Rice Lake CLS420 User manual

1
WINCH DIVISION
P.O. BOX 547 BROKEN ARROW, OK U.S.A. 74013
PHONE [phone] FAX [phone]
www.paccarwinch.com
LIT2429 R2
9-2010
Printed in U.S.A.
Copyright 2010
PACCAR Hoist Division
All Rights Reserved
GH30B
EQUAL SPEED HYDRAULIC HOIST
SERVICE AND MAINTENANCE MANUAL
-40XXXC
-40XXXD
w/FOUR BOLT SAE “C” & “D” FLANGE MOTORS
EQUAL SPEED GEARING WITH
AND WITHOUT FREE FALL

2
TABLE OF CONTENTS
INTRODUCTION
The following service instructions have been prepared to provide assembly, disassembly, and maintenance information
for the Gearmatic Model GH30B-40XXXC and 40XXXD. 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 com-
ponents 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 Support 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
BASIC OPERATION.........................................................................................................6
DESCRIPTION OF FREE FALL OPERATION.................................................................8
HYDRAULIC CIRCUIT.....................................................................................................9
WIRE ROPE INSTALLATION.........................................................................................10
HOIST OPERATION.......................................................................................................12
PREVENTATIVE MAINTENANCE .................................................................................13
RECOMMENDED PLANETARY GEAR OIL...................................................................16
OIL SAMPLING AND ANALYSIS....................................................................................17
RECOMMENDED BOLT TORQUE................................................................................17
TROUBLESHOOTING ...................................................................................................18
HOIST WITHOUT FREE FALL DISASSEMBLY.............................................................21
FREE FALL HOIST DISASSEMBLY...............................................................................23
BRAKE CYLINDER SERVICE .......................................................................................28
CABLE DRUM SERVICE...............................................................................................31
PRIMARY PLANET CARRIER SERVICE ......................................................................32
OUTPUT PLANET CARRIER SERVICE........................................................................34
OVER-RUNNING CLUTCH SERVICE...........................................................................35
BRAKE VALVE SERVICE...............................................................................................36
HOIST WITHOUT FREE FALL ASSEMBLY..................................................................37
FREE FALL HOIST ASSEMBLY.....................................................................................38
HOIST WITHOUT FREE FALL CROSS-SECTION AND PARTS KEY...........................40
FREE FALL HOIST CROSS-SECTION AND PARTS KEY.............................................42
METRIC CONVERSION TABLE ....................................................................................44

3
GH30 B - SPL - 40 XXXC - 04
GH30 - DESIGNATES GEARMATIC HOIST
B - EVOLUTIONARY DESIGNATION
SPL - SPECIAL ORDER DESIGNATION
40 - TOTAL GEAR REDUCTION (40:1)
XXXC - NO MOTOR SAE “C” FLANGE
XXXD - NO MOTOR SAE “D” FLANGE
04 - DRUM OPTION
FF - FREE FALL
EXPLANATION OF MODEL NUMBER
The primary housing is lubricated with gear oil on
this model GH30B. Hydraulic oil is NOT used for
flushing the primary housing on this hoist.
CAUTION
!
!

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”
technique.
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 Hoist 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 neces-
sary, use shim stock to insure proper mounting. The
mounting 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). Always
run a dedicated case drain hose to tank on two-speed
motors and piston motors. Limit back pressure to 30
psi on piston motors.
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-
position, four-way valve without detents and with a
spring centered motor spool such that the valve re-
turns 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.Ahigh 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)
lower 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 weld hoist to mounting surface. Welding may
not provide adequate structural support for hoist 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
! !
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.
CAUTION
WARNING
! !
This hoist must be used with a motor and brake valve
that is approved in writing by PACCAR Hoist Engineer-
ing Department. Improper hydraulic hook-up or failure
to use an approved brake valve could result in hoist fail-
ure and/or injury to personnel.
Using the free-fall brake to stop a load while it is in
free-fall may result in death, personal injury, or property
damage. For this reason, the full release free-fall circuit
must be activated by a detent switch or valve.
The primary housing is lubricated with gear oil on this
model GH30B. Hydraulic oil is NOT used for flushing the
primary housing on this hoist.
CAUTION
!
!

