Genie Z-45/25 Bi-Energy Service Manual

Also see for Z-45/25: Service manual Maintenance manual Operator's manual Operator's manual Service manual

Contents

Genie Z-45/25 Bi-Energy Service Manual Manual pdf 80 page image

4 - 16 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488July 2004Section 4 • Repair ProceduresREV A4-3Primary Boom Lift CylinderThe primary boom lift cylinder raises and lowersthe primary boom. The primary boom lift cylinder isequipped with a counterbalance valve to preventmovement in the event of a hydraulic line failure.How to Remove the PrimaryBoom Lift CylinderBodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2,Hydraulic Hoseand Fitting Torque Specifications.1 Raise the primary boom until the primary boomis horizontal.2 Raise the secondary boom until the primaryboom lift cylinder barrel-end pivot pin is abovethe turntable covers.3 Attach a 5 ton / 5000 kg overhead crane to theprimary boom for support. Do not lift the boom.4 Support the rod end and the barrel end of theprimary boom lift cylinder with a secondoverhead crane or similar lifting device.5 Tag, disconnect and plug the primary boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.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.6 Remove the pin retaining fastener from theprimary boom lift cylinder rod-end pivot pin. Usea soft metal drift to remove the pin.The primary boom will fall if notproperly supported when theprimary boom rod-end pivot pin isremoved.7 Place a support block across both turntablecovers under the primary boom lift cylinder.8 Lower the lift cylinder onto the block. Protect thecylinder rod from damage.Crushing hazard. The primaryboom lift cylinder could fall if notproperly supported.9 Remove the primary boom lift cylinder barrel-end pivot pin retaining fasteners. Do notremove the pin.10 Use a slide hammer to remove the barrel-endpivot pin. Carefully remove the primary boom liftcylinder from the machine.Crushing hazard. The lift cylindercould become unbalanced and fallif not properly supported andsecured to the lifting device.PRIMARY BOOM COMPONENTS