Top 5 Types of Heavy Equipment Machinery

Did you know that the global heavy equipment market is projected to hit $162.4 billion by 2027? For practitioners in field-based industries, heavy equipment machinery is a necessity. However, getting the right tools for an industrial or construction project is quite daunting.

You need to evaluate your project needs and pick heavy machinery suited for that job. In this article, we discuss the five common types of heavy equipment machinery:

1. Excavators

Excavators are among the most common heavy equipment machinery used in the construction sector. They consist of a cab, bucket, dipper, and boom. The cab, which houses the operator, sits on top of an undercarriage ferried by wheels or tracks.

Hydraulic excavators rely on hydraulic motors, hydraulic cylinders, and hydraulic fluid to function. They are ideal for digging foundations and trenches, forestry mulching, and material handling. You can also use them in general landscaping, open-pit mining, and snow removal.

2. Bulldozers

As a large-tracked heavy machine, a bulldozer has excellent mobility and ground holding capabilities. Their distinct application areas include mining, construction, and road building. Thanks to their wide tracks, they can move over muddy or sandy grounds without sinking.

Bulldozers comprise transmission systems that offer great tractive force when in use. Its machine parts include a heavy metal blade used in shoving debris/soil and pushing objects. In addition, bulldozers come with a ripper on the back used to break ground surface rock.

3. Compactors

Compactors come in three designs, which include the road roller, rammer, and plate compactor. Road rollers help compact crushed rock on slabs or stone foundations. Due to their smaller feet, rammer compactors help compact backfills in narrow trenches for gas or water supply pipes.

Plate compactors come with a vibrating baseplate used to compress gravel or soil for a stable subsurface. Both rollers and plates rotate rapidly to compact the matter underneath them. Choose a compactor with adequate power to compact soil or stones in the required depth.

4. Cranes

Cranes come equipped with sheaves, chains, and a hoist rope to lower and lift materials. They help load and unload freights in the transport industry and assemble materials in the manufacturing sector. You can also use them to move materials in the construction industry.

Tower cranes are the most common types of cranes used in constructing tall buildings. They are usually attached to sides of horizontal structures or fixed on a concrete slab. Choose a crane depending on the moving distance, lift height, and weight of the load.

5. Concrete Pumps

Concrete pumps help transfer liquid concrete into the area where you need to lay it down. They can either be mounted on a trailer/truck (line pump) or attached to a truck or semi-trailer (boom pump).

Evaluate your concrete output for a construction project before choosing a concrete pump. You should also consult with a heavy machinery mechanic to see if the pump specification suits your project.

Looking to Buy Heavy Equipment Machinery?

The heavy equipment machinery discussed above is suited for different projects and job sites. Always identify your need for getting the equipment and learn the maintenance needs before buying/renting it.

We offer an extensive collection of hoists and cranes for diverse industrial applications. Our experts also provide repairs, modernizations, and upgrades on the tools sold. We’ll help you get the right equipment once you contact us.

What to Look For When Purchasing Industrial Parts

In most manufacturing companies, buying industrial parts is an essential task in running daily operations. However, it can be expensive, so it is crucial to have the proper procurement and purchasing process.

You want to buy high-quality equipment that is the best fit for the job at a reasonable price.

Here are things to consider before committing your budget.

Price Negotiation

When considering where to get industrial parts, you should compare quotes from several different suppliers. You may be able to negotiate the price down if a supplier is prepared to beat a competitor’s offer. You might also be able to negotiate a discount for buying parts in bulk.

Decide whether you will buy used or new industrial parts. If you’re on a tight budget, buying used equipment could be an option.

Keep in mind that the lowest price may not be the best option if it compromises on quality. On the other hand, more expensive equipment may cost less in repairs over the long run and offer higher precision that minimizes costly mistakes.

Workforce Engagement

Determine how much work your employees will need to do to manage different types of equipment. Fully automated systems require a smaller workforce, freeing up the budget for other areas of the business. You should ensure you know how many employees you will need to install the parts and keep the equipment running.

