Terex Genie Z-45/25 Bi-Energy, Service Manual

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4 - 18 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 237062
September 2015 Section 4 • Repair Procedures
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 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 Raise the primary boom to a horizontal position.
2 Extend the primary boom until the primary boom
extension cylinder rod-end pivot pin is
accessible in the primary boom extension tube.
3 Remove the hose and cable guard from the
upper pivot.
4 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.
5 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.
6 Remove the barrel-end pivot pin retaining
fasteners.
7 Place a rod through the barrel-end pivot pin and
twist to remove the pin.
8 Support and slide the extension cylinder out of
the upper pivot.
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.
PRIMARY BOOM COMPONENTS