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 2 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 -800-225-8669 or engineering@bellpower.com. They will work with you to develop a more complete understanding of the scope of this repower project.
PLEASE READ ALL INSTRUCTIONS THOROUGHLY BEFORE STARTING REPOWER INSTRUCTION PACKET TIER 3 ENGINE REPOWER KIT 6G FOUR-WHEEL DRIVE LOADER W/6076A WWW.BELLPOWER.COM
BELL POWER SYSTEMS INSTALLATION INSTRUCTIONS TIER 3 REPOWER 6G LOADER W/6076A New Engine Prep. Install the 33502 5 x /8 fitting in to the oil port located at the second port in front of the flywheel housing just below the starter. Transfer the oil pressure-sending unit from old engine into that fitting. 2. Install the new temp sensor, p/n RE52722, into the o-ring port in the thermostat housing next to the thermostat cover. 3. Install () AT32396 hose barb fitting into the top port of the thermostat housing.. Install the rear engine mounts with the isolator holes facing the front of the block, left mount, p/n BELL587L, and right mount, BELL587R, using () 9M7789 M2x30 flange bolts. 5. Install fan drive support, p/n BELL590, using (2) 9M7835 M0x35 flange bolts. NOTE: Do not tighten bolts at this time. 6. Install the fan drive at a 6.9 height from crankshaft centerline using (2) 9M7786 M0x30 flange bolts. Tighten bolts installed in step # 5 at this time. 7. A/C UNITS ONLY: Install the idler pulley in the location as shown in attached photo 6G-BW. 8. Install the fan, p/n AT26236, and fan spacer, p/n R572, using () M0x70 bolts, p/n 9M8598. 9. A/C UNITS ONLY: Install A/C mounting bracket, p/n R522653, with bushing, p/n 28H2659, with the following flange bolts, () R36508 M0x95, () 9M7785 M0x25, () 9M7897 M8x35 and () M7298 M8 nut. Install A/C compressor using () 9M793 M8x90 flange bolts. NOTE: If a compressor is required, use A/C compressor p/n AH69875 (order separately). 0. NOTE: Order fan belt separately Without A/C, install fan belt p/n T8208. With A/C install fan belt p/n R2666.. Install fitting p/n AR0650 in the fuel outlet port of the fuel pressure pump. 2. Re-index the turbo compressor snail so that the compressor outlet is at approximately the 5 o clock position. 3. Weld the Deutsch plug bracket, p/n BELL552, to the engine lifting bracket on the right rear on the cylinder head. Then mount the ECU harness plug into it. INST6G76
BELL POWER SYSTEMS INSTALLATION INSTRUCTIONS TIER 3 REPOWER 6G LOADER W/6076A. Install oil pan drain valve, p/n AT5280, into the drain port on the right side of the pan. 5. Install the front engine mounts p/n BELL588L on the left side and p/n BELL588R on the right, using the following flange bolts, (2) 9M7793 M6x0, (2) 9M782 M6x60 and () M729 M6 nuts. 6. Install heater fitting p/n RE520229 and p/n RE59579 in the M8 x.5 port on the water pump. 7. Install heater fitting p/n R2366 and valve p/n AT370 into the rear port of the water galley in the engine block. INST6G76 2
