Gehl RS5-34 Service Manual Download Page 3 | Manualshive

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913241

Table of Contents

GENERAL

SECTION

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

ENGINE

Engine Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

ELECTRICAL

Electrical Schematic, Troubleshooting, Testing and Adjustment Procedures . . . . . . . . .301
Battery Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302

STEERING

Steering Control Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

POWER TRAIN

Transmission Removal and Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
Rear Axle Removal and Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .502
Front Axle Removal and Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .503

HYDRAULIC SYSTEM

Hydraulic Schematic, Troubleshooting, Testing and Adjustment Procedures . . . . . . . . .601
Hydraulic Pump Removal and Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602
Frame Leveling Cylinder Removal and Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . .603
Tilt Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .604
Hydraulic Cylinder Repair  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .605
Slave Cylinder Removal and Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .606
Lift Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .607
Boom Extend Cylinder Removal and Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .608

TELESCOPING BOOM

Boom Assembly Removal and Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .701
Single and Double Leaf Chain Adjustment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .702
Inner Boom Section Removal and Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .703
Telescoping Boom Double Chain and Roller Bearing Replacement  . . . . . . . . . . . . . . .704
Telescoping Boom Single Chain and Roller Bearing Replacement  . . . . . . . . . . . . . . . .705
Intermediate Boom Section Removal and Installation  . . . . . . . . . . . . . . . . . . . . . . . . . .706

CHASSIS

Hood and Cover Removal and Installation . . . . . . . . . . . . . . . . . . .See Section 201 or 501

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View thousands of Crane Specifications on FreeCraneSpecs.com

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Summary of Contents for RS5-34

Page 1: ...RS5 34 RS6 34 Telescopic Handler SERVICE MANUAL Form No 913241 View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs com...

Page 2: ...er The Table of Contents can be used to make the procedure you need to find an easier process Many pho tographs schematics and line art drawings are used to help perform the necessary repairs tests or...

Page 3: ...ion 602 Frame Leveling Cylinder Removal and Installation 603 Tilt Cylinder Removal and Installation 604 Hydraulic Cylinder Repair 605 Slave Cylinder Removal and Installation 606 Lift Cylinder Removal...

Page 4: ...View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs com...

Page 5: ...TED IN U S A 913241 PERSONAL SAFETY INFORMATION AND DECAL LOCATIONS RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on Fre...

Page 6: ...EMINDERS 2 MODIFICATIONS NAMEPLATES MARKINGS AND LOAD CAPACITIES 4 ROLL OVER PROTECTIVE STRUCTURE ROPS 4 PROTECT THE ENVIRONMENT 4 DECAL LOCATIONS 5 GENERAL INFORMATION 5 NEW DECAL APPLICATION 5 DECAL...

Page 7: ...ead and strictly followed Gehl Company cannot anticipate every situation that may constitute a hazard Therefore the following safety rules and reminders are not all inclusive and do not replace federa...

Page 8: ...unauthorized parts or substitute materials Use only Gehl Company approved parts Consult Gehl Company on changes additions or modifications that may be required for this machine to comply with various...

Page 9: ...eld when searching for hydraulic leaks grinding striking metal against metal or when working near batteries NEVER use your hands to search for hydraulic fluid leaks Use a piece of paper or cardboard E...

Page 10: ...placed at specific outward and upward distances ALWAYS be aware of load weights prior to attempting lift and placement with the machine ROLL OVER PROTECTIVE STRUCTURE ROPS Do not modify the ROPS in an...

Page 11: ...terial To apply a solid formed decal remove the smaller portion of the decal backing paper and apply this part of the exposed adhesive backing to the clean surface while maintaining proper position an...

Page 12: ...27 L65933 102027 L65937 06 07 08 09 GEHL 6 75 ANTI FREEZE HALF ZONE MARKER 5 EA NO 0 EXTENSION MARKER 1 EA NO 1 EXTENSION MARKER 1 EA 184069 056859 L62583 L67718 L67719 10 NO 2 EXTENSION MARKER 1 EA N...

Page 13: ...BOOM NOSE DECAL LOCATIONS FRAME AND BOOM REF NO DESCRIPTION RS8 44 PART NO 01 02 03 04 05 DANGER HANDS OUT WARNING PINCH POINT GEHL 6 75 HYDRAULIC OIL FILL WARNING NO RIDERS L70305 L65927 184069 13763...

Page 14: ...EVEL WARNING CARRY LOAD LOW F N R SHIFT MADE IN USA WARNING PARK BRAKE SEAT BELT L70306 L65930 L65926 L68295 140516 101506 07 08 STANDARD CARRIAGE LOAD CHART ROTATING CARRIAGE LOAD CHART BUCKET LOAD C...

Page 15: ...DECALS G 00015 1 2 1 4 3 1 913227 6PWP DECAL LOCATIONS PWP EQUIPPED UNITS REF NO DESCRIPTION RS8 44 PART NO 01 02 03 04 05 06 WARNING PERSONNEL LIFT WARNING WORK PLATFORM RULES PERSONNEL LIFT SAFETY R...

Page 16: ...View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs com...

Page 17: ...PRINTED IN U S A 913241 GENERAL INFORMATION AND SPECIFICATIONS RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCra...

Page 18: ...STENER ISO TORQUE CHART 1 STANDARD TORQUE DATA FOR HYDRAULIC TUBES AND FITTINGS 2 INDICATOR AND OPERATION SYMBOLS 3 FLUID CAPACITIES AND TYPES 4 GENERAL SPECIFICATIONS 5 GENERAL DIMENSIONS 8 RS5 34 LO...

Page 19: ...2720 3227 3688 1 1 2 1940 2200 2631 2983 3160 3560 4285 4827 NOTE 1 Bolt head identification marks as per grade Manufacturing marks will vary Thick nuts must be used with Grade 8 bolts NOTE Use these...

Page 20: ...FOR 37 FLARED FITTINGS O RING BOSS PLUGS ADJUSTABLE FITTING LOCK NUTS SWIVEL JIC 37 SEATS SIZE TUBING O D THREAD SIZE LB FT Nm LB FT Nm Inches mm Min Max Min Max Min Max Min Max 4 1 4 6 4 7 16 20 9 12...

Page 21: ...hide template information Alt to display template information Template Name OML_1_col 907871 Template Date 1994_04_22 Indicator and Operation Symbols View thousands of Crane Specifications on FreeCran...

Page 22: ...7 2 qts 16 3 L Coolant Type 50 50 mixture of Ethylene Glycol and Water Axle Each Differentials 9 6 qts 9 0 L Planetary Hubs each 0 6 qts 0 5 L Oil Type MobilFluid 422 423 or 80W90 Oil Meeting API GL 5...

Page 23: ...lanetaries Ratio overall 15 4 1 Engine Standard Make John Deere Model 4045T Type Diesel In line 4 Cyl Displacement 276 cu in 4 5 L Aspiration Turbo Charged High Idle Speed no load 2600 RPM Rated Speed...

Page 24: ...ow 25 PSI 172 kPa Hydraulic Strainer Location In Tank Suction Line Type 100 Mesh Replaceable Element Rated Flow 50 GPM 189 L min By Pass Pressure 3 PSI 21 kPa STEERING SYSTEM Type Fixed Displacement H...

Page 25: ...Backup Alarm 107 dB A Horn 111 dB A Neutral Start Switch Standard Headlights Optional Brake Tail Lights Standard LIFTING PERFORMANCE Maximum Lift Capacity 6000 lbs 2721 kg Maximum Lift Height 34 3 10...

Page 26: ...tires 48 1 2 m masonry carriage and 48 1 2 m pallet forks Recommended Tire Type 15 00 x 19 5 12 ply 405 70 R20 x M27 Traction Type Overall Length Less Forks 16 0 4 88 m Overall Width 7 10 2 39 m Overa...

