Proper Lubrication System:- Before Installing the gearboxes, it is necessary to fill the gearbox with proper Lubricant, with proper Lubricating quantity as specified by the Planetary Gearbox Manufacturer in Satara. For Vertical Mounted Gearboxes use of oil cups is very important.

1. HOW TO INCREASE THE LIFE OF YOUR INDUSTRIAL GEARBOX?
Gearbox is the driving heart of any machine or equipment, and hence the failure of the gearbox
is not desirable, as it costs a lot to the organization due to the failure of gearbox. At the point,
when a gearbox fails, it can dramatically affect the productivity, sometime it may shut down the
entire line, or in some cases, the whole plant, resulting into huge production loss or monetary
loss accounted due to downtime. In some applications, where human interference is connected,
the gearbox failure can harm the life of humans also. To avoid this, using gearboxes of highly
reliable gearbox manufacturer’s like “Top Gear” is of utmost importance. Top Gear
Transmissions offer a wide range of Transmission solutions, designed to get things up and
running again as quickly as possible and minimize downtime when the worst-case scenario
occurs. Top gear’s huge Research of more than 20 years, has enabled the design of reliable
gearboxes that put minimal service requirements and serves as failure avoidance.
With some added maintenance tips or safety precautions, the life of the gearbox can be further
increased.
MAINTENANCE TIPS FOR INCREASING THE LIFE OF
THE GEARBOX.
Before Installation & commissioning of gearboxes
1. Check the gearbox is operating within its manufacturer’s specification for both mechanical
and thermal ratings. On many occasions, gearboxes are put into an application beyond their
design specification and are being driven by an increased input power greater than the maximum
recommended.
2. Proper Lubrication System:- Before Installing the gearboxes, it is necessary to fill the gearbox
with proper Lubricant, with proper Lubricating quantity as specified by the Planetary Gearbox
Manufacturer in Satara. For Vertical Mounted Gearboxes use of oil cups is very important.

2. 3. Use the correct type of breathers and keep it clean for dirt and debris.
4. Before joining the gearbox and motor, clean the surfaces of mating parts. Properly remove the
Rust preventive applied by the gearbox manufacturer.
5. Proper alignment has to be done between the gearbox and motor shaft (either hollow or solid).
6. Before fitting the coupling & shaft diameter, for input and output shaft, ensure the size of
coupling as per the drawing. Ensure the bore tolerances of coupling and shaft tolerances, prevent
the heavy force fit or press fit.
7. Before connecting the planetary geared motor to the load, just as a safety measure observe the
noise, vibration, leakage and temperature of the gearbox. To prevent problems arising due to the
above parameters, Top Gear Tests, all the gearboxes for Leakage, Noise, Vibration &
temperature, strictly, before dispatching the gearbox to the customer.
8. For foot free(Solid input) gearboxes ensure the use of stoppers for gearbox and motor to
prevent the gearbox and motor from changing their original location.

3. AFTER INSTALLATION & COMMISSIONING OF GEARBOXES
1. Change the lubricant(oil) after specific hours of running, as recommended by the
manufacturer. After changing the oil, observe the old oil, as the presence of small metallic
particles may represent the wear of internal parts.
2. Regularly check for the leakages at the input and output shaft, joints, and plugs of the gearbox.
3. Observe the gearbox regularly for noise and vibration. Regular vibration analysis of the
internal bearings and gears will confirm any significant changes in the internal condition of the
gearbox.
4. Always monitor the signs for overheating of the gearbox, signs such as discolored or burnt
exterior paint, or dark oil in the sight glass indicates that there is excess heat rise inside the
gearbox. If possible, make use of an infrared temperature gun to Monitor the gearbox
temperature on a regular basis and to find out, if there are any sudden changes in temperature.
6. Inspect the gearbox for backlash and also for any increase, in the end, play or lift at the input
and output shafts. An increase in backlash may lead to gear teeth wear. And the increase in shaft
endplay or lift would indicate wear within the rolling elements of the bearings or even wear in
the bearing housings.
7. For No load and Load conditions observe the motor current, increase in the motor current than
normal current may indicate the jamming of parts which may lead to failure of bearings and
other parts.