BELL POWER SYSTEMS INSTALLATION INSTRUCTIONS TIER 3 REPOWER 6G LOADER W/6076A Machine Prep and Engine Installation. Drain fluids, remove hood, unhook and remove original engine from machine. 2. Remove radiator, and housing. 3. Remove and discard the ether injection system if equipped. NOTE: New engine is equipped with glow plugs.. Remove the curtain cover around the lower front of the cab. 5. Drill a hole in the cab floor next to the main wiring harness bundle. 6. Open the dash panel and remove and discard the ether injection push button. Install the fuse holder p/n HKP with a 5 amp fuse p/n AGC5, in its place. 7. Drill a 2 ¼ hole in the dash left of the existing panel ¾ up from the bend and centered between the outer edge of the dash and panel. See drawing # 6G-D. 8. Remove the existing throttle pedal and cable and discard. Install the new throttle pedal p/n AT323306 and gasket p/n T72927 in its place. 9. Install the Power View p/n PV0A into the dash per drawing #6G-D. Connect the ground wire from the Power View to a good ground source behind the original dash panel. 0. Run the wiring harness p/n BELL606, under the cab and attach the three pin flat connector to the throttle pedal. Then run the other leg into the cab through the hole previous drilled in the cab in step 5, and hook to the 2 lead on the Power View panel.. Remove the eyelet from the ether button ignition wire and crimp a female spade terminal in its place, plugging it into the HKP fuse holder. Tape off and tuck the other button wire back behind the dash. Plug the wire in the new harness with the female spade terminal from the PV0A to the HKP. 2. Secure the new harness p/n BELL606. 3. Transfer engine wiring harness from original engine to new repower engine. NOTE: The original wire for the new temp sensor in the thermostat housing will need to be lengthened by approximately 2.. Transfer the drive damper from the old engine to the flywheel of the new repower engine reusing original bolts. INST6G76 3
BELL POWER SYSTEMS INSTALLATION INSTRUCTIONS TIER 3 REPOWER 6G LOADER W/6076A 5. Install (2) T073 dust covers to the flywheel housing to cover the damper using (2) 9M7783 M0x6 flange bolts. 6. Install the original driveshaft. Reuse mounting hardware. 7. Place the engine into the machine reusing the mounting bolts, washers and nuts in both the front and rear mounts. NOTE: Replace isolators if they are unacceptable for reuse. 8. Plug the 3 pin connector (from the 2 pin harness) into the 3 pin connector from the original fuel shut-off solenoid. Plug harness p/n BELL606 into Deutsch plug on engine bracket on the right rear of the cylinder head. 9. Drill () 7/6 holes in the radiator housing as shown in drawing # 6G-CAC to allow the installation of the Charge Air Cooler (CAC). 20. Re-install the radiator and housing, reusing original hardware. Install radiator cap p/n RE2070. 2. Run the ECU power and ground wires (wires with eyelets) along the fuel return hose across the front of the engine towards the turbo side of the engine using (2) ¾ body clamps. Attaching them with the 2 outside front oil pan bolts. Connect them to the proper post on the battery using terminals. 22. Connect the original fuel suction hose to the engine lift pump. Hook up the return hose to the fuel pressure pump at the 90 fitting. 23. Connect the lower radiator pipe, p/n BELL59 with () 888 2 90 hose and a 3 long piece of 2 ½ hose, p/n 639 using (2) HC832 clamps and (2) HC80 clamps. 2. Connect the upper radiator pipe, p/n BELL595, with () 722 2 ¼ x 2 ½ hose, and a long piece of 2 ½ hose, p/n 639, using () HC80 clamps. 25. Install 2 of H005 5/6 hose between the hose barb in the upper thermostat housing and the 5/6 barb in the upper radiator pipe p/n BELL595 using (2) HC8M clamps. 26. Connect the cab heater supply hose to the shut-off valve located on the side of the new engine block. Replace the hose if needed. 27. Connect the cab heater return hose to the fitting located on the water pump. NOTE: A longer heater hose may be required. Replace the hose if needed. 28. Install the CAC mounting brackets p/n T59780 and T5978 with () M89028 /2 spacers using () 9M7835 M0x35 bolts and () M7296 M0 nuts. NOTE: The spacer goes between the mounting bracket and the radiator housing. INST6G76
