Genie Z-30/20N Service Manual page 66

Section 4 • Repair Procedures
PRIMARY BOOM COMPONENTS
11 Attach a lifting strap of ample capacity from an
overhead 5 ton / 5000 kg crane to the primary
boom for support.
12 Locate the cables from the primary boom cable
track to the platform control box. Number each
cable and its entry location at the platform
control box.
13 Open the platform control box.
14 Tag and disconnect each wire from the cables in
the platform control box.
15 Pull all the cables out of the platform control
box.
16 Remove the front counterweight cover.
17 Remove the extension boom drive limit switch
from the side of the primary boom at the pivot
end. Do not disconnect the wiring.
18 Tag, disconnect and plug the hydraulic hoses
from the jib boom/platform rotate manifold.
19 Pull all the electrical cables and hydraulic hoses
out of the plastic cable track. Then pull all the
electrical cables and hydraulic hoses out
through the boom rest pad.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
20 Remove the pin retaining fastener from the
master cylinder rod-end pivot pin. Use a soft
metal drift to remove the pivot pin. Pull the
cylinder back and secure it from moving.
4 - 16 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N
21 Tag, disconnect and plug the 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.
22 Attach a lifting strap from an overhead crane to
the primary boom lift cylinder.
23 Place 2 x 4 x 18 inch / 5 x 10 x 46 cm support
blocks under the cylinder, across the secondary
boom.
24 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 primary
boom lift cylinder could fall when it
is removed from the machine if not
properly supported.
25 Lower the rod end of the primary boom lift
cylinder onto support blocks. Protect the
cylinder rod from damage.
26 Remove the pin retaining fastener from the
primary boom pivot pin.
27 Remove the primary boom pivot pin with a soft
metal drift. Carefully remove the primary boom
assembly from the machine.
Crushing hazard. The primary
boom assembly could become
unbalanced and fall when
removed from the machine if not
properly supported by the
overhead crane.
June 2011
REV A
Part No. 139378