleaner saddle bracket on the muffler to the exhaust support bracket Figure 27 Muffler Support Code As Of Date Base 1142 1201 1324 1406 1503 16A6 1783 1909 2156
7. 624H Repower Work Instructions 6068HF285 624H 3 2 2 9 gt PYYYYYYYYYYYY YYYYYY 1000000000009 LLL TA DIPPFPPPPFFFE LIT FA 22222222202 200000 PI PR rr Revision 27 July 2010 Z Elise PRODUCTS INC JOHN DEERE Attention Service Manager Attention Experience has shown that putting Tier 2 and Tier 3 power plants into engine compartments designed for much older Tier and Tier 1 models almost always Involves trade offs and compromises You need to be aware that the equipment options on your candidate machine may differ from the options Installed on the prototype untt used for kit development Particular examples might include cabs on bulldozers and the presence of air conditioning In addition individual interpretations abound with respect to the best way to execute a repower For these reasons Western Power Products will not be responsible for any additional cost an installing dealer incurs to 1 adapt a kit to a machine configuration different from the machine used to develop the kit or 2 to provide additional kit elements or alternate component mounts or orientations employed to satisfy individual dealer preferences for their final repower product So before quoting always start with a thorough review the installation instructions and engine codes to identify potential areas you suspect might require additional material and labor If you are uncertain
8. artment e With cutting torch cut a hole below the ECU to route the wiring harness underneath the cab to engine and connect to ECU 6 Modifying Controls 6 1 1 Power View Installation gt lt gt Figure 11 Modified Instrument Panel with PowerView Remove the harness switches key switch and Power View from the Instrument panel Figure 12 RE534022B Instrument Panel Harness Using 1 inch hole saw cut a hole next to the floorboard and the hydraulic control panel Remove ashtray PowerView will be installed in the old ash tray location On the left hand side of the dash with 1 12 hole saw cut a hole even with the ashtray Route PowerView wiring connector to the hole on the left hand side of the dash Connect the PowerView to CAN Bus and power Install Power View in ash tray location Carefully route harness extension from the left side of the dash below and around the right side of the cab Ensure that the cable does not interfere or damage foot pedal controls Once past all foot pedals lift up the floor mat and run harness around the contour of the cab Reinstall floor mat v 5 TTE a Figure 13 Wiring Harness Routing Through Cab e Connect harness to the 21 pin connector through the 1 1 2 hole previously drilled through the cab and the hydraulic control box 6 1 2 Throttle Modification The mechanical throttle linkage must be changed to accommodate the new electronic engine Replace the mecha
9. eececeeeeeeseeaaaaaesssesseeseeeeees 7 Picure o Extension Harness to EC uy oso a unn n ded ham laaya u laqha Suma lodos sme tatas 7 Peut r ECU Mounin nee Da a uu Ska 8 Figure Pre threaded HOES u u uuu usa Mio aaa 8 Figure 9 Harness Routing Through ECU Compartmetnt 9 Figure 10 Underside of ECU Compartment 9 Figure 11 Modified Instrument Panel with Power View 10 Figure 12 RE334022B Instrument Panel Harness u u eesti a AA irae 11 Figure 13 Wiring Harness Routing Through d a 11 14 1 Analog Foot Throttle oorr ttp oen lt Hee vedette ped oe Yo uet due eae dee 12 Figure 15 Potentiometer Mounting On Accelerator 13 Figure 16 Underside of Accelerator with Potentiometer 13 our T Key S 14 Figure 18 New Exhaust Stack Air Cleaner 15 Preure 9 Ait leaner Mounn Soone dh nl u eee 16 Eroure 20 Adr Inlet Hose ROUN ei nutu A erste eee 16 Figure 21 M ftler Mountme9 Location ieu un qo aea oa Ran eda headed 17 22 Muti ler SUpport STACKS 17 Pisure 232 Vlocked Up iMuIrTlerSupporttBiacketuu uuu 2
10. ervice Manual e Remove air cleaner mounting bracket from old engine this will be used as the exhaust mounting bracket on the new engine 3 Service Radiator e Check radiator and service if necessary 1111 v Figure 1 Radiator Removal 4 Installing New Engine e Install new engine per service repair manual e Reinstall hydraulic pump Figure 2 New Engine Installation Re install radiator if 1t needed to be removed for service Connect radiator hoses new CAC pipes fuel lines 5 Wiring and Wire Harness Install wiring harness per service repair manual Be sure to keep harness away from high temperature locations such as the exhaust manifold Connect sensors to engine Secure harness to engine with zip ties Figure 4 Wiring Harness Routing Figure 5 Rear Left Wiring Harness Routing e Run excess wiring underneath the right side of the cab Figure 6 Extension Harness to ECU e On the right side of the cab use a 13mm wrench and undo the 2 screws holding the access panel closed Figure 8 Pre threaded Mounting Holes In the access panel you will find 2 power control modules and wiring Mount the engine control module to the pre threaded holes on the wall that separates the other power control module that it already installed see Figure 8 Pre threaded Mounting Holes L V T Ties re 25 ki i m qu Figure 10 Underside of ECU Comp
