2016 - 06 - PeG (Overhauling Report of MAAG Gear by Peter Gunsch)

FLSmidth MAAG Gear Report
Order No. 16’003’866

Gearbox type WPU-200/C
Keyword Chackwal
FLSmidth MAAG Gear AG
Lagerhausstrasse 11 · P.O. Box
8401 Winterthur · Switzerland
Tel +41 52 260 35 00 · Fax +41 52 260 35 35
Info@FLSmidthMaagGear.com · www.FLSmidthMaagGear.com
Table of Contents
1. General Information ............................................................... 1
1.1 Reason of visit ................................................................ 1

1.2 Situation on arrival ............................................................ 1
2. Summary of daily works............................................................... 2
3. Conclusion and recommendations / general remarks ......................... 3
4. Description of steps / findings and results ....................................... 3
5. Alignment protocol ..................................................................... 5
6. Pictures.................................................................................... 6
7. Spare parts recommendation: ....................................................... 7
7.1 Material over given to client ................................................. 7

8. Contact details customer ............................................................. 8
9. Attachments .............................................................................. 8
Doc. No. 2016_06_PeG Page 1

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1. General Information
Customer : Pakcem Limited Report no. : 2016_06_PeG
Contact person : Tabish Iqbal Report date : 03.07.2016
Country : Pakistan Date of Visit : 21.06.-05.07.2016
Keyword : Chackwal Service Engineer : Peter Gunsch
Gear type : WPU-200/C Serial no. : 16'003’866
Operating hours : 52 109
1.1 Reason of visit
Exchange of bevel gear, evaluation for spare parts for overhaul.
1.2 Situation on arrival
All oil pipes were removed.

Bolts at mill table where removed.
Ready to lift the mill table.

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2. Summary of daily works
Date Work performed
Site inspection.
22.06.2016
Discuss the coming works.
Remove all necessary bolts.
23.06.2016
Lift the mill table.
Remove dowel pins (one needed to cut off).
Move the gearbox away from the mill.
Remove the outlet flange, due to low crane capacity.
24.06.2016
Remove 2nd stage.
Remove sun pinion.
25.06.2016
Remove motor coupling.
Remove cover.
Remove bevel gear.
Clean casing 1st stage.
26.06.2016
Remove destroyed dowel pin.
Install bevel gear, tighten bolts.
Drill and ream holes for dowel pins at bevel gear.
27.06.2016
Install front cover.
Install coupling.
28.06.2016 Drill and ream holes for dowel pins at bevel gear.
Assemble gearbox.
29.06.2016
Move gearbox underneath mill.
Alignment of gearbox.
30.06.2016
Tighten foundation bolts.
Lower mill table.
01.07.2016
Tighten bolts of mill table
Connect oil pipes.
Connect electric wires
Start lubrication system.
02.07.2016
Refill oil.
Check oil distribution in the gearbox.
Start mill with no load.
03.07.2016
Paperwork.
04.07.2016 Final meeting.

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3. Conclusion and recommendations / general remarks
 The client has very limited time for this bevel gear exchange. It was decided to fulfil the
inspection of 2nd stage in another time of this year.
 From the old bevel gear stage only the casing with cover can be reused.
 Two planet shafts were stored at site: one new, one repaired.
 Mill start under load is earliest possible at 15. Of July.
4. Description of steps / findings and results
Outlet flange:
Few fine scratches = normal (OK)
Thrust Pads:
Few fine scratches = normal (OK)
Planets:
Tooth contact pattern = no offset visible (OK)
Planet Shafts:
In Position = no abnormalities visible (OK)
Bevel Gear:
Pinion = Damaged (NOT OK)
Gear = pair to pinion (NOT OK)
Axial bearing (No.: 7) = damaged (NOT OK)
Pinion bearing (No.: 3) = Destroys by removing (NOT OK)
Pinion bearing (No.: 9) = Destroys by removing (NOT OK)
Gear bearing (No.: 32) = not recommended to keep (NOT OK)
Gear bearing (No.: 33) = not recommended to keep (NOT OK)
Pinion sleeve = damaged (NOT OK)
Casing = can be reused without drilling (OK)
Casing cover = visible ok, without dismantling (OK)
Exchanged to new one = Tooth contact acc. to request (OK)

