Published 4-20-2015, Control # 502-01 7-23
RT540E SERVICE MANUAL POWER TRAIN
Troubleshooting Procedures
Removal
1. Extend and set the outriggers just enough to take up the
slack in the outrigger pads. Chock the wheels.
2. Position the boom over the side and stop the engine.
3. Remove the engine and transmission/torque converter
from the crane as an assembly. Refer to Engine, page 7-
1 in this Section.
4. Remove the hydraulic pumps from the transmission/
torque converter. Cover all openings. Refer to Hydraulic
Pumps, page 2-14 for removal of the pump.
NOTE: The transmission/torque converter weighs
approximately 374 kg (824.5 lb) dry.
5. Attach an adequate lifting device to the transmission/
torque converter and take up any slack.
6. Remove the hardware securing the drive plate assembly
to the flywheel.
7. Remove the hardware securing the transmission/torque
converter housing to the engine flywheel housing.
Installation
NOTE: The transmission/torque converter assembly
weighs approximately 374 kg (824.5 lb) dry.
1. If a new transmission/torque converter is to be installed,
remove all fittings and brackets from the old one and
install them in the same locations on the new
transmission/torque converter.
2. Install the piston and single section hydraulic pumps on
the transmission/torque converter. Refer to Hydraulic
Pumps, page 2-14 for installation of the hydraulic pump.
3. Position the transmission/torque converter to the engine
with the lifting device.
4. Remove all burrs from the flywheel mounting face and
nose pilot bore. Clean the drive plate surface with
solvent (Figure 7-11).
SYMPTOM PROBABLE CAUSE REMEDY
1. Low clutch pressure. a. Low oil level. a. Fill to proper level. Refer to
LUBRICATION (pg 9-1).
b. Clutch pressure regulating
valve spool stuck open.
b. Clean valve spool and housing.
c. Faulty charging pump. c. Replace pump.
d. Broken or worn clutch shaft or
piston sealing rings.
d. Replace clutch shaft or sealing
rings, as applicable.
e. Clutch piston bleed valve stuck
open.
e. Clean bleed valves thoroughly.
2. Low converter charging pump
pressure.
a. Low oil level. a. Fill to proper level.
b. Suction screen plugged. b. Clean suction screen.
c. Defective oil pump. c. Replace pump.
3. Overheating. a. Worn oil sealing rings. a. Remove, disassemble, and
rebuild converter assembly.
b. Worn oil pump. b. Replace pump.
c. Low oil level. c. Fill to proper level.
4. Noisy converter. a. Worn oil pump. a. Replace pump.
b. Worn or damaged bearings. b. A complete disassembly will be
necessary to determine what
bearing is faulty.
5. Lack of power. a. Low engine RPM at converter
stall.
a. Tune engine and check
governor.
b. See “Overheating” and make
same checks.
b. Make corrections as explained
in “Overheating.”
Reference Only
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