Consumption Needs

When you buy industrial parts, you need to know how much power they will consume and the type of connection they require. If the equipment requires large amounts of energy, you may need to install a commercial electricity connection.

You should be aware of how much energy the equipment will consume and whether different industrial parts have different consumption patterns. That will help you to plan the energy costs involved in your operations.

Maintenance

You should make sure you understand the maintenance requirements for the parts you purchase and whether they are suitable for your equipment. For example, when buying crane parts, the safety of the equipment is of the utmost importance to prevent accidents and comply with industry standards.

Find out whether you will need to install equipment such as ventilation to get the best out of the machinery. Will you be able to do the maintenance work yourself, or will you need to arrange and pay for regular servicing? Some suppliers offer tailored contracts for parts and maintenance as part of their aftermarket services.

Warranty and Insurance Coverage

Given the expense of buying industrial parts, it is essential to have warranty coverage. Check the details of the supplier’s warranty and what it covers. You may opt to buy an extended warranty for extra coverage.

You might also need to buy an insurance policy for construction equipment to cover damage caused by a natural disaster or fire.

Get Advice on Selecting the Best Industrial Parts

Buying industrial parts for your business is an important task that requires extensive research. You need to make sure the parts are a good fit for your equipment, are straightforward to install and maintain, and come with the right coverage in case something goes wrong.

Kor-Pak can help. Contact our team for a consultation on selecting the best industrial parts for your equipment. We can help you achieve the most efficient production, avoiding costly downtime.

5 Signs Your Construction Equipment Needs Repairs

Construction equipment can’t last forever, and sooner or later, you’ll need to repair it.

But how do you know when you need to repair equipment? We wanted to help by giving you some signs that your construction equipment might need some repairs.

Keep reading to learn the five common signs you may have failing equipment:

1. Visual Inspection

If you notice any of the following visual signs, get your construction equipment checked by a repair service:

  • The construction equipment is leaking hydraulic fluid (from the lines, valves, or hoses)
  • The construction equipment has hydraulic fluid dripping from it
  • Minerals have built up in your construction equipment’s lubricating oil

A professional service can check for these problems. They will inspect construction equipment that runs thousands of hours each year. If you take care of construction equipment repairs right away, you’ll save money in the long run on maintenance costs.

2. Abnormal Noise

If there is a strange noise coming from construction equipment, make sure to get it looked over by a repair service.

Some construction equipment noises include a grinding noise and a squealing noise. A repair service can check construction equipment for these problems by performing a “sound test.” But, first, they’ll need to shut down the construction equipment to avoid any abnormal sounds.

If you’re in doubt about construction equipment, have it checked out before damages cost more than repairs. There are enough costs in the construction industry — excessive wear does not need to be one.

3. Excessive Vibration

If your construction equipment vibrates too much, someone should check it right away before it breaks, and it costs more money to fix.

This is especially true if the vibration was not an issue with construction equipment before the maintenance work (for example, when there was a tire change). In this case, vibrations may be a sign of construction equipment problems.

4. Mechanical Problems

If construction equipment is trying to move but can’t, then you might have mechanical problems.

For example, construction equipment may be unable to move because of a problem with its tires or wheels. If construction equipment starts to develop mechanical problems, get them checked out by a repair service before the damage worsens and construction equipment costs rise.

Leaving mechanical problems unchecked can cause construction delays. It can also mean construction equipment will break down more often. Intervening will save construction management time and money.

5. Temperature Changes

If you notice any temperature changes coming from inside or outside your construction equipment, this could indicate a problem, and you should immediately take action.

Too many temperature changes can affect the properties of materials and the efficiency of construction equipment. This could make it dangerous or even ruin a construction project if the equipment doesn’t work right.

Temperature changes in construction equipment can mean that fuel burns quicker. A repair service can help you to prevent more damage from happening.

