FACHINI GEARS

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RIDUTTORI - GIUNTI - INGRANAGGI

www.fachini.it - e-mail:fachini@fachini.it

REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
PARAGRAPH
SHEET

REFERENCE
REDUCER type 2CP650

B2920
D6454A

-TECHNICAL DESCRIPTION

1.0

-INTRODUCTION
Warning
How to retrive information

2.0
2.1
2.2

-SAFETY RULES
Fire and explosion
Wxternal revolving parts
Noise
Lifting
Lubrication
Electrical gear
Maintenance
Hot parts
Lighting
Selection & Design

3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10

-STATE OF SUPPLY

4.0

-HANDLING & LIFTING

5.0

-STORAGE
Protection of the force-lubrication system
Protection under special environmental conditions
Warning

6.0
6.1
6.2
6.3

-INSTALLATION
Positioning
Coupling
Alignment
Temperature effect
Correcting alignment errors
Fastening

7.0
7.1
7.2
7.3
7.4
7.5
7.6

5
6

Clamping torque

Manuale: M109094

7.7

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REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
PARAGRAPH
SHEET

-LUBRICATION
Causes of internal temperature increases
Some remarks on lubrication choise
Approved types of lubricant
Splash Lubrication
Forced Lubrication
Filling with Lubricant

REFERENCE
8.0
8.1
8.2
8.3
8.4
8.5
8.6

-START UP
General conditions

9.0
9.1

10

-MAINTENANCE
Warning
Lubrication
Internal cleaning
Rotating parts
Artificial cooling
Checkin the reducer
Inspections
Restoration

11

-PROBLEMS; CAUSES AND REMEDIES

10.0
10.1
10.2
10.3
10.4
10.5
10.6
10.7
10.8
11.0

12

DISMANTLING

12.0

13

-LAY-OUT REDUCER

D6454A

14

-ASSEMBLY

B2920

-SPARE PRTS

Manuale: M109094

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REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
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SHEET

-SPEED REDUCER-

Manuale: M109094

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REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
PARAGRAPH
SHEET

1
1.0
1

REFERENCE

1.0

-TECHNICAL DESCRIPTION

D6450A
B2929

The main reduction gear can transmit the 225 kW, processing rated
power at the input speed equalling 1200 rpm and output speed
equalling 44.5 rpm (ratio 26.9457) with service factor >4.
The casing has an electro-welded structure that underwent welding
stress-relief treatment and following sandblasting operation
The gears are manufactured with case-hardening alloy steel with
ground teeth profile, and properly relief-ground to reduce load
concentrations.
The bearings are roller type and their processing expected life L10
equals >80,000 hours.
Reduction gear lubrication is splash system
The reduction gear is provided with large breathers.
Lubricant sealing in axes in & output areas is assured by suitable
sealing rings and labyrinth seals with points for greasing seals.

Manuale: M109094

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REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
PARAGRAPH
SHEET

2
2.0-2.1
1

REFERENCE

2.0

-INTRODUCTION
Fachini's reducing and multiplying gears are highly specialised
products, the outcome of close to 100 years' experience and the most
advanced design techniques to guarantee top quality. They are made
throughout with materials meeting the CE 2006/42 directivend in full
compliance with the strictest precision and safety limits as per UNIEN292. The expression "reducer" herein shall mean both reducing
and multiplying gear, hydraulic unit ,ecc.
When properly installed and serviced, reducers will perform without
problems uninterruptedly for a long time before replacement or major
overhauling are needed. This manual contains all the information for
proper storage, use and maintenance.
Compliance with the instructions herein is necessary to ensure proper
operation. It is recommended that such instructions be carefully read
and that a copy of this manual be kept available near the reducer.
The general information herein is valid for standard and special
reducers alike.

2.1

-Warning
Fachini's reducers are designed, built and sold
according to all the currently available technological and scientific
expertise. Since such expertise naturally develops and increases, the
manufacturers reserve the right to modify reducer components to
enhance their efficiency and safety. The user shall not tamper with or
modify the reducer and impair its reliability by changing the
contractual and operating conditions.
Within the EC, reducers shall not be commissioned before having the
machines to which they are attached certified that they comply with
the CE 2006/42 Machine Directive. The manufacturers of the
machine shall include the information herein in the manual
concerning the machine as a whole, as set forth in the definition of
machine design, UNI-EN292.
The customer shall be liable for the proper use of the supplied goods
and especially of fitting safety guards onto any outjutting rotating part.
Fachini shall not be responsible for any damage, harm or accident
due to improper use of such goods.

