Lull 944E-42 Parts Manual
8990462 644E-42,944E-42 3
TABLE OF CONTENTS
SECTION 1 - FRAME AND ATTACHING PARTS.............................................................................................................................. 11
FIGURE 1-1. MAIN FRAME COMPONENTS 644E (Prior to SN 0160048717, Excluding 0160045421)........................................ 12
FIGURE 1-2. MAIN FRAME COMPONENTS 944E (Prior to SN 0160041827) .............................................................................. 14
FIGURE 1-3. MAIN FRAME COMPONENTS (644E SN 160048717 to Present, Including 0160045421; 944E SN 160041827 to
Present) .......................................................................................................................................................................................... 18
FIGURE 1-4. ENGINE POD INSTALLATION (644E Prior to SN 0160048717, Excluding 0160045421; 944E Prior to SN
0160041827) .................................................................................................................................................................................. 22
FIGURE 1-5. ENGINE POD INSTALLATION (644E SN 1600408717 to Present, Including 0160045421; 944E SN 160041827 to
Present) .......................................................................................................................................................................................... 24
FIGURE 1-6. FENDER ASSEMBLY ............................................................................................................................................... 28
SECTION 2 - BOOM .......................................................................................................................................................................... 31
FIGURE 2-1. FIRST BOOM SECTION 644E ................................................................................................................................. 32
FIGURE 2-2. FIRST BOOM SECTION 944E ................................................................................................................................. 36
FIGURE 2-3. SECOND BOOM SECTION 644E ............................................................................................................................ 38
FIGURE 2-4. SECOND BOOM SECTION 944E ............................................................................................................................ 40
FIGURE 2-5. THIRD BOOM SECTION 644E ................................................................................................................................. 42
FIGURE 2-6. THIRD BOOM SECTION 944E ................................................................................................................................. 44
FIGURE 2-7. QUICK ATTACH ....................................................................................................................................................... 46
FIGURE 2-8. BOOM EXTEND CHAIN ........................................................................................................................................... 48
FIGURE 2-9. BOOM RETRACT CHAIN ......................................................................................................................................... 50
FIGURE 2-10. TRANSFER CARRIAGE INSTALLATION (644E Prior to SN 0160048717, Excluding 0160045421; 944E Prior to
SN 0160041827)............................................................................................................................................................................. 52
FIGURE 2-11. TRANSFER CARRIAGE INSTALLATION (644E SN 0160048717 to Present, Including 0160045421; 944E SN
0160041827 to Present) ................................................................................................................................................................. 54
SECTION 3 - ATTACHMENTS .......................................................................................................................................................... 57
FIGURE 3-1. BUCKETS ................................................................................................................................................................. 58
FIGURE 3-2. TILT CARRIAGE (644E Prior to SN 0160034164; 944E Prior to SN 0160034158) .................................................. 60
FIGURE 3-3. TILT CARRIAGE (644E SN 0160034164 through 0160051823; 944E SN 0160034158 through 0160051823) ....... 62
FIGURE 3-4. TILT CARRIAGE (644E SN 0160051824 to Present; 944E SN 0160051824 to Present) ......................................... 64
FIGURE 3-5. SIDE TILT CARRIAGE (Prior to SN 0160037794) .................................................................................................... 66
FIGURE 3-6. SIDE TILT CARRIAGE (SN 0160037794 to Present) ................................................................ ............................... 68
FIGURE 3-7. SWING CARRIAGE (Prior to SN 0160037794) ........................................................................................................ 70
FIGURE 3-8. SWING CARRIAGE (SN 0160037794 to Present) .................................................................................................... 72
FIGURE 3-9. SHEET MATERIAL HANDLER (Prior to SN 0160037794) ....................................................................................... 74
FIGURE 3-10. SHEET MATERIAL HANDLER (SN 0160037794 to Present) ................................................................................. 76
FIGURE 3-11. 3 FT TRUSS BOOM WITH WINCH ........................................................................................................................ 78
FIGURE 3-12. 10 FT TRUSS BOOM WITH WINCH (Prior to SN 0160037794) ............................................................................. 80
FIGURE 3-13. 12 FT TRUSS BOOM WITH WINCH (SN 0160037794 to Present) ........................................................................ 82
FIGURE 3-14. 10 FT TRUSS BOOM (Prior to SN 0160037794) .................................................................................................... 84
FIGURE 3-15. 12 & 15 FT TRUSS BOOM (Prior to SN 0160037794)............................................................................................ 86
FIGURE 3-16. 50 IN SINGLE FORK POSITIONING CARRIAGE ASSEMBLY .............................................................................. 88
FIGURE 3-17. 50 IN DUAL FORK POSITIONING CARRIAGE ASSEMBLY .................................................................................. 90
FIGURE 3-18. FORK MOUNTED LIFTING HOOK ......................................................................................................................... 92
FIGURE 3-19. FORKS .................................................................................................................................................................... 94
FIGURE 3-20. FORK MOUNTED PLATFORM............................................................................................................................... 96
FIGURE 3-21. CONCRETE BUCKET .......................................................................................................................................... 100
FIGURE 3-22. SWEEPER ASSEMBLY ........................................................................................................................................ 102
FIGURE 3-23. GRAPPLE BUCKET .............................................................................................................................................. 104
FIGURE 3-24. FORK PIN LOCK INSTALLATION ........................................................................................................................ 106
FIGURE 3-25. 8 FT STANDARD MAST ....................................................................................................................................... 108
FIGURE 3-26. 50 IN SIDE SHIFT CARRIAGE (644E SN 0160034164 to Present; 944E SN 0160034158 to Present) ............... 112
SECTION 4 - ENGINE AND ATTACHING PARTS .......................................................................................................................... 115
FIGURE 4-1. ENGINE INSTALLATION (644E Prior to SN 0160048717, Excluding 01600045421; 944E Prior to SN 0160041827,
Including 0160041849) ................................................................................................................................................................. 116
FIGURE 4-2. ENGINE INSTALLATION (644E SN 0160048717 to Present, Including 0160045421; 944E SN 0160041827 to
Present) ........................................................................................................................................................................................ 120
FIGURE 4-3. ENGINE (SN 0160041827 through 0160044164) ................................................................................................... 124
FIGURE 4-4. ENGINE (SN 0160044254 through 0160049550) ................................................................................................... 126
FIGURE 4-5. ENGINE (644E SN 0160048717 to Present, Including 0160045421; 944E SN 0160049678 to Present) ............... 128
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FIGURE 4-6. FUEL SYSTEM (644E Prior to SN 0160048717, Excluding 0160045421; 944E Prior to SN 0160041827) ............. 130
FIGURE 4-7. FUEL SYSTEM (644E SN 0160048717 to Present, Including 0160045421; 944E SN 0160041827 to Present) .... 134
FIGURE 4-8. RADIATOR AND OIL COOLER MOUNTING (644E SN 17569 through 20123, SN 0160002514 through
0160009050; 944E SN 17569 through 20123, SN 0160002514 through 0160009044) ................................................................ 136
FIGURE 4-9. RADIATOR AND OIL COOLER MOUNTING (644E SN 0160009073 through 0160043356; 944E SN 0160009075
through 0160041823) .................................................................................................................................................................... 138
FIGURE 4-10. RADIATOR AND OIL COOLER MOUNTING (644E SN 0160048717 to Present, Including 0160045421; 944E SN
0160041827 to Present) ................................................................................................................................................................ 140
FIGURE 4-11. AIR CLEANER INSTALLATION (644E SN 17569 through 20123, SN 0160002514 through 0160011781; 944E SN
17569 through 20123, SN 0160002514 through 0160011778) ..................................................................................................... 144