Fix Your Construction Equipment Today

Now that you know the signs to look out for, you can determine if your construction equipment needs repairs.

If construction equipment is starting to show signs of wear or problems, don’t wait! Contact a construction repair service right away.

Request a quote by contacting us today. 

Industrial Gearboxes: Types and Applications

For industrial processes, motors and other driving devices supply mechanical power to components to perform specific tasks. The amount of power provided can vary, which may at times be a higher power or speed that other components down the line can safely handle. Industrial gearboxes take the mechanical power and modify it so that the speed, torque, or other properties match better the operational power required for processes.

Gearboxes rely on the gear’s teeth and their orientation to modulate the power. Typically, straight teeth on the gear provide lower speed for applications, while a gear with spiral (helical) teeth offers higher speeds. Thus, a company has different gearboxes to select from based on their operational needs.

Types and Applications

Helical Gearboxes

Helical gearboxes have spiral teeth as the gearbox is fixed at an angle. This angle allows for more teeth to interact with each other in the same direction. As a result, this type of gearbox provides lower power. It may be found in elevators, coolers, conveyors, extruders, and heavy industrial applications.

Bevel Gearboxes

Bevel gearboxes have straight and spiral gear teeth. They are standard gearboxes for automobiles and power plants.

Bevel Helical Gearboxes

Bevel helical gearboxes have gear teeth on a cone-shaped surface as the teeth are curved. This type of gearbox is placed on non-parallel shafts as it provides rotary motions. Mining and quarry applications commonly have bevel helical gearboxes.

Worm Gearboxes

A worm gearbox has a wider wheel breadth. A screw thread, called the worm, on the axis meshes with the wheel’s teeth along the peripheral edge to turn the wheel. For industrial applications, the work gearbox is used in conveyor belts and lifts. They are also found on guitar tuning instruments.

Planetary Gearboxes

Planetary gearboxes get their names due to their designs that are similar to the solar system. For example, a center gear is like a sun as planetary gears rotate around the center mesh gear and a ring gear. Planetary gearboxes are found in cranes, lifts, and many machine tools.

There are many additional gearboxes other than the ones mentioned above. The gearbox may be specially designed for a specific operation, such as a crane duty gearbox made for construction and mining applications.

Gearbox Operation

Keep in mind that all gearboxes work in a very similar fashion. Gears will rotate based on the directional orientation of the power input and the gear’s direction. The speed and torque output can change depending on the size of the gears and the number of teeth on the gear wheel. So the lower the gear ratio, the higher the speed and less torque, while the higher gear ratio provides a lower speed and higher torque.

Industrial gearboxes are designed out of durable and strong materials to handle daily operations for extended periods. However, they may undergo excessive wear and tear as well as experiencing warning signs of potential malfunctions. Therefore, they should undergo regular inspection and maintenance to ensure the gearbox runs at its optimal level.

For more information about industrial gearboxes, reach out to Kor-Pak.

6 Considerations When Choosing a Coupling

Couplings are used in virtually every piece of power transmission equipment. Connecting motor and gearbox/reducer shafts to conveyors, pumps, compressors, and other machinery transmit torque while absorbing vibration and facilitating disassembly and maintenance.

The Importance of Coupling Selection

Whether designing new machinery or performing maintenance on something that’s seen years of service, it’s vital to use the proper coupling. But, unfortunately, choosing the cheapest or the best delivery is a recipe for performance problems and premature failure.

What’s more, when replacing a failing coupling, recognize that the OEM may not have specified one of the best quality. A coupling more appropriate to your application may last longer and lower your maintenance costs.

So with that background, let’s look at what your coupling supplier needs to know so they can recommend the most suitable product.

1. Torque and Speed

Handling these is the primary role of the coupling. Your coupling supplier needs to know both. Note that couplings are designed with an overload capability, typically 200% of the catalog torque limit, to accommodate start-up loads.

