SALALAH PORT SERVICES S. A. O. G.

( S. P. S. )

Twenty-three
RUBBER-TYRED CONTAINER HANDLING GANTRY
CRANES

MAINTENANCE MANUAL
OPERATING INSTRUCTION

REDUCER PART

SHANGHAI ZHENHUA PORT MACHINERY CO., LTD

June 2009
 INSTRUCTIONS OF REDUCER MODEL
FH495.40.A1A-00

SHANGHAI ZHENHUA HEAVY INDUSTRY CO.,LTD

May, 2009
 Instructions of the Reducer FH495.40.A1A-00

Contents

Construction drawings of the reducer model FH495.40.A1A-00 for Trolley

device.

1. Technical Specifications
2. Brief Introduction of Construction
3. Maintenance and Repair
4. Disassembly and Re-assembly of Major Components

Appendix I Spherical roller bearings (SKF)

Appendix II Oil seals (NOK)
Appendix III Lubricant Selection Table

ZPMC 1
 Instructions of the Reducer FH495.40.A1A-00

Preface
To operate and maintain the trolley device reducer correctly the customer shall read
these instructions carefully before operation.

This is a kind of cylindrical helical gear reducer with parallel shafts and 2 stages of
reduction. This type of reducer has 3 versions of layout (see the construction drawing)
and is suitable for trolley device. The gear strength and material quality are fully in
compliance with requirements of American standard ANSI/AGMA2101-D04.

The reducer is standard product of ZPMC and by many times improvement. Lubrication
is of bath and splash type. All the bearings are spherical (self-aligning) roller bearings
and Taper roller bearings that are sufficiently safe and reliable. This type of reducer has
been operated together with ZPMC’ container cranes in many important ports in the
world. Comments from the customers are appreciated for continuous improvement of
the product.

• In these instruction all the data are measured in the international unit system SI unit
(metric system).

ZPMC 2
 Instructions of the Reducer FH495.40.A1A-00

1. Technical Specification

1.1 Input speed 1800rpm

1.2 Reduction ratio 40.40
1.3 Centers between input and output: 495mm
1.4 Rated output torque 17000Nm
1.5 Lubrication oil: ISO VG 320
1.6 Oil volume ～30L

1.7 Max. operating oil pool temperature ≤95°C

1.8 Reducer efficiency >95%
1.9 Reducer noise level <85dB (A)（except the noise of drum

and electromotor）

1.10 Max. overall dimensions 1145*755*740

1.11 Net weight 592kg

2. Brief Introduction of Construction:

The reducer is horizontally mounted with parallel shafts and two stages of reduction
and cylindrical helical gears. The reducer has 3 versions of layout (see construction
drawing).
The housing is of split type. There is lubrication bath at bottom of the casing and lower
part of the gear of 1stand 2nd are immersed in the oil and when the gears running the oil
will be splashed to every meshed gear tooth surface and the race way of bearing for
lubrication and heat dissipation.

There is a view covers on the top of the upper housing, when it is opened the gear
meshing condition and backlash may be inspected through the hatch. The view cover is
fitted with an air filter C-M42×2 to keep the atmosphere pressure in the housing.
On the left side of the lower housing an oil drainage valve Q11F-16T (DN20) is fitted,
and can be opened for oil replacement or housing cleaning.

ZPMC 3
 Instructions of the Reducer FH495.40.A1A-00

An oil level indicator YWZ-76 is fitted on the left side of the housing (see the side view
on the construction drawing). The oil level of reducer shall be kept at its middle scale.
To prevent oil from going out, every through cover of the shaft is provided double-oil
seals and full of lubricant grease in between the two seals. Outside of bearing cover,
there is a grease nozzle, pour into grease time in order to reliability seal per 3 months.
Sealant are used in the surfaces of the link housing and the blank cover of bearing, it
can prevent oil leakage availability.

3. Maintenance and Repair

3.1 The reducer is delivered to the customer after it has been tested on the test rig at
the gearing manufacture factory of ZPMC. Parts in the housing are coated with
anti-corrosion grease.
3.2 After completion of the reducer manufacture the effective period of storage is six
months. It shall be inspected and maintained if a longer term of storage is needed.
3.3 Before operation of the reducer the anti-corrosion grease and lubrication grease on
the shaft end surface shall be removed.
3.4 During installation of the reducer on its base plate the error of coaxiality of input,
output shafts with the electric motor shaft, wire rope drum shaft shall be less than
0.1mm. After completion of adjustment, it will be bolted to the base.
3.5 Before operation the reducer shall be filled in with lubrication oil through the view
hatch. Please took off the plug and installed the air filter and let the water out. The
number of lubricant on the reducer’s name plate is only consult. The oil level shall
be kept to the middle scale of the liquid level gauge. During operation regularly
check the oil level to ensure sufficient lubrication at every lubrication point.
3.6 Changing the oil
3.6.1 Lubrication oil shall be periodically checked and replaced. After 400 hours of
first running the oil shall be replaced first time. Then every 5000 hours the oil
shall be replaced.
3.6.2 When changing the oil, always re-change the gear unit with the same type of oil.
Never mix different types of oil or oils made by different manufacturers. Never
mix synthetic oils with mineral-based oil to synthetic oil or from one type of
synthetic oil to another, flush the gear unit well with the new type of oil
beforehand. At every time of replacement the reducer shall be cleaned with
equal quality oil. It shall be avoided flushing the gear units with the soluble
liquid.

