PRESENTATION

ON
MAINTENANCE OF
GEARBOX

R K JAIN

MAINTENANCE OF GEARBOX
CEMENT PLANT EQUIPMENT ARE
EXPECTED TO WORK CONTINUOUSLY
WITH DESIRABLE CONDITION.
PREVENTIVE MAINTENANCE
1. INSPECTION
2. CONDITION BASED
3. TIME BASED (2000 ,5000 ,10000 HRS)
BREAKDOWN MAINTENANCE

INSPECTION CHECK POINTS

FRQ

CHECK POINTS

DAILY

OIL PRESSURE,TEMPRATURE,M/C LOAD

DAILY

NOISE,VIBRATION,LOOSENESS

DAILY

SUMP OIL LEVEL,LEAKAGES.

DAILY
MONTHLY

CLEANING
OIL CONTAMINATION,CONTROLS&ALARM
SYSTEM

MONTHLYCLEAN FILTER,BREATHER,NOZELS HOLE

MAN-HOLE INSPECTION (MHI) AFTER

2000 HOURS
Check gears for pitting, visual inspection of
1
gear teeth
2 Check flow of oil,
3 Check coupling Bolts alignment,
4 Clean breathers,
5 Check foundation bolts for looseness,
6 Check oil leakage, and force lubrication system
7

Check any or all points reported by the

preventive maintenance personnel

LIFT TOP COVER INSPECTION (LTC)

AFTER 5000 HOURS
1

All points covered by 2000 hours inspection and in addition

Check backlash, axial float,

Check gear meshing taking cellotape impression,color

marking

Check bearing clearance and rollers of bearing,

Check bearing cap bolts,

Check counter weights, rivets and dowels,

Check all tripping circuits fitting,

Check burrs and steps in gears, and

Check all points reported by the preventive maintenance

personnel.

COMPLETE REMOVAL OF GEAR

INSPECTION >10,000 HOURS
1
2
3

All points under 5000 hours inspection,

Check bearing housing for ovality, check bearing
clearance,
Cleaning of sump oil pathways, oil holes and oil
pipeline,

Check shaft level,

Check oil sample,

Check run out,

Clean oil cooler and filter,

Overhaul oil pump,change oil seals

Check shafts for surface and sub surface cracks.

PLANNING OF
MAINTENANCE
OBJECTIVE
SEQUENCE
IDENTIFICATION & PROCUREMENT OF
TOOLS,MEASURING PARTS AND SPARES.
INSPECTION PROCEDURE
TOLERANCE LIMIT
DOCUMENTATION BEFORE & AFTER
DISASSEMBLY

GEAR BOX LUBRICATION

SYSTEM
FORCE LUBRICATION

SEQUENCE OF DISASSEMBLY
MEASUREMENT OF CURRENT STATUS OF
ALIGNMENT
DECOUPLING OF INPUT & OUPUT COUPLING
DISCONNECTION OF INTERLOCKING &
POWER SUPPLY
DRAIN THE OIL.
REMOVAL OF END COVER.
REMOVEAL OF DOWELS.
DISMENTLING & LIFTING OF TOP COVER

SEQUENCE OF
DISMANTLING
REMOVAL OF OIL PIPELINE.

INSPECTION OF INTERNAL.
REMOVAL OF GEAR SHAFT ASSEMBLY.
SELF MADE DRAWING & PHOTOGRAPH OF PART.
REMOVAL OF OIL SEALS,BEARING & GEAR.
CLEANING & INSPECTION OF
PART( BEARING,TEETH,SHAFT,SEAL,PIPELINE
ETC.)
ARRANGE WORN OUT PARTS
A EACH STEP INSPECTION ARE MUST.

ASSEMBLY PROCEDURE OF
GEARBOX
CLEANING OF OIL SUMP,OIL HOLE & PATH WAS FILLING
CHECKING OF BEARING HOUSING BORE SIZE AND
OVALITY
INSPECTION OF BEARING BALLS,RACES,CAGESAND
CLEARANCE
CHECKING OF SIZE OF SHAFT,GEAR ID,KEY,CRACKS
AND OTHER DEFECTS
CHECKING OF GEAR TEETH
FITTING OF BEARING ,GEAR ,SHAFT & OIL SEALS.
POSITION OF SHAFT
CHECKING OF LEVEL AND AXIAL FLOAT
CHECK GEAR MESH AND BACKLASH.

