Terex Genie Z-45 DC, Service And Repair Manual, Page: 43 / 140

July 2020
Part No. 1297714GT Z ® -45 DC • Z ® -45 FE 33
Service and Repair Manual
The primary boom lift cylinder raises and lowers
the primary boom. The primary boom lift cylinder is
equipped with a counterbalance valve to prevent
movement in the event of a hydraulic line failure.
WARNING
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 Raise the secondary boom until the primary
boom lift cylinder barrel-end pivot pin is above
the turntable covers.
3 Attach a 5 ton / 5000 kg overhead lifting device
to the primary boom for support.
4 Raise the primary boom with the overhead
lifting device slightly to take the pressure off the
primary boom lift cylinder pivot pins.
5 Support the rod end and the barrel end of
the primary boom lift cylinder with a second
overhead lifting device or similar supporting
device.
6 Tag, disconnect and plug the primary boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
WARNING
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.
7 Remove the pin retaining fasteners from the
primary boom lift cylinder rod-end pivot pin.
Use a soft metal drift to remove the pin.
WARNING
Crushing hazard. The primary
boom will fall if not properly
supported when the primary
boom rod-end pivot pin is
removed.
8 Place a support block across both turntable
covers under the primary boom lift cylinder.
9 Lower the rod end of the lift cylinder onto the
block. Protect the cylinder rod from damage.
WARNING
Crushing hazard. The primary
boom lift cylinder could become
unbalanced and fall if not
properly supported by the lifting
device.
10 Remove the primary boom lift cylinder barrel-
end pivot pin retaining fasteners. Do not
remove the pin.
11 Use a slide hammer to remove the barrel-end
pivot pin. Carefully remove the primary boom
lift cylinder from the machine.
Primary Boom Components