Industrial Gearbox Repairs, Refurbishment & Maintenance

Industrial Gearbox Repairs

We know that when your gearbox breaks or develops a fault, your entire business operation can quickly grind to a halt, costing you a great deal of time and money. At Highfield Gears, we know that you need your gearbox back up and running as quickly as possible and to do this properly it requires a quality service from a gearbox centre that has been doing industrial gearbox repairs for decades, well luckily that’s exactly what the team here at Highfield Gears have been doing.

OUR PROCESS
INDUSTRIAL GEARBOX REPAIRS
WORM GEARBOX REPAIRS
BEVEL HELICAL GEARBOX REPAIRS
EXTRUDER GEARBOX REPAIRS

We have a range of gearbox services that can have your gearbox back up and running in no time. If you’re based in the UK in areas such as Huddersfield, Manchester, Birmingham, London or anywhere else across the country or further afield in Europe then feel free to get in touch with our team here at Highfield Gears online or by phone on 01484 531 010.

Our process.

Whether it is an industrial gearbox, planetary gearbox, a worm gearbox, helical gearbox or extruder gearbox that needs repairing you can expect the same cost-effective methods and impeccably high standard of service from our experts at Highfield Gears. Our specialists are passionate about helping our clients with their gearbox repairs and refurbishment because it is a much quicker and cheaper solution compared to full gearbox replacement.

Our team of experts can offer a whole host of services and draw on a wealth of experience that will help fix an array of potential issues to keep your gearbox working at normal levels, all for a fair price. We’re able to repair gearboxes from any type of brand or make and because our technicians operate 24/7 they can solve issues overnight, reducing turnaround times and ensuring your business is going from strength to strength.

In addition to these fast turnaround times, we’re also able to manufacture gear parts right here at our site in Huddersfield. That means you, and our team of experts, don’t have to wait days, potentially weeks, for a part. This in-house process speeds up the repair time and reduces the overall gearbox repair cost because things such as delivery prices and postage fees are no longer a factor. In-house manufacturing of gear parts also means we can retain the quality and track which parts are going into your gearbox more easily.

What follows is some of the main industrial gearbox services that we offer.

Industrial Gearbox Repairs

Industrial gearboxes transmit their mechanical energy to a range of output devices such as a motor. Industrial gearboxes allow a whole host of businesses and organisations to produce goods in ever more efficient and speedier ways. As great as industrial gearboxes are, when they go wrong they have the potential to halt all production.

Our team here at Highfield Gears will use their expertise to help repair your industrial gearbox equipment to full power in no time. From the minute your gearbox arrives at our workshop our team will get to work fixing it. It starts with a thorough inspection and vibration analysis from one of our gearbox specialists who analyse the internal parts of the gearbox. Once that is achieved our expert technicians can offer solutions and recommendations about how best to fix your gearbox so that it works, is reliable and is protected from a variety of future problems.

Your industrial gearbox repair service will always come with a detailed inspection report about what we have found, a summation of what our gearbox specialists did and any gearbox requirements we suggest you need.

No matter what is wrong with your gearbox, upon delivery of it, our expert technicians will draw on their months and years of experience, provide quality workmanship and have your industrial gearbox fixed so you have complete peace of mind that everything is sorted.

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Industrial Gearbox Repairs

What Causes Gearbox Failure?

In our years of offering key gearbox services to businesses and organisations, we have seen all sorts of issues and problems that turned once efficient gearbox units into seemingly obsolete gearboxes.

From common problems to more unusual ones, we have helped fix issues that other gearbox service centres simply could not. As engineering experts, we often get asked what causes gearbox failure and what can be done to ensure a unit is able to fulfil its capabilities in its factory, or warehouse. So here, we thought we’d talk about our experiences and describe four common problems that occur to industrial gearbox units that cause them to need a gearbox repairs service team, such as the one found at Highfield Gears.

Lubrication

Lubrication is key to a smooth-running gearbox. When used correctly, the lubricating oil forms a film across all parts of the gearbox to prevent the bearing and point of contact between the gears (commonly known as the gear mesh) from grinding against each other too much. Without thorough lubrication processes in place, the rolling, sliding, and tooth-on-tooth contact cannot turn the applications effectively, which leads to hindrances in the machine, breakdowns and, ultimately, downtime.

Arrangement

Our service engineers at our gearbox repair centre see the arrangement of a unit as one of the most important factors in ensuring it operates smoothly. If the arrangement within the parallel shafts, or right points shafts, are not exactly aligned, the gears, couplings, and components will not mesh in the way they were originally intended to when their original specifications were printed. All of this has the effect of putting undue weight on other areas of the gearbox, causing failure.

Abrasive wear and tear

Small filaments of material in the lubrication system can cause scratches and general wear and tear to a gearbox which can be detrimental if it isn't fixed in a suitable time period. This abrasion is free to go anywhere in the unit, because the oil is transmitting it through the components, and can cause all sorts of issues. Thankfully, our expert gearbox inspection services team will put in a place a filter system to ensure this abrasiveness won't be detrimental to the unit.

Breakage

A more obvious reason but no less important. All types of gearboxes can suffer a breakage - an entire tooth, or piece of tooth, can break away which can cause high-stress loads on other parts of the gearbox that are having to pick up the slack of the faulty, or broken, component.

Can A Gearbox Be Repaired?

While those four issues sound scary, the good thing is that, by working with an expert industrial gearbox service & repair team, these issues can be resolved and your new, or heritage brand gearbox can be back up and running in no time, especially if the issue is caught early.

Gearboxes may seem complicated, and to some extent they are but, ultimately, these products are made of parts and, to fix them, it’s simply a case of undergoing a thorough procedure to find out what is wrong, by doing a comprehensive gearbox inspection, and then applying solutions, and gearbox expertise, to fix it. There is no mystery or magic formula; it’s just a case of finding the problem and fixing it. This means that proper industrial gearbox repairs and refurbishment can, given enough time, fix almost every problem that these complicated, but straightforward, transmission solutions could be affected by.

