4100XPC Mechanical Systems Manual PDF

ES41157 Mechanical Systems Manual Preface
Preface
This manual is provided as a guide to personnel involved with the operation, maintenance and repair of this electric
mining shovel. We recommend that such personnel review and become familiar with the general procedures and
information contained within this manual. In addition, we recommend that this manual be kept readily available for
reference when repairs or maintenance are necessary.
Due to the complexities of mining equipment and the environment in which it operates, situations may arise which
are not directly discussed in detail in this manual. When such a situation arises, past experience, availability of
equipment, and common sense play a large part in what steps are to be taken. In addition, a P&H MinePro Ser-
vices representative is available to answer your questions and assist you upon request.
Copyright
Copyright © 2007 P&H Mining Equipment, Inc. All rights reserved. All materials contained herein are pro-
tected by United States copyright law and international treaties, and may not be reproduced, distributed,
transmitted, displayed, published or broadcast without the prior written permission of P&H Mining Equipment,
Inc. You may not alter or remove any trademark, copyright or other notice from copies of the content. All
rights in translations of these materials shall remain exclusively with P&H Mining Equipment.
Copyright © 2007 P&H Mining Equipment, Inc. Peak Services

Preface.fm -i- Preface, Version 00 - 06/07
ES41157 Mechanical Systems Manual
Peak Services Copyright © 2007 P&H Mining Equipment, Inc.

, Version 00 - 06/07 -ii- Preface.fm
ES4157 Mechanical Systems Manual Table of Contents
Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SECTION 1, Shovel Safety

1.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1.1 Safety Websites. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.2 Safe Operating Practices for Users of P&H Mining Equipment -
Electric Shovels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2.2 Qualifications for and Conduct of Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2.3 Operation Guidelines and Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.2.4 Responsibilities of All Crew Members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.2.5 Planning the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.3 Safety for Electrical and Electronic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
1.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
1.3.2 Maintenance Work Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
1.3.3 Electrical Safety Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
1.3.4 Electrical Shock Dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
1.4 Operation Near Electrical Lines Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
1.5 Safety Hazard Indicators, Decals, and Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
1.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
1.5.2 Hazard Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
1.5.3 Safety Hazard Decals and Signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
1.6 Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.58
1.6.1 MSHA Regulations Regarding Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.59
1.6.2 Fire Extinguisher Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.60
SECTION 2, Introduction
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.1.1 Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.1.2 Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2.2 Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2.3 Hoist System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2.4 Crowd System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2.5 Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2.6 Propel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2.7 Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.3.1 Deck Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

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2.4 Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
SECTION 3, General Assembly Procedures

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.2 Pre-Assembly General Cleaning and Protection Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.2.1 General Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.2.2 Protection Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.2.3 Hydraulic Torque Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3 Fasteners and Torquing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.3.2 Hardware Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3.3.3 Fastener and Torque Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3.3.4 Types of Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
3.3.5 Thread Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
3.3.6 Bolt Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
3.3.7 Supernuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
3.4 Interference Fit and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
3.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
3.4.2 Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
3.4.3 Couplings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
3.4.4 Dowel Pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
3.4.5 Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
3.4.6 Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
3.4.7 Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
3.4.8 Splines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
3.5 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
3.5.1 Bearing Storage, Interference Fit, and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
3.5.2 Types of Bearing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
3.6 Shrink Fit Clearances Required for Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
3.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
3.6.2 Clearance Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
3.7 Lubrication During Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
3.8 Guidelines for Gear Tooth Contact Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
3.8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
3.8.2 Contact Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
3.8.3 Record Keeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
3.9 Shimming Shaft and Bearing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
3.9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
3.9.2 Types of Shims and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49
3.9.3 Shimming Bearing Retainer Caps That Clamp Bearing Outer Races in Housing Bores.
3.52
3.9.4 Shimming Bearing Retainer Caps That Provide Clearance to Bearing Outer Races in
Housing Bores. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54
3.9.5 Shimming Shaft End Plates That Clamp Bearing Inner Races on Shaft Shoulders . 3.54

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3.9.6 Shimming to Seat an Inner Bearing Race or Member with Clearance Against a Shaft
Shoulder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57
3.10 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59
3.10.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59
3.10.2 Metal-to-Metal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.60
3.10.3 Installation and Assembly of O-Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.60
3.10.4 Assembly of Labyrinth Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.61
3.10.5 Installation and Assembly of Lip Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.62
3.10.6 Threaded Pipe Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.63
SECTION 4, General Inspection

4.1 Predictive Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1.1 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1.2 Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1.3 Drives (AC/DC converters, reactive power compensator) . . . . . . . . . . . . . . . . . . . . . 4.2
4.2 Wire Ropes and Strand Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
4.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
4.2.2 Criteria for Replacement of Running Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.2.3 Criteria for the Discard of Suspension Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
4.2.4 Criteria for the Discard of Strand Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
4.2.5 Inspection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
4.3 Gear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
4.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
4.3.2 Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
4.3.3 Plastic Deformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
4.3.4 Contact Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
4.3.5 Cracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
4.3.6 Fracture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
4.3.7 Bending Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
SECTION 5, Disc Brakes

5.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.2 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.2.1 Brake System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.2.2 Propel Brakes R42784D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
5.2.3 Crowd Brake R41760D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
5.2.4 Hoist Brakes R56316D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5.2.5 Swing Brakes R42786D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
5.2.6 Brake Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
5.2.7 Brake Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
5.3 A Warning About Stored Mechanical Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
5.3.1 Development of Mechanical Stored Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
5.3.2 Releasing Stored Energy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27


5.4 Removing Disc Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31
5.4.1 Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31
5.4.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32
5.4.3 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.37
5.5 Brake Removal Under Special Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.37
5.6 Preliminary Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39
5.7 Maintenance of Air System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39
5.7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40
5.7.2 Air Pressure Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40
5.7.3 Air Valve Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41
5.7.4 Quick Release Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.42
5.7.5 Brake Air Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43
5.8 Propel Brake Maintenance R42784 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.44
5.8.1 Releasing Propel Brakes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.45
5.8.2 Propel Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.49
5.8.3 Propel Brake Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50
5.8.4 Preventive Maintenance Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.51
5.8.5 Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.55
5.8.6 O-ring And Felt Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.58
5.8.7 Propel Brake Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.63
5.8.8 Propel Brake Performance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.75
5.8.9 Propel Brake Burnish-In Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.76
5.9 Releasing Upper Brakes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.77
5.9.1 Releasing Upper Brakes Using the Operator’s Controls . . . . . . . . . . . . . . . . . . . . . . 5.77
5.9.2 Releasing Upper Brakes Using the Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.79
5.9.3 Releasing Upper Brakes Using an External Air Supply . . . . . . . . . . . . . . . . . . . . . . 5.81
5.10 Crowd Brake Maintenance R41760D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.89
5.10.1 Crowd Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.89
5.10.2 Crowd Brake Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.90
5.10.3 Preventive Maintenance Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.91
5.10.4 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.95
5.10.5 O-ring and Felt Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.97
5.10.6 Crowd Brake Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.103
5.10.7 Crowd Brake Performance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.108
5.10.8 Crowd Brake Burnish-In Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.109
5.11 Hoist Brake Maintenance R56316D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.111
5.11.1 Hoist Brake Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.111
5.11.2 Hoist Brake Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.112
5.11.3 Preventive Maintenance Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.113
5.11.4 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.117
5.11.5 O-ring and Felt Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.119
5.11.6 Hoist Brake Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.125
5.11.7 Hoist Brake Performance Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.131
5.11.8 Hoist Brake Burnish-In Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.132


5.12 Swing Brake Maintenance R42786D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.134
5.12.1 Swing Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.134
5.12.2 Swing Brake Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.135
5.12.3 Preventive Maintenance Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.136
5.12.4 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.139
5.12.5 O-ring and Felt Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.139
5.12.6 Swing Brake Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.145
5.12.7 Swing Brake Performance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.152
5.12.8 Swing Brake Burnish-In Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.153
5.13 Brake Preventive Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.155
5.13.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.155
5.14 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.157
5.14.1 Brake Hold Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.159
SECTION 6, Machine Lower Assembly

6.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6.2 Component Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.2.1 Carbody R51403D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.2.2 Crawler Frames R54550D1/D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.2.3 Lower Rollers R54866F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.2.4 Front Idler Roller R41233F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.2.5 Rear Idler Roller R41233F1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.2.6 Crawler Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
6.2.7 Cable Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
6.3 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
6.3.1 Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
6.3.2 Preliminary Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
6.3.3 Carbody R51403D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
6.3.4 Crawler Frames R54550D1/D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
6.3.5 Lower Rollers R54866F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
6.3.6 Front Idler Roller R41233F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25
6.3.7 Rear Idler Roller R41233F1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.35
6.3.8 Crawler Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.41
6.3.9 Cable Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.53
SECTION 7, Propel System

7.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.2.1 Carbody R51403D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.2.2 Motor Mounting Base R46695D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
7.2.3 Propel Motor R41837F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.2.4 Propel Brake R42784D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.2.5 Propel Motor Blower R12599D1F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5


7.2.6 Propel Transmission 100J5800F5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
7.2.7 Tumbler Drive Shaft R41348F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.2.8 Drive Tumbler R54897F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.3 Propel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.3.1 Preliminary Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.3.2 Carbody R51403D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.3.3 Motor Mounting Base R46695D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.3.4 Propel Motor R41837F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
7.3.5 Propel Brake R42784D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
7.3.6 Propel Motor Blower R12599D1F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.26
7.3.7 Propel Transmission 100J5800F5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28
7.3.8 Tumbler Drive Shaft R41348F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
7.3.9 Drive Tumbler R54897F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45
SECTION 8, Machinery House and Exterior Walkways

8.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.2.1 Exterior Structures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.2.2 Hatch Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.2.3 Operator Cab Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
8.3 Shovel Exterior Walkways and Handrails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.3.2 Machinery House Walkways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
8.3.3 Gantry and Boom Walkways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
8.4 Boarding Stairway and Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
8.4.1 Boarding Stairways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
SECTION 9, AirScrubPro™
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9.1.1 High Efficiency Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9.1.2 Continuous Self Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
9.1.3 Easily Maintained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
9.1.4 Air Flow Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.1.5 Machinery House Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.1.6 Screw Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.1.7 Cold Weather Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
9.2.2 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
9.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
9.3.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
9.3.2 Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
9.3.3 Filter Cartridge Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15


9.3.4 Airlock Feeder Information 1037Z589 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
9.3.5 Screw Conveyor Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
9.3.6 Airlock Maintenance 1037Z589 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
9.4 Fault Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.4.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.4.2 Graphical User Interface (GUI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.4.3 Panel Fault Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
9.4.4 Fault Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
9.4.5 Graphical User Interface (GUI) Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
9.4.6 Intelligent Interface Module (IIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.31
9.4.7 Micro Memory Card (MMC) Description and Operation . . . . . . . . . . . . . . . . . . . . . . 9.33
9.4.8 LED Lights Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.36
9.4.9 Resetting the Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.40
9.4.10 Terminal Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.41
9.4.11 Control Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.42
9.4.12 Control Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.43
SECTION 10, Air Conditioning Units

10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
10.2 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
10.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
10.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
10.3.2 Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
SECTION 11, Swing System

11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
11.2 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
11.2.1 Swing Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
11.2.2 Swing Motor Blower (R47453F4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
11.2.3 Swing Transmission (100J5949F4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4
11.2.4 Swing Shaft (R41151F1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4
11.2.5 Swing Brakes (R42786D1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4
11.2.6 Swing Roller Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
11.2.7 Roller Circle Assembly (R43636 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6
11.2.8 Swing Ring Gear (R43636D1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7
11.2.9 Center Gudgeon, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7
11.2.10 Voltage Collector Assembly (R33149D9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
11.2.11 Air and Grease Swivel (R34804F4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
11.2.12 Swing Resolver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
11.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10
11.3.1 Preliminary Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10
11.3.2 Swing Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10
11.3.3 Swing Motor Blower (R47453F4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.22


11.3.4 Swing Transmission (100J5949F4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.24
11.3.5 Swing Shaft (R41151F1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.29
11.3.6 Swing Roller Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.36
11.3.7 Roller Circle Assembly (R43636). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.40
11.3.8 Swing Ring Gear (R31328D1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.41
11.3.9 Center Gudgeon R50370F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.45
11.3.10 Voltage Collector Assembly (R33149D9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.63
11.3.11 Air and Grease Swivel (R34804F4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.65
11.3.12 Swing Resolver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.68
SECTION 12, Hoist System

12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
12.2.1 Hoist Motors And Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
12.2.2 Hoist Gear Case R57767F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3
12.2.3 Hoist Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4
12.2.4 Hoist Limit Switch Sensor 979J247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5
12.2.5 Hoist Drum Shaft Assembly R58153F1/F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5
12.2.6 Hoist Ropes R23421D49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.6
12.2.7 Remote Hoist Controller R54705D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.6
12.2.8 Cable Tuggers R26969D5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.9
12.2.9 Hoist Gear Case Lubrication System R57234F1/F2 . . . . . . . . . . . . . . . . . . . . . . . 12.12
12.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.19
12.3.1 Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.19
12.3.3 Hoist Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.20
12.3.4 Hoist Motor Blower R12599D1F5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.28
12.3.5 Hoist Gear Case Assembly (R57767F1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.30
12.3.6 Hoist First Reduction Shaft Assembly R32779F3 . . . . . . . . . . . . . . . . . . . . . . . . . 12.47
12.3.7 intermediate Hoist Shaft R31793F1 (front) and R31793F2 (rear) . . . . . . . . . . . . . 12.52
12.3.8 Hoist Limit Switch Sensor 979J247F1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.58
12.3.9 Hoist Drum Shaft R58153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.60
12.3.10 Hoist Ropes R23421D49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.75
12.3.11 Hoist Cable Tuggers R26969D5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.79
12.3.12 Hoist Lube Pump Assembly R57213D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.82
12.3.13 Hoist Lube System Bypass Valve R57221D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.86
12.3.14 Oil Strainer Assembly (46Q108D3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.86
12.3.15 Oil Filter Assemblies (46U110D3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.90
SECTION 13, Attachment

13.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
13.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2
13.2.1 Gantry R39787F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3


13.2.2 Boom Assembly R52773F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4
13.2.3 Boom Wear Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5
13.2.4 Boom Point Assembly R42014F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5
13.2.5 Boom Suspension Cables 30U254D5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6
13.2.6 Cable Guide R42917F1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6
13.2.7 Boom Resolver Assembly R43964F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7
13.2.8 Dipper Trip Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
13.2.9 The function of the motor and drum assembly is to maintain a slight tension on the dip-
per trip cable during normal operation of the shovel, except for the dumping phase at which time the
motor torque is increased to actuate the dipper trip mechanism. . . . . . . . . . . . . . . . . . . . . . . . 13.10
13.2.10 Dipper Trip Cable R17556D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
13.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.11
13.3.1 Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.11
13.3.3 Gantry R39787F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.13
13.3.4 Boom Assembly R52773F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.15
13.3.5 Boom Wear Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.18
13.3.6 Boom Point Assembly R58150F1/F2/F3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.20
13.3.7 Boom Suspension Cables 30U254D5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.24
13.3.8 Cable Guide R42917F1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.27
13.3.9 Boom Resolver Assembly R43964F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.30
13.3.10 Dipper Trip Assembly R54947F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.32
13.3.11 Dipper Trip Motor and Drum Assembly R54946F2. . . . . . . . . . . . . . . . . . . . . . . 13.34
13.3.12 Dipper Trip Cable R17556D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.42
SECTION 14, Crowd System

14.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
14.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
14.2.1 Crowd Drive Assembly R42119F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
14.2.2 Automatic Tensioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4
14.2.3 Crowd Belt Tensioning System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.10
14.2.4 Crowd Gear Case R43474F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.18
14.2.5 Crowd First Reduction Shaft R41571F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.18
14.2.6 Crowd Second Reduction Shaft R40476F2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.19
14.2.7 Shipper Shaft R54042F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.19
14.2.8 Saddle Blocks R54373F3/F4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.20
14.2.9 Crowd Disc Brake R41760D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.21
14.2.10 Crowd Limit Switch Sensor 979J249F1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.21
14.2.11 Dipper Handles R52465F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.22
14.2.12 Dipper R47768F5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.23
14.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.31
14.3.1 Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.31
14.3.3 Crowd Motor R41837F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.33


14.3.4 Crowd Motor Sheave. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.36
14.3.5 PowerBand™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.37
14.3.6 Automatic Tensioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.45
14.3.7 Crowd Gear Case R43474F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.47
14.3.8 Crowd Limit Switch Resolver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.51
14.3.9 Crowd Gear Case Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 14.53
14.3.10 Crowd First Reduction Shaft R41571F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.55
14.3.11 Crowd Second Reduction Shaft R40476F2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.59
14.3.12 Shipper Shaft And Saddle Blocks (R54042F1) . . . . . . . . . . . . . . . . . . . . . . . . . 14.63
14.3.13 Dipper Handles R52465 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.92
14.3.14 Dipper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.104
14.3.15 SnubRite® Hydraulic Snubbers R52182 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.117
SECTION 15, Air System

15.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1
15.2.1 Air Compressor R36961D3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3
15.2.2 Air Control Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6
15.2.3 Air Dryer R37969F2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.13
15.2.4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.13
15.2.5 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.14
15.2.6 Air Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.15
15.2.7 Lubricator 46Z405D1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.16
15.2.8 Air Manifold Assembly (R42202F1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.16
15.2.9 Coop/Stair Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.18
15.2.10 Propel Brake Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.24
15.2.11 Auxiliary Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.26
15.2.12 Automatic Lubrication System Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.27
15.2.13 Upper Brake System Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.28
15.2.14 Automatic Lubrication System Sprayers Air Supply . . . . . . . . . . . . . . . . . . . . . . 15.30
15.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.31
15.3.1 Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.31
15.3.3 Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.32
15.3.4 Air Dryer R37969F2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.37
15.3.5 Air Receiver R42570D1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.43
15.3.6 Lubricator 46Z405D1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.45
15.3.7 Boarding Stairway Air System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.47
15.4 Boarding Stairway Air Cylinder (R51982D1, 38Q136) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.55
15.4.1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.55
15.4.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.55
15.4.3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.56
15.4.4 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.57
15.4.5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.57


15.4.6 Propel Brake Air System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.60
15.4.7 Automatic Lubrication System Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.64
15.4.8 Upper Brake Air System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.65
15.4.9 Lube Sprayers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.69
15.4.10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.72
15.5 Spray Valves (R5808F3, F6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.73
15.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.73
SECTION 16, Lubricant Specifications

16.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
16.2 Selection of Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
16.2.1 System Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
16.2.2 P&H Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
16.2.3 Operating in Cold Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
16.3 Selection of Gear Case Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3
16.3.1 Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3
16.3.2 ISO Grades of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5
16.4 Material Specification P&H No. 464 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5
16.4.1 Open Gear and Wire Rope Lubricant, Issue No. 9, 4-20-93 . . . . . . . . . . . . . . . . . . 16.5
16.5 Material Specification P&H No. 469 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.8
16.5.1 Multi-Purpose Grease, Extreme Pressure, Aluminum Complex Soap Base, Liquilon Sol-
id Lubricant Additive, Issue No. 1, 1-80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.8
16.6 Material Specification P&H No. 472 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.10
16.6.1 Multi-Purpose Grease; Extreme Pressure (EP), Issue No. 11, 2-24-95 . . . . . . . . 16.10
16.7.1 Synthetic Gear Oil; Extreme Pressure (EP), Issue No. 5, 2-24-95 . . . . . . . . . . . . 16.14
16.8.1 Gear Oil - Single Viscosity Grade; Extreme Pressure (EP), Issue No. 11, 2-1-93 16.16
16.10 Material Specification P&H No. 520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.22
16.10.1 Multi-Service Mining Lubricant, Issue No. 00, 3-97 . . . . . . . . . . . . . . . . . . . . . . . 16.22
SECTION 17, Lubrication Requirements

17.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
17.1.1 Lubrication Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
17.1.2 Automatic Lubrication System General Description . . . . . . . . . . . . . . . . . . . . . . . . 17.7
17.2 Electric Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.7
17.2.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.7
17.2.2 Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.7
17.2.3 Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.9
17.2.4 Lubrication Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.9
17.3 Grease Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.11
17.4 Installing Replacement Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.12


17.5 Lubrication After Extended Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.12
17.5.1 Hoist Gear Case Lubrication System R57234F1/F2 . . . . . . . . . . . . . . . . . . . . . . . 17.13
17.5.2 Hoist Lube Pump Assembly R57213D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.13
17.5.3 Hoist Lube System Bypass Valve R57221D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.18
17.5.4 Hoist Lube System Strainer 46Q108D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.18
17.5.5 Hoist Lube System Filter 46U110D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.20
17.6 Crowd Gear Case Lubrication System (R48499F1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.22
17.6.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.22
17.6.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.23
17.7 Lubrication System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.25
17.7.1 Oil Filters (46U110D1, D2) Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.25
17.7.2 Oil Strainer (46Q108D2, D3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.27
17.7.3 Lubrication Pump (37Z331D2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.29
17.7.4 Hoist And Crowd Lube Pump Flexible Coupling (18Z3706D2, D3) . . . . . . . . . . . . 17.34
17.7.5 Swing Lube Pump Flexible Coupling (18Z3706D4). . . . . . . . . . . . . . . . . . . . . . . . 17.35
17.7.6 Gear Reducer (53Z801) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.37
17.8 Centralized Transmission Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.41
17.9 Gear Case Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.42
SECTION 18, Automatic Lubrication System

18.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
18.2 Lube Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3
18.2.2 Four Zone System Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.7
18.3 Component Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.16
18.3.1 Lube Room I/O Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.16
18.3.2 Centurion Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.17
18.3.3 Touch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.18
18.3.4 Air Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.22
18.3.5 Lubrication Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.23
18.3.6 Lubrication Panel R54840F3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.27
18.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.35
18.4.1 Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.35
18.4.3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.36
18.4.4 Electrical and Electronic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.38
18.4.5 Air System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.38
18.4.6 Lubrication Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.39
18.4.7 Lube Tank Breathers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.42
18.4.8 Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.42
18.4.9 Air Motor and Pump R54687D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.43
18.4.10 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.43
18.5 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.55

ES41157 Mechanical Systems Manual List of Figures
List of Figures
Section 1: Shovel Safety
Figure 1-1: Improper Operating Practices Cause Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Figure 1-2: Shovel Deck Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.33
Figure 1-3: Lube Room, Hoist Drum Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34
Figure 1-4: Hoist Drum Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.35
Figure 1-5: Outside Shovel Opposite Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.35
Figure 1-6: Outside Shovel Right Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36
Figure 1-7: Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.37
Figure 1-8: Side Railing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38
Figure 1-9: Typical Outside Entrance Door to Machinery Area. . . . . . . . . . . . . . . . . . . . . . . . . . 1.38
Figure 1-10: Lower Access Door to Space Between Upper and Lower . . . . . . . . . . . . . . . . . . . 1.39
Figure 1-11: Main Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40
Figure 1-12: Auxiliary Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.41
Figure 1-13: Upper High Voltage Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.41
Figure 1-14: Suppression and Ground Fault Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42
Figure 1-15: Dipper Trip Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.43
Figure 1-16: RPC Switching Cabinet (Front). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44
Figure 1-17: RPC Switching Cabinet (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44
Figure 1-18: Converter Cabinet (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45
Figure 1-19: Converter Cabinet (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.46
Figure 1-20: Remote I/O Transfer Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.46
Figure 1-21: Transfer Contactor Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.47
Figure 1-22: Auxiliary Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.48
Figure 1-23: Control Cabinet - Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.49
Figure 1-24: Hoist Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50
Figure 1-25: Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51
Figure 1-26: Crowd and Propel Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51
Figure 1-27: Crowd and Propel Blower Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.52
Figure 1-28: Crowd Motor Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.52
Figure 1-29: Field Supply and Auxiliary Secondaries Breakers . . . . . . . . . . . . . . . . . . . . . . . . . 1.53
Figure 1-30: High and Low Voltage Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.53
Figure 1-31: 480VAC Panelboard #1 and #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.54
Figure 1-32: 120VAC and Flood Light Panelboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.54
Figure 1-34: Hoist, Swing, Propel Brake Exhaust Solenoid and Pressure Switch . . . . . . . . . . . 1.55
Figure 1-35: Operator’s Panelboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55
Figure 1-33: Machinery House Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55
Figure 1-36: Cable Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.56
Figure 1-37: Remote I/O Lube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.56
Figure 1-38: Applied to All Junction Box Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.56
Figure 1-39: Swing Lube Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.57
Figure 1-40: All Overhead Bus Covers (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.57
Figure 1-41: All Overhead Wire Trays (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.57
Figure 1-42: Fire Extinguisher - Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.58
Figure 1-43: Fire Extinguisher Sign. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.58
Copyright © 2007 Harnischfeger Corporation P&H Mining Equipment - Knowledge and Development
M0041157-00-ENLOF.fm -1- List of Figures, Version 00 - 06/07
List of Figures ES41157 Mechanical Systems Manual
List of Figures (Continued)

Section 2: Introduction
Figure 2-1: 4100XPC Outside View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Figure 2-2: 4100XPC Deck Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Section 3: General Assembly Procedures

Figure 3-1: Hydraulic Torque Wrench Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Figure 3-2: Typical Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Figure 3-3: Typical Pressure Adjustment on a HYTORC® Power Unit. . . . . . . . . . . . . . . . . . . . . 3.4
Figure 3-4: Gauge Accuracy ± 1% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Figure 3-5: Master Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Figure 3-6: Lubrication Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
Figure 3-7: Supernuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
Figure 3-8: Typical Supernut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
Figure 3-9: Examples of Torquing Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
Figure 3-10: Interference Fit, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
Figure 3-11: Do Not Heat with an Open Flame or Torch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
Figure 3-12: Use a Clean Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
Figure 3-13: Place a Rack on the Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
Figure 3-14: Checking the Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
Figure 3-15: Installing Bearing on Tight Inner Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
Figure 3-16: Installing Bearing with Tight Inner and Outer Bores . . . . . . . . . . . . . . . . . . . . . . . . 3.28
Figure 3-17: Installing Bearing with Tight Inner and Outer Bores Using Relieved Disk . . . . . . . 3.29
Figure 3-19: Using Removal Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
Figure 3-18: Transmitting Force Through Rolling Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
Figure 3-20: Removing a Bearing with a Puller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
Figure 3-21: Removing an Inner Ring with a Puller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
Figure 3-22: Removing a Bearing with a Press. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
Figure 3-23: Single Tapered Roller Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
Figure 3-24: Single Tapered Roller Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
Figure 3-25: Pinion with Single Tapered Roller Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
Figure 3-26: Using a Dial Indicator to Check End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
Figure 3-27: Double-Tapered Roller Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
Figure 3-29: Double-Tapered Roller Bearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
Figure 3-31: Spherical Roller Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
Figure 3-32: Spherical Roller Bearing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
Figure 3-33: One-Piece and Two-Piece Straight Roller Bearings . . . . . . . . . . . . . . . . . . . . . . . . 3.40
Figure 3-34: Acceptable Contact on Gear Tooth with End Crown on Pinion . . . . . . . . . . . . . . . 3.46
Figure 3-35: Acceptable Contact on Gear Tooth with Center Crown on Pinion . . . . . . . . . . . . . 3.46
Figure 3-37: Acceptable Contact on Gear Tooth with No Crown on Pinion or Gear . . . . . . . . . . 3.47
Figure 3-38: Unacceptable Contact on Gear Tooth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47
Figure 3-36: Acceptable Contact on Gear Tooth with Offset Crown on Pinion . . . . . . . . . . . . . 3.47
P&H Mining Equipment - Knowledge and Development Copyright © 2007 Harnischfeger Corporation
List of Figures, Version 00 - 06/07 -2- M0041157-00-ENLOF.fm

Figure 3-39: Plastic Shims Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
Figure 3-40: Slotted Sheet Metal Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51
Figure 3-41: Hoist Drum Shaft Bearing Retainer Shimming. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
Figure 3-42: End Plate Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.56
Figure 3-43: Boom Point Assembly Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58
Figure 3-44: Pipe Thread Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.64
Section 4: General Inspection

Figure 4-1: P&H MinePro® Services Predictive Diagnostics Van . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Figure 4-2: Hoist Ropes and Boom Suspension Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Figure 4-3: Wire Rope Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
Figure 4-4: Hoist Ropes (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Figure 4-5: Measuring Wire Rope Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
Figure 4-6: Sheave Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
Figure 4-7: Suspension Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
Figure 4-8: Gear Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Figure 4-9: Abrasion at the Tip of Gear Teeth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
Figure 4-11: Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
Figure 4-10: Scoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
Figure 4-12: Scuffing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Figure 4-13: Rolling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Figure 4-15: Progressive Pitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Figure 4-14: Initial Pitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Figure 4-16: Spalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
Figure 4-17: Fatigue Crack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
Figure 4-18: Brittle Fracture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
Figure 4-19: Tooth Shear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
Section 5: Disc Brakes

Figure 5-1: Disc Brake (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Figure 5-2: Brake Indicator Microswitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Figure 5-3: Brake System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Figure 5-4: Disc Brake (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Figure 5-5: Air Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Figure 5-6: Lower Air Control Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Figure 5-7: Quick Release Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Figure 5-8: Propel Brake Air Panel (top) and Maintenance Panel (bottom) . . . . . . . . . . . . . . . . . 5.6
Figure 5-9: Crowd Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
Figure 5-10: Upper Brake Air Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
Figure 5-11: Upper Brake Solenoid Air Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
Figure 5-12: Crowd Brake Pressure Transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
Figure 5-13: Quick Release Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
Figure 5-14: Hoist Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10

Figure 5-15: Upper Brake Air Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
Figure 5-16: Upper Brake Solenoid Air Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
Figure 5-17: Quick Release Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
Figure 5-18: Air Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
Figure 5-19: Double Redundancy Crossover Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
Figure 5-20: Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
Figure 5-21: Upper Brake Air Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
Figure 5-22: Brake Air Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
Figure 5-23: Quick Release Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
Figure 5-25: Brake Components (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
Figure 5-26: drive ring (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
Figure 5-27: Center Plate (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
Figure 5-28: Rotor (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
Figure 5-29: Cylinder Assembly (typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
Figure 5-30: Piston (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
Figure 5-31: Cylinder (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
Figure 5-32: Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
Figure 5-33: Quick Release Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
Figure 5-34: Air Brake Isolation Kit (closed position, for maintenance purposes only) . . . . . . . . 5.23
Figure 5-35: Brake Indicator Microswitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
Figure 5-36: Stored Energy Sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
Figure 5-37: Brake with Air Panel (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
Figure 5-38: Examples of Connection Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29
Figure 5-39: Manual Actuators on Brake Air Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30
Figure 5-40: Manual Brake Release Assembly
(locally fabricated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33
Figure 5-42: Connecting External Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35
Figure 5-43: Disc Brake Mounting Bolts (circled) (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.36
Figure 5-44: Star Bolting Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.38
Figure 5-45: Brake Air Pressure Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40
Figure 5-46: Brake Air Valve Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41
Figure 5-47: Quick Release Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.42
Figure 5-49: Propel Brake System Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.44
Figure 5-50: Propel Brake Maintenance Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.45
Figure 5-51: Propel Brake Maintenance Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46
Figure 5-52: Operation Warning Decal (Inside Cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.48
Figure 5-53: Propel Brake (R42784D1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.49
Figure 5-54: Evidence of O-Ring Leakage (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.52
Figure 5-55: Propel Brake Piston Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.54
Figure 5-56: Air Gap Split Shim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.56

Figure 5-58: Removing Socket Head Cap Screws from Piston (training brake shown) . . . . . . . 5.59
Figure 5-59: Installing Hex Head Cap Screws in Pressure Plate . . . . . . . . . . . . . . . . . . . . . . . . 5.59
Figure 5-60: Piston Clear of O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.60
Figure 5-61: Inspect Piston O-Ring Grooves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.61
Figure 5-62: Inspect Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.61
Figure 5-63: Installing Piston O-Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.61
Figure 5-64: Ends of Split Seal Before Cutting to Fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.62
(locally fabricated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.65
Figure 5-67: Connecting External Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.67
Figure 5-68: Disc Brake Mounting Bolts (circled) (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.68
Figure 5-71: Upper Brake Release Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.78
Figure 5-72: Manual Actuators on Upper System Brake Air Valves . . . . . . . . . . . . . . . . . . . . . . 5.80
Figure 5-73: Manual Brake Release Assembly (locally fabricated). . . . . . . . . . . . . . . . . . . . . . . 5.82
Figure 5-74: Disconnecting Air lines (hoist brake shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.83
Figure 5-75: Disconnecting Air lines (hoist brake shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.86
Figure 5-76: Crowd Brake (R41760D1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.89
Figure 5-77: Evidence of O-Ring Leakage (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.92
Figure 5-78: Air Gap Split Shim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.96
Figure 5-80: Removing Socket Head Cap Screws from Piston (training brake shown) . . . . . . . 5.99
Figure 5-81: Installing Hex Head Cap Screws in Pressure Plate . . . . . . . . . . . . . . . . . . . . . . . . 5.99
Figure 5-82: Piston Clear of O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.100
Figure 5-83: Inspect Piston O-Ring Grooves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.100
Figure 5-84: Inspect Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.101
Figure 5-85: Installing Piston O-Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.101
Figure 5-86: Ends of Split Seal Before Cutting to Fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.102
Figure 5-87: Star Bolting Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.105
Figure 5-89: Hoist Brake (R56316D1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.111
Figure 5-90: Evidence of O-Ring Leakage (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.114
Figure 5-91: Air Gap Split Shim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.118
Figure 5-93: Removing Socket Head Cap Screws from Piston (training brake shown) . . . . . . 5.121
Figure 5-94: Installing Hex Head Cap Screws in Pressure Plate . . . . . . . . . . . . . . . . . . . . . . . 5.121
Figure 5-95: Piston Clear of O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.122
Figure 5-96: Inspect Piston O-Ring Grooves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.122
Figure 5-97: Inspect Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.123
Figure 5-98: Installing Piston O-Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.123
Figure 5-99: Ends of Split Seal Before Cutting to Fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.124
Figure 5-100: Star Bolting Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.127

Figure 5-102: Swing Brake (R42786D1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.134
Figure 5-103: Evidence of O-Ring Leakage (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.137
Figure 5-104: Removing Socket Head Cap Screws from Piston (training brake shown) . . . . . 5.141
Figure 5-105: Installing Hex Head Cap Screws in Pressure Plate . . . . . . . . . . . . . . . . . . . . . . 5.141
Figure 5-106: Piston Clear of O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.142
Figure 5-107: Inspect Piston O-Ring Grooves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.143
Figure 5-108: Inspect Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.143
Figure 5-109: Installing Piston O-Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.143
Figure 5-110: Ends of Split Seal Before Cutting to Fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.144
Figure 5-113: Shimming the Swing Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.151
Figure 5-114: Analog Meters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.154
Section 6: Machine Lower Assembly

Figure 6-1: Lower Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Figure 6-2: Carbody (rear view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Figure 6-3: crawler frame (Right Side Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Figure 6-4: Lower Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Figure 6-5: Front Idler Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Figure 6-6: Rear Idler Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Figure 6-7: Crawler Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
Figure 6-8: Cable Reel (typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Figure 6-9: Shovel Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Figure 6-10: Carbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
Figure 6-11: Shear Ledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
Figure 6-12: Crawler Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
Figure 6-13: Guide Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
Figure 6-14: Guide Rail Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
Figure 6-15: Side Frame Rod Bolt Tightening Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
Figure 6-16: Typical SuperNut(TM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
Figure 6-17: Lower Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
Figure 6-18: Inspect Roller Bushing Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
Figure 6-19: Toenailing on Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
Figure 6-20: Replace Individual Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
Figure 6-21: Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23
Figure 6-22: Front Idler Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25
Figure 6-23: Inspecting Front Idler Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.26
Figure 6-24: Toenailing on Front Idler Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27
Figure 6-25: Inspecting Front Idler Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28
Figure 6-26: Front Idler Shaft Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.30
Figure 6-27: Bearing Block Removal Kit, R47712F1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.31
Figure 6-28: Front Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.33

Figure 6-29: Rear Idler Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.35
Figure 6-30: Positioning the Rear Idler Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.36
Figure 6-31: Toenailing on Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.37
Figure 6-32: Replace Individual Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.38
Figure 6-33: Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.39
Figure 6-34: Crawler Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.41
Figure 6-35: Crawler Track Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.42
Figure 6-36: Crawler Shim Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.43
Figure 6-37: Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.44
Figure 6-38: Positioning for Crawler Track Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.46
Figure 6-39: Front Idler Shims Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.47
Figure 6-40: Crawler Shim Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.47
Figure 6-41: Crawler Shoe Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.48
Figure 6-42: Position Pulling Vehicle for Track Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.49
Figure 6-43: Remove Shoe Link Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.49
Figure 6-44: Removing Crawler Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.50
Figure 6-45: Installing Crawler Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.51
Figure 6-46: Connect Track Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.52
Figure 6-47: Leave Nuts Loose and Tack Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.52
Figure 6-48: Cable Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.53
Figure 6-49: Right Angle Gear Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.55
Section 7: Propel System

Figure 7-1: Propel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Figure 7-2: Carbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Figure 7-3: Motor Mounting Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Figure 7-4: Propel Motor with Brake and Blower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
Figure 7-5: Propel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
Figure 7-6: Propel Motor Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
Figure 7-7: Propel Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
Figure 7-8: Drive Tumbler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
Figure 7-9: DELTA Shoe Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
Figure 7-10: Propel Motor Mounting Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
Figure 7-11: Bolt Pattern for Propel Motor Mounting Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
Figure 7-12: Propel Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
Figure 7-13: Motor Alignment Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
Figure 7-14: Propel Coupling Facial Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
Figure 7-15: Motor Alignment Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
Figure 7-16: Propel Motor Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
Figure 7-17: Typical Motor Lubrication Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
Figure 7-18: Propel Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
Figure 7-19: Propel Brake Maintenance Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
Figure 7-20: Propel Motor Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.26
Figure 7-21: Propel Planetary Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28

Figure 7-22: Remove spacer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30
Figure 7-23: Lifting the Propel Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31
Figure 7-24: Blocking the Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32
Figure 7-25: Lifting the Propel Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33
Figure 7-26: Propel Transmission Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.34
Figure 7-27: Measure Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.35
Figure 7-28: Tumbler and Tumbler Drive Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
Figure 7-29: Front Idler Shims Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.39
Figure 7-30: Tumbler Drive Shaft Counterbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.40
Figure 7-31: Installing Crawler Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.42
Figure 7-32: Drive Tumbler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45
Section 8: Machinery House and Exterior Walkways

Figure 8-1: Machinery House . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Figure 8-2: Machinery House Description (1 of 2). Legend is at Figure 9-3.. . . . . . . . . . . . . . . . . 8.3
Figure 8-3: Legend for Figures 9-2, and 9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
Figure 8-4: Machinery House Description (2 of 2). Legend is at Figure 9-3.. . . . . . . . . . . . . . . . . 8.4
Figure 8-5: Roof Hatch Covers (refer to legend at Table 9-1). . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Figure 8-6: Operator Cab Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
Figure 8-7: Winch Mounting Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
Figure 8-8: Shovel Roof Handrails (R54023F1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
Figure 8-9: Front House Catwalks and Handrails (R45025F1) . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
Figure 8-10: Gantry Platform (R44350F1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
Figure 8-11: Boom Platforms Module (R53675F1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
Figure 8-12: Boarding Stairway and Right Side Catwalks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
Section 9: AirScrubPro™
Figure 9-1: Air Filtration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Figure 9-2: Cartridge Replacement from Machinery House Roof . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
Figure 9-3: Air Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
Figure 9-4: Machinery House Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
Figure 9-5: Control Cabinet - Front Panel Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
Figure 9-6: Filter Order of Pulse Cleaning - View Standing in Front of Unit . . . . . . . . . . . . . . . . . 9.6
Figure 9-7: Trough and Screw Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
Figure 9-8: Airlock and Dust Collector Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
Figure 9-9: Blower Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
Figure 9-10: Checking Blade Setting/Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
Figure 9-11: Speed Switch Sensor Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
Figure 9-12: Air Filter Cartridge Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
Figure 9-13: Rotary Airlock Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
Figure 9-14: End Plate Setscrews. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
Figure 9-15: Airlock Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
Figure 9-16: Control Cabinet - Front Panel Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23

Figure 9-17: I/O Module Cleaning System and Conveyor Fault Indication . . . . . . . . . . . . . . . . . 9.24
Figure 9-18: Auger Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
Figure 9-19: Rotary Airlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
Figure 9-20: Intelligent Interface Module (IIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.31
Figure 9-21: Interface Module Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.32
Figure 9-22: Control Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.43
Section 10: Air Conditioning Units

Figure 10-1: Climate Control Openings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
Figure 10-2: Shovel Serial Number (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
Section 11: Swing System

Figure 11-1: Swing System Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
Figure 11-2: Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
Figure 11-3: Swing Motor Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
Figure 11-4: Swing Motor Blower Ducting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
Figure 11-5: Swing Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4
Figure 11-6: Swing Ring Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7
Figure 11-7: Center Gudgeon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7
Figure 11-8: High Voltage Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
Figure 11-9: Air and Grease Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
Figure 11-10: Swing Resolver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
Figure 11-11: Swing Motor and Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11
Figure 11-12: Swing Motor Removal (Motor Replacement or Repair) . . . . . . . . . . . . . . . . . . . 11.13
Figure 11-13: Swing Motor Removal (Transmission Replacement or Repair) . . . . . . . . . . . . . 11.15
Figure 11-14: Swing Motor (R43247F1 and F2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.17
Figure 11-15: Swing Coupling Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.18
Figure 11-16: Swing Motor Installation (Base on Transmission). . . . . . . . . . . . . . . . . . . . . . . . 11.20
Figure 11-17: Swing Motor Installation (Base on motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.21
Figure 11-18: Swing Motor Blower Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.23
Figure 11-19: Swing Transmission Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25
Figure 11-20: Removing/Installing Swing Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.26
Figure 11-21: Swing Shaft Installation/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.30
Figure 11-22: Swing Shaft Bearing Capsule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.35
Figure 11-23: Roller Circle Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.36
Figure 11-24: Upper Roller Path Assembly (R43700F1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.37
Figure 11-25: Location of Upper Path Retention Bolts (Typical) . . . . . . . . . . . . . . . . . . . . . . . . 11.39
Figure 11-26: Annual Swing Roller Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.40
Figure 11-27: Swing Ring Gear Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.41
Figure 11-28: Swing Ring Gear Shimming (typical) (Top View) . . . . . . . . . . . . . . . . . . . . . . . . 11.43
Figure 11-29: Center Gudgeon Assembly (R50370F1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.45
Figure 11-30: Center Gudgeon Nut Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.48
Figure 11-31: Center Gudgeon Lifting Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.51

Figure 11-32: Center Gudgeon Hydraulic Wrench (R47687F1) . . . . . . . . . . . . . . . . . . . . . . . . 11.53
Figure 11-33: Voltage Collectors and Center Gudgeon Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.54
Figure 11-34: Removing Swivel and Voltage Collectors (R35030) . . . . . . . . . . . . . . . . . . . . . . 11.55
Figure 11-35: Center Gudgeon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.58
Figure 11-36: Center Gudgeon Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.60
Figure 11-37: Voltage Collector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.63
Figure 11-38: Air and Grease Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.65
Figure 11-39: Assembled View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.66
Figure 11-40: Weld Mounting Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.66
Figure 11-41: Drive Pin Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.67
Figure 11-42: Swing Resolver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.68
Section 12: Hoist System

Figure 12-1: Hoist System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Figure 12-2: Hoist Motor and Blower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
Figure 12-3: Hoist Gear Case (R57767F1/F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3
Figure 12-4: Hoist Gear Case Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4
Figure 12-5: Hoist Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4
Figure 12-6: Hoist Limit Switch Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5
Figure 12-7: Hoist Drum Shaft Assembly (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5
Figure 12-8: Hoist Ropes R23421D49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.6
Figure 12-9: Remote Hoist Joystick Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.6
Figure 12-10: Hoist Remote Control Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7
Figure 12-11: Cable Tuggers (typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.9
Figure 12-12: Cable Tugger Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.10
Figure 12-13: Cable Tugger Pendant Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.10
Figure 12-14: Tugger Brake Manual Release Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
Figure 12-15: Hoist Gear Case Lubrication System Overview . . . . . . . . . . . . . . . . . . . . . . . . . 12.12
Figure 12-16: Hoist Lubrication System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
Figure 12-17: Pump Assembly R57213D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.14
Figure 12-18: Vacuum Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.14
Figure 12-19: Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15
Figure 12-20: Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15
Figure 12-21: Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.16
Figure 12-22: Distribution manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.16
Figure 12-23: Hoist Lube System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.18
Figure 12-24: Shovel Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.19
Figure 12-25: Hoist Motor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.21
Figure 12-26: Shaft Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.24
Figure 12-27: Alignment Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.25
Figure 12-28: Motor Blower Assembly (R12599D1F2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.29
Figure 12-29: Hoist Gear Case Mounting (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.30
Figure 12-30: Hoist Gear Case Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.31
Figure 12-31: Hoist Gear Case Support Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.33

Figure 12-32: Hoist Gear Case R57767F1/F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.35
Figure 12-33: Legend for Figure 12-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.36
Figure 12-34: Hoist Drum Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.38
Figure 12-35: Preparing Hoist Gear Case Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.40
Figure 12-36: V Ring Seal Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.41
Figure 12-37: Weld Flats to Bottom Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.42
Figure 12-39: Intermediate Shaft Assembly (R31793F1&F2) . . . . . . . . . . . . . . . . . . . . . . . . . . 12.45
Figure 12-40: Hoist Drum Shaft Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.46
Figure 12-41: First Reduction Shaft Assembly (R32779F3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.47
Figure 12-42: Double Tapered Roller Bearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.49
Figure 12-43: Bearing Capsule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.50
Figure 12-44: Intermediate Hoist Shaft (R31793) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.53
Figure 12-45: Intermediate Shaft Assembly (R31793F1&F2) . . . . . . . . . . . . . . . . . . . . . . . . . . 12.56
Figure 12-46: Hoist Limit Switch Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.58
Figure 12-47: Hoist Limit Switch Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.59
Figure 12-48: Hoist Drum Shaft Assembly R58153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.61
Figure 12-49: Legend for Figure 12-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.62
Figure 12-50: Hoist Drum Gear Bolt, 20Z1940D24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.63
Figure 12-51: Secure the Bearing Block to the Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.65
Figure 12-53: Hoist Drum Shaft Bearing Block Shim Locations . . . . . . . . . . . . . . . . . . . . . . . . 12.68
Figure 12-54: Measurement Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.69
Figure 12-56: Measuring Solder Thickness on Front Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.70
Figure 12-55: Applying Solder to Front Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.70
Figure 12-57: Gearing Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.72
Figure 12-59: Gear Tooth Contact Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.73
Figure 12-58: Applying Bluing Compound. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.73
Figure 12-60: Acceptable and Unacceptable Gear Contact Patterns . . . . . . . . . . . . . . . . . . . . 12.74
Figure 12-61: Side Stand Bearing Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.74
Figure 12-62: Hoist Rope Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.75
Figure 12-63: Hoist Rope Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.77
Figure 12-64: Hoist Cable Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.77
Figure 12-65: Attach New Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.78
Figure 12-66: Pull Cables In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.78
Figure 12-67: Electric Tugger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.79
Figure 12-68: Hoist Rope Tugger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.80
Figure 12-69: Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.86
Figure 12-70: Strainer Assembly - Photo Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.87
Figure 12-71: Servicing Gearcase Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.88
Figure 12-72: Magnet Locations - Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.89
Figure 12-73: Oil Filter (46U110D3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.90
Figure 12-74: Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.91
Figure 12-75: Filter Assembly (46U110D3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.92

Figure 12-76: Loosening Cover Capscrews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.93
Figure 12-77: Removing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.93
Figure 12-78: Removing Bypass Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.94
Figure 12-79: Removing Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.94
Section 13: Attachment

Figure 13-1: Attachment (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
Figure 13-2: Attachment Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2
Figure 13-3: Gantry R39787F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3
Figure 13-4: Boom Assembly R52773F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4
Figure 13-5: Boom Wear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5
Figure 13-6: Boom Point Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5
Figure 13-7: Boom Suspension Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6
Figure 13-8: Cable Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6
Figure 13-9: Boom Resolver Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7
Figure 13-10: Jacking the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.8
Figure 13-11: Crowd Joystick Controller and Crowd Brake Release Button . . . . . . . . . . . . . . . 13.9
Figure 13-12: Dipper Trip Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
Figure 13-13: Dipper Trip Cable R17556D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
Figure 13-15: Gantry R39787F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.13
Figure 13-16: Boom Assembly R52773F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.15
Figure 13-17: Boom Foot Pin Assembly (R43475)F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.16
Figure 13-18: Boom Wear Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.18
Figure 13-19: Boom Point Assembly R58150F1/F2/F3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.20
Figure 13-20: Boom Suspension Cable Lubrication Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.24
Figure 13-21: Support the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.25
Figure 13-22: Remove the Boom Suspension Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.26
Figure 13-23: Line Stripes on Suspension Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.26
Figure 13-24: Cable Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.27
Figure 13-25: Cable Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.28
Figure 13-26: Boom Resolver Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.30
Figure 13-27: Dipper Trip Assembly R54947F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.32
Figure 13-28: Dipper Trip Motor and Drum R54946F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.34
Figure 13-29: Dipper Trip Motor and Drum Assembly (R59556F2) . . . . . . . . . . . . . . . . . . . . . 13.36
Figure 13-30: Dipper Trip Transmission (R53914D2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.38
Figure 13-31: Manual Brake Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.39
Figure 13-32: Dipper Trip Cable Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.42
Figure 13-33: Attach Dipper Trip Cable to Dipper Trip Drum . . . . . . . . . . . . . . . . . . . . . . . . . . 13.43
Section 14: Crowd System

Figure 14-1: Crowd System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
Figure 14-2: Crowd System Components (Side View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2

Figure 14-3: Crowd Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
Figure 14-4: Hydraulic Power Unit R44023. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4
Figure 14-5: Hydraulic Solenoid Panel and Electrical Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5
Figure 14-6: Electrical Panel Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6
Figure 14-7: PVD Signal Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6
Figure 14-8: Hydraulic Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.8
Figure 14-9: Control Panel R44918F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.9
Figure 14-10: Crowd Belt Tensioning System Schematic (R43711) . . . . . . . . . . . . . . . . . . . . . 14.11
Figure 14-11: Schematic: Pump Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.13
Figure 14-12: Schematic: Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.14
Figure 14-13: Schematic: Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.16
Figure 14-14: Crowd Gear Case R43474F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.18
Figure 14-15: Shipper Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.19
Figure 14-16: Saddle Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.20
Figure 14-17: Crowd Second Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.20
Figure 14-18: Crowd Disc Brake R41760D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.21
Figure 14-19: Crowd Limit Switch Sensor 979J249F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.21
Figure 14-20: Dipper Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.22
Figure 14-21: Dipper (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.23
Figure 14-22: Dipper Identification Plate (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.23
Figure 14-23: Ground Engaging Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.24
Figure 14-24: Dipper Tooth Components (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.25
Figure 14-25: Dipper Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.26
Figure 14-26: Dipper Versus Tooth Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.27
Figure 14-27: Dipper Rake Versus Tooth Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.28
Figure 14-28: SnubRite® Hydraulic Snubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.30
Figure 14-29: SnubRite Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.30
Figure 14-31: Crowd Motor and Motor Mounting Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.33
Figure 14-32: Crowd Motor Ventilation Plate (32Q2031) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.35
Figure 14-33: Sheave Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.36
Figure 14-34: Power Band Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.38
Figure 14-35: Automatic Tensioner Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.41
Figure 14-36: Support Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.41
Figure 14-37: Crowd Motor Support Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.42
Figure 14-38: Power Band Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.43
Figure 14-39: Cylinder Mounting Pin Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.45
Figure 14-40: Automatic Tensioner Pump Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.45
Figure 14-41: Crowd Gear Case Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.47
Figure 14-42: Crowd Gear Case Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.47
Figure 14-43: Gear Case Cover Bolt Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.49
Figure 14-44: Prepare Blocking to Support Gear Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.50
Figure 14-45: Crowd Limit Switch Resolver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.51
Figure 14-46: First Reduction Shaft Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.55

Figure 14-47: Bushing Capsule and Setscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.58
Figure 14-48: Second Reduction Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.60
Figure 14-49: Shipper Shaft and Saddle Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.63
Figure 14-50: Saddle Block Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.64
Figure 14-51: Remove Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.66
Figure 14-52: Install Hydraulic Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.67
Figure 14-53: Locking Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.68
Figure 14-54: Shipper Shaft Appearance After Pulling to the Left . . . . . . . . . . . . . . . . . . . . . . 14.69
Figure 14-55: Install Hydraulic Ram on Right Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.70
Figure 14-56: Shipper Shaft Appearance After Pulling to the Right . . . . . . . . . . . . . . . . . . . . . 14.71
Figure 14-58: Hydraulic Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.73
Figure 14-60: Shipper Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.78
Figure 14-62: Saddle Block Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.81
Figure 14-63: Right and Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.82
Figure 14-64: Shipper Shaft Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.83
Figure 14-65: Lip Seal Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.84
Figure 14-66: Apply Sealing and Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.85
Figure 14-67: Components Are Not Symmetrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.86
Figure 14-68: Position the Shipper Shaft Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.87
Figure 14-69: Install Shipper Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.87
Figure 14-70: Meshing Splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.88
Figure 14-71: Install Bushing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.88
Figure 14-72: Install Shipper Shaft Pinion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.89
Figure 14-73: Timing Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.90
Figure 14-74: Install Seal and Lubricate Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.90
Figure 14-76: Adjusting Collar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.91
Figure 14-77: Dipper Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.92
Figure 14-78: Greenhorn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.93
Figure 14-79: Place the Loaded Dipper on the Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.95
Figure 14-80: Setup Push Button - Control Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.95
Figure 14-81: Boom Limits Setup - Navigation Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.96
Figure 14-82: Boom Limits Selection Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.96
Figure 14-83: Four Point Setup Push Button Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.97
Figure 14-84: Four Point Boom Limit Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.97
Figure 14-85: Lube/PLS Keyswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.98
Figure 14-87: Dipper Handle Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.100
Figure 14-88: Spacer for Dipper Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.101
Figure 14-89: Dipper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.104
Figure 14-91: Dipper Tooth Wear Caps (Circled Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.106

Figure 14-90: Dipper Tooth Wedge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.106
Figure 14-92: Primary Wear Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.107
Figure 14-93: Replaceable Outside Wear Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.108
Figure 14-94: Inside Wear Plate (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.109
Figure 14-95: Dipper Door Wear Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.110
Figure 14-96: Legend for Dipper Door Exploded Drawing (Figure 14-97) . . . . . . . . . . . . . . . 14.111
Figure 14-97: Dipper Door (refer to legend at Figure 14-96). . . . . . . . . . . . . . . . . . . . . . . . . . 14.112
Figure 14-98: Latching Mechanism Wear Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.114
Figure 14-99: Latch Bar Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.116
Figure 14-100: SnubRite® Hydraulic Snubber (Right hand shown; left opposite) . . . . . . . . . 14.117
Figure 14-101: Do Not Open Snubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.118
Figure 14-102: Lifting the Snubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.119
Section 15: Air System

Figure 15-1: Air Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1
Figure 15-2: Air System Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2
Figure 15-3: Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3
Figure 15-4: Compressor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.4
Figure 15-5: Compressor’s Touchpad and Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.7
Figure 15-6: Pressure Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.11
Figure 15-7: Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.13
Figure 15-8: Air System Schematic With Membrane Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . 15.14
Figure 15-9: Air Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.15
Figure 15-10: Reciever Automatic Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.15
Figure 15-11: System Transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.15
Figure 15-12: Air System Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.16
Figure 15-13: Air Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.16
Figure 15-14: Air Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.17
Figure 15-15: Boarding Stairway Air System Schematic (R15627). . . . . . . . . . . . . . . . . . . . . . 15.19
Figure 15-16: Regulator/Filter/Lubricator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.20
Figure 15-17: Boarding Stairway Manually Controlled Valves . . . . . . . . . . . . . . . . . . . . . . . . . 15.21
Figure 15-18: Location of Air Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.22
Figure 15-19: Boarding Stairway Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.23
Figure 15-20: Air Horn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.24
Figure 15-21: Air Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.24
Figure 15-22: Lower Air Control Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.25
Figure 15-23: Quick Release Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.25
Figure 15-24: Propel Brake Air Panel (top) and Maintenance Panel (bottom) . . . . . . . . . . . . . 15.26
Figure 15-25: Automatic Lubrication System Air Pressure Regulator . . . . . . . . . . . . . . . . . . . . 15.27
Figure 15-26: Auto Lube System Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.27
Figure 15-27: Upper Brake System Air Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.28
Figure 15-28: Quick Release Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.29
Figure 15-29: Brake Air Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.29
Figure 15-30: Automatic Lubrication System Air Valve Manifold . . . . . . . . . . . . . . . . . . . . . . . 15.30

Figure 15-32: Compressor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.32
Figure 15-33: Pressure Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.34
Figure 15-34: Change Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.36
Figure 15-35: Membrane Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.37
Figure 15-36: Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.38
Figure 15-37: Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.39
Figure 15-38: Automatic Drain Valve (R41033D1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.39
Figure 15-39: Dryer Filter and Element (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.41
Figure 15-40: Air Dryer Membrane Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.42
Figure 15-41: Air Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.43
Figure 15-42: Air Receiver Mounting Hardware (four places) . . . . . . . . . . . . . . . . . . . . . . . . . . 15.44
Figure 15-43: Air System Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.45
Figure 15-44: Boarding Stairway Filter/Regulator/Lubricator Assembly . . . . . . . . . . . . . . . . . . 15.48
Figure 15-45: Boarding Stairway Air Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.49
Figure 15-46: Air Lubricator (46Q38D9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.52
Figure 15-47: Air Regulators (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.53
Figure 15-48: Boarding Stairway Air Cylinder (38Q137) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.56
Figure 15-49: AirSrub Pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.59
Figure 15-50: Air Horn Air Pressure Regulator and Solenoid Valve . . . . . . . . . . . . . . . . . . . . . 15.60
Figure 15-51: Propel Brake Air Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.61
Figure 15-52: Propel Brake Air Valve Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.61
Figure 15-53: Quick Release Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.62
Figure 15-54: Air Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.63
Figure 15-55: Automatic Lubrication System Air Valve Manifold . . . . . . . . . . . . . . . . . . . . . . . 15.64
Figure 15-56: Upper Brake Air Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.65
Figure 15-57: Upper Brake Air Valve Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.66
Figure 15-59: Air Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.68
Figure 15-60: Lube Sprayer Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.69
Figure 15-61: Upper Brake Air Valve Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.70
Figure 15-63: Sprayer Air Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.72
Figure 15-64: Spray Valve With Cleanout Assembly (R5808F3, F6) . . . . . . . . . . . . . . . . . . . . 15.73
Section 16: Lubricant Specifications
Section 17: Lubrication Requirements

Figure 17-1: 4100XPC Upper Shovel Lubrication Diagram - Service Points . . . . . . . . . . . . . . . 17.2
Figure 17-2: 4100XPC Attachment and Lower Lubrication Diagrams - Service Points . . . . . . . 17.5
Figure 17-3: Typical Electric Motor Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.9
Figure 17-4: Swing Motor Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.10
Figure 17-5: Hoist Gear Case Lubrication System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 17.13
Figure 17-6: Lubrication Circulation Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.14

Figure 17-7: Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.18
Figure 17-8: Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.19
Figure 17-9: Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.20
Figure 17-10: Crowd Gear Case Lubrication System (Typical, 4100XPC Not Shown). . . . . . . 17.22
Figure 17-11: Crowd Gear Case Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.23
Figure 17-12: Oil Filter (46U110) - D1 Shown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.25
Figure 17-13: Oil Strainer (46Q108) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.27
Figure 17-14: Lubrication Pump (37Z331D2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.29
Figure 17-15: Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30
Figure 17-16: Hoist and Crowd Lubrication Flexible Coupling (18Z3706D2,D3) . . . . . . . . . . . 17.34
Figure 17-17: Aligning Coupling Halves (18Z3706 D2,D3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.35
Figure 17-18: Swing Lubrication Pump Flexible Coupling (18Z3706D4) . . . . . . . . . . . . . . . . . 17.36
Figure 17-19: Gear Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.37
Figure 17-20: Centralized Transmission Drain Line (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . 17.41
Figure 17-21: Centralized Transmission Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.41
Section 18: Automatic Lubrication System

Figure 18-1: Automatic Lubrication System (typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
Figure 18-2: Grease System Upper Zone and Lower Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3
Figure 18-3: Open Gear Lube System Upper Zone and Lower Zone . . . . . . . . . . . . . . . . . . . . . 18.4
Figure 18-4: Lincoln Four Zone System Pump and Vent Valve, Pumping . . . . . . . . . . . . . . . . . 18.6
Figure 18-5: Lincoln Four Zone System Pump and Vent Valve, Venting . . . . . . . . . . . . . . . . . . 18.7
Figure 18-6: Grease Pump Upper Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.9
Figure 18-7: Grease Lower Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.11
Figure 18-8: Open Gear Lube Upper Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.13
Figure 18-9: Four Zone Lincoln System Swing Open Gear Zone Schematic . . . . . . . . . . . . . . 18.15
Figure 18-10: Lube Room I/O Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.16
Figure 18-11: Control Cabinet With Centurion Control System and Touch Panel . . . . . . . . . . 18.17
Figure 18-12: Operations - Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.18
Figure 18-13: Operations - Shovel Lube System Status Screen. . . . . . . . . . . . . . . . . . . . . . . . 18.21
Figure 18-14: Setup - Lube Cycle Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.22
Figure 18-15: Lubrication Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.23
Figure 18-16: Lube Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.24
Figure 18-17: Lubrication Tank Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.24
Figure 18-18: Pump Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.25
Figure 18-19: Air Motor and Lubrication Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.25
Figure 18-20: Lubrication Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.27
Figure 18-21: SL-V Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.29
Figure 18-22: Injector Operation - Position 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.30
Figure 18-23: SL-1 and SL-11 Operation - Position 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.31
Figure 18-26: Pressure Transducer (R43284D1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.34

Figure 18-28: Lubrication Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.39
Figure 18-29: Lubrication Tank Filter Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.40
Figure 18-30: Quick Fill Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.41
Figure 18-31: Lubrication Tank Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.42
Figure 18-32: Pump Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.42
Figure 18-33: Air Motor and Lubrication Pump (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.43
Figure 18-34: SL-1 Injector Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.44
Figure 18-35: SL-11 Injector Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.44
Figure 18-36: SL-1 Injector Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.46
Figure 18-37: SL-1 Injector Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.47
Figure 18-38: Bleeding Air - Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.49
Figure 18-39: Bleeding Air - Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.49
Figure 18-40: Bleeding Air From Feeder Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.50
Figure 18-41: SL-11 Injector Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.51
Figure 18-42: Bleeding Air - Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.54
Figure 18-43: Bleeding Air - Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.54
Figure 18-44: Bleeding Air From Feeder Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.55
ES41157 Mechanical Systems Manual List of Tables
List of Tables
Section 1: Shovel Safety
Table 1-1: Do’s and Don’ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Table 1-2: Electrical Shock and Human Response. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
Table 1-3: Safety Hazard Decals and Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
Section 2: Introduction
Section 3: General Assembly Procedures

Table 3-1: Effects of Lubricant Types on Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
Table 3-2: Torque Value Chart for American Standard Screws and Bolts (Coarse Threads). . . 3.10
Table 3-3: Installing Supernuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
Table 3-4: Required Assembly Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
Table 3-5: Bronze Bushing Shrinkage on Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
Table 3-6: Cold Pin (Shaft) Shrinkage on Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
Table 3-7: Clearance Examples (all Measurements Inches). . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
Table 3-8: Plastic Shim Color Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
Table 3-9: Sheet Metal Shim Gauge Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51
Table 3-10: Thread Engagement of Standard Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.65
Section 4: General Inspection
Section 5: Disc Brakes

Table 5-1: Brake Specifications, Propel Brake (R42784D1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50
Table 5-2: Brake Specifications, Crowd Brake (R41760D1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.90
Table 5-3: Brake Specifications, Hoist Brake (R56316D1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.112
Table 5-4: Brake Specifications, Swing Brake (R42786D1) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.135
Table 5-5: 250 Hour Brake Inspection Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.156
Table 5-6: Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.157
Section 6: Machine Lower Assembly

Table 6-1: 4100XPC Data for Tensioning Kit R17981. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
Table 6-2: Side Frame Rod Bolt Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
Table 6-3: Lubrication, Cable Reel Gear Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.55
Section 7: Propel System
Section 8: Machinery House and Exterior Walkways

Table 8-1: Hatches and Covers (refer to Figure 9-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Section 9: AirScrubPro™
Table 9-1: Fan Blade Setting Chart Guide for Cartridge-Type Filtration . . . . . . . . . . . . . . . . . . . 9.13
Table 9-2: Current Draw and Horsepower for Cartridge-Type Filtration . . . . . . . . . . . . . . . . . . . 9.13
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List of Tables ES41157 Mechanical Systems Manual

Table 9-3: Fan Blade Setting Chart Guide for Cartridge-Type Filtration . . . . . . . . . . . . . . . . . . . 9.14
Table 9-4: Current Draw and Horsepower for Cartridge-Type Filtration . . . . . . . . . . . . . . . . . . . 9.14
Table 9-5: System Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
Table 9-6: Conveyor Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
Table 9-7: Cartridge Filter GUI Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
Table 9-8: Mode Selector Switch Positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.32
Table 9-9: Intelligent Interface Module (IIM) LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.37
Table 9-10: Intelligent Interface Module (IIM) LED Configuration Indicators. . . . . . . . . . . . . . . . 9.38
Table 9-11: IIM Terminal Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.41
Section 10: Air Conditioning Units
Section 11: Swing System

Table 11-1: Ring Gear Shim Thicknesses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.43
Section 12: Hoist System

Table 12-1: Lube Point Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.17
Table 12-2: Backlash Measurements and Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.71
Table 12-3: Lube Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.85
Section 13: Attachment
Section 14: Crowd System

Table 14-1: Suggested Starting Points for Adjusting the Tooth and Rake Angle . . . . . . . . . . . 14.29
Section 15: Air System

Table 15-1: Programmed Set Points - Single Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6
Table 15-2: Recommended Air Pressures for Air Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.23
Table 15-3: Programmed Set Points - Single Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.33
Table 15-4: Troubleshooting Air Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.54
Table 15-6: System Regulator Set Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.58
Section 16: Lubricant Specifications

Table 16-1: Gear Oil Operating Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3
Table 16-2: R36586 Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5
Table 16-3: Performance Requirements - P&H Specification 464 . . . . . . . . . . . . . . . . . . . . . . . 16.7
Table 16-4: Performance Requirements - P&H Specification 469 . . . . . . . . . . . . . . . . . . . . . . . 16.9
Table 16-5: Performance Requirements - P&H Specification 472 . . . . . . . . . . . . . . . . . . . . . . 16.12
List of Tables, Version 00 - 06/07 -2- M0041157-00-ENLOT.fm
ES41157 Mechanical Systems Manual List of Tables

Table 16-8: Performance Requirements - P&H Specification 497 (Continued) . . . . . . . . . . . . 16.18
Section 17: Lubrication Requirements

Table 17-1: 4100XPC Upper Shovel Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3
Table 17-2: 4100XPC Attachment and Lower Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . 17.6
Table 17-3: 4100XPC Shovel Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.7
Table 17-4: Lube Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.17
Table 17-5: Gear Case Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.42
Section 18: Automatic Lubrication System

Table 18-1: Automatic Lubrication System Controls and Indications . . . . . . . . . . . . . . . . . . . . 18.19
Table 18-2: Recommended Lubrication System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.37
Table 18-3: Injector Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.45
M0041157-00-ENLOT.fm -3- List of Tables, Version 00 - 06/07
List of Tables ES41157 Mechanical Systems Manual
List of Tables, Version 00 - 06/07 -4- M0041157-00-ENLOT.fm
ES41157 Mechanical Systems Manual Shovel Safety
Section 1
Shovel Safety
1.1 General Information

Since the earliest days of mining, the job of digging coal and other useful materials out of the earth has been con-
sidered one of the world’s most dangerous occupations. Public concern about the toll of deaths, injuries and
destruction in mine accidents has prompted passage of much-needed safety legislation and intensified the search
for safer methods and improved training practices and technology. Growing cooperation among industry, labor and
government also has contributed to making mining safer and more healthful, especially in recent years.
Safety and health in the United States mining industry has improved greatly since the early 20th Century. Total
mining fatalities reached the lowest level in history in 2004. Listed below are Safety Information Websites that can
assist in preventing mining accidents and injuries:
1.1.1 Safety Websites
NOTICE
P&H Mining Equipment uses the websites for United States safety authorities MSHA, OSHA
and NIOSH as sources of mining safety information in the development of technical documen-
tation for their products. Other regulatory governing bodies may have jurisdiction over your
operation. Nothing in this manual supersedes any of those organizations’ rules and regulations.
www.msha.gov. The U.S. Department of Labor’s Mine Safety and Health Administration (MSHA) helps to reduce
deaths, injuries, and illnesses in the nation’s mines with a variety of activities and programs. The agency develops
and enforces safety and health rules applying to all U.S. mines, helps mine operators who have special compliance
problems, and makes available technical, educational and other types of assistance. MSHA works cooperatively
with industry, labor, and other Federal and state agencies toward improving safety and health conditions for all
miners. MSHA’s responsibilities are spelled out in the Federal Mine Safety and Health Act of 1977.
www.osha.gov. The U.S. Department of Labor’s Occupational Safety and Health Administrations (OSHA) mission
is “to assure, so far as possible, every working man and woman in the nation safe and healthful working conditions”
by authorizing enforcement of the standards developed under the Occupational Safety and Health Act of 1970; by
assisting and encouraging the States in their efforts to assure safe and healthful working conditions; by providing
for research, information, education, and training in the field of occupational safety and health; and for other
purposes.
www.cdc.gov/niosh. The National Institute for Occupational Safety and Health (NIOSH) is the Federal agency
responsible for conducting research and making recommendations for the prevention of work-related disease and
injury. The Institute is part of the Centers for Disease Control and Prevention (CDC). NIOSH is responsible for con-
ducting research on the full scope of occupational disease and injury ranging from lung disease in miners to carpal
tunnel syndrome in computer users.

Sec01Safety.fm -1.1- Section 1, Version 00 - 06/07
Shovel Safety ES41157 Mechanical Systems Manual
1.2 Safe Operating Practices for Users of P&H Mining Equipment -

Electric Shovels
NOTICE
A review of many safety sources including MSHA, NIOSH, OSHA, ANSI, and various individual
mine safety policies was conducted to develop these safe operating practices recommenda-
tions. The purpose of these recommendations is to assist and support our customer in their
safety efforts in preventing accidents.
1.2.1 Introduction
P&H shovels are carefully designed, manufactured, and tested. When used properly by qualified operators, they
will give safe, reliable service. There are P&H offices worldwide to answer any questions about P&H products or
their safe use. The World Sales and Service Headquarters for P&H Mining Equipment is:
P&H Mining Equipment

4400 West National Avenue
P.O. Box 310
Milwaukee, WI 53201 USA
Telephone: (414) 671-4400
Because shovels are complex and contain massive pieces of equipment and have the ability to lift and move heavy
loads, they also have the potential for accidents if safe operating practices are not followed. This section is
intended to help prevent accidents which could result in injury, death, or property damage.
General safe practices for working machinery must be followed as well as safe operating practices. The following
P&H Mining Equipment recommendations are provided to supplement customer/owner, local or national safety
codes, rules or procedures.
1.2.2 Qualifications for and Conduct of Operators
The following P&H Mining Equipment recommendations are presented for the purpose of reducing the possibility of
personal injury, either to the operator, or to those who work on or in the area adjacent to the shovel. This documen-
tation is general in nature, and your shovel may not be equipped with all devices mentioned.

Section 1, Version 00 - 06/07 -1.2- Sec01Safety.fm
The operator of this shovel is urged to read this section carefully, and to avoid the hazardous operating conditions
described. All situations described in the following have, at one time or another, contributed to serious accidents.
Figure 1-1: Improper Operating Practices Cause Accidents
However, it is impossible to foresee all such conditions, and it must remain the responsibility of the mining com-
pany and the operator to anticipate and avoid any unsafe conditions not described in detail in this manual. It is
understood that safety rules within individual mining companies vary, and that, if a conflict exists, the rules of the
company take precedence over the suggestions contained herein.
1.2.2.1 Operators of P&H Electric Shovels
P&H Mining Equipment strongly recommends that only the following qualified personnel be permitted to operate a
shovel:
1. Designated qualified operators who have met the requirements of the operation tests and physical and mental
conditions.
2. Trainees under the direct supervision of a qualified operator.
3. Qualified maintenance and test personnel when required to do so in the performance of their duties.
4. Inspectors qualified to operate the shovel.
1.2.2.2 Operator Qualifications
P&H Mining Equipment strongly recommends that operators and operator trainees meet the following
qualifications:
1. Operators of P&H electric mining shovels must be required by the employer to pass a written examination
which accurately measures practical knowledge of the shovel, and an evaluated demonstration of the proper
methods and techniques to be used in operating the shovel, facilitated by a P&H Factory Authorized Trainer.
2. An operator must have vision of at least 20/30 Snellen in one eye and 20/50 Snellen in the other, with or with-
out corrective lenses. Good depth perception is required especially where truck loading is critical or must be
accomplished at some distance from the operator.

3. An operator must be able to distinguish colors, regardless of the position of the color, if color differentiation is
required for operation of the shovel.
4. An operator must have adequate hearing for the specific operation, with or without hearing aid.
5. An operator must have sufficient strength, endurance, agility, coordination, and speed of reaction to meet the
demands of shovel operation.
6. Evidence of physical defects or emotional instability that could render a hazard to the operator or others, or
which in the opinion of a qualified person could interfere with the operator’s performance may be cause for dis-
qualification. In such cases, specialized clinical or medical judgments and tests may be required.
7. Evidence that an operator is subject to seizures or loss of physical control is reason for disqualification.
Specialized medical tests may be required to determine these conditions.
8. Evidence that an operator is under the influence of alcohol or drugs is cause for disqualification.
9. An operator who is taking medication prescribed by a medical doctor must provide written assurance from that
doctor that the medication will not affect the operator’s ability to operate the shovel in a safe manner.
10. The operator must have a good attitude towards safety at all times.
1.2.2.3 Operator’s Conduct

Safety must always be the operator’s primary concern. An operator must refuse to operate the
shovel when a known unsafe condition exists. Consult your supervisor when safety is in doubt.
1. The operator must read and understand the Operator’s Manual and be familiar with all instructions and signs
on the shovel.
2. The operator must see that the shovel is in proper order before operating.
3. When physically or otherwise unfit, an operator must not engage in the operation of the shovel.
4. The operator must not engage in any practice that will divert attention while actually engaged in operating the
shovel.
5. The operator will ensure that people, other mining equipment, and material are kept out of the work area. Do
not operate the dipper over people. Never use the shovel dipper to lift or transport people.
6. The operator must give a warning signal prior to starting, operating, or traveling the shovel.
7. All controls must be tested by the operator before beginning a new shift. If any control does not operate prop-
erly, the operator must contact the appropriate maintenance department and have the controls repaired before
operating the shovel.
8. If adjustments or repairs are necessary, or any defects are known, the operator must promptly report the
defects to the appropriate maintenance department who will be responsible for the repair of the shovel. The
operator must also notify the next operator of any remaining uncorrected defects upon changing shifts.

1.2.2.4 Operator’s Functional Checks
The operator must make a safety check before starting to work each shift to see that the shovel is in proper order.
Some things to check are:
NOTICE
Checklists for Pre-Start, Start-Up, Parkup, and Shutdown are contained later in this manual.
• Check for warning tags or lockout tags on the starting controls; do not operate the controls until the tag has
been removed by the person who placed it there, or by a qualified person. Consult your mine site’s specific
lockout-tagout procedures.
• Check with mine maintenance and operations management to see that periodic maintenance and inspec-
tions have been performed and all necessary repairs made.
• Consult with mine management that scheduled inspection of load carrying members such as wire rope (dip-
per trip lines, hoist rope, suspension lines), boom, dipper handle and dipper has been conducted.
• Check that all equipment guards are in place and all inspection and cover plates are closed and locked.
• Look inside, outside and underneath the shovel to make sure everything is clear before starting or energiz-
ing the shovel.
• After starting the shovel, check all gauges and indicators for proper readings and operation.
• Test all controls for proper operation and controllability before shovel operation or travel, including a thor-
ough check of the brakes.
• Check audible warning devices and alarms used for backup warning for proper operation.
• During operation, be alert for unusual noises or vibrations; look and smell for unusual smoke or fumes.
1.2.3 Operation Guidelines and Suggestions
Table 1-1 contains suggested Do’s and Don’ts associated with P&H Electric Shovel operation.
Do Not Do
Do Not - set up too far from the dig Do - set up as close to the dig
face and over reach. face as possible for faster cycles
and better dipper fill factors.
Do Not - set up or dig in a setup with Do - try to set up with short swing
long swing angles. angles when possible.
Do Not - make sharp turns that plug Do - try to make gradual turns
the tracks with dirt and cause exces- when steering the shovel.
sive stress on crawlers.
Do Not - lean on the swing while Do - keep swing in neutral while

digging through the bank. digging through the bank.
Table 1-1: Do’s and Don’ts

Do Not Do
Do Not - use the material in the Do - start plugging the swing soon
truck to stop swing motion. enough to stop without hitting the
load.
Do Not - sweep the pit floor with the Do - clean the pit floor using nor-
dipper. mal digging motions.
Do Not - dig with corners of the Do - try to dig with the full width
dipper. of the dipper cutting edge.
Do Not - catch a bank collapse on a Do - swing the dipper in the clear

loaded dipper. or trip open the dipper door to
avoid catching a major bank
collapse.
Do Not - strike the track pads or tail Do - be aware of the location of

cable with the dipper. the track pads and tail cable at all
times.
Do Not - operate a shovel on a sur- Do - create a stable base to work

face where it is not stable (rocking up from, cut or fill to maintain
and down). stability.
Table 1-1: Do’s and Don’ts
1.2.4 Responsibilities of All Crew Members

Any unsafe condition or practice must be reported to the job supervisor and shovel operator.
Everyone who works around shovels, including support people and maintenance personnel, must obey all safety
hazard signs and watch out for their own safety and the safety of others in the area. Crew members setting up
machines or handling maintenance and repairs are expected to know proper procedures including lockout and
tagout practices.
Watch for hazards during operations and immediately alert the shovel operator of potential safety hazards such as
the unexpected presence of people, other equipment in the area, unstable ground, bank conditions, or approach-
ing storms.
1.2.5 Planning the Job
Most accidents can be avoided by careful job planning. The person in charge must have a clear understanding of
the work to be done, consider dangers or hazards, develop a plan to do the job safely, and then explain the plan to
all concerned. Factors such as the following should be considered:
• How can the shovel tail cable be safely moved at the work site?
• Is there other equipment, power lines, or structures which must be moved or avoided during movement of
the shovel?
• Is the surface strong enough to support the shovel and load?

• How and where will the removed materials be unloaded?
• What steps will be taken to keep unnecessary people and equipment at a safe distance from the work area?
These factors are not meant to be all encompassing, but only a starting point. Each job must be individually
considered.
1.3 Safety for Electrical and Electronic Equipment
1.3.1 General
The safety instructions given in this manual cover those problems encountered during normal daily operation of the
shovel. Additional precautions may be necessary to cover unusual circumstances. Be constantly alert for any
potentially dangerous conditions and report them immediately to your foreman or supervisor.
Working safely is the most important thing you can do. The following is a list of precautions. Of course there are
more precautions, but these are some you should think about. The keyword here is THINK.
• Never work alone.
• Never receive an intentional shock.
• Only work on, operate, or adjust equipment if you are authorized.
• Don’t work on energized equipment unless absolutely necessary.
• Keep loose tools, metal parts, and liquids from above electrical equipment.
• Never use steel wool or emery cloth on electric and electronic circuits.
• Never attempt to repair energized circuits except in an emergency.
• Never measure voltage in excess of 300 volts while holding the meter wire or probe.
• Use only one hand when operating circuit breakers or switches.
• Use proper tagout/lockout procedures for regular and preventive maintenance.
• Be cautious when working in voids or unvented spaces.
• Beware the dangers of working in elevated areas.
• Keep protective closures, fuse panels, and circuit breaker boxes closed unless you are actually working on
them.
• Never bypass an interlock unless you are authorized to do so by competent authority, and then properly tag
the bypass.

1.3.2 Maintenance Work Precautions
Inspection, service, and maintenance are essential elements in the proper operation and performance of shovels
and excavators. The following recommendations are provided to supplement past experience, knowledge, and
common sense of service personnel concerning potential hazards associated with inspection, service, and
maintenance.
1. Prior to undertaking any work on the equipment, the personnel performing the work shall notify the operator
about the nature and location of the job. Appropriate lockout and tagout procedures must be determined and
followed by all individuals involved to guard against potential hazards.
2. Before maintenance or service is attempted, the operator must park the machine in a location to avoid hazards
such as falling rocks and unstable ground. After parking the machine, the operator shall:
A. Set the dipper on the ground.
B. Set all brakes.
C. De-energize control functions.
D. Comply with lockout and tagout procedures.
3. Injury, death, and damage can occur if the machine is started before servicing is finished. Never start or oper-
ate the equipment if lockouts or tagouts are on the controls. Prior to starting the machine, look under, within,
and around the equipment.
4. Specific inspection, service, and maintenance instructions for P&H shovels or excavators are available from
product manuals and the P&H service network. Always read and follow instruction manuals and use the P&H
service network for assistance.
5. On hydraulic systems, release system pressure before attempting to make adjustments or repairs. Pressure in
hydraulic systems can be retained for long periods of time. If not properly released before maintenance people
attempt to work on the hydraulic system, this pressure can allow machinery to move or cause hot oil to shoot
out of the hose ends at high speed.
6. Maintenance and service can involve the handling of heavy parts or components, which can injure personnel.
Use lifting and handling equipment along with blocking to remove, support, and install heavy parts.
7. Ensure both ends of booms or cylinders are supported and the boom suspension lines completely slacked off
before moving pins. Never stand on, inside, under booms during erection or disassembly. Pin-connected
booms may fall if not properly supported when removing or installing pins.
8. When inspecting and retiring wire rope used on surface mining machines:
A. Mine management shall provide and appoint qualified personnel to inspect, prepare, and retain written
reports on wire rope inspections.
B. An inspection procedure should be established by Mine Management for each wire rope application on their
mining shovels or excavators.
C. Unless instructed otherwise, the frequency of inspections shall be established based upon operating shifts,
days, weeks, or months, depending upon anticipated rope life and working conditions.
D. An average wire rope life shall be established based upon the number of operating cycles, volume of material
handled, or weight of material handled. Replacement is determined from this established rope life analysis.

9. MSHA procedures require all wire rope be inspected daily to determine whether it should be replaced.
As a minimum, wire rope replacement should be performed when any of the following conditions exist:
A. Severe abrasion, scrubbing, peening, kinking, or broken outer wires.
B. Crushing, or other damage that distorts the rope’s structure.
C. Severe reduction of rope diameter or an observable increase in rope lay.
D. Bird-caging or other distortion indicating uneven distribution of load between rope strands.
E. Evidence of severe corrosion, particularly in the vicinity of attachments.
F. Heat damage from any source.
G. A rapid increase in the number of broken wires.
10. Wire rope end connections must be installed properly and inspected daily.
A. Wire rope secured with a wedge socket should be installed so that the load line is in a straight-line pull with
the eye of the socket; and the loaded part of the rope is not kinked where it leaves the wedge. The rope end
should always protrude at least 6 to 9 inches beyond the socket. Attach a short piece of wire rope to the
rope end with two wire rope clips to prevent the rope end from slipping out of the wedge socket.
11. Electrically powered shovels or excavators operate using high voltage wiring, components, and systems. This
voltage can kill or seriously injure people servicing, repairing, or working on the machines. Inspection, mainte-
nance, or service of any electrical component must be done by qualified personnel. All people working on or
around the equipment should read and obey hazard signs and always use lockout and tagout procedures.
12. All guards, signs, warning devices, and guarding devices must be in place and in working condition before the
shovel or excavator is placed back in operation after inspection, service, and maintenance.
13. Loose or missing hardware, bolts, or nuts should be properly tightened or replaced with the manufacturer’s
specified hardware. Refer to P&H Service and Parts sources for replacement parts.
14. If there is not enough wire rope on the drum, the rope can be pulled off. Allow for at least two wraps of wire
rope on drums when replacing the rope.
15. Electrical junction boxes for electrical motors can contain high voltage electrical power from multiple sources.
Before performing service on electrical junction boxes, determine that all electrical power from all sources has
been disconnected and locked out. Test the components within the electrical junction box to verify the electri-
cal power is disconnected.
1.3.3 Electrical Safety Principles
When planning and performing work on electrical systems and equipment, keep these principles in mind:
A. Plan every job.
B. Think about what could go wrong.
C. Use the right tools for the job.
D. Use procedures, drawings, and other documents as tools to do the job.

E. Isolate the equipment from energy sources.
F. Identify the electric shock and arc flash, as well as other hazards that may be present.
G. Minimize the hazard by guarding or approach limitations.
H. Test every circuit, every conductor, every time before you touch.
I. Use personal protective equipment (PPE) as a last line of defense in case something goes wrong.
J. Ensure service personnel have the skills, knowledge, tools, and experience to do this work safely.
1.3.4 Electrical Shock Dynamics
When working on the 4100XPC, service personnel must be aware of three important characteristics of possible
exposure to electrical shock. The three factors are:
A. PATH - of current into and out of the body.
B. AMOUNT - of current or energy flowing in the body.
C. DURATION OF EXPOSURE - degree of injury also depends on the duration and frequency of the current.
50Hz AC Current Response
0.5 - 3 mA Start to feel the energy, tingling

sensation
3 - 10 mA Experience pain, muscle contraction
10 - 40 mA Grip paralysis threshold (brain says let

go, but physically cannot do so)
30 - 75 mA Respiratory system shuts down
100 - 200 mA Experience heart fibrillation
200 - 500 mA Heart clamps tight
Over 1500 mA Tissue and organs burn
Table 1-2: Electrical Shock and Human Response
NOTICE
“SHOCK” injuries can resemble an “Iceberg” where most of the injuries are internal, with only
an entry and exit wound visible. Prompt attention is required by individuals specifically trained
to treat electrical injuries.
Accident victims can incur the following injuries from electrical shock:
A. Low-voltage contact wounds.
B. High-voltage contact wounds from entry and exit of electrical current.
C. Burns.

