Gehl RS5-34, RS6-34 Telescopic Handlers OEM Service & Repair Manual

RS5-34 RS6-34 Telescopic Handler SERVICE MANUAL Form No. 913241

INTRODUCTION With correct maintenance and proper use, this Gehl RS Telescopic Handler will give years of dependable service. This service manual is intended to be a guide in the assembly and disassembly, installation and removal, adjustment and testing, troubleshooting and replacement of components that together make up the Gehl RS5-34 Telescopic Handler. 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 adjust- ments that this RS Series Telescopic Handler needs to keep it in good running condition. If you have any additional questions, please contact your authorized Gehl dealer or call the Gehl Service Department for assistance.

PRINTED IN U.S.A. 1 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

Section 100 PRINTED IN U.S.A. 913241 PERSONAL SAFETY INFORMATION AND DECAL LOCATIONS RS5-34 Telescopic Handler

Template Name: OML_2_col Rac 0-00000 Template Date: 1997_02_12 Alt= to hide template information Alt+ to display template information SECTION TABLE OF CONTENTS SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 MANDATORY SAFETY SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SAFETY RULES AND REMINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 LOCATIONS - FRAME AND BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DECAL LOCATIONS - OPERATOR STATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DECAL LOCATIONS - PWP EQUIPPED UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

PRINTED IN U.S.A. 100-1 913241 Alt= to hide template information Alt+ to display template information Template Name: OML_1_col 907871 Template Date: 1994_04_22 RS5-34 Telescopic Handler PERSONAL SAFETY SAFETY The above Safety Alert Symbol means ATTENTION! ALWAYS BE ALERT! YOUR SAFETY IS INVOLVED! When you see this symbol, carefully read the message that follows and be alert to the possibility of injury or death. Gehl Company always takes safety into consideration when designing its products, and designs guards for exposed moving parts whenever it is possible and practical to do so. However, even with todays state-of-the-art technology, it must be recognized that in order to assure machine functionality for specific purposes not all machine hazards can be guarded or shielded. Decals are placed on the machine to warn of additional hazards and must be read 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 federal, state or local regulations, insurance needs or other safety code requirements. MANDATORY SAFETY SHUTDOWN PROCEDURE Before cleaning, lubricating or servicing this equipment: 1. Bring the machine to a full stop on 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 controls in NEUTRAL and set the park brake. 4. Idle the engine for gradual cooling. 5. Turn the key switch to OFF position and remove key (take key with you for security reasons). ONLY when you have taken these precautions can you be sure its safe to proceed. Failure to follow the above procedure could lead to serious personal injury or death. ! !

RS5-34 Telescopic Handler PERSONAL SAFETY PRINTED IN U.S.A. 100-2 913241 Alt= to hide template information Alt+ to display template information Template Name: OML_1_col 907871 Template Date: 1994_04_22 SAFETY RULES AND REMINDERS ● DO NOT start or operate the machine until you have read and understood the Operator’s Manual. You must become familiar with all operating controls, instruments and procedures before attempting operation or repair. ● If a service problem requires troubleshooting the machine under actual job site working conditions, unless you are totally familiar with the machine controls and operating procedures, have an experienced operator assist you. ● Always perform the Mandatory Safety Shutdown Procedure and relieve hydraulic circuit pressure before loosening or removing any hydraulic fittings or lines. ● If hydraulic cylinder repair is required, NEVER use pneumatic or hydraulic pressure to aid in cylinder disassembly. ● Always disconnect the battery before working on the electrical system. ● DO NOT start the machine from any position other than seated in the operator’s seat. ● If replacement parts are required, DO NOT use 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 regulations and safety requirements. Unauthorized modifications can cause serious injury or death. Anyone making such unauthorized modifications is solely responsible for the consequences. ● NEVER bypass (wire around) any safety switch or other safety device. Be sure all safety switches and devices are in proper working order before releasing the machine for operation. WARNING U.S. OSHA regulations require employers in general industry and the construction, shipyard and cargo-handling industries (excepting agricultural operations) to ensure that forklift operators are competent, as demonstrated by successful completion of a training course. The training course must consist of acombination of formal instruction and practical training, including both forklift- related and workplace-related topics, and evaluation of the operator’s performance in the workplace. All operator training and evaluation is to be conducted by persons who have the knowledge, training and experience to train and evaluate operators.

