Jamie Atkinson

ET3-029C: Practical Assessment

 Make sure that all the tools and equipment are checked to see if they are safe to use
before using them.
 Ensure that your work is clean and tidy before starting this assessment.
 You must have the correct PPE for the job.
 Make sure you have done a risk assessment before you commence the job and that all
the risks have been identified.
Potential Hazards

 Slips and trips: Make sure your workplace is clean and tidy so that there is a low chance
of slips and trips.
 Manual handling: Always use a crane for heavy loads and never lift something that is to
heavy for you.
 Crane: Make sure to wear a helmet and never stand underneath a load that is being
lifted.
 Sharp objects: When you are assembling and disassembling the gearbox make sure to
wear gloves incase of any sharp edges.
Personal Protective Equipment (PPE):

 Overalls: Prevents grease/oils from getting on your skin and stops sharp objects from
penetrating your skin.
 Helmet: Protects your head from falling objects.
 Gloves: Protects your hands from sharp objects.
 Safety glasses: Prevents and objects from entering your eyes.
 Steel toe cap boots: Protects your feet from any falling objects.
Tools and Equipment Used For The Task:

 Torque wrench (Nm)

1
Disassembly
1. Collect the gear box and the tools you need for the job.
2. I removed the sunk plug and the drained and fluids that where in the gearbox.
3. Next I attached eyebolts to the gearbox and preform a pre-flight check then I used the
crane to lift the gear box onto my work bench when I was to take it apart.
4. I also attached an eyebolt to the shaft of the worm wheel and used the crane to flip the
gearbox onto its side making sure to support it with wooden planks after I preform a
pre-flight check.
5. When the gear box is on its side, I use a marking pen to label the parts that I’m going to
remove and to mark where the parts go back onto the outer casing.
6. Using an adjustable spanner, I remove the two shaft cover plates on either side of the
worm shaft, making sure to keep all the bolts with the cover plates.
7. I then remove the small cover plate above the worm wheel and put it to one side.
8. After this I take the big cover plate off from above the wheel bearing so that the wheel
bearing is now exposed.
9. I then preform a pre-flight check and attach the crane to the eye bolt that I attached to
the shaft of the worm wheel and carefully lift it out of the outer casing of the gear box,
making sure to put it to one side on wooden planks to hold it steady.
10. When the worm wheel is out of the way I can manually lift the worm shaft and remove
it from the outer casing of the gearbox, placing in between two wooden planks so it
does not move.
11. Lastly remove all the old gaskets in the gearbox.

Fault Finding
After I had removed everything from the outer casing of the gearbox it was time to check if all
the parts where in a usable condition. For this a did a strip and inspection report that allowed
me to keep track of all the items and what might be wrong with them and how they could be
fixed or if they needed to be replaced. For the faults I found look at my strip and inspection
report.
The method of fault finding I used was called the 5-point Faultfinding approach. This method
has 5 steps, step 1. Gather information-in this step you ask anyone who works with the
equipment when and how they think the fault occurred, this step helps you to understand what
might’ve happen quicker allowing you to sort the problem out faster. Step 2. Analyse
information-decide the probable cause based on step 1 and any knowledge you may have of
these kinds of faults. Step 3. Investigate-in this step you attempt to find the fault based on your
analysis. Step 4. Rectify-once you have found the fault you should repair or replace it safely.
Step 5. Test-when the fault has been fixed test/inspect the workpiece to see if its up to
standard.

2
 Assemble
1. Firstly I fixed and replaced all of the parts that I said I need to in my strip and inspection
report.
2. I then replaced old gaskets with new ones.
3. The first thing I put back into the outer casing of the gearbox is the worm shaft.
4. Then I preform a pre-flight check and use the crane and attach it to the eye bolt on the
worm wheel and lower the worm wheel into the outer casing of the gearbox.
5. I would then place the big cover plate back over the worm wheel and line it up to my
marked lines, and then loosely tighten it up.
6. Next I would put the small cover plate back onto the big cover plate and loosely tighten
it into place, making sure that it lines up with my marks.
7. After that I would reattach the two worm shaft cover plates, making sure they line up
with the marks I made and loosely tightening them into place.
8. After everything is in place I would set a torque wrench to 30Nm and tighten all of the
bolts until you hear a click.
9. Turn the worm shaft and make sure that it turns.
10. Use the eyebolts that are already in place and lift the gearbox back upright I preformed
a pre-flight check before this.
11. When the gearbox was in an upright position I removed the eyebolt from the shaft of
the worm wheel, then I performed a pre-flight check and moved the gearbox onto a
pallet ready to be picked up using a crane.

Gearbox Maintenance

Measure Periods
Check oil temperature Daily
Check for unusual gear-unit noise Daily
Check oil level Monthly
Check gear-unit for leaks Monthly
Test the water content of the oil After approx. 400 operating hours, at least once per year
Preform the first oil change Approx. 400 operating hours after start up
Preform subsequent oil changes Every 24 months or 10000 operating hours
Clean the oil filter Every 3 months
Clean the air filter Every 3 months
Clean the breather screw Every 3 months
Clean fan and gear-unit Depending on requirements at least every two years
Type with oil-dam pipe: Recharge with grease Every 5000 operating hours or at least every 10 months
Refill Taconite seals with grease Every 3000 operating hours or at least every 6 months