Genie S-80 Service Manual page 171

Section 7 - Repair Procedures
BOOM COMPONENTS
S-85 Models: Remove the jib boom. See 3-1,
How to Remove the Jib Boom.
3 Remove the mounting fasteners from the
counterbalance valve manifold on the end of
the boom. Then remove the manifold and set it
aside.
4 Remove the drive speed limit switch
mounted on the side of the cable track. Do not
disconnect the wiring.
5 Support the cable track with an overhead
crane.
6 Remove the hose/cable cover from the pivot
end of the boom.
7 Remove the cable track mounting bolts at the
platform end of the boom.
8 Remove the side panel from the cable track to
access the cable track mounting bolts.
9 Remove the cable track mounting fasteners,
then remove the cable track from the
boom and lay it off to the side.
Component damage hazard.
The boom cable track
can be damaged if it is twisted.
10 Remove the turntable end cover.
11 Remove the retaining bolt from the master
cylinder rod-end pivot pin. Use a soft metal drift
to remove the pin. Pull the cylinder back and
secure it from moving.
12 Remove the drive speed limit switch
mounted on the inside of the pivot end of
the boom. Do not disconnect the wiring.
13 Tag, disconnect and plug the 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.
7 - 18
14 Attach an overhead 5 ton (4536 kg) crane to
the center point of the boom.
15 Attach a similar lifting device to the lift cylinder.
16 Use the crane to lift the boom to a horizontal
position.
17 Place support blocks under the cylinder, across
the turntable.
18 Remove the pin retaining fastener from the
boom lift cylinder rod-end pin. Use a soft metal
drift to remove the pin.
19 Lower the rod end of the lift cylinder onto
support blocks. Protect the cylinder rod from
damage.
20 Remove the pin retaining fastener from the
boom pivot pin.
21 Remove the boom pivot pin with a soft metal
drift, then carefully remove the boom from the
machine.
How to Disassemble
the Boom
1 Remove the boom. See 4-2,
How to Remove the Boom.
Genie S-80 & Genie S-85
Service Manual - First Edition
Crushing hazard. The boom lift
cylinder will fall unless it is
properly supported.
Crushing hazard. If the overhead
crane is not properly attached,
the boom may become
unbalanced and fall when it is
removed from the machine.
Complete disassembly of the
boom is only necessary
if the outer or inner boom tubes
must be replaced. The extension
cylinder can be removed without
completely disassembling of the
boom. See 4-4, How to Remove
the Extension Cylinder.
Part No. 34032