www.davidbrown.

com

Manufacturing and Service Centres
South Africa Benoni T +27 (0) 11 748 0000 F +27 (0) 11 421 2963 Northern Cape T +27 (0) 53 723 0000 F +27 (0) 53 723 0002 southafrica@davidbrown.com Australia Bulli T +61 (0) 2 4283 0300 F +61 (0) 2 4283 0305 Mackay T +61 (0) 7 4842 3222 F +61 (0) 7 4842 3232 Newcastle T +61 (0) 2 4028 5100 F +61 (0) 2 4028 5111 Perth T +61 (0) 8 9365 5555 F +61 (0) 8 9365 5556 australia@davidbrown.com Canada Montreal T +1 514 457 7700 F +1 514 457 7265 canada@davidbrown.com Chile Antofagasta T +56 (55) 492 800 chile@davidbrown.com China Changzhou T +86 (0) 519 8636 1256 F +86 (0) 519 8636 1355 china@davidbrown.com France Thann T +33 (0) 389 370 113 F +33 (0) 389 370 936 france@davidbrown.com India Hosur T +91 (0) 4344 422800 F +91 (0) 4344 422815 india@davidbrown.com

girth gears mill drives conveyor drives stacker reclaimers shovel and draglines hoist drives stealth drives winch / winder drives agitator drives slurry pump drives barring drives service and repairs

The mining industry driven by David Brown

Indonesia Surabaya T +62 31 891 0976-77 F +62 31 891 0978 indonesia@davidbrown.com UAE Dubai T +971 (0) 4 887 0274 F +971 (0) 4 887 0275 dubai@davidbrown.com USA Inez, KY T +1 855 693 2432 usa@davidbrown.com UK Huddersfield T +44 (0) 1484 465 500 F +44 (0) 1484 465 501 West Bromwich T +44 (0) 121 557 6334 F +44 (0) 121 520 0951 uk@davidbrown.com Zambia Kitwe T +260 212 210 642 F +260 212 210 645 zambia@davidbrown.com

pinions
Sales Offices
Australia Melbourne T +61 (0) 393 774 444 F +61 (0) 393 774 445 australia@davidbrown.com Brazil Campinas T +55 (11) 97027 7840 brasil@davidbrown.com Chile Santiago T +56 (2) 234 5000 chile@davidbrown.com India Bangalore T +91 (80) 4235 2800 F +91 (80) 4235 2820 india@davidbrown.com Indonesia Jakarta T +62 (21) 5289 1871 F +62 (21) 5299 4599 indonesia@davidbrown.com Morocco Casablanca T +212 0 522 354 149 F +212 0 522 354152 northwestafrica@davidbrown.com Singapore Sail Marina Bay T +65 6648 8245 singapore@davidbrown.com USA Waynesboro, VA T +1 855 693 2432 usa@davidbrown.com

Approved David Brown service and repair facility

Sweden Goteborg Moventas service and repair centre T +46 31 710 20 50 F +46 31 710 20 60 service@moventas.com France Craywick SGM service and repair centre T +33 (0) 389 370 113 F +33 (0) 389 370 936 france@davidbrown.com

Gearbox Emergency helpline T +44 (0) 1484 465666

Print date 11/12

Revision date 11/12

English version

Moventas approved service and repair centre We are certified to ISO9001:2008. Your David Brown representative should be consulted prior to product selection and use. In the interest of continuous technical development David Brown reserves the right to amend specifications and drawings without prior notice. 3X terms and conditions apply. Contact your local David Brown representative for details and to check eligibility.

