1.

Location of the reduction gear for hoisting

The hoisting reduction gear of our deck crane is provided in the crane post.
(hatched with light blue)

Reduction gear for hoisting

【Replacement】

VIEW A

Reduction gear
for luffing

Oil motor for luffing Drum for luffing

Counter balance valve

for hoisting

VIEW A

Drum for hoisting

Reduction gear for

Oil motor for hoisting hoisting【Replacement】

－1－
2. Preparation
TOOLS Q'ty REMARKS
① Wire rope Each 4 2.0m×φ8，2.0m×φ10，3.0m×φ12
② Chain block Each 4 0.5T，1T，1.5T
③ Clamp 2 1T
④ Shackle Each 4 1T，2T
⑤ Wire clamp ※No Photo 2 For φ33.5，φ28
⑥ Paint (Chugoku Marine Paints, LTD
Proper To paint
:Bannoh 200 N-8) ※No Photo
⑦ Tools (Spanner, Wrench) ※No Photo Proper To take off/install of each device
⑧ Hammer Each 1 Big, Medium, Small
⑨ Ratchet spanner 1 To take off the reduction gear
Refer to the attached drawing for
⑩ Jig for hoisting reduction gear 1 set
details
⑪ skid ※No Photo Proper Protection of each device
⑫ Wedge ※No Photo 2 To fix the drum for hoisting
⑬ Pipe or bar ※No Photo 2 To move the oil motor
⑭ Plastic bag ※No Photo Proper To take off the oil motor
For hoisting reduction gear：17L
⑮ Lubricating oil (ISO VG220) ※No Photo About 28L
For luffing reduction gear：11L
⑯ Working oil (ISO VG68) ※No Photo Proper To refill the tank
⑰ Oil container etc. ※No Photo 10L To take off the rubber hoses and pipes
⑱ Seal material (Three Bond : Fluid gasket1215)
Proper To install the oil motor
※No Photo

④
⑩
③

①
②

－2－
3. Working procedure
(1) Rest for jib

Set the reach of the crane to the rest.

And slack off on a luffing wire rope.

Next, lower the falling block until the hoisting Rest stand
wire rope slacks a little on the drum.

-NOTE-
Jib
Stop each drum so that each drain pipe is
located at the bottom dead point.
Deck

※ Only the drain pipe for hoisting will be Falling block

replaced.
Wire rope for hoisting
! DENGER Wire rope for luffing
Be sure to rest the jib first of all. Drum for luffing
A

Drum for hoisting Drain pipe

VIEW A

(2) Fixing of the hoisting and luffing wire

rope

Attach the chain block to the step behind the

operator’s cabin. Wire rope for Wire rope for
Next, attach the wire clamp to both hoisting and hoisting luffing
luffing wire ropes.
Wind the ①wire rope around there, and hang the
②chain block attached to the step behind the
operator’s cabin.
At that time, fix each wire rope so that the wire
rope slack around the drum.

①Wire rope

⑤Wire clamp

Step behind the operator’s cabin

Drum side ②Chain block

－3－
(3) Fixing of the hoisting and luffing drum

≪Hoisting drum≫ ⑫Wedge

Put the ⑪skid under the hoisting drum, to fix
the hoisting drum by using the ⑫wedge.

⑪Skid

≪Luffing drum≫
Hang down the ②chain block from the step behind Step behind the operator’s cabin
the operator’s cabin with ①wire rope.
Next, hang down the ②chain block from the loosen ①Wire rope
detector with ③clamp.
Wind the ①wire rope under the luffing drum, and
hang the drum by using the ②chain block. ②Chain block

Chain block from Chain block from step

loosen detector behind the operator’s
side cabin side

③Clamp
①Wire rope
Loosen detector

②Chain block

⑫Wedge

⑪Skid

(4) Stop of the electric motor

Stop the electric motor and turn off the breaker

on the control panel.

After that, carry out “tag-out” for other crews

not to start the crane.

Breaker

－4－
(5) Shutting the valves
Mechanical
Take off the mechanical lock part at the filter. lock part

Shut butterfly valves and stop valve.

(Arrowed，4 points)
Stop valve： Under the tank (a)
Butterfly valves： Under the tank (b)，
Both sides of the filter
(c)，(d)
Filter

b)Butterfly valve
a)Stop valve

d)Butterfly valve

c)Butterfly valve

(6) Taking off the ladder

Take off the ladder to take out the each device.

Ladder
! DENGER
Be sure to close the opening for fall prevention.

－5－
(7) Draining the lubricating oil from the
reduction gear Oil inlet

Open the plug of the oil inlet.

