How to protect your machinery from overheating

Gearboxes in summer operation

High ambient temperatures in summer put industrial gearboxes to the test. Rising oil temperatures, thinner lubricating films and accelerated ageing processes lead to increased wear, leaks and, in the worst case, unplanned downtime.

This article provides manufacturer-neutral advice on what maintenance engineers should be looking out for now and which measures are most effective.

Why heat affects drivers

• At high temperatures, the viscosity of the gearbox oil decreases: the lubricating film becomes thinner, putting greater strain on bearings and gears.
• The oil oxidises more quickly; additives break down faster and deposits build up.
• Seals age more quickly, harden and start to leak – small leaks become real problems.
• Dusty radiators, blocked fans and a lack of shade further drive up oil and housing temperatures.

Conclusion: If you don’t take action in the summer, you risk increased wear and tear and breakdowns during the peak season.

Typical symptoms during summer operation

• The oil turns dark, smells burnt or foams.
• Rising bearing or oil temperatures are becoming more common; limit values are being reached more frequently.
• Increased oil loss at shaft seals and housing joints.
• Clearly audible running noises under load, particularly after prolonged periods of production.

These signs can be observed across all manufacturers – whether SEW, Flender, Nord, Bonfiglioli, Brevini or Kachelmann: physics is physics.

Measures with the greatest impact

1. Ensure adequate cooling and airflow

• Clean fans, cooling fins and oil/air coolers; keep airways clear
• Avoid direct sunlight; shade power units
• Check the distance from heat sources (furnaces, engines, hydraulic units)

2. Adjust lubrication and oil management

• Maintain correct oil levels; document top-up quantities
• Review oil change intervals for continuous summer loads and bring them forward if necessary
• Use oils approved for high operating temperatures

3. Enhance condition monitoring

• Set tighter temperature limits in the control system
• Check sensors: verify temperature sensors, thermal switches and signal paths
• Monitor trends rather than just individual values – rising average values are warning signs

4. Check seals and ventilation

• Check shaft seals and housing seals for sweating/leaks.
• Keep vents clear; blocked ventilation increases internal pressure and the risk of leakage.

5. Spare parts provision

• Plan for critical parts such as seals, oil filters, fan motors and sensors in good time.
• Document type plates and parts lists so that you can react quickly if necessary.

Practical tips without the need for modifications

• Shift peak loads to cooler times of the day (early morning/late evening).
• After prolonged periods of inactivity, run the unit briefly at partial load to ensure the oil is distributed evenly.
• For outdoor installations, make use of simple shading; often, a well-placed cover is all that is needed.

Manufacturer-independent service: a single point of contact for all gearboxes

Kachelmann Getriebe provides support for equipment of all makes – from on-site inspections and repairs in our own workshop to the supply of spare parts and technical redesigns. This reduces complexity and speeds up troubleshooting: one team, one hotline, short lines of communication.

• On-site inspection with a clear assessment of the condition
• Repairs in the workshop with a transparent quote
• Spare parts service, including for third-party gearboxes
• Engineering/redesign when units are operating at their thermal limit

Technical enquiry regarding a gearbox currently in use?

Contact the service team directly: 09543-8455 11 | getriebe@kachelmann.de

FAQ: Quick answers for maintenance engineers

How can I prevent industrial gearboxes from overheating in summer?
To prevent industrial gearboxes from overheating in summer, the cooling fins and the fan should be cleaned regularly. In addition, the oil level should be maintained at the correct level, oil change intervals should be adjusted to suit summer loads, and the sensors should be checked regularly. Direct sunlight should also be avoided.

How can I tell if the gearbox is thermally overloaded?
Thermal overload in the gearbox can be identified by rising oil and bearing temperatures. Other signs may include dark or foul-smelling oil, leaks from seals, or increasing running noise.

What measures have the greatest impact without the need for modifications?
To prevent overheating and avoid gearbox failure, you can take the following immediate steps without any modifications: Firstly, we recommend cleaning the cooling system to ensure it is functioning correctly again. Other simple yet effective steps include providing shade for the equipment, shifting peak loads away from the very hot midday hours, and setting tighter control limits. Furthermore, care should always be taken to ensure that the vent remains clear.

Are measures against overheating manufacturer-independent?
Yes. Our recommendations for measures against overheating of your machinery apply to the thermal effects of all makes. The recommendations are therefore universal and applicable to all manufacturers.

Author
Andrea v. Wartenberg, Technical Service – Kachelmann Gearboxes
Specialism: Repair and optimization of industrial gearboxes of all makes in continuous operation.

Contact: 09543-8455 11 | getriebe@kachelmann.de