Paccar Winch Gearmatic GH30B Installation and user guide

1
WINCH DIVISION
P.O. BOX 547 BROKEN ARROW, OK U.S.A. 74013
PHONE [phone] FAX [phone]
www.paccarwinch.com
LIT2397_R3_3-2011
Printed in U.S.A. Copyright 2011
PACCAR Winch Division
All Rights Reserved
GH30B
HIGH SPEED REVERSE HYDRAULIC HOIST
SERVICE AND MAINTENANCE MANUAL

2
TABLE OF CONTENTS
INTRODUCTION
The following service instructions have been prepared to provide assembly, disassembly, and maintenance
information for the Gearmatic Model GH30B. It is suggested that before doing any work on these units, all assembly
and disassembly instructions should be read an understood.
Some illustrations in this manual may show details or attachments that are different from your hoist. Also,
some components have been removed for illustrative purposes.
Continuing product improvement may cause changes in your hoist, which are not included in this manual.
Whenever a question arises regarding your Gearmatic hoist or this manual, please contact Gearmatic Product Sup-
port Department for the latest available information.
Telephone- 1-918-251-8511
08:00-16:30 Central Time Zone, Monday thru Friday
FAX- 1-918-259-1575
www.paccarwinch.com
EXPLANATION OF MODEL NUMBER............................................................................3
GENERAL SAFETY RECOMMENDATIONS ...................................................................4
GENERAL INSTALLATION ..............................................................................................5
THEORY OF OPERATION...............................................................................................6
HYDRAULIC CIRCUIT.....................................................................................................7
WIRE ROPE INSTALLATION...........................................................................................8
HOIST OPERATION.......................................................................................................10
PREVENTATIVE MAINTENANCE .................................................................................11
RECOMMENDED PLANETARY GEAR OIL...................................................................13
OIL SAMPLING AND ANALYSIS....................................................................................14
RECOMMENDED BOLT TORQUE................................................................................14
TROUBLESHOOTING ...................................................................................................15
HOIST DISASSEMBLY...................................................................................................18
BRAKE CYLINDER........................................................................................................20
CABLE DRUM................................................................................................................22
PRIMARY PLANET CARRIER.......................................................................................23
OUTPUT PLANET CARRIER.........................................................................................25
OVER-RUNNING CLUTCH SERVICE...........................................................................26
HOISTASSEMBLY.........................................................................................................27
WINCH CROSS-SECTION AND PARTS KEY...............................................................28
METRIC CONVERSION TABLE ....................................................................................31

3
GH30 B - SPL - 40/9 120 - 04
GH - DESIGNATES GEARMATIC HOIST
B - EVOLUTIONARY DESIGNATION
SPL - SPECIAL ORDER DESIGNATION
40/9 - TOTAL GEAR REDUCTION (40:1 HOISTING; 9:1 LOWERING)
120 - MOTOR DISPLACEMENT (12 CU. IN/Rev)
04 - DRUM OPTION
EXPLANATION OF MODEL NUMBER

4
GENERAL SAFETY RECOMMENDATIONS
Safety for operators and ground personnel is of prime concern. Always take the necessary precautions to
ensure safety to others as well as yourself. To ensure safety, the prime mover and hoist must be operated with care
and concern for the equipment and a thorough knowledge of the machine’s performance capabilities. The following
recommendations are offered as a general safety guide. Local rules and regulations will also apply.
1. Be certain equipment (boom, sheave blocks, pen-
dants, etc.) is either lowered to the ground or blocked
securely before servicing, adjusting, or repairing
hoist.
2. Be sure personnel are clear of work area BEFORE
operating hoist.
3. Read all warning and caution tags provided for safe
operation and service of the hoist and become fa-
miliar with the operation and function of all controls
before operating the hoist.
4. Inspect rigging and hoist at the beginning of each
work shift. Defects should be corrected immediately.
Do not operate a hoist with defects.
5. Keep equipment in good operating condition. Per-
form scheduled servicing and adjustments listed in
the “Preventive Maintenance” section of this manu-
al.
6. An equipment warm-up procedure is recommended
for all start-ups and essential at ambient tempera-
tures below +40°F (+4°C).
7. Do not exceed the maximum pressure (PSI, kPa)
or flow (GPM, lpm) stated in the hoist specifications
found in the specific sales brochure.
8. Operate hoist line speeds to match job conditions.
9. Protective gloves should be used when handling wire
rope.
10. Never attempt to handle wire rope when the hook
end is not free. Keep all parts of body and clothing
clear of cable rollers, cable entry area of fairleads,
sheaves and hoist drum.
11. When winding wire rope on the hoist drum, never at-
tempt to maintain tension by allowing wire rope to slip
through hands. Always use “Hand-Over-Hand” tech-
nique.
12. Never use wire rope with broken strands. Replace
wire rope that is damaged. Refer to wire rope sup-
plier manual.
13. Do not weld on any part of the hoist without approval
from PACCAR Winch Engineering.
14. Use recommended hydraulic oil and gear lubricant.
15. Keep hydraulic system clean and free from contami-
nation at all times.
16. Use correct anchor for wire rope and pocket in
drum.
17. Do not use knots to secure or attach wire rope.
18. The Gearmatic designed wire rope anchors are not
intended to support the rated load. ALWAYS main-
tain a minimum of five (5) wraps of wire rope on the
drum. It is recommended that the last five (5) wraps
of wire rope be painted bright red to serve as a visual
reminder.
19. Never attempt to clean, oil or perform any mainte-
nance on a machine with the engine or prime mover
running, unless instructed to do so in this manual.
20. Never operate hoist controls unless you are properly
positioned at the operators station and you are sure
personnel are clear of the work area.
21. Assure that personnel who are responsible for hand
signals are clearly visible and that the signals to be
used are thoroughly understood by everyone.
22. Ground personnel should stay in view of the opera-
tor and clear of the hoist drum. Do not allow ground
personnel near wire rope under tension. A safe dis-
tance of 1½ times the working length of the wire rope
should be maintained.
23. Install guarding to prevent personnel from getting
any part of body or clothing caught at a point where
the cable is wrapped onto the drum or drawn through
guide rollers or potential “pinch points”.
24. Install switches or valves that will shut off power to
the hoist, in locations where they can be reached
by anyone entangled in the wire rope before being
drawn into the hoist or any “pinch point”.
25. “Deadman” controls, which automatically shut off
power to the hoist whenever the operator leaves his
station or releases the hoist control lever, should be
installed whenever practical.
26. Never allow anyone to position any part of body un-
der a suspended load.
27. Avoid sudden “shock” loads or attempting to “jerk” a
load free. This type of operation may cause heavy
loads, in excess of rated capacity, which may result
in failure of wire rope, hoist or crane structure.
28. Whenever possible, install the hoist in a location that
is not immediately adjacent to a “normal” operator’s
station.
29. All hoist controls shall be located within easy reach of
the operator. The controls shall be installed in such
a location that the operator is removed from the elec-
trical path to ground if the load, rigging, or wire rope
come in contact with or within proximity to an electri-
cally energized conductor.