FIGURE 4-12. AIR CLEANER INSTALLATION (644E SN 0160011807 through 0160043356; 944E SN 0160011804 through
0160041823) ................................................................................................................................................................................. 146
FIGURE 4-13. AIR CLEANER INSTALLATION (644E SN 0160048717 to Present, Including 0160045421; 944E SN 0160041827
to Present) ..................................................................................................................................................................................... 148
FIGURE 4-14. EXHAUST INSTALLATION (644E SN 17569 through 20123, SN 0160002514 through 0160009050; 944E SN
17569 through 20123, SN 0160002514 through 0160009044) ..................................................................................................... 150
FIGURE 4-15. EXHAUST INSTALLATION (644E SN 0160009073 through 0160043356; 944E SN 0160009075 through
0160041823) ................................................................................................................................................................................. 152
FIGURE 4-16. EXHAUST INSTALLATION (644E SN 0160048717 to Present, Including 01600405421; 944E SN 0160041827 to
Present) ......................................................................................................................................................................................... 154
SECTION 5 - DRIVE TRAIN ............................................................................................................................................................. 157
FIGURE 5-1. DRIVE TRAIN COMPONENTS ............................................................................................................................... 158
FIGURE 5-2. FRONT AXLE .......................................................................................................................................................... 160
FIGURE 5-3. FRONT AXLE - INPUT (Prior to SN 0160039830, Excluding 0160036724, 0160036811, 0160036907 and
0160037012) ................................................................................................................................................................................. 162
FIGURE 5-4. FRONT AXLE - INPUT (SN 0160039830 to Present, Including 0160036724, 0160036811, 0160036907 and
0160037012) ................................................................................................................................................................................. 166
FIGURE 5-5. FRONT AXLE - INPUT (Prior to SN 0160040124, Excluding 0160034634, 0160036710, 0160036722, 0160036735
and 0160036738) .......................................................................................................................................................................... 170
FIGURE 5-6. FRONT AXLE - INPUT (SN 0160040124 to Present, Including 0160034634, 0160036710, 0160036722,
0160036735 and 0160036738) ..................................................................................................................................................... 174
FIGURE 5-7. FRONT AXLE - LIMITED SLIP DIFFERENTIAL (644E Prior to SN 0160039830, Excluding 0160036724,
0160036811, 0160036907 and 0160037012; 944E Prior to SN 0160040124, Excluding 0160034634, 0160036710, 0160036722,
0160036735 and 0160036738) ..................................................................................................................................................... 178
FIGURE 5-8. FRONT AXLE - LIMITED SLIP DIFFERENTIAL (644E SN 0160039830 to Present, Including 0160036724,
0160036811, 0160036907 and 0160037012; 944E SN 0160040124 to Present, Including 0160034634, 0160036710,
0160036722, 0160036735 and 0160036738) ............................................................................................................................... 180
FIGURE 5-9. FRONT AXLE - AXLE CASING (644E Prior to SN 0160039830, Excluding 0160036724, 0160036811, 0160036907
and 0160037012; 944E Prior to SN 0160040124, Excluding 0160034634, 0160036710, 0160036722, 0160036735 and
0160036738) ................................................................................................................................................................................. 182
FIGURE 5-10. FRONT AXLE - AXLE CASING (644E SN 0160039830 to Present, Including 0160036724, 0160036811,
0160036907 and 0160037012; 944E SN 0160040124 to Present, Including 0160034634, 0160036710, 0160036722, 0160036735
and 0160036738) .......................................................................................................................................................................... 186
FIGURE 5-11. FRONT AXLE - M-DISC BRAKE (644E Prior to SN 0160039830, Excluding 0160036724, 0160036811,
0160036907 and 0160037012; 944E Prior to SN 0160040124, Excluding 0160034634, 0160036710, 0160036722, 0160036735
and 0160036738) .......................................................................................................................................................................... 188
FIGURE 5-12. FRONT AXLE - M-DISC BRAKE (644E SN 0160039830 to Present, Including 0160036724, 0160036811,
0160036907 and 0160037012; 944E SN 0160040124 to Present, Including 0160034634, 0160036710, 0160036722, 0160036735
and 0160036738) .......................................................................................................................................................................... 192
FIGURE 5-13. FRONT AXLE - BRAKE (644E Prior to SN 0160039830, Excluding 0160036724, 0160036811, 0160036907 and
0160037012; 944E Prior to SN 0160040124, Excluding 0160034634, 0160036710, 0160036722, 0160036735 and 0160036738)
...................................................................................................................................................................................................... 194
FIGURE 5-14. FRONT AXLE - BRAKE (644E SN 0160039830 to Present, Including 0160036724, 0160036811, 0160036907 and
0160037012; 944E SN 0160040124 to Present, Including 0160034634, 0160036710, 0160036722, 0160036735 and
0160036738) ................................................................................................................................................................................. 198
FIGURE 5-15. FRONT AXLE - JOINT HOUSING 644E (Prior to SN 0160039830, Excluding 0160036724, 0160036811,
0160036907 and 0160037012) ..................................................................................................................................................... 200
FIGURE 5-16. FRONT AXLE - JOINT HOUSING 944E (Prior to SN 0160040124, Excluding 0160034634, 0160036710,
0160036722, 0160036735 and 0160036738) ............................................................................................................................... 204
FIGURE 5-17. FRONT AXLE - JOINT HOUSING (644E SN 0160039830 to Present, Including 0160036724, 0160036811,
0160036907 and 0160037012; 944E SN 0160040124 to Present, Including 0160034634, 0160036710, 0160036722, 0160036735
and 0160036738) .......................................................................................................................................................................... 206
FIGURE 5-18. FRONT AXLE - PLANETARY DRIVE (Prior to SN 0160039830, Excluding 0160036724, 0160036811, 0160036907
and 0160037012) .......................................................................................................................................................................... 208
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FIGURE 5-19. FRONT AXLE - PLANETARY DRIVE (Prior to SN 0160040124, Excluding 0160034634, 0160036710,
0160036722, 0160036735 and 0160036738) ............................................................................................................................... 210
FIGURE 5-20. FRONT AXLE - PLANETARY DRIVE (644E SN 0160039830 to Present, Including 0160036724, 0160036811,
0160036907 and 0160037012; 944E SN 0160040124 to Present, Including 0160034634, 0160036710, 0160036722, 0160036735
and 0160036738).......................................................................................................................................................................... 212
FIGURE 5-21. REAR AXLE ................................ ................................ .......................................................................................... 214
FIGURE 5-22. REAR AXLE - INPUT (644E Prior to SN 0160039830, Excluding 0160036724, 0160036811, 0160036907 and
0160037012; 944E Prior to SN 0160040124, Excluding 0160034634, 0160036710, 0160036722, 0160036735 and 0160036738)
...................................................................................................................................................................................................... 216
FIGURE 5-23. REAR AXLE - INPUT (644E SN 0160039830 to Present, Including 0160036724, 0160036811, 0160036907 and
0160037012; 944E SN 0160040124 through 0160041823, Including 0160034634, 0160036710, 0160036722, 0160036735 and
0160036738) ................................................................................................................................................................................ 220
FIGURE 5-24. REAR AXLE - INPUT 944E (SN 0160041827 to Present) .................................................................................... 224
FIGURE 5-25. REAR AXLE - DIFFERENTIAL (644E Prior to SN 0160039830, Excluding 0160036724, 0160036811, 0160036907
and 0160037012; 944E Prior to SN 0160040124, Excluding 0160034634, 0160036710, 0160036722, 0160036735 and
0160036738) ................................................................................................................................................................................ 228
FIGURE 5-26. REAR AXLE - DIFFERENTIAL (644E SN 0160039830 to Present, Including 0160036724, 0160036811,
0160036907 and 0160037012; 944E SN 0160040124 to Present, Including 0160034634, 0160036710, 0160036722, 0160036735
and 0160036738).......................................................................................................................................................................... 230
FIGURE 5-27. REAR AXLE - AXLE CASING (644E Prior to SN 0160039830, Excluding 0160036724, 0160036811, 0160036907
and 0160037012; 944E Prior to SN 0160040124, Excluding 0160034634, 0160036710, 0160036722, 0160036735 and
0160036738) ................................................................................................................................................................................ 232
