330lc work instructions

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 1 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 1-800-225-8669 or [email protected]. 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

WWW.BELLPOWER.COM

INSTRUCTION PACKET

TIER 3 ENGINE REPOWER KIT

330LC EXCAVATOR

BELL POWER SYSTEMS INSTALLATION INSTRUCTIONS TIER 3 REPOWER 330LC EXCAVATOR

INST330LC 1

Machine Preparation

1. Discard the original CAC hoses and clamps.

2. 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 9/16” hole into the cab (boom side) behind the operator 7” from the rear and 2” up

from the air plenum. Feed BELL726 wire harness through the hole and run it down the hydraulic lines toward the engine.

6. Remove the (2) bolts from the lower window guard. Mount the BELL620 bracket with (2)

19M8262 M8 x 130 bolts, (1) BELL640 4 ¼” upper spacer and (1) BELL641 4 ½” lower spacer. Mount the PV101A. See photo “PV101 Mounting”

7. Plug the PVJR resistor into the PV101A “B” socket. Connect the BELL726 harness into

the “A” socket. Secure the harness as necessary.

8. Connect the other end of the BELL726 harness to the 21-pin connector and the 3-pin Packard connector per schematic.

9. Place (1) Bell 829 Sticker near other warning decals on the machine.


INST330LC 2

Engine Preparation

1. Re-use the original flywheel and drive coupling. Replace bolts based on what is needed for the engine. Torque to factory specifications.

2. Re-use the original engine mounts using (8) 19M7826 M16 x 70 flange bolts for the front

and (8) 19M7793 M16 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, FF100949 to the forward end of the engine with (3) 19M7865 M8 x 16 bolts. See “Photo 100-1002”.

6. Install (1) DH800228 hose adaptor to bracket FF100949 with (4) 19M7868 M8 x 30 bolts.

Place (4) 28H86 spacers between the adaptor and bracket.

7. Install (1) DH300174 hose to the turbo and DH800228 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 100-1101”.

9. Join connectors C07 and C02 together.

10. Install A/C compressor from old engine (if equipped).

11. Transfer cab heater fittings. The return line should be rerouted and connected to the

water pump inlet.

12. 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.

13. Remove oil pan and pickup. Replace with (1) RE523867 pick up tube, (1) RE523896 oil

pan, and (1) AT152180 oil drain valve. Refill oil pan.

14. Install the engine using old hardware if possible.

15. Use the following bolts to secure the old muffler bracket and old hydraulic pump assembly to the engine:

(3) 19M7835 M10 x 35 flange bolts


INST330LC 3

(5) 19M7786 M10 x 30 flange bolts

16. Connect the turbo to the muffler with the BELL794 pipe, (1) 89526K band clamp and (1) RE40048 clamp.

17. Connect the turbo outlet to the Charge Air Cooler (CAC) using the BELL792 pipe, (1)

R164193 3” hump hose, (1) T161983 90 deg. hose and (4) CT350L 3.5” constant torque clamps.

18. Connect the engine air inlet to the CAC using the BELL793 pipe, (2) TP1728000 90 deg.

silicon hoses and (4) CT350 3.5” constant torque clamps. Note: The longer leg of the pipe connects to the CAC elbow.

19. Take the 8581 2 1/2” 90 deg. radiator hose and cut (1) leg down to 5” overall length. This

end will be connected to the water pump inlet.

20. Place the 4400256 90 deg. hose and the 8581 90 deg. hose over their respective ends of the BELL725 pipe and connect them to the water pump inlet and lower coolant tube with (1) HC844, (1) HC 836 and (2) HC840 clamps.

21. Install the AT219654 upper coolant hose with (1) HC832 #32 clamp and (1) HC840 #40

clamp.

22. Connect the air filter hose to DH800228 intake adaptor pipe with the BELL724 elbow (long leg toward the air filter) with (1) 5H5 5” hump hose with 50R45 5” to 4.5” reducer, 55R50 5.5” to 5” reducer, (2) HC888 and (1) HC896 clamps.

23. Install T222360 ¾” NPT-5/16” hose barb fitting into thermostat housing.

24. Bolt R505515 bracket to the DH800228 intake hose adaptor with (1) 19M7866 M8 x 20

bolt.

25. Take (3’) of H10105 hose and run it from the barb fitting at thermostat housing to the radiator expansion tank. Secure the ends with (2) HC86M clamps. Clamp the center portion of the hose to the R505515 bracket with (1) ½” to 3/8” body clamp, (1) 19M7866 M8 x 20 bolt and (1) 14M7298 M8 nut.

26. Locate the throttle actuator. Remove the throttle cable and discard it.

27. Remove the (2) outer bolts from the machine throttle actuator support bracket and mount

the Bell 731A throttle actuator bracket. See photo “Throttle Linkage and Potentiometer”.


INST330LC 4

28. Bolt the throttle actuator 311789-002 to the bracket with (2) ¼”-28 x 5/8” bolts and locks. The label and adjustment screws should face outboard.

29. Mount the BELL731B throttle lever to the machine throttle actuator lever with (2) ¼”-20 x

¾” flange bolts and nuts.

30. Mount one end of the BELL732 throttle linkage to the BELL731B lever. Let the ball joint mounting stud rest on the bottom of the lever slot with the nut finger tight.

31. Rotate the shaft on the 311789-02 actuator clockwise until it stops. Connect the other

end of the throttle linkage to the 311814 lever and slide the lever over the actuator shaft. Tighten the ball joints and actuator lever. See photo “Throttle Linkage and Potentiometer”.

32. 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. 1000 RPM idle, 2000-2100 RPM fast idle.