D. Respiratory difficulties (the tongue may swell and obstruct the airway; or vaporized metal or heated air may
have been inhaled).
E. Infectious complications.
F. Injury to bone through falls, heat necrosis (death of tissue), and muscle contraction.
G. Injury to the heart such as ventricular fribillation, cardiac arrest, or stoppage.
H. Internal organ injuries.
I. Nerve and neurological damage.
1.4 Operation Near Electrical Lines Precautions
! DANGER
Keep clear of power lines when machine is in operation. Death or injury could result
should any part of the machine come within minimum distance of an energized power
line specified by local, state, and federal regulations.
Working in the vicinity of electrical power lines presents a very serious hazard and special precautions must be
taken. Safe operating practices require that you maintain the maximum possible distance from the lines and never
violate the minimum clearances.
Before working in the vicinity of power lines, the following precautions should be observed:
• Contact the owners of the power lines or the nearest electric utility before beginning work.
• Machine operator and electrical utility representative must jointly determine what specific precautions are
taken.
• Machine operator and electrical utility representative must confirm that all precautions are taken and fol-
lowed.
• Even when power lines are knowned to be locked out and tagged out, consider them to be energized.
• Inform all ground personnel to stand clear of the machine at all times.
• Use a signal person to guide the machine into close quarters. The sole responsibility of the signal person is
to observe the approach of the machine to the power line. The signal person must be in direct communica-
tion with the operator and the operator must pay close attention to the signals.

1.5 Safety Hazard Indicators, Decals, and Signs
1.5.1 General
Safety Hazard Indicators, Decals, and Signs identify potential safety hazards and prevent accidents by displaying
standard symbols, headers, and pictograms or custom graphics. Indicator, Decal, and Sign layouts, headers, and
graphics conform to current ANSI guidelines. They are commonly used for high voltage, personal protection, con-
fined space, and bilingual applications.
1.5.2 Hazard Indicators
DANGERS, WARNINGS, CAUTIONS, NOTICES, and SAFETY FIRSTS are used throughout our manuals to
emphasize important and critical instructions. DANGERS, WARNINGS, CAUTIONS, and SAFETY FIRSTS will
precede the paragraph or item to which they apply. NOTICES will follow the paragraph or item to which they apply.
DANGERS, WARNINGS, CAUTIONS, NOTICES and SAFETY FIRSTS are identified and defined as follows:
! DANGER
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury. This signal word will be limited to the most extreme situations.
! WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
! CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
CAUTION
A Caution without a Safety Alert Symbol (no Triangle and Exclamation Point) is used to
warn of hazards that result only in property damage.
NOTICE
Used to indicate a statement of company policy directly or indirectly related to the safety of per-
sonnel or protection of property. This signal word is not associated directly with a hazard or
hazardous situation and is not used in place of DANGER, WARNING, or CAUTION.

Used to indicate general instructions relative to safe working practices, remind of proper safety
procedures, and indicate the location of safety equipment.

1.5.3 Safety Hazard Decals and Signs
Most Safety Hazard Decals and Signs use pictographs and text to show, both graphically and verbally, where
potential safety hazards exist around the electric mining shovel. These decals and signs do not represent every
possible hazard and are not intended to be a substitute for safe working practices and good judgment.
This subtopic provides examples of Safety Hazard Decals and Signs found on a typical electric mining shovel. Be
certain everyone working on, or near, the shovel understands and knows how to avoid the hazards they represent.
! CAUTION
Do not remove, cover, paint over, or deface Safety Hazard Decals or Signs.
If they become damaged or obscured, request replacement decals and signs from your local MinePro Office.
1.5.3.1 Location
Safety Hazard Decals and Signs are located throughout the shovel in various location. Table 1-3 identifies and
describes the Safety Hazard Decals and Signs. Figures 1-2 through 1-41 detail their locations. Item numbers are
provided on these Figures for easy cross-reference back to Table 1-3.
Item Number Safety Hazard Decal/Sign Description
3, 7, 35 Notice Decal used with

32Q1805D_ to alert the
user of level of voltage
which may be present.
VOLTS
V
SEE
32Q1805D_
MAXIMUM LEVEL MAY BE PRESENT
32Q1780D_
ES02915a01
Table 1-3: Safety Hazard Decals and Signs

5 Warning Decal used to

alert user of hazardous
voltage inside.
Can cause severe injury
or death.
Disconnect tail cable
voltage and lock sup-
ply switch open.
Remove tail cable from
shovel.
Insure that all high
voltage is removed
from the shovel before
servicing switch.
ES02917a01

alert user of rotating
parts.
Can cause injury if con-
tacted. Do not remove
guard if shovel is
operating.
Replace guard before
operating the shovel.
Use lockout and tagout
procedures before
servicing.
ES02919a01
Table 1-3: Safety Hazard Decals and Signs (Continued)


alert user of unex-
pected crowd motor
base operation can
cause severe injury or
equipment damage.
Ensure all persons are
clear of the motor base,
sheaves and belt.
Establish method of
communication
between operator and
work crew.
Monitor site when oper-
ating controls.
ES02921a01
12 Caution Decal used to

alert user that opening
door will stop the
shovel.
Unexpected stopping or
abnormal performance
can cause personal
injury and property
damage.
Do not open the doors
when shovel is running.
ES02922a01
25 Yellow and black cau-

tion tape.
In compliance with
OSHA 1910.144(a)(3)
which states “Yellow
shall be the basic color
for designating caution
and for marking physi-
cal hazards such as:
Striking against, stum-
bling, falling, tripping,
and caught in
between.”
-5 ' #=


alert user that abnor-
mal performance can
cause personal injury
and property damage.
Probing test points or
removing printed circuit
cards will induce elec-
trical noise or card
damage when shovel is
operating.
Probe test points when
shovel is not operating.
Remove printed circuit
cards only after shovel
is shut down and Con-
trol Voltage Supply /
Relay Supply / Con-
stant Voltage Supply
Breakers are open.
ES02926a01


alert user of pressur-
ized air system.
Relieve air system
pressure before
servicing.
Read the maintenance
manual.
ES02928a01


alert user that hand-
held radio transmis-
sions in the operator’s
cab can cause unex-
pected shovel move-
ment resulting in
severe injury, death, or
property damage.
Do not operate hand-
held radio within 3 feet
of shovel joystick con-
trollers. Alert anyone
entering the operator’s
cab to turn off all hand-
held radios.
ES02929a01

alert user of rotating
parts and hazardous
voltage inside.
or death.
Keep fingers clear of
rotating machinery.
Disconnect power to all
circuits before opening
covers.
procedures before
servicing.
ES02930a01


mal performance can
and property damage.
Probing test points or
removing printed circuit
cards will induce elec-
trical noise or card
damage when shovel is
operating.
Probe test points when
shovel is not operating.
Remove printed circuit
cards only after shovel
is shut down and Con-
trol Voltage Supply /
Relay Supply / Con-
stant Voltage Supply
Breakers are open.
ES02932a01


alert user that unex-
pected machinery or
rope movement can
cause severe injury or
death.
Keep hands, body, and
clothing away from
machinery and ropes.
Always notify shovel
operator of your
presence.
Use pathways and hold
handrails.
ES02936a01

alert user of a hazard-
ous area where there
are falling or flying
objects, noise, tripping
or slipping, and mov-
ing machinery.
Can cause injury.
Wear head, hearing,
and eye protection.
Keep hands, body, and
clothing away from
machinery.
Watch your step.
ES02938a01


alert user that rotating
parts may cause severe
injury or death if
contacted.
Do not remove inspec-
tion cover if shovel is
operating.
Replace inspection
ROTATING PARTS MAY cover before operating
CAUSE SEVERE INJURY the shovel.
OR DEATH IF
CONTACTED.
DO NOT REMOVE
INSPECTION COVER
IF MACHINE IS
OPERATING.
REPLACE INSPECTION
COVER BEFORE
OPERATING MACHINE.
32Q1893
ES02980a01
42 Notice Decal used to

alert user to read the
Operator’s Manual
before attempting to
operate the shovel.
ES02939a01

alert user that opening
door will stop the
shovel.
Unexpected stopping or
OPENING DOOR STOPS MACHINE. abnormal performance
can cause personal
UNEXPECTED STOPPING OR ABNORMAL injury and property
PERFORMANCE CAN CAUSE PERSONAL damage.
INJURY AND PROPERTY DAMAGE.
Do not open doors
Do not open doors while machine
while shovel is running.
is running.
ES02942a01


alert user that hazard-
ous voltage is inside.
or death.
HAZARDOUS VOLTAGE INSIDE.
Keep all doors and cov-
CAN CAUSE SEVERE INJURY OR DEATH. ers closed.
Keep all doors and covers closed.
Do not open unless qualified and Do not open unless
authorized. qualified and
Disconnect power to all circuits. authorized.
Use lockout and tagout procedures Disconnect power to all
before servicing. circuits.
32Q1809D1
ES02944a01 Use lockout and tagout
procedure before
sevicing.
45 Danger Decal used to

voltage.
Will cause severe injury
or death.
HAZARDOUS VOLTAGE. Check for voltages
WILL CAUSE SEVERE INJURY OR DEATH. present.
Check for voltages present.
Use lockout and tagout procedures procedures before
before servicing.
servicing.
Disconnect power to all circuits.
Do not service unless qualified and authorized.
circuits.
32Q1810
ES02946a01
Do not service unless
qualified and
authorized.


alert user that falling
objects, during dig-
ging, can cause severe
injury or death.
Always notify shovel
operator of your
presence.
Never enter this area
while shovel is digging.
ES02948a01

alert user of Boarding
Ladder procedures.
ES02950a01


alert user of signal bell.
Pull cord to signal the
operator.
ES02952a01

alert user of ladder
control.
ES02954a01

alert user that hazard-
ous voltages may be
present.
or death.
HAZARDOUS Disconnect
VOLTAGE Power Disconnect power to all
MAY BE to all circuits.
PRESENT. Circuits.
CAN CAUSE Use lockout procedures before
SEVERE and tagout servicing.
INJURY procedures
OR DEATH. before
servicing
32Q1801D1
ES02956a01


voltages.
or death.
ply switch open before
removing cable.
Follow safe discharge
and protection proce-
dures for the cable ter-
minator.
ES02958a01

voltages.
or death.
ply switch open before
removing cable.
Follow safe discharge
and protection proce-
dures for the cable
terminator.
ES02960a01


alert user that step-
ping or sitting on cover
may cause collapse.
Can cause personal
injury and electrical
damage to enclosed
bus bar.
Do not sit or step on
bus bar covers.
ES02962a01

alert user that step-
ping or sitting on win-
dow may cause
collapse.
Can cause personal
injury.
Do not sit or step on
the window.
ES02964a01

alert user of a crush
and pinch hazard.
or death.
Stay clear of moving
winch rope and drum.
Do not stand behind
winch drum while oper-
ating controls.
ES02965a01


alert user that shovel
runaway or tip-over can
occur on slopes or
grades resulting in pos-
sible property damage,
severe injury or death.
ES02967a01

alert user that manual
brake release may
cause uncontrolled
shovel movement.
or property damage.
ES02968a01


alert user that severe
boom jacking, stage 2,
is considered an oper-
ating fault.
Frequent boom jacking
will increase boom
structural damage.
ES02969a01

alert of flammable
materials.
Can burn or ignite.
No smoking or open
flames inside this room.
Fire or explosion can
cause severe injury,
death or property
damage.
ES02970a01


alert that smoking or
open flames are not
allowed within the
general area.
ES02971a01

alert that no entry is
allowed unless autho-
rized to be in the area.
NO ENTRY
UNLESS
AUTHORIZED
-5 '% =

mal performance can
or property damage.
Do not open switch
ABNORMAL PERFORMANCE DO NOT OPEN SWITCH during normal
CAN CAUSE DURING NORMAL operation.
PERSONAL INJURY OPERATION.
OR PROPERTY DAMAGE.
32Q1770D1
ES02973a01


mal shovel perfor-
mance can cause
personal injury and
property damage.
Changing mode switch
will cause brake setting
and shovel shutdown.
Change mode with the
selector switch only
after shovel is shut
down.
ES02974a01

alert user that remov-
ing bolts will allow
cover to fall.
Falling dirt hazard.
Opening cover stops
shovel.
Support cover and
remove bolts carefully.
Lower cover slowly.
Protect against falling
dirt.
Close cover and re-bolt
properly:
1. Tighten nut and
bolt.
2. Insert cotter pin.
Bolt cover in place
before starting shovel.
-5 '%#=


alert user that the
upper rotates.
Severe injury or death
can occur if caught
between upper and
lower.
Do not enter if shovel is
operating.
procedures before
entering.
Observe working-in-
confined-space
procedures.
-5 '%$=
95 Decal used to alert user

of the fire extinguisher
location.
FIRE
E
X
T
I
N
G
U
I
S
H
E
R
-5 '%%=


voltages.
or death.
Check for voltages
present.
circuits. Use lockout
and tagout procedures
before servicing. Do not
service unless qualified
and authorized.
-5 '%&=

alert user of drum or
rope movement.
or death.
Do not stand on plat-
form when drum is
moving.
Secure platform to its
raised position before
the drum is moving.
-5 '%'=

Shovel
13 14 15 16
17
12
11 18
10
09 19
08 20
21
07
22
06
23
05
24
04
25
03
02 26
01
27
ES02875b01
Figure 1-2: Shovel Deck Plan

" $'
$&
$&
" %# %#
$'
%#
$'
"
-5 '=
Figure 1-3: Lube Room, Hoist Drum Area

39
104
62
39
62
62
62
104
ES02905a01
Figure 1-4: Hoist Drum Guard
41 47
75
75
25
47
46
49
49
ES02912b01
Figure 1-5: Outside Shovel Opposite Operator Cab

60
75
25
47
75
48
46
48
47
49
Figure 1-6: Outside Shovel Right Side

09
63
67 42
32
32
32
ES02894a01
Figure 1-7: Operator’s Cab

75
ES02909a01
Figure 1-8: Side Railing
%# "
$&
-5 '%=
Figure 1-9: Typical Outside Entrance Door to Machinery Area

' '
-5 '&=
Figure 1-10: Lower Access Door to Space Between Upper and Lower
Cabinets

44 07 44
44
ES02880a01
Figure 1-11: Main Transformer

07
44
44
ES02879a01
Figure 1-12: Auxiliary Transformer
07 07
07
45 45 44
45
44 44
81
81
07
ES02876a01
Figure 1-13: Upper High Voltage Cabinet

07 44
45
45
ES02877a01
Figure 1-14: Suppression and Ground Fault Cabinet

44
44
07 07 45 44 07
ES02878a01
Figure 1-15: Dipper Trip Resistors

07 45 45
44
44
45
44
07
07
45
43
34
07
43
45
ES02882a01
44 07 43 44 07
Figure 1-16: RPC Switching Cabinet (Front)
45 07 07 45
45
45
07
44
07
43
43 44
44 43
ES02882a02 44
45 43
Figure 1-17: RPC Switching Cabinet (Rear)

03 45 12
45 45
43 43
44
07
44
44
07
07
ES02883a01
Figure 1-18: Converter Cabinet (Front)

07 45 03 03 44 45
12
44 45
07 43
44
07
43
ES02883a02
Figure 1-19: Converter Cabinet (Rear)
34
07
ES02884a01
Figure 1-20: Remote I/O Transfer Cabinet

45
44
43
07
ES02885a01
Figure 1-21: Transfer Contactor Cabinet

30
44
45
07
55
43
44
45
07
55
43
ES02896a01
Figure 1-22: Auxiliary Cabinet

07 07
88
26
34
43
45 44
26
07
44
45
07
07
45
44
ES02910a01
Figure 1-23: Control Cabinet - Example
Motors

03
41
07
07
33
50
08
44
45
ES02886a01
Figure 1-24: Hoist Motor

03 41 33 33
07
44
45
41
ES02887a01
Figure 1-25: Swing Motor
33 44 45 07
41
ES02889a01
Figure 1-26: Crowd and Propel Motors

41 03
ES02888a01
Figure 1-27: Crowd and Propel Blower Motors
09
ES02893a01
Figure 1-28: Crowd Motor Base
Miscellaneous Components

07 45 44
ES02881a01
Figure 1-29: Field Supply and Auxiliary Secondaries Breakers
35 35
07 07
44 44
45
07 07
45
44
44
ES02890a01
Figure 1-30: High and Low Voltage Collector

07 07
44 44
45 45
ES02895a01
Figure 1-31: 480VAC Panelboard #1 and #2
44
07 07
44 44
45 45
44
ES02897a01
Figure 1-32: 120VAC and Flood Light Panelboard

07
ES02898a01
Figure 1-33: Machinery House Heater
66 66 66
07 07 07
ES02899a01
Figure 1-34: Hoist, Swing, Propel Brake Exhaust Solenoid and Pressure Switch
66
07
ES02899a02
Figure 1-35: Operator’s Panelboard

07
62
ES02900a01
Figure 1-36: Cable Winch
07
45
50
ES02902a01
Figure 1-37: Remote I/O Lube
% ""
-5 '$=
Figure 1-38: Applied to All Junction Box Covers

75
ES02911a01
44
45
07
Figure 1-39: Swing Lube Motor Control
44 59 07 101
ES02891a01
Figure 1-40: All Overhead Bus Covers (Typical)
44 07
ES02892a01
Figure 1-41: All Overhead Wire Trays (Typical)

1.6 Fire Extinguishers

Normally, a total of three (3) fire extinguishers are provided on the 4100XPC Mining Shovel. The agent used inside
the extinguishers is a monoammonium phosphate-based agent for use on Class A (wood, paper, cloth), Class B
(flammable liquids and gases), and Class C (electrical) fires. Refer to Figure 1-42.
Figure 1-42: Fire Extinguisher - Typical
Location of the individual fire extinguishers on the 4100XPC are customer dictated; however, a sign above the fire
extinguisher indicates where it is located. Refer to Figure 1-43.
FIRE
E
X
T
I
N
G
U
I
S
H
E
R
-5 '%%=
Figure 1-43: Fire Extinguisher Sign

1.6.1 MSHA Regulations Regarding Fire Extinguishers
1.6.1.1 Surface Coal Mining
30 CFR 77.1109 (2) Power shovels, draglines, and other large equipment shall be equipped with at least one por-
table fire extinguisher; however, additional fire extinguishers may be required by an authorized representative of
the Secretary.
30 CFR 77.1108-1 Type and capacity of fire fighting equipment.
Forfeiting equipment required under this §77.1108 shall meet the following minimum requirements:
• (b) Fire extinguishers. Fire extinguishers shall be:
• (1) Of the appropriate type for the particular fire hazard involved;
• (2) Adequate in number and size for the particular fire hazard involved;
• (3) Replaced immediately with fully charged extinguishers after any discharge is made from an extinguisher;
and
• (4) Approved by the Underwriter’s Laboratories, Inc., or the Factory Mutual Research Corp., or other com-
petent testing agency acceptable to the Mine Safety and Health Administration.
1.6.1.2 Surface Metal and Non-metal Mining
30 CFR 56.4203 Extinguisher recharging or replacement.
Fire extinguishers shall be recharged or replaced with a fully charged extinguisher promptly after any discharge.
1.6.1.3 Training and Retraining of Miners Working at Surface Mines
1. 30 CFR 48.25 Training of new miners; minimum courses of instruction; hours of instruction.
• (a) Each new miner shall receive no less than 24 hours of training as prescribed in this section. Except as
otherwise provided in this paragraph, new miners shall receive this training before they are assigned to work
duties. At the discretion of the District Manager, new miners may receive a portion of this training after
assignment to work duties: Provided, That no less than 8 hours of training shall in all cases be given to new
miners before they are assigned to work duties. The following courses shall be included in the 8 hours of
training: Introduction to work environment, hazard recognition, and health and safety aspects of the tasks to
which the new miners will be assigned. Following the completion of this preassignment training, new miners
shall then receive the remainder of the required 24 hours of training, or up to 16 hours, within 60 days. Oper-
ators shall indicate in the training plans submitted for approval whether they want to train new miners after
assignment to duties and for how many hours. In determining whether new miners may be given this train-
ing after they are assigned duties, the District Manager shall consider such factors as the mine safety
record, rate of employee turnover and mine size. Miners who have not received the full 24 hours of new
miner training shall be required to work under the close supervision of an experienced miner.
• (b) The training program for new miners shall include the following courses:

• (5) Escape and emergency evacuation plans; fire warning and fire fighting. The course shall include a
review of the mine escape system, and escape and emergency evacuation plans in effect at the mine; and
instruction in the fire warning signals and fire fighting procedures.
2. 30 CFR 48.26 Experienced miner training.
• (b) Experienced miners must complete the training prescribed in this section before beginning work duties.
Each experienced miner returning to mining following an absence of 5 years or more, must receive at least
8 hours of training. The training must include the following instruction:
• (5) Escape and emergency evacuation plans; fire warning and fire fighting. The course must include a
review of the mine escape system and the escape and emergency evacuation plans in effect at the mine,
and instruction in the fire warning signals and fire fighting procedures in effect at the mine.
3. 30 CFR 48.28 Annual refresher training program for miners; minimum courses of instruction; hours of instruc-
tion.
• (a) Each miner shall receive a minimum of 8 hours of annual refresher training as prescribed in this section.
• (b) The annual refresher training program for all miners shall include the following courses of instruction:
• (3) Escape and emergency evacuation plans; fire warning and fire fighting. The course shall include a
review of the mine escape system; escape and emergency evacuation plans in effect at the mine; and
instruction in the fire warning signals and fire fighting procedures.
1.6.2 Fire Extinguisher Safety
This subtopic provides information to the operator for determining whether or not to use a fire extinguisher to put
out a fire on the shovel. These are suggestions only and may be superseded by mine site specific rules and regu-
lations. Consult your supervisor or Safety Department representative as to your mine site’s specific rules regarding
your responsibilities in the case of a shovel fire.

Portable fire extinguishers discharge faster than most people think - most in less than 30 sec-
onds.
Use a mental checklist to make a fight-or-flight decision. Attempt to use an extinguisher only if all of the following
apply:
! WARNING
If any of these conditions have not been met, don't fight the fire yourself. Call for help,
and leave the area.
• The shovel is evacuated or is being evacuated.
• The mine site fire department has been or is being called.
• The fire is small, contained and not spreading beyond its starting point.

• The exit is clear, there is no imminent peril and you can fight the fire with your back to the exit.
• You can stay low and avoid smoke.
• The fire extinguisher is immediately at hand.
• You have read the instructions and know how to use the fire extinguisher.

If you have any doubt about your personal safety, or if you can not extinguish a fire, leave the
shovel immediately and close off the area (close any doors, but do not lock them). Contact the
mine site fire department to relay whatever information you have about the fire.
If you have decided to use the fire extinguisher follow these important safety precautions:
• Call for help.
• If possible, stay a safe distance away from the fire, approximately 6 to 10 feet minimum for most extinguish-
ers. Closer use of the extinguisher may lead to gouging of a liquid fuel which will cause the fire to spread
and grow rapidly in size as well as endanger the extinguisher operator.
The following steps apply when using the cartridge activated fire extinguisher:

Directions for proper fire extinguisher use are posted on the fire extinguisher.
! WARNING
Always check extinguisher lid for tightness. A loose lid may come off the extinguisher
when activating the extinguisher causing serious injury or death.
Step 1: Check the tightness of the extinguisher lid.
Step 2: Remove the extinguisher hose from its bracket, breaking the anti-tamper seal.
Step 3: Keep a firm grip on the nozzle assembly with the nozzle pointed away from your face. Keep the top of the
extinguisher pointed away from yourself and any other personnel in the immediate area.
Step 4: Activate the extinguisher by pushing down on the cartridge activation lever.
! CAUTION
Keep the fire extinguisher upright during use. Tipping the extinguisher may prevent the
agent from being discharged from the hose.
Step 5: Aim the nozzle at the base of the fire.

Step 6: Squeeze the activation lever at the end of the hose fully open.
Step 7: Sweep the extinguishing agent from side to side working from the lowest level of the fire up to the highest.
Maintain this sweeping action until the flame is put out.
NOTICE
Because the agent supplied in the extinguisher is a smothering agent and does not remove the
heat of the fire, monitor the site after the flames have been put out for 3-5 minutes for reflash.

Replace the used extinguisher with a full one as soon as possible and have the used one prop-
erly serviced.

ES41157 Mechanical Systems Manual Introduction
Section 2
Mechanical Maintenance Manual
Introduction
2.1 General
This manual provides the information required to repair and maintain the P&H Mining Equipment Model 4100XPC
Electric Mining Shovel.
2.1.1 Part Numbers
Repair parts information is provided in the LinkOne electronic parts manual that has been prepared for your shovel.
The shovel serial number is located inside the operator’s cab.
Part numbers are sometimes shown in this manual to identify specific assemblies and the information and proce-
dures that apply to that specific assembly. Since this book is not updated on a continuous basis, do not use these
part numbers to order repair parts.
NOTICE
Always obtain the part numbers from the up-to-date LinkOne electronic parts manual.
2.1.2 Applicability
All information in this manual, including descriptions, specifications, and illustrations is for P&H model 4100XPC
Electric Mining Shovel, Serial Number ES41156, at the time of publication. Product improvements, owner modifica-
tions, or other changes introduced after this manual was published are not covered.
Questions concerning the shovel or this manual should be referred to your P&H MinePro Services representative.
2.2 Description
2.2.1 General
The electric mining shovel is designed to load loose or fragmented material into trucks. These trucks then carry the
material to another location for disposition or processing. The shovel is designed to 3-pass load trucks, with each
pass taking approximately 30 seconds.
2.2.2 Electrical Systems
This mining shovel is powered and controlled electrically. All working functions of the mining shovel are driven by
electrical motors connected to mechanical transmissions.

Sec02Intro.fm -2.1- Section 2, Version 00 - 06/07
Introduction ES41157 Mechanical Systems Manual
The mine electrical distribution system supplies alternating current to the mining shovel through a tail cable that
connects to the rear of the carbody. Power from the tail cable connector on the lower frame is transferred to the
upper (revolving) frame through a high voltage collector system located between the upper and lower frames of the
mining shovel. High voltage from the mine is transformed into working levels and used to supply the mining shovel
auxiliary electrical systems and the electrical control system.
2.2.3 Hoist System
The hoist system contains two fast-response DC motors mounted at each end of the hoist transmission on the left-
hand side. The hoist motors are coupled to the ends of the hoist transmission first reduction pinion shafts which
drive the hoist transmission, and provide the mining shovel hoist motion.
A limit switch sensor is mounted to the rear intermediate shaft assembly. The limit switch is controlled by the Cen-
turion Control System and programmed through the Graphical User Interface (GUI).
2.2.4 Crowd System
A DC motor drives the crowd system. It is mounted on the boom with the crowd machinery. The crowd machinery
is securely housed on and in the crowd gear case, which is an integral part of the boom. A Power Band™ belt drive
system couples the crowd motor to the crowd transmission. This belt drive system affords shock protection while
the crowd machinery provides the shovel with crowd motion.
A limit switch sensor is mounted on the crowd transmission intermediate shaft on the right hand side of the crowd
gear case. The limit switch is controlled by the Centurion Control System and programmed through the GUI.
2.2.5 Swing System
The swing system of this mining shovel uses two swing transmissions, one located at the front of the revolving
frame and the other at the rear of the revolving frame. A vertically-mounted fast-response DC swing motor drives
each transmission, which provides the mining shovel with swing motion.
2.2.6 Propel System
To achieve forward and reverse propel motions and smooth differential steering, the propel system uses two inde-
pendent drive trains. Each drive train consists of a DC propel motor, a planetary propel transmission, a propel
brake assembly, a tumbler drive shaft, and a crawler side frame and crawler track assembly. The propel motors
mount on a base attached to the mining shovel’s carbody. The propel transmissions are secured to the crawler
side frames.
2.2.7 Brake Systems
The four major systems of this machine (hoist, crowd, swing, and propel) have braking systems. All of the brake
systems are designed and intended to function as static (holding) brakes only; they are neither designed nor
intended to provide dynamic braking (stopping). All brakes are disc brakes that are set by springs and released by
air pressure.

Section 2, Version 00 - 06/07 -2.2- Sec02Intro.fm
2.3 Components
Outside View.
12
11
13
10
09 14
08
07
06
05
15
17
04 18
16
03
19
20
02 21
01
ES4301b01
LEGEND 11. Boom Point Equalizers
01. Crawler Side Frame 12. Boom Point Sheaves
02. Propel Machinery 13. Hoist Ropes
03. Counterweight 14. Hoist Rope Equalizer
04. Machinery House 15. Dipper Body
05. Air Filtration / Pressurization System 16. Dipper Door
06. Gantry Tension member 17. Dipper Handle
07. Boom Suspension Cable Equalizers 18. Crowd Machinery
08. Gantry Compression member 19. Boom Mounting Pins
09. Operator’s Cab 20. Swing Gear
10. Boom Suspension Cables 21. Crawler Track
Figure 2-1: 4100XPC Outside View

2.3.1 Deck Layout
08 09 10 11 12 13 14
15
16
17
07
18
06
19
05
04
20
21
03 22
23
24
02
25
01
ES04302a01 29 28 27 26
LEGEND
01. Auxiliaries Transformer 15. Lubrication Room
02. Field Breakers and 16. Lubricant Tanks, 200 gallons each
Transformer Secondary Breakers 17. Hoist Motor Access Doors
03. Reactive Power Compensation (RPC) Cabinet 18. Front Hoist Brake
04. Rear Swing Motor and Transmission 19. High and Low Voltage Collectors
05. Rear Hoist Brake 20. Front Swing Motors and Transmissions
06. Transfer Cabinet 21. Hoist Drum Side Stand
07. Converter Cabinet 22. Control Cabinet
08. Rear Hoist Motor 23. Auxiliaries Load Center
09. Hoist Gear Case 24. Auxiliaries Cabinet
10. Air Compressor 25. Electronics Room
11. Hoist Drum 26. 120 VAC Load Center
12. Front Hoist Motor 27. High Voltage Cabinet
13. Auto Lube System Controls 28. Main Transformer
14. 240 Gallon Air Receiver (wall mounted) 29. Ground Fault Suppression Cabinet
Figure 2-2: 4100XPC Deck Plan

2.4 Terminology
For a better understanding of some frequently used technical words found in this manual, several are defined
below:
Attachment. An alternate designation for front end equipment. In the case of this mining shovel, it includes the dip-
per handle, boom, dipper and crowd machinery.
Bail. A yoke or spreader hinged to sides of shovel dipper, on which a hoist rope equalizer is mounted. Hoist ropes
pass through the equalizer for hoisting the dipper.
Carbody. The base upon which the upper and crawler side frames are mounted.
Crowd. Outward movement of dipper handle in relation to dipper handle axis (shipper shaft pinions) on boom.
Hoist. Process of lifting dipper.
Lower. The portion of the mining shovel on which the upper is mounted. It includes the carbody, crawlers, swing
gear, roller circle, and center gudgeon.
Left Side. Left side of mining shovel is to operator’s left when he is seated at controls and is facing forward with
attachment over front of lower frame.
Right Side. Right side of machine is to operator’s right when he is seated at controls and is facing forward with
attachment over front of lower frame.
Lower Machine Front. End of lower opposite the end on which propel machinery is mounted.
Lower Machine Rear. End of lower on which propel machinery is mounted.
Machinery Deck. Part of upper frame on which hoist and swing transmissions and major electrical panels mount.
Side Frame. Frame that attaches to carbody and mounts crawler tracks and crawler roller assemblies.
Swing. Function of rotating upper with respect to the lower, either to the right or left.
Upper. The portion of the mining shovel which is mounted on the lower. It includes the revolving frame, machinery
cab, operator’s cab, and all machinery mounted within the machinery cab.
Upper Machine Front. The front of the upper is the attachment end.
Upper Machine Rear. The rear end of the upper is where the counterweight is located.


ES41157 Mechanical Systems Manual General Assembly Procedures
Section 3
General Assembly Procedures
3.1 General
This section provides basic standards to be used when assembling components on P&H Mining Equipment. These
are meant to be general guidelines. Any specific or special assembly procedures will be called out in the individual
assembly sections to follow.
3.2 Pre-Assembly General Cleaning and Protection Covering

The purpose of this section is to establish methods for Pre-Assembly General Cleaning and Protection Covering
(after cleaning but prior to assembly). This standard applies to assembly activities of P&H Mining Equipment. It is
the responsibility of each mechanic to comply with the requirements of this standard to properly maintain P&H
Mining machinery.
The requirements are intended to assure that the quality of items is not degraded before or during assembly.
3.2.1 General Cleaning
1. Inspect equipment to ensure prior-operation cleaning has been done, such as removal of weld splatter and weld slag.
2. Remove and clean chips as follows:
A. Use hand power drill with drill bit (smaller diameter than drill hole diameter) to clean all chips and debris out
of tapped holes. Blow out lube holes.
B. Remove all chips that can get lodged in cracks and crevices.
C. Remove all chips and debris from gear cases and all pockets.
D. Degrease and clean chips with hot water mixed with general degreaser.
3. Remove vendor’s coating from non-sealed bearings with clean shop rag.
4. Remove all rust with suitable material such as Scotch-Brite™.
5. Ensure that all tapped holes, gear teeth edges, bores, milled surface edges, and areas that contact other com-
ponent parts are free of burrs, nicks, etc. For cosmetic purposes, also remove any other markings.
3.2.2 Protection Covering
1. Finish prime painting any areas missed by previous operation, such as inside of bearing caps, with care.
2. Mask as necessary machined surfaces that must not be coated.

Sec03GenAssy.fm -3.1- Section 3, Version 00 - 06/07
General Assembly Procedures ES41157 Mechanical Systems Manual
3. If parts are to be stored before being assembled, protection against corrosion is recommended. P&H parts are
generally treated using the following methods before being shipped:
A. The machined surfaces of the following types of parts are fog-sprayed with rust protection.
• Internal gear case walls, etc.
• Bearing cones
• Bores
• Dowels
• End caps
• Gears
• Fasteners and threads
• Machined surfaces (inside) of case
• Parting faces
• Pilot seats
• Pins
• Press fits
• Seals
• Shafts
• Spacers
• Splines
B. Additional recommended rust and corrosion preventives and protectants include:
• Plastic shrink wrap or small zip lock bags and sheets.
• Corrosion inhibitor, added to the working oil, also may be brushed on.
• Outdoor protective, water-based.
• Rust preventive.
• Protective shipping covering using plastic sheet wrap.

Section 3, Version 00 - 06/07 -3.2- Sec03GenAssy.fm
3.2.3 Hydraulic Torque Wrenches
3.2.3.1 General
Hydraulic torque wrenches enable the user to more easily accomplish bolting tasks with increased accuracy and
efficiency. These hydraulically operated units are capable of rapidly and accurately applying the high torque levels
that are required on our P&H mining equipment.
A key to maintaining the accuracy and repeatability of the hydraulic torque wrench system is to understand the
basic design and operation of the components. It is equally important to be aware of the maintenance that will
ensure system efficiency.
There are several hydraulic torque wrench systems on the market today. Each has different features, yet each is
similar in design. Accordingly, the wrench systems require similar levels of care and attention. Each manufacturer
provides Operation and Maintenance manuals for their equipment. Read and understand the requirements for your
particular system.
This subtopic emphasizes three key points:
1. Pressure required to produce a desired torque will differ significantly between models of hydraulic torque
wrenches. Even similarly rated wrenches from the same manufacturer may not produce the same torque at
identical pressure.
2. Proper lubrication and maintenance is important for the continued accuracy of any hydraulic wrench system.
3. Lubrication used on fasteners can have a significant impact on torque requirements.
3.2.3.2 Pressure vs. Torque
Torque generated by the wrench is a function of hydraulic pressure. The pressure pushes on the piston; the piston
rod pushes on the pivot arm. The length of the pivot arm within the wrench combines with the force of the piston
rod to create a specific output torque at a specific pressure.
Manufacturers create Pressure / Torque tables to guide tool operators in choosing the proper pressure setting for
the desired torque output. These Torque Conversion Tables will generally list values for all wrenches in a specific
design series.
02
01
LEGEND
01. Length
02. Force
ES01261b01
Figure 3-1: Hydraulic Torque Wrench Operation

3.2.3.3 Power Unit
The power source for most hydraulic torque wrench systems is a small, portable hydraulic power unit. These power
units are generally electric motor-driven but can also be obtained with an air-driven motor. The power units do not
produce large flow rates but they have the ability to reliably and repeatedly produce pressures to 10,000 psi
(690 bar).
Figure 3-2: Typical Power Source
All units contain an adjustment knob to set the desired pressure from a Pressure / Torque table. The knob is the
adjustable end of a relief valve that limits the amount of pressure that the pump will supply to the wrench (refer to
Figure 3-3).
Follow the manufacturer's instructions for connecting the wrench and adjusting the pressure. Keep in mind that the
adjusted pressure will be affected by the change in the oil temperature in the power unit. During periods of
extended operation, the oil temperature can increase substantially.
Adjusting
Thumbscrew
Locking
Ring
LEGEND
01. Adjusting
Thumbscrew
02. Locking Ring
ES1345_01
Figure 3-3: Typical Pressure Adjustment on a HYTORC® Power Unit

NOTICE
Periodically check the pressure to confirm that it is still at the desired value from the Pressure /
Torque Chart.
With frequent use, the internal parts of the power unit will become worn. Increased wear will reduce the efficiency
of the unit. The most notable symptom of a worn unit will be a more sluggish rise in pressure, or the inability to
achieve maximum rated pressure.
NOTICE
Monitor the operation and performance of the power unit. Overhaul as required or as recom-
mended by the manufacturer.
Note: HYTORC recommends overhaul every 2 years.
One prerequisite for producing accurate torque is to provide accurate pressure. A good power unit will provide any
pressure that the Pressure / Torque chart may require. The key is to accurately display that pressure.
ES1262_01
Figure 3-4: Gauge Accuracy ± 1%
Power Unit information provided by both HYTORC and Sweeney indicate that each unit has a pressure gauge with
a full-scale accuracy of ± 1%. The accuracy of the pressure gauge is an important factor in either manufacturer’s
claim of ± 3% wrench accuracy.
Neither manufacturer has indicated a specific calibration interval for the pressure gauge. While an “As Required”
calibration recommendation would seem vague or evasive, the need to calibrate must be dictated by more than the
“elapsed time since the last calibration.”
Due to the required accuracy of fastener tension on many of our machine assemblies, P&H recommends that ini-
tially, the pressure gauges be calibrated before each machine erection or major job. This is not intended to create
undue calibration requirements, but rather to provide the opportunity to know and understand the accuracy limita-
tions of the specific torque wrench system being used. If re-calibration procedures were to indicate no change in
accuracy, the interval between calibration could be increased. Obviously the severity and frequency of use will play
a roll in re-calibration decisions.

Here is a creative solution to monitoring pressure gauge accuracy. The recommendation is to have a “master
gauge” of increased quality and accuracy (as compared to the working gauge) available to check the power unit
before each job. The master gauge would be part of the torque wrench system. It could be installed in series in a
pressure line to confirm the indication of the gauge on the power unit and to identify the need for re-calibration
of the power unit gauge. The master gauge would be carefully protected and stored between uses. Refer to
Figure 3-5.
Calibrate the pressure gauge as required.
3.2.3.4 Preventive Maintenance
Preventive Maintenance requirements for all wrenches include a periodic inspection of mechanical components for
damage and of the hydraulic power unit for leakage. Follow the instructions in the Operation and Maintenance
Manual for your particular wrench.
1600 1800 2000

1400 2200
1200 2400
1000 2600
800 2800
600 3000
400 3200
200 3400
3600
PSI
er.0.9
ES1263_01
Figure 3-5: Master Gauge
With regard to maintaining Wrench System accuracy, two important factors are cleanliness and lubrication.
As indicated earlier in this document, the transfer of force from the cylinder rod to the rotating drive plate in the
Wrench Head is achieved by sliding contact of the rod on the curved surface of the plate. While both of these sur-
faces are hardened and ground, it is important to keep this point of contact clean and well-lubricated.
Similarly, the support for the rotating movement of the drive ratchet in the wrench body is provided by hardened
and ground surfaces of the ratchet hub and housing bore.
Most manufacturers include a section on disassembly, cleaning, and lubrication of the wrench assemblies in their
Operation and Maintenance Manuals. Typical statements of each manufacturer on the importance of cleanliness
and lubrication are:
A. “All moving parts should periodically be coated with a good quality NLGI#2 molybdenum disulfide grease.
Under harsh environmental conditions, cleaning and lubrication should be performed more frequently.”
B. “All moving parts should be coated periodically with Moly Paste Lubricant. The frequency of lubrication
depends on severity of use and working environment.”

There are many factors that determine the specific bolt torque requirements listed on assembly drawings. Engi-
neers consider such things as the bolt grade, the thread pitch, the clamping force required, and other conditions
that are not readily apparent when viewing the listed torque. One factor that plays a major part in the calculation of
the torque requirement is the lubrication of the bolt threads.
01
LEGEND
01. Torque Wrench
Areas to Be
Lubricated
ES1280_01
Figure 3-6: Lubrication Areas
The Chart of Torque Values (refer to Table 3-1) on the following page illustrates the effect on “tensioning” torque
when different bolt lubricants were used. It is evident that for a specific diameter bolt, tightened to a specific ten-
sion, there are many different torque requirements based solely on the type of bolt lubricant that is used.
As an example, for a 1-1/2 inch connector that required 78,835 pounds (35,760 kg) of bolt tension, the required
torque could vary from 4837 ft-lbs (6558 N·m) (dry) to only 834 ft-lbs (1131 N·m), depending on the type of lubri-
cant used. It is important to follow the assembly drawing instructions. In this instance, using the incorrect lubrica-
tion could produce improper torque…. Even if the torque wrench had been cleaned, and lubricated, and calibrated.

Heavy Minimum Example Example Example Example

Stud or Hex Nut Yield Bolt Lubricant Lubricant Lubricant Lubricant Machine Dry Steel
Bolt Size Size Strength Tension A B C D Oil on Steel
Inches Inches PSI Lbs. f* =.067 f =.085 f =.100 f =.110 f =.150 f =.400
3/4 1-1/4 105000 17754 104 137 157 171 224 559
7/8 1-7/16 105000 24495 165 218 250 272 358 893
1 1-5/8 105000 32129 245 325 373 405 533 1332
1-1/8 1-13/16 105000 41873 351 468 538 585 772 1994
1-1/4 2 105000 52905 483 647 746 811 1075 2720
1-3/8 2-3/16 105000 65226 644 867 1000 4090 1667 3678
1-1/2 2-3/8 105000 78835 834 1131 1307 1425 1896 4837
1-5/8 2-9/16 105000 93733 1071 1453 1682 1834 2445 6260
1-3/4 2-3/4 105000 109920 1338 1820 2109 2301 3072 7888
1-7/8 2-15/16 105000 127395 1646 2244 2602 2841 3798 9775
2 3-1/8 105000 146158 1997 2729 3157 3460 4630 11942
2-1/8 105000 166210 2395 3279 3809 4162 5575 14480
2-1/4 3-1/2 105000 187551 2843 3898 4531 4953 6641 17191
2-3/8 105000 210180 3343 4590 5339 5838 7834 20310
2-1/2 3-7/8 105000 234098 3898 5360 6238 6823 9162 23786
2-3/4 4-1/4 95000 258580 4691 6467 7533 8244 11085 28846
3 4-5/8 95000 310020 6087 8410 9803 10732 14447 37670
3-1/4 5 95000 366124 7735 10705 12488 13676 18428 48129
3-1/2 5-3/8 95000 426891 9656 13385 15622 17113 23079 60365
3-3/4 5-3/4 95000 492321 11871 16477 19241 21084 28453 74516
4 6-1/8 95000 562415 14401 20012 23379 25624 34603 90750
4-1/4 75000 50303 13631 18963 22162 24295 32826 86146
Example lubricant A has a base of Molybdenum Disulfide *f = coefficient of
NOTE:
Example lubricant B has a base of Molybdenum Lead Oxide & Graphite friction
Example lubricant C has a base of Copper & Graphite
Example lubricant D has a base of Nickel & Graphite
Table 3-1: Effects of Lubricant Types on Torque Values

3.3 Fasteners and Torquing
3.3.1 General
The purpose of this section is to establish methods used to obtain proper fastener torquing. This standard applies
to assembly activities of P&H Mining Equipment. It is the responsibility of each mechanic to comply with the
requirements of this standard to properly maintain P&H Mining machinery.
This procedure applies to all fasteners for final assembly that have torque requirements. Only calibrated torque
wrenches with capacity to achieve the specified torque values should be used.
If P&H Mining Equipment specifies a torque value for a fastener, it will be called out in the appropriate Assembly
section of that particular component. For fasteners where the torque is not otherwise specified, torque American
Standard screws and bolts to the values listed in Table 3-2.

3.3.1.1 Torque Value Chart for American Standard Screws and Bolts (Coarse Threads)
SAE Grade 5 SAE Grade 8

ASTM 325 ASTM 490 ASTM 574
Yield of Yield of Yield of

120,000 psi 150,000 psi 170,000 psi
Med. Carbon Alloy
Nominal Coarse Standard Heavy Socket Med. Carbon Heat Med. Carbon Alloy Steel Socket-Head
Bolt Threads Hex Nut Hex Nut Head T. Steel Hex-Head Steel Hex-Head Cap Screw
Size Flat Size Flat Size Key Size Bolts Bolts Rolled Threads
In Per In In In In Ft-Lb (Nm) 1* Ft-Lb (Nm) 1* Ft-Lb (Nm) 1*
1/4 20 7/16 1/2 3/16 9 (12) 12 (16) 16 (21)
5/16 18 1/2 9/16 1/4 18 (24) 25 (34) 32 (44)
3/8 16 9/16 5/8 5/16 31 (42) 44 (60) 58 (78)
7/16 14 5/8 3/4 3/8 50 (68) 71 (96) 92 (125)
1/2 13 3/4 7/8 3/8 76 (103) 108 (146) 141 (191)
9/16 12 13/16 15/16 1/2 110 (149) 155 (210) 185 (251)
5/8 11 15/16 1-1/16 1/2 152 (206) 214 (290) 255 (346)
3/4 10 1-1/8 1-1/4 5/8 269 (365) 380 (516) 454 (615)
7/8 9 1-5/16 1-7/16 3/4 434 (588) 613 (831) 731 (991)
1 8 1-1/2 1-5/8 3/4 650 (882) 919 (1246) 1095 (1485)
1-1/8 7 1-11/16 1-13/16 7/8 811 (1100) 1302 (1766) 1553 (2105)
1-1/4 7 1-7/8 2 7/8 1145 (1552) 1837 (2491) 2191 (2970)
1-3/8 6 2-1/16 2-3/16 1 1501 (2035) 2408 (3265) 2872 (3893)
1-1/2 6 2-1/4 2-3/8 1 1992 (2701) 3197 (4334) 3812 (5168)
1-3/4 5 2-5/8 2-3/4 1-1/4 3141 (4259) 5041 (6835) 6011 (8150)
2 4.5 3 3-1/8 1-1/2 4722 (6402) 7578 (10274) 9035 (12250)
2-1/4 4.5 – 3-1/2 1-3/4 6905 (9362) 11083 (15026) 13214 (17916)
2-1/2 4 – 3-7/8 1-3/4 9447 (12809) 15162 (20557) 18078 (24511)
2-3/4 4 – 4-1/4 2 12822 (17385) 20579 (27901) 24536 (33267)
3 4 – 4-5/8 2-1/4 16918 (22937) 27152 (36813) 32373 (43892)
3-1/4 4 – 5 2-1/4 21803 (29560) 34992 (47442) 41721 (56566)
3-1/2 4 – 5-3/8 2-3/4 27547 (37349) 44211 (59942) 52713 (71470)
3-3/4 4 – 5-3/4 2-3/4 34220 (46396) 54921 (74464) 65483 (88783)
4 4 – 6-1/8 3 41892 (56798) 67234 (91158) 80164 (108688)
The above torque values assume “dry” degreased threads. The use of thread lubricant, such as oil, grease, or Never-
Seez®, will lower the recommended torque by approzimately 25%. The “As Received” condition may be “wet” (lubricated)
or “dry” (degreased), and appropriate action must be taken. The type of lubricant can cause significant variation in torque
values. For torque ratings when applying Never-Seez to the threads, please see Service Letter 260 for specific torque re-
quirements. All torques are based on 70% of yield stress.
ES04930a01
Table 3-2: Torque Value Chart for American Standard Screws and Bolts (Coarse Threads)

3.3.2 Hardware Coatings
Use the following guidelines for particular types of fastening hardware or particular coatings of hardware (e.g.,
Never-Seez):
• Torque values are based on using plated hardware.
• If not stated, assume no coating is specified and do not use one.
• If a coating is specified, coat the threads and coat the underside (connection side) of the nut.
• Torque values for lubricated threads are generally about 25% lower than for dry threads.
• Torque values specified on assembly drawings take precedence over those published on standard torque
tables.
Bolts should be tightened using an appropriate size and capacity tool, whether it is 1/2", 3/4", or 1" drive. After a
fastener is torqued, the fastener may be marked by applying a line of enamel paint from the side of the fastener
head to the mating surface.
When torque sequencing requirements are specified, those requirements must be met. Torque will depend upon
the fastener’s size, grade, coarse or fine thread, and coating. Sometimes the fastener must be stretched or ten-
sioned with a special bolt tensioner tool. In that case, special instructions will be supplied separately.
After Grade 8 fasteners and above have been torqued to full load, they must not be reused. If removal is required,
discard the fasteners and replace them with new ones.
3.3.3 Fastener and Torque Procedures
If a torque value is not specified on the drawing, the torque charts may be used as a general guide. Unless speci-
fied otherwise, the following procedure should be used:
1. Clean any dirt or chips from the threads and bearing surfaces of all fasteners and clamped parts.
2. When lubricated fastener is specified, lubricate the threads and bearing surface under head.
3. If using air impacts, select a tool that can be adjusted to the required torque values in the steps below, and ver-
ify the settings with a standard torque wrench.
4. Torque all fasteners to 2/3 of their specified torque value. If the bolt pattern is circular, work in a crisscross or
star pattern to evenly distribute the bolt forces into the clamped parts. If the clamped parts are rotational, such
as bearings, rotate them while torquing to ensure proper alignment and seating of the parts. If the bolt pattern
is rectangular, then work from the middle of the pattern to the ends along the longer side and alternate back
and forth across the other direction.
! WARNING
Fasteners under high torques may fracture unexpectedly while being loosened or
torqued, causing the head to fly off with considerable force, causing serious personal
injury or death. Wear eye protection and face shields while turning fasteners. Use new
fasteners, and do not stand with any part of the head or body in line with the bolt hole

while the fasteners are being turned. Failure to follow these recommendations can result
in serious personal injury or death.
5. Torque all the fasteners to 100% of the specified torque following the same sequence as before. Continue
torquing at this setting until all fasteners are stabilized with no additional rotation of the fastener.
NOTICE
Do not overtorque fasteners. Do not use thread adhesive where it is not specified. Do use
thread lubricants where specified. Failure to follow these rules could result in increased difficulty
in removing fasteners and could lead to failure of the fastener.
3.3.4 Types of Fasteners
CAP SCREWS differ from BOLTS in that a bolt has a nut threaded on its end, while a cap screw is threaded into a
tapped hole. Types of cap screws will include Hex Head Cap Screws (HHCS) or Socket Head (sometimes known
as Allen Head) Cap Screws (SHCS).
ROD BOLTS are threaded on both ends. They typically have a nut threaded on each end.
STUDS are threaded into a tapped hole or welded into a hole and have one threaded end protuding. A nut is typi-
cally used on the protuding threaded end.
COUPLING BOLTS or BODY FIT BOLTS are special tight-fitting bolts that are used to locate and control move-
ment of the pieces being clamped together. When fitting these bolts in a new assembly, the holes are often reamed
to make a tight fit. It may be necessary to freeze bolts to install them. These bolts should be replaced when
removed; they should not be reused. Torques for these bolts are typically specified and are not standard torques
for the bolt size.
NUTS are threaded onto bolts, rod bolts, or studs.
LOCK NUTS are special nuts which contain special materials such as nylon which will help prevent the nut from
unthreading due to vibration.
HARDENED WASHERS are flat, hardened steel washers. These washers will not create a need for altering the
torque if they are used in an assembly.
LOCK WASHERS are spring-type (helical) or star-type washers that are used to help keep the associated nuts
from unthreading due to vibration. The use of lock washers in an assembly will limit the torque applied, as a high
torque will flatten the washer and cause it to deform (example: grade 5 bolt with lock washer uses a grade 2 torque).
SUPERNUTS™ are special fasteners that replace standard nuts. They are used in applications where large diam-
eter fasteners require a high torque value. The Supernut uses a series of jack screws around the circumference of
a threaded fastener to tension studs or bolts. These devices are available in numerous sizes, with varying numbers
of jack screws around the circumference of the tensioner. Figure 3-7 illustrates a typical Supernut.
HYTORC CLAMPS are special tensioners that replace nuts. The HYTORC clamp uses a special wrench which fits
in to large castellations in the clamp body. The wrench turns the outside sleeve of the clamp, which tensions the
stud or bolt. HYTORC clamps are currently only used as an option on the large rod bolts that attach the side frames
to the carbody.

3.3.5 Thread Coatings
Thread coatings consist of lubricants or adhesives for threads.
3.3.5.1 Thread Lubricants
Lubrication of threads is often specified in high torque applications. Never-Seez is used as the standard thread
lubricant. Other lubricants may be specified for special applications.
The use of lubricant on threads and under nuts will normally cause the fastener to turn easier and will mean a lower
torque value is needed to obtain the desired clamping force. Torque values for lubricated fasteners are usually pro-
vided. If the torque is not provided, a general rule of 75% of the normal (dry) torque specified in the torque chart
can be used.
When a special thread lubricant is specified, it is important to use the correct lubricant and the correct torque.
These lubricants are typically specified by part number to insure correct application. Using an incorrect torque or an
unspecified lubricant may result in an incorrect clamping force being obtained because the fastener turns easier or
harder than desired. Net result could be premature loosening and fatigue failure or overload failure.
3.3.5.2 Thread Adhesives
Thread adhesives are used in situations where high stress or vibration are expected to cause problems with the
fastener unthreading itself under load.
! WARNING
Using thread adhesives in high torque applications where a thread lubricant has been
specified may make it impossible to remove the fastener. Under high removal torque,
fasteners have been found to fail. If failure occurs, the fastener could become a projec-
tile. This could cause the fastener head to shoot away with considerable force, causing
personal injury or death. Avoid standing in line with fasteners being tightened or loos-
ened. Use thread adhesives only where specified.
Thread adhesives are specified by part number to ensure correct application.They are specified where they are
deemed appropriate. Thread adhesives should only be used where and as specified.
3.3.6 Bolt Tensioning
3.3.6.1 General
Bolt tensioning is used as a substitute for torquing in many areas of the modern mining shovel. Tensioning bolts
will produce more consistent and accurate clamping forces, and so is preferable to torquing for large bolts.
3.3.6.2 Types of Tensioning
The types of tensioning are often optional. Therefore, the tensioning used on particular shovels varies with the
options specified. As of the writing of this manual, the most common types of tensioning are: bolt tensioning for the
side frame rod bolts, tensioning using Supernuts, and tensioning using HYTORC clamps. Each of these three sys-
tems will be discussed in this manual.

The bolt tensioner used for side frame rod bolts is only used in the side frame area of the shovel. The information
for the side frame rod bolt tensioning is included in the discussion of the propel system and lower part of the shovel.
HYTORC clamps are currently only used as an option for side frame rod bolts. The information for the side frame
rod bolt tensioning is included in the discussion of the propel system and lower part of the shovel.
Supernuts may be used in several different areas of the shovel. A general description of Supernuts and general
procedure follows. Specific information will be included in the individual assembly sections of this manual.
3.3.7 Supernuts
Figure 3-7: Supernuts

3.3.7.1 General
The Supernut uses a series of jack screws around the circumference of a threaded tensioner to tension studs or
bolts. These devices are available in numerous sizes, with varying numbers of jack screws around the circumfer-
ence of the tensioner. Figure 3-8 illustrates a typical Supernut.
3 1 4
4 5
12
11 1
10 2
9 2 3
4
8 4
7 5
6
TC0309f
LEGEND 03. Jack Screws

01. Star Torque Pattern 04. Hardened Washer
02. Circle Torque Pattern 05. Tensioner Body
Figure 3-8: Typical Supernut
The main advantage of this tensioning system is that great clamping force can be achieved by using many jack
screws, without having to use great torque on any single jack screw. Therefore, the devices are relatively easy to
install, do not require great force to install, are easy to remove, and are reusable.

3.3.7.2 Installing Supernuts
All Supernuts are installed in the same general manner. However, the torque applied to jack screws and the torque
pattern in which the jack screws are tightened will vary, depending on the size of the device and the length of the
stud. A typical installation procedure is as follows:
1. Determine the target jack screw torque by referring to Table 3-3.
Application Supernut Initial Final Number Diameter of Size of QTY Lubricant

Diameter & Target Target of Jack Jack Socket Supernuts Required
(Part Torque Torque Screws Screws Required per for Jack
Number) (ft-lbs) (ft-lbs) per shovel Screws
Supernut
Boom Point 2.5-12UN 125 250 12 0.625-18UNF 0.5625" 4 JL-G

Bearing (R25192D1) (5/8") (9/16")
Block Studs
Hoist Drum 2.25-12UN 72 144 12 0.500-20UNF 0.4375" 8 JL-G

Shaft (R29759D1) (1/2") (7/16")
Bearing
Block Studs
Swing Gear 2.75-_UN 106 212 12 0.625-18UNF 0.5625" 20 JL-G

Bolts (R55500D1) (5/8") (9/16")
Table 3-3: Installing Supernuts
2. If using air impacts, select a tool with output of 90% to 100% of the target torque. Verify the torque output of air
impact with a standard torque wrench.
3. Clean the area around the stud or bolt to be tensioned, and remove all dirt and/or chips from the threads of the
stud or bolt and from the main internal threads of the tensioner. If multiple studs are being tightened, they
should be tightened in the correct torque pattern. Examples of torquing patterns are shown in Figure 3-9.
1
8 11
10 6
1 9 5 8 12 4
3 11 7 6 10 2 4
3
5 9
12 7
2
ES04917a01
Figure 3-9: Examples of Torquing Sequences
4. Lubricate the threads of the stud with a Never-Seez lubricant. Do not use Never-Seez on jack screws, which
must be lubricated by a special lubricant.

5. Place one Supernut with a hardened washer onto the stud to be tightened. (In the case of side frame rod bolts,
the washer and Supernut will be put on the rod bolt first and then the rod bolt will be installed).
6. Check the base of each tensioner to be sure that all jack screws are flush with (or recessed in) the base of the
tensioner. If any jack screw extends beyond the tensioner base, turn it back until it is flush with the base or
slightly recessed in the base.
7. Apply a light coating of lubricant to jack screw threads as follows (new assemblies are lubricated during
manufacture):
NOTICE
Never-Seez, or equivalent, is used only on the stud threads. Do not use Never-Seez, or equivalent, on
jack screw threads. Use only the specified lubricant on the jack screw threads.
A. If working with Supernut assemblies for side frame rod bolts (R38213D1), use low friction molybdenum
lubricant type JL-M. This lubricant is available in three sizes under the following P&H part numbers:
R38211D1 (brush top pint), R38211D2 (quart), and R38211D3 (gallon).
B. If working with Supernut assemblies for boom point sheaves, hoist drum shaft, swing gear, or any location
other than side frame rod bolts, use low friction graphite lubricant type JL-G. This lubricant is available in
three sizes under the following P&H part numbers: R38211D4 (brush top pint), R38211D5 (quart), and
R38211D6 (gallon).
NOTICE
Failure to lubricate properly or use of improper lubricant can affect torque readings for jack
screws, which will result in improper clamping force developed by Supernut assemblies.
8. If installing side frame rod bolts, follow Steps A, B, and C below. If installing a Supernut on an existing stud or
bolt, go to Step Step 9.
A. Thread one tensioner with hardened washer onto each rod bolt (the end with a 3/4-10 UNC threaded hole).
The end of each rod bolt should be even with, or slightly protruding above, the top of the jack screws in each
tensioner.
B. Make sure carbody and crawler frame are properly aligned and assure machined crawler frame pads are
tight against machined carbody sides. Insert rod bolts through crawler frame into carbody. Place long rod
bolts in the lower holes, short rod bolts in the upper holes.
C. Place a hardened washer and nut on each rod bolt, long and short, from inside the carbody. Snug the nut
until there are no gaps between the tensioner and crawler or the carbody and nut.
9. Spin the tensioners by hand down on the threads until they seat against the washer. For the side frames, the
tensioners should already be snug from Step Step 8. Back off all the tensioners to create about 1/16" to 1/8"
(1.59 to 3.18 mm) gap between tensioner bodies and washers. This gap will allow lubrication of jack screws while
in place.
10. Use the star pattern shown in Figure 3-9 to tighten only the four jack screws at the 12:00, 6:00, 9:00, and 3:00
o’clock positions to the proper Target Torque from Table 3-3. If multiple bolts or studs are being tightened,
always tighten all of them in the proper sequence before continuing with the next step.

11. After all tensioners being installed have been brought to the proper Initial Target Torque, use the star pattern
(shown in Figure 3-8) and torque the same four jack screws to the proper Final Target Torque.
12. At the Final Target Torque, tighten all jack screws in the circular pattern (shown in Figure 3-8) on all bolts or
studs (one round only).
NOTICE
As you tighten the jack screws, the bolt or stud will stretch, so by the time the circular pass is
completed, the first jack screw will be loose again.
13. Repeat Step Step 12 until all jack screws are “stabilized” (less than 20° rotation). This usually requires two to
four additional passes.
14. If using air tools, switch to a calibrated hand torque wrench when socket rotation is small. Use the hand wrench
to stabilize and confirm target torque.
15. Using a hand torque wrench, make a final pass on all jack screws following the patterns to confirm the Final
Target Torque from Table 3-3
3.3.7.3 Removing Supernuts (Service under 250°F) (121°C)
NOTICE
Removal requires strict adherence to procedures! Jack bolts must be unloaded gradually. If
most of the jack screws are fully unloaded prematurely, the remaining jack screws will carry the
entire load and will be difficult to turn. At the extreme, a jack screw tip can deform, making
removal difficult.
1. Spray jack screws with penetrating oil or hydraulic oil prior to start (especially if product is rusted).
2. Loosen each jack screw 1/4 turn following the circular pattern around the tensioner (one round only). When
you return to the first jack screw, it will be tight again. Do this for all tensioners on the joint prior to the next step.
Do not use air impact.
3. Repeat a second round the same as above for all tensioners.
4. Repeat a third round the same as above for all tensioners.
5. Continue until jack screws are loose. Remove the tensioners. Clean and lubricate the jack screws with proper
lubricant.
NOTICE
Usually, after the third round, an air impact tool can be used to remove the jack screws. Do not
use an air impact for the first three rounds. For long studs or rod bolts, more than three rounds
may be required before using air impact tools. Detailed instructions are shipped with Supernut
tensioners.

3.4 Interference Fit and Installation
3.4.1 General
This section includes information on interference fit and installation for these assemblies: bearings, bushings, cou-
plings, dowel pins, gears, keys, pins, and splines. This standard applies to assembly activities of P&H Mining
Equipment. It is the responsibility of each mechanic to comply with the requirements of this standard to properly
maintain P&H Mining machinery.
GN0118a01
Figure 3-10: Interference Fit, Typical
Interference fits are used in many assemblies. To achieve an interference fit one part may be heated to expand it
for assembly. Sometimes it is more convenient to cool a part, shrinking it to overcome an interference fit. Normally
the smaller part is heated or cooled, as it is easier to handle.
If heating a part, do not heat over an open flame or use a torch. Recommended heating methods include an oil
bath, clean oven with recirculating fan, or induction bearing heater.

GN0119a01
Figure 3-11: Do Not Heat with an Open Flame or Torch
If using an oil bath, plan to use enough oil. A smaller amount of oil may heat and cool too rapidly, causing the
part to heat unevenly. Use either quenching oil that has a minimum flash point greater than 300° F (149°C), or
transformer oil.

Use clean oil. If it is reused, filter it carefully. Clean the container and keep all contaminants away.
OIL
GN0120a01
Figure 3-12: Use a Clean Container
Place a rack at the bottom of the container and set the part on it. This will prevent the part from touching the hot
bottom. It will also separate the part from any contamination that may have settled on the bottom. A part may also
be hung suspended so that it does not touch the bottom.
GN0121a01
Figure 3-13: Place a Rack on the Bottom
To heat the part uniformly, place it in the bath as soon as heating starts, or allow sufficient time for entire part to
reach temperature. Stir oil and heat at 200° F (93°C) for 15 minutes. Check temperature by immersing a thermom-
eter near the part.

GN0122a01
Figure 3-14: Checking the Temperature
NOTICE
Refer to Subtopic 3.5.1 for information on interference fit and installation of bearing assemblies.
3.4.2 Bushings
1. Preparation
A. Measure bushing and mating bore/shaft for correct size and form.
B. Inspect bore/shaft and bushing for contamination, handling damage and other defects, especially on bush-
ing seating surfaces.
C. Remove all burrs from bushing and shaft/bore.
D. Clean bore/shaft and bushing as necessary to remove any contamination that will interfere with proper
engagement of bushing.
2. Heating Bushings
A. Bushing temperature should never exceed 300°F (149°C) when heating or bushing hardness and geometry
may be altered.
B. Use a surface temperature pyrometer to determine when a bushing has reached required temperature.
3. Freezing Bushings
A. When freezing bushings, determine temperature requirements to achieve desired shrink (refer to Topic 3.6).
B. Use a surface temperature pyrometer to determine when a bushing has reached required temperature.
4. Installation

A. Pre-grease shaft or bore just prior to installation (refer to Topic 3.7).
B. Bushings should engage bores and shafts without pressing when component sizes are to specification and
heating or freezing procedures are followed. If bushings become misaligned or will not fully engage, attempt
removal immediately. Check bore or bushing size against required dimension before proceeding. Press into
bore or onto shaft only if removal is not possible.
C. If bushings do not install properly, after removal, allow parts to return to ambient temperature and inspect for
correct bore, shaft and bushing size and form (roundness, inside/outside diameter).
D. If the bushing is not to be installed immediately, apply rust preventive to all exposed machined surfaces of
bushing assembly and cover with clean protective material (refer to Topic 3.2).
3.4.3 Couplings
1. Preparation
A. Measure coupling and mating shaft for correct size and form.
B. Inspect coupling, shaft, and splines for contamination, handling damage or other defects.
C. Remove all burrs from coupling, shaft, or splines.
D. Clean components as necessary to remove any contamination that will interfere with proper assembly.
2. Heating Couplings
A. Coupling temperature should never exceed 300°F (149°C) when heating or coupling hardness and geome-
try may be altered.
B. Use surface temperature pyrometer to determine when coupling has reached required temperature.
C. Heating method may be oil bath, clean oven with recirculating fan, or induction bearing heater.
3. Installation
A. Couplings should engage shafts without pressing when heating and component sizes are to specification. If
couplings become misaligned or will not fully engage, attempt removal immediately.
B. If couplings do not install properly, after removal, allow parts to return to ambient temperature and inspect
for correct shaft and coupling size and form.
C. If coupling is not to be installed immediately, apply rust preventive to all exposed machined surfaces of cou-
pling assembly and cover with clean protective material (refer to Topic 3.2).
3.4.4 Dowel Pins
1. Preparation
A. Measure dowel pin and mating hole for correct size and form.
B. Inspect dowel pin and mating hole for contamination, handling damage, and other defects.

C. Remove all burrs from pin and mating hole.
D. Clean dowel pin and hole as necessary to remove any contamination that will interfere with proper seating
of pin.
2. Freezing Dowel Pins
A. When freezing dowel pin, determine temperature requirements to achieve desired shrink (refer to Topic
3.6).
B. Use surface temperature pyrometer to determine when pin has reached required temperature.
3. Installation
A. Grease dowel pin O.D. before assembly (refer to Topic 3.2).
B. Dowel must have thru hole or air relief (flat or groove) on side to allow air escape for proper seating.
C. Check hole alignment prior to dowel installation.
D. Pin should seat in hole without pressing or with minimal force when freezing and component sizes are to
specification. If pin must be tapped in, use brass or mild steel bar. If pin becomes misaligned or will not fully
engage, attempt removal immediately. Press into hole only if removal is not possible.
E. If dowel pin does not install properly, after removal, allow parts to return to ambient temperature and inspect
for correct hole and pin size and form.
3.4.5 Gears
1. Preparation
A. Measure gear hub I.D. and mating shaft or pinion O.D. for correct size and form.
B. Inspect gear, shafts, bores, keys, and keyways for contamination, handling damage, and other defects.
C. Remove all burrs from gear, shafts, bores, keys, and keyways.
D. Clean gear, shafts, bores, keys, and keyways as necessary to remove any contamination that will interfere
with proper assembly of gear.
2. Heating Gears
A. Gear temperature should never exceed 300o F (149°C) when heating or material hardness and geometry
may be altered. If a higher temperature is required, contact P&H Mining Equipment Product Engineering for
approval.
B. Use surface temperature pyrometer to determine when gear has reached required temperature.
3. Installation
A. Grease gear bore just before assembly unless specifically noted otherwise in assembly instructions (refer to
Topic 3.2).
B. If gear becomes misaligned or will not fully engage, attempt removal immediately. Continue pressing onto
shaft only if removal is not possible.

C. If gear does not install properly, after removal, allow parts to return to ambient temperature and inspect for
correct bore/shaft size and form. Also check spline dimensions at several locations.
3.4.6 Keys
1. Preparation
A. Measure key and keyway for correct size and form.
B. Inspect key and keyway for contamination, handling damage, and other defects.
C. Remove all burrs from keys and keyways.
D. Clean key and keyway as necessary to remove any contamination that will interfere with proper seating of
key.
E. Pre-fit key before assembly and check key size to ensure tight fit into shaft and free fit into gear.
2. Freezing Keys
A. When freezing keys, determine temperature requirements to achieve desired shrink (refer to Topic 3.6).
B. Use surface temperature pyrometer to determine when key has reached required temperature.
3. Installation
A. Keys should seat in keyways with minimal force when freezing and component sizes are to specification. If
keys do not seat squarely, become misaligned or will not fully engage, attempt removal immediately. Apply
additional force only when removal is not possible.
B. If keys do not install properly, after removal, allow parts to return to ambient temperature and inspect for cor-
rect key and keyway size, orientation, and form. If necessary, machine key to increase chamfers to act as a
lead.
3.4.7 Pins
1. Preparation
A. Measure pin and mating bore for correct size and form.
B. Inspect pin and bore for contamination, handling damage, and other defects.
C. Remove all burrs from pin and bore.
D. Clean pin and bore as necessary to remove any contamination that will interfere with proper engagement of
pin.
E. Very few pins are press fit. Most are loose, but need lubrication. Apply a coat of Never-Seez to the pin.
2. Freezing Pins
A. If it is necessary to freeze pins, determine temperature requirements to achieve desired shrink (refer to
Topic 3.6).
B. Use a surface temperature pyrometer to determine when a pin has reached required temperature.

3. Installation
A. Lubricate pin O.D. just prior to assembly (refer to Topic 3.2).
B. Pins should engage in bores without pressing when heating, freezing, and component sizes are to specifica-
tion. If pin becomes misaligned or will not fully engage, attempt removal immediately. Press into bore only
when removal is not possible.
C. If pin does not install properly, after removal, allow parts to return to ambient temperature and inspect for
correct pin and bore size and form.
3.4.8 Splines
1. Preparation
A. Inspect splines for contamination, handling damage, and other defects.
B. Remove all burrs from shaft and mating bore.
C. Clean splines as necessary to remove any contamination that will interfere with proper engagement of
splines.
D. Measure shaft and mating bore for correct size and form. Measure over pins in several places (requires
proper inside and outside micrometers). (Note: this will not identify lead or spacing errors; consult MinePro.)
2. Installation
A. Pre-grease splines just prior to assembly (refer to Topic 3.2).
B. Spline fit components should engage without pressing when heating, freezing, and component sizes are to
specification. If splined components become misaligned or will not fully engage, attempt removal immedi-
ately. Press into mating component only if removal is not possible.
C. If parts do not engage properly, after removal, allow to return to ambient temperature and inspect for correct
spline size and form.
3.5 Bearings
Bearings are precision parts. To retain their accuracy and reliability they must be handled with care. They should be
protected against corrosion, kept clean from contamination from foreign materials, and should not be subjected to
sharp and heavy impacts. Most bearings are pressed onto the rotating member. For most applications on P&H
shovels, this is the shaft. One notable exception is the boom point sheaves, where the bearings are pressed into
the sheave bore.
3.5.1 Bearing Storage, Interference Fit, and Installation
1. Storage
A. Bearings should be stored in their original packing at room temperature and subject to a humidity of less
than 60%.
B. Bearings should be stored flat, particularly larger bearings that have relatively thin rings. They should be
supported over the total bearing circumference.

2. Preparation
A. Do not remove bearings from original packaging until ready for installation.
B. Remove supplier’s preservative from bearing using clean shop rags.
C. Measure bearing and mating bore/shaft for correct size and form.
D. Inspect for contamination, handling damage or other defects.
E. If compressed air is used to dry bearing, never spin the bearing as rollers or races may be damaged or
expelled with great force.
F. If this assembly will be standing for any length of time and not be installed and running, apply rust preventive
and cover with clean protective material (refer to Topic 3.2).
G. Many bearing components are manufactured as a matched set and must never be interchanged with com-
ponents from another bearing, even if that bearing has the same part number. This is always true for double-
tapered roller bearings used on P&H Mining Equipment.
3. Shaft/Bore Preparation
A. Inspect shaft/bore for contamination, handling damage and other defects, especially on bearing seating
surfaces.
B. Remove all burrs from shaft/bore.
C. Clean shaft/bore as necessary to remove any contamination that will interfere with proper seating of bearing.
4. Heating Bearings/Rings (refer to Topic 3.4).
A. Bearing/ring temperature should never exceed 300°F (149°C) when heating, or bearing hardness and
geometry may be altered.
B. Use surface temperature pyrometer to determine when bearing or ring has reached required temperature.
C. Heating method for bearings without shields or seals may be oil bath, clean oven with recirculating fan, a
special bearing heating plate, or an induction bearing heater. Bearings with shields or seals are packed with
grease by the manufacturer. They can be heated, but should not be heated in an oil bath.
5. Freezing Bearings/Rings
A. When freezing bearings or rings, determine temperature requirements to achieve desired shrink (refer to
Topic 3.6).
B. Use surface temperature pyrometer to determine when bearing or ring has reached required temperature.
6. Installation
A. Pre-grease bore (heated bearing) or ring (frozen bearing) just prior to installation with suitable grease (refer
to Topic 3.2).
B. Bearings should seat on shafts and in bores without pressing when component sizes are to specification
and heating or freezing procedures are followed. If bearings do not seat squarely, become misaligned or will
not fully engage, attempt removal immediately. Press onto shaft or into bore only if removal is not possible.
1). If the inner bore is tight, use a mild steel mounting sleeve to press on the inner bearing ring. Do not put
pressure on the outer ring, or damage to the bearing will result. Refer to Figure 3-15.

01 02
03
LEGEND
01. Shaft
02. Bearing
03. Mounting Sleeve
ES0604a_01
Figure 3-15: Installing Bearing on Tight Inner Bore
2). If the inner and outer bores are tight, use a mounting sleeve and disk (both of mild steel) to press
against both surfaces. Pressure should be applied on both the inner and outer ring, or damage to the
bearing will result. Refer to Figure 3-16.
01 02
03
04
LEGEND
01. Outer Bore
02. Bearing
03. Mounting Disk
04. Mounting Sleeve
05. Shaft
05 ESO605c_01
Figure 3-16: Installing Bearing with Tight Inner and Outer Bores
3). Figure 3-17 shows a bearing in which the rolling elements or cage protrudes beyond the races. If the
inner and outer bores are tight when installing a bearing of this type, a mounting sleeve and relieved
disk (both of mild steel) like the ones shown should be used. Pressure should be applied on both the
inner and outer ring, but not the rolling elements or cage.

01 02
03 04
LEGEND
01. Outer Bore
02. Bearing
03. Mounting Disk
04. Mounting Sleeve
05. Shaft
05 ES0606c_01
Figure 3-17: Installing Bearing with Tight Inner and Outer Bores Using Relieved Disk
C. If bearings did not install properly, after removal, allow parts to return to ambient temperature and inspect for
correct bore/shaft size and form.
D. Proper bearing seating should be checked by tapping the cup or cone in at least three places around the
face of the cup or cone with mild steel stock. After allowing the parts to return to ambient temperature, a
0.001" to 0.002" feeler gauge should also be used to verify seating between bearing race and shoulder of
bore or shaft.
E. The retainer plate should be put on the bearing after the bearing is installed to prevent it from creeping away
from shoulder upon cooling.
7. Lubrication
A. Lubricate all bearings prior to installation. Bearings will be lubricated by grease or by gear oil, depending on
the location on the machine. See more information on lubrication in Topic 3.2.
1). If bearing will be running in oil, do not pack bearing with grease.
a. Bearing should be lubricated by gear oil compatible with that which will be used to lubricate it while
running.
b. If this assembly will be standing for any length of time and not be installed and running, the gear oil
used to lubricate the bearing should be mixed with an oil-based corrosion inhibitor.
c. The bearing should be rotated to make sure it is well-coated with oil or oil/inhibitor mix.
2). If bearing will be grease lubricated, lubricate bearing with grease (refer to Topic 3.2).
a. Use grease compatible to that which will be used in the bearing once it is installed. In factory
assembly, P&H Manufacturing uses an aluminum complex grease (P&H 469).
b. Pack bearing by hand, use a bearing packer, or use a needle nose grease gun attachment to apply
grease to the bearing. Only partly fill (20 to 35% of free space) fast running bearings.
c. Rotate bearing at least one revolution to ensure that all surfaces are coated.

B. Apply grease as close to installation time as possible to avoid contamination.
C. Too much grease in the housing, especially at medium and higher speeds, will cause excess churning of the
grease and extremely high temperatures, which can harm both the bearing and the lubricant. Some grease
must be retained around the bearing; however, adequate space in the housing is required for excess grease
to be thrown from the bearing.
D. With oil or sump lubrication, a high oil level could cause churning which can cause overheating, oxidation
and foaming.
E. To maintain optimum lubricant stability and lubricating properties, lubricants with differing bases should not
be mixed. Contact your lubricant supplier for more information on compatibility.
8. Roller Bearing Removal
Several conditions will effect the removal of roller bearing assemblies. Types of bearings and the other compo-
nents surrounding the bearings must be taken into account. Sliding fits and interference fits must be determined.
Also important is to determine whether the bearing being removed will be reused. If the bearing will be scrapped,
care need not be taken to avoid damage to the bearing. If the bearing will be reused, damage to the bearing must
be avoided. In either case, damage to the other components of the entire assembly must be avoided or replace-
ment of the damaged components will be necessary.
As time passes the ring becomes embedded on the seat, making the force required for removal generally higher
than the installation force. Even with loose-fitted rings, fretting corrosion may make removal work difficult.
If the roller bearing is separable, the components can be separated first. The bearing inner ring can then be
removed from the shaft and the outer ring from the outer bore.
With non-separable bearings, first withdraw the ring with sliding fit from its seat and then dismount the tight-fitted
ring.
! CAUTION
When applying force to remove a bearing assembly, it is possible that the bearing could
fly apart with great force and throw the rolling elements and pieces of the hardened rings.
Always use safety glasses and other appropriate safety gear when removing bearings.
• It is important that the extracting tool be applied to the ring to be extracted to prevent the rollers from brinel-
ling the raceways. Figure 3-18 shows the puller force being transmitted through the rolling elements. This
will damage the bearing and this bearing should not be reused.

Figure 3-18: Transmitting Force Through Rolling Elements
• In addition, thin-walled outer rings involve the risk of ring fracture. A collar of unhardened steel should be
placed around the thin-walled outer ring if removing a bearing and transmitting the force through the rolling
elements is unavoidable or if scrapping the bearing (refer to Figure 3-19). The collar should have a thick-
ness greater than 1/4 of the bearing cross-section height. This applies especially to bearings of small cross-
section height and small contact angle (such as tapered roller and spherical roller bearings). This bearing
should not be reused.
Figure 3-19: Using Removal Collar

• Bearings may be removed using a bearing puller. Ensure that the puller is applying the force to the tight-fit-
ting ring only, and will not damage the rolling elements. Refer to Figure 3-20.
Figure 3-20: Removing a Bearing with a Puller
• If the inner ring is tight against a spacer and there is no access to the inner ring for a puller, it might be pos-
sible to pull both the spacer and bearing off together.
• An inner ring may be removed with a puller similar to the one shown in Figure 3-21. In this drawing there is
access to the inner ring sufficient to apply a puller. It may be extremely difficult to remove a tight-fitting inner
ring if no access exists to the inner ring or an adjacent spacer. If it is impossible to pull off an inner ring, it
can be cut off using a thin cutting wheel on a small grinder. The ring can be cut in two or more places and
then removed. Care should be taken to not cut into the shaft or other components. A cold chisel can be used
to finish the cut.
Figure 3-21: Removing an Inner Ring with a Puller

! CAUTION
When using a press to remove components, stand behind a suitable guard in case com-
ponents are expelled violently. Wear safety glasses and other suitable safety gear.
• Bearings can be removed using a press, as shown in Figure 3-22. Again, the contact with the bearing
should be made on the tight-fitting ring if the bearing is to be reused.
Figure 3-22: Removing a Bearing with a Press
• Smaller bearings can be driven off their seat with a hammer and a soft metal drift. Light hammer blows
should be applied evenly around the whole circumference of the tight-fitting ring. Do not hammer on the
other ring or the force will be transmitted through the rolling elements which will damage the bearing.
More removal information will be provided in the individual removal topics in this manual.

3.5.2 Types of Bearing Assemblies
Single Tapered Roller Bearing Assemblies
Figure 3-23: Single Tapered Roller Bearing
Single tapered roller bearing assemblies consist of two pieces: an outer race or cup, and an inner race or cone
with the caged rollers. As the bearing assembly comes from the manufacturer, it is not a matched set; however, if
bearings that have been in service are to be re-used, they should be treated as a matched set: parts should not
be interchanged with parts of other bearings.
LEGEND
01. Cup
02. Cone
Figure 3-24: Single Tapered Roller Bearing
Single tapered roller bearings are manufactured with separable raceways which permit axial movement of the cone
assembly relative to the cup. This allows the required internal clearance (end play) or preload (no clearance) to be
closely controlled and to be adjustable. On the negative side, this means that if the end play is not accurately con-
trolled at assembly, internal clearances can be significantly beyond acceptable limits. This will dramatically shorten
bearing life. The cone of the bearing may be heated for installation. If the assembly instructions require heating,
refer to Subtopic 3.5.1.
The cup of the bearing may be cooled for installation. If the assembly instructions require cooling, refer to Topic
3.6.

When installed, single tapered roller bearing assemblies must have clearance for end play. The clearance is adjust-
able and is usually adjusted by shimming. For information on shimming for this end play clearance, refer to Topic 3.9.
LEGEND
01. Bearing Housing 04. Bearing
02. Gear Case 05. Bearing Housing
03. Bearing 06. Shim Here
Figure 3-25: Pinion with Single Tapered Roller Bearing
Figure 3-25 shows a pinion with single tapered roller bearings. Single tapered roller bearings are used in pairs, as
shown. Each piece of the bearing assemblies shown have a slight interference fit. The cups of this assembly are
cooled and installed in the housing and retainer. The cones are heated and installed on the pinion. Shims are
installed between the housing and the gear case to control the end play of the assembly.
The end play of the assembly may be checked using a dial indicator. The indicator will be used to measure the
movement of the shaft. An eye bolt is threaded into the end of the shaft and is used to move the shaft (refer to
Figure 3-26).

03
02
01
LEGEND
01. Dial Indicator
02. Indicator Stand
06 03. Outer Bearing
05 04. Pinion Shaft
05. Welded Flat
04 06. Eye Bolt
07. Inner Bearing
(Not Shown)
ES0065l_01
Figure 3-26: Using a Dial Indicator to Check End Play
It is possible to check end play of an assembly with a cover or bearing retainer installed over the end of the shaft.
The eye bolt can be threaded through a hole in the cover. The dial indicator can be placed on the welded flat of the
eye bolt instead of the end of the shaft.

3.5.2.1 Double-Tapered Roller Bearing Assemblies
Figure 3-27: Double-Tapered Roller Bearing
Most double-tapered roller bearing assemblies consist of four pieces: two inner races or cones with the caged roll-
ers, a spacer that goes between the cones, and an outer race or cup (Figure 3-27). The bearing assembly comes
from the manufacturer as a matched set, and the parts should not be interchanged with parts of other bearings.
LEGEND
01. Cone 03. Cup
02. Spacer 04. Cone
The double-tapered roller bearing assembly will often be marked by the manufacturer to provide the assembler the
proper orientation of the pieces of the bearing assembly (refer to Topic 3-28). The cup is labelled A on one side
and C on the other. The two cones are labelled A and C respectively. It is important to match the correct cone to
the correct side of the cup to provide optimum fit (refer to Figure 3-29).

LEGEND 03. Cup

01. Cone Spacer A. “A” Label
02. Cone C. “C” Label
Figure 3-29: Double-Tapered Roller Bearing Assembly
Tapered roller bearing assemblies need end play clearance between the cup and the cones. The double-tapered
roller bearing assembly produces this end play by using a spacer between the two cones. The width of the spacer
keeps the cones from crushing in on the cup. The manufacturer can vary the end play of the bearing assembly by
varying the thickness of the spacer. It is important that the correct spacer be used with the correct bearing assem-
bly. Use the spacer the manufacturer has provided. The spacer must be kept in good condition. Hammer peens,
nicks, burrs, etc. on the spacer could have an adverse effect on the end play of the bearing assembly. The primary
advantage of this style of bearing is that no shimming is required to attain the proper adjustment, and any amount
of axial load will not influence the bearing end play or the bearing loads.
NOTICE
Some double-tapered roller bearing assemblies do not have spacers. In this case the cones are
manufactured to butt together and provide the correct clearance.

