How To Disassemble The Winch - Two Speed - Genie Superlift SL-5 Parts & Service Manual

Parts and Service Manual - First Edition
3-2
How to Disassemble the Winch
- Two Speed
Bodily injury hazard. Cables can
fray. Always wear adequate hand
protection when handling cable.
1 Fully lower the carriage.
2 Remove the cable retaining fastener from the
winch drum. Then remove the cable from the
drum.
3 Remove the handles from the pinion shaft.
4 Remove the drum bolt and the drum bolt
spacer. Then remove the drum and drum gear
cover and the housing spacer.
5 Remove the input shaft cover.
6 Remove the mounting fasteners from the spring
and ball housing.
7 Remove both the springs and the balls from the
housing.
8 Shift the input shaft into the neutral position.
9 Rotate the input shaft until the drive pin is
visible inside the input shaft gear.
10 Remove the drive pin with a soft metal drift.
11 Slide the input shaft out of the winch housing.
Note the location and position of
the components on the input
shaft.
12 Remove the retaining ring from the pinion shaft.
13 Gently pry the pinion shaft gears to the left,
over the woodruff keys.
14 Remove the lock nut from the end of the pinion
shaft (located on the outside of the winch
housing).
15 Slide the pinion shaft to the right and remove
the pinion spacer, pinion plate, ratchet gear,
and friction disks. Remove the pinion gear by
turning it counterclockwise, then slide it off the
left side of the shaft.
Part No. 32283
16 Remove both pinion bushings. Use a soft metal
drift equal to the outside diameter of the
bushing and tap with rubber mallet.
How to Assemble the Winch -
Two Speed
1 Place one side of the winch housing over a
vise. Open the vise until it is 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.
Repeat steps 1 and 2 to insert the other
bushing.
3 Add two drops of 30W oil to both pivot points
on each ratchet pawl.
4 Install the winch housing onto the mast. Be
sure the winch drum is towards the top.
5 Insert the longer threaded end of the pinion
shaft through the right bushing approximately
half way.
Genie Superlift
Section 6 - Repair Procedures
Place a block in between the walls
of the winch housing to prevent
the housing from bending while
removing the bushings.
Bodily injury hazard. Cables can
fray. Always wear adequate hand
protection when handling cable.
Refer to Section Six, Figure 7-N,
Two Speed Winch for exploded
view of the winch.
Use a piece of flatbar in between
the drift and the bushing to
prevent any damage to the
bushing.
Do not allow grease or oil onto the
friction disks or the ratchet gear.
WINCHES
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