IE S018INSPECTION REPORTS OF 2002 AND 2003
TRKP and EUK-160-1M drives: tooth grew back without teardown and still holds 18 months later
Gear teeth built up, chipped spots closed, bearings and splines ran on without replacement. 0.25–0.30 mm — tooth thickness at 2.24 mm depth, 3.70–3.90 → 4.00–4.10 mm; 2.1–3.0× — service life of TRKP gearbox bearings, 6–7 → 14–18 months; 1.8–2.6× — service life of cardan shaft splined joints, 7–8 → 18 months (2002–2003).
with signatures and stamps
What repeated across the whole sample
| REPORT DATE | OBJECTS MEASURED | TIME AFTER TREATMENT | WHAT WAS MEASURED |
|---|---|---|---|
| 22.10.2002 | 40 TRKP gearboxes with factory numbers, cars of the LVChD-3 assigned fleet | 350–400 h of operation | Tooth thickness of gear wheel and pinion, surface condition |
| 04.12.2003 | The same 40 TRKP gearboxes; EUK-160-1M drives, bearings, splined joints, MAV couplings | 1 year 1 month – 1 year 6 months | Tooth thickness, condition of surfaces and backlash, service life of units |
Tooth thickness of gear wheel and pinion — 40 control TRKP gearboxes
| STAGE | TOOTH THICKNESS AT 2.24 MM DEPTH | COATING BUILD-UP |
|---|---|---|
| Before treatment, May–July 2002 | 3.70–3.90 mm | initial condition |
| Operating time 350–400 h, report 22.10.2002 | 4.00–4.10 mm | +0.25 mm on average, 0.10–0.40 mm across gearboxes |
| Service 1–1.5 years, report 04.12.2003 | thickness held, no tooth wear found | +0.30 mm on average |
Measured per the Repair Rules at 2.24 mm depth from the tooth tip: drawing size 4.15 mm, reject limit 3.66 mm. Build-up obtained on all forty gearboxes.
Service life of drive units in operation
| UNIT | BEFORE TREATMENT | AFTER TREATMENT |
|---|---|---|
| Bearings No. 32311 and No. 309 of the TRKP drive gearbox | seizure after 6–7 months — the main cause of drive failure | 1.2–1.5 years in service without replacement, condition serviceable |
| Splined joints of the cardan shaft of the EUK-160-1M drive | wear, spalling and fracture of splines after 7–8 months | not a single failure over the whole observation period |
| Bearings No. 216 and No. 116 of the MAV clutch coupling | seizure — the main cause of drive failure | not a single failure over 1.5 years of service |
| Teeth of the bevel gearbox of the EUK-160-1M drive | tooth fractures were recorded by the depot | no fractures registered in 1.5 years after treatment |
Service lives of the units — from the failure statistics of the Odesa-Glavnaya depot. Per the conclusion of the report of 04.12.2003, the service life of these units grew about 3×.
Condition of the units at inspection
| WHAT WAS INSPECTED | BEFORE TREATMENT | AT THE CONTROL INSPECTION |
|---|---|---|
| Working surfaces of gear wheel and pinion teeth | chipping, pitting, scoring, scratches | smooth, free of chipping and scoring, covered with a thin metal-ceramic layer |
| Tooth roots and chipped areas | open defects of the working surface | filled in, contact area of the gear wheels increased |
| Backlash in bearings and splined joints | found | absent, bearings fully serviceable |
The inspection was carried out by the depot commission — before treatment and again on 01–03.12.2003, together with the control measurements.
Findings of the depot commission
Current equivalent
- Revitalizant gel for gearboxesGearboxes · transmissions · gear drives
- Revitalizant gel for compressors and bearingsCompressors · bearings · spindles
How such units are treated:
About this result:
Limits of this report: The results apply to the gearboxes and drive units of undercar generator drives of the TRKP and EUK-160-1M types on passenger cars of the Odesa-Glavnaya depot; with other units and operating modes the figures may differ. The treatment was performed by an official dealer of the XADO concern — Pridneprovskaya Transportnaya Kompaniya LLC.