2. Service Factors

Where will the coupling be installed, and what conditions will it see? For example, if it’s going outdoors, exposure to UV, ozone, low temperatures, and moisture likely take elastomeric couplings out of contention. Ask for couplings proven in your application and take manufacturer recommendations into account.

3. Space Available

The two factors are the gap between the shafts and the clearance around them. Some couplings, especially elastomeric units for high power and torque applications, have large outside diameters, so identify any restrictions.

When considering space constraints, you may encounter “torque density” or “power density.” This is the rated torque divided by the OD. Gear couplings have some of the highest torque density numbers.

4. Precision Required

In the context of couplings, this refers to:

  • Tolerance for angular and offset misalignment (you may need to trade one for the other)
  • Backlash (a key consideration in precision motion control)
  • Windup (technically, torsional deflection)

For each of these, determine the limit of what’s acceptable and communicate it to your supplier.

5. Accessibility and Maintainability Considerations

If access to the coupling is difficult, it’s essential to select for long life, low maintenance requirements, and ease of repair/replacement. For example, avoid couplings that need lubrication (like gear couplings) and consider repairable ones by replacing only the flexible elements. (Grid coupling elements are often the least expensive.)

6. The Vendor

Find a vendor that works with a long list of coupling manufacturers and understands what your application needs. Ask about availability, stocking policies, and delivery: when a coupling does go bad, you want to know you can get a replacement quickly! Consider price only once you have candidates that will meet the performance requirements.

Get the Right Coupling for the Job

Shaft couplings may appear inconsequential, but that’s only until they fail. When choosing new or replacement couplings, consider all aspects of the application and share these with your vendor. Kor-Pak works with leading coupling manufacturers and can advise on what you should use. Contact us to get started.

Brief Guide to Oil Rig Equipment

When it comes to operating factories, machines, vehicles, and even homes, the typical fuels used are gas and oil. In 2019, it was estimated that the world held 1,733.9 billion barrels of oil reserves, according to Discover Magazine. Finding this oil requires specialized equipment and exploration work to bring it up to the surface for processing. Oil rig equipment helps to extract the oil and petroleum from the land as well as from the sea.

Technology in the oil equipment industry has evolved for the exploration and drilling of oil to minimize damage to the ecosystem and prevent oil leaks that can harm the environment. From global positioning systems to remote sensing devices, these technologies are designed to help discover the possible location of oil reserves so that fewer exploratory wells are drilled. Check out our brief guide regarding some of the oil rig equipment used in this industry.

Mast

An essential structure on an oil rig is the mast. The mast, also called a derrick, holds and lifts the components used in the drilling operation. It acts as a lifting device for the drill string, such as the drill pipes and other accessories.

Drill String

The drill string refers to all the drill pipes, the bottom hole assembly, and all the other components used in the operation of the drill bit that will tun at the wellbore’s bottom. The drill string comprises the drill pipe, drill collars, drill jars, stabilizers, heavyweight drill pipe, and other tools.

Rotary Table

The rotary table is a section of the drill floor that rotates or spins. It provides power to the drill string and the bit as it moves in a clockwise rotation. The rotary table’s power is transmitted through the kelly bushing, as the entire rig is sometimes called a kelly drive rig. The rotary table may be used for primary power or backup power.

Top Drive

The top drive consists of a motor that is suspended at the top of the mast. The motor turns the drill string as an alternative to the rotary table and may be used in special circumstances. The top drive assists with the bore head drilling process.

Mud Pump

The mud pump is a reciprocating pump that circulates the drilling fluid (drilling mud) downhole along the drilling string and back up to the surface through the annulus, the space between the casing and wellbore or casing and tubing. This fluid circulation is at extremely high pressures.

Shale Shakers

Shale shakers are fluid separation systems that remove the large solids (cuttings) from the drilling fluid. Shale shakers help reduce drilling costs and make operations efficient while ensuring the drilling fluid circulates to keep the drill bit cool.

