As the components responsible for controlling speed, torque, and direction in motors, gearboxes are some of the most important elements in a modern industrial facility. They ensure the proper and precise functionality of all kinds of equipment from powered conveyor belts to advanced robotic assembly arms. Given how crucial they are, it’s important to know when your equipment needs maintenance to prevent costly breakdowns and extensive industrial gearbox repairs. Here are eight of the most common industrial gearbox warning symptoms that may indicate gearbox repair is needed.
1. Unusual noises
If a gearbox begins making grinding, whining, or rattling noises, that’s a clear sign that something is wrong. Scraping or grinding sounds may indicate worn-out or damaged gears, while any whining or humming noises could be the result of a bearing failure or insufficient lubrication. If there’s rattling, chances are there may be some loose components inside the gearbox.
2. Excessive vibrations
A gearbox that begins to vibrate more than expected means the unit is off-balance, which can lead to instability throughout the machinery. This may be caused by misaligned components as well as worn bearings or gears. There’s also a chance the issue may be elsewhere in the equipment, so it’s a good idea to look beyond the gearbox when this occurs.
3. Oil leaks
Seals that are old or damaged can cause oil to leak out of the gearbox. This can lead to the gearbox losing much-needed lubrication as well as the possibility of contaminants entering the unit. In both cases, the lifespan of the gearbox can be negatively affected. Regular checks are necessary to spot any leaks as soon as possible and prevent industrial gearbox failure.
4. Overheating
Excessive heat can have a negative impact on the performance and longevity of a gearbox, which is what makes checking the temperature of these components so important. Overheating typically is caused by insufficient lubrication or overloading the equipment beyond its specified capacity. If you notice these issues cropping up frequently, make sure the machinery is properly ventilated and pay attention to the environmental conditions surrounding it.
5. Decreased performance
A faulty gearbox that delivers reduced output or slower speeds than normal requires attention as soon as possible. There could be a host of issues at play, from improper use of lubricants to worn gears to faulty bearings. Addressing these gearbox problems as soon as they are found is key to restoring proper performance and productivity.
6. Gear slipping or sticking
When gears start to slip inside the gearbox, the culprit is most often worn teeth. Replacing these gears with new parts should alleviate this issue. If the gears are sticking, the problem is probably a lack of lubrication or a faulty synchronizer.
7. Unstable oil pressure
If the oil pressure is too low, it can have an adverse effect on lubrication levels and lead to premature gearbox failure. In most cases, this is the result of a damaged oil pump or a blockage in the lines.
8. Frequent shutdowns or stops
A gearbox that fails to engage or stops altogether can cause shutdowns throughout your operations. The most common causes of unexpected shutdowns in gearboxes are seized gears or excessive strain.
The importance of timely gearbox maintenance
Protecting your facility’s gearboxes is crucial for keeping your production level high and preventing costly shutdowns. If you happen to notice any of the warning signs listed above, it’s important to reach out and contact a professional to provide industrial gearbox repair service and keep your facility running as smoothly as possible.
Learn more about service options from STOBER by clicking the link below or contact us at (888) 786-2371 or email sales@stober.com.
Eight warning signs that you need industrial gearbox repair 
What is a planetary gearbox and how does it work? 
Keyed vs. keyless connections: What’s the difference and why does it matter? 
2025 STOBER scholarship winners announced