5
GENERAL INSTALLATION
1 The hoist must be mounted with the centerline of the
drum in a horizontal position. The mounting plane can
be rotated to any position around this centerline, pro-
viding the vent plug is positioned above the oil level.
2. When mounting the hoist, use grade 8 capscrews or
bolts and nuts using both mounting holes in each end
plate. Use narrow, hardened washers under the bolt
heads and nuts
3. The vent plug must always be located above the
horizontal centerline of the hoist drum. If the hoist is
mounted on a pivoting surface, be sure the vent re-
mains above the centerline at all times. If necessary,
reposition the bearing support.
4. It is important that the hoist be mounted on a surface
that will not flex when the hoist is in use, since this
could bind the working parts of the hoist. Also, be sure
the hoist is mounted on a flat surface. If necessary,
use shim stock to insure proper mounting. The mount-
ing surface must be flat within 0.020 inches (.5 mm).
5. Hydraulic lines and components that operate the hoist
should be of sufficient size to assure minimum back
pressure at the hoist motor ports. To insure adequate
static brake load holding ability, back pressure on the
hoist should not exceed 100 psi (690 kPa).
6. Make certain that the hoist drum is centered behind
the first sheave and the fleet angle does not exceed
1½ degrees.
The hoist should also be mounted perpendicular to an
imaginary line from the center of the drum to the first
sheave to ensure even spooling. (ref. drawing on page 4)
7. The hoist directional control valve must be a three-po-
sition, four-way valve without detents and with a spring
centered motor spool such that the valve returns to the
centered position whenever the handle is released,
and both work ports are opened to tank (open center,
open port, see schematic below).
8. The hydraulic oil filter should have a 10 micron nomi-
nal rating and be a full-flow type.
9. High quality hydraulic oil is essential for satisfactory
performance and long hydraulic system component
life.
Oil having 150 to 330 SUS viscosity at 100°F (38°C) and
viscosity index of 100 or greater will give good results un-
der normal temperature conditions. The use of an oil hav-
ing a high viscosity index will minimize cold-start trouble
and reduce the length of warm-up periods.A high viscosity
index will minimize changes in viscosity with correspond-
ing changes in temperature.
Maximum cold weather start-up viscosity should not ex-
ceed 5000 SUS with a pour point at least 20°F (11°C) low-
er than the minimum temperature.
In general terms; for continuous operation at ambient tem-
peratures between 50 and 110°F (10-43°C) use ISO VG
46 – 68 (SAE20); for continuous operation between 10
and 90°F (-12 and 32°C) use ISO VG 32 (SAE10W).
DO NOT use a control valve with any detents or latch-
ing mechanism that would hold the control valve in an
actuated or running position when the operator releas-
es the control handle. Use of the wrong type of control
valve could lead to unintentional operation of the hoist,
which could result in property damage, personal injury
or death.
DO NOT weld hoist to mounting surface. Welding may
not provide adequate structural support for winch loads.
This may cause loss of load control, which could result
in property damage, injury or death. Welding may also
damage bearings and seals, resulting in premature fail-
ure.
CAUTION
WARNING
! !
CAUTION
WARNING
! !