FIGURE 5-28. REAR AXLE - AXLE CASING (644E SN 0160039830 to Present, Including 0160036724, 0160036811,
0160036907 and 0160037012; 944E SN 0160040124 to Present, Including 0160034634, 0160036710, 0160036722, 0160036735
and 0160036738).......................................................................................................................................................................... 234
FIGURE 5-29. REAR AXLE - M-DISC BRAKE (644E Prior to SN 0160039830, Excluding 0160036724, 0160036811, 0160036907
and 0160037012; 944E Prior to SN 0160040124, Excluding 0160034634, 0160036710, 0160036722, 0160036735 and
0160036738) ................................................................................................................................................................................ 236
FIGURE 5-30. REAR AXLE - M-DISC BRAKE (644E SN 0160039830 to Present, Including 0160036724, 0160036811,
0160036907 and 0160037012; 944E SN 0160040124 to Present, Including 0160034634, 0160036710, 0160036722, 0160036735
and 0160036738).......................................................................................................................................................................... 240
FIGURE 5-31. REAR AXLE - BRAKE (644E Prior to SN 0160039830, Excluding 0160036724, 0160036811, 0160036907 and
0160037012; 944E Prior to SN 0160040124, Excluding 0160034634, 0160036710, 0160036722, 0160036735 and 0160036738)
...................................................................................................................................................................................................... 242
FIGURE 5-32. REAR AXLE - JOINT HOUSING (644E Prior to SN 0160039830, Excluding 0160036724, 0160036811,
0160036907 and 0160037012; 944E Prior to SN 0160040124, Excluding 0160034634, 0160036710, 0160036722, 0160036735
and 0160036738).......................................................................................................................................................................... 244
FIGURE 5-33. REAR AXLE - JOINT HOUSING (644E SN 0160039830 to Present, Including 0160036724, 0160036811,
0160036907 and 0160037012; 944E SN 0160040124 to Present, Including 0160034634, 0160036710, 0160036722, 0160036735
and 0160036738).......................................................................................................................................................................... 248
FIGURE 5-34. REAR AXLE - PLANETARY DRIVE (644E Prior to SN 0160039830, Excluding 0160036724, 0160036811,
0160036907 and 0160037012; 944E Prior to SN 0160040124, Excluding 0160034634, 0160036710, 0160036722, 0160036735
and 0160036738).......................................................................................................................................................................... 250
FIGURE 5-35. REAR AXLE - PLANETARY DRIVE (644E SN 0160039830 to Present, Including 0160036724, 0160036811,
0160036907 and 0160037012; 944E SN 0160040124 to Present, Including 0160034634, 0160036710, 0160036722, 0160036735
and 0160036738).......................................................................................................................................................................... 252
FIGURE 5-36. ZF TRANSMISSION ............................................................................................................................................. 254
FIGURE 5-37. ZF TRANSMISSION - ENGINE CONNECTION AND INPUT SHAFTS ................................................................ 256
FIGURE 5-38. ZF TRANSMISSION - GEARBOX HOUSING AND COUPLING LOCATION ....................................................... 258
FIGURE 5-39. ZF TRANSMISSION - COUPLING GROUP 1 644E ................................ ............................................................. 260
FIGURE 5-40. ZF TRANSMISSION - COUPLING GROUP 1 944E ................................ ............................................................. 262
FIGURE 5-41. ZF TRANSMISSION - COUPLING GROUP 2 644E ................................ ............................................................. 264
FIGURE 5-42. ZF TRANSMISSION - COUPLING GROUP 2 944E ................................ ............................................................. 266
FIGURE 5-43. ZF TRANSMISSION - COUPLING GROUP 3 644E ................................ ............................................................. 268
FIGURE 5-44. ZF TRANSMISSION - COUPLING GROUP 3 944E ................................ ............................................................. 270
FIGURE 5-45. ZF TRANSMISSION - COUPLING GROUP 4 644E ................................ ............................................................. 272
FIGURE 5-46. ZF TRANSMISSION - COUPLING GROUP 4 944E ................................ ............................................................. 274
FIGURE 5-47. ZF TRANSMISSION - REVERSING GEAR GROUP CV 644E ............................................................................. 276
FIGURE 5-48. ZF TRANSMISSION - REVERSING GEAR GROUP CV 944E ............................................................................. 278
FIGURE 5-49. ZF TRANSMISSION - REVERSING GEAR GROUP CR 644E ............................................................................ 280
FIGURE 5-50. ZF TRANSMISSION - REVERSING GEAR GROUP CR 944E ............................................................................ 282
FIGURE 5-51. ZF TRANSMISSION - OIL PUMP ................................................................................................ ......................... 284
FIGURE 5-52. ZF TRANSMISSION - CONTROL UNIT ............................................................................................................... 286
FIGURE 5-53. ZF TRANSMISSION - GEARSHIFT SYSTEM ...................................................................................................... 288
FIGURE 5-54. ZF TRANSMISSION - TRANSFER BOX .............................................................................................................. 290
FIGURE 5-55. DRIVE SHAFTS .................................................................................................................................................... 292
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FIGURE 5-56. TIRE AND RIMS 644E (Prior to SN 0160039830, Excluding 0160036724, 0160036811, 0160036907 and
0160037012) ................................................................................................................................................................................. 294
FIGURE 5-57. TIRE AND RIMS 644E (SN 0160039830 to Present, Including 0160036724, 0160036811, 0160036907 and
0160037012) ................................................................................................................................................................................. 296
FIGURE 5-58. TIRE AND RIMS .................................................................................................................................................... 298
SECTION 6 - CAB ............................................................................................................................................................................ 301
FIGURE 6-1. CAB ASSEMBLY ..................................................................................................................................................... 302
FIGURE 6-2. SOFT CAB ENCLOSURE ....................................................................................................................................... 304
FIGURE 6-3. CAB GLASS ............................................................................................................................................................ 306
FIGURE 6-4. DOOR ASSEMBLY ................................................................................................................................................. 308
FIGURE 6-5. OPERATOR'S COMPARTMENT - INNER PANELS ............................................................................................... 312
FIGURE 6-6. OPERATOR'S SEAT (644E SN 17569 through 20123, SN 0160002514 through 0160013109; 944E SN 17569
through 20123, SN 0160002514 through 0160013106) ................................................................................................................ 316
FIGURE 6-7. OPERATOR'S SEAT (644E SN 0160013127 to Present; 944E SN 0160013131 to Present) ................................. 318
FIGURE 6-8. REAR WINDOW (644E SN 17569 through 20123, SN 0160002514 through 0160009816; 944E SN 17569 through
20123, SN 0160002514 through 0160009818) ............................................................................................................................. 320
FIGURE 6-9. REAR WINDOW (644E SN 0160009474 to Present; 944E SN 0160009839 to Present) ........................................ 322
FIGURE 6-10. FRONT WINDSHIELD WIPER ASSEMBLY .......................................................................................................... 324
FIGURE 6-11. SKYLIGHT WIPER ASSEMBLY ............................................................................................................................ 326
FIGURE 6-12. WINDSHIELD GUARD .......................................................................................................................................... 328
FIGURE 6-13. MIRRORS .............................................................................................................................................................. 330
FIGURE 6-14. HEATER SYSTEM ................................................................................................................................................ 332
FIGURE 6-15. AIR CONDITIONING SYSTEM ............................................................................................................................. 334
FIGURE 6-16. VENTILATION HOSES AND VENTS ................................................................ .................................................... 338
SECTION 7 - CONTROLS ................................................................................................................................................................ 341
FIGURE 7-1. SERVICE BRAKE AND PEDAL ASSEMBLY .......................................................................................................... 342
FIGURE 7-2. THROTTLE GROUP INSTALLATION 644E (SN 17569 through 20115, SN 0160002519 through 0160003672,