Product catalogue

High quality | customer engineered | exceeding expectations

The mining industry driven by David Brown

David Brown offers an extensive product range to serve the mining and cement industries, including universal standard units through to specialist custom engineered orders. We can meet your needs whether that be one gearbox, shovel component or drive system or thousands. David Brown is committed to being the best in industry.
Geared for mining excellence Local engineering support in the same time zone, ensuring
quick turn-around

Custom engineering capabilities Extensive range of mining products from mining to port Global supply chains across five continents including
manufacturing and service capabilities

Coal
Products Above and below ground conveyor
drives Shovel and dragline replacement parts Stacker reclaimer replacement parts Pulverisers Agitator mixer drives

Iron ore
Products Girth gears, pinions, mill drives for
magnetite beneficiation Slurry pump gearboxes Conveyor drives Crushers Agitator mixer drives

Uranium
Products Girth gears, pinions, mill drives Conveyor drives Shovel and dragline replacement parts Crushers Agitator mixer drives

Best cost, quality and delivery times in the industry In-house full load test rig capabilities Global network of service centres, supported by strategically
placed mining manufacturing facilities other associated mining products

Bespoke design and repair of gearboxes for the mining

Repair to all David Brown and third party gearboxes and

industry: engineering, design, manufacturing, service and sales State of the art design tools, manufacturing equipment and quality processes

our expertise
across the entire mining process

Applying
Copper
Products Mills and crusher drives Drives for agitators & thickeners Shovel replacement parts Conveyor drives, girth gears, pinions,
mill drives for grinding mills

Gold, silver & platinum

Products Above and below ground conveyor
drives

Diamonds
Products Girth gears, pinions, mill drives for
grinding mills

Girth gears, pinions, mill drives for

grinding

Crushers Agitator mixer drives

Conveyor drives Crushers Agitator mixer drives

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Mining product catalogue

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The mining process

Shovel/ draglines

Mine

ROM Tip

Primary Milling
Woodchip Removal

Secondary Milling

Receiving Rail Bin Steel Balls Jaw Crusher

Steel Balls Water

Crushing Plant

Water

1 2

2 3

Primar y Mill Feed AG/SAG Mill Discharge Sump

Secondary Mill Feed Ball Mill

y Milling

Air Spray Water Senmin Frother Depressant

Primar y & Secondary Rougher Flotation 2 Banks

Air Spray Water Senmin Frother Senmin Depressant

Primar y & Secondary Cleaner Primar y & Secondary Re-Cleaner Flotation

5
Base Metal Re nery

Tailings Thickener
y Mill Feed

Concentrate Thickener
Tailings Sump To Cloudy Water Tank

Smelter

6 4

Water

To Dam

Air

Stacker/ reclaimer

Bulk port handing

No-one understands the demands of the mining process better than David Brown. We see the big picture and understand that any process is only as robust as its weakest link. David Brown is geared to deal with any challenge, at every stage of the process, anywhere in the world, at any time. Our diverse experience of mining, honed over decades of meeting complex engineering challenges in some of the worlds harshest operating conditions, ensures the absolute safety and reliability you need.

1 1 1 1 2 3

Electric face shovel spare parts Dragline spares & &

7 7

3 3 3 4 5 6 7

Hoist drives Slew drives

Pinions Mill drive gear units Barring drives Agitator drives

Conveyor drives Girth gears

Flotation drives Slurry pump drives

Stacker/reclaimer drives

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Proven engineering expertise

David Brown has a dedicated global team of design and application engineers, experienced in providing tailored solutions for all power transmission applications in the mining industry. All designs are optimised using state of the art design tools and crafted using the latest manufacturing equipment. Housings, couplings and shafts Designed to be thermally efficient Using the latest software design tools for FEA
analysis FEA and 3D modelling

State of the art manufacturing capabilities

David Brown has global engineering and manufacturing facilities equipped with latest gear manufacturing equipment machine tools. David Brown is fully accredited to ISO 9001 Worldwide facilities manufacturing Girth gears to 14.4m in diameter and up to 105,000kg
in weight

Pinions tailored to suit your requirements Annulus / internal ring gears up to 12m in
diameter

Induction hardening of external or internal

gears to 4.5m in diameter length

Gear design David Brown design to AS/AGMA, JIS, DIN

or ISO standards Designed to achieve optimal gear load conditions Using the latest software design tools for power transmission (vibration and noise analysis)

Requirements
Reliability Cost effectiveness Short delivery period

Case carburising to 3m diameter and 4.5m Nitrided heat treatment can be available
on request David Brown operates a zero defect policy

START

FINISH

Solutions
Trouble free operation Lowest lifetime cost Short lead times due to optimised supply chains Engineered around you!

