Manual de

Entrenamiento de
Sistemas Mecánicos
Pala Eléctrica Minera (Libro 2)
P&H 4100XPC (AC)

Prepared by:

M0041218-00-ES
 Shovel Mechanical Systems Training

Course Duration Course Objectives

Three days Upon completion of this course the student will
be able to:
Target Audience • Locate and identify major mechanical
This training is targeted for P&H MinePro systems, subsystems and components.
Service Engineers, Technicians, and • Identify and use available P&H
Maintenance and Supervisory personnel reference material to operate or
responsible for preventive and corrective maintain the shovel.
maintenance and servicing of P&H electric • Understand the design and function of
mining shovels. the various mechanical systems.
• Conduct preventive maintenance
Description inspections.
The course introduces the student to the • Perform maintenance adjustments and
operation and maintenance of P&H electric repairs.
mining shovels. It focuses on critical • Recognize safety hazards associated
knowledge and skills required in supporting with inspection, repair and maintenance
P&H electric mining shovels. All mechanical of shovel mechanical systems.
systems and adjustments are discussed.
Recommended preventive and corrective Main Concepts
maintenance procedures and practices are • Review of relevant P&H reference
also discussed. material
• Shovel motions and major components
Prerequisites
• Lower machine structure and Propel
Students should have a basic knowledge of
system
mechanical terminology and practical
experience with maintenance equipment. • Revolving frame and Swing system
• Hoist system
It is also suggested that students complete the • Boom assembly and Crowd system
following eLearning training modules: Product • Machinery house and Ventilation
Overview, General Assembly Procedures, system
Disc Brakes, Theory of Operation of the • Compressed air system
Propel, Swing, Hoist, and Crowd Systems, • Brake system
and Compressed Air and Lubrication systems. • Automatic lubrication system
• Inspections, tests and adjustments of
Course Location major mechanical systems
• Milwaukee • Preventive and corrective maintenance
• Field procedures
 Shovel Mechanical Systems Training

Day 1/2 Day 2/3

Sources of Information Shovel Structures: Attachment

• Mechanical Maintenance Manual • Boom, Handles and ABSS
• LinkOne Parts Book
• Service Bulletins, Notices and Letters Shovel Systems: Dippers
• MineNet • Dipper Wear Components
• Dipper Trip Mechanism
Shovel Orientation and Introduction • “SnubRite” Snubbers
• Shovel Orientation • Pitch Braces
• Mechanical and Structural Overview
Shovel Systems: Crowd
Safety Overview • Crowd System Overview
• Electrical and Mechanical Hazards • Crowd Belt Replacement and
• Stored Mechanical Energy Tensioning
• Shipper Shaft and Saddle Block
General Assembly Procedures Adjustments
• Bolt Torquing Principles and Practices
• Bolt Tensioning Shovel Systems: Compressed Air System
• “SuperNuts” • Air System Overview
• Bearing Types and Adjustment • Air Compressor
• Air System Control
Shovel Systems: Propel • Brake Air System
• Lower Structure and Lower Works • Lube Air System
• Propel System Overview
• DELTA Drive System Shovel Systems: Disc Brakes
• Crawler Track Tension Adjustment • Operation and Components Overview
• Disc Brake Safety
Shovel Systems: Machinery House • Disc Brake Maintenance
• House Ventilation and Pressurization
• AirScrubPro Shovel Systems: Lubrication System
• Types of Lubricants
Shovel Systems: Swing • Motor and Gearcase Lubrication
• Swing System Overview • Automatic Lubrication System Overview
• Center Gudgeon Nut Adjustment

Shovel Systems: Hoist

• Hoist System Overview
Una Historia de P&H Mining Equipment Inc.
Es una imagen impresionante, una de las tantas fotografías
captadas por el equipo del Apolo 11 durante la misión a
Esta es la historia detrás de
la luna que hizo historia en julio de 1969.
la marca comercial de P&H,
A medida que su nave se movía velozmente, el silencio
sobrecogedor alrededor del satélite natural de la tierra, y por sobre todo, de las
la imagen de su hogar de “mármol azul” ascendiendo
rápidamente por sobre el horizonte de la luna, dramatizó notables
la enormidad del milagro de la vida en nuestro planeta.
En 1969, en nuestro hogar habitaban 3.6 billones de personas que, a
personas. Esa cantidad crecería a 6.7 billones de personas
sólo 40 años más tarde en el 2009. partir de 1884,
Nuestra existencia en nuestro planeta tierra depende
de muchas cosas, incluyendo nuestra distancia afortunada
construyeron
de 93 millones de millas del sol, que hace posible un
modesto rango de temperaturas que mantienen nuestra
una de las
atmósfera y océanos que dan vida. Y la luna en sí ayuda
a frenar y controlar la velocidad de rotación de la
grandes
tierra, para brindar patrones climáticos moderados que
propician además una sorprendente gama de vida vegetal
empresas de
y animal. fabricación industrial que hoy
Sin embargo, más allá de estos factores, nos encontramos
por otra parte solos cuando se trata de sobrevivir. Nos en día sirve orgullosamente a la
valemos de la agricultura para proveer nuestro alimento y
de la industria forestal para suministrar los materiales de industria minera a nivel global.
construcción y el papel para la comunicación y embalaje.
Sobre todo, dependemos de una industria minera
altamente eficiente, para abastecer nuestra economía
Es una saga de la excelente
global de valiosos minerales y fuentes de energía para
ayudar a mantener la vida en nuestro planeta. Todos
artesanía y tenacidad
somos consumidores de minerales. perdurable de su objetivo.
En nueve de diez minas de superficie, usted encontrará
máquinas de excavación y perforación poderosas,
inteligentes, altamente productivas y fiables que llevan Esta es la historia de P&H
la familiar marca comercial negra y amarilla de “P&H”.
El sol nunca se pone sobre esa marca comercial.
Mining Equipment.
 que tenía sólo 27 años, siguió pensando “Podríamos usar
más el conocimiento sobre el maquinado que tenemos
aquí en este momento. Más herramientas, también.
Debo visitar a Henry Harnischfeger”.

La Preparación Pawling estaba impresionado con Henry Harnischfeger

de 29 años, con quien trabajó durante un tiempo en la
empresa de Máquinas de Coser Whitehill en Milwaukee.
Ofrece Henry era un excelente mecánico con ex celente
instinto para los negocios. Él llegó a Estados Unidos 12

Oportunidades años atrás de su tierra natal Alemania, donde aprendió

el oficio de cerrajería.
El joven Harnischfeger vio una gran oportunidad en la
rápida industrialización de la Costa Este de Estados
Pawling une fuerzas con Unidos. A la edad de 16 años, Henry
convenció a su padre para que lo
Harnischfeger dejara inmigrar a Estados Unidos a
Fue unos de esos deliciosos días del “verano buscar su fortuna. Un primo, Michael
indio” a fines de octubre de 1884 en Habig, había inmigrado a EE.UU. seis
Milwaukee, Wisconsin. Una helada mañana años atrás. Él le ofreció apoyo a Henry
rápidamente dio paso a un día asoleado, de – y un lugar donde quedarse hasta que
cielo azul, levantando el ánimo de todo el Harnischfeger pudiera establecer una
mundo. Ciertamente fue así para Alonzo posición y un lugar propio.
Pawling, ya que los rayos de sol llenaron su
oficina en el pequeño edificio de madera
de la fábrica, ubicado en 292 Florida El joven
Street al sur de Milwaukee. Alonzo estaba Harnischfeger
orgulloso de su Taller de Herramientas y estudió
Modelos en Milwaukee, inaugurado el
año anterior.
Ingeniería
Henry llegó a Castle
Sin embargo, a pesar del excelente día de otoño, Alonzo Garderns, New Jersey
estaba inquieto. Se acercaba otro invierno frío y oscuro. el 9 de abril de 1872.
La mayor preocupación de Pawling: La hipoteca de su Rápidamente encontró
negocio vencía en su totalidad en noviembre. trabajo como mecánico en
El negocio había sido aceptable y algunas veces la empresa de Máquinas
bueno para los modelos de fundición de madera y de Coser Singer. Cuando
componentes maquinados, que su taller producía para el negocio decayó, el joven
grandes firmas industriales en Milwaukee. Pero aún así, Harnischfeger rápidamente
el joven Pawling, un experto fabricante estable, a pesar encontró trabajo en otro lugar, incluyendo el trabajo
en locomotoras en Long Island, con Brown & Sharpe
fabricantes del compás de calibre Vernier, e incluso
como camarero en un bar de Brooklyn, New York,
cuando los trabajos industriales eran escasos. Henry se
dio cuenta de la importancia de la ingeniería a través de
su trabajo industrial, lo cual lo motivó para estudiar esa
disciplina en su tiempo libre.
En 1881, un diseñador de máquinas de coser invitó
a Henry Harnischfeger a unirse en su operación de
fabricación de la empresa de Máquinas de Coser
Whitehill, como jefe del taller de máquinas en
Milwaukee. Fue allí que Henry Los primeros clientes para
trabajó por primera vez con las plantillas de fundición, los
Alonzo Pawling. componentes de máquinas y
ensambles completos del Taller
Alonzo y Henry pronto se dieron de Máquinas y Modelos de
cuenta que el negocio de Whitehill Pawling & Harnischfeger, incluía
carecía de disciplina empresarial, a los fabricantes de máquinas
ya que luchaban por transformar de tejer, fabricantes de ladrillos,
eficazmente los requerimientos del fábricas de cerveza, fabricantes
cliente y los recursos de fabricación de motores a vapor, fábricas de
en máquinas de coser valiosas. equipos agrícolas y fabricantes
Para el otoño de 1883, Whitehill de máquinas tipográficas de
descontinuó su negocio de máquinas periódicos.
los
de coser y continuó como un taller Milw aukee fueron uno de
Las cervecerías en wling
de trabajos generales. entes de los productos de Pa
primeros cli má qu ina s
& Harnischfeger, prov
ee dores de
de ce rveza, Puentes-grúa:
Alonzo Pawling se fue de Whitehill en eles” o de barriles
selladoras de “pich ra la cerv ecería Un Producto de
1883 para iniciar su propio Taller de ricadas pa
incluyendo varias fab
Herramientas & Modelos en Milwaukee. Joseph Schlitz. su Propiedad
Sin embargo, su negocio necesitaba En 1887, justo tres años después de iniciar su negocio,
la ayuda urgente de un experto en mecanizado y un puente-grúa de desplazamiento aéreo construido
fabricación. Alonzo comprendió que para tener éxito por otra empresa, colapsó catastróficamente al intentar
en su negocio, necesitaría a su lado a alguien del calibre levantar una carga mucho más allá de su capacidad
del joven Henry Harnischfeger. nominal, en una fundición cerca del taller de Pawling
Para su alivio, Henry acordó unirse a Alonzo. Henry & Harnischfeger. Como la fundición, operada por la
trajo consigo una buena cantidad de capital – empresa Edward P. Allis, ya era cliente de Pawling &
aproximadamente $2,500 que invirtió en herramientas Harnischfeger y comprendían bien sus capacidades en
de mecanizado nuevas, más un caudal de conocimiento relación a la maquinaria industrial, comprometieron al
del trabajo industrial adquirido durante casi 16 años. pequeño Taller de Máquinas y Modelos para reconstruir
Harnischfeger también poseía una firme determinación la grúa – y mejorar su diseño si fuere del todo posible.
para que la empresa tuviera éxito a través de laexcelencia Pawling y Harnischfeger – y un socio llamado A.J. Shaw
en la entrega de calidad y servicios superiores al cliente. con cierta experiencia en puentes-grúa – reemplazó el
complejo sistema de cables y poleas de la grúa dañada
Nace un Negocio el 1 de por un conjunto simplificado de motores y cajas de
engranajes, uno por cada mecanismo de levante, carro
Diciembre de 1884
Alonzo Pawling y Henry Harnischfeger iniciaron su
sociedad con un contrato y un apretón de mano el 1 de
Diciembre de 1884 y comenzaron a trabajar. Resultó ser
otro invierno de una serie de cinco inviernos severos
en Milwaukee, gracias a muchos megatones de ceniza
volcánica y dióxido de azufre que habían sido inyectados
en la estratósfera de la tierra, por la espectacular
erupción el 26 de agosto de 1883 del volcán Krakatoa
en la lejana Indonesia – una tierra exótica donde un
día se ubicaría una mina de cobre y oro en la cima de
la montaña, la cual emplearía poderosas máquinas
excavadoras que llevarían la marca comercial inspirada
por Pawling & Harnischfeger.
Gracias a su enfoque en la calidad y el servicio de Pawling & Harnischfeger
trabajaron con el especialis
A.J. Shaw para reconstru ta en grúas
excelencia, Alonzo y Henry demostraron rápidamente ir un puente-grúa fallado
fábrica de Edward P. Allis de parte de la
su fiabilidad como proveedores del taller de máquinas y en 1888. Poco después, las
comenzaron a demandar fábricas
modelos para grandes fábricas en Milwaukee. más de dichas grúas diseña
construidas por Pawling das y
& Harnischfeger. Repent
empresa tenía una línea de inamente, la
productos totalmente de su
propiedad.
 de rodadura y puente. La grúa fue puesta en servicio partir: Por favor mantén para siempre la marca “P&H”
acomienzos de 1888 y fue un éxito inmediato. En a la vista en la línea de productos de la empresa de aquí
muy poco tiempo, Pawling & Harnischfeger estaban en adelante.
construyendo sus propios puentes grúas y expandiendo
su negocio para satisfacer la demanda. Ya que la marca P&H en ese entonces había establecido
claramente una reputación de Calidad excepcional y
un Servicio excelente, Henry gustosamente estuvo de
Los motores eléctricos se unieron acuerdo. Pawling fallecería tres años después.
a la gama de Productos P&H
En 1893, Pawling & Harnischfeger determinaron que Primeras Máquinas Excavadoras
necesitaban mayor control de calidad sobre los motores “P&H” en 1914
eléctricos que obtuvieron de otras empresas y aplicaron
a sus grúas. Cuando la empresa eléctrica Westinghouse Alrededor de 1914, apareció la primera máquina
compró a un rival, “P&H” de movimiento de tierra. Fue la compactadora
la empresa eléctrica / cortadora de pavimento P&H T-1, usada eficazmente
Gibbs, Pawling para iniciar y terminar las instalaciones de tuberías en
& Harnischfeger las calles de la ciudad. Después, siguieron las máquinas
se movieron zanjadoras tipo rueda y tipo rosario para proyectos de
rápidamente para agricultura y acueductos con mucho éxito.
comprar los activos
de ingeniería y
fabricación de Gibbs
Al necesitar mayor control sobre el diseño y la calidad y comenzaron a
de los motores eléctricos de CA y CC, obtenidos de fabricar sus propios
los proveedores de motores, Pawling & Harnischfeger
motores y controles
adquirieron en 1893 los derechos de ingeniería y
fabricación de la Empresa Eléctrica Gibbs. de CA y CC de
calidad industrial.
Sin embargo, en 1893 una sobre inversión en
ferrocarriles causó además un “pánico bancario”
general en todo EE.UU. La recesión subsiguiente
debilitó la demanda de las grúas.
Pawling & Harnischfeger se dieron cuenta que
necesitaban ampliar su línea de productos para
poder reducir el riesgo de la dependencia excesiva
en un sólo producto. Pero, ¿qué podría constituir esa
línea de producto? ¿Dónde podrían encontrarse las
oportunidades de crecimiento?
En ese entonces, Norte Americ estaba desarrollando
rápidamente su base industrial e infraestructura de Introducida en 1914, la compactadora P&H® T-1 fue la primera máquina
caminos y puertos, minas y sistemas de transmisión de de movimiento de tierra ofrecida por la empresa, la cual se convertiría en el
uso general. Existía una demanda creciente por máquinas actual P&H Mining Equipment. La T-1 estaba equipada con herramientas
excavadoras que pudieran mover un montón de tierra de corte de pavimento y una plancha plana usada para compactar la tierra
y acelerar aquellos proyectos. Pawling & Harnischfeger después de las instalaciones de cañerías.
– que en ese tiempo eran llamados simplemente como Alrededor de 1919 apareció una pala mecánica P&H®
“P&H” por su creciente número de agradecidos clientes 205. Ésta operaba bastante bien, pero tenía algunos
– comenzaron a buscar su propia línea de máquinas defectos de diseño. El personal de ingeniería y fabricación
excavadoras. de P&H abordó todas esas brechas del funcionamiento,
Sin embargo, Alonzo Pawling fue afectado con el lanzamiento de la pala mecánica P&H® 206.
repentinamente por una enfermedad crónica alrededor Con un balde con capacidad de ½ yarda cúbica, la pala
de 1911 y comprendió que necesitaba poner fin a su P&H 206 fue un éxito inmediato. Un lote de máquinas
participación en el negocio. Vendió sus intereses a Henry P&H 206 fueron pronto puestas en servicio en todo
Harnischfeger y le hizo simplemente una petición al Norteamérica y Sudamérica y más allá, incluyendo
Bombai, India.
Al mismo tiempo, P&H estableció una red de
mecánicos de servicio en regiones clave, para entregar
apoyo a los clientes de las palas de P&H. Desde
el inicio de su negocio, Pawling & Harnischfeger
entregaron apoyo a sus clientes con su servicio
experto. Esa política sería p ara siempre el objetivo
principal de
la filosofía de
entrega de
valores de la En 1927, las P&H 300 “convertibles” se unieron a la línea de productos
empresa. P&H. El cliente podía elegir entre muchas opciones funcionales, incluyendo
accesorios de palas mecánicas, dragas, “colectores de niveladora”, martinetes,
Durante la baldes bivalvo y grúas electroimán.
década de 1920,
la empresa
introdujo
La Gran Depresión Genera
una línea de Maniobras Estratégicas
máquinas P&H® Apareció un gran número de pedidos de máquinas
300 “8-in-1 P&H para la construcción y minería, así como también
convertibles” puentes-grúa P&H. Y luego, el mercado de valores
ra tip o ro sa rio que contaban
, una zanjado de Nueva York colapsó el 29 de octubre de 1929.
Alrededor de 1915 ra ca ñe ría s a
a zanja pa con una Para la primavera de 1930, la demanda de los equipos
P&H® 152, cava un al sures te de la
en lo que plataforma
través de la tierra,
P&H comenzó a colapsar. Lamentablemente, algunos
de
de P& H M ining Equipment al oeste común de clientes devolvieron sus máquinas P&H compradas
fábrica
Milw auke e. orugas de recientemente. La Gran Depresión había comenzado.
baja impulsión y una
tornamesa, según la cual el cliente podía elegir de un Henry Harnischfeger, el co-fundador de P&H, falleció
rango de opciones, incluyendo la pala mecánica, draga, en noviembre de 1930. Su hijo, Walter Harnischfeger,
grúa de gancho de construcción, balde bivalvo, martinete, asumió el rol de liderazgo y manejó la empresa con gran
magneto, “colector de niveladora” y máquina rellenadora. habilidad durante las próximas cuatro décadas.
Para gestionar mejor el 1930s Lanzamiento
riesgo comercial y generar
crecimiento y ganancias,
del Ward-Leonard
P&H comenzó a expandir Drive DC
las ofertas de sus productos También durante los años 1930, P&H
durante este tiempo, adoptó el accionamiento de motor de
incluyendo motores a CC Ward-Leonard, para su aplicación
gas, casas prefabricadas y en grúas y palas P&H. Los sistemas
máquinas soldadoras. Ward-Leonard contaba además con
Las máquinas soldadoras controles manuales que resultaron ser
fueron particularmente fáciles de usar, los cuales reemplazarían
importantes, porque al conjunto de grandes palancas
Para otorgar mayor resistencia, menor peso de que requerían una gran resistencia
P&H se había destacado trabajo y mayores cargas útiles, P&H comenzó a
por usar y desarrollar aplicar un diseño totalmente soldado a su línea de
los mejores procesos de productos, comenzando alrededor de 1932. Las
fabricación disponibles. palas P&H® 1200WL equipadas con controles de
Cada faceta del proceso de drives de CC Ward-Leonard estaban dentro de las
fabricación era de punta, primeras máquinas xcavadoras P&H totalmente
de materiales de fundición soldadas.
y tecnología avanzada a través del mecanizado
de componentes de
transmisión y fresado
de componentes
estructurales, para
lograr
una perfecta instalación
y un excelente
rendimiento En los año
s 1930, P&
de soldado H introdujo
de la máquina. Mientras ras por arc una línea
varillas de o eléctrico
la tecnología de la soldadura P&H y
uso industri para el
soldadura fue en su al.
mayor parte experimental
durante las primeras dos de brazos y manos
décadas de los años 1900, para empujar-jalar de parte del
para 1930 la aplicación operador de la máquina.La mayor
principios de comodidad para el operador
de la soldadura como
ilw au keanos salieron a ess
reemplazo para las máquinas Cientos de M el nuevo “Progr significó mayor estado de alerta y
bre de 19 36 a inspeccionar nset qu e ofrecía
de diseño remachado fue diciem
- un a estru ctura tipo Quo productividad de la máquina.
Home” de P& H uyendo aire
claramente una alternativa co nv enie ncia moderna, incl costo”
“todo tipo de no, a muy bajo
superior. cionad o pa ra verano e invier as, bien
“Existe una razón para
acondi es espacios
inco habitacion s y protegidas
esta comodidad y facilidad
y contaba con “c ente aisladas, sellada deoperación” se indicaba en un
P&H terminó la m pl etam
iluminadas, co
transformación de su línea . folleto de P&H en 1934. “Es por la
contra el clima”
de productos al diseño reducción del esfuerzo físico que
y fabricación totalmente el operador es capaz de hacer
soldados entre 1932 y 1935. más en un día de trabajo. Las máquinas son construidas
Para nuestros clientes, el valor obtenido incluyó máquinas para soportar castigos sin dañarse o sacrificar su eficacia.
más livianas y fuertes, las cuales podían entregar El cuerpo humano no lo es”.
una mayor carga útil al más bajo costo por tonelada.
Simultáneamente con este desarrollo, P&H comenzó a Con el comienzo de la Segunda Guerra Mundial en 1939,
diseñar y construir su propia línea de máquinas de arco- P&H comenzó firmemente a recuperarse del período
soldadura e insumos P&H para el uso industrial. de inactividad de la Gran Depresión. Cuando Estados
Unidos entró en el conflicto en 1941, P&H se concentró
en la construcción de grúas, montacargas y excavadoras
para la industria nacional y para usos militares. El esfuerzo
de la guerra requería enormes volúmenes de minerales y Palas Clase P&H 2800
las palas P&H vieron una gran demanda en la extracción
de minerales de hierro, cobre, bauxita, carbón y otras
Introducida en 1968
operaciones mineras. Fue también en 1968 que P&H introdujo una nueva
Durante la década pala eléctrica minera resistente, la P&H® 2800 Mark II.
de 1950, la línea de Las tres primeras P&H 2800 entraron en servicio en
productos P&H fue una mina de carbón metalúrgica al oeste de Canadá.
amplia y próspera. Veinte años después, cada una de esas máquinas
Hubo una buena originales seguía siendo altamente productiva y habían
demanda en superado mucho antes las 100,000 horas de trabajo.
toda la línea, Las palas eléctricas P&H Serie 2800 pronto se
desde motores convertirían en la serie mejor vendida de excavadoras
diesel, máquinas de cables
de soldar, eléctricas del
Durante la década
estabilizadores de 1950, la línea mundo de la
de carreteras de productos era moderna,
y viviendas P&H incluyó una marca que
prefabricadas las máquinas se mantendría
P&H hasta estabilizadoras
intacta hasta el
grúas-puente y de carreteras.
año 2010, cuando
de construcción serían superadas
P&H y también palas P&H. Sin por otro modelo
embargo, a mediados de 1960, de palas P&H
los retornos sobre la inversión de introducidas
la empresa en los motores diesel, en 1991, las
máquinas de soldar y viviendas P&H® 4100.
comenzaron a flaquear. Alrededor
de 1968, la empresa vendió dichas r vendidas de la era moderna
Una de las palas eléctricas mineras mejo
unidades de negocio y se concentró 2800 Mar k II. Las palas clase P&H 2800
surgió en 1968. Fue la P&H
amientas de carguío de alto
en sus productos principales que eran siguen siendo muy cotizadas como herr
las grúas, montacargas y palas. rendimiento 40 años después.
Las Mega-Fuerzas
de la década del 70
Desafían a P&H
Mientras sea posible, un negocio
concentra sus mayores esfuerzos
por lograr excelencia en la gestión
de su marketing y en las funciones
operacionales, financieras y
administrativas para obtener así el
crecimiento y la rentabilidad necesaria.
Sin embargo, hay épocas cuando las
poderosas fuerzas económicas y de
otra índole, pueden poner a prueba
incluso al mejor negocio gestionado,

El Área 1 del Edificio 110 de la fábrica P&H era el

área para armar grandes partidas de P&H® 255 y
otros modelos de excavadoras necesarias para la
construcción y la minería durante la Segunda Guerra
Mundial,incluyendo los proyectos de carreteras y
aeródromos manejados por el Cuerpo de Ingenieros
del Ejército de EE.UU. y el Cuerpo de Ingenieros de
la Marina de EE.UU.
 y eso es lo que sucedió fundador de la Empresa de Ingeniería Page con base
durante la década cerca de Chicago en 1903.
de 1970.
Mientras P&H diseñaba y construía una línea bien
Un fuerte aumento en considerada de dragas montadas sobre orugas, que
el volumen del papel van desde la P&H 300 en la década de 1920 hasta la
moneda emitido por P&H® 2355 a partir de 1980, la empresa reconoció
los bancos centrales, la oportunidad de ampliar su gama de soluciones de
condujeron a un manejo de materiales para la industria minera, mediante
difícil período de alza, la adquisición de la línea de productos de dragas móviles
estancamiento de la de Page Engineering. Al hacer esto, P&H se posicionó
inflación o “estan- para ofrecer una gama más amplia de opciones de alta
flación”. Los precios capacidad y rentabilidad para el movimiento de tierra,
de los commodities, con el fin de resolver cualquier desafío en el rajo.
en particular
del petróleo, se Los ingenieros de P&H comenzaron a realizar
construcción
La línea P&H de grúas de y un esfuerzo metódico para comprender y cubrir
camiones, orugas dispararon. El tipo
hidráulicas montadas en n entre las plenamente las necesidades y expectativas de los
acc identa dos , estuviero de cambio de divisas
para terrenos
en su clase entre el año 1920 y 1988 en llegó a ser altamente gerentes de
mejores
dicha línea de produc tos se vendió. volátiles. En dicho operaciones de las
que
ambiente, la gestión del negocio dragas móviles, para
de P&H se hizo cada vez más difícil y desafiante. una máquina ideal
que pudiera ofrecer
Por un lado, el alza de los precios del petróleo provocó una productividad
un movimiento hacia fuentes de energía alternativas, más excepcional,
baratas y abundantes. Esto llevó al desarrollo acelerado proporcionando
de regiones ricas en carbón como Powder River Basin a la vez la facilidad
en Wyoming y de otras grandes regiones productoras de mantenimiento
de carbón. En poco tiempo, aumentaría la demanda por para operaciones de
las palas P&H, aplicadas en el manejo de recubrimientos menor costo. Ese
en las minas de carbón. Es más, también creció la esfuerzo se tradujo
demanda por las grúas de construcción P&H, aplicadas en una línea de
en la construcción de oleoductos en Alaska y en otros dragas totalmente
proyectos de energía. renovada, la clase Terex continúa ofreciendo las grúas de
construcción “P&H”. Los ingenieros de
P&H 9020 de 60
®
Por otra parte, las tasas de interés del banco central se P&H Mining Equipment y el personal de
metros cúbicos, la cual fabricación se embarcó en un programa
elevaron para ayudar a reducir la inflación desbocada. El suscitó rápidamente para desarrollar una draga móvil P&H
débil dólar de EE.UU., comenzó pronto a recuperar su los pedidos desde totalmente nueva, basándose en la
valor frente a otras monedas. Las grúas de construcción las regiones ricas en información provista por los clientes.
que fueron fabricadas con los desvalorizados dólares de carbón como el este El resultado de las dragas clase P&H
EE.UU en Cedar Rapids, Iowa y Escanaba, Michigan ya de Australia, así como 9020 de 60 metros cúbicos, introducidas
no podían competir con modelos idénticos de más bajo también Canadá. en 1996, fue rápidamente reconocido como
costo, construidos por el concesionario de P&H Kobe una buena inversión para las mineras de
Steel en Japón. P&H vendió sus equipos de la línea de carbón en Australia y Canadá.
productos de construcción en 1988. Emergen las
palas P&H 4100
P&H adquiere las En el año 1988, también se vio la introducción de las
Dragas Móviles Page transmisiones planetarias P&H altamente confiables,
eficientes y fáciles de mantener. Las palas P&H, equipadas
Fue también en 1988 que P&H adquirió la línea de con transmisiones compactas de propulsión planetaria
productos de dragas móviles de Page Engineering de dual, demostraron rápidamente ganancias en su
Chicago. P&H estuvo ofreciendo dragas montadas maniobrabilidad y longevidad en el severo entorno de la
sobre orugas desde 1920. Sin embargo, el crédito de las minería. Hoy en día, las transmisiones planetarias P&H
primeras dragas prácticas pertenece a John W. Page, siguen siendo un factor valioso y ventajoso, clave para las
palas y las dragas P&H.
Debido a que los camiones de carga crecieron de manera más rápida y más inteligente, la P&H® 4100XPB y la
espectacular con respecto a su tamaño y carga útil de P&H® 4100BOSS desarrolladas principalmente para las
hasta 240 toneladas alrededor de 1990, los ingenieros y operaciones de carguío de arenas petrolíferas.
el personal de fabricación de P&H iniciaron un esfuerzo
para ofrecer una pala eléctrica más grande a la industria
minera. El resultado fue la pala P&H® 4100 introducida Sistemas Centurion,
en 1991 con una carga útil Drive AC, IPCC
significativamente mayor y Durante la primera década después del Milenio de 2000,
también con características P&H comenzó a aplicar en sus productos un poderoso
de mantención mejores y sistema nuevo de mando y control de máquinas. Conocido
más fáciles para lograr un como Centurion, el sistema rápido y de alta capacidad de
rendimiento de bajo costo control supervisor y adquisición de datos de la máquina,
por tonelada. harían posibles
grandes ganancias
debido a la eficacia
de la productividad,
fiabilidad y
mantenimiento de
la máquina.
ment
P&H Mining Equip Una pala P&H
clase P&H
introdujo la pala 4100BOSS de
4100 en 1991 .
drive AC surgió
sin problemas y El despliegue exitoso de
P&H con excelentes de drive AC en 2007, pro
las palas P&H 4100BOS
S
movió aún más las oferta
adquiere resultados en el de palas de drive AC, inc
luyendo las palas P&H
s
la línea de año 2007 en la 4100XPC de AC en 2010.
P&H Mining Equip región de arenas
perforación línea Gardner-Den
ment adquirió la
ver de equipos de petrolíferas de Canadá. Una
GD perforación de aguje
ros de tronadura pala P&H® 4100XPC de drive AC se une a la flota P&H y a
en 1991. Un progra
El equipo de ma de mejora la saga de la evolución tecnológica a partir del 2010.
continua, con orien
tación en el cliente
perforación rotatoria en los años subsigu
ientes, se traduciría En el 2008, P&H Mining Equipment anunció planes para
para agujeros de en modelos de alto
rendimiento, un nuevo sistema de procesamiento y manejo de material
tronadura se unió a incluyendo la perfo
radora para
la línea de productos trabajos pesados P& ® – un sistema de chancado y transporte en el rajo (IPCC)
H 320XPC.
P&H en 1991, con la caracterizado por presentar un chancador de minería
compra de la línea de productos Gardner-Denver. móvil P&H® 4170C adaptado para las palas eléctricas P&H
Al igual que con la línea de dragas móviles, los ingenieros y y equipado con la tecnología de chancado-transporte de
especialistas de fabricación de P&H lanzaron un programa Joy Mining Machinery. Los IPCC de P&H representan una
para comprender plenamente las necesidades del cliente, opción estratégica nueva e importante para el manejo de
y luego perfeccionar y elevar el rendimiento de una nueva material en las minas.
línea de productos de perforación P&H, comenzando
con una actualización de la estrella GD120 de peso
pesado para yacimientos de hierro y otras operaciones
en roca dura. La P&H® 120A pronto hizo su aparición y
encontró acogida en los severos medios mineros. Una
P&H 320XPC más avanzada es la más reciente, bien
recibida sucesora de la original GD120.
Otros avances importantes en la línea de productos
P&H durante la década de 1990, incluyó la más grande,

La próxima generación de la tecnología de movimiento de tierra de

P&H para las operaciones mineras de alto rendimiento, incluye los
sistemas de chancado-transporte en el rajo de P&H adaptados para
las palas eléctricas P&H.
 de las mejores máquinas en su tipo, adaptadas a las
necesidades del cliente con el fin de brindar mayor
productividad, fiabilidad y facilidad de mantenimiento.

Calidad,
Debido a su éxito, el cual se había logrado en gran parte
debido a la excelencia de su mano de obra, Pawling
& Harnischfeger se propusieron diseñar, construir y

Servicio y apoyar las mejores máquinas en su clase, utilizando los

mejores materiales
disponibles y los

Seguridad equipos y procesos

de fabricación de
última generación.
En 1929, P&H había
Calidad, Servicio y Seguridad: acumulado 45 años
Los principios que nos d experiencia y
había construido
representan una fuerza de
“Usted compra una pala o una grúa con un solo propósito trabajo de 2.000
– para manejar los materiales al menor costo posible. artesanos,
En el análisis final, el costo inicial de la pala o grúa no es ingenieros,
importante. Pero el costo por yarda es muy importante. personal de
Los usuarios están conscientes de esto y antes de comprar servicio y
consideran cuidadosamente al fabricante, su planta y administrativo
experiencia; las características de la construcción de la calificados. Su
máquina; el rendimiento de la máquina en terreno; y el fábrica en el oeste
servicio del fabricante”. de Milwaukee,
Wisconsin,
- Extracto del folleto de P&H “Greater Yardage at contenía una Extracto del folleto
Lower Cost”, publicado en 1929. de P&H de 1929 titu
considerable “Greater Yardage lado
at Lower Cost”.
inversión de
Calidad capital de US$ 10 millones en
Pawling y Harnischfeger estaban planta y equipos. Cada faceta del
plenamente conscientes de que proceso de fabricación era de
las máquinas que diseñaron y última generación.
construyeron necesitaban ofrecer
un rendimiento de valor superior La excelencia de la ingeniería
para sus clientes. Las palas mecánicas era de particular importancia
y otras máquinas de ese tipo para el negocio de P&H. Henry
aparecieron mucho antes de la puesta Harnischfeger, co-fundador de
en marcha de la empresa P&H. Fue P&H, vio que era adecuado
en 1835, que William Smith Otis estudiar ingeniería durante
colaboró con Charles Howe French sus primeros años en EE.UU.
para desarrollar la primera máquina de y supo que la empresa
movimiento de tierra a vapor. Muchas necesitaba una fortaleza
otras empresas estaban construyendo perdurable en relación a la
palas mecánicas cuando Pawling & disciplina, así como también
Harnischfeger empezaron a componer su a la fabricación, marketing,
propia línea de máquinas excavadoras. finanzas y administración de
ing
recursos humanos.
Para destacarse del resto en su campo, de 1927 “P&H Excavat
folleto
Pawling & Harnischfeger decidieron que Extracto del La fortaleza y la debilidad de
Equip m ent” .
tenían que concentrarse en la construcción todas las máquinas previas
eran como un libro abierto para los ingenieros de P&H. Servicio
Ellos conocían qué partes habían prestado un servicio
limitado y qué partes habían pasado la prueba de tiempo “Ceñida al costado de una montaña, en la cadena
sin romperse. Y por último, su enfoque era la Calidad en montañosa Cascade al oeste de EE.UU., una pala P&H
pos del valor del cliente. trabaja nivelando el terreno para una nueva carretera,
liderando un proyecto que podría involucrar cientos,
“Una excavadora representa una gran inversión y incluso miles de hombres”, menciona un pasaje de un
usted no puede permitirse el lujo de ofrecer diseños o folleto destacando los primeros 50 años de P&H en 1934.
experimentos no aprobados”, indicó un folleto de P&H “La actividad debe continuar. Cada hora cuenta. Cada
publicado en 1927. “Cuando usted compra una P&H, ciclo de excavación es importante.
obtiene una máquina que tiene un record establecido
para ofrecer una operación estable, fiable y obtener “Si algo se rompe, si esa pala es forzada a salir de servicio,
ganancias considerables. todo el trabajo deberá esperar.

“Las excavadoras están sujetas a esfuerzos anormales “Ahora, una pala P&H es construida para permanecer en
en servicio. Por esta razón, las excavadoras P&H se el trabajo. Pero el acero es sólo acero y de vez en cuando
construyen “totalmente de acero” de principio a fin. falla. Luego viene la prueba real de una organización de
Las zapatas de tracción, bastidores, carbody, tornamesa, servicio: Conseguir la pieza de repuesto rápidamente.
pedestales de tambor y otras partes son fundiciones Reducir la burocracia. ¡Darse prisa!”
de acero templado de una sola pieza, de extra grandes Desde el comienzo de su empresa, Pawling y
secciones y resistencia. Harnischfeger se concentraron en el Servicio en la misma
“Todos los engranajes son de acero con proporción que en
dientes de la Calidad. Debido
corte y piñones a que estaban más
cortados de piezas familiarizados con el
forjadas sólidas. diseño, los materiales,
El conjunto de ejes la mecánica y la
de transmisión es construcción de sus
de acero forjado equipos, brindaron
o es torneado con gusto a sus
de una aleación clientes el servicio,
de acero especial la reparación y la
y luego tratado reconstrucción de
térmicamente y apoyo necesarios
rectificado para para optimizar
lograr un encaje el valor de su
micrométrico. inversión en las
máquinas P&H.
“No existe un
sustituto para un buen A medida que la
material y mano de empresa P&H
un equipo de crecía, también lo
obra”. Cada parte de alrededor de 1936,
la jungla en alg ún lugar de México H. hizo el equipo de
P&H es del más alto En un claro de una pala P&
P& H camb ia las correas de oruga en servicio de P&H.
tipo de construcción, servicio de
fabricada en nuestros Al comienzo, era
propios talleres y bajo nuestra propia supervisión. La un equipo local de Milwaukee y luego fue una operación
construcción de calidad de P&H junto con las constantes regional en el Medio Oeste de EE.UU. A comienzos
mejoras se traducen en mayor vida útil y menor de 1900, los mecánicos de servicio de P&H estaban
mantención, lo cual a su vez significa mayores ganancias distribuidos en todo EE.UU. en lugares como Filadelfia,
para el cliente”. San Francisco, Los Angeles, Seattle, y Jacksonville. Ellos
estaban disponibles de un modo rápido. Era seguro decir
La excelencia de la calidad fue de primordial importancia que la excelencia del servicio de P&H había vendido
para Pawling y Harnischfeger desde el inicio de su muchas máquinas – y seguiría haciéndolo en los
empresa. La calidad sigue siendo un valor fundamental tiempos modernos.
para los empleados de P&H.
El equipo de servicio de P&H hace una pausa con un amigo canino en el sitio de armado de una draga P&H en Nuevo México en 1934.

Cuando los equipos P&H encontraron su camino hacia En los talleres y oficinas de P&H, en la mina y
las minas de todo el mundo, surgió una red global de dondequiera que vivan, viajen y jueguen, los empleados
servicio de apoyo y aumentó la dotación de mecánicos y de P&H y MinePro creen que todas las lesiones pueden
eléctricos para satisfacer las necesidades de los clientes. y deben prevenirse. Es tanto lo que depende de nuestra
En 1996, esa red global se formalizó en lo que hoy es capacidad para trabajar con seguridad.
conocido como P&H MinePro Services, compuesto por
2.000 especialistas de logística en bodega, mecánicos, Nuestras familias,
eléctricos y soldadores, todos los cuales se concentran nuestros clientes,
en ayudar a los clientes de P&H a mantener sus máquinas nuestros
P&H y otras maquinarias en funcionamiento para reducir compañeros
los costos de las operaciones. de trabajo,
y nuestras
Son empleados de MinePro con orgullo local. Son comunidades,
reclutados en y viven dentro de las regiones mineras, en todos se
las que prestan servicio. Ayudan a construir operaciones benefician
mineras sólidas y también comunidades. cuando vivimos y
trabajamos libre
de lesiones.
Seguridad
Nuestra capacidad para ofrecer a nuestros clientes La seguridad es
valiosos equipos y servicios de apoyo, depende de la base sobre la
nuestra capacidad para trabajar con seguridad y evitar cual todo es posible,
situaciones que pueden causar lesiones. incluso nuestra capacidad para ofrecer calidad y servicio
de valor excepcional para nuestros clientes.
P&H Mining Equipment y P&H MinePro Services adoptan
un esfuerzo concertado para la gestión de un lugar de
trabajo libre de lesiones.
 Grandes
Personas
Conducen
a P&H
La artesanía P&H y
nuestro objetivo tenaz
Era el año 1934. Fue a mediados de la era de la Gran
Depresión. El desempleo fue en un momento más del
25 por ciento de la fuerza de trabajo disponible.
P&H observó 50 años continuos de
operaciones en 1934. Nuestro negocio
había sido duramente golpeado, nuestros
clientes
se estaban
perjudicando, estándares
y muchos similares,
de nuestros durante los
empleados se próximos 125
ausentaron con años y aún
permisos. después. Gente
de ese calibre
Y aún así, continúa
continuamos. impulsando la
Resistimos. empresa P&H hasta este mismo día.
Salimos del paso.
Nos concentramos en “Hoy, no podemos mirar hacia atrás, sin mirar hacia
la calidad y el servicio. adelante”, declararon los empleados de P&H en nuestro
Y sobrevivimos. folleto de 1934 en conmemoración del 50º aniversario.
Desde luego, hubo muchas veces que el futuro parecía
Alonzo Pawling y Henry oscuro y amenazante. Pero cada vez, triunfó la artesanía y
Harnischfeger sabían que un propósito tenaz.
su empresa podía tener éxito mientras se aplicara una
buena disciplina en
la comprensión de
las necesidades y
expectativas de
sus clientes.
Ellos no vacilaron
en ese sentido. Su
compromiso con
la excelencia atrajo
un gran número de
personas con altos
“Si podemos seguir construyendo para satisfacer sus “Por el futuro, entonces... por otro y un nuevo comienzo,
demandas, no obstante exigentes; si podemos mantener dedicamos los recursos que un medio siglo ha construido
el ritmo de sus demandas; y si podemos contribuir, en para nosotros”.
cada uno de nuestros campos, con equipos que harán
su trabajo fielmente y económicamente – entonces los Lo que Alonzo Pawling y Henry Harnischfeger creyeron
próximos cincuenta años se harán cargo de sí mismos. y aplicaron con gran efecto en 1884, sigue vivo hasta el
día de hoy, mientras que P&H Mining Equipment sigue
progresando hacia un futuro emocionante.

Epílogo
Las Grúas “P&H” continúan para durar mucho tiempo - un enfoque de entrega
mientras que el Salón de la valiosa, basado enteramente en la preservación de los
Fama de la Minería honra a los principios fomentados por Alonzo Pawling y Henry
Harnischfeger a partir de 1884.
co-fundadores
de P&H Mientras tanto, casi 125 años
después que iniciaron el negocio
Éstas fueron parte de la primera que se transformaría P&H Mining
línea oficial de todos los productos Equipment, Alonzo Pawling y
P&H en 1887, pero 110 años más Henry Harnischfeger fueron
tarde, la línea de grúas industriales formalmente admitidos en el
P&H fue transferida al que es Salón de la Fama de la Minería
ahora Morris Material Handling, Nacional el 12 de septiembre de
reconocido a nivel mundial 2009 en Leadville, Colorado.
como un líder en la
solución de equipos para Al hacer esto, se unieron a más
el manejo de material. de 200 visionarios, inversionistas
y líderes que han contribuido a
Decenas de miles de grúas fortalecer y transformar la industria
que llevan la marca familiar minera que sigue evolucionando para apoyar
“P&H” fueron puestas en nuestra economía
servicio en todo el mundo y civilización a
desde 1887. Mientras que nivel global.
la mayoría estaba fuera
del ojo público en trabajos Fue un momento
de fabricación, bodegaje de orgullo y
y otras operaciones humildad donde
industriales, algunas eran una gran cantidad
muy visibles, incluyendo un de autoridades
tándem bien mantenido, y personas
influyentes de la Foto por cortesía de
de puentes-grúa P&H Un tándem de grúas P&H con capacidad para
150 toneladas del vintage de 1936 en Hoover Dam industria minera Craig Talbert
con capacidad para 150
toneladas, usadas en la (arriba) y un puente-grúa P&H de la era moderna de hoy en día se
operación de las turbinas que maniobra cátodos de cobre en una operación reunieron en Leadville – situado a más de
minera en Arizona (arriba). 10.000 pies sobre el nivel del mar en el
de la represa Hoover,
construida a mediados de histórico Rocky Mountains, una región minera
1930, a lo largo del límite de Nevada-Arizona en el Sud de plata, oro y molibdeno – para rendir un
Oeste de Estados Unidos. homenaje a estos dos artesanos industriales serios y
esforzados quienes enfocaron su visión y empresa en un
Morris Material Handling aplica la filosofía Lifelong camino hacia la excelencia aquel 1 de diciembre de 1884.
Lifting™, a sus grúas P&H que están diseñadas
 P&H Mining Equipment, Inc.
Una empresa de Joy Global Inc.
4400 W. National Ave
Milwaukee,WI 53214-3684
P.O. Box 310 / Milwaukee,WI 53201-0310
Fono: 414-671-4400 / Fax: 414-671-7604

www.phmining.com  www.minepro.com
X-5052 4BM-1109
P&H Shovel Models
Older Shovels 1500 & 1500DE (1950)
1300 1600 (1946)
1400 & 1400DE (1944) 1800 (1955)

1900 & 2100 Series

1900 (1963) 2100 (1963)
1900A (1968) 2100A
1900B (1968) 2100B (1966)
1900AL & 1900ALCLLR (1972) 2100BL & 2100BLM (1971)
2100BLE (1980)
2100XP (1991)
2100XPA (1992)

2300 & 2800 Series

2300 (1972) 2800 (1969)
2300MKII & 2300MKIILR 2800MKII
2300XP (1981) 2800XP (1982)
2300XPA & 2300XPALR (1987) 2800XPA (1988)
2300XPB (1994) 2800XPB (1992)

4100 Series 5700 Series

4100 (1991) 5700 & 5700LR (1978)
4100A & 4100ALR (1994) 5700DR (1987)
4100TS (1998) 5700XPA (1991)
4100XPB (2000)
4100BOSS (2000)

Electrical Types
Diesel With Single Magnetorque, (1400DE, & 1500DE)
Ward Leonard with Single Magnetorque, (All 1300,1400,1500, 1600, & 1800)
Ward Leonard with Double Magnetorque, (All 1900, 2100, 1900A, 2100A, 2100B, 1900AL,
1900ALCLLR, 2100BL, 2100BLM)
Older Air-Cooled, (1900B, 2300, 2800)
Oil Cooled, (2300MKII, 2300MKIILR, 2800MKII, 5700, 5700LR)
Newer Air Cooled with Relay Logic, (2100BLE 2100XP, 2300XP, 2800XP, 5700DR)
Air Cooled with PLC, (2100XPA, 2300XPA, 2300XPALR, 2800XPA, 4100, 5700XPA, 4100A,
4100ALR, 2300XPB, 2800XPB, 4100TS)

Mechanical Types-Propel
Upper Single Motor Propel with Hydraulic Steering, (All 1300, 1400, 1400DE, 1500, 1500DE,
1600, 1800, 1900, 2100, 1900A, 2100A, 1900B, 2100B)
Lower Single Motor Propel with Pneumatic Steering, (All 2800, 2300, 1900AL, 2100BL,
2300MKII, 2300MKIILR, 2800MKII, 2100BLE, 1900ALCLLR)
Lower Dual Motor Propel-XP Models with Belt Drive, (2300XP, 2800XP)
Lower Dual Motor Propel-5700 Type Propel, (5700, 5700LR)
Lower Dual Motor Propel with Planetary Drive (2300XPA, 2300XPALR, 2800XPA, 4100,
2100XP, 5700XPA, 2100XPA, 4100A, 4100ALR, 2300XPB, 2800XPB, 4100TS)
MechanicalTypes-Crowd
Torque-Tube Type Crowd, (All 1300, 1400, 1400DE, 1500, 1500DE, 1600, 1800, 1900, 2100,
1900A, 2100A, 1900B, 2100B, 1900AL, 1900ALCLLR, & Older 2100BL & BLM)
Power-Band Belt Type Crowd, (Newer 2100BL & BLM, All 2100BLE, 2100XP, 2100XPA, All
2300 Series, All 2800 Series, All 4100 Series, All 5700 Series)
 MILESTONES IN P&H ELECTRIC SHOVEL HISTORY
2100 1963 (34) 2300MKII 1972 (9) 2800MKI 1969 (7) 4100 1991 (24) 5700 LR 1978 (1)
2100A 1965 (?) 2300MKII 1966 (86) 2800MKII 1975 (43) 4100A 1994 (62) 5700 1980 (1)
2100B 1969 (39) 2300MKIILR 1977 (2) 2800XP 1982 (52) 4100ALR 1995 (1) 5700DR 1986 (1)
2100BLM 1971 (266) 2300XP 1981 (25) 2800XPA 1988 (49) 4100TS 1998 (6) 5700XPA 1990 (2)
2100BLE 1980 (30) 2300XPLR 1982 (7) 2800XPB 1993 (63) 4100XPB 1999 (36)
2100XP 1991 (4) 2300XPA 1987 (19) 4100BOSS 2001 (11)
2100XPA 1992 (2) 2300XPALR 1990 *(6)
2100BLE III 1984 (2) 2300XPB 1993 (12)

MAJOR MECHANICAL IMPROVEMENTS YEAR MODEL OLDER MODELS YEAR

Propel in the Lower 1969 2800MKI 1550 1958

Power Band Crowd 1969 2800MKI 1600 1959
Dual Hoist Drive 1969 2800MKI 1800 1958
Pin Lug Dipper Handle 1975 2800MKI 1900 1964
Dual Propel Drive 1981 2800XP 1900AL 1973
Planetary Propel 1984 2300XPA
Planetary Swing 1988 2800XPA
Modular Hoist Drive 1988 2800XPA
Sealed Electrical Room 1991 4100
Straight Leg Handle 1991 4100
Modular Crowd Case 1991 4100
Truss Style House 1991 4100
Sprocket Drive (Delta) 1998 4100TS
Auto Belt Tensioner 1998 4100XPB
Disc Brake Propel For MKII Single Prop 2000 2800MKII
Planetary Dipper Trip 2000 4100XPB
Pulse Type Filter System 2003 4100XPB
Shimless Saddle Block 2004 4100XPB
Above Deck Collectors 1998 4100TS
Doweled Crawler Connection 1999 4100XPB
50 RC Lower Rollers 1999 4100XPB
Oversized Lube Tanks 2003 4100XPB

( ) Numbers in parenthesis are quantities sold as of April 2005, as such future quantities may vary on models still in production.
* With new firing circuits and modern regulators.

k data shexeng products featurecomp/ milestones all shovels.xls

MilestonesShovels.xls 12/1/2010
Serial Number Milestones Page One

Electric Mining Shovels

Milwaukee-Old System Licensees

E09740-E55325 P&H Electric Shovels KOBE (Japan)

Milestones Old System

E10000 1400 (East Division, Southwestern Portland J02607-J24499 P&H-Kobe Electric
Cement)(1946) Shovels
E11175 1600 (BC Operations)(1946)
E12312 1400DE (Drummond Dolomite)(1948) Milestones
E14530 1500 (NewYork Trap Rock)(1950) J02607 1400 (Ube Cement-
E15000 1855 (Leeper, G.A. Stiles)(1952) Japan)(1964)
E18000 1800 (Cyprus Bagdad)(1955) J03466 1400DE (Geraldton
E25300 2100 (Girardville-Sullivan Trail)(1963) Operations-Australia)(1965)
E25630 1900 (ASARCO Mission)(1963) J03480 1600 (Savage River-
E29420 1900A (CVRD Conceicao)(1968) Australia)(1966)
E29480 1500DE (Carlin Gold)(Newmont)(1967) J06001 1900A (Mt. Newman-
E30040 1900B (Anamax-Twin Buttes)(Cyprus Australia)(1968)
Sierrita)(1968) J06090 2100B (Cardinal River Coal-
E30060 2800 (Kaiser)(Elkview Coal)(1969) Canada)(1969)
E32280 2100BL (Cyprus Sierrita)(1971) J11870 2100BL (Atlas Con. Mining-
E34060 2300 (Magma Copper-Pinto Valley)(1972) Cebu, Philippines)(1973)
E34160 1900AL (Inspiration Copper)(Cyprus J14700 1900AL (Mica Creek/Mt. Isa-
Miami)(1972) Australia)(1975)
E41500 5700LR (Arch of West Virginia- J16155 2800MKII (Premier
Ruffner)(1978) Mine/Wesfarmers-Australia)(1976)
E48105 2100BLE (Spring Creek)(1980) J18720 2300MKII (Bayswater-
E48150 2355E (Coal Systems-Oak Grove)(1981) Australia)(1978)
E50010 2300XP (Thompson Creek)(1981) J20936 1300 (Barsua/Hindustan Steel-
E50150/C12 2300XP (Thompson Creek)(Cyprus India)
Sierrita)(1981)(1997) J24290 2300XP (Kuzbas-Siberia,
E50830 2800XP (LTV Steel-Erie Mine)(1982) Russia)(1982)
E53290 2800XPAC (Powder River Coal-
Caballo)(1987) New System-April 1982
E53550 5700DR (Great Lakes Dock & Dredge)(1987) KA... 1400’s (none built)
E54060 2300XPA (Kennecott Energy-Colowyo)(1987) KB0004-KB0005 1400DE’s (KB0004
E54355 2800XPA (Powder River Coal-Rochelle)(1988) Mano River)
E54800 5700XPA (Coal & Allied-Mt. Thorley)(1991) KE0085-KE0087 1600’s (KE0085
E54895 4100 (Powder River Coal-Caballo)(1991) Golden Sunlight, Montana)(1984)
E55055 2100XP (Placer Development-Endako)(1991) KF0072-KF0123 1900AL’s (KF0072
E55105 2100XPA (Phalaborwa, S. Africa)(1992) Optimum Collieries, S. Africa)(1983)
E55261 2800XPB (Kennecott Copper-Bingham KG0064-KG0079 2100BL’s (KG0064
Canyon)(1992) 2100BLE Bullmoose, Canada)(1983)
E55291 2300XPB (Placer Dome- Dome KH0022-KH0029 2300’s (KH0022
Expansion)(1994) 2300XPLR New Vaal, S. Africa)(1985)
E55294 4100A (PD Morenci)(1994) KJ0014-KJ0049 2800’s (KJ 0014
E55325 4100A (Cyprus-Sierrita)(1995) Last Electric 2800MKII Phalaborwa, S. Africa)(1983)
Shovel Scheduled Using Old System
What’s in a Serial Number? Page Two

Electric Shovels Continued

Milwaukee New System Licensees Continued
ES2368-... P&H 2300XPB (ES2368 Iscor- CHINA
Sischen)(1996) CT10005-CT10030 2300XP’s
ES28121-... P&H 2800XPB (ES28121 IOC-Carol (CT10030 Dexing Copper)
Lake)(1996) CT20005-CF20030 2800XP’s (CF20030
ES4144-... P&H 4100A (ES4144 PD-Morenci)(1995) Heidelgou Mine-Zungheer Coal)
ES4185 P&H 4100TS (Suncor-Steepbank)(1998) CF-Fularji, CT-Taiyuan
ES4192 P&H 4100XPB (Triton-North Rochelle)(2000)
ES41114 P&H 4100BOSS (Syncrude-Aurora)(2000)
Draglines
301-410 Page Draglines, various
Drills models (410 Page 736 Luscar/Manalta,
1000-1114 GD 120’s (1114 PD Morenci) Montgomery)
1501-1505 GD 80’s (1503 CVG FMO San Isidro) D54670 & D54680 P&H 752 (Jordan
2001-2014 GD60’s (2005 FMSA Mina de Fabrica) Phasphate-Eshidya)
1601-1624 GD100’s (1624 Titania Postboks) D54900 P&H 757 (British Coal-
1801-1824 GD 70’s (1824 Syferfontein Colliery) Stobswood)
1825 P&H 70A (1825 MICARE) D55100 P&H 757 (MICARE)
1625-1626 P&H 100A (1625 Kennnecott Energy- D59021 P&H 9020 (Bulga)
Cordero Rojo) DL9020002-... P&H 9020 (DL9020002
(4)1627-1633 P&H 100B’s (41633 DeBeers Jwaneng) Ensham)
(4)1115-1119 GD120’s (PD La Candelaria)
(4)1120-1129 P&H 120A’s (BD1129 Line Creek Hydraulic Excavators
Resources)) G79078-G79094 P&H 1200
(BD)10036-... P&H 100XP’s (BD10036 Royal Oaks G78078 (Black Creek Land- Upshur
Kemess) County Project)(1979) Germany
(BD)120130-... P&H 120A’s (BD120130 SPL
Toquepala) E52960-E54325 P&H 1200(&B’s)
(BD)250101-... P&H 250XP’s (250101 Ensham) E52960 1200 (Craigsville)(1983)

E(or H, or HE)54340-E55240 P&H

1550 & P&H 2250(&A’s)
E54340 1550 (Cyprus Bagdad)(1989)
E54875 2250 (Moolman Bros
Potgeitersrus)(1990) These numbers
were scheduled with the electric shovels,
etc.

(H)E57022-E57029 P&H 1550 (E57029

1550 Dolet Hills) (H)E57508-E57514
P&H 2250(&A’s) (E57514 2250A Rand
Mining) E57... Hydraulic only & in
numeric sequence
HE2215-... P&H 2250A (HE2215 USX
Minntac)
© 2010 P&H Mining Equipment Inc. All rights reserved
 44 4100XPC P&H 4100-Series
since 2006
Shovels
45 400XPB
since 1999

13 4100C BOSS
since 2006

17 4100BOSS

10 4100C
since 1997 218
P&H 4100-Series
since 2006 shovels sold since 1991

89 4100A & 4100

since 1991

© 2010 P&H Mining Equipment Inc. All rights reserved

 P&H 4100-Series Shovels

= Coal = Copper = Oil Sands = Gold = Iron Ore

© 2010 P&H Mining Equipment Inc. All rights reserved

 4100XPC Specifications

• Nominal Payload
– 109 metric ton
– 120 short ton
• Nominal Dipper Capacity
– 61.2 m3
– 80.0 yd3
• Working Weight
– 1,537 metric ton
– 1,694 short ton
• Dumping Height w/ Bail
– 9.5 m
– 31 ft

© 2010 P&H Mining Equipment Inc. All rights reserved

 P&H Drive Systems: A History of Growing Success

• P&H, ABB in longstanding technical partnership since 1970s

• Joint development of industry-first static DC drive
• Joint AC-drive research, trials during 80s and 90s
• Centurion developed and released in 2004 for both new
machines and upgrades to existing machines
• AC Drive design and implementation for mining shovels
released in 2007

Mining-Duty, Centurion-Based AC Drive

© 2010 P&H Mining Equipment Inc. All rights reserved

 A Winning Partnership

• Joint development, introduction of

state-of-art AC-drive P&H 4100
BOSS electric mining shovel for
Oil Sand application 2005-2007
• Flawless start-up in 2007
• Electrical and motor reliability
objectives exceeded – Up to 10%
increase in productivity
• Seven (7) AC-drive P&H 4100 BOSS
shovels now placed into service
• First 4100XPC AC currently in
assembly; with three (3) more currently
scheduled for operation in Canada.

Mining-Duty, Centurion-Based AC Drive

© 2010 P&H Mining Equipment Inc. All rights reserved

 Compact ABB Multidrive

• Compact-design ABB ACS800

MultiDrive provides highly
precise Direct Torque Control
• Motor speeds ramped up,
maintained and ramped
down with ABB patented
motor control algorithm –
best dynamic response
• ABB ACS800 MultiDrive
enables adaptive, integrated
control over multiple drive
motors, safety functions ABB ACS800 MultiDrive

Mining-Duty, Centurion-Based AC Drive

© 2010 P&H Mining Equipment Inc. All rights reserved

 ACS800 Multi-drive Construction
ISU: 10 x 580KVA
Hst: 8 X 580KVA
Crd: 2 X 580KVA
Swg: 6 X 580KVA
Prp: 4 X 580KVA

ISU - LCL filter

Modules DC- Fuse

DC- Power Module

Contact Unit

Busbar
connection
Motor-

© 2010 P&H Mining Equipment Inc. All rights reserved

 Inverter Supply Unit

• Joint ABB / P&H Application Design

• Design factors included vibration
measurements, field experience
• Designed and built in accordance
with P&H, EU, US and factory
shock and vibration control
standards
• Finite Element Analysis and
complete ‘shake and shock’ test
while running 690V / 10kW motor
at full load applied to verify design,
manufacturing

Mining-Duty, Centurion-Based AC Drive

© 2010 P&H Mining Equipment Inc. All rights reserved

 Inverter Supply Unit

• Innovative, compact, air-cooled,

energy-efficient
• Maintenance-friendly,
easy-to-replace ISU modules
• Inverter Supply Unit replaces
Reactive Power Compensation
unit used on DC-drive shovels
• 690-volts operating voltage

ABB Inverter
Supply Unit

Mining-Duty, Centurion-Based AC Drive

© 2010 P&H Mining Equipment Inc. All rights reserved

 Modular Rear Room

• ISUs and auxiliary transformer

contained within factory-
assembled ‘rear room’ module
• Module helps shorten field
assembly time, promotes
maintenance efficiencies
• Electrical components are wired in
the easier-to-control environment
of the factory with the wires and
cables terminated, wrapped and
made ready for roll-out and quick
installation at the mine site

Mining-Duty, Centurion-Based AC Drive

© 2010 P&H Mining Equipment Inc. All rights reserved

 P&H Centurion®:
The Heart of P&H Electric Mining Shovels
• Proven and highly advanced communications,
command and control system
• Designed to support proven P&H motor and
power conversion technology
• Platform for productivity and cost-reducing
technologies, current and future
• Over 200+ machines operating
worldwide with Centurion Systems

Mining-Duty, Centurion-Based AC Drive

© 2010 P&H Mining Equipment Inc. All rights reserved

 Centurion Control System

Technology Platform for

Future Advancements
•Improved Haulage Efficiency
•3 Second Decrease In Propel
Transfer Time*
•1.5 Second Decrease In Cycle Time*
•Reduced Electrical Troubleshooting Time
– 2% to 4% Reduction *

*Results based on conversion of Analog

Electro-torque system to Centurion Control System

Mining-Duty, Centurion-Based AC Drive

© 2010 P&H Mining Equipment Inc. All rights reserved

 Centurion Control Cabinet

Interface to AC drives
Hoist
gearcase
lube pump
drive

Supervisory
Controller Trip-
Trip-Rite drive
Smart I/O

© 2010 P&H Mining Equipment Inc. All rights reserved

 Powerful, User-Friendly GUI

• GUI linked via Centurion to

Smart I/O network provides
enhanced diagnostics
• Simplified troubleshooting
with fast access to fault
data, diagnostics
• Maintenance personnel can
download software to
controller, drives via GUI
• If drive fault occurs, Centurion
provides before- and after-
incident data for analysis

Mining-Duty, Centurion-Based AC Drive

© 2010 P&H Mining Equipment Inc. All rights reserved

 Loading Control Center

• The bygone ‘operator cab’

is now the Loading
Control Center,
providing exceptional:
– Communication
– Command
– Control

Mining-Duty, Centurion-Based AC Drive

© 2010 P&H Mining Equipment Inc. All rights reserved

 Loading Control Center

• Helps transform shovel operator

role to ‘Loading Control Manager’
with greater command and control
over loading operations
• Graphical User Interface (GUI)
serves as portal for shovel systems
operation and health information
• Optimized control platform
secure-mount welded to machinery
house with good loading area
sight lines and ergonomics
inspired by numerous ‘voice
of customer’ inputs

Mining-Duty, Centurion-Based AC Drive

© 2010 P&H Mining Equipment Inc. All rights reserved

 Centurion-Enabled, Performance-Boosting Options

TripRite
•Self-regulating trip torque
delivers just the right amount to
the dipper door
•Eliminates resistor bank control
•Upgradeable to existing P&H
shovels

Mining-Duty, Centurion-Based AC Drive

© 2010 P&H Mining Equipment Inc. All rights reserved

 PreVail® Remote Health Monitoring
Reliability Productivity Predictability

Lowest Cost / Ton

1. Dashboards = Simple illustration making sense of all the data

2. Analysis Tools = Simple diagnostics supported by OEM expertise
3. Historical Diagnostics = Enables predictability of future events
4. Reporting Tools = Permits users to export information into Mine
planning and reporting systems

KPI Dashboards Analysis Tools Historical Diagnostics Reporting Tools

Mining-Duty, Centurion-Based AC Drive

Under Final Development

© 2010 P&H Mining Equipment Inc. All rights reserved
 PreVail Architecture
Historical Diagnostics KPI Dashboards Real-Time Displays

PreVail™ via the Web

PreVail Via the Internet
FW
Milwaukee NETWORK

FW Process A&E
Data Concentrator PreVail™ Server Historian Historian
Mine NETWORK
Data Logger
Buffer Sensor & Alarm Data
Data Logger (Balance of fleet)
Buffer Sensor & Alarm Data

Under Final Development

© 2010 P&H Mining Equipment Inc. All rights reserved
 Track Shield™ = Crawler Collision Avoidance

• Collision Avoidance System

• Assist’s Operator to Prevent Costly
Collisions of Dipper to Track’s
• Especially Critical for Applications
that Dig of the Tracks (Modified
Drive By Loading)
• Reduces Structural Damage
Caused by Collisions
– Tracks
– Track Frames
– Carbody
– Dipper Handle
– Booms

Mining-Duty, Centurion-Based AC Drive

Under Final Development

© 2010 P&H Mining Equipment Inc. All rights reserved
 Proven Motor Designs

• P&H experience in
design and manufacture
of AC motors since 1893
• Current P&H AC motors
based on proven AC and DC
motor designs, experience
• HAF8412 Hoist Motor rated
at 1,600 HP at 714 rpm,
690 volts, 24 Hz
• HAF7510 Crowd / Swing /
Propel motor rated at 730 HP
at 982 rpm, 690 volts, 33 Hz

Rugged P&H AC Motors

© 2010 P&H Mining Equipment Inc. All rights reserved

 Effective Motor Designs

• Hoist motors: 2 X P&H HAF8412

1600HP/1194 kW each
• Crowd motor: 1 X P&H HAF7510
730 HP/545 kW
• Propel motors: 2 X P&H HAF7510
730 HP/545 kW each
• Swing motors: 3 X P&H HAF7510
730 HP/545 kW each
• Commonality of Motors
– Swing and Propel are
Interchangeable
– Crowd Motor has same
frame size

Rugged P&H AC Motors

© 2010 P&H Mining Equipment Inc. All rights reserved

 Increased Shovel Performance

• Increased speed, peak HP

• Improved thermal design limits
full-load temperature rise to
Class B level
• Rugged, mining-duty
mechanical design
• Proven bearing
technology applied

Rugged P&H AC Motors

© 2010 P&H Mining Equipment Inc. All rights reserved

 Increased Shovel Performance

• INPRO brass bearing seals for

improved protection from
contaminants
• Lower inertia for improved
performance
• Premium insulation (Class H or
higher)
• Insulated bearing with shaft
grounding feature

Rugged P&H AC Motors

© 2010 P&H Mining Equipment Inc. All rights reserved

 Improved Electrical Availability

• Active front end mitigates

incoming power issues
• AC motors require fewer static
maintenance checks
• Planned maintenance activity
is more efficient, less frequent
• Inverter Supply Units (ISUs)
require minimal maintenance
• Overall system reliability
improvements help increase 1% - 3% improvement in shovel
shovel availability availability translates to over
1.8 million metric tons per year
increased production

Rugged P&H AC Motors

© 2010 P&H Mining Equipment Inc. All rights reserved

 Summary: Rugged P&H AC Motors

• Designed for increased

shovel performance
• Rugged, mining-duty
mechanical design
• Proven bearing technology applied
• Lower inertia for improved
performance
• Improved Electrical Availability
• Overall system reliability
improvements help increase
shovel availability

Rugged P&H AC Motors

© 2010 P&H Mining Equipment Inc. All rights reserved

 Rigorous Testing – Continuous Design

• P&H Finite Element Analysis (FEA) expertise,

state-of-art NASTRAN tools, extensive testing
applied to design all structures
• Strain gauges applied to obtain
precise loading conditions
• Over 40 P&H 4100XPC machines
placed into service since 2006
• Consistent, customer-driven
design process applied to
continuously improve
P&H shovel systems

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Tough, Proven, Reliable

• LOWER ASSEMBLY: Carbody,

crawler frames, AC propel motors
and planetary transmission sets
• Deep-section carbody
design with large center
gudgeon casting
• Factory-machined components
with no field welding required
• Proven design on P&H 2800-
and 4100-series shovels
• Designed for ease of service and durability
• Solid, stable, reliable

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Crawler Frames

• Solid one-piece, heavy-duty

hardened lower rails without
welded ring plates

• Replaceable,
cast top
slide rails

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Carbody Enhancements

• Improved Designs
• Thicker plates
• Improved Welds

VALUE:
• Longer Life
• Less Maintenance

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Crawler Frame Connection
• Optional
HyTorc
tensioning
system

• Optional
SuperNut
system

VALUE: Ease of assembly

and lower maintenance
requirements

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Better Clearance

• P&H 4100XPC
counterweight profile now
aligns with counterweight
box for increased
clearance

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Propel System Enhancements

• Side frame increased

plate thickness
• Longer splines on
the tumbler and final
drive shaft
• Upgraded front idler
• Transmission redesigned
for 7 percent ratio increase,
performance gains
• Uses same P&H AC motors proved
on AC P&H 4100 BOSS shovels

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Propel System Front Idler Upgrade

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Propel System Upgraded Design
Modified original bearing block
Lube line
cover

Retaining 11” diameter /

ring 27.94 cm
shaft

Rock and
dirt guard
Brass
bushing
Modified original Idler Splined sleeve insert
AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Propel System Upgraded Design

Top View

Front View

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Upgrade Design Benefits

• Reduced bearing stresses by 50%

• Bearing blocks removed
without breaking track
• Sealed system to prevent
grit contamination
• Splined connection

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Upgrade Design Benefits

• Shaft seats in bushing

• Adjustable retaining rings –
accommodate up to 3.25”
of total wear
• Current P&H standard SL-V XL
injectors
• Upgrade can use original idler and
bearing blocks

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Upgraded Propel Lube Distribution System Design

Input Input

Bushing Lube

Thrust Plate Lube

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Hardened Lower Rollers

• 31” (787mm) diameter

solid forged construction
• Proprietary P&H
spin-hardening process
• Hardness of roller is over
50 Rockwell inch deep
• Longer life of rollers,
shoes and greater MTBF

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 DELTA System Standard

• Deep-Engaging, Long-life
Track Assembly
• Good engagement,
even with loose tracks
• Low track tension
results in smooth shoe
engagement and
low stress
• Long life, greatly reduced
maintenance requirements

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Crawler Shoes

• Manganese steel:
Tough, impact-resistant,
work-hardens
• Excellent cold weather
impact strength properties
• No pin bushings required
• Strong roller path, robust
lug design – long-lasting in
the harshest environments
• Improvement over earlier
4100XPB designs

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Crawler Shoe Pins

• 5” induction-hardened link
pins, floating design (4.5”
diameter on 2800XPC)
• Less pin wear = less pitch
change = less adjustment
• Dramatic fatigue life
improvement
• Field experience showing pins
achieve same life as shoes

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Planetary Propel

• P&H-designed,
P&H-made for mining.
Not off-the-shelf.
• Modular and rebuildable
• Exchange units lower MTTR

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Planetary Propel

• 360 planetary
P&H shovels sold
• Utilize bronze thrust
surfaces for increased
service life
• Over 1,350 planetary
P&H transmissions in
operation
• Provides years of trouble-
free service

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Propel Output Shaft

• Large-diameter spline
on final drive shaft
• Shaft can be replaced
with transmission in place
• Transmission can be
replaced with shaft in place
• Long life, less downtime,
better MTBF and MTTR

• V-seals and thrust washers

protect splines and bearings
• Longer 24-inch (versus
previous 17.3-inch) spline to
better match life of tumbler lugs

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Swing System

• Three swing units for

quick swing cycle time
• Same AC motors
applied and proven on
AC P&H 4100 BOSS
• Same upgraded, proven
transmission as applied
to AC P&H 4100 BOSS
• Higher swing speeds

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Above-Deck HV Collector System

• No high voltage components

in roller circle area
• Safety locked viewing window
• Convenient access for ring and
brush inspection without
machine shutdown

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Center Gudgeon

• Forged pin adjustable

from upper deck
• Reliable
cascaded
interference
fit in carbody

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Revolving Frame

Changes shown in yellow

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 New P&H 4100XPC AC roller circle design

PREVIOUS DESIGN NEW DESIGN

• 7 inch profile • 9.5 inch profile

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 AC Hoist Gearcase Weldment

• Thicker plate construction

• Increase in center distances –
1st and 2nd Reductions
• 100% FEA – Lower stress,
reduced stress concentrations
• Inspection holes and lifting
lugs built into design.
• Stiffer structures result in
better bearing life

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 AC Hoist Gearcase Weldment

Enhanced Reliability
• Addresses structural cracking
at lugs
• Ease of inspection
• Jacking bolts – Ease of
maintenance

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 4100XPC AC Hoist Gearcase

• Simplified thick plate

construction
• Reduced stress
concentrations
– 100% FEA
• Increase in center distances
– 1st and 2nd Reductions
• Ease of Inspection
– Inspection holes and lifting
lugs built into design
• Ease of maintenance
– Jacking Bolts

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Breather * Heavier Plate Construction
*Increased
Inspection Hoist Drum
Points

Input Guard

2nd Reduction
Bearing Block

Increased Brake
Drum Shaft Retained Torque
w/ Split Collar

Lube Filter & Pump * Integral Drum

Assembly Wedge Support Blocks
Lock

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 P&H 4100XPC AC Hoist Gearcase Mounting

Hoist Gearcase Support

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Optional Brake Removal System

• I-beam easily installed

on roof beams
• Also used for
removing blowers
• Trolley unit can be used
with snatch blocks or
come-a-longs
• Ring installs on brake to
ease rolling on floor for
removal and can be left on

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 P&H Boom Structure

• Proven P&H design with extensive

FEA and strain gauge analysis
• Robust twin handle design for heavy
duty digging applications
• Improved handle rub bar geometry
• Heavy and stable for
tough digging
Improved
handle rub bar
geometry for
improved
service

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Boom Walkway

• Rugged square tube design

• Low-profile rails positioned
to evade rope contact

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Gantry
New Compression
• New Tension members Member Head to
provided to prevent Eliminate Weld-On
Bosses
cracking at pin bores
• No weld on bosses
• Same pin in tension
Pin-On Catwalk
member Attachments

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Crowd System

• New Saddle block assembly

• Crowd belt Auto-
Tensioner upgrade
• New shipper shaft –
oversized splines
• Larger racks & pinions
• No hydraulics to maintain

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Crowd Platforms

• Rugged square
tube design
• Generous space for
maintenance activities
• Robust system for
durability and
maintenance efficiency

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 New Saddle Blocks

• Increased Availability & Safety

• Reduces Maintenance Requirements
– Longer Maintenance Intervals
– Reduced Downtime to adjust
– Less Equipment required
– Fewer Procedures to Follow
• Combines time proven concepts
with tested and prototyped
improvements

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Adjustable Saddleblocks

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Crowd Belt Auto-Tensioner

• Improved Automation and

more consistent belt-
tensioning forces
• Centurion programming
updated and hydraulic
circuitry improved
• Ultimate value:
Significant belt
life increase

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Shipper Shaft

• Longer shaft
• Larger-diameter spline
• Larger bushing in boom
• Larger bushings in
saddle blocks New style
• Adjusting threads Old style
outside of saddle blocks
to ease adjusting
• Easier to maintain and
longer lasting

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Shipper Shaft
New Saddle Blocks For
Improved Wear Plate
Adjustment and Increased
Bearing Area On Shipper
Shaft

Proven Bull Gear and

Shipper Shaft Pinions

Proven Longer Shipper

Shaft for Improved Saddle
Block Bearing Area

New Adjusting Collar Assembly for

Improved End Play Adjustment
AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Dipper Handle

• Robust P&H twin-leg design

• Geometry optimized for
fatigue resistance in shock
and high load conditions
• Dual-leg design maintains
stable dipper trajectory –
better fill in all digging
conditions – especially in
tough digging

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Modularity

• RH Electrical Room
• Factory assembled,
pre-wired control cabinets
• Clean isolated room for
electronics and service
personnel
• MineAir HVAC system
• Three doors and ample space
for maintenance

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Modularity

Modular Lube System Room

• Factory assembled pre-wired,
pre-plumbed air and lube
systems
• Easy access to pumps, tanks,
and all lube components

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Centralized Automatic Lubrication System

• Large tanks hold 1000 600-gallon grease

reservoir
gallons (3200 kg lube) 400-gallon
OGL reservoir
• Standard 4 zone system
• Pressure sensing at
injector banks
• Lube level indicators
• Robust system well
suited for cold, severe
weather applications
Tank heater
option improves
lube system
performance in
cold-weather
environments

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 AirScrubPro Air Filtration System

• Powerful, high-efficiency
machinery house systems
air-filtration system
• Screens-out 99.7% of
unwanted particles
• Effective down to
0.2 micron-size dust particles
• Helps increase solid state
component life
• Protects motors against
harmful dust infiltration
• Available as an upgrade for
existing P&H shovels

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

P&H Optima® Dippers

• Optimized geometry for

copper and coal
applications now available
• Weight-efficient, but
designed for long MTBF
• Adjustable pitch braces and
SnubRite hydraulic snubbers
• Proven productivity
• Reduce energy required
for greater fill factors

AC-Matched P&H Mechanical, Structural Systems

 Notable Improvements & Benefits

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 P&H AC-Drive Shovels are exceeding
customer requirements and expectations
• 3% faster cycle times
• 2.5% increase in availability
• 5% increase in productivity

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 P&H AC-Drive Shovels are exceeding
customer requirements and expectations
• Noticeable increase in SPEED – hoist,
lowering, retract/crowd, swing, propel
• Excellent steering performance
• Extremely pleased with faster Rapid
Propel Transfer speed (delay time
reduced, safety checks made)
• Faster re-positioning of shovel for
optimized dig, truck-loading trajectories

AC-Matched P&H Mechanical, Structural Systems

© 2010 P&H Mining Equipment Inc. All rights reserved

 Final Thoughts

• At P&H, we are passionate about

‘getting it right’
• 125 years of mining success
• Great results from AC systems
• Improvements throughout
• Combining best proven technologies
with most reliable mechanical /
structural systems in mining industry
• The result: The 4100XPC AC is one of the best and most
productive digging machines in the world today

© 2010 P&H Mining Equipment Inc. All rights reserved

 Thank You

© 2010 P&H Mining Equipment Inc. All rights reserved

1.0 Specifications

2.0 Service Bulletins

Service Notices

3.0 Upgrade Kits

4.0 Minesite Insights

5.0 Miscellaneous
 Tab 1

Specifications
 Operating
4100XPC Specification
Electric Mining Shovel
Digital AC Drive Control

meters

feet
22 72.2

20 65.6

18 59.1

16 52.5

14 45.9

12 39.4

10 32.8

8 26.2

4100 6 19.7
XPC

4 13.1

2 6.6

0 0

2 6.6
meters 6 4 2 0 2 4 6 8 10 12 14 16 18 20 22 24
feet 19.7 13.1 6.6 0 6.6 13.1 19.7 26.2 32.8 39.4 45.9 52.5 59.1 65.6 72.2 78.7
C
 L  ROTATION

Working Ranges Capacity

Height of Cut 16.8 m 55 ft. 2 in. Nominal Pay Load 108.9 mt 120 st

Radius of Cut 23.9 m 78 ft. 8 in. Nominal Dipper Capacity

SAE struck 61.2 m3 80.0 yd3
Dumping Height* (Door Open) 9.5 m 31 ft. 0 in. SAE 2:1 67.6 m3 88.4 yd3

Floor Level Radius 16.0 m 52 ft. 6 in. Rated Suspended Load 195 mt 215 st

Tail Swing Radius 9.8 m 32 ft. 3 in. Optimum Truck Size 172-363 mt 190-400 st
(400 st truck shown)
Operator Eye Level 10.1 m 33 ft. 1 in.

* Height shown with bail-type dipper. Heights will be greater with

bail-less or compact-bail dippers. Actual dumping height can be
greater than door clearance height.
 Electrical Control Dipper & Dipper Trip
• Centurion Supervisory Controller provides direct integrated • P&H OPTIMA dippers combine consistent productivity with high
communication with motor drives giving precise motor control and durability and maintainability. Dippers are configured to mine specific
fast cycle times. Real-time multi-tasking capability allows for optimal conditions and capacity requirements from a variety of combinations
machine logic sequencing, monitoring and control. of body and lip designs, as well as other unique P&H technologies.
• Centurion I/O System uses ‘Profibus’ communication protocol Specific wear packages and GET styles can be cooperatively
for seamless integration of all shovel subsystems and future specified.
expandability. Low-voltage 24V DC I/O drop points feature open and
• P&H TripRite system utilizes a brushless DC electric motor with
short circuit detection for improved diagnostics and troubleshooting.
sealed planetary drive unit for reliable trip and slack take up
• Centurion Information System’s enhanced Graphical User Interface operation.
(GUI) features intuitive, icon-based screens to display vital
information such as shovel status, troubleshooting information, and
optional production monitoring data and operator feedback.
Hoist
• All gearing housed in single enclosed gear case with filtered and
Electrical Control Systems cooled oil fed to all bearings in addition to splash lubrication for
reliable operation and ease of maintenance.
• Large 68" diameter hoist drum for extended rope bending life.
ELECTRICAL DRIVE RATINGS
Ferrule becket system and dual electric tuggers are standard for
(50°C, 2000m) Drive Power
efficient rope change.
IGBT Supply Unit (ISU) 4550 kVA • Spring set air release disc brakes - one per motor.
Crowd Motion 1160 kVA
Hoist Motion 4640 kVA
Propel Motion 2320 kVA
Crowd
Swing Motion 2320 kVA • Powerband V-belt drive between motor and gear case absorbs
shock loads.
• First and second reduction gearing in enclosed gear case for
The electrical drive system is comprised of a multi drive platform, reliable splash lubrication, ease of maintenance, and extended
sharing a common DC bus between the IGBT Supply Unit (ISU) component life.
and the motor drive Inverter Units (INU). The fully regenerative
ISU controls the power flow to and from the shovel, maintaining a • Twin leg dipper handle with torsion box and rack and pinion drive has
unity power factor with extremely low harmonic content. The fully inherent stability in the bank for optimal digging.
regenerative INU controls the power flow to and from the individual • Spring set air release disc brake.
AC motors.

P&H AC FAST RESPONSE MAIN MACHINERY MOTORS Swing

Hoist Motor Continuous rating @ 690 volts Total 2388kW/3200hp • Three modular P&H planetary gear cases of proven design and a
(Two used) Peak developed power 2976kW/3990hp single piece forged swing gear transmit torque for fast cycle times.
• Spring set air release disc brakes - one per motor.
Swing Motor Continuous rating @ 690 volts Total 1090kW/1460hp
(Three used) Peak developed power 1380kW/1850hp • Splash lube optional filtration system.

Crowd Motor Continuous rating @ 690 volts Total 545kW/730hp

(One used) Peak developed power 774kW/1037hp
Propel
Propel Motor Continuous rating @ 690 volts Total 1090kW/1460hp
(Two used) Peak developed power 1678kW/2250hp • Propel on demand provides rapid transfer to propel mode. Rapid
transfers allow frequent positioning of the shovel to the bank resulting
in faster cycle times and more efficient digging.
• Two rugged P&H planetary gear cases of proven design
Power Requirements independently transmit torque to the drive sprockets, producing
the tractive effort required for fast, efficient propel and positioning
Supply Voltage* 7200 or 13800V 6000, 6600, 7200 or 11000 operations.
3 Phase, 60 Hz 3 Phase, 50 Hz. • P&H DELTA Drive low tension sprocket drive system with heavy duty
cast crawler shoes.
Supply Transformer (Minimum) 3750 kVA
• Spring set air release disc brakes - one per motor.
Minimum Short Circuit VA Available at Shovel 30 MVA
*Voltage per customer requirements

Cable Data
TRANSFORMER
Main Transformer 4000 kVA Hoist (wire rope) 73 mm 2.87 in. dia.
Auxiliaries Transformer 400 kVA
Suspension (bridge strand) 102 mm 4.00 in. dia.
Control/Lighting Supply Winding 50 kVA
Note: Transformer capacities may vary depending on options. Dipper Trip (wire rope) 19 mm 0.75 in. dia.
 Overall Dimensions
A Width 14.4 m 47 ft.   1 in.
B Length 15.0 m 49 ft.   4 in.
C Height Over Gantry 14.7 m 48 ft.   3 in.
1930 mm (std.) 76 in. (std.)
D Width of Crawler Shoes
2210 mm 87 in.    
E Width of Crawlers (std.) 10.5 m 34 ft.   5 in.
F Length of Crawlers 11.7 m 38 ft.   6 in.
G Ground Clearance 0.7 m   2 ft.   2 in.
H Height — Ground to Bottom of Counterweight Slabs 3.6 m 11 ft. 10 in.

I Height — Ground to Bottom of Counterweight 3.6 m 11 ft. 10 in.

A B

C 4100
XPC

I
H
G

D
F
E

Machinery Deck Plan

REAR MACHINE HOUSE I/O BOX LUBRICATION ROOM
AIR COMPRESSOR LUBE SYSTEM CONTROLS

HOIST MOTOR
HOIST LUBE RESERVOIR
MOTOR (2270 LITER/600 GAL. GREASE
1513 LITER/400 GAL. OGL)
INVERTER
AIR RECEIVER
(908 LITER/240 GAL.)

SWING MOTOR AND HOIST MOTOR

TRANSMISSION ACCESS DOORS
HIGH AND LOW VOLTAGE
COLLECTORS
(DECK MOUNTED)
HOIST DRUM
SWING
MOTOR AND
TRANSMISSION
MAIN TRANSFORMER
120 VAC
LOAD CENTER
GROUND FAULT
CABINET CENTURION
CONTROL CABINET
AUXILIARY TOUCH SCREEN MONITOR
TRANSFORMER
SECONDARY BREAKERS AUXILIARIES LOAD CENTER

AUXILIARIES
TRANSFORMER MOTOR CONTROL
HIGH VOLTAGE
CENTER
CABINET WITH
ISOLATORS ELECTRONICS ROOM
 Ground Pressure & Weight Features And Customization
BEARING AREA - GROUND PRESSURE The 4100XPC is built with several features to enhance safety,
Standard: reliability, and productivity over the life cycle of the operation.
Crawler Bearing Area 34.58 m2 53,597 in2 • Automatic Lubrication and Compressed Air Systems with
76" Shoes/ 1930mm advanced diagnostic and control
Crawler Ground Pressure 434.4 kPa 63.0 psi • Temperature Monitoring System for all motors, drum shaft
76" Shoes/ 1930mm bearings, shipper shaft bearings
• Automatic Boom Soft Setdown System (ABSS) and Boom
Optional: Profile Protection Envelope to help prevent excessive loading to
Crawler Bearing Area 39.58 m2 61,354 in2 the attachment during operation
87" Shoes/ 2210mm
• Anti-Swing-in-Bank system to reduce excessive side loading on
Crawler Ground Pressure 379.9 kPa 55.1 psi handle and attachment
87" Shoes/ 2210mm • Remote hoist control pendant and hoist rope winch to assist in
safe and efficient rope changeouts
WEIGHTS - APPROXIMATE* • House Pressurization System to provide filtered air for cooling
Working Weight (with Dipper, Approx. Wt.) and dust repression
76" Shoes/1930mm 1,532,235 kg 3,378,000 lbs
87" Shoes/2210mm 1,536,771 kg 3,388,000 lbs The standard shovel can be customized for local and minesite
specific conditions in the following areas:
Counterweight (Punchings)**   204,100 kg   450,000 lbs • Operator Cab
* All weights subject to 5% variation. • Climate Control
** To be furnished by customer. • Cold Weather Equipment
• Technology and Software
• Electrical and Mechanical Systems
Lighting • Maintenance Systems

Standard: Metal Halide, 400 W, high intensity discharge (HID)

primary exterior floodlights (11) mounted on the
operator’s cab, RH room, LH room and machinery
house. Secondary exterior floodlight combination of
Halogen, 500 W (3) and fluorescent lights (6) mounted
under revolving frame. Incandescent lights (5) outside
cab and house doors and (1) inside operator’s cab.
Fluorescent lights (23) illuminate interior of the
machinery house, RH and LH room.
Optional: High Pressure Sodium, 400 W or 1000 W primary
exterior floodlights.

Loading Control Center

SPACE FOR MINE
COMMUNICATIONS
ANTE ROOM EQUIPMENT
(SHOWN WITH
OPTIONAL TOILET)
TOUCHSCREEN GUI
AND OPTIONAL REMOTE
ELECTRICAL CAMERA SYSTEM
CABINET

SPACE FOR APPLIANCES ARMREST MOUNTED,

PISTOL GRIP JOYSTICKS
TRAINER’S STATION

LOCKERS
6-WAY POWER ADJUSTABLE AIR SUSPENSION
STORAGE CABINET SEAT WITH HEAT AND VIBRATORY MASSAGE

NOTE: All designs, specifications and components of

the equipment described above are subject to change at
manufacturer’s sole discretion at any time without advance
P&H MinePro Services notice. Data published herein is informational in nature
and shall not be construed to warranty the suitability of
1-888-MINEPRO the equipment for any particular purpose as performance
Outside the U.S. and Canada may vary with conditions encountered. The only warranty
Phone: (414) 671-4400 applicable is our standard written warranty for this equipment.
Fax: (414) 671-7306 P&H and P&H MinePro Services are trademarks of
www.minepro.com Joy Global Inc. or one of its affiliates.
www.phmining.com © 2010 P&H Mining Equipment Inc. All rights reserved.

XS-4722 PDF-710
 TheComparisonFiles
A Guide to P&H Mining Equipment Inc.

4100 XPC
The AC Difference

Summary
This document highlights key similarities and
differences of the P&H® 4100 XPC DC
machine and P&H 4100 XPC AC machine.
For further information, please contact your
local P&H MinePro Services representative.

Electrical 4100XPC AC Difference

Motors AC Motors (Brushless, No Commutator, No exposed un-insulated conductors)
Drive System AC Drive System with ISU and Inverters replaces RPC with Converters and Transfer Switch
RH Room AC Control Cabinet with updated MCC
Slip Rings 3 AC rings plus one ground ring for each motor vs. 2 armature rings and 2 field rings for each motor
Transfer Cabinet Removed
Main Transformer 4MVA transformer replaces 3MVA transformer
Auxiliary Transformer Winding for DC motor field exciter feeds removed
High Voltage Cabinet Same design different fuses
Lower HV Disconnect No change
Lower Control Cabinet Expanded I/O
Circuit Breaker Cabinet Expanded from 14 spaces to 22 spaces
LH Room Expanded I/O
 Mechanical 4100XPC AC Difference
Rollers and Roller Paths Increased from 7 inches to 9.5 inches
Carbody Same outer geometry but built to accommodate wider roller and roller paths
Revolving Frame Thicker rear gantry lugs, thicker hoist gearcase lugs eliminating boss plates and 2 piece bottom plate
Gantry No boss plate and improved gantry platform for easier installation
Boom New lubed boom rub rails, thicker internal stiffness and upgraded boom wear bar construction
Dipper Handles No Change
Crawler Frames 4100XPC AC features the new splined front idler
(including Front Idlers and Tumblers)
Swing Transmissions No Change
Propel Transmissions Ratio increased 7%
Saddle Blocks No change
Hoist Drum Assembly Larger bull gear for increased ratio and larger capacity bearing
Hoist Gearcase Increased ratio and larger intermediate bearings.
Rear Room New modular design; enclosed rear room
LH/RH Room No change
Ring Gear AC ring gear has additional mounting holes. Interchangeable to DC; not vice versa
Hoist Rope Tugger Right angle gearbox, tugger location moved towards the rear of the house
Counterweight Box Designed to accommodate rear room
Shipper Shaft No Change
Center Gudgeon No Change
Propel Motor Base New Design to accommodate AC Motors
Machinery House House design changed with addition of enclosed Rear Room
Dipper Trip No Change
Hatch Covers Flat roof design with Mebac
Swing Shafts No Change
Operator Coop No Change
Crawler Shoe Pins No Change
Crawler Rod Bolts No Change
Hoist Ropes No Change
Troughs Changed to accommodate AC requirements
Stairways Upper stairways moved away from sidewalls-other stairways same
Air Compressor No Change
Air Conditioner No Change
Crowd/Swing XMSN Filter Flow Sensor added
Dipper No Change

NOTE: All designs, specifications and components of equipment described

above are subject to change at manufacturer’s sole discretion at any time
P&H Mining Equipment Inc. without advance notice. Data published herein is informational in nature
A Joy Global Inc. Company and shall not be construed to warrant suitability of product for any particular
purpose as performance may vary with conditions encountered. The
Box 310  •  Milwaukee,Wisconsin 53201 USA only warranty applicable is our standard written warranty for this product.
Phone: (414) 671-4400  •  Fax: (414) 671-7306 P&H and P&H MinePro Services are trademarks of Joy Global Inc. or one
www.phmining.com   www.minepro.com of its affiliates. © 2010 P&H Mining Equipment Inc. All rights reserved.

XS-5086 TBD-TBD
 DIGITAL DC DRIVE CONTROL

meters

feet
22 72.2

20 65.6

18 59.1

16 52.5

14 45.9

12 39.4

10 32.8

8 26.2

4100XPC
6 19.7

4 13.1

2 6.6

0 0

2 6.6
meters 6 4 2 0 2 4 6 8 10 12 14 16 18 20 22 24
feet 19.7 13.1 6.6 0 6.6 13.1 19.7 26.2 32.8 39.4 45.9 52.5 59.1 65.6 72.2 78.7
C
L ROTATION

WORKING RANGES CAPACITY

Height of Cut 16.8 m 55 ft. 2 in. Nominal Pay Load 104.3 mt 115 st

Radius of Cut 23.9 m 78 ft. 8 in. Nominal Dipper Capacity

SAE struck 58.6 m3 77.0 yd3
Dumping Height* (Door Open) 9.5 m 31 ft. 0 in. SAE 2:1 64.8 m3 84.7 yd3

Floor Level Radius 16.0 m 52 ft. 6 in. Rated Suspended Load 188 mt 208 st

Tail Swing Radius 9.8 m 32 ft. 3 in. Optimum Truck Size 172-363 mt 190-400 st
(400 st truck shown)
Operator Eye Level 10.1 m 33 ft. 1 in.

* Height shown with bail-type dipper. Heights will be greater with

bail-less or compact-bail dippers. Actual dumping height can be
greater than door clearance height.
 ELECTRICAL CONTROL DIPPER & DIPPER TRIP
• Centurion Supervisory Controller provides direct integrated • P&H OPTIMA dippers combine consistent productivity with high
communication with motor drives giving precise motor control and durability and maintainability. Dippers are configured to mine specific
fast cycle times. Real-time multi-tasking capability allows for optimal conditions and capacity requirements from a variety of combinations
machine logic sequencing, monitoring and control. of body and lip designs, as well as other unique P&H technologies.
• Centurion I/O System uses ‘Profibus’ communication protocol Specific wear packages and GET styles can be cooperatively
for seamless integration of all shovel subsystems and future specified.
expandability. Low-voltage 24V DC I/O drop points feature open and • P&H TripRite system utilizes a brushless DC electric motor with
short circuit detection for improved diagnostics and troubleshooting.
sealed planetary drive unit for reliable trip and slack take up
• Centurion Information System’s enhanced Graphical User Interface operation.
(GUI) features intuitive, icon-based screens to display vital
information such as shovel status, troubleshooting information, and
optional production monitoring data and operator feedback.
• P&H Digital DC Drive provides precise, reliable, solid state power to
the main motion motors. HOIST
• All gearing housed in single enclosed gear case with filtered oil
circulation for reliable splash lubrication and ease of maintenance.
• Large 68" diameter hoist drum for extended rope bending life.
ELECTRICAL CONTROL SYSTEMS Ferrule becket system and dual electric tuggers are standard for
efficient rope change.
P&H DIGITAL DC STATIC DC POWER CONVERSION AND REACTIVE POWER
COMPENSATION • Spring set air release disc brakes - one per motor.

Hoist**/Propel Swing Crowd/Propel

Continuous
Armature
Converter KW
2x1860 kW 1860 kW 1860 kW CROWD
Rating @ 600 VDC*
• Powerband V-belt drive between motor and gear case absorbs shock
15 Sec. Armature loads.
Converter Current 3700 amp. 3700 amp. 3700 amp.
Rating* • First and second reduction gearing in enclosed gear case for reliable
splash lubrication, ease of maintenance, and extended component
Continuous Field life.
150 amp. 150 amp. 150 amp.
Converter Rating*
• Twin leg dipper handle with torsion box and rack and pinion drive has
* Rated at 600 V and based on outside ambient temperature of 50°C or 122°F. inherent stability in the bank for optimal digging.
** Cascaded hoist converters.
• Spring set air release disc brake.
P&H DIGITAL DC AUTOMATIC REACTIVE POWER COMPENSATION*
60 Hz. (7 step) 50 Hz (8 step)
Switched Steps +4725 kVAR Total +6000 kVAR Total
* Nominal rating at rated capacitor voltage (600 VAC)
* Rated at 600 V and based on outside ambient temperature of 50°C or 122°F.
SWING
** Cascaded hoist converters.
• Three modular P&H planetary gear cases of proven design and a
P&H DC FAST RESPONSE MAIN MACHINERY MOTORS single piece forged swing gear transmit torque for fast cycle times.
Hoist Motor Continuous rating @ 600 volts Total 1887kW/2530hp
(Two used) Peak developed power 2770kW/3713hp • Spring set air release disc brakes - one per motor.

Swing Motor Continuous rating @ 550 volts Total 1119kW/1500hp

T
(Three used) Peak developed power 1340kW/1796hp
Crowd Motor Continuous rating @ 550 volts Total 537kW/720hp
(One used) Peak developed power 530kW/710hp PROPEL
Propel Motor Continuous rating @ 550 volts Total 1074kW/1440hp • Two rugged P&H planetary gear cases of proven design
(Two used) Peak developed power 1434kW/1922hp independently transmit torque to the drive sprockets, producing
the tractive effort required for fast, efficient propel and positioning
operations.
• P&H DELTA Drive low tension sprocket drive system with heavy
POWER REQUIREMENTS duty cast crawler shoes.
• Spring set air release disc brakes - one per motor.
Supply Voltage* 7200 or 13800V 6000, 6600, 7200 or 11000
3 Phase, 60 Hz 3 Phase, 50 Hz.
Supply Transformer (Minimum) 3750 kVA
Minimum Short Circuit VA Available at Shovel 30 MVA CABLE DATA
*Voltage per customer requirements
Hoist (wire rope) 70 mm 2.75 in. dia. (std.)
TRANSFORMER
73 mm 2.87 in. dia. (opt.)
Main Armature Transformer 3000 kVA
Auxiliaries-Field Transformer 435 kVA Suspension (bridge strand) 102 mm 4.00 in. dia.
Control/Lighting Supply Winding 50 kVA
Dipper Trip (wire rope) 19 mm 0.75 in. dia.
Note: Transformer capacities may vary depending on options.
 OVERALL DIMENSIONS
A Width 14.4 m 47 ft. 1 in.
B Length 15.0 m 49 ft. 4 in.
C Height Over Gantry 14.7 m 48 ft. 3 in.
1930 mm (std) 76 in. (std)
D Width of Crawler Shoes
2210 mm 87 in.
E Width of Crawlers (std.) 10.5 m 34 ft. 5 in.
F Length of Crawlers 11.7 m 38 ft. 6 in.
G Ground Clearance 0.7 m 2 ft. 2 in.
H Height — Ground to Bottom of Counterweight Slabs 2.4 m 7 ft. 10 in.

I Height — Ground to Bottom of Counterweight 3.6 m 11 ft. 10 in.

A B

4100XPC
C

I
H
G

D
F
E

MACHINERY DECK PLAN

CONVERTER AIR COMPRESSOR LUBRICATION ROOM

CABINET LUBE SYSTEM CONTROLS

HOIST HOIST MOTOR

MOTOR
LUBE RESERVOIR
(2270 LITER/600 GAL. GREASE
TRANSFER CABINET 1513 LITER/400 GAL. OGL)

AIR RECEIVER
SWING MOTOR AND ( 908 LITER/240 GAL.)
TRANSMISSION

HOIST MOTOR
REACTIVE POWER ACCESS DOORS
COMPENSATION
HIGH AND LOW VOLTAGE
CABINET
COLLECTORS
(DECK MOUNTED)
HOIST DRUM
SWING
MOTOR AND
TRANSMISSION
MAIN TRANSFORMER
120 VAC
LOAD CENTER
GROUND FAULT,
SUPPRESSION CABINET CENTURION
CONTROL CABINET
FIELD BREAKERS TOUCH SCREEN MONITOR
TRANSFORMER
SECONDARY BREAKERS AUXILIARIES LOAD CENTER

AUXILIARIES
TRANSFORMER MOTOR CONTROL
HIGH VOLTAGE
CENTER
CABINET WITH
ISOLATORS ELECTRONICS ROOM
 GROUND PRESSURE & WEIGHT FEATURES AND CUSTOMIZATION
BEARING AREA - GROUND PRESSURE The 4100XPC is built with several features to enhance safety,
Standard: reliability, and productivity over the lifecycle of the operation.
Crawler Bearing Area 34.58 m2 53,597 in2 • Automatic Lubrication and Compressed Air Systems with
76" Shoes/ 1930mm advanced diagnostic and control
Crawler Ground Pressure 411.1 kPa 59.6 psi • Temperature Monitoring System for all DC motors, drum shaft
76" Shoes/ 1930mm bearings, shipper shaft bearings
• Automatic Boom Soft Setdown System (ABSS) and Boom
Optional:
Profile Protection Envelope to help prevent excessive loading to
Crawler Bearing Area 39.58 m2 61,354 in2
the attachment during operation
87" Shoes/ 2210mm
• Anti-Swing-in-Bank system to reduce excessive side loading on
Crawler Ground Pressure 362.6 kPa 52.6 psi handle and attachement
87" Shoes/ 2210mm • Remote hoist control pendant and hoist rope winch to assist in
safe and efficient rope changeouts
WEIGHTS - APPROXIMATE*
• House Pressurization System to provide filtered air for cooling
Working Weight (with Dipper, Approx. Wt.) and dust repression
76" Shoes/1930mm 1,459,200 kg 3,217,000 lbs
87" Shoes/2210mm 1,463,800 kg 3,227,000 lbs The standard shovel can be customized for local and minesite
specific conditions in the following areas:
Counterweight (Punchings)** 192,300 kg 424,000 lbs
• Operator Cab
* All weights subject to 5% variation. • Climate Control
** To be furnished by customer. • Cold Weather Equipment
• Technology and Software
• Electrical and Mechanical Systems
• Maintenance Systems

LIGHTING
Standard: Metal Halide, 400 W, high intensity discharge (HID)
primary exterior floodlights (11) mounted on the
operator’s cab, RH room, LH room and machinery
house. Halogen, 500 W secondary exterior floodlights
(7) mounted under revolving frame corners, machinery
house and above cab door. Incandescent lights (5)
outside cab and house doors and (1) inside operator’s
cab. Fluorescent lights (23) illuminate interior of the
machinery house, RH and LH room.
Optional: High Pressure Sodium, 400 W or 1000 W primary
exterior floodlights. Secondary exterior floodlight
combination of Halogen, 500 W (3) and fluorescent
lights (6) mounted under revolving frame.

LOADING CONTROL CENTER

SPACE FOR MINE
COMMUNICATIONS
ANTE ROOM EQUIPMENT
(SHOWN WITH
OPTIONAL TOILET)
TOUCHSCREEN GUI
AND OPTIONAL REMOTE
ELECTRICAL CABINET CAMERA SYSTEM

SPACE FOR APPLIANCES

ARMREST MOUNTED,
PISTOL GRIP JOYSTICKS
TRAINER’S STATION

LOCKERS
6-WAY POWER ADJUSTABLE AIR SUSPENSION
STORAGE CABINET SEAT WITH HEAT AND VIBRATORY MASSAGE

NOTE: All designs, specifications and components of equipment described above are subject to change at manufacturer’s sole discretion at any time without
advance notice. Data published herein is informational in nature and shall not be construed to warrant suitability of machine for any particular purpose as
performance may vary with conditions encountered. The only warranty applicable is our standard written warranty for this machine.

P&H Mining Equipment • Box 310 • Milwaukee, Wisconsin 53201 USA

XS-3923-1 2AG-207
 4100XPC TECHNICAL DESCRIPTION
January, 2007

The P&H 4100XPC is a heavy duty electric mining shovel which provides a 115 ton (104.3
metric ton) nominal payload capacity specifically designed to operate in mines for high
productive loading of 190 ton to 400 ton (172 metric ton to 363 metric ton) haul trucks and
larger.

This technical description is provided to compliment the 4100XPC main machine

specification XS-3923 -1.

ELECTRICAL POWER SYSTEM

POWER SUPPLY
Electrical power to the shovel is Customer supplied via a trailing cable. Recommended
SHD-GC trailing cables, for 7,200 volt supply, are:

#2 AWG/35mm² 2800 ft./854m.

#1 AWG/50mm² 3400 ft./1050m.
1/0 AWG/55mm² 4250 ft./1300m.

Electrical equipment on the shovel is designed for an incoming supply of 3 phase, 60 hertz, 7,200
or 13,800 volts. Secondary voltage for auxiliary motors is 3 phase, 60 hertz, 480 volts.
Alternatively, the electrical equipment is designed for an incoming supply of 3 phase, 50 hertz,
6000, 6600, 7200, or 11,000 volts. Secondary voltage for auxiliary motors is 3 phase, 50 hertz,
380 or 415 volts. Recommended 30 MVA, short circuit capacity, at the shovel.

LOWER HIGH VOLTAGE DISCONNECT SWITCH

Electrical power is brought to the shovel by connection of the trailing cable to the lower high
voltage (HV) disconnect switch, which is mounted on the rear of the carbody. A cable coupler is
mounted on this switch and mating PLM coupler is provided for the trailing cable end. The
switch provides a visible disconnect, grounding, and a safety key interlock which energizes or
disconnects electrical power to the entire machine. HV wiring runs from this switch through the
carbody to the HV collector rings on the upper deck. The standard cable coupler is a PLM brand
quick disconnect type. Other coupling styles are available upon request.

HIGH AND LOW VOLTAGE COLLECTOR RINGS

Both the high voltage and low voltage collectors are mounted in one large above deck cabinet.
The HV collector ring cabinet has been configured such that the same basic cabinet can be used

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 Model 4100XPC
Technical Description

for all incoming power supplies up to 13.8 kV. The LV collector rings, which transmit lower
voltage power from the upper to the lower, are deck mounted above the high voltage collectors in
the one assembly above the center gudgeon. Internally mounted lights and viewing windows are
provided for inspection. Doors, which contain the fixed viewing windows, are Kirk key
protected.

UPPER HIGH VOLTAGE DISCONNECT

Fully contained cabinet contains two visible high voltage disconnects to 1) isolate the entire
upper HV supply, and 2) isolate the primary of the Main Transformer, vacuum contactor, line-to-
line and line-to-ground lightning arrestors for surge suppression. Current limiting HV fuses
provide short circuit protection for the primary of the Main Transformer and the primary of the
Auxiliary Transformer

MAIN TRANSFORMER
Designed for mining shovel service, 3000KVA rated, dry type; Delta/Wye connected,
minimizing third harmonic current flow to external circuits, simplified ground fault detection.
Transformer can accommodate unequal loading, has ±5% voltage taps, and temperature
monitored windings. Main Transformer provides power for the Converter Cabinet motion
thyristor bridges which control the power to the DC drive motor armatures and fields. For power
monitoring, a , Multilin MTM-Plus meter module is provided as standard.

AUXILIARY TRANSFORMER
Like the main transformer, the auxiliary transformer is designed for mining shovel service is of
the dry type, and is Delta/Wye connected. It is rated at 435 KVA. Four (4) secondary windings
provide power for:
(1) 60HZ/480 Volts (Alternatively 50HZ/380 or 415 Volts) for utilities and auxiliary motors.
Power from the transformer flows to an Auxiliary Load Center, Auxiliary Cabinet motors.
(2) Shielded winding supply for the Control System
(3) Field supply voltage to the DC drive motor, field power bridges.
(4) Lighting and GPO’s supply, 50 KVA rated, and distributed through the 120 VAC
(alternately 240V) load center

POWER CONVERTER CABINET

The P&H Digital DC power conversion system contains six-thyristor three-phase bridges used to
statically convert AC supply power to controlled DC supply to motion drive motor armatures for
speed and torque regulation. This thyristor bridge inherently allows for invert regenerated DC
energy to AC power during motion deceleration. The regenerated power is used to supply the on
board needs with the excess going back to the mine network for energy savings.

Thyristors are mounted in easily accessible heat sinks and are forced air cooled. A patented fast
acting over-current diverter system senses and limits the over-current to the DC motors
eliminating destructive flash-overs.

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POWER DISTRIBUTION
All High Voltage cables are run in metal conduit. An enclosed overhead copper bus system is
used to carry the current from the main transformer to the converter cabinet. All other wiring is
generally run in raised troughs on the machinery deck floor. Power cables are Hypalon insulated.

REACTIVE POWER COMPENSATION (RPC) SYSTEM

Housed in a rugged, ventilated cabinet, the RPC system contains stepped tuned banks of
capacitors and reactors, automatically and synchronously switched on and off the line to maintain
average system power factor near unity. Tuned banks provide a high level of filtering of the
predominant harmonics generated by the converters. Synchronously applied stepped
compensation eliminates transients during application and disconnection.

TRANSFER CABINET
The transfer cabinet contains heavy duty contactors to transfer the power from the hoist and
crowd converters to the propel motors in the propel mode. Transfer is initiated by a push button
on the console in the operator’s cab with all sequencing handled automatically by the supervisory
control system.

DC DRIVE MOTORS
P&H designed, manufactured, and tested motors are made specifically for mining service duty,
with Class "H" insulating system. Drive motors are equipped with RTD’s to monitor motor
bearings and winding temperatures, and all are equipped with heavy duty blowers with screen
protected air inlets. Optional brush grades are available for unusual operating conditions.

Remote Hoist Pendant Controller included in machinery house with variable speed control to
turn hoist drum during hoist rope changes.

ELECTRICAL CONTROL SYSTEM

P&H CENTURION™ SHOVEL CONTROL SYSTEM
The P&H Centurion™ Shovel Control System provides the supervisory control of the shovel
drives and executes the sequencing and monitoring functions, and consists of the supervisory
control computer and supporting hardware devices and software programs. The system is
comprized of three basic areas which are: 1) the onboard graphical user interface (GUI), 2) the
remote input/output (I/O) devices and communication interface, and 3) the individual drive
controllers.

The architecture provides connectivity from components on the shovel to the onboard GUIs and
provides diagnostic and monitoring capabilities. The application code residing within the
supervisory controller is based on the IEC 61131 standard. The control system uses Profibus over
fiber optic and copper media for communications with the various system components.

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SUPERVISORY CONTROL CABINET

Components for the P&H Centurion™ Shovel Control System are housed in a rugged,
maintenance friendly cabinet, which is located in the RH Electronics room. The drive system for
the P&H TripRite dipper trip system is also housed in the Supervisory Control Cabinet.

LOWER CONTROL CABINET

The lower control cabinet is mounted on the back of the carbody, and contains remote I/O, motor
starters for the propel motor blowers, air solenoid valves for the brakes, and electrical
convenience outlets.

REMOTE I/O’S
The supervisory control system functions with remote I/O in several locations such as lower
propel, LH lube room, RPC cabinet, converter cabinet, transfer cabinet, auxiliary cabinet, and
operators cab.

AUTOMATIC ATTACHMENT PROTECTION SYSTEM

Hoist and crowd/retract limits are set on the GUI touch screen located at the loading control
center in the operator's cab. A boom profiling limit is included to help prevent contact of the
handle torsion box and dipper with boom. The ABSS (Automatic Boom Soft Set-down) feature
is part of the control system and minimizes boom jacking and the associated impact of abruptly
lowering the boom from a jacked condition.

MOTOR CONTROL CENTER (MCC)

A large maintenance friendly cabinet contains individual motor starters and circuit breakers,
which provide thermal and short circuit protection for each motor. For electrical isolation, the
controls for each individual motor are housed in an individual cubicle. In addition to motor
control, there are cubicles to control house heaters and lights. The MCC is located in the
environmentally controlled RH electronics room.

OPERATOR INTERFACE
LOADING CONTROL CAB

The operator is stationed in a roomy cab that is mounted on the right hand side of the machine
above the electrical room. The operator is positioned at a 15 degree angle off of the cab
centerline toward the dipper. Operator has wide view of the dipper and bank and surrounding
loading area. Cab is FOPS (Falling Object Protection System) certified, and has sound level
below 70 dBA while the shovel is operating when the door is closed. A catwalk system provides
access for cleaning, maintenance, or replacement of the windows. Access to the cab roof is
provided via ladder and roof handrails. A single two tone air horn mounted on the RH room is
also included.

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 Model 4100XPC
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All windows are tinted safety glass. The front windows are 0.75 inch / 18 mm thick laminated
safety glass. Side and door windows are fixed in place and made from 0.25 inch / 6 mm
tempered glass. The standard cab features storage lockers, desk/counter space, and provisions for
mounting mine supplied microwave or toaster oven, and a refrigerator. There is a work space
with seat for an operator trainer located behind the operator. A separate room is located behind
the operator cab that can be customized by the mine for additional storage or used for a toilet
room.

LOADING CONTROL CENTER

The P&H Loading Control Center provides a single location of control for shovel operation and
truck loading. The standard seat base is an air suspension type which can be adjusted for
operators height and weight. The seat has an automotive style power system which provides
vertical and fore / aft motion of the seat base relative to the joysticks. The seat has heat, lumbar
support, and massage, and is mounted on a base that has a pivoting, angled footrest that swivels
into two positions based on the operator’s height.

The joystick contollers are Hall-Effect, pistol grip style with both push button, trigger switch, and
rocker switches built into the grips. There is a single console on the left hand side of the operator.
All control devices and most auxiliary devices are located within reach of the seated operator.
An AM/FM radio receiver with 5 disc CD changer is included. The console has provisions for
mounting the standard P&H GUI touch screen as well as optional and mine supplied items such
as camera monitors, radios, and dispatch screens.

GRAPHIC USER INTERFACE (GUI)

The GUI has menus and information screens that allow the operator to display information, and
perform various operation functions. The basic functions performed by the GUI are:
• Display machine operating status
• Display and set hoist and crowd limit setting (boom profiling)
• Provide fault enunciation and alerts
• Display temperature monitoring
• Display boom jacking status
• Display boarding ladder positions
• Display lubrication system settings and status
• Provide for manual initiation of lubrication cycles

STANDARD DIAGNOSTICS
The Centurion GUI provides the following standard diagnostics:
• Standard Temperature Monitoring system - all DC motors (windings and bearings), drum
shaft bearings boom shipper shaft bushings, and ambient air temperature. Graphical
temperature shown on touch screens.
• Drive programming and analysis software to allow maintenance personnel to record and
perform on line diagnostics of main motion drive parameters, settings, and performance.

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 Model 4100XPC
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• Control logic software to allow maintenance personnel to view controller logic program,
verify functions, and force parameters for diagnostic purposes.
• Input/Output (I/O) divice monitioring and fault detection system to identify location and type
of fault.

CLIMATE CONTROL
An optional P&H MineAir Systems MAS 1500 mine duty air conditioner unit is available. A
single unit can be fitted to the operator cab, or two units can be fitted, one for the cab and one for
the electronics room. Each MAS 1500 unit is capable of delivering 14 kW cooling (48000
BTU/Hr), and 18kW heating. Units are fitted with an efficient air filtration system, which
pressurizes the cab and electrical room.

LIGHTING
Primary exterior floodlights: Standard lights are Metal Halide, 400 watt, 60HZ/120V
(alternatively 50HZ/220V), high intensity discharge (HID) units.

Standard primary exterior floodlight locations (nine are wide beam and two very narrow beam)
are as follows:
• Two (2) on front of operator’s cab, below the front window.
• Two (2) on top front of lube room
• Two (2) right side of house
• Two (2) top rear of house
• One (1) on front of house below RH room
• One (1) on front of house below LH room
• One (1) top left side of house

Secondary exterior floodlights: Standard are Halogen, 500 watt units. Standard secondary
exterior floodlight locations are as follows
• One (1) above operator’s cab door
• Two (2) on the lower front of machinery house
• Four (4) under revolving frame corners
Exterior incandescent: Five (5), 100 watt; one (1) at each machinery house door and one (1) at
operator’s cab door.

Interior lighting: Twenty three (23) fluorescent lights are provided to illuminate the machinery
house, RH electrical room and LH lube room.

Operator’s cab lighting: Incandescent 100 watt ceiling light.

ELECTRICAL CONVENIENCE OUTLETS

Electrical outlets for 110/120 volt supply are conveniently located:
• One (1) in lower control box on rear of carbody
• Two (2) Under revolving frame platforms

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 Model 4100XPC
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• Seven (7) In machinery house

• One (1) on RH catwalk
• Two (2) In RH electronics room
• One (1) In LH lube room
• Three (3) In Operator’s cab
• Two (2) On house roof

Outlets are GFI protected. GPO’s are 15 amp, duplex, NEMA 5-15 straight blade devices, 2
pole, 3 wire grounded and 125V rated. Special instrument outlets are located in the Supervisory
Control Cabinet.

Three (3) 60HZ/460V (Alt. 50HZ/380V) outlets are also provided; one (1) in RH electronics
room, one (1) in LH lube room and one (1) in Operator’s cab. These outlets are 20 amp, 3 wire,
4 pole, IEC 309 type. A single welder outlet receptacle (60Hz/460V, alternatively 50Hz/380V) is
provided, located near the RH door in the machinery house.

MECHANICAL SYSTEMS
CRAWLER DRIVE SYSTEM
The P&H DELTA crawler drive system incorporates rugged lug and tumbler sprocket design
concepts, with the tumbler engagement close to the link pin center lines.

CRAWLER SHOES
Deep section, cast manganese shoes are connected with 5 inch alloy steel induction hardened
pins through machined, line-bored holes. Shoes are designed specifically for the P&H DELTA
style drive system. Standard crawler shoes width is 76 inches (1930mm).

CRAWLER FRAMES
The frames are heavy welded box section designs with bolted fit to carbody under full shear
ledge support with large dowels to prevent movement in the bolted connection. There is no field
welding required in the connection. There are eight (8) lower rollers, and a front, and a rear idler
in each frame. The front idler is a large diameter manganese casting mounted on two (2) heavy
duty bushings. Lower rollers and idlers are V-ring sealed to exclude contaminates. Hardened
wear surfaces minimize crawler frame wear. Rollers and idlers are straddle mounted with special
alloy brass bushings. “P&H 50+” lower rollers are hardened to over 50 on the Rockwell C scale.
Replaceable pin-on, high hardness cast slide bars on top of each frame support the crawler shoes.

CARBODY
The carbody is a heavy welded high strength low alloy steel structure of cellular deep box
sections, built around a large center hub casting. The flat-top design with deep section
diaphragm plates provide direct support of the roller path. The carbody interior is painted white
and is equipped with an electrical convenience outlet for trouble light use. Swing gear and lower

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 Model 4100XPC
Technical Description

swing roller path are mounted on the top of the carbody with dowels and bolts. The crawler
frames are connected to the carbody by a full length shear ledge and long rod bolts. Heavy duty
shear dowels prevent crawler frame movement relative to the carbody in the event of significant
loss of clamping force. Both the carbody and crawler frames are designed to withstand the high
level of crawler frame connection bolt tension. The crawler frame connection bolts produce very
high clamping forces between the crawler frame and carbody machined surfaces. The standard
tensioning system for the rod bolts consist of simple bolt and nut arrangement.

DUAL PLANETARY PROPEL SYSTEM

Dual independent P&H DC drive motors rated at 1350hp/1007kW total continuous power at
550V and 1974hp/1472kW total peak developed horsepower, drive the propel system and are
load sharing controlled. Motors are mounted in a propel motor base which is bolted to the rear of
the carbody. Motor frame adjusting screws are integral to the base for ease of alignment, and the
motors are directly connected to P&H planetary propel transmissions with a gear coupling. The
planetary propel transmissions are directly mounted to each crawler frame, and provide
differential speed and counter-rotational steering capability. All gearing is forged, anti-friction
bearing mounted, and all external gears are case hardened and ground. Propel transmissions are
designed with bath and splash lubrication to all gearing and bearings.

The P&H DELTA drive system has a raised final propel drive shaft and tumbler. The final
propel drive shaft is spline connected to the planetary transmission and tumbler, and is mounted
on anti-friction bearings. The outboard spherical bearing is encapsulated to prevent crawler frame
damage in the event of a bearing failure. V-ring seals are used to seal out dirt and seal in
lubricant.

CENTER GUDGEON
The Center Gudgeon is a hollow heavy duty forging used to connect the upper revolving frame to
the lower carbody. Acme threads are provided on the upper and lower end of the gudgeon. The
gudgeon is a cascaded interference type fit in the center hub casting of the carbody. A locking
mechanism on the upper threads allows fine adjustment capabilities and positive retention of nut
position. Gudgeon center hole is used for electrical wiring, lube, and air lines between upper
revolving frame and lower machinery.

REVOLVING FRAME
The revolving frame is a heavy welded high strength low alloy steel structure of cellular deep
box sections built around a large center castingwith an integral structure for mounting dipper
bumpers on the front. The rolled, full depth turret plates align with the swing roller path and
provide 360° direct load transfer. A wide roller path support pad on the underside of the frame
provides a pilot ring to prevent radial movement of the upper path. The counterweight box
mounting face at the rear of the revolving frame is full depth to match counterweight box depth.
Deck machinery is mounted via tapped holes or pin supported and no internal access is required
to mount the machinery. A standard drain system allows for the hoist and swing transmissions to

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 Model 4100XPC
Technical Description

be evacuated through piping to below the revolving frame deck (crowd drains to boom foot
platform).

COUNTERWEIGHT BOX AND CASTINGS

A sectioned counterweight box is mounted to the rear of the revolving frame to accommodate the
counterweight ballast. Large solid castings are mounted to the rear of the counterweight box to
provide a stabilizing moment.

DECK PLAN
Side platforms, which mount to the revolving frame, extend the deck width. A conveniently
arranged floor plan with abundant space facilitates maintenance. Side platform mountings extend
to the full depth of the revolving frame.

ELECTRONICS ROOM (RH ROOM)

A separate large room is mounted on front right corner of the revolving frame and houses the
supervisory control cabinet for the P&H Centurion™ Shovel Control System, as well as auxiliary
cabinets with ample space to mount additional cabinetry. The room is insulated with 1.0
inch/25.4mm material; equipped with 0.75 hp fresh air blower (not used with optional air
conditioner), secondary wall and door air filter, and louvered front wall vent panel. Optionally,
this room can be further environmentally controlled with air conditioning and/or heaters. Three
(3) doors are provided for improved access; one (1) leading to machinery house and one (1) to
outside catwalk and one (1) to the boom foot area. Window in front door allows for front
end/attachment viewing while working in electronics room. RH room also is the support base for
the RH elevated operator’s cab. Removable fiberglass false floor system is provided for ease of
wiring.

LUBRICATION ROOM (LH ROOM)

A separate room is mounted on front left corner of the revolving frame, which houses lube tanks,
pumps, plumbing, and most of the air system components including the receiver. Room is
insulated with 1 inch / 25 mm material with a durable surface that can be cleaned. The room can
be optionally heated for improved cold weather operation. Two (2) doors are provided one (1) to
the outside catwalk and one (1) to the boom foot area. Hinged and removable doors are also
provided for access to the front hoist motor.

MACHINERY HOUSE
Truss style roof with weather tight, removable hatch covers for accessibility to internal
machinery. A constant slope roof and flexible rubber seal system between flexing components
shed water and dirt from the roof. Roof panels are strategically located to direct crane picks of
major deck mounted components as required. Two large Lexan skylights provide light to the
house in the event of power loss to the shovel to aid in egress.

HOUSE PRESSURIZATION AND FILTRATION

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 Model 4100XPC
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The machinery house is pressurized with filtered air to reduce dust ingress and to provide clean
cooling air for components the standard centrifugal inertial filter system. Ambient air is drawn
from the forward facing intake hoods by two large vane axial fans and passes through the filter
panels which removes airborne dust particles and allows the cleaned air to pass through to the
machinery house. Bleed airflow is created by two blowers and carries dirty air through ducts to
the outside at the rear of the house. Clean house air is directed in the rear portion of the
machinery house to provide greater cooling of deck mounted components. Access is provided to
filter and blower units from the house roof.

The 4100XPC shovel can be ordered with an optional Airscrub Pro high efficiency house air
filtration system. The Airscrub Pro system is a cartridge filtration system that is 99.9% efficient
by weight at .3 micron and greater particulate size. The air inlet is located at the top of the unit
and is protected by an expansive rain/snow hood, which limits the ingress of moisture in the air
and dust from the roof into the filters. There are two main 40 hp two-stage blowers that provide
airflow through the filters and into the machinery house. Dirty air is trapped on the outside of
self-cleaning, replaceable filter cartridges while clean airflow continues through the cartridges
and into the machinery house. The filter cartridges are automatically cleaned by regularly timed
blasts of pressurized air. Accumulated dust and dirt on the outside of the cartridges falls into a
hopper and a screw type conveyor automatically carries the dust off the machine and onto the
ground. Filter cartridges are replaceable from the machinery house roof. Access to make fan
blade setting adjustments is achieved through an access door in the outlet duct for the top blades,
and through machinery house for the bottom blades.

COLD WEATHER EQUIPMENT

The RH and LH rooms are equipped with insulation as a standard feature. The air valves for the
lower works are located in the heated lower control cabinet as standard, and the automatic
moisture dump valve for the main air receiver is located in the heated LH lube room as standard.
Heating options are available.

BOARDING AND ACCESS

A right side pneumatic controlled stairway and left side vertical pull-down ladder are interlocked
to de-energize swing and propel functions when in down position for safety. Catwalk/platforms,
with grated metal surface, hand rails, and toe boards are provided in access areas. Roof grating is
mechanically attached to allow removal for roof cleaning. Grating configured to allow natural
drainage without blocking flow thus minimizing how often it has to be removed.

HOIST DRIVE SYSTEM

Dual P&H DC motors rated at 2380hp/1775kW total continuous power at 550V and
3295hp/2458kW total peak developed power drive a modular gearcase pinned to the revolving
frame. First reduction is helical gear set, second reductions spur and a reversible spur drum gear.
All gearing is forged, machined, case hardened and ground. Transmission is oil tight with anti-
friction bearings. The hoist gearcase oil filtration system uses a variable speed, positive
displacement pump to supply filtered oil directly to the nine bearings in the hoist gearcase. Oil is

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 Model 4100XPC
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also dripped over the first reduction gear mesh on each side of the case, for a total of eleven lube
points. The system also includes low oil level sensing and an integral oil cooler to help maintain
acceptable oil viscosity during warm weather operation.

The standard hoist drum is a large 68 inch (1727 mm) pitch diameter drum with through shaft
and flame hardened grooves. Standard hoist rope is 2.75 inch (70 mm) diameter cable fully
plastic impregnated and compacted, for longer life, and can accommodate optional 2.875 inch
(73 mm) diameter ropes. Hoist drum and cable are provided with high capacity Ferrule Beckett
fittings to simplify cable change out. Hoist limits are programmable from operator's cab. Hoist
drum bearings are equipped for temperature monitoring.

HOIST CABLE TUGGER

Dual electric driven tuggers are standard to assist with hoist cable changes and each tugger has
3000 lb.(1361 kg) rated pulling capacity.

SWING DRIVE SYSTEM

Swing power is provided by three (3) series connected P&H DC drive motors rated at
1500hp/1119kW total continuous power at 550V and 2313hp/1725kW total peak developed
power. P&H Planetary transmissions are mounted front and rear of swing gear for even loading.
Some components are interchangeable with first and second reductions in Propel transmissions
minimize parts stocking requirements. Planetary swing transmissions are designed with bath and
splash lubrication for all bearings and gearing. An optional oil filtration system is available.

Swing shafts are mounted on anti-friction bearings and are removable without disturbing the
transmission. Forged swing gear, 17 foot-2 inch/5.23m diameter with a large 14-1/2
inch/368mm tooth face for reduced loading. Swing circle uses a quantity of 55 tapered rollers,
10 inch/254mm in diameter, carried on self-lubricating bushings. Rollers and roller paths are
high alloy, forged, quenched and tempered to a high hardness. Full circle of rollers are in contact
with the 360° upper and 360° lower roller paths, which have a wide mounting surface to the
carbody and revolving frame. Upper path is dual flanged mounted with guarding to retain
mounting hardware in the event of loss, and the lower path is clip mounted to the carbody on the
inner diameter and retained by the ring gear outer diameter. Gear shrouding system prevents
contamination of gear and roller path area, and can be opened to enable inspection of gear and
roller circle.

CENTRALIZED LUBRICATION SYSTEM

An automatic centralized lubrication system is standard and provides metered amounts of
lubricant to major systems, which require grease and open gear lubrication. Lincoln 75:1 ratio air
driven pumps are used. Large lubricant reservoirs are mounted in the lubrication room, and are
equipped with heaters. The tanks are plumbed through the front lube room wall, and have cam
lock fittings to allow filling from the outside of the lubrication room. The grease reservoir is 600
gallon / 2271 liter capacity, and the open gear reservoir is 400 gallon / 1514 liter capacity. There
are level sensors on each reservoir to monitor lubricant quantity. The lubricant level is shown on

4100XPC Detailed Technical Descrption Jan 2007.doc

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 Model 4100XPC
Technical Description

a display unit mounted in the lube room, and on the GUI. The standard centralized lubrication is
a two pump / four zone arrangement. The grease system has two zones, one for the upper and
attachment, and the other for the lower. The open gear system has two zones, one for the
attachment and on covering the ring gear and roller path area. There are pressure sensors at each
major injector grouping to display system pressure on the GUI for alarm and diagnostic purposes.

AIR SYSTEM
Compressed air is provided for lube pumps, lube sprayers, disc brakes, hoist cable tugger, air
operated stairway, horn, and operators seat. Standard air compressor is a Sullair Model ES-8-
30XH, rotary screw type, 30 HP, 95ACFM at 60HZ (77ACFM at 50HZ), floor mounted, with
separate 240 gallon capacity air receiver which is ceiling mounted in the lubrication room. The
ES-8 is designed for cold weather operation.

BRAKES
All motions have disc brakes which are spring set and air release style. Brakes have replaceable
wear surfaces, and a low abrasion, high heat capacity friction material is used. Each brake is
equipped with centering mechanisms to minimize contact of frictional surfaces when brake is
released, and all brakes have electric set/release and wear detection.

BOOM
66 foot-2 inch (20.17m) length set at a 45° angle; welded structure of high strength low alloy
steel for cold weather toughness; extra width and depth for high load capability; 80 inch
(2032mm) pitch diameter point sheaves, split bearing block mounted for maintenance ease.
Boom suspension cables are 4.00 inch (102 mm) structural strand. Integral lifting lugs and wear
resistant side boxes are incorporated. Boom is connected to revolving frame lugs with heavy
duty lubricated pins retained with split collars.

CROWD SYSTEM
Crowd and retract of the dipper is accomplished by one (1) P&H DC motor rated at
720hp/537kW continuous power at 550V and 1162hp/867kW peak developed power. The motor
drives the P&H - POWERBAND "V" BELT - shock absorbing/system to modular, enclosed,
transmission with spur gear reduction to manganese racks and forged, machined and hardened
crowd pinions. A transmission oil filtration system with basket strainers, 20 micron filtration,
pump, and motor is included. V-belt sheaves are fully machined and balanced. Gearing is
forged, case hardened and ground; mounted with encapsulated, pre-adjusted bearings. A self-
adjusting crowd belt-tensioning device is incorporated to eliminate variations in V-belt
adjustment and thus allows an overall reduction in operating belt tension. Adjustment is
automatic with no need for anyone to be on the boom. Single piece saddle blocks are adjusted
with a separate hydraulic jacking tool which also allows for removal of crowd pinions.
Crowd/retract limits are programmable from operator's cab.

DIPPER HANDLE

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 Model 4100XPC
Technical Description

34 foot-1.875 inch (10.41m) effective length; high strength low alloy, cold weather steel; straddle
design, straight legs and large cast manganese racks providing strength for corner tooth digging
loads. Handle geometry enables internal inspection and repair of torsion box area.

DIPPER TRIP
Dipper trip system is a 10HP; brushless DC motor driving planetary gearing to a heavy duty
drum. The solid state drive components for the dipper trip system are located in the supervisory
control cabinet, and are adjustable through the GUI. Both ferrule becket and cable clamp
connection capability is provided for securing dipper trip cable to the drum. Trip line is
connected to dipper latch lever bar via a two part sheave system on the dipper door. An integral
disk brake on the motor sets when not in use.

DIPPER
OPTIMA 100 Plus dippers have been designed specifically for the 4100XPC for a variety of ore,
waste, and overburden applications. Standard equipment on the dippers includes adjustable pitch
braces and P&H Snubrite™ hydraulic snubbers.

PAINT
Standard exterior is P&H Yellow and Black. Yellow on machinery house and operator’s cab.
Black on lower, attachment, catwalks and handrail. (Lower HV disconnect switch is painted
red). Interior of house, RH and LH rooms, carbody, revolving frame, boom and all electrical
cabinet interiors are painted high visibility white.

WEIGHTS
Working weight of the P&H Model 4100XPC with nominal dipper and 76 inch (1930mm) wide
crawler shoes is 3,138,000 lbs. (1,423,129 kg.)

OPTIONAL ITEMS

P&H DIPPER
• P&H Optima 115 Dippers are available to optimize fill factors and payloads in any
application.

ELECTRICAL EQUIPMENT
• High Altitude 3048 - 4270 m / 10000 to 14000 ft main single voltage transformer

NOTE: For dual voltage transformers and other special applications, contact shovel
marketing. Voltages less than 6000V are not applicable for 4100XPC.

LIGHTING
• Primary exterior lighting (11) high pressure sodium, 60Hz, 120V, 400W
• Primary exterior lighting (11) high pressure sodium, 60Hz, 120V, 1000W

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 Model 4100XPC
Technical Description

• Primary exterior lighting (11) high pressure sodium, 50Hz, 220V, 400W
• Primary exterior lighting (11) high pressure sodium, 50Hz, 220V, 1000W
• Primary exterior lighting (11) metal halide, 50Hz, 220V, 400W
• Secondary exterior; (3) Halogen, 500W and (6) Fluorescent under revolving frame

AIR SYSTEM
• Dual (2) Sullair, Model ES-8-30XH rotary screw air compressors with automatic switching,
floor mounted; each with 30HP motor (95 ACFM at 60Hz, 77 ACFM at 50 Hz). One (1)
separate 240 gallon air receiver in lube room.
• Membrane air dryer system for rotary screw air compressor (Note: Only one unit required for
single or dual compressors)
• Air hose reel w/30m/100ft of hose

NOTE: Consult Shovel Marketing for applicability of other compressors.

LUBRICATION SYSTEM
• Wiggins quick fill connectors for lube tanks
• Lube tank pre-filters, one system for open gear tank and one for grease tank.
• Lube tank heaters, open gear and grease tanks.

BOARDING ACCESS
• Left hand air stairway-in place of standard left hand pull down ladder

HOIST CABLE
• 2.875" dia., 376' long 8x37 RLL plastic impregnated compacted

CRAWLER SHOES
• 87" wide, flat manganese with 5" induction hardened pins
• 110" wide (SPECIAL), flat manganese with 5" induction hardened pins

NOTE: For 110" shoes, cleated shoes and any special shoe requirements, contact Shovel
Marketing for lead time and pricing

PAINT
• Color Change using P&H paint spec.
• Customer Logo on machine away from P&H logo and model name, painted, one or two
colors, customer to supply template
• Customer Numbers painted on machine

OPERATOR CAB
• Front window electric wiper and spray wash system

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 Model 4100XPC
Technical Description

• Sliding windows – two sliding windows with screens in place of side trainer and rear window
– 0.25 inch / 6mm tempered tinted glass
• Incinerating toilet system for utility room
• Video Monitoring System (Intec)- four (4) color cameras and two (2) color monitors for blind
spot monitoring - inside and outside of machinery house
• Satellite radio receiver in place of AM/FM/CD (Customer specify XM or Sirius)
• Sun shades, pull down - front window only
• Sun shades, pull down - all windows
• Air Horn - dual two tone mounted on RH electronics and LH lube room
• Electric Horn with adjustable volume - single in place of standard air horn
• Electric Horn with adjustable volume - dual, mounted on RH electronics and LH lube room
in place of standard single air.

CLIMATE CONTROL
• Mine Air Systems unit for operator's cab only; Model MAS 1500, cooling to 48,000 BTU/hr
(14kW), heating to 18kW; with air filter-pressurizer and R407C refrigerant
• Mine Air Systems units for operator's cab and electronics room; two (2) Model MAS 1500
units; cooling to 96,000 BTU/hr. (28 kW) total, heating to 36 kW total; with air filter-
pressurizer and R407C refrigerant (Note: Deletes blower in electronics room)
• Sigma unit for operator's cab only; Model MPV7; cooling to 24,000 BTU/hr. (7kW), heating
7 kW; with air filter-pressurizer and R134a refrigerant
• Sigma unit for operator's cab and electronics room; one Model MPV15; cooling to 15kW,
heating 2-stage 18kW; with air filter-pressurizer and R134a refrigerant (Note: Deletes blower
in electronics room)

NOTE: A/C is mandatory for electronics room in high ambient temperature environments

JIB HOIST
• Swing jib hoist; 8.9 kN / 2,000 lb. capacity mounted outside LH lube room

FIRE SUPPRESSION
• Fire extinguisher, 20lb. dry chemical, Model I-A-20G, (3 standard)

Note: Fire suppression systems are locally contracted by P&H MinePro Services. Typical
systems consist of clean agent suppression system for electrical cabinets, RH room, LH
room, and collector ring assembly.

TRAIL CABLE REEL

• Trail Cable Reel, air drive, level winding, 48" diameter drum
• Trail Cable Reel, hydraulic over electric drive, level winding, 48" diameter drum.
• Mounting material for trail cable reel (air or hydraulic)

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 Model 4100XPC
Technical Description

COLD WEATHER EQUIPMENT

• 2.5cm / 1 inch insulation in machinery house
• 7.5KW heater in operator's cab (not required if Cab AC option is chosen)
• 15 kW heater in RH electrical room
• 20 kW heater in LH lube room
• Strip heaters for main control cabinets
• Strip heaters for main D.C. motors
• Strip heaters for main and auxiliary transformers
• 40 kW machinery house heater, maximum of 3, each

NOTE: Membrane air dryer should be included in cold weather applications.

TECHNOLOGY AND SOFTWARE

• Extended Upper Temperature Monitoring system - standard plus crowd gearcase bearings,
hoist gearcase bearings, swing shaft bearings, upper gearcase oil, and center gudgeon hub.
• Extended Lower Temperature Monitoring system - standard plus final drive bearings and
propel gearcase oil.
• P&H Optidig II operator assist tool that co-ordinates the hoist and crowd motions to prevent
the dipper from stalling while digging.
• Motivator Mode software to modify drive performance and RPC function in order to allow
mine supplied motivator at the trail cable voltage to be used to propel.
• ShoveLink Remote Communications Version I - software for mine supplied computer and
ethernet based communication link. Software allows user to veiw electrical feedback, sensor
information, diagnostics, and GUI screens in real time. Maximum of two (2) users per shovel.
• P&H Payload dipper load weighing system
• P&H Payload Plus dipper load weighing system with auto calibration and NIST calibrated
and certified boom point pin load cell.
• P&H Payload Reporter – Microsoft® SQL server, web-browser based reporting package
produces single or fleet based production reports from Payload Plus data.

MISCELLANEOUS ELECTRICAL
• Electrical Cabinet Filters for RPC and converter cabinets
• Extra Welder Outlet in machinery house, near LH door. 2 max.
• Ground Fault Protection for welder outlets. 3 max.
• Extra Welder Outlet (600V) in machinery house including transformer and ground fault
protection. 4 max.
• Emergency Lighting Unit - six lights total per unit - two (2) on power supply and four (4)
remote mounted - field installed
• Communication System (Gai-Tronics), 3-way, field installed, one on exterior, one in machine
house, and one in operator cab.

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 Model 4100XPC
Technical Description

• Trail Cable Connector Extension with PLM cable coupler to extend trail cable connector to
rear of propel motor base. (Note: Not for use with trail cable reel. Coupler types other than
standard PLM must be specified)

MISCELLANEOUS MECHANICAL
• Central Drain System for hoist and swing transmissions - field installed
• Lube Filtration with 20 micron filter on each swing transmission
• Blower and Brake Removal System in machinery house - field installed
• P&H Air Scrub Pro high efficiency house pressurization system in place of std
• Convex Mirrors - two (2) rectangular 16.50" x 24.75” on front of machine
• Tow Lug, Front of carbody - field installed
• Tow Lugs, Rear, two (2) on rear of carbody - field installed
• Hoist Drum Lock System which provides a mechanical lock to prevent movement of
suspended handle and dipper - field installed
• Slack Hoist Cable Detection system
• Fall Protection Lanyard Attachment points - field installed
• Removable Handrail System for hatch cover openings - field installed
• SuperNut rod bolt connection for crawler frames in place of standard nut.
• HYTORC rod bolt connection for crawler frames in place of standard nut. (Does not include
HYTORC tooling which is required for tensioning)
• Export packing
• Counterweight ballast, 265 lbs./cu.ft. minimum density. Contact product engineering for
ballast amount. Delivered to USA site, DOMESTIC PACKED
• Counterweight ballast, 265 lbs./cu.ft. minimum density. Contact product engineering for
ballast amount. Delivered to USA site, EXPORT PACKED

TOOLS, TEST EQUIPMENT AND ASSEMBLY AIDS

• HYTORC tooling (hydraulic power pack not included)
• For other tools and test equipment including software contact P&H Service Department.

TECHNICAL DOCUMENTATION

• Operator's Manual, CD ROM, (3 std), each extra

• Operator's Manual, hard copy (3 std), each extra
• Mechanical Systems Manual, CD ROM, (3 std), each extra
• Mechanical Systems Manual, color hard copy, each
• Electrical Systems Manual, CD ROM, (3 std), each extra
• Electrical Systems Manual, color hard copy, each
• Parts Manual, hard copy, each (see note below)
• Electrical Data Manual, hard copy, each (see note below)

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 Model 4100XPC
Technical Description

Note: The LinkOne Viewer allows the end user to print individual pages or complete parts
manuals. P&H Mining Equipment grants the end users of its parts manual the authority to
print hard copy manuals as required. Electronic copy can be installed on as many
computers as desired.

Note: Specify English or Spanish language. Consult Peak Services for other language
requirements.

CUSTOMER SUPPLY ITEMS

Unless otherwise stated in a P&H proposal, required items that are not included in our basic
machine supply are:
• Machine erection, including erection tools and equipment
• Counterweight ballast, approximately 424,000 lbs/192,300 kg with a minimum density of
265 lbs. per cubic foot (4,245 kg/m3) (Final counterweight determined by application.)
• Fluids/lubricants
• Trailing cable and electrical power supply.

*****

P&H - An enduring symbol of quality and reliability

NOTE: All designs, specifications and components of equipment described above are subject to change at manufacturer’s
sole discretion at any time without advance notice. Data published herein is informational in nature and shall not be construed to
warrant suitability of machine for any particular purpose as performance may vary with conditions encountered. The only warranty
applicable is our standard written warranty for this machine.

