Terex Genie S-60 HF, Service And Repair Manual

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April 2021 Service and Repair Manual
Boom Components
Part No. 1288652GT S ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™ 57
How to Replace the Boom
Extend/Retract Cables
Note: The cable pulleys must also be replaced
when replacing the cables.
1 Remove the boom extension cylinder. Refer
to Repair Procedure, How to Remove the
Boom Extension Cylinder
.
Boom extend cables:
2 Remove the cables from the lower boom
extend cable bracket that attaches to the
number 3 boom tube.
3 Remove the rue rings and clevis pins from the
boom extend cables located near the extend
cable break limit switch.
4 Remove the external snap rings from the
boom extend cable pulley pivot pin. Use a soft
metal drift to remove the pin.
Note: When driving the pivot pin out, be sure to
drive it from the shaped end of the pin.
5 Remove the pulley and boom extend cables
from the extension cylinder assembly. Discard
the old cables and pulleys.
6 Route the new boom extend cables through
the boom extend pulley bracket.
7 Install the new boom extend cable pulley,
pivot pin and snap rings.
Note: Be sure the boom extend cables are routed
through the grooves of the pulley and the upper
wear pad on the extension cylinder.
8 Install the boom extend cable clevis pins and
rue rings to the pivot plate near the cable
break limit switch.
9 Install the boom extend cables to the lower
extend cable bracket that mounts to the
number 3 boom tube.
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.