Assembly and load testing

All gearboxes and associated mining products following strict quality control guidelines and review before being shipped to our customers worldwide. Our full load testing capabilities includes the measurement of temperature, vibration and noise and provision for supply of full inspection and documentation packs. David Brown offers no-load spin testing and full scale load testing of stand alone gear units or complete drive assemblies depending on customer requirements. Testing facilities vary worldwide with capaibilities to test gearboxes exceeding 3MW.

Quality control
Equipped with the latest and best gear inspection equipment available. Modern manufacturing and service facilities showcase our abilities. David Brown utilises the latest onboard and stand alone gear measurement technology. Inspection equipment is integrated with manufacturing processes to ensure optimum quality at minimum lead time.

With proven expertise and global capabilities, David Brown gives you peace of mind throughout the whole process
Mining product catalogue
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Engineering and manufacturing capabilities

David Brown has a dedicated global team of mining design and application engineers to provide around the clock support. David Brown mining products are designed using state of the art design software for gears, shafts and housings, aiming to be your complete gearing authority. We have skilled technicians and engineers ready to solve your gearbox and associated product needs. We can design from scratch or service and upgrade an existing product. Whether you wish to change the ratio or an existing gearbox, David Brown is your one stop gearbox shop. We can evaluate your current gearbox and replacements which offer higher ratings to maximise your process. Send us your gearbox during a regular shutdown and we will evaluate its condition. We can make drop-in assemblies that will help minimise downtime. A team of skilled professionals provide expert assistance who can either work from detailed engineered drawings or from sample pieces. If required, original engineered specifications and drawings can be designed and developed. David Brown is your complete mining solution provider however complex or time dependant your requirements are. David Brown manufactures gears and gearboxes to any rating or gear grade currently in existence and draw on their wealth of engineering expertise across the world.

Quality and testing

David Brown ulilises some of the industrys most sophisticated gear inspection machines. This ensures David Brown products are of the highest quality and robustness. Our fully automatic CNC controlled gear measuring machines are designed for larger work piece diameters up to 3000mm and 14m on board measuring. These measuring machines are suitable for testing spur and helical gears as well as hobs, shaper cutters, worm gears and bevel gears. The machines are also critical to establish the exact tooth profile of the sample part and to ensure manufacturing processes are constantly checked against design intent. David Brown offers full scale load testing of gearbox products if requested by customers. No-load spin testing and full scale load testing of stand alone gear units or complete HV drive assemblies are available. For more information, ask a David Brown representative.

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Complete mining product range

David Brown aims to supply our customers with the most innovative and cost effective engineered solutions for all type of geared products found in the mining industry. Our products are renowned worldwide for their reliability in assurance critical applications such as grinding and conveying where failure means lost production and profits.

Every David Brown product is Engineered around you

Conveyor drives
The CX range of gearboxes has been field tested over many years operating in some of the harshest environments.

Stacker/reclaimer drives
David Brown has a long history of manufacturing and servicing geared drives for stackers and reclaimers. Long travel drives Conveyor drives Bucket wheel drives

Mill drives
The MXR range of mill drives is specifically designed for mill applications across a range of minerals.

Pinions
David Brown can manufacture both integral and non-integral mill pinions, for SAG and ball mills applications and rotary kilns.

Girth gears
Girth gear are used to drive horizontal grinding mills globally. Our girth gear products have a large global installed base with applications in the copper, gold, iron ore, cement, diamond, coal and platinum industries.

Shovel and dragline components

David Brown can service existing or supply upgraded replacement gearboxes, pinions and rack components for shovels and draglines.

