Gearn Offshore Inc.

H-Drive 2
User Guide
1/14/14

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
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Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
Table of Contents

Page Contents
5 Contact Information
7 System Specifications
8 Installation Guide
9 Powering Up Guide
10 Offshore Operations Guide
11 Maintenance Guide
12 Lubrication
13 Component Part Numbers & Spare Parts
15 Detailed Component Identification
25 Detailed Component Description
29 Troubleshooting

Appendix A Electrical and Hydraulic Schematics

Appendix B Drawings

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
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Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
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Contact Information:
Tim Gearn
President
3510 Hwy 385
Hereford, Texas 79045
E-mail timgearn@gearnoffshore.com
Phone 806 364 6900
Fax 806 364 6120
Cellular 806 681 9200

Keith Ann Gearn

Vice President - Financial
3510 Hwy 385
Hereford, Texas 79045
E-mail keithnn@gearnoffshore.com
Phone 806 364 6900
Fax 806 364 6120
Cellular 806 681 9202

Jason Gearn P.E.

General Manager
3510 Hwy 385
Hereford, Texas 79045
E-mail jasongearn@gearnoffshore.com
Phone 806 364 6900
Fax 806 364 6120
Cellular 281 773 5330

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
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Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
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System Specifications:

Maximum Torque During Testing 206,000 ft-lb

Vertical Load Capacity 30,000 lb
Trucking Width (With 2 Outriggers Removed) 89 in
Total Width with Outriggers 193 in
Height 37 in
OD of Basket Support Ring 89 in
ID of Basket Support Ring 65 in
Total Shipping Weight (All Components) 15,000 lb
Input Power 3-phase, 4-wire, 480 VAC, 60 Hz, 60A
Input Power Cable Not Supplied
Length of Hydraulic Lines from HPU to H-Drive 40 ft
Length of Electrical Cable from HPU to Remote 40 ft
Electrical Environmental Rating NEMA 4X, as fully assembled (all covers in place)
Lifting Hardware Required for HPU • Forklift Slots
• Slings Used with Forklift Slots
• 4 Shackles 6.5 ton 1” Pin & 4 Slings 6 ft Each Minimum
Lifting Hardware Required for H-Drive 4 Shackles 6.5 ton 1” Pin & 4 Slings 16 ft Each minimum
Gear Grease Required Mobil Premium Lubricating Grease
(used at greasing points and gear surfaces) or equivalent, XHB-222 used
Gearbox Oil Required MobilGear 600 XP Series
Hydraulic Oil Required Mobil DTE 10 Series

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 8

Installation Guide:
Prior to any installation of the H-Drive, it is imperative that the specifications of the job be analyzed to determine that the H-Drive
is fit for purpose for the application. Any deviations from the stated specifications for the H-Drive will lead to poor performance
offshore.
Before further operations are performed, review the lubrication requirements for the gearboxes on the previous page.
The first step in preparing the H-Drive for installation is ensuring that the unit is ready to be moved. Check that the electrical and
hydraulic connections from the HPU to the H-Drive is undamaged, and free of obstructions. Unwire the primary input power
from its existing power source (if applicable). For the HPU, check that the remote is secured inside. If the H-Drive is to be
moved with the outriggers detached, make sure that all bolts and other covers are gathered. It is recommended to move the H-
Drive with the outriggers attached. NOTE: the H-Drive cannot be lifted with a basket installed!
Next, identify the lift points and tie down points on the HPU and H-Drive indicated by the labels on each item. The HPU may be
lifted through the forklift slots using slings or the lifteyes located on top. The H-Drive is lifted from the four lifteyes located
inside the basket ring. The lifteyes are rated for a 6.5 ton, 1” pin bolt-type anchor shackles.
Prepare the H-Drive for lifting. Install the shackles and slings on the H-Drive. Review all rigging for security. Place the H-Drive
exactly where it is to be operated, with attention paid to where the HPU will be placed and the umbilical will be routed.
After the H-Drive and HPU are placed, route the hydraulic and electrical lines starting from the H-Drive to the HPU. There are
two 1” hydraulic hoses and one 1/2” hydraulic hose that are attached to the H-Drive and have quick couplers on the HPU end.
These are the primary forward and reverse lines and the case drain line. There is also a small electrical cable that is hard-wired
into the H-Drive and has a plug on the HPU side. This is the electrical cable is to connect the pressure transducer to the remote
display. This is for information purposes only about the realized pressure at the H-Drive and the status of the parking brakes.
Remove the remote from the HPU and locate it on the deck where the H-Drive is to be controlled. This step is important to
visualize all hazards during operations. Plug the remote into the receptacle located next to the hydraulic quick couplers.
Wire the HPU to a power source. The power cable to the HPU is not supplied. It may be wired to a generator or ship's supply.
Route the electrical cable through the provided penetration on the side of the HPU and into the external power termination
enclosure. This enclosure is identified by the large electrical shutoff in the center. Be sure to have the shutoff switch in the off
position before wiring.
Once all of the components for the H-Drive system are placed, then they must be secured. The H-Drive may be welded or clipped
to the deck along all of the horizontal plates lying directly on the deck. WARNING: The H-Drive can generate large
horizontal forces, so the tiedown method and process must be engineered to provide sufficient strength. Injury or death
could occur if this warning is not heeded. HPU AND the umbilical must also be fully secured. If the H-Drive becomes
dislodged, the umbilical will drag the HPU along with it. If the electrical umbilical is secured independently to the deck, the
dangers of this would be reduced. The remote is not intended to be secured to the deck. It is considered more safe to be able to
easily relocate it based on field conditions.
Now the system is ready to power up.
NOTE: Do not install the basket on the H-Drive until it has been operated at its current location. Any
troubleshooting is best done without a basket installed.

