The Situation
A FALK dual output gearbox was received with extensive internal damage affecting several critical components. Inspection identified broken teeth on both the input pinion and output wheels, while the output shafts had become bent and required replacement. Further assessment revealed wear and damage to the output idler bore, along with issues affecting the seal retention arrangement.
With multiple component failures present, the gearbox required a comprehensive repair strategy to restore reliability and return the unit to operation.
The Solution
Our engineering team carried out a full refurbishment programme to address all identified defects. The casing bore was machined back to specification to restore correct tolerances, while modifications were made to the output cover and a new retaining plate was manufactured to improve the seal retention arrangement.
All bearings and seals were replaced as part of the overhaul, and the gearbox was rebuilt using customer-supplied shafts and gear components. Following assembly, the unit underwent thorough testing and final inspection to verify performance and ensure readiness for service.
The Result
The completed refurbishment restored the gearbox to full operational condition, resolving the effects of gear failure, shaft damage, and casing wear. By combining precision machining, component replacement, and detailed inspection procedures, the gearbox was successfully returned to site ready for reliable service.