Manuale: M109094

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REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
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SHEET

2
2.2
2

REFERENCE

2.2

-How to Retrieve Information on Reducers

Hereafter a list of the information that mighttbe useful to the customer

and its location.

Location:
Nameplate
Nameplate
All drawings
Technical data
Nameplate
Layout dwg
Lubrication data (recommended Nameplate
type of lubrificant , quantity , plant Layout dwg
component location , etc.)
INFORMATION
Factory number
Reducer type

Overall dimensions of reducer and

attachments
List of external attachments
(coupling , brakes , pumps)
List of wear parts to be replaced
after a given time (bearings , etc.)

Layout dwg

List of gears

Schematic
dwg
All drawings

Materials

Layout dwg
Schematic
dwg

Because of the importance of the nameplate data, the nameplate

shall always be clean, undamaged and clearly visible.

Manuale: M109094

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REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
PARAGRAPH
SHEET

3
3.0 / 3.3
3

REFERENCE
3.0

-SAFETY RULES
Familiarity with the following data is necessary for safety. Therefore,
such data shall be brought to the attention of those involved in
selecting Fachini reducers, of the engineer in charge of designing the
machines to which the reducers shall be attached and of those in
charge of installation, operation and maintenance.
Fachini's reducers run safely and reliably when properly selected,
installed, checked and operated. As for any other mechanical facility,
specific precautions shall be taken as a protection against those
hazards that cannot be eliminated at design stage (UNIEN292,
2006/42/CE).
The following list does not rank the hazards according to their
importance, since the hazard level depends on external conditions; it
is therefore important that the entire list be examined.

3.1

-Fire & Explosion

- Oil vapours build up in the reducer; unshielded lights in the vicinity
of the casing's openings might cause fires and explosions.
- In case of fire or overheating above 300C, some materials such as
plastics might be broken down and develop fumes. Avoid exposure to
such fumes; handle burnt residues with protective gloves.
- Put out fires with the same tools as used for
the machine (fire extinguishers, foam).

3.2

-External Revolving Parts

The couplings and shaft ends shall be protected to prevent physical
contact and the catching of garments. The guards shall be sheet steel
or mesh and rigidly fastened (cf. UNI-EC 349, UNI-EC 294). In
special cases, mobile guards may be used, cf. UNI-EC 292.

3.3

- Noise
High speed of reducers and driven machinery might cause harmful
noisepollution levels in case of protracted exposure. Under such
conditions, operators shall wear adequate ear-protection. For the
reduction of noise-exposure hazards, CE 86/188.

Manuale: M109094

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REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
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SHEET

3
3.4 / 3.7
4

REFERENCE
3.4

-Lifting
To lift reducer, only use the attachment points shown in the layout.
Use of improper attachment points may endanger personnel and
damage the reducer or other goods.

3.5

-Lubrication (UNI-EN 292, CEN TC114 /W412)

- Protracted contact with the lubricant may be harmful to the skin:
comply with supplier's instructions for use.
- Check reducer's type of lubrication before filling. Carefully read and
follow all instructions herein and nameplate indications. An error may
cause mechanical damage and harm personnel in extreme cases.
- Prevent lubricant contamination; shield seals against weather and
solar radiation with water-repellent grease.

3.6

-Electrical Gear
Strictly comply with the warnings affixed to the electrical gear. Cut off
main switch before working on reducer or attached machinery to
prevent accidental starts.

3.7

-Maintenance
- Before working on reducer or attached
machinery, make sure that the loads are
removed and the electric mains cut off. If required, secure suitable
mechanical facilities to block the moving parts. Remove blocks when
work is done.
- Make sure that reducer is properly serviced during operation, with
suitable tools and Fachini-approved spare parts. Consult this manual
befo
re maintenance work

Manuale: M109094

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REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
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3
3.8 / 3.10
5

REFERENCE
Before performing any maintenance intervention, see the manual.
Make sure that all works are carried out in extremely "safe"
conditions.
The works in the hydraulic system must be performed when it is at
rest.
It is prohibited to work, loosen the flanges and the pipings when the
system is pressurised. Stop the pumps and discharge the residual
pressure.
Pay attention to prevent and protect the environment from ecological
contaminations caused by leakages or oil failures.
Warning: during oil change and topping-up operations, act in
compliance with the precautions that concern the protection of the
ecological environment; do not leave areas with scattered oil, as it
may be dangerous: use absorbing materials and cleaning solvents
3.8

- Hot Parts
- The reducer may overheat in operation and cause burnings. Avoid
accidental contact.
- After protracted running, the lubricant and lubrication system may
attain temperatures
that will cause burnings. Let cool down before touching or opening
the reducer.