Double-tapered roller bearing assemblies will typically have a retainer plate or spacer against the cones and the
cones will be clamped together tightly (refer to Figure 3-30). This clamping must be tight to hold the cones tightly
on the spacer. A loose fit could affect the bearing assembly end play.
01 02
03 04
LEGEND
01. Pinion
02. Spacer
03. Bearing
04. Cover
05. Retainer Plate
06 05 06. Dowel Pin
TC0135h
The cup is often a sliding fit and if so needs no cooling to be installed. Because it is a sliding fit, its movement must
be controlled to keep it from spinning in the bore. The cup shown in Figure 3-30 shows holes in the cup, which fit
over a dowel pin installed in the bore of the bearing block of the gear case. When installing the bearing, it must be
rotated to align the hole with the pin. The pin will not allow the cup to rotate. Also common is a cup with a sliding fit
clamped in place by the outer bearing cover or retainer. For more information on clamping outer races with a bear-
ing retainer and the associated shimming procedures, refer to Topic 3.9.
3.5.2.2 Spherical Roller Bearing Assemblies
Figure 3-31: Spherical Roller Bearings
Spherical roller bearings (Figures 3-31, and 3-32) have spherical rollers that share a common configuration with
their inner and outer rings. These matching spherical surfaces enable the bearings to compensate for higher levels
of shaft deflections and for modest misalignment between a rotating shaft and the bearing housing. Spherical roller
bearings are non-separable and are one-piece assemblies.
Spherical roller bearings are often used in areas where the shaft may experience higher levels of deflection, as the
spherical rollers will allow this motion better than a tapered roller bearing.

LEGEND
01. Rollers
02. Outer Ring
03. Inner Ring
Figure 3-32: Spherical Roller Bearing Assembly
The outer ring is often a sliding fit and if so needs no cooling to be installed. Because it is a sliding fit, its movement
must be controlled to keep it from spinning in the bore. It is common to see the outer race be clamped in place by
the outer bearing cover or retainer. For more information on clamping outer races with a bearing retainer and the
associated shimming procedures, refer to Topic 3.9.
The inner ring is also often a sliding fit and if so needs no heating. It is usually held to the shaft by a retainer plate
as shown in Figure 3-30.
3.5.2.3 Cylindrical (Straight) Roller Bearing Assemblies
Figure 3-33 shows drawings of one-piece and two-piece roller bearing assemblies. These assemblies are separa-
ble. The inner ring of both types is a separate piece. It is not included in the nomenclature “one-piece” or “two-
piece” bearing, and is installed separately.
LEGEND
01. One Piece Bearing 03. Caged Rollers
02. Outer Ring 04. Inner Ring and Spacer
Figure 3-33: One-Piece and Two-Piece Straight Roller Bearings

The outer ring is often a sliding fit and if so needs no cooling to be installed. Because it is a sliding fit, its movement
must be controlled to keep it from spinning in the bore.The outer ring is often clamped in place by the outer bearing
cover or retainer. For more information on clamping outer rings with a bearing retainer and the associated shim-
ming procedures, refer to Topic 3.9.
The inner ring may be an interference fit and if so will be heated for installation. It may also be a sliding fit and if so
needs no heating. If it is a sliding fit, it is usually held to the shaft by a retainer plate as shown in Figure 3-30. In
some instances a special adhesive is used to glue the inner ring to the shaft.
A needle roller bearing is a variation of the cylindrical roller bearing with thin, long rollers called needle rollers.
3.6 Shrink Fit Clearances Required for Assembly
3.6.1 General
This specification covers the clearances required for assembly based on Running or Sliding Fits Class RC4. Clear-
ances required for Close Fit or Shrink Fit Assemblies using Liquid Nitrogen or Dry Ice will also be defined.
Drawings and tables located in the individual inspection topics give ranges of nominal dimensions that can be used
to make sure parts are not worn and out of tolerance.
NOTICE
Information included in this subtopic refers to fitting of assemblies using freezing of a compo-
nent to ease assembly. Information for fitting of assemblies using heating of a component to
ease assembly is included in Topic 3.4. As a general rule, if freezing a component for internal
installation, the external component is not also heated.
Actual Clearance or Interference - To determine the actual clearance, subtract the I.D. from the O.D. of the parts to
be assembled. A negative number indicates a clearance fit and a positive number indicates an interference fit.
Required Assembly Clearance - To determine the proper clearance for ease of assembly refer to Table 3-4.
Nominal Size Range (Inches) Class RC4 Clearance (Inches)
0.71 - 1.19 0.0028

1.19 - 1.97 0.0036
1.97 - 3.15 0.0042
3.15 - 4.73 0.0050
4.73 - 7.09 0.0057
7.09 - 9.85 0.0066
9.85 - 12.41 0.0075
12.41 - 15.75 0.0087
15.75 - 19.69 0.0105
Table 3-4: Required Assembly Clearances

Required Shrinkage. If the absolute value of the actual clearance is greater than or equal to the required clear-
ance, freezing of the part’s O.D. is not required. If the absolute value of the actual clearance is less than the
required clearance, freezing will be necessary to shrink the O.D. and permit easy assembly. The amount of shrink-
age is determined by adding the actual to the required. Refer to Subtopic 3.6.2 for examples of how to use the fol-
lowing tables to determine the amount of shrinkage that must be performed.
Freezing. To determine how cold a part needs to be, refer to:
• Table 3-5 for shrinkage of bronze bushings.
• Table 3-6 for shrinkage of solid pins or shafts.
BRONZE BUSHING SHRINKAGE ON DIAMETER

(Based on bronze bushings at 60° F before chilling. Dimensions inches.)
BUSHING O.D. (-75° F) (-100° F) (-125° F) (-150° F)
4.000 0.006 0.007 0.008 0.009
5.000 0.007 0.009 0.010 0.012
6.000 0.009 0.011 0.012 0.014
7.000 0.010 0.012 0.014 0.016
8.000 0.012 0.014 0.016 0.018
9.000 0.013 0.016 0.018 0.021
10.000 0.015 0.018 0.020 0.023
11.000 0.016 0.019 0.022 0.025
12.000 0.018 0.021 0.024 0.028
13.000 0.019 0.023 0.026 0.030
14.000 0.021 0.025 0.028 0.032
15.000 0.022 0.026 0.031 0.035
16.000 0.024 0.028 0.033 0.037
17.000 0.025 0.030 0.035 0.039
18.000 0.027 0.032 0.037 0.042
19.000 0.028 0.033 0.039 0.044
20.000 0.030 0.035 0.041 0.046
21.000 0.031 0.037 0.043 0.049
22.000 0.033 0.039 0.045 0.051
23.000 0.034 0.040 0.047 0.053
24.000 0.036 0.042 0.049 0.055
25.000 0.037 0.044 0.051 0.058
Table 3-5: Bronze Bushing Shrinkage on Diameter

Cold Pin (Shaft) Shrinkage on Diameter

(Based on Steel Pins at 60o F Before Chilling. Dimensions inches)
Pin Diameter or Dry Ice Liquid Nitrogen

Bushing O.D. (-100o F)
(-200o F) (-300o F)
4 0.004 0.007 0.010
5 0.006 0.008 0.012
6 0.007 0.010 0.014
7 0.008 0.012 0.017
8 0.009 0.014 0.019
9 0.010 0.015 0.022
10 0.011 0.017 0.024
11 0.012 0.019 0.026
12 0.013 0.020 0.029
13 0.014 0.022 0.031
14 0.015 0.024 0.034
15 0.017 0.025 0.036
16 0.018 0.027 0.038
17 0.019 0.029 0.041
18 0.020 0.030 0.043
19 0.021 0.032 0.046
20 0.022 0.034 0.048
21 0.023 0.035 0.051
22 0.024 0.037 0.053
23 0.025 0.039 0.055
24 0.027 0.041 0.058
25 0.028 0.042 0.060
Table 3-6: Cold Pin (Shaft) Shrinkage on Diameter
3.6.2 Clearance Examples
Examples of measurements and shrinkage required are given in Table 3-7.
In Example #1 a shaft must be installed in a bore. The clearance at ambient temperature is measured to be more
than the clearance required (from Table 3-4). No freezing is required for this fit.
In Example #2 a shaft must be installed in a bore. The clearance at ambient temperature is measured to be an
interference fit. The required clearance is then added to the amount of interference to indicate the required shrink-
age. The Temperature required to obtain this shrinkage is determined to be 200°F. This indicates that the shaft
should be frozen with Liquid Nitrogen to a temperature of -200°F.

In Example #3 a bushing must be installed in a bore. The clearance at ambient temperature is measured and
although an interference fit does not exist, the fit is tighter than the required clearance. The required clearance is
then added to the clearance amount to indicate the required shrinkage. The Temperature required to obtain this
shrinkage is determined to be -150°F. This indicates that the shaft should be frozen with Liquid Nitrogen to a tem-
perature of -150°F.
Clearance Examples (all Measurements Inches)
Examples Actual Clearance Required Required Shrinkage Required

(Measured) Clearance Temperature
(From Table 3-4) (From Table 3-5
or Table 3-6)
Example #1 Shaft O.D. 5.000 From Table 3-4 From Table 3-6
Bore I.D. -5.006 5" Shaft Not Required Shrinking
-0.006 0.0057 Actual Clearance Not Required
=0.006
Example #2 Shaft O.D. 6.0100 From Table 3-4 (Actual Clearance) From Table 3-6
Bore I.D. -6.0060 6" Shaft 0.0040 Temperature
0.0040 0.0057 (Required Clearance) Required
+0.0057
-200o F
(Required Shrinkage)
0.0097
Example #3 Bushing O.D. 8.0000 From Table 3-4 (Actual Clearance) From Table 3-5
Bore I.D. 8.0049 8" Bushing O.D. -0.0049 Temperature
-0.0049 0.066 (Required Clearance) Required
+.0066 -150°F
(Required Shrinkage)
0.017
Table 3-7: Clearance Examples (all Measurements Inches)
3.7 Lubrication During Assembly

The purpose of this topic is to address lubrication recommendations for assembly operations. This standard
applies to assembly activities of P&H Mining Equipment. It is the responsibility of each mechanic to comply with the
requirements of this standard to properly maintain P&H Mining machinery.
1. Check clearance and alignment of lube passages. Ensure labyrinth seals are correctly assembled per Sub-
topic 3.10.4.
2. Lubricate bearings per Subtopic 3.5.1.
3. Protectants and Lubricants:
• An oil-based corrosion inhibitor may be necessary if a gear case, or other assembly normally filled with oil,
is to be stored.
• Coupling: Motor to Swing Transmission — (5%) VCI (vapor corrosion inhibitors) - Pack /Texaco Multifak®
EP2 - Brown-Colored Grease.

• O-rings should be coated with grease before installation. Parts assembled in the factory will typically use an
aluminum complex grease (P&H 469).
• Couplings should be greased and the o-rings or seals coated with a petroleum-resistant sealing grease
(P&H 499).
• Lip Seal Cavities should be coated with grease before installation. The grease used should be compatible
with the grease that will be applied when it is installed on the machine. Parts assembled in the factory will
typically use an aluminum complex grease (P&H 469).
• Gear-and-shaft assemblies should be coated with grease where mating or where parts are slid across a
tight fit during assembly. The grease used should be compatible with the grease that will be applied when it
is installed on the machine. Parts assembled in the factory will typically use an aluminum complex grease
(P&H 469). Individual assembly procedures may specify a special grease or assembly paste.
• Prepump lube lines, bearings, and cavities whenever possible.
• Spline fits of all kinds should have Never-Seez applied. This includes couplings to shafts, pinions/gears to
shafts, and transmissions to shafts (but not inside a transmission).
• Threaded ends of shafts and pins should be coated with an aluminum complex grease (P&H 469).
• Non-rotating, non-lubricated pin connections should be coated with Never-Seez before assembly.
3.8 Guidelines for Gear Tooth Contact Patterns
3.8.1 General
This topic is to establish procedures for the minimum acceptable tooth contact pattern for gears after rolling the
mesh under no-load condition. The objective of this procedure is to provide and keep records of tooth contact pat-
tern for gears.
3.8.2 Contact Checks
The following procedure shall be followed for a contact check:
1. After final assembly of the gear set, rotate the assembly so the gear makes at least one complete revolution.
2. Apply a thin uniform layer of Dykem® Hi-Spot Blue no. 107 bluing compound to both sides of one tooth on the
pinion.
3. Roll the gear mesh until the blued pinion tooth comes in contact with a set of gear teeth. Roll pinion backward
and forward a few times to adequately transfer a layer of bluing onto the flanks of the adjoining set of gear
teeth. Mark the gear rim at that location, i.e. the location of the blued set of teeth, with a letter “A” using a paint
marking pen.
4. Apply 3M Scotch® Book Tape of proper width to cover face of gear tooth for transferring bluing impression of
gear teeth to the book tape. 3M Scotch Book Tape is available at any office product store and it is available in
different widths.

5. Paste book tape with bluing impression on the form # or document # containing information about the
machine’s serial number and the part number of the gear assembly being tested, the part numbers of the gear
and pinion, and the location on the gear, i.e. “A”.
6. Check contact pattern for acceptable contact pattern per Figures 3-34,, 3-35, 3-36, and 3-37.
7. Repeat steps 2 through 6 for two additional locations on gear, approximately 120° away from test location “A”
and mark these locations “B” and “C”.
Contact Deviation
If a contact pattern other than those shown in Step Step 6 above are observed, or contact patterns like those
shown in Figure 3-38 are observed, the assembly must be further evaluated to determine what is causing the unac-
ceptable contact pattern. The percentage of contact must not be less than that specified for the assembly. If the
root cause is found to be something that can not be corrected, it should be documented and forwarded to your P&H
MinePro Service representative for disposition.
The figures that follow show acceptable contact on gear teeth with various pinion configurations.
01 02 03
04 04 04
ES0620c_01
LEGEND
01. Ideal Center Contact - End Crown 03. Cross Bearing Misalignment - End Crown
02. Parallel Misalignment - End Crown 04. Uncrowned Length
Figure 3-34: Acceptable Contact on Gear Tooth with End Crown on Pinion
01 02 03
ES0619e_01
LEGEND 02. Parallel Misalignment - Center Crown

01. Ideal Center Contact - Center Crown 03. Cross Bearing Misalignment - Center Crown
Figure 3-35: Acceptable Contact on Gear Tooth with Center Crown on Pinion

04 04 04
01 02 03
ES0621c_01
LEGEND
01. Ideal Center Contact - Offset Crown 03. Cross Bearing Misalignment - Offset Crown
02. Parallel Misalignment - Offset Crown 04. Uncrowned Length
Figure 3-36: Acceptable Contact on Gear Tooth with Offset Crown on Pinion
01 02 03
ES0622c_01
LEGEND 02. Parallel Misalignment - No Crown
01. Ideal Center Contact - No Crown 03. Cross Bearing Misalignment - No Crown
Figure 3-37: Acceptable Contact on Gear Tooth with No Crown on Pinion or Gear
Refer to Figure 3-38. The figure below shows unacceptable contact in gear teeth.
*
*
06 06
01 02 03
04 05 ES0623c_01
LEGEND
01. Unacceptable Contact - Center Crown 04. Unacceptable Contact - Tip Contact Only
02. Unacceptable Contact - End Crown 05. Unacceptable Contact - Root Contact Only
03. Unacceptable Contact - Offset Crown *Any contact in Crown Area
Figure 3-38: Unacceptable Contact on Gear Tooth

3.8.3 Record Keeping
All records of form or document containing contact pattern must be kept on file permanently. In addition, these
records must be traceable to the gear case assembly by Serial Number and, in turn, the individual gear compo-
nents that went into the assembly by part numbers.
3.9 Shimming Shaft and Bearing Assemblies
3.9.1 General
These procedures apply to assembly activities on P&H Mining Equipment. These procedures are meant to define
the proper method for shimming shaft and bearing assemblies for clamping or end-play allowance. It is the respon-
sibility of all personnel to comply with the requirements of this standard to maintain a quality product.
Shims are also used in many areas of the shovel to adjust a gap for alignment. An example of this would be shim-
ming under the motor feet when aligning the motor shaft and gear case input shaft when doing coupling align-
ment. Shimming of this type will be called out in the individual installation or assembly topics for those particular
components.
1. Specific drawing or assembly instructions take precedence over these general procedures. Shimming to adjust
shaft and bearing assemblies is generally specified when necessary to:
• Clamp the bearing outer races in their housing.
• Provide clearance of the bearing outer race in their housing.
• Clamp the bearing inner race against a shaft shoulder.
• Seat an inner bearing race or member with clearance against a shaft shoulder.
• Adjust the internal preload or clearance end-play in single row tapered roller bearings.
• Shims may be used as a gasket. Instead of using a paper gasket, shim(s) may be used to seal between two
pieces, such as a cover and a housing. Many other areas where shims are used must be made oil-tight. A
leak may occur if the parts are not fit together correctly or if the shims are improperly calculated or installed.
2. Do not substitute shim materials without approval from P&H Mining Equipment Product Engineering.
3. Gauging; use of the appropriate measuring tools is required.
• Feeler gauges: metal gauges of varying thickness for measuring gaps or spaces between components to
thousandths of an inch.
• Depth micrometer: instrument for measuring the depth of holes, slots or depressions to thousandths of an
inch.
• Micrometer: instrument for measuring the width or thickness of components to thousands of an inch.
• Dial indicator: for measuring relative movement between parts for measuring gaps or spaces between com-
ponents to thousandths of an inch.

Shims will be measured in thousandths of an inch. One thousandth of an inch is equal to 0.0010". Shims used on
assemblies manufactured by P&H Mining Equipment typically do not use shims with metric thicknesses. Shim
thicknesses are in inches and should be calculated in inches, although a reference thickness in millimeters may be
provided.
3.9.2 Types of Shims and Use
Shims used on P&H Mining equipment are generally made from either plastic or metal material. They will be spec-
ified in technical manuals or drawings, and parts manuals or material lists by P&H part number.
Shims of many different thicknesses may be used on mining shovels. It is critical to determine the correct thickness
of the shims to be used so they are not applied incorrectly. Some shims have the thickness printed or stamped on
them. Others use different colors for different thicknesses. When in doubt the thickness should be checked with a
micrometer.
Three or more different thicknesses of shims will generally be called out on the material list or drawing for most
assemblies that require measurement and shimming. The number and thickness of shims must be determined
after the fit of the components is carefully measured. The amount of gap that is desired will be specified in the indi-
vidual assembly or installation topic.
Using the measurement and the specified gap, the correct total thickness of shims will be calculated. Once the total
amounted is calculated, the shim pack will be made up by selecting shims of different thicknesses and adding them
together to make up the total calculated amount. Examples are furnished at the end of this topic.
As a general rule, when selecting shims for a shim pack, shims of the largest possible thickness should be used
first. See the example below:
It is determined that the amount of shims needed is 0.050" (1.27 mm). Two thicknesses are available: 0.0200"
(0.508 mm) and 0.0050" (0.127 mm). In this example, 2 of the 0.0200" (0.508 mm) shims and 2 of the 0.0050"
(0.127 mm) shims are used. The total shim amount is now the 0.050" (1.27 mm) needed.
It is also usually desirable to use at least one shim of a small thickness when assembling a shim pack. It is not
uncommon to need minor adjustments to a shim pack once installed before final torquing of the fit. If the shims
selected for a shim pack are all of a large thickness, it will be necessary to remove a large shim and install smaller
shims in its place to make a minor adjustment. It would be much easier to just remove one small shim. When deal-
ing with large heavy components, or components where a number of screws are already installed, this could save
a lot of work. See the example below:
Plastic shims are being used to shim a bearing retainer for an assembly using single-tapered roller bearings.
The shim pack has been calculated to be 0.0200" (0.508 mm). Shims available are 0.0200" (0.508 mm),
0.0100" (0.254 mm), and 0.0050" (0.127 mm). In this example, 1 of the 0.0100" shims and 2 of the 0.0050"
(0.127 mm) shims are used. After the shims are installed and the cap screws are torqued the bearing clear-
ance is checked with a dial indicator. The clearance is found to be approximately 0.0050" (0.127 mm) too great
(we have over-shimmed by 0.0050" [0.127 mm]). In this case the cap screws can be loosened and 1 of the
0.0050" (0.127 mm) shims can be carefully removed with a razor knife without undoing the whole assembly.
3.9.2.1 Plastic Shims
Plastic shims are used extensively on assemblies on P&H Mining equipment. These shims are often color-coded.
Each different color refers to a particular thickness of the shim material.
Figure 3-38 shows an example where three different shim thicknesses have been provided. Each different thick-
ness is color-coded. The color-code and thickness for these plastic shims is shown in Table 3-8.

LEGEND
01. Blue Shim, 0.0050" thick 02. Transmatte Shim, 0.0075" thick 03. Yellow Shim, 0.0200" thick
Figure 3-39: Plastic Shims Example
Plastic Shim Stock Color Code for P&H Mining Equipment
Color Thickness Thickness Color Thickness Thickness

(inches) (mm) (inches) (mm)
Silver 0.0005 0.0127 Brown 0.0100 0.2540
Amber 0.0010 0.0254 Black 0.0125 0.3175
Purple 0.0015 0.0381 Pink 0.0150 0.3810
Red 0.0020 0.0508 Yellow 0.0200 0.5080
Green 0.0030 0.0762 White 0.0250 0.6350
Tan 0.0040 0.1016 Coral 0.0300 0.7620
Blue 0.0050 0.1270 Clear* 0.0400 1.0160
Transmatte** 0.0075 0.1905 Clear* 0.0500 1.2700
*The last color specified is Coral. Shims of a thickness larger than the Coral shim are made from clear plastic
stock.
**The color referred to as Transmatte can be described as a transparent matte color. It is transparent and
looks very similar to a Clear shim (see * above). However the Transmatte shim is very thin (0.0075") and
should be easy to differentiate from a Clear shim, which would be quite stiff. If there is any doubt the thick-
ness should be checked with a micrometer. Transmatte may also be referred to as simply Matte color in some
descriptions.
Table 3-8: Plastic Shim Color Code
3.9.2.2 Sheet Metal Shims
Shims made of sheet metal shim stock are common on P&H Mining Equipment. The metal shims are not color-
coded but often have the thickness printed on them. When in doubt, check the thickness with a micrometer.
Sheet metal shim stock may also be specified using the standard sheet metal gauge thicknesses. Table 3-9 shows
the sheet metal shim gauge numbers and the corresponding thicknesses.

Gauge Inches mm Gauge Inches mm
#3 0.2391 6.0731 #20 0.0359 0.9119
#4 0.2242 5.6947 #21 0.0329 0.8357
#5 0.2092 5.3137 #22 0.0299 0.7595
#6 0.1943 4.9352 #23 0.0269 0.6833
#7 0.1793 4.5542 #24 0.0239 0.6071
#8 0.1644 4.1758 #25 0.0209 0.5309
#9 0.1495 3.7973 #26 0.0179 0.4547
#10 0.1345 3.4163 #27 0.0164 0.4166
#11 0.1196 3.0378 #28 0.0149 0.3785
#12 0.1046 2.6568 #29 0.0135 0.3429
#13 0.0897 2.2784 #30 0.0120 0.3048
#14 0.0747 1.8974 #31 0.0105 0.2667
#15 0.0673 1.7094 #32 0.0097 0.2464
#16 0.0598 1.5189 #33 0.0090 0.2286
#17 0.0538 1.3665 #34 0.0082 0.2083
#18 0.0418 1.2141 #35 0.0075 0.1905
#19 0.0418 1.0617 #36 0.0067 0.1702
Table 3-9: Sheet Metal Shim Gauge Standards
Figure 3-40 shows two examples of slotted steel shims. The slots can be used as an insertion for a feeler gauge.
When the shims are installed and clamped in place, the shim pack thickness can be verified by inserting a feeler
gauge at the slots and measuring. Note that on the left shim 2 of the holes are not slotted. This special shim is used
on a gear case. These two holes must be oil-tight around two bolts. It is important this special shim gets installed
correctly, as orienting the slots onto the two oil-tight bolts would cause it to leak. Follow the specified procedure in
the assembly procedure provided.
Figure 3-40: Slotted Sheet Metal Shims

Shims are normally specified by P&H part number. Use the appropriate shim for the job specified. Some assembly
procedures may provide shim dimensions and specifications. These are provided so that the shims can be made
locally. Follow the assembly procedures or the drawing provided.
3.9.3 Shimming Bearing Retainer Caps That Clamp Bearing Outer Races in
Housing Bores
Use the following procedures to shim bearing retainers that clamp bearing outer races in housing bores:
1. With components (less shims) assembled, take up on retainer bolts in steps to 50% of full torque using a
torque pattern. Refer to Topic 3.3 for torque procedures. Rotate shaft while torquing to ensure bearing race is
fully seated in bore. Rap on housing next to bearing end retainer with a brass bar to help settle bearing outer
race in housing bore. Do not rap on bearing retainer.
2. Loosen retainer bolts evenly in steps using a torque pattern and retorque in sequence to 10% of full torque.
3. With feeler gauges, measure the gap between the retainer flange and the housing at four places evenly
spaced around the retainer and determine the average of the measurements. If the four measurements vary by
more than 0.010" (0.254 mm), repeat steps 1 and 2 above. If measurements still vary by more than 0.010"
(0.254 mm), further investigation to correct the problem is required.
4. From the shim pack select the shims that give this measurement less the clamping amount specified in the
assembly instructions or drawing. Check the total selected shim thickness with a micrometer. This will fill the
gap less a small amount to provide positive clamping of the bearing outer race yet allow the retainer flange to
bear down tightly against the shims to seal the gear case. Torque the retainer bolts to 10% of full torque and
check for looseness in the shims. If the shims are clamped down tight, repeat steps 1 thru 4; otherwise, torque
bolts to specified torque in sequence. After final torquing, the shims should be clamped tight.
NOTICE
When the measurement is not a multiple of the smallest available shim, the calculated shim
pack can not be obtained. Example: calculated shim pack equals 0.028" but the smallest shim
available is 0.005". It will not be possible to make a shim pack of 0.028" so the nearest possible
shim pack should be used. If a range is not specified for the desired shim amount, the best
judgment of the technician must be used (see the example below). For any questions, contact
your local P&H MinePro representative for guidance.
A practical example follows:
1. When installing the gear case cover plate for the hoist drum shaft (Figure 3-41), the cover will press against a
bearing retainer (10) which presses against the outer race of the bearing (11). Shims (05) are installed between
the cover plate and the gear case bearing block.
2. Assembly instructions are to measure gap between cover plate and gear case bearing block without shims and
with bearing tight against shoulder. Using the above procedure a measurement is taken of the gap between the
cover plate and the gear case bearing block, and is found to be 0.038".
3. Further instructions are to install shims equal to 0.010" less than the measured gap to insure bearing lockup. A
shim pack of 0.028" is calculated by subtracting (0.038"-0.010"=0.028"). The available shims are 0.005",
0.0075", and 0.020". This would mean a shim pack measuring 0.0275" in total can be used.

LEGEND
01. Cap Screw 08. Retainer Plate
02. Washer 09. Shims
03. Club 10. Bearing Retainer
04. Cover Plate 11. Spherical Bearing
05. Shims 12. Not Used
06. Tie Wire 13. Spacer
07. Cap Screw 14. Spacer
Figure 3-41: Hoist Drum Shaft Bearing Retainer Shimming

3.9.4 Shimming Bearing Retainer Caps That Provide Clearance to Bearing Outer Races in
Housing Bores
Use the following procedures to shim bearing retainer caps that provide clearance to bearing outer races in hous-
ing bores:
1. With components, less shims, assembled, take up on retainer bolts to 50% of full torque in sequence, refer to
Topic 3.3, while rotating shaft to ensure bearing race is seated and pushed far enough into bore. Rap on hous-
ing next to bearing end retainer with a brass bar to help settle bearing outer race in housing bore. Do not rap on
retainer.
2. Loosen retainer bolts evenly in sequence and retorque in sequence to 10% of full torque.
3. With feeler gauges measure the gap between the retainer flange and the housing at four places evenly spaced
around the retainer and determine the average of the measurements. If the four measurements vary by more
than 0.010", repeat steps 1 and 2. If measurements still vary by more than 0.010", further investigation to cor-
rect the problem is required.
4. From the shim pack select the shims that give this measurement plus the clearance amount specified on the
drawing. Check the total selected shim thickness with a micrometer. This will fill the gap plus provide the
required additional space for clearance for the bearing outer race and allow the retainer flange to bear down
tight against the shims to seal the gear case. Torque the retainer bolts to 10% of full torque and verify the shims
are clamped tight. If the shims are loose, repeat steps 1 through 4, otherwise torque bolts to specified torque in
sequence.
NOTICE
pack can not be obtained. Example: calculated shim pack equals 0.028", but the smallest shim
available is 0.005". It will not be possible to make a shim pack of 0.028", so the nearest possible
judgment of the technician must be used. For any questions, contact your local P&H MinePro
representative for guidance.
3.9.5 Shimming Shaft End Plates That Clamp Bearing Inner Races on Shaft Shoulders
Use the following procedures to shim shaft end plates that clamp bearing inner races on shaft shoulders:
1. With components (less shims) assembled, tighten on retainer bolts to 50% of full torque in sequence (refer to
Topic 3.3).

3. With a depth gauge measure the gap between the end plate and the shaft through holes in the plate. Two
holes are often provided for measurement. It is preferable to measure at both of the holes and take the aver-
age of the two measurements. To obtain the gap, take the depth measured and subtract the thickness of the
end plate as measured with a micrometer.
4. From the shim pack select the shims that give this measurement less the clamping amount specified on the
drawing. This will fill the gap less a small amount to provide positive clamping of the bearing inner race yet
allow the shaft end plate to bear down tight against the shims to prevent it from flexing against the bolts under
operating loads.
NOTICE

15, 16
01
02 10 13
06, 09
11
05 08
07
14 18, 19
03 12
04 17
TC0425b
LEGEND 10. O-ring

01. First Reduction Hoist Pinion 11. O-ring
02. Roller Bearing 12. O-ring
03. Bearing Spacer 13. Shims
04. Bearing Capsule 14. Shims
05. Bearing Retainer 15. Cap Screw
06. Seal Retainer 16. Lock Washer
07. End Plate Retainer 17. Set Screw
08. Disc Brake Hub 18. Cap Screw
09. Oil Seal 19. Tie Wire
Figure 3-42: End Plate Shimming
1. When installing the end plate for the hoist first reduction shaft (07, Figure 3-42), the end plate will clamp the
bearing (02) against the shoulder of the pinion (01). Because this is a double-tapered roller bearing, it is also
important that the inner races and spacer of the bearing be clamped together tightly. Shims (14) are installed
between the end plate and the end of the shaft to control the size of the gap between the shaft and end plate.
A gap must exist to provide positive clamping. But if the gap is too great it could allow the end plate to flex,
which could cause the cap screws (18) to loosen or break.

2. Assembly instructions are to measure gap without shims and with cap screws drawn up snug against plate.
Using the above procedure a measurement is taken of the gap between the end plate and the shaft, and is
found to be 0.123" (3.124 mm).
3. Further instructions are to install shims equal to 0.010" to 0.015" less than the measured gap to insure bearing
lockup. A shim pack of 0.108" to 0.113" is calculated by subtracting. The available shims are 0.005", 0.010",
0.020", and 0.040". This would mean a shim pack measuring 0.110" in total can be used.
3.9.6 Shimming to Seat an Inner Bearing Race or Member with Clearance Against a Shaft
Shoulder
Use the following procedures to shim to seat an inner bearing race or member with clearance against a shaft
shoulder:
1. With components, less shims, assemble take up on retainer bolts to 50% of full torque in sequence (refer to
Topic 3.3).
NOTICE
At this point the assembly instructions will often instruct the retainer bolts to be torqued to a
specified value for the measurement. Follow specific assembly instructions when applicable.
It is also common for the instructions to specify tightening retainer bolts while turning the shaft,
and feel for resistance to rotation as a sign the bearings are at a light preload. Measurement
would then take place at this light preload. Follow specific assembly instructions when applica-
ble.
3. With a depth gauge, measure the gap between the pin retainer end plate and the shaft through holes in the
plate. Two holes are often provided for measurement. It is preferable to measure at both holes and take the
average of the two measurements. To obtain the gap, take the depth measured and subtract the thickness of
the end plate as measured with a micrometer.
4. From the shim pack select the shims that give this measurement plus the clearance amount specified on the
drawing. This will seat the bolts, yet allow the assembly to have relative motion. If the assembly permits, verify
the existence of end play after assembly.
NOTICE

LEGEND
01. Key
02. Pin
03. Bearing Retainer
04. Roller Bearing
05. Sheave
06. Roller Bearing
08. Spacer
10. Roller Bearing
11. Sheave
12. Roller Bearing
14. Spacer
15. Shims
16. Pin Retainer End Plate
17. Cap Screw
18. Tie Wire
Figure 3-43: Boom Point Assembly Shimming

When installing the pin retainer end plate (16, Figure 3-43) for the boom point assembly, the pin retainer end plate
will press on four bearing retainers (03, 07, 09, and 13). These retainers are each mated to the inner race of a
single-tapered roller bearing (04, 06, 10, and 12). Because these are single-tapered roller bearings, it is important
that the inner races of the bearing are not clamped tightly against the outer races: end play must be included in the
assembly. Shims (15) are installed between the pin retainer end plate (16) and the end of the pin (02) to control the
size of the gap between the shaft and retainer plate. The correct gap must exist to provide the desired end play for
the bearings. This end play is critical to the life of the bearings.
1. Assembly instructions are without shims in place, gradually tighten two cap screws at 180° apart while rotating
both sheaves. Continue until you notice a slight drag on the sheaves. This would indicate a very slight preload
on the bearings.
2. At this point, measure the gap between the pin (02) end and retainer plate (16). For our example, a measure-
ment is taken of the gap between the pin retainer plate and the pin, and is found to be 0.212".
3. Further instructions are to install shim pack of thickness equalling the measured gap plus 0.000" to 0.005". The
available shim sizes are 0.005", 0.020", 0.0598" (#16 gauge), and 0.1793" (#7 gauge). Using one #7 gauge
shim, the shim pack used would be 0.1793". Add a 0.020" shim, and the shim pack becomes 0.1993". Finally,
adding 3 of the 0.015" shims would add 0.045" to the total shim pack, giving a final shim pack thickness of
0.2143". Installing our shim pack should give the assembly approximately 0.0023" end play.
NOTICE
It is extremely important when installing single-tapered roller assemblies like the boom point
assembly to add the shim amount to the measured gap, not subtract. If subtraction is used
here, and the shim pack becomes less than the measured gap, the bearings would not have
end play but would have a preload, which will affect the bearing life and performance.
4. After installing the shims and torquing the end plate, check the assembly by rotating the sheaves by hand.
Sheaves should not be harder to turn than in Step Step 1 above.
NOTICE
The complete assembly instructions are included in the boom point assembly, section x[?].
3.10 Sealing
3.10.1 General
This procedure applies to the P&H Mining Equipment assembly activity to establish methods of proper application,
installation, and assembly of seals and sealants.
It is the responsibility of all personnel to comply with the requirements of this standard to maintain a quality product.
The following procedures apply to typical seal and sealant applications on P&H Mining equipment.

3.10.2 Metal-to-Metal Joints
Use these general rules when working with metal-to-metal joints:
1. Ensure mating machined surfaces are free of debris and excess corrosion inhibitors.
2. Ensure mating surfaces are free of nicks, gouges, and burrs throughout. A single-cut flat mill file can be used to
remove any minor surface prominences.
3. Clean entire surface area(s) where sealant is to be applied, following the instructions included with the sealant.
Check expiration date on sealant to make sure sealant shelf life has not been exceeded.
4. Use only the sealant specified in the Maintenance Manual or on the Engineering Drawings that are provided.
Apply it only to the joint surface(s) shown on the drawing. Follow the application instructions included with the
sealant. Pay particular attention to the thickness specified with instructions.
NOTICE
Be careful not to allow sealant to get into any o-ring grooves or onto the o-ring itself if they are
present on the same surface(s) that the sealant will be applied to.
5. Protect the installed sealing material and non-coated mating surfaces from debris and damage until the two
surfaces are mated with each other at assembly. Follow instructions supplied with sealant as to time allowed
between its application and the mating of the two surfaces together.
3.10.3 Installation and Assembly of O-Rings
O-ring type seals are used as “continuous” (closed end), “split”, or “non-continuous” (open end) configurations. Fol-
lowing are procedures to be used for each of the three o-ring types.
3.10.3.1 Continuous Type O-Rings (As Received)
1. Assure machined grooves are free of debris and excess corrosion inhibitors.
2. Assure edges and ends of grooves are free of nicks, gouges, and burrs.
3. Assure all surfaces that o-ring will come in contact with during installation are free of nicks, gouges, and burrs.
4. Lubricate o-ring and all surfaces that will come in contact with the o-ring during installation with a thin film of a
suitable bearing grease.
5. Where necessary, cover irregular surfaces such as steps on O.D.’s and splines and keyways with tape or a thin
film of other suitable material. Also coat these surfaces with a thin film of bearing grease. This will prevent the
o-ring from catching on these surfaces as they are passed over.
6. Install o-ring into the groove. Be careful not to over-stretch or excessively roll it on itself when positioning it on
the part and sliding it towards and into the groove.
7. Protect the installed o-ring from debris and damage until mated with other components at assembly. (If in a
split bore, keep o-ring out of bore until cover is installed to avoid stretching o-ring.)

3.10.3.2 Split Type O-Ring
1. Ensure o-ring is cut to length such that there is a slight stretch after installation. Use o-ring groove as template
for length. Ensure cut ends are smooth and square.
2. Clean ends, apply adhesive, P&H Part Number 21Z516D2, or the part number specified on assembly drawing
and fasten ends together per instructions included with the adhesive.
3. Repeat steps 1 through 7 given under Subtopic 3.10.3.1.
3.10.3.3 Non-Continuous Type O-Ring (Open End)
1. Assure machined grooves are free of debris and excess corrosion inhibitors.
2. Assure edges and ends of grooves and corners in the groove pattern are free of nicks, gouges, and burrs.
3. Install o-ring into the groove. Carefully wrap it around any corners in groove pattern. Do not stretch o-ring dur-
ing installation! O-ring should extend beyond the end of the groove. Do not cut off excess length at this time. (It
will be cut flush with ends of groove once mating part is installed against it.) A thin film of bearing grease may
be applied to help hold o-ring in place, however, do not apply grease at end of o-ring or groove.
4. Protect the o-ring from debris and damage until mated with other components at assembly.
5. Assemble parts and clamp with fasteners specified.
6. Cut off excess o-ring material flush with end of o-ring groove using a sharp tool.
7. Use RTV (Room Temperature Vulcanizing) compound, P&H Part Number 21Z587D11 or other specified on
assembly drawing, force it into the end of the o-ring groove, making sure that all air gaps between the groove
and compressed o-ring are filled. Remove excess caulking by smoothing it flush with the edge of the groove
using a suitable straight edge tool.
3.10.4 Assembly of Labyrinth Seals
Labyrinth Seals achieve their sealing performance through the close clearances between the adjoining parts in the
assembly and the slinging action to the oil that contacts the rotating member(s) of the assembly. In addition the
drain holes and passages for the lubricant that is caught by the non-rotating member(s) must be of such a size and
contour to allow all lubricant to freely flow back into the enclosed part of the gear case structure. By adhering to the
following steps a functional Labyrinth Seal assembly will be assured.
1. Ensure all machined surfaces on all parts of the Labyrinth Seal are free of debris and excess corrosion inhibitors.
2. Ensure all mating surfaces and all surfaces that come in close contact with each other after assembly are free
of nicks, gouges and burrs. Pay particular attention to the O.D. surfaces of the slinger member ring(s) and col-
lection grooves I.D. surfaces in the mating outer member(s).
3. Ensure all lubricant drain passages within the gear case structure are continuous and free of debris or other
obstructions.
4. Ensure all lubricant drain passages in all non-rotating part(s) that collect lubricant are free of debris or other
obstructions.
5. Assemble all parts as shown in the Maintenance Manual or in the engineering drawing if provided.

6. Assure that all contacting passage ways between the assembled parts and the gear case structure are in-line
and will allow an unobstructed draining of collected lubricant after assembly.
7. Shim all anti-friction bearings as specified in the Maintenance Manual or in the engineering drawing if provided.
8. With all shims and / or gaskets in place, finish assembling any remaining parts on the shaft and properly torque
fasteners on both ends of the shaft assembly as specified in the Maintenance Manual or in the engineering
drawing if provided.
9. Rotate the shaft assembly and verify that no metal contact is taking place between any members of the Laby-
rinth Seal assembly. Where axial clearance exists within the shaft assembly, such as with most anti-friction
bearings, remove all such clearance in one direction before rotating the shaft. Repeat this procedure while
removing the axial clearance in the opposite direction.
Technician Tip
On occasion, rubbing may occur under load due to shaft deflections (e.g., crowd motor). Clear-
ance should be checked under load and rotation using a suitable device such as a heat gun.
3.10.5 Installation and Assembly of Lip Seals
Lip type seals are used as “continuous” (closed end) and “split” configurations. Some seal radially, and some by
clamping the side faces. Assemblies are designed differently for each type. Following are procedures to be used
for each of the two lip seal types.
3.10.5.1 Continuous Type Lip Seal (As Received)
1. Assure machined bores are free of debris and excess corrosion inhibitors.
2. Assure edge of bore that seal will press into is free of nicks, gouges, and burrs.
3. Assure all O.D. surfaces that seal will come in contact with during installation are free of nicks, gouges, and
burrs.
4. Lubricate seal lip and all surfaces that will come in contact with the seal lip during installation with a thin film of
a suitable bearing grease.
5. Where necessary, cover irregular surfaces such as steps on O.D.’s and splines and keyways with tape or a thin
film of other suitable material to guide it and act as shoehorn during installation of parts that slide into it. Also
coat these surfaces with a thin film of bearing grease.
6. Check assembly drawing for proper orientation of lip prior to installation.
7. Install seal into the bore. Press seal uniformly near its outer diameter. Be careful not to distort the outer diame-
ter (in particular a metal housing) or touch the seal lip spring or the lip itself with any installation tools during the
installation process. Check to verify 360° lip contact.
8. Protect the installed seal, and particularly the lip itself, from debris and damage until mated with other compo-
nents at assembly.

3.10.5.2 Split Type Lip Seal (As Received)
1. Ensure seal ends are cut smooth.
2. If specified, fasten seal ends together. Clean ends, apply adhesive, P&H Part Number as specified on the
drawing, and fasten ends together per instructions included with the adhesive. Where a garter spring is
involved, connect ends together in seal before installation.
3. Ensure machined bores are free of debris and excess corrosion inhibitors.
4. Ensure edge of bore that seal will press into is free of nicks, gouges, and burrs.
5. Ensure all O.D. surfaces that seal will come in contact with during installation are free of nicks, gouges, and
burrs.
6. Lubricate seal lip, and all surfaces that will come in contact with the seal lip during installation with a thin film of
a suitable bearing grease.
7. Where necessary cover irregular surfaces such as steps on O.D.’s, splines and keyways, with tape or a thin
film of other suitable material to guide it and act as shoehorn during installation of parts that slide into it. Also
coat these surfaces with a thin film of bearing grease.
8. Check drawing for proper orientation of lip and for proper location of split after installation.
9. Install seal into the bore. Press seal uniformly near its outer diameter. Be careful not to distort the outer diame-
ter (in particular a metal housing) or touch the seal lip spring or the lip itself with any installation tools during the
installation process. Check to verify 360° lip contact.
10. Protect the installed seal, and particularly the lip itself, from debris and damage until mated with other compo-
nents at assembly.
11. Seals that don’t seal on the O.D. must be clamped across their width.
NOTICE
In some instances the ends of a split seal may require a vulcanizing or special process when
being joined together. Follow the procedure specified in the assembly instructions.
3.10.6 Threaded Pipe Joints
1. Assure mating pipe threads are free of debris.
2. Assure mating pipe threads are free of nicks, gouges, and burrs.
3. Clean male and female threads where sealant is to be applied, following the instructions included with the pipe
thread sealant (also commonly referred to as “pipe dope”). Do not use Teflon® tape.
4. Apply a thin coat of pipe thread sealant to the male threads.

NOTICE
It is more important to cover all the threads completely rather than putting a heavy coat on only
some of the threads or only partially around them.
5. Apply a heavy coat (only enough to fill the “V” of the thread) of pipe thread sealant to only approximately the
first two threads of the female threads.
6. Protect the applied sealant and threads from debris and damage until the two surfaces are threaded together
at assembly. Follow instructions supplied with pipe thread sealant as to time allowed between its application
and the mating of the two surfaces together.
02 01
LEGEND
01. Imperfect Threads
Due to Chamfer
on Die ES0521b01
02. Taper of Thread
1 in 16 Measured
on Diameter
Figure 3-44: Pipe Thread Engagement

Thread Engagement of Standard Pipe
Nominal Outside Threads Hand-tight Effective Thread,

Pipe Diameter of Pipe per Inch Engagement External
Size (D) (L1) (L2)
Inches Inches Inches Threads Inches Threads
1/16 0.3125 27 0.160 4.32 0.2611 2.05

1/8 0.405 27 0.1615 4.36 0.2639 7.12
1/4 0.540 18 0.2278 4.10 0.4018 7.23
3/8 0.675 18 0.240 4.32 0.4078 7.34
1/2 0.840 14 0.320 4.48 0.5337 7.47
3/4 1.050 14 0.339 4.75 0.5457 7.64
1 1.315 11¾ 0.400 4.60 0.6828 7.85
1 1/4 1.660 11¾ 0.420 4.83 0.7068 8.13
1 1/2 1.900 11¾ 0.420 4.83 0.7235 8.32
2 2.375 11¾ 0.436 5.01 0.7565 8.70
2 1/2 2.875 8 0.682 5.46 1.1375 9.10
3 3.500 8 0.766 6.13 1.2000 9.60
3 1/2 4.000 8 0.821 6.57 1.2500 10.00
4 4.500 8 0.844 6.75 1.3000 10.40
5 5.563 8 0.937 7.50 1.4063 11.25
6 6.625 8 0.958 7.66 1.5125 12.10
8 8.625 8 1.063 8.50 1.7125 13.70
10 10.750 8 1.210 9.68 1.9250 15.40
12 12.750 8 1.360 10.88 2.1250 17.00
Table 3-10: Thread Engagement of Standard Pipe
7. Assemble the parts. Use the thread engagement length found in Table 3-10 as a rough guide for proper thread
engagement and tightening. Typically tightening using standard pipe wrenches or mechanics wrenches and
applying normal ergonomic force is sufficient to achieve a functional pipe thread seal.
NOTICE
High pressure applications, usually those utilizing extra-strong or double-extra-strong pipe and
fittings, may require additional torque to properly seal the joint. Whenever in question as to the
adequacy of the joint to resist leakage, make a sample joint and pressure test it with a suitable
gas or liquid.


ES41157 Mechanical Systems Manual General Inspection
Section 4
General Inspection
4.1 Predictive Diagnostics
Figure 4-1: P&H MinePro® Services Predictive Diagnostics Van
P&H Mining Equipment recommends that regular testing be conducted on the four motion systems (hoist, crowd,
swing, propel) of the mining shovel. Regular testing should include sampling oils, analyzing vibration, and checking
for excessive heat buildup.
P&H has dedicated technicians specifically trained in Predictive Diagnostics. P&H MinePro Predictive Diagnostics
personnel are available to provide immediate, on-site information. The Predictive Diagnostics team will check:
4.1.1 Motors
• Collect and analyze vibration data on rolling element bearing housing and associated blower motor.
• Electrically test and visually inspect DC motors off-line to determine winding integrity.
4.1.2 Transmissions
• Sample and screen lubricating fluid for bulk chemistry change, viscosity change, contamination and relative
wear particle concentration.
• Perform detailed oil analysis where necessary.

Sec04GenInsp.fm -4.1- Section 4, Version 00 - 06/07
General Inspection ES41157 Mechanical Systems Manual
• Collect and analyze vibration data on rolling element bearing housings.
4.1.3 Drives (AC/DC converters, reactive power compensator)
• Scan all components visible through opened cabinet doors using infrared thermography.
• Survey system for corona, insulation tracking, partial discharge and arcing using ultrasonic detection.
Regular monitoring by P&H Predictive Diagnostics personnel should be included in any inspection plan of a P&H
mining shovel. Information on the Predictive Diagnostics service is available from your local P&H MinePro office.
4.2 Wire Ropes and Strand Cables
Figure 4-2: Hoist Ropes and Boom Suspension Cables
4.2.1 General
To achieve greatest reliability, availability and performance, always replace wire rope according to the equipment
manufacturer’s or wire rope manufacturer’s specifications. Ideally, frequent inspections should be used to deter-
mine that point at which the rope has nearly reached the end of its service life. Ropes should be changed as late as
possible, but before they break. While regular inspection and maintenance are required for maximum wire rope life,
sometimes those services don’t get the attention they deserve. The result can be many thousands of dollars
wasted due to untimely rope change-outs, machine downtime and lost productivity.
It is important to follow the specifications for length, diameter, class construction, breaking force, and type of rope
attachments or terminations. Maintaining two-and-one-half to three wraps of rope on the drum for all authorized
working conditions determines the shortest length.
NOTICE
Physical dimensions of the outer geometry of rope attachments can vary from one manufac-
turer to another. Do not change suppliers without first verifying that the rope and its attachments
will fit into physical opening and permit the normal range of movement after installation. For
best results, always use P&H MinePro Wire Rope.

Section 4, Version 00 - 06/07 -4.2- Sec04GenInsp.fm
No precise rules can be given for determining the exact time for replacement of wire rope and strand since many
variable factors are involved. Variables that can affect rope and strand life include:
• Number of hours in service.
• Type of application (how the rope is used, the loads applied to it, and frequency of use).
• Presence of plastic coating.
• Frequency of lubrication, or lack of lubrication (uncoated rope).
• Effect of a corrosive environment.
• Rock damage.
• A lack of maintenance, which contributes to reduced rope and strand working life.
The remaining strength and safety of a wire rope or strand in continued use is determined by careful inspection for
signs of deterioration.
NOTICE
Change-out criteria will vary based on the application. Hoist rope replacement criteria, for
example, will differ from trip rope discard criteria.
Use the following criteria when evaluating the condition (strength and safety) of wire rope and strand. If any doubt
exists about the remaining useful life of a wire rope or strand, it should be removed from service.
LEGEND
01. Core
02. Outer Wire
03. Wire
04. Strand
Figure 4-3: Wire Rope Construction

4.2.2 Criteria for Replacement of Running Ropes
Figure 4-4: Hoist Ropes (Typical)
1. While no regulatory criteria exist for mining shovels, six or more randomly distributed broken wires in one lay,
or three or more broken wires in one strand in one lay.
A rope lay is the length along a rope that corresponds to one full turn of a strand around the rope. Pick one
strand, and imagine a longitudinal line along the length of the rope. Pick a starting point on one strand on that
line, and follow that strand around the rope until it again reaches the longitudinal line. The length from start to
finish is one rope lay.
• The number of wire breaks that cannot be accepted varies with rope usage and construction. For general
applications, this six-and-three criteria is satisfactory.
• Mine operators using draglines apply this criteria for hoist ropes only.
2. One outer wire that is broken at the contact point with the core of the rope and that has worked its way out of
the rope structure and protrudes or loops out from the rope structure.
3. Wear of one-third of the diameter of outside individual wires from abrasion as the rope moves through an abra-
sive medium or over drums and sheaves.
4. Kinking, crushing, cutting, “birdcaging”, un-stranding or any other damage resulting in distortion of the rope
structure.
5. Evidence of any heat damage from any cause, including an electric arc.
6. Protruding core (from an opening between strands).
7. Valley breaks — when two or more wire fractures are found.
8. Severe corrosion — particularly in the vicinity of end attachments.
9. Reductions from nominal rope diameter of more than 10% of a new rope after installation or an observable
increase in rope lay length. This reduction can be attributed to:
• Loss of core support from inner wire breakage.
• Internal or external corrosion.
• Wear of outside wires from excessive external abrasion.

LEGEND
01. Actual Diameter
02. Correct
03. Incorrect
Figure 4-5: Measuring Wire Rope Diameter
• Loosening or tightening of rope lay.
• Rope stretch.

• “Ironing” or “milking” of strands (progressive movement of strands along the axis of the rope resulting from a
rope’s movement through a restricted passage such as a tight sheave).
LEGEND
01. Check Sheave Grooves for
Cracks and Wear
02. Cable “Print” in Sheave Could
Damage New Cable
03. Check Sheave Bearings for
Wobble, Ease of Rotation and
Lubrication
Figure 4-6: Sheave Inspections

4.2.3 Criteria for the Discard of Suspension Cables
Figure 4-7: Suspension Cables
Bridge Strand. The replacement criteria for bridge strand suspension cables is 25% of the outer wires broken.
Wire Rope. Replacement criteria for wire rope suspension cables are:
1. More than two broken wires in one strand in one rope lay.
2. More than six broken wires in a length of one rope lay.
These inspection criteria are for mining shovels.
4.2.4 Criteria for the Discard of Strand Cables
1. Visible or sounding breaks in 25% of the outer wires or 10% of the total, whichever is less; or 10% loss of
strength based on size and load capacity of each broken wire.
2. Significant rust staining at the socket termination, indicating internal corrosion and possible wire breaks.
3. Significant reduction in diameter at the socket, indicating internal core breakage.
4. Excess catenary — the curve assumed by a perfectly flexible inextensible cord of uniform density and cross
section hanging freely from two fixed points — indicating internal wire breaks and loss of load-carrying ability.
4.2.5 Inspection Guidelines
1. Inspect the rope throughout its length.
2. Examine the termination points at the end of both moving and stationary ropes.
3. Any portion of a moving rope that encounters repetitive contact and flexing operations such as blocks, drums
or sheaves.
4. Any part of the rope exposed to repeated or prolonged wear conditions, abrasion, heat, or corrosive environments.

4.3 Gear Inspection
Figure 4-8: Gear Inspection
4.3.1 General
Gears should be inspected on a regular basis. P&H Mining Equipment recommends that gears be visually
inspected every year. If operating conditions are extreme or if oil analysis is not a regular part of maintenance pro-
cedures, more frequent visual inspections are recommended.
These inspections will show the condition of the gears. The inspection will be somewhat subjective, since one
observer’s “failure” is another observer’s “run-in”. There is no single definition of gear failure: whether or not a gear
has failed depends on the specific application. Regular inspection will reveal trends, however; depending on
observed wear, preventive or corrective actions can be implemented before catastrophic failure occurs. Addition-
ally, these inspections can be of significant value in predictive maintenance and planned component replacement
programs.
The inspection parameters described in this section are points of observation for gear trains in P&H mining equip-
ment. They are typical of conditions associated with the way these machines are operated. The list is not exhaus-
tive. The inspector must use judgment and experience in recommending preventive or corrective actions based on
conditions observed.
4.3.2 Wear
Wear is a term describing change to a gear tooth surface involving the removal or displacement of material, due to
mechanical, chemical, or electrical action. Several classifications of wear are covered in the following paragraphs.
4.3.2.1 Adhesion
Adhesion is caused by transfer of material from one tooth surface to another due to microwelding and tearing. It is
confined to surface films and oxide layers on the tooth surface. It can be classified as Mild, Moderate, or Severe.
Mild adhesion typically occurs during running-in and usually subsides after it has smoothed the tooth surfaces by
removing minor imperfections through local wear. To the unaided eye, the tooth surface appears undamaged and
the original machining marks are visible.

Adhesion is classified as Moderate if it removes some or all of the original machining marks from the active surface
of the tooth. Under certain conditions, adhesion may cause continuous removal of surface films and oxide layers,
resulting in Severe wear. Other terms for severe adhesion include scoring and scratching.
PROBABLE CAUSE: Lubricant viscosity is too low.
CORRECTIVE ACTION: Increase oil viscosity.
4.3.2.2 Abrasion
Abrasion occurs when hard particles such as scale, rust, sand, or metallic debris are suspended in the lubricant.
Damage will result if particles with a hardness near or above that of the gear tooth surface and with a diameter the
same or larger than the thickness of the film are trapped between meshing teeth. Other terms describing this con-
dition are cutting and burnishing.
Grease lubricated drives are particularly prone to this problem since any random particles are not washed away
but retained near the mesh. Open gears, which are often lubricated with adhesive lubricants, are particularly prone
to this type of problem.
Figure 4-9: Abrasion at the Tip of Gear Teeth
Scoring. Scoring is, in reality, scratching and is classified as a form of abrasive wear. If the combination of load,
sliding velocity, and oil temperature reach a critical value (dependent on material/lube combination), the oil film
separating the mating surfaces is destroyed and metal-to-metal contact occurs. If the surface pressure and sliding
velocity are high enough, instantaneous welding of the asperities will then occur. As the gears continue to rotate,
the welds break.
Scoring is not a result of fatigue. Although its effect worsens with time and the destruction of the tooth profile is pro-
gressive, it will usually occur within the first 10 to 30 minutes of operation at a specific condition or it will not occur
at all at that specific condition. The word specific is emphasized because if conditions change, scoring can occur at
any time. For example, if load is increased; if the load capacity of the lubricant is diminished (by contamination,
heat, etc.); if contamination is introduced; or if operating speed is changed, scoring may occur in a very short time
in a gear case that has been operating satisfactorily for a long period of time. If conditions are severe enough, even
rather short transient conditions can produce scoring. Because scoring is not related to fatigue, gear cases (espe-
cially those working under high speed, high load conditions) should always be examined visually.

Figure 4-10: Scoring
If the operating conditions are far beyond the critical point or if moderate scoring is not recognized and dealt with,
scoring will generally lead to destruction of the tooth profile. Profile destruction will result in a stress concentration
point along the pitchline. Frequently, this results in pitting and spalling in the pitchline area. The integrity of the gear
train then degenerates, eventually resulting in the production of fine metal particles, destruction of the tooth profile,
and finally breakage of the tooth.
4.3.2.3 Polishing
Polishing is fine-scale abrasion that causes gear teeth to have a bright finish. The gear tooth surface may be
smooth or wavy with local bumps. Polishing is promoted by chemically active lubricants that are contaminated with
fine abrasives.
Figure 4-11: Polishing

Mild polishing occurs typically during run-in and stops before the machining marks are worn away. Polishing is con-
sidered moderate if some, but not all, of the original machining marks are still visible. When all of the original
machining marks are worn from the surface of the tooth, the polishing is considered severe.
PROBABLE CAUSE: Contaminants in the lubricant; improper lubricant viscosity.
CORRECTIVE ACTION: Be certain that the system is clean at start-up and that it does not get contaminated during
operation. All P&H gear cases are lubricated using a bath and splash system. Oil in these systems should be changed
at least every 6 months. More frequent oil changes may be required in extreme operating conditions. Abrasive failures
may occur after other failures (such as a bearing failure) if the gear case is not thoroughly flushed at overhaul or if
repairs are made on-site.
Some gear cases, such as shovel hoist gear cases and others, also use a circulating oil system. Circulating oil sys-
tems are equipped with strainers and filters. Strainers should be removed and cleaned at every preventive mainte-
nance; filters (both in-line and breather) should be monitored closely and cleaned or replaced when indicated.
4.3.2.4 Scuffing
Scuffing is severe adhesion that causes transfer of metal from one tooth surface to another due to welding and
tearing. Scuffing is not a result of fatigue, and it may occur instantaneously.
Scuffing is classified as mild if it occurs only on small areas of the teeth and is confined to the peaks of the surface
asperities. Moderate scuffing occurs in patches that cover significant portions of the teeth. If the operating condi-
tions do not change, moderate scuffing may be progressive. Severe scuffing occurs on significant portions of the
gear tooth. In some cases the surface material may be plastically deformed and displaced over the tip of the tooth
or into the root of the tooth. Unless corrective measures are taken, severe scuffing is usually progressive.
Figure 4-12: Scuffing

4.3.2.5 Corrosion
Corrosion is the chemical or electrochemical reaction between the surface of a gear and its environment. Corrosion
within a gear case can lead to destructive wear. The effect of the corrosion is two-fold. First, the finish on the teeth
is damaged by the corrosion and, second, by reducing the area in contact, the unit loading on the tooth surface is
increased. In both cases, wear will accelerate.
P&H specifies Extreme Pressure (EP) oil for lubricating gear cases. EP oils are chemically active; when they break
down, corrosive chemicals in the lubricant attack gear teeth. This can cause corrosion.
Corrosion may also be the result of contamination from outside sources. Corrosive atmospheres can enter the box
through the breathers and thus damage the system. In such cases, effort should be made to reduce or eliminate
the source of contamination. Even relatively innocuous environments can cause corrosion if some component
reacts unfavorably with the oil. For example, some synthetic oils are quite hygroscopic; thus, if operated in even a
mildly humid atmosphere, they readily absorb water. If the gear case is used frequently and the operating temper-
ature of the oil gets high enough, the water is released from the oil and little harm is done. If however the operating
temperature is low or if the gear case is not operated for long periods of time, corrosion could occur.
PROBABLE CAUSES: Oil breakdown; contamination of lubricant from outside sources; chemicals on tooth surfaces
from storage or surface treatments.
CORRECTIVE ACTION: Monitor oil condition and/or change frequently. Protect gear case oil from the environment or
remove source of contamination. Control processes to insure removal of such contaminants.
COMMENT: EP oils are chemically active and must be monitored frequently to insure that they are not breaking down.
4.3.3 Plastic Deformation
Plastic deformation is permanent deformation that occurs when the stress exceeds the yield strength of the mate-
rial. It may occur at the surface or subsurface of the active flanks of the gear teeth due to high contact stress, or at
the root fillets of the gear teeth due to high bending stress.
4.3.3.1 Tip-to-Root Interference
Plastic deformation, adhesion, and abrasion may occur on the tooth tips of one gear and in the roots of the mating
gear teeth due to tip-to-root interference. The area of greatest concern is the dipper handle rack as it meshes with
the shipper shaft pinion. If the specified clearances and adjustments are not maintained on this system, pinion
damage can result.
4.3.3.2 Rolling
Plastic deformation may occur on the active flanks of gear teeth caused by high contact stresses in combination
with both the rolling and sliding action of the gear mesh. Displacement of surface material may form a groove along
the pitchline and burrs on the tips and in the roots of the driving gear teeth. The surface material of the driven gear
may be displaced toward the pitchline forming a ridge.

Figure 4-13: Rolling
4.3.4 Contact Fatigue
Pitting (Macropitting). Macropitting may occur when fatigue cracks initiate either at the surface of the gear tooth
or at a shallow depth below the surface. The crack usually propagates for a short distance in a direction roughly
parallel to the tooth surface before turning or branching to the surface. When the cracks have grown long enough
to separate a piece of the surface material, a pit is formed. The edges of a pit are usually sharp and angular.
Cracks may be found near the boundary of the pit and fatigue “beach marks” may be evident on the crater bottom.
Based on the nature and severity of the damage, macropitting can be categorized as non-progressive, progres-
sive, flake, or spall.
Initial Pitting. Nonprogressive macropitting normally consists of small pits less than 0.040" (1 mm) in diameter.
They occur in localized areas and tend to redistribute the load by removing high asperities. When the load is more
evenly distributed, the macropitting stops.

Figure 4-14: Initial Pitting
Progressive Pitting. Progressive macropitting normally consists of pits significantly larger than 0.040" (1 mm) in
diameter. Pitting of this type may continue at an increasing rate until a significant portion of the tooth surface has
pits of various shapes and sizes.
Figure 4-15: Progressive Pitting
Flake Pitting. Flake macropitting consists of pits that are relatively shallow but large in area. The fatigue crack
extends from an origin at the surface of the tooth in a fan-shaped manner until thin flakes of material break out and
form a triangular crater.

Spalling. Spall macropitting is progressive macropitting that occurs when pits coalesce and form irregular craters
that cover a significant area of the tooth surface.
Figure 4-16: Spalling
Micropitting. Micropitting gives the gear tooth a frosted, matte, or gray stained appearance. Under magnification,
the surface appears to be covered by very fine pits (normally less than 0.0008" [20 µm] deep). Metallurgical sec-
tions through the micropits show fatigue cracks that are inclined to the surface at an angle of less than 45°. The
cracks may extend deeper than the visible micropits. Micropitting occurs most frequently on surface hardened gear
teeth, although it may also occur on through-hardened gear teeth. It may occur anywhere on the active profile of
the gear tooth.
Subcase Fatigue. Subcase fatigue, sometimes called case crushing, may occur in surface-hardened gears (such
as P&H Mining Equipment’s induction hardened and/or flame hardened gears). The origin of the fatigue crack is
below the surface of the gear teeth in the transition zone between the case and core. Typically, the crack runs par-
allel to the surface of the gear tooth before branching to the surface. The branched cracks may appear at the sur-
face as fine longitudinal cracks on only a few teeth. The surface may break away. Fatigue beach marks may be
evident on the crater bottom formed by propagation of the main crack.
4.3.5 Cracking
Aside from cracks in the gear tooth root fillets caused by bending fatigue, cracks may occur elsewhere on the gear
due to mechanical, thermal, or other stresses.

4.3.5.1 Fatigue Cracks
Fatigue cracks are cracks which propagate under the influence of repeated alternating or cyclic stresses which are
below the tensile strength of the material. These cracks can appear in tooth flanks and in tooth root fillets. If not
detected and corrected, fatigue cracks often lead to fatigue fracture.
Figure 4-17: Fatigue Crack
4.3.6 Fracture
When a gear tooth is overloaded it may fail by plastically deforming or fracturing. If it fractures, the failure may be a
ductile fracture preceded by appreciable plastic deformation, a brittle fracture with little prior plastic deformation, or
a mixed mode fracture exhibiting both ductile and brittle characteristics. Fatigue failures usually culminate in a frac-
ture when the fatigue cracks grow to a point where the remaining tooth section can no longer support the load. In
this sense the remaining material is overloaded; however, the fracture is a secondary failure mode that is caused
by the primary mode of fatigue cracking. Fractures are classified as brittle or ductile depending on their macro-
scopic and microscopic characteristics.
Overload breakage usually occurs as a result of a single application, or very few applications, of very high load.
Sometimes a crack initiated by an overload will progress as a fatigue crack with slow propagation, usually with evi-
dence of fretting corrosion in the region of the initial crack. There are three types of overload fracture: brittle frac-
ture, ductile fracture, and mixed mode fracture.

4.3.6.1 Brittle Fracture
Brittle fractures, also called fast fractures, are characterized by rapid crack propagation without appreciable gross
plastic deformation. Brittle fractures have a bright, granular appearance. The fracture surface is generally flat and
perpendicular to the direction of the maximum tensile stress. Radial ridges or a chevron pattern may be present on
the fracture surface pointing toward the origin of the crack. On a microscopic level, brittle fracture typically consists
of transgranular cleavage facets or intergranular facets.
Figure 4-18: Brittle Fracture
If the load applied to a gear set causes stresses in excess of the ultimate strength of the material, an overload
fracture will occur. Overload fractures occur suddenly, and usually several adjacent teeth will fail almost
simultaneously.
4.3.6.2 Ductile Fracture
Ductile fractures are sometimes called smearing. They are characterized by tearing of metal accompanied by
gross plastic deformation. Ductile fractures have a gray, fibrous appearance. The fracture surface may have a flat
or slant orientation to the direction of the maximum tensile stress. The fracture surface may terminate with a shear
lip that extends along the nonworking side of the gear tooth.
4.3.6.3 Mixed Mode Fracture
A local area of a fracture surface may exhibit both ductile and brittle characteristics. Under these conditions, the
fracture is termed mixed mode (or semi-brittle). This is not to be confused with a fracture surface having features
that suggest successive crack propagation by different mechanisms, such as a fatigue crack causing a ductile
fracture.

4.3.6.4 Tooth Shear
When teeth are sheared from gears, the appearance of the sheared surfaces is similar to that of machined sur-
faces. Tooth shear is almost always caused by a single severe overload.
Figure 4-19: Tooth Shear

4.3.7 Bending Fatigue
4.3.7.1 General
Fatigue is a progressive failure consisting of three distinct stages:
Stage 1 Crack initiation;
Stage 2 Crack propagation;
Stage 3 Fracture.
Most of the fatigue life is occupied by stages 1 and 2 until the cracks grow to critical size where a sudden fracture
occurs in stage 3. The fracture may be ductile, brittle, or mixed mode, depending upon the roughness of the mate-
rial and the magnitude of the applied stress. During stage 1 the peak bending stress is less than the yield strength
of the material and no gross yielding of the gear teeth occurs. However, local plastic deformation may occur in
regions of stress concentrations or areas of structural discontinuities such as surface notches, grain boundaries, or
inclusions. The cyclic, plastic deformation usually occurs on slip planes that coincide with the direction of maximum
shear stress. The cyclic slip continues within the slip planes of a few grains, usually near the surface where the
stress is highest, until microcracks are initiated. The cracks grow in the planes of maximum shear stress until they
form a major crack.
The stage 2 propagation phase begins when the crack turns and grows across grain boundaries in a direction
approximately perpendicular to the maximum tensile stress. During the propagation phase, the plastic deformation
is confined to a small zone at the leading edge of the crack, and the surfaces of the fatigue crack usually appear
smooth without signs of gross plastic deformation. Under the scanning electron microscope, contours, called
fatigue striations, may be seen on a fatigue-cracked surface. They are thought to be associated with alternating
blunting and sharpening of the crack tip and correspond to the advance of the crack during each stress cycle. The
orientation of the striations is at 90° to the crack advance. If the crack propagates intermittently, it may leave a pat-
tern of macroscopically visible “beach marks”. These marks correspond to positions of the crack front where the
crack stopped. The origin of the fatigue crack is usually on the concave side of curved beach marks and is often
surrounded by several concentric beach marks. Beach marks may not be present, especially if the fatigue crack
grows without interruption under cyclic loads that do not vary in magnitude. The presence of beach marks is a
strong indication that the crack was due to fatigue; but not absolute proof, because other failure modes may leave
beach marks (for example, stress corrosion under changing environment). If there are multiple crack origins, each
producing separate crack propagation zones, ratchet marks may be formed. They are caused when adjacent
cracks, propagating on different planes, join together to form a step. Ratchet marks are often present on fatigue-
cracked surfaces of gear teeth because the stress concentration in the root fillet frequently initiates multiple fatigue
cracks.
4.3.7.2 Low Cycle Fatigue
Low cycle fatigue is defined as fatigue where macroscopic plastic strain occurs in every cycle and the number of
cycles to failure is low (typical about 1,000 to 10,000). Cracks may initiate within the gear teeth, as well as on the
surface, and a smaller fraction of the life is spent initiating rather than propagating cracks.

4.3.7.3 High Cycle Fatigue
High cycle fatigue is defined as fatigue where the cyclic stress is below the yield strength of the material and the
number of cycles to failure is high. Most gear tooth bending failures are due to high cycle fatigue rather than low
cycle fatigue. A large fraction of the life is spent initiating rather than propagating cracks.
Root Fillet Cracks. Although bending fatigue cracks may occur elsewhere, they usually initiate in the root fillet on
the tensile side of the gear tooth.
Profile Cracks. Fatigue cracks may initiate on the active surface of the gear tooth if there are stress concentra-
tions caused by macropits or material flaws.
Tooth End Cracks. Fatigue cracks may initiate at an end of the gear tooth if the load is concentrated at the tooth
end. Stress concentrations or material flaws at the ends of the teeth may also be responsible for tooth end cracks.

ES41157 Mechanical Systems Manual Disc Brakes
Section 5
Disc Brakes
5.1 General
Figure 5-1: Disc Brake (typical)
Disc brakes are used as holding brakes on the hoist, crowd, swing and propel motions.
Disc brakes are set by springs and released by compressed air. They are designed as parking (holding) brakes
only, and are considered “static” brakes. All shovel motions are designed to be stopped by electrical control, and
then once stopped, held by the disc brakes. The disc brakes are capable of stopping and holding a motion in a
moving condition, but repeated use in this manner will lead to premature failure of disc brake components. Proper
operation is to first stop the motion with the motors. Then, when all motion has stopped, apply the brakes.
5.2 Theory of Operation

The shovel’s Centurion Control System program contains the logic that controls shovel functions. Among these
systems are the shovel brakes, which depend on air pressure to release. Air pressure is made available when the
Centurion Control System causes the air solenoid valve to function, and that is dependent on the Centurion Control
System receiving specified inputs. For example, some of these required inputs are that the shovel main air pres-
sure must be at least 125 psi, the shovel must be in RUN mode, and the operator BRAKE RELEASE push button
must be pressed. When the Centurion Control System senses all required inputs and does not sense any limiting
inputs, then the brake air valve solenoid will be energized, and the brake will be released. When the Centurion
Control System senses further inputs (specified air pressure at the brake air pressure transducer and confirmation

Sec05Brakes.fm -5.1- Section 5, Version 00 - 06/07
Disc Brakes ES41157 Mechanical Systems Manual
from the brake release indicator that the brake has released), the Centurion Control System will permit function of
the motion controller.
Each brake has two proximity sensors. A brake set/release indicator indicates when the brake is released; a brake
wear indicator indicates when the brake is worn to the point where service is required. These sensors are adjusted
at the factory and should not require further adjustment. In the event of physical damage requiring adjustment or
replacement of these indicators, contact your local P&H MinePro Services representative.
02
01
LEGEND
01. Brake Set/Release Indicator
02. Brake Wear Indicator
ES0435a01
Figure 5-2: Brake Indicator Microswitches

Section 5, Version 00 - 06/07 -5.2- Sec05Brakes.fm
5.2.1 Brake System Schematic
13 14
27
12
12
11 26 26
11
20 25 25
10 10
09 09 24 24
19
08 08 23
23
18
B A B A
B A
22 22
07 P P P
17
B A
06 07 P
21
05 34
33 33 32
04
33
32
03 31 32
02 31
31
30
30 30
16
15 29 29
TC2071c 29
B A
01 P
28
LEGEND
01. Air Line from Air Receiver 18. Crowd Brake Pressure Transducer
02. Air Swivel 19. Quick Release Valve
03. Lower Air Control Cabinet 20. Crowd Brake
04. Check Valve 21. Hoist Brake Valve
05. Lower Air Pressure Regulator 22. Quick Release Valve
06. Cable Reel Valve (spare) 23. Hoist Brake
07. Propel Brake Valve 24. Hoist Brake Pressure Transducer
08. Quick Release Valve 25. Hoist Brake Redundant Air Valve
09. Propel Brake 26. Hoist Brake Air Panel
10. Propel Brake Air Panel 27. Hoist Brake Redundant Exhaust Line
11. Propel Brake Pressure Transducer 28. Swing Brake Air Valve
12. Propel Brake Redundant Air Valve 29. Quick Release Valve
13. Propel Brake Maintenance Valve 30. Swing Brake
14. Redundant Exhaust Line 31. Swing Brake Air Pressure Transducer
15. Shut-Off Valve 32. Swing Brake Redundant Air Valve
16. Upper Air Pressure Regulator 33. Swing Brake Air Panel
17. Crowd Brake Valve 34. Swing Brake Redundant Exhaust Line
Figure 5-3: Brake System Schematic

5.2.2 Propel Brakes R42784D1
Figure 5-4: Disc Brake (typical)
One propel brake is mounted on each of the two propel motors on the propel motor armature shaft. The propel
brakes hold the shovel from moving when the shovel is parked, and they provide resistance for engaging the bank
when the shovel is digging.
Air from the main air receiver is plumbed through the air swivel mounted above the high and low voltage collector
assemblies in front of the hoist drum.
Figure 5-5: Air Swivel

The air line goes through the center gudgeon and to the lower air control cabinet at the back of the carbody.
ES04331b01
Figure 5-6: Lower Air Control Cabinet
Inside the lower air control cabinet is a check valve. This keeps the air that is being used to release the propel
brakes from being stolen by some other system. The air pressure regulator is set to 105 psi (7.25 bar). There are
three air valves. the top and bottom air valves are for the left and right propel brakes. The air valve in the middle is
for a cable reel; if there is no cable reel, this valve acts as a spare.

From the lower air control cabinet, the air is plumbed to the quick release valve that is attached to the propel brake.
01
04
03
LEGEND
01. Inlet
02. Exhaust
03. Outlet
ES04322a01 04. Brake
02
Figure 5-7: Quick Release Valve
At the top of the brake, another air line is plumbed to the propel brake air panel mounted on the side of the motor
mounting base.
Figure 5-8: Propel Brake Air Panel (top) and Maintenance Panel (bottom)
Inside the panel are a pressure transducer and a normally open solenoid-controlled air valve. The pressure trans-
ducer indicates to the Centurion Control System that there is sufficient air pressure to cause the hoist brake to
release. If this signal is not present, the brake will set and the operator’s hoist controller will not function. The air
valve, controlled by the Centurion Control System, closes when the brake releases. This prevents air pressure

from escaping through the valve and allows air pressure to build and cause the brake to release. When the brake
sets, the redundant air valve opens to provide an additional passage to exhaust air and ensure quick and sure
brake setting. The two redundant air valves are joined by a redundant exhaust line, so that if one of the valves
sticks in the closed position, both brakes will still have an exhaust path independent of the quick release valve.
Installed in this line is the maintenance valve. The maintenance valve, operated by controls on the Propel Brake
Maintenance Panel, causes the release of one of the propel brakes while the other brake remains set, permitting
inspection and maintenance of the propel brakes without losing control of the shovel.
There is no separate control for the propel brakes. Propel brake release is part of the sequence of events when the
operator places the shovel in PROPEL mode. Before the Centurion Control System will complete that sequence,
the Centurion Control System must detect certain inputs from sensors around the shovel. Among these inputs are
proximity switches on boarding stairways and the boarding ladders. If the stairways and ladders are not up, the
propel system will not become active and the propel brakes will not release.
5.2.3 Crowd Brake R41760D1
Figure 5-9: Crowd Brake
The crowd brake is mounted on the left end of the crowd transmission input shaft. It holds the dipper handles from
moving when the shovel is not in digging mode, and works in conjunction with the hoist brakes to hold a suspended
load, if necessary, when the shovel is digging.

Air from the main air receiver is plumbed to the upper air control panel in the lubrication room on the front left cor-
ner of the machinery deck..
ES04316a01
Figure 5-10: Upper Brake Air Pressure Regulator
From the upper air control panel, the air is plumbed to the upper brake solenoid air valve bank mounted on the lube
room wall just to the right of the upper air control panel. The first valve on the manifold is the crowd brake valve (it
is labeled CROWD).
Figure 5-11: Upper Brake Solenoid Air Valve Bank

The crowd brake does not have a brake air panel. The crowd brake air pressure transducer, therefore, is plumbed
directly after the air valve.
Figure 5-12: Crowd Brake Pressure Transducer
The air line continues out to the boom where it attaches to the quick release valve. The quick release valve is
attached to the brake, which is the last component in the crowd brake system.

5.2.4 Hoist Brakes R56316D1
Figure 5-14: Hoist Brakes
The hoist brakes are mounted on the right end of the hoist transmission input shafts, one at the front of the gear
case and one at the rear. These brakes hold the hoist motion. When the shovel is parked, with the dipper on the
ground, the hoist brakes prevent the hoist ropes from spooling off the hoist drum. When the shovel is in production,
the hoist brakes, in conjunction with the crowd brake, enable the operator to suspend a loaded dipper while waiting
for the next haul unit to arrive.

ES04316a01
room wall just to the right of the upper air control panel. The second valve on the manifold is the hoist brake valve
(it is labeled HOIST).
Figure 5-16: Upper Brake Solenoid Air Valve Bank

From the hoist air valve, the air is plumbed out of the lube room and continues under the machinery deck to the
quick release valve that is attached to the lower cylinder port on each hoist brake.
01
04
03
LEGEND
01. Inlet
02. Exhaust
03. Outlet
02
Another air line is threaded into a port on the top of the cylinder. This line goes to the hoist brake air control panel,
which is mounted above the brake on the side of the hoist gear case.
03
02
04 LEGEND
01. From Brake
02. Pressure Transducer
01 03. Normally Open Air Valve
04. Exhaust
ES04324a01
Figure 5-18: Air Control Panel

from escaping through the valve and allows air pressure to build and cause the brake to release.
An additional air line, plumbed along the top of the hoist gear case cover, connects the exhaust lines of the front
and rear hoist brakes. The purpose of this double-redundancy crossover line is to ensure that when the brakes are
set, even if one of the secondary solenoid valves fails to open, the air pressure from both brakes will still have an
exhaust path.
Figure 5-19: Double Redundancy Crossover Line
5.2.5 Swing Brakes R42786D1
Figure 5-20: Swing Brake
The swing brakes are mounted on the upper end of the swing motor armature shafts, two at the front of the revolv-
ing frame and one at the rear. These three brakes hold the swing motion. A quick release valve is threaded into the
brake cylinder at the side on each of the three swing brakes. When the shovel is parked, if the dipper is not on the
ground, the swing brakes prevent the upper from rotating.

ES04316a01
room wall just to the right of the upper air control panel. The third valve on the manifold is the swing brake valve (it
is labeled SWING).
Figure 5-22: Brake Air Valves

From the hoist air valve, the air is plumbed out of the lube room and continues under the machinery deck and up
the side of the swing motor to the quick release valve that is attached to a port on the side of each swing brake.
01
04
03
LEGEND
01. Inlet
02. Exhaust
03. Outlet
04. Brake
ES04322a01
02
Another air line is threaded into a port on the opposite side of the cylinder. This line goes to the swing brake air
control panel, which is mounted on the side of the swing motor.
03
02
04 LEGEND
01. From Brake
04. Exhaust
ES04324a01

An additional air line, plumbed along the sides of the swing motors and in cable trays under the deck plating, con-
nects the exhaust lines of all three swing brakes. The purpose of this double-redundancy crossover line is to
ensure that when the brakes are set, even if two of the secondary solenoid valves fail to open, the air pressure
from all three brakes will still have an exhaust path.
5.2.6 Brake Components.
09 10 11 12 13 14
08
07
15
06
05 16
04
17
03
02
01 18
ES04321a01
26 25 24 23 22 21 20 19
LEGEND
01. Drive Ring 10. Inner O-ring Seal 20. Outer Rotor Positioning
02. Inner Rotor 11. Piston Cap Screw Spring
03. Center Plate Positioning 12. Cover Plate 21. Inner Rotor Positioning Cup
Spring 13. Cover Plate Screw 22. Inner Rotor Positioning
04. Outer Rotor 14. Brake Spring Spring
05. Pressure Plate 15. Rod Bolt Stud Nut 23. Brake Hub Retainer Plate
06. Cylinder 16. Rod Bolt 24. Tie Wire
07. Outer O-ring Seal 17. Center Plate 25. Brake Hub Retainer Plate Cap
08. Felt Dust Seal 18. Wear Ring Screw
09. Piston 19. Brake Mounting Bolt 26. Brake Hub
Figure 5-25: Brake Components (typical)
Refer to Figure 5-25. The drawing shows a dual-rotor swing brake; other brakes have essentially the same compo-
nents.

The drive ring (Item 01) mounts to the gear case (hoist and crowd) or to the motor (swing and propel). drive rings
often have vent slots, and are sometimes covered by shrouds. Refer to Figure 5-26.
Figure 5-26: drive ring (typical)
Rod bolts (15) are inserted into the base of the housing. These rod bolts hold the cylinder (06) and the housing (01)
together, and also act to secure the wear surfaces (wear ring (18), center plate (17), and/or pressure plate (05),
depending on model) from spinning when the brakes are released. The wear surfaces are able to slide on the rod
bolts.
Figure 5-27: Center Plate (typical)
Rotors (02 and 04) are splined to the brake hub (26). In a typical two-rotor arrangement, they are positioned
between the pressure plate (05) and the center plate (17), and between the center plate (17) and the wear ring
(18).
Rotors are equipped with friction pads on both sides, held together by common rivets. These sintered metallic pads
are specifically formulated to provide the braking friction necessary for the shovel application and to resist fading
so that the braking efficiency will remain constant.
When the brake is set, these rotors are clamped by springs (14) against the wear surfaces, providing braking
torque and preventing the transmission shaft or the motor shaft from turning. When the brake is released, air gaps
are provided between the friction pads and the wear surfaces, permitting the shaft to turn.

Figure 5-28: Rotor (typical)
It is these friction pads that wear, becoming thinner during normal operation. This causes the piston to travel farther
when the brake sets. Measuring piston travel is used during Preventive Maintenance inspections to determine a
brake’s total accumulated internal wear.
The cylinder assembly consists of several components that act together to provide the brake function. Refer to Fig-
ure 5-29.
01
02
03
04
05
ES04340a01
LEGEND 03. Cylinder (Item 06, Figure 5-25)

01. Piston ((Item 09, Figure 5-25) 04. Pressure Plate (Item 05, Figure 5-25)
02. Piston Cap Screw (Item 11, Figure 5-25) 05. Brake Spring (Item 14, Figure 5-25)
Figure 5-29: Cylinder Assembly (typical)

The cylinder (03) is bolted to the housing by the rod bolt nuts. Inside the cylinder is the piston (01). The piston is not
physically connected to the cylinder; however, it is bolted to the pressure plate (04) by the piston cap screws (02).
01
02
03
04
05
ES04341a01
LEGEND 03. Inner O-ring

01. Piston (underside) 04. Outer O-ring
02. Cap Screw Hole 05. Felt Seal
Figure 5-30: Piston (typical)
Refer to Figure 5-30. The piston (01) moves within the cylinder. When the brake is released, air pressure moves
the cylinder outward. The O-rings (03 and 04) act as air seals (the felt seal, 05, helps keep dust out of the cylinder).

Refer to Figure 5-32. The pressure plate (05) is bolted to the piston (09) by the piston cap screws (11). When the
piston moves, the pressure plate moves with it.
01
02
03
04
ES04342a01
LEGEND
01. Tapped Hole for Piston Cap Screw 03. Pressure Plate
02. Hole for Rod Bolt 04. Brake Spring
Figure 5-31: Cylinder (typical)
Refer to Figure 5-31. Between the pressure plate and the cylinder are the brake springs. When the brake is
released, the air pressure under the piston forces the piston outward, bringing the pressure plate with it. The brake
springs, mounted between the pressure plate and the cylinder, become compressed. The resulting gaps between
the rotors and the wear plates permit the motor shaft or the transmission shaft to turn.
When the brake is set, the air is exhausted from under the piston and the springs expand, exerting pressure on the
pressure plate and holding the rotors against the wear surfaces, thereby preventing the brake hub (and the motor
or transmission shaft) from turning.

