Extension Cylinders - Genie S-105 Service Manual

June 2011
REV A
4-4

Extension Cylinders

The primary boom extension cylinder is located
inside the boom assembly and incorporates cables
and pulleys that are responsible for extending the
number 2 and 3 boom tubes. The secondary boom
extension cylinder (S-120 and S-125 models) is
located underneath the number 0 boom tube and is
responsible for extending the number 1 boom tube.
The extension cylinders are equipped with
counterbalance valves to prevent movement in the
event of a hydraulic line failure.
How to Remove the Primary
Boom Extension Cylinder
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: 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 Two, Hydraulic Hose and Fitting
Torque Specifications.
1 Raise the boom to a horizontal position.
2 Remove the retaining fasteners from the boom
end cover at the pivot end of the boom.
Remove the cover from the machine.
Part No. 102916
3 Remove the access cover retaining fasteners
from both sides of the boom. Remove the
access covers.
4 Secure the number 2 and number 3 boom tubes
together with a strap or chain to prevent them
from moving.
5 Remove the cable clamp from the cable break
limit switch wiring.
6 Disconnect the wiring connector from the cable
break limit switch.
7 Tag, disconnect and plug the hydraulic hoses
from the primary boom extension cylinder. Cap
the fittings on the cylinder.
S-100 • S-105 • S-120 • S-125
Section 4 • Repair Procedures
BOOM COMPONENTS
a cable break limit switch
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.
a
4 - 45