Repair & Renew

If Falk made it new, Falk Renew can make it NEW AGAIN! If Falk built it, Falk Renew can rebuild it! Or repair, replace, or restore it. All to original specifications. All for much less than the cost of a new unit. All complete with a 1 YEAR WARRANTY!

• Mar-Dustrial has experience repairing many different makes, including:
  Dodge, Farrell, Foote-Jones, Hansen, Lightnin, Philadelphia and Western.
• Falk Renew can repair damaged assemblies, replace worn parts, restore all the original Falk designed-in, built-in power and precision. Falk Renew can recondition your Falk equipment for "as new" performance and productivity.
• Immediate availability of original sales, engineering, and production data allows Falk Renew to respond to inquiries promptly, permits Falk Renew to rebuild worn Falk equipment with minimum re-engineering and maximum shop economy.
• A Falk Renew rebuild will put your equipment back on line quickly and save you both time and money. Your Falk equipment is critical to your operation; it's just as critical that you have Falk Renew attend to your repair or rebuild needs. Please contact us with questions. Request Falk bulletin 921001B for more information.

Customer Service

Providing customers with personalized service is Mar-Dustrial's main goal. We understand many of your speed reducers are in critical applications that you can not afford to be without. Mar-Dustrial processes rush jobs 24 hours a day - 7 days a week. For example; Saturday evening rolls around and a critical application fails on your night crew. Instead of waiting until Monday morning, call Mar-Dustrial and the person on call will help you arrange shipping that night. A crew of our mechanics will meet your reducer when it arrives at our shop. They will work around the clock until it is repaired. If we're not waiting on parts, we can often times get the reducer back in 24 hours. Whatever the case, you can relax knowing Mar-Dustrial will do whatever it takes to get you up and running as soon as humanly possible. You will never have to wait until we open on Monday!

The Crew

Experienced, professional, factory trained mechanics and machinists enable Mar-Dustrial to repair your gearbox right the first time, every time. Regardless of make and model, our repair facility has over 100 years experience repairing speed reducers of almost all manufacturers.

The Shop

Mar-Dustrial has a complete machine shop designed and equipped for the sole purpose of repairing speed reducers. A high pressure steam room allows us to thoroughly clean all the speed reducers we repair prior to inspection. Lathes, both large and small, allow us to manufacture parts, like shafts, from factory drawings when they are not available from the OEM. A large capacity boring mill allows us to repair even the largest housings with spun bearing bores that would otherwise have to be replaced, making these types of repairs uneconomical. When necessary, we can perform vibration analysis of a repaired speed reducer to give our customers a benchmark of performance before it is put into service. A fully adjustable test bench allows us to "Spin Test" the reducers after repair.

The Inventory

Mar-Dustrial stocks the largest inventory of surplus Falk parts in the industry. Seen here are pictures of inventory in our Portland warehouse. We also maintain an off-site warehouse full of housings and complete speed reducers. When we purchase surplus speed reducers, new or used, we thoroughly clean, inspect, and inventory them. Often times we “part out” these speed reducers, scrap the worn parts and inventory the good parts. This not only allows us to have the parts we need in stock, but also helps to keep the cost down on repairs. We will always show cost savings for using surplus parts versus new parts on the repair estimate.

The Process

1. Reducer Inspection:

Inspection Report: Each speed reducer received is tagged with a job number, and undergoes a thorough inspection. The inspection report includes details on the customers application such as equipment or stores numbers, possible reasons for failure (i.e. jammed conveyor), and any special customer requests. The inspection report covers reducer details such as name tag data, manufacturer data, mounted accessories, and reducer history.

Steam Cleaning: The reducer exterior is cleaned of all contaminates prior to disassembly, ensuring any contaminates found inside the reducer can be used to help determine the cause of failure.

Disassembly: The reducer is completely disassembled, including removal of bearings, seals, shims & gaskets and any accessories such as coupling hubs, fans, oil pumps, or cooler assemblies.

Determine cause of failure: All bearings, seals, gearing, shaft seal areas and key ways are inspected for excessive wear patterns. Oil troughs and passageways are inspected for contamination. Housing measurements are taken to determine whether bearing bore tolerances are within factory specifications.

2. Repair Estimate:

Condition report: A summary of the overall condition of the reducer including gear teeth wear, shaft wear, housing bearing bore tolerances, and anything unusual found during the inspection process.

Failure Analysis: A brief report listing any possible causes found which may have contributed to the reducer failure. If curative measures are known they are listed for review.

Proposal: A summary of the corrective repair work to be completed which always includes stripping and degreasing, replacement of all bearings, seals, shims, and gaskets. A timely delivery estimate is provided on a non-overtime basis. Delivery may be improved in a “BREAKDOWN” situation.

3. Repair Procedure:

• The reducer housing and all components are thoroughly stripped and degreased. The housing is stripped of all paint and contaminates using a “Hot Tank” process.
• 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.
• To ensure quality, our policy is to use only original manufacturer parts.
• 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 has experience repairing reducers from most manufacturers, including:

Abort Alten Baldor Beloit Black Clawson Boston Brevini Browning Burhans-Sharpe Chemineer Cleveland Cone Drive D.O. James David Brown Delroyd Dodge Dorris Durst Eimco Electra Elliot Enviro Fairfield Falk Farrell Flender Foote-Jones Gloucester

Grant Gryrol Hamilton Hansen Holroyd Horsburg & Scott Hub City Jeffery Johnson Koellmann Leroy Sumer Lightnin Link Belt Litton Lufkin Marland Marley Milwaukee Mitsubishi Monarch Morse Nord Nuttall Ohio Pacific Western Philadelphia PT Tech Radicon

Reliance Renold Reuland Rexnord Rotex S-A Santasalo Sew-EuroDrive Shimpo SKK SM-Cyclo Sprout Sterling Straightline Svedala Twin Disc U.S. Varidrive Val-Met Vari-Master Vogel Voith Morden Westech Western Westinghouse WGW Winsmith