5.2.7 Brake Operation.
09 10 11 12 13 14
08
07
15
06
05 16
04
17
03
02
01 18
ES04321a01
26 25 24 23 22 21 20 19
LEGEND
01. Drive Ring 10. Inner O-ring Seal 20. Outer Rotor Positioning
02. Inner Rotor 11. Piston Cap Screw Spring
03. Center Plate Positioning 12. Cover Plate 21. Inner Rotor Positioning Cup
Spring 13. Cover Plate Screw 22. Inner Rotor Positioning
04. Outer Rotor 14. Brake Spring Spring
05. Pressure Plate 15. Rod Bolt Stud Nut 23. Brake Hub Retainer Plate
06. Cylinder 16. Rod Bolt 24. Tie Wire
07. Outer O-ring Seal 17. Center Plate 25. Brake Hub Retainer Plate Cap
08. Felt Dust Seal 18. Wear Ring Screw
09. Piston 19. Brake Mounting Bolt 26. Brake Hub
Figure 5-32: Brake Operation
When the brake is released, air pressure enters the brake cylinder and causes the piston to move outward. An
inner O-ring and an outer O-ring act as air seals. The pressure plate is bolted to the piston and as the piston moves
outward, the pressure plate moves with it. When the pressure plate comes in contact with the cylinder, outward
movement stops. A gap opens between the pressure plate and the brake rotor. Internal springs expand to position
the rotors and the wear plates. This provides clearance between the rotor friction pads and the brake wear sur-
faces. The brake hub is free to spin. The rotors are splined to the brake hub, and when the pressure plate opens a
space, the rotors are free to rotate and they are also free to slide along the brake hub splines. The wear plates do
not rotate; however, they are free to slide along the rod bolts.
When the brake is set, the air is removed from under the piston. The brake springs force the pressure plate back
against the brake rotor, the internal springs compress, and the pressure plate clamps the rotors between the wear
plates. This prevents the hub from spinning.

If electric power fails, or if air pressure is lost, and when an automatic shutdown occurs, the brake will set, stopping
movement and holding the current position until power and controller reference are restored.
CAUTION
While it may be necessary to use the disc brakes to stop the motion on some occasions,
repeated automatic setting of the brakes while under load will lead to premature failure
of the brake. Use the electric motors to stop the motion under normal circumstances,
and determine and repair the cause of automatic shutdowns of the shovel to prevent pre-
mature brake failure.
5.2.7.1 Quick Release Valves
Each brake is equipped with a quick release valve. The quick release valve allows air to escape from the brake
rapidly when the brake is set, thereby reducing or eliminating a time lag between the time the operators presses
the brake SET button and the time the brake actually sets
01
02
06 05
04
07
03
LEGEND
01. Gasket
02. Bypass Passage
02 03. Inlet
04. Cover
01 05. Diaphragm
06. Body
05 07. Outlet
08. Exhaust
ES04323a01
Figure 5-33: Quick Release Valve Operation
Refer to Figure 5-33. When the brake release solenoid (Figure 5-16) is energized, air flows from the air valve into
the quick release valve inlet (Item 02). As the air presses against the diaphragm (04), the diaphragm is forced
against the exhaust port, keeping it closed. Air continues to flow around the diaphragm (Item 05) through the
bypass passages (Items 01), through the outlet and into the brake. Once the brake releases, pressure within the
quick release valve equalizes.
As long as the pressure is equal on both sides of the quick release valve, the diaphragm stays pressed against the
exhaust port and keeps the air from exhausting.
When the brake is set, the air valve (Figure 5-16) closes and exhausts air through the air valve manifold. This
reduces the air pressure at the quick release valve inlet (Item 03). At this point, the pressure at the outlet (Item 07)
is greater than the pressure at the inlet, and the pressure from the outlet forces the diaphragm (Item 05) away from

the exhaust port (Item 08) and allows air from the brake to exhaust quickly from the brake cylinder. This assures
that the brake will set quickly when the operator presses the brake set button.
5.2.7.2 Air Brake Isolation Kit
Brakes, other than the crowd brake, may have a ball valve attached to the quick release valve inlet. This ball valve
allows maintenance personnel to isolate a brake from the main air system so that individual brakes can be
released while maintaining control of the system. Refer to Figure 5-34.
ES1570c03
Figure 5-34: Air Brake Isolation Kit (closed position, for maintenance purposes only)
CAUTION
Isolation Kit Valves must be in the open position during normal operation, or the brakes
will be destroyed. P&H Mining Equipment recommends that the valves be locked in the
open position and unlocked only when necessary for maintenance purposes.

5.2.7.3 Brake Indicator Microswitches
02
01
ES0435a01
LEGEND
01. Brake Set/Release Indicator 02. Brake Wear Indicator
Figure 5-35: Brake Indicator Microswitches
All 4100XPC disc brake assemblies are equipped with proximity sensors. Each brake has two proximity sensors:
Brake Release Indicator (Item 01, Figure 5-35)
When the brake is set, the plunger is extended by an internal spring and the switch is open. The Centurion Control
System senses that the brake is set.
When the brake is released, the plunger is pushed into retract by the bracket. The Centurion Control System
senses that the brake is released. This signal is required before the controller will be able to function.
Brake Wear Indicator (Item 02, Figure 5-35)
Under normal conditions, the plunger is extended by an internal spring and the switch is open. When the switch
closes, this indicates that the piston has moved farther into the cylinder than specified for acceptable wear limits.
The Centurion Control System will send a signal to the GUI to inform the operator that service is required, but no
shutdown will occur.
5.3 A Warning About Stored Mechanical Energy

Control of Hazardous Energy is something that all of us encounter on a daily basis, whether at home or at work.
For mines, each site should have its own Hazardous Energy Control Guideline. Within that guideline, provisions
should be made for all types of energy, including electrical, mechanical, and fluid power. The information contained
in this P&H Service Bulletin is intended to raise awareness of one aspect of hazardous energy - a version of poten-
tial energy referred to as mechanical stored energy, and in particular, how it relates to two separate and distinct

maintenance procedures on electric mining shovels manufactured by P&H Mining Equipment: 1) manual release of
the brakes, and 2) brake removal.
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 5-36: Stored Energy Sources
! WARNING
Uncontrolled release of mechanical stored energy can cause unexpected movement,
resulting in severe personal injury or death. Always release mechanical stored energy
before maintaining or removing disc brakes on P&H Mining Shovels.
The disc brakes used on P&H Mining Shovels are spring-set, air-release holding brakes, with the air supply con-
trolled electronically. That means the disc brakes will be in a set condition when either air or electrical power is
removed. Once the disc brakes are set, however, they have the ability to store and hold mechanical energy. This
Service Bulletin will describe how this energy can be created, and how to properly control or release that energy
before initiating any maintenance work on the shovel.

5.3.1 Development of Mechanical Stored Energy
The priority in disc brake removal is the release of mechanical stored energy. To avoid injury, refer to Figure 5-36
as you familiarize yourself with how mechanical stored energy can develop in drivetrains. Following are some
examples of how stored energy can develop in a drivetrain:
• The dipper is suspended. Gravity is trying to pull the dipper down. Releasing the brakes manually or remov-
ing the disc brakes will result in a release of mechanical stored energy, allowing the dipper to fall.
• The dipper is on the ground but the hoist ropes 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 stored energy in the
hoist and/or crowd brakes. Releasing these brakes manually or removing the brakes will result in a release
of mechanical stored energy, allowing the bail to fall forward.
• The dipper is on the ground with the hoist ropes slack, but the crowd disc brake has not yet been released.
In this case, the handle and dipper 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 gravity may shift backward
causing the shovel to rock backward, and movement of the dipper handle relative to the boom, causing the
crowd machinery to rotate.
• Soft ground conditions can result in shifting of the machine, changing the way gravity affects structures and
drivetrains. Maintenance work can take anywhere from several minutes to weeks to complete. The ground
conditions can change over the duration of maintenance work. If, for example, a crawler or jack stand
begins to sink into the ground, the shovel will move. What had been stable before the shovel moved has
now been affected differently by gravity. Mechanical stored energy has now developed within the drivetrain.
Mechanical stored energy has been created during the maintenance job itself. Therefore, it is imperative to
visually inspect the shovel as maintenance work progresses, and verify that mechanical stored energy has
not redeveloped in a disc brake.
• A shovel parked with the boom in a jacked condition (i.e., the suspension cables are slack). This would cre-
ate stored energy in the crowd system, as the crowd would be supporting the weight of the boom. Manually
releasing the crowd brake or removing the crowd brake will result in a release of mechanical stored energy,
allowing the boom to set down.
• A shovel parked on non-level ground. Not only does this affect movement in both propel and swing, it can
also affect stability of the shovel, which can create stored energy in any motion (hoist, crowd, swing, or pro-
pel) due to machine rocking on the non-level ground. Manually releasing or removing any of the brakes will
result in a release of mechanical stored energy, resulting in unpredictable movement.
• A shift of a shovel's center of gravity due to particular tasks (jacking, lifting, pushing or major component
removal) performed. Manually releasing or removing any of the brakes will result in a release of mechanical
stored energy, resulting in unpredictable movement.
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 energy under any condition should be used. Plan each task
and the sequences of the maintenance work in advance to avoid unnecessary development of mechanical stored
energy and the release of such energy when it develops.
5.3.1.1 Example
The following is an example of the effect of stored energy:

While performing repairs to a P&H shovel crowd gearbox assembly, a technician was in the process of removing
the disc brake to gain access to the first reduction pinion. The disc brake mounting bolts were removed one at a
time. When the last bolt was removed, the disc brake spun causing injury.
In this case, mechanical stored energy developed from gravity acting on the crowd system. The only thing keeping
the crowd system from being pulled by gravity was the disc brake. The disc brake was fixed to the gearbox by
mounting bolts. When the mounting bolts were removed, the disc brake was no longer capable of holding the
weight. This released the mechanical stored energy, causing the input pinion -- and the disc brake that was
attached to it -- to spin.
5.3.1.2 Solution
Simply releasing disc brakes from the operator’s cab while the shovel is running will not release all stored energy in
the system. Under normal operating conditions, the electrical drive system will hold the shovel in whatever position
the operator requires. For example, when the dipper is suspended and the hoist controller is in the neutral position,
the electric motors will hold the dipper in that suspended position. When the brake is set, the dipper is still sus-
pended, but it is held by the hoist brakes. The hoist brakes, then, are still holding mechanical stored energy. In
order to release mechanical stored energy, both of the hoist brakes must be manually released at the same time
when the motors are not able to hold the position (that is, the shovel is shut down).
Likewise, any mechanical stored energy that develops within any of the shovel motion drivetrains (crowd, hoist,
swing or propel) must be released by releasing all of the brakes in the system while the shovel is shut down. This
must be completed before attempting to remove the brake from the machine. Follow these steps:
! WARNING
Unexpected machine movement can result in serious personal injury or death. Never
manually release disc brakes when the shovel is parked on an incline, on unlevel
ground, on soft ground, or while the dipper or bail is suspended.
Several personnel are required to complete this task:
Technicians. One person must be at each of the brakes on the system. The technicians will also remove the
brake(s) if that task is to be performed.
Brake Valve Operator. One person must be in the lubrication room. This person will apply the manual actuator on
the brake air valve.
Guard. One person must be in a location to see and communicate with the area where the machinery is expected
to move to ensure that all personnel are kept clear of the area.
5.3.2 Releasing Stored Energy
5.3.2.1 Discussion
Under normal operation, when the brakes release, the motors maintain the position of each of the shovel motion
components (swing, hoist, crowd and propel). When the brakes are set, the components are held in their current
position by the brakes.
Because of this, releasing the brakes when the motors are running will not release stored energy. To release stored
energy, the brakes must be released when the motors are not functioning.

5.3.2.2 Procedure
1. Properly park the shovel on a flat, even grade, properly compacted and stable ground, with the dipper resting
on the ground (dipper front face flat on ground, dipper heel and dipper lip both contacting ground), the dipper
bail forward with the hoist ropes slack, and suspension cables tight (boom not jacked). Use mechanical stops,
locks, and chocks appropriately to properly park the shovel.
2. Shut the shovel down and apply locks and tags according to the lockout/tagout procedure.
05
LEGEND
04 01. Air Supply Line
02. Quick Release Valve
03 03. Air Port
04. Brake
05. Air Port
02
01
Figure 5-37: Brake with Air Panel (typical)
3. On systems with air panels (refer to Figure 5-37), disconnect the line from the air port (05) and install a plug.
(On systems without air panels, that port is already plugged.)
NOTICE
On all systems, the port opposite the quick release valve must be plugged before continuing.

4. Confirm air pressure in the main air receiver is at least 105 psi. This can be confirmed by reading the gauge at
the operator’s console. If there is not sufficient air pressure in the system, disconnect the air line between air
lubricator and the air pressure regulator and attach an external air source of at least 105 psi.
NOTICE
The specific location for connecting the external air source will vary depending on the model of shovel
and the system where the air is to be applied. Refer to Figure 5-38 for examples of connection points.
Note that in all instances, the connection point should be just upstream of the brake air pressure regula-
tor.
ES04650a01
Figure 5-38: Examples of Connection Points

! WARNING
Using the air valve will cause uncontrolled movement of machine components, which
can cause severe personal injury or death. Additional personnel are required to com-
plete this task. It is imperative to establish a means of communication among these per-
sons.
5. When a technician is present at each of the brakes to be released and ready, notify the brake valve operator.
Figure 5-39: Manual Actuators on Brake Air Valves
6. Confirm with the guard that the area is clear and the brake can be released.
7. Have the brake valve operator identify the air valve that provides air to the brake to be operated. Labels are
attached near the valve.
! WARNING
Unexpected movement of shovel components could result in serious personal injury or
death. Brakes may be holding large amounts of stored mechanical energy. Be prepared
for significant movement of major shovel components when brakes are released. Ensure
that all personnel are clear of the major components affected by the associated brake
system.
8. Notify all crew members that the brake is about to be released. Have the brake valve operator use a 1/8"-diam-
eter rod (or a similar suitable device) to press the manual actuator button (indicated by the white arrows in Fig-
ure 5-72) on the valve that provides air to the brake to be operated. The brake valve operator must maintain
pressure on the manual actuator button 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 associated
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
resulting in severe personal injury or death. If in Step 9 above the brake discs do not
rotate and come to rest, proceed directly to the brake removal procedures described in
Brake Removal Under Special Conditions.
It is now acceptable to perform inspections, replace components, take measurements, and perform other mainte-
nance actions. When maintenance is complete, restore the system to its original configuration as follows:
A. If an external air source was used, remove the external air line connection and reattach the system air line
(refer to Figure 5-38).
B. On systems with air panels, remove the air port plug and reassemble the brake panel air line (refer to Figure
5-37).
5.4 Removing Disc Brakes
! WARNING
(refer to Releasing Stored Energy) before removing disc brakes on P&H Mining Shovels.
5.4.1 Discussion
Before removing a brake, confirm that stored energy has been released as described in the topic Releasing Stored
Energy.
Following the procedures in the topic Releasing Stored Energy accomplishes two things: First, it demonstrates that
the brake is operating normally (i.e, components are free to move and the brake is not seized); second, it releases
stored mechanical energy.

Even though the stored mechanical energy has been released, changes in the physical condi-
tion of the shovel could cause stored mechanical energy to redevelop. For this reason, P&H
Mining Equipment recommends that only one brake be removed from the machine at a time.
The remaining brakes will stay installed and set to inhibit unexpected movement. Completely
reinstall each brake before removing any other brake.
NOTICE
On the crowd system, only one brake holds the crowd motion. When removing a crowd brake,
be particularly certain to release mechanical stored energy before removing the brake, since
there will be no other brake holding the motion.

5.4.2 Procedure
1. Confirm that the shovel is properly parked on properly compacted and stable ground on a flat, even grade, with
the dipper resting on the ground (dipper front face flat on ground, dipper heel and dipper lip both contacting
ground), the dipper bail forward with the hoist ropes slack, and suspension cables tight (boom not jacked). Use
mechanical stops, locks, and chocks appropriately to properly park the shovel.
! WARNING
Modifying the brake air system could cause unpredictable brake operation or brake fail-
ure, resulting in severe personal injury or death. Before beginning work, tag lines and
make sketched, photographic, or digital images of the connections to ensure that you
will be able to return the system to its original configuration.

Use the following procedure to release a brake using an external air supply line.
06.
01.
05. 07.
02.
03.
04.
LEGEND 04. To Atmosphere

01. To Brake 05. Regulator and Gauge
02. Supply Valve 06. Check Valve
03. Exhaust Valve 07. Quick Disconnect

(locally fabricated)
Fabricate an assembly similar to what is shown in Figure 5-73. Components include:
An External Source of Air (105 psi)
Air Hose and Fittings
Two Ball Valves
Regulator capable of 105 psi, with gauge
Check Valve
One Pipe Tee
One Pipe Plug

Refer to Figure 5-41 and release the brake as follows:
05
04
LEGEND
02 03. Air Port
04. Brake
01 05. Air Port
! CAUTION
Compressed air spray can injure eyes and ears. Wear eye and ear protection when
releasing compressed air.
1. Disconnect the existing brake air supply line (01) where it is connected at the quick release valve (02).
2. If the disc brake has a brake solenoid panel, remove the exhaust line at the brake outlet (05) and install a pipe
plug in the brake outlet (on brakes without brake solenoid panels, this port is already plugged).
3. On the fabricated manual release assembly, close both the supply valve and the exhaust valve. Attach the
quick disconnect fitting of the fabricated manual release assembly to the external air supply.

4. Open the exhaust valve. Attach the assembly hose to the Quick Release Valve at the brake.
ES1570b03
Figure 5-42: 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 of stored mechanical energy. Unexpected move-
ment of shovel components could result in serious personal injury or death. Be prepared
that all personnel are clear of the major motions affected by the associated brake sys-
tem.
6. Open the supply ball valve. The air should now release the brake.
! WARNING
If a disc brake will not open and the piston does not move outward, the normal brake
removal procedure must not be used. Refer to Brake Removal Under Special Conditions.
7. Maintain the air pressure in the brake to keep the brake open and prevent redevelopment of stored energy as
the brake is being removed.

! WARNING
Inadequate lifting of heavy components can cause serious injury or death. Support the
brake being removed with a suitable sling or other support. Disc brakes can weigh up to
1700 pounds (770 kg).
Figure 5-43: Disc Brake Mounting Bolts (circled) (Typical)
8. There are typically twelve mounting bolts (visible mounting bolts in Figure 5-43 are circled in white). Loosen the
mounting bolts one at a time. Do not remove any of the bolts at this time. Loosen the bolts that are in the most
difficult access areas first, and work around to the mounting bolts where access is easiest.
9. Loosen the last mounting bolt (most likely at the 12 o'clock position) one turn only.
10. Re-verify that brake components are released and not binding using one of the techniques below:
A. Place a pry bar under the brake. The brake should move slightly on the mounting bolts when pried.
B. Observe the rotors inside the brake. Use a pry bar or large screw driver to move the rotors on the brake hub.
! WARNING
resulting in severe personal injury or death. If any binding (resistance) 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 procedures described in Brake Removal Under Spe-
cial Conditions.
11. Remove the bolts from the brake mounting flange.
12. To set the brake, close the supply ball valve and open the exhaust ball valve.

Technician Tip
If there is any doubt as to the development of stored energy, the outside air source can remain
connected until the entire disc brake is removed from the hub. Be aware that maintaining an
outside air source will cause the rotors to drop inside the disc brake as the disc brake is slid off
the hub. Alignment will be required before the disc brake is reinstalled.
! WARNING
ure, resulting in severe personal injury or death. Refer to tags on air lines and to
sketched, photographic, or digital images of the connections to ensure that you return
all connections to the original configuration.
13. When installing the replacement brake, be certain to reconnect the brake air system as it was before perform-
ing this disassembly procedure.
5.4.3 Conclusion
As discussed above, mechanical stored energy in disc brakes can affect maintenance activities in a number of
ways. It is important to have a full understanding of the shovel and how components interact. If questions arise dur-
ing maintenance activities for P&H Surface Mining Equipment, please refer to the applicable P&H Equipment man-
uals or contact your local MinePro Representative before proceeding with maintenance work.
5.5 Brake Removal Under Special Conditions

If a brake cannot be released, or in situations where the brake components do not move normally during a release
and set cycle, the brake may be storing large amounts of mechanical energy. In such cases, do not attempt normal
brake removal. Instead, carefully disassemble the brake in place. Use the following procedure to disassemble a
brake that is suspected of still being under load or tension.
! WARNING
Sudden and unexpected release of mechanical stored energy may cause violent spin-
ning of the brake, brake components, and the transmission input shaft, as well as major
component movement, resulting in severe personal injury or death. Ensure that all per-
sonnel are clear of major motions affected by the associated brake system.

LEGEND
First Round
Second Round
Third Round
Fourth Round
ES04329b01
Figure 5-44: Star Bolting Pattern
1. Using a star pattern as shown in Figure 5-100, back off two turns at a time on each rod bolt stud nut until all are
removed. The brake air cylinder assembly should slowly move outward as this is being done. The brake piston
will appear to depress inward.
NOTICE
If the brake is under a load, internal components may rotate gradually as the rod bolt nuts are
loosened. Be prepared for possible movement of associated motion components.
2. Remove all air piping connections.
! WARNING
If the brake internal components have not rotated, the brake may still be under load ten-
sion. Be very careful as the rotors could break loose and turn at any time.
3. Install eye bolts in the lifting holes tapped into the piston as a lift point.
4. Use the appropriate slings and chain hoist or crane for the weight of the brake assembly. A brake may weigh
up to 1286 lbs (583 kg). Remove the brake air cylinder assembly.
5. Remaining alert at all times for potential sudden movement of brake components, remove brake components
in order:
• Outer Rotor
• Center Plate(s)
• Inner Rotor(s)
• Wear Ring
• Brake Hub

Technician Tip
A sledge hammer may be used to break loose parts and release tension. A cutting torch may be
necessary to cut and remove seized components.
6. Support the weight of the drive ring with slings and a suitable lifting device. The drive ring may weigh up to 200
lbs (91 kg).
7. Loosen and remove the drive ring mounting bolts and remove the drive ring.
5.6 Preliminary Maintenance Procedures

Before performing maintenance, the shovel should be parked properly and shut down. P&H recommendations are:
• Move the shovel away from the high wall to a solid and level area.
• 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 dipper and dipper handles area to prevent other personnel from working near
or under the dipper and handles while the brakes are being released.
! WARNING
Unexpected movement of shovel components may result in serious personal injury,
death, and equipment damage. Be prepared for movement of major shovel components
controlled by the various brakes that may occur when performing maintenance proce-
dures. Ensure that all personnel are clear of the major motions affected by the brake to
be released.
• Confirm that all personnel are clear of the motor, gear case, shaft assemblies, and other moving compo-
nents of the drive system for the brake to be released.
5.7 Maintenance of Air System Components

Confirm preliminary maintenance procedures have been completed. Refer to Topic 5.6.

5.7.1 General
Inspect all air lines for damage, kinking, leaks, or blockages. Replace any lines that are determined to be unsuit-
able.
5.7.2 Air Pressure Regulators
01 02
LEGEND 02. Propel Brake Air Pressure Regulator
01. Upper Brake Air Pressure Regulator (in lower air control cabinet at the back of
(on air control panel in lube room) the carbody)
Figure 5-45: Brake Air Pressure Regulators
5.7.2.1 Inspection and Adjustment
Verify the upper brake air pressure regulator (Item 01, Figure 5-45) is set for 100 psi and that the propel brake air
pressure regulator (Item 02, Figure 5-45) is set for 105 psi. If the regulator is set too high, damaged O-rings and
pistons could result; if it is set too low, damage from overheating could destroy the brake.
5.7.2.2 Maintenance and Repairs
No field maintenance or repair procedure is prescribed for the air pressure regulator. Refer to the LinkOne elec-
tronic parts manual and replace damaged regulators with the same part number as the one removed.

5.7.3 Air Valve Manifolds
01 02
LEGEND 02. Propel Brake Air Valve Manifold
01. Upper Brake Air Valve Manifold (in lower air control cabinet at the back of
(on air control panel in lube room) the carbody)
Figure 5-46: Brake Air Valve Manifolds
5.7.3.1 Inspection
Inspect exhaust mufflers on the brake air valve manifolds for damage and blockage due to contamination or icing.
Inspect brake air supply lines for damage, deterioration due to age or contamination, and blockage due to pinching.
Repair or replace components as required.
If the exhaust lines are blocked, pinched or iced, the air valve manifold will not be able to exhaust its air pressure. If
that happens, the quick release valve won’t function (refer to Subtopic 5.2.7.1).
Inspect brake exhaust air piping for damage and blockage due to pinching, contamination, or icing. Repair or
replace components as required.
5.7.3.2 Repair and Replacement
No field maintenance or repair procedure is prescribed for the air valves. Refer to the LinkOne electronic parts
manual and replace damaged air valves with the same part number as the one removed. As an alternative, replace
the entire manifold with the same part number as the one removed.

5.7.4 Quick Release Valve
LEGEND
01. Body 03. Diaphragm
02. Cover 04. Gasket
Figure 5-47: Quick Release Valve Components
5.7.4.1 Inspection
The quick release valve should hold air when the brake is released. If leakage occurs between the body and the
cover, the gasket should be replaced. If leakage occurs from the exhaust port, the diaphragm should be replaced.
5.7.4.2 Repair
Repair is limited to the replacement of the gasket and the diaphragm. Repair kits are available through your local
P&H MinePro Services representative.

5.7.5 Brake Air Control Panel
03
02
04 LEGEND
01. From Brake
04. Exhaust
ES04324a01
5.7.5.1 Pressure Transducer
Inspection
Inspection of the pressure transducer is limited to operational observation. If the propel system fails to operate, the
transducer may not be reporting air pressure accurately.
Maintenance and Repair
No field maintenance or repair procedure is prescribed for the pressure transducers. Refer to the LinkOne elec-
tronic parts manual and replace damaged transducers with the same part number as the one removed.
5.7.5.2 Normally Open Air Valve
Inspection
When the brake is released, this valve should close. If air continues to exhaust through the valve when the brake is
released, replace the valve.
When the brake is set, this valve should open. If air does not exhaust through the valve when the brake is set,
replace the valve.
No field maintenance or repair procedure is prescribed for the air valve. Refer to the LinkOne electronic parts man-
ual and replace damaged air valves with the same part number as the one removed.

5.8 Propel Brake Maintenance R42784
09
01
08
07 02
03
06
04
05
ES0540a01
LEGEND: 05. Left Propel Brake (holds left track)

01. High Voltage Disconnect 06. Right Propel Brake (not visible) (holds right track)
02. Trail Cable Coupler 07. Brake Air Panel for Right Propel Brake
03. Propel Motor Mounting Base (at rear of carbody) 08. Propel Brake Maintenance Control Panel
04. Brake Air Panel for Left Propel Brake 09. Lower Air Control Cabinet
Figure 5-49: Propel Brake System Locator

5.8.1 Releasing Propel Brakes for Maintenance
! WARNING
Uncontrolled movement resulting from the release of mechanical stored energy may
cause severe personal injury or death. Read and understand Topic 5.3, A Warning About
Stored Mechanical Energy, and Topic 5.9, Releasing Upper Brakes for Maintenance,
before releasing any brake for maintenance. In any situation where there is doubt
regarding mechanical stored energy, do not begin work until you have contacted a per-
son who is qualified and authorized to assist in making such determinations. Contact
your local P&H MInePro Services representative whenever such assistance is appropri-
ate.
The ability to manually release the brakes is necessary when performing maintenance on the propel brakes and
other components of the propel system. The propel brake system on the 4100XPC shovel is equipped with a Pro-
pel Brake Maintenance Control system. The Propel Brake Maintenance Control allows maintenance personnel to
manually release the propel brakes from a remote control panel located on the left side of the motor mounting base
near the propel motors. Refer to Figure 5-50.
ES04332b01
Figure 5-50: Propel Brake Maintenance Control Panel

5.8.1.1 Propel Brake Maintenance Control Operation
01
02
03
ES04313a01
LEGEND 02. Brake Release Left

01. Run / Maintenance Selector Switch 03. Brake Release Right
! WARNING
Unexpected stopping or abnormal machine operation can cause serious personal injury,
death, or damage to property. Do not operate switch when the shovel is running. Turning
the keyswitch initiates a 30 second delayed shutdown. Read and understand all instruc-
tions in this manual before operating the Propel Brake Maintenance Control.
Use the following procedures to release a propel brake using the Propel Brake Maintenance Control:
Technician Tip
This task requires two persons. The assistant should be stationed at the propel brake release
station and the technician at the propel brake.
1. Confirm preliminary maintenance procedures have been completed. Refer to Topic 5.6.

! CAUTION
Releasing one of the propel brakes can cause machine movement due to the release of
stored energy, resulting in personal injury. Instruct all ground personnel to stand clear of
the shovel while the brake is being released.
2. Do a thorough walk-around of the shovel to ensure other personnel are aware that the propel brake is to be
released. Instruct all personnel to stand clear while the brake is being released.
3. Turn the selector switch to the MAINTENANCE position.
! WARNING
Releasing the propel brake may cause slight machine movement, which is normal. More
than nominal movement indicates a more serious condition, which could result in severe
personal injury or death. If the shovel continues to move, release the push button to set
the brake.
4. Push the BRAKE RELEASE, LEFT push button to release the left propel brake, or the BRAKE RELEASE,
RIGHT push button to release the right propel brake. Only one of the propel brakes may be released at a time
using the Propel Brake Maintenance Control. The push button must be held in to keep the brake released.
Releasing the push button will cause the brake to set.
! WARNING
Releasing the push button while maintenance is being performed will cause the brake to
set, which could cause injury to the technician working on the brake. Do not release the
push button while someone is working on the brake.
5. Continue to hold the push button to manually release the brake while maintenance is being performed.
6. Perform the necessary propel system maintenance.
7. Release the push button to set the brake.
8. Push the other propel brake push button to release the other propel brake if needed.
9. Return the selector switch to the RUN position when finished to resume normal operation. The shovel will not
start with the selector switch in the MAINTENANCE position.
10. Close the enclosure door securely to prevent component contamination.

11. When all personnel have vacated the propel motor area and are safely away from the shovel, the tags on the
Operator’s Controls can be removed. Slowly and carefully confirm brake operation and function using the static
tests listed in subsection 5.13.2 before allowing the shovel to return to production.
ES0548_01
Figure 5-52: Operation Warning Decal (Inside Cover)

5.8.2 Propel Brake Components
12
13
03
01 02
06
10 01 02
04
07
05
08
05
09 04
11 10
TC0455b
LEGEND 09. Rod Bolt Stud Assembly

01. Center Plate 05. Pressure Plate 10. Drive Ring
02. Wear Plate 06. Indicator Assembly 11. Brake Mounting Bolt
03. Cylinder 07. Piston 12. Set/Release Switch
04. Rotor 08. O-rings 13. Wear Switch
Figure 5-53: Propel Brake (R42784D1)

5.8.3 Propel Brake Specifications
Piston Procedure/Action Result/Action

Travel
0.470" If piston travel is less than the mea-

With 1 to 2 shims and piston travel exceeds the
(7/16” surement, continue to measure every
measurement, remove 1 shim. Annotate brake.
11.9 mm) 250 hours.
0.470"
With no shims and piston travel exceeds the
(7/16” Note and record new piston travel.
measurement, replace brake.
11.9 mm)
0.220"
Minimum piston travel to provide minimum air If less than the measurement, deter-
(1/4”
gaps. mine the cause.
5.6 mm)
Air Pressure Data
Minimum/Recommended Air Pressure 105 PSI (6.9 bar)
Brake Release Pressure 65 PSI (3.7 bar)
Torque Data
Piston Hex head socket bolts 200 - 220 ft-lbs (276 - 304 N·m)
Rod bolt stud nuts 90 - 100 ft-lbs (124 - 138 N·m)
Brake mounting bolts 140 - 160 ft-lbs (194 - 221 N·m)
Hub retainer plate bolts 20 ft-lbs (27.6 N·m) w/tie wire
Weights
Propel Brake Assembly, R42784D1 690 lbs (303 kg)
Brake Cylinder Assembly 328 lbs (144 kg)
Drive Ring 149 lbs (66 kg)
Rotors (two required) 49 lbs (22 kg) each
Center Plate 76 lbs (33 kg)
Wear Plate 55 lbs (24 kg)
Table 5-1: Brake Specifications, Propel Brake (R42784D1)
NOTICE
Engineering specifications for piston travel measurements indicated in Table 5-1 are to hun-
dredths of an inch. For best results, use a scale with graduations to hundredths of an inch.
Fractional and metric approximations are provided for reference only.

5.8.4 Preventive Maintenance Inspections
Inspect the propel brakes during Preventive Maintenance periods.
5.8.4.1 Tools and Equipment Required
1. Warning Tag and Lockout Lock
2. Scale with 1/100" graduations
3. Flashlight
4. Note Paper and Pencil
5. Two 3/4-Inch Pipe Plugs
6. Adjustable Wrench
7. Open End Wrenches
8. Spray Window Cleaner or Soap/Water Solution
9. Air Pressure Supply
5.8.4.2 Visual Inspection
1. Inspect for oil or grease contamination that could adversely affect the ability of the brake to hold the load.
Locate and repair the source of contamination, and clean contaminated areas with a suitable solvent.
2. Inspect for loose or broken brake fasteners. Replace broken fasteners and torque fasteners as necessary.
3. Inspect the drive ring for indications of overheating, including discoloration of the drive ring. If any evidence of
overheating is noted, a serious condition exists that could cause sudden failure of the brake. Refer to Crowd
Brake Replacement and replace the brake.
4. Inspect between the piston and the cylinder for visual signs of air leakage. This is typically made evident by the
combination of dust and lubricant buildup on the face of the brake cylinder (refer to Figure 5-54). If such evi-
dence is noted, refer to Subtopic 5.11.5 and replace the O-rings.

Figure 5-54: Evidence of O-Ring Leakage (Typical)
5. Inspect for an accumulation of dirt and/or wear material within the drive ring. Clean out the accumulations, and
note the amount and condition of the wear material. If the wear material is excessive or has large pieces, refer
to Crowd Brake Replacement and replace the brake.
6. Verify that brake dust covers and dirt shields are correctly installed.
5.8.4.3 Mechanical Inspection
! WARNING
ate.
1. Release the brake and keep it released.
2. Verify that the center plate of the crowd brake is positioned by centering springs.
3. Using a pry bar, verify that the brake rotors move freely back and forth on the brake hub.

! CAUTION
Compressed air spray can injure eyes and ears, and breathing contamination particu-
lates can cause respiratory injury. Wear appropriate eye and ear protection and a respi-
rator when blowing out wear particles.
4. Blow out wear particles with non-lubricated compressed air to remove contaminants that will cause premature
brake failure.
5. Set and release the brake and observe the movement of the piston within the cylinder. Movement should be
smooth and even. Set the brake. If the piston moved slowly or did not move evenly, refer to Subtopic 5.8.6 and
replace the O-rings.
5.8.4.4 Piston Travel Measurement
NOTICE
The brake is equipped with a “brake worn” proximity switch, which is designed to alert the operator when the
brake’s piston travel exceeds a set dimension. P&H Mining Equipment recommends that In addition to relying on
the protection provided by the switch, maintenance procedures should include measuring piston travel at preven-
tive maintenance sessions. Piston travel provides an accurate picture of the total amount of internal wear on the
brake, and if tracked over time, can provide maintenance planners with valuable information regarding how and at
what intervals brakes wear. This can be of significant value for Planned Component Replacement or Predictive
Maintenance programs.
Measure piston travel as follows:

1. Observe the brake piston where it sits in the brake cylinder. Note whether the upper edge of the piston is sunk
within the cylinder or extends above it.
Figure 5-55: Propel Brake Piston Travel
2. With the brake set, note and record the measurement between the outer edge of the piston flange and the
outer face of the cylinder.
! WARNING
Stored Mechanical Energy, and Subtopic 5.8.1, Releasing Propel Brakes for Mainte-
nance, before releasing any brake for maintenance. In any situation where there is doubt
ate.
3. Release the brake as described in Subtopic 5.8.1 and repeat the measurement.
4. With the brake released, note and record the measurement between the outer edge of the piston flange and
the outer face of the cylinder. Set the brake.
5. Calculate the actual piston travel by subtracting the second measurement from the first measurement. Record
piston travel on the 250 Hour Brake Inspection Worksheet.
6. Refer to Table 5-1 to determine appropriate action based on piston travel measurements.
Technician Tip
Specifications in Table 5-1 are for brakes that wear evenly throughout their lives. To avoid dam-
age to brake that could occur if the friction pad rivets score the wear surfaces, consider adopt-
ing a policy that rather than removing the final shim, the brake should be replaced when one

shim remains and piston travel exceeds specification. Return worn brakes to P&H MInePro Ser-
vices for rebuild.
5.8.4.5 Operational Inspections
Inspections conducted when the shovel is in normal operation can determine some abnormal brake conditions that
cannot be easily discovered during Preventive Maintenance Inspections. If any of the following conditions are
noted, immediate corrective action is indicated.
Air Leaks With Brake Set
Air leaks with the brake set indicate problems in the brake air solenoid valves or their manifold. When the brakes
are set and the shovel is not operating, listen for air leaks at exhaust ports of the Solenoid Valve, the Quick
Release Valves, Redundant Solenoid Valves and Manifold Exhaust Ports. If air leakage is detected, repair or
replace the associated air solenoid valve (refer to Subtopic 5.7.3).
Air Leaks With Brake Released
With the shovel not shut down and the dipper on the ground, have an assistant release the brake by pressing the
button on the Propel Brake Maintenance Panel.
Check for leaks at the Quick Release Valve (QRV) exhaust port. Repair or replace the QRV if air leakage is
detected (refer to Subtopic 5.7.4).
Check for air leaks at the exhaust port of each Brake Air Panels (on the motor mounting base. Replace the redun-
dant air solenoid valve if air leakage is detected (refer to Subtopic 5.7.5.2).
Check for air leaks between the piston and the cylinder. Look for evidence of air leakage. Listen and feel for air
leakage. Replace damaged piston O-rings if leakage is detected (refer to Subtopic 5.8.6.3).
Chattering or Rattles
When the shovel is operating, listen from the operator’s cab for excessively noisy brake operation. Chattering may
indicate worn springs or inadequate air pressure. Rattling could be caused by loose friction pad components. If
noisy operation is noted, replace the brake (refer to Subtopic 5.8.7.
Heat Generation
Soon after the shovel is shut down from normal operation, carefully inspect for overheating. If the drive ring is hot to
the touch, replace the brake.
5.8.5 Adjustments
When the brake is new, shims are installed between the drive ring and the cylinder. As the brake wears, shims are
removed to restore original braking torque and original piston travel.
5.8.5.1 Inspection and Adjustment When Shims Are Installed
If shims are present between the cylinder and the housing and piston travel exceeds 0.312" (5/16" or 7.937 mm),
remove one shim as follows:

! WARNING
ate.
1. Release the brake.
2. With the brake released, equally back off the rod bolt stud nuts approximately 1/4 inch (6.35 mm).
Technician Tip
Turning rod bolt stud nuts with the brake set will damage or destroy the rod bolt stud threads.
Releasing the brake removes the spring pressure from the rod bolt stud nuts. Release the
brake before turning the rod bolt stud nuts.
3. Set the brake. Spring pressure will cause the brake cylinder assembly to move outward, creating a gap of
approximately 1/4" (6.35 mm) between the cylinder and the housing.
TC1570
Figure 5-56: Air Gap Split Shim

4. Use a large flat head screwdriver to pry out and remove one split shim (refer to Figure 5-91). Retain this shim
for future overhaul. Tag or store the shim in a location where it will be associated with the brake from which it
was removed when the brake is removed for overhaul.
5. Release the brake again. This will remove spring pressure from the rod bolt stud nuts and allow the rod bolt
nuts to be tightened.
LEGEND
First Round
Second Round
Third Round
Fourth Round
ES04329b01
6. Using a star pattern, initially tighten the rod bolt stud nuts (refer to Figure 5-57).
7. Set the brake.
8. Using a star pattern, tighten the rod bolt stud nuts to 110 - 120 ft-lbs (152 - 165 N·m).
9. Measure and record piston travel. Piston travel should be between 0.250" and 0.375" (1/4" and 3/8”, or
6.35mm and 9.525mm). Provide this information to your maintenance planner.
10. Install the air piping to original configuration if any changes have been made.
CAUTION
Improperly adjusted or maintained brakes can be destroyed in a very short time during
operation. After any brake inspection or maintenance and before resuming operations,
conduct inspections on brakes using static and dynamic tests specified in Subtopic
5.8.8.
5.8.5.2 Inspection and adjustment when no shims are installed
If no shims are in place and piston travel exceeds 0.312" (5/16" or 7.937 mm), the brake must be replaced. Refer to
Hoist Brake Replacement.

5.8.6 O-ring And Felt Seal Replacement
1. Warning Tag
2. Lockout Lock
4. Flashlight
5. One 3/4-Inch Pipe Plug
6. Four Threaded Rods (same thread size as brake’s socket head cap screws) OR Four Hex Head Cap Screws
(at least one inch longer than the socket head cap screws and same thread size)
7. Hooked Needle
8. Thread
11. Impact Wrench
12. Torque Wrench Hex Drives
13. Chain Hoist and Slings
14. Eye Bolts
15. Permanent Marker
16. Eye Protection
17. Soft Rubber Mallet
5.8.6.2 Piston Removal
Technician Tip
An assistant is required to help remove and install disc brake components.
2. Remove all air piping connections to the brake.
3. Remove the four fasteners that secure the small dust cover over the socket head cap screws on the face of the
piston. Remove the dust cover.

4. Remove the quick release valve (QRV).
Technician Tip
Match marking the piston to the cylinder will save time at reassembly when it is necessary to
realign bolt holes and install eye bolts in the correct positions.
5. With the brake set, remove the piston as follows:
! CAUTION
Air pressure in the brake could cause the piston to be forced out of the cylinder unex-
pectedly, causing personal injury. Do not have air pressure on the brake when removing
the socket head cap screws.
A. Remove the socket head cap screws that fasten the pressure plate to the piston as shown in Figure 5-58.
Figure 5-58: Removing Socket Head Cap Screws from Piston (training brake shown)
B. Install the four hex head cap screws at 90 degree intervals around the pressure plate as shown in Figure 5-
59.
Figure 5-59: Installing Hex Head Cap Screws in Pressure Plate

Technician Tip
Four threaded rods can be used instead of the four hex head cap screws. If rods are used,
install them equally, 90 degrees apart. The rods or cap screws are used to guide the brake pis-
ton and prevent it from twisting and binding within the air cylinder when it is being removed or
installed.
! CAUTION
Compressed air may be contaminated with wear particles from inside the brake, which
can injure eyes and ears. Wear a face shield and safety glasses as protection against fly-
ing particles as the piston seal is broken. Keep hands and face clear of the piston when
air pressure is being applied.
6. Install an air fitting and connect an external air supply regulated to 35 psi (2.4 bar).
Technician Tip
A blow gun also works well to remove the piston. To use a blow gun, leave the air line discon-
nected from the brake, and when ready just blow a small amount of air in the brake.
7. Use the air supply ball valve or blow gun to apply a slight amount of air pressure to assist in removal. As the
piston begins to move, the assistant should use the soft rubber mallet to gently keep the piston perpendicular
to the cylinder so it will not bind.
8. When the piston has traveled far enough to clear the O-ring seals (Figure 5-60) turn off the air supply.
Figure 5-60: Piston Clear of O-Rings
9. If hex head cap screws were used as guides, remove them. Take the piston to a flat and clean work surface.
5.8.6.3 O-ring and Felt Seal Replacement
1. Remove inner and outer O-rings and the felt dust seal.

2. Clean and inspect the piston seal grooves for burrs and sharp edges. Repair by filing, sanding, or grinding.
Figure 5-61: Inspect Piston O-Ring Grooves
3. Clean and inspect the cylinder for burrs or sharp edges. Repair by filing, sanding, or grinding lightly, taking care
not to damage the aluminum.
Figure 5-62: Inspect Cylinder
A. Lubricate replacement O-rings with a light coating of petroleum jelly or multi-purpose grease (MPG). Do not
stretch the O-rings.
B. Install piston O-rings by folding them over the piston edge and into the O-ring groove. Refer to Figure 5-63.
Figure 5-63: Installing Piston O-Rings

4. Install the split felt dust seal as follows.
Technician Tip
The dust seal is not symmetrical. The wide face of the seal should be placed into the groove. If
the narrow face of the seal is placed into the groove, it will be difficult to insert the piston into the
cylinder.
A. Start the felt seal end at any point on the piston by pressing the seal into the dust seal channel. Continue
feeding and pressing the seal into position around the circumference of the piston. The ends of the seals are
straight cut. When you have circled the piston with the seal, estimate and cut off the remainder of the seal.
Discard the remainder. Butt the two ends of the seal together, and press inward (refer to Figure 5-64).
Stretch the seal slightly and trim the edges again.
B. Using a hooked needle and thread, sew the ends of the felt seal together.
Figure 5-64: Ends of Split Seal Before Cutting to Fit
5.8.6.4 Piston Installation
1. If using the four threaded rods, align the match marks and mount the piston onto the rods. Carefully push the
piston into the cylinder, taking care not to pinch the seals. Expect difficulty with the dust seals.
2. If using the four hex head cap screws, align the match marks and mount the piston on the cylinder. Install the
four hex head cap screws. Carefully push the piston into the cylinder, taking care not to pinch the seals. Expect
difficulty with the dust seals.
3. As the piston enters the cylinder, use a thin piece of plastic or metal to fold the seals back into their grooves.
Fully seat the piston within the cylinder.
4. Start the socket head cap screws by hand. Use a dowel bar to move the piston into alignment with the cylinder.
Tighten the socket head cap screws evenly and secure them using a star pattern as a tightening sequence.
Torque the piston socket head cap screws to 200 - 220 ft-lbs (276 - 304 N·m)
5. Install the dust cover plate.
6. Return the brake to normal operation by removing temporary plugs and air piping and reinstalling original
plugs, air piping connections and quick release valves (QRV).
7. Perform a 250-hour inspection of the disc brake assembly.
8. Remove lockout and tagout devices.

CAUTION
5.8.8.
5.8.7 Propel Brake Replacement
1. Warning Tag
2. Lockout Lock
4. Flashlight
• An External Source of Air (105 psi)
• Air Hose and Fittings
• Two Ball Valves
• Regulator capable of 105 psi, with gauge
• Check Valve
• One Pipe Tee
• One Pipe Plug
8. Impact Wrench with Sockets
9. Torque Wrench
10. Large Screwdriver
12. Three Eye Bolts
13. Hex Drivers

14. Cutting Tools
15. Propel Brake Removal Jig, P&H Part Number R51334D1
5.8.7.2 Propel Brake Removal
! WARNING
(refer to Releasing Stored Energy) before removing disc brakes on P&H Mining Shovels.
Before removing a brake, confirm that stored energy has been released as described in topic Releasing Stored
Energy.
Following the procedures in the topic Releasing Stored Energy accomplishes two things: First, it demonstrates that
the brake is operating normally (i.e, components are free to move and the brake is not seized); second, it releases
stored mechanical energy.

Even though the stored mechanical energy has been released, changes in the physical condi-
tion of the shovel could cause stored mechanical energy to redevelop. For this reason, P&H
Mining Equipment recommends that only one brake be removed from the machine at a time.
The remaining brakes will stay installed and set to inhibit unexpected movement. Completely
reinstall each brake before removing any other brake.
Proceed as follows:
1. Confirm that the shovel is properly parked on properly compacted and stable ground on a flat, even grade, with
the dipper resting on the ground (dipper front face flat on ground, dipper heel and dipper lip both contacting
! WARNING
ure, resulting in severe personal injury or death. Before beginning work, tag lines and
make sketched, photographic, or digital images of the connections to ensure that you
will be able to return the system to its original configuration.

Use the following procedure to release a brake using an external air supply line.
06.
01.
05. 07.
02.
03.
04.
LEGEND 04. To Atmosphere

01. To Brake 05. Regulator and Gauge
03. Exhaust Valve 07. Quick Disconnect

(locally fabricated)
An External Source of Air (105 psi)
Air Hose and Fittings
Two Ball Valves
Regulator capable of 105 psi, with gauge
Check Valve
One Pipe Tee
One Pipe Plug

Refer to Figure 5-41 and release the brake as follows:
05
04
03
LEGEND
03. Air Port
01 04. Brake
05. Air Port
! CAUTION
1. Disconnect the existing brake air supply line (02) where it is connected at the quick release valve (01).
2. If the disc brake has a brake solenoid panel, remove the exhaust line at the brake outlet (05) and install a pipe
plug in the brake outlet (on brakes without brake solenoid panels, this port is already plugged).

ES1570b03
! WARNING
ment of shovel components could result in serious personal injury or death. Be prepared
that all personnel are clear of the major motions affected by the associated brake sys-
tem.
! WARNING
If a disc brake will not open and the piston does not move outward, the normal brake
removal procedure must not be used. Refer to Brake Removal Under Special Conditions.
7. Maintain the air pressure in the brake to keep the brake open and prevent redevelopment of stored energy as
the brake is being removed.

! WARNING
brake being removed with a suitable sling or other support. Disc brakes can weigh up to
1700 pounds (770 kg).
Figure 5-68: Disc Brake Mounting Bolts (circled) (Typical)
8. There are typically twelve mounting bolts (visible mounting bolts in Figure 5-43 are circled in white). Loosen the
mounting bolts one at a time. Do not remove any of the bolts at this time. Loosen the bolts that are in the most
difficult access areas first, and work around to the mounting bolts where access is easiest.
9. Loosen the last mounting bolt (most likely at the 12 o'clock position) one turn only.
10. Re-verify that brake components are released and not binding using one of the techniques below:
A. Place a pry bar under the brake. The brake should move slightly on the mounting bolts when pried.
B. Observe the rotors inside the brake. Use a pry bar or large screw driver to move the rotors on the brake hub.
! WARNING
resulting in severe personal injury or death. If any binding (resistance) 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 procedures described in Brake Removal Under Spe-
cial Conditions.
11. Remove the bolts from the brake mounting flange.

Technician Tip
If there is any doubt as to the development of stored energy, the outside air source can remain
connected until the entire disc brake is removed from the hub. Be aware that maintaining an
outside air source will cause the rotors to drop inside the disc brake as the disc brake is slid off
the hub. Alignment will be required before the disc brake is reinstalled.
! WARNING
ure, resulting in severe personal injury or death. Refer to tags on air lines and to
sketched, photographic, or digital images of the connections to ensure that you return
all connections to the original configuration.
13. When installing the replacement brake, be certain to reconnect the brake air system as it was before perform-
ing this disassembly procedure.
5.8.7.3 Propel Brake Removal Jig, P&H Part Number R51334D1
To provide a method for removing the propel brakes, P&H Mining Equipment has designed a Propel Brake
Removal Jig (R51334D1).
! WARNING
cause severe personal injury or death. The brake must be released and set without the
motors running before beginning to remove the brake from the shovel in order to release
any stored mechanical energy. Read and understand Topic 5.3, A Warning About Stored
Mechanical Energy, and Topic 5.9, Releasing Upper Brakes for Maintenance, before
attempting to remove the brake. If the brake piston does not move outward, the brake
has not been released and there is still a potential for mechanical stored energy. If out-
ward movement of the piston cannot be confirmed, the brake must not be removed and
must be disassembled in place. Refer to Topic 5.5.
NOTICE
An assistant and a means of communication are required to remove or install disc brake
assemblies. The assistant will release the brake. The assistant should be positioned at the
Swing Brake Air Valve in the lube room (refer to Subtopic 5.9.2) or at the external air supply
(refer to Subtopic 5.9.3). With the technician at the brake, have the assistant release and set
the brake by operating the brake as described in Subtopic 5.9.2 or Subtopic 5.9.3.

! WARNING
When removing the brake, it is imperative that the brake be released and set several
times with the shovel shut down and the motors inactive. To avoid this step could result
in serious injury or death. Prior to attempting to removing the brake, release and set the
brake using the procedures outlined in Subtopic 5.9.2 or Subtopic 5.9.3.
2. Have the assistant release and set the brake using procedures specified in Subtopic 5.8.1.1. Verify that the
brake releases and sets by observing and/or measuring brake piston travel. If the brake does not release, or if
there is any indication that the brake is seized or bound in any way, do not attempt to remove the brake using
these instructions; rather, follow the instructions in Subtopic 5.8.7.4.
3. Remove the center cover from the brake.
4. Remove four (4) of the 3/4" Socket Head Cap Screws, 90° apart, from the piston.
5. Attach the brake removal jig to the brake using four (4) Socket Head Cap Screws, 3/4"-10 UNC x 5". Torque
cap screws to 150 Ft-lbs (203 N·m).
! WARNING
Improper lifting of heavy components can cause serious injury or death. Use a shackle
with a load rating of at least 2 tons (1815 kg). Propel brakes weigh approximately 690
pounds (303 kg).
6. Attach a crane to the lifting points. Use a shackle with a load rating of at least 2 tons. Ensure that there is no
slack in the crane lifting line. Use a come-along to balance the load and keep it straight.
8. Loosen the brake mounting cap screws.
NOTICE
If binding of the bolts is felt while removing the bolts by hand or by hand tools, arrange the chain
hoist or crane that will be used to remove the brake to support the weight of the brake. Release
and set the brake again. Do not attempt to remove brake further if brake continues to bind or
attempts to rotate. If it is impossible to remove load tension by releasing the brake, re-tighten
the cap screws and discontinue removing the brake. Suspect the brake of still being under ten-
sion. Follow the procedures in Subtopic 5.8.7.4.
9. Remove the brake mounting cap screws by hand.
10. Set the brake and remove all piping connections.
11. Using the jig and crane, remove the brake assembly from the brake hub.
12. Lower the brake to the ground and remove the four cap screws used to attach the brake to the jig. Reinstall the
four 3/4" Socket Head Cap Screws to the brake piston and torque them to 200 - 220 Ft-lbs (271 - 298 N·m).

13. Replace the center cover.
14. Clean and inspect the brake hub for chucking damage. Repair the splines by filing or replace the hub assem-
bly. Lubricate the hub splines with a light coating of lubricant (do not use anti-seize). Do not over lubricate or
the lubricant may foul the brake.
15. Return the brake assembly to your local P&H MinePro Services repair facility for Encore remanufacture.
5.8.7.4 Propel Brake Removal -- Special Conditions
If a brake cannot be released, or in situations where the brake piston does not move normally during a release and
set cycle, the brake may be storing large amounts of mechanical energy. In such cases, do not attempt normal
! WARNING
ning of the brake, its components, and the transmission input shaft, as well as major
movement of the dipper and dipper handles, resulting in severe personal injury or death.
Read and understand Topic 5.3, A Warning About Stored Mechanical Energy, before pro-
ceeding. Ensure that all personnel are clear of major motions affected by the associated
brake system.
1. Confirm preliminary maintenance procedures have been completed. Refer to subsection 5.6.
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NOTICE
loosened. Be prepared for possible movement of the shovel and the propel drive train.

! WARNING
! WARNING
with a load rating of at least 2 tons (1815 kg). The propel brake cylinder assembly weighs
approximately 477 pounds (216 kg).
8. Lift the cylinder assembly away from the brake.
! WARNING
in order:
• Outer Rotor
• Center Plate
• Inner Rotor
• Wear Ring
• Brake Hub
Technician Tip

! WARNING
Improper lifting of heavy components can cause serious injury or death. Support the
brake being removed with a suitable sling or other support. The drive ring weighs
approximately 149 lbs (66 kg).
10. Support the weight of the drive ring with slings and a suitable lifting device. The drive ring weighs approxi-
mately 149 lbs (66 kg).
5.8.7.5 Propel Brake Installation
NOTICE
An assistant and a means of communication are required to install disc brake assemblies. The
assistant will release the brake. The assistant should be positioned at the Propel Brake Mainte-
nance Control Panel. With the technician at the brake, have the assistant release and set the
brake when directed in the following procedure to operate the brake. Refer to subsection 5.3.
1. Confirm preliminary maintenance procedures have been completed. Refer to Topic 5.6
2. Inspect the brake hub. If the brake hub splines have any nicks or burrs, repair the splines by filing or replace
the hub assembly. Lubricate the hub splines with a light coating of lubricant (do not use anti-seize). Do not over
lubricate or the lubricant may foul the brake.
3. Verify that the brake part number is correct.
! WARNING
with a load rating of at least 2 tons (1815 kg). Propel brakes weigh approximately 690
pounds (303 kg).
8. Install the air supply piping and quick release valve (QRV) as follows:
A. Install the air piping and QRV at the 6 o’clock position.
B. Remove the plug from the air port at the 12 o’clock position.

C. Install exhaust air piping that leads to the redundant solenoid panel.
9. Lift the brake into mounting position. If the brake assembly is not completely seated on its mounting base due
to misalignment of the brake hub splines and the brake rotor splines, manually apply air pressure to release
the brake. With the brake in the released condition, twist and turn the brake assembly, while applying pressure
against the brake. When the brake is fully seated, align the drive ring in its correct mounting position and install
four mounting cap screws at equally spaced points.
Technician Tip
The propel brake is a multiple-rotor brakes. If the rotors are not aligned, it may be necessary to
disassemble and install the brake one component at a time.
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10. Install the remaining mounting cap screws. Tighten evenly to 200 Ft-lbs (271 N·m) using the star pattern shown
in Figure 5-70.
11. Measure and record piston travel. Piston travel should be between 0.125" and 0.3125" (1/8” to 5/16", or 3.175
mm to 7.937 mm). Provide piston travel information to your maintenance planner.
NOTICE
Some documentation requires measurement of total air gap. Since air gaps are created when
the piston moves outward, total air gap and piston travel are the same. In order to assure suffi-
cient air gap, piston travel must be not less than 0.125".
12. Return the shovel to the normal shut down condition.

CAUTION
Improperly installed or adjusted brakes can be destroyed in a very short time during
operation. Before resuming operations, inspect the brakes using static and dynamic
tests specified in Topic 5.8.8.
5.8.8 Propel Brake Performance Tests
5.8.8.1 General
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.
5.8.8.2 Verification Of Static Holding Torque
Check the static holding torque by applying maximum load with the motor stopped. These tests should be per-
formed after any maintenance has been completed on brakes and prior to returning the shovel to operation.
! WARNING
Be prepared for shovel movement which may occur during static holding torque verifica-
tion. Such movement may result in severe injury or death as well as damage to the
equipment. Ensure that all personnel are clear of shovel.
Move the shovel to an incline of approximately 15% grade. Place the shovel in CROWD mode. The shovel should
not move.
5.8.8.3 Verification Of Dynamic Braking Torque
! WARNING
This dynamic braking torque verification procedure has been developed only as a
severe system test to be used by inspectors in determining regulatory compliance. It is
not intended to be used as a normal check by the user. Excessive dynamic brake testing
will cause premature wear to the brake and could cause it to fail under emergency stop
conditions, which may result in severe personal injury, death, or property damage.
Under normal conditions, dynamic braking is accomplished electrically by positioning the joystick controller so that
the motion does not move.
The mechanical disc brakes must also be capable of stopping the motion. By design, braking torque is less than
stall torque, in order to inhibit damage to the gearing. Motions will continue (within tolerance) after the brake is
applied.

! WARNING
Be prepared for shovel movement which may occur during static holding torque verifica-
tion. Such movement may result in severe injury or death as well as damage to the
equipment. Ensure that all personnel are clear of shovel.
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.
If either static braking or dynamic braking does not perform as specified, thoroughly inspect the brakes. Also
inspect the air system and the electrical system as they apply to brakes. Refer to subsection 5.5 of this manual and
to subsection 4.5 of the Air & Lubrication Systems Manual for more information.
5.8.9 Propel Brake Burnish-In Procedures
5.8.9.1 General
All P&H Electric Mining Shovels that are equipped with disc brakes use brakes with metallic friction pad linings.
These brakes are responsible for holding the motion still when the motion is not being used. They are also respon-
sible for stopping the motion in an emergency stop situation.
The burnish process is intended to promote the formation of an oxide film on both the lining and the opposing sur-
face. This layer protects the surfaces from corrosion and premature wear, and provides consistent coefficients of
friction over the life of the brake.
5.8.9.2 Burnish-in Procedure
This procedure assumes that the brake has been properly installed in accordance with applicable instructions.
Confirm that running clearances are within the specifications for the brake.
! WARNING
Be prepared for movement of major shovel components which will occur during the bur-
nish-in procedure. Such movement may result in severe injury or death. Ensure that all
personnel are clear of shovel motions affected by these procedures.
1. Press the PROPEL button to put the shovel in propel mode.
2. Move both joystick controllers 1/4 forward from center to propel the shovel at 1/4 speed.
3. With the shovel propelling at 1/4 speed, press the CROWD button to set the propel brakes.
4. Wait one minute. After the one-minute wait, use a hand-held temperature monitor to check the temperature of
the brake center plates and pressure plates. Temperature must be below 300°F (149°C).
5. Repeat steps 1 through 4 three more times.
6. Press the PROPEL button to put the shovel in propel mode.
7. Move both joystick controllers 1/2 forward from center to propel the shovel at 1/2 speed.

8. With the shovel propelling at 1/2 speed, press the CROWD button to set the propel brakes.
9. Wait two minutes. After the two-minute wait, use a hand-held temperature monitor to check the temperature of
10. Repeat steps 6 through 9 seven more times.
After performing the burnish-in procedure, conduct a brake static holding torque test as described in Subtopic
5.8.8.2. To further test the entire brake system including the air system under dynamic conditions, if desired, per-
form the brake dynamic torque test as described in Subtopic 5.8.8.3.
5.9 Releasing Upper Brakes for Maintenance
5.9.1 Releasing Upper Brakes Using the Operator’s Controls
! WARNING
When preparing for brake removal, do not use the operator’s controls to release the
brake. When removing the brake, it is imperative that the brake be released and set sev-
eral times while shovel is shut down and the motors are not active. To avoid this step
could result in serious injury or death. When removing the brake, use the procedures
outlined in Subtopic 5.9.2 or Subtopic 5.9.3.
Releasing the brakes requires two people. An assistant should be stationed at the control console in the operator’s
station, and the technician at the brake. It is important to establish a means of communication between the two per-
sons. When notified by the technician, the assistant should release and set the brake being inspected, using the
operator controls.
Technician Tip
When releasing one hoist or swing brake, the other brake(s) in the system should be isolated
from the main air supply by removing the lock from the ball valve attached to the quick release
valve inlet (refer to Figure 5-34) and closing it. This allows the brake being inspected to release
without releasing the other brakes in the system. Be sure to return the ball valve to the open
position when maintenance is completed.

1. Start the shovel using approved start-up procedures. Refer to the Operator’s Manual.
10
09
08 11
12 13 14 15
07 06 05 04
ES04422b01
03 02 01
LEGEND
01. Graphical User Interface (GUI) 10. Hoist Brake Set Switch Position
(refer to Operations Main Screen) 11. Hoist Brake Release Switch Position
02. Left Joystick Controller 12. Swing Brake Status Indicator*
03. Left Switch Panel 13. Hoist Brake Status Indicator*
04. Propel Active Switch Position 14. Crowd Brake Status Indicator*
05. Propel Inactive Switch Position 15. Propel Brake Status Indicator*
06. Swing Brake Release Switch Position
07. Swing Brake Set Switch Position *These are on the Operations Main Screen. White
08. Crowd Brake Release Switch Position indicates brake is not released; Amber indicates
09. Crowd Brake Set Switch Position brake is released.
Figure 5-71: Upper Brake Release Switches
2. Refer to Figure 5-71 and proceed as follows:

! WARNING
Be prepared for movement of major shovel components controlled by the various brakes
that may occur when performing maintenance procedures. Unexpected movement of
shovel components may result in serious personal injury, death, and equipment damage.
Ensure that all personnel are clear of the major motions affected by the associated brake
system.
A. Swing Brake control is on the left switch panel (Item 03).
1). When the swing brake is set, the swing brake release portion of the swing brake rocker switch (Item 07)
displays a red light, indicating that the swing brakes are set. Pressing the lower portion of the rocker
switch (Item 06) sends a brake release request to the Centurion Control System. When the brake
releases, the red light goes out to indicate that the swing motion is now active.
2). To set the swing brake, press the upper portion of the swing brake rocker switch (Item 07). The brakes
will set and the red light will illuminate, indicating that the swing brakes are set and that the swing
motion is now inactive.
B. Crowd Brake control is on the left joystick controller (Item 02).
1). When the crowd brake is set, the crowd brake release portion of the crowd brake rocker switch (Item 09)
displays a red light, indicating that the crowd brake is set. Pressing the lower portion of the rocker switch
(Item 08) sends a brake release request to the Centurion Control System. When the brake releases, the
red light goes out to indicate that the crowd motion is now active.
2). To set the crowd brake, press the upper portion of the crowd brake rocker switch (Item 09). The brake
will set and the red light will illuminate, indicating that the crowd brake is set and that the crowd motion
is now inactive.
C. Hoist Brake control is on the left joystick controller (Item 02).
1). When the hoist brakes are set, the hoist brake release portion of the hoist brake rocker switch (Item 10)
displays a red light, indicating that the hoist brakes are set. Pressing the lower portion of the rocker
switch (Item 11) sends a brake release request to the Centurion Control System. When the brake
releases, the red light goes out to indicate that the hoist motion is now active.
2). To set the hoist brake, press the upper portion of the hoist brake rocker switch (Item 10). The brake will
set and the red light will illuminate, indicating that the hoist brakes are set and that the hoist motion is
now inactive
5.9.2 Releasing Upper Brakes Using the Air Valve
When releasing one hoist or swing brake, the other brake(s) in the system should be isolated from the main air
supply by removing the lock from the ball valve attached to the quick release valve inlet and closing it. This allows
the brake being inspected to release without releasing the other brake(s) in the system, which permits the remain-
ing brake(s) to exert holding force on the motion. Be sure to return the ball valve to the open position when mainte-
nance is completed.
An assistant should be at the upper air valve manifold in the lubrication room, and the technician should be at the
brake. It is important to establish a means of communication between the two persons.

Release and set the brake being inspected as follows:.
Figure 5-72: Manual Actuators on Upper System Brake Air Valves
2. Confirm air pressure in the main air receiver is at least 100 psi. This can be confirmed by reading the gauge at
the operator’s console. If there is not sufficient air pressure in the system, do not use this procedure. Instead,
use the procedure described in Subtopic 5.9.3.
3. Identify the air valve that provides air to the brake to be operated. Labels are attached above the valve.
! WARNING
ment of shovel components could result in serious personal injury, death, and substan-
tial equipment damage. Be prepared for significant movement of major shovel
components when brakes are released. Ensure that all personnel are clear of the major
motions affected by the associated brake system.
4. To release the brake, use a 1/8"-diameter rod (or a similar suitable device) to press the manual actuator button
(indicated by the white arrows in Figure 5-72) on the valve that provides air to the brake to be operated. Main-
tain pressure on the manual actuator button for as long as the brake is to be released.
5. To set the brake, remove pressure from the manual actuator button.

5.9.3 Releasing Upper Brakes Using an External Air Supply
! WARNING
ure. Before beginning work, tag lines and make sketched, photographic, or digital
images of the connections to ensure that you will be able to return the system to its orig-
inal configuration.
If the shovel’s compressed air system is not available, or if there is some other reason the manual actuators on the
air valves are not to be used, the brake assemblies can be released manually using an external air line. Use the
following procedure to release a hoist, crowd, or swing brake using an external air supply line.
• An External Source of Air (105 psi)
• Air Hose and Fittings
• Two Ball Valves
• Regulator capable of 105 psi, with gauge
• Check Valve
• One Pipe Tee
• One Pipe Plug (3/4" NPT for hoist brakes, 1/2" NPT for swing brakes)

06.
01.
05. 07.
02.
03.
04.
LEGEND 04. Exhaust Port

01. To Brake 05. Regulator with Gauge
03. Exhaust Valve 07. Quick Disconnect Fitting
Figure 5-73: Manual Brake Release Assembly (locally fabricated)
5.9.3.2 Brake Release Procedure
Perform the following steps:
! CAUTION

2. Disconnect the existing brake air supply line where it is connected at the quick release valve (See Figure 5-74).
The quick release valve has a diaphragm inside that opens or closes the exhaust port based on air pressure
differential. For more information see Subtopic 5.7.4
06. 06.
07. 07.
05. 05.
04. 04.
02. 02.
03. 01. 03.
07.
ES1570_01 ES1570_02
LEGEND
01. From Primary Air Supply 05. Brake Outlet
02. Quick Release Valve 06. Redundant Solenoid Panel
03. Brake Inlet 07. Exhaust
04. Brake
Air Flow
Figure 5-74: Disconnecting Air lines (hoist brake shown)
3. On hoist and swing brakes, remove the exhaust line at the brake outlet (opposite the Quick Release Valve).
Install a pipe plug in the brake outlet. (this step is not required on the crowd brake).

ES1570_03
! WARNING
8. Perform the maintenance task.
! CAUTION
CAUTION
ure. Refer to tags on air lines and to sketched, photographic, or digital images of the

connections made at disassembly to ensure that you return all connections to the origi-
nal configuration.
10. Reconnect the brake air system as it was before this procedure.
5.9.3.3 Brake Release Pressure Test
The same external air supply arrangement can be used to confirm brake release pressure. Each brake has a spe-
cific release pressure indicated in the specifications table. If the brake springs become weak, the brake will not hold
reliably. Weak springs also cause a reduction of release pressure. Confirm brake release pressure (and conse-
quently, braking torque) by testing as follows:
! CAUTION

2. Disconnect the existing brake air supply line where it is connected at the quick release valve (See Figure 5-75).
The quick release valve has a diaphragm inside that opens or closes the exhaust port based on air pressure
differential. For more information see Subtopic 5.7.4
06. 06.
07. 07.
05. 05.
04. 04.
02. 02.
03. 01. 03.
07.
ES1570_01 ES1570_02
LEGEND
01. From Primary Air Supply 05. Brake Outlet
02. Quick Release Valve 06. Redundant Solenoid Panel
03. Brake Inlet 07. Exhaust
04. Brake
Air Flow
Figure 5-75: Disconnecting Air lines (hoist brake shown)
3. On hoist and swing brakes, remove the exhaust line at the brake outlet (opposite the Quick Release Valve).
Install a pipe plug in the brake outlet. (this step is not required on the crowd brake).

ES1570_03
! WARNING
8. Close the supply ball valve and open the exhaust ball valve to set the brake.
9. Set the regulator on the manual release assembly to 0 psi.
10. Open the supply ball valve. Gradually increase the setting on the regulator until the piston moves fully outward.
Note and record the pressure setting.
! CAUTION

CAUTION
ure. Refer to tags on air lines and to sketched, photographic, or digital images of the
connections made at disassembly to ensure that you return all connections to the origi-
nal configuration.
If the brake release pressure recorded in Step 10 above is lower than the specified brake release pressure, replace
the brake. Otherwise, reconnect the brake air system as it was before this procedure.

5.10 Crowd Brake Maintenance R41760D1
5.10.1 Crowd Brake Components
12
13
03
01 02
06
10 01 02
04
07
05
08
05
09 04
11 10
TC0455b
LEGEND 09. Rod Bolt Stud Assembly

01. Center Plate 05. Pressure Plate 10. Drive Ring
02. Wear Plate 06. Indicator Assembly 11. Brake Mounting Bolt
03. Cylinder 07. Piston 12. Set/Release Switch
04. Rotor 08. O-rings 13. Wear Switch
Figure 5-76: Crowd Brake (R41760D1)

5.10.2 Crowd Brake Specifications
Measure- Procedure/Action Result/Action

ment

11.9 mm) 250 hours.
0.470"
11.9 mm)
0.220"
(1/4”
5.6 mm)
Air Pressure Data
Torque Data
Brake mounting bolts 265 ft-lbs (366.5 N·m)
Hub retainer plate bolts 150 ft-lbs (207 N·m) w/tie wire
Weights
Crowd Brake Assembly, R41760D1 690 lbs (303 kg)
Rotors (two required) 49 lbs (22 kg) each
Center Plate 76 lbs (33 kg)
Table 5-2: Brake Specifications, Crowd Brake (R41760D1)
NOTICE

Inspect the crowd brake during Preventive Maintenance periods.
3. Flashlight
overheating is noted, a serious condition exists that could cause sudden failure of the brake. Refer to Crowd

to Crowd Brake Replacement and replace the brake.
! WARNING
ate.
2. Verify that the center plate of the crowd brake is positioned by centering springs.

! CAUTION
brake failure.
smooth and even. Set the brake. If the piston moved slowly or did not move evenly, refer to Subtopic 5.10.5
and replace the O-rings.
NOTICE
2. With the brake set, note and record the measurement between the outer edge of the piston flange and the
inner edge of the cylinder.
! WARNING
ate.
3. Release the brake as described in Topic 5.9 and repeat the measurement.

4. With the brake released, note and record the measurement between the edge of the piston and the outer edge
of the cylinder. Set the brake.
6. If piston travel exceeds 0.3125" (3/16", or 7.937 mm) and at least one shim is in place, remove one shim. If no
shims are in place, replace the brake.
Technician Tip
Specifications are for brakes that wear evenly throughout their lives. To avoid damage to brake
that could occur if the friction pad rivets score the wear surfaces, consider adopting a policy that
rather than removing the final shim, the brake should be replaced when one shim remains and
piston travel exceeds 0.3125". Return worn brakes to P&H MInePro Services for rebuild.
! WARNING
Working around moving machinery, or in spaces where movement is restricted, or at ele-
vations above 6 feet, present hazardous situations which could cause serious personal
injury or death. Do not work on the boom when the shovel is in operation.
Air leaks with the brake set indicate problems in the brake air solenoid valves or their manifold. When the brakes
are set and the shovel is not operating, listen for air leaks at exhaust ports of the Solenoid Valve, the Quick
Release Valves and Manifold Exhaust Ports. If air leakage is detected, repair or replace the associated air solenoid
valve.
With the shovel not shut down and the dipper on the ground, have an assistant release the brake by operating the
manual override on the crowd brake air valve.
detected.
Check for air leaks at the exhaust port of each Brake Air Panels (on the hoist gear case). Replace the redundant air
solenoid valve if air leakage is detected.
leakage. Replace damaged piston O-rings if leakage is detected.

When the shovel is operating, listen from the operator’s cab for excessively noisy brake operation. Chattering may
indicate worn springs or inadequate air pressure. Rattling could be caused by loose friction pad components. If
noisy operation is noted, replace the brake.
Heat Generation
Soon after the shovel is shut down from normal operation, carefully inspect for overheating. If the drive ring is hot to
the touch, replace the brake.
5.10.4 Adjustment
5.10.4.1 Inspection and adjustment when shims are installed
! WARNING
ate.
Technician Tip

TC1570
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7. Set the brake.
9. Measure and record piston travel. Piston travel should be between 0.250" and 0.375" (1/4" and 3/8”, or
CAUTION
5.10.7.
5.10.4.2 Inspection and Adjustment When No Shims Are Installed
5.10.5 O-ring and Felt Seal Replacement
1. Warning Tag
2. Lockout Lock
4. Flashlight
7. Hooked Needle
8. Thread
11. Impact Wrench

14. Eye Bolts
16. Eye Protection
Technician Tip
Technician Tip
! CAUTION

81.
Technician Tip
installed.
! CAUTION

Technician Tip
9. If hex head cap screws were used as guides, remove them. Take the piston to a flat and clean work surface.
5.10.5.3 Seal Replacement

Technician Tip
cylinder.

7. Reinstall the brake shroud.
CAUTION
5.10.7.

5.10.6 Crowd Brake Replacement
1. Warning Tag
2. Lockout Lock
4. Flashlight
9. Impact Wrench
10. Impact Wrench Sockets
11. Torque Wrench
14. Three Eye Bolts
15. Hex Drivers
16. Cutting Tools
5.10.6.2 Crowd Brake Removal -- Normal Procedure
! WARNING
must be disassembled in place. Refer to Subtopic 5.10.6.3.

NOTICE
2. Remove the brake cover.
! WARNING
3. Have the assistant release and set the brake using procedures specified in Subtopic 5.9.2 or Subtopic
5.9.3. Verify that the brake releases and sets by observing and/or measuring brake piston travel. If the brake
does not release, or if there is any indication that the brake is seized or bound in any way, do not attempt to
remove the brake using these instructions; rather, follow the instructions in Subtopic 5.10.6.3.
NOTICE
6. Remove the brake mounting bolts by hand.
8. Move the brake assembly outward a small distance. Locate the lifting hole at the 12 o’clock position of the
brake mounting flange and install one eye bolt with a nut.
9. Using the appropriate slings and chain hoist or crane for the weight of the brake, support the brake assembly.
The crowd brake assembly weighs approximately 690 lbs (303 kg).
10. Using the chain hoist or crane, remove the brake assembly from the brake hub.

5.10.6.3 Crowd Brake Removal -- Special Conditions
! WARNING
brake system.
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NOTICE
loosened. Be prepared for possible movement of the dipper handles and associated motion
components.

5. The cylinder assembly weighs approximately 328 lbs (144 kg). Use the appropriate slings and chain hoist or
crane for the weight of the brake assembly. Remove the brake air cylinder assembly.
! WARNING
in order:
• Outer Rotor
• Center Plate
• Inner Rotor
• Wear Ring
• Brake Hub
Technician Tip
! WARNING
5.10.6.4 Crowd Brake Installation
NOTICE
assistant will release the brake. The assistant should be positioned at the Operator’s Controls.
With the technician at the brake, have the assistant release and set the brake when directed in
the following procedure to operate the brake. Refer to subsection 5.3.

4. Install one eyebolt into the lifting hole at the 12 o’clock position on the brake mounting flange.
! WARNING
brake being installed with a suitable sling or other support. The crowd brake weighs
5. Using appropriate slings and chain hoist or crane for the weight of the brake, lift and mount the brake assembly
onto the brake hub. The crowd brake weighs approximately 690 lbs (303 kg). Do not remove the lifting device
at this time.
6. Install the air supply piping and quick release valve (QRV) at the 6 o’clock position.
7. If the brake assembly is not completely seated on its mounting base due to misalignment of the brake hub
splines and the brake rotor splines, manually apply air pressure to slightly release the brake. With the brake in
the released condition, twist and turn the brake assembly, while applying pressure against the brake. When the
brake is fully seated, align the drive ring in its correct mounting position and install four mounting cap screws at
equally spaced points.
Technician Tip
On multiple rotor brakes, if the rotors are not aligned, it may be necessary to disassemble and
install the brake one component at a time.
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8. Install the remaining mounting cap screws. Tighten evenly to 265 Ft-lbs (366.5 N·m) using the star pattern
shown in Figure 5-88.
9. Install and align the dust cover so that the gap is at the 6 o’clock position.
10. Measure and record piston travel. Piston travel should be between 0.125" and 0.3125" (1/8” to 5/16", or 3.175
mm to 7.937 mm). Provide piston travel information to your maintenance planner.
NOTICE
CAUTION
5.10.7 Crowd Brake Performance Tests
5.10.7.1 General
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.
! WARNING
Be prepared for movement of major shovel components which may occur during static
holding torque verification. Such movement may result in severe injury or death as well
as damage to the equipment. Ensure that all personnel are clear of shovel motions
affected by these procedures.
Place the dipper handles parallel to the ground and 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 above the
ground. Apply the crowd brake. The dipper should not move.

! WARNING
applied.
! WARNING
Be prepared for movement of major shovel components which will occur during
dynamic braking torque verification. Such movement may result in severe injury or
death as well as damage to the equipment. Ensure that all personnel are clear of shovel
motions affected by these procedures.
Bring the dipper handles to the carry position. Lower the dipper handles to the fully vertical position. Crowd until the
dipper is 5 feet above the ground. Set the hoist brakes. With the shovel running and the crowd brake released,
apply the emergency stop. The dipper should stop within five feet of crowd travel.
If either static braking or dynamic braking do not perform as specified, thoroughly inspect the brakes. Also inspect
the air system and the electrical system as they apply to brakes. Refer to subsection 5.5 of this manual and to sub-
section 4.5 of the Air & Lubrication Systems Manual for more information.
The preceding dynamic tests will test only the hoist 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 brake must be thoroughly
inspected.
5.10.8 Crowd Brake Burnish-In Procedures
5.10.8.1 General
sible for stopping the motion in an emergency stop situation. The burnish process is intended to promote the for-
mation of an oxide film on both the lining and the opposing surface. This layer protects the surfaces from corrosion
and premature wear, and provides consistent coefficients of friction over the life of the brake.

! WARNING
1. With the dipper empty, retract to the retract limit. Lower the dipper 10°.
2. Move the joystick controller 1/4 forward from center to crowd the dipper at 1/4 speed until the dipper handles
are centered over the crowd pinions. Apply the crowd brake.
the brake center plate and/or the brake pressure plate. Temperature must be below 300°F (149°C).
5. With the dipper empty, retract to the retract limit. Lower the dipper 10°.
6. Move the joystick controller 1/2 forward from center to crowd the dipper at 1/2 speed until the dipper handles
are approximately centered over the crowd pinions. Apply the crowd brake.
the brake center plate and/or the brake pressure plate. Temperature must be below 300°F (149°C).
9. Following any inspection or maintenance the brakes should be tested. Slowly and carefully confirm brake oper-
ation and function using the static tests listed in subsection 5.13.2 before allowing the shovel to return to pro-
duction.

5.11 Hoist Brake Maintenance R56316D1
5.11.1 Hoist Brake Components
03
04 05
06
02
07
01 17
08
09
10
11 ES04421a01
16 15 14 13 12
LEGEND 08. Piston
01. Brake Hub 09. O-rings
02. Rotors 10. Felt Seal
03. Wear Plate 12. Cylinder
04. Center Plate 13. Pressure Plate
05. Indicator Assembly 14. Drive Ring
06. Set/Release Switch 15. Center Plates
07. Wear Switch 16. Mounting Bolt
Figure 5-89: Hoist Brake (R56316D1)

5.11.2 Hoist Brake Specifications
Measure- Procedure/Action Result/Action

ment

16.5 mm) 250 hours.
0.650"
16.5 mm)
0.270"
(9/32”
6.9 mm)
Air Pressure Data
Torque Data
Brake mounting bolts 265 ft-lbs (366.5 N·m) with Loctite
Hub retainer plate bolts 265 ft-lbs (366.5 N·m) w/tie wire
Weights
Hoist Brake Assembly, R56316D1 1644 lbs (746 kg)
Rotors (three required) 68 lbs (31 kg) each
Center Plates (two required) 212 lbs (96 kg) each
Table 5-3: Brake Specifications, Hoist Brake (R56316D1)
NOTICE

Inspect the hoist brakes during Preventive Maintenance periods.
3. Flashlight
overheating is noted, a serious condition exists that could cause sudden failure of the brake. Refer to Hoist

to Hoist Brake Replacement and replace the brake.
! WARNING
ate.
2. Verify that the center plate of each hoist brake is positioned by centering springs.

! CAUTION
brake failure.
NOTICE
2. With the brake set, note and record the measurement between the edge of the piston and the inner edge of the
cylinder.
! WARNING
ate.

6. If at least one shim is in place and piston travel exceeds 0.375" (3/8", or 9.525 mm), remove one shim. If no
shims are in place and piston travel exceeds 0.3125" (3/16", or 7.937 mm), the brake must be replaced. Refer
to
Technician Tip
Specifications are for brakes that wear evenly throughout their lives. To avoid damage to brakes
that could occur if the friction pad rivets score the wear surfaces, consider adopting a policy that
rather than removing the final shim, the brake should be replaced when one shim remains and
piston travel exceeds 0.375". Return worn brakes to P&H MInePro Services for rebuild.
Air leaks with the brake set indicate problems in the brake air solenoid valves or their manifold. Listen for air leaks
at exhaust ports of the Solenoid Valves, Redundant Air Valves, Quick Release Valves and Manifold Exhaust Ports.
If air leakage is detected, repair or replace the associated air solenoid valve.
detected.
leakage. If necessary, inspect for air leakage by spraying glass cleaner or soap solution on the face of the piston
and cylinder, then watching for bubbles. Replace damaged piston O-rings if leakage is detected.
Chattering may indicate worn springs or inadequate air pressure. Rattling could be caused by loose friction pad
components. If noisy operation is noted, replace the brake.
Heat Generation
If the drive ring is hot to the touch, replace the brake.

5.11.4 Adjustment
5.11.4.1 Inspection and adjustment when shims are installed
! WARNING
ate.
Technician Tip

TC1570
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7. Set the brake.
9. Measure and record piston travel. Piston travel should be between 0.270" and 0.650" (17/64” and 5/8”, or
CAUTION
5.11.7.
5.11.4.2 Inspection and adjustment when no shims are installed
1. Warning Tag
2. Lockout Lock
4. Flashlight
7. Hooked Needle
8. Thread
11. Impact Wrench

14. Eye Bolts
16. Eye Protection
Technician Tip
3. Remove the redundant solenoid panel piping at the 12 o’clock position and install one 3/4" NPT pipe plug into
the air port.
Technician Tip
! CAUTION

94.
Technician Tip
installed.
! CAUTION

Technician Tip
10. If hex head cap screws were used as guides, remove them. Place the piston on a flat and clean work surface.

Technician Tip
cylinder.

CAUTION
5.11.6.3.

