2015
CPU Gearbox Overhauling
Submitted by: Inspection Team Members
Under supervision: Eng. Ashraf Fahmi Preventive Maintenance Manger
M.Gamal [Type the company name] 3/12/2015
pg. 0
Table of content 1. Introduction
Page 2
2. Surveying and Site Inspection
Page 2
3. 1st stage Disassembly
Page 2
3.1 1st stage transfer
Page 2
3.2 1st Sun pinion disassembly
Page 4
3.3 1st Casing disassembly
Page 8
3.4 1st Planets carrier disassembly
Page 10
3.5 1st Ring Gear carrier disassembly
Page 13
3.6 1st Bearings white metal ultrasonic check
Page 15
3.7 1st Re- assembly
Page 16
4. 2st stage Maintenance
Page 33
4.1 2st Casing disassembly
Page 33
4.2 2st Planets carrier disassembly
Page 35
4.3 2nd Stage Planets gear shafts replacement
Page 40
4.4 2nd Stage Sun pinion, Planet gears and Ring gear inspection
Page 47
4.5 2nd Stage Planets carrier bearings inspection
Page 49
Inspection Dept.
Page 1 of 59
Table of content 1. Introduction
Page 2
2. Surveying and Site Inspection
Page 2
3. 1st stage Disassembly
Page 2
3.1 1st stage transfer
Page 2
3.2 1st Sun pinion disassembly
Page 4
3.3 1st Casing disassembly
Page 8
3.4 1st Planets carrier disassembly
Page 10
3.5 1st Ring Gear carrier disassembly
Page 13
3.6 1st Bearings white metal ultrasonic check
Page 15
3.7 1st Re- assembly
Page 16
4. 2st stage Maintenance
Page 33
4.1 2st Casing disassembly
Page 33
4.2 2st Planets carrier disassembly
Page 35
4.3 2nd Stage Planets gear shafts replacement
Page 40
4.4 2nd Stage Sun pinion, Planet gears and Ring gear inspection
Page 47
4.5 2nd Stage Planets carrier bearings inspection
Page 49
Inspection Dept.
Page 1 of 59
1. Introduction This report represents an illustration for events and timing timin g for gear box overhauling.
2. Surveying and Site Inspection Day 1
24.04.2015
Maag specialist has inspected the site and decides to: 1. 1st stage must be transferred to the work shop to be inspected. 2. 2nd stage will be at the site to be inspected.
3. 1st stage Disassembly 3.1 1st stage transfer Day 1
24.04.2015
The 1st stage has been hanged by means of wires from its upper suspension point to be lifted by the the overhead crane see Fig 3.2 The 1st stage has been lifted li fted by the overhead crane and moved over cement mill mil l 1 gear box to be out of the cement mill room.
Fig 3.1
st
The 1 stage has been slightly down to make the stage hanged from its bottom suspension point to be lifted by ASEC mobile crane.
Inspection Dept.
Page 2 of 59
ASEC mobile crane has started to lift the stage from bottom slowly at the same time the overhead crane move the stage down, making the stage rotated upside down. A small carrying loader has moved under the stage, and then the stage has been seated on wooden blocks at loader surface by moving both cranes wires down see Fig 3.2.
Fig 3.2
After securing the package the carrying loader has moved to the work shop. The mobile cranes with the help of work shop overhead crane have lifted the stage and seated it down on 3 frame supports see fig 3.3.
Fig 3.3
Inspection Dept.
Page 3 of 59
3.2 1st Sun pinion disassembly Day 2
25.04.2015
The cover of the 1 st stage has been suspended by the overhead crane. The fastening bolts no 110, 30 have been released and centering pins no 50 have been removed see drawing 3.1. By jack bolts no 120 the upper half cover pushed outside axially then by similar jack bolts the upper half cover pushed up vertically sees drawing 3.1, fig 3.4.
Drawing 3.1
Fig 3.4
Inspection Dept.
Page 4 of 59
The stage planets carrier has been supported by a hydraulic jack to prevent carrier fall down when the sun pinion bearing dismantled see drawing 3.2, fig 3.5.
Drawing 3.2
Fig 3.5
Inspection Dept.