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 9

Powering Up Guide:
The H-Drive is requires an electrical supply of 480 VAC, 3-phase, 60 Hz @ 60A. Wire the input power cable to a generator or
the ship's supply. Use the shutoff switch on the HPU to de-energize it. Check that each hot wire is not grounded or shorted to
another wire. Check that the ground wire is grounded. Remove the remote from the HPU and plug it in. Make sure the E-Stop
button is pressed in.
Use the following procedure every time the H-Drive is powered up for the first time for a job:
1. Examine all electrical and hydraulic connections.
2. Examine the security of the tie downs of all components.
3. Examine the main gear. Look for any debris stuck in the gear grease or any other item that would be a hazard to the
rotation of the H-Drive.
4. Make sure the electrical disconnect switch for the incoming power in the HPU is off.
5. Place the remote a safe distance from any electrical or hydraulic hazards.
6. Check the hydraulic oil fill level.
7. Make sure the shutoff valve for the hydraulic tank is open.
8. Never close the shutoff valve for the hydraulic tank unless the tank is being removed from the HPU.
9. Make sure the E-Stop button on the remote is pressed in (in the off position).
10. Make sure the Manual/Remote switch in the electrical panel of the HPU is set to Remote.
11. Make sure the E-Stop button on the HPU is pressed in (in the off position).
12. Now turn on the power source.
13. Now turn on the electrical disconnect switch for the incoming power.
14. Now turn on the E-Stop button on the HPU. The system should light up but not turn on the motor.
15. Now turn on the E-Stop button on the remote VERY BREIFLY. The remote should light up and the motor should turn
on.
16. Verify the rotation direction of the motor.
17. If the direction is reversed, turn off the power source, change the wiring inside the incoming power electrical enclosure
on the HPU and check rotation again.
18. Now turn on the E-Stop button on the remote for 1-2 seconds and listen and look for problems.
19. Now turn on the E-Stop button on the remote for 5-10 seconds and listen and look for problems.
20. Now turn on the E-Stop button on the remote and leave it on.
21. Use the remote joystick to slowly rotate the H-Drive in both directions.
22. Allow the H-Drive to rotate all the way around in each direction and flush the air from the hydraulic lines.
23. Continue to rotate the H-Drive for about 5 minutes in each direction to ensure proper hydraulic fluid flow.
24. Listen for any squeaking which indicates that additional lubrication should be applied to all greasing points.
25. The H-Drive is ready to add the basket.
The basket and the hardware used to attached the basket must be evaluated to support the torque and attachment requirements of
the H-Drive. Gearn Offshore makes no claims of liability for any hardware that is attached to the H-Drive. Make sure that the
basket is centered on the H-Drive with a tolerance of +/- 3”.
With the basket installed and secured, the H-Drive should be rotated for enough time (15+ minutes) to ensure the load is stable,
and no other problems arise. Press the E-Stop button several times from a full speed to establish that the brakes are working
normally. Once these steps have been taken, the H-Drive is prepared for operation. Any time the unit is powered off, the remote
should be returned to the cabinet and the primary power should be switched off. The basket should be secured to the deck.

