Gearbox Repair
Welcome to Hanson Gear Works, a globally renowned leader in gearbox repair. For many years, our vision has been anchored in customer satisfaction, driving us to excel as a premier machine Grinding and Rebuilding company. We prioritize delivering high-quality goods and services at competitive prices, ensuring our customers receive fast and dependable service of the highest caliber.
Specializing in all makes and models of gears, gearbox repair, and rotating equipment, Hanson Gear Works boasts state-of-the-art technology and a unique remanufacturing approach. Upon receipt of your equipment, our meticulous process begins with thorough cleansing to remove debris, grease, and oil.
We then conduct detailed inspections, utilizing advanced magnaflux technology to detect chips, cracks, flaking, and wear on gears and shafts. Any components found to be compromised are either repaired or replaced to meet or exceed OEM specifications. Gears may be remanufactured, rebuilt, or rehardened as necessary, while shaft journals and bearing surfaces are meticulously repaired to exact specifications.
Our comprehensive service includes providing options, upgrades, and replacements, with or without manufacturer drawings. Moreover, we possess the capability to reverse-engineer any gear by employing comprehensive measurements.
Ground and Carburized Gears
The presence of teeth grinding and carburizing significantly impacts gear performance. Teeth grinding enhances gear silence, increases gearbox capacity strength, and extends gear life. However, it also incurs additional costs and may not be suitable for all gears. For high precision beyond grinding, shaving and flame hardening processes are available, utilizing shaving cutters with pitch diameters matched to gears.
We look forward to serving you at Hanson Gear Works, where precision meets reliability!
Why chose us?
- Advanced technology for precise gearbox repair
- Skilled technicians ensure original performance
- Prompt service with up to 50% savings compared to OEM
- Trustworthy, cost-effective solutions for your gearbox needs
We handle various types of gearbox damage, including gear wear, shaft misalignment, and bearing issues. Our skilled technicians utilize advanced technology and precision techniques to address a wide range of gearbox issues.
Absolutely! Our team is equipped to respond immediately to service calls and emergency repairs, minimizing disruptions to your operations.
Our repair process includes comprehensive inspections, surface grinding, and heat treating. We go beyond standard repairs, addressing issues like teeth grinding and carburizing to extend the life of gears and enhance overall gearbox durability.
Whether it’s gear cutting, welding, or heat treating, we offer customized solutions to restore your gearbox to optimal performance.
Gearbox repair is essential across multiple industries, including manufacturing, mining, energy, marine, and transportation. Companies operating heavy machinery rely on efficient gearbox function to maintain production flow, reduce downtime, and optimize operational costs. Whether it’s for conveyor systems, turbines, or industrial mixers, a well-maintained gearbox ensures smooth and reliable performance.
Common indicators of gearbox failure include excessive noise, overheating, vibration, oil leaks, and loss of efficiency. If your gearbox is making grinding or whining noises, it may indicate worn gears or insufficient lubrication. Overheating often signals internal friction issues, while vibrations can be caused by misalignment or bearing failure. Addressing these symptoms early can prevent more severe damage and costly replacements.
Remanufacturing a gearbox offers significant cost savings—often up to 50% compared to purchasing a new one. Additionally, repairs take less time than ordering new equipment, minimizing downtime. A remanufactured gearbox can be restored to meet or exceed OEM specifications, ensuring reliability and extended service life. By contrast, replacing a gearbox often requires lengthy lead times and higher upfront investment.
Yes, we offer warranty coverage on all gearbox repairs to ensure peace of mind. Our comprehensive repair process ensures that each component is thoroughly inspected, refurbished, or replaced, ensuring reliability and longevity. Specific warranty terms vary based on the type of repair, but we stand behind our workmanship and use only high-quality materials.
Absolutely! We specialize in reverse-engineering gears and gearbox components using advanced measuring techniques and precision technology. Whether original blueprints are missing or outdated, we can recreate gears with exact specifications, ensuring compatibility and performance.
Advantages of Gearbox Repair Services
Cost Savings: Repairing or remanufacturing a gearbox can result in substantial cost savings—often up to 50%—compared to purchasing a brand-new unit. This makes repairs an economically viable option for businesses looking to optimize their budget while maintaining equipment efficiency. Additionally, unexpected breakdowns can lead to unplanned expenditures, and a timely gearbox repair can prevent excessive costs associated with complete replacements, transportation, and installation of new equipment.
Minimized Downtime: Industrial operations rely on smooth and uninterrupted machinery performance. Ordering a brand-new gearbox can take weeks or even months, causing significant disruptions in production and revenue loss. A repair, on the other hand, can be completed in a fraction of the time, allowing businesses to get back to full operational capacity quickly. With skilled technicians and advanced repair techniques, downtime is minimized, ensuring that workflow remains uninterrupted and productivity is maintained.
Extended Equipment Lifespan: A well-maintained gearbox can significantly outlast one that is neglected. Regular servicing, preventive maintenance, and timely repairs help address minor issues before they escalate into major failures. Restoring damaged gears, shafts, and bearings allows businesses to maximize the longevity of their existing equipment instead of prematurely replacing costly machinery. By keeping the gearbox in optimal condition, companies can extend the useful life of their assets, reducing the frequency of replacements and enhancing return on investment.
Enhanced Performance: Over time, gearboxes can suffer from wear and tear, leading to reduced efficiency, increased energy consumption, and poor performance. Precision repair techniques such as gear grinding, carburizing, and surface treatments restore the original strength and accuracy of the gearbox components. This ensures smoother operation, improved torque transmission, and reduced friction, ultimately enhancing the overall performance of the machinery. Additionally, a properly repaired gearbox can improve fuel efficiency and energy consumption in industrial applications, leading to long-term operational savings.
