Genie GTH-844, Service And Repair Manual

Page: 43 / 187

April 2017 Service and Repair Manual
Boom Components
Part No. 1272854 GTH-844 31
How t o R eplac e t he F or k Level C yli nder and/ or Auxili ar y H oses
How to Replace the Fork Level
Cylinder and/or Auxiliary Hoses
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications,
Hydraulic Hose and Fitting Torque
Specifications.
1 Fully retract the boom.
2 Fully lower the tips of the lifting forks.
3 Remove the cover from the fork end of the
boom.
4 Attach a lifting strap from an overhead crane to
the top of the lifting fork frame. Support the
frame. Do not apply any lifting pressure.
5 Disconnect and plug the fork level cylinder
supply hoses at the cylinder manifold or the
auxiliary supply hoses at the quick connect
fittings. 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.
6 Working near the center of the boom
assembly, tag, disconnect and plug the
hydraulic hoses from the hydraulic hard lines
under boom tube number number 1. Cap the
hard lines.
7 Securely connect a 30 feet / 10 m length of
rope to each end of the hoses disconnected in
steps 5 and 6. Securely tie off the other end of
each section of rope to the boom structure.
8 Remove the hose clamp at the fork end of the
boom by loosening the hose clamp bolt located
on the top of the boom.
9 Remove the cover from the pivot end of the
boom and remove the hose sheave cover.
1 hose sheave cover
2 cover retaining bolts
Note: Partial extension of the boom on some
machines may be necessary to access the sheave
cover fasteners.