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
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Offshore Operation Guide:

WARNING: THIS OPERATIONS GUIDE ASSUMES THAT THE OPERATORS (YOU) HAVE
FULLY UNDERSTOOD AND CONFIGURED THE FOLLOWING:
INPUT POWER WITH CUTOFF SWITCH
FULLY SECURED LOAD TO H-DRIVE
FULLY SECURED H-DRIVE TO SHIP
FULLY SECURED HPU TO SHIP
FULLY READ AND UNDERSTAND THIS OPERATION MANUAL IN ITS ENTIRETY

THIS H-DRIVE IS A HIGH TORQUE DEVICE THAT CAN CAUSE

EXTREME DAMAGE TO PROPERTY AND PERSONNEL IF NOT
PROPERLY CONFIGURED

Once the H-Drive is ready for operation:

Release the binding securing the load to the basket.
Lower (reel out) the load until the load can safely maintain tension on the basket.
Once the load can maintain tension against the basket, try several times to raise the load (reel in) to establish that the H-Drive has
full control of the load. Do these operations SLOWLY.
Continue to lower the load. As the weight on the H-Drive increases, it is important to continue to raise the load a small amount to
ensure the H-Drive has full control of the load.

WARNING:
It is imperative that the operator (you) learn to use the joystick to slow and stop the load, and to not rely on, or
get in the habit of using the brakes to stop the load each time. The joystick must be operated with a very slow
hand. Any sudden motion of the joystick can induce an unintended result.

Once the load is fully deployed in the water, it should once again be raised and lowered repeatedly to ensure the H-Drive has full
control of the load.
Continue to lower the load. As the load approaches the bottom, use the joystick to slow and stop the load.
When raising a load after deployment, it is important to maintain a smooth, continuous upward motion. Pay careful attention to
anything that could hang or foul during reel in. The H-Drive is very powerful and uses full power regardless of rotation rate. If
anything that snags during reel in will cause extremely large forces to occur immediately.
Once the load is nearly reeled in, it is important to slow the H-Drive using the joystick. The drive will have a tendency to
continue to rotate as part of a “ramp down” process. With little load the the H-Drive, the brakes may be successfully engaged to
fine-tune the positioning.
When finished, cover HPU, unplug the power and tie down the empty basket.

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 11

Maintenance Guide:
To help ensure long life of the H-Drive system, it is recommended to perform the following inspection and
maintenance of the HPU and H-Drive after 30 days from its first use and every 6 months after that.

Inspect for hydraulic leaks.

Clean and inspect the inside and outside of each electrical enclosure:
• Remote
• HPU
• H-Drive

Clean/tighten the electrical connections throughout the system.

Clean and inspect each hydraulic hose

Clean and inspect each hydraulic fitting, including:

• Motor/gearbox/brake
• HPU

Check fluid levels in the hydraulic oil reservoir and the gearbox reservoirs.

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 12

Lubrication:
There are three different lubrication requirements of the H-Drive system:

• Hydraulic oil for the hydraulic system: Mobil DTE 10 Excel 68

• Gear oil for the gearbox and brake: Mobil Gear 600XP 320
• Grease for the axle brass bearings and open gears: Mobil Premium Lubricating Grease XHB-222

Hydraulic Oil
The hydraulic oil used in the system is a premium quality anti-wear mineral based hydraulic oil. Gearn
recommends Mobil DTE 10 Excel 68. Contact Gearn Offshore with questions about other oils that are
compatible. The system requires approximately 100 gallons of oil to fill the system for the first time.

The Greasing System

The H-Drive is designed to be greased from two grease point panels located on two opposing arms. The
grease used is a premium lubricating grease (Mobil Premium Lubricating Grease XHB-222). Each of the
horizontal brass plates used to support the vertical weight is individually greased by a single port. The brass
ring used to support the horizontal loads from the basket is greased by 4 individual ports. Each of the brass
plates are grooved at the greasing points to allow the grease to make full contact with the mating surfaces.
Note that this grease should only be applied when the H-Drive squeaks during rotation.

Additionally, the gear surfaces are also greased using a premium lubricating grease (Mobil Premium
Lubricating Grease XHB-222). This grease is used as a corrosion protection barrier, so it should be done
any time the unit has been in use or has been stored for longer than 3 months. It is important that when the
gear is greased, care should be taken to find and remove any debris that could become lodged between the
gears.

