4 - 20 Genie Z-60/34 Part No. 75861November 2003Section 4 • Repair ProceduresREV APRIMARY BOOM COMPONENTS4-3Primary Boom Lift CylinderHow to Remove thePrimary Boom Lift CylinderBodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools result in death or seriousinjury and significant componentdamage. Dealer service is stronglyrecommended.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 Two, HydraulicHose and Fitting TorqueSpecifications.1 Raise the primary boom enough to access theprimary boom lift cylinder rod-end pivot pin.2 Attach a 5 ton/5,000 kg overhead crane to theprimary boom for support. Do not lift the boom.3 Place a 24 inch/61 cm long block of woodacross the lower secondary boom leveling linksto support the primary boom lift cylinder whenthe rod-end pivot pin is removed.4 Support the rod end of the primary boom liftcylinder with an appropriate lifting device.5 Remove the pin retaining fasteners from theprimary boom lift cylinder rod-end pivot pin.Then use a soft metal drift to remove the pin.6 Lower the rod end of the cylinder onto the blockthat was placed on the lower secondary boomleveling links. Then lower the primary boomonto the boom rest.7 Raise the secondary boom enough to accessthe primary boom lift cylinder barrel-endpivot pin.8 Tag, disconnect and plug the hydraulic hosesfrom the primary boom lift cylinder. Cap thefittings on the cylinder.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.9 Place another 24 inch/61 cm long block of woodacross the lower secondary boom leveling linksto support the primary boom lift cylinder whenthe barrel-end pivot pin is removed.10 Support the barrel end of the primary boom liftcylinder with an appropriate lifting device.