Page 5 of 59
The fastening bolts of radial bearing (sun pinion bearing) no.1 has been loosened see drawing 3.3. The sun pinion no.2 has been hanged by means of wires, and by the overhead crane the sun pinion has been lifted steady until the pinion has been came out from its position see drawing 3.3,fig 3.6,3.7.
1 3 2
Drawing 3.3
Fig 3.6
Inspection Dept.
Page 6 of 59
Fig 3.7
The sun pinion has been moved away from the stage, and seated down on a rubber bed see fig 3.8.
Fig 3.8
Inspection Dept.
Page 7 of 59
The sun pinion assembly has been hanged by fabric wire; the upper half of sun pinion bearing has been hanged by chain block. The radial bearing halves fastening bolts have been dismantled, and by chain block the upper half of bearing has been lifted up away of its position. By the fabric wire the sun pinion has been lifted to make the lower half of radial bearing free see fig 3.9.
Fig 3.9
3.3 1st Casing disassembly Day 2
25.04.2015
The fastening bolts of 1st stage casing with the 1 st stage ring gear carrier no.150 have been dismantled; by tightening reject bolt no.160 casing has been separated about the ring gear carrier see drawing 3.4. Casing has been hanged by means of chain blocks and wires, by the overhead crane the casing has been lifted until it has been free to move it away then it has been seated at ground above wooden blocks see fig 3.10.
Drawing 4.4
Drawing 3.4
Inspection Dept.
Page 8 of 59
Fig 3.10
Day 3
26.04.2015
The Radial bearing no.2 of planet carrier has been dismantled by: 1. The edge of the rectangular lock washer has been straightened see fig 3.11. 2. Fastening bolts of bearing key plate (lock plate) have been dismantled see fig 3.12. 3. 2 bolts have been erected at the reject thread position, the bearing has been moved up by screwing bolts down see fig 3.13, 3.14. 4. The bearing hanged by means of wires, it has been lifted out of its casing by the overhead crane and seated at the ground above rubber bed to be inspected see fig 3.15.
Fig 3.11
Inspection Dept.
Fig 3.12
Fig 3.13
Page 9 of 59
Fig 3.14
Fig 3.15
st
3.4 1 Planets carrier disassembly Day 2
25.04.2015
Planet carrier has been hanged by means of chain blocks and wires, by the overhead crane the planets carrier has been lifted up until it has been free to move it away, and then it has been seated at ground above rubber bed see fig 3.16, 3.17.
Fig 3.16
Inspection Dept.
Page 10 of 59
Fig 3.17
Planet carrier has been hanged by means of chain blocks and wires; by the overhead crane the planet carrier has been lifted up and seated over the 3 frame supports after lifting the ring gear carrier away of frame supports see fig 3.18.
Fig 3.18
Inspection Dept.
Page 11 of 59
Fastening bolts no.50 of planet shaft no.20 to planet carrier no.10 have been dismantled by electric spanner see drawing 3.4, fig 3.17.
Drawing 3.6 Drawing 3.4
Fig 3.17
Inspection Dept.
Page 12 of 59
3.5 1st Ring Gear carrier disassembly Day 3
26.04.2015
Ring gear carrier has been hanged by means of chain blocks and wires, by the overhead crane the ring gear carrier has been lifted up and seated over the 3 frame supports after lifting planets carrier away from frame supports see drawing 3.7, fig 3.18.
Drawing 3.7
Fig 3.18
The Radial bearing no.3 of planet carrier has been dismantled by: 1. The bearing hanged by means of chain blocs just for securing as shown in Fig 3.18. 2. The edge of the rectangular lock washer has been straightened see drawing 3.7. 3. Fastening bolts of bearing key plate (lock plate) have been dismantled see fig 3.19. 4. By pushing the bearing down by a wooden block pit by the pit, the bearing has been moved down out of its housing with the control of suspension see fig 3.20,21.
Inspection Dept.
Page 13 of 59
X Drawing 3.7
Fig 3.18
Fig 3.19
Fig 3.20
Fig 3.21
Inspection Dept.