Gearbox Oil Reservoir

Each gearbox has an oil reservoir that is used to keep the gearbox completely full of oil while also allowing
it to breathe as the oil contracts and expands. The oil used is MobilGear 600 Series. This reservoir is
located next to each pinion cover, and should be checked prior to each job by removing the breather cap. If
there is any oil in the reservoir, NO oil should be added – this oil will expand when the H-Drive is
operating. The quantity generally required to be added would be about 75 mL for each gearbox.

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 13

Component Part Numbers & Spare Parts:

The following table lists all significant part numbers purchased for the H-Drive. Use these part numbers to
reference individual specifications for each component in the databook.

Spare Qty Item Part Number Manufacturer Vendor

Remote Enclosure on HPU
Remote Enclosure CHJ1008HWPL1LG Hoffman Elliott Electric
1 Brake Indicator Light (Freewheel) FVLU24LB-PLLBE C3 C3 Controls
1 Brake Indicator Light (Brake) FVLU24LB-PLLBE C3 C3 Controls
1 Joystick PRO-5 101.7612 JR Merritt JR Merritt
1 Precision Digital Panel Meter PD765-7R2-00 Precision Digital Precision Digital
1 Power on Switch (Remote) FVPPM24LR-IMCRD-NO C3 C3 Controls

Main Disconnect Enclosure on HPU

Main Disconnect Enclosure HW-J141206CHQRW Wiegmann Automation Direct
125A Main Disconnect PDS2-3125-PHMRY11 C3 C3 Controls
Enclosure Power Indicator Light 22RL480LR-XPLRD C3 C3 Controls

High Voltage Enclosure on HPU

High Voltage Enclosure HW-J181608CHQRW Wiegmann Automation Direct
2P 0.5A Supplemental Protection WMZS2C00 Eaton Automation Direct
2P 5A Supplemental Protection WMZS2C05 Eaton Automation Direct
Circuit Breaker 100A HMCP100R3 Eaton Elliott Electric
NEMA Size 3 Contactor AN19KNO Eaton Elliott Electric
Overload C440B1A100SF3 Eaton Elliott Electric
110 VAC Coil for Contactor 92756-1 Eaton Elliott Electric
8-Pin Socket Relay (24 VDC Coil) RR2P-U 24V IDEC Elliott Electric
150 VA Transformer C01S0E2A Eaton Elliott Electric

Low Voltage Enclosure on HPU

Low Voltage Enclosure HW-J181608CHQRW Wiegmann Automation Direct
16A Main Disconnect DDS2-316-MDHGRY C3 C3 Controls
1 Power on Switch (HPU) FVPPM24LR-IMCRD-NO C3 C3 Controls
1P 5A Supplemental Protection WMZS1C05 Eaton Automation Direct
Power Supply - 120W 24 VDC PS5R-SF24 IDEC Elliott Electric
1 Oil Filter Warning Light FVPTT24LR-GIPBCRD C3 C3 Controls
1 Remote / Manual Selector Switch SS02-SHGN-NC-NC/NONC C3 C3 Controls
1 Encoder Cable 18ga 8C 24 VDC x 40'
Electrical Plug CA3101E20-11P PEI Genesis PEI Genesis
Dust Cap for Plug MS25043-20D PEI Genesis PEI Genesis
Receptacle CA3106E20-11S PEI Genesis PEI Genesis
Dust Cap for Receptacle MS25042-20D PEI Genesis PEI Genesis

HPU Hydraulics
50 HP Motor GT1237 326TTFCA6028 Marathon IBT
Filter Pressure Switch LFT-1010 Schroeder Hydraquip
3 Pressure Gauge 3000 psi (qty 2) 203L-254-3000 Eng Specialty Products Fluid Line
Filler Breather w/Dipstick LENZ57XL-40-dip-24 Lenz Hydraquip
2" Tank Isolation Valve V520P-32 Parker Fluid Line
Suction Strainer AS-50-2-100-RV3 Flow Ezy Fluid Line
1 Pressure Filter Housing RT1KKZ10P20P20P16 Schroeder Hydraquip
1 Replacement Filter Element KKZ10 Schroeder Hydraquip
1 Hydraulic Pump PVM141 123AL01333A Vickers Hydraquip
1 Hydraulic Valve PVG100 161F4172 Danfoss Hydraquip
1 Hydraulic Valve Solenoid, PVES 157B4833 Danfoss Hydraquip

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 14

Component Part Numbers & Spare Parts – Continued:

