Genie GTH-636 Service Manual page 91

June 2007
REV C
How to Replace the Fork Rotate
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 fork until they
rest on the ground.
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 Attach a lifting strap from a second overhead
crane to the barrel end of the fork level cylinder.
Support the cylinder. Do not apply any lifting
pressure.
6 Remove the fasteners securing the level
cylinder rod end pivot pin to the lifting fork
frame.
7 Use a soft metal drift to remove the pivot pin.
Crushing hazard. The cylinder
could fall if not properly supported
when the pivot pin is removed
from the machine.
Crushing hazard. The lifting fork
frame could fall if not properly
supported when the pivot pin is
removed from the machine.
8 Raise the fork level cylinder enough to access
the supply hoses at the inside of the boom
gooseneck.
Note: It may be necessary to tilt the fork frame
away from the boom to provide room to raise the
cylinder.
Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056
Section 4 • Repair Procedures
9 Tag, disconnect and plug the fork rotate
cylinder supply hoses at the fittings inside the
boom gooseneck. Cap the fittings.
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.
10 Remove the clamp securing the hoses to the
front of the boom.
11 Tag, disconnect and plug the hydraulic hoses
from the hydraulic hard lines at the bulkhead
under the number 1 boom tube. Cap the hard
lines.
c
a b
a boom tube number 3
b boom tube number 2
c boom tube number 1
12 Securely connect a 30 foot / 10 m length of rope
to each end of the hoses disconnected in steps
9 and 11. Securely tie off the other end of each
section of rope to the boom structure.
13 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.
BOOM COMPONENTS
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