11. ine configuration requires modifications to the hood to accept the new air cleaner and exhaust The Tier III 6068HF285 2 valve engine only comes in front exhaust configuration so the change from a rear exhaust engine to front exhaust necessitates the relocation of the air cleaner See WRP624HAO01 HOOD MODIFICATION TEMPLATE for a 1 1 scale template of where to cut the new holes for the exhaust stack The old exhaust stack hole 1s used for the air cleaner The following figures point out the purpose of each modification to the hood e Mount Air Cleaner in old Exhaust Stack Location Mount the Exhaust Stack as shown in Figure 18 New Exhaust Stack and Air Cleaner Locations Figure 18 New Exhaust Stack and Air Cleaner Locations e Cut holes in hood according to WRP624HAO01 o The drawing is a top view Align the drawing with the back edge of the hood and existing slot o The portion to cut will create a second exhaust stack mount which looks like the standard exhaust stack mount 7 1 Air Cleaner Mounting e Install air cleaner in location of the previous muffler Y Figure 19 Air Cleaner Mounting e Use washers to space the saddle brackets from the top of the hood e Secure air inlet hose to turbo 7 2 Exhaust Mounting Z q m PIU l a EY 1 v by BE M ffler Mounting Location Figure 21 Mu Figure 22 Muffler Support Bracket The muffler
12. nical system with the throttle potentiometer e Remove old pedal and cable e Install new pedal with provided WRP624HAO02 bracket Route throttle sensor wires through floor of cab and to 21 pin instrumentation and controls connector on the wiring harness e See AGII P 11 for additional details on the foot throttle Electrical Hook up To attach the primary analog throttle to the JDEC controller a Packard 3 way Male Connector P N 12015793 using 12033674 terminals needs to be attached to the John Deere wiring hamess pins as shown Analog Throttle M is the 5V reference voltage pin L is the throttle signal pin is the ground The corresponding connection in the throttle connector is as follows 5 VOLTS CE suv GRND B A GHAD AAA Figure 14 AG 11 Analog Foot Throttle Wiring Figure 15 Potentiometer Mounting On Accelerator Pedal Figure 16 Underside of Accelerator with Potentiometer 6 2 Key Switch KEY SWIICH we 74 Battery i Start 21 PIN CONNECTOR To the B terminal of the battery 12 AWG To the starter relay 12 AWG To alternator ignition 18 AWG Switched B power to the ECU ON OFF 12 AWG fuse and diagnostic gage 14 AWG Figure 17 Key Switch Key Switch Install the wiring harness into the original key switch or transfer the key switch from the RE534022B instrument panel 7 Hood Modifications The new eng
13. t of harness 402 mm fan height No Fan Pulley Belt Tensioner Auto High Mount amp Low Mount Alternator for use w Aux Drive Oil Filter RH Low Rear Extension Harness 21 Pin Customer Panel Interface Harness to Instrument Panel 12 Foot 3 7M Qty 1 packaged amp shipped w engine Customer Panel Interface Harness Remote Mounted ECU to Instrument Panel packaged amp shipped w engine contains the 21 amp 23 pin connectors 9 pin diagnostic connector starter relay leads power ground leads TVP Aux Power CAN Terminator Remote On Emission Label Tier 3 Industrial Applications 185hp 138kW thru 200hp 149kW No Software Trim Appendix Electronics No Gauge x S S yellow red yellow red Use for any non sensor ground lights gauge power etc CAN shield To any CAN connectors including the PowerView Diagnostic gauge 1 12 O N N N 8 12 8 o 12 1 red Battery power to ECU switched Must be wired to the Ignition terminal of key switch 3 Warning lamp driver To ground side of the warning lamp 12 5 Alternator ignition Should be wired to the or Ignition terminal of the ignition switch Tachometer output A synthesized frequency signal that can be used to drive a non CAN elec tronic tachometer Primary analog throttle To center sensing terminal of the primary analog throttle potentiometer input voltage or throttle emulator Throttle switch 2 sta
14. te or Ramp Resume Coast Bump Speed To the 2 state throttle speed select switch and or the cruise resume coast Down switch E reen For adjustable 3 state throttle option orange For adjustable 3 state throttle option DE10 Standard ECU Circuit Number is 022 Not available on DE10 Standard ECU orange red 4 Q9 cO t 98 brown violet 914 yellow 914 yellow Co D o o D c 3 Q E jad lt BL m w R Figure 28 21 pin Deutsch Instrument Panel Connector emn DN man NNT Low u CAN Complete 21 Pin Connector Wiring Figure 29 21 pin Deutsch Instrument Panel and Controls Frequenoy Oe Analog Lc Kay CE witoh Tafahi lE Po Analog F LIT STI fink Drv 2s Bink Drv 71 X Analog Freq c st fink Drv 2 Analag2dz2 FLITEU amp wltoh Ia D amp wlitoh Seto hac TIP Swltoh Swiluh A Fo Analog CSO nmakim Frequenay OIE 32 FET Anzingdb5 Pu7sa Analog Swilah a g F ED L16 Application batt Commanibik B Powerir d E c GAR High yen j CAN Shield yal E J133307nberface EN
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