Lull 944E-42 Service Manual - Manual (Page 111)

7-9 944E-42
Engine
7.9 ENGINE REPLACEMENT
7.9.1 Engine Removal
Note: The radiator and oil cooler must be removed from
the machine before engine removal. Refer to
Section
7.4, “Engine Cooling System.” Several additional
components must be removed before engine removal.
They will be addressed in the following procedures.
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. Remove the engine cover.
6. Drain and remove the radiator assembly. Refer to
Section 7.4.2, “Radiator/Oil Cooler and
Replacement.”
7. Label, disconnect and cap the heater hoses
attached to the engine (if equipped).
8. Disconnect block heater cord from the engine (if
equipped).
Note: The engine harness is routed and attached to the
engine using hold-down clamps and plastic wire ties at
various places on the engine. Before removing engine,
ensure that the harness has been completely separated
(disconnected) from the engine. Move the harness clear
of the engine, and with the help of an observer, ensure
that the engine clears the harness during removal.
9. Label and disconnect all electrical wire connections
on the engine.
10. Label, disconnect and cap the fuel inlet line at the
fuel lift pump.
11. Label, disconnect and cap the fuel return line from
the injector pump.
12. Label, disconnect and cap the engine oil filter inlet
hose at the engine.
13. Label, disconnect and cap the engine oil filter return
hose from the engine.
14. Remove the engine oil filter assembly.
15. Remove the engine-to-transmission drive shaft.
Refer to Section 5.4.3, “Drive Shaft Removal.”
Note: Before the engine can be removed from the
machine, the air conditioning hoses need to be removed
from the air conditioning compressor. This procedure
must be completed by an authorized air conditioning
service technician. This service technician will also need
to be available when the new engine is installed to re-
install the air conditioning hoses and to the air
conditioning compressor.
16. Remove the air cleaner assembly. Refer to Section
7.8.1, “Air Cleaner Assembly Removal.”
17. Remove the exhaust pipe from the exhaust manifold.
Refer to Section 7.7.1, “Exhaust System Removal.”
18. Remove all of the hydraulic oil from the reservoir and
system. The receptacle must be large enough to
hold 50 gallons of oil. Remove the drain plug (1) and
allow the oil to drain into the receptacle. Dispose of
used oil at an approved recycling facility.
Note: If an oil evacuation system is available, removal
of the hydraulic oil can best be accomplished by
evacuating the oil through the filler tube.
19. Clean and reinstall the drain plug (1) into the
reservoir. Torque the drain plug to 25-40 lb-ft
(34-54 Nm).
20. Loosen the hose clamps and remove the lower
section hydraulic suction hose from the hydraulic
reservoir fitting (2).
21. Disconnect the hydraulic oil temperature switch
connector (3).
MU7390
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