ASSEMBLY PROCEDURE OF
GEARBOX

FILLING OF OIL
CHECKING OF LUBRICATION SYSTEM
CLOSING OF TOP COVER WITH
SEALANT,DOWELLING & TIGHTING BOLTS
DIAGONALLY
FIX BEARING COVER WITH SEALANTS & GASKETS
WITH RECOMMENDED GAP.
ALIGNMENT WITH CONNECTING MACHINE
COUPLE THE MOTOR
FIXING OF VIBRO SWITCH,THERMO SWITH,LEVEL
SWITCH

GAP BETWEEN BEARING & COVER TOUNG

(COLLER)

DO NOT USE IN
ASSEMBLY
DO NOT USE WOOD IN PUSHING OF
BEARING
NEVER USE COTTON WASTE
DO NOT KEEP ANY THING LOOSE IN
POCKET
NEVER USE WRONG TOOLS , SPANNER &
MEASURING TOOLS
NEVER USE NON RECOMMENDED
LUBRICANTS.

SAFETY PRECAUTION DURING

DISASSEMBLY & ASSEMBLY
USE PROPER LIFTING CAPACITY TOOLS.
AVOID PEOPLE SHOULD NOT COMING
UNDER LOAD.
GEAR SHOULD NOT COME IN CONTACT
STEEL ROPE.
KEEP PART ON CLEAN SHEET OR WOOD.
SPILLED OIL SHOULD BE
REMOVED/SHOAKED.
ALL SAFETY GUARD SHOULD INSTALLED.
SITE CLEANING BEFORE OPERATION.

PRESENTATION
ON
DISASSEMBLY AND
ASSEMBLY
OF GEARBOX

NS RAJPUT

WHAT IS DIS ASSEMBLY ?

DISMENTLING OF AN EQUIPMENT
INSPECTION OF ALL PARTS
TAKE CORRECTIVE ACTION FOR
REPAIRING
OR REPLACING THE PARTS.

NEED FOR DISASSEMBLY OF

GEARBOX
CEMENT PLANT EQUIPMENT ARE
EXPECTED TO WORK CONTINUOUSLY
WITH DESIRABLE CONDITION.
PREVENTIVE MAINTENANCE
1. INSPECTION
2. CONDITION BASED
3. TIME BASED (2000 ,5000 ,10000 HRS)
BREAKDOWN MAINTENANCE

INSPECTION CHECK POINTS

FRQ

CHECK POINTS

DAILY

OIL PRESSURE,TEMPRATURE,M/C LOAD

DAILY

NOISE,VIBRATION,LOOSENESS

DAILY

SUMP OIL LEVEL,LEAKAGES.

DAILY
MONTHLY

CLEANING
OIL CONTAMINATION,CONTROLS&ALARM
SYSTEM

MONTHLYCLEAN FILTER,BREATHER,NOZELS HOLE

MAN-HOLE INSPECTION (MHI) AFTER

2000 HOURS
Check gears for pitting, visual inspection of
1
gear teeth
2 Check flow of oil,
3 Check coupling Bolts alignment,
4 Clean breathers,
5 Check foundation bolts for looseness,
6 Check oil leakage, and force lubrication system
7

Check any or all points reported by the

preventive maintenance personnel

LIFT TOP COVER INSPECTION (LTC)

AFTER 5000 HOURS
1

All points covered by 2000 hours inspection and in addition

Check backlash, axial float,

Check gear meshing taking cellotape impression,color

marking

Check bearing clearance and rollers of bearing,

Check bearing cap bolts,

Check counter weights, rivets and dowels,

Check all tripping circuits fitting,

Check burrs and steps in gears, and

Check all points reported by the preventive maintenance

personnel.

