POWER TRAIN RT540E SERVICE MANUAL
7-2 Published 4-20-2015, Control # 502-01
Maintenance
Engine Removal
1. Set the outriggers and position the boom to over the
side.
2. Open and remove the hood door assembly.
3. Disconnect the air filter tubing at the engine and air
cleaner. Remove and lay aside.
4. Disconnect the exhaust tubing at the engine and muffler.
Lay to the side.
5. Tag and disconnect the engine electrical harness
connector from the carrier harness connector and
battery cables.
6. Remove the start and grid heater relay panel and place
to the side of the frame. Lay the relay panel with the
harness on the engine. If a remote crank option is
present, disconnect the remote crank harness connector
from the engine harness and tie up excess harness so it
is out of the way.
7. Drain the engine coolant system.
8. Drain the engine lubrication system.
9. Drain the transmission/torque converter oil system.
10. Evacuate A/C system and capture refrigerant.
11. Remove the engine hood assembly and pump cover
from the machine.
12. Disconnect and remove the drive shaft(s) between the
transmission/torque converter and the axle(s). Refer to
DRIVE LINES in this Section.
13. Tag and disconnect all lines from the radiator.
Disconnect the coolant level sensor harness from the
engine harness and tie up excess harness so it is out of
the way. Remove the radiator. Refer to Radiator
Removal and Installation (pg 7-19) l in this Section.
14. Tag and disconnect all lines and tubing from the engine,
transmission/torque converter, and all other
components.
NOTE: The engine and transmission/torque converter
assembly weighs approximately 1200 kg (2646
pounds).
15. Attach to the engine a lifting device capable of
supporting the weight of the engine and transmission/
torque converter.
16. With the lifting device supporting the weight of the
engine, remove the capscrews, washers and locknuts
securing the front of the engine to the frame.
17. Remove the capscrews, washers, nuts, insulator and
mounting plate securing the rear of the engine to the
frame.
18. Using the lifting device, lift the engine and transmission/
torque converter as an assembly from the crane.
19. If a new engine is to be installed, remove all
components, fittings, etc., from the old engine and install
them on the new engine in the same locations.
NOTE: Ensure that the same grade hardware, torque
values, and Loctite as were installed by the factory
are used.
DANGER
The lifting device must be able to support the combined
weight of the engine and transmission.
Reference Only
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