Key factors to improve Gearbox Maintenance and Lifespan

At FGGS Field Services, from our unique expertise with FLENDER High-Speed gearboxes, lifespan of an industrial gearbox can vary significantly depending on several factors, including the quality of the gearbox, its design, the operating conditions, the gearbox maintenance practices, and the specific application it is used for. Generally, a well-designed and well-maintained industrial gearbox can last for several years or even decades. Here are some key factors that can influence the lifespan of an industrial gearbox:


High-quality gearboxes from reputable manufacturers tend to have a longer lifespan than lower-quality ones.

Design and Engineering

Gearboxes designed for durability and reliability can have a longer service life than those with less robust designs.

Operating Conditions

The operating environment, load, speed, and temperature can impact the wear and tear on the gearbox. Extreme conditions may reduce the gearbox’s lifespan.


Regular and proper maintenance, including timely lubrication, inspections, and replacement of worn parts, can significantly extend the gearbox’s life.

Overload and Misuse

Operating the gearbox beyond its rated capacity or misusing it can lead to premature failure.

Shock Loads

Frequent or excessive shock loads can accelerate wear and reduce the gearbox’s lifespan.


Excessive vibration can be detrimental to the gearbox’s internal components, affecting its longevity.


Proper lubrication is essential for reducing friction and wear. Inadequate or improper lubrication can lead to premature failure.

Material Quality

The materials used in the construction of the gearbox, such as gears and bearings, can influence its durability.


The type of application and the frequency of gearbox usage can impact its lifespan.

With all these factors in mind, some industrial gearboxes can last 10 to 30 years or more with proper care and maintenance. However, some gearboxes might need replacement or major overhauls sooner, especially in demanding or harsh operating conditions.

It’s essential to work closely with authorized maintenance providers, follow their maintenance guidelines, and monitor the gearbox’s performance to ensure its longevity. If you have a FLENDER High-Speed Gearbox due for inspection, contact us to learn more about your repair, maintenance or replacement needs at or call us at (203) 268 5961.

With FGGS you can count on the best!

Another successful job completed by the Field Engineering team.

FGGS is known for handling jobs worldwide, so it was good to stay local and provide engineering services and support on a scope of work composed of a full overhaul on a Siemens 42,500KW steam turbine package. In addition, FGGS swapped out the Gearset and Bearings on the unit. Upon visual inspection, FGGS noted that there was burned oil deposit on the toothing. Brown coloration due to varnishing was observed, as well as an abnormal pattern observed on the non-active flank on the turbine side. 

FGGS scope of work was to performed a Major Inspection on the gearbox:

    • Inspection allowed the check of functional clearances and measurement;
    • All bearings have been replaced per OEM specification.
    • New Gear set was installed and old one sent for refurbishment.
    • New Labyrinth seals were installed.
    • All gearbox parameters are within Flender-Graffenstaden specification and the inspection carried out per Flender-Graffenstaden work procedures.

FGGS performed an alignment check and correction was performed in order to ensure the proper operation of the machine. The unit started up successfully and all vibration and temperature readings were under the alarm values and within FG spec. It was another successful job completed by the Field Engineering team.