INTRO

TRANSMISSION
REBUILDS

Vancouver based United Gear & Machine Works Ltd. has been in business for over 50 years and
has been providing Western Canada with the highest quality gear box rebuild services for over 20
years. United Gear has risen above the competition through our commitment to quality and
continuous product improvement. When United Gear is selected as your transmission rebuild
partner you will:

- Benefit from a quick turn around of your transmission

- Compliment your Condition Based Maintenance with numerous improvements designed
to extend component life.
- Obtain a partner that understands and will work with you to make quality and design
improvements.
 RECENT HISTORY
ROPE SHOVEL TRANSMISSION REBUILDS

MACHINE TYPE # of REBUILDS

P&H2800 XPA/XPB/XPC Swing 8
P&H 2800 XPA/XPB Propel 6
CAT 7495 Swing 7
CAT 7495 Propel 4
CAT 7495 Hoist 4

All transmission rebuilds are the product of an in depth reverse engineering process which allows
the experienced staff at United Gear to identify the unique wear patterns and OEM weaknesses.
Working with mine management (to help understand the unique operational requirements) our staff
can identify and will collaborate on recommended improvements. With the focus on continual
improvement, we can provide the added confidence in extending component life, shorten rebuild
time, and improve operating costs.
 EXPANDED HISTORY
MINING TRANSMISSION REBUILDS

P&H 2800 XPA/XPB/XPC SWING TRANSMISSION REBUILDS

• 16 rebuilds / refurbishments
• UG also understands that these transmissions are the same as those used on P&H 4100
shovels, where they have 3 swing transmissions rather than the 2 on 2800 shovels
• Over a dozen improvements – most advanced swing UG rebuilds
• UG has manufactured 5 complete new swing transmissions with (1) presently in stock.

P&H 2800 XPA/XPB/XPC PROPEL TRANSMISSION REBUILDS

• 14 rebuilds / refurbishments
• UG expects to get a 2800 XPC Propel transmission for reverse engineering in the near
future. (It is our understanding that these are essentially the same as the XPA /XPB
model with the exception of a larger output internal spline with an extra tooth.)
• UG has also manufactured 2 complete new propel transmissions.
 EXPANDED HISTORY
MINING TRANSMISSION REBUILDS

BUCYRUS 49HR PROPEL TRANSMISSIONSS

• 19 rebuilds / refurbishments
• The upgrades we have completed on this model of transmission are as follows:
Upgraded forged material versus OEM cast steel for gearing components
• We have also built other upgraded components for the 49R series of drills; for example
rack pinions with hardened and ground gear teeth.

In addition to the above shovel and drill transmissions, UG has also rebuilt 10 Lohmann &
Stolterfoht (L&S) Apron feeder transmissions. The significance of these rebuilds with respect
to mining shovel transmissions is that they are planetary transmissions, and L&S provides
planetary propel transmission for several brands of hydraulic shovels, so there should be a
very good opportunity on these rebuilds for the customers who have them. UG has also
rebuilt complete pump drives for a number of mining shovels, drills etc.
 OUR PROCESS
TRANSMISSION REPAIR AND RETURN

Step 1. Learn and understand historical transmission

performance, hours, failure modes, etc.

Step 2. Review planned maintenance intervals for

transmissions including: PDM methods, fleet
component repair intervals, and spare WORN INPUT COUPLING 7495 SWING
transmission availability.

Step 3. Recommend a complimenting parts

inventory of long lead items to support a quick
turnaround.

Step 4. Initiate repair and return program with first

rebuild.

2ND REDUCTION 7495 SWING

CARRIER DAMAGED BEARING
AND SEAL JOURNALS
 7495 SWING
UPGRADES & IMPROVEMENTS

7495 SWING TRANSMISSION

MAJOR UPGRADES

SUN PINIONS AND ALL OTHER EXTERNAL GEARS

• Sun pinion shafts (B-212120 & B212126) material is forged for improved toughness and
hardness properties.
• All case hardened gearing conforms to AGMA recommended case depth.
• All other external gearing (B-212121, B-212127, B-212130 and B-212131) is
manufactured from forged material with a superior toughness.
• All gearing is ground to a minimum AGMA 11 quality with geometry modifications
(crowning, tip relief, and tip radius) which allows for a smoother and longer
operational life.

IMPACT: These geometry improvements allow for an improved contact pattern and
operational load balance reducing wear and pitting.

INTERNAL RING GEARS

• Ring gears B-212123 and B-212129 are manufactured using a custom forged steel–
normalized, quenched and tempered. This material has a higher yield strength and
superior wear resistance.
 7495
7495 SWING
SWING transmission
TRANSMISSION
MAJOR
MAJOR UPGRADES
UPGRADES

CARRIERS:
• B-212124 1st Stage carrier is made from a custom forged material – normalized,
quenched and tempered. This material has a higher yield strength and superior wear
resistance versus the OEM cast material
• B-212132 2nd Stage carrier is made from a custom forged material – normalized,
quenched and tempered with a superior grain structure and yield strength compared
to the OEM cast carrier.
• Output bearing journal location has been tolerance increased +0.0010”-+ 0.0015 to
allow for closer tolerance fit to the bearing to help prevent bearing journal fretting from
normal operational deflections which occur from the thin wall carrier design.

