Lull 944E-42 Service Manual - Manual (Page 109)

7-7 944E-42
Engine
f. Fuel Tank Installation
1. Set the fuel tank on to the tank support.
2. Secure the fuel tank retaining panel with the two
previously removed capscrews. Torque to 38-59 lb-ft
(50-80 Nm).
3. Install the fuel tank drain plug (3/8 in. NPT square
head).
4. Connect the fuel level gauge wire to the fuel tank
sender.
5. Uncap and connect the previously labeled fuel lines
to their appropriate locations.
6. Fill the tank according to specifications. Refer to
Section 2.4, “Fluid and Lubricant Capacities.”
7. Check tank for leaks.
8. Properly connect the batteries.
9. Close and secure the engine cover.
7.6.3 After Fuel System Service
1. Drain and flush the fuel tank if it was contaminated.
2. Vent air from the fuel system in accordance with the
instructions found in the appropriate Operator &
Safety Manual.
3. Fill the fuel tank with fresh, clean diesel fuel as
required.
7.7 ENGINE EXHAUST SYSTEM
Rattles and noise vibrations in the exhaust system are
usually caused by misalignment or parts. When aligning
the system, leave all capscrews and nuts slightly loose
until all parts are properly aligned, then tighten all
fasteners working from the front of the system to the rear.
When replacing the muffler, also replace the tail pipe.
Before assembling components, use exhaust system
sealer at all slip joint connections.
When installing exhaust system components, allow
sufficient clearance between the components and other
pipes, hoses and wiring that could be adversely affected
by excessive heat.
7.7.1 Exhaust System Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake, and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine
should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the batteries.
5. Loosen the hose clamps (1) and remove the thermal
insulation socks on the exhaust (2) and flex pipe (3).
6. Loosen and remove the exhaust pipe heat shield (4).
7. Loosen the lower clamp (5) attaching the exhaust
pipe to the muffler.
8. Loosen and remove the bolts and brackets (6)
holding the muffler to the frame. Remove the muffler.
9. Loosen the upper clamps (7) on the exhaust pipe
and remove the exhaust pipe (2).
10. Loosen the clamp (8) on the flex pipe (3) and remove
the flex pipe (2).
11. Loosen the V-band clamp (9) securing the outlet
exhaust pipe (10) to the engine turbo outlet. Remove
the exhaust pipe.
7.7.2 Exhaust System Installation
Note: Keep all clamps loosened until entire exhaust
system is in place.
1. Install the outlet exhaust pipe (10) to the engine
turbo outlet and tighten the V-band clamp (9) ONLY
enough to hold the outlet exhaust pipe in place.
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