We’re confident that when you come and meet the gearbox site services team you’ll feel reassured that this is a group that knows what they are doing and can undergo a gearbox repair that solves problems, big or small. What follows are some ways you can keep your gearbox in good condition, then we’re going on to talk about some of the main industrial gearbox services that we offer.

Features And Benefits Of Working With Highfield Gears

Opting to work with us comes with it a whole host of benefits, features, and advantages. As we'll explain, working with Highfield Gears is a process unlike any other.

Rather than outsourcing all your issues to third parties that could cut costs for us, we opt to keep everything in house. We’ll produce every component, run every test, and rebuild every unit at our Huddersfield headquarters. This gives our clients peace of mind because quality control is kept extremely high, and they know that we’re not relying on third parties, either in the UK or overseas, to supply parts.

Our services include entire rebuild options for gearboxes that have numerous faults. While reconditioning and repairing is usually a cheaper option, in some cases, an entire rebuild is needed. We can strip gearboxes up to 18 tonnes right down to their individual parts and create best-fit solutions that will have them looking, sounding, and feeling brand new.

Our quick turnaround time is another feature that we’re extremely proud of. Our cutting-edge equipment and in-house machining mean we can assess, act, and test quickly and comprehensively, without any dip in quality. This reduces the costs for businesses and minimises downtime. Once we have your unit in-house, we’ll work quickly and with precision to get your transmission unit fixed, back to the correct specification, in a relatively short space of time.

As we explain further down the page, our 24/7 emergency service is another key feature of our offering. We always have a group of Highfield staff who are ready and waiting to receive your transmission drive units at any time of the day or night. In a world where the regular 9-5 is changing, the need for businesses to have access to five-star repair services in the middle of the night, or over a weekend, is more important than ever. We know you have important orders to fulfil, targets to hit, and stakeholders to satisfy, which is why we’re delighted to offer this service.

We have comprehensive OEM (Original Equipment Manufacturer) experience meaning we can produce parts and components that are of the same standard and quality as those that were created by the original manufacturer. Working with an OEM such as ourselves means you can save money purchasing gear spares and other parts that are just as good as what the original makers created.

At Highfield Gears, we’re proud that we are, and will always be, a British company with no offshore plants. While other companies decided to move abroad to save money on labour and parts, we decided to stay in Huddersfield, in England, and keep hiring talented workers from this country. We’ve created a team filled with expertise and are proud to have kept talented people in work with good-paying jobs.

The final benefit of working with us is our near 100 years of experience. This is the kind of experience that money can’t buy, you simply can’t learn 10 decades of experience, you have to live it, and we have. Years of working in the industrial gearbox industry on transmission motor units mean that there aren’t many problems we haven’t fixed.

If you want solutions that are going to work and last for years to come, then Highfield Gears are the obvious choice.

10 Ways To Keep Gearboxes Well Maintained

Gearbox replacement is a last resort and an expensive one. And, while repairs from Highfield Gears are available with competitive and transparent prices, it’s best to try and keep your gearbox well maintained in-house to avoid spending significant investment on repairs or upgrades. To help keep your transmission units ticking over, we’ve compiled 10 things that you can do to ensure your industrial gearbox is well maintained.

Undergo vibration analysis

Very often, industrial gearboxes operate in noisy environments, making it hard to hear for faults or potential problems. Vibration analysis reduces the impact of noise on your ability to check for faults. By analysing how much vibration is occurring within the bearings and gears you can determine what condition the gearbox as a whole is in and prevent unplanned downtime.

Check for shaft end play, including backlash

Checking for any increase in a backlash between the gear mesh can help you work out how much gear wear there is because said wear is minute, and may not be visible. Use a dial indicator to check for this, both between the gear mesh and the input and output shafts, as mentioned, the lack of visible damage means that a dial is necessary to ensure you can spot any issues. Shaft end play and potential backlash may indicate damaging wear in the bearings, and their housings.

Inspect gear wear regularly

Regular inspection of your gears will ensure you’re always aware of anything that may need to be looked at further. Remove the inspection covers, use an endoscope, and look for pitting and spalling. Inspecting gear wear may also reveal misalignment that needs to be corrected immediately before a bigger problem occurs later.

Take the temperature

An industrial gearbox that overheats can cause a total malfunction that may very well write the unit off, as well as being an obvious fire hazard. It’s important, therefore, to check the temperature, and take care to look for signs of overheating such as burnt paint and dark oil. Using an infrared gun will help you spot any unusual temperature changes, allowing you to act fast to avoid having to invest in a brand-new gearbox.

Check lubrication levels

A properly lubricated gearbox will stop components parts from overheating, or grinding to a halt. The importance of the right lubricant cannot be overstated, therefore, ensure you and your team are regularly checking lubrication levels and topping up as and when it is needed. Keeping on top of this, as part of your maintenance routine, will go a long way to keeping your gearbox in good condition.

See if the breathers are letting particles in

Breathers are located on the gearbox and help it breathe and maintain good ventilation which keeps the temperature down and allows the gearbox to run at high capacity while keeping cool. If the breathers are faulty they could let in harmful particles, dust, water, or debris that will severely impact the components. Check your breathers and maintain them to ensure they are letting the right things in, and keeping the bad stuff out.

Maintain strong shaft seals

Similar to breathers, shaft seals need to be kept sealed to stop outside debris or pollution from damaging your gearbox. Shaft seals are vital and should be replaced immediately at the first sign of wear because contamination and leakage can cause serious damage.

Keep a clean environment

As good practice, keep the space around the gearbox clean and make sure team members are regularly keeping the floors tidy and ensuring there is adequate ventilation. It may seem a bit silly but keeping a sanitary area that is free of dust and dirt will go a long way to keeping your gearbox running smoothly, it shouldn’t be underestimated.

Gearbox ratings

All gearboxes come with a specification from the manufacturer that provides insight into the mechanical benchmarks as well as thermal ratings. Regularly check the current performance against these benchmarks and if anything irregular occurs, it could be a sign that something is wrong.

