Genie S-80 Service Manual page 121

February 2017
9 Remove the fasteners from the retaining
blocks from the extension cylinder saddle.
Remove the blocks.
Note: Access the fasteners through the access
hole in the outer boom tube at the pivot end.
10 Disconnect the wire connector to the extend
cable break limit switch.
11 Remove the retaining fasteners that secure
the extend cable mounting plates to the inside
of the number 1 boom tube.
1 extend cable lock nuts
2 extend cable mounting plate
3 extend cable mounting plate fastener
4 extend cable bracket
12 Pull back on the extend cable mounting plate
until it clears the blocks welded to the inside of
the number 1 boom tube.
Part No. 1259369GT
13 Lift up the extend cable mounting plate and
push the extend cables towards the platform
to create slack in the cables. Rest the cable
and bracket assembly on top of the extend
cylinder.
14 Locate the lower extend cable bracket on the
bottom of the number 3 boom tube.
15 Remove the lower extend cable bracket
mounting fasteners and pull back on the
bracket to release it from the number 3 boom
tube.
16 While pushing the lower extend cable bracket
towards the platform, pull the extend cable
mounting plate towards the pivot end of the
boom.
17 Secure the extend cable bracket and cables to
the cylinder to prevent them from falling off
when removing the cylinder.
18 Remove the external snap rings from the
extension cylinder pin at the pivot end of the
boom.
19 Use a soft metal drift to remove the pin.
20 Tag, disconnect and plug the boom extension
cylinder hydraulic hoses. Cap the fittings on
the cylinder.
21 Attach a lifting strap from a 5 ton / 5000 kg
overhead crane to the lug at the rod end of the
boom extension cylinder.
S-80 • S-85 • S-80X
Service Manual
Boom Components
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.
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