REDUCER

INSTRUCTIONS OF REDUCER MODEL
FVS395.30.D3B-00
SHANGHAI ZHENHUA HEAVY INDUSTRIES CO.,LTD

October， 2009
Instruction of Gantry Reducer FVS395.30.D3B-00
Contents
Construction drawings of the reducer model FVS395.30.D3B-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
Appendix III Lubricant Selection Table
ZPMC
Page 1
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).
ZPMC
Page 2
1. Technical Specification
1.1 Input speed 2000rpm
1.2 Reduction ratio 30.112
1.3 Centers between input and output 395mm
1.4 Rated output torque 12800N.m
1.5 Brand of lubrication oil: ISO VG 320
1.6 Lubrication oil volume 45L
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 1265*550*500
1.10 Net weight 456kg
2. Brief Introduction of Construction:
The reducer is vertically mounted with parallel shafts and three stages of
reduction and cylindrical helical 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 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 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.
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
ZPMC
Page 3
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.
3.1 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.
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.
ZPMC
Page 4
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
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.
ZPMC
Page 5
(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. 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.
ZPMC
Page 6
(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
Appendix I: Spherical roller bearings (SKF)
No. Description Model size Quantity

Tapered roller
1 SKF 30313 J2/Q 65*140*36 1
bearings
Tapered roller
2 SKF 32314 J2/Q 70*150*54 1
bearings
Tapered roller
3 SKF 32311 J2 55*120*45.5 2
bearings
Spherical roller
4 SKF 22314 E 70*150*51 2
bearings
Spherical roller
5 SKF 23124 CC/W33 120*200*62 1
bearings
Spherical roller
6 SKF 22222 E 110*200*53 1
bearings
Note: The above table just lists the type of SKF bearing. Other brands can be selected
according to the relevant SKF type.
ZPMC
Page 8
Appendix II: oil seals
No. Model Size Quantity
1 NOK TC AE 3234 F2 60*85*12 1
2 TTO TC 65*80*8 1
3 NOK SC AC 4346 F0 120*150*14 2
ZPMC
Page 9
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
460 EP 460 634 460
460
Energol
320 EP 320 632 320
Mineral 320
Oils
Energol
220 EP 220 630 220
220
Energol
150 EP 150 629 150
150
Energol
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 -20°
C ~ +80°C.
ZPMC
Page 10
FH1650 SERIES
Shanghai Zhenhua Port Machinery Co., Ltd.

October, 2005
Instruction of Reducer FH1650 series
Contents
Construction drawings of the reducer model FH1650 series for main hoist
Appendix I Spherical roller bearings (SKF)

Appendix II Oil seals (NOK)
ZPMC 1
Preface
To operate and maintain and repair the main 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 4 stages of reduction. This type of reducer is suitable for main 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 2001-B88. The spherical roller bearings fixed in the reducer are SKF
bearings.
The reducer is standard product of ZPMC and by many times improvement.

Lubrication is of bath and splash type. All the bearings are shperical (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
1.2 Reduction ratio

FH1650.104 FH1650.116 FH1650.125
103.87 116.444 125.315
1.3 Centers between input and output 1650mm
1.4 Output torque Nm

FH1650.104 FH1650.116 FH1650.125
540000 540000 540000
1.5 Brand of lubrication oil ISO VG 320
1.6 Lubrication oil volume 400L
1.7 Max. operating oil temp ≤80°C

1.9 Reducer noise level <85dB (A)
The reducer is horizontally mounted with parallel shafts and three 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 cover 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.
ZPMC 3
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.
An oil level indicator YWZ-80 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.

the gearing manufacture factory of ZPMC. Parts in the casing are coated with
anti-corrosion grease and enclosed without lubrication oil.
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 coaxality of input,
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.
3.6.1 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
ZPMC 4

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.
3.7 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.
3.9 Regularly check the coaxality 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 vapour 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.
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.
retainers. Check the oil seals.

ZPMC 5

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.
(5) After inspection and part replacement the re-assembly shall be done in the
reverse order.
(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 10°C soda water or 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 0.2-0.50mm.

high speed stage: 0.185mm
intermediate stage: 0.210mm
ZPMC 6
intermediate stage: 0.250mm

low speed stage: 0.280mm
(7) Contact spots on gear teeth surface shall not be less than 45% 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.
(8) 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
(9) When the bearings, gears, oil seals and the parts that have relative movement
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.