Be in regular contact with the experts at Highfield Gears

The 10th and final thing to do to ensure a well-maintained gearbox is to be in touch with our team here at Highfield Gears. The more we know about the performance of your gearbox, the easier we can help and stop small problems in their tracks. Our team is always on hand to offer advice, answer questions, and help you diagnose problems on the spot.

Worm Gearbox Repairs

Consisting of a shaft with a spiral thread that engages and drives a toothed wheel, worm gearboxes are found in a variety of places such as elevators, large trucks and conveyor belts. Gear models such as the worm wheel and worm gearbox allow businesses or organisations to select the rotational speed and allows for more torque to come from geared motors which can help operate heavy machinery.

Once they have access to your worm gearbox it will be in safe hands and our team of experts will go about ensuring that all elements of it are working efficiently, giving you complete peace of mind. From gears, gearing and pinions to shafts, bearings, seals and gadgets right the way through to full worm gearbox repairs, we’re able to do it all. We have the tools available to manufacture worm gearbox components on-site or we can reverse engineer parts that are in a worn or damaged condition. All this saves you waiting months for spare parts to arrive, speeding up the process and ensuring your worm gearbox is back working for you in good time.

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Worm Gearbox Repairs

Bevel Helical Gearbox Repairs

Helical gearboxes are a type of cylindrical gear that has a large contact ratio, this type of gear is quiet, has far less vibration than other gears and can power large forces. Unlike spur gears, helical gearboxes have teeth that are cut at an angle that faces the gear. Helical gearboxes are highly durable and are ideal for load applications. These types of transmission are used by a range of sectors from the fertiliser, earth-moving and port industries right the way through to the textile, steel and oil industries.

The drive components found in helical gearboxes allow them to carry a far greater load because more than one tooth is in contact while the gear is in operation. Their efficiency and ability to work without making lots of noise is why they are so popular but when they break they can be difficult to fix because of their intricacies. Fortunately, our team has worked with helical and double helical gearboxes for years and can spot the signs of damage. The experts at our gearbox centre will pay close attention to analysis and reports of your helical gearbox drive components before going ahead and making the necessary repairs, installing new parts or completely overhauling the gearbox if necessary. Our ability to do what is necessary should give you peace that you’re getting quality service and advice from helical gearbox maintenance experts.

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Bevel Helical Repair - Gearbox Specialists

Extruder Gearbox Repairs

Having built and reconditioned plenty of extruder gearboxes in our decades of helping customers across the UK and Europe the team here at Highfield are perfectly placed to undergo analysis and offer a quality service, based on those results, to help fix or repair your extruder gearbox. Whether you need your extruder gearbox reconditioning or you just need a few new parts added to it the team at our Huddersfield-based service repair centre can offer bespoke solutions so that your gearbox is restored to its original specs for a fraction of the money you would have to spend if you completely replaced it.

From checking and analysing to supplying you with your working extruder gearbox our reputation as a leading company that offers a high standard of service puts us in an ideal place to support your efforts to fix your extruder gearbox. We’ll take our core values and combine them with quality workmanship and before you know it your working extruder gearbox will be operating at normal levels and leaving our gearbox repairs workshop.

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Extruder Gearbox Repairs

Planetary Gearbox Repairs

A faulty gearbox such as this requires specialist treatment thanks to its complexities and delicate setup, both of which ensure good operational performance. Planetary gearboxes are types of gearboxes that come under the term 'epicyclic gearing'. This term relates to a drive that consists of one small gear in the centre of a wider gear wheel, and within that, two to three gears orbit the centre gear (most commonly called a sun gear or sun wheel). When a mechanical component breaks in this type of gearbox, it can be severely detrimental because of the delicacy with which everything is built - all parts rely on each other and, therefore, every element of a planetary gearbox is an essential component.

The team at our gearbox repair shop are well versed in the gearbox issues that arise from planetary gearboxes and will follow strict procedures to ensure that each part is repaired, reconditioned, or upgraded, as well as passing necessary strength tests so that you can rest assured knowing each component can handle the daily stresses that are put upon it. We’ll use cutting-edge diagnostic equipment and treat even the most minor repairs with the utmost care and consideration, all the while providing you with detailed reports and pictures so that you’re aware of every step we’re taking, and why.

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Industrial Gearbox Repairs

Bevel Gearbox Repairs

Named because of the components that are housed inside, bevel gearboxes are some of the most common types of units in service today. Virtually all gearbox manufacturers make some form of bevel gearbox and you'll more than likely use them to power your industrial equipment. As a result of this popularity, the professional gearbox repair team at our gearbox repair shop based in Huddersfield have successfully repaired hundreds of these, in all different sizes and states. Our ability to work on transmissions that weigh anything up to 18 tonnes means that no matter what size your bevel gearbox is, or which major manufacturers helped build it, we can assess the issue, rebuild or recondition essential components, and have it back up and running in no time at all.

Our visual assessment, and thorough reports, are all a part of our excellent service and help to form a holistic industrial gearbox repair process that not only fixes the immediate problems with your bevel gearbox but takes steps to make simple repairs to other smaller issues before they manifest into something that stops your business in its tracks. And, the best part is that we do everything at affordable rates and transparent prices which are accurate to the scale of the job. We’ll always be upfront about this and if an entire transmission replacement is needed, we’ll quote for that. Similarly, if it’s just a few parts that are causing the gearbox fault, we can offer you a great price.

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Industrial Gearbox Repairs

Spur Gearbox Repairs

As cost-effective and robust as these affordable gearboxes are, there will come a time, hopefully later rather than sooner, that they need some form of repair. Spur gearboxes are extremely common and consist of cylindrical shaped tooth components. Spur gearboxes are some of the simplest transmission units out there, in part because of their symmetrical, evenly distributed teeth shape. Problems with spur gearboxes arise when teeth become worn and reduce the smooth transition needed. There are, of course, dozens of other reasons why these gearboxes will suffer a loss of drive and impact your ability to power machinery and other equipment that keeps your business ticking along.

