ENGINE AND ENGINE SYSTEMS 5540F/YB5515 SERVICE MANUAL
6-8 Published 10-21-2010, Control# 198-04
Installation
1. Attach a hoist to the engine the same way removal was
accomplished.
2. Lift the engine into place over the chassis. Tilt the engine
at about a 30° angle to insert the engine into the chassis.
Lower the engine into the chassis and set the
transmission on a trolley jack. Remove the sling and pull
jack.
3. Move the engine and transmission into the chassis until
the rear mounting bolts, washers, rubber mounts and
nuts can be installed and tightened.
4. Install the rear axle.
a. Locate the rear axle under its mounting location.
Raise the axle and mounting bracket into position
and install the eight mounting bolts and flat
washers.
b. Install the front engine mounting hardware.
c. Connect the brake lines to the axle.
d. Connect the hydraulic hoses to the steering
cylinders.
5. Connect the suction hose to the hydraulic tank and the
hydraulic pump suction manifold.
6. Connect the hydraulic hoses to the four sections of the
hydraulic pump.
7. Fill the hydraulic tank.
8. Connect the engine ground cable to the engine.
9. If equipped, install the cold start kit.
10. Connect the throttle linkage to the engine.
11. Connect the exhaust pipe to the engine manifold. If a
gasket is used, install a new gasket.
12. Connect the drive shaft(s) to the engine. See Axles/
Drive Shafts/Wheels and Tires, Section 8.
13. Connect the fuel lines to the fuel tank.
NOTE: The diesel fuel supply fuel line must be bled of air
before engine can be started. Refer to the engine
operator’s manual furnished with this crane, for
bleeding procedure.
14. Install the air cleaner and intake hose.
15. Install the radiator in place on the chassis.
16. Connect the transmission cooling lines to the radiator.
Connect the upper and lower radiator hoses.
17. Connect the hot water heater hoses to the engine.
18. Fill the radiator with recommended coolant.
19. Connect the transmission wire harness to the instrument
panel wire harness.
20. Connect the transmission high temperature switch lead
to the switch.
21. Connect the engine wire harness to the frame wire
harness.
22. Install the engine cover and rear cover plate.
23. Connect the battery cables to the battery.
24. Check complete installation to be sure all components
are installed and secure.
25. Fill the engine and transmission with recommended oil.
26. Start the engine. Continue to add transmission fluid until
transmission cooling lines are full. Add fluid as needed
to fill the cooling system.
27. Adjust the throttle control, if necessary.
28. Steer the rear wheels in both directions several times to
remove air from the steering circuit.
29. Bleed air from brake lines. Refer to Section 9.
30. Stop the engine and check for leaks. Tighten fittings if
necessary.
DUAL FUEL ENGINE AND ENGINE
SYSTEMS
General
These instructions are written for worldwide use. In territories
where legal requirements govern engine smoke emissions,
noise, safety factors, etc., then all instructions, data and
dimensions given must be applied in such a way that, after
maintaining or repairing the engine, it does not contravene
regulations when in use.
NOTE: These instructions cover only the routine
maintenance of the engine. Refer to the engine
manual furnished with the crane for engine
diagnosis, repair and component replacement.
Engine Types
Both the two wheel drive and four wheel drive machines use
a GM 4.3L dual fuel engine.
Engine Performance
Engine performance is very important to the operation of the
crane, The engine is the drive for the hydraulic pump, which
supplies power to operate the work functions of the crane.
For maximum power the engine must be kept in good
working condition.
Reference Only
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