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 DIGITAL DC DRIVE CONTROL

meters

feet
22 72.2

20 65.6

18 59.1

16 52.5

14 45.9

12 39.4

10 32.8

8 26.2

4100XPC
6 19.7

4 13.1

2 6.6

0 0

2 6.6
meters 6 4 2 0 2 4 6 8 10 12 14 16 18 20 22 24
feet 19.7 13.1 6.6 0 6.6 13.1 19.7 26.2 32.8 39.4 45.9 52.5 59.1 65.6 72.2 78.7
C
L ROTATION

WORKING RANGES CAPACITY

Height of Cut 16.8 m 55 ft. 2 in. Nominal Pay Load 108.9 mt 120 st

Radius of Cut 23.9 m 78 ft. 8 in. Nominal Dipper Capacity

SAE struck 61.2 m3 80.0 yd3
Dumping Height* (Door Open) 9.5 m 31 ft. 0 in. SAE 2:1 67.6 m3 88.4 yd3

Floor Level Radius 16.0 m 52 ft. 6 in. Rated Suspended Load 195 mt 215 st

Tail Swing Radius 9.8 m 32 ft. 3 in. Optimum Truck Size 172-363 mt 190-400 st
(400 st truck shown)
Operator Eye Level 10.1 m 33 ft. 1 in.

* Height shown with bail-type dipper. Heights will be greater with

bail-less or compact-bail dippers. Actual dumping height can be
greater than door clearance height.
 ELECTRICAL CONTROL DIPPER & DIPPER TRIP
• Centurion Supervisory Controller provides direct integrated • P&H OPTIMA dippers combine consistent productivity with high
communication with motor drives giving precise motor control and durability and maintainability. Dippers are configured to mine specific
fast cycle times. Real-time multi-tasking capability allows for optimal conditions and capacity requirements from a variety of combinations
machine logic sequencing, monitoring and control. of body and lip designs, as well as other unique P&H technologies.
• Centurion I/O System uses ‘Profibus’ communication protocol Specific wear packages and GET styles can be cooperatively
for seamless integration of all shovel subsystems and future specified.
expandability. Low-voltage 24V DC I/O drop points feature open and • P&H TripRite system utilizes a brushless DC electric motor with
short circuit detection for improved diagnostics and troubleshooting.
sealed planetary drive unit for reliable trip and slack take up
• Centurion Information System’s enhanced Graphical User Interface operation.
(GUI) features intuitive, icon-based screens to display vital
information such as shovel status, troubleshooting information, and
optional production monitoring data and operator feedback.
• P&H Digital DC Drive provides precise, reliable, solid state power to
the main motion motors. HOIST
• All gearing housed in single enclosed gear case with filtered oil
circulation for reliable splash lubrication and ease of maintenance.

ELECTRICAL CONTROL SYSTEMS • Large 68" diameter hoist drum for extended rope bending life.
Ferrule becket system and dual electric tuggers are standard for
P&H DIGITAL DC STATIC DC POWER CONVERSION AND REACTIVE POWER efficient rope change.
COMPENSATION • Spring set air release disc brakes - one per motor.
Hoist**/Propel Swing Crowd/Propel
Continuous
Armature
2x1860 kW 1860 kW 1860 kW
Converter KW
Rating @ 600 VDC*
CROWD
15 Sec. Armature • Powerband V-belt drive between motor and gear case absorbs shock
Converter Current 3700 amp. 3700 amp. 3700 amp. loads.
Rating*
• First and second reduction gearing in enclosed gear case for reliable
Continuous Field splash lubrication, ease of maintenance, and extended component
150 amp. 150 amp. 150 amp.
Converter Rating* life.
* Rated at 600 V and based on outside ambient temperature of 50°C or 122°F. • Twin leg dipper handle with torsion box and rack and pinion drive has
** Cascaded hoist converters. inherent stability in the bank for optimal digging.
P&H DIGITAL DC AUTOMATIC REACTIVE POWER COMPENSATION* • Spring set air release disc brake.
60 Hz. (7 step) 50 Hz (8 step)
Switched Steps +4725 kVAR Total +6000 kVAR Total
* Nominal rating at rated capacitor voltage (600 VAC)
* Rated at 600 V and based on outside ambient temperature of 50°C or 122°F. SWING
** Cascaded hoist converters.

P&H DC FAST RESPONSE MAIN MACHINERY MOTORS • Three modular P&H planetary gear cases of proven design and a
Hoist Motor Continuous rating @ 600 volts Total 2148kW/2880hp single piece forged swing gear transmit torque for fast cycle times.
(Two used) Peak developed power 2770kW/3713hp • Spring set air release disc brakes - one per motor.
Swing Motor Continuous rating @ 550 volts Total 1119kW/1500hp
T
(Three used) Peak developed power 1340kW/1796hp
Crowd Motor Continuous rating @ 550 volts Total 537kW/720hp
(One used) Peak developed power 530kW/710hp
PROPEL
Propel Motor Continuous rating @ 550 volts Total 1074kW/1440hp
(Two used) Peak developed power 1434kW/1922hp • Two rugged P&H planetary gear cases of proven design
independently transmit torque to the drive sprockets, producing
the tractive effort required for fast, efficient propel and positioning
operations.
• P&H DELTA Drive low tension sprocket drive system with heavy
POWER REQUIREMENTS duty cast crawler shoes.
Supply Voltage* 7200 or 13800V 6000, 6600, 7200 or 11000 • Spring set air release disc brakes - one per motor.
3 Phase, 60 Hz 3 Phase, 50 Hz.
Supply Transformer (Minimum) 3750 kVA
Minimum Short Circuit VA Available at Shovel 30 MVA
*Voltage per customer requirements CABLE DATA
TRANSFORMER
Main Armature Transformer 3000 kVA Hoist (wire rope) 73 mm 2.87 in. dia.
Auxiliaries-Field Transformer 450 kVA Suspension (bridge strand) 102 mm 4.00 in. dia.
Control/Lighting Supply Winding 50 kVA
Dipper Trip (wire rope) 19 mm 0.75 in. dia.
Note: Transformer capacities may vary depending on options.
 OVERALL DIMENSIONS
A Width 14.4 m 47 ft. 1 in.
B Length 15.0 m 49 ft. 4 in.
C Height Over Gantry 14.7 m 48 ft. 3 in.
1930 mm (std) 76 in. (std)
D Width of Crawler Shoes
2210 mm 87 in.
E Width of Crawlers (std.) 10.5 m 34 ft. 5 in.
F Length of Crawlers 11.7 m 38 ft. 6 in.
G Ground Clearance 0.7 m 2 ft. 2 in.
H Height — Ground to Bottom of Counterweight Slabs 2.4 m 7 ft. 10 in.

I Height — Ground to Bottom of Counterweight 3.6 m 11 ft. 10 in.

A B

4100XPC
C

I
H
G

D
F
E

MACHINERY DECK PLAN

CONVERTER AIR COMPRESSOR LUBRICATION ROOM

CABINET LUBE SYSTEM CONTROLS

HOIST HOIST MOTOR

MOTOR
LUBE RESERVOIR
(2270 LITER/600 GAL. GREASE
TRANSFER CABINET 1513 LITER/400 GAL. OGL)

AIR RECEIVER
SWING MOTOR AND ( 908 LITER/240 GAL.)
TRANSMISSION

HOIST MOTOR
REACTIVE POWER ACCESS DOORS
COMPENSATION
HIGH AND LOW VOLTAGE
CABINET
COLLECTORS
(DECK MOUNTED)
HOIST DRUM
SWING
MOTOR AND
TRANSMISSION
MAIN TRANSFORMER
120 VAC
LOAD CENTER
GROUND FAULT,
SUPPRESSION CABINET CENTURION
CONTROL CABINET
FIELD BREAKERS TOUCH SCREEN MONITOR
TRANSFORMER
SECONDARY BREAKERS AUXILIARIES LOAD CENTER

AUXILIARIES
TRANSFORMER MOTOR CONTROL
HIGH VOLTAGE
CENTER
CABINET WITH
ISOLATORS ELECTRONICS ROOM
 GROUND PRESSURE & WEIGHT FEATURES AND CUSTOMIZATION
BEARING AREA - GROUND PRESSURE The 4100XPC is built with several features to enhance safety,
Standard: reliability, and productivity over the lifecycle of the operation.
Crawler Bearing Area 34.58 m2 53,597 in2 • Automatic Lubrication and Compressed Air Systems with
76" Shoes/ 1930mm advanced diagnostic and control
Crawler Ground Pressure 418.9 kPa 60.8 psi • Temperature Monitoring System for all DC motors, drum shaft
76" Shoes/ 1930mm bearings, shipper shaft bearings
• Automatic Boom Soft Setdown System (ABSS) and Boom
Optional:
Profile Protection Envelope to help prevent excessive loading to
Crawler Bearing Area 39.58 m2 61,354 in2
the attachment during operation
87" Shoes/ 2210mm
• Anti-Swing-in-Bank system to reduce excessive side loading on
Crawler Ground Pressure 369.5 kPa 53.6 psi handle and attachement
87" Shoes/ 2210mm • Remote hoist control pendant and hoist rope winch to assist in
safe and efficient rope changeouts
WEIGHTS - APPROXIMATE*
• House Pressurization System to provide filtered air for cooling
Working Weight (with Dipper, Approx. Wt.) and dust repression
76" Shoes/1930mm 1,486,900 kg 3,278,000 lbs
87" Shoes/2210mm 1,491,400 kg 3,288,000 lbs The standard shovel can be customized for local and minesite
specific conditions in the following areas:
Counterweight (Punchings)** 204,100 kg 450,000 lbs
• Operator Cab
* All weights subject to 5% variation. • Climate Control
** To be furnished by customer. • Cold Weather Equipment
• Technology and Software
• Electrical and Mechanical Systems
• Maintenance Systems

LIGHTING
Standard: Metal Halide, 400 W, high intensity discharge (HID)
primary exterior floodlights (11) mounted on the
operator’s cab, RH room, LH room and machinery
house. Halogen, 500 W secondary exterior floodlights
(7) mounted under revolving frame corners, machinery
house and above cab door. Incandescent lights (5)
outside cab and house doors and (1) inside operator’s
cab. Fluorescent lights (23) illuminate interior of the
machinery house, RH and LH room.
Optional: High Pressure Sodium, 400 W or 1000 W primary
exterior floodlights. Secondary exterior floodlight
combination of Halogen, 500 W (3) and fluorescent
lights (6) mounted under revolving frame.

LOADING CONTROL CENTER

SPACE FOR MINE
COMMUNICATIONS
ANTE ROOM EQUIPMENT
(SHOWN WITH
OPTIONAL TOILET)
TOUCHSCREEN GUI
AND OPTIONAL REMOTE
ELECTRICAL CABINET CAMERA SYSTEM

SPACE FOR APPLIANCES

ARMREST MOUNTED,
PISTOL GRIP JOYSTICKS
TRAINER’S STATION

LOCKERS
6-WAY POWER ADJUSTABLE AIR SUSPENSION
STORAGE CABINET SEAT WITH HEAT AND VIBRATORY MASSAGE

NOTE: All designs, specifications and components of equipment described above are subject to change at manufacturer’s sole discretion at any time without
advance notice. Data published herein is informational in nature and shall not be construed to warrant suitability of machine for any particular purpose as
performance may vary with conditions encountered. The only warranty applicable is our standard written warranty for this machine.

P&H Mining Equipment • Box 310 • Milwaukee, Wisconsin 53201 USA

XS-4189 2AG-207
 4100XPC TECHNICAL DESCRIPTION
120 ton Payload Specification
January, 2007

The P&H 4100XPC is a heavy duty electric mining shovel which under this specification
provides a 120 ton (108.9 metric ton) nominal payload capacity specifically designed to operate
in mines for high productive loading of 240 ton to 400 ton (218 metric ton to 363 metric ton)
haul trucks and larger.

This technical description is provided to compliment the 4100XPC main machine

specification XS-4189.

ELECTRICAL POWER SYSTEM

POWER SUPPLY
Electrical power to the shovel is Customer supplied via a trailing cable. Recommended
SHD-GC trailing cables, for 7,200 volt supply, are:

#2 AWG/35mm² 2800 ft./854m.

#1 AWG/50mm² 3400 ft./1050m.
1/0 AWG/55mm² 4250 ft./1300m.

Electrical equipment on the shovel is designed for an incoming supply of 3 phase, 60 hertz, 7,200
or 13,800 volts. Secondary voltage for auxiliary motors is 3 phase, 60 hertz, 480 volts.
Alternatively, the electrical equipment is designed for an incoming supply of 3 phase, 50 hertz,
6000, 6600, 7200, or 11,000 volts. Secondary voltage for auxiliary motors is 3 phase, 50 hertz,
380 or 415 volts. Recommended 30 MVA, short circuit capacity, at the shovel.

LOWER HIGH VOLTAGE DISCONNECT SWITCH

Electrical power is brought to the shovel by connection of the trailing cable to the lower high
voltage (HV) disconnect switch, which is mounted on the rear of the carbody. A cable coupler is
mounted on this switch and mating PLM coupler is provided for the trailing cable end. The
switch provides a visible disconnect, grounding, and a safety key interlock which energizes or
disconnects electrical power to the entire machine. HV wiring runs from this switch through the
carbody to the HV collector rings on the upper deck. The standard cable coupler is a PLM brand
quick disconnect type. Other coupling styles are available upon request.

HIGH AND LOW VOLTAGE COLLECTOR RINGS

 Model 4100XPC 120 Ton Payload
Technical Description

Both the high voltage and low voltage collectors are mounted in one large above deck cabinet.
The HV collector ring cabinet has been configured such that the same basic cabinet can be used
for all incoming power supplies up to 13.8 kV. The LV collector rings, which transmit lower
voltage power from the upper to the lower, are deck mounted above the high voltage collectors in
the one assembly above the center gudgeon. Internally mounted lights and viewing windows are
provided for inspection. Doors, which contain the fixed viewing windows, are Kirk key
protected.

UPPER HIGH VOLTAGE DISCONNECT

Fully contained cabinet contains two visible high voltage disconnects to 1) isolate the entire
upper HV supply, and 2) isolate the primary of the Main Transformer, vacuum contactor, line-to-
line and line-to-ground lightning arrestors for surge suppression. Current limiting HV fuses
provide short circuit protection for the primary of the Main Transformer and the primary of the
Auxiliary Transformer

MAIN TRANSFORMER
Designed for mining shovel service, 3000KVA rated, dry type; Delta/Wye connected,
minimizing third harmonic current flow to external circuits, simplified ground fault detection.
Transformer can accommodate unequal loading, has ±5% voltage taps, and temperature
monitored windings. Main Transformer provides power for the Converter Cabinet motion
thyristor bridges which control the power to the DC drive motor armatures and fields. For power
monitoring, a , Multilin MTM-Plus meter module is provided as standard.

AUXILIARY TRANSFORMER
Like the main transformer, the auxiliary transformer is designed for mining shovel service is of
the dry type, and is Delta/Wye connected. It is rated at 435 KVA. Four (4) secondary windings
provide power for:
(1) 60HZ/480 Volts (Alternatively 50HZ/380 or 415 Volts) for utilities and auxiliary motors.
Power from the transformer flows to an Auxiliary Load Center, Auxiliary Cabinet motors.
(2) Shielded winding supply for the Control System
(3) Field supply voltage to the DC drive motor, field power bridges.
(4) Lighting and GPO’s supply, 50 KVA rated, and distributed through the 120 VAC
(alternately 240V) load center

POWER CONVERTER CABINET

The P&H Digital DC power conversion system contains six-thyristor three-phase bridges used to
statically convert AC supply power to controlled DC supply to motion drive motor armatures for
speed and torque regulation. This thyristor bridge inherently allows for invert regenerated DC
energy to AC power during motion deceleration. The regenerated power is used to supply the on
board needs with the excess going back to the mine network for energy savings.

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Thyristors are mounted in easily accessible heat sinks and are forced air cooled. A patented fast
acting over-current diverter system senses and limits the over-current to the DC motors
eliminating destructive flash-overs.

POWER DISTRIBUTION
All High Voltage cables are run in metal conduit. An enclosed overhead copper bus system is
used to carry the current from the main transformer to the converter cabinet. All other wiring is
generally run in raised troughs on the machinery deck floor. Power cables are Hypalon insulated

REACTIVE POWER COMPENSATION (RPC) SYSTEM

Housed in a rugged, ventilated cabinet, the RPC system contains stepped tuned banks of
capacitors and reactors, automatically and synchronously switched on and off the line to maintain
average system power factor near unity. Tuned banks provide a high level of filtering of the
predominant harmonics generated by the converters. Synchronously applied stepped
compensation eliminates transients during application and disconnection.

TRANSFER CABINET
The transfer cabinet contains heavy duty contactors to transfer the power from the hoist and
crowd converters to the propel motors in the propel mode. Transfer is initiated by a push button
on the console in the operator’s cab with all sequencing handled automatically by the supervisory
control system.

DC DRIVE MOTORS
P&H designed, manufactured, and tested motors are made specifically for mining service duty,
with Class "H" insulating system. Drive motors are equipped with RTD’s to monitor motor
bearings and winding temperatures, and all are equipped with heavy duty blowers with screen
protected air inlets. Optional brush grades are available for unusual operating conditions.

Remote Hoist Pendant Controller included in machinery house with variable speed control to
turn hoist drum during hoist rope changes.

ELECTRICAL CONTROL SYSTEM

P&H CENTURION™ SHOVEL CONTROL SYSTEM
The P&H Centurion™ Shovel Control System provides the supervisory control of the shovel
drives and executes the sequencing and monitoring functions, and consitsts of the supvisory
control computer and supporting hardware devices and software programs. The system is
comprized of three basic areas which are: 1) the onboard graphical user interface (GUI), 2) the
remote input/output (I/O) devices and communication interface, and 3) the individual drive
controllers.

The architecture provides connectivity from components on the shovel to the onboard GUIs and
provides diagnostic and monitoring capabilities. The application code residing within the

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supervisory controller is based on the IEC 61131 standard. The control system uses Profibus over
fiber optic and copper media for communications with the various system components.

SUPERVISORY CONTROL CABINET

Components for the P&H Centurion™ Shovel Control System are housed in a rugged,
maintenance friendly cabinet, which is located in the RH Electronics room. The drive system for
the P&H TripRite dipper trip system is also housed in the Supervisory Control Cabinet.

LOWER CONTROL CABINET

The lower control cabinet is mounted on the back of the carbody, and contains remote I/O, motor
starters for the propel motor blowers, air solenoid valves for the brakes, and electrical
convenience outlets.

REMOTE I/O’S
The supervisory control system functions with remote I/O in several locations such as lower
propel, LH lube room, RPC cabinet, converter cabinet, transfer cabinet, auxiliary cabinet, and
operators cab.

AUTOMATIC ATTACHMENT PROTECTION SYSTEMS

Hoist and crowd/retract limits are set on the GUI touch screen located at the loading control
center in the operator's cab. A boom profiling limit is included to help prevent contact of the
handle torsion box and dipper with boom. The ABSS (Automatic Boom Soft Set-down) feature
is part of the control system and minimizes boom jacking and the associated impact of abruptly
lowering the boom from a jacked condition.

MOTOR CONTROL CENTER (MCC)

A large maintenance friendly cabinet contains individual motor starters and circuit breakers,
which provide thermal and short circuit protection for each motor. For electrical isolation, the
controls for each individual motor are housed in an individual cubicle. In addition to motor
control, there are cubicles to control house heaters and lights. The MCC is located in the
environmentally controlled RH electronics room.

OPERATOR INTERFACE
LOADING CONTROL CAB

The operator is stationed in a roomy cab that is mounted on the right hand side of the machine
above the electrical room. The operator is positioned at a 15 degree angle off of the cab
centerline toward the dipper. Operator has wide view of the dipper and bank and surrounding
loading area. Cab is FOPS (Falling Object Protection System) certified, and has sound level
below 70 dBA while the shovel is operating when the door is closed. A catwalk system provides
access for cleaning, maintenance, or replacement of the windows. Access to the cab roof is

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provided via ladder and roof handrails. A single two tone air horn mounted on the RH room is
also included.

All windows are tinted safety glass. The front windows are 0.75 inch / 18 mm thick laminated
safety glass. Side and door windows are fixed in place and made from 0.25 inch / 6 mm
tempered glass. The standard cab features storage lockers, desk/counter space, and provisions for
mounting mine supplied microwave or toaster oven, and a refrigerator. There is a work space
with seat for an operator trainer located behind the operator. A separate room is located behind
the operator cab that can be customized by the mine for additional storage or used for a toilet
room.

LOADING CONTROL CENTER

The P&H Loading Control Center provides a single location of control for shovel operation and
truck loading. The standard seat base is an air suspension type which can be adjusted for
operators height and weight. The seat has an automotive style power system which provides
vertical and fore / aft motion of the seat base relative to the joysticks. The seat has heat, lumbar
support, and massage, and is mounted on a base that has a pivoting, angled footrest that swivels
into two positions based on the operator’s height.

The joystick contollers are Hall-Effect, pistol grip style with both push button, trigger switch, and
rocker switches built into the grips. There is a single console on the left hand side of the operator.
All control devices and most auxiliary devices are located within reach of the seated operator.
An AM/FM radio receiver with 5 disc CD changer is included. The console has provisions for
mounting the standard P&H GUI touch screen as well as optional and mine supplied items such
as camera monitors, radios, and dispatch screens.

GRAPHIC USER INTERFACE (GUI)

The GUI has menus and information screens that allow the operator to display information, and
perform various operation functions. The basic functions performed by the GUI are:
• Display machine operating status
• Display and set hoist and crowd limit setting (boom profiling)
• Provide fault enunciation and alerts
• Display temperature monitoring
• Display boom jacking status
• Display boarding ladder positions
• Display lubrication system settings and status
• Provide for manual initiation of lubrication cycles

STANDARD DIAGNOSTICS, TECHNOLOGY AND SOFTWARE

• P&H Payload Plus dipper load weighing system with auto calibration and NIST calibrated
and certified boom point pin load cell.

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• P&H Optidig II operator assist tool that co-ordinates the hoist and crowd motions to prevent
the dipper from stalling while digging.
• Extended Upper and Lower Temperature Monitoring system - all DC motors (windings and
bearings), drum shaft bearings boom shipper shaft bushings, ambient air temperature, crowd
gearcase bearings, hoist gearcase bearings, swing shaft bearings, upper gearcase oil, center
gudgeon hub, final drive bearings and propel gearcase oil. Graphical temperature display
shown on touch screens.
• Drive programming and analysis software to allow maintenance personnel to record and
perform on line diagnostics of of main motion drive paramerters, settings, and performance.
• Control logic software to allow maintenace personnel to view conroller logic program, verify
functions, and force parameters for diagnostic purposes.
• Input/Output (I/O) divice monitioring and fault detection system to identify location and type
of fault.

CLIMATE CONTROL
An optional P&H MineAir Systems MAS 1500 mine duty air conditioner unit is available. A
single unit can be fitted to the operator cab, or two units can be fitted, one for the cab and one for
the electronics room. Each MAS 1500 unit is capable of delivering 14 kW cooling (48000
BTU/Hr), and 18kW heating. Units are fitted with an efficient air filtration system, which
pressurizes the cab and electrical room.

LIGHTING
Primary exterior floodlights: Standard lights are Metal Halide, 400 watt, 60HZ/120V
(alternatively 50HZ/220V), high intensity discharge (HID) units.

Standard primary exterior floodlight locations (nine are wide beam and two very narrow beam)
are as follows:
• Two (2) on front of operator’s cab, below the front window.
• Two (2) on top front of lube room
• Two (2) right side of house
• Two (2) top rear of house
• One (1) top left side of house

Secondary exterior floodlights: Standard are Halogen, 500 watt units. Standard secondary
exterior floodlight locations are as follows
• One (1) above operator’s cab door
• Two (2) on the lower front of machinery house
• Four (4) under revolving frame corners
Exterior incandescent: Five (5), 100 watt; one (1) at each machinery house door and one (1) at
operator’s cab door.

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Interior lighting: Twenty three (23) fluorescent lights are provided to illuminate the machinery
house, RH electrical room and LH lube room.

Operator’s cab lighting: Incandescent 100 watt ceiling light.

ELECTRICAL CONVENIENCE OUTLETS

Electrical outlets for 110/120 volt supply are conveniently located:
• One (1) in lower control box on rear of carbody
• Two (2) Under revolving frame platforms
• Seven (7) In machinery house
• One (1) on RH catwalk
• Two (2) In RH electronics room
• One (1) In LH lube room
• Three (3) In Operator’s cab
• Two (2) On house roof

Outlets are GFI protected. GPO’s are 15 amp, duplex, NEMA 5-15 straight blade devices, 2
pole, 3 wire grounded and 125V rated. Special instrument outlets are located in the Supervisory
Control Cabinet.

Three (3) 60HZ/460V (Alt. 50HZ/380V) outlets are also provided; one (1) in RH electronics
room, one (1) in LH lube room and one (1) in Operator’s cab. These outlets are 20 amp, 3 wire,
4 pole, IEC 309 type. A single welder outlet receptacle (60Hz/460V, alternatively 50Hz/380V) is
provided, located near the RH door in the machinery house.

MECHANICAL SYSTEMS
CRAWLER DRIVE SYSTEM
The P&H DELTA crawler drive system incorporates rugged lug and tumbler sprocket design
concepts, with the tumbler engagement close to the link pin center lines.

CRAWLER SHOES
Deep section, cast manganese shoes are connected with 5 inch alloy steel induction hardened
pins through machined, line-bored holes. Shoes are designed specifically for the P&H DELTA
style drive system. Standard crawler shoes width is 76 inches (1930mm).

CRAWLER FRAMES
The frames are heavy welded box section designs with bolted fit to carbody under full shear
ledge support with large dowels to prevent movement in the bolted connection. There is no field
welding required in the connection. There are eight (8) lower rollers, and a front, and a rear idler
in each frame. The front idler is a large diameter manganese casting mounted on two (2) heavy
duty bushings. Lower rollers and idlers are V-ring sealed to exclude contaminates. Hardened

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wear surfaces minimize crawler frame wear. Rollers and idlers are straddle mounted with special
alloy brass bushings. “P&H 50+” lower rollers are hardened to over 50 on the Rockwell C scale.
Replaceable pin-on, high hardness cast slide bars on top of each frame support the crawler shoes.

CARBODY
The carbody is a heavy welded high strength low alloy steel structure of cellular deep box
sections, built around a large center hub casting. The flat-top design with deep section
diaphragm plates provide direct support of the roller path. The carbody interior is painted white
and is equipped with an electrical convenience outlet for trouble light use. Swing gear and lower
swing roller path are mounted on the top of the carbody with dowels and bolts. The crawler
frames are connected to the carbody by a full length shear ledge and long rod bolts. Heavy duty
shear dowels prevent crawler frame movement relative to the carbody in the event of significant
loss of clamping force. Both the carbody and crawler frames are designed to withstand the high
level of crawler frame connection bolt tension. The crawler frame connection bolts produce very
high clamping forces between the crawler frame and carbody machined surfaces. The standard
tensioning system for the rod bolts consist of simple bolt and nut arrangement.

DUAL PLANETARY PROPEL SYSTEM

Dual independent P&H DC drive motors rated at 1350hp/1007kW total continuous power at
550V and 1974hp/1472kW total peak developed horsepower, drive the propel system and are
load sharing controlled. Motors are mounted in a propel motor base which is bolted to the rear of
the carbody. Motor frame adjusting screws are integral to the base for ease of alignment, and the
motors are directly connected to P&H planetary propel transmissions with a gear coupling. The
planetary propel transmissions are directly mounted to each crawler frame, and provide
differential speed and counter-rotational steering capability. All gearing is forged, anti-friction
bearing mounted, and all external gears are case hardened and ground. Propel transmissions are
designed with bath and splash lubrication to all gearing and bearings.

The P&H DELTA drive system has a raised final propel drive shaft and tumbler. The final
propel drive shaft is spline connected to the planetary transmission and tumbler, and is mounted
on anti-friction bearings. The outboard spherical bearing is encapsulated to prevent crawler frame
damage in the event of a bearing failure. V-ring seals are used to seal out dirt and seal in
lubricant.

CENTER GUDGEON
The Center Gudgeon is a hollow heavy duty forging used to connect the upper revolving frame to
the lower carbody. Acme threads are provided on the upper and lower end of the gudgeon. The
gudgeon is a cascaded interference type fit in the center hub casting of the carbody. A locking
mechanism on the upper threads allows fine adjustment capabilities and positive retention of nut
position. Gudgeon center hole is used for electrical wiring, lube, and air lines between upper
revolving frame and lower machinery.

REVOLVING FRAME

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The revolving frame is a heavy welded high strength low alloy steel structure of cellular deep
box sections built around a large center casting with an integral structure for mounting dipper
bumpers on the front. The rolled, full depth turret plates align with the swing roller path and
provide 360° direct load transfer. A wide roller path support pad on the underside of the frame
provides a pilot ring to prevent radial movement of the upper path. The counterweight box
mounting face at the rear of the revolving frame is full depth to match counterweight box depth.
Deck machinery is mounted via tapped holes or pin supported and no internal access is required
to mount the machinery. A standard drain system allows for the hoist and swing transmissions to
be evacuated through piping to below the revolving frame deck (crowd drains to boom foot
platform).

COUNTERWEIGHT BOX AND CASTINGS

A sectioned counterweight box is mounted to the rear of the revolving frame to accommodate the
counterweight ballast. Large solid castings are mounted to the rear of the counterweight box to
provide a stabilizing moment.

DECK PLAN
Side platforms, which mount to the revolving frame, extend the deck width. A conveniently
arranged floor plan with abundant space facilitates maintenance. Side platform mountings extend
to the full depth of the revolving frame.

ELECTRONICS ROOM (RH ROOM)

A separate large room is mounted on front right corner of the revolving frame and houses the
supervisory control cabinet for the P&H Centurion™ Control System, as well as auxiliary
cabinets with ample space to mount additional cabinetry. The room is insulated with 1.0
inch/25.4mm material; equipped with 0.75 hp fresh air blower (not used with optional air
conditioner), secondary wall and door air filter, and louvered front wall vent panel. Optionally,
this room can be further environmentally controlled with air conditioning and/or heaters. Three
(3) doors are provided for improved access; one (1) leading to machinery house and one (1) to
outside catwalk and one (1) to the boom foot area. Window in front door allows for front
end/attachment viewing while working in electronics room. RH room also is the support base for
the RH elevated operator’s cab. Removable fiberglass false floor system is provided for ease of
wiring.

LUBRICATION ROOM (LH ROOM)

A separate room is mounted on front left corner of the revolving frame, which houses lube tanks,
pumps, plumbing, and most of the air system components including the receiver. Room is
insulated with 1 inch / 25 mm material with a durable surface that can be cleaned. The room can
be optionally heated for improved cold weather operation. Two (2) doors are provided one (1) to
the outside catwalk and one (1) to the boom foot area. Hinged and removable doors are also
provided for access to the front hoist motor.

MACHINERY HOUSE

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Truss style roof with weather tight, removable hatch covers for accessibility to internal
machinery. A constant slope roof and flexible rubber seal system between flexing components
shed water and dirt from the roof. Roof panels are strategically located to direct crane picks of
major deck mounted components as required. Two large Lexan skylights provide light to the
house in the event of power loss to the shovel to aid in egress.

AIRSCRUB PRO HOUSE AIR FILTRATION AND PRESSURIZATION

The Airscrub Pro high efficiency filtration system cleans and pressurizes the air in the machinery
house. The Airscrub Pro system is a cartridge filtration system that is 99.9% efficient by weight
at .3 micron and greater particulate size. The air inlet is located at the top of the unit and is
protected by an expansive rain/snow hood, which limits the ingress of moisture in the air and
dust from the roof into the filters. There are two main 40 hp two-stage blowers that provide
airflow through the filters and into the machinery house. Dirty air is trapped on the outside of
self-cleaning, replaceable filter cartridges while clean airflow continues through the cartridges
and into the machinery house. The clean air duct is equipped with a pressure transducer that
measures the pressure drop across the filters. When the pressure drop across the filters indicates
that the filters are dirty, the filter cartridges are automatically cleaned by blasts of pressurized air.
Accumulated dust and dirt on the outside of the cartridges falls into a hopper and a screw type
conveyor automatically carries the dust off the machine and onto the ground. Filter cartridges are
replaceable from the machinery house roof. Access to make fan blade setting adjustments is
achieved through an access door in the outlet duct for the top blades, and through machinery
house for the bottom blades.

COLD WEATHER EQUIPMENT

The RH and LH rooms are equipped with insulation as a standard feature. The air valves for the
lower works are located in the heated lower control cabinet as standard, and the automatic
moisture dump valve for the main air receiver is located in the heated LH lube room as standard.
Heating options are available.

BOARDING AND ACCESS

A right side pneumatic controlled stairway and left side vertical pull-down ladder are interlocked
to de-energize swing and propel functions when in down position for safety. Catwalk/platforms,
with grated metal surface, hand rails, and toe boards are provided in access areas. Roof grating is
mechanically attached to allow removal for roof cleaning. Grating configured to allow natural
drainage without blocking flow thus minimizing how often it has to be removed.

HOIST DRIVE SYSTEM

Dual P&H DC motors rated at 2884hp/2152kW total continuous power at 600V and
3873hp/2889W total peak developed power drive a modular gearcase pinned to the revolving
frame. First reduction is helical gear set, second reductions spur and a reversible spur drum gear.
All gearing is forged machined, case hardened and ground. Transmission is oil tight with anti-
friction bearings. The hoist gearcase oil filtration system uses a variable speed, positive

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displacement pump to supply filtered oil directly to the nine bearings in the hoist gearcase. Oil is
also dripped over the first reduction gear mesh on each side of the case, for a total of eleven lube
points. The system also includes an integral oil cooler to help maintain acceptable oil viscosity
during warm weather operation.

The standard hoist drum is a large 68 inch (1727 mm) pitch diameter drum with through shaft
and flame hardened grooves. Hoist rope diameter on the 120 ton payload machine is 2.875 inch
(73 mm) cable fully plastic impregnated and compacted, for longer life. Hoist drum and cable
are provided with high capacity Ferrule Beckett fittings to simplify cable change out. Hoist limits
are programmable from operator's cab. Hoist drum bearings are equipped for temperature
monitoring.

HOIST CABLE TUGGER

Dual electric driven tuggers are standard to assist with hoist cable changes and each tugger has
3000 lb.(1361 kg) rated pulling capacity..

SWING DRIVE SYSTEM

Swing power is provided by three (3) series connected P&H DC drive motors rated at
1500hp/1119kW total continuous power at 550V and 2313hp/1725kW total peak developed
power. P&H Planetary transmissions are mounted front and rear of swing gear for even loading.
The swing transmissions are designed with bath and splash lubrication for all bearings and
gearing. An oil filtration system with basket strainers, 20 micron filter, pump, and motor is
included on each transmission. Some components are interchangeable with first and second
reductions in Propel transmissions minimize parts stocking requirements.

Swing shafts are mounted on anti-friction bearings and are removable without disturbing the
transmission. Forged swing gear, 17 foot-2 inch/5.23m diameter with a large 14-1/2
inch/368mm tooth face for reduced loading. Swing circle uses a quantity of 55 tapered rollers,
10 inch/254mm in diameter, carried on self-lubricating bushings. Rollers and roller paths are
high alloy, forged, quenched and tempered to a high hardness. Full circle of rollers are in contact
with the 360° upper and 360° lower roller paths, which have a wide mounting surface to the
carbody and revolving frame. Upper path is dual flanged mounted with guarding to retain
mounting hardware in the event of loss, and the lower path is clip mounted to the carbody on the
inner diameter and retained by the ring gear outer diameter.. Gear shrouding system prevents
contamination of gear and roller path area, and can be opened to enable inspection of gear and
roller circle.

CENTRALIZED LUBRICATION SYSTEM

An automatic centralized lubrication system is standard and provides metered amounts of
lubricant to major systems, which require grease and open gear lubrication. Lincoln 75:1 ratio air
driven pumps are used. Large lubricant reservoirs are mounted in the lubrication room, and are
equipped with heaters. The tanks are plumbed through the front lube room wall, and have cam
lock fittings to allow filling from the outside of the lubrication room. The grease reservoir is 600

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gallon / 2271 liter capacity, and the open gear reservoir is 400 gallon / 1514 liter capacity. There
are level sensors on each reservoir to monitor lubricant quantity. The lubricant level is shown on
a display unit mounted in the lube room, and on the GUI. The standard centralized lubrication is
a two pump / four zone arrangement. The grease system has two zones, one for the upper and
attachment, and the other for the lower. The open gear system has two zones, one for the
attachment and on covering the ring gear and roller path area. There are pressure sensors at each
major injector grouping to display system pressure on the GUI for alarm and diagnostic purposes.

AIR SYSTEM
Compressed air is provided for lube pumps, lube sprayers, disc brakes, hoist cable tugger, air
operated stairway, horn, and operators seat. Standard air compressor is a Sullair Model ES-8-
30XH, rotary screw type, 30 HP, 95ACFM at 60HZ (77ACFM at 50HZ), floor mounted, with
separate 240 gallon capacity air receiver which is ceiling mounted in the lubrication room. The
ES-8 is designed for cold weather operation.

BRAKES
All motions have disc brakes which are spring set and air release style. Brakes have replaceable
wear surfaces, and a low abrasion, high heat capacity friction material is used. Each brake is
equipped with centering mechanisms to minimize contact of frictional surfaces when brake is
released, and all brakes have electric set/release and wear detection.

BOOM
66 foot-2 inch (20.17m) length set at a 45° angle; welded structure of high strength low alloy
steel for cold weather toughness; extra width and depth for high load capability; 80 inch
(2032mm) pitch diameter point sheaves, split bearing block mounted for maintenance ease.
Boom suspension cables are 4.00 inch (102 mm) structural strand. Integral lifting lugs and wear
resistant side boxes are incorporated. Boom is connected to revolving frame lugs with heavy
duty lubricated pins retained with split collars.

CROWD SYSTEM
Crowd and retract of the dipper is accomplished by one (1) P&H DC motor rated at
675hp/504kW continuous power at 550V and 1162hp/867kW peak developed power. The motor
drives the P&H - POWERBAND "V" BELT - shock absorbing/system to modular, enclosed,
transmission with spur gear reduction to manganese racks and forged, machined and hardened
crowd pinions. A transmission oil filtration system with basket strainers, 20 micron filtration,
pump, and motor is included. V-belt sheaves are fully machined and balanced. Gearing is
forged, case hardened and ground; mounted with encapsulated, pre-adjusted bearings. A self-
adjusting crowd belt-tensioning device is incorporated to eliminate variations in V-belt
adjustment and thus allows an overall reduction in operating belt tension. Adjustment is
automatic with no need for anyone to be on the boom. Single piece saddle blocks are adjusted
with a separate hydraulic jacking tool which also allows for removal of crowd pinions.
Crowd/retract limits programmable from operator's cab.

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DIPPER HANDLE
34 foot-1.875 inch (10.41m) effective length; high strength low alloy, cold weather steel; straddle
design, straight legs and large cast manganese racks providing strength for corner tooth digging
loads. Handle geometry enables internal inspection and repair of torsion box area.

DIPPER TRIP
Dipper trip system is a 10HP; brushless DC motor driving planetary gearing to a heavy duty
drum. The solid state drive components for the dipper trip system are located in the supervisory
control cabinet, and are adjustable through the GUI. Both ferrule becket and cable clamp
connection capability is provided for securing dipper trip cable to the drum. Trip line is
connected to dipper latch lever bar via a two part sheave system on the dipper door. An integral
disk brake on the motor sets when not in use.

DIPPER
OPTIMA 120 dippers have been designed specifically for coal overburden applications.
Standard equipment on the dippers include adjustable pitch braces and P&H Snubrite™
hydraulic snubbers.

PAINT
Standard exterior is P&H Yellow and Black. Yellow on machinery house and operator’s cab.
Black on lower, attachment, catwalks and handrail. (Lower HV disconnect switch is painted
red). Interior of house, RH and LH rooms, carbody, revolving frame, boom and all electrical
cabinet interiors are painted high visibility white.

WEIGHTS
Working weight of the P&H Model 4100XPC with nominal dipper and 76 inch (1930mm) wide
crawler shoes is 3,138,000 lbs. (1,423,129 kg.)

OPTIONAL ITEMS
ELECTRICAL EQUIPMENT
• High Altitude 3048 - 4270 m / 10000 to 14000 ft main single voltage transformer.

NOTE: For dual voltage transformers and other special applications, contact shovel
marketing. Voltages less than 6000V are not applicable for 4100XPC.

LIGHTING
• Primary exterior lighting (11) high pressure sodium, 60Hz, 120V, 400W
• Primary exterior lighting (11) high pressure sodium, 60Hz, 120V, 1000W
• Primary exterior lighting (11) high pressure sodium, 50Hz, 220V, 400W
• Primary exterior lighting (11) high pressure sodium, 50Hz, 220V, 1000W
• Primary exterior lighting (11) metal halide, 50Hz, 220V, 400W

4100XPC 120 Ton Payload Detailed Technical Description Jan 2007

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 Model 4100XPC 120 Ton Payload
Technical Description

• Secondary exterior; (3) Halogen, 500W and (6) Fluorescent under revolving frame

AIR SYSTEM
• Dual (2) Sullair, Model ES-8-30XH rotary screw air compressors with automatic switching,
floor mounted; each with 30HP motor (95 ACFM at 60Hz, 77 ACFM at 50 Hz). One (1)
separate 240 gallon air receiver in lube room.
• Membrane air dryer system for rotary screw air compressor (Note: Only one unit required for
single or dual compressors)
• Air hose reel w/30m/100ft of hose

NOTE: Consult Shovel Marketing for applicability of other compressors.

LUBRICATION SYSTEM
• Wiggins quick fill connectors for lube tanks
• Lube tank pre-filters, one system for open gear tank and one for grease tank.
• Lube tank heaters, open gear and grease tanks.

BOARDING ACCESS
• Left hand air stairway-in place of standard left hand pull down ladder

CRAWLER SHOES
• 87" wide, flat manganese with 5" induction hardened pins
• 110" wide (SPECIAL), flat manganese with 5" induction hardened pins

NOTE: For 110" shoes, cleated shoes and any special shoe requirements, contact Shovel
Marketing for lead time and pricing

PAINT
• Color Change using P&H paint spec.
• Customer Logo on machine away from P&H logo and model name, painted, one or two
colors, customer to supply template
• Customer Numbers painted on machine

OPERATOR CAB
• Front window electric wiper and spray wash system
• Sliding windows – two sliding windows with screens in place of side trainer and rear window
– 0.25 inch / 6mm tempered tinted glass
• Incinerating toilet system for utility room
• Video Monitoring System (Intec)- four (4) color cameras and two (2) color monitors for blind
spot monitoring - inside and outside of machinery house
• Satellite radio receiver in place of AM/FM/CD (Customer specify XM or Sirius)
• Sun shades, pull down - front window only

4100XPC 120 Ton Payload Detailed Technical Description Jan 2007

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 Model 4100XPC 120 Ton Payload
Technical Description

• Sun shades, pull down - all windows

• Air Horn - dual two tone mounted on RH electronics and LH lube room
• Electric Horn with adjustable volume - single in place of standard air horn
• Electric Horn with adjustable volume - dual, mounted on RH electronics and LH lube room
in place of standard single air.

CLIMATE CONTROL
• Mine Air Systems unit for operator's cab only; Model MAS 1500, cooling to 48,000 BTU/hr
(14kW), heating to 18kW; with air filter-pressurizer and R407C refrigerant
• Mine Air Systems units for operator's cab and electronics room; two (2) Model MAS 1500
units; cooling to 96,000 BTU/hr. (28 kW) total, heating to 36 kW total; with air filter-
pressurizer and R407C refrigerant (Note: Deletes blower in electronics room)
• Sigma unit for operator's cab only; Model MPV7; cooling to 24,000 BTU/hr. (7kW), heating
7 kW; with air filter-pressurizer and R134a refrigerant
• Sigma unit for operator's cab and electronics room; one Model MPV15; cooling to 15kW,
heating 2-stage 18kW; with air filter-pressurizer and R134a refrigerant (Note: Deletes blower
in electronics room)

NOTE: A/C is mandatory for electronics room in high ambient temperature environments

JIB HOIST
• Swing jib hoist; 8.9 kN / 2,000 lb. capacity mounted outside LH lube room

FIRE SUPPRESSION
• Fire extinguisher, 20lb. dry chemical, Model I-A-20G, (3 standard)

Note: Fire suppression systems are locally contracted by P&H MinePro Services. Typical
systems consist of clean agent suppression system for electrical cabinets, RH room, LH
room, and collector ring assembly.

TRAIL CABLE REEL

• Trail Cable Reel, air drive, level winding, 48" diameter drum
• Trail Cable Reel, hydraulic over electric drive, level winding, 48" diameter drum.
• Mounting material for trail cable reel (air or hydraulic)

COLD WEATHER EQUIPMENT

• 2.5cm / 1 inch insulation in machinery house
• 7.5KW heater in operator's cab (not required if Cab AC option is chosen)
• 15 kW heater in RH electrical room
• 20 kW heater in LH lube room
• Strip heaters for main control cabinets
• Strip heaters for main D.C. motors

4100XPC 120 Ton Payload Detailed Technical Description Jan 2007

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 Model 4100XPC 120 Ton Payload
Technical Description

• Strip heaters for main and auxiliary transformers

• 40 kW machinery house heater, maximum of 3, each

NOTE: Membrane air dryer should be included in cold weather applications.

TECHNOLOGY AND SOFTWARE

• Motivator Mode software to modify drive performance and RPC function in order to allow
mine supplied motivator at the trail cable voltage to be used to propel.
• ShoveLink Remote Communications Version I - software for mine supplied computer and
ethernet based communication link. Software allows user to veiw electrical feefback, sensor
information, diagnostics, and GUI screens in real time. Maximum of two (2) users per shovel.
• P&H Payload Reporter – Microsoft® SQL server, web-browser based reporting package
produces single or fleet based production reports from Payload Plus data.

MISCELLANEOUS ELECTRICAL
• Electrical Cabinet Filters for RPC and converter cabinets
• Extra Welder Outlet in machinery house, near LH door. 2 max.
• Ground Fault Protection for welder outlets. 3 max.
• Extra Welder Outlet (600V) in machinery house including transformer and ground fault
protection. 4 max.
• Emergency Lighting Unit - six lights total per unit - two (2) on power supply and four (4)
remote mounted - field installed
• Communication System (Gai-Tronics), 3-way, field installed, one on exterior, one in machine
house, and one in operator cab.
• Trail Cable Connector Extension with PLM cable coupler to extend trail cable connector to
rear of propel motor base. (Note: Not for use with trail cable reel. Coupler types other than
standard PLM must be specified)

MISCELLANEOUS MECHANICAL
• Central Drain System for hoist and swing transmissions - field installed
• Blower and Brake Removal System in machinery house - field installed
• Convex Mirrors - two (2) rectangular 16.50" x 24.75 on front of machine
• Tow Lug, Front of carbody - field installed
• Tow Lugs, Rear, two (2) on rear of carbody - field installed
• Hoist Drum Lock System which provides a mechanical lock to prevent movement of
suspended handle and dipper - field installed
• Slack Hoist Cable Detection system
• Fall Protection Lanyard Attachment points - field installed
• Removable Handrail System for hatch cover openings - field installed
• SuperNut rod bolt connection for crawler frames in place of standard nut.
• HYTORC rod bolt connection for crawler frames in place of standard nut. (Does not include
HYTORC tooling which is required for tensioning)

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 Model 4100XPC 120 Ton Payload
Technical Description

• Export packing
• Counterweight ballast, 265 lbs./cu.ft. minimum density. Contact product engineering for
ballast amount. Delivered to USA site, DOMESTIC PACKED
• Counterweight ballast, 265 lbs./cu.ft. minimum density. Contact product engineering for
ballast amount. Delivered to USA site, EXPORT PACKED

TECHNICAL DOCUMENTATION

• Operator's Manual, CD ROM, (3 std), each extra

• Operator's Manual, hard copy (3 std), each extra
• Mechanical Systems Manual, CD ROM, (3 std), each extra
• Mechanical Systems Manual, color hard copy, each
• Electrical Systems Manual, CD ROM, (3 std), each extra
• Electrical Systems Manual, color hard copy, each
• Parts Manual, hard copy, each (see note below)
• Electrical Data Manual, hard copy, each (see note below)

Note: The LinkOne Viewer allows the end user to print individual pages or complete parts
manuals. P&H Mining Equipment grants the end users of its parts manual the authority to
print hard copy manuals as required. Electronic copy can be installed on as many
computers as desired.

Note: Specify English or Spanish language. Consult Peak Services for other language
requirements.

CUSTOMER SUPPLY ITEMS

Unless otherwise stated in a P&H proposal, required items that are not included in our basic
machine supply are:
• Machine erection, including erection tools and equipment
• Counterweight ballast, approximately 424,000 lbs/192,300 kg with a minimum density of
265 lbs. per cubic foot (4,245 kg/m3) (Final counterweight determined by application.)
• Fluids/lubricants
• Trailing cable and electrical power supply.

*****

P&H - An enduring symbol of quality and reliability

4100XPC 120 Ton Payload Detailed Technical Description Jan 2007

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 Model 4100XPC 120 Ton Payload
Technical Description

NOTE: All designs, specifications and components of equipment described above are subject to change at manufacturer’s
sole discretion at any time without advance notice. Data published herein is informational in nature and shall not be construed to
warrant suitability of machine for any particular purpose as performance may vary with conditions encountered. The only warranty
applicable is our standard written warranty for this machine.

4100XPC 120 Ton Payload Detailed Technical Description Jan 2007

Page 18 of 18
 ®

4100XPB
ELECTRIC MINING SHOVEL

OPERATING SPECIFICATIONS

meters
feet
22 72.2

20 65.6

18 59.1

16 52.5

14 45.9

12 39.4

10 32.8

8 26.2

6 19.7

4 13.1

2 6.6

0 0

2 6.6
meters 6 4 2 0 2 4 6 8 10 12 14 16 18 20 22 24
feet 19.7 13.1 6.6 0 6.6 13.1 19.7 26.2 32.8 39.4 45.9 52.5 59.1 65.6 72.2 78.7
C
L ROTATION

CAPACITY WORKING RANGES

Nominal Payload 104 m ton 115 ton Height of Cut (Max) 18.06 m 59 ft. 3 in.
3 3
Nominal Dipper Capacity 55.8 m 73 yd Radius of Cut (Max) 23.80 m 78 ft. 1 in.
(SAE struck) Depth of Cut (Max) 1.93 m 6 ft. 4 in.
Rated Suspended Load 188,241 kg 415,000 lbs
Dumping Height (Max) 10.44 m 34 ft. 3 in.
Optimum Truck Size 172-363 m ton 190-400 ton Floor Level Radius 16.94 m 55 ft. 7 in.

Tail Swing Radius 9.83 m 32 ft. 3 in.

PERFORMANCE
Operator Eye Level 10.08 m 33 ft. 1 in.
Peak Propel Speed 1.6 km/h 1.0 mile/h

Gradability (Continuous) 17% 17%

 MACHINERY DECK PLAN
SWING MOTOR AND HOIST AIR COMPRESSOR HOIST HOIST LUBRICATION ROOM
TRANSMISSION MOTOR DRUM MOTOR

LUBE SYSTEM
CONTROLS

CONVERTER
CABINET LUBE RESERVOIR
(200 GAL. EACH)

AIR RECEIVER
(WALL MOUNTED
240 GAL.)
TRANSFER
CABINET
HOIST MOTOR
ACCESS DOORS

HIGH AND LOW

VOLTAGE COLLECTORS
(DECK MOUNTED)

REACTIVE POWER
COMPENSATION
CABINET SWING MOTOR AND
TRANSMISSION

FIELD BREAKERS 120 VAC

TRANSFORMER LOAD CENTER
SECONDARY BREAKERS
CONTROL CABINET
PROGRAMMABLE
TOUCH SCREEN MONITOR
AUXILIARIES MOTION CONTROLS
TRANSFORMER

AUXILIARIES
LOAD CENTER

AUXILIARIES
CABINET

OAP WITH
OPTIONAL SYSTEMS
GROUND FAULT, MAIN HIGH VOLTAGE CABINET
SUPPRESSION CABINET TRANSFORMER WITH ISOLATORS ELECTRONICS ROOM

ELECTRICAL

INCOMING SUPPLY REQUIREMENTS P&H DIGITAL DC STATIC DC POWER CONVERSION

Supply Voltage* 7200 or 13800V 6000, 6600 or 11000V Hoist**/Propel Swing Crowd/Propel
3 Phase, 60 Hz 3 Phase, 50 Hz.
Continuous Armature
Supply Transformer (Minimum) 3750 kVA Converter KW Rating 2x1860 kW 2x1860 kW 1860 kW
@ 600 VDC*
Minimum Short Circuit VA Available at Shovel 30 MVA
15 Sec. Armature
*Voltage per customer requirements. Converter Current 3700 amp. 3700 amp. 3700 amp.
Rating*

TRANSFORMER Continuous Field

Converter Rating* 150 amp. 150 amp. 150 amp.
Main Armature Transformer 3000 kVA
* Based on outside ambient temperature of 50°C or 122°F.
Auxiliaries-Field Transformer 435 kVA ** Cascaded hoist converters.

Control/Lighting Supply Winding 50 kVA

P&H DC FAST RESPONSE MAIN MACHINERY MOTORS
Note: Transformer capacities may vary depending on options.
Hoist Motor Continuous rating @ 600 volts Total 1887kW/2530hp
(Two used) Peak developed power 2889kW/3873hp
P&H DIGITAL DC AUTOMATIC
REACTIVE POWER COMPENSATION* Swing Motor Continuous rating @ 550 volts Total 1119kW/1500hp
(Three used) Peak developed power 1725kW/2313hp
60 Hz. (9 step) 50 Hz. (8 step)
Crowd Motor Continuous rating @ 550 volts Total 537kW/720hp
Switched Steps +6075 kVAR Total +6000 kVAR Total (One used) Peak developed power 867kW/1162hp
*Nominal rating at rated capacitor voltage (600 VAC) Propel Motor Continuous rating @ 550 volts Total 1074kW/1440hp
(Two used) Peak developed power 1372kW/1839hp
 SUPERVISORY CONTROL AND DIAGNOSTICS
P&H CENTURION™ • Digital controls provide constant power characteristics for optimal
INTEGRATED PERFORMANCE PLATFORM motion speeds which reduce overall cycle time.
• One-time setup of electrical parameters provide consistent optimum
• Centurion Supervisory Controller provides direct integrated comuni-
operation.
cation with motor drives giving precise motor control and fast cycle
times. Real-time multi-tasking capability allows for optimal machine
logic sequencing, monitoring and control. FEATURES AND OPTIONS
• Centurion I/O System uses ‘Profibus’ communication protocol for • Standard Automatic Lubrication System has advanced diagnostic
seamless integration of all shovel subsystems and future expandabil- and control functions for optimized lubrication and ease of lube sys-
ity. Low-voltage 24V DC I/O drop points feature open and short cir- tem maintenance.
cuit detection for improved diagnostics and troubleshooting.
• Standard Automatic-Boom-Soft-Setdown and Boom Profile Protection
• Centurion Information System’s enhanced Graphical User Interface Envelope help protect structures from excessive loading.
(GUI) features intuitive, icon-based screens to display vital informa-
• Standard Anti-Swing-in-Bank reduces excessive side loading.
tion such as shovel status, troubleshooting information, and optional
production monitoring data and operator feedback. • Options are available to tailor the 4100XPB to specific requirements
• Optional Optidig™ automatically coordinates hoist and crowd
motions while in the bank to improve dig cycle time and optimize
P&H DIGITAL DC DRIVES
power usage.
• P&H Digital DC Drive provides precise, reliable, solid state power to • Optional remote communications provide remote data transmission
the main motion motors, and has been proven on hundreds of units, and other high level control and diagnostic capabilities to improve
logging tens of millions of productive hours. overall loading productivity.

MECHANICAL
HOIST PROPEL
• All gearing housed in single enclosed gear case with filtered oil circu- • Two rugged planetary gear cases of proven design transmit torque to
lation for reliable splash lubrication, ease of maintenance, and the drive sprockets, producing the tractive effort required for fast, effi-
extended component life. cient propel and positioning operations.
• Large 68" diameter hoist drum for extended rope bending life. • P&H DELTA Drive low tension sprocket drive system for improved
Ferrule becket system and dual electric tuggers are standard for effi- lower works availability and life.
cient rope change. • Two spring set air release disc brakes - one per motor.
• Two spring set air release disc brakes - one per motor.

DIPPER
CROWD
• OPTIMA™ PLUS dipper design provides excellent fill factors and
• Powerband V-belt drive between motor and gear case absorbs shock nominal 115 ton (104 metric ton) capacity.
loads. • OPTIMA™ PLUS 80 and 90 dippers are interchangeable when lower
• First and second reduction gearing in enclosed gear case for reliable nominal capacity is required.
splash lubrication, ease of maintenance, and extended component
life.
DIPPER TRIP
• Twin leg dipper handle with torsion box and rack and pinion drive has
inherent stability in the bank for optimal digging. • P&H TripRite system utilizes a brushless DC electric motor with
• Single spring set air release disc brake. sealed planetary drive unit for reliable trip and slack take up
operation.

SWING
AIR FILTRATION
• Three modular planetary gear cases of proven design and a single
piece forged swing gear transmit torque for fast cycle times. • Inertial filtration system is standard.
• Three spring set air release disc brakes - one per motor. • High efficiency P&H AirScrubPro cartridge filtration system is
available.

LOADING CONTROL CENTER

CONSOLE FOR CLIMATE CONTROL
AND ACCESSORIES
OPTIONAL
AUXILIARY SEAT

POST MOUNTED
TOUCHSCREEN GUI AND
SPACE FOR MINE INFORMATION
SYSTEMS MONITORS

POWER ADJUSTABLE ARMREST MOUNTED,

AIR SUSPENSION PISTOL GRIP JOYSTICKS
6 WAY SEAT WITH HEAT AND
VIBRATORY MASSAGE
 GENERAL MACHINE SPECIFICATIONS

A B

H
G
D F
E

GENERAL DIMENSIONS BEARING AREA - GROUND PRESSURE

A Overall Width 14.35 m 47 ft. 1 in. Standard:

B Overall Length 14.33 m 47 ft. 0 in. Crawler Bearing Area 34.58 m2 53,597 in2
76" Shoes/ 1930mm
C Overall Height over Gantry 14.35 m 47 ft. 1 in.
Crawler Ground Pressure 412.0 kPa 59.75 psi
D Width of Crawler Shoes 1930 mm 76" (Std.) 76" Shoes/ 1930mm
2210 mm 87"
Optional:
E Overall Width of Crawlers (Std) 10.48 m 34 ft. 5 in.
Crawler Bearing Area 39.58 m2 61,354 in2
F Overall Length of Crawlers 11.72 m 38 ft. 6 in. 87" Shoes/ 2210mm
G Ground Clearance 0.66 m 2 ft. 2 in. Crawler Ground Pressure 361.2 kPa 52.38 psi
H Height – Ground to Bottom 87" Shoes/ 2210mm
of Counterweight 3.18 m 10 ft. 5 in.

WEIGHTS - APPROXIMATE*
CABLE DATA Working Weight (with Dipper, Approx. Wt.)
Hoist (wire rope) 70 mm 2.75" dia. (Std.) 76" Shoes/1930mm 1,453,000 kg 3,202,500 lbs
73 mm 2.875" dia. (Opt.)
87" Shoes/2210mm 1,458,000 kg 3,213,500 lbs
Suspension (bridge strand) 102 mm 4" diameter
Counterweight (Punchings)** 192,400 kg 424,000 lbs
Dipper Trip (wire rope) 19 mm 0.75" diameter
* All weights subject to 5% variation.
** To be furnished by customer.

NOTE: All designs, specifications and components of equipment described above are subject to change
at manufacturer’s sole discretion at any time without advance notice.
Data published herein is informational in nature and shall not be construed to warrant suitability
of machine for any particular purpose as performance may vary with conditions encountered.
The only warranty applicable is our standard written warranty for this machine.

P&H Mining Equipment ◆ Box 310 ◆ Milwaukee, Wisconsin 53201 USA

XS-1689-3 2AG-105
 4100XPB TECHNICAL DESCRIPTION
July 19, 2004

The P&H 4100XPB is a heavy duty electric mining shovel which provides a 115 ton (104.3
metric ton) nominal payload capacity specifically designed to operate in mines for high
productive loading of 240 ton to 400 ton (218 metric ton to 363 metric ton) haul trucks and
larger.

This technical description is provided to compliment the 4100XPB main machine

specification XS-1689-2.

ELECTRICAL POWER SYSTEM

POWER SUPPLY
Electrical power to the shovel is Customer supplied via a trailing cable. Recommended
SHD-GC trailing cables, for 7,200 volt supply, are:

#2 AWG/35mm² 2800 ft./854m.

#1 AWG/50mm² 3400 ft./1050m.
1/0 AWG/55mm² 4250 ft./1300m.

Electrical equipment on the shovel is designed for an incoming supply of 3 phase, 60 hertz, 7,200
or 13,800 volts. Secondary voltage for auxiliary motors is 3 phase, 60 hertz, 480 volts.
Alternatively, the electrical equipment is designed for an incoming supply of 3 phase, 50 hertz,
6000, 6600, 7200, or 11,000 volts. Secondary voltage for auxiliary motors is 3 phase, 50 hertz,
380 or 415 volts. Recommended 30 MVA, short circuit capacity, at the shovel.

LOWER HIGH VOLTAGE DISCONNECT SWITCH

Electrical power is brought to the shovel by connection of the trailing cable to the lower high
voltage (HV) disconnect switch, which is mounted on the rear of the carbody. A cable coupler is
mounted on this switch and mating PLM coupler is provided for the trailing cable end. The
switch provides a visible disconnect, grounding, and a safety key interlock which energizes or
disconnects electrical power to the entire machine. HV wiring runs from this switch through the
carbody to the HV collector rings on the upper deck. The standard cable coupler is a PLM brand
quick disconnect type. Other coupling styles are available upon request.
 Model 4100XPB July 19, 2004
Technical Description

HIGH AND LOW VOLTAGE COLLECTOR RINGS

Both the high voltage and low voltage collectors are mounted in one large above deck cabinet.
The HV collector ring cabinet has been configured such that the same basic cabinet can be used
for all incoming power supplies up to 13.8 kV. The LV collector rings, which transmit lower
voltage power from the upper to the lower, are deck mounted above the high voltage collectors in
the one assembly above the center gudgeon. Internally mounted lights and viewing windows are
provided for inspection. Doors, which contain the fixed viewing windows, are Kirk key
protected.

UPPER HIGH VOLTAGE DISCONNECT

Fully contained cabinet contains two visible high voltage disconnects to 1) isolate the entire
upper H.V. supply, and 2) isolate the primary of the Main Transformer, vacuum contactor, line-
to-line and line-to-ground lightning arrestors for surge suppression. Current limiting H.V. fuses
provide short circuit protection for the primary of the Main Transformer and the primary of the
Auxiliary Transformer

MAIN TRANSFORMER
Designed for mining shovel service, 3000KVA rated, dry type; Delta/Wye connected,
minimizing third harmonic current flow to external circuits, simplified ground fault detection.
Transformer can accommodate unequal loading, has ±5% voltage taps, and temperature
monitored windings. Main Transformer provides power for the Converter Cabinet motion
thyristor bridges which control the power to the DC drive motor armatures and fields.

AUXILIARY TRANSFORMER
Like the main transformer, the auxiliary transformer is designed for mining shovel service is of
the dry type, and is Delta/Wye connected. It is rated at 435 KVA. Four (4) secondary windings
provide power for:
(1) 60HZ/480 Volts (Alternatively 50HZ/380 or 415 Volts) for utilities and auxiliary motors.
Power from the transformer flows to an Auxiliary Load Center, Auxiliary Cabinet motors.
(2) Shielded winding supply for the Control System
(3) Field supply voltage to the DC drive motor, field power bridges.
(4) Lighting and GPO’s supply, 50 KVA rated, and distributed through the 120 VAC
(alternately 240V) load center

POWER CONVERTER CABINET

The P&H Digital DC power conversion system contains six-thyristor three-phase bridges used to
statically convert AC supply power to controlled DC supply to motion drive motor armatures for
speed and torque regulation. This thyristor bridge inherently allows for invert regenerated DC
energy to AC power during motion deceleration. The regenerated power is used to supply the on
board needs with the excess going back to the mine network for energy savings.

4100XPB Technical Description July 2004.doc

Page 2 of 16
 Model 4100XPB July 19, 2004
Technical Description

Thyristors are mounted in easily accessible heat sinks and are forced air cooled. A patented fast
acting over-current diverter system senses and limits the over-current to the DC motors
eliminating destructive flash-overs.

POWER DISTRIBUTION
All High Voltage cables are run in metal conduit. An enclosed overhead copper bus system is
used to carry the current from the main transformer to the converter cabinet. All other wiring is
generally run in raised troughs on the machinery deck floor. Power cables are Hypalon insulated

REACTIVE POWER COMPENSATION (RPC) SYSTEM

Housed in a rugged, ventilated cabinet, the RPC system contains stepped tuned banks of
capacitors and reactors, automatically and synchronously switched on and off the line to maintain
average system power factor near unity. Tuned banks provide a high level of filtering of the
predominant harmonics generated by the converters. Synchronously applied stepped
compensation eliminates transients during application and disconnection.

TRANSFER CABINET
The transfer cabinet contains heavy duty contactors to transfer the power from the hoist and
crowd converters to the propel motors in the propel mode. Transfer is initiated by a push button
on the console in the operator’s cab with all sequencing handled automatically by the supervisory
control system.

DC DRIVE MOTORS
P&H designed, manufactured, and tested motors are made specifically for mining service duty,
with Class "H" insulating system. Drive motors are equipped with RTD’s to monitor motor
bearings and winding temperatures, and all are equipped with heavy duty blowers with screen
protected air inlets. Optional brush grades are available for unusual operating conditions.

ELECTRICAL CONTROL SYSTEM

P&H CENTURION™ IPP (INTEGRATED PERFORMANCE PLATFORM)
The P&H Centurion™ IPP provides the supervisory control of the shovel drives and executes the
sequencing and monitoring functions, and consitsts of the supvisory control computer and
supporting hardware devices and software programs. The system is comprized of three basic
areas which are: 1) the onboard graphical user interface (GUI), 2) the remote input/output (I/O)
devices and communication interface, and 3) the individual drive controllers.

The system uses an open concept design to allow for third party integration. The architecture
provides connectivity from components on the shovel to the onboard GUIs and provides
diagnostic and monitoring capabilities. The application code residing within the supervisory
controller is based on the IEC 61131 standard. The control system uses Profibus over fiber optic
and copper media for communications with the various system components.

4100XPB Technical Description July 2004.doc

Page 3 of 16
 Model 4100XPB July 19, 2004
Technical Description

SUPERVISORY CONTROL CABINET

Components for the P&H Centurion™ IPP are housed in a rugged, maintenance friendly cabinet,
which is located in the RH Electronics room.

LOWER CONTROL CABINET

The lower control cabinet is mounted on the back of the carbody, and contains remote I/O, motor
starters for the propel motor blowers, air solenoid valves for the brakes, and electrical
convenience outlets.

REMOTE I/O’S
The supervisory control system functions with remote I/O in several locations such as lower
propel, LH lube room, RPC cabinet, converter cabinet, transfer cabinet, auxiliary cabinet, and
operators cab.

AUTOMATIC ATTACHMENT PROTECTION SYSTEMS

Hoist and crowd/retract limits are set on the GUI touch screen located at the loading control
center in the operator's cab. A boom profiling limit is included to help prevent contact of the
handle torsion box and dipper with boom. The ABSS (Automatic Boom Soft Set-down) feature
is part of the control system and minimizes boom jacking and the associated impact of abruptly
lowering the boom from a jacked condition.

MOTOR CONTROL CENTER (MCC)

A large maintenance friendly cabinet contains individual motor starters and circuit breakers,
which provide thermal and short circuit protection for each motor. For electrical isolation, the
controls for each individual motor are housed in an individual cubicle. In addition to motor
control, there are cubicles to control house heaters and lights. The MCC is located in the
environmentally controlled RH electronics room.

OPERATOR INTERFACE
OPERATOR CAB
A separate, roomy, high-visibility cab is rigidly mounted and offset in an elevated position on the
shovel's right hand side. Freezer style handles are equipped on the cab door. Non-glass areas of
the cab are insulated for temperature and sound control. The sound level inside the cab is below
70dBA while the shovel is operating, and with the door closed. All windows other than the front
window are tinted safety glass. The standard front window glass is 0.38 inch / 9mm thick
laminated safety glass. An industrial grade, single arm electric window wiper system is standard.

A standard single 2-tone air signal horn is standard equipment, and is mounted on front of RH
room. Sound level rating of the standard air horn is 123 dBA at the source.

P&H LOADING CONTROL CENTER

4100XPB Technical Description July 2004.doc

Page 4 of 16
 Model 4100XPB July 19, 2004
Technical Description

The P&H Loading Control Center provides a single location of control for shovel operation and
truck loading. An additional work area with an optional seat is provided immediately behind the
operator for use by training or other personnel.

The standard seat base is an air suspension type which can be adjusted for operators height and
weight. The seat has an automotive style power system which provides vertical and fore / aft
adjustment to allow custom fitting of the joysticks to individual operators. The seat has heat,
lumbar support, and massage. The entire seat, armrest assembly is mounted to a vibration
isolated sled with an integral footrest. The angled footrest swivels into two positions based on
the operator’s height.

The joystick contollers are Hall-Effect, pistol grip style with both push button, trigger switch, and
rocker switches built into the grips. There is a single console on the left hand side of the operator.
All control devices needed by the operator while operating the shovel and loading trucks are
located in a zone of comfort for easy access with minimal movement. Devices needed for
auxillary functions such as those climate control and lighting are located within reach of the
operator while seated.. The console also features an expandable media mounting post to which
the P&H GUI is mounted as standard. Post sections can be added to mount remote camera
monitors as well as dispatch screens.

The climate control ducting in the cab is located above and below the operator. There are
controls to allow regulation of air flow between window defrost, the vents at the feet, and the
vents at the midlevel of the operator.

GRAPHIC USER INTERFACE (GUI)

The GUI has menus and information screens thatallow the operator todisplay information, and
perform various operation functions. The basic functions of the GUI are:
• Display machine operating status
• Display and set hoist and crowd limit setting (boom profiling)
• Provide fault enunciation and alerts
• Display temperature monitoring bar graphs
• Display boom jacking status
• Display boarding ladder positions
• Display lubrication system settings and status
• Provide for manual initiation of lubrication cycles

CLIMATE CONTROL
An optional P&H MineAir Systems MAS 1500 mine duty air conditioner unit is available. A
single unit can be fitted to the operator cab, or two units can be fitted, one for the cab and one for
the electronics room. Each MAS 1500 unit is capable of delivering 14 kW cooling (48000
BTU/Hr), and 18kW heating. Units are fitted with an efficient air filtration system, which
pressurizes the cab and electrical room.

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LIGHTING
Primary exterior floodlights: Standard lights are Metal Halide, 400 watt, 60HZ/120V
(alternatively 50HZ/220V), high intensity discharge (HID) units.

Standard primary exterior floodlight locations (nine are wide beam and two very narrow beam)
are as follows:
• Two (2) on front of operator’s cab, below the front window.
• Two (2) on top front of lube room
• Two (2) right side of house
• Two (2) top rear of house
• One (1) top left side of house

Secondary exterior floodlights: Standard are Halogen, 500 watt units. Standard secondary
exterior floodlight locations are as follows
• One (1) above operator’s cab door
• Two (2) on the lower front of machinery house
• Four (4) under revolving frame corners
Exterior incandescent: Five (5), 100 watt; one (1) at each machinery house door and one (1) at
operator’s cab door.

Interior lighting: Twenty three (23) fluorescent lights are provided to illuminate the machinery
house, RH electrical room and LH lube room.

Operator’s cab lighting: Incandescent 100 watt ceiling light.

One (1) portable halogen trouble light is also provided as standard for primary use at convenient
roof top outlets.

ELECTRICAL CONVENIENCE OUTLETS

Electrical outlets for 110/120 volt supply are conveniently located:
• One (1) in lower control box on rear of carbody
• Two (2) Under revolving frame platforms
• Eight (8) In machinery house
• One (1) on RH catwalk
• Two (2) In RH electronics room
• One (1) In LH lube room
• Three (3) In Operator’s cab
• Two (2) On house roof

Outlets are GFI protected. GPO’s are 15 amp, duplex, NEMA 5-15 straight blade devices, 2
pole, 3 wire grounded and 125V rated.

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Special instrument outlets are located in the Supervisory Control Cabinet.

Three (3) 60HZ/460V (Alt. 50HZ/380V) outlets are also provided; one (1) in RH electronics
room, one (1) in LH lube room and one (1) in Operator’s cab. These outlets are 20 amp, 3 wire,
4 pole, IEC 309 type.

A single welder outlet receptacle (60Hz/460V, alternatively 50Hz/380V) is provided, located

near the RH door in the machinery house.

MECHANICAL SYSTEMS
CRAWLER DRIVE SYSTEM
The P&H DELTA crawler drive system incorporates rugged lug and tumbler sprocket design
concepts, with the tumbler engagement close to the link pin center lines.

CRAWLER SHOES
Deep section, cast manganese shoes are connected with 5 inch alloy steel induction hardened
pins through machined, line-bored holes. Shoes are designed specifically for the P&H DELTA
style drive system. Standard crawler shoes width is 76 inches (1930mm).

CRAWLER FRAMES
The frames are heavy welded box section designs with bolted fit to carbody under full shear
ledge support with large dowels to prevent movement in the bolted connection. There is no field
welding required in the connection. There are eight (8) lower rollers, and a front, and a rear idler
in each frame. The front idler is a large diameter manganese casting mounted on two (2) heavy
duty bushings. Lower rollers and idlers are V-ring sealed to exclude contaminates. Hardened
wear surfaces minimize crawler frame wear. Rollers and idlers are straddle mounted with special
alloy brass bushings. “P&H 50+” lower rollers are hardened to over 50 on the Rockwell C scale.
Replaceable pin-on, high hardness cast slide bars on top of each frame support the crawler shoes.

CARBODY
The carbody is a heavy welded high strength low alloy steel structure of cellular deep box
sections, built around a large center hub casting. The flat-top design with deep section
diaphragm plates provide direct support of the roller path. The carbody interior is painted white
and is equipped with an electrical convenience outlet for trouble light use. Swing gear and lower
swing roller path are mounted on the top of the carbody with dowels and bolts. The crawler
frames are connected to the carbody by a full length shear ledge and long rod bolts. Heavy duty
shear dowels prevent crawler frame movement relative to the carbody in the event of significant
loss of clamping force. Both the carbody and crawler frames are designed to withstand the high
level of crawler frame connection bolt tension. The crawler frame connection bolts produce very
high clamping forces between the crawler frame and carbody machined surfaces. The standard
tensioning system for the rod bolts consist of simple bolt and nut arrangement.

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DUAL PLANETARY PROPEL SYSTEM

Dual independent P&H DC drive motors rated at 1350hp/1007kW total continuous power at
550V and 1974hp/1472kW total peak developed horsepower, drive the propel system and are
load sharing controlled. Motors are mounted in a propel motor base which is bolted to the rear of
the carbody, and motor frame adjusting screws are integral to the base for ease of alignment, and
the motors are directly connected to P&H planetary propel transmissions with a gear coupling.
The planetary propel transmissions are directly mounted to each crawler frame, and provide
differential speed and counter-rotational steering capability. All gearing is forged, anti-friction
bearing mounted, and all external gears are case hardened and ground.

The P&H DELTA drive system has a raised final propel drive shaft and tumbler. The final
propel drive shaft is spline connected to the planetary transmission and tumbler, and is mounted
on anti-friction bearings. The outboard spherical bearing is encapsulated to prevent crawler frame
damage in the event of a bearing failure. V-ring seals are used to seal out dirt and seal in
lubricant.

CENTER GUDGEON
The Center Gudgeon is a hollow heavy duty forging used to connect the upper revolving frame to
the lower carbody. Acme threads are provided on the upper and lower end of the gudgeon. The
gudgeon is a cascaded interference type fit in the center hub casting of the carbody. A locking
mechanism on the upper threads allows fine adjustment capabilities and positive retention of nut
position. Gudgeon center hole is used for electrical wiring, lube, and air lines between upper
revolving frame and lower machinery.

REVOLVING FRAME
The revolving frame is a heavy welded high strength low alloy steel structure of cellular deep
box sections built around a large center casting. It incorporates an elevated boom foot to
accommodate large dippers in the tucked position under the boom. The rolled, full depth turret
plates align with the swing roller path and provide 360° direct load transfer. Roller path support
pad on frame underside is wider and provides a pilot ring to prevent radial movement of the
upper path. The counterweight box mounting face at the rear of the revolving frame is full depth
to match counterweight box depth, which adds stiffness and minimizes field welding. Deck
machinery is mounted via tapped holes or pin supported and no internal access is required to
mount the machinery. A standard drain system allows for the hoist and swing transmissions to
be evacuated through piping to below the revolving frame deck (crowd drain to boom foot
platform).

COUNTERWEIGHT BOX AND CASTINGS

A sectioned counterweight box is mounted to the rear of the revolving frame to accommodate the
counterweight ballast. Large solid castings are mounted to the rear of the counterweight box to
provide a stabilizing moment.

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DECK PLAN
Side platforms, which mount to the revolving frame, extend the deck width. Conveniently
arranged floor plan with abundant space facilitates maintenance. Side platform mountings extend
to the full depth of the revolving frame.

ELECTRONICS ROOM (RH ROOM)

A separate large room is mounted on front right corner of the revolving frame and houses the
supervisory control cabinet for the P&H Centurion™ IPP, as well as auxiliary cabinets with
ample space to mount additional cabinetry. The room is insulated with 1.0 inch/25.4mm
material; equipped with 0.75 hp fresh air blower (not used with optional air conditioner),
secondary wall and door air filter, and louvered front wall vent panel. Optionally, this room can
be further environmentally controlled with air conditioning and/or heaters. Three (3) doors are
provided for improved access; one (1) leading to machinery house and one (1) to outside catwalk
and one (1) to the boom foot area. Window in front door allows for front end/attachment
viewing while working in electronics room. RH room also is the support base for the RH
elevated operator’s cab. Removable fiberglass false floor system is provided for ease of wiring.

LUBRICATION ROOM (LH ROOM)

A separate room is mounted on front left corner of the revolving frame, which houses lube tanks,
pumps, plumbing, and most of the air system components including the receiver. Room is
insulated with 1 inch / 25 mm material with a durable surface that can be cleaned. The room can
be optionally heated for improved cold weather operation. Two (2) doors are provided one (1) to
the outside catwalk and one (1) to the boom foot area. Hinged and removable doors are also
provided for access to the front hoist motor.

MACHINERY HOUSE
Truss style roof with weather tight, removable hatch covers for accessibility to internal
machinery. A constant slope roof and flexible rubber seal system between flexing components
shed water and dirt from the roof. Roof panels are strategically located to direct crane picks of
major deck mounted components as required. Two large Lexan skylights provide light to the
house in the event of power loss to the shovel to aid in egress.

HOUSE PRESSURIZATION AND FILTRATION

The machinery house is pressurized with filtered air to reduce dust ingress and to provide clean
cooling air for components by a modular centrifugal inertial filter system. Ambient air is drawn
from the forward facing intake hoods by two large vane axial fans and passes through the filter
panels which removes airborne dust particles and allows the cleaned air to pass through in to the
machinery house. Bleed airflow is created by two blowers and carries dirty air through ducts to
the outside at the rear of the house. Clean house air is directed in the rear portion of the
machinery house to provide greater cooling of deck mounted components. Access is provided to
filter and blower units from the house roof.

COLD WEATHER EQUIPMENT

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The RH and LH rooms are equipped with insulation as a standard feature. The air valves for the
lower works are located in the heated lower control cabinet as standard, and the automatic
moisture dump valve for the main air receiver is located in the heated LH lube room as standard.
Heating options are available.

BOARDING AND ACCESS

A right side pneumatic controlled stairway and left side vertical pull-down ladder are interlocked
to de-energize swing and propel functions when in down position for safety. Catwalk/platforms,
with grated metal surface, hand rails, and toe boards are provided in access areas. Roof grating is
mechanically attached to allow removal for roof cleaning. Grating configured to allow natural
drainage without blocking flow thus minimizing how often it has to be removed.

HOIST DRIVE SYSTEM

Dual P&H DC motors rated at 2380hp/1775kW total continuous power at 550V and
3295hp/2458kW total peak developed power drive a modular gearcase pinned to the revolving
frame. First reduction is helical gear set, second reductions spur and a reversible spur drum gear.
All gearing is forged machined, case hardened and ground. Transmission is oil tight with anti-
friction bearings and standard oil filtration and circulation system. Gearing is splash lubricated
and does not require lube flow to operate. A lube pump and filtration system is standard, and is
designed for use with high viscosity lubricants, even in cold temperatures

The standard hoist drum is a large 68 inch (1727 mm) pitch diameter drum with through shaft
and flame hardened grooves. Standard hoist rope is 2.75 inch (70 mm) diameter cable fully
plastic impregnated and compacted, for longer life, and can accommodate optional 2.875 inch
(73 mm) diameter ropes. Hoist drum and cable are provided with high capacity Ferrule Beckett
fittings to simplify cable change out. Hoist limits are programmable from operator's cab. Hoist
drum bearings are equipped for temperature monitoring.

HOIST CABLE TUGGER

Dual electric driven tuggers are standard to assist with hoist cable changes and each tugger has
3000 lb.(1361 kg) rated pulling capacity..

SWING DRIVE SYSTEM

Swing power is provided by three (3) series connected P&H DC drive motors rated at
1500hp/1119kW total continuous power at 550V and 2313hp/1725kW total peak developed
power. P&H Planetary transmissions are mounted front and rear of swing gear for even loading.
Some components are interchangeable with first and second reductions in Propel transmissions
minimize parts stocking requirements.

Swing shafts are mounted on anti-friction bearings and are removable without disturbing the
transmission. Forged swing gear, 17 foot-2 inch/5.23m diameter with a large 14-1/2
inch/368mm tooth face for reduced loading. Swing circle uses a quantity of 55 tapered rollers,
10 inch/254mm in diameter, carried on self-lubricating bushings. Rollers and roller paths are

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high alloy, forged, quenched and tempered to a high hardness. Full circle of rollers are in contact
with the 360° upper and 360° lower roller paths, which have a wide mounting surface to the
carbody and revolving frame. Upper path is dual flanged mounted with guarding to retain
mounting hardware in the event of loss, and the lower path is clip mounted to the carbody on the
inner diameter and retained by the ring gear outer diameter.. Gear shrouding system prevents
contamination of gear and roller path area, and can be opened to enable inspection of gear and
roller circle.

CENTRALIZED LUBRICATION SYSTEM

An automatic centralized lubrication system is standard and provides metered amounts of
lubricant to major systems, which require grease and open gear lubrication. Lincoln 75:1 ratio air
driven pumps are used. Large lubricant reservoirs are mounted in the lubrication room, and are
equipped with heaters. The tanks are plumbed through the front lube room wall, and have cam
lock fittings to allow filling from the outside of the lubrication room. The grease reservoir is 600
gallon / 2271 liter capacity, and the open gear reservoir is 400 gallon / 1514 liter capacity. There
are level sensors on each reservoir to monitor lubricant quantity. The lubricant level is shown on
a display unit mounted in the lube room, and on the GUI. The standard centralized lubrication is
a three pump / three zone arrangement with a pump for each zone. The grease system has two
zones, one for the upper and attachment, and the other for the lower. The open gear system is a
single zone covering the attachment and ring gear and roller path area. There are pressure sensors
at each major injector grouping to display system pressure on the GUI for alarm and diagnostic
purposes.

Optionally, a two pump / four zone system is available which uses two pumps and directional
valves to divide the flow of lubricant. The open gear system has two zones, one for the
attachment, and the other zone for the swing gear and roller path area. The grease system has two
zones, one for the upper and attachment, and the other for the lower.

ENCLOSED GEAR CASE LUBRICATION

All gear cases are designed with bath and splash lubrication to all gearing and bearings. A lube
filtration system is standard for the hoist and crowd gear cases with basket strainers, 20 micron
filtration, pump, and motor. The crowd gearcase drain is plumbed to the boom foot area as
standard.

AIR SYSTEM
Compressed air is provided for lube pumps, lube sprayers, disc brakes, hoist cable tugger, air
operated stairway, horn, and operators seat. Standard air compressor is a Sullair Model ES-8-
30XH, rotary screw type, 30 HP, 95ACFM at 60HZ (77ACFM at 50HZ), floor mounted, with
separate 240 gallon capacity air receiver which is ceiling mounted in the lubrication room. The
ES-8 is designed for cold weather operation.

BRAKES

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All motions have oversized, low maintenance disc brakes, which are spring set and air release
style. Brakes have replaceable wear surfaces, and a low abrasion, high heat capacity friction
material is used. Each brake is equipped with centering mechanisms to minimize contact of
frictional surfaces when brake is released, and all brakes have electric set/release and wear
detection.

BOOM
66 foot-2 inch (20.17m) length set at a 45° angle; welded structure of high strength low alloy
steel for cold weather toughness; extra width and depth for high load capability; 80 inch
(2032mm) diameter point sheaves, split bearing block mounted for maintenance ease. Boom
suspension cables are 4.00 inch (102 mm) structural strand. Integral lifting lugs and wear
resistant side boxes are incorporated. Boom is connected to revolving frame lugs with heavy
duty lubricated pins retained with split collars. Boom geometry resists boom jacking, and the
need for boom bumpers to be welded to the boom is eliminated through the use of a revolving
frame bumper.

CROWD SYSTEM
Crowd and retract of the dipper is accomplished by one (1) P&H DC motor rated at
675hp/504kW continuous power at 550V and 1162hp/867kW peak developed power. The motor
drives the P&H - POWERBAND "V" BELT - shock absorbing/system to modular, enclosed,
transmission with spur gear reduction to manganese racks and forged, machined and hardened
crowd pinions. V-belt sheaves are fully machined and balanced. Gearing is forged, case
hardened and ground; mounted with encapsulated, pre-adjusted bearings. A self-adjusting crowd
belt-tensioning device is incorporated to eliminate variations in V-belt adjustment and thus
allows an overall reduction in operating belt tension. Adjustment is automatic with no need for
anyone to be on the boom. Single piece saddle blocks are also hydraulically adjusted and allow
for removal of crowd pinions. Crowd/retract limits programmable from operator's cab.

DIPPER HANDLE
35 foot-0 inch (10.67m) effective length; high strength low alloy, cold weather steel; straddle
design, straight legs and large cast manganese racks providing strength for corner tooth digging
loads. Handle geometry enables internal inspection and repair of torsion box area.

DIPPER TRIP
Dipper trip system is a durable 10HP; brushless DC motor driving planetary gearing to a heavy
duty drum. The solid state drive components for the dipper trip system are located in the
supervisory control cabinet, and are fully adjustable through the GUI. Both ferrule becket and
cable clamp connection capability is provided for securing dipper trip cable to the drum. Trip
line is connected to dipper latch lever bar via a two part sheave system on the dipper door. An
integral disk brake on the motor sets when not is use. Increased trip capability to minimize
adjustment frequency.

DIPPER

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OPTIMA 100 Plus dippers have been designed specifically for the 4100XPB advanced digging
geometry for proper filling and low cost of operation. Standard equipment on the dippers include
adjustable pitch braces and P&H Snubrite™ hydraulic snubbers to prevent damaging dipper door
closing impact. Nominal rated dipper size is 73 cubic yard ( 55.8 cubic meters ). A nominal 67
cubic yard (51.2 cubic meter) dipper size is also available for even pass truck loading matches in
a wide variety of ore, waste, and overburden applications. To further optimize truck matching,
dipper capacity can be adjusted slightly upwards or downwards through the application of ledge
and in-fill plates.

PAINT
Standard exterior is P&H Yellow and Black. Yellow on machinery house and operator’s cab.
Black on lower, attachment, catwalks and handrail. (Lower HV disconnect switch is painted
red). Interior of house, RH and LH rooms, carbody, revolving frame and lower boom section and
all electrical cabinet interiors are painted high visibility white. Optional color change, customer
logo, and numbering is available.

WEIGHTS
Working weight of the P&H Model 4100XPB with nominal dipper and 76 inch (1930mm) wide
crawler shoes is 3,138,000 lbs. (1,423,129 kg.)

OPTIONAL ITEMS DESCRIPTIONS

OPERATOR CAB
• Pull down mylar shades (front window only)
• Pull down mylar shades (all windows)
• Front window, laminated safety glass (0.750” thick)
• Front window, laminated safety glass (1.188” thick)
• Cigarette lighter and ashtray – to be used for 12V power supply for convenience.
• Passenger seat – fold down in rear of cab for convenience
• Table – fold down for operator and mine personnel convenience.
• Second, 2-tone, air horn, mounted on front of LH lube room
• Single electric horn in place of standard air horn on RH room
• Second electric horn, mounted on front of LH lube room

AIR CONDITIONER
• Mine Air Systems unit for operator’s cab only (RH or LH); Model MAS 1500, (60HZ/460V
or 50HZ/380V); cooling 48, 000BTU/14KW at 60HZ, heating to 18KW at 480V; with PUR-
PAK 1000 pressurizer and R407C refrigerant
• Mine Air Systems units for operator’s cab (RH or LH) and RH electronics room; two (2)
Model MAS 1500 units (60HZ/460V or 50HZ/380V); cooling 96,000 TBU/hr./28 kW total at
60Hz, heating to 36 kW total at 480V; with PUR_PAC 1000 pressurizer and R407C
refrigerant (Note: Deletes blower in RH room, #3.2.1)

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• Sigma unit for operator’s cab (RH cab only) and RH electronics room; one Model MPV15,
60HZ/460V or 50HZ/380V); cooling 15KW at 60HZ, heating 2-stage 18KW at 460V; with
pressurization and R134a refrigerant (Note: Deletes blower in RH room, #3.2.1)

JIB HOIST
• Swing jib hoist; 8.9kN / 2,000 lb. Capacity (60HZ, 460V), mounted outside LH lube room
• Swing jib hoist; 8.9 kN / 2,000 lb capacity (50HZ, 380V), mounted outside LH lube room

FIRE SUPPRESSION
• Fire extinguisher, 20lb. Dry chemical, Model 1-A-20G, (3 are standard) each extra unit

TRAIL CABLE REEL

• P&H Power Reel (Harnaust Mfg.), air drive trail cable reel, 48” dia drum
• Cable reel (IWM Mfg.), hydraulic over electric drive, 48” dia drum
• Mounting material for P&H Power Reel trail cable reel

COLD WEATHER EQUIPMENT

• 2.5cm / 1 inch insulatin in machinery house
• Heater/defroster ducting in cab directed to operators feet and front window
• 7.5KW heater in operator’s cab
• 15 KW heater in RH electrical room
• 20 KW heater in LH lube room
• Strip heaters for main control cabinets
• Strip heaters for main D.C. motors
• Strip heaters for main transformers
• 40 KW machinery house heater maximum of 3, each

MISCELLANEOUS ELECTRICAL
• Extended upper temperature monitoring system – standard plus crowd gearcase bearings,
hoist gearcase bearings, swing shaft bearings, gearcase oil (5 cases), boom shipper shaft
bearing, and center gudgeon hub.
• Extended lower temperature monitoring system – standard plus over temperature indication
for final drive bearings and gearcase oil (2 cases).
• P&H Optidig operator assist tool that co-ordinates the hoist and crowd motions to prevent the
dipper from stalling while digging.
• P&H i2T Remote Communications Ready Package (complete) including connection port of
shovel, base station PC with software installed. (Modem and radio communications
hardware is required, and is not provided by P&H.)
• P&H i2T Remote Communications Ready Package (no base station) including connection
port on shovel. (This option used when base station for other i2T shovels is on site) (Modem
and radio communications hardware is required, and is not provided by P&H).

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• Electrical cabinet filters for RPC and converter cabinets - fitted to the cabinet doors and
provides an additional level of filtration for the electrical components.
• Hoist control with variable speed control in machinery house - allows hoist system to be
operated within view of the drum to improve ease of hoist rope change outs.
• Extra welder outlet in machinery house, near LH door. (60HZ, 460V or 50HZ, 380V) – price
each, 2 max
• Ground fault protection for welder outlets – price each, 3 max
• Emergency lighting unit (two lights per unit), each:
− Without installation wiring
− With installation wiring
• Communication system, 3-way
• Trailing cable connector extension with PLM cable coupler (w/o cable) (Not for use with trail
cable reel) - exetends cable coupling connection from the lower high voltage disconnect
cabinet to a convenient location by the propel motor base.

MISCELLANEOUS MECHNICAL
• Wiggins quick fill connectors for lube tanks, mounted on outside front lube room wall (note:
deducts standard 2” cam lock fittings) to allow quicker fill of the two lubricant reservoirs.
• Central drain system for hoist and swing transmissions (crowd drain to boom foot platform
standard) - allows for all systems to be drained to a convenient central location.
• Lube filtration with 20 micron filter on each swing transmission (3 total)
• Air hose reel w/30m/100ft of hose - conveniently mounted in the machinery house as a
general purpose air supply, and features a filter, regulator, and 50 feet (15.2 m) of hose on a
retractable reel.
• Blower motor and brake removal system in machinery house
• AirScrubPro high efficiency house Pressurization system in place of standard. The
AirScrubPro system is a cartridge filtration system that is 99.9% efficient by weight at .3
micron and greater particulate size. The air inlet is located at the top of the unit and is
protected by an expansive rain/snow hood, which limits the ingress of moisture in the air and
dust from the roof into the filters. There are two main 40 hp two-stage blowers that provide
airflow through the filters and into the machinery house. Dirty air is trapped on the outside of
self-cleaning, replaceable filter cartridges while clean airflow continues through the
cartridges and into the machinery house. The clean air duct is equipped with a pressure
transducer that measures the pressure drop across the filters. When the pressure drop across
the filters indicates that the filters are dirty, the filter cartridges are automatically cleaned by
blasts of pressurized air. Accumulated dust and dirt on the outside of the cartridges falls into
a hopper and a screw type conveyor automatically carries the dust off the machine and onto
the ground. Filter cartridges are replaceable from the machinery house roof. Access to make
fan blade setting adjustments is achieved through an access door in the outlet duct for the top
blades, and through machinery house for the bottom blades.
• Two (2) rectangular 16.50” x 24.75”, convex mirrors - (two supplied), mounted on the
shovel, one on the right side near the operators cab, and the second above the LH room, to
provide additional visibility for the operator.

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• Tow lug on front of carbody, field installed

• Tow lugs, two (2) on rear of carbody, field installed
• SUPERBOLT® tensioning system for rod bolt connection for crawler frames
• HYTORK® tensioning system for rod bolt connection for crawler frames.
• Counterweight ballast (265 lbs/cu. Ft. minimum density), approximately 424,000 lbs.,
delivered to USA site either domestic or export packed
• Export packing

TECHNICAL DOCUMENTATION
As standard, each P&H shovel Purchaser is supplied in English language, the following
documents:
• Operator Manual (three hard copies and three electronic copies)
• Mechanical Systems Manual (three electronic copies)
• Electrical Data and Wiring Listing (one electronic LinkOne format copy)
• Parts Manual (one electronic LinkOne format copy)

CUSTOMER SUPPLY ITEMS

Unless otherwise stated in a P&H proposal, required items, not included in our basic machine
supply are:
• Machine erection, including erection tools and equipment
• Counterweight ballast, approximately 424,000 lbs/192,300 kg with a minimum density of
265 lbs. per cubic foot (4,245 kg/m3) (Final counterweight determined by application.)
• Fluids/lubricants
• Trailing cable and electrical power supply.

*****

P&H - An enduring symbol of quality and reliability

NOTE: All designs, specifications and components of equipment described above are subject to change at manufacturer’s
sole discretion at any time without advance notice. Data published herein is informational in nature and shall not be construed to
warrant suitability of machine for any particular purpose as performance may vary with conditions encountered. The only warranty
applicable is our standard written warranty for this machine.

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 Digital Drive control

operating specification

meters

feet
22 72.2

20 65.6

18 59.1

16 52.5

14 45.9

12 39.4

10 32.8

8 26.2

4100C 6 19.7

4 13.1

2 6.6

0 0

2 6.6
meters 6 4 2 0 2 4 6 8 10 12 14 16 18 20 22 24
feet 19.7 13.1 6.6 0 6.6 13.1 19.7 26.2 32.8 39.4 45.9 52.5 59.1 65.6 72.2 78.7
C
  L Rotation

Working Ranges Capacity

Height of Cut 15.8 m 51 ft. 10 in. Nominal Pay Load 81.6 mt 90 st

Radius of Cut 24.7 m 80 ft. 11 in. Nominal Dipper Capacity

SAE struck 45.9 m3 60.0 yd3
Dumping Height* (Door Open) 9.1 m 30 ft. 0 in. SAE 2:1 50.8 m3 66.4 yd3

Floor Level Radius 16.4 m 53 ft. 8 in. Rated Suspended Load 154.2 mt 170 st

Tail Swing Radius 10.2 m 33 ft. 4 in. Optimum Truck Size 172-363 mt 190-400 st
(240 st truck shown)
Operator Eye Level 9.8 m 32 ft. 0 in.

* Height shown with bail-type dipper. Heights will be greater with

bail-less or compact-bail dippers. Actual dumping height can be
greater than door clearance height.
 Electrical Control Dipper & Dipper Trip
• Centurion Supervisory Controller provides direct integrated • P&H OPTIMA dippers combine consistent productivity with high
comunication with motor drives giving precise motor control and durability and maintainability. Dippers are configured to mine specific
fast cycle times. Real-time multi-tasking capability allows for optimal
conditions and capacity requirements from a variety of combinations
machine logic sequencing, monitoring and control.
of body and lip designs, as well as other unique P&H technologies.
• Centurion I/O System uses ‘Profibus’ communication protocol Specific wear packages and GET styles can be cooperatively
for seamless integration of all shovel subsystems and future specified.
expandability. Low-voltage 24V DC I/O drop points feature open and
short circuit detection for improved diagnostics and troubleshooting. • P&H TripRite system utilizes a brushless DC electric motor with
sealed planetary drive unit for reliable trip and slack take up
• Centurion Information System’s enhanced Graphical User Interface operation.
(GUI) features intuitive, icon-based screens to display vital
information such as shovel status, troubleshooting information, and
optional production monitoring data and operator feedback.

Hoist
• All gearing housed in single enclosed gear case with filtered oil
circulation for reliable splash lubrication and ease of maintenance.
Electrical DRIVE • Large diameter hoist drum for extended rope bending life. Ferrule
becket system and dual electric tuggers are standard for efficient
P&H Digital DC STATIC DC POWER CONVERSION AND REACTIVE POWER  rope change. Dual electric tugger option is available.
Compensation
• Spring set air release disc brakes - one per motor.
Hoist**/Propel Swing Crowd/Propel
Continuous
Armature
2x1860 kW 1860 kW 1860 kW
Converter KW
Rating @ 600 VDC* Crowd
15 Sec. Armature
Converter Current 3700 amp. 3700 amp. 3700 amp. • Powerband V-belt drive between motor and gear case absorbs shock
Rating* loads.
Continuous Field • First and second reduction gearing in enclosed gear case for reliable
150 amp. 150 amp. 150 amp. splash lubrication, ease of maintenance, and extended component
Converter Rating*
life.
* Based on outside ambient temperature of 50°C or 122°F.
** Cascaded hoist converters. • Twin leg dipper handle with torsion box and rack and pinion drive has
inherent stability in the bank for optimal digging.
P&H Digital DC Automatic REACTIVE POWER  Compensation*
• Spring set air release disc brake.
60 Hz. (7 step) 50 Hz (8 step)
Switched Steps +4725 kVAR Total +4500 kVAR Total
*Nominal rating at rated capacitor voltage (600 VAC)

P&H DC FAST RESPONSE MAIN MACHINERY MOTORS Swing

Hoist Motor Continuous rating @ 600 volts Total 1887kW/2530hp
(Two used) Peak developed power 2697kW/3615hp • Two modular P&H planetary gear cases of proven design and a
single piece forged swing gear transmit torque for fast cycle times.
Swing Motor Continuous rating @ 550 volts Total 746kW/1000hp
(Two used) Peak developed power 1257kW/1685hp • Spring set air release disc brakes - one per motor.

Crowd Motor Continuous rating @ 550 volts Total 537kW/720hp

(One used) Peak developed power 547kW/733hp
Propel Motor Continuous rating @ 550 volts Total 716kW/960hp
(Two used) Peak developed power 1263kW/1693hp Propel
• Two rugged P&H planetary gear cases of proven design
independently transmit torque to the drive sprockets, producing
the tractive effort required for fast, efficient propel and positioning
operations.
• P&H DELTA Drive low tension sprocket drive system with heavy duty
Power Requirements cast crawler shoes.
• Spring set air release disc brakes - one per motor.
Supply Voltage* 4160 or 7200V 5000, 6000 or 6600
3 Phase, 60 Hz 3 Phase, 50 Hz.
Supply Transformer (Minimum) 3000 kVA
Minimum Short Circuit VA Available at Shovel 25 MVA
*Voltage per customer requirements
Cable Data
TRANSFORMER Hoist (wire rope) 67 mm 2.62 in. dia. (std.)
Main Armature Transformer 2500 kVA 70 mm 2.75 in. dia. (opt.)
Auxiliaries-Field Transformer 450 kVA Suspension (bridge strand) 102 mm 4.00 in. dia.
Control/Lighting Supply Winding 50 kVA
Note: Transformer capacities may vary depending on options.
Dipper Trip (wire rope) 19 mm 0.75 in. dia.
 overall Dimensions
A Width 13.1 m 43 ft.   0 in.

B Length 15.8 m 51 ft.   8 in.

C Height Over Gantry 12.6 m 41 ft.   5 in.

1930 mm (std.) 76 in. (std.)

D Width of Crawler Shoes
2210 mm 87 in.    

E Width of Crawlers (std.) 9.9 m 32 ft.   4 in.

F Length of Crawlers 11.6 m 38 ft.   0 in.

G Ground Clearance 1.1 m   3 ft.   6 in.

H Height — Ground to Bottom of Counterweight 2.8 m   9 ft.   1 in.

B
A

C 4100C

H
G

D
F
E

Machinery Deck Plan

AIR COMPRESSOR LUBRICATION ROOM

HOIST MOTOR HOIST MOTOR

Reactive Power LUBE RESERVOIR

Compensation (522 LITER/138 GAL. each)
CABINET
LOW VOLTAGE
SWING MOTOR AND COLLECTOR
TRANSMISSION
SWING
TRANSFER CABINET MOTOR AND
TRANSMISSION
Converter Cabinet
HOIST DRUM
accessory panel
120 VAC
LOAD CENTER
GROUND FAULT
Suppression CABINET
Centurion
secondary CONTROL CABINET
breaker cabinet Touch Screen
Monitor

auxiliaries
Motor control
TRANSFORMER
center

MAIN TRANSFORMER auxiliary load

center
HIGH VOLTAGE CABINET
WITH ISOLATORS ELECTRONICS ROOM
 Ground Pressure & Weight FEATURES AND CUSTOMIZATION
BEARING AREA - GROUND PRESSURE The 4100C is built with several features to enhance safety,
Standard: reliability, and productivity over the lifecycle of the operation.
Crawler Bearing Area 34.69 m2 53,767 in2 • Automatic Lubrication and Compressed Air Systems with
76" Shoes/ 1930 mm advanced diagnostic and control
Crawler Ground Pressure 351 kPa 50.98 psi • Temperature Monitoring System for all DC motors, drum shaft
76" Shoes/ 1930 mm bearings, shipper shaft bearings
• Automatic Boom Soft Setdown System (ABSS) and Boom
Optional: Profile Protection Envelope to help prevent excessive loading to
Crawler Bearing Area 39.71 m2 61,549 in2 the attachment during operation
87" Shoes/ 2210 mm • Anti-Swing-in-Bank system to reduce excessive side loading on
Crawler Ground Pressure 308 kPa 44.70 psi handle and attachement
87" Shoes/ 2210 mm • Remote hoist control pendant and hoist rope winch to assist in
safe and efficient rope changeouts
WEIGHTS - APPROXIMATE* • House Pressurization System to provide filtered air for cooling
Working Weight (with Dipper, Approx. Wt.) and dust repression
76" Shoes/1930 mm 1,243,300 kg 2,741,000 lbs
The standard shovel can be customized for local and minesite
87" Shoes/2210 mm 1,247,800 kg 2,751,000 lbs specific conditions in the following areas:
Counterweight (Punchings)** 195,500 kg 431,000 lbs • Operator Cab
• Climate Control
* All weights subject to 5% variation.
• Cold Weather Equipment
** To be furnished by customer.
• Technology and Software
• Electrical and Mechanical Systems
• Maintenance Systems

Lighting
Standard: Metal Halide, 400 W, high intensity discharge (HID)
primary exterior floodlights (11) mounted on the
operator’s cab, RH room, LH room and machinery
house. Halogen, 500 W secondary exterior floodlights
(7) mounted under revolving frame corners, machinery
house and above cab door. Fluorescent lights (20)
illuminate interior of the machinery house, RH and LH
room.
Optional: High Pressure Sodium, 400 W or 1000 W primary
exterior floodlights. Secondary exterior floodlight
combination of Halogen, 500 W (3) and fluorescent
lights (6) mounted under revolving frame.

Loading Control Center

space for Mine
communications
Ante room equipment
(shown with
optional toilet)
Touchscreen Gui
and Optional remote
Electrical Cabinet camera system

Space for appliances

Armrest mounted,
pistol grip joysticks
Trainer’s Station

Lockers
6-way Power Adjustable Air Suspension
Storage Cabinet seat with heat and vibratory massage

NOTE: All designs, specifications and components of equipment described above are subject to change at manufacturer’s sole discretion at any time without
advance notice. Data published herein is informational in nature and shall not be construed to warrant suitability of machine for any particular purpose as
performance may vary with conditions encountered. The only warranty applicable is our standard written warranty for this machine.

P&H Mining Equipment  •  Box 310  •  Milwaukee, Wisconsin 53201 USA

XS-4187 2AG-207
 4100C TECHNICAL DESCRIPTION
January, 2007

The P&H 4100C is a heavy duty electric mining shovel which provides a 90 ton (81.7 metric ton)
nominal payload capacity specifically designed to operate in mines for high productive loading
of 190 ton to 360 ton (218 metric ton to 327 metric ton) haul trucks and larger.

This technical description is provided to compliment the 4100C main machine specification
XS-4187.

ELECTRICAL POWER SYSTEM

POWER SUPPLY
Electrical power to the shovel is Customer supplied via a trailing cable. Recommended
SHD-GC trailing cables, for 7,200 volt supply, are:

#2 AWG/35mm² 3000 ft./914m.

#1 AWG/50mm² 3700 ft./1128m.
1/0 AWG/55mm² 4550 ft./1387m.

Electrical equipment on the shovel is designed for an incoming supply of 3 phase/60 hertz/4,160
or 7,200 volts. Secondary voltage for auxiliary motors is 3 phase/60 hertz/480 volts.
(Alternatively, designed for an incoming supply of 3 phase/50 hertz/3,300, 6000, 6600, 7200, or
11,000 volts. Secondary voltage for auxiliary motors is 3 phase/50 hertz/380 or 415 volts).

Recommended 25 MVA, short circuit capacity, at the shovel.

LOWER HIGH VOLTAGE DISCONNECT SWITCH

Electrical power is brought to the shovel by connection of the trailing cable to the lower HV
disconnect switch which is mounted on the rear of the carbody. A cable coupler is mounted on
this switch and mating PLM coupler is provided for the trailing cable end. The switch provides a
visible disconnect, grounding, and a safety key interlock which energizes or disconnects
electrical power to the entire machine. HV wiring runs from this switch through the carbody to
the HV collector rings on the upper deck. The standard cable coupler is a PLM brand quick
disconnect type. Other couplings are available upon request.
 Model 4100C
Technical Description

HIGH VOLTAGE COLLECTOR RINGS

High voltage collector rings consist of three (3) power and one (1) ground ring, and are mounted
on top of the carbody. All rings are extra wide to provide proper contact with collector shoes
which are mounted under the revolving frame. Ring access is protected by bolted carbody hole
covers.

LOW VOLTAGE COLLECTOR RINGS

Low voltage collector rings, which transmit lower voltage power from upper to lower are deck
mounted above the center gudgeon. The LV collector cover is window equipped for viewing of
rings and brushes for inspection.

UPPER HIGH VOLTAGE DISCONNECT

Fully contained cabinet contains two visible high voltage disconnects to 1) isolate the entire
upper H.V. supply, and 2) isolate the primary of the Main Transformer, vacuum contactor, line-
to-line and line-to-ground lightning arrestors for surge suppression. Current limiting HV fuses
provide short circuit protection for the primary of the Main Transformer and the primary of the
Auxiliary Transformer

MAIN TRANSFORMER
Designed for mining shovel service, 2500KVA rated, dry type; Delta/Wye connected,
minimizing third harmonic current flow to external circuits, simplified ground fault detection.
Transformer can accommodate unequal loading, has ±5% voltage taps, and temperature
monitored windings. Main Transformer provides power for the Converter Cabinet motion
thyristor bridges which control the power to the DC drive motor armatures and fields. For power
monitoring a Multilin MTM-Plus meter module is provided as standard.

AUXILIARY TRANSFORMER
Like the main transformer, the auxiliary transformer is designed for mining shovel service, is of
the dry type, and is Delta/Wye connected. It is rated at 325 KVA. Four (4) secondary windings
provide power for:
(1) 60HZ/480 Volts (Alternatively 50HZ/380 or 415 Volts) for utilities and auxiliary motors.
Power from the transformer flows to an Auxiliary Load Center, Auxiliary Cabinet motors.
(2) Shielded winding supply for the Control System
(3) Field supply voltage to the DC drive motor, field power bridges.
(4) Lighting and GPO’s supply, 45 KVA rated, and distributed through the 120 VAC
(alternately 240V) load center

POWER CONVERTER CABINET

The P&H Digital DC power conversion system contains the simple six-thyristor three-phase
bridges used to statically convert AC supply power to controlled DC supply to motion drive
motor armatures for speed and torque regulation. This thyristor bridge inherently also allows for

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 Model 4100C
Technical Description

invert regenerated DC energy to AC power during motion deceleration. The regenerated power
is used to supply the on board needs with the excess going back to the mine network for energy
savings.

Thyristors are mounted in easily accessible heat sinks and are forced air-cooled. A patented fast
acting over-current system, diverter system, senses and limits the over-current to the DC motors
eliminating destructive flashovers.

POWER DISTRIBUTION
All High Voltage cables are run in metal conduit. An enclosed over head copper bus system is
used to carry the power from the Main Transformer to the Converter cabinet. All other wiring is
generally run in raised troughs on the machinery deck floor. Power cables are XLPO (cross-
linked polyolefin) insulated

REACTIVE POWER COMPENSATION (RPC) SYSTEM

Housed in a rugged, ventilated cabinet, the RPC system contains stepped tuned banks of
capacitors and reactors, automatically and synchronously switched on and off the line, to
maintain average system power factor near unity. Tuned banks provide a high level of harmonics
filtering of the predominant harmonics generated by the converters. Synchronously applied
stepped compensation eliminates transients during application and disconnection.

TRANSFER CABINET
The transfer cabinet contains heavy duty contactors to transfer the power from the hoist and
crowd converters to the propel motors in the propel mode. Transfer is initiated by a push button
on the console in the operator’s cab with all sequencing handled automatically by the
programmable industrial controller.

DC DRIVE MOTORS
P&H designed, manufactured, and tested motors are specifically for mining service duty, with
Class "H" insulating system. Drive motors are equipped with RTD’s to monitor motor bearings
and winding temperatures, and all are equipped with heavy duty blowers with screen protected
air inlets. Optional brush grades are available for unusual operating conditions.

Remote Hoist Pendant Controller included in machinery house with variable speed control to
turn hoist drum during hoist rope changes.

ELECTRICAL CONTROL SYSTEM

P&H CENTURION™ SHOVEL CONTROL SYSTEM
The P&H Centurion™ Shovel Control System provides the supervisory control of the shovel
drives and executes the sequencing and monitoring functions, and consists of the supervisory
control computer and supporting hardware devices and software programs. The system is

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 Model 4100C
Technical Description

comprised of three basic areas: 1) the onboard graphical user interface (GUI), 2) the remote
input/output (I/O) devices and communication interface, and 3) the individual drive controllers.

The architecture provides connectivity from components on the shovel to the onboard GUIs and
provides diagnostic and monitoring capabilities. The application code residing within the
supervisory controller is based on the IEC 61131 standard. The control system uses Profibus over
fiber optic and copper media for communications with the various system components.

SUPERVISORY CONTROL CABINET

Components for the P&H Centurion™ Shovel Control System are housed in a rugged,
maintenance friendly cabinet, which is located in the RH Electronics room. The drive system for
the P&H TripRite dipper trip system is also housed in the Supervisory Control Cabinet.

LOWER CONTROL CABINET

The lower control cabinet is mounted on the back of the carbody, and contains remote I/O, motor
starters for the propel motor blowers, air solenoid valves for the brakes, and electrical
convenience outlets.

REMOTE I/O’S
The supervisory control system functions with remote I/O in several locations such as lower
propel, LH lube room, RPC cabinet, converter cabinet, transfer cabinet, auxiliary cabinet, and
operators cab.

AUTOMATIC ATTACHMENT PROTECTION SYSTEMS

Hoist and crowd/retract limits are set on the GUI touch screen located at the loading control
center in the operator's cab. A boom profiling limit is included to help prevent contact of the
handle torsion box and dipper with boom. The ABSS (Automatic Boom Soft Set-down) feature
is part of the control system and minimizes boom jacking and the associated impact of abruptly
lowering the boom from a jacked condition.

MOTOR CONTROL CENTER (MCC)

A large maintenance friendly cabinet contains individual motor starters and circuit breakers,
which provide thermal and short circuit protection for each motor. For electrical isolation, the
controls for each individual motor are housed in an individual cubicle. In addition to motor
control, there are cubicles to control house heaters and lights. The MCC is located in the
environmentally controlled RH electronics room.

OPERATOR INTERFACE
LOADING CONTROL CAB

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 Model 4100C
Technical Description

The operator is stationed in a roomy cab that is mounted on the right hand side of the machine
above the electrical room. The operator is positioned at a 15 degree angle off of the cab
centerline toward the dipper. The operator has a wide view of the dipper and bank and
surrounding loading area. The cab is FOPS (Falling Object Protection System) certified, and has
sound levels below 70 dBA while the shovel is operating when the doors and windows are
closed. A standard front window wiper system is provided. A catwalk system provides access
for cleaning, maintenance, or replacement of the windows. Access to the cab roof is provided via
ladder and roof handrails. A single two tone air horn mounted on the RH room is also included.

All windows are tinted safety glass. The front windows are 0.375 inch / 9.5 mm thick laminated
safety glass. Side and door windows are fixed in place and made from 0.25 inch / 6 mm
tempered glass. The standard cab features storage lockers, desk/counter space, and provisions for
mounting mine supplied microwave or toaster oven and refrigerator. There is a work space with
seat for an operator trainer located behind the operator. A separate room is located behind the
operator cab that can be customized by the mine for additional storage or used for a toilet.

P&H LOADING CONTROL CENTER

The P&H Loading Control Center provides a single location of control for shovel operation and
truck loading.
The standard seat base is an air suspension type which can be adjusted for operators height and
weight. The seat has an automotive style power system which provides vertical and fore / aft
adjustment to allow custom fitting of the joysticks to individual operators. The seat has heat,
lumbar support, and massage. The entire seat, armrest assembly is mounted to a vibration
isolated sled with an integral footrest. The angled footrest swivels into two positions.

The joystick contollers are Hall-Effect, pistol grip style with both push button, trigger switch, and
rocker switches built into the grips. There is a single console on the left hand side of the operator.
All control devices and most auxilary functions such as those for climate control and lighting are
located within reach of the operator while seated. An AM/FM radio receiver with 5 disc CD
changer is included. The console has provisions for mounting the standard P&H GUI touch
screen as well as optional and mine supplied items such as camera monitors, radios, and dispatch
screens.

GRAPHIC USER INTERFACE (GUI)

The GUI has menus and information screens thatallow the operator todisplay information, and
perform various operation functions. The basic functions performed by the GUI are:
• Display machine operating status
• Display and set hoist and crowd limit setting (boom profiling)
• Provide fault enunciation and alerts
• Display temperature monitoring bar graphs
• Display boom jacking status
• Display boarding ladder positions

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 Model 4100C
Technical Description

• Display lubrication system settings and status

• Provide for manual initiation of lubrication cycles

STANDARD DIAGNOSTICS
The Centurion GUI provides the following standard diagnostics:
• Standard Temperature Monitoring system - all DC motors (windings and bearings), drum
shaft bearings boom shipper shaft bushings, and ambient air temperature. Graphical
temperature shown on touch screens.
• Drive programming and analysis software to allow maintenance personnel to record and
perform on line diagnostics of main motion drive paramerters, settings, and performance.
• Control logic software to allow maintenance personnel to view controller logic program,
verify functions, and force parameters for diagnostic purposes.
• Input/Output (I/O) divice monitioring and fault detection system to identify location and type
of fault.

CLIMATE CONTROL
An optional P&H MineAir Systems MAS 1500 mine duty air conditioner unit is available. A
single unit can be fitted to the operator cab, or two units can be fitted, one for the cab and one for
the electronics room. Each MAS 1500 unit is capable of delivering 14 kW cooling (48000
BTU/Hr), and 18kW heating. Units are fitted with an efficient air filtration system, which
pressurizes the cab and electrical room.

LIGHTING
Primary exterior floodlights: Standard lights are Metal Halide, 400 watt, 60HZ/120V
(alternatively 50HZ/220V), high intensity discharge (HID) units.

Standard primary exterior floodlight locations (nine are wide beam and two very narrow beam)
are as follows:
• Two (2) on front of operator’s cab, below the front window.
• Two (2) on top front of lube room
• Two (2) right side of house
• Two (2) top rear of house
• One (1) on front of house below RH room
• One (1) on front of house below LH room
• One (1) top left side of house

Secondary exterior floodlights: Standard are Halogen, 500 watt units. Standard secondary
exterior floodlight locations are as follows
• One (1) above operator’s cab door
• Two (2) on the lower front of machinery house
• Four (4) under revolving frame corners

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 Model 4100C
Technical Description

Exterior incandescent: Five (5), 100 watt; one (1) at each machinery house door and one (1) at
operator’s cab door.

Interior lighting: Twenty (20) fluorescent lights are provided to illuminate the machinery house,
RH electrical room and LH lube room.

Operator’s cab lighting: Incandescent 100 watt ceiling light.

One (1) portable halogen trouble light is also provided as standard for primary use at convenient
roof top outlets.

ELECTRICAL CONVENIENCE OUTLETS

Electrical outlets for 110/120 volt supply are conveniently located:
• One (1) in lower control box on rear of carbody
• Two (2) under revolving frame platforms
• Seven (7) In machinery house
• One (1) on RH catwalk
• Two (2) in RH electronics room
• One (1) in LH lube room
• Three (3) in Operator’s cab
• Two (2) on house roof

Outlets are GFI protected. GPO’s are 15 amp, duplex, NEMA 5-15 straight blade devices, 2
pole, 3 wire grounded and 125V rated.

Special instrument outlets are located in the Supervisory Control Cabinet.

Three (3) 60HZ/460V (Alt. 50HZ/380V) outlets are also provided; one (1) in RH electronics
room, one (1) in LH lube room and one (1) in Operator’s cab. These outlets are 20 amp, 3 wire,
4 pole, IEC 309 type.

A single welder outlet receptacle (60Hz/460V, alternatively 50Hz/380V) is provided, located

near the RH door in the machinery house.

MECHANICAL SYSTEMS
CRAWLER DRIVE SYSTEM
The crawler drive system incorporates rugged lug and tumbler and sprocket design concepts. On
the P&H sprocket style drive system, the shoe and tumbler engagement is close to the link pin
centerlines.

CRAWLER SHOES

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 Model 4100C
Technical Description

Deep section, cast manganese shoes are connected with 5 inch alloy steel induction hardened
pins through machined, line-bored holes. Shoes are designed specifically for the P&H sprocket
style drive system. Standard crawler shoes width is 76 inches (1930mm).

CRAWLER FRAMES
The frames are a heavy welded box section designs with bolted fit to carbody under full shear
ledge support with large dowels to prevent movement in the bolted connection. There is no field
welding required in the connection. There are eight (8) lower rollers, a front, and a rear idler in
each frame. The front idler is large diameter manganese casting, which is mounted on two (2)
heavy duty bushings. Lower rollers and idlers are V-ring sealed to exclude contaminates and
hardened wear surfaces protect crawler frame wear. Rollers and idlers are straddle mounted with
special alloy brass bushings. “P&H 50+” lower rollers are hardened to over 50 on the Rockwell
C scale. Replaceable pin-on, high hardness, wear resistant cast slide bars on top of each frame
support the crawler shoes.

CARBODY
The carbody is a heavy welded high strength low alloy steel structure of cellular deep box
sections, built around a large center hub casting. The flattop design with deep section diaphragm
plates provides direct support of roller path. Carbody interior is painted white and is equipped
with an electrical convenience outlet for trouble light use. Swing gear and lower swing roller
path are mounted on the top of the carbody with dowels and bolts. The crawler frames are
connected to the carbody by a full-length shear ledge and long rod bolts. Both carbody and
crawler frames designed to withstand the high level of crawler frame connection bolt tension.
The crawler frame connection bolts produce very high clamping forces between the crawler
frame and carbody machined surfaces. The standard tensioning system for the rod bolts consist
of simple bolt and nut arrangement.

DUAL PLANETARY PROPEL SYSTEM

Dual independent P&H DC drive motors rated at 960hp/716kW total continuous power at 550V
and 1639hp/1223kW total peak developed horsepower, drive the propel system and are load
sharing controlled. Motors are mounted in a propel motor base which is bolted to the rear of the
carbody. Motor frame adjusting screws are integral to the base for ease of alignment, and the
motors are directly connected to P&H planetary propel transmissions with a gear coupling. The
planetary propel transmissions are directly mounted to each crawler frame, and provide
differential speed and counter-rotational steering capability. All gearing is forged, anti-friction
bearing mounted, and all external gears are case hardened and ground. Propel transmissions are
designed with bath and splash lubrication to all gearings and bearings.

The P&H DELTA drive system has a raised final propel drive shaft and tumbler. The final
propel drive shaft is spline connected to the planetary transmission and tumbler, and is mounted
on anti-friction bearings. The outboard spherical bearing is encapsulated to prevent crawler frame

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 Model 4100C
Technical Description

damage in the event of a bearing failure. V-ring seals are used to seal out dirt and seal in
lubricant.

CENTER GUDGEON
The Center Gudgeon is a hollow heavy-duty forging used to connect the upper revolving frame to
the lower carbody. Acme threads are provided on the upper and lower end of the gudgeon. The
gudgeon is a cascaded interference type fit in the center hub casting of the carbody. A locking
mechanism on the upper threads allows fine adjustment capabilities and positive retention of nut
position. Gudgeon center hole is used for electrical wiring, lube, and airlines between upper
revolving frame and lower machinery.

REVOLVING FRAME
The revolving frame is a heavy welded high strength low alloy steel structure of cellular deep
box sections built around a large center casting. The rolled, full depth internal turret plates align
with the swing roller path and provide 360° direct load transfer support. A wide roller path
support pad on the underside of the frame provides a pilot ring to prevent radial movement of the
upper path. Deck machinery is mounted via tapped holes or pin supported and no internal access
is required to mount the machinery. A standard drain system allows for the hoist and swing
transmissions to be evacuated through piping to below the revolving frame deck (crowd drains to
boom foot platform).

COUNTERWEIGHT BOX AND CASTINGS

A sectioned counterweight box is mounted to the rear of the revolving frame to accommodate the
counterweight ballast. Large solid castings are mounted to the rear of the counterweight box to
provide a stabilizing moment.

DECK PLAN
Side platforms, which mount to the revolving frame, extend the deck width. Conveniently
arranged floor plan with abundant space facilitates maintenance.

ELECTRONICS ROOM
A separate large room is mounted on front right corner of the revolving frame and houses the
supervisory control cabinet and motor control center. It is insulated with 0.5 inch/12.7mm
material; equipped with 0.75 hp fresh air blower (not used with optional air conditioner),
secondary wall and door air filter, and louvered front wall vent panel. Two (2) doors are provided
for improved access; one (1) leading to machinery house and one (1) to outside catwalk. RH
room also is the support base for the RH elevated operator’s cab.

LUBRICATION ROOM
A separate room is mounted on front left corner of the revolving frame, which houses lube tanks,
pumps, plumbing, and controls (remote I/O connection for lube system monitoring and control);

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 Model 4100C
Technical Description

and most air system components including the receiver. Room is insulated with 0.5
inch/12.7mm material, and can be optionally heated for improved cold weather operation.

MACHINERY HOUSE
Truss style roof with weather tight, removable hatch covers for accessibility to internal
machinery. Roof panels are strategically located to direct crane picks of major deck mounted
components as required.

HOUSE PRESSURIZATION AND FILTRATION

House is pressurized and air is filtered by a high efficiency inertial filter system. Ambient air is
drawn from the forward facing intake hoods by two large vane axial fans and passes through the
filter panels which removes airborn dust particles and allows the cleaned air to pass through to
the machinery house. Bleed airflow is created by two blowers and carries dirty air through ducts
to the outside at the rear of the house. Clean house air is directed to the rear portion of the house
to provide greater cooling of deck mounted components. Access is provided to filter and blower
units from the house roof.

The 4100C shovel can be ordered with an optional Airscrub Pro high efficiency house air
filtration system. The Airscrub Pro system is a cartridge filtration system that is 99.9% efficient
by weight at .3 micron and greater particulate size. The air inlet is located at the top of the unit
and is protected by an expansive rain/snow hood, which limits the ingress of moisture in the air
and dust from the roof into the filters. There are two main 40 hp two-stage blowers that provide
airflow through the filters and into the machinery house. Dirty air is trapped on the outside of
self-cleaning, replaceable filter cartridges while clean airflow continues through the cartridges
and into the machinery house. The filter cartridges are automatically cleaned by regularly timed
blasts of pressurized air. Accumulated dust and dirt on the outside of the cartridges falls into a
hopper and a screw type conveyor automatically carries the dust off the machine and onto the
ground. Filter cartridges are replaceable from the machinery house roof. Access to make fan
blade setting adjustments is achieved through an access door in the outlet duct for the top blades,
and through machinery house for the bottom blades.

COLD WEATHER EQUIPMENT

The RH and LH rooms are equipped with insulation as a standard feature. The air valves for the
lower works are located in the heated lower control cabinet as standard, and the automatic
moisture dump valve for the main air receiver is located in the heated LH lube room as standard.
Heating options are available.

BOARDING AND ACCESS

A right side pneumatic controlled stairway and left side vertical pull-down ladder are interlocked
to de-energize swing and propel functions when in down position for safety. Catwalk/platforms,
with grated metal surface, hand rails, and toe boards are provided in access areas. Roof grating is
welded to roof panels.

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 Model 4100C
Technical Description

HOIST DRIVE SYSTEM

Dual P&H DC motors rated at 2530hp/1887kW total continuous power at 550V and
3823hp/2889kW total peak developed power drive a modular gearcase pinned to the revolving
frame. First reduction is helical gear set, second reductions spur and a reversible spur drum gear.
All gearing is forged machined, case hardened and ground. Transmission is oil tight with anti-
friction bearings and standard oil filtration and circulation system. Gearing is splash lubricated. A
lube pump and filtration system is standard, and is designed for use with high viscosity
lubricants, even in cold temperatures.

The hoist drum is a large 65 inch (1651 mm) pitch diameter drum with through shaft and flame
hardened grooves. Standard hoist rope is 2.625 inch (67 mm) diameter cable fully plastic
impregnated and compacted. Hoist drum grooving is machined to accept 2.75 inch (70 mm)
diameter hoist rope. Hoist drum and cable are provided with high capacity Ferrule Beckett
fittings to simplify cable change out. Hoist limits are programmable from operator's cab. Hoist
drum bearings are equipped for temperature monitoring.

HOIST CABLE TUGGER

Dual electric driven tuggers are standard to assist with hoist cable changes and each tugger has
3000 lb.(1361 kg) rated pulling capacity.

SWING DRIVE SYSTEM

Swing power is provided by two (2) P&H DC drive motors rated at 1000hp/746kW total
continuous power at 550V, and 1662hp/1239kW total peak developed power and are connected
in series. P&H Planetary transmissions are mounted front and rear of swing gear for even
loading. Some components are interchangeable with first and second reductions in the propel
transmissions minimizing parts stocking requirements. Planetary swing transmissions are
designed with bath and splash lubrication for all bearings and gearing. An optional oil filtration
system is available.

Swing shafts are mounted on anti-friction bearings and are removable without disturbing the
transmission. Forged swing gear has 17 foot-2 inch/5.23m diameter with a large 14.5
inch/368mm tooth face width. Swing circle uses a quantity of 54 tapered rollers, 10 inch/254mm
in diameter, carried on self-lubricating bushings. Rollers and roller paths are high alloy, forged,
quenched and tempered to a high hardness. Full circle of rollers are in contact with the 360°
upper and 360° lower roller paths, which have a wide mounting surface to the carbody and
revolving frame. Upper path is dual flanged mounted with guarding to retain mounting hardware
in the event of loss, and the lower path is clip mounted to the carbody on the inner diameter and
retained by the ring gear outer diameter.. Gear shrouding system prevents contamination of gear
and roller path area, and can be opened to enable inspection of gear and roller circle.

CENTRALIZED LUBRICATION SYSTEM

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 Model 4100C
Technical Description

An automatic centralized lubrication system is standard and provides metered amounts of

lubricant to all major systems requiring grease and open gear lubrication. Lincoln 75:1 ratio air
drive pumps are used. Lube system, is programmable industrial controller controlled and is
monitored through touch-screen MMI’s. Large 138 gallon open gear and 138 gallon grease
maximize operating time. A lube filtration system is standard for the hoist and crowd gear case.

AIR SYSTEM
Compressed air is provided for lube pumps, lube sprayers, disc brakes, hoist cable tugger, air
operated stairway, horn, and operators seat. Standard air compressor is a rotary screw type, floor
mounted, with separate 200 gallon capacity air receiver which is ceiling mounted in the
lubrication room. The compressor is designed for cold weather operation.

BRAKES
All motions have disc brakes, which are spring set-air released. Brakes have replaceable wear
surfaces, and a low abrasion, high heat capacity friction material is used. Select brakes are
equipped with centering mechanisms to minimize contact of frictional surfaces when brake is
released.

BOOM
64 foot (19.51m) length set at a 45° angle; welded structure of high strength low alloy steel for
cold weather toughness; extra width and depth for high load capability; 96 inch (2438mm)
diameter point sheaves, split bearing block mounted for maintenance ease. Boom suspension
cables are 4 inch (103 mm) structural strand. Integral lifting lugs and wear resistant side boxes
are incorporated. Boom is connected to revolving frame lugs with heavy duty lubricated pins
retained with split collars. Boom bumpers are mounted to the boom to reduce damage from
contact with the handle torsion box.

CROWD SYSTEM
Crowd and retract of the dipper is accomplished by one (1) P&H DC motor rated at
720hp/537kW continuous power at 550V and 1162hp/867kW peak developed power driving the
P&H - POWERBAND "V" BELT - shock absorbing/system to modular, enclosed, transmission
with spur gear reduction to manganese racks and forged, machined and hardened crowd pinions.
V-belt sheaves are fully machined and balanced. Gearing is forged, case hardened and ground;
mounted with encapsulated, pre-adjusted bearings. A transmission oil filtration system with
basket strainers, 20 micron filtration pump and motor is included. Single piece saddle blocks are
hydraulically adjusted and allow for removal of crowd pinions. Crowd/retract limits
programmable from the operator's cab.

DIPPER HANDLE
35 foot (10.67m) effective length; high strength low alloy, cold weather steel; straddle design,
straight legs and large cast manganese racks providing strength for corner tooth digging loads.
Handle geometry provides for torsion box clearance with the boom.

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 Model 4100C
Technical Description

DIPPER TRIP
Dipper trip system is a 10HP; brushless DC motor driving planetary gearing to a heavy duty
drum. The solid state drive components for the dipper trip system are located in the supervisory
control cabinet, and are adjustable through the GUI. Both ferrule becket and cable clamp
connection capability is provided for securing dipper trip cable to the drum. Trip line is
connected to dipper latch lever bar via a two part sheave system on the dipper door. An integral
disk brake on the motor sets when not in use.

PAINT
Standard exterior is P&H Yellow and Black. Yellow on machinery house and operator’s cab.
Black on lower, attachment, catwalks and handrail. (Lower HV disconnect switch is painted
red). Interior of house, RH and LH rooms, carbody, revolving frame and lower boom section and
all electrical cabinet interiors are painted high visibility white.

WEIGHTS
Working weight of the P&H Model 4100C with nominal dipper and 76 inch (1930mm) wide
crawler shoes is 2,741,000 lbs. (1,247,833 kg.)

OPTIONAL ITEMS DESCRIPTIONS

P&H DIPPER
• P&H Optima 90 Dippers are available to optimize fill factors and payloads in any
application.

ELECTRICAL EQUIPMENT
• High Altitude 3048 - 4270 m / 10000 to 14000 ft main transformer

LIGHTING
• Primary exterior lighting (11) high pressure sodium, 60Hz, 120V, 400W
• Primary exterior lighting (11) high pressure sodium, 60Hz, 120V, 1000W
• Primary exterior lighting (11) high pressure sodium, 50Hz, 220V, 400W
• Primary exterior lighting (11) high pressure sodium, 50Hz, 220V, 1000W
• Primary exterior lighting (11) metal halide, 50Hz, 220V, 400W
• Secondary exterior; (3) Halogen, 500W and (6) Fluorescent under revolving frame

AIR SYSTEM
• Dual (2) rotary screw air compressors with automatic switching, floor mounted. One (1)
separate 200 gallon air receiver in lube room.

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 Model 4100C
Technical Description

• Membrane air dryer system for rotary screw air compressor (Note: Only one unit required for
single or dual compressors)
• Air hose reel w/30m/100ft of hose

NOTE: Consult Shovel Marketing for applicability of other compressors

LUBRICATION SYSTEM
• Wiggins quick fill connectors for lube tanks
• Lube tank pre-filters, one system for open gear tank and one for grease tank.
• Lube tank heaters, open gear and grease tanks.

BOARDING ACCESS
• Left hand air stairway-in place of standard left hand pull down ladder

HOIST CABLE
• 2.875" dia., 376' long 8x37 RLL plastic impregnated compacted

CRAWLER SHOES
• 87" wide, flat manganese with 5" induction hardened pins

PAINT
• Color Change using P&H paint spec.
• Customer Logo on machine away from P&H logo and model name, painted, one or two
colors, customer to supply template
• Customer Numbers painted on machine

OPERATOR CAB
• Front window electric wiper and spray wash system
• Sliding windows – two sliding windows with screens in place of side trainer and rear window
– 0.25 inch / 6mm tempered tinted glass
• Incinerating toilet system for utility room
• Video Monitoring System (Intec)- four (4) color cameras and two (2) color monitors for blind
spot monitoring - inside and outside of machinery house
• Satellite radio receiver in place of AM/FM/CD (Customer specify XM or Sirius)
• Sun shades, pull down - front window only
• Sun shades, pull down - all windows
• Air Horn - dual two tone mounted on RH electronics and LH lube room
• Electric Horn with adjustable volume - single in place of standard air horn
• Electric Horn with adjustable volume - dual, mounted on RH electronics and LH lube room
in place of standard single air.

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 Model 4100C
Technical Description

CLIMATE CONTROL
• Mine Air Systems unit for operator's cab only; Model MAS 1500, cooling to 48,000 BTU/hr
(14kW), heating to 18kW; with air filter-pressurizer and R407C refrigerant
• Mine Air Systems units for operator's cab and electronics room; two (2) Model MAS 1500
units; cooling to 96,000 BTU/hr. (28 kW) total, heating to 36 kW total; with air filter-
pressurizer and R407C refrigerant (Note: Deletes blower in electronics room)
• Sigma unit for operator's cab only; Model MPV7; cooling to 24,000 BTU/hr. (7kW), heating
7 kW; with air filter-pressurizer and R134a refrigerant
• Sigma unit for operator's cab and electronics room; one Model MPV15; cooling to 15kW,
heating 2-stage 18kW; with air filter-pressurizer and R134a refrigerant (Note: Deletes blower
in electronics room)

NOTE: A/C is mandatory for electronics room in high ambient temperature environments

JIB HOIST
• Swing jib hoist; 8.9 kN / 2,000 lb. capacity mounted outside LH lube room

FIRE SUPPRESSION
• Fire extinguisher, 20lb. dry chemical, Model I-A-20G, (3 standard)

Note: Fire suppression systems are locally contracted by P&H MinePro Services. Typical
systems consist of clean agent suppression system for electrical cabinets, RH room, LH
room, and collector ring assembly.

TRAIL CABLE REEL

• Trail Cable Reel, air drive, level winding, 48" diameter drum
• Trail Cable Reel, hydraulic over electric drive, level winding, 48" diameter drum.
• Mounting material for trail cable reel (air or hydraulic)

COLD WEATHER EQUIPMENT

• 2.5cm / 1 inch insulation in machinery house
• 7.5KW heater in operator's cab (not required if Cab AC option is chosen)
• 7.5 kW heater in RH electrical room
• 7.5 kW heater in LH lube room
• Strip heaters for main control cabinets
• Strip heaters for main D.C. motors
• Strip heaters for main and auxiliary transformers
• 40 kW machinery house heater, maximum of 3, each

NOTE: Membrane air dryer should be included in cold weather applications.

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 Model 4100C
Technical Description

TECHNOLOGY AND SOFTWARE

• Extended Upper Temperature Monitoring system - standard plus crowd gearcase bearings,
hoist gearcase bearings, swing shaft bearings, upper gearcase oil, and center gudgeon hub.
• Extended Lower Temperature Monitoring system - standard plus final drive bearings and
propel gearcase oil.
• P&H Optidig II operator assist tool that co-ordinates the hoist and crowd motions to prevent
the dipper from stalling while digging.
• Motivator Mode software to modify drive performance and RPC function in order to allow
mine supplied motivator at the trail cable voltage to be used to propel.
• ShoveLink Remote Communications Version I - software for mine supplied computer and
ethernet based communication link. Software allows user to veiw electrical feedback, sensor
information, diagnostics, and GUI screens in real time. Maximum of two (2) users per shovel.
• P&H Payload dipper load weighing system
• P&H Payload Plus dipper load weighing system with auto calibration and NIST calibrated
and certified boom point pin load cell.
• P&H Payload Reporter – Microsoft® SQL server, web-browser based reporting package
produces single or fleet based production reports from Payload Plus data.

MISCELLANEOUS ELECTRICAL
• Electrical Cabinet Filters for RPC and converter cabinets
• Extra Welder Outlet in machinery house, near LH door. 2 max.
• Ground Fault Protection for welder outlets. 3 max.
• Extra Welder Outlet (600V) in machinery house including transformer and ground fault
protection. 4 max.
• Emergency Lighting Unit - six lights total per unit - two (2) on power supply and four (4)
remote mounted - field installed
• Communication System (Gai-Tronics), 3-way, field installed, one on exterior, one in machine
house, and one in operator cab.
• Trail Cable Connector Extension with PLM cable coupler to extend trail cable connector to
rear of propel motor base. (Note: Not for use with trail cable reel. Coupler types other than
standard PLM must be specified)

MISCELLANEOUS MECHANICAL
• Central Drain System for hoist and swing transmissions - field installed
• Lube Filtration with 20 micron filter on each swing transmission
• Blower and Brake Removal System in machinery house - field installed
• P&H Air Scrub Pro high efficiency house pressurization system in place of std
• Convex Mirrors - two (2) rectangular 16.50" x 24.75” on front of machine
• Tow Lug, Front of carbody - field installed
• Tow Lugs, Rear, two (2) on rear of carbody - field installed

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 Model 4100C
Technical Description

• Hoist Drum Lock System which provides a mechanical lock to prevent movement of
suspended handle and dipper - field installed
• Slack Hoist Cable Detection system
• Fall Protection Lanyard Attachment points - field installed
• Removable Handrail System for hatch cover openings - field installed
• SuperNut rod bolt connection for crawler frames in place of standard nut.
• HYTORC rod bolt connection for crawler frames in place of standard nut. (Does not include
HYTORC tooling which is required for tensioning)
• Export packing
• Counterweight ballast, 265 lbs./cu.ft. minimum density. Contact product engineering for
ballast amount. Delivered to USA site, DOMESTIC PACKED
• Counterweight ballast, 265 lbs./cu.ft. minimum density. Contact product engineering for
ballast amount. Delivered to USA site, EXPORT PACKED

TOOLS, TEST EQUIPMENT AND ASSEMBLY AIDS

• HYTORC tooling (hydraulic power pack not included)
• For other tools and test equipment including software contact P&H Service Department.

TECHNICAL DOCUMENTATION

• Operator's Manual, CD ROM, (3 std), each extra

• Operator's Manual, hard copy (3 std), each extra
• Mechanical Systems Manual, CD ROM, (3 std), each extra
• Mechanical Systems Manual, color hard copy, each
• Electrical Systems Manual, CD ROM, (3 std), each extra
• Electrical Systems Manual, color hard copy, each
• Parts Manual, hard copy, each (see note below)
• Electrical Data Manual, hard copy, each (see note below)

Note: The LinkOne Viewer allows the end user to print individual pages or complete parts
manuals. P&H Mining Equipment grants the end users of its parts manual the authority to
print hard copy manuals as required. Electronic copy can be installed on as many
computers as desired.

Note: Specify English or Spanish language. Consult Peak Services for other language
requirements.

CUSTOMER SUPPLY ITEMS

Unless otherwise stated in a P&H proposal, required items, not included in our basic machine
supply are:

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 Model 4100C
Technical Description

• Machine erection, including erection tools and equipment

• Counterweight ballast, approximately 431,000 lbs/195,498 kg with a minimum density of
265 lbs. per cubic foot (4,245 kg/m3) (Final counterweight determined by application.)
• Fluids/lubricants
• Trailing cable and electrical power supply.

*****

P&H - An enduring symbol of quality and reliability

NOTE: All designs, specifications and components of equipment described above are subject to change at manufacturer’s
sole discretion at any time without advance notice. Data published herein is informational in nature and shall not be construed to
warrant suitability of machine for any particular purpose as performance may vary with conditions encountered. The only warranty
applicable is our standard written warranty for this machine.

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 ®

4100A
ELECTRIC MINING SHOVEL

OPERATING SPECIFICATIONS

meters
feet
22 72.2

20 65.6

18 59.1

16 52.5

14 45.9

12 39.4

10 32.8

8 26.2

6 19.7

4 13.1

2 6.6

0 0

2 6.6
meters 6 4 2 0 2 4 6 8 10 12 14 16 18 20 22 24
feet 19.7 13.1 6.6 0 6.6 13.1 19.7 26.2 32.8 39.4 45.9 52.5 59.1 65.6 72.2 78.7
C
L ROTATION

CAPACITY
WORKING RANGES
Nominal Pay Load 81.6 m ton 90 ton
Height of Cut (Max) 16.38 m 53 ft. 9 in.
Nominal Dipper Capacity 47.4 m3 62 yd3
(SAE struck) Radius of Cut (Max) 24.79 m 81 ft. 4 in.

Rated Suspended Load 154,221 kg 340,000 lbs Depth of Cut (Max) 1.73 m 5 ft. 8 in.

