COURSE OVERVIEW:

Industrial gearboxes are the mechanical muscle of the plant, transferring torque and adjusting speeds for pumps, conveyors, and compressors. This course provides a comprehensive roadmap for managing the lifecycle of these critical assets, from the initial engineering selection to the execution of complex repairs. Participants will examine the geometry and kinematics of various gear types—spur, helical, bevel, and planetary understanding how each design handles different load profiles and directional requirements.

The maintenance and inspection sections focus on the internal health of the unit. We will detail the specific lubrication requirements that prevent metal-to-metal contact, focusing on the role of extreme pressure (EP) additives and synthetic oils in protecting teeth surfaces. Attendees will learn to utilize non-destructive testing and advanced condition monitoring techniques, such as oil debris analysis and vibration spectroscopy, to identify early signs of pitting, spalling, and scuffing before they lead to catastrophic failure.

Troubleshooting and repair are addressed through a hands-on technical lens. The course covers the precise arts of gear tooth contact pattern analysis and shaft alignment, which are essential for ensuring even load distribution across the gear face. Participants will study the steps involved in a full gearbox overhaul, including bearing replacement, seal installation, and the critical measurements of backlash and endplay. This holistic approach ensures that gearboxes operate at peak efficiency with minimal downtime.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1.  Select the correct gearbox type and ratio for a specific mechanical application.

2.  Interpret gearbox nameplate data and service factors (AGMA/ISO).

3.  Evaluate the benefits of helical versus planetary gear arrangements.

4.  Monitor and interpret lubrication health through oil analysis reports.

5.  Identify common gear failure modes like micropitting and plastic deformation.

6.  Perform gear tooth contact pattern checks using "Blueing" compounds.

7.  Execute precision bearing replacements and shaft seal installations.

8.  Diagnose gearbox noise and vibration issues using frequency analysis.

9.  Measure and adjust gear backlash and axial endplay.

10.  Implement effective cooling strategies for high-horsepower gear units.

11.  Troubleshoot overheating and oil leakage in enclosed gear drives.

12.  Conduct a structured root cause failure analysis (RCFA) for gear systems.

13.  Develop a comprehensive preventive maintenance schedule for gearboxes.

TARGET AUDIENCE:

Mechanical Maintenance Engineers, Reliability Technicians, Workshop Supervisors, and Plant Operators responsible for the upkeep of industrial drive systems.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.