ABSTRACT

This document present information on

overhauling a gear box of a dumper
using the standard

NAMES

Amogelang Ramphaleng

Boitumelo Lebaleng

GEAR BOX
OVERHAUL
Table of Contents
BACKGROUD INFORMATION...................................................................................2

DISMANTLING THE GEAR BOX................................................................................2

INSPECTION................................................................................................................3

 Bearings.............................................................................................................3

 The driver gear..................................................................................................4

 The driven gear.................................................................................................4

ASSEMBLY OF THE GEAR BOX...............................................................................5

BACKGROUD INFORMATION
A corrective maintenance for a gear box used for dampers was carried out as the
gear box was damaged. The driving shaft had snapped from the side of the motor.
Therefore, the shaft had to be replaced as well as any other defects that may be
found during the process of overhauling the gear box.

DISMANTLING THE GEAR BOX

Figure 1 by Boitumelo lebaleng.Dismantled gear box

 Before dismantling the gear box, the tools that were to be used were
identified.
The outer parts of the gear box casing are joined by bolts, and to determine
the size of spanners that were to be used, a veneer calliper was used to
measure the inside circumference of the bolt, and the formula below is used
to determine the size of the spanner to be used.

3
× bolt ¿ spanner ¿ ¿
2
 Now when dismantling the gear box, the sides and parts that can easily be
removed to access more parts or actually open the gear box were identified
first then detached using the required tools.
 Before removing any part or cover, a corresponding mark was made so that
during the assembly, it will be easy to assemble everything to its initial
position as it was.
 After removing the outer covers of the gear box, the shafts and the gears
were now accessible.
 The driving shaft, which is also the driving worm gear was removed first. But
before removing the gear, the bearing had to be removed, the shaft had
bearings on both ends. Since it was a small gears box, the bearings were
removed by just tapping with a chisel and a hammer. The shaft was then
pulled out of the gear box casing.
 After removing the driving worm gear, the driven gear was now exposed and
easy to remove, and was just removed by pulling it out.
 The driven shaft of the driven gear was removed at last

INSPECTION
 An inspection was made even during the process of dismantling the gear box.
A close observation was made when removing the different parts as to what
was removed first, in what position and in what state to make the further
inspections and assembling easier.

 Bearings
o The bearings used for the gear box were tapered roller bearings.
o The bearings on both side were okay and in a good condition when
being inspected.
o But then they got damaged during the process of removing the driving
gear, so they couldn’t be reused afterwards.
o Therefore, the bearing numbers were noted so that they could be
replaced with new ones.
o The bearing number for the bearings is;
HR 30303J Japan Y NSK
  3 – symbolises the type of bearing used, and in this case, 3 is
for tapered roller bearings
 03 – Is the dimension index.
 03 - Is used to determine the diameter of the shat going inside
the inner race of the bearing. The number is multiplied by 5 to
get the diameter of the shaft. In this case, diameter of the shaft
is 15mm.

 The driver gear

Figure 2 by Boitumelo Lebaleng. Drive gear

o The driver gear was in a good condition. No sign of wear or any

interference with the driven gear.
o The driving shat had snapped, therefore the whole driving worm
gear needed a replacement.
o The possible causes of the shaft failure were;
 Overdrive of an actuator
 The universal joint attached to the gear box by a linkage
could have jammed, maybe due to lack of lubrication.

 The driven gear

Figure 3by Boitumelo Lebaleng. Driven gear

o During inspection, the driven gear was in a good condition, no sign

of any mechanical failure.
o The O-rings in the driven gear were also in a good condition.

ASSEMBLY OF THE GEAR BOX

 After all the inspection was made, the gear box was then ready for
assembly.
 The principle we used when assembling the gear box was that whatever
that was dismantled the first will the last to be assembled and vice
versa.
 Using the bearing identification number that we got from the old bearings
that were removed from the driving shaft, new bearings were collected
from the stored department.
 Also the O-ring needed a replacement since they were old and we did not
know the last time they were replaced, even though there no visible
defects they were bound to fail if put back on the gear box.
 The bearings used for the driving shaft, the outer race can detach from the
bearing frame and the inner race of the bearing. In that case, we fixed the
bearing into the shaft by tapping them with a small hammer to their resting
position where they won’t slip from the shaft
 The driven gear was then put back into the gear box casing. Crease was
then applied on the driven gear and its surrounding.
 The outer race of the bearings was then fixed into the gear box casing.
 The driver gear was then put back into the gear box casing by rotating it
forward till the bearings reached the outer race, and then creased.
 The driven shaft was then put back at last
 Before closing the gear box casing, the driver gear was rotated manually
to see if the gears work, and they worked perfectly.
 All the lids of the gear box were then closed and all the bolts screwed
back in. all these covers were replaced using the corresponding marks
just to ensure that we leave everything in their original positions.