Genie Super Tower, Service Manual

Page: 42 / 45

Service Manual September 2016
Winches
34 Super Tower Part No. 115411
How to Assemble a Two-speed
Winch
Bodily injury hazard. Cables can
fray. Always wear adequate
hand protection when handling
cable.
Note: Refer to the Repair Procedure figure,
Two-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. Line up the tab on the bushing
to the hole in the winch housing. Tap the drift
with a rubber mallet to push the bushing into
place.
3 Repeat steps 1 and 2 to insert the other
bushing.
Note: Use a piece of flat bar or wood between the
drift and the bushing to prevent any damage to the
bushing.
4 Add two drops of 30W oil to both pivot points
on each ratchet pawl.
Bodily Injury Hazard.
Over-lubrication of the ratchet
paw lt 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 on 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 right
side bushing.
7 Apply a small amount of multi-purpose grease
to the large threaded section of the pinion
shaft,under the gear nut. Slide the pinion shaft
gears onto the pinion shaft. Install the pinion
gear onto the pinion shaft with the gears
toward the right side of the winch housing.
Screw onto large threads hand tight.
8 Install, in order, a friction disk, a ratchet gear,
a friction disk, a pinion plate and a pinion
spacer onto the pinion shaft.
Component damage hazard. Do
not allow grease or oil onto the
brake disk, ratchet gear or the
teflon spacer.
9 Install the pinion shaft retaining ring onto the
pinion shaft.
Note: Use your fingers to push the ratchet pawls
outwards while pushing the pinion shaft through the
left bushing. Be sure the ratchet pawls are in firm
contact with the ratchet gear and that all parts
move freely.
10 Install the lock nut on the left side of the pinion
shaft.
11 Install the input shaft approximately half way
through the left side of the winch housing.
12 Slide the left side bushing, spring and ball
housing, spacer, input shaft gears and right
side bushing onto the input shaft.
13 Install the ball and spring into the spring and
ball housing. Install the mounting fasteners.