6
THEORY OF OPERATION
Description of Winch
The winch has three basic parts.
1. Primary planet gear housing and motor assembly
2. Output planet gear housing
3. Drum assembly
Planetary Gear Train
The hydraulic motor shaft is coupled to the inner race of
the overrunning brake clutch. The primary sun gear in cou-
pled to the opposite side of the overrunning clutch. When
hoisting, the motor drives the primary sun gear through the
splined connection of the overrunning clutch. The primary
planet gears walk around the primary ring gear - which is
held static by spring force on the brake plates - and drive
the primary planet carrier.
The primary planet carrier drives the output sun gear shaft
which passes through the drum and drives the output
planet gears. As the output planet gears are driven by the
sun gear shaft, the planet gears walk around the ring gear
machined in the final drive housing and drive the output
planet carrier. As the output planet carrier rotates, it drives
the drum through a splined connection.
When lowering, the brake is release allowing the primary
ring gear to rotate effectively removing the primary gear re-
duction which for a given flow rate results in higher speeds
lowering than hoisting.
Brake System
The brake system is composed of four basic compo-
nents;
1. Spring applied friction disc brake
2. Overrunning brake clutch assembly
3. Brake piston and cylinder
4. Ring gear
The friction disc brake consists of alternately stacked fric-
tion and steel brake discs. The steel brake discs are ex-
ternally splined to the primary housing and cannot rotate.
The friction discs are internally splined to the primary ring
gear which is also splined to the outer hub of the overrun-
ning brake clutch assembly. The primary brake springs
apply force on the pressure plate which acts through a
spacer to apply force to the friction discs preventing them
from rotating relative to the steel discs.
The primary ring gear is held static by the friction brake
when hoisting, but when lowering it rotates with the outer
race of the overrunning clutch. This gives the winch more
gear reduction when hoisting than when lowering and re-
sults in higher drum speeds for the same motor input rpm
when lowering.
The overrunning clutch locks the motor shaft and input sun
gearto the ring gear. Thisprevents the motor shaft or input
sun gear from rotating unless the brake is released allow-
ing the friction discs to rotate relative to the steel discs.
When hoisting or pulling a load, the overrunning clutch al-
lows free rotation of the motor shaft and primary sun gear.
The sprag cams lay over and permit the shafts splined to
the overrunning clutch inner race to turn freely. The fric-
tion brake remains fully applied - the winch brake is not
released during hoisting or reel-in operations.
When the hoisting operation is stopped, the load attempts
to turn the primary sun gear in the lowering direction. This
causes the sprag cams to immediately engage the lock
the primary sun gear to the overrunning clutch outer race
which is held static by the ring gear and friction brake.
When the winch is powered to lower, the motor and gear
train will he held by the brake until sufficient pressure
is supplied to the brake release piston to overcome the
brake spring force. With no load on the winch, approxi-
mately 400 PSI is required to compress the brake springs
and allow the friction brake discs to turn free of the steel
brake discs. As lowering pressure increases, the brake
releases allowing the motor to drive the gear train to pay-
out the cable.
When the directional control valve is returned neutral, the
lowering pressure will drop and the brake will apply to hold
the load.
If the load on the winch drum tries to drive the motor faster
than the supply of oil will permit (it tries to drive the mo-
tor as a pump), the hydraulic lowering pressure acting on
the brake piston will decrease. Since the spring force is
the same as before, this will result in more net braking
effort. In this way, a balance pressure is supplied to the
motor and brake release piston according to the load on
the winch drum.
Stopped
Holding
Load
Figure 3
Load Attempts to
Rotate Shaft in Op-
posite Direction.
Brake Clutch Locks
Sun Gear Shaft to
Friction Brake.
Static Friction Brake Applied
Sprag Cams
Ring Gear
Figure 2
Static Friction Brake Applied
Hoisting
Permits Free Shaft
Rotation
While Hoisting
Sprag Cams

7
It is necessary to circulate oil through the primary housing.
This provides cooling for the brake and also insures that
the primary housing is completely filled with oil.
Figure 4 illustrates a basic hydraulic circuit. Oil is circu-
lated through the primary housing so that it enters through
the brake cooling orifice and leaves at port “Q”. Port “Q”
should be located as close to top dead center as possi-
ble.
In order to maintain maximum efficiency in the winch, se-
lect the size of hydraulic lines according to the maximum
volume of oil to be used in the winch (see Table). If the
hydraulic lines used are too small, they may cause exces-
sive back pressure at the reverse motor port sufficient to
release the brake (125 psi maximum) (9/kg/cm2).
Thesizesshowninthetable are to be usedasaguideonly.
If trouble is experienced due to the use of long hoses it will
be necessary to use hoses which are one size larger.
Line from Port Q – ¾” (19 mm) Minimum
Once the hydraulic circuit has been completed, bleed all
air from the primary housing before running the winch.
In order to obtain smooth control during low speed lower-
ing, it is recommended that the hydraulic pump is operated
at maximum gpm (l/min) and that the control valve is used
to control the speed.
HYDRAULIC CIRCUIT
PUMP
VALVE
CONTROL
10
MICRON
RETURN
LINE FILTER
COOLING OIL RETURN LINE
MIN HOSE SIZE 3/4 IN. ID LOW PRESS
MAX 15 PSI BACK PRESSURE AT PORT "Q"
MAX 100 PSI
RETURN LINE PRESSURE
PORT "Q"
HOSE REQUIREMENTS
Oil Flow GPM
(l/min)
Pressure Lines
Inside Dia.
Return Lines
Inside Dia.
81-125 GPM
(304-473 l/min)
2 in.
(51 mm)
2-1/2 in.
(64 mm)
36-60 GPM
(136-227 l/min)
1-1/4 in.
(32 mm)
1-3/4 in.
(44 mm)
61-80 GPM
(228-303 l/min)
1-1/2 in.
(38 mm)
2 in.
(51 mm)
Figure 4
The pressure in the winch case due to circulation must
never exceed 15 psi. Excessive pressures will damage
seals.
CAUTION
BRAKE COOLING PORT
BRAKE RELEASE
ROTATION

8
THE CABLE ANCHORS ALONE ON HOISTS ARE NOT INTENDED TO HOLD RATED LOADS.
Hoist loads applied directly to the wire rope anchor may cause the wire rope to pull free and result in the sudden loss
of load control and cause property damage, personal injury or death. A minimum of 5 wraps of wire rope must be left
on the drum barrel to achieve rated load.
CAUTION
WARNING
! !
The wedge and anchor pocket must be clean and dry. The
end of the wire rope being anchored to the drum must be
clean and dry and not frayed. Anything on the end of the
wire rope to keep it from fraying (i.e. tape or wire) must not
be in contact with the wedge when the installation is com-
plete. Consult the wire rope manufacturer on the proper
treatment of the dead end of the wire rope.
Some rope manufacturers recommend when using rota-
tion resistant wire rope, that the rope end be seized, weld-
ed or brazed before inserting the wire rope into the wedge
socket to prevent core slippage or loss of rope lay.
Take the free end of the wire rope and insert it through
the small opening on the cable drum flange. Loop the
wire rope and push the free end about 3/4 of the way back
through the pocket. Install the wedge as shown in figure
1, then pull the slack out of the wire rope. The “dead” end
of the rope needs to extend slightly beyond the end of the
wedge as shown in figure 2.
Using a hammer and brass drift, drive the wedge as deep
into the pocket as possible to ensure it is fully seated and
no further movement is detected. Applying a load on the
wire rope will also help seat the wedge in the pocket.
Check to ensure the wedge does not protrude from either
end of the pocket, causing it to interfere with proper spool-
ing of wire rope onto the drum (see figures 1 & 2).
If there is interference or the wedge does not seat firmly,
contact the Gearmatic Product Support Department at
1-918-251-8511 to determine the proper wedge size.
It is important that the wire rope have the proper tension-
ing when it is installed on the drum. When the wire rope
is first installed, you should operate the hoist, with light
to moderate loads, with reeving that let’s you place these
loads on the block and the drum with all the rope off the
drum except for the last five wraps.
WIRE ROPE INSTALLATION
CABLE WEDGE PLACEMENT
CABLE
CABLE DRUM
CABLE POCKET COVER
CABLE WEDGE

