INSTRUCTIONS OF REDUCER MODEL

FH1005.142.F1B-00

SHANGHAI ZHENHUA HEAVY INDUSTRY CO.,LTD

July, 2010
 Instructions of the Reducer FH1005.142.F1B-00

Contents

Construction drawings of the reducer model FH1005.142.F1B-00

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

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 Instructions of the Reducer FH1005.142.F1B-00

Preface
To operate and maintain the 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 4 stages of reduction. This type of reducer is suitable for trolley 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 and by many times improvement. Lubrication
is of bath and splash type. All the bearings are spherical (self-aligning) 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).

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 Instructions of the Reducer FH1005.142.F1B-00

1. Technical Specification

1.1 Input speed 1800rpm

1.2 Reduction ratio 142.46
1.3 Centers between input and output: 1005mm
1.4 Rated output torque 130000Nm
1.5 Lubrication oil: ISO VG 320
1.6 Oil volume 110L

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 1980*1050*1070

1.11 Net weight 3256kg

2. Brief Introduction of Construction:

The reducer is horizontally mounted with parallel shafts and four stages of reduction
and cylindrical helical gears. The reducer has 2 versions of layout (version G/H , see
construction drawing).
The housing is of split type and consists of upper and lower housing. There is
lubrication bath at bottom of the casing, the 1nd 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 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 housing is
fitted with an air filter C-M42x2 to keep the atmosphere pressure in the housing.
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.

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 Instructions of the Reducer FH1005.142.F1B-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 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

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 Instructions of the Reducer FH1005.142.F1B-00

oil, 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 affect the service life.
3.10 Storage: ZPMC reducer passed trial run check, anti-rust for inner parts, coating
anti-rust oil and lubricate grease on shaft surface, then refer 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.

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 Instructions of the Reducer FH1005.142.F1B-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 0.2 - 0.4mm.
(6) Min. backlash of gearing
high speed stage: 0.160mm

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 Instructions of the Reducer FH1005.142.F1B-00

intermediate stage: 0.185mm

intermediate stage: 0.210mm
output speed stage: 0.250mm

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 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.

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 Instructions of the Reducer FH1005.142.F1B-00

Appendix I: Roller Bearings (SKF)

No. Description Model Size Quantity

Spherical roller SKF
1 65*140*33 2
bearings 21313 E
Spherical roller SKF
2 90*160*40 2
bearings 22218 E
Spherical roller SKF
3 110*180*69 2
bearings 24122 CC/W33
Spherical roller SKF
4 180*280*74 2
bearings 23036 CC/W33
Spherical roller SKF
5 280*420*106 2
bearings 23056 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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 Instructions of the Reducer FH1005.142.F1B-00

Appendix II: oil seals (NOK)

No. Model Size Quantity

1 SC AC 3409 G2 65*90*13 1

2 SB AB 3409 G1 65*90*13 1

3 SC AC 5558 E1 280*316*18 2

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 Instructions of the Reducer FH1005.142.F1B-00

Appendix III: Lubricant Selection Table

400C Viscosity Examples of lubricants

Lubricant ISO-VG
GB5903-95 CALTEX
mm2/s
Energol Mobilgear
Meropa SPARTAN Omala
VG 460 L-CKC 460 GR-XP 600 XP
460 EP 460 460
460 460
Energol Mobilgear
Meropa SPARTAN Omala
VG 320 L-CKC 320 GR-XP 600 XP
Mineral 320 EP 320 320
320 320
Oils
1) Mobilgear
Energol Meropa SPARTAN Omala
VG 220 L-CKC 220 600 XP
GR-XP 220 220 EP 220 220
220
Energol Mobilgear
Meropa SPARTAN Omala
VG 150 L-CKC 150 GR-XP 600 XP
150 EP 150 150
150 150

Low Pour Meropa Omala LPP

Point
VG 320 / / 320 / / 320
Mineral
Oils Meropa Omala LPP
2) VG 220 / / 220 / / 220

Meropa Mobil SHC 634

Enersyn Omala
VG 460 / SG-XP 460
Synthetic / Mobilgear SHC HD 460
EP 460 XMP 460
Meropa Mobil SHC 632
Enersyn Omala
Synthetic
VG 320 L-CKT 320
SG-XP 320
Synthetic / Mobilgear SHC HD 320
EP 320 XMP 320
Oils
3) Meropa Mobil SHC 630
Enersyn Omala
VG 220 L-CKT 220
SG-XP 220
Synthetic / Mobilgear SHC HD 220
EP 220 XMP 220
Enersyn Meropa Mobil SHC 629
Omala
VG 150 / SG-XP Synthetic / Mobilgear SHC HD 150
150 EP 150 XMP 150

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 Instructions of the Reducer FH1005.142.F1B-00

Note：
1) Mineral oils in accordance with designation GB5903-95. They are suitable for
operating temperature approx -100C ~ +900C. (short time +1000C)
2) Low Pour Point Mineral Oils is just used in ZPMC’s gear box for the first time
fill-in. They are suitable for operating temperature approx -200C ~ +900C. (short
time +1000C)
3) The synthetic oils have a wider temperature range and a higher viscosity index than
the mineral oils. They are suitable for operating temperature approx -350C ~
+1000C.

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