Barring drives
These drives are traditionally a multiple reduction unit.

Dredge drives
The dredge drives can be designed and supplied to suit your requirements. Committed to providing high-class products with rapid turnaround.

Winder drives
Mine hoists and associated equipment are available in many types and sizes and can be supplied as geared or as direct drives. David Brown can custom design to your exact specifications.

Slew drives
David Brown has been manufacturing slew drives for a number of years. We have an enviable reputation for reliability and craftsmanship.

Pump drives
David Brown has supplied pump drives for centrifugal and positive displacement pumps.

Agitator drives
Mineral processing plants require special heavy duty drives, these applications require consideration around load generated, during the processes. David Brown has designed tanks with diverse applications that are vertically mounted for high efficiency.

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Mining product catalogue

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Conveyor drive systems

Reliable | efficient | effective solutions
The CX range of helical and bevel helical gear units is designed to meet the most arduous of power transmission application needs. Reliable and efficient in operation, it provides a cost effective solution to all our customers needs. Designed to David Browns proven quality standards, these quiet running units provide exceptional levels of performance, versatility and life expectancy to meet the demanding requirements of modern industry.
Key features Gearbox, hold backs, brakes and fluid couplings
for mineral transport systems to over 3000kW per unit remperature, noise and vibration

Product range
Starting at 185mm final centres, biggest size extends to 800mm final centres. Gearing and bearing life is optimised for target ratios to suit conveyor drive applications.
Speed range (input speeds) 580 rpm to 1750 rpm Humidity up to 100% including direct rain Ambient temperature range -20C to 45C (-4F to 113F) Maximum operating sump temperature 90C (194F) Nominal rated sump temperature 80C (176F) Mean time to repair 50,000 hours Product life span 7 - 10 years 3 years warranty, 5 years optional (subject to maintenance agreement)

Gearing design
Units can be rated to all international standards such as: DIN, AGMA, and ISO BS. Right angle units 2 and 3 stage as well as 2 stage 1450, parallel units for conveyor application. 1 stage parallel units can be available but not as standard. The scope of configuration offerings and ratio by size range for the CX product line
2-stage parallel (P2) 185 to 800 2-stage right angle (R2) 400 - 800 3-stage right angle (R3) 185 to 800

Special feature options

Alignment free tunnel mount is available on selected drives Output shaft cover (for unused output extension) Double lipped seals Non-contact double grease labyrinth shaft sealing (input or output) Forced lube and heating system Immersion heater Base mounted on torque arms for shaft mounts Fluid coupling Brakes Flywheels

Drives can be load tested and measured prior to dispatch for Elimination of external cooling or lubrication system Increased reliability with no loss in performance Double ended output and invertible design for minimised
spares requirements

Drives can be load tested and proved in up to 45oC in

ambient conditions

High thermal efficiency allowing higher balanced

mechanical loading

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Mining product catalogue

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The CX range of helical and bevel gear units is designed to meet the most arduous of power transmission application needs. Reliable and efficient in operation, they provide a cost-effective solution to all our customers needs.

Mines are often located in the harshest and most remote locations on Earth. The CX range of conveyor drive gearboxes has been specifically designed to meet our customers demands. The CX delivers highest reliability for lowest cost and builds on proven performance of our conveyor drive gearboxes and systems. David Browns conveyor drives have been in operation for decades, some surviving hurricanes and sweltering 45oC temperatures, virtually maintenance free.
Key benefits Ductile iron two piece housing ensures easy
serviceability during maintenance auxiliary cooling systems required

Let David Brown solve your conveyor gearing problems, no matter how big or small

Reference list includes: Projects

Iron Ore Export Terminal Iron Ore Export Terminal Iron Ore Export Terminal Iron Ore Export Terminal Coal Export Terminal Coal Export Terminal Iron Ore Mine Iron Ore Mine Coal Mine Coal Mine Coal Mine Diamond Mine