INST330LC 5

Photo 100-1002

Photo 100-1101


INST330LC 6

Throttle Linkage and Potentiometer


INST330LC 7

Battery Cable Mounting

PV101 Mounting *Miscellaneous pictures provided for visual reference.

http://jdpsconfigurator.deere.com/HTML/products/840335309/XIE8209/987358212914/REPORTS/S014309_config_results.html[1/25/2010 3:27:09 PM]

Product: RG 6090HF485 Diesel Engine (3045F) Specification Name: 90H485330LC Specification Number: S014309Create Date: 18Dec2008 Build Number: 1 Customer Name:

Code DescriptionAs OfDate

05Jan2009

Base RG 6090HF485 Diesel Engine (3045F)

1101 Rocker Arm Cover, Rear Fill, w/o J.D. Name Plate

1302 Crankshaft Damper, Dual Damper, Adjustable Fan Drive, Two 1/2" V-Belt Grooves

1405 Flywheel Housing, SAE #2, Gray Iron, w/ Provision for Electronic Tach Drive

1599 No Flywheel Housing

1603 Fuel System, Denso High Pressure Common Rail, Industrial Low Power, 205kW and below

1915 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 andCompatible w/ LH Pan Mount Dipstick

2106 Thermostat Cover, Dual, RH Horizontal Outlet (convertible to LH Horizontal)

23AL Fan Drive (1:1), Adjustable, Set at 12.5", HD, 6-Bolt, 8-Ribbed Poly-Vee & One 8.25" P.D. 1/2" V-Belt Groove

2428 Fan Belt, 12.5" Adjustable (1:1), for Small Frame Alternator Mounting, No Alternator, No Air Conditioning, BLIND FOR ROADTEC

2699 No Engine Cylinder Block Heater

2802 Exhaust Manifold, High Mount, Rear Exhaust

2901 Vent System , Vent Hose Length 43" (1091mm)

3005 24V Denso, 10.5HP, LH 3-Bolt Type 1 Mount, Gear Reduction, Sealed for Wet Clutch

3199 No Alternator

3511 24V, RH Side, Engine Mounted, Primary Filter,10 Micron, w/ Water Separator & Secondary Filter, 2 Micron, Water-In-Fuel Sensor, Low Pressure Fuel Sensor,Electric Fuel Transfer Pump

3902 Thermostat Housing, Adjustable Fan Drive

4020 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)

5299 No Gear-Driven Aux Drive Capability (Straight Engine Oil Cooler Tubes)

5402 Air Intake Hose, 4" to 5", 90 Degree, Rear Exhaust

5513 Engine Wood Transport Pallet

5604 Industrial Yellow (Finish Coat)

5901 Oil Filter, Top Load, Rear Exhaust, Engine Mounted, Non-Aux Drive

6204 Alternator Mounting, Fan Drive w/ Tensioner, Adjustable Position Fan, Small Frame Alternator, Bosch or Denso

6499 No Exhaust Elbow

6523 24V, High Mount, Rear Exhaust, Low Power Industrial (168kW/225hp thru 205kW/275hp), for use w/ Aux Drive Options

7236 24V, 250 Hp (187 kW) @ 2000 RPM, 10% PB, 35% TR

7499 No AC Compressor or Mounting Bracket

7701 Timing Gear Cover, Non Aux-Drive Capable

7899 No Air Compressor (For use w/ other than 5201 LH Aux Drive Base Unit)

8301 ECU Software, John Deere Custom Performance - Low Power, 168kW (225hp) thru 205kW (275 hp) Industrial Applications (Maximum 500 Hour Oil ChangeInterval)

8401 Engine Mounted ECU, w/Wiring Harness Between Engine Sensors & ECU and Attaching Hardware, Factory Installed

9216 Customer/Panel Interface Harness, Engine Mounted ECU to Instrument Panel, packaged & shipped w/engine (contains the 21 & 23 pin connectors, starter relayleads, power/ground leads, TVP, Aux Power, CAN Terminator, Remote On/Off and Fuse

9305 Emission Label, Tier 3 Industrial Application (225hp/168kW to 275hp/205kW)

9499 No Software

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DRAWING

SCALESHEET OF

MATERIAL

REVISION;DATE;DESCRIPTION BELL POWER SYSTEMS INC.34 PLAINS ROADESSEX, CT 06426

JD330LC Parts List

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4/27/2009

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FINISH

Parts ListDESCRIPTIONPART NUMBERQTYITEM

3.5" Constant Torque ClampCT350L813" CAC HoseR16419312Upper CAC PipeBELL7211390 deg. HoseT16198314#32 Hose ClampHC83215Upper Coolant HoseAT21965416#40 Hose ClampHC8401790 deg. HoseDH30017418#88 ClampHC88819Band Clamp89526K110Exhaust PipeBELL723111Flange ClampRE40048112Hose AdaptorDH8002281135"-4.5" Reducer50R45114#96 ClampHC8962155" Hump Hose5H5116Intake PipeBell 724117#40 Hose ClampHC840218Lower Coolant Pipe (pump side)BELL725119#36 Hose ClampHC83612090 deg. Hose4400259121#44 Hose ClampHC844122Coolant Pipe8073677123Hose ClampTY22473124Lower Radiator Hose4400256125Hose ClampTY22472126Oil Drain ValveAT15218012790 deg. Hose8581128Oil PanRE523896129BracketFF100949130¾” NPT-5/16” Hose Barb FittingT22236013190 deg. Silicon HoseTP1728000232Lower CAC PipeBELL722133

12

13

141

5

6

7

1

321

331

32

31

1

89

10

11

12131415

1615

17

1829

28

18

19

2720

21

22

23 2425

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330lc work instructions

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