Published 4-20-2015, Control # 502-01 2-15
RT540E SERVICE MANUAL HYDRAULIC SYSTEM
No. 2 Pump Installation
1. Install new gasket material to the pump mounting flange.
2. Install pump on to left front of engine with capscrews and
washers. Make sure gear teeth mesh properly. Torque
capscrews to 85 to 93 Nm (63 to 69 lb-ft).
3. Connect the distribution and supply lines as tagged
during removal.
No. 3 Pump Removal
1. For ease of removal, gain access to the pump by
removing the engine hood.
2. Tag and disconnect the supply line from the pump. Cap
or plug the line and port.
3. Tag and disconnect the pump distribution line(s) from
the pump. Cap or plug the line(s) and port.
4. Remove the capscrews and washers attaching the No. 3
pump to the No. 1 pump. Remove the pump.
5. Remove the gasket material from the drive pad on the
No. 1 pump.
6. Cover the drive pad’s opening to prevent dirt from
entering.
No. 3 Pump Installation
1. Clean and prime the mounting surfaces with Loctite
7649 primer.
2. Apply Loctite 518 sealant to the pump mounting flange.
3. Install pump on to pump No. 1 with capscrews and
washers. Make sure gear teeth mesh properly. Torque
capscrews to spec listed in Fasteners and Torque
Values, page 1-11.
4. Connect the distribution and supply lines as tagged
during removal.
Testing After Rebuild or Replacement
1. Operate the pump for at least two minutes at zero
pressure and moderate speed (not over 1500 rpm).
2. Touch pump to verify it has not become hot from binding.
Listen for abnormal noises indicating low hydraulic oil
level or internal pump problems. If the pump appears to
be operating satisfactorily, increase the rpm by steps,
until reaching governed rpm. Operate pump about five
minutes while checking for proper operation and
leakage. Fix leaks; make repairs as needed.
3. Cycle the components the pump powers to verify the
pump drives them all properly.
Hydraulic Gear Pump Start-up Procedure
1. Ensure the reservoir is filled with the proper hydraulic
fluid to the high level mark on the reservoir sight gauge.
2. Ensure no air is entering the pump inlet, and that the
pump suction or inlet fluid is not bleeding back to the
reservoir when the engine is stopped, by making sure all
suction or inlet lines are air tight.
NOTE: The following step can be done before the pump is
installed by removing the plastic cap from “T1” port,
and checking to ensure “T2” port on the opposite
side of the pump is plugged. Fill housing full of
hydraulic oil through “T1” port. Re-install the plastic
cap and then install the pump.
3. Remove adapter and hose from “T1” port, and check to
ensure “T2” port on the opposite side of the pump is
plugged. Fill housing full of hydraulic oil through “T1”
port. Re-install the adapter and hose into the “T1” port.
4. Start the engine.
a. Idle engine for two to three minutes with no
functions actuated. Check for leaks and repair if
required. Lay hand on pump to check for excessive
heat build-up. If the pump section is too hot to touch,
stop immediately. If the pump makes excessive
noise, air is probably entering the pump keeping it
CAUTION
Do not feed hot hydraulic oil into a cold pump. This may
cause the pump to seize.
CAUTION
Absolute cleanliness is essential when working on the
hydraulic pumps. Always work in a clean area. The
presence of dirt and foreign materials in the system can
result in serious damage or inadequate operation.
CAUTION
When removing the pump, keep the pump as level as
possible to avoid damaging the input spline.
CAUTION
Do not feed hot hydraulic oil into a cold pump. This may
cause the pump to seize.
CAUTION
If the pump becomes hot to the touch, it is binding and
may seize. Stop engine, disassemble pump, and repair it
so it will not bind.
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