Hydraulic Hoses; How To Replace The Fork Level And/Or Auxiliary Cylinder Hoses, Gth-1056 - Genie GTH-1056 Service And Repair Manual

Service and Repair Manual
Boom Components
1-6

Hydraulic Hoses

How to R eplac e the F or k Level and/or Auxili ar y C yli nder H oses, GTH-1056
How to Replace the Fork Level
and/or Auxiliary Cylinder Hoses,
GTH-1056
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
Replace the lower 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.
34
7 Working near the center of the boom
assembly, tag, disconnect and plug the
hydraulic hoses from the hydraulic hard lines
under boom tube number number 1. Cap the
hard lines.
8 Securely connect a 30 feet / 10 m length of
rope to the end of each hose disconnected in
steps 6 and 7. Securely tie off the other end of
each section of rope to the boom structure.
9 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.
10 Remove the rope from the hose. Discard the
hose.
11 Securely install a section of rope onto the
correct end of the new hose assembly.
12 Install the new hose assembly into the boom
by routing the hose under the roller at the pivot
end of the boom. Using the rope, carefully pull
the hose through the boom until the end is
accessible.
13 Install both ends of the hose assembly onto the
correct connection points. Torque to
specification. Refer to Specifications.
14 Repeat this procedure for the remaining hose
to be replaced, beginning with step 8.
15 Install the cable bridge rear mount bracket
onto the cable bridge and the boom assembly.
Securely tighten the fasteners. Do not over
tighten.
16 Remove the lifting strap from the fork frame.
17 Install the cover onto the rear of the boom.
Install and securely tighten the retaining
fasteners.
GTH-1056
April 2017
Part No. 1278145