Shanghai Zhenhua Heavy Industry Co., Ltd.

Replacing procedure of trolley gear box bearing

Replacing procedure of trolley gear box bearing

Suitable conditions
When the gear box works too long and bearing will reach its life expectancy;
The bearing is failed and needs to be replaced;
Other reasons please refer to this document when the relevant parts of mechanism
need to be disassembled.

1. Composition of the main trolley:

Replacing the bearing of gear box is not very complex. But as a component of the trolley
drive we should consider from the entire device in order to make the work more efficient
when it needs to be replaced. Fig.1 is the trolley drive.
Following: 1-encoder2-drum3-motor4-brake5-wire rop6-gear box7-clutch handle
of the emergency drive8 -emergency motor/gear box.

Fig.1

We could know as per fig.1 that is easy to replace the bearing of the middle shaft. However,
we must disassemble the relevant component before replace the bearing of high/low speed
shaft. For example, we must move motor and disassemble coupling and gear box to replace
the bearing. Later a detailed demonstration about the replacement of the bearing of high/low
speed shaft will be made.

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1 Jun, 2011
 Shanghai Zhenhua Heavy Industry Co., Ltd. Replacing procedure of trolley gear box bearing

2. Safety requirements
The following safety rules must be known before work starting
Establish a working group contains several crafts including locksmith, electrician and
rigger before working. The team leader takes charge of harmonizing and safety. All
the local rules and laws should be followed during the working period.
Read the following procedures carefully before the working.
Read all warnings and instruction signs at entrance.
Keep the working field clean and enough space.
Trolley should be stopped at the parking position and lock up/tag up. Nobody run the
equipments after work starting.

Cautions: Use necessary safety equipments and uniforms, such as hard cap, safety
shoes, gloves and safety belts etc.

4. Working preparation
1Necessary toolsincluding different standard wrenches(internal hexagonal wrenches and
adjustable wrenches), pliers, electric
tools, suitable pullers, sling and
shackles etc. 2) The necessary
materials must be prepared before
work, such as bearings. In addition,
all types of seal ring should be
prepared as well in order to replace
the failed one. 3) Auxiliary materials,
such as rags, waste oil barrel, seal
glue, cleaner etc.

5. Bearing replacement on high

Fig. 2 speed shaft (or middle shaft)
5.1 Disassembly of High speed
coupling on motor side.
Composition :1-gear box side half coupling/bolts;2-brake disc3-elastic spider4-spider
couplingnylon5-motor/ half coupling6-brake7-base bolt.Fig.2
5.1.1 Procedures:
1Remove all bolts 7 on motor base. Loosen the lock bolts around feet;
2Move motor 5 away from gear box with service crane. Put down safely.

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2 Jun, 2011
 Shanghai Zhenhua Heavy Industry Co., Ltd. Replacing procedure of trolley gear box bearing

3Remove all bolts on the brake base. Loosen the lock bolts
4Release the brake 6 with manual handle, move the entire brake away;
5Disassemble the half coupling bolt 1 of the gear box side, remove half elastic spider 4
and elastic body 3. The disassemble work on motor side complete.

5.2 Disassemble the connection on emergency drive side

Composition1-clutch2 -half coupling on gear box side; 3-base bolt; 4-clutch sleeve; 5
-Emergency motor/gear box. Fig. 3

Figure 3.
5.2.1 Procedures:
1Unfasten all bolt on clutch base , as well as emergency gear box/ motor;
2Remove clutch and emergency gear box/motor with service crane and put down safely
that will not capsizing. The disassembling work on emergency drive side complete.

Cautions In the process of disassembly, the position of relevant components should

be marked. It will be helpful in the process of re-assembly. While the relevant
electro circuit is interference with disassembly, remove them discretionarily. When
disassemble the motor, brake or emergency drive, remove the connection of the cable
terminal, the power shall turn off and tag up. Warning people keep away.
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3 Jun, 2011
 Shanghai Zhenhua Heavy Industry Co., Ltd. Replacing procedure of trolley gear box bearing

5.3 Remove half coupling on motor side:

Refer to fig.4. Remove
the coupling with pullers.
1-gear box; 2-puller; 3-half
coupling; 4-jack; The puller
can be made by ourselves or
buy standard products, such
as three-claw puller. 50-ton
jack is enough.

Cautions The puller

should be vertical with input
axis line in order to ensure
the movement direction of the
Fig. 4
piston of jack is the same as
axis line. Control jack
carefully, otherwise the shaft of gear box or coupling may be damaged while the coupling
gets off.

5.4 Remove half coupling on the emergency drive side:

Refer to fig.5. We can take off
the coupling with pullers.
1-gear box; 2-half coupling;
3-jack 4-puller. The puller can
be made by ourselves or buy
standard piece such as
three-claw puller. 50-ton jack is
enough.

CautionsThe puller should

be vertical with input axis line in
order to ensure the movement Fig.5
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4 Jun, 2011
 Shanghai Zhenhua Heavy Industry Co., Ltd. Replacing procedure of trolley gear box bearing

direction of the piston of jack is the same as axis line. Control jack carefully, otherwise
the shaft of gear box or coupling may be damaged while the coupling get off.

5.5 Disassemble the gear box

Refer to fig.6. Where: 1-upper cover2- bolt3-liftup bolt;4-bearing cover5-bearing cover
bolt6-input shaft
The shaft should be taken
out from the box before
replacing bearings. So
disassemble the gear box is
necessary.
1) Remove all bolts 5 of
bearing cover 4 (6 covers in
total) and remove the cover.
One low speed shaft cover
can not take off before the
coupling off, retain it on the
shaft.
Fig. 6
2Unfasten all bolts 2;
3Scrape the paint between
upper and lower cover in order to disassemble the box;
4Turn the lift-up bolts both sides as clockwise, until the upper cover and lower cover
separate from each other.
5 Move the upper cover to the certain place while all the disassembled bolts and covers
should be also placed properly.