Page 27: ...1 Template Date 1994_04_22 RS5 34 Telescopic Handler GENERAL RS5 34 Load Zone Charts Decal 101570 Standard Carriage Decal 101572 1 3 Cu Yd Bucket Decal 101666 Rotating Carriage Decal 101574 8 Ft Truss...

Page 28: ...formation Alt to display template information Template Name OML_1_col 907871 Template Date 1994_04_22 RS5 34 Load Zone Charts Decal 101573 Winch Boom Decal 103334 PWP View thousands of Crane Specifica...

Page 29: ...201 PRINTED IN U S A 913241 ENGINE REMOVAL AND INSTALLATION RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSp...

Page 30: ...lay template information SECTION TABLE OF CONTENTS GENERAL INFORMATION 1 ENGINE REMOVAL 1 MANDATORY SAFETY SHUTDOWN PROCEDURE 1 RELIEVE HYDRAULIC OIL PRESSURE 1 ENGINE INSTALLATION 12 View thousands o...

Page 31: ...ure to follow the above procedure could lead to death or serious injury RELIEVE HYDRAULIC OIL PRESSURE 1 Engage the park brake 2 Lower equipment to the ground Return the engine to idle for 30 seconds...

Page 32: ...s cover 2 STEP 5 G0905082 Loosen the four thumbscrews 1 and remove the radiator grille 2 STEP 6 G0905080 Loosen the two thumbscrews 1 and remove the radiator cover 2 STEP 7 G0905083 G0905081 Remove th...

Page 33: ...TE Attaching a hose to the drain valves will help direct the coolant to the container STEP 11 After all the coolant has drained close both drain valves Recycle or dispose of coolant in an environmenta...

Page 34: ...uel return line STEP 16 G0905146 Remove the fuel supply line from the fuel pump Install a cap on the fuel pump and a plug in the line STEP 17 G0905147 Label and remove the wires from the starter relay...

Page 35: ...e engine NOTE There is coolant trapped in the hoses and engine that will drain when the hoses are removed STEP 21 G1158MP If equipped remove the hose adapter from the water pump STEP 22 G0905148 Loose...

Page 36: ...G0905151 Loosen the four fan mounting bolts Do not remove the bolts at this time STEP 26 G1005008 Use a 1 2 ratchet on the tensioner pulley to rotate the tensioner pulley counterclockwise to release t...

Page 37: ...1 and the right radiator panel 2 STEP 29 G0905158 Remove the four fan bearing mounting bolts 1 and the fan bearing assembly 2 STEP 30 G0905159 Remove the six mounting bolts 1 and the fan shroud 2 STEP...

Page 38: ...between the top mounting bracket and alternator for installation STEP 34 G0905164 Remove the three bolts 1 and the alternator left side mounting bracket 2 STEP 35 G0905166 Remove the band clamp from...

Page 39: ...e in the bottom of the housing bell and into the ring gear STEP 39 G0705030 Rotate the flywheel until one of the flexplate bolts is in the 6 o clock position STEP 40 G0705024 Remove the flywheel to fl...

Page 40: ...ct 2 from the turbocharger and air cleaner assembly STEP 44 G0905175 Cap or plug the turbocharger inlet STEP 45 G1005011 Loosen the two bolts 1 and remove the air cleaner assembly 2 STEP 46 G0905178 R...

Page 41: ...throttle cable mounting bracket 2 STEP 49 G0605124 G0705035 Remove the center bolt from the front two engine mounts STEP 50 G0905181 Move the engine rearward until the flexplate 1 is clear of the hous...

Page 42: ...lifting brackets or rings and a hoist STEP 54 G0905183 G0905182 Lift the engine high enough for the oil pan to clear the frame rail Move the engine over the engine compartment and lower until the hou...

Page 43: ...d the upper housing bell bolts 2 Do not tighten at this time STEP 57 G0605124 Install the center bolts lock washers and lock nuts in the two front engine mounts Do not tighten the nuts at this time ST...

Page 44: ...he muffler bracket 1 to the right side of the engine using the two bolts 2 STEP 61 G0905179 G0905168 Remove the lifting bracket or ring from the head Remove the lifting device and the hoist G0705071 N...

Page 45: ...heel to flexplate bolt Repeat Steps 61 and 62 until all eight bolts are installed STEP 64 Torque the flywheel to flexplate bolts to 35 to 40 lb ft 48 to 54 Nm STEP 65 G0705023 Install the rubber acces...

Page 46: ...left side mounting bracket 1 using the three bolts 2 and nuts STEP 70 G1005003 Position the alternator in place Install the lower mounting bolt and nut STEP 71 G1005004 Install the top mounting bolt...

Page 47: ...05159 Install the fan shroud 1 using the six bolts 2 Torque the bolts to 12 to 14 lb ft 16 18 Nm STEP 76 G1005005 Place the fan inside the fan shroud STEP 77 G1005006 Install the fan bearing assembly...

Page 48: ...433MA Route the serpentine belt 1 around the pulleys as shown Use a 1 2 drive ratchet on the tensioner pulley 2 to rotate the tensioner counterclockwise and install the belt over the pulley STEP 80 G0...

Page 49: ...905150 Install the right side fan guard 1 using the four bolts 2 STEP 82 G1005009 G1005010 Install the right radiator panel 1 using the three bolts 2 STEP 83 G0905148 Install the upper radiator hose 1...

Page 50: ...supply 1 and return 2 hoses on the engine Tighten the hose clamps STEP 86 G0605144 Loosen the terminal screw and insert the starter relay wire from the solenoid Tighten the screw STEP 87 G0905170 Ins...

Page 51: ...hrottle cable onto the throttle cable mount bracket STEP 92 G0905139 Install the throttle linkage 1 and the fuel shut off solenoid wire 2 on the fuel injector pump STEP 93 G0905138 Reconnect the wire...

Page 52: ...formation STEP 96 G0905174 G0905172 Install the air inlet duct 1 between the turbocharger and the air cleaner assembly Tighten the two hose clamps 2 STEP 97 G1005015 G0905079 Position the transmission...

Page 53: ...ML_2_col 907871E Template Date 1997_02_12 STEP 98 G1005013 G1005014 Install the two left side fasteners in the transmission cover STEP 99 G0905061 G0905083 Position the engine cover 1 and install the...

Page 54: ...905080 Install the radiator cover 1 using the two thumb screws 2 STEP 102 G0905082 Install the radiator grill 1 using the four thumb screws 2 STEP 103 G0905077 Install the fuel filter access cover 1 u...

Page 55: ...t Fill the crankcase with the specified oil Bleed the fuel system by following the procedures in the Service As Required section of the Engine Operation and Maintenance Manual STEP 107 Start the engin...

Page 56: ...View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs com...

Page 57: ...A 913241 ELECTRICAL SCHEMATICS TROUBLESHOOTING TESTING ADJUSTMENT PROCEDURES RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specificati...

Page 58: ...T TROUBLESHOOTING 5 INSTRUMENT PANEL OR PANEL BULB REPLACEMENT 6 ELECTRICAL SCHEMATICS 8 ELECTRICAL SYSTEM TESTS 10 BATTERY TEST 10 FUSE POWER TESTS 11 IGNITION RELAY TESTS 12 STARTER AND STARTER RELA...

Page 59: ...f solenoid and the fuse NO Is the transmission shift lever in neutral NO Move the shift lever to the neutral position YES Is the battery fully charged NO Charge or replace the battery YES Is the batte...

Page 60: ...relay Replace the battery cables between the starter and the battery With the key switch ON and the starter switch depressed is there 12 volts at the starter terminal of the starter relay Replace the...

Page 61: ...alve cartridge NO Is the park brake fuse open YES Replace the fuse NO Is there 12 volts to the park brake relay switch terminal 4 YES NO Is there 12 volts to the relay coil terminal 3 Repair or replac...

Page 62: ...olenoid valve cartridge Is there 12 volts at the park brake relay coil terminal 3 YES NO Replace the park brake relay Is there 12 volts at the 2 terminal of the park brake switch YES NO Is there 12 vo...

