Genie Super Tower, Service Manual

Page: 38 / 45

Service Manual September 2016
Winches
30 Super Tower Part No. 115411
How to Assemble a One-speed
Winch
Bodily injury hazard. Cables can
fray. Always wear adequate
hand protection when handling
cable.
Note: Refer to the Repair Procedure figure, One
Speed Winch Assembly
, for an exploded view.
1 Place one side of the winch housing over the
jaws of a vise. Open the vise until the jaws are
wider than the outside diameter of the
bushing.
2 Insert a soft metal drift through the opposite
bushing hole. Tap the drift with a rubber mallet
to push the bushing into place.
3 Repeat steps 1 and 2 to insert the other
bushing.
4 Add two drops of 30W oil to both pivot points
on each ratchet pawl.
Bodily Injury Hazard.
Over-lubrication of the ratchet
pawl may result in oil coming in
contact with the surface of the
winch brake leading to an unsafe
working condition. Do not allow
any oil on the brake or pressure
plate.
5 Install the winch housing onto the mast. Be
sure the winch drum is toward the top.
6 Insert the longer threaded end of the pinion
shaft approximately halfway through the left
bushing.
7 Apply a small amount of multi-purpose grease
to the large threaded section of the pinion
shaft, under the gear nut. Screw the pinion
gear onto the pinion shaft with the gears
toward the left side of the winch housing.
8 Install, in order, a brake disk, a ratchet gear, a
brake disk, a pinion plate and a pinion spacer
onto the pinion shaft.
Component damage hazard. Do
not allow grease or oil onto the
brake disks or the ratchet gear.
Note: The teeth on the ratchet gear must curve
away from the right side of the winch housing.
9 Push the pinion shaft to the right, through the
right pinion bushing, and install the pinion
shaft retaining ring.
Note: Use your fingers to push the ratchet pawls
outward while pushing the pinion shaft through the
right bushing. Be sure the ratchet pawls are in firm
contact with the ratchet gear and that all parts
move freely.
10 Install the two jam nuts to the right side of the
pinion shaft one at a time, and tighten.
11 Position both handles on the pinion shaft in
opposite directions. Install and tighten the lock
nuts.