April 2017 Service and Repair ManualBoom ComponentsPart No. 1272854 GTH-844 31How to R eplac e the F or k Level C yli nder and/or Auxili ar y H osesHow to Replace the Fork LevelCylinder and/or Auxiliary HosesNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or hoseend must be replaced. All connections must betorqued to specification during installation. Refer toSpecifications, Hydraulic Hose and Fitting TorqueSpecifications.1 Fully retract the boom.2 Fully lower the tips of the lifting forks.3 Remove the cover from the fork end of theboom.4 Attach a lifting strap from an overhead crane tothe top of the lifting fork frame. Support theframe. Do not apply any lifting pressure.5 Disconnect and plug the fork level cylindersupply hoses at the cylinder manifold or theauxiliary supply hoses at the quick connectfittings. Cap the fittings.Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.Component damage hazard.Hoses can be damaged if theyare kinked or pinched.6 Working near the center of the boomassembly, tag, disconnect and plug thehydraulic hoses from the hydraulic hard linesunder boom tube number number 1. Cap thehard lines.7 Securely connect a 30 feet / 10 m length ofrope to each end of the hoses disconnected insteps 5 and 6. Securely tie off the other end ofeach section of rope to the boom structure.8 Remove the hose clamp at the fork end of theboom by loosening the hose clamp bolt locatedon the top of the boom.9 Remove the cover from the pivot end of theboom and remove the hose sheave cover.1 hose sheave cover2 cover retaining boltsNote: Partial extension of the boom on somemachines may be necessary to access the sheavecover fasteners.
