Bodily Injury Hazard. Spraying - Genie GTH-636 Service Manual

Section 4 • Repair Procedures
BOOM COMPONENTS
How to Disassemble the Boom
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
GTH-644, GTH-842 and GTH-844:
1 Remove the extension cylinder. See 1-4, How
to Remove the Boom Extension Cylinder .
2 Remove the boom. See 1-2, How to Remove
the Boom .
3 Tag, disconnect and plug the hydraulic hoses
from the fork level cylinder manifolds. 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.
4 Attach a lifting strap from an overhead crane to
the barrel end of the fork level cylinder. Support
the cylinder. Do not apply any lifting pressure.
4 - 6 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056
5 Remove the fasteners securing the fork level
cylinder pivot pin to the boom.
6 Use a soft metal drift to remove the pivot pin.
Remove the cylinder from the machine.
Crushing hazard. The cylinder will
fall if not properly supported when
the pivot pin is removed from the
machine.
7 Tag, disconnect and plug the hydraulic hoses
from the hydraulic hard lines at the top of the
number 1 boom tube. Cap the hard lines.
a c
b
g
a boom tube number 3
b boom tube number 2
c boom tube number 1
d retraction chain
e extension chain
f fixed chain block
g chain tensioner
8 Remove the fasteners and clamps securing the
hydraulic hard lines to the number 1 boom tube.
Remove the hard lines and set them to the side.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
June 2007
REV C
e
f d
Part No. 97487