Published 4-20-2015, Control # 502-01 7-25
RT540E SERVICE MANUAL POWER TRAIN
5. Check the engine flywheel and housing for conformance
to standard S.A.E. No. 3-S.A.E. J-927 tolerance
specifications for bore size, pilot bore runout and
mounting face flatness. Measure and record engine
crankshaft end play.
6. Install two 63.5 mm (2.50 in) long transmission to
flywheel housing guide studs in the engine flywheel
housing as shown in the figure titled Transmission/
Torgue Converter Installation. Rotate the engine
flywheel to align a drive plate mounting screw hole with
the flywheel housing front access hole.
7. Install a 101.6 mm (4.00 in) long drive plate locating stud
0.3750-24 fine thread in a drive plate nut.
8. Rotate the transmission/torque converter to align the
locating stud in the drive plate with the flywheel drive
plate mounting screw hole positioned in step 6. Locate
the transmission on the flywheel housing, aligning the
drive plate to the flywheel and the transmission to the
flywheel housing guide studs. Install the transmission to
flywheel housing nuts and washers. Tighten the bolts to
41 to 43 Nm (30 to 32 lb-ft). Remove the transmission to
engine guide studs. Install the two remaining bolts and
washers and tighten the bolts to 41 to 43 Nm (30 to 32
lb-ft).
9. Remove the drive plate locating stud. Install one drive
plate attaching screw and lockwasher. Snug the screw
but do not tighten. NOTE: Some engine flywheel
housings have a hole located on the flywheel housing
circumference in line with the drive plate screw access
hole. A screwdriver or pry bar used to hold the drive
plate against the flywheel will facilitate installation of the
drive plate screws. Rotate the engine flywheel and install
the remaining seven flywheel to drive plate attaching
screws and lockwashers. Snug the screws but do not
tighten. After all eight screws and lockwashers have
been installed, torque the screws to 38 to 41 Nm (28 to
30 lb-ft). This will require torquing each screw, then
rotating the engine flywheel until all eight screws have
been torqued.
10. Measure the engine crankshaft end play after the
transmission/torque converter has been completely
installed on the engine flywheel. This value must be
within 0.025 mm (0.001 in) of the end play recorded in
step 5.
11. Install the engine and transmission/torque converter in
the crane as an assembly. Refer to Engine Installation,
page 7-5.
12. Service the crane as required in Servicing the Crane
After Transmission/Torque Converter Overhaul (pg 7-
25) in this section.
13. Cycle all functions and observe for proper operation.
Servicing the Crane After Transmission/
Torque Converter Overhaul
The transmission/torque converter and its allied hydraulic
system are important links in the drive line between the
engine and the wheels. The proper operation of either the
unit or the system depends greatly on the condition and
operation of the other; therefore, whenever repair or
overhaul of the transmission/torque converter is performed,
the balance of the system must be considered before the job
can be considered completed.
After the overhauled or repaired transmission/torque
converter has been installed in the crane, the oil cooler and
connecting hydraulic system must be thoroughly cleaned.
This can be accomplished in several ways, and a degree of
good judgement must be exercised as to the method
employed.
The following are considered the minimum steps to be taken:
1. Drain the entire system thoroughly.
2. Disconnect and clean all hydraulic lines. Where feasible,
hydraulic lines should be removed from the machine for
cleaning.
3. Replace oil filter elements, cleaning out the filter cases
thoroughly.
4. The oil cooler must be thoroughly cleaned. The cooler
should be back flushed with oil and compressed air until
all foreign material has been removed. Flushing in the
direction of normal oil flow will not adequately clean the
cooler. If necessary, the cooler assembly should be
removed for cleaning, using oil, compressed air and a
steam cleaner for that purpose.
5. Remove the drain plug from the transmission/torque
converter and inspect the interior of the unit housing,
gears, etc. If the presence of considerable foreign
material is noted, it will be necessary for the unit to be
removed, disassembled, and cleaned thoroughly. It is
realized this entails extra labor, however, such labor is a
minor cost compared to the cost of difficulties which can
result from the presence of such foreign material in the
system.
6. Assemble all components and use only the type oil
recommended. Fill the transmission through the fill pipe
until fluid is at the top of the fill range on the dipstick. Run
the engine for two minutes at idle (950 rpm) to prime the
torque converter and hydraulic lines. Recheck the level
of oil in the transmission with the engine running at idle
(950 rpm). Add oil as necessary to bring the level to the
LOW mark on the dipstick. After the oil temperature
CAUTION
Do not use flushing compounds for cleaning purposes.
Reference Only
To Next Page
Loading...
Need help?
General