ZPMC 4
 Instructions of the Reducer FH495.40.A1A-00

3.6.3 Fill the gear unit with fresh oil using a filter (max. mesh 25 μ m). Remember to fill
the oil pockets on the inside housing.
3.6.4 The oil level must be at the upper mark on the oil dipstick.
3.6.5 You should inspect lubricant quality periodicity, example: viscosity 、 oxide 、
the waste of additive , if these points didn’t accord, please replace all lubricant
oil.
3.7 Bearings and oil seals’ lubrication: commend using the lithium-base grease, period
adding ration lubrication according to the requirement of the grease nipple‘s plate.
3.8 Periodically check the installation bolts for loosening.
3.9 Regularly check the coaxiality of input and output shafts to avoid the reducer from
vibration, heating and abnormal wearing that affects the service life.
3.10 Storage: ZPMC reducer passed trial run check, anti-rust for inner parts, coating
anti-rust oil and lubricates grease on shaft surface then refers it to the customer. For
long-term storage reducer, laying down effective safeguard is duty of reducer owner.
We advice the storage place is dryness, the temperature is controlled. It isn’t allow
storage at the place where appear dew point, in order to avoid of vapor condense on
the surface of gear, pinion and bearing. Check the inner parts of reducer every month. If
the moisture is found, removed at once, recoat anti-rust oil to protect.
3.11 For the reducer of long-distance transport, prevent due to a difference
temperature change, the parts surface form dew lead to rust. before sent out goods,
add in lubricating oil and rust inhibitor. When the reducer is used, only check up
water in the housing, if there is no, and not have to change lubricate oil.
3.12 Correct operation, maintenance comply with these instructions may ensure
long service life of the reducer, and the reducer life is same as crane. However, the
customer shall establish maintenance and overhaul plan in accordance with the
actual operation condition. The aim is providing the reducer on adjustment after a
certain long operation for longer service life. Normally, overhaul interval shall be 3-5
years depending on actual operation of the crane by the customer.
3.13 Major items of inspection during overhauling:
(1) Any pitting, peeling off, scratch, serious wear etc. on gear teeth surfaces.
(2) Check bearing rollers, internal and external raceway surface, any damage of
retainers.
(3) Check the oil seals.
(4) Clean all the parts, housing and oil passages.
3.14 Inspection, parts and oil replacement shall be carefully recorded.

ZPMC 5
 Instructions of the Reducer FH495.40.A1A-00

4. Disassembly and Re-assembly of Components

Normally the reducer shall not be disassembled unless during overhauling or the
accidental trouble interfere the normal operation of the reducer.
Care shall be taken for following matters if the customer considers it is necessary to
disassemble the reducer himself:
4.1 Order of disassemble
(1) Remove the blank covers of the intermediate shaft at both end of the housing, and
remove the through covers.
(2) Remove the tapered pin on the faying surface of housing connection bolts, nuts
and separate the upper housing and the lower housing by using disassembling
screw.
(3) Remove the upper housing and then the pinion shaft and its components,
intermediate gear shaft and output gear shaft can be removed out of the lower
housing and disassembled.
(4) If no damage off any component or part is found during inspection further
disassembly is not necessary. If any part is damaged for some component, then
only this component shall be disassembled.
(5) After inspection and part replacement the re-assembly shall be done in the reverse
order.

4.2 Points for attention during re-assembly

(1) To avoid from knocking, damaging any fitted surfaces of parts and components
and correct by using oilstone if damaged, scratched.
(2) Before re-assembly thoroughly cleans the gears, bearings, shafts, the metal
powder of the housing, dirt and other foreign matters.
(3) Clean all parts, components and the housing with kerosene and dry them by using
compressed air.
(4) Horizontally place the lower housing and install the components in the order of low
speed shaft, intermediate shaft, high speed shaft in the housing and adjust these
components properly in axial position, then install and adjust end covers, install the
oil seal at both ends of the shafts.
(5) Adjust axial clearance of bearing to 0.10 - 0.20mm
(6) Min. backlash of gearing
High speed stage: 0.185-0.290mm.

ZPMC 6
 Instructions of the Reducer FH495.40.A1A-00

Low speed stage: 0.210-0.330mm.

Contact spots on gear teeth surface shall not be less than 40% along the tooth
height and not less than 70% along tooth length. The spots distribution shall be around
the middle zone of the tooth face.
(7) After the above adjustment and installation have been completed place the upper
housing in position, Firstly set the tapered pin into the pin hole, then fit the securing
bolts, nuts. The faying surfaces may be coated with sealing coating.
(8) When the bearings, gears, oil seals and the parts which have relative movement
are fitted up a little clean oil shall be poured onto them to avoid dry friction during
first run.
(9) If oil seals are aged, fractured or seriously worn out they shall be replaced timely.
(10) The securing bolts (8.8 grade), screws (8 grade) shall be tightened with specified
torque as shown in the following table.

Bolt diameters (mm) M16 M18 M20 M24 M30 M36

Tightening moment （kg·m) 16 22 32 56 108 191

(12) The customer shall damage no any part or component during the reducer
disassembly.
(13) After re-assembly the reducer shall be run without load in both directions for at
least 0.5 hour.
(14) During trial run check every joint surface and sealing and there shall not be any
leakage.
(15) During trial run noise level shall not be higher than 85dB and no vibration by
hand feeling.
(16) Turn the input shaft by hand; it shall be manoeuvrable without any jam.
(17) If need be buy vulnerability spare parts that according to the recommendation of
the appendix.