Page 14 of 59
3.6 1st Bearings white metal ultrasonic check Day 9
02.05.2015
Planets shafts have been hanged by wires at the overhead crane one by one then lifted out of their positions to be checked by ultrasonic crack detector see fig 3.22, 3.23 and they were in good condition.
Fi 3.22
Fig 3.23
Bearing no.1, 2, and 3 white metals have been checked by ultrasonic crack detector and they were in good condition.
Inspection Dept.
Page 15 of 59
3.7 1st Stage Re- assembly Day 12
5.05.2015
Planets shafts have been hanged by wires at the overhead crane one by one then lifted out of their positions then it transferred to be seated upon a wooden table see fig 3.24.
Fig 3.24
Planets shafts have been lightly scraped to remove the carbonized layer of white metal see fig 3.25.
Fig 3.25
Inspection Dept.
Page 16 of 59
The 3 planet gears have been moved out from its carrier to be inspected and to be cleaned by hanging the gear from eye bolt at the overhead crane then it has been lifted slightly to put some of rounded Teflon bars between the gear and receiving table to be used as a bearing see fig 3.26. Using a flat wooden block to push the gear out with the control of the overhead crane see fig 3.27
Fig 3.26
Fig 3.27
Maag specialist has inspected the thrust rings of planets then they have been light scraped and polished to remove traces and notches.
Fig 3.28
Inspection Dept.
Page 17 of 59
After finishing inspection of planets and their trust ring, planets have been re assembled again at the planet carrier. Planet gear has been inserted by using the over headstand to lift the gear and Teflon rounded bars under the gear used as a bearing and by pushing the gear inside the planet carrier using a wooden block block the gear has been moved to its place see fig 3.28 .
Fig 3.28
Lube oil pipes nozzles of planets gear and sun pinion no.1 have been cleaned from scales by solvent see drawing 3.8. Lube pipe has been lifted by hand after erecting an eye bolt at its internal thread see fig 3.29.
Drawing 3.8
Inspection Dept.
Page 18 of 59
Fig 3.29
After cleaning Maag specialist has inspected the radial bearing no.3 visually then he decided to re-erect the bearing after doing light scraping for the white metal to remove traces and scratches see fig 4.30.
Fig 3.30
Day 13
6.05.2015
The last planet gear has been inserted inside the planet carrier. After cleaning Maag specialist has inspected the radial bearing no 3 visually then he decided to re-erect the bearing after doing light scraping for the white metal to remove traces and scratches.
Inspection Dept.
Page 19 of 59
Planet shafts have been erected one by one at their positions, starting with hanging the planet shaft from eye bolt at the overhead crane then it moving towards the planet carrier see fig 3.31. Grease layer has been applied on planet shaft see fig 3.32. Maag specialist has lifted the planet shaft over its specific position at the planet carrier since every planet shaft has a specified planet gear and a specified position at the planet which can be determined by the impeded number at planet carrier surface and planet shaft surface see fig 3.33. With maximum care Maag specialist started to insert the planet shaft steady and slowly in the planet gear bore with the control at planet gear position by pushing it by metallic bar to suit the planet shaft see fig 3.34.
Fig 3.31
Fig 3.33
Fig 3.32
Fig 3.34
Fig 3.34
Inspection Dept.
Page 20 of 59
The fastening bolts no.1 of the 3 planet gear shafts have been retightened with the specified torque 75 NM after applying thread locker on the bolt see drawing 3.9 fig 3.34.
1
Drawing 3.9
Fig 3.35
Inspection Dept.
Page 21 of 59
After cleaning Maag specialist has inspected the radial bearing no.2 visually then he decided to re-erect the bearing after doing light scraping for the white metal to remove traces and scratches. Radial bearing no.2 has been hanged by wire and chain block at the overhead crane and it has been moved above the 1st stage casing. By using a fill the housing and surface of radial bearing no .2 have been polished to remove traces and notches see fig 3.35.
Fig 3.35
Grease layer has been applied on radial bearing surface to ease bearing insertion see fig 3.36. Maag specialist has lifted the radial bearing over its position at the 1 st casing then with maximum care Maag specialist started to insert the radial bearing no.2 steady and slowly in its housing with keeping it in a horizontal position by the control of suspension wires and chain block to prevent the bearing from tilting see fig 3.36.