9
Cable Wedge Installation for -07 Drums
Check to ensure the wedge does not protrude from either
end of the pocket, causing it to interfere with proper spool-
ing of wire rope onto the drum (see figures 9 & 10). If there
is interference or the wedge does not seat firmly, contact
the Braden Product Support Department at 918-251-8511
to determine the proper wedge size.
It is important that the wire rope have the proper tension-
ing when it is installed on the drum. When the wire rope
is first installed, you should operate the hoist, with light
to moderate loads, with reeving that let’s you place these
loads on the block and the drum with all the rope off the
drum except for the last three wraps.
WIRE ROPE WEDGE PART NUMBERS
WEDGE PART NO.
24493 for 1/2 thru 5/8 in. (13 - 16 mm)
* 24494 for 3/4 thru 1 in. (19 - 25 mm)
* Standard Anchor
Incorrect Installation
Wedge pulled too far
through anchor pocket
Wedge not
fully seated
• Wire rope not tight against wedge
• Wedge may be too large • “Dead” end of wire rope and/or wedge may interfere with proper spooling
• Wedge may be too small
Figure 9 Figure 10
Correct Installation
Wedge and wire rope
fully seated in pocket
Drive from
this side
Figure 8
Figure 7

10
HOIST OPERATION
The following warnings and instructions are basic to safe hoist operation. Please read them carefully and follow them
each time your hoist is operated. These instructions are provided in addition to any information furnished by the Original
Equipment Manufacturer. Equipment operators should be completely familiar with the overall operation of the piece of
equipment on which the hoist is mounted (i.e. crane, truck crane, etc.). If you have any questions concerning the safe
operation of this hoist or the equipment it is mounted on, contact the equipment manufacturer that installed the hoist, or
the Braden Product Support Department at 1-918-251-8511, Monday through Friday, 0800 to 1630 hours CST, by fax at
1-918- 259-1575, or via the internet at www.paccarwinch.com.
Warm-up Procedures
A warm-up procedure is recommended at each start-up
and is essential at ambient temperatures below +40°F
(4°C).
The engine should be run at its lowest recommended RPM
with the hydraulic hoist control valve in neutral allowing
sufficient time to warm up the system. The hoist should
then be operated at low speeds, raise and lower with no
load on the hook, several times to prime all lines with warm
hydraulic oil, and to circulate gear lubricant through the
planetary gear sets.
Afterthehoist/boomisproperlypositioned,werecommend
the operator slowly pay-out, then haul-in a short length of
cable. The hoist should perform these operations in a
smooth and controlled manner. If the hoist does not oper-
ate smoothly or makes any unusual sounds, the source of
the problem should be identified and corrected before any
attempt is made to lift a load.
Slowly pay-out wire rope from the hoist drum until it reach-
es the load. Securely fasten the hoist cable to the load
and be sure all ground personnel are a safe distance from
the load. Slowly lift the load a short distance and stop. A
small amount of “bounce” may be observed, depending on
the weight of the load, size and type of wire rope, reeving
and the amount of boom extension. Allow the load to sta-
bilize and then watch for any sign of downward movement
or cable drum rotation. The hoist static brake should hold
the load in place without allowing any downward move-
ment at all. If the load creeps down, it should be lowered
to the ground immediately and the source of the problem
identified and corrected.
If the hoist is holding the load securely, proceed with nor-
mal operations in accordance with the equipment manu-
facturer’s operating procedures and load charts.
If the hoist is mounted on a crane that has an extend-
able boom, care must be taken to pay-out cable as the
boom is extended. Failure to pay-out sufficient cable
could result in a “two-blocking” condition that could
result in damage to and/or failure of the hoist, cable,
sheaves and/or boom.
CAUTION
Ground personnel must stay in view of the operator and
clear of the load and hoist drum at all times. Do not
allow personnel near the hoist line under tension. Do
not allow personnel near the hoist drum while the hoist
is in operation. Do not allow personnel to be in line
with the load. Do not allow personnel to stand under a
suspended load. A safe distance of at least 1½ times
the working length of the cable should be maintained by
ground personnel. A broken cable and/or lost load may
cause property damage, personal injury or death
Failure to use the proper type and viscosity of planetary
gear oil may contribute to intermittent brake clutch slip-
page which could result in property damage, severe
personal injury or death. Some gear lubricants contain
large amounts of EP (extreme pressure) and anti-fric-
tion additives which may contribute to brake slippage
and damage to brake friction discs or seals. Oil viscosity
with regard to ambient temperature is also critical to reli-
able brake operation. Our tests indicate that excessive-
ly heavy or thick gear oil may contribute to intermittent
brake slippage. Make certain that the gear oil viscosity
used in your hoist is correct for your prevailing ambient
temperature.
Failure to properly warm up the hoist, particularly un-
der low ambient temperature conditions, may result in
temporary brake slippage due to high back pressures
attempting to release the brake, which could result in
property damage, severe personal injury or death.