5.11.6 Hoist Brake Replacement
1. Warning Tag
2. Lockout Lock
4. Flashlight
9. Impact Wrench
11. Torque Wrench
14. Three Eye Bolts
15. Hex Drivers
16. Cutting Tools
5.11.6.2 Hoist Brake Removal -- Normal Procedure)
! WARNING

NOTICE
Hoist Brake Air Valve in the lube room (refer to Subtopic 5.9.2) or at the external air supply
2. Remove the brake cover.
! WARNING
Unexpected movement of shovel components may result in serious personal injury,
death, and equipment damage. Be prepared for movement of major of the dipper, dipper
bail, dipper handles, hoist drum, and other components that may occur when releasing
the hoist brakes or performing maintenance. Ensure that all personnel are clear of major
! WARNING
Sudden and unexpected release of mechanical stored energy may cause the brake to
spin, resulting in severe personal injury or death. The brake must be released before
preceding. Read and understand Topic 5.3, A Warning About Stored Mechanical Energy,
and Topic 5.9, Releasing Upper Brakes for Maintenance, before attempting to remove the
brake. If the brake piston does not move outward, the brake has not been released and
there is still a potential for mechanical stored energy. If outward movement of the piston
cannot be confirmed, the brake must not be removed and must be disassembled in
place. Refer to Topic 5.11.6.3.
3. Have the assistant release and set the brake using procedures specified in Topic 5.9. Verify that the brake
releases and sets by observing and/or measuring brake piston travel. If the brake does not release, or if there
is any indication that the brake is seized or bound in any way, do not attempt to remove the brake using these
instructions; rather, follow the instructions in Subtopic 5.11.6.3.
NOTICE

8. Move the brake assembly outward a small distance. Locate the lifting hole at the 12 o’clock position on the
brake mounting flange and install one eye bolt with a nut.
9. Using the appropriate slings and chain hoist or crane, support the brake assembly. The hoist brake weighs
10. Using the chain hoist or crane, remove the brake assembly from the brake hub.
5.11.6.3 Hoist Brake Removal -- Special Conditions
! WARNING
brake system.
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NOTICE
! WARNING
5. Use the appropriate slings and chain hoist or crane for the weight of the brake assembly. The hoist brake
weighs approximately 1286 lbs (583 kg). Remove the brake air cylinder assembly.
! WARNING
in order:
• Outer Rotor
• Center Plate
• Inner Rotor
• Wear Ring
• Brake Hub
Technician Tip

5.11.6.4 Hoist Brake Installation
NOTICE
assistant will release the brake. The assistant should be positioned at the Hoist Remote Con-
trol. With the technician at the brake, have the assistant release and set the brake when
directed in the following procedure to operate the brake. Refer to Topic 5.9.
4. Install one eyebolt into the lifting hole at the 12 o’clock position on the brake mounting flange.
! WARNING
brake being installed with a suitable sling or other support. The hoist brake weighs
onto the brake hub. The hoist brake weighs approximately 1644 lbs (748 kg). Do not remove the lifting device
at this time.
A. Install the air piping and QRV at the 6 o’clock position.
B. Remove the plug from the air port at the 12 o’clock position.
C. Install exhaust air piping that leads to the redundant solenoid panel.

Technician Tip
On multiple rotor brakes, if the rotors are not aligned, it may be necessary to disassemble and
install the brake one component at a time.
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9. Install and align the dust cover so that the gap is at the 6 o’clock position or so that there is an opening to the
ventilation slots.
10. Measure and record piston travel. Piston travel should be between 0.250" and 0.375" (1/4” to 3/8", or 6.35 mm
to 9.525 mm). Provide piston travel information to your maintenance planner.
NOTICE
CAUTION

5.11.7 Hoist Brake Performance Tests
5.11.7.1 General
Brake performance tests should be used to test for brake performance or for problems in the brake system. There
are two types of performance tests following: brake static holding torque tests and brake dynamic braking torque
tests.
! WARNING
Fill the dipper and position the dipper approximately 15-20 inches above the ground. Apply the hoist brakes. The
dipper should not move.
! WARNING
applied.
! WARNING
These procedures require shovel components to move. Such movement may result in
severe injury or death if personnel are not kept clear of moving machinery. Ensure that
all personnel are clear of shovel motions affected by these procedures.
Fill the dipper and bring the dipper handles to the carry position. Lower the dipper until it is approximately one dip-
per height above the ground. Set the crowd and swing brakes. With the shovel running and the hoist brakes
released, apply the emergency stop. The dipper should stop within before it touches the ground.

If any problems are noted during these tests, the brakes and the brake air systems should be thoroughly inspected.
Refer to subsection 5.5 of this manual and to subsection 4.5 of the Air & Lubrication Systems Manual for more
information.
The preceding dynamic tests will test only the hoist brake system and its air system independent from other brake
inspected.
5.11.8 Hoist Brake Burnish-In Procedures
5.11.8.1 General
! WARNING
1. Raise the empty dipper to the upper limit.
2. Move the joystick controller 1/4 forward from center to lower the dipper at 1/4 speed until the dipper handles
are approximately parallel to the ground. Apply the hoist brakes.
5. Raise the empty dipper to the upper limit.
6. Move the joystick controller 1/2 forward from center to lower the dipper at 1/2 speed until the dipper handles
are approximately parallel to the ground. Apply the hoist brakes.


5.12 Swing Brake Maintenance R42786D1
5.12.1 Swing Brake Components
11
02 03 04 05
01
06
10 09 08 07 TC0453b
LEGEND
01. Indicator Assembly 07. Drive Ring
02. O-rings 08. Pressure Plate
03. Piston 09. Rotor
04. Rod Bolt Stud Assembly 10. Mounting Shim Location
05. Cylinder 11. Wear Switch
06. Mounting Bolt 12. Set/Release Switch
Figure 5-102: Swing Brake (R42786D1)

5.12.2 Swing Brake Specifications
Piston Travel Measurements
Measurement Procedure/Action Result/Action
0.200"
When piston travel exceeds the measurement,
1/4” Note and record new piston travel.
replace brake.
9.525 mm
0.100"
With brake released, measure the minimum air If less than 0.120" (3.175 mm), determine
1/8”
gap tabulated below. cause.
3.175 mm
Minimum Air Gap Measurements
Measurement Procedure/Action Result/Action
0.015" With the brake released, measure and record If less than 0.015" (0.4 mm) minimum gap,
1/64” the air gap between the friction pad and the equalize by shimming between motor and
0.4 mm pressure plate. Record measurement as GP1. brake.
With the brake released, measure and record

0.015" If less than 0.015" (0.4 mm) minimum gap,
the air gap between the friction pad and the
1/64” equalize by shimming between motor and
lower wear surface. Record measurement as
0.4 mm brake.
GP2.
0.100" Add GP1 and GP2. This is the total air gap.
1/8” Equalize the air gap on both sides of the friction If less than 0.100" (3.2 mm) (the
3.2mm pad using the shimming procedure in the minimum) determine cause.
Result/Action column.
Air Pressure Data
Brake Differential Pressure Switch Setting 70 PSI (4.8 bar) and 40 PSI (2.8 bar)
Torque Data
Piston Hex Head Socket Bolts 50 - 55 ft-lbs (6.9 - 7.6 kg/m)
Rod Bolt Stud Nuts 70 - 80 ft-lbs (9.6 - 11 kg/m)
Brake Mounting Bolts 150 ft-lbs (20.25 kg/m)
Hub Retainer Plate 20 ft-lbs (2.7 kg/m w/tie wire)
Weight Data
Rotor 48 lbs (22 kg)
Table 5-4: Brake Specifications, Swing Brake (R42786D1)

NOTICE
Inspect the swing brakes during Preventive Maintenance periods.
3. Flashlight
overheating is noted, a serious condition exists that could cause sudden failure of the brake. Refer to Subtopic
5.12.6 and replace the brake.

to Hoist Brake Replacement and replace the brake.
! WARNING
ate.
2. Verify that the center plate of each hoist brake is positioned by centering springs.

! CAUTION
brake failure.
NOTICE
2. With the brake set, note and record the measurement between the edge of the piston and the inner edge of the
cylinder.
! WARNING
ate.

6. If piston travel exceeds 0.375" (3/8", or 9.525 mm), the brake must be replaced. Refer to Subtopic 5.12.6.
Air leaks with the brake set indicate problems in the brake air solenoid valves or their manifold. Listen for air leaks
at exhaust ports of the Solenoid Valves, Redundant Air Valves, Quick Release Valves and Manifold Exhaust Ports.
If air leakage is detected, repair or replace the associated air solenoid valve.
detected.
leakage. If necessary, inspect for air leakage by spraying glass cleaner or soap solution on the face of the piston
and cylinder, then watching for bubbles. Replace damaged piston O-rings if leakage is detected.
Chattering may indicate worn springs or inadequate air pressure. Rattling could be caused by loose friction pad
components. If noisy operation is noted, replace the brake.
Heat Generation
If the drive ring is hot to the touch, replace the brake.
5.12.4 Adjustment
The swing brakes have no procedure specified to restore original braking torque and original piston travel. Adjust-
ment of minimum air gap is a normally only required at brake installation, and is covered in Subtopic 5.12.6.4.
1. Warning Tag

2. Lockout Lock
4. Flashlight
7. Hooked Needle
8. Thread
11. Impact Wrench
14. Eye Bolts
16. Eye Protection
Technician Tip
3. Remove the redundant solenoid panel piping at the 12 o’clock position and install one 3/4" NPT pipe plug into
the air port.

Technician Tip
! CAUTION
94.

Technician Tip
installed.
! CAUTION
Technician Tip
10. If hex head cap screws were used as guides, remove them. Place the piston on a flat and clean work surface.


Technician Tip
cylinder.

Improperly adjusted or maintained brakes can be destroyed in a very short time during opera-
tion. After any brake inspection or maintenance and before resuming operations, conduct
inspections on brakes using static and dynamic tests specified in Subtopic 5.12.7.
5.12.6 Swing Brake Replacement
1. Warning Tag
2. Lockout Lock
4. Long Feeler Gauges
5. Flashlight
10. Impact Wrench
12. Torque Wrench
15. Two 5/8" Eye Bolts
16. Hex Drivers
17. Cutting Tools
5.12.6.2 Swing Brake Removal -- Normal Procedure)
! WARNING

NOTICE
! WARNING
2. Have the assistant release and set the brake using procedures specified in Subtopic 5.9.2 or Subtopic 5.9.3.
Verify that the brake releases and sets by observing and/or measuring brake piston travel. If the brake does not
release, or if there is any indication that the brake is seized or bound in any way, do not attempt to remove the
brake using these instructions; rather, follow the instructions in Subtopic 5.12.6.3.
NOTICE
If binding of the bolts is felt while removing the bolts by hand or by hand tools, release and set
the brake again. Do not attempt to remove brake further if brake continues to bind or attempts
to rotate. If it is impossible to remove load tension by releasing the brake, re-tighten the cap
screws and discontinue removing the brake. Suspect the brake of still being under tension. Fol-
low the procedures in Subtopic 5.12.6.3.
6. Once all stud nuts have been removed, set the brake. The brake should now lift up roughly 1/2 to 1 inch.
Remove all air piping from the brake.
7. Install eye bolts in the lifting holes tapped into the cylinder as a lift point.
8. Use the appropriate slings and chain hoist or crane for the weight of the brake cylinder assembly. The swing
brake weighs approximately 488 lbs (196 kg). Remove the brake air cylinder assembly.

5.12.6.3 Swing Brake Removal -- Special Conditions
! WARNING
brake system.
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NOTICE

! WARNING
4. Install eye bolts in the lifting holes tapped into the cylinder as a lift point.
5. Use the appropriate slings and chain hoist or crane for the weight of the brake cylinder assembly. The swing
brake cylinder assembly weighs approximately 310 lbs (141 kg). Remove the brake air cylinder assembly.
! WARNING
If the brake rotor is bound, it could be supporting considerable rotational energy. Test
the rotor to determine if it is loose and at ease by pushing on it using a long tool such as
a sledge hammer handle or a stick before attempting to remove it. It should be possible
to push on the rotor and overcome the springs holding it up to move it slightly down
towards the wear plate (item 07) under it. If the rotor has sustained considerable dam-
age, and remains firmly in contact of the bottom wear plate, suspect it of being seized
and proceed to Subtopic 5.12.6.3.
in order:
• Rotor
• Wear Ring
• Brake Hub
Technician Tip
! WARNING

5.12.6.4 Swing Brake Installation
NOTICE
assistant will release the brake. With the technician at the brake, have the assistant release and
set the brake when directed in the following procedure to operate the brake. Refer to Topic 5.9.
4. Install eyebolts into the lifting holes in the cylinder.
! WARNING
brake being installed with a suitable sling or other support. The swing brake weighs
onto the swing motor. The swing brake weighs approximately 488 lbs (196 kg).
Technician Tip
Adjustments that may be needed after the air gap is verified may require the brake to be lifted
off the motor. Do not remove the lifting device at this time.
A. Install the air piping and QRV at the port nearest the inlet line.
B. Remove the plug from the air port nearest the exhaust line.
C. Install exhaust air piping that leads to the redundant solenoid panel on the side of the motor.

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To ensure adequate running clearance, measure the gaps above and below the rotor when the brake is released.
To adjust the gaps, add or remove shims between the brake and the motor. The normal shim set includes:
• Shim 20P1759D7, 005" (.12 mm), quantity: 2
Shims are split; to keep the brake straight on the motor, the two halves must be used together. Refer to Figure 5-
113 and proceed as follows:

01
02
04 03
ES04423a01
LEGEND
01. Upper Air Gap 03. Shims
02. Lower Air Gap 04. Swing Motor
Figure 5-113: Shimming the Swing Brake Assembly
A. Release the brake as described in Topic 5.9.
B. With the brake released, insert a feeler gauge between the pressure plate and the rotor. Note and record the
gap between the pressure plate and the rotor (upper gap). The gap must be not less than .015" (1/64”, or .4
mm). If the gap is smaller than specified, add one or more shims between the motor and the drive ring to
cause the gap to be at least the minimum gap. The gap will increase by the same dimension as the shim
that is installed.
C. With the brake released, insert a feeler gauge between the rotor and the wear ring. Note and record the gap
between the rotor and the wear ring (lower gap). The gap must be not less than .015" (1/64”, or .4 mm). If
the gap is smaller than specified, remove one or more shims between the motor and the drive ring to cause
the gap to be at least the minimum. The gap will increase by the same dimension as the shim that is
removed.
D. Determine the total air gap by adding the upper gap measured in step B to the lower gap measured in step
C. The total air gap must be not less than 0.125" (1/8”, or 3.2 mm).
Technician Tip
Gaps should be as close to equal as possible, not only to maximize cooling but to maintain
even wear on both sides of the rotor. Since the total air gap is specified to be 0.125", the ideal
gap would be about .062" (1/64”, or .4 mm) on both sides of the rotor.
9. Total piston travel should be between 0.125" and 0.375" (1/4” to 3/8", or 6.3 mm to 9.5 mm). Provide piston
travel information to your maintenance planner.

10. Remove the lifting devices.
11. Remove lockout and tagout devices and return the shovel to the normal shut down condition.
CAUTION
5.12.7 Swing Brake Performance Tests
5.12.7.1 General
Brake performance tests should be used to test for brake performance or for problems in the brake system. There
are two types of performance tests following: brake static holding torque tests and brake dynamic braking torque
tests.
! WARNING
1. Place the shovel on its maximum propel grade of 15%.
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 and set the swing brakes. The dipper should
not move.
! WARNING

applied.
! WARNING
These procedures require shovel components to move. Such movement may result in
severe injury or death if personnel are not kept clear of moving machinery. Ensure that
all personnel are clear of shovel motions affected by these procedures.
NOTICE
Two persons are required for this test.
With the shovel on level ground and the dipper full, place the dipper in the carry position. Set the hoist and crowd
brakes. Swing the upper and have the helper observe the ARM VOLTS meter (Figure 5-38). 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°.
If any problems are noted during these tests, the brakes and the brake air systems should be thoroughly inspected.
Refer to subsection 5.5 of this manual and to subsection 4.5 of the Air & Lubrication Systems Manual for more
information.
The preceding dynamic tests will test only the swing brake system and its air system independent from other brake
inspected.
5.12.8 Swing Brake Burnish-In Procedures
5.12.8.1 General

! WARNING
1. Establish an appropriate means of communication and have a helper observe the analog meters on the Con-
trol Cabinet in the Right-hand Room (refer to Figure 5-114). With Test Selector in the RUN position and the
Meter Selector in the SWING position, read the ARM VOLTS meter.
Figure 5-114: Analog Meters
2. With the empty dipper in the carry position, move the swing controller to the right.
3. Have the helper observe the ARM VOLTS meter (Figure 5-114) and report when voltage reaches +200V.
Return the joystick to the neutral position.
4. Have the helper observe the ARM VOLTS meter and report when voltage declines to +150V. Apply the swing
brakes.
the brake center plates and/or pressure plates. Temperature must be below 300°F (149°C).
7. With the empty dipper in the carry position, move the swing controller to the right.
8. Have the helper observe the ARM VOLTS meter (Figure 5-114) and report when voltage reaches +400V.
return the joystick to the neutral position.
9. Have the helper observe the ARM VOLTS meter and report when voltage declines to +300V. Apply the swing
brakes.
the brake center plates and/or pressure plates. Temperature must be below 300°F (149°C).

12. Following any inspection or maintenance the brakes should be tested. Slowly and carefully confirm brake oper-
ation and function using the static tests listed in Subtopic 5.12.7 before allowing the shovel to return to produc-
tion.
5.13 Brake Preventive Maintenance Checklist
5.13.1 General
All disc brakes must be inspected every 250 hours of operation to ensure correct operation. Component wear must
be measured and recorded to prevent premature component failure during shovel operation. Failure to perform the
250-hour inspections on schedule can result in a serious brake condition going undetected.
The Brake Preventive Maintenance Checklist is provided to assist maintainers in recording necessary information.
Please refer to Table 5-5, which may be reproduced as required.

P&H 4100XPC 250 Hour Disc Brake Inspection Worksheet
Shovel Identification
Hoist Hoist Swing Swing Swing Pro- Pro- Crow

Brake Front Rear Left Right Rear pel pel d Remarks
Front Front Right Left
0.650" 0.650" 0.31" 0.31" 0.31"

Maximum Travel 5/8” 5/8” no no no 5/16" 5/16" 5/16"
with Shims 16.5 16.5 shims shims shims 7.937 7.937 7.937
mm mm mm mm mm
0.650" 0.650" 0.37" 0.37" 0.37" 0.31" 0.31" 0.31"

Maximum Travel 5/8” 5/8” 1/4” 1/4” 1/4” 5/16" 5/16" 5/16"
with no Shims 16.5 16.5 9.525 9.525 9.525 7.937 7.937 7.937
mm mm mm mm mm mm mm mm
0.270" 0.270" 0.12" 0.12" 0.12" 0.12" 0.12" 0.12"

Minimum
17/64” 17/64” 1/8” 1/8” 1/8” 1/8" 1/8" 1/8"
Clearance
6.9 6.9 3.175 3.175 3.175 3.175 3.175 3.175
Air Gap
mm mm mm mm mm mm mm mm
Shims
Remaining
Inspect Brake
Date/Hours Piston Travel Measurements Remarks
Table 5-5: 250 Hour Brake Inspection Worksheet

5.14 Troubleshooting
Problem Possible Cause Action Reference
Bring shovel to a non-hold

Brake Hold Mode Subtopic 5.14.1
configuration
Wait for compressor to bring

air in the receiver up to pres- Subtopic 15.2.6
sure
Insufficient Air Pressure Confirm air pressure regula-
tor is set for 100 psi for
Subtopic 5.7.2
upper brakes and 105 psi for
propel brakes.
Inspect supply air valve

function. Replace valve if it
Faulty Supply Air Valve Subtopic 5.7.3
doesn’t shift to “open”
Brake Won’t Release,
quickly and smoothly.
Releases Slowly or
Drags Inspect for leaks in supply
line, Quick Release Valve, O-
Operational
Air leaks in system rings, redundant solenoids or
Inspections
exhaust lines. Repair any
leaks detected.
Inspect for overheating. If

the brake is discolored or
shows other evidence that it Visual Inspection
has overheated, replace the
Components are binding brake.
Inspect for physical damage

to rod bolts. If rod bolts are Visual Inspection
bent, replace the brake.
Table 5-6: Troubleshooting Table




Subtopic 5.7.3
doesn’t shift to “closed”
quickly and smoothly
Inspect compressed air sup-

ply for water, rust, sludge, or
other contaminants. Take Subtopic 15.2.6
corrective action as appro-
priate.
Air pressure not exhausted Inspect function of redun-

Brake won’t set, dant air solenoid valve.
sets slowly, or doesn’t Subtopic 5.7.2
Replace valve if it doesn’t
hold open quickly and smoothly.
Inspect exhaust lines at the

supply valve manifold, QRV,
redundant solenoid, and the
crossover connection for Visual Inspection
kinking, dirt/debris, insects,
or ice. Clear or replace
exhaust lines as necessary.
Confirm brake release pres-

Springs are weak, damaged sure. If the brake releases at
Subtopic 5.9.3.3
or broken a pressure less than speci-
fied, replace the brake.
Measure piston travel. If pis-

ton travel exceeds spec and
shims are mounted between
Friction Pads worn past Piston Travel
the cylinder and the drive
acceptable limits. Measurement
ring, remove one shim. If no
shims are present, replace
the brake.

Use electric motor control to

stop the motion. Use the disc
Topic 5.1
brakes only as holding
brakes.
Dynamic Braking or Testing Perform routine operational
Subtopic 5.8.8
testing using static holding
Subtopic 5.10.7
torque testing only. Reserve
Subtopic 5.11.7
dynamic braking torque test-
Subtopic 5.12.7
ing for regulatory testing.
Confirm air pressure regula-

tor is set for 100 psi for
Insufficient Air Pressure Subtopic 5.7.2
upper brakes and 105 psi for
propel brakes.

Brake Overheats Faulty Supply Air Valve Subtopic 5.7.3
doesn’t shift to “open”
quickly and smoothly.
Inspect for leaks in supply

line, Quick Release Valve, O-
Air leaks in system rings, redundant solenoids or Visual Inspection
exhaust lines. Repair any
leaks detected.


Springs are weak, broken or

missing
Piston Travel
Noisy Brake Operation Friction pads are loose or Replace Brake
Measurement
missing
Rotor(s) out of balance
5.14.1 Brake Hold Mode
The shovel’s Centurion Control System provides the output signals necessary to operate the brake control sys-
tems. Before a brake can be released, the Centurion Control System must receive certain inputs (such as sufficient
air pressure, correct operating mode, absence of active faults, etc.) before it will provide the output necessary to
permit the hoist, crowd, or swing brakes to release and for their systems to become active. If the brakes are set
and the required inputs are not detected, these brakes will not release. If the brakes are released and any of these
inputs are lost, the brakes will set and will not release when the brake release push button is pushed.
The following paragraph describe some hold mode situations and the action required to release the brake.

5.14.1.1 Low Brake System Air Pressure
If the air pressure in the individual brake system, as measured by each brake system’s air pressure transducer, is
below the minimum setpoint, the brake system will go into hold mode. Wait until air pressure is above the setting
called for in the Centurion Control System before attempting to release the brakes.
5.14.1.2 Propel Mode
When the shovel is in propel mode, the hoist and crowd brakes cannot be released. Transfer the shovel back into
dig mode to release the hoist and crowd brakes.
5.14.1.3 Hoist Lower Limit
When the hoist limit switch reaches its lower limit, the hoist brakes will set automatically and go into hold mode.
Press and hold the hoist brake release button while simultaneously hoisting until the limit switch returns to the nor-
mal operating range.
5.14.1.4 Hoist Remote Control Mode
If the Hoist Remote Controller is in the REMOTE mode, the hoist brakes cannot be released using the operator’s
control.
5.14.1.5 Stage 2 Boom Jacked
When the shovel’s boom is jacked enough to enter a stage 2 condition, the hoist, crowd, and swing brakes will set
automatically and go into a hold mode. To restore normal function, hold the crowd brake release button while simul-
taneously retracting until the boom returns to normal operating configuration.
5.14.1.6 Boarding Stairway or Ladder Not Completely Up
When the boarding stairway or ladder is not fully up, as sensed by a proximity switch, the swing and propel brakes
will go into hold mode. Place the stairway or ladder fully up to restore normal operation.
5.14.1.7 Shovel in Control Test Mode
When the shovel is in control test mode, the brake control systems will simulate a brake released condition when
the brake release push button is pushed. The indicator lamp will indicate that the brake is released, but no air pres-
sure will be applied to the brake. This control test mode is only for electrical maintenance personnel to use for test-
ing purposes and should not be used except by qualified electrical maintenance personnel. Return the switch to
RUN·mode to restore normal operation.

ES41157 Mechanical Systems Manual Machine Lower Assembly
Section 6
Machine Lower Assembly
6.1 General
03
04
06
06
07
01
02
ES03639c01
LEGEND 04. Lower Air Control Cabinet

01. Left Drive Tumbler 05. Carbody
02. Left Side Frame 06. Center Gudgeon Support Casting
03. Left Crawler Track 07. Lower High Voltage Cabinet
Figure 6-1: Lower Machine
The propel system (refer to Section 7) is responsible for moving the machine forward and backwards, for turning
left and right, and is capable of counter-rotation. The propel machinery is mounted at the rear of the carbody and
crawler frames. The crawler frames are bolted to the carbody. The carbody has shear ledges that rest on the
crawler frames. The track consists of several shoes linked together that wraps around the crawler frame and pro-
vides a continuous path on which the shovel rides.

Sec06Lower.fm -6.1- Section 6, Version 00 - 06/07
Machine Lower Assembly ES41157 Mechanical Systems Manual
A large casting is mounted in the center of the carbody to accept the center gudgeon, which holds the upper revolv-
ing frame and the carbody together. The swing ring gear mounts to the top of the carbody.
The two crawler track assemblies are mounted on the crawler frames. Each track can be independently operated
in either the forward or reverse direction by an individual propel module, thus providing differential steering.
The two propel modules are identical except for position. The propel system is covered in Section 7.
6.2 Component Description
6.2.1 Carbody R51403D1
Figure 6-2: Carbody (rear view)
The carbody is the base of the shovel. The carbody supports the upper machinery, which rotates on a lower roller
path that is attached to the upper portion of the carbody. Also attached to the upper portion of the carbody is the
swing ring gear, which engages swing pinions that extend through the revolving frame from the swing machinery in
the machinery house.
Machined surfaces on both sides accept the crawler frames. Machined surfaces on the rear accept the mounting
base for the propel motors. Also attached at the rear of the carbody are the lower high voltage cabinet (on the right
rear corner) and the lower air control cabinet (on the left rear corner).

Section 6, Version 00 - 06/07 -6.2- Sec06Lower.fm
6.2.2 Crawler Frames R54550D1/D2
Figure 6-3: crawler frame (Right Side Shown)
Two crawler frames are attached to the carbody, one on each side. crawler frames have shear ledges that support
the weight of the carbody; in addition, the sideframes are attached by means of 12 rod bolts.
6.2.3 Lower Rollers R54866F1
Figure 6-4: Lower Rollers
Eight lower rollers (refer to Figure 6-4) are pin-mounted at the bottom of the crawler side frames, held in place and
prevented from turning by retaining pins and cotter pins. They distribute the machine weight to the crawler track.
The lower rollers are bronze bushed from each side. The rollers turn on fixed roller pins that are pinned to the
crawler frame. They have a machined spherical rolling face that matches a concave roller path in the crawler
shoes. Thrust washers mounted on each side of a roller absorb thrust forces developed between the rollers and
side frame during propel steering.
The lower roller assemblies are pressure lubricated with grease by the automatic lubrication system.
Roller assemblies include v-ring seals that protect the bushings and thrust washers from contamination to help
extend bushing life.

6.2.4 Front Idler Roller R41233F1
Figure 6-5: Front Idler Roller
The front idler roller, mounted at the front of each crawler frame, consists of a roller with a bushing, two bearing
blocks, a shaft, and retaining pins with cotter pins.
The front idler is of double web construction. The idler shaft is of large diameter to tolerate maximum tipping loads,
and of uniform diameter to avoid stress concentration. Shims between the idler bearing blocks and the crawler side
frames provide for crawler track adjustment.
The front idler roller assemblies maintain alignment of the crawler tracks as they rotate from the top of the crawler
frame to the lower rollers.
6.2.5 Rear Idler Roller R41233F1
LEGEND
01. Rear Idler Roller
02. Lower Rollers
Figure 6-6: Rear Idler Roller
The rear idler roller assembly, mounted low at the rear of each crawler frame, consists of a roller with bushings and
thrust washers, a shaft, and a retaining pin with cotter pins.

The rear idler roller assemblies maintain alignment of the crawler tracks as they leave the ground and pass up the
rear of the side frames to engage the drive tumbler.
The rear idler roller bushings and thrust washers are grease lubricated by the automatic lubrication system.
6.2.6 Crawler Track
Figure 6-7: Crawler Track
The crawler track supports and distributes the weight of the shovel to the ground, providing a relatively small
ground pressure. A new crawler track consists of 42 cast manganese shoes that are 76" (1.93 m) wide. They are
pinned together to form a continuous path on which the shovel rides. The roller path is reinforced internally, and
features peening grooves to accommodate metal flow as the shoes wear. Shoes work-harden to provide an
extremely durable wear surface.

6.2.7 Cable Reel
Figure 6-8: Cable Reel (typical)
The cable reel assembly is mounted on the rear of the carbody. It is a level winding reel used to retrieve and pay
out the power cable to keep the length of the cable as short as practical.
The cable reel is powered by an air motor mounted on the cable reel frame. The air motor drives the cable reel
through a chain sprocket arrangement which powers the level wind mechanism. During normal operation, a certain
amount of tension is maintained on the cable because pressure is supplied to the hydraulic motor by the pump.
Level wind trolly travel speed is adjusted to suit cable size by selecting the proper sprocket arrangement inside the
reel housing.
Refer to Figure 6-8. The cable reel functions when the shovel transfers to PROPEL mode. When the cable reel is
on, it is applying constant pressure in the take-up direction to provide enough tension on the cable to keep it from
unspooling, but low enough to permit the cable to come off the reel when the shovel is traveling away from the sup-
ply.

6.3 Maintenance
6.3.1 Part Numbers
The shovel serial number is located inside the operator's cab.
Figure 6-9: Shovel Serial Number
NOTICE
6.3.2 Preliminary Maintenance Procedures
to be lowered.
• Place barricades around the work area to prevent other personnel from working near or under the work area
while maintenance activities are taking place.

! WARNING
nance, before releasing any brake for maintenance. Be prepared for movement of major
shovel components controlled by the various brakes that may occur when performing
maintenance procedures. Ensure that all personnel are clear of the major motions
affected by the brake to be released. In any situation where there is doubt regarding
mechanical stored energy, do not begin work until you have contacted a person who is
qualified and authorized to assist in making such determinations. Contact your local
P&H MInePro Services representative whenever such assistance is appropriate.
Figure 6-10: Carbody
6.3.3.1 Inspection
Periodic inspections of the carbody and crawler frames are recommended to check for structural cracks, tightness
of crawler frame rod bolts, proper lubrication, and the condition of the propel machinery.

Shear Ledges
Figure 6-11: Shear Ledge
Shear ledges run from the front to the back of the carbody at the upper portion of both sides. These shear ledges
support and distribute the weight of the shovel to the crawler frames.
Inspect shear ledges for cracking. Cracking is often due to loose connections between the carbody and the crawler
frame. If cracking is found, two actions are required:
1. Repair cracking as soon as it is discovered.
2. Re-tighten the rod bolts that hold the crawler frames to the carbody.
6.3.3.2 Repairs
Repair consists of weld repair of cracks, proper tightening of rod bolt fasteners, and replacement of worn or dam-
aged parts.
6.3.3.3 Replacement
The carbody is typically good for the life of the machine. If the carbody needs to be replaced, all of the components
must be removed from the old carbody and placed on the new carbody. Refer to individual components for replace-
ment procedures. Also, if carbody replacement is anticipated, seek guidance from your local P&H MInePro Ser-
vices representative.

6.3.4 Crawler Frames R54550D1/D2
Figure 6-12: Crawler Frame
6.3.4.1 Inspection
Initial Inspection
• After 250 hours of operation, recheck rod bolt tension and retighten as required.
Preventive Maintenance Inspections
• structural cracks
• tightness of crawler frame rod bolts
• proper lubrication
• condition of the moving machinery.
• excessive carbody to frame movement.
This should be done on a regular basis whether or not movement is observed.
6.3.4.2 Repair
Cracks

Weld cracks as soon as they appear. Refer to Section 5, Maintenance Welding for welding procedures.
Loose Rod Bolt Fasteners
Recheck rod bolt tension and retighten as required.
Technician Tip
While checking rod bolt tension, be sure the inner rod bolt nut is seated tightly. Be sure the ten-
sioner operates freely with no binding.
If excessive crawler frame-to-carbody movement is still observed, proceed as follows.

Model Rod Req’d Actual Preload 75% Final 100% Rod Bolt
Bolt Clamping Length of Pressure Pressure Stretch at
Diam. Force/Bolt Rod Bolt 100% Pre-
load
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”
Table 6-1: 4100XPC Data for Tensioning Kit R17981
Measure rod bolt length using ultrasound both before and after tensioning. The rod bolt preload equates directly to
the difference in length before and after tensioning. To use this method, proceed as follows:
1. Refer to Table 6-1 to determine rod bolt stretch at 100% preload.
2. Measure the length of each rod bolt ultrasonically with the nuts snugged up, but with no preload. Record this
measurement.
3. Measure the length of each rod bolt when it is tensioned to 100% preload. The increase in length should corre-
spond with that shown in Table 6-2.
NOTICE
The actual rod bolt lengths in Table 6-2 are nominal. If the ultrasonically measured bolt lengths
differ from the lengths in Table 6-2, it will be necessary to recalculate the hydraulic pressures
and 100% preload stretch measurements to adjust for the different rod bolt length. Contact your
local P&H MinePro Representative for assistance in making these calculations.

Guide Rails R17736F1/F2
Figure 6-13: Guide Rails
Replaceable guide rails pin to structures at the top of the crawler frame to provide a replaceable wear surface on
which the track rides as it moves across the top of the crawler frame.
When the guide rails are cracked, broken, or excessively worn, replace them as follows (refer to Figure 6-14):
LEGEND
01. Guide Rail
a. Front (1)
b. Rear (3)
02. Cotter Pin
03. Retainer Pin
04. Washer
Figure 6-14: Guide Rail Removal
1. Remove crawler track as described in Subtopic 6.3.8.
2. Remove cotter pins from retainer pins.

3. Remove pins and washers from guide rail.
! WARNING
Failure to use an adequate lifting device to lift the parts of the lower roller assembly dur-
ing the removal and disassembly procedures can cause the part to fall resulting in per-
sonal injury or death. Be sure the lifting device has a rated capacity equal to or
exceeding the weight of the part being lifted. Front guide rails weigh approximately 901
lbs (409 kg); rear guide rails weigh approximately 860 lbs (390 kg).
4. Use adequate lifting equipment to lift the guide rail from the crawler frame.
5. Use adequate lifting equipment to lift the replacement guide rail into position.
6. Install pins and washers.
7. Install cotter pins.
8. Install crawler track as described in Subtopic 6.3.8
9. Worn Or Damaged Parts
Replace all excessively worn or damaged parts.
6.3.4.3 Replacement
While the crawler frame, as well as most of its components, can be replaced when damaged or excessively worn,
the crawler frames are generally replaced as a unit during rebuilding or recommissioning procedures. To replace a
crawler frame, proceed as follows:
1. Confirm that the shovel is properly parked on well-compacted and stable ground on a flat, even grade, with the
dipper resting on the ground (dipper front face flat on ground, dipper heel and dipper lip both contacting
3. Jack and crib the carbody on the side where the crawler frame is to be removed.
4. Remove all lubrication piping from the injector bank at the rear of the crawler frame and from the injector bank
near the front idler roller.
! WARNING
The propel brake is mounted to the propel motor. Removing the propel motor coupling
will disconnect the propel brake from the crawler frame. Uncontrolled release of
mechanical stored energy can cause unexpected movement, resulting in severe per-
sonal injury or death. Release stored mechanical energy or block the crawler frame prior
to removing the propel motor coupling. Refer to Topic 5.3.
5. Disconnect the propel motor coupling.

6. Loosen and remove the rod bolt nuts (both inside and outside) and remove the rod bolts.
7. Remove the side frame from the carbody.
8. Proceed as described in Subtopic 6.3.4.4.
6.3.4.4 Installation
1 9 13 5 8 4
16 12
11 15 14 10
3 7 6 2
TC2020A
Figure 6-15: Side Frame Rod Bolt Tightening Sequence
The SuperNut™ uses a series of jackscrews around the circumference of a threaded tensioner to tension studs or
bolts, see Figure 6-16. Detailed instructions on using Supernuts™ for tensioning are shown in Subtopic 3.3.7.
Preparation
Typical preparations will include the following:
1. Determine the target jackscrew torque. See Table 6-2.
2. If using air impact tools, select a tool with an output of 90 to 100% of the final target torque. Verify the torque
output of the air impact tool with a standard torque wrench.
3. Clean the area around the rod bolt to be tensioned and remove all dirt and/or chips from the threads of the rod
bolt and the tensioner. If multiple studs are being tightened, tighten them in the correct order. Refer to Figure 6-
15.
4. Lubricate the threads of the rod bolt, the large hex nuts, and the main threads of the SuperNut™ tensioner with
an anti-seize lubricant.
NOTICE
Do not use anti-seize on jackscrew threads. The use of improper lubricant can affect torque
readings for jackscrews, which will result in improper clamping force developed by SuperNut™.

01
3 4
2
02 03
05
01
12
11 1
10 2
9 3
8 4
7 5
6
03
05
02
TC0309e
LEGEND 03. Tensioner
01. Jacking Screws 04. Star Pattern
02. Hardened Washer 05. Circular Pattern
Figure 6-16: Typical SuperNut(TM)
5. If the SuperNuts have been previously tensioned, remove each jackscrew and lubricate the jackscrew threads
and tip with molybdenum lubricant R38211D1, D2, or D3. If this is a new installation, the SuperNut™ jack-
screws should already be lubricated.

6. Check to see that the jackscrews are flush with the bottom or slightly recessed in the SuperNut™ tensioner. If
any jackscrew extends beyond the tensioner base, back it off until it is flush with the base or slightly recessed.
7. Thread one tensioner with hardened washer onto each rod bolt (the end with a 3/4"-10UNC threaded hole).
The end of each rod bolt should be even with, or slightly protruding above the top of the jackscrews in each
tensioner.
8. Be certain that carbody and crawler frame are properly aligned. Assure that the machined crawler frame pads
are tight against machined carbody sides. Insert rod bolts through crawler frame into carbody. Place long rod
bolts in the lower holes. Place short rod bolts in the upper holes.
9. 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 crawler or the carbody and nut.
10. Back off all of the SuperNut™ tensioners to create from 1/16 to 1/8" (1.5875 to 3.175 mm) gap between nut
bodies and washers. This will allow lubrication of the jackscrews while in place on the rod bolts.
6.3.4.5 Tension Side-Frame Rod Bolts with SuperNuts™
SuperNut™ Initial Final Number of Size Size QTY Lubricant

Diameter Target Target Jackscrew Jack- Socket Bolts Required
Torque Torque per screws per for
(ft-lbs) (ft-lbs) SuperNut™ Shovel Jackscrews
4” 132 188 14 .75” .625” 32 JL-M
Table 6-2: Side Frame Rod Bolt Tensioning
Proceed as follows:
1. Using the Star Pattern torque four jackscrews on each tensioner at (12:00, 6:00, 9:00, & 3:00) to the initial tar-
get torque shown in Table 6-2. Use the sequence shown in Figure 6-15.
2. Using the Star Pattern, torque the same four jackscrews on each tensioner to the final target torque shown in
Table 6-3. Use the sequence shown in Figure 6-15.
3. Tighten all jackscrews in the circular pattern (shown in Figure 6-34) on all studs to the final target torque shown
in Table 6-3 (one round only). Use the sequence shown in Figure 6-15.
NOTICE
As you tighten the jackscrews, the stud will stretch, so by the time the circular pass is com-
pleted, the first jackscrew will be loose again.
4. Repeat Step 3 until all jackscrews are “stabilized”. (less than 20° rotation). This usually requires two to four
additional passes.
NOTICE
If using air tools, switch to a calibrated hand torque wrench when socket rotation is small. Use
the hand wrench to stabilize and confirm target torque.

5. Use the hand wrench to make a final pass on the jackscrews using the circular pattern to confirm the final tar-
get torque listed in Table 6-2.
6. When installation is completed, the installation will be as shown in Table 6-2.
04
02
01 03
05
06
07
08
09
10
TC1664c
LEGEND
01. Inner Nut 06. Short Rod Bolt Assembly
02. Hardened Washer 07. Hardened Washer
03. Carbody 08. SuperNut™
04. Fitted Dowel 09. Protective Cover
05. Side Frame Assembly 10. Long Rod Bolt Assembly
Figure 6-1: Rod Bolts Installed with SuperNuts™
6.3.4.6 Removing SuperNuts™ - Service Under 250 F
NOTICE
Removal requires strict adherence to this procedure! Jackbolts must be unloaded gradually. If
most of the jackscrews are fully unloaded prematurely, the remaining jackscrews will carry the

entire load and will be difficult to turn. With extreme abuse of this type a jackscrew tip can
deform, making removal difficult.
a. Remove as follows:
1. Spray jackscrews with penetrating oil or hydraulic oil prior to attempting to remove them, especially if they are
rusted.
2. Loosen each jackscrew 1/4 turn following the circular pattern around the tensioner. Do this for one round only.
When you return to the first jackscrew, it will be tight again. Do this for all studs on the joint.
3. Repeat step 2 and continue in the same fashion until all jackscrews are loose. Remove, clean, and lubricate
the jackscrews with the JL-M lubricant listed in subsection .
NOTICE
Once the jack screws are loose, an air impact tool can be used to complete the loosening. For
very long rod bolts or studs, several rounds may be required before using air impact tools.
Detailed instructions are packed with the SuperNuts™.

6.3.5 Lower Rollers R54866F1
01 02 03 04
01
A
05
06
07
07
B
08
LEGEND
01. Hardened Wear Plate
02. Bushing A: View for Front Roller*
03. Roller B: View for All Rollers Except Front Roller*
04. Crawler Frame
05. Retainer Tube
06. Retainer Pin *Right-hand shown. Lube flats go to the rear on all
07. Thrust Washer pins except the Rear Idler Pin. Rear Idler Pin
08. V-Ring Seal flats go towards the front of the machine.
Figure 6-17: Lower Rollers
6.3.5.1 Inspection
Inspect the lower rollers every 750 hours as follows:
• Check roller for excessive wear, cracks, spalling, or distortion.
• Check retaining pin and cotter pins for security.
• Check for proper lubrication.
• Check condition of V-ring seals.
• Inspect hardened wear plates inside crawler frames.

• Check the roller bushing clearances as follows (Refer to Figure 6-18):
01
ES04663d01
LEGEND
01. Roller to be Inspected
Figure 6-18: Inspect Roller Bushing Clearances
A. Dig a hole approximately 12 inches (30 cm) deep using the mining shovel.
B. Propel the mining shovel until the roller to be inspected is over the hole.
C. Using a suitable pry bar under the roller, lift the roller and measure the movement of the roller.
D. Replace the roller bushings and thrust washers if the movement approaches 3/16 inch (4.76 mm).
6.3.5.2 Lubrication
Lower rollers are lubricated by multi-purpose grease from the automatic lubrication system. No hand lubrication is
required. Refer to Section 18 for information regarding the automatic lubrication system.

6.3.5.3 Repair
Repair of the roller is limited to the replacement of worn or damaged parts and grinding of roller plastic flow or “toe-
nailing.”
01 01
LEGEND
01. Plastic Flow
Figure 6-19: Toenailing on Lower Roller
Refer to Figure 6-19. As the roller works, the metal at the outer edge of the roller tends to flow under the weight of
the shovel. This is a normal process; however, if the plastic flow interferes with the lugs on the crawler shoe, both
components can be damaged. Trim flow using an air arc as necessary to eliminate interference between the roller
and the crawler shoe lugs.
6.3.5.4 Replacement
NOTICE
Introducing a new roller into a worn crawler system will cause premature wear to the new roller
itself and may accelerate wear to that crawler system. P&H Mining Equipment recommends
that the roller assemblies be replaced only as part of a complete overhaul of a single crawler
frame (R.H. or L.H. side), replacing all rollers, idlers, tumbler and complete crawler track. Limit
individual roller replacement to replacing broken rollers only. Consult your local P&H MinePro
Services representative.
Removal and Disassembly
! WARNING
exceeding the weight of the part being lifted.

If removing a roller in the field, refer to Figure 6-20 and proceed as follows: If removing the roller from a crawler
frame that has been removed from the mining shovel, proceed to Step 5.:
01
ES04663d01
LEGEND
01. Roller to be Replaced
Figure 6-20: Replace Individual Roller
1. Use the dipper to dig a hole approximately 36” (one meter) deep. Support and crib the hole to prevent cave-in.
2. Propel the shovel until the roller to be replaced is over the hole.
! CAUTION
Falling track shoes or rollers can cause serious personal injury. Support shoes when
link pins are removed, and support the roller when the roller pin is removed.
3. Separate the crawler track by removing the link pin retaining hardware and link pins.
4. Disconnect the grease connection to the roller pin.

5. Remove the cotter and retaining pins.
01
02
03
a
LEGEND 02. Hydraulic Ram

01. Strongback 03. Roller Shaft
Figure 6-21: Roller Removal
6. Fabricate a strongback (refer to Figure 6-21) and weld it to the crawler frame. Contact your local P&H MinePro
Services representative if necessary for welding procedures.
7. Support the roller, using suitable blocking, so it will not fall or roll when the roller pin is removed.
Technician Tip
The thrust washers on each side of the roller are loose fitting and will fall when the roller pin or
roller is removed.
8. Using the hydraulic ram supplied with the shovel tool kit, press the roller pin from the roller and crawler frame.
The roller pin weighs approximately 680 lbs (308 kg).
9. Using a suitable device, lower the roller from the crawler side frame. The roller weighs approximately 2,100 lbs
(952.6 kg).
10. Use a suitable puller and remove the roller bushings.
Assembly and Installation
1. Assemble and install a lower roller as follows:
! WARNING
ing the installation and assembly procedures can cause the part to fall resulting in per-

2. Freeze and install the two bushings in the bore of the roller.
3. Lubricate the bore of the bushings with multi-purpose grease.
4. Install V-ring seals on thrust washers.
5. Install the thrust washers on each side of the roller. Multi-purpose grease applied to the thrust washers will
help hold the thrust washers in place against the roller.
6. Coat V-ring seals liberally with grease.
7. Position the roller under the side frame Insert sheet metal guides against the face of each seal to guide the
roller into the crawler frame without damaging the seals. Raise it into position using a suitable lifting device.
Use sheet metal against the face of each seal to guide the roller into the crawler frame without damaging the
seals.
8. Install the roller pin so that the retainer pin hole is aligned with the retainer tube. The flat of the pin must be
toward the rear of the crawler.
9. After the pin has been installed through the roller, install the retaining and cotter pins.
10. Connect the separated crawler track and adjust as described in the crawler track adjustment topic.
11. Connect the grease line to the roller pin.
12. Cycle the automatic lubrication system for the lower to lubricate the lower roller.

6.3.6 Front Idler Roller R41233F1
LEGEND 11. Drilled Pin

01. Front Idler Roller 06. Hardened Washer 12. Shims
02. Bushing 07. Spacer 13. Pin
03. V-ring Seal 08. Guard 14. Drilled Pin
04. Thrust Washer 09. Bearing Block 15. Not used
05. Hex Head Cap Screw 10. Cotter Pin 16. Idler Shaft
Figure 6-22: Front Idler Roller
6.3.6.1 Inspection
Inspect the front idler every 750 hours checking the following:

• Check idler for excessive wear, cracks or distortion.
• Check retaining pins and cotter pins for security.
• Refer to and check Figure 6-23 and inspect the idler roller bushing and thrust washer clearances as follows:
01
ES04663e01
LEGEND
01. Front Idler
Figure 6-23: Inspecting Front Idler Bushings
Dig a hole approximately 12 inches (30 cm) deep using the mining shovel.
Propel the mining shovel until the idler roller to be inspected is over the hole.
Using a suitable pry bar under the roller, lift the roller and measure the movement of the roller.
Replace the roller bushings and thrust washers if the radial movement approaches 3/16 inch (4.76 mm).

6.3.6.2 Adjustments
The front idler roller adjusts the track tension. Refer to Subtopic 6.3.8.2.
6.3.6.3 Lubrication
Front idler rollers are lubricated by multi-purpose grease from the automatic lubrication system. No hand lubrica-
tion is required. Refer to Section 18 for information regarding the automatic lubrication system.
6.3.6.4 Repair
Repair of the front idler roller is limited to the replacement of worn or damaged parts and grinding of roller plastic
flow or “toenailing.”
TC1617c
Figure 6-24: Toenailing on Front Idler Roller
components can be damaged. Trim flow using an air arc as necessary to eliminate interference between the front
idler roller and the crawler shoe lugs.
6.3.6.5 Removal
NOTICE
Introducing a new front idler roller into a worn crawler system will cause premature wear to the
new idler itself and may accelerate wear to that crawler system. P&H Mining Equipment recom-
mends that the front idler assemblies be replaced only as part of a complete overhaul of a sin-
gle crawler frame (R.H. or L.H. side), replacing all rollers, idlers, tumbler and complete crawler
track. Limit individual idler replacement to replacing broken idlers only. Consult your local P&H
MinePro Services representative.
! WARNING

Remove and disassemble the crawler idler assembly as follows: (see Figure 6-25).
Preparation:
01
ES04663e01
LEGEND
01. Front Idler
Figure 6-25: Inspecting Front Idler Bushings
Refer to Figure 6-25 and proceed as follows:
1. Dig a hole approximately 1 foot deep in front of the crawler track.
2. Propel the mining shovel forward until the front idler roller is over the hole, similar to Figure 6-26.
3. Tagout the crawler controls to guard against inadvertent travel or crawler movement.

4. Disconnect the lubrication line from the idler roller shaft.
5. Remove the shim retaining pins and forward set of shims on both sides of the idler assembly.
6. Install the two hydraulic rams, sleeves and threaded rods, supplied in the mining shovel tool kit, (see Figure 6-
36) on each side of the crawler frame. Using the rams, apply equal force to each end to move the idler shaft
forward until the rear set of shims are loose. Be sure to move the idler shaft the same distance on both sides of
the crawler frame. Remove the rear set of shims and back off the two hydraulic jacks to allow the idler roller to
retract fully.
NOTICE
The idler roller will not retract by itself. Engage reverse propel to pull the idler back. Engage for-
ward propel to loosen the crawler track at the front of the shovel.
7. Remove the crawler shoe link pin retaining cap screws from the shoe nearest the bottom of the idler roller (see
Figure 6-5).
! WARNING
A falling shoe could cause serious injury or death. Keep entire body clear of the area
near or under the crawler shoe when removing link pins.
8. Attach a sling to the front portion of the crawler track and pull the crawler track toward the rear of the crawler
frame until the shoes just clear the idler.
9. Secure the top crawler track to the side frame. This will prevent it from sliding off the crawler track guide.
10. Block the idler to prevent it from rolling.
11. Remove the cotter pins and the bearing retainer pins.
NOTICE
The bearing blocks are equipped with wedge slots. If the bearing block cannot be removed, use
a wedge in the slot provided in the bearing block to break the bearing block free of the shaft.
Alternatively, use the strong back and hydraulic ram in Step 1 and Step 2 to remove the shaft
and outboard bearing block together, then press the shaft from the outboard bearing block. If a
wedge is used, the bearing block should be replaced during installation (see Figure 6-26).
12. Remove the bearing block on the outboard side of the crawler frame.
NOTICE
Two methods of idler removal are discussed. The first is the standard method using standard
tools and equipment. The second uses a special tool. Refer to Removal Using Bearing Block
Removal Kit, R47712F1.

Standard Removal
1. Fabricate a strongback similar to that shown in Figure 6-26 and weld it to the crawler frame.
2. Using the hydraulic ram supplied with the mining shovel tool kit, press the shaft from the idler and crawler
frame. Support the shaft as it is pressed from the idler so it does not fall. The shaft weighs approximately 1,525
lbs (692 kg).
3. Using a suitable lifting device, lift the idler from the crawler frame. The idler weighs approximately 9,400 lbs
(4,265 kg).
A
04
05
03
06
02
LEGEND
01. Wedge Slot
02. Idler Shaft
03. Bearing Block
04. Crawler Frame 07
05. Strongback
06. Hydraulic Ram
07. Front Idler Roller 01 TC2018
08
Figure 6-26: Front Idler Shaft Removal (Typical)
NOTICE
The thrust washers on the idler are loose fitting. Care must be taken to keep these washers
from falling when the idler is being removed.
4. Using a suitable puller, remove the idler bushings.

Removal Using Bearing Block Removal Kit, R47712F1
! WARNING
The jack bracket weighs approximately 680 lbs. Failure to use an adequate lifting device
to lift the parts of the front idler roller assembly and the jack bracket during the removal
and disassembly procedures can cause the part to fall resulting in personal injury or
death. Be sure the lifting device has a rated capacity exceeding the weight of the part
being lifted.
LEGEND
01. Idler Roller
02. Bearing Block
03. Drilled Pin
04. Bearing Block Guard
05. Shaft
06. Cap Screws, Washers,
and Spacers
07. Cotter Pin
08. Hydraulic Ram
09. Shims
10. Jack Bracket
1 2
3 4 10
10 9
ES1557b_01
Figure 6-27: Bearing Block Removal Kit, R47712F1
5. Attach jack bracket (item 10, Figure 6-27) to the side frame using the guard cap screws and washers. Lubri-
cate cap screw threads and under the heads with anti-seize and torque them to 1450 ft-lbs.

6. Support each thrust washer so it doesn’t fall once the bearing block is jacked clear of it.
7. Use the R24805D2 ram included with the shovel for tensioning the track. Install hydraulic ram and shims. To
start, have ram fully retracted, and fill remaining space with shims. There are 2 each of 3 shim thicknesses
included with the kit (6 shims total):.5 inch,.75 inch, and 1 inch.
CAUTION
The ram has a maximum 4 inch stroke. Exceeding this stroke could cause damage to the
ram. Use shims to take up the distance, and do not over stroke the ram.
Technician Tip
Once started, use the track adjusting sleeve and spacer (Figure 6-27) to extend the ram further.
In order to install these, removal of some shims may be necessary.
8. Remove the bearing block. Support entire bearing block/jack bracket assembly with appropriate lifting equip-
ment.
9. The same tool kit can now be used on the other end of the shaft. Press the shaft out of the other idler block,
then pull or push it from the idler and crawler frame. Support the shaft as it is removed from the idler so it does
not fall. The shaft weighs approximately 1,525 lbs (692 kg).
10. Using a suitable lifting device, lift the idler from the crawler frame. The idler weighs approximately 9,400 lbs
(4,265 kg).
11. Cut and/or press bushings from the idler.

02
01 03
LEGEND
07 04 01. Bearing Block
02. Idler
03. Pin
04. Bushing
05. V-ring Seal
06 05 06. Thrust Washer
07. Pin Retainer
TC1617b
Figure 6-28: Front Idler Assembly
! WARNING
Failure to use an adequate lifting device to lift the parts of the front idler assembly dur-
ing the assembly and installation procedures can cause the part to fall resulting in per-
Refer to Figure 6-28 and assemble the front idler assembly as follows:
1. Freeze and install the idler bushings in the bore of the idler.
2. Apply a small amount of grease to the thrust washer grooves on the idler. Fit the thrust washers on the idler.
The grease will hold the thrust washers in place during assembly.
3. Using a suitable lifting device, position the idler in place in the side frame. The idler weighs approximately
9,400 lbs (4,265 kg).
4. Using a lifting device, install the idler shaft. The shaft weighs approximately 1,525 lbs (692 kg).

NOTICE
The flat side of the shaft should face toward the rear of the mining shovel and the lube fitting
toward the center of the machine.
5. Install the bearing blocks, one on each side of the shaft. Install the bearing retainer pins and cotter pins.
6. Install the crawler track as follows (see Figure 6-45):
A. Install two link pins in the crawler shoe of the top portion of the crawler track. Position a pulling vehicle at the
front of the mining shovel, in line with the crawler track shoe and to the pulling vehicle.
B. Take up the tension of the sling. Remove the previously installed securing device which is holding the
crawler track in place.
C. Pull the crawler track until it is tight. Secure the belt to prevent it from becoming slack.
D. Release the tension and disconnect the sling. Allow the crawler track to hang down over the idler.
E. Raise the lower crawler shoe. Mate the end of the crawler shoes and install the two link pins. Install the link
pin hardware on both sides of the crawler shoe. Refer to Subtopic 6.3.8.4.
7. Adjust the crawler track. Refer to Subtopic 6.3.8.2.
8. Connect the grease line to the idler shaft.
9. Cycle the automatic lubrication system for the lower to lubricate the front idler.

6.3.7 Rear Idler Roller R41233F1
01
LEGEND
02. Crawler Frame
03. Retainer Pin
04. Cotter Pin
05. Thrust Washer
06. V-ring Seal
02 07. Busing
08. Pin
03
04
08
05
05
06
07 06
07
ES04664a01
Figure 6-29: Rear Idler Roller
6.3.7.1 Inspection
Inspect the rear idler every 750 hours checking the following:
• Check idler for excessive wear, cracks or distortion.
• Check retaining pins and cotter pins for security.

• Check the roller bushing and thrust washer clearances as follows:
01
ES04663f01
LEGEND
Figure 6-30: Positioning the Rear Idler Roller
1). Dig a hole approximately 12 inches (300 mm) deep using the mining shovel.
2). Propel the mining shovel until the roller to be inspected is over the hole (see Figure 6-30).
3). Using a suitable pry bar under the roller, lift the roller and measure the movement of the roller.
4). Replace the roller bushings and thrust washers if the radial movement approaches 3/16 inch (4.76 mm).
6.3.7.2 Lubrication
Rear idler rollers are lubricated by multi-purpose grease from the automatic lubrication system. No hand lubrication
is required. Refer to Section 18 for information regarding the automatic lubrication system.

6.3.7.3 Repair
Repair of the rear idler roller is limited to the replacement of worn or damaged parts and grinding off roller plastic
flow or “toenailing.”
ES04664b01
Figure 6-31: Toenailing on Lower Roller
components can be damaged. Trim flow using an air arc as necessary to eliminate interference between the roller
and the crawler shoe lugs.
6.3.7.4 Replacement
NOTICE
Introducing a new rear idler roller into a worn crawler system will cause premature wear to the
new roller itself and may accelerate wear to that crawler system. P&H Mining Equipment rec-
ommends that the idler assemblies be replaced only as part of a complete overhaul of a single
crawler frame (R.H. or L.H. side), replacing all rollers, idlers, tumbler and complete crawler
track. Limit individual idler replacement to replacing broken idler rollers only. Consult your local
Removal and Disassembly
! WARNING

If removing a roller in the field, refer to Figure 6-32 and proceed as follows: If removing the roller from a crawler
frame that has been removed from the mining shovel, proceed to Step 5.:
01
ES04663f01
LEGEND
01. Idler to be Replaced
Figure 6-32: Replace Individual Roller
1. Use the dipper to dig a hole approximately 36” (one meter) deep. Support and crib the hole to prevent cave-in.
2. Propel the shovel until the roller to be replaced is over the hole.
! CAUTION
Falling track shoes or rollers can cause serious personal injury. Support shoes when
link pins are removed, and support the roller when the roller pin is removed.
3. Separate the crawler track by removing the link pin retaining hardware and link pins.
4. Disconnect the grease connection to the roller pin.

5. Remove the cotter and retaining pins.
03
01
02 04 ES04667a01
LEGEND
01. Hydraulic Ram 03. Rear Idler Roller
02. Strongback 04. Pin
Figure 6-33: Roller Removal
6. Fabricate a strongback (refer to Figure 6-33) and weld it to the crawler frame.
7. Support the roller, using suitable blocking, so it will not fall or roll when the roller pin is removed.
Technician Tip
The thrust washers on each side of the roller are loose fitting and will fall when the roller pin or
roller is removed.
8. Using the hydraulic ram supplied with the shovel tool kit, press the roller pin from the roller and crawler frame.
The roller pin weighs approximately 680 lbs (308 kg).
9. Using a suitable device, lower the roller from the crawler side frame. The roller with bushings weighs approxi-
mately 4040 lbs (1832.5 kg).
10. Use a suitable puller and remove the roller bushings.
Assembly and Installation
1. Assemble and install a lower roller as follows:
! WARNING
ing the installation and assembly procedures can cause the part to fall resulting in per-

exceeding the weight of the part being lifted. The roller with bushings weighs approxi-
mately 4040 lbs (1832.5 kg)
2. Freeze and install the two bushings in the bore of the roller.
3. Lubricate the bore of the bushings with multi-purpose grease.
4. Install the thrust washers on each side of the roller. Multi-purpose grease applied to the thrust washers will
help hold the thrust washers in place against the roller.
5. Position the roller under the side frame Insert sheet metal guides against the face of each seal to guide the
roller into the crawler frame without damaging the seals. Raise it into position using a suitable lifting device.
Use sheet metal against the face of each seal to guide the roller into the crawler frame without damaging the
seals.
6. Install the roller pin so that the retainer pin hole is aligned with the retainer tube. The flat of the pin must be
toward the rear of the crawler.
7. After the pin has been installed through the roller, install the retaining and cotter pins.
8. Connect the separated crawler track and adjust as described in Subtopic 6.3.8.2.
9. Connect the grease line to the idler pin.
10. Cycle the automatic lubrication system for the lower to lubricate the lower roller.

6.3.8 Crawler Track
Figure 6-34: Crawler Track
The crawler track is made up of crawler shoes pinned to each other forming a movable track on which the shovel
rides. The crawler track evenly distributes the weight of the shovel on the ground.

6.3.8.1 Inspection
Inspect the crawler track daily to check for the following:
05
03
01
04
02
TC0415a
LEGEND 03 Nut
01. Link Pin Hardware 04. Pin
02. Dowel Pin 05. Crawler Shoe
Figure 6-35: Crawler Track Components
• Check for loose or missing crawler shoe pin securing bolts.
• Check the crawler shoe pin holes for excessive wear (elongation).
• Check for broken shoes.
• Check for excessive slack in the crawler track.
6.3.8.2 Adjustment
Adjust the crawler track tension as follows:
1. Remove the cotter pin and adjusting rod (Figure 6-36), one on each side of the front idler roller.

01
03
02
05
LEGEND
06
01. Retainer Pins
02. Hydraulic Pump Lines
04 03. Bearing Block
08 04. Adjusting Rod
05. Shims
07 06. Adjusting Sleeve
07. Spacer
TC0582e 08. Hydraulic Ram
Figure 6-36: Crawler Shim Removal
NOTICE
Before tensioning the crawler track the shovel should be propelled in a forward motion. This will
put crawler track slack on top of belt and make crawler track adjustment easier. However, in
order to inspect the track tension, the shovel should be propelled in reverse to produce slack as
shown in Figure 6-37. After the amount of slack has been observed, then propel forward to
position the track to be tightened.
2. Remove the forward set of shims and install the hydraulic ram, sleeve and adjusting rod supplied with the min-
ing shovel on each side of the idler assembly. See Figure 6-36.
3. Be sure to move the idler roller the same distance on both sides of the idler assembly.
NOTICE
Inspect the position of the hydraulic ram to verify that the ram is seated and supported in the
cradle before extending the ram. Observe the position of the ram while it is being extended to
confirm that it remains seated and supported.

4. Pump the hydraulic ram until the track tension is correct (refer to Figure 6-37). The shoe beneath the rear idler
should be in position so that the shoe is held down by the idler, but is just ready to begin to tilt upward. When
track tension is correct, there should be some slight slack between the rear idler and the tumbler, and there
should also be a gentle slope as the track crosses the side frame rail. Then, fill the space behind the roller
bearing block with shims that were removed from the front of the bearing block
01
02
LEGEND
01. Track has no sag;
it is too tight.
02. Track has slight sag;
tension is correct.
03. Track has significant sag;
it is too loose.
03
ES1244b01
Figure 6-37: Track Tension
NOTICE
Over-tensioning the track can cause link pins to break or may pull lugs off shoes. Correct track
tension should be slightly loose (see Figure 6-37).

5. Reduce pressure from the pump. Install the remaining shims in the space in front of the bearing block.
NOTICE
If all shims have been used for adjustment, operate shovel until track tension is loose. Then
remove one shoe and readjust tension.
6. Slide the retainer pins on each side into position and install a cotter pin.
7. Remove the hydraulic ram and clear all tools and equipment from the crawler tracks.
8. Cycle the automatic lubrication system for the lower to lubricate the front idler roller.
9. Propel the mining shovel in reverse while watching the crawler pads leave the bottom of the drive tumbler. Use
Figure 6-37 as a guide as to proper track tension.
6.3.8.3 Repair
As the shovel works, the shoes work-harden. Metal moves within the shoes, and the peening grooves in the roller
path provide a place for metal to go. In some instances, the metal flow builds up on the leading edge of the shoe
and causes interference with the adjoining shoe. This metal flow should be removed with an air arc.
No other repair is specified for the crawler track. Damaged or broken components should be replaced.
6.3.8.4 Replacement
Replacement of individual components should be limited to the replacement of broken or excessively worn parts.
When the crawler track needs to be replaced, the entire crawler frame should be rebuilt, including new rollers,
idlers, and tumbler.
Removal
Remove one crawler track as follows:
Technician Tip
Remove only one crawler track at a time. Use the other belt to move the shovel to the front or
rear.
1. Dig a hole approximately 1 foot deep in front of the crawler track.

2. Propel the mining shovel forward until the front idler roller is over the hole, similar to Figure 6-38.
01
ES04663e01
Figure 6-38: Positioning for Crawler Track Removal
3. Apply lockout and tagout procedures to guard against inadvertent travel or crawler movement.
4. Disconnect the lubrication line from the idler roller shaft.

5. Remove the shim retaining pins and forward set of shims on both sides of the idler assembly. Figure 6-39 illus-
trates the idler area appearance at this time.
Figure 6-39: Front Idler Shims Removed
6. Install the two hydraulic rams, sleeves and threaded rods, supplied in the mining shovel tool kit, on each side of
the crawler frame. Using the rams, apply equal force to each end to move the idler shaft forward until the rear
set of shims are loose. Be sure to move the idler shaft the same distance on both sides of the crawler frame.
Refer to Figure 6-40
Figure 6-40: Crawler Shim Removal

7. Remove the rear set of shims and back off the two hydraulic jacks to allow the idler roller to retract fully.
Technician Tip
The idler roller will not retract by itself. Engage reverse propel to pull the idler back. Engage for-
ward propel to loosen the crawler track at the front of the shovel.
8. Remove the crawler shoe link pin retaining cap screws from the shoe nearest the bottom of the idler roller (see
Figure 6-41).
05
03
01
04
02
TC0415a
LEGEND 03 Nut
01. Link Pin Hardware 04. Pin
02. Dowel Pin 05. Crawler Shoe
Figure 6-41: Crawler Shoe Disassembly

9. Position a pulling vehicle at the front of the mining shovel in line with the crawler track. Refer to Figure 6-42)
Figure 6-42: Position Pulling Vehicle for Track Removal
10. Attach a sling near the top front portion of the crawler track and to the pulling vehicle.
! WARNING
A falling shoe could cause serious injury or death. Do not stand with feet near or put
hands under the crawler shoe when removing link pins.
11. Remove the shoe link pins.
Figure 6-43: Remove Shoe Link Pin

! WARNING
A moving crawler track will cause severe personal injury or death. Due to its weight, the
crawler track may begin to slide free as it is pulled off the crawler frame. Be sure that all
personnel are clear of the crawler track when it is being removed.
12. Remove tagout sign from controls and propel the shovel in reverse while moving the pulling vehicle in the
same direction at the same speed until the belt is off the top wear bars. Then slowly back up the pulling vehicle
until the remaining crawler shoes are positioned flat on the ground. Refer to Figure 6-44.
Figure 6-44: Removing Crawler Track

Installation
Install the crawler track as follows:
NOTICE
Do not install a new crawler track on a crawler with a worn drive tumbler and crawler rollers.
Install new rollers and drive tumbler or premature wear of all crawler components will result.
1. Propel the shovel in reverse until the rear idler is near the end of the crawler track.
Figure 6-45: Installing Crawler Track

2. Attach a cable to the crawler track at the rear idler end of the shovel. Run the cable over the top of the crawler
frame to the front of the shovel.
3. Attach the end to a pulling vehicle and pull the crawler track. Simultaneously propel the shovel slowly forward.
4. Stop the pulling vehicle when all slack is used up in the crawler system.
5. Slack off on the towing cable and remove it from the crawler track.
6. Lift the lower portion of the crawler track and join it with the upper portion. Secure it using the link pins. Lubri-
cate the link pins with a high-solids lubricant such as open gear lubricant.
Figure 6-46: Connect Track Shoes
7. Install the link pin retainer cap screw and nut. The retaining pin must be loose. Do not tighten the nut. Leave a
0.25 inch gap between the nut and the shoe.
8. Tack weld the nuts to the bolts.
Figure 6-47: Leave Nuts Loose and Tack Weld
9. Adjust the crawler track tension as described in Subtopic 6.3.8.2.

6.3.9 Cable Reel
Figure 6-48: Cable Reel
6.3.9.1 Inspection
Visually inspect the condition of the cable reel components. Check for cracks, wear, or damage. Repair or replace
the components of the cable reel as revealed through this inspection.
! WARNING
Working on or near rotating machinery while in operation is hazardous and can result in
the injury or death of personnel. Shut down operation of the drill, and use lockout/tagout
procedures prior to working on or near rotating machinery.
1. Lock out and tag the operator controls to prevent inadvertent movement of the machine during maintenance
activities.
2. Inspect the following: .
• Drive chain for wear and tension.
• Chain sprockets for wear.
• Right angle gear reducer for leaks.
• Cable reel structure, for cracks.
6.3.9.2 Adjustment
Level Wind Drive

The level wind drive trolley is driven by a chain and sprocket arrangement from the reel drum. Trolley travel speed
is determined by the gear ratio of the output sprocket on the right angle bevel drive and the level wind sprocket and
should not require adjustment.
NOTICE
If the trolley travel distance is too short or too long due to a change in the diameter of the trail
cable, the output sprocket and level wind sprocket can be replaced with a new set. Refer to
Subtopic 6.2.7.
6.3.9.3 Periodic Maintenance
Check Right Angle Bevel Gear Drive Oil Level
! WARNING
Working on or near the cable reel while the drill is operating is hazardous and can result
in injury or death. Shut down operation of the drill, and lock out and tag the operator
controls prior to working on or near the cable reel.
1. Lock out and tag the operator controls to prevent inadvertent movement during maintenance activities.
2. Remove the oil level plug (01), and check the oil level. The oil should be at the lower edge of the plug opening.

3. If the oil is below the lower edge of the oil level plug opening, remove the vent plug (02) and add oil, of the type
specified in Table 6-3, through the vent plug opening.
LEGEND
01. Oil Level Plug
02. Vent Plug
02
01
BD0572a01
Figure 6-49: Right Angle Gear Reducer
The cable reel gear reducer uses gear oil, Material Specification P&H 497. Viscosity is indicated by a letter, and
should be selected according the expected extreme ambient temperatures. Refer to Table 6-3. This must be a high
quality, well-refined mineral base, multi-purpose petroleum gear oil compounded with extreme pressure additives
for higher load carrying ability:
P&H
Specification
Ambient Temperature Range Number ISO Grade AGMA Grade SAE Grade
-20 °F (-29 °C) or lower 497C 68 2EP 80W
-20 °F to 20 °F (-29 °C to -7 °C) 497D 100 3EP 80W
20 °F to 110 °F (-7 °C to 43 °C) 497E 150 4EP 85W

Above 110 °F (43 °C) 497F 220 5EP 90W
Table 6-3: Lubrication, Cable Reel Gear Reducer
Change Oil in Right Angle Bevel Gear Drive

! WARNING
Working on or near the cable reel while the drill is operating is hazardous and can result
in injury or death. Shut down operation of the drill, and lock out and tag the operator
controls prior to working on or near the cable reel.
1. Lock out and tag the operator controls to prevent inadvertent movement during maintenance activities.
2. Remove the oil level plug (01) and vent plug (02).
3. Remove the oil drain plug and drain the oil into a suitable container.
NOTICE
The capacity of the right angle bevel gear drive is 1.5 pints.
4. Clean the oil drain plug. Apply a coating of pipe thread sealant, and install the drain plug.
5. Add oil of the type specified in Table 6-3 through the vent plug opening until the level reaches the bottom of the
oil level plug hole.
6. Clean the oil level and vent plugs. Apply pipe thread sealant to the oil level and vent plugs and install the plugs
securely.
Lubricate Grease Fittings
• On either side of the frame, lubricate the drum bearing grease fittings using extreme pressure grease.
• Lubricate the guide roller and trolley wheel grease fittings using extreme pressure grease.
6.3.9.4 Repair
Repair of the cable reel is limited to the replacement of worn or broken components.

ES41157 Mechanical Systems Manual Propel System
Section 7
Propel System
7.1 General
01
02
03
04
05
06
07
08
09
ES03639b01
LEGEND 05. Left Propel Motor Blower

01. Left Drive Tumbler 06. Left Propel Brake
02. Left Propel Transmission 07. Motor Mounting Base
03. Left Motor Coupling 08. Right Propel Transmission
04. Left Propel Motor 09. Right Drive Tumbler
Figure 7-1: Propel System
The propel system machinery is mounted on the carbody and side frames. Refer to Figure 8-1.
The two propel modules are identical except for position and each consists of the following:

Sec07Propel.fm -7.1- Section 7, Version 00 - 06/07
Propel System ES41157 Mechanical Systems Manual
1. A fast response reversible direct current propel motor that is direct coupled to a triple reduction planetary pro-
pel transmission.
2. A propel disc brake mounted on the propel motor shaft. This brake is a spring-set, air-released holding brake
used to prevent the shovel from being propelled when digging or after it has been shut down. This brake is not
intended to stop the shovel when it is moving.
3. A propel transmission that drives a splined crawler drive shaft. The drive shaft is splined to both the transmis-
sion and its drive tumbler.
4. The drive tumbler engages the track shoes on the crawler belts, propelling the crawler either forward or to the
rear, as determined by the operators controls. Each track can be independently operated in either the forward
or reverse direction by an individual propel module, thus providing differential steering.
5. A cable reel attached to the rear of the carbody provides control over the trail cable as the shovel maneuvers in
the pit.
Figure 7-2: Carbody
The carbody acts as the base of the shovel. The side frames, which provide support and control for the crawler
track, are attached to the carbody. At the rear of the carbody, machined surfaces are provided to accept the motor
mounting base.

Section 7, Version 00 - 06/07 -7.2- Sec07Propel.fm
7.2.2 Motor Mounting Base R46695D1
Figure 7-3: Motor Mounting Base
The motor mounting base is attached to the carbody. It holds the propel motors with their brakes as well as several
air control components that are used in brake operation and maintenance.

7.2.3 Propel Motor R41837F1
Figure 7-4: Propel Motor with Brake and Blower
The propel system is powered by two fast response, reversible dc motors. The motors are identical, but are
mounted in opposite directions. Each motor is operated independently. Each motor is cooled by forced air from a
ventilation blower.
7.2.4 Propel Brake R42784D1
Figure 7-5: Propel Brake
Each motor has a propel brake which is mounted on the motor shaft. Whenever the shovel is not being propelled,
the spring-set, air-released propel brakes are set to prevent undesired movement.

7.2.5 Propel Motor Blower R12599D1F1
Figure 7-6: Propel Motor Blower
A blower motor is attached to each propel motor to provide cooling.
7.2.6 Propel Transmission 100J5800F5
Figure 7-7: Propel Transmission
The propel transmission is a three-reduction planetary unit with a 206:1 reduction ratio. The first reduction is a
straight spur reduction, while the second and third reductions are planetary reductions. the transmission is bath-
and-splash lubricated, and hold approximately 100 gallons of gear oil.
The planetary transmission is mounted on the crawler frame. It is directly coupled to the propel motor output shaft.
The third reduction carrier is splined to accept the tumbler drive shaft, which functions as the transmission output
shaft.

7.2.7 Tumbler Drive Shaft R41348F1
The tumbler drive shaft is spline-fit into the propel transmission’s third reduction carrier. It is supported on the
inboard end by a bearing inside the transmission, and on the outboard end by a bearing in the crawler frame.
The drive tumbler is spline-fit onto the outboard end of the tumbler drive shaft.
7.2.8 Drive Tumbler R54897F1
Figure 7-8: Drive Tumbler
The 4100XPC features the Deep Engaging Long-Life Track Assembly (DELTA). This system was specifically
designed for the 4100XPC with a view to significantly reduce the problems of pitch mismatch, excessive track ten-
sion, and severe toe nailing evident on earlier crawler systems. All the components of the DELTA system have
been re-engineered using the latest in design technologies.

The sprocket-type drive tumbler for the DELTA system is designed to maintain accurate pitch by allowing the shoes
to engage deep into the tumbler, driving near the pitch line. The pitch of the DELTA tumbler is designed to match a
variety of shoe pitches, thus eliminating the need for “overpitch” tumblers.
Figure 7-9: DELTA Shoe Engagement
Theory of operation for crawler track shoes is discussed in detail in Subtopic 7.2.6.
7.3 Propel System Maintenance
to be lowered.
! WARNING

Confirm that all personnel are clear of any motor, gear case, shaft assemblies, and other moving components of
drive system(s) before releasing any brake.
.Refer to Subtopic 7.3.1.

7.3.3 Motor Mounting Base R46695D1
Figure 7-10: Propel Motor Mounting Base
.The motor mounting base is bolted to machined surfaces at the rear of the carbody. It supports both propel motors,
along with their blower motors and their brakes. It also supports the propel brake air solenoid panels and the propel
brake maintenance panel.

ES04682a01
Figure 7-11: Bolt Pattern for Propel Motor Mounting Base
! WARNING
propel motor mounting base with a suitable sling or other support. The propel motor
mounting base weighs 18,341 pounds (8,319.5 kg) with no components attached.
Twenty-two Grade 5 Hex Head Cap Screws with heavy-duty nuts and hardened washers (refer to the LinkOne
electronic parts manual for part numbers) attach the motor mounting base. Refer to Figure 8-7. Lubricate threads
and under the heads of the cap screws with Never Seize and torque to 3472 ft-lbs (4707 N·m).
7.3.3.2 Inspection
.Inspect the motor mounting base for cracks, loose or missing fasteners, and integrity of components.
7.3.3.3 Repair
.Repair is limited to weld repair of cracks and the replacement of worn or broken parts. Weld repairs must be com-
pleted in accordance with published P&H specifications. Refer to Section 5, Maintenance Welding.
7.3.4 Propel Motor R41837F1
Each motor has a propel brake which is mounted on the motor shaft. Whenever the shovel is not being propelled,
the spring set-air released propel brakes are set to prevent undesired movement. Refer to Section 6, Disc Brakes
for information concerning all disc brakes.
6. Propel Motor Removal
7. Refer to Figure 8-8 and remove the propel motor as follows:

02 04
03
01
05
06
07
09 08
TC1618a

01. Propel Brake 06. Jam Nuts
02. Jam Nut 07. Motor Mounting Bolts
03. Motor Adjusting Bolts 08. Bushing
04. Jam Nut 09. Shims
Figure 7-12: Propel Motor Removal
1. Position the mining shovel on level ground with the boom over the L.H. crawler frame. Block the crawlers to
prevent free rolling of the mining shovel during service to the propel components.
2. Place the dipper on the ground.
! WARNING
Contact with energized electrical circuits can cause severe personal injury or death. Use
lockout/tagout procedures and test before servicing propel motors.

3. Open, lock open, and tag electrical connections to the propel motor and the propel blower motor.Release the
propel brake before disconnecting the air line to the propel brake. Failure to release the brake may result in
unexpected “spinning” of the coupling assembly, which can cause severe injury or death.
4. Disconnect air lines to the propel disc brake.
5. Cap the air lines and the disc brake ports to prevent dirt from entering the air system.
6. If necessary, remove the disc brake (refer to Topic 6.8) and the propel motor blower assembly, see the disc
brake removal topic in Section 5, Disc Brakes topic and Subtopic 8.3.5.
7. Remove the motor coupling guard.
8. Match mark the motor coupling halves and spacer.
9. Place a pan under the coupling to catch the grease when coupling halves are separated.
10. Remove the coupling bolt assemblies and coupling spacer.
11. To remove the outer propel motor install lifting swivel eyes, attach a lifting sling to the lifting eyes, and use the
lifting device to support the propel motor.
! WARNING
The propel motor weighs approximately 12,150 lbs (5,510 kg) with the blower and disc
brake and 11,000 lbs (4,990 kg) without the blower and disc brake. Use lifting device suit-
ably rated for lifting the propel motor. Using improper lifting device could cause the pro-
pel motor to fall resulting in severe personal injury or death.
12. Match mark the motor mounts, motor adjusting bolts, and shims.
13. Remove the motor mounting bolts and lift the propel motor from the motor mounting base.
14. Remove the inner propel motor by lifting it through the motor base and pulling it out from above the motor
base.
7.3.4.1 Propel Motor Installation
Before installing a propel motor, check the propel motor mounting base for proper installation on the carbody. Refer
to Subtopic 8.3.2.
Refer to Figure 8-8 and install the motor as follows:
1. Attach swivel eyes or lifting lugs to the replacement propel motor. If a replacement motor is being installed, be
sure the motor covers are in the same locations as on the motor being replaced.
! WARNING
Failure to use an adequate lifting device can cause the motor to fall, causing severe
injury or death. Be sure the lifting device, including swivel eyes, has a rated capacity
exceeding the weight of the motor, which is approximately 12,150 lbs (5,510 kg).

2. Raise the motor into position on the motor base.
3. Install one large .375 inch thick shim at each of the four motor feet. Lubricate the motor mounting bolts with
anti-seize, and install the motor mounting bolts, nuts, and washers.
4. Perform the motor alignment procedures. Refer to Subtopic 8.3.3.2.
5. Tighten the motor mounting bolts to 2,310 ft-lbs (3,132 N·m).
6. Install the coupling gaskets, cap screws, lock washers, and nuts. Tighten the cap screws and nuts.
7. Fill the coupling with grease as follows:
A. Rotate the coupling until the fill plugs are in the horizontal position.
B. Remove the fill plugs on both sides of the coupling (180° apart). Install grease fittings on one side.
C. Slowly fill the coupling to the overflow with grease (the 4100XPC Air and Lubrication manual for lubrication
specifications).
D. Remove the grease fittings and install the coupling fill plugs using gasket sealant. Tighten plugs securely.
8. If removed, install the disc brake. See the propel disc brake installation procedure in Section 6, Disc Brakes.
9. If removed, install the propel blower assembly. Refer to Subtopic 8.3.5.

7.3.4.2 Propel Motor Alignment
01
02
LEGEND
01. Parallelism (Angular Misalignment)
02. Vertical Axial (Offset) Misalignment
03 03. Horizontal Axial (Offset) Misalignment
04. Shaft-to-Shaft Clearance (Facial Gap)
04
ES04683a01
Figure 7-13: Motor Alignment Dimensions
General
Both propel motor shafts must be aligned to the transmission first reduction input shafts for proper operation, as
described below.
To simplify coupling alignment of the propel motor, a Primary Coupling Alignment Procedure has been developed
for the 4100XPC model shovel. This procedure allows for more rapid alignment by using simplified procedures and
larger tolerances than previously used on P&H mining shovels. This primary procedure is acceptable provided that
measurements fall within parameters given within the procedure. Always perform the alignment in the order
described, or improper alignment will result.
NOTICE
If measurements fall outside of these parameters, the technician must proceed to the Contin-
gent Coupling Alignment Procedure that follows the primary procedure.
Primary Coupling Alignment Procedure

In Subtopic 8.3.3.1, a .375 inch thick shim was specified for installation at each of the four feet of the propel motor.
Normally the alignment should fall within the given measurements using these large shims. Each motor mounting
bolt is also guided through the motor base by a bushing. This bushing should normally control horizontal movement
of the motor and shaft-to-shaft clearance of the coupling during this primary procedure. This procedure assumes
that the coupling spacer has been removed and the coupling halves and hubs have been installed on the motor
shaft and transmission shaft. The procedure also assumes a dial indicator will be used to verify measurements.
Measurements should be taken with motor mounting bolts properly torqued.
Shaft-to-Shaft Clearance (Facial Gap)
01 02 03 04 05 06
07
TC0436C
LEGEND 04. Propel Transmission Input Shaft

01. Propel Motor 05. Propel Transmission Coupling Hub
02. Propel Motor Coupling Hub 06. Propel Transmission
03. Propel Motor Armature Shaft 07. Propel Coupling Facial Gap
Figure 7-14: Propel Coupling Facial Gap
Refer to Figure 8-10. Measure and record the Facial Gap (shaft-to-shaft) distance between the motor and transmis-
sion shafts. If the motor is a replacement for a previous motor and the former gap is available, replicate the previ-
ous gap. Otherwise, if the measured distance is between 13.1875 in (335 mm) and 13.3125 in (338 mm), go on to
Angular Misalignment. If the gap is not within these measurements, go to Subtopic.and adjust the gap before pro-
ceeding.
Angular Misalignment
Measure and record the Angular Misalignment (see Figure 3-1) of the two shafts as follows:

1. To make this measurement set up the aligning clamp and dial indicator to read off the face of the coupling hub.
2. Rotate the motor shaft until the indicator is at the top (12 o’clock) position. Set the dial indicator to zero.
Technician Tip
When installing the dial indicator, it should be positioned so it is near the middle of its measure-
ment range. Then when it is zeroed, it will be capable of reading movement in either direction.
3. Rotate the motor shaft and dial indicator one complete rotation while watching the movement of the dial indica-
tor. Check the dial indicator reading every 90 degrees. Total variation should not be more than .030" (.76 mm).
Offset Misalignment
Measure and record the horizontal and vertical offset alignment as follows:
1. Set up the aligning clamp and dial indicator to read off the rim of the coupling hub
$
%
#
" &
!

6+$'

Figure 7-15: Motor Alignment Adjustments
2. Rotate the motor shaft until the indicator is at the top (12 o’clock) position. Set the dial indicator to zero.

Technician Tip
ment range. Then when it is zeroed, it will be capable of reading movement in either direction.
3. Rotate the motor shaft and dial indicator one complete rotation while watching the movement of the dial indica-
tor. Check the dial indicator reading every 90 degrees. Total variation should not be more than .030 in
(.76 mm). (This should result in a total horizontal or vertical offset misalignment of not more than .150 in.
(3.8mm).
If measurements described above can be obtained using just the .375 inch shims and the motor mounting bolt
bushings, motor alignment is finished. If measurements above can not be attained, go to the Contingent Coupling
Alignment Procedure.