Many other oil rig technologies and equipment are used—ensuring that the equipment functions correctly and that replacement parts are available in case of breakage, allows an oil rig to function optimally when extracting petroleum and oil from the earth’s depths. Here at Kor-Pak, we offer oil rig equipment. Contact us for more information.

Torque Limiter Maintenance, Repair, and Replacement

Torque limiters are critical elements in rotational machine assemblies that protect against instantaneous overload conditions.

Overloads are often multivariable and caused by both mechanical and electrical factors. Therefore, a torque-limiting switch is implemented to mitigate potential overload damage, regardless of the root cause. Limiters establish a peak value for torque-generated force in a system.

Rotational components operate uninterrupted within the bounds of the set torque limit. When the limit is exceeded, the operating machine is immediately detached from the load. The load separation stops the overload cascade from surging through the system, avoiding potential damage to the machine and its operators.

Proper maintenance and repair scheduling of limiter components should be prioritized in any heavy-duty, high-cycle operation. Machine troubleshooting can be conducted after a power failure, but any resulting damage cannot be undone. Effective use of a torque limiter circumvents much of the risk inherent to equipment failures.

Torque limiters are mostly autonomous but are not immune to malfunction or regular wear and tear. Several operative signals may indicate your torque limiter needs repair or replacement.

1. Abnormal Sounds at Start-Up

A sudden separation from loading elements is not a gentle process. During successful operation, torque limiters generate noise – and this should be expected.

On occasion, a torque-based system may emit a grinding, slamming, screeching, or whirring noise on start-up. These sounds can be accompanied by non-typical rumbling or physical motion in the equipment (as if a component was being tossed around). However, if the system is operating beneath the torque threshold set by the limiter, there should be no rattling, slipping, or squealing from the protective component.

Assess the characteristics of the noise and when it occurs. For example, if there are consistent noises at start-up, the torque limiter may be improperly installed, damaged, or over-slipping.

2. Motor Will Not Turn-Over / Start

Depending on the equipment, the torque limiter may be implicated in no-start conditions.

For example, electric engines that demand maximal torque at start-up – zero revolutions – may trigger immediate slippage by the torque limiter. As a result, the motor will be unable to turn over. A no-start might be accompanied by the sounds noted above, ignition chugging, or another rattling in the equipment.

3. Torque Limiter Slippage

Torque limiters are designed to slip – that’s how they can disengage from the load component. However, a total slippage of the limiter can mean operators will be unable to start or re-engage the equipment. Thus, slippage is undesirable below the set torque threshold. Coincidentally, over-slippage tends to be responsible for many situations involving abnormal noises and no-start motor conditions.

The type of torque limiter affects the mode of slippage. For example, friction plate, magnetic particle, and magnetic hysteresis torque limiters use different slip mechanisms to achieve the same operational goal.

Kor-Pak Torque Limiter Services

Troubleshooting points of failure in heavy equipment is a punishing process regarding downtime and operational costs.

Kor-Pak is equipped with the resources to provide consultative, repair, and replacement services for your torque limiters. Contact us for more information.

EMG Thruster Maintenance and Repair

The high demand for EMG thruster units often results in low stock across distribution channels. Replacing an electrohydraulic thruster can impair project lead times significantly and introduce a significant cost burden. Adhering to a proper repair and maintenance protocol enables a quicker and more economical turnaround.

Design and Operation

ELDRO and ELHY electrohydraulic thrusters are built with scalable, long-term use in mind. Versatility in a wide range of environmental and project-specific scenarios is prioritized in the design.

Primary design features include:

  • Reliability and long service life
  • Minimized regulating periods – fast response
  • Multipurpose designs may be specified for the environment
  • Operational overload protection
  • Straightforward assembly, disassembly, and installation
  • Multidirectional motor rotation – removing the need for reversing contractor components
  • Switching frequency graded to 2000 cycles per hour
  • Adjustable stroke
  • Modifiable lift and lower times

EMG thrusters are commonly employed industrially in crane, mining, and conveyor machinery. Systems demanding high-duty cycles in harsh operative conditions can stand to benefit from an electrohydraulic thruster unit.

