Gearbox Repair Process

As a certified Falk RENEW facility, we take a meticulous approach to gearbox repair. Don’t let our fast turnaround fool you – we leave no stone unturned when inspecting and preparing your speed reducer for reassembly. Not only will we recondition your unit to operate at its peak performance level, but we’ll gather as much information as we can about why it failed.

STEP 1: Speed Reducer Inspection

Our Falk RENEW technicians thoroughly inspect and clean every speed reducer we repair. On your unit’s arrival, we’ll compile an inspection report that includes all of the information you provide – such as details about the application, possible reasons for failure and any special requests you have – as well as relevant manufacturer data.

Steam cleaning: Before disassembling your reducer, we’ll clean its exterior of all contaminants to ensure that any found inside the reducer can be used to help determine the cause of failure.

Disassembly: Next, we’ll take apart the entire reducer, which entails removing all bearings, seals, shims and gaskets, along with any accessories such as coupling hubs, fans, oil pumps or cooler assemblies.

Determine cause of failure: To help us understand why the unit failed, we’ll inspect all bearings, seals, gearing, shaft seal areas and key ways for excessive wear patterns. We’ll also examine oil troughs and passageways for contamination and take housing measurements to determine whether bearing bore tolerances are within factory specifications.

STEP 2: Speed Reducer Repair Estimate

Once the reducer has been carefully inspected, we’ll present you with an estimate before performing any gearbox repairs. This includes a summary of the unit’s overall condition; a failure analysis; and a proposal detailing the repair work needed.

Condition report: We’ll note anything unusual we found during the inspection, such as gear teeth wear, shaft wear and housing bearing bore tolerances.

Failure analysis: Possible causes of failure will be reported here, along with a list of known curative measures.

Proposal: Our gearbox repair proposal will summarize the work required to return your reducer to like-new condition. This always includes the stripping and degreasing of all components and the replacement of all bearings, seals, shims and gaskets. We’ll also offer a timely delivery estimate on a non-overtime basis (although delivery time may be improved in breakdown situations).

STEP 3: Speed Reducer Repair Procedure

To ensure the quality of our gearbox repairs, our policy is to use only original manufacturer parts. We begin by thoroughly stripping and degreasing the reducer housing and all components. The housing is stripped of paint and contaminants via a hot tank process. Then the reassembly process begins:

• Oil troughs and passageways are cleaned and checked for unobstructed flow. All components are checked for condition prior to installation.
• Shaft seal surfaces are examined and, if necessary, chromed and ground to factory tolerances.
• Gearing is magnafluxed to check for cracks that are not visible.
• All-new bearings, seals, shims and gaskets are installed.
• The reducer is assembled in a clean environment to factory specifications. All clearances, bearing floats or pre-loads are carefully set.
• Reducers are painted upon completion. Special epoxy paint is available for harsh environments.

Mar-Dustrial’s Falk RENEW facility has experience repairing reducers from most manufacturers, including: