P&H Rope Shovel Terminology

Hofmann Improved P&H Parts

 Hofmann Swing Transmission
• P/No. 100J5949F4 suits :
- 2800XPA, 2800XPB and 2800XPC
- 4100A, 4100C, 4100XPB and 4100XPC
Form ground ring
• Offered as new or service exchange.
gear to AGMA 12
• Completely re-engineered.
(minimum)
• Fully interchangeable.
• Upgraded materials, heat treatment, accuracy
and surface finish.
• All internal gearing carburised using ‘HofCARB’
process (60-62HRc) producing greater tooth
strength higher surface hardness and increased
wear resistance.
• Precision of all gearing to AGMA 12 minimum
quality including ring gear.

SOLUTION PROBLEM
New replaceable bronze 1st Reduction Gear teeth
PROBLEM thrust washer added. pitting and cracking around
Case hardened cap added to Induction Hardened tooth root
the end of the Sun Pinion.

Damage to sun pinion

SOLUTION
and retainer plate from
thrust ball arrangement, Single piece forging,
resulting in the ball Carburised (60-62HRc)
falling out and and precision form ground
destroying transmission to AGMA 12 minimum
 Hofmann Swing Shaft Assemblies
Tapered Bore Sleeve on OEM
shaft creeps due to thermal
PROBLEM expansion and bearing preload is
lost. The bearing frets on the shaft
causing a stress concentration.
Fatigue loading results in failure.

Hofmann Engineering SWING SHAFTS are designed with a

SOLUTION positive stop shoulder that prevents the sleeve moving during
thermal expansion thus eliminating loss in bearing preload.

Sleeve SWING PINIONS are Full Contour

design Induction Hardened. The effective
case depth is varied from 8mm at the
Shaft design
tooth tip to 10mm to eliminate a hard
Positive stop brittle tooth tip. Also Available as
Upgraded Hof-Carb hardened
pinions (60-62HRc)

10mm

Positive shoulder on shaft prevents the

bearing sleeve moving during operation
thus bearing preload is maintained 8mm
 Hofmann 4100XPB Swing Gear Assembly

PROBLEM
SWING GEAR ASSEMBLY
• Suitable for 4100A / 4100C / 4100XPB machines
• Split (2-piece) or single (1-piece) gear design
• Replaceable thrust rail (8-piece)
• 6.0” Roller assembly

Tapered joint face and Hofnuts

Spalling on Excessive wear on inside prevent tangential separation
lower rail thrust face of swing gear force and hence fatigue cracking

No relief for Replaceable

metal particles Thrust Rail

SOLUTION
Fitted bolts with
6.0” wide roller Hofnuts secure the
assembly splitline with 190T
of clamping force

OEM DESIGN HOFMANN DESIGN HOFMANN DESIGN

Rollers thrust against the inside of the gear Rollers thrust against a replaceable thrust The gear can be
producing considerable wear. Metal rail. A relief area under the thrust rail is supplied as a split 2-piece construction.
particles are trapped on the roller path designed to trap metal particles, thus A taper joint face and Hofnuts prevent gear
damaging the surface leading to spalling. reducing roller path damage. tooth separation forces and fatigue.
 Hofmann 4100XPC Swing Gear Assembly
UPGRADED 4100XPC SWING GEAR ASSEMBLY: Tapered joint face and Hofnuts
• Part No. R61040F6 suitable for new 4100XPC machines prevent tangential separation
PROBLEM force and hence fatigue cracking
• Can be retrofit to 4100A/ 4100C/ 4100XPB machines
• Retrofit requires re-drilling of upper and lower rail mounting holes in
carbody and revolving frame.
• Rails forged AS1444-4340 modified steel, hardened 360-390BHN
• Rollers forged AS1444-4340 steel, hardened 380-410BHN
• Gear forged AGMA Grade 2 material, 330-360BHN
Excessive wear on lower rail
resulting in wear step sub-surface Stronger bolting for
fatigue fracture and spalling upper and lower rails
Increased width of Rollers and
Relief on rail edges
Roller Path for higher load
to prevent wear step
carrying capacity

No relief for Replaceable

metal particles Thrust Rail

SOLUTION
Fitted bolts with
Wear step 7.25” wide Hofnuts secure the
location roller assembly splitline with 190T
of clamping force

