Boom Lift Cylinder; Extension Cylinders - Genie S-80 Service Manual

Section 7 - Repair Procedures
BOOM COMPONENTS
4-3

Boom Lift Cylinder

How to Remove the Boom
Lift Cylinder
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 Raise the boom until the boom is horizontal.
2 Place support blocks under the cylinder across
the turntable.
3 Support the boom with an overhead crane.
Do not lift the boom.
4 Support the balance point of the boom lift
cylinder with an overhead crane or similar lifting
device.
Crushing hazard. If the overhead
crane is not properly attached,
the lift cylinder may become
unbalanced and fall when it is
disconnected from the machine.
5 Tag, disconnect and plug the boom lift 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.
6 Remove the mounting fasteners from the lift
cylinder mounting bracket.
7 Remove the pin retaining fastener from the lift
7 - 20
cylinder rod-end pivot pin. Use a soft metal drift
to remove the pin, then allow the lift cylinder to
rest on the blocks. Protect the cylinder rod
from damage.
8 With the lift cylinder being supported by the
overhead crane, pull the cylinder toward the
platform until it is out.
4-4

Extension Cylinders

The extension cylinder consists of two cylinders
that are fastened together. The first cylinder
extends and retracts the number 2 boom tube.
The second cylinder extends and retracts the
number 3 boom tube. The extension cylinders are
equipped with counterbalance valves to prevent
movement in the event of a hydraulic line failure.
How to Remove the
Extension Cylinders
1 Extend the boom all the way to full extension.
2 Remove the mounting fasteners from the guide
pads, located on the outside of the number 3
boom tube.
3 Retract the boom until the cylinder rod-end pin
is accessible in the number 3 boom tube.
Genie S-80 & Genie S-85
Service Manual - First Edition
Crushing hazard. The lift
cylinder will fall unless it is
properly supported.
Component damage hazard. The
cables and hydraulic hoses can
be damaged if the lift cylinder is
pulled across them.
This procedure requires specific
repair skills, lifting equipment and
a suitable workshop. Attempting
this procedure without these skills
and tools may cause death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Part No. 34032