Published 4-20-2015, Control # 502-01 2-5
RT540E SERVICE MANUAL HYDRAULIC SYSTEM
MAINTENANCE
Hydraulic Oil Recommendations.
For the hydraulic oil specifications, refer to Section 9 -
LUBRICATION.
Draining and Flushing
If a component has been changed because of a failure that
might allow metal or abrasive particles to enter the system,
all systems must be thoroughly checked, drained, and
flushed.
1. Remove the reservoir drain plug. Allow about three
minutes after hydraulic oil stops flowing from the drain
port for the side walls to drain.
2. Clean and install the reservoir plug and fill the reservoir
with a 50/50 mixture of fuel oil and clean hydraulic oil.
3. Cycle the crane through all functions several times.
Then return the crane to its stowed position and turn the
front and rear wheels to the extreme left. Shut down the
engine.
4. Remove the reservoir drain plug and drain the reservoir.
Clean and install the drain plug and fill the reservoir with
clean hydraulic oil.
NOTE: Draining the various components will be aided by
connecting a drain line in place of the disconnected
return line.
5. Disconnect the return line from the lift cylinder and raise
the boom to maximum elevation.
6. Connect the cylinder return line and lower the boom to
its stowed position. Replenish the reservoir hydraulic oil
level as required.
7. Disconnect the return line from an outrigger extension
cylinder and fully extend the outrigger.
8. Connect the outrigger return line and retract the
outrigger. Replenish the reservoir hydraulic oil level as
necessary.
9. Repeat Steps 7 and 8 for the remaining outriggers.
10. Disconnect the return lines from a pair of outrigger jack
cylinders and activate the cylinders to their maximum
down positions.
11. Connect the return lines and raise the outrigger jack
cylinders to the stowed position. Replenish the reservoir
hydraulic oil level as necessary.
12. Repeat Steps 10 and 11 for the remaining two outrigger
cylinders.
13. Disconnect the return line from the telescope cylinder
and fully extend the boom.
14. Connect the return line and retract the boom. Replenish
the reservoir hydraulic oil level as necessary.
15. Disconnect the return lines from both front steer
cylinders and turn the front wheels to the extreme right.
16. Connect the return lines and turn the front wheels to the
extreme left and then back to center. Replenish the
reservoir hydraulic oil level as necessary.
17. Repeat Steps 15 and 16 for the rear steering cylinders.
18. Raise the crane on outriggers.
19. Disconnect the line from port A of the axle lockout valve.
20. Using a jack under the rear wheel on one side of the
crane, jack up the wheel to maximum travel.
21. Connect the line to port A of the axle lockout valve and
disconnect the line from Port B.
22. Repeat step 19 using the other rear wheel.
23. Connect the line to port B of the axle lockout valve.
Energize the axle lockout valve. Replenish the reservoir
hydraulic oil level as necessary.
24. Disconnect the return line from the main hoist motor and
fully hoist up the hoist.
25. Connect the return line to the main hoist motor and fully
hoist down the hoist, then hoist up again. Replenish the
reservoir hydraulic oil level as necessary.
26. Repeat Steps 24 and 25 for the auxiliary hoist as
necessary.
27. Disconnect one of the lines from the swing motor and
drive the motor in the direction it will go.
28. Connect the line to the swing motor, then drive the swing
motor in the opposite direction until the boom is centered
and forward. Replenish the reservoir hydraulic oil level
as necessary.
CAUTION
Hydraulic oil supply lines must be connected to the
cylinders when flushing the system.
CAUTION
When draining the outrigger cylinders, always operate
either both front or both rear cylinders together to prevent
twisting the crane.
CAUTION
When hydraulic oils are changed or added, ensure that
hydraulic oils of different manufacturers are of the same
specifications. Discoloration may occur.
Reference Only
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