BELL POWER SYSTEMS INSTALLATION INSTRUCTIONS TIER 3 REPOWER 6G LOADER W/6076A 29. Install the CAC p/n AT7679 with () 9M8003 M0x0 bolts and () M7296 M0 nuts. See drawing # 6G-CAC. 30. Install the upper CAC pipe between the cooler and the engine intake, p/n BELL596 with () R693 hose (cooler end), and () H5203 2 ½ x 3 hose using (3) CT350L 3.5 clamps and () CT300L 3 clamp. 3. Install lower CAC pipe between the cooler and the turbo compressor snail, p/n BELL597 with () H5203hose, () R5655 hose, (2) R053 clamps, () CT350L 3.5 clamp and () CT300L 3 clamp. 32. Install new fan guards, p/n AT76907 and AT76908. 33. Install the new hood p/n BELL59. 3. Install the air cleaner on top of the hood and connect it with the inlet pipe p/n BELL598 using () 90L0 x 90 elbow with (2) HC872 clamps and () HC888 clamp. Replace filter elements if needed. Filter part numbers AR80653 inner and AR80652 outer (not supplied). 35. Install new muffler p/n AT6720 using the Bell 69 adapter and two clamps, 90873A and 90875A. 36. Reinstall the curtain around lower cab previously removed in step #. 37. Fill cooling system and pressure check for leaks. NOTE: Use only John Deere recommended antifreeze. 38. Check engine oil level and add as needed. NOTE: Use only John Deere break-in oil. 39. Check hydraulic oil level, add as needed. 0. Place () Bell 829 Sticker near other warning decals on the machine.. Machine should be ready to start and test run. INST6G76 5
BELL POWER SYSTEMS INSTALLATION INSTRUCTIONS TIER 3 REPOWER 6G LOADER W/6076A Photo INST6G76 6
http://jdpsconfigurator.deere.com/html/products/75295309/xie8209/60955290/rep... Page of 0/3/2008 Product: PE 6068HF85 Diesel Engine (268JF) Specification Name: 68HPP6G Specification Number: S290 Create Date: 2Apr2007 Build Number: 2 Customer Name: Code Description As Of Date 2Apr2007 Base PE 6068HF85 Diesel Engine (268JF) Rocker Arm Cover, No Fill, w/ J.D. Embossed Logo 20 Oil Filler, RH 32 Crankshaft Pulley, 88mm (7.7"), Standard Duty Damper 05 Flywheel Housing, SAE #3, LH, 3 Bolt Type Starter Mount 503 Flywheel for SAE #3,.5" OCC, 29 Tooth 8/0 Pitch Ring Gear 7BL Air Intake, Vertical Air Inlet 9AC Oil Pan, Sheet Metal, Shallow Sump, 5 Int Off-Level, 27.0L 236 Fan Housing, Cast Iron Bracket, Heavy Duty Bearing, compatible w/ 258mm (0.2") fan height 2EM 258mm (0.2) Fan Height @ 0.93: Fan Drive Ratio and 290mm (.") Fan Height @.02 Fan Drive Ratio 2699 No Engine Cylinder Block Heater 2873 EM, High Mount Turbo, Front Exhaust, w/ehaust Elbow Pad 297 Vent System, 90 Elbow w/o clamp, 00mm Vent Hose 3006 2V Denso, 6. HP, LH, 3-Bolt, Type Mount, Gear Reduction 338 2V, Small Frame, 65 Amp Bosch, w/wiring Harness 35DZ 6.0", 2 Micron Final Fuel Filter, RH Side Mount 36 Front Plate, Auxiliary Drive 002 Dipstick, RH Side Service 99 No Auxiliary Front Drive Pulley 327 Glowplugs, 2V 35 Timing Gear Cover, Aux-Drive, High Flow Iron