Optimum Truck Size 172-363 m ton 190-400 ton Dumping Height (Max) 9.19 m 30 ft. 2 in.
Floor Level Radius 16.31 m 53 ft. 6 in.
PERFORMANCE Tail Swing Radius 10.16 m 33 ft. 4 in.
Peak Propel Speed 0.98 km/h 0.61 mile/h Operator Eye Level 9.75 m 32 ft. 0 in.
Gradability (Continuous) 14% 14%
 MACHINERY DECK PLAN
SWING MOTOR AND HOIST HOIST HOIST
TRANSMISSION MOTOR AIR COMPRESSOR DRUM MOTOR
LUBE TANKS
REACTIVE POWER
COMPENSATION
CABINET

LOW VOLTAGE
COLLECTOR

TRANSFER
CABINET

SWING MOTOR
AND
TRANSMISSION

CONVERTER CONTROL CABINET

CABINET W/ TOUCH SCREEN
GRAPHICAL USER
INTERFACE (GUI)

FIELD BREAKER

GROUND
FAULT
CABINET

AUXILIARY LOAD
CENTER HIGH VOLTAGE
CABINET WITH
ISOLATORS
AUXILIARY
FIELD
TRANSFORMER AUXILIARY
CABINET
GROUND FAULT
SUPPRESSION CABINET
120 VAC
LOAD
MAIN CENTER
TRANSFORMER

ELECTRICAL

INCOMING SUPPLY REQUIREMENTS P&H DIGITAL DC STATIC DC POWER CONVERSION

Supply Voltage* 4160 or 7200V 5000, 6000 or 6600V Hoist**/Propel Swing Crowd/Propel
3 Phase, 60 Hz 3 Phase, 50 Hz.
Continuous Armature
Supply Transformer (Minimum) 3000 kVA Converter KW Rating 2x1860 kW 1860 kW 1860 kW
@600 VDC*
Minimum Short Circuit VA Available at Shovel 25 MVA
15 Sec. Armature
*Voltage per customer requirements. Converter Current 3700 amp. 3700 amp. 3700 amp.
Rating*

TRANSFORMER Continuous Field

Converter Rating* 150 amp. 150 amp. 150 amp.
Main Armature Transformer 2500 kVA
* Based on outside ambient temperature of 50°C or 122°F.
Auxiliaries-Field Transformer 450 kVA ** Cascaded hoist converters.

Control/Lighting Supply Winding 50 kVA

P&H DC FAST RESPONSE MAIN MACHINERY MOTORS
Note: Transformer capacities may vary depending on options.
Hoist Motor Continuous rating @600 volts Total 1887kW/2530hp
(Two used) Peak developed power 2889kW/3873hp
P&H DIGITAL DC AUTOMATIC
REACTIVE POWER COMPENSATION* Swing Motor Continuous rating @ 550 volts Total 746kW/1000hp
(Two used) Peak developed power 1239kW/1662hp
60 Hz. (7 step) 50 Hz. (6 step)
Crowd Motor Continuous rating @ 550 volts Total 537kW/720hp
Switched Steps +4725 kVAR Total +4500 kVAR Total (One used) Peak developed power 867kW/1162hp
*Nominal rating at rated capacitor voltage (600 VAC) Propel Motor Continuous rating @ 550 volts Total 716kW/960hp
(Two used) Peak developed power 1222kW/1639hp
 SUPERVISORY CONTROL AND DIAGNOSTICS
P&H CENTURION™ • Digital controls provide constant power characteristics for optimal
INTEGRATED PERFORMANCE PLATFORM motion speeds which reduce overall cycle time.
• One-time setup of electrical parameters provide consistent optimum
• Centurion Supervisory Controller provides direct integrated comuni-
operation.
cation with motor drives giving precise motor control and fast cycle
times. Real-time multi-tasking capability allows for optimal machine
logic sequencing, monitoring and control. FEATURES AND OPTIONS
• Centurion I/O System uses ‘Profibus’ communication protocol for • Standard Automatic Lubrication System has advanced diagnostic
seamless integration of all shovel subsystems and future expandabil- and control functions for optimized lubrication and ease of lube sys-
ity. Low-voltage 24V DC I/O drop points feature open and short cir- tem maintenance.
cuit detection for improved diagnostics and troubleshooting.
• Standard Automatic-Boom-Soft-Setdown and Boom Profile Protection
• Centurion Information System’s enhanced Graphical User Interface Envelope help protect structures from excessive loading.
(GUI) features intuitive, icon-based screens to display vital informa-
• Standard Anti-Swing-in-Bank reduces excessive side loading.
tion such as shovel status, troubleshooting information, and optional
production monitoring data and operator feedback. • Options are available to tailor the 4100A to specific requirements
• Optional Optidig™ automatically coordinates hoist and crowd
motions while in the bank to improve dig cycle time and optimize
P&H DIGITAL DC DRIVES
power usage.
• P&H Digital DC Drive provides precise, reliable, solid state power to • Optional remote communications provide remote data transmission
the main motion motors, and has been proven on hundreds of units, and other high level control and diagnostic capabilities to improve
logging tens of millions of productive hours. overall loading productivity.

MECHANICAL
HOIST PROPEL
• All gearing housed in single enclosed gear case with filtered oil circu- • Two rugged planetary gear cases of proven design transmit torque to
lation for reliable splash lubrication, ease of maintenance, and the drive sprockets, producing the tractive effort required for fast, effi-
extended component life. cient propel and positioning operations.
• Large diameter hoist drum for extended rope bending life. Ferrule • P&H DELTA Drive low tension sprocket drive system for improved
becket system and single electric tugger are standard for efficient lower works availability and life.
rope change. Dual electric tugger option is available. • Two spring set air release disc brakes - one per motor.
• Two spring set air release disc brakes - one per motor.
DIPPER
CROWD • OPTIMA™ PLUS dipper design provides excellent fill factors and
nominal 90 ton (82 metric ton) capacity.
• Powerband V-belt drive between motor and gear case absorbs shock
loads.
• First and second reduction gearing in enclosed gear case for reliable DIPPER TRIP
splash lubrication, ease of maintenance, and extended component
life. • P&H TripRite system utilizes a brushless DC electric motor with
sealed planetary drive unit for reliable trip and slack take up
• Twin leg dipper handle with torsion box and rack and pinion drive has
operation.
inherent stability in the bank for optimal digging.
• Single spring set air release disc brake.
AIR FILTRATION

SWING • Dynavane inertial filtration system is standard.

• High efficiency P&H AirScrubPro cartridge filtration system is
• Two modular planetary gear cases of proven design and a single available.
piece swing gear transmit torque for fast cycle times.
• Two spring set air release disc brakes - one per motor.

LOADING CONTROL CENTER

CONSOLE FOR CLIMATE CONTROL
AND ACCESSORIES
OPTIONAL
AUXILIARY SEAT

POST MOUNTED
TOUCHSCREEN GUI AND
SPACE FOR MINE INFORMATION
SYSTEMS MONITORS

POWER ADJUSTABLE ARMREST MOUNTED,

AIR SUSPENSION PISTOL GRIP JOYSTICKS
6 WAY SEAT WITH HEAT AND
VIBRATORY MASSAGE
 GENERAL MACHINE SPECIFICATIONS

A B

H
G
D
F
E

GENERAL DIMENSIONS BEARING AREA - GROUND PRESSURE

A Overall Width 13.16 m 43 ft. 2 in. Standard:

B Overall Length 15.24 m 50 ft. 0 in. Crawler Bearing Area 34.69 m2 53,767 in2
76" Shoes/ 1930 mm
C Overall Height over Gantry 12.62 m 41 ft. 5 in.
Crawler Ground Pressure 351 kPa 50.98 psi
D Width of Crawler Shoes 1930 mm 76" (Std.) 76" Shoes/ 1930 mm
2210 mm 87"
Optional:
E Overall Width of Crawlers (Std) 9.86 m 32 ft. 4 in.
Crawler Bearing Area 39.71 m2 61,549 in2
F Overall Length of Crawlers 11.58m 38 ft. 0 in. 87" Shoes/ 2210 mm
G Ground Clearance 1.07 m 3 ft. 6 in. Crawler Ground Pressure 308 kPa 44.70 psi
H Height – Ground to Bottom 87" Shoes/ 2210 mm
of Counterweight 2.77 m 9 ft. 1 in.

WEIGHTS - APPROXIMATE*
CABLE DATA Working Weight (with Dipper, Approx. Wt.)
Hoist (wire rope) 70 mm 2.75" diameter 76" Shoes/1930 mm 1,243,297 kg 2,741,000 lbs
67 mm 2.625" diameter
87" Shoes/2210 mm 1,247,833 kg 2,751,000 lbs
Suspension (bridge strand) 102 mm 4" diameter
Counterweight (Punchings)** 195,498 kg 431,000 lbs
Dipper Trip (wire rope) 19 mm .75" diameter
* All weights subject to 5% variation.
** To be furnished by customer.

NOTE: All designs, specifications and components of equipment described above are subject to change
at manufacturer’s sole discretion at any time without advance notice.
Data published herein is informational in nature and shall not be construed to warrant suitability
of machine for any particular purpose as performance may vary with conditions encountered.
The only warranty applicable is our standard written warranty for this machine.

P&H Mining Equipment ◆ Box 310 ◆ Milwaukee, Wisconsin 53201 USA

XS-1488-2 2AG-105
 4100A TECHNICAL DESCRIPTION
June 28, 2004

The P&H 4100A is a heavy duty electric mining shovel which provides a 90 ton (81.7 metric ton)
nominal payload capacity specifically designed to operate in mines for high productive loading
of 240 ton to 360 ton (218 metric ton to 327 metric ton) haul trucks and larger.

This technical description is provided to compliment the 4100A main machine specification
XS-1488-1.

ELECTRICAL POWER SYSTEM

POWER SUPPLY
Electrical power to the shovel is Customer supplied via a trailing cable. Recommended
SHD-GC trailing cables, for 7,200 volt supply, are:

#2 AWG/35mm² 2800 ft./853m.

#1 AWG/50mm² 3400 ft./1294m.
1/0 AWG/55mm² 4250 ft./1585m.

Electrical equipment on the shovel is designed for an incoming supply of 3 phase/60 hertz/4,160
or 7,200 volts. Secondary voltage for auxiliary motors is 3 phase/60 hertz/480 volts.
(Alternatively, designed for an incoming supply of 3 phase/50 hertz/3,300, 6000, 6600, 7200, or
11,000 volts. Secondary voltage for auxiliary motors is 3 phase/50 hertz/380 or 415 volts).

Recommended 25 MVA, short circuit capacity, at the shovel.

LOWER HIGH VOLTAGE DISCONNECT SWITCH

Electrical power is brought to the shovel by connection of the trailing cable to the lower HV
disconnect switch which is mounted on the rear of the carbody. A cable coupler is mounted on
this switch and mating PLM coupler is provided for the trailing cable end. The switch provides a
visible disconnect, grounding, and a safety key interlock which energizes or disconnects
electrical power to the entire machine. HV wiring runs from this switch through the carbody to
the HV collector rings on the upper deck. The standard cable coupler is a PLM brand quick
disconnect type. Other couplings are available upon request.

HIGH VOLTAGE COLLECTOR RINGS

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Technical Description

High voltage collector rings consist of three (3) power and one (1) ground ring, and are mounted
on top of the carbody. All rings are extra wide to provide proper contact with collector shoes
which are mounted under the revolving frame. Ring access is protected by bolted carbody hole
covers.

LOW VOLTAGE COLLECTOR RINGS

Low voltage collector rings, which transmit lower voltage power from upper to lower are deck
mounted above the center gudgeon. The LV collector cover is window equipped for viewing of
rings and brushes for inspection.

UPPER HIGH VOLTAGE DISCONNECT

Fully contained cabinet contains two visible high voltage disconnects to 1) isolate the entire
upper H.V. supply, and 2) isolate the primary of the Main Transformer, vacuum contactor, line-
to-line and line-to-ground lightning arrestors for surge suppression. Current limiting HV fuses
provide short circuit protection for the primary of the Main Transformer and the primary of the
Auxiliary Transformer

MAIN TRANSFORMER
Designed for mining shovel service, 2500KVA rated, dry type; Delta/Wye connected,
minimizing third harmonic current flow to external circuits, simplified ground fault detection.
Transformer can accommodate unequal loading, has ±5% voltage taps, and temperature
monitored windings. Main Transformer provides power for the Converter Cabinet motion
thyristor bridges which control the power to the DC drive motor armatures and fields.

AUXILIARY TRANSFORMER
Like the main transformer, the auxiliary transformer is designed for mining shovel service, is of
the dry type, and is Delta/Wye connected. It is rated at 325 KVA. Four (4) secondary windings
provide power for:
(1) 60HZ/480 Volts (Alternatively 50HZ/380 or 415 Volts) for utilities and auxiliary motors.
Power from the transformer flows to an Auxiliary Load Center, Auxiliary Cabinet motors.
(2) Shielded winding supply for the Control System
(3) Field supply voltage to the DC drive motor, field power bridges.
(4) Lighting and GPO’s supply, 45 KVA rated, and distributed through the 120 VAC
(alternately 240V) load center

POWER CONVERTER CABINET

The P&H Digital DC power conversion system contains the simple six-thyristor three-phase
bridges used to statically convert AC supply power to controlled DC supply to motion drive
motor armatures for speed and torque regulation. This thyristor bridge inherently also allows for
invert regenerated DC energy to AC power during motion deceleration. The regenerated power
is used to supply the on board needs with the excess going back to the mine network for energy
savings.

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Thyristors are mounted in easily accessible heat sinks and are forced air-cooled. A patented fast
acting over-current system, diverter system, senses and limits the over-current to the DC motors
eliminating destructive flashovers.

POWER DISTRIBUTION
All High Voltage cables are run in metal conduit. An enclosed over head copper bus system is
used to carry the power from the Main Transformer to the Converter cabinet. All other wiring is
generally run in raised troughs on the machinery deck floor. Power cables are XLPO (cross-
linked polyolefin) insulated

REACTIVE POWER COMPENSATION (RPC) SYSTEM

Housed in a rugged, ventilated cabinet, the RPC system contains stepped tuned banks of
capacitors and reactors, automatically and synchronously switched on and off the line, to
maintain average system power factor near unity. Tuned banks provide a high level of harmonics
filtering of the predominant harmonics generated by the converters. Synchronously applied
stepped compensation eliminates transients during application and disconnection.

TRANSFER CABINET
The transfer cabinet contains heavy duty contactors to transfer the power from the hoist and
crowd converters to the propel motors in the propel mode. Transfer is initiated by a push button
on the console in the operator’s cab with all sequencing handled automatically by the
programmable industrial controller.

DC DRIVE MOTORS
P&H designed, manufactured, and tested motors are specifically for mining service duty, with
Class "H" insulating system. Drive motors are equipped with RTD’s to monitor motor bearings
and winding temperatures, and all are equipped with heavy duty blowers with screen protected
air inlets. Optional brush grades are available for unusual operating conditions.

ELECTRICAL CONTROL SYSTEM

P&H CENTURION™ IPP (INTEGRATED PERFORMANCE PLATFORM)
The P&H Centurion™ IPP provides the supervisory control of the shovel drives and executes the
sequencing and monitoring functions, and consitsts of the supvisory control computer and
supporting hardware devices and software programs. The system is comprized of three basic
areas which are: 1) the onboard graphical user interface (GUI), 2) the remote input/output (I/O)
devices and communication interface, and 3) the individual drive controllers.

The system uses an open concept design to allow for third party integration. The architecture
provides connectivity from components on the shovel to the onboard GUIs and provides
diagnostic and monitoring capabilities. The application code residing within the supervisory
controller is based on the IEC 61131 standard. The control system uses Profibus over fiber optic
and copper media for communications with the various system components.

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SUPERVISORY CONTROL CABINET

Components for the P&H Centurion™ IPP are housed in a rugged, maintenance friendly cabinet,
which is located in the RH Electronics room.

LOWER CONTROL CABINET

The lower control cabinet is mounted on the back of the carbody, and contains remote I/O, motor
starters for the propel motor blowers, air solenoid valves for the brakes, and electrical
convenience outlets.

REMOTE I/O’S
The supervisory control system functions with remote I/O in several locations such as lower
propel, LH lube room, RPC cabinet, converter cabinet, transfer cabinet, auxiliary cabinet, and
operators cab.

AUTOMATIC ATTACHMENT PROTECTION SYSTEMS

Hoist and crowd/retract limits are set on the GUI touch screen located at the loading control
center in the operator's cab. A boom profiling limit is included to help prevent contact of the
handle torsion box and dipper with boom. The ABSS (Automatic Boom Soft Set-down) feature
is part of the control system and minimizes boom jacking and the associated impact of abruptly
lowering the boom from a jacked condition.

MOTOR CONTROL CENTER (MCC)

A large maintenance friendly cabinet contains individual motor starters and circuit breakers,
which provide thermal and short circuit protection for each motor. For electrical isolation, the
controls for each individual motor are housed in an individual cubicle. In addition to motor
control, there are cubicles to control house heaters and lights. The MCC is located in the
environmentally controlled RH electronics room.

OPERATOR INTERFACE
OPERATOR CAB
A separate, roomy, high-visibility cab is rigidly mounted and offset in an elevated position on the
shovel's right hand side. Freezer style handles are equipped on the cab door. Non-glass areas of
the cab are insulated for temperature and sound control. The sound level inside the cab is below
70dBA while the shovel is operating, and with the door closed. All windows other than the front
window are tinted safety glass. The standard front window glass is 0.38 inch / 9mm thick
laminated safety glass. An industrial grade, single arm electric window wiper system is standard.

A standard single 2-tone air signal horn is standard equipment, and is mounted on front of RH
room. Sound level rating of the standard air horn is 123 dBA at the source.

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P&H LOADING CONTROL CENTER

The P&H Loading Control Center provides a single location of control for shovel operation and
truck loading. An additional work area with an optional seat is provided immediately behind the
operator for use by training or other personnel.

The standard seat base is an air suspension type which can be adjusted for operators height and
weight. The seat has an automotive style power system which provides vertical and fore / aft
adjustment to allow custom fitting of the joysticks to individual operators. The seat has heat,
lumbar support, and massage. The entire seat, armrest assembly is mounted to a vibration
isolated sled with an integral footrest. The angled footrest swivels into two positions based on
the operator’s height.

The joystick contollers are Hall-Effect, pistol grip style with both push button, trigger switch, and
rocker switches built into the grips. There is a single console on the left hand side of the operator.
All control devices needed by the operator while operating the shovel and loading trucks are
located in a zone of comfort for easy access with minimal movement. Devices needed for
auxillary functions such as those climate control and lighting are located within reach of the
operator while seated.. The console also features an expandable media mounting post to which
the P&H GUI is mounted as standard. Post sections can be added to mount remote camera
monitors as well as dispatch screens.

The climate control ducting in the cab is located above and below the operator. There are
controls to allow regulation of air flow between window defrost, the vents at the feet, and the
vents at the midlevel of the operator.

GRAPHIC USER INTERFACE (GUI)

The GUI has menus and information screens thatallow the operator todisplay information, and
perform various operation functions. The basic functions of the GUI are:
• Display machine operating status
• Display and set hoist and crowd limit setting (boom profiling)
• Provide fault enunciation and alerts
• Display temperature monitoring bar graphs
• Display boom jacking status
• Display boarding ladder positions
• Display lubrication system settings and status
• Provide for manual initiation of lubrication cycles

CLIMATE CONTROL
An optional P&H MineAir Systems MAS 1500 mine duty air conditioner unit is available. A
single unit can be fitted to the operator cab, or two units can be fitted, one for the cab and one for
the electronics room. Each MAS 1500 unit is capable of delivering 14 kW cooling (48000

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BTU/Hr), and 18kW heating. Units are fitted with an efficient air filtration system, which
pressurizes the cab and electrical room.

LIGHTING
Primary exterior floodlights: Standard lights are Metal Halide, 400 watt, 60HZ/120V
(alternatively 50HZ/220V), high intensity discharge (HID) units.

Standard primary exterior floodlight locations (nine are wide beam and two very narrow beam)
are as follows:
• Two (2) on front of operator’s cab, below the front window.
• Two (2) on top front of lube room
• Two (2) right side of house
• Two (2) top rear of house
• One (1) top left side of house

Secondary exterior floodlights: Standard are Halogen, 500 watt units. Standard secondary
exterior floodlight locations are as follows
• One (1) above operator’s cab door
• Two (2) on the lower front of machinery house
• Four (4) under revolving frame corners
Exterior incandescent: Five (5), 100 watt; one (1) at each machinery house door and one (1) at
operator’s cab door.

Interior lighting: Twenty (20) fluorescent lights are provided to illuminate the machinery house,
RH electrical room and LH lube room.

Operator’s cab lighting: Incandescent 100 watt ceiling light.

One (1) portable halogen trouble light is also provided as standard for primary use at convenient
roof top outlets.

ELECTRICAL CONVENIENCE OUTLETS

Electrical outlets for 110/120 volt supply are conveniently located:
• One (1) in lower control box on rear of carbody
• Two (2) under revolving frame platforms
• Seven (7) In machinery house
• One (1) on RH catwalk
• Two (2) in RH electronics room
• One (1) in LH lube room
• Three (3) in Operator’s cab
• Two (2) on house roof

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Outlets are GFI protected. GPO’s are 15 amp, duplex, NEMA 5-15 straight blade devices, 2
pole, 3 wire grounded and 125V rated.

Special instrument outlets are located in the Supervisory Control Cabinet.

Three (3) 60HZ/460V (Alt. 50HZ/380V) outlets are also provided; one (1) in RH electronics
room, one (1) in LH lube room and one (1) in Operator’s cab. These outlets are 20 amp, 3 wire,
4 pole, IEC 309 type.

A single welder outlet receptacle (60Hz/460V, alternatively 50Hz/380V) is provided, located

near the RH door in the machinery house.

MECHANICAL SYSTEMS
CRAWLER DRIVE SYSTEM
The crawler drive system incorporates rugged lug and tumbler and sprocket design concepts. On
the P&H sprocket style drive system, the shoe and tumbler engagement is close to the link pin
centerlines.

CRAWLER SHOES
Deep section, cast manganese shoes are connected with 5 inch alloy steel induction hardened
pins through machined, line-bored holes. Shoes are designed specifically for the P&H sprocket
style drive system. Standard crawler shoes width is 76 inches (1930mm).

CRAWLER FRAMES
The frames are a heavy welded box section designs with bolted fit to carbody under full shear
ledge support with large dowels to prevent movement in the bolted connection. There is no field
welding required in the connection. There are eight (8) lower rollers, a front, and a rear idler in
each frame. The front idler is large diameter manganese casting, which is mounted on two (2)
heavy duty bushings. Lower rollers and idlers are V-ring sealed to exclude contaminates and
hardened wear surfaces protect crawler frame wear. Rollers and idlers are straddle mounted with
special alloy brass bushings. “P&H 50+” lower rollers are hardened to over 50 on the Rockwell
C scale. Replaceable pin-on, high hardness, wear resistant cast slide bars on top of each frame
support the crawler shoes.

CARBODY
The carbody is a heavy welded high strength low alloy steel structure of cellular deep box
sections, built around a large center hub casting. The flattop design with deep section diaphragm
plates provides direct support of roller path. Carbody interior is painted white and is equipped
with an electrical convenience outlet for trouble light use. Swing gear and lower swing roller
path are mounted on the top of the carbody with dowels and bolts. The crawler frames are
connected to the carbody by a full-length shear ledge and long rod bolts. Both carbody and
crawler frames designed to withstand the high level of crawler frame connection bolt tension.

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The crawler frame connection bolts produce very high clamping forces between the crawler
frame and carbody machined surfaces. The standard tensioning system for the rod bolts consist
of simple bolt and nut arrangement.

DUAL PLANETARY PROPEL SYSTEM

Dual independent P&H DC drive motors rated at 960hp/716kW total continuous power at 550V
and 1639hp/1223kW total peak developed horsepower, drive the propel system and are load
sharing controlled. Motors are mounted in a propel motor base which is bolted to the rear of the
carbody, and motor frame adjusting screws are integral to the base for ease of alignment, and the
motors are directly connected to P&H planetary propel transmissions with a gear coupling. The
planetary propel transmissions are directly mounted to each crawler frame, and provide
differential speed and counter-rotational steering capability. All gearing is forged, anti-friction
bearing mounted, and all external gears are case hardened and ground.

The P&H Sprocket drive system has a raised final propel drive shaft and tumbler. The final
propel drive shaft is spline connected to the planetary transmission and tumbler, and is mounted
on anti-friction bearings. The outboard spherical bearing is encapsulated to prevent crawler frame
damage in the event of a bearing failure. V-ring seals are used to seal out dirt and seal in
lubricant.

CENTER GUDGEON
The Center Gudgeon is a hollow heavy-duty forging used to connect the upper revolving frame to
the lower carbody. Acme threads are provided on the upper and lower end of the gudgeon. The
gudgeon is a cascaded interference type fit in the center hub casting of the carbody. A locking
mechanism on the upper threads allows fine adjustment capabilities and positive retention of nut
position. Gudgeon center hole is used for electrical wiring, lube, and airlines between upper
revolving frame and lower machinery.

REVOLVING FRAME
The revolving frame is a heavy welded high strength low alloy steel structure of cellular deep
box sections built around a large center casting. The rolled, full depth internal turret plates align
with the swing roller path and provide 360° direct load transfer. Roller path support pad on
frame underside is wider and provides a pilot ring to prevent radial movement of the upper path.
Deck machinery is mounted via tapped holes or pin supported and no internal access is required
to mount the machinery. A standard drain system allows for the hoist and swing transmissions to
be evacuated through piping to below the revolving frame deck (crowd drain to boom foot
platform).

COUNTERWEIGHT BOX AND CASTINGS

A sectioned counterweight box is mounted to the rear of the revolving frame to accommodate the
counterweight ballast. Large solid castings are mounted to the rear of the counterweight box to
provide a stabilizing moment.

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DECK PLAN
Side platforms, which mount to the revolving frame, extend the deck width. Conveniently
arranged floor plan with abundant space facilitates maintenance.

ELECTRONICS ROOM
A separate large room is mounted on front right corner of the revolving frame and houses the
supervisory control cabinet and motor control center. It is insulated with 0.5 inch/12.7mm
material; equipped with 0.75 hp fresh air blower (not used with optional air conditioner),
secondary wall and door air filter, and louvered front wall vent panel. Two (2) doors are provided
for improved access; one (1) leading to machinery house and one (1) to outside catwalk. RH
room also is the support base for the RH elevated operator’s cab.

LUBRICATION ROOM
A separate room is mounted on front left corner of the revolving frame, which houses lube tanks,
pumps, plumbing, and controls (remote I/O connection for lube system monitoring and control);
and most air system components including the receiver. Room is insulated with 0.5
inch/12.7mm material, and can be optionally heated for improved cold weather operation.

MACHINERY HOUSE
Truss style roof with weather tight, removable hatch covers for accessibility to internal
machinery. Roof panels are strategically located to direct crane picks of major deck mounted
components as required.

HOUSE PRESSURIZATION AND FILTRATION

House is pressurized and air is filtered by a high efficiency inertial filter system.

COLD WEATHER EQUIPMENT

The RH and LH rooms are equipped with insulation as a standard feature. The air valves for the
lower works are located in the heated lower control cabinet as standard, and the automatic
moisture dump valve for the main air receiver is located in the heated LH lube room as standard.
Heating options are available.

BOARDING AND ACCESS

A right side pneumatic controlled stairway and left side vertical pull-down ladder are interlocked
to de-energize swing and propel functions when in down position for safety. Catwalk/platforms,
with grated metal surface, hand rails, and toe boards are provided in access areas. Roof grating is
welded to roof panels.

HOIST DRIVE SYSTEM

Dual P&H DC motors rated at 1880hp/1402kW total continuous power at 550V and
3358hp/2505kW total peak developed power drive a modular gearcase pinned to the revolving
frame. First reduction is helical gear set, second reductions spur and a reversible spur drum gear.

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All gearing is forged machined, case hardened and ground. Transmission is oil tight with anti-
friction bearings and standard oil filtration and circulation system. Gearing is splash lubricated. A
lube pump and filtration system is standard, and is designed for use with high viscosity
lubricants, even in cold temperatures.

The hoist drum is a large 65 inch (1651 mm) pitch diameter drum with through shaft and flame
hardened grooves. Standard hoist rope is 2.625 inch (67 mm) diameter cable fully plastic
impregnated and compacted. Hoist drum grooving is machined to accept 2.75 inch (70 mm)
diameter hoist rope. Hoist drum and cable are provided with high capacity Ferrule Beckett
fittings to simplify cable change out. Hoist limits are programmable from operator's cab. Hoist
drum bearings are equipped for temperature monitoring.

HOIST CABLE TUGGER

An electric driven tugger is standard to assist with hoist cable changes. Standard tugger
configuration has as single 2000 lb.(907 kg) rated winch. An additional 2000 lb. (907 kg) winch
is available.

SWING DRIVE SYSTEM

Swing power is provided by two (2) P&H DC drive motors rated at 1000hp/746kW total
continuous power at 550V, and 1662hp/1240kW total peak developed power and are connected
in series. P&H Planetary transmissions are mounted front and rear of swing gear for even
loading. Some components are interchangeable with first and second reductions in the propel
transmissions minimize parts stocking requirements.

Swing shafts are mounted on anti-friction bearings and are removable without disturbing the
transmission. Forged swing gear has 17 foot-2 inch/5.23m diameter with a large 14.5
inch/368mm tooth face width. Swing circle uses a quantity of 54 tapered rollers, 10 inch/254mm
in diameter, carried on self-lubricating bushings. Rollers and roller paths are high alloy, forged,
quenched and tempered to a high hardness. Full circle of rollers are in contact with the 360°
upper and 360° lower roller paths, which have a wide mounting surface to the carbody and
revolving frame. Upper path is dual flanged mounted with guarding to retain mounting hardware
in the event of loss, and the lower path is clip mounted to the carbody on the inner diameter and
retained by the ring gear outer diameter.. Gear shrouding system prevents contamination of gear
and roller path area, and can be opened to enable inspection of gear and roller circle.

CENTALIZED LUBRICATION SYSTEM

An automatic centralized lubrication system is standard and provides metered amounts of
lubricant to all major systems requiring grease and open gear lubrication. Lincoln 75:1 ratio air
drive pumps are used. Lube system, is programmable industrial controller controlled and is
monitored through touch-screen MMI’s. Large 138 gallon open gear and 138 gallon grease
maximize operating time. All gear cases are designed with bath and splash lubrication to all
gearing and bearings. A lube filtration system is standard for the hoist and crowd gear case.

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AIR SYSTEM
Compressed air is provided for lube pumps, lube sprayers, disc brakes, hoist cable tugger, air
operated stairway, horn, and operators seat. Standard air compressor is a Sullair Model ES-8-
30XH, rotary screw type, 30 HP, 95ACFM at 60HZ (77ACFM at 50HZ), floor mounted, with
separate 200 gallon capacity air. The ES-8 is designed for cold weather operation. Other air
compressors are available when specified

A high capacity membrane air dryer system is available (Only one unit required for single or dual
air compressors) which provides dry air with a -40° F (-40° C) dew point to the reservoir for dry
air in all functions. The membrane dryer features a low maintenance membrane technology, and
is complete with filters and automatic control system. The membrane dryer system is housed in a
sturdy enclosure, and is mounted in the lubrication room. The membrane dryer system cannot be
used with piston type compressors.

BRAKES
All motions have disc brakes, which are spring set-air released. Brakes have replaceable wear
surfaces, and a low abrasion, high heat capacity friction material is used. Select brakes are
equipped with centering mechanisms to minimize contact of frictional surfaces when brake is
released.

BOOM
64 foot (19.51m) length set at a 45° angle; welded structure of high strength low alloy steel for
cold weather toughness; extra width and depth for high load capability; 96 inch (2438mm)
diameter point sheaves, split bearing block mounted for maintenance ease. Boom suspension
cables are 4 inch (103 mm) structural strand. Integral lifting lugs and wear resistant side boxes
are incorporated. Boom is connected to revolving frame lugs with heavy duty lubricated pins
retained with split collars. Boom bumpers are mounted to the boom to reduce damage from
contact with the handle torsion box.

CROWD SYSTEM
Crowd and retract of the dipper is accomplished by one (1) P&H DC motor rated at
720hp/537kW continuous power at 550V and 975hp/727kW peak developed power driving the
P&H - POWERBAND "V" BELT - shock absorbing/system to modular, enclosed, transmission
with spur gear reduction to manganese racks and forged, machined and hardened crowd pinions.
V-belt sheaves are fully machined and balanced. Gearing is forged, case hardened and ground;
mounted with encapsulated, pre-adjusted bearings. Single piece saddle blocks are hydraulically
adjusted and allow for removal of crowd pinions. Crowd/retract limits programmable from
operator's cab.

DIPPER HANDLE

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35 foot (10.67m) effective length; high strength low alloy, cold weather steel; straddle design,
straight legs and large cast manganese racks providing strength for corner tooth digging loads.
Handle geometry provides for torsion box clearance with the boom.

DIPPER TRIP
Dipper trip system is a durable 15HP/11kW, AC wound rotor motor drive through planetary
gearing to a heavy duty drum. Both ferrule becket and cable clamp connection capability is
provided for securing dipper trip cable to the drum. Trip line is connected to dipper latch lever
bar a handle mounted banjo arm.

DIPPER
P&H OPTIMA 90HD dippers have been designed specifically for the 4100A for proper filling
and low cost of operation. Standard equipment on the dippers include adjustable pitch braces
and P&H Snubrite™ hydraulic snubbers to prevent damaging dipper door closing impact.
Nominal rated dipper size is 62 cubic yard ( 47.4 cubic meters ).

PAINT
Standard exterior is P&H Yellow and Black. Yellow on machinery house and operator’s cab.
Black on lower, attachment, catwalks and handrail. (Lower HV disconnect switch is painted
red). Interior of house, RH and LH rooms, carbody, revolving frame and lower boom section and
all electrical cabinet interiors are painted high visibility white.

WEIGHTS
Working weight of the P&H Model 2800XPB with nominal dipper and 76 inch (1930mm) wide
crawler shoes is 2,732,000 lbs. (1,239,214 kg.)

OPTIONAL ITEMS DESCRIPTIONS

OPERATOR CAB
• Pull down mylar shades (front window only)
• Pull down mylar shades (all windows)
• Front window, laminated safety glass (0.750” thick)
• Front window, laminated safety glass (1.188” thick)
• Cigarette lighter and ashtray – to be used for 12V power supply for convenience.
• Passenger seat – fold down in rear of cab for convenience
• Table – fold down for operator and mine personnel convenience.
• Second, 2-tone, air horn, mounted on front of LH lube room
• Single electric horn in place of standard air horn on RH room
• Second electric horn, mounted on front of LH lube room

AIR CONDITIONER

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• Mine Air Systems unit for operator’s cab only (RH or LH); Model MAS 1500, (60HZ/460V
or 50HZ/380V); cooling 48, 000BTU/14KW at 60HZ, heating to 18KW at 480V; with PUR-
PAK 1000 pressurizer and R407C refrigerant
• Mine Air Systems units for operator’s cab (RH or LH) and RH electronics room; two (2)
Model MAS 1500 units (60HZ/460V or 50HZ/380V); cooling 96,000 TBU/hr./28 kW total at
60Hz, heating to 36 kW total at 480V; with PUR_PAC 1000 pressurizer and R407C
refrigerant (Note: Deletes blower in RH room, #3.2.1)
• Sigma unit for operator’s cab (RH cab only) and RH electronics room; one Model MPV15,
60HZ/460V or 50HZ/380V); cooling 15KW at 60HZ, heating 2-stage 18KW at 460V; with
pressurization and R134a refrigerant (Note: Deletes blower in RH room, #3.2.1)

JIB HOIST
• Swing jib hoist; 8.9kN / 2,000 lb. Capacity (60HZ, 460V), mounted outside LH lube room
• Swing jib hoist; 8.9 kN / 2,000 lb capacity (50HZ, 380V), mounted outside LH lube room

FIRE SUPPRESSION
• Fire extinguisher, 20lb. Dry chemical, Model 1-A-20G, (3 ares tandard) each extra unit

TRAIL CABLE REEL

• P&H Power Reel (Harnaust Mfg.), air drive trail cable reel, 48” dia drum
• Cable reel (IWM Mfg.), hydraulic over electric drive, 48” dia drum
• Mounting material for P&H Power Reel trail cable reel

COLD WEATHER EQUIPMENT

• 2.5cm / 1 inch insulatin in machinery house
• Heater/defroster ducting in cab directed to operators feet and front window
• 7.5KW heater in operator’s cab
• 15 KW heater in RH electrical room
• 20 KW heater in LH lube room
• Strip heaters for main control cabinets
• Strip heaters for main D.C. motors
• Strip heaters for main transformers
• 40 KW machinery house heater maximum of 3, each

MISCELLANEOUS ELECTRICAL
• Extended upper temperature monitoring system – standard plus crowd gearcase bearings,
hoist gearcase bearings, swing shaft bearings, gearcase oil (5 cases), boom shipper shaft
bearing, and center gudgeon hub.
• Extended lower temperature monitoring system – standard plus over temperature indication
for final drive bearings and gearcase oil (2 cases).
• P&H Optidig operator assist tool that co-ordinates the hoist and crowd motions to prevent the
dipper from stalling while digging.

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 Model 2800XPB
Technical Description

• P&H i2T Remote Communications Ready Package (complete) including connection port of
shovel, base station PC with software installed. (Modem and radio communications
hardware is required, and is not provided by P&H.)
• P&H i2T Remote Communications Ready Package (no base station) including connection
port on shovel. (This option used when base station for other i2T shovels is on site) (Modem
and radio communications hardware is required, and is not provided by P&H).
• Electrical cabinet filters for RPC and converter cabinets - fitted to the cabinet doors and
provide an additional level of filtration for the electrical components.
• Hoist control with variable speed control in machinery house - allows hoist system to be
operated within view of the drum to improve ease of hoist rope change outs.
• Extra welder outlet in machinery house, near LH door. (60HZ, 460V or 50HZ, 380V) – price
each, 2 max
• Ground fault protection for welder outlets – price each, 3 max
• Emergency lighting unit (two lights per unit), each:
− Without installation wiring
− With installation wiring
• Communication system, 3-way
• Trailing cable connector extension with PLM cable coupler (w/o cable) (Not for use with trail
cable reel) - exetends cable coupling connection from the lower high voltage disconnect
cabinet to a convenient location by the propel motor base.

MISCELLANEOUS MECHNICAL
• Wiggins quick fill connectors for lube tanks, mounted on outside front lube room wall (note:
deducts standard 2” cam lock fittings) to allow quicker fill of the two lubricant reservoirs.
• Central drain system for hoist and swing transmissions (crowd drain to boom foot platform
standard) - allows for all systems to be drained to a convenient central location.
• Lube filtration with 20 micron filter on each swing transmission (3 total)
• Air hose reel w/30m/100ft of hose - conveniently mounted in the machinery house as a
general purpose air supply, and features a filter, regulator, and 50 feet (15.2 m) of hose on a
retractable reel.
• Blower motor and brake removal system in machinery house
• High Efficiency House Pressurization System (Torit) in place of standard
• Two (2) rectangular 16.50” x 24.75”, convex mirrors - (two supplied), mounted on the
shovel, one on the right side near the operators cab, and the second above the LH room, to
provide additional visibility for the operator.
• Tow lug on front of carbody, field installed
• Tow lugs, two (2) on rear of carbody, field installed
• SUPERBOLT® tensioning system for rod bolt connection for crawler frames
• HYTORK® tensioning system for rod bolt connection for crawler frames.
• Counterweight ballast (265 lbs/cu. Ft. minimum density), approximately 420,000 lbs.,
delivered to USA site either domestic or export packed
• Export packing

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 Model 2800XPB
Technical Description

TOOLS, TEST EQUIPMENT, AND ASSEMBLY AIDS

• HiTorque tooling to be used with hydraulic pack

TECHNICAL DOCUMENTATION
As standard, each P&H shovel Purchaser is supplied in English language, the following
documents:
• Operator Manual (electronic format on CD and in hard copy)
• Mechanical Systems Manual (electronic format on CD, hard copy optional)
• Link-One format Electrical Data and Wiring Listing
• Link-One format Electronic Parts Manual

CUSTOMER SUPPLY ITEMS

Unless otherwise stated in a P&H proposal, required items, not included in our basic machine
supply are:
• Machine erection, including erection tools and equipment
• Counterweight ballast, approximately 420,000 lbs/190,500 kg with a minimum density of
265 lbs. per cubic foot (4,245 kg/m3) (Final counterweight determined by application.)
• Fluids/lubricants
• Trailing cable and electrical power supply.

*****

P&H - An enduring symbol of quality and reliability

NOTE: All designs, specifications and components of equipment described above are subject to change at manufacturer’s
sole discretion at any time without advance notice. Data published herein is informational in nature and shall not be construed to
warrant suitability of machine for any particular purpose as performance may vary with conditions encountered. The only warranty
applicable is our standard written warranty for this machine.

4100A 2005 Ver 1 Technical Description.doc

Page 15 of 15
 DIGITAL DC DRIVE CONTROL

meters

feet
22 72.2

20 65.6

18 59.1

16 52.5

14 45.9

12 39.4

10 32.8

8 26.2

2800XPC 6 19.7

4 13.1

2 6.6

0 0

2 6.6
meters 6 4 2 0 2 4 6 8 10 12 14 16 18 20 22 24
feet 19.7 13.1 6.6 0 6.6 13.1 19.7 26.2 32.8 39.4 45.9 52.5 59.1 65.6 72.2 78.7
C
L ROTATION

WORKING RANGES CAPACITY

Height of Cut 16.6 m 54 ft. 6 in. Nominal Pay Load 63.5 mt 70 st

Radius of Cut 24.2 m 79 ft. 3 in. Nominal Dipper Capacity

SAE struck 35.7 m3 47.0 yd3
Dumping Height* (Door Open) 9.1 m 30 ft. 0 in. SAE 2:1 39.2 m3 51.2 yd3

Floor Level Radius 16.4 m 53 ft. 9 in. Rated Suspended Load 117.9 mt 130 st

Tail Swing Radius 9.9 m 32 ft. 6 in. Optimum Truck Size 172-240 mt 190-265 st
(240 st truck shown)
Operator Eye Level 9.6 m 31 ft. 4 in.

* Height shown with bail-type dipper. Heights will be greater with

bail-less or compact-bail dippers. Actual dumping height can be
greater than door clearance height.
 ELECTRICAL CONTROL DIPPER & DIPPER TRIP
• Centurion Supervisory Controller provides direct integrated • P&H OPTIMA dippers combine consistent productivity with high
communication with motor drives giving precise motor control and durability and maintainability. Dippers are configured to mine specific
fast cycle times. Real-time multi-tasking capability allows for optimal conditions and capacity requirements from a variety of combinations
machine logic sequencing, monitoring and control. of body and lip designs, as well as other unique P&H technologies.
• Centurion I/O System uses ‘Profibus’ communication protocol Specific wear packages and GET styles can be cooperatively
for seamless integration of all shovel subsystems and future specified.
expandability. Low-voltage 24V DC I/O drop points feature open and • P&H TripRite system utilizes a brushless DC electric motor with
short circuit detection for improved diagnostics and troubleshooting.
sealed planetary drive unit for reliable trip and slack take up
• Centurion Information System’s enhanced Graphical User Interface operation.
(GUI) features intuitive, icon-based screens to display vital
information such as shovel status, troubleshooting information, and
optional production monitoring data and operator feedback.
• P&H Digital DC Drive provides precise, reliable, solid state power to
the main motion motors. HOIST
• All gearing housed in single enclosed gear case with filtered oil
circulation for reliable splash lubrication and ease of maintenance.
• Large 56" diameter hoist drum for extended rope bending life.
ELECTRICAL DRIVE Ferrule becket system and dual electric tuggers are standard for
efficient rope change. Dual electric tugger option is available.
P&H DIGITAL DC STATIC DC POWER CONVERSION AND REACTIVE POWER
• Spring set air release disc brakes - one per motor.
COMPENSATION
Hoist**/Propel Swing Crowd/Propel
Continuous
Armature
Converter KW
2x1860 kW 1860 kW 1860 kW CROWD
Rating @ 600 VDC*
• Powerband V-belt drive between motor and gear case absorbs shock
15 Sec. Armature loads.
Converter Current 3700 amp. 3700 amp. 3700 amp.
Rating* • First and second reduction gearing in enclosed gear case for reliable
splash lubrication, ease of maintenance, and extended component
Continuous Field life.
150 amp. 150 amp. 150 amp.
Converter Rating*
• Twin leg dipper handle with torsion box and rack and pinion drive has
* Rated at 600 V and based on outside ambient temperature of 50°C or 122°F.
inherent stability in the bank for optimal digging.
** Cascaded hoist converters.
• Spring set air release disc brake.
P&H DIGITAL DC AUTOMATIC REACTIVE POWER COMPENSATION*
60 Hz. (7 step) 50 Hz (8 step)
Switched Steps +4725 kVAR Total +4500 kVAR Total
* Nominal rating at rated capacitor voltage (600 VAC)
* Rated at 600 V and based on outside ambient temperature of 50°C or 122°F.
SWING
** Cascaded hoist converters.
• Two modular P&H planetary gear cases of proven design and a
P&H DC FAST RESPONSE MAIN MACHINERY MOTORS single piece forged swing gear transmit torque for fast cycle times.
Hoist Motor Continuous rating @ 600 volts Total 1194kW/1600hp
(Two used) Peak developed power 2065kW/2768hp • Spring set air release disc brakes - one per motor.

Swing Motor Continuous rating @ 550 volts Total 746kW/1000hp

T
(Two used) Peak developed power 1080kW/1448hp
Crowd Motor Continuous rating @ 550 volts Total 537kW/720hp
(One used) Peak developed power 592kW/793hp PROPEL
Propel Motor Continuous rating @ 550 volts Total 612kW/820hp
• Two rugged P&H planetary gear cases of proven design
(Two used) Peak developed power 1112kW/1491hp
independently transmit torque to the drive sprockets, producing
the tractive effort required for fast, efficient propel and positioning
operations.
• P&H DELTA Drive low tension sprocket drive system with heavy
duty cast crawler shoes.
POWER REQUIREMENTS
• Spring set air release disc brakes - one per motor.
Supply Voltage* 4160 or 7200V 3000, 5000, 6000 or 6600
3 Phase, 60 Hz 3 Phase, 50 Hz.
Supply Transformer (Minimum) 2500 kVA
Minimum Short Circuit VA Available at Shovel 22 MVA CABLE DATA
*Voltage per customer requirements

TRANSFORMER Hoist (wire rope) 60 mm 2.38 in. dia.

Main Armature Transformer 2000 kVA Suspension (bridge strand) 90 mm 3.50 in. dia.
Auxiliaries-Field Transformer 450 kVA
Dipper Trip (wire rope) 13 mm 0.50 in. dia.
Control/Lighting Supply Winding 50 kVA
 OVERALL DIMENSIONS
A Width 13.1 m 43 ft. 0 in.

B Length 14.8 m 48 ft. 8 in.

C Height Over Gantry 12.4 m 40 ft. 9 in.

1422 mm (std) 56 in. (std.)

D Width of Crawler Shoes
1829 mm 72 in.

E Width of Crawlers (std.) 9.0 m 29 ft. 8 in.

F Length of Crawlers 10.8 m 35 ft. 5 in.

G Ground Clearance 1.0 m 3 ft. 4 in.

H Height — Ground to Bottom of Counterweight 2.7 m 8 ft. 10 in.

B
A

C 2800XPC

H
G

D
F
E

MACHINERY DECK PLAN

AIR COMPRESSOR LUBRICATION ROOM

HOIST MOTOR HOIST MOTOR

REACTIVE POWER LUBE RESERVOIR

COMPENSATION (522 LITER/138 GAL. EACH)
CABINET
LOW VOLTAGE
SWING MOTOR AND COLLECTOR
TRANSMISSION
SWING
TRANSFER CABINET MOTOR AND
TRANSMISSION
CONVERTER CABINET
HOIST DRUM
ACCESSORY PANEL
120 VAC
LOAD CENTER
GROUND FAULT
SUPPRESSION CABINET
CENTURION
SECONDARY CONTROL CABINET
BREAKER CABINET TOUCH SCREEN
MONITOR

AUXILIARIES
MOTOR CONTROL
TRANSFORMER
CENTER

MAIN TRANSFORMER AUXILIARY LOAD

CENTER
HIGH VOLTAGE CABINET
WITH ISOLATORS ELECTRONICS ROOM
 GROUND PRESSURE & WEIGHT FEATURES AND CUSTOMIZATION
BEARING AREA - GROUND PRESSURE The 2800XPC is built with several features to enhance safety,
Crawler Bearing Area 23.94 m2 37,112 in2 reliability, and productivity over the lifecycle of the operation.
56" Shoes/ 1422mm • Automatic Lubrication and Compressed Air Systems with
Crawler Ground Pressure 442 kPa 64.10 psi advanced diagnostic and control
56" Shoes/ 1422mm • Temperature Monitoring System for all DC motors, drum shaft
bearings, shipper shaft bearings
Optional:
• Automatic Boom Soft Setdown System (ABSS) and Boom
Crawler Bearing Area 30.78 m2 47,716 in2
Profile Protection Envelope to help prevent excessive loading to
72” Shoes/ 1829 mm
the attachment during operation
Crawler Ground Pressure 345 kPa 50.09 psi • Anti-Swing-in-Bank system to reduce excessive side loading on
72” Shoes/ 1829 mm handle and attachement
• Remote hoist control pendant and hoist rope winch to assist in
WEIGHTS - APPROXIMATE* safe and efficient rope changeouts
Working Weight (with Dipper, Approx. Wt.)
• House Pressurization System to provide filtered air for cooling
56" Shoes/1422mm 1,079,000 kg 2,379,000 lbs and dust repression
72" Shoes/1829mm 1,084,000 kg 2,390,000 lbs
The standard shovel can be customized for local and minesite
Counterweight (Punchings)** 230,000 kg 507,000 lbs specific conditions in the following areas:
• Operator Cab
* All weights subject to 5% variation.
** To be furnished by customer. • Climate Control
• Cold Weather Equipment
• Technology and Software
• Electrical and Mechanical Systems
• Maintenance Systems

LIGHTING
Standard: Metal Halide, 400 W, high intensity discharge (HID)
primary exterior floodlights (11) mounted on the
operator’s cab, RH room, LH room and machinery
house. Halogen, 500 W secondary exterior floodlights
(7) mounted under revolving frame corners, machinery
house and above cab door. Fluorescent lights (20)
illuminate interior of the machinery house, RH and LH
room.
Optional: High Pressure Sodium, 400 W or 1000 W primary
exterior floodlights. Secondary exterior floodlight
combination of Halogen, 500 W (3) and fluorescent
lights (6) mounted under revolving frame

LOADING CONTROL CENTER

SPACE FOR MINE
COMMUNICATIONS
ANTE ROOM EQUIPMENT
(SHOWN WITH
OPTIONAL TOILET)
TOUCHSCREEN GUI
AND OPTIONAL REMOTE
ELECTRICAL CABINET CAMERA SYSTEM

SPACE FOR APPLIANCES

ARMREST MOUNTED,
PISTOL GRIP JOYSTICKS
TRAINER’S STATION

LOCKERS
6-WAY POWER ADJUSTABLE AIR SUSPENSION
STORAGE CABINET SEAT WITH HEAT AND VIBRATORY MASSAGE

NOTE: All designs, specifications and components of equipment described above are subject to change at manufacturer’s sole discretion at any time without
advance notice. Data published herein is informational in nature and shall not be construed to warrant suitability of machine for any particular purpose as
performance may vary with conditions encountered. The only warranty applicable is our standard written warranty for this machine.

P&H Mining Equipment • Box 310 • Milwaukee, Wisconsin 53201 USA

XS-4186 2AG-207
 2800XPC TECHNICAL DESCRIPTION
January, 2007

The P&H 2800XPC is a heavy duty electric mining shovel which provides a 70 ton (63.5 metric
ton) nominal payload capacity specifically designed to operate in mines for high productive
loading of 190 ton to 260 ton (172 metric ton to 236 metric ton) haul trucks and larger.

This technical description is provided to compliment the 2800XPC main machine

specification XS-4186.

ELECTRICAL POWER SYSTEM

POWER SUPPLY
Electrical power to the shovel is Customer supplied via a trailing cable. Recommended
SHD-GC trailing cables, for 7,200 volt supply, are:

#2 AWG/35mm² 3350 ft./1021m.

#1 AWG/50mm² 4100 ft./1250m.
1/0 AWG/55mm² 5100 ft./1555m.

Electrical equipment on the shovel is designed for an incoming supply of 3 phase/60 hertz/4,160
or 7,200 volts. Secondary voltage for auxiliary motors is 3 phase/60 hertz/480 volts.
(Alternatively, designed for an incoming supply of 3 phase/50 hertz/3,300, 6000, 6600, 7200, or
11,000 volts. Secondary voltage for auxiliary motors is 3 phase/50 hertz/380 or 415 volts).
Recommended 22 MVA, short circuit capacity, at the shovel.

LOWER HIGH VOLTAGE DISCONNECT SWITCH

Electrical power is brought to the shovel by connection of the trailing cable to the lower HV
disconnect switch which is mounted on the rear of the carbody. A cable coupler is mounted on
this switch and mating PLM coupler is provided for the trailing cable end. The switch provides a
visible disconnect, grounding, and a safety key interlock which energizes or disconnects
electrical power to the entire machine. HV wiring runs from this switch through the carbody to
the HV collector rings on the upper deck. The standard cable coupler is a PLM brand quick
disconnect type. Other couplings are available upon request.

HIGH VOLTAGE COLLECTOR RINGS

 Model 2800XPC
Technical Description

High voltage collector rings consist of three (3) power and one (1) ground ring, and are mounted
on top of the carbody. All rings are extra wide to provide proper contact with collector shoes
which are mounted under the revolving frame. Ring access is protected by bolted carbody hole
covers.

LOW VOLTAGE COLLECTOR RINGS

Low voltage collector rings, which transmit lower voltage power from upper to lower are deck
mounted above the center gudgeon. The LV collector cover is window equipped for viewing of
rings and brushes for inspection.

UPPER HIGH VOLTAGE DISCONNECT

Fully contained cabinet contains two visible high voltage disconnects to 1) isolate the entire
upper H.V. supply, and 2) isolate the primary of the Main Transformer, vacuum contactor, line-
to-line and line-to-ground lightning arrestors for surge suppression. Current limiting HV fuses
provide short circuit protection for the primary of the Main Transformer and the primary of the
Auxiliary Transformer

MAIN TRANSFORMER
Designed for mining shovel service, 2000KVA rated, dry type; Delta/Wye connected,
minimizing third harmonic current flow to external circuits, simplified ground fault detection.
Transformer can accommodate unequal loading, has ±5% voltage taps, and temperature
monitored windings. Main Transformer provides power for the Converter Cabinet motion
thyristor bridges which control the power to the DC drive motor armatures and fields. For power
monitoring a Multilin MTM-Plus meter module is provided as standard.

AUXILIARY TRANSFORMER
Like the main transformer, the auxiliary transformer is designed for mining shovel service, is of
the dry type, and is Delta/Wye connected. It is rated at 325 KVA. Four (4) secondary windings
provide power for:
(1) 60HZ/480 Volts (Alternatively 50HZ/380 or 415 Volts) for utilities and auxiliary motors.
Power from the transformer flows to an Auxiliary Load Center, Auxiliary Cabinet and
motors.
(2) Shielded winding supply for the Control System
(3) Field supply voltage to the DC drive motor, field power bridges.
(4) Lighting and GPO’s supply, 45 KVA rated, and distributed through the 120 VAC
(alternately 240V) load center

POWER CONVERTER CABINET

The P&H Digital DC power conversion system contains the simple six-thyristor three-phase
bridges used to statically convert AC supply power to controlled DC supply to motion drive
motor armatures for speed and torque regulation. This thyristor bridge inherently also allows for
invert regenerated DC energy to AC power during motion deceleration. The regenerated power

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 Model 2800XPC
Technical Description

is used to supply the on board needs with the excess going back to the mine network for energy
savings.

Thyristors are mounted in easily accessible heat sinks and are forced air-cooled. A patented fast
acting over-current system, diverter system, senses and limits the over-current to the DC motors
eliminating destructive flashovers.

POWER DISTRIBUTION
All High Voltage cables are run in metal conduit. An enclosed over head copper bus system is
used to carry the power from the Main Transformer to the Converter cabinet. All other wiring is
generally run in raised troughs on the machinery deck floor. Power cables are XLPO (cross-
linked polyolefin) insulated

REACTIVE POWER COMPENSATION (RPC) SYSTEM

Housed in a rugged, ventilated cabinet, the RPC system contains stepped tuned banks of
capacitors and reactors, automatically and synchronously switched on and off the line, to
maintain average system power factor near unity. Tuned banks provide a high level of harmonics
filtering of the predominant harmonics generated by the converters. Synchronously applied
stepped compensation eliminates transients during application and disconnection.

TRANSFER CABINET
The transfer cabinet contains heavy duty contactors to transfer the power from the hoist and
crowd converters to the propel motors in the propel mode. Transfer is initiated by a push button
on the console in the operator’s cab with all sequencing handled automatically by the
programmable industrial controller.

DC DRIVE MOTORS
P&H designed, manufactured, and tested motors are specifically for mining service duty, with
Class "H" insulating system. Drive motors are equipped with RTD’s to monitor motor bearings
and winding temperatures, and all are equipped with heavy duty blowers with screen protected
air inlets. Optional brush grades are available for unusual operating conditions.

A Remote Hoist Pendant Controller is included in the machinery house with variable speed
control to turn the hoist drum during hoist rope changeouts.

ELECTRICAL CONTROL SYSTEM

P&H CENTURION™ SHOVEL CONTROL SYSTEM
The P&H Centurion™ Shovel Control System provides the supervisory control of the shovel
drives and executes the sequencing and monitoring functions, and consists of the supervisory
control computer and supporting hardware devices and software programs. The system is
comprised of three basic areas: 1) the onboard graphical user interface (GUI), 2) the remote
input/output (I/O) devices and communication interface, and 3) the individual drive controllers.

2800XPC Detailed Technical Description Jan 2007.doc

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 Model 2800XPC
Technical Description

. The architecture provides connectivity from components on the shovel to the onboard GUIs
and provides diagnostic and monitoring capabilities. The application code residing within the
supervisory controller is based on the IEC 61131 standard. The control system uses Profibus over
fiber optic and copper media for communications with the various system components.

SUPERVISORY CONTROL CABINET

Components for the P&H Centurion™ Shovel Control System are housed in a rugged,
maintenance friendly cabinet, which is located in the RH Electronics room. The drive system for
the P&H TripRite dipper trip system is also housed in the Supervisory Control Cabinet.

LOWER CONTROL CABINET

The lower control cabinet is mounted on the back of the carbody, and contains remote I/O, motor
starters for the propel motor blowers, air solenoid valves for the brakes, and electrical
convenience outlets.

REMOTE I/O’S
The supervisory control system functions with remote I/O in several locations such as lower
propel, LH lube room, RPC cabinet, converter cabinet, transfer cabinet, auxiliary cabinet, and
operators cab.

AUTOMATIC ATTACHMENT PROTECTION SYSTEMS

Hoist and crowd/retract limits are set on the GUI touch screen located at the loading control
center in the operator's cab. A boom profiling limit is included to help prevent contact of the
handle torsion box and dipper with boom. The ABSS (Automatic Boom Soft Set-down) feature
is part of the control system and minimizes boom jacking and the associated impact of abruptly
lowering the boom from a jacked condition.

MOTOR CONTROL CENTER (MCC)

A large maintenance friendly cabinet contains individual motor starters and circuit breakers,
which provide thermal and short circuit protection for each motor. For electrical isolation, the
controls for each individual motor are housed in an individual cubicle. In addition to motor
control, there are cubicles to control house heaters and lights. The MCC is located in the
environmentally controlled RH electronics room.

OPERATOR INTERFACE
LOADING CONTROL CAB

The operator is stationed in a roomy cab that is mounted on the right hand side of the machine
above the electrical room. The operator is positioned at a 15 degree angle off of the cab
centerline toward the dipper. The operator has a wide view of the dipper and bank and

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 Model 2800XPC
Technical Description

surrounding loading area. The cab is FOPS (Falling Object Protection System) certified, and has
sound levels below 70 dBA while the shovel is operating when the doors and windows are
closed. A standard front window wiper system is provided. A catwalk system provides access
for cleaning, maintenance, or replacement of the windows. Access to the cab roof is provided via
ladder and roof handrails. A single two tone air horn mounted on the RH room is also included.

All windows are tinted safety glass. The front windows are 0.75 inch / 18 mm thick laminated
safety glass. Side and door windows are fixed in place and made from 0.25 inch / 6 mm
tempered glass. The standard cab features storage lockers, desk/counter space, and provisions for
mounting mine supplied microwave or toaster oven and refrigerator. There is a work space with
seat for an operator trainer located behind the operator. A separate room is located behind the
operator cab that can be customized by the mine for additional storage or used for a toilet.

LOADING CONTROL CENTER

The P&H Loading Control Center provides a single location of control for shovel operation and
truck loading.

The standard seat base is an air suspension type which can be adjusted for an operator’s height
and weight. The seat has an automotive style power system which provides vertical and fore / aft
adjustment to allow custom fitting of the joysticks to individual operators. The seat has heat,
lumbar support, and massage. The entire seat, armrest assembly is mounted to a vibration
isolated sled with an integral footrest. The angled footrest swivels into two positions.

The joystick contollers are Hall-Effect, pistol grip style with both push button, trigger switch, and
rocker switches built into the grips. There is a single console on the left hand side of the operator.
All control devices and most auxilary functions such as those climate control and lighting are
located within reach of the operator while seated. An AM/FM radio receiver with 5 disc CD
changer is included. The console has provisions for mounting the standard P&H GUI touch
screen as well as optional and mine supplied items such as camera monitors, radios, and dispatch
screens.

GRAPHIC USER INTERFACE (GUI)

The GUI has menus and information screens thatallow the operator todisplay information, and
perform various operation functions. The basic functions performed by the GUI are:
• Display machine operating status
• Display and set hoist and crowd limit setting (boom profiling)
• Provide fault enunciation and alerts
• Display temperature monitoring
• Display boom jacking status
• Display boarding ladder positions
• Display lubrication system settings and status
• Provide for manual initiation of lubrication cycles

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 Model 2800XPC
Technical Description

STANDARD DIAGNOSTICS
The Centurion GUI provides the following standard diagnostics:
• Standard Temperature Monitoring system - all DC motors (windings and bearings), drum
shaft bearings boom shipper shaft bushings, and ambient air temperature. Graphical
temperature shown on touch screens.
• Drive programming and analysis software to allow maintenance personnel to record and
perform on line diagnostics of main motion drive paramerters, settings, and performance.
• Control logic software to allow maintenance personnel to view controller logic program,
verify functions, and force parameters for diagnostic purposes.
• Input/Output (I/O) divice monitioring and fault detection system to identify location and type
of fault.

CLIMATE CONTROL
An optional P&H MineAir Systems MAS 1500 mine duty air conditioner unit is available. A
single unit can be fitted to the operator cab, or two units can be fitted, one for the cab and one for
the electronics room. Each MAS 1500 unit is capable of delivering 14 kW cooling (48000
BTU/Hr), and 18kW heating. Units are fitted with an efficient air filtration system, which
pressurizes the cab and electrical room.

LIGHTING
Primary exterior floodlights: Standard lights are Metal Halide, 400 watt, 60HZ/120V
(alternatively 50HZ/220V), high intensity discharge (HID) units.

Standard primary exterior floodlight locations (nine are wide beam and two very narrow beam)
are as follows:
• Two (2) on front of operator’s cab, below the front window.
• Two (2) on top front of lube room
• Two (2) right side of house
• Two (2) top rear of house
• One (1) on front of house below RH room
• One (1) on front of house below LH room
• One (1) top left side of house

Secondary exterior floodlights: Standard are Halogen, 500 watt units. Standard secondary
exterior floodlight locations are as follows
• One (1) above operator’s cab door
• Two (2) on the lower front of machinery house
• Four (4) under revolving frame corners
Exterior incandescent: Five (5), 100 watt; one (1) at each machinery house door and one (1) at
operator’s cab door.

Interior lighting: Twenty (20) fluorescent lights are provided to illuminate the machinery house,
RH electrical room and LH lube room.

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 Model 2800XPC
Technical Description

Operator’s cab lighting: Incandescent 100 watt ceiling light.

One (1) portable halogen trouble light is also provided as standard for primary use at convenient
roof top outlets.

ELECTRICAL CONVENIENCE OUTLETS

Electrical outlets for 110/120 volt supply are conveniently located:
• One (1) in lower control box on rear of carbody
• Two (2) under revolving frame platforms
• Seven (7) In machinery house
• One (1) on RH catwalk
• Two (2) in RH electronics room
• One (1) in LH lube room
• Three (3) in Operator’s cab
• Two (2) on house roof

Outlets are GFI protected. GPO’s are 15 amp, duplex, NEMA 5-15 straight blade devices, 2
pole, 3 wire grounded and 125V rated.

Special instrument outlets are located in the Supervisory Control Cabinet.

Three (3) 60HZ/460V (Alt. 50HZ/380V) outlets are also provided; one (1) in RH electronics
room, one (1) in LH lube room and one (1) in Operator’s cab. These outlets are 20 amp, 3 wire,
4 pole, IEC 309 type.

A single welder outlet receptacle (60Hz/460V, alternatively 50Hz/380V) is provided, located

near the RH door in the machinery house.

MECHANICAL SYSTEMS
CRAWLER DRIVE SYSTEM
The P&H DELTA crawler drive system incorporates a rugged lug and sprocket design concept
with shoe and tumbler engagement close to the link pin centerlines.

CRAWLER SHOES
Deep section, cast manganese shoes are connected with 4.5 inch alloy steel induction hardened
pins through machined, line-bored holes. Shoes are designed specifically for the P&H DELTA
sprocket style drive system. Standard crawler shoes width is 56 inches (1422mm). Shoe width of
72 inch (1829mm) is available, as are cleated shoe upon request.

CRAWLER FRAMES

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The frames are a heavy welded box section designs with bolted fit to carbody under full shear
ledge support. There is no field welding required in the connection. There are eight (8) lower
rollersand a front and rear idler in each frame. The front idler is a large diameter manganese
casting, which is mounted on two (2) heavy duty bushings. Lower rollers and idlers are V-ring
sealed to exclude contaminates and hardened wear surfaces protect crawler frame wear. Rollers
and idlers are straddle mounted with special alloy brass bushings. “P&H 50+” lower rollers are
hardened to over 50 on the Rockwell C scale. Replaceable pin-on, high hardness, wear resistant
cast slide bars on top of each frame support the crawler shoes.

CARBODY
The carbody is a heavy welded high strength low alloy steel structure of cellular deep box
sections, built around a large center hub casting. The flattop design with deep section diaphragm
plates provides direct support of roller path. Carbody interior is painted white and is equipped
with an electrical convenience outlet for trouble light use. Swing gear and lower swing roller
path are mounted on the top of the carbody with dowels and bolts. The crawler frames are
connected to the carbody by a full-length shear ledge and rod bolts. Both carbody and crawler
frames designed to withstand the high level of crawler frame connection bolt tension. The
crawler frame connection bolts produce very high clamping forces between the crawler frame
and carbody machined surfaces. The standard tensioning system for the rod bolts consist of
simple bolt and nut arrangement.

DUAL PLANETARY PROPEL SYSTEM

Dual independent P&H DC drive motors rated at 820hp/612kW total continuous power at 550V
and 1440hp/1074kW total peak developed horsepower, drive the propel system and are load
sharing controlled. Motors are mounted in a propel motor base which is bolted to the rear of the
carbody. Motor frame adjusting screws are integral to the base for ease of alignment, and the
motors are directly connected to P&H planetary propel transmissions with a gear coupling. The
planetary propel transmissions are directly mounted to each crawler frame, and provide
differential speed and counter-rotational steering capability. All gearing is forged, anti-friction
bearing mounted, and all external gears are case hardened and ground. Propel transmissions are
designed with bath and splash lubrication to all gearing and bearings.

The P&H Sprocket drive system has a raised final propel drive shaft and tumbler. The final
propel drive shaft is spline connected to the planetary transmission and tumbler, and is mounted
on anti-friction bearings. The outboard spherical bearing is encapsulated to prevent crawler frame
damage in the event of a bearing failure. V-ring seals are used to seal out dirt and seal in
lubricant.

CENTER GUDGEON
The Center Gudgeon is a hollow heavy-duty forging used to connect the upper revolving frame to
the lower carbody. Acme threads are provided on the upper and lower end of the gudgeon. The
gudgeon is a cascaded interference type fit in the center hub casting of the carbody. A locking
mechanism on the upper threads allows fine adjustment capabilities and positive retention of nut

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 Model 2800XPC
Technical Description

position. Gudgeon center hole is used for electrical wiring, lube, and airlines between upper
revolving frame and lower machinery.

REVOLVING FRAME
The revolving frame is a heavy welded high strength low alloy steel structure of cellular deep
box sections built around a large center casting. The rolled, full depth internal turret plates align
with the swing roller path and provide 360° direct load transfer support. A wide roller path
support pad on the underside of the revolving frame provides a pilot ring to prevent radial
movement of the upper path. Deck machinery is mounted via tapped holes or pin supported and
no internal access is required to mount the machinery. A standard drain system allows for the
hoist and swing transmissions to be evacuated through piping to below the revolving frame deck
(crowd drains to boom foot platform).

COUNTERWEIGHT BOX
A sectioned counterweight box is mounted to the rear of the revolving frame to accommodate the
counterweight ballast.

DECK PLAN
Side platforms, which mount to the revolving frame, extend the deck width. A conveniently
arranged floor plan with abundant space facilitates maintenance.

ELECTRONICS ROOM
A separate large room is mounted on front right corner of the revolving frame and houses the
supervisory control cabinet and motor control center. It is insulated with 0.5 inch/12.7mm
material; equipped with 0.75 hp fresh air blower (not used with optional air conditioner),
secondary wall and door air filter, and louvered front wall vent panel. Two (2) doors are provided
for improved access; one (1) leading to machinery house and one (1) to outside catwalk. The RH
room also is the support base for the RH elevated operator’s cab.

LUBRICATION ROOM
A separate room is mounted on front left corner of the revolving frame, which houses lube tanks,
pumps, plumbing, and controls (remote I/O connection for lube system monitoring and control);
and most air system components including the receiver. Room is insulated with 0.5
inch/12.7mm material, and can be optionally heated for improved cold weather operation.

MACHINERY HOUSE
Truss style roof with weather tight, removable hatch covers for accessibility to internal
machinery. Roof panels are strategically located to direct crane picks of major deck mounted
components as required.

HOUSE PRESSURIZATION AND FILTRATION

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House is pressurized and air is filtered by a high efficiency inertial filter system. Ambient air is
drawn from the forward facing intake hoods by two large vane axial fans and passes through the
filter panels which remove airborn dust particles and allow the cleaned air to pass through to the
machinery house. Bleed airflow is created by two blowers and carries dirty air through ducts to
the outside rear of the house. Clean house air is directed to the rear portion of the house to
provide greater cooling of deck mounted components. Access is provided to filter and blower
units from the house roof.

COLD WEATHER EQUIPMENT

The RH and LH rooms are equipped with insulation as a standard feature. The air valves for the
lower works are located in the heated lower control cabinet as standard, and the automatic
moisture dump valve for the main air receiver is located in the heated LH lube room as standard.
Heating options are available.

BOARDING AND ACCESS

A right side pneumatic controlled stairway and left side vertical pull-down ladder are interlocked
to de-energize swing and propel functions when in down position for safety. Catwalk/platforms,
with grated metal surface, hand rails, and toe boards are provided in access areas. Roof grating is
welded to roof panels.

HOIST DRIVE SYSTEM

Dual P&H DC motors rated at 1600hp/1194kW total continuous power at 550V and
2833hp/2113kW total peak developed power drive a modular gearcase pinned to the revolving
frame. First reduction is helical gear set, second reductions spur and a reversible spur drum gear.
All gearing is forged machined, case hardened and ground. Transmission is oil tight with anti-
friction bearings. Gearing is splash lubricated. A lube pump and filtration system is standard, and
is designed for use with high viscosity lubricants, even in cold temperatures.

The hoist drum is a large 56 inch (1422 mm) pitch diameter drum with through shaft and flame
hardened grooves. Standard hoist rope is 2.375 inch (60 mm) diameter cable fully plastic
impregnated and compacted. Hoist drum and cable are provided with high capacity Ferrule
Beckett fittings to simplify cable change out. Hoist limits are programmable from operator's cab.
Hoist drum bearings are equipped for temperature monitoring.

HOIST CABLE TUGGER

An electric driven tugger is standard to assist with hoist cable changes. Standard tugger
configuration has as single 2000 lb.(907 kg) rated winch. An additional 2000 lb. (907 kg) winch
is available for greater capacity faster rope changes.

SWING DRIVE SYSTEM

Swing power is provided by two (2) P&H DC drive motors rated at 1000hp/746kW total
continuous power at 550V and 1546hp/1153kW total peak developed power and are connected in
series. P&H Planetary transmissions are mounted front and rear of swing gear for even loading.

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Some components are interchangeable with first and second reductions in Propel transmissions
minimizing parts stocking requirements. Planetary swing transmissions are designed with bath
and splash lubrication for all bearings and gearing. An optional oil filtration system is available.

Swing shafts are mounted on anti-friction bearings and are removable without disturbing the
transmission. Cast swing gear has 17 foot-2 inch/5.23m diameter with a large 13 inch/330mm
tooth face width. Swing circle uses a quantity of 55 tapered rollers, 10 inch/254mm diameter,
carried on self-lubricating bushings. Rollers and roller paths are high alloy, forged, quenched and
tempered to a high hardness. Full circle of rollers are in contact with the 360° upper and 360°
lower roller paths which have a wide mounting surface to the carbody and revolving frame.
Upper path is dual flanged mounted with guarding to retain mounting hardware in the event of
loss, and the lower path is clip mounted to the carbody on the inner diameter and retained by the
ring gear outer diameter.

CENTRALIZED LUBRICATION SYSTEM

An automatic centralized lubrication system is standard and provides metered amounts of
lubricant to all major systems requiring grease and open gear lubrication. Lincoln 75:1 ratio air
drive pumps are used. The lube system is controlled by the Centurion Shovel Control System
and can be monitored and adjusted through the touch-screen GUI’s. Large 138 gallon open gear
and 138 gallon grease maximize operating time. All gear cases are designed with bath and splash
lubrication to all gearing and bearings. A lube filtration system is standard on the hoist and
crowd gear case.

AIR SYSTEM
Compressed air is provided for lube pumps, lube sprayers, disc brakes, hoist cable tugger, air
operated stairway, horn, and operators seat. Standard air compressor is a rotary screw type, floor
mounted, with separate 200 gallon capacity air. The compressor is designed for cold weather
operation.

A high capacity membrane air dryer system is available (Only one unit required for single or dual
air compressors) which provides dry air with a -40° F (-40° C) dew point to the reservoir for dry
air in all functions. The membrane dryer features a low maintenance membrane technology, and
is complete with filters and automatic control system. The membrane dryer system is housed in a
sturdy enclosure, and is mounted in the lubrication room. The membrane dryer system cannot be
used with piston type compressors.

BRAKES
All motions have disc brakes which are spring set-air released. Brakes have replaceable wear
surfaces, and a low abrasion, high heat capacity friction material is used. Select brakes are
equipped with centering mechanisms to minimize contact of frictional surfaces when brake is
released.

BOOM

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58 foot- (17.67m) length set at a 45° angle; welded structure of high strength low alloy steel for
cold weather toughness; extra width and depth for high load capability; 96 inch (2438mm)
diameter point sheaves, split bearing block mounted for maintenance ease. Boom suspension
cables are 3.50 inch (89 mm) structural strand. Integral lifting lugs and wear resistant side boxes
are incorporated. Boom is connected to revolving frame lugs with heavy duty lubricated pins
retained with split collars. Boom bumpers are mounted to the boom to reduce damage from
contact with the handle torsion box.

CROWD SYSTEM
Crowd and retract of the dipper is accomplished by one (1) P&H DC motor rated at
720hp/537kW continuous power at 550V and 775hp/578kW peak developed power driving the
P&H - POWERBAND "V" BELT - shock absorbing/system to modular, enclosed, transmission
with spur gear reduction to manganese racks and forged, machined and hardened crowd pinions.
V-belt sheaves are fully machined and balanced. Gearing is forged, case hardened and ground;
mounted with encapsulated, pre-adjusted bearings. A transmission oil filtration system with
basked strainers, 20 micron filtration, pump and motor is included. Single piece saddle blocks
are hydraulically adjusted and allow for removal of crowd pinions. Crowd/retract limits
programmable from the operator's cab.

DIPPER HANDLE
34 foot (10.36m) effective length; high strength low alloy, cold weather steel; straddle design,
straight legs and large cast manganese racks providing strength for corner tooth digging loads.
Handle geometry provides for torsion box clearance with the boom. A stress relieved handle is
available for cold temperature and high impact applications when specified.

DIPPER TRIP
Dipper trip system is a durable 10 HP electrically commutated motor drive through planetary
gearing to a heavy duty drum. The solid state drive components for the dipper trip system are
located in the supervisory control cabinet, and are adjustable through the GUI. Both ferrule
becket and cable clamp connection capability is provided for securing dipper trip cable to the
drum. Trip line is connected to dipper latch lever bar a handle mounted banjo arm. An integral
disc brake on the motor sets when not in use.

PAINT
Standard exterior is P&H Yellow and Black. Yellow on machinery house and operator’s cab.
Black on lower, attachment, catwalks and handrail. (Lower HV disconnect switch is painted
red). Interior of house, RH and LH rooms, carbody, revolving frame and lower boom section and
all electrical cabinet interiors are painted high visibility white.

WEIGHTS
Working weight of the P&H Model 2800XPC with nominal dipper and 56 inch (1422mm) wide
crawler shoes is 2,220,000 lbs. (1,006,992 kg.)

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OPTIONAL ITEMS DESCRIPTIONS

DIPPER
OPTIMA 60 and HD dippers have been designed specifically for the 2800XPC for proper filling
and low cost of operation. Standard equipment on the dippers include adjustable pitch braces
and P&H Snubrite™ hydraulic snubbers to prevent damaging dipper door closing impact.
Nominal rated dipper size is 46 cubic yard ( 35.2 cubic meters ).

ELECTRICAL EQUIPMENT
• Dual voltage main transformer
• High Altitude 3048 - 4270 m / 10000 to 14000 ft main single voltage transformer

NOTE: For dual voltage transformers and other special applications, contact shovel
marketing.

LIGHTING
• Primary exterior lighting (11) high pressure sodium, 60Hz, 120V, 400W
• Primary exterior lighting (11) high pressure sodium, 60Hz, 120V, 1000W
• Primary exterior lighting (11) high pressure sodium, 50Hz, 220V, 400W
• Primary exterior lighting (11) high pressure sodium, 50Hz, 220V, 1000W
• Primary exterior lighting (11) metal halide, 50Hz, 220V, 400W
• Secondary exterior; (3) Halogen, 500W and (6) Fluorescent under revolving frame

AIR SYSTEM
• Dual (2) rotary screw air compressors with automatic switching, floor mounted. One (1)
separate 200 gallon air receiver in lube room.
• Membrane air dryer system for rotary screw air compressor (Note: Only one unit required for
single or dual compressors)
• Air hose reel w/30m/100ft of hose

NOTE: Consult Shovel Marketing for applicability of other compressors.

LUBRICATION SYSTEM
• Wiggins quick fill connectors for lube tanks

BOARDING ACCESS
• Left hand air stairway-in place of standard left hand pull down ladder

CRAWLER SHOES
• 72" wide, flat manganese with induction hardened pins

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NOTE: For cleated shoes and any special shoe requirements, contact Shovel Marketing for
lead time and pricing

PAINT
• Color Change using P&H paint spec.
• Customer Logo on machine away from P&H logo and model name, painted, one or two
colors, customer to supply template
• Customer Numbers painted on machine

OPERATOR CAB
• Front window electric wiper and spray wash system
• Sliding windows – two sliding windows with screens in place of side trainer and rear window
– 0.25 inch / 6mm tempered tinted glass
• Incinerating toilet system for utility room
• Video Monitoring System (Intec)- four (4) color cameras and two (2) color monitors for blind
spot monitoring - inside and outside of machinery house
• Satellite radio receiver in place of AM/FM/CD (Customer specify XM or Sirius)
• Sun shades, pull down - front window only
• Sun shades, pull down - all windows
• Air Horn - dual two tone mounted on RH electronics and LH lube room
• Electric Horn with adjustable volume - single in place of standard air horn
• Electric Horn with adjustable volume - dual, mounted on RH electronics and LH lube room
in place of standard single air.

CLIMATE CONTROL
• Mine Air Systems unit for operator's cab only; Model MAS 1500, cooling to 48,000 BTU/hr
(14kW), heating to 18kW; with air filter-pressurizer and R407C refrigerant
• Mine Air Systems units for operator's cab and electronics room; two (2) Model MAS 1500
units; cooling to 96,000 BTU/hr. (28 kW) total, heating to 36 kW total; with air filter-
pressurizer and R407C refrigerant (Note: Deletes blower in electronics room)
• Sigma unit for operator's cab only; Model MPV7; cooling to 24,000 BTU/hr. (7kW), heating
7 kW; with air filter-pressurizer and R134a refrigerant
• Sigma unit for operator's cab and electronics room; one Model MPV15; cooling to 15kW,
heating 2-stage 18kW; with air filter-pressurizer and R134a refrigerant (Note: Deletes blower
in electronics room)

NOTE: A/C is mandatory for electronics room in high ambient temperature environments

JIB HOIST
• Swing jib hoist; 8.9 kN / 2,000 lb. capacity mounted outside LH lube room

FIRE SUPPRESSION

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• Fire extinguishers, 20lb. dry chemical, Model I-A-20G, (3 are standard)

Note: Fire suppression systems are locally contracted by P&H MinePro Services. Typical
systems consist of clean agent suppression system for electrical cabinets, RH room, LH
room, and collector ring assembly.

TRAIL CABLE REEL

• Trail Cable Reel, air drive, level winding, 48" diameter drum
• Trail Cable Reel, hydraulic over electric drive, level winding, 48" diameter drum.
• Mounting material for trail cable reel (air or hydraulic)

COLD WEATHER EQUIPMENT

• 2.5cm / 1 inch insulation in machinery house
• 7.5KW heater in operator's cab (not required if Cab AC option is chosen)
• 7.5 kW heater in RH electrical room
• 7.5 kW heater in LH lube room
• Strip heaters for main control cabinets
• Strip heaters for main D.C. motors
• Strip heaters for main and auxiliary transformers
• 40 kW machinery house heater, maximum of 3, each

NOTE: Membrane air dryer should be included in cold weather applications.

TECHNOLOGY AND SOFTWARE

• Extended Upper Temperature Monitoring system - standard plus crowd gearcase bearings,
hoist gearcase bearings, swing shaft bearings, upper gearcase oil, and center gudgeon hub.
• Extended Lower Temperature Monitoring system - standard plus final drive bearings and
propel gearcase oil.
• P&H Optidig II operator assist tool that co-ordinates the hoist and crowd motions to prevent
the dipper from stalling while digging.
• Motivator Mode software to modify drive performance and RPC function in order to allow
mine supplied motivator at the trail cable voltage to be used to propel.
• ShoveLink Remote Communications Version I - software for mine supplied computer and
ethernet based communication link. Software allows user to view electrical feedback, sensor
information, diagnostics, and GUI screens in real time. Maximum of two (2) users per shovel.
• P&H Payload Plus dipper load weighing system with auto calibration and NIST calibrated
and certified boom point pin load cell.
• P&H Payload Reporter – Microsoft® SQL server, web-browser based reporting package
produces single or fleet based production reports from Payload Plus data.

MISCELLANEOUS ELECTRICAL
• Electrical Cabinet Filters for RPC and converter cabinets

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• Extra Welder Outlet in machinery house, near LH door. 2 max.

• Ground Fault Protection for welder outlets. 3 max.
• Extra Welder Outlet (600V) in machinery house including transformer and ground fault
protection. 4 max.
• Emergency Lighting Unit - six lights total per unit - two (2) on power supply and four (4)
remote mounted - field installed
• Communication System (Gai-Tronics), 3-way, field installed, one on exterior, one in machine
house, and one in operator cab.
• Trail Cable Connector Extension with PLM cable coupler to extend trail cable connector to
rear of propel motor base. (Note: Not for use with trail cable reel. Coupler types other than
standard PLM must be specified)

MISCELLANEOUS MECHANICAL
• Central Drain System for hoist and swing transmissions - field installed
• Lube Filtration with 20 micron filter on each swing transmission
• Blower and Brake Removal System in machinery house - field installed
• P&H Air Scrub Pro high efficiency house pressurization system in place of std
• Convex Mirrors - two (2) rectangular 16.50" x 24.75” on front of machine
• Tow Lug, Front of carbody - field installed
• Tow Lugs, Rear, two (2) on rear of carbody - field installed
• Hoist Drum Lock System which provides a mechanical lock to prevent movement of
suspended handle and dipper - field installed
• Slack Hoist Cable Detection system
• Fall Protection Lanyard Attachment points - field installed
• Removable Handrail System for hatch cover openings - field installed
• SuperNut bolt connection for ring gear mounting
• SuperNut rod bolt connection for crawler frames in place of standard nut.
• HYTORC rod bolt connection for crawler frames in place of standard nut. (Does not include
HYTORC tooling which is required for tensioning)
• Export packing
• Counterweight ballast, 265 lbs./cu.ft. minimum density. Contact product engineering for
ballast amount. Delivered to USA site, DOMESTIC PACKED
• Counterweight ballast, 265 lbs./cu.ft. minimum density. Contact product engineering for
ballast amount. Delivered to USA site, EXPORT PACKED

TOOLS, TEST EQUIPMENT AND ASSEMBLY AIDS

• HYTORC tooling (hydraulic power pack not included)
• For other tools and test equipment including software contact P&H Service Department.

TECHNICAL DOCUMENTATION

• Operator's Manual, CD ROM, (3 std), each extra

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 Model 2800XPC
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• Operator's Manual, hard copy (3 std), each extra

• Mechanical Systems Manual, CD ROM, (3 std), each extra
• Mechanical Systems Manual, color hard copy, each
• Electrical Systems Manual, CD ROM, (3 std), each extra
• Electrical Systems Manual, color hard copy, each
• Parts Manual, hard copy, each (see note below)
• Electrical Data Manual, hard copy, each (see note below)

Note: The LinkOne Viewer allows the end user to print individual pages or complete parts
manuals. P&H Mining Equipment grants the end users of its parts manual the authority to
print hard copy manuals as required. Electronic copy can be installed on as many
computers as desired.

Note: Specify English or Spanish language. Consult Peak Services for other language
requirements.

CUSTOMER SUPPLY ITEMS

Unless otherwise stated in a P&H proposal, required items, not included in our basic machine
supply are:
• Machine erection, including erection tools and equipment
• Counterweight ballast, approximately 500,000 lbs/226,800 kg with a minimum density of
265 lbs. per cubic foot (4,245 kg/m3) (Final counterweight determined by application.)
• Fluids/lubricants
• Trailing cable and electrical power supply.

*****

P&H - An enduring symbol of quality and reliability

NOTE: All designs, specifications and components of equipment described above are subject to change at manufacturer’s
sole discretion at any time without advance notice. Data published herein is informational in nature and shall not be construed to
warrant suitability of machine for any particular purpose as performance may vary with conditions encountered. The only warranty
applicable is our standard written warranty for this machine.

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 ®

2800XPB
ELECTRIC MINING SHOVEL

OPERATING SPECIFICATIONS

meters
feet
22 72.2

20 65.6

18 59.1

16 52.5

14 45.9

12 39.4

10 32.8

8 26.2

6 19.7

4 13.1

2 6.6

0 0

2 6.6
meters 6 4 2 0 2 4 6 8 10 12 14 16 18 20 22 24
feet 19.7 13.1 6.6 0 6.6 13.1 19.7 26.2 32.8 39.4 45.9 52.5 59.1 65.6 72.2 78.7
C
L ROTATION

CAPACITY
WORKING RANGES
Nominal Pay Load 63.5 m ton 70 ton
Height of Cut (Max) 16.15 m 53 ft. 0 in.
Nominal Dipper Capacity 35.2 m3 46 yd3
(SAE struck) Radius of Cut (Max) 23.90 m 78 ft. 5 in.

Rated Suspended Load 117,934 kg 260,000 lbs Depth of Cut (Max) 1.73 m 5 ft. 8 in.

Optimum Truck Size 170-240 m ton 187-265 ton Dumping Height (Max) 9.45 m 31 ft. 0 in.
Floor Level Radius 15.85 m 52 ft. 0 in.
PERFORMANCE Tail Swing Radius 9.91 m 32 ft. 6 in.
Peak Propel Speed 1.08 km/h .67 mile/h Operator Eye Level 9.55 m 31 ft. 4 in.
Gradability (Continuous) 12% 12%
 MACHINERY DECK PLAN
SWING MOTOR AND HOIST HOIST
TRANSMISSION MOTOR AIR COMPRESSOR DRUM
REACTIVE POWER HOIST
COMPENSATION CABINET MOTOR

LUBE RESERVOIRS
(138 gal. each)

LOW VOLTAGE
TRANSFER COLLECTOR
CABINET

CONVERTER
CABINET

FIELD BREAKER
SWING MOTOR AND
TRANSMISSION
GROUND FAULT
CABINET

CONTROL CABINET
AUXILIARY LOAD W/ TOUCH SCREEN
CENTER GRAPHICAL USER
INTERFACE (GUI)

AUXILIARY
FIELD
TRANSFORMER AUXILIARY
CABINET

GROUND FAULT MAIN HIGH VOLTAGE 120 VAC

SUPPRESSION CABINET TRANSFORMER CABINET WITH LOAD
ISOLATORS CENTER

ELECTRICAL

INCOMING SUPPLY REQUIREMENTS P&H DIGITAL DC STATIC DC POWER CONVERSION

Supply Voltage* 4160 or 7200V 3000, 5000, 6000 or 6600V Hoist**/Propel Swing Crowd/Propel
3 Phase, 60 Hz 3 Phase, 50 Hz.
Continuous Armature
Supply Transformer (Minimum) 2500 kVA Converter KW Rating 2x1860 kW 1860 kW 1860 kW
@600 VDC*
Minimum Short Circuit VA Available at Shovel 22 MVA
15 Sec. Armature
*Voltage per customer requirements. Converter Current 3700 amp. 3700 amp. 3700 amp.
Rating*

TRANSFORMER Continuous Field

Converter Rating* 150 amp. 150 amp. 150 amp.
Main Armature Transformer 2000 kVA
* Based on outside ambient temperature of 50°C or 122°F.
Auxiliaries-Field Transformer 450 kVA ** Cascaded hoist converters.

Control/Lighting Supply Winding 50 kVA

P&H DC FAST RESPONSE MAIN MACHINERY MOTORS
Note: Transformer capacities may vary depending on options.
Hoist Motor Continuous rating @550 volts Total 1171kW/1570hp
(Two used) Peak developed power 2113kW/2833hp
P&H DIGITAL DC AUTOMATIC
REACTIVE POWER COMPENSATION* Swing Motor Continuous rating @ 550 volts Total 746kW/1000hp
(Two used) Peak developed power 1153kW/1546hp
60 Hz. (7 step) 50 Hz. (6 step)
Crowd Motor Continuous rating @ 550 volts Total 317kW/425hp
Switched Steps +4725 kVAR Total +4500 kVAR Total (One used) Peak developed power 578kW/775hp
*Nominal rating at rated capacitor voltage (600 VAC) Propel Motor Continuous rating @ 550 volts Total 612kW/820hp
(Two used) Peak developed power 1182kW/1585hp
 SUPERVISORY CONTROL AND DIAGNOSTICS
P&H CENTURION™ • Digital controls provide constant power characteristics for optimal
INTEGRATED PERFORMANCE PLATFORM motion speeds which reduce overall cycle time.
• One-time setup of electrical parameters provide consistent optimum
• Centurion Supervisory Controller provides direct integrated comuni-
operation.
cation with motor drives giving precise motor control and fast cycle
times. Real-time multi-tasking capability allows for optimal machine
logic sequencing, monitoring and control. FEATURES AND OPTIONS
• Centurion I/O System uses ‘Profibus’ communication protocol for • Standard Automatic Lubrication System has advanced diagnostic
seamless integration of all shovel subsystems and future expandabil- and control functions for optimized lubrication and ease of lube sys-
ity. Low-voltage 24V DC I/O drop points feature open and short cir- tem maintenance.
cuit detection for improved diagnostics and troubleshooting.
• Standard Automatic-Boom-Soft-Setdown and Boom Profile Protection
• Centurion Information System’s enhanced Graphical User Interface Envelope help protect structures from excessive loading.
(GUI) features intuitive, icon-based screens to display vital informa-
• Standard Anti-Swing-in-Bank reduces excessive side loading.
tion such as shovel status, troubleshooting information, and optional
production monitoring data and operator feedback. • Options are available to tailor the 2800XPB to specific requirements
• Optional Optidig™ automatically coordinates hoist and crowd
motions while in the bank to improve dig cycle time and optimize
P&H DIGITAL DC DRIVES
power usage.
• P&H Digital DC Drive provides precise, reliable, solid state power to • Optional remote communications provide remote data transmission
the main motion motors, and has been proven on hundreds of units, and other high level control and diagnostic capabilities to improve
logging tens of millions of productive hours. overall loading productivity.

MECHANICAL
HOIST PROPEL
• All gearing housed in single enclosed gear case with filtered oil circu- • Two rugged planetary gear cases of proven design transmit torque to
lation for reliable splash lubrication, ease of maintenance, and the drive sprockets, producing the tractive effort required for fast, effi-
extended component life. cient propel and positioning operations.
• Large 56" diameter hoist drum for extended rope bending life. • P&H DELTA Drive low tension sprocket drive system for improved
Ferrule becket system and single electric tugger are standard for lower works availability and life.
efficient rope change. Dual electric tugger option is available. • Two spring set air release disc brakes - one per motor.
• Two spring set air release disc brakes - one per motor.
DIPPER
CROWD • OPTIMA™ PLUS 60 dipper design provides excellent fill factors and
nominal 70 ton (63.5 metric ton) capacity.
• Powerband V-belt drive between motor and gear case absorbs shock
loads.
• First and second reduction gearing in enclosed gear case for reliable DIPPER TRIP
splash lubrication, ease of maintenance, and extended component
life. • P&H TripRite system utilizes a brushless DC electric motor with
sealed planetary drive unit for reliable trip and slack take up
• Twin leg dipper handle with torsion box and rack and pinion drive has
operation.
inherent stability in the bank for optimal digging.
• Single spring set air release disc brake.
AIR FILTRATION

SWING • Dynavane inertial filtration system is standard.

• High efficiency P&H AirScrubPro cartridge filtration system is
• Two modular planetary gear cases of proven design and a single available.
piece swing gear transmit torque for fast cycle times.
• Two spring set air release disc brakes - one per motor.

LOADING CONTROL CENTER

CONSOLE FOR CLIMATE CONTROL
AND ACCESSORIES
OPTIONAL
AUXILIARY SEAT

POST MOUNTED
TOUCHSCREEN GUI AND
SPACE FOR MINE INFORMATION
SYSTEMS MONITORS

POWER ADJUSTABLE ARMREST MOUNTED,

AIR SUSPENSION PISTOL GRIP JOYSTICKS
6 WAY SEAT WITH HEAT AND
VIBRATORY MASSAGE
 GENERAL MACHINE SPECIFICATIONS

A B

H
G
D
F
E

GENERAL DIMENSIONS BEARING AREA - GROUND PRESSURE

A Overall Width 13.11 m 43 ft. 0 in. Standard:

B Overall Length 15.24 m 50 ft. 0 in. Crawler Bearing Area 23.94 m2 37,112 in2
56" Shoes/ 1422 mm
C Overall Height over Gantry 12.42 m 40 ft. 9 in.
Crawler Ground Pressure 442 kPa 64.10 psi
D Width of Crawler Shoes 1422 mm 56" (Std.) 56" Shoes/ 1422 mm
1829 mm 72"
Optional:
E Overall Width of Crawlers (Std) 9.04 m 29 ft. 8 in.
Crawler Bearing Area 30.78 m2 47,716 in2
F Overall Length of Crawlers 10.80 m 35 ft. 5 in. 72" Shoes/ 1829 mm
G Ground Clearance 1.02 m 3 ft. 4 in. Crawler Ground Pressure 345 kPa 50.09 psi
H Height – Ground to Bottom 72" Shoes/ 1829 mm
of Counterweight 2.69 m 8 ft. 10 in.

WEIGHTS - APPROXIMATE*
CABLE DATA Working Weight (with Dipper, Approx. Wt.)
Hoist (wire rope) 60 mm 2.375" diameter 56" Shoes/1422 mm 1,079,000 kg 2,379,000 lbs
Suspension (bridge strand) 90 mm 3.5" diameter 72" Shoes/1829 mm 1,084,000 kg 2,390,000 lbs
Dipper Trip (wire rope) 13 mm 0.5" diameter Counterweight (Punchings)** 229,971 kg 507,000 lbs

* All weights subject to 5% variation.

** To be furnished by customer.

NOTE: All designs, specifications and components of equipment described above are subject to change
at manufacturer’s sole discretion at any time without advance notice.
Data published herein is informational in nature and shall not be construed to warrant suitability
of machine for any particular purpose as performance may vary with conditions encountered.
The only warranty applicable is our standard written warranty for this machine.

P&H Mining Equipment ◆ Box 310 ◆ Milwaukee, Wisconsin 53201 USA

XS-1607-2 2AG-305
 2800XPB TECHNICAL DESCRIPTION
June 28, 2004

The P&H 2800XPB is a heavy duty electric mining shovel which provides a 70 ton (63.5 metric
ton) nominal payload capacity specifically designed to operate in mines for high productive
loading of 190 ton to 260 ton (172 metric ton to 236 metric ton) haul trucks and larger.

This technical description is provided to compliment the 2800XPB main machine

specification XS-1607.

ELECTRICAL POWER SYSTEM

POWER SUPPLY
Electrical power to the shovel is Customer supplied via a trailing cable. Recommended
SHD-GC trailing cables, for 7,200 volt supply, are:

#2 AWG/35mm² 2800 ft./853m.

#1 AWG/50mm² 4250 ft./1294m.
1/0 AWG/55mm² 5200 ft./1585m.

Electrical equipment on the shovel is designed for an incoming supply of 3 phase/60 hertz/4,160
or 7,200 volts. Secondary voltage for auxiliary motors is 3 phase/60 hertz/480 volts.
(Alternatively, designed for an incoming supply of 3 phase/50 hertz/3,300, 6000, 6600, 7200, or
11,000 volts. Secondary voltage for auxiliary motors is 3 phase/50 hertz/380 or 415 volts).
Recommended 22 MVA, short circuit capacity, at the shovel.

LOWER HIGH VOLTAGE DISCONNECT SWITCH

Electrical power is brought to the shovel by connection of the trailing cable to the lower HV
disconnect switch which is mounted on the rear of the carbody. A cable coupler is mounted on
this switch and mating PLM coupler is provided for the trailing cable end. The switch provides a
visible disconnect, grounding, and a safety key interlock which energizes or disconnects
electrical power to the entire machine. HV wiring runs from this switch through the carbody to
the HV collector rings on the upper deck. The standard cable coupler is a PLM brand quick
disconnect type. Other couplings are available upon request.

HIGH VOLTAGE COLLECTOR RINGS

 Model 2800XPB
Technical Description

High voltage collector rings consist of three (3) power and one (1) ground ring, and are mounted
on top of the carbody. All rings are extra wide to provide proper contact with collector shoes
which are mounted under the revolving frame. Ring access is protected by bolted carbody hole
covers.

LOW VOLTAGE COLLECTOR RINGS

Low voltage collector rings, which transmit lower voltage power from upper to lower are deck
mounted above the center gudgeon. The LV collector cover is window equipped for viewing of
rings and brushes for inspection.

UPPER HIGH VOLTAGE DISCONNECT

Fully contained cabinet contains two visible high voltage disconnects to 1) isolate the entire
upper H.V. supply, and 2) isolate the primary of the Main Transformer, vacuum contactor, line-
to-line and line-to-ground lightning arrestors for surge suppression. Current limiting HV fuses
provide short circuit protection for the primary of the Main Transformer and the primary of the
Auxiliary Transformer

MAIN TRANSFORMER
Designed for mining shovel service, 2000KVA rated, dry type; Delta/Wye connected,
minimizing third harmonic current flow to external circuits, simplified ground fault detection.
Transformer can accommodate unequal loading, has ±5% voltage taps, and temperature
monitored windings. Main Transformer provides power for the Converter Cabinet motion
thyristor bridges which control the power to the DC drive motor armatures and fields.

AUXILIARY TRANSFORMER
Like the main transformer, the auxiliary transformer is designed for mining shovel service, is of
the dry type, and is Delta/Wye connected. It is rated at 325 KVA. Four (4) secondary windings
provide power for:
(1) 60HZ/480 Volts (Alternatively 50HZ/380 or 415 Volts) for utilities and auxiliary motors.
Power from the transformer flows to an Auxiliary Load Center, Auxiliary Cabinet motors.
(2) Shielded winding supply for the Control System
(3) Field supply voltage to the DC drive motor, field power bridges.
(4) Lighting and GPO’s supply, 45 KVA rated, and distributed through the 120 VAC
(alternately 240V) load center

POWER CONVERTER CABINET

The P&H Digital DC power conversion system contains the simple six-thyristor three-phase
bridges used to statically convert AC supply power to controlled DC supply to motion drive
motor armatures for speed and torque regulation. This thyristor bridge inherently also allows for
invert regenerated DC energy to AC power during motion deceleration. The regenerated power
is used to supply the on board needs with the excess going back to the mine network for energy
savings.

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 Model 2800XPB
Technical Description

Thyristors are mounted in easily accessible heat sinks and are forced air-cooled. A patented fast
acting over-current system, diverter system, senses and limits the over-current to the DC motors
eliminating destructive flashovers.

POWER DISTRIBUTION
All High Voltage cables are run in metal conduit. An enclosed over head copper bus system is
used to carry the power from the Main Transformer to the Converter cabinet. All other wiring is
generally run in raised troughs on the machinery deck floor. Power cables are XLPO (cross-
linked polyolefin) insulated

REACTIVE POWER COMPENSATION (RPC) SYSTEM

Housed in a rugged, ventilated cabinet, the RPC system contains stepped tuned banks of
capacitors and reactors, automatically and synchronously switched on and off the line, to
maintain average system power factor near unity. Tuned banks provide a high level of harmonics
filtering of the predominant harmonics generated by the converters. Synchronously applied
stepped compensation eliminates transients during application and disconnection.

TRANSFER CABINET
The transfer cabinet contains heavy duty contactors to transfer the power from the hoist and
crowd converters to the propel motors in the propel mode. Transfer is initiated by a push button
on the console in the operator’s cab with all sequencing handled automatically by the
programmable industrial controller.

DC DRIVE MOTORS
P&H designed, manufactured, and tested motors are specifically for mining service duty, with
Class "H" insulating system. Drive motors are equipped with RTD’s to monitor motor bearings
and winding temperatures, and all are equipped with heavy duty blowers with screen protected
air inlets. Optional brush grades are available for unusual operating conditions.

ELECTRICAL CONTROL SYSTEM

P&H CENTURION™ IPP (INTEGRATED PERFORMANCE PLATFORM)
The P&H Centurion™ IPP provides the supervisory control of the shovel drives and executes the
sequencing and monitoring functions, and consitsts of the supvisory control computer and
supporting hardware devices and software programs. The system is comprized of three basic
areas which are: 1) the onboard graphical user interface (GUI), 2) the remote input/output (I/O)
devices and communication interface, and 3) the individual drive controllers.

The system uses an open concept design to allow for third party integration. The architecture
provides connectivity from components on the shovel to the onboard GUIs and provides
diagnostic and monitoring capabilities. The application code residing within the supervisory
controller is based on the IEC 61131 standard. The control system uses Profibus over fiber optic
and copper media for communications with the various system components.

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 Model 2800XPB
Technical Description

SUPERVISORY CONTROL CABINET

Components for the P&H Centurion™ IPP are housed in a rugged, maintenance friendly cabinet,
which is located in the RH Electronics room.

LOWER CONTROL CABINET

The lower control cabinet is mounted on the back of the carbody, and contains remote I/O, motor
starters for the propel motor blowers, air solenoid valves for the brakes, and electrical
convenience outlets.

REMOTE I/O’S
The supervisory control system functions with remote I/O in several locations such as lower
propel, LH lube room, RPC cabinet, converter cabinet, transfer cabinet, auxiliary cabinet, and
operators cab.

AUTOMATIC ATTACHMENT PROTECTION SYSTEMS

Hoist and crowd/retract limits are set on the GUI touch screen located at the loading control
center in the operator's cab. A boom profiling limit is included to help prevent contact of the
handle torsion box and dipper with boom. The ABSS (Automatic Boom Soft Set-down) feature
is part of the control system and minimizes boom jacking and the associated impact of abruptly
lowering the boom from a jacked condition.

MOTOR CONTROL CENTER (MCC)

A large maintenance friendly cabinet contains individual motor starters and circuit breakers,
which provide thermal and short circuit protection for each motor. For electrical isolation, the
controls for each individual motor are housed in an individual cubicle. In addition to motor
control, there are cubicles to control house heaters and lights. The MCC is located in the
environmentally controlled RH electronics room.

OPERATOR INTERFACE
OPERATOR CAB
A separate, roomy, high-visibility cab is rigidly mounted and offset in an elevated position on the
shovel's right hand side. Freezer style handles are equipped on the cab door. Non-glass areas of
the cab are insulated for temperature and sound control. The sound level inside the cab is below
70dBA while the shovel is operating, and with the door closed. All windows other than the front
window are tinted safety glass. The standard front window glass is 0.38 inch / 9mm thick
laminated safety glass. An industrial grade, single arm electric window wiper system is standard.

A standard single 2-tone air signal horn is standard equipment, and is mounted on front of RH
room. Sound level rating of the standard air horn is 123 dBA at the source.

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 Model 2800XPB
Technical Description

P&H LOADING CONTROL CENTER

The P&H Loading Control Center provides a single location of control for shovel operation and
truck loading. An additional work area with an optional seat is provided immediately behind the
operator for use by training or other personnel.

The standard seat base is an air suspension type which can be adjusted for operators height and
weight. The seat has an automotive style power system which provides vertical and fore / aft
adjustment to allow custom fitting of the joysticks to individual operators. The seat has heat,
lumbar support, and massage. The entire seat, armrest assembly is mounted to a vibration
isolated sled with an integral footrest. The angled footrest swivels into two positions based on
the operator’s height.

The joystick contollers are Hall-Effect, pistol grip style with both push button, trigger switch, and
rocker switches built into the grips. There is a single console on the left hand side of the operator.
All control devices needed by the operator while operating the shovel and loading trucks are
located in a zone of comfort for easy access with minimal movement. Devices needed for
auxillary functions such as those climate control and lighting are located within reach of the
operator while seated.. The console also features an expandable media mounting post to which
the P&H GUI is mounted as standard. Post sections can be added to mount remote camera
monitors as well as dispatch screens.

The climate control ducting in the cab is located above and below the operator. There are
controls to allow regulation of air flow between window defrost, the vents at the feet, and the
vents at the midlevel of the operator.

GRAPHIC USER INTERFACE (GUI)

The GUI has menus and information screens thatallow the operator todisplay information, and
perform various operation functions. The basic functions of the GUI are:
• Display machine operating status
• Display and set hoist and crowd limit setting (boom profiling)
• Provide fault enunciation and alerts
• Display temperature monitoring bar graphs
• Display boom jacking status
• Display boarding ladder positions
• Display lubrication system settings and status
• Provide for manual initiation of lubrication cycles

CLIMATE CONTROL
An optional P&H MineAir Systems MAS 1500 mine duty air conditioner unit is available. A
single unit can be fitted to the operator cab, or two units can be fitted, one for the cab and one for
the electronics room. Each MAS 1500 unit is capable of delivering 14 kW cooling (48000

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 Model 2800XPB
Technical Description

BTU/Hr), and 18kW heating. Units are fitted with an efficient air filtration system, which
pressurizes the cab and electrical room.

LIGHTING
Primary exterior floodlights: Standard lights are Metal Halide, 400 watt, 60HZ/120V
(alternatively 50HZ/220V), high intensity discharge (HID) units.

Standard primary exterior floodlight locations (nine are wide beam and two very narrow beam)
are as follows:
• Two (2) on front of operator’s cab, below the front window.
• Two (2) on top front of lube room
• Two (2) right side of house
• Two (2) top rear of house
• One (1) top left side of house

Secondary exterior floodlights: Standard are Halogen, 500 watt units. Standard secondary
exterior floodlight locations are as follows
• One (1) above operator’s cab door
• Two (2) on the lower front of machinery house
• Four (4) under revolving frame corners
Exterior incandescent: Five (5), 100 watt; one (1) at each machinery house door and one (1) at
operator’s cab door.

Interior lighting: Twenty (20) fluorescent lights are provided to illuminate the machinery house,
RH electrical room and LH lube room.

Operator’s cab lighting: Incandescent 100 watt ceiling light.

One (1) portable halogen trouble light is also provided as standard for primary use at convenient
roof top outlets.

ELECTRICAL CONVENIENCE OUTLETS

Electrical outlets for 110/120 volt supply are conveniently located:
• One (1) in lower control box on rear of carbody
• Two (2) under revolving frame platforms
• Seven (7) In machinery house
• One (1) on RH catwalk
• Two (2) in RH electronics room
• One (1) in LH lube room
• Three (3) in Operator’s cab
• Two (2) on house roof

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 Model 2800XPB
Technical Description

Outlets are GFI protected. GPO’s are 15 amp, duplex, NEMA 5-15 straight blade devices, 2
pole, 3 wire grounded and 125V rated.

Special instrument outlets are located in the Supervisory Control Cabinet.

Three (3) 60HZ/460V (Alt. 50HZ/380V) outlets are also provided; one (1) in RH electronics
room, one (1) in LH lube room and one (1) in Operator’s cab. These outlets are 20 amp, 3 wire,
4 pole, IEC 309 type.

A single welder outlet receptacle (60Hz/460V, alternatively 50Hz/380V) is provided, located

near the RH door in the machinery house.

MECHANICAL SYSTEMS
CRAWLER DRIVE SYSTEM
The crawler drive system incorporates rugged lug and tumbler and sprocket design concepts. On
the P&H sprocket style drive system, the shoe and tumbler engagement is close to the link pin
centerlines.

CRAWLER SHOES
Deep section, cast manganese shoes are connected with 4.5 inch alloy steel induction hardened
pins through machined, line-bored holes. Shoes are designed specifically for the P&H sprocket
style drive system. Standard crawler shoes width is 56 inches (1422mm). Shoe width of 72 inch
(1829mm) is available, as are cleated shoe upon request.

CRAWLER FRAMES
The frames are a heavy welded box section designs with bolted fit to carbody under full shear
ledge support with large dowels to prevent movement in the bolted connection. There is no field
welding required in the connection. There are eight (8) lower rollers, a front, and a rear idler in
each frame. The front idler is a large diameter manganese casting, which is mounted on two (2)
heavy duty bushings. Lower rollers and idlers are V-ring sealed to exclude contaminates and
hardened wear surfaces protect crawler frame wear. Rollers and idlers are straddle mounted with
special alloy brass bushings. “P&H 50+” lower rollers are hardened to over 50 on the Rockwell
C scale. Replaceable pin-on, high hardness, wear resistant cast slide bars on top of each frame
support the crawler shoes.

CARBODY
The carbody is a heavy welded high strength low alloy steel structure of cellular deep box
sections, built around a large center hub casting. The flattop design with deep section diaphragm
plates provides direct support of roller path. Carbody interior is painted white and is equipped
with an electrical convenience outlet for trouble light use. Swing gear and lower swing roller
path are mounted on the top of the carbody with dowels and bolts. The crawler frames are
connected to the carbody by a full-length shear ledge and long rod bolts. Both carbody and

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 Model 2800XPB
Technical Description

crawler frames designed to withstand the high level of crawler frame connection bolt tension.
The crawler frame connection bolts produce very high clamping forces between the crawler
frame and carbody machined surfaces. The standard tensioning system for the rod bolts consist
of simple bolt and nut arrangement.

DUAL PLANETARY PROPEL SYSTEM

Dual independent P&H DC drive motors rated at 820hp/612kW total continuous power at 550V
and 1440hp/1074kW total peak developed horsepower, drive the propel system and are load
sharing controlled. Motors are mounted in a propel motor base which is bolted to the rear of the
carbody, and motor frame adjusting screws are integral to the base for ease of alignment, and the
motors are directly connected to P&H planetary propel transmissions with a gear coupling. The
planetary propel transmissions are directly mounted to each crawler frame, and provide
differential speed and counter-rotational steering capability. All gearing is forged, anti-friction
bearing mounted, and all external gears are case hardened and ground.

The P&H Sprocket drive system has a raised final propel drive shaft and tumbler. The final
propel drive shaft is spline connected to the planetary transmission and tumbler, and is mounted
on anti-friction bearings. The outboard spherical bearing is encapsulated to prevent crawler frame
damage in the event of a bearing failure. V-ring seals are used to seal out dirt and seal in
lubricant.

CENTER GUDGEON
The Center Gudgeon is a hollow heavy-duty forging used to connect the upper revolving frame to
the lower carbody. Acme threads are provided on the upper and lower end of the gudgeon. The
gudgeon is a cascaded interference type fit in the center hub casting of the carbody. A locking
mechanism on the upper threads allows fine adjustment capabilities and positive retention of nut
position. Gudgeon center hole is used for electrical wiring, lube, and airlines between upper
revolving frame and lower machinery.

REVOLVING FRAME
The revolving frame is a heavy welded high strength low alloy steel structure of cellular deep
box sections built around a large center casting. The rolled, full depth internal turret plates align
with the swing roller path and provide 360° direct load transfer. Roller path support pad on
frame underside is wider and provides a pilot ring to prevent radial movement of the upper path.
Deck machinery is mounted via tapped holes or pin supported and no internal access is required
to mount the machinery.
A standard drain system allows for the hoist and swing transmissions to be evacuated through
piping to below the revolving frame deck (crowd drain to boom foot platform).

COUNTERWEIGHT BOX
A sectioned counterweight box is mounted to the rear of the revolving frame to accommodate the
counterweight ballast.

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 Model 2800XPB
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DECK PLAN
Side platforms, which mount to the revolving frame, extend the deck width. Conveniently
arranged floor plan with abundant space facilitates maintenance.

ELECTRONICS ROOM
A separate large room is mounted on front right corner of the revolving frame and houses the
supervisory control cabinet and motor control center. It is insulated with 0.5 inch/12.7mm
material; equipped with 0.75 hp fresh air blower (not used with optional air conditioner),
secondary wall and door air filter, and louvered front wall vent panel. Two (2) doors are provided
for improved access; one (1) leading to machinery house and one (1) to outside catwalk. RH
room also is the support base for the RH elevated operator’s cab.

LUBRICATION ROOM
A separate room is mounted on front left corner of the revolving frame, which houses lube tanks,
pumps, plumbing, and controls (remote I/O connection for lube system monitoring and control);
and most air system components including the receiver. Room is insulated with 0.5
inch/12.7mm material, and can be optionally heated for improved cold weather operation.

MACHINERY HOUSE
Truss style roof with weather tight, removable hatch covers for accessibility to internal
machinery. Roof panels are strategically located to direct crane picks of major deck mounted
components as required.

HOUSE PRESSURIZATION AND FILTRATION

House is pressurized and air is filtered by a high efficiency inertial filter system.

COLD WEATHER EQUIPMENT

The RH and LH rooms are equipped with insulation as a standard feature. The air valves for the
lower works are located in the heated lower control cabinet as standard, and the automatic
moisture dump valve for the main air receiver is located in the heated LH lube room as standard.
Heating options are available.

BOARDING AND ACCESS

A right side pneumatic controlled stairway and left side vertical pull-down ladder are interlocked
to de-energize swing and propel functions when in down position for safety. Catwalk/platforms,
with grated metal surface, hand rails, and toe boards are provided in access areas. Roof grating is
welded to roof panels.

HOIST DRIVE SYSTEM

Dual P&H DC motors rated at 1570hp/1171kW total continuous power at 550V and
2570hp/1917kW total peak developed power drive a modular gearcase pinned to the revolving
frame. First reduction is helical gear set, second reductions spur and a reversible spur drum gear.

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Technical Description

All gearing is forged machined, case hardened and ground. Transmission is oil tight with anti-
friction bearings and standard oil filtration and circulation system. Gearing is splash lubricated. A
lube pump and filtration system is standard, and is designed for use with high viscosity
lubricants, even in cold temperatures.

The hoist drum is a large 56 inch (1422 mm) pitch diameter drum with through shaft and flame
hardened grooves. Standard hoist rope is 2.375 inch (60 mm) diameter cable fully plastic
impregnated and compacted. Hoist drum and cable are provided with high capacity Ferrule
Beckett fittings to simplify cable change out. Hoist limits are programmable from operator's cab.
Hoist drum bearings are equipped for temperature monitoring.

HOIST CABLE TUGGER

An electric driven tugger is standard to assist with hoist cable changes. Standard tugger
configuration has as single 2000 lb.(907 kg) rated winch. An additional 2000 lb. (907 kg)
winche is available for greater capacity and even faster rope changes.

SWING DRIVE SYSTEM

Swing power is provided by two (2) P&H DC drive motors rated at 1000hp/746kW total
continuous power at 550V and 1546hp/1153kW total peak developed power and are connected in
series. P&H Planetary transmissions are mounted front and rear of swing gear for even loading.
Some components are interchangeable with first and second reductions in Propel transmissions
minimize parts stocking requirements.

Swing shafts are mounted on anti-friction bearings and are removable without disturbing the
transmission. Forged swing gear has 17 foot-2 inch/5.23m diameter with a large 13 inch/330mm
tooth face width. Swing circle uses a quantity of 54 tapered rollers, 10 inch/254mm in diameter,
carried on self-lubricating bushings. Rollers and roller paths are high alloy, forged, quenched and
tempered to a high hardness. Full circle of rollers are in contact with the 360° upper and 360°
lower roller paths which have a wide mounting surface to the carbody and revolving frame.
Upper path is dual flanged mounted with guarding to retain mounting hardware in the event of
loss, and the lower path is clip mounted to the carbody on the inner diameter and retained by the
ring gear outer diameter.. Gear shrouding system prevents contamination of gear and roller path
area, and can be opened to enable inspection of gear and roller circle.

CENTALIZED LUBRICATION SYSTEM

An automatic centralized lubrication system is standard and provides metered amounts of
lubricant to all major systems requiring grease and open gear lubrication. Lincoln 75:1 ratio air
drive pumps are used. Lube system, is programmable industrial controller controlled and is
monitored through touch-screen MMI’s. Large 138 gallon open gear and 138 gallon grease
maximize operating time. All gear cases are designed with bath and splash lubrication to all
gearing and bearings. A lube filtration system is standard for the hoist and crowd gear case.

AIR SYSTEM

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Compressed air is provided for lube pumps, lube sprayers, disc brakes, hoist cable tugger, air
operated stairway, horn, and operators seat. Standard air compressor is a Sullair Model ES-8-
30XH, rotary screw type, 30 HP, 95ACFM at 60HZ (77ACFM at 50HZ), floor mounted, with
separate 200 gallon capacity air. The ES-8 is designed for cold weather operation. Other air
compressors are available when specified

A high capacity membrane air dryer system is available (Only one unit required for single or dual
air compressors) which provides dry air with a -40° F (-40° C) dew point to the reservoir for dry
air in all functions. The membrane dryer features a low maintenance membrane technology, and
is complete with filters and automatic control system. The membrane dryer system is housed in a
sturdy enclosure, and is mounted in the lubrication room. The membrane dryer system cannot be
used with piston type compressors.

BRAKES
All motions have disc brakes which are spring set-air released. Brakes have replaceable wear
surfaces, and a low abrasion, high heat capacity friction material is used. Select brakes are
equipped with centering mechanisms to minimize contact of frictional surfaces when brake is
released.

BOOM
58 foot- (17.67m) length set at a 45° angle; welded structure of high strength low alloy steel for
cold weather toughness; extra width and depth for high load capability; 96 inch (2438mm)
diameter point sheaves, split bearing block mounted for maintenance ease. Boom suspension
cables are 3.50 inch (89 mm) structural strand. Integral lifting lugs and wear resistant side boxes
are incorporated. Boom is connected to revolving frame lugs with heavy duty lubricated pins
retained with split collars. Boom bumpers are mounted to the boom to reduce damage from
contact with the handle torsion box.

CROWD SYSTEM
Crowd and retract of the dipper is accomplished by one (1) P&H DC motor rated at
425hp/317kW continuous power at 550V and 630hp/470kW peak developed power driving the
P&H - POWERBAND "V" BELT - shock absorbing/system to modular, enclosed, transmission
with spur gear reduction to manganese racks and forged, machined and hardened crowd pinions.
V-belt sheaves are fully machined and balanced. Gearing is forged, case hardened and ground;
mounted with encapsulated, pre-adjusted bearings. Single piece saddle blocks are hydraulically
adjusted and allow for removal of crowd pinions. Crowd/retract limits programmable from
operator's cab.

DIPPER HANDLE
34 foot (10.36m) effective length; high strength low alloy, cold weather steel; straddle design,
straight legs and large cast manganese racks providing strength for corner tooth digging loads.

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 Model 2800XPB
Technical Description

Handle geometry provides for torsion box clearance with the boom. A stress relieved handle is
available for cold temperature and high impact applications when specified.

DIPPER TRIP
Dipper trip system is a durable 15HP/11kW, AC wound rotor motor drive through planetary
gearing to a heavy duty drum. Both ferrule becket and cable clamp connection capability is
provided for securing dipper trip cable to the drum. Trip line is connected to dipper latch lever
bar a handle mounted banjo arm.

DIPPER
OPTIMA 60 and HD dippers have been designed specifically for the 2800XPB for proper filling
and low cost of operation. Standard equipment on the dippers include adjustable pitch braces
and P&H Snubrite™ hydraulic snubbers to prevent damaging dipper door closing impact.
Nominal rated dipper size is 46 cubic yard ( 35.2 cubic meters ).

PAINT
Standard exterior is P&H Yellow and Black. Yellow on machinery house and operator’s cab.
Black on lower, attachment, catwalks and handrail. (Lower HV disconnect switch is painted
red). Interior of house, RH and LH rooms, carbody, revolving frame and lower boom section and
all electrical cabinet interiors are painted high visibility white.

WEIGHTS
Working weight of the P&H Model 2800XPB with nominal dipper and 56 inch (1422mm) wide
crawler shoes is 2,220,000 lbs. (1,006,992 kg.)

OPTIONAL ITEMS DESCRIPTIONS

OPERATOR CAB
• Pull down mylar shades (front window only)
• Pull down mylar shades (all windows)
• Front window, laminated safety glass (0.750” thick)
• Front window, laminated safety glass (1.188” thick)
• Cigarette lighter and ashtray – to be used for 12V power supply for convenience.
• Passenger seat – fold down in rear of cab for convenience
• Table – fold down for operator and mine personnel convenience.
• Second, 2-tone, air horn, mounted on front of LH lube room
• Single electric horn in place of standard air horn on RH room
• Second electric horn, mounted on front of LH lube room

AIR CONDITIONER

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 Model 2800XPB
Technical Description

• Mine Air Systems unit for operator’s cab only (RH or LH); Model MAS 1500, (60HZ/460V
or 50HZ/380V); cooling 48, 000BTU/14KW at 60HZ, heating to 18KW at 480V; with PUR-
PAK 1000 pressurizer and R407C refrigerant
• Mine Air Systems units for operator’s cab (RH or LH) and RH electronics room; two (2)
Model MAS 1500 units (60HZ/460V or 50HZ/380V); cooling 96,000 TBU/hr./28 kW total at
60Hz, heating to 36 kW total at 480V; with PUR_PAC 1000 pressurizer and R407C
refrigerant (Note: Deletes blower in RH room, #3.2.1)
• Sigma unit for operator’s cab (RH cab only) and RH electronics room; one Model MPV15,
60HZ/460V or 50HZ/380V); cooling 15KW at 60HZ, heating 2-stage 18KW at 460V; with
pressurization and R134a refrigerant (Note: Deletes blower in RH room, #3.2.1)

JIB HOIST
• Swing jib hoist; 8.9kN / 2,000 lb. Capacity (60HZ, 460V), mounted outside LH lube room
• Swing jib hoist; 8.9 kN / 2,000 lb capacity (50HZ, 380V), mounted outside LH lube room

FIRE SUPPRESSION
• Fire extinguisher, 20lb. Dry chemical, Model 1-A-20G, (3 ares tandard) each extra unit

TRAIL CABLE REEL

• P&H Power Reel (Harnaust Mfg.), air drive trail cable reel, 48” dia drum
• Cable reel (IWM Mfg.), hydraulic over electric drive, 48” dia drum
• Mounting material for P&H Power Reel trail cable reel

COLD WEATHER EQUIPMENT

• 2.5cm / 1 inch insulatin in machinery house
• Heater/defroster ducting in cab directed to operators feet and front window
• 7.5KW heater in operator’s cab
• 15 KW heater in RH electrical room
• 20 KW heater in LH lube room
• Strip heaters for main control cabinets
• Strip heaters for main D.C. motors
• Strip heaters for main transformers
• 40 KW machinery house heater maximum of 3, each

MISCELLANEOUS ELECTRICAL
• Extended upper temperature monitoring system – standard plus crowd gearcase bearings,
hoist gearcase bearings, swing shaft bearings, gearcase oil (5 cases), boom shipper shaft
bearing, and center gudgeon hub.
• Extended lower temperature monitoring system – standard plus over temperature indication
for final drive bearings and gearcase oil (2 cases).
• P&H Optidig operator assist tool that co-ordinates the hoist and crowd motions to prevent the
dipper from stalling while digging.

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 Model 2800XPB
Technical Description

• P&H i2T Remote Communications Ready Package (complete) including connection port of
shovel, base station PC with software installed. (Modem and radio communications
hardware is required, and is not provided by P&H.)
• P&H i2T Remote Communications Ready Package (no base station) including connection
port on shovel. (This option used when base station for other i2T shovels is on site) (Modem
and radio communications hardware is required, and is not provided by P&H).
• Electrical cabinet filters for RPC and converter cabinets - fitted to the cabinet doors and
provide an additional level of filtration for the electrical components.
• Hoist control with variable speed control in machinery house - allows hoist system to be
operated within view of the drum to improve ease of hoist rope change outs.
• Extra welder outlet in machinery house, near LH door. (60HZ, 460V or 50HZ, 380V) – price
each, 2 max
• Ground fault protection for welder outlets – price each, 3 max
• Emergency lighting unit (two lights per unit), each:
− Without installation wiring
− With installation wiring
• Communication system, 3-way
• Trailing cable connector extension with PLM cable coupler (w/o cable) (Not for use with trail
cable reel) - exetends cable coupling connection from the lower high voltage disconnect
cabinet to a convenient location by the propel motor base.

MISCELLANEOUS MECHNICAL
• Wiggins quick fill connectors for lube tanks, mounted on outside front lube room wall (note:
deducts standard 2” cam lock fittings) to allow quicker fill of the two lubricant reservoirs.
• Central drain system for hoist and swing transmissions (crowd drain to boom foot platform
standard) - allows for all systems to be drained to a convenient central location.
• Lube filtration with 20 micron filter on each swing transmission (3 total)
• Air hose reel w/30m/100ft of hose - conveniently mounted in the machinery house as a
general purpose air supply, and features a filter, regulator, and 50 feet (15.2 m) of hose on a
retractable reel.
• Blower motor and brake removal system in machinery house
• High Efficiency House Pressurization System (Torit) in place of standard
• Two (2) rectangular 16.50” x 24.75”, convex mirrors - (two supplied), mounted on the
shovel, one on the right side near the operators cab, and the second above the LH room, to
provide additional visibility for the operator.
• Tow lug on front of carbody, field installed
• Tow lugs, two (2) on rear of carbody, field installed
• SUPERBOLT® tensioning system for rod bolt connection for crawler frames
• HYTORK® tensioning system for rod bolt connection for crawler frames.
• Counterweight ballast (265 lbs/cu. Ft. minimum density), approximately 500,000 lbs.,
delivered to USA site either domestic or export packed
• Export packing

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 Model 2800XPB
Technical Description

TOOLS, TEST EQUIPMENT, AND ASSEMBLY AIDS

• HiTorque tooling to be used with hydraulic pack

TECHNICAL DOCUMENTATION
As standard, each P&H shovel Purchaser is supplied in English language, the following
documents:
• Operator Manual (electronic format on CD and in hard copy)
• Mechanical Systems Manual (electronic format on CD, hard copy optional)
• Link-One format Electrical Data and Wiring Listing
• Link-One format Electronic Parts Manual

CUSTOMER SUPPLY ITEMS

Unless otherwise stated in a P&H proposal, required items, not included in our basic machine
supply are:
• Machine erection, including erection tools and equipment
• Counterweight ballast, approximately 500,000 lbs/226,800 kg with a minimum density of
265 lbs. per cubic foot (4,245 kg/m3) (Final counterweight determined by application.)
• Fluids/lubricants
• Trailing cable and electrical power supply.

*****

P&H - An enduring symbol of quality and reliability

NOTE: All designs, specifications and components of equipment described above are subject to change at manufacturer’s
sole discretion at any time without advance notice. Data published herein is informational in nature and shall not be construed to
warrant suitability of machine for any particular purpose as performance may vary with conditions encountered. The only warranty
applicable is our standard written warranty for this machine.

2800XPB Technical Description June 2004.doc

Page 15 of 15
 DIGITAL DC DRIVE CONTROL

meters

feet
22 72.2

20 65.6

18 59.1

16 52.5

14 45.9

12 39.4

10 32.8

8 26.2

6 19.7
2300XPC
4 13.1

2 6.6

0 0

2 6.6
meters 6 4 2 0 2 4 6 8 10 12 14 16 18 20 22 24
feet 19.7 13.1 6.6 0 6.6 13.1 19.7 26.2 32.8 39.4 45.9 52.5 59.1 65.6 72.2 78.7
C
L ROTATION

WORKING RANGES CAPACITY

Height of Cut 13.5 m 44 ft. 3 in. Nominal Pay Load 45.4 mt 50 st

Radius of Cut 21.3 m 70 ft. 0 in. Nominal Dipper Capacity

SAE struck 25.5 m3 33.0 yd3
Dumping Height* (Door Open) 8.5 m 28 ft. 0 in. SAE 2:1 28.1 m3 36.7 yd3

Floor Level Radius 14.2 m 46 ft. 7 in. Rated Suspended Load 90.7 mt 100 st

Tail Swing Radius 10.1 m 33 ft. 0 in. Optimum Truck Size 109-218 mt 120-240 st
(200 st truck shown)
Operator Eye Level 7.9 m 26 ft. 0 in.

* Height shown with bail-type dipper. Heights will be greater with

bail-less or compact-bail dippers. Actual dumping height can be
greater than door clearance height.
 ELECTRICAL CONTROL DIPPER & DIPPER TRIP
• Centurion Supervisory Controller provides direct integrated • P&H OPTIMA dippers combine consistent productivity with high
comunication with motor drives giving precise motor control and durability and maintainability. Dippers are configured to mine specific
fast cycle times. Real-time multi-tasking capability allows for optimal
conditions and capacity requirements from a variety of combinations
machine logic sequencing, monitoring and control.
of body and lip designs, as well as other unique P&H technologies.
• Centurion I/O System uses ‘Profibus’ communication protocol Specific wear packages and GET styles can be cooperatively
for seamless integration of all shovel subsystems and future specified.
expandability. Low-voltage 24V DC I/O drop points feature open and
short circuit detection for improved diagnostics and troubleshooting. • Adjustable-torque electric motor with geared drive unit for reliable trip
and slack take-up operation.
• Centurion Information System’s enhanced Graphical User Interface
(GUI) features intuitive, icon-based screens to display vital
information such as shovel status, troubleshooting information, and
optional production monitoring data and operator feedback.

HOIST
• All gearing housed in single enclosed gear case with filtered oil
circulation for reliable splash lubrication and ease of maintenance.
ELECTRICAL DRIVE • Large diameter hoist drum for extended rope bending life. Ferrule
becket system and dual electric tuggers are standard for efficient
P&H DIGITAL DC STATIC DC POWER CONVERSION AND REACTIVE POWER
rope change. Dual electric tugger option is available.
COMPENSATION
• Spring set air release disc brakes - one per motor.
Hoist**/Propel Swing Crowd/Propel
Continuous
Armature
2x1320 kW 830 kW 830 kW
Converter KW
Rating @ 600 VDC*
15 Sec. Armature
CROWD
Converter Current 3100 amp. 1650 amp. 1650 amp.
• Powerband V-belt drive between motor and gear case absorbs shock
Rating*
loads.
Continuous Field
150 amp. 150 amp. 150 amp. • First and second reduction gearing in enclosed gear case for reliable
Converter Rating*
splash lubrication, ease of maintenance, and extended component
* Based on outside ambient temperature of 50°C or 122°F. life.
** Cascaded hoist converters. • Twin-leg dipper handle with torsion box and rack and pinion drive has
inherent stability in the bank for optimal digging.
P&H DIGITAL DC AUTOMATIC REACTIVE POWER COMPENSATION*
• Spring set air release disc brake.
60 Hz. 50 Hz
Switched Steps +2025 kVAR Total +2062.5 kVAR Total

*Nominal rating at rated capacitor voltage (600 VAC)

P&H DC FAST RESPONSE MAIN MACHINERY MOTORS

SWING
Hoist Motor Continuous rating @ 600 volts Total 1074kW/1440hp • Two modular P&H planetary gear cases of proven design and a
(Two used) Peak developed power 1442kW/1933hp single piece forged swing gear transmit torque for fast cycle times.
Swing Motor Continuous rating @ 550 volts Total 306kW/410hp • Spring set air release disc brakes - one per motor.
(Two used) Peak developed power 748kW/1002hp
Crowd Motor Continuous rating @ 550 volts Total 395kW/530hp
(One used) Peak developed power 441kW/591hp
Propel Motor Continuous rating @ 550 volts Total 612kW/820hp
(Two used) Peak developed power 943kW/1264hp PROPEL
• Two planetary gear boxes of proven design independently transmit
torque directly to the drive sprockets, producing the tractive effort
required for fast, efficient propel and positioning operations.
• P&H drive system with heavy duty cast crawler shoes.
POWER REQUIREMENTS
• Spring-set air-release disc brakes - one per motor.
Supply Voltage* 4160 or 7200V 3300, 5000, 6000 or 6600
3 Phase, 60 Hz 3 Phase, 50 Hz.
Supply Transformer (Minimum) 2000 kVA
Minimum Short Circuit VA Available at Shovel 16 MVA
*Voltage per customer requirements CABLE DATA
TRANSFORMER
Main Armature Transformer 2000 kVA Hoist (wire rope) 57 mm 2.25 in. dia.
Auxiliaries-Field Transformer 325 kVA Suspension (bridge strand) 83 mm 3.25 in. dia.
Control/Lighting Supply Winding 45 kVA
Note: Transformer capacities may vary depending on options. Dipper Trip (wire rope) 13 mm 0.50 in. dia.
 OVERALL DIMENSIONS
A Width 12.5 m 40 ft. 10 in.

B Length 15.0 m 49 ft. 4 in.

C Height Over Gantry 11.6 m 38 ft. 0 in.

1321 mm (std) 52 in. (Std.)

D Width of Crawler Shoes
1778 mm 70 in.

E Width of Crawlers (std.) 8.7 m 28 ft. 5 in.

F Length of Crawlers 9.9 m 32 ft. 4 in.

G Ground Clearance 0.9 m 3 ft. 0 in.

H Height — Ground to Bottom of Counterweight 2.6 m 8 ft. 5 in.

A B

C 2300XPC

H
G

D
F
E

MACHINERY DECK PLAN

AIR COMPRESSOR LUBRICATION ROOM

HOIST MOTOR HOIST MOTOR

HIGH VOLTAGE CABINET LUBE RESERVOIR

WITH ISOLATORS (401 LITER/106 GAL. EACH)

AUXILIARY TRANSFORMER LOW VOLTAGE

SUPPRESSION CAB COLLECTOR

SWING MOTOR AND SWING

TRANSMISSION MOTOR AND
TRANSMISSION
MAIN TRANSFORMER
HOIST DRUM
DIPPER TRIP
RESISTORS TRANSFER CABINET

AUXILIARY FIELD 120 VAC

TRANSFORMER LOAD CENTER

GROUND FAULT CENTURION

SUPPRESSION CABINET CONTROL CABINET
TOUCH SCREEN
FIELD BREAKER MONITOR

AUXILIARY LOAD CENTER CONVERTER CABINET

REACTIVE POWER ELECTRONICS ROOM

COMPENSATION
CABINET AUXILIARY CABINET
 GROUND PRESSURE & WEIGHT FEATURES AND CUSTOMIZATION
BEARING AREA - GROUND PRESSURE The 2300XPC is built with several features to enhance safety,
Standard: reliability, and productivity over the lifecycle of the operation.
Crawler Bearing Area 19.92 m2 30,880 in2 • Automatic Lubrication and Compressed Air Systems with
52” Shoes/ 1321 mm advanced diagnostic and control
Crawler Ground Pressure 381 kPa 55.3 psi • Temperature Monitoring System for all DC motors, drum shaft
52” Shoes/ 1321 mm bearings, shipper shaft bearings
• Automatic Boom Soft Setdown System (ABSS) and Boom
Optional: Profile Protection Envelope to help prevent excessive loading to
Crawler Bearing Area 26.82 m2 41,570 in2 the attachment during operation
70” Shoes/ 1778 mm • Anti-Swing-in-Bank system to reduce excessive side loading on
Crawler Ground Pressure 288 kPa 41.8 psi handle and attachement
70” Shoes/ 1778 mm • Remote hoist control pendant and hoist rope winch to assist in
safe and efficient rope changeouts
WEIGHTS - APPROXIMATE* • House Pressurization System to provide filtered air for cooling
Working Weight (with Dipper, Approx. Wt.) and dust repression
52” Shoes/1321 mm 774,800 kg 1,708,000 lbs
The standard shovel can be customized for local and minesite
70” Shoes/1778 mm 787,500 kg 1,736,000 lbs specific conditions in the following areas:
Counterweight (Punchings)** 136,100 kg 300,000 lbs • Operator Cab
• Climate Control
* All weights subject to 5% variation.
• Cold Weather Equipment
** To be furnished by customer.
• Technology and Software
• Electrical and Mechanical Systems
• Maintenance Systems

LIGHTING
Standard: Metal Halide, 400 W, high intensity discharge (HID)
primary exterior floodlights (11) mounted on the
operator’s cab, RH room, LH room and machinery
house. Halogen, 500 W secondary exterior floodlights
(7) mounted under revolving frame corners, machinery
house and above cab door. Fluorescent lights (20)
illuminate interior of the machinery house, RH and LH
room.
Optional: High Pressure Sodium, 400 W or 1000 W primary
exterior floodlights. Secondary exterior floodlight
combination of Halogen, 500 W (3) and fluorescent
lights (6) mounted under revolving frame.

LOADING CONTROL CENTER

SPACE FOR MINE
COMMUNICATIONS
ANTE ROOM EQUIPMENT
(SHOWN WITH
OPTIONAL TOILET)
TOUCHSCREEN GUI
AND OPTIONAL REMOTE
ELECTRICAL CABINET CAMERA SYSTEM

SPACE FOR APPLIANCES

ARMREST MOUNTED,
PISTOL GRIP JOYSTICKS
TRAINER’S STATION

LOCKERS
6-WAY POWER ADJUSTABLE AIR SUSPENSION
STORAGE CABINET SEAT WITH HEAT AND VIBRATORY MASSAGE

NOTE: All designs, specifications and components of equipment described above are subject to change at manufacturer’s sole discretion at any time without
advance notice. Data published herein is informational in nature and shall not be construed to warrant suitability of machine for any particular purpose as
performance may vary with conditions encountered. The only warranty applicable is our standard written warranty for this machine.

P&H Mining Equipment • Box 310 • Milwaukee, Wisconsin 53201 USA

XS-4185 2AG-207
 2300XPC TECHNICAL DESCRIPTION
January, 2007

The P&H 2300XPC is a heavy duty electric mining shovel which provides a 50 ton (45.4 metric
ton) nominal payload capacity specifically designed to operate in mines for high productive
loading of 120 ton to 240 ton (109 metric ton to 218 metric ton) and larger haul trucks and
larger.

This technical description is provided to compliment the 2300XPC main machine

specification, XS-4185.

ELECTRICAL POWER SYSTEM

POWER SUPPLY
Electrical power to the shovel is Customer supplied via a trailing cable. Recommended
SHD-GC trailing cables, for 7,200 volt supply, are:

#4 AWG/25mm² 2500 ft./762m.

#2 AWG/35mm² 3900 ft./1189m.
#1 AWG/50mm² 4800 ft./1463m.
#1/0 AWG/55 mm2 6000 ft./1829m.

Electrical equipment on the shovel is designed for an incoming supply of 3 phase/60 hertz/4,160
or 7,200 volts. Secondary voltage for auxiliary motors is 3 phase/60 hertz/480 volts.
(Alternatively, designed for an incoming supply of 3 phase/50 hertz/3,300, 6000, 6600, or 7200
volts. Secondary voltage for auxiliary motors is 3 phase/50 hertz/380 or 415 volts).
Recommended feeder transformer is 2000 kVA, with a minimum of 16 MVA short circuit
capacity available at the shovel terminals.

LOWER HIGH VOLTAGE DISCONNECT SWITCH

Electrical power is brought to the shovel by connection of the trailing cable to the lower HV
disconnect switch which is mounted on the rear of the carbody. A cable coupler is mounted on
this switch and mating PLM coupler is provided for the trailing cable end. The switch provides a
visible disconnect, grounding, and a safety key interlock which energizes or disconnects
electrical power to the entire machine. HV wiring runs from this switch through the carbody to
the HV collector rings. The standard cable coupler is a PLM brand quick disconnect type. Other
couplings are available upon request.
 Model 2300XPC
Technical Description

HIGH VOLTAGE COLLECTOR RINGS

High voltage collector rings consist of three (3) power and one (1) ground ring, and are mounted
on top of the carbody. All rings are extra wide to provide proper contact with collector shoes that
are mounted under the revolving frame. Ring access is protected by bolted carbody hole covers.

LOW VOLTAGE COLLECTOR RINGS

Low voltage collector rings, which transmit lower voltage power from upper to lower are deck
mounted above the center gudgeon. The LV collector cover is window equipped for viewing of
rings and brushes for inspection.

UPPER HIGH VOLTAGE DISCONNECT

Fully contained cabinet contains two visible high voltage disconnects to 1) isolate the entire
upper H.V. supply, and 2) isolate the primary of the Main Transformer, vacuum contactor, line-
to-line and line-to-ground lightning arrestors for surge suppression. Current limiting HV fuses
provide short circuit protection for the primary of the Main Transformer and the primary of the
Auxiliary Transformer

MAIN TRANSFORMER
Designed for mining shovel service, 2000KVA rated, dry type; Delta/Wye connected,
minimizing third harmonic current flow to external circuits, simplified ground fault detection.
Transformer can accommodate unequal loading, has ±5% voltage taps, and temperature
monitored windings. The Main Transformer provides power for the Converter Cabinet motion
thyristor bridges which control the power to the DC drive motor armatures and fields.

AUXILIARY TRANSFORMER
Like the main transformer, the auxiliary transformer is designed for mining shovel service, is of
the dry type, and is Delta/Wye connected. It is rated at 325 KVA. Four (4) secondary windings
provide power for:
(1) 60HZ/480 Volts (Alternatively 50HZ/380 or 415 Volts) for utilities and auxiliary motors.
Power from the transformer flows to an Auxiliary Load Center and Auxiliary Cabinet
motors.
(2) Shielded winding supply for the Control System
(3) Field supply voltage to the DC drive motor, field power bridges.
(4) Lighting and GPO’s supply, 45 KVA rated, and distributed through the 120 VAC
(alternately 240V) load center

POWER CONVERTER CABINET

The P&H Digital DC power conversion system contains the simple six-thyristor three-phase
bridges used to statically convert AC supply power to controlled DC supply to motion drive
motor armatures for speed and torque regulation. This thyristor bridge inherently also allows for
invert regenerated DC energy to AC power during motion deceleration. The regenerated power
is used to supply the on board needs with the excess going back to the mine network for energy
savings.

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 Model 2300XPC
Technical Description

Thyristors are mounted in easily accessible heat sinks and are forced air-cooled. A patented fast
acting over-current system, diverter system, senses and limits the over-current to the DC motors
eliminating destructive flashovers.

POWER DISTRIBUTION
All High Voltage cables are run in metal conduit. An enclosed over head copper bus system is
used to carry the power from the Main Transformer to the Converter cabinet. All other wiring is
generally run in raised troughs on the machinery deck floor. Power cables are XLPO (cross-
linked polyolefin) insulated

REACTIVE POWER COMPENSATION (RPC) SYSTEM

Housed in a rugged, ventilated cabinet, the RPC system contains stepped tuned banks of
capacitors and reactors, automatically and synchronously switched on and off the line, to
maintain average system power factor near unity. Tuned banks provide a high level of harmonics
filtering of the predominant harmonics generated by the converters. Synchronously applied
stepped compensation eliminates transients during application and disconnection.