HOUSING BORE REPAIRS:

• The OEM lower housing plate utilizes a low Bhn hardness. United Gear has repaired
many of these bores as a result of spun bearing races and fretting damage. When
repairing these bores we use AISI 4340 HTSR steel sleeves that are interference fit and
machined to the required final bore tolerance. These sleeves create a superior bearing
support and resist directional plastic deformation resulting in longer operational stability.
 7495 PROPEL TRANSMISSION
MAJOR UPGRADES

SUN PINIONS AND ALL OTHER EXTERNAL GEARS

• Sun pinion shafts B-212240 and B-212248 use AISI 3312 forged bar stock material with
a superior toughness (Yield Strength) with 36-38 Rc. core hardness. Sun pinions have
additional deep chill (Dry Ice) process added to the tempering process to maximize
toughness at all operating temperatures. (Lowers the retained austenite levels further
and converts to martensite.)
• All case hardened gearing utilizes maximum recommend AGMA case depth based
on gear tooth pitch geometry.
• All other external gearing B-212235, B-212236, B-212241 and B-212149 uses improved
forged normalized steel with a superior toughness (Yield Strength) with 36-38 Rc core
hardness.
• All gearing is ground to AGMA 11 quality minimum with geometry modification to
allow for smoother longer operational life expectancy. (Crowning, Tip Relief and Tip
Radius Modifications - Except Spiral Bevel Set) These features allow for a better
contact pattern and operational load balance which results in less wear and pitting.

INTERNAL RING GEARS

• Dbl. Internal ring gear B-212243 is manufactured using an improved forged alloy –
normalized, quenched and tempered to 330- 360 Bhn hardness.
 7495PROPEL
7495 SWINGTRANSMISSION
TRANMISSION
MAJOR
MAJOR UPGRADES
UPGRADES

INPUT BEARING AXIAL SETTING LOCK NUT UPGRADE:

• United Gear has designed an upgraded right-hand to left-hand thread interlock nut B-
214127. This upgraded nut assembly cannot loosen unless a total failure of threads
occurs and any loosening effect would effectively tighten the assembly due to the finer
left-hand thread pitch on locking jam nut. The OEM gearboxes use a Spieth
compression right-hand thread lock nut on the spiral bevel main bearing setting. The
issue is over time from shock loads, and other forces the nut can be plastically
deformed and loosen allowing setting on the bearings to change. In the worse case,
the nut can loosen significantly causing catastrophic failure to occur at the input spiral
bevel set stage.

HOUSING BORE REPAIRS:

• The OEM housings have lower Bhn. hardness steel used in the manufacturing. United
Gear when repairing would use improved steel sleeves that are interference fit installed
and machined to required final bore tolerance. These sleeves create superior support
for the bearings and resist directional plastic deformation of bores and tolerances
degrading required for longer operation stability. Typically the sleeve process increases
the material general hardness to 320 Bhn.
 7495PROPEL
7495 SWINGTRANSMISSION
TRANMISSION
MAJOR
MAJOR UPGRADES
UPGRADES

CARRIERS:
• B-212241 2nd Stage carrier would be made using an improved forged alloy – normalized,
quenched and tempered. This material has a higher yield strength and superior wear
resistance versus the OEM casting material. We do not currently have a drawing
produced for this component, but have samples available. B-212251 3rd Stage carrier
would be made using an improved forged steel – normalized, quenched and
tempered. We do not currently have a drawing produced for this component, but have
samples available.
REBUILD PROCESS
WHAT COMES NEXT FOR YOUR 7495 TRANSMISSION REBUILD?
PROCESS:
1. Customer issues a purchase order to
initiate the shipping and disassembly for
quote.
2. Transmission is received at United Gear
and is externally cleaned and general
condition documented.
3. Transmission is completely disassembled,
each part is identified chronologically.
4. All critical parts are photographed,
measured, and documented.
5. Parts are tagged “acceptable”,
“repairable” and/or “rejected”.
6. A 3rd party Magnetic Particle Inspection is
completed on all parts.
7. As a result of the MPI, any flaw is
documented.
8. An inspection and 3 axis measurement of
all housing bores is completed and
photographed.
9. An inspection report and repair quote is
generated for the customer. Examples
are provided in Appendix 1.
10. On approval the transmission is rebuilt,
tested, and returned to the customer.
.
7495 SWING REBUILD ESTIMATE
An average of recent 7495 swing
transmission re-bearing/re-seal rebuilds:
$[]
(bearings and seals only)
An average of recent rebuilds:
$[]
Notes:
• A bearing and seals rebuild typically
requires 6-8 weeks during normal
workload.
• Currently delivery on bearings and seal
kit is 12-14 weeks subject to prior sales.
PRICE:
An average of recent 7495 propel
transmission rebuilds:
$[]
 APPENDIX 1
EXAMPLE SWING INSPECTION REPORT

For information on United

Gear products, visit us at
www.unitedgear.com

(c) United Gear & Machine

Works Ltd.
All Rights reserved.
 Mobile Equipment
Transmission – new and rebuild

United Gear & Machine Works Ltd. is a Canadian company that has been in business for over 50
years. We have been providing the mining industry with the highest quality products since then.
Our commitment to quality and continuous improvement is part of our genes. Specifically for the
mining industry, we offer the following :

- New transmissions for :

- 495HR/HF Swing - 2800XPA/XPB Swing
- 495HR/HF Hoist - 2800XPA/XPB Propel
- 495HR/HF Propel - 4100XPB Swing
- 49R/HR Propel
- Rebuilds for :
- Rope shovels all models, hoist, crowd, swing, propel transmissions
- Hydraulic excavators all models, swing, propel transmissions
- Drills all models, propel, hoist, rotary transmissions

Propel Transmission

Hoist Transmission

Swing Transmission

For information on United

Gear products, visit us at
www.unitedgear.com

(c) United Gear & Machine

Works Ltd.
All Rights reserved.