Control No. : GB-0207_Rev 3.

Gearbox Instruction Manual

 Table of Contents

1. Safety instructions ---------------------------------------------------------------------------------------------------- 3

2. Summary ---------------------------------------------------------------------------------------------------------------- 4

3. Inspection, transportation and storage ---------------------------------------------------------------------- 4 ~ 5

4. Installation ---------------------------------------------------------------------------------------------------------- 6 ~ 9

5. Operation --------------------------------------------------------------------------------------------------------- 9 ~ 11

6. Routine inspection and repair ------------------------------------------------------------------------------ 11 ~ 12

7. Lubricants ------------------------------------------------------------------------------------------------------- 13 ~ 14

8. Troubleshooting ------------------------------------------------------------------------------------------------------ 15

9. Reducer structure --------------------------------------------------------------------------------------------- 16 ~ 17

10. Quality assurance --------------------------------------------------------------------------------------------------- 18

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1. Safety instructions
1.1 Introduction
This gearbox may cause serious injury or property damage due to high voltages, rotating bodies and
hot surfaces. Installation, maintenance and repair must be performed by qualified and trained personnel
in compliance with safety regulations and standards. To avoid possible hazards, you should be fully
aware of the safety precautions listed in this manual.
Be sure to read all instructions in this manual before installation or operation.

1.2 Warning, caution, notice

This instruction manual contains warnings, cautions, and notices to emphasize important safety-
related phrases. The warnings, cautions, and notices in this manual are defined as follows.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in injury or property damage.

1.3 Safety precautions

 If it is used in personnel transport equipment, install a safety protection device on the

device side. Equipment malfunction may result in personal injury or property damage.
 When used for lifting equipment, install a safety protection device to prevent falling.
Equipment malfunction may result in personal injury or property damage.

 Use only within the design specifications of the gearbox. If used for other purposes,
damage to the product may result in physical or material damage.
 Do not modify the parts or the product at your own discretion. Any modifications may
cause abnormal or serious injury or property damage.
 Do not damage the nameplate.

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2. Summary
This manual has been written to ensure the safe and correct use of Hyosung gearbox. Improper
installation, use and maintenance of the gearbox may cause fire, explosion or electric shock, so you are
advised to read this manual before handling the product. After reading, always keep the manual where
you can see it.

3. Inspection, transportation and storage

3.1 Inspection
(1) For damage that may occur during shipment, please check for damage immediately upon receipt
of the product.
(2) Make sure that the type, voltage, reduction gear ratio, input rotation number and serial number on
the name plate match the specifications of the product, and check that the shaft rotates correctly
when rotated by hand, and that the amount of the oil and grease is appropriate. If a problem arises,
contact your dealer, our sales team or after-sales service department after checking the product
specifications and serial number.

< NAME PLATE >

(1) Type of the Gearbox
(2) Input Power
(3) Input RPM
(4) Ratio of Reduction
(5) Serial No.

3.2 Transportation
Be sure to use lifting devices for reducers with lifting devices. Be careful not to damage the main parts
such as shafts, piping, and fittings during installation.

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 Do not lift the machinery using the lifting hooks of the reducer together. Failure to observe this
may result in serious injury from falling.

 When transporting, please check the top and bottom of the product and check the condition of the
lifting hook and mounting bolt. Also, please check the weight of the reducer and carry it by using
the equipment that matches the weight.
 Do not walk under a crane with a suspended reducer. Falling or overturn can lead to fatal injuries
to your body or death.

3.3 Storage
The reducer shall be stored in a place where there is no vibration in the room, little changes in
temperature and clean, dry and well-ventilated place. If stored for a long-term of more than 3
months, it shall be managed as follows;
(1) To prevent rust of bearings and gears, rotate the shaft for at least 5 minutes every two
months.
(2) Rustproof coatings are applied to prevent rusting during delivery, but rust may occur depending
on storage conditions, so you are advised to check regularly.
* Since exposed parts exposed to the outside such as the output shaft may rust during storage,
apply solvent-diluted rust-preventive oil (equivalent to JIS NP19) periodically.
(3) Oil seal may age due to temperature or ambient environment. To prevent oil seal aging, store
oil seal at ambient temperature of 15 - 30 ℃, humidity of 40 - 70%. Also, be careful not to
expose the oil seal to direct light (sunlight), dust or ozone. After long-term storage, check for
any defect before use, and replace if there is any defect. Oil seal is a consumable and if it is
not used for a long time, it becomes aged (oxidized) and causes leakage.
(4) If you do not use the reducer when it’s mounted for more than 3 months, cover the entire reducer
with a waterproof cover in a place with high humidity or where there is a risk of intrusion of
water and foreign matters, and put the desiccant inside and seal it. Replace the desiccant
regularly.
(5) When storing for more than 6 months, seal the product after injecting an appropriate amount
of vapor-resistant anti-corrosive oil (equivalent to JIS NP20).
(6) Before starting the load operation, check for abnormal sound, vibration, or heat.
If there is something wrong, contact your dealer, our sales team or after-sales service
department.

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4. Installation
4.1 Installation site conditions
(1) Use at an indoor location with an elevation of 1000 m or less and an ambient temperature of -
10 °C to 40 °C.
Please consult with our technical department when using the reducer in places where altitude and
ambient temperature are considerably low or high.
(2) For installation, select a place with good ventilation, low dust and humidity, and easy inspection
(3) Avoid locations where moisture, oil, and explosive gases are present or vibration is transmitted
severely.

 Do not turn the package upside down for transportation, causing the product to face downwards.
Failure to observe this may result in serious injury from falling or overturn
 Your life will be at risk due to falling if you work underneath the product while it is being
transported with a crane, etc.

 Make sure that there are no obstacles around the reducers. There is a risk of fire due to cooling
deterioration.
 Do not touch the shaft end, inner diameter part, key area, etc. of the reducer with bare hands.
 Install a device that prevents penetration of oil vapors into food machines, etc. where oil should
not get inside. Oil steam or debris can cause defective products.

4.2 Foundation and installation

(1) When installing the reducer on a concrete foundation, make sure that the base surface is
sufficiently higher than the bottom surface to ensure that the drainage is good and that all
mounting surfaces are securely supported on the mounting surface. If necessary, use a shim.
(2) If it is fixed to the mounting bracket, make sure that the mounting angle is within ±1° of the floor,
and the dynamic load may be added during operation, which may cause vibration, so the
structure must be solid.
If the installation condition is improper, it may cause breakdown due to vibration, so please take a
caution.

4.3 Load connection

(1) Products delivered with a bed are delivered with the alignment of the bed and the reducer already

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adjusted, but during transportation or installation, the alignment of the product may be misaligned.
As misalignment may affect vibration, noise and service life, you are advised to check the
alignment again during installation.
(2) When mounting couplings, pulleys, sprockets, etc. consider the deviation of the parts and lubricate
them, and hit them softly with things such as a resin hammer to insert them in a way to avoid
shock and damage. Or, heat the coupling with an appropriate temperature to insert it into the axis
without too much effort.
If the coupling is heated up excessively, the oil seal may leak and cause oil leakage.

<No impact on the input and output shaft >

(3) It is advisable to use the reducer by direct coupling, and use flexible couplings as much as
possible.
(4) When mounting the coupling, make sure that the center of the reducer shaft and the overloaded
machine shaft are aligned straight.
(5) In general, the coupling method and tolerance of coupling are as follows.
Graduation in the direction Axial direction graduation
Types of coupling
perpendicular to the axis r=200mm

Fixed coupling 0.03 0.02

Gear coupling 0.05 0.05
Flexible coupling 0.1 0.1

Perpendicular orientation of axis

Axial Direction

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* If the graduation radius based on the reference axial direction is larger or smaller than r=200 mm, it
becomes larger or smaller in proportion to the reference value in the above table.
* When installed under the best conditions, please fix the reducer position with the knock pin.
(6) When installing sprockets and gears, select the sprocket and gear diameter according to the follow
formula so that the load acts on the center of the output shaft, and insert them fully under the
protrusion of the shaft as much as possible before use.
Chain sprocket gear pitch circle diameter>= 4Xoutputshaftdiamter
(7) When mounting sprockets, pulleys and gears on the input/output shaft, attach them to the main
body of the reducer as shown below. (L2 is better than L1 for reducer service life)

< Bad example > < Good example >

(8) When connecting sprockets, pulleys and gears, make sure that the axes of the reducers and the
load machine are parallel to each other so that the sprockets, pulleys and gears are aligned on
center on both sides and perpendicular to the axis.

(9) When connecting to another machine with sprockets and a chain, the length shall be such that the
chain does not become loose.
(10) Belt tension and pulley diameter have a great influence on bearing horizontal and axial strength
of reducer, so it is recommended to install and use them in compliance with the KS M 6535
specification.
As a principle, the speed of the V-belt shall be up to 30 m/sec.

 Install a safety cover on the rotating part to prevent direct contact with the human body.

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 When connecting the reducer to the equipment, the error should be within the control value
indicated in the instruction manual, drawings, catalogs and so on. Failure to do so may result in
damage.
 Use fastening bolts conforming to the standards shown in the drawings, catalogs, etc. In case of
damage, flying debris may result in serious injury or damage to the product.
 Check the direction of rotation before connecting to the machine. Reverse rotation may cause
damage to the unit.
 When the connection between the product and the counterpart machine is a belted connection, if
the degree of parallelization with the pulley is directly connected, manage the degree of the direct
connection within the control range. Also, be sure to install a protective net to prevent any
injury/damage caused by the belt.
 When installing the reducer, vibration, noise, etc. may occur due to the occurrence of
misalignment when assembling the motor and reducer, and the reducer and passive equipment,
the deformation of the axis may occur above the regulated amount and there is the possibility of
the axis being cut or damaged, and it may have a detrimental effect on the internal bearings
 Excessive impact such as steel hammer on the reducer output shaft may cause output shaft, gear,
bearing damage and casing damage.

5. Operation
5.1 Basic checklist
After installation, check the following during commissioning the reducer.
(1) Is the connection to the main body accurate?
(2) Are the mounting bolts securely tightened?
(3) Do the direction you want to use and the direction of rotation match?
(4) Has the oil been filled up to the oil level indicator line?

5.2 Test operation

After checking the basic checklist, gradually increase the load from the no-load condition for operation
and check whether there are any problems as shown below. If the cause of a problem is not clear, stop
operation and contact your dealer, our sales team or after-sales service department.

Checklist during commissioning

Is the mounting surface level?

Are there any abnormal Does the mounting structure lack strength or is there any
sounds or vibrations? resonance?
Does the axis center with the body match?
Is the vibration of the main body delivered to the reducer?

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Does the motor current value exceed the rated current value listed
Is the reducer surface
on the nameplate?
temperature unusually
Is the voltage rise and fall of the motor too big?
high?
Is the ambient temperature of the place of use high?
Is the oil level adequate?
Is there any differential pressure due to foreign matters in the filter?
Is the discharge pressure adequate (1.5 to 2.5 bar if not indicated)?
Is the oil flowing smoothly in the piping?
Is the oil pump not Is the suction pipe fully open?
circulating? Is not there a shortage of oil?
Is there any abnormality in the motor power connection for pump
drive?
Is there any problem with oil leakage or oil seal on the pump shaft?

 Do not approach the rotating body during operation. Contact with the body or loose clothing may
result in serious injury or death.
 Be sure to confirm the direction of rotation before operation. Rotation in the opposite direction may
cause property damage due to human and equipment accidents.

 If there is any oil pump for cooling, make sure that the oil pump is operating normally. The reducer
may overheat.
 If there is excessive internal pressure in the pump before the pump starts up, the oil seal may be
damaged and the pump may not start up.
 Ensure that cooling water is supplied normally to the oil cooler. It may overheat due to the loss of
the cooling in the oil cooler
 Turn on the main power only after lubricant is sufficiently supplied inside the reducer.
If operated without sufficient lubrication, it may cause burnout of the reducer.
 Be careful of the contact of the hand or body on the surface of the reducer in operation. The
surface of the reducer in operation may be extremely hot, which may cause burn injury.
 If abnormal noise or excessive noise occurs during operation, stop operation immediately and
contact your dealer, our sales team or after-sales service department.
 Do not open the maintenance cover or the oil inlet cover. Lubricant may come out.

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 When reversing the reducer, make sure the reducer comes to stop before start-up again. Product
damage may occur
 When a problem occurs, stop operation.

6. Routine inspection and repair

6.1 Routine inspection
Please perform the below. Failure to carry out daily inspections may cause malfunction.
Inspection item Details of inspection
Abnormal sound Is driving noise suddenly changing?
Is the vibration of the reducer suddenly changed or the vibration level
Vibration
high?

Is the reducer surface temperature abnormally high? (90℃ or higher)

Surface Or does it rapidly rise?

temperature (Although the temperature rise of the reducer in operation differs
Oil level depending on the model, there is no particular problem if the surface
temperature of the reducer is about 80°C and there is a slight vibration.)
Does the oil level decrease?
Oil leakage Is there oil leakage in the oil seal area?
Mounting bolt Is the bolt loose?
Chain, V-belt Has the chain or V-belt been damaged?
Abnormal sound Is driving noise suddenly changing?
If any abnormality is confirmed during routine inspection, please take appropriate measures as
described in "8. Troubleshooting". If this does not work, please contact us.
 Check the condition of the reducer mounting surface and alignment every 6 months - 1 year.
 Oil seal is a consumable and needs to be replaced periodically, and if the surrounding condition is
severe (dust, gas, high temperature, etc.), hardening or aging (oxidation) will occur quickly,
shortening the service life and causing leakage.