As part of our friendly service, we’ll examine all aspects of your spur gearbox, not just the broken components, and use our diagnostic equipment so that the problem is repaired, and the necessary actions are taken to prevent further issues from emerging. Just because spur gearboxes are common, that in no way means your problem is any less important or unique. We understand this and will treat each gearbox uniquely while, at the same time, using our decades of knowledge to fix the problem, be it a loss of drive, or component damage, in a reasonable time, at an affordable price.

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Spur Gears

How Much Does Gearbox Repair Cost?

Gearbox repair costs are as varied as the solutions that need to be carried out to fix them, truth be told. Numerous factors such as level of damage, size of the unit, the complexity of the problem, and location of the gearbox will all impact the overall cost. Here at Highfield Gears, you can be assured that we’ll be upfront about the cost and the amount needed to ensure that the problem is properly fixed. We won’t try and skimp on a solution if it means it might be cheaper because that is only going to cause you more problems in the long run. On the other hand, we aren’t going to make unnecessary modifications that cause the price to rise astronomically. It’s all about balance – fixing the immediate problem in front of us, and then making appropriate, relevant changes to stop it from happening in the future.

While the cost of repair is varied and largely unknown until an inspection has occurred, what is known is the cost of not repairing an issue, or letting something develop into a more detrimental problem. The cost of doing this is incredibly high, and outweighs any kind of cost needed to fix or repair the problem – that much we’re sure of. Too often we have seen businesses who have waited too long to get something fixed, or not invested in preventive maintenance from the start, and have soon found that their industrial gearbox has become an asset that is costing them more money than it is making.

To learn more about pricing, feel free to get in touch with our team who will discuss payment options and plans. Please know that whatever the problem, the price we will quote will be fair and reflect the solutions that are needed to fix the issue. We haven’t remained successful for nearly a hundred years by ripping people off, or charging exorbitant fees – that is simply not the Highfield Gears way.

The Gearbox Brands We Can Work On

We have the capabilities to repair, recondition, or upgrade transmission units from many different manufacturers.

We have amassed drawings, specifications, and case studies that we draw on to help clients who are having problems. These have been collected over the years we have been operating and should give you the reassurance that whatever gearbox you have, our experienced team can fix them.

Famous suppliers of Aston Martin’s gearboxes, DB Santasalo (the DB standing for David Brown) manufacture transmission units and we have the ability to work on their products, which are used by businesses up and down the country. US-based Radicon has been supplying their various Radicon Industrial Gearbox units to commercial businesses across America, Europe, and the UK. We are delighted to have the knowledge and insight to be able to undergo thorough gearbox service & repair solutions for these units.

While they may be known for their domestic white goods, commercially, Siemens produce some of the most popular transmission units which are supplied across the UK. If you own a Siemens product, and it breaks, rest assured that our complete gearbox maintenance service is more than capable of fixing any and all issues that may arise. A market leader in the world of custom fluid agitation systems, Chemineer creates products that help power industrial mixers and other similar solutions. As with the other brands mentioned, we have worked on products from this gearbox manufacturer before, and are more than comfortable repairing and refitting components and parts.

As well as those four that we’ve just mentioned, we also offer solutions for the following manufacturers:

  • Hansen
  • Sumitomo
  • Flender
  • Renold

How A Gearbox Works

In one form or another, gearboxes have been around for a very long time. The first gearbox was invented back in 1904, over 115 years ago, and was called the 'horseless carriage’ gearbox. It was invented by the Sturtevant brothers who were based in Boston, Massachusetts, in the United States. While this was the first of many automatic gearboxes made, it wasn't mass-produced and was only available for a select few. The masses would have to wait 35 years, a world war, and an economic collapse, until they could enjoy the benefits of affordable gearboxes, when, in 1939, General Motors released the Hydramatic three-speed automatic gearbox, by which time Highfield Gears had already been around for 12 years!

Since that invention back in the early 20th century, gearboxes have gotten bigger, more efficient, and able to power a host of different applications from the car, right the way through to industrial equipment that helps brew beer, make steel, and mass-produce products. And, while most people may be able to point to a gearbox and recognise it, not many would know how it works. Of course, here at Highfield Gears, the inner workings of industrial gearboxes is our life. There’s not a day that goes by where we don’t think about couplings, seals, grinding, boring, and bevels, but for the average industrial gearbox owner they may not be aware of the science that goes into ensuring their machinery works smoothly. Here, we’re going to be looking at how a gearbox works in a little more detail so that you’ll be able to spot issues, understand what to look for, and maybe fix small problems yourself.

A gearbox is a unit that is made up of mechanical components, most notably, gears. These gear rotate within the casing and can be designed in various ways, depending on the intended application. The gears can interact to, for example, increase or decrease speeds, change the direction of an application, or alter the levels of torque. The gearbox works by transferring energy between gears so that the application (e.g. machinery) that it is powering enacts the process that it is designed for. Gearboxes and their components form part of the wider transmission system which is responsible for making the machine work, and ‘go’.

In industrial gearboxes, the different couplings, gears, and shafts all work together to affect the speed and process of the application. These components must be synced, well-made, and constantly monitored to ensure they are all doing their part, and are all working together so that power flows smoothly between components. If any of these things aren’t in sync it can cause disruption and put pressure on other areas of the process which will, very quickly, result in faults and potential breakdowns. Similarly, if industrial gearboxes aren’t monitored regularly then small issues could manifest into something greater, resulting in a replacement gearbox. It’s important when understanding how a gearbox works, to set performance benchmarks and have clear expectations of how your transmission units should perform. By doing this, you’ll be able to spot problems quicker because you’ll have an idea of how your transmission systems work during ‘normal’ times.

That aside, all gearboxes work in broadly the same way, the rotational direction of the gears will depend on the direction of input and the gear orientation. They are used to maintain the direction of rotation, while also converting either torque or power between the respective inputs to help the applications reach the necessary speed to carry out their task. Clearly, their uses are multiple and you’ll find industrial gearboxes in machining tools, construction machinery, power transporters, or anything that requires a change in speed, direction, or torque.

What you’ll find ‘under the hood’ of a gearbox will vary depending on the type of unit you have. Most are almost always made of some sort of metal such as iron, aluminium, or a brass-like material, and some units can be made using polycarbonates or plastics. The choice of material will need to be carefully considered as the wrong material can cause overheating, and excess wear and tear.