3.9

- Lighting
Install local lights where adjustments and maintenance work will be
done. Prevent blinking or glare, which might cause dangerous
situations.

3.10

- Selection & Design

-Do not connect Fachini reducers to kinematic chains running under
critical flexural or torsional conditions and do not install in
environments that are subject to severe vibration.
-The reducer shall not be operated at speed, power, load and torque
values other than those for which it was designed and built.

Manuale: M109094

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REDUCER type 2CP560

GENERAL MANUAL
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4
4.0
6

REFERENCE
4.0

-STATE OF SUPPLY
The scope of supply is specified in the shipment documents and the
relevant completeness must be checked at the time of receipt. In
case of transport damages or lacking products, they must be
immediately signalled.
Fachini reducers are thoroughly stand-tested using suitable
instruments and as requested by the customer.
Unless otherwise stated in the contract, reducers are coated with red
anti-oil paint inside and with a synthetic primer and synthetic enamel
outside.
This coating provides adequate protection for normal industrial
environments and can be covered with further coats of synthetic
paint. When aggressive environmental conditions
are expected, special paints shall be used.
Unless otherwise specified by the customer, the painted reducer is
shipped unpacked, possibly simply fastened to wooden slats; any
breakable accessory is separately packed.
Reducers are shipped without lubricant, which shall be provided by
the customer before starting up.
All unpainted internal and external parts are coated with an antioxidant product, compatible with the lubricant. Wipe shaft ends clean
with solvents before starting up.
Reducers are treated for max. 4 months sheltered storage. When
other conditions apply, follow instructions on storage (chapter. 2
paragraph 6).

Manuale: M109094

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REDUCER type 2CP560

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5/6
5.0/6.0
7

REFERENCE
5.0

-HANDLING & LIFTING

D6454A
Lift and move reducer using the appropriate lugs and holes and rope
slings; for large reducers, also sling the bottom part below the casing
joint. Before lifting make sure that the selected eyebolts and brackets
will carry the weight of the entire reducer and not just that of the
upper half-casing.
If not, specific lifting points shall be provided for
the bottom half-casing. Reducer weight and lifting point location are
shown in the layout drawing D6454A.
To move reducers with the lubrication system on board, it is
recommended that any easily damaged part be removed, all
openings be sealed against foreign matter and the inside protected
against attack by external agents.

6.0

-STORAGE
Unless otherwise specified, reducers shall be stored packed in an
ambient sheltered against large temperature changes, moisture,
aggressive chemicals and vibration. When the reducer is not packed,
protect with polyethylene sheeting. To prevent damage to internal
components, place reducer on slats.
Internal and external machined parts shall be protected against
condensation-caused oxidation. Clean parts carefully and smear with
a specific, lubricant-compatible antioxidant as recommended by the
producer. Remove protective coating from external parts before start
up; use special diluents and operate in a well ventilated room,
avoiding contact with the skin; do not smoke during this operation.
Protect rolling bearings by packing with grease; clean with fuel oil
and dispose of the grease-fuel oil mixture before start up.
It is prohibited to put weights onto the oil power units.

Manuale: M109094

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REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
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6
6.1/6.3
8

REFERENCE
6.1

6.2

6.3

- Protection of the Forced-Lubrication System

Fill pumps and motor pumps with highviscosity
oil; loosen fittings, seal delivery and intake ports with wooden or
Neoprene plugs, fill piping with oil and seal. Before start up, flush with
fuel oil and fill pumps with lubricating oil. Spray antioxidant on filter
cartridges and body; eliminate with mineral oil before start up.
Accurately plug all inlet and outlet ports of heat-exchanger. Remove
plugs before start up.
Wrap electric instruments with polyethylene sheeting and make sure
that the contacts are protected with silicone-based or similar
antioxidant.
- Protection under Special Environmental Conditions
If reducer is exposed to moisture and large temperature changes,
place hygroscopic material in the casing and replace regularly at
intervals depending on the conditions; remove before start up.
If reducer is stored in a highly aggressive environment, apply special
paints.
-Warning
For very long storage periods, crank outlet shaft by hand by one
revolution every 4-6 months and check antioxidant coat for
effectiveness.

