DRAGLINE

PARTS & SERVICES

• CATERPILLAR/BUCYRUS/MARION
• KOMATSU/P & H • UDD

With a long engineering and manufacturing

background in dragline components, Hofmann
Engineering supply the full range of new
and refurbished dragline parts that are
interchangeable with the OEM’s. All major
mechanical components are available including
the swing base, rack, rails and rollers, walking
eccentrics, cams, shafts, gearboxes and boom
point sheaves. In situ induction hardening of
rope drums by Hofmann’s Site Team reduces
downtime.

SWING RACK ASSEMBLIES

• Forged alloy steel rack rims Q&T to
330BHN combined with fabricated
construction. UDD MECHANICAL
• High performance racks with a unique CONVERSIONS
heat treatment procedure that increases
Hofmann Engineering completely designed,
the hardness to 450BHN.
manufactured and installed the mechanical
• Swing pinions are full contour induction
drive for the UDD (Universal Dig and Dump)
hardened.
dragline.
Our concept provides a free-floating,
alignment free, shaft mounted, modular
gearbox that bolts to the side of the rope
drum. This gearbox contains HofCarb
carburised and precision ground gearing
with a filtered oil recirculation system.
Being shaft mounted and modular enables
this gearbox to be pre-test run and changed
out in under one shift without requiring INPUT MOTOR PINIONS
realignment.
•D
 ouble helical hard cut narrow gap. Case
carburised to 60-62HRC and finished to
RACK AGMA 12 quality.
SEGMENTS •Q
 uench and tempered to 360 BHN and cut
to AGMA 10 quality as per OEM design.
RAILS & ROLLER ASSEMBLY •F
 ully assembled •C
 ARB bearing aligment technology with
and inspected eccentric cartridges can also be used on
• Original or 3rd (thrust) rail designs. in-house prior Bucyrus machines to give over a 200%
• Laser tracking inspection to 40 micron to on-site improvement in bearing life.
accuracy. installation.
©Copyright 2019, Hofmann Engineering Pty Ltd.
 RACKS, RAILS & ROLLERS
• Improved material chemistry to achieve
increased hardness and superior mechanical
properties.
• High quality forgings fully ultrasonically
tested to AS1065 Level 1.
• Complete assemblies trial fitted prior to
despatch.

PROPEL ECCENTRICS

1. FORGED 2. FORGED FABRICATED 3. CAST VERSION

• A single piece quench and tempered • Eccentric casting fully machined. •E
 ccentrics also available as an original
forging results in superior mechanical cast version.
• Forged steel version available from
properties.
AS1444-4330 steel. •H
 ardness achieved: 220-260 BHN.
• Hardness achieved:
• Hardness achieved: 270-300 BHN.
320-350 BHN. 4. FULL REFURBISHMENT
•W
 elding, stress relieving and machining back
to as new dimension including the spline.

SWING BASE TUBS

•M  anufactured with a minimum of 80mm plate for the
circumferential diaphragm sections.
•S  tress relieving is carried out on the full tub quadrant sections.
• Supplied in 5 major fabricated sections for ease of site assembly
with minimal site installation time required.
• Includes general thickening of bulkhead diaphragms.
• Includes 2 pinion change-out holes (with covers and lower
support structures.)

©Copyright 2019, Hofmann Engineering Pty Ltd.

 DRUM GEARS INTERMEDIATE ASSEMBLY SELF ALIGNING PINIONS
• New forged steel gears 330 to 360 BHN • Intermediate gears: forged steel, staggered •S
 elf-aligning gearing technology maintains
precision cut to AGMA 10. tooth, double helical, through hardened 100% contact in operation.
• Mechanically re-rimmed gears: Replace the 330 to 360BHN, precision cut to AGMA 10 •D
 ouble helical zero-gap 19” face width,
gear teeth with a bolt on arrangement to quality. carburized to 60-62HRc and precision
save time and money. • Intermediate shafts: forged steel, spline ground to AGMA 12 quality.
• Re-rimmed gears: Remove old rim and weld coupling carburised to 60-62HRc, precision •S
 pherical bearings carburised to 60-62HRc
new rim to hub with submerged arc full cut to AGMA 12 quality. and lapped for 100% contact, oil lubricated.
penetration weld. • CARB bearings increase bearing life by up
to 200%.

PROPEL GEARS PROPEL SHAFTS SWING PINIONS

• New or reclaimed hub. • New shafts of high quality alloy forging with •F  orged High Alloy steel precision ground
• Reversible gear rim on the same side hub a higher forging reduction. to AGMA12.
thus doubling the life of the gear. • Quench and tempered to achieve hardness • Induction hardened full contour induction
• Mechanically fastened rim can be replaced of 320-360 BHN. hardened to 54-58HRc 8mm thick case.
independently of hub. • Polished and shot-peened radii and • Impact resistant core hardness of
• Forged steel gear rim, through hardened transitional areas to increase strength. 280-310BHN.
gear 330 to 360BHN, precision cut to
AGMA 10.

ROPE SHEAVES 8200 HOIST ARRANGEMENT GEARBOX MODULE

• New forged steel rope sheaves, full contour • Modular design allows quick and easy •M  aintenance and testing of gearbox can
induction hardened grooves to 55HRC for a change out. be done in a clean workshop rather than
case depth of 6mm. • Rigid construction reduces distortion and inside the dragline.
• Repaired sheaves by full penetration gear misalignment. • Installation requires less skill and accuracy
submerge arc welding the worn groove and • Interchangeability between gearboxes and with the self aligning pinion.
then induction hardening. gearing. •G  earing: forged steel, carburised to 60 ± 2
• Self-aligning technology maintains 100% HRC, high precision ground.
contact during floor deflection.
©Copyright 2019, Hofmann Engineering Pty Ltd.
 OEM HOFMANN
DRUM DRUM

1 2
SHAFT MOUNTED GEARBOX ROPE DRUM DESIGN ROPE DRUM MACHINING
• Modular design allows quick and easy • Finite element analysis to eliminate the • All rope drums are fully machined in-house
change out in one shift. tendency of OEM rope drum internal from the initial fabrication preparations
stiffeners to crack. right through to cutting of the rope
• Rigid construction reduces distortion and
• Hofmann Engineering design removes all grooves, turning of the flanges and drilling
gear misalignment.
internal lateral stiffeners and increases the and tapping of the holes. This ensures
• Free floating isolated from dragline floor drum shell forging thickness to reduce that complete control of the project is
distortion. stress. maintained and the highest standards of
• Alignment free gearbox bolts directly to the quality are guaranteed.
hoist drum.

3 4
INDUCTION HARDENING ROPE DRUM CLAMPS
SWING PLANETARY • New forged steel drums: fully fabricated • Unique design developed by Hofmann
using full penetration welds and then full Engineering.
contour induction hardened to 55 HRC for a • Clamp is integrated into the rope drum
• The swing gears are manufactured from case depth of 6mm.
high quality alloy steel forgings and heat center flange.
treated to increase load carrying capacities. • Worn drums: all cracks are removed • Precision machined.
before the drum is built up with 30mm of
• All gearing is ground to high AGMA quality. submerged arc weld, machined and then • Case hardened.
induction hardened. • Optimized for weight.
• Greater clamping force.

CENTRE PINTLE HOIST/DRAG BULL GEARS

• Designed using FEA modeling to reduce • New forged steel 3 piece design.
the magnitude of stress and reduce stress • The spider is an AISI 1444/4140 quench and tempered forging with a hardenss range
concentrations. of 280-320 BHN instead of a casting.
• New forged steel construction overcomes • The gear rim forging is AISI 1444/4330 quench and tempered with hardness of
cast steel cracking problems. 320-360 BHN. This forging offers better mechanical properties to go along with the
increased hardness.
• Depending on customer preference, can be supplied in parts or as an assembly.

©Copyright 2019, Hofmann Engineering Pty Ltd.