The gear teeth are also a common component of the unit and, like the material selected, the type of teeth will greatly alter the performance. Regular gear teeth will be used for slower applications whereas helical gears (those that are curved or positioned at an angle) will be used for higher speed applications that need to quickly, and smoothly, transfer power.

Important Gearbox Components

Here, we're looking at some of the key components that make up an industrial gearbox, these terms are commonly used and these descriptions will help you better understand their role, and the importance of maintaining them properly.

Clutch

A term you associate with vehicles, clutches are also found in industrial gearboxes. Their function is to help aid the transmission of torque from the rotating driving motor to the transmission. The clutch is one of the most important parts of the process and helps ensure that the shafts it is connected to spin at the right speed and transmit power properly.

Input shaft

An input shaft transfers the rotations found in the crankshaft and feeds that into the transmission. As we’ll touch on, gears are needed to transfer the rotation effectively to the application that is being powered.

Gears

The gears that are housed in a gearbox have three main functions, they can increase torque to the equipment that is being driven by the gearbox, they can reduce the speed generated by the motor, and alter the direction of the rotating shafts. They operate together and transmit power by engaging one another via their gear teeth.

Centre differential

Centre differentials are built into transmission units, usually between the front and rear axles, to make up for the different wheel speeds between them. A well-maintained centre differential prevents torsional drivetrain stress and distributes these forces equally.

Reverse gears

A reverse gear is relatively straightforward, it is a gear found in the unit that is angled in the opposite direction of the other gears. This gear can be used when you want to reverse the direction of the application. Given there is usually only one reverse gear, the speed with which this happens is much slower because there aren’t as many gears to transmit the power.

Axle

A front or rear axle is a key component of any gearbox, be it an industrial one, or one that helps to power a car. The axle is a rod-shaped component that supports the weight of the gearbox and rotates the individual gears at their desired speed.

Repairs and Refurbishment: How We Fix Your Transmission Units

Our holistic range of gearbox services is varied, meaning we’re able to help with a variety of different issues at various stages of severity and complexity. From re-engineering obsolete components, right the way through to creating individual parts, based on original manufacturers specifications, and overhauling entire units through refurbishment and upgrade – we can do it all. When your transmission unit arrives at our service centre in Huddersfield, our team may use one, or several, of those solutions to not only fix your initial problem but to improve gearbox performance so that it performs better than originally expected. This kind of above and beyond service, twinned with the fact that everything we do is done in-house, puts us ahead of competitors and makes us a true one-stop-shop company. For more information about these services please read on, or alternatively, get in touch with our team who would be happy to discuss your gearbox problems further and help you determine what selection of solutions are needed to get your systems back up and running. What follows is a detailed list of the services that we offer.

Inspection

Treatments are nothing without first undergoing a proper diagnosis. We'll breakdown your gearbox and go through, component by component, to find out what has gone wrong based on what is in front of us and your experiences with this faulty transmission. This inspection process is arguably the most important phase because, without it, we're unable to make any informed decisions or enact any proper solutions, leaving you worse off than when you arrived. We'll use cutting-edge tools that get into your gearbox on a granular level to determine the problem and appropriate response times needed to fix it. Very often the problem may not be as bad as initially thought, this minor gearbox repair, as well as being a nice surprise, will save you money, reduce any scheduled downtime, and before you know it, your gearbox will be back up and running - all this because a proper inspection was undertaken from the outset.

Gearbox repair

Our bread and butter service - gearbox repair is what we know and love, and the service we have offered for nearly a century. We love the problem-solving elements of this particular service and the satisfaction of knowing we have used our years of collective experience to help another UK business with its transmission issues. Repair is a big word and covers a whole range of solutions such as gearbox stripping, where we take apart the unit and fix the individual components before rebuilding, and undergoing gearbox installation, to ensure things are working better than before. It can also incorporate fixing lubrication distribution to ensure abrasive wear and tear doesn't cause issues or fixing filtration and ventilation systems to stop overheating, or small particles of waste, damaging internal components.

Upgrade

We're passionate about ensuring businesses don't have to suffer from poor gearbox performance and, just because one or two components are broken, that shouldn't mean you have to invest thousands in a new unit. Thankfully, we can upgrade parts, leading to an overall better gearbox, and improve performance figures so it feels like you have a brand new unit. Regardless of brand, type or model, we can help increase capacity and overall operating capabilities thanks to our gearbox overhaul and upgrade services.

Recondition

When old parts are worn or in need of repair, we're able to use the latest gear cutting and milling tools to replace the original gear and shaft components and recondition the gearbox so that it is like new once again. Very often, one or two parts will be causing the entire gearbox to fail so all that needs to be done is to get into the unit, undergo an aforementioned inspection, and reengineer the damaged gears and/or shaft, supply new bearings and oil seals and build the gearbox back up to be tested. We can take worn parts and replace them working from a drawing or reengineering them from the sample. Whatever you come to us with, there's a very good chance we're able to use our reconditioning skills to sort it.

Gearbox Spares

When unexpected issues affect your business's capability the need for rapid spare parts, to limit downtime, is essential. Our team can provide spare parts from our Huddersfield-based factory very quickly and can engineer parts, gears, couplings, and components to a high degree of accuracy and quality. We know the importance of this vital service which is why we have invested in the best technology to ensure we can offer a fast service that doesn't sacrifice any other important factors such as strength and accuracy.

Preventative Maintenance And Proactive Condition Management

Prevention is better than the cure, as the old saying goes. We believe in this mantra wholeheartedly and, as a result, offer comprehensive preventative maintenance and proactive condition management services that gets in there and fixes small issues, such as a build-up of filament, before they are left too long and result in something more detrimental that causes bigger problems, for both your business and its bottom line. By consistently making small repairs we are also able to keep an eye on your gearbox and monitor its performance - this level of surveillance is incredibly beneficial, and leaves you to focus on other business issues knowing any small problems that occur are going to be fixed right away, for a fraction of the cost.