6
BASIC OPERATION
DESCRIPTION OF HOIST
The GH30B-XXXXXC or XXXXXD and two-speed hoists
are made up of the following sub-assemblies:
1. Hydraulic motor and brake valve
2. Brake cylinder and brake clutch assembly
3. Hoist base components
4. Hoist drum and gear train
THEORY OF OPERATION
The primary sun gear is directly coupled to the hydraulic
motor by the inner race of the brake clutch assembly. As
the motor turns in the hoisting direction, the planetary as-
semblies reduce the input speed of the motor and rotate
the hoist drum. The output carrier is splined to the drum,
and the drum rotates in the same direction as the input
shaft. In the hoisting direction, the static brake remains
fully applied and the input shaft rotates freely through the
sprag clutch. When the motor is stopped, the load tries to
rotate the hoist gear train in the opposite direction. The
sprag clutch on the input shaft immediately locks up, al-
lowing the fully applied static brake to hold the load. See
Dual Brake System - Operation for a detailed description
of the lowering sequence of operation.
Dual Brake System – Description
The dual brake system consists of a dynamic brake sys-
tem and a static brake system.
The dynamic brake system has two operating compo-
nents:
1. Brake valve assembly
2. Hydraulic motor
The brake valve is basically a counterbalance valve with
improved metering. It contains a check valve to allow free
flow of oil in the hoisting direction.
STATIC
BRAKE
MOTOR
BRAKE
VALVE
PUMP
TO
TANK
LOW PRESSURE MEDIUM PRESSURE HIGH PRESSURE
FIGURE 2
STATIC
BRAKE
BRAKE
VALVE
PUMP
TO
TANK
LOW PRESSURE MEDIUM PRESSURE HIGH PRESSURE
FIGURE 3
STATIC
BRAKE
MOTOR
BRAKE
VALVE
PUMP
TO
TANK
LOW PRESSURE MEDIUM PRESSURE HIGH PRESSURE
FIGURE 4

7
When lowering a load very slowly for precise positioning,
very little oil flow actually occurs through the hoist motor.
The pressure will build up to a point where the static brake
will release sufficiently to allow the load to rotate the motor
through its own internal leakage. This feature results in a
very slow speed and extremely accurate positioning.
The friction brake receives very little wear in the lowering
operation. All of the heat generated by the lowering and
stopping of a load is absorbed by the hydraulic oil where it
can be readily dissipated.
The static brake is released by the brake valve pilot pres-
sure at a pressure lower than that required to open the
pilot operated spool valve. This sequence assures that
dynamic braking takes place in the brake valve and that
little, if any, heat is absorbed by the friction brake.
The static friction brake is a load holding brake only and
has nothing to do with dynamic braking or rate of descent
of a load.
The brake clutch is splined to the primary sun gear shaft
between the motor and the primary sun gear. It will allow
this shaft to turn freely in the direction to raise a load and
lock up to force the brake discs to turn with the shaft in the
direction to lower a load. Figures 5 and 6.
The hydraulic cylinder, when pressurized, will release the
spring pressure on the brake discs, allowing the brake
discs to turn freely.
Dual Brake System – Operation
When hoisting a load, the brake clutch which connects the
motor shaft to the primary sun gear, allows free rotation.
The sprag cams lay over and permit the inner race to turn
free of the outer race. Figure 5. The static friction brake
remains fully engaged. The hoist, in raising a load, is not
affected by any braking action. Figure 2.
When the lifting operation is stopped, the load attempts to
turn the primary sun gear in the opposite direction. This
reversed input causes the sprag cams to instantly roll up-
ward and firmly lock the shaft to the fully engaged friction
brake. Figure 6.
When the hoist is powered in reverse, to lower the load,
the motor cannot rotate until sufficient pilot pressure is
present to open the brake valve. Figures 3 & 4. The fric-
tion brake within the hoist will completely release at a
pressure lower than that required to open the brake valve.
The extent to which the brake valve opens will determine
the amount of oil that can flow through it and the speed
at which the load will be lowered. Increasing the flow of
oil to the hoist motor will cause the pressure to rise and
the opening in the brake valve to enlarge, speeding up
the descent of the load. Decreasing this flow causes the
pressure to lower and the opening in the brake valve to
decrease thus slowing the descent of the load.
When the control valve is shifted to neutral, the pressure
will drop and the brake valve will close, stopping the load.
The friction brake will engage and hold the load after the
brake valve has closed.
Stopped,
holding
load
Sprag
Cams
Static Friction Brake Applied
Figure 6
Hoisting
Sprag
Cams
Static Friction Brake Applied
Figure 5