Qty
27 14 20 23 20 94 6 18 7 110 100 50

Motor Size
630 - 800kW 710 - 1120kW 185 - 900kW 450 - 710kW 630 - 830kW 7.5 -450kW 1000kW 315 - 1000kW 315 - 450kW 110 - 500kW 110kW 315-450kW

Heat dissipating cooling fins increases efficiency, no

Bevel or parallel input shaft options Rigid high speed cartridge design Minimises noise due to optimised geometries Keyed or shrink fit (oil injection) coupling options

Existing designs exist to 3MW capacity, as the industry demands larger drives

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Stacker reclaimer

Dependable systems to guarantee efficient running of the bulk material handling process.

Highest quality | international quality standards | designed to last

These enormous machines are crucial in the transportation of bulk materials in ports, mines and processing plants, therefore it is vital to use high quality and reliable products in all its components.
Complete conveyor systems for the stacker We can design and manufacture all kinds of conveyor systems to suit your specifications; radial stackers, belt conveyors, coal conveyors, screw conveyors, bucket elevators or load hoppers. Cases are manufactured using high grade castings or
fabrications

Superior quality and built-to-last construction Longer life needing minimal maintenance and service Drive systems for the bucker wheel excavator Bucket wheel excavators have been used in mining as long as most can remember. David Brown can supply reliable drive systems for bucket wheel elevators as well as components for conveyor belts, spreaders, crushing stations, mine materials and waste. Components built to last Heavily engineered for heavy usage Reliability and performance, second to none Manufactured to customers specifications and to service
requirements

A range of components offering high reliability and

performance

Bogie drive expert

Flexible design to meet your specific needs and requirements

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Managing your equipment requirements with expert

in-house designing, machining and testing capabilities international quality standards

Heavy industrial components made especially to exceed

Mining product catalogue

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Mill drives
Single reduction, parallel shaft reducers

Simple | durable | cost effective

With more than 150 years of gearing expertise of manufacturing, designing and developing gearing solutions, David Brown offers a range of horizontal mill drive reducers. The MXR series is a simple, durable unit designed to achieve cost effective solutions designed for various mill applications.

The MXR series is specially optimised and available as both replacement units, or designed as part of a MXR mill drive system to achieve the most economic solution
Key benefits Reducers and their ratios are selected to compliment the
girth gear design and reduce the cost of the entire system perfect shaft alignment and flat sealing surfaces

Key features
Single stage design which covers ratios from 5.8 to 7:2 Powers ranging to 16Mw Four unit sizes are available as standard Can be single or double reduction, depending on the required ratio and motor speed

Specially optimised ratios are available on request for re Double extended input shafts are supplied as standard

placement units, or designed as part of a MXR mill drive system to achieve the most economic solution for main motor and barring/inching drive inputs and for extended output shafts

Provision for lubricant inlet and drain pipe connections Units operate using dry-sump technology to improve A large inspection cover is provided which allows for

Gear cases are machined using CNC technology, ensuring All shaft extensions are keyed according to industry

are provided, but can be changed to suit client specific requirements efficiency, which do not operate with an oil level in the unit, therefore no dipstick or oil level sight glass is required inspection of gear teeth and lubricant spray patterns gear housing

Triple reduction drives are available for kiln and dryers Cast or fabricated gear casings

Gear cases are manufactured from high quality cast iron

accepted standards, imperial shaft extensions are also available of an external iubrication system as required

Adequate cooling and lubrication is achieved with the use Ductile iron material offering excellent properties preventing
distortion after initial manufacturing and good damping properties, reducing noise emissions and dynamic deflections

Durable lifting points are provided on both halves of the All gear cases are shot blasted before priming and painting.
Painting according to customer specification available on request

The development of the MXR series is another example of David Browns superior technical expertise

Gear cases designed in fabricated steel and ductile iron

(SG iron), using state-of-the-art FEA technology for optimal stiffness, that ensures tooth contact and load distribution

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Gears and shafts

David Brown gear geometry is optimised to provide excellent torque to centre distance ratios with good load sharing characteristics to achieve maximum performance. A proven double helical design eliminates axial thrust loads reducing equivalent bearing loads and extending bearing life. All gears are manufactured using high quality alloy case hardening steels to provide long life wear resistance. CNC gear grinding technology improves gear tooth surface finish and accuracy for optimal performance. AGMA 2000 A88 Q12 gears are standard. Shafts and keyways are designed for an infinite life under normal operating conditions and standard keyway dimensions are used. Special shaft diameters and lengths can be accommodated on request.

