Gearbox Repair Services

When you’re in need of industrial gearbox repair our experienced technicians are rapidly accessible and prepared to work with you to get your gearbox up and running in the shortest possible time.

EMX Industrial Repair can service any type of single-stage and multi-stage gearboxes, including worm, helical, or bevel helical geared. Once our expert staff has determined the extent of the work necessary, we provide a detailed quote for the restoration. We know how critical it is to get your equipment back in operation as quickly as possible. We’ll provide quality restoration at a fair price, as well as courteous service and quick turnarounds. Repairing an existing gearbox to a good as new standard, can cost considerably less than a replacement unit and can even reduce turnaround time. Our mechanical experience enables us to deliver proven gearbox repair for common gearbox brands, such as Falk, Hansen, Lufkin, Flender, and SEW.

If necessary, our team will work to minimize the costs associated with removing your gearbox from its application.

  • Repair of any type and brand of industrial gearbox
  • Shorter turnaround times and cost effectiveness
  • Root Cause failure analysis
  • Bringing your process back up to 100% operational availability in the shortest possible time

EMX Electro-Mechanical repairs and rebuilds gearboxes, reducers and gearmotors from various manufacturers and types:

  • Speed ReducersHelical-Gear-motor
  • Speed Increasers
  • Torque Arm Reducers
  • Mixers
  • Planetary Gearboxes
  • Variable Speed Gearboxes
  • Cooling Tower Drives
  • Gearmotors
  • Bevel Gear reducers
  • Torque Arms

Gearbox Repair

Incoming Inspection

EMX Motor Repair Shop performs a thorough appraisal of the gearbox condition, asimg_product3 received, to determine what specific repairs are needed as well as to find unsuspected trouble, perhaps unrelated to the obvious defect. Our technicians diagnose cause and effect to help prevent a recurrence. The gearbox may have been sent to our Repair Facility with limited external evidence as to the nature and location of trouble. What seems wrong may be correctable in several ways. Our appraisal will include a complete review of the following conditions of each part of the gearbox: General cleanliness, Cracked or broken welds or castings, Missing hardware, Wear or rub marks, including fretting, discoloration, charring, or other evidence of overheating , Looseness at mating fits, Corrosion, moisture, or oil leaking from the machine. Digital Photographs of any abnormal conditions found are part of the appraisal process and inspection report. Our Gearbox includes dissassembly, detailed inspections, and measurements to identify mechanical damage.

Incoming Tests

Prior to an incoming run test, we perform the following and record information where appropriate: Gearbox will be mechanically inspected to determine if shaft turns freely, Verify that bearings are lubricated, If conditions permit, the gearbox will be run at reduced speed initially. If the test is successful, Results are recorded, and then the gearbox will be run at full rated speed, if possible. The intent of the “As Received”, no load, run test is to get the gearbox operating safely up to top speed for bearing temperature, and vibration checks prior to dissassembly. If the “As Received” gearbox conditions permit, the gearbox shall be run to 100% speed for these tests.

Disassembly & Inspection

Before any disassembly is begun, parts will be marked (i.e., brackets, frame, covers, and brush holders). Brackets and bearings should be identified as pairs. Check and record rotor air gap.  Frame-mounted devices will be identified and recorded. Electrical wiring is recorded, sketched, and marked before disconnecting (for external connection).

Gearbox components & parts are thoroughly cleaned. Steam cleaning is the preferred method. Shafts will be checked for wear, cracks, scoring and straightness. (NEMA MG 1-2003 Rev.1-2004, Section 1, Part 4 Par. 4.11); cracks, corrosion; scoring or galling. Shaft extensions should be smooth, polished and concentric with the shaft center. Shaft extension dimensions and permissible runout will be checked and Diameter Tolerances for NEMA/IEC frame size machines compared. Keyseat/ Keyway Width Tolerances checked against NEMA/IEC Frame Size machines Tables. Keyseats will be true and Figure-4-Exploded-view-of-the-GRC-gearboxaccommodate keys to tap fit. If the shaft requires repair, worn surfaces can be restored within our Machine Shop to factory specification. Ball or Roller Bearings (Antifriction bearings) are comprehensively inspected for condition of lubricant; dirt, rust, or moisture; fretting corrosion; thermal discoloration; pitting or spalling of balls, rollers, or races; broken or missing retainers. Sleeve Bearings are checked to  be uniform in diameter, of proper fit in the housing, smooth internally and suitably grooved for adequate distribution of lubricant.  Bearing Housings and Shaft bearing fits are measured and compared to manufacturer’s specifications. Any fits that are not within tolerance are restored to original factory specification. Seals & Seal clearance are set to original equipment manufacturer’s specifications if available. Oils used will compatible with the customer’s lubricant Frame and Bearing Housings will be examined for defects; Corrosion; structural weld integrity; blocked drains, breathers, or ventilating air passages; paralleling of feet. Cracks and breaks are repaired and fits restored to manufacturer’s specifications.

Assembly

All mechanical repairs on shafts, bearing journals, end bells, and other equipment are handled in-house by experienced machinists. All Electric Motor assemblies are made in accordance with good machine shop practices. If the shaft requires replacement, a newbig_gears1 shaft will be made of A.I.S.I. 4140 Steel HRHT (Hot Rolled Heat Treated). Under special cases, shaft material will be replaced with 316 stainless or User approved material. Gearboxes will be assembled in a manner that will ensure proper fit and alignment. Ball and Roller Bearings are fitted to shafts by heat-expanding the inner bearing race in accordance with the bearing manufacturer’s recommendations, however, not to exceed 250°F, using an oil-bath heater or an induction heater. Check and record runout, endplay and backlash. All bolts, nuts, etc., will be replaced as required with SAE grade 5 or better and torqued to Industry standards. On metric fasteners we will use a grade 8.8 or better. All assembled components will be checked to ensure secure fits. All covers on openings in the frames or housings will be fastened in a closed position.

Final Testing

EMX also employs the most complete and thorough after-repair test procedures in the industry. We perform bench and system tests to ensure that every repaired gearbox will operate to factory specification. A written record of all tests and inspection results will be
furnished to the user upon completion of repairs.

Completed apparatus will be externally cleaned and painted to specification. Shaft extensions are treated to prevent corrosion.

Packaging and Transportation

Varitron-industrial-bevel-spiral-helical-gear-box-gearbox-HBAfter completion of the repair and testing, the machine will be packed in a manner
suitable for the form of transport to be used. Packing and transport will be as arranged with the customer. Oil-lubricated machines will be shipped without oil, and the need for lubricant clearly identified.

EMX is a Total Solution Provider. We can handle turnkey project management, from Design to Build to Installation to Ongoing Engineering Support and Maintenance.

 

 

EMX Gearbox Services

Precision Installation, Maintenance and Repair Service. Emergency Services are available 24 hours a day, 365 days a year.