Page 63: ...he steer mode selector switch YES NO Repair or replace the wire between the switch and the solenoid Replace the steer mode selector switch NO Replace the fuse Is there 12 volts at the fuse terminals o...

Page 64: ...instrument panel STEP 3 G0805142 Pull the instrument panel out from the dash mark the position of all wires and connectors on the instrument panel for reassembly Remove the wires and connectors STEP...

Page 65: ...ion Alt to display template information Template Name OML_2_col 907871E Template Date 1997_02_12 STEP 6 G0805182 Install the instrument panel 1 using the six screws 2 1 2 2 2 2 2 2 View thousands of C...

Page 66: ...play template information Template Name OML_2_col 907871E Template Date 1997_02_12 ELECTRICAL SCHEMATICS RS5 34 Telescopic Handler ELECTRICAL G0805233 View thousands of Crane Specifications on FreeCra...

Page 67: ...hide template information Alt to display template information Template Name OML_2_col 907871E Template Date 1997_02_12 ELECTRICAL SCHEMATICS G0805234 View thousands of Crane Specifications on FreeCra...

Page 68: ...ositive test lead to the positive post 1 and the negative test lead to the negative post 2 of the battery The multimeter should read 12 to 13 volts If there is no voltage replace the battery If there...

Page 69: ...n the positive battery cable 1 and the battery post 2 check the wiring for shorts to ground If there is no voltage recharge or replace the battery Install the positive battery cable 1 on the battery F...

Page 70: ...ay or repair or replace the wires between the relay socket and the battery If there is 12 to 13 volts proceed to the next step STEP 6 G0805154 With the relay removed connect the positive test lead to...

Page 71: ...s no voltage proceed to the next step If there is 12 to 13 volts and the starter does not turn over the engine repair or replace the starter and or the starter solenoid STEP 11 G0805183 Turn the key s...

Page 72: ...5161 Connect the positive test lead to the battery red wire of the key switch The multimeter should read 12 to 13 volts If there is no voltage check the ignition fuse the 60 amp in line fuse below the...

Page 73: ...oceed to the next step STEP 17 G0805164 Connect the positive test lead to the white wire terminal of the starter button Place the transmission lever in the neutral position turn the key switch to the...

Page 74: ...ad 12 to 13 volts If there is no voltage proceed to the next step If there is 12 to 13 volts but the engine will not start replace the fuel shut off solenoid valve STEP 21 G0805166 Check the fuel shut...

Page 75: ...switch to the ON position If there is no voltage replace the red wire between the fuse and the relay If there is 12 to 13 volts proceed to the next step STEP 24 G0805169 Connect the positive test lea...

Page 76: ...cing the park brake solenoid valve STEP 27 G0805078 Move the park brake switch to the ON position The multimeter should read 0 volts If there is no voltage and the park brake will not apply replace th...

Page 77: ...ke switch If there is 12 to 13 volts but no voltage at Step 24 replace the tan red wire between the switch and the relay STEP 31 G0805078 Move the park brake switch to the OFF position The multimeter...

Page 78: ...ead 12 to 13 volts If there is no voltage proceed to Step 42 STEP 36 G0805083 If there is 12 to 13 volts but the 4 wheel steer mode does not function replace the solenoid valve Connect the wire harnes...

Page 79: ...ceed to the next step STEP 40 G0805179 Connect the positive test lead to the green wire terminal of the steer mode switch With the key switch in the ON position and the steer mode switch in the 4 WHEE...

Page 80: ...Template Date 1997_02_12 Alt to hide template information Alt to display template information STEP 42 G0805182 Install the instrument panel 1 using the six screws 2 1 2 2 2 2 2 2 View thousands of Cra...

Page 81: ...302 PRINTED IN U S A 913241 BATTERY REMOVAL AND INSTALLATION RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneS...

Page 82: ...ate information Alt to display template information SECTION TABLE OF CONTENTS MANDATORY SAFETY SHUTDOWN PROCEDURE 1 BATTERY REMOVAL 1 BATTERY INSTALLATION 2 View thousands of Crane Specifications on F...

Page 83: ...TERY REMOVAL STEP 1 G0805075 Loosen the two thumbscrews 1 and remove the battery access cover 2 STEP 2 G0905001 Remove the negative battery cable from the battery WARNING BATTERY ACID CAUSES SEVERE BU...

Page 84: ...nt BATTERY INSTALLATION STEP 6 G0905004 Carefully lower the batter y into the batter y compartment WARNING Always remove the negative battery cable first so you do not cause a spark at the battery A s...

Page 85: ...on the positive battery post STEP 9 G0905001 Install the negative battery cable on the negative battery post STEP 10 G0805075 Install the battery access cover 1 and secure using the two thumbscrews 2...

Page 86: ...View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs com...

Page 87: ...TED IN U S A 913241 STEERING CONTROL VALVE REMOVAL AND INSTALLATION RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on Fre...

Page 88: ...Alt to display template information SECTION TABLE OF CONTENTS MANDATORY SAFETY SHUTDOWN PROCEDURE 1 STEERING CONTROL VALVE REMOVAL 1 STEERING CONTROL VALVE INSTALLATION 3 View thousands of Crane Spec...

Page 89: ...nt to the ground 3 Place controls in NEUTRAL and set the park brake 4 Idle the engine for gradual cooling 5 Turn the keyswitch to OFF position and remove the key Take the key with you for security rea...

Page 90: ...he gear selector STEP 6 G0905015 Remove the two bolts 1 and gear selector 2 from the steering column STEP 7 G0905042 Remove the six screws 1 from the instrument panel 2 Pull the instrument panel 2 out...

Page 91: ...nd plugs on all hoses and hydraulic fittings to prevent contaminating the hydraulic system STEP 11 G0905038 Support the steering control valve and remove the four mounting bolts Remove the steering co...

Page 92: ...ng column using the two bolts 2 STEP 17 G0905016 Connect the electrical harness to the connector on the bottom of the gear selector STEP 18 G0905014 Install the steering wheel 1 and the steering wheel...

Page 93: ...l limits and back the other way to their limits Repeat this procedure several times until the air is removed from the circuit STEP 22 Shut off the engine check for leaks Correct any leakage found Chec...

Page 94: ...View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs com...

Page 95: ...PRINTED IN U S A 913241 TRANSMISSION REMOVAL AND INSTALLATION RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCran...

Page 96: ...lt to display template information SECTION TABLE OF CONTENTS TRANSMISSION REMOVAL 1 TRANSMISSION REMOVAL 1 MANDATORY SAFETY SHUTDOWN PROCEDURE 1 TRANSMISSION INSTALLATION 10 View thousands of Crane Sp...

Page 97: ...tract the boom and lower the attachment tool to the ground Idle engine for gradual cooling 3 Place controls in neutral and apply parking brake 4 Shut off the engine and remove the key ONLY when you ha...

Page 98: ...ver 2 STEP 7 G0905082 Loosen the four thumbscrews 1 and remove the radiator grille 2 STEP 8 G0905080 Loosen the two thumbscrews 1 and remove the radiator cover 2 STEP 9 G0905083 G0905084 Remove the fo...

Page 99: ...tall a plug in the hose and a cap on the fitting STEP 13 G0905131 Remove the two hydraulic pump mounting bolts STEP 14 G0905087 Remove the hydraulic pump Position the pump where it will not interfere...

Page 100: ...5091 Label and disconnect the transmission temperature sender wire STEP 19 G0905092 Label and disconnect the four electrical connectors for the gear selection solenoids STEP 20 G0905093 Label and disc...

Page 101: ...rear drive shaft to the transmission STEP 25 G0905096 Remove the four bolts securing the rear drive shaft to the rear axle and remove the rear drive shaft STEP 26 G0905045 Remove the four bolts securi...

Page 102: ...ywheel to flex plate bolts Rotate the flywheel by inserting a pry bar through the inspection hole in the bottom of the bellhousing and into the ring gear STEP 31 G0905101 Rotate the flywheel until one...