Manuale: M109094

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PARAGRAPH
7.0 / 7.1
SHEET
9
REFERENCE
CHAPTER

7.0

-INSTALLATION
For optimum operation, carefully follow these installation instructions,
with special attention to two points:
1. Right internal alignment: gear meshing should not be
compromised by warping of the casing due to unstable,
settling or uneven foundations (7.1). Such mistakes may
cause uneven gear load, raise noise level in operation and
damage tooth surface.
2. Right external position and alignment: the driving and driven
shafts shall be propely positioned and lined up to the reducer
shafts to prevent casing warping and shaft and bearing
overload. Such mistakes may cause damage to shafts and
bearings and local overheating, which produce abnormal
noise, mistakenly attributed to gear defects.

7.1

- Positioning
When deciding where to install the machine, sufficient space should
be left for inspection and maintenance purposes and for the
necessary cooling air stream for heat removal. Comply with
ergonomic principles (CEN/TC122) to control operator's stress and
physical fatigue by improving operating conditions and reliability.
Refer to Fachini if room temperature lies below 0C or above 40C.
For open-air installation provide shelter against poor weather
conditions without impeding air circulation around the casing.
Reducer foundations can be classified in three groups:
A) RIGID FOUNDATIONS: thick concrete beds and heavy steel
structures, not exposed to variable loads.
B) ELASTIC FOUNDATIONS: Lightweight steel or wooden
structures.
C) UNSTABLE FOUNDATIONS: Those that can change their
configuration because of earth settling or external forces

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7
7.2 / 7.3
10

REFERENCE
Cases B and C should be reported to Fachini when placing the order.
Whichever the type of foundation, reducer and primary motor should
preferably be mounted on a common bedframe, made fast with
suitable bolts and leave sufficient space for the tightening tools so as
to facilitate adjusting and dismantling.
As far as the supporting base is concerned, the allowed flatness
tolerance equals 0.05 mm x metre
As far as the power unit is concerned, the aforesaid tolerance can
equal 2 mm x metre
7.2

Couplings
Elastic, toothed and rigid couplings are those more currently used.
With rigid couplings, do not attempt to line up the reducer, motor and
driven machinery by tightening the coupling bolts, as shaft stiffness is
never adequate. As a result, alignment would be poor and stresses
occur in shafts, bearings and coupling.
When the coupled shaft is subjected to external thrust, it shall be
insulated from the reducer unless the bearings and foundations are
designed to take up the thrust. Insulation is obtained by using a
coupling having an axial play.
Warning: Dimensions and tollerance for the shaft and hole to see the
assembly drawing B2929A

7.3

- Alignment
To proceed with the alignment, the axial displacement of the coupled
shafts has first to be measured to determine an adequate tolerance
with respect to axis or couplingface play. Runout and angle error can
be separately measured and corrected if necessary in both vertical and
horizontal planes.
ANGOLARITY. The shaft axes are not parallel and intersecate on the
plane between coupling faces (Fig. 1). When the faces are flawlessly
machined, the angle error can be measured with both shafts standing
still with a feeler gauge at 4 points spaced by 90 (Fig.3). Readings at
1 and 3 indicate the error in the vertical plane; readings at 2 and 4,
that inthe horizontal plane. Since the coupling faces are usually not
flawlessly machined, a dynamic measurement method can be used: it
calls for marking a spot on both faces; keeping the two spots coupled
and rotating the faces, the distance between the faces is measured
every quarter of a revolution.

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REDUCER type 2CP560

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7
2
7.3
11

REFERENCE
ECCENTRICITY. Shaft axes are parallel but not coaxial (Fig. 2). Prior
to reading eccentricity correct the angle error, especially in the vertical
plane. Eccentricity is measured in a similar way as the angle error.
In this case, the readings are taken with a dial gauge fastened to one
face and bearing on the flange or hub of the other (Fig. 4).
In any case, unless laser-instruments are used, straightforward
directions cannot be given to determine correction, as correction
depends on the specific case; it is mainly a matter of experience.
Should such experience not be available, we shall be glad to help and
determine the acceptable tolerance for any application.