COMPLETE REMOVAL OF GEAR

INSPECTION >10,000 HOURS
1
2
3

All points under 5000 hours inspection,

Check bearing housing for ovality, check bearing
clearance,
Cleaning of sump oil pathways, oil holes and oil
pipeline,

Check shaft level,

Check oil sample,

Check run out,

Clean oil cooler and filter,

Overhaul oil pump,change oil seals

Check shafts for surface and sub surface cracks.

PLANNING OF DIS
ASSEMBLY
OBJECTIVE OF DISASSEMBLY
SEQUENCE OF DISASSEMBLY
IDENTIFICATION & PROCUREMENT OF
TOOLS,MEASURING PARTS AND SPARES.
INSPECTION PROCEDURE
TOLERANCE LIMIT
DOCUMENTATION BEFORE & AFTER
DISASSEMBLY

GEAR BOX LUBRICATION

SYSTEM
FORCE LUBRICATION

GEAR BOX BEARING COVER

SEQUENCE OF DISASSEMBLY
MEASUREMENT OF CURRENT STATUS OF
ALIGNMENT
DECOUPLING OF INPUT & OUPUT COUPLING
DISCONNECTION OF INTERLOCKING &
POWER SUPPLY
DRAIN THE OIL.
REMOVAL OF END COVER.
REMOVEAL OF DOWELS.
DISMENTLING & LIFTING OF TOP COVER

SEQUENCE OF
DISMANTLING
REMOVAL OF OIL PIPELINE.

INSPECTION OF INTERNAL.
REMOVAL OF GEAR SHAFT ASSEMBLY.
SELF MADE DRAWING & PHOTOGRAPH OF PART.
REMOVAL OF OIL SEALS,BEARING & GEAR.
CLEANING & INSPECTION OF
PART( BEARING,TEETH,SHAFT,SEAL,PIPELINE
ETC.)
ARRANGE WORN OUT PARTS
A EACH STEP INSPECTION ARE MUST.

ASSEMBLY PROCEDURE OF
GEARBOX
CLEANING OF OIL SUMP,OIL HOLE & PATH WAS FILLING
CHECKING OF BEARING HOUSING BORE SIZE AND
OVALITY
INSPECTION OF BEARING BALLS,RACES,CAGESAND
CLEARANCE
CHECKING OF SIZE OF SHAFT,GEAR ID,KEY,CRACKS
AND OTHER DEFECTS
CHECKING OF GEAR TEETH
FITTING OF BEARING ,GEAR ,SHAFT & OIL SEALS.
POSITION OF SHAFT
CHECKING OF LEVEL AND AXIAL FLOAT
CHECK GEAR MESH AND BACKLASH.

ASSEMBLY PROCEDURE OF
GEARBOX

FILLING OF OIL
CHECKING OF LUBRICATION SYSTEM
CLOSING OF TOP COVER WITH
SEALANT,DOWELLING & TIGHTING BOLTS
DIAGONALLY
FIX BEARING COVER WITH SEALANTS & GASKETS
WITH RECOMMENDED GAP.
ALIGNMENT WITH CONNECTING MACHINE
COUPLE THE MOTOR
FIXING OF VIBRO SWITCH,THERMO SWITH,LEVEL
SWITCH

GEAR BOX LUBRICATION

SYSTEM
FORCE LUBRICATION

GAP BETWEEN BEARING & COVER TOUNG

(COLLER)

DO NOT
DO NOT USE WOOD IN PUSHING OF
BEARING
NEVER USE COTTON WASTE
DO NOT KEEP ANY THING LOOSE IN
POCKET
NEVER USE WRONG TOOLS , SPANNER &
MEASURING TOOLS
NEVER USE NON RECOMMENDED
LUBRICANTS.

SAFETY PRECAUTION DURING

DISASSEMBLY & ASSEMBLY
USE PROPER LIFTING CAPACITY TOOLS.
AVOID PEOPLE SHOULD NOT COMING
UNDER LOAD.
GEAR SHOULD NOT COME IN CONTACT
STEEL ROPE.
KEEP PART ON CLEAN SHEET OR WOOD.
SPILLED OIL SHOULD BE
REMOVED/SHOAKED.
ALL SAFETY GUARD SHOULD INSTALLED.
SITE CLEANING BEFORE OPERATION.