GEARING

GEARING
GIRTH GEARS . PINIONS . GEARBOX REBUILDS

DESIGN MANUFACTURE REFURBISHMENT INSTALLATION

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GIRTH GEARS AND PINIONS

Our Services
HARCLIFF MINING SERVICES provides a
comprehensive range of services for the
design, manufacture, repair and installation
of girth gears and pinions for use in
applications including grinding mills, rotary
kilns, dryers and scrubbers. In addition, it
has a dedicated works facility for industrial
gearbox rebuilds and refurbishments and
the production of drop-in replacements
for mill drives and planetary units. The
installation and commissioning of new or
refurbished products is conducted by a
highly experienced team of field service
specialists.

Design
Design capabilities are not confined
exclusively to the manufacture of new
products and extend to the modification and
improvement of existing gear assemblies.
Amendments to gear tooth geometry and
judicious material selection increase flank
durability and root strength service factors,
while ensuring fitment compatibility with
the original gear unit or set.

All calculations are performed in

accordance with the latest American
Gear Manufacturers Association (AGMA)
standards and subjected to finite element
analysis to identify potential stress areas.
Harcliff Mining Services employs the latest in
gear calculation software, including KISSsoft
and Inventor modelling, both essential tools
in the design process.

Materials
• Girth gears are produced from ASTM A 148 cast steel, grades CrMo or CrNiMo alloy steels heat treated up
to 320BHN
• Pinions are produced from CrNiMo through hardened alloy steel to 400BHN or 17CrNiMo6/18CrNiMo8/
EN36B case carburised and hardened to 55-60HRC.

Manufacturing
• Girth gears are manufactured from carbon and alloy steel castings with a capacity of up to 150 tons or
Ø12.5m per gear set
• Pinions and gear box internals are manufactured from hardened or case-hardened alloy steel forgings
• Gear tooth and root areas are subjected to grinding with the latest generation Klingelnberg Höfler profile
grinding technology, ensuring a high degree of accuracy in gear manufacture
• In-board testing head enables the production of gear quality inspection graphs to verify tooth profile, lead,
pitch, run out and span values and deviations.
Girth Gears
• Steel castings with a capacity of up to 150 tons per gear set
• Ladle refining is an important feature of the casting process as it removes impurities from the final cast and
helps to accurately control chemical compositions
• We employ the world’s largest liquid quenching facilities to ensure uniform hardness throughout the
component
• Machining and gear hobbing up to Ø12.5mm, 1,200mm face widths
• Max module = 42 mod.

Pinions
• A vacuum degassing furnace is used prior to casting ingots to ensure forgings have high-quality mechanical
properties
• Gear grinding is conducted to a minimum accuracy of AGMA Q12 class or higher.
 GEARING

GEARBOX REBUILDS
• Full refurbishment services to all makes of gear units, including test running
• In-house design and manufacture of ‘drop-in’ mill drives
• Modernise existing gearboxes, including improvements to lubrication systems, gear materials and tooth
designs
• All rebuilds include on-site installation
• Condition monitoring is one of our specialities.
GEARING

WORLD-CLASS GEAR GRINDING TECHNOLOGY

HARCLIFF MINING SERVICES has invested in a Höfler Rapid 2000 cylindrical gear grinding machine
manufactured by the Klingelnberg Group, one of the world’s leading producers of precision gear grinding
and measuring equipment.

The grinder produced by Klingelnberg’s manufacturing facility in Ettlingen, Germany, has enabled HARCLIFF
to supply gears of the highest quality to both domestic and export markets. Precision gear components
and pinions are manufactured to standards well above traditional hobbing and gear shaping manufacturing
methods and in a wide range of dimensions. These can extend up to 2m in diameter and 14 tons in weight
with a module range of 1-50.

Another gain from the use of this advanced technology is that manufacturing cycle times are significantly
shorter, enabling an even faster response to meet customer needs.

Accuracy Classes Achievable:

• AGMA Q12 and higher
• Super-fine surface finish (<0,8Ra)
GEARING

HARCLIFF MINING SERVICES

HARCLIFF MINING SERVICES is an acknowledged
global specialist in the design, manufacture and
refurbishment of new and existing equipment for
the mining, minerals processing, pyroprocessing,
cement, power generation and petrochemical
sectors. Aftermarket support, installation and
relocation are crucial aspects of the company’s
service offering and are conducted by highly
experienced teams with years of expertise in the
field.

HARCLIFF MINING SERVICES manufactures

and refurbishes:
• Grinding mills and components
• Rotary scrubbers
• Gearing and gear units
• Electric rope shovel and hydraulic shovel spares
• Kiln and dryer components
• Wear parts
• Industrial gearbox rebuilds and drop-in
replacement gear units
• Crusher repairs and parts.

61/62 Fleming Road, Meadowdale, Germiston, 1614

PO Box 2019, Bedfordview, 2008, South Africa

Telephone: +27 11 392 1714/6

info@harcliff.co.za

MEMBER

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