Genie GTH-636 Service Manual page 89

June 2007
REV C
How to Replace the Fork Level
Cylinder Hoses
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 Fully retract the boom.
2 Fully lower the tips of the lifting forks.
3 Remove the covers from both ends of the
boom.
4 Attach a lifting strap from an overhead crane to
the top of the lifting fork frame. Support the
frame. Do not apply any lifting pressure.
5 Tag, disconnect and plug the fork level cylinder
supply hoses at the cylinder manifold. Cap the
fittings on the manifold.
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.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
6 Tag, disconnect and plug the hydraulic hoses
from the hydraulic hard lines at the top of the
number 1 boom tube. Cap the hard lines.
a c
b
a boom tube number 3
b boom tube number 2
c boom tube number 1
Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056
Section 4 • Repair Procedures
7 Securely connect a 30 foot / 10 m length of rope
to each end of the hoses disconnected in steps
5 and 6. Securely tie off the other end of each
section of rope to the boom structure.
8 Working at the pivot end of the boom, select
one of the hoses. Pull the hose out of the boom.
Note: Rope coming loose from either end of the
hose or the boom during hose removal may result
in a difficult reassembly. Be sure each section of
rope is securely attached to both the hose and the
boom structure before pulling the hose out of the
boom.
9 Remove the rope from each end of the hose.
Discard the hose.
10 Securely install a section of rope onto each end
of the new hose assembly.
11 Install the new hose assembly into the boom by
routing the hose over the roller at the pivot end
of the boom. Using the rope, carefully pull the
hose through the boom until each end is
accessible.
12 Install both ends of the hose assembly onto the
correct connection points. Torque to
specification. Refer to Section 2, Specifications .
13 Repeat this procedure for the remaining hose to
be replaced, beginning with step 8.
14 Remove the lifting strap from the fork frame.
15 Install the covers onto the front and rear of the
boom. Install and securely tighten the retaining
fasteners.
16 Bleed the fork level circuit. See 1-3, How to
Bleed the Lift/Tilt Circuit .
BOOM COMPONENTS
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