Page 103: ...0905126 Remove the lower housing bell bolts STEP 36 G0905123 Loosen and remove the band clamp securing the exhaust pipe to the turbocharger STEP 37 Remove the exhaust pipe from the machine STEP 38 G09...

Page 104: ...olts securing the transmission to the right side transmission mounting bracket STEP 42 G0905160 Remove the right side transmission mounting bolt 1 washer lock nut and the mounting bracket 2 STEP 43 G1...

Page 105: ...lay template information Template Name OML_2_col 907871E Template Date 1997_02_12 STEP 45 G0705058 Pull the transmission forward to disengage it from the engine and lift it out of the machine View tho...

Page 106: ...he housing bell STEP 47 G1005021 Align the transmission with the guide studs in the housing bell Push the transmission towards the engine until the mounting flanges on the housing bell and transmissio...

Page 107: ...he left side mounting bracket to the transmission STEP 52 G0905127 Install the lower housing bell bolts STEP 53 Torque the housing bell bolts to 40 to 45 lb ft 54 to 61 Nm STEP 54 G0905133 Install the...

Page 108: ...a pry bar through the inspection hole in the bottom of the housing bell and into the ring gear STEP 57 G0705070 Rotate the flywheel until the bolt hole in the flywheel is at approximately 6 o clock a...

Page 109: ...n the bottom of the housing bell STEP 62 G0905044 Position the front shaft drive and install the four bolts securing it to the front axle STEP 63 G0905045 Install the four bolts secure the front shaft...

Page 110: ...5097 Install the muffler clamp securing the exhaust pipe to the muffler STEP 68 G0905090 Remove the cap and plug and install the lower transmission cooling line STEP 69 G0905089 Remove the cap and plu...

Page 111: ...er STEP 73 G0905124 Install the bolt 1 securing the two ground wires 2 STEP 74 G0905093 Reconnect the two wires to the reverse pressure switch STEP 75 G0905091 Reconnect the transmission temperature s...

Page 112: ...lange contacts the transmission STEP 79 G0905131 Install the two pump mounting bolts Torque the bolts to 80 to 90 lb ft 110 to 122 Nm STEP 80 Remove the cap from the hydraulic pump fittling and the pl...

Page 113: ...3 G1005016 G1005017 Install the two remaining engine cover bolts STEP 84 G0905080 Install the radiator cover 1 using the two thumb screws 2 STEP 85 G0905082 Install the radiator grill 1 using the four...

Page 114: ...display template information STEP 87 G1005015 G0905079 Install the right side mounting bolts STEP 88 G1005014 G1005013 Install the left side mounting bolts STEP 89 G0905077 Install the fuel filter acc...

Page 115: ...ator s Manual for the specified transmission fluid STEP 92 Start the engine and check for leaks If no leaks appear continue to run the engine and test the transmssion steering and hydraulic functions...

Page 116: ...View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs com...

Page 117: ...02 PRINTED IN U S A 913241 REAR AXLE REMOVAL AND INSTALLATION RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCrane...

Page 118: ...template information GENERAL TABLE OF CONTENTS GENERAL INFORMATION 1 REAR AXLE REMOVAL 1 MANDATORY SAFETY SHUTDOWN PROCEDURE 1 RELEASE HYDRAULIC OIL PRESSURE 1 REAR AXLE INSTALLATION 4 View thousands...

Page 119: ...full stop on a level surface If parking on a slope or hillside cannot be avoided park across the slope and block the tires 2 Fully retract the boom and lower the attachment to the ground 3 Place contr...

Page 120: ...ses for correct assembly Loosen and remove the two hydraulic hoses from the steering cylinder STEP 5 Install caps and plugs on all hoses and hydraulic fittings to prevent contaminating the hydraulic s...

Page 121: ...905060 Place two 10 ton hydraulic bottle jacks under the frame in the location shown STEP 12 G0905055 Have an assistant balance the axle assembly using a long pipe or bar inserted through the eye bolt...

Page 122: ...le only enough to remove the wheels and tires Support the axle on adequate stands Leave the hoist connected to ensure that the axle does not fall during wheel removal procedure STEP 17 G0905 Remove th...

Page 123: ...ntil the jack stands are clear STEP 24 Adjust the jackstands to allow the frame to be lowered onto the axle assembly STEP 25 Lower the jacks and align the mounting bolt holes in the axle with the hole...

Page 124: ...econnect the brake hose to the fitting on the axle assembly STEP 30 G0905044 G0905045 Reinstall the driveshaft to the transmission and to the rear axle using the bolts and lock washers NOTE Use Loctit...

Page 125: ...4 wheel steering position Turn the steering wheel in one direction until the wheels reach their travel limits and then back the other way to their travel limits Repeat this procedure several times un...

Page 126: ...View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs com...

Page 127: ...3 PRINTED IN U S A 913241 FRONT AXLE REMOVAL AND INSTALLATION RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCrane...

Page 128: ...template information SECTION TABLE OF CONTENTS GENERAL INFORMATION 1 FRONT AXLE REMOVAL 1 MANDATORY SAFETY SHUTDOWN PROCEDURE 1 RELIEVING HYDRAULIC PRESSURE 1 FRONT AXLE INSTALLATION 5 View thousands...

Page 129: ...machine to a full stop on a level surface If parking on a slope or hillside cannot be avoided park across the slope and block the tires 2 Fully retract the boom and lower the attachment to the ground...

Page 130: ...vot pin on the frame leveling cylinder STEP 4 G0805208 Remove the lower pivot pin from the frame leveling cylinder STEP 5 G0805044 Disconnect the driveshaft from the front axle by removing the four bo...

Page 131: ...correct assembly Loosen and remove the two brake hoses from the axle STEP 11 Install caps and plugs on all hoses and brake fittings to prevent contaminating the brake system STEP 12 G0905064 Position...

Page 132: ...ust the jack stands to a height that will keep the wheels approximately 2 inches off the surface when the bottle jacks are removed STEP 18 Lower the bottle jacks equally and remove STEP 19 G0905072 Us...

Page 133: ...After the axle is removed have adequate stands or work surface to support the axle safety while performing the repair procedure FRONT AXLE INSTALLATION STEP 26 G0905073 Carefully roll the axle and flo...

Page 134: ...ard pressure equally from side to side on each jack STEP 32 G0905064 Remove the jack stands Lower the bottle jacks equally and remove STEP 33 Tighten the wheel nuts to a torque of 450 ft lbs 610 Nm ST...

Page 135: ...ign the driveshaft yokes Use Loctite 271 Thread Lock or equivalent on the threads of the driveshaft mounting bolts STEP 38 G0905067 Install the driveshaft to the transmission using the four bolts and...

Page 136: ...ve the steer mode switch to the 4 wheel steering position Turn the steering wheel in one direction until the wheels reach their travel limits and then back the other way to their travel limits Repeat...

Page 137: ...13241 BP0508 HYDRAULIC SCHEMATICS TROUBLESHOOTING TESTING ADJUSTMENT PROCEDURES RS5 6 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifi...

Page 138: ...View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs com...

Page 139: ...R QUICK TEST 21 TILT CYLINDER DIRECT TEST 21 TILT CYLINDER LOAD CHECK VALVE QUICK TEST 24 TILT CYLINDER LOAD CHECK VALVE DIRECT TEST 24 EXTENSION CYLINDER QUICK TEST 26 EXTENSION CYLINDER DIRECT TEST...

Page 140: ...transmission provides hydraulic flow to the steering system and the flow divider The flow divider directs flow to the joystick control valves the SAHR Spring Applied Hydraulic Release park brake the...

Page 141: ...njury WARNING To prevent damage and or personal injury when using an in line flowmeter for testing ALWAYS be sure the load valve on the flowmeter is fully OPEN before starting the engine PRESSURE CHEC...

