INSTRUCTIONS OF REDUCER MODEL

FKR555.109.D4A-00

SHANGHAI ZHENHUA HEAVY INDUSTRY CO.,LTD

November， 2009
 Instruction of Gantry Reducer FKR555.109.D4A-00

Contents

Construction drawings of the reducer model FKR555.109.D4A-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

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 Instruction of Gantry Reducer FKR555.109.D4A-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 bevel gear and cylindrical helical gear
reducer with perpendicularity and 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) and is suitable for gantry device or other mechanism which has the same
requirements, 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.
All the bearings are sufficiently safe and reliable. 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 FKR555.109.D4A-00

1. Technical Specification

1.1 Input speed 1800rpm

1.2 Reduction ratio 109.038

1.3 Centers between input and output 555mm

1.4 Rated output torque 30000Nm

1.5 Brand of lubrication oil: ISO VG 220

1.6 Lubrication oil volume 70L

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 1120*990*660

1.11 Net weight 840kg

2. Brief Introduction of Construction:

The reducer is vertically mounted with parallel and perpendicularity shafts and
three stages of reduction and bevel gears and cylindrical helical gears. The reducer has
2 symmetrical versions of layout (version I and II, see construction drawing). The 2
versions may be manufactured symmetrically in pairs. 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.
The output shaft is a hollow shaft with shrink disc, and direct installed on the
wheel shaft of gantry device which is very simple and easy.
There is lubrication bath at bottom of the casing and the oil height is higher than
the 1st stages gear. 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 hatch cover on the top of and 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-M16 to keep the atmosphere
pressure in the casing.

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 Instruction of Gantry Reducer FKR555.109.D4A-00

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.
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 or 2 years the
oil shall be replaced. (synthetic oil: 10000 hours or 4 years of service)
3.6.2 In the case of larger oil quantities, an analysis should be carried out before
cleaning or changing the oil.
3.6.3 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 oil with mineral oil or with other synthetic oil. When changing from
mineral oil to synthetic oil or from one type oil to another, flush the gear unit well
with the new type of oil beforehand. At every time of replacement the reducer oil,

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 Instruction of Gantry Reducer FKR555.109.D4A-00

the housing must be flushed with oil to remove sludge, metallic particles and oil
residue. It shall be avoided flushing the gear units with the soluble liquid.
3.6.4 Ensure that all residues have been removed before filling with fresh oil.
3.6.5 Drain the oil while it is still warm, i.e. immediately after switching the machinery
off.
3.6.6 Stop the gear unit by switching off the drive assembly.
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

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 Instruction of Gantry Reducer FKR555.109.D4A-00

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:

(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 hollow 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 Spherical roller bearings to 0.10~0.15mm(first stage).

0.10~0.15mm(second stage). 0.20-0.30mm(third stage).

(6) The minimum gear's lateral clearance

high speed stage: 0.100mm
intermediate stage: 0.185mm
low speed stage: 0.210mm

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 Instruction of Gantry Reducer FKR555.109.D4A-00

(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. The spots distribution shall be
around the middle zone of the tooth face. For bevel gear, at least 60% of on the face
width and 65% of on the total face depth.

(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 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.

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 Instruction of Gantry Reducer FKR555.109.D4A-00

Appendix I: Spherical roller bearings (SKF)

No. Description Model size Quantity

Tapered roller SKF
1 60*130*48.5 2
bearings 32312
Tapered roller SKF
2 65*120*32.75 2
bearings 32213
Spherical roller SKF
3 80*170*58 2
bearings 22316 CC/W33
Spherical roller SKF
4 180*280*74 2
bearings 23036 CC/W33

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

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 Instruction of Gantry Reducer FKR555.109.D4A-00

Appendix II: oil seals (NOK)

No. Model Size Quantity

1 TC AE 3234 F2 60*85*12 1

2 SC AC 3234 E0 60*85*12 1

3 TC AE 4898 E5 180*210*16 2

4 SC AC 4897 F0 180*210*15 2

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 Instruction of Gantry Reducer FKR555.109.D4A-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 choose a low temperature product of the correspond
model, They are suitable for operating temperature from -200C ~ +800C.

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