Abstract
This chapter identifies common gearbox problems and their causes. A primary cause of failure is that the gear sets are designed for operation in one direction only. Failure often is caused by inappropriate bidirectional operation of the gearbox or backward installation of the gear set. Unless specifically manufactured for bidirectional operation, the “nonpower” side of the gear's teeth is not finished. Therefore, this side is rougher and does not provide the same tolerance as the finished “power” side. Gear overload is another leading cause of failure. In some instances, the overload is constant, which is an indication that the gearbox is not suitable for the application. In other cases, the overload is intermittent and occurs only when the speed changes or specific production demands cause a momentary spike in the torsional load requirement of the gearbox. Misalignment, both real and induced, is another primary root cause of gear failure.
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