544G Repower Work Instructions 6068HF285-544G
Contents
1. 29 nen ust tabla eus roca cusd aste tei uUs 30 1 Parts Table 1 Parts List CATEGORY PART QTY DESCRIPTION KIT 6068HF285 544G CAC 51 200 300 300 2 2 2 HUMP COUPLER 1 2 3 CLAMP _ o O OSATO y y O Po 59789 7169780 O RADIATOR 1173771 RADIATOR HOSE GREEN STRIPE 18P 200 CAC D amp A 45 DEGREE BEND AR40418 TY 22472 EXHAUST PM86144M MUFFLER 9 15881 EXHAUST CLAMP 2208386 EXHAUST EXTENSION AND RAIN CUT EUM 4 X3 TUBING 4 X 3 SLEEVE 1 75 RADIATOR HOSE CLAMP 2 RADIATOR HOSE CLAMP FAN AT211347 26 BLOWER FAN CC 19M7898 FAN BOLTS R524736 3 937 FAN SPACER RE534022B 141332120 0 o O oOo o oo 7832121 1 HARNESS SERVICE JUMPER aras2122 1 PLATE ACCEL SERVICE REPOWER BRACKET 1 REMOTE MOUNTING BRACKET AIR CLEANER AIR CLEANER KIT AIR CLEANER AT225535B RE67747 HOSE CLAMP 135501 10825 H88782 FILTER AIR CLEANER ELBOW HOSE R517439 WRP624HA02 R123468 AIR FLOW TUBE ACCELERATOR PEDAL MOUNTING PLATE V BELT 65 157 8 GROOVE 19M7944 R500509 M10X120 FLANGED BOLT BRACKET SUPPORT LH BOLT Due to differences in configurations you may need to supply miscellaneous mounting hardware 2 I Removing Old Engine Remove old engine according to the 544G Service Manual Remove d2. 168mm 6 61 Diameter 338mm 13 3 Fan Height 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 140hp 104kW Appendix Electronics No Gauge EEE 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 N N N 8 12 8 O O 12 1 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 Acc y or Ignition terminal of the ignition switch Tachometer output A synthesized freguency 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 state or Ramp Resum
3. Minimum Throttle Offset 0 increase Maximum Throttle Offset 270 rpm decrease Throttle Rate Standard Maximum Ramp Rate 3 sec Exponentia Ramp Step 1 6 _ Envelope Calculation Figure 20 Trim Features John Deere Custom Performance Trim Features Enable the Digital 3 state throttle and set the Maximum Throttle to 2200rpm Throttle Switch Low Position Tape or zip tie the Throttle switch to the off position The adjustable 3 state throttle must be set in the Low Speed position for the foot throttle to work with the 3 sate throttle Bump Enable Switch Off Position Tape or zip tie the Bump Enable switch to the off position The Bump Enable switch serves as a lock for the Bump switch to make sure the operating speed 15 not changed accidentally or as a result of a Bump circuit failure 6 3 Key Switch KEY SWITCH ACC Start 21 PIN CONNECTOR 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 O fuse and diagnostic gage 14 AWG Figure 21 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 engine configuration requires modifications to the hood to accept the new air cleaner new CAC and exhaust The Tier III 6068HF285 2 valve engine only c
4. nt A L EET T TT EN ru a A rum F Werte mu Ex r5 at sal uk EL yat Eri A uk Talk ernakr x i Ei t lt Ent E Lr rte Lm batt Tni iarter Interface AlroFier HF Restriction a Switch pu p A e 2 Secondary ignition or Analog c Throttle Ny my a Comman ce 4 ir p ru ee ul al Remote amp ulce Cruicexraka lanitian Er a a zm n H gu E L J F JL Ti 1 Shutdown Multi State Throttle ix ais e sje u v e e u n z e Figure 31 Wiring Harness
5. Connect harness to the 21 pin connector through the 1 12 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 mechanical system with the throttle potentiometer Remove old pedal and cable Install new pedal with provided WRP624HA02 bracket e Route throttle sensor wires through floor of cab and to 21 pin instrumentation and controls connector on the wiring harness See AGII P 11 for additional details on the foot throttle Electrical Hook up To attach the primary analog throttle to the JOEC 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 C is the ground The corresponding connection in the throttle connector is as follows TC 5 VOLTS C u E SIGNAL GAND pu Figure 17 AG 11 Analog Foot Throttle Wiring V U N Figure 18 Potentiometer Mounting On Accelerator Pedal Figure 19 Underside of Accelerator with Potentiometer 6 2 3 State Throttle Must Install For Maximum Throttle Feature Digital Lhrottle Enable Digital Throttle 2 State Throttle 3 State Throttle Ramp Throttle Throttle Adjustments Throttle Out of Range Recovery Idle Recovery
