GEAR BOX SPEED REDUCERS
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.
2. Repair Estimate:
A detailed report of the overall condition of the reducer including gears, shafts, housing & bearing bore areas will be inspected and if anything unusual is found during the inspection process, it will be noted on your report and quote supplied to you by your sales person.
The Proposal will also include A summary of the corrective repair work to be completed which always includes: replacement of all bearings, seals, gaskets & shims, along with our findings during the thoral inspection.
A timely delivery estimate is provided on a non-expedited bases.
A expedited Delivery is always available in A “BREAKDOWN” situation.
3. Repair Procedure:
- The reducer housing and all components are thoroughly stripped and degreased.
- 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, repaired back to O.E.M specifications.
- Gearing is magnafluxed and checked for cracks that are not visible.
- To ensure quality, our policy is to use only original manufacturer specifications.
- 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 Tested and prepared for shipping.
All speed reducers or assemblies will be:
- Completely disassembled.
- Hot Tank Stripped.
- Cleaned, wire brushed of all rust and grease.
- Inspected and/or tested as follows:
- 1. Measure all “fits” and compare with original drawing dimensions. Provide photographs and/or sketches for assembly.
- 2. Cases, housings, etc. – will be visually inspected for cracks and other signs of wear.
- 3. Shafts & Gearing – visually inspect and dimensionally checked, for possible reuse.
A detailed line by line quotation of all work required to recondition the assembly/speed reducer will be prepared and include:
- Listing of any new parts required.
- Summary of required procedures to return reusable parts to print specification.
- Summary of price for labor and all materials to complete the job.
You must approve repair prior to any work proceeding.
- MMR supplies you with a 18 month warranty when we have all the recommended repairs in our quote.
- If the job is not awarded MMR Inc. there will be no charge for the quotation.
MMR Repair Specifications:
- All fits will be returned to original size using either; plating, sleeving and/or welding and machining which ever way our engineering dept recommends at time of rebuild.
- Repair may be made by manufacturing or repairing the old existing shaft.
- Will be straight and finished in accordance with tolerances and finish specifications as indicated from the O.E.M
- New shafting provided will match the specifications the O.E.M
- Exposed threads, shaft ends and couplings will be protected with an anti-rust protection coating prior to shipping your Gear Box.
- Will be dimensionally inspected to customer prints, manufacturers’ prints, or reverse engineered.
- New gearing provided will meet or exceed the specifications and dimensions of the O.E.M
4. Cases, Housing, etc.
- Fits – All fits will be returned to original size and relative centers using either; sleeving and/or welding and machining as approved by the customer and the MMR engineering dept.
- All bolts, studs, pipe plugs, and other fittings will be removed and the holes re-tapped as necessary.
- Bolts, studs, and pipe fittings may be reused if they are in good condition.
- Replacement bolts, studs, and pipe fittings will be of equivalent grade and material unless otherwise specified.
- Customer must approve any print modifications prior to implementation.
5. Assembly and Test Procedures
- All seals, shims, and gaskets will be replaced.
- All bearings will be replaced.
- All hardware will be reused or replaced depending upon condition.
- All repaired and overhauled units will be run tested to check contact patterns, clearances, backlash, and freedom of movement.
- When pressure lubricated units are involved, QRS will pressure test the unit when applicable.
6. Painting and Identification
All speed reducers will have:
- Exterior surfaces cleaned of all loose scale and rust.
- Entire Housing surfaces cleaned of all dirt and oil.
- One coat of light blue enamel applied on the exterior, unless otherwise specified by the customer.
- A new identification tag will be installed to each overhauled speed reducer with the following information:
- 1. Date overhauled
- 2. Our job number
- All openings are properly protected with plugs or cover.
- All units are shipped dry from MMR The unit shall be marked to indicate that lubricant must be added prior to operation.
Run Test Procedure:
- 1. Firmly mount gearbox to be tested to run test stand.
- 2. Fill the unit with oil.
- 3. Attach the oil pumping station to the unit if required.
- 4. Hook up all run test equipment.
- 5. Check and document temperature.
- 6. Start test motor and set variable RPM to the gearbox requirements.
- 7. Attach gearbox to test motor and record decibel reading during run test.
- 8. Check all sealed areas for any oil leakage.
- 9. Gearbox bearing temperature will be checked and documented at several intervals during testing.
- 10. Vibration and other nondestructive testing per customer requirements are available.