Emergency Industrial Gearbox Repair Service

However thoroughly you watch your gearbox and its performance levels, occasionally, something out of the blue will cause you to need last-minute emergency repairs at the most inconvenient times, such as the weekend, the middle of the night, or during a business period where orders for a big contract need to be fulfilled. We know the stresses, both on employees and finances, that broken machinery can have on a company which is why we offer a truly 24/7 emergency service that can undergo gearbox repair, and gearbox inspection services, any time of day or night. You can rest easy knowing a group of experts are awake, even when your business isn’t, ready and eager to fix the issues to the same high standard and quality that we are known for here at Highfield Gears.

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Gearbox Refurbishment

One of the most popular services we offer here at Highfield Gears, as well as industrial gearbox repair, is industrial gearbox refurbishment. Gearbox reconditioning and refurbishment is a very popular option because it is, on the whole, a much more cost-effective solution, with lower average prices, when compared to entire gearbox replacement that can cost thousands of pounds more. In addition, by improving your existing gearbox, you don't have to tweak settings or retrofit parts to fit in with your current machining process. With refurbishment, all you're doing is improving the existing individual parts and putting the gearbox back together.

We’re well versed in gearbox refurbishment and thanks to our experience with units from a wide range of popular global gearbox manufacturers, such as DB Santasalo, Hansen, and Radicon, to name but a few, we can recondition and upgrade existing parts easily. At our gearbox repair shop, we will begin the process by breaking down the gearbox into its component parts, before examining each and everyone for wear and tear and apparent faults, such as missing teeth, and then assess what needs to be done to improve performance.

If a part is worn or can no longer be used, we can reverse engineer these components based on the part, and existing drawings, so that you have a brand new part, that is the exact same as the old one. This saves so much time having to alter components after the fact. The new part is bespoke, made to your exact measurements, and can slot straight into your gearbox. If you’re worried about these parts not meeting standards, fear not. All our manufacturing is carried out to exact ISO standards that ensure consistency, and product strength, and help to bring old gearboxes up to new standards, without the expensive outlay.

At Highfield Gears, we use our gear refurbishment service as an opportunity to advise, provide insight, and help you prevent future damage. This proactive element of our service is loved by our customers who feel empowered to spot problems if they occur later in the gearboxes’ life. If we spot common problems, we can advise on how best to avoid them and how to alter the performance of your gearbox so that it is more gentle on the component parts, without sacrificing the efficiency that helps you produce products quickly. We can schedule regular maintenance and checks so that the gearbox you own lasts longer, doesn’t need replacing, and just requires semi-regular refurbishments from a team that knows your transmission units inside out. Managing your assets like this is priceless, and will save you a great deal of money over the long term.

To learn more about our refurbishment service, how we avoid an entire gearbox rebuild and create new gearbox components, feel free to get in touch with our team who will happily walk you through the process and show you how our service can help you save money, and improve performance.

Why Choose Highfield Gears?

When industrial gearbox failure strikes, you need things back up and running immediately in a way that is comprehensive and cost-efficient. All these factors need to align quickly so that you can get your unit back up and running without spending thousands on unnecessary work.

By repairing an existing gearbox, you can save money and bring your manufacturing capacity back to 100% in no time at all. This is especially true when you compare this to the length of time, usually several weeks, that you’d have to wait to buy, and install, a brand-new gearbox. In short, repairing issues is the most logical option in 99% of cases.

With 90+ years of experience in the industrial gearbox repair industry, we’re able to sort any issue in your gearbox, regardless of the year made, brand, original manufacturer, or specifications. All this can either be done on-site, at your premises, or our team can take your gearbox and bring it to our bespoke gear centre where we’ll enact a mixture of those aforementioned solutions to get things back up and running in no time at all. We’re all about keeping downtime to an absolute minimum, and our ability to provide a service that is quick, and correct, is something we pride ourselves on, no matter how advanced or complex modern-day industrial gearboxes are.

While we have been around for a long time, this doesn’t mean we are stuck in our ways. We’re always looking on the horizon for the latest piece of machinery, solution, or technology that is going to provide our valued customers with an even quicker, more thorough, service. Over the decades we have been in business, we’ve been able to invest in the latest equipment of the day, and are always ready to spend more so that you benefit further from our products and services.

Case Studies: How We've Helped Global Brands With Their Industrial Gear Units

A century's worth of experience has allowed us to work with some truly global brands.

These household names are known throughout the UK, and the rest of the world, and rely on geared motor units to create the products that we all know and love. We’re honoured that, when things go wrong, they come to us over another global competitor in the gearbox industry that has offshore plants in far-flung places. Our clients appreciate the fact we have remained in the UK and continue to employ some of the world’s best industrial gearbox repair men and women. Our personal service, vast knowledge, and experienced engineers are just a few of the reasons they come back to us when they require repairs, reconditioning, or gearbox upgrades. Here, we’re showcasing three examples of how we’ve helped these brands get their gearboxes back up and running. These are just three examples, in the decades we’ve been working we have helped other household names such as Ineos and Tata Steel. We hope these case studies emphasise the exceptionally high standard of workmanship that we undergo on a broad range of gearboxes and power transmissions.

If you have any further questions about how we can help, please fill out the contact form on this page and a member of our team will be in touch to discuss your issues and provide you with a competitive quotation.

Lubrizol

The Lubrizol Corporation is a chemicals provider for the transportation, industrial, and consumer markets.

They supply a complete range of chemicals such as engine oils, additives for industrial lubricants, gasoline, and diesel fuel. Their headquarters is based in Wickliffe, Ohio but they have a plant right here in the UK, in north Wales. The team from Wales came to us with a series of issues and thanks to our cutting-edge equipment, and detailed reporting, we were able to limit crippling downtime costs and have the Manchester Lubrizol plant back up and running.

To start with, the input bearing had entirely collapsed, as had the high-speed input shaft, which was far beyond repair. Also, both Redn bearings had significant damage and pitting to them. The Epicyclic uni also had a great deal of internal damage because of recent bearing failure and internal components flying around and damaging parts.

