MITSUBISHI HYDRAULIC DECK CRANE

REPLACEMENT PROCEDURE of REDUCTION GEAR

for HOISTING
(FOR REMOVABLE FLANGE TYPE)

Nov.2009

SHIMONOSEKI SHIPYARD & MACHINERY WORKS

[17 sheets with cover]

DR00500580
This document is described on a replacement procedure of the reduction gear for hoisting,
for MITSUBISHI DECK CRANE.

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 Each 4 1T，2T
④ Wire clamp ※No Photo 1 For φ33.5
⑤ Hammer Each 1 Big, Medium, Small
⑥ Ratchet spanner 1 To take off the reduction gear
Refer to the attached drawing for
⑦ Jig for hoisting reduction gear 1 set
details
⑧ Skid ※No Photo Proper Protection of each device
⑨ Wedge ※No Photo 2 To fix the drum for hoisting
⑩ Plastic bag ※No Photo Proper To take off the oil motor
For hoisting reduction gear：17L
⑪ Lubricating oil (ISO VG220) ※No Photo About 28L
For luffing reduction gear:11L
⑫ Working oil (ISO VG68) ※No Photo Proper To refill the tank
⑬ Oil container etc. ※No Photo 10L To take off the rubber hoses and pipes
⑭ Seal material (Three Bond : Fluid gasket1215)
Proper To install the oil motor
※No Photo
⑮ Paint (Chugoku Marine Paints, LTD
Proper To paint
:Bannoh 200 N-8) ※No Photo
⑯ Tools (Spanner, Wrench) ※No Photo Proper To take off/install of each device

③
⑦

①
②

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

Set the reach of the crane to the rest.

Next, lower the falling block until the hoisting

wire rope slacks a little on the drum. Rest stand

-NOTE-
Stop each drum so that each drain pipe is
Jib
located at the bottom dead point.
Deck
! DENGER
Be sure to rest the jib first of all. Falling block

Wire rope for hoisting

Wire rope for luffing
Drum for luffing
A

Drum for hoisting Drain pipe

VIEW A

(2) Fixing of the hoisting wire rope

Attach the chain block to the step behind the

operator’s cabin.
Next, attach the ④wire clamp to hoisting wire Wire rope for Wire rope for
rope. hoisting luffing
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.
Wire rope for hoisting

①Wire rope

④Wire clamp

Step behind the operator’s cabin

Drum side ②Chain block

－3－
(3) Fixing of the hoisting drum

Put the ⑧skid under the hoisting drum, to fix

the hoisting drum by using the ⑨wedge. ⑨Wedge

⑧Skid

Hoisting drum

⑨Wedge
⑧Skid

(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.

： IMAGE START

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

Open the plug of the oil inlet.

Open the drain pipe’s cap and drain the

lubricating oil． VIEW Oil inlet
(Hoisting reduction gear：14Lit)

： IMAGE START
Drain pipe

Oil inlet point

Oil inlet

Drain point

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 and the hoisting
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.

： IMAGE START
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 hoisting ②Chain block

motor

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

： IMAGE START

－7－
(11) Attaching a plastic bag

Attach a ⑩plastic bag to receive lubricating oil

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

⑩Plastic bag

(12) 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 ⑧skid 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 ⑧skid

： IMAGE START

(13) Taking out the hoisting motor

Take out the hoisting motor by using the ②chain

block outside the machine room.

： IMAGE START

－8－
(14) Taking off the bolts for hoisting Bolts for hoisting reduction gear
reduction gear

Take off the bolts for hoisting reduction gear.

(2 points)

： IMAGE START

(15) Taking off the flange for hoisting

reduction gear

Reeve the ① wire rope through bolt holes of ②Chain block

flange and pull the flange by using the ②chain
block.
①Wire rope
The flange is coming out a little, wind the
①wire rope around the flange and hoist up the
flange by using the ②chain block.

： IMAGE START
②Chain block

①Wire rope

(16) Taking out the flange for hoisting ②Chain block

reduction gear

Take out the hoisting motor by using the ②chain

block outside the machine room.
①Wire rope

： IMAGE START

－9－
(17) Taking off the bolts for hoisting
reduction gear Bolts for hoisting
reduction gear
Take off the bolts for the hoisting reduction
gear．

： IMAGE START

(18) Pull out the hoisting reduction gear

⑦Jig for hoisting reduction gear
Attach the ⑦jig for hoisting reduction gear. Nut
Next, pull out the hoisting reduction gear by
revolution the nut.

After the hoisting reduction gear is coming out

a little, put the ⑧ skid under the hoisting
reduction gear．

⑧Skid
： IMAGE START

Nut

－10－
(19) 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.
①Wire rope

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

： IMAGE START

(20) 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

(21) Taking the drain plug of hoisting

reduction gear

Take off the drain plug．

Drain plug

－11－
(22) Carrying the hoisting reduction gear into
the post ②Chain block

Carry the hoisting reduction gear into the post ①Wire rope
by using the ②chain block．

： IMAGE START

(23) Installation the new hoisting reduction

gear

Put the ⑧skid to match their height to that of

the hoisting reduction gear to be able to guide
them.
Set the ⑧skid
Guide the reduction gear to put the ⑧skid.
Be sure to match the position of the drain plug
to the pipe.

： IMAGE START

(24) 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.

： IMAGE START

－12－
(25) 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．

： IMAGE START Inside shaft

(26) Attaching the flange for hoisting Bolts for hoisting reduction gear
reduction gear

Carry the flange for hoisting reduction gear.

Next, tighten the bolts of hoisting reduction
gear.(2 points)

・Tightening torque (M24 points)：583 N･m

・Tightening torque (M22 points)：452 N･m

： IMAGE START

(27) Applying the seal material

Apply the ⑭seal material to the contact surface

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

! CAUTION
Be sure to apply the ⑭ seal material to the
contact surface of the oil motor.

： IMAGE START

Apply the seal material

－13－
(28) 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

： IMAGE START
Bolts for the oil motor

(29) Reinstalling the pipes and rubber hoses

Install the pipes and rubber hoses around the

hoisting counter balance valve and the oil motor.

： IMAGE STAT

－14－
(30) 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)

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.
Oil inlet

Level gauge

Proper quantity
level

(31) Release the lashing of the wire rope

Release the lashing of the wire rope.

(32) Attaching the ladder

Attach the ladder．

Ladder

： IMAGE START

－15－
(33) 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

(34) Filling the tank

Fill the tank with new ⑫working oil.

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

(35) 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．

(36) Painting

Carry out the touch up paint at this time.

Paint brand：Bannoh200 N-8

－以上－

－16－