How To Remove A Mast Assembly - Genie DPL-25S Service Manual

Section 7 - Repair Procedures
MAST ASSEMBLY
4-2

How to Remove a Mast Assembly

This procedure requires specific
repair skills, lifting equipment and
a suitable workshop. Attempting
this procedure without these skills
and tools may result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
1 Remove the platform. See 5-1, How to Remove
the Platform.
2 Remove the cross braces (X pattern) from the
mast assemblies.
3 Remove the sequencing cable adjustment nut
from each cable.
4 Loosen the sequencing cable pulley mounting
bolts. Do not remove them.
Mast assembly - steer handle end:
5 Remove the junction box from the mast.
Mast assembly - ladder end:
5 Remove the electrical cable mounting clamps
from the side of the mast.
Remove the junction box and electrical cable
from the side of the mast.
Remove the ladder upper mounting bolts.
Mast assembly - both:
6 Attach an overhead crane to the mast.
7 Remove the base-end cover to access the
hydraulic hoses.
7 - 16 DPL-25S • DPL-30S • DPL-35S Super Series
8 Tag, disconnect and cap the lift cylinder
hydraulic hoses. Remove the flow control valve
from the cylinder. Plug the cylinder ports.
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.
9 Remove the strut mounting fasteners.
10 Remove the four mast mounting fasteners.
Push the fasteners toward the mast for
clearance during mast removal.
11 Carefully lift and remove the mast. Do not
damage the lift cylinder hydraulic fittings when
removing the mast.
Crushing hazard. The mast will fall
unless it is properly supported.
12 Place two saw horses under the mast.
13 Lower the bottom of the mast onto one saw
horse and continue to lower the mast until the
top is resting on the second saw horse. The
mast should be resting on the carriage side.
How to Disassemble the Mast
This procedure requires specific
repair skills, lifting equipment and
a suitable workshop. Attempting
this procedure without these skills
and tools may result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
1 Remove the mast. See How to Remove a Mast
Assembly.
2 Remove the mounting fasteners from the
cylinder mounting plates.
September 2016
Part No. 40462