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Gear reducer:
Nominal pre-stress anchor bolts = acc. FLS manual (950 bar)
Actual pre-stress anchor bolts = 950 bar (OK)
Nominal positioning = 4 taper pins
Actual positioning = 3 taper pins (OK)
Nominal wedging = 4 wedges or bolts
Actual wedging = 4 bolts (OK)
Nominal orifices = 2 ( acc. manual)
Actual orifices (trust bearing/bevel gear) =  12mm,  11mm (OK)
Oil supply unit

Nominal filling level (LP tank, ISO VG 320) = 6600 l
Actual filling level (LP tank, ISO VG 320) = 6600 l (OK)
Instruments
Nominal accuracy = ± 1%
Actual accuracy = ± 1% (OK)
Interlocking
Nominal = standard, acc. manual
Actual = standard, acc. manual (OK)
Operating data (NO LOAD)

Nominal = limits acc. manual
Actual = limits acc. manual (OK)

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5. Alignment protocol
Vertical Alignment
Before Alignment:
Coupling Angularity “CA” 0.04
Coupling Offset “CO” 0.12
Front feet “F1” -0.20
Rear feet “F2” -0.40
After Alignment
Horizontal Alignment
Before Alignment:
After Alignment
Note: All measurements in millimeter unit. Shim were placed under the front and rear feet 0.2
and 0.4mm respectively

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6. Pictures
Cleaning of base plate Drilling of holes for dowel pins
Oil system CCS

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7. Spare parts recommendation:
Or complete new bevel gear stage
7.1 Material over given to client
2Pc. Loctite 243, 50ml

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8. Contact details customer
Plant Manager
Name: Irshad Ali Ameer
E-mail: ialiameer@pakcem.com.pk
Phone No.: 0092 514020 100
Mobile No.: 0092 322 5000221
Maintenance manager
Name: Intizar Ahmad
E-mail: iahmad@pakcem.com.pk
Phone No.: 0092 514020 222
Mobile No.: 0092 322 8282809
Contact for spare parts:

Name: Intizar Ahmad
E-Mail: iahmad@pakcem.com.pk
Phone: +92 (51) 4020222
Adress Plant / Office: Choiie Mallot Road
Tehsil Kalar Kahar
DistrictChakwal, Chakwal
9. Attachments
none
The customer agrees herewith on both the performed work and the contents of this site report.
He also confirms having received a copy of this site report (signed by both parties).
FL Smidth MAAG Gear AG Purchaser / Customer
Mr. Name Mr. Name

FLSmidth MAAG Field Engineer Titel

2016 - 06 - PeG (Overhauling Report of MAAG Gear by Peter Gunsch)

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FLSmidth MAAG Gear Report

Order No. 16’003’866

1.1 Reason of visit ................................................................ 1

3. Conclusion and recommendations / general remarks ......................... 3

4. Description of steps / findings and results ....................................... 3

5. Alignment protocol ..................................................................... 5

7. Spare parts recommendation: ....................................................... 7

7.1 Material over given to client ................................................. 7

Doc. No. 2016_06_PeG Page 1

Customer : Pakcem Limited Report no. : 2016_06_PeG

Contact person : Tabish Iqbal Report date : 03.07.2016

Country : Pakistan Date of Visit : 21.06.-05.07.2016

Keyword : Chackwal Service Engineer : Peter Gunsch

Gear type : WPU-200/C Serial no. : 16'003’866

Operating hours : 52 109

1.1 Reason of visit

Exchange of bevel gear, evaluation for spare parts for overhaul.

1.2 Situation on arrival

All oil pipes were removed.

Doc. No. 2016_06_PeG Page 1

2. Summary of daily works

Date Work performed

Doc. No. 2016_06_PeG Page 2

3. Conclusion and recommendations / general remarks

4. Description of steps / findings and results

Doc. No. 2016_06_PeG Page 3

Oil supply unit

Operating data (NO LOAD)

Doc. No. 2016_06_PeG Page 4

Doc. No. 2016_06_PeG Page 5

Cleaning of base plate Drilling of holes for dowel pins

Oil system CCS

Doc. No. 2016_06_PeG Page 6

7. Spare parts recommendation:

Or complete new bevel gear stage

7.1 Material over given to client

2Pc. Loctite 243, 50ml

Doc. No. 2016_06_PeG Page 7

8. Contact details customer

Contact for spare parts:

FL Smidth MAAG Gear AG Purchaser / Customer

Mr. Name Mr. Name

Doc. No. 2016_06_PeG Page 8

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