Genie S-80 Service Manual page 117

February 2017
9 Slowly operate the overhead crane to apply
tension to the lifting straps. Do not attempt to
lift the machine with the overhead crane.
10 Locate and remove the counterweight
retaining fastener at the center of the
counterweight. Carefully lift the counterweight
upwards and remove the counterweight from
the machine. Set the counterweight on the
ground. Do not leave the counterweight
suspended above the ground.
Crushing hazard. The turntable
counterweight will fall if not
properly supported by the
overhead crane resulting in
death or serious injury. Keep
personnel away from the area
when removing the
counterweight.
11 Attach lifting straps from a 5 ton / 5000 kg
overhead crane to each end of the boom.
Support the boom. Do not apply any lifting
pressure.
12 Support and secure the rod end of the boom
lift cylinder to a second overhead crane or
similar lifting device.
13 Remove the lift cylinder rod-end pivot pin
retaining fasteners. Use a soft metal drift to
remove the pin.
Crushing hazard. The boom
could fall if not properly
supported when the lift cylinder
rod-end pivot pin is removed.
Part No. 1259369GT
14 Using auxiliary power, activate the boom down
function so the cylinder will retract. Retract the
cylinder just enough until the rod end of the
cylinder will clear the mounting bracket on the
boom. Turn the machine off.
15 Using the overhead crane, carefully lower the
boom lift cylinder and allow it to rest on the
boom rest pad. Protect the cylinder rod from
damage.
16 Remove the boom end cover retaining
fasteners and remove the cover.
17 Tag, disconnect and plug the boom extension
cylinder hydraulic hoses. Cap the fittings on
the cylinder.
18 Tag and disconnect the electrical connector
for the cable break limit switch.
19 Tag and disconnect all boom wire harness
electrical connectors located at the pivot end
of the boom.
S-80 • S-85 • S-80X
Service Manual
Boom Components
Crushing hazard. The boom lift
cylinder could fall if not properly
supported and secured to the
lifting device.
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.
97