ELDRO

ELDRO thrusters are built according to a coaxial functional assembly comprised of an electric motor and hydraulic unit. Implicit to a hydraulic system, thrust is generated via an appropriate operating fluid modulated by a centrifugal pump. The piston is designed to retract automatically if operational power is lost, and the brake springs will lock into place.

ELHY

ELHY brake thrusters are compact, low-noise units provided in several models bearing the same general structure. A three-phase motor is housed at the base, attached to a terminal box. The hydraulic pump is seated atop the motor, which connects to the piston and rod shaft. The ELHY model is crafted to ensure last-line defense against power failures and operative malfunctions.

Risk Factors

Electrohydraulic thrusters are often subject to extreme conditions. The intentional balancing of a thruster’s internal components and casings requires special awareness on behalf of operator and machine wellbeing.

EMG units are equipped with positional measurement systems and internal level indicators. These mechanisms indicate stroke path, piston rod depth, and release or brake position. In addition, limit switches may be utilized to provide more sophisticated data. Careful monitoring of EMG measurements can give a predictable baseline and point toward equipment fitness.

Corrosion is an active risk for any mechanism operating in high relative humidity or conditions where excessive condensation builds. EMG thrusters are fitted with redundant seals and protective tubing, but increased protection is recommended for intensive circumstances. Operators may consider the use of parking heaters or specialized sealing paint for the housing structure.

Repair and Maintenance Protocol

Kor-Pak offers consultations for use and rapid turnover repair services of EMG thruster units.

Our standard repair process involves complete strip-down disassembly of the electrohydraulic unit. Kor-Pak conducts a thorough visual inspection of each component. Housing, motor, piston, and brake assemblies are evaluated for damage related to corrosion, impact, and excessive wear. Bearings, seals, gaskets, and paint are replaced as part of our service.

Each repaired unit is put through a load and environmental condition check, then certified by Kor-Pak’s specialists.

Contact us for a quote or additional information.

4 Uses for Hydraulic Clamps

There is a vital part of production in the heavy machine industry that is often overlooked.

Workholding.

Positioning, supporting, and clamping are critical steps in workholding. However, when it comes to clamping, hydraulic clamps are the superior choice.

Hydraulic clamps have many advantages. They produce accurate and repeatable processes while using less space. As a result, they save time and money.

Does your industry use hydraulic clamps? Read on to learn four essential uses of hydraulic clamps in a variety of industries.

1. Industrial Mobile Hydraulics

Industrial uses of hydraulics extend beyond plant processing machinery and automated production lines.

In industrial mobile hydraulics, an operator manually controls the hydraulic system. Building and construction equipment often contain hydraulics. Example vehicles include tractors, backhoes, excavators, and cranes.

Excavators are an excellent opportunity to see hydraulic clamps in action.

Wheeler and crawler excavators use hydraulic clamps. Heavy machinery operators use the clamps to remove unwanted debris or place materials.

Clamps keep the material secure for loading and handling.

2. Hydraulic Drilling Rigs

Hydraulic fracturing is one of the most advanced mining technologies today.

Drilling uses hydraulics to extract unused gas and oil from the Earth’s surface. It pushes a high-pressure mixture of water, sand, and chemical additives through cracks in the earth. This forces the resources out.

These applications, and many others, benefit from hydraulic pipe clamps. A hydraulic pipe clamp is a convenient way of fastening a tube, pipe, and hose to a fixed point.

These hydraulic clamps reduce system noise, vibration, and damage caused by flex fatigue. Thus, they are vital for long-term safety and performance.

3. Maritime Technology

Hydraulic clamps play an essential role in marine applications. They are essential to maintain control and stability of leisure and commercial vessels.

Many ship parts use hydraulic systems.

