Gearbox Overhaul in a Mining Conveyor System – Restoring Power and Performance in the Field

In mining operations, conveyor systems are the lifeline of material movement. Whether transporting crushed stone, raw ore, or overburden, these massive belts operate under intense loads for long hours in harsh environments. At the heart of each conveyor lies the gearbox—an essential component that converts motor speed and torque to match system demands. When a gearbox fails, the entire operation suffers.

Industrial & Mining Services (IMS) specializes in field-ready gearbox overhaul and repair for mining conveyor systems across Georgia and the Southeast. From thermal overload and seal failure to shaft misalignment and gear wear, our technicians restore gearboxes to peak condition while minimizing costly downtime.

Why Gearbox Overhaul Is Critical in Mining

• High torque loads
• 24/7 operation under stress
• Dust, moisture, and heat exposure
• Start-stop shock loading
• Progressive wear over time

Even top gearbox brands require periodic service to avoid failures and ensure reliability.

Case Study: Failed Gearbox on a 60" Conveyor in Central Georgia

A large crushed stone plant near Macon, GA contacted IMS after observing:

• Drive vibration
• Oil leakage from input shaft
• Audible whining during start-up
• Gearbox logged 28,000+ hours

Step-by-Step: Gearbox Overhaul and Repair

Step 1: Safety Lockout and Assessment

• Vibration analysis
• Thermal scan of gearbox
• Oil sample extraction
• Motor alignment check

Step 2: Removal and Transport

• Rigging and lift equipment used
• Labeling for reassembly accuracy
• Secure transport to IMS machine shop

Step 3: Disassembly and Root Cause Analysis

• Pitted bearings and worn seals
• Gear scoring and rust trails
• Dust intrusion via failed breather

Step 4: Overhaul Procedures

• Shafts straightened and measured
• Gears cleaned and backlash verified
• New SKF bearings and Viton seals
• Resurfaced and painted housing

Step 5: Reassembly and Testing

• New synthetic oil added
• Breather replaced
• 2-hour test run at operating temperature
• Final vibration and temperature logged

Step 6: Field Reinstallation

• Laser-aligned motor and reducer
• New coupling installed
• Run test under full load
• Post-install inspection completed

Results Summary

Metric	Before Repair	After Overhaul
Vibration RMS	0.48 in/sec	0.12 in/sec
Bearing Temp	190°F	135°F
Gear Wear Noise	High	Minimal
Oil Condition	Contaminated	Clean
Downtime Risk	High	None

IMS Gearbox Services Include

• Gearbox rebuilds
• Seal and bearing replacement
• Gear repair and lapping
• Shaft straightening and alignment
• Oil analysis and flushing
• Laser shaft alignment
• Emergency service calls
• Preventive maintenance plans

Brands We Service

• Falk
• Dodge
• SEW Eurodrive
• Rexnord
• Flender
• Sumitomo
• Bonfiglioli
• Hansen

Why Choose IMS

• Certified millwrights and rebuild specialists
• MSHA-compliant safety procedures
• Fast turnaround and emergency support
• Full reporting and photographic documentation

Targeted SEO Keywords

• mining conveyor gearbox overhaul
• gearbox repair service georgia
• industrial gearbox rebuild macon
• conveyor reducer rebuild georgia
• gearbox bearing replacement mining
• heavy-duty gearbox repair southeast
• emergency gearbox service quarry
• mining drive unit failure fix
• shaft alignment conveyor motor
• oil contamination gearbox
• vibrating gearbox troubleshooting
• mining equipment gearbox maintenance
• aggregate conveyor gearbox fix
• reducer housing leak repair
• mining conveyor gearbox vibration
• seal replacement gearbox mining
• gearbox field service macon ga
• conveyor system power transmission
• reducer rebuild quarry site
• oem gearbox parts replacement
• gear scoring repair services
• gearbox diagnostics industrial plant
• preventive gearbox service plan
• laser alignment conveyor gearbox
• gearbox inspection mining operations

Client Testimonial

“IMS saved us from losing an entire week of production. They removed the gearbox, rebuilt it like new, and had us running again in two days. It’s been humming ever since.”
– Plant Manager, Aggregate Producer, Central Georgia

Keep Your Gearbox—and Your Operation—Moving

Gearbox issues can be silent killers in mining operations. Don’t wait for failure. IMS offers field and in-shop gearbox repair services that restore your equipment with minimal downtime.

Contact Industrial & Mining Services today to schedule a gearbox inspection or set up a preventive maintenance agreement.