Tightening moment k · ) 16 22 32 71 108 191
disassembly.
(13) After re-assembly the reducer shall be run without load in both directions for at
least 1 hour.
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
Appendix I: Roller Bearings (SKF)
No. Description Model Size Quantity

Spherical roller
1 SKF 22322CC/W33 110*240*80 2
bearings
Spherical roller
2 SKF 23226CC/W33 130*230*80 2
bearings
Spherical roller
3 SKF 24138CC/W33 190*320*128 2
bearings
Spherical roller
4 SKF 22252CC/W33 260*480*130 2
bearings
Spherical roller
5 SKF 23072CC/W33 360*540*134 2
bearings
ZPMC 8
Appendix II: oil seals (NOK)
1 NOK AB 4212 A3 110*140*14
2 NOK AC 4212 F6 110*140*14
3 NOK AB 5846 A0 360*420*25
1 NOK AB 4212 A3 110*140*14
2 NOK AC 4212 F6 110*140*14
3 NOK AB 5846 A0 360*420*25
ZPMC 9
Lubricant Selection Table

Lubricant ISO-VG
GB5903-95 CALTEX
mm2/s
Energol
680 EP 680 636 680
680
Energol
460 EP 460 634 460
460
Energol
3200 EP 320 632 320
Mineral 320
Oils
Energol
220 EP 220 630 220
220
Energol
150 EP 150 629 150
150
Energol
100 EP 100 627 100
100
Note
They are suitable for operating temperature from -80C~ +800C
values stated, the oil selected should be checked for suitability.
ZPMC 10
FH495 SERIES
Shanghai Zhenhua Port Machinery Co., Ltd.

October , 2005
Instructions of the Reducer FH495 series
Contents
Construction drawings of the reducer model FH495 SERIES for Trolley device
Appendix I Spherical roller bearings (SKF)

Appendix II Oil seals (NOK)
ZPMC 1
Preface
To operate and maintain the trolley device reducer correctly the customer shall read
these instructions carefully before operation.
This is a kind of horizontally mounted bevel gear and cylindrical helical gear reducer
with perpendicularity and parallel shafts and 2 stages of reduction. This type of reducer
has 3 versions of layout (Versions c,d,h, see the construction drawing) and is suitable
for trolley device with rated output torque of 2*8400N.M The gear strength and material
quality are fully in compliance with requirements of American standard
ANSI/AGMAZ001-B88. The anti-friction bearings fixed in the reducer are SKF bearings.
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).
ZPMC 2

1.2 Reduction ratio 40.40
1.3 Centers between input and output: 495mm
1.4 Rated output torque 2*8400Nm
1.5 Lubrication oil: ISO VG 320 or AGMA-5EP
1.6 Oil volume 30L
1.7 Max. operating oil temp. ≤80°C

1.9 Reducer noise level <85dB
The reducer is horizontally mounted with parallel shafts and three stages of reduction
and cylindrical helical gears. The reducer has 3 versions of layout (version c,d,h , 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 stages 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 are 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 view cover 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-40T (DN20) is fitted,
and can be opened for oil replacement or housing cleaning.
An oil level indicator YWZ-80 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.
ZPMC 3
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.

the gearing manufacture factory of ZPMC. Parts in the housing are coated with
anti-corrosion grease.
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 coaxality of input,
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
3.6.1 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
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.
ZPMC 4
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.
3.9 Regularly check the coaxality 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.
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.
retainers.
(3) Check the oil seals.

accidental trouble interfere the normal operation of the reducer.
ZPMC 5
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.
(5) After inspection and part replacement the re-assembly shall be done in the reverse
order.

(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 10°C soda water or 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 - 0.3m.
high speed stage: 0.185mm ~0.29mm
intermediate stage: 0.21mm ~0.33mm
Contact spots on gear teeth surface shall not be less than 45% 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.
ZPMC 6
(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
(8) When the bearings, gears, oil seals and the parts which have relative movement
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.