Steering gears, bow and stern thrusters, and engine rooms contain hydraulic parts. In addition, maintenance systems such as pumps, jacks, and deck machines also use hydraulic systems.

One interesting use of hydraulic clamps is boat leveling systems.

Boat levelers correct listing in certain sea conditions. These systems use hydraulics for smooth trimming actions. Hydraulic hose clamps are vital to the proper function of leveling systems.

4. Aerospace Industry

Aerospace applications such as planes, rockets, and spaceships also use hydraulic systems.

Hydraulics, including clamps, are active in steering and braking. They are also used to adjust wing retraction or landing gear and open or close doors.

The aerospace industry faces unique conditions. Therefore, when choosing materials, you must consider many variables. These include extreme temperatures, high-frequency vibrations, and harsh chemical usage.

Hydraulic hose clamps are critical in these conditions. They maintain stability, safety, and proper function.

Choose the Right Hydraulic Clamps For Your Needs

Hydraulic systems have many uses across several heavy machine industries. So it’s easy to see that hydraulic clamps are vital tools.

To achieve safe and consistent workholding, hydraulic clamps are a great option. They can help you save time, money, and space while producing reliable results. 

Need help choosing the right hydraulic clamp for your needs?

Kor-Pak is here to help. Please browse our products or contact us today.

7 Signs Your Industrial Gearbox Needs Servicing

Gearboxes are the unsung heroes of power transmission. They take the motor output and change speed, torque, and direction to what’s needed to drive essential equipment. Conveyor systems, pumps, mixers, and a host of other machinery rely on gearboxes for their operation.

When a gearbox fails, the equipment or process being driven stops. That unplanned downtime translates to lost production, late deliveries, and increased costs.

An excellent way to avoid problems like these is by carrying out regular inspections. They don’t need to take long; you just need to know what to look for. Here are seven signs that your gearbox needs attention.

1. Oil Leaking from Shaft Seals

Gearbox oil lubricates and cools. If it’s leaking, the level will be low, which leads to other problems. (See below.) Oil leaks usually appear as dark streaks or tearstains in the paint directly below where shafts exit the gearbox housing.

2. Running Abnormally Hot

Heat causes expansion — that takes up clearances and leads to more wear. A simple check is to place a hand on the housing. To get more sophisticated, use a handheld IR thermometer or even a thermal camera. If you see smoke or the paint is becoming discolored, you’ve got a severe overheating problem.

3. Unusual Noise and/or Vibration

These go hand-in-hand, but in noisy environments, it’s hard to pick up abnormal sounds. Vibration, however, will tell you if something is going wrong. So, again, a hand check is good, but the instrumentation is better. You might even want to install vibration monitoring equipment on critical pieces of the plant.

4. Low Oil Level

If the manufacturer put a sight glass on the housing, it’s there for a reason. Make sure you can see oil at the correct level. If not, plan on topping it up as soon as possible.

5. Low Oil Pressure

Hard to tell without a pressure gauge, but low oil pressure suggests the pump is failing. If the gauge is reading low, plan on making repairs soon.

6. Damaged Gear Teeth

Take a cover off and check the condition of the teeth. If necessary, get hold of an endoscope for a close-up examination. Spalling or other signs of wear suggest alignment, bearing, or temperature problems. If one or more teeth are missing, it might be that the gearbox is being overloaded. Schedule repair or replacement as soon as possible.

7. Blocked Breathers

Breathers let air move in and out of the gearbox housing. If they get blocked, this airflow stops. It could lead to raised temperatures, and it may also mean the gearbox has ingested particulates from the air. Clean the breather and change the oil!

A common challenge with monitoring gearboxes is, can you be sure something has changed? It’s good practice to take pictures and make notes on every inspection. You might even video it running. This way, if you suspect a problem, you can check whether you see something new or just normal operation.

What To Do If You See Problems?

We’re specialists in industrial gearboxes and power transmission products. Contact Us for all your spares, servicing, and replacement equipment needs.