TRANSFER CABINET
The transfer cabinet contains heavy duty contactors to transfer the power from the hoist and
crowd converters to the propel motors in the propel mode. Transfer is initiated by a push button
on the console in the operator’s cab with all sequencing handled automatically by the
programmable industrial controller.

DC DRIVE MOTORS
P&H designed, manufactured, and tested motors are specifically designed for mining service
duty, with Class "H" insulating system. Drive motors are equipped with RTD’s to monitor motor
bearings and winding temperatures, and all are equipped with heavy duty blowers with screen
protected air inlets. Optional brush grades are available for unusual operating conditions.

ELECTRICAL CONTROL SYSTEM

P&H CENTURION™ SHOVEL CONTROL SYSTEM
The P&H Centurion™ Shovel Control System provides the supervisory control of the shovel
drives and executes the sequencing and monitoring functions, and consists of the supervisory
control computer and supporting hardware devices and software programs. The system is
comprised of four basic areas: 1) the Centurion™ Supervisory Controller, 2) the onboard
graphical user interface (GUI), 3) the remote input/output (I/O) devices and communication
interface, and 4) the individual drive controllers.

The system uses an open concept design to allow for third party integration. The architecture
provides connectivity from components on the shovel to the onboard GUIs and provides
diagnostic and monitoring capabilities. The application code residing within the supervisory

2300XPC Detailed Technical Description Jan 2007.doc

Page 3 of 17
 Model 2300XPC
Technical Description

controller is based on the IEC 61131 standard. The control system uses Profibus over fiber optic
and copper media for communications with the various system components.

SUPERVISORY CONTROL CABINET

Components for the P&H Centurion™ Shovel Control System are housed in a rugged,
maintenance friendly cabinet, which is located in the RH Electronics room.

LOWER CONTROL PANEL

The lower control panel is mounted inside the carbody, and contains remote I/O, air solenoid
valves for the brakes, and an electrical convenience outlet.

REMOTE I/O’S
The supervisory control system functions with remote I/O in several locations such as lower
propel, LH lube room, RPC cabinet, converter cabinet, transfer cabinet, auxiliary cabinet, and
operators cab.

AUTOMATIC ATTACHMENT PROTECTION SYSTEMS

Hoist and crowd/retract limits are set on the GUI touch screen located at the loading control
center in the operator's cab. A boom profiling limit is included to help prevent contact of the
handle torsion box and dipper with boom. The ABSS (Automatic Boom Soft Set-down) feature
is part of the control system and minimizes boom jacking and the associated impact of abruptly
lowering the boom from a jacked condition.

OPERATOR INTERFACE
LOADING CONTROL CAB
The operator is stationed in a roomy cab that is mounted on the right hand side of the machine
above the electrical room. The operator is positioned at a 15 degree angle off of the cab
centerline toward the dipper. The operator has a wide view of the dipper and bank and
surrounding loading area. The cab is FOPS (Falling Object Protection System) certified, and has
sound levels below 70 dBA while the shovel is operating when the doors and windows are
closed. A standard front window wiper system is provided. A catwalk system provides access
for cleaning, maintenance, or replacement of the windows. Access to the cab roof is provided via
ladder and roof handrails. A single two tone air horn mounted on the RH room is also included.

All windows are tinted safety glass. The front windows are 0.75 inch / 18 mm thick laminated
safety glass. Side and door windows are fixed in place and made from 0.25 inch / 6 mm
tempered glass. The standard cab features storage lockers, desk/counter space, and provisions for
mounting mine supplied microwave or toaster oven and refrigerator. There is a work space with
seat for an operator trainer located behind the operator. A separate room is located behind the
operator cab that can be customized by the mine for additional storage or used for a toilet..

2300XPC Detailed Technical Description Jan 2007.doc

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 Model 2300XPC
Technical Description

P&H LOADING CONTROL CENTER

The P&H Loading Control Center provides a single location of control for shovel operation and
truck loading. An additional work area with a trainer’s seat is provided immediately behind the
operator.

The standard seat base is an air suspension type which can be adjusted for operators height and
weight. The seat has an automotive style power system which provides vertical and fore / aft
adjustment to allow custom fitting of the joysticks to individual operators. The seat has heat,
lumbar support, and massage. The entire seat, armrest assembly is mounted to a vibration
isolated sled with an integral footrest. The angled footrest swivels into two positions based on
the operator’s height.

The joystick contollers are Hall-Effect, pistol grip style with both push button, trigger switch, and
rocker switches built into the grips. There is a single console on the left hand side of the operator.
All control devices needed by the operator while operating the shovel and loading trucks are
located in a zone of comfort for easy access with minimal movement. Devices needed for
auxillary functions such as those climate control and lighting are located within reach of the
operator while seated.. The console also features an expandable media mounting post to which
the P&H GUI is mounted as standard. Post sections can be added to mount remote camera
monitors as well as dispatch screens.

The climate control ducting in the cab is located above and below the operator. There are
controls to allow regulation of air flow between window defrost, the vents at the feet, and the
vents at the midlevel of the operator.

GRAPHIC USER INTERFACE (GUI)

The GUI has menus and information screens thatallow the operator to display information, and
perform various operation functions. The basic functions of the GUI are:
• Display machine operating status
• Display and set hoist, crowd, and boom protection limits
• Provide fault annunciation and alerts
• Display temperature monitoring bar graphs
• Display boom jacking status
• Display boarding ladder positions
• Display lubrication system settings and status
• Provide for manual initiation of lubrication cycles
• Provide troubleshooting information to maintenance personnel

STANDARD DIAGNOSTICS
The Centurion GUI provides the following standard diagnostics:
• Standard Temperature Monitoring system - all DC motors (windings and bearings), drum
shaft bearings boom shipper shaft bushings, and ambient air temperature. Graphical
temperature shown on touch screens.

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 Model 2300XPC
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• Drive programming and analysis software to allow maintenance personnel to record and
perform on line diagnostics of main motion drive paramerters, settings, and performance.
• Control logic software to allow maintenance personnel to view controller logic program,
verify functions, and force parameters for diagnostic purposes.
• Input/Output (I/O) divice monitioring and fault detection system to identify location and type
of fault.

CLIMATE CONTROL
An optional P&H MineAir Systems MAS 1000 mine duty air conditioner unit is available. A
single unit can be fitted to the operator cab, or two units can be fitted, one for the cab and one for
the electronics room. Units can be fitted with an efficient air filtration system, which can
pressurize the cab and electrical room.

LIGHTING
Primary exterior floodlights: Standard lights are Metal Halide, 400 watt, 60HZ/120V
(alternatively 50HZ/220V), high intensity discharge (HID) units. Optional 400W High Pressure
Sodium, and Optional 1000W High Pressure Sodium HID lighting systems are also available for
greater lighting intensity.
Standard primary exterior floodlight locations (nine are wide beam and two very narrow beam)
are as follows:
• Two (2) on front of operator’s cab, below the front window.
• Two (2) on top front of lube room
• Two (2) right side of house
• Two (2) top rear of house
• One (1) top left side of house
• One (1) on front of house below RH room
• One (1) on front of house below LH room

Secondary exterior floodlights: Standard are Halogen, 500 watt units. Standard secondary
exterior floodlight locations are as follows
• One (1) above operator’s cab door.
• Two (2) lower front of machinery house.
• Four (4) under revolving frame corners.

Exterior incandescent: Five (5), 100 watt; one (1) at each machinery house door and one (1) at
operator’s cab door.

Interior lighting: Twenty two (20) fluorescent lights are provided to illuminate the machinery
house, RH electrical room and LH lube room.

Operator’s cab lighting: Incandescent 100 watt ceiling light. Consoles are back lighted with
dimmer switch control.

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 Model 2300XPC
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One (1) portable halogen trouble light is also provided as standard for primary use at convenient
roof top outlets.

ELECTRICAL CONVENIENCE OUTLETS

Electrical outlets for 110/120 volt supply are conveniently located:
• One (1) in lower works located in the carbody
• Two (2) under revolving frame platforms
• Seven (7) In machinery house
• One (1) inside house near RH door
• Two (2) in RH electronics room
• One (1) in LH lube room
• Three (3) in Operator’s cab
• Two (2) on house roof

Outlets are GFI protected. GPO’s are 15 amp, duplex, NEMA 5-15 straight blade devices, 2
pole, 3 wire grounded and 125V rated.

Special instrument outlets are located in the Supervisory Control Cabinet.

Three (3) 60HZ/460V (Alt. 50HZ/380V) outlets are also provided; one (1) in RH electronics
room, one (1) in LH lube room and one (1) in Operator’s cab. These outlets are 20 amp, 3 wire,
4 pole, IEC 309 type.

A single welder outlet receptacle (60Hz/460V, alternatively 50Hz/380V) is provided, located

near the RH door in the machinery house.

MECHANICAL SYSTEMS
CRAWLER DRIVE SYSTEM
The crawler drive system incorporates a rugged lug and tumbler design.

CRAWLER SHOES
Deep section, cast manganese shoes are connected with 4.5 inch alloy steel induction hardened
pins through machined, line-bored holes. Shoes are designed specifically for the P&H Advanced
Drive System (ADS) tumbler style drive system. Standard crawler shoes width is 52 inches
(1321mm). Shoe width of 70 inch (1778mm) is available. Cleated shoes are also available.
P&H DELTA sprocket style drive system optionally available with 52 inch (1321 mm) shoes.

CRAWLER FRAMES
The frames are a heavy welded box section design with bolted fit to carbody under full shear
ledge support. There is no field welding required in the connection. There are eight (8) lower
rollers, a front, and a rear idler in each frame. The front idler is a large diameter manganese

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 Model 2300XPC
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casting, which is mounted on two (2) heavy duty bushings. Lower rollers and idlers are V-ring
sealed to exclude contaminants and hardened wear surfaces protect crawler frame wear. Rollers
and idlers are straddle mounted with special alloy brass bushings. Replaceable pin-on, high
hardness, wear resistant cast slide bars on top of each frame support the crawler shoes.

CARBODY
The carbody is a heavy welded high strength low alloy steel structure of cellular deep box
sections, built around a large center hub casting. The flat-top design with deep section
diaphragm plates provides direct support of roller path. Carbody interior is painted white and is
equipped with an electrical convenience outlet for trouble light use. Swing gear and lower swing
roller path are mounted on the top of the carbody with dowels and bolts. The crawler frames are
connected to the carbody by a full-length shear ledge and long rod bolts. Both carbody and
crawler frames designed to withstand the high level of crawler frame connection bolt tension.
The crawler frame connection bolts produce very high clamping forces between the crawler
frame and carbody machined surfaces. The standard tensioning system for the rod bolts consists
of a simple bolt and nut arrangement.

DUAL PLANETARY PROPEL SYSTEM

Dual independent P&H DC drive motors rated at 820hp/612kW total continuous power at 475V
and 1410hp/1052kW total peak developed horsepower, drive the propel system and are load
sharing controlled. Motors are mounted in a propel motor base which is bolted to the rear of the
carbody, and motor frame adjusting screws are integral to the base for ease of alignment, and the
motors are directly connected to P&H planetary propel transmissions with a gear coupling. The
planetary propel transmissions are directly mounted to each crawler frame, and provide
differential speed and counter-rotational steering capability. All gearing is forged, anti-friction
bearing mounted, and all external gears are case hardened and ground.

The P&H tumbler drive system has a raised final propel drive shaft and tumbler. The final
propel drive shaft is spline connected to the planetary transmission and tumbler, and is mounted
on anti-friction bearings. The outboard spherical bearing is encapsulated to prevent crawler frame
damage in the event of a bearing failure. V-ring seals are used to seal out dirt and seal in
lubricant.

CENTER GUDGEON
The Center Gudgeon is a hollow heavy-duty forging used to connect the upper revolving frame to
the lower carbody. Acme threads are provided on the upper end of the gudgeon. The gudgeon is a
cascaded interference type fit in the center hub casting of the carbody. A locking mechanism on
the upper threads allows fine adjustment capabilities and positive retention of nut position. The
gudgeon center hole is used for electrical wiring, lube, and air-lines between revolving frame and
lower machinery.

REVOLVING FRAME

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The revolving frame is a heavy welded high strength low alloy steel structure of cellular deep
box sections built around a large center casting. The rolled, full depth internal turret plates align
with the swing roller path and provide 360° direct load transfer. Roller path support pad on
frame underside provides a pilot ring to prevent radial movement of the upper path. Deck
machinery is welded to the deck or mounted via tapped holes. No internal access is required to
mount the machinery. A standard drain system allows for the hoist and swing transmissions to
be evacuated through piping to below the revolving frame deck.

COUNTERWEIGHT BOX
A sectioned counterweight box is mounted to the rear of the revolving frame to accommodate the
counterweight ballast.

DECK PLAN
Side platforms, which mount to the revolving frame, extend the deck width. Conveniently
arranged floor plan with abundant space facilitates maintenance.

ELECTRONICS ROOM
A separate large room is mounted on front right corner of the revolving frame and houses the
supervisory control cabinet and auxiliary cabinet. It is insulated with 0.5 inch/12.7mm material;
equipped with 0.75 hp fresh air blower (not used with optional air conditioner) and louvered
front wall vent panel. Access to the electronics room is provided via one door within the
machinery house. The RH room also is the support base for the RH elevated operator’s cab.

LUBRICATION ROOM
A separate room is mounted on front left corner of the revolving frame, which houses lube tanks,
pumps, plumbing, and controls (remote I/O connection for lube system monitoring and control);
and most air system components. Room is insulated with 0.5 inch/12.7mm material, and can be
optionally heated for improved cold weather operation.

MACHINERY HOUSE
Truss style roof with weather tight, removable hatch covers for accessibility to internal
machinery. Roof panels are strategically located to direct crane picks of major deck mounted
components as required.

HOUSE PRESSURIZATION AND FILTRATION

House is pressurized and air is filtered by a high efficiency inertial filter system.

COLD WEATHER EQUIPMENT

The RH and LH rooms are equipped with insulation as a standard feature. The air valves for the
lower works are located in the heated lower control box as standard. Heating options are
available.

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BOARDING AND ACCESS

A right side pneumatic controlled stairway and left side vertical pull-down ladder are interlocked
to de-energize swing and propel functions when in down position for safety. Catwalk/platforms,
with grated metal surface, hand rails, and toe boards are provided in access areas. Roof grating is
welded to roof panels.

HOIST DRIVE SYSTEM

Dual P&H DC motors rated at 1440hp/1074kW total continuous power at 550V and
1933hp/1442kW total peak developed power drive a gearcase welded to the revolving frame.
The first reduction is a helical gear set and the second reduction consists of a spur and a
reversible spur drum gear. All gearing is forged, machined, case hardened and ground.
Transmission is oil tight with anti-friction bearings and standard oil filtration and circulation
system. Gearing is splash lubricated. A lube pump and filtration system is standard, and is
designed for use with high viscosity lubricants, even in cold temperatures.

The hoist drum is a large 56 inch (1422 mm) pitch diameter drum with through shaft and flame
hardened grooves. Standard hoist rope is 2.25 inch (57 mm) diameter cable fully plastic
impregnated and compacted. Hoist drum and cable are provided with high capacity Ferrule
Beckett fittings to simplify cable change out. Hoist limits are programmable from operator's cab.
Hoist drum bearings can be equipped for temperature monitoring.

HOIST CABLE TUGGER

A single electrically driven hoist rope tugger is standard. 2000 lb (8.9 kN) rated winche.

SWING DRIVE SYSTEM

Swing power is provided by two (2) P&H DC drive motors rated at 410hp/306kW total
continuous power and at 550V and 577hp/430kW total peak developed power. They are
connected in series. P&H Planetary transmissions are mounted front and rear of swing gear for
even loading. Some components are interchangeable with first and second reductions in Propel
transmissions minimizing parts stocking requirements. Planetary swing transmissions are
designed with bath and splash lubrication for all bearings and gearing. An optional oil filtration
system is available.

Swing shafts are mounted on anti-friction bearings and are removable without disturbing the
transmission. The cast swing gear has a pitch diameter of 191 inches/4848 mm with a large 10
inch/254mm tooth face width. Swing circle uses a quantity of 54 tapered rollers, carried on self-
lubricating bushings. Rollers and roller paths are high alloy steel, forged, and quenched and
tempered to a high hardness. Full circle of rollers are in contact with the 360° upper and 360°
lower roller paths that have a wide mounting surface to the carbody and revolving frame. Upper
path is dual flanged mounted, and the lower path is clip mounted to the carbody on the inner
diameter and retained by the ring gear outer diameter.

CENTRALIZED LUBRICATION SYSTEM

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Technical Description

An automatic centralized lubrication system is standard and provides metered amounts of

lubricant to all major systems requiring grease and open gear lubrication. Lincoln 75:1 ratio air
drive pumps are used. The lube system is controlled by the Centurion supervisory controller and
is monitored through touch-screen GUI’s. Large 106 gallon open gear and 106 gallon grease
maximize operating time. All gear cases are designed with bath and splash lubrication to all
gearing and bearings. A lube filtration system is standard on the crowd and hoist gearcases.

AIR SYSTEM
Compressed air is provided for lube pumps, lube sprayers, disc brakes, air operated stairway,
horn, and operators seat. Standard air compressor is a rotary screw type, floor mounted, with
separate remote mounted 120 gallon capacity air receiver. The compressor is designed for cold
weather operation.

BRAKES
All motions have disc brakes that are spring set-air released. Brakes have replaceable wear
surfaces, and a low abrasion, high heat capacity friction material is used. Select brakes are
equipped with centering mechanisms to minimize contact of frictional surfaces when brake is
released.

BOOM
The boom is a 56 foot- (17.07m) length set at a 45° angle; welded structure of high strength low
alloy steel for cold weather toughness; extra width and depth for high load capability; 85 inch
(2159mm) diameter point sheaves, split bearing block mounted for maintenance ease. Boom
suspension cables are 3.25 inch (83 mm) structural strand. Integral lifting lugs and wear resistant
side boxes are incorporated. Boom is connected to revolving frame lugs with heavy duty
lubricated pins retained with split collars. Boom bumpers are mounted to the boom to reduce
damage from contact with the dipper.

CROWD SYSTEM
Crowd and retract of the dipper is accomplished by one (1) P&H DC motor rated at
530hp/395kW continuous power at 550V and 1002hp/747kW peak developed power driving the
P&H - POWERBAND "V" BELT - shock absorbing/system to modular, enclosed, transmission
with spur gear reduction to manganese racks and forged, machined and hardened crowd pinions.
V-belt sheaves are fully machined and balanced. Gearing is forged, case hardened and ground;
mounted with encapsulated, pre-adjusted bearings. A transmission oil filtration system with
basket strainers, 20 micron filtration, pump and motor is included. Single piece saddle blocks are
hydraulically adjusted and allow for removal of crowd pinions. Crowd/retract limits
programmable from operator's cab.

DIPPER HANDLE
The dipper handle is a 31 ft 10 in (9.70m) effective length; high strength low alloy, cold weather
steel; straddle design, with straight legs and large cast manganese racks providing strength for
corner tooth digging loads. Handle geometry provides for torsion box clearance with the boom.

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A stress relieved handle is available for cold temperature and high impact applications when
specified.

DIPPER TRIP
Dipper trip system is a 10HP; brushless DC motor driving planetary gearing to a heavy duty
drum. The solid state drive components for the dipper trip system are located in the supervisory
control cabinet, and are adjustable through the GUI. Both ferrule becket and cable clamp
connection capability is provided for securing dipper trip cable to the drum. Trip line is
connected to dipper latch lever bar via a two part sheave system on the dipper door. An integral
disk brake on the motor sets when not in use.

PAINT
Standard exterior is P&H Yellow and Black. Yellow on machinery house and operator’s cab.
Black on lower, attachment, catwalks and handrail. (Lower HV disconnect switch is painted
red). Interior of house, RH and LH rooms, carbody, revolving frame and lower boom section and
all electrical cabinet interiors are painted high visibility white.

WEIGHTS
Working weight of the P&H Model 2300XPB with nominal dipper and 52 inch (1321mm) wide
crawler shoes is 1,708,000 lbs. (774,548 kg.)

OPTIONAL ITEMS DESCRIPTIONS

DIPPER
Dippers have been designed specifically for the 2300XPC for proper filling and low cost of
operation. Standard equipment on the dippers include pitch braces and P&H friction disc
snubbers to prevent damaging dipper door closing impact. Nominal rated dipper size is 33 cubic
yard ( 25.0 cubic meters ).

ELECTRICAL EQUIPMENT
• High Altitude 1830 - 4270 m / 6000 to 14000 ft main single voltage transformer
• Dual voltage main transformer

NOTE: For dual voltage transformers and other special applications, contact shovel
marketing.

LIGHTING
• Primary exterior lighting (11) high pressure sodium, 60Hz, 120V, 400W
• Primary exterior lighting (11) high pressure sodium, 60Hz, 120V, 1000W
• Primary exterior lighting (11) high pressure sodium, 50Hz, 220V, 400W
• Primary exterior lighting (11) high pressure sodium, 50Hz, 220V, 1000W
• Primary exterior lighting (11) metal halide, 50Hz, 220V, 400W

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• Secondary exterior; (3) Halogen, 500W and (6) Fluorescent under revolving frame

AIR SYSTEM
• Dual (2) rotary screw air compressors with automatic switching, floor mounted. One (1)
separate 120 gallon air receiver in lube room.
• Membrane air dryer system for rotary screw air compressor (Note: Only one unit required for
single or dual compressors)
• Air hose reel w/30m/100ft of hose

NOTE: Consult Shovel Marketing for applicability of other compressors.

LUBRICATION SYSTEM
• Wiggins quick fill connectors for lube tanks

BOARDING ACCESS
• Left hand air stairway-in place of standard left hand pull down ladder

CRAWLER SHOES
• 70" wide, flat manganese shoes (ADS)
• 70” wide, cleated manganese shoes (ADS)
• 52” wide flat manganese shoes (DELTA)
• 52” wide cleated manganese shoes (DELTA)

PAINT
• Color Change using P&H paint spec.
• Customer Logo on machine away from P&H logo and model name, painted, one or two
colors, customer to supply template
• Customer Numbers painted on machine

OPERATOR CAB
• Front window electric wiper and spray wash system
• Sliding windows – two sliding windows with screens in place of side trainer and rear window
– 0.25 inch / 6mm tempered tinted glass
• Video Monitoring System (Intec)- four (4) color cameras and two (2) color monitors for blind
spot monitoring - inside and outside of machinery house
• Satellite radio receiver in place of AM/FM/CD (Customer specify XM or Sirius)
• Sun shades, pull down - front window only
• Sun shades, pull down - all windows
• Air Horn - dual two tone mounted on RH electronics and LH lube room
• Electric Horn with adjustable volume - single in place of standard air horn
• Electric Horn with adjustable volume - dual, mounted on RH electronics and LH lube room
in place of standard single air.

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 Model 2300XPC
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CLIMATE CONTROL
• Mine Air Systems unit for operator's cab only; Model MAS 1500, cooling to 48,000 BTU/hr
(14kW), heating to 18kW; with air filter-pressurizer and R407C refrigerant
• Mine Air Systems units for operator's cab and electronics room; two (2) Model MAS 1500
units; cooling to 96,000 BTU/hr. (28 kW) total, heating to 36 kW total; with air filter-
pressurizer and R407C refrigerant (Note: Deletes blower in electronics room)

NOTE: A/C is mandatory for electronics room in high ambient temperature environments

JIB HOIST
• Swing jib hoist; 8.9 kN / 2,000 lb. capacity mounted outside LH lube room

FIRE SUPPRESSION
• Fire extinguisher, 20lb. dry chemical, Model I-A-20G, (3 are standard)

Note: Fire suppression systems are locally contracted by P&H MinePro Services. Typical
systems consist of clean agent suppression system for electrical cabinets, RH room, LH
room, and collector ring assembly.

TRAIL CABLE REEL

• Trail Cable Reel, air drive, level winding, 48" diameter drum
• Trail Cable Reel, hydraulic over electric drive, level winding, 48" diameter drum.
• Mounting material for trail cable reel (air or hydraulic)

COLD WEATHER EQUIPMENT

• 2.5cm / 1 inch insulation in machinery house
• 7.5 kW heater in operator's cab (not required if Cab AC option is chosen)
• 7.5 kW heater in RH electrical room
• 7.5 kW heater in LH lube room
• Strip heaters for main control cabinets
• Strip heaters for main D.C. motors
• Strip heaters for main and auxiliary transformers
• 40 kW machinery house heater, maximum of 3, each

NOTE: Membrane air dryer should be included in cold weather applications.

TECHNOLOGY AND SOFTWARE

• Extended Upper Temperature Monitoring system - standard plus crowd gearcase bearings,
hoist gearcase bearings, swing shaft bearings, upper gearcase oil, and center gudgeon hub.
• Extended Lower Temperature Monitoring system - standard plus final drive bearings and
propel gearcase oil.

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• P&H Optidig II operator assist tool that co-ordinates the hoist and crowd motions to prevent
the dipper from stalling while digging.
• Motivator Mode software to modify drive performance and RPC function in order to allow
mine supplied motivator at the trail cable voltage to be used to propel.
• ShoveLink Remote Communications Version I - software for mine supplied computer and
ethernet based communication link. Software allows user to veiw electrical feedback, sensor
information, diagnostics, and GUI screens in real time. Maximum of two (2) users per shovel.

MISCELLANEOUS ELECTRICAL
• Electrical Cabinet Filters for RPC and converter cabinets
• Extra Welder Outlet in machinery house, near LH door. 2 max.
• Ground Fault Protection for welder outlets. 3 max.
• Extra Welder Outlet (600V) in machinery house including transformer and ground fault
protection. 4 max.
• Emergency Lighting Unit - six lights total per unit - two (2) on power supply and four (4)
remote mounted - field installed
• Communication System (Gai-Tronics), 3-way, field installed, one on exterior, one in machine
house, and one in operator cab.
• Trail Cable Connector Extension with PLM cable coupler to extend trail cable connector to
rear of propel motor base. (Note: Not for use with trail cable reel. Coupler types other than
standard PLM must be specified)

MISCELLANEOUS MECHANICAL
• Central Drain System for hoist and swing transmissions - field installed
• Lube Filtration with 20 micron filter on each swing transmission
• Blower and Brake Removal System in machinery house - field installed
• Convex Mirrors - two (2) rectangular 16.50" x 24.75” on front of machine
• Tow Lug, Front of carbody - field installed
• Tow Lugs, Rear, two (2) on rear of carbody - field installed
• Slack Hoist Cable Detection system
• Fall Protection Lanyard Attachment points - field installed
• Removable Handrail System for hatch cover openings - field installed
• Supernut bolt connection for ring gear mounting
• SuperNut rod bolt connection for crawler frames in place of standard nut.
• HYTORC rod bolt connection for crawler frames in place of standard nut. (Does not include
HYTORC tooling which is required for tensioning)
• Dual electrically driven tuggers. 2 x 2000 lb (8.9 kN) rated winches.
• Export packing
• Counterweight ballast, 265 lbs./cu.ft. minimum density. Contact product engineering for
ballast amount. Delivered to USA site, DOMESTIC PACKED
• Counterweight ballast, 265 lbs./cu.ft. minimum density. Contact product engineering for
ballast amount. Delivered to USA site, EXPORT PACKED

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TOOLS, TEST EQUIPMENT AND ASSEMBLY AIDS

• HYTORC tooling (hydraulic power pack not included)
• For other tools and test equipment including software contact P&H Service Department.

TECHNICAL DOCUMENTATION

• Operator's Manual, CD ROM, (3 std), each extra

• Operator's Manual, hard copy (3 std), each extra
• Mechanical Systems Manual, CD ROM, (3 std), each extra
• Mechanical Systems Manual, color hard copy, each
• Electrical Systems Manual, CD ROM, (3 std), each extra
• Electrical Systems Manual, color hard copy, each
• Parts Manual, hard copy, each (see note below)
• Electrical Data Manual, hard copy, each (see note below)

Note: The LinkOne Viewer allows the end user to print individual pages or complete parts
manuals. P&H Mining Equipment grants the end users of its parts manual the authority to
print hard copy manuals as required. Electronic copy can be installed on as many
computers as desired.

Note: Specify English or Spanish language. Consult Peak Services for other language
requirements.

CUSTOMER SUPPLY ITEMS

Unless otherwise stated in a P&H proposal, required items, not included in our basic machine
supply are:
• Machine erection, including erection tools and equipment
• Counterweight ballast with a minimum density of 265 lbs. per cubic foot (4,245 kg/m3) (Final
counterweight determined by application.)
• Fluids/lubricants
• Trailing cable and electrical power supply.

*****

P&H - An enduring symbol of quality and reliability

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Technical Description

NOTE: All designs, specifications and components of equipment described above are subject to change at manufacturer’s
sole discretion at any time without advance notice. Data published herein is informational in nature and shall not be construed to
warrant suitability of machine for any particular purpose as performance may vary with conditions encountered. The only warranty
applicable is our standard written warranty for this machine.

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 2300XP Series B
®

DC ELECTROTORQUE® MINING SHOVEL

DUAL PLANETARY PROPEL & SWING

OPERATING SPECIFICATIONS
C
A1
A
G

R1
Q3
Q3
R
Q2
H N
Q1
Q

F
2300XPB
2300XPB
45¡
45° B

I P2
S
P1 E
P E1

M O

L B1
J K
D

C
L ROTATION 105J1791 (ref.)

CAPACITY GENERAL DIMENSIONS

Clearance Height of Boom
Rated Suspended Load 200,000 lbs. 90,718 kg F 56 ft. 6 in. 17.22 m
Point Sheave
G Clearance
Dipper Capacity (Nominal) 33 yd 3
25.2 m 3
Radius of Boom 54 ft. 4 in. 16.56 m
Point Sheave
3 3
Dipper Capacity (Range) 26-48 yd. 9.9-36.7 m H Radius of Counterweight 33 ft. 0 in. 10.06 m
ATTACHMENT I Max. Height Over Gantry 38 ft. 0 in. 11.58 m
Overall Width of Crawlers
Boom Angle 450 450 J 28 ft. 7 in. 8.71 m
(52"/1320 mm Shoes)
Boom Length 56 ft. 0 in. 17.07 m K Overall Length of Crawlers 32 ft. 9 in. 9.98 m
L Ground Clearance 3 ft. 0 in. 0.91 m
Effective Dipper Handle 31 ft. 10 in. 9.70 m
M Height
Length – Ground to Bottom 8 ft. 11 in. 2.72 m
of Counterweight
WORKING RANGES Center of Rotation to Boom
N 11 ft. 0 in. 3.35 m
Foot Pin
A Dumping Radius at Max. Lift 58 ft. 4 in. 17.78 m Height – Ground to Boom
0 13 ft. 2 in. 4.01 m
Foot Pin
A1 Dumping Radius (Max.) 61 ft. 8 in. 18.64 m
P Height – Ground to Top of House 24 ft. 4 in. 7.42 m
B Height of Cut (Max.) Bail-less 50 ft. 0 in. 15.54 m
P1 Height – Ground to Top of
Bail type 45 ft. 0 in. 13.72 m 30 ft. 10 in. 9.40 m
Operator Compartment
P2 Height
B1 Depth of Cut (Max.) 5 ft. 8 in. 1.73 m – Ground to Top 35 ft. 0 in. 10.67 m
of Plenum Cover
C Digging Radius (Max.) 70 ft. 2 in. 21.39 m Q Width of House 28 ft. 0 in. 8.53 m
Width of Left-Hand Catwalk
D Floor Level Radius 51 ft. 3 in. 15.62 m Q1 and 36 ft. 5 in. 11.10 m
Stair Platform
Dumping Height (Max.) – Width of House and
E 28 ft. 7 in. 8.71 m Q2 Operator 34 ft. 5 in. 10.49 m
Door Open Compartment
Width of Left-Hand Catwalk and
Dumping Height at Max. Q3 Operator Compartment 40 ft. 10 in. 12.45 m
E1 18 ft. 10 in. 5.74 m Catwalk
Radius – Door Open
R Overall Length of House 41 ft. 1 in. 11.91 m
R1 Overall Length of House and 45 ft. 4 in. 13.21 m
Operator Compartment
NOTE: Working ranges A through E1 may vary based on dipper selection. Since
Height – Ground to
each application varies, please consult P&H Mining Equipment for correct choice of S 26 ft. 11 in. 8.31 m
dipper capacity. Operator Eye Level
 MAIN MACHINE SPECIFICATIONS

INCOMING SUPPLY REQUIREMENTS MAIN MACHINERY MOTORS

Supply Voltage 4160 or 7200 Volts 3000,5000, 6000 P&H DC FAST RESPONSE MOTORS*
3 Phase, 60 Hz. or 6600 Volts Hoist Motor H.P at 550 Volts D.C. (Continuous) Total 1440
3 Phase, 50 Hz.
(Two K-700 Peak H.P. Developed 2370
Supply Transformer (Minimum) 2000 KVA (units used) Motor Ventilation Blown
Minimum Short Circuit VA Available at Shovel 16 MVA Swing Motor H.P at 550 Volts D.C. (Continuous) Total 530
(Two K-287 units Peak H.P. Developed 1090
ELECTRICAL COLLECTOR SYSTEM used in series) Motor Ventilation Blown
High Voltage Mounted Between Frames, 7,500 Volts Crowd Motor H.P at 550 Volts D.C. (Continuous) 410
Low Voltage Deck Mounted (One K-408 Peak H.P. Developed 575
unit used) Motor Ventilation Blown
HIGH VOLTAGE SWITCHGEAR Propel Motor H.P. at 550 Volts D.C.(Continuous) Total 820
High-Voltage Load Break Air Disconnect Incoming Power (Two K-408 Peak H.P. Developed 1130
to Upper Equipment units used) Motor Ventilation Blown
High-Voltage Load Break Air Disconnect Incoming Power
to Main Transformer *Specifically designed for Electrotorque® system.
High-Voltage Vacuum Contactor Primary Side
of Main Transformer AUXILIARY MOTORS*
High-Voltage Load Break Air Disconnect Incoming Power
to Lower of Machine Dipper Trip 15 H.P.
Hoist Motor Blowers (Two Used) Each 10 H.P.
TRANSFORMERS Crowd Motor Blower 7.5 H.P.
Main Armature Transformer 1500 KVA Propel Motor Blowers (Two Used) Each 2 H.P.
Auxiliaries-Field Transformer 325 KVA Swing Motor Blowers (Two Used) Each 5 H.P.
Relays/Lighting Supply Winding 45 KVA Converter Blowers (Two Used) Each 2 H.P.
Note: Transformer capacities may vary depending on options. RPC Blowers - (One Used) 2 H.P.
(Two Used) 0.33 H.P.
ELECTRICAL CONTROL Control Cabinet Blower 0.33 H. P.
P&H Electrotorque® System, Analog Control with Thyristor Machinery Cab Blowers (Two Used) Each 25 H.P.
Convertors and Static Synchronous Reactive Power Compensation. Fresh Air Blower (Operator's Compartment & Electronics Room)** 0.75 H.P
Programmable Logic Controller for sequencing, lube and limits control. Upper Lube Pump Motor, Hoist 7.5 H.P.
Touch-Screen MMI in Operator's Cab for Fault Read-Out, Limits Air Compressor Motor 30 H.P.
Setting, Machine, System and Lube Status and PLC I/O Status. *Horsepower shown are for 60 Hz. operation – may vary for 50 Hz. operation.
**Fresh air blower supplied only if air conditioning unit is not installed.
GUI in Electronics Room: Same as MMI plus Lube Setting, Motor
Temperature Trending and Daily Fault Logging.
OPERATING STATION
ELECTRICAL PROTECTION Hoist/Propel-Swing Controller Right Joystick
Primary Lightning Arresters Line-to-Line Crowd/Propel- Horn and Dipper Trip Left Joystick
Line-to-Ground Propel Steering Independent Crawler Control, Joysticks
Main Armature Transformer Thermal and ‹ Dig -- Propel Mode Transfer
Instantaneous Overload Push-Button Panel
‹ Brake Set -- Hoist, Crowd, Swing
High Voltage Current-Limiting Fuses with Status Lights
‹ Brake Release -- Hoist, Crowd, Swing Directly interfaced
Auxiliaries–Field Transformer High Voltage ‹ All Brakes Set
Current Limiting Fuses to PLC via
‹ System Status-Visual Communication Link
Auxiliary Supplies Thermal and Short-Circuit
Protection for all Auxiliary Motors.
Branch Circuit Protection. System Status-Alarms Audible Alarms with Distinct Tones
Armature Supply Thermal and Instantaneous Overload
Diverter Circuit Man-Machine Interface with touch screen for fault read-out, shovel
(Electronic Over-Current Protection) and system status and limit setting.
Field Supply Circuit Breakers
Console Illumination (Dimmable) Panel Lights
DC Motors Thermal Monitoring of
Field and Bearing Temperatures Operator's Seat, Joysticks and Footrest Adjustable

DC ELECTROTORQUE® STATIC POWER CONVERSION CABLE DATA Type Size Length

Hoist /Propel Swing Crowd/Propel Hoist 2.25" ***304'
2
14
(2 required) 57mm 92.7 m
Continuous Armature
Converter KW 2 x1320 KW 830 KW 830 KW Boom Suspension ** 3.25" *57'-9"
Rating @ 600 VDC1 (4 required) 83 mm 15.39 m
15 Sec. Armature 0.5" 90'
Dipper Trip - Electric 12
Converter Current 3100 Amp. 1650 Amp. 1650 Amp. 13 mm 27.4 m
Rating1 *45o boom angle ** Galvanized structural strand *** With ferrule beckets
Continuous Field, 150 Amp. 150 Amp. 150 Amp.
Converter Rating1 LUBRICATION SYSTEM
1 Based on outside ambient temperature of 50oC. or 122oF.
2 Cascaded hoist converters. Type Centralized, Dual Line,
STANDARD AUTOMATIC Programmable from GUI
REACTIVE POWER COMPENSATION* Grease Reservoir 106 gallon / 401 liter
60 Hz. (4 step) 50 Hz. (4 step) Open Gear Lube Reservoir 106 gallon / 401 Iiter
Switched Steps +2700 KVAR Total +2812.5 KVAR Total
*Nominal rating at rated capacitor voltage (600 VAC)
 DRIVE MACHINERY AND PERFORMANCE CURVES
HOIST MACHINERY PROPEL MACHINERY
Drum Pitch Dia. 56"/1422 mm Front Idler Dia. 65.75"/1670 mm
Drum Groove Arrangement Single Part Quadruplex Rear Idler Dia. 38"/965 mm
(Flame Hardened) Hoist Cable Gear Case Oil Tight
Gear Case Enclosed, Oil Tight Gear Case Bearings Spherical, Straight & Tapered Roller
Drum Shaft Bearings Tapered Roller Propel Transmission (Two Used) Triple Reduction
Other Bearings Tapered and Straight Roller lst Red.-Spur/2nd & 3rd Red.-Planetary
First Reduction Gearing Modified Helical Propel Disc Brake (Two Used) Spring Set-Air Release
Second Reduction Gearing Spur Brake Location End Of Motor Shaft
Hoist Disc Brakes (Two Used) Spring Set-Air Release Center to Center of Tumblers 24'-3"/7.39 m
Hoist Brake Location Motor Pinion Shaft Number of Lower Rollers, Each Crawler Frame 8
Boom Point Sheaves Pitch Dia. 85"/2159 mm Diameter of Lower Rollers 25"/635 mm
Boom Point Bearing Tapered Roller Standard 52"/1321 mm
Lubrication Pumped and Filtered Oil Bath Width of Crawler Shoes Optional 70"/1778 mm
Hoist Limit Switches Programmable from Operator’s Cab Pitch of Crawler Shoes 52" & 70" 20.5"/521 mm
Number of Crawler Shoes 52" & 70" 84
HOIST PERFORMANCE (Both Crawlers)
23HST007 Steering Counter-Rotational and
Differential Motor Speed
Bail Pull (x1000 pounds)

500 Travel speed 0.78 mph / 1.25 kph

Propel Grade - Uphill 15% Continuous
400
HOISTING
300
PROPEL PERFORMANCE
200 LOWERING
1000

23PRO002
(x1000 pounds)

100
Tractive Effort

800

0 600
0 40 80 120 160 200 240 280 320
400
Bail Speed (fpm)
200

SWING MACHINERY 0

Gear Case (Two Used) Oil Tight 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

Gear Case Bearings Spherical, Straight & Tapered Roller Propel Speed (mph)
Swing Transmission (Two Used) Double Reduction
lst Red.–Spur
2nd Red.–Planetary CROWD MACHINERY
Swing Gear External Cut Teeth Gear Case Oil Tight, Welded Integral with Boom
Swing Gear Dia. 16’1"/4.90 m Gear Case Bearings
Teeth External Cut (Shielded) 10”/254 mm First & Second Reduction Straight & Tapered Roller
Swing Disc Brakes (Two Used) Spring Set-Air Release Shipper Shaft Bearing Sleeve
Brake Location Motor Shaft Shipper Shaft Bearing Dia. 14.25"/362 mm
Type of Roller Circle Tapered Roller Crowd Transmission Powerband "V" Belt
Number of Rollers in Roller Circle 54 to Spur Gear Reduction
Tapered Roller Diameter 8.5"/216 mm V-Belt Adjuster Hydraulic Ram (Pressure Regulated)
Roller Track Mean Diameter 13'-4"/4.06 m Shipper Pinion Pitch Dia. 22.25"/565 mm
Type of Fastening to Upper Center Gudgeon Crowd Disc Brake Spring Set-Air Release
Location of Gudgeon Adjusting Nut On Upper Crowd Brake Location First Reduction Pinion Shaft
Splash Lubrication to Upper Gearing and Bearings Access to Crowd Machinery Railed Platform
Crowd/Retract Limit Switch Programmable from Operator's Cab
SWING PERFORMANCE
2000 CROWD PERFORMANCE
23SWG001

175
(x1000 pound-feet)

23CRD006

1500
(x1000 pounds)

150
Swing Torque

Crowd Effort

125
1000 100

75

500 50

25

0 0
0 0.5 1 1.5 2 2.5 3 3.5 4 0 20 40 60 80 100 120

Swing Speed (rpm) Crowd Speed (fpm)

 WEIGHTS AND GROUND PRESSURE
WEIGHTS – APPROXIMATE* BEARING AREA – GROUND PRESSURE
Working Weight Standard:
(with Dipper, Approx. Wt.) Crawler Bearing Area 30,750 in2
52” Shoes/1321 mm 1,707,557 lbs. 52" Shoes/1321 mm 198,399 cm2
774,548 kg Crawler Ground Pressure 55.53 PSI
70” Shoes/1778 mm 1,735,847 lbs. 52" Shoes 3.91 kg/cm2
787,380 kg Optional:
Shipping Weight Crawler Bearing Area 41,400 in2
(with Dipper) 70" Shoes/1778 mm 267,113 cm2
52” Shoes 1,407,557 lbs Crawler Ground Pressure 41.93 PSI
638,468 kg 70" Shoes 2.95 kg/cm2
70” Shoes 1,435,847 lbs.
651,300 kg *All weights subject to 5% variation
Counterweight 300,000 lbs. **To be furnished by customer, not included in shipping weight.
(Punchings)** 136,080 kg Minimum density 265 lbs./cu. ft. Actual weight of counterweight may vary
based on dipper selection.
Consult P&H Mining Equipment to verify counterweight and density requirements.

MACHINERY DECK PLAN

SWING MOTOR AND HOIST HOIST HOIST

TRANSMISSION MOTOR DRUM MOTOR

HIGH VOLTAGE
CABINET WITH
ISOLATORS

MAIN
TRANSFORMER SWING MOTOR AND
TRANSMISSION

TRANSFER
CABINET

AUXILIARIES CABINET
SUPRESSION CABINET
PROGRAMMABLE LIMIT
DIPPER TRIP SWITCH & PROGRAMMABLE
RESISTORS MESSAGE DISPLAY

AUXILIARIES /
FIELD LIGHTING
TRANSFORMER
OPERATOR’S
COMPARTMENT
ELEVATED
ABOVE
MACHINERY
DECK
REACTIVE POWER CONVERTER CONTROL PROGRAMMABLE
COMPENSATION CABINET CABINET LOGIC CONTROLLER
CABINETS CABINET

105J1722

NOTE: All designs, specifications and components of equipment described above are subject to change
at manufacturer’s sole discretion at any time without advance notice.
Data published herein is informational in nature and shall not be construed to warrant suitability
of machine for any particular purpose as performance may vary with conditions encountered.
The only warranty applicable is our standard written warranty for this machine.

P&H Mining Equipment ◆ Box 310 ◆ Milwaukee, Wisconsin 53201 USA

XS-1237-7 1AG-0604
 P&H MODEL 2300XPB
(w/P&H ELECTROTORQUE ® CONTROL)
TECHNICAL DESCRIPTION

The P&H 2300XPB is a heavy duty electric mining shovel which provides a 50 ton
(45.4 tonne) payload capacity specifically designed to operate in mines for high productive
loading of 150 ton to 200 ton (136 tonne to 182 tonne) haul trucks.

This description is provided to compliment the 2300XPB main machine specification

XS-1237-6.

Design details and advantages provided on the P&H 2300XPB are from the ground up.

POWER SUPPLY

Electrical power to the shovel is Customer supplied via a trailing cable. Recommended
SHD-GC trailing cables, for 7,200 volt supply, are:
#4 AWG/25mm² 3200 ft./975m.
#2 AWG/35mm² 4800 ft./1463m.
#1 AWG/50mm² 5900 ft./1798m.

Electrical equipment on the shovel is designed for an incoming supply of 3 phase/60 hertz/4,160
or 7,200 volts. Secondary voltage for auxiliary motors is 3 phase/60 hertz/480 volts.
(Alternatively, designed for an incoming supply of 3 phase/50 hertz/3300, 5000, 6000, or 6600
volts. Secondary voltage for auxiliary motors is 3 phase/50 hertz/380 or 415 volts).

Recommended 16 MVA, short circuit capacity, at the shovel.

The superior electrical equipment is designed to accommodate voltage fluctuations of +10% to -

20% without any deterioration in operating performance. Also allow for using longer trailing
cable length.

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(Ver .001) September 1999
CRAWLER SHOES

Deep section, cast manganese steel shoes are connected with large 3.75" alloy steel induction
hardened pins through machined, line-bored holes. Shoes have heavy duty drive lugs, large
connecting lugs and improved roller path support. Standard crawler shoes are 52" (1321 mm)
wide resulting in a 55.53 PSI (3.91 kg/cm³) ground bearing pressure (GBP).

Manganese steel provides for excellent work hardening properties. Optional shoe width, 70”
(1778mm) available for reduced GBP.

CRAWLER FRAMES

Wide spread for stability and steerability, with extra heavy duty welded box section construction.
Bolted to carbody under full shear ledge support with wrap around design at drive end of frame
to support gear box. Eight (8) lower rollers and large front and rear idlers in each frame
distribute the machine weight in the 32'-9" (9.98m) overall length frame. Lower rollers are V-
ring sealed to exclude contaminates and hardened wear surfaces protect crawler frame wear.
Rollers and idlers are straddle mounted with special alloy brass bushings. “P&H 50+” lower
rollers are hardened to Rockwell 50c or more. Replaceable pin on, high Brinnel cast slide bars
on top of the frame provide crawler shoe support with reduced maintenance.

More solid machine support with components designed for longer life and reduced maintenance.
Does not require field welding for crawler frame to carbody connection.

CARBODY

One piece, welded radial construction with high strength low alloy cold weather tough steel plate,
heavy duty center casting assembly welded to thick bottom plate and top plate with roller circle
pad for optimum load distribution. Flat-top design with deep section diaphragm plates to provide
direct support of roller path. Carbody interior is painted white for improved visibility and
equipped with an electrical convenience outlet for trouble light use. Swing gear and lower swing
roller path and HV collector rings are mounted to the top of the carbody. Crawler frames are
bolted to sides of carbody which is supported with a full length shear ledge. Both carbody and
crawler frames designed to withstand high levels of bolt tension to prevent crawler frame
movement.

Deep section design improves strength and minimizes the number of weld joints.

DUAL PLANETARY PROPEL SYSTEM

Dual independent P&H DC drive motors, rated at 820hp/612kW total continuous power at 550V
and 1130hp/843kW total peak developed power drive the propel system, and are load sharing
controlled. Motors are mounted in a propel motor base which is bolted to the rear of the carbody.
Efficient straight-line drive to P&H rugged service designed planetary propel transmissions,

2300XPB001.DOC 2300XPB Technical Description Page 2 of 15

(Ver .001) September 1999
directly mounted to each crawler frame give differential speed and provide counter-rotational
steering capability. The unique P&H designed and manufactured triple reduction transmission in
a three (3) tier box contains four (4) planet dual gear sets generating a meshed tooth load of only
20% of traditional spur gear sets. All gearing is forged, anti-friction bearing mounted and
internal gears are case hardened and ground.

Better maneuverability over single drive system; improved mechanical efficiency over spur
gearing; reduced maintenance (no clutches, open brakes, or bushing mounted gears); and first
two gear stages have common parts with the swing planetaries.

A high drive final Propel System design provides a raised final propel drive shaft and tumbler.
Large final propel drive shaft is spline connected to the planetary transmission and tumbler,
mounted on anti-friction bearings. Outboard spherical bearing is encapsulated. Face seals are
used to seal out dirt and seal in lubricant.

Elevated position protects drive shafts and bearings from impact loads, reduces dirt intrusion,
removes machine weight loads and has less shoes in contact with tumbler reducing effects of
shoe stretch.

LOWER HIGH VOLTAGE DISCONNECT SWITCH

Electrical power is brought to the shovel by connection of the trailing cable to this lower HV
disconnect switch which is mounted on the rear of the carbody . A PLM cable coupler (PMG-
415A) is mounted on this switch and mating PLM coupler (QSFL-415A) is provided for the
trailing cable end. Switch provides a visible disconnect, grounding and safety key interlock
which safely energizes or disconnects electrical power to the entire machine. HV wiring runs
from this switch through the carbody to the HV collector rings.

HIGH VOLTAGE COLLECTOR RINGS

HV ring, three (3) power and one (1) ground, are mounted on top of the carbody. They are extra
wide for excellent contact with collector shoes mounted under the revolving frame. Rings access
is protected by bolted carbody hole covers.

CENTER GUDGEON

Center gudgeon is a hollow heavy duty forging used to connect the upper revolving frame to the
lower carbody. A robust locking mechanism allows fine adjustment capabilities. Acme threads
are provided on upper end of the gudgeon, lower end is shrunk fit to the carbody center hub.
Gudgeon center hole is used for electrical wiring and lube line between upper revolving frame
and lower machinery.

REVOLVING FRAME

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(Ver .001) September 1999
Heavy welded high strength low alloy steel structure of cellular deep box sections. The 360°
radial full depth diaphragms align with the swing roller path for excellent load transfer. Deck
machinery is mounted via tapped holes or welded eliminating requirement for internal access.
Roller path support pad is mounted on frame underside.

Frame depth for decreased deflections and stresses. Smooth load transfer is provided between
roller circle and revolving frame.

COUNTERWEIGHT BOX

A large counterweight box is mounted to the rear of the revolving frame, which accommodates
the counterweight ballast.

DECK PLAN

Side platforms which mount to the revolving frame extend the deck width. Conveniently
arranged floor plan with abundant space improves maintenance accessibility and provides a
cleaner working environment.

Single level design, eliminates difficulties of internal stairways.

RH ELECTRONICS ROOM

A separate, large, room is mounted on front right corner of the revolving frame, which houses
more environmentally sensitive electronics; P&H Electrotorque®, Control, PLC and Auxiliary
Cabinets. It is insulated with ½”/12.7mm material; equipped with 0.75HP fresh air blower (not
used with optional air conditioner), secondary wall and door air filter, and louvered front wall
vent panel. Optionally, this room can be further environmentally controlled with air conditioning
and/or heaters.

A door provides access to the machinery house. Front wall louvered vent allows for front
end/attachment viewing while working in electronics room. RH room also is the support base for
the RH elevated operator’s cab.

Environmentally controlled, cleaner pressurized double air filtered for improved electronic
component life.

LH LUBE ROOM

A separate room is mounted on front left corner of the revolving frame, which houses; lube
tanks, pumps, plumbing, and controls (remote I/O connection for touch-screen operator
monitoring and control); and air system components. Room is insulated with ½”/12.7mm
material, and can be optionally heated for improved cold weather operation.

2300XPB001.DOC 2300XPB Technical Description Page 4 of 15

(Ver .001) September 1999
MACHINERY HOUSE

Truss style provides maximum possible roof hatch accessibility and steel panel sections designed
to reduce joint stresses and improve weather tightness. House is pressurized and air is filtered by
a high efficiency Dyna-Vane system for cleaner operation.

ACCESS

A right side pneumatic controlled stairway and left side vertical pull-down ladder are interlocked
to de-energize swing and propel functions when in down position for safety. Catwalk/platforms,
with grated metal surface, hand rails, and toe boards are provided in access areas.

More, lighted outside access doors; three (3) to machinery house, one (1) to LH lube room and
one (1) to operator’s cab

LOW VOLTAGE COLLECTOR RINGS

LV collector rings, which transmits lower voltage power from upper to lower are deck mounted
above the center gudgeon.

LV collector cover is window equipped for easy viewing of rings and brushes.

P&H ELECTROTORQUE ® CONTROL

Shovel drives and systems are controlled by a technically advanced P&H DC analog control
system, which statically converts and inverts power, using pulse transformer fired thyristors.
Programmable Logic Controllers (PLC’s), with an Allen Bradley SLC 504 processor, are used
for sequencing. Remote I/O’s are used to provide PLC inputs and outputs close to their point of
use. Touch-screen MMI and GUI for settings and diagnostics.

P&H Electrotorque ® provides:

− Control design simplicity, which does not require high level electronics experts for
troubleshooting and maintenance.
− High static component efficiency with single step AC to DC conversion
− P&H Electrotorque® control, proven by use on hundreds of P&H mining shovels with
millions of operating hours.

From the HV collectors, P&H Electrotorque ® components include:

High Voltage Cabinet, with 2 visible high voltage disconnects to 1) isolate the entire upper H.V.
supply 2) isolate the primary of the Main Transformer, vacuum contactor, line-to-line and line-
to-ground lightning arrestors for surge suppression.

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(Ver .001) September 1999
Current limiting H.V. fuses are used to provide short circuit protection for the primary of the
Main Transformer and the primary of the Auxiliary Transformer.

Main Transformer, designed for mining shovel service, 1500KVA rated, dry type; Delta/Wye
connected, minimizing third harmonic current flow to external circuits, simplified ground fault
detection and can accommodate unequal loading; ±5% voltage taps, and temperature monitored
windings. Main Transformer provides power for the Converter Cabinet motion thyristor bridges
which control the power to the DC drive motor armatures.

Higher capacity for more working power, built for dependability and monitored for
performance.

Power Distribution
All High Voltage cables are run in metal conduit. An enclosed over head copper bus system is
used to carry the current from the Main Transformer to the Converter cabinet. All other wiring is
generally run in raised troughs on the machinery deck floor. Power cables are Hypalon insulated.

Reactive Power Compensation (RPC) Cabinet, contains stepped tuned banks of capacitors and
reactors, automatically and synchronously switched on and off the line, to maintain average
system power factor near unity. Tuned banks provide a high level of harmonics filtering of the
predominant harmonics generated by the converters. Synchronously applied stepped
compensation eliminates transients during application and disconnection.

Near unity power factor at peak power and near unity average power factor provides electrical
power cost savings. Harmonic filtering to IEEE standards and synchronous application limits
the potential of line disturbances.

Converter Cabinet, contains the simple six-thyristor three-phase bridges used to statically convert
AC supply power to controlled DC supply to motion drive motor armatures for speed and torque
regulation. This thyristor bridge inherently also allows for invert regenerated DC energy to AC
power during motion deceleration. The regenerated power is used to supply the on board needs
with the excess going back to the mine network for energy savings.

Thyristors are mounted in easily accessible heat sinks and forced air cooled. A patented fast
acting overcurrent system, Diverter System, senses and limits the overcurrent to the DC motors
eliminating destructive flashovers.

Power regeneration, as much as 10-15% of electrical energy used each digging cycle, improves
efficiency and can reduce electrical power consumption costs. Diverter Control saves potential
component failure costs.

Transfer Cabinet contains heavy duty contactors to transfer the power from the hoist and crowd
converters to the propel motors in the propel mode. Transfer is simply initiated by a push button
on the console in the operator’s cab with all sequencing handled automatically by the PLC.

2300XPB001.DOC 2300XPB Technical Description Page 6 of 15

(Ver .001) September 1999
Control Cabinet components for the analog P&H Electrotorque Control System contains
equipment performing three main functions. One is the equipment to provide DC power to the
DC drive motor fields. There is a separate field exciter for each main motion. The second is to
provide protective and interfacing functions, such as control of the diverter circuits; and DC
motor voltage and current feedback isolation and scaling. The third is to house the electronic
control cards for the DC drive motor armature and field controls; and RPC switching control.

PLC Cabinet contains Programmable Logic Controllers (PLC’s) with an AB-SLC 504 processor
, and rack mounted Input Output (I/O) modules for logic and sequencing. A touchscreen GUI
(Graphical User Interface) for fault read-out, lube setting and limit switch monitoring, machine
and system status, Help Screens, PLC I/O status, temperature monitoring and trending of drive
motors windings and bearings and hoist drum bearings and fault history files.

The P&H Electrotorque control system, delivering outstanding control of drive motions and
auxiliaries; and parameter setting capabilities; a high level of system monitoring and
information access for maintenance ease.

Remote I/O’s are used in six (6) locations; lower propel, LH lube room, RPC cabinet, converter
cabinet, transfer cabinet, and auxiliary cabinet for close to point of use PLC inputs and outputs.

Places I/O closer to equipment being sensed or controlled and simplifies wiring.

Auxiliary Transformer, like the Main Transformer is designed for mining shovel service, dry
type, Delta/Wye connected. It is rated at 325 KVA. Four (4) secondary windings provide power
for:
(1) 60HZ/480 Volts (Alternatively 50HZ/380 or 415 Volts) for utilities and auxiliary motors.
Power from the transformer flows to an Auxiliary Load Center, Auxiliary Cabinet, motors.
(2) Shielded winding supply for the Control System
(3) Field supply voltage to the DC drive motor, field power bridges.
(4) Lighting and GPO’s supply, 45 KVA rated, and distributed through the 120 VAC Load
Center.

High capacity with reserve for additional equipment add-ons.

Auxiliary Cabinet contains individual motor starters which provide thermal and short circuit
protection for each motor for maintenance ease. It is located in the environmentally controlled
RH electronics room.

Operator Control interface with the Electrotorque system is through:

− Joystick controllers for direction and speed or torque signals to the Control Cabinet
controlling the DC motion drive motors.
− Integrated push-buttons and with Remote I/O on the operator’s console which directly
interfaces with the PLC for start, stop and brake functions. Back lighted, labeled buttons and
status lights for reading and status determination ease.
− Touch-screen MMI (man-machine interface) provides primary system information including:

2300XPB001.DOC 2300XPB Technical Description Page 7 of 15

(Ver .001) September 1999
 • Machine operating status,
• Hoist and Crowd limit setting (boom profiling),
• Faults and alerts,
• Temperature monitoring bar graphs of bearing and motor windings,
• Boom Jacking status
• Boarding Ladder positions
• Manual lubrication capability (settings made on the Control Cabinet GUI)

Easier control and data to improve productivity. Simple and effective primary means to alert the
Operator to the machine operating status, faults and limit setting.

DRIVE MOTORS

P&H designed, manufactured and tested motors, specifically for mining service duty, with Class
"H" insulating system. Fast response to P&H Electrotorque ® control. Drive motors are
equipped with RTD’s to monitor motor bearings and winding temperatures; all are equipped
with heavy duty blowers with screen protected air inlets. Optional brush grades for unusual
operating conditions.

P&H designed and built for single source responsibility. Built with more iron and copper than
typical DC motors for improved performance and reliability. P&H “ENCORE” exchanges,
available for reduced downtime.

HOIST DRIVE SYSTEM

Dual P&H DC motor drive, rated at 1440hp/1074kW total continuous power at 550V and
2370hp/1768kW peak developed power, with modular transmission welded to deck. First
reduction is helical gear set, second reductions spur and a reversible spur drum gear. All gearing
is forged machined, case hardened and ground. Transmission is oil tight with anti-friction
bearings and oil pump filtering arrangement.

Enlarged digging envelope, higher bail pull and dual drive efficiency all contribute to excellent
cutting force even at high speeds.

Dual hoist motor system reduces mechanical inertia for rapid reversals and provides balanced
loading which reduces gear load on hoist drum shaft bearings. Reversible drum gear increases
gear service life.

Standard is a large 56" (1397 mm) pitch diameter drum with through shaft and flame hardened
grooves; spools 2.25" (57 mm) cable fully plastic impregnated and compacted for longer life.
Hoist drum and cable are provided with Ferrule Beckett fittings to simplify cable change out.
Hoist limits are programmable from operator's cab. Hoist drum bearings are RTD equipped for
temperature monitoring.

2300XPB001.DOC 2300XPB Technical Description Page 8 of 15

(Ver .001) September 1999
Full length Hoist drum shaft negates any possible drum flexing from impact loads. Larger Hoist
Drum diameter of 56" provides improved Hoist rope service life. Large ferrules and beckets
improve resistance to Ferrule pull-off. Plastic impregnated cables reduce drum and sheaves
grooving wear.

HOIST CABLE TUGGER

An electric driven tugger is installed to assist with hoist cable changes.

Tugger is large, 2000 lb.(907 Kg), unit to simplify and speed cable changes. Optional or dual
electric tuggers are available.

SWING DRIVE SYSTEM

Swing power is provided by two (2) P&H DC drive motors, rated at 530hp/395kW total
continuous power at 550V and 1090hp/813kW total peak developed power, connected in series.
P&H Dual Planetary transmissions are mounted front and rear of swing gear for even loading.
Some components are interchangeable with first and second reductions in Propel transmissions
minimize parts stocking requirements. Swing shafts are mounted on anti-friction bearings and
removable without disturbing the transmission. Cast swing gear, 16'-1" (4.90m) diameter with a
large 10" (254mm) tooth face for reduced loading. Swing circle uses 54, 8.5" (216mm) tapered
rollers carried on self-lubricating bushings. Roller paths are high carbon steel, forged, quenched
and tempered to a high hardness.

No deck welding of swing transmissions to complicate maintenance. Fore and aft positioning for
more even swing gear wear. Easier access to individual components reduces maintenance
downtime.

LUBRICATION

An automatic, centralized dual line system is provided using Farval injectors, three (3) Lincoln
75:1 ratio air drive pumps and is controlled and monitored through touch-screen MMI’s which
have malfunction alarm and reduces lubricant consumption. Large, 106 gallon oil and 106 gallon
grease on-board reservoirs maximize operating time. A large, separately enclosed, insulated left
hand lubrication room is standard. All gear cases are designed with reliable bath and splash
lubrication to all gearing and bearings. A lube filtration system is standard for the hoist gear
case.

AIR SYSTEM

Compressed air is provided for lube pumps, lube sprayers, disc brakes, hoist cable tugger, air
operated stairway, horn, windshield wipers and washer. Standard air compressor is a Sullair,

2300XPB001.DOC 2300XPB Technical Description Page 9 of 15

(Ver .001) September 1999
Model ES-8-30XH, rotary screw type, 30HP, 95ACFM at 60HZ (77ACFM at 50HZ), floor
mounted, with separate 200 gallon capacity air receiver.

Higher capacity, more compact compressor with advanced electronic control delivers more air
with greater reliability. Membrane air dryer option for superior cold weather performance.

BRAKES

All motions have oversized, low maintenance disc brakes which are spring set-air released for
fail-safe operation.

Redundant solenoid valves are used on the hoist and swing to enhance brake setting to improve
reliability.

OPERATOR'S CAB

A separate, roomy, high-visibility cab is rigidly mounted and offset in an elevated position on the
shovel's right hand side. Freezer style door handles are equipped on cab door. Non-glass areas of
the cab are insulated for temperature and sound control.

Front window is a large, sloped single piece and all windows are tinted safety glass. A slide-by
window is provided on each side; and lower windows provide for crawler frame viewing. Air
operated front window wipers and washer are included. A fold out walkway is used in front of
the cab for window cleaning access.

The Operator's seat and independently mounted control consoles are slanted fifteen degrees
inward towards the boom, for improved sightlines to the dipper. Consoles are angled upward
toward the operator to be closer and more easily read. The seat has air suspension with
adjustment for operator's weight and features back angle positioning, four way lumbar
adaptations, vertical height selection and a footrest. Adjustable armrests relieve the strain of
straight shoulder-to-hand joystick operation. Joystick controls are seat mounted in each armrest.

Touch-screen Man Machine Interface (MMI) for machine operating status, boom jacking status,
boarding ladder positions, faults, alerts/alarms, temperature monitoring, limit switch setting
(boom profiling), and lubrication monitoring and manual operation.

Cab amenities include a forced air comfort heater, electric fan, inclinometer, AM/FM radio with
CD, closet and three electrical convenience outlets.

Ergonomically designed for operator comfort and productivity.

LIMIT SWITCHES

2300XPB001.DOC 2300XPB Technical Description Page 10 of 15

(Ver .001) September 1999
Hoist and Crowd/retract limits are set on the MMI touch screen located in the Operator's cab,
eliminating the requirement of adjustment at the Crowd Transmission. A boom profiling limit is
included to help prevent accidental contact of handle torsion box and dipper with boom.

Soft set-down feature after boom jacking minimizes impact.

LIGHTING

Standard lighting systems are:

Primary exterior floodlights: Metal Halide, 400 watt, 60HZ/120V (alternatively 50HZ/220V),
high intensity discharge (HID) units. Nine (9) are wide beam and two (2) very narrow beam;
located-

• Two (2) on top front of operator’s cab. (RH wide beam; LH very narrow beam)
• Two (2) on top front of lube room. (RH very narrow beam; LH wide beam)
• Two (2) right side of house
• Two (2) top rear of house
• One (1) top left side of house

Secondary exterior floodlights: Halogen, 500 watt units. Seven (7) lights located -
• One (1) above operator’s cab door.
• Two (2) lower front of machinery house.
• Four (4) under revolving frame corners.

Exterior incandescent: Five (5), 100 watt; one (1) at each machinery house door and one (1) at
operator’s cab door.
Interior lighting: Twenty (20) fluorescent lights are provided to illuminate the machinery house,
RH electrical room and LH lube room.

Operator’s cab lighting: Incandescent 100 watt ceiling light. Consoles are back lighted with
dimmer switch control.
One (1) portable halogen trouble light is also provided for primary use at convenient roof top
outlets.

P&H lighting systems provide for excellent exterior and interior illumination, with minimum
intensity fluctuation, providing improved operating and maintenance visibility.

ELECTRICAL CONVENIENCE OUTLETS

Electrical outlets for 110/120 volt supply are conveniently located:

− One (1) Inside carbody

− Two (2) Under revolving frame platforms

2300XPB001.DOC 2300XPB Technical Description Page 11 of 15

(Ver .001) September 1999
− Seven (7) In machinery house
− One (1) In RH electronics room
− One (1) In LH lube room
− Three (3) In Operator’s cab
− Two (2) On house roof

Outlets are GFI protected. GPO’s are 15 amp, duplex, NEMA 5-15 straight blade devices, 2
pole, 3 wire grounded and 125V rated.

Special instrument outlets are located in the Control Cabinet.

Three (3) 60HZ/460V (Alt. 50HZ/380V) outlets are also provided; one (1) in RH electronics
room, one (1) in LH lube room and one (1) in Operator’s cab. These outlets are 20 amp,
3 wire, 4 pole, IEC 309 type.

Less time spent looking for a convenient plug-in.

BOOM

56'-0" (17.07m) length set at 45 angle; welded structure of high strength low alloy steel, for cold
weather toughness; extra depth for high load capability; large 85" (2159mm) diameter point
sheaves, split bearing block mounted for maintenance ease. Boom suspension cables are 3.25"
(83mm) galvanized structural strand cable. Integral lifting lugs and wear resistant side boxes are
incorporated. Boom is connected to revolving frame lugs with heavy duty lubricated pins
retained with split collars.

Boom structural strength and torsional rigidity provides solid support of crowd gear case and
twin leg dipper handle.

CROWD SYSTEM

Crowd and retract of the dipper is accomplished by a P&H DC motor rated at 410hp/306kW
continuous power at 550V and 575hp/429kW peak developed power driving through a unique
P&H - POWERBAND "V" BELT - shock absorbing/system to modular, enclosed, transmission
with spur gear reduction to simple rack and pinions. V-belt sheaves are fully machined and
balanced. Gearing is forged, case hardened and ground; mounted on
pre-adjusted bearings. Pressure regulated hydraulic ram for simple "V" belt adjustment. Single
piece saddle blocks are also hydraulically adjusted and allow for easy removal of crowd pinions.
Crowd/retract limits programmable from operator's cab.

Power band provides buffer between motor and crowd gearing to absorb shock loads. Modular
gear case can be removed as a unit simplifying maintenance and repair. Rack and pinion crowd
provides a positive crowd force for better control and more effective engagement of the dipper in
the bank material. Significantly lower operating cost than a drum driven rope crowd system.

2300XPB001.DOC 2300XPB Technical Description Page 12 of 15

(Ver .001) September 1999
DIPPER HANDLE

31'-0" (9.70m) effective length; high strength low alloy, cold weather steel; straddle design with
deep box, straight legs and oversized cast manganese racks providing superior strength to cope
with corner tooth digging loads.

Dual straight legs maintain a uniform cutting force across entire width of dipper lip for better
fill and less time in bank. This high torsional rigidity forces the dipper to hold horizontal and
dig, rather than twist around difficult bank material.

DIPPER TRIP

Dipper trip system is a 15HP, AC motor drive through spur gearing to a heavy duty drum.
Dipper trip cable is ferrule beckett connected to the drum and connected through a dipper handle
mounted banjo to the dipper latch lever with single part cable.

DIPPER

Nominal rated dipper size is 33 cubic yard ( 25.2 cubic meters ). Dippers are quoted separately as
each application is individually reviewed.

P&H “Optima” mining shovel dippers are defined to provide size and design tailored to
optimize your minesite productivity.

PAINT

Standard exterior is P&H Yellow and Black. Yellow on machinery house and operator’s cab.
Black on lower, attachment, catwalks and handrail. (Lower HV disconnect switch is painted
red).

Interior of house, RH and LH rooms, carbody, revolving frame and lower boom section and all
electrical cabinet interiors are painted high visibility white.

WEIGHTS

Estimated working weight of the P&H Model 2300XPB (Specification XS-1237-6) with nominal
dipper and 52" wide crawler shoes is 1,707,557lbs/774,548kg.

Pound for pound, built heavy duty: a great productivity investment for an extended service life.

2300XPB001.DOC 2300XPB Technical Description Page 13 of 15

(Ver .001) September 1999
TECHNICAL DOCUMENTATION

As standard, each P&H shovel Purchaser is supplied three (3) copies in English language of the
following documents:
− Operator’s Manual
− Shop Manual
− Electrical Troubleshooting Manual
− Commissioning Manual
− Electrical Data and Wiring details

One (1) Parts Manual is provided in electronic format, Link-One.

Well organized documentation to ease operation, maintenance and parts procurement.

CUSTOMER SUPPLY ITEMS:

Unless otherwise stated in a P&H proposal, required items, not included in our basic machine
supply are:
* Machine erection, including erection tools and equipment
* Counterweight ballast, approximately 300,000 lbs. (136,080 kg) with a minimum density
of 265 lbs. per cubic foot (4,245 kg/m²)
* Fluids/lubricants
* Trailing cable and electrical power supply.

2300XPB001.DOC 2300XPB Technical Description Page 14 of 15

(Ver .001) September 1999
OPTIONS

Contact your local P&H MinePro Services representative for available options and/or shovel
modifications to tailor the P&H Model 2300XPB to your specific mines requirements.

AFTERMARKET SERVICES

Contact you local P&H MinePro Services representative for details on available services to help
improve your mines productivity and better control operating costs.

P&H - Your Long Term Partner in Productivity

NOTE: All designs, specifications and components of equipment described above are subject to change at
manufacturer’s sole discretion at any time without advance notice.

Data published herein is informational in nature and shall not be construed to warrant suitability of machine for any
particular purpose as performance may vary with conditions encountered.

The only warranty applicable is our standard written warranty for this machine.

2300XPB001.DOC 2300XPB Technical Description Page 15 of 15

(Ver .001) September 1999
 ®

2300XPA
ELECTRIC MINING SHOVEL

OPERATING SPECIFICATIONS

meters
feet
22 72.2

20 65.6

18 59.1

16 52.5

14 45.9

12 39.4

10 32.8

8 26.2

6 19.7

4 13.1

2 6.6

0 0

2 6.6
meters 6 4 2 0 2 4 6 8 10 12 14 16 18 20 22 24
feet 19.7 13.1 6.6 0 6.6 13.1 19.7 26.2 32.8 39.4 45.9 52.5 59.1 65.6 72.2 78.7
C
L ROTATION

CAPACITY
Nominal Payload 36.3 m ton 40 ton
3 WORKING RANGES
Nominal Dipper Capacity 20.65 m 27 yd3
(SAE struck) Height of Cut (Max) 15.39 m 50 ft. 6 in.

Rated Suspended Load 77.1 m ton 85 ton Radius of Cut (Max) 21.54 m 70 ft. 8 in.

Optimum Truck Size 109-181 m ton 120-200 ton Dumping Height (Max) 9.91 m 32 ft. 6 in.

Floor Level Radius 15.27 m 50 ft. 1 in.

PERFORMANCE Tail Swing Radius 8.61 m 28 ft. 3 in.
Peak Propel Speed 1.26 km/h 0.78 mile/h Operator Eye Level 7.77 m 25 ft. 6 in.
(Dual Propel)

Gradability (Continuous) 19% 19%

 MACHINERY DECK PLAN
HIGH VOLTAGE SWING HOIST HOIST COMPRESSOR HOIST HOIST
CABINET TRANSMISSION MOTOR TRANSMISSION MOTOR DRUM
AND MOTOR

MAIN
TRANSFORMER

SWING
TRANSMISSION
AND MOTOR

AUXILIARIES/FIELD REACTIVE POWER CONVERTER CONTROL AUXILIARIES

TRANSFORMER COMPENSATION CABINET CABINET CABINET
CABINETS

ELECTRICAL

INCOMING SUPPLY REQUIREMENTS P&H DIGITAL DC STATIC DC POWER CONVERSION

Supply Voltage* 4160 or 7200V 3300, 5000, 6000 or 6600V Hoist**/Propel Swing Crowd/Propel
3 Phase, 60 Hz 3 Phase, 50 Hz.
Continuous Armature
Supply Transformer (Minimum) 2000 kVA Converter KW Rating 2x810 kW 760 kW 760 kW
@550 VDC*
Minimum Short Circuit VA Available at Shovel 16 MVA
15 Sec. Armature
*Voltage per customer requirements. Converter Current 2700 amp. 1650 amp. 1650 amp.
Rating*

TRANSFORMER Continuous Field

Converter Rating* 150 amp. 150 amp. 150 amp.
Main Armature Transformer 2000 kVA
* Based on outside ambient temperature of 50°C or 122°F.
Auxiliaries-Field Transformer 325 kVA ** Cascaded hoist converters.

Control/Lighting Supply Winding 45 kVA

P&H DC FAST RESPONSE MAIN MACHINERY MOTORS*
Note: Transformer capacities may vary depending on options.
Hoist Motor Continuous rating @475 volts Total 1000kW/1340hp
(Two used) Peak developed power 1357kW/1820hp
P&H DIGITAL DC AUTOMATIC
REACTIVE POWER COMPENSATION* Swing Motor Continuous rating @ 475 volts Total 380kW/510hp
(Two used) Peak developed power 746kW/1000hp
60 Hz. 50 Hz.
Crowd Motor Continuous rating @ 475 volts Total 298kW/400hp
Fixed Bank +675 kVAR +750 kVAR (One used) Peak developed power 365kW/490hp
Three Switched Steps +2025 kVAR Total +2062.5 kVAR Total Propel Motor Continuous rating @ 475 volts Total 559kW/750hp
(Two used) Peak developed power 1122kW/1505hp
Total Compensation +2700 kVAR Total +2812.5 kVAR Total

*Nominal rating at rated capacitor voltage (600 VAC) *Specifically designed for P&H Digital DC system.
 SUPERVISORY CONTROL AND DRIVES
P&H CENTURION™ • Digital controls provide constant power characteristics for optimal
INTEGRATED PERFORMANCE PLATFORM motion speeds which reduce overall cycle time.
• One-time setup of electrical parameters provide consistent optimum
• Centurion Supervisory Controller provides direct integrated comuni-
operation.
cation with motor drives giving precise motor control and fast cycle
times. Real-time multi-tasking capability allows for optimal machine
logic sequencing, monitoring and control. FEATURES AND OPTIONS
• Centurion I/O System uses ‘Profibus’ communication protocol for • Standard Automatic-Boom-Soft-Setdown and Boom Profile Protection
seamless integration of all shovel subsystems and future expandabil- Envelope help protect structures from excessive loading.
ity. Low-voltage 24V DC I/O drop points feature open and short
• Standard Anti-Swing-in-Bank reduces excessive side loading.
circuit detection for improved diagnostics and troubleshooting.
• Options are available to tailor the 2300XPA to specific requirements
• Centurion Information System’s enhanced Graphical User Interface
(GUI) features intuitive, icon-based screens to display vital informa- • Optional Optidig™ automatically coordinates hoist and crowd
tion such as shovel status, troubleshooting information, and optional motions while in the bank to improve dig cycle time and optimize
production monitoring data and operator feedback. power usage.
• Optional remote communications provide remote data transmission
and other high level control and diagnostic capabilities to improve
P&H DIGITAL DC DRIVES
overall loading productivity.
• P&H Digital DC Drive provides precise, reliable, solid state power to
the main motion motors, and has been proven on hundreds of units,
logging tens of millions of productive hours.

MECHANICAL
HOIST PROPEL
• All gearing housed in single enclosed gear case with filtered oil circu- • Two planetary transmissions of proven design transmit torque directly
lation for reliable lubrication, ease of maintenance, and extended to the drive sprockets, producing the tractive effort required for fast,
component life. efficient propel and positioning operations.
• Large diameter hoist drum for extended rope bending life. Ferrule • Dual independent counter-rotational propel for steering.
becket system and cable tugger are standard for efficient rope • Two spring-set air-release disc brakes - one per motor.
change.
• Two spring-set air-release disc brakes - one per motor.
DIPPER
• P&H high-production dipper provides nominal 40-ton / 36.3 metric
CROWD
ton capacity.
• Powerband V-belt drive between motor and gear case absorbs shock
loads.
DIPPER TRIP
• First and second reduction gearing in enclosed gear case for reliable
splash lubrication, ease of maintenance, and extended component • Adjustable-torque electric motor with geared drive unit for reliable trip
life. and slack take-up operation.
• Twin-leg dipper handle with torsion box and rack-and-pinion drive has
inherent stability in the bank for optimal digging.
AIR FILTRATION
• Single spring-set air-release disc brake.
• High-efficiency ‘Dynavane’ filtration system pressurizes machinery
house.
SWING
• Two spur gear transmissions of proven design and a single-piece
AUTOMATIC LUBRICATION
swing gear transmits torque for fast cycle times.
• Two spring-set air-release disc brakes - one per motor. • Centralized system with air operated pumps lubricates bearings
and open gears.

OPERATOR'S STATION
SIDE CONSOLE GRAPHICAL USER INTERFACE (GUI)
• Push button controls for start, stop, • System parameter display
reset and brake set/release • Motion limit settings via touch screen
• Climate controls, wipers, lights and • Lube and air system displays
other optional equipment control

LH JOYSTICK
• Crowd (propel)
SEAT • Dipper trip - horn
• Air ride
• Suspension seat
• Joysticks in armrests RH JOYSTICK
• Hoist (propel)
• Swing
 GENERAL MACHINE SPECIFICATIONS

2300XPA
C

H
G
D F
E

GENERAL DIMENSIONS BEARING AREA - GROUND PRESSURE

A Overall Width 10.46 m 34 ft. 4 in. Standard:

B Overall Length 13.15 m 43 ft. 2 in. Crawler Bearing Area 19.92 m2 30,880 in2
52" Shoes/ 1321 mm
C Overall Height over Gantry 11.12 m 36 ft. 6 in.
Crawler Ground Pressure 353 kPa 51.2 psi
D Width of Crawler Shoes 1321 mm 52" (Std.) 52" Shoes/ 1321 mm
1778 mm 70"
Optional:
E Overall Width of Crawlers (Std) 8.66 m 28 ft. 5 in.
Crawler Bearing Area 26.82 m2 41,570 in2
F Overall Length of Crawlers 9.86 m 32 ft. 4 in. 70" Shoes/ 1778 mm
G Ground Clearance 0.91 m 3 ft. 0 in. Crawler Ground Pressure 265 kPa 38.5 psi
H Height – Ground to Bottom 70" Shoes/ 1778 mm
of Counterweight 2.55 m 8 ft. 4.5 in.

WEIGHTS - APPROXIMATE*
CABLE DATA Working Weight (with Dipper, Approx. Wt.)
Hoist (wire rope) 57 mm 2.25" dia. (Std.) 52" Shoes/1321 mm 716,676 kg 1,580,000 lbs
Suspension (wire rope) 70 mm 2.75" diameter 70" Shoes/1778 mm 725,748 kg 1,600,000 lbs
Dipper Trip (wire rope) 13 mm 0.5" diameter Counterweight (Punchings)** 119,748 kg 264,000 lbs

* All weights subject to 5% variation.

** To be furnished by customer.

NOTE: All designs, specifications and components of equipment described above are subject to change
at manufacturer’s sole discretion at any time without advance notice.
Data published herein is informational in nature and shall not be construed to warrant suitability
of machine for any particular purpose as performance may vary with conditions encountered.
The only warranty applicable is our standard written warranty for this machine.

P&H Mining Equipment ◆ Box 310 ◆ Milwaukee, Wisconsin 53201 USA

XS-3206 2AG-105
 2300XPA TECHNICAL DESCRIPTION
February 21, 2005

The P&H 2300XPA is a heavy duty electric mining shovel which provides a 40 ton (36.3 metric
ton) nominal payload capacity specifically designed to operate in mines for high productive
loading of 150 ton to 260 ton (136 metric ton to 236 metric ton) haul trucks and larger.

This technical description is provided to compliment the 2300XPA main machine

specification X-3206.

ELECTRICAL POWER SYSTEM

POWER SUPPLY
Electrical power to the shovel is Customer supplied via a trailing cable. Recommended
SHD-GC trailing cables, for 7,200 volt supply, are:

#4 AWG/25mm² 3200 ft./975m.

#2 AWG/35mm² 4800 ft./1463m.
#1 AWG/50mm² 5900 ft./1798m.

Electrical equipment on the shovel is designed for an incoming supply of 3 phase/60 hertz/4,160
or 7,200 volts. Secondary voltage for auxiliary motors is 3 phase/60 hertz/480 volts.
(Alternatively, designed for an incoming supply of 3 phase/50 hertz/3,300, 6000, 6600, or 7200
volts. Secondary voltage for auxiliary motors is 3 phase/50 hertz/380 or 415 volts).
Recommended 16 MVA, short circuit capacity, at the shovel.

LOWER HIGH VOLTAGE DISCONNECT SWITCH

Electrical power is brought to the shovel by connection of the trailing cable to the lower HV
disconnect switch which is mounted on the rear of the carbody. A cable coupler is mounted on
this switch and mating PLM coupler is provided for the trailing cable end. The switch provides a
visible disconnect, grounding, and a safety key interlock which energizes or disconnects
electrical power to the entire machine. HV wiring runs from this switch through the carbody to
the HV collector rings. The standard cable coupler is a PLM brand quick disconnect type. Other
couplings are available upon request.

HIGH VOLTAGE COLLECTOR RINGS

 Model 2300XPA
Technical Description

High voltage collector rings consist of three (3) power and one (1) ground ring, and are mounted
on top of the carbody. All rings are extra wide to provide proper contact with collector shoes
which are mounted under the revolving frame. Ring access is protected by bolted carbody hole
covers.

LOW VOLTAGE COLLECTOR RINGS

Low voltage collector rings, which transmit lower voltage power from upper to lower are deck
mounted above the center gudgeon. The LV collector cover is window equipped for viewing of
rings and brushes for inspection.

UPPER HIGH VOLTAGE DISCONNECT

Fully contained cabinet contains two visible high voltage disconnects to 1) isolate the entire
upper H.V. supply, and 2) isolate the primary of the Main Transformer, vacuum contactor, line-
to-line and line-to-ground lightning arrestors for surge suppression. Current limiting HV fuses
provide short circuit protection for the primary of the Main Transformer and the primary of the
Auxiliary Transformer

MAIN TRANSFORMER
Designed for mining shovel service, 2000KVA rated, dry type; Delta/Wye connected,
minimizing third harmonic current flow to external circuits, simplified ground fault detection.
Transformer can accommodate unequal loading, has ±5% voltage taps, and temperature
monitored windings. Main Transformer provides power for the Converter Cabinet motion
thyristor bridges which control the power to the DC drive motor armatures and fields.

AUXILIARY TRANSFORMER
Like the main transformer, the auxiliary transformer is designed for mining shovel service, is of
the dry type, and is Delta/Wye connected. It is rated at 325 KVA. Four (4) secondary windings
provide power for:
(1) 60HZ/480 Volts (Alternatively 50HZ/380 or 415 Volts) for utilities and auxiliary motors.
Power from the transformer flows to an Auxiliary Load Center, Auxiliary Cabinet motors.
(2) Shielded winding supply for the Control System
(3) Field supply voltage to the DC drive motor, field power bridges.
(4) Lighting and GPO’s supply, 45 KVA rated, and distributed through the 120 VAC
(alternately 240V) load center

POWER CONVERTER CABINET

The P&H Digital DC power conversion system contains the simple six-thyristor three-phase
bridges used to statically convert AC supply power to controlled DC supply to motion drive
motor armatures for speed and torque regulation. This thyristor bridge inherently also allows for
invert regenerated DC energy to AC power during motion deceleration. The regenerated power
is used to supply the on board needs with the excess going back to the mine network for energy
savings.

Tech Desc 2300XPA.doc Page 2 of 14

 Model 2300XPA
Technical Description

Thyristors are mounted in easily accessible heat sinks and are forced air-cooled. A patented fast
acting over-current system, diverter system, senses and limits the over-current to the DC motors
eliminating destructive flashovers.

POWER DISTRIBUTION
All High Voltage cables are run in metal conduit. An enclosed over head copper bus system is
used to carry the power from the Main Transformer to the Converter cabinet. All other wiring is
generally run in raised troughs on the machinery deck floor. Power cables are XLPO (cross-
linked polyolefin) insulated

REACTIVE POWER COMPENSATION (RPC) SYSTEM

Housed in a rugged, ventilated cabinet, the RPC system contains stepped tuned banks of
capacitors and reactors, automatically and synchronously switched on and off the line, to
maintain average system power factor near unity. Tuned banks provide a high level of harmonics
filtering of the predominant harmonics generated by the converters. Synchronously applied
stepped compensation eliminates transients during application and disconnection.

TRANSFER CABINET
The transfer cabinet contains heavy duty contactors to transfer the power from the hoist and
crowd converters to the propel motors in the propel mode. Transfer is initiated by a push button
on the console in the operator’s cab with all sequencing handled automatically by the
programmable industrial controller.

DC DRIVE MOTORS
P&H designed, manufactured, and tested motors are specifically designed for mining service
duty, with Class "H" insulating system. Drive motors are equipped with RTD’s to monitor motor
bearings and winding temperatures, and all are equipped with heavy duty blowers with screen
protected air inlets. Optional brush grades are available for unusual operating conditions.

ELECTRICAL CONTROL SYSTEM

P&H CENTURION™ IPP (INTEGRATED PERFORMANCE PLATFORM)
The P&H Centurion™ IPP provides the supervisory control of the shovel drives and executes the
sequencing and monitoring functions, and consitsts of the supervisory control computer and
supporting hardware devices and software programs. The system is comprized of three basic
areas which are: 1) the onboard graphical user interface (GUI), 2) the remote input/output (I/O)
devices and communication interface, and 3) the individual drive controllers.

The system uses an open concept design to allow for third party integration. The architecture
provides connectivity from components on the shovel to the onboard GUIs and provides
diagnostic and monitoring capabilities. The application code residing within the supervisory
controller is based on the IEC 61131 standard. The control system uses Profibus over fiber optic
and copper media for communications with the various system components.

Tech Desc 2300XPA.doc Page 3 of 14

 Model 2300XPA
Technical Description

SUPERVISORY CONTROL CABINET

Components for the P&H Centurion™ IPP are housed in a rugged, maintenance friendly cabinet,
which is located in the RH Electronics room.

LOWER CONTROL PANEL

The lower control panel is mounted inside the carbody, and contains remote I/O, air solenoid
valves for the brakes, and an electrical convenience outlet.

REMOTE I/O’S
The supervisory control system functions with remote I/O in several locations such as lower
propel, LH lube room, RPC cabinet, converter cabinet, transfer cabinet, auxiliary cabinet, and
operators cab.

AUTOMATIC ATTACHMENT PROTECTION SYSTEMS

Hoist and crowd/retract limits are set on the GUI touch screen located at the loading control
center in the operator's cab. A boom profiling limit is included to help prevent contact of the
handle torsion box and dipper with boom. The ABSS (Automatic Boom Soft Set-down) feature
is part of the control system and minimizes boom jacking and the associated impact of abruptly
lowering the boom from a jacked condition.

OPERATOR INTERFACE
OPERATOR CAB
A separate, roomy, high-visibility cab is rigidly mounted and offset in an elevated position on the
shovel's right hand side. Freezer style handles are equipped on the cab door. Non-glass areas of
the cab are insulated for temperature and sound control. The sound level inside the cab is below
70dBA while the shovel is operating, and with the door closed. All windows other than the front
window are tinted safety glass. The standard front window glass is 0.38 inch / 9mm thick
laminated safety glass. An industrial grade, single arm electric window wiper system is standard.

A standard single 2-tone air signal horn is standard equipment, and is mounted on front of RH
room. Sound level rating of the standard air horn is 123 dBA at the source.

P&H LOADING CONTROL CENTER

The P&H Loading Control Center provides a single location of control for shovel operation and
truck loading. An additional work area with an optional seat is provided immediately behind the
operator for use by training or other personnel.

The standard seat base is an air suspension type which can be adjusted for operators height and
weight. The seat has an automotive style power system which provides vertical and fore / aft
adjustment to allow custom fitting of the joysticks to individual operators. The seat has heat,

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 Model 2300XPA
Technical Description

lumbar support, and massage. The entire seat, armrest assembly is mounted to a vibration
isolated sled with an integral footrest. The angled footrest swivels into two positions based on
the operator’s height.

The joystick contollers are Hall-Effect, pistol grip style with both push button, trigger switch, and
rocker switches built into the grips. There is a single console on the left hand side of the operator.
All control devices needed by the operator while operating the shovel and loading trucks are
located in a zone of comfort for easy access with minimal movement. Devices needed for
auxillary functions such as those climate control and lighting are located within reach of the
operator while seated.. The console also features an expandable media mounting post to which
the P&H GUI is mounted as standard. Post sections can be added to mount remote camera
monitors as well as dispatch screens.

The climate control ducting in the cab is located above and below the operator. There are
controls to allow regulation of air flow between window defrost, the vents at the feet, and the
vents at the midlevel of the operator.

GRAPHIC USER INTERFACE (GUI)

The GUI has menus and information screens thatallow the operator todisplay information, and
perform various operation functions. The basic functions of the GUI are:
• Display machine operating status
• Display and set hoist and crowd limit setting (boom profiling)
• Provide fault enunciation and alerts
• Display temperature monitoring bar graphs
• Display boom jacking status
• Display boarding ladder positions
• Display lubrication system settings and status
• Provide for manual initiation of lubrication cycles

CLIMATE CONTROL
An optional P&H MineAir Systems MAS 1000 mine duty air conditioner unit is available. A
single unit can be fitted to the operator cab, or two units can be fitted, one for the cab and one for
the electronics room. Units can be fitted with an efficient air filtration system, which can
pressurize the cab and electrical room.

LIGHTING
Primary exterior floodlights: Standard lights are Metal Halide, 400 watt, 60HZ/120V
(alternatively 50HZ/220V), high intensity discharge (HID) units.

Standard primary exterior floodlight locations (nine are wide beam and two very narrow beam)
are as follows:
• Two (2) on top front of operator’s cab

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 Model 2300XPA
Technical Description

• Two (2) on top front of lube room

• Two (2) right side of house
• Two (2) top rear of house
• One (1) top left side of house

Secondary exterior floodlights: Standard are Halogen, 500 watt units. Standard secondary
exterior floodlight locations are as follows
• One (1) above operator’s cab door
• Two (2) on the lower front of machinery house
• Four (4) under revolving frame corners
Exterior incandescent: Five (5), 100 watt; one (1) at each machinery house door and one (1) at
operator’s cab door.

Interior lighting: Twenty (20) fluorescent lights are provided to illuminate the machinery house,
RH electrical room and LH lube room.

Operator’s cab lighting: Incandescent 100 watt ceiling light.

One (1) portable halogen trouble light is also provided as standard for primary use at convenient
roof top outlets.

ELECTRICAL CONVENIENCE OUTLETS

Electrical outlets for 110/120 volt supply are conveniently located:
• One (1) in lower works located in the carbody
• Two (2) under revolving frame platforms
• Seven (7) In machinery house
• One (1) inside house near RH door
• Two (2) in RH electronics room
• One (1) in LH lube room
• Three (3) in Operator’s cab
• Two (2) on house roof

Outlets are GFI protected. GPO’s are 15 amp, duplex, NEMA 5-15 straight blade devices, 2
pole, 3 wire grounded and 125V rated.

Special instrument outlets are located in the Supervisory Control Cabinet.

Three (3) 60HZ/460V (Alt. 50HZ/380V) outlets are also provided; one (1) in RH electronics
room, one (1) in LH lube room and one (1) in Operator’s cab. These outlets are 20 amp, 3 wire,
4 pole, IEC 309 type.

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 Model 2300XPA
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A single welder outlet receptacle (60Hz/460V, alternatively 50Hz/380V) is provided, located

near the RH door in the machinery house.

MECHANICAL SYSTEMS
CRAWLER DRIVE SYSTEM
The crawler drive system incorporates a rugged lug and tumbler design.

CRAWLER SHOES
Deep section, cast manganese shoes are connected with 4.5 inch alloy steel induction hardened
pins through machined, line-bored holes. Shoes are designed specifically for the P&H sprocket
style drive system. Standard crawler shoes width is 52 inches (1321mm). Shoe width of 70 inch
(1778mm) is available. Cleated shoes are also available.

CRAWLER FRAMES
The frames are a heavy welded box section design with bolted fit to carbody under full shear
ledge support. There is no field welding required in the connection. There are eight (8) lower
rollers, a front, and a rear idler in each frame. The front idler is a large diameter manganese
casting, which is mounted on two (2) heavy duty bushings. Lower rollers and idlers are V-ring
sealed to exclude contaminants and hardened wear surfaces protect crawler frame wear. Rollers
and idlers are straddle mounted with special alloy brass bushings. Replaceable pin-on, high
hardness, wear resistant cast slide bars on top of each frame support the crawler shoes.

CARBODY
The carbody is a heavy welded high strength low alloy steel structure of cellular deep box
sections, built around a large center hub casting. The flat-top design with deep section
diaphragm plates provides direct support of roller path. Carbody interior is painted white and is
equipped with an electrical convenience outlet for trouble light use. Swing gear and lower swing
roller path are mounted on the top of the carbody with dowels and bolts. The crawler frames are
connected to the carbody by a full-length shear ledge and long rod bolts. Both carbody and
crawler frames designed to withstand the high level of crawler frame connection bolt tension.
The crawler frame connection bolts produce very high clamping forces between the crawler
frame and carbody machined surfaces. The standard tensioning system for the rod bolts consists
of a simple bolt and nut arrangement.

DUAL PLANETARY PROPEL SYSTEM

Dual independent P&H DC drive motors rated at 750hp/559kW total continuous power at 475V
and 1505hp/1122kW total peak developed horsepower, drive the propel system and are load
sharing controlled. Motors are mounted in a propel motor base which is bolted to the rear of the
carbody, and motor frame adjusting screws are integral to the base for ease of alignment, and the
motors are directly connected to P&H planetary propel transmissions with a gear coupling. The
planetary propel transmissions are directly mounted to each crawler frame, and provide

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 Model 2300XPA
Technical Description

differential speed and counter-rotational steering capability. All gearing is forged, anti-friction
bearing mounted, and all external gears are case hardened and ground.

The P&H tumbler drive system has a raised final propel drive shaft and tumbler. The final
propel drive shaft is spline connected to the planetary transmission and tumbler, and is mounted
on anti-friction bearings. The outboard spherical bearing is encapsulated to prevent crawler frame
damage in the event of a bearing failure. V-ring seals are used to seal out dirt and seal in
lubricant.

CENTER GUDGEON
The Center Gudgeon is a hollow heavy-duty forging used to connect the upper revolving frame to
the lower carbody. Acme threads are provided on the upper end of the gudgeon. The gudgeon is a
cascaded interference type fit in the center hub casting of the carbody. A locking mechanism on
the upper threads allows fine adjustment capabilities and positive retention of nut position. The
gudgeon center hole is used for electrical wiring, lube, and air-lines between revolving frame and
lower machinery.

REVOLVING FRAME
The revolving frame is a heavy welded high strength low alloy steel structure of cellular deep
box sections built around a large center casting. The rolled, full depth internal turret plates align
with the swing roller path and provide 360° direct load transfer. Roller path support pad on
frame underside provides a pilot ring to prevent radial movement of the upper path. Deck
machinery is welded to the deck or mounted via tapped holes. No internal access is required to
mount the machinery. A standard drain system allows for the hoist and swing transmissions to
be evacuated through piping to below the revolving frame deck.

COUNTERWEIGHT BOX
A sectioned counterweight box is mounted to the rear of the revolving frame to accommodate the
counterweight ballast.

DECK PLAN
Side platforms, which mount to the revolving frame, extend the deck width. Conveniently
arranged floor plan with abundant space facilitates maintenance.

ELECTRONICS ROOM
A separate large room is mounted on front right corner of the revolving frame and houses the
supervisory control cabinet and auxiliary cabinet. It is insulated with 0.5 inch/12.7mm material;
equipped with 0.75 hp fresh air blower (not used with optional air conditioner) and louvered
front wall vent panel. Access to the electronics room is provided via one door within the
machinery house. The RH room also is the support base for the RH elevated operator’s cab.

LUBRICATION ROOM

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A separate room is mounted on front left corner of the revolving frame, which houses lube tanks,
pumps, plumbing, and controls (remote I/O connection for lube system monitoring and control);
and most air system components. Room is insulated with 0.5 inch/12.7mm material, and can be
optionally heated for improved cold weather operation.

MACHINERY HOUSE
Truss style roof with weather tight, removable hatch covers for accessibility to internal
machinery. Roof panels are strategically located to direct crane picks of major deck mounted
components as required.

HOUSE PRESSURIZATION AND FILTRATION

House is pressurized and air is filtered by a high efficiency inertial filter system.

COLD WEATHER EQUIPMENT

The RH and LH rooms are equipped with insulation as a standard feature. The air valves for the
lower works are located in the heated lower control box as standard. Heating options are
available.

BOARDING AND ACCESS

A right side pneumatic controlled stairway and left side vertical pull-down ladder are interlocked
to de-energize swing and propel functions when in down position for safety. Catwalk/platforms,
with grated metal surface, hand rails, and toe boards are provided in access areas. Roof grating is
welded to roof panels.

HOIST DRIVE SYSTEM

Dual P&H DC motors rated at 1340hp/1000kW total continuous power at 475V and
1820hp/1357kW total peak developed power drive a gearcase welded to the revolving frame.
The first reduction is a helical gear set and the second reduction consists of a spur and a
reversible spur drum gear. All gearing is forged, machined, case hardened and ground.
Transmission is oil tight with anti-friction bearings and standard oil filtration and circulation
system. Gearing is splash lubricated. A lube pump and filtration system is standard, and is
designed for use with high viscosity lubricants, even in cold temperatures.

The hoist drum is a large 56 inch (1422 mm) pitch diameter drum with through shaft and flame
hardened grooves. Standard hoist rope is 2.25 inch (57 mm) diameter cable fully plastic
impregnated and compacted. Hoist drum and cable are provided with high capacity Ferrule
Beckett fittings to simplify cable change out. Hoist limits are programmable from operator's cab.
Hoist drum bearings can be equipped for temperature monitoring.

HOIST CABLE TUGGER

An air driven tugger is standard to assist with hoist cable changes. Standard tugger configuration
is a single 2000 lb.(907 kg) rated winch.

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 Model 2300XPA
Technical Description

SWING DRIVE SYSTEM

Swing power is provided by two (2) P&H DC drive motors rated at 510hp/380kW total
continuous power at 475V and 1000hp/746kW total peak developed power and are connected in
series. P&H spur gear transmissions are mounted front and rear of swing gear for even loading.

Swing shafts are mounted on anti-friction bearings and are removable without disturbing the
transmission. Forged swing gear has 191 inch/4848 mm diameter with a large 10 inch/254mm
tooth face width. Swing circle uses a quantity of 54 tapered rollers, carried on self-lubricating
bushings. Rollers and roller paths are high alloy steel, forged, and quenched and tempered to a
high hardness. Full circle of rollers are in contact with the 360° upper and 360° lower roller
paths which have a wide mounting surface to the carbody and revolving frame. Upper path is
dual flanged mounted, and the lower path is clip mounted to the carbody on the inner diameter
and retained by the ring gear outer diameter.

CENTALIZED LUBRICATION SYSTEM

An automatic centralized lubrication system is standard and provides metered amounts of
lubricant to all major systems requiring grease and open gear lubrication. Lincoln 75:1 ratio air
drive pumps are used. Lube system, is programmable industrial controller controlled and is
monitored through touch-screen MMI’s. Large 106 gallon open gear and 106 gallon grease
maximize operating time. All gear cases are designed with bath and splash lubrication to all
gearing and bearings. A lube filtration system is standard for the hoist gear case.

AIR SYSTEM
Compressed air is provided for lube pumps, lube sprayers, disc brakes, hoist cable tugger, air
operated stairway, horn, and operators seat. Standard air compressor is a Quincy model F350, 10
HP, 37.4 CFMFA at 50HZ, floor mounted, with separate 120 gallon capacity air. The F350 can
be outfitted for cold weather operation. Other air compressors are available.

BRAKES
All motions have disc brakes which are spring set-air released. Brakes have replaceable wear
surfaces, and a low abrasion, high heat capacity friction material is used. Select brakes are
equipped with centering mechanisms to minimize contact of frictional surfaces when brake is
released.

BOOM
The boom is a 50 foot- (15.24m) length set at a 45° angle; welded structure of high strength low
alloy steel for cold weather toughness; extra width and depth for high load capability; 85 inch
(2159mm) diameter point sheaves, split bearing block mounted for maintenance ease. Boom
suspension cables are 2.75 inch (70 mm) structural strand. Integral lifting lugs and wear resistant
side boxes are incorporated. Boom is connected to revolving frame lugs with heavy duty
lubricated pins retained with split collars. Boom bumpers are mounted to the boom to reduce
damage from contact with the dipper.

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 Model 2300XPA
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CROWD SYSTEM
Crowd and retract of the dipper is accomplished by one (1) P&H DC motor rated at
400hp/298kW continuous power at 475V and 490hp/365kW peak developed power driving the
P&H - POWERBAND "V" BELT - shock absorbing/system to modular, enclosed, transmission
with spur gear reduction to manganese racks and forged, machined and hardened crowd pinions.
V-belt sheaves are fully machined and balanced. Gearing is forged, case hardened and ground;
mounted with encapsulated, pre-adjusted bearings. Single piece saddle blocks are hydraulically
adjusted and allow for removal of crowd pinions. Crowd/retract limits programmable from
operator's cab.

DIPPER HANDLE
The dipper handle is a 31 ft 10 in (9.70m) effective length; high strength low alloy, cold weather
steel; straddle design, with straight legs and large cast manganese racks providing strength for
corner tooth digging loads. Handle geometry provides for torsion box clearance with the boom.
A stress relieved handle is available for cold temperature and high impact applications when
specified.

DIPPER TRIP
Dipper trip system is a durable 15HP/11kW, AC wound rotor motor drive through spur gearing
to a heavy duty drum. Both ferrule becket and cable clamp connection capability is provided for
securing dipper trip cable to the drum. Trip line is connected to dipper latch lever bar a handle
mounted banjo arm.

DIPPER
Dippers have been designed specifically for the 2300XPA for proper filling and low cost of
operation. Standard equipment on the dippers include pitch braces and P&H friction disc
snubbers to prevent damaging dipper door closing impact. Nominal rated dipper size is 27 cubic
yard ( 20.65 cubic meters ).

PAINT
Standard exterior is P&H Yellow and Black. Yellow on machinery house and operator’s cab.
Black on lower, attachment, catwalks and handrail. (Lower HV disconnect switch is painted
red). Interior of house, RH and LH rooms, carbody, revolving frame and lower boom section and
all electrical cabinet interiors are painted high visibility white.

WEIGHTS
Working weight of the P&H Model 2300XPA with nominal dipper and 52 inch (1321mm) wide
crawler shoes is 1,650,000 lbs. (748,427 kg.)

OPTIONAL ITEMS DESCRIPTIONS

OPERATOR CAB

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 Model 2300XPA
Technical Description

• Pull down mylar shades (front window only)

• Pull down mylar shades (all windows)
• Front window, laminated safety glass (0.750” thick)
• Front window, laminated safety glass (1.188” thick)
• Cigarette lighter and ashtray – to be used for 12V power supply for convenience.
• Passenger seat in rear of cab for convenience
• Table for operator and mine personnel convenience.
• Single air horn on RH room

AIR CONDITIONER
• Mine Air Systems unit for operator’s cab only (RH or LH); Model MAS 1000
• Mine Air Systems units for operator’s cab (RH or LH) and RH electronics room; two (2)
Model MAS 1000 units
• Sigma unit for operator’s cab (RH cab only); one Model MPV9
• Sigma unit for operator’s cab (RH cab only) and RH electronics room; two (2) Model MPV9
units

FIRE SUPPRESSION
• Fire extinguisher, 20lb. Dry chemical, Model 1-A-20G, (3 are standard)

TRAIL CABLE REEL

• P&H Power Reel (Harnaust Mfg.), air drive trail cable reel
• Cable reel (IWM Mfg.), hydraulic over electric drive
• Mounting material for P&H Power Reel trail cable reel

COLD WEATHER EQUIPMENT

• 2.5cm / 1 inch insulatin in machinery house
• Standard Heater/defroster ducting in cab directed to operators feet and front window
• Standard 7.5KW heater in operator’s cab
• 7.5 KW heater in RH electrical room
• 7.5 KW heater in LH lube room
• Strip heaters for main control cabinets
• Strip heaters for main D.C. motors
• Strip heaters for main transformers
• 40 KW machinery house heater maximum of 3

MISCELLANEOUS ELECTRICAL
• Extended upper temperature monitoring system – standard plus crowd gearcase bearings,
hoist gearcase bearings, swing shaft bearings, gearcase oil (5 cases), boom shipper shaft
bearing, and center gudgeon hub.
• Extended lower temperature monitoring system – standard plus over temperature indication
for final drive bearings and gearcase oil (2 cases).

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• P&H Optidig II operator assist tool that co-ordinates the hoist and crowd motions to prevent
the dipper from stalling while digging.
• Electrical cabinet filters for RPC and converter cabinets - fitted to the cabinet doors and
provide an additional level of filtration for the electrical components.
• Hoist control with variable speed control in machinery house - allows hoist system to be
operated within view of the drum to improve ease of hoist rope change outs.
• Extra welder outlet in machinery house, near LH door. (60HZ, 460V or 50HZ, 380V) – price
each, 2 max
• Ground fault protection for welder outlets – price each, 3 max
• Emergency lighting unit (two lights per unit), each:
− Without installation wiring
− With installation wiring
• Communication system, 3-way
• Trailing cable connector extension with PLM cable coupler (w/o cable) (Not for use with trail
cable reel) - exetends cable coupling connection from the lower high voltage disconnect
cabinet to a convenient location by the propel motor base.

MISCELLANEOUS MECHNICAL
• Wiggins quick fill connectors for lube tanks, mounted on outside front lube room wall (note:
deducts standard 2” cam lock fittings) to allow quicker fill of the two lubricant reservoirs.
• Central drain system for hoist and swing transmissions (crowd drain to boom foot platform
standard) - allows for all systems to be drained to a convenient central location.
• Air hose reel w/30m/100ft of hose - conveniently mounted in the machinery house as a
general purpose air supply, and features a filter, regulator, and 50 feet (15.2 m) of hose on a
retractable reel.
• Two (2) rectangular 16.50” x 24.75”, convex mirrors - (two supplied), mounted on the
shovel, one on the right side near the operators cab, and the second above the LH room, to
provide additional visibility for the operator.
• Tow lug on front of carbody, field installed
• Tow lugs, two (2) on rear of carbody, field installed
• SUPERBOLT® tensioning system for rod bolt connection for crawler frames
• HYTORQ® tensioning system for rod bolt connection for crawler frames.
• Counterweight ballast (265 lbs/cu. Ft. minimum density)
• Export packing

TOOLS, TEST EQUIPMENT, AND ASSEMBLY AIDS

• HiTorq tooling to be used with hydraulic pack

TECHNICAL DOCUMENTATION
As standard, each P&H shovel Purchaser is supplied in English language, the following
documents:

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 Model 2300XPA
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• Operator Manual (electronic format on CD and in hard copy)

• Mechanical Systems Manual (electronic format on CD, hard copy optional)
• Link-One format Electrical Data and Wiring Listing
• Link-One format Electronic Parts Manual

CUSTOMER SUPPLY ITEMS

Unless otherwise stated in a P&H proposal, required items, not included in our basic machine
supply are:
• Machine erection, including erection tools and equipment
• Counterweight ballast with a minimum density of 265 lbs. per cubic foot (4,245 kg/m3) (Final
counterweight determined by application.)
• Fluids/lubricants
• Trailing cable and electrical power supply.

*****

P&H - An enduring symbol of quality and reliability

NOTE: All designs, specifications and components of equipment described above are subject to change at manufacturer’s
sole discretion at any time without advance notice. Data published herein is informational in nature and shall not be construed to
warrant suitability of machine for any particular purpose as performance may vary with conditions encountered. The only warranty
applicable is our standard written warranty for this machine.

Tech Desc 2300XPA.doc Page 14 of 14

 Assembly Procedure

assembly Assistance
With the purchase of your Model 4100XPC electric mining shovel,
a P&H MinePro Services advisor will be provided for a period of 50
working days to assist the purchaser or the purchaser’s assembly
contractor with the assembly of the machine. The purchaser should
arrange to assemble, test and place the machine into operation during
this 50 day period. 4100XPC

The P&H MinePro Services advisor can provide advice only. He

is available to advise the purchaser or the purchaser’s assembly
contractor on assembly sequences, commissioning procedures, testing
and other assembly details as requested, but is not authorized to
supervise workers or to direct the assembly, testing or commission- SAFETY: All safety related equipment requirements and procedures are
ing in any way. The purchaser will be required to provide all tools, the responsibility of the Purchaser and or designated Assembly
equipment and personnel needed to assemble the machine, as well Contractor and should be in accordance with all applicable
as supervision of personnel erecting the machine. For example, MSHA, Local Mine, State Authorities and regulations.
the P&H MinePro Services advisor is available to consult with NOTE: The purchaser is to supply all necessary start-up lubrication
supervisory personnel on questions such as places to make hitches materials, oils, greases, etc., per P&H specifications.
on components, but P&H Mining Equipment will not be responsible
for placement of such hitching or for working with lifting equipment.
P&H Mining Equipment will not be liable in any event for any indirect, Site and Material Location
special or consequential damages. Purchaser shall indemnify and hold
P&H Mining Equipment harmless for all liability for damage to property Assembly site preparation is the responsibility of the Purchaser and
or personal injury (including death) arising out of purchaser’s assembly, should be a flat leveled area, with good drainage, and stable under
testing or placing into service of the machine. footing to support the lifting equipment and their floats or outriggers
The P&H MinePro Services advisor is not authorized to approve during any lift to be made.
modifications to the machine that are not covered by the machine The area required is approximately 300 feet (91.4 m) square, with a
data sheet, nor will P&H Mining Equipment accept any back-charge tool shed.
for any unauthorized modifications made. (See section titled “Machine
Modification Procedure”.)
The purchaser or the purchaser’s assembly contractor should contact Machine Modification Procedure
the nearest P&H Mining Equipment regional office to schedule the P&H
MinePro Services advisor. We ask the purchaser, prior to the arrival During the shovel assembly process, the shovel purchaser will
of P&H MinePro Services advisor, to issue a purchase order covering sometimes request alterations to the standard machine design. Some
the P&H MinePro Services advisor. The first 50 normal working days of the more-commonly requested modifications affect lubrication
will be on a no charge basis. Any days beyond the first 50 days will be systems, walkways, hand rails, lighting systems and guards.
charged against the purchase order at established service rates. While some modifications might improve the ability of the purchaser
The normal working day for the P&H MinePro Services advisor is to utilize and maintain the shovel, some modifications might in fact
eight hours on site per day. The normal work week is five days per adversely affect productivity over time or have significant safety impli-
week (Monday through Friday excluding holidays). Time spent on cations not readily ascertainable.
site beyond the normal work week or day will be charged against the Accordingly, it is imperative that any modifications sought by the
purchase order at established service overtime rates. shovel purchaser of the kind noted above (or any other significant
modifications) be discussed with your P&H MinePro Services
shovel project manager. In turn, your shovel project manager will
assembly Personnel Requirements discuss your requests with P&H Mining Equipment shovel design
engineers to determine if the modifications can be carried out. P&H
The assembly history for the Model 4100XPC indicates assembly Mining Equipment and P&H MinePro Services make every effort to
can be made within 5200-5500 man-hours. The history also indicates accommodate the purchaser’s requests while taking into consider-
that if proper manpower is not available, the 50 working day period of ation the machine’s optimal productivity and mine application, as well
assembly and placement into operation will be exceeded. We therefore as current design and safety specifications and regulations.
advise that the following labor types be available at various stages of It is most important that any modification to the machine be
machine assembly. documented so that P&H Mining Equipment and P&H MinePro
4 – Laborers (for the purpose of 4 – Mechanics / Millwrights Services can maintain current drawings and specifications for your
cleaning parts before they 4 – Electricians electric shovel. Furthermore, any future service involving the P&H
undergo assembly) 3 – Welders Mining Equipment engineering staff can be expedited if modifications
are known and documented.
After the initial cleaning and opening of the packing cases, the four Please be aware that any modification performed without P&H Mining
laborers may be replaced by additional mechanics and millwrights, as Equipment and P&H MinePro Services concurrence might void the
the tasks of the mechanics and millwrights will be more prevalent. warranty.
We have not included the supervision mentioned previously. The Some modifications requested by the purchaser can be accommo-
necessary mechanical and electrical supervision should be present dated at no additional charge. However, some modifications require
when the various trades are involved in the assembly of the machine. additional welding or other services that cannot be absorbed by P&H
This listing does not include crane operators or oilers (if there is a Mining Equipment or P&H MinePro Services. The purchaser will be
requirement for their use). notified of such costs in advance of the work being performed.
 BASIC RIGGING MATERIAL REQUIREMENTS BASIC TOOL REQUIREMENTS (continued)
Cranes 6 — 6 ton come-alongs
Two (2) heavy-lift cranes are required at the start of the assembly, 6 — 1/5 ton come-alongs
staying on-site until all the heavy lifts are completed and the boom 4 — 3/4 ton come-alongs
has been pinned to the revolving frame. After raising the boom, the 2 — 1/2" torque wrenches
balance of the assembly process can proceed with one (1) rough- 1 — 3/4" torque wrench
terrain crane in the 30-ton to 50-ton (27,216-kg to 45,360-kg) class. 1 — 1" torque wrench
1 — torque multiplier 181/2 : 1
Heavy-lift crane size requirements are based on many factors, 1 — 48" aluminum pipe wrench
including crane access to heavy lifts, type of crane used, cold 2 — 24" pipe wrenches
weather capacity de-rating, reach, and pick-and-carry capability. 1 — 24" aluminum pipe wrench
1 — 24" chain wrench
Therefore, in extreme cold weather environments, two 225-ton 1 — 24" crescent wrench
(204,120-kg) cranes are recommended. In moderate weather, one 1 — open end wrenches 5/16" through 21/2" in 1/16" increments
150-ton (136,080 kg) and one 190-ton (172,368-kg) crane are 1 — hammer wrenches 11/8" through 31/8" in 1/16" increments
recommended for heavy lifts. 1 — 4" hammer wrench
Cables / Slings Basic Power Tools
4 — 2-1/2" x 25' 4 — 1-3/4" x 20' 4 — 1-1/2" x 20' 1 — pneumatic air wrench, 1/2" drive, with sockets from 1/2" to 11/4",
in 1/8" increments
4 — 1" x 12' 2 — 1-1/2" x 20' 4 — 3/4" x 10' 1 — spray paint gun
2 — 1-1/4" x 20' 2 — 5/8" x 20' 1 — air powered grinder, 9" right angle disc
10 — smaller cables (1/2" and 3/8", 15' long) to handle the misc. 1 — air powered 1/4" pencil grinder
material, such as brakes, blower motors, boxes, cab sections, 1 — air powered chipping hammer w/chisels
etc. 1 — welding machine, 400 amp capacity (portable gasoline or
Assortment of nylon slings diesel driven), including 100' long welding cables
1 — portable air compressor, 150 CFM capacity, with 2 ea. 100'
Shackles and Pins long hoses with inline oilers
2 — 85-ton shackles 4 — 55-ton shackles 1 — portable light plant or electric power supply if needed
4 — 35-ton shackles 4 — 25-ton shackles 1 — electric heated rod oven
Pins – six (6) each in the following sizes: 1/4", 3/8", 1/2", 3/4", 1" 2 — oxygen/acetylene burning sets with 75' hose
2 — 50-ton hydraulic jacks
Blocking (Hardwood) 2 — 1/2" electric drills
40 ea. 8" x 8" or 10" x 10" in 6', 4', and 2' lengths 2 — 1/2" cordless drills
Plywood and 2" lumber (available from shipping crates / boxes) 1 — 1/2" angle drill
This material is used for setting the various components on 2 — 3/8" electric drills
the ground. The carbody is blocked 48" high for side frame 1 — magnetic drill
clearance with shoes on. 1 — 11/2" drive pneumatic impact wrench
Optional Time-Saving Equipment 2 — 1" drive pneumatic impact wrenches
1 — 10-ton* (9.072 kg.) forklift. 1 — 3/4" Super-bolt impact wrench
2 — 3/4" drive pneumatic wrenches
4 — 1/4" die grinders
9 — 5" grinders
BASIC tool REQUIREMENTS 5 — 7" grinders
2 — straight grinders
Basic Hand Tools
Basic Electrical Tools 2 — reciprocating saws
2 — 6" screwdrivers 1/4" face 1 — knock out punch set 1 — soldering gun
2 — 8" screwdrivers 3/8" face 1 — hydraulic hand pump 6 — 600 amp welders
2 — 12" screwdrivers 1/2" face knock out punch kit 4 — wire feeders
2 — 15" adjustable open end wrenches 1 — hole saw kit 4 — air arcs
2 — 12" adjustable open end wrenches 2 — manual Crimpers 1 — diesel genset - 300 kW
4 — 12" long bastard files 1 — hydraulic crimpers
6 — 4" paint brushes for use with cleaning solvent 3 — heat guns
1 — crosscut saw
3 — 36" wrecking bars Miscellaneous Items 100 — lbs. 3/32" weld rod
2 — 20 lb. sledge hammers 3 — tarpaulins, 30' x 30' 300 — lbs. 1/8" weld rod
4 — 2 lb. ball peen hammers 2 — 12' step ladders - straight 200 — lbs. 3/16" weld rod
6 — putty knives 3" wide 2 — 20' extension ladders (low hydrogen, pre-dried)
1 — heavy-duty mechanic’s tool set 2 — barrels of cleaning solvent 300 — feet manila rope
2 — wire brushes 20 — rolls masking tape 1" 100 — lbs. cleaning rags
3 — each tapered drifts, 12" long, 5/8" and 5/8" dia. 50 — sheets of fine emery cloth 2000 — lbs. (approx.) dry ice
2 — 1/2" drive socket wrench sets, including two extensions, 50 — sheets of medium emery (the exact quantity
ratchet and sockets, from 7/16" to 11/4", in 1/8" increments cloth required will depend
13/4" drive socket wrench set, including ratchet and sockets, 2 — wooden stairway with upon location of
from 1" to 3", in 1/8" increments railing for boarding source and ambient
25 — rolls black plastic electrical temperature)
6 — 3-ton come-alongs
tape — or —
2 — standard bolt tap set—1/4" to 11/2" in 1/8" increments Liquid Nitrogen - 4 bottles,
25 — rolls of friction tape
2 — drill bit set—3/16" to 5/8" in standard increments 5 — anti-seize lubricant (cans) approximately 370 lbs.
1 — set of rotary files for pencil grinder 5 — dye check kits for of product each bottle
1 — 3/4" drive breaker bar checking welds (NDT-PT) and must have liquid
1 — 1" drive breaker bar 6 — fire extinguishers—20 lb. withdrawal capabilities
1 — 1" drive socket wrench set, ratchet and sockets, from 11/16" dry chemical type 3 — 6-foot step ladder
through 31/2" in 1/16" increments 3 — 8-foot step ladder
1 — 1" Swivel Painting supplies
1 — 11/2" Swivel Assorted-color electrical tape
1 — 1” to 11/2" Adapter
1 — 11/2" to 1" Adapter The above tool listing indicates the basic minimum range and quantity
1 — set of 11/2" drive sockets from 2" through 4¾" in 1/16" of tools recommended. The list is not intended to be all-inclusive.
increments Data Codes
Extensions: 2 — 3/4" drive by 8", 1— 3/4" drive by 13", *1 ton = 2,000 pounds (907.2 kg)
2 — 1" drive by 8", 1 — 1" drive by 13", 1 — 11/2" drive by 12" 10' = 10 feet (305 cm) 10" = 10 inches (25.4 cm)
 4100XPC Lifting or Hitching Points and approximate weights* of major items
99,000 lbs. 64,000 lbs.
(44,906 kg) (29,030 kg)
w/o Trans Pick point note: w/o Trans
Use both outer holes of this one
lug when lifting in this position. Pick point note:
The side loading to any welded-on
Use this one lug when lifting lug cannot exceed ±5° from the vertical.
lifting in this position.
* Weights are ±10%. For actual weight of each component, refer to packing list.

Crawler (top view shown) w/o Trans w/o Shoes-Weight: 163,000 (73,937 kg)

125,875 lbs. 61,225 lbs. Crawler shoes:76" (1.93 m)

(57,097 kg) (27,772 kg)
w/ trans w/ trans 42 Shoes each Belt - Weight: 165,100 lbs.
(74,888 kg)
Pick point note:
Use both outer holes of this one
lug when lifting in this position. Pick point note: Crawler shoes: 87" (2.21 m)
12'-0" Use this one lug when 42 Shoes each Belt - Weight: 175,000 Lbs.
(3.66 m) lifting in this position. (79,379 Kg.)

Center Gudgeon
Crawler (top view shown) w/o Shoes-Weight: 187,100 (84,869 kg) Weight: 9,050 lbs. (4,105 kg)

36'-8" 22"
(11.18 m) (559 mm) 12" (305 mm)
Pick point note:
7'-8" Use both lugs
(2.33 m) (one each side) 123.25"
when lifting in (3.13 m)
this position.
Crawler Frame w/o Shoes Dry ice to freeze center gudgeon (shown above) for
Pick point note: field installation into carbody. The quantity will depend
Use only top on location of supplier, and ambient temperature.
holes of these 98,650 lbs. 98,650 lbs.
lugs (one each (44,747 kg) (44,747 kg) Carbody
side) when lifting
in this position. Total Weight:
197,300 lbs.
(44,747 kg) } Includes:
Swing Roller Carrier Ring
Lower Swing Roller Path

98,650 lbs. 98,650 lbs.

(44,747 kg) (44,747 kg)

16'-3"
(4.95 m)
20'-0"
8'-1" (6.10 m)
(2.45 m)

24'-7" 16'-8"
(7.49 m) (5.08 m) 17'-5"
(5.31 m)
88,880 lbs. 124,120 lbs. 76 yd (58.1 m3) Bail Type Dipper
3

(40,316 kg) CL Rotation (56,301 kg) 175,000 lbs.

(79,380 kg)

Typical values only; there is no standard dipper.

11'-4"
(3.45 m)

48,025 lbs. 48,025 lbs.

(21,784 kg) (21,784 kg)
35'-6"
(10.82 m)
213,000 lbs. (96,617 kg)
31'-10"
(9.69 m)

Revolving Frame w/Sidestand

99,600 lbs. Includes: 113,400 lbs.

(45,179 kg) Upper Roller Path (51,438 kg)
Misc. Wiring Troughs 13'-0"
(3.96 m)

Total Weight
96,050 lbs.
(43,568 kg)
15'-1"
(4.6 m)

5'-0" 5'-8"
(1.52 m) (1.71 m)

Counterweight Box
4100XPC Lifting or Hitching Points and approximate weights* of major items

Note: Use these machined holes as hitch

points. Do not use the welded-on lugs to The side loading to any
raise the boom.
welded-on lifting lug cannot exceed
13'-11"
±5° from the vertical.
(4.24 m)
* Weights are ±10%. For actual weight of each component, refer to
packing list.
68'-0"
(20.73 m)

63,500 lbs. 82,500 lbs.

(28,804 kg) (37,422 kg)
Bare Bare

9'-5"
(2.86 m)

Bare Boom includes:

Fully Dressed Bare – Lube material
247,500 lbs. 146,000 lbs.
(112,266 kg) (66,226 kg)
Fully-dressed Boom includes:
**133,000 lbs. – Boom Point Assembly
(60,328 kg) – Crowd Machinery
Fully Dressed – Hoist Rope Guide
– Dipper Trip Machinery
– Catwalks

** Hitch point load encountered when raising a

fully-dressed boom into position.

Handle Layout

10'-6"
(3.20 m)

40'-11"
(12.47 m)

36,170 lbs. 61,330 lbs.

(16,407 kg) (27,819 kg)

14'-4"
(4.36 m)

7'-7"
(2.31 m)

97,500 lbs.
(44,226 kg)

Counterweight Slabs

4'-10"
(1.47 m)
2'-6" 2'-10" 1'-11"
(.76 m) (.86 m) (.58 m)

24,400 lbs. 24,400 lbs. 24,610 lbs. 24,610 lbs. 25,060 lbs. 25,060 lbs. 18,110 lbs. 32,590 lbs.
(11,091 kg) (11,091 kg) (11,187 kg) (11,187 kg) (11,391 kg) (11,391 kg) (8,232 kg) (14,813 kg)

10'-0" 10'-0" 10'-0" 8'-8" 8'-8"

(3.05 m) (3.05 m) (3.05 m) (2.64 m) (2.64 m)

5'-0" (1.52 m) 6'-6" (1.98 m) 7'-0" (2.13 m) 6'-7" (1.96 m)

48,800 lbs. (22,182 kg) 49,220 lbs. (22,373 kg) 50,120 lbs. (22,782 kg) 50,700 lbs. (23,045 kg)
Center “&” Section (1) Inner-Mid “P” Section (1) Outer-Mid Sections (2) Wing Sections (2)
Inner-Mid “H” Section (1)
 site layout

95

120 118 DIPPER

116 Figure 1 depicts the recommended placement
121 119 of parts at the assembly site. Each item shown
90 is numbered and refers to the Component List
(Tables 1 and 2) which give the approximate
23 weights of the components. For the actual
85 weights, refer to the machine packing list.
42 43

HANDLE
DIPPER
80

51 26
55 149
75 130 134 54
56 150 179
131 135 156
132 136 154 155
57 52
133 137 152
70
138 142 147
69 70

112 112 140

65
127 145 146 141 151 175 178
158 165
82 128 76 40 144
159 164
60 COUNTER WEIGHT 76 143
185 63
BOX 160 163
63 34 16 77
31 71 72
64 161 162
85
55 38 64
49 35 34 166 168
47 65 98 169 170
65
41 99
66 74 171 172
50
21 REVOLVING 173 174
FRAME
22 15
96
4 HOIST
45 153 97 24 CASE
CRAWLER CRAWLER RING
183 SHOES S S SHOES GEAR
58 100 I I 17
176 D D 180 74 78
177 E CARBODY E 25
40 102
22 1 181 HOIST
182 F F 184 DRUM
103 R R 12
A A 18 115 73
TOOL
CONTAINER M M ROLLER 75 79
35 E E 30
CARRIER
13
PROPEL 167
7
LUNCH

MOTOR 5 6 95
ROOM

14
83
30 87 BASE 129 130 8 9 10
37 60
106 11 16 113 44
6 61 BOOM
19 107
25 13 127
93
126 32 GANTRY
14 104 108
105
29
GANTRY
20 124 122 33 TENSION
90 157 MEMBERS
125 123
91 36 139 28
110
15

NOTE 59
Electrical cabinets, transformers, BOOM
10 AC & DC motors, etc. must be POINT
stored under cover until required. SHEAVES
(67)

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
METERS
Figure 1
 4100XPC component list - US & Canada   Table 1
Site Approx Weight* Site Approx Weight*
Location Description of Contents Lbs. Kg Location Description of Contents Lbs. Kg
Carbody Components Revolving frame Components (continued)
129 Cabinet - Control - Lower - Skid 740 336 138 Hoist Gear Case - I/O Cabinet Assy - Box 390 177
130 Cabinet - Switch - Lower Disc. - Box 1,042 473 24 Hoist Gear Case Assembly - Pc 37,000 16783
1 Carbody - Lower - Pc 195,000 88452 79 Hoist Motor Assembly Hardware - Box 524 238
62 Carbody Stairs Installation - Skid 570 259 74 Hoist Motor Base - Skid 6,070 2753
18 Center Gudgeon Assembly - Box 13,800 6260 75 Hoist Motor Base - Skid 6,070 2753
2 Crawler - L/H (w/o Transmission) - Pc 164,400 74572 78 Hoist Motor Front - (K1980) - Skid 20,640 9362
3 Crawler - R/H (w/o Transmission) - Pc 164,400 74572 78 Hoist Motor Front (K1690) - Skid 19,125 8675
xx Crawler Frame Dowel Rod Bolts - Box 2,820 1279 79 Hoist Motor Rear - (K1980) - Skid 20,640 9362
6 Crawler Frame Installation (Bolts) - Box 11,400 5171 79 Hoist Motor Rear (K1690) - Skid 19,125 8675
14 Crawler Shoe Pin Hardware - Box 1,376 624 145 Hood Half - Rear Roof ( 1 of 2 ) - Skid 4,140 1878
13 Crawler Shoe Pins #1 - Box 6,262 2840 146 Hood Half - Rear Roof ( 2 of 2 ) - Skid 4,140 1878
13 Crawler Shoe Pins #2 - Box 6,202 2813 112 House - Angle, Jacking Installation - Box 884 401
14 Crawler Shoe Pins #3 - Box 6,202 2813 54 House - Center Beam - Skid 4,800 2177
Crawler Shoes - Shipped Direct - appx 42 skids @ 8,000 lbs ea 149 House - Center Front Panel - Skid 2,060 934
5 Propel Motors & Base Assembly - Pc 43,000 19505 150 House - Hatch Cover Front - L/H - Skid 1,460 662
29 Propel Transmission (1 of 2) - Skid 25,000 11340 158 House - Hatch Cover Front - R/H - Skid 1,460 662
30 Propel Transmission (2 of 2) - Skid 25,000 11340 159 House - Hatch Covers - Box 5,765 2615
37 Propel Transmission Bolts - Hardware - Box 388 176 160 House - Installation Assembly - Box 3,000 1361
4 Swing - Ring Gear - Pc 23,000 10433 161 House - Panel - Front - L/H - Skid 1,000 454
7 Swing Component Installation - Box 3,112 1412 162 House - Panel - Front - R/H - Skid 1,000 454
8 Swing Rollers ( 1 of 3 ) - Box 2,322 1053 163 House - Panel - Rear Wall - Box 14,420 6541
9 Swing Rollers ( 2 of 3 ) - Box 2,322 1053 164 House - Panel - Side Wall - Box 8,760 3974
10 Swing Rollers ( 3 of 3 ) - Box 2,310 1048 20 House - Roof Grating - Box 2,540 1152
87 Tools - Hydraulic and Miscellaneous - Box 918 416 165 House - Shims / Covers - Box 382 173
179 Wiper Assembly - Roller Circle Inst. - Box 804 365 166 I-Beam Framing - Box 10,000 4536
167 L/H Room Assembly - Pc 20,500 9299
Revolving frame Components 58 Ladder - Vertical Pull-down - Skid 1,760 798
25 Air Compressor - Box 1,550 703 142 Light - Interior Installation - Box 922 418
180 Air Compressor - Duct Bleed Component - Box 274 124 184 Oil Seal Installation Kit - Box 264 120
181 Air Compressor Installation - Box 362 164 40 Operators Coop - Pc 11,860 5380
85 Air Conditioner / Plate Assembly - Box 3,394 1540 40 Ops Coop - Roof Grating Installation - Skid 420 191
182 Brake Removal Kit (Bolts under Platform) - Box 1,400 635 143 Ops Coop - Access Ladder - Skid 750 340
41 Buss Bar Assembly ( 1 of 2 ) - Box 1,460 662 144 Ops Coop - Awning Installation - Box 2,780 1261
41 Buss Bar Assembly ( 2 of 2 ) - Box 1,020 463 168 Plat Mdl. Assembly - Upper - Box 720 327
100 Cabinet - Converter - Skid 12,500 5670 35 Platform - R/H Room Elevated Platform - Pc 11,200 5080
98 Cabinet - High-Voltage - Skid 2,850 1293 34 Platform - Rear L/H - Pc 12,000 5443
97 Cabinet - Main Transformer - Skid 25,000 11340 72 Platform - Rear R/H - Pc 12,000 5443
102 Cabinet - R.P.C. - Skid 18,000 8165 169 Platform L/H Room - Pc 11,900 5398
101 Cabinet - Transfer - Contactor - Skid 1,514 687 128 Pressurization Sys. - Silencer Installation - Box 1,726 783
22 Catwalk - Air - Stair - Crate 2,040 925 127 Pressurization Sys. - Truss Hood - Skid 460 209
22 Catwalk - Operators Cab - Skid 2,480 1125 82 Pressurization System (AirScrubPro) - Pc 34,500 15649
21 Catwalk #1 - Skid 4,080 1851 71 R/H Room Assembly - Pc 19,500 8845
22 Catwalk #2 - Crate 4,740 2150 21 Railings - Crate 4,520 2050
147 Control Assembly Filter - Box 450 204 151 Revolving Frame - Lifting Lugs - Box 764 347
178 Controller - Stair Air R/H Assy. - Box 560 254 15 Revolving Frame - Upper - Pc 213,600 96889
177 Counterweight - Flat Stock - Filler - Box 202 92 170 Side Beams - Roof - Box 4,350 1973
31 Counterweight - Troughing - Box 3,060 1388 171 Sky Light (1 of 2) - Box 374 170
16 Counterweight Box - Pc 98,000 44453 172 Sky Light (2 of 2) - Box 168 76
47 Counterweight Mounting Bolts - Box 1,368 621 173 Sky Light Guards - Skid 348 158
63 Counterweight Slab ( & ) - Pc 50,000 22680 49 Slipring Mounting Parts - Box 752 341
64 Counterweight Slab ( H ) - Pc 50,000 22680 174 Stairway - Air / LWR - R/H - Skid 1,280 581
63 Counterweight Slab ( P ) - Pc 50,000 22680 22 Stairway - Air UPR/LWR/RH - Skid 1,996 905
64 Counterweight Slab Middle Section - Pc 50,000 22680 113 Swing Guards - Box 1,380 626
65 Counterweight Slab Middle Section - Pc 50,000 22680 76 Swing Installation Components - Box 3,112 1412
65 Counterweight Slab Wing Section - Pc 50,000 22680 152 Swing Motor Troughing - Box 708 321
66 Counterweight Slab Wing Section - Pc 50,000 22680 76 Swing Motors (3 units, ea. weighing) - Skid 10,000 4536
39 Crowd Motor Blower - Box 694 315 83 Swing Shaft ( 1 of 3 ) - Pc 5,440 2468
176 Crowd Transmission Lube - Box 729 331 84 Swing Shaft ( 2 of 3 ) - Pc 5,440 2468
116 Dipper Assembly Variable 44 Swing Shaft ( 3 of 3 ) - Pc 5,620 2549
141 Dirt Chute - Box 1,168 530 77 Swing Trans. (3 units, ea weighing) - Skid 12,750 5783
112 Dirt Chute - Hood Assembly - Box 518 235 153 Swing Transmission Drain Assembly - Box 438 199
140 Dirt Chute - Tube Assembly - Skid 256 116 38 Swivel Grease Assembly - Box 5,650 2563
185 Duct Swing Blower Assembly 440 200 154 Temperature Monitoring Kit - Box 538 244
130 Electrical - Cable - I/O Profibus Installation - Box 556 252 183 Transformer - Main - Duct Installation - Box 580 263
131 Electrical - Upper Cable Tray Installation - Box 1,005 456 99 Transformer - Auxilliary Field - Skid 6,532 2963
132 Electrical - Wire Installation - Loose ( 1 of 3 ) - Box 458 208 155 Winch - Elec. - Windshield Install - Box 956 434
133 Electrical - Wire Installation - Loose ( 2 of 3 ) - Box 1,096 497
134 Electrical - Wire Installation - Loose ( 3 of 3 ) - box 1,090 494 Boom/Handle Components
96 Electrical Shipping Materials - Box 373 169 95 Boom - Electrical Materials - Box 414 188
135 Floodlight Installation - 400W - Box 1,218 552 156 Boom - Jack Stands - Box 1,134 514
136 Floodlight Installation - 500W - Box 306 139 60 Boom - Trip Sheave Bracket Assembly - Skid 792 359
137 Floodlight Material - Box 336 152 19 Boom Assembly - Pc 148,000 67133
33 Gantry - Tension Members (2 units, each weighing) - Pc 9,800 4445 127 Boom Foot Pin Assembly - Box 2,226 1010
32 Gantry Assembly - Pc 35,900 16284 67 Boom Point Sheave Assembly - Pc 13,500 6124
28 Gantry Assembly Parts - Box 976 443 157 Cable - Hoist - Guide - Skid 2,186 992
175 Gantry Boot Assembly - Box 265 120 12 Cable - Hoist - Tugger Installation - Skid 2,880 1306
36 Gantry Platform Assembly - Skid 2,865 1300 104 Cable - Hoist ( 1 of 2 ) - Pc 6,240 2830
139 Gantry Platform Ladder Assembly - Skid 622 282 105 Cable - Hoist ( 2 of 2 ) - Pc 6,240 2830
73 Hoist Drum Assembly - Pc 53,000 24041 106 Cable - Suspension ( 1 of 2 ) - Pc 11,500 5216
17 Hoist Drum Assembly Cabinet Bracing Box 850 386 107 Cable - Suspension ( 2 of 2 ) - Pc 11,500 5216
51 Hoist Drum Guard Installation - Box 1,300 590 125 Catwalk - Lower Boom Assembly - Skid 1,366 620
 4100XPC component list - US & Canada   Table 1
Site Approx Weight* Site Approx Weight*
Location Description of Contents Lbs. Kg Location Description of Contents Lbs. Kg
Boom/Handle Components (continued) Boom/Handle Components (continued)
122 Catwalk - Platform - Boom - Skid 4,227 1917 42 Saddle Block ( 1 of 2 ) - Pc 11,500 5216
123 Catwalk - Sdl Blk / Lower Boom L/H - Skid 3,890 1765 43 Saddle Block ( 2 of 2 ) - Pc 11,500 5216
124 Catwalk - Sdl Blk / Lower Boom R/H - Skid 3,890 1765 90 Shipper Shaft - Box 16,600 7530
126 Crowd Drive Assembly - Box 1,442 654 110 Shipper Shaft Gear - Box 7,600 3447
93 Crowd Gear Case Cover - Pc 13,940 6323 59 Shipper Shaft Pinions - Box 4,610 2091
108 Crowd Motor and Base - Skid 14,800 6713 118 Snubber Kit (SnubRite) - ( 1 of 2 ) - Box 1,574 714
61 Dipper Trip Drum & Motor Assembly, R/H - Skid 2,234 1013 119 Snubber Kit (SnubRite) - ( 2 of 2 ) - Box 1,574 714
23 Handle - Dipper - Pc 99,870 45301 120 Snubber Mounting Kit (SnubRite) - Box 830 376
60 Handle - Sheave Bracket Assembly - Skid 782 355 122 Stairs - Boom - Skid 3,280 1488
121 Pitch Brace Assembly - Adjustable - Skid 3,365 1526

Weights are ±10%. For actual weight of each component, refer to packing list.