Fig 3.35
Inspection Dept.
Page 22 of 59
The radial bearing has been moved downward in it housing slowly by lowering the crane, then Maag specialist push the bearing down using a wooden block until it has been seated properly see fig 3.36.
Fig 3.36
The key plates of radial bearing 2 have been erected with its lock washer see fig 3.37
Fig 3.37
Ring gear carrier has been hanged by means of chain blocks and wires at the overhead crane, by the overhead crane the ring gear carrier has been lifted up and seated over the 3 frame supports after lifting planets carrier away of frame supports see drawing 3.10
Drawing 3.10
Inspection Dept.
Page 23 of 59
Radial bearing no.3 has been hanged by wire and chain block at the overhead crane and it has been moved above wooden table which moved under the ring carrier see fig 3.37.
Fig 3.37
Radial bearing no.3 has been re-hanged by wire and chain block through the ring carrier housing opening see fig 3.38. By using a file the housing and surface of radial bearing no .3 have been polished to remove traces and notches.
Fig 3.38
After applying a layer of grease on the bearing housing, the radial bearing no.3 has been lifted up slowly and steady until it has been inserted in its housing see fig 3.39.
Fig 3.39
Inspection Dept.
Page 24 of 59
The radial bearing no.3 has been kept in a horizontal position to prevent the bearing from tilting by using a depth gauge and control in suspension wires and chain block during lifting the bearing to be inserted in its housing see fig 3.40.
Fig 3.40
The key plates of radial bearing no.3 have been erected with its lock washer see fig 3.41.
Fig 3.41
A grease layer has been applied at all planet gears and ring gear surfaces to protect metal surface from corrosion during storing period.
Inspection Dept.
Page 25 of 59
A hydraulic jack has been seated under the ring gear carrier at the position of planet carrier shaft to carry the planet carrier during assembly see drawing 3.11.
Drawing 3.11
Planet carrier has been hanged by means of wire and chain blocks to be erected.
With maximum care Maag specialist has been lifted he planet carrier with keeping its position horizontally by the control of spirit level over the ring carrier to assemble the planet carrier shaft to radial bearing no.3 after applying grease layer on bearing surface.
After adjusting planet carrier position respect to the radial bearing Maag specialist has started to move the crane down making planet carrier shaft inserted in bearing slowly and steady see fig 3.42.
Fig 3.42
Planet carrier shaft has been moved in to the bearing until the planet gears reached to ring gear so that it has been needed to adjust the planet gear position by rotation and a little radial push to make planet gear tooth path through ring gear teeth see fig 3.43.
Inspection Dept.
Page 26 of 59
Fig 3.43
Hydraulic jack piston has been adjusted to carry the planet carrier instead of the overhead crane see fig 3.44.
Day 14
7.05.2015
Fig 3.44
1st casing has been hanged by means of chain blocks and wires at the overhead crane, by the overhead crane the casing has been lifted up with keeping it in a horizontal position by the control of spirit level, and moved over the assembled planet carrier after applying a grease layer on bearing surface and planet carrier shaft. After adjusting casing (the radial bearing no 2) position respect to planet carrier shaft Maag specialist has started to move the crane down making planet carrier shaft inserted in bearing slowly and steady see fig 3.45.
Inspection Dept.
Page 27 of 59
Fig 3.45
1st has been prevented to be tilted during assembly by the control in distance between its flange and ring gear carrier flange in addition rotating the 1st casing see fig 3.46.
Fig 3.46
Inspection Dept.
Page 28 of 59
The 1st stage casing flange and ring gear carrier flange have been covered with silicon then Maag specialist has completed lowering the casing. Casing orientation has been adjusted by rotating the casing until marks –which have been marked before dismantling - have been matched see fig 3.47
Fig 3.47
Fastening bolts no.150 of ring gear with the casing has been re tightened after tapered pin no.180 have been fitted see drawing 3.12 and fig 3.48.
Fig 3.48
Drawing 3.12
After cleaning the radial bearing no.1 it has been checked visually. Radial bearing no.1 has been assembled half by half to the sun pinion shaft, and then fastening bolts have been retightened after applying thread locker on the bolt see fig 3.49.
