Genie S-80 Service Manual page 112

Section 4 • Repair Procedures
BOOM COMPONENTS
3 Raise the boom until the short and long link arm
to boom pivot pins are above the turntable
covers.
4 Place a block of wood measuring
4 x 4 x 60 inches / 10 x 10 x 152 cm under the
long link arm, across the turntable covers.
5 Slowly lower the boom until the long link arm
contacts the wood block. Do not rest the entire
weight of the boom on the block. Turn the
machine off.
Component damage hazard. The
turntable covers can become
damaged if the weight of the boom
is allowed to rest on the block.
6 Place wood blocks between the short link arm
and the turntable weldment for support.
7 Insert a 1.125 x 12 inches / 32 x 300 mm
eye-bolt through each hole located on the top
surface of the counterweight. Secure the eye-
bolts in position with flat washers and nuts.
8 Securely attach lifting straps or chains with a
minimum rating of 5 tons / 5000 kg to the lifting
points on the top of the turntable counterweight.
Attach the lifting straps or chains to a
5 ton / 5000 kg overhead crane.
Note: A spreader bar and other hardware may be
needed to safely remove the counterweight.
4 - 22
9 Slowly operate the overhead crane to apply
tension to the lifting straps. Do not attempt to lift
the machine with the overhead crane.
10 Locate and remove the counterweight retaining
fastener at the center of the counterweight.
Carefully lift the counterweight upwards and
remove the counterweight from the machine.
Set the counterweight on the ground. Do not
leave the counterweight suspended above the
ground.
11 Attach lifting straps from a 5 ton / 5000 kg
overhead crane to each end of the boom.
Support the boom. Do not apply any lifting
pressure.
12 Support and secure the rod end of the boom lift
cylinder to a second overhead crane or similar
lifting device.
13 Remove the lift cylinder rod-end pivot pin
retaining fasteners. Use a soft metal drift to
remove the pin.
S-80 • S-85 • S-80X
February 2012
Crushing hazard. The turntable
counterweight will fall if not
properly supported by the
overhead crane resulting in death
or serious injury. Keep personnel
away from the area when
removing the counterweight.
Crushing hazard. The boom could
fall if not properly supported when
the lift cylinder rod-end pivot pin is
removed.
Part No. 122985