4100XPC component list - export   Table 2

Approx Approx
Weight* Weight*
Description of Contents Lbs. Kg Description of Contents Lbs. Kg
Carbody Components Revolving frame Components (continued)
Cabinet - Control - Lower - Skid 874 396 Electrical - Upper Cable Tray Installation - Box 1,864 846
Cabinet - Switch - Lower Disc. - Box 1,042 473 Electrical - Wire Installation - Loose ( 1 of 3 ) - Box 458 208
Carbody - Lower - Pc 195,000 88452 Electrical - Wire Installation - Loose ( 2 of 3 ) - Box 1,754 796
Carbody Stairs Installation - Skid 570 259 Electrical - Wire Installation - Loose ( 3 of 3 ) - Box 878 398
Center Gudgeon Assembly - Box 13,800 6260 Electrical Shipping Materials - Box 373 169
Crawler - L/H (w/o Transmission) - Pc 165,000 74844 Emergency Light Installation - Box 272 123
Crawler - R/H (w/o Transmission) - Pc 165,000 74844 Floodlight Installation - 400W - Box 1,286 583
Crawler Frame Dowel Rod Bolts - Box 2,820 1279 Floodlight Installation - 500W - Box 490 222
Crawler Frame Installation (Bolts) - Box 11,400 5171 Floodlight Material - Box 404 183
Crawler Shoe Pin Hardware - Box 1,376 624 Gantry - Tension Members (2 units, each weighing) - Pc 9,800 4445
Crawler Shoe Pins #1 - Box 6,316 2865 Gantry Assembly - Pc 35,900 16284
Crawler Shoe Pins #2 - Box 6,316 2865 Gantry Assembly Parts - Box 992 450
Crawler Shoe Pins #3 - Box 6,316 2865 Gantry Boot Assembly - Box 270 122
Crawler Shoes - Shipped Direct - appx 42 skids @ 8,000 lbs ea Gantry Platform Assembly - Skid 2,865 1300
Propel Motors & Base Assembly - Pc 43,000 19505 Gantry Platform Ladder Assembly - Skid 622 282
Propel Transmission (1 of 2) - Box 25,920 11757 Hoist Drum Assembly - Pc 53,000 24041
Propel Transmission (2 of 2) - Box 25,000 11340 Hoist Drum Assembly Cabinet Bracing - Box 1158 525
Propel Transmission Bolts - Hardware - Box 388 176 Hoist Drum Guard Installation - Box 1,300 590
Swing - Ring Gear - Pc 23,200 10524 Hoist Drum Lock Assembly - Box 2432 1103
Swing Component Installation - Box 3,112 1412 Hoist Gear Case - I/O Cabinet Assy - Box 390 177
Swing Rollers ( 1 of 3 ) - Box 2,356 1069 Hoist Gear Case Assembly - Pc 37,000 16783
Swing Rollers ( 2 of 3 ) - Box 2,356 1069 Hoist Motor Assembly Hardware - Box 524 238
Swing Rollers ( 3 of 3 ) - Box 2,356 1069 Hoist Motor Base - Skid 6,070 2753
Tools - Hydraulic and Miscellaneous - Box 992 450 Hoist Motor Base - Skid 6,070 2753
Wiper Assembly - Roller Circle Inst. - Box 868 394 Hoist Motor Front - (K1690) - Skid 20,240 9181
Revolving frame Components Hoist Motor Front - (K1980) - Skid 21,840 9907
Air Compressor - Box 1,586 719 Hoist Motor Rear - (K1690) - Skid 20,240 9181
Air Compressor - Duct Bleed Component - Box 278 126 Hoist Motor Rear - (K1980) - Skid 21,840 9907
Air Compressor Installation - Box 880 399 Hood - Rope Guide - Skid 1340 608
Air Conditioner / Plate Assembly - Box 3,980 1805 Hood Half - Rear Roof ( 1 of 2 ) - Skid 4,140 1878
Brake Removal Kit (Bolts under Platform) - Box 1,400 635 Hood Half - Rear Roof ( 2 of 2 ) - Skid 4,140 1878
Buss Bar Assembly ( 1 of 2 ) - Box 1,960 889 House - Angle, Jacking Installation - Box 908 412
Cabinet - Converter - Skid 12,500 5670 House - Center Beam - Skid 4,950 2245
Cabinet - High-Voltage - Box 4,200 1905 House - Center Front Panel - Skid 2,060 934
Cabinet - Main Transformer - Skid 27,900 12655 House - Filtration Elec. Installation - Box 366 166
Cabinet - R.P.C. - Skid 24,000 10886 House - Hatch Cover Front - L/H - Skid 1,460 662
Cabinet - Transfer - Contactor - Box 1,766 801 House - Hatch Cover Front - R/H - Skid 1,460 662
Catwalk - Air - Stair - Crate 3,880 1760 House - Hatch Covers - Box 5,765 2615
Catwalk - Operators Cab - Skid 2,480 1125 House - Heater Installation Kit - Box 427 194
Catwalk #1 - Crate 5,300 2404 House - Installation Assembly - Box 2,212 1003
Catwalk #2 - Crate 2,040 925 House - Panel - Front - L/H - Pc 1,000 454
Controller - Stair Air R/H Assy. - Box 560 254 House - Panel - Front - R/H - Pc 1,000 454
Counterweight - Flat Stock - Filler - Box 221 100 House - Panel - Rear Wall - Box 14,420 6541
Counterweight - Troughing - Box 3,060 1388 House - Panel - Side Wall - Box 8,760 3974
Counterweight Box - Pc 98,000 44453 House - Roof Grating - Box 2,540 1152
Counterweight Mounting Bolts - Box 1,396 633 House - Shims / Covers - Box 382 173
Counterweight Slab ( & ) - Pc 50,000 22680 I-Beam Framing - Box 9,600 4355
Counterweight Slab ( H ) - Pc 50,000 22680 L/H Room Assembly - Pc 20,500 9299
Counterweight Slab ( P ) - Pc 50,000 22680 Ladder - Vertical Pull-down - Skid 1,760 798
Counterweight Slab Middle Section - Pc 50,000 22680 Light - Interior Installation - Box 968 439
Counterweight Slab Middle Section - Pc 50,000 22680 Oil Seal Installation Kit - Box 274 124
Counterweight Slab Wing Section - Pc 50,000 22680 Operators Coop - Box 13,360 6060
Counterweight Slab Wing Section - Pc 50,000 22680 Ops Coop - Roof Grating Installation - Skid 420 191
Crowd Motor Blower - Duct - Box 734 333 Ops Coop - Access Ladder - Skid 860 390
Crowd Transmission Lube - Box 768 348 Ops Coop - Awning Installation - Box 2,780 1261
Dipper Assembly Variable Plat Mdl. Assembly - Upper - Box 720 327
Dirt Chute - Box 1,000 454 Platform - R/H Room Elevated Platform - Pc 11,200 5080
Dirt Chute - Hood Assembly - Box 528 240 Platform - Rear L/H - Pc 12,000 5443
Duct Swing Blower Assembly - Box 286 130 Platform - Rear R/H - Pc 12,000 5443
Electrical - Cable - I/O Profibus Installation - Box 556 252 Platform L/H Room - Pc 11,900 5398
 4100XPC component list - export   Table 2
Approx Approx
Weight* Weight*
Description of Contents Lbs. Kg Description of Contents Lbs. Kg
Revolving frame Components (continued) Boom/Handle Components (continued)
Pressurization Sys. - Silencer Installation - Box 1,748 793 Boom Foot Pin Assembly - Box 2,226 1010
Pressurization Sys. - Truss Hood - Skid 680 308 Boom Point Sheave Assembly - Pc 13,500 6124
Pressurization System (AirScrubPro) - Pc 34,500 15649 Cable - Hoist - Guide - Skid 2,186 992
R/H Room Assembly - Pc 19,500 8845 Cable - Hoist - Tugger Installation - Skid 2,880 1306
Railings - Crate 3,900 1769 Cable - Hoist ( 1 of 2 ) - Pc 6,240 2830
Resolver Cable Installation - Box 526 239 Cable - Hoist ( 2 of 2 ) - Pc 6,240 2830
Revolving Frame - Lifting Lugs - Box 1,198 543 Cable - Suspension ( 1 of 2 ) - Pc 11,500 5216
Revolving Frame - Upper - Pc 214,000 97070 Cable - Suspension ( 2 of 2 ) - Pc 11,500 5216
Side Beams - Roof - Box 4,350 1973 Cable Installation - Boom Material - Box 308 140
Sky Light (1 of 2) - Box 404 183 Catwalk - Lower Boom Assembly - Skid 1,270 576
Sky Light (2 of 2) - Box 190 86 Catwalk - Platform - Boom - Skid 4,048 1836
Sky Light Guards - Skid 355 161 Catwalk - Sdl Blk / Lower Boom L/H - Skid 3,890 1765
Slipring Mounting Parts - Box 789 358 Catwalk - Sdl Blk / Lower Boom R/H - Skid 3,890 1765
Stairway - Air / LWR - R/H - Skid 1,280 581 Crowd Drive Assembly - Box 1,454 660
Stairway - Air UPR/LWR/RH - Skid 1,996 905 Crowd Gear Case Cover - Pc 14,940 6777
Swing Guards - Box 1,380 626 Crowd Motor and Base - Box 15,640 7094
Swing Installation Components - Box 3,112 1412 Dipper Trip Drum & Motor Assembly, R/H - Skid 2,310 1048
Swing Motor Troughing - Box 774 351 Handle - Dipper - Pc 99,870 45301
Swing Motors (3 units, ea. weighing) - Skid 10,750 4876 Handle - Sheave Bracket Assembly - Skid 790 358
Swing Shaft ( 1 of 3 ) - Pc 5,556 2520 Pitch Brace Assembly - Adjustable - Skid 3,910 1774
Swing Shaft ( 2 of 3 ) - Pc 5,556 2520 Saddle Block - Wear Plate - Skid 1,268 575
Swing Shaft ( 3 of 3 ) - Pc 5,556 2520 Saddle Block ( 1 of 2 ) - Skid 12,000 5443
Swing Trans. (3 units, ea weighing) - Skid 13,500 6124 Saddle Block ( 2 of 2 ) - Skid 12,000 5443
Swing Transmission Drain Assembly - Box 450 204 Sheave Brackets - Box 850 386
Swing Transmission Lube Assembly - Box 1,516 688 Shipper Shaft - Box 16,600 7530
Swivel Grease Assembly - Box 5,650 2563 Shipper Shaft - Bushings - Box 2,665 1209
Temperature Monitoring Kit - Box 672 305 Shipper Shaft Assembly - Box 1,164 528
Transformer - Main - Duct Installation - Box 596 270 Shipper Shaft Gear - Box 7,600 3447
Transformer - Auxilliary Field - Skid 7,461 3384 Shipper Shaft Pinions - Box 4,640 2105
Winch - Elec. - Windshield Install - Box 956 434 Snubber Kit (SnubRite) - ( 1 of 2 ) - Box 1,590 721
Boom/Handle Components Snubber Kit (SnubRite) - ( 2 of 2 ) - Box 1,590 721
Boom - Electrical Materials - Box 420 191 Snubber Mounting Kit (SnubRite) - Box 852 386
Boom - Jack Stands - Box 1,134 514 Stairs Boom - Skid 3,280 1488
Boom Assembly - Pc 148,000 67133

Weights are ±10%. For actual weight of each component, refer to packing list.

electrical test equipment requirements

Basic Electrical Test Instrumentation Recommended to Commission and Maintain Centurion Digital Drive Mining Excavator.
Recommended Maintenance Test Equipment Available through P&H and other Vendors.

Description P&H Part # Description P&H Part

DMM (Digital MultiMeter) #Clamp-On Ammeter—1A to 600A AC / 1000A (DC)
Fluke Model 23 89Z514D12 Fluke Model i1010 89Z514D15
Alternate DMM—Fluke, Model 87 1089Z275 High Voltage Differential Probe—P5200 89Z515D21
Oscilloscope Laptop computer—Consult service department
Tektronix Model THS720A (Hand-held, Dual Trace, for specs N/A
Digital, Storage, Battery Powered, Soft Case) Scope Drive Communications (hardware and software) R40775D3
w/120V / 60Hz Adapter 89Z515D16
RPC Capacitor Test unit 89Z508D1
120V / 50 Hz AC Adapter (240V Adapters Available) 89Z515D30
Hard Carrying Case 89Z515D26 Voltage Divider R1192F1
X10 Probe (1kV) 89Z515D17 Hand-held Drive Programmer, ABB CDP-312R R46072D7
R5-232 to 485 Converter—for loading ABB drive 2 Meter Connection Cable R46072D8
firmware ABB NPCU-01-KIT R49117D1
SCR (Thyristor) Tester 89Z511D1
Megger—500V & 1000V Scales (hand-crank /w case)
James D. Biddle Cat. 21158 89Z496

NOTE: All designs, specifications and components of equipment described above are subject to change at manufacturer’s sole discretion at any time without
advance notice. Data published herein is informational in nature and shall not be construed to warrant suitability of machine for any particular purpose as
performance may vary with conditions encountered. The only warranty applicable is our standard written warranty for this machine.

P&H Mining Equipment  •  Box 310  •  Milwaukee, Wisconsin 53201 USA

XS-4222 PDF408
 ®

4100XPB
ELECTRIC MINING SHOVEL

ERECTION PROCEDURE
ERECTION ASSISTANCE

With the purchase of your Model 4100XPB electric mining shovel, a

P&H MinePro Services advisor will be provided for a period of 50
working days to assist the purchaser or the purchaser’s erection
contractor with the erection of the machine. The purchaser sould
arrange to erect, test and place the machine into operation during
this 50 day period.
The P&H MinePro Services advisor can provide advice only. He is
available to advise the purchaser or the purchaser’s erection con-
tractor on erection sequences, commissioning procedures, testing
and other erection details as requested, but is not authorized to
supervise workers or to direct the erection, testing or commissioning
in any way. The purchaser will be required to provide all tools,
equipment and personnel needed to erect the machine, as well as SAFETY: All safety related equipment requirements and
supervision of personnel erecting the machine. For example, the procedures are the responsibility of the Purchaser and
P&H MinePro Services advisor is available to consult with supervi- or designated Erection Contractor and should be in
sory personnel on questions such as places to make hitches on accordance with all applicable MSHA, Local Mine, State
components, but P&H Mining Equipment will not be responsible for Authorities and regulations.
placement of such hitching or for working with lifting equipment.
P&H Mining Equipment will not be liable in any event for any indi- NOTE: The purchaser is to supply all necessary start-up
rect, special or consequential damages. Purchaser shall indemnify lubrication materials, oils, greases, etc., per P&H
and hold P&H Mining Equipment harmless for all liability for damage specifications.
to property or personal injury (including death) arising out of pur-
chaser’s erection, testing or placing into service of the machine. ERECTION SITE AND MATERIAL LOCATION
The P&H MinePro Services advisor is not authorized to approve
modifications to the machine that are not covered by the machine Erection site preparation is the responsibility of the Purchaser and
data sheet, nor will P&H Mining Equipment accept any back-charge should be a flat leveled area, with good drainage, and stable under
for any unauthorized modifications made.(See section titled footing to support the lifting equipment and their floats or outriggers
“Machine Modification Procedure”.) during any lift to be made.
The purchaser or the purchaser’s erection contractor should contact The area required is approximately 300 feet (91.4 m) square, with a
the nearest P&H Mining Equipment regional office to schedule the tool shed.
P&H MinePro Services advisor. We ask the purchaser, prior to the
arrival of P&H MinePro Services advisor, to issue a purchase order MACHINE MODIFICATION PROCEDURE
covering the P&H MinePro Services advisor. The first 50 normal
During the shovel erection process, the shovel purchaser will some-
working days will be on a no charge basis. Any days beyond the first times request alterations to the standard machine design. Some of
50 days will be charged against the purchase order at established the more-commonly requested modifications affect lubrication sys-
service rates. tems, walkways, hand rails, lighting systems, guards and PLCs.
The normal working day for the P&H MinePro Services advisor is While some modifications might improve the ability of the purchaser
eight hours on site per day. The normal work week is five days per to utilize and maintain the shovel, some modifications might in fact
week (Monday through Friday excluding holidays). Time spent on adversely affect productivity over time or have significant safety
site beyond the normal work week or day will be charged against implications not readily ascertainable.
the purchase order at established service overtime rates.
Accordingly, it is imperative that any modifications sought by the
shovel purchaser of the kind noted above (or any other significant
ERECTION PERSONNEL REQUIREMENTS modifications) be discussed with your P&H MinePro Services shov-
The erection history for the Model 4100XPB indicates erection can be el project manager. In turn, your shovel project manager will discuss
made within 5200-5500 man-hours. The history also indicates that if your requests with P&H Mining Equipment shovel design engineers
to determine if the modifications can be carried out. P&H Mining
proper manpower is not available, the 50 working day period of erec- Equipment and P&H MinePro Services make every effort to accom-
tion and placement into operation will be exceeded. We therefore modate the purchaser’s requests while taking into consideration the
advise that the following labor types should be available at various machine’s optimal productivity and mine application, as well as cur-
stages of machine erection. rent design and safety specifications and regulations.
4—Laborers (for the purpose of cleaning parts before they undergo It is most important that any modification to the machine be docu-
assembly) mented so that P&H Mining Equipment and P&H MinePro Services
3—Mechanics can maintain current drawings and specifications for your electric
1—Millwright shovel. Furthermore, any future service involving the P&H Mining
3—Electricians Equipment engineering staff can be expedited if modifications are
2—Welders known and documented.
Please be aware that any modification performed without P&H
After the initial cleaning and opening of the packing cases, the four Mining Equipment and P&H MinePro Services concurrence might
laborers may be replaced by additional mechanics and mill-wrights, void the warranty.
as the tasks of the mechanics and millwrights will be more prevalent.
Some modifications requested by the purchaser can be accommo-
We have not included the supervision mentioned previously. The nec- dated at no additional charge. However, some modifications require
essary mechanical and electrical supervision should be present when additional welding or other services that cannot be absorbed by
the various trades are involved in the erection of the machine. P&H Mining Equipment or P&H MinePro Services. The purchaser
will be notified of such costs in advance of the work being per-
This listing does not include crane operators or oilers (if there is a formed.
requirement for their use).

1
BASIC RIGGING MATERIAL REQUIREMENTS BASIC HAND TOOLS (continued)
2—wire brushes
Cranes
3—each tapered drifts, 12" long, 5/8" and 3/4" dia.
Two (2) heavy-lift cranes are required at the start of the erection, 2—1/2" drive socket wrench sets, including two extensions,
staying on-site until all the heavy lifts are completed and the boom ratchet and sockets, from 7/16" to 1-1/4", in 1/8"
has been pinned to the revolving frame. After raising the boom, the increments
balance of the erection process can proceed with one (1) rough-ter- 1—3/4" drive socket wrench set, including two extensions,
rain crane in the 30-ton to 50-ton (27,216-kg to 45,360-kg) class. ratchet and sockets, from 1" to 3", in 1/8" increments
6—3-ton come-alongs
Heavy-lift crane size requirements are based on many factors, 2—standard bolt tap set—1/4" to 1-1/2" in 1/8" increments
including crane access to heavy lifts, type of crane used, cold 2—drill bit set—3/16" to 5/8" in standard increments
weather capacity de-rating, reach, and pick-and-carry capability. 1—set of rotary files for pencil grinder
Therefore, in extreme cold weather erection environments, two 225- 1—torque wrench
ton (204,120-kg) cranes are recommended. In moderate weather, 1—torque multiplier (2,500 ft.-lbs. capacity)
one 150-ton (136,080 kg) and one 190-ton (172,368-kg) crane are
recommended for heavy lifts.
Basic Power Tools
Cables 1—1/2" drive reversible electric drill motor 110 vac
4—2.5" x 25' 4—1-3/4" x 20' 4—1-1/2" x 20' 1—pneumatic air wrench, 1/2" drive, with sockets from
4—1" x 12' 2—1-1/2" x 20' 4—3/4" x 10' 1/2" to 1-1/4", in 1/8" increments
2—1-1/4" x 20' 2—5/8" x 20' 1—spray paint gun
10—smaller cables (1/2" and 3/8", 15' long) to handle the 1—air powered grinder, 9" right angle disc
miscellaneous material, such as brakes, blower 1—air powered 1/4" pencil grinder
motors, boxes, cab sections, etc. 1—air powered chipping hammer w/chisels
Assortment of nylon slings 1—welding machine, 400 amp capacity (portable gasoline
or diesel driven), including 100' long welding cables
Shackles and Pins 1—portable air compressor, 150 CFM capacity, with 2 ea.
Four (4) 85-ton shackles 100' long hoses with inline oilers
Four (4) 55-ton shackles 1—portable light plant or electric power supply if needed
Four (4) 35-ton shackles 1—electric heated rod oven
Four (4) 25-ton shackles 2—oxygen/acetylene burning sets with 75' hose
Pins -- six (6) each in the following sizes: 1/4", 3/8", 1/2", 3/4", 1" 2—50-ton hydraulic jacks
Blocking (Hardwood) Basic Miscellaneous Items
40 ea. 8" x 8" or 10" x 10" in 6', 4', and 2' lengths 3—tarpaulins, 30' x 30'
Plywood and 2" lumber (available from shipping crates / boxes) 2—15' step ladders
2—24' extension ladders
This material is used for setting the various components 2—barrels of cleaning solvent
on the ground. The carbody is blocked 48" high for side
frame clearance with shoes on. 20—rolls masking tape 1"
50—sheets of fine emery cloth
Optional Time-Saving Equipment 50—sheets of medium emery cloth
One 10-ton* (9.072 kg.) forklift. 2—wooden stairway with railing for boarding
25—rolls black plastic electrical tape
25—rolls of friction tape
BASIC TOOL REQUIREMENTS 5—anti-seize lubricant (cans)
Basic Hand Tools 5—dye check kits for checking welds (NDT-PT)
6—fire extinguishers—20 lb. dry chemical type
2—6" screwdrivers 1/4" face 100—lbs. each—3/16" and 3/32" weld rod—hydrogen (pre-dried)
2—8" screwdrivers 3/8" face 300—feet manila rope
2—12" screwdrivers 1/2" face 100—lbs. cleaning rags
2—15" adjustable open end wrenches 2000-lbs. (approx.) dry ice(the exact quantity required will depend
2—12" adjustable open end wrenches upon location of source and ambient temperature) or,
4—12" long bastard files Liquid Nitrogen - 4 bottles, approximately 370 lbs. of product
6—4" paint brushes for use with cleaning solvent each bottle and must have liquid withdrawal capabilities
1—crosscut saw 1—6-foot step ladder
3—36" wrecking bars 1—8-foot step ladder
2—20 lb. sledge hammers Painting supplies
4—2 lb. ball peen hammers Assorted-color electrical tape
6—putty knives 3" wide
1—heavy-duty mechanic’s tool set
The above tool listing indicates the basic minimum range and
quantity of tools recommended. The list is not intended to be
all-inclusive.

Data Codes
*1 ton = 2,000 pounds (907.2 kg)
10' = 10 feet (305 cm) 10" = 10 inches (25.4 cm)

2
 4100XPB LIFTING OR HITCHING POINTS AND APPROXIMATE WEIGHTS* OF MAJOR ITEMS
99,000 lbs. 64,000 lbs.
(44,906 kg) (29,030 kg)
w/o Trans Pick point note: w/o Trans Caution: The side loading to any welded-on
Use both outer holes of this one
lug when lifting in this position. Pick point note:
lifting lug cannot exceed ±5° from the vertical.
Use this one lug when
lifting in this position. * Weights are ±10%. For actual weight of each component, refer to packing list.

Crawler (top view shown) w/o Trans w/o Shoes-Weight: 163,000 (73,937 kg)

125,875 lbs. 61,225 lbs. Crawler shoes:76" (1.93 m)

(57,097 kg) (27,772 kg)
w/ trans w/ trans 42 Shoes each Belt - Weight: 165,100 lbs.
(74,888 kg)
Pick point note:
Use both outer holes of this one
lug when lifting in this position. Pick point note: Crawler shoes: 87" (2.21 m)
12'-0" Use this one lug when 42 Shoes each Belt - Weight: 175,000 Lbs.
(3.66 m) lifting in this position. (79,379 Kg.)

Center Gudgeon
Crawler (top view shown) w/o Shoes-Weight: 187,100 (84,869 kg) Weight: 9,050 lbs. (4,105 kg)

36'-8" 22"
(11.18 m) (559 mm) 12" (305 mm)
Pick point note:
7'-8" Use both lugs
(2.33 m) (one each side) 123.25"
when lifting in (3.13 m)
this position.
Crawler Frame w/o Shoes Dry ice to freeze center gudgeon (shown above) for
Pick point note: field installation into carbody. The quantity will depend
Use only top on location of supplier, and ambient temperature.
holes of these 98,650 lbs. 98,650 lbs.
lugs (one each (44,747 kg) (44,747 kg) Carbody
side) when lifting
in this position. Total Weight:
98,650 lbs.
(44,747 kg)
} Includes:
Swing Roller Carrier Ring
Lower Swing Roller Path

98,650 lbs. 98,650 lbs.

(44,747 kg) (44,747 kg)

16'-3"
(4.95 m)
20'-0"
8'-1" (6.10 m)
(2.45 m)

24'-7" 16'-8"
(7.49 m) (5.08 m) 17'-5"
(5.31 m)
88,880 lbs. 124,120 lbs. 3
76 yd (58.1 m3) Bail Type Dipper
(40,316 kg) CL Rotation (56,301 kg)
175,000 lbs.
(79,380 kg)

Typical values only; there is no standard dipper.

11'-4"
(3.45 m)

48,025 lbs. 48,025 lbs.

(21,784 kg) (21,784 kg)
35'-6"
(10.82 m)

213,000 lbs. (96,617 kg)

31'-10"
(9.69 m)

Revolving Frame w/Sidestand

99,600 lbs. Includes: 113,400 lbs.

(45,179 kg) Upper Roller Path (51,438 kg)
Misc. Wiring Troughs 13'-0"
(3.96 m)

Total Weight
96,050 lbs.
(43,568 kg)
15'-1"
(4.6 m)

5'-0" 5'-8"
(1.52 m) (1.71 m)

Counterweight Box

3
4100XPB LIFTING OR HITCHING POINTS AND APPROXIMATE WEIGHTS* OF MAJOR ITEMS

Note: Use these machined holes as hitch

points. Do not use the welded-on lugs to Caution: The side loading to any
raise the boom.
welded-on lifting lug cannot
13'-11"
exceed ±5° from the vertical.
(4.24 m)
* Weights are ±10%. For actual weight of each
component, refer to packing list.
68'-0"
(20.73 m)

63,500 lbs. 82,500 lbs.

(28,804 kg) (37,422 kg)
Bare Bare

9'-5"
(2.86 m)

Bare Boom includes:

Fully Dressed Bare – Lube material
247,500 lbs. 146,000 lbs.
(112,266 kg) (66,226 kg)
Fully-dressed Boom includes:
**125,000 lbs. – Boom Point Assembly
(56,700 kg) – Crowd Machinery
Fully Dressed – Hoist Rope Guide
– Dipper Trip Machinery
– Catwalks

** Hitch point load encountered when raising a

fully-dressed boom into position.

Handle Layout

10'-6"
(3.20 m)

40'-11"
(12.47 m)

36,170 lbs. 61,330 lbs.

(16,407 kg) (27,819 kg)

14'-4"
(4.36 m)

7'-7"
(2.31 m)

97,500 lbs.
(44,226 kg)

Counterweight Slabs

4'-10"
(1.47 m)
2'-6" 2'-10" 1'-11"
(.76 m) (.86 m) (.58 m)

24,400 lbs. 24,400 lbs. 24,610 lbs. 24,610 lbs. 25,060 lbs. 25,060 lbs. 18,110 lbs. 32,590 lbs.
(11,091 kg) (11,091 kg) (11,187 kg) (11,187 kg) (11,391 kg) (11,391 kg) (8,232 kg) (14,813 kg)

10'-0" 10'-0" 10'-0" 8'-8" 8'-8"

(3.05 m) (3.05 m) (3.05 m) (2.64 m) (2.64 m)

5'-0" (1.52 m) 6'-6" (1.98 m) 7'-0" (2.13 m) 6'-7" (1.96 m)

48,800 lbs. (22,182 kg) 49,220 lbs. (22,373 kg) 50,120 lbs. (22,782 kg) 50,700 lbs. (23,045 kg)
&” Section (1)
Center “& Inner-Mid “PP” Section (1) Outer-Mid Sections (2) Wing Sections (2)
Inner-Mid “HH” Section (1)

4
Figure 1 SITE LAYOUT

95 Figure 1 depicts the recommended placement of

DIPPER parts at the erection site. Each item shown is
116 numbered and refers to the Component List
(Table 1) which gives the approximate weights of
90
the components. For the actual weights, refer to
the machine packing list.
23
85 42 43

HANDLE
DIPPER
80

51 26
55
75 54
56

57 52
70
69 70

112 112
65

76 40
60 COUNTER WEIGHT 76
63
BOX
63 34 16 77
31 71 72
64 85
55 38 64
49 35 34
47 65 98
65
41 99
66 74
50
82 21 REVOLVING
FRAME
22 15
96
4 HOIST
45 97 24 CASE
CRAWLER CRAWLER RING
SHOES S S SHOES GEAR
58 100 I I 17
D D 74 78
102 E CARBODY E 25
40 HOIST
22 F 1 F
103 12 DRUM
R R
A A 18 115 73
TOOL
CONTAINER M M ROLLER 75 79
35 E E 30
CARRIER
13
PROPEL
LUNCH
ROOM

MOTOR 5 6 95 14 7
83
30 87 BASE 8 9 10
37 60 106
48
11 16 113 44
6 61 BOOM
19 107
25 13
93
14 104 108 32 GANTRY
105
29
GANTRY
20 33 TENSION
90 MEMBERS

91 36 28
110
15

NOTE 59
Electrical cabinets, transformers, BOOM
10 AC & DC motors, etc. must be POINT
stored under cover until required. SHEAVES
(67)

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
METERS

5
Table 1 4100XPB COMPONENT LIST - U.S. & CANADA
Site APPROX. WEIGHT* Site APPROX. WEIGHT*
Location DESCRIPTION OF CONTENTS LBS. KG. Location DESCRIPTION OF CONTENTS LBS. KG.

Carbody Components 85
49
Air Conditioner Box
Slipring Parts Box
3,740
465
1700
211
32 Gantry 35,900 16318
0 Crawler Shoes- Shipped Direct
33 Gantry Tension Members
13 Crawler Shoe Pins #1 6,980 3173
(2 units, each weighing »»»»»»»»»»»»»»»»») 9,800 4455
13 Crawler Shoe Pins #2 6,980 3173
36 Gantry Platform Skid 3,240 1473
14 Crawler Shoe Pins #3 6,980 3173
28 Gantry Parts Box 918 417
14 Crawler Shoe Pin Hardware 1,750 795
12 Hoist Rope Tugger Skid 3,020 1373
1 Carbody 195,000 91136
25 Air Compressor Box 1,520 691
2 Crawler - Left-Hand 169,050 76841
58 Pull-down Ladder Skid 1,760 800
3 Crawler - Right-Hand 169,050 76841
22 Air Ladder Skid 2,920 1327
6 Crawler Frame Dowels and Bolts 10,500 4773
82 Pressurization Unit 26400 12000
29 Propel Transmission 24,500 11136
112 Machinery House Assembly Parts / Hardware 766 348
30 Propel Transmission 24,500 11136
112 House Rear Enclosure Angles Box 920 418
37 Propel Transmission Hardware 200 91
54 Center Beam Skid 5,080 2309
5 Propel Motors and Base Assembly 48,000 21818
55 Panel Left R43043D1 2,985 1357
5 Propel Motor Base Assembly Parts 1,352 615
56 Panel Right R43045D1 2,985 1357
87 Tools - Hydraulic and Miscellaneous 900 409
57 Left Center Panel R43049D1 2,954 1343
4 Ring Gear - Swing 22,205 10093
69 Right Center Panel R43050D1 2,954 1343
115 Carrier Ring 0
70 Hatch Cover Front Skid 1,460 664
8 Box Swing Rollers ( 1 of 3 ) 2,310 1050
26 Hatch Cover Front Skid 1,460 664
9 Box Swing Rollers ( 2 of 3 ) 2,310 1050
51 Hoist Cable Hood 1,340 609
10 Box Swing Rollers ( 3 of 3 ) 2,310 1050
112 Rear Roof and Pressurization Hardware 580 264
7 Lower Parts Box 2,000 909
112 Hood / Dirt Chute House Box 520 236
45 Cable Reel Box 2,041 928
20 Crate - House Roof Grating 2,380 1082
18 Center Gudgeon Box 13,800 6273
21 Crate - Railings #1 3,800 1727
62 Carbody Stairs Installation Skid 500 227
21 Crate - Catwalks #2 3,000 1364
83 Towing Lug Assembly Lower Box 1,160 527
22 Crate - Catwalks #3 2,060 936
xx Box - Dowels 2,850 1295
22 Crate - Catwalks #4 2,740 1245
Revolving Frame Components 22
116
Crate - Catwalks #5
Dipper Assembly
3,040
Variable
1382
Variable
97 Main Transformer 24,300 11045
15 Revolving Frame 213,000 96818
100 Converter Cabinet 13,500 6136
16 Counterweight Box 96,050 43659
102 R.P.C. Cabinet 21,000 9545
63 Counterweight Slab ( P ) 49,220 22373
98 High-Voltage Cabinet 3,000 1364
63 Counterweight Slab ( & ) 48,800 22182
99 Auxilliary Field Transformer 5,500 2500
64 Counterweight Slab ( H ) 48,940 22245
101 Transfer Cabinet Contactor 1,300 591
64 Counterweight Slab Middle Section 49,400 22455
41 Buss Bars, Box 1,520 691
65 Counterweight Slab Middle Section 50,120 22782
96 Electrical Shipping Materials Box 373 170
65 Counterweight Slab Wing Section 50,700 23045
96 Cable Installation Resolver Box 181 82
66 Counterweight Slab Wing Section 50,700 23045
103 Cabinet Assembly, Dipper Trip Box 840 382
47 Counterweight Mounting Bolts Box 1,238 563
83
84
Swing Shaft ( 1 of 3 )
Swing Shaft ( 2 of 3 )
5,660
5,660
2573
2573
Boom Components
44 Swing Shaft ( 3 of 3 ) 5,660 2573
19 Shovel Boom 151,000 68614
31 Box Trough Installation Counterweight 2,500 1136
67 Boom Point Sheave Assembly 14,100 6409
38 Box Swivel Assembly 5,600 2545
90 Shipper Shaft Box 9,400 4273
113 Swing Gear Guards 880 400
91 Retainers “Shipper Shaft” 1,220 555
24 Hoist Gear Case 37,000 16818
59 Shipper Shaft Pinions 4,450 2023
17 Drain Assembly XMSN Central Box 400 182
110 Shipper Shaft Gear 6,541 2973
17 Hoist Drum Assembly Cabinet Bracing Box 850 386
42 Boom Saddle Block 12,000 5455
73 Hoist Drum Assembly 53,000 24091
43 Boom Saddle Block 12,000 5455
74 Hoist Motor Base 7,800 3545
108 Crowd Motor and Base 14,800 6727
75 Hoist Motor Base 7,801 3546
93 Crowd Case Cover 12,700 5773
78 Hoist Motor Front 19,700 8950
61 Dipper Trip Assembly, Right-Hand Box 2,185 993
79 Hoist Motor Rear 19,700 8950
60 SK Trip Sheave Bracket Assembly - Boom 726 330
79 Hoist Motor Assembly Parts 595 270
95 Miscellaneous Electrical Materials - Boom 380 173
76 Swing Motors (3 units, each weighing »»»»»»») 10,000 4544
106 Suspension Cable 11,000 5000
77 Swing Tranmissions (3 units, each weighing»»») 13,000 5907
107 Suspension Cable 11,001 5000
39 Crowd Motor Blower 780 355
104 Hoist Cable 5,400 2455
34 Left-Hand Room Platform 11,900 5409
105 Hoist Cable 5,401 2455
72 Left-Hand Elevated Section 18,000 8182
23 Dipper Handle 97,500 44318
35 Right-Hand Room Platform 11,200 5091
60 SK Sheave Bracket Assembly - Handle 790 359
71 Right-Hand Elevated Section 19,500 8864
40 Operator’s Coop 11200 5091
76 Swing Transmission Assembly Parts 540 245
11 Swing Transmission Lube System 1,270 577

Weights are ±10%. For actual weight of each component, refer to packing list.

6
Table 2 4100XPB COMPONENT LIST - EXPORT
Site APPROX. WEIGHT* Site APPROX. WEIGHT*
Location DESCRIPTION OF CONTENTS LBS. KG. Location DESCRIPTION OF CONTENTS LBS. KG.

Carbody Components 85
49
Air Conditioner Box
Slipring Parts Box
4,114
512
1870
232
0 Crawler Shoes- Shipped Direct 32 Gantry 39,490 17950
13 Crawler Shoe Pins #1 7,678 3490 33 Gantry Tension Members
(2 units, each weighing »»»»»»»»»»»»»»»»») 10,780 4901
13 Crawler Shoe Pins #2 7,678 3490
36 Gantry Platform Skid 3,564 1620
14 Crawler Shoe Pins #3 7,678 3490
28 Gantry Parts Box 1,010 459
14 Crawler Shoe Pin Hardware 1,925 875
12 Hoist Rope Tugger Skid 3,322 1510
1 Carbody 214,500 100250
25 Air Compressor Box 1,672 760
2 Crawler - Left-Hand 185,955 84525
58 Pull-down Ladder Skid 1,936 880
3 Crawler - Right-Hand 185,955 84525
22 Air Ladder Skid 3,212 1460
6 Crawler Frame Dowels and Bolts 11,550 5250
82 Pressurization Unit 29,040 13200
29 Propel Transmission 26,950 12250
112 Machinery House Assembly Parts / Hardware 843 383
30 Propel Transmission 26,950 12250
112 House Rear Enclosure Angles Box 1,012 460
37 Propel Transmission Hardware 220 100
54 Center Beam Skid 5,588 2540
5 Propel Motors and Base Assembly 52,800 24000
55 Panel Left R43043D1 3,284 1493
5 Propel Motor Base Assembly Parts 1,487 677
56 Panel Right R43045D1 3,286 1493
87 Tools - Hydraulic and Miscellaneous 990 450
57 Left Center Panel R43049D1 3,249 1477
4 Ring Gear - Swing 24,426 11102
69 Right Center Panel R43050D1 3,249 1477
115 Carrier Ring 0
70 Hatch Cover Front Skid 1,606 730
8 Box Swing Rollers ( 1 of 3 ) 2,541 1155
26 Hatch Cover Front Skid 1,606 730
9 Box Swing Rollers ( 2 of 3 ) 2,541 1155
51 Hoist Cable Hood 1,474 670
10 Box Swing Rollers ( 3 of 3 ) 2,541 11550
112 Rear Roof and Pressurization Hardware 638 290
7 Lower Parts Box 2,200 1000
112 Hood / Dirt Chute House Box 572 260
45 Cable Reel Box 2,245 1021
20 Crate - House Roof Grating 2,618 1190
18 Center Gudgeon Box 15,180 6900
21 Crate - Railings #1 4,180 1900
62 Carbody Stairs Installation Skid 550 250
21 Crate - Catwalks #2 3,300 1500
83 Towing Lug Assembly Lower Box 1,276 580
22 Crate - Catwalks #3 2,266 1030
xx Box - Dowels 3,135 1425 22 Crate - Catwalks #4 3,014 1370
22 Crate - Catwalks #5 3,344 1520
Revolving Frame Components 116 Dipper Assembly Variable Variable
97 Main Transformer 26,730 12150
15 Revolving Frame 234,300 106500 100 Converter Cabinet 14,850 6750
16 Counterweight Box 105,655 48025 102 R.P.C. Cabinet 23,100 10500
63 Counterweight Slab ( P ) 54,142 24610 98 High-Voltage Cabinet 3,300 1500
63 Counterweight Slab ( & ) 53,680 24400 99 Auxilliary Field Transformer 6,050 2750
64 Counterweight Slab ( H ) 53,834 24470 101 Transfer Cabinet Contactor 1,430 650
64 Counterweight Slab Middle Section 54,340 24701 41 Buss Bars, Box 1,672 760
65 Counterweight Slab Middle Section 55,132 25060 96 Electrical Shipping Materials Box 410 187
65 Counterweight Slab Wing Section 55,770 25350 96 Cable Installation Resolver Box 199 90
66 Counterweight Slab Wing Section 55,770 25350 103 Cabinet Assembly, Dipper Trip Box 924 420
47 Counterweight Mounting Bolts Box 1,362 619
83
84
Swing Shaft ( 1 of 3 )
Swing Shaft ( 2 of 3 )
6,226
6,226
2830
2830
Boom Components
44 Swing Shaft ( 3 of 3 ) 6,226 2830 19 Shovel Boom 151,000 68614
31 Box Trough Installation Counterweight 2,750 1250 67 Boom Point Sheave Assembly 14,100 6409
38 Box Swivel Assembly 6,160 2800 90 Shipper Shaft Box 9,400 4273
113 Swing Gear Guards 968 440 91 Retainers “Shipper Shaft” 1,220 555
24 Hoist Gear Case 40,700 18500 59 Shipper Shaft Pinions 4,450 2023
17 Drain Assembly XMSN Central Box 440 200 110 Shipper Shaft Gear 6,541 2973
17 Hoist Drum Assembly Cabinet Bracing Box 935 425 42 Boom Saddle Block 12,000 5455
73 Hoist Drum Assembly 58,300 26500 43 Boom Saddle Block 12,000 5455
74 Hoist Motor Base 8,580 3900 108 Crowd Motor and Base 14,800 6727
75 Hoist Motor Base 8,580 3900 93 Crowd Case Cover 12,700 5773
78 Hoist Motor Front 21,670 9845 61 Dipper Trip Assembly, Right-Hand Box 2,185 993
79 Hoist Motor Rear 21,670 9845 60 SK Trip Sheave Bracket Assembly - Boom 726 330
79 Hoist Motor Assembly Parts 655 297 95 Miscellaneous Electrical Materials - Boom 380 173
76 Swing Motors (3 units, each weighing »»»»»»») 11,000 4998 106 Suspension Cable 11,000 5000
77 Swing Tranmissions (3 units, each weighing»»») 14,300 6498 107 Suspension Cable 11,001 5000
39 Crowd Motor Blower 858 391 104 Hoist Cable 5,400 2455
34 Left-Hand Room Platform 13,090 5950 105 Hoist Cable 5,401 2455
72 Left-Hand Elevated Section 19,800 9000 23 Dipper Handle 97,500 44318
35 Right-Hand Room Platform 12,320 5600 60 SK Sheave Bracket Assembly - Handle 790 359
71 Right-Hand Elevated Section 21,450 9750
40 Operator’s Coop 12,320 5950
76 Swing Transmission Assembly Parts 594 270
11 Swing Transmission Lube System 1,397 635

Weights are ±10%. For actual weight of each component, refer to packing list.

7
ELECTRICAL TEST EQUIPMENT REQUIREMENTS Alternate AC/DC current probe—Columbia
Basic Electrical Test Instrumentation Required by Customer to Electric Type AX /w five (5) current ranges R89Z367
Commission and Maintain Electrotorque Mining Excavator.
Laptop computer 1.4GB hard drive (minimum),
Recommended Maintenance Test Equipment Available 120 MHz (minimum), floppy - 10X CD-ROM, audio
through P&H and other Vendors. PCMCIA, carry case, ethernet port and
Windows 98 OS N/A
Description P&H Part #
Drive communication software
DMM (Digital MultiMeter) ◆ RSLogix 500 (customer copy) 79Z5311D6
◆ Fluke Model 23 89Z514D12 ◆ RSLogix 500 (P&H copy) 79Z4937D12
◆ Alternate DMM—Fluke, Model 87 1089Z275 ◆ RSLinx (included with RSLogix)
Oscilloscope ◆ PC Anywhere software R41705D1
◆ Tektronix Model THS710 (Hand-held, Dual Trace, ◆ Drive Windows (includes specialized interface card)
Digital, Storage, Battery Powered, Soft Case) Scope
w/120V / 60Hz Adapter 89Z515D15 PCMCIA card and cable (included in laptop)
◆ 120V / 50 Hz AC Adapter (240V Adapters Available) 89Z515D30 (A-B 1784-PCMC) unit required for customer use 79Z4936D6
◆ Hard Carrying Case 89Z515D26
◆ X10 Probe (1kV) 89Z515D17 PCMCIA card and cable (included in laptop)
(A-B 1784-PCMC) unit required for P&H use 79Z4937D9

Chart Recorder—Hioki, Model 8807 Drive communications (hardware and software) N/A
(order each of the following parts separately)
◆ Recorder (120/240V-50/60 Hz) R10945D1 Modem serial cable N/A
◆ Carrying Case - Soft R10945D2
◆ AC Adapter 90 - 250V, 50/60 Hz R10945D3 Start-up limiting resistor - 200-ohm, 6000-watt 80Z984D1
◆ Battery Pack, Rechargable R10945D4
◆ Recording Paper (10 Rolls) R10945D5 Reference pushbutton unit R40602D1

Alternate Chart Recorder—Astro-Med Dash 2 RPC Capacitor Test unit 89Z508D1

two-channel field recorder with data capture
◆ Astro-Med DASH2MT 89Z835D3 Voltage Divider R1192F1
◆ Chart Paper 89Z835D4 Alternate Voltage Divider 89Z510D1

Hand-held Drive Programmer, ABB CDP-312 R42375D27

Megger—500V & 1000V Scales (hand-crank /w case)
James D. Biddle Cat. 21158 89Z496 SCR (Thyristor) Tester 89Z511D1
Clamp-On Ammeter—1A to 600A AC / 1000A (DC)
Fluke Model i1010 89Z514D15

NOTE: All designs, specifications and components of equipment described above are subject to change
at manufacturer’s sole discretion at any time without advance notice.
Data published herein is informational in nature and shall not be construed to warrant suitability
of machine for any particular purpose as performance may vary with conditions encountered.
The only warranty applicable is our standard written warranty for this machine.

P&H Mining Equipment ◆ Box 310 ◆ Milwaukee, Wisconsin 53201 USA

XS-1789 8 2AG-601
 4100C
assembly Procedure

assembly Assistance
With the purchase of your Model 4100C electric mining shovel, a P&H
MinePro Services advisor will be provided for a period of 50 working
days to assist the purchaser or the purchaser’s erection contractor with
the assembly of the machine. The purchaser should arrange to erect,
test and place the machine into operation during this 50 day period.
4100C
The P&H MinePro Services advisor can provide advice only. He
is available to advise the purchaser or the purchaser’s assembly
contractor on assembly sequences, commissioning procedures, testing
and other assembly details as requested, but is not authorized to
supervise workers or to direct the assembly, testing or commission-
ing in any way. The purchaser will be required to provide all tools, SAFETY: All safety related equipment requirements and procedures are
equipment and personnel needed to assemble the machine, as well the responsibility of the Purchaser and or designated Assembly
as supervision of personnel erecting the machine. For example, Contractor and should be in accordance with all applicable
the P&H MinePro Services advisor is available to consult with MSHA, Local Mine, State Authorities and regulations.
supervisory personnel on questions such as places to make hitches NOTE: The purchaser is to supply all necessary start-up lubrication
on components, but P&H Mining Equipment will not be responsible materials, oils, greases, etc., per P&H specifications.
for placement of such hitching or for working with lifting equipment.
P&H Mining Equipment will not be liable in any event for any indirect,
special or consequential damages. Purchaser shall indemnify and hold Site and Material Location
P&H Mining Equipment harmless for all liability for damage to property
or personal injury (including death) arising out of purchaser’s assembly, Assembly site preparation is the responsibility of the Purchaser and
testing or placing into service of the machine. should be a flat leveled area, with good drainage, and stable under
The P&H MinePro Services advisor is not authorized to approve footing to support the lifting equipment and their floats or outriggers
modifications to the machine that are not covered by the machine during any lift to be made.
data sheet, nor will P&H Mining Equipment accept any back-charge The area required is approximately 300 feet (91.4 m) square, with a
for any unauthorized modifications made.(See section titled “Machine tool shed.
Modification Procedure”.)
The purchaser or the purchaser’s assembly contractor should contact
the nearest P&H Mining Equipment regional office to schedule the P&H Machine Modification Procedure
MinePro Services advisor. We ask the purchaser, prior to the arrival
of P&H MinePro Services advisor, to issue a purchase order covering During the shovel assembly process, the shovel purchaser will
the P&H MinePro Services advisor. The first 50 normal working days sometimes request alterations to the standard machine design. Some
will be on a no charge basis. Any days beyond the first 50 days will be of the more-commonly requested modifications affect lubrication
charged against the purchase order at established service rates. systems, walkways, hand rails, lighting systems and guards.
The normal working day for the P&H MinePro Services advisor is While some modifications might improve the ability of the purchaser
eight hours on site per day. The normal work week is five days per to utilize and maintain the shovel, some modifications might in fact
week (Monday through Friday excluding holidays). Time spent on adversely affect productivity over time or have significant safety impli-
site beyond the normal work week or day will be charged against the cations not readily ascertainable.
purchase order at established service overtime rates. Accordingly, it is imperative that any modifications sought by the
shovel purchaser of the kind noted above (or any other significant
modifications) be discussed with your P&H MinePro Services
shovel project manager. In turn, your shovel project manager will
Personnel Requirements discuss your requests with P&H Mining Equipment shovel design
engineers to determine if the modifications can be carried out. P&H
The assembly history for the P&H Model 4100C indicates assembly Mining Equipment and P&H MinePro Services make every effort to
can be made within 5200-5500 man-hours. The history also indicates accommodate the purchaser’s requests while taking into consider-
that if proper manpower is not available, the 50 working day period ation the machine’s optimal productivity and mine application, as well
of assembly and placement into operation will be exceeded. We as current design and safety specifications and regulations.
therefore advise that the following labor types should be available at
various stages of machine assembly. It is most important that any modification to the machine be
4— Laborers (for the purpose 1— Millwright documented so that P&H Mining Equipment and P&H MinePro
of cleaning parts before 3— Electricians Services can maintain current drawings and specifications for your
their assembly) 2— Welder electric shovel. Furthermore, any future service involving the P&H
3— Mechanics Mining Equipment engineering staff can be expedited if modifications
After the initial cleaning and opening of the packing cases, the two are known and documented.
laborers may be replaced by additional mechanics and millwrights, as Please be aware that any modification performed without P&H Mining
the tasks of the mechanics and millwrights will be more prevalent. Equipment and P&H MinePro Services concurrence might void the
Not included in the above workforce list are the supervisory personnel warranty.
mentioned previously. The necessary mechanical and electrical Some modifications requested by the purchaser can be accommo-
supervision should be present when the various trades are involved in dated at no additional charge. However, some modifications require
the assembly of the machine. additional welding or other services that cannot be absorbed by P&H
This listing does not include crane operators or oilers (if there is a Mining Equipment or P&H MinePro Services. The purchaser will be
requirement for their use). notified of such costs in advance of the work being performed.
 BASIC RIGGING MATERIAL REQUIREMENTS BASIC TOOL REQUIREMENTS (continued)
Cranes 6 — 6 ton come-alongs
Two (2) heavy-lift cranes are required at the start of the erection, 6 — 1/5 ton come-alongs
staying on-site until all the heavy lifts are completed and the boom 4 — 3/4 ton come-alongs
has been pinned to the revolving frame. After raising the boom, the 2 — 1/2" torque wrenches
balance of the assembly process can proceed with one (1) rough 1 — 3/4" torque wrench
terrain crane in the 30-ton to 50-ton (27,216 kg to 45,360 kg) class. 1 — 1" torque wrench
1 — torque multiplier 181/2 : 1
Heavy-lift crane size requirements are based on many factors, 1 — 48" aluminum pipe wrench
including crane access to heavy lifts, type of crane used, cold 2 — 24" pipe wrenches
weather capacity de-rating, reach, and pick-and-carry capability. 1 — 24" aluminum pipe wrench
1 — 24" chain wrench
Therefore, in extreme cold weather erection environments, two 225- 1 — 24" crescent wrench
ton (204,120 kg) cranes are recommended. In moderate weather, 1 — open end wrenches 5/16" through 21/2" in 1/16" increments
one 150-ton (136,080 kg) and one 190-ton (172,368 kg) crane are 1 — hammer wrenches 11/8" through 31/8" in 1/16" increments
recommended for heavy lifts. 1 — 4" hammer wrench
Cables / Slings Basic Power Tools
4 — 2-1/2" x 25' 4 — 1-3/4" x 20' 4 — 1-1/2" x 20' 1 — pneumatic air wrench, 1/2" drive, with sockets from 1/2" to 11/4",
4 — 1" x 12' 2 — 1-1/2" x 20' 4 — 3/4" x 10' in 1/8" increments
2 — 1-1/4" x 20' 2 — 5/8" x 20' 1 — spray paint gun
1 — air powered grinder, 9" right angle disc
10 — smaller cables (1/2" and 3/8", 15' long) to handle the misc. 1 — air powered 1/4" pencil grinder
material, such as brakes, blower motors, boxes, cab sections, etc. 1 — air powered chipping hammer w/chisels
Assortment of nylon slings 1 — welding machine, 400 amp capacity (portable gasoline or
Shackles and Pins diesel driven), including 100' long welding cables
4 — 85-ton shackles 4 — 55-ton shackles 1 — portable air compressor, 150 CFM capacity, with 2 ea. 100'
4 — 35-ton shackles 4 — 25-ton shackles long hoses with inline oilers
1 — portable light plant or electric power supply if needed
Pins -- six (6) each in the following sizes: 1/4", 3/8", 1/2", 3/4", 1" 1 — electric heated rod oven
Blocking (Hardwood) 2 — oxygen/acetylene burning sets with 75' hose
40 ea. 8" x 8" or 10" x 10" in 6', 4', and 2' lengths 2 — 50-ton hydraulic jacks
Plywood and 2" lumber (available from shipping crates / boxes) 2 — 1/2" electric drills
2 — 1/2" cordless drills
This material is used for setting the various components on the 1 — 1/2" angle drill
ground. The carbody is blocked 48" high for side frame clearance 2 — 3/8" electric drills
with shoes on. 1 — magnetic drill
1 — 11/2" drive pneumatic impact wrench
Optional Time-Saving Equipment 2 — 1" drive pneumatic impact wrenches
One 10-ton* (9.072 kg.) forklift. 1 — 3/4" Super-bolt impact wrench
2 — 3/4" drive pneumatic wrenches
4 — 1/4" die grinders
9 — 5" grinders
BASIC tool REQUIREMENTS 5 — 7" grinders
2 — straight grinders
Basic Hand Tools Basic Electrical Tools 2 — reciprocating saws
2 — 6" screwdrivers 1/4" face 1 — knock out punch set 1 — soldering gun
2 — 8" screwdrivers 3/8" face 1 — hydraulic hand pump 6 — 600 amp welders
2 — 12" screwdrivers 1/2" face knock out punch kit 4 — wire feeders
2 — 15" adjustable open end wrenches 1 — hole saw kit 4 — air arcs
2 — 12" adjustable open end wrenches 2 — manualCrimpers 1 — diesel genset - 300 kW
4 — 12" long bastard files 1 — hydraulic crimpers
6 — 4" paint brushes for use with cleaning solvent 3 — heat guns
1 — crosscut saw
3 — 36" wrecking bars Miscellaneous Items 100 — lbs. 3/32" weld rod
2 — 20 lb. sledge hammers 3 — tarpaulins, 30' x 30' 300 — lbs. 1/8" weld rod
4 — 2 lb. ball peen hammers 2 — 12' step ladders - straight 200 — lbs. 3/16" weld rod
2 — 20' extension ladders (low hydrogen, pre-dried)
6 — putty knives 3" wide
2 — barrels of cleaning solvent 300 — feet manila rope
1 — heavy-duty mechanic’s tool set 100 — lbs. cleaning rags
20 — rolls masking tape 1"
2 — wire brushes 50 — sheets of fine emery cloth 2000 — lbs. (approx.) dry ice
3 — each tapered drifts, 12" long, 5/8" and 5/8" dia. 50 — sheets of medium emery (the exact quantity required
2 — 1/2" drive socket wrench sets, including two extensions, cloth will depend upon location
ratchet and sockets, from 7/16" to 11/4", in 1/8" increments 2 — wooden stairway with of source and ambient
13/4" drive socket wrench set, including ratchet and sockets, railing for boarding temperature)
from 1" to 3", in 1/8" increments 25 — rolls black plastic electrical — or —
6 — 3-ton come-alongs tape Liquid Nitrogen - 4 bottles,
2 — standard bolt tap set—1/4" to 11/2" in 1/8" increments 25 — rolls of friction tape approximately 370 lbs. of
2 — drill bit set—3/16" to 5/8" in standard increments 5 — anti-seize lubricant (cans) product each bottle and
1 — set of rotary files for pencil grinder 5 — dye check kits for must have liquid withdrawal
1 — 3/4" drive breaker bar checking welds (NDT-PT) capabilities
1 — 1" drive breaker bar 6 — fire extinguishers—20 lb. 3 — 6-foot step ladder
1 — 1" drive socket wrench set, ratchet and sockets, from 11/16" dry chemical type 3 — 8-foot step ladder
through 31/2" in 1/16" increments Painting supplies
1 — 1" Swivel Assorted-color electrical tape
1 — 11/2" Swivel
1 — 1” to 11/2" Adapter The above tool listing indicates the basic minimum range and quantity
1 — 11/2" to 1" Adapter of tools recommended. The list is not intended to be all-inclusive.
1 — set of 11/2" drive sockets from 2" through 4¾" in 1/16"
increments Data Codes
Extensions: 2 — 3/4" drive by 8", 1— 3/4" drive by 13", 2 — 1" *1 ton = 2,000 pounds (907.2 kg)
drive by 8", 1 — 1" drive by 13", 1 — 11/2" drive by 12" 10' = 10 feet (305 cm) 10" = 10 inches (25.4 cm)
 4100C Lifting or Hitching Points and approximate weights* of major items
77,000 lbs. 92,500 lbs.
(34,927 kg) CL Rotation (41,958 kg)

10'-10" X
(3.30 m) X
6'-6"
(1.98 m)
X
X
Width: 15'-1" (4.60 m)
Crawler (R.H. shown) w/o Shoes-Weight: 172,000 (78,019 kg)
Weight: 169,500 lbs. (76,890 kg)

29'-6" (8.99 m) 120,000 lbs. 52,000 lbs.

Revolving Frame w/Sidestand (54,432 kg) (23,588 kg)

34'-7" (10.54 m)

41,125 lbs. 41,125 lbs.

(18,655 kg) (18,655 kg) 7'-4"
(2.24 m)

Crawler Frame w/o Shoes

5'-7"
(1.7 m)

Crawler shoes:72" (1.83 m)

44 Shoes each Belt - Weight: 140,000 lbs.
Counterweight Box (63,504 kg)
Width: 13'-11" (4.24 m)
Weight 82,250 lbs. (37,309 kg)
Crawler shoes: 84" (2.13 m)
44 Shoes each Belt - Weight: 151,000 Lbs.
(68,494 Kg.)

3'-4" 4'-2"
(1.02 m) (1.27 m)
92,500 lbs. 92,500 lbs.
(41,957 kg) (41,957 kg)

25,000 lbs. 25,000 lbs. 25,000 lbs. 25,000 lbs. 25,000 lbs. 25,000 lbs.
(11,340 kg) (11,340 kg) (11,340 kg) (11,340 kg) (11,340 kg) (11,340 kg)
7'-9" Width: 22'-6"
(2.36 m) Weight: 185,000 lbs.
(With Roller Path)
(83,915 kg)

7'-4" 7'-4" 7'-4"

(2.24 m) (2.24 m) (2.24 m) 16'-3" (4.95 m)
Carbody

8'-10" (2.69 m) 9'-9" (2.97 m) 9'-9" (2.97 m)

Wing Sections (2) Mid Sections (2) Center Section (1)
Counterweight Slabs
Weight: 50,000 lbs. (each) (22,680 kg)
15'-6"
(4.72 m)
85,300 lbs. 43,500 lbs.
(38,691 kg) (19,731 kg) Width: 17'-0" (5.2 m)
137,500 lbs. ** Weight: 150,000 lbs. (68,040 kg)
(62,369 kg)
Note: Use 3.00” machined holes as hitch
points. Do not use the welded-on lugs to ** Hitch point load encountered
raise the boom. when raising a fully-dressed
boom into position. 15'-0" (4.57 m)

56 yd³ (42.8 m³) Bail-less Dipper

Width: 14'-1" (4.29 m) Typical values only; there is no standard dipper.
Bare Boom Weight: 129,800 lbs. (58,877 Kg.) 8'-0"
Fully-Dressed Boom weight: 231,500 Lbs. (2.44 m)
(105,008 Kg.)

65'-10" (20.05 m) Center Gudgeon

Weight: 6,600 lbs. (2,994 kg)

52,850 lbs.
30,570 lbs.
(23,973 kg) 20"
(13,867 kg) 11" (279 mm)
(508 mm)

Dipper Handle
111.6" (2.82 m)
6'-0" (1.83 m)
Dry ice to freeze center gudgeon (shown above) for field installation into carbody.
Width: 10'-7"(3.23 m)
The quantity will depend on location of supplier, and ambient temperature.
Weight: 83,420 lbs (37,840 kg)
36'-3" (11.04 m)
The side loading to any welded-on lifting
lug cannot exceed ±5° from the vertical.
*Weights are ± 10%. For the actual weight of each component, refer to the packing list.
U.S. AND CANADIAN SHIPMENTS

95

DIPPER
Figure 1 depicts the recommended placement
90
67 of parts at the erection site. Each item shown
is numbered and refers to the Component List
(Table 1) which gives the approximate weights
68
of the components. For the actual weights, refer
85 66 66 to the machine packing list. The item numbers
shown in Figure 1 and Table 1 correspond to the
machine packing list, items 1 through 62. Items

HANDLE
DIPPER
80 beyond 62 are randomly applied.

75

52
50
70
53

65

70
60 71
COUNTER WEIGHT
34 BOX 72 46 26
73
55
47 49 32
20
44 71 74
50
21 REVOLVING
38 FRAME
39 22
45 HOIST
27 CASE
29 RING
31 14 S S 17 GEAR
41 30 36 I I 1
D D
40 37 E CARBODY E 12
40 2 HOIST
63 15 F F 18
11 7 DRUM
R R
TOOL A A 23
CONTAINER M M ROLLER
35 16 E E 19 CARRIER

69 69
LUNCH
ROOM

13 6 13 PROPEL 62
MOTOR 25
30 45 BASE 8 9 10
5 33
48 24 28 51
54 BOOM
35
25 55
56 59 60 61 59 GANTRY

57
20 GANTRY LEGS
64

65
58
3
15
43

NOTE BOOM
10 POINT
Electrical cabinets, transformers,
AC & DC motors, etc. must be
stored under cover until required.
5

0 5 10 15 20 25 30 35 40 45 50 55 60 65
METERS

Figure 1
 4100C COMPONENT LIST - U.S. & CANADA
Approx. Weight*
Assemblies without Pre-Assigned Box or Approx. Weight*
BOX or Crate Numbers
CRATE #
Description of Contents Lbs. Kg Description of Contents Lbs. Kg
1 Kit #1 Hardware for Revolving Frame 855 388 Air Tugger Bracket 850 385
2 Kit #2 Hardware for Carbody 1,170 531 Auxiliary & Field Transformer 5,200 2,358
Kit #3-If this is packed inside of the boom hardware Auxiliary Control Cabinet 1,200 544
3
box, then the boom hardware box will be box #3 300 136 Boom 128,800 58,423
4 Contains Kit #4 Hardware for Cab & Upper 1,205 546 Boom Point Sheave Assembly 14,250 6,463
5 Contains Kit #5 Hardware for Catwalk & Carbody with Lube and Collector Shoes 185,000 83,915
Railing 515 234 Center Gudgeon Assembly 9,000 4,082
6 Corduroy Bolt Box 6,000 2,721 Control Cabinet 2,000 907
7 Lower Assembly Parts 4,000 1,814 Converter 10,300 4,672
8 House Rollers 2,150 975 Counterweight Box 81,850 37,127
9 House Rollers 2,150 975 Counterweight Cast Assembly-4 pcs. 50,000 22,680
10 House Rollers 2,150 975 Crowd Motor Assembly 13,800 8,260
11 Assembly Tools 950 431 Crowd Motor Base 2,950 1,338
12 High-Voltage Guards 1,550 703 Crowd Motor Cover 15,800 7,166
13 Crawler Shoe Pin and Hardware 9,210 4,177 Crowd Transmission 15,800 7,166
14 Crawler Shoe Pin and Hardware 9,210 4,177 Dipper (See Packing List for Weight)
Shoe Size 5.0” Pins 5.0” Pins Gantry Compression Member Assembly 21,900 9,932
15 Crawler Shoe 72” (183 cm) 3,460 1,573 Gantry Tension Members 11,950 5,420
16 Crawler Shoe 76” (193 cm) 3,795 1,725 Handle 84,600 38,374
17 Crawler Shoe 84” (213 cm) 3,720 1,691 High Voltage Cabinet 1,300 590
18 Crawler Shoe 87” (221 cm) 3,915 1,780 Hoist Cable Reels (each) 5,740 2,603
19 Crawler Shoe 96” (244 cm) 4,820 2,191 Hoist Drum Assembly 52,600 23,860
Crawler Shoe 108” (274 cm) 5,095 2,316 Hoist Motor Base, Front 3,900 1,769
20 House Cab Parts 450 204 Hoist Motor Base, Rear 3,900 1,769
21 House Panels 3,800 1,723 Hoist Motor Front 17,000 7,711
22 Boarding Stairway/Ladder 2,630 1,193 Hoist Motor Rear 17,000 7,711
23 Spherical Washer 400 181 Hoist Transmission Assembly 34,075 15,454
24 Low-Voltage Collector 1,200 544 Left Hand Elevated Section 12,850 5,828
25 Air Compressor 2,350 1,066 Main Transformer & Supp. Cabinet 21,475 9,739
26 Troughs and False Floor 2,550 1,156 Operator’s Coop 18,300 8,301
27 Swing Shafts 9,650 4,377 Propel Motor Base 23,300 10,569
28 Gantry Parts 2,150 975 Propel Motor 7,060 3,202
29 Paint 450 204 Rear Enclosures 14,100 6,395
30 Carbon Dioxide Cylinders 200 91 Rear Roof Section 12,243 5,554
31 Upper Assembly Parts 750 340 Revolving Frame (Including Sidestand) 171,750 77,905
32 Air Duct Kit “Bleed Rear Roof” 350 159 Right Hand Elevated Section 17,850 8,097
33 Shear Bar Kit “Carbody” 2,200 998 Right Hand Platforms 11,117 5,042
34 Left Hand and Right Hand Platforms 15,600 7,075 Roller Carrier Ring 2,584 1,172
35 Boom Electrical 950 431 RPC Cabinets 15,900 7,211
36 Miscellaneous-Electrical 1,500 680 RPC Switching Cabinet 2,700 1,224
37 Miscellaneous-Wire 1,050 476 Saddle Blocks (each) 11,150 5,057
38 Floodlights 600 272 Shipper Shaft 13,000 5,896
39 Heaters “Portable” 500 227 Shipper Shaft Gear 6,900 3,129
40 House Lighting Kit 850 385 Sideframe Left with Transmission 156,400 70,943
41 Buss Bars 3,500 1,587 Sideframe Right with Transmission 156,400 70,943
42 Boarding Ladder Material 200 91 Suspension Cables (each) 11,350 5,148
43 Shipper Shaft Adjusters 450 204 Swing Gear 21,000 9,525
44 Remaining Floodlight Assy. & Hard. 600 272 Swing Motor Front 8,600 3,900
45 Air Conditioner Parts 150 68 Swing Motor Rear 8,600 3,900
46 Logo Letters 1,175 533 Swing Transmission/Front Motor 14,300 6,486
47 Counterweight Box Reinforcement 2,050 930 Swing Transmission/Rear Motor 14,300 6,486
48 Boom-Sealtite-4” 500 227 Transfer Cabinet 1,200 544
49 Mounting Bolts-Cast Counterweight 300 136
50 Canopy Arch 9,600 4,354
51 Hoist Cable Hoods 3,950 1,791
52 Hatch Covers 6,800 3,084
53 Side Beams 3,500 1,587
54 Railing Crate 3,400 1,542
55 Catwalks #1 1,850 839
56 Catwalks #2 3,500 1,587
57 Catwalks #3 3,650 1,655
58 Boom Platforms 7,750 3,515
59 Shipper Shaft Pinions 4,450 2,018
60 Shipper Shaft Retainer w/Washer 650 295
61 Shipper Shaft Retainer w/Washer 650 295
62 Lower Disconnect Switch 850 385
63 House Heaters 150 68
Weights are ±10%. For actual weight of each component, refer to packing list.
Table 1
EXPORT SHIPMENTS

Figure 2 depicts the recommended placement

95 of parts at the erection site. Each item shown
DIPPER is numbered and refers to the Component List
(Table 2) which gives the approximate weights
of the components. For the actual weights, refer
90
to the machine packing list. The item numbers
shown in Figure 2 and Table 2 correspond to the
23 machine packing list.
85 42 43

HANDLE
DIPPER
80

104 105
75

52
50
70
53

65

63
82
60 COUNTER WEIGHT 64
BOX
34 16 65 46 26
66
55
47 49 83
20
44 71 112
50
21 REVOLVING
38 FRAME
15 74
39 22
4 75 HOIST
45 27 24 CASE
29 CRAWLER CRAWLER RING
31 SHOES S S SHOES GEAR
41 30 36 I I
D D
40 37 E CARBODY E 12
40 113 HOIST
87 F 1 F
11 7 DRUM
R R
TOOL A A 73
CONTAINER M M ROLLER
35 E 2 3 E CARRIER
5 18
76 77
LUNCH

14 6 13 62 17
ROOM

PROPEL
110 MOTOR 25
30 45 BASE 8 9 10
61 94 48
72 28 51
54 108 BOOM
19 35
25 55
56 59 60 60 59 32 GANTRY

57
20 33 GANTRY LEGS 114
69 90

70
93 58 106 107
95
15

BOOM
10 POINT
67

0 5 10 15 20 25 30 35 40 45 50 55 60 65
METERS
Figure 2
 4100C component list - export
Site Approx. Weight* Site Approx. Weight*
Location Description of Contents Lbs. Kg Location Description of Contents Lbs. Kg
1 Carbody with Lube and Collector Shoes 185,000 83,915 57 Catwalks #3 3,550 1,610
2 Sideframe (Left) with Transmission 156,400 70,943 58 Boom Platforms 7,750 3,515
3 Sideframe (Right) with Transmission 156,400 70,943 59 Shipper Shaft Pinions 4,450 2,018
4 Swing Gear 21,000 9,525 60 Crowd Motor Blower 750 340
5 Propel Motor Base 23,300 10,568 61 Dipper Trip Motor 1,875 850
6 Corduroy Bolt Box 6,000 2,721 62 Lower Disconnect Switch 850 385
7 Lower Assembly Parts 4,000 1,814 63 Counterweight Cast Assembly - 4 pcs. 50,000 22,680
8 House Rollers 2,150 975 64 Counterweight Cast Assembly - 4 pcs. 50,000 22,680
9 House Rollers 2,150 975 65 Counterweight Cast Assembly - 4 pcs. 50,000 22,680
10 House Rollers 2,150 975 66 Counterweight Cast Assembly - 4 pcs. 50,000 22,680
11 Assembly Tools 7,500 3,401 67 Boom Point Sheave Assembly 14,250 6,463
12 High-Voltage Guards 1,550 703 68 Center Beams 3,500 1,587
13 Crawler Shoe Pin and Hardware 9,210 4,177 69 Catwalks #4 1,350 612
14 Crawler Shoe Pin and Hardware 9,210 4,177 70 Catwalks #5 2,500 1,134
15 Revolving Frame (Including Sidestand) 171,750 77,905 71 Right Hand Elevated Section 17,850 8,097
16 Counterweight Box 81,850 37,126 72 Left Hand Elevated Section 12,850 5,828
17 Air Receiver Tank Box (Optional) 1,100 499 73 Hoist Drum Assembly 52,600 23,859
18 Center Gudgeon Assembly 9,000 4,082 74 Hoist Motor Base, Front 3,900 1,769
19 Boom 128,800 58,423 75 Hoist Motor Base, Rear 3,900 1,769
20 House Cab Parts 950 431 76 Swing Transmission/Front Motor 14,300 6,486
21 House Panels 3,800 1,723 77 Swing Transmission/Rear Motor 14,300 6,486
22 Boarding Stairway/Ladder 2,630 1,193 78 Hoist Motor Front 17,000 7,711
23 Handle 84,600 38,374 79 Hoist Motor Rear 17,000 7,711
24 Low-Voltage Collector (Part of Box 11) 80 Swing Motor Front 8,600 3,900
25 Air Compressor 2,350 1,066 81 Swing Motor Rear 8,600 3,900
26 Troughs and False Floor 2,550 1,156 82 Pressurization System 21,000 9,526
27 Swing Shafts 9,650 4,377 Opt. Presssurization System (AirScrubPro) 34,950 15,853
28 Gantry Parts 2,150 975 83 Air Duct Kit “Bleed Rear Roof” 1,900 862
29 Paint 450 204 84 Air Duct Kit “Bleed Rear Roof” 1,900 862
30 Carbon Dioxide Cylinders 200 91 85 Air Conditioner 2,600 1,179
31 Upper Assembly Parts 8,000 3,628 86 Right Hand Boom Extension 4,500 2,041
32 Gantry Compression Member 22,500 10,206 87 Operator’s Coop 18,300 8,301
33 Gantry Tension Members 11,950 5,420 88 Boom Catwalk #1 3,000 1,361
34 Left Hand and Right Hand Platforms 15,600 7,076 89 Boom Catwalk #2 3,250 1,474
35 Boom Electrical 850 386 90 Shipper Shaft 13,000 5,896
36 Gantry Platform 2,800 1,270 91 Bearing Retainers 2,200 998
37 Miscellaneous - Wire 1,050 476 92 Crowd Motor Assembly 13,800 6,259
38 Floodlights 600 272 93 Crowd Case Cover 15,800 7,166
39 Platform Supports R/L Hand 3,000 1,361 94 Crowd Motor Base 2,950 1,338
40 House Lighting Kit 850 385 95 Boom Hardware 1,050 476
41 Buss Bars 3,500 1,587 96 Load Center Panel 2,500 1,134
42 Saddle Blocks (each) 11,150 5,057 97 Main Transformer & Supp. Cabinet 21,475 9,741
43 Saddle Blocks (each) 11,150 5,057 98 High Voltage Cabinet 1,300 590
44 Floodlight Assembly and Hardware 1,125 510 99 Auxiliary & Field Transformer 5,200 2,358
45 Air Tugger Bracket 850 385 100 Converter 10,300 4,672
46 Logo Letters 1,175 533 101 Transfer Cabinet 1,200 544
47 Counterweight Box Reinforcement 2,050 930 102 RPG Switching Cabinet 2,700 1,224
48 Boom-Sealtite - 4” 500 227 103 Dipper Trip Resistor Assembly 1,950 884
49 Low Voltage Cover Guard 700 317 104 Reel Hoist Cable 5,800 2,630
50 Canopy Arch 9,600 4,354 105 Reel Hoist Cable 5,800 2,630
51 Hoist Cable Hoods 3,950 1,791 106 Suspension Cables (each) 11,350 5,148
52 Hatch Covers 6,800 3,084 107 Suspension Cables (each) 11,350 5,147
53 Side Beams 3,500 1,587 108 Shipper Shaft Gear 6,900 3,129
54 Railing Crate 3,400 1,542 109 Left Hand Boarding Ladder 1,750 794
55 Catwalks #1 1,850 839 110 Kit Boxes
56 Catwalks #2 3,500 1,587 111 Air Conditioner Parts
112 Rear Enclosure Panels

Table 2

Weights are ±10%. For actual weight of each component, refer to packing list.
 electrical test equipment requirements
Basic Electrical Test Instrumentation Recommended to Commission and Maintain Centurion Digital Drive Mining Excavator.
Recommended Maintenance Test Equipment Available through P&H and other Vendors.

Description P&H Part # Description P&H Part #

DMM (Digital MultiMeter) Drive Communications (hardware and software) R40775D3
Fluke Model 23 89Z514D12 RPC Capacitor Test unit 89Z508D1
Alternate DMM—Fluke, Model 87 1089Z275
Voltage Divider R1192F1
Oscilloscope
Hand-held Drive Programmer, ABB CDP-312R R46072D7
Tektronix Model THS720A (Hand-held, Dual Trace,
Digital, Storage, Battery Powered, Soft Case) Scope 2 Meter Connection Cable R46072D8
w/120V / 60Hz Adapter 89Z515D16 SCR (Thyristor) Tester 89Z511D1
120V / 50 Hz AC Adapter (240V Adapters Available) 89Z515D30
Hard Carrying Case 89Z515D26
X10 Probe (1kV) 89Z515D17
R5-232 to 485 Converter—for loading ABB drive
firmware ABB NPCU-01-KIT R49117D1
Megger—500V & 1000V Scales (hand-crank /w case)
James D. Biddle Cat. 21158 89Z496
Clamp-On Ammeter—1A to 600A AC / 1000A (DC)
Fluke Model i1010 89Z514D15
High Voltage Differential Probe—P5200 89Z515D21
Laptop computer—Consult service department
for specs N/A

NOTE: All designs, specifications and components of equipment described above are subject to change at manufacturer’s sole discretion at any time without
advance notice. Data published herein is informational in nature and shall not be construed to warrant suitability of machine for any particular purpose as
performance may vary with conditions encountered. The only warranty applicable is our standard written warranty for this machine.

P&H Mining Equipment  •  Box 310  •  Milwaukee, Wisconsin 53201 USA

XS-4462 2AG-07
 ®

4100 Series A
DC ELECTROTORQUE® MINING SHOVEL
DUAL PLANETARY PROPEL & SWING

ERECTION PROCEDURE
ERECTION ASSISTANCE

With the purchase of your Model 4100A electric mining shovel, a P&H
MinePro Services advisor or MinePro Contract Services person will
be provided for a period of 50 working days to assist the purchaser or
the purchaser’s erection contractor with the erection of the machine.
The purchaser should arrange to erect, test and place the machine
into operation during this 50 day period.
The P&H MinePro Services advisor can provide advice only. He is
available to advise the purchaser or the purchaser’s erection contrac-
tor on erection sequences, commissioning procedures, testing and
other erection details as requested, but is not authorized to supervise
workers or to direct the erection, testing or commissioning in any way.
The purchaser will be required to provide all tools, equipment and
personnel needed to erect the machine, as well as supervision of per- SAFETY: All safety related equipment requirements and
sonnel erecting the machine. For example, the P&H MinePro Services procedures are the responsibility of the Purchaser and
advisor is available to consult with supervisory personnel on ques- or designated Erection Contractor and should be in
tions such as places to make hitches on components, but P&H Mining accordance with all applicable MSHA, Local Mine, State
Equipment will not be responsible for placement of such hitching or Authorities and regulations.
for working with lifting equipment. P&H Mining Equipment will not be
liable in any event for any indirect, special or consequential damages. NOTE: The purchaser is to supply all necessary start-up
Purchaser shall indemnify and hold P&H Mining Equipment harmless lubrication materials, oils, greases, etc., per P&H
for all liability for damage to property or personal injury (including specifications.
death) arising out of purchaser’s erection, testing or placing into serv-
ice of the machine. ERECTION SITE AND MATERIAL LOCATION
The P&H MinePro Services advisor is not authorized to approve mod-
ifications to the machine that are not covered by the machine data Erection site preparation is the responsibility of the Purchaser and
sheet, nor will P&H Mining Equipment accept any back-charge for any should be a flat leveled area, with good drainage, and stable under
unauthorized modifications made.(See section titled “Machine footing to support the lifting equipment and their floats or outriggers
Modification Procedure”.) during any lift to be made.
The purchaser or the purchaser’s erection contractor should contact The area required is approximately 300 feet (91.4 m) square, with a
the nearest P&H Mining Equipment regional office to schedule the tool shed.
P&H MinePro Services advisor. We ask the purchaser, prior to the
arrival of P&H MinePro Services advisor, to issue a purchase order MACHINE MODIFICATION PROCEDURE
covering the P&H MinePro Services advisor. The first 50 normal work-
During the shovel erection process, the shovel purchaser will some-
ing days will be on a no charge basis. Any days beyond the first 50 times request alterations to the standard machine design. Some of
days will be charged against the purchase order at established serv- the more-commonly requested modifications affect lubrication sys-
ice rates. tems, walkways, hand rails, lighting systems, guards and PLCs.
The normal working day for the P&H MinePro Services advisor is While some modifications might improve the ability of the purchaser
eight hours on site per day. The normal work week is five days per to utilize and maintain the shovel, some modifications might in fact
week (Monday through Friday excluding holidays). Time spent on site adversely affect productivity over time or have significant safety
beyond the normal work week or day will be charged against the pur- implications not readily ascertainable.
chase order at established service overtime rates.
Accordingly, it is imperative that any modifications sought by the
shovel purchaser of the kind noted above (or any other significant
ERECTION PERSONNEL REQUIREMENTS modifications) be discussed with your P&H MinePro Services shov-
The erection history for the Model 4100A indicates erection can be el project manager. In turn, your shovel project manager will discuss
made within 5200-5500 man-hours. The history also indicates that if your requests with P&H Mining Equipment shovel design engineers
to determine if the modifications can be carried out. P&H Mining
proper manpower is not available, the 50 working day period of erec- Equipment and P&H MinePro Services make every effort to accom-
tion and placement into operation will be exceeded. We therefore modate the purchaser’s requests while taking into consideration the
advise that the following labor types should be available at various machine’s optimal productivity and mine application, as well as cur-
stages of machine erection. rent design and safety specifications and regulations.
4—Laborers (for the purpose of cleaning parts before they undergo It is most important that any modification to the machine be docu-
assembly) mented so that P&H Mining Equipment and P&H MinePro Services
3—Mechanics can maintain current drawings and specifications for your electric
1—Millwright shovel. Furthermore, any future service involving the P&H Mining
3—Electricians Equipment engineering staff can be expedited if modifications are
2—Welders known and documented.
Please be aware that any modification performed without P&H
After the initial cleaning and opening of the packing cases, the four Mining Equipment and P&H MinePro Services concurrence might
laborers may be replaced by additional mechanics and mill-wrights, void the warranty.
as the tasks of the mechanics and millwrights will be more prevalent.
Some modifications requested by the purchaser can be accommo-
We have not included the supervision mentioned previously. The nec- dated at no additional charge. However, some modifications require
essary mechanical and electrical supervision should be present when additional welding or other services that cannot be absorbed by
the various trades are involved in the erection of the machine. P&H Mining Equipment or P&H MinePro Services. The purchaser
will be notified of such costs in advance of the work being per-
This listing does not include crane operators or oilers (if there is a formed.
requirement for their use).

1
BASIC RIGGING MATERIAL REQUIREMENTS BASIC HAND TOOLS (continued)
Cranes 2—wire brushes
3—each tapered drifts, 12" long, 5/8" and 3/4" dia.
Two (2) heavy-lift cranes are required at the start of the erection, 2—1/2" drive socket wrench sets, including two extensions,
staying on-site until all the heavy lifts are completed and the boom ratchet and sockets, from 7/16" to 1-1/4", in 1/8"
has been pinned to the revolving frame. After raising the boom, the increments
balance of the erection process can proceed with one (1) rough-ter- 1—3/4" drive socket wrench set, including two extensions,
rain crane in the 30-ton to 50-ton (27,216-kg to 45,360-kg) class. ratchet and sockets, from 1" to 3", in 1/8" increments
6—3-ton P&H hoists
Heavy-lift crane size requirements are based on many factors, 2—standard bolt tap set—1/4" to 1-1/2" in 1/8" increments
including crane access to heavy lifts, type of crane used, cold 2—drill bit set—3/16" to 5/8" in standard increments
weather capacity de-rating, reach, and pick-and-carry capability.
1—set of rotary files for pencil grinder
Therefore, in extreme cold weather erection environments, two 225- 1—torque wrench
ton (204,120-kg) cranes are recommended. In moderate weather, 1—torque multiplier (2,500 ft.-lbs. capacity)
one 150-ton (136,080 kg) and one 190-ton (172,368-kg) crane are
recommended for heavy lifts.
Basic Power Tools
Cables 1—1/2" drive reversible electric drill motor 110 vac
4—2.5" x 25' 4—1-3/4" x 20' 4—1-1/2" x 20' 1—pneumatic air wrench, 1/2" drive, with sockets from
4—1" x 12' 2—1-1/2" x 20' 4—3/4" x 10' 1/2" to 1-1/4", in 1/8" increments
2—1-1/4" x 20' 2—5/8" x 20' 1—spray paint gun
10—smaller cables (1/2" and 3/8", 15' long) to handle the 1—air powered grinder, 9" right angle disc
miscellaneous material, such as brakes, blower 1—air powered 1/4" pencil grinder
motors, boxes, cab sections, etc. 1—air powered chipping hammer
Assortment of nylon slings 1—welding machine, 400 amp capacity (portable gasoline
or diesel driven), including 100' long welding cables
Shackles and Pins 1—portable air compressor, 150 CFM capacity, with 2 ea.
Four (4) 85-ton shackles 100' long hoses with inline oilers
Four (4) 55-ton shackles 1—portable light plant or electric power supply if needed
Four (4) 35-ton shackles 1—electric heated rod oven
Four (4) 25-ton shackles 2—oxygen acetylene burning sets with 75' hose
Pins -- six (6) each in the following sizes: 1/4", 3/8", 1/2", 3/4", 1" 2—50-ton hydraulic jacks
Blocking (Hardwood) Basic Miscellaneous Items
40 ea. 8" x 8" or 10" x 10" in 6', 4', and 2' lengths 3—tarpaulins, 30' x 30'
Plywood and 2" lumber (available from shipping crates / boxes) 2—15' step ladders
2—24' extension ladders
This material is used for setting the various components 2—barrels of cleaning solvent
on the ground. The carbody is blocked 48" high for side
frame clearance with shoes on. 20—rolls masking tape 1"
50—sheets of fine emery cloth
Optional Time-Saving Equipment 50—sheets of medium emery cloth
One 10-ton* (9.072 kg.) forklift. 2—wooden stairway with railing for boarding
25—rolls black plastic electrical tape
25—rolls of friction tape
BASIC TOOL REQUIREMENTS 5—anti-seize lubricant (cans)
Basic Hand Tools 5—dye check kits for checking welds (NDT-PT)
6—fire extinguishers—20 lb. dry chemical type
2—6" screwdrivers 1/4" face 100—lbs. each—3/16" and 3/32" weld rod—hydrogen (pre-dried)
2—8" screwdrivers 3/8" face 300—feet manila rope
2—12" screwdrivers 1/2" face 100—lbs. cleaning rags
2—15" adjustable open end wrenches 2000-lbs. (approx.) dry ice(the exact quantity required will depend
2—12" adjustable open end wrenches upon location of source and ambient temperature) or,
4—12" long bastard files Liquid Nitrogen - 4 bottles, approximately 370 lbs. of product
6—4" paint brushes for use with cleaning solvent each bottle and must have liquid withdrawal capabilities
1—crosscut saw 1—6-foot step ladder
3—36" wrecking bars 1—8-foot step ladder
2—20 lb. sledge hammers Painting supplies
4—2 lb. ball peen hammers Assorted-color electrical tape
6—putty knives 3" wide
1—heavy-duty mechanic’s tool set
The above tool listing indicates the basic minimum range and
quantity of tools recommended. The list is not intended to be
all-inclusive.

Data Codes
*1 ton = 2,000 pounds (907.2 kg)
10' = 10 feet (305 cm) 10" = 10 inches (25.4 cm)

2
 4100A LIFTING OR HITCHING POINTS AND APPROXIMATE WEIGHTS* OF MAJOR ITEMS

77,000 lbs. 92,500 lbs.

(34,927 kg) CL Rotation (41,958 kg)

10'-10"
(3.30 m) X X
6'-6"
(1.98 m)
X
X
Width: 15'-1" (4.60 m)
Crawler (R.H. shown) w/o Shoes-Weight: 172,000 (78,019 kg)
Weight: 169,500 lbs. (76,890 kg)

29'-6" (8.99 m) 120,000 lbs. 52,000 lbs.

Revolving Frame w/Sidestand (54,432 kg) (23,588 kg)

34'-7" (10.54 m)

41,125 lbs. 41,125 lbs.

(18,655 kg) (18,655 kg) 7'-4"
(2.24 m)

Crawler Frame w/o Shoes

5'-7"
(1.7 m)

Crawler shoes:72" (1.83 m)

44 Shoes each Belt - Weight: 140,000 lbs.
Counterweight Box (63,504 kg)
Width: 13'-11" (4.24 m)
Weight 82,250 lbs. (37,309 kg)
Crawler shoes: 84" (2.13 m)
44 Shoes each Belt - Weight: 151,000 Lbs.
(68,494 Kg.)

3'-4" 4'-2"
(1.02 m) (1.27 m)
92,500 lbs. 92,500 lbs.
(41,957 kg) (41,957 kg)

25,000 lbs. 25,000 lbs. 25,000 lbs. 25,000 lbs. 25,000 lbs. 25,000 lbs.
(11,340 kg) (11,340 kg) (11,340 kg) (11,340 kg) (11,340 kg) (11,340 kg)
7'-9" Width: 22'-6"
(2.36 m) Weight: 185,000 lbs.
(With Roller Path)
(83,915 kg)

7'-4" 7'-4" 7'-4"

(2.24 m) (2.24 m) (2.24 m) 16'-3" (4.95 m)
Carbody

8'-10" (2.69 m) 9'-9" (2.97 m) 9'-9" (2.97 m)

Wing Sections (2) Mid Sections (2) Center Section (1)
Counterweight Slabs
Weight: 50,000 lbs. (each) (22,680 kg)
15'-6"
(4.72 m)
85,300 lbs. 43,500 lbs.
(38,691 kg) (19,731 kg) Width: 17'-0" (5.2 m)
137,500 lbs. ** Weight: 150,000 lbs. (68,040 kg)
Note: Use 3.00” machined holes as hitch (62,369 kg)
points. Do not use the welded-on lugs to
raise the boom.
15'-0" (4.57 m)

56 yd³ (42.8 m³) Bail-less Dipper

Width: 14'-1" (4.29 m) Typical values only; there is no standard dipper.
Bare Boom Weight: 129,800 lbs. (58,877 Kg.) 8'-0"
Fully-Dressed Boom weight: 231,500 Lbs. (2.44 m)
(105,008 Kg.)

Center Gudgeon
65'-10" (20.05 m)
Weight: 6,600 lbs. (2,994 kg)

52,850 lbs.
30,570 lbs.
(23,973 kg) 20"
(13,867 kg) 11" (279 mm)
(508 mm)

Dipper Handle
111.6" (2.82 m)
6'-0" (1.83 m)
Dry ice to freeze center gudgeon (shown above) for field installation into carbody.
Width: 10'-7"(3.23 m)
The quantity will depend on location of supplier, and ambient temperature.
Weight: 83,420 lbs (37,840 kg)
36'-3" (11.04 m) *Weights are ±10%. For actual weight of each component, refer to packing list.

** Hitch point load encountered when raising a fully-dressed boom into position.
Caution: The side loading to any welded-on lifting lug cannot
exceed ±5° from the vertical.

3
Figure 1 U.S. AND CANADIAN SHIPMENTS

95
Figure 1 depicts the recommended placement of
DIPPER
parts at the erection site. Each item shown is
numbered and refers to the Component List
67
90 (Table 1) which gives the approximate weights of
the components. For the actual weights, refer to
68 the machine packing list. The item numbers
85 shown in Figure 1 and Table 1 correspond to the
66 66
machine packing list, items 1 through 63. Items
beyond 63 are randomly applied.

HANDLE
DIPPER
80

75

50 52
70
53

65

70
60 71
COUNTER WEIGHT
34 BOX 72 46 26
73
55
47 49 32
20
44 71 74
50
21 REVOLVING
38 FRAME
39 22
45 HOIST
27 RING CASE
29
31 14 S S 17 GEAR
41 30 36 I I 1
D D
40 37 E CARBODY E 12
40 2 HOIST
63 15 F F 18
11 7 DRUM
R R
TOOL A A 23
CONTAINER M M ROLLER
35 16 E E 19 CARRIER

69 69
LUNCH
ROOM

13 6 13 PROPEL 62
MOTOR 25
30 45 BASE 8 9 10
5 33
48 24 28 51
54 BOOM
35
25 55
56 59 60 61 59 GANTRY

57
20 GANTRY LEGS
64

65
3 58
15

NOTE 43
Electrical cabinets, transformers,
BOOM
10 AC & DC motors, etc. must be POINT
stored under cover until required.

0 5 10 15 20 25 30 35 40 45 50 55 60 65
METERS

4
Table 1 4100A COMPONENT LIST - U.S. & CANADA
BOX or APPROX. WEIGHT* BOX or APPROX. WEIGHT*
CRATE # DESCRIPTION OF CONTENTS LBS. KG. CRATE # DESCRIPTION OF CONTENTS LBS. KG.
1 Kit #1 Hardware for Revolving Frame 855 388 60 Shipper Shaft Retainer w/Washer 650 295
2 Kit #2 Hardware for Carbody 1,170 531 61 Shipper Shaft Retainer w/Washer 650 295
3 Kit #3-If this is packed inside of the boom 62 Lower Disconnect Switch 850 385
hardware box, then the boom hardware
box will be box #3 300 136 63 House Heaters 150 68
4 Contains Kit #4 Hardware for Cab & Upper 1,205 546
5 Contains Kit #5 Hardware for Catwalk &
Railing 515 234 Assemblies without Pre-Assigned
6 Corduroy Bolt Box 6,000 2,721 Box or Crate Numbers
7 Lower Assembly Parts 4,000 1,814
APPROX. WEIGHT*
8 House Rollers 2,150 975 DESCRIPTION OF CONTENTS LBS. KG.
9 House Rollers 2,150 975
10 House Rollers 2,150 975 Air Tugger Bracket 850 385
11 Assembly Tools 950 431 Auxiliary & Field Transformer 5,200 2,358
12 High-Voltage Guards 1,550 703 Auxiliary Control Cabinet 1,200 544
13 Crawler Shoe Pin and Hardware 9,210 4,177 Boom 128,800 58,423
14 Crawler Shoe Pin and Hardware 9,210 4,177 Boom Point Sheave Assembly 14,250 6,463
Shoe Size 5.0" Pins 5.0" Pins Carbody with Lube and Collector Shoes 185,000 83,915
15 Crawler Shoe 72" (183 cm) 3,460 1,573 Center Gudgeon Assembly 9,000 4,082
16 Crawler Shoe 76" (193 cm) 3,795 1,725 Control Cabinet 2,000 907
17 Crawler Shoe 84" (213 cm) 3,720 1,691 Converter 10,300 4,672
18 Crawler Shoe 87" (221 cm) 3,915 1,780 Counterweight Box 81,850 37,127
19 Crawler Shoe 96" (244 cm) 4,820 2,191 Counterweight Cast Assembly-4 pcs. 50,000 22,680
Crawler Shoe 108" (274 cm) 5,095 2,316 Crowd Motor Assembly 13,800 8,260
20 House Cab Parts 450 204 Crowd Motor Base 2,950 1,338
21 House Panels 3,800 1,723 Crowd Motor Cover 15,800 7,166
22 Boarding Stairway/Ladder 2,630 1,193 Crowd Transmission 15,800 7,166
23 Spherical Washer 400 181 Dipper (See Packing List for Weight)
24 Low-Voltage Collector 1,200 544 Gantry Compression Member Assembly 21,900 9,932
25 Air Compressor 2,350 1,066 Gantry Tension Members 11,950 5,420
26 Troughs and False Floor 2,550 1,156 Handle 84,600 38,374
27 Swing Shafts 9,650 4,377 High Voltage Cabinet 1,300 590
28 Gantry Parts 2,150 975 Hoist Cable Reels (each) 5,740 2,603
29 Paint 450 204 Hoist Drum Assembly 52,600 23,860
30 Carbon Dioxide Cylinders 200 91 Hoist Motor Base, Front 3,900 1,769
31 Upper Assembly Parts 750 340 Hoist Motor Base, Rear 3,900 1,769
32 Air Duct Kit “Bleed Rear Roof” 350 159 Hoist Motor Front 17,000 7,711
33 Shear Bar Kit “Carbody” 2,200 998 Hoist Motor Rear 17,000 7,711
34 Left Hand and Right Hand Platforms 15,600 7,075 Hoist Transmission Assembly 34,075 15,454
35 Boom Electrical 950 431 Left Hand Elevated Section 12,850 5,828
36 Miscellaneous-Electrical 1,500 680 Main Transformer & Supp. Cabinet 21,475 9,739
37 Miscellaneous-Wire 1,050 476 Operator’s Coop 12,500 5,669
38 Floodlights 600 272 Propel Motor Base 23,300 10,569
39 Heaters “Portable” 500 227 Propel Motor 7,060 3,202
40 House Lighting Kit 850 385 Rear Enclosures 14,100 6,395
41 Buss Bars 3,500 1,587 Rear Roof Section 12,243 5,554
42 Boarding Ladder Material 200 91 Revolving Frame (Including Sidestand) 171,750 77,905
43 Shipper Shaft Adjusters 450 204 Right Hand Elevated Section 17,850 8,097
44 Remaining Floodlight Assy. & Hard. 600 272 Right Hand Platforms 11,117 5,042
45 Air Conditioner Parts 150 68 Roller Carrier Ring 2,584 1,172
46 Logo Letters 1,175 533 RPC Cabinets 15,900 7,211
47 Counterweight Box Reinforcement 2,050 930 RPC Switching Cabinet 2,700 1,224
48 Boom-Sealtite-4" 500 227 Saddle Blocks (each) 11,150 5,057
49 Mounting Bolts-Cast Counterweight 300 136 Shipper Shaft 13,000 5,896
50 Canopy Arch 9,600 4,354 Shipper Shaft Gear 6,900 3,129
51 Hoist Cable Hoods 3,950 1,791 Sideframe Left with Transmission 156,400 70,943
52 Hatch Covers 6,800 3,084 Sideframe Right with Transmission 156,400 70,943
53 Side Beams 3,500 1,587 Suspension Cables (each) 11,350 5,148
54 Railing Crate 3,400 1,542 Swing Gear 21,000 9,525
55 Catwalks #1 1,850 839 Swing Motor Front 8,600 3,900
56 Catwalks #2 3,500 1,587 Swing Motor Rear 8,600 3,900
57 Catwalks #3 3,650 1,655 Swing Transmission/Front Motor 14,300 6,486
58 Boom Platforms 7,750 3,515 Swing Transmission/Rear Motor 14,300 6,486
59 Shipper Shaft Pinions 4,450 2,018 Transfer Cabinet 1,200 544

*Weights are ±10%. For actual weight of each component, refer to packing list.

5
PLACEMENT
Figure 2 OF ITEMS FOR ERECTION - EXPORT
EXPORT SHIPMENTS

95 Figure 2 depicts the recommended placement of

DIPPER parts at the erection site. Each item shown is
numbered and refers to the Component List
(Table 2) which gives the approximate weights of
90
the components. For the actual weights, refer to
the machine packing list. The item numbers
23 shown in Figure 2 and Table 2 correspond to the
85 42 43 machine packing list.

HANDLE
DIPPER
80

104 105
75

52
50
70
53

65

63
82
60 COUNTER WEIGHT 64
BOX
34 16 65 46 26
66
55
47 49 83
20
44 71 112
50
21 REVOLVING
38 FRAME
15 74
39 22
4 75 HOIST
45 27 24 CASE
29 CRAWLER CRAWLER RING
31 SHOES S S SHOES GEAR
41 30 36 I I
D D
40 37 E CARBODY E 12
40 113 HOIST
87 F 1 F
11 7 DRUM
R R
TOOL A A 73
CONTAINER M M ROLLER
35 E 2 3 E CARRIER
5 18
76 77
LUNCH
ROOM

14 6 13 PROPEL 62 17
110 MOTOR 25
30 45 BASE 8 9 10
61 94 48
72 28 51
54 108 BOOM
19 35
25 55
56 59 60 60 59 32 GANTRY

57
20 33 GANTRY LEGS 114
69 90

70
93 58 106 107
95
15
NOTE
Electrical cabinets, transformers,
AC & DC motors, etc. must be BOOM
10 POINT
stored under cover until required. 67

0 5 10 15 20 25 30 35 40 45 50 55 60 65
METERS

6
Table 2 4100A COMPONENT LIST - EXPORT
BOX or APPROX. WEIGHT* BOX or APPROX. WEIGHT*
CRATE # DESCRIPTION OF CONTENTS LBS. KG. CRATE # DESCRIPTION OF CONTENTS LBS. KG.
1 Carbody with Lube and Collector Shoes 185,000 83,915 57 Catwalks #3 3,550 1,610
2 Sideframe (Left) with Transmission 156,400 70,943 58 Boom Platforms 7,750 3,515
3 Sideframe (Right) with Transmission 156,400 70,943 59 Shipper Shaft Pinions 4,450 2,018
4 Swing Gear 21,000 9,525 60 Crowd Motor Blower 750 340
5 Propel Motor Base 23,300 10,568 61 Dipper Trip Motor 1,875 850
6 Corduroy Bolt Box 6,000 2,721 62 Lower Disconnect Switch 850 385
7 Lower Assembly Parts 4,000 1,814 63 Counterweight Cast Assembly - 4 pcs. 50,000 22,680
8 House Rollers 2,150 975 64 Counterweight Cast Assembly - 4 pcs. 50,000 22,680
9 House Rollers 2,150 975 65 Counterweight Cast Assembly - 4 pcs. 50,000 22,680
10 House Rollers 2,150 975 66 Counterweight Cast Assembly - 4 pcs. 50,000 22,680
11 Assembly Tools 7,500 3,401 67 Boom Point Sheave Assembly 14,250 6,463
12 High-Voltage Guards 1,550 703 68 Center Beams 3,500 1,587
13 Crawler Shoe Pin and Hardware 9,210 4,177 69 Catwalks #4 1,350 612
14 Crawler Shoe Pin and Hardware 9,210 4,177 70 Catwalks #5 2,500 1,134
15 Revolving Frame (Including Sidestand) 171,750 77,905 71 Right Hand Elevated Section 17,850 8,097
16 Counterweight Box 81,850 37,126 72 Left Hand Elevated Section 12,850 5,828
17 Air Receiver Tank Box (Optional) 1,100 499 73 Hoist Drum Assembly 52,600 23,859
18 Center Gudgeon Assembly 9,000 4,082 74 Hoist Motor Base, Front 3,900 1,769
19 Boom 128,800 58,423 75 Hoist Motor Base, Rear 3,900 1,769
20 House Cab Parts 950 431 76 Swing Transmission/Front Motor 14,300 6,486
21 House Panels 3,800 1,723 77 Swing Transmission/Rear Motor 14,300 6,486
22 Boarding Stairway/Ladder 2,630 1,193 78 Hoist Motor Front 17,000 7,711
23 Handle 84,600 38,374 79 Hoist Motor Rear 17,000 7,711
24 Low-Voltage Collector (Part of Box 11) 80 Swing Motor Front 8,600 3,900
25 Air Compressor 2,350 1,066 81 Swing Motor Rear 8,600 3,900
26 Troughs and False Floor 2,550 1,156 82 Pressurization System 21,000 9,526
27 Swing Shafts 9,650 4,377 83 Air Duct Kit “Bleed Rear Roof” 1,900 862
28 Gantry Parts 2,150 975 84 Air Duct Kit “Bleed Rear Roof” 1,900 862
29 Paint 450 204 85 Air Conditioner 2,600 1,179
30 Carbon Dioxide Cylinders 200 91 86 Right Hand Boom Extension 4,500 2,041
31 Upper Assembly Parts 8,000 3,628 87 Operator’s Coop 12,500 5,670
32 Gantry Compression Member 22,500 10,206 88 Boom Catwalk #1 3,000 1,361
33 Gantry Tension Members 11,950 5,420 89 Boom Catwalk #2 3,250 1,474
34 Left Hand and Right Hand Platforms 15,600 7,076 90 Shipper Shaft 13,000 5,896
35 Boom Electrical 850 386 91 Bearing Retainers 2,200 998
36 Gantry Platform 2,800 1,270 92 Crowd Motor Assembly 13,800 6,259
37 Miscellaneous - Wire 1,050 476 93 Crowd Case Cover 15,800 7,166
38 Floodlights 600 272 94 Crowd Motor Base 2,950 1,338
39 Platform Supports R/L Hand 3,000 1,361 95 Boom Hardware 1,050 476
40 House Lighting Kit 850 385 96 Load Center Panel 2,500 1,134
41 Buss Bars 3,500 1,587 97 Main Transformer & Supp. Cabinet 21,475 9,741
42 Saddle Blocks (each) 11,150 5,057 98 High Voltage Cabinet 1,300 590
43 Saddle Blocks (each) 11,150 5,057 99 Auxiliary & Field Transformer 5,200 2,358
44 Floodlight Assembly and Hardware 1,125 510 100 Converter 10,300 4,672
45 Air Tugger Bracket 850 385 101 Transfer Cabinet 1,200 544
46 Logo Letters 1,175 533 102 RPG Switching Cabinet 2,700 1,224
47 Counterweight Box Reinforcement 2,050 930 103 Dipper Trip Resistor Assembly 1,950 884
48 Boom-Sealtite - 4” 500 227 104 Reel Hoist Cable 5,800 2,630
49 Low Voltage Cover Guard 700 317 105 Reel Hoist Cable 5,800 2,630
50 Canopy Arch 9,600 4,354 106 Suspension Cables (each) 11,350 5,148
51 Hoist Cable Hoods 3,950 1,791 107 Suspension Cables (each) 11,350 5,147
52 Hatch Covers 6,800 3,084 108 Shipper Shaft Gear 6,900 3,129
53 Side Beams 3,500 1,587 109 Left Hand Boarding Ladder 1,750 794
54 Railing Crate 3,400 1,542 110 Kit Boxes
55 Catwalks #1 1,850 839 111 Air Conditioner Parts
56 Catwalks #2 3,500 1,587 112 Rear Enclosure Panels

*Weights are ±10%. For actual weight of each component, refer to packing list.

7
ELECTRICAL TEST EQUIPMENT REQUIREMENTS
Basic Electrical Test Instrumentation Required by Customer to
Commission and Maintain Electrotorque Mining Excavator.
Description P&H Part #
Multimeter 89Z514D12
Oscilloscope & Accessories 89Z515D16
High Voltage Differential Probe 89Z515D21
Recorder, Waveform R10945D28
Megger 89Z496
Mod Assy, Drv, Keypad Terminal R46072D7
Mod Assy, Drv, Lead for CDP 312 R46072D8
Tool, RS-232/485 Interface R49117D1
Computer Sim. to R24834D5
but w/ Windows XP Pro TBA
Software, Computer R41705D1
Software, Drives Window R40775D3
Network Connection Cable (7 foot) R44337D2
Test Fixture Capacitor Unit 89Z508D1
Resistor Assembly, Voltage Divider R1192F1
SCR (Thyristor) Tester 89Z511D1
Static Grounding Wrist Strap R48105D5
Flexible Current Probe R55482D1
Power Supply (Optional) R55482D2
Resistor Assembly, Startup Limiting (Optional) 80Z984D1

NOTE: All designs, specifications and components of equipment described above are subject to change
at manufacturer’s sole discretion at any time without advance notice.
Data published herein is informational in nature and shall not be construed to warrant suitability
of machine for any particular purpose as performance may vary with conditions encountered.
The only warranty applicable is our standard written warranty for this machine.

P&H Mining Equipment ◆ Box 310 ◆ Milwaukee, Wisconsin 53201 USA

XS1213-4 8 1AG-305
 2800XPC
Assembly Procedure

assembly Assistance
With the purchase of your Model 2800XPB electric mining shovel,
a P&H service advisor will be provided for a period of 50 working
days to assist the purchaser or the purchaser’s assembly contractor
with the assembly of the machine. The purchaser should arrange to
assemble, test and place the machine into operation during this 50
day period. 2800XPC

The P&H MinePro Services advisor can provide advice only. He

is available to advise the purchaser or the purchaser’s assembly
contractor on erection sequences, commissioning procedures,
testing and other assembly details as requested, but is not
authorized to supervise workers or to direct the assembly, testing SAFETY: All safety related equipment requirements and procedures are
or commissioning in any way. The purchaser will be required to
provide all tools, equipment and personnel needed to assemble the the responsibility of the Purchaser and or designated Assembly
machine, as well as supervision of personnel erecting the machine. Contractor and should be in accordance with all applicable
For example, the P&H service advisor is available to consult with OH&S, Local Mine and Provincial Authorities and regulations.
supervisory personnel on questions such as places to make hitches NOTE: The purchaser is to supply all necessary start-up lubrication
on components, but P&H Mining Equipment will not be responsible
for placement of such hitching or for working with lifting equipment. materials, oils, greases, etc., per P&H specifications.
P&H Mining Equipment will not be liable in any event for any indirect,
special or consequential damages. Purchaser shall indemnify and
hold P&H Mining Equipment harmless for all liability for damage Site and Material Location
to property or personal injury (including death) arising out of
purchaser’s erection, testing or placing into service of the machine. Assembly site preparation is the responsibility of the Purchaser and
should be a flat leveled area, with good drainage, and stable under
The P&H service advisor is not authorized to approve modifications
to the machine that are not covered by the machine data sheet, footing to support the lifting equipment and their floats or outriggers
nor will P&H Mining Equipment accept any backcharge for any during any lift to be made.
unauthorized modifications made. The area required is approximately 300 feet (91.4 m) square, with a
The purchaser or the purchaser’s assembly contractor should tool shed.
contact the nearest P&H Mining Equipment regional office to
schedule the P&H service advisor. We ask the purchaser, prior to the
arrival of P&H service advisor, to issue a purchase order covering Machine Modification Procedure
the P&H service advisor. The first 50 normal working days will be on
a no charge basis. Any days beyond the first 50 days will be charged During the shovel assembly process, the shovel purchaser will
against the purchase order at established service rates. sometimes request alterations to the standard machine design. Some
of the more-commonly requested modifications affect lubrication
The normal working day for the P&H service advisor is eight hours
on site per day. The normal work week is five days per week systems, walkways, hand rails, lighting systems, guards and
(Monday through Friday excluding holidays). Time spent on site Centurion System controls.
beyond the normal work week or day will be charged against the While some modifications might improve the ability of the purchaser
purchase order at established service overtime rates. to utilize and maintain the shovel, some modifications might in fact
adversely affect productivity over time or have significant safety impli-
cations not readily ascertainable.
Personnel Requirements Accordingly, it is imperative that any modifications sought by the
shovel purchaser of the kind noted above (or any other significant
The assembly history for the Model 2800XPC indicates assembly modifications) be discussed with your P&H MinePro Services
can be made within 5200-5500 man-hours. The history also indicates shovel project manager. In turn, your shovel project manager will
that if proper manpower is not available, the 50 working day period of discuss your requests with P&H Mining Equipment shovel design
erection and placement into operation will be exceeded. We therefore engineers to determine if the modifications can be carried out. P&H
advise that the following labor types should be available at various Mining Equipment and P&H MinePro Services make every effort to
stages of machine assembly. accommodate the purchaser’s requests while taking into consider-
6 – Laborers (for the purpose 1 – Millwright ation the machine’s optimal productivity and mine application, as well
of cleaning parts before 2 – Electricians as current design and safety specifications and regulations.
they undergo assembly) 1 – Welder It is most important that any modification to the machine be
3 – Mechanics documented so that P&H Mining Equipment and P&H MinePro
Services can maintain current drawings and specifications for your
After the initial cleaning and opening of the packing cases, the six electric shovel. Furthermore, any future service involving the P&H
laborers may be replaced by additional mechanics and millwrights, as Mining Equipment engineering staff can be expedited if modifications
the tasks of the mechanics and millwrights will be more prevalent. are known and documented.
We have not included the supervision mentioned previously. The Please be aware that any modification performed without P&H Mining
necessary mechanical and electrical supervision should be present Equipment and P&H MinePro Services concurrence might void the
when the various trades are involved in the assebmly of the machine. warranty.
This listing does not include crane operators or oilers (if there is a Some modifications requested by the purchaser can be accommo-
requirement for their use). dated at no additional charge. However, some modifications require
additional welding or other services that cannot be absorbed by P&H
Mining Equipment or P&H MinePro Services. The purchaser will be
notified of such costs in advance of the work being performed.
 BASIC RIGGING MATERIAL REQUIREMENTS BASIC TOOL REQUIREMENTS (continued)
Cranes 6 — 6 ton come-alongs
Two (2) heavy-lift cranes are required at the start of the erection, 6 — 1/5 ton come-alongs
staying on-site until all the heavy lifts are completed and the boom 4 — 3/4 ton come-alongs
has been pinned to the revolving frame. After raising the boom, the 2 — 1/2" torque wrenches
balance of the erection process can proceed with one (1) rough- 1 — 3/4" torque wrench
terrain crane in the 30-ton to 50-ton (27,216-kg to 45,360-kg) class. 1 — 1" torque wrench
1 — torque multiplier 18 1/2 : 1
Heavy-lift crane size requirements are based on many factors, 1 — 48" aluminum pipe wrench
including crane access to heavy lifts, type of crane used, cold 2 — 24" pipe wrenches
weather capacity de-rating, reach, and pick-and-carry capability. 1 — 24" aluminum pipe wrench
1 — 24" chain wrench
Therefore, in extreme cold weather erection environments, two 225- 1 — 24" crescent wrench
ton (204,120-kg) cranes are recommended. In moderate weather, 1 — open end wrenches 5/16" through 21/2" in 1/16" increments
one 150-ton (136,080 kg) and one 190-ton (172,368-kg) crane are 1 — hammer wrenches 11/8" through 31/8" in 1/16" increments
recommended for heavy lifts. 1 — 4" hammer wrench

Cables / Slings Basic Power Tools

4 — 13/4" x 20' 4 — 1" x 12' 1 — pneumatic air wrench, 1/2" drive, with sockets from 1/2" to
2 — 11/2" x 20' 4 — 3/4" x 10' 11/4", in 1/8" increments
2 — 11/4" x 20' 2 — 5/8" x 20' 1 — spray paint gun
10 — smaller cables (1/2" and 3/8", 15' long) to handle the 1 — air powered grinder, 9" right angle disc
miscellaneous material, such as brakes, blower 1 — air powered 1/4" pencil grinder
1 — air powered chipping hammer w/chisels
motors, boxes, cab sections, etc.
1 — welding machine, 400 amp capacity (portable gasoline or
Assortment of nylon slings diesel driven), including 100' long welding cables
Shackles and Pins 1 — portable air compressor, 150 CFM capacity, with 2 ea. 100'
4 — 23/4" (with 5" throat opening and 12 deep) for long hoses with inline oilers
lifting revolving frame 1 — portable light plant or electric power supply if needed
6 ea. 1/4", 3/8", 1/2", 3/4", 1" 1 — electric heated rod oven
2 — oxygen/acetylene burning sets with 75' hose
Blocking (Hardwood) 2 — 50-ton hydraulic jacks
40 ea. 8" x 8" or 10" x 10" in 6', 4', and 2' lengths 2 — 1/2" electric drills
1 — bag wooden wedges 2 — 1/2" cordless drills
1 — 1/2" angle drill
This material is used for setting the various components on the 2 — 3/8" electric drills
ground. The carbody is blocked 48" high for side frame clearance 1 — magnetic drill
with shoes on. 1 — 11/2" drive pneumatic impact wrench
Optional Time-Saving Equipment 2 — 1" drive pneumatic impact wrenches
1 — 3/4" Super-bolt impact wrench
One 10-ton* (9.072 kg.) telescopic (or “zoomboom”) forklift.
2 — 3/4" drive pneumatic wrenches
All-terrain manlift.
4 — 1/4" die grinders
9 — 5" grinders
5 — 7" grinders
BASIC tool REQUIREMENTS 2 — straight grinders

Basic Hand Tools Basic Electrical Tools

2 — 6" screwdrivers 1/4" face 1 — knock out punch set 2 — reciprocating saws
2 — 8" screwdrivers 3/8" face 1 — hydraulic hand pump 1 — soldering gun
2 — 12" screwdrivers 1/2" face knock out punch kit 6 — 600 amp welders
2 — 15" adjustable open end wrenches 1 — hole saw kit 4 — wire feeders
2 — 12" adjustable open end wrenches 2 — manualCrimpers 4 — air arcs
4 — 12" long bastard files 1 — hydraulic crimpers 1 — diesel genset - 300 kW
6 — 4" paint brushes for use with cleaning solvent 3 — heat guns
1 — crosscut saw
3 — 36" wrecking bars Miscellaneous Items 00 — lbs. 3/32" weld rod
1
2 — 20 lb. sledge hammers 3 — tarpaulins, 30' x 30' 300 — lbs. 1/8" weld rod
4 — 2 lb. ball peen hammers 2 — 12' step ladders - straight 200 — lbs. 3/16" weld rod
6 — putty knives 3" wide 2 — 20' extension ladders low hydrogen, pre-dried
1 — heavy-duty mechanic’s tool set 2 — barrels of cleaning solvent 300 — feet manila rope
2 — wire brushes 20 — rolls masking tape 1" 100 — lbs. cleaning rags
3 — each tapered drifts, 12" long, 5/8" and 3/4" dia. 50 — sheets of fine emery cloth 2000 — lbs. (approx.) dry ice
2 — 1/2" drive socket wrench sets, including two extensions, 50 — sheets of medium emery (the exact quantity required
ratchet and sockets, from 7/16" to 11/4", in 1/8" increments cloth will depend upon location
2 — wooden stairway with of source and ambient
1 — 3/4" drive socket wrench set, including ratchet and sockets,
railing for boarding temperature)
from 1" to 3", in 1/8" increments
25 — rolls black plastic electrical — or —
6 — 3-ton come-alongs
tape Liquid Nitrogen - 4 bottles,
2 — standard bolt tap set—1/4" to 11/2" in 1/8" increments
25 — rolls of friction tape approximately 370 lbs. of
2 — drill bit set—3/16" to 5/8" in standard increments product each bottle and
1 — set of rotary files for pencil grinder 5 — anti-seize lubricant (cans)
5 — dye check kits for must have liquid withdrawal
1 — 3/4" drive breaker bar capabilities
1 — 1" drive breaker bar checking welds (NDT-PT)
6 — fire extinguishers—20 lb. 3 — 6-foot step ladder
1 — 1" drive socket wrench set, ratchet and sockets, from 11/16" 3 — 8-foot step ladder
through 31/2" in 1/16" increments dry chemical type
Painting supplies
1 — 1" Swivel Assorted-color electrical tape
1 — 1-1/2" Swivel
1 — 1" to 11/2" Adapter The above tool listing indicates the basic minimum range and quantity
1 — 11/2" to 1" Adapter of tools recommended. The list is not intended to be all-inclusive.
1 — set of 11/2" drive sockets from 2" through 43/4" in 1/16"
increments Data Codes
Extensions: 2 — 3/4" drive by 8", 1— 3/4" drive by 13", 2 — 1" *1 ton = 2,000 pounds (907.2 kg)
drive by 8", 1 — 1" drive by 13", 1 — 11/2" drive by 12" 10' = 10 feet (305 cm) 10" = 10 inches (25.4 cm)
 2800XPC Lifting or Hitching Points and approximate weights* of major items

72,100 lbs. 86,700 lbs. The side loading to any welded-on

(32,704 kg) (39,326 kg)
CL Rotation
lifting lug cannot exceed ±5° from the vertical.
* Weights are ±10%. For actual weight of each component, refer to packing list.

6'-6" (1.98 m)

Width: 15'-0" (4.57 m) 10'-10"

Rev. Frame (Bare) - Weight: 158,800 lbs. (72,030 kg) (3.30 m)
29'-6" (8.99 m)
Rev. Frame (Bare) w/Sidestand
Crawler (R.H. shown) w/o Shoes-Weight: 149,600 (67,857 kg)
10,000 lbs. 10,000 lbs.
(4,530 kg) (4,530 kg)

104,400 lbs. 45,200 lbs.

(47,355 kg) (20,502 kg)
33'-6" (10.21 m)
9'-0"
(2.74 m)
6'-10"
(2.08 m)

31'-0" (9.45 m)

Width: 12'-3" (3.74 m)

House Pressurization

43,250 lbs. 43,250 lbs.

(19,618 kg) (19,618 kg)

Crawler shoes: 56" (1.42 m)

51 Shoes each Belt - Weight: 99,000 lbs.
(44,906 kg)
5'-4"
(1.63 m)
Crawler shoes: 72" (1.85 m)
51 Shoes each Belt - Weight: 112,200 lbs.
(50,894 kg)
30'-10"
(9.39 m)

Width: 14'-4" (4.37 m) 80,000 lbs. 84,000 lbs. 84,000 lbs.

Weight: 86,500 lbs. (39,236 kg) (36,287 kg) **Hitch Point load encountered (38,102 kg) (38,102 kg)
Counterweight Box when raising a fully-dressed
128,100 lbs. 125,000 lbs.** boom into position.Use 3.00"
(58,105 kg) (56,699 kg) machined holes as hitch points.
Do not use the welded-on lugs
to raise the boom. 7'-9"
(2.36 m)

Width: 14'-0" (4.27 m)

Bare Boom Weight: 130,900 lbs. (59,375 kg) 9'-0"
(2.74 m) 16'-3"
Fully-Dressed Boom Weight: 208,100 lbs. (94,393 kg) (4.95 m)
Width: 22'-6" (6.86 m)
Weight: 168,000 lbs. (76,204 kg)
Carbody
59'-6" (18.12 m) w/o Point Sheaves

33,500 lbs. 45,000 lbs.

(15,195 kg) (20,412 kg)

15'-0"
(4.57 m)
5'-11" (1.80 m)

39'-8" (12.09 m) 15'-0"

(4.57 m)
Width: 10'-6" (3.20 m)
Weight: 75,500 lbs. (35,607 kg) 46 cu yd (35.2m3)
Total Weight: 130,000 lbs. (61,236 kg)

Typical values only; there is no standard dipper.

11" Weight: 6,600 lbs. (2,994 kg) 20"

(279 mm) Center Gudgeon (508 mm) Dry ice to freeze center gudgeon
(shown at left) for field installation
into carbody. The quantity will
depend on location of supplier,
and ambient temperature.

111'-6" (28.35 m)
7
1

SITE LAYOUT - U.S. and CanadA

95
Figure 1 depicts the recommended placement
DIPPER of parts at the erection site. Each item shown
is numbered and refers to the Component List
67 (Table 1) which give the approximate weights of
90
the components. For the actual weights, refer to
68 the machine packing list.
85 66 66

HANDLE
DIPPER
80

75

52
50
70
53

65

70
60 71
COUNTER WEIGHT
34 BOX 72 46 26
73
55
47 49 32
20
44 71 74
50
21 REVOLVING
38 FRAME
39 22
45 HOIST
27 CASE
29 RING
31 14 S S 17 GEAR
41 30 36 I I 1
D D
40 37 E CARBODY E 12
40 2 HOIST
63 15 F F 18
11 7 DRUM
R R
TOOL A A 23
CONTAINER M M ROLLER
35 16 E E 19 CARRIER

69 69
LUNCH
ROOM

13 6 13 PROPEL 62
MOTOR 25
30 45 BASE 8 9 10
5 33
48 24 28 51
54 BOOM
35
25 55
56 59 60 61 59 GANTRY

57
20 GANTRY LEGS
64

65
3 58
15
43
NOTE: Electrical cabinets, BOOM
10 transformers, AC & DC motors, POINT

etc. must be stored under cover

until required.
5

0 5 10 15 20 25 30 35 40 45 50 55 60 65
METERS

Figure 1
 2800XPC component list - U.S. & Canada
Site Approx. Weight* Site Approx. Weight*
Location Description of Contents Lbs. Kg Location Description of Contents Lbs. Kg
1 Kit #1 Hardware for Revolving Frame 855 388 59 Shipper Shaft Pinions 2,350 1,066
2 Kit #2 Hardware for Carbody 1,170 531 60 Shipper Shaft Retainer w/Washer 650 295
Kit #3-If this is packed inside of the boom 61 Shipper Shaft Retainer w/Washer 650 295
3 hardware box, then the boom hardware 300 136 62 Lower Disconnect Switch 900 406
box will be box #3 63 House Heaters 150 68
4 Contains Kit #4 Hardware for Cab & Upper 1,205 546
Contains Kit #5 Hardware for Catwalk & Assemblies without Pre-Assigned
5 515 234
Railing Box or Crate Numbers
6 Corduroy Bolt Box 6,000 2,721
7 Lower Assembly Parts 4,000 1,814 Approx. Weight*
8 House Rollers 2,150 975 Description of Contents Lbs. Kg
9 House Rollers 2,150 975 Air Tugger Bracket 950 431
10 House Rollers 2,150 975 Auxiliary & Field Transformer 4,200 1,905
11 Assembly Tools 950 431 Auxiliary Control Cabinet 1,200 544
12 High-Voltage Guards 1,550 703 Boom 130,900 59,375
13 Crawler Shoe Pin and Hardware 8,125 3,685 Boom Point Sheave Assembly 13,900 6,304
14 Crawler Shoe Pin and Hardware 8,125 3,685 Carbody with Lube and Collector Shoes 168,000 76,204
Shoe Size 4.5" Pins 4.5" Pins Center Gudgeon Assembly 9,350 4,240
15 Crawler Shoe 52" (132 cm) Control Cabinet 2,000 907
16 Crawler Shoe 55" (140 cm) 1,865 846 Converter 10,950 4,966
17 Crawler Shoe 70" (178 cm) Counterweight Box 86,500 39,236
18 Crawler Shoe 72" (183 cm) 2,100 952 Counterweight Cast Assembly-4 pcs.
19 Crawler Shoe 84" (213 cm) 3,470 1,574 Crowd Motor Assembly 6,800 3,084
Crawler Shoe 96" (244 cm) 4,565 2,070 Crowd Motor Base 2,200 998
20 House Cab Parts 450 204 Crowd Motor Cover 8,100 3,673
21 House Panels 3,800 1,723 Crowd Transmission
22 Boarding Stairway/Ladder 2,630 1,193 Dipper (See Packing List for Weight)
23 Spherical Washer 400 181 Gantry Compression Member Assembly 23,000 10,431
24 Low-Voltage Collector 1,200 544 Gantry Tension Members 11,950 5,420
25 Air Compressor 2,100 952 Handle 78,500 35,607
26 Troughs and False Floor 2,550 1,156 High Voltage Cabinet 2,100 952
27 Swing Shafts 8,450 3,832 Hoist Cable Reels (each) 4,300 1,950
28 Gantry Parts 2,100 952 Hoist Drum Assembly 41,500 18,824
29 Paint 450 204 Hoist Motor Base, Front 3,600 1,633
30 Carbon Dioxide Cylinders 250 113 Hoist Motor Base, Rear 3,600 1,633
31 Upper Assembly Parts 700 317 Hoist Motor Front 6,150 2,789
32 Air Duct Kit “Bleed Rear Roof” 350 159 Hoist Motor Rear 6,150 2,789
33 Not Applicble Hoist Transmission Assembly 25,600 11,612
34 Left Hand and Right Hand Platforms 12,990 5,892 Left Hand Elevated Section 12,800 5,806
35 Boom Electrical 400 181 Main Transformer & Supp. Cabinet 16,700 7,575
36 Miscellaneous-Electrical 1,500 680 Operator’s Coop 18,300 8,301
37 Miscellaneous-Wire 1,200 544 Propel Motor Base 23,300 10,568
38 Floodlights 400 181 Propel Motor 6,000 2,721
39 Heaters “Portable” 500 227 Rear Enclosures 14,100 6,395
40 House Lighting Kit 850 385 Rear Roof Section 12,243 5,553
41 Buss Bars 3,500 1,587 Revolving Frame (Including Sidestand) 158,800 72,030
42 Boarding Ladder Material 200 91 Right Hand Elevated Section 12,600 5,715
43 Shipper Shaft Adjusters 450 204 Right Hand Platforms 11,117 5,042
44 Remaining Floodlight Assy. & Hard. 600 272 Roller Carrier Ring 2,584 1,172
45 Air Conditioner Parts 150 68 RPC Cabinets 15,000 6,803
46 Logo Letters 1,175 533 RPC Switching Cabinet 2,700 1,224
47 Counterweight Box Reinforcement Saddle Blocks (each) 9,525 4,320
48 Boom-Sealtite-4" 500 227 Shipper Shaft 8,000 3,628
49 Mounting Bolts-Cast Counterweight 300 136 Shipper Shaft Gear 5,600 2,540
50 Canopy Arch 11,250 5,102 Sideframe Left with Transmission 149,600 67,857
51 Hoist Cable Hoods 4,700 2,132 Sideframe Right with Transmission 149,600 67,857
52 Hatch Covers 4,380 1,986 Suspension Cables (each) 9,600 4,354
53 Side Beams 3,250 1,474 Swing Gear 18,000 8,163
54 Railing Crate 3,400 1,542 Swing Motor Front 8,800 3,991
55 Catwalks #1 1,850 839 Swing Motor Rear 8,800 3,991
56 Catwalks #2 3,650 1,655 Swing Transmission/Front Motor 14,300 6,486
57 Catwalks #3 4,400 1,995 Swing Transmission/Rear Motor 14,300 6,486
58 Boom Platforms 7,200 3,265 Transfer Cabinet 1,750 794

Weights are ±10%. For actual weight of each component, refer to packing list.

Table 1
SITE LAYOUT - Export

95
Figure 2 depicts the recommended placement
DIPPER of parts at the erection site. Each item shown
is numbered and refers to the Component List
90 (Table 2) which give the approximate weights of
the components. For the actual weights, refer to
23 the machine packing list.
85 42 43

HANDLE
DIPPER
80

104 105
75

50 52
70
53

65

63
82
60 COUNTER WEIGHT 64
BOX
34 16 65 46 26
66
55
47 49 83
20
44 71 112
50
21 REVOLVING
38 FRAME
15 74
39 22
4 75 HOIST
45 27 24 CASE
29 CRAWLER CRAWLER RING
31 SHOES S S SHOES GEAR
41 30 36 I I
D D
40 37 E CARBODY E 12
40 113 HOIST
87 F 1 F
11 7 DRUM
R R
TOOL A A 73
CONTAINER M M ROLLER
35 E 2 3 E CARRIER
5 18
76 77
LUNCH

14 6 13 62 17
ROOM

PROPEL
110 MOTOR 25
30 45 BASE 8 9 10
61 94 48
72 28 51
54 108 BOOM
19 35
25 55
56 59 60 60 59 32 GANTRY

57
20 33 GANTRY LEGS 114
69 90

70
93 58 106 107
95
15

NOTE: Electrical cabinets, BOOM

10 POINT
transformers, AC & DC motors, 67
etc. must be stored under cover
5
until required.

0 5 10 15 20 25 30 35 40 45 50 55 60 65
METERS

Figure 2
 2800XPC component list - Export
Site Approx. Weight* Site Approx. Weight*
Location Description of Contents Lbs. Kg Location Description of Contents Lbs. Kg
1 Carbody with Lube and Collector Shoes 168,000 76,204 57 Catwalks #3 4,400 1,995
2 Sideframe (Left) with Transmission 149,600 67,857 58 Boom Platforms 7,200 3,265
3 Sideframe (Right) with Transmission 149,600 67,857 59 Shipper Shaft Pinions 2,350 1,065
4 Swing Gear 18,000 8,163 60 Crowd Motor Blower 750 340
5 Propel Motor Base 23,300 10,568 61 Dipper Trip Motor 950 431
6 Corduroy Bolt Box 6,000 2,721 62 Lower Disconnect Switch 900 408
7 Lower Assembly Parts 4,000 1,814 63 Counterweight Cast Assembly - 4 pcs.
8 House Rollers 2,150 975 64 Counterweight Cast Assembly - 4 pcs.
9 House Rollers 2,150 975 65 Counterweight Cast Assembly - 4 pcs.
10 House Rollers 2,150 975 66 Counterweight Cast Assembly - 4 pcs.
11 Assembly Tools 7,500 3,401 67 Boom Point Sheave Assembly 13,900 6,304
12 High-Voltage Guards 1,550 703 68 Center Beams 3,500 1,587
13 Crawler Shoe Pin and Hardware 8,125 3,685 69 Catwalks #4 1,350 612
14 Crawler Shoe Pin and Hardware 8,125 3,685 70 Catwalks #5 2,500 1,134
15 Revolving Frame (Including Sidestand) 158,800 72,030 71 Right Hand Elevated Section 12,600 5,714
16 Counterweight Box 86,500 39,236 72 Left Hand Elevated Section 12,800 5,805
17 Air Receiver Tank Box (Optional) 1,100 499 73 Hoist Drum Assembly 41,500 18,824
18 Center Gudgeon Assembly 9,350 4,240 74 Hoist Motor Base, Front 3,600 1,633
19 Boom 130,900 59,375 75 Hoist Motor Base, Rear 3,600 1,633
20 House Cab Parts 950 431 76 Swing Transmission/Front Motor 14,300 6,485
21 House Panels 3,800 1,723 77 Swing Transmission/Rear Motor 14,300 6,485
22 Boarding Stairway/Ladder 2,630 1,193 78 Hoist Motor Front 6,150 2,789
23 Handle 78,500 35,607 79 Hoist Motor Rear 6,150 2,789
24 Low-Voltage Collector (Part of Box 11) 80 Swing Motor Front 8,800 3,991
25 Air Compressor 2,100 952 81 Swing Motor Rear 8,800 3,991
26 Troughs and False Floor 2,550 1,156 82 Pressurization System 21,000 9,524
27 Swing Shafts 8,450 3,832 83 Air Duct Kit “Bleed Rear Roof” 1,900 862
28 Gantry Parts 84 Air Duct Kit “Bleed Rear Roof” 1,900 862
29 Paint 450 204 85 Air Conditioner 2,600 1,179
30 Carbon Dioxide Cylinders 250 113 86 Right Hand Boom Extension 4,600 2,086
31 Upper Assembly Parts 7,000 3,175 87 Operator’s Coop 18,300 8,301
32 Gantry Compression Member 22,500 10,206 88 Boom Catwalk #1 3,000 1,361
33 Gantry Tension Members 11,950 5,420 89 Boom Catwalk #2 3,250 1,474
34 Left Hand and Right Hand Platforms 12,990 5,891 90 Shipper Shaft 8,000 3,628
35 Boom Electrical 400 181 91 Bearing Retainers
36 Gantry Platform 2,800 1,270 92 Crowd Motor Assembly 6,800 3,084
37 Miscellaneous - Wire 1,200 544 93 Crowd Case Cover 8,100 3,674
38 Floodlights 400 181 94 Crowd Motor Base 2,200 998
39 Platform Supports R/L Hand 3,000 1,361 95 Boom Hardware 1,050 476
40 House Lighting Kit 850 385 96 Load Center Panel 2,500 1,134
41 Buss Bars 3,500 1,587 97 Main Transformer & Supp. Cabinet 16,600 7,530
42 Saddle Blocks (each) 9,525 4,320 98 High Voltage Cabinet 2,100 952
43 Saddle Blocks (each) 9,525 4,320 99 Auxiliary & Field Transformer 4,200 1,905
44 Floodlight Assembly and Hardware 1,125 510 100 Converter 10,950 4,966
45 Air Tugger Bracket 950 431 101 Transfer Cabinet 1,750 794
46 Logo Letters 1,175 533 102 RPG Switching Cabinet 2,700 1,224
47 Counterweight Box Reinforcement 103 Dipper Trip Resistor Assembly 1,950 884
48 Boom-Sealtite - 4" 500 227 104 Reel Hoist Cable 4,300 1,950
49 Low Voltage Cover Guard 700 317 105 Reel Hoist Cable 4,300 1,950
50 Canopy Arch 11,250 5,102 106 Suspension Cables (each) 9,600 4,354
51 Hoise Cable Hoods 4,700 2,132 107 Suspension Cables (each) 9,600 4,354
52 Hatch Covers 4,380 1,986 108 Shipper Shaft Gear 5,600 2,540
53 Side Beams 3,250 1,474 109 Left Hand Boarding Ladder 1,750 794
54 Railing Crate 3,400 1,542 110 Kit Boxes
55 Catwalks #1 1,850 839 111 Air Conditioner Parts
56 Catwalks #2 3,850 1,746 112 Rear Enclosure Panels

Weights are ±10%. For actual weight of each component, refer to packing list.

Table 2
 electrical test equipment requirements
Basic Electrical Test Instrumentation Recommended to Commission and Maintain Centurion Digital Drive Mining Excavator.
Recommended Maintenance Test Equipment Available through P&H and other Vendors.

Description P&H Part # Description P&H Part #

DMM (Digital MultiMeter) Drive Communications (hardware and software) R40775D3
Fluke Model 23 89Z514D12 RPC Capacitor Test unit 89Z508D1
Alternate DMM—Fluke, Model 87 1089Z275
Voltage Divider R1192F1
Oscilloscope
Hand-held Drive Programmer, ABB CDP-312R R46072D7
Tektronix Model THS720A (Hand-held, Dual Trace,
Digital, Storage, Battery Powered, Soft Case) Scope 2 Meter Connection Cable R46072D8
w/120V / 60Hz Adapter 89Z515D16 SCR (Thyristor) Tester 89Z511D1
120V / 50 Hz AC Adapter (240V Adapters Available) 89Z515D30
Hard Carrying Case 89Z515D26
X10 Probe (1kV) 89Z515D17
R5-232 to 485 Converter—for loading ABB drive
firmware ABB NPCU-01-KIT R49117D1
Megger—500V & 1000V Scales (hand-crank /w case)
James D. Biddle Cat. 21158 89Z496
Clamp-On Ammeter—1A to 600A AC / 1000A (DC)
Fluke Model i1010 89Z514D15
High Voltage Differential Probe—P5200 89Z515D21
Laptop computer—Consult service department
for specs N/A

NOTE: All designs, specifications and components of equipment described above are subject to change at manufacturer’s sole discretion at any time without
advance notice. Data published herein is informational in nature and shall not be construed to warrant suitability of machine for any particular purpose as
performance may vary with conditions encountered. The only warranty applicable is our standard written warranty for this machine.

P&H Mining Equipment  •  Box 310  •  Milwaukee, Wisconsin 53201 USA

XS-4463 2AG-07
 ®

2800XP Series B
DC ELECTROTORQUE® MINING SHOVEL
DUAL PLANETARY PROPEL & SWING

ERECTION PROCEDURE

ERECTION ASSISTANCE ERECTION PERSONNEL REQUIREMENTS

With the purchase of your Model 2800XPB electric mining The erection history for the Model 2800XPB indicates erection
shovel, a P&H service advisor will be provided for a period can be made within 5200-5500 man-hours. The history also
of 50 working days to assist the purchaser or the purchaser’s indicates that if proper manpower is not available, the 50
erection contractor with the erection of the machine. The pur- working day period of erection and placement into operation
chaser should arrange to erect, test and place the machine will be exceeded. We therefore advise that the following labor
into operation during this 50 day period. types should be available at various stages of machine erection.
The P&H MinePro Services advisor can provide advice only. He 6—Laborers (for the purpose of cleaning parts before their
is available to advise the purchaser or the purchaser’s erection assembly)
contractor on erection sequences, commissioning procedures, 3—Mechanics
testing and other erection details as requested, but is not 1—Millwright
authorized to supervise workers or to direct the erection, 2—Electricians
testing or commissioning in any way. The purchaser will be 1—Welder
required to provide all tools, equipment and personnel needed
to erect the machine, as well as supervision of personnel After the initial cleaning and opening of the packing cases, the
erecting the machine. For example, the P&H service advisor six laborers may be replaced by additional mechanics and mill-
is available to consult with supervisory personnel on questions wrights, as the tasks of the mechanics and millwrights will be
such as places to make hitches on components, but P&H Mining more prevalent.
Equipment will not be responsible for placement of such
hitching or for working with lifting equipment. P&H Mining We have not included the supervision mentioned previously.
Equipment will not be liable in any event for any indirect, The necessary mechanical and electrical supervision should
special or consequential damages. Purchaser shall indemnify be present when the various trades are involved in the
and hold P&H Mining Equipment harmless for all liability erection of the machine.
for damage to property or personal injury (including death)
arising out of purchaser’s erection, testing or placing into This listing does not include crane operators or oilers (if
service of the machine. there is a requirement for their use).

The P&H service advisor is not authorized to approve modifi- SAFETY: All safety related equipment requirements and
cations to the machine that are not covered by the machine procedures are the responsibility of the Purchaser
data sheet, nor will P&H Mining Equipment accept any back- and or designated Erection Contractor and should
charge for any unauthorized modifications made. be in accordance with all applicable MSHA,
Local Mine, State Authorities and regulations.
The purchaser or the purchaser’s erection contractor
should contact the nearest P&H Mining Equipment regional NOTE: The purchaser is to supply all necessary start-up
office to schedule the P&H service advisor. We ask the lubrication materials, oils, greases, etc., per P&H
purchaser, prior to the arrival of P&H service advisor, to specifications.
issue a purchase order covering the P&H service advisor.
The first 50 normal working days will be on a no charge
basis. Any days beyond the first 50 days will be charged ERECTION SITE AND MATERIAL LOCATION
against the purchase order at established service rates.
Erection site preparation is the responsibility of the Purchaser
The normal working day for the P&H service advisor is and should be a flat leveled area, with good drainage, and
eight hours on site per day. The normal work week is stable under footing to support the lifting equipment and their
five days per week (Monday through Friday excluding floats or outriggers during any lift to be made.
holidays). Time spent on site beyond the normal work week
or day will be charged against the purchase order at The area required is approximately 300 feet (91.4 m) square,
established service overtime rates. with a tool shed.

1
BASIC RIGGING MATERIAL REQUIREMENTS BASIC HAND TOOLS (continued)
Cranes 2—wire brushes
3—each tapered drifts, 12” long, 5/8” and 3/4” dia.
One truck crane with 100-ton* (90,720 kg.) capacity and
one truck crane with 140-ton* (127,008 kg.) capacity. One 2—1/2” drive socket wrench sets, including two extensions,
truck crane will be required for 45 working days for each ratchet and sockets, from 7/16” to 1-1/4”, in 1/8”
machine during the erection period. The second truck crane increments
will only be required for the first 20 working days of the 1—3/4” drive socket wrench set, including two extensions,
erection for each machine. ratchet and sockets, from 1” to 3”, in 1/8” increments
6—3-ton P&H hoists
One 20-30-ton* (18,144-27,216 kg.) rough terrain crane 2—standard bolt tap set—1/4” to 1-1/2” in 1/8” increments
Cables 2—drill bit set—3/16” to 5/8” in standard increments
1—set of rotary files for pencil grinder
4—1-3/4” x 20’ 4—1” x 12’
1—torque wrench
2—1-1/2” x 20’ 4—3/4” x 10’
1—torque multiplier (2,500 ft.-lbs. capacity)
2—1-1/4” x 20’ 2—5/8” x 20’
10—smaller cables (1/2” and 3/8”, 15’ long) to handle the Basic Power Tools
miscellaneous material, such as brakes, blower
motors, boxes, cab sections, etc. 1—1/2” drive reversible electric drill motor 110 vac
1—pneumatic air wrench, 1/2” drive, with sockets from
Shackles 1/2” to 1-1/4”, in 1/8” increments
4—2-3/4” (with 5” throat opening and 12 deep) for 1—spray paint gun
lifting revolving frame 1—air powered grinder, 9” right angle disc
6 ea. 1/4”, 3/8”, 1/2”, 3/4”, 1” 1—air powered 1/4” pencil grinder
1—air powered chipping hammer
Blocking (Hardwood)
1—welding machine, 400 amp capacity (portable gasoline
40 ea. 8” x 8” or 10” x 10” in 6’, 4’, and 2’ lengths or diesel driven), including 100’ long welding cables
1—bag wooden wedges 1—portable air compressor, 150 CFM capacity, with 2 ea.
100’ long hoses with inline oilers
This material is used for setting the various components 1—portable light plant or electric power supply if needed
on the ground. The carbody is blocked approximately 48” high
for side frame clearance with shoes on. 1—electric heated rod oven
2—oxygen acetylene burning sets with 75’ hose
Optional Time Saving Equipment 2—50-ton hydraulic jacks
One 10-ton* (9.072 kg.) forklift. Basic Miscellaneous Items
3—tarpaulins, 30’ x 30’
BASIC TOOL REQUIREMENTS 2—15’ step ladders
2—24’ extension ladders
Basic Hand Tools 2—barrels of cleaning solvent
2—6” screwdrivers 1/4” face 20—rolls masking tape 1”
2—8” screwdrivers 3/8” face 50—sheets of fine emery cloth
2—12” screwdrivers 1/2” face 50—sheets of medium emery cloth
2—15” adjustable open end wrenches 2—wooden stairway with railing for boarding
2—12” adjustable open end wrenches 25—rolls black plastic electrical tape
4—12” long bastard files 25—rolls of friction tape
6—4” paint brushes for use with cleaning solvent 5—anti-seize lubricant (cans)
1—crosscut saw 5—dye check kits for checking welds
3—36” wrecking bars 6—fire extinguishers—20 lb. dry chemical type
2—20 lb. sledge hammers 100---lbs. each---3/16” and 3/32” weld rod---hydrogen (pre-dried)
4—2 lb. ball peen hammers 300—feet manila rope
6—putty knives 3” wide 100—lbs. cleaning rags
2000-lbs. (approx.) dry ice (the exact quantity required will depend
upon location of source and ambient temperature)

Data Codes
*1 ton = 2,000 pounds (907.2 kg)
10’ = 10 feet (305 cm) 10” = 10 inches (25.4 cm)

2
2800XPB LIFTING OR HITCHING POINTS AND APPROXIMATE WEIGHTS* OF MAJOR ITEMS
72,100 lbs. 86,700 lbs.
(32,704 kg.) (39,326 kg.)
CL Rotation

10'-10"
6'-6" (3.30 m)
(1.98 m)

Width: 15'-0" (4.57 m)

Rev. Frame (Bare)- Weight: 158,800 lbs. (72,030 kg.) Crawler (R.H. shown) w/o Shoes-Weight: 149,600 lbs. (67,857 kg.)
29'-6" (8.99 m)
Revolving Frame (Bare) w/Sidestand 45,200 lbs.
104,400 lbs.
(47,355 kg.) (20,502 kg.)
10,000 lbs. 10,000 lbs.
(4,530 kg.) (4,530 kg.) 33'-6" (10.21 m)

6'-10"
(2.08 m)
9’-0”
(2.74 m)

31’-0”
Width 12’-3” (3.738 m)
House Pressurization
Crawler shoes 56" (1.42 m) Wide
51 Shoes each Belt-Weight: 99,000 Lbs.
43,250 lbs. 43,250 lbs. (44,906 Kg.)
(19,618 kg.) (19,618 kg.)

Crawler shoes 72" (1.85 m) Wide

51 Shoes each Belt-Weight: 112,200 Lbs. (50,894 kg.)

5'-4"
(1.63 m)

84,000 lbs.
84,000 lbs.
(38,102 kg.)
30’-10” (38,102 kg.)
(9.39 m)
Counterweight Box 80,000 lbs.
Width: 14’-4” (4.37 m) (36,287 kg.)
128,100 lbs.
(58,105 kg.) Weight: 86,500 (39,236 kg.) 125,000 lbs.**
(56,699 kg.) 7'-9"
(2.36 m) Width: 22’-6” (6.86 m)
Weight: 168,000 lbs.
(76,204 kg.)

