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EP-CTU3500 Planetary Track Drive Gearbox – 35,000 Nm
Brevini CTU3500 Compatible Replacement | EVER POWER
The EP-CTU3500 addresses the most demanding segment of the tracked equipment market – machines where every unplanned stoppage costs thousands of dollars per hour. Replacing the Brevini riduttori CTU3500, this 3-to-4-stage planetary drive delivers 35,000 Nm of output torque with a broad ratio range of 35:1 to 200:1, making it the right choice for large mining excavators, crawler drilling rigs and heavy offshore construction platforms.
Product Overview
Served industries: 40-60 t mining hydraulic excavators, large rock drill crawler carriers, heavy tracked load-out platforms, large-scale tracked crane undercarriages and slow-speed tracked industrial transfer cars. The EP-CTU3500 is optionally supplied with a dual-speed engagement mechanism – allowing the operator to select a high-torque low-speed mode for digging and a higher-speed mode for tramming, all within the same gearbox body.
Technical Parameters
| Parameter | Value |
|---|---|
| Model | EP-CTU3500 |
| Replaces | Brevini riduttori CTU3500 |
| Max Output Torque | 35,000 Nm |
| Gear Stages | 3 – 4 |
| Ratio Range | 35:1 – 200:1 |
| Max Input Speed | 2,200 rpm |
| Continuous Thermal Limit | 55 kW |
| Dual Speed | Optional (hydraulic ratio change) |
| Housing Material | GGG50 ductile iron + epoxy-chromate coat |
| Protection Class | IP68 |
| Operating Temp. | -35 degC to +85 degC |
| Approx. Weight | ~128 kg |
| Brake | Spring multi-disc failsafe / hydraulic release |
Working Principle
The optional dual-speed mechanism works by hydraulically engaging or disengaging the third planetary stage. In low-speed mode all three or four stages are active, providing maximum torque for trench pushing and hard-ground travel. In high-speed mode the third stage is bridged by a hydraulically actuated clutch pack, effectively reducing the active stage count by one and increasing output shaft speed for fast tramming. Speed change occurs under load, managed by the machine’s travel control valve.
The fourth stage (in 4-stage configurations) uses a wide-face planet gear extending the tooth contact length by 30% compared to standard width, directly increasing the continuous power rating of the output stage without increasing the housing diameter.
Core Advantages
| ◼ Dual-Speed Option Hydraulic ratio change in the gearbox – high torque for work, high speed for tramming. No separate two-speed motor needed. |
◼ Wide-Face Final Stage Planet 30% longer tooth contact face – increases continuous power capacity without housing upsizing. |
| ◼ 35:1 – 200:1 Ratio Range Single platform covers diverse machine speed requirements from slow transfer cars to fast large excavators. |
◼ -35 degC Arctic Capability Cold-rated FKM seals and low-pour-point PAO oil variant available for northern operations. |
| ◼ Brevini CTU3500 Direct Replacement Same bolt pattern and hydraulic port layout – mounts directly in place of the original unit. |
|
Structure and Material Technology
The housing is cast from GGG50 ductile iron and externally coated with epoxy-chromate primer + polyurethane topcoat (720-hour salt spray). Gear steels are 18CrNiMo7-6 vacuum-arc-remelted for maximum core toughness under impact loading. Wide-face planet gear blanks are individually balanced after machining to minimise vibration at high input speeds. The dual-speed clutch pack uses sintered metal friction discs rated for 50,000 engagement cycles without measurable wear.
Typical Application Scenarios
| Industry | Machine Type | Dual-Speed Benefit |
|---|---|---|
| Mining | 50 t excavator, open-cast coal | High torque for face digging; fast travel between faces reduces cycle time. |
| Drilling | Large crawler rock drill carrier | Slow precise positioning at drill hole; fast tramming to next location. |
| Civil | Heavy tracked load-out platform | 200:1 ratio for ultra-slow heavy load positioning; stable brake hold on incline. |
| Offshore | Tracked platform leg jack system | High output torque for leg jacking; precise slow positioning during seafloor engagement. |
Selection Guide
- Dual-Speed Required? – Specify if the machine requires two distinct travel speed ranges from a single motor.
- Stage Count – 3-stage for 35:1-100:1; 4-stage for 100:1-200:1.
- Continuous Duty vs. Intermittent – Confirm duty cycle for thermal rating; 55 kW continuous is the standard limit.
- Clutch Engagement Frequency – For dual-speed, state expected speed changes per hour to confirm clutch life.
- Arctic Service – Specify PAO VG 100 oil + low-temperature FKM seal grade for below -25 degC ambient.
Talk to our heavy equipment specialists for a dual-speed sizing study.
Brevini CTU3500 vs. EVER POWER EP-CTU3500
Disclaimer: EVER POWER references the Brevini riduttori CTU3500 model number solely to help customers identify a compatible replacement. We do not manufacture or imply affiliation with Brevini. No intellectual property of Brevini is reproduced. Our replacement unit is an independently designed product that is dimensionally and functionally compatible.
| Aspect | Brevini CTU3500 | EVER POWER EP-CTU3500 |
|---|---|---|
| Price | High OEM tier | Competitive (material saving, same performance) |
| Lead Time | 12-20 weeks | 4-7 weeks |
| Dual-Speed Option | Available (at premium) | Standard catalogue option |
| Arctic Rating | Special order | -35 degC as standard option |
| Max Ratio (single unit) | Standard range | Up to 200:1 |
EVER POWER supplies matched hydraulic travel motors for EP-CTU3500. Request a complete drive package.
Quality Certifications and Service Commitment
- ISO 9001:2015 – Full production documentation and traceability.
- CE Marking – Machinery Directive 2006/42/EC compliance.
- 18-month warranty from shipment date.
- Emergency spare parts including clutch disc sets and seal kits dispatched within 48 hours.
More about EVER POWER at our About Us page.
Case Studies – Engineer Field Notes
| Country | Application | Feedback |
|---|---|---|
| Russia | 50 t excavator at Siberian coal mine, -32 degC winter operation | “Arctic option was mandatory. Not a single cold-start seal failure in two winters. The dual-speed function reduced our tramming time between faces by 20%.” – Mine Equipment Manager, Kemerovo. |
| USA | Large crawler drill carrier for quarry blasting, Nevada | “The wide-face planet was the key selling point for us. Our previous gearbox ran hot on continuous drilling positioning cycles. This one stays cool.” – Fleet Superintendent, Elko. |
| Chile | Tracked heavy load-out platform, copper mine, 4,000 m altitude | “200:1 ratio let us use a smaller hydraulic motor, reducing energy consumption on our battery-hybrid carrier. EVER POWER’s engineering team provided altitude de-rating calculations on request.” – Project Engineer, Antofagasta. |
Frequently Asked Questions
Q: Can the dual-speed clutch be retrofitted to a standard unit already installed?
A: No. The dual-speed mechanism requires a dedicated housing boss and internal clutch bore. It must be specified at order. Retrofitting in the field is not feasible.
Q: What happens if the dual-speed clutch fails in the field?
A: On clutch failure the unit defaults to its lowest gear (highest torque) mode – the machine can still travel and work, but at reduced speed. A spare clutch disc set can be fitted by a skilled mechanic in approximately 4 hours.
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