Applications
David Brown services and repairs systems provided by other manufacturers. Machinery serviced includes:
Semi autogenous mills (SAG) and autogenous mills (AG) Ball, rod or tube mills Rotary kilns and dryers girth gears with tangent plate designs Reference list includes: Job No
705080 705064 705060

Customer
Gold mine Gold mine Uranium production manufacturer Nickel mining manufacturer Mineral ore manufacturer Platinium manufacturer Uranium manufacturer Gold mine Copper mine Platinium mine Copper mine Platinium mine Copper mine Platinium mine Copper mine Gold mine

Description
Valemt gear unit ratio 7,937:1 40 gear unit as per ratio 7654RH David Brown 836crs gear unit SPS170 gear unit same as 710021 TPS108 Extended L series BEW SB40 gear unit new gearbox David Brown 26 gear unit same as -80 David Brown 36wide type gear unit David Brown 36 wide type gear unit David Brown 810crs gear unit David Brown size 36 wide type gear unit David Brown 810crs gear unit BEW SBN28 gear unit ratio 5,654:1 David Brown 925crs gear unit David Brown 36 gear units David Brown 810crs gear unit

Bearings
Standard spherical roller bearings are used and only approved brands are installed. Spherical roller bearings offer excellent radial and axial load carrying capacity. Axial loads however impact significantly on bearing life. The use of double helical gearing eliminates the axial load as well as the need for additional thrust bearing requirements, reducing the cost and number of components. Reliability is increased by the simplicity of the design. The bearing life is calculated in accordance with the ISO method. No bearing life modification factors are used, all are L10h basic. More information on this subject is available from our application engineers.

Lubrication
External lubrication systems allow closer monitoring of gear unit lubrication through temperature, pressure and flow transducers. Oil filtering and cooling, as well as the ability to indicate water contamination, ensures adequate lubricant viscosity that maintains hydrodynamic oil film between the active components. The MXR reducer internal lubrication system comprises of dedicated bearing feed lines, as well as gear mesh sprays from both the entering, as well as exiting sides of the mesh to ensure adequate cooling and lubrication.

705058 705050 705051 705042 705038 705034 705029 705028 705023 705022 705005 705003 700275

Sealing
All shaft seals are designed as a combination of mechanical and contact sealing. The leak proof design consists of flingers eliminating the bulk of the lubricant, lip seal and a grease purged labyrinth that eliminates dust contamination. A complete non-contact arrangement is also available on request.

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Pinions
Operational excellence | precision engineering | flexible designs
David Brown designs and manufactures high torque precision integral and non-integral pinions for SAG and ball mill applications and rotary kilns.

Mill pinions manufactured up to 50 module Pinion shafts of up to 4m can be manufactured and carburised A maximum gear face width of 1.2m Profile and lead optimisation using latest design software and gear manufacturing equipment Mill pinions can be manufactured as integral with the shaft or non-integral (removable)

High torque, high precision design and manufacturing capabilities at David Brown

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Girth gears
Quality craftmanship | established product | highest integrity
David Brown girth gears are used to drive horizontal grinding mills globally. Girth gears manufactured by David Brown have reached a high installed base with worldwide applications in copper, gold, iron-ore, cement, diamond, coal and platinum industries.

David Brown engineers the correct solution, offering high reliability with lowest lifetime cost.