Fig.1- Angularity

Fig.2- Eccentricity

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7
7.4
12

REFERENCE

Fig.3- Angularity measure

Fig.4- Eccentricity measure

7.4

-Temperature Effect
Temperature variations cause the shaft size to change. The coupling of
a long shaft with one fixed point should allow sufficient axial
displacements to accommodate the difference between max.
temperature and min. temperature length (Fig. 5).

Fig.5--Axial displacements
The single fixed point principle is generally applicable: when two
shafts, each having its fixed point, have to be coupled, the free ends of
both shafts should be free to expand. This rule shall be strictly
complied with when coupling the reducer to electric motors running on
spherical bearings.

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PARAGRAPH
7.5/7.6
SHEET
13
REFERENCE
Temperature changes also affect the distance between foundation and
shaft; when the temperature difference between casing and motor or
driven machine is high, the resulting change in height may be
appreciable.
As an example, let us consider the height change in a iron casing
having H = 700 mm initial height over the foundation and 30C
temperature difference.
Iron's linear expansion coefficient being 0.000012, runout, if corrected
cold, will attain 0.000012x700x30 = 0.252 mm.
Especially for large reducers, these conditions may cause significant
increase of bearing load and abnormal vibration.
In some cases it is recommended to select a tolerance that will yield
the proper alignment under standard operating conditions.
CHAPTER

7.5

-Correcting Alignment Errors

Any misalignment shall be corrected without causing structural
deformation.
Before start up, gear meshing should be checked; after running under
load for a short time, inspect the tooth surfaces.
To obtain better alignment on concrete foundations, embed rectangular
steel plates in the concrete corresponding with the foundation-bolt
holes.
Adjusting large reducers is made easier by the levelling bolts near the
foundation bolts.
For reducers with outboard-mounted bearings, special care is needed
since misalignment is the main cause of uncontrolled overload on the
shaft.
For hollow-shaft reducers, align the shaft horizontally and follow the
above instructions; for installation, see the relevant drawings.

7.6

-Fastening
After alignment, the motor, reducer and driven machine shall be
adequately made fast.
The reducer's bottom face is machined; this face should preferably be
fully in contact with the plane on which the reducer is being placed.
Before mounting the foundation bolts, make sure that the bedplate is
not warped; when gears and motors are delivered fully assembled and
aligned, check alignment again after tightening the foundation bolts.

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PARAGRAPH
7.7
SHEET
14
REFERENCE
CHAPTER

consegnati completamente assemblati ed allineati al supporto, It is

advisable to apply lateral stops or dowel pins on the bedframe as a
datum point and to prevent shifting under an external load. If dowel pins
are preferred, two of them, placed as far as possible from each other,
should be sufficient to preserve alignment.
Prevention and safety devices should be available if accidental oil
leakages might cause major damage; check all parts to be inspected for
accessibility.
7.7

-Clamping torque
Recommended clamping torques to tighten screws and tie-rods for
Fachini products.
Passo
grosso
M8x1.25
M10x1.5
M12x1.75
M14x2
M16x2
M18x2.5
M20x2.5
M22x2.5
M24x3
M27x3
M30x3.5
M33x3.5
M36x4
M39x4
M42x4.5
M45x4.5
M48x5
M52x5
M56x5.5
M60x5.5
M64x6
M68x6

Manuale: M109094

M (mN)
mat. 4.8
7
15
25
40
60
85
120
160
210
305
410
555
710
920
1140
1425
1710
2190
2720
3390
4100
4970

M (mN)
mat. 8.8
15
30
50
80
125
170
240
320
415
610
825
1110
1425
1840
2280
2845
3420
4375
5440
6780
8195
9940

Passo
fine
M12x1.25
M14x1.5
M16x1.5
M18x1.5
M20x1.5
M22x1.5
M24x2
M27x2
M30x2
M33x2
M36x3
M39x3
M42x3
M45x3
M48x3
M52x3
M56x4
M60x4
M64x4
M68x4
M72x6
M76x6
M80x6

M (mN)
mat. 4.8
27
45
65
95
130
170
220
320
445
590
735
945
1190
1480
1810
2300
2800
3470
4240
5130
5800
6875
8080

M (mN)
mat. 8.8
54
86
129
185
260
345
440
640
890
1180
1465
1890
2385
2960
3620
4595
5585
6935
8485
10250
11585
13750
16160

Pagina 18 di 18

FACHINI GEARS

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REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
PARAGRAPH
SHEET

8
8.0 / 8.3
15

REFERENCE
8.0

-LUBRICATION
Lubrication fulfils two essential functions in a reducer: it protects gears
and bearings against premature wear and transfers the heat that builds
up in the casing to a coolant or any other refrigerating facility.