Page 142: ...ick Control and Park Brake Pressure Relief Valve 350 psi 24 bar Pump Steering Modulation Relief Valve 2000 psi 172 bar Service Brake Valve Modulation Pressure 435 psi 30 bar Main Control Valve Relief...

Page 143: ...ressure at the JP port of the flow divider Does the pressure gauge read YES NO YES NO NO YES YES NO YES NO 350 psi 24 bar Repair or replace the joystick control Test the pressure of the PB port of the...

Page 144: ...est the pressure at the LH lift cylin lift cylinder der left side hose Does the pressure gauge read 3000 psi 207 bar Repair or replace the left side lift cylinder Repair or replace the RH and Repair o...

Page 145: ...0 psi 172 bar Repair or replace the extend cylinder Adjust the extend pressure relief valve in the control valve and retest the extend pressure Does the gauge read 2500 psi 172 bar If the extend retra...

Page 146: ...07 bar Repair or replace the tilt cylinder Adjust the tilt pressure relief valve in the tilt control valve and retest the tilt up Does the gauge read 3000 psi 207 bar If the tilt does not work after a...

Page 147: ...ure at the MP test port of the flow divider Retract the boom to the end of the cylinder stroke and hold Does the pressure gauge read 3000 psi 207 bar Test the pressure at the J port of the flow divide...

Page 148: ...lve Does the pressure gauge read 2500 psi 172 bar If the problem is in front steer mode only Repair or replace the repair or replace the front steer cylinder Steering Control Valve If the problem is i...

Page 149: ...display template information Template Name OML_1_col 0 00000 Template Date 1994_04_22 RS5 6 34 Telescopic Handler HYDRAULICS HYDRAULIC SCHEMATICS G0805235 View thousands of Crane Specifications on Fr...

Page 150: ...display template information Template Name OML_1_col 0 00000 Template Date 1994_04_22 RS5 6 34 Telescopic Handler HYDRAULICS HYDRAULIC SCHEMATICS G0805236 View thousands of Crane Specifications on Fr...

Page 151: ...play template information Template Name OML_1_col 0 00000 Template Date 1994_04_22 HYDRAULIC SCHEMATIC WITH PWP RS5 6 34 Telescopic Handler HYDRAULICS G0805237 View thousands of Crane Specifications o...

Page 152: ...template information Template Name OML_1_col 0 00000 Template Date 1994_04_22 RS5 6 34 Telescopic Handler HYDRAULICS HYDRAULIC SCHEMATIC WITH PWP CONT D G0805238 View thousands of Crane Specification...

Page 153: ...05082 G0805118 Install a 5000 psi 345 bar pressure gauge to the MP test port on the flow divider Start the engine and fully retract the boom and hold The pressure gauge should read 3000 psi 207 bar ST...

Page 154: ...ce the flow divider 1 2 FLOW DIVIDER PRESSURE TEST STEP 6 G0805118 Install a 5000 psi 345 bar pressure gauge on the MP test port on the flow divider Start the engine and fully retract the boom and hol...

Page 155: ...gine NOTE If the boom lowers while the engine is off proceed to Step 19 STEP 13 G0805189 Place a support stand under the attachment end of the boom STEP 14 G0805088 G0805089 Remove the hose 1 from the...

Page 156: ...3 bar continue with the next step STEP 16 G0805092 Shut off the engine Remove the cap from the counter balance valve on the lift cylinder STEP 17 G0805090 Loosen the lock nut 1 and turn the adjusting...

Page 157: ...eter to the left hose and the outlet hose 2 of the flowmeter to the cylinder left port STEP 21 G0805016 Open the load control valve of the flowmeter Start the engine and run at 1000 RPM STEP 22 G08050...

Page 158: ...opposite side lift cylinder Install a plug in the hose 1 and a cap on the cylinder port 2 STEP 25 G0805077 Start the engine and run at 1000 RPM Hold the joystick in the LOWER position If the pressure...

Page 159: ...207 bar proceed to the Main Control Valve Pressure Relief Test and Adjustment section of this manual STEP 29 G0805086 Tilt the attachment mount up until the tilt cylinder reaches the end of its stroke...

Page 160: ...o the next step STEP 32 G0805100 Shut off the engine Remove the slave cylinder hoses Install plugs in the hose ends and caps on the fittings STEP 33 G0805077 Start the engine and run at idle RPM Hold...

Page 161: ...lt down port 2 of the tilt cylinder Cap the cylinder port and install a 5000 psi 345 bar pressure gauge and hose on the cylinder supply hose 1 2 1 2 STEP 38 G0805077 G0805098 Start the engine and run...

Page 162: ...the joystick in the TILT UP position The pressure gauge should read 3000 psi 207 bar If the pressure is less than 3000 psi 207 bar go to Step 30 of the Tilt Cylinder Direct Test If the pressure is 300...

Page 163: ...cover on the valve cartridge STEP 45 G0805106 Loosen the lock nut 1 and turn the adjusting screw 2 counterclockwise to increase and clockwise to decrease the pressure NOTE One turn of the adjusting sc...

Page 164: ...ressure is more than 3000 psi 207 bar proceed to the Main Control valve Pressure Relief Test and Adjustment section of this manual If the pressure is less than 3000 psi 207 bar proceed to the next ste...

Page 165: ...nd STEP 51 G0805077 Start the engine and run at 1000 RPM Move the joystick into the BOOM RETRACT position and hold The pressure gauge should read 3000 psi 207 bar If the pressure is 3000 psi 207 bar r...

Page 166: ...ar If the pressure is less than 1500 psi 103 bar proceed to the next step If the pressure is more than 1500 psi 103 bar proceed to Step 58 STEP 55 G0805077 Retract the boom to the end of the extension...

Page 167: ...psi 103 bar as the boom is retracted If the gauge is not at 1500 psi 103 bar proceed to the next step STEP 58 G0805112 G0805113 Shut off the engine Remove the cover from the counter balance valve NOTE...

Page 168: ...05117 Start the engine and run at 1000 RPM Tilt the frame to the right until the frame leveling cylinder reaches the end of its stroke and hold The pressure gauge should read 2000 psi 138 bar If the p...

Page 169: ...IGHT position The pressure gauge should read 2000 psi 138 bar If the pressure is less than 2000 psi 138 bar proceed to the next step STEP 64 G0805122 Shut off the engine Remove the pressure gauge from...

Page 170: ...ehind both rear wheels STEP 67 G0805193 Install a 5000 psi 345 bar pressure gauge and hose on the SP test port of the flow divider NOTE The hose must be long enough to observe the pressure gauge from...

Page 171: ...DIRECT TEST STEP 71 G0805193 Shut off the engine Remove the pressure gauge from the SP test port on the flow divider STEP 72 G0805121 Remove the supply hose 1 from the tilt right rod port 2 of the fra...

Page 172: ...ld the adjusting screw from turning and tighten the lock nut Repeat Steps 73 and 75 until the pressure gauge reads 1500 psi 103 bar If the adjusting screw does not change the pressure replace the coun...

Page 173: ...G0805126 Repeat Steps 73 74 and 75 except read the pressure gauge as the frame is in the TILT LEFT mode and adjust the tilt left counterbalance valve 1 STEP 79 G0805125 Remove the pressure gauge 1 fr...

Page 174: ...ystick in the RETRACT position The pressure gauge should read 3000 psi 207 bar If the pressure is less than 3000 psi 207 bar proceed to the next step If the pressure is more than 3000 psi 207 bar proc...

Page 175: ...uge reads 3000 psi 207 bar If the pressure can be adjusted to 3000 psi 207 bar proceed to Step 84 If the pressure is more than 3000 psi 207 bar and does not change when the adjusting screw 3 is turned...

Page 176: ...be long enough to observe the pressure gauge from inside the cab or standing clear of the forklift STEP 88 G0805077 Start the engine and run at 1000 RPM The park brake must be ON Hold the joystick in...