Excluding 19557 and 0160003489) ............................................................................................................................................... 344
FIGURE 7-3. THROTTLE GROUP INSTALLATION 644E (SN 0160003690 through 0160043356, Including 19557, 20118 and
0160003489) ................................................................................................................................................................................. 346
FIGURE 7-4. THROTTLE GROUP INSTALLATION 944E (SN 17569 through 20123, SN 0160002514 through 0160016057) ... 348
FIGURE 7-5. THROTTLE GROUP INSTALLATION 944E (SN 0160016083 through 0160041849, Excluding 0160041827) ...... 350
FIGURE 7-6. THROTTLE GROUP INSTALLATION (644E SN 0160048717 to Present, Including 0160045421; 944E SN
0160041827 to Present, Excluding 0160041849) ......................................................................................................................... 352
FIGURE 7-7. STEERING COLUMN .............................................................................................................................................. 354
FIGURE 7-8. FRAME LEVEL CONTROL VALVE ASSEMBLY ..................................................................................................... 356
FIGURE 7-9. JOYSTICK CONTROL VALVE ASSEMBLY ............................................................................................................ 358
FIGURE 7-10. JOYSTICK CONTROL VALVE ASSEMBLY, (SINGLE) ........................................................................................ 360
SECTION 8 - HYDRAULIC CIRCUITS ............................................................................................................................................. 363
FIGURE 8-1. PUMP, SUCTION AND RETURN (644E SN 17569 through 20123, SN 0160002514 through 0160003108; 944E SN
17569 through 20123, SN 0160002514 through 0160003140) ..................................................................................................... 364
FIGURE 8-2. PUMP, SUCTION AND RETURN (644E SN 0160003109 through 644E; 944E SN 0160003141 through 944E) ... 368
FIGURE 8-3. PUMP, SUCTION AND RETURN (644E SN 0160048717 to Present, Including 0160045421; 944E SN 0160041827
to Present) ..................................................................................................................................................................................... 372
FIGURE 8-4. SERVICE AND PARKING BRAKE .......................................................................................................................... 376
FIGURE 8-5. EXTEND/RETRACT AND LIFT/LOWER (644E SN 17569 through 20118, SN 0160002519 through 644E; 944E SN
18554 through 20123, SN 0160002514 through 944E) ................................................................................................................. 380
FIGURE 8-6. EXTEND/RETRACT AND LIFT/LOWER (644E SN 0160003604 to Present; 944E SN 0160003602 to Present) ... 384
FIGURE 8-7. ATTACHMENT TILT AND AUXILIARY (644E SN 17569 through 19385; 944E SN 17569 through 19385) ............ 388
FIGURE 8-8. ATTACHMENT TILT AND AUXILIARY (644E SN 19386 through 20118, SN 0160002519 through 0160003108;
944E SN 19386 through 20123, SN 0160002514 through 0160003140) ...................................................................................... 392
FIGURE 8-9. ATTACHMENT TILT AND AUXILIARY (644E SN 0160003109 to Present; 944E SN 0160003141 to Present) ..... 396
FIGURE 8-10. FRAME LEVEL/STABIL-TRAK (SN 17569 through 18460) ................................................................................... 400
FIGURE 8-11. FRAME LEVEL/STABIL-TRAK (SN 18461 through 20118, SN 0160002519 to Present) ..................................... 402
FIGURE 8-12. TILT COMPENSATION CYLINDER (644E SN 17569 through 20118, SN 0160002519 through 0160003583, SN
0160002514 through 0160003587; 944E SN 18554 through 20123) ............................................................................................ 404
FIGURE 8-13. TILT COMPENSATION CYLINDER (644E SN 0160003604 to Present; 944E SN 0160003602 to Present) ........ 406
FIGURE 8-14. TRANSFER CARRIAGE ........................................................................................................................................ 408
FIGURE 8-15. STEERING CYLINDER ......................................................................................................................................... 410
FIGURE 8-16. FRONT JOYSTICK ................................................................................................................................................ 414
FIGURE 8-17. REAR JOYSTICK (SN 17569 through 18460) ....................................................................................................... 416
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FIGURE 8-18. REAR JOYSTICK (644E SN 18461 through 20123, SN 0160002514 to Present; 944E SN 18554 through 20123,
SN 0160002514 to Present) ......................................................................................................................................................... 418
FIGURE 8-19. SINGLE JOYSTICK .............................................................................................................................................. 420
FIGURE 8-20. TRANSMISSION OIL COOLER ASSEMBLY (644E Prior to SN 0160048717, Excluding 01600045421; 944E Prior
to SN 0160041827)....................................................................................................................................................................... 422
FIGURE 8-21. TRANSMISSION OIL COOLER ASSEMBLY (644E SN 0160048717 to Present, Including 0160045421; 944E SN
0160041827 to Present) ............................................................................................................................................................... 424
FIGURE 8-22. OIL COOLER (644E Prior to SN 0160048717, Excluding 0160045421; 944E Prior to SN 0160041827) ............. 426
FIGURE 8-23. OIL COOLER (644E SN 0160048717 to Present, Including 0160045421; 944E SN 0160041827 to Present) ..... 428
SECTION 9 - HYDRAULIC COMPONENTS ................................................................................................ .................................... 431
FIGURE 9-1. EXTEND/RETRACT CYLINDER (644E SN 17569 through 20123, SN 0160002514 through 0160005325, Excluding
0160004236 and 0160004237) ..................................................................................................................................................... 432
FIGURE 9-2. EXTEND/RETRACT CYLINDER (644E SN 0160005784 to Present, Including 0160004236 and 0160004237) .... 434
FIGURE 9-3. EXTEND/RETRACT CYLINDER (944E SN 18554 through 20123, SN 0160002514 through 0160005729) .......... 436
FIGURE 9-4. EXTEND/RETRACT CYLINDER (SN 0160005814 to Present) ............................................................................. 438
FIGURE 9-5. LIFT CYLINDER ..................................................................................................................................................... 440
FIGURE 9-6. LIFT CYLINDER (944E SN 18554 through 20123, SN 0160002514 through 0160005729) .................................. 442
FIGURE 9-7. LIFT CYLINDER 944E (SN 0160005814 to Present) .............................................................................................. 444
FIGURE 9-8. ATTACHMENT TILT CYLINDER 644E ................................................................................................................... 446
FIGURE 9-9. ATTACHMENT TILT CYLINDER 944E ................................................................................................................... 448
FIGURE 9-10. FRAME LEVEL CYLINDER .................................................................................................................................. 450
FIGURE 9-11. FRAME LEVEL CYLINDER (944E SN 17569 through 20123, SN 0160002514 through 0160004849, Excluding
0160004238 and 0160004239) ..................................................................................................................................................... 452
FIGURE 9-12. FRAME LEVEL CYLINDER (944E SN 0160004927 to Present, Including 0160004238 and 0160004239)......... 454
FIGURE 9-13. STABIL-TRAK CYLINDER .................................................................................................................................... 456
FIGURE 9-14. STABIL-TRAK CYLINDER (944E SN 17569 through 20123, SN 0160002514 through 0160004849, Excluding
0160004238 and 0160004239) ..................................................................................................................................................... 458
FIGURE 9-15. STABIL-TRAK CYLINDER (944E SN 0160004927 to Present, Including 0160004238 and 0160004239) ........... 460
FIGURE 9-16. TILT COMPENSATION CYLINDER 644E ............................................................................................................ 462
FIGURE 9-17. TILT COMPENSATION CYLINDER 944E ............................................................................................................ 464
FIGURE 9-18. TRANSFER CYLINDER ........................................................................................................................................ 466
FIGURE 9-19. GEAR PUMP (644E Prior to SN 0160048717, Excluding 0160045421) ............................................................... 468
FIGURE 9-20. GEAR PUMP (Prior to SN 0160041827) ............................................................................................................... 470
FIGURE 9-21. GEAR PUMP (SN 0160041827 through 0160046530) ......................................................................................... 472
FIGURE 9-22. GEAR PUMP (644E SN 0160048717 to Present, Including 0160045421; 944E SN 0160046623 to Present) ..... 474
FIGURE 9-23. MAIN CONTROL VALVE (644E SN 17569 through 20123, SN 0160002514 through 0160003074; 944E SN 17569
through 20123, SN 0160002514 through 0160003090)................................................................................................................ 476
FIGURE 9-24. MAIN CONTROL VALVE (644E SN 0160003088 to Present; 944E SN 0160003092 to Present) ........................ 480
FIGURE 9-25. PILOT SELECT VALVE ASSEMBLY, (DUAL JOYSTICK) .................................................................................... 482
FIGURE 9-26. PILOT SELECT VALVE ASSEMBLY, (SINGLE JOYSTICK) ................................................................................ 484
