Mining Gearbox Rebuild, Conveyor Reducer Repair and Custom Mining Gears
Grinding mills, crushers, apron feeders and overland conveyors run drives that were specified decades ago. We manufacture replacement gears and shafts for them, and rebuild the gearboxes, including units whose original maker no longer supports them.
Mining and mineral processing drives we work on
Mineral processing is unusually hard on gearing: shock loading from uncrushed feed, abrasive dust ingress, and duty cycles that never stop. These are the drives we are most often asked about.
- SAG, ball and rod mill girth gears, pinions and centre-drive reducers
- Jaw, cone and gyratory crusher drives and countershafts
- Apron feeder and grizzly feeder gearboxes
- Overland and in-plant conveyor drive reducers and backstops
- Stacker, reclaimer and shiploader slew and travel drives
- Mine hoist and winder gearing, including friction and drum hoists
- Thickener and clarifier rake drives
- Vibrating screen exciter gears and shafts
- Rotary dryer and kiln drives in salt, potash and lime plants
- Bucket elevator head shafts and drive gearing
Gearbox rebuild
Strip, clean, inspect and report. We measure every gear and journal against drawing or calculated geometry, replace what is out of tolerance, and reassemble to spec with a documented build record.
Custom gears and shafts
Spur, helical, double helical, bevel and planetary gearing cut to order. Pinion shafts, countershafts and head shafts machined complete.
Obsolete drive support
Where the OEM has discontinued the unit or the plant has outlived its supplier, we reverse engineer the internals from the worn parts so the existing housing stays in service.
What usually brings a mining drive to us
The failure is rarely a surprise once the unit is open. The problem is sourcing the part.
| What fails | What we supply |
|---|---|
| Pitted or spalled mill pinion teeth | Replacement pinion cut to the existing girth gear, matched to measured tooth geometry |
| Abrasive wear on conveyor reducer gearing | New gear sets and shafts, with bearing journals restored to size |
| Cracked crusher countershaft | Replacement shaft machined complete, with keyways and tapers to the original fits |
| Feeder gearbox with no parts available | Internals reverse engineered from the worn components |
| Hoist gearing beyond repair limits | New gear set manufactured to the existing centres and housing |
| Rake drive worm set wiped | Replacement worm and wheel manufactured as a matched pair |
Working from no drawings
Most of the drive components we are asked for are no longer manufactured, and the original drawings are long gone. We reverse engineer from the worn part itself: the component is measured, the tooth geometry and fits are established, material is confirmed, and a replacement is cut to suit the existing housing, shafts and bearings so nothing else in the assembly has to change.
Where a gear has failed because of a design limitation rather than wear, we will say so and propose the change rather than reproduce the fault.
Quality and documentation
Euro Gear operates an ISO 9001:2015 certified quality management system. EN 10204 3.1 material certification is available on request, with mill traceability. Components bound for the United Kingdom or European Union ship as partly completed machinery with a Declaration of Incorporation.
Lead times
We are built around planned work: shutdowns, turnarounds and scheduled overhauls booked in advance, where the component has to be right and on site for a known date. Tell us the outage date and we will tell you honestly whether we can meet it. We do not offer field service or emergency breakdown attendance.
Common questions
- Can you make a mill pinion without the original drawing?
- Yes. We measure the mating girth gear and the worn pinion to establish the tooth geometry, centre distance and fits, then cut a replacement to suit. This is the majority of the mining work we do.
- Do you rebuild gearboxes from makers that no longer exist?
- Yes, and it is a common reason plants come to us. If the housing and shafts are sound, the internals can be reverse engineered and the unit returned to service without changing the installation.
- Can you match our existing gear quality grade and material?
- We confirm material before quoting and manufacture to the grade the application requires. Material certification to EN 10204 3.1 is available on request.
- Do you attend site for breakdowns?
- No. We are a manufacturing shop, built around planned shutdown and overhaul work rather than emergency field attendance.
- What do you need from us to quote?
- Photographs of the gearbox nameplate and the worn component are usually enough to start. Drawings help but are not required.
Send us the part
A photograph of the nameplate and the worn component is usually enough for us to tell you whether we can help. Drawings are welcome but not required.