An old PIV/ Werner Reimers gearbox was presented to us for inspection. It is a right angle gearbox with a 1:1 ratio and a 1 input/ 2 output shaft configuration. In the application, the gearbox input shaft is vertical and the two outputs are horizontal. The output shafts counter-rotate. They drive two screw conveyors which move and compact wood chips. The gearbox is part of the hopper of a biomass combustion installation by Kara Energy Systems (link). This is a pretty old installation, delivered in 1980.
Gearbox main data:
- Type nr.: L51 B88-M-1-0
- Serial nr.: 446 172 G2
- i= 1
- P= 4,37 kW
- n2 = 50 rpm
- M2 = 834 Nm
- Lubrication: Oil, Mobilgear 629 (replaced by: Mobilgear 600 XP 150)
- Filling quantity: 4 liters
- Oil service interval: 2500 operating hours
- Gear type: Klingelnberg (Cyclo-Palloid)
The gearbox was taken out of the installation because it had completely jammed and did not move anymore. In the time leading up to the failure, noises were heard from the gearbox.
The gearbox had been rebuilt in 2007.
The general approach was to do a disassembly and inspection, report the results and decide on whether to rebuild or replace.
First step was to remove the side cover:
What we saw was a big mess. Much dirt and not a drop of oil. Obviously wood dust had worked its way into the gearbox and likewise, the oil had found its way out! The input shaft could only be rotated a very small amount before it jammed. Metal chips (likely from a bearing cage) were present. We knew right away that this was not going to be an easy fix.
From experience we know that a rebuild was going to be costly. Because of the age of the gearbox, a direct replacement was out of the question. PIV/ Werner Reimers is now Brevini (link), and this type of gearbox has gone out of production a long time ago.