 Do not go near the rotating body (shaft, etc.) when performing maintenance or inspection during
operation.
Contact with the product may result in contact with the body or loose clothes, resulting in serious
injury or death.

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 When inspecting the pulley surface at stop, turn off the power of the motor and after the reducer
comes to complete stop before inspection. Your hand may get stuck in the geared area of the pulley
and injured.
 Do not operate the unit until the safety cover is installed outside after inspection.
If operated before the installation of the safety cover, body or clothing may be caught on the
rotating body during operation, resulting in death or serious injury.
 When disassembling shrink discs of products using hollow shaft and shrink discs, do not
disassemble the absolute fastening bolts completely until the locking ring or pressure ring has
been loosened.
When the fastening bolt is completely disassembled, life may be at risk due to ring separation from
to residual stress.

 Since the surface of the reducer is hot, do not touch it with bare hands. It may cause burns.
 Do not disassemble the maintenance cover during operation. High-temperature lubricant may
splatter.
 After checking the reducer, check the tools and other materials used for the inspection.
They can get inside the reducer and left as foreign matter, and damage the parts.

6.2 Disassembly and assembly

 Repair, disassembly and assembly must be done by a professional. Equipment damage may
occur.

6.3 Disposal

 When disposing the reducer, dispose the oil that has been injected as the designated waste, and
dispose the casing and gears with the oil drained as the scrap iron.

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7. Lubricants
7.1 Lubricant change
(1) Perform the 1st lubricant change within 500 hours or within 2 months from starting operation.
Afterwards, perform 2nd lubricant change within 2,500 hours or 6 months.
(2) Afterwards, if the surface temperature of the housing is less than 70°C, replace it every 5,000
hours or 1 year, whichever comes first.
(3) If the housing surface temperature is over 70°C, replace it every 2,500 hours or every 6
months.
(4) In a place where the ambient temperature changes rapidly, or in an atmosphere with a lot of
corrosive gas, the lubricating oil ages quickly, so please inquire with the lubricant manufacturer.
(5) The lubricant to be disposed after oil change should be classified as designated waste and
disposed of according to the regulations.
(7) Oil filling
Lubrication is performed through the oil filler port on the top of the main unit and lubricated to
the appropriate scale of the oil gauge or oil level meter. When checking the flow rate with the oil gauge,
make sure to check the scale of the oil level gauge and if the amount of lubricant is too little, it may
damage the gear or the bearing. The oil level is based on when the reducer is at a stop, and when the
pump starts up, the oil level may decrease.

< Location of the oil inlet, outlet, air vent and oil level gauge >
(8) Oil amount per specification
Please refer to either the approved reducer specification or catalogue for the required oil amount per
specification and contact our technical or after-sales service department for any other non-standard
specification.

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(9) Lubricant selection

Ambient Viscosity (40℃) Recommended maker
temperature ISO VG HOUGHTON MOBIL SHELL SK(GULF)
31℃ MP GEAR OIL MOBIL GEAR SHELL OMALA EP LUBRICANT
320
-50℃ 320 600 XP 320 320 320
0℃ MP GEAR OIL MOBIL GEAR SHELL OMALA EP LUBRICANT
220
-30℃ 220 600 XP 220 220 220
Less than MP GEAR OIL MOBIL GEAR SHELL OMALA EP LUBRICANT
150
0℃ 150 600 XP 150 150 150
Above 50℃ Inquire us

(10) Oil drainage

When the lubricating oil is warm, drain the oil out through the drain plug on the bottom of the
main body. Please treat waste oil as designated waste at this time.
(11) Grease lubrication
Some axis, bearing or oil seal may be lubricated with grease.
In such cases, grease nipples are installed, so make sure that you know where and how many
those nipples are installed before filling.
The grease filled upon delivery shall be refilled generally depending on number of input
revolutions, at every 1500 hours in case of 750RPM or less, or 750 to 1500RPM every 1000
hours.