Tightening moment k · ) 16 22 32 71 108 191
disassembly.
(13) After re-assembly the reducer shall be run without load in both directions for at
least 1 hour.
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
Appendix I: Roller Bearings (SKF)
No. Description Model Size Quantity

Spherical roller
1 SKF22310CC/W33 50*110*40 2
bearings
Spherical roller
2 SKF 22313CC/W33 65*140*48 2
bearings
Spherical roller
3 SKF 22317CC/W33 85*180*60 2
bearings
ZPMC 8
Appendix II: oil seals (NOK)
ZPMC 9
Appendix III: Lubricant Selection Table

Lubricant ISO-VG
GB5903-95 CALTEX
mm2/s
Energol
680 EP 680 636 680
680
Energol
460 EP 460 634 460
460
Energol
3200 EP 320 632 320
Mineral 320
Oils
Energol
220 EP 220 630 220
220
Energol
150 EP 150 629 150
150
Energol
100 EP 100 627 100
100
Note
They are suitable for operating temperature from -80C~ +800C
values stated, the oil selected should be checked for suitability.
ZPMC 10

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INSTRUCTIONS OF REDUCER MODEL

SHANGHAI ZHENHUA HEAVY INDUSTRIES CO.,LTD

Construction drawings of the reducer model FVS395.30.D3B-00 for gantry

Appendix I Spherical bearings (SKF)

1.1 Input speed 2000rpm

1.2 Reduction ratio 30.112

1.3 Centers between input and output 395mm

1.4 Rated output torque 12800N.m

1.5 Brand of lubrication oil: ISO VG 320

1.6 Lubrication oil volume 45L

1.7 Max. operating oil pool temperature ≤95°C

1.9 Max. overall dimensions 1265*550*500

1.10 Net weight 456kg

2. Brief Introduction of Construction:

3. Maintenance and Repair

(3) Check the oil seals.

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

4. Disassembly and Re-assembly of Components

4.2 Points for attention during re-assembly

(6) Min. backlash of gearing

Bolt diameters (mm) M16 M18 M20 M24 M30 M36

(13) After 0.5 hour.

Appendix I: Spherical roller bearings (SKF)

No. Description Model size Quantity

Appendix II: oil seals

No. Model Size Quantity

1 NOK TC AE 3234 F2 60*85*12 1

3 NOK SC AC 4346 F0 120*150*14 2

Appendix III: 3Lubricant Selection Table

Shanghai Zhenhua Port Machinery Co., Ltd.

2. Brief Introduction of Construction

3. Maintenance and Repair

4. Disassembly and Re-assembly of Major Components

Appendix I Spherical roller bearings (SKF)

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

1.1 Input speed 2000rpm

1.2 Reduction ratio

1.3 Centers between input and output 1650mm

1.4 Output torque Nm

1.5 Brand of lubrication oil ISO VG 320

1.6 Lubrication oil volume 400L

1.7 Max. operating oil temp ≤80°C

1.11 Net weight 9600kg

2. Brief Introduction of Construction:

3. Maintenance and Repair

beforehand. At every time of replacement the reducer shall be cleaned with

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

4. Disassembly and Re-assembly of Components

4.2 Points for attention during re-assembly

(5) Adjust axial clearance of bearing to 0.2-0.50mm.

(6) Min. backlash of gearing

intermediate stage: 0.250mm

Bolt diameters (mm) M16 M18 M20 M24 M30 M36

Appendix I: Roller Bearings (SKF)

No. Description Model Size Quantity

Appendix II: oil seals (NOK)

No. Model Size Quantity

1 NOK AB 4212 A3 110*140*14

2 NOK AC 4212 F6 110*140*14

3 NOK AB 5846 A0 360*420*25

1.9 Max. overall dimensions 1265550500

1 NOK TC AE 3234 F2 608512 1

3 NOK SC AC 4346 F0 12015014 2

1 NOK AB 4212 A3 11014014

2 NOK AC 4212 F6 11014014

3 NOK AB 5846 A0 36042025

1 NOK AB 4212 A3 11014014

2 NOK AC 4212 F6 11014014

3 NOK AB 5846 A0 36042025