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Falk Gearbox Rebuild Case Study (Model 525)

When a Falk gearbox fails, GearWorld Is here 24/7 for any Emergency situation. We get you up and running fast to Reduce Your Down-Time. GearWorld does not apply a band-aid solution, we diagnose and repair the actual problem to meet or exceed OEM specs.
This case study review of our work was sent to us from a Prominent US powerstation client.
CLICK TO READ THIS CASE STUDY:
Industrial Gearbox Reducer Rebuild

Having two ISO certified facilities in Illinois, and one Texas, makes our shops highly accessible and available to your operation. Repairing an existing Falk industrial gearbox is a faster and more cost-effective solution than purchasing a new replacement Falk gearbox. When it comes to a gearbox repair or rebuild:

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Falk Gearbox
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Falk Gearbox Rebuild Case Study (Model 525)

FALK GEAR REDUCER
Rebuilt Falk Gear Reducer with Flywheel

This Case Study Was Supplied to us by our client, the actual end user, because of the precision work Gear World Performed on the Falk Gear Reducer.

“All soft foot checks and alignment accuracy exceed the OEM requirements.”

Installation of Falk 525AB3-AS Reducer

On North Conveyor
Job Started   02-04-2019. |. Job Completed   02-15-2019

Reducer rebuilt by Gear World / Advanced Gear in Chicago, IL    

  Removal of previous Falk 525 reducer began on 10-12-2018 after a catastrophic failure upon start up. .Damage may be seen in the pictures below.

Falk Gearbox Repair1

Repairs Performed by Advanced Gearbox ServicesAfter removal, unit was shipped to Gear World / Advanced Gearbox Services in Chicago for repairs. As can be seen below, the following work was performed on the gearbox.


Description:  Falk 525 Reducer Rebuild and Recondition Gearbox. Manufacture / Fabricate Bevel gear as per OEM per sample from the box. Material Used – Material AISI 8620H 
Rebuild and Recondition Gearbox. Manufacture / Fabricate pinion shaft as per sample OEM. Used – Material AISI 8620H Manufactured Blanks then recut-teeth | Replacing all bearings | Replacing all seals | Minor Repairs on the gear housing / casing.Heat Treating – Material being AISI 8620H, Carburize and Harden 58-62 Rockwell“C”scale. The effective case depth would be per AGMA standards, 10-12% of tooth thickness at equal Addendum point.


Manufactured a cooling fan blade brand new. Repaired the fan cover, and 4 Seal plates. Repair the worn areas of the bull gear shaft. Main Drive Housing area, weld, machine, line bore, chromeplate and grind back to OEM sizes.FabricateExtra Gear Set

Installation of Falk 525AB3-AS Reducer

Job Started  02-04-2019 / Job Completed   02-15-2019

  As can be seen in the following report, close attention was paid to detail, cleanliness, and accuracy. All soft foot checks and alignment accuracy exceed the OEM requirements.  The Falk 525 Reducer was filled with the recommended ISO320 gear oil specified by Falk. 

When installation was complete, lube oil pump was started and the belt was ran in creep drive approximately 5 hours before starting the main drive motor. Unit was ran with the belt unloaded for 3 days. Vibration data was collected when the reducer was unloaded and had reached operating temperature. With the belt unloaded, on 2-18-19 overall level at the input shaft was .072 in. sec. And on 2-22-19 with the belt loaded, it was .105 in. sec. These levels are climbing slightly, but are not concerning, as they are still low levels and should trend down as the gears run-in. Temperatures at the bearings look good, all are below 160 degrees with ambient temperatures of approx. 50 degrees. Gear Mesh Frequencies are reasonable on all shafts in the gearbox.

Preparation for Installation

When the rebuilt reducer arrived on 2-4-19, top cover was removed to add ISO320 gear oil. This also gives us the opportunity to take pictures of the gearbox interior. Below are pictures of the Gearbox when delivered to Facility. Note that the shafts were greased and stretch wrapped to prevent rust, complete interior of the gearbox was painted with Glyptal, and the mesh pattern of the ring and pinion was very close to center of teeth as they should be. 

FALK GEAR REDUCER
Falk Gearbox Rebuilt Professionally Shipped, Packed and Arrived Safely in Mint Condition at our Plant

The pics below are of the base when the previous reducer was removed and after it was cleaned. As can be seen in the pics below, everything was cleaned, including both coupling hubs, prior to the initial setting of the reducer

The pictures below are of the rebuilt reducer bottom side. Gearbox underside was thoroughly cleaned before setting onto the base.

Falk 525 Reducer Soft Foot Checks

After the Falk 525 reducer was set into place, all attachment bolts were tightened. A dial indicator was set up and zeroed on a foot, the attachment bolt loosened, indicator movement was noted, and the appropriate shim was installed under that foot. This procedure was repeated for the 5 remaining attachment bolts until soft foot was eliminated at all 6 mounting points. See picture below.

Zeroed Out Dial Indicator on Falk Gearbox Foot

Falk 525 Reducer Soft Foot Data

The amount of soft foot after installation for each attachment point of the main drive reducer is listed below.