Key features Girth gears can be manufactured in 2,3,4,5,6 or 8 segments

and both T and Y section gears

Manufactured in temperature controlled rooms, to ensure

highest accuracy and efficiency of manufacture between 180-350 BHN

Weight optimised through FEA simulation Power range up to 10,000 MW Smaller girth gears of 7m or less in diameter Largest gears 7m to 14m High integrity girth gears to AGMA level 10 and beyond, ideal for all type of horizontal mills

Girth gears can be manufactured for hardness ranges Can be manufactured from either cast steel to BS3100

Ductile Iron to ASTM A536, or fabricated forged steel plate

Manufacturing equipment with integral meshing facilities

and with machine measuring equipment ensures David Brown can conform to specification

Up to 105,000kg in weight

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Mining product catalogue

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Reference list includes: Gear OD [mm]

3548 4416 4885 5029 5469 5580 5683 5700 5700 5875 6063 6070 6160 6251 6850

Mass [kg]
5079 6520 10752 8199 100072 16356 13460 16356 16356 18000 14772 14657 12460 17567 22087

Power [kW]
400 600 1000 N/S N/S N/S 725 N/S 1800 N/S N/S N/S N/S 1850 2800

Material
Cast Steel Ductile Iron Fabricated Cast Steel Ductile iron Cast Steel Cast Steel Cast Steel Cast Steel Fabricated Cast Steel Cast Steel Cast Steel Cast Steel Cast Steel

Gear OD [mm]
7583 8456 8869 8974 9135 9568 9670 9969 10069 10267 11410 11576 11708 12142 12378

Mass [kg]
45565 57127 43116 41724 76851 38796 55410 51659 30762 92370 74420 43210 50980 92000 56582

Power [kW]
1 x 5200 1 x 6500 5000 N/S N/S N/S 1 x 5200 2 x 5200 5000 N/S 6500 N/S N/S N/S 2 x 4103

Material
Cast Steel Cast Steel Cast Steel Ductile Iron Cast Steel Cast Steel Cast Steel Cast Steel Cast Steel Cast Steel Cast Steel Ductile Iron Cast Steel Ductile Iron Ductile Iron

Investment in advanced machining and gear cutting technology, combined with development of new materials and techniques used in the manufacturing process, has seen David Brown rewrite the handbook on girth gears

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Shovel and dragline components

Critical failure analysis | product enhancement | optimising solutions
Shovels and draglines are used extensively in the copper, gold, iron ore, coal and diamond industries to remove overburden and minerals. David Brown can service existing as well as supply upgrade replacement gearboxes and components.
Key benefits Replacement components engineered to optimise and extend product
reliability Options for preventative maintenance, contracts and scheduled servicing Service, repair and upgrade of existing equipment, gearboxes and components Options for service exchange or drop in replacement units Most machine models covered

Reference list includes: Machine Types

P&H shovels Bucyrus shovels Bucyrus shovels P&H dragline Bucyrus draglines Marion draglines

Machine Model
2800XPB,2800XPC,4100A, 4100XPB & 4100XPC 495Bl,495Bll,495HD,495HF, 495HR,495HR2 182M 752 1260W,1370W,1570W, W2000 7400,8050,8200,8750

Products serviced Crowd gearboxes, shafts,

pinions and racks Propel planetary drives and gearboxes Hoist planetary drives, gearboxes and rope drums Swing planetary drives, gearboxes, shafts and pinions Drag gearboxes and rope drums

Product improvements
Failure analysis Design parameter analysis Material selection Heat treatment procedures Gear cutting technology and accuracy Bearing and seal selection Lubrication selection

David Brown is heavily focused on product improvement. Our objective is to understand component failures and engineer them out David Brown can repair, manufacture and upgrade full shovel and dragline transmissions as well as geared components for OEMs such as: P&H, Bucyrus, Page, Ransomes & Rapier, Manitowoc , Taiyuan and OMZ
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Mining product catalogue

Gearboxes and transmissions

David Brown goes to the very heart of the mining industry, providing tailored gear products and systems, inspection and maintenance with thorough service and repairs to all parts of the mining process including; extraction, processing and transportation. The portfolio of David Brown ranges from universal standard units through to application specific gear units and customer specific solutions. Being an integral part of industry for more than 150 years, with a demonstrable track record, the David Brown name speaks for itself. A one stop shop for your mining requirements, the best-in-class solution provider.

