Custom Machining Solutions gearbox rebuild

Industrial gearboxes are the backbone of heavy machinery, ensuring smooth power transmission across various industries. Proper maintenance and timely repairs are crucial for maximizing efficiency and preventing costly downtime. In this guide, we will cover the repair procedures for leading gearbox brands, helping manufacturers keep their equipment in top condition.

Before diving into brand-specific repairs, it’s important to recognize common gearbox problems:

• Overheating – Caused by inadequate lubrication or excessive load.
• Unusual Noise – Grinding or clicking sounds often indicate worn-out bearings or misalignment.
• Oil Leaks – A sign of seal failure or casing cracks.
• Vibration – Often linked to misalignment, imbalance, or gear wear.
• Reduced Efficiency – Due to excessive friction, lubrication failure, or internal damage.

 SEW-Eurodrive Gearbox Repair

• Inspection: Check for worn-out bearings, misalignment, and oil contamination.
• Disassembly: Remove the gearbox cover and extract gears and bearings.
• Reconditioning: Replace damaged bearings, seals, and re-align components.
• Lubrication: Use SEW-Eurodrive-approved lubricants.
• Reassembly & Testing: Ensure proper alignment before final testing under load conditions.

Flender (Siemens) Gearbox Repair

• Diagnostics: Utilize vibration analysis and thermal imaging.
• Gear & Shaft Assessment: Check for pitting, scoring, and micro-cracks.
• Bearing Replacement: Install OEM bearings to restore precision.
• Housing Restoration: Repair cracks using metal stitching or welding.
• Performance Testing: Run the gearbox under load to verify repairs.

Bonfiglioli Gearbox Repair

• Disassembly: Clean and examine all internal components.
• Gear Realignment: Check planetary gears for signs of wear.
• Sealing & Lubrication: Install high-quality oil seals and refill with approved lubricant.
• Final Testing: Ensure torque output meets factory specifications.

Sumitomo Drive Technologies Gearbox Repair

• Cycloidal Gear Check: Inspect for wear on eccentric bearings.
• Shaft Alignment: Correct any misalignment to prevent excessive wear.
• Seal & Gasket Replacement: Prevent oil leakage and contamination.
• Dynamic Testing: Validate rotational smoothness before reinstallation.

Nord Drivesystems Gearbox Repair

• Gear Inspection: Identify any damage to helical, bevel, or worm gears.
• Housing Restoration: Replace cracked casings to maintain structural integrity.
• Lubrication Analysis: Ensure the correct viscosity oil is used.
• Operational Testing: Verify torque and efficiency post-repair.

Brevini (Dana) Gearbox Repair

• Planetary Gear Replacement: Swap out worn-out components.
• Seal & Bearing Inspection: Ensure proper lubrication retention.
• Load Simulation: Test under operational conditions before reinstallation.

Hansen Industrial Transmissions (Regal Rexnord) Gearbox Repair

• Teardown & Diagnosis: Identify worn bearings and misalignment.
• Component Reconditioning: Regrind or replace gears if necessary.
• Final Testing: Conduct vibration and noise level assessments.

David Brown Santasalo Gearbox Repair

• Gearing Refurbishment: Recut or replace damaged gears.
• Alignment Check: Use laser alignment tools.
• Final Verification: Conduct load testing before deployment.

Radicon (Elecon) Gearbox Repair

• Oil Analysis: Check for contaminants.
• Bearing & Seal Overhaul: Replace with OEM parts.
• Run Testing: Ensure smooth torque transmission.

Dodge (ABB Baldor) Gearbox Repair

• Gear Wear Inspection: Identify damaged teeth.
• Lubrication System Flush: Remove old oil and replace with fresh lubricant.
• Vibration Testing: Confirm operational stability.

Other Notable Brands and Their Repair Processes

• Winsmith – Focus on worm gear realignment and lubrication flush.
• Cone Drive – Specialized double-enveloping worm gear checks.
• Zollern – Precision planetary gear analysis and reconditioning.
• Bauer Gear Motor – Motor coupling alignment and efficiency tuning.
• Rossi (Habasit Group) – High-torque gear replacement and thermal inspection.

Final Thoughts

Regular maintenance and timely repairs are essential to extending the life of industrial gearboxes. By following these brand-specific repair procedures, manufacturers can enhance efficiency, minimize downtime, and protect their investments.

Need professional gearbox repair services? Gearbox Network provides expert diagnostics, repair, and maintenance for all major brands. Contact us today for a consultation!

Our cutting-edge equipment and skilled machinists enable us to deliver high-volume production runs with consistent quality and efficiency. We specialize in producing parts for the automotive, aerospace, and medical industries.

We offer reverse engineering services to help you replicate or improve existing parts. Our team can use a combination of 3D scanning and modeling techniques to create accurate CAD models from physical parts.

In addition to machining, we offer welding and fabrication services to help you produce complex assemblies and structures. Our skilled welders and fabricators can work with a variety of materials including steel, aluminum, and titanium.

We understand that unexpected breakdowns can be costly and disruptive. That's why we offer emergency gearbox rebuild repair services to get you back up and running as quickly as possible. Our team can work around the clock to get your equipment back in operation.

We can design and manufacture custom tooling to help you optimize your manufacturing process. Our team has experience working with a variety of tooling types including jigs, fixtures, and cutting tools.

We offer precision grinding services to help you achieve tight tolerances on your parts. Our state-of-the-art grinding machines can produce parts with exceptional surface finishes and dimensional accuracy.