FIGURE 9-27. ACCUMULATOR CHARGE VALVE ASSEMBLY ................................................................................................. 486
FIGURE 9-28. STABIL-TRAK CYLINDER VALVES ..................................................................................................................... 490
FIGURE 9-29. AUXILIARY DUMP VALVE ASSEMBLIES (644E SN 19402 through 20118, SN 0160002519 through 0160003074;
944E SN 19402 through 20123, SN 0160002514 through 0160003072) ..................................................................................... 492
FIGURE 9-30. VALVE TRAY ASSEMBLY, (DUAL JOYSTICK) (SN 17569 through 19401) ........................................................ 494
FIGURE 9-31. VALVE TRAY ASSEMBLY, (DUAL JOYSTICK) (644E SN 18065 through 20123, SN 0160002514 through
0160003074; 944E SN 18065 through 20123, SN 0160002514 through 0160003072) ............................................................... 496
FIGURE 9-32. VALVE TRAY ASSEMBLY, (DUAL JOYSTICK) (644E SN 0160003088 to Present; 944E SN 0160003086 to
Present) ........................................................................................................................................................................................ 498
FIGURE 9-33. VALVE TRAY ASSEMBLY, (SINGLE JOYSTICK) (644E SN 18065 through 20123, SN 0160002514 through
0160003074; 944E SN 18065 through 20123, SN 0160002514 through 0160003072) ............................................................... 500
FIGURE 9-34. VALVE TRAY ASSEMBLY, (SINGLE JOYSTICK) (644E SN 0160003088 to Present; 944E SN 0160003086 to
Present) ........................................................................................................................................................................................ 502
FIGURE 9-35. HYDRAULIC TANK ASSEMBLY (644E Prior to SN 0160048717, Excluding 0160045421; 944E SN 0160041827 to
Present) ........................................................................................................................................................................................ 504
FIGURE 9-36. HYDRAULIC TANK ASSEMBLY (644E SN 0160048717 to Present, Including 0160045421; 944E SN 0160041827
to Present) .................................................................................................................................................................................... 508
FIGURE 9-37. ACCUMULATORS ASSEMBLY ............................................................................................................................ 510
FIGURE 9-38. DIAGNOSTIC PRESSURE TAPS ......................................................................................................................... 512
FIGURE 9-39. SIDE TILT CARRIAGE CYLINDER....................................................................................................................... 514
FIGURE 9-40. 72IN 90 SWING CARRIAGE CYLINDER .............................................................................................................. 516
FIGURE 9-41. GRAPPLE BUCKET CYLINDER........................................................................................................................... 518
FIGURE 9-42. 50 IN SIDE SHIFT CARRIAGE CYLINDER (644E SN 0160034164 to Present; 944E SN 0160034158 to Present)
...................................................................................................................................................................................................... 520
8990462 644E-42,944E-42 9
TABLE OF CONTENTS
SECTION 10 - ELECTRICAL ............................................................................................................................................................ 523
FIGURE 10-1. BATTERY AND VEHICLE GROUND CABLES (Prior to SN 01600487817, Excluding 0160045421) ................... 524
FIGURE 10-2. BATTERY AND VEHICLE GROUND CABLES (Prior to SN 0160041827)............................................................ 526
FIGURE 10-3. BATTERY AND VEHICLE GROUND CABLES (644E SN 0160048717 to Present, Including 0160045421; 944E SN
0160041827 to Present) ................................................................................................................................................................ 528
FIGURE 10-4. POWER COMPONENTS 644E (SN 17569 through 20115, SN 0160002519 through 0160003672, Excluding
19557 and 0160003489) ............................................................................................................................................................... 532
FIGURE 10-5. POWER COMPONENTS 644E (SN 0160003690 through 0160043356, Including 19557, 20118 and 0160003489)
...................................................................................................................................................................................................... 534
FIGURE 10-6. POWER COMPONENTS 944E (Prior to SN 0160041827) ................................................................................... 536
FIGURE 10-7. POWER COMPONENTS (644E SN 0160048717 to Present, Including 0160045421; 944E SN 0160041827 to
Present) ......................................................................................................................................................................................... 540
FIGURE 10-8. OPEN CAB ELECTRICAL COMPONENTS (SN 17569 through 19041) ............................................................... 542
FIGURE 10-9. OPEN CAB ELECTRICAL COMPONENTS (644E SN 19042 through 20123, SN 0160002514 through
0160034284; 944E SN 19042 through 20123, SN 0160002514 through 0160034278) ................................................................ 544
FIGURE 10-10. OPEN CAB ELECTRICAL COMPONENTS (644E SN 0160034285 to Present; 944E SN 0160034279 to Present)
...................................................................................................................................................................................................... 548
FIGURE 10-11. CLOSED CAB ELECTRICAL COMPONENTS .................................................................................................... 550
FIGURE 10-12. FUSES, RELAYS AND FLASHER BOX (644E SN 19042 through 20123, SN 0160002514 through 0160034284;
944E SN 19042 through 20123, SN 0160002514 through 0160034278) ...................................................................................... 552
FIGURE 10-13. FUSES, RELAYS AND FLASHER BOX (644E SN 0160034285 to Present; 944E SN 0160034279 to Present) 556
FIGURE 10-14. SENSOR COMPONENTS ................................................................................................................................... 560
FIGURE 10-15. CONTROL COMPONENTS ................................................................................................................................ 564
FIGURE 10-16. TRANSMISSION COMPONENTS ....................................................................................................................... 566
FIGURE 10-17. TRANSMISSION HARNESS ............................................................................................................................... 568
FIGURE 10-18. ENGINE HARNESS (644E SN 0160048717 to Present, Including 0160045421; 944E SN 0160041827 to Present)
...................................................................................................................................................................................................... 570
FIGURE 10-19. ECM CAB HARNESS (644E SN 0160048717 to Present, Including 0160045421; 944E SN 0160041827 to
Present) ......................................................................................................................................................................................... 572
FIGURE 10-20. FAN RELAY HARNESS ...................................................................................................................................... 574
FIGURE 10-21. JUMPER HARNESS ............................................................................................................................................ 576
SECTION 11 - DECALS ................................................................................................................................................................... 579
FIGURE 11-1. DECALS (644E Prior to SN 0160048717, Excluding 0160045421; 944E Prior to SN 0160041827) ..................... 580
FIGURE 11-2. DECALS (644E SN 0160048717 to Present, Including 0160045421; 944E SN 0160041827 to Present) ............. 584
SECTION 12 - OPTIONS .................................................................................................................................................................. 589
FIGURE 12-1. ROADLIGHT INSTALLATION ............................................................................................................................... 590
FIGURE 12-2. WORKLIGHT INSTALLATION .............................................................................................................................. 596
FIGURE 12-3. BEACON AND STROBE LIGHT ............................................................................................................................ 600
FIGURE 12-4. SWING CARRIAGE CYLINDER ASSEMBLY ROSENBOOM ............................................................................... 602
FIGURE 12-5. SWING CARRIAGE CYLINDER ASSEMBLY ENERGY ....................................................................................... 604
FIGURE 12-6. 48IN, 50IN, 60IN & 72IN SIDE TILT CARRIAGE CYLINDER ................................................................................ 606
FIGURE 12-7. COLD START OPTION ......................................................................................................................................... 608
SECTION 13 - RECOMMENDED SPARE PARTS ........................................................................................................................... 611
FIGURE 13-1. RECOMMENDED SPARE PARTS ........................................................................................................................ 612
PART NUMBER INDEX .................................................................................................................................................................... 617
10 644E-42,944E-42 8990462
SECTION 1 - FRAME AND ATTACHING PARTS
SECTION 1 - FRAME AND ATTACHING PARTS
8990462 644E-42,944E-42 11
SECTION 1 - FRAME AND ATTACHING PARTS
FIGURE 1-1. MAIN FRAME COMPONENTS 644E (Prior to SN 0160048717, Excluding 0160045421)
12 644E-42,944E-42 8990462
SECTION 1 - FRAME AND ATTACHING PARTS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1
N.S.S.
