Terex Genie Z-40, Service And Repair Manual

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Service and Repair Manual June 2022
Primary Boom Components
38 Z ® -62/40 Part No. 1268555GT
4-4 Pri mar y Boo m Extensi on Cylin der 4-4
Primary Boom Extension
Cylinder
The primary boom extension cylinder extends and
retracts the primary boom extension tube.The
primary boom extension cylinder is equipped with
counterbalance valves to prevent movement in the
event of a hydraulic line failure.
How to Remove the Primary
Boom Extension Cylinder
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 (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 Raise the primary boom to a horizontal
position.
2 At the pivot end of the boom, remove the
cover from the end of the #1 boom tube.
3 At the pivot end of the boom, remove the
retaining fasteners and blocks securing the
extend cylinder to the #2 boom tube through
the access holes in the #1 boom tube.
4 Extend the primary boom until the primary
boom extension cylinder rod-end pivot pin is
accessible in the primary boom extension
tube.
5 Tag, disconnect and plug the primary boom
extension cylinder hydraulic hoses. Cap the
fittings on the cylinder.
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.
6 At the platform end of the boom, remove the
external snap rings from the extension
cylinder rod-end pivot pin. Use a soft metal
drift to remove the pin.
7 At the pivot end of the boom, remove the
retaining fasteners and blocks securing the
extend cylinder to the #1 boom tube'
8 Support and slide the extension cylinder out
of the primary boom.
Crushing hazard. The extension
cylinder could fall when removed
from the extension boom if not
properly supported.
Component damage hazard. Be
careful not to damage the
counterbalance valves on the
primary boom extension cylinder
when removing the cylinder from
the primary boom.
Component damage hazard.
Hoses and cables can be
damaged if the primary boom
extension cylinder is dragged
across them.
Note: Note the length of the cylinder after removal.
The cylinder must be at the same length for
installation.