INSPECTION REPORT

Ver. Issue Date Made by Checked By Approved By

00 18/03/2019 Mohd Shakir Alias Mohd Shakir

MANUAL GEARBOX HOUSING

INSPECTION & ASSESSMENT REPORT

1000 - PDC - 20190318

This document contains RKK Dinamik Sdn Bhd legal entity proprietary and confidential information that is legally privileged and
is intended only for the person or entity to which it is addressed and any unauthorized use is strictly prohibited. It is provided for
limited purpose and shall not be reproduced, stored electronically, transferred to other documents, disseminated or disclosed
to any third parties without the prior written consent of the relevant RKK Dinamik Sdn Bhd legal entity. Any attachments are
subject to the specific restrictions and confidentiality regulations stated therein and shall be treated accordingly. The document
is to be returned upon request and in all events upon completion of use for which it was provided.
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Table of Contents

1. Introduction ..................................................................................................................... 3

1.1. Purpose ........................................................................................................................ 3

2. Inspection & Assessment ............................................................................................... 4

2.1. Gearbox Housing ......................................................................................................... 5

2.1.1. Gearbox housing ........................................................................................................ 5

2.1.2. Worm Gear. ................................................................................................................ 5

2.1.3. Worm Shaft ................................................................................................................ 5

2.1.4. Handwheel Gearbox Housing ..................................................................................... 5

2.1.5. Manual Driven Spur Gear ........................................................................................... 5

2.1.6. Manual Drive Spur Gear. ............................................................................................ 6

2.1.7. Handwheel ................................................................................................................. 6

2.1.8. Coatings ..................................................................................................................... 6

3. Discussion ....................................................................................................................... 7

Conclusion .............................................................................................................................. 8

Annex A – Inspection Photos ................................................................................................ 9

Annex B – Proposed Brand New Gearbox ..........................................................................19

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1. Introduction

Manual actuated gearbox housing were received from Langsat Terminal Sdn Bhd for a full
assessment and inspection for possibility of rework and repair.

The manual actuated gearbox housing sub assembly were pre-inspected in Tanjung Langsat
warehouse facility. It was noted that the smaller gearbox casing/ cover for the manual handwheel
was missing and the threaded connection for the housing of the manual handwheel cover is
damage. RKK personnel has advised that the item to be sent to RKK Workshop for further
inspection and assessment as to oversee the level of damage to the housing.

It was delivered to RKK base in Kawasan Perindustrian Kota Puteri, Johor and arrived for further
inspection on March 14, 2019.

This report is generated after a thorough inspection and assessment of the gearbox housing and
this report is documented for the following:

Material Number Description Serial Number

Manual Gearbox

1.1. Purpose

The purpose of this inspection is to prepare a thorough inspection and assessment report of the
damages for the gearbox housing. This report will ONLY cover the gearbox housing and its sub
component attached to it for compilation and submission for client review.

All damage observed during the inspection and assessment has been recorded and included in
the document. Where deemed necessary, disposition or recommendation will be advised
accordingly.
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2. Inspection & Assessment

This section contains the detailed condition of the gearbox housing and its sub components. The
gearbox subassembly is dismantled and full assessment of the condition and defects were
recorded. Visual inspection is performed on the housing and its sub-assemblies.

The proposed repair scope of each affected components are kept within the section presented
in this document.

The inspection and assessment covers following areas:

a. Gearbox housing
b. Worm gear
c. Worm shaft
d. Handwheel gearbox housing
e. Spur gear
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2.1. Gearbox Housing

2.1.1. Gearbox housing

The gearbox housing threaded holes for the handwheel gearbox housing is damaged. The thread
happened to be stripped off from the gearbox housing due to excessive load given by the work
shaft to the assembly. Axial movement within the worm shaft would be possible root cause for
this issue.

The material for the housing is made of cast iron, thus patch work of welding and machining back
to its original shape and size is not advisable due to uncertainties of the material loading integrity
after the work been carried out. There’s a potential that these cast iron will crack again during
operation due to cast iron are brittle and susceptible to crack and would not be able to handle
the load given during operation.

2.1.2. Worm Gear.

The item is in good shape. Minimal neglectable wear is observed on the component itself. .

2.1.3. Worm Shaft

The item is in good shape. Minimal neglectable wear is observed on the component itself. Thrust
bearing assembly were observed to be in good condition and can be re-use back if required.

2.1.4. Handwheel Gearbox Housing

The item is in good shape, in good condition and can be re-use back if required. The cover for
the housing is missing. Will need to fabricate new if required.

2.1.5. Manual Driven Spur Gear

The item is in good shape, in good condition and can be re-use back if required.
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2.1.6. Manual Drive Spur Gear.

This component is missing from the sub assembly. Will need to fabricate new if required.

2.1.7. Handwheel
Item not received when the subassembly delivered.

2.1.8. Coatings
Going by its appearance, the gearbox cover will required a full refurbishment. A new set of seals
are required as well. A major coating rework is required on the component and replacement of
item as indicated above are needed prior to coatings.
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3. Discussion

Almost all damages to the gearbox housing will required a repair of one kind or another. The
number of repairs needed is substantial. Most of the repair required are mainly on the interface
area for the manual gearbox housing and others requires replacement part.

With the evidence gathered so far, it appears that damages to the indicated area is beyond
repaired. Other than stripped thread and crack on the threaded area, the housing is found to
have crack around the damage area thus making it impossible to repair.

Taking all the above into consideration, it is doubtful that the housing can be repaired
economically and with confidence.
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Conclusion

The report is comprehensive and identifies all affected areas and a scope of work for each repair
required together with the degree of difficulty and the risks associated in carrying out those
repairs. Section 3, contains an analysis of the repair work scope, assessment of risks and RKK
recommendations. With regards to the housing, the report is clear in that the gearbox housing
damage is beyond repair. Hence RKK recommendation is to scrap the gearbox housing and
proposed of a brand new gearbox presented in the Annex B of the report.
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Annex A – Inspection Photos

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Annex B – Proposed Brand New Gearbox