ZPMC 7
 Instructions of the Reducer FH495.40.A1A-00

Appendix I: Roller Bearings (SKF)

No. Description Model Size Quantity

Spherical roller
1 SKF 22317 E 85*180*60 2
bearings
Spherical roller
2 SKF 22313 E 65*140*48 2
bearings
Spherical roller
3 SKF 22310 E 50*110*40 2
bearings

Note: The above table just lists the type of SKF bearing. Other brands can be selected
according to the relevant SKF type.

ZPMC 8
 Instructions of the Reducer FH495.40.A1A-00

Appendix II: oil seals (NOK)

C/D style
No. Model Size Quantity
1 NOK SC AC 2864 K0 50*72*12 2

2 NOK SC AC 3842 G0 85*110*13 4

M style
No. Model Size Quantity
1 NOK SC AC 2864 K0 50*72*12 4

2 NOK SC AC 3842 G0 85*110*13 4

ZPMC 9
 Instructions of the Reducer FH495.40.A1A-00

Appendix III: Lubricant Selection Table

400C Viscosity Examples of lubricants

Lubricant ISO-VG
GB5903-95 CALTEX
mm2/s
Energol
Meropa SPARTAN Mobilgear Omala
VG680 L-CKC680 GR-XF
680 EP 680 636 680
680
Energol
Meropa SPARTAN Mobilgear Omala
VG460 L-CKC460 GR-XF
460 EP 460 634 460
460
Energol
Meropa SPARTAN Mobilgear Omala
VG320 L-CKC320 GR-XF
320 EP 320 632 320
Mineral 320
Oils
Energol
Meropa SPARTAN Mobilgear Omala
VG220 L-CKC220 GR-XF
220 EP 220 630 220
220
Energol
Meropa SPARTAN Mobilgear Omala
VG150 L-CKC150 GR-XF
150 EP 150 629 150
150
Energol
Meropa SPARTAN Mobilgear Omala
VG100 L-CKC100 GR-XF
100 EP 100 627 100
100

Note：
1. Mineral base gear oils in accordance with designation GB5903-95.
They are suitable for operating temperature from -80C~ +800C。
2. If the operating temperature of the gear unit exceeds or undershoots the limit
values stated, the oil selected should be checked for suitability.

ZPMC 10
 B1 B2 7 8 B3 B1 31 B4 27 B5 B6 28 21 22 B7 B8 B9 B10 B11 B12 1
A向 B13

Mata patameter
285 210 input speed 1800rpm
output torque 17000N.M
Radio 40.40

油嘴注油提示
在每工作 500 小时之后，从油嘴
加入 10 克锂基润滑脂。

油嘴注油提示
在每工作 500 小时之后，从油嘴
加入 10 克锂基润滑脂。
~760

95
300

B-B C-C
0
22-0.052 0
14-0.043

25
222.5 50
6-∅22 85 85
392 385 80

48.5
80

85
300
937
360

29 B14 9 B15 B6 10 B16 B6 11 B17 B6 23 B18 12 B19 13 B20 B6 14 18 B21 15 B22 B6 B23
M型type (FH495.40M.A1B-00) C型type (FH495.40C.A1B-00) D型type (FH495.40D.A1B-00) 31 RSA01C 注油警示牌Greasr Caution 4 3

∅95
30 RSGP02-30 加油管路pipe 4 3
29 RSAJ-01 过渡接头tie-in 1
10

28 RSNP02-02 公司铭牌ZPMC name plate 1

∅80m6
27 B25x55.A 键key B25X55 1
130

B B 26 B14x55.A 键key B14X55 2 1

∅45m6 25 B20x40.A 键key B20x40 1

80
24 B22x115.A 键key B22X115 2
23 RSIW04-170*200 衬 垫 gasket 1
22 RSIW02-170*200 视孔盖Inspect plate 1
21 FH495B-24 轴 套sleeve II 1
20 FH495B-23 隔环 Ring 2 1
18 FH495B-22 轴端板 end board 2 1
17 FH495B-21 盖 板 cover board 2 1
240

B27 GB32.1-88 螺栓M10X25 Bolt 4 2

225
16 FH495B-20 透盖 through cover II 2 1
B26 NOK oilsealing NOK SC型 AC2864K0 50X72X12 4 2
15 FH495B-19 端 盖end cover I 0 1
B25 GB5781-86 螺栓M8X16 Bolt 8 4
14 FH495B-18 轴 套sleeve I 1
B24 GB32.1-88 螺栓M12X45 Bolt 8 4
13 FH495B-17 端 盖end cover II 2
B23 GB/T288-94 bearing 22310c/W33/c3 50X110X40 2
B22 GB32.1-88 螺栓M12X30 Bolt 4
12 FH495B-16 隔环 Ring 2
11 FH495B-15 轴端板 end board 2
B21 GB/T288-94 bearing 22313C/W33 65X140X48 2
10 FH495B-14 盖 板 cover board 2
B20 GB32.1-88 螺栓M12X25 Bolt 12
GB/T288-94
9 FH495B-13 透盖 through cover II 1
B19 bearing 22317C/W33 85X180X60 2
8 FH495B-12 箱盖cover 1
B18 NOK oil sealing NOK SC型AC3842G0 85X110X13 4
7 FH495B-11 箱体case 1
B17 GB32.1-88 螺栓M12X25 Bolt 4
M C/D
225

