Replace The Winch Friction Disks; Inspect The Cable And Cable Pulleys - Terex Genie 9595-101 Service Manual

June 2018
C-3

Replace the Winch Friction Disks

Genie specifications require that this procedure be
performed every 1000 hours or annually,
whichever comes first.
Maintaining the winch is essential to good machine
performance and safe operation. An unsafe
working condition exists if the winch has excessive
wear and/or does not operate smoothly, free of
hesitation and binding.
1 Replace the winch friction disks. See Repair
Procedure, How to Disassemble a One-speed
Winch, or How to Disassemble a Two-speed
Winch.
Part No. 115409
Checklist C Procedures
C-4
Inspect the Cable and Cable
Pulleys
Genie specifications require that this procedure be
performed every 1000 hours or annually,
whichever comes first.
Detection of damage to cable or pulleys is essential
for safe machine operation. An unsafe working
condition exists if these components are damaged
and do not operate smoothly. The inspection of this
system allows the inspector to identify changes in
the operating condition that might indicate damage.
Note: The mast must be disassembled during the
annual inspection of the machine, otherwise the
cable, cable pulleys and mast rollers are only
partially visible for inspection.
1 Disassemble the mast assembly. Refer to
Repair Procedure, How to Disassemble the
Mast Assembly.
2 Visually inspect the cable and components for
the following:
• frayed or broken wire strands
• kinks in the cable
• corrosion
• paint or foreign materials
• split or cracked swaged end(s)
• upper and lower mounting brackets are
properly secured
• no broken or damaged pulleys
• no unusual or excessive pulley wear
• no broken or damaged mast rollers
• no unusual or excessive mast roller wear
3 Assemble the mast assembly. Refer to Repair
Procedure, How to Assemble the Mast
Assembly.
Superlift Contractor
Service Manual
Bodily injury hazard. Beware of
sharp edges. Wear protective
gloves when performing this
procedure.
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