Genie GTH-636 Service Manual page 92

Section 4 • Repair Procedures
BOOM COMPONENTS
14 Remove the rope from each end of the hose.
Discard the hose.
15 Securely install a section of rope onto each end
of the new hose assembly.
16 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.
17 Install both ends of the hose assembly onto the
correct connection points. Torque to
specification. Refer to Section 2, Specifications .
18 Repeat this procedure for the remaining hose to
be replaced, beginning with step 13.
19 Install the fork level cylinder. Use a soft metal
drift to install the cylinder pivot pins.
20 Install and securely tighten all pivot pin retaining
fasteners.
21 Remove the lifting strap from the fork frame and
fork level cylinder.
22 Install the covers onto the front and rear of the
boom. Install and securely tighten the retaining
fasteners.
Bleed the Fork Rotate Circuit:
23 Start the engine and warm to operating
temperature.
24 Looking from the cab towards the front of the
boom, fully rotate the lifting fork frame in a
clockwise direction. Turn the engine off.
25 Disconnect the hydraulic hose with the straight
connector end fitting from the cylinder manifold.
26 Securely install a 24 inch / 60 cm hose
extension into the hose disconnected in step
25. Place the other end of the hose into a
suitable container to collect hydraulic fluid.
4 - 22 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056
27 Start the engine and activate the fork rotate
counter clockwise function until a steady stream
of oil without air bubbles is flowing from the
bleeder hose.
Note: This removes residual air from the barrel end
of the cylinder circuit.
28 Looking from the cab towards the front of the
boom, fully rotate the lifting fork frame in a
clockwise direction. Turn the engine off.
29 Remove the hose extension from the hose.
30 Install the hose with the straight connector end
fitting onto the cylinder manifold. Torque to
specification. Refer to Section 2, Specifications .
31 Disconnect the hydraulic hose with the 90°
connector end fitting from the cylinder manifold.
32 Securely install a 24 inch / 60 cm hose
extension into the hose disconnected in step
31. Place the other end of the hose into a
container to collect hydraulic fluid.
33 Start the engine and activate the fork rotate
clockwise function until a steady stream of oil
without air bubbles is flowing from the bleeder
hose.
Note: This removes residual air from the rod end of
the cylinder circuit.
34 Looking from the cab towards the front of the
boom, fully rotate the lifting fork frame in a
counter clockwise direction. Turn the engine off.
35 Remove the hose extension from the hose.
36 Install the hose with the 90° connector end
fitting onto the cylinder manifold. Torque to
specification. Refer to Section 2, Specifications .
37 Remove the lifting strap from the fork frame.
June 2007
REV C
Part No. 97487