B16 GB32.1-88 螺栓M10X20 Bolt 12

240

B15 GB32.1-88 螺栓M12X45 Bolt 16

6 FH495.40.A1B-06 输出轴Output shaft 1
5 FH495.40.A1A-05 齿轮Gear 2 1
B14 JISB0203 平头油嘴 1/4 nozzle 4 3
4 FH495.40.A1A-04 齿轮轴Pinion shaft 2 1
B13 GB5783-86 螺栓M12x50 Bolt 2
3 FH495.40.A1A-03 齿轮Gear I 1
B12 GB117-86 圆锥销A16X60 2
2 FH495.40M.A1A-02 双头高速轴Hi shaft I 1
B11 液位计oil level indicator YWZ-76 1
2 FH495.40C.A1A-02 单头高速轴Hi shaft I 1
C ∅45m6 C
B10 螺塞ZG3/4" plug 1
1 FH495.40.A1A-01 减速器标牌name plate 1
B9 GB3289.26-82 内接头connectZG3/4" 1
80

each total
∅80m6 B8 Q11F-40T 放油阀 valve DN20 1 NO. SUB-NO. or STDD NAME & SIZE MTRL or STYLE QTY/set WEIGHT
NOTE

空滤器 air filter C-M42X2

130

B7 1 PROJECT: DESIGN STAGE: SCALE: 1:3

6 5 4 3 2
B6 钢丝 1(软) wire ITEM NAME: PROJ.
B5 GB32.1-88 螺栓M10X25 Bolt 8 减速箱 Reducer DRAW NO: FH495.40.A1A-00
B4 GB827-86 铆钉rivet 2x6 pin 24 20
DSGN 组件
26 20 19 25 18 B6 B27 B26 B25 17 B6 B24 16 B3 GB5782-86 螺栓M16X215 Bolt 12
TRACE APP.

∅95
B2 GB5782-86 螺栓M16X75 Bolt 6 ZPMC DRAW CHCK SET/CRANE
10

B1 GB889-86 六角锁紧螺母16 Nut 16 CHCK VER. WEIGHT 592.2

 INSTRUCTIONS OF REDUCER MODEL
FH1660.144.C1A-00

SHANGHAI ZHENHUA HEAVY INDUSTRY CO.,LTD

May, 2009
 Instruction of Reducer FH1660.144.C1A-00

Contents

Construction drawings of the reducer model FH1660.144.C1A-00 for main hoist

1. Technical Specifications

2. Brief Introduction of Construction

3. Maintenance and Repair

4. Disassembly and Re-assembly of Major Components

Appendix I Spherical roller bearings (SKF)

Appendix II Oil seals (NOK)
Appendix III Lubricant Selection Table

ZPMC 1
 Instruction of Reducer FH1660.144.C1A-00

Preface
To operate and maintain and repair the hoist reducer correctly, the customer shall
read these instructions carefully before operation.

This is a kind of horizontally mounted cylindrical helical gear reducer with parallel
shafts and four stages of reduction. This type of reducer is suitable for hoist or other
mechanism which has the same requirements. The gear’s strength and material
quality are fully in compliance with requirements of American standard ANSI/AGMA
2101-D04.

The reducer is standard product of ZPMC and by many times improvement.

Lubrication is of bath and splash type. All the bearings are spherical (self-aligning)
roller bearings and sufficiently safe and reliable. This type of reducer has been
operated together with container cranes in many important ports in the world.
Comments from the customers are appreciated for continuous improvement of the
product.

• In these instruction all the data are measured in the international unit system SI unit
(metric system).

ZPMC 2
 Instruction of Reducer FH1660.144.C1A-00

1. Technical Specification

1.1 Input speed 2000rpm

1.2 Reduction ratio 144.244

1.3 Centers between input and output 1660mm

1.4 Output torque 620000Nm

1.5 Brand of lubrication oil ISO VG 320

1.6 Lubrication oil volume 860L

1.7 Max. operating oil pool temperature ≤95°C

1.8 Reducer efficiency >95%
1.9 Reducer noise level <85dB (A)（except the noise of drum

and electromotor）

1.10 Max. overall dimensions 2940*1850*1764*

1.11 Net weight 12081kg

2. Brief Introduction of Construction:

The reducer is horizontally mounted with parallel shafts and four stages of
reduction and cylindrical helical gears.
The housing is of split type and consists of upper and lower housing. There is
lubrication bath at bottom of the casing, the 1st gear and 2nd pinion are placed under
the section, all of this shaft parts are immersed in the oil and when the gears running
the oil will be splashed to every meshed gear tooth surface and the race way of
bearing for lubrication and heat dissipation.
There is two view hatch covers on the top of the upper housing, when it is
opened the gear meshing condition and backlash may be inspected through the
hatch. The hatch cover is fitted with an air filter C-M60X2 to keep the atmosphere
pressure in the casing.
On the left side of the lower housing an oil drainage valve Q11F-16T
（DN25） is fitted, and can be opened for oil replacement or housing cleaning.

ZPMC 3
 Instruction of Reducer FH1660.144.C1A-00

An oil level indicator YWZ-76 is fitted on the left side of the casing (see the
side view on the construction drawing). The oil level of reducer shall be kept at its
middle scale.
To prevent oil from going out, every through cover of the shaft is provided
double-oil seals and full of lubricant grease in between the two seals. Outside of
bearing cover, there is a grease nozzle, pour into grease time in order to reliability
seal. Sealant are used in the surfaces of the link housing and the blank cover of
bearing, it can prevent oil leakage availability.