1
MAIN FRAME
2 8307221
3
PLAIN WASHER, 10mm
3 8303755
3
HEX HD CAPSCREW, 10X1.5X30mm, GR8.8
4 7300534
1
LOWER BATTERY SUPPORT
5 7300260
1
ENGINE MOUNT FRAME
6 8310625
2
HEX LOCKNUT, 12-1.75mm
7 7301149
2
CYLINDER MOUNTING PIN
8 7139886
2
PIN RETAINER SPACER
9 8310657
2
PLAIN WASHER,12 mm
10
8310656
2
HEX HD CAPSCREW, 12-1.75X60mm, GR8.8
11
7301096
NLA
LULL LOGO PLATE, (no longer available, use items 33 & 34 for
replacement)
12
7301098
NLA
LOGO BACKUP PLATE, (no longer available, use items 33 & 34 for
replacement)
13
8307220
4
FLAT WASHER, 12mm
14
8310625
4
HEX LOCKNUT, 12-1.75mm
15
8310424
2
HEX HD CAPSCREW, 8-1.25X90mm, GR8.8
16
7137142
2
CYLINDER PIN
17
8520001
2
LUBE FITTING, 1/8
18
8305654
2
HEX LOCKNUT, M8-1.25
19
8050001
2
SELF ALIGN BEARING, 1.4995X1.307
20
8310539
4
PLAIN WASHER, 1.25-1.375-2.5
21
0683020
4
HEX HD CAPSCREW, 1.25-7-2.5, GR8
22 Ref
HEX HD CAPSCREW, 1.25-7-4, GR8, (See CAB SECTION for
Breakdown)
23 Ref
CAB SUPPORT WASHER, (See CAB SECTION for Breakdown)
24 Ref
CAB MOUNT SHEER PIN, (See CAB SECTION for Breakdown)
25 Ref
CAB REAR SUPPORT, (See CAB SECTION for Breakdown)
26 Ref
HEX HD CAPSCREW, 12-1.75X40mm, GR8.8, (See CAB
SECTION for Breakdown)
27 Ref
PLAIN WASHER, 0.5, (See CAB SECTION for Breakdown)
28 Ref
HEX HD CAPSCREW, 12-1.75X40mm, GR8.8, (See CAB
SECTION for Breakdown)
29 Ref
CAB MOUNT STEP, (See CAB SECTION for Breakdown)
30 Ref
CAB FRONT SUPPORT, (See CAB SECTION for Breakdown)
31
8321701
4
HEX HD CAPSCREW, 20-2.5X150mm, GR8.8
32
7300754
2
TC STOP BLOCK
33
3575924
1
FRAME COVER PLATE
34
10704216
4
HEX HD CAPSCREW, 12-1.75X110mm, GR8.8
35 Ref
FRONT AXLE, (See DRIVE TRAIN SECTION for Breakdown)
36 Ref
REAR AXLE, (See DRIVE TRAIN SECTION for Breakdown)
37 Ref
FRAME SWAY CYLINDER, (See HYDRAULIC COMPONENTS
SECTION for Breakdown)
38 Ref
STABIL-TRAK CYLINDER, (See HYDRAULIC COMPONENTS
SECTION for Breakdown)
FIGURE 1-1. MAIN FRAME COMPONENTS 644E (Prior to SN 0160048717, Excluding 0160045421)
8990462 644E-42,944E-42 13
SECTION 1 - FRAME AND ATTACHING PARTS
FIGURE 1-2. MAIN FRAME COMPONENTS 944E (Prior to SN 0160041827)
14 644E-42,944E-42 8990462
SECTION 1 - FRAME AND ATTACHING PARTS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1
N.S.S.
