Genie S-60 HC, Service Manual

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4 - 34 S-60 • S-65 • S-60 TRAX • S-65 TRAX Part No. 147753
S-60 HC • S-60X • S-60XC
December 2013 Section 4 • Repair Procedures
Boom retract cables:
10 Remove the cotter pins and clevis pins from the
boom retract cables at the platform end of the
boom.
Note: Always use a new cotter pin when installing a
clevis pin.
11 Remove the wear pad fasteners from the upper
wear pads on the number 1 boom tube. Remove
the wear pads.
Note: Pay attention to the location of each wear
pad and the quantity of shims for each one.
12 Attach a lifting strap from an overhead crane to
the platform end of the boom.
13 Raise the boom using the overhead crane and
place a wood block under the number 2 boom
tube between the number 1 and number 2 boom
tubes for support. This will create clearance
between the boom tubes to remove the retract
cables.
14 Attach the cable pulling tool or a rope to one of
the boom retract cables at the pivot end of the
boom.
Note: A cable pulling tool is available through Genie
Service Parts Department (Genie part no. 94510)
15 At the platform end of the boom, pull on the
boom retract cable that has the rope attached
to it.
16 Pull the old cable completely out of the boom
tube. Remove the rope. Discard the old boom
retract cable.
17 Securely attach the rope to the same end of the
new boom retract cable.
18 At the pivot end of the boom, carefully pull the
rope with the new retract cable attached.
19 Pull the new cable towards the pivot end of the
boom until the end of the cable is at the end of
the boom tube. Remove the rope.
20 Repeat steps 14 through 19 for the other boom
retract cable.
21 At the platform end of the boom, install the
retract cables, clevis pins and new cotter pins
to the adjustment plate.
22 Remove and discard the old boom retract
pulleys from the pivot end of the boom
extension cylinder.
23 Install the new boom retract pulleys to the pivot
end of the boom extension cylinder.
24 Install the boom extension cylinder assembly
into the boom.
Note: Before lowering the extension cylinder into
the saddles of the number 1 boom tube, wrap the
boom retract cables around the pulleys.
25 Adjust the boom extend/retract cables.
See 4-5, How to Adjust the Boom Extend/
Retract Cables.
BOOM COMPONENTS