Evolutionary Gearbox Solutions

The Gearbox Hospital - Emergency Repairs and Spares

  • We run innovative and customer oriented gearboxes hospital i.e. Urgent gear repairing unit at our Sangli work.

  • This unit is leaded by Directors to reduce break-down time extensively with instant decisions & innovative techniques.

  • We overhaul & repair all sorts of gearboxes and related drive parts. We are active in all high-demand market segments of industry. Where our customers expect the fastest response.

Due to extensive repair experience of more than 1000 gearboxes, (Including Ex-Employers, now we have standardize the repair procedure of all types of gearboxes what customers have to do is contact us. We are available for 24 hours, All week days for urgent response to you,

Our standard delivery time in crises-2/3 days for simple gears, & 1 week for hardened – ground gears (after receipt of material).

We keep most of the materials in stocks at our forger for urgent raw material…

We also have know how and expertise of latest metal rebuilding techniques like Laser cladding , cold welding for providing breathing time till new part get ready.

Step-1 :- Emergency contact (24 h support for gearbox breakdown) 

A sugar factory suffers from power turbine gearbox damage & plant shut down. The delivery time for a new, OEM-built gearbox is 3 months. The customer contacts Max- Gears for emergency gearbox repair.
Step-2:- Onsite inspection and dismantling of the gearbox

The first step is to establish the condition of the gearbox with gear clearances, contact patterns bearing settings and gear sizes, damage (crack) examination. All being carefully recorded during the gearbox dismantling. After the in depth investigation is complete, the best available option is offered to customer with budgetary cost.
Step-3:- Fast transport of required raw materials & damaged parts to our workshop. 

Our procurement department avails for forgings till the damaged parts reach to us. Within no time the details of profile are recorded on latest G.M.M. (Gear Measuring Machine) or C.M.M. (Coordinate Measuring Machine) & Preparation of urgent drawings is completed parallely.

Step-4:- inspection report and final failure analysis.

Ones again the detail inspection & failure analysis is done in presence customer representative. We have complete range of innovative tools, 500 Ton press, and various special jigs for dismantling of any type of Gears. Our special team has developed great expertise for same.
Step-5:- Fast gearbox repair & manufacturing of the damaged part
The damaged parts are repaired urgently.
We have complete manufacturing facilities with all types of machines & checking equipment’s.
Gear blanking – heavy duty turning / threading, key way milling, drilling Etc.
Gear cutting for both internal / external gears
All grinding – bore face grinders, bearing / gear seating grinders / profile grinders Etc.
Step-6:- Gearbox assembly and test run

The gearbox is assembled again. The test runs assures or Defines the expected life of gears & load customer can put. Generally we do urgent repairs in two days. Run gearbox at site for few months.till that keep ready new spares with precious reverse engineering for customers as emergency replacement.
Step-7:- Transportation & onsite assembly of the gearbox and related parts

We provide detailed report to customer for whole procedure. Also attend commissioning the gearbox till it gains its performance to customer expectations or committed by us in previous report.

Design, Manufacturing, Supply and Services

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