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Technical Evaluation

Customer: Engineer/ Technician: Date:

NEOMILLE Cleiton Coutinho 29/11/2023
Contact / Department: E-mail.: Tel.:
ROBERTO GIANOLLA / SERVICE Choose an item. 11 5188-
Equiament: Model: Serial Number:
GEARBOX GEARBOX 20 kNm DD

Geabox serial no: PI / NF: Product Number:

KR2152G04 379375B / 56.026 61241654-80

1. Photografic record of the equipment.

Receipt

Packaging:
☐ Mounted ☒ Partially disassembled ☐ Loose ☒ Separator disassembled
gearbox
☐ Disassembled ☐ Pallet ☒ Box/Crate

Decanter items:
Lower base ☐ Yes ☒ No ☐ N/A Main engine ☐ Yes ☒ No ☐ N/A
Top base ☐ Yes ☒ No ☐ N/A Auxiliary engine ☐ Yes ☒ No ☐ N/A
Hood ☐ Yes ☒ No ☐ N/A Case protection ☐ Yes ☒ No ☐ N/A
Gearbox ☒ Yes ☐ No ☐ N/A Cylinder ☐ Yes ☒ No ☐ N/A
Bearings ☐ Yes ☒ No ☐ N/A Screw Conveyor ☐ Yes ☒ No ☐ N/A
Feet ☐ Yes ☒ No ☐ N/A Smaller cube ☐ Yes ☒ No ☐ N/A
Adapter / Pulley ☐ Yes ☒ No ☐ N/A Biggest cube ☐ Yes ☒ No ☐ N/A
Feeding Tube ☐ Yes ☒ No ☐ N/A Special tools ☐ Yes ☒ No ☐ N/A
Note:

2. Gearbox

Classified by Alfa Laval as: Business

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Technical Evaluation

Disassembly

When the top cover was removed, there was a lack

External visual assessment of the box, the gearbox is
of oil and the presence of filings, apparently from
partially open, it has already had a pre-evaluation by
damaged gears.
the customer.

The lid and bottom are damaged and there is crusted material in the highlighted area and
the screws are out of torque; therefore, all parts will be replaced. Gears will also be stressed
due to contact with other damaged teeth.

Classified by Alfa Laval as: Business

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Technical Evaluation

During disassembly it was found that the first stage components were excessively damaged, with the initial
gears completely damaged and locked. There are no conditions for using the complete piece.

Classified by Alfa Laval as: Business

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Technical Evaluation

The initial stage shows damaged gears and jamming, due to the damage found we requested this complete
set.

Highlighting the condition of the completely damaged gear set components.

The highlighted smaller shaft has its gear teeth completely damaged, and the bearing is locked due to the presence of
filings. Due to the proportion of the damage found, we requested the replacement of the components of this set.

Classified by Alfa Laval as: Business

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Technical Evaluation

After removing the cover from the second and third stages, only the dirt that remained encrusted on the
edges of the box was highlighted.

The wear marks found on the bushings of the internal gears of the box may have been caused by operating
with filings in the oil, which end up spreading throughout the lubrication assembly and passing between
.
these devices Due to the proportions of the damage found, we requested the replacement of the
components of this set.

Classified by Alfa Laval as: Business

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Technical Evaluation

We drained the oil from the gearbox, as the box was already open, the oil level was very low.

Gearbox completely disassembled and we can say that there will be a need for replacement, there is
irreparable damage to gears.

Parts sent to metrology for checking according to the original project drawing.

Classified by Alfa Laval as: Business

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Technical Evaluation

Fig. 1.3.2.6 Tooth Breakage.

Tooth Breakage/Damage

If parts of one or more teeth, or even a complete tooth, break, this generally indicates excessive overloading of
the reducer, and the machine's adjustments must be checked.
In this case, all gears must be replaced, as residual material may have come into contact with or even stuck to
other gear teeth.

If tooth damage is found:

1. Replace all gears in the gearbox.
2.Check the machine settings.

Classified by Alfa Laval as: Business

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Technical Evaluation

3. Final Considerations

The equipment arrived at the service center partially disassembled, without the torque arm disassembled.

The gearbox had a low oil level and the magnetic plugs contained filings.

During disassembly it was found that the first stage components were excessively damaged, with the initial
gears completely damaged and locked at first.

The wear marks found on the bushings of the internal gears of the box may have been caused by operating
with filings in the oil, which end up spreading throughout the lubrication assembly and passing between these
devices.

After inspection and analysis of the equipment design, we recommend replacing the parts

indicated in the quote.

4. Recommendations

Replace parts that show wear beyond their safety limits, as they can cause serious damage or
fatal injuries.

Use original parts and services from Alfa Laval, aiming to guarantee the best performance and adequate
maintenance of the equipment. Alfa Laval assumes no responsibility for the safe operation of equipment
where non-genuine parts have been used.

Check the equipment manual for the type of lubricating oil that should be used, the quantity and the
appropriate interval for change, to avoid premature wear of parts and unexpected equipment stops.

Carry out periodic cleaning according to the needs of the process in which the equipment is used.

Do not exchange parts from one machine to another. Major parts cannot be replaced without balancing the
entire rotor.

Reginaldo Marinho
Supervisor de Serviços - Workshop Repair Telefone:
+55 11 5188-6058
E-mail: reginaldo.marinho@alfalaval.com

Classified by Alfa Laval as: Business