Width: 14’-0” (4.27 m) 16'-3" (4.95 m)

Bare Boom Weight: 130,900 lbs. (59,375 kg.) 9'-0" Carbody
Fully - Dressed Boom weight: 208,100 lbs. (94,393 kg.) (2.74 m)

59’-6” (18.12 m) w/o Point Sheaves

33,500 lbs. 45,000 lbs. 15'-0" (4.57 m)

(15,195 kg.) (20,412 kg.)
Width: 15’-0” (4.57 m)
Weight: 130,000 lbs
(61,236 kg.)

5’-11” (1.80 m)

Width: 10'-6" (3.20m) 15'-0" (4.57 m)

Weight: 78,500 lbs. (35,607 kg.)
46 yd³ (35.2 m³) Dipper w/Bail
39’-8” (12.09 m)
Typical values only; there
is no standard dipper.

Dry ice to freeze center gudgeon (shown below) for field installation into carbody.
The quantity will depend on location of supplier, and ambient temperature.

** Hitch Point load encountered

when raising a fully-dressed Boom
into position.
Note: Use 3.00” Machined holes
11” (279mm) CENTER GUDGEON 20” (508mm) as hitch points. Do not use the
Weight: 6,600 lbs. (2994 kg.) welded-on lugs to raise the Boom.
Caution: Any welded-on lifting
lugs must “not” be side loaded,
in-line only.

111.6" (2835mm)

*Weights are ± 10%. For actual weight of each component, refer to packing list.

3
Figure 1 U.S. AND CANADIAN SHIPMENTS

95
Figure 1 depicts the recommended placement of
DIPPER
parts at the erection site. Each item shown is
numbered and refers to the Component List
67
90 (Table 1) which gives the approximate weights of
the components. For the actual weights, refer to
68 the machine packing list. The item numbers
shown in Figure 1 and Table 1 correspond to the
85 66 66 machine packing list, items 1 through 63. Items
beyond 63 are randomly applied.

HANDLE
DIPPER
80

75

50 52
70
53

65

70
60 71
COUNTER WEIGHT
34 BOX 72 46 26
73
55
47 49 32
20
44 71 74
50
21 REVOLVING
38 FRAME
39 22
45 HOIST
27 RING CASE
29
31 14 S S 17 GEAR
41 30 36 I I 1
D D
40 37 E CARBODY E 12
40 2 HOIST
63 15 F F 18
11 7 DRUM
R R
TOOL A A 23
CONTAINER M M ROLLER
35 16 E E 19 CARRIER

69 69
LUNCH
ROOM

13 6 13 PROPEL 62
MOTOR 25
30 45 BASE 8 9 10
5 33
48 24 28 51
54 BOOM
35
25 55
56 59 60 61 59 GANTRY

57
20 GANTRY LEGS
64

65
3 58
15
43
NOTE
Electrical cabinets, transformers, BOOM
10 AC & DC motors, etc. must be POINT
stored under cover until required.

0 5 10 15 20 25 30 35 40 45 50 55 60 65
METERS

4
Table 1 2800XPB COMPONENT LIST - U.S. & CANADA
BOX or APPROX. WEIGHT BOX or APPROX. WEIGHT
CRATE # DESCRIPTION OF CONTENTS LBS. KG. CRATE # DESCRIPTION OF CONTENTS LBS. KG.
1 Kit #1 Hardware for Revolving Frame 855 388 59 Shipper Shaft Pinions 2,350 1,066
2 Kit #2 Hardware for Carbody 1,170 531 60 Shipper Shaft Retainer w/Washer 650 295
3 Kit #3-If this is packed inside of the boom 61 Shipper Shaft Retainer w/Washer 650 295
hardware box, then the boom hardware
box will be box #3 300 136 62 Lower Disconnect Switch 900 406
4 Contains Kit #4 Hardware for Cab & Upper 1,205 546 63 House Heaters 150 68
5 Contains Kit #5 Hardware for Catwalk &
Railing 515 234
Assemblies without Pre-Assigned
6 Corduroy Bolt Box 6,000 2,721 Box or Crate Numbers
7 Lower Assembly Parts 4,000 1,814
8 House Rollers 2,150 975 APPROX. WEIGHT
DESCRIPTION OF CONTENTS LBS. KG.
9 House Rollers 2,150 975
10 House Rollers 2,150 975 Air Tugger Bracket 950 431
11 Assembly Tools 950 431 Auxiliary & Field Transformer 4,200 1,905
12 High-Voltage Guards 1,550 703 Auxiliary Control Cabinet 1,200 544
13 Crawler Shoe Pin and Hardware 8,125 3,685 Boom 130,900 59,375
14 Crawler Shoe Pin and Hardware 8,125 3,685 Boom Point Sheave Assembly 13,900 6,304
Shoe Size 4.5” Pins 4.5” Pins Carbody with Lube and Collector Shoes 168,000 76,204
15 Crawler Shoe 52” (132 cm) Center Gudgeon Assembly 9,350 4,240
16 Crawler Shoe 55” (140 cm) 1,865 846 Control Cabinet 2,000 907
17 Crawler Shoe 70” (178 cm) Converter 10,950 4,966
18 Crawler Shoe 72” (183 cm) 2,100 952 Counterweight Box 86,500 39,236
19 Crawler Shoe 84” (213 cm) 3,470 1,574 Counterweight Cast Assembly-4 pcs.
Crawler Shoe 96” (244 cm) 4,565 2,070 Crowd Motor Assembly 6,800 3,084
20 House Cab Parts 450 204 Crowd Motor Base 2,200 998
21 House Panels 3,800 1,723 Crowd Motor Cover 8,100 3,673
22 Boarding Stairway/Ladder 2,630 1,193 Crowd Transmission
23 Spherical Washer 400 181 Dipper (See Packing List for Weight)
24 Low-Voltage Collector 1,200 544 Gantry Compression Member Assembly 23,000 10,431
25 Air Compressor 2,100 952 Gantry Tension Members 11,950 5,420
26 Troughs and False Floor 2,550 1,156 Handle 78,500 35,607
27 Swing Shafts 8,450 3,832 High Voltage Cabinet 2,100 952
28 Gantry Parts 2,100 952 Hoist Cable Reels (each) 4,300 1,950
29 Paint 450 204 Hoist Drum Assembly 41,500 18,824
30 Carbon Dioxide Cylinders 250 113 Hoist Motor Base, Front 3,600 1,633
31 Upper Assembly Parts 700 317 Hoist Motor Base, Rear 3,600 1,633
32 Air Duct Kit “Bleed Rear Roof” 350 159 Hoist Motor Front 6,150 2,789
33 Not Applicble Hoist Motor Rear 6,150 2,789
34 Left Hand and Right Hand Platforms 12,990 5,892 Hoist Transmission Assembly 25,600 11,612
35 Boom Electrical 400 181 Left Hand Elevated Section 12,800 5,806
36 Miscellaneous-Electrical 1,500 680 Main Transformer & Supp. Cabinet 16,700 7,575
37 Miscellaneous-Wire 1,200 544 Operator’s Coop 12,100 5,488
38 Floodlights 400 181 Propel Motor Base 23,300 10,568
39 Heaters “Portable” 500 227 Propel Motor 6,000 2,721
40 House Lighting Kit 850 385 Rear Enclosures 14,100 6,395
41 Buss Bars 3,500 1,587 Rear Roof Section 12,243 5,553
42 Boarding Ladder Material 200 91 Revolving Frame (Including Sidestand) 158,800 72,030
43 Shipper Shaft Adjusters 450 204 Right Hand Elevated Section 12,600 5,715
44 Remaining Floodlight Assy. & Hard. 600 272 Right Hand Platforms 11,117 5,042
45 Air Conditioner Parts 150 68 Roller Carrier Ring 2,584 1,172
46 Logo Letters 1,175 533 RPC Cabinets 15,000 6,803
47 Counterweight Box Reinforcement RPC Switching Cabinet 2,700 1,224
48 Boom-Sealtite-4” 500 227 Saddle Blocks (each) 9,525 4,320
49 Mounting Bolts-Cast Counterweight 300 136 Shipper Shaft 8,000 3,628
50 Canopy Arch 11,250 5,102 Shipper Shaft Gear 5,600 2,540
51 Hoist Cable Hoods 4,700 2,132 Sideframe Left with Transmission 149,600 67,857
52 Hatch Covers 4,380 1,986 Sideframe Right with Transmission 149,600 67,857
53 Side Beams 3,250 1,474 Suspension Cables (each) 9,600 4,354
54 Railing Crate 3,400 1,542 Swing Gear 18,000 8,163
55 Catwalks #1 1,850 839 Swing Motor Front 8,800 3,991
56 Catwalks #2 3,650 1,655 Swing Motor Rear 8,800 3,991
57 Catwalks #3 4,400 1,995 Swing Transmission/Front Motor 14,300 6,486
58 Boom Platforms 7,200 3,265 Swing Transmission/Rear Motor 14,300 6,486
Transfer Cabinet 1,750 794

*Weights are + 10%. For actual weight of each component, refer to packing list.

5
PLFA
igCuEre
ME2NT OF ITEMS FOR ERECTIOEN
XP-O
ERXT
POSR
HTIPMENTS

95
Figure 2 depicts the recommended placement of
DIPPER
parts at the erection site. Each item shown is
numbered and refers to the Component List
90 (Table 2) which gives the approximate weights of
the components. For the actual weights, refer to
23 the machine packing list. The item numbers
85
shown in Figure 2 and Table 2 correspond to the
42 43
machine packing list.

HANDLE
DIPPER
80

104 105
75

50 52
70
53

65

63
82
60 COUNTER WEIGHT 64
BOX
34 16 65 46 26
66
55
47 49 83
20
44 71 112
50
21 REVOLVING
38 FRAME
15 74
39 22
4 75 HOIST
45 27 24 CASE
29 CRAWLER CRAWLER RING
31 SHOES S S SHOES GEAR
41 30 36 I I
D D
40 37 E CARBODY E 12
40 113 HOIST
87 F 1 F
11 7 DRUM
R R
TOOL A A 73
CONTAINER M M ROLLER
35 E 2 3 E CARRIER
5 18
76 77
LUNCH
ROOM

14 6 13 PROPEL 62 17
110 MOTOR 25
30 45 BASE 8 9 10
61 94 48
72 28 51
54 108 BOOM
19 35
25 55
56 59 60 60 59 32 GANTRY

57
20 33 GANTRY LEGS 114
69 90

70
93 58 106 107
95
15
NOTE
Electrical cabinets, transformers,
AC & DC motors, etc. must be BOOM
10 POINT
stored under cover until required. 67

0 5 10 15 20 25 30 35 40 45 50 55 60 65
METERS

6
Table 2 2800XPB COMPONENT LIST - EXPORT
BOX or APPROX. WEIGHT BOX or APPROX. WEIGHT
CRATE # DESCRIPTION OF CONTENTS LBS. KG. CRATE # DESCRIPTION OF CONTENTS LBS. KG.
1 Carbody with Lube and Collector Shoes 168,000 76,204 57 Catwalks #3 4,400 1,995
2 Sideframe (Left) with Transmission 149,600 67,857 58 Boom Platforms 7,200 3,265
3 Sideframe (Right) with Transmission 149,600 67,857 59 Shipper Shaft Pinions 2,350 1,065
4 Swing Gear 18,000 8,163 60 Crowd Motor Blower 750 340
5 Propel Motor Base 23,300 10,568 61 Dipper Trip Motor 950 431
6 Corduroy Bolt Box 6,000 2,721 62 Lower Disconnect Switch 900 408
7 Lower Assembly Parts 4,000 1,814 63 Counterweight Cast Assembly - 4 pcs.
8 House Rollers 2,150 975 64 Counterweight Cast Assembly - 4 pcs.
9 House Rollers 2,150 975 65 Counterweight Cast Assembly - 4 pcs.
10 House Rollers 2,150 975 66 Counterweight Cast Assembly - 4 pcs.
11 Assembly Tools 7,500 3,401 67 Boom Point Sheave Assembly 13,900 6,304
12 High-Voltage Guards 1,550 703 68 Center Beams 3,500 1,587
13 Crawler Shoe Pin and Hardware 8,125 3,685 69 Catwalks #4 1,350 612
14 Crawler Shoe Pin and Hardware 8,125 3,685 70 Catwalks #5 2,500 1,134
15 Revolving Frame (Including Sidestand) 158,800 72,030 71 Right Hand Elevated Section 12,600 5,714
16 Counterweight Box 86,500 39,236 72 Left Hand Elevated Section 12,800 5,805
17 Air Receiver Tank Box (Optional) 1,100 499 73 Hoist Drum Assembly 41,500 18,824
18 Center Gudgeon Assembly 9,350 4,240 74 Hoist Motor Base, Front 3,600 1,633
19 Boom 130,900 59,375 75 Hoist Motor Base, Rear 3,600 1,633
20 House Cab Parts 950 431 76 Swing Transmission/Front Motor 14,300 6,485
21 House Panels 3,800 1,723 77 Swing Transmission/Rear Motor 14,300 6,485
22 Boarding Stairway/Ladder 2,630 1,193 78 Hoist Motor Front 6,150 2,789
23 Handle 78,500 35,607 79 Hoist Motor Rear 6,150 2,789
24 Low-Voltage Collector (Part of Box 11) 80 Swing Motor Front 8,800 3,991
25 Air Compressor 2,100 952 81 Swing Motor Rear 8,800 3,991
26 Troughs and False Floor 2,550 1,156 82 Pressurization System 21,000 9,524
27 Swing Shafts 8,450 3,832 83 Air Duct Kit “Bleed Rear Roof” 1,900 862
28 Gantry Parts 84 Air Duct Kit “Bleed Rear Roof” 1,900 862
29 Paint 450 204 85 Air Conditioner 2,600 1,179
30 Carbon Dioxide Cylinders 250 113 86 Right Hand Boom Extension 4,600 2,086
31 Upper Assembly Parts 7,000 3,175 87 Operator’s Coop 12,100 5,488
32 Gantry Compression Member 22,500 10,206 88 Boom Catwalk #1 3,000 1,361
33 Gantry Tension Members 11,950 5,420 89 Boom Catwalk #2 3,250 1,474
34 Left Hand and Right Hand Platforms 12,990 5,891 90 Shipper Shaft 8,000 3,628
35 Boom Electrical 400 181 91 Bearing Retainers
36 Gantry Platform 2,800 1,270 92 Crowd Motor Assembly 6,800 3,084
37 Miscellaneous - Wire 1,200 544 93 Crowd Case Cover 8,100 3,674
38 Floodlights 400 181 94 Crowd Motor Base 2,200 998
39 Platform Supports R/L Hand 3,000 1,361 95 Boom Hardware 1,050 476
40 House Lighting Kit 850 385 96 Load Center Panel 2,500 1,134
41 Buss Bars 3,500 1,587 97 Main Transformer & Supp. Cabinet 16,600 7,530
42 Saddle Blocks (each) 9,525 4,320 98 High Voltage Cabinet 2,100 952
43 Saddle Blocks (each) 9,525 4,320 99 Auxiliary & Field Transformer 4,200 1,905
44 Floodlight Assembly and Hardware 1,125 510 100 Converter 10,950 4,966
45 Air Tugger Bracket 950 431 101 Transfer Cabinet 1,750 794
46 Logo Letters 1,175 533 102 RPG Switching Cabinet 2,700 1,224
47 Counterweight Box Reinforcement 103 Dipper Trip Resistor Assembly 1,950 884
48 Boom-Sealtite - 4” 500 227 104 Reel Hoist Cable 4,300 1,950
49 Low Voltage Cover Guard 700 317 105 Reel Hoist Cable 4,300 1,950
50 Canopy Arch 11,250 5,102 106 Suspension Cables (each) 9,600 4,354
51 Hoise Cable Hoods 4,700 2,132 107 Suspension Cables (each) 9,600 4,354
52 Hatch Covers 4,380 1,986 108 Shipper Shaft Gear 5,600 2,540
53 Side Beams 3,250 1,474 109 Left Hand Boarding Ladder 1,750 794
54 Railing Crate 3,400 1,542 110 Kit Boxes
55 Catwalks #1 1,850 839 111 Air Conditioner Parts
56 Catwalks #2 3,850 1,746 112 Rear Enclosure Panels

*Weights are + 10%. For actual weight of each component, refer to packing list.

7
ELECTRICAL TEST EQUIPMENT REQUIREMENTS Recommended Maintenance/Commissioning Test
Equipment Available only through P&H
Basic Electrical Test Instrumentation Required by Customer To
Commission and Maintain Electrotorque Mining Excavator. Description P&H Part #
Recommended Maintenance Test Equipment Available Start-Up Resistor—200 Ohms, 6 kW 80Z984D1
through P&H and other Vendors. RPC/Step Reference Unit 89Z866
Reference/Pushbutton Unit 89Z833D1
Description P&H Part #
Capacitor Unit 89Z508D1
DMM (Digital MultiMeter) Voltage Divider R1192F1
Fluke Model 23 89Z514D12 SCR (Thyristor) Tester 89Z511D1
Alternate DMM—Fluke, Model 87 1089Z275 Test Probes w/Banana Plugs (6 Req’d.) 79Z2738D2
Oscilloscope
Tektronix Model THS710 (Handheld, Dual Trace,
Digital, Storage, Battery Powered, Soft Case) Scope
w/120V / 60Hz Adapter 89Z515D15
120V / 50 Hz AC Adapter (240V Adapters Available) 89Z515D30
Hard Carrying Case 89Z515D26
X10 Probe (1kV) 89Z515D17

Chart Recorder—Hioki, Model 8804

Memory Recorder (Order each part separately)
Recorder (120/240V-50/60 Hz) R10945D1
Carrying Case - Soft R10945D2
AC Adapter 90 - 250V, 50/60 Hz R10945D3
Battery Pack, Rechargable R10945D4
Recording Paper (10 Rolls) R10945D5

Alternate Chart Recorder—Astro- Med, Dash 2MT

Two-Channel Field Recorder
Astro-Med DASH2MT 89Z835D2
Chart Paper 89Z835D2
Megger—500V & 1000V Scales
James G. Biddle 21158 89Z496
Camp-On Ammeter—1A to 1000A AC/DC
Fluke Model 80i—KW 89Z514D14
PLC Communications Computer w/PLC5
Communication Software, Carrying Case
and Allen-Bradley PCMCIA Interface R24834D2

Note: All designs, specifications and components of equipment described above are subject to change at manufacturer’s sole discretion at any time without advance notice. Data
published herein is informational in nature and shall not be construed to warrant suitability of machine for any particular purpose as performance may vary with conditions encountered.
The only warranty applicable is our standard written warranty for this machine. P&H Mining Equipment, Box 310, Milwaukee, Wisconsin 53201.
A Harnischfeger Industries Company.

XS1394 8 2CCI-1197
 2300XPC
assembly Procedure

assembly Assistance
With the purchase of your Model 2300XPC electric mining shovel,
a P&H MinePro Services advisor will be provided for a period of 50
working days to assist the purchaser or the purchaser’s assembly
contractor with the assembly of the machine. The purchaser should
arrange to assembly, test and place the machine into operation during
this 50 day period. 2300XPC

The P&H MinePro Services advisor can provide advice only. He

is available to advise the purchaser or the purchaser’s assembly
contractor on assembly sequences, commissioning procedures, testing
and other assembly details as requested, but is not authorized to
supervise workers or to direct the assembly, testing or commission- SAFETY: All safety related equipment requirements and procedures are
ing in any way. The purchaser will be required to provide all tools, the responsibility of the Purchaser and or designated Assembly
equipment and personnel needed to assemble the machine, as well Contractor and should be in accordance with all applicable
as supervision of personnel erecting the machine. For example, MSHA, Local Mine, State Authorities and regulations.
the P&H MinePro Services advisor is available to consult with NOTE: The purchaser is to supply all necessary start-up lubrication
supervisory personnel on questions such as places to make hitches materials, oils, greases, etc., per P&H specifications.
on components, but P&H Mining Equipment will not be responsible for
placement of such hitching or for working with lifting equipment. P&H
Mining Equipment will not be liable in any event for any indirect,special Site and Material Location
or consequential damages. Purchaser shall indemnify and hold P&H
Mining Equipment harmless for all liability for damage to property or Assembly site preparation is the responsibility of the Purchaser and
personal injury (including death) arising out of purchaser’s assembly, should be a flat leveled area, with good drainage, and stable under
testing or placing into service of the machine. footing to support the lifting equipment and their floats or outriggers
The P&H MinePro Services advisor is not authorized to approve modi- during any lift to be made.
fications to the machine that are not covered by the machine data The area required is approximately 300 feet (91.4 m) square, with a
sheet, nor will P&H Mining Equipment accept any back-charge for tool shed.
any unauthorized modifications made. (See section titled “Machine
Modification Procedure”.)
The purchaser or the purchaser’s assembly contractor should contact Machine Modification Procedure
the nearest P&H Mining Equipment regional office to schedule the P&H
MinePro Services advisor. We ask the purchaser, prior to the arrival During the shovel assembly process, the shovel purchaser will
of P&H MinePro Services advisor, to issue a purchase order covering sometimes request alterations to the standard machine design. Some
the P&H MinePro Services advisor. The first 50 normal working days of the more-commonly requested modifications affect lubrication
will be on a no charge basis. Any days beyond the first 50 days will be systems, walkways, hand rails, lighting systems and guards.
charged against the purchase order at established service rates. While some modifications might improve the ability of the purchaser
The normal working day for the P&H MinePro Services advisor is to utilize and maintain the shovel, some modifications might in fact
eight hours on site per day. The normal work week is five days per adversely affect productivity over time or have significant safety impli-
week (Monday through Friday excluding holidays). Time spent on cations not readily ascertainable.
site beyond the normal work week or day will be charged against the Accordingly, it is imperative that any modifications sought by the
purchase order at established service overtime rates. shovel purchaser of the kind noted above (or any other significant
modifications) be discussed with your P&H MinePro Services
shovel project manager. In turn, your shovel project manager will
discuss your requests with P&H Mining Equipment shovel design
Personnel Requirements engineers to determine if the modifications can be carried out. P&H
Mining Equipment and P&H MinePro Services make every effort to
History for the P&H Model 2300XPC indicates assembly can be made accommodate the purchaser’s requests while taking into consider-
within 5200-5500 man-hours. The history also indicates that if proper ation the machine’s optimal productivity and mine application, as well
manpower is not available, the 50 working day period of erection and
placement into operation will be exceeded. We therefore advise that as current design and safety specifications and regulations.
the following labor types should be available at various stages of It is most important that any modification to the machine be
machine assembly. documented so that P&H Mining Equipment and P&H MinePro
6— Laborers (for the purpose 1— Millwright Services can maintain current drawings and specifications for your
of cleaning parts before 2— Electricians electric shovel. Furthermore, any future service involving the P&H
their assembly) 1— Welder
3— Mechanics Mining Equipment engineering staff can be expedited if modifications
are known and documented.
After the initial cleaning and opening of the packing cases, the two
laborers may be replaced by additional mechanics and millwrights, as Please be aware that any modification performed without P&H Mining
the tasks of the mechanics and millwrights will be more prevalent. Equipment and P&H MinePro Services concurrence might void the
Not included in the above workforce list are the supervisory personnel warranty.
mentioned previously. The necessary mechanical and electrical Some modifications requested by the purchaser can be accommo-
supervision should be present when the various trades are involved in dated at no additional charge. However, some modifications require
the assembly of the machine. additional welding or other services that cannot be absorbed by P&H
This listing does not include crane operators or oilers (if there is a Mining Equipment or P&H MinePro Services. The purchaser will be
requirement for their use). notified of such costs in advance of the work being performed.
 BASIC RIGGING MATERIAL REQUIREMENTS BASIC TOOL REQUIREMENTS (continued)
Cranes 6 — 6 ton come-alongs
Two (2) heavy-lift cranes are required at the start of the erection, 6 — 1/5 ton come-alongs
staying on-site until all the heavy lifts are completed and the boom 4 — 3/4 ton come-alongs
has been pinned to the revolving frame. After raising the boom, the 2 — 1/2" torque wrenches
balance of the erection process can proceed with one (1) rough 1 — 3/4" torque wrench
terrain crane in the 30-ton to 50-ton (27,216 kg to 45,360 kg) class. 1 — 1" torque wrench
1 — torque multiplier 181/2 : 1
Heavy-lift crane size requirements are based on many factors, 1 — 48" aluminum pipe wrench
including crane access to heavy lifts, type of crane used, cold 2 — 24" pipe wrenches
weather capacity de-rating, reach, and pick-and-carry capability. 1 — 24" aluminum pipe wrench
1 — 24" chain wrench
Therefore, in extreme cold weather erection environments, two 225- 1 — 24" crescent wrench
ton (204,120 kg) cranes are recommended. In moderate weather, 1 — open end wrenches 5/16" through 21/2" in 1/16" increments
one 150-ton (136,080 kg) and one 190-ton (172,368 kg) crane are 1 — hammer wrenches 11/8" through 31/8" in 1/16" increments
recommended for heavy lifts. 1 — 4" hammer wrench
Cables / Slings Basic Power Tools
1 — pneumatic air wrench, 1/2" drive, with sockets from 1/2" to 11/4",
4—1 / " x 20'
3 4 4—1" x 12'
in 1/8" increments
2—11/2" x 20' 4—3/4" x 10' 1 — spray paint gun
2—11/4" x 20' 2—5/8" x 20' 1 — air powered grinder, 9" right angle disc
10—smaller cables (1/2" and 3/8", 15' long) to handle the 1 — air powered 1/4" pencil grinder
miscellaneous material, such as brakes, blower 1 — air powered chipping hammer w/chisels
motors, boxes, cab sections, etc. 1 — welding machine, 400 amp capacity (portable gasoline or
diesel driven), including 100' long welding cables
Shackles and Pins 1 — portable air compressor, 150 CFM capacity, with 2 ea. 100'
4—23/4" (with 5" throat opening and 12 deep) for long hoses with inline oilers
lifting revolving frame 1 — portable light plant or electric power supply if needed
6 ea. 11/4", 3/8", 11/2", 3/4", 1" 1 — electric heated rod oven
2 — oxygen/acetylene burning sets with 75' hose
Blocking (Hardwood)
2 — 50-ton hydraulic jacks
40 ea. 8" x 8" or 10" x 10" in 6', 4', and 2' lengths 2 — 1/2" electric drills
1—bag wooden wedges 2 — 1/2" cordless drills
1 — 1/2" angle drill
This material is used for setting the various components on the 2 — 3/8" electric drills
ground. The carbody is blocked 48" high for side frame clearance 1 — magnetic drill
with shoes on. 1 — 11/2" drive pneumatic impact wrench
2 — 1" drive pneumatic impact wrenches
Optional Time-Saving Equipment
1 — 3/4" Super-bolt impact wrench
One 10-ton* (9.072 kg.) forklift. 2 — 3/4" drive pneumatic wrenches
4 — 1/4" die grinders
9 — 5" grinders
BASIC tool REQUIREMENTS 5 — 7" grinders
2 — straight grinders
Basic Hand Tools Basic Electrical Tools 2 — reciprocating saws
2 — 6" screwdrivers 1/4" face 1 — knock out punch set 1 — soldering gun
2 — 8" screwdrivers 3/8" face 1 — hydraulic hand pump 6 — 600 amp welders
2 — 12" screwdrivers 1/2" face knock out punch kit 4 — wire feeders
2 — 15" adjustable open end wrenches 1 — hole saw kit 4 — air arcs
2 — 12" adjustable open end wrenches 2 — manualCrimpers 1 — diesel genset - 300 kW
4 — 12" long bastard files 1 — hydraulic crimpers
6 — 4" paint brushes for use with cleaning solvent 3 — heat guns
1 — crosscut saw 100 — lbs. 3/32" weld rod
Miscellaneous Items
3 — 36" wrecking bars 3 — tarpaulins, 30' x 30' 300 — lbs. 1/8" weld rod
2 — 20 lb. sledge hammers 2 — 12' step ladders - straight 200 — lbs. 3/16" weld rod
4 — 2 lb. ball peen hammers 2 — 20' extension ladders (low hydrogen, pre-dried)
6 — putty knives 3" wide 2 — barrels of cleaning solvent 300 — feet manila rope
1 — heavy-duty mechanic’s tool set 20 — rolls masking tape 1" 100 — lbs. cleaning rags
2 — wire brushes 50 — sheets of fine emery cloth 2000 — lbs. (approx.) dry ice
3 — each tapered drifts, 12" long, 5/8" and 5/8" dia. 50 — sheets of medium emery (the exact quantity required
2 — 1/2" drive socket wrench sets, including two extensions, cloth will depend upon location
ratchet and sockets, from 7/16" to 11/4", in 1/8" increments 2 — wooden stairway with of source and ambient
13/4" drive socket wrench set, including ratchet and sockets, railing for boarding temperature)
from 1" to 3", in 1/8" increments 25 — rolls black plastic electrical — or —
6 — 3-ton come-alongs tape Liquid Nitrogen - 4 bottles,
2 — standard bolt tap set—1/4" to 11/2" in 1/8" increments 25 — rolls of friction tape approximately 370 lbs. of
2 — drill bit set—3/16" to 5/8" in standard increments 5 — anti-seize lubricant (cans) product each bottle and
1 — set of rotary files for pencil grinder 5 — dye check kits for must have liquid withdrawal
1 — 3/4" drive breaker bar checking welds (NDT-PT) capabilities
1 — 1" drive breaker bar 6 — fire extinguishers—20 lb. 3 — 6-foot step ladder
1 — 1" drive socket wrench set, ratchet and sockets, from 11/16" dry chemical type 3 — 8-foot step ladder
through 31/2" in 1/16" increments Painting supplies
1 — 1" Swivel Assorted-color electrical tape
1 — 11/2" Swivel
1 — 1” to 11/2" Adapter The above tool listing indicates the basic minimum range and quantity
1 — 11/2" to 1" Adapter of tools recommended. The list is not intended to be all-inclusive.
1 — set of 11/2" drive sockets from 2" through 4¾" in 1/16"
increments Data Codes
Extensions: 2 — 3/4" drive by 8", 1— 3/4" drive by 13", 2 — 1" *1 ton = 2,000 pounds (907.2 kg)
10' = 10 feet (305 cm) 10" = 10 inches (25.4 cm)
drive by 8", 1 — 1" drive by 13", 1 — 11/2" drive by 12"
2300XPC Lifting or Hitching Points and approximate weights* of major items

The side loading to

56,432 lbs. 52,091 lbs. any welded-on lifting lug cannot
(25,597 kg.) (23,628 kg.)
CL Rotation exceed ±5° from the vertical.
*Weights are ± 10%. For the actual weight of each
component, refer to the packing list.

7'-8" 10'-2"
(2.32 m) (3.11 m)

Width: 11'-6" (3.51 m)

Rev. Frame (Bare)- Weight: 108,523 lbs. (49,225 kg.) Crawler (R.H. shown) w/o Shoes-Weight: 119,000 lbs. (53,977 kg.)
29'-0" (8.84 m)
44,880 lbs.
74,120 lbs. (20,357 kg.)
83,250 lbs. (33,620 kg.)
(37,762 kg.) CL Rotation
79,350 lbs.
(35,993 kg.) 31'-5" (9.58 m)

11'-10"
(3.61 m) 6'-2"
(1.88 m)

15'-4" (4.66 m) R. Tail Swing

Crawler shoes 52" (1.32 m) Wide
Revolving Frame w/ sidestand, hoist case, swing 41 Shoes each Belt-Weight: 60,250 lbs.
Transmissions w/o Motors-Weight: 162,600 lbs. (73,754 kg.) (27,329 kg.)

62,800 lbs. 51,700 lbs.

(28,486 kg.) (23,451 kg.)

71,000 lbs. 71,000 lbs.

(32,205 kg.) (32,205 kg.)

10'-10"
(3.30 m)
Width 10'-3" (3.12 m)
6'-2" Width: 22'-2" (6.76 m)
(1.88 m) Weight: 142,000 lbs.
Boom w/ Sheaves Weight: 114,500 lbs. (51,936 kg.)
Boom w/o Sheaves: Weight: 105,140 lbs. (47,691kg.) (64,410 kg.)

60'-7" (18.47 m)
57'-7" (17.56 m) Boom w/o Point Sheaves 15'-4" (4.67 m)
Carbody

21,741 lbs. 32,950 lbs.

(9,862 kg.) (14,946 kg.)
14'-7"
(4.45 m)
Width: 13'-10" (4.22 m)
Weight: 112,000 lbs
5’-0” (1.52 m) (50,802 kg.)

Width: 8'-4" (2.54 m)

Weight: 54,691 Lbs. (24,807 kg.)
13'-9" (4.19 m)
35'-6" (10.82 m)
Dipper Handle
33 yd³ (25.2 m³) Dipper w/Bail

Dry ice is required to freeze center gudgeon (shown below) for field installation into
carbody. The quantity will depend on location of supplier and ambient temperature.
Alcohol used with dry ice will speed up the process.

CENTER GUDGEON

Weight = 6,397 lbs. (2,902 kg.)

8" (203mm) 18.5" (470mm)

106.0" (2692mm)
 U.S. AND CANADIAN SHIPMENTS

95

DIPPER
Figure 1 depicts the recommended placement
90 of parts at the erection site. Each item shown
is numbered and refers to the Component List
(Table 1) which gives the approximate weights
of the components. For the actual weights, refer
85
to the machine packing list. The item numbers
SADDLE SADDLE shown in Figure 1 and Table 1 correspond to the
BLOCK BLOCK

HANDLE
machine packing list, items 1 through 59. Items

DIPPER
80 beyond 59 are randomly applied.

75

45 47
70
48

65

60
COUNTERWEIGHT
30 BOX
42 23

55
43 29
17
40
REAR
50 ENCLOSURES
18 REVOLVING
34 FRAME
35 19
45 HOIST
24 TRANS-
26 SWING
28 S S GEAR MISSION
37 27 32 I I 1
D D
36 33 E CARBODY E 12
40 2 HOIST
58 15/16 F F 15/16
11 7 DRUM
R R
TOOL A A 20
CONTAINER M M ROLLER
35 E E CARRIER
RING
59
LUNCH
ROOM

14 6 13 PROPEL 57
MOTOR 22
30 41 BASE 8 9 10
5
44 21 25 46
49 BOOM
31
25 50
GANTRY
51 54 55 56 54 COMPRESSION
MEMBER
52
20
GANTRY
TENSION
53 MEMBERS
3
15
39

NOTE BOOM
10 POINT
Electrical cabinets, transformers, SHEAVES
AC & DC motors, etc. must be
stored under cover until required.
5

0 5 10 15 20 25 30 35 40 45 50 55 60 65
METERS

Figure 1
 2300XPC COMPONENT LIST - U.S. & CANADA
Approx. Weight*
Assemblies without Pre-Assigned Box or Approx. Weight*
BOX or Crate Numbers
CRATE #
Description of Contents Lbs. Kg Description of Contents Lbs. Kg
1 Kit #1 Hardware for Revolving Frame 675 306 Air Tugger Bracket 850 386
2 Kit #2 Hardware for Carbody 550 249 Auxiliary & Field Transformer 5,200 2,359
3 Kit #3-If this is packed inside of the boom 300 136 Auxiliary Control Cabinet 1,200 544
4 Contains Kit #4 Hard. for Cab & Upper 450 204 Boom 105,140 47,691
5 Contains Kit #5 Hard. for Catwalk & Railing 300 136 Boom Point Sheave Assembly 9,360 4,246
6 Corduroy Bolt Box 1,000 454 Carbody with Lube and Collector Shoes 142,000 64,410
7 Lower Assembly Parts 1,400 635 Center Gudgeon Assembly 10,624 4,819
8 House Rollers 2,100 953 Control Cabinet 2,000 907
9 House Rollers 2,100 953 Converter 10,300 4,672
10 House Rollers 2,100 953 Counterweight Box 96,040 43,563
11 Assembly Tools 950 431 Crowd Motor Assembly 6,300 2,858
12 High-Voltage Guards 1,550 703 Crowd Motor Base 1,500 680
13 Crawler Shoe Pins and Hardware 2,850 1,293 Crowd Case Cover 1,200 544
14 Crawler Shoe Pins and Hardware 2,850 1,293 Dipper (See Packing List for Weight) — —
15 Shoe Size 3.75” Pins 3.75” Pins Gantry Compression Member Assembly 21,000 9,525
16 Crawler Shoe 70” (178 cm) - optional 1,745 792 Gantry Tension Members (each) 3,320 1,506
17 House Cab Parts 940 426 Handle 54,691 24,807
18 House Panels 3,300 1,497 High Voltage Cabinet 3,046 1,382
19 Boarding Stairway/Ladder 915 415 Hoist Cable Reels (each) 3,250 1,474
20 Spherical Washer 250 113 Hoist Drum Assembly 29,580 13,417
21 Low-Voltage Collector 1,250 567 Hoist Motor Base, Front 2,366 1,073
22 Air Compressor 1,400 635 Hoist Motor Base, Rear 2,366 1,073
23 Troughs and False Floor 3,600 1,633 Hoist Motor Front 11,000 4,990
24 Swing Shafts 2,162 981 Hoist Motor Rear 11,000 4,990
25 Gantry Parts 1,250 567 Hoist Transmission Assembly 23,378 10,604
26 Paint 450 204 Left Hand Elevated Section 7,200 3,266
27 Carbon Dioxide Cylinders 400 181 Main Transformer & Supp. Cabinet 15,500 7,031
28 Upper Assembly Parts 1,175 533 Operator’s Coop 18,300 8,301
29 Air Duct Kit “Bleed Rear Roof” 450 204 Propel Motor Base 9,260 4,200
30 Left Hand and Right Hand Platforms 9,350 4,241 Propel Motor 6,100 2,767
31 Boom Electrical 600 272 Rear Enclosures 8,432 3,825
32 Miscellaneous-Electrical 500 227 Rear Roof Section 20,971 9,512
33 Miscellaneous-Wire 500 227 Revolving Frame (Including Sidestand) 108,523 49,225
34 Floodlights 450 204 Right Hand Elevated Section 6,160 2,794
35 Heaters “Portable” 377 171 Right Hand Platforms 5,920 2,685
36 House Lighting Kit 360 163 Roller Carrier Ring 3,110 1,411
37 Buss Bars 3,500 1,588 RPC Cabinets 11,850 5,375
38 Boarding Ladder Material 150 68 RPC Switching Cabinet 2,700 1,225
39 Shipper Shaft Adjusters 300 136 Saddle Blocks (each) 7,560 3,429
40 Remaining Floodlight Assy. & Hard. 175 79 Shipper Shaft 5,845 2,651
41 Air Conditioner Parts - optional 400 181 Shipper Shaft Gear 3,770 1,710
42 Logo Letters 1,175 533 Sideframe (Left) with Transmission 119,000 53,977
43 Counterweight Box Reinforcement 250 113 Sideframe (Right) with Transmission 119,000 53,977
44 Boom-Sealtite-4” 500 227 Suspension Cables (each) 3,600 1,633
45 Canopy Arch 4,221 1,915 Swing Gear 19,900 9,026
46 Hoist Cable Hoods 1,000 454 Swing Motor Front 7,270 3,298
47 Hatch Covers 3,087 1,400 Swing Motor Rear 7,270 3,298
48 Side Beams 2,802 1,271 Swing Transmission/Front Motor 15,350 6,963
49 Railing Crate 1,516 688 Swing Transmission/Rear Motor 15,350 6,963
50 Catwalks #1 2,058 933 Transfer Cabinet 1,500 680
51 Catwalks #2 2,120 962
52 Catwalks #3 1,200 544
53 Boom Platforms 12,000 5,443
54 Shipper Shaft Pinions (each) 1,085 492
55 Shipper Shaft Retainer w/Washer 600 272
56 Shipper Shaft Retainer w/Washer 600 272
57 Lower Disconnect Switch 900 408
58 House Heaters 150 68
59 Air Conditioner - optional 3,000 1,361
Weights are ±10%. For actual weight of each component, refer to packing list.

Table 1
EXPORT SHIPMENTS

95
Figure 2 depicts the recommended placement
DIPPER of parts at the erection site. Each item shown
is numbered and refers to the Component List
90 (Table 2) which gives the approximate weights
of the components. For the actual weights, refer
to the machine packing list. The item numbers
23
shown in Figure 2 and Table 2 correspond to the
85 42 43 machine packing list.

HANDLE
DIPPER
80

75

52
50
70
53

65

78
60 COUNTERWEIGHT
BOX
34 16
46 26
67
55
47 79 80
20
44 68 108
50
21 REVOLVING
38 FRAME
15 70
39 22 109
4 71 HOIST
45 27
29 CRAWLER CRAWLER SWING TRANS-
31 SHOES S S SHOES GEAR MISSION
41 30 36 I I
D D
40 37 E CARBODY E 12
40 HOIST
117 F 1 F
11 7 DRUM
R R
TOOL A A 69
113 114
CONTAINER M M ROLLER
35 E 2 3 E CARRIER
5 18
RING
72 73
LUNCH
ROOM

14 6 13 PROPEL 62 17
MOTOR 25
30 45 81 106 BASE 8 9 10
61 107 90 5
48
24 28 51
54 104 BOOM
35 49
25 55 19
GANTRY
56 59 59 32 COMPRESSION
115 116 MEMBER
57
20 33 GANTRY
65 86 TENSION
MEMBERS
66
89 104 58 102 103
91
15

BOOM
10 POINT
63 SHEAVES

0 5 10 15 20 25 30 35 40 45 50 55 60 65
METERS

Figure 2
 2300XPC component list - export
Site Approx. Weight* Site Approx. Weight*
Location Description of Contents Lbs. Kg Location Description of Contents Lbs. Kg
1 Carbody with Lube and Collector Shoes 142,000 64,410 60 Crowd Motor Blower 361 164
2 Sideframe (Left) with Transmission 119,000 53,977 61 Dipper Trip Motor 600 272
3 Sideframe (Right) with Transmission 119,000 53,977 62 Lower Disconnect Switch 800 363
4 Swing Gear 19,900 9,026 63 Boom Point Sheave Assembly 9,360 4,246
5 Propel Motor Base 9,260 4,200 64 Center Beams 800 363
6 Corduroy Bolt Box 1,000 454 65 Catwalks #4 900 408
7 Lower Assembly Parts 1,400 635 66 Catwalks #5 800 363
8 House Rollers 2,100 953 67 Right Hand Elevated Section 6,160 2,794
9 House Rollers 2,100 953 68 Left Hand Elevated Section 7,200 3,266
10 House Rollers 2,100 953 69 Hoist Drum Assembly 29,580 13,417
11 Assembly Tools 950 431 70 Hoist Motor Base, Front 2,366 1,073
12 High-Voltage Guards 1,550 703 71 Hoist Motor Base, Rear 2,366 1,073
13 Crawler Shoe Pins and Hardware 2,850 1,293 72 Swing Transmission/Front Motor 15,350 6,963
14 Crawler Shoe Pins and Hardware 2,850 1,293 73 Swing Transmission/Rear Motor 15,350 6,963
15 Revolving Frame (Including Sidestand) 108,523 49,225 74 Hoist Motor Front 11,000 4,990
16 Counterweight Box 96,040 43,563 75 Hoist Motor Rear 11,000 4,990
17 Air Receiver Tank Box (Optional) — — 76 Swing Motor Front 7,270 3,298
18 Center Gudgeon Assembly 10,624 4,819 77 Swing Motor Rear 7,270 3,298
19 Boom 105,140 47,691 78 Pressurization System 20,900 9,480
20 House Cab Parts 940 426 79 Air Duct Kit “Bleed Rear Roof” 450 204
21 House Panels 3,300 1,497 80 Air Duct Kit “Bleed Rear Roof” 450 204
22 Boarding Stairway/Ladder 915 415 81 Air Conditioner - optional 3,000 1,361
23 Handle 54,691 24,807 82 Right Hand Boom Extension 1,200 544
24 Low-Voltage Collector 1,250 567 83 Operator’s Coop 18,300 8,301
25 Air Compressor 1,400 635 84 Boom Catwalk #1 950 431
26 Troughs and False Floor 3,600 1,633 85 Boom Catwalk #2 950 431
27 Swing Shafts 2,162 981 86 Shipper Shaft 5,845 2,651
28 Gantry Parts 1,250 567 87 Bearing Retainers 600 272
29 Paint 450 204 88 Crowd Motor Assembly 6,300 2,858
30 Carbon Dioxide Cylinders 400 181 89 Crowd Case Cover 1,200 544
31 Upper Assembly Parts 1,175 533 90 Crowd Motor Base 1,500 680
32 Gantry Compression Member 21,000 9,525 91 Boom Hardware 400 181
33 Gantry Tension Members (ea., 2 pieces) 3,320 1,506 92 Load Center Panel 1,350 612
34 Left Hand and Right Hand Platforms 9,350 4,241 93 Main Transformer & Supp. Cabinet 15,500 7,031
35 Boom Electrical 600 272 94 High Voltage Cabinet 3,046 1,382
36 Gantry Platform 1,000 454 95 Auxiliary & Field Transformer 5,200 2,359
37 Miscellaneous - Wire 450 204 96 Converter 10,300 4,672
38 Floodlights 450 204 97 Transfer Cabinet 1,500 680
39 Platform Supports R/L Hand 800 363 98 RPC Switching Cabinet 2,700 1,225
40 House Lighting Kit 360 163 99 Dipper Trip Resistor Assembly 585 265
41 Buss Bars 3,500 1,588 100 Hoist Cable Reel 3,250 1,474
42 Saddle Block 7,560 3,429 101 Hoist Cable Reel 3,250 1,474
43 Saddle Block 7,560 3,429 102 Suspension Cables (each) 3,600 1,633
44 Floodlight Assembly and Hardware 600 272 103 Suspension Cables (each) 3,600 1,633
45 Air Tugger Bracket 850 386 104 Shipper Shaft Gear 3,770 1,710
46 Logo Letters 1,175 533 105 Left Hand Boarding Ladder 1,400 635
47 Counterweight Box Reinforcement 250 113 106 Kit Boxes 3,000 1,361
48 Boom-Sealtite - 4” 500 227 107 Air Conditioner Parts - optional 400 181
49 Low Voltage Cover Guard 1,200 544 108 Rear Enclosure Panels 7,820 3,547
50 Canopy Arch 4,221 1,915 109 Hoist Transmission Assembly 23,378 10,604
51 Hoist Cable Hoods 1,000 454 110 Propel Motor 6,100 2,767
52 Hatch Covers 3,087 1,400 111 RPC Cabinets 11,850 5,375
53 Side Beams 2,802 1,271 112 Control Cabinet 2,000 907
54 Railing Crate 1,516 688 113 Roller Carrier Ring 3,110 1,411
55 Catwalks #1 2,058 933 114 Spherical Washer 250 113
56 Catwalks #2 2,120 962 115 Shipper Shaft Retainer w/Washer 600 272
57 Catwalks #3 1,200 544 116 Shipper Shaft Retainer w/Washer 600 272
58 Boom Platforms 12,000 5,443 117 House Heaters 150 68
59 Shipper Shaft Pinions (each) 1,085 492
Weights are ±10%. For actual weight of each component, refer to packing list.
Table 2
 electrical test equipment requirements
Basic Electrical Test Instrumentation Recommended to Commission and Maintain Centurion Digital Drive Mining Excavator.
Recommended Maintenance Test Equipment Available through P&H and other Vendors.

Description P&H Part # Description P&H Part #

DMM (Digital MultiMeter) Drive Communications (hardware and software) R40775D3
Fluke Model 23 89Z514D12 RPC Capacitor Test unit 89Z508D1
Alternate DMM—Fluke, Model 87 1089Z275
Voltage Divider R1192F1
Oscilloscope
Hand-held Drive Programmer, ABB CDP-312R R46072D7
Tektronix Model THS720A (Hand-held, Dual Trace,
Digital, Storage, Battery Powered, Soft Case) Scope 2 Meter Connection Cable R46072D8
w/120V / 60Hz Adapter 89Z515D16 SCR (Thyristor) Tester 89Z511D1
120V / 50 Hz AC Adapter (240V Adapters Available) 89Z515D30
Hard Carrying Case 89Z515D26
X10 Probe (1kV) 89Z515D17
R5-232 to 485 Converter—for loading ABB drive
firmware ABB NPCU-01-KIT R49117D1
Megger—500V & 1000V Scales (hand-crank /w case)
James D. Biddle Cat. 21158 89Z496
Clamp-On Ammeter—1A to 600A AC / 1000A (DC)
Fluke Model i1010 89Z514D15
High Voltage Differential Probe—P5200 89Z515D21
Laptop computer—Consult service department
for specs N/A

NOTE: All designs, specifications and components of equipment described above are subject to change at manufacturer’s sole discretion at any time without
advance notice. Data published herein is informational in nature and shall not be construed to warrant suitability of machine for any particular purpose as
performance may vary with conditions encountered. The only warranty applicable is our standard written warranty for this machine.

P&H Mining Equipment  •  Box 310  •  Milwaukee, Wisconsin 53201 USA

XS-4464 PDF108
 ®

2300XPB
DC ELECTROTORQUE® MINING SHOVEL
DUAL PLANETARY PROPEL & SWING

ERECTION PROCEDURE

ERECTION ASSISTANCE ERECTION PERSONNEL REQUIREMENTS

With the purchase of your P&H Model 2300XPB electric mining The erection history for the P&H Model 2300XPB indicates erection
shovel, a P&H MinePro® Services advisor will be provided for a can be made within 5200-5500 man-hours. The history also
period of 50 working days to assist the purchaser or the indicates that if proper manpower is not available, the 50
purchaser’s erection contractor with the erection of the machine. working day period of erection and placement into operation
The purchaser should arrange to erect, test and place the machine will be exceeded. We therefore advise that the following labor
into operation during this 50 day period. types should be available at various stages of machine erection.
The P&H MinePro Services advisor can provide advice only. He 6—Laborers (for the purpose of cleaning parts before their
is available to advise the purchaser or the purchaser’s erection assembly)
contractor on erection sequences, commissioning procedures, 3—Mechanics
testing and other erection details as requested, but is not 1—Millwright
authorized to supervise workers or to direct the erection, testing 2—Electricians
or commissioning in any way. The purchaser will be required to 1—Welder
provide all tools, equipment and personnel needed to erect the
machine, as well as supervision of personnel erecting the After the initial cleaning and opening of the packing cases, the
machine. For example, the MinePro service advisor is available six laborers may be replaced by additional mechanics and mill-
to consult with supervisory personnel on questions such as places wrights, as the tasks of the mechanics and millwrights will be
to make hitches on components, but P&H MinePro Services will more prevalent.
not be responsible for placement of such hitching or for working
with lifting equipment. In addition, the necessary mechanical and electrical supervision
should be present when the various trades are involved in the
The P&H service advisor is not authorized to approve erection of the machine.
modifications to the machine that are not covered by the machine
data sheet, nor will P&H Mining Equipment or P&H MinePro Crane operators or oilers (if there is a requirement for their use)
Services accept any back-charge for any unauthorized modifica- should also be available as needed.
tions made.
SAFETY: All safety related equipment requirements and
The purchaser or the purchaser’s erection contractor procedures are the responsibility of the Purchaser
should contact the nearest P&H MinePro Services regional and/or designated Erection Contractor and should
office to schedule the MinePro service advisor. We ask the be in accordance with all applicable MSHA,
purchaser, prior to the arrival of the MinePro service advisor, to Local Mine, State Authorities and regulations.
issue a purchase order covering the service advisor only. The first
50 normal working days will be on a no charge basis. Any days NOTE: The purchaser is to supply all necessary start-up
beyond the first 50 days will be charged against the purchase lubrication materials, oils, greases, etc., per P&H
order at established service rates. No items or conditions con- specifications.
tained in the purchase order will operate to modify these or any
other terms or conditions related to this service.

The normal working day for the service advisor is eight hours ERECTION SITE AND MATERIAL LOCATION
on site per day. The normal work week is five days per week
(Monday through Friday excluding holidays). Time spent on site Erection site preparation is the responsibility of the Purchaser
beyond the normal work week or day will be charged against the and should be a flat leveled area, with good drainage, and
purchase order at then current established service overtime rates. stable under footing to support the lifting equipment and their
floats or outriggers during any lift to be made.
The area required is approximately 300 feet (91.4 m) square,
with a tool shed.

1
BASIC RIGGING MATERIAL REQUIREMENTS BASIC TOOL REQUIREMENTS (continued)
Cranes Basic Power Tools
One truck crane with 100-ton* (90,720 kg.) capacity and 1—1/2" drive reversible electric drill motor 110 vac
one truck crane with 140-ton* (127,008 kg.) capacity. One 1—pneumatic air wrench, 1/2" drive, with sockets from
truck crane will be required for 45 working days for each 1/2" to 1-1/4", in 1/8" increments
machine during the erection period. The second truck crane 1—spray paint gun
will only be required for the first 20 working days of the
erection for each machine. 1—air powered grinder, 9" right angle disc
1—air powered 1/4" pencil grinder
One 20-30-ton* (18,144-27,216 kg.) rough terrain crane* 1—air powered chipping hammer
Cables 1—welding machine, 400 amp capacity (portable gasoline
or diesel driven), including 100' long welding cables
4—1-3/4" x 20' 4—1" x 12' 1—portable air compressor, 150 CFM capacity, with 2 ea.
2—1-1/2" x 20' 4—3/4" x 10' 100' long hoses with inline oilers
2—1-1/4" x 20' 2—5/8" x 20' 1—portable light plant or electric power supply if needed
10—smaller cables (1/2" and 3/8", 15' long) to handle the 1—electric heated rod oven
miscellaneous material, such as brakes, blower 2—oxygen acetylene burning sets with 75' hose
motors, boxes, cab sections, etc.
2—50-ton hydraulic jacks
Shackles
Basic Miscellaneous Items
4—2-3/4" (with 5" throat opening and 12 deep) for
lifting revolving frame 3—tarpaulins, 30' x 30'
6 ea. 1/4", 3/8", 1/2", 3/4", 1" 2—15' step ladders
2—24' extension ladders
Blocking (Hardwood) 2—barrels of cleaning solvent
40 ea. 8" x 8" or 10" x 10" in 6', 4', and 2' lengths 20—rolls masking tape 1"
1—bag wooden wedges 50—sheets of fine emery cloth
50—sheets of medium emery cloth
This material is used for setting the various components 2—wooden stairway with railing for boarding
on the ground. The carbody is blocked approximately 48" high
for side frame clearance with shoes on. 25—rolls black plastic electrical tape
25—rolls of friction tape
Optional Time Saving Equipment 5—anti-seize lubricant (cans)
One 10-ton* (9,072 kg.) forklift. 5—dye check kits for checking welds
6—fire extinguishers—20 lb. dry chemical type
100—lbs. each—3/16" and 3/32" weld rod—hydrogen (pre-dried)
BASIC TOOL REQUIREMENTS 300—feet manila rope
Basic Hand Tools 100—lbs. cleaning rags
2000-lbs. (approx.) dry ice (the exact quantity required will depend
2—6" screwdrivers 1/4" face upon location of source and ambient temperature
2—8" screwdrivers 3/8" face
2—12" screwdrivers 1/2" face
2—15" adjustable open end wrenches Data Codes
2—12" adjustable open end wrenches
*1 ton = 2,000 pounds (907.2 kg)
4—12" long bastard files 10' = 10 feet (305 cm) 10" = 10 inches (25.4 cm)
6—4" paint brushes for use with cleaning solvent
1—crosscut saw
3—36" wrecking bars
2—20 lb. sledge hammers
4—2 lb. ball peen hammers
6—putty knives 3" wide
2—wire brushes
3—each tapered drifts, 12" long, 5/8" and 3/4" dia.
2—1/2" drive socket wrench sets, including two extensions,
ratchet and sockets, from 7/16" to 1-1/4", in 1/8"
increments
1—3/4" drive socket wrench set, including two extensions,
ratchet and sockets, from 1" to 3", in 1/8" increments
6—3-ton P&H hoists
2—standard bolt tap set—1/4" to 1-1/2" in 1/8" increments
2—drill bit set—3/16" to 5/8" in standard increments
1—set of rotary files for pencil grinder
1—torque wrench
1—torque multiplier (2,500 ft.-lbs. capacity)

2
2300XPB LIFTING OR HITCHING POINTS AND APPROXIMATE WEIGHTS* OF MAJOR ITEMS

56,432 lbs. 52,091 lbs.

(25,597 kg.) (23,628 kg.)
CL Rotation

7'-8" 10'-2"
(2.32 m) (3.11 m)

Width: 11'-6" (3.51 m)

Rev. Frame (Bare)- Weight: 108,523 lbs. (49,225 kg.) Crawler (R.H. shown) w/o Shoes-Weight: 119,000 lbs. (53,977 kg.)
29'-0" (8.84 m)
74,120 lbs. 44,880 lbs.
(33,620 kg.) (20,357 kg.)
83,250 lbs.
(37,762 kg.) C
L Rotation 79,350 lbs. 31'-5" (9.58 m)
(35,993 kg.)

11'-10" 6'-2"
(3.61 m) (1.88 m)

15'-4" (4.66 m) R. Tail Swing

Crawler shoes 52" (1.32 m) Wide
Revolving Frame w/ sidestand, hoist case, swing 41 Shoes each Belt-Weight: 60,250 lbs.
Transmissions w/o Motors-Weight: 162,600 lbs. (73,754 kg.) (27,329 kg.)

62,800 lbs. 51,700 lbs.

(28,486 kg.) (23,451 kg.)

71,000 lbs. 71,000 lbs.

(32,205 kg.) (32,205 kg.)

10'-10"
(3.30 m)
Width 10'-3" (3.12 m)
6'-2" Width: 22'-2" (6.76 m)
Boom w/ Sheaves Weight: 114,500 lbs. (51,936 kg.) (1.88 m) Weight: 142,000 lbs.
Boom w/o Sheaves: Weight: 105,140 lbs. (47,691kg.) (64,410 kg.)

60'-7" (18.47 m)
57'-7" (17.56 m) Boom w/o Point Sheaves 15'-4" (4.67 m)
Carbody

21,741 lbs. 32,950 lbs.

(9,862 kg.) (14,946 kg.)
14'-7"
(4.45 m)
Width: 13'-10" (4.22 m)
Weight: 112,000 lbs
5’-0” (1.52 m) (50,802 kg.)

Width: 8'-4" (2.54 m)

Weight: 54,691 Lbs. (24,807 kg.)
13'-9" (4.19 m)
35'-6" (10.82 m)
Dipper Handle
33 yd³ (25.2 m³) Dipper w/Bail

Dry ice is required to freeze center gudgeon (shown below) for field installation into
carbody. The quantity will depend on location of supplier and ambient temperature.
Alcohol used with dry ice will speed up the process.

CENTER GUDGEON

Weight = 6,397 lbs. (2,902 kg.)

8" (203mm) 18.5" (470mm)

106.0" (2692mm)

*Weights are ± 10%. For the actual weight of each component, refer to the packing list.

3
 Figure 1 U.S. AND CANADIAN SHIPMENTS

95
Figure 1 depicts the recommended placement of
DIPPER
parts at the erection site. Each item shown is
numbered and refers to the Component List
90 (Table 1) which gives the approximate weights of
the components. For the actual weights, refer to
the machine packing list. The item numbers
85 shown in Figure 1 and Table 1 correspond to the
machine packing list, items 1 through 62. Items
SADDLE SADDLE
BLOCK BLOCK beyond 62 are randomly applied.

HANDLE
DIPPER
80

75

45 47
70
48

65

60
COUNTERWEIGHT
30 BOX
42 23

55
43 29
17
40
REAR
50 ENCLOSURES
18 REVOLVING
34 FRAME
35 19
45 HOIST
24 TRANS-
26 SWING
28 S S GEAR MISSION
37 27 32 I I 1
D D
36 33 E CARBODY E 12
40 2 HOIST
58 15/16 F F 15/16
11 7 DRUM
R R
TOOL A A 20
CONTAINER M M ROLLER
35 E E CARRIER
RING
59
LUNCH
ROOM

14 6 13 PROPEL 57
MOTOR 22
30 41 BASE 8 9 10
5
44 21 25 46
49 BOOM
31
25 50
GANTRY
51 54 55 56 54 COMPRESSION
MEMBER
52
20
GANTRY
TENSION
53 MEMBERS
3
15

NOTE 39
Electrical cabinets, transformers,
BOOM
10 AC & DC motors, etc. must be POINT
stored under cover until required. SHEAVES

0 5 10 15 20 25 30 35 40 45 50 55 60 65
METERS

4
Table 1 2300XPB COMPONENT LIST - U.S. & CANADA

BOX or APPROX. WEIGHT Assemblies without Pre-Assigned

CRATE # DESCRIPTION OF CONTENTS LBS. KG. Box or Crate Numbers LBS. KG.
1 Kit #1 Hardware for Revolving Frame 675 306 APPROX. WEIGHT
2 Kit #2 Hardware for Carbody 550 249 DESCRIPTION OF CONTENTS LBS. KG.
3 Kit #3-If this is packed inside of the boom Air Tugger Bracket 850 386
hardware box, then the boom hardware Auxiliary & Field Transformer 5,200 2,359
box will be box #3 300 136 Auxiliary Control Cabinet 1,200 544
4 Contains Kit #4 Hard. for Cab & Upper 450 204 Boom 105,140 47,691
5 Contains Kit #5 Hard. for Catwalk & Boom Point Sheave Assembly 9,360 4,246
Railing 300 136
Carbody with Lube and Collector Shoes 142,000 64,410
6 Corduroy Bolt Box 1,000 454
Center Gudgeon Assembly 10,624 4,819
7 Lower Assembly Parts 1,400 635
Control Cabinet 2,000 907
8 House Rollers 2,100 953
Converter 10,300 4,672
9 House Rollers 2,100 953
Counterweight Box 96,040 43,563
10 House Rollers 2,100 953
Crowd Motor Assembly 6,300 2,858
11 Assembly Tools 950 431
Crowd Motor Base 1,500 680
12 High-Voltage Guards 1,550 703
Crowd Case Cover 1,200 544
13 Crawler Shoe Pins and Hardware 2,850 1,293
Dipper (See Packing List for Weight) — —
14 Crawler Shoe Pins and Hardware 2,850 1,293
Gantry Compression Member Assembly 21,000 9,525
Shoe Size 3.75" Pins 3.75" Pins
Gantry Tension Members (each) 3,320 1,506
15 Crawler Shoe 52" (132 cm) - standard 1,400 635
Handle 54,691 24,807
16 Crawler Shoe 70" (178 cm) - optional 1,745 792
High Voltage Cabinet 3,046 1,382
17 House Cab Parts 940 426
Hoist Cable Reels (each) 3,250 1,474
18 House Panels 3,300 1,497
Hoist Drum Assembly 29,580 13,417
19 Boarding Stairway/Ladder 915 415
Hoist Motor Base, Front 2,366 1,073
20 Spherical Washer 250 113
Hoist Motor Base, Rear 2,366 1,073
21 Low-Voltage Collector 1,250 567
Hoist Motor Front 11,000 4,990
22 Air Compressor 1,400 635
Hoist Motor Rear 11,000 4,990
23 Troughs and False Floor 3,600 1,633
Hoist Transmission Assembly 23,378 10,604
24 Swing Shafts 2,162 981
Left Hand Elevated Section 7,200 3,266
25 Gantry Parts 1,250 567
Main Transformer & Supp. Cabinet 15,500 7,031
26 Paint 450 204
Operator’s Coop 13,900 6,305
27 Carbon Dioxide Cylinders 400 181
Propel Motor Base 9,260 4,200
28 Upper Assembly Parts 1,175 533
Propel Motor 6,100 2,767
29 Air Duct Kit “Bleed Rear Roof” 450 204
Rear Enclosures 8,432 3,825
30 Left Hand and Right Hand Platforms 9,350 4,241
Rear Roof Section 20,971 9,512
31 Boom Electrical 600 272
Revolving Frame (Including Sidestand) 108,523 49,225
32 Miscellaneous-Electrical 500 227
Right Hand Elevated Section 6,160 2,794
33 Miscellaneous-Wire 500 227
Right Hand Platforms 5,920 2,685
34 Floodlights 450 204
Roller Carrier Ring 3,110 1,411
35 Heaters “Portable” 377 171
RPC Cabinets 11,850 5,375
36 House Lighting Kit 360 163
RPC Switching Cabinet 2,700 1,225
37 Buss Bars 3,500 1,588
Saddle Blocks (each) 7,560 3,429
38 Boarding Ladder Material 150 68
Shipper Shaft 5,845 2,651
39 Shipper Shaft Adjusters 300 136
Shipper Shaft Gear 3,770 1,710
40 Remaining Floodlight Assy. & Hard. 175 79
Sideframe (Left) with Transmission 119,000 53,977
41 Air Conditioner Parts - optional 400 181
Sideframe (Right) with Transmission 119,000 53,977
42 Logo Letters 1,175 533
Suspension Cables (each) 3,600 1,633
43 Counterweight Box Reinforcement 250 113
Swing Gear 19,900 9,026
44 Boom-Sealtite-4" 500 227
Swing Motor Front 7,270 3,298
45 Canopy Arch 4,221 1,915
Swing Motor Rear 7,270 3,298
46 Hoist Cable Hoods 1,000 454
Swing Transmission/Front Motor 15,350 6,963
47 Hatch Covers 3,087 1,400
Swing Transmission/Rear Motor 15,350 6,963
48 Side Beams 2,802 1,271
Transfer Cabinet 1,500 680
49 Railing Crate 1,516 688
50 Catwalks #1 2,058 933
51 Catwalks #2 2,120 962
52 Catwalks #3 1,200 544
53 Boom Platforms 12,000 5,443
54 Shipper Shaft Pinions (each) 1,085 492
55 Shipper Shaft Retainer w/Washer 600 272
56 Shipper Shaft Retainer w/Washer 600 272
57 Lower Disconnect Switch 900 408
58 House Heaters 150 68
59 Air Conditioner - optional 3,000 1,361

*Weights are ± 10%. For the actual weight of each component, refer to the packing list.

5
Figure 2 EXPORT SHIPMENTS

95 Figure 2 depicts the recommended placement of

DIPPER parts at the erection site. Each item shown is
numbered and refers to the Component List
(Table 2) which gives the approximate weights of
90
the components. For the actual weights, refer to
the machine packing list. The item numbers
23 shown in Figure 2 and Table 2 correspond to the
85 42 43 machine packing list.

HANDLE
DIPPER
80

75

50 52
70
53

65

78
60 COUNTERWEIGHT
BOX
34 16
46 26
67
55
47 79 80
20
44 68 108
50
21 REVOLVING
38 FRAME
15 70
39 22 109
4 71 HOIST
45 27
29 CRAWLER CRAWLER SWING TRANS-
31 SHOES S S SHOES GEAR MISSION
41 30 36 I I
D D
40 37 E CARBODY E 12
40 HOIST
117 F 1 F
11 7 DRUM
R R
TOOL A A 69
113 114
CONTAINER M M ROLLER
35 E 2 3 E CARRIER
5 18
RING
72 73
LUNCH
ROOM

14 6 13 PROPEL 62 17
MOTOR 25
30 45 81 106 BASE 8 9 10
61 107 90 5
48
24 28 51
54 104 BOOM
35 49
25 55 19
GANTRY
56 59 59 32 COMPRESSION
115 116 MEMBER
57
20 33 GANTRY
65 86 TENSION
MEMBERS
66
89 104 58 102 103
91
15
NOTE
Electrical cabinets, transformers,
AC & DC motors, etc. must be BOOM
10 POINT
stored under cover until required. 63 SHEAVES

0 5 10 15 20 25 30 35 40 45 50 55 60 65
METERS

6
Table 2 2300XPB COMPONENT LIST - EXPORT
BOX or APPROX. WEIGHT BOX or APPROX. WEIGHT
CRATE # DESCRIPTION OF CONTENTS LBS. KG. CRATE # DESCRIPTION OF CONTENTS LBS. KG.
1 Carbody with Lube and Collector Shoes 142,000 64,410 60 Crowd Motor Blower 361 164
2 Sideframe (Left) with Transmission 119,000 53,977 61 Dipper Trip Motor 600 272
3 Sideframe (Right) with Transmission 119,000 53,977 62 Lower Disconnect Switch 800 363
4 Swing Gear 19,900 9,026 63 Boom Point Sheave Assembly 9,360 4,246
5 Propel Motor Base 9,260 4,200 64 Center Beams 800 363
6 Corduroy Bolt Box 1,000 454 65 Catwalks #4 900 408
7 Lower Assembly Parts 1,400 635 66 Catwalks #5 800 363
8 House Rollers 2,100 953 67 Right Hand Elevated Section 6,160 2,794
9 House Rollers 2,100 953 68 Left Hand Elevated Section 7,200 3,266
10 House Rollers 2,100 953 69 Hoist Drum Assembly 29,580 13,417
11 Assembly Tools 950 431 70 Hoist Motor Base, Front 2,366 1,073
12 High-Voltage Guards 1,550 703 71 Hoist Motor Base, Rear 2,366 1,073
13 Crawler Shoe Pins and Hardware 2,850 1,293 72 Swing Transmission/Front Motor 15,350 6,963
14 Crawler Shoe Pins and Hardware 2,850 1,293 73 Swing Transmission/Rear Motor 15,350 6,963
15 Revolving Frame (Including Sidestand) 108,523 49,225 74 Hoist Motor Front 11,000 4,990
16 Counterweight Box 96,040 43,563 75 Hoist Motor Rear 11,000 4,990
17 Air Receiver Tank Box (Optional) — — 76 Swing Motor Front 7,270 3,298
18 Center Gudgeon Assembly 10,624 4,819 77 Swing Motor Rear 7,270 3,298
19 Boom 105,140 47,691 78 Pressurization System 20,900 9,480
20 House Cab Parts 940 426 79 Air Duct Kit “Bleed Rear Roof” 450 204
21 House Panels 3,300 1,497 80 Air Duct Kit “Bleed Rear Roof” 450 204
22 Boarding Stairway/Ladder 915 415 81 Air Conditioner - optional 3,000 1,361
23 Handle 54,691 24,807 82 Right Hand Boom Extension 1,200 544
24 Low-Voltage Collector 1,250 567 83 Operator’s Coop 13,900 6,305
25 Air Compressor 1,400 635 84 Boom Catwalk #1 950 431
26 Troughs and False Floor 3,600 1,633 85 Boom Catwalk #2 950 431
27 Swing Shafts 2,162 981 86 Shipper Shaft 5,845 2,651
28 Gantry Parts 1,250 567 87 Bearing Retainers 600 272
29 Paint 450 204 88 Crowd Motor Assembly 6,300 2,858
30 Carbon Dioxide Cylinders 400 181 89 Crowd Case Cover 1,200 544
31 Upper Assembly Parts 1,175 533 90 Crowd Motor Base 1,500 680
32 Gantry Compression Member 21,000 9,525 91 Boom Hardware 400 181
33 Gantry Tension Members (ea., 2 pieces) 3,320 1,506 92 Load Center Panel 1,350 612
34 Left Hand and Right Hand Platforms 9,350 4,241 93 Main Transformer & Supp. Cabinet 15,500 7,031
35 Boom Electrical 600 272 94 High Voltage Cabinet 3,046 1,382
36 Gantry Platform 1,000 454 95 Auxiliary & Field Transformer 5,200 2,359
37 Miscellaneous - Wire 450 204 96 Converter 10,300 4,672
38 Floodlights 450 204 97 Transfer Cabinet 1,500 680
39 Platform Supports R/L Hand 800 363 98 RPC Switching Cabinet 2,700 1,225
40 House Lighting Kit 360 163 99 Dipper Trip Resistor Assembly 585 265
41 Buss Bars 3,500 1,588 100 Hoist Cable Reel 3,250 1,474
42 Saddle Block 7,560 3,429 101 Hoist Cable Reel 3,250 1,474
43 Saddle Block 7,560 3,429 102 Suspension Cables (each) 3,600 1,633
44 Floodlight Assembly and Hardware 600 272 103 Suspension Cables (each) 3,600 1,633
45 Air Tugger Bracket 850 386 104 Shipper Shaft Gear 3,770 1,710
46 Logo Letters 1,175 533 105 Left Hand Boarding Ladder 1,400 635
47 Counterweight Box Reinforcement 250 113 106 Kit Boxes 3,000 1,361
48 Boom-Sealtite - 4" 500 227 107 Air Conditioner Parts - optional 400 181
49 Low Voltage Cover Guard 1,200 544 108 Rear Enclosure Panels 7,820 3,547
50 Canopy Arch 4,221 1,915 109 Hoist Transmission Assembly 23,378 10,604
51 Hoist Cable Hoods 1,000 454 110 Propel Motor 6,100 2,767
52 Hatch Covers 3,087 1,400 111 RPC Cabinets 11,850 5,375
53 Side Beams 2,802 1,271 112 Control Cabinet 2,000 907
54 Railing Crate 1,516 688 113 Roller Carrier Ring 3,110 1,411
55 Catwalks #1 2,058 933 114 Spherical Washer 250 113
56 Catwalks #2 2,120 962 115 Shipper Shaft Retainer w/Washer 600 272
57 Catwalks #3 1,200 544 116 Shipper Shaft Retainer w/Washer 600 272
58 Boom Platforms 12,000 5,443 117 House Heaters 150 68
59 Shipper Shaft Pinions (each) 1,085 492 *Weights are ± 10%. For actual weight of each component, refer to packing list.

7
ELECTRICAL TEST EQUIPMENT REQUIREMENTS Recommended Maintenance/Commissioning Test
Equipment Available only through P&H
Basic Electrical Test Instrumentation Required by Customer To
Commission and Maintain Electrotorque Mining Excavator. Description P&H Part #
Recommended Maintenance Test Equipment Available Start-Up Resistor—200 Ohms, 6 kW 80Z984D1
through P&H and other Vendors. RPC/Step Reference Unit 89Z866
Reference/Pushbutton Unit 89Z833D1
Description P&H Part #
Capacitor Unit 89Z508D1
DMM (Digital MultiMeter) Voltage Divider R1192F1
Fluke Model 23 89Z514D12 SCR (Thyristor) Tester 89Z511D1
Alternate DMM—Fluke, Model 87 1089Z275 Test Probes w/Banana Plugs (6 Req’d.) 79Z2738D2
Oscilloscope
Tektronix Model THS710 (Handheld, Dual Trace,
Digital, Storage, Battery Powered, Soft Case) Scope
w/120V / 60Hz Adapter 89Z515D15
120V / 50 Hz AC Adapter (240V Adapters Available) 89Z515D30
Hard Carrying Case 89Z515D26
X10 Probe (1kV) 89Z515D17

Chart Recorder—Hioki, Model 8804

Memory Recorder (Order each part separately)
Recorder (120/240V-50/60 Hz) R10945D1
Carrying Case - Soft R10945D2
AC Adapter 90 - 250V, 50/60 Hz R10945D3
Battery Pack, Rechargable R10945D4
Recording Paper (10 Rolls) R10945D5

Alternate Chart Recorder—Astro- Med, Dash 2MT

Two-Channel Field Recorder
Astro-Med DASH2MT 89Z835D2
Chart Paper 89Z835D2
Megger—500V & 1000V Scales
James G. Biddle 21158 89Z496
Clamp-On Ammeter—1A to 1000A AC/DC
Fluke Model 80i—KW 89Z514D14
PLC Communications Computer w/PLC5
Communication Software, Carrying Case
and Allen-Bradley PCMCIA Interface R24834D2

NOTE: All designs, specifications and components of equipment described above are subject to change
at manufacturer’s sole discretion at any time without advance notice.
Data published herein is informational in nature and shall not be construed to warrant suitability
of machine for any particular purpose as performance may vary with conditions encountered.
The only warranty applicable is our standard written warranty for this machine.

P&H Mining Equipment ◆ Box 310 ◆ Milwaukee, Wisconsin 53201 USA

XS-1341 8 2AG-303
 ! WARNING
SHOVEL RUNAWAY OR TIP-OVER CAN OCCUR
ON SLOPES OR GRADES RESULTING IN
POSSIBLE PROPERTY DAMAGE, SEVERE
INJURY OR DEATH.
DO NOT EXCEED MAXIMUM GRADES LISTED BELOW
OR IN OPERATOR’S MANUAL.

4100XPB SAFE OPERATING GRADE LIMITS

CONTINUOUS 17%
UPHILL FORWARD 30 MIN 20%
MAX 20%

CONTINUOUS 20%
DOWNHILL 30 MIN 20%
MAX 20%

TRAVERSE SHORT DURATION 10%

PARKING UPHILL AND DOWNHILL 20%

UPHILL AND DOWNHILL

DIGGING 8%
OVER FRONT OF CARBODY

WHEN PROPELLING ON ANY GRADE PROPEL ON TRAVERSE GRADES

DIPPER HANDLES MUST BE FULLY FOR SHORT DURATION ONLY.
EXTENDED AND HORIZONTAL
WITH DIPPER DOOR OPEN.

R48147D1
 ! WARNING
SHOVEL RUNAWAY OR TIP-OVER CAN OCCUR
ON SLOPES OR GRADES RESULTING IN
POSSIBLE PROPERTY DAMAGE, SEVERE
INJURY OR DEATH.
DO NOT EXCEED MAXIMUM GRADES LISTED BELOW
OR IN OPERATOR’S MANUAL.

4100A SAFE OPERATING GRADE LIMITS

CONTINUOUS 14%
UPHILL FORWARD 30 MIN 18%
MAX 20%

CONTINUOUS 20%
DOWNHILL 30 MIN 20%
MAX 20%

TRAVERSE SHORT DURATION 10%

PARKING UPHILL AND DOWNHILL 20%

UPHILL AND DOWNHILL

DIGGING 8%
OVER FRONT OF CARBODY

WHEN PROPELLING ON ANY GRADE PROPEL ON TRAVERSE GRADES

DIPPER HANDLES MUST BE FULLY FOR SHORT DURATION ONLY.
EXTENDED AND HORIZONTAL
WITH DIPPER DOOR OPEN.

R48147D3
 ! WARNING
SHOVEL RUNAWAY OR TIP-OVER CAN OCCUR
ON SLOPES OR GRADES RESULTING IN
POSSIBLE PROPERTY DAMAGE, SEVERE
INJURY OR DEATH.
DO NOT EXCEED MAXIMUM GRADES LISTED BELOW
OR IN OPERATOR’S MANUAL.

2800MkII SAFE OPERATING GRADE LIMITS

CONTINUOUS 4%
UPHILL FORWARD 30 MIN 6%
MAX 15%

CONTINUOUS 15%
DOWNHILL 30 MIN 15%
MAX 15%

TRAVERSE SHORT DURATION 10%

PARKING UPHILL AND DOWNHILL 15%

UPHILL AND DOWNHILL

DIGGING 8%
OVER FRONT OF CARBODY

WHEN PROPELLING ON ANY GRADE PROPEL ON TRAVERSE GRADES

DIPPER HANDLES MUST BE FULLY FOR SHORT DURATION ONLY.
EXTENDED AND HORIZONTAL
WITH DIPPER DOOR OPEN.

R48147D11
 Tab 2

Service Bulletins
Relieving Stored Energy Electric Shovel Service Bulletin 141

Service Bulletin

Subject: Relieving Stored Energy in Two-pump, Four-zone Lubrication Systems

Document ID: SB-ES-141 Version: 00
Product Code: 1289 Date: July 12, 2010
Models Affected: 4100XPB, 4100XPC
Applicable to Assembly: R54840F_ Lube Panels
P&H Product Support Department Electric Mining Shovels

1.0 Introduction

The purpose of this bulletin is to provide information for relieving stored energy in pressurized lubrication
lines in automatic lubrication systems with control panel R54840. Some 4100XPB and 4100XPC shovels
have a R54840 control panel on the automatic lubrication systems, and these systems must be
depressurized prior to performing maintenance on the system or its components. This Service Bulletin
describes a procedure for relieving the system pressure and supplements the mechanical maintenance
manual. Distribute a copy of this Service Bulletin to all personnel who perform maintenance on
these lubrication systems.

2.0 Discussion

2.1 System Description

Automatic lubrication systems with control panel R54840 have manual return valves and electrically
controlled zone and vent solenoid valves with manual overrides.

Centurion controlled shovels (4100XPC and some 4100XPB or retrofitted 4100XPB) have 24 volt DC control
voltage for the solenoid valves (R54840F3) while non-Centurion shovels will likely have 110 VAC control
voltage (R54840F1 or F2).

2.2 Stored Energy in the Automatic Lubrication System

Residual pressure can remain in hydraulic lines when the system is at rest. This pressure is a form of
stored energy and must not be present in the system when maintenance is performed on the system. The
following procedure provides steps for relieving stored energy.

Copyright © 2010 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
SB-ES-141.doc Page 1 of 4 SB-ES-141, Version 00 – 07/10
Relieving Stored Energy Electric Shovel Service Bulletin 141

3.0 Recommended Actions

3.1 Procedure for Relieving Stored Energy in the Automatic Lubrication System

1. Locate the following components on the schematic (Figure 1) and in the photographs (Figures 2-5):
• Lower grease zone valve (item 02)
• Upper grease zone value (item 09)
• Two (2) manual return valves (item 05)
• Grease vent valve (item 07)
• Pressure gauges (items A, A, B, and C)

LEGEND
01. Lower Grease System
02. Lower Grease Zone Valve
03. Accumulator
04. Filter
GAUGES
05. Manual Return Valves (2)
06. Pump A. (Qty. 2)
07. Grease Vent Valve B. (Qty. 1)
08. Pressure Relief Valve C. (Qty. 1)
09. Upper Grease Zone Valve
10. Check Valves (2)
11. Upper Grease System
Figure 1: Schematic of 54840F_ Lube System, Grease System Shown

Copyright © 2010 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
SB-ES-141.doc Page 2 of 4 SB-ES-141, Version 00 – 07/10
Relieving Stored Energy Electric Shovel Service Bulletin 141

05
Manual
Return
Valves

Gauges A
04
Gauge B
Filter

Figure 2: Figure 3:
Vent Valves on Lube Panel R54840F3 Filter, Manual Return Valves, and Gauges (Typical)

2. Open manual return valves (05) and check pressure gauges.

3. Push manual override push-buttons on vent valves with screwdriver (see Fig. 4).
4. Check pressure gauges.

07
Grease Vent
Valve
Gauge C

Figure 4: Push-Button on Vent Valve Figure 5: View from Above Vent Valves

Copyright © 2010 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
SB-ES-141.doc Page 3 of 4 SB-ES-141, Version 00 – 07/10
Relieving Stored Energy Electric Shovel Service Bulletin 141

3.2 Safety Instructions

Always assume that pressure may be present and must be relieved from a lubrication system. Shut
down and depressurize the system and follow lockout/tagout procedures for maintenance of the
lubrication system.

High-pressure oil or grease can spray and penetrate skin or eyes, causing serious personal
injury. Use extreme caution when working around lubrication systems and wear appropriate
face and body protection. Shut down and depressurize the system and follow lockout and
tagout procedures for disassembly or assembly of the lubrication system. Inspect for
evidence of leaks, loose connections, or ruptured components during shutdown periods.
Get medical aid immediately if lubricant sprays into the eyes or penetrates into the skin.

4.0 Summary
Stored energy must be removed from automatic lubrication systems with control panel R54840. Distribute
a copy of this Service Bulletin to all personnel that will perform maintenance on the lube system on shovels
equipped with a lube panel R54840. Contact your local P&H MinePro representative for any questions on
this topic.

Copyright © 2010 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
SB-ES-141.doc Page 4 of 4 SB-ES-141, Version 00 – 07/10
Saf-T-Climb on Electric Mining Shovels P&H Service Bulletin SB-ES-140

Service Bulletin

Subject: Saf-T-Climb Fall Protection Systems

Document ID: SB-ES-140 Version: 00
Product Code: 1173 Date: March 17, 2010
Models Affected: 2800XPC, 4100C BOSS, and 4100XPB/C Shovels
Applicable to Assembly: R59509F1, R65725D1, and LYT_5611F1
P&H Product Support Department Electric Mining Shovels

1.0 Introduction

The manufacturer of the Saf-T-Climb Fall Protection system issued a product warning and product recall.
After investigation, P&H is now recommending that the Saf-T-Climb Fall Protection system be replaced with
D-Ring kits for the boom application of P&H Electric Mining Shovels.

2.0 Purpose

The Purpose of this Service Bulletin is to announce a recommendation by P&H that the Saf-T-Climb Fall
Protection system be replaced with D-Ring kits for the boom application of P&H Electric Mining Shovels.

3.0 Discussion

Some P&H shovel boom walkways have been equipped with Saf-T-Climb tie-off systems. Table 1 shows
the P&H shovel models that use the Saf-T-Climb tie-off system and the P&H part number of the systems.

P&H Part Number P&H Models Used

R59509F1 4100XPB/C Shovels
R65725D1 2800XPC and 4100C BOSS Shovels
LYT_5611F1 4100XPB Shovels
Table 1: Part Numbers and Models Where Used

These Saf-T-Climb tie-off systems were not supplied as standard equipment for all machines built. Your
local P&H MinePro Service Department can assist in determining if your P&H machines contain the subject
tie-off systems.

P&H Mining Equipment recommended that the Saf-T-Climb Fall Protection system supplied on shovel
booms not be used until further notice in P&H Service Bulletin #SB-DRL-036, dated October 27, 2009,
regarding the Saf-T-Climb manufacturer’s product warning. P&H is now recommending that the Saf-T-
Climb Fall Protection system be replaced with D-Ring kits for the boom application of P&H Electric Mining
Shovels. Use of the Saf-T-Climb system requires using the sleeve and harness supplied with that system.
Once the D-Ring kit is installed, using fall protection on the boom will not require any special equipment; a
standard harness can be used with the D-Rings. In addition, use of the Saf-T-Climb on the shovel boom
may require using one hand to slide the sleeve up the rail due to the angle of the boom and rail.

Kit R55588F1 should be used as a replacement to the Saf-T-Climb system. It provides D-Rings that are
used as tie-off points on a shovel boom. After installing this kit, the Saf-T-Climb rail should be removed
and use of the Saf-T-Climb system will be discontinued.

Copyright © 2010 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
SB-ES-140.doc Page 1 of 2 SB-ES-140, Version 00 – 03/10
Saf-T-Climb on Electric Mining Shovels P&H Service Bulletin SB-ES-140

Contact your local P&H MinePro Service Department for more information.

4.0 Conclusion

P&H is now recommending that the Saf-T-Climb Fall Protection system be replaced with D-Ring kits for the
boom application of P&H Electric Mining Shovels.

5.0 Actions

Tag and remove from service all Saf-T-Climb Saf-T-Grip Sleeves. Use alternate forms of fall protection to
replace the use of the Saf-T-Grip Sleeves. Follow all local regulations for required fall protection.

Contact your local P&H MinePro Service Department for information on Kit R55588F1, which provides D-
Rings that are used as tie-off points on a shovel boom.

Copyright © 2010 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
SB-ES-140.doc Page 2 of 2 SB-ES-140, Version 00 – 03/10
Brake Performance Tests Electric Shovel Service Bulletin 138

Service Bulletin

Subject: Brake Performance Tests

Document ID: SB-ES-138 Version: 00
Product Code: Date: Sept. 22, 2009
Models Affected: All
Applicable to Assembly:
P&H Product Support Department Electric Mining Shovels

1.0 Introduction

Under normal operation, P&H DC electric mining shovel brakes are intended to be used in a static
application as holding brakes. However, from time to time, brakes are used dynamically to stop a moving
load. Brake performance tests should be used to confirm brake performance or to identify problems in the
brake system. There are two types of performance tests following: brake static holding torque tests and
brake dynamic braking torque tests.

The dynamic braking torque tests should not be performed until a complete
maintenance check of the brakes and the air system is performed. See Section 3.3
Verification Of Dynamic Braking Torque for more information.

2.0 Purpose

The Purpose of this Service Bulletin is to establish static and dynamic brake tests for P&H DC electric
mining shovels equipped with disc brakes.

3.0 Discussion

3.1 General

The procedures included in this Service Bulletin address both current and existing P&H DC electric mining
shovels equipped with disc brakes.

Brakes should be inspected mechanically before any tests are performed. Refer to the shovel’s mechanical
maintenance manual and perform a thorough inspection of each brake. Also inspect the air system and the
electrical system as they apply to brakes. Use the Mechanical Maintenance Manual for the shovel as
reference and also the following Service Bulletins:

• SB-ES-132 - Mechanical Stored Energy in Disc Brake

• SB-ES-115 - Loss of Motion Control Due To Air System Component Malfunction

• SB-ES-113 - Consequences of Manual Release of Motion Brakes

• SB-ES-124 - Disc Brake Burnish-In Procedures

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Brake Performance Tests Electric Shovel Service Bulletin 138

• SB-ES-136 - 4100XPB/XPC Brake Inspection Measurements

The tests included in this Service Bulletin supersede any information in any Service Bulletin previously
issued by P&H Mining Equipment for P&H DC electric mining shovels. This Service Bulletin also supersedes
any information in P&H Mechanical Maintenance Manuals issued before the date of this Bulletin.

Proper operating technique is to use the motors for stopping motion (dynamic braking). Under normal
conditions, dynamic braking is accomplished electrically by using the joystick controller to stop the motion
with torque from the motors. Once the motors have stopped all motion, the brakes are used to keep the
motion stopped without the use of the motors.

New disc brakes must be properly burnished before being used. Procedures for burnishing disc
brakes are provided in Electric Shovel Service Bulletin SB-ES-124. These procedures include
performing the static brake test as described in this Service Bulletin following the brake burnishing.

3.2 Verification of Static Holding Torque

Testing the brake Static Holding Torque will determine the ability of the brakes to hold the load of the
system. Check the static holding torque by applying maximum load with the motor stopped.

It is difficult to provide static brake tests for the shovel that would safely test the brakes to
maximum rated torque. The static brake tests provided in this Service Bulletin are intended to
provide a minimum baseline for performance.

These tests should be performed after any maintenance has been completed on brakes and prior to
returning the shovel to operation.

Brakes should be inspected mechanically before any tests are performed. Refer to the shovel’s
mechanical maintenance manual and perform a thorough inspection of each brake and SB-ES-136
for the 4100XPB/C machines. Included in this inspection should be the recommended inspection to
ensure that each brake is within proper adjustment for wear. Adjust or replace each brake as
necessary. The brake air system should also be inspected thoroughly before the static tests are
performed. Each brake system should be tested with the shovel in park configuration to determine
that the brakes are all setting without delays and that all air system components are functioning
correctly.

Before performing any static brake tests, the shovel should be placed in an appropriate position. Park the
shovel on a level surface away from the bank or high wall unless otherwise indicated in the test
description. The operator must park the machine in a location to avoid hazards such as falling rocks and
unstable ground. Rotate the upper so that the dipper is at the front of the shovel to begin the test unless
otherwise indicated.

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Unexpected machine movement can strike or crush, resulting in severe personal injury
or death. Be prepared for movement of major shovel components that may occur
during static holding torque verification. Ensure that all personnel are clear of shovel
motions affected by these procedures.

Hoist: Fill the dipper and position the dipper full 15 - 20 inches (38 - 51 cm) above the ground. Apply the
hoist brakes. The dipper should not move.

Crowd: With an empty dipper, place the dipper handles parallel to the ground. Fully retract the dipper
handles. Lower the dipper so that the dipper handles are in the fully vertical position. Crowd out until the
dipper is approximately 15 – 20 inches (38 - 51 cm) above the ground. Apply the crowd brake. The dipper
should not move.

Propel: By positioning the shovel on a grade, gravity can be used to produce a load on the propel brakes
for testing.

1. Propel the shovel to the base of a normal grade that will be encountered during normal shovel
operation (8% grade maximum for this test). Propel the shovel slightly more than one shovel
length up the grade.

2. Use the propel joysticks to brake the propel motion to stop propel movement and then transfer the
shovel to crowd or dig mode. The shovel should not roll down more than 5 feet (1.5 m).

Swing: By positioning the shovel on a grade, gravity can be used to produce a load on the swing brakes
for testing.

1. Propel the shovel to the base of a normal grade that will be encountered during normal shovel
operation (8% grade maximum for this test). Propel the shovel slightly more than one shovel
length up the grade.

2. Fill the dipper and place it in the carry position and set the hoist and crowd brakes.

3. Rotate the upper so that the boom is over the side of the carbody, causing gravity to work against
the swing motion due to the grade. Use the swing joystick to brake the swing motion to stop swing
movement and then set the swing brakes. The brakes should hold the upper in position and
prevent it from rotating.

If a brake system (hoist, crowd, swing, or propel) does not pass the static holding torque test,
brake(s) in that system should receive an immediate thorough mechanical inspection. The shovel
should not be operated until all brake systems pass the static holding torque tests.

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3.3 Verification Of Dynamic Braking Torque

Proper operating technique is to use the motors for stopping motion (dynamic braking). Under normal
conditions, dynamic braking is accomplished electrically by using the joystick controller to stop the
motion.

The mechanical disc brakes must also be capable of stopping the motion. Situations will occur while the
shovel is operating that will require the brakes to perform dynamic braking. Examples would be the shovel
operating with the brakes released and experiencing one of the following situations: shovel or substation
electrical faults or trips, shovel immediate shut downs, or loss of power to the shovel. Motions will continue
(within tolerance) after the brake is applied.

Before performing any dynamic brake tests the shovel should be placed in an appropriate position. Park
the shovel on a level surface away from the bank or high wall unless otherwise indicated in the test
description. The operator must park the machine in a location to avoid hazards such as falling rocks and
unstable ground. Rotate the upper so that the dipper is at the front of the shovel to begin the test unless
otherwise indicated.

It is difficult to provide dynamic brake tests for the shovel that would safely test the brakes to
maximum rated torque. The dynamic brake tests provided in this Service Bulletin are intended to
provide a minimum baseline for performance.

This dynamic braking torque verification procedure has been developed only as a severe system
test to be used in response to reports of brake system malfunctions. It is not intended to be
used as a frequent normal check or Preventive Maintenance by the user. It is
recommended that these tests be performed not more than once a year unless system
malfunctions are being experienced.

Excessive dynamic brake testing will cause accelerated wear to the brakes. Excessive
wear could cause the brakes to fail under emergency stop conditions, which may result
in severe personal injury or death.

Brakes should be inspected mechanically before any tests are performed. Refer to the shovel’s
mechanical maintenance manual and perform a thorough inspection of each brake and SB-ES-136
for the 4100XPB/C machines. Included in this inspection should be the recommended inspection to
ensure that each brake is within proper adjustment for wear. Adjust or replace each brake as
necessary. The brake air system should be inspected thoroughly before the dynamic tests are
performed. Each brake system should be tested with the shovel in park configuration to determine
that the brakes are all setting without delays and that all air system components are functioning
correctly.

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Moving machinery can strike or crush, resulting in severe personal injury or death.
These procedures require shovel components to move. Be prepared for movement of
major shovel components that will occur during dynamic braking torque verification.
Ensure that all personnel are clear of shovel motions affected by these procedures.

Hoist: Fill the dipper and lower the dipper until it is approximately 2 to 5 feet (.6 m to 1.5 m) maximum
distance above the ground over a loose pile of material. Set the crowd and swing brakes. With the shovel
running and the hoist brakes released, apply the emergency stop. The dipper should stop before it touches
the pile.

Crowd: With an empty dipper, place the dipper handles in the carry position. Lower the dipper handles to
the fully vertical position. Crowd out until the dipper is 5 feet (1.5 m) above the ground. Set the hoist and
swing brakes. With the shovel running and the crowd brake released, apply the emergency stop. The
dipper should stop within 5 feet (1.5 m) of crowd travel.

Propel: The shovel should be on level ground with room to propel forward. Place the shovel in propel
mode.

The propel dynamic brake test will be performed while the shovel is in motion. It is
critical that the speed be under control and monitored. Do not exceed the speed
recommended for this test. Performing this test while under a speed exceeding the
recommendation can cause severe personal injury and damage to equipment.

Position the propel joysticks forward the required travel to produce approximately 25% maximum speed
(refer to Section 3.4 to determine the recommended method for monitoring propel system speed). Once
this speed has been achieved, press the emergency stop button. The shovel should stop within 5 to 10 feet
(1.5 to 3 m).

Swing: With the shovel on level ground and the dipper full, place the dipper in the carry position. Set the
hoist and crowd brakes.

The swing dynamic brake test will be performed while the shovel is in motion. It is
critical that the speed be under control and monitored. Do not exceed the speed
recommended for this test. Performing this test while under a speed exceeding the
recommendation can cause severe personal injury and damage to equipment.

Swing the upper to produce approximately 25% maximum speed (refer to Section 3.4 to determine the
recommended method for monitoring swing system speed). Once this speed has been achieved, press the
emergency stop button. Rotation should stop within 20°.

If a brake system (hoist, crowd, swing, or propel) does not pass the dynamic braking torque test,
the brake air system should receive an immediate thorough inspection. Also the brake(s) in that

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system should receive an immediate thorough mechanical inspection. The shovel should not be
operated until the brake system passes the dynamic braking torque test.

These dynamic tests will test only the individual brake system and its air system independent from
other brake systems. Some hoist, crowd, or swing brake problems may only show up if multiple
brakes and the corresponding air systems are in use. If a reported problem cannot be reproduced
with the static test, proceed to the dynamic test. If the problem still cannot be reproduced, perform
the tests again while leaving the other two motions released. If the problem is reproduced with the
integrated test, both the air system and the brakes must be thoroughly inspected.

3.3 Speed Monitoring for Swing and Propel Dynamic Brake Tests

The Swing and Propel Dynamic Brake tests are detailed in Section 3.3. Performing these two tests requires
placing the shovel in a carefully controlled motion and applying the brakes. A means to control and monitor
the speed of the motion is required to prevent excessive speed from occurring while performing the tests.

Figure 1 shows the Shovel Operation Display Values Screen of a typical shovel GUI. To view this screen,
press the button indicated by the arrow while on the GUI main screen.

Figure 1: Meters Displayed on GUI

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Motor armature voltage relates directly to motor speed on P&H DC electric mining shovels. Observing the
armature voltage of a motion is the recommended method of monitoring controlled speed for that motion.
The armature voltage will be displayed as a negative value on the Armature Voltage meter when reversing
direction in that motion. As an example, Figure 2 shows the meters displayed for the swing motion. The
Armature Voltage meter is indicated with an arrow.

Figure 2: Swing Meters Displayed on GUI

The Test Selector switch on the Control Cabinet pictured in Figure 3 should remain in
the RUN position while performing brake performance tests. NEVER turn this switch to
one of the test positions while the shovel is running. Rotating this switch out of the
RUN postion while the shovel is in Run Condition will cause an immediate shovel
shutdown and can cause severe personal injury and damage to equipment.

On shovels not equipped with this GUI screen, armature voltage can be monitored on the analog meter
panel on the control cabinet. This meter panel includes a METER SELECTOR switch that must be rotated to
the correct position for the desired motion. Figure 3 shows an example of an analog meter panel with the
METER SELECTOR switch in the SWING position to monitor the swing system. The swing armature voltage
would be displayed on the ARM VOLTS meter. When using the analog meters, a technician must be
stationed at the control cabinet to observe the meter and communication must be established between
that technician and the operator.

Figure 3: Analog Meters on Control Cabinet

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The Swing and Propel Dynamic Braking tests will be performed while the shovel is in
motion. It is critical that the speed be under control and monitored. Do not exceed the
speed recommended for this test. Performing these tests while under a speed
exceeding the recommendation can cause severe personal injury and damage to
equipment.

When performing the Swing or the Propel Dynamic Braking test, the brakes on all other motions should be
set to ensure that only the motion being tested is under power. The speed of the motion being tested
should be limited to no more than 25%. Maximum speed for the swing or propel motion would be achieved
when the armature voltage is at 600V in either a positive or negative direction. A reading of not more
than 150V in the positive direction will be used for the Swing or Propel Dynamic Braking test,
which should achieve approximately 25% of maximum speed of that motion as displayed on
the appropriate meter on either the GUI or the analog meter panel. This method of controlling
and monitoring the speed should be used when performing the Swing and Propel Dynamic Braking tests
described in Section 3.2 of this Service Bulletin.

4.0 Conclusion

Brake Performance Tests should be used to confirm brake performance or to identify problems in the brake
system. There are two types of performance tests included in this Service Bulletin: brake static holding
torque tests and brake dynamic braking torque tests.

5.0 Actions

Replace any previous correspondence from P&H Mining Equipment regarding Brake Performance Tests for
P&H DC Electric Mining Shovels with the information contained in this Service Bulletin.

Perform Brake Performance Tests as described in this Service Bulletin. If any questions arise concerning
the contents of this Service Bulletin, contact your local P&H MinePro office for clarification.

Copyright © 2009 P&H Mining Equipment, Inc. P&H Product Support

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Pressure Testing Couplings 44Z2664D3 Electric Shovel Service Bulletin SB-ES-137

Service Bulletin

Subject: Pressure Testing Couplings 44Z2664D3

Document ID: SB-ES-137 Version: 00
Product Code: 1176, 2023 Date: August 31, 2009
Models Affected: 4100XPB, 4100XPC, 320XPC, 250XP
Applicable to Assembly: See Discussion Below
P&H Product Support Department Electric Mining Shovels

1.0 Introduction

The manufacturer has recalled a select group of Pressure Testing Couplings supplied to P&H. The recalled
parts are described in the Discussion section below.

2.0 Purpose

The purpose of this Service Bulletin is to announce a recall of a select group of P&H Part Number
44Z2664D3 - Pressure Testing Couplings.

3.0 Discussion

P&H has received notification that the manufacturer of pressure testing couplings used in several P&H
assemblies are being recalled. The P&H part number of the couplings is 44Z2664D3.

The pressure testing couplings to be recalled were shipped by P&H between the dates of March 2008 and
June 2009. Table 1 shows a list of machines/ orders that may be affected. All components on the list
shown in Table 1 should be inspected to determine if the fittings are affected by the recall.

Most of the couplings were shipped from P&H as a component of one of several assemblies. The following
assemblies supplied by P&H were identified as containing the pressure test coupling:

• R56088D1 Cylinder, Crowd Belt Tensioner assemblies of P&H 4100XPB and 4100XPC mining
shovels

• R43711D1 Cylinder, Crowd Belt Tensioner assemblies of P&H 4100XPB and 4100XPC mining
shovels

• R55420F2 T-Tank assemblies of P&H 320XPC blasthole drills

• R26085D1 Regeneration Manifolds of P&H 250XP blasthole drills

• R60343D1 Valve Bank 1 Modules of 250XP Blasthole Drills

In addition a few 44Z2664D3 fittings have been shipped as replacement parts not attached to a finished
assembly.

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Pressure Testing Couplings 44Z2664D3 Electric Shovel Service Bulletin SB-ES-137

Machine Serial Number/

Part/ Assembly Sales/ Transport Order Number Sold to Party
44Z2664D3, COUPLING PRESS TEST
Parts Order Southern Peru Copper
Parts Order Southern Peru Copper
Parts Order Hibbing
Parts Order Southern Peru Copper
Parts Order Antofogasta
R55420F2-SS, TANK, T ASSEMBLY DUAL TOWER
Supplied with Machine 320159
Supplied with Machine 320160
Supplied with Machine 320162
R26085D1, Regeneration Manifold w/ pressure cutout
Parts Order Gillette
Parts Order Antofogasta
R56088D1, CYLINDER ASSY,CROWD MOTOR,UCS
Parts Order Morenci
Parts Order Elko
Supplied with Machine 41179
Supplied with Machine 41175
Supplied with Machine 41171
Supplied with Machine 41172
Supplied with Machine 41180
Parts Order Morenci
Parts Order Elko
Supplied with Machine 41181
Supplied with Machine 41184
Supplied with Machine 41183
Parts Order Australasia (Bassendean)
Supplied with Machine 41198
R43711D1, CYLINDER,CROWD BELT TNSN
Parts Order Antofogasta
Parts Order St. Albans, WV
Parts Order Sparwood, British Columbia
R60343D1, ASSEMBLY, VB1
Parts Order Gillette

Table 1: Affected Machines/ Orders

The manufacturer has also provided P&H with a description of the suspect fittings. The manufacturer
originally supplied these fittings with a yellow zinc color finish. The fittings with this color are not subject to
the recall.

The manufacturer recently began supplying the fittings with a dull gray finish, called Chrome 6 Free by the
Manufacturer. These fittings are subject to the recall. Figure 1 shows a Chrome 6 Free fitting and a yellow
zinc fitting. None of the Chrome 6 Free fittings were supplied before March 2008.

The manufacturer has corrected the suspected problem with the fittings and is now inspecting them 100%
before shipping them. These new fittings will also have a gray or silver color but will have a letter “R”
stamped in the hex portion of the fitting (see Figure 2).

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Pressure Testing Couplings 44Z2664D3 Electric Shovel Service Bulletin SB-ES-137

NOT Subject to Recall

Yellow Zinc
Test Fitting

Subject to Recall
Chrome 6 Free
Test Fitting

Figure 1: Fitting Visual Differences

Stamped Letter
R

Figure 2: New Fitting

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Pressure Testing Couplings 44Z2664D3 Electric Shovel Service Bulletin SB-ES-137

Use caution when working on the component that contains the fitting. Make certain the
hydraulic system is depressured and perform lockout/tagout on the pump or hydraulic
source before attempting to remove the fitting. Failure to do this could result in severe
personal injury or death. The component manufacturer’s recall states, “the diameter of
the undercut of the swivel nut of the device was not manufactured to prescribed
tolerances and this could lead to a situation where the test point body will not be held
in place by the wire nail and could be expelled under severe pressure.”

Inspect your inventory and/or machines and notify your local MinePro Representative if you have the
recalled fittings. If you have a recalled part on a machine and have good parts in inventory replace the
recalled fitting and MinePro will replenish the inventory. If you do not have the inventory notify MinePro
and P&H will ship MinePro the replacement(s). P&H is requiring return of the recalled fittings to establish a
count for records. Please make sure that the fittings are returned to MinePro when the replacement part is
received.

4.0 Conclusion

The manufacturer has recalled the Pressure Testing Coupling supplied to P&H. The P&H part number is
44Z2664D3.

5.0 Actions

Inspect Inventory and/or machines.

Notify your local MinePro Representative for replacements for the recalled fittings. Return the fittings to
MinePro once the replacement has been received.

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SUBJECT: 4100XPB/XPC Brake Inspection
BULLETIN: SB-ES-136
Measurements
MODELS AFFECTED: 4100XPB and 4100XPC VERSION: 00
APPLICABLE TO ASSEMBLIES: See Table in
DATE: April 21, 2009
Discussion
PRODUCT CODE: 1015, 1031,
SPECIAL NOTE:
1161, 1144

1.0 Introduction

Disc Brake inspection measurements for P&H 4100XPB and 4100XPC shovels have been updated.
All maintenance personnel going forward should use the inspection measurements provided in this
Service Bulletin to ensure that inspections are performed using the correct data.

2.0 Purpose

The purpose of this Service Bulletin is to provide updated inspection measurements for the disc
brakes used on 4100XPB and 4100XPC shovels.

3.0 Discussion

The disc brakes used on P&H shovels experience wear over time. Adjustments can be performed to
the brakes to bring a worn brake back within correct operating specification. To determine when
adjustments must be made to brakes, and to determine when the brake has reached maximum
wear and needs to be replaced, the shovel’s maintenance manual has published reference
inspection measurement specifications. When performing the inspection measurement on a disc
brake, it is critical that the correct inspection reference measurement specifications are used.

Refer to the appropriate P&H Mechanical Maintenance Manual for detailed procedures on
how to make inspection wear measurements.

All maintenance personnel going forward should use the inspection measurements provided here in
Table 1 to ensure that inspections are performed using the correct data. The reference
measurements provided in Table 1 will also appear in Mechanical Maintenance Manuals provided for
4100XPC shovels with serial number ES41183 and newer. The measurements in Table 1 supercede
all measurements for Mechanical Maintenance Manuals for 4100XPB and 4100XPC shovels with
serial numbers ES41181 and lower.

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4100XPB/XPC Brake Inspection Measurements Electric Shovel Service Bulletin Number 136

P/N Motion new adjust maximum minimum

R42784D1 Propel .22 7/32 .31 5/16 .31 5/16 .19 3/16
R41760D1 Crowd .22 7/32 .31 5/16 .31 5/16 .19 3/16
R41894D1 2 Disc Hoist .25 1/4 .38 3/8 .38 3/8 .22 7/32
R56316D1 3 Disc Hoist .27 17/64 .40 13/32 .40 13/32 .24 15/64
R45976D1* Swing Brake .10 3/32 n/a n/a .20 13/64 .07 1/16
R42786D1 Swing Brake .10 3/32 n/a n/a .20 13/64 .07 1/16
All measurements given in inches
* The R45976D1 Swing brake was used on only the first few 4100XPB shovels built and
has probably been superceded to the R42786D1 brake. See the Mechanical Maintenance
Manual ES4100XPB-02-MS for more details.
Table 1: 4100XPB/XPC Brake Inspection Measurements

A short explanation of the measurements provided in Table 1:

New – refers to nominal travel of a new brake.

Adjust - when the brake travel reaches this measurement a shim should be removed. Note that
Swing brakes do not contain adjustment shims.

Maximum - with no adjustment shims remaining, the brake should be replaced when the brake
travel measurement reaches this.

Minimum – the minimum travel clearance the brake should be operated at. If the brake travel is
measured to be less than this specification, the brake should be removed and inspected.

It is possible to do an adequate job of measuring for this inspection using a simple

mechanical scale. The fractional measurements are supplied as this is not meant to be a
measurement with an extremely fine tolerance such as thousands of an inch.

4.0 Conclusion

This Service Bulletin updates inspection specifications previously provided in P&H Mechanical
Maintenance Manuals for all disc brakes on 4100XPB/XPC shovels.

5.0 Actions

Refer to Table 1 of this Service Bulletin for the current inspection specifications for all disc brakes
used on 4100XPB/XPC shovels.

Copyright © 2009 P&H Mining Equipment, Inc. P&H Product Support

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SUBJECT: Brake Air Isolation BULLETIN: SB-ES-135
MODELS AFFECTED: All VERSION: 00
APPLICABLE TO ASSEMBLIES: DATE: July 03, 2009
SPECIAL NOTE: PRODUCT CODE: 1232, 1137

1.0 Introduction

Engineering has released new Brake Air Isolation for P&H shovels. This Air Isolation provides
hardware that separates the air supplies to the Hoist, Crowd, and Swing brake systems with check
valves to eliminate the possibility of the air back-feeding between the supply valves. It also
provides 3-way valves that can be used to isolate each of these brake systems.

2.0 Purpose

The purpose of this Air Isolation is to separate each motion’s brake air system and also to provide
maintenance valves to allow lockout isolation of the brake supply lines during maintenance
operations.

3.0 Discussion

Brake air control systems on P&H shovels have remained relatively unchanged over the years, and
also relatively consistent in layout and theory of operation across model lines, for reliability reasons
and to encourage familiarity in the system to aid in troubleshooting. Consequently, major changes
driven by technology and customer requests for customization based on site-specific maintenance
practices need to be carefully considered and deliberately executed.

3.1 Existing System

Existing P&H shovels have used one common brake supply air valve manifold located in the lube
room that contains the three brake supply valves that supply the hoist, swing, and crowd brakes as
shown in Figure 1. These three electric solenoid directional control supply valves are interconnected
through the common manifold that provides the base to which the supply valves are attached. Note
that these supply valves are often referred to as Mac valves due to the valve manufacturer’s name.

The three brake supply air valves supply lubricated and filtered air to the hoist, swing, and crowd
brakes. A single air regulator is located directly before the brake supply valves to regulate the
pressure to the three brake systems. Shut off valves or check valves are not installed between the
supply valves and the brakes, as this would not allow the brake Quick Release Valves (QRV’s) to
function as intended.

The actual location of the supply valve manifold in the lube room varies depending on the shovel
model and its lube room configuration.

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Figure 1: Brake Supply Valves (Typical)

On these existing systems, the supply valve manifold joins the three supply valves. When the
supply valves are open, it is possible for air from one brake system to back-feed into another brake
system. (e.g.: The swing brake air supply valve is open and the swing brakes are pressurized.
When the supply valve for the hoist brakes opens, some of the air from the swing brake system can
back-feed into the hoist brake system.)

Back-feeding can cause the pressure in a brake system to drop below its normal operating pressure
momentarily. This momentary pressure drop can cause the air pressure monitor (transducer) to
detect low air pressure, and may cause a brake to set automatically. (e.g.: Assume the swing
brakes are released, and the operator releases the hoist brakes. With back-feeding the swing
brakes may set automatically.) When this situation has been observed, it has often been found that
the brake air supply needs attention. If this air supply flow is restricted, or if there is a drop in
pressure in the air system upstream of the brake supply regulator, the chance of air back-feeding
increases.

Make sure that the hoist/swing/crowd brake supply regulator normal setpoint of 100 PSI is
maintained. If the regulator setpoint is too low, it will increase the chance of a momentary
low operating pressure. If the regulator setpoint is too high, the air pressure can exceed the

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recommended operating pressure of the brakes, which can cause damage to the brake O-
ring seals.

3.2 New System

On some recent new shovel orders, customers have specifically requested isolation valves between
the three supply valves and the brake systems. After careful consideration of customer needs, and
after technical evaluation of reliability and serviceability, P&H has decided to adopt a change in the
design for the brake air supply valves. This change is to separate the brake air systems into three
separate air circuits. The supply valves will no longer be interconnected as a group on one common
manifold. This allows isolation of one brake air system without affecting the other brake systems.

Shovels equipped with this update will now have a new Brake Air Isolation Panel that contains three
separate brake supply valves. This update also provides a small brake air isolation manifold. The
new air panel and manifold are shown in Figure 2. Location of these components in the lube room
(left hand room) will vary depending on the shovel model and its lube room configuration.

Figure 2: Location of Components in Left Hand Room (4100XPC Shown)

Figure 3 shows a schematic of the new system. Figure 4 shows the brake isolation manifold, which
contains three check valves located below the manifold to provide the isolation of the air to the
hoist, swing, and crowd brake circuits. These check valves will prevent the possibility of air back-
feeding from one brake system to the other two.

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Brake Air Isolation Electric Shovel Service Bulletin Number 135

Figure 3: Brake Air Schematic of New System

Figure 4: Brake Isolation Manifold

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Brake Air Isolation Electric Shovel Service Bulletin Number 135

Figure 5 shows a drawing of the brake air isolation panel. The existing supply valve setup shown in
Figure 1 is replaced with three individual supply valves for the hoist, swing, and crowd brakes. Each
valve is mounted on its own manifold. A three-way hand isolation valve is located directly after
each supply valve in the new setup. A fourth isolation valve is provided to shut off all air going to
the air swivel for the shovel lower supply. Figure 6 shows a 3-D view of the same panel without
hoses.

LEGEND:
A. Air Lines
from Brake
Isolation
Manifold
B. To Crowd
Brake
Pressure
Transducer
C. To Swivel for
Machine
Lower Air
Supply
D. To Crowd
Brake
E. To Swing
Brakes
F. To Hoist
Brakes
G. Air Regulator
Assembly
H. Air Supply
from Oiler to
Air Manifold

Figure 5: Brake Air Isolation Panel (4100XPC shown)

LEGEND: B. Manual Push Button D. Solenoid Valve Body

A. Isolation Valve C. Solenoid Manifold E. Exhaust Muffler
Figure 6: 3-D View of Brake Air Isolation Panel

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Brake Air Isolation Electric Shovel Service Bulletin Number 135

The three-way hand valves can be actuated and locked in position to isolate the brakes from the air
supply for maintenance. These three-way isolation valves will exhaust any residual pressure in the
brake lines when they are actuated. One valve of this type is shown in Figure 7. The handle has a
small window that indicates the valve’s position. The left view shows the valve in normal (Supply)
position and the indicator window reads SUP. In this position, the valve outlet (B) is connected to
the supply port (A). The right view shows the valve in isolation (Exhaust) position and the indicator
window reads EXH. In this position, the valve outlet (B) is connected to the exhaust port on the
bottom of the valve (C). Note that in this position a lock can be placed through the lockout rings of
the valve to lock the valve in the isolation position.

LEGEND:
A. Input
Port
B. Outlet
Port
C. Exhaust
Port
D. Flow
Arrow
E. Actuator
Knob
F. Indicator
Window
G. Lockout
Ring

Figure 7: Isolation Valve

3.3 Application

This air isolation change will appear as standard equipment on new built shovels in the future. At
this time the first planned serial numbers for this change are as follows: 4100XPC – ES41187,
4100C – ES41195, 2800XPC – ES28179, and 4100C BOSS – ES41199.

Upgrade kits have been made to apply this air isolation to existing machines. Kit R63113F_ is
applicable to all modern P&H electric shovels that are equipped with the single brake supply valve
manifold similar to the one pictured in Figure 1. Mounting locations will vary depending on the left
hand room assembly of the particular shovel.

Kit R63113F1 has been released for use on shovels equipped with the Centurion (24 V) control
system. Kit R63113F2 will be released shortly for shovels not equipped with the Centurion control
system. Installation instructions are provided with the new kit, reference drawing R63113F_.

4.0 Conclusion

This Air Isolation upgrade provides hardware that separates the air supplies to the Hoist, Crowd,
and Swing brake systems and provides 3-way valves that can be used to isolate the air supplies to
each of these brake systems.

5.0 Actions

Contact your local P&H MinePro representative for more information. Refer to this Service Bulletin.

Copyright © 2009 P&H Mining Equipment, Inc. P&H Product Support

SB-ES-135.doc Page 6 of 6 SB-ES-135, Version 00 – 07/09
SUBJECT: Mine Air Systems Fuse Holder Orientation BULLETIN: SB-ES-134
MODELS AFFECTED: All MineAir Systems Model 1500,
VERSION: 00
1000, and 400 Units Shipped Prior to June 2008
APPLICABLE TO ASSEMBLIES: See Discussion DATE: 05 September, 2008
SPECIAL NOTE: PRODUCT CODE: 1094

Introduction

P&H Mine Air Systems has discovered that the fuse holders in the electrical boxes found on MineAir
Systems (MAS) 1500, 1000, and 400 units have been installed backwards. P&H part numbers for
these assemblies are R52590D_, R35715D_, R56709D_, MNM150-MXH-01, NPMNM150-SXH-01,
NPM100-MXH-01, NPMNM100-SXH/10, NPMNM150-SXH-01.

Purpose

This Service Bulletin provides instructions for correcting the orientation of the fuse holders.

Discussion

P&H Mine Air Systems has discovered that the fuse holders in the electrical boxes found on MAS
1500, 1000, and 400 units have been installed backwards. Although this does not affect operation
of the Mine Air units it is recommended that the fuse holders be re-oriented per the instructions
below. The existing orientation potentially could expose personnel to live voltages when the fuse
holder is opened.

Isolate the MineAir unit and perform lockout/tagout prior to accessing components
inside the electrical box. Failure to do this will cause exposure to electrical power
which could cause severe personal injury or death.

Existing Fuse Holder Orientation

Figure 1 shows the orientation of the fuse holders before the recommended change. Note that the
Orange LED on each fuse holder is oriented towards the hinge side of the box (see also Figure 2).

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MineAir Systems Fuse Holder Orientation Electric Shovel Service Bulletin Number 134

Hinge

Fuse
Holders

Figure 1: Electrical Box Shown with Lid Removed

Orange LED
oriented on
hinge side of
E-box (this is
the incorrect
orientation)

Figure 2: Close-up of Fuse Holders (Incorrect Orientation)

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MineAir Systems Fuse Holder Orientation Electric Shovel Service Bulletin Number 134

Figure 3 shows the fuse holders after the orientation has been corrected.

Orange LED
oriented
away from
hinge side of
box
(Corrected
Orientation)

Figure 3: Close-up of Fuse Holders (Corrected Orientation)

This correction is accomplished by disconnecting the wires from the fuse holders and removing
them, then rotating the fuse holders 180 degrees and re-connecting the wires.

Be sure to verify that all electrical connections are correct and relabel the fuse holders so
that they contain the correct labels or stickers after the fuse holders have been reoriented.

Conclusion

A change is required to the fuse holders for the MineAir units called out in this Service Bulletin to
provide the correct orientation of the fuse holders.

Actions

Reorient and install the fuse holders as discussed above for all MineAir 1000, 1500, and 400 units
(P&H part numbers R52590D_, R35715D_, R56709D_, MNM150-MXH-01, NPMNM150-SXH-01,
NPM100-MXH-01, NPMNM100-SXH/10, and NPMNM150-SXH-01). Contact your local P&H MinePro
representative with any questions and refer to this Service Bulletin.

Copyright © 2008 P&H Mining Equipment, Inc. P&H Product Support

SB-ES-134.doc Page 3 of 3 SB-ES-134, Version 00 – 09/08
SUBJECT: Hoist Drum Gear Bolts BULLETIN: SB-ES-133
MODELS AFFECTED: All 2800 and 4100 Series Electric
VERSION: 00
Mining Shovels
APPLICABLE TO ASSEMBLIES: see in Introduction DATE: 16 May 2008
SPECIAL NOTE: PRODUCT CODE: 1007

Introduction

It is the intent of this Service Bulletin that all hoist drum gears on subject machines be standardized
as Grade 8 Coupling Bolts (P&H part number 20Z1940D24) with tack welded nuts. Inspect and
replace coupling bolts as recommended in this Service Bulletin. Coupling Bolts are used to fasten
the hoist drum gear to the hoist drum. The hoist drum shaft assemblies affected are: R41175F_ or
R58153F_ for 4100XPB’s, R56860F_ for 4100BOSS’s, 910J663F_ for 4100A and 4100C shovels,
910J640F_ for 2800XPB’s.

Purpose

The purpose of this Service Bulletin is to communicate an upgrade of bolts on 2800 and 4100
Series P&H Electric Mining Shovel hoist drum shaft assemblies and to provide specifications and
procedures for assembling the hoist drum gear to the hoist drum on P&H Electric Mining Shovels.

Discussion

It is the intent of this Service Bulletin that all hoist drum gears on subject machines be standardized
as Grade 8 Coupling Bolts (P&H part number 20Z1940D24) with tack welded nuts. Bolts referred to
as coupling bolts are a special, body-fit bolt and are meant to be a tight fit in the hole. All work is
direct-replacement; no additional machining is required. This standardization is without regard to
the fasteners that were installed at the factory. Accordingly, this Service Bulletin supersedes
instructions in service manuals and parts manuals that may relate to hardware used for mounting
the hoist drum gear to the hoist drum for all 2800-Series and 4100-Series Electric Mining Shovels.

RECOMMENDED ACTIONS

The next time the hoist gear case cover is removed for any reason, inspect the hardware used to
attach the hoist drum gear to the hoist drum. It is recommended that all hardware be eventually
upgraded as described on Page 2 of this Service Bulletin. The bolts should be inspected each time
the cover is removed, and upgraded the next time the gear must be removed from the drum or the
bolts indicate replacement is necessary.

Again, the intent is to have all 2800 and 4100 series shovels eventually upgraded to the hardware
specified on page 2 of this Service Bulletin.

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Hoist Drum Gear Bolts Electric Shovel Service Bulletin Number 133

Figure 1 below shows the location of the subject coupling bolts.

Figure 1: Hoist Drum Coupling Bolts

INSPECTION

The part number for the coupling bolt to be used

going forward is 20Z1940D24. P&H specifications
call for this to be a grade 8 coupling bolt. In the
past, grade 5 coupling bolts have been installed
on some P&H shovels for this application. The
coupling bolts should look as pictured in Figure 2.
The heads of the grade 8 coupling bolts should
have “A490” stamped on them. If they do not
have this stamped on the head, they are not P&H
part number 20Z1940D24 coupling bolts.

Figure 2: Head of 20Z1940D24 Coupling Bolt

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Hoist Drum Gear Bolts Electric Shovel Service Bulletin Number 133

HOIST DRUM GEAR FASTENING PROCEDURE

1. Freeze Grade 8 coupling bolts (P&H Part Number 20Z1940D24) using liquid nitrogen, dry
ice, or other appropriate agent.

The coupling bolts are meant to be a tight, body fit in the holes, although not a press fit. If
the holes in the drum and/or the gear have been damaged to make the bolts a loose fit, it
may be necessary to ream the holes and install oversize bolts. In the event this occurs
contact your local MinePro service department for guidance.

2. Coat threads and under heads of the coupling bolts with Never Seez (anti-seize) or
equivalent.

3. Install the coupling bolts, hardened washers (P&H Part Number 18Z694D14), and hex nuts
(P&H Part Number 20Z1081D14) to secure the hoist second reduction gear to the hoist
drum.

4. Tighten nuts to a final lubricated torque of 2370 ft lbs (3213 Nm) using a star or cross
torque pattern. This should be done in at least three passes: use 2/3 final torque (1580 ft
lbs or 2142 Nm) for initial pass, final torque for the next pass, use the final pass to verify
the final torque has stabilized.

5. Tack-weld the nut to the bolt shank as shown in Figure 1.

Conclusion

Hoist drum shaft assemblies for all model 2800 and 4100 shovels should use the 20Z1940D24
grade 8 coupling bolts in the future to attach the hoist drum gear to the hoist drum. Use the
procedure described above to install these bolts.

Actions

Perform the inspections and replacement of bolts as seen above in the discussion.

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 SERVICE BULLETIN
ELECTRIC MINING SHOVELS

SUBJECT: Mechanical Stored Energy in Disc Brakes BULLETIN: EMS-SB-132

MODEL APPLICABLE TO: All Models with Disc Brakes VERSION: Version 00
SPECIAL NOTE: DATE: 03/06

INTRODUCTION contained in this P&H Service Bulletin is intended to raise

awareness of one aspect of hazardous energy - a ver-
sion of potential energy referred to as mechanical stored
Control of Hazardous Energy is something that all of us
energy, and in particular, how it relates to two separate
encounter on a daily basis, whether at home or at work.
and distinct maintenance procedures on electric mining
For mines, each site should have its own Hazardous
shovels manufactured by P&H Mining Equipment: 1)
Energy Control Guideline. Within that guideline, provi-
manual release of the brakes, and 2) brake removal.
sions should be made for all types of energy, including
electrical, mechanical, and fluid power. The information

01
03
02

04

06
08

ES0442b01
05
07
LEGEND
01. Potential Energy Stored in the Boom Suspension System
02. Potential Energy Stored in the Hoist Brakes
03. Horizontal
04. Potential Energy Stored in the Crowd Brake
05. Shovel on Non-level Ground
06. Expected Dipper Motion if Stored Energy is Released
07. Dipper Resting Position
08. Potential Energy Stored in the Propel Brakes

Figure 1: Stored Energy Sources

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Mechanical Stored Energy in Disc Brakes Electric Mining Shovel Service Bulletin Number 132

PURPOSE Development of Mechanical Stored Energy

The purpose of this Service Bulletin is to provide P&H The priority in disc brake removal is the release of
Mining Equipment end-users with information regarding mechanical stored energy. To avoid injury, refer to Figure
controlling mechanical stored energy. There are two 1 as you familiarize yourself with how mechanical stored
areas of discussion: energy can develop in drivetrains. Following are some
examples of how stored energy can develop in a drive-
1. RELEASING STORED ENERGY prior to working on or train:
removing disc brakes.
2. REMOVING DISC BRAKES after stored mechanical • The dipper is suspended. Gravity is trying to pull
energy has been released.
the dipper down. Releasing the brakes manually
or removing the disc brakes will result in a release
of mechanical stored energy, allowing the dipper
to fall.
DISCUSSION
• The dipper is on the ground but the hoist ropes
NOTICE and bail are still taut. In this case, if the hoist ropes
are tight, there must be load somewhere in the
hoist and crowd drives, thus creating mechanical
The information in this Service Bulletin is stored energy in the hoist and/or crowd brakes.
generic in nature and is provided as a sup- Releasing these brakes manually or removing the
plement to existing federal regulations and brakes will result in a release of mechanical stored
guidelines. P&H Mining Equipment highly energy, allowing the bail to fall forward.
recommends that readers refer to their fed-
eral, state, and local laws, ordinances, reg- • The dipper is on the ground with the hoist ropes
ulations, administrative rulings, orders, and slack, but the crowd disc brake has not yet been
appropriate P&H manuals prior to conduct- released. In this case, the handle and dipper
ing any maintenance activity or task. weight can pull the front of the shovel down. When
the crowd brake is manually released, or when the
crowd brake is removed, the shovel center of
! WARNING gravity may shift backward causing the shovel to
rock backward, and movement of the dipper han-
Uncontrolled release of mechanical dle relative to the boom, causing the crowd
stored energy can cause unexpected machinery to rotate.
movement, resulting in severe personal
injury or death. Always release mechan- • Soft ground conditions can result in shifting of the
machine, changing the way gravity affects struc-
ical stored energy before maintaining or
tures and drivetrains. Maintenance work can take
removing disc brakes on P&H Mining anywhere from several minutes to weeks to com-
Shovels. plete. The ground conditions can change over the
duration of maintenance work. If, for example, a
The disc brakes used on P&H Mining Shovels are spring- crawler or jackstand begins to sink into the
set, air-release holding brakes, with the air supply con- ground, the shovel will move. What had been sta-
trolled electronically. That means the disc brakes will be ble before the shovel moved has now been
in a set condition when either air or electrical power is affected differently by gravity. Mechanical stored
removed. Once the disc brakes are set, however, they energy has now developed within the drivetrain.
have the ability to store and hold mechanical energy. This Mechanical stored energy has been created dur-
Service Bulletin will describe how this energy can be cre- ing the maintenance job itself. Therefore, it is
ated, and how to properly control or release that energy imperative to visually inspect the shovel as main-
before initiating any maintenance work on the shovel. tenance work progresses, and verify that mechan-
ical stored energy has not redeveloped in a disc
brake.

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Mechanical Stored Energy in Disc Brakes Electric Mining Shovel Service Bulletin Number 132

• A shovel parked with the boom in a jacked condi- energy, causing the input pinion -- and the disc brake that
tion (i.e., the suspension cables are slack). This was attached to it -- to spin.
would create stored energy in the crowd system,
as the crowd would be supporting the weight of Solution
the boom. Manually releasing the crowd brake or
removing the crowd brake will result in a release Simply releasing disc brakes from the operator’s cab
of mechanical stored energy, allowing the boom to while the shovel is running will not release all stored
set down. energy in the system. Under normal operating conditions,
the electrical drive system will hold the shovel in what-
• A shovel parked on non-level ground. Not only ever position the operator requires. For example, when
does this affect movement in both propel and the dipper is suspended and the hoist controller is in the
swing, it can also affect stability of the shovel, neutral position, the electric motors will hold the dipper in
which can create stored energy in any motion that suspended position. When the brake is set, the dip-
(hoist, crowd, swing, or propel) due to machine per is still suspended, but it is held by the hoist brakes.
rocking on the non-level ground. Manually releas- The hoist brakes, then, are still holding mechanical
ing or removing any of the brakes will result in a stored energy. In order to release mechanical stored
release of mechanical stored energy, resulting in energy, both of the hoist brakes must be manually
unpredictable movement. released at the same time when the motors are not able
to hold the position (that is, the shovel is shut down).
• A shift of a shovel's center of gravity due to partic-
ular tasks (jacking, lifting, pushing or major com- Likewise, any mechanical stored energy that develops
ponent removal) performed. Manually releasing or within any of the shovel motion drivetrains (crowd, hoist,
removing any of the brakes will result in a release swing or propel) must be released by releasing all of the
of mechanical stored energy, resulting in unpre- brakes in the system while the shovel is shut down. This
dictable movement. must be completed before attempting to remove the
brake from the machine. Follow these steps:
Due to the number of situations that can cause or result
in development of mechanical stored energy, a process
that allows for the safe release of mechanical stored ! WARNING
energy under any condition should be used. Plan each
task and the sequences of the maintenance work in Unexpected machine movement can
advance to avoid unnecessary development of mechani- result in serious personal injury or
cal stored energy and the release of such energy when it death. Never manually release disc
develops. brakes when the shovel is parked on an
incline, on unlevel ground, on soft
Example ground, or while the dipper or bail is
suspended.
The following is an example of the effect of stored
energy: Several personnel are required to complete this task:

While performing repairs to a P&H shovel crowd gearbox Technicians. One person must be at each of the brakes
assembly, a technician was in the process of removing on the system. The technicians will also remove the
the disc brake to gain access to the first reduction pinion. brake(s) if that task is to be performed.
The disc brake mounting bolts were removed one at a
time. When the last bolt was removed, the disc brake Brake Valve Operator. One person must be in the lubri-
spun causing injury. cation room. This person will apply the manual actuator
on the brake air valve.
In this case, mechanical stored energy developed from
gravity acting on the crowd system. The only thing keep- Guard. One person must be in a location to see and
ing the crowd system from being pulled by gravity was communicate with the area where the machinery is
the disc brake. The disc brake was fixed to the gearbox expected to move to ensure that all personnel are kept
by mounting bolts. When the mounting bolts were clear of the area.
removed, the disc brake was no longer capable of hold-
ing the weight. This released the mechanical stored

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Mechanical Stored Energy in Disc Brakes Electric Mining Shovel Service Bulletin Number 132

1. RELEASING STORED ENERGY Procedure

1. Properly park the shovel on a flat, even grade, prop-

Discussion erly compacted and stable ground, with the dipper
resting on the ground (dipper front face flat on
Under normal operation, when the brakes release, the
ground, dipper heel and dipper lip both contacting
motors maintain the position of each of the shovel motion
ground), the dipper bail forward with the hoist ropes
components (swing, hoist, crowd and propel). When the
slack, and suspension cables tight (boom not
brakes are set, the components are held in their current
jacked). Use mechanical stops, locks, and chocks
position by the brakes.
appropriately to properly park the shovel.
Because of this, releasing the brakes when the motors
2. Shut the shovel down and apply locks and tags
are running will not release stored energy. To release
according to the lockout/tagout procedure.
stored energy, the brakes must be released when the
motors are not functioning.

05

LEGEND
04 01. Air Supply Line
02. Quick Release Valve
03 03. Air Port
04. Brake
05. Air Port
02

01

Figure 2: Brake with Air Panel (typical)

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Mechanical Stored Energy in Disc Brakes Electric Mining Shovel Service Bulletin Number 132

3. On systems with air panels (refer to Figure 2), dis- cient air pressure in the system, disconnect the air
connect the line from the air port (05) and install a line between air lubricator and the air pressure regu-
plug. (On systems without air panels, that port is lator and attach an external air source of at least 105
already plugged.) psi.

NOTICE NOTICE
On all systems, the port opposite the quick The specific location for connecting the exter-
release valve must be plugged before con- nal air source will vary depending on the model
tinuing. of shovel and the system where the air is to be
applied. Refer to Figure 3 for examples of con-
4. Confirm air pressure in the main air receiver is at nection points. Note that in all instances, the
least 105 psi. This can be confirmed by reading the connection point should be just upstream of the
gauge at the operator’s console. If there is not suffi- brake air pressure regulator.

ES04650a01

Figure 3: Examples of Connection Points

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Mechanical Stored Energy in Disc Brakes Electric Mining Shovel Service Bulletin Number 132

mechanical energy. Be prepared for sig-

! WARNING nificant movement of major shovel
components when brakes are released.
Using the air valve will cause uncon- Ensure that all personnel are clear of
trolled movement of machine compo- the major components affected by the
nents, which can cause severe personal associated brake system.
injury or death. Additional personnel
are required to complete this task. It is 8. Notify all crew members that the brake is about to be
imperative to establish a means of com- released. Have the brake valve operator use a 1/8"-
munication among these persons. diameter rod (or a similar suitable device) to press
the manual actuator button (indicated by the white
5. When a technician is present at each of the brakes to arrows in Figure 4) on the valve that provides air to
be released and ready, notify the brake valve opera- the brake to be operated. The brake valve operator
tor. must maintain pressure on the manual actuator but-
ton for as long as the brake is to be released.

9. When the disc brake mechanically opens, there will

normally be at least some movement of the associ-
ated components. Have the technicians observe the
disc brake rotors (one technician for each brake) as
they rotate and come to rest. This indicates that
stored energy has been released.

! WARNING
Uncontrolled release of mechanical
stored energy can cause unexpected
movement, resulting in severe personal
injury or death. If in Step 9 above the
Figure 4: Manual Actuators on Brake Air Valves brake discs do not rotate and come to
rest, proceed directly to the brake
6. Confirm with the guard that the area is clear and the
removal procedures described in
brake can be released.
APPENDIX A.
7. Have the brake valve operator identify the air valve
that provides air to the brake to be operated. Labels It is now acceptable to perform inspections, replace com-
are attached near the valve. ponents, take measurements, and perform other mainte-
nance actions. When maintenance is complete, restore
the system to its original configuration as follows:
! WARNING A. If an external air source was used, remove the
external air line connection and reattach the sys-
Unexpected movement of shovel com- tem air line (refer to Figure 3).
ponents could result in serious per-
sonal injury or death. Brakes may be B. On systems with air panels, remove the air port
holding large amounts of stored plug and reassemble the brake panel air line (refer
to Figure 2).

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Mechanical Stored Energy in Disc Brakes Electric Mining Shovel Service Bulletin Number 132

2. REMOVING DISC BRAKES pletely reinstall each brake before remov-

ing any other brake.

! WARNING NOTICE
Uncontrolled release of mechanical
stored energy can cause unexpected On the crowd system, only one brake holds
movement, resulting in severe personal the crowd motion. When removing a crowd
injury or death. Always release mechan- brake, be particularly certain to release
ical stored energy (refer to RELEASING mechanical stored energy before removing
STORED ENERGY) before removing the brake, since there will be no other
disc brakes on P&H Mining Shovels. brake holding the motion.

Discussion Procedure

Before removing a brake, confirm that stored energy has 1. Confirm that the shovel is properly parked on prop-
been released as described in topic RELEASING erly compacted and stable ground on a flat, even
STORED ENERGY. grade, with the dipper resting on the ground (dipper
front face flat on ground, dipper heel and dipper lip
Following the procedures in the topic RELEASING both contacting ground), the dipper bail forward with
STORED ENERGY accomplishes two things: First, it the hoist ropes slack, and suspension cables tight
demonstrates that the brake is operating normally (i.e, (boom not jacked). Use mechanical stops, locks, and
components are free to move and the brake is not chocks appropriately to properly park the shovel.
seized); second, it releases stored mechanical energy.
2. Shut the shovel down and apply locks and tags
according to the lockout/tagout procedure.

  
Even though the stored mechanical energy ! WARNING
has been released, changes in the physi-
Modifying the brake air system could
cal condition of the shovel could cause
cause unpredictable brake operation or
stored mechanical energy to redevelop.
brake failure, resulting in severe per-
For this reason, P&H Mining Equipment
sonal injury or death. Before beginning
recommends that only one brake be
work, tag lines and make sketched, pho-
removed from the machine at a time. The
tographic, or digital images of the con-
remaining brakes will stay installed and set
nections to ensure that you will be able
to inhibit unexpected movement. Com-
to return the system to its original con-
figuration.

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Mechanical Stored Energy in Disc Brakes Electric Mining Shovel Service Bulletin Number 132

Use the following procedure to release a brake using an Fabricate an assembly similar to what is shown in Figure
external air supply line. 5. Components include:

An External Source of Air (105 psi)

Air Hose and Fittings

06.
Two Ball Valves
01.
Regulator capable of 105 psi, with gauge

05. 07. Check Valve

02.
One Pipe Tee

One Pipe Plug

03.
04. Refer to Figure 6 and release the brake as follows:

LEGEND 04. To Atmosphere

01. To Brake 05. Regulator and Gauge
02. Supply Valve 06. Check Valve
03. Exhaust Valve 07. Quick Disconnect

Figure 5: Manual Brake Release Assembly

(locally fabricated)

05

04
LEGEND
03 01. Air Supply Line
02. Quick Release Valve
02 03. Air Port
04. Brake
01 05. Air Port

Figure 6: Brake with Air Panel (typical)

P&H Mining Equipment - Knowledge and Development Copyright © 2006 Harnischfeger Corporation
EMS-SB-132, Version 00 - 03/06 Page 8 of 12 EMS-SB-132.fm
Mechanical Stored Energy in Disc Brakes Electric Mining Shovel Service Bulletin Number 132

that all personnel are clear of the major

! CAUTION motions affected by the associated
brake system.
Compressed air spray can injure eyes
and ears. Wear eye and ear protection 6. Open the supply ball valve. The air should now
when releasing compressed air. release the brake.

1. Disconnect the existing brake air supply line (01)

where it is connected at the quick release valve (02). ! WARNING
2. If the disc brake has a brake solenoid panel, remove If a disc brake will not open and the pis-
the exhaust line at the brake outlet (05) and install a ton does not move outward, the normal
pipe plug in the brake outlet (on brakes without brake brake removal procedure must not be
solenoid panels, this port is already plugged). used. Refer to APPENDIX A.
3. On the fabricated manual release assembly, close 7. Maintain the air pressure in the brake to keep the
both the supply valve and the exhaust valve. Attach brake open and prevent redevelopment of stored
the quick disconnect fitting of the fabricated manual energy as the brake is being removed.
release assembly to the external air supply.

4. Open the exhaust valve. Attach the assembly hose to

the Quick Release Valve at the brake.
! WARNING
Inadequate lifting of heavy components
can cause serious injury or death. Sup-
port the brake being removed with a
suitable sling or other support. Disc
brakes can weigh up to 1700 pounds
(770 kg).

ES1570b03

Figure 7: Connecting External Air Supply

5. Make sure the supply ball valve is closed. Close the

exhaust ball valve. Activate the external air supply.
Set the regulator on the manual release assembly to
100 psi.

! WARNING
Brakes may be holding large amounts
Figure 8: Disc Brake Mounting Bolts (circled) (Typical)
of stored mechanical energy. Unex-
pected movement of shovel compo-
8. There are typically twelve mounting bolts (visible
nents could result in serious personal mounting bolts in Figure 8 are circled in white).
injury or death. Be prepared for signifi- Loosen the mounting bolts one at a time. Do not
cant movement of major shovel compo- remove any of the bolts at this time. Loosen the bolts
nents when brakes are released. Ensure

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EMS-SB-132.fm Page 9 of 12 EMS-SB-132, Version 00 - 03/06
Mechanical Stored Energy in Disc Brakes Electric Mining Shovel Service Bulletin Number 132

that are in the most difficult access areas first, and remain connected until the entire disc
work around to the mounting bolts where access is brake is removed from the hub. Be aware
easiest. that maintaining an outside air source will
cause the rotors to drop inside the disc
9. Loosen the last mounting bolt (most likely at the 12 brake as the disc brake is slid off the hub.
o'clock position) one turn only.
Alignment will be required before the disc
10. Re-verify that brake components are released and
brake is reinstalled.
not binding using one of the techniques below:

A. Place a pry bar under the brake. The brake should ! WARNING
move slightly on the mounting bolts when pried.
Modifying the brake air system could
B. Observe the rotors inside the brake. Use a pry bar cause unpredictable brake operation or
or large screw driver to move the rotors on the brake failure, resulting in severe per-
brake hub. sonal injury or death. Refer to tags on
air lines and to sketched, photographic,
! WARNING or digital images of the connections to
ensure that you return all connections
Uncontrolled release of mechanical to the original configuration.
stored energy can cause unexpected
movement, resulting in severe personal 13. When installing the replacement brake, be certain to
reconnect the brake air system as it was before per-
injury or death. If any binding (resis-
forming this disassembly procedure.
tance) is felt as the bolts are being
removed, stored mechanical energy is
still present. Reinstall all bolts and pro-
ceed directly to the brake removal pro- CONCLUSION
cedures described in APPENDIX A.
As discussed above, mechanical stored energy in disc
11. Remove the bolts from the brake mounting flange. brakes can affect maintenance activities in a number of
ways. It is important to have a full understanding of the
12. To set the brake, close the supply ball valve and shovel and how components interact. If questions arise
open the exhaust ball valve. during maintenance activities for P&H Surface Mining
Equipment, please refer to the applicable P&H Equip-
ment manuals or contact your local MinePro Representa-
Technician Tip tive before proceeding with maintenance work.
If there is any doubt as to the development
of stored energy, the outside air source can

P&H Mining Equipment - Knowledge and Development Copyright © 2006 Harnischfeger Corporation
EMS-SB-132, Version 00 - 03/06 Page 10 of 12 EMS-SB-132.fm
Mechanical Stored Energy in Disc Brakes Electric Mining Shovel Service Bulletin Number 132

APPENDIX A
! WARNING
Brake Removal Under Special Conditions Sudden and unexpected release of
mechanical stored energy may cause
If a brake cannot be released, or in situations where the
violent spinning of the brake, brake
brake components do not move normally during a
release and set cycle, the brake may be storing large
components, and the transmission
amounts of mechanical energy. In such cases, do not input shaft, as well as major component
attempt normal brake removal. Instead, carefully disas- movement, resulting in severe personal
semble the brake in place. Use the following procedure to injury or death. Ensure that all person-
disassemble a brake that is suspected of still being under nel are clear of major motions affected
load or tension. by the associated brake system.