11
Aregularprogramofpreventivemaintenanceforyour plan-
etary hoist is required to minimize the need for emergency
servicing and promote safe, reliable hoist operation.
The user of Gearmatic hoist products is responsible for
hoist inspection, testing, operator training and mainte-
nance noted below with frequency dependent upon the
severity of the hoist duty cycle and the thoroughness of
the preventive maintenance program. Field experience,
supported by engineering tests, indicate the three service
procedures listed below are the most critical to safe, reli-
able hoist operation and MUST be observed.
•Regular Gear Oil Changes -
•Use of Proper Gear Oil – recommended type for prevail-
ing ambient temperatures and additives.
•Periodic Disassembly and Inspection of All Wear Com-
ponents – in compliance with ANSI specification B30.5c,
1987 and API RP 2D.
Crane inspection records as well as records of preventive
maintenance, repairs and modifications must be available
for a minimum of five (5) years. These records should in-
clude but not limited to, hoist model and serial number,
name and employer of repair technician, date and descrip-
tion of work performed.
Pre-use Inspection (each shift the hoist is used): This in-
spection must be performed prior to placing the crane into
service and then as necessary during the day for extended
operation.
1. Check for external oil leaks and repair as necessary.
This is extremely important due to the accelerated
wear that can be caused by insufficient lubricating
oil in the hoist. Lubricant level must be visible in the
lower half of the sight glass. Use only recommended
lubricants. See Recommended Lubricants chart in this
manual.
2. Check hydraulic plumbing for damage, such as chafed
or deteriorating hoses and repair as necessary.
3. Visually inspect for loose or missing bolts, pins, keep-
ers or cotter pins and replace or tighten as necessary.
4. Thegearoil shouldbechangedafterthe first100hours
of operation or 30 days. The regular gear oil change
intervals may be adopted after the first oil change.
5. Inspect the full length of wire rope, rigging and all
sheaves according to the wire rope and crane manu-
facturer’s recommendations.
6. A warm-up procedure is recommended at each start-
up and is mandatory at ambient temperatures below
+40°F (4°C). The engine should be run at its lowest
RPM with the hydraulic hoist control in neutral allow-
ing sufficient time to warm up the system. The hoist
should then be operated at low speeds, hoisting and
lowering with no load, several times to prime all hy-
draulic lines with warm oil and to circulate lubricant
through the planetary gear sets.
Quarterly Inspection (every 3 months) or monthly in Se-
vere Duty Applications or prior to placing the machine in
service if it has not been used for three months or more.
1. Perform the Pre-use Inspection.
2. Inspect all hoist fasteners for tightness and corrosion.
Replace all corroded fasteners and tighten per the
torque specifications on page 11.
3. The hydraulic system filters should be changed after
the first 50 hours of operation then every 500 hours
or quarterly or in accordance with the crane manufac-
turer’s recommendations.
4. Take a sample of the gear oil from the hoist drum fol-
lowing the oil sampling procedure on page 16. The oil
sample must be taken prior to changing the gear oil.
Analyze the sample for wear metals, viscosity, signs of
overheating, oxidation, water and other contaminants.
If the oil sample contains an unusual amount of metal-
lic particles, the hoist should be removed from service
and undergo a tear-down inspection.
Annual Inspection, Testing & Preventive Maintenance
or semi-annually in Severe Duty Applications.
1. Perform the Pre-Use and Quarterly Inspections.
2. Change the lubricating oil in the hoist drum after an oil
sample is taken.
Failure to properly warm up the hoist, particularly un-
der low ambient temperature conditions, may result in
temporary brake slippage due to high back pressures
attempting to release the brake, which could result in
property damage, severe personal injury or death.
CAUTION
WARNING
! !
The gear oil must be changed to remove wear particles
that impede reliable and safe operation of the brake
clutch and erode bearings and seals. Failure to change
gear oil at recommended intervals may contribute to in-
termittent brake slippage, loss of load control, injury or
death.
PREVENTATIVE MAINTENANCE

12
The gear oil should be changed whenever the ambient
temperature changes significantly and an oil from a differ-
ent viscosity range would be more appropriate. Oil viscos-
ity is critical to reliable brake clutch operation. Our tests
indicate that excessively heavy or thick gear oil may con-
tribute to intermittent brake clutch slippage. Make certain
the gear oil viscosity used in your hoist is correct for your
prevailing ambient temperature.
NOTE: If the oil sampling/analysis has not been performed
as required, tear-down inspections will be required. Refer
to Hoist Disassembly section of this
manual.
To change the winch gear oil, remove the drain plugs on
both ends of the winch and the drain plug in the drum.
Ensure both end housings are vented for faster draining.
After all the oil is drained, reinstall the drain plugs and re-
fill the output housing with one of the recommended oils
listed on page 12 to the oil level plug or sight gage. Fill the
primary housing with hydraulic system oil.
3. The vent plug is located in the drum bearing sup-
port. It is important to keep the vent plug clean and unob-
structed. Whenever the gear oil is changed, the vent plug
should be removed, cleaned in solvent and reinstalled. Do
not paint over the vent plug or replace with a solid plug or
grease fitting.
Failure to use the proper type and viscosity gear oil may
result in loss of load control, property damage, injury or
death.
DO NOT insert fingers through oil drain hole to de-
termine drain hole alignment. Movement of the drum
could result in sever injury should appendages be pres-
ent in the drain hole.
OIL DRAIN
VENT/ OIL FILL
OIL LEVEL
SIGHT GAUGE
FREE FALL
SECTION VENT
SERIAL NUMBER
LOCATION
HOIST CIRCULATION
RETURN PORT
LOWERING
PORT
HYDRAULIC OIL DRAIN
HOISTING
PORT
CABLE DRUM
OIL DRAIN