6. engine air inlet 1142 1204 1324 1406 1503 1684 1783 1908 2156 2201 2342 2496 2699 28AV 2957 3006 3138 35ED 3614 3999 4002 4199 4399 4447 5204 5399 5569 5603 5722 5902 6099 6288 6387 6438 65RN 6730 6901 Appendix A 6068HF285 Engine Specification Table 2 Engine Option Codes PE 6068HF285 Diesel Engine 2684F Rocker Arm Cover Rear Fill w John Deere Nameplate Oil Filler LH w Spacer 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 800cc Flow Injector Industrial 104kW 140hp Air Intake Vertical Intake Oil Pan Aluminum Center Sump w Heater Ports 35 Off Level 19L Thermostat Cover Vertical Outlet Single Thermostat Two Sensor Ports Thermostat Single Fan Housing Nodular Iron Heavy Duty Bearing Fan Height Less Than 402mm 15 8 Max 12kg Fan No Fan Belt w Idler Pulley pulley required for all A C and Fan Heights 290mm 11 4 amp Below 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 12V Denso 6 0 HP 4 5 kW LH 3 Bolt Type 1 Mount Gear Reduction 12V 75 Amp I
7. threaded holes on the wall that separates the other power control module that it already installed see Figure 10 ECU Mounting Bracket Figure 11 Harness Routing Through Compartment Figure 12 Underside of ECU Compartment 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 vw Figure 13 Modified Instrument Panel with Power View Remove the wiring harness switches and Power View from the instrument panel key switch see Figure 14 Using 1 2 inch hole saw cut a hole next to the floorboard and 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 gt A L Figure 15 Power View Mounting Plate Front Side 1 y 4 Yt gt Figure 16 Wiring Harness Routing Under Cab
8. 5446 Repower Work Instructions 6068HF285 544G Revision B 27 July 2010 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 0 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 unit 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 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 SMAG Repo
9. e 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 t 98 brown violet 914 yellow 914 yellow Co D o o D rt c 3 Q S jad lt BEE w R Figure 29 21 pin Deutsch Instrument Panel Connector emn SSS Low u CAN Complete 21 Pin Connector Wiring Figure 30 21 pin Deutsch Instrument Panel and Controls Fraquenoy J Analog Li Fay CE witoh tafnh 2 li Po Analog FUT So fink Drv 2s Bink Drv 71 X 2 fink Drv 2 Analag2dz2 52 amp wltoh Ia D amp wlitoh Seto hac TF Swltoh Swiluh A FO Analog CSO Anabgz FO Frequenay ZZ Exotatlan OIE 452 F20 PUTS Z Fregn n s oo Analog Swilah a ED L16 Application att Commanibik Fcier redi E CAN High yen x ge CAN je Shield yal E J133307nberface EN D Eris eral s GREEN T J Paia esa Ta
10. ent 12 122 Underside or ECU Compartient u 12 Figure 13 Modified Instrument Panel with 13 Figure 14 RE534022B Instrument Panel Harness 14 Figure 15 Power View Mounting Plate Front 1 14 Figure 16 Wirme Harness Routine Under Cab sun a u 15 Figure 17 AG 11 Analog Foot Throttle Wiring aaa 16 Figure 18 Potentiometer Mounting On Accelerator Pedal 17 Figure 19 Underside of Accelerator with 17 Ue 20 Tem Features e Saati atta ea hende ou tbe 18 etes tud 19 Figure 20 New Exhaust Stack CAC and Cleaner 20 P re M untine I OCaLb lOfi pisces o ae a bes 21 Figure 22 CAC Mountme to Lett 810 amp 07 HOO ui das a k 22 Figure 23 CAC Mounting to Top Right Side of Hood esee 25 Figure 24 Air Cleaner Mounting To Underside of Hood a 24 Fievuf 25H0L CAC Tube an 25 Fisure 20 old CAC Tube Moni less 26 Figure 27 21 pin Deutsch Instrument Panel 29 Figure 30 21 pin Deutsch Instrument Panel and