We fixed all these issues for Lubrizol in no time at all. On a component level, we created a new high-speed input shaft and supplied new ground sleeves and cycloid discs. As well as our five-star maintenance, we also fitted new bearings and seals to ensure the components wouldn’t be affected by external factors.

Highfield Gears Specialist showing a younger engineer the specifications

Tata Steel

Tata Steel is a company that is extremely well known. This conglomerate operates in plenty of sectors, from the car market to the steel industry.

As a result, they have plants all across the world, including Port Talbot in Wales. The team there came to Highfield Gears to discuss a problem they were having with one of their gearbox units that was hampering their ability to meet their business goals.

Upon inspection, it was clear that these problems were very real, and causing serious damage. The output couplings were very worn, with significant damage due to twisting that had occurred. Reduction pinions and wheelsets were countersunk and there were large screws stuck into the housing, right between the bearings.

After cleaning the gear case, to get a better visual, we saw that the bearing houses had worn down significantly both on the drive and non-drive end. On top of this, the output bearing was completely destroyed and would need to be replaced. To solve this vast number of issues, a holistic, joined-up approach would be needed. This was needed to fix both the initial problems that had caused the failures, and stop any future problems from manifesting into something bigger.

Our team got to work fitting a new bearing housing, pinion shaft, and reduction wheel. We also proactively refitted the existing couplings so that any future transmission performance would be optimised. After finally fitting new seals, fasteners, and bearings, our team then thoroughly tested the unit. These final checks are just as important as the repair process as they allow us to test the performance of the new components to their limits to see if they meet the high standards that we’re known for. We supplied the unit back to Tata Steel only after we were happy that the repairs we made were up to scratch.

Highfield Gears Specialist working on Gearbox Repairs

Ardagh Glass

The Ardagh Group produces glass and metal products from plants in their home country of Luxembourg, and in the UK.

Founded in 1932 they are one of the largest producers of metal and glass in the world. Their Barnsley team came to us when their industrial units were suffering from serious damage and wear. After initial consultations, and learning more about the problems the client was facing, we went ahead and devised a bespoke plan that would deal with all the problems Ardagh Glass was facing in an efficient time.

Upon inspection, we found that one of several inputs had no drive and a splined shaft between the bevel wheel. The pinion on the spur and the secondary B shaft had sheared entirely, causing the tapered roller bearing to collapse entirely.

The lubrication system in the gear case needed a new pipe after it had failed, and there was also major damage to the bearings and seals which all needed replacing. Once we had created detailed reports of all the issues we discovered, we got to work fixing them. We repiped the lubrication system and replaced the two splined shafts with upgraded ones that would last for years to come. We also used our cutting-edge technology to manufacture new coupling flanges and locknuts that would be fitted to the hypoid spiral bevel pinion.

As with other clients, we underwent thorough testing of these new components to ensure they would work once they were back in Ardagh Glass’s plant.

Gearbox Refurbishment

Industrial Gearbox Repairs & Refurbishment

Our gearbox specialists offer end-to-end industrial gearbox repair & refurbishment services for all types of industrial gearboxes with easy maintenance.

We have an experienced and friendly industrial gearbox specialist team, and we know that when your gearbox is down, you need to get the issue sorted quickly and efficiently. Sometimes a straight replacement is not the fastest and most cost-effective solution, and we are here to get you back up and running as soon as possible. We can help with everything, from industrial gearboxes and geared motors all the way through to large heavy duty custom-built crane gearboxes, pulverising mill gearboxes and extruder power transmissions.

Our industrial gearbox services can help with all types of gearboxes, including:

  • Helical speed increasers
  • Shaft-mounted reducers
  • Cooling tower gearboxes
  • Extruder gearboxes
  • Mixer Gearboxes
  • Single & double reduction worm reducers
  • Helical & helical bevel reducers
  • Variators
  • Bevel Helical
  • Planetary units
  • Epicyclic units

If you are wondering, “where can I find an industrial gearbox repair near me?”, our industrial gearbox specialist team can help you with:

  • Quick collection, strip down and diagnosis
  • Detailed inspection report and industrial gearbox repair report
  • OEM warranty
  • Washdown and steam clean facility following your industrial gearbox rebuild
  • On-site support available for industrial gearbox maintenance, inspections, plant removal, and installation work
  • Oil analysis, root cause failure analysis, and vibration analysis services
  • Call system in place for all industrial gearbox repair services for full breakdown attendance

Industrial gearbox refurbishment services will be followed by a range of comprehensive tests to ensure they are all the highest standard before being recommissioned.

Diagnostics and inspections

Industrial gearbox repairs always start with an inspection and diagnostics so you know exactly what state your equipment is in. We have the capacity to visit your facility and carry out inspections on any brand of gearbox and we can offer you:

  • Visual inspections
  • Sketches on internal parts including gears, shafts, etc.
  • Vibration analysis
  • Oil analysis
  • Assessment of the condition through a detailed report
  • Non-load test

Our industrial gearbox specialist will then repair your equipment and deliver them back to you as though they were new. We will bring your gearbox back to our facilities and perform a thorough industrial gearbox service including dismantling, cleaning, and inspection. We will inform you about the best possible, most cost-effective solution to get you back up and running again.

In most cases, you will not have to pay for a brand-new gearbox. In order to improve the performance of your application, we can help with an industrial gearbox refurbishment to help improve the performance, increase durability, and reinforce the critical elements to help your equipment go further.

Industrial gearboxes maintenance

If you want to stay on the top of your game, we can help you to plan and schedule industrial gearbox maintenance services so you won’t be caught short. Our industrial gearbox services include:

  • Preventative industrial gearboxes maintenance to identify critical wear of components
  • Manufacturing / supplying of replacement parts and critical elements
  • Technical advice from our industrial gearbox specialist
  • Industrial gearbox refurbishment or replacement

With the help of our knowledgeable experts, we will perform your industrial gearbox repairs to the highest standards to keep you up and running.

Why choose us for your industrial gearbox repair?

