The Situation
A David Brown 3-stage planetary gearbox, critical to marine capstan operations at a busy port, was showing significant signs of wear. Corrosion, worn components, and an obsolete motor had left the system unreliable and inefficient — threatening vital vessel handling operations.
With the gearbox playing an essential role in mooring and cargo handling, downtime was not an option. The client required a complete refurbishment, ensuring full mechanical integrity, compatibility with modern systems, and long-term reliability in a harsh marine environment.
The Solution
The HAYLEY 247 DEXIS engineering team undertook a comprehensive overhaul, combining precision restoration with modern upgrades. Upon inspection, the gearbox was found to have corroded surfaces and worn internal components, including a damaged output shaft seal journal and missing spacers. Our engineers set to work restoring the unit to peak condition through a series of specialist repair processes:
– Reclaimed the output shaft seal journal using metal spraying, restoring its original profile and sealing surface.
– Manufactured and installed new spacers and replaced worn bushes to ensure precise alignment and smooth operation
– Replaced the obsolete electric motor with a new, fully compatible unit – improving reliability and efficiency
– Shotblasted and painted the gearbox casing, drum and mounting plate to protect against corrosion and provide a high-quality finish
Each stage of the refurbishment was carried out to exact specifications, ensuring the gearbox met operational demands and modern performance standards.
The Result
The refurbished David Brown gearbox was returned to service looking and performing like new. Its restored mechanical integrity and upgraded motor deliver smoother, more reliable performance — essential for safe, efficient port operations. This project demonstrates HAYLEY 247 DEXIS capability in complex marine engineering refurbishments, combining mechanical expertise, precision machining, and rapid turnaround to keep critical operations moving. When reliability matters, HAYLEY 247 DEXIS delivers engineering solutions built to withstand even the toughest environments.
