Genie GTH-1048, Service Manual

Page: 81 / 214

Section 4 • Repair Procedures March 2015
4 - 12 GTH-1048 • GTH-1056 Part No. 123701
How to Disassemble the Boom,
GTH-1048
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2,
Hydraulic Hose and
Fitting Torque Specifications.
1 Remove the extension cylinder. See 1-4, How
to Remove the Extension Cylinder.
2 Remove the boom. See 1-2, How to Remove
the Boom.
3 Select a lift cylinder. Remove the fasteners
securing the lift cylinder rod-end pivot pin to the
boom.
4 Using a lifting strap from an overhead crane,
support the lift cylinder. Do not apply any lifting
pressure.
5 Use a soft metal drift to remove the lift cylinder
rod-end pivot pin. Remove the cylinder from the
boom.
Crushing hazard. The cylinder
could become unbalanced and fall
if not properly supported when
removed from the machine.
6 Repeat this procedure beginning with step 3 for
the other lift cylinder.
7 Remove the fastener securing the fork level
cylinder rod-end pivot pin to the fork frame
mount.
8 Use a soft metal drift to remove the rod-end
pivot pin.
9 Attach a lifting strap from an overhead crane to
the barrel end of the fork level cylinder. Support
the cylinder. Do not apply any lifting pressure.
10 Tag, disconnect and plug the fork level cylinder
hoses from the cylinder manifolds. Cap the
fittings.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched
11 Remove the fasteners securing the fork level
cylinder barrel-end pivot pin to the boom.
12 Use a soft metal drift to remove the pivot pin.
Remove the cylinder from the boom.
Crushing hazard. The cylinder
could fall if not properly supported
when the pivot pin is removed
from the machine.
13 Remove the inspection cover at the pivot end of
the boom.
14 Remove the hose keepers from the hose roller
assembly.
Note: The hose keepers ensure that the hoses do
not jump off the hose rollers.
BOOM COMPONENTS