3. Maintenance and Repair

3.1 The reducer is delivered to the customer after it has been tested on the test rig at
the gearing manufacture factory of ZPMC. Parts in the housing are coated with
anti-corrosion grease.
3.2 After completion of the reducer manufacture the effective period of storage is six
months. It shall be inspected and maintained if a longer term of storage is
needed.
3.3 Before operation of the reducer the anti-corrosion grease and lubrication grease
on the shaft end surface shall be removed.
3.4 During installation of the reducer on its base plate the error of coaxiality of input,
output shafts with the electric motor shaft, wire rope drum shaft shall be less than
0.1mm. After completion of adjustment, it will be bolted to the base.
3.5 Before operation the reducer shall be filled in with lubrication oil through the view
hatch. Please took off the plug and installed the air filter and let the water out.
The number of lubricant on the reducer’s name plate is only consult. The oil level
shall be kept to the middle scale of the liquid level gauge. During operation
regularly check the oil level to ensure sufficient lubrication at every lubrication
point.
3.6 Changing the oil
3.6.1 Lubrication oil shall be periodically checked and replaced. After 400 hours of
first running the oil shall be replaced first time. Then every 5000 hours the oil
shall be replaced.
3.6.2 When changing the oil, always re-change the gear unit with the same type of
oil. Never mix different types of oil or oils made by different manufacturers.
Never mix synthetic oils with mineral-based oil to synthetic oil or from one
type of synthetic oil to another, flush the gear unit well with the new type of oil
beforehand. At every time of replacement the reducer shall be cleaned with

ZPMC 4
 Instruction of Reducer FH1660.144.C1A-00

equal quality oil. It shall be avoided flushing the gear units with the soluble
liquid.
3.6.3 Fill the gear unit with fresh oil using a filter (max. mesh 25 μ m). Remember to
fill the oil pockets on the inside housing.
3.6.4 The oil level must be at the upper mark on the oil dipstick.
3.6.5 You should inspect lubricant quality periodicity, example: viscosity 、 oxide 、
the waste of additive , if these points didn’t accord, please replace all lubricant
oil.
3.7 Bearings and oil seals’ lubrication: commend using the lithium-base grease,
period adding ration lubrication according to the requirement of the grease nipple
‘s plate.
3.8 Periodically check the installation bolts for loosening.
3.9 Regularly check the coaxiality of input and output shafts to avoid the reducer from
vibration, heating and abnormal wearing that affects the service life.
3.10 Storage: ZPMC reducer passed trial run check, anti-rust for inner parts,
coating anti-rust oil and lubricates grease on shaft surface then refers it to the
customer. For long-term storage reducer, laying down effective safeguard is duty of
reducer owner. We advice the storage place is dryness, the temperature is
controlled. It isn’t allow storage at the place where appear dew point, in order to
avoid of vapor condense on the surface of gear, pinion and bearing. Check the inner
parts of reducer every month. If the moisture is found, removed at once, recoat anti-
rust oil to protect.
3.11 For the reducer of long-distance transport, prevent due to a difference
temperature change, the parts surface form dew lead to rust. Before sent out
goods, add in lubricating oil and rust inhibitor. When the reducer is used, only
check up water in the housing, if there is no, and not have to change lubricate oil.
3.12 Correct operation, maintenance comply with these instructions may ensure
long service life of the reducer, and the reducer life is same as crane. However,
the customer shall establish maintenance and overhaul plan in accordance with
the actual operation condition. The aim is providing the reducer on adjustment
after a certain long operation for longer service life. Normally, overhaul interval
shall be 3-5 years depending on actual operation of the crane by the customer.
3.13 Major items of inspection during overhauling:

(1) Any pitting, peeling off, scratch, serious wear etc. on gear teeth surfaces.

(2) Check bearing rollers, internal and external raceway surface, any damage of
retainers.

(3) Check the oil seals.

ZPMC 5
 Instruction of Reducer FH1660.144.C1A-00

(4) Clean all the parts, housing and oil passages.

3.14 Inspection, parts and oil replacement shall be carefully recorded.

4. Disassembly and Re-assembly of Components

Normally the reducer shall not be disassembled unless during overhauling or the
accidental trouble interfere the normal operation of the reducer. Care shall be taken
for following matters if the customer considers it is necessary to disassemble the
reducer himself:
4.1 Order of disassemble
(1) Remove the blank covers of the intermediate shaft at both end of the casing, and
remove the dust-tight covers.

(2) Remove the tapered pin on the faying surface of housing connection bolts, nuts
and separate the upper housing and the lower housing by using disassembling
screw.

(3) Remove the upper housing and then the pinion shaft and its components,
intermediate gear shaft and output gear shaft can be removed out of the lower
housing and disassembled.

(4) If no damage off any component or part is found during inspection further
disassembly is not necessary. If any part is damaged for some component, then
only this component shall be disassembled.

(5) After inspection and part replacement the re-assembly shall be done in the
reverse order.

4.2 Points for attention during re-assembly

(1) To avoid from knocking, damaging any fitted surfaces of parts and components
and correct by using oilstone if damaged, scratched.

(2) Before re-assembly thoroughly cleans the gears, bearings, shafts, the metal
powder of the housing, dirt and other foreign matters.

(3) Clean all parts, components and the casing with kerosene and dry them by using
compressed air.

(4) Horizontally place the lower casing and install the components in the order of low
speed shaft, intermediate shaft, high speed shaft in the housing and adjust these
components properly in axial position, then install and adjust end covers, install
the oil seal at both ends of the shafts.

(5) Adjust axial clearance of bearing to 0.2-0.40mm.

ZPMC 6
 Instruction of Reducer FH1660.144.C1A-00

(6) Min. backlash of gearing

high speed stage: 0.230mm
second stage: 0.285mm
third stage: 0.320mm
low speed stage: 0.320mm
Contact spots on gear teeth surface shall not be less than 35% along the
tooth height and not less than 60% along tooth length. The spots distribution shall be
around the middle zone of the tooth face.

(7) After the above adjustment and installation have been completed place the cover
casing in position, Firstly set the tapered pin into the pinhole, then fit the securing
bolts, nuts. The faying surfaces may be coated with sealing coating.