Spare Qty Item Part Number Manufacturer Vendor

H-Drive
Transducer Enclosure HW-N4X332 Wiegmann Automation Direct
Pressure Transducer SPT25-10-0300A Prosense Automation Direct
Gearbox (qty 2) RR3200 A3 MS 62.4 RRUSA RRUSA
Hydraulic Motor (qty 2) MLHT200G2A03/06 0064 RRUSA RRUSA
Hydraulic Brake (qty 2) RFF 5/85 RRUSA RRUSA
Shuttle Valve for Brake CP120-1-B-6SME1343 Parker Hydradyne
Needle Valve N800S Parker Hydradyne
Counterbalance Valve XMM 1FU3-42 Sun Hydradyne
1 Grease Tubing 1/8” x 100 ft
36 Grease Tube Fittings Straight Parker
16 Grease Tube Fittings Elbow Parker
16 Grease Zerks Parker

Hydraulic Hoses
Size x Length Termination A Termination B
1 1” Hose x 3' 16 FJX @ CB Valve 16 FJX 90-deg Sweep FJX @ Bulkhead
1 1” Hose x 3' 16 FJX @ CB Valve 16 FJX 90-deg Sweep FJX @ Bulkhead
1 1” Hose x 40' 16 FJX @ Bulkhead Quick Coupler @ HPU
1 1” Hose x 40' 16 FJX @ Bulkhead Quick Coupler @ HPU
1 1” Hose x 6' 16 FJX @ CB Valve 16 FJX 90-deg Sweep FJX @ Motor A
1 1” Hose x 6' 16 FJX @ CB Valve 16 FJX 90-deg Sweep FJX @ Motor A
1 1” Hose x 6's 16 FJX @ CB Valve 16 FJX 90-deg Sweep FJX @ Motor B
1 1” Hose x 6' 16 FJX @ CB Valve 16 FJX 90-deg Sweep FJX @ Motor B
1 1/2” Hose x 40' 8 FJX @ Bulkhead Quick Coupler @ HPU
1 1/4” Hose x 2' 4 FJX @ Gearbox A 4 FJX @ Gearbox Reservoir A
1 1/4” Hose x 2' 4 FJX @ Gearbox B 4 FJX @ Gearbox Reservoir B
1 1/4” Hose x 2' 4 FJX @ Shuttle Valve 4 FJX @ Before CB Valve
1 1/4” Hose x 2' 4 FJX @ Shuttle Valve 4 FJX @ Before CB Valve
1 1/4” Hose x 2' 4 FJX @ Bulkhead 4 FJX @ Case Drain T
1 1/4” Hose x 8' 4 FJX @ Shuttle Valve 4 FJX @ Motor A Case Drain
1 1/4” Hose x 8' 4 FJX @ Shuttle Valve 4 FJX @ Motor B Case Drain

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 15

Component Identification - HPU Electrical Enclosures:

Description
Upper Right – Incoming Power Termination Enclosure, Includes the Power Disconnect Switch

Upper Left – Low Voltage Enclosure, Includes the following switches located left to right: Remote / Manual Switch, Filter
Replacement Switch, E-Stop Pushbutton, Power Off Switch

Lower Left – High Voltage Enclosure, Includes circuit breaker, motor starter, transformer, supplimentary overload protection

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 16

Component Identification - Electrical Enclosure Close Ups:

Description
Right – Incoming Power Termination Enclosure, Includes the Power Disconnect Switch

Left – Low Voltage Enclosure Includes (left to right)

• Remote / Manual Switch
• Filter Replacement Switch (Push to Test Lamp)
• E-Stop Pushbutton
• Power Off Switch

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 17

Component Identification - Electrical Enclosure Close Ups:

Description
High Voltage Electrical Enclosure Includes (left to right):

• Circuit Breaker
• Contactor & Overload
• Socket Relay to Engage Contactor
• Incoming / Outgoing Supplimental Circuit Protection
• 120 VAC Tranformer

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 18

Component Identification – Remote Enclosure:

Description
Bottom Left – E-Stop Pushbutton / Power Indicator Light

Top Left – Panel Meter to Display Rotation Pressure

Top Right - Blue Freewheel Light (shown not lit)

Middle Right – Electric Joystick

Bottom Right - Blue Brakes Set Light (shown illuminated)

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 19

Component Identification – HPU:

Color Description
Oil Type Part Number

Oil Fill Cap

Replace Oil Filter Pressure Switch

Replacement Filter Part Number

Primary Oil Return Line (Tank Line)

Hydraulic Motor Case Drain

Remove Bolts to Remove Filter

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 20

Component Identification - HPU – Continued:

Color Description
Manual Joystick

Warning – Do not use manual joystick handle when in Remote Mode – damage to the valve will occur!

