READ COMPLETELY BEFORE QUOTING REPOWER

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Walter Cox
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1 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 when installing a newer Tier or Tier 3 model engine. Please be aware that the equipment options on your candidate machine many differ from the options on the machine this kit was developed on. Examples might include but are not limited to, the presence of air conditioning, serial number breaks, adaptation components, additional components and /or alternate components. Due to these circumstances and with respect to the best way and/or individual interpretations to execute a repower, Bell Power Systems will not be responsible for any additional installation cost incurred. Before quoting, review the repower instructions, components supplied and engine option codes to get a full understanding what is required to perform this repower. If you identify any areas of concern or have any question please contact Bell Power Systems engineering department at or engineering@bellpower.com. They will work with you to develop a more complete understanding of the scope of this repower project.

2 PLEASE READ ALL INSTRUCTIONS THOROUGHLY BEFORE STARTING REPOWER INSTRUCTION PACKET TIER 3 ENGINE REPOWER KIT 330LC EXCAVATOR

3 Machine Preparation. Discard the original CAC hoses and clamps.. Discard the lower coolant hose that connects the steel adaptor to the water pump inlet and the upper radiator hose. 3. Remove the original primary fuel filter and reroute the fuel feed and return lines to come up in front of the engine mounts. Discard the old filter. 4. Remove and discard the muffler to turbo exhaust pipe. 5. Drill a 9/6 hole into the cab (boom side) behind the operator 7 from the rear and up from the air plenum. Feed BELL76 wire harness through the hole and run it down the hydraulic lines toward the engine. 6. Remove the () bolts from the lower window guard. Mount the BELL60 bracket with () 9M86 M8 x 30 bolts, () BELL640 4 ¼ upper spacer and () BELL64 4 ½ lower spacer. Mount the PV0A. See photo PV0 Mounting 7. Plug the PVJR resistor into the PV0A B socket. Connect the BELL76 harness into the A socket. Secure the harness as necessary. 8. Connect the other end of the BELL76 harness to the -pin connector and the 3-pin Packard connector per schematic. 9. Place () Bell 89 Sticker near other warning decals on the machine. INST330LC

4 Engine Preparation. Re-use the original flywheel and drive coupling. Replace bolts based on what is needed for the engine. Torque to factory specifications.. Re-use the original engine mounts using (8) 9M786 M6 x 70 flange bolts for the front and (8) 9M7793 M6 x 40 flange bolts for the rear. 3. Re-use the original alternator, fan belt and idler pulley. 4. Re-use the original fan drive, fan spacer, and bolts. 5. Install bracket, FF00949 to the forward end of the engine with (3) 9M7865 M8 x 6 bolts. See Photo Install () DH8008 hose adaptor to bracket FF00949 with (4) 9M7868 M8 x 30 bolts. Place (4) 8H86 spacers between the adaptor and bracket. 7. Install () DH30074 hose to the turbo and DH8008 adaptor. 8. Connect the ECU harness to the ECU and secure it to the engine in a manner that allows access to the diagnostic connector. See Photo Join connectors C07 and C0 together. 0. Install A/C compressor from old engine (if equipped).. Transfer cab heater fittings. The return line should be rerouted and connected to the water pump inlet.. Transfer the original oil sending unit and temperature sender. The temp sender goes into the port on the inlet side of the water pump. Lengthen the wire as necessary. 3. Remove oil pan and pickup. Replace with () RE53867 pick up tube, () RE53896 oil pan, and () AT580 oil drain valve. Refill oil pan. 4. Install the engine using old hardware if possible. 5. Use the following bolts to secure the old muffler bracket and old hydraulic pump assembly to the engine: (3) 9M7835 M0 x 35 flange bolts INST330LC