11. omes in front exhaust configuration so the change from a rear exhaust engine to front exhaust necessitates the relocation of the air cleaner The following figures point out the purpose of each modification to the hood e Mount the Exhaust Stack as shown in Figure 23 Muffler Mounting Location e Mount the CAC to the underside of the hood e Mount Air Cleaner in old Exhaust Stack Location 7 1 Figure 23 Muffler Mounting Location 7 2 Mounting Mounting to Left Side of Hood Figure 24 Figure 25 Mounting to Right Side of Hood Use tubes to align CAC Mark where to drill hood and left side to CAC supports Drill holes for CAC supports Mount CAC 7 3 Air Cleaner Mounting Mount Hood to 544G e The Air Cleaner will be installed in the location of the previous engine s exhaust stack e Install turbo inlet hose and use hose to adjust the forward aft position of the air cleaner in the saddle brackets Figure 26 Cleaner Mounting Underside of Hood Align air inlet to go through the existing hole in the hood e Mark the hood where to drill to mount the saddle brackets e Bolt the air cleaner to underside of the hood 8 Tube Mounting Figure 27 Tube Mounting Install hot CAC tube from turbo to lt Figure 28 Cold Tube Mounting Install cold tube from CAC to the
12. rive adapter from old engine Remove motor mounts from old engine Service Radiator Check radiator and service if necessary Installing New Engine Install drive adapter on new engine Modify Front Right Motor Mount Install motor mounts Install new engine per service repair manual Reinstall hydraulic pump R 1 9 gt Figure 1 Installed Drive Adapter New Engine i Wie Figure 2 Reason for Modifying Front Right Motor Mount Figure 3 Motor Mount Modification Figure 4 Motor Mount Modification Figure 5 Front Right Motor Mount Installed New Engine Figure 6 New Engine Installation Re install radiator if t needed to be removed for service Connect radiator hoses fuel lines 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 7 Wiring Harness Routing Figure 8 Rear Left Wiring Harness Routing Run excess wiring underneath the right side of cab right side of the cab undo 2 screws holding access panel closed d hi Figure 9 ECU Mounting Location Figure 10 ECU Mounting Bracket In the access panel you will find 2 power control modules and wiring Mount the engine control module to the pre
13. skra 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 for Low 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 Low 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 129kW 173hp and below RH Low Rear Oil Filter Base Engine Sensors Serial Number Plate 72MM 12V 140Hp 104kW 2400 0 PB 30 TR 7499 7899 8171 83EJ 8454 8608 8718 8843 9109 9113 93GR 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 104kW 140HP 500 Hour Change Interval Remote Mounted ECU 12V w wiring harness and hardware installed ECU shipped loose Distributor OEM Installed w 10 foot of harness less than 402mm fan height
14. wer Work Mouchos 1 g 1 Bess os res 5 2 6 O CICS IACI QUO Re vina an g As Em 6 4 NEW Enfii jsseoo ads daina 6 gt Marie and Wire Hamne S 9 6 Modil yns a 13 6 2 State Throttle Must Install For Maximum Throttle 18 Od einer EOD 19 7 Hood MOGHICAUONS eu v ze sada es 20 S VAS ODONIS ass ss a 21 Uu ERNIS eos sv sv ma gads 22 Mo Air Cleaner WO UMN nennen 23 CAC Mouniine Auer us d uat Lot do tal oo tes a 25 Appendix A 6068HF285 Engine Specification eene nnn 27 ApDendbb BIeCHOBIeS ae tM E 20 Figures and Tables Figure 1 Installed Drive Adapter on New Engine 7 Figure 2 Reason for Modifying Front Right Motor Mount essere 7 Fiere Motor Mount Modification did ei an l didi eu 8 Ficure 4 Motor Mount MOdI1 16410 susci neta v ca iur 8 Figure 5 Front Right Motor Mount Installed on New Engine essere 9 Fieur 6 New Engine Installation sauer 9 Procure 7 Warme Harness Routine anne p da EE E 10 Figure 8 Rear Left Wiring Harn ss ROUU IS ale 10 ECU Mou tine anne sig ds E 11 Kisure 10 BC U Brac Ket u ae NNO 11 Figure 11 Harness Routing Through ECU Compartm
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