Genie Z80/60 Service Manual page 136

Section 4 • Repair Procedures
BOOM COMPONENTS
How to Remove the Primary
Boom
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: Perform this procedure with the boom in the
stowed position.
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 Remove the jib boom. See 3-1, How to Remove
the Jib Boom.
2 Remove the fasteners securing the limit switch
to the primary boom at the pivot end of the
boom. Do not disconnect the wiring. Move the
limit switch to a safe location.
3 Tag and disconnect the wire harness from the
primary boom angle sensor (PBAS).
Note: The primary boom angle sensor is located
inside the primary boom at the pivot end.
4 - 34
4 Tag, disconnect and plug the primary boom
extension cylinder hydraulic hoses. Cap the
fittings on the cylinder. Tag, disconnect and
plug the hydraulic hoses routed through the
primary boom at the union.
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 Attach a lifting strap from an overhead crane to
the barrel end of the primary boom lift cylinder.
6 Remove the pin retaining fasteners from the
primary boom lift cylinder barrel-end pivot pin.
7 Place blocks under both ends of the primary
boom lift cylinder for support.
8 Use a soft metal drift to remove the barrel-end
pivot pin. Rest the barrel end of the primary
boom cylinder on the blocks.
Crushing hazard. The primary
boom could become unbalanced
and fall if not properly supported
when the pivot pin is removed.
9 Attach a lifting strap from an overhead crane to
the primary boom lift cylinder linkage arm.
Support the arm.
10 Remove the pin retaining fasteners from the
primary boom lift cylinder linkage arm where it
connects to the primary boom.
Z-80/60
June 2011
REV D
Part No. 88619