13
Recommended Planetary Gear Oil
Failure to use the proper type and viscosity of planetary gear oil may contribute to intermittent brake clutch slippage
which could result in property damage, severe personal injury or death. Some gear lubricants contain large amounts
of EP (extreme pressure) and anti-friction additives which may contribute to brake slippage and damage to brake
friction discs or seals. Oil viscosity with regard to ambient temperature is also critical to reliable brake operation. Our
tests indicate that excessively heavy or thick gear oil may contribute to intermittent brake slippage. Make certain that
the gear oil viscosity used in your hoist is correct for your prevailing ambient temperature.
PREVAILING AMBIENT TEMPERATURE
oF -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 oF
AGMA 5 EP, ISO VG 220
AGMA 4 EP, ISO VG 150
MOBILGEAR SHC 150
SYNTHETIC OR EQUIVALENT
oC -40 -30 -20 -10 0 10 20 30 40 50 oC
NOTE: SHADED TEMPERATURE RANGE IN THE CHART ABOVE NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS: OFFSHORE
CRANES, SUSTAINED FAST DUTY CYCLES OR FREQUENT LIFTING.
i
TexacoShell
Meropa 150
Meropa 220
Omala 150
Omala 220
Chevron
Gear Compounds EP 150
Gear Compounds EP 220
PREVAILING AMBIENT TEMPERATURE
oF -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 oF
AGMA 5 EP, ISO VG 220
AGMA 4 EP, ISO VG 150
SYNTHETIC OR EQUIVALENT
oC -40 -30 -20 -10 0 10 20 30 40 50 oC
NOTE: SHADED TEMPERATURE RANGE IN THE CHART ABOVE NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS: OFFSHORE
CRANES, SUSTAINED FAST DUTY CYCLES OR FREQUENT LIFTING.
i
TexacoShell
Meropa 150
Meropa 220
Omala 150
Omala 220
Chevron
Gear Compounds EP 150
Gear Compounds EP 220
TexacoMobil Shell
Meropa 150
Meropa 220
Omala 150
Omala 220
Chevron
Gear Compounds EP 150
Gear Compounds EP 220
MOBILGEAR 600 XP 220 OR EQUIVALENT
MOBILGEAR 600 XP 150 OR EQUIVALENT
Mobilgear 600 XP 150
Mobilgear 600 XP 220
Planetary hoists are factory filled with Mobilgear 600 XP 150, or equivalent. Consult your oil supplier for other equivalent
oils if required.
Tear-down Inspection
Any hoist that has not been subjected to regular oil sample
analysis should undergo a tear-down inspection every 24
months. Also, if a hoist has an unknown history of repair
and/or maintenance, the hoist should undergo a tear-down
inspection prior to being placed into service.
A tear-down inspection of the hoist should include the
complete disassembly, cleaning, inspection and replace-
ment of all worn, cracked, corroded or distorted parts such
as pins, bearings, shafts and brake components. All seals
and o-rings should be replaced during a tear-down inspec-
tion. Always use new Spirol pins in the planet gear shafts.
Any deficiency must be corrected
Immediately.
Before placing the hoist back in service, the rebuilt hoist
must be pull tested to the rated load of the hoist with a
dynamometer or equivalent measuring device. The hoist
should be dynamically tested by rotating the drum several
times, in both raising and lowering directions, while un-
der load of at least 30 % of the hoist rated lifting capacity.
Check for smooth, quiet operation during this procedure.
OIL CAPACITY FOR THE GH30B
-01 and -04 DRUM EQUIPPED IS 12 PINTS (5.68 LITER)

14
OIL SAMPLING AND ANALYSIS
Proper oil sampling and analysis of the sample, is a vital
part of a comprehensive preventive maintenance program.
Information obtained from the oil analysis is best utilized in
conjunction with a regular program of preventive mainte-
nance. The early warning of abnormal wear provided by
an analysis program allows the user to substitute preven-
tive maintenance for a far more costly and dangerous fail-
ure that may lead to loss of load control that could result in
property damage, personal injury or death. Early detection
of accelerated component wear allows the scheduling of
corrective maintenance and can reduce in-operation fail-
ures and costly down time.
Taking a Valid Oil Sample
Prepare the hoist by cleaning the drain area and drain ex-
tension tube in order to obtain an uncontaminated sample.
Operate the hoist in both directions for one to two minutes
and then take the oil sample from the drain port as soon as
possible. Do not take the sample from the first oil out of the
drain port. Take a sample from the mid-stream flow of the
oil to obtain an accurate representation of the oil condition.
After taking an oil sample, refill hoist with recommended
lubricant.
Analysis
General Guide Lines
(After approximately 250 hours of operation)
Note: The first oil change usually contains more “wear
metals”. Following the initial break-in period, the wear
metal levels should stabilize at a lower number.
Iron Contaminates
100 to 400 ppm Normal
400 to 700 ppm Caution – Abnormal Sample (monitor
more frequently), tear-down inspection may be required.
701 ppm & up Unacceptable – Abnormal Sample (tear
down inspection required)
In all contaminate monitoring, equally important as the
level of contamination, is the change in the amount of con-
tamination compared to previous samples.
Moisture contamination will lead to the formation of acids
that damage all internal components. Silica found in the oil
typically indicates “dirt” and contaminated lubricant supply
or poor maintenance practices.
Hot oil may cause personal injury and/or burns to un-
protected skin. Make certain the oil has cooled to a safe
temperature (less than 110°F or 43°C) before taking an
oil sample, changing oil or servicing the hoist.
RECOMMENDED BOLT TORQUE
The general purpose torque shown in the chart applies to SAE Grade 5 & Grade 8 bolts, studs and standard steel full,
thick and high nuts.
Higher or lower torques for special applications will be specified such as the use of spanner nuts, nuts on shaft ends,
jam nuts and where distortion of parts or gaskets is critical.
Lubricated torque values based on use of SAE 30 engine oil applied to threads and face of bolt or nut.
Dry Lubed Dry Lubed Dry Lubed Dry Lubed
Torque (LB-FT)
Grade 5
Grade 8
1/4
20
28
5/16
3/8
18
24
16
24
7/16
1/2
9/16
5/8
8
6
12
9
17
13
24
18
45
35
70
50
23
31
50
35
80
110
80
150
110
110
55
75
150
115
210
160
14
20
13
20
12
18
11
18
265
200
Torque (LB-FT)
Grade 5
Grade 8
380
280
7/8
9
14
420
325
600
450
3/4
10
16
680
1 1/8
7
12
790
590
1290
970
1
8
14
640
7
12
1120
835
910
485
1460
1820
1360
1 3/8
6
12
1460
1095
2385
1790
1 1/4
3160
2370
RECOMMENDED FASTENER TORQUE
Bolt Dia.
Inches
Thds Per
Inch
Bolt Dia.
Inches
Thds Per
Inch
1 1/2
6
12
1940