OEM DESIGN HOFMANN DESIGN HOFMANN DESIGN

Rollers thrust against the inside of the gear Wider Rollers thrust against a replaceable The gear can be
producing considerable wear. Metal thrust rail. A relief area under the thrust rail supplied as a split 2-piece construction.
particles are trapped on the roller path is designed to trap metal particles, thus A taper joint face and Hofnuts prevent gear
damaging the surface leading to spalling. reducing roller path damage. tooth separation forces and fatigue.
 Hofmann Propel Transmission
New replaceable bronze thrust
PROBLEM SOLUTION washer and case hardened cap • P/No. 100J5800F2 to suit 2800XPA, 2800XPB, 2800XPC,
added to the Sun Pinion. 4100A and 4100C models
• P/No. 100J5800F6 to suit 4100XPB and 4100XPC models
Damage to 2nd Offered as new or service exchange.
reduction sun • Completely re-engineered and fully interchangeable.
pinion and retainer • Upgraded materials, heat treatment, accuracy and surface
plate from thrust finish.
ball arrangement • All internal gearing carburised using ‘HofCARB’ process
(60-62HRc) producing greater tooth strength higher surface
Forged, carburised (60-62HRc) hardness and increased wear resistance.
SOLUTION gearing, precision form ground • Precision form grinding of all gearing except 3rd reduction
PROBLEM to AGMA 12 minimum. Ring Gear to AGMA 12 minimum quality.
• Accurately cut 3rd reduction internal ring gear to AGMA 10
OEM Induction minimum quality.
hardened gearing

Induction hardened thrust area

SOLUTION on planet carrier to prevent
PROBLEM
metal scuffing during start/stop
operation.
Damage to 2nd
reduction ring gear
from 3rd reduction
planet carrier
 Hofmann Propel UPGRADE Kit
43T Spline Planet Carrier to suit
100J5800F2 Transmission A common problem with the 4100A machine is torsional
PROBLEM
fatigue failure of the propel shaft due to overload.

• To increase the number of splines on the propel shaft

SOLUTION
from 43 teeth to 47 teeth, thus increasing its diameter
and strength.
1 • Modify the existing planet carrier spline from 43-teeth to
a 47-teeth. The existing planet carrier can be used and
modified. The existing hub is machined out and a new
forged hub is welded into position using a full penetration
weld prior to machining.
• The upgrade is also possible for 2800XPA, 2800XPB and
2800XPC machines where they may be working with a
fleet of 4100XPB or 4100XPC machines and require a
spare 100J5800F6 transmission suitable for all
machines. In this case upgrade the propel shaft.
2

43Tooth 47Tooth
3

47T Spline Planet Carrier 47Tooth 47Tooth

to suit 100J5800F6
Transmission
 Hofmann Propel Shafts
Excessive Propel shafts to suit:
spline wear 2800XPA, 2800XPB, 2800XPC
PROBLEM
4100, 4100A, 4100C, 4100XPB, 4100XPC

SOLUTION To increase the fatigue strength of the propel

shaft, the spline on the drive (transmission) end
is induction hardened to 54HRc. Induction
hardening increases the compressive stresses in
surface of the material, thus increasing the
fatigue strength and wear resistance.

Cracking in
PROBLEM
spline teeth

Torsional fatigue
PROBLEM failure at the drive
(transmission) end
INDUCTION HARDENED REGION
Hofmann Crowd Transmission
• INPUT PINION: manufactured from 18CrNiMo7 material, carburised to 60-62HRc
using ‘HofCARB’ process and precision form ground to AGMA 12 minimum quality.
• INTERMEDIATE GEAR: forge fabricated, using a AS1444-4330 rim, induction
hardened to 56-58HRc and precision form ground to AGMA 12 minimum quality.
• INTERMEDIATE PINION: manufactured from 18CrNiMo7 material, carburised to
60-62HRc using ‘HofCARB’ process and precision form ground to AGMA12 quality.
• SHIPPER SHAFT: AS1444-4340 material, through hardened to 320-350BHN
• SHIPPER SHAFT GEAR: forge fabricated gear, using a AS1444-4330 rim, full
contour induction hardened to 56-58HRc and hard cut to AGMA 10 minimum quality.
• SHIPPER SHAFT PINIONS: forged AS1444-4340 material, rough machined and
through hardened 350-390BHN prior to finish machining (AGMA 10 minimum
quality).
Hofmann Hoist Gearing
• INPUT PINION: Single helical, manufactured from 18CrNiMo7 material, carburised
to 60-62HRc using ‘HofCARB’ process and precision form ground to AGMA 12
minimum quality.
• INTERMEDIATE GEAR: Single helical, forge fabricated gear, using a AS1444-4330
rim, full contour induction hardening to 56-58HRc and precision form ground to
AGMA 12 minimum quality.
• INTERMEDIATE PINION: manufactured from 18CrNiMo7 material, carburised to
60-62HRc using ‘HofCARB’ process and precision form ground to AGMA12
minimum.
• DRUM GEAR: Single helical, forge fabricated gear, using a AS1444-4330 rim,
quench and tempered or full contour induction hardening to 56-58HRc and hard cut
to AGMA 10 minimum quality.
 Hofmann Site Services / Installations
INSPECTION (Level-Align Machine) LIFTING (complete shovel lifts) MACHINING (Machining of mounting areas)

INSTALLATION (Swing gear assembly installations)