Air Preheater Gearboxes

Corporate Organization Chart

The Marmon Group Railway Equipment & Services Group
Penn Machine Company Johnstown, PA

Midwest Gear Twinsburg, OH

Penn Locomotive Gear Blairsville, PA

Rail Trans Division Blairsville, PA

The Marmon Group is an international association of more than 100 autonomous manufacturing & service companies, based in Chicago, IL

The Marmon Group 2003

Today, The Marmon Group comprises more than 100 member companies that operate approximately 550 facilities in more than 40 countries and employ about 35,000 people. Forbes places The Marmon Group at 20th on its list of the largest privately held companies in the United States. In 2003, member companies completed more than 30 acquisitions with a total investment of about $300 million. In most cases, the acquisitions complimented existing businesses, including wire and cable, medical products, water treatment, retail store displays and industrial materials. Member companies also built or expanded more than 20 new factories, offices or distribution centers during the year. While the member companies operate independently, a small professional organization in Chicago, Illinois - The Marmon Group, Inc. manages and invests the member companies financial resources and advises them on accounting, tax, finance, legal, regulatory, real estate and other matters.

History
1920 - Company founded as the Penn Smokeless Coal Company 1960 - Began to diversify
Steel/General Industry Transportation

1965 - Bought manufacturing rights to PCC Resilient Wheels 1989 - Purchased Midwest Gear Company 1994 - Rail Trans Division (Gearbox Repair) established 1995 - Marmon Group purchases National Mine Service 1998 - Penn Machine purchases Winchester Tool and Machine 2002 - Rail Trans Division relocated to new 50,000 sq. ft. facility in Blairsville, Pennsylvania

Midwest Gear
Midwest Gear was founded in 1972 in Twinsburg, Ohio. Since then we have been manufacturing high quality products for both large and small manufacturers in a wide variety of industries including Steel, Automotive, Agriculture, Forestry, Paper, Construction, Packaging, Transportation and Strip and Underground Mining. We can produce a wide range of custom gear products including pinions, sprockets, pinion shafts and wheels as well as providing precision gear grinding and cut teeth subcontracting.

Our modern manufacturing plant of 27,000 square feet is conveniently located on Route 82 just minutes from the Ohio Turnpike (I-80) and near routes I-271 and I-480.

Penn Machine Company

Rail Trans Division Industrial Repair

Gear Box Manufacturing and Repair Facility Opened May 2002

Gearbox Manufacturing & Repair

Penn Machine Gearbox Customer List

ALSTOM / Air Preheater Company Wellsville, NY AK Steel Middletown, OH Washington Metro Area Transit Authority Washington, DC Commonwealth Aluminum Lewisport, KY Chicago METRO Chicago, IL

Wise Metals Muscle Shoals, AL Melroe Corporation / Bobcat Division Bismarck, ND Cotta Transmission Rockford, IL Baltimore Mass Transit Authority Baltimore, MD Alstom Transportation, Inc. Hornell, NY

Gearbox Manufacturing & Repair

Penn Machine Company manufactures industrial gearboxes to customer furnished drawings and specifications. We also rebuild and repair used gearboxes to like new or upgraded condition. With 75 years of gear engineering experience and our ability to manufacture gears up to AGMA Quality Class 12, we fully warranty performance of all our products. Product range:
Parallel Shaft Drives Right Angle Worm Drives Right Angle Bevel Drives Planetary Drives Concentric Drives

All gearboxes, whether new or rebuilt are run-tested using the latest vibration analysis equipment at the rated RPM. All gearboxes received for remanufacture are first cleaned, disassembled and inspected. The customer is provided a written failure analysis and a detailed quotation for necessary repairs. All repairs are to be per customer review and approval.

Gearbox Manufacturing and Repair

Right angle spiral bevel drive for a steel mill continuous caster

Overhead crane trolley drive

OVERHAUL AND REPAIR PROCEDURES AND PRACTICES FOR SPEED REDUCERS AND ASSEMBLIES GENERAL MECHANICAL REPAIR SPECIFICATIONS 1. All speed reducers shall be: A. Have housings sandblasted and primed (for purposes of inspecting housing for cracks) B. Dismantled completely C. Cleaned free of all rust and grease D. Inspected and / or tested as follows: Measure all "fits" and compare with original drawing dimensions. Provide sketches for assembly. (2) Cases, housings, etc. - will be visually inspected for cracks and other signs of wear. (3) Shaft Gearing - visually inspect and dimensionally checked, for possible reuse. A report of work required to recondition the assembly / speed reducer shall be prepared which shall include: A. Listing of new parts required B. Summary of required reconditioning to return reusable parts to print specification C. Summary of price for labor and all materials to complete the job Customer is to approve repair prior to any work proceeding. A. Penn Machine Company will give a one-year warranty when we have replaced all parts, bearings, and seals as recommended in our quote. If the job is not awarded to Penn Machine Company, compensation for disassembly labor, cleaning, inspection, and freight will be made to Penn Machine Company. (1)

2.

3.

REPAIR SPECIFICATIONS A. Fits (1) All fits shall be returned to original size and relative centers using either; plating, sleeving and / or welding as approved by the customer. Shafting (1) Repair may be by plating and grinding or sleeving and machining. (2) Shall be straight and finished in accordance with tolerances and finish specifications as indicated on appropriate drawings. (3) New shafting provided shall match the specifications and dimensions of the original part as per customer print. (4) Exposed threads and shaft ends will be protected with at least one layer of cardboard or similar material, held firmly in place with tape. Gearing (1) Will be dimensionally inspected to customer prints. (2) New gearing provided shall match the specifications and dimensions of the original parts as per customer print. Cases, Housing, etc. (1) Fits - See 4-a. above. (2) All bolts, studs, pipe plugs, and other fittings shall be removed and the holes re-tapped as necessary. (3) Bolts, studs, and pipefittings may be reused if in good condition. (4) Replacement bolts, studs, and pipe fittings shall be of equivalent grade and material unless otherwise specified. All print modifications must be approved by customer prior to implementation.

B.

C.

D.

E.

ASSEMBLY AND TEST SPECIFICATIONS A.

B. C. D. E. All seals and gaskets will be replaced. All bearings will be replaced. All speed reducer overhauls and repairs shall be run tested to check freedom of movement clearances, contact patterns, and backlash. Where pressure lubricated units are involved, the assembly shall be pressure tested where applicable. Painting and Identification 1. All speed reducers will have: (a) Exterior surfaces cleaned of all loose scale and rust. (b) Exterior surfaces will have one coat of Red Oxide Primer applied followed by one coat of industrial Grey enamel unless otherwise specified by the customer. (c) A new identification tag will be installed to each overhauled speed reducer with the following information: 1. Date overhauled 2. Serial number 3. Ratio Shipment 1. All openings are to be properly protected with plugs or covers. The unit shall be marked to indicate that lubricant must be added prior to operation.

F.
G.

PENN MACHINE COMPANY RUN TEST PROCEDURE

1. Firmly mount gearbox to be tested to run test stand.

2.
3. 4. 5. 6. 7. 8. 9.

Fill the unit with Penn Machine Company run test lubricant.
Attach the oil pumping station to the unit if required. Hook up all run test equipment including vibration analysis monitor. Check plant noise level with decibel meter. Start test motor and set variable RPM to the gearbox requirements. Check test motor noise level with decibel meter. Attach gearbox to test motor and record decibel reading during run test. Check all gearbox sealed areas for any oil leakage.

10. Record vibration analysis data and gearbox bearing temperature after one hour of testing.

Overhaul Procedures
The overhaul process begins with a visual inspection of the exterior of the unit (noting any abnormalities) If equipped with an overrunning clutch, the rotation of the input shaft is checked and noted for reassembly purposes

Sandblasting
All Air Preheater gearbox housings are sandblasted in order to visually check for cracks and abnormalities.

Disassembly
The next step is the disassembly of the gearbox.

Inspection
A visual inspection of the gearing is done at this time to determine if it is suitable to be subjected to the NDT to qualify it for reuse

Cleaning
The next process is to clean the housing and all components so they are free from dirt, grease, and oil residue Several different measures are employed to achieve this result

Cleaning
In cases where there is an abundance of grease and oil, the gear case is first cleaned in a solvent parts washer to remove the majority of the contamination

Cleaning
From the solvent parts washer, the unit is then placed in a water based, heated, high pressure cleaning tank to remove the remainder of the residue

Cleaning
The result of this process is a clean housing both inside and out Additional cleaning is also done to components with a wire wheel, surface conditioning pad and other hand tools to achieve the desired results

Mag Particle Testing

All shafts and gearing that have passed visual inspection are now checked for cracks with a MagnaFlux tester

Dimensional Testing
All shaft fits and gear and housing bores are dimensionally checked against manufacturers specifications

Quotation
Determinations have been made to all components. A quotation and report is sent to the customer for approval to proceed with the repair.

Assembly
All overhauls include new bearings, seals, shims, gaskets, fasteners and where applicable overrunning clutch

Setting Pinion Depth

The first step in the assembly process is to set the spiral bevel pinion depth to the specifications for the particular gear set This setting achieves the proper contact pattern on the gear set Pinion depth is set to OEM specification

Backlash Setting
Next the proper shims are determined to achieve the correct backlash for the spiral bevel gear set Measurements are taken at the pitch line diameter

Assembly
The remainder of the gearing is installed into the housing and covers are installed A special fixture is used to ensure the change gear cover is properly positioned for seal alignment This cover is then drilled and doweled in place so alignment can be maintained during future repairs

Run Test
Upon completion of assembly, the gearbox is then taken to the run test area It is subjected to a one hour run test to check for noise, heat, vibration and leaks

Painting
After a successful run test the unit is taken to the paint booth It is then sprayed with an industrial grade epoxy primer

Identification
An AGMA name plate is installed on the gearbox with all pertinent information regarding ratio, horsepower, capacities, serial number, date of manufacture, speed and lubrication

Shipping
The unit is then carefully prepared for shipping

Quality Assurance
The quality of a gearbox begins with engineering. Although the majority of our business has been engineered by our customer we do have our own engineering capabilities and experienced gear engineers that review all drawings before manufacturing.

All inspection records are maintained and can be provided to the customer upon request. In addition, the calibration of machines, checking, testing and measuring equipment is performed on a strict schedule and fully documented.