15
TROUBLESHOOTING
TROUBLE PROBABLE CAUSE REMEDY
A
Winch will not pull maxi-
mum load. 1. System relief valve may be set too low.
2. If this trouble occurs suddenly after working
at a maximum pull, a particle of dirt may be
lodged under the system relief valve, hold-
ing it partially open. If this is the cause, a
considerable loss in line speed may be no-
ticed as the load on the cable is increased.
3. If the pump is belt driven, the belts may be
slipping.
4. The oil level in the reservoir may be too low.
The suction line may be restricted or have
an air leak causing cavitation at the inlet
port. This will cause the pump to make a
whining noise.
5. The winch may be mounted on an uneven
or flexible surface which causes distortion of
the winch base and binding of the gear train.
Binding in the gear train will absorb horse-
power needed to generate the rated line pull
and cause heat.
6. Be certain hydraulic system temperature is
not more than 180 degrees F. Excessive
hydraulic oil temperatures increase motor
internal leakage and reduce motor perfor-
mance.
7. Winch line pull rating is based on 1st layer
of wire rope. Expected line pull may be in
excess of winch rating.
8. After all the causes listed above have been
investigatedand itisfound thatthewinch will
stall at maximum pressure without develop-
ing the maximum pull on the bare drum, the
trouble may be in the winch.
Install a pressure gauge in the hoisting port and apply
a stall pull on the winch. If pressure is low, increase
relief valve setting until recommended pressure is ob-
tained.
NOTE: If pressure does not increase in proportion to
adjustment, relief valve may be contaminated or worn
out. In either case, the relief valve may require disas-
sembly or replacement.
Remove relief valve, disassemble and clean parts
thoroughly in a suitable solvent. Reassemble and in-
stall relief valve. Reset pressure according to specifi-
cations.
Check belts when pump is at full PSI (kg/cm2) (stall
pull on winch). Tighten belts if they are found to be
slipping.
Check oil level in the reservoir. Check the suction line
for damage, externally and internally. Replace suction
line if necessary.
Reinforce mounting surface.
If necessary, use steel shim stock to level winch.
First loosen, then evenly retighten all winch mounting
bolts to recommended torque.
Same as remedy for A-5.
Same as remedy for B-4.
Refer to winch performance charts for additional in-
formation.
Install a pressure gauge in the motor haul-in port and
apply a stall pull on the winch. If the pressure is up to
maximum and the bare drum line pull is less than the
specified line pull, the trouble may be in the winch or
hydraulic motor.
Disassemble winch according to disassembly instruc-
tions and check that gear train turns freely. If gear
train is found to be satisfactory, inspect the hydraulic
motor, according to the service instructions for the hy-
draulic motor.

16
TROUBLESHOOTING
TROUBLE PROBABLE CAUSE REMEDY
B
Considerable reduction
in line speed. 1. Same as A-2.
2. Same as A-4.
3. Same as A-6.
4. If this trouble has increased gradually, the
hydraulic pump or winch motor may be
worn.
Same as remedy for A-2.
Same as remedy for A-4.
Same as remedy for A-5 and B-4.
Remove and inspect pump. If satisfactory, consult the
disassembly instructions for the winch and remove
and inspect the motor according to the service instruc-
tions for the hydraulic motor.
C
Reverse speed is
slower than forward
speed.
1. Control valve may be restricted in its travel.
2. Same as A-1.
3. Oil may be too thick causing a high resis-
tance to rotation at the brake plates and
causing the relief valve to by-pass.
4. Same as F-1.
Check the travel of the control valve spool. The spool
travel should be the same in both directions.
Same as remedy for A-1.
Follow warm-up procedure in “Preventive Mainte-
nance” section.
Same as remedy for F-1.
D
Brake will not hold when
control valve is returned
to neutral after lifting a
load.
1. Excessive system back pressure acting on
the brake release port.
2. Friction brake will not hold due to worn or
damaged brake discs.
3. Brake clutch is slipping.
Install a pressure gauge at the lowering port of the
hydraulic motor. Operate the pump at full throttle and
monitor pressure in “neutral” and haul-in positions. If
the pressure is greater than 100 PSI, check for restric-
tions in the return line from the winch to the control
valve and the control valve to the reservoir.
Disassemble winch to inspect/replace worn parts.
Improper hydraulic oil may cause the brake clutch to
slip. Replace brake parts and refill reservoir with rec-
ommended hydraulic oil.
Brake clutch may be damaged or worn. Disassemble
and inspect brake clutch.
E
Brake will not control or
stop the load when low-
ering.
1. Same as D-1, 2, or 3.
2. Winch is being overloaded.
3. After the causes listed above have been
investigated and found to be satisfactory,
the trouble may be in the winch.
Same as remedies for D-1, 2, or 3.
Install a pressure gauge at the haul-in port and apply
a stall pull on the winch. If the pressure is higher
than the maximum specified PSI, reduce the pres-
sure.
Disassemble the primary drive assembly according
to the disassembly instructions. Inspect the brake
springs, brake plate and brake hub assembly. Check
that the brake hub assembly will “lock up” in the
required direction of rotation.