Eco-Friendly Solution: Repairing and remanufacturing gearboxes contribute to sustainable business practices by reducing industrial waste. When companies opt for repairs instead of purchasing new gearboxes, fewer components end up in landfills, and the need for manufacturing new parts is reduced. This not only lowers the environmental impact but also helps conserve raw materials and energy used in the production of new gearboxes. Businesses looking to adopt greener operational strategies can benefit from gearbox repair as an environmentally responsible alternative to disposal and replacement.
Custom Modifications & Upgrades: In many cases, repairing a gearbox presents an opportunity to improve upon its original design. Remanufactured gearboxes can be enhanced with modern materials, upgraded components, and advanced manufacturing techniques to increase durability and efficiency. Companies can take advantage of custom modifications such as improved heat treatment processes, high-precision machining, and optimized lubrication systems to enhance the performance of their gearbox beyond its original specifications. This not only helps in improving overall machinery performance but also future-proofs the equipment against wear and tear.
Step-by-Step Gearbox Repair Process
Initial Assessment & Inspection:
- When the gearbox arrives at our facility, it undergoes a thorough external examination to assess any visible damage. This includes checking for cracks, leaks, misalignments, and signs of excessive wear.
- Our technicians document all customer concerns, previous operational issues, and performance history to gain a complete understanding of the gearbox’s condition.
- We perform an initial diagnostic assessment to determine whether the gearbox requires minor repairs, part replacements, or a full remanufacturing process.
Cleaning & Disassembly:
- Before any detailed inspection, the gearbox is meticulously cleaned to remove built-up oil, grease, dirt, and other contaminants. This step is crucial for identifying hidden damage that may not be visible under layers of grime.
- Once clean, the gearbox is carefully disassembled by skilled technicians using precision tools. Every component, including gears, shafts, bearings, and seals, is removed methodically to prevent further damage.
- Disassembly is conducted in a controlled environment to ensure no additional debris enters the gearbox during the process.
Detailed Inspection & Diagnostics:
- Advanced diagnostic techniques, including magnaflux testing, are used to identify hidden cracks, internal wear, and potential points of failure. This technology allows us to detect even microscopic defects that could compromise performance.
- Each component is analyzed for tolerance deviations, misalignment, and fatigue. High-precision measurements are taken to determine if parts fall within OEM specifications or if adjustments are required.
- Gear teeth, shafts, and bearings are carefully examined to determine whether they can be restored or need complete replacement.
Component Repair & Replacement:
- Depending on the inspection results, various repair techniques are applied. Worn gears may undergo grinding to restore surface precision, carburizing for enhanced durability, or re-hardening to strengthen their structure.
- Damaged shafts are either repaired through precision welding and machining or replaced entirely if beyond repair.
- Bearings, seals, and gaskets that no longer meet performance standards are replaced with high-quality components to ensure the gearbox operates smoothly and efficiently.
- If necessary, we reverse-engineer custom components to match the exact specifications of the original part, even when manufacturer drawings are unavailable.
Reassembly & Testing:
- The gearbox is reassembled using precision alignment techniques to ensure all components fit together flawlessly. Any misalignment at this stage can lead to premature failure, so our technicians carefully calibrate every part.
- Load and function tests are conducted under simulated real-world conditions to evaluate the gearbox’s performance, torque transmission, noise levels, and overall efficiency.
- Any minor adjustments needed to enhance operational reliability are made before finalizing the reassembly.
Final Quality Assurance:
- A rigorous final inspection is performed to ensure all repaired and replaced components meet or exceed OEM specifications.
- The gearbox undergoes another round of performance testing to confirm that it functions optimally under expected operating conditions.
- Customers receive a comprehensive report detailing the repairs performed, materials used, and recommendations for ongoing maintenance to maximize the gearbox’s lifespan.
Delivery & Ongoing Support:
- Once the gearbox passes all quality control checks, it is securely packaged for delivery or prepared for on-site installation.
- We provide continued technical support, offering guidance on proper lubrication, maintenance schedules, and operational best practices to help clients prevent future issues.
Our commitment to customer satisfaction extends beyond the repair process, ensuring that businesses can rely on their gearbox for long-term performance with minimal downtime.
Industries We Serve
At Hanson Gear Works, our gearbox repair services cater to a diverse range of industries that rely on precision-engineered components for seamless operations. We provide expert repair and remanufacturing solutions to extend the lifespan of critical machinery, ensuring minimal downtime and maximum efficiency.
1. Manufacturing & Heavy Industry
Industrial production relies on gearboxes for conveyor systems, assembly lines, and automated machinery. Our repair services help manufacturers maintain efficiency and prevent costly production delays.
2. Oil & Gas
From drilling rigs to refinery equipment, oil and gas operations require robust gearboxes that can withstand extreme conditions. Our repairs restore performance, ensuring safe and reliable operations.
3. Power Generation
Gearboxes in turbines, generators, and hydroelectric plants must function flawlessly to maintain energy output. Our precision repair solutions enhance reliability for both conventional and renewable energy sectors.
4. Mining & Construction
Heavy-duty machinery in mining and construction depends on high-torque gearboxes. We repair and reinforce gears to withstand heavy loads, impact stress, and continuous operation.
5. Marine & Transportation
Ship propulsion systems, rail locomotives, and industrial transport equipment require precise gearbox performance. Our services ensure durability and efficiency for marine and heavy vehicle applications.
6. Agriculture & Food Processing
Farming equipment, grain conveyors, and food production machinery rely on smooth gearbox operations. We restore and enhance these components to optimize agricultural and food industry performance.
Hanson Gear Works supports businesses across multiple industries with expert gearbox repair services, helping them avoid costly replacements and keep their equipment running efficiently.
Revitalize Your Machinery Today!
Contact Us for Expert Gearbox Repairs and Precision Solutions.