8
DESCRIPTION OF FREE-FALL OPERATION
Free Fall
Brake Release Port
Using the free-fall brake to stop a load while it is
in free-fall may result in death, personal injury, or
property damage. For this reason, the full release
free-fall circuit must be activated by a detent switch
or valve.
CAUTION
WARNING
! !
The primary sun gear is directly coupled to the hydraulic
motor by over-running clutch in the static brake assembly.
As the motor turns in the hoisting direction the planetary
assemblies reduce the input speed of the motor and rotate
the final planet carrier and hoist drum.
The Free-Fall assembly contains the final drive planetary
reduction for the hoist. The final planet carrier is connect-
ed to the cable drum by splines and the internal ring gear
is mounted on ball bearings. The internal ring gear is kept
from rotating by a multi-disc brake. The brake is applied
by springs that force the piston against the pressure plate
which prevents the ring gear from rotating.
When hydraulic oil is introduced into the annular area
between the piston and the freefall housing, the effective
spring load is reduced as the hydraulic pressure increas-
es. When a load is suspended on the hoist cable and hy-
draulic pressure is applied to move the piston to the end of
its travel, or the full release position, the internal ring gear
and output carrier will rotate and allow the load to drop
freely to the ground.
The free fall circuit must be activated by a detent switch.
Release of the freefall brake with use of a metered and
controlled hydraulic signal must be done by means of a
detent type control. Using the freefall brake to stop a load
during lowering once the freefall brake has been pressur-
ized may result in hoist damage.
Free Fall Release Pressures:
Initial Release - 420 psi (2896 kPa)
Full Release - 550 psi (3792 kPa)
Maximum Pressure - 1500 psi (10,340 kPa)

9
In order to maintain maximum efficiency in the hoist, se-
lect the size of hydraulic lines according to the maximum
volume of oil to be used in the hoist (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).
Thesizesshowninthetablearetobeusedasaguideonly.
If trouble is experienced due to the use of long hoses it will
be necessary to use hoses which are one size larger.
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
HOIST BRAKE
BRAKE
VALVE
PUMP
CONTROL
VALVE
HOIST ASSEMBLY
W/BRAKE VALVE
& STATIC BRAKE
BR
DR
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)
HOIST BRAKE
BRAKE
VALVE
2-SPEED
SELECTOR
VALVE
PUMP
CONTROL
VALVE
HOIST ASSEMBLY
W/BRAKE VALVE
& STATIC BRAKE
TP
BR
DR
A
SINGLE SPEED MOTOR TWO-SPEED MOTOR

10
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.
WIRE ROPE INSTALLATION
Winches built in August 2010 and later will be supplied
with a cable drum that has two wire rope anchor pockets to
enable the winch to be configured for underwound (Model
code U) applications. Make certain to install the wire rope
in the anchor pocket that is correct for your application.
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 Technical 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 hook block and the drum with all the rope off
the drum except for the last five wraps.
WIRE ROPE INSTALLATION
A
B
CABLE WEDGE PLACEMENT
CABLE POCKET COVER
CABLE WEDGE
CABLE DRUM
CABLE
Attempting to use the incorrect wire rope anchor pocket
may cause permanent damage to wire rope, cable drum
and wire rope slipping free of wedge. These conditions
may result in loss of load control, property damage, in-
jury or death.
A) Wire rope anchor pocket for standard rotation. Drum
rotates counter clockwise (CCW) to hoist a load when
viewed from the motor end.
B) Wire rope anchor pocket for underwound rotation. U
is the last character in the model code. Drum rotates
clockwise (CW) to hoist a load when viewed from the
motor end.

11
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

12
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/boomis properly positioned, we recommend
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.
Using the free-fall brake to stop a load while it is in
free-fall may result in death, personal injury, or property
damage. For this reason, the full release free-fall circuit
must be activated by a detent switch or valve.
CAUTION
WARNING
! !

13
Aregularprogramofpreventivemaintenanceforyourplan-
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 pre-
vailing ambient temperatures and additives.
• Periodic Disassembly and Inspection of All Wear Com-
ponents– incompliancewithANSIspecificationB30.5c,
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
inspection must be performed prior to placing the crane
into service and then as necessary during the day for ex-
tended 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 neces-
sary.
4. Thegearoilshouldbechangedafterthefirst100hours
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