(8) When the bearings, gears, oil seals and the parts that have relative movement
are fitted up a little clean oil shall be poured onto them to avoid dry friction during
first run.

(9) If oil seals are aged, fractured or seriously worn out they shall be replaced
timely.

(10) The securing bolts (8.8 grade), screws (8 grade) shall be tightened with
specified torque as shown in the following table.

Bolt diameters (mm) M16 M18 M20 M24 M30 M36

Tightening moment （kg·m) 16 22 32 56 108 191

(12) The customer shall damage no any part or component during the reducer
disassembly.

(13) After re-assembly the reducer shall be run without load in both directions for at
least 0.5 hour.

(14) During trial run check every joint surface and sealing and there shall not be any
leakage.

(15) During trial run noise level shall not be higher than 85db and no vibration by
hand feeling.

(16) Turn the input shaft by hand, it shall be manoeuvrable without any jam.

(17) If need be buy vulnerability spare parts that according to the recommendation
of the appendix.

ZPMC 7
 Instruction of Reducer FH1660.144.C1A-00

Appendix I: Roller Bearings (SKF)

No. Description Model Size Quantity

Spherical roller SKF
1 110*200*69.8 2
bearings 23222CC/W33/C3
Spherical roller
2 SKF 23228CC/W33 140*250*88 2
bearings
Spherical roller
3 SKF 24044CC/W33 220*340*118 2
bearings
Spherical roller
4 SKF 22256CC/W33 280*500*130 2
bearings
Spherical roller
5 SKF 23072CC/W33 360*540*134 2
bearings

Note: The above table just lists the type of SKF bearing. Other brands can be selected
according to the relevant SKF type.

ZPMC 8
 Instruction of Reducer FH1660.144.C1A-00

Appendix II: oil seals (NOK)

G/H STYLE

No. Model Size Quantity

1 NOK AC 4212 F6 SC 110*140*14 1

2 NOK AB 4212 A3 SB 110*140*14 1

3 NOK AB 5846 A0 大径 SB 360*420*25 2

A/B STYLE

No. Model Size Quantity

1 NOK AC 4212 F6 SC 110*140*14 2

2 NOK AB 4212 A3 SB 110*140*14 2

3 NOK AB 5846 A0 大径 SB 360*420*25 2

ZPMC 9
 Instruction of Reducer FH1660.144.C1A-00

Lubricant Selection Table

400C Viscosity Examples of lubricants

Lubricant ISO-VG
GB5903-95 CALTEX
mm2/s
Energol
Meropa SPARTAN Mobilgear Omala
VG680 L-CKC680 GR-XF
680 EP 680 636 680
680
Energol
Meropa SPARTAN Mobilgear Omala
VG460 L-CKC460 GR-XF
460 EP 460 634 460
460
Energol
Meropa SPARTAN Mobilgear Omala
VG320 L-CKC320 GR-XF
320 EP 320 632 320
Mineral 320
Oils
Energol
Meropa SPARTAN Mobilgear Omala
VG220 L-CKC220 GR-XF
220 EP 220 630 220
220
Energol
Meropa SPARTAN Mobilgear Omala
VG150 L-CKC150 GR-XF
150 EP 150 629 150
150
Energol
Meropa SPARTAN Mobilgear Omala
VG100 L-CKC100 GR-XF
100 EP 100 627 100
100

Note：
1. Mineral base gear oils in accordance with designation GB5903-95.
They are suitable for operating temperature from -80C~ +800C。
2. If the operating temperature of the gear unit exceeds or undershoots the limit
values stated, the oil selected should be checked for suitability.

ZPMC 10
 INSTRUCTIONS OF REDUCER MODEL
FVS445.30.D1A-00

SHANGHAI ZHENHUA HEAVY INDUSTRY CO.,LTD

May， 2009
 Instruction of Gantry Reducer FVS445.30.D1A-00

Contents

Construction drawings of the reducer model FVS445.30.D1A-00 for gantry

device

1. Technical Specifications
2. Brief Introduction of Construction
3. Maintenance and Repair
4. Disassembly and Re-assembly of Major Components

Appendix I Spherical bearings (SKF)

Appendix II Oil seals (NOK)
Appendix III Lubricant Selection Table

ZPMC
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 Instruction of Gantry Reducer FVS445.30.D1A-00

Preface
To operate and maintain and repair the gantry device reducer correctly the
customer shall read these instructions carefully before operation.
This is a kind of vertically mounted cylindrical helical gear reducer with parallel
shafts and 3 stages of reduction. This type of reducer has 2 symmetrical versions of
layout (Versions I and II, see the construction drawing) .The gear strength and material
quality are fully in compliance with requirements of American standard
ANSI/AGMA2101-D04.
The reducer is standard product of ZPMC. Lubrication is of bath and splash type.
This type of reducer has been operated together with container cranes in various Ports,
such as North America, South America and Southeast Asia, etc. Comments from the
customers are appreciated for continuous improvement and sophisticated of the
product.

z In these instruction all the data are measured in the international unit system SI unit
(metric system).