RS5-34 Telescopic Handler PERSONAL SAFETY PRINTED IN U.S.A. 100-3 913241 Alt= to hide template information Alt+ to display template information Template Name: OML_1_col 907871 Template Date: 1994_04_22 ● Always use good judgement, care and common sense. Be sure the work method, procedure and equipment you choose are safe for you and other persons. ● Be sure all doors, guards or shields removed to perform service are correctly installed before operating or releasing the machine for use. ● Never use fuel, gasoline, naptha or other volatile fluids for cleaning purposes. Use only approved cleaning solvents for cleaning. ● Never run the engine in a closed building. Proper ventilation is required under all circumstances. ● Keep shop floors clean. Wipe up fluid spills immediately to prevent falls and possible injury. ● Periodically inspect all lifting fixtures, chains and slings for damage. Never exceed the load rating of lifting fixtures, chains and slings. ● DO NOT use the machine stabilizers to lift and support the machine to perform service of any kind. Use only adequate jacks for lifting, and blocking or jack stands for support. NEVER rely on jacks alone to support the machine. ● Always wear appropriate personal safety gear as required by working conditions and regulations. DO NOT wear loose or baggy clothing while performing maintenance or service on the machine. ● Protect your eyes! Always wear safety glasses with side shields or a full face shield 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. Escaping fluid under pressure can be invisible and can penetrate the skin causing serious injury. If any fluid is injected into your skin, seek medical attention at once. Injected fluid must be surgically removed by a doctor familiar with this type of injury or gangrene may result. ● If any safety decals are missing, damaged or painted over, replace the decal. If parts are replaced that have safety decals, be sure to install a new decal. ● To prevent unexpected movement, securely block working elements when repairing or changing working tool parts such as cutting edges. ● Use extreme caution when removing radiator caps, drain plugs, grease fitting or pressure taps. Park the machine and let it cool down before opening a pressurized compartment. ● When inflating tires, use a self-attaching inflation chuck with remote shutoff and stand clear of the tire. ● When necessary to tow the machine, do not exceed the recommended towing speed. Be sure the towing machine has sufficient braking capacity to stop the towed load. If the towed machine cannot be braked, a tow bar must be used or two towing machines must be used - one in front pulling and one in the rear to retard. Avoid towing over long distances. ● Whenever servicing or replacing hardened pins, etc. use a brass drift or other suitable material between the hammer and pin.

RS5-34 Telescopic Handler PERSONAL SAFETY PRINTED IN U.S.A. 100-4 913241 Alt= to hide template information Alt+ to display template information Template Name: OML_1_col 907871 Template Date: 1994_04_22 MODIFICATIONS, NAMEPLATES, MARKINGS AND LOAD CAPACITIES Modifications and additions, that affect load capacity or safe operation shall NOT be performed without the manufacturer’s prior written approval. Where such authorization is granted, tags or decals shall be changed accordingly. All attachments MUST be marked to identify the attachment(s), show the approximate weight of the machine and attachment(s) combination, and the total load capacity with attachment(s) at maximum elevation with load laterally centered. Always make sure all nameplates, caution and instruction markings are in place and legible. Local government regulations may require local decals, which then become the responsibility of the local owner to provide. Study the Load Zone Charts carefully. They show the maximum capacity to be lifted and 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 any manner. Unauthorized modifications such as welding, drilling, cutting or adding components can weaken the structure and reduce its protective ability. If a ROPS is subjected to roll-over or other damage, it must be replaced. Do not attempt to repair a ROPS. PROTECT THE ENVIRONMENT Before you service this machine and before you dispose of the old fluids and lubricants, always remember the environment. DO NOT drain oil or fluids into the ground or into containers that can leak. Also, dispose of batteries and oil filters in accordance with local regulations. Check with your local environmental or recycyling center for correct disposal information. WARNING Construction equipment can be dangerous if improperly operated or maintained. This machine should be operated and maintained only by trained and experienced people who have read, understood and complied with the Operator’s Manual.

Gehl RS5-34, RS6-34 Telescopic Handlers OEM Service & Repair Manual

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