Open the drain pipe’s cap and drain the

lubricating oil． VIEW Oil inlet Drain pipe

・Hoisting reduction gear ・・・ 14Lit

・Luffing reduction gear ・・・ 11Lit

Drain pipe

≪For luffing≫ ≪For hoisting≫

Oil inlet point Oil inlet point

Oil inlet

Oil inlet

Drain point Drain point

Cap
Cap

－6－
(8) Taking off pipes and rubber hoses
Hoisting control valve
Prepare the oil container to take off pipes.

Take off the rubber hoses connected to the

hoisting counter balance valve, the hoisting and
luffing motor. Luffing motor

Take off the 2 pipes connected to the hoisting

counter balance valve and 1 pipe connected to the
hoisting control valve.(arrowed with green)

! CAUTION Hoisting counter

After taking off the rubber hoses and pipes, balance valve
cover flanges and fittings with plastic bags.

Hoisting motor

(9) Taking off the solenoid valve and remote

control valve

Take off the rubber hoses connected the solenoid

valve and remote control valve. Solenoid valve
Then, take off the bracket with solenoid valve
and remote control valve.

Remote control valve

(10) Preparation of suspending the luffing

motor
②Chain block
Wind the ①wire rope on the luffing motor, and
hook that by the ②chain block.

①Wire rope

－7－
(11) Attaching a plastic bag

Attach a ⑭plastic bag to receive lubricating oil

coming out from the reduction gear before the
luffing motor is taken off.

(12) Taking off the bolts for luffing motor

Bolts for the luffing motor
Take off the bolts for luffing motor.
The lubricating oil flows out from the contact
face between the motor and the reduction gear.
(a small quantity)

Be sure not to loosen

！ these bolts.

(13) Taking out the luffing motor

Take out the luffing motor by using the ②chain

block outside the machine room.

(14) Preparation of suspending the hoisting ②Chain block

motor

Wind the ①wire rope on the hoisting motor, and ①Wire rope
hook that by the ②chain block.

－8－
(15) Attaching a plastic bag

Attach a ⑭plastic bag to receive lubricating oil

coming out from the reduction gear before the
hoisting motor is taken off.

⑭Plastic bag

(16) Taking off the bolts for hoisting motor

Be sure not to loosen
！ these bolts.
Take off the bolts for hoisting motor.
The lubricating oil flows out from the contact
face between the motor and the reduction gear.
(a small quantity)
Bolts for the hoisting motor
Set the ⑪skid under the hoisting motor not to
contact the shaft side of the motor to the
reduction gear or the which directly by its
weight.
Set the ⑪skid

(17) Taking out the hoisting motor

Take out the hoisting motor by using the ②chain

block outside the machine room.

－9－
(18) Lifting the control valve pedestal
Bolts for control
Take off the bolts of the control valve pedestal.
valve pedestal

Hang the pipe of control valve by using the

②chain block, to hold the control valve pedestal
at the current position.

②Chain block

①Wire rop

(19) Taking off the connection bar of the winch

Connection bar of winch
Take off the connection bar of the winch.

－10－
(20) Taking off the bolts for side frame

Take off the bolts of the side frame.

Bolts for the

side frame

(21) Taking off the bolts for the luffing

reduction gear

Take off the bolts for the luffing reduction

gear.

Bolts for luffing

reduction gear

(22) Taking off the bolts for hoisting Bolts for hoisting
reduction gear reduction gear

Take off the bolts for the hoisting reduction

gear．

－11－
(23) Taking off the side frame
②Chain block
Hang the ①wire rope to the eye plate of side
frame upper part. And pull the side frame by using
the ②chain block.

Move the side frame at the shaded area not to

cause an obstruction. ①Wire rope

(24) Taking off the bolts for hoisting

reduction gear Bolts for hoisting
reduction gear
Take off the bolts for hoisting reduction gear．

－12－
(25) Pull out the hoisting reduction gear
⑩Jig for hoisting reduction gear
Attach the ⑩jig for hoisting reduction gear.
Next, pull out the hoisting reduction gear by Nut
revolution the nut.

After the hoisting reduction gear is coming out

a little, put the ⑪ skid under the hoisting
reduction gear．
⑪Skid

Nut

(26) Taking out the hoisting reduction gear

Wind the ①wire rope on hoisting reduction gear,

and hook the wire rope to the ②chain block. ②Chain block
Take out the hoisting reduction gear outside the
machine room.

! DENGER ①Wire rope

Pay attention not to get hands in the hoisting
gear during taking off.

(27) Replacement of drain pipe

Remove the drain pipe in the hoisting drum.

Drain pipe
And, fit the new drain pipe in the drum.
Wind the seal tape on the thread of the drain
pipe.

