Genie Z80/60 Service Manual page 150

Section 4 • Repair Procedures
BOOM COMPONENTS
3 Remove the fasteners securing the cable track
trays and cable track clamps to the secondary
extension boom.
4 Remove the external snap rings from the
extension cylinder rod-end pivot pin.
5 Use a soft metal drift to remove the pin.
6 Remove the access cover from the platform
end of the secondary boom.
7 Working at the platform end, place blocks under
the barrel end of the secondary boom extension
cylinder for support.
8 Remove the barrel-end retaining fasteners.
9 Using a suitable lifting device, lift the extension
cylinder to clear the saddle blocks
10 Support and slide the extension cylinder out of
the boom extension and place it on a structure
capable of supporting it.
Crushing hazard. The secondary
boom extension cylinder could
become unbalanced and fall if not
properly supported when removed
from the machine.
Component damage hazard.
When removing the secondary
boom extension cylinder from the
machine, be careful not to damage
the counterbalance valves at the
barrel end of the cylinder.
Component damage hazard.
Cables and hoses can be
damaged if the cylinder is pulled
across them.
4 - 48
11 Tag, disconnect and plug the secondary boom
extension cylinder hydraulic hoses. Cap the
fittings on the cylinder.
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.
12 Remove the cable track fasteners and cable
track support tubes from the extension cylinder.
Component damage hazard. Be
careful not to damage the
secondary boom retract limit
switch when installing the cylinder
assembly into the secondary
boom. Secure the roller arm to the
switch body during assembly.
Z-80/60
June 2011
REV D
Part No. 88619