1
MAIN FRAME
2 8303755
3
HEX HD CAPSCREW, 10X1.5X30mm, GR8.8
3 8307221
3
PLAIN WASHER, M10
4 7300534
1
LOWER BATTERY SUPPORT
5 7300535
1
UPPER BATTERY SUPPORT
6 8310709
1
CLAMP KNOB STUD, 10-1.5X40mm
7 8307221
1
PLAIN WASHER, 10mm
8 8310070
1
PUSH NUT, 3/8X13/16
9 7300448
1
ENGINE MOUNT FRAME
10
8310625
2
HEX LOCKNUT, 12-1.75mm
11
8310713
4
HEX HD CAPSCREW, 20-2.5X130mm, GR8.8
12
7301149
2
CYLINDER MOUNTING PIN
13
7139886
2
PIN RETAINER SPACER
14
8310657
2
PLAIN WASHER, 12mm
15
8310656
2
HEX HD CAPSCREW, 12-1.75X60mm, GR8.8
16
7301096
NLA
LULL LOGO PLATE, (no longer available, use items 41 & 42 for
replacement)
17
7301098
NLA
LOGO BACKUP PLATE, (no longer available, use items 41 & 42 for
replacement)
18
8307220
4
FLAT WASHER, 12mm
19
8310625
4
HEX LOCKNUT, 12-1.75mm
20
8310424
2
HEX HD CAPSCREW, 8-1.25X90mm, GR8.8
21
7137142
2
CYLINDER PIN
22
8520001
2
LUBE FITTING, 1/8
23
8305654
2
HEX LOCKNUT, 8-1.25mm
24
8050001
2
SELF ALIGN BEARING, 1.4995X1.307
25
8310539
4
PLAIN HARDENED WASHER, 1.25-1.375-2.5
26
0683020
4
HEX HD CAPSCREW, 1.25-7-2.5, GR8
27 Ref
HEX HD CAPSCREW, 1.25-7- 4, GR8, (See CAB SECTION for
Breakdown)
28 Ref
CAB SUPPORT WASHER, (See CAB SECTION for Breakdown)
29 Ref
CAB MOUNT SHEER PIN, (See CAB SECTION for Breakdown)
30 Ref
CAB REAR SUPPORT, (See CAB SECTION for Breakdown)
31
7301516
1
COUNTERWEIGHT
32
8310426
8
PLAIN WASHER, 20mm
33
8305655
4
HEX LOCKNUT, 20-2.5mm
34 Ref
HEX HD CAPSCREW, 12-1.75X35mm, GR8.8, (See CAB
SECTION for Breakdown)
35 Ref
PLAIN WASHER, 0.500, (See CAB SECTION for Breakdown)
36 Ref
HEX HD CAPSCREW, 12-1.75X40mm, GR8.8, (See CAB
SECTION for Breakdown)
37 Ref
CAB MOUNT STEP, (See CAB SECTION for Breakdown)
38 Ref
CAB FRONT SUPPORT, (See CAB SECTION for Breakdown)
39
8321701
4
HEX HD CAPSCREW, 20-2.50X150mm, GR8.8
40
7300754
2
TC STOP BLOCK
41
3575924
1
FRAME COVER PLATE
42
10704216
4
HEX HD CAPSCREW, 12-1.75X110mm, GR8.8
43 Ref
FRONT AXLE, (See DRIVE TRAIN SECTION for Breakdown)
44 Ref
REAR AXLE, (See DRIVE TRAIN SECTION for Breakdown)
45 Ref
FRAME SWAY CYLINDER, (See HYDRAULIC COMPONENTS
SECTION for Breakdown)
FIGURE 1-2. MAIN FRAME COMPONENTS 944E (Prior to SN 0160041827)
8990462 644E-42,944E-42 15
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
46 Ref
STABIL-TRAK CYLINDER, (See HYDRAULIC COMPONENTS
SECTION for Breakdown)
SECTION 1 - FRAME AND ATTACHING PARTS
16 644E-42,944E-42 8990462
SECTION 1 - FRAME AND ATTACHING PARTS
FIGURE 1-3. MAIN FRAME COMPONENTS (644E SN 160048717 to Present, Including 0160045421;
944E SN 160041827 to Present)
18 644E-42,944E-42 8990462
SECTION 1 - FRAME AND ATTACHING PARTS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001143083
Ref
FRAME INSTALLATION, (644E), (not available to order, see items
1 thru 6 & 8 thru 10 for service)
A
1001120707
Ref
FRAME INSTALLATION, (944E), (not available to order, see items
1 thru 10 for service)
A 1
Ref
TRANSFER CYLINDER, (See HYDRAULIC COMPONENTS
SECTION for Breakdown)
2
7300726
Ref
FRAME LEVEL INSTALLATION, (not available to order, see items
101 thru 111 for service)
E 3 7300727
Ref
STABIL-TRAK CYLINDER INSTALLATION, (not available to
order, see items 102 thru 111 & 151 for service)
D
4
7300753
Ref
TRANSFER CYLINDER STOP INSTALLATION, (not available to
order, see items 201 & 202 for service)
AD
5
7300859
Ref
TRANSFER CYLINDER MOUNTING INSTALLATION, (not
available to order, see items 251 & 252 for service)
AD
6
7301097
Ref
FRAME COVER INSTALLATION, (not available to order, see
items 301 thru 304 for service)
D 7 7301146
Ref
COUNTERWEIGHT INSTALLATION, (944E), (not available to
order, see items 351 thru 354 for service)
B
8
7301222
1
HOSE TRAY ASSEMBLY
E 8 7301868
AR
1IN ADHESIVE TAPE
9 N.S.S.
1
WELDMENT
10 Ref
TRANSFER CARRIAGE INSTALLATION, (See BOOM SECTION
for Breakdown )
101
Ref
FRAME LEVEL CYLINDER, (See HYDRAULIC COMPONENTS
SECTION for Breakdown)
102
7137142
2
PIN 103
7139886
2
PIN SPACER
104
7301149
2
PIN 105
8050001
2
BEARING
106
8305654
2
HEX NUT, M8X1.25
107
8310656
2
HEX HD CAPSCREW, M12X60, GR8.8, (torque to 59-106 Nm/4478 lb-ft)
108
8310424
2
HEX HD CAPSCREW, M8X90, GR8.8, (torque to 17-31 Nm/13-23
lb-ft) 109
8310625
2
HEX NUT, M12X1.75
110
8310657
2
WASHER, 12mm
111
8520001
2
GREASE FITTING
151
Ref
STABIL-TRAK CYLINDER, (See HYDRAULIC COMPONENTS
SECTION for Breakdown)
201
7300754
2
TC STOP BLOCK
202
8321701
4
HEX HD CAPSCREW, M20X150, GR8.8
251
7300503
1
PIN 252
8630026
2
RETAINING RING
301
3575924
1
FRAME COVER PLATE
302
8307220
4
WASHER, 12mm
303
8310625
4
HEX NUT, M12X1.75
304
10704216
4
HEX HD CAPSCREW, M12X110, GR8.8
351
1001094782
1
COUNTERWEIGHT, (944E)
352
8305655
4
HEX NUT, M20X2.5, (torque to 295-530 Nm/218-391 lb-ft), (944E)
353
8310426
8
WASHER, 20mm, (944E)
354
8321701
4
HEX HD CAPSCREW, M20X150, GR8.8, (944E)
401
Ref
ENGINE POD INSTALLATION, (See ENGINE POD INSTALLATION
FIGURE 1-3. MAIN FRAME COMPONENTS (644E SN 160048717 to Present, Including 0160045421;
944E SN 160041827 to Present)
8990462 644E-42,944E-42 19
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
for Breakdown )
SECTION 1 - FRAME AND ATTACHING PARTS
20 644E-42,944E-42 8990462
SECTION 1 - FRAME AND ATTACHING PARTS
FIGURE 1-4. ENGINE POD INSTALLATION (644E Prior to SN 0160048717, Excluding 0160045421;
944E Prior to SN 0160041827)
22 644E-42,944E-42 8990462
SECTION 1 - FRAME AND ATTACHING PARTS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1
7300609
1
HOOD ASSEMBLY
2 7300364
1
HOOD LATCH ASSEMBLY, (includes item 3)
3 8342813
1
HOOD LATCH KEY
4 8310664
4
SOCKET HD CAPSCREW, M4X25, GR12.9
5 8310491
4
PLAIN WASHER, 4mm
6 3290405
4
TORX HEX NUT, M4-0.7
7 8277172
1
TRIM SEAL
8 7300630
2
HOOD HINGE
9 8310614
8
FLANGE SOCKET HEX HD CAPSCREW, M10X30
10
8305038
8
HEX NUT, M10X1.5
11