Forward Speed Adjustment Lock Nut

Forward Speed Adjustment

Reverse Speed Adjustment Lock Nut

Reverse Speed Adjustment

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 21

Component Identification - HPU – Continued:

Color Description
H-Drive Rotation Speed Adjustment

H-Drive Rotation Speed Adjustment Lock Nut

Pressure Line

Load Sense Line

Case Drain Line

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 22

Component Identification – H-Drive:

Color Description
Parking Brake

Hydraulic Motor

Gearbox Oil Reservoir

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 23

Component Identification - H-Drive – Continued:

Color Description
Gearbox

Rotation Pressure Transducer

Parking Brake

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 24

Component Identification – H-Drive – Continued:

Color Description
Pressure Transducer Electrical Junction Enclosure

Counterbalance Valve

Shuttle Valve

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 25

Detailed Hydraulic Description:

Low Voltage Electrical Enclosure
This is the enclosure that houses the 24 VDC power supply used throughout the system.

Remote / Manual Selector Switch

Turns power on to the system if the Remote/Manual Switch is in remote mode. It is highly recommended to
start and operate the H-Drive in remote mode. This will ensure maximum safety for the operator because of
the high pressure of the hydraulics.

Emergency Shut-Off, Power Switch

Turns power on to the system. If the Remote/Manual Switch is in manual mode, the unit will turn on and
pressurize. If it is in remote mode, the H-Drive will not turn on until the Remote Power Switch is turned on.
This switch will immediately shut off the system for emergency conditions. IMPORTANT: Always turn off
this switch when the H-Drive is not in use.

Filter Replacement Light

The oil filter has a filter replacement pressure switch. This will close when rotating the H-Drive when the
flow is restricted by a dirty filter. The replace oil filter light will indicate when the filter should be changed.
This should be evaluated when the H-Drive is rotating at its full operating speed. The light has a push to
test feature that will make sure the lamp is functioning properly.

Oil Fill Cap

This is the location to add oil to the system. This cap will allow the tank to breathe for thermal expansion.

Replace Oil Filter Pressure Switch

The oil filter has a filter replacement pressure switch. This will close when rotating the H-Drive when the
flow is restricted by a dirty filter. The replace oil filter light will indicate when the filter should be changed.
This should be evaluated when the H-Drive is rotating at its full operating speed.

Primary Oil Return Line (Tank Line)

This is the primary hydraulic oil return line.

Remove Bolts to Remove Filter

Removing these four bolts will allow the filter element to be removed and replaced. It should replaced
according to the maintenance schedule. To replace the filter, remove the four bolts on the top of the filter
and lift the cover off. The filter is still inside the filter housing. Rotate the filter counterclockwise to
remove it.

Oil Tank Cleanout (not shown in pictures)

This is a cover used to clean out the hydraulic tank when servicing. This should only be done according to
the maintenance schedule. It is located on the left end when facing the front of the power unit.

Hydraulic Motor Case Drain Line

This hose is directly connected from the filter to the motor case drain to minimize the back pressure. This is
also the return line for the brakes.

Manual Joystick
This is the manual joystick for rotating the H-Drive in manual mode. IMPORTANT: Never attempt to
move this joystick by hand when operating in remote mode. This will damage the valve. When operating

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 26
in manual mode, always operate the joystick with slow, smooth movements. Always bring the H-Drive to a
stop using the joystick before changing the direction of rotation.

Warning Label
Never attempt to move this joystick by hand when operating in remote mode. This will damage the valve.

Rotation Pressure Gauge

This is the gauge that indicates the pressure in the system required to rotate the H-Drive. Note that this
pressure does not equal the pulling tension. The pulling tension depends on the diameter of the attached
basket. The smaller the diameter the greater the tension.

Forward Speed Adjustment Screw / Lock Nut

This is an adjustment screw for setting the maximum forward speed of the H-Drive. This should only be
used to change the forward speed as it compares the to reverse speed. It is recommended not to change this
setting without consulting Gearn Offshore. To change the speed of the H-Drive, it is preferred to use the
pump displacement adjustment. Doing so will reduce the amount of oil the pump generates, thus reducing
the power requirements and oil heating.

To use the speed adjustment screw, turn on the power and loosen the nut that locks the screw in place.
Rotate the screw inward one turn at a time while rotating without load to slow the H-Drive until the desired
speed is reached. Re-tighten the nut to secure the adjustment screw.