Contingent Coupling Alignment Procedure
02 04
03
01
05
06
07
09 08
TC1618a

01. Propel Brake 06. Jam Nuts
02. Jam Nut 07. Motor Mounting Bolts
03. Motor Adjusting Bolts 08. Bushing
04. Jam Nut 09. Shims
Figure 7-16: Propel Motor Alignment
To begin the Contingent Coupling Alignment Procedure, the motor must be supported so that the motor mounting
bolts may be removed. Once the motor mounting bolts have been removed, remove the bushings that guide the
bolts from the motor base (refer to Figure 8-12). Re-insert the mounting bolts and tighten them finger tight.
The first step is to use the jack screws to adjust the shaft-to-shaft clearance. (Facial Gap). Next, use shims to make
the horizontal adjustment. Once the shimming is complete, use adjusting screws to make the vertical adjustment.
Facial Gap Adjustment

Measure and record the Facial Gap (shaft-to-shaft) distance between the motor and transmission shafts (see Fig-
ure 2-1). Adjust the Facial Gap using jack screws until it falls into correct measurement parameters. If the motor is
a replacement for a previous motor and the former gap is available, replicate the previous gap. Otherwise, the
measured distance desired is between 13.1875 in (335 mm) and 13.3125 in (338 mm). Ideal measurement is 13.25
in (336.5 mm). When acceptable measurement has been achieved, tighten down jam nuts on adjustment jack
screws. Go on to Horizontal Angularity Alignment.
Horizontal Angularity Alignment
Use shims to adjust the motor shaft so that it is parallel to the transmission input shaft in the horizontal plane. Pro-
ceed as follows:
1. Remove the spacer between the coupling halves. See Figure 2-1.
2. Position the aligning tool post so that the indicator is measuring off the face of the propel motor shaft. Rotate
the motor shaft until the indicator is at the side (3 o’clock) position. Set the dial indicator to 0.0 inches or mm.
Technician Tip
ment range. Then, when it is zeroed, it will be capable of reading movement in either direction.
3. Rotate the aligning tool posts 180 degrees (to the 9 o’clock position) and read the dial indicator. If the motor
shaft and first reduction shaft are in correct horizontal alignment, the variation will be less than 0.006" (0.152
mm). If there is a reading, this will indicate the direction and the distance that the motor must be moved in order
to make it parallel to the first reduction shaft. The front or rear of the motor must be moved sideways. Shim the
front or rear feet of the motor and continue to measure and adjust until the shafts are parallel within 0.006"
(0.152 mm) or less.
As an example, if the first indicator measurement is 0.030" (0.762 mm), install a trial shim of a known
thickness. If the measurement now reads 0.015" (0.381 mm), installing another shim of the same thick-
ness should bring the shafts nearly into alignment.
4. Once the shafts are parallel within 0.006" (0.152 mm) or less, proceed to horizontal offset alignment.
Horizontal Offset Alignment
Use shims to correct for horizontal offset misalignment. Proceed as follows:
1. Position the aligning tool post so that the indicator will ride off the rim of the coupling hub. Rotate the motor
shaft until the indicator is at the side (3 o’clock) position and set the dial indicator to 0.0 inches or mm.
2. Rotate the aligning tool posts 180 degrees (to the 9 o’clock position) and read the dial indicator. Then divide
the reading by 2. The result indicates the amount of horizontal offset misalignment. If the motor and first reduc-
tion shafts are in correct alignment, the result will be 0.060" (1.524 mm) or less variation.
3. If the misalignment is more than 0.060" (1.524 mm), add or remove shims equally at all four motor feet to raise
or lower the motor until the reading is within tolerance.
4. Proceed to vertical parallelism alignment.
Vertical Parallelism Alignment

Use the jack screws to make the motor shaft parallel to the first reduction shaft in the vertical plane. Proceed as fol-
lows:
1. Install aligning clamp post and indicator to take readings off the face of the shafts.
2. Rotate the motor shaft until the indicator is at the top (12 o’clock) position. Set the dial indicator to 0.0 inches.
Technician Tip
3. Rotate the aligning tool posts 180° and read the dial indicator. If the motor shaft and first reduction shaft are in
correct vertical alignment, the variation will be less than 0.006" (0.152 mm). This reading will indicate the direc-
tion and the distance that the motor shaft must be moved in order to make it parallel to the first reduction shaft.
4. Match mark the head of the vertical adjustment jackscrew, turn the jackscrew a specific number of flats, and
repeat the measurement. As an example: Assume the measurement was +0.040" (1.016 mm). Two flats turn
resulted in a measurement of 0.032" (0.508 mm). Therefore, two flats turn resulted in a 0.008" (0.203 mm)
movement. This means that another 8 flat movement should bring the two shafts into proper vertical parallel
alignment.
5. Continue to adjust until the indicator variation is .006" (0.152 mm) or less.
6. Proceed to vertical offset alignment.
Vertical Offset Alignment
Use jack screws to correct for vertical offset of the motor shaft and the first reduction shaft. Proceed as follows:
1. Position the aligning tool so the indicator will read off the rim of the coupling hub. Rotate the motor shaft until
the indicator is at the top (12 o’clock) position. Position the indicator in the middle of its range and set the dial
indicator to 0.0 inches or mm.
Technician Tip
2. Rotate the aligning tool post 180 degrees and read the dial indicator. Divide the reading by 2. The result indi-
cates the distance the motor must be moved vertically to achieve correct vertical alignment.
3. If the motor shaft is higher than the first reduction shaft, all vertical adjustment jackscrews should be backed off
an equal amount. If the motor shaft is lower than the first reduction shaft, all vertical adjustment jackscrews
should be turned in an equal amount.
NOTICE
Be sure to adjust all vertical adjustment jackscrews an equal amount or the shafts will not
remain parallel.

4. Repeat the above steps until the dial indicator reads 0.060" (1.524 mm) or less variation.
5. Tighten the jam nuts on the vertical adjustment screws.
6. Repeat all of the above alignment checks in the same order they were first performed to make sure that adjust-
ments have not been changed and that all indicator readings are within the correct tolerance.
7. Tighten the motor mounting bolts to 2,310 ft-lbs (3,132 N·m) with lubrication (anti-seize).
8. Install the coupling spacer and grease baffles. Align with the match marks made during disassembly.
9. Tighten the coupling mounting cap screws to 133 ft-lbs (180.3 N·m).
7.3.4.3 Inspection
.Inspect the propel motor components every 750 hours checking the following:
• Check propel motor, propel blower, and motor mounting bolts for tightness.
• Check electrical connections to the propel motor and propel blower motor for tightness.
• Check motor coupling bolts for tightness.
• Check the propel motor ventilation for proper air flow.
• Check the propel motor, blower and blower motor, and motor coupling for proper lubrication and the tight-
ness of the mounting bolts. Lubricate the propel motors as instructed on the motor lubrication plates. Lubri-
cate the propel motor couplings every 6 months.

7.3.4.4 Lubrication
Figure 7-17: Typical Motor Lubrication Label
.Each motor built by P&H Mining Equipment has a lubrication tag attached. It is important to follow the instructions
on the label related to lubrication interval, lubricant volume and specifications, and lubricating procedures.
7.3.4.5 Periodic Maintenance and Repair
! WARNING
Contact with energized electrical circuits can cause death or severe personal injury. Use
lockout/tagout procedures and be certain that electric motors are maintained and
repaired only be persons who are qualified and authorized.
Refer the propel motor to electrical maintenance personnel who are qualified and authorized to work on and near
energized electrical equipment. Repair of motor coupling is limited to replacement of worn or damaged parts.

7.3.4.6 Replacement
02 04
03
01
05
06
07
09 08
TC1618a
Figure 7-18: Propel Motor Removal
Refer to Figure 8-14 and remove a propel motor as follows:
1. Position the mining shovel on level ground with the boom over the L.H. crawler frame. Block the crawlers to
prevent free rolling of the mining shovel during service to the propel components.
! WARNING
3. Open, lock open, and tag electrical connections to the propel motor and the propel blower motor.
! WARNING

ate.
The ability to manually release the brakes is necessary when performing maintenance on the propel brakes and
other components of the propel system. The propel brake system on the 4100XPC shovel is equipped with a Pro-
pel Brake Maintenance Control system. The Propel Brake Maintenance Control allows maintenance personnel to
manually release the propel brakes from a remote control panel located on the left side of the motor mounting base
near the propel motors. Refer to Figure 8-15.
ES04332b01
! WARNING
Unexpected stopping or abnormal machine operation can cause serious personal injury,
death, or damage to property. Do not operate switch when the shovel is running. Turning
the keyswitch initiates a 30 second delayed shutdown. Read and understand all instruc-
tions in this manual before operating the Propel Brake Maintenance Control.
4. Refer to Subtopic 6.8.1.1 to use the Propel Brake Maintenance Control Panel (Figure 8-15) to release the pro-
pel brake and dissipate stored mechanical energy.
5. Disconnect air lines to the propel disc brake.
6. Cap the air line and the disc brake inlet port to prevent dirt from entering the air system.
7. If necessary, remove the disc brake (refer to Subtopic 6.8.7) and the propel motor blower assembly (refer to
Subtopic 8.3.5).

11. Remove the coupling bolt assemblies and coupling spacer.
12. To remove the outer propel motor install lifting swivel eyes, attach a lifting sling to the lifting eyes, and use the
lifting device to support the propel motor.
! WARNING
The propel motor weighs approximately 12,150 lbs (5,510 kg) with the blower and disc
brake and 11,000 lbs (4,990 kg) without the blower and disc brake. Use lifting device suit-
ably rated for lifting the propel motor. Using improper lifting device could cause the pro-
pel motor to fall resulting in severe personal injury or death.
13. Match mark the motor mounts, motor adjusting bolts, and shims.
14. Remove the motor mounting bolts and lift the propel motor from the motor mounting base.
15. Remove the inner propel motor by lifting it through the motor base and pulling it out from above the motor
base.
7.3.5 Propel Brake R42784D1
Due to the similarities of all disc brakes on this shovel, maintenance and repair information for all disc brakes has
been consolidated into one comprehensive write-up. Refer to Section 6, Disc Brakes for information concerning
propel disc brakes.

7.3.6 Propel Motor Blower R12599D1F1
LEGEND
01. Blower Motor Assembly
02. Blower Wheel
03. Motor
Figure 7-20: Propel Motor Blower
7.3.6.1 Installation and Removal
! WARNING
Installation
1. Ensure that the shovel is parked on a flat, level surface. Apply lockout/tagout procedures.
2. Using a suitable lifting device, lift the blower assembly into place on the propel motor.
3. Install mounting hardware. Tighten mounting bolts to 31 ft-lbs (41 N·m).
4. Confirm proper air flow.
Removal
1. Ensure that the shovel is parked on a flat, level surface. Apply lockout/tagout procedures.

2. Lock open circuit breaker, disconnect, and tag the electrical wiring to the blower motor.
3. Remove the blower assembly mounting hex head cap screws and lock washers. Using a suitable lifting device,
lift the blower assembly from the propel motor.
7.3.6.2 Inspection
.Inspect for loose or missing mounting hardware, excessive vibration, proper air flow direction, and cracking.
7.3.6.3 Repair
Repair of the blower assembly is limited to replacing defective parts.

7.3.7 Propel Transmission 100J5800F5
SIGHT
PLUG
Figure 7-21: Propel Planetary Transmission
7.3.7.1 General
CAUTION
There have been a number of instances where welding has been performed on the pro-
pel transmission second or third reduction housings (refer to Figure 1-21). Second and
third reduction ring gears are cut into the housing forgings. Welding on the transmission
will render the ring gears unfit for further use, since it will cause internal cracking. There
is no acceptable reason to make any weld to propel transmissions.
7.3.7.2 Removal
Remove a propel transmission as follows:

! WARNING
Unexpected shovel travel can cause severe injury or death. Block the crawler tracks with
suitable blocking material to prevent the shovel from rolling free. Removal of the trans-
mission disconnects the propel brakes.
1. Park the mining shovel on level ground with the boom foot area of the upper frame over one of the crawler
frames. Use suitable blocking to block crawler tracks.
2. 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.
3. Set all the brakes.
! WARNING
Unexpected movement of the propel motor during servicing can cause personal injury.
Use lockout/tagout procedures and test propel motor to prevent accidental propel motor
movement during propel transmission service procedures.
4. Use lockout/tagout procedures to disconnect power to the propel motors to prevent accidental movement dur-
ing service procedures.
! WARNING
Uncontrolled movement resulting from the release of mechanical stored energy when
the propel transmission coupling is disconnected may cause severe personal injury or
death. Read and understand Topic 6.3, A Warning About Stored Mechanical Energy
before disconnecting the propel transmission coupling. Failure to release stored energy
before disconnecting the coupling halves can cause the coupling to break loose vio-
lently. Stand clear of the shovel and release stored energy before undoing the coupling.
In any situation where there is doubt regarding mechanical stored energy, do not begin
work until you have contacted a person who is qualified and authorized to assist in mak-
ing such determinations. Contact your local P&H MInePro Services representative when-
ever such assistance is appropriate.

1. Refer to Subtopic 6.8.1.1 to use the Propel Brake Maintenance Control Panel (Figure 8-15) to release the pro-
pel brake and dissipate stored mechanical energy.
Figure 7-22: Remove spacer
2. Remove the coupling bolt assemblies and coupling spacer. Measure and record the end gap between the cou-
pling hubs.
3. Remove the crawler drive shaft. Refer to Subtopic 1.3.8.
4. Remove the two drain plugs located in the second and third reduction sections and drain the oil from the trans-
mission housing into suitable containers. The housing contains approximately 100 gallons (378.5 liters).
5. Match mark the transmission to the crawler side frame to aid in installation.
! WARNING
Failure to use an adequate lifting device to lift the propel transmission can cause the
transmission to fall causing personal injury or death. Be sure the lifting device has a
rated capacity equal to or exceeding the weight of the propel transmission. The propel
transmission weighs approximately 24,500 lbs (11,113.2 kg).

Figure 7-23: Lifting the Propel Transmission
6. Attach two swivel ring bolts (P&H Part Number 6Q483D3) and a lifting device to the transmission as shown in
Figure 1-23.
NOTICE
High torque will make cap screw removal difficult when removing the transmission. This high
torque requirement necessitates the use of a high capacity torque tool capable of accommodat-
ing the small clearance between the cap screw socket and the transmission case. The effort to
remove an installed cap screw will be higher than the mounting torque. However, not every
hydraulic torque wrench of the required capacity has a low profile head. P&H Mining Equipment
has identified hydraulic torque wrenches that have both the capacity and the low profile neces-
sary to properly torque the mounting bolts without interference with the transmission case. The
torque wrenches are available through P&H MinePro Services under part numbers 21U10D_
and 21U11D_. The torque wrenches include a control console available in five different voltage
and frequency combinations or one compressed air drive.
! WARNING
Snapping off mounting cap screws during tightening and loosening procedures can
cause the cap screw head to shoot away from the transmission causing personal injury
or death. Always wear safety glasses and a face shield. Avoid standing in line of cap
screws being tightened or loosened. Do not stand near or touch the parts of the torque
wrench while loosening or tightening the mounting cap screws.
7. Use the lifting device to support the transmission. Break loose all the transmission mounting cap screws before
removing them. Remove the transmission mounting cap screws and discard them. New cap screws will be
used during reassembly.

NOTICE
Failure to support the propel transmission assembly properly after removal from the crawler
frame could result in damage to the bearings. Support the propel transmission with blocking
under the lip of the third reduction ring gear (refer to Figure 1-24). Blocking must provide at
least 7" (17.8 cm) clearance in order to prevent the outboard bell housing from coming into con-
tact with the ground.
Figure 7-24: Blocking the Transmission
8. Remove the transmission from the crawler side frame and place it on blocking with the input segment facing up
General
When using a hydraulic wrench assembly, be sure to follow the instructions on the drawings which accompany the
wrench.
New socket head cap screws must be used when reinstalling a transmission. The high torque applied to the cap
screw sockets at installation and removal will cause the socket to become deformed. The result is that the hex
wrench bit may slip in the socket, damaging the cap screw, wrench, or both. High strength cap screws such as
these, taken to their recommended torque, will be under a very high pre-load. It has been confirmed from field
experience that re-used cap screws can fracture while being torqued. When this fracture occurs at the cap screw
head, the head can fly from the cap screw with considerable force in an axial direction (approximately in line with
the bolt hole). Therefore the following precautions must be observed.

! WARNING
Cap Screws may fracture unexpectedly while being torqued, causing the head to fly off
with considerable force, resulting in serious personal injury or death. Wear eye protec-
tion and face shields while tightening transmission mounting cap screws. Use new cap
screws. Do not touch any portion of the wrench, actuator, reaction plate, back anchor, or
adjustable bracket. Do not stand with any part of the head or body in line with the cap
screw hole while the transmission mounting cap screws are being torqued. Failure to
follow these recommendations can result in serious personal injury or death.
The required mounting cap screw final torque for the planetary propel transmissions is 2,850 ft-lbs (3864 N·m). The
threads of these cap screws are lubricated with Never-Seez before installation. The effort to remove an installed
cap screw will be higher than the mounting torque. A high capacity hydraulic torque wrench is recommended. How-
ever, not every hydraulic torque wrench of the required capacity has a low profile head. P&H Mining Equipment has
identified hydraulic torque wrenches that have both the capacity and the low profile necessary to properly torque
the mounting bolts without interference with the transmission case.
The torque wrenches are available through P&H MinePro Services under part numbers 21U10D_ and 21U11D_.
The torque wrenches include a control console available in five different voltage and frequency combinations or
one compressed air drive. Since parts of these wrenches are usable on both the swing and propel transmissions, it
is not necessary to order two complete assemblies.
Installation Procedure
To install a propel transmission, proceed as follows:
LEGEND
01. Swivel Ring Bolt
02. Input Coupling
03. Mounting Bolt
01
02
F2705a
03
Figure 7-25: Lifting the Propel Transmission
1. Attach two swivel ring bolts (P/N 6Q483D3) and a lifting device to the transmission as shown in Figure 1-25.
The transmission weighs approximately 24,500 lbs (11,113.2 kg).

! WARNING
The propel transmission weighs approximately 24,500 lbs (11,113.2 kg). Failure to use an
adequate lifting device to lift the propel transmission can cause the transmission to fall
resulting in personal injury or death. Be sure the lifting device has a rated capacity equal
to or exceeding the weight of the propel transmission.
2. Lift the transmission into place on the crawler side frame. Align the transmission as shown in Figure 1-26.
Figure 7-26: Propel Transmission Installation Position
3. Make sure the mounting surfaces on the transmission and crawler frame are clean.
! WARNING
Snapping off mounting bolts during tightening and loosening procedures can cause the
bolt head to shoot away from the transmission causing personal injury or death. Always
wear safety glasses and a face shield. Avoid standing in line of bolts being tightened or
loosened. Do not stand near or touch the parts of the torque wrench while loosening or
tightening the mounting bolts. Always use new bolts when installing the transmission
assembly.
4. Align the match marks on the transmission and the crawler side frame and install new mounting cap screws.
Torque the 36 mounting cap screws as follows:
A. Apply a light coating of Never-Seez to the threads and under the heads of 1-1/2 inch diameter Socket Head
Cap Screws.

B. Tighten two cap screws 180° apart to 2,140 ft-lbs (2,901.4 N·m).
C. Tighten two cap screws 180° apart and 90° from the two cap screws in step B to 2,140 ft-lbs (2,901.4 N·m).
D. Continue this cross-bolting pattern until all of the cap screws have been torqued to 2,140 ft-lbs (2,901.4
N·m).
E. Repeat steps B, C, and D increasing the torque to 2,850 ft-lbs (3,864 N·m).
NOTICE
The center of the propel transmission input shaft is 5.823 inches higher than the center of the
transmission. See Figure 1-26.
5. Install the crawler drive shaft as described in Subtopic 1.3.8.
Figure 7-27: Measure Gap
6. With the transmission mounted on the crawler frame, check for the clearance shown in Figure 1-27. This check
ensures that internal components are not thrust together due to resistance between the crawler drive shaft and
the splined transmission carrier.
A. Remove the sight plug. See Figure 1-21.
B. Measure the distance from the top of the hub of the first reduction gear to the top of the second reduction
sun gear shaft. It must fall within the range shown on Figure 1-27.

NOTICE
If the measurement does not fall within the specified range, consult your local MinePro Repre-
sentative.
7. Add approximately 100 gallons (378.5 liters) of gear oil. Refer to Section 16, for gear oil specifications.
8. Align motor and transmission shafts as described in subsection 1.3.4.2.
9. Connect the motor and transmission couplings. Lubricate the couplings as described in the Lubrication Sec-
tion.
10. Install the coupling guard.
! WARNING
11. Follow lockout/tagout procedures; then re-connect the propel motors.
7.3.7.4 Assembly and Disassembly
Assembly and disassembly require experience and special tools which may not be available at the mine site.
Should the transmission require an overhaul, P&H Mining Equipment recommends contact with P&H MinePro Ser-
vices to arrange for the overhaul through the P&H ENCORE program.
7.3.7.5 Inspection
.Daily
With the shovel on a flat, level surface, observe the sight glass in the first reduction bearing retainer. Oil should be
visible half-way up the sight glass.
250 Hours (Preventive Maintenance Inspection)
Check for loose or missing bolts.
Service breather on the transmission housing.
Check/Replace the filter on the oil circulation system.
Perform oil analysis.
6 Months / 2000 hours
Change oil.

NOTICE
If oil analysis includes reports of viscosity and other key specifications, and indicates that the oil
meets original specifications, oil change intervals can be adjusted based on the results of oil
analysis.
7.3.7.6 Lubrication
The propel transmission holds approximately 100 gallons (378.5 liters) of gear oil. Refer to the Lubrication Section
for gear oil specifications.

7.3.8 Tumbler Drive Shaft R41348F1
LEGEND
01. Hex Head Cap Screw 09. Drilled Head Cap Screw 17. Drive Tumbler
02. Hardened Washer 10. #6 Wire Gauge Tie Wire 18. Shaft
03. Dowel Pin 11. Spherical Roller Bearing 19. Thrust Washer
04. Bearing Retainer 12. Bearing Capsule 20. Seal Carrier
05. Shim 13. Thrust Washer 21. Split Oil Seal
06. Shim 14. V-Ring Seal 22. Seal Retainer
07. Shim 15. Socket Head Cap Screw 23. Plain Washer
08. End Cap 16. Lock Washer 24. Socket Head Cap Screw
Figure 7-28: Tumbler and Tumbler Drive Shaft

7.3.8.1 Removal and Disassembly
Remove and disassemble a crawler drive shaft as follows: (refer to Figure 1-28)
1. Position the shovel on level ground.
C. Disconnect the crawler belt assembly as follows:
Figure 7-29: Front Idler Shims Removed
A. Refer to Figure 1-29 and remove the shim retaining pins and shims on both sides of the idler assembly.
B. Disconnect the crawler belt behind the rear idler roller by removing the lock plates, cap screws, and link
pins.
C. Attach a sling to the upper end of the crawler track and to a pulling vehicle. Take up the slack in the sling.
D. Slowly propel the mining shovel forward while simultaneously moving the pulling vehicle in the same direc-
tion.
E. When the upper end of the crawler track is free of the drive tumbler, stop propelling forward. Attach a secur-
ing device to the crawler belt and the crawler frame to prevent the crawler belt from moving when the sling
to the pulling vehicle is removed.
F. Remove the sling from the crawler track.
2. Position the front of the upper frame over the side of the lower frame.
3. Place the dipper so that it is resting on the ground.
4. Set all brakes.
! WARNING
Unexpected movement of the mining shovel or mining shovel components can result in
severe personal injury or death. Place the dipper so that it is resting on the ground and

shut down the mining shovel using lockout/tagout procedures to prevent accidental
shovel start-up and movement.
5. Use lockout/tagout procedures to shut down the mining shovel.
6. Disconnect the automatic lubrication lines to the crawler drive shaft.
7. Refer to Figure 1-28 and remove bearing cap screws (01), and hardened washers (02). Remove dowel pin
(03), bearing retainer (04), and shims (05, 06, and/or 07).
8. Remove tie wire (10), cap screws (09), and end cap (08).
9. Support drive tumbler (17) with blocking so that it can not move.
! WARNING
Failure to use an adequate lifting device to lift the crawler drive shaft assembly can
cause the assembly to fall, resulting in personal injury or death. Be sure the lifting
device has a rated capacity equal to or exceeding the weight of the part to be lifted.
TC0146
Figure 7-30: Tumbler Drive Shaft Counterbalance
10. In order to keep the drive shaft assembly balanced during removal, it is necessary to provide an approximately
equal counter-balancing weight by one of the two methods illustrated in Figure 1-30.

NOTICE
End of shaft must be supported until shaft has been pulled from the transmission splines. After
shaft clears the splines (10.4 inches), full counterbalance weight of the shaft is required.
A. The top view of Figure 1-30 illustrates the use of the special tool used for shaft removal. After this tool is
bolted to the end of the drive shaft, it is necessary to attach sufficient weight to the eyebolt at the right hand
end of the tool to counterbalance the weight of the shaft assembly. The drive shaft with bearing and bearing
capsule weighs approximately 5,300 lbs(2,405 kg).
B. The bottom view of Figure 1-30 illustrates how a spare crawler drive shaft can be used to counterbalance
the weight of the shaft being removed.
11. Pull the drive shaft from the crawler frame. The drive shaft with bearing and bearing capsule weighs approxi-
mately 5,300 lbs (2,405 kg).
12. Remove bearing capsule (item 10, Figure 1-28) with bearing (09) by pulling them from the end of drive shaft
(16).
13. Using a suitable puller, remove bearing (09) from capsule (10).
7.3.8.2 Assembly and Installation
Refer to Figure 1-28 and assemble and install a crawler tumbler and drive shaft as follows:
1. Install seals (14) into thrust washers (13) and (19) and install the thrust washers onto the tumbler with cap
screws (15) and washers (16). Torque the cap screws to 150 ft-lbs (204 N·m).
2. To prevent damage to the v-ring seals, liberally grease the lip of the v-ring seals. Then, place a thin piece of
sheet metal against the face of each thrust washer to protect the seal lips while guiding the tumbler into the
crawler frame.
3. Using a suitable lifting device, place drive tumbler (17) into position in the crawler frame. Remove the two
pieces of sheet metal.
NOTICE
The tumbler bore and the bores in the crawler frame must be aligned as closely as possible.
4. Support the tumbler with suitable blocking so that it will not move.
5. Install drive shaft (16) as follows:
A. Lubricate the shaft splines with multipurpose grease.
B. Counterbalance the shaft using one of the methods shown in Figure 1-31.
C. Attach a suitable lifting device as shown. Lift the drive shaft into position next to the crawler frame and align
the shaft with the bores of the drive tumbler and propel transmission. The drive shaft weighs approximately
4,550 lbs (2,065 kg).

13
14 17
16 12
15
12
11
13
14
A
01
02
06
04
08
07
B
09
10
03
05
18
19
20
21
22 TC1665C
LEGEND 10. Bearing Capsule 20. Seal Retainer
01. Cap Screw 11. Thrust Washer 21. Washer
02. Washer 12. Seal 22. Cap Screw
03. Dowel Pin 13. Cap Screw
04. Bearing Cap 14. Washer A: Gap, .011"-.056"
05. Shims 15. Drive Tumbler (0,3mm-1,4mm)
06. End Cap 16. Shaft
07. Cap Screw 17. Thrust Washer B: Gap, 1.49"-1.69"
08. Tie Wire 18. Seal Carrier (37,8mm-42,9mm)
09. Bearing 19. Double Split Seal
Figure 7-31: Installing Crawler Drive Shaft
D. Check shaft alignment with the splined receptacle in the transmission third reduction segment. If necessary,
disconnect the motor coupling spacer and rotate the transmission input shaft to align the shaft splines and
the splined receptacle in the third reduction carrier.
E. Slowly insert the shaft through the crawler frame and drive tumbler into the splined receptacle in the trans-
mission. If necessary, again rotate the transmission input shaft to align the shaft splines and the splined
receptacle in the transmission.

NOTICE
Do not apply excessive force to the shaft while inserting it into the transmission. Doing so may
damage transmission bearings.
6. Install bearing capsule (10) in the bore of the crawler side frame.
7. Install bearing (09) on shaft (16) making sure it is seated against the shoulder of the shaft.
8. Install bearing retainer (06) with cap screws (07) and secure the cap screws with tie wire (08).
9. Install bearing cap (04) as follows:
A. Install bearing cap (04) with cap screws and washers (01 and 02). Tighten the cap screws snugly.
B. Measure the gap between end cap (04) and the side frame. Shims (05) should be equal to the measured
gap minus 0.010″ (0.254 mm).
C. Remove bearing cap (04) and re-install it with shims (05), using cap screws (01) and washers (02). Align the
notch in the flange of the bearing capsule (10) so that the opening in the “U” shaped lubrication fitting guard
faces the front of the crawler frame.
D. Install dowel pin (03) in the bearing cap.
E. Tighten cap screws (01) to 1,120 ft-lbs (1,518 N·m).
10. Install split seal (19) and secure it with seal retainer (20) and its retaining hardware.
11. Remove the blocking from the tumbler.
12. If the propel motor coupling spacer was removed, install it. See subsection 1.3.4.1.
13. Install the crawler belt as follows:
A. Attach a sling to the crawler belt and a pulling vehicle. Simultaneously propel the mining shovel in reverse
and use the pulling vehicle to pull the crawler belt toward the rear of the crawler frame enough to relieve ten-
sion on the device securing the crawler belt to the crawler frame.
B. Remove the securing device from the crawler frame and the crawler belt.
C. Continue to pull the crawler belt with the pulling vehicle while propelling in reverse until the rear idler is con-
tacting the second shoe from the end of the crawler belt.
D. Secure the crawler belt to the crawler side frame so that it will not move.
E. Lift the lower portion of the crawler belt and join it with the upper portion. Secure it using the link pins.
F. Install the link pin and link pin hardware (see Figure 6-53).
G. Adjust the crawler belt tension. See Subtopic 6.3.6.2.
14. Remove the device securing the crawler belt to the crawler frame.
15. Using Lockout/tagout procedures, start-up the mining shovel.

16. Install the lubrication lines to the bearing retainer and inside of the crawler frame and cycle the automatic lubri-
cation for the lower.
7.3.8.3 Inspection
.Inspect the crawler drive shaft assemblies every 750 hours checking the following:
• Check for proper lubrication. Grease should be visible around the drive tumbler seals.
• Check for excessively worn or damaged components.
• Check for loose or missing bolts and cap screws.
• Check for proper drive tumbler to crawler belt engagement.
• Check for cracking of shims.
• Check for cracked shaft splines.
7.3.8.4 Lubrication
.The inboard bearing that supports the tumbler drive shaft is inside the propel transmission. It is lubricated by gear
oil within the transmission.
The outboard bearing that supports the tumbler shaft is in the crawler frame. It is lubricated by grease from the
automatic lubrication system. This grease is also used to lubricate the outer drive tumbler seal.
The inner drive tumbler seal is lubricated by grease from the automatic lubrication system.
7.3.8.5 Repair
.Limit repair of the crawler drive shaft assembly to the replacement of worn, damaged, or missing parts.

7.3.9 Drive Tumbler R54897F1
Figure 7-32: Drive Tumbler
1. Remove the tumbler drive shaft as described in Subtopic 1.3.8.
! WARNING
Failure to use an adequate lifting device to lift the crawler drive shaft assembly can
cause the assembly to fall, resulting in personal injury or death. Be sure the lifting
device has a rated capacity equal to or exceeding the weight of the part to be lifted.
2. Using a suitable lifting device, remove drive tumbler from the side frame. The tumbler weighs approximately
9,800 lbs (4,450 kg).
3. If necessary, remove v-ring seals from the tumbler.
7.3.9.2 Inspection
Inspect the tumbler thrust washers (bolted to the side frames) for excessive wear. If the overall width of either
thrust washer is one inch or less, replace both thrust washers.
Inspect tumbler lugs and splines for excessive wear. If wear is excessive, replace the tumbler.

7.3.9.3 installation
1. Fill the seal cavities in the tumbler with multipurpose grease. This grease will hold the seals in place during
installation.
2. Install seals (12) into the tumbler.
3. To prevent damage to the v-ring seals, liberally grease the lip of the v-ring seals. Then, place a thin piece of
sheet metal against the face of each thrust washer to protect the seal lips while guiding the tumbler into the
crawler frame.
4. Using a suitable lifting device, place drive tumbler into position in the crawler frame. Remove the two pieces of
sheet metal.
NOTICE
The tumbler bore and the bores in the crawler frame must be aligned as closely as possible.
5. Support the tumbler with suitable blocking so that it will not move.
6. Refer to Subtopic 1.3.8.2 and install the drive tumbler shaft.

ES41157 Mechanical Systems Manual Machinery House and Exterior Walkways
Section 8
Machinery House and Exterior Walkways
8.1 General
Figure 8-1: Machinery House
This section covers the machinery house assembly, including the operator’s cab. It includes service procedures for
the house ventilation and filtration system. Drawings showing the gantry platform and the exterior walkways and
hand rails of the house and boom are also shown.
The house main structure consists of a group of large weldments including the left hand room (lube room), the right
hand room (electrical room), the front enclosure panels, the operator’s cab and support assembly, the rear roof
assembly, and the rear enclosure. The house assembly, along with its attached platforms and counterweight (bal-
last) boxes, rests on the revolving frame. The house assembly components are bolted together, and are provided
with numerous pinned and sealed hatches.
The machinery house is pressurized and ventilated by means of two motor-driven blower units, which are located
in an assembly mounted on the rear roof section of the house assembly. Air is drawn from the outside of the
machinery house and blown through filter assemblies into the machinery house. The air flows through the house

Sec08House.fm -8.1- Section 8, Version 00 - 06/07
Machinery House and Exterior Walkways ES41157 Mechanical Systems Manual
and is exhausted to the outside through openings in the house. This ensures clean fresh air for cooling the electri-
cal equipment inside the machinery house, and eliminates recirculation of hot contaminated air. The pressurization
helps reduce dust entry from the outside.
The machinery house roof, gantry, and boom have numerous walkways constructed of grip-strut with attached
handrails. Ladders and stairways are also supplied to gain access to all external components

Section 8, Version 00 - 06/07 -8.2- Sec08House.fm
8.2 Description
8.2.1 Exterior Structures.
Figure 8-2: Machinery House Description (1 of 2). Legend is at Figure 9-3.
LEGEND 12. Roof Grating 24. Roof Beam Shim

01. RH Room 13. Rain Hood 25. Roof Beam Shim
02. LH Room 14. Bleed Duct 26. Roof Beam Shim
03. Roof Beams 15. Duct Clamp 27. House Fan Silencer
04. Front Wall 16. Duct Mounting Strap 28. Not used
05. House Side Walls 17. Flex Joint Side Bracket 29. Roof Beam Hardware
06. Rear House 18. Flex Joint Top Bracket 30. Front Enclosure Hardware
07. Rear Roof 19. Extruded Seal 31. Rooms to Platforms Hardware
08. Hood/Dirt Chute 20. Flex Joint Cover 32. Side Walls Hardware
09. Roof Hatch Covers 21. Flex Joint Cover 33. Rear Roof Hardware
10. Gantry Boots 22. Foam Gasket 34. OPerator’s Cab Hardware
11. Operator’s Cab 23. Weather Sealant 35. Flex Joint Hardware
Figure 8-3: Legend for Figures 9-2, and 9-4

Figure 8-4: Machinery House Description (2 of 2). Legend is at Figure 9-3.
8.2.2 Hatch Covers
The house assembly is sectionally designed with removable hatch covers and sections. The hatch covers and
removable sections allow for easy machinery house assembly and service of major machinery components
enclosed in the machinery house. The hatch assemblies are pinned in place, with some hatches having additional
screws that must be removed. Refer to Figure 9-5 and Table 9-1.

Figure 8-5: Roof Hatch Covers (refer to legend at Table 9-1)
Item Description Part Number Approximate

No. Lifting
Weight
Lbs Kg
01 Right Front Side Hatch Cover R43728D1 606 275
02 Left Front Side Hatch Cover R43726D1 505 229
03 Center Front Hatch Cover R43703D1 200 91
04 Right Center Side Hatch Cover R43712D1 464 211
04 Left Center Side Hatch Cover R43712D1 464 211
05 Center Hatch Cover R43693D1 258 117
Table 8-1: Hatches and Covers (refer to Figure 9-5)

Item Description Part Number Approximate

No. Lifting
Weight
Lbs Kg
06 Right Rear Side Hatch Cover R43423D2 512 232
07 Left Rear Side Hatch Cover R43423D1 512 232
08 Center Rear Hatch Cover R43454D1 263 119
09 Right Outside Gantry Hatch Cover R43655D1 87 40
10 Right Inside Gantry Hatch Cover R43656D1 65 30
11 Left Outside Gantry Hatch Cover R43617D1 97 44
12 Left Inside Gantry Hatch Cover R43602D1 82 37
13 Right Front Hatch Cover R43953D1 920 417
14 Left Front Hatch Cover R43953D2 920 417
15 Skylight 31Q140 263 119
16 Skylight 31Z41 409 186
17 Left Hand Room Outside Cover R43410D1 555 252
Table 8-1: Hatches and Covers (refer to Figure 9-5)
Hatch assemblies must be removed to access equipment inside the machinery house assembly. The following
subsections discuss removal and installation of the hatches and covers on the machinery house roof.
8.2.2.1 Hatch Cover Removal
Servicing of equipment inside the machinery house may require the removal of one or more hatch covers. Refer to
Figure 9-5 and remove hatch cover(s) as follows:
1. Remove fastening pins from the hatch mounting brackets.
2. Fasten suitable lifting slings to the cover lifting handles.
! WARNING
A falling hatch cover can cause severe injury, death, or equipment damage. Be sure the
lifting slings are securely attached to the hatch cover. Be sure the crane used to lift the
hatch cover has a rated capacity exceeding the weight of the hatch cover being lifted.
The weight of the various hatch covers ranges from approximately 65 lbs (29.5 kg) to 920
lbs (417 kg).
3. Using a suitable crane, remove the hatch cover from the machinery house. The various hatch covers weigh
approximately 65 lbs (29.5 kg) to 920 lbs (417 kg).
8.2.2.2 Hatch Cover Installation
Refer to Figure 9-5 and install roof hatch covers as follows:

1. With suitable lifting device, lift the hatch cover. The various hatch covers weigh approximately 65 lbs (29.5 kg)
to 920 lbs (417 kg).
2. Inspect the rubber sealing gasket around the inner edge of the cover. Ensure the gasket is free from damage
and fastened in place. Repair or replace the gasket if necessary.
! WARNING
A falling hatch cover can cause severe injury, death, or property damage. Be sure the lift-
ing slings are securely attached to the hatch cover. Be sure the crane used to lift the
hatch cover has a rated capacity exceeding the weight of the hatch cover being lifted.
The weight of the various hatch covers ranges from approximately 65 lbs (29.5 kg) to 920
lbs (417 kg).
3. Lift the cover assembly into place on the opening, with the mounting brackets aligned.
4. Install the cover latch pins in the mounting bracket. Install any other equipment or hardware that was removed
to gain access to the hatch.
8.2.2.3 House Roof Section Removal
Servicing of equipment inside the machinery house may require the removal of one or more sections of the house
roof. Refer to Figure 9-2 and remove house roof section(s) as follows:
1. Determine which panels and sections require removal.
! WARNING
Contact with energized electrical circuits can cause personal injury or death. Use lock-
out/tagout procedures and test before removing any electrical wiring.
2. Use lockout/tagout procedures to disconnect or move all electrical wiring attached to the section to be
removed.
3. Attach suitable slings to the section to be removed.
4. Remove mounting screws, washers and locknuts from the mating flanges etc.
! WARNING
A falling house roof section can cause severe injury, death, or property damage. Be sure
the lifting slings are securely attached to the section being lifted. The weights of these
sections vary. Be sure the crane used to lift the section has a rated capacity exceeding
the weight of the section being lifted.
5. Lift the section from the roof, taking care not to damage the section weather stripping.
8.2.2.4 House Roof Section Installation
Refer to Figure 9-2 and install a roof section as follows:

1. Apply a sealant (P&H 32Z1806) to the joining surfaces, as required, to seal bolted seams and joints.
2. With a suitable lifting device, position the section in place and align the screw holes. Install flange head lock
screws with nuts in the screw holes and tighten.
3. Connect all electrical wiring that was disconnected during removal.
4. Use lockout/tagout procedures to start up the shovel.
8.2.3 Operator Cab Winch
8.2.3.1 General
Figure 8-6: Operator Cab Winch
Two winches are mounted atop the operator’s cab to assist in raising and lowering the cab windows. Winches can
be mounted in a variety of configurations depending on which windows need to be lifted.
! WARNING
Intentional misuse of these winches can cause objects to fall from the operator’s cab
roof, resulting in severe injury, death, or property damage. Only use winches to lift and
lower operator’s cab windows. Be sure the lifting hooks are securely attached to the win-
dow being lifted. The weights of these windows vary. Always verify that the winch is
capable of lifting the weight of the window being lifted. Winch capacity is limited to 525
lbs (238 kg) each. Always follow proper rigging and lifting procedures.
Each winch is a worm gear electric winch with a ½ horsepower motor and internal load brake with a 16 foot (4.9 m)
pendant equipped with a handheld controller with UP and DOWN push buttons. A 16 foot (4.9 m) power cord plugs
in to a 115 volt, 50 or 60 Hz power outlet that is mounted on the operator’s cab roof.
CAUTION
The power outlet’s weatherproofing is only effective when the cover is closed. Unplug
the winch when not in use.
Each winch is equipped with 45 feet (13.7 meters) of 5/16" (7.9 mm) diameter 7 x 19 galvanized aircraft cable. The
cable has a swag connector to connect the line to the winch drum, and a swivel, hook, and latch attached to the
free end.

8.2.3.2 Operation
To operate the winch, proceed as follows:
! CAUTION
Improper lifting techniques can cause serious personal injury. At least two persons are
required to lift the winch cover. The winch cover weighs approximately 65 lbs (29.5 kg).
1. Remove the winch cover by removing the mounting bolts. Lift the cover using the handles provided and place
the cover away from the working area.
2. If the front windshield is to be replaced, the winches are properly mounted to provide lifting for the windshield.
If other windows are to be replaced, mount the winches in a suitable location. Refer to Winch Mounting Options
below.
3. Insert the plug on the power cord into the power outlet mounted on the operator cab roof.
4. Using the pendant controller, press the DOWN push button to allow the winch cable to play out. Reeve the
cable over the sheaves and continue until the cable is at the desired location.
5. Attach the hook securely to the lifting point on the window. Remove slack on the winch cable so that the cable
will support the weight of the window.
! WARNING
If the window is not properly controlled, it could strike persons on the catwalk and knock
them off the catwalk, resulting in severe personal injury or death. Always wear approved
fall protection devices and stay out of the line of fire of the window.
6. To remove the window, remove the mounting hardware, lift the window from the cab structure and place it on
the ground; to install the window, lift the window into position on the cab structure and secure it with mounting
hardware.

8.2.3.3 Mounting Options
2 3
1 4
Figure 8-7: Winch Mounting Options
Refer to Figure 8-7. The winch mounting plate is oriented such that when the winches are mounted in their storage
position, they can be used to lift and lower the cab windshield without changing their positions. Once the cover is
removed, the cables can be reeved over the sheaves that are mounted on the forward corners of the operator’s
cab roof.
To raise or lower side windows, the winches can be mounted in different configurations, depending on the window
being replaced:
• To work with the windshield, keep the winches in the storage configuration (Positions 1 and 2).
• To work with windows on the left side of the cab, move the winch from Position 2 to Position 4.
• To work with windows on the right side of the cab, move the winch from Position 1 to Position 3.
8.3 Shovel Exterior Walkways and Handrails
8.3.1 General
The shovel exterior walkways consist of the house roof, coop roof, catwalks, gantry platform, boom platforms and
catwalks, and the ladders, stairways, handrails, etc. that connect them. Designated walkways consist of grip-strut
walkways with handrails.

LEGEND:
01. Right Inside Boom Entrance Roof Handrail 12. Right Outside Boom Entrance Roof Handrail
02. Left Inside Boom Entrance Roof Handrail 13. Front Gantry Rear Handrails
03. Right Rear Roof Handrail 14. Front Gantry Left Outside Handrail
04. Left Rear Roof Handrail 15. Front Gantry Right Outside Handrail
05. Right Rear Roof Side Handrail 16. Handrail Bracket
06. Left Rear Roof Side Handrail 17. Access Chain and Snap
07. Left Front Roof Handrail 18. Access Plate
08. Left Front Roof Side Handrail 19. Hoist Cable Chute Handrail
09. Right Center Roof Side Handrail 20. Not Used
10. Left Center Roof Side Handrail 21. Flange Locking Cap Screw
11. Left Outside Boom Entrance Roof Handrail 22. Flange Locking Nut
Figure 8-8: Shovel Roof Handrails (R54023F1)

! CAUTION
All walkways, platforms, catwalks, stairways, ladders, and handrails should be inspected
on a regular basis to determine if any components have broken loose due to impact or
vibration. Always use personal fall protection equipment and follow tie-off procedures
as specified by all applicable safety requirements.
Walkways are welded or bolted in place.
! CAUTION
Keep all shovel walkways clean of lubricant build-up. Lubricant build-up and/or spills
can cause slip hazards which can result in serious personal injury.
Keep all shovel walkways clean of lubricant build-up and/or spills. Clean lubricant build-up from all walkways and
open areas on a regular basis.
! WARNING
Damaged walkways and/or handrails could allow persons to fall, resulting in injury or
death. Do not place heavy tools or components onto walkways, or use handrails as sup-
ports. Placing heavy objects on walkways or handrails could damage the structural
integrity of the walkways or handrails and cause them to lose the ability to support per-
sonnel safely.
Shovel exterior walkways are designed to carry weight of personnel, not large components or heavy tools and
equipment. Never use walkways as temporary resting areas for tools or components. Components not supported
by appropriate lifting devices should be placed on the ground.
8.3.2 Machinery House Walkways
The machinery house walkways are shown on Figures 9-6, and 9-7.
The entire exterior edge of the house roof is ringed by handrails. A catwalk runs along the outside of the coop to
give access to the outer coop wall.
One catwalk on the right of the house runs from the exit doors of the right hand room to the boom foot pin area.
One catwalk on the left front of the house runs from the exit door of the left hand room to the boom foot pin area.
These catwalks allow easy access to the boom foot pins (refer to Figure 9-7).
Catwalks on both the right and left lower levels of the machinery house allow movement between the right and left
hand rooms and the machinery house. These catwalks also serve as landings for the boarding stairway and pull-
down ladder, which are used to gain access to the shovel from the ground.
Permanently fixed stairways on right and left sides of the machinery house allow access to the house roof and
operator’s coop.

LEGEND 05. Handrail 09. Catwalk Handrail

01. Catwalk Handrail 06. Handrail 10. Handrail
02. Catwalk Handrail 07. Left Front Catwalk 11. Right Front Catwalk
03. Catwalk Handrail 08. Belt Adjustment Hand- 12. Front Operator’s Coop
04. Handrail rail and Catwalk Catwalk
Figure 8-9: Front House Catwalks and Handrails (R45025F1)
8.3.3 Gantry and Boom Walkways
The gantry platform can be accessed by climbing a stairway from the house roof. The gantry platform allows
access to the gantry for inspection and maintenance purposes. It is also used to inspect the suspension cables.
The platform allows maintenance access to the suspension cables when the cables will be removed or replaced.
Access to the boom is accomplished by crossing one of two platforms from the house roof. Once on the boom
walkways, there are ladders and stairways between the catwalks that make up the individual levels. Access to all
major components can be accomplished with one of the platforms or catwalks.

LEGEND
01. Gantry Catwalk 06. Handrail 11. Catwalk Support
02. Gantry Catwalk 07. Handrail 12. Hex Head Cap Screw
03. Ladder 08. Brace 13. Hex Head Cap Screw
04. Ladder 09. Catwalk Support 14. Hex Head Cap Screw
05. Handrail 10. Catwalk Support 15. Hex Head Cap Screw
Figure 8-10: Gantry Platform (R44350F1)

LEGEND
01. Lower Boom Catwalk
03. Lower Boom Stairs
04. Lower Boom Stairs
05. Right Saddle Block
Catwalk
06. Left Saddle Block Catwalk
07. Right Boom Stairs
08. Left Boom Stairs
10. Boom Catwalk
11. Upper Boom Stairs
12. Boom Stairway
13. Boom Stairs
Figure 8-11: Boom Platforms Module (R53675F1)

! CAUTION
Keep all shovel walkways clean of lubricant build-up. Lubricant build-up and/or spills
can cause slip hazards which can result in serious personal injury.
Keep all boom walkways clean of lubricant build-up and/or spills. Clean lubricant build-up from all walkways and
open areas on a regular basis.
Although the walkways are designed to give maximum possible access to all major components, it may be neces-
sary to use a boom truck or other elevated platform as additional access for maintenance. Use only equipment
approved for lifting persons, use appropriate fall protection devices as required by applicable safety regulations,
and follow operating procedures provided with the equipment.
8.4 Boarding Stairway and Ladder

As standard equipment, the mining shovel is equipped with an air-operated boarding stairway (see Figure 9-10) on
the coop side of the shovel. This stairway can be viewed from the operator’s coop, and therefore should be the
principal means of boarding and exiting the shovel. On the opposite side of the shovel is a pull-down ladder (see
Figure 9-11) which can be used as a secondary means of boarding or exiting the shovel.
As a customer option, the shovel may be equipped with a boarding stairway on both sides of the shovel. The
shovel may also be equipped with a stairway on neither side of the shovel.
Both the stairway and the ladder may contact the crawler tracks of the shovel if lowered while the shovel is not
swung in the correct position. When lowering the stairway or ladder, the shovel should first be swung so that the
tracks are not in the way.
8.4.1 Boarding Stairways
Two boarding stairways, one on either side of the shovel, provide means of access to the machine. Each boarding
stairway has two large air cylinders attached to it. The cylinders are used to raise the stairway and hold it in place,
as well as to lower it. Air control valves are used to actuate the stairway air system, and flow control valves are
used to control the raising and lowering speed. The entire stairway air control system is detailed in Subtopic 15.2.9
A counterweight is also attached to the stairway to assist in balancing out the stairway’s weight.
A proximity-type limit switch is attached to the catwalk near the rear of the shovel. When the stairway is in the fully
raised position, the proximity switch is activated by a plate, which is attached to the stairway. This activation signals
the shovel’s Centurion Control System that the stairway is in the raised position.
NOTICE
The proximity switch and activation plate must be aligned correctly to allow the plate to be well
within the range of the switch when the stairway is in the raised position to prevent false signals.

03
05
04
02
05
01
ES1072b_01
LEGEND: 03 Location of Hand Valve

01. Proximity Switch Activating Plate 04. Air Cylinders and Counterweight
02. Location of Proximity Switch 05. Stairway
Figure 8-12: Boarding Stairway and Right Side Catwalks
CAUTION
The air pressure for the stairway must be adjusted correctly. Inadequate air pressure
could allow the stairway to drift or bounce while in the raised condition, which could

cause the swing and propel brakes to set unexpectedly. This could cause unpredictable
operating conditions as well as damage to the brakes or other equipment.
The shovel’s Centurion Control System is programmed to set the swing and propel brakes automatically if the
boarding stairway is not in the raised position.
! WARNING
Persons entering the shovel swing radius without notifying the operator could be
crushed by the shovel, a haul truck, or other vehicle. Never approach the shovel or lower
the stairway or boarding ladder without first making contact with the operator. Stay out
of the swing radius of the shovel and clear of the paths of haul trucks and any other
vehicles until the operator has signalled it is safe to enter.
Three pull-cords are located at the rear of the shovel near the end of the stairway. One pull-cord can be pulled to
activate an alarm in the operator’s cab to signal the operator that someone wishes to board the shovel. The other
two cords are attached to a rocker assembly, which activates one of the two valves that control the stairway’s posi-
tion. Pulling on one of these cords should raise or lower the stairway. The other valve to control the stairway oper-
ation is located on the landing at the top of the stairway (Item 03, Figure 9-10). There is no stairway control from
the operator’s cab.

ES41157 Mechanical Systems Manual AirScrubPro™
Section 9
AirScrubPro™
Figure 9-1: Air Filtration System
9.1 General
Cartridge type filtration systems are commonly installed at industrial or testing facilities that require hazardous dust
to be filtered out of the air for human comfort and safety. We have engineered our air filtration/pressurization sys-
tem to adapt these modular units designed for static factory applications to a dynamic mining shovel environment.
To insure that the unit holds up under a shovel’s dynamic loads, we have incorporated “heavy-duty” features in the
mounting, fabrication, and conveyor aspects of the unit. In addition we have added protection to the air inlet area to
significantly reduce ingestion of rain and snow.
9.1.1 High Efficiency Filters
The air filtration system is 99.9% efficient by weight at 0.3 micron and greater particulate.

Sec09ASP.fm -9.1- Section 9, Version 00 - 06/07
AirScrubPro™ ES41157 Mechanical Systems Manual
9.1.2 Continuous Self Cleaning
Dirty air is trapped on the outside of the filter cartridges. Clean air flow continues through to the inside of the car-
tridges and then into the machinery house. There is a continuous cleaning cycle where cartridges are self cleaned
with periodic blasts of air blown into the center of each cartridge from the inside-out. Each blast consists of 1.5
cubic feet of air pulsed over a 0.1 second interval through each cartridge one cartridge at a time. Accumulated dust
and dirt on the outside of the cartridge is blown off and falls into a hopper below. A screw conveyor carries the dust
off of the machine and onto the ground automatically. The cleaning pulses continue programmed to occur every 20
seconds with subsequent filter openings in a programmed firing order, until all openings, one at a time, are purged
from the inside out. The cycle then starts all over with the first cartridge 20 seconds later, thereby exhibiting a “con-
tinuous” self cleaning feature.
9.1.3 Easily Maintained
wh03123a
Figure 9-2: Cartridge Replacement from Machinery House Roof
At some point the cartridges accumulate enough dirt in spite of the cleaning cycles, and the operator is alerted to
this with a diagnostic message warning that the cartridges must be replaced. Cartridges are easily replaceable
from the machinery house roof as shown in Figure 9-2. Refer to Subtopic 9.3.1.1 concerning inspection and to
Subtopic 9.3.3 for filter cartridge replacement.

Section 9, Version 00 - 06/07 -9.2- Sec09ASP.fm
9.1.4 Air Flow Description
LEGEND:
01. Rear Machinery
House Assembly
02. Hopper with Screw 05
03. Cartridge Filter Unit
04. Air Flow
05. Inlet Hood
06. Outlet Duct 04 06
07. Two-Stage Blower
08. Discharge to
Machinery House
03 07
08
02
01
front of shovel
ES03234d01
Figure 9-3: Air Flow Diagram
Air inlet is located at top of unit protected by an expansive rain/snow inlet hood, which prevents moisture and dust
from being sucked in. A large two-stage blower provides sufficient air flow even at 10,000 ft. (3,048 m) and with
dirty filters. This prolongs life of individual cartridge filters before replacement is necessary.
Blowers are mounted horizontally. With the inlet hood and outlet duct removed, the blowers may be directly
removed straight up and out of the machine. Alternately, the entire filtration unit including blowers and outlet duct
may be removed as a unit.
Fan blade setting adjustments are achieved through an access door in the outlet duct for top blades, and through
the machinery house for bottom blades. Recommended fan blade settings for particular elevations from 0 to
15,000 ft. (0 to 4,572 m) are published in Tables 9-1, through 9-4 of this document.
The relatively high intake prevents ingestion of accumulated dust and snow from the machinery house roof.
The inlet hood prevents rain and snow from falling into the inlet area of the filter and acts as a plenum that reduces
capture velocity of the air entering the system. The lower the capture velocity, the more difficult it is for the air
stream to capture raindrops or snowflakes and suck them into the air flow. The hood inlet is lower than the actual
unit inlet on top of unit. This forces raindrops or snow to have to travel upward against gravity before they have a
chance at being ingested.

9.1.5 Machinery House Assembly
03
04
02
01
LEGEND
01. Outlet Duct
02. Bolted Access Door
05 03. Inlet Hood
04. Rear Machinery House Assembly
06 05. Cartridge Filter Unit
07 06. Screw Conveyor
House AssemblyB 07. Airlock Mechanism
Figure 9-4: Machinery House Assembly
The rear machinery house assembly is designed to support and cradle the cartridge unit so as to support it in a
dynamic mining shovel environment. Rubber gaskets applied to all internal joints exposed to air flow protect
against leaks caused by vibration.
Refer to Figure 9-4. A flexible hose which leads down from the airlock mechanism (07) to the ground for dumping
of dust is not shown.
The outlet duct is an airtight connection between the cartridge filter unit and the blower inlet. The outlet duct covers
and protects the blowers and the solenoid cleaning system in back of the unit from weather exposure. Bolted
access doors on each side of the outlet duct allow access inside for upper-end blower blade setting and solenoid
valve replacement and inspection.
9.1.6 Screw Conveyor
The forward portion of the filter assembly features a screw conveyor which carries collected dust in an enclosed
trough to the right-hand side of machine.
9.1.7 Cold Weather Kit
The cold weather upgrade kit is applicable to all AirScrubPro units. The purpose of this upgrade is to keep the air
solenoids and air solenoid valves warm and frost free as temperatures drop below 50° F (10° C). When the temper-
ature drops below that point, heat trace cable heats up the component it is wrapped around. There are three sepa-
rate heat trace cable runs, one for each filter sub unit.

9.2.1 Overview
Driven by an airstream generated by the house main blowers, contaminated dusty air enters the dust collector top
inlet area which is shielded by an immense inlet hood. The inlet hood itself acts to minimize rain, snow, and dust
ingestion, since these particulates would have to travel upward against gravity to enter the intake airstream. The
large opening that the inlet hood provides further reduces the “capture velocity” responsible for drawing in these
contaminants.
Dust is collected on the outside surface of the filter cartridges. The clean, filtered air flows through the center of the
filter cartridges into the clean air outlet duct, past the house main blowers, through the blower silencers, and into
the machinery house. Clean machinery house air is used as a source of cooling air for numerous motor and electri-
cal cabinet blowers. A constant flow of clean air is needed in the machinery house to help purge the house of heat
buildup and to maintain a constant positive house pressure relative to the outside. The positive house pressure
helps to prevent dust from being drawn into the house through rope, door, and vent openings.
9.2.2 Normal Operation
When the machine is started in the normal and customary manner from the operator’s cab, the filter control panel is
remotely initiated via a dry contact signal. The control panel is mounted in the rear of the machinery house near the
converter cabinets. Refer to Figure 9-5.
01
LEGEND
01. Control Cabinet 02
02. Nameplate 03
03. Screw Conveyor Selection 04
Continuous/Auto 05
04. New Filters Installed Reset 06
05. Light, Screw Conveyor On 07
06. Light, Screw Conveyor Off
07. Fault Indicator (red light) and 08
Fault Reset Push Button
08. Manual Filter Clean mode
Switch
09. Pressure Differential Display
10. Pilot Lights
11. Hour Meter
12. Disconnect Handle ES04283b01
09 10 11 12
Figure 9-5: Control Cabinet - Front Panel Closed

As long as the machine is powered and the main blowers are operating, the control panel is active and the live air
stream is being filtered. There is an hour meter located on the control panel door that records total hours of car-
tridge filter unit operation. This timer should be used by maintenance personnel to help record pressure setting
changes and any maintenance done on the unit.
Two main 40 hp two-stage blowers pull air through the cartridge filter system, pressurize the house, and purge
cooling air. The blade setting of these blowers, i.e., the angular pitch of the blades for sufficient air flow, is depen-
dent on altitude and power source operating frequency.
The actual pressure drop reading across the filter cartridges will be digitally indicated on the pressure differential
display on the front of the control panel. As the filters get dirty over their one to two year expected lifetime, the pres-
sure drop across the filters will rise even though they are constantly and automatically cleaned with bursts of com-
pressed air. The main blowers cannot create the necessary air flow to maintain house pressure when the filter
pressure drop exceeds maximum specified limits. When the specified pressure drop limits are reached, the car-
tridge filters must be replaced.
9.2.2.1 Filter Cleaning
Figure 9-6: Filter Order of Pulse Cleaning - View Standing in Front of Unit
Filter cartridges are cleaned automatically and sequentially. As long as the main blowers are running, filter purging
will occur every 20 seconds according to the firing order shown in Figure 9-6.
During the filter purge, a solenoid valve is energized, causing the corresponding diaphragm valve to send a 0.1
second pulse of 1.5 cubic feet of compressed air (regulated at 90 psi) through the filter from the inside outward,
blowing the collected contaminants from the outside surfaces of the filter. These pulses are programmed to occur
every 20 seconds on subsequent cartridges determined by a solid-state control timer until the machine is shut
down.
When the machine is shut down, the cleaning cycle is programmed to remain on for 10 more minutes. This allows
for each cartridge to get an additional burst of purging air without the main blowers operating at the same time. The
benefit is that the purged dust will not get sucked back into the cartridges, but will fall directly into the trough below.
Further manual cleaning without the blower on can be achieved with the manual filter clean mode switch on the
control panel shown in Figure 9-5.
The dislodged contaminants are allowed to fall into a trough underneath the filter unit and are automatically carried
off the machine by a screw conveyor that lies inside the bottom of the trough.

9.2.2.2 Screw Conveyor
conveyor motor
01 02 03 04
LEGEND
01. Conveyor Motor 03. Trough
02. Conveyor Drive 04. Screw Conveyor
Figure 9-7: Trough and Screw Conveyor
Most of the dust falling from the cartridge filters from the blasts of pulsed air will fall into a trough at the bottom of
the filter unit. Inside this trough is a 6" (152 mm) diameter screw conveyor that turns and conveys the collected
dust to the rear of the right-hand side of the machine. Refer to Figure 9-7.
The screw conveyor system has two modes, Auto and Continuous. A selector switch on the front of the filter control
panel selects the mode. In addition there are two lights on the front door of the filter control that indicate whether
the screw conveyor is ON or OFF.
Auto Mode
When in Auto mode, the screw conveyor will turn on for a set amount of time when the fans are running. The con-
veyor will wait 50 minutes and then turn on for 10 minutes. The cycle will repeat as long as the filter “Auto-
Continuous” switch is in Auto, the house fans are running, and there are no faults in the system.
Continuous Mode
When in Continuous mode, the conveyor will turn on continuously whenever the switch is placed in the Continuous
position and there are no conveyor faults in the system.

Refer to Figure 9-8. An airlock (3) device mounted at the end of the trough ensures dust is carried off the machine.
From here, a 5" (127 mm) diameter hose will channel dust to the bottom of the machine at grade level. The rotary
screw conveyor is controlled by a timer in the Programmable Logic Controller (Centurion Control System), and can
be programmed to operate for a portion of every hour. Constant operation of the screw conveyor is not necessary
and the timed feature keeps wear and tear on the screw conveyor to a minimum.
LEGEND 01
01. Trough with Screw
Conveyor
02. Airlock
Drive Chain
03. Airlock
04. Zero Speed Switch
05. Hose
02
03
04
05
ES03119a01
Figure 9-8: Airlock and Dust Collector Hose
A zero speed switch (04) incorporated into the screw conveyor assembly, mounted at the end of the rotary airlock
device, provides a signal to the Centurion Control System indicating whether or not the screw conveyor is turning.
If the screw is supposed to be turning but the zero speed switch indicates otherwise, a fault message will appear
on the operator’s touch screen, “The Zero Speed Switch Did Not Close When The Conveyor Should Be Moving.”
An alarm will sound warning of a 30-second delayed shutdown of the shovel.
If there is abnormal drag on the screw conveyor motor, motor speed reducer, screw conveyor, and/or rotary airlock,
an overload relay will trip and the operator will receive the fault message, “Screw Conveyor Overload Is Tripped.”
An alarm will sound warning of a 30-second delayed shutdown of the shovel.

9.3 Maintenance
9.3.1 Inspection
9.3.1.1 Filters
Filters are not inspected visually; rather, they are inspected by referring to the diagnostic indicators on the Graphi-
cal User Interface (GUI) at the operator’s station.
If the diagnostic “Filters Getting Clogged” is active, the system is indicating that the filter pressure drop high limit
has been reached. This high limit was factory programmed according to the expected altitude and operating fre-
quency as shown in Tables 9-1, and 9-3 under “MAX Filter Pressure Drop Indicating Need to Replace Filters.”
When this diagnostic is active, confirm that spare filters are available. If not, order new filters as soon as possible.
If the diagnostic “Filters Are Clogged” is active, the system is indicating that the filters are clogged and they must
be replaced. That is, the pressure drop across the filters has reached or exceeded the Max Pressure Drop limits of
Tables 9-1, and 9-3, they cannot get clean to reduce that pressure drop, and their useful life has ended. If the filters
are not replaced within 48 hours, a machine shutdown will occur.
CAUTION
Failure to replace the filter cartridges at this time will result in low machinery house
pressure, dust ingestion into machinery house, heat buildup, and possible overheating
of electrical components including the motion motors and main blowers.
9.3.1.2 Airlock 1037Z589
The airlock is a precision piece of equipment operating with small internal clearances. Check the interior of the air-
lock for any foreign materials that might cause the airlock to bind while in operation. Any distortion in the housing
will cause the rotor to rub against the housing and thus cause premature failure to the airlock. If the airlock needs
service, contact your local P&H MinePro Services representative.
9.3.1.3 Screw Conveyor
! WARNING
Contact with energized electrical circuits or with moving conveyor components could
cause severe personal injury or death. Always follow lockout and tagout procedures
before removing any covers, guards, or access panels on the screw conveyor
equipment.
To inspect, remove top trough cover and note if bearing is equally spaced within the pipe opening. If bearing has
dropped excessively from a concentric location within the pipe, bearing must be replaced.
• Lubricate the screw conveyor bearing on the airlock end with multipurpose grease (one fitting) every 3 to 6
months.
• The screw conveyor hanger bearing has impregnated graphite lubricant so no lubrication is required. How-
ever, it must be inspected every 3 to 6 months for excessive wear.

• The screw conveyor bearing on the driven end is lubricated by the drive gear box oil. Change the oil in the
gear drive box every 2 years.
Rotary airlock is sealed and lubricated for life; no maintenance needed unless it gets clogged up.
NOTICE
In case of clogging, the screw conveyor can be opened from bottom access panels on the air fil-
tration unit. The conveyor also has three access panels on the run between the air filtration unit
and the rotary airlock. These access panels are bolted every 16" (406 mm) and panels are gas-
keted. There is no need to replace gaskets.
9.3.1.4 Blower Fan R52632F1
Access to make fan blade setting adjustments is achieved through an access door in the outlet duct for top blades,
and through the machinery house for bottom blades. Inspect the ventilation system every 250 hours as follows.
! WARNING
Moving fans can cut and/or crush causing personal injury or death to personnel in the
fan housing. Follow lockout and tagout procedures and disconnect the power to the fans
before performing fan inspection, cleaning or service procedures.
• Check to insure air inlet screens are free of large debris which might reduce air flow.
• Check blower mounting for security.
• Check to make sure fan blades are tight and are all set at the same angle.
• Check the blades for dirt accumulations and debris. A light coating of dust on the blades is normal and will
not impair the operation or efficiency of the fans. In some installations the blades may accumulate a thicker
deposit of surface dirt due to the sticky character of an unusual dust, or due to the presence of oil mist or
similar vapors in the air. When the accumulated deposit reaches a thickness of 1/8 inch (3.2mm), the blades
should be cleaned.
At least twice a year, perform a detailed inspection to make sure the fan blades are clean and that they are set at
the proper pitch. Refer to Subtopic 9.3.2.1.
9.3.2 Adjustments
9.3.2.1 Fan Blades
The amount of air supplied to the machinery house is highly dependent upon the pitch setting of the blower fan
blades. The blower blades are preadjusted to a setting of 14 by the manufacturer. However, this setting is adjusted
during shovel manufacture to the setting(s) shown in Tables 9-1, through 9-4 as a function of altitude and operating
frequency. The settings should be checked when the blowers are installed, and whenever the filters are serviced.

NOTICE
Adjustment made to the blower can affect the filter’s capabilities to remove dust particles from
the incoming air. Improper blower adjustment could cause higher amounts of dust contamina-
tion to pass through the filters into the machinery house.
06 05
02
01
03
04
05
F
l 06
o
w 07
08
ES04282b01
02
Legend 03. Fan Blades 06. Lubrication Fittings

01. Nose 04. Housing 07. Fan Blades
02. Screen Guards 05. Electrical Junction Box 08. Motor
Figure 9-9: Blower Components
To adjust the blower fan blades:
1. Remove the inlet cover from the fan housing.
2. Remove the nose from the fan rotor, refer to Figure 9-9.
3. Check the setting of each blade as indicated by the blade position index stamped on the hub next to each indi-
vidually adjusted blade, as shown in Figure 9-10. Refer to Table 9-1 or 9-3 for the correct blade settings.

NOTICE
All blades must be set to the same set point or the fan will be unbalanced and vibration will
result.
4. If a blade setting is incorrect, adjust the settings as follows:
A. Loosen the blade locknut for blade to be adjusted.
B. Set the blade index mark at the required blade setting and tighten the locknut.
NOTICE
Setting the blade angles to a higher number than recommended can overload the motor, result-
ing in shovel shutdown.
0
8
16
01
Legend 02
01. Index Mark
02. Blade Lock Nut
ES04278a01
Figure 9-10: Checking Blade Setting/Adjustment

50 Hz Applications
Altitude Blade Setting Per-Fan Flow House Pressure MAX Filter

Recommended Expected (ACFM) Expected Pressure Drop
("wg) Indicating
Need To
Feet Meters Clean Dirty Clean Dirty Replace Filters
Filters Filters Filters Filters ("wg)
0 0 14 24,300 18,750 0.50 0.12 8.00
5,000 1,524 14 24,300 18,750 0.42 0.10 7.00
10,000 3,048 13 27,500 21,700 0.58 0.20 6.00
15,000 4,572 13 27,500 21,700 0.48 0.17 5.00
Table 9-1: Fan Blade Setting Chart Guide for Cartridge-Type Filtration
50 Hz Applications
Altitude Current Draw Fan Brake Current Draw Fan Brake

per Fan Horse- per Fan Horse-
@460V* power** @460V* power**
(Amps) (BHP) (Amps) (BHP)
Feet Meters Clean Dirty Clean Dirty Clean Dirty Clean Dirty
Filters Filters Filters Filters Filters Filters Filters Filters
0 0 44.9 48.7 42.0 45.5 44.9 48.7 42.0 45.5
5,000 1,524 37.4 40.9 35.0 8.3 37.4 40.9 35.0 8.3
10,000 3,048 37.4 39.6 35.0 37.0 37.4 39.6 35.0 37.0
15,000 4,572 30.6 33.9 28.6 31.7 30.6 33.9 28.6 31.7
* Motor Ratings @ 460V, 3Ø, 50Hz; 48.3 Full Load Amps; 59.0 Airover Amps.
** Fan Horsepower is rated at 40 hp; can be taken up to 50 hp “air over” MAX rating.
Table 9-2: Current Draw and Horsepower for Cartridge-Type Filtration

50 Hz Applications
Altitude Blade Setting Per-Fan Flow House Pressure MAX Filter

Recommended Expected (ACFM) Expected Pressure Drop
("wg) Indicating
Need To
Feet Meters Clean Dirty Clean Dirty Replace Filters
Filters Filters Filters Filters ("wg)
0 0 11 25,300 19,300 0.60 0.15 8.00
5,000 1,524 11 25,300 19,300 0.50 0.12 7.00
10,000 3,048 10 26,900 20,700 0.53 0.16 6.00
15,000 4,572 10 26,900 20,700 0.44 0.13 5.00
Table 9-3: Fan Blade Setting Chart Guide for Cartridge-Type Filtration
50 Hz Applications
Altitude Current Draw per Fan Fan Brake

(Amps) Horsepower**
(BHP)
Clean Filters Dirty Filters
Feet Meters 380V 415V 380V 415V Clean Dirty Filters

Filters
0 0 54.4 49.8 54.4 49.8 42.0 42.0
5,000 1,524 45.7 41.9 45.2 41.4 35.3 34.9
10,000 3,048 42.7 39.1 43.4 39.7 33.0 33.5
15,000 4,572 35.1 32.1 35.3 32.4 27.1 27.3
* Motor Ratings @ 380V, 3Ø, 50 Hz: 57.5 Full Load Amps; 72.0 Airover Amps
Motor Ratings @ 415V, 3Ø, 50 Hz: 54.4 Full Load Amps; 66.4 Airover Amps
** Fan Horsepower is rated at 40 hp; can be taken up to 50 hp “air over” MAX rating.
NOTES:
1. There are two sets of fan blades per fan, one set on each end of the fan motor
2. Access one set of blades from inside the filter plenum; access the other set from
inside the rear of the machinery house.
3. All blades must be set at the same blade number setting.
Table 9-4: Current Draw and Horsepower for Cartridge-Type Filtration

9.3.2.2 Speed Switch Adjustment 1079Z8303
The speed switch monitors screw conveyor rotation by sensing the pulser wrap rotating in front of the sensor. The
speed switch produces a control signal which is sent to the conveyor control.
The speed switch must be adjusted to provide correct gap between the speed switch and the sensor wrap. Refer to
Figure 9-11 for proper gap distance.
01
A A
02 01
03
ES04276a02
Legend 02. Pulser Wrap

01. Speed Switch 03. Screw Conveyor Shaft
Dimension “A” 1/16" - 1/4"
Figure 9-11: Speed Switch Sensor Gap
9.3.3 Filter Cartridge Replacement
The filters are mounted such that they can be easily accessed from the shovel roof. They are held in place with
access covers and knobs. They are not heavy enough to require lifting equipment.
Filter maintenance is limited to replacement. Replacement takes place when the system is no longer able to clean
the filters any more. A short time before the filters need to be replaced, the system produces an alarm saying “Fil-
ters Getting Clogged”. At this point it is advisable to order new filters.
All filters must be replaced at the same time. If only a few filters are replaced, most of the incoming air will follow
the path of least resistance and flow through the new filters and not the dirty ones. This will drastically reduce the
life of the few new filters.

Figure 9-12: Air Filter Cartridge Replacement
NOTICE
When the filters can not be cleaned by the system, an alarm saying “Filters Are Clogged” will be
produced and a system shutdown will be initiated within 48 hours.
9.3.4 Airlock Feeder Information 1037Z589
! DANGER
Contact with energized circuits will cause death or severe personal injury. Keep chain
guard in place and keep both inlet and outlet covered when the feeder is connected to a
power source.
CAUTION
The airlock is a precision piece of equipment and can be easily damaged if not handled
properly by personnel trained to work on precision equipment. Do not try to force the
rotor to turn with your hands. After disconnecting power to the airlock feeder, use a
board between the blades or use a pipe wrench on the non-drive end of the rotor shaft in
order to turn the airlock rotor by hand. If the rotor does not turn relatively easy, look for
the cause of the problem. There are numerous reasons why the airlock rotor could be
binding. If you are unable to find the problem yourself, consult your local P&H MinePro


Watch what you are doing. Use common sense. Do not attempt to operate Airlock Feeder with-
out the chain guard in place and without inlet and outlet covers in place.
DCP1193a
Figure 9-13: Rotary Airlock Feeder
An airlock feeder is a precision piece of equipment operating with small internal clearances. Any distortion in the
housing will cause the rotor to rub against the housing and thus cause premature failure of the airlock.
CAUTION
Before operation, confirm that the gear motor has oil to the proper level.
Most gear motors (but not all) are shipped with a sufficient quantity of lubricant for operation. It is the user’s respon-
sibility to ensure proper oil level in the gear motor.
Most gear motors are provided with three pipe plugs at different levels. The top (breather) plug is where oil is put in
the gear head with breather plug removed. The center plug, when removed, is used to indicate when the proper
amount of oil is in the gear head. When oil starts flowing out of the center plug (with plug removed), sufficient oil is
in the gear head and both the top (breather) plug and center plug can be replaced. The purpose of the bottom
(magnetic) plug is to be able to remove the oil from the gear head. It should be in place except to drain oil out of the
gear head. The maintenance technician should check and make sure the breather plug is the highest of three plugs
and the magnetic plug is the lowest of the three plugs.
Before operating the airlock, the motor should be bumped to determine the proper direction of rotation.
9.3.5 Screw Conveyor Maintenance
9.3.5.1 Periodic Maintenance Procedures
Periodic inspection and maintenance should be conducted every 250 hours as follows:
1. Inspect all internal and external bearings for excessive wear of bearing or shaft.

2. Inspect bearings in hangers and their housings for excessive wear, apparent lack of lubrication, and for out-of-
round condition.
3. Inspect the flight (forward) edge of the screw conveyor for appropriate thickness and for wear or damage.
4. Inspect coupling bolts at the drive shaft. Remove and inspect the bolt for wear. Inspect the holes for damage.
5. Inspect all other coupling bolts and nuts for external wear or loss.
6. Inspect all seals for leakage.
7. Check bearing bolts, flange bolts and cover bolts for loose, damaged, or missing bolts and nuts.
8. Check all gasket joints for leaking.
9.3.6 Airlock Maintenance 1037Z589
The airlock is a precision piece of equipment operating with small internal clearances. Any distortion in the housing
will cause the rotor to rub against the housing and thus cause premature failure to the airlock.
9.3.6.1 Lubrication Instructions
A shaft bearing and three seals are provided in each end plate. Each bearing is equipped with two grease retention
seals and is factory lubricated. These bearings do not require re-lubrication for the lifetime of the bearing.
9.3.6.2 Rotor Shaft Packing Rings
! WARNING
The screw conveyor can pinch, crush and cut, resulting in severe personal injury or
death. Always follow lockout and tagout procedures before removing any covers,
guards, or access panels on the screw conveyor equipment.
CAUTION
The airlock is a precision piece of equipment and can be easily damaged if not handled
properly by personnel trained to work on precision equipment. Do not try to force the
rotor to turn with your hands. After disconnecting power to the airlock feeder, use a
board between the blades or use a pipe wrench on the non-drive end of the rotor shaft in
order to turn the airlock rotor by hand. If the rotor does not turn relatively easy, look for
the cause of the problem. There are numerous reasons why the airlock rotor could be
binding. If you are unable to find the problem yourself, consult your local P&H MinePro
1. U-cup packing rings are endless. U-cups are self energizing and need very little compression in order to be an
effective shaft seal. Too much compression will damage them.
2. Installation of new U-cup packing rings:
A. Remove end plates. See Subtopic 9.3.6.3.

B. Before installing, dip new U-cup packing rings in a light oil. Press three rings into each end plate with lips
toward the inside. Install the gland plate screws with an allen wrench until very light resistance can be felt,
then lock the screws in place with the jam nuts against the bearing housing.
C. After both housing end plates have been installed per Subtopic 9.3.6.4, check the U-cup packing rings to
make sure they have only a slight amount of compression. Back off the two gland plate screws enough to be
sure the U-cups are not being compressed and then retighten the gland plate screws and their gland nuts.
Do not compress the U-cup packing rings. The gland plate screws should be tightened only enough to snug
the U-cup packing rings down against the packing seat. With the roller chain removed and the airlock feeder
NOT connected to the power source, the rotor should rotate with some resistance caused by the lightly com-
pressed U-cup packing rings when pulling on the rotor vanes using a piece of 2x4 lumber approximately 3’
(0.9 m) long between the vanes. As a safety precaution, do not pull on the rotor vanes with your fingers.
9.3.6.3 End Plate Disassembly
! WARNING
Always Lockout and Tagout power before removing any covers, guards, or access pan-
els on the screw conveyor equipment.
! CAUTION
The screw conveyor can pinch, crush or cut, resulting in personal injury. Do not rotate or
pull on airlock rotor by hand. Always use a suitable tool.
1. Before either end plate is disassembled, the drive assembly must be removed.
2. Remove air purge hardware from both end plates if so equipped.
Figure 9-14: End Plate Setscrews
3. Loosen the packing gland plate and bearing setscrews on both end plates.
4. Remove the hex bolts which fasten the non-drive end plate to the cylinder housing.

5. Pull the non-drive end plate off the rotor shaft. Do not attempt to remove the end plate by forcing a wedge
between the plate and housing. This could mar the machined surfaces of the housing and end plate. Do not
hammer on the end of the rotor shaft with a steel hammer as this will deform the shaft. If force is required, use
a gear puller or use a wood block on the end of the rotor shaft to hammer on. Be careful not to damage the
center in the end of the rotor shaft. Note the number of shims on the non-drive end so the same number can be
re-installed.
6. Extract the rotor from the cylinder housing. If force is necessary to remove the rotor, use a block of wood on the
rotor shaft to hammer on or a gear puller. Avoid setting the removed rotor on concrete or other hard surfaces,
as the machined rotor blade tips might be damaged.
7. Upon completion of Steps Step 4, Step 5, and Step 6, remove the hex bolts which fasten the drive end plate to
the cylinder. The drive end plate should then be separated from the housing. Use a 2x4 of the proper length to
pound on interior of end plate if force is required. Note the number of shims on the drive end of the cylinder
housing, so the same number can be re-installed.
8. If replacement of bearings is necessary, remove the shaft bearing from the end plate by use of a soft metal or
fiber drift. Do not mar or dent any machined surfaces.
9.3.6.4 End Plate Assembly
1. Insert a shaft bearing in each end plate. The bearing should be a light press fit. Be sure the bearing is pressed
down against the bearing snap ring.
2. For installation of shaft seals, refer to Subtopic 9.3.6.2.
3. For easier installation of the end plates, leave the packing gland plates loose.
4. Before installing the drive end plate, polish the sealing surfaces and the bearing journals with a fine (100 grit or
finer) emery cloth. Be sure there is no foreign matter on the machined mating surfaces.
5. Install the drive end plate and tighten the hex bolts to fasten the drive end plate to the cylinder housing. Move
from bolt to bolt (not adjacent bolts) and tighten each down gradually.
6. Install the rotor assembly. Be sure not to scratch or mar the machined surfaces of the housing.
7. Repeat steps 4 and 5 for the non-drive end plate assembly.
8. Tighten down the packing gland plate screws. Refer to Subtopic 9.3.6.2 for information for the proper compres-
sion of the packing rings.
9. Check the axial clearances between the rotor and the end plate. To increase the total axial clearance, a shim or
shims must be added. To decrease the total axial clearance, a shim or shims must be removed. Each shim is
0.003" (0.08 mm) thick. An end plate assembly must be removed in order to add or remove end plate shims.

01 02
03 04 05 06
A
07
08
09
A
10
11
12
ES04277a02
B B 13
LEGEND 05. Flat Washer

01. Cylinder 06. Lock Nut
02. Rotor Assembly 07. Gland Plate Screw
03. End Plate 08. Bearing
04. Gland Plate 09. Shaft Packing
Location Clearance
Rotor and Housing “A” 0.005"
Rotor and End Plate “B” 0.010"
Figure 9-15: Airlock Clearances

9.4 Fault Diagnostics
9.4.1 General Information
Help Screens are designed to assist the operator and maintenance technician in identifying and isolating malfunc-
tions with systems used on a P&H Mining Shovel.
The following information is provided in case of a Graphical User Interface or Panelview fault message for the P&H
AirScrubPro Filtration System.
9.4.2 Graphical User Interface (GUI)
The cleaning system and conveyor faults will be shown as a GUI or Panelview fault message. The fault descrip-
tions are:
HOUSE FILTER CONTROL SYSTEM IS NOT ACTIVE.
FILTER SYSTEM FAULT: NO PRESSURE SENSOR INPUT.
FILTER SYSTEM FAULT: NEW FILTER MUST BE SET.
FILTER SYSTEM FAULT: FILTERS ARE GETTING CLOGGED.
FILTER SYSTEM FAULT: FILTERS ARE CLOGGED.
CONVEYOR SYSTEM FAULT: SCREW CONVEYOR OVERLOAD IS TRIPPED.
CONVEYOR SYSTEM FAULT: THE ZERO SPEED SWITCH IS CLOSED WHEN THE CONVEYOR SYSTEM
SHOULD BE STOPPED.
CONVEYOR SYSTEM FAULT: THE ZERO SPEED SWITCH DID NOT CLOSE WHEN THE CONVEYOR
SHOULD BE MOVING.
CONVEYOR SYSTEM FAULT: THE CONVEYOR CONTACT AUXILIARY IS CLOSED. THE CONTACTOR
SHOULD BE OPEN.
CONVEYOR SYSTEM FAULT: THE CONVEYOR CONTACT AUXILIARY IS NOT CLOSED WHEN THE CON-
TACTOR SHOULD BE ENERGIZED.
TEMPERATURE FAULT: DIFFERENTIAL PRESSURE SENSOR IS NOT AT THE PROPER TEMPERATURE.

9.4.3 Panel Fault Indication
The cleaning system and conveyor faults will be shown on a 4 Digital Output 24 VDC Module located in the filter
control system enclosure. The seventh module from the left-hand side will sequentially display the system faults.
The lights will flash the fault for 5 seconds then flash the next fault for 5 seconds, etc.
01
02 03
04
05
09
06
Legend
01. Control Cabinet
02. Power Supply
03. Transformer
04. Switch, Disconnect
05. Fuse Block 07
06. Contactor
07. Heater, 100W
08. Terminal Blocks 08
09. I/O Module, Fault Display ES04283a04
Figure 9-16: Control Cabinet - Front Panel Open

Fault Light Light Light Light

# 1 2 5 6
1 ON
2 ON
3 ON ON
4 ON
5 ON ON
6 ON ON
7 ON ON ON
8 ON
9 ON ON
10 ON ON
Figure 9-17: I/O Module Cleaning System and Conveyor Fault Indication
9.4.3.1 Filtration System Faults
Fault Number Description

1 No Pressure Sensor Input. The system has detected that the differential pressure
signal is missing. The differential pressure sensor is located in a junction box
enclosure located in the blower plenum. Check the pressure display on the front of
the filter enclosure. Check the pressure sensor and wiring.
2 New Filter Must Be Set. The system has detected that the pressure differential has
decreased substantially more than it had been, which indicates the filters may
have been changed. If the filters have been changed, then the “New Filters
Installed Reset” button on the control panel must be used to reset the system. If
new filters have not been installed, then some of the filters may have broken
through and are no longer filtering the air.
3 Filters Are Getting Clogged. The system has detected that the filters are approach-
ing a clogged filter condition. At this point it is advisable to order new filters.
4 Filters Are Clogged. The system is indicating that the filters are clogged and must
be replaced. The programmed logic allows 48 hours before the machine shuts
down. If the problem is not corrected, the machine will shut down every 48 hours
on this fault.
Table 9-5: System Faults


10 Differential Pressure Sensor Is Not At The Proper Temperature. The system has
detected that the junction box housing the differential pressure sensor in the
house filter plenum is too cold. Check to see if the enclosure heater is operational.
Table 9-5: System Faults
9.4.3.2 Conveyor Faults
The filter screw conveyor system has two modes, Auto and Manual. A selector switch on the front of the filter con-
trol panel selects the mode. In addition there are two lights on the front door of the filter control which indicate
whether the screw conveyor is ON or OFF.
Auto Mode: When in auto mode, the screw conveyor will turn on for a set amount of time when the house fans are
running. The conveyor will wait 50 minutes and then turn on for 10 minutes. The cycle will repeat as long as the fil-
ter control “Auto-Manual” switch is in Auto, the house fans are running, and there are no faults in the system.
Manual Mode: When in manual mode, the conveyor will turn on continuously whenever the switch is placed in the
Manual position if there are no conveyor faults in the system.
The following screw conveyor faults can stop the operation of the screw conveyor.

