Genie GTH-636 Service Manual page 74

Section 4 • Repair Procedures
BOOM COMPONENTS
How to Remove the 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: 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 lifting fork. See 1-2, How to
Remove the Lifting Fork .
2 Tag, disconnect and plug the two large
hydraulic hoses from the manifolds of the
extension cylinder. Cap the fittings on the
manifolds.
GTH-644, GTH-842 and GTH-844:
3 Tag, disconnect and plug the hydraulic hoses
from the hydraulic hard lines adjacent to the
extension cylinder at the pivot end of the boom.
Cap the fittings on the hard lines.
4 Remove the fasteners and clamps securing the
hydraulic hoses, disconnected in steps 2 and 3,
to the boom. Lay the hoses off to the side.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
4 - 4 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056
a c
b
e
f
3-section boom
a boom tube number 3
b boom tube number 2
c boom tube number 1
d extension cylinder retaining pin
e extension cylinder support loop
f extension cylinder rod end nut
GTH-636, GTH-1048 and GTH-1056:
5 Tag, disconnect and plug the remaining boom
supply hoses at the respective manifolds. Cap
the fittings on the manifolds.
All models:
6 Attach a lifting strap from an overhead
10 ton / 10,000 kg crane to the boom. Support
the boom. Do not apply any lifting pressure.
7 Select a boom lift cylinder. Attach a lifting strap
from an overhead 1 ton / 1000 kg crane to the
cylinder. Support the cylinder. Do not apply any
lifting pressure.
8 Remove the fasteners securing the lift cylinder
rod end pivot pin to the boom.
a lift cylinder
b rod end pivot pin
c barrel end pivot pin
June 2007
REV C
d
a
b
c
Part No. 97487