Falk Gearbox Soft Foot Tolorances
Falk Gearbox Soft Foot Tolerances

Falk 525 Reducer Shim Data

The thickness and location of shims at each attachment point of the main drive reducer are listed below.

Falk Gearbox Shim Data
Falk Gearbox Shim Data

Falk 525 Output Shaft Face Readings

The pic below shows how face readings for the F12N Falk reducer were obtained on the output shaft for alignment. A set of feeler gauges were used and measured with a 1” micrometer. Face readings are in the illustration below.

Falk 525 Output Shaft Rim Readings

The pic below shows how rim readings for F12N were obtained on the output shaft for alignment. A dial indicator was attached to the reducer output shaft coupling by means of a chain clamp, readings are in the illustration below. The Top + Bottom readings should equal the Side + Side but they do not because of coupling eccentricity. But the alignment still exceeds excellent tolerances for a 34 RPM shaft. For information purposes, the Falk manual states that a straight edge alignment is satisfactory. We strive to be as close to zero as possible.

F12N Drive Motor Soft Foot Data

Due to damage to the previous drive motor, it was replaced with a rebuilt motor. This allowed us to perform a thorough cleaning of the base and motor underside. After setting in place, the main drive motor was checked for soft foot in the same manner as the main reducer using an indicator.

Soft foot readings for the main drive motor are in the illustration below.

Falk Soft Foot Drive Motor Readings

F12N Drive Motor Alignment Data

The coupling alignment from the F12N main drive motor to the input shaft of the Falk 525 reducer was performed using a CSI 2140 Laser Alignment system. When alignment was complete, all tolerances were in the excellent category as seen by the star on the analyzer for a 1781 RPM shaft. (actual shaft speed is 1781 RPM)

The thickness and location of shims at each attachment point of the main drive motor are listed below.

Falk Drive Motor Shim Thicknesses

F12N Drive Motor Alignment Data

Below is the CSI Alignment Report for the F12 North Conveyor Main Drive Motor to the Falk 525 Reducer. As can be seen at the bottom of the report, set 1 is where we started with the alignment and set 7 is at completion. Both vertical and horizontal planes fell in the excellent condition range. 

Falk Alignment Report Summary

Creep Drive Reducer Soft Foot Data

After alignment of the main drive motor, the creep drive reducer was checked for soft-foot in the same manner as the main reducer using an indicator.

Falk Gearbox Creep Drive Soft Foot Data
Falk Gearbox Creep Drive Soft Foot Data

Soft foot readings for the creep drive reducer are in the illustration below.

Falk Gearbox Creep Drive Soft Foot Readings
Falk Gearbox Creep Drive Soft Foot Readings

Creep Drive Reducer Alignment Data

The coupling alignment from the creep reducer to the 1stintermediate shaft of the main reducer was also performed using a CSI 2140 Laser Alignment system. When alignment was complete, all tolerances were in the excellent category on the analyzer for a 550 RPM shaft. (actual shaft speed is 523 RPM)

Falk Gearbox Creep Drive Soft Foot Alignment Readings
Falk Gearbox Creep Drive Soft Foot Alignment Readings

The thickness and location of shims at each bolt on the creep reducer are listed below.

Falk Gearbox Creep Drive Soft Foot Alignment Readings
Falk Gearbox Creep Drive Soft Foot Alignment Readings

Creep Drive Reducer Alignment Data

Below is the CSI Alignment Report for the F12 North Conveyor Creep Drive Reducer to the Falk 525 Reducer 1stIntermediate Shaft. As can be seen at the bottom of the report, set 1 is where we started with the alignment and set 10 is at completion. Both vertical and horizontal planes fell in the excellent condition range. 

Creep Drive Motor Soft Foot Data

Next, the creep drive motor was checked for soft-foot in the same manner as the main reducer using an indicator.

Falk Gearbox Soft Foot Data

Soft foot readings for the creep drive motor are in the illustration below.

Falk Creep Drive Motor Reading
Falk Creep Drive Motor Reading

Creep Drive Motor Alignment Data

The coupling alignment from the creep motor to the creep reducer was also performed with a CSI 2140 Laser Alignment system. When alignment was complete, all tolerances were in the excellent category on the analyzer for a 1770 RPM shaft. (actual shaft speed is 1770 RPM)

Falk Gearbox Creep Drive Motor
Falk Gearbox Creep Drive Motor

Creep Drive Motor Alignment Data

Below is the CSI Alignment Report for the F12 North Conveyor Creep Drive Motor to the Creep Drive Reducer. As can be seen at the bottom of the report, set 1 is where we started with the alignment and set 3 is at completion. Both vertical and horizontal planes fell in the excellent condition range. 

Falk Gearbox Creep Drive Motor
Falk Gearbox Creep Drive Motor

F12 North Input Shaft Spectral Data

Falk Gearbox Input Shaft Spectral Data
Falk Gearbox Input Shaft Spectral Data

Falk Gearbox Input Shaft Spectral Data

Falk Gearbox Input Shaft Spectral Data
Falk Gearbox Input Shaft Spectral Data

F12 North Output Shaft Spectral Data

Falk Gearbox output Shaft Spectral Data
Falk Gearbox output Shaft Spectral Data
Falk Gearbox BeforeFalk Gearbox After

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