8310621
8
FEND WASHER, 10-5/16-18mm, THD
12
8303784
8
HEX HD CAPSCREW, M10X20, GR8.8
13
7300687
1
GAS STRUT BRACKET
14
8702162
1
GAS STRUT SPRING, 10X22, 550N
15
8702163
1
LOCKING GAS STRUT SPRING, 10X22, 550N
16
8340038
4
BALL STUD, 10mm, 5/16-18
17
8702164
2
SPRING CLIP RETAINER
18
8303777
2
HEX HD CAPSCREW, M10X35, GR8.8
19
7301312
1
HOOD LATCH NUT PLATE
20
7301371
1
LATCH CATCH PLATE
21
7301373
1
LATCH CATCH PLATE, 7 GA SPACER
22
7301372
1
HOOD LATCH NUT PLATE
23
7300370
1
ENGINE MOUNT SKIRT
24
8310693
6
HEX FLANGE SCREW, M8X25, GR8.8
25
8307203
2
WASHER
26
8305654
2
HEX LOCKNUT, M8X1.25
FIGURE 1-4. ENGINE POD INSTALLATION (644E Prior to SN 0160048717, Excluding 0160045421;
944E Prior to SN 0160041827)
8990462 644E-42,944E-42 23
SECTION 1 - FRAME AND ATTACHING PARTS
FIGURE 1-5. ENGINE POD INSTALLATION (644E SN 1600408717 to Present, Including 0160045421;
944E SN 160041827 to Present)
24 644E-42,944E-42 8990462
SECTION 1 - FRAME AND ATTACHING PARTS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001112264
Ref
ENGINE POD INSTALLATION, (not available to order, see items 1
thru 11 for service)
C
1
0683020
4
HEX HD CAPSCREW, 1-1/4X2-1/2, GR8, (torque to 1213 to 2183
lb-ft/1645-2960 Nm)
2
8310539
4
WASHER, 1-1/4
3 1001112271
1
WELDMENT
4 0761010
15
HEX HD CAPSCREW, M10X20, GR8.8, (torque to 50 Nm/37 lb-ft)
5 4832000
15
LOCKWASHER, 10mm
6 90206196
7.5 in
TRIM 7
1001125456
1
COOLER COVER PLATE
8 1001125457
1
ENGINE COVER PLATE
9 1001125458
1
ENGINE POD COVER PLATE
10
1001125459
1
ENGINE POD COVER PLATE
11
1001125720
1
ENGINE POD COVER PLATE, (includes item 51)
B
51
1001125721
1
FOAM SEAL
1001125402
Ref
ENGINE POD COVER INSTALLATION, (not available to order, see
items 101 thru 104 for service)
A
101
8305654
2
HEX NUT, M8X1.25
102
8307203
12
WASHER, 5/16
103
8310693
10
HEX FLANGE SCREW, M8X25, GR8.8, (torque to 13-23 lb-ft/1831 Nm)
104
1001125401
1
ENGINE POD COVER ASSEMBLY
1001112381
Ref
HOOD INSTALLATION, (not available to order, see items 201 thru
213 for service)
C
201
7300687
1
GAS STRUT BRACKET
202
7301370
1
LATCH ASSEMBLY, (includes items 301 thru 307)
AB
203
7301526
AR
10 GAUGE SHIM
204
7301527
AR
16 GAUGE SHIM
205
8303784
8
HEX HD CAPSCREW, M10X20, GR8.8, (torque to 25-44 lb-ft/3460 Nm)
206
8310621
8
WASHER, 10mm
207
8340038
2
BALL STUD, 10mm, (torque to 12-21 lb-ft)
208
8702164
4
SPRING RETAINER CLIP
209
1001112382
1
HOOD ASSEMBLY, (includes items 401 thru 414)
D
210
8702162
2
GAS SPRING
213
1001125463
1
FOAM SEAL
301
7301312
1
HOOD LATCH PLATE
302
7301371
1
LATCH CATCH PLATE
303
7301372
AR
HOOD LATCH PLATE
304
7301373
AR
LATCH CATCH PLATE, 7 GA SPACER
305
7301526
AR
20 GAUGE SHIM
306
7301527
AR
16 GAUGE SHIM
307
8303777
2
HEX HD CAPSCREW, M10X35, GR8.8, (torque to 34-61 Nm/25-45
Nm) 401
3290405
4
HEX LOCKNUT, M4X0.7
402
7300364
1
HOOD LATCH ASSEMBLY
402
8342813
1
HOOD LATCH KEY
403
7300634
1
REAR HINGE BRACKET
404
7300645
1
GAS SPRING BRACKET
405
7300943
1
FRONT HINGE BRACKET
FIGURE 1-5. ENGINE POD INSTALLATION (644E SN 1600408717 to Present, Including 0160045421;
944E SN 160041827 to Present)
8990462 644E-42,944E-42 25
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
406
8277172
1
SEAL 407
8305038
8
HEX NUT, M10X1.5
408
8310491
4
WASHER, 4mm
409
8310614
8
FLANGE SOCKET HEX HD CAPSCREW, M10X30
410
8310664
4
SOCKET HD CAPSCREW, M4X25, GR12.9, (torque to 2-4 lb-ft/3-5
Nm) 411
8340038
2
BALL STUD, 10mm
412
1001112383
1
HOOD ASSEMBLY, (includes items 501 thru 506)
D
413
7300630
2
REAR HINGE
414
1001131991
56.3 in
BULB SEAL
501
1001125299
1
SIDE MESH
502
1001125301
1
REAR MESH
504
1001112384
1
BASE MOLD HOOD
505
1001112386
1
TOP MESH
506
1001112387
1
SIDE MESH
SECTION 1 - FRAME AND ATTACHING PARTS
26 644E-42,944E-42 8990462
SECTION 1 - FRAME AND ATTACHING PARTS
FIGURE 1-6. FENDER ASSEMBLY
28 644E-42,944E-42 8990462
SECTION 1 - FRAME AND ATTACHING PARTS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
7301311
Ref
FENDER INSTALLATION, (644E), (944E, if equipped), (not
available to order, see items 1 thru 5 for service)
AB
1001109604
Ref
FENDER INSTALLATION, (944E, if equipped with Solid Tire
1001105703, 1001105703 & 01151109), (not available to order, see
items 1 thru 7 for service) (SN 160037902 to Present)
A
1
7150695
2
LEFT FRONT/RIGHT REAR FENDER ASSEMBLY, (includes
items 101 thru 107)
G 2 7150696
2
RIGHT FRONT/LEFT REAR FENDER ASSEMBLY, (includes
items 101 thru 107)
G
3
8310164
16
HEX HD CAPSCREW, M12X40, GR8.8
3
0701221
16
HEX HD CAPSCREW, M12X65, GR8.8, (944E, if equipped with
Solid Tire 1001105703), (torque to 43-78 lb-ft/58-106 Nm) (SN
160037902 to Present)
4
8310308
16
WASHER, 1/2
5 8307025
16
LOCKWASHER, 12mm
5
4832100
16
SPRING LOCKWASHER, 12 mm, (944E, if equipped with Solid
Tire 1001105703) (SN 160037902 to Present)
6
8526007
AR
LOCTITE 242, (apply to item 3)
7
1001109573
8
SHIM, (944E, if equipped with Solid Tire 1001105703) (SN
160037902 to Present)
101
7150668
1
FENDER MOUNT (SN 17569 through 20123, SN 0160002514
through 0160025339)
101
0903609
1
FENDER MOUNT (SN 0160025381 to Present)
102
7150706
1
FENDER
103
8303626
4
HEX HD CAPSCREW, 1/2-13X1-1/2, GR5
104
8305644
6
HEX LOCKNUT, 1/2-13 (SN 17569 through 20123, SN
0160002514 through 0160025339)
104
8305644
4
HEX LOCKNUT, 1/2-13 (SN 0160025381 to Present)
105
8307206
12
PLAIN WIDE WASHER, 1/2 (SN 17569 through 20123, SN
0160002514 through 0160025339)
105
8307206
8
PLAIN WIDE WASHER, 1/2 (SN 0160025381 to Present)
106
6623576
1
FENDER SUPPORT (SN 17569 through 20123, SN 0160002514
through 0160025339)
107
8303625
2
HEX HD CAPSCREW, 1-1/2-13X1-1/2, GR5 (SN 17569 through
20123, SN 0160002514 through 0160025339)
FIGURE 1-6. FENDER ASSEMBLY
8990462 644E-42,944E-42 29
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