LEGEND
First Round
Second Round
Third Round
Fourth Round

ES04329b01

Figure 9: Star Bolting Pattern

1. Using a star pattern as shown in Figure 9, back off load tension. Be very careful as the
two turns at a time on each rod bolt stud nut until all rotors could break loose and turn at any
are removed. The brake air cylinder assembly should time.
slowly move outward as this is being done. The
brake piston will appear to depress inward. 3. Install eye bolts in the lifting holes tapped into the pis-
ton as a lift point.

NOTICE 4. Use the appropriate slings and chain hoist or crane

for the weight of the brake assembly. A brake may
If the brake is under a load, internal com- weigh up to 1286 lbs (583 kg). Remove the brake air
ponents may rotate gradually as the rod cylinder assembly.
bolt nuts are loosened. Be prepared for
possible movement of associated motion 5. Remaining alert at all times for potential sudden
components. movement of brake components, remove brake com-
ponents in order:
2. Remove all air piping connections.
• Outer Rotor

! WARNING • Center Plate(s)

If the brake internal components have • Inner Rotor(s)

not rotated, the brake may still be under

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EMS-SB-132.fm Page 11 of 12 EMS-SB-132, Version 00 - 03/06
Mechanical Stored Energy in Disc Brakes Electric Mining Shovel Service Bulletin Number 132

• Wear Ring torch may be necessary to cut and remove

seized components.
• Brake Hub
6. Support the weight of the drive ring with slings and a
suitable lifting device. The drive ring may weigh up to
Technician Tip 200 lbs (91 kg).

A sledge hammer may be used to break 7. Loosen and remove the drive ring mounting bolts and
loose parts and release tension. A cutting remove the drive ring.

P&H Mining Equipment - Knowledge and Development Copyright © 2006 Harnischfeger Corporation
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 SERVICE BULLETIN
ELECTRIC MINING SHOVELS

SUBJECT: Orientation of Machined Flat on Lower Roller and

BULLETIN: SB-ES-128
Idler Pins
MODEL APPLICABLE TO: All VERSION: Version 00
SPECIAL NOTE: DATE: 03/03

INTRODUCTION DISCUSSION
Corduroy or crawler lower roller and idler pins have a LOWER ROLLERS AND FRONT IDLERS
machined flat on one side of the pin. Orientation of this
flat is important to lubrication of the pin, as the lubricant Lower roller pins and front idler pins on P&H shovels
exits through a hole drilled through the flat. A review of should have the machined flat oriented to face the rear of
P&H maintenance manuals have found inconsistency the machine (see Figure 1).
and errors in regard to this orientation.

PURPOSE NOTICE
Newer pins also have the machined flat on the
The purpose of this service bulletin is to establish the cor- head of the pin that is visible from the outside.
rect orientation of the flat on all lower roller and idler pins On older pins, the side of the head should be
on P&H shovels. This information is to correct past errors marked so that the location of the flat can be
in maintenance manuals and to reinforce the importance observed after the pin is installed.
of the correct orientation.

LEGEND 2. Roller 4. Flat on Pin

1. Bushings 3. Pin 5. Flat on Pin Head

Figure 1: Typical Lower Roller Flat Orientation

Copyright © 2003 Harnischfeger Corporation P&H Mining Equipment - Technical Communications

ems_128.fm Page 1 of 2 SB-ES-128, Version 00 - 03/03
Orientation of Machined Flat on Lower Roller and Idler Pins Electric Mining Shovel Service Bulletin Number 128

REAR IDLERS

Older shovels had a full-size tumbler that reached from

the ground to the top of the crawler side frame. These
systems have a drive tumbler assembly that included
bushings to support the tumbler drive shaft. These type
of machines do not have an enlarged rear idler roller.

Newer High-Drive systems have a smaller tumbler that

was raised off the ground to eliminate impacts, and bear-
ings instead of bushings. The shovels with the high drive
systems have a rear idler roller located to the rear of the
rear-most lower roller. This rear idler roller is larger than
the lower rollers. The crawler belt wraps around this rear
idler as it transitions up from the ground to the raised
drive tumbler.

On high-drive shovels equipped with rear idler rollers, the

pin orientation should have the machined flat facing the REAR IDLER
ES1244a_01
front of the shovel, which means the rear idler is opposite
of all the lower rollers and front idlers.
Figure 2: Rear Idler Location

P&H Mining Equipment - Technical Communications Copyright © 2003 Harnischfeger Corporation

SB-ES-128, Version 00 - 03/03 Page 2 of 2 ems_128.fm
 SERVICE BULLETIN
ELECTRIC MINING SHOVELS

SUBJECT: Hoist Rope Cable Tugger Operating Considerations BULLETIN: SB-ES-127

MODEL APPLICABLE TO: All VERSION: Version 00

SPECIAL NOTE: DATE: 11/02

INTRODUCTION lems resulting from improper air system maintenance,

please refer to Service Bulletin EMS 115.
Machines have always been equipped with tuggers
mounted behind the hoist drum to use in pulling in new
hoist ropes. They can also be used to remove the old ! WARNING
ropes from the machine. Wire rope tuggers, whether air
or electric, should be used with caution as they present
Dropping a raised load can cause
some risk of damage to equipment or injury to personnel severe personal injury, death or equip-
if improperly installed, maintained, or used. ment damage. Be sure lifting equipment
capacity exceeds the weight of the com-
ponent being lifted and the lifting equip-
PURPOSE ment is securely attached to the
component being lifted. Stay clear when
Rope tuggers are selected on the basis of their line pull lifting, lowering or moving components
and the winding capacity of the drum. The tugger should with lifting equipment.
not be replaced with a will-fit unit unless consideration is
given to the rated load, motor stall torque, tugger rope
Always remain clear of a suspended load. Depending
size and construction, and the breaking strength of the
upon the procedure employed to change hoist ropes, it
tugger rope. Tugger installation is called out on num-
will be necessary to some extent to be in the area under-
bered P&H drawings and P&H MinePro should be con-
neath the boom point sheaves to handle the new hoist
sulted if a modification to the installation is desired.
ropes on the ground. Fabricating reel stands on a sled or
trailer to support the reels of new rope not only adds to
DISCUSSION the efficiency of the rope payout from the reel, but it pre-
vents damage to the rope that can result from dragging it
Tuggers should be maintained in the same way as air or through the dirt/over rocks or from pulling kinks taught
electric hoists. On air-operated units, the air exhaust muf- that have slipped over the side of the reel.
fler must be installed and maintained in good condition.
Ear protection should be worn in the area of an operating
air tugger to prevent potential hearing loss. The air sys-
tem supplying an air tugger must be properly maintained
so that only clean, dry air is applied to the tugger motor.
In-line lubrication can be provided but the oil must be
compatible with pneumatic components utilizing o-rings
and gaskets. Air pressure to operate the tugger must not
be increased above the OEM recommended level on
P&H excavators. Two models of air tuggers have been
used on P&H shovels, P&H part numbers 30Z103 and
R24974. For 30Z103 air tuggers the air regulator should
be set at 80 PSI. For R24974 air tuggers the air regulator
should be set at 90 PSI. With respect to potential prob-
Figure 1: Cable Reel Stands

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ems_127.fm Page 1 of 2 SB-ES-127, Version 00 - 11/02
Hoist Rope Cable Tugger Operating Considerations Electric Mining Shovel Service Bulletin Number 127

Though it might be considered expedient, the old ropes In fact, a new part number (R25924D2) has been
should never be cut free and allowed to freefall from the assigned to this 3/8 inch rope and the old 5/16 inch rope
point sheaves. The hoist rope tugger should be used to is no longer available from P&H for this application. Part
ease the old ropes off of the machine. of the decision to make this change is based on the
desire to increase the design factor of the tugger rope.
Inspect the tugger rope for broken wires, kinks, bird-cag- The minimum design factor for the 3/8 inch rope in the
ing, evidence of unlaying, corrosion, or other mechanical tugger application is calculated with 80 feet of rope on
damage. Internal rope damage is often not evident on the drum. It should be noted that the 80 feet of rope on
visual inspection. the drum is significant given that there is nothing to snag
the rope on until the hoist rope ends reach the boom
Regular replacement of the tugger rope based on usage point sheaves when pulling in new ropes. The nominal
is highly recommended even if damage is not evident. breaking strength of the 3/8 inch rope is 7.55 tons.
Inspect the pathway from the point sheaves, down the
boom, into the house, and onto the drum for obstructions Information on available P&H hoist rope cable tuggers is
that could be damaged by either easing the old ropes out shown in Table 1.
or pulling the new ropes in. Obstructions can also snag
the connection between the tugger rope and the new Nominal
Hoist Rope
hoist rope when pulling in new ropes. Observers, in com- Recommended Breaking
Cable Tugger
munication with tugger operators, should be positioned in Cable Strength of
Description
safe places and at safe distances to watch for potential Cable
snags. If care is not exercised in reeving in the new Electric Tugger R25924D2
ropes, a snag could cause the tugger motor to generate 7.55 Tons
30Z181D_ (.375"x160’)
stall torque almost immediately with the result that worn
or poorly maintained tugger rope might part and cause Electric Tugger R25924D1
13.30 Tons
the load to freefall. R26969D_ (.50"x160’)

Air Tugger R25924D2

The 30Z181D_ electric tugger is a purchased part that 7.55 Tons
30Z103 (.375"x160’)
has been used on P&H electric excavators since about
1972. It is rated at 1850 lbs. line pull, and has for many Air Tugger R25924D1
13.30 Tons
years been equipped with 5/16 inch diameter rope. The R24974D1 (.50"x160’)
tugger in this configuration has safely provided satisfac- Note: Breaking strength of cable is shown. Tugger mini-
tory performance. Over the years, the hoist ropes on mum design factor varies depending on tugger model
machines have increased in diameter and, consequently, and amount of cable on the tugger drum.
in weight. While the tugger is still capable of pulling in the
new, larger-diameter ropes, it is recommended that the Table 1: Hoist Rope Cable Tugger Specifications
tugger rope be increased in size from 5/16 inch diameter
to 3/8 inch diameter.

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation

SB-ES-127, Version 00 - 11/02 Page 2 of 2 ems_127.fm
 SERVICE BULLETIN
ELECTRIC MINING SHOVELS

SUBJECT: Disc Brake Burnish-In Procedures BULLETIN: EMS-124

MODEL APPLICABLE TO: Mining Shovels using Disc Brakes VERSION: 00
SPECIAL NOTE: DATE: April 2002

INTRODUCTION sonnel are clear of shovel motions

affected by these procedures.
All P&H Electric Mining Shovels that are
equipped with disc brakes use brakes with metal- Propel Brakes
lic friction pad linings. These brakes are responsi-
ble for holding the motion still when the motion is 1. Press the PROPEL button to put the shovel in
not being used. They are also responsible for stop- propel mode.
ping the motion in an emergency stop situation. 2. Move both joystick controllers 1/4 forward
from center to propel the shovel at 1/4 speed.
PURPOSE 3. With the shovel propelling at 1/4 speed, press
the CROWD button to set the propel brakes.
The purpose of this bulletin is to provide the pro-
cedure for a burnishing process for metallic-lined 4. Wait one minute. After the one-minute wait,
brakes as recommended by the brake manufacturer. use a hand-held temperature monitor to check
The procedure applies to all disc brakes, regardless the temperature of the brake center plates and
pressure plates. Temperature must be below
of size and configuration. The burnish process is
300°F (149°C).
intended to promote the formation of an oxide film
on both the lining and the opposing surface. This 5. Repeat steps 1 through 4 three more times.
layer protects the surfaces from corrosion and pre- 6. Press the PROPEL button to put the shovel in
mature wear, and provides consistent coefficients of propel mode.
friction over the life of the brake.
7. Move both joystick controllers 1/2 forward
from center to propel the shovel at 1/2 speed.
BURNISH-IN PROCEDURE
8. With the shovel propelling at 1/2 speed, press
This procedure assumes that the brake has been the CROWD button to set the propel brakes.
properly installed in accordance with applicable 9. Wait two minutes. After the two-minute wait,
instructions. Confirm that running clearances are use a hand-held temperature monitor to check
within the specifications for the brake. the temperature of the brake center plates and
pressure plates. Temperature must be below
300°F (149°C).

These procedures require shovel com- 10.Repeat steps 6 through 9 seven more times.
ponents to move. Such movement
may result in severe injury or death if Hoist Brakes
personnel are not kept clear of mov-
1. Raise the empty dipper to the upper limit.
ing machinery. Ensure that all per-

P&H Mining Equipment- Technical Communications Copyright © 2002 Harnischfeger Corporation

VER 00, 04-02 Page 1 of 4 SB-EMS-124
2. Move the joystick controller 1/4 forward from 7. Wait two minutes. After the two-minute wait,
center to lower the dipper at 1/4 speed until use a hand-held temperature monitor to check
the dipper handles are approximately parallel the temperature of the brake center plate and/
to the ground. Apply the hoist brakes. or the brake pressure plate. Temperature must
be below 300°F (149°C).
3. Wait one minute. After the one-minute wait,
use a hand-held temperature monitor to check 8. Repeat steps 5 through 7 seven more times.
the temperature of the brake center plates and
pressure plates. Temperature must be below Swing Brakes
300°F (149°C).
1. Establish an appropriate means of communica-
4. Repeat steps 1 through 3 three more times. tion and have a helper observe the analog
5. Raise the empty dipper to the upper limit. meters on the Control Cabinet in the Right-
hand Room (refer to Figure 1). With Test Selec-
6. Move the joystick controller 1/2 forward from tor in the “Run” position and the Meter Selec-
center to lower the dipper at 1/2 speed until tor in the “Swing” position, read the ARM
the dipper handles are approximately parallel
VOLTS meter.
to the ground. Apply the hoist brakes.
7. Wait two minutes. After the two-minute wait,
use a hand-held temperature monitor to check
the temperature of the brake center plates and
pressure plates. Temperature must be below DC AMPERES DC AMPERES DC VOLTS

300°F (149°C).
FLD CURRENT ARM CURRENT ARM VOLTS
8. Repeat steps 5 through 7 seven more times.
TEST SELECTOR METER SELECTOR
Crowd Brake ARM
TEST
FIELD
TEST CONTROL
TEST SWING
HOIST
OPER.
REF.
SWING
OPER.
REF.
CROWD/
RUN AUX. CROWD/ PROPEL
HOIST HOURS SWING HOURS TEST
1. With the dipper empty, retract to the retract CROWD HOURS PROPEL HOURS
PROPEL

HOIST
OPER. REF.
MANUAL
KVAR
REF.
limit. Lower the dipper 10°. OFF RPC
STEP
IND.
1V=1

2. Move the joystick controller 1/4 forward from STEP

center to crowd the dipper at 1/4 speed until

the dipper handles are centered over the crowd TC0332a
pinions. Apply the crowd brake.
Figure 1: Analog Meters
3. Wait one minute. After the one-minute wait,
use a hand-held temperature monitor to check 2. With the empty dipper in the carry position,
the temperature of the brake center plate and/ move the swing controller to the right.
or the brake pressure plate. Temperature must
be below 300°F (149°C). 3. Have the helper observe the ARM VOLTS
meter (Figure 1) and report when voltage
4. Repeat steps 1 through 3 three more times. reaches +200V. Return the joystick to the neu-
5. With the dipper empty, retract to the retract tral position.
limit. Lower the dipper 10°. 4. Have the helper observe the ARM VOLTS
6. Move the joystick controller 1/2 forward from meter (Figure 1) and report when voltage
center to crowd the dipper at 1/2 speed until declines to +150V. Apply the swing brakes.
the dipper handles are approximately centered 5. Wait one minute. After the one-minute wait,
over the crowd pinions. Apply the crowd brake. use a hand-held temperature monitor to check

P&H Mining Equipment- Technical Communications Copyright © 2002 Harnischfeger Corporation

VER 00, 04-02 Page 2 of 4 SB-EMS-124
 the temperature of the brake center plates Swing: Fill the dipper and place it in the carry
and/or pressure plates. Temperature must be position. With the shovel at its maximum propel
below 300°F (149°C). grade of 15% and the loaded dipper in the carry
position, rotate the upper so that the boom is over
6. Repeat steps 1 through 5 three more times.
the side of the carbody and set the swing brakes.
7. With the empty dipper in the carry position, The dipper should not move.
move the swing controller to the right.
Under normal conditions, dynamic braking is
8. Have the helper observe the ARM VOLTS
accomplished electrically by positioning the joy-
meter (Figure 1) and report when voltage
stick controller so that the motion does not move.
reaches +400V. return the joystick to the neu-
tral position. The mechanical brake must also be capable of
9. Have the helper observe the ARM VOLTS stopping the motion. By design, braking torque is
meter (Figure 1) and report when voltage less than stall torque, in order to inhibit damage
declines to +300V. Apply the swing brakes. to the gearing. Motions will continue (within tol-
erance) after the brake is applied.
10.Wait two minutes. After the two-minute wait,
use a hand-held temperature monitor to check
the temperature of the brake center plates VERIFICATION OF
and/or pressure plates. Temperature must be DYNAMIC BRAKING TORQUE
below 300°F (149°C).
11.Repeat steps 7 through 10 seven more times.
Verification of Dynamic Braking
VERIFICATION OF Torque is to be done only as a part of
STATIC HOLDING TORQUE this burnish-in procedure. It is not
intended that this procedure be used
After performing the burnish-in procedure, check as a normal check of brake function.
the static holding torque by applying maximum Excessive brake testing could cause
load with the motor stopped. the brake to fail under emergency
stop conditions, which may result in
severe personal injury, death, or prop-
erty damage.
Be prepared for movement of major
shovel components which may occur
during static holding torque verifica-
tion. Such movement may result in
These procedures require shovel com-
severe injury or death as well as dam-
ponents to move. Such movement may
age to the equipment. Ensure that all
result in severe injury or death if per-
personnel are clear of shovel motions
sonnel are not kept clear of moving
affected by these procedures.
machinery. Ensure that all personnel
are clear of shovel motions affected
Hoist: Fill the dipper and position the dipper 15-
by these procedures.
20 inches above the ground. Apply the hoist
brakes. The dipper should not move.
Hoist: Fill the dipper and bring the dipper han-
Crowd: Fully retract the dipper handles and dles to the carry position. With the shovel run-
bring them to the fully vertical position. Apply ning and the hoist brakes released, apply the
the crowd brake. The dipper should not move. emergency stop. The dipper should stop within its
own height.
Propel: Move the shovel to an incline of approxi-
mately 15% grade. Place the shovel in CROWD Crowd: Bring the dipper handles to the fully ver-
mode. The shovel should not move. tical position. Crowd or retract until the dipper is

P&H Mining Equipment- Technical Communications Copyright © 2002 Harnischfeger Corporation

VER 00, 04-02 Page 3 of 4 SB-EMS-124
15 feet above the ground. With the shovel run-
ning and the crowd brake released, apply the
emergency stop. The dipper should stop within
five feet.
Swing: With the shovel on level ground and the
dipper full, place the dipper in the carry position.
Swing the upper and have the helper observe the
ARM VOLTS meter (Figure 1). When voltage
reaches +500V, Return the joystick to the neutral
position. When voltage declines to +450V, apply
the emergency stop. Rotation should stop within
60°.
Propel: Place the shovel on a 15% down slope.
Press the PROPEL button to put the shovel in
propel mode. Move the two joystick controllers
fully forward to propel the shovel at full speed.
With the shovel propelling at full speed, apply the
emergency stop. The shovel should stop within
five feet.

P&H Mining Equipment- Technical Communications Copyright © 2002 Harnischfeger Corporation

VER 00, 04-02 Page 4 of 4 SB-EMS-124
SUBJECT: Electric Shovel Motor Lubrication
BULLETIN: SB-ES-112
Recommendations
MODELS AFFECTED: All VERSION: 01
APPLICABLE TO ASSEMBLIES: DATE: 12 September, 2008
PRODUCT CODE: 1075,
SPECIAL NOTE:
1080, 1196, 1141

1.0 Introduction

Service Bulletin SB-ES-112, Version 00 was released in 06/98. This bulletin provides a procedure for
lubricating the bearings on all main motion AC and DC motors manufactured by P&H for mining
shovels. This Version 01 will update this Service Bulletin.

2.0 Purpose

The purpose of this Service Bulletin is to provide information on lubricating the main motion motors
on P&H mining shovels.

3.0 Discussion

Motors for most P&H Mining Shovels are equipped with a combination of a spherical roller bearing
on the drive end and a cylindrical roller bearing on the opposite drive end. Exceptions to this are
motors that have a ball bearing and a cylindrical roller bearing on the opposite end from the ball
bearing. Shaft end play is controlled by the mounted bearing internal clearance plus the axial space
between the outer race and the bearing caps.

Because of the severe shock encountered in mining service, extra heavy press fits between inner
races and shafts are used. In addition, all inner races of the locked bearings are secured by
locknuts.

3.1 General Lubrication

Bearings of all motors are lubricated with grease prior to leaving the factory or P&H rebuild
facilities.

Motors are designed to have specific lubricant inlet and outlet (drain) fittings and the grease can
only be properly applied in one way. For this reason, the inlets are fitted with a grease fitting and
the outlet is equipped with a pipe plug or a relief fitting.

Never attempt to pump grease into the bearings through the outlet.

Copyright © 2008 P&H Mining Equipment, Inc. P&H Product Support

SB-ES-112 Ver01.doc Page 1 of 6 SB-ES-112, Version 01 – 09/08
EMS Motor Lubrication Recommendations Electric Shovel Service Bulletin Number 112

Very few grease inlets and outlets on motor bearings have the grease fitting or the plug located
right at the end head of the motor. For reasons of accessibility, most inlet and outlet points are
fitted with a short length of pipe and the grease fitting or the plug is installed at the end of the
pipe. These short pipes are filled with grease at the factory or rebuild facility. However, in some
cases, such as with swing motors, a length of hose is substituted for the pipe and these hoses
might not be filled with grease.

Ensure that flexible hose extensions to the grease inlet are filled with a compatible grease
before putting the machine into operation. Also ensure that all grease lines are attached
correctly (see section 3.5). Figure 1 shows a swing motor lubrication line that was found
disconnected while doing a machine inspection.

Figure 1: Disconnected Motor Lubrication Line

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EMS Motor Lubrication Recommendations Electric Shovel Service Bulletin Number 112

3.2 Lubrication Interval and Amount

Each motor is equipped with a metal tag similar to the one shown in Figure 2. The motor tag
contains general information, refer to this Service Bulletin for specific information as to quantity of
grease and interval. This Service Bulletin will supercede all information in Maintenance Manuals
until such time as they are updated to the latest information contained within this Bulletin.

Figure 2: Existing Motor Lubrication Tag

Generally, adding a little grease at more frequent intervals is preferred to a larger amount of grease
at infrequent intervals. For this reason, it is the recommendation of P&H Mining Equipment that
main motion electric motors be lubricated every 500 hours of machine operation.

Do not use the individual motion hour meters to determine lubrication intervals. Machine
operation hours should be used for all main motion electric motors to indicate the interval
that they should be lubricated. Example if the shovel has 500 hours of machine operation
and 50 propel hours, the propel motors should be lubricated.

The amount of grease applied to each bearing on hoist, swing, and propel motors should be ½
ounce at each 500 hour interval. The bearings of the crowd motor should receive 1 ounce of grease
at each 500 hour interval. More grease is recommended for the crowd motor due to the loading
that the crowd drive belt places on the motor bearings.

The amount of grease produced by a particular grease gun should be verified to make sure
that the amount is measured as the motor is being lubricated. Verify the output of the
grease gun being used and be consistent when lubricating the motors. As an example: a
common, cartridge-type grease gun was tested and found to expel approximately 0.05 cu in
of grease per stroke. Whether the “oz.” (ounce) unit of measure is considered to be volume

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EMS Motor Lubrication Recommendations Electric Shovel Service Bulletin Number 112

or weight, the amount of grease expelled by a “standard” grease gun in 10 strokes was
found to be about equal to 1/2 oz. This may not be consistent for all grease guns and
should be verified to ensure the motor receives the correct amount of grease. Add grease
slowly until either the motor receives the correct measured amount of grease or grease is
expelled from the drain line, whichever happens first.

3.3 Lubrication Procedures

Failure to exercise care while working around rotating equipment can result in injury
or death. Shutdown the shovel and perform lockout/tagout before accessing the
motors for any maintenance function. Establish positive communications with the
operator’s station and notify all personnel working inside and outside of the machine
while work is being performed. Ensure that guards are in place when finished.

Prior to greasing each bearing, wipe the grease fittings using a clean dry cloth and thoroughly clean
the grease gun fitting. Remove the drain plug and remove any hardened grease. Remove hardened
grease inside grease tubes with a long drill bit or a suitable cleaning device if necessary. Choose
something that will not break off inside the tube while cleaning.

The grease should be added as soon as possible after the motors were in operation, so that the
motors are still warm. Pump the grease into the bearing slowly and gradually with a hand operated
grease gun (see section 3.2 for the amount of grease and the frequency). Leave the outlet (drain)
holes open and run the motor to relieve pressure and until no more grease is expelled (20 minutes
or longer). Then replace the drain plugs.

Over greasing the bearings in vertical applications may cause premature bearing
failure and physical injury if grease should drip on the commutator and flashover
occur (see Figure 3). To avoid over-greasing when re-packing bearings, fill the cavity
1/3 to 1/2 full.

While it is important not to over-grease any bearing, it is especially important that the top bearing
on vertical applications not be over-greased. Over-greasing the bearings can cause bearing failure.

In addition to causing premature bearing failure, excess grease can drip onto the commutator and
adjacent parts and cause a flashover. Avoid contaminating the commutator and windings with
grease during assembly and maintenance.

When re-packing the bearings, only fill the cavity about 1/3 to 1/2 full. Do not pack the cavity
completely full.

Make no attempt to ‘purge’ motor bearings by pumping large volumes of grease into the bearings.
There are labyrinth passages within the motor end heads that will pass grease internally without
forcing it out of the drain. Purging will result in over greasing the bearing which will lead to failure
and can lead to flashing as noted in the CAUTION above.

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EMS Motor Lubrication Recommendations Electric Shovel Service Bulletin Number 112

LEGEND 03. Bearing

01. Bearing 04. Drain Plug
02. Drain Plug 05. Grease Fitting

Figure 3: Vertical Motor Bearing Lubrication

3.4 Grease Selection

The grease must be compatible with that used at manufacture. The grease required is an extreme
pressure (EP) grease with an NLGI specification of 0, 1, or 2 conforming to P&H spec 472A, 472B,
or 472C, respectively. Ensure that the correct NLGI grade of grease is used for the ambient
temperature. Refer to Service Bulletin 84 for P&H lube specifications.

Under no circumstances should greases containing molybdenum disulfide (MOS2) or graphite be

used in electric motor applications because of the electrical conductivity of these solids.
Contamination of the commutator and adjacent parts with conductive greases will promote
flashovers.

If the wrong grease is used or if the grease is suspected of being contaminated, both the bearing
and the bearing cavity should be completely cleaned of all greases using a suitable solvent.

3.5 Installing a Replacement Motor

Although all the bearings in the motors on new machines are packed with grease at the factory or
rebuild center, it is still necessary to check all of the flexible hoses connected to the inlets during
the machine build or Encore unit installation, especially on the swing (see Figure 1).

The supply hose must be disconnected from the fitting on the end head of the motor. Grease must
be pumped through the grease fitting until the lube comes out of the end of the hose. Then

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EMS Motor Lubrication Recommendations Electric Shovel Service Bulletin Number 112

reconnect the hose. This procedure is necessary because there is not a sure way to tell when the
hose has been filled and to continue to pump grease into the fitting while waiting for it to come out
of the drain will only result in over greasing.

Follow the lubrication procedures outlined in paragraph 3.3 above. Best practices suggest that all of
the main motion motors should be set up on the machine build site so that they can be run at no
load for a few hours. A welding machine can be used to do this.

Consideration must be given to the NLGI grade of grease to use at the machine build and the
builder must be cognizant of the fact that the standard grade of lubricant used in the factory and
most repair facilities is NLGI 2. NLGI 2 might be totally inappropriate for machines in cold climates.
At the build site it might be necessary to move the motors indoors and to perform the no load runs
and lubrication procedure in a warmer environment. Follow instructions on all tags or decals
attached to the motor.

3.6 Lubrication After Extended Storage

The grease used as a bearing lubricant will gradually deteriorate when the motor is idle for
extended periods. The bearing grease could become contaminated during storage in dirty
environments but the separation of the oil from the soap matrix of the grease is the most likely
form of deterioration. The oil separation leaves only the soap matrix which is not, in itself, an
effective lubricant. Therefore, if the motor has been stored in a protected area for a period of 8
months or more, the old grease must be removed from the bearings and capsules and the bearings
relubricated with fresh, clean grease meeting the applicable specification described in 3.4 above.

Relubrication is also recommended following storage outdoors or in a contaminated environment

for a period of 5 months or longer.

P&H Mining Equipment recommends that motors never be stored outdoors.

Bearings are greased completely at the factory. If the bearing and capsule has been cleaned out,
each bearing should be packed between 1/2 and 2/3 full of grease upon installation. A layer of
grease should be added to both inner and outer bearing capsules by the labyrinth seals to seal out
dirt and grime during shipping and storage. Do not over grease. Operate the motor at a lower rpm
and light loads for a few minutes after installation.

3.7 Lubrication of Remanufactured Motors

Follow the procedures outlined in section 3.3 above when installing ENCORE or rebuilt motors.

4.0 Conclusion

Lubrication of P&H main motion electric motors should follow P&H’s recommendations.

5.0 Actions

Follow the recommendations in this Service Bulletin regarding lubrication of all P&H main motion
electric motors.

Copyright © 2008 P&H Mining Equipment, Inc. P&H Product Support

SB-ES-112 Ver01.doc Page 6 of 6 SB-ES-112, Version 01 – 09/08
 SERVICE BULLETIN
ELECTRIC MINING SHOVELS

SUBJECT: Crawler Belt Adjustment Procedures BULLETIN: EMS-109

MODEL APPLICABLE TO: 2300XPB, 2800XPB, 4100A Excavator VERSION: 00

SPECIAL NOTE: DATE: June 19, 1998

GENERAL should be seated properly between the drive tumbler

lugs. Both the entering and exiting shoe lugs should
smoothly engage and disengage the drive tumbler
This bulletin provides crawler belt adjustment procedures lugs. There should be no banging, grinding, or jerking
for the 2300XPB, 2800XPB, and the 4100A mining from either the entering or exiting shoe lugs. Figure 2
shovels. The procedure is similar for all three machines. shows engagement of a properly tensioned crawler
belt. Note the gap between the drive tumbler lug tip
CRAWLER BELT INSPECTION and the shoe. This gap is normal as the shoe exits.
3. Figure 2 also shows marginal engagement between
the exiting shoe lug and the drive tumbler lug. In this
case, crawler belt tension is too loose and tension
! WARNING
DANGER must be adjusted according to this procedure.
It is necessary to operate the excavator during
the crawler belt inspection. To avoid injury or REQUIRED TOOLS
death the crawler machinery observer should
be in constant communication with the opera-
tor. When moving next to the excavator, the The 2300XPB, 2800XPB and 4100A shovels are shipped
observer must be watchful for tripping haz- with the required belt adjusting tools.
ards, which could cause him to fall into the
equipment or excavators path.
! WARNING
DANGER
Proceed as follows:
Do not substitute makeshift blocks, pipes,
beams, etc., for the following tools. The force
1. With the observer in position as shown in Figure 1,
required to adjust the crawler belt could
propel the excavator forward. While propelling, the cause such arrangements to dislodge and
observer should view the drive tumbler as indicated. cause serious injury or death.

The 2300XPB shovel is equipped with the following

NOTICE tools (refer also to Figure 3):
It is important to have the operator position the • Two 100-ton hydraulic rams (P/N 21Z864D1)
controllers as shown in Figure 1 when propelling.
• Two idler adjustment sleeves (P/N 18P8627)
The crawler drive tumbler being observed is then
under full load. • Two threaded rods (P/N 19P829)
2. When observing a properly tensioned crawler belt • Two hydraulic hoses (P/N 44Z179D3)
travel around the drive tumbler, the loaded shoe lugs • Two hydraulic pumps (P/N 45Z320)

Harnischfeger Institute - Technical Communications P&H Mining Equipment

VER 00, 06-98 Page 1 of 6 SB EMS-109
 Figure 1. Crawler Belt Drive Observation

Figure 2. Crawler Belt Tension

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VER 00, 06-98 Page 2 of 6 SB EMS-109
 Figure 3. Crawler Belt Adjustment Tools – 2300XPB Excavator

Harnischfeger Institute - Technical Communications P&H Mining Equipment

VER 00, 06-98 Page 3 of 6 SB EMS-109
The 2800XPB and 4100A shovels are equipped with the
following tools (refer also to Figure 4): NOTICE
• Two 141-ton hydraulic rams (P/N21Q53D3) Propel the shovel in the forward direction prior to
shutting it down in order to bring the loose portion
• Two idler adjustment sleeves (P/N 21N71D1) of the belt to the top.
• Two idler adjustment rods (P/N 21N71D2)
2. Shut down the excavator; lock out and tag out the con-
• Two idler adjustment spacers (P/N 18P8869D1) trols.

• Two hydraulic hoses (P/N 44Z179D3) 3. Verify that all hydraulic ram hoses and connecting
hardware are in good working condition.
• Two hydraulic pumps (P/N 45Z320)
4. Verify that the sleeves, spacers, and rods are straight
A complete set of tools must be installed, one on the and in good condition.
inboard and one on the outboard side of the crawler belt 5. Remove the cotter pin and the shim retaining pin, one
being adjusted.
on each side of the idler assembly, so that the shims
can be removed or installed.
New P&H 2300XPB, 2800XPB, and 4100A excavators
are designed with a cradle that is an integral part of the 6. Remove the forward set of shims and install the rams
crawler frame. (Figure 5 shows a 4100A crawler frame and adjusting devices on both sides of the idler assem-
with cradle.) Once the ram is set in the cradle, it does not bly as shown in Figures 3 or 4, depending on the exca-
need to be held in position. The cradle is designed to fit vator model.
the rams supplied with the shovel. Older models of the
7. Extend the rams just enough to hold everything in
excavators do not have a cradle. It is recommended that a
cradle be fabricated and welded to the crawler frame. place while in the cradle structure.

8. Carefully check to verify that the ram, sleeves, rods,

NOTICE and spacers are properly seated and in a straight line.

Figure 5 is provided as an example only. Due to 9. Slowly and uniformly extend both rams simulta-
variations in machines and hydraulic rams, it will neously to move the idler shaft forward.
be necessary to measure the individual units to
determine the cradle dimensions. Contact your NOTICE
P&H MinePro representative if you need more
information concerning the fabrication and instal- Be sure both rams are extended forward uniform-
lation of a cradle weldment on your machine. ly. If only one ram is used, or if the two rams are
unevenly extended, the idler shaft will be cocked
in the side frame and the bearing blocks may bind
PROCEDURE in their slots.

10. Move the idler assembly forward until the crawler belt
Adjust the crawler belts as follows: appears to be tight.

NOTICE NOTICE

The crawler shoes must be free of mud and dirt to If further adjustment is required after the rams
obtain an accurate adjustment. have reached the end of their stroke, retract the
rams and turn the adjusting rod out of the adjust-
ing sleeve until it once again engages the bearing
1. Park the shovel in an area that is flat, level, away from
block. Extend the rams evenly, moving shims as
hazards, well compacted, preferably with a hard
necessary. If still more adjustment is required, in-
floor, and with good drainage in case of rain.

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VER 00, 06-98 Page 4 of 6 SB EMS-109
 Figure 4. Crawler Belt Adjustment Tools – 2800XPB and 4100A Ecavators

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VER 00, 06-98 Page 5 of 6 SB EMS-109
 stall the spacer between the rams and the adjust-
ing sleeves.

! WARNING
DANGER
This procedure must be performed with the
excavator shut down. If, for any reason, it be-
comes necessary to move the excavator at
this point, clear the area and only propel the
excavator in the forward direction. Moving in
the reverse direction with the adjustment
tools installed will cause the ram to explode,
which could injure or kill anyone in the vicini-
ty of the excavator.

11. Fill the space behind the roller bearing blocks with
shims, using the shims that were removed from the Figure 5. Hydraulic Ram Adjustment Cradle (4100A)
front of the bearing block. Be sure to install the same
number of shims on each side of the idler assembly.
The number and size of shims must be identical on
both sides of the idler assembly to prevent cocking
and binding of the bearing blocks.
12. Back off on the jack and install the remaining shims
in the space in front of the bearing block.
13. Insert the shim retaining pin in the shims on each side
of the idler assembly and install the cotter pins to
secure the shim retaining pins in position.
14. Remove the hydraulic jack and all tools and equip-
ment
15. Repeat the crawler belt inspection to ensure that the
loaded shoe lugs are properly seated between the
drive tumbler lugs as shown in Figure 2.

If necessary, repeat the above procedure to obtain the

correct crawler belt tension.

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VER 00, 06-98 Page 6 of 6 SB EMS-109
SUBJECT: Motor Vent cover Bulletin: SB-ES-30
APPLICABLE TO: Motors Listed VERSION: 01
SPECIAL NOTE: DATE: 4/10/07

INTRODUCTION

P&H motors are shipped with a weather seal and vent covers are installed to prevent dust or
water from damaging the motor during shipment.

This bulletin has been issued to remind field and maintenance personnel to removal all
weather seal and the vent covers designated on the appropriate diagram attached to this
bulletin.
.

PURPOSE

To remind field personnel that the appropriate vent covers are removed when a motor is
installed to provide adequate ventilation while in the motor is in operation.
.

DISCUSSION

Tables and diagrams are attached to this Service Bulletin to assist you with identifying
which vent covers must be removed for proper operation of the motor. Locate your machine
model motor in the first column of the applicable table and review the diagram number
referenced in the second column of that table to achieve proper air flow for that motor.
.
The tables represent all four motor motions: Hoist, Crowd, Swing and Propel.

The P&H Part Number and specific motor weight provided in the third and fourth columns
of each table are provided for informational purposes only.
 Diagram
DESCRIPTION Number PART NO. Weight

MOTOR, K1980 HOIST

4100XPB, XPC ( 120T ) 1 EBM1822F1 19,300

MOTOR, K-1690 HOIST

4100XPB, XPC, 4100A 1 EBM1705F1 16,600

MOTOR, K-1690 HOIST

4100TS 1 EBM1705F1 16,600

MOTOR, K1690B HOIST R50400D1

4100XPB, 4100BOSS 2 R50400D2 18,300
R50400D3
MOTOR, MPK1690 HOIST,AFT
4100A 2 83010-1 21,500

MOTOR, K-1250, HOIST

4100A, 2800XPB 1 EBM1747F1 15,150

MOTOR, K-925, HOIST

2800XP/B/C 1 EBM1774F1 12,300

MOTOR, K-700, HOIST

2300XP/B 1 EBM686F1 10,670

Table 1

Diagram
DESCRIPTION Number PART NO. Weight

MOTOR, K-700B CROWD

4100XPB, XPC, 2800XPC 9 EBM1687F1 11,000

MOTOR, K-700, CROWD

4100A ,4100TS 5 EBM1155F1 10,700

MOTOR, K-700, CROWD

4100TS, 4100A, 4100BOSS 5 EBM1686F1 10,700

MOTOR, K-489, CROWD

2800XP/B 6 EBM1706F1 6,800

MOTOR, K-408, CROWD

2300XP/B 6 EBM1834F1 6,300

Table 2

2
 Diagram
DESCRIPTION Number PART NO. Weight

MOTOR, K-558A, SWING

4100 XPB,XPC 7 EBM1498F1 7,300

MOTOR, K-558A, SWING

4100A, 4100TS, 2800XP/B/C 8 EBM1498F1 7,300

MOTOR, K-558A, SWING

4100TS 8 EBM1498F1 7,300

MOTOR, K-287, SWING

2300XP/B 8 EBM1643F1 3,870

Table 3

Diagram
DESCRIPTION Number PART NO. Weight

MOTOR, K-558B PROPEL

4100A. 4100TS 3 EBM1153F1 7,700

MOTOR, K-558B PROPEL

4100A, 4100TS, 4100BOSS 3 EBM1618F1 7,700

MOTOR, K-408 PROPEL

2800XP/B/C, 2300XP/B 6 EBM1834F1 6,300

MOTOR, K-700B PROPEL

4100XPB, XPC 4 EBM1687F1 11,000

Table 4

3
Air Removable covers for optional side
Inlet air discharge (both sides of motor)

Air Discharge

Diagram 1

4
Air
Inlet

Air Discharge

Diagram 2

5
Remove these covers for exhaust elbow
Assembly (Air Exhaust)

Diagram 3

6
 Apply exhaust screen or
elbow

Cover applied for propel

application
Diagram 4

7
Air Discharge
Air inlet

Diagram 5

8
Air Discharge Air inlet
(bottom) (bottom)

Diagram 6

9
Air Discharge
Air Inlet

Diagram 7

10
Air Inlet Air Discharge

Diagram 8

11
Cover applied for Crowd
application only

Cover applied for Crowd

application only

Apply cover both sides for

Crowd application

Crowd inlet Crowd exhaust

(no cover) (no cover)

Crowd inlet

Diagram 9

12
 

7DE

Service1RWLFHV
Boom Wear Box Inspections Electric Shovel Service Notice 026

Service Notice

Subject: Boom Wear Box Inspections

Document ID: SN-ES-026 Version: 00
Product Code: 1151 Date: November 03, 2009
Models Affected: All 4100 Series and 2800 XPB/C Shovels
Applicable to Assembly: Boom Structure
P&H Product Support Department Electric Mining Shovels

1.0 Introduction

Boom wear boxes should be inspected. This inspection criterion will help determine when the wear boxes
should be repaired.

2.0 Purpose

The Purpose of this Service Notice is to provide clarification of the boom wear box inspection procedure.

3.0 Discussion

3.1 General

The term “boom wear box” refers to the two parts of the boom that come in contact with the dipper
handle legs. Items 2 in Figure 1 below show the boom wear boxes on a shovel boom.

LEGEND:
01. Boom Assembly
02. Boom Wear Box (1 Each
Side of Boom)
03. Nominal Width
04. Machined Surface
(Reference Point)

Figure 1: Boom Wear Boxes

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SN-ES-026.doc Page 1 of 4 SN-ES-026, Version 00 – 11/09
Boom Wear Box Inspections Electric Shovel Service Notice 026

A reference measurement used for the boom structures of P&H electric shovels is the nominal width of the
boom, see item 3 of Figure 1. The standard nominal width of the shovel boom for all P&H 4100 Series and
2800 XPB/C shovel models is 89.5 inches (2273.3 mm). The nominal distance between the dipper handle
legs on these shovels is 90 inches (2286 mm). These nominal dimensions assume new structures; there
are tolerances to each of these nominal measurements.

Other shovel models and older 2800 shovel models have narrower booms, and narrower handle
assemblies. Adjust the following inspections to match the nominal width of the particular shovel
model being inspected. This nominal width can be measured from the outer plates of the wear
boxes across the boom as shown in Inspection A of this Service Notice.

Wear boxes will experience wear over time because they form the widest portion of the boom and are the
areas that contact the dipper handles. Structural damage to the wear boxes can also occur from impacts
with the dipper handles.

Damage from impacts often occurs because the saddle blocks and shipper shaft have not been
adjusted as specified. Improper operator techniques such as swinging while the dipper is engaged
with the bank or sweeping the pit floors with the dipper can also cause impact damage.

If the width of the boom becomes too small due to wear or damage of the wear boxes, it will allow
excessive lateral movement of the dipper handles causing the shipper shaft, pinions, and the saddle blocks
to experience damage or rapid wear.

The boom wear boxes should be inspected at every major boom inspection. Past inspection guidelines for
the wear boxes have involved measuring the width of the boom.

Another reference used in the past is to measure the distance between the handle and the boom wear box
on each side of the boom and use these two measurements to determine the amount of wear. This can be
misleading, as the dipper handles may also be worn or damaged. Using this type of measurement is not
recommended for wear box inspections.

The inspection guidelines contained in this Service Notice should be used for all P&H 4100 series and
2800XPB/C electric shovels going forward. Disregard any inspection guidelines found in previous Service
Bulletins or Maintenance Manuals.

3.2 Wear Box Inspection

Use the following Inspections A and B to inspect the boom wear boxes.

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Boom Wear Box Inspections Electric Shovel Service Notice 026

Inspection A – Overall Width of the Boom

Inspection A uses simple measurements to determine the boom’s nominal overall width and the overall
width at the area of most wear on the boom.

1. First, determine the nominal width of the boom by measuring across the boom (see item 03 of
Figure 1) at an area where the wear boxes have experienced little or no wear (usually near the end
of the wear boxes). As noted in section 3.1, the nominal width of all 4100 series and 280XPB/C
shovels is 89.5 inches (2273.3 mm).

At the extreme ends of the wear boxes, the boom wear box width tapers off. Do not make any
measurements in this tapered area.

2. Second, locate the area on the boom wear box outer plates (the plates that contact the dipper
handles) that has experienced the most wear, usually in the center of the wear boxes where the
handles are located during the dig and swing cycles. Measure across the boom where the wear
boxes have experienced the most wear. Perform this measurement in several places to ensure that
the area of most wear has been measured.

a. If a boom with a nominal width of 89.5 inches (2273.3 mm) is measured to be 89 inches (2260.6
mm) or larger in the area of most wear, the boom wear box inspection is complete. No repair is
needed at this time.

b. If 88.5 inches (2247.9 mm) or smaller, the boom wear boxes should be repaired.

c. If the measurement is between 89 inches (2260.6 mm) and 88.5 inches (2247.9 mm), continue
with the more detailed Inspection B below.

It is possible to have one side of the boom with greater than .5 inch (12.7 mm) wear or damage
while the other side has only slight wear or damage. If the measurement is between 89 inches
(2260.6 mm) and 88.5 inches (2247.9 mm), each side should be inspected as shown in Inspection
B.

Inspection B – Detailed Inspection

The boom has a nominal width of 89.5 inches (2273.3 mm). If the boom is measured from the boom
centerline to the outer edge of the boom wear box on either side, ½ of the nominal width of the boom
would be 44.75 inches (1136.65 mm) – these measurements can be seen on the bottom of Figure 2. If the
measurement from the centerline of the boom to the outer plate of the wear box is found to be less than
44.25 inches (1124 mm) on either side, the wear boxes on both sides of the boom should be repaired.
This would be .5 inch (12.7 mm) of wear or damage on either side. Reference measurements will allow
each side to be measured without determining where the centerline is.

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SN-ES-026.doc Page 3 of 4 SN-ES-026, Version 00 – 11/09
Boom Wear Box Inspections Electric Shovel Service Notice 026

Use the machined surface of the boom

indicated as item 04 in Figure 1 on each
side of the boom as a reference point. The
distance between these machined surfaces
(distance A on Figure 2) for any 4100
series shovel should be 81.0 inches
(2057.4) (again there are machine
tolerances but we will use this dimension).
½ of the nominal width of the boom would
be 44.75 inches (1136.65 mm). If the
measurement from the centerline of the
boom to the outer plate of the wear box is
found to be less than 44.25 inches (1124
mm), the wear boxes on both sides of the
4100 series shovel should be repaired.
Measure the distance to the outer plate of
the wear box from the machined reference
surface. When measured as shown in
Figure 2, if dimension B is measured to be
less than 3.75 inches (95.25 mm) on
either side, the wear boxes for a 4100
series shovel should be repaired.
Figure 2: Cross Section of 4100 Series Boom

2800XPB/C shovels have a dimension A of 79 inches (2006.6 mm) between the machined surfaces shown
on the top of Figure 2. Substitute 79 inches when performing Method 2 for a 2800XPB/C shovel. ½ of the
nominal width would be 44.75 inches (1136.65 mm). When measured as shown in Figure 2, if dimension B
is measured to be less than 4.75 inches (120.65 mm) on either side, the wear boxes for a 2800XPB/C
shovel should be repaired.

A laser tool can be used to make measurements as shown in Figure 2. For shovels other than 4100 series
or 2800XPB/C, the laser tool could be used to measure a distance like the Dimension A shown on Figure 2,
which can then be used as a reference for calculating the centerline of the boom. Once the centerline is
calculated, use .5 inch (12.7 mm) of wear on either side as the repair criteria for the wear boxes.

Repair of wear boxes involves removing the old plate and welding a new plate in place. Cracks should be
repaired when they are found. Additional internal stiffeners can be added to wear boxes to help prevent
damage from impacts. Contact your P&H MinePro Services representative for further information or
assistance. Ultrasonic inspection (UT) can also be used to inspect the thickness of plates.

4.0 Conclusion

Boom wear boxes should be inspected. Use the inspection criteria shown in this Service Notice for 4100
series and 2800XPB/C shovels.

5.0 Actions

Keep a copy of this Service Notice with the Mechanical Maintenance Manual and inform maintenance
personnel that this procedure clarifies and supersedes the procedure in the manual.

Copyright © 2009 P&H Mining Equipment, Inc. P&H Product Support

SN-ES-026.doc Page 4 of 4 SN-ES-026, Version 00 – 11/09
SUBJECT: Mine Air Systems Blower Pack Extension NOTICE: SN-ES-021
MODELS AFFECTED: All VERSION: 00
APPLICABLE TO ASSEMBLIES: MAS 1500 Units (P&H DATE: 17 September,
R52590D_, MNM150-MXH-01, and NPMNM150-SXH-01) 2008
SPECIAL NOTE: PRODUCT CODE: 1094

1.0 Introduction

P&H Mine Air Systems has identified an upgrade to MineAir Systems (MAS) 1500 unit blower packs
that increases heater element life and heating capacity.

2.0 Purpose

The purpose of this Service Notice is to identify an upgrade kit that has been released for the
blower packs on MAS 1500 units.

3.0 Discussion

3.1 General

MAS 1500 units have used the following assembly part numbers: R52590D_, MNM150-MXH-01,
NPMNM150-SXH-01. This kit should be applied to all MAS 1500 units shipped prior to August 2008.
The blower pack for the MineAir MAS 1500 Unit is shown in Figure 1.

LEGEND:
01. Mounting Angle
02. Blower Pack Base
03. High Limit Switch

Figure 1: Blower Pack Before Installation of Extension Kit

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Mine Air Systems Blower Pack Extension Electric Shovel Service Notice Number 021

The subject kit provides an extension to the blower pack that will fit under the unit shown in Figure
1. This extension kit will change the air flow through the heating elements. Apply kit (P&H Part
Number) NPMNMA-15-001-A-RF to all MAS 1500 units shipped prior to August 2008.

This kit can also be ordered directly from P&H Mine Air Systems. Figure 2 shows the materials
included in the kit. The details of these materials can be found in the parts list included with the kit.
The kit also includes one tube of high temperature silicon (not shown in Figure 2).

LEGEND:
01. Flat Washer (Qty 24) 04. Hex Head Capscrew (Qty 6) 07. Flat Washer (Qty 2)
02. Lock Washer (Qty 6) 05. Machine Screw (Qty 2) 08. Cap Screw (Qty 6)
03. Nylock Nut (Qty 12) 06. Lock Washer (Qty 2) 09. Blower Pack Extension

Figure 2: Blower Pack Extension and Hardware Kit

3.2 Blower Pack Removal and Disassembly

Follow these steps to remove the blower pack from the MAS 1500 unit.

Ensure that the shovel has been shut down and that proper park-up procedures have
been used. Disconnect the breaker that supplies power to the MineAir unit and
perform lockout/tagout to prevent power from being applied while work is being
performed on the unit.

1. Disconnect the blower pack cable ends, P1 and P2 from the underside of the electrical box
(see Figure 3). Figure 4 shows a schematic of the unit.

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Mine Air Systems Blower Pack Extension Electric Shovel Service Notice Number 021

Figure 3: Cables P1 and P2

Figure 4: Schematic
2. Remove the blower pack from the unit. Make sure that the high limit switch (item 03, Figure
1) does not bang against the evaporator coil.

3. Remove left and right mounting angles (item 01, Figure 1) and set aside for later use.

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4. Disconnect wires from the high limit switch: disconnect wire #37 from the NC terminal and
the COMMON wire from the Common terminal (see Figure 5). Note that there have been
three different vintages of the high limit switch used on MAS 1500 units, each of which is
shown in Figure 5.

Figure 5: High Limit Switch Connections

5. Remove the high limit switch from the blower pack and set aside the switch and the #8
hardware (items 5, 6, and 7 in Figure 2) for later use.

6. Remove the heat rack from the blower pack.

7. Unscrew L1, L2, and L3 from the heater rack (see Figure 6).

Figure 6: Heater Rack Electrical Detail

8. Set aside the heat rack (see Figure 7) for re-install at later stage.

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Figure 7: Heat Rack

3.3 Extension Kit Assembly and Installation

The extension kit (see Figure 2) and its hardware can now be attached to the base of the blower
pack. Figure 8 shows the extension kit being attached onto the blower pack.

Note: Item numbers are the same as listed in Figure 2.

Figure 8: Extension Kit Attachment

The capscrews (item 8, Figure 8) must be installed with the head on the inside and
nylock nut on outside as shown in both Figures 2 and 8. If the capscrew is installed in
the other direction, it could cause a short circuit by contacting the heater elements.

1. Mount the extension kit onto the blower pack as shown using the hardware from the kit and
also the #8 hardware (items 5, 6, and 7 in Figure 2) previously removed. Make sure the
capscrews (item 8) are installed correctly as called out in the CAUTION above.

2. Prior to mounting the heat rack, hook up L1, L2, and L3 ensuring the screws are tight (see
Figure 6).

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3. Mount the heat rack in the extension using the hardware as shown in Figure 9. Attach the
angles that were previously removed. Pay attention to the location of the capscrews (item 8,
Figure 8) to make sure they do not contact the heating elements when the rack is installed.

Figure 9: Heat Rack and Angles Installation

4. Reconnect the high limit switch: reconnect wire #37 to the NC terminal and the COMMON
wire to the COMMON terminal as shown in Figure 5.

5. Mount the high limit switch to blower pack extension using machine screws and washers (5,
6, and 7) as shown in Figure 8.

6. Apply the high temp silicone included with the kit all around the seam between the blower
pack and the extension.

7. Reconnect the blower pack cable ends P1 and P2 (see Figures 3 and 4) back into the
sockets on the underside of the electrical box.

8. Install the blower pack back into the MAS 1500 unit, taking care that the high limit switch
does not bang against the evaporator coil.

9. Mount the blower support brackets as shown in Figure 10 using the existing blower pack
and coil mounting hardware. There are two different brackets: one for the side near the gas
powered strut (11) and one for the hinge side (12). Slight modification (bending) of the
support brackets may be necessary for correct fit-up.

10. Undo the lockout/tagout and test the unit. To test, use an ohm meter and take readings as
shown below:

OHM Readings: L1-L2 Æ (P1) F-E Æ 25 ± 5 Ω

L2-L3 Æ (P1) E-D Æ 25 ± 5 Ω
L3-L1 Æ (P1) D-F Æ 25 ± 5 Ω

If your readings are not as indicated above, check the connections of L1, L2, and L3, check
the heat rack, then retest the unit. If your readings still are not as indicated above, then
contact your local MinePro office for assistance.

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Figure 10: Blower Pack Support Brackets

4.0 Conclusion

The kit shown in this Service Notice will increase heater element life and heating capacity of the
blower pack. It should be installed before the cold season.

5.0 Actions

P&H Mine Air Systems recommends that this kit be installed on all MineAir Systems (MAS) 1500 unit
blower packs that were shipped prior to August 2008.

Copyright © 2008 P&H Mining Equipment, Inc. P&H Product Support

SN-ES-021.doc Page 7 of 7 SN-ES-021, Version 00 – 09/08
SUBJECT: Hoist Gearcase Support Retainer Capscrew NOTICE: SN-ES-020
MODELS AFFECTED: 4100BOSS, 4100XPB, 4100XPC VERSION: 00
APPLICABLE TO ASSEMBLIES: See in Discussion DATE: 09 September, 2008
SPECIAL NOTE: PRODUCT CODE: 1233

Introduction

There have been reports of failures of the retaining capscrew in the inclined wedge hoist gearcase
support. A replacement capscrew and new torque will be applied to this assembly in the future.

Purpose

The purpose of this Service Notice is to inform of a change in the part number of the retaining
capscrew in the gearcase support assembly and the corresponding new torque.

Discussion

R57939F_ is the gearcase support assembly used on 4100XPB/C shovels and 4100 BOSS shovels.
For the hoist gearcase module R58671F2 (4100C BOSS AC shovels), the gearcase support is part of
the BOM of the gearcase module.

The part in question is the .5” capscrew used to retain the round lock plate. This capscrew is shown
in Figure 1 indicated by the arrow.

Figure 1: Hoist Gearcase Support (R57939F_) Retainer Capscrew

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The original fastener on R57939F_ was a 20Z1703D99, grade 5 flange head locking screw (see
Figure 1). The R58671F2 gearcase module (see Figure 2) calls out grade 5 hex head capscrew
20Q260D328 (item 06) and hardened washer 18Z694D6 (item 07).

LEGEND:
01. Warning Sign
02. Wedge
03. Lock Plate
04. Lower Block
05. Hex Head Capscrew (Jack
Screw)
06. Retainer Capscrew
07. Hardened Washer
08. Shim Plates
09. Right Keeper (shown)
10. Left Keeper (opposite)

Figure 2: Gearcase Support (from Module R58671F2)

The grade 5 fastener will be upgraded to a 0630V081 socket head capscrew (SHCS) for either
gearcase support. Figure 3 shows a generic drawing of a SHCS. The 18Z694D6 hardened washer
should be used with this socket head capscrew in this application.

Figure 3: Socket Head Capscrew (SHCS)

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The material make-up of the 0630V081 socket head capscrew is a high grade (A574). The new
torque for the socket head capscrew is 108 ftlb (146 Nm) "dry".

Do not torque the original grade 5 capscrew to this higher torque value as the torque
is too great for that particular fastener.

If the retainer capscrew has broken loose, the support assembly will have to be reset before
installing the new capscrew.

If one gearcase support moves then the rest of them should be checked and the retainer
capscrews upgraded as a group.

Figure 4 shows an exploded view of the components of the R57939F_ gearcase support assembly.

LEGEND
01. Hex Head
Bolt (Jack
Screw)
02. Flange
Locking
Screw
03. Lock Plate
04. Retainer
05. Lower Block
06. Wedge
07. Upper Block
08. Shim
09. Caution Sign
(Not Shown)

Figure 4: Gearcase Support Assembly Components (R57939F_)

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Use the following steps to install a gearcase support (see Figure 4):

The following procedure is similar for either the gearcase support in Figure 2 or Figure 4.
The torque values and measurements given are common to both. Note: there is no upper
block in Figure 2, the upper face of the wedge fits against the bottom of the gearcase.

1. Lube the sliding surfaces of the lower block, wedge, and upper block and the large jack bolt
threads with anti-seize.

2. Insert the jack screw and turn 6 turns (approximately 1 inch or 25 mm) into wedge.

3. Add shims under lower block until top of block is within 1/8” (3 mm) of gearcase.

4. Turn the jack screw to raise the block until tight against gearcase in all 4 locations.

Jack screw torque should not exceed 386 ft. lbs. (523 Nm).

5. Torque the jack screw to 386 ft. lbs. (523 Nm). Do not exceed this torque.

6. Lock the jack screw using the retainer, lock plate, and new socket head capscrew 0630V081
(item 2) and hardened washer 18Z694D6. Torque the socket head capscrew to 108 ftlb
(146 Nm) "dry".

7. Weld keeper (shown in phantom in Figure 4) in place around the bottom of the block to
prevent movement.

Conclusion

Installing a 0630V081 socket head capscrew as the retainer capscrew in the gearcase support
assembly will allow a higher torque to be applied. This will provide greater strength to the retainer.

Actions

Install 0630V081 socket head capscrews as directed in the Discussion above. Apply these
capscrews as needed to retain the gearcase support assemblies on the affected shovel models.

Copyright © 2008 P&H Mining Equipment, Inc. P&H Product Support

SN-ES-020.doc Page 4 of 4 SN-ES-020, Version 00 – 09/08
SUBJECT: Latch Upgrade Kit for Mine Air Units NOTICE: SN-ES-17
MODELS AFFECTED: MAS 400, 1000, and 1500 units VERSION: 00
APPLICABLE TO ASSEMBLIES: R52590D_, R35715D_,
DATE: November 18, 2008
R56709D_
SPECIAL NOTE: PRODUCT CODE: 1094

Introduction

P&H Mine Air Systems has released an upgrade kit for an improved adjustable latch for the Mine Air
Units. These latches can be used on MAS 400, 1000, and 1500 units. The adjustable latches can be
tightened to provide better tension on lids to improve performance under vibration. This Service
Notice identifies the kit that can be ordered to replace the original latch with the new adjustable
latch.

Purpose

To upgrade standard latches to adjustable latches on MAS 400, 1000, and 1500 units to provide
better tension on lids.

Discussion

Typically MAS 400, 1000, and 1500 units manufactured prior to September 2007 would have been
equipped with the original non-adjustable latches.

For each MAS 400, 1000, or 1500 Unit: Order P&H part number NPMN20-00-000, quantity
of 6 (one kit contains one latch and hardware).

Figure 1: Original Latch – Non-Adjustable

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Figure 2: New Latch - Adjustable

Kit Installation Procedure

1. Fasten plate (see item 1 in Figure 3) to case with #10 screws (see item 6, quantity 2), using
existing holes.

Figure 3: Latch Kit Installation

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2. Drill 2 holes, ¼” diameter, using the lower holes in the plate as a template.

3. Fasten latch and bottom of plate using #8 screws (see item 3, quantity 2).

Conclusion

The upgrade kit will allow the non-adjustable latches on MAS 400, 1000, and MAS 1500 units to be
replaced with adjustable latches as shown in the Discussion above.

Actions

Upgrade standard latches to adjustable latches on MAS 400, 1000, and 1500 units to improve the
tension that the latches provide on the lid.

Copyright © 2008 P&H Mining Equipment, Inc. P&H Product Support

SN-ES-17.doc Page 3 of 3 SN-ES-17, Version 00 – 11/08
SUBJECT: Importance of Lubricating Couplings NOTICE: SN-ES-016
MODELS AFFECTED: All Models VERSION: 00
APPLICABLE TO ASSEMBLIES: Gear Couplings DATE: 14 May, 2008
PRODUCT CODE: 1020,
SPECIAL NOTE:
1021, 1022

Introduction

Lubrication has the biggest impact on the overall performance and life of a gear coupling. This
Service Notice will discuss lubrication of couplings on P&H mining shovels.

Purpose

Provide lubrication information for gear couplings on P&H mining shovels.

Discussion

Lubrication has a big impact on the overall performance and life of a gear coupling. Correct
interval, method, and grease specification should be followed to ensure long life of a gear coupling.
Lack of lubrication can cause rapid wear and failure of a gear coupling.

At installation the coupling must be greased with the correct amount of lubricant. First, coat the
gear teeth of the hubs and the sleeves with grease before final installation. This ensures that at
initial start-up the gear teeth are operating on a film of lubricant. Some studies have shown that
this alone can significantly increase the life of the coupling. After installation, pump the correct
amount of lubricant into the coupling before operation.

A good rule of thumb for proper lube amount is to place the lube plugs, usually drilled 180 degrees
apart on the flange, on the horizontal. Remove both lube plugs and fill from one side. When
lubricant begins to discharge from the opposite lube port, there is sufficient grease in the coupling
and the lube plugs can be reinstalled. The correct amount of lubricant required for each individual
coupling can be obtained from the manufacturer if a question arises.

Stored system pressure can cause severe personal injury or death. Always expect
that every component of an air, lube or hydraulic system could be pressurized at any
time. Take steps to assure that the pressure is safely relieved before attempting to
perform any work on the system or a component that is or was connected to one of
these systems, such as the manually lubricated coupling assembly being referred to
in this Service Notice.

A coupling has an open plug used for venting pressure as grease is pumped into the cavity of the
coupling. When greasing the coupling, confirm that air and lubricant is purging from the vent hole.

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If purging is not occurring, assume the cavity contains stored energy and take appropriate
hazard control steps to relieve the pressure or investigate potential blockage, before
continuing greasing or lubrication operation.

A typical gear coupling will have lubrication holes on the flange of each coupling half. Each half
must be greased, as the grease from one side will not flow over to the other coupling half.

Just as too little grease can cause the coupling to fail, too much grease can impede the circulation
of the lubricant within the coupling. The grease will not be able to circulate through the gear mesh
and dissipate the heat. It is not uncommon for a failed coupling to have clean grease on either side
of the gear mesh, while the grease in the mesh has separated and broken down. This is an
example of over lubrication. This is more common in P&H applications on couplings equipped with
o-rings rather than grease seals, as the o-rings have more tendencies to trap hydraulic pressure in
the coupling.

As regular maintenance, P&H recommends that all gear couplings be greased using the above
method every 1000 machine operating hours.

The reference to hours is total machine operating hours, not individual motor hours. This
includes the propel motor coupling, which should be greased every 1000 machine operating
hours, not propel hours.

The type of lubricant recommended for gear couplings is P&H specification 472: Multipurpose
Grease, Extreme Pressure (EP). This material specification defines using NLGI grade grease: “The
preferred grade is NLGI #2. However, an NLGI #1 or #0 may be required for proper dispensing at
low temperatures.” Specification 472 further states: “A lithium complex synthetic grease which
meets the requirements of P&H 472B is the preferred grade for all temperature ranges. A lithium
complex non-synthetic grease that meets the requirements of P&H 472C is a suitable alternative. At
lower temperature ranges, a lithium complex non-synthetic grease which meets the requirements
of P&H 472A or P&H 472B may be recommended by the lubricant supplier.”

A complete copy of P&H specification 472 can be obtained from P&H upon request.

Conclusion

Couplings should be greased using the correct interval, method, and grease specification.

Actions

Lubricate couplings as specified in this Service Notice.

Copyright © 2008 P&H Mining Equipment, Inc. P&H Product Support

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SUBJECT: Auxiliary Transformer Removal NOTICE: SN-ES-15
MODELS AFFECTED: 4100XPB, 4100XPC VERSION: 00
APPLICABLE TO ASSEMBLIES: Kit R63946F1 DATE: 13 May, 2008
PRODUCT CODE: 1206,
SPECIAL NOTE:
1004

Introduction

To assist in the removal of the Auxiliary Transformer from a 4100XPB/C shovel, a Rear Panel
Removal Kit (R63946F1) has been developed. This allows for the plenum weight to be removed
from the rear wall panel so that the wall panel adjacent to the auxiliary transformer can be
removed.

Purpose

This Service Notice documents a procedure to accompany kit R63946F1. The kit is used to modify
the shovel’s rear wall panels and beams to allow removal of the auxiliary transformer.

Discussion

To assist in the removal of the Auxiliary Transformer, a Rear Panel Removal Kit (R63946F1) has
been developed. This kit provides brackets to be used for the procedure detailed here. The
brackets help to remove the plenum weight from the rear wall panel. Figure 1 shows the location of
the transformer, the breaker cabinet that is attached to it, and the counterweight that must be
removed.

LEGEND:

A. Auxiliary
Transformer
B. Breaker Cabinet
C. Counterweight (to
be removed)

Figure 1: Location of Transformer

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Follow this procedure to remove the auxiliary transformer:

1) Before performing maintenance, the shovel should be parked properly and shut down. P&H
general recommendations are:

• Move the shovel away from the high wall to a solid and level area. In this instance,
also make sure that there is plenty of room in the area of the rear walls to allow
access for lifting and removal equipment.

• Position the shovel so that the revolving frame is in position with the crawler side
frame to allow the stairway to be lowered.

• Lower the dipper until it is resting on the ground. Set the hoist brakes with the bail
raised. Use caution that the hoist ropes are not damaged by the bail being lowered.

• Press the STOP button on the operator’s console. Lock out and tag out operator
controls as prescribed by applicable regulations and by local policy.

• Place barricades around the work area to prevent other personnel from working near
or under the work area while maintenance activities are taking place.

Contact with energized electrical circuits can cause serious injury or death. Always
use lockout and tagout procedures to disconnect power prior to shovel maintenance
or repair.

2) Perform lockout and tagout.

3) Remove all the wiring attached to the auxiliary transformer (labeled A in Figure 1), fire
suppression, and the auxiliary transformer brace. Tip up the floor cable tray (see Figure 2).
Tie up the cable trough, which is mounted to the rear side panel, to the plenum and remove
the mounting bolts.

Figure 2: Floor Cable Tray Tipped Up

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4) There is a small breaker cabinet (see Figure 3) attached to the side of the auxiliary
transformer. This breaker cabinet will be attached to the new transformer. The breaker
cabinet can be removed from the transformer before removing the transformer (thus not
having to remove wiring leaving the cabinet) or after removing the transformer. If removed
before transformer removal, disconnect the cabinet now and lean it off to the side.
Alternatively, remove the transformer and circuit breaker cabinet as an assembly and
reattach the circuit breaker cabinet to the new transformer prior to reassembly.

5) Cut the welds that attach the transformer to the counter weight box (see Figure 3).

Breaker Cabinet

Transformer
Mounting

Figure 3: Transformer Mounting

6) Pull the transformer away from the wall to get access to the wall bolts for removal.

7) Cut the lower front edge of the rear side panel (by house “I” beam) to remove a small
rectangular piece from the bottom. Figure 4 shows the panel after the piece has been
removed (red dashed line shows original, blue dashed line shows where it was cut). This will
allow the panel to slide over the floor-mounting angle. On new build shovels the panel has
been changed so that this piece is not included so no cutting is needed here.

Figure 4: Rear Side Panel After Removal

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8) Figure 5 shows the rear side panel (01) as it is fastened to the floor-mounted angle (03).
The angle is welded to the counterweight box and will not be removed. The panel may be
welded to the angle and the counterweight box along the outside edge where the weld
symbol is shown. If so, this weld will have to be removed before removing the panel (see
step 13). When the panel is loose, it will have to be slid rearward to come out from behind
the house side panel and catwalk kick plate (see step 15).

LEGEND:

01. Rear Side Panel

02. Bolt
03. Floor Mounted
Angle

Figure 5: Rear Side Panel

9) Remove the bolts on the rear roof beam on the left and the RPC cabinet brace.

10) Remove the rear side panel floor and plenum bolts. Loosen the plenum to rear wall bolts
around to where the house fans are. This relieves some pressure on the rear side panel.

11) Center a 10 Ton hydraulic jack on each of the two support brackets located at the front
right corner and rear corner of the plenum (these are the two brackets that were added
with kit R63946F1). Apply 20 Ton lifting load to the plenum.

There will not be a gap between the top of the right rear panel and the plenum after
applying the lifting load.

12) Remove the right rear corner counter weight from the machine (this is labeled C in Figure
1). Also remove rear hand railing to allow for easier removal of wall and transformer.

13) Cut the weld along lower edge of the rear wall, if rear wall has been welded to the
counterweight box or the floor mounted angle.

14) Use lifting lugs on rear wall panel to hold panel in place during removal. Figure 6 shows the
wall being supported by a crane. Note the counter weight has been removed to ease the
removal of the wall panel.

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Figure 6: Rear Wall Panel Removal

Use guidelines and recommendations provided by the lifting equipment OEM when
lifting loads. Be sure lifting equipment capacity exceeds the weight of the component
being lifted and the lifting equipment is securely attached to the component being
lifted. Stay clear when lifting, lowering, or moving components with lifting equipment.
The right rear wall panel weighs approximately 3000 lbs (1360 kg).

15) The wall needs to come back before it can be removed because of the sidewall overlap and
the catwalk. Push the wall panel out from the opening and remove.

16) The right side catwalk handrail can be removed for transformer clearance.

Use guidelines and recommendations provided by the lifting equipment OEM when
lifting loads. Be sure lifting equipment capacity exceeds the weight of the component
being lifted and the lifting equipment is securely attached to the component being
lifted. Stay clear when lifting, lowering, or moving components with lifting equipment.
The auxiliary transformer weighs approximately 5000 lbs (2270 kg).

17) Use a forklift to remove the transformer from right rear opening. Figure 6 shows a forklift
being positioned to remove the transformer.

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Figure 7: Removing Transformer

18) If the breaker cabinet was not removed from the old transformer, remove it now and attach
it to the new transformer.

19) Use the forklift to lift the new auxiliary transformer into the panel opening. Review the
Warning about lifting equipment that precedes step 17.

20) Position the wall vertical and start it into position behind the catwalk. The wall can be pulled
forward with come-alongs (1 on top and 1 on the bottom). The forklift can be used to pull
the wall out or push it in depending on where the top bolts lined up. Review the Warning
about lifting equipment that precedes step 15. Install and torque all bolts. Figure 5 shows
the correct weld symbol for the bottom of the panel, it should be a full butt weld to fill in
the void between the panel and the counterweight box. This will help prevent the panel
from shaking loose.

21) Pull the transformer back into position with come-a-longs and weld it. The same auxiliary
transformer top is used so the cabinet brace alignments should be checked prior to welding
the transformer to the counter weight box.

22) Reinstall the counter weight and handrail. Reinstall the bolts on the rear roof beam and the
RPC cabinet brace.

23) Reinstall the fire suppression, aux transformer brace, and the floor cable tray. If not
already done, attach the breaker cabinet to the transformer. Rewire the auxiliary
transformer. Install the mounting bolts for the cable trough to the rear side panel.

Conclusion

Application of the brackets detailed in kit R63946F1 will ease the removal of the transformer. This
kit can be applied before it is necessary to remove the transformer. The procedure shown in this
Service Notice can be used to remove the transformer.

Actions

Kit R63946F1 can be applied to all existing 4100XPB and 4100XPC shovels as needed to help
remove the auxiliary transformer.

Copyright © 2008 P&H Mining Equipment, Inc. P&H Product Support

SN-ES-15.doc Page 6 of 6 SN-ES-15, Version 00 – 05/08
SUBJECT: Rear House Wall to Counterweight Box Weld NOTICE: SN-ES-012
MODELS AFFECTED: 4100XPB, 4100XPC, 4100C,
VERSION: 00
2800XPC
APPLICABLE TO ASSEMBLIES: R61110F1, R45399,
DATE: 5 August, 2008
R54040, R58770, R56217,
SPECIAL NOTE: PRODUCT CODE: 1004

Introduction

The weld symbol on the assembly drawings showing the connection of the rear house wall to the
top of the counterweight box has been misread in the past. Engineering has clarified the weld type
that should be applied.

Purpose

The purpose of this Service Notice is to provide clarification to the type of weld used to secure the
Rear House Wall to the top of the counterweight box.

Discussion

The weld symbol on the assembly drawing is shown in Figure 1 below. The symbol for this weld
used to secure the floor mounted jacking angles to the counterweight box specified for the outside
edge of the weld to be a continuous, fully welded joint. The symbol also specified a 3 – 7 skip weld
for the inside edge. On some shovels the skip weld has been inadvertently applied to the outside
edge. This could lead to weld failure.

LEGEND:

01. Rear Wall Panel

02. Bolt Assembly
03. Floor Mounted
Jacking Angle

Figure 1: Rear Wall Panel Weld Symbol (from R61110F1)

Copyright © 2008 P&H Mining Equipment, Inc. P&H Product Support

SN-ES-012.doc Page 1 of 3 SN-ES-012, Version 00 – 08/08
Rear House Wall to Counterweight Box Weld Electric Shovel Service Notice Number 012

To provide further clarification to the weld symbol, the text “Full Butt Weld on Outside” is being
added to the assembly drawings, as shown in Figure 1.

The jacking angles are welded to the counterweight box and the wall panels are bolted to the
jacking angles and also bolted to each other. The angles are referred to as jacking angles, because
the washers in the bolt assembly (item 2, Figure 1) can be placed between the angle and the
flange of the wall to lift up the wall for leveling purposes. The components of a full rear wall
assembly can be seen in Figure 2.

LEGEND: 05. Right Center Panel 10. Jacking Angle

01. Left Panel 06. Jacking Angle 11. Shim
02. Center Panel 07. Jacking Angle 12. Hex Head Cap Screw
03. Right Panel 08. Jacking Angle 13. Self Locking Nut
04. Left Center Panel 09. Jacking Angle 14. Plain Washers
Figure 2: Rear Wall Components

Copyright © 2008 P&H Mining Equipment, Inc. P&H Product Support

SN-ES-012.doc Page 2 of 3 SN-ES-012 DRAFT, Version 00 – 08/08
Rear House Wall to Counterweight Box Weld Electric Shovel Service Notice Number 012

The full weld on the outside of this joint should be applied to new shovel builds. It should also be
applied to existing machines if the weld must be redone or repaired.

Conclusion

Apply a continuous, fully welded joint to the outside of the jacking angles to secure them to the
counterweight box, as show in the weld symbol in Figure 1.

Actions

This Service Notice is for information purposes only, no action is needed unless welding the joint
called out.

Copyright © 2008 P&H Mining Equipment, Inc. P&H Product Support

SN-ES-012.doc Page 3 of 3 SN-ES-012 DRAFT, Version 00 – 08/08
SUBJECT: Hoist Drum Hub and Web Plates NOTICE: SN-ES-10
MODELS AFFECTED: All 4100 Models, 2800XPA,
VERSION: 00
2800XPB, 2800XPC
APPLICABLE TO ASSEMBLIES: R41000D1, R59389D1,
DATE: 28 March, 2008
718N320D1/D2, 718N416
SPECIAL NOTE: PRODUCT CODE: 1007

Introduction

On each end of the hoist drum is a hub that the hoist drum shaft passes through. This hub is
welded into the web plates of the drum. The hubs, web plates, and the welds of the hoist drum
should receive regular weld and crack inspection using a magnetic particle (MT) or dye penetrant
(PT) test. To improve the fatigue resistance in this area it is recommended that the welds be
ground and blended smooth.

Purpose

To recommend weld inspection of the hub and web plates, for cracking on the hoist drum
assembly. Also the hub-to-web welds should be ground and blended smooth wherever access
allows.

Discussion

The hub area of the hoist drum is shown in Figure 1 below. The hoist drum has a hub on each end.

LEGEND:
1 1. Hub Area of
Drum

Figure 1: Hoist Drum Hub Area (Both Ends of Drum)

Copyright © 2008 P&H Mining Equipment, Inc. P&H Product Support

SN-ES-10.doc Page 1 of 4 SN-ES-10, Version 00 – 03/08
Hoist Drum Hub and Web Plates Electric Shovel Service Notice Number 10

When performing structural inspections of the shovel, an inspection of the hoist drum assembly in
the hub area should be performed. It also should be inspected thoroughly whenever the drum or
shaft has been removed, to allow for repairs before installing again. A general method would be as
follows:

1. Inspect using Magnetic Particle (MT) for cracks on the drum hub area external surfaces on
both ends of the drum. If MT is not available, use Dye Penetrant (PT). If the shaft has been
removed, then inspect the internal surface as well. The internal surfaces are more difficult
to access, but can be reached through the drum shaft hole.

2. If cracks are found, they should be gouged out and repaired. Contact your local MinePro
office for assistance on obtaining a repair procedure. If the cracks are deep or on the inside,
the web plate of the drum should be removed in order to repair.

3. Grind and blend the ENTIRE circumference of each of the welds between the drum hub and
web plate making it smooth and polished. Verify that all discontinuities are removed with
MT testing. Grind the drum on both ends, and the internal surfaces if possible. Again, try to
access them through the hole if the web has not been removed.

If no cracks are found during the inspection, it is still recommended to grind smooth the welds
wherever access permits as it provides significant increase to fatigue life.

Red Arrows Show Hub-to-Web Weld Areas

Figure 2: Location of Hub-to-Web Welds

Copyright © 2008 P&H Mining Equipment, Inc. P&H Product Support

SN-ES-10.doc Page 2 of 4 SN-ES-10, Version 00 – 03/08
Hoist Drum Hub and Web Plates Electric Shovel Service Notice Number 10

Figure 3 below shows the hub-to-web weld after it has been ground and blended.

Figure 3: Hoist Drum Hub-to-Web Weld

A tip for internal visual inspection: on the side of the drum opposite the gearcase, there are small
holes in the drum’s web plates (see Figure 3). Small covers are welded over these holes on the
finished drum (see Figure 4). By removing one or more covers, the internal side of the web plate
on the gearcase side of the drum can be viewed. A flashlight can be used to light the inside of the
drum. It may be possible to view some of the internal side of the web plate opposite of the
gearcase by using a small inspection mirror through the hole.

When viewing the inside of the web plate on the gearcase side, look for the presence of oil inside
the drum. Oil inside the drum could be a sign that the gearbox end of the drum hub is cracked and
oil is leaking into the drum from the gearcase.

Copyright © 2008 P&H Mining Equipment, Inc. P&H Product Support

SN-ES-10.doc Page 3 of 4 SN-ES-10, Version 00 – 03/08
Hoist Drum Hub and Web Plates Electric Shovel Service Notice Number 10

Figure 4: Cover for Hole in Web Plate

Conclusion

A thorough inspection of the hub, web plates, and welds on the hoist drum assembly is
recommended on a regular basis.

If cracks are detected, correct repair procedures should be used. Contact your local P&H MinePro
office for weld repair procedures and reference this Service Notice.

The hub-to-web welds should be ground and blended smooth wherever access allows.

Actions

Perform the inspection as detailed in the Discussion of this Service Notice. Grind smooth and blend
the welds as discussed in this Service Notice.

Copyright © 2008 P&H Mining Equipment, Inc. P&H Product Support

SN-ES-10.doc Page 4 of 4 SN-ES-10, Version 00 – 03/08
Date: 25 September, 2007 Priority: 2
Version: 00
Sequential Number: SN-ES-009
Product Code: 1154, 1051, 1001
Subject: Structures in Tension
Applicable to assembly: Various suspension rope, gantry, boom and revolving frame
assemblies.
Models affected: All P&H Electric Mining Shovels

Introduction:

The booms on all P&H Electric Mining Shovels are held in position using a gantry
assembly. The gantry assembly consists of a number of weldments, lugs, equalizers,
and cables. The gantry assembly is subject to tension loads generated from the digging
operation. As with any loaded structure, the gantry components are in turn, affected by
fatigue due to those loads. The difference with structures loaded in tension, is that any
generated fatigue crack will propagate faster than if loaded in compression.

Purpose:

This Service Notice is to remind all customers to conduct periodic inspections of

structures that are in tension.

Discussion:

By their nature, all cracks in a tension structure (such as a boom or A-frame) should be
considered serious, as fatigue cracks subjected to pure tension loading will propagate
faster than cracks subject to compression loading. In this section, we illustrate the more
commonly reported crack locations (identified in red in the illustrations beginning on
page 2 of this Service Notice) to use as examples for inspection locations.

Depending on where the crack initiates, the inspection method can range from visual all
the way to UT. The specific inspection method will vary depending on both the location
and type of crack we are trying to find. Typically PT or MT would be used for cracks that
initiate at a surface, and UT is used for cracks that initiate sub-surface. These
inspection methods can also assist in determining sufficiency of a weld or a structure for
a particular application.

1
Revolving Frame Deck Lug and Welds to Revolving Frame:

Tension Member Lugs and welds:

Vintage Tension Members:

2
Compression Member Lower Boss Plates Weld, Lug Plate Joint, Radii Plates on
Upper Tension Lug:

Suspension Equalizer Link Welds:

Vintage Gantry Equalizer Link Welds

3
Suspension Equalizer Pin Keepers the Connecting Link:

Welding Extraneous Objects to the Tension Structures.

Do not weld or attach anything to tension structures as this may cause additional
unwanted stress to these structures. Brackets and fire extinguisher mounts should not
be located on tension structures. Also, lamination plates or other modifications should
never be added without written consent from P&H Product Engineering. Lamination
plates can disrupt the flow of tension forces and cause unwanted stress risers. If any
such items are discovered, they are to be removed and the resulting blemish should be
blend-ground smooth and returned to its original condition.

Conclusion:
The inspection areas illustrated in this Service Notice reflect the locations of commonly
reported crack initiation sites. This is not intended to be a comprehensive list though, as
many unique situations occur around the world based on application. This Service
Notice is intended to bring attention to the process of inspection and repair of fatigue
cracks for structures in tension, as fatigue cracks will propagate faster under tensional
loading vs compressive loading. Managing fatigue cracking of tension structures is
important for the life of a structure. Cracks not inspected on a regular basis or not
repaired in a timely manner, may result in damage to the equipment or components,
unscheduled equipment downtime, or, in the most severe cases, structural failure.
Regular inspections can prevent such failures and avoid damage to the P&H Shovel.

Actions:
Regularly inspect the gantry assembly, along with the entire P&H shovel for cracks.
Visual, PT, MT, and UT methods are necessary for identifying cracks and repairing them
as soon as possible. Choosing the appropriate inspection method will vary depending
on the component itself, as well as how the actual crack typically develops in that
particular component.

Please contact your local P&H MinePro Services for further information regarding
appropriate inspection and repair methods for your specific P&H Electric Mining Shovel.

P&H Product Support

Milwaukee Wisconsin

4
Date: 30 May, 2007 Priority: 3
Version: 00
Sequential Number: SN-ES-008
Product Code: #1090
Subject: Trail Cable Length
Applicable to assembly: All Shovels
Models affected: All Models

Trail Cable Length

Introduction

Over the years, we have received a number of customer requests regarding the general
subject of acceptable trail cable lengths required to properly run a P&H Electric Mining
Shovel. The answer to that request can vary dramatically depending on conditions at
the minesite, governed by limitations due to fundamental electrical theory. To help
assist customers with this topic, we have generated this Service Notice in order to
provide some guidance on trail cable lengths for proper shovel operation.

Purpose

Provide guidelines of trail cable lengths for P&H Electric Mining Shovels.

Term Definitions

Shovel – A P&H Electric Mining Shovel. Electrical systems include Centurion platforms,
Electrotorque platforms, and Magnatorque platforms, as noted in the charts.
Grid – Minesite electrical power distribution system.
Stable Grid – Grid that supplies electrical power in a stable manner.
Weak Grid – Grid that supplies electrical power with instabilities.
Trail Cable – The grid electrical supply line, after the last substation, used to power the
shovel.
Line voltage – Voltage carried on the Trail Cable connecting the shovel.
Overvoltage – Voltage of Trail Cable exceeds nominal.
Undervoltage – Voltage of Trail Cable lacks nominal.
Trip – Shovel shutdown caused by protective circuitry.
Theory of Trail Cable Length Limitations

It is well known that for a given load current, trail cable impedance in conjunction with
the impedance of the grid determine the reduction (Regulation) in line voltage applied to

1
a shovel. It follows that as the trail cable lengthens, the reduction in voltage to the shovel
will increase. In turn, this reduction in voltage can adversely affect the proper electrical
performance of the shovel, thereby placing limits on the length of the trail cable.

Placing limits on the trail cable length also provides a means to control the amount of
distributed capacitance that will exist in a length limited trail cable.

All mine trail cables exhibit three fundamental electrical parameters, resistance,
inductance and capacitance, based on their internal construction. The resistance and
inductance (impedance) are determined by the size of the copper conductor per unit
length. The capacitance, per unit length, is determined from construction of the trail
cable itself (conductors, insulation around the conductors, and the braided copper shield
around the insulation). As the trail cable lengthens, the distributed capacitance will
increase.

Power line disturbances such as lighting strikes, or a more common solid state drive
“notching effect”, will have a tendency to discharge and charge the cable capacitance. In
this process, a damped voltage oscillation will occur whose magnitude, in the form of an
overvoltage, will be governed by the amount of trail cable capacitance available. As a
first order effect, the frequency of the oscillation will be governed by the amount of
inductance in the grid and the trail cable capacitance.

These damped oscillations will appear on the voltage applied to the shovel and thus will
be treated as an overvoltage by the control system. The result of those conditions will
stress the insulation levels and ratings of electrical components including the drive
motors. If the voltage oscillations magnify, the resulting stress on all components,
electrical and mechanical, will also increase due to excessive control system shutdowns.

So based on the above, maintaining trail cable lengths within practical limits will aid in
controlling line voltage regulation and transient overvoltages, ultimately leading to a
more stable, reliable, operating shovel.

Specifications

The P&H Engineering criteria for a grid is one that keeps the voltage at the shovel's
terminals within 5% of nominal on a static basis. Our undervoltage circuits trip the
shovel when the voltage dips to 80% (or –20%) of nominal. If you limit the static voltage
swing to 5% by good control of substation capacity and trail cable characteristics, then
the shovel has 15% of the allowable voltage swing to use on a dynamic basis, before a
trip due to undervoltage. More importantly, it gives a lot of margin for the shovel to
operate in tough digging without having nuisance trips. If the machine is operated under
conditions constantly close to the -20% trip point, there will be many shutdown faults.
While these faults are easily recoverable by the operator—he simply starts up again—
they are very detrimental to the shovel itself. The DC motors, motor drives, brakes,
gearing, and structures all experience accelerated wear due to the nuisance trips and
the energy that must be dissipated during these shutdown events.

2
To assist with the determination of the trail cable length, P&H has assembled charts,
based on Shovel Model number and line voltage that list a recommended value for trail
cable length based on a 5% voltage drop. These cable sizes should not be exceeded.

For an example, see the chart below for a 2800XPB. If the shovel is fed from 7200V,
and the desire is to run with 5000 feet of cable, then the appropriately sized cable would
be 1/0 AWG.

Alternatively, if the customer already has selected the cable size, the chart tells you the
maximum length of cable the operator may use for the static 5% voltage drop. For
example: if you have 2/0 AWG cable, the maximum length of trailing cable that may be
used based on our 5% criteria is 6384 feet.

Trail Cable Length Guidelines

The trail cable lengths given in the accompanying charts should be considered
guidelines for operation. They should be adjusted accordingly based on the
performance of the shovel at each individual minesite.

It is important to note that this information is based on a properly functioning shovel

electrical control system. It is also important to note that conditions can change rapidly
at individual minesites, which in turn alter either the grid or shovel performance.

If questions arise during determination of trail cable lengths, or any of the variables
associated with this topic, please contact your local MinePro representative.

3
MODEL 1900AL TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

1900AL 530 1450 2.3 3/0 1850

4/0 2246
250MCM 2621
350MCM 3346
500MCM 4308

1900AL 530 1450 3.3 1 2089

1/0 2590
2/0 3237
3/0 3808
4/0 4625
250MCM 5395
350MCM 6888
500MCM 8869

1900AL 530 1450 4.16 2 2708

1 3319
1/0 4115
2/0 5144
3/0 6052
4/0 7349
250MCM 8574
350MCM 10945
500MCM 14094

1900AL 530 1450 5 4 2563

2 3911
1 4795
1/0 5945
2/0 7432
3/0 8743
4/0 10617
250MCM 12386
350MCM 15812
500MCM 20361

ER39.05.05.12 5/29/07
MODEL 1900AL TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

1900AL 530 1450 5.5 4 3101

2 4733
1 5801
1/0 7194
2/0 8992
3/0 10579
4/0 12846
250MCM 14987
350MCM 19132
500MCM 24636

1900AL 530 1450 6 4 3690

2 5632
1 6904
1/0 8561
2/0 10702
3/0 12590
4/0 15288
250MCM 17836
350MCM 22769
500MCM 29319

1900AL 530 1450 6.6 4 4465

2 6815
1 8354
1/0 10359
2/0 12949
3/0 15234
4/0 18498
250MCM 21581
350MCM 27551
500MCM 35476

ER39.05.05.12 5/29/07
MODEL 1900AL TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

1900AL 530 1450 7.2 4 5314

2 8111
1 9942
1/0 12328
2/0 15410
3/0 18130
4/0 22015
250MCM 25684
350MCM 32788
500MCM 42220

ER39.05.05.12 5/29/07
MODEL 2100BL TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

2100BL 760 1600 2.3 4/0 2036

250MCM 2375
350MCM 3032
500MCM 3904

2100BL 760 1600 3.3 1/0 2347

2/0 2934
3/0 3451
4/0 4191
250MCM 4890
350MCM 6242
500MCM 8038

2100BL 760 1600 4.16 2 2454

1 3008
1/0 3730
2/0 4662
3/0 5485
4/0 6660
250MCM 7770
350MCM 9919
500MCM 12773

2100BL 760 1600 5 4 2322

2 3545
1 4345
1/0 5388
2/0 6735
3/0 7923
4/0 9621
250MCM 11225
350MCM 14330
500MCM 18452

ER39.05.05.12 5/29/07
MODEL 2100BL TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

2100BL 760 1600 5.5 4 2810

2 4289
1 5258
1/0 6519
2/0 8149
3/0 9587
4/0 11642
250MCM 13582
350MCM 17339
500MCM 22327

2100BL 760 1600 6 4 3344

2 5104
1 6257
1/0 7759
2/0 9698
3/0 11410
4/0 13855
250MCM 16164
350MCM 20635
500MCM 26571

2100BL 760 1600 6.6 4 4047

2 6176
1 7571
1/0 9388
2/0 11735
3/0 13806
4/0 16764
250MCM 19558
350MCM 24968
500MCM 32150

ER39.05.05.12 5/29/07
MODEL 2100BL TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

2100BL 760 1600 7.2 4 4816

2 7350
1 9010
1/0 11172
2/0 13966
3/0 16430
4/0 19951
250MCM 23276
350MCM 29714
500MCM 38262

ER39.05.05.12 5/29/07
MODEL 2100BLE/XPA TRAIL CABLE
MODEL KVA KVA CABLE FEET
AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

2100BLE/XPA 600 1800 3.3 1/0 2347

2/0 2934
3/0 3451
4/0 4191
250MCM 4890
350MCM 6242
500MCM 8038

2100BLE/XPA 600 1800 4.16 2 2181

1 2674
1/0 3315
2/0 4144
3/0 4875
4/0 5920
250MCM 6907
350MCM 8817
500MCM 11354

2100BLE/XPA 600 1800 5 4 2064

2 3151
1 3862
1/0 4789
2/0 5987
3/0 7043
4/0 8552
250MCM 9978
350MCM 12737
500MCM 16402

2100BLE/XPA 600 1800 5.5 4 2498

2 3813
1 4673
1/0 5795
2/0 7244
3/0 8522
4/0 10348
250MCM 12073
350MCM 15412
500MCM 19846

ER39.05.05.12 5/29/07
MODEL 2100BLE/XPA TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

2100BLE/XPA 600 1800 6 4 2973

2 4537
1 5562
1/0 6897
2/0 8621
3/0 10142
4/0 12315
250MCM 14368
350MCM 18342
500MCM 23618

2100BLE/XPA 600 1800 6.6 4 3597

2 5490
1 6730
1/0 8345
2/0 10431
3/0 12272
4/0 14901
250MCM 17385
350MCM 22194
500MCM 28578

2100BLE/XPA 600 1800 7.2 4 4281

2 6534
1 8009
1/0 9931
2/0 12414
3/0 14604
4/0 17734
250MCM 20690
350MCM 26412
500MCM 34010

ER39.05.05.12 5/29/07
MODEL 2300XP/XPA TRAIL CABLE
MODEL KVA KVA CABLE FEET
AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

2300XP/XPA 650 2900 3.3 3/0 1904

4/0 2312
250MCM 2698
350MCM 3444
500MCM 4435

2300XP/XPA 650 2900 4.16 1/0 2058

2/0 2572
3/0 3026
4/0 3675
250MCM 4287
350MCM 5473
500MCM 7047

2300XP/XPA 650 2900 5 2 1956

1 2397
1/0 2973
2/0 3716
3/0 4372
4/0 5308
250MCM 6193
350MCM 7906
500MCM 10180

2300XP/XPA 650 2900 5.5 2 2366

1 2901
1/0 3597
2/0 4496
3/0 5290
4/0 6423
250MCM 7494
350MCM 9566
500MCM 12318

ER39.05.05.12 5/29/07
MODEL 2300XP/XPA TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

2300XP/XPA 650 2900 6 4 1845

2 2816
1 3452
1/0 4281
2/0 5351
3/0 6295
4/0 7644
250MCM 8918
350MCM 11385
500MCM 14660

2300XP/XPA 650 2900 6.6 4 2233

2 3408
1 4177
1/0 5180
2/0 6474
3/0 7617
4/0 9249
250MCM 10791
350MCM 13775
500MCM 17738

2300XP/XPA 650 2900 7.2 4 2657

2 4055
1 4971
1/0 6164
2/0 7705
3/0 9065
4/0 11007
250MCM 12842
350MCM 16394
500MCM 21110

ER39.05.05.12 5/29/07
MODEL 2300XPB/C TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

2300XPB 720 3000 3.3 4/0 2235

250MCM 2608
350MCM 3329
500MCM 4287

2300XPB 720 3000 4.16 1/0 1989

2/0 2486
3/0 2925
4/0 3552
250MCM 4144
350MCM 5290
500MCM 6812

2300XPB 720 3000 5 2 1891

1 2317
1/0 2874
2/0 3592
3/0 4226
4/0 5131
250MCM 5987
350MCM 7642
500MCM 9841

2300XPB 720 3000 5.5 2 2288

1 2804
1/0 3477
2/0 4346
3/0 5113
4/0 6209
250MCM 7244
350MCM 9247
500MCM 11908

ER39.05.05.12 5/29/07
MODEL 2300XPB / C TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

2300XPB 720 3000 6 2 2722

1 3337
1/0 4138
2/0 5172
3/0 6085
4/0 7389
250MCM 8621
350MCM 11005
500MCM 14171

2300XPB 720 3000 6.6 4 2158

2 3294
1 4038
1/0 5007
2/0 6259
3/0 7363
4/0 8941
250MCM 10431
350MCM 13316
500MCM 17147

2300XPB 720 3000 7.2 4 2568

2 3920
1 4805
1/0 5959
2/0 7448
3/0 8763
4/0 10640
250MCM 12414
350MCM 15847
500MCM 20406

ER39.05.05.12 5/29/07
MODEL 2800XP/XPA TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

2800XP/XPA 880 3400 4.16 2/0 2194

3/0 2581
4/0 3134
250MCM 3657
350MCM 4668
500MCM 6011

2800XP/XPA 880 3400 5 1 2045

1/0 2535
2/0 3169
3/0 3729
4/0 4528
250MCM 5282
350MCM 6743
500MCM 8683

2800XP/XPA 880 3400 5.5 2 2018

1 2474
1/0 3068
2/0 3835
3/0 4512
4/0 5478
250MCM 6392
350MCM 8159
500MCM 10507

2800XP/XPA 880 3400 6 2 2402

1 2944
1/0 3651
2/0 4564
3/0 5369
4/0 6520
250MCM 7606
350MCM 9710
500MCM 12504

ER.39.05.05.12 5/29/07
MODEL 2800XP/XPA TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

2800XP/XPA 880 3400 6.6 4 1904

2 2906
1 3563
1/0 4418
2/0 5522
3/0 6497
4/0 7889
250MCM 9204
350MCM 11750
500MCM 15130

2800XP/XPA 880 3400 7.2 4 2266

2 3459
1 4240
1/0 5258
2/0 6572
3/0 7732
4/0 9389
250MCM 10953
350MCM 13983
500MCM 18006

2800XP/XPA 880 3400 11 4 5290

2 8074
1 9897
1/0 12272
2/0 15340
3/0 18047
4/0 21914
250MCM 25566
350MCM 32638
500MCM 42027

ER.39.05.05.12 5/29/07
MODEL 2800XPB/C TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

2800XPB 940 3500 4.16 2/0 2131

3/0 2507
4/0 3045
250MCM 3552
350MCM 4535
500MCM 5839

2800XPB 940 3500 5 1 1986

1/0 2463
2/0 3079
3/0 3622
4/0 4398
250MCM 5131
350MCM 6551
500MCM 8435

2800XPB 940 3500 5.5 2 1961

1 2403
1/0 2980
2/0 3725
3/0 4383
4/0 5322
250MCM 6209
350MCM 7926
500MCM 10206

2800XPB 940 3500 6 2 2333

1 2860
1/0 3547
2/0 4433
3/0 5216
4/0 6334
250MCM 7389
350MCM 9433
500MCM 12147

ER39.05.05.12 5/29/07
MODEL 2800XPB / C TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

2800XPB 940 3500 6.6 4 1850

2 2823
1 3461
1/0 4292
2/0 5365
3/0 6311
4/0 7664
250MCM 8941
350MCM 11414
500MCM 14697

2800XPB 940 3500 7.2 4 2201

2 3360
1 4119
1/0 5107
2/0 6384
3/0 7511
4/0 9120
250MCM 10640
350MCM 13583
500MCM 17491

2800XPB 940 3500 11 4 5138

2 7843
1 9614
1/0 11921
2/0 14901
3/0 17531
4/0 21288
250MCM 24836
350MCM 31705
500MCM 40826

ER39.05.05.12 5/29/07
MODEL 4100A/TS/BOSS/C TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

4100A/TS/BOSS 1080 3900 4.16 2/0 1913

3/0 2250
4/0 2732
250MCM 3188
350MCM 4069
500MCM 5240

4100A/TS/BOSS 1080 3900 5 1/0 2210

2/0 2763
3/0 3251
4/0 3947
250MCM 4605
350MCM 5879
500MCM 7570

4100A/TS/BOSS 1080 3900 5.5 2 1961

1 2403
1/0 2980
2/0 3725
3/0 4383
4/0 5322
250MCM 6209
350MCM 7926
500MCM 10206

4100A/TS/BOSS 1080 3900 6 2 2094

1 2567
1/0 3183
2/0 3979
3/0 4681
4/0 5684
250MCM 6631
350MCM 8465
500MCM 10901

ER39.05.05.12 5/29/07
MODEL 4100A/TS/BOSS/C TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

4100A/TS/BOSS 1080 3900 6.6 2 2534

1 3106
1/0 3851
2/0 4814
3/0 5664
4/0 6878
250MCM 8024
350MCM 10243
500MCM 13190

4100A/TS/BOSS 1080 3900 7.2 4 1976

2 3015
1 3696
1/0 4584
2/0 5729
3/0 6741
4/0 8185
250MCM 9549
350MCM 12190
500MCM 15697

4100A/TS/BOSS 1080 3900 11 4 4611

2 7038
1 8628
1/0 10698
2/0 13373
3/0 15733
4/0 19104
250MCM 22289
350MCM 28453
500MCM 36639

ER39.05.05.12 5/29/07
MODEL 4100A/TS/BOSS/C TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

4100A/TS/BOSS 1080 3900 13.8 4 7258

2 11078
1 13579
1/0 16838
2/0 21048
3/0 24762
4/0 30068
250MCM 35080
350MCM 44782
500MCM 57665

ER39.05.05.12 5/29/07
MODEL 4100XPB/C TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

4100XPB 1280 4100 6 2 1992

1 2442
1/0 3028
2/0 3785
3/0 4453
4/0 5407
250MCM 6308
350MCM 8053
500MCM 10369

4100XPB 1280 4100 6.6 2 2410

1 2955
1/0 3664
2/0 4579
3/0 5388
4/0 6542
250MCM 7632
350MCM 9744
500MCM 12547

4100XPB 1280 4100 7.2 2 2868

1 3516
1/0 4360
2/0 5450
3/0 6412
4/0 7786
250MCM 9083
350MCM 11596
500MCM 14931

ER39.05.05.12 5/29/07
MODEL 4100XPB/C TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

4100XPB 1280 4100 11 4 4386

2 6695
1 8207
1/0 10177
2/0 12721
3/0 14966
4/0 18173
250MCM 21201
350MCM 27065
500MCM 34851

4100XPB 1280 4100 13.8 4 6904

2 10537
1 12917
1/0 16017
2/0 20021
3/0 23554
4/0 28601
250MCM 33368
350MCM 42598
500MCM 54852

ER39.05.05.12 5/29/07
MODEL 5700XPA TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

5700XPA 1550 5800 4.16 4/0 1837

250MCM 2143
350MCM 2736
500MCM 3524

5700XPA 1550 5800 5 2/0 1858

3/0 2186
4/0 2654
250MCM 3097
350MCM 3953
500MCM 5090

5700XPA 1550 5800 5.5 2/0 2248

3/0 2645
4/0 3212
250MCM 3747
350MCM 4783
500MCM 6159

5700XPA 1550 5800 6 1/0 2140

2/0 2675
3/0 3148
4/0 3822
250MCM 4459
350MCM 5692
500MCM 7330

5700XPA 1550 5800 6.6 1 2089

1/0 2590
2/0 3237
3/0 3808
4/0 4625
250MCM 5395
350MCM 6888
500MCM 8869

ER39.05.05.12 5/29/07
MODEL 5700XPA TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

5700XPA 1550 5800 7.2 2 2028

1 2486
1/0 3082
2/0 3853
3/0 4532
4/0 5504
250MCM 6421
350MCM 8197
500MCM 10555

5700XPA 1550 5800 11 4 3101

2 4733
1 5801
1/0 7194
2/0 8992
3/0 10579
4/0 12846
250MCM 14987
350MCM 19132
500MCM 24636

5700XPA 1550 5800 13.8 4 4880

2 7449
1 9131
1/0 11322
2/0 14153
3/0 16650
4/0 20218
250MCM 23588
350MCM 30112
500MCM 38775

ER39.05.05.12 5/29/07
MODEL 5700XPA TRAIL CABLE

MODEL KVA KVA CABLE FEET

AVERAGE PEAK KV SIZE PER 5%
AWG Vdrop

5700XPA 1550 5800 14.4 4 5314

2 8111
1 9942
1/0 12328
2/0 15410
3/0 18130
4/0 22015
250MCM 25684
350MCM 32788
500MCM 42220

ER39.05.05.12 5/29/07
Date: 30 May, 2007 Priority: 3
Version: 00
Sequential Number: SN-ES-007
Product Code: #1090
Subject: Transient Voltage Filter Kit
Applicable to assembly: Main Transformers
Models affected: 4100 Series Shovels

INTRODUCTION: This Service Notice has been written to notify Shovel end users about the
benefits of the recently released R61350F1 Transient Filter Kit.

DISCUSSION:

Reports have been received regarding high commutator stress damage on hoist motors, mainly
on larger P&H Shovel models. The commutator stresses have reportedly resulted in accelerated
brush wear, commutator wear, arc horn damage, and an increased number of hoist diverter trip
faults. After an in-depth Engineering review, it has been determined that under certain
conditions, electrical transients can develop on the minesite power lines (grid) which are
associated with the extended length of trail cables, coupled with the pit power distribution
electrical characteristics. These transients can have a detrimental effect on the life and
commutation capabilities of the shovel’s DC motors.

Commutator performance issues are present to some degree and some regularity on many DC
motor applications. Collectively, the right combination of trail cable lengths, trail cable diameters,
and soft power grids will contribute to commutator stresses and performance issues. Under
certain conditions, large transients are realized that can be beyond the ability of the shovel
motors and other electrical components to accommodate. Additionally, the larger motors used on
the newer shovels produce more work and output, consume more energy, and therefore are
subject to a larger range of transients than smaller motors and smaller shovels. The combination
of these factors makes the requirement for clean power in larger shovels more critical than
previously seen on smaller shovels.

To assist customers with balancing pit power characteristics and shovel performance, P&H has
developed a Transient Filter Kit, R61350F1. The purpose of the kit is to minimize the effect of the
transients (discussed above) on DC motor performance. Two filters are used - one filter on each
of the main transformer secondaries. Past experience has shown a significant decrease in hoist
motor commutator arcing along with a decrease in the number of diverter trips after installation of
the kit. The same beneficial effect has been noted on the crowd motor, and to a lesser degree,
the swing motors.

This Transient Filter Kit is not required for all applications. In many mines with a strong grid and
reasonable trail cable lengths, this kit would not be required. However, if grid conditions are
resulting in excessive diverter trips and a high degree of commutator stress, this kit should be
very beneficial to minimize the effects of poor power supply conditions.

For more information on this Transient Filter Kit, please contact your local MinePro
representative.

1
Date: 15 September, 2005 Priority: 1
Version: 00
Sequential Number: SN-ES-002
Product Code: #009
Subject: Hoist Second Reduction Shaft Assembly
Applicable to assembly: R31793F_ and R32239F_
Models affected: All 4100TS, 4100BOSS and 4100XPB shovels.

Several shovels have experienced catastrophic failures of the second reduction hoist pinion
shaft R37179D1 or D2.

It has been discovered that the spacer R32337D1 spins on the shaft which causes pitting and
scoring. This leads to crack initiation on the end face of the pinion teeth. The cracks propa-
gate down the tooth root and around the transition radii between the bearing journal
and the external teeth. This ultimately leads to pinion fracture.

Shaft loading and deflections are directly related to the risk of spacer spinning
and thus the generation of a crack. Any alteration in original design or
standard operating practice may increase the risk of shaft failure.

Spacer R32337D1

Pinion Shaft R37179D1 or D2

Second reduction pinion shaft assembly R31793F_ or R32239F_

 1
2
3

Pinion shaft R37179D1 or D2 in production.

#1, Area where spacer scrubs against edge face of pinion teeth.
#2, Transition radii between bearing fit diameter and teeth.
#3, Bearing fit diameter.

1
1
2 2
Spacer,R32337D1 Spacer, R32337D2

Spacer for pinion shaft assembly R31793F_ and R32239F_

#1, Pinion tooth edge face contact area has been increase on the “D2” to
remove it from the high stressed area in the tooth root.
#2, Bearing inner race contact edge.

2
 Shown with new
spacer R32337D2

Pinion Shaft
R37179D1 or D2

Second reduction pinion shaft assembly R31793F_ or R32239F_

3
 1
2

Above, Pinion shaft bearing fit area, R37179D1 or D2. The bearing has a two piece inner race.
#1 Outboard inner race was not spinning.
#2 Inboard inner race was spinning on shaft (adjacent spacer R32337D1).

Above, the spacer, R32337D1, has been spinning on the shaft causing spalling and scoring.

4
Right, Small crack emanating from the scrub-
bing area. This was directly under a tooth root
area where the heat from induction hardening
affected the hardness. This crack was so fine
that it was not detectable using dry powder
Magnetic-Particle inspection methods. It is the
earliest example of a crack we have.

Below, The spinning spacer has caused

heavy spalling and scoring on the end of
the pinion face through the heat effected
areas of the induction hardening process.

5
Short and long term corrective action plan:

First: All hoist second reduction pinion shafts in operation are to be inspected:
Preferred inspection method to be Wet Fluorescent Magnetic-Particle, as the cracks may
be very small. The inspection should be performed through the access windows in the top
of the gear case. The hoist brakes and coupling bolts will need to be released to allow for a
100% inspection of these pinions; see page #7.
If a crack were to be found in the root, then it would have grown from the side face of
the shaft and would be considered serious. The shaft will need to be removed and re-
placed at this time.
If no cracks are found, the inspection should be repeated every 1000 hours until a
planned removal and rebuild of the shaft assembly can be performed.
At this time, visually inspect the hoist drum gear for possible end loading and cracking
should also be performed; see page #12. If there is a lot of end loading or cracking, the
pinion may be cracked, in some middle stage of failure, or completely fractured.

Second: For shafts that have more than 6000 service hours, plans should be made for their
removal. The spacer must be changed from R32337D1 to R32337D2 and the shafts are to
be crack inspected and manually reworked in the spacer scrubbing area.
A: The bearing should be removed in such a manor as to not damage any of the compo-
nents. These bearings have a long lead time and are in short supply. The old bearings
can be reused or rebuilt by grinding and installing oversize rollers. Please contact P&H
Operations for further information.
B: Inspection of the scrubbing area on the shaft should be performed using Wet Fluores-
cent Magnetic-Particle method. The cracks can be so fine that Dry Powder Magnetic-
Particle will not detect a crack.
C: If no cracks exist, the spacer scrubbing area will need to be flapper sanded to remove all
spalling and scoring. The radii between the bearing fit diameter and the teeth should
also be flapper sanded to remove any tool marks.
D: If very small cracks or deep spalling exist, grind them out with a stone or metal burr and
perform step-C above.
E: If any large cracks are found, the shaft must be scrapped.

Third: Effective immediately, All new manufactured assemblies will have the new R32337D2
spacer and the shaft will have minor improvements. The shaft will call for shot peening in the
transition radii and the shaft will be made to a higher final hardness.

6
 Spacer 32337D1

Crack Initiation Sites

Inspection Zones

Above, the rear pinion viewed through the access window. Inspect the tooth roots, three roots
at a time, until every tooth has been checked. Inspect blue areas shown above (adjacent to
the spacer).

Below, is an example of what the front pinion would appear like. This is opposite to the rear
pinion.

7
 3

Above, Fractured pinion face reveals.

#1 Crack initiation locations.
#2 Spacer had been spinning against pinion edge face.
#3 Initiation location of crack that fractured the shaft.

8
 Above and below, cracks do propagate down the tooth root before final fracture.
If caught in the early stages, the actual crack may be very short and tightly packed.

9
 2

Crack inspection of end face:

#1, Example of cracks tested with dry powder Magnetic-Particle with white
contrast paint.
#2, Contrast paint was wiped away beyond area to reveal the wear pattern caused
by the spacer ring R32337D1.

10
 1

Cracks observed with dry powder Magnetic-Particle without white contrast paint.
1#, Crack started to grow down the tooth root. This could be easily found by
inspections through the gearbox inspection covers without shaft disassembly.
#2, Proof that the cracks are emanating from the scrubbing area under the spacer
ring R32337D1.

11
Right and below,
These are examples of
secondary damaged caused
to the drum gear when the
pinion shaft actually
fractures into two pieces
and end loads the gear face.

12
 Tab 3

Upgrade Kits
 TheSolutionFiles
A Guide to P&H Mining Equipment Inc.

Egress Window Product Application

P&H® shovel models:

Upgrade •• 2300XPC / 2800XPC

•• 4100C / 4100C BOSS
•• 4100C BOSS AC / 4100XPC
The egress window allows personnel to exit through the
window onto the machinery house roof. •• 4100XPC AC

Features and Benefits

•• Provides a second exit from inside
the Operator’s Cab. Egress Window

•• Easily removed by rotating levers

upward and pushing the window out.
•• Laminated Glass thickness is
available in three sizes:
.25” (6.35mm)
.75” (19.05mm)
1.19” (30.23mm)

NOTE: All designs, specifications and components of

equipment described above are subject to change at
manufacturer’s sole discretion at any time without advance
notice. Data published herein is informational in nature
and shall not be construed to warranty the suitability of
product for any particular purpose as performance may
P&H MinePro Services vary with conditions encountered. The only warranty
1-888-MINEPRO applicable is our standard written warranty for this product.
Outside the U.S. and Canada P&H and P&H MinePro Services are trademarks of
Phone: (414) 671-4400 / Fax: (414) 671-7306 Joy Global Inc. or one of its affiliates.
www.minepro.com www.phmining.com © 2011 P&H Mining Equipment Inc. All rights reserved.

XS-5382 PDF-0611
Egress Window Installation Upgrade Confidential – Internal Distribution Only

Knowledge Base Document

CONFIDENTIAL (INTERNAL DISTRIBUTION ONLY) Date: June 24, 2011

Subject: Egress Window Installation Upgrade for R58698F1 Operator’s Cabs
Product Code: 1253 Document ID: 2010-12-14 Version: 01
Models Affected: 2300XPC, 2800XPC, 4100C BOSS, 4100C BOSS AC,
4100C, 4100XPC
Applicable to Assembly: Operator’s Cab
P&H Product Support Department KITS & UPGRADES

1.0 History / Background

The Egress Window Installation Upgrade R64284F_ provides a second exit in the operator’s cab for use
when the entry/exit door is blocked. This upgrade is applicable to the R58698F1 cabs used on most C-
series shovels and can be installed to replace the large existing trainer’s window on the left side of the
Operator’s Cab (See Figure 1).

The Egress Window Installation Upgrade may be applied at the owner’s discretion. Representatives of the
P&H MinePro Services Organization are encouraged to contact their respective customers to discuss the
benefits of this change, and to check if additional information on this topic is required.

Egress Window

Figure 1: Inside Cab View of Egress Window

Copyright © 2011 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
2010-12-14 Ver01.doc Page 1 of 4 2010-12-14, Version 01 – 06/11
Egress Window Installation Upgrade Confidential – Internal Distribution Only

Egress Window

Figure 2: Outside Cab View Of Egress Window

2.0 Why Should We Sell and Install This Upgrade?

• Provides a second exit from inside the Operator’s Cab.

o In case of an emergency, where the entry/exit door is blocked, the occupants of the
operator’s cab can exit through the egress window.
• Easily removed by rotating levers upward and pushing the window out.
o No special requirements for lifting. Easy to remove.
• Laminated glass thickness is available in three thicknesses to meet mine requirements; .25”
(6.35mm), .75” (19.05mm) & 1.19” (30.23mm).

o Glass is laminated with gray tint and conforms to ASTM C-1172.

3.0 Value Proposition Statement

The Egress Window Upgrade offers a second exit for use when the operator’s cab entry/exit door is
blocked, providing an added level of safety and confidence for the shovel operator.

Copyright © 2011 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
2010-12-14 Ver01.doc Page 2 of 4 2010-12-14, Version 01 – 06/11
Egress Window Installation Upgrade Confidential – Internal Distribution Only

4.0 Recommended Action

Mines that currently have the existing R58698F1 Operator’s Cab should be presented with the Solutions
File XS-5382 to provide information about the upgrade.
If our Customers are interested, please review and quote material part number, R64284F1, F2 & F3. The
P&H part number determines the thickness of the glass.

The R64284F_ kits have been developed to fit the R58698F1 Operator’s Cabs. At this time, kits are
not available for other Cabs.

For more information regarding the egress window: see TheSolutionFiles – XS-5382.
Document ID: 2010-12-14 Ver01
Product Issue Tracker Database: PIT #10537

5.0 Application

The Marketing Managers will target market this upgrade to mines with applicable electric shovels in their
respective MinePro regions. They will provide all required information to enable MinePro to effectively
promote this upgrade. Table 1 lists those electric shovels with R58698F1 Operator’s Cabs that were not
originally equipped with the egress window.

Note: it is also possible to apply this kit to a shovel that has been equipped with an R58698F1 as a cab
upgrade.

Table 1: Operator Cabs without the Egress Window

S/N Customer Location Marketing Manager
ES2382 Kuzbasskaya - Toplivnaya Russia International
ES2383 Jiangxi Copper – Dexing Mine China International
ES2384 Kuzbasskaya - Toplivnaya Russia International
ES2385 Jiangxi Copper – Dexing Mine China International
ES2387 Zarechniy Russia International

ES28163 Grupo Mexico Mexico America’s South

ES28164 CCI Northshore Hibbing, MN America’s North
ES28165 CCI Northshore Hibbing, MN America’s North
ES28166 Hibbing Taconite Hibbing, MN America’s North
ES28167 CVG Ferrominera Venezuela America’s South
ES28168 Kennecott Copper – Bingham Can. Salt Lake City, Ut America’s South
ES28169 Societe Nationale - SNIM Mauritania International
ES28170 CCI Northshore Hibbing, MN America’s North
ES28171 Kennecott Copper – Bingham Can. Salt Lake City, Ut America’s South
ES28172 CCI Empire/Tilden Negaunee, MI America’s North
ES28173 Rio Tinto/IOCC Canada America’s North
ES28174 Cerro Verde Mine Peru America’s South
ES28175 Rio Tinto/IOCC Canada America’s North
ES28176 Societe Nationale - SNIM Mauritania International

Copyright © 2011 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
2010-12-14 Ver01.doc Page 3 of 4 2010-12-14, Version 01 – 06/11
Egress Window Installation Upgrade Confidential – Internal Distribution Only

S/N Customer Location Marketing Manager

ES41155 Phelps Dodge - Morenci Arizona America’s South
ES41158 Barrick Goldstrike Nevada America’s South
ES41159 Phelps Dodge – Morenci Arizona America’s South
ES41160 PFCC – An Tai Bao China International
ES41162 Phelps Dodge – Morenci Arizona America’s South
ES41163 Macarthur Coal Australia Australasia
ES41164 Suncor Energies Canada America’s North
ES41165 PFCC – An Tai Bao China International
ES41167 Suncor Energies Canada America’s North
ES41168 AMSA – Minera Esperanza Chile America’s South
ES41169 Kiewit Leasing – Buckskin Gillette America’s North
ES41171 PFCC – An Tai Bao China International
ES41172 PFCC – An Tai Bao China International
ES41175 FMI - Morenci Arizona America’s South
ES41176 Gibraltar Mines Canada America’s North
ES41177 AMSA – Minera Esperanza Chile America’s South
ES41178 EVCC Fording River - Teck Canada America’s North
ES41179 AMSA – Minera Esperanza Chile America’s South
ES41182 Syncrude – Mildred Lake Canada America’s North
ES41183 FMI – Morenci Arizona America’s South
ES41184 Kuzbassrazrezugol Russia International
ES41185 Suncor Energies Canada America’s North
ES41186 FMI - Morenci Arizona America’s South
ES41187 FMI - Sierrita Arizona America’s South
ES41188 Cerro Verde Peru America’s South
ES41189 Suncor Energies Canada America’s North
ES41190 Prairie Mines & Royalty Ltd. Canada America’s North
ES41191 Line Creek Operations - Tech Canada America’s North
ES41192 PRCC – North Antelope/Rochelle Gillette America’s North
ES41193 RTCA – Hail Creek Australia Australasia
ES41194 PRCC – North Antelope/Rochelle Gillette America’s North
ES41195 Boliden Mineral AB Europe International
ES41197 Kennecott Copper – Bingham Cany. Salt Lake City, UT America’s South
ES41199 Falkirk Mine Gillette America’s North
ES41211 PCS Phosphates Florida America’s North

Copyright © 2011 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
2010-12-14 Ver01.doc Page 4 of 4 2010-12-14, Version 01 – 06/11
 TheSolutionFiles
A Guide to P&H Mining Equipment Inc.

Auto Crowd Belt Product Application

• 4100XPC

Tensioner Upgrade • 4100XPB

• Available for both Centurion™
and Non-Centurion applications
Summary Description
An updated auto crowd belt tensioner Mechanical changes include improved
system is available that provides more cylinder rod geometry for increased
reliable performance. service durability. The cylinder rod end
is manufactured from high-strength
Benefits steel for increased bore strength and
• Rugged, new mechanical and reliability. A spherical bushing is now
electrical components along with added to the cylinder rod end for
a simplified control system help effective alignment and contact with the
increase crowd belt tensioner motor base. Longer cylinder mounting
performance and reliability. pins incorporate a bolt-and-nut fastener
for increased reliability over previous
• Reduces operating cost by maintaining
cotter pin fastener design. Updated cylinder assembly
proper belt tension. This provides
maximum belt life and reduces Hydraulic changes include test ports
damage to crowd motor bearings now added to the cylinder to aid in
and shaft due to over-tensioned belts. bleeding the system. This system now
uses sequence and relief valves for
increased pressure control reliability
over the previous proportioning valve
and amplifier card design. For non-
Centurion applications, a new program
is installed and original I/O is used. A
new electrical control cabinet is located
in the lube room for convenient access
in a lower-vibration environment.
Application view

NOTE: All designs, specifications and components of

the equipment described above are subject to change at
manufacturer’s sole discretion at any time without advance
notice. Data published herein is informational in nature
and shall not be construed to warranty the suitability of
the equipment for any particular purpose as performance
P&H MinePro Services may vary with conditions encountered. The only warranty
1-888-MINEPRO applicable is our standard written warranty for this equipment.
Outside the U.S. and Canada P&H, P&H MinePro Services and Centurion are trademarks
Phone: (414) 671-4400 / Fax: (414) 671-7306 of Joy Global Inc. or one of its affiliates.
www.minepro.com www.phmining.com © 2010 P&H Mining Equipment Inc. All rights reserved.

XS-4877 PDF-1110
Automatic Crowd Belt Tension System Improvements Confidential – Internal Distribution Only

Knowledge Base Document

CONFIDENTIAL (INTERNAL DISTRIBUTION ONLY) Date: June 10, 2010

Subject: Automatic Crowd Belt Tension System Improvements
Product Code: 1176, 1177 Document ID: 2010-06-10 Version: 00
Models Affected: All 4100 XPB/XPC
Applicable to Assembly: Crowd Belt Tensioning System
P&H Product Support Department KITS & UPGRADES

1.0 Introduction
Engineering released kit R62844F_ in 2009 to improve the Automatic Crowd Belt Tension System on P&H
4100XPB and XPC shovels.

2.0 Purpose
The purpose of this document is to provide information on the Automatic Crowd Belt Tension System
improvements.

3.0 Discussion
An Automatic Crowd Belt Tension (CBT) System is standard on models 4100XPB and 4100XPC. Kit
R62844F_ provides improvements to the CBT System used on existing 4100XPB and 4100XPC shovels. The
improvements include a simplified hydraulic and electrical control system, which delivers stable system
pressure, and improved system diagnostics. Mechanical improvements were also made, which include
improved rod and rod end geometry, and the location of the manifold was moved from the cylinder to the
lube room where there is less vibration. The new system is more reliable, easier to commission, and easier
to maintain.

Refer to Service Letter SL-ES-314, Automatic Crowd Belt Tension System Upgrade for more details
concerning the Automatic Crowd Belt Tensioner kit features and installation.

Installation of kit R62844F_ is considered optional. Contact Product Support for help in determining which
kit option should be applied.

Programming changes to support the improvement were included in the Centurion V4.9 update.
Centurion shovels must use Version 4.9 or higher when using the CBT improvement. Application of
the improvement to a non-Centurion machine requires updated programming, which requires an
RFPD to be submitted to Electrical Development Engineering. Contact Product Support for
assistance.

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3.1 Application

The R62844F_ Automatic Crowd Belt Tensioner kit is applicable to all 4100XPB and 4100XPC electric
shovels (see Table 1 for a list of machines).

S/N CUSTOMER LOCATION REGION

ES41151 An Tai Bao China & Mongolia International
ES41154 An Tai Bao China & Mongolia International
ES41160 An Tai Bao China & Mongolia International
ES41161 An Tai Bao China & Mongolia International
ES41165 Anjialing Mine China & Mongolia International
ES41171 Anjialing Mine China & Mongolia International
ES41172 An Tai Bao China & Mongolia International
ES41184 Taldinsky Russia & CIS International

ES41105 Blackwater Mine North East Region Australasia

ES41107 Goonyella-Riverside North East Region Australasia
ES41109 Goonyella-Riverside North East Region Australasia
ES41112 Hunter Valley Operations South East Region Australasia
ES41143 Callide North East Region Australasia
ES41145 Dawson North East Region Australasia
ES41147 Dawson North East Region Australasia
ES41156 Peak Downs North East Region Australasia
ES41157 Saraji North East Region Australasia
ES41173 Clermont Coal North East Region Australasia
ES41193 Hail Creek North East Region Australasia
ES41200 Peak Downs North East Region Australasia

ES41100 Escondida Chile Americas South

ES41101 Morenci Southwest Operations Americas South
ES41102 Radomiro Tomic Chile Americas South
ES41106 Los Pelambres Chile Americas South
ES41108 Escondida Chile Americas South
ES41110 Los Pelambres Chile Americas South
ES41120 Sossego Brazil Americas South
ES41121 Escondida Chile Americas South
ES41126 Escondida Chile Americas South
ES41129 Escondida Chile Americas South
ES41135 Spence Chile Americas South
ES41136 Spence Chile Americas South
ES41137 Spence Chile Americas South
ES41142 Cananea Operations Mexico & Central America & Caribbean Americas South
ES41144 Los Pelambres Chile Americas South
ES41146 Goldstrike Mine Nevada Operations Americas South
ES41148 Cortez Hills Nevada Operations Americas South
ES41152 Morenci Southwest Operations Americas South
ES41153 Radomiro Tomic Chile Americas South
Table 1: Applicable Machines (continued on next page)

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S/N CUSTOMER LOCATION REGION

ES41155 Morenci Southwest Operations Americas South
ES41158 Goldstrike Mine Nevada Operations Americas South
ES41159 Morenci Southwest Operations Americas South
ES41162 Morenci Southwest Operations Americas South
ES41168 Esperanza Chile Americas South
ES41175 Morenci Southwest Operations Americas South
ES41177 Esperanza Chile Americas South
ES41179 Esperanza Chile Americas South
ES41180 Andina Chile Americas South
ES41181 Andina Chile Americas South
ES41183 Morenci Southwest Operations Americas South
ES41186 Morenci Southwest Operations Americas South
ES41187 Sierrita Southwest Operations Americas South
ES41188 Cerro Verde Mine Peru Americas South
ES4195 Chuquicamata Mine Chile Americas South
ES4196 Radomiro Tomic Chile Americas South
ES4197 Chuquicamata Mine Chile Americas South
ES4198 Cananea Operations Mexico & Central America & Caribbean Americas South

ES41103 Highvale Mine Canada - Western Canada Americas North

ES41104 Thunder Mine East Western US Operations Americas North
ES41111 Belle Ayr Western US Operations Americas North
ES41113 Greenhills Operations Canada - Western Canada Americas North
ES41116 Elkview Operations Canada - Western Canada Americas North
ES41118 Thunder Mine East Western US Operations Americas North
ES41124 Antelope Mine Western US Operations Americas North
ES41125 Twilight Appalachia Americas North
ES41132 Cardinal River Operations Canada - Western Canada Americas North
ES41134 Fording River Operations Canada - Western Canada Americas North
ES41139 Elkview Operations Canada - Western Canada Americas North
ES41141 Antelope Mine Western US Operations Americas North
ES41169 Buckskin Mine Western US Operations Americas North
ES41178 Fording River Operations Canada - Western Canada Americas North
ES41191 Line Creek Operations Canada - Western Canada Americas North
ES41192 North Antelope and Rochelle Mine Western US Operations Americas North
ES41194 North Antelope and Rochelle Mine Western US Operations Americas North
ES41198 Antelope Mine Western US Operations Americas North
ES41201 North Antelope and Rochelle Mine Western US Operations Americas North
ES41205 Buckskin Mine Western US Operations Americas North
ES4192 Black Thunder Mine Western US Operations Americas North
ES4193 North Antelope and Rochelle Mine Western US Operations Americas North
Table 1: Applicable Machines (continued)

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Four versions of the CBT improvement kit have been created to account for whether the machine has
Centurion or non-Centurion control, and whether or not the CBT power unit, located in the lube room,
needs replacing. The following Table 2 summarizes the kit numbers:

Kit Part Number Model New Power Unit Supplied?

R62844F1 4100XPB/XPC non-Centurion No
R62844F2 4100XPB/XPC non-Centurion Yes
R62844F3 4100XPB/XPC Centurion No
R62844F4 4100XPB/XPC Centurion Yes
Table 2: Kit Part Numbers

3.2 Advantages of an Automatic Crowd Belt Tensioner

Some advantages of an automatic crowd belt tension system as opposed to manual tensioning of the
crowd belts are listed below:

• The belt tension adjustment is made during machine start up at a predetermined interval in the PLC
program. This adjustment takes approximately 75 seconds.
• Accurate belt tensioning at set intervals as designated in the PLC program help eliminate belt
damage due to improper belt tension.
• Damage to crowd motor bearings and shafts caused by excessive belt tension will be minimized.
• Down time and maintenance are reduced.
• Allows manual operation of the system to adjust the belts during maintenance, or for belt
replacement.

4.0 Conclusion
If more information on Automatic Crowd Belt Tension kit is required, contact P&H Product Support.

5.0 Actions
This kit can be applied to any 4100XPB or 4100XPC machine. Refer to Service Letter SL-ES-314, Automatic
Crowd Belt Tension System Upgrade for specific details.

Document ID: 2010-06-10

Product Issue Tracker Database: PIT #10009

Copyright © 2010 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
2010-06-10.doc Page 4 of 4 2010-06-10, Version 00 – 06/10
 TheSolutionFiles
A Guide to P&H Mining Equipment Inc.

Adjustable Saddle Block Product Application

P&H® shovel models
Routine saddle block adjustment extends the life of the handle structures, crowd •• 4100A
pinions & racking. This saddle block upgrade provides for easier adjustment, more •• 4100C
adjustability and mechanical and structural improvements. •• 4100XPB
Features and Benefits Upper Wear Plate
•• 4100XPC
Reduced maintenance requirements Adjustment Bolts •• 4100TS
and costs due to: •• 4100 BOSS
•• Elimination of shims on lower •• 4100C BOSS
wear plate.
•• Easily adjustable – threaded
adjusting tubes.
•• Extended life wear plates.
•• High strength bronze lower wear
plate reduces damage to handle. Bronze
•• Improved access to upper wear Wear Plate
plate bolts.
•• The structural design facilitates
multiple rebuilds. Inboard View
•• Eligible for the P&H® Encore
(Component Exchange Program).

Two Threaded
Adjusting
Tubes

Outboard View

NOTE: All designs, specifications and components of

the equipment described above are subject to change
at manufacturer’s sole discretion at any time without
advance notice. Data and descriptions published herein
are informational in nature and shall not be construed to
warranty the service or the suitability of the equipment
for any particular purpose as performance may vary with
P&H MinePro Services conditions encountered. The only warranty applicable is our
1-888-MINEPRO standard written warranty for this equipment or service.
Outside the U.S. and Canada
Phone: (414) 670-4400 / Fax: (414) 670-7306 P&H, P&H MinePro Services and Encore are
trademarks of Joy Global Inc. or one of its affiliates.
www.minepro.com www.phmining.com © 2011 P&H Mining Equipment Inc. All rights reserved.
XS-5381 PDF-0611
Adjustable Saddle Block Upgrade Confidential – Internal Distribution Only

Knowledge Base Document

CONFIDENTIAL (INTERNAL DISTRIBUTION ONLY) Date: June 23, 2011

Subject: Adjustable Saddle Block Upgrade, R71417F1, R71417F2, R70535F1
Product Code: 1155, 1156 Document ID: 2011-03-23 Version: 01
Models Affected: 4100A, 4100C, 4100XPB, 4100XPC, 4100TS, 4100BOSS,
4100C BOSS
Applicable to Assembly: Saddle Block / Shipper Shaft Assemblies
P&H Product Support Department KITS & UPGRADES

1.0 History / Background

The Adjustable Saddle Block Upgrade Kit was introduced to simplify maintenance and extend the life of
saddle block assemblies. The new saddle block has a threaded adjusting tube feature that replaces the
shim-able vertical wear plate. Design improvements to the saddle block include a bronze vertical wear
plate with greater adjustability, a stronger saddle block structure, and a wider saddle block hub. The wider
hub is provided on the 4100XPB / XPC only, other models use the same width hub as standard saddle
blocks.

The Adjustable Saddle Block Upgrade Kit may be applied at the owner’s discretion. Representatives of the
P&H MinePro Services organization are encouraged to contact their respective customers to discuss the
benefits of this optional kit, and to check if additional information on this topic is required.

Easily Accessible Adjusting Steel Upper Wear Plates

Bolts for Upper Wear Plate

Two Threaded Adjusting Tubes Bronze Vertical Wear Plate

Figure 1: Outside View of Adjustable Saddle Block Figure 2: Inside View of Adjustable Saddle Block

Copyright © 2011 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
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Adjustable Saddle Block Upgrade Confidential – Internal Distribution Only

2.0 Why Are We Offering This Upgrade?

• Elimination of shims on lower wear plate

o Saddle block adjustments are less time consuming and more likely to be maintained regularly.
Regular saddle block maintenance extends the life of the saddle block structures, crowd pinion,
handle racking and other associated material.

• Easily adjustable - threaded adjusting tubes replace shims on lower wear plate.

o Two threaded tubes that are easily accessible from the outboard catwalks replace the
adjustment shims.

• Extended Life wear plates.

o Lower wear plate material is high strength bronze and increased thickness. Upper wear plate is
the standard steel material, but with increased thickness for longer life.

o Thicker to provide extended life.

• High strength bronze lower wear plate reduces damage to handle.

o The vertical wear plates are made of high strength bronze, which reduces galling.

• Improved access to Upper wear plate bolts.

o The bolts were moved to the top of the saddle blocks, which makes them more accessible for
adjustment and inspection. Also, in moving the bolt adjustment to the top of the saddle block,
the bolts were made longer to improve the bolt under tension.

o Plates are thicker to allow for more wear and deeper thread engagement.

• The structural design facilitates multiple rebuilds.

o The saddle block structure for the 4100XPB / XPC itself has a wider hub and the bend radius on
the inside plate of the saddle block weldment is doubled, which increases the strength of the
saddle block structure.

• Eligible for Component Exchange Program (CEP).

o The CEP program allows the customer submit a core saddle block and receive a rebuilt unit.

3.0 Value Proposition Statement

The Adjustable Saddle Block Upgrade Kit simplifies maintenance in this area and extends the life of saddle
block structures, resulting in a reduction to maintenance costs and unplanned downtime.

Copyright © 2011 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
2011-03-23 Ver01.doc Page 2 of 9 2011-03-23, Version 01 – 06/11
Adjustable Saddle Block Upgrade Confidential – Internal Distribution Only

4.0 Recommended Action

Send the Solutions File marketing brochure to customers who have shovels using the original style saddle
block to generate interest.

For upgrades to 41000XPB and 4100XPC shovels review and quote material part numbers R71417F1 and
R71417F2.

For upgrades to 4100A, 4100C, 4100TS, 4100 BOSS, 4100C BOSS review and quote material part number
R70535F1.

NOTE: New production shovels are now being equipped with the adjustable saddle blocks.

Information for the Adjustable Saddle Block Upgrade Kit can be found in:

• “The SolutionsFiles” document #XS-5381

• Product Issue Tracker Database: PIT #10588

6.0 Application

The Marketing Managers will target market this upgrade to their respective MinePro regions that have
electric shovels with the original version of the saddle blocks. They will provide all required information to
enable MinePro to effectively promote this upgrade. Following is a list of electric shovels, which have the
original version saddle blocks.

