How To Assemble The Manual Winch - Genie Lift Service Manual

Service Manual
Base Assembly
1-4 1-4 H ow to As sem ble the M anual Winch
How to Assemble the Manual
Winch
Bodily injury hazard. Cables can
fray. Always wear adequate
hand protection when handling
cable.
Note: Refer to the illustration,
an exploded view.
1 Place one side of the winch housing over a
vise. Open the vise until it is wider than the
outside diameter of the pinion shaft 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.
Note: Use a piece of flat bar in between the drift
and the bushing to prevent any damage to the
bushing.
Note: Repeat steps 1 and 2 to insert the other
bushing.
3 Carefully lubricate the pivot point on the
ratchet pawl with 30W oil.
Bodily Injury
Hazard. Over-lubrication of the
ratchet pawl may result in oil
coming in contact with the surface
of the winch brake disk or the
winch pressure plate, leading to
an unsafe working condition. Do
not allow any oil on the brake or
pressure plate.
34
Winch Assembly
, for
Genie Lift
4 Install the winch housing onto the machine. Be
sure the winch drum is towards the right.
5 Insert the threaded end of the pinion shaft
through the large bushing. Then insert the
other end of the pinion shaft through the small
bushing.
6 Push the pinion shaft toward the small
bushing. Install the brake disk, ratchet gear
and pressure plate.
Note: The teeth on the ratchet gear must curve
away from the drum.
7 Push the pinion shaft toward the large
bushing. Install the pinion shaft retaining ring.
Note: Push the ratchet pawl outwards while
pushing the pinion shaft through the large bushing.
Be sure the ratchet pawl is in firm contact with the
ratchet gear and all parts move freely.
8 Install the handle adaptor, spring and handle
adaptor mounting nut. Tighten the mounting
nut. Do not over-tighten the nut.
9 Lubricate the outside of the drum spacer that
goes through the cable drum with automotive
grease. Insert the drum spacer into the cable
drum.
10 Install the cable drum so that the drum gears
mesh with the ratchet gears on the pinion
shaft.
11 Install the drum bolt through the winch housing
and drum with the head of the drum bolt on the
small bushing side of winch.
September 2016
Part No. 115417