Genie S-80 Service Manual page 120

Section 4 • Repair Procedures
BOOM COMPONENTS
17 Visually inspect the cable break limit switch arm
to be sure the wheel of the limit switch arm is
centered in the notch of the pivot plate.
Note: If the boom extend cables are adjusted
evenly, the wheel of the limit switch arm should be
centered in the notch of the pivot plate.
a
b c
Illustration 2
a cable break limit switch
b extend cable adjustment nut
c extend cable pivot plate
18 Install the boom end cover at the pivot end of
the boom.
19 Fully retract and lower the boom to the stowed
position.
4 - 30
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. See
Section 4-4, 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.
S-80 • S-85 • S-80X
February 2012
Part No. 122985