GML—800

Workshop Repair Manual

(Winch & Gearbox)
This manual has been written to aid in the strip down and re-
build of the Wienold GML-800 series Gearbox and Winch.

The unit uses a standard worm drive winch coupled with a tri-
ple input 3 speed gearbox which allows the user to use a
range of speeds to position and then move the load.

The winch and gearbox are the only items which are funda-
mentally different to a standard Genie SLA series mast winch
therefore previous in-house or manufacturer training is suffi-
cient for the strip down and rebuild of the rest of the machine
The manufacturer's gearbox/worm wheel winch combination as a whole, as intended, enables the worm wheel winch to
be operated with a hand-held cordless screwdriver and/or in hand crank mode. The load is lifted by turning the crank
clockwise. Lowering the load is done by turning the crank handle counterclockwise. The 1:1 Ratio input must only be
operated by hand

The deflection shaft 2.5:1 and the drive shaft 6.25:1 may be driven with a cordless screwdriver with a max. power of
500w

Gear unit maintenance

The gears were completely lubricated at the manufacturing plant. The input, deflection and output shafts are mounted
maintenance-free. In order to maintain a good serviceability and service life, the chains must be lubricated weekly with
chain spray. For this purpose, guide the dosing tube of the spray can vertically up to the chain via the 2 holes in the base
plate of the gear unit (Fig 1) turn the gear unit and spray the chain. Repeat this procedure for the 2nd chain.

Fig 1
Number Qty Description Size
1 1 Rear housing plate
2 1 Front housing plate
3a 1 Sheet metal2, left
3b 1 Sheet metal2, right
4 1 Sheet metal2, top
5 1 sheet metal2 bottom
6 1 protective sleeve
7 2 protective sleeve

8 3 flange plate
9 1 flange plate
10 1 Shaft 1
11 1 Sprocket Wheel Disc
12 1 Shaft 2
13 6 Spacer Bolt
14 2 Endless Roller Chain
15 1 Pipe Clamp
16 1 Pipe Clamp
17 1 Crank Handle
18 2 Rivet
19 4 Rivet
20 16 Discs (spacers)
21 14 Cheese Head Screw M8
22 8 Cheese Head Screw M8
23 1 Cheese Head Screw M6
24 2 Hex Head Screw M6
25 2 Hex Head Screw M6
26 2 Hex Head Screw M8
28 30 Spring Washer A8
29 8 Washer A6
30 2 Washer A8
31 3 Hex Nut M6
32 6 Hex Nut M8
33 2 Hex Nut M6
Remove the 6 x M8 screws holding the front housing plate Remove the protective sleeves - 4 x M8
screws and 4 x dome nuts

Remove the front housing plate to expose Remove the flange plates from the 6:1 and
the gears 2.5:1 input shaft bearings — be careful not to
lose the coach bolts
 2.5:1 Input Shaft

6:1 Input Shaft 1:1 Input Shaft

Remove the side and lower housing plates if still
attached to the rear housing plate

Remove the 6:1 input shaft, inspect the bearings, shaft and toothed
cog for wear or damage—Note ensure correct amount of spacers
between the bearing and toothed cog
Remove the 2.5:1 Input shaft inspect the bearings, shaft and toothed cog
for wear or damage—Note ensure correct amount of spacers between
the bearings and toothed cogs

Check both drive chains for wear,

corrosion or damage
Remove the M6 Bolt and nut holding the Toothed cog on
Remove the 4 bolts securing the Rear
the 1:1 Input shaft and remove the cog, check for damage
housing plate to the worm drive winch

Remove the 4 cheese head nuts and 2 hex head nuts on the front face of the
worm drive winch to release the worm drive shaft
Remove the worm drive shaft—Check the brake disc, ratchet wheel,
bearing and bearing cover disc are all present. Clean the ratchet wheel
using emery cloth and check for damage. Check brake disc for damage
and contamination
Check condition of winch ratchet pawls, ensure spring is correctly
seated, check and clean bearing seat.
 Bearing

Bearing cover disc

Ratchet Wheel

Brake Disc

Re-assemble worm drive shaft as shown– lightly grease the bearing and end of the shaft once assembled
Refit the worm drive assembly into the winch, ensure the ratchet pawls engage positively on the
ratchet wheel by rotating the shaft through a complete revolution
Refit front bracket of winch, rear housing plate of the gearbox and the 1:1 Input shaft toothed cog

Replace input shafts and chains—lubricate using chain lubricant

Refit flange plates to onto the front housing plate and carefully lift into place to guide onto the
input shaft bearings.

Align the side plates and tighten the assembly together— Tip catch the 6 x M8 bolts before fitting
the side plates as the small mortice joints have a tendency not to hold very well, tightening the
bolts when everything is in place will draw all the joints together
Carry out function test of the winch unit, - check it’s free of tight spots, unusual noises and
operates smoothly.

Carry out light load test of 80kg to unit to check efficiency of the brake unit