Maintenance and Engineering

Gearbox Maintenance and Failure Analysis

Gearboxes transmit power in conveyors, mills, cranes and countless machines. This course covers gearbox types, gear and bearing failure modes, lubrication, condition monitoring by vibration and oil analysis, inspection techniques, overhaul practices and root cause analysis of gearbox failures.

5 days Classroom or live online English

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Take the course details with you.

Download the full standard outline: why attend, methodology, objectives, audience, competencies, the daily outline and current plans.

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Why attend

From knowledge to real-world impact.

Gearbox failures cause long and expensive downtime. You will learn to maintain gearboxes and diagnose problems early.

Workplace challenges

Professional Problems This Course Is Designed to Solve

The programme explores practical approaches to the following challenges. Results depend on how the learning is applied in your organisation.

Difficulty translating subject knowledge into practical workplace decisions.
Inconsistent approaches to the activities covered in the course outline.
Lack of a structured plan for applying and reviewing new skills.

Course methodology

How you will learn.

Failure mode identification exercises, oil and vibration data interpretation, case studies and maintenance planning.

Course objectives

What you'll take away.

By the end of this course, participants will be able to:

Explain gearbox types and components
Identify gear and bearing failure modes
Apply correct lubrication practices
Monitor gearboxes using vibration and oil analysis
Inspect and overhaul gearboxes
Analyse root causes of gearbox failures

Target audience

Who should attend.

This course is suitable for:

Maintenance technicians and engineers
Reliability engineers
Condition monitoring staff
Mining and heavy industry engineers
Maintenance supervisors

Target competencies

Capabilities you will build.

Participants will develop competencies in:

Failure mode recognition
Lubrication
Condition monitoring
Overhaul practice
Root cause analysis

Course outline

Your learning journey.

A focused, practical outline with time to explore, apply and reflect.

Day 1Gearbox Basics

09:00–10:08Gear types
10:08–11:00Bearings
11:00–11:30Coffee break
11:30–11:45Bearings (continued)
11:45–12:53Applications
12:53–14:00Exercise

Day 2Failure Modes

09:00–10:08Pitting and wear
10:08–11:00Tooth breakage
11:00–11:30Coffee break
11:30–11:45Tooth breakage (continued)
11:45–12:53Bearing failures
12:53–14:00Case study

Day 3Lubrication

09:00–10:08Lubricant selection
10:08–11:00Oil levels and temperatures
11:00–11:30Coffee break
11:30–11:45Oil levels and temperatures (continued)
11:45–12:53Contamination
12:53–14:00Workshop

Day 4Condition Monitoring

09:00–10:08Vibration signatures
10:08–11:00Oil and wear debris analysis
11:00–11:30Coffee break
11:30–11:45Oil and wear debris analysis (continued)
11:45–12:53Inspection
12:53–14:00Exercise

Day 5Overhaul and RCA

09:00–10:08Overhaul practices
10:08–11:00Alignment
11:00–11:30Coffee break
11:30–11:45Alignment (continued)
11:45–12:53Root cause analysis
12:53–14:00Action plan

The timings provided are estimates and may vary depending on the number of participants and the discussions taking place during the sessions. They are indicative only and do not constitute a binding commitment.

Dates & venues

Find a session that works for you.

Confirmed dates accept registration requests. Tentative dates are enquiry only.

Good to know

A few things to know.

How is the course delivered?

Our classroom programmes combine facilitated discussion, case studies, exercises and reflection. The precise format will be confirmed before enrolment.

Can you deliver this programme for our team?

Yes, you can enquire about a tailored programme. Share your goals, group size and preferred dates with our learning team.

Will I receive a certificate?

Participants who complete the programme receive a Smart Horizon certificate of attendance. Smart Horizon programmes are not externally accredited and do not award a professional qualification, licence or designation. Where a course title or outline refers to a professional certification (for example, AACE International's Certified Cost Professional), the programme supports learning and preparation only; the credential itself is awarded solely by the relevant professional body under its own application and examination requirements.

What should I confirm before booking travel?

Please confirm the session, exact venue, accessibility arrangements, fees and any visa requirements with the team before arranging travel. Tentative dates are not confirmed sessions.

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