8.1

-Causes of Internal Temperature Increases

Temperature increases are due to two factors:
- Friction between two parts (gearteeth, bearings); it depends on power
output and oil's friction-reducing capability.
- Oil churning in the reducer and oil resistance in bearings and gears,
depending on oil viscosity and severity of churning.
Gear lubricants operate under harsh conditions, since tooth pressure
can attain several tonnes per cm2.
Oil's protective efficiency generally increases with its viscosity, while
churning-induced heating also increases with viscosity.

8.2

-Some Remarks on Lubricant Choice

Most industrial reducers run satisfactorily with mineral oils containing
anti-rust and antioxidation additives. For special reducers, an oil for
very high pressure shall be specified. EP (Extreme Pressure) additives
allow the gearteeth to withstand greater loads than those allowable
when using straight
mineral oil.
Oils of similar viscosity but of different brands and types can
significantly differ in terms of lubricating properties and stability; oil
being as important as the gearwheels and pinions for power drives, it is
better to use top-grade oils only.

8.3

-Approved Types of Lubricant

Oil type and recommended viscosity under normal operating and
environmental conditions show on the nameplate and layout drawing.
Suppliers are responsible for the quality of the lubricants.
Special care shall be used with synthetic oils, as they are not
compatible with mineral oils and negatively affect paints and gaskets.
Before going over from mineral to synthetic oil, thoroughly clean all the
parts in contact with the oil and flush the system with the same oil that
will be used in operation. In any case, consult with the supplier of the
oil.

Manuale: M109094

Pagina 19 di 19

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REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
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8
8.4 / 8.6
16

REFERENCE
8.4

-Splash Lubrication
The simplest lubrication method utilizes the churning of the oil induced
by the revolving gears; the results are fair as long as the peripheral
speed is below 12.5 m/s.
The oil stand should be accurately maintained to have the gearwheels
immersed by some 20-40 mm; should the level increase above this
value, churning-induced heating might significantly increase, with
consequent waste of power and excessive operating temperature.
Oil level shows in the layout drawing.
When the reducer is started up, oil level changes because some of it is
thrown by centrifugal force onto the casing walls and gearwheel motion
causes the oil to accumulate unevenly.
Oil level can also increase or decrease depending on where the level
gauge is located with respect to the wheels' sense of rotation.
If stick-type level gauges are dismantled and mounted again, check
that they are put back where they belong by placing a reference mark
on the stick before removal.

8.5

-Forced Lubrication
Large reducers and those for which splash lubrication is unsuitable are
equipped with a forced-lubrication system, generally installed on board
the machine.
When natural heat dissipation is not sufficient, a heat exchanger,
mostly of the water-oil type, is added.
In some cases, the forced-lubrication system consists of a separate
unit, not necessarily installed close to the reducer; the latter is
equipped with oil-inlet and outlet fittings.
Before start up, ascertain that the forcedlubrication system is operative
and that all the electrical instruments issue a positive response

8.6

-Filling with Lubricant

Fachini's reducers are shipped without lubricant, which shall be poured
into the required level before start up, through the vent or inspection
ports. For this procedure, also refer to the layout drawing.
Before filling, make sure that all the parts that were removed for
shipping are properly reinstalled.

Manuale: M109094

Pagina 20 di 20

FACHINI GEARS

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REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
PARAGRAPH
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9
9.0
17

REFERENCE
9.0

-START UP
Prior to start up carry out the following checks:

Check that the necessary lubricant was introduced into the

reduction gear; check the oil level by means of the oil dipstick or
from the peephole with stopped pump.
Check that the shafts can rotate freely in their normal sense of
rotation.
Check that the motor turns in the right sense, especially for
reducers equipped with an anti-reversal device. The gears'
sense of rotation show in the assembly drawing.
Check that the system is clean from any trace of dirt in order to
prevent the oil from being contaminated.
All pumps and filters must be de-aerated before the start-up.
Start the pump of the hydraulic power unit . For the pumps, only
one direction of rotation is tolerated. Keep the oil lubrication
system operating for 15 min. before starting the reduction gear.
Check the flow-rate and the circulation of the cooling water.
Check reducer operation by running in succession at 25%,
50%, 75% and 100% of rated load, for a few minutes each time.
During this test, the temperature might significantly rise and will
then stabilize within 4 or 6 hours.
Check for any unforeseen axial thrust on the input and output
shafts, which might endanger operation.
Check fitting and screw tightening.
Do not modify the adjustment of control or pressure limiting
valves..