Reverse Speed Adjustment Screw / Lock Nut

This is an adjustment screw for setting the maximum reverse speed of the H-Drive. This should only be
used to change the reverse speed as it compares the to forward speed. It is recommended not to change this
setting without consulting Gearn Offshore. To change the speed of the H-Drive, it is preferred to use the
pump displacement adjustment. Doing so will reduce the amount of oil the pump generates, thus reducing
the power requirements and oil heating.

To use the speed adjustment screw, turn on the power and loosen the nut that locks the screw in place.
Rotate the screw inward one turn at a time while rotating without load to slow the H-Drive until the desired
speed is reached. Re-tighten the nut to secure the adjustment screw.

Tank Drain Valve

This is a valve used to drain (or sample) the oil from the tank. It has a male quick coupler equivalent to
AEROQUIP G5602-8-10-MALE.

Tank Drain Quick Coupler

This is a male quick coupler equivalent to AEROQUIP G5602-8-10-MALE.

Tank Supply Shut-Off Valve

Never close this valve during normal circumstances. This valve is to only be used when the hydraulic tank
is removed from the HPU. The hose will fail catastrophically if the valve is closed when the pump is
activated.

Remote Emergency Shut-Off, Power Switch

Turns power on to the system if the Remote/Manual Switch is in remote mode. This can also be used to
immediately shut off the H-Drive in an emergency. It is highly recommended to start and operate the H-
Drive in remote mode. This will ensure maximum safety for the operator because of the high pressure of
the hydraulics. IMPORTANT: Always turn off this switch when the H-Drive is not in use.

Remote Rotation Pressure Gauge

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 27
This is the digital meter (gauge) located on the remote that indicates the pressure in the system required to
rotate the H-Drive. This pressure is in psi. Note that this pressure does not equal the pulling tension. The
pulling tension depends on the diameter of the attached basket. This meter also controls two blue indicator
lights located inside the remote. These lights indicate that the H-Drive's brakes are set or they are in
freewheel. If the pressure is below about 500 psi, then the brakes are set, otherwise the brakes are released.
This meter and the two indicator lights do not affect any operations of the H-Drive, they are only for
information.

Electric Joystick
This is the electric joystick for rotating the H-Drive in remote mode. Always operate the joystick with slow,
smooth movements. Always bring the H-Drive to a stop using the joystick before changing the direction of
rotation. The button on top of the joystick is not used and does not affect the H-Drive operation.

H-Drive Rotation Speed Adjustment / Lock Nut

This is the adjustment to reduce the maximum amount of oil flow from the pump. This is the preferred
means of changing the speed of the H-Drive. It is best to set the maximum speed of the H-Drive as slow as
possible while still maintaining work production. To use the pump displacement adjustment, loosen the hex
nut and rotate the square screw inward one turn at a time while rotating without load to slow the H-Drive
until the desired speed is reached. Re-tighten the nut to secure the adjustment screw.

Pressure Line
This is the primary pressure output from the hydraulic pump.

Load Sense Line

This is the pressure line that communicates the demand from the valve to the pump. This allows the pump
to operate as pressure compensating and load sensing. The pump will not build significant pressure until the
valve is operated, thus reducing the hydraulic heating and filtration load.

Case Drain Line

This relieves pressure from the casing of the hydraulic pump. If the hydraulic lines are ever disassembled
from pump, then the case of the pump should be filled with hydraulic oil by removing this connection and
filling it manually.

Parking Brake
This parking brake is spring applied / hydraulically released. When pressure from either the A or B lines
from the valve are pressurized, the brake will automatically release. The brake will reset when the pressure
from the valve is removed. It has one pressure input, and the springs will force the oil back out of this line
to reset the brake.

Hydraulic Motor
This hydraulic motor requires that the case drain be directly connected back to the filter to reduce back
pressure.

Gearbox Oil Reservoir

This is a small reservoir that allows the oil in the gearbox to expand when in operation. This is also where
oil is to be added to the gearbox as required. When the gearbox is cold, it is recommended to have only a
small amount of oil in the bottom of the reservoir. Do not fill the reservoir when the gearbox is cold.

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 28
Gearbox
This gearbox must always have oil shown in the gearbox oil reservoir.

Rotation Pressure Transducer

This pressure transducer transmits the pressure to the remote display. It is measured at the brake, which
accurately shows pressure for both the forward and reverse directions.

Pressure Transducer Electrical Junction Enclosure

This is the connection point between the long wire from the power unit and the transducer.