Inspection Dept.
Page 29 of 59
Fig 3
The sun pinion has been hanged by wires at the crane, and then it has been lifted over the assembled first stage after applying a grease layer on the shaft. After adjusting the sun pinion position respect to assembled first stage (radial bearing no.2) Maag specialist has started to move the crane down making sun pinion shaft inserted in bearing no.2 slowly and steady see fig 3.50.
Fig 3.50
Maag specialist has adjusted the orientation of the radial bearing to make the oil path (oil duct) at the radial bearing to meet the oil path at the bearing of 1 st stage planet carrier by rotating the radial bearing until pin at bearing has been seated at its position in planet carrier then the fastening bolts have been retightened with the specified torque 400 NM. Fig 3.51,3.52.
Fig 3.51
Inspection Dept.
Page 30 of 59
Fig 3.52
Inspection Dept.
Page 31 of 59
Inspection Dept.
Page 32 of 59
4. 2st stage Maintenance 4.1 2st Casing disassembly Day 6
29.04.2015
The upper front casing of the 2 st stage has been suspended by the overhead crane. The fastening bolts no 100, 230 have been released and centering pins no 130 have been removed see drawing 4.1. By jack bolts no 230 the upper half cover pushed outside axially then by similar jack bolts no.110 the upper half cover pushed up vertically see drawing 4.1. Upper Rear cover
Upper front cover
2
1
1
3
1
2
2
3
Drawing 4.1
By the same way the upper rear casing of the 2 st stage has been removed see fig4.1.
Inspection Dept.
Page 33 of 59
Fig 4.1
The cover of the 2 st stage has been suspended by the overhead crane. The fastening bolts no 1, 3 have been released and centering pins no 4 have been removed see drawing 4.1. By jack bolts no 2 the cover pushed outside axially, and then the cover has been lifted by the overhead crane.
Fig 4.2
Inspection Dept.
Page 34 of 59
4.2 2st Planets carrier disassembly Day 7
30.04.2015
The housing upper half of the 2 st stage planet carrier radial bearing fastening bolts has been released. The housing upper half of the 2 st stage planet carrier radial bearing has been hanged by means of wire then lifted by the overhead crane.
Fig 4.3
Maag special tools have been erected between the planet carrier and lower front casing to prevent the planet carrier from axial displacement and to lift the planet carrier see drawing 4.2, fig4.4.
Fig 4.4
Inspection Dept.
Page 35 of 59
Maag special tools have been erected at planet gear sides to lift the planet gear about 0.2 mm to make its shaft free to move out see fig 4.5,drawing 4.2.
Fig 4.5
Drawing 4.2
Drawing 4.2
Inspection Dept.
Page 36 of 59
By 2 dial gauges the lifting displacement has been controlled to prevent any excessive or little displacement occurring in one side that achieve good alignment for the planet gear and minimize any friction during the planet shaft moving out see fig 4.6.
Fig 4.6
Maag special tool for planet shaft has been hanged by means of wire at the overhead crane and in addition to chain block to help in tool position control see fig 4.7.
Fig 4.7
Inspection Dept.
Page 37 of 59
Maag tool moved towards the planet shaft, and inserted in the planet shaft through hole see fig 4.8, drawing 4.3
Fig 4.8
Fig 4.8
Inspection Dept.
Drawing 4.3
Page 38 of 59
Flat plate with 2 anchor bolts has been fitted behind the Maag tool as axial lock see fig 4.9.
Fig 4.9
By the overhead crane Maag specialist has adjusted the lifting tool position up and down then he has dragged the planet shaft out steady until the shaft has been completely out see fig 4.10.
Fig 4.10
Inspection Dept.
Page 39 of 59
With maximum care the planet shaft has been seated upon the ground over wooden table, see fig 4.11.
Fig 4.11
4.3 2nd Stage Planets gear shafts replacement Day 7
30.04.2015
New planet shafts have been transferred from the store to the site; suspension plate has been erected to the new planet shaft. By the overhead crane the planet shaft has been lifted to be out from its shipping box, and then it has been seated upon the ground see fig 4.12.
Fig 4.12
Inspection Dept.