5 (5) 9M7786 M0 x 30 flange bolts 6. Connect the turbo to the muffler with the BELL794 pipe, () 8956K band clamp and () RE40048 clamp. 7. Connect the turbo outlet to the Charge Air Cooler (CAC) using the BELL79 pipe, () R hump hose, () T deg. hose and (4) CT350L 3.5 constant torque clamps. 8. Connect the engine air inlet to the CAC using the BELL793 pipe, () TP deg. silicon hoses and (4) CT constant torque clamps. Note: The longer leg of the pipe connects to the CAC elbow. 9. Take the 858 / 90 deg. radiator hose and cut () leg down to 5 overall length. This end will be connected to the water pump inlet. 0. Place the deg. hose and the deg. hose over their respective ends of the BELL75 pipe and connect them to the water pump inlet and lower coolant tube with () HC844, () HC 836 and () HC840 clamps.. Install the AT9654 upper coolant hose with () HC83 #3 clamp and () HC840 #40 clamp.. Connect the air filter hose to DH8008 intake adaptor pipe with the BELL74 elbow (long leg toward the air filter) with () 5H5 5 hump hose with 50R45 5 to 4.5 reducer, 55R to 5 reducer, () HC888 and () HC896 clamps. 3. Install T360 ¾ NPT-5/6 hose barb fitting into thermostat housing. 4. Bolt R50555 bracket to the DH8008 intake hose adaptor with () 9M7866 M8 x 0 bolt. 5. Take (3 ) of H005 hose and run it from the barb fitting at thermostat housing to the radiator expansion tank. Secure the ends with () HC86M clamps. Clamp the center portion of the hose to the R50555 bracket with () ½ to 3/8 body clamp, () 9M7866 M8 x 0 bolt and () 4M798 M8 nut. 6. Locate the throttle actuator. Remove the throttle cable and discard it. 7. Remove the () outer bolts from the machine throttle actuator support bracket and mount the Bell 73A throttle actuator bracket. See photo Throttle Linkage and Potentiometer. INST330LC 3

6 8. Bolt the throttle actuator to the bracket with () ¼ -8 x 5/8 bolts and locks. The label and adjustment screws should face outboard. 9. Mount the BELL73B throttle lever to the machine throttle actuator lever with () ¼ -0 x ¾ flange bolts and nuts. 30. Mount one end of the BELL73 throttle linkage to the BELL73B lever. Let the ball joint mounting stud rest on the bottom of the lever slot with the nut finger tight. 3. Rotate the shaft on the actuator clockwise until it stops. Connect the other end of the throttle linkage to the 384 lever and slide the lever over the actuator shaft. Tighten the ball joints and actuator lever. See photo Throttle Linkage and Potentiometer. 3. Fill cooling system and pressure check for leaks. NOTE: Use only John Deere recommended antifreeze. 33. Check engine oil level and add as needed. NOTE: Use only John Deere break-in oil. 34. Check hydraulic oil level, add as needed. 35. Machine should be ready to start and test run. 36. After machine is running, check the throttle functions and adjust linkage as necessary. 000 RPM idle, RPM fast idle. INST330LC 4