Document ID: 2011-03-23 Ver. 01

Copyright © 2011 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
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Adjustable Saddle Block Upgrade Confidential – Internal Distribution Only

Table 1: Saddle Block Applicability

ELECTRIC SHOVELS WITH OLD STYLE SADDLE BLOCKS & SHORT SHIPPER SHAFT (203.5”)
MODEL SERIAL# CUST.# CUSTOMER COUNTRY REGION
Rio Tinto Coal Australia;Mitsubishi Coal
Development Pty Ltd;Nippon Steel
4100A E55288 342 Australia Pty Ltd;Posco Australia Pty Ltd Australia Australasia
4100A E55294 10 Freeport-McMoRan Copper & Gold Inc. United States Americas South
4100A E55297 11 Freeport-McMoRan Copper & Gold Inc. United States Americas South
4100A E55298 12 Freeport-McMoRan Copper & Gold Inc. United States Americas South
4100A E55302 336 Peabody Energy Corp. United States Americas North
4100A E55304 SH004 Newmont Gold Corporation Indonesia Australasia
4100A E55305 2 Southern Peru Copper Corporation Peru Americas South
4100A E55306 103 Peabody Energy Corp. United States Americas North
4100A E55308 15 Freeport-McMoRan Copper & Gold Inc. Indonesia Australasia
4100A E55309 ES55 RTZ United States Americas South
4100A E55311 204 BHP Billiton Plc. Australia Australasia
4100A E55319 321 Teck Resources Limited Canada Americas North
4100A E55320 108 Peabody Energy Corp. United States Americas North
4100A E55321 SHE34 BHP Billiton Plc.;Mitsubishi Corporation Australia Australasia
341 -
4100A E55322 Tiger Rio Tinto Coal Australia Australia Australasia
4100A E55323 14501 Freeport-McMoRan Copper & Gold Inc. Chile Americas South
4100A E55324 14502 Freeport-McMoRan Copper & Gold Inc. Chile Americas South
4100A E55325 14544 Freeport-McMoRan Copper & Gold Inc. United States Americas South
4100XPB ES41100 SHE0065 BHP Billiton Plc. Chile Americas South
4100XPB ES41101 39 Freeport-McMoRan Copper & Gold Inc. United States Americas South
Corporacion Nacional del Cobre de Chile
4100XPB ES41102 205 (CODELCO) Chile Americas South
4100XPB ES41103 146 TransAlta Centralia Generation LLC Canada Americas North
4100XPB ES41104 1212 No Parent Company Found United States Americas North
SHE
4100XPB ES41105 0032 BHP Billiton Plc. Australia Australasia
4100XPB ES41106 3 Minera Los Pelambres Chile Americas South
BHP Billiton Plc.;Mitsubishi
4100XPB ES41107 SHE 33 Corporation;Mitsui & Co. of Japan Australia Australasia
4100XPB ES41108 SHE0066 BHP Billiton Plc. Chile Americas South
BHP Billiton Plc.;Mitsubishi
4100XPB ES41109 SHE 35 Corporation;Mitsui & Co. of Japan Australia Australasia
4100XPB ES41110 4 Minera Los Pelambres Chile Americas South
4100XPB ES41111 10 Alpha Coal West United States Americas North
4100XPB ES41112 343 Rio Tinto Coal Australia Australia Australasia
4100XPB ES41113 30 Teck Resources Limited Canada Americas North
4100BOSS ES41114 1182 Syncrude Canada Ltd. Canada Americas North
4100A ES41115 SH005 Newmont Gold Corporation Indonesia Australasia
4100XPB ES41116 322 Teck Resources Limited Canada Americas North
4100A ES41117 SH006 Newmont Gold Corporation Indonesia Australasia

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Adjustable Saddle Block Upgrade Confidential – Internal Distribution Only

ELECTRIC SHOVELS WITH OLD STYLE SADDLE BLOCKS & SHORT SHIPPER SHAFT (203.5”)
MODEL SERIAL# CUST.# CUSTOMER COUNTRY REGION
4100XPB ES41118 1214 Thunder Mine East United States Americas North
4100BOSS ES41119 1603 Suncor Energy Inc. Canada Americas North
4100XPB ES41120 ES3001 Vale Brazil Americas South
4100XPB ES41121 SHE 67 BHP Billiton Plc. Chile Americas South
4100BOSS ES41122 1183 Syncrude Canada Ltd. Canada Americas North
4100BOSS ES41123 1184 Syncrude Canada Ltd. Canada Americas North
4100BOSS ES41127 1185 Syncrude Canada Ltd. Canada Americas North
4100BOSS ES41128 1604 Suncor Energy Inc. Canada Americas North
4100BOSS ES41130 1186 Syncrude Canada Ltd. Canada Americas North
4100BOSS ES41131 1187 Syncrude Canada Ltd. Canada Americas North
4100BOSS ES41133 1605 Suncor Energy Inc. Canada Americas North
4100BOSS ES41138 1188 Syncrude Canada Ltd. Canada Americas North
4100BOSS ES41140 1606 Suncor Energy Inc. Canada Americas North
4100C
BOSS AC ES41149 1607 Suncor Energy Inc. Canada Americas North
4100C ES41150 Freeport-McMoRan Copper & Gold Inc. Peru Americas South
4100C ES41163 Macarthur Coal Limited Australia Australasia
4100C
BOSS AC ES41164 1608 Suncor Energy Inc. Canada Americas North
4100C
BOSS ES41166 1001 Canadian Natural Resources Limited Canada Americas North
4100C
BOSS AC ES41167 1609 Suncor Energy Inc. Canada Americas North
4100C
BOSS ES41170 1002 Canadian Natural Resources Limited Canada Americas North
4100C
BOSS ES41174 1003 Canadian Natural Resources Limited Canada Americas North
4100C ES41176 #2 Taseko Mines Ltd. Canada Americas North
4100C
BOSS ES41182 Nov-89 Syncrude Canada Ltd. Canada Americas North
4100C
BOSS AC ES41185 1610 Suncor Energy Inc. Canada Americas North
4100C
BOSS AC ES41189 1611 Suncor Energy Inc. Canada Americas North
4100C ES41190 Prairie Mines & Royalty Ltd. Canada Americas North
4100C ES41195 Boliden AB Sweden International
4100C ES41197 RTZ United States Americas South
4100C
BOSS ES41208 11-100 Syncrude Canada Ltd. Canada Americas North
4100A ES4144 24 Freeport-McMoRan Copper & Gold Inc. United States Americas South
4100A ES4145 14548 Freeport-McMoRan Copper & Gold Inc. United States Americas South
4100A ES4146 25 Freeport-McMoRan Copper & Gold Inc. United States Americas South
4100A ES4147 State Government of South Australia Australia Australasia
4100A ES4148 16 Freeport-McMoRan Copper & Gold Inc. United States Americas South
4100A ES4149 10 Freeport-McMoRan Copper & Gold Inc. United States Americas South

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ELECTRIC SHOVELS WITH OLD STYLE SADDLE BLOCKS & SHORT SHIPPER SHAFT (203.5”)
MODEL SERIAL# CUST.# CUSTOMER COUNTRY REGION
4100A ES4150 ES56 RTZ United States Americas South
4100A ES4151 518 Asarco Inc. United States Americas South
BHP Billiton Plc.;Mitsubishi
4100A ES4152 SHE31 Corporation;Mitsui & Co. of Japan Australia Australasia
4100A ES4153 4 Southern Peru Copper Corporation Peru Americas South
4100A ES4154 ES01 Asarco Inc. United States Americas South
Freeport-McMoRan Copper & Gold
Inc.;Freeport-McMoRan Copper & Gold
Inc.;Freeport-McMoRan Copper & Gold
4100A ES4155 20 Inc. Chile Americas South
4100A ES4156 205 BHP Billiton Plc. Australia Australasia
4100A ES4157 1 Southern Peru Copper Corporation Peru Americas South
Corporacion Nacional del Cobre de Chile
4100A ES4158 201 (CODELCO) Chile Americas South
4100A ES4159 Chevron Resources United States Americas North
Freeport-McMoRan Copper & Gold
Inc.;Freeport-McMoRan Copper & Gold
Inc.;Freeport-McMoRan Copper & Gold
4100A ES4160 21 Inc. Chile Americas South
Corporacion Nacional del Cobre de Chile
4100A ES4161 202 (CODELCO) Chile Americas South
4100A ES4162 106 Peabody Energy Corp. United States Americas North
Freeport-McMoRan Copper & Gold
Inc.;Freeport-McMoRan Copper & Gold
Inc.;Freeport-McMoRan Copper & Gold
4100A ES4163 22 Inc. Chile Americas South
Corporacion Nacional del Cobre de Chile
4100A ES4164 100 (CODELCO) Chile Americas South
Corporacion Nacional del Cobre de Chile
4100A ES4165 101 (CODELCO) Chile Americas South
4100A ES4166 11 Freeport-McMoRan Copper & Gold Inc. United States Americas South
4100A ES4167 23 Freeport-McMoRan Copper & Gold Inc. United States Americas South
4100A ES4168 3 Teck Resources Limited Canada Americas North
4100A ES4169 SH002 Newmont Gold Corporation Indonesia Australasia
4100A ES4170 SH003 Newmont Gold Corporation Indonesia Australasia
Corporacion Nacional del Cobre de Chile
4100A ES4171 203 (CODELCO) Chile Americas South
4100A ES4172 Boliden AB Sweden International
4100A ES4173 Chevron Resources United States Americas North
4100A ES4174 PE06 Minera del Norte, S.A. de C.V. Mexico Americas South
4100A ES4175 337 Peabody Energy Corp. United States Americas North
4100A ES4176 PE007 Minera del Norte, S.A. de C.V. Mexico Americas South
4100A ES4177 107 Peabody Energy Corp. United States Americas North
4100A ES4178 1 Minera Los Pelambres Chile Americas South
4100A ES4179 SH001 Newmont Gold Corporation Indonesia Australasia

Copyright © 2011 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
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Adjustable Saddle Block Upgrade Confidential – Internal Distribution Only

ELECTRIC SHOVELS WITH OLD STYLE SADDLE BLOCKS & SHORT SHIPPER SHAFT (203.5”)
MODEL SERIAL# CUST.# CUSTOMER COUNTRY REGION
4100A ES4180 ES57 RTZ United States Americas South
4100A ES4181 ES02 Asarco Inc. United States Americas South
4100A ES4182 211 Antofagasta Minerals Chile Americas South
4100A ES4183 FS10 Xstrata Plc Australia Australasia
4100A ES4184 6 Rio Tinto Minerals United States Americas South
4100TS ES4185 1601 Suncor Energy Inc. Canada Americas North
4100TS ES4186 1178 Syncrude Canada Ltd. Canada Americas North
4100TS ES4187 1179 Syncrude Canada Ltd. Canada Americas North
4100A ES4188 7 Rio Tinto Minerals United States Americas South
4100A ES4189 3 Southern Peru Copper Corporation Peru Americas South
4100TS ES4190 1180 Syncrude Canada Ltd. Canada Americas North
4100A ES4191 2 Southern Peru Copper Corporation Peru Americas South
shovel
4100XPB ES4192 #20 Arch Minerals Inc. United States Americas North
4100XPB ES4193 109 Peabody Energy Corp. United States Americas North
4100TS ES4194 1602 Suncor Energy Inc. Canada Americas North
Corporacion Nacional del Cobre de Chile
4100XPB ES4195 C200 (CODELCO) Chile Americas South
Corporacion Nacional del Cobre de Chile
4100XPB ES4196 204 (CODELCO) Chile Americas South
Corporacion Nacional del Cobre de Chile
4100XPB ES4197 C230 (CODELCO) Chile Americas South
4100XPB ES4198 27 Southern Copper Minera Mexico Mexico Americas South
4100TS ES4199 1181 Syncrude Canada Ltd. Canada Americas North

Copyright © 2011 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
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Adjustable Saddle Block Upgrade Confidential – Internal Distribution Only

ELECTRIC SHOVELS WITH OLD STYLE SADDLE BLOCKS & LONG SHIPPER SHAFT (224.5”)
MODEL MODEL MODEL MODEL MODEL MODEL
4100XPB ES41124 151516 RTZ-CRA Mining International United States Americas North
4100XPB ES41125 Massey Energy United States Americas North
4100XPB ES41126 69 BHP Billiton Plc. Chile Americas South
4100XPB ES41129 SHE0070 BHP Billiton Plc. Chile Americas South
4100XPB ES41132 10 Teck Resources Limited Canada Americas North
S305 (# 5
4100XPB ES41134 Shovel) Teck Resources Limited Canada Americas North
4100XPB ES41135 1 BHP Billiton Plc. Chile Americas South
4100XPB ES41136 2 BHP Billiton Plc. Chile Americas South
4100XPB ES41137 3 BHP Billiton Plc. Chile Americas South
4100XPB ES41139 323 Teck Resources Limited Canada Americas North
4100XPB ES41141 151517 RTZ-CRA Mining International United States Americas North
4100XPB ES41142 29 Southern Copper Minera Mexico Mexico Americas South
4100XPB ES41143 208 Anglo American Australia Australasia
4100XPB ES41144 Minera Los Pelambres Chile Americas South
4100XPB ES41145 Anglo American Australia Australasia
4100XPB ES41146 191 Barrick Gold Corporation United States Americas South
4100XPB ES41147 Anglo American Australia Australasia
4100XPB ES41148 341 Barrick Gold Corporation United States Americas South
4100XPB ES41151 1746 PingShuo First Coal Company China International
Freeport-McMoRan Copper & Gold
4100XPB ES41152 40 Inc. United States Americas South
Corporacion Nacional del Cobre de
4100XPB ES41153 206 Chile (CODELCO) Chile Americas South
4100XPC ES41154 1747 PingShuo First Coal Company China International
Freeport-McMoRan Copper & Gold
4100XPC ES41155 42 Inc. United States Americas South
BHP Billiton Plc.;Mitsubishi
4100XPC ES41156 SHE36 Corporation Australia Australasia
BHP Billiton Plc.;Mitsubishi
4100XPC ES41157 SHE37 Corporation Australia Australasia
4100XPC ES41158 192 Barrick Gold Corporation United States Americas South
Freeport-McMoRan Copper & Gold
4100XPC ES41159 41 Inc. United States Americas South
4100XPC ES41160 1749 PingShuo First Coal Company China International
4100XPC ES41161 1748 PingShuo First Coal Company China International
Freeport-McMoRan Copper & Gold
4100XPC ES41162 43 Inc. United States Americas South
4100XPC ES41165 3010 PingShuo First Coal Company China International
4100XPC ES41168 Antofagasta Minerals Chile Americas South
4100XPC ES41169 2927 Kiewit Mining Leasing Co United States Americas North
4100XPC ES41171 3011 PingShuo First Coal Company China International
4100XPC ES41172 1750 PingShuo First Coal Company China International

Copyright © 2011 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
2011-03-23 Ver01.doc Page 8 of 9 2011-03-23, Version 01 – 06/11
Adjustable Saddle Block Upgrade Confidential – Internal Distribution Only

ELECTRIC SHOVELS WITH OLD STYLE SADDLE BLOCKS & LONG SHIPPER SHAFT (224.5”)
MODEL MODEL MODEL MODEL MODEL MODEL
4100XPC ES41173 SH001 Rio Tinto Limited Australia Australasia
Freeport-McMoRan Copper & Gold
4100XPC ES41175 44 Inc. United States Americas South
4100XPC ES41177 Antofagasta Minerals Chile Americas South
S306 (#6
4100XPC ES41178 Shovel) Teck Resources Limited Canada Americas North
4100XPC ES41179 Antofagasta Minerals Chile Americas South
Corporacion Nacional del Cobre de
4100XPC ES41180 Chile (CODELCO) Chile Americas South
Corporacion Nacional del Cobre de
4100XPC ES41181 Chile (CODELCO) Chile Americas South
Freeport-McMoRan Copper & Gold
4100XPC ES41183 45 Inc. United States Americas South
4100XPC ES41184 OAO Kuzbassrazrezugol Russia International
Freeport-McMoRan Copper & Gold
4100XPC ES41186 46 Inc. United States Americas South
Freeport-McMoRan Copper & Gold
4100XPC ES41188 Inc. Peru Americas South
4100XPC ES41191 # 1 Shovel Teck Resources Limited Canada Americas North
4100XPC ES41192 110 Peabody Energy Corp. United States Americas North
4100XPC ES41193 SH014 Rio Tinto Limited Australia Australasia
4100XPC ES41194 111 Peabody Energy Corp. United States Americas North
4100XPC ES41196 1751 PingShuo First Coal Company China International
4100XPC ES41198 518 RTZ-CRA Mining International United States Americas North
4100XPC ES41201 112 Peabody Energy Corp. United States Americas North
4100XPC ES41204 PingShuo First Coal Company China International
4100XPC ES41205 38 Kiewit Mining Leasing Co United States Americas North
4100XPC ES41206 PingShuo First Coal Company China International

Copyright © 2011 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
2011-03-23 Ver01.doc Page 9 of 9 2011-03-23, Version 01 – 06/11
 TheSolutionFiles
A Guide to P&H Mining Equipment Inc.

3-Disc Hoist Brake Product Application

• Applicable to P&H® 2800XPA /

Upgrade
XPB / 4100, 4100A, 4100C,
4100XPB, 4100TS and
4100BOSS shovels

Summary
For added hoist brake and thermal capacity
over what is available from standard 2-disc
hoist brakes, a new 3-disc hoist brake upgrade
is available for P&H electric mining shovels.

Benefits
Aims to reduce maintenance time,
minimize downtime and lower
production cost through increased:
• Braking capacity
• Thermal capacity
• Longer hoist brake life

Description
For increased braking and thermal
capacity performance, P&H Mining
Equipment Inc. now has available a
3-disc hoist brake system.

NOTE: All designs, specifications and components of equipment described

above are subject to change at manufacturer’s sole discretion at any time
without advance notice. Data published herein is informational in nature and
P&H MinePro Services shall not be construed to warranty the suitability of product for any particular
1-888-MINEPRO purpose as performance may vary with conditions encountered. The
Outside the U.S. and Canada only warranty applicable is our standard written warranty for this product.
Phone: (414) 671-4400 / Fax: (414) 671-7306 P&H and P&H MinePro Services are trademarks of Joy Global Inc. or one
www.minepro.com  www.phmining.com of its affiliates. © 2010 P&H Mining Equipment Inc. All rights reserved.

XS-5162 PDF-510
Three-Disc Hoist Brake Upgrades Confidential – Internal Distribution Only

Knowledge Base Document

CONFIDENTIAL (INTERNAL DISTRIBUTION ONLY) Date: Feb 17, 2010

Subject: Three-Disc Hoist Brake Upgrades
Product Code: 1015 Document ID: 2010-02-17 Version: 00
Models Affected: 4100 Series Shovels and 2800XPA/XPB Shovels Originally
Equipped with Two-Disc Hoist Brakes
Applicable to Assembly: Hoist First Reduction Shaft Assemblies
P&H Product Support Department KITS & UPGRADES

1.0 Introduction

Engineering has released upgrades for select shovel models to replace the original two-disc hoist brakes
with three-disc brakes.

2.0 Purpose

The Purpose of this document is to provide information on upgrade kits that are available to convert select
model shovels from a two-disc hoist brake to a three-disc brake.

3.0 Discussion

• Kit R59826F_ applies to 4100, 4100A, 4100C, and 4100TS models. The 3-disc brake will have 22-25%
more thermal capacity than the 2-disc brake depending on operating conditions and will increase
torque capacity by 22%. See the kit drawing for more details.

• Kit R56398F_ applies to 4100XPB and 4100 BOSS models. The 3-disc brake will have 22-25% more
thermal capacity than the 2-disc brake depending on operating conditions and will increase torque
capacity by 11%. See the kit drawing for more details.

• 2800XPA/XPB - There is no kit established for these models, so individual parts have to be ordered. No
change is required to the pinion shaft. This will increase torque capacity by 18%, thermal capacity by
22%.
o The P/N for the three-disc hoist brake is R27275D1.
o The 15N784D2 hub used with the two-disc brake must be changed to the 15N784D5 hub,
which is 2.25 inches longer and will accommodate the three-disc brake.
o Also required is retainer plate 18T8493D3 to fit in the D5 hub, which has a slightly smaller
counter bore than the D2 hub. Replace retainer plate hardware, do not re-use.

There have been requests to rework a three-disc brake hub to accept a two-disc hoist brake.
Drawing R59907 shows a rework that can be performed to the hub for this purpose. R59907D1 is
for use on 4100A machines with hoist brake upgrade R59826F2 using shaft R56366D1. R59970D2
is for use on 4100XPB machines with hoist brake upgrade R56398F2 using shaft R56366D1, or first
reduction hoist shaft assembly R32779D1 using shaft R56366D1.

Copyright © 2010 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
2010-02-17.doc Page 1 of 2 2010-02-17, Version 00 – 02/10
Three-Disc Hoist Brake Upgrades Confidential – Internal Distribution Only

The added disc provides 50% more brake contact area, which improves braking ability. This will increase
hoist brake component life and increase time between necessary maintenance.

4.0 Conclusion

The kits apply to all the models listed above that are currently equipped with two disc hoist brakes.

5.0 Actions

Contact P&H Product Support for more information if needed.

Document ID: 2010-02-17

Copyright © 2010 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
2010-02-17.doc Page 2 of 2 2010-02-17, Version 00 – 02/10
 TheSolutionFiles
A Guide to P&H Mining Equipment Inc.

‘Stinger’ Assembly Product Application

• Applicable to DC and AC shovels

Summary Description
This mechanical arm mounted to the • The “stinger” power cable support
propel works at the aft end of a P&H arm provides a secure mount path
electric mining shovel provides control for the final 3 or 4 meters of the
over the final few meters of incoming incoming power cable where it
power supply or “tail” cable, helping engages with the power supply
to keep it at a safe distance above and coupling at the back end of the shovel
away from the crawlers during shovel amid the propel machinery works.
re-positioning maneuvers.
• The support arm is built to support
Benefits the power cable,
keeping it at a
• Helps increase useful life of your
height-adjustable
electric mining shovel incoming
distance above
power supply cable, by providing a
ground level and
secure support pathway.
helping to prevent
• Aims to lower maintenance cost the shovel crawler
associated with the power cable belts from over-
being overrun by the shovel crawler running the cable
belts during shovel repositioning. during shovel
propel maneuvers.
• Reduces the need for mine
personnel to monitor power cable • Cable support
during shovel maneuvers. kit replacement
parts are available
• Helps reduce shovel re-positioning
should the mechanism
time for increased shovel loading time
become damaged.
and productivity.
• The stinger can be removed
for maintenance if required.

NOTE: All designs, specifications and components of equipment described

above are subject to change at manufacturer’s sole discretion at any time
without advance notice. Data published herein is informational in nature and
P&H MinePro Services shall not be construed to warranty the suitability of product for any particular
1-888-MINEPRO purpose as performance may vary with conditions encountered. The
Outside the U.S. and Canada only warranty applicable is our standard written warranty for this product.
Phone: (414) 671-4400 / Fax: (414) 671-7306 P&H and P&H MinePro Services are trademarks of Joy Global Inc. or one
www.minepro.com  www.phmining.com of its affiliates. © 2010 P&H Mining Equipment Inc. All rights reserved.

XS-5160 PDF-510
Stinger Assembly Kits Confidential – Internal Distribution Only

Knowledge Base Document

CONFIDENTIAL (INTERNAL DISTRIBUTION ONLY) Date: Feb. 12, 2010

Subject: Stinger Assembly Kits
Product Code: 1139 Document ID: 2010-02-12 Version: 00
Models Affected: P&H 4100XPB/XPC, 4100BOSS/C BOSS, 2800XPB/XPC,
DC Shovels and also P&H AC Shovels
Applicable to Assembly:
P&H Product Support Department KITS & UPGRADES

1.0 Introduction

Engineering has released drawing R67800, which provides kits for a cable stinger assembly.

2.0 Purpose

The Purpose of this document is to provide information on stinger assembly kits now available for P&H
electric mining shovels.

3.0 Discussion

The stinger kits will provide an extended support for the tail cable when propelling or steering. A stinger
extends the support of the tail cable when steering or backing up, which reduces the chances of tail cable
damage.

A stinger can help eliminate the need for a worker to monitor the position of the tail cable during the
digging or propel modes. The tail cable is protected from damage in sharp turns, due to the generous lead
at the stinger end. Shovel move times can be reduced.

• Kit R67800F1 applies to 2800XPB, 2800XPC, 4100XPC AC, and 4100 BOSS AC.
• Kit R67800F2, applies to 4100XPB, 4100XPC DC, 4100 BOSS, and 4100C BOSS DC.

The stinger height can be adjusted to compensate for pit floor conditions. The stinger can be easily
removed to perform maintenance tasks.

4.0 Conclusion

Stinger assembly kits are now available for P&H electric mining shovels.

5.0 Actions

See drawing R67800 for more information on the stinger kits.

Document ID: 2010-02-12

Copyright © 2010 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
2010-02-12.doc Page 1 of 1 2010-02-12, Version 00 – 02/10
 TheSolutionFiles
A Guide to P&H Mining Equipment Inc.

Dipper Handle Lifting Product Application

• Applicable to P&H® 2800XPA /

Lug Kit
XPB / XPC, 4100A / A-LR / C /
TS / XPB / XPC / BOSS and
C BOSS shovels

Summary
This kit provides a convenient
and single means for lifting and
maneuvering the dipper handles
of a P&H electric mining shovel.
The lifting lug end-cap is welded
to the dipper handle leg.
Description
Benefits • The dipper handle
• Helps reduce downtime as this kit lifting lug kit provides
promotes convenient rigging for replacement end-cap
dipper handle lifts and maneuvers. weldments.
• Potential for reduced dipper handle • The added lifting lugs
damage inflicted during lifts and facilitate rigging, lifting
maneuvers, minimizing cost. and maneuvering of
• Makes possible dipper handle lifts the dipper handle
and maneuvers without need for during shovel assembly, overhaul
lifting cable protectors, helping procedures and maintenance.
reduce the chance of damage
to slings.
• Aims to reduce time required to
rig, lift and maneuver dipper handle.

NOTE: All designs, specifications and components of equipment described

above are subject to change at manufacturer’s sole discretion at any time
without advance notice. Data published herein is informational in nature and
P&H MinePro Services shall not be construed to warranty the suitability of product for any particular
1-888-MINEPRO purpose as performance may vary with conditions encountered. The
Outside the U.S. and Canada only warranty applicable is our standard written warranty for this product.
Phone: (414) 671-4400 / Fax: (414) 671-7306 P&H and P&H MinePro Services are trademarks of Joy Global Inc. or one
www.minepro.com  www.phmining.com of its affiliates. © 2010 P&H Mining Equipment Inc. All rights reserved.

XS-5155 PDF-510
Dipper Handle Lifting Lug Kit Confidential – Internal Distribution Only

Knowledge Base Document

CONFIDENTIAL (INTERNAL DISTRIBUTION ONLY) Date: January 25, 2010

Subject: Dipper Handle Lifting Lug Kit
Product Code: 1189 Document ID: 2010-01-25 Version: 00
Models Affected: 2800XPA/B/C, 4100A/C/ALR, and 4100TS/BOSS/C BOSS
Applicable to Assembly: Dipper Handles
P&H Product Support Department KITS & UPGRADES

1.0 Introduction

Engineering has released upgrade kits that provide lifting lugs for the dipper handles.

2.0 Purpose

The Purpose of this document is to describe the lifting lug kits for the dipper handle assemblies.

3.0 Discussion

These kits will provide a means to lift the handle during installation, removal or transport. This will provide
a safe and reliable hitch point that can be used to remove, replace and transport the handles. Chance of
the handles being damaged during removal and installation is reduced. Lifting cables will not be damaged
by contact with the boom wear boxes. Handle change out time is reduced. Use of lifting cable protectors
will no longer be required.

Figure 1: Lifting Lug

Copyright © 2010 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
2010-01-25.doc Page 1 of 2 2010-01-25, Version 00 – 01/10
Dipper Handle Lifting Lug Kit Confidential – Internal Distribution Only

Engineering has released ERN 5504239, which provides kit R68335F1. This provides lifting lugs on the
greenhorn end of the dipper handles for 2800XPA/B/C using handles/legs part numbers R60054/R11414,
R40374/R40373, R11749/R11414, R11750/R11414, R11749/R11414, 11J3999/711J169, 11J4077/711J192,
and 11J4078/711J192.

ERN 5504239 also released kit R68130F1. This kit applies to machines using handles/legs part numbers
R2254/R2253, which covers 4100A, 4100C, 4100TS, 4100BOSS, and 4100C BOSS series; and
R7345/R6580, which covers the 4100ALR.

An earlier kit, R46361D1/D2 provides a similar upgrade for the 4100XPB shovels.

Refer to the drawings listed above for kit instructions.

4.0 Conclusion

Lifting lug kits are available for the dipper handles of the shovel models listed above.

5.0 Actions

Refer to the drawings listed above. Contact P&H Product Support for more information.

Document ID: 2010-01-25

Product Issue Tracker Database: PIT #10772

Copyright © 2010 P&H Mining Equipment, Inc. – All Rights Reserved P&H Product Support
2010-01-25.doc Page 2 of 2 2010-01-25, Version 00 – 01/10
 TheSolutionFiles
A Guide to P&H Mining Equipment

Front Idler Upgrade System Requirements

• Certain 2800 Series Shovels

• Certain 4100 Series Shovels

Summary • Bushing wear is better monitored and
Continuously striving to provide reliable managed with the help of adjustable
and innovative products and reducing retaining rings that can accomodate
customers costs, P&H is now offering up to 3.25” / 8.25 cm of thrust face
the newly developed Front Idler total wear.
Upgrade for certain model 2800 and
• Current P&H standard lube injectors
4100 series machines.
now supply additional lubricant more
This solution now offers many efficiently to critical wear surfaces
advantages over the current design. from both sides independently.

Benefits • Provides an option of using a new

• 50% less bearing stress achieved idler and bearing blocks or recycling
by relocating the bushings’ position the existing idler and bearing blocks
outward and increasing bearing area. by reworking them to the new
upgrade geometry.
• Bearing blocks can be removed
without breaking the track, reducing
maintenance cost.

• Splined connection between idler

and shaft provides strength, allows
rotation of the idler and shaft as a
unit, and significantly reduces bearing
loads and component wear.

• Rotating shaft now seats itself into the

stationary bushings, resulting in less
contact stress and wear to both the
shaft and the bushings.
 Description
The front idler upgrade design features specific product improvements developed to extend life and reduce the overall
operating cost of the assembly. Details are individually identified below:

Increased Moment Arm Adjustable Retaining Ring

Force on new bushing = F/2

Idler y

Shaft

Crawler
Frame

Force on original bushing = F

The reduction in bearing stress is mainly occurring in the Up to 3.25” / 8.25cm of wear on the bushing thrust face can
steering mode because the moment arm to resist the steering be taken up by adjusting the retaining collars.The collars allow
loads has been increased.This reduces the contact load on the for a visual indication of bushing wear.
bushings by half.

Bushing Wear
BUSHING WEAR
Contaminant Guard
Current Design New Design

As Force Force
New:

stationary shaft - spinning shaft -

spinning bushing stationary bushing

Worn: Force Force

Decreased Equivalent
bushing area bushing area

Among the most significant factors in extending bushing life is Contamination between the idler bushing and the shaft
the incorporation of a splined connection between the idler surface is a major source of premature wear.The new design
and shaft.This factor greatly impacts the wear pattern of the features heavy duty, steel reinforced, polyurethane seals to
bushing as demonstrated in the illustration above. provide greater protection to critical wear areas.

Box 310  •  Milwaukee,Wisconsin 53201 USA

Phone: (414) 671-4400  •  Fax: (414) 671-7306
NOTE: All designs, specifications and components of the equipment described above are subject to change at the manufacturer’s sole discretion at any
time without advance notice. Data published herein is informational in nature and shall not be construed to warranty the suitability of the equipment for any
particular purpose as performance may vary with the conditions encountered. The only warranty applicable is our standard written warranty for this equipment.
P&H is a trademark of Joy Global Inc. or one of its affiliates. © 2009 P&H Mining Equipment Inc. All rights reserved.

XS-4862 PDF-509
P&H Product Support Department

TO: Service Document Distribution List

FROM: P&H Product Support DATE: January 8, 2009

SUBJECT: Hoist Gearcase Kits DOCUMENT ID: 2009-01-08

CC:

Internal Memo
Purpose

The purpose of this document is to communicate kits that have been developed for hoist gearcases on
4100BOSS, 4100XPB/XPC, and 4100TS shovels. Kits have been released to provide an upgraded hoist
gearcase assembly, mounting pin assembly, gearcase support assembly, hoist lube system, and variable
speed lube pump drive for models 4100 BOSS, 4100TS, and 4100XPB. Another kit also provides the option
of adding upgraded revolving frame hoist gearcase lugs in addition to the upgraded gearcase assembly kit.

Discussion

Use table 1 below to determine the appropriate upgrade kit part # for each particular application.

Gearcase Only Upgrade Gearcase + Lug Upgrade

Model Revolving Frame
Kit Part # Kit Part #
4100TS R31762F1 R62615F1 R62615F3
4100BOSS R48831F1 R62615F1 R62615F3
R44692F1
4100XPB/XPC R62615F2 R62615F4
R54415F1-F3
Table 1: Gearcase Kits Application

Application to model 4100TS requires motor setting and drive parameter changes to account for
gear ratio changes. Also when using this kit on 4100TS or 4100BOSS shovels (R62615F1 or F3) the
hoist drum flanges and beckets will need to be reworked slightly in order to make the existing
drums compatible with the new gearcase, this is shown on Rev 4 of drawing R62615. The upgraded
lube system will require new controller and GUI programs, which will be supplied by P&H electrical
engineering.

As seen in the application table above, these kits can be applied to 4100TS/BOSS/XPB/XPC models.
R62615F1 and F2 include a complete hoist gearcase module assembly and all of the necessary components
for mounting and installation. This includes instructions for re-machining the existing revolving frame lug
bores and new oversized replacement bushings for those bores. Kits R62615F3 and F4 include the same
features as F1 and F2 but also include a hoist lug replacement kit, R65301F_. The hoist lug replacement kit
provides new heavy-duty hoist lugs for the revolving frame and is recommended but not required for use
with the upgraded gearcase.

Copyright © 2009 P&H Mining Equipment, Inc. P&H Product Support

2009-01-08.doc Page 1 of 4 2009-01-08, Version 00 – 01/09
General Information Service Document No. 2009-01-08 Confidential – Internal Distribution Only

The following are some of the improvements made to the new gearcase and associated components
included with this upgrade kit:

• Heavy-duty construction
o The new gearcase base is constructed of heavy 2.50” main plates with no gussets. The
previous gearcase used 1.00” plate with extensive gussets. This greatly reduces the amount
of welding needed on the new case.
o Simple construction eliminates bosses and stiffeners and reduces the chance for cracking.
o Stiffer construction will help extend bearing life.
o Made from P&H 50 material, which is stronger with better toughness.
o FEA (Finite Element Analysis) was performed on this gearcase and shows lower stresses and
less stress concentrations throughout.

• Ease of use
o More inspection holes
The existing gearcase has two holes in the base and two in the cover. The new
design has two in the base and 10 in the cover. This allows for more complete gear
inspection without turning the hoist drum. It also allows for inspection of the
shoulder bolts that hold the drum gear to the hoist drum.
o Most of the connections for hoses and wiring are attached to the gearcase base - this allows
for removal of the gearcase cover with minimal steps.

• Use of bearing capsules

o Prevent damage to the gearcase.
o The bearing and capsule can be removed and replaced with a larger bearing if desired.

• 1st Reduction gear

o This gear now uses the tube style design, which improves gear stiffness and life.
o Tube style gear also accommodates new drum lock design (see below).

• 2nd Reduction shaft assembly

o Larger shaft to increase stiffness and improve bearing alignment
o Larger bearing for better performance and life

• Simplified and improved drum lock

o A new method of locking the hoist drum has been incorporated into this gearcase. A pin is
now inserted through the wall of the gearcase, through one of the tubes in the 1st
reduction gear and through the wall on the opposite side of the gearcase. This type of lock
has a much simpler design than the “hockey stick” version that uses the flange on the drum
and is easier to use.

• Improved lubrication system

o Positive lube flow to every bearing and the input gear mesh.
o Over 1GPM to each hoist input tapered bearing to reduce heating.
o Variable speed AC drive to adjust pump flow from 1 to 10 GPM (compensates for oil
viscosity).
o Cooler incorporated into system to further cool transmission and maintain oil viscosity

• All bearings have provisions for temperature & vibration sensors

o Bearing RTD’s are included with this kit as part of the variable speed lube pump drive kit.

Copyright © 2009 P&H Mining Equipment, Inc. P&H Product Support

2009-01-08.doc Page 2 of 4 2009-01-08, Version 00 – 01/09
General Information Service Document No. 2009-01-08 Confidential – Internal Distribution Only

• Triple disc brake

o A triple disc brake comes standard with this upgrade kit. This set-up offers improved brake
torque.
Note: Some existing shovel models may have already come with or have been
upgraded to a triple disc hoist brake.

• Hoist Gearcase Support

o Improved Hoist Gearcase Support System (Wedge Supports) included with this upgrade.
The wedge style supports are an improvement over the “jack-screw” system for the
following reasons:
Easily and continually adjustable by simply torquing a bolt; no extra jacks are
necessary and nothing has to be re-welded. This ensures a tight fit to the gearcase
and eliminates chucking.
Greater contact area with gearcase prevents plates from “pounding out”.

• Additional improvements can be realized by including the hoist lug replacement kit (included with
R62615F3 and F4) with the gearcase upgrade.
o Heavy duty hoist lugs without bosses improve life and reduce chance for cracking
o Accept larger 6.00” diameter hoist mounting pins
o Accept flanged revolving frame bushings, which are captured between the inside face of the
lug and the hoist gearcase.
o The bushings and the mounting pins are held in place with rods and oversized washers;
there are no welded on collars needed for this application.

The complete procedure for installing this hoist gearcase upgrade kit can be found on drawing R62615 and
the drawings of the components that are included with the kit. The installation procedure will vary slightly
from model to model. Some important installation issues to note include: Application to a 4100TS machine
requires motor setting and drive parameter changes in order to account for the gear ratio change applied
on the upgraded gearcase assembly. When using this kit on 4100BOSS/TS machines, the hoist drum
flanges and beckets will need to be reworked slightly in order to make the existing drums compatible with
the new gearcase. The upgraded lube system will require new controller and GUI programs, which will be
supplied by P&H electrical engineering.

Figures 1 and 2 on the next page show views of the old and new gearcases.

Action

The intention of this document is to inform the readers of the hoist gearcase upgrade kits available. For
any questions, contact P&H Product Support.

Document ID: 2009-01-08

Copyright © 2009 P&H Mining Equipment, Inc. P&H Product Support

2009-01-08.doc Page 3 of 4 2009-01-08, Version 00 – 01/09
General Information Service Document No. 2009-01-08 Confidential – Internal Distribution Only

S AC

Figure 1: Original Gearcase (machining only) Shown on a 4100BOSS Revolving Frame

Figure 2: Upgraded Gearcase (machining only) Shown on a 4100BOSS Revolving Frame

Copyright © 2009 P&H Mining Equipment, Inc. P&H Product Support

2009-01-08.doc Page 4 of 4 2009-01-08, Version 00 – 01/09
 Tab 4

Minesite Insights
 Minesite Insights

Maintenance and Update Tips for P&H Mining Equipment

Electric Shovels, Drills, Draglines and Hydraulic Excavators August, 1997

How To Maximize The Life

And Perfor mance Of The
P&H ‘PowerBand ’ Crowd Drive
TM

Back in 1969, P&H introduced the PowerBandTM

crowd drive system to the mining world. No more
torque tubes or worm gears. No crowd ropes.
Instead, P&H shovel users now had an effective new
crowd delivery mechanism on their digging machines.

PowerBand is a simple, efficient and economical

power transmission system that was first used on the
P&H 2800MkI shovels built for Kaiser Resources in
British Columbia.
WHAT IS POWERBAND DRIVE?
PowerBand Drive is a V-belt drive that uses multiple
V-belts joined together by a high-strength tie band to
provide lateral rigidity. V-belts offer a number of P&H PowerBandTM crowd drive system.
advantages:
POWERBAND BELT LIFE
! Efficient power transfer. The life of PowerBand crowd drive belts depends on
! Simplified design — eliminating gears, a number of factors such as ...
torque tubes, and so on. ! Type and manufacturer of the belt
! Shock loading protection stemming from the ! Operations
elasticity of the belts. " Material " Blasting " Operator technique

! Simplified motor alignment. ! Maintenance

" Installation " Adjustment
! Reduced maintenance requirements.
! High ambient temperatures
Over the last 28 years, the PowerBand crowd drive
concept has proved itself during millions of hours of P&H uses belts selected for the application from
shovel operation all over the world under conditions suppliers whose belts have shown superior
ranging from the heat of the Sahara Desert to the performance under field conditions.
extreme cold of Siberia. Because PowerBand belts The material being excavated and the blasting can
are so reliable, they are often forgotten — until play a large part in belt life. Material that is blocky
problems, in particular, short belt life occur. Belt
and doesn’t fragment well must be “dug” rather than
maintenance will be discussed later in this article.
loaded. Hard toe conditions and variations in
Please turn to page 2.
P&H ‘PowerBand’ Crowd Drive models in the near future. Because of the new
Continued from page 1. materials and belt construction, maintenance must
undergo change.
operator technique result in the high shock loads As an example, shovel operators have traditionally
mentioned above when the operator jams the dipper been instructed to notify maintenance whenever they
into the toe or is forced to chip away at material. hear crowd belts slip and squeal. The new belts do
not squeal when they slip, so periodic checking of
Hard digging conditions are especially troublesome
belt tension becomes more important. Belt tensioning
during the belt break-in period when a sequence of will be discussed later in this article.
slip and re-tension can occur.
REGULARLY SCHEDULED INSPECTIONS AND ADJUSTMENTS
In the end, because all of the above considerations
must be dealt with by the maintenance team, proper Regular inspections of the crowd drive system doesn’t
have to be complicated. Start by listening, smelling,
installation and adjustment are probably the biggest
looking, and touching.
factors in determining crowd belt life. A thorough
understanding of the conditions and their While the shovel is operating, listen for any unusual
consequences will prove invaluable in ensuring that sounds that could indicate a problem. Especially on new
the belts get through the break-in period and shovels, do not depend on the operators to alert you to
ultimately provide acceptable life. A lot of patience unusual noises. The newer operator cabs are better
insulated and thus much quieter than on older machines.
helps, too.
Operator awareness of unusual sounds can also be
CROWD BELT PRODUCT KNOWLEDGE
impaired if the in-cab radio/stereo system is used.
The need for crowd belt product knowledge starts in Any unusual aromas — like burning rubber — are
the purchasing department. If the buyers are buying also an indication of belts that have been slipping.
belts strictly on price, belt life will be low.
When the shovel is shut down, remove the cover
Belts supplied by P&H are engineered to meet the from the belt case and visually inspect the belts and
requirements of the drive system on a particular the sheaves. Any signs of glazing or burning are
model shovel. Belts must be purchased as matched- signs of slipping belts. Also look for unusual
length sets. accumulations of debris in the belt case. This could
be an indication of motor mis-alignment, or perhaps
P&H will only supply PowerBand belts in matched
that the belts are nearing the end of their useful life.
sets. It is important that the belts be stored in the
If there are any signs of cracking, fraying or unusual
warehouse as sets and installed on the shovel as a set.
POWERBAND BELT IMPROVEMENTS
As P&H mining shovels have increased in size, and
with increasing load capacities, the construction of
belts specified by P&H have undergone changes.
As an example, the belts now specified on Model
4100s and 2800XPBs feature aramid tensile
(Kevlar™) cords for increased strength, durability,
and virtually zero stretch. Consequently, the need for
frequent re-tensioning during the break-in period is
eliminated. The rubber compound has been changed
to a chloroprene rubber compound for increased heat
resistance.
The new belts also feature a specially treated cover
which slips under impact-loading while withstanding
slip and shear forces at rated load without generating
excessive heat. The new belts are also precision- PowerBand crowd belt life depends on a number of
factors, including the material being excavated,
matched to maximize power absorption and belt life.
blasting, operator technique, high ambient
This new-type belt will be available for other P&H temperatures and belt installation and adjustment.

2 Minesite Insights
wear, the belts should be
replaced. TABLE A: Crowd Belt Settings for P&H 4100, 4100A and 4100A/LR

Touch test: Being very Machine Type 4100 4100A 4100A/LR

careful, place your hand on the Crowd Motor K1010 K700 K700
belts. If you cannot hold your P&H Belt R17893D1* R17893D1* R17893D1**
hand on the belts for five (5) New Decal R29599D1 R29599D1 R29599D1
seconds, the belts are running too Hydraulic Cylinder 21Z1047 21Z1047 21Z1047
hot — and you must determine
why. Quite often, excessive heat
INITIAL SETTINGS
is caused by frequent slipping of
Pretension (psi) 200 0 0
the belts. In hot climates you
might consider cleaning the Tension (psi) 600 600 300
outside of the belt case RETENSION SETTINGS
occasionally. Oil and dirt buildup Pretension (psi) 1300 800 800
will act as an insulation and Tension (psi) 1700 1200 1075
cause the belts to run hotter.
Additional Notes: * Belt R17893D1 supersedes belt 7Z399D14.
The effect of temperature on **Belt R17893D1 supersedes belt 7Z430D5.
belt life is important. It is Belt R17893D1 is not a standard Kevlar belt, and should not
be substituted with such.
estimated that a 36-degree
Fahrenheit rise in ambient
temperature will reduce a belt’s FIGURE 1 - Belt-Tensioning
life by 50%. Your hand can System for Models 4100 and 4100A.
tolerate about 140 degrees F,
which is the maximum PowerBand
temperature at which a belt Assembly
should run, provided the ambient
temperature is under 110
degrees F.
Excessive slippage due to loose
belt tension or very difficult, high-
impact digging can increase a belt’s Belt-
operating temperature. Tensioning
Temperatures above 160 degrees F Assembly
will significantly shorten the life of
the belt.
Belt tension should be checked
as part of the inspection
procedure. The procedure for
checking and adjusting belt
tension will vary depending on
the model of shovel, type of belt
used, and the type of crowd
motor on a particular shovel.
Details on this will follow.
DIAGNOSING BELT FAILURE
Frequently, in an attempt to
identify the cause of poor belt
life, especially after the failure of

Please turn to page 4.

Minesite Insights 3
P&H ‘PowerBand’ Crowd Drive ! Is the sheave cutting the belt?
Continued from page 3. Belt failures are rarely, if ever, caused by a defect in
a number of belts in quick succession, attention is the sheaves. However, mis-alignment of the sheaves
focused on the belt sheaves, prompting such questions might be a contributor.
as... The appearance of a broken belt can provide a clue
! Are the grooves the correct depth? to the cause of the failure. Shredded belts are an
! Are they the correct angle? Continued on page 5.

Note that pressure / tension data for the original 7Z399D_ belts used earlier on 2800XPA / B and 4100s
is not included in Tables A and B. Field experience strongly indicates that application variables
(digging, operator techniques, belt stretch, maintenance practices, and so on) make the definition of a
specific practice impractical, and that the alternative is trial-and-error. For this reason, the original belt
has been superseded.
Usage of these new settings with the original-style belts will likely cause premature belt breakage
during the break-in period if difficult digging is encountered.

TABLE B: Crowd Belt Settings for P&H Models 2100, 2300 and 2800
Machine Type 2100BL/BLM 2100BLE, XP, 2300XP, 2300XPA*, 2300XPA**, 2800XP, 2800XPB
XPA, XPB MK-II, LR XP/LR, XPA/LR XPB XPA, MK-II

Crowd Motor CR-63C K300 K408/K489 K408 K408 K408 /K489 K489

P&H Belt 7Z399D5 7Z399D5 7Z399D3 7Z399D3 7Z399D3 R17893D2 17893D2

New Decal R29602D1 R29602D1 R29603D1 R29603D1 R29603D1 R29605D1R29605D1

Hydraulic 21Z767 21Z767 21Z767 21Z767 21Z767 21Z767 21Z767

Cylinder
Initial Tension 1400 1850 1600 1800 2000 2150 2250

Retension 500 1200 725 1050 1300 1250 1600

Additional Notes: * 2300XPA models with the 100J4416 boom configuration shown at lower left.
** 2300XPA models with the 100J5562 boom configuration shown at lower right.
***Belt number R17893D2 supersedes belt number 7Z399D7.

100J4416 BOOM
CONFIGURATION

100J5562 BOOM
CONFIGURATION

4 Minesite Insights
indication of high heat, most likely due to slipping. Make sure that proper tools are available.
Belts will slip if tensioned improperly, especially Check to make sure that the crowd belt case is in
during the break-in period of a belt that is not made good condition, and that everything is tight.
up of aramid tensile cords (Kevlar™).
Above all, when changing belts, make sure proper
Once a belt slips, it glazes and is more likely to slip lockout / tagout procedures are used.
again. The result can be a destructive spiral of re- PROPER BELT INSTALLATION PROCEDURES
tensioning a slipping belt to higher and higher
When installing new belts, make sure both belts are
tension. Under these conditions, a belt could fail
replaced with a matched set. If only one belt is
either due to slip, or it could fail from over-
replaced, the new belt will carry the entire load and
tensioning. Over-tensioning could also result in
will fail prematurely.
reduced shaft and bearing life.
Make sure that the pulleys are in good condition.
A clean break in a belt is an indication of over- Remove any burrs or sharp edges that may be present.
tensioning and overload. Overload can occur when a Check the pulleys for overall condition.
properly tensioned belt is subjected to high shock
loads. Shock loads occur when a drive is quickly Make sure the sheave grooves are clean. If
stalled from high speed. Due to the rapid stopping of necessary, use a non-flammable, non-petroleum
the motion, the crowd reference is usually solvent to clean the grooves. Petroleum solvents may
maintained. Add to this the inertia of the drive leave a residue that could cause the belts to slip under
components, and the instantaneous torque seen at the Please turn to page 6.
belt can be greater than 300% of
stall torque, resulting in a torque FIGURE 2 -
overload failure of the belt. It is Belt-Tensioning System for Models 2100, 2300
this type of failure that is and 2800.
addressed with the new
R17893D_ belts.
POWERBAND BELT MAINTENANCE Adjusting Nut
Adjusting Rod
An effective crowd belt Jam Nut & Cover
maintenance program consists of
several elements: Jam Nut
! Maintaining a safe working
environment. Crowd Motor Hydraulic
! Belt product knowledge. Cylinder

! Proper belt installation

procedures. Pump
Assembly
! Regularly scheduled
inspections and
adjustments.
! Troubleshooting.
MAINTAINING A SAFE WORKING
ENVIRONMENT

Before working on the crowd

drive system, make sure the
shovel is parked on level ground
— with the dipper resting on the
ground — away from the working
face, with all of the brakes set.
Make sure that all walkways
and platforms are in good
condition and clear of
slipping and tripping hazards.
Minesite Insights 5
Crowd system maintenance same theory — is used on P&H Models 2100, 2300
Continued from page 5 . and 2800. Remember that on these systems, higher
hydraulic pressure results in higher belt tension.
load. The use of belt dressing is specifically not
When P&H introduced the Model 4100 shovel, the
recommended.
crowd belt tensioning system was changed. On the
When installing new belts, make sure that the 4100 and 4100A, the belt tensioning system is located
tensioning system is backed off far enough to allow at the bottom end of the motor table. In this system,
the belts to slide into place without being forced. gravity acting on the motor table provides the belt
Never use a pry bar or lever to force the belts over the tension. The hydraulic cylinder and adjusting rod
“V” grooves. It is possible to damage the belts limit the amount of belt tension caused by gravity. In
causing short life. the 4100 system, higher hydraulic pressure results in
lower belt tension. Lower hydraulic pressure results
It is a good idea to check motor alignment when in higher belt tension.
replacing belts. Simply place a straight edge or MODEL 4100, 4100A AND 4100A/LR CROWD BELTS
stretch a string across the two sheaves. If the straight
The P&H part number for the new-style belts for
edge is touching the two sheaves at four points, the
models 4100, 4100A and 4100A/LR is R17893D1.
motor is aligned. As a general rule, sheave mis-
This part number supplies one set of two belts that
alignment should be less than 1/2-degree or 1/10-inch are precision-matched in length.
per foot of drive center distance.
Remember, these belts are not ordinary Kevlar
The crowd belt adjusting system on P&H shovels is belts, and using these pressures with a Kevlar belt
really quite simple. The motor is mounted on a table other than R17893D_ can result in significantly
that pivots (see Figure 2). increased impact-loading to the gearing. Ordinary
MANUAL CROWD BELT TENSIONING SYSTEMS Kevlar belts can grab and instantaneously transmit
many times the rated horsepower. Therefore, their
Originally, a threaded adjusting rod and adjusting nut
use is not recommended.
are mounted to the boom on the upper side of the
motor table. Because the new belts are so different, the
Turning the nut procedure for tensioning is also different. It is
upwards tightens important to follow the new tensioning procedures
the belts, and with the new belts. These new procedures only apply
turning it to the belts supplied by P&H under part number
downward R17893D1.
loosens the belts. Also, make sure that the hydraulic cylinder in the
The procedure belt-tensioning system is the correct P&H part
is to measure the number. The hydraulic cylinder should be 21Z1047.
center-to-center If some other cylinder is used, the belt tension might
distance of the sheaves, and then turn the adjusting not be correct for a given hydraulic pressure.
nut in the belt-tightening direction until the center-to- Refer to Table A. P&H engineering has tabulated
center distance increases 1/8-inch. Continue to do all of the data required to properly tension the crowd
this until the belts will not slip when the operator belt. Notice that the same part number belt is
crowds into the bank. You then increase the center- specified for all three models of 4100 — the adjusting
to-center distance another 1/8-inch. pressures (and resulting belt tension) vary by model
and by crowd motor frame number.
HYDRAULIC CROWD BELT TENSIONING SYSTEMS
The next line says “New Decal.” This is the part
In later shovel models, P&H added a hydraulic
number of a decal that can be applied over the
cylinder to assist in raising and lowering the table.
original plaque. The new decal has the revised
Proper belt tension is specified in terms of hydraulic
adjustment procedure and hydraulic pressures to be
pressure. Remember that if a hydraulic cylinder is
used with the new-style belts.
replaced, it must be replaced with an identical
cylinder. If the replacement cylinder is not identical, The part number of the new decal is R29599D1. If
a different belt tension will result for a given you would like copies of the decal, contact your
hydraulic pressure. regional P&H MinePro Services office when you
place your order for the new belts. P&H stands ready
The same basic system — different components, but
6 Minesite Insights
to provide you with this important information the rod nut. Back-off the rod nut from the clevis
reference tool at no charge. The next line on the approximately 2 inches. Do not let the rod disengage
chart lists the P&H part number of the hydraulic from the clevis. SLOWLY release the pressure (load)
cylinder used in the adjusting system. in the hydraulic hand pump until the pressure gage
The bottom half of the table deals with actual indicates the Pretension pressure shown in the
adjusting pressures. These pressures were determined Retension section of Table A.
by P&H engineering and were confirmed by field Now operate the manual pump until the pressure
experience. gage indicated the Tension pressure shown in the
IMPORTANT: The INITIAL belt settings are Retension section of Table A. Turn the adjusting rod
used when a new set of belts is installed and nut upward until it is against the upper clevis.
tensioned for the first time. After the belts have Continue turning the nut upward until the pressure on
run for three (3) shifts, they are adjusted to the the gage just begins to drop. Align the adjusting rod
RETENSION belt settings. to the nearest hole in the clevis and lock in place with
Both the Initial and Retension belt sections of the the pin and cotter pin. Release the hydraulic pressure
table specify a PRETENSION and a TENSION from the cylinder.
setting.
REMOVING AND INSTALLING 4100 CROWD BELTS
The Pretension setting results in a higher belt
tension to make sure that the belts are fully seated in To remove and install new crowd belts, remove the
the sheave grooves. Once the Pretension setting is smaller diameter pin from the upper clevis of the
accomplished, operate the hydraulic pump until the holding rod assembly. Then pump the hydraulic hand
tension pressure is reached. pump until the motor base lifts approximately 2
Remember this about the relationship between inches away from the upper clevis. Tighten the rod
crowd-adjustment hydraulic pressure and belt tension nut against the upper clevis. Continue to alternately
on P&H Model 4100s: raise the motor base (2 inches) and tighten the rod nut
against the clevis until the crowd belts can be
# Lower hydraulic pressure = higher belt removed and installed on the sheaves.
tension.
CAUTION! Due to motor weight when
# Higher hydraulic pressure = lower belt hydraulic pressure is released, the motor base and
tension.
motor can pivot downward rapidly causing injury
Check the adjustments of the belt after three shifts of and damage. To prevent this from happening, do
operation using the Retension Settings in Table A. not allow the adjusting rod to disengage from the
Check and retension the belts every 2,000 hours of clevis at any time. Make sure the adjusting rod
operation using the Retension settings. nut is tight against the upper clevis when motor
ADJUSTING 4100, 4100A AND 4100A/LR CROWD BELTS base has been raised to its final position to
remove or install crowd belts.
Before adjusting or replacing the crowd belts, read
the appropriate section in the shop manual to become Next remove the old belts and install the new belts.
familiar with the procedures and cautions and Back off the adjusting rod nut from the clevis
warnings. The illustrations in the shop manual will approximately two (2) inches. Bleed off hydraulic
show details of the adjusting mechanism more clearly pressure to lower the motor base. Alternately back
than is possible in this publication. off the nut and release hydraulic pressure until the
Remember that the crowd belts are adjusted by crowd belts are tight. Then refer to Table A —
means of a hydraulic pump and cylinder. Before any INITIAL SETTINGS (for P&H 4100, 4100A and
adjustments are made, inspect all components for any 4100A/LR crowd belts) and release the hydraulic
signs of wear or abuse. Do not use any hydraulic pressure until the gage reads the proper pretension
components which appear damaged. Refer to Table B pressure. Now pressurize the hydraulic cylinder to
in this publication for adjustment pressures. Also, see the tension pressure — NEW BELT SETTINGS.
Figure 2. Turn the adjusting rod nut against the upper clevis
To retension the crowd belts, first remove the until the pressure gage reading just starts to drop.
smaller diameter pin from the upper clevis of the Align the adjusting rod to the nearest hole in the
holding rod assembly. Next, pump the hydraulic clevis and lock in place with the pin and cotter pin.
pump until the motor base just starts to lift away from
Please turn to page 8.

Minesite Insights 7
Crowd system maintenance retension pressures listed in Table B.
Continued from page 7. Instruction decals for the new-style belts installed
on 2800s will be available, free of charge, from your
Readjust the belts after three (3) shifts of operation local P&H MinePro Services office. Ask for decal
using the retension settings (Table A — Crowd Belt P&H part number R29605D1.
Settings for 4100 and 4100A). Check and readjust
the crowd belt tension every 2,000 hours. CROWD BELTS — 2100S AND 2300S

MODEL 2800 MKII, 2800XPA, 2800XPB CROWD BELTS Polyester PowerBand belts are still standard for the
2100s and 2300s. However, because of research done
Up until this time, the standard crowd belt on all 2800
by engineering, we are recommending that using
models has been 7Z399D7. These belts have been
superseded by P&H engineering to new aramid cord different adjusting pressures will result in even better
belts, P&H part number R17893D2. The new-style belt life. Table B lists the new recommended
belt requires different hydraulic adjusting pressures. adjusting pressures. If you would like decals that list
See Table B — Crowd Belt Settings for P&H Models the new recommendations, contact your local P&H
2100, 2300 and 2800 — for the new adjusting MinePro Services office and ask for decal R29602D1
pressures. for 2100s, or decal part number R29603D1 for 2300s.
The actual adjusting procedure is the same as with The decals are free of charge.
the old-style belts, but the adjusting pressures change. New aramid belts for these machines are also
See Table B for the new adjusting pressures. Also, optionally available and would use the same pressure
with the new belts, retension (readjust) them after setting in Table B. However, they only receive one
three (3) shifts of operation using the Retension retensioning after three (3) shifts. #
pressures listed in Table B. Check and retension the This article was researched and drafted by
belts every 2,000 hours of operation using the
Jim Wohlitz, Joe Colwell and Nate Rife.

Minesite Insights is published quarterly to provide information updates of interest to P&H Mining Equipment customers and the
P&H MinePro Services team. If you have ideas or suggestions for topics, or if you need extra copies of a back issue, please fax this
information to Mark Dietz in the P&H Mining Equipment Marketing Communication Department, (414) 671-7249.
IMPORTANT: If we need to revise or update the mailing list for better delivery to you, please fax us this information.

X - 1489

PERMIT NO. 463 West Milwaukee, WI 53214

P.O. Box 310
MILWAUKEE, WI
4400 West National Avenue
PAID P&H Mining Equipment
U.S. POSTAGE
BULK RATE
Minesite Insights
 June 2005
Originally Issued August 2003

‘DELTA’ Track Tension To help ensure

optimal DELTA
Adjustment Procedure drive system
Since it was introduced in 2000, the P&H DELTA (Deep- performance and
Engaging, Long-life Track Assembly) crawler belt drive component life,
system has been applied by a growing number of mines the following
as a retrofit to their P&H electric shovels. Originally track tension
designed for 4100XPBs, the DELTA system is also adjustment
available for 4100s, 4100As, 2800XPAs, 2800XPBs and procedure is
2300XPBs. provided.

Featuring a sprocket-type drive tumbler, the DELTA Inspect System

system is designed to maintain accurate pitch by Periodically
allowing the shoes to engage deep into the tumblers, The crawler track is made up of crawler shoes pinned to
driving near the pitch line. each other forming a movable track upon which the
Inherent with the sprocket-style design is an increase in mining shovel rides. The crawler track evenly distributes
engagement surface area between shoe drive lug and the the weight of the mining shovel on the ground. Inspect
tumbler pocket, providing for, among other things, the crawlers periodically (after first reverse-propelling)
reduced duty-cycle loading, extended shoe and tumbler to check for the following:
life, and improved track efficiency and tractive effort. • Loose or missing crawler shoe pin-securing bolts.
DELTA drive systems also allow the track to operate with • Excessive wear (elongation) of the shoe pin holes.
a lower level of track tension (loose belt tension) – a • Broken shoes (wings) and/or broken pins.
tensioning requirement that is different than what is • Binding between shoes. Inspect the ends of the roller
specified for other high-drive machines. On DELTA path for binding as viewed from the rear of the
systems, tight track tension is not required to maintain machine. If binding is occurring, contact MinePro for
tumbler engagement. Instead, the tracks should be run a trimming instructions.
bit loose, allowing for some slack in the belt. The looser • Excessive slack in the crawler slack (see illustration
tracks on the DELTA drive system reduces pin- and pin- below ‘Track Tension’ for examples of track-correct,
lug-loading when operating the shovel on uneven ground. track-too-tight and track-too-loose conditions).

‘DELTA’ Drive System Track Tension

Reverse propel, then stop the shovel and observe:

track-too-tight track-correct track-too-loose

If you determine that the shovel’s DELTA crawler track
is too tight or too loose, the following procedure should
be followed to bring about correct track tension.
NOTE: The crawler shoes must be free of mud and
dirt to obtain an accurate adjustment. Also, the shovel
must be parked in an area that is level, away from
hazards, well compacted — preferably with a hard floor Roller Path Tumbler
Lug
— and with good drainage in case of rain.
Inspect for
Interference
Tension Adjustment Procedure Here

1. Propel the shovel forward first. After the shovel

has been propelled in reverse in order to carry out the
track inspection, the shovel should then be propelled 5. Remove the forward set of shims and install the
forward in order to bring the loose portion of the belt hydraulic ram, sleeve and adjusting rod supplied with
to the top. This will take-up the slack at the tumbler the mining shovel on each side of the idler assembly.
and the belt will no longer hang (as needed for the 6. Be sure to move the idler roller the same distance
visual inspection), but it will be necessary for the on both sides of the idler assembly.
slack to be on top to make the tension-adjustment
process easier. 7. Pump the hydraulic ram until the track tension is
correct. When track tension is correct, there should
2. Shut down the shovel. Lock-out and tag-out the be some slack between the rear idler and the tumbler
controls. as shown on page 1. Avoid over-tightening the track.
3. Verify that the rams, sleeves, spacers and rods 8. Fill the space behind the front idler bearing block
provided in the track adjustment tool kit are straight with shims that were removed from the front of the
and in good condition. Verify that all hydraulic ram bearing block. Be sure to insert the same number and
hoses and connecting hardware are in good condition. size of shims on each side of the bearing block.
WARNING: The rams, sleeves, spacers and Notice
rods provided are chosen to fit correctly and safely in Over-tensioning the track can cause link pins and / or
the provided area. Adjusting the track should not be shoes to break.
attempted using anything else as a spacer as it could
cause the ram assembly to fly out while under continued on page 24
pressure, which could cause serious personal injury
or death.
4. Remove the cotter pin and shim-retaining pin, one
on each side of the idler assembly.

Idler end of crawler frame shown without rams, Tools

sleeves, spacers and rods.
2 Minesite Insights
9020 Fairlead Frame Adjustment Procedure
The Fairlead Frames on the model 9020 dragline must be Re-install the outer circle of bolts and torque them to
adjusted periodically due to wear of the lower thrust 1,463 ft-lbs.
washer. If this is not done, the excessive up and down
movement coupled with ingress of dirt will shorten
component life. SHIMS AVAILABLE

The “GAP” at the bottom of the Lower Pivot Pin as (Suggest 12 of each be on hand. This is enough to
shown in the sketch below should be checked after every cover two (2) Fairlead Frames.)
1000 hours of operation or whenever excessive HALF SHIM – 0.180" THICK – P.N. R1710D1
movement is observed or pounding action is taking
place. This happens when the drag rope is in contact HALF SHIM – 0.075" THICK – P.N. R1710D2
with the Upper Vertical Sheave and has sufficient load to HALF SHIM – 0.020" THICK – P.N. R1710D3
raise the assembly and allow it to drop down suddenly
HALF SHIM – 0.0075" THICK – P.N. R1710D4
such as during bucket dumping.

NOTE: When fully assembled and all lower bolts

tightened, no gap will be present. To check the gap,
the outer circle of bolts must be loosened or removed,
allowing the Lower Pivot Pin to drop and the lower
surface of the pin’s head to contact the Thrust Washer.
Visually verify that this has happened. This will reveal
a “GAP” clearance between the lower retainer plate
and the bottom of the fairlead frame. This gap when
now measured should be from 0.005" to 0.015".

If the gap is greater than this value, add a combination of

shims (see list of shims, thickness and part numbers
below) until the correct gap of between 0.005" to 0.015"
is achieved AFTER the outer circle of bolts have been
re-tightened. (Hint: It might be easier to install the
shims if the bolts in the inner circle are loosened. Screw
these out no more than four (4) turns, which will add
about 1/2 inch to the installation clearance.) Gap
If the inner circle of bolts have been loosened, turn them Fairlead Lower Pin (No gap when
fully assembled)
back in and torque to 1,463 ft-lbs.

Materials, Procedures Available for 4100XPB

Bail Support or Dipper-Handling Kit
Engineering recently released document R51443F_ to Not called out on the drawing are two wire rope slings
provide materials and procedures for adding lugs on the 220" long with an allowable working load of 55 tons
dipper handle torsion box for the purpose of anchoring a each. These slings must have a shackle on each end
wire rope sling to assist in holding the bail during hoist with a pin size not larger than 3" in diameter and not
rope change-out or to manipulate the handle when smaller than 2-5/8" in diameter to match the strength of
changing the dipper. the rope sling.
Document page F1 applies to 4100XPB serial number
ES41107 and older. Document page F2 applies to serial
number ES41108 and newer.
Minesite Insights 3
 Dipper Trip Settings 4. Latch lever travel not parallel to the slot in the hinge
arm and rubbing occurring
Mine maintenance people often ask about what their 5. Machine no longer has banjo on handle or two-part
limitations are regarding adjusting the line pull on their sheave assembly on door (lost mechanical
dipper trip unit. This really becomes an issue when the advantage)
trip doesn’t work properly. Not working properly can 6. Too much slack between the banjo arm and the latch
mean many things. It could mean it takes 3 – 4 lever.
applications to trip the dipper or it could mean it won’t
7. Deflector sheaves not free-turning.
trip at all. The other possibility is that it trips before the
operator wants to, resulting in a lost pass. 8. Motor damaged and not producing the required
torque.
To operate efficiently, the dipper should always open 9. Friction plugs (older spur gear systems) on the drum
with one application of the trip. If this does not happen, set for too high of a friction level.
cycle time is lost and extra heating occurs in the motor. 10. Resistors not adjusted to the optimum resistance for
There are many reasons for not being able to trip in one the desired torque / line pull.
application...
Each of these can be corrected by one method or
1. Too large of a payload sitting on the door creating another:
too much friction
1. Operators sometimes rest the door on the load in the
2. Too large of an engagement between the latch bar truck to relieve the load on the latch bar. This is not
and the dutchman. the best practice due to wear on the door and side
3. Too high of a friction coefficient between the load on front end.
latchbar and the dutchman, sometimes due to a 2. Adjust the bar engagement (see maintenance
rough-welded surface. manual). More than .75" may be required to prevent
false trips.

Shovel Model 2100BL, BLE

2300XP, XPA, XPB 4100, 4100A
2800XP, XPA, XPB High Inertia
Drum Assembly 923J79F2 923J79F2 100J5518F2 100J5518F2
Motor Assembly EBM656F1A EBM656F1A EBM656F1A EBM656F1E
Voltage Frequency 50 HZ (380v) 60 HZ 50 HZ (380v) 60 HZ
Effective Trip Line Pull
Dipper Trip Comparative Data

Recommended
Resistance (ohms) 1.5 2.3 1.5 2.3
Line Pull (lbs.) 1227.0 1227.0 2290.4 2290.4
Stator Line Amps 62.0 72.0 62.0 72.0
Rotor Line Amps 78.0 62.0 78.0 62.0
Maximum Trip Line Pull
Resistance (ohms) 1.0 1.0 1.0 1.0
Line Pull (lbs.) 1384.8 1533.8 2584.9 2863.0
Stator Line Amps 77.0 92.0 77.0 92.0
Rotor Line Amps 101.0 106.0 101.0 106.0
Effective Slack Line Pull
Recommended
Resistance (ohms) 43.0 43.0 43.0 43.0
Line Pull (lbs.) 87.6 78.9 163.6 147.2
Stator Line Amps 10.0 10.0 10.0 10.0
Rotor Line Amps 4.0 4.0 4.0 4.0
Maximum Slack Line Pull
Resistance (ohms) 35.0 35.0 35.0 35.0
Line Pull (lbs.) 105.2 105.2 196.3 196.3
Stator Line Amps 11.0 11.0 11.0 11.0
Rotor Line Amps 5.0 5.0 5.0 5.0

4 Minesite Insights
 3. Lubricating helps but only for a short time (be alert, as compared to the attached table and is lower than the
however, to the possibility that lubrication might recommended value. If true, setting at the recommended
cause nuisance trips). Grind repair welds on latchbar value will increase line pull and result in more reliable
smooth to reduce friction with the dutchman. tripping. If you are already past the recommended
4. Check location of deflector sheave or banjo on handle settings and tripping is still unreliable, check out the
and adjust location until lever pulls parallel to slot. other eight potential causes listed above and verify that
5. Consult manufacturer (MinePro) they aren’t the cause.
6. Take up excessive slack between banjo and latch If no other cause can be found and the recommended
lever. settings are insufficient still, consideration can be given
7. Clean out sheaves and brackets and check bearings to trying the maximum setting. Care and monitoring is
and bushings for free rotation. If this doesn't resolve required to verify that no problem of overheating is
it, consult manufacturer (MinePro) occurring. On the face of it, one would suspect that
8. Consult manufacturer (MinePro) increasing current and therefore torque, that the result
9. Adjust per manual. If unit has internal brake, adjust has to be more heating. In reality, that may not be
it. necessarily true. If you were taking 3-4 applications of
10. Adjust per recommendations in this article the trip to get the door to open, that four applications of
current will, from an RMS heating point of view
As stated, optimizing the line pull is the purpose of this represent much more heating than one application of the
article. Increasing the line pull should not be used as a trip at the maximum settings. Again, monitoring will
solution if the other nine items haven’t been addressed. tell if overheating is occurring. Using a temperature
Still, we believe that many trip units on P&H shovels probe, check the motor frame temperature and verify
are not at the optimum adjustment for various reasons. that it isn’t more than 90 deg. C above ambient. If not, it
One of the reasons is that the setting indicated on the can continue at the higher settings. If it is above this
wiring schematic is not the current recommended value continued on page 6

Shovel Model
4100A, 4100TS 4100BOSS 4100XPB
Low Inertia Planetary Planetary
100J5518F3 100J5518F3 R48511F1A R48511F1A R43627F1A R43627F1A Drum Assembly
EBM734F1A EBM734F1E EBM1539FIE EBM1539FIE EBM1539F1E EBM1539F1E Motor Assembly
50 HZ (380v) 60 HZ 50 HZ (380v) 60HZ 50HZ 60HZ Voltage Frequency
EffectIve Trip Line Pull
Recommended
2.1 2.3 1.8 2.1 1.8 2.1 Resistance (ohms)
2290.4 2290.4 2385.6 2385.6 2385.6 2385.6 Line Pull (lbs.)
52.0 60.0 46 62 46 62 Stator Line Amps
67.0 53.0 58 78 58 78 Rotor Line Amps
Maximum Trip Line Pull
2.1 2.3 1.5 1.5 1.5 1.5 Resistance (ohms)
2290.4 2290.4 2726.4 2726.4 2726.4 2726.4 Line Pull (lbs.)
52.0 61.0 57 65 57 65 Stator Line Amps
61.0 60.0 72 80 72 80 Rotor Line Amps
Effective Slack Line Pull
Recommended
36.0 40.0 40 56 40 56 Resistance (ohms)
147.2 147.2 142 142 142 142 Line Pull (lbs.)
22.0 21.0 16 19 16 19 Stator Line Amps
5.0 5.0 4 3.2 4 3.2 Rotor Line Amps
Maximum Slack Line Pull
30.0 32.0 36 50 36 50 Resistance (ohms)
196.3 170.4 170.4 170.4 170.4 170.4 Line Pull (lbs.)
23.0 22.0 16 19 16 19 Stator Line Amps
6.0 6.0 4 3.5 4 3.5 Rotor Line Amps

Minesite Insights 5
 temperature, turn down the settings and consult with makes a difference in trip performance. As stated earlier,
manufacturer on other ways to improve trip reliability. these values are likely to differ from those on your
schematic. Where differences exist, we recommend
Slack take-up settings can be optimized also. If false
using the values in the attached table. If you are
tripping occurs, consider lower current. This may cause
unfamiliar with the procedures to make these
excessive slack in the cable when crowding in or out
adjustments, refer to the following article (that ran in
and possibly getting snagged on the truck. Excessive
MineSite Insights Issue No. XS-2344) for detailed
slack could also result in damage to the motor caused by
adjustment instructions.
rapid motor reversal as the motor is winding in and the
dipper is crowding out. If excessive slack occurs, try As dippers and payloads have increased in size and
raising the current and monitor for false trips. weight, these type of problems have increased. P&H
continues to try to optimize the dipper trip systems to
The table presented on pages 4-5 provides the
cope with these increasingly higher loads. Higher
recommended and maximum settings for every current
capacity, lower maintenance units are being developed
model in the field. Both trip and slack take-up values
and will soon be offered as upgrades on older shovels.
are provided. One item of note is that being 50 or 60 Hz

Dipper Trip Quick Check: brush connection to the brush arm. The resistance
measured is phase-to-phase, which is double the
How to Measure Dipper Trip resistance in each secondary leg.
Secondary Resistance To With the shorting contactor open, the measured slack
take-up phase-to-phase resistance, divided by 2,
Help Ensure Optimal Dipper should be between the recommended and maximum
Trip Performance values specified in the table located on pages 4-5.

If you are experiencing certain problems with the dipper a. Measure phases 1-2 _____________________
trip mechanism on your P&H electric shovel, problems b. Measure phases 2-3 _____________________
such as…
c. Measure phases 1-3 _____________________
• Excessive cable droop during retract
• An overly tight cable during retract and crowd that NOTE: The shorting contactor is located in the transfer
causes nuisance dipper trips, or perhaps cabinet on old machines (4100TS and below), while on
new machines (4100XPB and 4100BOSS) they are
• Difficulty resetting the latch bar due to high slack take- located in the Auxiliary Cabinet.
up tension
… you should be able to handle those problems with the
5. Manually engage the shorting contactor in the
procedure outlined below.
transfer cabinet that shorts-out the slack resistors and
Procedure for Measuring Dipper Trip Secondary leaves only the trip resistors in the rotor secondary.
Resistance: As in step 4, measure the following phase-to-phase
trip resistance, divided by 2, should be between the
1. Shut down machine to remove power, making certain
recommended and maximum values as specified in
required lockout / tag-out procedures are followed.
the table located on pages 4-5.
2. Open the Auxiliary cabinet to ensure power is
a. Measure phases 1-2 _____________________
disconnected and also ensure that the slack shorting
contactor is open (refer to nearby schematic). b. Measure phases 2-3 _____________________
3. At the dipper trip motor, open the brush inspection b. Measure phases 1-3 _____________________
cover and remove the brushes so they are not
6. Perform the resistance measurements for both motors
touching the slip rings.
(if applicable).
4. Using a Fluke Digital Multimeter (Example: Fluke (If using the dual motor Dipper Trip system)
23) measure the resistance phase-to-phase on the
6 Minesite Insights
 ADJUST EACH PHASE
TO RECOMMENDED
RESISTANCE

ES1822_01
Example of Dipper Trip Motor Schematic

NOTE: Reference Machine Schematics to ensure that Adjust the Trip secondary resistance if:
you identify the correct resistance reading. Please
The operator is tripping the dipper multiple times to get
refer to the information provided in the nearby sidebar
article titled ‘Dipper Trip Settings: Recommended the dipper to trip, decrease the secondary resistance. Do
versus Maximum’. not reduce the resistance below the minimum.
Adjustment of the Trip secondary resistance should not
automatically be set to the minimum since the minimum
‘Rules of Thumb’ resistance results in high motor currents and temperature
• If the cable is tight going out and tight coming in – the and shorter motor life. Only adjust to the minimum if
problem is electrical. necessary.

• If the cable is loose going out and loose coming in –

the problem is electrical. EDITOR’S NOTE:
‘Déjà vu’ … All Over Again
• If the cable is tight going out and loose coming in – the
problem is mechanical. This edition of Minesite Insights probably looks
familiar to regular readers of this newsletter:
Adjust the dipper trip Slack Take-Up secondary
The articles headlined ‘Dipper Trip Quick Check’
resistance if:
and ‘Shovel Hoist Drum Alignment Procedure’ first
1. The cable droop is excessive during crowd retract. appeared in the April 2002 edition. The articles re-
If the dipper trip motor does not tighten the cable appeared in the August 2003 edition of Minesite
before the crowd retract reverses direction, the Insights, containing valuable added information and
snapping of the cable can result in damage to the graphics.
dipper trip motor / gear box and cause nuisance Our purpose for re-issuing the August 2003 edition,
tripping of the dipper. Decrease the resistance to however, is to provide you with some updated,
increase take-up torque until the cable droop is simplified information contained within the main article
minimal. that begins on page 8.
2. If the cable remains too tight during retract and Titled ‘Guidelines, Settings Outlined for Crawler
crowd causing the dipper to nuisance trip, increase Frame Bolting Procedure,’ this article now contains
the secondary resistance to decrease the take-up simplified reference tables on pages 15, 16 and 17
provided by our colleagues in the Service Support and
torque.
Engineering areas of P&H Mining Equipment.
3. If there are problems in resetting the latch bar due to
We believe you will find this updated edition of
high slack take-up cable tension, increase the Minesite Insights to be of continuing reference value
secondary resistance to decrease the take-up torque. for your shovel maintenance management program.

Minesite Insights 7
Guidelines, Settings
Outlined For Crawler Frame
Bolting Procedure
From time to time, questions arise with regard to how
best to mount the crawler frames to the carbody of the
P&H electric mining shovel. The inquiries are prompted
for various reasons, including the occasional
maintenance-related breakage of over-tightened rod bolts
and also the availability of several crawler frame bolting
procedure options.
What follows is information about the “preload”
principle at work in the effective mounting of crawler
frames to the mining shovel carbody. Also presented are
guidelines and settings for effective crawler frame
mounting.
Bolts generate preload for needed friction
Mining shovel crawlers must be mounted tight to the
carbody along the shear ledge. The principle behind the
bolting of crawlers is the need for the crawler to Properly preloaded rod bolts produce needed friction
maintain a degree of freedom and elasticity in relation to between the carbody and the crawler frames of the
the various loads applied without over-stressing the P&H electric shovel. Shown above is the ‘TorqueRite’
structures. clamping system available through MinePro.

The sole purpose of the bolts is to generate a required

level of preload, which in turn produces friction between The primary cause of bolt breakage can be traced to not
the mated-machined pads of the carbody and the crawler applying specified torque to the bolts. Boom point bolts,
frames. This friction is critical in minimizing relative for example, and most of the bolts used on shovels rarely
motion between the structures. Relative motion fail due to overload. Rather, they fail in cyclical fatigue
stemming from inadequate preload friction between the in either the tensile mode or the bending mode.
carbody and the crawler frame can cause shear ledge
In either case, the bolts fail in these modes only if the
deformation and also cracking of one or both of the
bolt is subjected to external cyclical loads beyond the
structures.
preload.
Excessive bolt torque, on the other hand, can distort
By their inherent nature, axial-loaded bolts that are
structures and also lead to cracking and bolt breakage.
preloaded – in effect, stretched or torqued to a
It is for this reason that maintaining required torque or
recommended setting that is greater than the maximum
preload is so important.
cyclical load – will not experience fatigue. The same
holds true for bolts loaded in shear. If the friction
NOTICE created by bolt-clamping load exceeds the external shear
The amount of clamping force achieved by an individual forces, the bolt will see no fatigue.
rod can be inspected by measurement — using
ultrasound — of the amount the rod bolt has stretched When bolts are preloaded, the preload forces apply
under tension. Because of machine tolerances in the rod compressive stresses to the components being clamped.
bolt length, the rod bolts should each be measured with When cyclical loads are applied, they are directed to
ultrasound before tension is applied. These pre-stretch unloading the compressive stresses that join the crawler
measurements are necessary to calculate the stretch frames to the carbody – and not to stretching the bolts.
amount after tension, and should be logged for future As such, if the preload is higher than the highest cyclical
use. The rod bolts should be numbered so that the load, the bolts will not experience fatigue.
correct measurements can be applied to each rod bolt
after they have been installed. Then, by subtracting the Proper procedures key
ultrasound measurement while under tension from the to attaining needed friction
pre-stretch measurement, the amount of stretch can be Despite application of recommended crawler frame
obtained. bolting procedures, bolt preload is sometimes lost over

8 Minesite Insights
time due to causes that include… For a new shovel (or an older shovel with reinstalled
Insufficient preload (caused by insufficient lube, crawlers), crawler frame bolts should be checked for
uncalibrated tooling or improper procedures), required preload after the first two months or 1,000 hours
of operation, and annually thereafter. Bolts should be
Structural deformation,
checked for evidence of breakage or cracking.
Yielding of plate material beneath the clamping
nut, and Bolt fastener / tensioner methods outlined
Bolt length (shorter bolts lose preload at a faster Several types of crawler frame bolt fastener / tensioner
rate versus longer bolts for the same change in methods have been used on P&H electric shovels up to and
stretch). including the 4100XPB and 4100BOSS models. They
For the above-noted reasons, proper procedures must be include…
applied in order to obtain needed friction between the P&H ‘TORQUERITE™’ clamp method (also
carbody and the crawler frames. known as HYTORC™ clamp method)
Crawler frames must be mounted tight to the carbody SUPERNUTS™ method
along the shear ledge. Bolts should be checked for Hydraulic bolt tensioning kit method (see
preload with a calibrated torque wrench. After several Service Bulletin EMS123)
bolts have been torqued-up to 50% to 60% of Standard hydraulic torque wrench method
recommended preload, double-check the crawler frame /
Illustrations and a brief description of each method are
carbody interface for proper alignment.
presented as follows...
continued on page 10

TORQUERITE Clamping System

TORQUERITE clamps solve several bolt-
NOTE: 4100XPB carbody /
tensioning problems:
crawler frame example used
throughout this article on Reduce bolt installation / removal time
clamping system procedures. (by up to 96%) and cost
Maintain proper torque setting, even in
high-vibration applications
Reduce safety concerns
No actuator arm required
NOTE: TORQUERITE clamps are equipped
with protective covers to keep debris
away from clamps.

Outer Sleeve
Inner Sleeve Inner Sleeve
Drive Slots

Outer
Sleeve
Bolt

The TORQUERITE clamp pulls the

bolt longitudinally, with all work Washer With
performed by the outer sleeve. Internal Splines
Inner Sleeve-to-Washer Splines

Minesite Insights 9
TORQUERITE™ SIDE FRAME CLAMPS nuts to that there are no gaps between the TORQUERITE
clamps and the side frame.
TORQUERITE™ clamps (illustrated on previous page) are
used to tension side frame bolts on some 4100XPB 6. Set the pressure on the hydraulic pump to 3,500 PSI.
shovels. The clamps operate as follows… Follow the pattern shown in the illustration ‘Side Frame
Bolt Tensioning Sequence’ on page 12. Install the
1. The inner sleeve is threaded internally to fit on the
tensioning wrench to the first nut, lining-up the outer
rod bolt. It is also threaded externally to fit threads on
sleeve castellations and inner sleeve splines with the
the outer sleeve. The clamping force is achieved by
wrench. The wrench will hold itself in position. No
counter action between the internal and external sleeves.
reaction arm is needed to anchor the wrench.
2. The outer sleeve has slots that fit the tensioning
7. Cycle the tensioning wrench until it stalls. Clamp
wrench. The inner sleeve also has splines that anchor the
will be tensioned to initial preload.
wrench so that no movement arm is needed to hold the
wrench. 8. Continue to tension all clamps to initial preload using
pattern shown on page 12.
3. The washer has reaction splines on the outer diameter
to ensure positive mating with the tension wrench / 9. Repeat steps 6, 7, and 8 using required pump
HYTORC™ clamp. Splines on the washer inner diameter pressure to achieve the final preload.
mate with splines on the inner sleeve. This arrangement 10. Return wrench to first clamp and test all clamps to
ensures a non-slip friction surface for the wrench and ensure final preload has stabilized.
prevents transmission of rotary force to the rod bolt.
11. Install the protective debris covers.
P&H TORQUERITE Tensioning Procedure
Re-Lubricating and Re-Tensioning TORQUERITE
NOTE: The following procedure assumes installation of Clamps
new side frame bolts. Skip these steps involving
installation of rod bolts if rod bolts are already installed. It is highly recommended that TORQUERITE clamps be re-
lubricated whenever they are re-tensioned. To do this,
NOTE: This procedure assumes standard 4" side the TORQUERITE clamps must be removed from the rod
frame rod bolts. bolts one at a time.

1. Clean any debris from the threads of all rod bolts and Once the TORQUERITE clamp has been removed, it should
from the internal threads of all TORQUERITE clamps. be disassembled. The threads of the inner and outer
sleeves should be cleaned.
2. TORQUERITE clamps are lubricated at assembly. If
they are being re-used or if it is suspected that they need Anti-seize should be used to lubricate rod bolt threads.
re-lubrication, please refer to the re-lube instructions The outer threads of the inner sleeve, and the inner
following this section. The washer surface that contacts threads of the outer sleeve, should be lubricated using
the outer sleeve must be lubricated with type G-N metal type G-N metal assembly paste (P&H part number
assembly paste (P&H part number R47225) each time R47225). In addition, the contact surface between the
the clamp is tensioned. large washer and the outer sleeve must be lubricated with
type G-N metal assembly paste each time the clamp is
3. Lubricate one end of each rod bolt with anti-seize tensioned.
and install washer and TORQUERITE clamps onto that end.
Inner sleeve must be retracted 1/16" to 1/8" inside washer. When re-installing, install washer and TORQUERITE
The clamp should be turned by splines of inner sleeve. clamp onto the rod bolt. The inner sleeve must be
Do not turn by the outer sleeve while installing. A retracted 1/16" to 1/8" inside the washer. The clamp should
special tool (R47214D101 or R47214D201) can be be turned by the splines of the inner sleeve. Do not turn
purchased for insertion into splines to turn the clamp by the outer sleeve while installing. A special tool
assemblies. (R47214D101) can be purchased for insertion into
splines to turn clamp assemblies.
4. With the carbody and side frames properly aligned,
and assuring that the side frame pads are against the The TORQUERITE clamp can then be tensioned to proper
carbody, insert rod bolts with TORQUERITE clamps. final tension using a pump pressure of 5,300 PSI.
Insert short rod bolts in the upper holes, and long rod Tensioning with SUPERNUTS™
bolts in the lower holes.
The SUPERNUTS tensioning system uses a series of
5. Inside the carbody, lubricate rod bolt ends and install jackscrews around the circumference of a threaded
hardened washers and nuts on all rod bolts. Snug the tensioner to tension studs or bolts. These devices are
10 Minesite Insights
‘SUPERNUTS ’ TM
The SUPERNUTS tensioning system uses a
Method series of jackscrews around the circumference
of a threaded tensioner to tension studs or
bolts. The advantage of the SUPERNUTS
system is that great clamping force can be
achieved by using many jackscrews without
having to use great torque on any single
jackscrew.
NOTE: SUPERNUTS clamps are equipped with
protective covers to keep debris away from
clamps.

Typical SUPERNUT shown below...

TM Jackscrews
Jackscrews Tensioner

1
Tensioner 11 12 1
10 2
3 4 9 3
Hardened
Washer 8 4
2 7 5
6
Hardened
Washer Star Pattern Circular Pattern

available in numerous sizes, with varying numbers of 3. Clean the area around the stud to be tensioned and
jackscrews around the circumference of the tensioner. A remove all dirt and / or chips from the threads of the stud
SUPERNUT is shown in the above illustration. and from the main internal threads of the tensioner. If
multiple studs are being tightened, they should be
The main advantage of the SUPERNUTS tensioning system
tightened in the correct torque pattern (see illustration
is that great clamping force can be achieved by using
‘Side Frame Bolt Tensioning Sequence on page 12).
many jackscrews without having to use great torque on
any single jackscrew. Therefore, the devices are 4. Lubricate the threads of the stud with an anti-seize
relatively easy to install, they do not require great force lubricant.
to install, they are easy to remove, and they are re-
5. Place one SUPERNUT with a hardened washer onto the
useable.
stud to be tightened. In the case of side frame rod bolts,
All SUPERNUTS are installed in the same general manner. the washer and SUPERNUT will be put on the rod bolt first
However, the torque applied to jackscrews and the torque and then the rod bolt will be installed.
pattern in which the jackscrews are tightened will vary
6. Check the base of each tensioner to be sure that all
depending on the size of the device and the length of the
jackscrews are flush with (or recessed in) the base of the
stud. A typical installation procedure is as follows…
tensioner. If any jackscrew extends beyond the tensioner
1. Determine the target jackscrew torque (see tables on base, turn it back until it is flush with the base or slightly
pages 16 and 17). Note that a jack bolt torque may be recessed in the base.
stamped on the SuperNut. If this stamped torque number
7. Apply a light coating of lubricant to jackscrew
happens to conflict with the value in the table at the end
threads as follows (NOTE: New assemblies are lubricated
of this article, use the value noted in the table.
during manufacture; do not use anti-seize on jackscrew
2. If using an air impact wrench, select a tool with threads).
output of 90% to 100% of the target torque. Verify the
A. If working with SUPERNUT assemblies for side frame
torque output of the air impact wrench with a standard
rod bolts, use low-friction molybdenum lubricant type
torque wrench.
Continued on page 12
Minesite Insights 11
 JL-M. This lubricant is available in three sizes under 10. Use the Star Pattern (see illustration, page 11) to
the following P&H part numbers: R38211D1 (brush- tighten only the four jackscrews at the 12:00, 6:00, 9:00
top pint); R38211D2 (quart); and R38211D3 (gallon). and 3:00 positions to the proper Target Torque from
tables at end of this article. If multiple studs are being
B. If working with SUPERNUT assemblies for boom point
tightened, always tighten all of them in the proper
sheaves, hoist drum shaft or swing gear, use low-
sequence before continuing with the next step.
friction graphite lubricant type JL-G (P&H part
numbers R38211D4 brush-tip pint, R38211D5 quart 11. After all tensioners on all studs being installed have
or R38211D6 gallon). been brought to the proper Initial Target Torque, use the
star pattern (see illustration, previous page) and torque
NOTE: Failure to lubricate properly — or using improper the same four jackscrews to the proper Final Target
lubricant — can affect torque readings for jackscrews, Torque.
resulting in improper clamping force developed by the
SuperNut. Do not use anti-seize on jackscrew threads. 12. At the Final Target Torque, tighten all jackscrews in
the circular pattern on all studs (one round only).
8. If installing side frame rod bolts, use the following
steps… NOTE: As you tighten the jackscrews, the stud will
stretch, so by the time the circular pass is completed,
A. Thread one tensioner along with one hardened washer the first jackscrew will be loose again.
onto each rod bolt (the end with a .75-10 UNC
threaded hole). The end of each rod bolt should be 13. Repeat Step 12 until all jackscrews are “stabilized”
even with, or slightly protruding above the top of the (less than 20° rotation). This usually requires two to four
jackscrews in each tensioner. additional passes.
B. With the carbody and the crawler frames properly 14. If using air tools, switch to a calibrated hand torque
aligned, and assuring that the machined crawler frame wrench when socket rotation is small. Use the hand
pads are tight against the machined carbody sides, wrench to stabilize and confirm target torque.
insert rod bolts through the crawler frame into the
15. Using a hand torque wrench, make a final pass on all
carbody. Place long rod bolts in the lower holes.
jackscrews following the patterns to confirm the Final
Place short rod bolts in the upper holes.
Target Torque from tables on pages 16 and 17.
C. From inside the carbody, on each rod bolt (long and
short), place a hardened washer and nut. Snug the nut
until there are no gaps between the tensioner and SUPERNUTS Removal Procedure
crawler, or the carbody and nut. (Service Under 250°)
9. Spin the tensioners by hand down on the threads until NOTE: Removal requires strict adherence to
they seat against the washer. For the side frames, the procedures. Jackbolts must be unloaded gradually. If
tensioners should already be snug from Step 8. Back-off most of the jackscrews are fully unloaded prematurely,
all the tensioners to create about 1/16" to 1/8" gap between the remaining jackscrews will carry the entire load and
nut bodies and washers. This gap will allow lubrication will be difficult to turn. With extreme abuse, a
of jackscrews while in place. jackscrew tip can deform, making removal difficult.

Side Frame Bolt

Tensioning Sequence

1 9 13 5 8 16 12 4

3 11 15 7 6 14 10 2

12 Minesite Insights
1. Spray jackscrews with penetrating oil or hydraulic oil (although it is less accurate than the TORQUERITE or
prior to start (especially if components are rusted). SUPERNUT methods).
2. Loosen each jackscrew ¼-turn following the circular It eliminates the need for use of a crane and
pattern around the tensioner (one round only). When you wrenches.
return to the first jackscrew, it will be tight again. Do Since the rod bolts are being tensioned rather than
this for all studs on the joint prior to the next step. Do torqued, there is no need to weld nut-locking plates or
not use air impact tools. “keepers” inside the carbody to prevent the inner nuts
from turning (this also applies to the TORQUERITE and
3. Repeat a second round the same as above for all
SUPERNUT methods).
studs.
Kit R17981 includes a portable air-driven or electric
4. Repeat a third round the same as above for all studs.
pump, a hose assembly, and a bolt tensioner (see page 13
5. Continue until jackscrews are loose. Remove, clean illustration). The pump used must have a minimum
and lubricate the jackscrews with proper lubricant. capacity of 10,000 PSI.
NOTE: Usually after the third round, an air impact tool In operation, the tensioner is threaded onto the rod bolt.
can be used to remove the jackscrews. Do not use an As hydraulic pressure is applied, the rod bolt is stretched.
air impact tool for the first three rounds. For long studs Once the target pressure is attained, the rod bolt nut is
or tie rods, more than three rounds may be required then turned down with the T-bolt handle of the tensioner.
before using air impact tools. Detailed instructions are
shipped with tensioning nuts. When hydraulic pressure is relieved, the rod bolt nut
retains the tension and the hydraulic tensioner can then
be removed and threaded onto the next bolt.
Hydraulic Rod Bolt Tensioning Kit
What follows is the procedure for tensioning side frame
Hydraulic side frame rod bolt tensioning by means of kit
rod bolts using the hydraulic bolt tensioner…
R17981 was implemented as the standard method
beginning with mining shovel serial number ES4157. 1. With carbody and crawler frames properly aligned
This method presents several advantages over the original and machined crawler pads tight against machined
torque method, including… carbody sides, insert rod bolts through a crawler frame
It is more accurate because it eliminates any variance into carbody.
in preload due to friction while torquing the rod bolts continued on page 14

Hydraulic Bolt
Tensioning Method T-Bolt
In operation, the tensioner is threaded onto the Handle
rod bolt. As hydraulic pressure is applied, the
rod bolt is stretched and the rod bolt nut is
turned-down with the T-Bolt Handle of the
tensioner. When hydraulic pressure is relieved,
the rod bolt nut retains the tension.

Input
Pressure

Tensioner
Installation
(Typical)

Minesite Insights 13
2. From inside the carbody, place one hardened washer D. During tensioning, observe the stroke of the tensioner
and one hex nut on each rod bolt. Turn the hex nut until to be sure it does not exceed ½-inch (12.7mm). Seal
between 1.81" and 1.94" of rod bolt protrudes through damage may occur if this maximum travel is
the nut. Repeat for all rod bolts. exceeded. Check by measuring the travel of the
3. From outside the crawler frame, lubricate the threads spring plate at the top of the cylinder. If the tensioner
and be sure that the inner nut travels freely for the entire does not have a return spring assembly, check the
length of the outer thread. Place one hardened washer and travel of the piston beyond the top of the cylinder.
one hex nut on each rod bolt. Turn the hex nut until snug. NOTE: The pressures listed in the table on page 16
Check length of rod bolt protruding through the nut on the apply only to hydraulic bolt tensioner (P&H Part
outside. Length must be between .12" and .25" less than Number R18024). The use of any other tensioning
the height of a nut. If not, adjust the inside nut accordingly. system will require different pressures than those
4. Tighten rod bolts in the sequence shown in the page 12 listed in table below. Contact your P&H MinePro
illustration ‘Side Frame Bolt Tensioning Sequence’ to representative for assistance if another tensioner is
the 75% preload pressure shown in the table below (for a used.
4100XPB as an example). Proceed as follows… E. Pressurize the tensioner until 75% preload pressure is
indicated on the gauge. See table below. This can be
A. Place the bolt tensioner over the rod bolt nut until the done by regulating air pressure (200:1 ratio) or by
base of the tensioner butts up squarely on the outer side using the activation button and monitoring hydraulic
of the crawler frame. Be sure the tensioner is well- pressure.
centered and the nut socket is aligned with the nut. Be
sure the hardened washer does not interfere with the F. Using the T-bolt handle on the tensioner (see
tensioner alignment. lllustration on page 13), turn the rod bolt nut down
until it bottoms and seat it with a firm twist. Be sure
NOTE: The tensioning head assembly weighs the nut is seated against the crawler frame and the
approximately 220 lbs. (100 kg). hardened washer.
NOTE: Do not apply pressure to the tensioner before it NOTE: Hand-tighten the rod bolt nut only. Do not
is properly connected to the rod bolt. The piston seals hammer the T-bolt handle.
may travel beyond the cylinder or the spring plate may
be damaged. Tensioner must be seated against crawler G. Release pump pressure. The rod bolt has now been
side plate. tensioned to 75% preload.
B. Thread the puller bar of the bolt tensioner onto the H. Remove the bolt tensioner by unscrewing the puller
rod bolt until the upper face of the rod bolt bottoms bar and lifting the tensioner off the rod bolt. NOTE:
on the piston. It should not bottom on the rod nut. Leave the release valve open while moving the
Then back the puller bar off a quarter-turn (90 tensioner to the next rod bolt to be tightened so the
degrees). piston can return to its retracted position.
NOTE: If components are not seated properly before 5. After all rod bolts have been preloaded to 75% as
tensioning, piston travel could exceed the maximum of described above, tension them to the final 100% value
½-inch (12.7mm). Monitor this travel during tensioning shown in table below, again using the sequence shown in
and do not exceed it or seal damage will occur. illustration ‘Side Frame Bolt Tensioning Sequence’
C. Support the bolt tensioner until the hydraulic pressure and procedures outlined in Step 4.
begins to build to prevent the weight of the tensioner 6. Mount a second nut on the crawler frame end of each
from resting on the nut and obstructing its rotation. rod bolt to protect the rod bolt threads.
Do not force wedges under the tensioner or support it
in any way that would obstruct its natural axial 7. Tack-weld the second rod bolt nut to the first nut.
alignment when pressure begins to build. This completes side frame bolt tensioning by the
hydraulic kit method. When done, the side frame bolts
WARNING: Bolt projectiles from over-tightening will be installed as shown in the illustration on page 15.
and breaking bolts can cause severe injury or
death. Operate bolt tensioner to prevent over- NOTE: To prevent excessive side frame movement and
tightening and breaking of bolts. Stay clear of the subsequent deterioration of the side frame / carbody
bolts and their potential projectile path when using interface, it is imperative that the clamping force listed
a bolt tensioner. Be sure to follow all safety in the table below be obtained and maintained.
requirements outlined in the manual that
accompanies the hydraulic tensioner kit.
14 Minesite Insights
Standard Hydraulic Torque Wrench Method
Determine the target hex nut torque (see
Crawler Frame Bolt Tables at end of this
report) and use a hydraulic torque wrench
to attain the recommended preload setting.
Follow the ‘Side Frame Bolt Tensioning
Sequence’ illustrated on page 12. This
method requires welding keepers inside
the carbody to prevent rod bolts from
turning (although if specified, a new
shovel will be equipped with factory-
installed keepers).

NOTICE This relaxation is allowable until it reaches the minimum

The specified Final Pressure for the hydraulic tensioner clamping force which is 700 KIPS. When a clamping
will actually produce a clamping force slightly higher than force less than this minimum is reached, the rod bolt
the specified minimum of 700 KIPS. The corresponding should be re-tensioned. This minimum clamping force
amount of rod bolt stretch achieved will also exceed the can be inspected by measuring the rod bolt stretch.
minimum required and is represented in the table as X. When the rod bolt stretch measured is less than X-J, the
As the rod bolt is worked, the initial tension will relax. rod bolt should be re-tensioned.

Crawler Frame Bolt Stretch and Preload Tables

ORIGINAL NOMINAL NOMINAL
BOLT DIA. CLAMP LOAD CLAMP LOAD NOM. LENGTH STRETCH
MODEL 2300XPB INCHES POUNDS REF POUNDS INCHES INCHES
54060 - ES2367
UPPER 3.25 246000 370000 39.00 0.058
LOWER 3.25 246000 370000 39.00 0.058
ES2368 - PRESENT
UPPER 3.25 492000 492000 34.75 0.069
LOWER 3.25 492000 492000 51.75 0.102
MODEL 2800XPB
54335 - ES28124
UPPER 3.75 260000 430000 51.00 0.066
LOWER 3.75 260000 430000 51.00 0.066
ES28125 - PRESENT
UPPER 3.75 640000 640000 40.13 0.078
LOWER 3.75 640000 640000 60.13 0.116
MODEL 4100
54895 - 55274
UPPER 3.75 260000 430000 51.00 0.066
LOWER 3.75 260000 430000 51.00 0.066
MODEL 4100, A
55275 - ES5146
UPPER 3.75 430000 640000 10.50 0.020
LOWER 3.75 430000 640000 59.50 0.115
MODEL 4100A, TS, BOSS
ES4157 - PRESENT
UPPER 4.00 700000 700000 40.5 0.075
LOWER 4.00 700000 700000 60.5 0.112
MODEL 4100XPB
UPPER 4.00 700000 700000 47.8 0.089
LOWER 4.00 700000 700000 70.32 0.131

Minimum clamp load values listed are the same values for a number of years and in many cases are greater than the values originally specified for the particular
machine. The original values are shown in the column listed as “original clamp loads”. These were increased years ago because of the beneficial effects of less shear
ledge movement. In this particular, the minimum clamp loads are those increased values. The “maximum” values shown on this chart provide an upper limit so as to
provide a range and also to compensate for relaxation of the bolt. The maximum value is 10% higher than the minimum value, which is a typical relaxation factor for this
size and length of bolt.
Bolt stretch data is supplied for use in verifying that the proper preload has been achieved or to record changes in stretch that would indicate loss or reduction of preload
on each individual bolt.

Minesite Insights 15
 Hydraulic Rod Bolt Tensioning Procedure Values for 4100XPB (see pages 15-17 for complete charts)

Rod Required Actual Rod Bolt

Bolt Clamping Length of Preload 75% Final 100% Stretch at
Bolt Position Diameter Force/Bolt Rod Bolt Pressure Pressure 100% Preload*
Top Rod Bolt 4" 700 KIPS 47.82" 6,250 PSI 8,350 PSI .0891"
Bottom Rod Bolt 4" 700 KIPS 70.32" 6,000 PSI 8,000 PSI .1304"

*NOTE: This stretch will be the same for a given preload no matter which tensioning method is applied. The proper preload can be validated using ultrasonic
testing to measure the change in length.

Crawler Frame Bolting Information for P&H Model 4100-Class Shovels

TorqueRite Method Nom. Nom.

Nom. Wrench/Tool# Pressure6 Wrench/Tool# Pressure6
4100 Shovel Serial # Nut Size Preload6 T600 (PSI)6 T900 (PSI)6
54895 - 55274 (4100s) 3.75" 430,000 R45046D21 6500 R45046D73 3500
55275 - ES 4156 (4100/A) 3.75" 640,000 R45046D21 9500 R45046D73 5200
ES4157 - Present (4100A/TS/BOSS) 4.00" 700,000 R45046D12 N/A5 R45046D64 6800
ES4192 - Present (4100XPB) 4.00" 700,000 R45046D12 N/A5 R45046D64 6800
1
Drive for T600 (3.75" nut size) is part number R47214D2 (85 lbs/38.55 kg) 3 Drive for T900 (3.75" nut size) is part number R47214D7 (165 lbs/74.84 kg)
2
Drive for T600 (4.00" nut size) is part number R47214D1 (90 lbs/40.82 kg) 4 Drive for T900 (4.00" nut size) is part number R47214D6 (170 lbs/77.11 kg)
5
Both T600 and T900 wrenches can be used. T900 is larger and heavier but will handle the full range of preloads of all models. T600 will not handle the full range.
6
Preloads and pressures listed are minimum requirements. Refer to table on bolt stretch and J factor.
Maximum values of preload and pressure are determined by multiplying minimum value times J factor.
Assembly Lubricant Required for TorqueRite Assemblies: Dow-Corning G-N Metal Assembly Paste

SuperNut Method Jackscrew Torque SuperNut Jackscrew/ Jackscrew Torque

Nom. Initial (75%) Part Number/ Socket Nom. Final
4100 Shovel Serial # Bolt Size Preload6 (ft/lbs) Installation Size (in.) (ft/lbs)
54895 - 55274 (4100s) 3.75" 430,000 94 R38213D1 .75/.562 134
R38222
55275 - ES4156 (4100, 4100A) 3.75" 640,000 140 R38213D1 .75/.562 200
R38222
ES4157 - Present (4100A/TS/BOSS) 4.00" 700,000 132 R38214D1 .75/.625 188
R38223
ES4192 - Present (4100XPB) 4.00" 700,000 132 R38214D1 .75/.625 188
R46759
6
Preloads and pressures listed are minimum requirements. Refer to table on bolt stretch and J factor.
Maximum values of preload and pressure are determined by multiplying minimum value times J factor.

Tensioning Method
Nom. 75% Preload Tensioner Nom.
4100 Shovel Serial # Bolt Size Preload6 Preassure (PSI) Part Number Pressure (PSI)
54895 - 55274 (4100s) 3.75" 430,000 3420 N/A 4560
55275 - ES4156 (4100, 4100A) 3.75" 640,000 5100 N/A 6800
ES4157 - Present (4100A/TS/BOSS) 4.00" 700,000 5570 R17981F5/F6 7430
ES4192 - Present (4100XPB) 4.00" 700,000 5570 R17981F5/F6 7430
6
Preloads and pressures listed are minimum requirements. Refer to table on bolt stretch and J factor.
Maximum values of preload and pressure are determined by multiplying minimum value times J factor.

Standard Hydraulic
Torque Wrench Method
Nom. 75% Preload Nom.6
4100 Shovel Serial # Bolt Size Preload6 Torque (ft/lbs) Torque (ft/lbs)
54895 - 55274 (4100s) 3.75" 430,000 15,000 20,000
55275 - ES4156 (4100, 4100A) 3.75" 640,000 22,500 30,000
ES4157 - Present (4100A/TS/BOSS) 4.00" 700,000 26,250 35,000
ES4192 - Present (4100XPB) 4.00" 700,000 26,250 35,000
6
Preloads and pressures listed are minimum requirements. Refer to table on bolt stretch and J factor.
Maximum values of preload and pressure are determined by multiplying minimum value times J factor.

16 Minesite Insights
Crawler Frame Bolting Information for P&H Model 2800-Class Shovels
TorqueRite Method Nom. Wrench/Tool # Nom. Pressure6 Wrench/Tool Nom.
2800 Shovel Serial # Bolt Size Preload 6
T600 1
(PSI)6 T9001 (PSI)6
54335 - ES28124 (2800XPA) 3.75" 430,000 R45046D2 6500 R45046D7 3500
ES28125 - Present (2800XPB) 3.75" 640,000 R45046D2 9500 R45046D7 5200
1
Drive for T600 (3.75" nut size) is part number R47214D2 (85 lbs/38.55 kg) 3 Drive for T900 (3.75" nut size) is part number R47214D7 (165 lbs/75.84 kg)
6
Preloads and pressures listed are minimum requirements. Refer to table on bolt stretch and J factor.
Maximum values of preload and pressure are determined by multiplying minimum value times J factor.
Assembly Lubricant Required for TorqueRite Assemblies: Dow-Corning G-N Metal Assembly Paste

SuperNut Method Jackscrew Torque SuperNut Jackscrew/ Jackscrew Torque

Nom. Initial (75%) Part Number/ Socket Nom.6 Final
2800 Shovel Serial # Bolt Size Preload6 (ft/lbs) Installation Size (in.) (ft/lbs)
54335 - ES28124 (2800XPA) 3.75" 430,000 94 R38213D1 .75/.562 134
R38222
ES28125 - Present (2800XPB) 3.75" 640,000 140 R38213D1 .75/.562 200
R38222
6
Preloads and pressures listed are minimum requirements. Refer to table on bolt stretch and J factor.
Maximum values of preload and pressure are determined by multiplying minimum value times J factor.

Tensioning Method Nom. 75% Preload Tensioner Nom.

2800 Shovel Serial # Bolt Size Preload6 Preassure (PSI) Part Number Pressure (PSI)
54335 - ES 28124 (2800XPA) 3.75" 430,000 3420 N/A 4560
ES28125 - Present (2800XPB) 3.75" 640,000 5100 R17981F3/F4 6800
6
Preloads and pressures listed are minimum requirements. Refer to table on bolt stretch and J factor.
Maximum values of preload and pressure are determined by multiplying minimum value times J factor.

Standard Hydraulic
Torque Wrench Method Nom. 75% Preload Nom.6
2800 Shovel Serial # Bolt Size Preload6 Torque (ft/lbs) Torque (ft/lbs)
54335 - ES28124 (2800XPA) 3.75" 430,000 15,000 20,000
ES28125 - Present (2800XPB) 3.75" 640,000 22,500 30,000
6
Preloads and pressures listed are minimum requirements. Refer to table on bolt stretch and J factor.
Maximum values of preload and pressure are determined by multiplying minimum value times J factor.

Crawler Frame Bolting Information for P&H Model 2300-Class Shovels

TorqueRite Method Nom. Wrench/Tool # Nom. Pressure6 Wrench/Tool Nom.
2300 Shovel Serial # Bolt Size Preload6 T6001 (PSI)6 T9001 (PSI)6
54060 - ES2367 (2300XPA) 3.25" 370,000 R45046D3 5500 R45046D8 2950
ES2368 - Present (2300XPB) 3.25" 492,000 R45046D3 7350 R45046D8 3900
5
Drive for T600 (3.25" nut size) is part number R47214D3 (80 lbs/36.29 kg) 6 Drive for T900 (3.25" nut size) is part number R47214D8 (160 lbs/72.58 kg)
6
Preloads and pressures listed are minimum requirements. Refer to table on bolt stretch and J factor.
Maximum values of preload and pressure are determined by multiplying minimum value times J factor.
Assembly Lubricant Required for TorqueRite Assemblies: Dow-Corning G-N Metal Assembly Paste

SuperNut Method Jackscrew Torque SuperNut Jackscrew/ Jackscrew Torque

Nom. Initial (75%) Part Number/ Socket Nom.6
2300 Shovel Serial # Bolt Size Preload6 (ft/lbs) Installation Size (in.) Final (ft/lbs)
54060 - ES2367 (2300XPA) 3.25" 370,000 81 R38212D1 .75/.562 116
R38221
ES2368 - Present (2300XPB) 3.25" 492,000 108 R38212D1 .75/.562 154
6
Preloads and pressures listed are minimum requirements. Refer to table on bolt stretch and J factor.
Maximum values of preload and pressure are determined by multiplying minimum value times J factor.

Tensioning Method Nom. 75% Preload Tensioner Nom.

2300 Shovel Serial # Bolt Size Preload6 Preassure (PSI) Part Number Pressure (PSI)
54060 - ES2367 (2300XPA) 3.25" 370,000 4160 N/A 5550
ES2368 - Present (2300XPB) 3.25" 492,000 5530 R17981F1/F2 7380
6
Preloads and pressures listed are minimum requirements. Refer to table on bolt stretch and J factor.
Maximum values of preload and pressure are determined by multiplying minimum value times J factor.

Standard Hydraulic
Torque Wrench Method Nom. 75% Preload Nom.6
2300 Shovel Serial # Bolt Size Preload6 Torque (ft/lbs) Torque (ft/lbs)
54060 - ES2367 (2300XPA) 3.25" 370,000 11,250 15,000
ES2368 - Present (2300XPB) 3.25" 492,000 15,000 20,000
6
Preloads and pressures listed are minimum requirements. Refer to table on bolt stretch and J factor.
Maximum values of preload and pressure are determined by multiplying minimum value times J factor.

Minesite Insights 17
Shovel Hoist Drum Alignment Procedure
Misalignment of the hoist drum gear will
cause end-loading of the gear teeth, and Hoist Drum Gear Hoist Drum
pitting on the mating pinions. Second Reduction
Gear (Spur)
Pitting typically results on one end of the
gear teeth on one of the pinions – and on
the other end on the opposite pinion. Hoist Drum
To avoid this problem, the hoist drum Side Stand
must undergo an alignment whenever a
hoist drum assembly is installed in a Mating Pinion
machine – either during a machine Second Reduction
erection or during a maintenance Pinion (Spur)
procedure.
Alignment of the hoist drum gear requires First Reduction Hoist Disc
shimming under and in front of the Gears (helical) Brake
sidestand bearing block. The objective of
this procedure is three-fold...
• To achieve equal backlash across
the gear face, First Reduction Pinion
(helical)
• To check for and bring about
good contact patterns in the front Hoist Motors
and rear gear mesh, and
• To eliminate any evidence of
misalignment.

NOTE: This procedure applies to P&H shovel models

2300XPA / XPB, 2800XPA / XPB, 4100 / 4100A,
4100TS / BOSS and 4100XPB.

Applying Solder to the Front Pinion: Note - points Measuring Solder Thickness on Front Pinion:
‘A’ and ‘B’ are on the load side. Points ‘C’ and ‘D’ are Measure the thickness near the pitch line
on the non-load side. Solder lines are placed 1.25" to (approximately 1.35" from tooth tip) using a
1.5" from each end (distance depends upon the micrometer or vernier caliper.
shovel model; refer to Table 1 on page 21 for
recommended placement).

18 Minesite Insights
Materials required for this procedure include... 2800-class shovels) to 1.5" from each end of the gear
(P&H 4100-class shovels).
Solder (~.125" diameter solid – for best results, do
not use hollow-core solder) Procedure for Checking Backlash:
Dykem Hi-Spot Blue 107, Prussian Blue, or PT-650 1. Attach solder to the front pinion to make contact
Tooth-Marking Grease approximately 1.00 inch from each end of the drum
3M Scotch-brand #845 book tape (2" - 3" wide) gear (1.25" or 1.5" from each end of the pinion),
Duct tape depending upon the shovel model (see Table 1, page
Degreaser 22). Position the solder in the pinion tooth as shown in
Rags the lower left photograph on the previous page, with
ends attached to adjacent teeth with duct tape.
Machine Conditions to Consider
2. When checking the front mesh, rotate the gear
The ideal circumstance under which to perform the pinion by turning the rear input coupling (conversely,
hoist drum gear alignment is on a fully assembled when checking the rear mesh, rotate the gear pinion by
machine. This might not be practical, however.
turning the front input coupling). Rotate the input
Take note of machine conditions that can affect how coupling clockwise (while facing gear case) until the
this procedure will be carried out. For example... second reduction pinion rotates one complete turn.
• Is the machine complete?
3. Carefully remove and measure each solder sample
• Is the boom pinned and raised?
from the pinion, making sure not to mix-up locations.
• Is all of the counterweight installed?
Measure the thickness near the pitch line using a
• Is all cribbing removed from under the
micrometer or vernier caliper as shown in the lower
counterweight?
right photograph on page 18 titled ‘Measuring Solder
Be alert to the above-noted conditions and other such
Thickness on Front Pinion’.
machine conditions that might affect the procedure and
plan accordingly. continued on page 20

Checking Backlash
Prior to taking any measurements, if the gear case Measurement Locations:
cover is not installed or torqued-down, make sure
all bearings are properly seated in the gear case 2 Front - Outboard
bores. This can be visually checked with feeler
gauges. 4 Rear - Outboard
Measure total backlash in both the front and rear
pinion/gear meshes. Two solder samples will be
taken for the front mesh, and two for the rear mesh
(refer to photograph on the page 18 titled ‘Applying
Solder to Front Pinion’ and also the illustration at
right titled ‘Measurement Locations’).
Solder samples 1 and 2 will be applied to the front
inboard and outboard, respectively. Samples 3 and 4
will be applied to the rear inboard and outboard,
respectively. 1 Front - Inboard

A total of eight measurements will be taken (please

refer to Table 1 displayed on page 22 for a listing 3 Rear - Inboard
of measurement locations). Recommended
measurement locations depend on pinion face
width. Solder placement distance from each end of Front of Machine
the gear ranges from 1.25" (P&H 2300- through

Minesite Insights 19
4. Record the thickness measurements for the load and
non-load side for the inboard and outboard locations in
Table 1 (use the table or a facsimile of the table shown
on page 22).
5. Repeat steps 1 through 4 for the rear pinion / gear
mesh.
6. Use the formulas in Table 1 on page 22 to calculate
the amount of shimming required. If you have the
spreadsheet program, simply enter the values in the
boxes and the program will automatically perform the
calculations. If not, then carry out calculations using the
formulas and factors provided in Table 1.
7. Install the required amount of shims and repeat steps
1 through 6 until correct alignment is achieved. Shim Applying Bluing Compound to the load side of one
the sidestand bearing block to the nearest .005". (Refer to tooth on the front pinion (NOTE: The load side of the
top tooth faces toward the front of the machine on both
example Table 1 shown on page 21.)
pinions).
8. Check backlash in front and rear 1st reduction gear
mesh using a dial indicator or the lead method. Refer to 3. Apply a thin layer of bluing compound to the load
Table 2 for acceptable backlash measurements. side of one tooth on the front pinion (see photo at the top
of this page). A “thin film” is defined as .0003"
(.008mm) to .0005" (.012mm) thick. A thin film is best
Procedure for Checking Contact Pattern: attained by wiping the compound on the tooth and then
1. After final assembly of the gear set, rotate the pinions using a rag or finger to remove any excess. Excessive
so that the drum gear makes at least one complete film thickness will result in false contact readings.
revolution. NOTE: The pinion teeth are crowned, therefore full
contact across the gear face width should not be visible.
2. Thoroughly clean the teeth of the pinions and drum
gear with degreaser. 4. Roll the gear mesh by turning the input coupling
clockwise (while facing gear case) until the blue pinion

Torque direction of drum gear

Procedure Reference Illustration
under load

Non-load side
of tooth Load side
of tooth

Non-load
Load side side of
of tooth tooth

Shim here for

horizontal
Shim here for vertical adjustment
adjustment

Front of machine

20 Minesite Insights
tooth comes in contact with a gear tooth to transfer the 8. Repeat steps 1 through 7 for the rear pinion / gear
bluing compound from the pinion tooth onto the gear mesh.
tooth.
Deviation
5. Apply 3M book tape of 2.5" to 3" width to cover the
If contact patterns other than those shown in MOP 9.3
face of the gear tooth. Doing so will result in transfer of
(see illustration on page 23 titled Acceptable Contact
the bluing impression on the gear tooth to the book tape.
on Gear Tooth with Center Crown on Pinion) are
6. Paste the book tape with the bluing impression onto observed, or if contact patterns similar to those shown in
the rectangle panels representing the gear tooth sides the illustration below titled Unacceptable Contact Wear
being examined for contact patterns (please refer to the on Gear Tooth, assembly personnel must further
illustration titled ‘Gear Tooth Contact Patterns’ on page evaluate and determine what might be causing the
23). Record the gear and pinion part numbers. alignment problem.
7. Check for acceptable contact pattern per
manufacturing operation procedure MOP 9.3 (refer to continued on page 22
illustration titled Acceptable / Unacceptable Contact
Patterns on page 23).

Example - 4100XPB Down .010" & Back .010"

Minesite Insights 21
Backlash Measurement Chart

Table 2 - First Reduction Hoist Gearing Backlash

1st 1st Nominal

Reduction Reduction Backlash in 1st
Model Pinion Gear Reduction Gear Mesh

2300XPA 1N1061 1J333 .010" - .021"

2300XPB 1J386D1 1J384D1 .012" - .022"

2800XPA 1N1467 1J388D1 .012" - .024"

2800XPB 1N1033C1 1J389D1 .012" - .024"

4100/4100A 1J327 1J328 .015" - .027"

4100TS 1J355D1 1J356D1 .015" - .027"

4100XPB/BOSS R31816D1 R31817D2 .015" - .027"

22 Minesite Insights
 Acceptable Contact On Gear Tooth with Center Crown on Pinion

Ideal Center Contact - Center Crown Parallel Misalignment - Center Crown Cross Bearing Misalignment - Center Crown

Unacceptable Contact On Gear Tooth

OR

OR

Unacceptable Contact - Center Crown Unacceptable - Tip Contact Only Unacceptable - Root Contact Only
Figure 1

Gear Tooth Contact Patterns

Pinion Part Number: ___________ Drum Gear Part Number: _____________ Drum Gear Serial Number: __________

Display Front Pinion / Gear Mesh below by applying 3M book tape imprinted with bluing compound:
Tip

Root

Display Rear Pinion / Gear Mesh below by applying 3M book tape imprinted with bluing compound:
Tip

Root

NOTE: The above ‘Gear Tooth Contact Pattern Indicator Panel’ is approximately half the required size needed to
carry out the Pinion / Gear Mesh bluing compound analysis. Therefore, please put the above rectangular graphic /
illustration on a photocopy machine and enlarge it to 200% of its current size (print on 11x17-inch paper stock). Doing
so will provide you with properly sized panels needed to carry out a key task in the Hoist Drum Alignment Procedure.

Minesite Insights 23
Procedures Identified for Minimizing
Hoist Rope Swaged Ferrule Pull-Off
Recent, seemingly random reports of the swaged ferrule Mechanical removal by use of a rotary wire brush is
pulling off of a hoist rope on model 4100A machines considered to be more efficient than removal by
have undergone a review, and a common factor emerged chemicals or by heat.
– namely, the fact that these events seem to occur on new
Excessive heat might result in annealing of the drum
machines or on machines on which a new hoist drum had
grooves, thereby creating a more serious problem.
been installed.
After the paint is removed, the rope grooves should be
Paint is applied to the hoist rope grooves on new hoist
cleaned with a solvent to ensure all grease is removed
drums. It is possible that the presence of this paint might
before installing the hoist ropes.
reduce the effectiveness of the “dead wraps” of the hoist
rope on the drum. Dead wraps help reduce the amount Although reports of this problem have been limited to
of bail pull exerted upon the ferrules. 4100A machines, the recommended preventive effort
noted above can be applied to all machine models with
Dead wrap effectiveness is a function of the friction
ferrule / becket hoist ropes.
between the rope and the groove. The paint applied to
the drum evidently results in a lower coefficient of
NOTE: MinePro now offers a kit (R52838) enabling use
friction than what would occur if the drum groove had a of longer (8") ferrules with a minor rework of the becket
bare steel surface. sockets.
Therefore, it is recommended that the paint be removed
from the rope grooves on new hoist drums.

‘DELTA’ Track Tension Adjustment Procedure continued from page 2

9. Back-off on the jack. Install the remaining shims in 13. Propel the mining shovel in reverse while
the space in front of the bearing block. observing track tension. If tension appears to be too
tight or too loose, re-adjust as necessary (refer back
10. Slide the retainer pins on each side into position and
to illustration ‘Track Tension’ on page 1).
install a cotter pin.
14. If the track remains too loose after adjusting the
11. Remove the hydraulic jack and clear all tools and
front idler completely forward, remove one shoe.
equipment from the crawler tracks.
Repeat adjustment procedure.
12. Cycle the automatic lubrication system for the
lower to lubricate the front idler roller.

Minesite Insights is published periodically to provide information updates of interest to P&H Mining Equipment customers and the P&H
MinePro Services team. If you have ideas or suggestions for topics, or if you need extra copies of a back issue, please fax this information to
Mark Dietz in the P&H Mining Equipment Marketing Communication Department, (414) 671-7249.
IMPORTANT: If we need to revise or update the mailing list for better delivery to you, please fax us this information.

NOTE: Descriptions and representations of equipment conditions and configurations provided in this publication are subject to change at the
manufacturer’s sole discretion at any time without advance notice. Information published herein shall not be construed to warrant suitability of
machine(s) for any particular purpose as performance may vary with conditions encountered. The only warranty applicable is our standard
written warranty for specific machines.
XS - 3484 2.1AG605
 Tab 5

Miscellaneous
 Disc Brake Spring Information
J. Whitcomb 7/11/07
Spring Spring Spring Full Release Spring
Brake Part # Motion Spring Color Comments
Qty. Diameter Length Air Pressure Vendor #
15R7 Hoist 16 2.00 4.50 gold 59 205143
15R9D1 Crowd 12 1.50 4.00 gold / red * 52 205159 spring replaced by 210248
15R9D4 Propel 10 1.50 4.50 gold / red ** 55 205155
15R12D1 Swing 10 1.25 3.50 gold / red * 57 205349 spring replaced by 205362-A
15R12D2 Swing 10 1.25 3.00 green 48 203373
15R12D3 Swing 10 1.25 3.50 blue 27 203633
15R12D4 Swing 8 1.25 3.00 green 38 203373
15R12D5 Swing 12 1.25 3.50 blue 32 203633
15R12D6 Swing 8 1.25 3.50 blue 22 203633
15R12D7 Swing 9 1.25 3.50 gold / red * 51 205349
15R12D8 Swing 12 1.25 3.50 gold / red * 68 205349 spring replaced by 205362-A
15R14D6 Swing 10 1.25 3.50 gold / red * 57 205349
R24170D1 Hoist 10 2.00 5.00 red 53 209577
R41894D1 Hoist 16 2.00 5.00 red 85 209577
R53630D1 Hoist 16 2.00 5.00 red 85 209577
R41760D1 Crowd 10 1.50 4.50 gold / red ** 54 205155
R53137D1 Crowd 12 1.50 4.00 red 52 210248
R42786D1 Swing 9 1.50 4.00 yellow 61 205401-A
R42784D1 Propel 12 1.50 4.50 gold / red ** 65 205155
* Original spring was gold - replaced by a red spring with a new part number.
** Spring part number 205155 was orignally gold - changed to red in 2001.
 2 PUMP 4 ZONE
AUTOMATIC
LUBRICATION SYSTEM
INTRODUCTION

The 2 pump 4 zone automatic lubrication system is the standard on all

4100XPC’s and is an option on all other machines. The system began as a
retrofit to address the issue of open gear lubrication. On the 3 pump 3 zone
automatic lubrication system the upper (boom) open gear system and the lower
(ring gear and house rollers) open gear systems were operated at the same time.
This made it difficult to control the amount of open gear lube going to both
locations. The 3 pump 3 zone lube system is used on both the Lincoln (pressure
switches and injectors) and Farval (reversing and metering valves) automatic
lubrication systems.
With the 2 pump 4 zone system, the upper open gear and lower open gear
systems can be controlled separately. The one constraint is this system is only
available in a Lincoln configuration. The Lincoln configuration lends itself to the 2
pump 4 zone configuration.
Upgrading an existing 3 pump 3 zone Farval system requires not only the 2
pump 4 zone kit but also a conversion to a Lincoln supply system.
The 2 pump 4 zone system is still functionally performing the same tasks as the 3
pump 3 zone system, just with better control. The use of pressure transducers
allows the system more consistently operate the injectors.
DIFFERENCES BETWEEN THE 2 PUMP 4 ZONE AND 3
PUMP 3 ZONE LINCOLN SYSTEMS
The first recognizable difference between the two systems is the use of zone
valves in the 2 pump 4 zone system. The zone valves direct lube to the
appropriate areas. 4 zone valves for 4 zones.

Next the 2 pump 4 zone system has only 2 lubrication pumps instead of 3. In the
3 pump 3 zone there is a lube pump for upper grease, lower grease and open
gear. In the 2 pump 4 zone there is an grease pump and an open gear pump.

Normally closed electric vent valves are used in the 2 pump 4 zone system
where the vent valves in the 3 pump 3 zone system were air operated normally
open. They still perform the same function, just in a different fashion.
2 pump 4 zone systems are equipped with pressure transducers verses the
pressure switches in the standard 3 pump 3 zone systems. Some 3 pump 3
zone systems are equipped with pressure transducers and some older 2 pump 4
zone systems have pressure switches.

The introduction of accumulators reduces pressures spikes and thereby the

system has a more consistent operation.
MECHANICAL COMPONENTS
• Lubrication Tank
o Equipped with Mega Lube Tanks. These are high capacity tanks
that can hold enough grease to go between PM days.
• Lubrication Pump
o Air operated.
• Filter
o Filters the lube supplied to each zone.
o 30 mesh
• Bypass valves
o Allows manual venting of the system to tank. The zone valve must
be open to vent entire system to tank.
o Allows both sides of the filter to be vented to remove filter.
• Accumulator
o Suppresses pressure spikes.
• Pressure gauges
o Measures pressure on both sides of the filter.
• Mechanical relief valve
o Overpressure protection for the system. Usually set at about 4000
psi.
• Check valve
o Allows for individual venting of the upper and lower zones with the
use of one vent valve.
o Prevent pressurizing up the other zone when one is pressurizing.
• Injectors
o Supply grease to vital points.
o Empties and fills on the same cycle.

ELECTRICAL COMPONENTS
• Supply breaker
o Supplies 120VAC to the power filter.
• Power filter
o Supplies filtered power to the 24VDC power supply and the
Milltronics Level Detector.
• DC power supply
o Supplies 24 VDC to the IO and IO loads.
• OBT (Optical bus terminal)
o Converts the fiber optic signal to copper and visa versa.
o Powered by 24VDC
• Standard Density IO
o Address 2.30
o Powered by 24VDC
o Fiber optic Profibus communications
 o All lube room and some hoist temperatures are controlled or
monitored here.
• Tank Level Detection System
o Level sensor
♦ Installed on top of each lube tank.
♦ Uses sonar to detect level.
o Level detector
♦ Siemens Milltronics Multi Ranger 100.
♦ Communicates to the AC800 via a SmartLinx card.
♦ Generates the pulse and converts the return signal value to
a useful number.
♦ Gives a local readout of each tank level.
♦ Detects 25% full and empty signals used by the AC800
program.
♦ Uses Dolphin software. Actual program may be supplied by
Mine Pro.

ELECTROMECHANICAL COMPONENTS
• MAC valves
o Located in lube room.
o 24VDC.
o Supply air to each pump.
o Supply air to the ring gear spray.
o Can be mechanically operated.
• Zone valves
o Located in lube room.
o 24VDC
o Supplies lube to a specific zone.
o One open at a time.
o Can be mechanically operated.
o Same valves as the vent valves.
• Vent valves
o Located in lube room.
o 24VDC.
o Vents pressure from the system.
o Can be mechanically operated.
o Same valves as the zone valves.
• Transducers
o Measures vital points near the injectors to ensure the injectors have
opearated. It does not directly monitor the injector, just the
pressure.
o Locations
♦ Boom point (upper grease).
♦ Mid boom (upper grease, 2) (upper open gear).
 ♦ Lube room wall by the left front swing motor (upper grease).
♦ Revolving frame in the compartment above the rear part of
the ring gear (lower open gear).
♦ In or around the lower IO cabinet (lower grease).
o 0 to 5000 psi transducer range.
o 5.5296 division factor
♦ 9954 raw input = 1800 psi.
♦ 11612 raw input = 2100 psi.
o They look like the brake transducers, but the brake transducers are
0 to 300 psi.
THEORY OF OPERATION

Both grease cycles and both open gear cycles operate on the same principle so
only one system will be covered.

Differences between all the cycles.

1. The upper grease system has 4 pressure transducers that must build up
to a certain pressure then vent down to a certain pressure. All other
systems only have one pressure transducer.
2. The lower open gear has a spray valve that is used to spray the open gear
on the ring gear. The spray valve opens when the open gear pump starts
during the lower open gear cycle. It closes 10 seconds after the pump
stops. This clears any open gear out of the tip of the nozzle.
3. The lower grease operates on 2 separate timers.
a. The first timer is active when in dig mode and the hoist brakes are
released.
b. The second timer is active when in propel mode. The time between
cycles is shorter in propel to add more grease to the lower rollers
during propel.

Lubrication cycles can be initiated in 3 different ways. The timer for the
associated system reaches 0, the local pushbutton on the lube IO panel is
pressed or the system is activated by pressing the appropriate button on either
GUI. No matter which action initiates the cycle, the logic is the same.

For cycle to begin in dig mode, the shovel must be started and the hoist brakes
released. The timer for the automatic cycle is only initiated when the hoist
brakes are released in run mode.

For a cycle to begin in propel mode, the shovel must be started and in propel
mode. The timer for the automatic cycle is only initiated when in propel mode.

A manual cycle can be initiated any time power is supplied to all IO’s, no IO’s are
faulted and the AC800 program is running with no faults. This include while the
shovel is running and shutdown.

Once the program detects a cycle to start, it first checks air pressure. If air
pressure is below 100 psi a cycle cannot be initiated. If the main air pressure is
good, It then checks to see if any other cycles are operating. If so, the requested
cycle is put into a queue.

First the outputs to the pump MAC valve and appropriate zone valve are
energized. This causes grease or open gear to be sent to all the injectors in the
system. If the lower open gear cycle is initiated, the spray MAC valve output is
energized. At this time the time between cycle timer is reset to the preset value
as set on the GUI.
The operation of the injectors causes pressure to build up in the system. Once
required pressure has been reached the injectors have operated the pressure
rise portion of the cycle has been completed.

The program then de-energizes the output to the pump and energizes the output
to the vent valve. The output to the zone valve stays energized to vent the
pressure in the entire system. In the lower open gear system, the spray valve
MAC valve output stays energized for 10 seconds longer. Once system
pressure reaches 500 psi on all pressure transducers, the pressure drop portion
of the cycle is complete.

The program de-energizes the outputs to both the zone and vent valves. At this
time is a lubrication cycle has been successfully completed. Any other cycles in
the queue will now be initiated.

If a lube fault occurs during the cycle, a 30 second shutdown will occur. The only
way to clear a lube fault is to successfully complete a lube cycle on the faulted
system. No other lube system cycles can start until the completion a successful
cycle in the faulted system.
UPPER GREASE CYCLE
LOWER GREASE CYCLE
UPPER OPEN GEAR CYCLE
LOWER OPEN GEAR CYCLE
LUBE SYSTEM FUNCITON BLOCKS
FAULTS
• Upper grease fault
o Caused when the upper grease system does not pressure up to
required pressures within 3 minutes of initiating an upper grease
command.
♦ 4 points
◊ Boom Point 1800 psi
◊ Right Saddleblock 1800 psi
◊ Left Saddleblock 1800 psi
◊ House 2100 psi
o Caused when the upper grease system does not vent pressure
down to 500 psi within 3 minutes of completing the pressure up
cycle.

• Lower grease lube fault

o Caused when the lower grease system does not pressure up to
required pressures within 3 minutes of initiating an upper grease
command.
♦ 1 point
◊ Sideframes 1800 psi
o Caused when the lower grease system does not vent pressure
down to 500 psi within 3 minutes of completing the pressure up
cycle.

• Upper open gear lube fault

o Caused when the upper open gear system does not pressure up to
required pressures within 3 minutes of initiating an upper grease
command.
♦ 1 point
◊ All boom 2100 psi
o
o Caused when the upper open gear system does not vent pressure
down to 500 psi within 3 minutes of completing the pressure up
cycle.

• Lower open gear lube fault

o Caused when the lower open gear system does not pressure up to
required pressures within 3 minutes of initiating an upper grease
command.
♦ 1 point
◊ All ring gear and house rollers 2100 psi
o
o Caused when the lower open gear system does not vent pressure
down to 500 psi within 3 minutes of completing the pressure up
cycle.
TROUBLESHOOTING
• Description
o All faults are troubleshot in the same fashion. All lube systems
operate on the same principle.
o All faults will just give a lube system fault. It is up to you to
determine when the fault is occurring during the lube cycle.
♦ Pressure rise faults.
◊ Occur at 3 minutes from the cycle start command.
◊ Will only occur if pressure has not reach the set point
on all transducers in the system.
♦ Pressure drop faults.
◊ Occur at 3 minutes after all transducers in the system
have reach proper pressure.
◊ Will only occur if pressure has not dropped to 500 psi
on all transducers in the system.
o If you are going to use the IO screen on the GUI or the lube block in
the AC800 program, verify the value of the pressure transducer
input is not 32767 and it is moving, or bouncing around a value.
♦ If it is 32767 verify the wiring and wiring polarity. If all is
good, replace the transducer.
• Pressure Rise Faults
o Faults while the pump and zone valve commands are true.
♦ Check tank level.
♦ Check for leaks in the system between the zone valve and
all injectors.
♦ Check for injectors bypassing internally.
♦ Check for the pump is operating.
◊ Check MAC valve operation manually.
◊ Check electrical signal at MAC valve.
◊ Check air supply to MAC valve.
◊ Check air supply from MAC valve to pump.
♦ Check the silver ball valves on both sides of the filter are
closed.
♦ Check the zone valve is open.
◊ Check the signal at the valve. Check the red LED is
lit.
◊ Check wiring in the Hirschman connector.
◊ Crack a line downstream of the zone valve to ensure
lube is coming out. Use a bucket to prevent a
creating a hazard.
♦ Check the vent valve is not stuck open.
♦ Check the relief valve is not misadjusted.
♦ Check the relief valve has not failed open.
♦ Check for proper signals coming back from the transducers.
 ◊ To verify signal, there are 2 ways to do this.
• On the GUI IO screen, look at the value on
each transducer input. Ensure it is not 32767.
If you divide the value read by 5.5296 you will
get the actual pressure
• Look at the lube block in the AC800 program.
Ensure it is not 32767. If you divide the value
read by 5.5296 you will get the actual pressure
◊ Refer to the previous drawing to determine what value
each pressure transducer should read as a good
pressure.
♦ Check the line feeding the transducers for obstructions.
• Pressure Drop Faults
o Faults while the zone and vent valve commands are true.
♦ An obstruction could exist between the check valve and the
lube tank.
♦ The vent valve could be closed.
◊ Manually activate the vent valve and verify a change
in system pressure.
• If pressure suddenly drops, the vent valve is
stuck closed, electrically or mechanically.
◊ Check for the LED is lit on the vent valve.
◊ Check wiring in the vent valve Hirschman connector.
♦ The line between the vent valve and the check valve could
be obstructed.
♦ The check valve could be stuck closed.
2 Pump 4 Zone Automatic Lubrication System
Electrical Inputs

Name Type Component Location Program Variable Name Address I/O

Upper Grease Cycle Pushbutton Lube Room I/O Panel in Lube Room Application_1.IO.Lube.UPR_GREASE_BUT 2.30.1.2 Lube
Lower Grease Cycle Pushbutton Lube Room I/O Panel in Lube Room Application_1.IO.Lube.LWR_GREASE_BUT 2.30.1.1 Lube
Upper Open Gear Cycle Pushbutton Lube Room I/O Panel in Lube Room Application_1.IO.Lube.UPR_OPEN_GEAR_BUT 2.30.1.3 Lube
Lower Open Gear Cycle Pushbutton Lube Room I/O Panel in Lube Room Application_1.IO.Lube.ROLLER_CIRCLE_OPEN_GEAR_BUT 2.30.2.0 Lube
Alarm Silence Pushbutton Lube Room I/O Panel in Lube Room Application_1.IO.Lube.ALARM_SILENCE_BUT 2.30.1.0 Lube
Boom Point Grease Pressure Transducer Boom @ Boom Point Application_1.IO.Lube.BOOM_PT_GREASE_PRES 2.31.3.0 Boom
LH Saddleblock Grease Pressure Transducer Boom between Saddleblocks Application_1.IO.Lube.LH_SADDLE_BLK_GREASE_PRES 2.31.4.0 Boom
RH Saddleblock Grease Pressure Transducer Boom between Saddleblocks Application_1.IO.Lube.RH_SADDLE_BLK_GREASE_PRES 2.31.3.1 Boom
Upper Grease Pressure Transducer Machinery House @ Lube Room Wall Application_1.IO.Lube.UPR_GREASE_PRES 2.30.4.0 Lube
Lower Grease Pressure Transducer Carbody @Lower I/O Cabinet Application_1.IO.Lube.LWR_GREASE_PRES 1.13.13.0 Lower
Upper OGL Pressure Transducer Boom between Saddleblocks Application_1.IO.Lube.OG_LUBE_PRES 2.31.4.1 Boom
Lower OGL Pressure Transducer Near Rear Spray Nozzles in Revolving Frame Application_1.IO.Lube.ROLLER_PATH_GREASE_PRES 2.22.13.0 Control Cab

Electrical Outputs

Name Type Component Location Program Variable Name Address I/O

Grease Pump Solenoid Lube Room Application_1.IO.Lube.GREASE_PUMP_AIR_SOL 2.30.12.1 Lube
Open Gear Pump Solenoid Lube Room Application_1.IO.Lube.OPEN_GEAR_PUMP_AIR_SOL 2.30.11.1 Lube
Open Gear Spray Solenoid Lube Room Application_1.IO.Lube.OPEN_GEAR_AIR_SPRAY_SOL 2.30.12.0 Lube
Upper Grease Supply Solenoid Lube Room Application_1.IO.Lube.UPPER_GREASE_SUPPLY_SOL 2.30.17.1 Lube
Lower Grease Supply Solenoid Lube Room Application_1.IO.Lube.LOWER_GREASE_SUPPLY_SOL 2.30.18.0 Lube
Grease Vent Solenoid Lube Room Application_1.IO.Lube.GREASE_VENT_SOL 2.30.17.0 Lube
Upper Open Gear Supply Solenoid Lube Room Application_1.IO.Lube.UPPER_OG_SUPPLY_SOL 2.30.20.0 Lube
Lower Open Gear Supply Solenoid Lube Room Application_1.IO.Lube.LOWER_OG_SUPPLY_SOL 2.30.20.1 Lube
Open Gear Vent Solenoid Lube Room Application_1.IO.Lube.OG_VENT_SOL 2.30.18.1 Lube
Upper Grease Indication LED Lube Room I/O Panel in Lube Room Application_1.IO.Lube.UPR_GREASE_IND 2.30.8.2 Lube
Lower Grease Indication LED Lube Room I/O Panel in Lube Room Application_1.IO.Lube.LWR_GREASE_IND 2.30.8.1 Lube
Upper Open Gear Indication LED Lube Room I/O Panel in Lube Room Application_1.IO.Lube.UPR_OPEN_GEAR_LUBE_IND 2.30.8.3 Lube
Lower Open Gear Indication LED Lube Room I/O Panel in Lube Room Application_1.IO.Lube.ROLLER_CIRCLE_LUBE_IND 2.30.9.0 Lube
Lube Alarm Siren Lube Room I/O Panel in Lube Room Application_1.IO.Lube.LUBE_ROOM_ALARM 2.30.8.0 Lube
Lube Alarm Silence LED Lube Room I/O Panel in Lube Room Application_1.IO.Lube.ALARM_SILENCE_IND 2.30.9.2 Lube
Insert
Blank
Colored
Paper
Divider
Page
Here
T H E L AT E S T P R O D U C T S A N D N E W S F O R L I N C O L N C U S T O M E R S

SOLUTIONS
MAY 2005 VOL. 6, NO. 4

The New SL-V XL

High-Output
Injector
Lincoln’s Newest Member of the
SL-V Injector Family Increases
Output and Significantly Lowers
Installation Cost

All of the features

and benefits of the
standard SL-V plus
the ability to mount
in the same manifolds
as the SL-V and
SL-1 injectors

Two SL-V XL
injectors provide
22% more output
than one SL-11

One SL-V XL can

replace more than
three standard
output injectors

Longer life for

trouble-free
performance

TWO YEAR
WARRANTY
 Benefits of the SL-V XL
Versatility
Two cross-ported SL-V XL injectors can deliver 22%
more output than one standard high-output injector,
plus installation is quicker and easier because of manifold
mounting. Manifold mounting means greater flexibility
because SL-V XL injectors can be installed along with, or
in place of, SL-1 and SL-V injectors. This flexibility gives
the user a choice to upgrade their systems all at once or
as individual injectors are replaced.
Additionally, the output of one SL-V XL injector is more
than three times than that of a single standard injector,
significantly reducing system and inventory costs.
Users also have an alternative to costly dual-line systems.
Having more output (up to .305 in3/stroke), faster venting,
and higher operating pressures, the SL-V XL performs like
a dual-line system but with much less installation cost.
Dual-line systems can utilize longer supply lines but have
greater installation costs due to increased material and labor.
The SL-V XL vents as much as 80 times faster than other
standard high-output injectors. It has a maximum operating
pressure of 6,000 psi and vents at 1,000 psi allowing for
less time between lube events. Standard injectors have a
maximum pressure of 3,500 psi and vent at 600 psi. With
the new, patented SL-V XL injector, using thicker grease,
running longer or smaller supply lines, and eliminating
grease change-outs in cold weather means increased
performance with less cost.

1.48
(38)

2.45
(62)

1.66
(42)
12.64
11.16 (321)
(283)
8.72
7.06 (221)
Because the SL-V XL is a high-output (179)
injector, six new color-coded Spectrum 1.89
1.44 1.89
Adjustment Sleeves have been added (37) (48) (48)
to the four standard sleeves available
with the SL-V injector. These additional
sleeves allow users to precisely set
injector output for each lube event.
SL-1 SL-V SL-V XL SL-11
2 SL-1 Manifold Compatible Hard Piped
Increase Your System’s Performance
With Patented SL-V Technology
Visual Bypass Indicator
The visual bypass indicator alerts maintenance personnel
when an internal seal is failing and needs replacement,
saving costs and expensive downtime.
Clear Polycarbonate Protective Cap
The water-tight, clear polycarbonate cap on the SL-V XL
injector is O-ring sealed, UV resistant, and keeps abrasive
dirt and dust away from the cycle pin indicator while
allowing a fast confirmation of injector performance.
Use Thicker Lubricants
Higher viscosity lubricants are almost always preferred
for lubrication systems. Thicker greases stay in bearings
longer and provide better protection against debris
and washout. The SL-V XL has a 6,000 psi pressure
capability and vents at 1,000 psi allowing higher
viscosity lubricants to be used.
Run Longer Supply Lines
The longer the supply line, the longer it takes the supply
line pressure to vent, which potentially increases the
minimum time between lube events. The SL-V’s
superior venting capability performs as well as dual-line
systems with reduced plumbing cost.
100% Compatibility with the SL-1 and SL-V Injectors
All SL-V, SL-V XL and SL-1 injectors can be mounted in SL-V and SL-V XL injectors
the same manifold. This means substantial cost and time mounted in a standard Lincoln manifold
savings because special mounting hardware (clamps,
brackets, and fittings) and additional plumbing labor
are no longer needed for large lubrication applications.

SL-V XL Saves . . .
Materials:
No Extra Fittings SL-V XL

No Extra Inventory Installation
Labor:
Half the Installation Time is Faster,

No Custom Fabrication

SL-V XL is Pre-Mounted and Tested Less Costly,
Replacement
Longer Life, Higher Performance and More
Costs: Backed by a Two-Year Warranty Efficient 3
 Technical Specifications
11/4"
(32mm)
13/16" 13/16"
(30mm) (30mm)
113/16"
(284mm)

1/8"
NPTF
103/16"
3/4" 13/32" (248mm)
(10.3mm)
(19mm) Mounting 1/8"
Holes NPTF

21/8" 3/8"
(54mm) NPTF
(both ends)
3/8"
NPTF

11/2" A 13/8"
(38mm) B (35mm)
85780-3 85781 85782
Specifications:
Output in3 (cc) Operating Pressure Connections
Series Material Manifold Injector
Min Max Min Max Typical Vent Inlet Outlet
Carbon 0.015 0.305 1850 psig 6000 psig 2500 psig 1000 psig 3/8" 1/8"
SL-V XL
Steel (0.25) (5.00) 128 bar 413 bar 172 bar 69 bar NPTF(F) NPTF(F)
Note: Two SL-V XL Injectors are required to replace one SL-11 Injector

Manifold-Type Injectors:
Number of Dimension A Dimension B
Model Type Outlets in. mm in. mm
85780-1 One Injector Manifold 1 21/2 63
85780-2 Two Injector Manifold 2 Single Mounting Hole 3 76
85780-3 Three Injector Manifold 3 11/4 32 41/4 108
85780-4 Four Injector Manifold 4 21/2 63 51/2 140
85780-5 Five Injector Manifold 5 33/4 95 63/4 171
85780-6 Six Injector Manifold 6 5 127 8 203
85781 Replacement for Manifold Injectors
85782 Single Injector/No Manifold (3/8" NPTF(M) inlet)

Spectrum Adjustment Sleeves:

Model Number Output Ratio from Ratio from Sleeve
(10/bag only) in3 (cc) Minimum Output Maximum Output Color
N/A 0.015 (0.25) 1 0.05 NA
85785-1 0.030 (0.50) 2 0.10 red
85785-2 0.045 (0.75) 3 0.15 silver
85785-3 0.060 (1.00) 4 0.20 gold
85785-4 0.075 (1.25) 5 0.25 green
85785-5 0.113 (1.88) 7.5 0.37 black
85785-6 0.150 (2.50) 10 0.50 purple
85785-7 0.188 (3.13) 12.5 0.62 blue
85785-8 0.225 (3.75) 15 0.75 orange
85785-9 0.263 (4.38) 17.5 0.87 brown
85785-10 0.300 (5.00) 20 1.00 yellow

Lincoln Industrial Corp. Phone 314-679-4200 Form 442988 (5/05)

One Lincoln Way Fax 314-679-4359 © Copyright 2005
St. Louis, MO 63120-1578 www.lincolnindustrial.com Printed in U.S.A.
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