Page 177: ...si 24 bar proceed to the next step STEP 92 G0805185 Shut off the engine Remove the pressure gauge from the solenoid supply hose 1 and install the supply hose 1 on the solenoid 2 STEP 93 G0805134 G0805...

Page 178: ...e pressure is less than 350 psi 24 bar but was at 350 psi 24 bar when the park brake switch was ON repair or replace the park brake in the front axle If the pressure is 350 psi 24 bar but the park bra...

Page 179: ...38 bar If the pressure is less than 2000 psi 138 bar proceed to the next step If the pressure is 2000 psi 138 bar but the steering does not work properly check the steering linkage and pivot points an...

Page 180: ...run at 1000 RPM Turn the steering wheel in one direction until the wheels reach their travel limits and hold Slowly close the load control valve If the pressure is less than 2000 psi 138 bar repair or...

Page 181: ...PRINTED IN U S A 913241 HYDRAULIC PUMP REMOVAL AND INSTALLATION RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCra...

Page 182: ...ormation Alt to display template information SECTION TABLE OF CONTENTS MANDATORY SAFETY SHUTDOWN PROCEDURE 1 HYDRAULIC PUMP REMOVAL 1 HYDRAULIC PUMP INSTALLATION 3 View thousands of Crane Specificatio...

Page 183: ...ls in NEUTRAL and set the park brake 4 Idle the engine for gradual cooling 5 Turn the keyswitch to OFF position and remove the key Take the key with you for security reasons ONLY when you have taken t...

Page 184: ...t hydraulic hoses for correct assembly STEP 6 G0905106 Disconnect the remaining hydraulic hoses from the hydraulic pump Install plugs in the hoses and caps on the fittings STEP 7 G0905110 G0905111 Rem...

Page 185: ...aft 1 with the gear drive 2 in the transmission Slide the shaft into the transmission until the mounting flange contacts the transmission STEP 11 G0905115 Install the two pump mounting bolts Tighten t...

Page 186: ...evel Start the engine and check for leaks If no leaks appear continue to run the engine and test the steering and hydraulic functions for operation Shut off the engine and check the hydraulic reservoi...

Page 187: ...TED IN U S A 913241 FRAME LEVELING CYLINDER REMOVAL AND INSTALLATION RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on Fr...

Page 188: ...ion SECTION TABLE OF CONTENTS MANDATORY SAFETY SHUTDOWN PROCEDURE 1 RELIEVING HYDRAULIC PRESSURE FOR THE FRAME LEVELING CYLINDER 1 FRAME LEVELING CYLINDER REMOVAL 2 FRAME LEVELING CYLINDER INSTALLATIO...

Page 189: ...hese precautions can you be sure it is safe to proceed Failure to follow the above procedure could lead to death or serious injury RELIEVE HYDRAULIC OIL PRESSURE 1 Engage the park brake 2 Lower equipm...

Page 190: ...ain control valve and remove the rubber boot Using a screwdriver turn the screw IN clockwise until it bottoms then turn it OUT counterclockwise until it bottoms Reinstall the rubber boot NOTE See Sect...

Page 191: ...g the hydraulic system STEP 7 G0805211 Loosen and remove the retaining bolt 1 and nut 2 from the upper pivot pin STEP 8 G0805212 Remove the upper pivot pin from the frame leveling cylinder STEP 9 Remo...

Page 192: ...hydraulic fittings and hoses STEP 13 G0805208 Using a pry bar extend the cylinder rod enough to install the pivot pin Install the lower pivot pin STEP 14 G0805207 Install and tighten the retainer pin...

Page 193: ...h the park brake on engine running and the boom raised approximately 2 feet 0 6 m tilt the frame fully to the left and then to the right Repeat this procedure several times to remove air from the hydr...

Page 194: ...View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs com...

Page 195: ...PRINTED IN U S A 913241 TILT CYLINDER REMOVAL AND INSTALLATION RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCra...

Page 196: ...mplate information SECTION TABLE OF CONTENTS MANDATORY SAFETY SHUTDOWN PROCEDURE 1 RELIEVING HYDRAULIC PRESSURE FOR THE TILT CYLINDER 1 TILT CYLINDER REMOVAL 2 TILT CYLINDER INSTALLATION 4 View thousa...

Page 197: ...jury RELIEVE HYDRAULIC OIL PRESSURE 1 Engage the park brake 2 Lower equipment to the ground Return the engine to idle for 30 seconds then shut down the engine 3 Turn the keyswitch on Operate the joyst...

Page 198: ...til it bottoms Reinstall the rubber boot TILT CYLINDER REMOVAL NOTE See Section 605 of this Service Manual for the repair of this cylinder STEP 1 G0805214 Loosen and remove the retainer bolt 1 and nut...

Page 199: ...0805222 Remove the retainer bolt 1 and nut 2 from the upper pivot pin IMPORTANT Protect the chrome finish in the cylinder rod at all times Damage to surface of the rod can cause premature seal failure...

Page 200: ...11 G0805217 Install the retainer bolt 1 and nut 2 in the upper pivot pin and tighten Remove the lifting strap and chain hoist from the tilt cylinder STEP 12 Remove the caps and plugs from the fitting...

Page 201: ...lower pivot pin STEP 18 Use a grease gun with the specified grease to lubricate the upper and lower pin grease fittings STEP 19 G0805077 With the park brake on and the engine running fully retract an...

Page 202: ...View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs com...

Page 203: ...on 605 PRINTED IN U S A 913241 HYDRAULIC CYLINDER REPAIR RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs...

Page 204: ...ion Alt to display template information SECTION TABLE OF CONTENTS GENERAL INFORMATION 1 MANDATORY SAFETY SHUTDOWN PROCEDURE 1 CYLINDER DISASSEMBLY 1 CYLINDER ASSEMBLY 5 View thousands of Crane Specifi...

Page 205: ...clean hydraulic fluid Using an engine piston ring compressor to compress the piston seals tightly for a short period of time will often aid in the assembly procedure MANDATORY SAFETY SHUTDOWN PROCEDU...

Page 206: ...set screw from the cylinder gland ring nut STEP 4 G1534MP Loosen and remove the gland nut from the cylinder STEP 5 G1535MP Remove the rod assembly from the cylinder IMPORTANT Protect the chrome finish...

Page 207: ...e piston STEP 10 G1541MP Loosen and remove the nut from the cylinder rod NOTE The nut is retained with thread lock compound and may require heat to remove STEP 11 G1542MP Remove the piston from the cy...

Page 208: ...and discard the inner wear ring from the head gland STEP 17 G1547MP Remove and discard the inner seal from the head gland STEP 18 G1548MP Remove and discard the O rings and backup rings from the count...

Page 209: ...sembled Use crocus cloth to remove any minor nicks or scratches STEP 22 G1551MP Inspect the cylinder rod for any nicks scratches or scoring Roll the rod on a hard flat surface to check for any bending...

Page 210: ...land over the threads and onto the cylinder rod STEP 28 G1537MP Install a new backup ring 1 and O ring 2 on the head gland STEP 29 G1543MP Install the backup washer 1 and O ring 2 on the cylinder rod...

Page 211: ...he two wear rings on the piston Apply a thin coat of oil on the seal and wear rings prior to installation of the rod assembly STEP 35 Remove the rod from the vise Clamp the base end of the barrel in a...

Page 212: ...new nylon locking insert inside the set screw hole Install the set screw in the gland nut Torque the set screw to 5 to 7 ft lbs 7 to 9 Nm STEP 39 G1548MP Lubricate and install new O rings 1 and backu...

Page 213: ...PRINTED IN U S A 913241 SLAVE CYLINDER REMOVAL AND INSTALLATION RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCra...

Page 214: ...plate information SECTION TABLE OF CONTENTS MANDATORY SAFETY SHUTDOWN PROCEDURE 1 RELIEVING HYDRAULIC PRESSURE FOR THE SLAVE CYLINDER 1 SLAVE CYLINDER REMOVAL 2 SLAVE CYLINDER INSTALLATION 3 View thou...