Manuale: M109094

Pagina 21 di 21

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REDUCER type 2CP560

GENERAL MANUAL
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9 / 10
9.1/10.2
18

REFERENCE
9.1

-General Conditions
In reducers running on rolling bearings oil temperature shall not exceed
80C nor bearing temperature 90C; minimum oil pressure is 0.5-0.7
bar. For friction bearings, oil temperature shall not exceed 65C nor
bearing temperature 75C; minimum oil pressure is 0.5-0.7 bar.
Max. oil pressure is 3.5 bar, automatically controlled by a valve at
circuit end, inside the reducer.
For reducers with forced lubrication, first start the pump to check for
operativeness; after start up, record pressure and temperature data.

10.0

-MAINTENANCE
The concept of maintenance complies with the EN 133006 standard and
includes the fields that concern preventive maintenance, inspection and
restoration.

10.1

-Warning
During rotation an explosive oil-vapour mixture forms in the reducer;
wait for the vapour to escape before approaching the open reducer.
Should abnormal conditions (noise, vibration, etc.) arise in operation,
stop reducer, identify and eliminate the cause.
All work shall be executed by suitably trained personnel in compliance
with the current safety regulations.

10.2

-Lubrication
At the beginning of operation periodically check oil conditions; change
if cloudy, or if containing metal particles.
Check oil level weekly with the machine standing still; top up as
required.
Check seals for leaks and replace as required; seal life depends on
speed, temperature and environmental
conditions.
When changing the oil, use the same type as previously, showing on
the nameplate.
Change oil after 400-600 hours of operation the first time; afterwards
every 5000-8000 hours of operation under standard conditions (max.
room temperature 40C), or more frequently under harsher conditions.

Manuale: M109094

Pagina 22 di 22

FACHINI GEARS

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REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
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10
10.3/10.6
19

REFERENCE
Always drain the old oil from the drain hole under the casing (see
layout dwg). It is suggested that the oil be chemically analyzed by the
supplier.
In forced-lubrication reducers, clean the piping, nozzles and filter
quarterly, check that the oil flows freely and systematically check the
efficiency of the control device.
10.3

-Internal Cleaning
Yearly clean the inside if possible; wash casing and gears with bland,
non-aggressive solvent and flush with the same oil to be used in
operation.
Avoid skin contact with solvents.

10.4

-Rotating Parts
Periodically check bearings and gears for wear with suitable
commercially available instruments.
Replace as required or apply to Fachini specifying reducer type, factory
number and drawing number of the part to be replaced.

10.5

-Artificial Cooling
If fans are used, do not impair the air stream that removes the heat, do
not remove fan cover, make sure that air temperature is below 40C;
keep fan and fan cover clean.
When water-oil exchangers are used, always let a trickle of water
through even when no heat is to be removed; inspect exchangerevery
2-3 months and make sure that the water lines are not clogged.
Replace water lines if completely clogged; if only partly clogged, rinse
in countercurrent with a 10% hydrochloric acid-water solution or similar
fluid, then dispose of the last trace of corrosive solution by flushing with
hot water for some minutes.
For removable-bundle exchangers, when clogged by sludge or waterentrained solids, dismantle the two plates that seal the water circuit,
ram out the pipes and rinse with a water jet.

10.6

-Checking the Reducer

In case of trouble, contact Fachini beforedismantling for inspection or
repairs.

Manuale: M109094

Pagina 23 di 23

FACHINI GEARS

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REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
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10
10.7
20

REFERENCE
10.7

-Inspections
It is necessary to schedule a set of inspections according to system
complexity and operation continuity by deciding the frequency of the
inspections and specifying the checks into particular lists.
Inspection entries are listed below; the customer can add inspection
steps, which are considered necessary according to its own experience
for the type of work being carried out:

Check of liquid levels: low levels may be caused by leakages

Check about exchanger efficiency, water must be clean
Check of external sealing, visual inspection of the system to
identify possible leakages
Check of temperatures
Check of pressures
Visual inspection of fluid contamination and, if necessary, by
means of specific chemical analyses
Check of filter clogging, there is a clogging alarm and pressure
measurement instruments before and after the same filter
Check of noise levels
Check of power and speed.