Water Pump, Fan Mount 520 Gear Driven Auxiliary Drive w/shipping Cover 5399 No Fuel Heater 502 90 Degree Inlet Elbow, for use w/front Exhaust, w/sensor jumper harness 5580 Shipping Stand, Metal, without adapter, for shipment of two (2) engines 5603 Industrial Yellow 570 Water Pump Inlet, Forward Orientation 6099 No Auxiliary Fan Drive Pulley 627 Alternator Mounting, Bosch, 5-20 Amp, Auto Tensioner, for Aux-Drive 6360 RH, engine mounted primary filter, high RH rear engine mounted final filter - air compressor compatible 635 Exhanust Elbow, Front or Rear Exhaust Turbochargers 65MY 2V, High Mount, Front Exhaust, Industrial Low Power 677 Base Engine Sensors 6895 Single Damper, Standard Duty or Heavy Duty, Compatible w/single or Dual Auxiliary Belt Drive 72HW SOFT & EMIS LABEL,9KW@2200, 2V 799 No Air Conditioning Compressor or Air Conditioning Compressor 7899 No Air Compressor 869 R.H. Side, Engine Mounted, High R.H. Side, 6.0", 30 Micron Primary Fuel Filter w/water Separator and W.I.F Sensor 83CV ECU Software, John Deere Custom Performance - Low Power, 3kW (80hp) thru 9kW (200 hp) Industrial Applications (500 Hour Oil Change Interval) 826 Engine Mounted ECU, Rear of Head, w/wiring Harness Between Engine Sensors & ECU and hardware, Factory Installed 8630 203mm (8.0") Diameter, 258mm (0.2") Fan Height 878 Belt Tensioner, Auto for use w/aux-drive 883 Oil Filter, RH Low Rear 890 EGR System, Long Cooler, Sheet Metal Oil Pan
B 3 Parts List ITEM QTY PART NUMBER DESCRIPTION ADD'L PARTS NEEDED Bell 587L Left Rear Leg 2 Bell 587R Right Rear Leg 3 Bell 588L Left Front Leg Bell 588R Right Front Leg 5 Bell 590 Fan Drive Support 6 Bell 597 CAC Out Pipe x CT350L, x CT300L 7 Bell 596 CAC In Pipe 3 x CT350L, x CT300L 8 Bell 598 Intake Pipe x HC888, x HC872 9 Bell 59 Lower Coolant Pipe x 639, 2 x HC80 0 Bell 595 Upper Coolant Pipe x 722, x 639, x HC80 888 2" 90 Deg Elbow 2 x HC832 2 90L0 " 90 Deg. Elbow x HC872 3 R5655 Turbo Hose 2 x R053 R693 Hump Hose 3 in 5 2 H5203 2.5"-3" Hump Hose 6 R572 Fan Spacer 7 0C70HCSC M0 X 70 Bolts 8 2 9M7835 M0X35 Bolts 9 AT76907 /2 Fan Guard 20 AT76908 /2 Fan Guard 2 AT76779 CAC Cooler x 9M8003, x M7296 22 T5978 Upper CAC Bracket 2 x M89028, 2 x 9M7835, 2 x M7279 23 T59780 Lower CAC Bracket 2 x M89028, 2 x 9M7835, 2 x M7279 2 AT26236 Fan 25 Bell 552 Harness Mounting Bracket 26 2 9M7786 M0X30 Bolts 27 9M7789 M2X30 Bolts 28 9M782 M6X60 29 M729 M6 Nut 8 5 26 20 9 7 2 2 22 9 0 2 7 5 28 29 3 38 5 0 23 8 6 23 25 3 27 B A 30 33502 5 X/8" Street Elbow 3 AT32396 Hose Barb Fitting 2 x HC8M, 2 x H005 32 R2366 Heater Adaptor 33 AT370 Heater Valve 3 RE520229 Heater Fitting 35 RE5008 Temp Sensor 36 AR0650 Fuel Pump fitting 37 AT5280 Oil Drain Valve 38 9M7793 M6X0 Bolts 39 Bell 606 Engine Harness 0 AT6720 Muffler x Bell69, x 90873A, x 90875A 3 3/8/2007 MATERIAL/FINISH ADD'L COMMENTS 2 BELL POWER SYSTEMS INC. 36 PLAINS ROAD ESSEX, CT 0626 DRAWING SCALE 6G-PL SHEET OF A
3 2 B 2.500 9.500 2 6 2.500 ITEM 2 3 5 6 7 8 QTY 8 Parts List PART NUMBER AT66537 M89028 T5978 T59780 AT76779 9M7835 9M8003 M7296 DESCRIPTION Rear Housing Spacer Upper Bracket Side Bracket CAC Hex Bolt Hex Bolt Hex Nut B 8.25 3 8 7 5 A MATERIAL/FINISH 2/9/2007 A ADD'L COMMENTS BELL POWER SYSTEMS INC. 36 PLAINS ROAD ESSEX, CT 0626 DRAWING 6G-CAC 3 2 SCALE SHEET OF
BELL POWER SYSTEMS BILL OF MATERIALS Pedal/ CAN Harness REVISED: 0-2-06 D.R. DEERE POWER