Genie GTH-636 Service Manual page 82

Section 4 • Repair Procedures
BOOM COMPONENTS
10 Attach a lifting strap from an overhead crane to
the extension cylinder. Support the cylinder. Do
not apply any lifting pressure.
11 Remove the nut securing the rod end of the
extension cylinder to the number 1 boom tube.
12 Extend the number 1 boom tube until the hose
manifolds are accessible.
Crushing hazard. The boom
assembly could fall when the
number 1 boom tube is extended if
not properly supported and
attached to the overhead crane.
13 Tag, disconnect and plug the hydraulic hoses at
the top of the hose manifolds at the top of the
number 1 boom tube. Cap the fittings.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
Note: Do not remove the hose manifolds at this
time.
14 Remove the wear pads of the number 0 boom
tube at the front end of the boom.
15 Manually return the boom tubes to the stowed
position.
16 Remove the access cover from the rear of the
boom.
17 Working with a screwdriver inside the rear of
the boom, carefully remove eight of the external
hinge link tabs from the end of the cable track
where it attaches to the number 3 boom tube.
18 Using a screwdriver, carefully separate the
cable track from the cable track mount at the
rear of the number 3 boom tube.
4 - 12 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056
19 Loosen evenly, then remove, the fasteners
securing the chain tensioners of the boom tube
2 extension chains to the number 0 boom tube.
20 Remove the fasteners securing the fixed chain
block of the boom tube 2 retraction chain to the
top of the number 0 boom tube near the front of
the tube.
Note: The fixed chain block of the boom tube 2
retraction chain is secured to the inside of the
number 0 boom tube and is hidden from view when
installed.
21 Using a chain of sufficient capacity, secure
together the numbers 1, 2 and 3 boom tubes.
Note:To secure the boom tubes together, it may be
helpful to loosen the boom roller fasteners at one
side of the boom, wrapping the chain around the
boom roller pin between the nut and the side of the
boom.
22 Attach a lifting strap from an overhead crane to
the numbers 1, 2 and 3 boom tube assemblies
at the fork end of the boom.
23 Support and slide the numbers 1, 2 and 3 boom
tube assemblies approximately halfway out of
the number 0 boom tube.
Crushing hazard. The boom
assembly could become
unbalanced and fall when the
numbers 1, 2 and 3 boom tubes
are moved if not secured together.
24 If equipped, remove the fasteners securing the
side wear pads to the number 0 boom tube, and
remove the wear pads.
June 2007
REV C
Part No. 97487