Page 40 of 59
The protective cover of the planet shaft has been removed, and with applying solvent the anticorrosion layer has been cleaned.
Fig 4.13
The new planet shaft has been prepared to be lifted by the Maag tool by seating the the shaft horizontally slowly and steady, the rigger has moved Maag tool to be inserted inside the planet shaft hole see fig 4.14.
Fig 4.14
Inspection Dept.
Page 41 of 59
Day 8
01.04.2015
The thrust ring of planet shaft has been checked by the Maag specialist and it was in conditions see fig 4.15.
Fig 4.16
The planet shaft has been moved toward the gearbox, applying grease (EP0) was very necessary to protect the white metal during storing from corrosion and localized loading see fig 4.17.
Fig 4.16
Inspection Dept.
Page 42 of 59
The Maag specialist has assembled the planet shaft in its position by moving the package inside planet gear bore carefully.
Fig 4.16
Inspection Dept.
Page 43 of 59
By 2 hydraulic jack and flat plate the planet shaft has been dragged axially , after adjusting shaft orientation where threads of fastening bolts at planet shaft must match the holes at planet carrier in order to assemble fastening blots which will be retighten with the specific torque later see fig 4.17.
Ddddd
Fig 4.17
Inspection Dept.
Page 44 of 59
All special tools have been removed. The housing of bearing no.4 has been re-erected. The 2nd stage planet carrier has been rotated to make other planet shaft at vertical position by lifting the overhead crane and the wire that attached at the output drive flange of the gearbox see fig 4.18
Fig 4.18
Inspection Dept.
Page 45 of 59
All steps above have been repeated for other planet shaft see fig 4.19.
Day 9
02.04.2015
All steps above have been repeated for the last planet shaft see fig 4.20.
Fig 4.19
Day 9
02.04.2015
All steps above have been repeated for other planet shaft see fig 4.19.
Fig 4.20
Inspection Dept.
Page 46 of 59
4.4 2nd Stage Sun pinion, Planet gears and Ring gear inspection Day 9
02.04.2015
The coupling sleeve has been dragged out axially using 2 hydraulic jacks with flat plate attached to the intermediate coupling sleeve by anchor bolts the coupling sleeve has been dragged out. The coupling sleeve has been hanged by fabric wire and completed moving out by chain block until the sun pinion has been appeared see fig 4.21.
Fig 4.21
The fastening bolts of the axial lock split cover no 14 see drawing 4.4 of the internal coupling have been disassembled from the coupling sleeve 13 around the circumference.
Drawing 4.4
Inspection Dept.
Page 47 of 59
The coupling sleeve has been dragged slowly and steady out from sun pinion see fig 4.22
.
Fig 4.22
By Maag special tool the sun pinion has been dragged out from planet carrier see fig 4.23.
Fig 4.23
Inspection Dept.
Page 48 of 59
Unfortunately the sun pinion has a defected tooth has been discovered after inspection see fig 4.24.
Fig 4.24
Planet gear and ring gear have been inspected and they are in good conditions.
4.5 2nd Stage Planets carrier bearings inspection Day 9
02.04.2015
Maag special tools for lifting the planets carrier has been erected, then housing of the front bearing no.4 has been disassembled and moved away see drawing 4.5 and fig 4.25.
Drawing 4.5
Inspection Dept.
Page 49 of 59
Day 10
03.05.2015
By screw up the lifting tool the planet carrier moved vertically up with control in the distance by dial gauge that has been put under planet carrier shaft see fig 4.24.
Fig 4.23
Inspection Dept.
Page 50 of 59
After making sure that a clearance has been made around the circumference of the bearing by filler gauge, the radial bearing turned slightly by anchor bolts fitted at its internal thread holes until the fastening bolts of bearing halves have been appeared. Fastening bolts of bearing halves from one side have been disassembled then the radial bearing has been turned to make the other side fastening bolts dis assembled after applying some of grease to ease turning process. See fig 4.25
Fi 4.25
After dismantling the fastening bolts of the radial bearing halves it has been turned to make the bottom half at a horizontal position, then it has been hanged from eye bolts at the overhead crane see fig 40.26. With maximum care the bearing half has been lifted then it has been seated upon wooden table see fig 40.26.
