Inspection and repair project on ULSTEIN 4500AGC-KP gearbox

This client from Belgium came to us with this ULSTEIN 4500AGC-KP. We inspected the gearbox and performed a repair. After a succesful testrun we shipped the gearbox back to the client.

This report presents the findings and repair information of the performed repairs onboard a ship location Schiedam, the Netherlands.

GBS international was invited to perform the above mentioned work.

Scope of work:

- Repair Propulsion GBX SB & PS
- PTO-shaft renew bearings o OD-box overhaul o Distribution station overhaul / repair o Oil filter unit repair o Oil cooler overhaul

PTO shaft PS was found with a high axial movement this was caused by a faulty bearing. The axial movement was visible at the generator coupling. The bearing cage was broken hereby the rolling element were found inside the gearbox carter. These rolling elements were taken out and the gearbox is cleaned inside. The PTO shaft bearings were replaced and the axial movement is readjusted to 0.10mm.

PTO shaft SB had also a high axial movement. This was also discovered by the movement of the generator coupling. PTO shaft bearings were replaced and the axial movement is readjusted to 0.10mm.

OD-box SB & PS were found with damages in the bore at the location of O-ring seals. The damages were refurbished by laser cladding and machining.

Distribution station SB & PS were found with a faulty clutch piston. The piston is oversized replaced and the piston bore is minimal machined to a smooth surface.

Oil filter unit SB & PS were found with damages in the bore at the location of the O-ring seal. The damages were refurbished by laser cladding and machining.
Oil cooler SB & PS were preventive overhauled. After overhaul the coolers were pressure tested at 6 bar.

The alignment of SB & PS generator were checked. PS alignment was found ok. SB generator is realigned by the company SKF and SB generator is refitted with adjustable vibracons. Also SB coupling elements were renewed.

Recommendation

- After 720 running hours generator coupling bolts SB & PS needed to be checked if they are stil on the correct torque.