17
TROUBLESHOOTING
TROUBLE PROBABLE CAUSE REMEDY
F
The winch will not lower
the load or not lower the
load smoothly
1. The friction brake may not be releasing as a
result of a defective brake piston seal.
NOTE: If the brake piston seal is defective,
you will usually notice excessive oil flow
from the winch vent line.
2. Friction brake will not release as a result of
damaged brake disc.
3. Hydraulic system flow too low for smooth op-
eration of winch motor and brake release.
4. Same as B-4.
5. Same as A-3.
6. Same as A-5.
7. Control valve handle being operated too
quickly.
8. No oil circulating through the winch.
9. Control Valve does not have good metering
characteristics.
Check brake piston seals.
Disassemble brake to inspect brake discs.
Operate pump at maximum RPM.
Same as remedy for B-4.
Same as remedy for A-3.
Same as remedy for A-5.
Operatecontrolvalvesmoothlywhenstartingandstop-
ping a load. Conduct operator training as required.
Install oil circulation line. See section on hydraulic cir-
cuit.
See “Winch Installation” sections for control valve
specifications.
G
The winch runs hot. 1. Same as A-5.
2. Be certain that the hydraulic system tem-
perature is not more than 180 degrees F.
Excessive hydraulic oil temperatures may
be caused by:
A. Plugged heat exchanger.
B. Too low or high oil level in hydraulic reser-
voir.
C. Same as A-1.
D. Hydraulic pump not operating efficiently.
3. Excessively worn or damaged internal winch
parts.
4. Circulation oil drain line may be restricted.
Same as remedy for A-5.
Thoroughly clean exterior and flush interior.
Fill/drain to proper level.
Same as remedy or A-1.
Remove and inspect pump.
Check suction line for damage. If pump is belt driven,
belts may be slipping. Replace/tighten belts.
Disassemble winch to inspect/replace worn parts.
Inspect the vent drain line for damage or restrictions.
H
Winch “chatters” while
raising rated load. 1. Same as A-1.
2. Same as B-4.
3. Same as F-3.
4. Same as F-7.
Same as remedy for A-1.
Same as remedy for B-4.
Same as remedy for F-3.
Same as remedy for F-7.

18
The GH30B weighs approximately 1500 lbs (680 kg). Make
certain lifting equipment has adequate capacity. Using under-
sized or poorly maintained lifting equipment may result in a
dropped load, property damage injury or death.
CAUTION
HOIST DISASSEMBLY
1. Remove the wire rope from the hoist. Drain the gear
oil by removing the oil fill plug and the drain plug from
the output gear side of the hoist. Drain the hydraulic oil
from the input side of the winch by removing the drain
plug and the return hose.
2. Remove the hydraulic hoses and mounting bolts, and
clean the outside surface of the hoist in preparation for
disassembly. To ease aligning parts on reassembly,
mark the winch bolted connections with a paint pin or
scribe line.
3. Stand the hoist on the output end. Remove the seven
capscrews (17) and lockwashers (16) securing the mo-
tor to the primary housing cover and lift the motor off
the hoist. Remove and discard the motor flange o-ring
(19) and the brake release o-ring (30).
OIL DRAIN
HOIST
OIL DRAIN
17
16
30
19
4. Remove Overrunning clutch assembly
5. Note: The brake parts group will come out of the winch
with the primary housing cover because the parts are
captured by the retaining ring (209). Remove the
spring tension from the primary housing cover (201) by
loosening the six capscrews (17) one turn each alter-
nating across the housing. Remove the primary hous-
ing cover turning in a slight rotary motion when lifting
out of the housing.
5. Remove the divider plates (211), brake plates (212),
and spacer (213.)
17
201
213
213
211
212

19
6. Remove the primary sun gear (7),ring gear (6), Thrust
Bearing (48), and primary carrier assembly (300)
7. Mark the tie plates to the side of the winch to ease re-
assembly. Remove the tie-plate capscrews and lock-
washers and remove the tie-plates (21).
300
6
7
48
21
1
2
8. Remove the primary housing (2) and end-plate (1). Use
eye-bolts and lift straight up off of the drum.
9. Remove the sun gear shaft (5). Use lifting clamps to
lift the drum assembly straight up and off of the final
drive housing.
10. Place the final drive housing with the drum side down
and remove capscrews (17) and lockwashers (16).
Remove final drive housing cover (4).
11. Remove thrust washer (26), thrust button (27), and
output planet carrier assembly (400).
Refer to subassembly sections for disassembly and as-
sembly of subassemblies.

20
209
201
208
210
207
202
204
203
205
206
BRAKE CYLINDER
DISASSEMBLY
1. A hydraulic press or spring compressor tool is re-
quired to disassemble the brake subassembly. Place
the brake subassembly on the press with the primary
housing cover (201) down. Place a heavy steel bar
across the large diameter of the pressure plate (210)
and compress the springs until spring force is removed
from the retaining ring (209). Remove the retaining
ring with retaining ring pliers. Slowly release the press
force on the pressure plate.
2. Remove the pressure plate (210), spring separator
(208), and springs (207).
3. Remove the brake piston (202) from the primary hous-
ing cover (201). Remove the o-rings and back-up
rings from the brake piston and discard (items 203,
204, 205, and 206).
Clean and Inspect
1. Thoroughly clean and inspect all parts. Check seal-
ing surfaces on the primary housing cover and brake
piston. Ensure the brake release port is clean and free
of debris.
2. Place brake friction disc on a flat surface and check
for distortion with a straight edge. Friction material
should appear even across the entire surface with the
groove pattern visible. Replace friction discs or divider
plates if distorted, burned, wear is uneven, or splines
are worn to a point.
3. Check brake spring free length. Minimum free length
is 2.910. If it is required by measurement to replace
one spring, you must replace all springs.