Inspection Dept.
Page 51 of 59
After cleaning Maag specialist has inspected the bearing visually then he decided to re-erect the bearing after doing light scraping for it to remove traces and scratches see fig 4.26.
Fig 4.26
After the cleaning the planet carrier shaft and applying a grease layer on its surface, the radial bearing moved to be assembled at its position then the surface of radial bearing has been polished by sand paper see fig 4.27.
Inspection Dept.
Page 52 of 59
After erecting anchor bolts which used in bearing rotation, and erecting the radial bearing halves fastening bolts the radial bearing has been turned with help of chain block to make the top half at a horizontal position, then it has been hanged from eye bolts at the overhead crane see fig 40.27.
Fig 4.27
With maximum care the bearing half has been lifted then it has been seated upon wooden table see fig 40.28.
Inspection Dept.
Page 53 of 59
After cleaning Maag specialist has inspected the bearing visually then he decided to re-erect the bearing after doing light polishing for the white metal to remove traces and dirt see fig 4.29.
Fig 4.29
After the cleaning the planet carrier shaft and applying a grease layer on its surface the radial bearing moved to be assembled at its position then the surface of radial bearing has been polished by fill see fig 4.30, 4.31.
The radial bearing halves fastening bolts have been erected see fig 4.32 The housing of bearing no.4 has been re-erected see fig 4.33.
Inspection Dept.
Page 54 of 59
By the same procedure the radial bearing no.5 has been inspected and re-erected again. The planet carrier has been lifted by Maag special tools with the help of hydraulic jack. The lifting distance has been controlled by dial gauge and inserting filler gauge around the circumference See fig 4.34.
Fig 4.34
After making sure that a clearance has been made around the circumference of the bearing by filler gauge, the radial bearing turned slightly by anchor bolts fitted at its internal thread holes until the fastening bolts of bearing halves have been appeared see fig 4.35. Fastening bolts of bearing halves from one side have been disassembled then the radial bearing has been turned to make the other side fastening bolts dis assembled after applying some of grease to ease turning process. After dismantling the fastening bolts of the radial bearing halves it has been turned to make the bottom half at a horizontal position, then it has been hanged from eye bolts at the overhead crane see fig 4.36. With maximum care the bearing half has been lifted then it has been seated upon wooden table see fig 4.37.
Inspection Dept.
Page 55 of 59
After cleaning Maag specialist has inspected the bearing visually then he decided to re-erect the bearing after doing light scraping for it to remove traces and scratches see fig 4.38.
Fig 4.38
After the cleaning the planet carrier shaft and applying a grease layer on its surface, the radial bearing moved to be assembled at its position then the surface of radial bearing has been polished by sand paper see fig 4.39.
After erecting anchor bolts which used in bearing turning, and erecting the radial bearing halves fastening bolts the radial bearing has been turned with help of a chain block to make the top half at a horizontal position see fig 4.40 The bearing top half has been hanged from eye bolts at the overhead crane, then with maximum care it has been lifted then it has been seated upon a wooden table see fig 40.41.
Fig 4.39
Inspection Dept.
Fig 4.40
Fig 4.41
Page 56 of 59
After cleaning Maag specialist has inspected the bearing visually then he decided to re-erect the bearing without doing any action even polishing see fig 4.42.
Fig 4.42
Day 11
04.05.2015
After the cleaning the planet carrier shaft and applying a grease layer on its surface, the top half of radial bearing moved to be assembled at its position then the surface of radial bearing has been polished by sand paper see fig 4.43.
The radial bearing halves fastening bolts have been erected see fig 4.44. The housing of bearing no.5 has been re-erected see fig 4.45.
Fig 4.42
Inspection Dept.
Fig 4.44
Fig 4.45
Page 57 of 59
Lube oil pipes nozzles of planets gear and sun pinion no.1 have been cleaned from scales see drawing 4.6 and fig 4.46.
Drawing 4.6
Fig 4.46
With rotating the planet carrier fastening bolts of the 3 planet gear shafts have been retightened with the specified torque 140 NM after applying thread locker on the bolt see fig 4.47.
Inspection Dept.
Fig 4.47
Page 58 of 59
