Genie GTH-1048 Service Manual page 91

Section 4 • Repair Procedures
BOOM COMPONENTS
Replace the upper hoses:
1 Fully retract the boom.
2 Fully lower the tips of the lifting forks.
3 Remove the covers from the pivot end 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 Working at the pivot end of the boom, remove
the fasteners securing the cable bridge rear
mount bracket to the boom assembly. Remove
the bracket from the boom.
6 Tag, disconnect and plug the hydraulic hoses at
the hard lines of the cable bridge. 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.
7 Return the cable bridge to its original position.
8 Working at the fork end of the boom, tag,
disconnect and plug the fork level cylinder
hoses at the cylinder manifolds. Cap the fittings.
9 Models with auxiliary function: Working at
the fork end of the boom, tag, disconnect and
plug the auxiliary hoses at the fittings. Cap the
fittings.
4 - 22
10 Working at the fork end of the boom, remove
the fasteners securing the cable bridge slider to
the cable bridge. Remove the slider from the
boom.
Note: Pay attention to how the hoses are routed
before removing the slider from the boom.
Note: During reassembly, it may be helpful to use
tape to secure the bolts to the cable bridge when
installing the cable bridge slider.
11 Remove the fasteners securing the cable track
to the cable track mount bracket.
12 Remove the fasteners securing the cable track
mount bracket to the cable bridge. Remove the
bracket from the boom.
13 Carefully pull the cable track through the
opening at the front of boom until the hose
connections are accessible.
14 Tag, disconnect and plug the affected hoses.
Cap the fitting. Remove the hose from the cable
track.
15 Install the new hose assembly and torque to
specification. Refer to Section 2, Specifications .
16 Install the cable bridge and cable track into the
boom.
17 Install the cable track mount bracket and cable
bridge slider. Securely tighten all fasteners. Do
not over tighten.
18 Working at the pivot end of the boom, install the
hydraulic hoses onto the hard lines of the cable
bridge and torque to specification. Refer to
Section 2, Specifications .
19 Install the cable bridge mount bracket onto the
cable bridge and the boom assembly. Securely
tighten all fasteners. Do not over tighten.
20 Install the cover onto the rear of the boom.
Install and securely tighten the retaining
fasteners.
GTH-1048 • GTH-1056
March 2015
Part No. 123701