Testing
End of Line Gearbox Testing - Hyster-Yale
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Project overview
A global manufacturer in the materials handling sector required a turnkey end-of-line (EOL) gearbox testing solution to support their New Product Introduction (NPI) programme. The goal was to bring gearbox manufacturing in-house and ensure every unit was fully validated before installation into forklift trucks such as the Hyster H1.6–2.0A.
The requirement was clear: develop a 100% end-of-line gearbox test system capable of identifying faults before assembly into the truck – eliminating costly strip-downs and gearbox swaps that would otherwise require many hours of labour.
Project Goals:
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Deliver right-first-time gearboxes
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Prevent costly rework after gearbox installation into the truck
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Provide secure, production-ready test control
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Ensure 100% functional validation before vehicle assembly
the solution
Incotech delivered a fully bespoke, PLC-controlled end-of-line gearbox test system engineered for secure, repeatable production use.
The machine integrates pressure, speed, clutch fill, torque, and valve testing, alongside controlled oil heating and advanced particle counting for cleanliness verification. Automatic spline engagement and multi-stage filtration ensure reliable operation.
Built under ISO 9001 standards, the system was remotely accepted during COVID restrictions, installed in Northern Ireland, and commissioned with full training. Ongoing technical support continues as production develops.
Core Technologies Integrated
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PLC control system
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PWM valve control
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Heating oil system for temperature stabilisation
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Pressure testing
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Speed testing
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Clutch fill time measurement
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Input drive torque measurement
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Automatic spline engagement for input drive
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Multi-stage oil filtration
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State-of-the-art oil particle counting for oil cleanliness
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Full data acquisition and traceability
Key Benefits
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Early Fault Detection: Gearbox defects are identified before installation into the forklift truck, preventing costly strip-down and replacement.
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Production Confidence: 100% end-of-line validation ensures every gearbox meets performance criteria.
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Secure & Robust Control: PLC-based architecture prevents unauthorised changes and ensures repeatability.
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Advanced Diagnostics: Integrated torque, pressure, speed, clutch timing, and oil cleanliness testing provides comprehensive performance insight.
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True Turnkey Delivery: From specification refinement to commissioning and training—even during a global pandemic.
SEE WHAT OUR CUSTOMERS THINK
"Working with Incotech Ltd has been consistently positive. Their professionalism, flexible scheduling, and adaptability make collaboration seamless. As a trusted HYMH partner, their technical expertise, customer service, and teamwork set them apart in the testing equipment field. I highly recommend them to any organization seeking reliable engineering solutions and support."
DARREN FLETT: SYSTEMS LEAD, DRIVE TRAIN
‘I just wanted to send you a message to thank all at Incotech for their support and dedication to the leak test fixture that you have delivered against our very difficult timing plans. The customer was very pleased with the fixture that you produced and we had good feedback on our process. Once again thank you all at Incotech for their hard work on this.’
MARC PIDGEON - COMMODITY BUYER
‘I want to personally thank you all for your efforts and the work that has been completed both on the test stand design, implementing the great changes to the current rig design process, the validation of the test stand, both within India, and the UK. As well as the smooth transport and installation in India.’
‘I just wanted to thank you very much for the excellent response to our ‘plea for help’. Your swift response to repair our Middlemarch Dyno, meant we were able to carry out some extra testing for our crucial customer deadline on a Friday evening. This made a huge difference to the data we submitted and I am very grateful for your support to achieve this.’
MIKE DOWSETT - SENIOR MANAGER
‘Incotech is known to us as a very well experienced engineering company providing hi-tech special purpose machinery and test equipment. They were engaged in the design and manufacture of highly sophisticated electrical and hydraulic test rigs for our domestic and commercial water products. We are very pleased with the final result and thank their dedicated team with their client oriented approaches and transparent technical practices.’
NURCAN SIPAHI - MANUFACTURING ENGINEER