： IMAGE START

－13－
(28) Taking the drain plug of hoisting
reduction gear

Take off the drain plug．

Drain plug

(29) Carrying the hoisting reduction gear into

the post
②Chain block
Carry the hoisting reduction gear into the post
by using the ②chain block．

①Wire rope
： IMAGE START

(30) Installation the new hoisting reduction

gear

Put the ⑪skid to match their height to that of

the hoisting reduction gear to be able to guide
them.
Guide the reduction gear to put the ⑪skid.
Set the ⑪sikd
Be sure to match the position of the drain plug
to the pipe.

－14－
(31) Tightening the bolts for hoisting
reduction gear

Attach the drain pipe after tightening a few

bolts for hoisting reduction gear.
Bolts for hoisting
Next, tighten the other bolts for hoisting reduction gear
reduction gear.

(32) Adjusting the oil inlet point of hoisting

reduction gear
Oil inlet
Adjust the oil inlet point by revolution the
inside shaft.(to upper part)
Be sure to make the surface of hoisting reduction
gear parallel to the ground．

Inside shaft

(33) Moving the side frame

Move the side frame to the installation position ②Chain block

by using the ②chain block．
①Wire rope

(34) Tightening the bolts for luffing

reduction gear

Tighten the bolts of the luffing reduction gear.

Tightening torque：337N･m

Bolts for luffing

reduction gear

－15－
(35) Tightening the bolts for hoisting
reduction gear

Tighten the bolts of the hoisting reduction gear．

Tightening torque：452N･m

Bolts for hoisting

reduction gear

(36) Tightening the bolts for side frame

Tighten the bolts of the side frame．

Bolts for the side frame

(37) Attaching the control valve pedestal

Bolts for control
Tighten the bolts of control valve pedestal. valve pedestal

(38) Attaching the connection bar of winch

Attach the connection bar of winch．

Connection bar of winch

－16－
(39) Applying the seal material

Apply the ⑱seal material to the contact surface

of the hoisting motor and luffing motor.
Seal material brand：Three Bond fluid gasket 1215

! CAUTION
Be sure to apply the ⑱ seal material to the
contact surface of the oil motor.

Apply the seal material

(40) Installation the hoisting motor Coupling for motor

Carry the hoisting motor to the motor

installation position.
Next，insert the coupling of the reduction gear
to the motor shaft.

Shaft for
oil motor

After that， tighten the bolts of the oil motor.

Tightening torque：583N･m

Bolts for the oil motor

－17－
(41) Installation the luffing motor Coupling for motor

Carry the luffing motor to the motor installation

position.
Next，insert the coupling of the reduction gear
to the motor shaft.

Shaft for
oil motor

After that， tighten the bolts of the oil motor.

Tightening torque：337N･m

Bolts for the oil motor

(42) Reinstalling the pipes and rubber hoses

Install the pipes and rubber hoses around the

hoisting counter balance valve and the oil motor.

－18－
(43) Supplying the lubricating oil for
reduction dear Oil inlet

Close the drain pipe’s cap and refill the

reduction gear with new oil.

The proper quantity level is at the height of the VIEW Oil inlet Drain pipe
level gauge is proper quantity level.
・Hoisting reduction gear ・・・ 17Lit
・Luffing reduction gear ・・・ 11Lit

And the same brand and viscosity described on the

manual must be used．(ISO VG 220) Drain pipe

Reset the new seal tape of the oil inlet plug and
re-fit the plug.
≪For luffing≫ ≪For hoisting≫

Oil inlet
Oil inlet

Level gauge

Level gauge

Proper Proper
quantity level quantity level

(44) Release the lashing of the wire rope

Release the lashing of the wire rope.

(45) Attaching the ladder

Attach the ladder．

Ladder

－19－
(46) Opening the valves

Open the butterfly valves and stop valve.

(Arrowed,4 points)
Stop valve： Under the tank (a) b)Butterfly valve
Butterfly valves： Under the tank (b)
a)Stop valve
Both sides of the filter
(c)，(d)

! CAUTION
Make sure to open those valves fully.
If those valves remain closed or opened
insufficiently, the hydraulic device will burst
at the start of the main motor.
d)Butterfly valve

c)Butterfly valve

(47) Filling the tank

Fill the tank with new ⑭working oil.

Same brand and viscosity described on the manual
must be used.(ISO VG 68)

(48) Vent the air

Turn on the breaker on the control panel and take

off the caution tag.
Carry out a gradual start of the main motor
(inching operation) and vent the air in the
hydraulic device．

(49) Painting

Carry out the touch up paint at this time.

Paint brand：Bannoh200 N-8

－END－

－20－