7 Photo Photo 00-0 INST330LC 5

8 Throttle Linkage and Potentiometer INST330LC 6

9 Battery Cable Mounting PV0 Mounting *Miscellaneous pictures provided for visual reference. INST330LC 7

10 Product: RG 6090HF485 Diesel Engine (3045F) Specification Name: 90H485330LC Specification Number: S04309 Create Date: 8Dec008 Build Number: Customer Name: Code Description As Of Date 05Jan009 Base RG 6090HF485 Diesel Engine (3045F) 0 Rocker Arm Cover, Rear Fill, w/o J.D. Name Plate 30 Crankshaft Damper, Dual Damper, Adjustable Fan Drive, Two /" V-Belt Grooves 405 Flywheel Housing, SAE #, Gray Iron, w/ Provision for Electronic Tach Drive 599 No Flywheel Housing 603 Fuel System, Denso High Pressure Common Rail, Industrial Low Power, 05kW and below 95 Oil Pan, Aluminum, Deep Center Sump (Bottom, LH, RH and Rear Drains), Off-Level Capability: 30 Degree Cont, 45 Degree Int, includes Oil Drain Valve and Compatible w/ LH Pan Mount Dipstick 06 Thermostat Cover, Dual, RH Horizontal Outlet (convertible to LH Horizontal) 3AL Fan Drive (:), Adjustable, Set at.5", HD, 6-Bolt, 8-Ribbed Poly-Vee & One 8.5" P.D. /" V-Belt Groove 48 Fan Belt,.5" Adjustable (:), for Small Frame Alternator Mounting, No Alternator, No Air Conditioning, BLIND FOR ROADTEC 699 No Engine Cylinder Block Heater 80 Exhaust Manifold, High Mount, Rear Exhaust 90 Vent System, Vent Hose Length 43" (09mm) V Denso, 0.5HP, LH 3-Bolt Type Mount, Gear Reduction, Sealed for Wet Clutch 399 No Alternator 35 4V, RH Side, Engine Mounted, Primary Filter,0 Micron, w/ Water Separator & Secondary Filter, Micron, Water-In-Fuel Sensor, Low Pressure Fuel Sensor, Electric Fuel Transfer Pump 390 Thermostat Housing, Adjustable Fan Drive 400 Dipstick, RH Side, Top Service, 45 Degree Oil Pan, use w/ Top Load Oil Filter 4397 Air Intake, Standard, w/o Air Intake Heater (provides Ether Starting Aid capability) 599 No Gear-Driven Aux Drive Capability (Straight Engine Oil Cooler Tubes) 540 Air Intake Hose, 4" to 5", 90 Degree, Rear Exhaust 553 Engine Wood Transport Pallet 5604 Industrial Yellow (Finish Coat) 590 Oil Filter, Top Load, Rear Exhaust, Engine Mounted, Non-Aux Drive 604 Alternator Mounting, Fan Drive w/ Tensioner, Adjustable Position Fan, Small Frame Alternator, Bosch or Denso 6499 No Exhaust Elbow 653 4V, High Mount, Rear Exhaust, Low Power Industrial (68kW/5hp thru 05kW/75hp), for use w/ Aux Drive Options 736 4V, 50 Hp ( RPM, 0% PB, 35% TR 7499 No AC Compressor or Mounting Bracket 770 Timing Gear Cover, Non Aux-Drive Capable 7899 No Air Compressor (For use w/ other than 50 LH Aux Drive Base Unit) 830 ECU Software, John Deere Custom Performance - Low Power, 68kW (5hp) thru 05kW (75 hp) Industrial Applications (Maximum 500 Hour Oil Change Interval) 840 Engine Mounted ECU, w/wiring Harness Between Engine Sensors & ECU and Attaching Hardware, Factory Installed 96 Customer/Panel Interface Harness, Engine Mounted ECU to Instrument Panel, packaged & shipped w/engine (contains the & 3 pin connectors, starter relay leads, power/ground leads, TVP, Aux Power, CAN Terminator, Remote On/Off and Fuse 9305 Emission Label, Tier 3 Industrial Application (5hp/68kW to 75hp/05kW) 9499 No Software 3:7:09 PM]

11 B A ITEM QTY 8 4 Parts List PART NUMBER CT350L R6493 BELL7 T6983 HC83 AT9654 HC840 DH30074 HC K BELL73 RE40048 DH R45 HC896 5H5 Bell 74 HC840 BELL75 HC HC TY TY47 AT RE53896 FF00949 T360 TP78000 BELL7 3 DESCRIPTION 3.5" Constant Torque Clamp 3" CAC Hose Upper CAC Pipe 90 deg. Hose #3 Hose Clamp Upper Coolant Hose #40 Hose Clamp 90 deg. Hose #88 Clamp Band Clamp Exhaust Pipe Flange Clamp Hose Adaptor 5"-4.5" Reducer #96 Clamp 5" Hump Hose Intake Pipe #40 Hose Clamp Lower Coolant Pipe (pump side) #36 Hose Clamp 90 deg. Hose #44 Hose Clamp Coolant Pipe Hose Clamp Lower Radiator Hose Hose Clamp Oil Drain Valve 90 deg. Hose Oil Pan Bracket ¾ NPT-5/6 Hose Barb Fitting 90 deg. Silicon Hose Lower CAC Pipe MATERIAL /7/009 REVISION;DATE;DESCRIPTION FINISH BELL POWER SYSTEMS INC. 34 PLAINS ROAD ESSEX, CT B A DRAWING JD330LC Parts List 4 3 SCALE P/N SHEET OF

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