Counterbalance Valve
This valve helps to prevent the H-Drive from rotating in reverse when tension is applied. It will not allow
oil from the power unit to flow to the hydraulic motor unless the pressure into the counterbalance valve is as
great as the pressure from the hydraulic motor to the counterbalance valve.

Shuttle Valve
This valve will transmit hydraulic pressure to release the brakes when either the A or B lines from the power
unit valve have pressure.

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 29

Troubleshooting:

Problem Cause Solution

The hydraulic pump Cause 1: Solution 1:

makes an unusually The hydraulic oil level is low. Add hydraulic oil.
loud noise.
Cause 2: Solution 2:
There is air in the hydraulic Rotate the H-Drive to push the air out of the
system. system.
The H-Drive makes Cause: Solution:
noise when it is The axle requires more Apply grease using the grease points to the
rotating. lubrication. axle.
The speed of the H- Cause: Solution:
Drive is too slow or The speed adjustment needs Change the pump displacement adjustment as
too fast. changing. required.
The H-Drive does Cause: Solution:
not rotate with the The motor is spinning the wrong Verify the rotation of the motor and correct
pump on and the oil way. it.
filled.

Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
 Page 30

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Gearn Offshore Inc ● 3510 S US Highway 385 ● Hereford, TX 79045 ● 806-364-6900 Phone ● 806-364-6120 Fax
Gearn Offshore inc
Gearn Offshore inc
Gearn Offshore inc
 8 7 6 5 4 3 2 1

Maximum Testing Torque 206,000 ft-lb [280,300 N-m]

Vertical Load Capacity 30,000 lb [13,6-7 kg]
Maximum Rotation Rate 1 RPM
Trucking Width (with 2 Outriggers Removed) 89 in [2.26m]
Height 37 in [0.94 m] D
D
OD of Basket Support Ring 89 in [2.26 m]
ID of Basket Support Ring 65 in [1.65 m]
Total Shipping Weight (Not Including Container) 15,000 lb
Required Input Power* 480 VAC, 60 Hz, 60A
Length of Hydraulic Lines to Control Unit 40 ft [12.2m]
Length of Electrical Umbilical to Remote 40 ft [12.2m]
Removable Electrical Environmental Rating NEMA 4X with All Covers in Place
Outrigger

C C

TRUE 89"
(Shipping Width)

Removable
B Outrigger B

D:\Dropbox\GearnOffshore\_JobFiles\GO1313_H-Drive_McD\Solid\H-Drive02\H-Drive002
HPU and Remote Not Shown
1
37 4 " 193"
Tolerances
Unless otherwise Specified

DIMENSIONS ARE IN INCHES

TOLERANCES:
A FRACTIONAL 1
16"

ANGULAR: MACH 0.1

H-Drive 2 A
BEND 0.5
NAME DATE TWO PLACE DECIMAL .03"
THREE PLACE DECIMAL .005"
DRAWN JAG 8/27/13
PROPRIETARY AND CONFIDENTIAL
JAG THE INFORMATION CONTAINED IN THIS
REVISION 1 8/28/13 FINISH
DRAWING IS THE SOLE PROPERTY OF
SIZE DWG. NO. REV
REVISION 2

REVISION 3
- GEARN OFFSHORE, INC. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GEARN OFFSHORE, INC. IS
B H-Drive002 1b
REVISION 4 PROHIBITED. NTS SHEET 19 OF 19
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1

D D

Ou
trig
ge r
s
H-D Ou
rive trig
C
ge r C

s
HPU
Spares

B B

Packing Arrangment

D:\Dropbox\GearnOffshore\_JobFiles\GO1313_H-Drive_McD\Solid\H-Drive02\H-Drive002
Tolerances
Unless otherwise Specified

DIMENSIONS ARE IN INCHES

TOLERANCES:
A FRACTIONAL 1
16"

ANGULAR: MACH 0.1

H-Drive 2 A
BEND 0.5
NAME DATE TWO PLACE DECIMAL .03"
THREE PLACE DECIMAL .005"
DRAWN JAG 8/27/13
PROPRIETARY AND CONFIDENTIAL
JAG THE INFORMATION CONTAINED IN THIS
REVISION 1 8/28/13 FINISH
DRAWING IS THE SOLE PROPERTY OF
SIZE DWG. NO. REV
REVISION 2

REVISION 3
- GEARN OFFSHORE, INC. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GEARN OFFSHORE, INC. IS
B H-Drive002 1b
REVISION 4 PROHIBITED. NTS SHEET 17 OF 18
8 7 6 5 4 3 2 1