5 Screw Conveyor Overload Is Tripped. The system has indicated that the screw conveyor
motor overload has tripped. The overload must be manually reset in the filter control
enclosure. Check to see if the screw conveyor is rotating freely and not jammed.
6 The Zero Speed Switch Is Closed When The Conveyor Should Be Moving. The system
has detected that the zero speed switch is indicating the screw conveyor is moving
when it should not be moving.
7 The Zero Speed Switch Did Not Close When The Conveyor Should Be Moving. The sys-
tem has detected that the screw conveyor is not turning. Visually check to see if the
screw conveyor is jammed or the speed sensor is out of position.
8 The Conveyor Contactor Auxiliary Is Closed. The Contactor Should Be Open. The system
has detected that the screw conveyor contactor auxiliary contact is closed when the
contactor should be open.
9 The Conveyor Contact Auxiliary Is Not Closed When The Contactor Should Be Energized.
The system has detected that the screw conveyor contactor auxiliary contact did not
close when the contactor should have been closed.
Table 9-6: Conveyor Faults
9.4.4 Fault Diagnosis
9.4.4.1 Fault 2: New Filter Must Be Set
The system has detected that the pressure differential has decreased substantially more than it had been, which
indicates that the filters may have been changed. If the filters have been changed then the “New Filters Installed
Reset” button on the control panel must be used to reset the system.

NOTICE
If new filters have not been installed then some of the filters may have broken through and are
no longer filtering the air. Refer to Subtopic 9.3.1 for air filter inspection and to Subtopic 9.3.3
for maintenance.
9.4.4.2 Fault 3: Filters Are Getting Clogged
Order new filters.
• The pressure differential across the cartridge filters has temporarily exceeded the highest pressure
differential that the main blowers can handle.
• This is an indication that the cartridge filters are clogged to the extent that their useful life is nearing
an end. There will be lower machinery house pressure and possible rise in machinery house tem-
perature, because the main blower fans will not deliver as much air flow.
NOTICE
It is highly recommended to order new filters at this time.
9.4.4.3 Fault 4: Filters Are Clogged
Replace Filters.
• The pressure differential across the cartridge filters has exceeded the highest pressure differential
(the maximum filter pressure drop) that the main blowers can handle.
• The filter cleaning can no longer clean the filters to achieve a lower pressure differential.
• The main blower fans can no longer provide the air flow needed to pressurize the machinery house.
CAUTION
Failure to replace the cartridge filters at this time will result in low machinery house
of electrical components.
9.4.4.4 Fault 5: Screw Conveyor Overload Is Tripped
The screw conveyor motor overload relay has tripped due to abnormal drag on one or more of the following com-
ponents in the screw conveyor system:
• Screw conveyor motor
• Motor speed reducer
• Screw conveyor

• Rotary airlock
! WARNING
Rotating machinery can pinch, crush, and cut, resulting in severe personal injury or
death. Follow lockout and tagout procedures before removing guards, access doors,
and covers. Do not step on cover or guard. Do not reach into screw conveyor while
screw is turning or while there is residual potential rotational load present once obstacle
is removed. Securely fasten guards, access doors, and covers before returning equip-
ment to operation.
Step 1: Check to see if there is an obstacle caught in either the screw conveyor or rotary airlock.
Figure 9-18: Auger Motor

Figure 9-19: Rotary Airlock
• Visual access to the airlock can be achieved by removing access cover over the auger trough fur-
thest to outboard side of auger discharge.
• Access panels are removable on top of auger extension over entire length of filter unit.
• Three access panels to screw conveyor directly below filter unit are located facing front of machine.
Step 2: Remove access panels to inspect screw conveyor.
• Once panel is removed from filter base, another panel (with handles) must be removed for direct
access to screw conveyor.
• A fourth access panel is located on auger motor end facing the back of the machine.
• Screw conveyor can be manually rotated
Step 3: Remove obstacles from trough and screw conveyor.
9.4.4.5 Fault 7: The Zero Speed Switch Did Not Close
! WARNING
Rotating machinery can pinch, crush, and cut, resulting in severe personal injury or
death. Follow lockout and tagout procedures before removing guards, access doors,
and covers. Do not step on cover or guard. Do not reach into screw conveyor while
screw is turning or while there is residual potential rotational load present once obstacle
is removed. Securely fasten guards, access doors, and covers before returning equip-
ment to operation.
Screw conveyor should be rotating but is not. Auger motor driving screw conveyor is not overloaded and is rotating.
There is a break in one or more of the following components in the auger system:

• Screw conveyor
• Screw conveyor shear bolt connection (just outside filter unit in trough)
• Auger motor drive shaft
• Rotary airlock chain drive
• Zero speed switch
Inspect the rotary airlock chain.

Keep hands and fingers out of the screw conveyor trough while rotating screw.
Screw conveyor can be manually rotated with a wrench from auger motor end to help troubleshooting efforts.
9.4.5 Graphical User Interface (GUI) Messages
Table 9-7 describes fault diagnostic messages displayed on the operator’s GUI related to the P&H Cartridge-Type
Air Filtration and Pressurization System.
GUI Display Diagnostic Explanation
House Filter Control System Is Not Active
No Pressure Sensor Input The system has detected that the differential pressure sig-
nal is missing.
New Filter Must Be Set The system has detected that the pressure differential has
decreased substantially more than it had been, which indi-
cates the filters may have been changed.
Filters Are Getting Clogged The pressure differential across the cartridge filters
indicates that the filters are approaching a clogged filter
condition. At this point it is advisable to order new filters.
Filters Are Clogged The pressure differential across the cartridge filters has
exceeded the highest allowable pressure differential as set
by the pressure differential switch, the filters are clogged
and must be replaced.
Screw Conveyor Overload Is Tripped There is an abnormal drag on the screw conveyor motor,
the speed reducer, the rotary airlock, or the conveyor
itself. A 30-second delayed shutdown will occur.
The Zero Speed Switch Closed When The The speed switch is indicating that the screw conveyor is
Conveyor Should Be Stopped moving when it should not be. A 30-second delayed shut-
down will occur.
The Zero Speed Switch Did Not Close Screw conveyor is supposed to be turning, but zero speed
When The Conveyor Should Be Moving switch indicates that it is stopped. A 30-second delayed
shutdown will occur.
Table 9-7: Cartridge Filter GUI Messages

GUI Display Diagnostic Explanation
The Conveyor Contactor Auxiliary Is The screw conveyor contactor auxiliary contact is closed
Closed when the contactor should be open.
The Conveyor Contact Auxiliary Is Not The screw conveyor contactor auxiliary contact did not
Closed When The Contact Should Be close when the contactor should have been closed.
Energized
Differential Pressure Sensor Is Not At The The junction box housing the differential pressure sensor in
Proper Temperature the house filter plenum is too cold.
Table 9-7: Cartridge Filter GUI Messages

9.4.6 Intelligent Interface Module (IIM)
9.4.6.1 General Information
The Intelligent Interface Module (IIM) controls the operation of the air filtration unit. It is a component of the Remote
I/O System. The IIM is an Intelligent Pre-Processing Unit, or I-Slave. It enables you to decentralize control tasks.
A Remote I/O System with an IIM can exercise full independent control over a process related functional unit and
can be used as a stand-alone CPU. The use of the IIM leads to modularization and standardization of process-
related functional units.
Several LED’s are located on the front of the Intelligent Interface

Module. The Run, Stop, On, BF, SF, and FRCE LED’s display
important information on the states of the Module to the user.
The IIM has the following 6 LED’s. Refer to Subtopic 9.4.8.
• SF LED (system fault) - Indicates the

presence of a fault in the Remote I/O
System.
• BF LED (Bus Fault) - Indicates the pres-

ence of faults on the Profibus DP-V1.
• On LED - Indicates that the Remote I/O

System is connected to a power supply.
• FRCE LED - Indicates that a force

request is active.
• Run LED - Indicates that the CPU com-

ponent of the IIM is in the Run mode.
• Stop LED - Indicates that the CPU com-

ponent of the IIM is in the Stop mode.
Figure 9-20: Intelligent Interface Module (IIM)

9.4.6.2 Mode Selector Switch
The positions of the mode selector are located on the front of the IIM. Refer to Figure 9-20 for switch positions.
Position Function Description
Run Run mode The CPU executes the user program.
Stop Stop The CPU does not execute the user program.
Mode Programs can:
Be downloaded from the Interface Module using a Laptop PC.
Be transferred to the Interface Module using a Laptop PC.
MRES Memory Momentary-contact position of the mode selector for resetting the
Reset Interface Module memory.
NOTICE
You must adhere to a specific sequence when reset-
ting the Interface Module memory using the Mode
Selector Switch.
Table 9-8: Mode Selector Switch Positions
9.4.6.3 Memory
The memory of the IIM can be divided into three areas.
Figure 9-21: Interface Module Memory
Load Memory
The load memory is installed on the Micro Memory Card (MMC). The Load Memory is used to record code and
data blocks as well as system data (configuration, module parameters, etc.).
Blocks which are designated as non-processing-related are recorded in the load memory.

The complete configuration data for a project can also be stored on the MMC.
The program in the MMC is always retentive. When downloaded, it is stored on the MMC such that it is unaffected
by power failures and is not erased by memory resets.
NOTICE
The Intelligent Interface Module can only be operated with the MMC inserted.
Working Memory
The working memory is integrated on the IIM and cannot be expanded. It is used to process the codes and data of
the user program. Program processing is only performed at the working memory and system memory.
The working memory of the IIM is retentive if the MMC is inserted. The data in the working memory is saved on the
MMC if the power supply is interrupted.
System Memory
The system memory is integrated on the IIM and cannot be expanded. It contains:
• The address areas “memory markers”, “timers”, and “counters”.
• The process images of the inputs and outputs.
• The local data.
For memory markers, timers, and counters, you can configure (Properties of the CPU, Retentive tab) which parts
are to be retentive and which parts are to be initialized with “0” when a complete restart (warm restart) is
performed.
The diagnostic buffer, transmission rate, as well as the run-time meter are generally stored in the retentive memory
on the CPU. Retentivity of the transmission rate ensures that your CPU is still able to communicate following a
power failure, a memory reset, or the loss of communication parameters (by removing the MMC or erasing the
communication parameters.
Retentivity
The IIM has a retentive memory. The retentivity is provided on the MMC and IIM. The retentivity means that the
content of the retentive memory is retained even following power off and a restart (warm restart).
9.4.7 Micro Memory Card (MMC) Description and Operation
A 64K Micro Memory Card (MMC) is used as a memory module for the Intelligent Interface Module (IIM). The MMC
can be used as a load memory and portable data carrier. It is an essential requirement for operating the IIM. The
following data is stored on the MMC:
• User program (all blocks)

• Archives and recipes
• Configuration data
• Data for an operating system update, operating system backup
CAUTION
The module content of an MMC can be corrupted if the card is removed while a write
operation is being performed. If this happens, the MMC must be erased or formatted in
the IIM. Never remove the MMC in Run mode. It should only be removed when the IIM is
in the power off or Stop mode and only if the Laptop PC is not currently performing a
write access operation. If in the Stop mode you are not sure whether or not the Laptop
PC is performing a write access operation (e.g. loading/erasing a block), unplug the
communication connections beforehand.
The service life of an MMC mainly depends on the following factors:
• The number of erasing and programming operations.
• External influences such as ambient temperature.
At the ambient temperature of up to 140° F (60° C), the service life of an MMC with a maximum 100,000 erase/
write operations is 10 years.
CAUTION
To prevent data loss, do not exceed the maximum number of erase/write operations.
9.4.7.2 Removing and Inserting the MMC
The IIM cannot run if there is no MMC inserted. Practical operation is only possible if an MMC has been inserted
and a memory reset has been performed.
Removal and insertion of an MMC is detected by the IIM in all operating modes. To remove the MMC, proceed as
follows:
CAUTION
The module content of an MMC can be corrupted if the card is removed while a write
operation is being performed. If this happens, the MMC must be erased or formatted in
the IIM. Never remove the MMC in Run mode. It should only be removed when the IIM is
in the power off or Stop mode and only if the Laptop PC is not currently performing a
write access operation. If in the Stop mode you are not sure whether or not the Laptop
PC is performing a write access operation (e.g., loading/erasing a block), unplug the
communication connections beforehand.
Step 1: Place the IIM in the Stop mode.

Step 2: There is an eject button on the memory card slot to enable you to remove the card easily. To eject the
card, press the button with a small screwdriver or a ballpoint pen.
Step 3: When the MMC is removed, the IIM requests a memory reset.
To insert the MMC with the appropriate user program, proceed as follows:
! CAUTION
Make sure the MMC to be inserted contains the user program appropriate for the IIM and
Remote I/O System. An incorrect user program can have serious effects on the process-
ing and shovel motion and/or characteristics. This may cause personal injury or prop-
erty damage.
Step 1: Insert he MMC into the proper slot on the IIM.
Step 2: The IIM will request a memory reset. If the IIM requests a memory reset again, this probably means that
an incorrect MMC or an MMC with a firmware update has been inserted.
Step 3: Start the IIM.
9.4.7.3 Backing Up the Operating System on the MMC
To back up the operating system, proceed as follows:
Step 1: Insert a 4MB MMC into the IIM slot. The IIM will request a memory reset.
Step 2: Press and hold the Mode Selector Switch in the MRES position.
NOTICE
The Mode Selector Switch is spring loaded so that it will return to the STOP position when
released. Hold the switch in the MRES position during Step 3.
Step 3: While holding the Mode Selector Switch in the MRES position, switch the power off then on. The Stop,
Run and FRCE LED’s will start flashing.
Step 4: Allow the Mode Selector Switch to return to the Stop position.
Step 5: Briefly, press the Mode Selector Switch to the MRES position and immediately allow it to snap back to the
Stop position.
The IIM starts to back up the operating system on the MMC.
All of the IIM LED’s illuminate during backup.
The Stop LED flashes after the backup has been completed. In this way, the IIM requests a memory reset.
Step 6: Remove the MMC card for safe storage.

NOTICE
Install a MMC before restarting the system. The IIM cannot run if there is no MMC inserted.
9.4.7.4 Formatting the MMC Prior to a Memory Reset
In certain exceptional cases, the MMC will have to be formatted. Refer to Subtopic 9.4.9.2 for the formatting
procedure.
• The module type is not a user module.
• The MMC has not yet been formatted, is faulty, or the data is corrupted.
• The content of the MMC has been designated as invalid.
• The Load User Program operation has been interrupted by power off.
• The Programming operation has been interrupted by power off.
• A fault has occurred during evaluation of the module content prior to a memory reset.
• A fault has occurred during formatting, or formatting could not be performed.
If one of the above-described faults has occurred, the IIM also requests another memory reset after a memory
reset has been performed. The content of the MMC is retained until the special measure has been completed,
unless the Load User Program or Programming operations are interrupted by power off.
9.4.8 LED Lights Description
For the CPU component of the Intelligent Interface Module there are two separate LED’s that indicate the operat-
ing modes of the CPU:
• RUN
• STOP
You can obtain additional information on the Power Supply of the CPU, on force requests, and on general errors
via three additional LED’s: On, FRCE, and SF.

When the On LED is off, either no supply voltage or insufficient supply voltage is being applied to the electronic
components/sensors of the Remote I/O System. The cause is likely to be a defective fuse or inadequate or nonex-
istent system voltage.
LED Description Function
On Comes on when the supply voltage is applied to the Intel-

Power On ligent Interface Module (IIM).
(green)
Run Lights up continuously when the IIM component is pro-

Run mode cessing the user program.
(green) Flashes at 2 Hz during the start-up of the IIM component:
• For at least 3 seconds, but the start-up of the IIM

component can also be shorter.
• During the start-up of the IIM component, the Stop

LED also lights up; when the Stop LED goes off, the
outputs are enabled.
Flashes at 0.5 Hz when the IIM has reached a break-point
you have set. At the same time the Stop LED comes on.
Stop Lights up when the IIM component:

Stop Mode
• Is not processing a user program.
(yellow)
• Has reached a break point you have set at the same

time the Run LED flashes at 0.5 Hz.
Flashes at 0.5 Hz, when the IIM component requests a
memory reset.
FRCE Lights up when a force request is active.

Force Request
Active
(yellow)
Table 9-9: Intelligent Interface Module (IIM) LED Indicators

LED Description Function
SF Lights up in the event of:

Group Error
• Programming errors.
(red)
• Parameter assignment errors.
• Calculation errors.
• Timing errors.
• Remote I/O errors.
• Hardware errors.
• Firmware errors.
Table 9-9: Intelligent Interface Module (IIM) LED Indicators
If the BF and SF LED’s light up or flash, the Remote I/O System is not configured correctly. The table below shows
the possible error indications together with their meanings and necessary action. It also shows the LED states for
Profibus DP-V1 slave operation.
BF LED SF Description Cause Error Handling

LED
On On No connection • The Intelligent Interface Module (IIM) Check that the connector
to the DP-V1 is in the active mode = Bus short-cir- for the Profibus DP-V1 is
Master. cuit. inserted correctly.
Check whether the bus
• The IIM is in the passive mode = cable to the DP-V1 Mas-
Transmission rate detection No ter is defective.
active mode at bus, DP-V1 Master
does not exist or is switched off, or
bus connection disrupted.
• SF is on due to station failure.

Table 9-10: Intelligent Interface Module (IIM) LED Configuration Indicators

BF LED SF Description Cause Error Handling

LED
Flashing On Parameter • Slave not configured or incorrectly Check the hardware of

assignment configured. the Remote I/O System.
error; there is Check the configuration
no data and parameterization of
• Incorrect but permissible station
exchange. the Remote I/O System.
address configured.
Check the settings for
• Configured address areas of the the configured address
actual configuration not identical to areas for the DP-V1
the target configuration. Master.
• Station failure of a configured sender

in direct data communications.
• DP-V1 Master does not exist or is

switched off.
Off On Fault in slave: DP-V1 Master in Stop. Switch the DP-V1 Mas-
Diagnostic ter to Run mode.
Interrupt.
Off Off Data exchange The target configuration and actual config- This is the normal condi-
taking place. uration of the Remote I/O System match. tion, no action is
required.
Table 9-10: Intelligent Interface Module (IIM) LED Configuration Indicators

9.4.9 Resetting the Memory
The memory of the IIM must be reset under the following conditions:
• To erase retentive areas (memory markers, timers, counters).
• If the IIM requests a memory reset by flashing the Stop LED.
The following are possible reasons why the IIM requests the memory reset function:
• The Remote I/O is starting up for the first time.
• Inconsistent memory areas.
• The MMC has been replaced.
When the IIM requests a memory reset (the Stop LED flashes slowly), format it by operating the Mode Selector
Switch.
9.4.9.1 Memory Reset Procedure
To reset the Memory of the IIM with the Mode Selector Switch, perform the following steps:
Step 1: Place the Mode Selector Switch in the Stop position.
Step 2: Press down and hold the Mode Selector Switch in the MRES (Memory Reset) position. Hold down the
Mode Selector Switch in this position until the Stop LED illuminates for the second time (3 seconds).
NOTICE
The Mode Selector Switch is spring loaded so that it will return to the STOP position when
Step 3: Allow the Mode Selector Switch to return to the Stop position.
Step 4: Within 3 seconds, press and hold the Mode Selector Switch back to the MRES position until the Stop LED
flashes rapidly (at 2Hz). When the IIM has completed the memory reset function, the Stop LED will cease
flashing and remains illuminated.
9.4.9.2 Formatting the MMC
To format the MMC with the Mode Selector Switch, perform the following steps:
NOTICE
Make sure the steps are performed in the specific times given, otherwise the MMC will not be
formatted and will reassume the Memory Reset status. The MMC is only formatted if a format-
ting condition exists and not when a memory reset is requested after a module is changed. In
this case, switching to MRES only results in a standard memory reset whereby the content of
the module remains valid.

Step 1: Place the Mode Selector Switch in the Stop position.
NOTICE
The Mode Selector switch is spring loaded so that it will return to the Stop position when
Step 2: Press down and hold the Mode Selector Switch in the MRES (Memory Reset) position for approximately
9 seconds or until the Stop LED stops flashing.
Step 3: Within 3 seconds after the Stop LED stops flashing, release the Mode Selector Switch then immediately
move it back to the MRES position. The Stop LED flashes during the formatting procedure.
9.4.10 Terminal Assignment
Table 9-11 details the terminal assignments of the Intelligent Interface Module (IIM) for the RS-485, Profibus DP-
V1 with fiber-optic cable interface, and 24 VDC.
View Signal Name Description
1 --- ---
2 M24 External 24 VDC Supply
3 RxD/TxD-P Data Line B
4 RTS Request To Send
5 M5V2 Data Reference Potential (from the station)
6 P5V2 Supply Plus (from the station)
7 P24 External 24 VDC Supply
8 RxD/TxD-N Data Line A
9 --- ---
Top Receive
Bottom Transmit
Receiver
Transmitter
Table 9-11: IIM Terminal Assignments

View Signal Name Description
1L+ 2L+ 1M 2M 1L+ 24 VDC
2L+ 24 VDC (to loop through)
1M Chassis Ground
2M Chassis Ground (to loop through)
Table 9-11: IIM Terminal Assignments
9.4.11 Control Monitor
9.4.11.1 Differential Pressure Sensor
When the pressure drop across the filters first reaches the maximum pressure switch setting, there will be a diag-
nostic warning message to the operator: “Filters Are Getting Clogged; Time To Order New Filters.” This message
will stay displayed on the operator GUI screen even if the filters have been cleaned and pressure has dropped.
When pressure drop across the filters reaches an additional 0.25" wg, another diagnostic warning message is dis-
played to the operator, “Filters Are Clogged; Replace Filters”. This message should be heeded immediately (see
Caution below). This message will stay on until the filters are replaced.
If the diagnostic “Filters Are Clogged” is active, the system is indicating that the filters are clogged and they must
be replaced. That is, the pressure drop across the filters has reached or exceeded the Max Pressure Drop limits of
Tables 9-1, and 9-3, they cannot get clean to reduce that pressure drop, and their useful life has ended. If the filters
are not replaced within 48 hours, a machine shutdown will occur.
CAUTION
Failure to replace the cartridge filters at this time will result in low machinery house
of electrical components, including the motion motors and main blowers.

9.4.12 Control Junction Box
The control junction box is mounted outside the plenum and contains the pulse jet sequencer board, pressure
transducer, valve terminal strips, and a thermostat and heater.
02 03
01
04
Legend
02. Thermostat
03. 100W Heater
04. Pulse Jet Sequencer Board ES04280a01
Figure 9-22: Control Junction Box


ES41157 Mechanical Systems Manual Air Conditioning Units
Section 10
Air Conditioning Units
10.1 General
This 4100XPC Electric Mining Shovel has a Sigma Model M20 heating/air conditioning system. The heating/air
conditioning unit is located next to the operator’s cab on the machinery house roof. They are connected to the cab
by duct work. A second air conditioner unit is used to cool the right hand room where the Centurion Control System
and other heat sensitive electronic controls are located.
10.2 Operation
Figure 10-1: Climate Control Openings
Heated or cooled air is directed into the operator’s cab through numerous adjustable openings. The openings may
be rotated to change the direction of the air flow.
10.3 Maintenance
10.3.1 General
Maintenance on HVAC systems should be performed only by personnel who are qualified and authorized to work
on such equipment. Contact your local P&H MinePro Services representative whenever advanced work is neces-
sary.
Normal maintenance is limited to:
• Changing filters.
• Cleaning coils.

Sec10SigmaAir.fm -10.1- Section 10, Version 00 - 06/07
Air Conditioning Units ES41157 Mechanical Systems Manual
• Checking fasteners and fittings for tightness and inspecting the unit for structural damage or stress cracks.
10.3.2 Part Numbers
The shovel serial number is located inside the operator’s cab.
Figure 10-2: Shovel Serial Number (Typical)
NOTICE
! WARNING
Contact with energized electrical circuits in the unit could cause severe personal injury
or death. Follow all lockout/tagout procedures to remove power to the unit prior to per-
forming any filter change.
Follow all specific lockout/tagout procedures to remove power from the unit.
Refer to the manufacturer’s literature for procedures for changing filters, cleaning coils, and other maintenance
requirements.

Section 10, Version 00 - 06/07 -10.2- Sec10SigmaAir.fm
ES41157 Mechanical Systems Manual Swing System
Section 11
Swing System
11.1 General
Figure 11-1: Swing System Machinery
The swing system is designed to swing the shovel upper in relation to the lower. The system is powered by three
blower-cooled P&H direct current, reversible electric motors acting through three-reduction planetary swing trans-
missions. The system brake and the motor blower are mounted at the upper end of the swing motor.
The swing shaft extends from the swing planetary transmission through the revolving frame. At the lower end of the
shaft, a swing pinion is attached. The swing pinion meshes with a large ring gear that is attached to the top of the
carbody to provide the rotational motion of the upper relative to the lower.

Sec11Swing.fm -11.1- Section 11, Version 00 - 06/07
Swing System ES41157 Mechanical Systems Manual
11.2.1 Swing Motors
Figure 11-2: Swing Motor
11.2.1.1 General
The swing motors are mounted on the swing transmissions as shown in Figure 11-1. Each motor is furnished with
a blower for forced air cooling.
A holding brake is mounted on the upper end of the motor rotor shaft. Each rotor shaft is coupled to a swing trans-
mission, which drives the swing shafts. The swing shafts turn the upper in relation to the lower.

Section 11, Version 00 - 06/07 -11.2- Sec11Swing.fm
11.2.2 Swing Motor Blower (R47453F4)
Figure 11-3: Swing Motor Blower
The swing motor blower (01, Figure 11-3) is provided with a directional arrow to indicate proper direction of rota-
tion. Correct rotation is important since it determines the volume of air flow through the swing motor. If a new motor
is installed, always check for correct rotation.
Figure 11-4 shows the ducting for the front swing motor blowers.

LEGEND
01. Ducting
02. Swing Motor Blower
-5 #!%=
Figure 11-4: Swing Motor Blower Ducting

11.2.3 Swing Transmission (100J5949F4)
LEGEND
01. Swing Transmission
02. Coupling Half
03. Pipe Plug
04. Bearing Retainers
05. Dipstick
06. Drain Pipes (not shown)
07. First reduction Cover
08. Socket Head Cap Screw
09. Input Pinion Shaft
Figure 11-5: Swing Transmission
Each transmission (Figure 3-2) is a double reduction speed reducer. The transmission consists of an input pinion
shaft (09) and internal double reduction planetary gearing. The swing shaft is splined to the second reduction plan-
etary carrier.
The transmission gears and bearings are splash lubricated with the oil specified in the Air and Lubrication manual.
11.2.4 Swing Shaft (R41151F1)
The three swing shafts transfer motor torque from the swing transmissions to the swing ring gear to rotate the
shovel upper on the lower. The swing shafts are lubricated by the automatic grease lubrication system.
11.2.5 Swing Brakes (R42786D1)
Due to the similarities of all disc brakes on this shovel, maintenance and repair information has been consolidated
into one comprehensive discussion. Refer to Section 5, Disc Brakes of this manual for information concerning disc
brakes.

11.2.6 Swing Roller Paths
The roller paths are machined tracks mounted on the carbody and the revolving frame to provide smooth tapered
bearing surfaces for the roller circle to travel between. The roller paths are stamped "Front of Machine" for orienta-
tion.
The upper roller path is bolted to the bottom of the revolving frame. It contacts a shear ledge which assists in secur-
ing it. The shear ledge is welded to the revolving frame.
The lower roller path is held in position by clips and also contacts the swing ring gear, which assists in securing it.
Because of the contact with the ring gear the lower roller path is not likely to move. Therefore, the roller path
inspection procedure is devoted primarily to the upper roller path.
The swing gear is secured by four grade 5 cap screws and numerous SuperNuts (TM).

11.2.7 Roller Circle Assembly (R43636
02.
01.
03.
05.
04.
05. TC0128
07.
06.
LEGEND 04. Pin
01. Lube Fitting 05. Carrier Wing
02. Roller 06. Thrust Washer
03. Self-locking Cap Screw 07. Bushing
Figure 0-1: Roller Circle
The roller circle consists of a carrier ring and fifty-five tapered rollers with bushings and their retaining pins, thrust
washers and lubrication fittings. The rollers act as bearings between the upper roller path on the revolving frame
and the lower path on the carbody.
Each tapered roller is pin mounted in equally spaced bores around the carrier ring. During shovel operation, the
rollers travel between the upper and lower roller paths on a film of sprayed lubricant from the automatic lubrication
system to enable the upper to swing in relation to the lower.

11.2.8 Swing Ring Gear (R43636D1)
Figure 11-6: Swing Ring Gear
The swing ring gear is the round stationary gear which is mounted on the carbody. The swing shaft pinions engage
the swing ring gear. The swing shaft pinions drive the upper around the circumference of the ring gear, thus
enabling the upper, which pivots on the center gudgeon, to swing in relation to the lower.
The ring gear is fastened to the carbody by two types of bolts and shear pins. Four of the bolts are secured by
angled nuts. The four ring gear bolts with shear pins and angled nuts are located two per side, near the lateral cen-
terline of the shovel.
The remaining 20 ring gear bolts are secured by 20 SuperNuts (TM).
11.2.9 Center Gudgeon,
Figure 11-7: Center Gudgeon
The center gudgeon is mounted in the carbody. It acts to hold the upper and lower sections of the shovel is the
appropriate relationship. At the top of the center gudgeon, near the forward area of the hoist drum and below the

high and low voltage collector cabinet, is an adjusting nut that is used to make clearance adjustments. The center
gudgeon nut is secured in the adjusted position by a locking key.
The center gudgeon is the pivot pin for the revolving frame. the center gudgeon nut provides adjustment capability
to compensate for wear of the swing roller paths and roller circle rollers, as well as the spherical washer and thrust
washer that are installed under the nut.
The spherical washer and thrust washer must to be replaced when damaged or worn down to the point that further
nut adjustment will no longer compensate for the accumulated wear on the roller paths and rollers.
11.2.10 Voltage Collector Assembly (R33149D9)
Figure 11-8: High Voltage Collector
Collector rings for high and low voltage are mounted above the center gudgeon assembly, just forward of the hoist
drum. The cabinet contains two assemblies: On the lower section, the high voltage collector rings transfer incoming
voltage (6600 volts) from the stationary lower to the revolving upper. The upper section contains the low voltage
collector rings, which transfer voltages between 600 and 120 volts from the revolving frame back to the lower
machine to power components such as the people motors, heaters, lights, etc.

11.2.11 Air and Grease Swivel (R34804F4)
Figure 11-9: Air and Grease Swivel
At the top of the collector assembly is the swivel that allows air for the brakes and grease for the automatic lubrica-
tion system to be transferred from the rotating upper to the stationary lower. One air line is plumbed into the lower
air control cabinet on the left rear area of the carbody. One lubrication line provides multipurpose grease for the
lower lubrication system.
11.2.12 Swing Resolver
Figure 11-10: Swing Resolver
Above the air and grease swivel is mounted a resolver for the swing system. This provides swing positional infor-
mation to the Centurion Control System for use in cable reel protection and other applications.

11.3 Maintenance
to be lowered.
! WARNING
11.3.2 Swing Motor
11.3.2.1 Swing Motor Removal
There are two procedures for removing a swing motor. The two procedures are basically the same, except that the
point of disconnect changes. They are:
1. Removing a swing motor in order to repair the swing motor. If this is your purpose, the motor may be removed
with the motor base remaining installed on the swing transmission. Follow procedures indicated in Subtopic ,
and then remove the motor as described in Subtopic .
2. Removing a swing motor in order to remove the swing transmission for repair. If that is your purpose, the motor
may be removed with the motor base as a unit. Follow procedures indicated in Subtopic , and then remove the
motor as described in Subtopic .

01 02 04
03
05
06
07
13
08
12
09
10 11
ES1353a_01
LEGEND 07. Retainer

01. Blower 08. Coupling Hub
02. 1.25" Eyebolt 09. Motor Mounting Bolts
03. Swing Brake 10. Mounting Base
04. Coupling Hub 11. Swing Transmission
05. O Rings and O Ring Retainer 12. Snap Ring
06. Coupling Sleeve 13. Retainer Mounting Bolts
Figure 11-11: Swing Motor and Coupling
Preparation for Removal of Swing Motor
Prepare to remove a swing motor as follows:
1. Park the shovel on a level surface away from the bank or high wall.
2. Position the shovel upper so the access stairway can be safely lowered.
3. Lower the dipper to the ground with the bail raised and set the hoist brakes.
NOTICE
Be careful not to damage the hoist ropes when lowering the dipper bail.
4. Set all brakes and press the STOP button to shut down the shovel.

! WARNING
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.
5. Perform the appropriate lockout and tagout procedures to electrical supply. Refer to qualified electrical person-
nel for details.
6. Remove hatch covers and canopy sections as required. Refer to Subtopic 8.2.2.1 for hatch cover removal pro-
cedures.
Swing Motor Removal (repair or replace swing motor)
! WARNING

LEGEND
01. Swing Motor
02. Swing Brake
03. Motor Coupling Half
04. Coupling Sleeve
05. Motor Base
07. Cap Screw
08. Cap Screw
09. Cap Screw
10. Cap Screw
11. Cap Screw
12. Wire Trough
13. Blower
14. Access Cover
Figure 11-12: Swing Motor Removal (Motor Replacement or Repair)
Refer to Figure 11-12 and remove the swing motor as follows:
1. Have a qualified electrical technician tag and disconnect all electrical connections to the blower motor (13).
2. Disconnect and remove the flexible exhaust hoses.
3. Disconnect and remove the air supply line to the swing brake (02).
4. Remove the access cover (14) from motor base (05). The cover bolts are torqued to 20 ft-lbs (27 N.m).
5. Disconnect coupling sleeve (04) from motor shaft coupling hubs (03) by removing the lower snap ring and slid-
ing the sleeve down until it clears the motor shaft hub.

A. Remove six motor mount cap screws (11) and the hardened washers beneath them. These cap screws are
torqued to 650 ft-lbs (881 N.m).
! WARNING
Failure to use an adequate lifting device could cause the assembly to fall, resulting in
severe injury or death. Use a lifting device rated higher than the weight of the swing
motor assembly including disc brake and blower. This assembly weighs approximately
8200 lbs. (3726 kg).
CAUTION
Lift motor only with 1.25" eye bolts or P&H welded lugs on the motor. Do not use brake
mounting or mounting bolts for motor lifting.
6. Using a suitable lifting device, lift the motor assembly straight up and out of the shovel. Motor base (05, Figure
11-12) will remain installed on the swing transmission (06).
7. Position the motor assembly on suitable blocking.

Swing Motor Removal (repair or replace transmission)
! WARNING
LEGEND
01. Swing Motor
02. Swing Brake
04. Coupling Sleeve
05. Transmission Coupling Half
07. Cap Screw
08. Cap Screw
09. Cap Screw
10. Cap Screw
11. Transmission Coupling Hub
Figure 11-13: Swing Motor Removal (Transmission Replacement or Repair)

Refer to Figure 11-13 and remove the swing motor as follows:
1. Have a qualified electrical technician tag and disconnect all electrical connections to the blower motor (13).
2. Disconnect and remove the flexible exhaust hoses.
3. Disconnect and remove the air supply line to the swing brake (02).
4. Remove the access cover (14) from motor base (05). The cover bolts are torqued to 20 ft-lbs (27 N.m).
5. Disconnect coupling sleeve (04) from motor shaft coupling hubs (03) by removing the lower snap ring and slid-
ing the sleeve down until it clears the motor shaft hub.
A. Remove six motor mount cap screws (9) and their nuts and washers. These cap screws are torqued to 1120
ft-lbs (1518 N.m).
B. Remove one motor mount cap screw (10) and its nut and washer. This cap screw is torqued to 1950 ft-lbs
(2644 N.m).
! WARNING
Failure to use an adequate lifting device could cause the assembly to fall, resulting in
9325 lbs. (4237 kg).
! WARNING
Using a suitable lifting device, lift the motor assembly straight up and out of the shovel.
Motor base (05) will remain installed on the motor.
NOTICE
Lift motor only with 1.25" eye bolts or P&H welded lugs on the motor. Do not use brake mount-
ing or mounting bolts for motor lifting.
6. Position the motor assembly on suitable blocking.
Remove Coupling
1. Remove the parts of the coupling from the motor shaft as follows:
A. Remove retainer (07, Figure 11-11) from the end of the swing motor shaft. Break the tie wire and remove
cap screws (13). Cap Screws (13) are torqued to 75 ft-lbs (101.7 N.m).
B. Remove coupling hub (04) from the motor shaft.
C. Remove the snap ring from coupling hubs (04 and 08).
D. Remove the O-rings and O-ring retainers from the two coupling hubs. Remove and discard the inner and
outer O-rings.

2. Remove the parts of the coupling from the transmission input shaft as follows:
A. Remove coupling sleeve (06) by lifting it upward, over coupling hub (08).
B. Remove coupling hub (08) from the transmission input shaft.
11.3.2.2 Swing Motor Inspection and Repair
Inspect swing motors periodically to ensure that the motor mounting bolts and coupling bolts are secure, that there
is proper air flow in the correct direction (refer to Figure 11-14), that lubrication is being performed, that wiring is
secure and that there is no abnormal or excessive wear or damage.
Repair of electric motors must be performed only by persons who are authorized and qualified. Refer to the Electri-
cal Department or to P&H MinePro Services electric motor rebuild facilities.
Inspect and service the swing brake as instructed in Section 5, Disc Brakes of this manual.
AIR FLOW
01
02
03
AIR FLOW
04
05
ES1352a_01
06
LEGEND
01. Swing Motor Blower 04. Mounting Bolts
02. Swing Brake 05. Motor Base
03. Swing Motor 06. Swing Transmission
Figure 11-14: Swing Motor (R43247F1 and F2)

11.3.2.3 Swing Motor Installation.
01 02 04
03
05
06
07
13
08
12
09
10
11
ES1353a_01
LEGEND 07. Retainer

01. Blower 08. Coupling Hub
02. 1.25" Eyebolt 09. Motor Mounting Bolts
03. Swing Brake 10. Mounting Base
04. Coupling Hub 11. Swing Transmission
05. O Rings and O Ring Retainer 12. Snap Ring
06. Coupling Sleeve 13. Retainer Mounting Bolts
Figure 11-15: Swing Coupling Hub
1. Refer to Figure 11-15 and install the coupling on the motor shaft as follows:
NOTICE
Always use new O-rings.
A. Lubricate and install new inner and outer O-rings in the two O-ring retainers (05).
B. Install an O-ring retainer (05) onto the motor coupling hub (04) using a rotating motion to avoid damaging
the inner O-ring. Secure the retainer by installing a snap ring (12) in the groove on the side of the coupling
hub.
C. Install the coupling hub with the larger opening (04) onto the motor output shaft. Secure this hub with
retainer plate (07) and cap screws (13). Tighten the cap screws to 75 ft-lbs (101.7 N.m) and tie wire cap
screws.
2. Refer to Figure 11-15 and install the coupling on the transmission shaft as follows:

A. Place a snap ring (12) over the transmission shaft and allow it to rest on the top of the transmission (11).
Then place the remaining O-ring retainer (05) on top of the snap ring, allowing both parts to rest on the top
of the transmission.
B. Lubricate the inner splines on coupling hub (08) and the splines on the transmission shaft with a coating of
multi-purpose grease.
C. Install the coupling hub with the smaller opening (08) onto the transmission input shaft.
D. Slide coupling sleeve (06) onto hub (08).
! WARNING
Failure to use an adequate lifting device could cause the assembly to fall, causing
8200 lbs. (3726 kg). If lifting motor and motor base together the weight is 9325 lbs. (4237
kg).

NOTICE
If the swing motor mounting base is mounted to the transmission, go to Step 3;
if the swing motor mounting base is mounted to the motor, go to Step 4.
LEGEND
01. Swing Motor
02. Swing Brake
04. Coupling Sleeve
05. Motor Base
07. Cap Screw
08. Cap Screw
09. Cap Screw
10. Cap Screw
11. Cap Screw
12. Wire Trough
13. Blower
14. Access Cover
Figure 11-16: Swing Motor Installation (Base on Transmission)
3. Refer to Figure 11-16. Using a suitable lifting device, install the swing motor assembly onto the motor base (05,
Figure 3-1). Secure the motor by installing mounting cap screws (11) and their hardened washers. Torque the
cap screws to 650 ft-lbs (881 N.m). Continue to Step 4.

LEGEND
01. Swing Motor
02. Swing Brake
04. Coupling Sleeve
05. Transmission Coupling Half
07. Cap Screw
08. Cap Screw
09. Cap Screw
10. Cap Screw
11. Transmission Coupling Hub
Figure 11-17: Swing Motor Installation (Base on motor)
A. Using a suitable lifting device, install the swing motor and motor base onto the swing transmission (06, Fig-
ure 11-17). Secure the motor by installing mounting cap screws (09 and 10) and their hardened washers.
Torque the cap screws to 650 ft-lbs (881 N.m).
B. Tighten the one cap screw (10) to 1120 ft-lbs (1519 N.m).

• Cap Screw (10) is (P/N 20Q259D620, 1-1/4-7UNC x 5) Grade 5.
• Hex nut for cap screw (10) is (P/N 20Q271D80, 1-1/4-7UNC).
• Hardened washer is (P/N 18Z694D12), 1-1/4".
C. Tighten six cap screws (09) to 1950 ft-lbs (2644 N.m).
4. If the coupling halves do not line up properly, connect the air line to the swing brake and release the brake to
allow the motor shaft to turn.
5. Raise coupling sleeve (05, Figure 6-1) onto motor shaft coupling hub (03).
6. Install O-ring retainer (04) onto hub (03) and into the bore of sleeve (05) with a rotating motion to avoid damage
to the O-rings.
7. Install a snap ring (08) in the groove of coupling hub (03).
8. Connect the electrical wiring to the motor and motor blower. Use the tags installed during the removal proce-
dure for reference.
9. Install the flexible hose which conducts exhaust air from the blower.
10. Lubricate the swing motor bearings as instructed on the motor lubrication tags attached to the motor.
11.3.3 Swing Motor Blower (R47453F4)
11.3.3.1 Motor Blower Inspection
Inspect swing motor blowers periodically to ensure that the mounting bolts are secure, that there is proper air flow
in the correct direction, that wiring is secure and there is no excessive or abnormal wear or damage.
Repair of electric motors must be performed only by persons who are authorized and qualified. Refer to the Electri-
cal Department or to P&H MinePro Services electric motor rebuild facilities.

11.3.3.2 Motor Blower Removal
LEGEND
01. Motor
02. Bracket
03. Blower Wheel
04. Split Bushing
05. Cap Screws
06. Intake Housing
Figure 11-18: Swing Motor Blower Removal
Refer to Figure 11-18 and remove the blower from the swing motor as follows:
! WARNING
Contact with energized electrical circuits can cause serious injury or death. Always use
lockout and tagout procedures to disconnect power during service operations.
1. Disconnect and remove the flexible exhaust ducting (01, Figure 12-2).
2. Disconnect electrical leads to motor (01).
3. Remove the blower as an assembly.

11.3.3.3 Motor Blower Repair and Maintenance
Repair of the blower assembly is limited to replacement of motor (01) or the blower wheel (03). Split bushing (04)
and cap screw (05) are furnished with the wheel.
Blower motor bearings should be greased during lubrication PM.
11.3.3.4 Motor Blower Installation
Installation is the reverse of removal. Always check the direction of motor rotation and be sure it agrees with the
directional arrow on the blower provided. Change the direction of motor rotation by switching any two of the motor
leads, if rotation is incorrect.
NOTICE
Simply checking air flow direction is insufficient to verify direction of blower rotation. Blower will
push a smaller volume of air in the correct direction if rotation is incorrect. Check direction of
rotation using arrow.
11.3.4 Swing Transmission (100J5949F4)
CAUTION
Field reports have cited instances where the base plate of a swing transmission was
welded to the ring gear and where a lifting eye was welded to the outside of the ring gear.
Do not perform any welding procedure on the swing transmission second reduction
(ring gear) section. Welding on the ring gear will cause internal cracking and render the
gear unfit for further use.
11.3.4.1 Transmission Inspection
Inspect swing transmissions during preventive maintenance periods, checking for loose or missing hardware, and
oil leaks at parting surfaces or bolt holes. Check oil level and add oil as necessary.

Check breather and breather element and service as necessary.
LEGEND
01. Input Pinion Shaft 07. Planetary Pinion
02. Pipe Plug 08. Second Reduction Ring Gear
03. Sun Gear 09. Planetary Carrier
04. Bearing Retainer 10. Retainer Plate
05. First Reduction Gear 11. Bottom Plate
06. Support Ball and Thrust Washer 12. Mounting Screws
Figure 11-19: Swing Transmission Inspection
Refer to Figure 11-19. Inspect the swing transmission every six months to help prevent damage that could be
caused by excessive wear on the support ball and thrust washer (Item 06). Excessive wear can cause the sun gear
to drop onto the carrier retainer plate. If this happens, metallic wear debris could damage roller bearings and gear
teeth and make a major overhaul of the transmission necessary.
Refer to Figure 11-19 and inspect the transmission for wear as follows:
1. Remove the pipe plug in the center of the bearing retainer.
2. Insert a 1"-8UNC eyebolt into the pipe plug hole and thread it fully into the top of the sun gear.
3. Mark the eyebolt where it enters the bearing retainer. Then, using a suitable lifting device, lift the sun gear
upward as far as it will go. Measure the distance the sun gear can be lifted.
4. If the total travel is 3/8" (8.128 mm) or greater, replacement of the support ball and thrust washer is recom-
mended. Consult your local P&H MinePro Services representative for guidance.

11.3.4.2 Transmission Removal
LEGEND
02. Coupling Half
03. Pipe Plug
04. Bearing Retainers
05. Dipstick
06. Dip Tube
07. First reduction Cover
09. Input Pinion Shaft
Figure 11-20: Removing/Installing Swing Transmission
Refer to Figure 11-20 and remove a swing transmission as follows:
1. Refer to Subtopic 11.3.1 and ensure that the preliminary maintenance procedures have been completed.
2. If a front swing transmission is being removed, remove the hoist cable guard.
3. Remove the swing motor as described in Swing Motor Removal (repair or replace transmission).
4. Drain the oil from the transmission housing into suitable containers. The drain outlet is located under the
revolving frame. The housing contains approximately 70 gallons (264 liters) of oil.
5. Remove the dip tube (Item 06) and the drain pipe (not shown).
6. Clean the outside of the transmission housing.

Technician Tip
The high torque makes cap screw removal difficult. This high torque and space restrictions
make it necessary to use a hydraulic torque wrench that is capable of operating in the small
space between the cap screw head and the transmission and can provide the torque necessary
to remove the cap screws. Cap Screws are installed with 822 ft-lbs (1114 N.m) of torque; once
the cap screws are set, a higher torque is required to remove them.
7. Remove cap screws (08, Figure 11-20) as follows:
! WARNING
A cap screw may fracture unexpectedly while being loosened and the head may fly off
with considerable force, resulting in severe personal injury or death. Wear eye protec-
tion and face shields. Do not touch any portion of the wrench, actuator, reaction plate,
back anchor, or adjustable bracket. Do not stand with any part of your head or body in
line with the bolt hole while cap screws are being loosened.
A. These cap screws are torqued to 822 ft-lbs (1114 N.m). Using a star pattern, loosen the cap screws to
approximately 50% torque.
B. Repeat the process until they can be removed.
8. Install three 1-1/4-7UNC swivel type eyebolts (P&H P/N 6Q483D3) in the tapped holes in the side of first reduc-
tion cover (07).
! WARNING
Failure to use an adequate lifting device could cause the transmission to fall, causing
transmission. This assembly weighs approximately 12,300 lbs. (5579 kg).
9. Using a suitable lifting device, remove the transmission.
11.3.4.3 Transmission Repair
CAUTION
Contact your local P&H MinePro Field Service Representative for guidance before
attempting repairs. Strict adherence to procedures is critical to ensure proper transmis-
sion performance.
Internal parts of the swing transmission are not provided as overhauling the transmission requires experience and
special tools which may not be available at the mine site. Should the transmission require overhaul, contact P&H
MinePro Services to arrange for overhaul through the P&H ENCORE PLUS™ Component Exchange Program.

11.3.4.4 Transmission Installation
When using a hydraulic bolt tightening wrench, be sure to follow the instructions on the drawings which accompany
the wrenches.
Use new mounting cap screws when installing a transmission. The high torque applied to the cap screw sockets
may cause the sockets to become deformed. The result is that the hex wrench bit may slip in the socket, damaging
the cap screw, the wrench, or both. High strength cap screws, taken to their recommended torque, will be under a
very high pre-load. It has been confirmed by field experience that reused cap screws can fracture while being
torqued. When such a fracture occurs at the cap screw head, the head can fly from the cap screw with consider-
able force in a direction approximately in line with the bolt hole. Therefore, the following precautions must be
observed.
! WARNING
A cap screw may fracture unexpectedly while being torqued and the head may fly off
with considerable force, resulting in severe personal injury or death. Wear eye protec-
tion and face shields. Use new cap screws and do not touch any portion of the wrench,
actuator, reaction plate, back anchor, or adjustable bracket. Do not stand with any part of
your head or body in line with the bolt hole while cap screws are being tightened or loos-
ened.
Technician Tip
The high torque makes torquing the cap screws difficult. This high torque and space restrictions
make it necessary to use a hydraulic torque wrench that is capable of operating in the small
space between the cap screw head and the transmission and can provide 822 ft-lbs (1114 N.m)
of torque.
Install a swing transmission as follows:
1. Clean the deck and mounting surface of the transmission deck plate.
! WARNING
Failure to use an adequate lifting device could cause the transmission to fall, causing
transmission. This assembly weighs approximately 12,300 lbs. (5579 kg).
2. Align the one 3/4” cap screw holes on the transmission and on the deck to ensure proper transmission align-
ment. Lower the transmission into position on the deck plate.
NOTICE
The transmission dipstick will interfere with installation of the cap screw directly below it. The
dipstick must be removed from the transmission to install this cap screw in the hole.
3. Apply anti-seize compound to the threads of 1-inch diameter socket head cap screws (08, Figure 11-20) and
tighten them as follows:

A. Tighten two cap screws (180 degrees apart) to 615 ft-lbs (834 N.m).
B. Tighten two screws 90 degrees from each of the first two cap screws to 615 ft-lbs (834 N.m).
C. Continue the cross-bolting pattern until all of the cap screws have been tightened to 615 ft-lbs (834 N.m).
D. Repeat the above steps, tightening the cap screws to 822 ft-lbs (1114 N.m).
4. Lubricate with anti-seize and install the one 3/4" socket head cap screw and torque to 453 ft-lbs (614 N.m).
5. Install the oil drain and dipstick tubes.
6. Add oil of the type and quantity described in Section 16 through the dipstick tube.
7. Install the swing motor as described in Subtopic 11.3.2.3.
11.3.5 Swing Shaft (R41151F1)
11.3.5.1 Inspection and Repair
During PM, inspect the swing shafts periodically for proper lubrication, excessive wear, and cracked, chipped, or
broken pinion gear teeth.
P&H Mining Equipment recommends that each swing shaft be inspected every 6 months using ultrasonic inspec-
tion. To allow this inspection without removal of the shaft, a special fixture (P/N R40831F1) has been designed.
This fixture supports the pinion so that the retainer plate on the end of the shaft can be removed, allowing inspec-
tion of the shaft with the pinion still in place. The retainer plate is then reinstalled and the fixture removed. Instruc-
tions are provided with the fixture. Contact your local P&H MinePro Services representative for further information.
Inspect each swing pinion once a year using a pinion inspection gauge to check for wear. Instructions for use are
furnished with the gauge. Contact your local P&H MinePro Services representative for further information.
Swing shaft repairs are limited to the replacement of worn or damaged parts.

11.3.5.2 Swing Shaft Removal
NOTICE
The swing pinion can be removed without removing the swing shaft. If pinion removal is all that
is required, refer to Subtopic 11.3.5.3.
LEGEND
01. Shaft
02. Spacer
03. V-ring Seal
04. Spherical Roller
Bearing
05. O-ring
06. Retainer Plate
07. Grease Seal
22 23 08. Pinion
09. Pinion Retainer
Gap
01 10. Cap Screw
11. Shims
12. Tie Wire
02 13. Retainer Plate
14. Tie Wire
03 20 18 21 15. Cap Screw
19 16. Shims
04 17. Bearing Capsule
17 18. Cap Screw
19. Serrated Washer
20. Dirt Shield
21. Access Holes
05 22. Measurement
06 14 16 Location -- Pinion
23. Measurement
07 15
08 Location -- Shaft
09 10 11 12 13 F4251b
Figure 11-21: Swing Shaft Installation/Removal
Refer to Figure 11-21 and remove a swing shaft as follows:
1. Swing the upper so that the swing shaft to be removed is positioned over the front of the carbody, between the
crawlers.
2. Lower the dipper to the ground.

! WARNING
3. Refer to Subtopic 11.3.1 and confirm completion of preliminary maintenance procedures.
4. Open the control cabinet in the right hand electrical room and lock out and tag the control and relay circuit
breakers.
5. Place blocking under the swing shaft (01) to prevent the shaft from falling when removing retainer plate (12). A
swing shaft assembly weighs approximately 5,300 lbs (2405 kg).
NOTICE
A fixture (P/N R40827) is available to aid in removal and installation of swing shaft assemblies.
Instructions for use are provided with the fixture.
! WARNING
A swing shaft assembly weighs approximately 5300 lbs (2405 kg). If cap screws (13) are
removed from retainer plate (06) without properly supporting the swing shaft, the shaft
can fall, causing severe injury or death. Use extreme care when loosening cap screws
(13) and be sure adequate blocking or support fixtures are in place before removing the
cap screws. Swing shaft assemblies are top heavy and tend to tip while being lowered.
Always support or tie-off the top of the swing shaft to prevent it from tipping when it
clears the revolving frame. If the shaft is broken, parts of the shaft assembly may not
come out of the carbody when the swing shaft assembly is removed. These parts may
later be dislodged and fall, causing injury or death.
6. Disconnect automatic lubrication lines to the swing shaft. Support the shaft with a forklift or blocking and
remove tie wire (14) and cap screws (13). Lower the swing shaft assembly from the carbody and set the shaft
on blocking with the input end up.
NOTICE
The bearing capsule (19) will remain in the revolving frame. Refer to Subtopic 11.3.5.7 for the
procedure for replacing a bearing capsule.
7. Remove dirt shield (18) and V-ring seal (03) from the revolving frame. Discard the seal.

8. Retain shims (15) so that the shim pack can be duplicated during reinstallation.
NOTICE
A new shim pack will be required for assembly.
11.3.5.3 Remove Swing Pinion Only
If only the swing pinion is to be removed, leaving the rest of the swing shaft in the upper, refer to Figure 11-21 and
proceed as follows:
1. Support the pinion (08) with adequate blocking or with supporting fixture (P/N R40831F1). The pinion weighs
2. Remove tie wire (11), cap screws (09), and retainer plate (12). Retain shims (10) so that the shim pack can be
duplicated during reinstallation.
NOTICE
3. Lower the pinion off the shaft.
11.3.5.4 Disassemble Swing Shaft Assembly
Refer to Figure 11-21 and disassemble a swing shaft assembly as follows:
1. Remove tie wire (11), cap screws (09), and retainer plate (12). Retain shims (10) for use during reinstallation.
NOTICE
2. Remove pinion (08) and retainer plate (06).
3. Remove seal (07) and O-ring (05) from retainer plate (06).
4. Pull bearing (04) from shaft (01) and remove spacer (02). Bearing (04) is a spherical roller bearing.
11.3.5.5 Assemble Swing Shaft Assembly
Refer to Figure 11-21 and assemble a swing shaft assembly as follows:
CAUTION
Bearing (04) must be preheated prior to installation on the swing shaft. Extreme care
must be taken to assure that it is never heated over 300°F (148°C). Do not use a torch to
heat the bearing. Refer to Topic 3.5 for information concerning installation of this type of
bearing.

1. Preheat bearing.
2. Clean the shaft and spacer with solvent, especially where contact will be made.
3. Coat the contact surfaces of spacer (02) and shaft (01) with locking compound (P&H P/N 21Z516D9) and
install the spacer on the shaft. Do not allow the compound to extend into the bearing area of the shaft.
NOTICE
Once locking compound has been installed it is important to work quickly through step 7 to
ensure locking compound sets correctly. Locking compound working time is approximately 1
hour.
4. Apply a thin even coat of assembly paste (P&H P/N R20429D1) to the shaft bearing area. Install heated bear-
ing (04) on shaft (01) against spacer (02).
5. Install O-ring (05) and seal (07) on retainer plate (06).
6. Install assembled retainer plate (06) and pinion (08) on shaft (01) while bearing is still warm.
7. Install retainer plate (12) and secure it with cap screws (09). Tighten the cap screws to 375 ft-lbs (508 N.m)
with no shims in place.
8. Calculate the gap between swing shaft (01) and retainer plate (12) by making two measurements with a depth
micrometer, measuring through the two access holes in plate (12). The measurements are:
A. Measurement 1 is to determine the distance from the outer surface of plate (12) to the end swing shaft (01).
Record the measurement.
B. Measurement 2 is to determine the distance from the outer surface of plate (12) to the end of pinion (08).
Record the measurement.
9. Subtract measurement No. 2 from measurement No. 1. The result is the gap between plate (12) and shaft (01),
which will be used in step 9 to determine the quantity of shims (10) which are required.
10. Repeat steps 6 and 7 at the other access hole on retainer plate (12). Then, determine the average of the two
gaps for shim calculation in step 10 of this procedure.
11. Remove cap screws (09) and plate (12).
12. Install a shim pack equal to the average gap determined in step 8 above minus 0.005 to 0.010 inch (0.127 to
0.254 mm) beneath plate (12) and secure with cap screws (09).
13. Tighten cap screws (09) to 1365 ft-lbs (1851 N.m) and secure them with tie wire.
11.3.5.6 Install Swing Shaft
Refer to Figure 11-21 and install a swing shaft as follows:

! WARNING
Dropping a raised load can result in severe injury or death. Use caution when lifting the
swing shaft. Swing shafts are top-heavy and can tip when being lifted. Be sure to support
the top of the shaft to prevent tipping during installation.
1. If they were removed, install dirt shield (18) and new V-ring seal (03).
2. Raise the assembled swing shaft into position in the revolving frame, making sure the splines on the end of
shaft (01) fully enter the splines on the second reduction carrier. The swing shaft assembly weighs approxi-
mately 5,300 lbs (2405 kg).
3. Install retainer plate (06) and secure it with cap screws (13). Snug tighten the cap screws.
4. Measure the gap between retainer plate (06) and the revolving frame.
5. Remove cap screws (13) and retainer plate (06).
6. Install a shim pack (15) equal to the measured gap minus 0.010 inch (0.254 mm).
7. Install retainer plate (06) and secure it with cap screws (13). Tighten the cap screws to 1463 ft-lbs (1984 N.m).
Secure them with tie wire (14).
8. Install the automatic lube lines.
11.3.5.7 Replace Swing Shaft Bearing Capsule
Refer to and replace the swing shaft bearing capsule as follows:
NOTICE
The swing shaft bearing capsule can not be removed without jacking up the revolving frame to
allow the capsule to clear the swing gear. Consult your local P&H MinePro Representative on
the availability of a specialized split capsule for repair applications.
1. Remove the swing shaft as described in Subtopic 11.3.5.2.
2. Support the bearing capsule (Figure 2-1) using hydraulic jacks.
3. Using a suitable puller, remove the bearing capsule from the bore in the revolving frame. The bearing capsule
weighs approximately 260 lbs (113.4 kg).
Install a replacement bearing capsule as follows:
NOTICE
It is assumed that the revolving frame is still jacked up to allow installation.
1. Clean the O.D. of the bearing capsule and the I.D. of the bore in the revolving frame.

01
LEGEND
01. Setscrews
02. Flat on Flange of Bushing
03. Centerline of Machine
02
03
fig3_09
Figure 11-22: Swing Shaft Bearing Capsule
2. Apply adhesive (P&H P/N 21Z516D9) to the O.D. of the bearing capsule and the I.D. of the bore in the revolv-
ing frame.
3. Install the bearing capsule in the bore with the flat on the flange of the bearing capsule facing the center of the
revolving frame. The flat must be perpendicular to the front-to-back centerline of the revolving frame. The bear-
ing capsule weighs approximately 260 lbs (113.4 kg).
4. Support the bearing capsule in place.
5. Drill two new holes for setscrews along the interface between the flange of the bearing capsule and the coun-
terbore in the revolving frame as shown in Figure 11-22. Use a 21/32 inch (0.6563 inch) drill and drill the holes
2.44 inches (61.976 mm) deep. The holes should be 180 degrees apart and must be centered along the inter-
face between the edge of the bearing capsule flange and the edge of the counterbore in the revolving frame.
6. Tap the drilled holes for 3/4-10UNC-2B threads, 1.62 inches (41.148 mm) deep.
7. Install the two setscrews flush with the surface of the revolving frame.
8. Measure the bearing capsule bore in several places. If it is out of round by more than 0.027 inches (0.6858
mm) contact your local P&H MinePro Field Representative for assistance.
9. Install the lubricating line to the bearing capsule.
10. Install the swing shaft as described in Subtopic 11.3.5.6.
11.3.5.8 Swing Brakes
Due to the similarities of all disc brakes on this shovel, maintenance and repair information has been consolidated
into one comprehensive discussion. Refer to Section 5, Disc Brakes, of this manual for information concerning disc
brakes.

11.3.6 Swing Roller Paths
01 01
10
08 09
02
11
03
12
04 15
05
13
14
07 06
TC1616d
LEGEND
01. Weld 06. Clip 11. Cap Screw
02. Shear Ledge 07. Super Nut™ 12. Shear Pin
03. Upper Roller Path 08. Swing Gear 13. Angled Nut
04. Roller 09. Roller 14. Clip
05. Lower Roller Path 10. Swing Gear 15. Lower Roller Path
Figure 11-23: Roller Circle Components
11.3.6.1 General
The roller paths are machined tracks mounted on the carbody and the revolving frame to provide smooth tapered
bearing surfaces for the roller circle to travel between. The roller paths are stamped “Front of Machine” for orienta-
tion.
The upper roller path is bolted to the bottom of the revolving frame. It contacts a shear ledge which assists in secur-
ing it. The shear ledge is welded to the revolving frame.
The lower roller path is held in position by clips and also contacts the swing ring gear, which assists in securing it.
Because of the contact with the ring gear the lower roller path is not likely to move. Therefore, the roller path
inspection procedure is devoted primarily to the upper roller path.
As shown in Figure 11-23, the swing gear is secured by four grade 5 cap screws and numerous SuperNuts™.
Torque values for both fasteners are included in Tables 8-1 and 8-2 in this section. For further information concern-
ing SuperNuts, refer to Subtopic 3.3.7.
11.3.6.2 Swing Roller Path Inspections
250 Hour Inspection

The swing roller paths and related components should be inspected every 250 hours for proper lubrication and
excessive wear.
Six Month (Semi-Annual) Inspection
Every six months, inspect the upper roller path. Inspect inner and outer mounting bolts, the nut and bold retainers,
and the shear ledge to assess their integrity.
01
02
01
02 07
06
03 03
07
04 08
09 10
05 10
02
04
02
08
09
ES04812a01
02
05
LEGEND
01. Hex Head Bolt 06. Revolving Frame
02. Hardened Washer 07. Shear Ledge
03. Weld 08. Hex Head Cap Screw
04. Nut Retainer 09. Cap Screw Retainer
05. Nut 10. Upper Roller Path
Figure 11-24: Upper Roller Path Assembly (R43700F1)
Technician Tip
This is a two person job with one person inside inspecting the inner path components and the
outside person inspecting the outer path components. As a safety precaution, the two inspec-
tors should be in radio contact at all times.

! WARNING
Movement of the shovel upper while a person is in the inspection area could cause
severe personal injury or death. Never, under any circumstances, move the upper with
someone inside the inspection area. Always leave the inspection area before rotating the
upper to the next position.
Because the viewing port only allows a small part of the upper roller path to be viewed at one time, it is necessary
to rotate the shovel upper in small increments and inspect the visible area. The inspector must then leave the
inspection area and the upper must be rotated to bring another area into view so the inspector can check it.
Proceed as follows:
1. Refer to Subtopic 11.3.1 and confirm completion of preliminary maintenance procedures.
2. Follow the Kirk Key Interlock procedures to open the manhole hatches on the bottom of the carbody and enter
the inspection area.
Technician Tip
Smaller people will experience less difficulty in entering this area. Space is very limited.
3. Thoroughly clean the inside diameter of the upper roller path and adjacent areas, since welding may be
required.
CAUTION
If parts are broken, find and dispose of the broken parts. Loose parts on the roller path
can cause severe damage when the upper is rotated.
4. Inspect both the inside and outside surfaces of the upper roller path with two inspectors working simulta-
neously. As the upper path is being inspected, inspect the toes of the weld between the shear ledge (Figure
10-1) and the revolving frame for cracks, using dye penetrant. If cracking is evident, refer to Subtopic 11.3.6.3
and repair immediately. Consult your P&H MinePro Services Representative for assistance or further informa-
tion.
5. Note and record the specific location of broken bolts and nut retainers and the extent and nature of any cracks
on the form provided as Figure 11-25. FAX a copy of this form to your local P&H MinePro Services Represen-
tative for use in determining whether further corrective action is required.
NOTICE
If replacement of a roller path is required, it is necessary to jack up the revolving frame.
Because of the variety of tools and methods which can be employed, consult your local
MinePro Field Services Representative for assistance.
6. When the inspection is completed, remove all tools from the inspection area, exit the area, and lock the hatch
covers.

LEFT 210
200 220
190
230
180
281 291
271 301
170 261 311
321 240
251
331
341
160 241
351 250
231 361
221 371
150 260
211 381
201 391
140 10
191 11
21 20
181
130
171 31
41
161 61 51 30
120
151
141 71
110 131 81 40
121 111 101 91
100 50
TC1519
90 60
70 FRONT
80 RIGHT
Figure 11-25: Location of Upper Path Retention Bolts (Typical)
7. Return power to the shovel and slowly rotate the upper to verify correct operation.
11.3.6.3 Upper Roller Path Repair
When cracks are identified during inspection, repairs should be made immediately.

The following repairs require welding. Be sure the area is clean to prevent a fire hazard.
1. Refer to Figure 10-2. If retainers (02 or 03) or bolts (04 or 05) are damaged or broken, remove the retainers
using a torch. Then, remove the damaged cap screw(s) and replace with new ones. Use adhesive (P&H P/N
21Z743 - Loctite 277) and tighten cap screws (05) to 1820 ft-lbs (2468 N.m) using a torque wrench. Tighten
cap screws (04) to 910 ft-lbs (1234 N.m).
Cap Screws (04) are: P&H P/N 0630V158, 1-8UNC x 4-1/2", Grade 8 socket head
Cap Screws (05) are: P&H P/N 20Q325D627, 1-1/4-7UNC x 8-1/2" Grade 8 hex head

2. Whenever an area has been inspected, the inside inspector must leave the shovel while the upper is rotated to
the next inspection position.
11.3.7 Roller Circle Assembly (R43636)
11.3.7.1 Inspection
1. Inspect the rollers in the roller circle every 250 hours for wear and broken parts.
08
08 04
03
A
A
04 05
05
TC1616d
Figure 11-26: Annual Swing Roller Inspection
2. Once a year, inspect the rollers in the roller circle. Note and record the distance between the roller face and the
inside surface of the ring gear (dimension A, Figure 11-26). Gap is 5.454" 141” (138.5mm ± 3.6mm) when the
system is new. When the gap increases by ½", consult with your local P&H MinePro Services representative.
If any roller requires replacement due to excessive wear or damage, all rollers in the live roller circle should be
replaced. New rollers will be over-sized in relation to the remaining worn rollers and will cause damage to the new
roller, the roller paths, carbody, and revolving frame structures. If it becomes necessary to replace one or more
tapered rollers, contact your local P&H MinePro Representative for assistance.
NOTICE
Swing rollers can not be removed without jacking up the revolving frame to allow the roller to
clear the swing gear. Consult your local P&H MinePro Services Representative for information
or assistance.

11.3.8 Swing Ring Gear (R31328D1)
03
01 02
04
TC0317a
LEGEND
01. Grade 5 Cap Screw 03. Special “MT” Bolt
02. Shear Pin 04. SuperNut™
Figure 11-27: Swing Ring Gear Fasteners
NOTICE
Because of the variety of tools and equipment which can be used and because methods of
removing and replacing the swing ring gear will vary depending on local circumstances, this
section does not include instructions for removal or replacement of the swing ring gear. Consult
your local MinePro Representative for assistance.
The ring gear is fastened to the carbody by two types of bolts and shear pins. Four of the bolts are secured by
angled nuts (10, Figure 2-1). The four ring gear bolts with shear pins and angled nuts are located two per side, near
the lateral centerline of the shovel.
The remaining 20 ring gear bolts are secured by 20 SuperNuts™.

The swing ring gear has a machined groove on the inside circumference which assists in securing the lower roller
path. The opposite side of the path is secured by clips.
11.3.8.2 Ring Gear Inspection
250 Hour Inspection
Every 250 hours of operation, visually inspect the ring gear and related components for the following:
• Proper Lubrication
• Broken, cracked or missing gear teeth
• Damaged related components
Annual Inspection
Once a year, perform the following inspections:
• Inspect for gear tooth wear using a gear tooth wear inspection gauge. Contact your P&H MinePro Repre-
sentative for information and assistance.
• Inspect gear teeth for fatigue cracking, particularly at the front of the machine.
• Inspect roller circle wear into the inside of the swing ring gear using a swing ring gear I.D. inspection gauge.
Contact your P&H MinePro Representative for information and assistance.
• Inspect the ring gear for proper fastener tightness, gaps between the swing ring gear and the carbody at bolt
locations and/or any evidence of swing ring gear movement as follows:
1. Park the shovel on a level surface away from the bank or high wall. Block the crawler belt to prevent shovel
movement.
3. Refer to Figure 11-28 and check for a gap at all mounting bolt locations. If a gap exists at any location, loosen
all ring gear fasteners, including the four bolts with shear pins and angled nuts, and all SuperNuts. Refer to
subsection 2.3.7.3 for the procedure for loosening SuperNuts.
NOTICE
The swing ring gear must be completely flat against the carbody.
4. Tighten the four bolts (01, Figure 11-27) to 731 ft-lbs (991 N.m). These are the bolts located on either side of
the lateral centerline of the shovel.
5. Check the gap between the swing ring gear and the carbody at each fastener location, for a distance of 5
inches (127 mm) on each side of all fasteners. Check this measurement on the inside and outside of the ring
gear at each fastener location. If the gap differs at one or more locations, record the average of the two read-
ings.

04
05
03
H-TYP
TACK
02
01 A-A
63
1.
A
R
11.00”
5.50”
SHIM
3.25”
7.63”
TC1520b
Figure 11-28: Swing Ring Gear Shimming (typical) (Top View)
SHIMS, R7365D_
D_ P&H Material Thickness
D1 111 .010"
D2 111 .015"
D3 111 .020"
D4 154 .060" (16 ga.)
Table 11-1: Ring Gear Shim Thicknesses
6. If a gap of 0.010" (0.254 mm) or larger exists at any location, measure and record the gap at all locations.
NOTICE
If any gap is greater than 0.185" (4.699 mm) consult P&H Mining Engineering.

7. Refer to Figure 11-28 and build a shim pack for each location. The shim packs must be equal to the measured
gap plus 0.000" to 0.005" (0.127 mm). Shims can be made locally or purchased from P&H using the part num-
bers shown.
8. Loosen fasteners as required to install the shim packs.
9. Tighten the four grade 5 cap screws to 50% final torque (731 ft-lbs (991 N.m)).
10. Tighten the four grade 5 cap screws to 100% final torque (1463 ft-lbs (1984 N.m)).
11. Tack weld shims at each location together and to the carbody. Do not weld to the ring gear.
12. Tighten all SuperNuts. Refer to Subtopic 3.3.7 for information concerning SuperNut installation.
13. Use lockout/tagout procedures to return the shovel to operational status.
11.3.8.3 Swing Gear Repair
Repair of the swing ring gear consists of grinding out small cracks, welding cracks in the gear, replacing broken
teeth, or building up a new tooth where a tooth is cracked off and lost. Contact your local MinePro Representative
for information concerning tooth repair.

11.3.9 Center Gudgeon R50370F1
01
02
06
03
04
05
07
16 08
15 11
17
12
09
09
ES1365a_01
10
08
09
14 13 08
LEGEND 06. Center Gudgeon 12. Slide Plate

01. Cap Screw 07. Adjusting Collar 13. Hardened Washer
02. Locking Key 08. Cap Screw 14. Cap Screw
03. Shim 09. Hardened Washer 15. Wedge Plate
04. Adjusting Nut 10. Nut 16. Ring Plate
05. Spherical Washer 11. Keeper Plate 17. Thrust Washer
Figure 11-29: Center Gudgeon Assembly (R50370F1)

11.3.9.1 \Center Gudgeon Inspection
Inspect the center gudgeon every 750 hours as follow:
1. Check for proper lubrication.
2. Check for proper adjustment of the center gudgeon nut as follows:
A. Position the shovel on level ground with the upper facing forward in relation to the carbody.
B. Position the dipper handles so they are at 90 degrees to the boom.
C. Set the dipper on the ground so the weight of the dipper and handles is supported. Crowd out slowly so that
the shovel rocks slightly backward. Do not jack the boom. The purpose of this step is to lift the revolving
frame upward enough to check for roller to roller path clearances at the front of the shovel.
D. Shut the shovel down and tag out the start button.
! CAUTION
Unexpected movement of the shovel upper could result in crushing injury. When check-
ing the amount of lift off of the swing rollers or the amount of gap between the upper
roller path and the rollers, never put your hands in a position where they could be
pinched if the upper should suddenly fall. Serious injury or death could result.
E. At the front of the shovel, measure and record the amount of lift off of the swing rollers or the amount of gap
between the upper roller path and the rollers.
F. If the gap is less that 0.250" (6.35 mm), no adjustment is required. If the gap is greater, adjust the center
gudgeon nut as described in Subtopic 11.3.9.2.
3. Check the tightness of the adjusting Collar (07, Figure 11-29) as follows:
A. Start the shovel, empty the dipper (if necessary) and place the dipper handles parallel to the ground.
B. Crowd the dipper handles fully outward.
C. Check the tightness of adjusting collar (07) by placing a feeler gauge between the adjusting collar and car-
body. If more than .005" exists, tighten the adjusting collar as described in Subtopic 11.3.9.3.
NOTICE
It will be necessary to remove the items mounted above the center gudgeon prior to removing
the center gudgeon nut (04, Figure 12-3) to replace spherical washer (05) and thrust washer
(17) when they are worn to the point that they can no longer be successfully adjusted.
Center gudgeon adjustments can be made without removing the items mounted above it. See subsection 11.11.6.
11.3.9.2 Center Gudgeon Nut Adjustment
Preparation
Prepare to adjust the center gudgeon nut as follows:

1. Clear all personnel from the shovel and from the ground around the shovel.
2. Empty the dipper, release the brakes, and place the dipper handle in the horizontal position.
3. Crowd the dipper all the way out and set all brakes. Then, open the dipper door.
4. Verify that rollers at the front and the rear of the shovel are in contact with the upper roller path.
5. Shut the shovel down. Use lockout and tagout procedures to disconnect and isolate tail cable power from the
shovel.
! WARNING
Contact with energized electrical circuits can cause severe personal injury or death.
Cables carrying dangerous voltages run through the center gudgeon. Do not push sharp
objects into or cut into the center gudgeon wiring. Always use prescribed lockout and
tagout procedures to disable the shovel start-up circuits to prevent unexpected shovel
movement.
6. Open the high voltage disconnect switch located on the rear of the carbody.
7. Expose the adjusting nut by removing the access screen (Item 09, Figure 11-30) on the base of the high volt-
age collector assembly.

Adjustment
05.
01.
02.
03. 06.
04.
07.
04.
08.
01.
03.
09.
02.
ES1054_01
LEGEND 05. Air and Grease Swivel

01. Center Gudgeon 06. Low Voltage Collector Enclosure
02. Adjusting Nut 07. High Voltage Collector Enclosure
03. Locking Key 08. Lock
04. Drilled Head Cap Screws 09. Access Screen
Figure 11-30: Center Gudgeon Nut Adjustment
Refer to Figure 11-30 and adjust the center gudgeon nut as follows:
NOTICE
Two people are required to tighten the adjusting nut.
1. Break the tie wire and remove cap screws (04) that hold locking key (03) in lock nut (02).
2. Match mark the nut to the center gudgeon (01). Then, remove the locking key.
3. Using a 2-1/4" diameter bar in diametrically opposing holes (if clearance permits), manually loosen the center
gudgeon nut from 1/4 to 1/2 turn. If the nut cannot be turned, recheck the shovel level to eliminate binding.

CAUTION
Do not hammer on the adjusting bar or swing the upper to tighten the nut. Permanent
damage to the center gudgeon and adjusting nut threads could result.
4. Tighten the center gudgeon manually as tightly as possible.
5. Locate the place where the slot in the adjusting nut lines up with the slot in the center gudgeon. Insert the lock-
ing key into the slot.
NOTICE
It may be necessary to back off the adjusting nut slightly to get the nut slots to line up with the
slots in the center gudgeon. Do not tighten the nut further to align the slots.
6. Coat the threads of cap screws (04) with anti-seize. Install the locking key (03) and cap screws (04) and torque
the cap screws to 56 ft-lbs (75.9 N.m). Install tie wire to secure the cap screws.
7. Observe the match marks made at the beginning of the adjustment. Make a permanent record of the number
of increments by which the adjustment was changed.
8. Remove all tools and debris from the inside of the collector housing.
9. Make sure all personnel, both on and around the shovel, are clear. Then remove lockout/tagout materials and
restart the shovel.
10. Reinspect the gap at the front of the upper as described in Subtopic 11.3.9.1. The adjustment must have
reduced the gap to less than 0.250" (6.35 mm). If the gap still exceeds 0.250", it will be necessary to replace
the spherical and thrust washers (06 and 17, Figure 11-29), since they have been worn to the point that they
can no longer be adjusted properly. In that case, refer to Subtopic 11.3.9.5.
11. Note and record the machine hours and change in the gap measured.
12. Reinstall the access screens on the high voltage collector.
13. Return the shovel to service. Monitor the center gudgeon nut and spherical washer closely for signs of over-
heating for the first operating shift.
11.3.9.3 Center Gudgeon Adjusting Collar Adjustment
NOTICE
Center gudgeon adjusting collar wrench (R46379F1) may be obtained from P&H. Contact your
local P&H MinePro representative for information.
! WARNING
Damage to electrical cables could cause electrocution hazards, resulting in severe per-
sonal injury or death. Because of the potential for damage to electrical cables, the lifting

wrench described in Step 14 cannot be used to tighten the adjusting collar if electrical
cables are run through the center gudgeon before the adjusting collar is tightened. If
electrical cables have already been run through the center gudgeon, refer instead to
Subtopic 11.3.9.4 and use the hydraulic wrench to tighten the adjusting collar.
! WARNING
Attach the safety sling (07, Figure 8-1) to the top of the center gudgeon before attempt-
ing to thread the adjusting collar on the bottom of the center gudgeon. This will prevent
the nut from falling. If the collar falls, serious injury or death may occur.

14. Refer to Figure 11-34 and install the adjusting collar, using the lifting wrench, as follows:
%
&
$
#
05
#
!
-5 "$!>
"
LEGEND 04. Lifting Wrench

01. Center Gudgeon 05. Washers (8 required)
02. Seal Retainer 06. Adjusting Collar
03. Wrench Stabilizer 07. Safety Sling
Figure 11-31: Center Gudgeon Lifting Wrench
Technician Tip
For improved clearance, the “T” handle of the lifting wrench can be removed and then installed
once the wrench is in position. A single 1" bolt and nut attach the “T” handle to the lifting
wrench.

A. Attach the adjusting collar (06, Figure 8-1) to the base of the lifting wrench (04), using the 1"-8 bolts and the
eight washers (5) between the nut and the wrench as shims.
! WARNING
Excessive vertical load may cause the wrench to break, resulting in severe personal
injury or death. Do not allow the lifting device to exceed a vertical load of 4,000 lbs.
B. Attach the eyebolt on the lifting wrench (A) to a suitable lifting device, and pull the lifting wrench and adjust-
ing collar up to a point just beneath the bottom of the center gudgeon.
! WARNING
Falling components can crush, resulting in severe personal injury or death. Do not
attempt to thread the adjusting collar on the center gudgeon before the safety sling is
installed to prevent the adjusting collar from falling.
C. Install the safety sling (07) on the top of the center gudgeon.
D. Begin to thread the adjusting collar (06) onto the center gudgeon.
E. The wrench stabilizer (3) must be tack welded to the carbody. It is used to minimize wrench deflection when
tightening the adjusting collar. Install “T” handle to base of lifting nut with 1" bolt and nut.
F. Tighten adjusting collar (06) until it’s threads are fully engaged on the bottom of the center gudgeon. When
the adjusting collar is fully tightened, the gap between the adjusting collar and the carbody should be less
than .002" for 75% of the contact area.
NOTICE
If the lifting wrench is unable to torque the adjusting collar tight, it will be necessary to install the
adjusting collar using the hydraulic wrench shown in Subtopic 11.3.9.4. If the adjusting collar
has been tightened sufficiently, proceed to Subtopic 11.3.9.7.
G. Remove the lifting wrench and wrench stabilizer.

11.3.9.4 Adjusting Collar Using Hydraulic Wrench
02
08, 09
04
05
06
07
01
08, 09
03
01 ES0265b01
LEGEND 05. Pin

01. Bracket 06. Cotter Pin
02. Retainer Plate 07. Washer
03. Hydraulic Cylinder 08. Cap Screw
04. Clevis Eye 09. Hardened Washer
Figure 11-32: Center Gudgeon Hydraulic Wrench (R47687F1)
If cables have been run through the center gudgeon, or if the lifting wrench is unable to tighten the adjusting collar
to specifications, it will be necessary to install the adjusting collar using the hydraulic wrench. The hydraulic wrench
can also be used for re-tightening of the adjusting collar.
Proceed as follows:
1. Refer to Figure 11-36 and remove retaining plates (07, 08, and 09) and tapped plate (14) from the bottom of
the center gudgeon.
2. Refer to Figure 11-32. Attach reaction plate (02 to the adjusting collar with one cap screw and washer (08 and
09) at the point shown in View B.
3. Rotate the reaction plate until it intersects the slot in wrench bracket (01). See the Assembly View. This will
establish the proper height to weld the bracket.

4. Weld bracket (01) in place as shown in View A. Install the remaining cap screws and washers (08 and 09).
5. Install cylinder (03) and clevis eye (04) and attach the clevis eye to the reaction plate using hardware (05, 06,
and 07).
6. Tighten the adjusting collar using the hydraulic cylinder. If the cylinder completes it’s stroke but the adjusting
collar is not completely seated, move reaction plate (2) to the next adjacent bolt holes and continue to jack until
the nut is fully seated.
NOTICE
The hydraulic wrench may also be used to remove the nut by placing the jack on the opposite
side of the bracket and repositioning the plate.
11.3.9.5 Replacing Spherical and Thrust Washers
Figure 11-33: Voltage Collectors and Center Gudgeon Nut
If adjustment of the center gudgeon nut will not return the gap between the swing rollers and the upper roller path
to 0.250" (6.35mm) or less, replace the spherical washer (05, Figure 11-29) and thrust washer (17) as follows:
1. Position the shovel on a flat level surface.
2. Extend the dipper handles fully and position the dipper about two inches off the ground to ease removal of the
center gudgeon nut.
3. Set all brakes. Press the STOP button to shut down the shovel.

4. Remove all necessary hatch covers. Refer to Section 8, Machinery House and Exterior Walkways for proce-
dures.

LEGEND 08. Not Used 16. Grease Guard

01. Air and Grease Swivel 09. Slip ring Guard 17. Grease Guard
02. Not Used 10. Slip ring Guard 18. Locking Screw
03. Mounting Post 11. Locking Screw 19. Nut
04. Mounting Post 12. Not Used 20. Locking Screw
05. Cap Screw 13. Rectangular Block 21. Low Voltage Collector
06. Nut 14. Split Bushing 22. High Voltage Collector
07. Washer 15. Not Used 23. Drive Pins
Figure 11-34: Removing Swivel and Voltage Collectors (R35030)

! DANGER
Contact with high voltage will cause death or severe personal injury. Disconnect all
power to the high and low voltage collectors. Use lockout and tagout procedures and
test for power at the collectors before removing the high or low voltage collector
Remove the air and lubrication swivel assembly (Figure 11-9).
5. Refer to Figure 11-34 and remove the low voltage collector enclosure covers.
6. Disconnect and tag all wiring to the collector rings and brushes. Remove the complete high and low voltage
collector assembly (21 and 22, Figure 11-34) and the high and low voltage guards, being careful to avoid dam-
age to all wires, cables and electrical connections.
! WARNING
Dropping a raised load can cause severe personal injury or death. Be sure the lifting
equipment is rated to exceed the weight of the complete assembly, which is approxi-
mately 5200 lbs (2359 kg) and that it is firmly attached to the swivel. Stay clear when lift-
ing, lowering, or moving components with lifting equipment.
7. Refer to Figure 11-29 and remove the center gudgeon adjusting nut (04) and spherical and thrust washers (05
and 17) as follows:
A. Loosen and remove cap screws (01).
B. Remove locking key (02).
C. Disconnect the lube line attached to thrust washer (17).
D. Loosen and remove adjusting nut (04). The nut weighs approximately 1950 lbs (885 kg).
E. Remove spherical washer (05) and thrust washer (17). The spherical washer weighs 575 lbs (261 kg) and
the thrust washer weighs 440 lbs (200 kg).
! WARNING
Use an adequate lifting device to handle the nut and washers. Failure to do so could
cause injury or death.
8. Refer to Figure 11-29 and install the new spherical and thrust washers as follows:
A. Ensure that new washers (05 and 17) are free from burrs, scratches or other damage.
B. Install new thrust washer (17) and connect the lube line.
C. Apply a coat of lubricant to the surface of the thrust washer.
D. Lubricate and install new spherical washer (05).