Page 215: ...injury RELIEVE HYDRAULIC OIL PRESSURE 1 Engage the park brake 2 Lower equipment to the ground Return the engine to idle for 30 seconds then shut down the engine 3 Turn the keyswitch on Operate the jo...

Page 216: ...ll the rubber boot SLAVE CYLINDER REMOVAL STEP 1 G0905005 Disconnect both hydraulic hoses from the slave cylinder STEP 2 Install caps and plugs on all hoses and hydraulic fittings to prevent contamina...

Page 217: ...pper pivot pin STEP 7 G0905009 Remove the upper pivot pin STEP 8 Remove the slave cylinder from the machine SLAVE CYLINDER INSTALLATION STEP 9 G0905010 G0905011 Using a hoist and lifting strap install...

Page 218: ...ap and hoist from the slave cylinder STEP 12 G0905007 Using a pry bar extend the slave cylinder rod enough to install the lower pivot pin Install the lower pivot pin NOTE Align the pivot pin holes wit...

Page 219: ...grease STEP 16 Start the engine Move the machine to an open area and park on a level surface Apply the park brake Raise and lower the boom several times until all air is removed from the circuit STEP...

Page 220: ...View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs com...

Page 221: ...PRINTED IN U S A 913241 LIFT CYLINDER REMOVAL AND INSTALLATION RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCra...

Page 222: ...mplate information SECTION TABLE OF CONTENTS MANDATORY SAFETY SHUTDOWN PROCEDURE 1 RELIEVING HYDRAULIC PRESSURE FOR THE LIFT CYLINDER 1 LIFT CYLINDER REMOVAL 2 LIFT CYLINDER INSTALLATION 3 View thousa...

Page 223: ...EVE HYDRAULIC OIL PRESSURE 1 Engage the park brake 2 Lower equipment to the ground Return the engine to idle for 30 seconds then shut down the engine 3 Turn the keyswitch on Operate the joystick in ea...

Page 224: ...E See Section 605 of this Service Manual for the repair of this cylinder STEP 1 G0805223 Mark the hydraulic hoses for correct assembly Disconnect the two hydraulic hoses from the lift cylinder STEP 2...

Page 225: ...ift cylinder from the machine using the hoist NOTE If necessary use this same procedure to remove the opposite side lift cylinder LIFT CYLINDER INSTALLATION STEP 9 G0805229 Using the hoist and lifting...

Page 226: ...th the hole in the cylinder mount and reinstall the lower pivot pin Use care not to damage the grease fitting STEP 13 G0805224 Install and tighten the retainer bolt 1 and nut 2 in the lower pivot pin...

Page 227: ...pen area and park on a level surface Apply the park brake Raise and lower the boom several times until all air is removed from the circuit STEP 18 Lower the boom and shut off the engine Check for leak...

Page 228: ...View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs com...

Page 229: ...NTED IN U S A 913241 BOOM EXTEND CYLINDER REMOVAL AND INSTALLATION RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on Free...

Page 230: ...ate information SECTION TABLE OF CONTENTS MANDATORY SAFETY SHUTDOWN PROCEDURE 1 RELIEVING HYDRAULIC PRESSURE FOR THE EXTEND CYLINDER 1 EXTEND CYLINDER REMOVAL 2 EXTEND CYLINDER INSTALLATION 4 View tho...

Page 231: ...s injury RELIEVE HYDRAULIC OIL PRESSURE 1 Engage the park brake 2 Lower equipment to the ground Return the engine to idle for 30 seconds then shut off the engine 3 Turn the keyswitch on Operate the jo...

Page 232: ...or the repair of this cylinder STEP 1 G0905040 Mark the hydraulic lines for correct assembly Loosen and remove the two lines from the extend cylinder STEP 2 Install caps and plugs on all hydraulic fit...

Page 233: ...strap STEP 7 G0905050 G0905024 Using a hoist and lifting strap position the lifting strap around the rod end of the extend cylinder Apply upward pressure to remove the slack from the lifting strap ST...

Page 234: ...les with the holes in the cylinder mount STEP 11 G0905030 Install the retainer bolt 1 and nut 2 and tighten Remove the hoist and lifting strap STEP 12 G0905032 Position a hoist and lifting strap aroun...

Page 235: ...m the hydraulic fittings and hoses STEP 17 G0905040 Reconnect the two hydraulic lines to the boom extend cylinder and tighten STEP 18 Use a grease gun with the specified grease to lubricate the forwar...

Page 236: ...View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs com...

Page 237: ...PRINTED IN U S A 913241 BOOM ASSEMBLY REMOVAL AND INSTALLATION RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCra...

Page 238: ...RMATION 1 BOOM ASSEMBLY REMOVAL 1 MANDATORY SAFETY SHUTDOWN PROCEDURE 1 RELEASE HYDRAULIC OIL PRESSURE 1 RELIEVING HYDRAULIC PRESSURE FOR THE TILT CYLINDER 2 RELIEVING HYDRAULIC PRESSURE FOR THE BOOM...

Page 239: ...t connected to each end of the boom BOOM ASSEMBLY REMOVAL STEP 1 Park the unit on a solid level surface with adequate room for boom removal Place wood blocks under the nose portion of the boom and low...

Page 240: ...g a screwdriver turn the screw IN clockwise until it bottoms then turn it OUT counterclockwise until it bottoms Reinstall the rubber boot G0805102 6 Locate the attachment Tilt Down section rear sectio...

Page 241: ...o equal length chains to the lifting links Apply upward pressure with an adequate size hoist until the chains are tight NOTE If only the boom pivot shaft is to be replaced it will not be necessary to...

Page 242: ...assembly Disconnect the four hydraulic hoses from the bulkhead STEP 6 Install caps and plugs tightly on all hydraulic hoses and fittings to prevent contaminating the hydraulic system STEP 7 G0805226...

Page 243: ...the boom pivot shaft from the boom assembly STEP 11 Lift the rear of the boom assembly high enough to clear the bearings and upright standard If necessary lift and adjust the front of the boom so tha...

Page 244: ...he retainer bolt hole in the pivot shaft is aligned with the retainer bolt hole in the frame STEP 13 G1005030 Install and tighten the retainer bolt 1 and nut 2 in the pivot pin STEP 14 Remove the caps...

Page 245: ...9 G0805231 Install the top pivot pin in both lift cylinders Complete Steps 9 10 and 11 of Section 607 of this manual for correct procedures STEP 20 G0805199 Install the boom rear cover 1 using the fou...

Page 246: ...View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs com...

Page 247: ...PRINTED IN U S A 913241 SINGLE AND DOUBLE LEAF CHAIN ADJUSTMENT RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCra...

Page 248: ...NTS GENERAL INFORMATION 1 BOOM ASSEMBLY REMOVAL 1 MANDATORY SAFETY SHUTDOWN PROCEDURE 1 RELIEVING HYDRAULIC PRESSURE FOR THE TILT CYLINDER 2 RELIEVING HYDRAULIC PRESSURE FOR THE BOOM EXTEND CYLINDER 2...

Page 249: ...PROCEDURE BEFORE cleaning adjusting lubricating or servicing this unit 1 Stop machine on a level surface AVOID parking on a slope but if necessary park across the slope and block the tires 2 Fully re...

Page 250: ...sheaves If the distance measured is 12 375 inch 314 3 mm or more the chain should be replaced See Sections 704 and 705 of this manual for the correct single and double chain replacement procedures IM...

Page 251: ...INTED IN U S A 913241 INNER BOOM SECTION REMOVAL AND INSTALLATION RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeC...

Page 252: ...NTENTS MANDATORY SAFETY SHUTDOWN PROCEDURE 1 RELIEVING HYDRAULIC PRESSURE FOR THE TILT CYLINDER 1 RELIEVING HYDRAULIC PRESSURE FOR THE BOOM EXTEND CYLINDER 2 GENERAL INFORMATION 2 INNER BOOM REMOVAL 2...

