Any industrial equipment with moving parts will wear out and need replacement over time. In a high-volume industry, replacing worn parts can be a costly and time-consuming venture. However when it comes to power transmission equipment, worn-out parts can often be restored or rebuilt like new, for a fraction of the cost of replacing them.
For example, worn or damaged gearboxes and speed reducers of any make or model can generally be restored to working condition at a factory-authorized Falk Renew facility — often within 24 hours.
Here’s a look at how this process works:
STEP 1: Inspection
Each speed reducer is steam cleaned to remove any contaminates before disassembly, so any contaminates found within the reducer can be used to help determine why the product failed. The reducer is then entirely taken apart. All bearings, seals, shims and gaskets are removed, as well as any accessories such as fans, coupling hubs or oil pumps.
The parts are then examined to determine the cause of failure. This process includes:
- Inspecting bearings, seals, gearing and shaft seal areas for unusual or excessive wear patterns.
- Checking oil troughs and passageways for contamination.
- Taking housing measurements to find out whether bearing bore tolerances comply with factory specifications.
STEP 2: Repair Estimate
A full report is then issued, detailing the reducer’s overall condition and offering an analysis of potential causes for the failure. A list of curative measures, if known, is also supplied. Finally, the report includes a summary of the repair work needed, along with an time estimate for completion and delivery.
STEP 3: Reducer Repairs
Once all components of the reducer have been inspected, the unit is carefully cleaned and reassembled, using replacements for any worn or damaged parts. All reassembly occurs in a clean environment, and the reducer is thoroughly tested before it is returned.
Also included in the repair process:
- The housing and all components of the reducer are stripped and degreased. Paint and contaminates are removed from the housing via a “hot tank” process.
- Oil troughs and passageways are cleaned and checked to ensure unobstructed flow.
- Shaft seal areas are examined, and if necessary, are chromed and ground to factory tolerances.
- Gearing is tested to reveal any invisible cracks.
- All bearings, seals, shims and gaskets are replaced using parts from the original manufacturer.
- The reducer is reassembled to factory specifications, with all clearances, bearing floats or pre-loads set.
- The housing is repainted. For harsh environments, epoxy paint can be used.
Because the Falk Renew program requires factory-trained mechanics working in a high-quality environment, there are only a handful of authorized facilities in the United States. To learn more about Falk Renew, contact Mar-Dustrial.
Posted under Products/Services on Wednesday, January 19th, 2011