MEC/Mechanical/TBT-MEC-009

Gearbox and Coupling Installation

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Gearboxes and couplings connect motors to driven equipment including pumps, conveyors, and mixers.
Gearboxes are heavy precision assemblies; a typical industrial unit weighs from 100kg to several tonnes.
Coupling alignment between the motor and gearbox shafts must be within thousandths of a millimetre.
Misalignment causes vibration, premature bearing failure, and coupling destruction within weeks of operation.
Lifting gearboxes requires rated slings positioned at the designated lifting points to prevent tilting.
Coupling guards must be fitted before any rotating trial or commissioning takes place.
Oil-filled gearboxes must be filled to the correct level with the specified lubricant grade.
Shaft keys, keyways, and taper locks must be correctly fitted to transmit torque without slipping.
LOTO isolation of all energy sources is required before starting any gearbox or coupling work.
PUWER 1998 and LOLER 1998 apply to gearbox installation, lifting, and guarding requirements.

Entanglement	Exposed couplings and shafts rotating at speed catch clothing, hair, and hands, causing fatal entanglement injuries.
Crush injuries	Heavy gearboxes dropped during lifting or tilting from incorrect sling positions crush workers underneath.
Equipment damage	Poor alignment and incorrect oil fill destroy gearboxes within weeks, causing costly shutdowns and replacement.

Don't

Lift gearboxes using rated slings at the manufacturer designated lifting points only.
Align the motor and gearbox shafts using laser alignment to the specified tolerance.
Fit coupling guards before any rotation test or commissioning takes place.
Fill gearboxes to the correct level with the specified lubricant grade.
Confirm LOTO isolation of all energy sources before starting installation work.
Fit shaft keys, keyways, and taper locks correctly to the torque specification.
Check coupling alignment again after the system has been run and reached temperature.
Brief the installation team on the lifting method and alignment requirements.
Record alignment readings and oil fill details for the maintenance handover.
Inspect coupling elements for wear and damage before fitting to the shafts.

DON'T lift gearboxes from points other than the designated lifting lugs.
DON'T run the motor or driven equipment with coupling guards removed.
DON'T energise the system without confirming shaft alignment is within tolerance.
DON'T fill gearboxes with the wrong oil grade or to an incorrect level.
DON'T work on couplings or gearboxes without confirmed LOTO isolation.
DON'T force misaligned shafts together; correct the alignment before coupling.
DON'T use worn or damaged coupling elements; replace them with new components.
DON'T skip the hot alignment check after the first run at operating temperature.
DON'T leave shaft keys loose; they must be fully engaged before tightening locks.
DON'T attempt to manually move heavy gearboxes without mechanical lifting aids.

See also: MEICA Safety Awareness | Pump Installation and Alignment

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