14
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: Iftheoil 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 hoist gear oil, remove the drain plugs on
both ends of the hoist and the drain plug in the drum. En-
sure both end housings are vented for faster draining. Af-
ter all the oil is drained, reinstall the drain plugs and refill
the hoist housing with one of the recommended oils listed
on page 12 to the oil level plug or sight gage.
3. The vent plug is located in the support end housing
cover. It is important to keep the vent plug clean and
unobstructed. 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.
OIL DRAIN
VENT/OIL FILL
CABLE DRUM
OIL DRAIN
SERIAL NUMBER
LOCATION
OIL DRAIN
HOISTING
PORT
DRAIN TO TANK
LOWERING PORT
OIL LEVEL PLUG
OR SIGHT GAUGE
OIL FILL
HOIST
HOIST WITHOUT FREE FALL

15
SERIAL NUMBER
LOCATION
OIL DRAIN
OIL LEVEL
SIGHT GAUGE
OIL FILL
HOIST
HOISTING
PORT
OIL DRAIN
OIL FILL VENT
CABLE DRUM
OIL DRAIN
LOWERING
PORT
DRAIN TO TANK
FREEFALL BRAKE
RELEASE PORT
(To Be Assembled in
Vertical Position)
FREE FALL HOIST

16
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.
RECOMMENDED PLANETARY GEAR OIL
PREVAILING AMBIENT TEMPERATURE
o
F -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130
o
F
AGMA 5 EP, ISO VG 220
AGMA 4 EP, ISO VG 150
MOBILGEAR SHC 150
SYNTHETIC OR EQUIVALENT
o
C -40 -30 -20 -10 0 10 20 30 40 50
o
C
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
RECOMMENDED PLANETARY GEAR OIL
PREVAILING AMBIENT TEMPERATURE
o
F -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130
o
F
AGMA 5 EP, ISO VG 220
AGMA 4 EP, ISO VG 150
SYNTHETIC OR EQUIVALENT
o
C -40 -30 -20 -10 0 10 20 30 40 50
o
C
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 24 PINTS (11.4 LITER)
FREE FALL UNIT IS 30 PINTS (14.2 LITERS)
The primary housing is lubricated with gear oil on
this model GH30B. Hydraulic oil is NOT used for
flushing the primary housing on this hoist.
CAUTION
!
!

17
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 inspec-
tion 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

18
TROUBLESHOOTING
TROUBLE PROBABLE CAUSE REMEDY
A
Hoist 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 hoist may be mounted on an uneven
or flexible surface which causes distortion of
the hoist 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. Hoist line pull rating is based on 1st layer
of wire rope. Expected line pull may be in
excess of hoist rating.
8. After all the causes listed above have been
investigated and it is found that the hoist will
stall at maximum pressure without develop-
ing the maximum pull on the bare drum, the
trouble may be in the hoist.
Install a pressure gauge in the hoisting port and apply
a stall pull on the hoist. 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 hoist). Tighten belts if they are found to be slip-
ping.
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 hoist.
First loosen, then evenly retighten all hoist mounting
bolts to recommended torque.
Same as remedy for A-5.
Same as remedy for B-4.
Refer to hoist performance charts for additional infor-
mation.
Install a pressure gauge in the motor haul-in port and
apply a stall pull on the hoist. 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 hoist or
hydraulic motor.
Disassemble hoist 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.

19
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 hoist 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 hoist and remove and
inspect the motor according to the service instructions
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.
5. Brake valve not operating properly.
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.
Inspect brake valve.
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 hoist to the control
valve and the control valve to the reservoir.
Disassemble hoist 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 valve will not
control or stop the load
when lowering.
1. Brake valve not operating properly.
2. Same as D-1, 2, or 3.
3. Hoist is being overloaded.
4. After the causes listed above have been
investigated and found to be satisfactory,
the trouble may be in the hoist.
Inspect brake valve.
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 hoist. If the pressure is higher than
the maximum specified PSI, reduce the pressure.
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.

20
TROUBLESHOOTING
TROUBLE PROBABLE CAUSE REMEDY
F
The hoist will not lower
the load or not lower the
load smoothly
1. Brake valve not operating properly.
2. The friction brake may not be releasing as a
result of a defective brake piston seal.
3. Friction brake will not release as a result of
damaged brake disc.
4. Hydraulic system flow too low for smooth
operation of hoist motor and brake release.
5. Same as B-4.
6. Same as A-3.
7. Same as A-5.
8. Control valve handle being operated too
quickly.
9. Control Valve does not have good metering
characteristics.
Inspect brake valve.
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.
See “Hoist Installation” sections for control valve spec-
ifications.
G
The hoist 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 hoist
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 hoist to inspect/replace worn parts.
Inspect the vent drain line for damage or restrictions.
H
Hoist “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.