Gearbox Overhaul and
Repair Procedures

Every assembly undergoes our rigorous 7-step repair procedure.

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QRS Standard Overhaul and
Repair Procedures and Practices

QRS General Mechanical Repair Specifications

1. 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:
    • Measure all "fits" and compare with original drawing dimensions. Provide photographs and/or sketches for assembly.
    • Cases, housings, etc. - will be visually inspected for cracks and other signs of wear.
    • Shafts & Gearing - visually inspect and dimensionally checked, for possible reuse.

2. 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.

3. You must approve repair prior to any work proceeding.

  • QRS will give a one-year warranty when we have replaced all parts, bearings, and seals as recommended in our quote.
  • If the job is not awarded to QRS, compensation for disassembly labor, cleaning, inspection, and freight will be made to Quality Reducer Service, Inc.

QRS Repair Specifications:

1. Fits

  • All fits will be returned to original size and relative centers using either; plating, sleeving and/or welding and machining as approved by the customer.

2. Shafting

  • Repair may be made by plating and grinding, or machining and sleeving.
  • Will be straight and finished in accordance with tolerances and finish specifications as indicated on appropriate drawings.
  • New shafting provided will match the specifications and dimensions of the original part as per customer print.
  • Exposed threads, shaft ends and couplings will be protected with an anti-rust protection coating prior to shipping your Gear Box.

3. Gearing

  • Will be dimensionally inspected to customer prints, manufacturers' prints, or reverse engineered. See attached literature from our gear manufacturing facility, Circle Gear, Inc.
  • New gearing provided will meet or exceed the specifications and dimensions of the original parts as per customer print.
  • QRS has a direct affiliation with Circle Gear and Machine Company.

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
  • 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 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:

      • Date overhauled
      • Our job number
      • Your purchase order number

7. Shipment

  • All openings are properly protected with plugs or cover.
  • All units are shipped dry from QRS 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 QRS Company run test lubricant.
  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.