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 Instruction of Gantry Reducer FVS445.30.D1A-00

1. Technical Specification

1.1 Input speed 1750rpm

1.2 Reduction ratio 29.781

1.3 Centers between input and output 445mm

1.4 Rated output torque 15000N.M

1.5 Brand of lubrication oil: ISO VG 320

1.6 Lubrication oil volume 50L

1.7 Max. operating oil pool temperature ≤95°C

1.8 Reducer efficiency >95%
1.1 Reducer noise level <85dB (A)（except the noise of drum

and electromotor）

1.9 Max. overall dimensions 1275*590*580

1.10 Net weight 610kg

2. Brief Introduction of Construction:

The reducer is vertically mounted with parallel shafts and three stages of
reduction and cylindrical helical gears and bevel gears. The structure is welded. The
casing is of split type with horizontal and vertical faying surfaces consisting of left case,
right case and bottom case.
There is lubrication bath at bottom of the casing and the oil height is higher than
st
the 1 stages gear. When the gears run, oil will be splashed to every meshed gear tooth
surface and the race way of bearing for lubrication and heat dissipation.
There is a view hatch cover on the side of the cover casing. When it is opened
the gear meshing condition and backlash may be inspected through the hatch. The
hatch cover is fitted with an air filter C-M12 to keep the atmosphere pressure in the
casing.
Under the bottom of casing an oil drainage valve Q11F-16T (DN20) is fitted, and
can be opened for oil replacement or casing cleaning. An oil level indicator YWZ-76 is
fitted on the left side of the casing. The oil level of reducer shall be kept at its middle
scale.

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 Instruction of Gantry Reducer FVS445.30.D1A-00

To prevent oil from going out, every hollow cover of the shaft is provided with
framework oil ring. It can prevent oil leaking out from casing and also prevent dust
entering casing from environment. Sealant are used in the surfaces of the link casing
and the blank cover of bearing, it can prevent oil leakage availability.

3. Maintenance and Repair

3.1 The reducer is delivered to the customer after it has been tested on the test rig at
the gearing manufacture factory of ZPMC. Parts in the housing are coated with anti-
corrosion grease.
3.2 After completion of the reducer manufacture the effective period of storage is six
months. It shall be inspected and maintained if a longer term of storage is needed.
3.3 Before operation of the reducer the anti-corrosion grease and lubrication grease on
the shaft end surface shall be removed.
3.4 During installation of the reducer on its base plate the error of coaxiality of input,
output shafts with the electric motor shaft, wire rope drum shaft shall be less than
0.1mm. After completion of adjustment, it will be bolted to the base.
3.5 Before operation the reducer shall be filled in with lubrication oil through the view
hatch. Please took off the plug and installed the air filter and let the water out. The
number of lubricant on the reducer’s name plate is only consult. The oil level shall be
kept to the middle scale of the liquid level gauge. During operation regularly check
the oil level to ensure sufficient lubrication at every lubrication point.
3.6 Changing the oil
3.6.1 Lubrication oil shall be periodically checked and replaced. After 400 hours of first
running the oil shall be replaced first time. Then every 5000 hours the oil shall be
replaced.
3.6.2 When changing the oil, always re-change the gear unit with the same type of oil.
Never mix different types of oil or oils made by different manufacturers. Never
mix synthetic oils with mineral-based oil to synthetic oil or from one type of
synthetic oil to another, flush the gear unit well with the new type of oil
beforehand. At every time of replacement the reducer shall be cleaned with
equal quality oil. It shall be avoided flushing the gear units with the soluble liquid.
3.6.3 Fill the gear unit with fresh oil using a filter (max. mesh 25 μ m). Remember to fill
the oil pockets on the inside housing.
3.6.4 The oil level must be at the upper mark on the oil dipstick.

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 Instruction of Gantry Reducer FVS445.30.D1A-00

3.6.5 You should inspect lubricant quality periodicity, example: viscosity 、 oxide 、
the waste of additive , if these points didn’t accord, please replace all lubricant
oil.
3.7 Bearings and oil seals’ lubrication: commend using the lithium-base grease, period
adding ration lubrication according to the requirement of the grease nipple ‘s plate.
3.8 Periodically check the installation bolts for loosening.
3.9 Regularly check the coaxiality of input and output shafts to avoid the reducer from
vibration, heating and abnormal wearing that affects the service life.
3.10 Storage: ZPMC reducer passed trial run check, anti-rust for inner parts, coating
anti-rust oil and lubricates grease on shaft surface then refers it to the customer. For
long-term storage reducer, laying down effective safeguard is duty of reducer owner. We
advice the storage place is dryness, the temperature is controlled. It isn’t allow storage
at the place where appear dew point, in order to avoid of vapor condense on the surface
of gear, pinion and bearing. Check the inner parts of reducer every month. If the
moisture is found, removed at once, recoat anti-rust oil to protect.
3.11 For the reducer of long-distance transport, prevent due to a difference
temperature change, the parts surface form dew lead to rust. Before sent out goods,
add in lubricating oil and rust inhibitor. When the reducer is used, only check up
water in the housing, if there is no, and not have to change lubricate oil.
3.12 Correct operation, maintenance comply with these instructions may ensure long
service life of the reducer, and the reducer life is same as crane. However, the
customer shall establish maintenance and overhaul plan in accordance with the
actual operation condition. The aim is providing the reducer on adjustment after a
certain long operation for longer service life. Normally, overhaul interval shall be 3-5
years depending on actual operation of the crane by the customer.
3.13 Major items of inspection during overhauling:
(1) Any pitting, peeling off, scratch, serious wear etc. on gear teeth surfaces.
(2) Check bearing rollers, internal and external raceway surface, any damage of
retainers.

(3) Check the oil seals.

(4) Clean all the parts, housing and oil passages.

3.14 Inspection, parts and oil replacement shall be carefully recorded.

4. Disassembly and Re-assembly of Components

Normally the reducer shall not be disassembled unless during overhauling or the
accidental trouble interfere the normal operation of the reducer. Care shall be taken for

ZPMC
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 Instruction of Gantry Reducer FVS445.30.D1A-00

following matters if the customer considers it is necessary to disassemble the reducer

himself:

(1) Remove the blank covers at both end of the casing, and remove the dust-tight
covers.