CautionsThe upper and lower covers usually hold tightly and sometimes the lift-up bolts
may not help. So we need assistant measures as knock box flange or insert wedge into
the joint line between the upper and lower cover. Lift the upper cover up smoothly by
service crane to avoid sway and injure person when the joint is loose enough.

5.6 Replace high speed shaft bearings

5.6.1 Remove the bearings
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5 Jun, 2011
 Shanghai Zhenhua Heavy Industry Co., Ltd. Replacing procedure of trolley gear box bearing

The replacement of bearing is definitely easy when the box is disassembled. Take the
entire high speed shaft out from the box, send it to the worktable in workshop and remove
the bearings. The tolerance
between bearing and shaft is
interference fit or transition fit, but
the diameter is small so its easy to
remove. Pressing machine or
standard three-claw puller can be
used if convenient, otherwise the
puller shall be made and apply with
the jack together to remove the
bearings. Heating the inner ring of
the bearing which will not be
recycled may help to remove the
Fig.7 bearing easily.

5.6.2 Replace the bearing

The option are follows:
Shaft can be put into refrigerator to freeze (or use dry ice) if condition permit while put the
bearing in high temperature place. Then shaft and bearing can be assembled easily.
Assemble the bearing with pressing machine directly
Hit the bearing with nonmetal or soft metal hammer and assemble the bearing on the
shaft; When hit with hammer, the force must be uniformity roundly to avoid deviation and
damage the bearing.
Use bracket and jack together to install the bearings.

Other middle shaft bearing also can be replaced as per above method accordingly.

6 Replacement of low speed shaft bearing

Before removing the drum which connect with lower speed shaft, we need to release the
trolley tension cylinder at back reach, keep the wire rope loose, and ensure it will not run
automatically during working period except the required safety and preparation work.

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6 Jun, 2011
 Shanghai Zhenhua Heavy Industry Co., Ltd. Replacing procedure of trolley gear box bearing

Fig. 8
6.1 Remove the drum
Replace bearing on the drum side of low speed shaft, have to remove the drum, take the
low speed shaft coupling off, and then replace the bearing. Refer to fig.8. 1-drum bracket
2-wooden block 3-base foot bolts4-drum5-coupling cover/bolt/washer6-coupling
7-carrying ring8 -drum cover.
The detailed procedure as follows:
Unfasten bolts 3;
Remove bolts of drum cover and move cover 8;
Separate the drum 4 and gearbox with service crane in machinery house and put it on
the wooden block 2 steadily;
Unfasten the bolts, washers from low speed shaft, and remove drum cover 5.

Cautions Drum 4 and coupling 6 is not only connected with teeth but also with a carrying
ring 7, so the force should be high enough to ensure the drum can be removed out. The
teeth profiles on carrying ring and coupling both have arc gear form, not straight, so pulling
direction could be at an angle in different directions when the drum is being moved out, it is
helpful to the disassembling work.

6.2 Remove the low speed shaft coupling:

Tailor-made pullers or similar design products can be used to remove the low speed shaft
coupling. Refer to fig.9. According to the requirements, the tolerance between bearing and
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7 Jun, 2011
 Shanghai Zhenhua Heavy Industry Co., Ltd. Replacing procedure of trolley gear box bearing

shaft is interference fit. It needs enough force to take off.

Usually there are 6 auxiliary holes on the coupling of low speed shaft (can not be found in
early product).These holes are prepared for screws on puller specially. According to the
calculation, the pulling force is more than 350 tons, so the capacity of 350Ts jack shall be
applied at least.
The pullers can be made at site according to the size of coupling after disassembly of the
drum.

Cautions Couplings on the

trolley, main hoist and boom hoist
may be different on size, and the
positions of holes are also
different. Moreover, the same
type coupling has different
diameter connecting with lower
speed shaft of the gearbox.

6.3 Disassemble gear box

Refer to item 5.5.

Fig.9
6.4 Replace bearing
Refer to item 5.6.

7. Reassembly
Usually the entire trolley drive needs to be reassembled after completing replacement of the
bearing. Reassembly can refer to disassembly process accordingly. Meanwhile, the
component need to be assembled according to the relative requirements.

8. Other
The replacement of bearing of gear box is very complex. Actually, the disassembly work is
not just simply reverse to the assembling work. Usually the assembly work will be more
important and meticulous and it contains the following extra works:
Oil. The oil in the gear box should be drained if necessary and box should be cleaned.
Refill the oil after finishing assembly. Use the same type of new oil if necessary.
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8 Jun, 2011
 Shanghai Zhenhua Heavy Industry Co., Ltd. Replacing procedure of trolley gear box bearing

The seam of upper and lower box need to be cleaned out when the gear box will be
reassembled. Then apply the sealant on seam, as well as on all covers to avoid oil
leaking.
Alignment. Once all components are on position, alignment need to carry out, such as
motor, drum and emergency drive. The method of alignment work refers to the relevant
files.
Adjusting. Brake needs to install mainly and require checking offset distance, balance
and compensation again. It needs to adjust again if necessary. The adjusting method
refers to relevant files.

9. Test

Release lock and tag. Run and confirm trolley can work normally.

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9 Jun, 2011