 After completely stopping the reducer in operation, cool it for more than 2 hours to check that the
lubricant has cooled before replacing the lubricant.
 Not adhering to the replacement time of the reducer lubricant may result in overheating and
burnout due to the decreased viscosity of lubricants.
 Follow the instruction manual to replace the lubricant. Be sure to use the lubricant specified in the
instruction manual and completely stop the reducer and replace the oil to match the oil gauge
level.

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8. Troubleshooting
Problem Cause Measure
Overload operation Operate with proper load

Insufficient or excessive lubricant Adjust to the indicator of the oil level meter

Defective or unsuitable lubricant Replace aged or contaminated with new lubricant

Bearing gap too small Bearing clearance adjustment

Heating Defective oil seal Oil seal replacement

The shaft is warped or the tension of the connection is Check axis, adjust tension

high.

Bearing defects (abrasion, roughness) Replacing bearings

Friction of parts Correction after disassembly and inspection

Regular noise - Poor gear condition,

Replace gear & bearing, replenish & replace lubricant
Bearing damage

High metal sound - lack of lubricant Replenish & replace lubricant

Severe/strang
Irregular noise (strange noise)-foreign matter entered,
e noise Remove (clean) foreign substance, replace bearing
Bearing damaged

The fastened area is loose

Inspect after disassembly, remove/replace the cause
(Shaft, gear and flange connection)

Teeth worn out Replace gear & bearing, replenish & replace lubricant

Intrusion of foreign matters Replenish & replace lubricant

Bearing wear and tear Replace bearing

Excessive Loose mounting bolts and fixing bolts Fasten bolt
vibration
Loose assembly part (shaft, gear) Reassembly after disassembly and inspection

Axis is not straight. Check the load connection and reconnect

Case and connection damaged Replace

Oil seal damage and hardening Replace oil seal

Defective packing (connection) Replace packing and reseal

Loose oil drainage plug Fasten securely (Teflon tape)

Broken and loose oil level gauge Replace

Oil leakage
Leakage of other welding parts Re-weld or replace

Input/output shaft wear (sealing area) Replace output shaft, plate or insert a sleeve

Lack of input/output cover grease (vertical type) Replenish the grease on the cover

Wrong attachment of the parts Contact us

Warning) When replacing gears, axis, case, etc., please contact us, and temporary measures or
wrong part replacement damages the entire machine, so be extremely cautious

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9. Reducer structure

<SK TYPE>

<SH TYPE>

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<SHB TYPE>

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10. Quality assurance

10.1 Warranty
When operating under normal conditions, such as proper installation, operation and maintenance as
described in the instruction manual, we guarantee that the reducer will operate normally during the
warranty period.

10.2 Scope of warranty

We guarantee the problems that occur in performance, materials and appearance of reducers.

10.3 Limited Warranty

(1) When defective products are used when mounting a reducer or connecting to another device
(2) When maintenance is not carried out and the product is not used under normal conditions
(3) When used under severe environment than normal environment
(4) When the reducer is modified or the structure is changed.
(5) If a secondary failure occurs in the reducer due to a faulty connecting device
(6) Breakdown due to force majeure such as earthquake, fire, flood, lightning
(7) Other cases in which misuse of users is certain

10.4 When contacting us

If you have any questions or concerns about the product, please check the following:
(1) Description on the nameplate
A. Manufacture number
B. Product type
C. Power/input RPM/reduction ratio
(2) Operating environment
A. Types and operating conditions of load
B. Period of use
C. Installation place and other particulars

The contents of this manual are subject to change without notice.

We are fully committed to the contents of this manual, but please contact us if you find anything unclear or missing.

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Contact us

■ A/S Application
Domestic 080-024-8282
International +82-55-268-8282
E – Mail hicoservice@hyosung.com

■ Sales Team
Domestic Sales TEL : +82-2-707-6322~8 FAX : +82-2-707-6444
Motor Agency Sales TEL : +82-2-707-6330 FAX : +82-2-707-6447
Plant & Marine Sales TEL : +82-55-268-8572,8574~7 FAX : +82-55-268-8579

■ Technical enquiry
Design Team TEL : +82-55-279-7130 FAX : +82-55-279-7159

■ Homepage http://www.hyosungheavyindustries.com

Address (Headquarters): 119, Mapodae-Ro, Mapo-Gu, Seoul, Republic of Korea

Address (Changwon): 303, Gongdan-Ro, Seongsan-gu, Changwon-si, Gyeongsangnam-do, 642-
290 Republic of Korea

ⓒ Copyright 2019 HYOSUNG HEAVY INDUSTRIES CORPORATION

All rights reserved. Contents are subject to change without notice.