We offer a wide range of industrial gearbox services, including repairs, refurbishments, and maintenance. Our trained experts will ensure that your gearbox is repaired and installed to the highest of standards, and we are always on hand no matter what the issue. When you choose our industrial gearbox services, you can expect:

  • 24/7 support from our dedicated site
  • A name that is trusted by some of the world’s biggest brands
  • Industrial gearbox services for any industrial brand, type, and model
  • Fully assessment management and maintenance for your equipment
  • Nearly 100 years of experience from our trained and skilled professionals
  • State of the art equipment to provide thorough analysis and diagnostics

Industrial gearbox repair services

Whether you are searching for ‘industrial gearbox repair near me’ or ‘industrial gearbox services near me’, we are your one-stop solution to spare you the stress of heavy duty gearbox repair services. We know that speed is essential when you are in need of an industrial gearbox repair, and that’s why we are here 24/7 whenever you need our services, including repairs, refurbishment, maintenance and gearbox repairs.

FAQs

Each industrial gearbox repair will differ, depending on the problem and the work involved. All of our quotes are made on an individual basis following a thorough inspection and diagnosis, and we aim to offer you the quickest and more cost-effective solution to get you back up and running again.

It is not always necessary to replace the whole gearbox when something goes wrong, and in most cases an industrial gearbox repair is the quickest and most cost-effective solution. If we cannot simply repair it, we always have the option of a total industrial gearbox rebuild or refurbishment to give you the most for your money.

Industrial gearboxes are extremely durable machines that can withstand high temperatures, pressures, and difficult conditions. The most common issues that you will encounter with your gearbox include misalignment, lubrication issues, bearing problems, thermal instability, and torsional and lateral vibrations. If you encounter any of these, then call us today for industrial gearbox repairs.

Most industrial gearboxes will last for around 20 years, but only if they are taken care of properly. It is important that you have our gearbox inspected regularly and ensure proper maintenance is scheduled. This way, you can keep an eye out for mechanical problems and get them fixed straight away.

A refurbished industrial gearbox is as good as a brand-new gearbox if it is worked on by an industrial gearbox specialist. All our parts are OEM guaranteed, and you will find that your industrial gearbox refurbishment will last as long as a brand new one – especially if you take care of it and schedule regular maintenance to keep your equipment running smoothly.

The industrial gearbox refurbishment and reconditioning involves a complete disassembly of the gearbox to allow a full analysis of the components. All of the worn components are then replaced, including bearings, gears, gaskets / seals and any other damaged parts. These parts are then replaced, and the gearbox is assembled and tested to ensure its efficiency and operation.

A reconditioned gearbox is basically the same as having a new gearbox, but without the high price tag. All of the critical components such as bearings and seals are changed, as well as anything else that doesn’t meet the high standard criteria.

How long your rebuild will take will vary for each individual project, but we will always aim to be as fast as possible. You can choose between a regular or an emergency industrial gearbox repair, so you know we will always be working within your budget and your timeframe.

Common signs of gearbox damage include excessive noise, oil spills, cracks and vibration. Usually, you will be able to repair or refurbish your industrial gearbox, which will save you a hefty bill. However, if you ignore common issues and signs that your gearbox needs some attention, then you can end up damaging it beyond repair – and you will have to fork out for a new gearbox. Get in touch today for an inspection to find out what options are available for you today.

Get In Touch With Highfield Gears Today

Our Huddersfield location makes us ideally suited to help businesses and organisations across England, Wales, Scotland, Northern Ireland and further afield in Europe. We’re customer focussed and are only happy until you are, which is why we work all hours at our service repair centre offering a quality service. We never tire of knowing that a job has met our stringent quality checks and is back helping you make your business go from strength to strength.

If you’re based near Huddersfield, the surrounding cities and towns such as Sheffield, Leeds or Barnsley or further afield in the UK or Europe and are after advice from a team of people who are experts at industrial gearbox repairs and reconditioned gearboxes then get in touch with the team here at Highfield Gears on 01484531010 or email us at sales@hgi-uk.co.uk – the team at our gearbox centre look forward to helping you.

    Glossary

    As one of the largest gearbox repair companies in the north of England, which have repaired thousands of gearboxes, we’re accustomed to all the industry terms and phrases. There is a great deal out there and they can feel a bit confusing so, to help you, we’ve compiled a simple glossary that addresses some key phrases so the next time something goes wrong with your gearbox, you’ll be able to explain the problem using accurate terms.

    Hobbing

    This is a term that refers to the process of cutting teeth into a gear blank (a gear without any teeth).

    Torque

    A measure of gear’s rotational tendency in response to a force. Torque is measured in Newton-meters (Nm).

    Pitch Circle

    An imaginary circle that rolls against the pitch circle of the connected gear.

    Clearance

    The clearance of a gear is the distance, radially, from the top of one tooth to the bottom of another tooth on the corresponding gear.

    Full-depth

    Full gear depth is calculated as Addendum (the distance between the pitch circle and outermost gear circle) + Dedendum (distance between the pitch circle and innermost circle of a gear).

    Diametrical pitch

    This is the number of teeth per unit volume.

    Face width

    Face width is measured by measuring the length of the tooth parallel to the gear axes.

    Gear ratios

    An important phrase, this ratio is calculated as the number of teeth in a larger gear by the number of teeth in the smaller gear. For instance, if a large gear had 40 teeth, and the smaller gear it is attached to had 20 teeth, the ratio would be 2:1.

    Rack

    A rack is a gear that is a straight line, with an equal amount of teeth across it. It usually forms part of a rack and pinion set.

    Whole depth

    This term describes the depth of engagement of two gears, or the sum of their addendums. The typical depth is usually the depth to which a tooth extends into the tooth space of a mating gear.

    Internal gear

    A type of gear that has teeth on the inner cylindrical circle.

    Base helix angle

    This is the term that describes the base cylinder of an involute gear that a tooth makes with the axis of the gear.

    Axial thickness

    The distance parallel to the axis between two pitch line elements on the same tooth.

    Addendum

    This is the distance (either radially or perpendicular) between the pitch circle and the top of the tooth.

    Base tooth thickness

    This is the term that describes the distance on the base circle in the plane of rotation between involutes of the same pitch.