3.

Part list 2-3 pages

Here, you will give a concise, informed summary for every part of the gearbox. Divide this section into
major and minor parts. Your discussion on major parts (i.e., 3.1) will be very brief, as these parts are
covered in greater detail in sections 6 and 7 of the report.

 3.1 Major parts

o Include one single paragraph, where you state:
o What are the three major parts of the gearbox? (i.e., housing, worm wheel, worm
shaft)
o What are the main functions of each of the major parts?
o What are main materials used for each of the major parts?
o What are the main manufacturing processes used for each of the major parts?
o Remember, this single paragraph is intended to be a brief summary of sections 6 and 7 which
cover the aspects in more detail. It is best to first complete sections 6 and 7 before
attempting section 3.1.
 3.2 Minor parts
o 3.2.1. Bearings
o 3.2.2. Circlips
o 3.2.3. Spacers
o 3.2.4. Gaskets
o 3.2.5. Seals
o 3.2.6. Cap
o 3.2.7. Screws

For minor parts, under each subheading (e.g., 3.2.1) include the following:

- An image (photo or drawing) of the part, that is annotated (i.e., labelled with arrows and notation
pointing to some key features)
- Two paragraphs discussing:
- Is this minor part ‘off-the-shelf’ or ‘VF30-specific’?
- Function of the part
- Key features of part and how these facilitate the function (use your image to assist your
discussion)
- The material used for this part. Include justification and evidence (in the form of references
and observations)

The manufacturing process used for this part. Include justification and evidence (in the form of references
and observations)
4 Disassembly and assembly 2 pages
 Under the main heading, begin with a brief introductory paragraph on gearbox assembly. Topics
could include, but may not be limited to:
o The need for assembly/disassembly procedures in relation to gearbox maintenance
o Where/when/by whom might gearbox assembly/disassembly be carried out?
o What are key safety considerations when performing assembly/disassembly of a gearbox?
 4.1. VF30 Disassembly Procedure
o 4.1.1. Pre-Disassembly Inspection
 What checks did you do beforehand to reveal an internal problem?
o 4.1.2. Disassembly Procedure
 The disassembly procedure should be written as if you were recording a formal
maintenance procedure. It should include descriptive paragraphs, explaining the
disassembly steps. Do not copy or re-write the given instructions.
 To be written in past tense, third person
 Include as much ‘tacit knowledge’/extra detail from the workshop as possible, such
as
 Tools used.
 Maintenance actions
 Part replacement
 Points where extra care taken.
 Note: If steps were mentioned in the workshop, but not explicitly performed,
you should not omit these. Instead, include these steps and write them as if they
were performed.
 4.2. VF30 Assembly Procedure
o 4.2.1. Pre-Assembly Inspection
 What specific damage or faults might you look for on certain parts prior to
assembly?
 Which parts might need more frequent replacing?
o 4.2.2. Assembly Procedure (same as 4.1.2)
o 4.2.3. Post-Assembly inspection and ongoing servicing
 Checks to ensure good operation immediately after assembly.
 What servicing will need to be done in the future?
5 Part relationships 3 pages
 Provide a brief paragraph under the main heading which introduces the three main sub-assemblies of
the gearbox.
 5.1. Housing sub-assembly
o 5.1.1. Parts
 What parts form the sub-assembly?
o 5.1.2. Arrangement
 What are the part locations in the sub-assembly?
 Why are the parts arranged in this way?
o 5.1.3 Fitment
 Discuss some key fits in the housing sub-assembly (use terminology from the ISO
recommended fits table on blackboard)
 Repeat for ‘5.2. Worm wheel sub-assembly’ and ‘5.3. Worm shaft sub-assembly’.
 5.4. Table of Fits.
o List a total of at least 5 fits from sections 5.1.3, 5.2.3, and 5.3.3 in the table provided on pg.
15 of this brief.

Parts Type of fit Code Fit description Justification

x y Transition H7/ Location fit This fit provides almost zero clearance. It allows
k6 for precisely locating parts. Part x and y require
precise location. They also have a key between
them to prevent relative slippage. Accordingly, a
transition location fit is most suitable.
Etc.