Before finding the right solution, we had to undergo an inspection to figure out what was wrong, and what steps we needed to take. Our findings showed us that Heavy pitting and line marks seen on teeth of Input pinion and output wheel, Light corrosion seen face and whole body.

Within the gearcase itself, we found that the bores were within the accepted tolerance but the lube system in the gearcase needed re-piping after failure.

In general, there was damage to the bearings and seals, all of which would need replacing.

It was clear that the gearbox had a lot of problems, so after informing the client about the issues and the client's permission by supplying photographs and a detailed inspection report, we started working to address the issues.

We began by re-piping the lube system. we opened the gearbox, removed input pinion, and output wheel for machining process on it. first, we removed all corrosion by using suitable agent. We did first grinding process for removing dent and pitting. Then, did buffing process for smoothness. After that did NDE on components and gearbox casing.

We also fitted brand new bearings, seals, and fasteners to ensure a smooth power transmission at time of gearbox assembled. We did no load test on our works shop after that. In which we checked temperature, vibration, and noise level a different interval time.

we had finish repairing work of gear unit and installed it to customer site. We tested (in load condition) the refurbished gearbox to our incredibly high standard to ensure everything was running smoothly, and that the gearbox could be used for its intended application.

Once our specialists got to inspect the details of the gearbox. They make inspection report to quickly discovered series of issues and make workflow chart to quick resolution of it.

They visually checked Input pinion shaft and noticed that there is very heavy corrosion, Scratch mark and pitting observed on outer diameter and Input bearing pitted due to more RPM.

Checked Intermediate gear wheel & pinion in which all inter mediate bearing are good condition, Heavy corrosion, Scratch mark and pitting observed on outer diameter. Keyway & oil seal dia. damage. Also, observed Slight burr at output pair tooth. (Gearwheel & Pinion).

Inspections and diagnostics complete, we got to work applying our bespoke solutions to the problem to ensure that Lubrizol would have a gearbox that was back working to the standards they expect.

We started by manufacturing and fitting a new high-speed input pinion shaft with keyway. Also changed the oil seal.

Burrs were removed from the intermediate gear wheel and pinion by a grinding and polishing process. Built up a new output shaft through reverse engineering.

We did no load test on our works shop, in Which we checked temperature, vibration, and noise level to ensure everything was running smoothly, and that the gearbox could be used for its intended application.

Upon inspection by our skilled engineers, we found heavy damage on the keyway of the inner diameter of the hollow shaft. It was also found that the outer diameter of the shaft was heavily rusted and bore heavy scratches.

Heavy dent and corrosion observed on outer dia. Of output shaft’s, Keyway also damage, Slight pitting & wear marks observed on 1st intermediate pair, 2nd intermediate & output wheel.

The gearbox repair team then moved on to cleaning the gearbox. the only solution that would work would be a complete replacement.

Our experts have observed the problem and made a report on what needs to be done in this gearbox and started the work under the guidance of the production head.

First replaced the output oil seal, made a new keyway through CNC machine. Then, a machining process was performed on the shaft to remove traces of rust and heavy scratches.

Using all suitable agent to remove corrosion. We manufactured a new output solid shaft and made a keyway on it. We also refitted the existing input coupling with new keys to improve power transmission and overall performance and supplied new bearings, seals, and fasteners.

Once we had finished repairing the gear unit, we then tested the rebuilt gearbox to our incredibly high standard, to ensure everything was running smoothly, and that the gearbox could be used for its intended application.

We’re proud to be able to offer a wide range of gear services and overhauling solutions., we have the equipment and technology in house to make the parts that help us fix and repair new or reconditioned gearboxes.

our service engineer visited at customer site for visual inspection of gearbox. They observed and noted that there is Dent & scratch marks, corrosion too at input pinion. Also found Pitting scratch marks and oil seal damage. In intermediate Spiral bevel Pinion & wheel found Bearing choke up at Spiral Pinion Tooth side & spline side, built up edges & brush observed on gear teeth, Dent & scratch marks observed at input pinion and Corrosion Observed at Pinion.

we suggested to the customer that due to lack of skill labour and necessary tools, the work at the site was not possible, so the work of this gearbox will have to be done at our workshop.

After the gearbox reaches our workshop, our skill fitter team disassembles it completely and the service engineer prepares an inspection report so that we can know what the problem with the gearbox is. After that our production department made a workflow chart according to the priority of the work.

As per the workflow chart, our technical team start the repairing of gearbox. They first completely disassembled the gear box and took out Input Pinion, Intermediate Spiral bevel Pinion & wheel, Planet Carrier with Sun Gear Wheel, Sun Pinion, and Output shaft. Grinding and polishing work was done as per requirement. Sun pinion which was completely worn out was reverse engineered and rebuilt. Deburring on spline, gear teeth were also smoothed using suitable tools. The condition of Bering was correct so there was no need to change it.

After fully servicing the gear box, our QC department will do no load test of the gear box, and check the noise, vibration, temperature at 1-1-hour intervals, and check if there is any oil leakage Yes or No. Installed it at the customer's site only after satisfactory condition and tested it under full load as well. Customer is very happy because of our service and fast delivery.