Genie Z-45/25 Bi-Energy Service Manual page 78

Section 4 • Repair Procedures
PRIMARY BOOM COMPONENTS
4 Remove the cable track. See 4-1, How to
Remove the Cable Track.
5 Raise the primary boom to a horizontal position.
6 Remove the hose and cable cover from the
upper pivot.
7 Remove the pin retaining fastener from the
master cylinder barrel-end pivot pin. Use a soft
metal drift to remove the pin. Then lower the
cylinder and let it hang down.
Component damage hazard.
When lowering the master cylinder
down, be sure not to damage the
master cylinder hoses or fittings.
8 Locate the primary boom drive speed limit
switch inside of the upper pivot.
9 Remove the primary boom drive speed limit
switch mounting fasteners. Do not disconnect
the wiring.
10 Locate the primary boom extension drive speed
limit switch inside of the extension boom.
11 Remove the primary boom extension drive
speed limit switch mounting fasteners. Do not
disconnect the wiring.
12 Pull the limit switch and the wiring out of the
extension tube and move it out of the way.
13 Tag, disconnect and plug the primary boom
extension cylinder hydraulic hoses. Cap the
fittings on the cylinder.
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.
4 - 14 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy
14 Remove the hose clamp at the pivot end of the
boom.
15 Attach a 5 ton / 5,000 kg overhead crane to the
center point of the primary boom.
16 Attach a similar lifting device to the primary
boom lift cylinder.
17 Place support blocks under the primary boom
lift cylinder.
18 Remove the pin retaining fastener from the
primary boom lift cylinder rod-end pivot pin. Use
a soft metal drift to remove the pin.
Crushing hazard. The boom lift
cylinder and primary boom will fall
if not properly supported.
19 Lower the rod end of the primary boom lift
cylinder onto support blocks. Protect the
cylinder rod from damage.
20 Remove the pin retaining fastener from the
primary boom pivot pin.
21 Remove the primary boom pivot pin with a soft
metal drift, then carefully remove the primary
boom from the machine and place it on a
structure capable of supporting it.
Crushing hazard. The primary
boom could become unbalanced
and fall when removed from the
machine if not properly attached to
the overhead crane.
July 2004
REV A
Part No. 106488