Manuale: M109094

Pagina 24 di 24

FACHINI GEARS

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REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
PARAGRAPH
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11
11.0
21

REFERENCE
11.0

-PROBLEMS, CAUSES AND REMEDIES

The problems listed below are considered as a simple support to
search for the causes.
They represent a first suggestion and often it is necessary to consider
other components, too, to search for the origin of a malfunction.
In case of doubt, it is advisable to ask for the support of Fachinis
engineers.
Problems
High oil temperature

Low oil temperature

Low oil pressure

High oil pressure

Manuale: M109094

Possible cause
Air trapped in the
exchanger

Remedies
Deaerate the
exchanger

Dirty exchanger

Clean the exchanger

Damaged bearings

Check bearing
temperatures and
replace them, if
necessary
Wait

The working
temperature has not
been reached yet
Clogged filter

If the filter alarm is

ON, drain or replace
the filter cartridge

Clogged suction duct

Drain the piping

The pump intakes air

As above

Low oil viscosity

Check the oil and, if

necessary, change it

Defective pump

Switch to the spare

pump, repair or
replace
Wait

The reduction gear

has not reached the
working temperature
yet

Pagina 25 di 25

FACHINI GEARS

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REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
PARAGRAPH
SHEET

11
11.0
22

REFERENCE

Problems
High oil pressure

Residue in the filters

High consumption of
oil

Manuale: M109094

Possible cause
Remedies
Clogged oil piping
Identify the clogging
towards the reduction and restore
gear
Check the oil and, if
High oil viscosity
necessary, change it
Dirty pipings
Clean and vent the
pipings
Material being
removed due to the
scraping off of the
reduction gear

Check teeth and

bearings, if any;
remove the defects

Dirty oil

Change the oil

Material being
removed due to the
scraping off of the
pump
Oil leakages

Switch to the spare

pump, repair or
replace the defective
pump
Identify the leakage
and restore

Leakage from highspeed or low-speed

shaft

Replace the gaskets

or the sealing rings

Leakages in the
exchanger

Identify the leakage

and restore, or
replace the
exchanger

Pagina 26 di 26

FACHINI GEARS

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REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
PARAGRAPH
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12
3
12.0
23

REFERENCE
12.0 -DISMANTLING
In general, this operation does not pose huge problems. Detach all
external piping and the coupling, remove screws, tierods and covers
and dismantle all components.
To reassemble proceed in the reverse order; smear casing and cover
joint faces with silicone sealant to prevent leaks.

All the above information is based on the current

level of knowledge and on our evalutation of potential
hazards. For further information , suggestions and
advise , write or call:
FACHINI GEARS S.p.A.
Corso Europa, 81
I-20017 Rho (Milano)
Tel. +39 - 02 - 9301231
Fax. +39 - 02 - 9316606
http://www.fachini.it

E-mail. fachini@fachini.it

Manuale: M109094

Pagina 27 di 27

FACHINI GEARS

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RIDUTTORI - GIUNTI - INGRANAGGI

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REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
PARAGRAPH
SHEET

LAY-OUT DRAWING

13
24

D6454A

DRAWING\D6454A.pdf

Manuale: M109094

Pagina 28 di 28

FACHINI GEARS

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RIDUTTORI - GIUNTI - INGRANAGGI

www.fachini.it - e-mail:fachini@fachini.it

REDUCER type 2CP560

GENERAL MANUAL
CHAPTER
PARAGRAPH
SHEET

ASSEMBLY DRAWING

7
14
25

B2929A

DRAWING\B2920.pdf

Manuale: M109094

Pagina 29 di 29

FACHINI GEARS

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REDUCER type 2CP560

GENERAL MANUAL

SPARE PARTS

DESCRIPTION

DRAWING

POS.
1

PINION SHAFT Ist REDUCTION

B2920
B2920

GEAR Ist REDUCTION

B2920

PINION SHAFT IInd REDUCTION

B2920

GEAR IInd REDUCTION

B2920

SLOW SHAFT

B2920

BEARING 22222

B2920

BEARING 22236

B2920

BEARING 23040

B2920

GASKET TYPE SCA 13017016-VITON

B2920

10

GASKET TYPE DPSM 13017012-VITON

B2920

10A

GASKET TYPE DPSM 18407-VITON

B2920

11

GASKET TYPE SCA 22026016-VITON

B2920

12

GEARS CASING

Manuale: M109094

Pagina 30 di 30