Page 253: ...equipment to the ground Return the engine to idle for 30 seconds then shut off the engine 3 Turn the key switch on Operate the joystick in each direction Confirm that there is no attachment or unit mo...

Page 254: ...o t Usin g a screwdriver turn the screw IN clockwise until it bottoms then turn it OUT counterclockwise until it bottoms Reinstall the rubber boot G0805102 8 Locate the attachment Boom Retract section...

Page 255: ...four bolts 1 and the boom rear access cover 2 STEP 7 G1005040 Use a crow foot wrench with a long extension to reach in and loosen the locking nut on the chain clevis Once the locking nut is loosened...

Page 256: ...two top slide pads and shims 3 and the two side slide pads and shims 4 from the rear of the inner boom STEP 9 G0805216 G1005044 Mark the hydraulic hoses for correct assembly Loosen and remove the two...

Page 257: ...and lifting strap around the inner boom section Pull the inner boom section out from the intermediate section approximately 12 inches 300 mm STEP 13 G1005070 G1005071 Loosen and remove the bolts lock...

Page 258: ...sheave pin 1 and the front chain sheave 2 STEP 19 Begin sliding the inner boom section from the intermediate boom Before the inner boom section is completely removed put a wood block under the nose p...

Page 259: ...nner boom in until there is approximately 12 inches 300 mm of the inner boom sticking out of the intermediate boom STEP 25 Using the hoist and lifting strap apply upward pressure to the inner boom STE...

Page 260: ...bs 41 Nm STEP 30 Remove the lifting strap and hoist from the inner boom STEP 31 Push the intermediate and inner boom fully into the main boom this will allow enough room to reinstall the single chain...

Page 261: ...nect the two hydraulic hoses 2 to the tilt cylinder STEP 37 G1005089 G1005089 Reinstall the two side slide pads and shims 1 and the two top slide pads and shims 2 to the rear of the inner boom using t...

Page 262: ...on the bracket Check the amount of clevis extending from the bracket then adjust to achieve the boom setting 2 inches 50 8 mm dimension shown Install the locking nut STEP 40 G1005039 Reinstall the two...

Page 263: ...nder and install the pivot pin in the rod end of the cylinder See Section 608 of this manual for correct procedures STEP 43 Start the engine and check boom operation in a clear area STEP 44 Shut down...

Page 264: ...View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs com...

Page 265: ...U S A 913241 TELESCOPING BOOM DOUBLE CHAIN AND ROLLER BEARING REPLACEMENT RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications...

Page 266: ...to display template information SECTION TABLE OF CONTENTS DOUBLE CHAIN ROLLER BEARING REMOVAL 1 MANDATORY SAFETY SHUTDOWN PROCEDURE 1 DOUBLE CHAIN ROLLER BEARING INSTALLATION 4 View thousands of Crane...

Page 267: ...off the engine and remove the key ONLY when you have taken these precautions can you be sure it is safe to proceed Failure to follow the above procedure could lead to death or serious personal injury...

Page 268: ...STEP 10 G1619MP Install the adjustment clevis on to the new chain using the retainer pin and one cotter pin STEP 11 G1616MP Position the chain in the clevis at the rear of the inner boom section Inst...

Page 269: ...p and over the sheaves and place each clevis through the mounting holes in the outer boom section securing it with one nut NOTE Check the condition of the sheave and roller bearing at this time Procee...

Page 270: ...chains over the front of the inner boom section STEP 23 G1649MP Loosen and remove the bolt 1 and nut 2 from the front sheave pin STEP 24 G1648MP Remove the sheave pin STEP 25 Remove the roller bearing...

Page 271: ...ner bolt holes are lined up STEP 28 G1649MP Install the retainer bolt and nut through the pin and tighten STEP 29 G1655MP Pull the double chain assembly up and over the sheaves and place each clevis t...

Page 272: ...View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs com...

Page 273: ...U S A 913241 TELESCOPING BOOM SINGLE CHAIN AND ROLLER BEARING REPLACEMENT RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications...

Page 274: ...on Alt to display template information GENERAL TABLE OF CONTENTS MANDATORY SAFETY SHUTDOWN PROCEDURE 1 REMOVAL 1 INSTALLATION 3 SINGLE CHAIN ROLLER BEARING REPLACEMENT 5 View thousands of Crane Specif...

Page 275: ...e the key ONLY when you have taken these precautions can you be sure it is safe to proceed Failure to follow the above procedure could lead to death or serious personal injury STEP 2 G1635MP Remove th...

Page 276: ...h the clevis forward and remove both nuts from the clevis STEP 9 Remove the single chain by pulling out from the rear of the boom Remove the rope from the single chain clevis and leave the rope in pla...

Page 277: ...f the boom pull the new chain in place with the rope while you guide the chain into position STEP 15 G1005040 Position the single chain over the bearing and insert the clevis end into the mounting hol...

Page 278: ...d over the sheaves and place each clevis through the mounting holes in the outer boom securing each with one nut STEP 20 Torque the double chains See Section 702 of this manual for correct procedure S...

Page 279: ...rear sheave pin Remove the single chain from the sheave pulley and position the single chain out of the way STEP 28 G1660MP Remove the grease fitting from the sheave pin Remove the sheave pin from th...

Page 280: ...o display template information STEP 32 G1659MP Install the retainer bolt and nut through the pin and tighten Reposition the single chain over the sheave pulley STEP 33 Reinstall the inner boom section...

Page 281: ...ED IN U S A 913241 INTERMEDIATE BOOM SECTION REMOVAL AND INSTALLATION RS5 34 Telescopic Handler View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on F...

Page 282: ...o display template information GENERAL TABLE OF CONTENTS MANDATORY SAFETY SHUTDOWN PROCEDURE 1 GENERAL INFORMATION 1 INTERMEDIATE BOOM REMOVAL 1 INTERMEDIATE BOOM INSTALLATION 5 View thousands of Cran...

Page 283: ...dure could lead to death or serious bodily injury GENERAL INFORMATION If slide pad replacement is required see Section 707 of this manual for correct procedure INTERMEDIATE BOOM REMOVAL STEP 1 G100508...

Page 284: ...he two side slide pads on the rear of the intermediate boom STEP 5 G1005051 Remove the two side slide pads and shims from the rear of the intermediate boom STEP 6 G1005066 Use a hoist and lifting stra...

Page 285: ...P 9 G1005062 G1005053 Loosen and remove the two bolts and remove the left side slide pad and shim from the front of the outer boom STEP 10 G1005068 Loosen and remove the bolts and washers from the two...

Page 286: ...g the hoist and lifting strap pull the intermediate boom out of the outer boom approximately 108 inches 2 74 mm Lower the hoist and measure from the end of the intermediate boom section back 84 inches...

Page 287: ...e lifting strap to the end of the intermediate boom section apply upward pressure and slide the intermediate boom section into the outer boom until there is approximately 12 inches 300 mm left stickin...

Page 288: ...threads of the bolts and torque to 30 ft lbs 41 Nm STEP 24 G1005053 G1005062 Reinstall the side slide pad and shim to the front of the outer boom using the bolts and washers Use Loctite 271 red Thread...

Page 289: ...r equivalent on the threads of the bolts and torque to 30 ft lbs 40 7 Nm STEP 27 Remove the lifting strap and push the intermediate boom section into the outer boom as far as possible STEP 28 G1005078...

Page 290: ...threads of the bolts and torque to 30 ft lbs 41 Nm Bend up each end of the lock plates STEP 30 G1623MP Apply grease to the inside bottom and top surfaces of the intermediate boom section where the pad...

Page 291: ...View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs com...

Page 292: ...179 West Bend WI 53095 0179 U S A www gehl com 913241 AP1105 2005 Gehl Company PRINTED IN U S A All Rights Reserved View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane...

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