Hoist
Mine hoists and associated equipment are available in many types and sizes and can supplied as geared drives. David Brown can custom design to your exact specifications.

Agitator drives
Gearboxes for agitators, thickeners and mixer systems used in mineral processing and water treatment industries.

Stealth drives
Patented conveyor drive for most demanding noise requirements. Acoustically designed cathedral shape for lowest noise transmission.

Slurry pump drives

Slurry pumps can be made available in both horizontal and vertical configurations to meet your requirements. These products offer exceptional quality and reliability, minimising downtime in operation.

Winch or winder drives

David Brown can design and manufacture specialist hoists and winches for custom applications for a number of industries including mining. We can offer both repairs and refurbishments with quick turnarounds to improve efficiency and reliability.

Barring drives
To meet high power specifications, bucket wheels use barring drives. To reduce speed and power, a smaller barring drive can be used. Barring drives and clutches can be designed and supplied to match the gearbox if required.

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product catalogue MiningMining product catalogue

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Service and repair

Global service centres repair and refurbish all gearbox types including worm, planetary, parallel, helical and spur gears. David Brown can repair any damaged gearbox, including the remanufacture of broken or pitted gears and shafts. We can repair almost anything, whatever the make or model. David Brown is recognised as a mining gear specialist, with existing facilities operating closely to its customers. We focus on building and maintaining long term relationships with all our key channel stakeholders; OEMs, engineering houses, prime maintenance contractors and mining operators.

Advice Giving our customers sound technical advice

with speedy repairs and upgrades Offering the best solution to fix your problem Maximise operational ability

Quotations Competitively priced at your specified lead

time Honest and professional service

Project management Co-ordinate teams to offer repairs and

redelivery of your gearbox and other associated products Pro-active to work around you Fully supported teams, backed by a global network and expertise

Site services Global fast response, with the best and

dedicated engineers In situ inspections Full asset management services Warrant parts and services to minimise downtime impact Gearbox repairs and upgrades

Spares
David Brown can offer spares for all David Brown products and manufacture any required parts

Repairs
David Brown can offer repairs on or offsite on all makes and models of gearboxes and associated products

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David Brown understands that fast response is key to any customer requiring aftermarket services. Our dedicated service centre engineers and support ensure your gear system, whatever the make or model, is up and running optimising performance, and minimising downtime.

before

after

before

after

before

after

before

after

before

after

before

after

Whatever the make or model we can inspect, overhaul and repair your gearbox
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David Brown has more than 150 years experience in supplying specialised gear units for the metals industry, giving us worldwide references in almost every application, and a detailed knowledge of the specialised requirements of gear units in the metals industry.

Our product range includes the full range of custom engineered gearboxes for all applications including some of the largest rolling mill drives; these can be engineered to meet your new equipment specifications, or designed as drop in solutions to replace existing machinery, often with significant capacity and reliability upgrades. Our services include on site and off site maintenance and repair services, both for David Brown and competitor gearboxes, including the capability to engineer out known problems and provide product upgrades.

Key features We offer a 3 year extended warranty package on gearboxes

serviced, repaired and upgraded by David Brown facilities world-wide

Available at all David Brown service and manufacturing We can repair, upgrade and maintain any type of gearbox for
any industrial application

Services offered
Full diagnostic and performance testing Inspection and maintenance with in-depth reporting Consulting failure analysis and strain gauging Repairs, overhauls and upgrades Retrofit replacement gearboxes On-site / offsite support Asset management Strategic spares management 3 year warranty package

3X terms and conditions apply. For eligibility contact your local David Brown office.
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