The Situation
A Morgan Worcester 3-stage high-speed increaser gearbox arrived at our facility in a partially stripped condition, exhibiting significant wear across several critical components. Detailed inspection revealed oversize bearing housings, heavily worn input and output shaft journals, and extensive damage to the 72T lower output helical wheel. To restore reliability and performance, the gearbox required a comprehensive refurbishment and component replacement programme.
The Solution
Our engineering team carried out a complete overhaul and restoration of the gearbox, addressing all areas of wear and damage.
Key works included:
– Machining and sleeving all six bearing housings to restore correct tolerances
– Manufacturing a new EN24T input shaft to replace the worn original component
– Supplying and fitting a hardened, gear-ground replacement 72T lower output helical wheel
– Replacing lubrication pipework to ensure reliable oil distribution throughout the gearbox
– Refurbishing internal components where appropriate
– Preparing the gearbox casing through shot blasting and application of a protective coating
– Completing a full rebuild and testing programme to verify performance and reliability
All work was completed in accordance with strict engineering standards to ensure long-term operational integrity.
The Result
The gearbox was successfully rebuilt, tested, and returned to site ready for service. By restoring critical tolerances, replacing damaged components, and refurbishing key assemblies, we extended the operational life of the unit and returned it to reliable working condition. The completed refurbishment provided a cost-effective alternative to replacement while ensuring dependable performance for the customer’s ongoing operations.