(2) Remove the tapered pin and the connection bolts and nuts on the faying surface of
bottom casing with left casing and right casing, and separate the cover casing and
the casing by using disassembling screw.

(3) Remove the left-cover casing and right-cover casing and then the 3rd shaft and its
components, remove the output gear wheel shaft from the lower-cover casing and
disassembled.

(4) If no damage off any component or part is found during inspection further
disassembly is not necessary. If any part is damaged for some component, then
only this component shall be disassembled.

(5) After inspection and part replacement the re-assembly shall be done in the reverse
order.

4.2 Points for attention during re-assembly

(1) To avoid from knocking, damaging any fitted surfaces of parts and components and
correct by using oilstone if damaged, scratched.

(2) Before re-assembly thoroughly clean the gears, bearings, shafts the casing of the
metal powder, dirt and other foreign matters.

(3) Clean all parts, components and the casing with kerosene and dry them by using
compressed air.

(4) Horizontally place the lower casing and install the components in the order of low
speed shaft, intermediate shaft, high speed shaft in the casing and adjust these
components properly in axial position, then install and adjust oil shield discs and end
covers at both ends of the shafts.

(5) Adjust axial clearance of conical bearing to 0.05~0.10mm(first stage). Adjust axial
clearance of Spherical roller bearing to 0.10~0.15mm(second stage) 0.20-
0.30mm(third stage).

(6) Min. backlash of gearing

high speed stage: 0.16mm
middle stage: 0.185mm
low speed stage: 0.185mm

(7) Contact spots on gear teeth surface shall not be less than 35% along the tooth
height and not less than 60% along tooth length. For bevel gear, at least 60% of on
ZPMC
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 Instruction of Gantry Reducer FVS445.30.D1A-00

the face width and 65% of on the total face depth. The spots distribution shall be
around the middle zone of the tooth face.

(8) After the above adjustment and installation have been completed place the cover
casing in position, Firstly set the tapered pin into the pin hole, then fit the securing
bolts, nuts. The faying surfaces may be coated with sealing coating.

(9) When the bearings, gears, oil seals and the parts which have relative movement
are fitted up a little clean oil shall be poured onto them to avoid dry friction during
first run.

(10) If oil seals are aged, fractured or seriously worn out they shall be replaced timely.

(11) The securing bolts (8.8 grade) , screws (8 grade) shall be tightened with specified
torque as shown in the following table.

Bolt diameters (mm) M16 M18 M20 M24 M30 M36

Tightening moment （kg·m) 16 22 32 56 108 191

(12) The customer shall damage no any part or component during the reducer
disassembly.

(13) After 0.5 hour.

(14) During trial run check every joint surface and sealing and there shall not be any
leakage.

(15) During trial run noise level shall not be higher than 85db and no vibration by hand
feeling.

(16) Turn the input shaft by hand, it shall be manoeuvrable without any jam.

(17) If need be buy vulnerability spare parts that according to the recommendation of
the appendix.

ZPMC
Page 7
 Instruction of Gantry Reducer FVS445.30.D1A-00

Appendix I: Spherical roller bearings (SKF)

No. Description Model size Quantity

Tapered roller
1 SKF 32213 J2/Q 65*120*32.75 1
bearings
Tapered roller
2 SKF 32214 J2/Q 70*125*33.25 1
bearings
Tapered roller
3 SKF 32312 J2/Q 60*130*48.5 2
bearings
Spherical roller
4 SKF 23218 CC/W33 90*160*52.4 2
bearings
Spherical roller
5 SKF 23126 CC/W33 130*210*64 2
bearings

Note: The above table just lists the type of SKF bearing. Other brands can be selected
according to the relevant SKF type.

ZPMC
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 Instruction of Gantry Reducer FVS445.30.D1A-00

Appendix II: oil seals

No. Model Size Material Quantity

1 NOK TC AE 3222 A0 60*82*12 NBR 1

2 NOK SC AC 3389 E0 65*82*10 NBR 1

3 NOK SC AC 4399 E1 125*155*14 NBR 2

ZPMC
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 Instruction of Gantry Reducer FVS445.30.D1A-00

Appendix III: 3Lubricant Selection Table

400C Viscosity Examples of lubricants
Lubrican
t ISO-VG
GB5903-95 CALTEX
mm2/s
Energol
Meropa SPARTAN Mobilgear Omala
VG680 L-CKC680 GR-XF
680 EP 680 636 680
680
Energol
Meropa SPARTAN Mobilgear Omala
VG460 L-CKC460 GR-XF
460 EP 460 634 460
460
Energol
Meropa SPARTAN Mobilgear Omala
VG320 L-CKC320 GR-XF
320 EP 320 632 320
Mineral 320
Oils
Energol
Meropa SPARTAN Mobilgear Omala
VG220 L-CKC220 GR-XF
220 EP 220 630 220
220
Energol
Meropa SPARTAN Mobilgear Omala
VG150 L-CKC150 GR-XF
150 EP 150 629 150
150
Energol
Meropa SPARTAN Mobilgear Omala
VG100 L-CKC100 GR-XF
100 EP 100 627 100
100

Note：
1. Mineral base gear oils in accordance with designation GB5903-95.
They are suitable for operating temperature from -80C~ +800C。
2. If the operating temperature of the gear unit exceeds or undershoots the limit
values stated, the oil selected should be checked for suitability.

ZPMC
Page 10