Terex Genie Load Lifter, Service Manual

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Service Manual September 2016
Base Assembly
20 Load Lifter Part No. 115415
1-2
How to Disassemble the Winch
1 Fully lower the carriage.
2 Remove the cable retaining fastener from the
winch drum. Unwind the cable from the winch
drum.
Bodily injury hazard. Cables
can fray. Always wear adequate
hand protection when handling
cable.
3 Remove the winch handle from the winch.
4 Remove the two jam nuts from the pinion
shaft.
5 From the platform side of the machine, rotate
the pinion shaft counterclockwise until the
shaft is removed. Be sure to hold the winch
components in place while removing the
pinion shaft.
Note: Before disassembling, note the quantity and
location of the shims, between the winch drum and
bushing.
6 Remove the pinion shaft bushings. Use a soft
metal drift equal to the outside diameter of the
bushing and tap with a rubber mallet.
How to Assemble the Winch
1 Clean and inspect the winch components
before installing.
Note: Refer to the illustration, Winch Assembly , for
an exploded view.
2 Install the pinion shaft bushings. Use a soft
metal drift equal to the outside diameter of the
bushing and tap with a rubber mallet until fully
seated.
3 Apply a small amount of lithium grease to the
large threaded section of the pinion shaft.
4 Insert the pinion shaft through the pinion shaft
spacer and the winch drum.
5 Install the brake disk, ratchet gear and UHMW
brake disk in respective order onto the pinion
shaft.
Component damage hazard. Be
sure the pinion shaft is threaded
all the way into the winch drum
before tightening the two jam
nuts.
Component damage hazard. Do
not allow grease or oil onto the
brake disks or the ratchet gear.
6 Install the two jam nuts and the handle onto
the winch shaft.
7 Route the cable around the winch and install
the cable retaining fastener. Be sure the end
of the cable does not extend past the edge of
the winch drum.