PROJECT OVERVIEW
HAYLEY 247 DEXIS was commissioned by a leading supplier in the industrial minerals industry – to overhaul a critically worn International Combustion LM12 Double Reduction Bevel/Helical Mill Gearbox. The gearbox was suffering from a suspected input bearing failure due to oil starvation, likely caused by blocked pipework. The unit was collected on 08.02.24, with the inspection report completed by 26.03.24, and delivery estimated within 8-9 weeks from order confirmation. This project aimed to restore full mechanical function, enhance operational safety, and significantly extend the unit’s service life.
SCOPE OF WORK
HAYLEY 247 DEXIS carried out a complete in-house overhaul of the LM12 Mill Gearbox. The process began with a full strip-down and internal inspection to assess the extent of wear and damage. All bearings and seals were replaced as part of the refurbishment. Worn journals were reclaimed using precision metal spraying techniques to restore their original dimensions and performance characteristics. The team also manufactured new components, including shafts, locknuts, and pump parts, tailored specifically for this gearbox using high-grade materials. Where possible, existing gears were dressed and reused to maintain efficiency and reduce costs. Internal and external pipework was thoroughly cleaned and flushed to prevent future lubrication issues. The project concluded with a final rebuild, comprehensive test run, and preparation for delivery, ensuring the unit met performance and reliability standards.
KEY HIGHLIGHTS
- Discovery of extensive previous repairs, including metal stitching and sleeving
- Input bearing failure traced to oil starvation from blocked lubrication pipework
- Gear teeth damage identified, requiring MPI (Magnetic Particle Inspection) and crack detention
- Use of high-grade materials including EN24T and 4145 alloy steels for custom shafts
- High-precision engineering restored full functionality and extended gearbox lifespan
WHY CHOOSE HAYLEY 247 DEXIS?
HAYLEY 247 DEXIS was chosen for our rapid response, technical versality, and end-to-end service capabilities. Our team managed every aspect of the project – from inspection and diagnostics to manufacturing, assembly, and final testing – all under one roof. Our reputation for handling complex gearbox overhauls with precision and reliability made us the ideal partner for this high-value repair. With HAYLEY 247 DEXIS, clients gain peace of mind knowing critical industrial assets are in expect hands.