NOTICE
Be sure the grease bores of the thrust washer and spherical bearing are aligned. Excessive
wear of center gudgeon components will result if this is not done.
E. See that the threads of adjusting nut (04) and center gudgeon (06) are in good condition and that the spher-
ical surface of the adjusting nut is free of burrs.
! CAUTION
Do not use a hammer or the swing motion of the shovel to tighten the adjusting nut. This
will cause serious damage to the center gudgeon and adjusting nut.
F. Install the adjusting nut on the center gudgeon. Tighten the adjusting nut as instructed in Subtopic 11.3.9.2.
9. Install the high and low voltage collector assembly on the center gudgeon as follows:
NOTICE
As a general rule, steps A through H below must be followed to ensure proper alignment every
time a collector ring unit is installed on a machine. This is especially true after servicing or
rebuild of the collector ring or when replacing with a new collector ring.
10. Route all wires, cables, and grease lines through the center gudgeon. Then, refer to Figure 11-34 and proceed
as follows:
A. Assemble upper mounting posts (3) as shown. Snug bolts (5) to approximately 50 ft-lbs (67.8 N.m).
B. Position spacers (13) on top of the center gudgeon as shown in view A-A.
C. Insert split centering bushings (14) into the 1-1/2" drilled holes in the top of the center gudgeon.
D. Lower the assembly until drive pins (23) engage split bushings (14) in the center gudgeon. Feed bundles of
cables and hoses down the center gudgeon bore as the assembly is lowered. After the drive pins are
engaged, rotate the assembly to align junction boxes and cut-outs with the front of the shovel. Ensure that
the assembly is aligned square to the centerlines of the shovel. Continue to lower the assembly until the 25"
diameter drive plate rests on rectangular block spacers (13).
E. Position lower mounting posts (4) around upper mounting posts (3) while the assembly rests on spacers
(13). Again, ensure that the assembly is aligned square to the centerlines of the shovel. Tack weld the
mounting posts (3 and 4) together. Then, tack weld posts (4) to the revolving frame.
NOTICE
Contact your local P&H MinePro Services representative for preheat, positioning, welding, and
grinding technique information.
F. Finish welding the mounting posts together. Finish welding the mounting posts to the revolving frame.
G. Remove the split centering bushings (14) and spacers (23). If necessary, loosen items 05, 06, and 07 and
slightly lift the assembly to aid in the removal of these items.

H. Torque cap screws (5) to 150 ft-lbs (203.4 N.m).
I. Attach guards (09 and 10) and secure with locking screws (11).
J. Attach grease guards (16 and 17) to the revolving frame with locking screws (20).
11. Install the air and grease swivel assembly and the swing resolver if they have been removed.
12. Make proper connections to all electrical, air and grease lines
13. Install the access cover on the high voltage collector.
14. Install any hatch covers removed. Refer to Subtopic 8.2.2.4.
15. Use lockout and tagout procedures to start the shovel. Then, Using correct starting procedures, check center
gudgeon adjustment as described in Subtopic 11.3.9.1.
16. Readjust the center gudgeon nut after 360 hours of operation to compensate for wear-in of the new washers.
11.3.9.6 Replacing Center Gudgeon
Figure 11-35: Center Gudgeon
Preparing to Replace the Center Gudgeon

CAUTION
Replacing the center gudgeon is a complex repair that involves undecking the revolving
frame and freezing the center gudgeon to remove it from or install it in the carbody.
Improper procedures can result in significant property damage. Always contact your
local P&H MinePro Services representative for assistance before attempting to undeck
the shovel or remove and replace the center gudgeon.
NOTICE
The following procedure assumes that the shovel has been undecked and the old center gud-
geon has been removed. contact your local P&H MinePro Services representative for assis-
tance in accomplishing these tasks.

Field Installation of Center Gudgeon
12º 15 05
C 04
C
17
02
03 02
C
01
18
06
01
A
14
B
06
08
09
07
10,11 12,13 12,13,14
09
08
07
ES2464c01
19
LEGEND
01. Gudgeon Assembly 11. Hardened Washer A: Clearance Point A
02. Gudgeon Nut 12. Cap Screw B: Clearance Point B
03. Spherical Washer 13. Hardened Washer
04. Key 14. Tapped Plate
05. Cap Screw 15. Tie Wire C: Make adjustments in 12°
06. Adjusting Collar 16. Sealant (Not shown) Increments, then install lock-
07. Retainer Plate 17. Shim ing key. Use shim 17 only if
08. Retainer Plate 18. Seal/Retainer the key doesn’t fit without it.
09 Retainer Plate 19. Bracket for
10. Cap Screw Hydraulic Wrench
Figure 11-36: Center Gudgeon Assembly

NOTICE
The diameters of the carbody and center gudgeon cascade. The center gudgeon must only be
removed and installed from the top.
1. Coat the carbody bores with a thin even coat of assembly paste (P&H P/N R204291).
2. Double deck the shovel by placing the revolving frame in position over the carbody.
3. Align the upper center gudgeon bore to the lower bore using alignment pin (R50577F1).
4. Remove adjusting collar (06, Figure 11-36), retaining plates (7, 8 and 9), tapped plate (14), and hardware from
the bottom of the center gudgeon.
5. Freeze the center gudgeon using liquid nitrogen. Then, verify clearance with carbody bores, at clearance
points A and B, Figure 11-34.
NOTICE
There is a step on the center gudgeon just above point B. When lowered into position the gud-
geon should bottom out on this step.
The dimensions at clearance points A & B are:
Lower Bore Upper Bore
Carbody Bore 21.6245 ± 0.0010 22.0200 ± .0010"
Gudgeon Bore 21.6335 ± 0.0015" 22.0265 ± .0015"
Press Fit 0.0065 ± 0.0025" 0.0065 ± .0025"
Table 11-1:
NOTICE
Freezing the center gudgeon to -200°F (-129°C) will achieve a clearance of .030" (.762mm).
Freezing the center gudgeon to -300°F (-184°C) will achieve a clearance of .045" (1.143 mm).
! WARNING
Dropping a raised load can cause injury or death. Be sure the lifting equipment is rated
to exceed the weight of the center gudgeon, which is approximately 9050 lbs (4105 kg)
and that it is firmly attached to the center gudgeon. Stay clear when lifting, lowering, or
moving components with lifting equipment. Serious injury or death can occur if this pre-
caution is not observed.

NOTICE
The frozen center gudgeon and attached components are extremely brittle. Avoid impact load-
ing on any of the components.
6. Using suitable lifting equipment, lower the center gudgeon into place. The center gudgeon weighs approxi-
11.3.9.7 Install Locking and Retainer Plates
1. See Figure 6-1 and install retainer plates (07, 08, and 09) and tapped plates (14).
2. Snug up all fasteners (10, 11, 12, 13, and 14).
3. Weld the 0.70" V-groove between Items (07) and (08). Do not weld to the gudgeon or the nut.
4. Weld the .50" fillet between items (07) and (09). Weld the .50" bevel weld between item (09) and the carbody.
5. Refer to Figure 6-1. Lubricate and torque all cap screws to the following values:
• Cap Screws (10). Tighten to 1365 ft-lbs (1850 N.m).
• Cap Screws (12). Tighten to 680 ft-lbs (922 N.m). There are two rows of item (12).
6. Adjust the center gudgeon adjusting nut as described in Subtopic 11.3.9.2.
NOTICE
The center gudgeon seal and retainer (02, Figure 11-31) can be installed any time after the
gudgeon has been installed. If it has not been installed, it should be done now.
7. Install the swivel and high and low voltage collectors as instructed in Subtopic 11.3.9.5.
8. Using proper techniques, return the shovel to service and carefully observe the center gudgeon area for over-
heating or other problems for the first operating shift.

11.3.10 Voltage Collector Assembly (R33149D9)

LEGEND 08. Not Used 16. Grease Guard
01. Air and Grease Swivel 09. Slip ring Guard 17. Grease Guard
02. Not Used 10. Slip ring Guard 18. Locking Screw
03. Mounting Post 11. Locking Screw 19. Nut
04. Mounting Post 12. Not Used 20. Locking Screw
05. Cap Screw 13. Rectangular Block 21. Low Voltage Collector
06. Nut 14. Split Bushing 22. High Voltage Collector
07. Washer 15. Not Used 23. Drive Pins
Figure 11-37: Voltage Collector Assembly
11.3.10.1 General
Collector rings for high and low voltage are mounted above the center gudgeon assembly, just forward of the hoist
drum. The cabinet contains two assemblies: On the lower section, the high voltage collector rings transfer incoming
voltage (6600 volts) from the stationary lower to the revolving upper. The upper section contains the low voltage

collector rings, which transfer voltages between 600 and 120 volts from the revolving frame back to the lower
machine to power components such as the people motors, heaters, lights, etc.
11.3.10.2 Removal
Refer to Figure 11-37 and remove the voltage collector assembly as follows:
! WARNING
Contact with energized circuits can cause injury or death. Disconnect all power to the
high and low voltage collectors. Use lockout and tagout procedures and test for power
at the collectors before removing the high or low voltage collector.
1. Remove the air and lubrication swivel assembly as described in Subtopic 11.3.11.
2. Remove the swing resolver as described in Subtopic 11.3.12.
3. Remove the low voltage collector enclosure covers.
4. Disconnect and tag all wiring to the collector rings and brushes. Remove the complete high and low voltage
collector assembly and the high and low voltage guards, being careful to avoid damage to all wires, cables and
electrical connections.
! WARNING
Dropping a raised load can cause injury or death. Be sure the lifting equipment is rated
to exceed the weight of the complete voltage collector assembly, which is approximately
5200 lbs (2359 kg) and that it is firmly attached to the swivel. Stay clear when lifting, low-
ering, or moving components with lifting equipment.

11.3.11 Air and Grease Swivel (R34804F4)
09
10
11
08
12
07
LEGEND
06 01. Voltage Collector Cabinet
02. slip ring Assembly
03. Drive Plate
05
04. Centering Fixture
05. Swivel Mounting Ring
06. Shims
04 07. Floating Spacer
08. Swivel Assembly
09. Mounting Bolts
03
10. Air Port
11. Grease Port #1
02 12. Grease Port #2
01
ES05086a01
Figure 11-38: Air and Grease Swivel
At the top of the collector assembly is the swivel that allows air for the brakes and grease for the automatic lubrica-
tion system to be transferred from the rotating upper to the stationary lower. One air line is plumbed into the lower
air control cabinet on the left rear area of the carbody. One lubrication line provides multipurpose grease for the
lower lubrication system.The other grease port is not used.
11.3.11.1 Removal
Refer to Figure 11-38. Remove the mounting bolts (9) and remove the swivel from the collector cabinet.
11.3.11.2 Simple Installation
If the swivel is removed from the collector cabinet and the entire unit is still assembled, refer to Figure 11-38 and
proceed as follows:

1. Observing the locations of the air and grease ports (10, 11 and 12), align the mounting holes and place the
swivel assembly on the collector cabinet.
2. Install the mounting bolts (9) and torque to 75 ft-lbs dry.
11.3.11.3 Complete Installation
If the swivel has not been previously assembled, refer to Figure 11-38 and proceed as follows:
1. Place the centering fixture (Item 03) over the 9.990" (25.4 mm) diameter drive plate on top of the slip ring
assembly.
2. Pilot the swivel mounting ring around the centering fixture. Ensure that the tapped holes in the swivel mounting
ring are facing up.
Figure 11-39: Assembled View
3. Position the swivel mounting ring such that the tapped holes align with the slip ring centerlines as shown in Fig-
ure 11-39. Note the orientation of the grease and air ports with respect to the enclosure.
H
.38
ES05089a01
Figure 11-40: Weld Mounting Ring
4. Weld the swivel mounting ring to the top of the slip ring enclosure with 4 equally spaced welds (4" x 3/8") (10
cm x 9.5 mm).

5. Remove the centering ring.
6. Press four drive pins into the aluminum drive plate at the top of the slip ring assembly. Assemble three male
connectors and caps into the ports in the swivel housing.
7. Place floating spacer over the drive pins pressed into the aluminum drive plate. The four 3/8" holes will not be
used.
01
01
ES05087a01
Figure 11-41: Drive Pin Position
8. Press three drive pins into the bottom of the swivel spool as shown in Figure 11-41.
9. Assemble three male connectors into ports on the bottom of the swivel spool.
10. Assemble hose clamp (Item 10) to the 3/4" (19 mm) I.D. low pressure air hose and swivel hose end supplied
with the slip ring assembly.
11. Fit the swivel to the mounting ring without connecting the hoses. Looking through the viewing slots in the
mounting ring, verify that the drive pins are engaged in the floating spacer and that a gap exists between the
bottom of the swivel spool and the top surface of the floating spacer. Measure the gap using feeler gauges.
12. If no gap exists, or if the gap is less than .030" (.762 mm), the swivel must be shimmed. Reconnect hoses and
shim as required under the 16" (40.6 cm) mounting flange until a gap of .030" - .120" (.8 mm - 3 mm) is
achieved. Ports of swivel and hose ends should be labeled. Connect hoses so that labels are consistent.
Check the gap with feeler gauges through the spacer. Also ensure that four nuts and rod bolts on the aluminum
drive plate do not interfere with the bottom of the spool when the swivel is torqued down.
13. Torque mounting bolts to 75 ft-lbs (101.7 N·m) dry.

11.3.12 Swing Resolver
08 09 10
11
07
12
06 13
14
01 15
05
16
04
17
03
02
18
ES05090a01
LEGEND
01. Helical Coupling 10. Clamp
02. Front of Machine 11. Resolver
03. Swivel Flange 12. Hex Head Bolt
04. Swivel Assembly 13. Heavy Hex Nylon Locking Nut
05. Swivel Extension Shaft 14. Washer
06. Tool Removal Direction 15. Clamp Body
07. Alignment Tool 16. Shims
08. Alignment Tool Set Screw 17. Resolver Bracket
09. Resolver Shaft 18. Mounting Bolts
Figure 11-42: Swing Resolver
A resolver for the swing system is mounted above the air and grease swivel. This provides swing positional infor-
mation to the Centurion Control System for use in cable reel protection and other applications.
The swing resolver installation procedure uses a coupling alignment tool to ensure that the helical spring coupling
is aligned between the two shafts so that it can achieve a natural 90-degree bend with little or no axial stretch or
compression.
Refer to Figure 11-42 and install the swing resolver as follows:
1. Apply an even coat of loctite to the extension shaft (05) threads. Thread the extension shaft into the grease/air
swivel until the shoulder on the shaft is flush with the grease/air swivel. Torque to a maximum of 161 ft-lbs (218
N·m).

2. Note the orientation of the bracket on the forward side of the swivel mounting flange. Remove three existing
swivel mounting bolts (18). Re-use these swivel mounting bolts to mount the swing resolver bracket (17).
Torque the mounting bolts to 75 ft-lbs (101.7 N·m) dry.
3. Position the clamp body (15) on the mounting bracket as shown. Discard the unused half of the clamp body.
4. Loosely assemble the resolver (11) and the resolver clamp (10) using the hex head cap screw (12), washer
(14), and the nylon locking heavy hex nut (13).
5. Push the alignment tool (07) completely onto the resolver shaft (09). Confirm that the tool bore bottoms out on
the resolver shaft. Then secure the coupling alignment tool (07) to the resolver shaft (09) with the two set
screws (08).
6. Manipulate the resolver with the loose hardware until the other end of the alignment tool is fully and properly
seated onto the swivel extension shaft (05) as shown.
7. Measure the gap between the clamp body (15) and the top of the swivel bracket (17). Use shims provided to
assemble a shim pack equal to the size of the gap.
8. Disassemble the resolver (11) and clamp (10). Insert the assembled shim pack (16) under the clamp body
(15).
9. Adjust the positions of the clamp body and resolver to completely seat the alignment tool (07) on both the
resolver shaft (09) and the swivel extension shaft (05).
10. Once the alignment tool is fully seated on both shafts with shims in place, secure the clamp body (15) using the
mounting hardware (12, 13 and 14).
11. Loosen the coupling tool set screws and pull the tool straight off the resolver shaft as shown (06). Tool can be
saved for future use.
12. Install the helical coupling (01). End bores must bottom out (maximum engagement is .355" or about 9 mm) on
the shafts. Push one end bore onto the swivel adapter shaft (05) and the other end bore onto the resolver shaft
(09). If necessary, the coupling can be manually compressed to manipulate it into the correct position.
13. Torque the four coupling cap screws (two on each hub) to 19 in-lbs (2.15 N·m).


ES41157 Mechanical Systems Manual Hoist System
Section 12
Hoist System
12.1 General
Figure 12-1: Hoist System
The hoist system is used to lift the dipper. Power for the hoist is provided by two P&H fast response, direct current,
reversible motors that drive a double reduction transmission.
The two motors drive the gearing within the hoist transmission gear case to rotate the drum shaft. Drum rotation
reels the hoist ropes in or out, hoisting or lowering the dipper.
The hoist brakes are spring set, air released disc-type holding brakes that are mounted on the hoist transmission
gear case at the end of each of the two first reduction shafts opposite the hoist motors. The disc brakes are spline-
mounted to each first reduction shaft. The two sets of hoist motors, first reduction shafts and intermediate shafts
are fully synchronized to provide smooth, powerful hoist motion.
Hoist system lubrication is provided by bath and splash, by a supplemental pressure lubrication system, and by the
automatic lubrication system. The gear case systems provide lubrication to the transmission bearings and the
gearing. The automatic lubrication system provides lubrication to the hoist drum shaft bearing in the sidestand.

Sec12Hoist.fm -12.1- Section 12, Version 00 - 06/07
Hoist System ES41157 Mechanical Systems Manual
12.2.1 Hoist Motors And Blowers
Figure 12-2: Hoist Motor and Blower
Hoist power is provided by two fast-response, reversible DC motors coupled to the two first reduction shafts of the
hoist transmission. The motors are specifically designed to operate in conjunction with the shovel’s Centurion™
control system. Each motor has a blower mounted on it to provide cooling.
The hoist motors are mounted on a motor base assembly and use shear blocks, alignment screws, and shims for
alignment.

Section 12, Version 00 - 06/07 -12.2- Sec12Hoist.fm
12.2.2 Hoist Gear Case R57767F1
Figure 12-3: Hoist Gear Case (R57767F1/F2
12.2.2.1 General
The hoist gear case is an oil-tight case that houses the hoist transmission gearing and also functions as one of the
side stands for the hoist drum assembly. The gear case is fabricated of sturdy, all welded construction with liberal
ribbing for strength and stability. A one-piece gear case cover bolted to the gear case base provides a housing for
the hoist transmission and support for the bearings and shaft assemblies.
The mating flange of the gear case cover and gear case base uses an O-ring and a silicon RTV sealant to make
the gear case oil tight. Lip seals are used in the hoist gear case to seal the various shaft assemblies including the
hoist drum.
The hoist gear case contains approximately 165 gallons (625 liters) of gear oil for bath and splash lubrication of the
transmission. The hoist gear case also has an external oil circulation system that pumps oil from the gear case
through a filter, and then returns the oil back into the gear case through the bearing retainers to provide additional
lubrication to the bearings, as well as through discharge points located in the gear case cover.

Figure 12-4: Hoist Gear Case Support
The hoist gear case is attached to the floor of the machinery deck by two large pins. Underneath the hoist gear
case, one in each corner where the pins pass through, are wedge assemblies. These wedge assemblies are used
to prevent movement between the gear case and the floor. If the hoist gear case is allowed to move with respect to
the floor, the alignment of the hoist couplings will be affected.
When the hoist gear case is mounted to the revolving frame, the two pins are installed, then the four wedge assem-
bly blocks are turned up until they provide a tight fit between the pins and bushings.
12.2.3 Hoist Disc Brake
Figure 12-5: Hoist Brake
been consolidated into one comprehensive section. Refer to Section 5, Disc Brakes.

12.2.4 Hoist Limit Switch Sensor 979J247
Figure 12-6: Hoist Limit Switch Sensor
The limit switch sensor is coupled to the left end of the hoist rear intermediate shaft. It consists of a resolver and
mounting assembly as shown in Figure 12-6.
The resolver contains a speed reducer and a variable transformer. The speed reducer allows the transformer
adjustment to rotate less than one full turn. As it turns, the output of the transformer changes. The control unit mon-
itors the output of the resolver. When the output of the transformer reaches one of the programmed limits that func-
tion is shut down. The reverse function will still be operational.
12.2.5 Hoist Drum Shaft Assembly R58153F1/F2
Figure 12-7: Hoist Drum Shaft Assembly (typical)
The hoist drum shaft supports the hoist drum, which supports the hoist ropes. The hoist drum shaft is supported on
the left end by the hoist gear case, and on the right end by the hoist drum side stand. The hoist drum gear (hoist
second reduction gear) is bolted to the hoist drum. The assembly is sealed to prevent leakage from the gear case.
When the hoist drum turns in the take-up direction, hoist ropes that are attached to the dipper are pulled in, and the
ropes pull the dipper upward. When the hoist drum turns in the opposite direction, the ropes are allowed to pay out,
and the dipper lowers by gravity.

12.2.6 Hoist Ropes R23421D49
Figure 12-8: Hoist Ropes R23421D49
This shovel uses a matched pair of standard ropes. Ropes are 8 X 37, IWRC, Preformed, Extra Improved Plow
Steel grade, Right Lang Lay compacted, Fully Plastic Impregnated. They are a matched set, equal in length and
diameter. The nominal length of the cables is 376’ (114.6 m); and the nominal diameter is 2¾” (7 cm).
Each matched set consists of two lengths of cable from the same master reel with a ferrule becket on each end of
each length. If the two matched cables are not mounted on the same reel, each reel of the same matched set will
have a tag that includes the part number (R23421D49), the P&H Purchase Order Number, and the marking for
either “Piece 1 of 2” or “Piece 2 of 2”. Cables are hairpin wound.
12.2.7 Remote Hoist Controller R54705D1
This controller allows a maintenance technician to operate the hoist drum remotely. Refer to Figure 12-9.
Figure 12-9: Remote Hoist Joystick Controller


The hoist machinery should never be operated by means of the remote hoist controller unless a
qualified shovel operator is in the operator’s station. The qualified operator must have a clear
view of the dipper handles, dipper, and the hoist ropes and must have a positive means of com-
munication with the remote hoist controller operator.
12.2.7.1 Operation Procedure
This procedure details the steps for remote hoist operation.

If a problem is observed, the operator or designated person at the operator’s station has normal
machine stop, brake set functions, and Emergency Stop functions.
Step 1: Establish communications between the work crew, remote hoist controller operator and personnel sta-
tioned at the Operator’s Station.
Step 2: The remote hoist controller operator must notify the person at the operator’s station and the support crew
on the ground that remote operation of the hoist is to begin.
Step 3: Ensure that the shovel is shut down. If not, direct the shovel operator to shut down the shovel.
Figure 12-10: Hoist Remote Control Selector Switch
Step 4: Transfer hoist control from the operator’s station by turning the OPERATION LOCATION selector on the
Control Cabinet (refer to Figure 12-10) to the LOCAL position.


Maintain the presence of a qualified person or operator in the operator cab while the hoist
remote control is being used. This person will act as the work site monitor for the duration of the
maintenance procedure.
Step 5: Start the shovel from the operator’s station.

If it is necessary to shut the machine down from the remote hoist controller, push the Stop push
button on the remote controller joystick. This button will shut the shovel down in the same man-
ner as the Stop button on Operator’s Right Switch Panel Assembly.
Step 6: Prior to releasing the hoist brakes, inform all personnel that the remote hoist controller operation is to
commence.
Step 7: Direct the operator at the Operator’s Station to sound the horn.
! WARNING
Unexpected movement of the hoist machinery can cause severe personal injury or
death. Ensure all persons are clear of the shovel and hoist machinery before releasing
the hoist brakes. Keep this area clear until hoist brakes are released.
Step 8: Press the Brake Release push button on the remote controller to release the hoist brakes.
Step 9: Confirm that the Brake Release push button indicator is displayed on the Touch Panel screen.
NOTICE
If this indicator does not light, verify the status of the hoist brakes by contacting the operator at
the Operator’s Station.
! WARNING
Moving components can crush, causing severe personal injury or death. Ensure that all
persons are clear of the shovel and hoist machinery while the hoist machinery is in
motion.
Step 10: Rotate the hoist drum in the lowering direction as follows:
• Press and hold the Up/Down Switch in the down direction.
• To stop the drum rotation, release the Up/Down Switch.
• To set the hoist brakes, press the Set push button on the remote hoist controller.

Step 11: Rotate the hoist drum in the hoisting direction as follows:
• Press and hold the Up/Down Switch in the up direction.
• To stop the drum rotation, release the Up/Down Switch.
• To set the hoist brakes, press the Set push button on the remote hoist controller.
Step 12: Terminate remote hoist control as follows:
• Set the hoist brakes. Press the Set push button on the remote hoist controller.
• Confirm with the Operator’s Station operator that the brake set indicator on the left joystick controller and the
touch panel are illuminated.
• Shut down the shovel by pressing the Start switch on the Right Switch Panel Assembly to OFF.
• On the operator’s touch panel disable remote hoist control.
• Transfer hoist control back to the operator’s station by turning the OPERATION LOCATION selector on the
Control Cabinet (refer to Figure 12-10) to the OP. COOP position.
12.2.8 Cable Tuggers R26969D5
Figure 12-11: Cable Tuggers (typical)
12.2.8.1 General
The rope tuggers are for maintenance purposes only. Their primary purpose is to assist in removing the old hoist
ropes from the hoist drum and to pull new hoist ropes into the machinery house for attachment onto the drum.

Tugger control electrical panels are mounted to the wall near the front right corner of the machinery deck (refer to
Figure 12-12). There is one control panel for each of the two rope tuggers. One rope tugger is required for each of
the two hoist cables (i.e., to bring in all four rope ends, two tuggers must work together).
Figure 12-12: Cable Tugger Controls
12.2.8.2 Operation
! WARNING
Moving components can crush, and cables can break, causing severe personal injury or
death. Ensure that all persons are clear of the hoist drum while the hoist tuggers are in
motion.
Figure 12-13: Cable Tugger Pendant Control

The tuggers are controlled by pendant controls that are attached to 50-foot cables to allow the maintainer to oper-
ate the tuggers from a position close to the hoist drum. Press the UP button to bring ropes onto the drum; press the
DOWN button to play ropes out. Refer to Figure 12-13.
12.2.8.3 Manual Release Operation
! WARNING
Falling hoist ropes can crush, causing severe personal injury or death. Ensure that all
persons are clear of the hoist drum and the tugger ropes when releasing tugger brakes
manually.
ES02504c01
Figure 12-14: Tugger Brake Manual Release Levers
The manual release levers (refer to Figure 12-14) are located on the back of the brake opposite the input hub.
If it is necessary to manually release the brake, simultaneously turn the two levers counterclockwise approximately
90 degrees to their stop positions. The manual release levers will reset automatically the next time the brake is
energized. They may also be moved into the reset position manually.

12.2.9 Hoist Gear Case Lubrication System R57234F1/F2
ES04430a01
Figure 12-15: Hoist Gear Case Lubrication System Overview
12.2.9.1 General
The hoist gear case lubrication system includes a pump, strainer, and filter. An oil cooler is mounted under the plat-
form. The cooler is equipped with an electric fan that will automatically be turned on and off as the system deems
necessary. The pump motor is controlled by a variable frequency drive. The drive will cause the pump to be turned
on or off and the pump speed varied to help control oil flow and temperature.
The pump output is directed to the bearings of the gear case. There are also pump output lines plumbed into each
end of the gear case (front and rear) at the location of the input pinion.

12.2.9.2 Components
LEGEND 06. RTD 12. Motor

01. Bypass Relief Valve 07. Pump 13. Filter
02. Shut-off Valve 08. Vacuum Transducer 14. Shut-off Valve
03. Dipstick 09. Shut-off Valve 15. Gauge
04. Shut-off Valve 10. Bypass Line 16. Gauge
05. Strainer 11. Shut-off Valve 17. Gauge
Figure 12-16: Hoist Lubrication System Components

Pump Assembly R57213D1
Figure 12-17: Pump Assembly R57213D1
Refer to Figure 12-17. The pump assembly (Item 07, Figure 12-16) features a 5 HP, 1750 RPM inverter duty elec-
tric motor driving a positive displacement gear pump with 1.00 NPT ports through a 2.58:1 gear reducer. The motor
is controlled by a variable frequency drive.
Vacuum transducer R58344D1
Figure 12-18: Vacuum Transducer
Refer to Figure 12-18. A 24VDC vacuum transducer (Item 08, Figure 12-16) with a DIN 43650 connector is
installed in the suction line to provide vacuum data to the Centurion Control System, which will use that information
to control the speed of the pump through the variable frequency drive.
Oil Cooler R57212D1
The oil cooler is suspended below the machinery deck to cool the hoist transmission oil. It is cooled by a fan that is
driven by a 1 HP electric motor.

• Bypass valve R57221D1
Figure 12-19: Bypass Valve
Refer to Figure 12-19. The bypass valve (Item 01, Figure 12-16) is set at 100 psi (not to exceed 150 psi)
Strainer 46Q108D2
Figure 12-20: Strainer
Refer to Figure 12-20. The strainer (Item 05, Figure 12-16) has a removable 10-mesh basket that allows cleaning
without removing the strainer body. It uses 2.00 NPT ports.

Filter 46U110D1
Figure 12-21: Filter
Refer to Figure 12-21. The filter (Item 13, Figure 12-16) is a 20 micron double element cartridge filter with 35 psi
by-pass.
Distribution manifolds (R57233F1/F2)
Figure 12-22: Distribution manifold
Distribution manifolds, one toward the front and one toward the rear on top of the gear case, direct the flow of oil to
the lubrication points. An integral pressure gauge permits monitoring of oil pressure along the flow path.

Restrictor fittings (44Z2243D4-D7)
Restrictor fittings are used to divert the majority of the system flow to the bearings on the first reduction shafts.
There are a total of 7 restrictors in the system. There are three orifice sizes: .125" (3.2mm); .187" (4.8mm); and
.250" (6.4mm). No restrictors are used on the 4 bearings on the first reduction shafts. The system lubricates bear-
ings on both ends of both first reduction shafts; both ends of both intermediate shafts; and the compressor end of
the hoist drum shaft (the bearing on the opposite end of the hoist drum shaft is lubricated by the automatic lubrica-
tion system). THe system also provides lubrication directly to the front and rear first reduction gear meshes. Refer
toTable 12-1
Component Lube Point Restriction
Front First Reduction Shaft Shaft Bearing (compressor side) none
Shaft Bearing (drum side) none
First Reduction mesh 0.250"
Front Intermediate Shaft Shaft Bearing (compressor side) 0.125"
Shaft Bearing (drum side) 0.187"
Hoist Drum Shaft Shaft Bearing (compressor side) 0.187"
Rear Intermediate Shaft Shaft Bearing (compressor side) 0.125"
Shaft Bearing (drum side) 0.187"
Rear First Reduction Shaft Shaft Bearing (compressor side) none
Shaft Bearing (drum side) none
First Reduction mesh 0.250"
Table 12-1: Lube Point Descriptions
12.2.9.3 Parameters
Pump Motor Speed: Min. 175 RPM, Max 1300 RPM
Maximum Pump Vacuum Pressure = 7 inHg vac (178 mmHg vac)
Maximum Pump Motor Torque = 100% of continuous rating
12.2.9.4 Operation
When the shovel starts, the electric motor on the pump starts and achieves its minimum speed of 175 rpm. The
motor gradually increases in speed until the vacuum transducer indicates a vacuum of 7"Hg. The Variable Speed
Drive will cause the pump motor to slow down or speed up as required to maintain the 7"Hg vacuum. The torque
rating and the speed will limit the motor, so it is possible to run at maximum speed without obtaining a reading of
7"Hg vacuum at the pump inlet.
To protect the pump against cavitation during cold weather operation, a cold weather startup mode actuates. If the
motor speed is within 30 rpm of minimum for 1 minute, the motor stops for 5 minutes. It then starts for 1 minute. It
will continue starting and stopping until the 30 rpm range on motor speed is exceeded. If the motor is in cold
weather start-up mode and the temperature of the oil is greater than or equal to 10°C (50°F), the program will turn
off the pump and display a blocked line fault.

When the motor speed is at maximum for 1 minute and the temperature of the oil is at or above 40°C (104°F), the
cooler fan will turn on. The cooler fan will turn off when the motor speed drops to 1000 rpm or the lube temperature
is below 30°C (86°F).
Program logic is designed to detect low oil level in the gear case. If the pump motor is turning at maximum speed
and there is less than 1"Hg vacuum, the program displays a low oil level fault on the GUI. Refer to the hoist lube
system schematic in Figure 12-23.
0-160 PSI 0-160 PSI
0-30 inHg
0-300 PSI 30-100 PSI 0-160 PSI 0-160 PSI
10 MESH
(1910 MICRON)
20 MICRON
5 HP
M ES04434b01
1 HP
Figure 12-23: Hoist Lube System Schematic

12.3 Maintenance
12.3.1 Part Numbers
NOTICE
to be lowered.

! WARNING
! WARNING
12.3.3 Hoist Motor
12.3.3.1 Hoist Motor Removal
Refer to Figure 12-25 and remove a hoist motor as follows:
1. Confirm that all preliminary maintenance procedures described in Subtopic 12.3.2 have been completed.
cedures.
! WARNING
Contact with energized circuits could cause death or severe personal injury. Use lock-
out/tagout procedures and test before installing electrical connections.
1. Mark and disconnect the electrical connections to the blower motor.
2. Remove the blower and blower motor from the hoist motor.
3. Remove the hoist motor coupling guard.
4. Remove the hoist motor coupling bolts.

LEGEND
01. Air Inlet 05. Motor Coupling
02. Blower 06. Adjusting Screw
03. Blower Motor 07. Mounting Hardware
04.Main motor 08. Air Exhaust
Figure 12-25: Hoist Motor Mounting
NOTICE
The coupling halves used to connect the hoist motor to the hoist transmission are machined for
use together. Mark each set of coupling halves before separation to insure they are returned to
the same position during reassembly.
5. Place a pan under the coupling and slide the coupling halves apart. Remove grease from the coupling.
6. Measure the distance between coupling hubs. This distance should be used as a reference when the motor is
installed again.

! WARNING
7. Mark and disconnect the electrical connections to the motor.
! WARNING
Unexpected machine movement could cause an uncontrolled component to fall from its
mounting area onto personnel, crushing and resulting in serious injury or death. Always
attach an appropriate lifting device capable of lifting the hoist motor prior to removing
the mounting hardware. The hoist motor weighs 19,000 pounds (6,800 kg).
8. Remove hand hole covers located on the hoist motor and hoist motor base. Working through the hand holes,
remove the hoist motor mounting cap screws. Cap Screws are torqued to 1950 ft-lbs 2644 N·m.
9. Loosen the adjusting screws on the motor base.
! WARNING
Dropping a raised load can crush, resulting in severe personal injury or death. Be sure
lifting equipment capacity exceeds the weight of the component being lifted and the lift-
ing equipment is securely attached to the component being lifted. Stay clear when lifting,
lowering or moving components with lifting equipment. The hoist motor with blower
weighs approximately 19,000 lbs (6,800 kg).
10. Using the lifting lugs provided on the motor, lift the motor from the base.
11. Mark the location of the shim packs under the motor mounting pads. Retain these shims for use during installa-
tion.
12. Remove the keeper plate, then using a suitable puller, remove the coupling half from the motor shaft.
12.3.3.2 Hoist Motor Installation
Refer to Figure 12-25 and install a hoist motor as follows:
cedures.
! WARNING
3. Install coupling half on motor shaft, if it was removed.

A. Confirm that the coupling half is a match for coupling half on hoist first reduction shaft.
B. Coupling manufacturers recommend that couplings be used as a matched set. Mixing old and new coupling
components could result in problems at fit-up.
C. Replace seal in coupling sleeve. Slide coupling sleeve onto motor shaft.
D. Heat coupling hub (maximum 300°F (149°C)) to install. Press onto motor shaft with threaded puller holes
facing away from motor.
E. Install coupling retainer plate and tighten bolts snug tight.
F. Measure gap between coupling retainer plate and motor shaft end.
G. Remove coupling retainer plate and install shims equal to measured gap minus .010" (.254 mm).
H. Install coupling retainer plate and torque bolts to 266 ft-lbs (361 N·m).
Motor Alignment
When a hoist motor is removed and reinstalled, the motor and transmission first reduction shafts must be parallel
and axially aligned. See Figure 19-1. The tolerance used for all planes of the alignment is .010" (0.254 mm) Total
Indicator Runout (TIR). Prepare for motor alignment as follows:
1. Verify operation of dial indicator.
2. Inspect mounting surface to be certain that it is smooth and free of any nicks or burrs.
3. Use a feeler gauge to check for and correct soft foot or damaged foot.
4. Check runout of the motor shaft.
5. Check runout of the coupling hub both axially and facially.
Align the motor as follows.
1. Install the motor base shim packs that were removed when the motor was removed to their original location.
Since the motor will probably not be the one that was removed, it may be necessary to re-shim for proper align-
ment.
NOTICE
Do not block air discharge opening with shims.
2. Using the lifting lugs provided on the motor, lift the motor to the base.
3. Using the alignment screws, position the hoist motor on the motor base so the space between the coupling
hubs is correct as measured during removal. See Figure 12-26. Note that the coupling sleeves must be on the
shafts -- one on the motor shaft and one on the transmission input shaft -- before the coupling hubs are
installed. The two coupling sleeve halves and can be moved out of the way to facilitate alignment, then
installed after alignment.
4. To make the motor and first reduction shafts parallel in the vertical plane, align them as follows:

LEGEND
A: Horizontal and Vertical
Angular Alignment
B: Horizontal Offset Alignment
C: Vertical Offset Alignment
ES04860a01 D D: Facial Gap Alignment
Figure 12-26: Shaft Alignment
A. With the coupling disconnected and the sleeves pulled apart, check for a gap of 1.44" ± .12" (36.6mm ±
3mm) between the motor and transmission coupling hubs. Adjust if required.
B. Slide the coupling sleeves apart to mount alignment tools.
NOTICE
A special dial indicator or adapter may be necessary because of the small distance between the
coupling faces.
C. Install the alignment tools as shown in Figure 12-27 B so that readings are taken from the face of the trans-
mission first reduction shaft coupling hub.
D. Rotate the motor shaft until the indicator is at the top or 12 o’clock position to begin. Set the dial indicator to
0.0 inches or millimeters.

02
03
01 04
02
03
01 04
B
TC0422B
LEGEND
01. Motor A: Measuring Rim for
02. Alignment Tool Post Axial Alignment
03. Dial Indicator B: Measuring Face for
04. Transmission Parallel Alignment
Figure 12-27: Alignment Indicator

NOTICE
When positioning the dial indicator, it should be actuated until the pointer is near the middle of
its measurement range. Then when it is zeroed it will be capable of reading movement in both
the positive and negative directions.
E. Rotate the aligning tool posts 180° to the 6 o’clock position and read the dial indicator. Observe the direction
the indicator moves, because this indicates the direction that the motor must be moved to bring it into align-
ment with the first reduction shaft. If the Total Indicator Runout (TIR) is greater than .010" (.254mm), add or
subtract shims under one end of the motor (front or back). Shims must be added or subtracted depending
on if the indicator reading was positive or negative.
Technician Tip
To determine the correct amount of shims, a trial shim can be used. Install or remove one trial
shim and read the change. Example: The measurement read was a positive .040". One .010"
shim was installed under both of the rear feet of the motor. The measurement was taken again.
This time the reading was a positive .032". The .010" shim caused a movement of .008". This
means that another .040" shim under both rear motor feet should bring the two shafts within
vertical parallel alignment. The required tolerance for proper alignment is .010" (0.381 mm) TIR
or less. Proceed to vertical offset alignment.
5. To correct for vertical offset of the motor shaft and the first reduction shaft, proceed as follows:
A. Position the aligning tool post as shown in Figure 12-27 A so that readings are taken from the rim of the
transmission first reduction shaft coupling hub. Rotate the motor shaft until the indicator is on the top or 12
o’clock position. Position the indicator in the middle of its range and set the dial indicator to 0.0 inches or mil-
limeters.
NOTICE
B. Rotate the motor shaft 180° to the 6 o’clock position and read the dial indicator. Divide the reading by 2. This
indicates the amount the motor must be moved vertically. If the motor shaft is higher than the first reduction
shaft an equal amount of shims should be removed from under all four of the motor feet. If the motor shaft is
lower than the first reduction shaft an equal amount of shims must be installed under all four of the motor
feet.
NOTICE
Be sure to remove or add an equal amount of shims under each foot, or the shafts will not
remain parallel.
C. Repeat Steps A and B until the dial indicator reads .010" (0.254mm) TIR or less. Proceed to horizontal par-
allel alignment.
6. To make the motor and first reduction shaft parallel in the horizontal plane, proceed as follows:

A. Position the aligning tool post as shown in Figure 12-27 B so that the indicator is measuring off the face of
the transmission first reduction shaft coupling hub. Rotate the motor shaft until the indicator is at the side or
3 o’clock position. Set the dial indicator to 0.0 inches or millimeters.
NOTICE
B. Rotate the aligning tool posts 180° to the 9 o’clock position and read the dial indicator. This indicates the
direction that the motor must be moved to make it parallel with the first reduction shaft. The jack screws
located at the sides of the motor feet are used to make the horizontal adjustments. The motor can be moved
by turning in the correct jack screw, which will push the motor sideways. This reading on the dial indicator is
an indication that the motor shaft and first reduction shaft are not horizontally parallel. To correct, the front or
rear of the motor must be moved sideways. Mark the head of the jack screw and count the number of flats
used to move the motor and repeat the measurement (ex: turn the jack screw two flats, then measure). Con-
tinue to measure and adjust until the measurement reads within .010" (.254mm) TIR or less.
C. As an example, for the first measurement the indicator reads .060". Turn the jack screw to move the rear of
the motor 3 flats on the jack screw head. The measurement now reads .030" and turning the jack screw 3
more flats the measurement should be at or near the tolerance.
D. Proceed to Horizontal Offset alignment.
7. To correct for horizontal offset misalignment, proceed as follows:
A. Position the aligning tool post as shown in Figure 12-27 A so that the indicator will read off the rim of the
coupling hub. Rotate the motor shaft until the indicator is at the side or 3 o’clock position and set the dial
indicator to 0.0 inches or millimeters.
NOTICE
A. Rotate the aligning tool posts 180° to the 9 o’clock position and read the dial indicator. This indicates the
amount of horizontal axial misalignment.
B. If the TIR is greater than .010" (.254mm), adjust both the front and rear jack screws until reading on the indi-
cator is within the .010" (.254mm) TIR tolerance.
8. Repeat all four alignment checks to make sure adjustments have not moved and that indicator readings are
within the .010” (.254mm) TIR tolerance.
9. Working through the hand hole openings, located on the motor and the motor base, install the motor mounting
cap screws. Tighten cap screws to 1950 ft-lbs (2644 N·m).
10. Install hand hole covers.
11. Make electrical connections to the motor.
12. Connect the coupling halves. Torque the bolts to 313 ft-lbs (424 N·m) dry or 235 ft-lbs (319 N·m) lubricated.

NOTICE
The spacer or spacer halves must be installed before connecting the coupling halves together.
Failure to install the spacer can lead to damage of the seals and/or the seal retaining rings.
13. Grease the couplings. Remove one plug 180° from the grease fitting and pump grease until lubricant comes
out of the open hole. Replace the plug and fitting.
14. Install the blower and blower motor.
15. Make electrical connections to the blower motor.
16. Replace all machinery house roof panels, curtain wall panels, and canopy sections. Refer to Subtopic 8.2.2 for
installation procedures.
17. Remove lockout and tagout devices, restore electrical power and notify the work crew that power is restored.
12.3.4 Hoist Motor Blower R12599D1F5
12.3.4.1 Description
The hoist motor blower assembly is a single inlet blower with a bracket mounted motor. The blower assembly is
mounted on top of each hoist motor. A protective screen is mounted on the inlet of the blower housing.
12.3.4.2 Removal
Refer to Figure 12-28, and remove the hoist motor blower assembly (09) as follows:
! WARNING
Contact with energized circuits can cause serious personal injury or death. Always use
lockout and tagout procedures and test before disconnecting electrical connections.
1. Perform the appropriate lockout and tagout procedures to the blower supply circuit breaker to prevent acciden-
tal start-up while maintenance is being performed.
2. Mark and disconnect the electrical connections from the blower motor.
! WARNING
Failure to use an adequate lifting device, or using improper lifting techniques during any
lifts, could cause the blower assembly to fall causing serious personal injury or death.
Be sure the lifting device has a rated capacity exceeding the weight of the blower assem-
bly. The blower assembly weighs approximately 240 kg (530 lbs).
3. Attach a suitable lifting device to support the weight of the blower assembly.
4. Remove the fourteen flange head capscrews that secure the blower assembly to the hoist motor.
5. Using a suitable lifting device, remove the blower assembly from the hoist motor.

12.3.4.3 Blower Disassembly/Assembly
Disassemble and assemble the hoist motor blower assembly using Figure 12-28 as a guide.
! WARNING
Failure to use an adequate lifting device, or using improper lifting techniques during any
lifts, could cause the blower assembly to fall causing serious personal injury or death.
Be sure the lifting device has a rated capacity exceeding the weight of the blower assem-
bly. The blower assembly weighs approximately 240 kg (530 lbs).
01
08 09
06 07
05
04
10
11
02 03
ES04313a01
12
14 13
LEGEND
01. Motor Blower Assembly 08. Flange Nuts
02. Capscrews 09. Motor
03. Flat Washers 10. Capscrews
04. Screen 11. Blower Housing
05. Inlet Cone 12. Blower Wheel
06. Capscrews 13. Taper lock Hub
07. Flat Washer 14. Capscrews
Figure 12-28: Motor Blower Assembly (R12599D1F2)
Install the blower assembly as follows:
1. Lift the blower and motor assembly onto the hoist motor.

2. Install the fourteen spacers and flange head capscrews that secure the blower assembly to the hoist motor.
Evenly tightening each capscrew to 27 N·m (20 ft-lbs).
! WARNING
Contact with energized circuits can cause serious personal injury or death. Always use
lockout and tagout procedures and test before connecting electrical connections.
3. Connect the electrical connections.
4. Check the blower for proper rotation.
12.3.5 Hoist Gear Case Assembly (R57767F1)
12.3.5.1 Hoist Gear Case Mounting
Figure 12-29: Hoist Gear Case Mounting (typical)
The hoist gear case is attached to the floor of the machinery deck by two large pins. There are bushings in the
revolving frame lug holes and the hoist gear case holes for the pins. Retainers should be welded to the revolving
frame lugs to prevent the bushings from drifting out.

LEGEND
01. Hex Head Bolt
07
02. Flange Locking Screw
03. Lock Plate
04. Retainer
05. Lower Block
06. Wedge 06
07. Upper Block
08. Shims
05
04
03
02
01
08
ES05079a01
Figure 12-30: Hoist Gear Case Support
Underneath the hoist gear case, one in each corner where the pins pass through, are four supports that are used to
tighten the bushings and pins to prevent movement between the gear case and the floor. If the hoist gear case is
allowed to move with respect to the floor, the alignment of the hoist couplings will be affected.
Refer to Figure 12-30 and install the hoist gear case supports as follows:
1. Lubricate the sliding surfaces of the Lower Block (05), the Wedge (06), and the Upper Block (07) with Never
Seez.
2. Insert the bolt (01) and turn 6 turns (1" (2.54 cm)) into the block.
3. Add shims (08) under the block (05) until the top of the support is within .125" (1/8" or 3.2 mm) of the gear
case.
4. Turn bolt (01) to raise the support until it is tight against the gear case. Be certain that all four supports are tight
against the gear case before proceeding.
5. Torque bolt (01) to 386 ft-lbs (523.35 N·m).
6. Lock bolt (01) in place using the retainer (04), lock plate (03) and locking flange screw (02).
12.3.5.2 Inspection
Inspect the hoist gear case assembly every 1,000 hours. The inspection should include the following:

• Check the level of the gear case oil using the dipstick provided. Check the oil level while the shovel is
parked on level ground.
• Check the gear case for evidence of oil leaks.
• Check the breather element indicators and change if indicated.
• Check gear case mounting pins and retainers to ensure pins are not drifting. Check gear case mounting pin
bushings and retainers to confirm bushings are not drifting. If no bushing retainers are installed and bush-
ings are found to be walking out of their bores, install Bushing Retainer Kit R49780. Contact your local
MinePro Services representative for further information.
• Check all the mounting bolts for tightness. Include all gear case base and cover mounting bolts.
! WARNING
Unexpected gear movement can pinch or crush during close inspections resulting in
personal injury. View gears through inspection openings and keep hands out until the
system is shutdown and locked out.
NOTICE
The inspection of transmission gears requires a qualified operator at the shovel controls. The
shovel must be started so the gears can be jogged for inspection at various points around their
perimeter. The bucket must be on the ground. A reliable means of direct communication
between the operator and the gear inspector is required and the gearing must not be moved
while the inspector is viewing the gears. The inspector should mark the gears so that he can tell
when they have been inspected around their complete perimeter. While the gears are being
moved (jogged) to another location, the gear case covers must be reinstalled.
• Open the inspection covers and inspect for cracks in the gear teeth, unusual wear, galling, scoring or spal-
ling. Refer to Topic 4.3 for further information regarding gear inspection criteria.
• Check the gear case for cracks. Include the bearing blocks, the base mounting flange, and the gear case
mounting lugs and welds to the floor.
• Check the gear case oil for metal particles.
• Confirm that the gear case mounting pins are tight. If not, adjust the gear case supports as discussed in
Subtopic 12.3.5.3.

12.3.5.3 Adjustment
LEGEND
01. Hex Head Bolt
02. Flange Locking 07
Screw
03. Lock Plate
04. Retainer
05. Lower Block 07
06
06. Wedge
07. Upper Block
08. Shims
01 04
05
04
03
02
03
01
02
08 08
05
ES05079b01
Figure 12-31: Hoist Gear Case Support Adjustment
Refer to Figure 12-31 and adjust the hoist gear case supports as follows:
1. Remove the flange locking screw (02), lock plate (03) and retainer (04).
2. Turn bolt (01) to raise the support until it is tight against the gear case. If tight support cannot be achieved, turn
bolt (01) outward as needed and add shims (08) under the block (05) until the top of the support is within .125"
(1/8" or 3.2 mm) of the gear case.
3. Turn bolt (01) to raise the support until it is tight against the gear case. Be certain that all four supports are tight
against the gear case before proceeding.
4. Torque bolt (01) to 386 ft-lbs (523.35 N·m).
5. Lock bolt (01) in place using the retainer (04), lock plate (03) and locking flange screw (02).
12.3.5.4 Repair
Repair to the hoist gear case is limited to the replacement of worn or damaged components.
12.3.5.5 Disassembly
Complete disassembly of the hoist gear case, to include removal of the transmission, may require the removal and/
or repositioning of major components and assemblies not covered in this manual. The following procedures dis-

cuss removal of the gear case cover; removal and disassembly of the transmission components are discussed
immediately following.
! CAUTION
Rope weight can cause unexpected drum rotation and cause unexpected gear move-
ment that can pinch or crush resulting in severe personal injury. Remove the hoist ropes
from the hoist drum and perform lockout and tagout procedures before disassembling
the hoist gear case.
2. Remove the hoist ropes from the hoist drum.
3. Refer to Subtopic 8.2.2 and remove machinery house hatch covers and/or canopy sections as necessary.
4. Remove or reposition the gantry or gantry platforms as necessary.
5. Drain oil from the gear case into suitable containers. The hoist gear case capacity is 165 gallons (625 liters).
6. Disconnect the automatic lubrication systems as needed to remove the gear case cover. Refer to the Lubrica-
tion Section for details.

Figure 12-32: Hoist Gear Case R57767F1/F2

LEGEND 18. Filter Indicator 37. Hex Nut 59. Low Pressure Hose
01. Gear Case 19. Breather Filter 38. Rod Bolt 60. Hose Strap
02. First Reduction 20. Filter Replacement 39.Hardened Washer 61. Medium Pressure
Shaft Element 40. Hex Nut Hose
03. Front Intermediate 21. Reducing Tee 41. Hex Head Cap Screw 62. Hose End
Shaft 22. Pipe Bushing 42. Hex Nut 63. Connector Plate
04. Not Used 23. Oil Dam (Not 43. Hardened Washer 64. Lube Fitting
05. Rear Intermediate Shown) 44. Hex Head Cap Screw 65. Pipe Connector
Shaft 24. Flat 45. Lock Washer 66. 90 Pipe Elbow
06. Not Used 25. Super Nut 46. Hex Head Cap Screw 67. Hose Clamp
07. Air Control Panel 26. Sealant 47. Hardened Washer 68. Double Hose Clamp
08. Hoist Gear Case 27. O-Ring 48. Hex Head Cap Screw 69. Hoist Drum Seal
Lubrication System 28. Lube Instruction 49. Conical Lock Pusher Tool (Not
09. Bushing Sign Washer Shown)
10. Bushing 29. Not Used 50. Street Elbow 70. Lifting Shackle
11. Hoist Coupling 30. Hoist Gear Case I/O 51. Pipe Nipple 71. Notice Sign
Guard Cable Installation 52. Quick Release Valve 72. Hoist Gear Case
12. Oil Seal Retainer 31. Dowel Pin 53. 90 Pipe Elbow Remote I/O
13. Gasket 32. Dowel Pin 54. Pipe Connector 73. Cover Ring
14. Not Used 33. Hardened Washer 55. Hose End 74. Cover Plate
15. Hand Hole Cover 34. Hex Nut 56. Hose Clamp 75. Gasket
16. Hand Hole Gasket 35. Rod Bolt 57. Hex Head Cap Screw 76. Hex Head Cap Screw
17. Breather Base 36. Hardened Washer 58. Lock Washer 77. Hardened Washer
A: Outboard Side B: Inboard Side
Figure 12-33: Legend for Figure 12-32
Refer to Figure 12-32 and remove the hoist gear case cover as follows:
1. Disconnect and tag the wiring to the hoist limit switch sensor located on the end of the intermediate shaft.
2. Remove the hoist limit switch sensor from the rear intermediate shaft, as described in Subtopic 12.3.8.4.
3. Remove the upper three cap screws (13) from each of the four of the intermediate shaft bearing retainers. Cap
Screws are torqued to 650 ft-lbs (881 N·m). Loosen the lower cap screws on all four bearing retainers.
4. Remove the upper four cap screws from the hoist drum shaft bearing retainer. Cap Screws are lubricated and
torqued to 200 ft-lbs (361 N·m). Loosen the lower cap screws on bearing retainer.
5. Remove the Supernuts™ from hoist drum shaft bearing block rod bolts (21). Refer to Subtopic 3.3.7.
6. Remove the two rod bolts (24), nuts (25) and hardened washers (26) from each of the four intermediate shaft
bearing blocks. Rod bolt nuts are lubricated and torqued to 3743 ft-lbs (5075 N·m).
7. Remove the hoist drum oil seal retainer ring sections and remove the oil seals from the oil seal cavity as nec-
essary.
8. Remove the hardware securing the hoist gear case cover to the base (01).

! WARNING
Failure to use an adequate lifting device or using improper lifting techniques during any
lifts for the gear case cover removal procedures could cause the cover to fall and crush,
causing severe personal injury or death. Be sure the lifting device has a rated capacity
equal to or exceeding the weight of the item being lifted. The gear case cover weighs
approximately 6,700 lbs (3,040 kg).
9. Using a suitable crane lift the hoist gear case cover assembly from the gear case base, being careful that the
sealant compound on the cover mating flange is equally free all around the gear case. Lift the cover through
the canopy opening and place the cover on blocks. The gear case cover weighs approximately 6,700 lbs
(3,040 kg).
12.3.5.6 Assembly
Preliminary Preparation
• Prior to the assembling the hoist gearcase it is recommended that you make sure:
• Bearing blocks are free from nicks and burrs.
• Seal surfaces are clean and free of old sealing material.
• Dowel pins are in the bearing blocks for pin mounted bearings.
• Oil dams should be in bearing blocks where specified and be in good condition. The oil dam should be con-
nected to the bearing block with an oil-tight weld.
• Gearcase is clean and clear of tools, rags, etc.
• Components have been inspected and/or repaired.
• Hoist gearcase base mounting pins are properly installed.

Hoist Drum Seals
LEGEND
01 02 03
01. V-ring Seal
02. Clamp
03. Seal Contact Surface
04. Capscrew
05. Seal Retainer and Gasket
06. Split Seal (2)
07. Seal Spacer
08. Distance - Seal to Face
45 to 57 mm (1.75 to 2.25 in.)
04
05
06
08 07 ES04398a01
Figure 12-34: Hoist Drum Seals
Three seals are used on the hoist drum. A V-ring seal is located inside of the gearcase, and its lip contacts the
cover and base. Two outer lip split seals provide added protection against leaks.
V-ring Seal. This seal is a primary component in the effort to prevent leaks, as it should deflect most of the gear oil
back into the gearcase and prevent it from leaking out. The V-ring seal (Item 01, Figure 12-34) is installed at the
factory, and the ends of the seal are permanently connected. Because the seal is not considered a field maintain-
able component, this section does not include detailed information. If the V-ring seal requires replacement, contact
your P&H MinePro Services representative for more information.
The V-ring seal should be fastened to the hoist drum with the seal retainer. Make sure the retainer is installed cor-
rectly to prevent movement of the seal. The correct distance of the seal from the inside face of the gearcase must
be maintained in order to ensure that the seal functions as designed. If the seal is too far away from the inside face,
the seal will leak. Do not grease the area under the V-ring seal where it contacts the drum, as this may allow the
seal to creep away from the inside face.
The correct distance measured from the seal to the inside face of the gearcase is shown as item 7 of Figure 12-34.
Also shown is the distance from the flange of the hoist drum (item 8 of Figure 12-34). The distance 7 is the signifi-
cant distance; the distance 8 is given for reference, as when the cover is off it is difficult to measure distance 7.
Technician Tip
The hoist drum split seals can be installed on the drum prior to the drum shaft assembly instal-
lation into the gearcase. They be installed or replaced after the drum shaft assembly has been

installed into the gearcase assembly, without removing the gear case cover. We believe it is
easier to install them before the gear case cover is installed, and the following discussion is
written to that condition. If seals are not installed at this time, they will be installed in Step 10.
Hoist Drum Split Seals. 1.With the hoist drum shaft assembly on blocks, install the two split seals (06, Figure 12-
34) on the hoist drum as follows:
A. Check the diameter of the hoist drum and the length of the seal springs.
NOTICE
New drum seals are cut to a specific length for a hoist drum seal area diameter and should not
be shortened. If the drum is on the small side of the specified limits, and the spring length is of
nominal length, the seal manufacturer recommends that the seal spring length be shortened to
adjust the seal for a tighter seal. However, it is recommended that the spring not be shortened
substantially, ideally it should be left at original length. Do not trim the ends of the seal, or problems
will result with the seal.
B. Make sure the hoist drum seal surface is thoroughly clean and free from nicks and scratches.
C. Lubricate the hoist drum seal surface and the seal lips with a light coat of multi-purpose grease.
D. Separate the ends of the first split seal (06, Figure 12-34) and place the seal around the hoist drum shaft
with the butt joint 45° from the top of the hoist drum. Ensure the seal spring cavity will face into the gearcase
when fully seated.
NOTICE
The two drum seals are split with the butt joints positioned 90° apart from each other, and both
located 45° from top center of the seal cavity. The seal springs have hook and eye fasteners
located 90° away from the butt joints of the seals.
E. Lubricate the seal spring and install the spring around the hoist drum shaft. Connect the spring ends and
insert the spring into the seal lip groove. Position the spring end connection 90° from the seal butt joint.
NOTICE
If spring is not strong enough to hold seal in place, duct tape ends together and in place until
ready to install in gearcase.
F. Install the seal spacer (04). The spacer is one-piece and is supplied long and must be trimmed so the ends
fit snugly and force the spacer against the bore of the case. Spacer is plastic and should also be taped in
place until ready to install in case.
G. Repeat Steps D through F for the other hoist drum seal and spring. Position the butt joint of the second seal
90° from the first seal.
H. Install gasket and seal retainer (05, Figure 12-34) with capscrews (03) on both the gearcase base and the
cover. The seal retainer is in four pieces, the gasket is in halves. If the gasket has round tabs on each end,
the tabs must be oriented so they will fit together when the cover is installed. Capscrews should only be
turned in a few turns. By leaving capscrews loose, the retainer and gasket can be held out away from seal
area for clearance when drum is installed.

Cover Installation
01 01 01 01
02 02 02 02
03 03
04 04
05 05
01 01
04 04 ES04862a01
02 02 02 02
01 01 01 01
LEGEND
01. Hex Head Cap Screw
02. Dowel Pin
03. Dowel Pin
04. Rod Bolt
05. Rod Bolt
Figure 12-35: Preparing Hoist Gear Case Base
2. Inspect the parting face of the gear case base and confirm that the mating surface is clean, dry, and free of
nicks or burrs.
3. Install the O-ring seals in the O-ring grooves.
4. Refer to Figure 12-35 and apply a coat of LocTite UltraBlack #598 (P&H Part Number 21Z587D2) to the twelve
shaded areas.
! WARNING
lifts for the gear case cover removal procedures could cause the cover to fall and crush,
resulting severe personal injury or death. Be sure the lifting device has a rated capacity
equal to or exceeding the weight of the item being lifted. The gear case cover weighs
5. Using a suitable crane, lift the hoist gear case cover assembly into position over the gear case base. The gear
case cover weighs approximately 6,700 lbs (3,040 kg).

Figure 12-36: V Ring Seal Clearance
6. Refer to Figure 12-36. Lubricate the surface where the V-ring seal lip will be in contact.
7. Lower the gear case cover until it approximately one inch (2.54 cm) above the gear case base. Observe the V-
Ring seal (refer to Figure 12-36) and be certain that the seal is not pinched or caught as the gear case cover is
being lowered. Use a screwdriver or other suitable tool to push inward on the seal so that it mates with the
inside surface of the gear case. Rotate the drum 180°. Check to ensure that the seal is pressing against the
inside of the surface at all points around the hoist drum.
8. Lower the gear case cover, being careful to align the bolt holes on the gear case cover to the holes on the mat-
ing flange of the gear case base.
9. Install -- but do not tighten -- fastening hardware. Where lubricating is directed, lubricate threads and under the
bearing surfaces with Never Seez or equivalent. Refer to Figure 12-35 and proceed as follows:
A. Item 04 (8 places):
1). Install a hardened washer and a hex nut on one end of each of eight rod bolts.
2). At each position, lubricate the threads on the other end of the rod bolt and insert the rod bolt into the
bores of the intermediate shaft bearing with hardened washers and hex nuts at the bottom. Install a
hardened washer and a hex nut at the upper end of the rod bolt. Do not tighten at this time.

H(TYP.)
.25
ES04782b01
Figure 12-37: Weld Flats to Bottom Nuts
3). On the lower end of each rod bolt, weld a flat onto the nut as shown in Figure 12-37.
B. Item 05 (4 places): Install unlubricated rod bolts with hardened washers and hex nuts. Also thread a Super-
Nut onto each rod bolt. Do not tighten at this time.
C. Item 01 (26 places): Lubricate hex head cap screws and install them with the heads downward. Install a
hardened washer and hex nut on the upper end and tighten the nuts finger tight.
D. Item 02 (8 places): Lubricate dowel pins and install with hardened washers and hex nuts. Do not tighten at
this time.
E. Item 03 (2 places): Lubricate dowel pins and install with hardened washers and hex nuts. Do not tighten at
this time.

10. Refer to Figure 12-38 install the hoist drum split seals (18Q360D5) as follows:
A. Check the diameter of the hoist drum and the length of the seal springs. If the drum is on the small side of
the specified limits and the spring length is of nominal length, shorten the spring as necessary. Do Not trim
the ends of the seal, or problems will result with the seal.
NOTICE
New drum seals are cut to a specific length for a hoist drum seal area diameter. The seal man-
ufacturer recommends that the seal spring length be shortened to adjust the seal for a tighter
seal.
B. Ensure the hoist drum seal surface is thoroughly clean and free from nicks and scratches.
C. Lubricate the hoist drum seal surface and the seal lips with a light coat of multipurpose grease. Do not
grease the outer part of the seal.
D. Separate the ends of one of the split oil seals and place the seal around the hoist drum shaft with the butt
joint 45° from the top of the hoist drum. Ensure the seal spring cavity will face into the gear case when fully
seated.
NOTICE
The two oil seals are split with the butt joints positioned 90° apart from each other, and both
E. Lubricate the seal spring and install the spring around the hoist drum shaft. Connect the spring ends and
F. Install the seal spacer.

G. Repeat Steps 4D through 4E for the remaining hoist drum seal and spring. Position the butt joint of the sec-
ond seal 90° from the first seal.
H. Confirm that the hoist drum oil seals are seated properly.
I. Tighten the seal retainer cap screws until the retainer just begins to flex (do not bend the retainer).
11. Refer to Figure 12-35 and continue to secure the gear case cover as follows:
A. Tighten the nuts of the grade 5 hex head cap screws (Item 01) in equal steps, alternating from one side of
the gear case to the other until all nuts are torqued to 488 ft-lbs (662 N·m).
B. Tighten the nuts on the intermediate shaft bearing block rod bolts (Item 04) in equal alternating steps from
one side to the other. Torque to 3,743 ft-lbs (5,074.8 N·m).
C. Tighten the Supernut™ on the hoist drum shaft bearing block rod bolts (Item 05). Refer to Subtopic 3.3.7.2.
D. Tighten the nuts on dowel pins (Item 02). Torque the nuts to 840 ft-lbs (1,139 N·m).
E. Tighten the nuts on dowel pins (Item 03). Torque the nuts to 840 ft-lbs (1,139 N·m).

02
13
07 01 10 14
05 04 03
23
12
26 15
27
09
25 17
18
24 19
20 08
21
13
22 11
11 14
13
14
TC0135D
Legend 07. Bearing Retainer 14. Lock washer 22. Shim

01. Pinion Shaft 08. Bearing Retainer 15. Lock Wire 23. O-ring
02. Gear 09. End Plate 17. Shim 24. Shaft Extension *
03. Spacer 10. O-ring 18. Shim 25. Oil Seal *
04. Spacer 11. Dowel Pin 19. Shim 26. Cap Screw *
05. Bearing 12. Cap Screw 20. Shim 27. Washer *
06. Bearing 13. Cap Screw 21. Shim
* These components are only on rear intermediate assembly, where the limit switch assembly is attached.
Figure 12-39: Intermediate Shaft Assembly (R31793F1&F2)
12. Refer to Figure 12-39 and install the intermediate shaft bearing retainers as follows:
A. Lubricate O-rings (10) and install in bearing retainers (07) and (08).
B. Install cap screws (13) and lockwashers (14).

C. Torque cap screws (13) evenly and in steps to 650 ft-lbs (881 N·m).
01
02
03
04
ES04863a01
LEGEND
01. Cover Ring 03. Cover Plate Bolt
02. Cover Ring Bolt 04. Cover Plate
Figure 12-40: Hoist Drum Shaft Cover
13. Refer to Figure 12-40 and install the cover assembly on the hoist drum shaft bearing block as follows:
A. Install cover ring (01). Lubricate the cover ring bolts and tighten until snug. Bearing should be tight against
inner shoulder.
B. Measure gap between the cover ring (01) and the gear case with a feeler gauge in four places. Use the
average gap for shim calculation.
C. Remove the ring (01) and install a shim pack equal to the measured gap minus .010" (0.254 mm).
D. Install the ring (01) with shims (09). Torque cover ring bolts to 200 ft-lbs (271 N·m).
E. Install cover plate (04). Lubricate the cover plate bolts (03) and torque to 56 ft-lbs (75.9 N·m).
12.3.5.7 Lubrication
Lubrication of the hoist gear case is provided by the hoist lubrication system. For theory of operation, refer to Sub-
topic 12.2.9; for maintenance procedures for hoist lubrication system components, refer to individual component
maintenance procedures beginning with Subtopic 12.3.12.

12.3.6 Hoist First Reduction Shaft Assembly R32779F3
33
34
37
33
12 14 34 09 28 23 02 01 03 25 29
26
36 10
22
18
27 21
04 24 27 36
20
06 24
35
15
16
35 13 19 32 07 05 08 32
30
31
11
30 17
31
ES04864a01
LEGEND 13. End Plate Retainer 26. O-ring

01. First Reduction Hoist Pinion 14. Coupling Hardware Kit 27. Shims
02. Roller Bearing 15. Disc Brake Hub 28. Shims
03. Roller Bearing 16. Disc Brake 29. Shims
04. Bearing Spacer 17. Disc Brake Cover 30. Cap Screw
05. Bearing Spacer 18. End Plate Retainer 31. Lock Washer
06. Bearing Spacer 19. Seal Retainer 32. Setscrew
07. Bearing Capsule 20. Oil Seal 33. Cap Screw
08. Bearing Capsule 21. Oil Seal 34. Washer
09. Bearing Retainer 22. O-ring 35. Cap Screw
10. Bearing Retainer 23. O-ring 36. Tie Wire
11. Seal Retainer 24. O-ring 37. Cap Screw
12. Coupling Half 25. O-ring
Figure 12-41: First Reduction Shaft Assembly (R32779F3)
The hoist first reduction shaft cannot be removed from the hoist gear case base as an assembly. Removal of the
first reduction shaft is accomplished by disassembling it from the hoist gear case base. Refer to Figure 12-41 and
disassemble the first reduction shaft as follows:

! CAUTION
Rope weight can cause system components to rotate and crush, resulting in personal
injury. Remove the hoist ropes from the hoist drum before performing removal of the
first reduction shaft.
2. Remove the hoist ropes from the hoist drum.
3. Refer to Subtopic 5.11.6 and remove the hoist disc brake, including the disc brake hub.
4. Disconnect coupling half (12) and move the hoist motor back about six inches to allow room to remove cap
screws (35) that secure end plate retainer (13).
! WARNING
Failure to use an adequate lifting device or use of improper lifting techniques can cause
the first reduction shaft to fall causing severe injury or death. Be sure the lifting device
has a rated capacity exceeding the weight of the item being lifted.
5. Remove tie wire (36), cap screws (35) and retainer (13) from shaft (01). Cap Screws are torqued to 266 ft-lbs
(361 N·m). Shims (27) will now be free.
6. Remove coupling half (12), spacer (04), and O-ring (24).
7. Support shaft (01) so it can not fall.
8. Using a suitable puller, remove shaft (01) from the disc brake side of the gear case. Bearing capsule (08) and
other parts of the disc brake end of the gear case will come off on shaft (01). Items on the motor side of the
shaft pinion will remain in place, except the cone of bearing (02) which will come out on the shaft.
9. Disassemble the parts remaining on shaft (01) as necessary.
10. Remove the parts on the hoist motor side of the gear case as follows:
A. Remove cap screws (33), lockwashers (34) and bearing retainer (09). Cap Screws are torqued to 266 ft-lbs
(361 N·m). Shims (28) will now be free.
B. Remove hardware (30 and 31) to remove seal retainer (19) and seal (20). Retainer seal cap screws are
torqued to 9 ft-lbs (12.2 N·m).
C. Pull the outer race of bearing (02) from bearing capsule (07) and then remove the bearing capsule. Remove
and discard O-rings (22 and 23).
Inspection of the first reduction shafts is performed during periodic inspection and overhaul of the hoist gear case
and transmission.
Clean and inspect all parts. Check the parts visually for cracks, breaks, or excessive wear.
P&H Mining Equipment recommends replacement of all bearings upon reassembly of any major component; how-
ever, if the bearing is intended to be re-used, it must be inspected. Visually inspect the exterior of the bearings for

cracks in the races or broken or damaged separators or rollers. If the bearing has been overheated, it will be a
brownish blue or bluish black color. If any of these signs appear, replace the bearing.
Repair of an first reduction shaft assembly is limited to the replacement of all O-rings, and parts found to be dam-
aged or excessively worn.
12.3.6.3 Assembly
Refer to Figure 12-41 and assemble the first reduction shaft as follows:
2. Install the heated cone of bearing (03) on the disc brake side of shaft (01). Make sure the heel of the bearing
cone is seated against the shoulder on the shaft.
Figure 12-42: Double Tapered Roller Bearing Assembly
NOTICE
Bearing cones must be preheated prior to installation on the shaft. Extreme care must be taken
to assure bearings are never heated over 300°F (148°C), since overheating will damage the
bearings.
3. Install the spacer of bearing (03) on the disc brake side of shaft (01). Make sure the spacer is seated against
the bearing cone.
NOTICE
Some double row matched bearings are etched with letters on the sides of the cones and cups.
It does not matter which side goes on the shaft first. The important thing is that the lettered parts
match when the bearing is installed, as shown in Figure 12-42. “A” side of cone matches “A”
side of cup. “C” side of cone matches “C” side of cup.

4. Install the cup of bearing (03) in bearing capsule (08).
5. Lubricate and install new O-ring (25) in the groove on the outside of bearing capsule (08).
6. Place bearing capsule (08) over the disc brake side of the shaft until the bearing cup is seated on the bearing
cone.
7. Install the heated cone of bearing (03) on the disc brake side of the shaft until the cone is seated in the bearing
cup.
8. Install spacer (05) on the hoist motor side of shaft (01).
9. Using a suitable lifting device, install the partially assembled shaft into the disc brake side of the gear case
base. Slowly rotate the bearing capsule to avoid pinching or stretching O-ring (25) as the bearing capsule is
installed. The partially assembled shaft weighs approximately 450 lbs (204 kg)
TC2064a
Figure 12-43: Bearing Capsule
10. Rotate the bearing capsule until the flat area on the bearing capsule is aligned with the lower left screw hole
(refer to Figure 12-43).
NOTICE
After installation, the flat on bearing capsule (08) should be aligned with the lower left screw
hole to permit setscrew (32) to be installed and to prevent rotation of the bearing capsule (Fig-
ure 12-43).
11. Install new seal (21) in the bore in retainer (10). Secure the seal in place with seal retainer (11), lock washer
(31) and cap screw (30). Torque cap screw (30) to 9 ft-lbs (12.2 N·m).
12. Lubricate and install new O-ring (26) in the groove on the face of the retainer.
13. Install retainer (10) on the disc brake side of the gear case. Make sure that the hole for setscrew (32) is
aligned with the flat on bearing capsule (08) at the lower left screw hole.
14. Install cap screws (33) with washers (34). Torque the cap screws to 265 ft-lbs (359.3 N·m).
15. To determine the thickness of the shim pack for retainer (10), proceed as follows:

A. Make sure that the retainer cap screws (33) are torqued to 265 ft-lbs (359.3 N·m) to seat the bearings.
B. Loosen the cap screws, then tighten to 35 ft-lbs (47.5 N·m).
C. Measure the gap between the gear case and the retainer at four locations, 90° apart.
D. The shim pack should equal the average gap plus .000 to .002" (.000 to .051 mm).
16. Install the shim pack, retainer (10) and cap screws (33) with washers (34). Torque the cap screws to 265 ft-lbs
(259.3 N·m).
17. Install setscrew (32) x 1¼" Hex Socket Set Screw with knurled cup point). Torque the setscrew to 30 ft-lbs
(40.7 N·m).
18. Lubricate and install new O-ring (24) in the groove in the bore of spacer (06). Install the spacer on the disc
brake side of the shaft with the beveled end of the spacer seated against the bearing cone.
19. Lubricate and install new O-ring (25) in the groove in the outside of bearing capsule (08).
20. Install bearing capsule (07) over the motor end of shaft (01). Rotate the bearing capsule to avoid pinching or
stretching O-ring (23) as the bearing capsule is installed.
NOTICE
After installation, the flat on bearing capsule (07) should be aligned with the lower left screw
hole to permit setscrew (32) to be installed and to prevent rotation of the bearing capsule (see
Figure 12-43).
21. Install bearing (02) on the motor side of shaft (01). Make sure that the bearing is seated against spacer (05).
22. Install new seal (20) in the bore in retainer (09). Secure the seal in place with seal retainer (19), lock washer
(31) and cap screw (30).
23. Lubricate and install new O-ring (22) in the groove on the face of the retainer.
24. Install retainer (09) over the motor end of shaft (01), making sure that the hole for setscrew (32) is aligned with
the flat on bearing capsule (07). Install cap screws (33) with washers (34). Torque the cap screws to 265 ft-lbs
(259.3 N·m).
25. To determine the thickness of the shim pack for retainer (09), proceed as follows:
A. Make sure that the retainer cap screws are torqued to 265 ft-lbs (259.3 N·m) to seat the bearings.
B. Loosen the cap screws, then tighten to 35 ft-lbs (47.5 N·m).
C. Measure the gap between the gear case and the retainer at four locations, 90° apart.
D. The shim pack should equal the average gap plus .000 to .002" (.000 to .051 mm).
26. Install the shim pack, retainer (09) and cap screws (33) with washers (34). Torque the cap screws to 265 ft-lbs
(259.3 N·m).
27. Install setscrew (32). Torque the setscrew to 30 ft-lbs (40.7 N·m).

28. Lubricate and install new O-ring (24) in the groove in the bore of spacer (04). Install the spacer on the motor
side of the shaft with the beveled end of the spacer seated against the bearing race.
29. Install coupling half (12) on the motor end of shaft (01).
30. To determine the thickness of the shim pack between retainer plate (13) and the end of the shaft, proceed as
follows:
A. Install retainer plate (13) and cap screws (35). If necessary, tighten the cap screws to make sure that the
coupling half is seated against spacer (04). Loosen the cap screws and re-tighten snug tight.
B. Measure the gap between retainer plate (13) and the end of the shaft.
C. The shim pack should equal the measured gap less 0.010".
31. Install the shim pack, retainer plate (13) and cap screws (35). Torque the cap screws to 265 ft-lbs (259.3 N·m).
Secure the cap screws with tie wire (36).
32. Install brake hub (15) on shaft (01).
33. Install retainer plate (18) and cap screws (35).
34. To determine the thickness of the shim pack between retainer plate (18) and the end of the shaft, proceed as
follows:
A. Install retainer plate (18) and cap screws (35). If necessary, tighten the cap screws to make sure that the
coupling half is seated against spacer (06). Loosen the cap screws and re-tighten snug tight.
B. Measure the gap between retainer plate (18) and the end of the shaft.
C. The shim pack should equal the measured gap less 0.010".
35. Install the shim pack, retainer plate (18) and cap screws (35). Torque the cap screws to 265 ft-lbs (259.3 N·m).
Secure the cap screws with tie wire (36).
36. Install the disc brake as described in the Assembly and Installation topic in Subtopic 5.11.6.
37. Connect and align the hoist motor coupling as described in Subtopic 12.3.3.2.
12.3.7 intermediate Hoist Shaft R31793F1 (front) and R31793F2 (rear)
Refer to Figure 12-44 and disassemble the intermediate hoist shaft as follows:
2. Remove lockwire (06), cap screws (07), end plates (08) and shim packs (09 and 21) from the ends of pinion
shaft (17).Cap Screws are torqued to 650 ft-lbs (881 N·m).
3. On the rear shaft only, remove cap screws (14), lockwashers (15) and shaft extension (16).Cap Screws are
torqued to 650 ft-lbs (881 N·m).
4. Using a suitable puller, remove bearings (10 and 19) from the ends of shaft (17).

LEGEND
02. Washer 13. Gear
03. Retainer 14. not used
04. Oil Seal 15. not used
05. O-ring 16. Extension Shaft
06. Lockwire 17. Pinion Shaft
08. End Plate 19. Bearing
09. Shims 20. O-ring
10. Bearing 21. Shims
11. Dowel Pin 22. Bearing Retainer
Figure 12-44: Intermediate Hoist Shaft (R31793)

5. Remove spacer (18) from the pinion end of shaft (17).
6. Using a suitable puller, remove gear (13) from the shaft.
12.3.7.2 Inspection
! WARNING
Unexpected gear movement can pinch or crush during close inspections resulting in
personal injury. View gears through inspection openings and keep hands out until the
system is shut down and locked out.
Inspect the intermediate shaft gear and pinion annually for cracks and fractures. Inspection covers have been pro-
vided in the hoist gear case to gain access to the gearing.
12.3.7.3 Repair
Repair of the intermediate pinion shaft assembly consists of replacing all excessively worn or broken parts.
12.3.7.4 Assembly
To assemble the intermediate shaft assembly, proceed as follows (see Figure 12-44):
NOTICE
Bearing cones must be preheated prior to installation on the shaft. Extreme care must be taken
to assure bearings are never heated over 300°F (148°C), since overheating will damage the
bearing.
2. Using a press, press gear (13) on pinion shaft (17). Gear is symmetrical and can be reversed.
3. On the spur gear end (left end) of shaft (17), slide spacer (12) against the hub of spur gear (13).
NOTICE
Double row tapered roller bearings on this machine are matched bearings. Parts of a matched
bearing should not be interchanged with parts of identical bearings. The bearing cones and
bearing cup of a matched bearing must be installed on a shaft in the same order that the new
bearing comes packaged in.
4. Preheat and install one cone of bearing (10) tight against spacer (12).
NOTICE
Some double row matched bearings are etched with letters on the sides of the cones and cups.
It does not matter which side goes on the shaft first. The important thing is that the lettered parts

match when the bearing is installed as shown in Figure 12-42. “A” side of cone matches “A”
side of cup, “C” side of cone matches “C” side of cup.
5. Install the cup of bearing (10) over the installed cone. Install the cone spacer and the remaining preheated
cone over pinion shaft (17) into the bearing cup.
6. Install spacer (18) and preheat and install one cone of bearing (19) on the other end of pinion shaft (17).
7. Install the bearing cup, cone spacer and the remaining cone of bearing (19).
8. On the rear intermediate shaft only, install extension shaft (16) and secure with cap screws and washer.
9. To determine the thickness of shim packs (21 and 09), proceed as follows:
A. Install end plates (08) with cap screws (07) on each end of shaft (17). Tighten the cap screws finger tight.
B. Measure the gap between each end plate (08) and the ends of the shaft.
C. Make a shim pack for each end of the shaft using shims (21 and 09) equal to each measured gap less
0.010".
10. Remove the cap screws and retainers.
11. Install shim packs (09 and 11) and end plates (08) with cap screws (07). Tighten cap screws (07) to 650 ft-lbs
(881 N·m). Secure the cap screws in place using lockwire (06).

02
13
07 01 10 14
05 04 03
23
12
26 15
27
09
25 17
18
24 19
20 08
21
13
22 11
11 14
13
14
TC0135D
Legend 07. Bearing Retainer 14. Lock Washer 22. Shim

01. Pinion Shaft 08. Bearing Retainer 15. Lock Wire 23. O-ring
02. Gear 09. End Plate 17. Shim 24. Shaft Extension *
03. Spacer 10. O-ring 18. Shim 25. Oil Seal *
04. Spacer 11. Dowel Pin 19. Shim 26. Cap Screw *
05. Bearing 12. Cap Screw 20. Shim 27. Washer *
06. Bearing 13. Cap Screw 21. Shim
* These components are only on rear intermediate assembly where the limit switch assembly is attached.
Figure 12-45: Intermediate Shaft Assembly (R31793F1&F2)
Refer to Figure 12-45 and install the intermediate hoist shaft assemblies into the hoist gear case as follows:

Check that the intermediate shaft bearing blocks in the gear case are clean and free from burrs, and ensure that
dowel pins are installed in the bottom of the bearing blocks.
! WARNING
lifts for the intermediate shaft installation procedures could cause the item being lifted to
fall, causing severe personal injury or death. Be sure the lifting device has a rated capac-
ity equal to or exceeding the weight of the item being lifted.
2. Lift the intermediate pinion shaft assembly into position in the hoist gear case. Make sure the pinion and gear
teeth engage properly with the teeth on the input pinion, and on the hoist drum gear. The intermediate shaft
assembly weighs approximately 5,000 pounds (2,270 kg).
CAUTION
When lifting the intermediate shaft assemblies into position, insure that the bores in the
bearing races mounted on the shaft assembly are aligned with the dowel pins in the gear
case bearing block, or damage to the bearings may result. Also make sure that the pins
are the proper length and are seated properly in the holes. If the pins are too high, dam-
age to the bearings will result.
3. Install the gear case cover as described below in the “Hoist Gear Case Cover Installation” topic.

12.3.8 Hoist Limit Switch Sensor 979J247F1
01
02
04
05 08
06
07 09
03
10
11
12
13
19
18
17
A01
16
14
15
LEGEND 05. Retainer Plate 10. Locking Screw 14. Mounting Bracket
01. Coupling 06. Locking Plate 11. Coupling Guard 15. Nut
02. Resolver 07. Nut 12. Lock Washer 16. Lock Washer
03. Conduit Connector 08. Locking Screw 13. Socket Head Cap 17. Lock Washer
04. Rubber Pad 09. Cover Screw 18. Cap Screw
12.3.8.1 Inspection
Inspect the hoist limit switch assembly during Preventive Maintenance periods. Check for integrity of components,
secure mounting, and missing or broken parts.
Consult with operators to ensure that hoist limits are working properly. If erratic performance occurs and the pro-
gramming is correct, check for loose or damaged mounting hardware between the adapter shaft on the hoist inter-
mediate shaft, on the coupling, or on the sensor shaft.
12.3.8.2 Adjustment
The sensor itself requires no adjustment. Hoist limits are adjusted through the GUI. Refer to the Operator’s Manual
for information regarding setting hoist limits.

12.3.8.3 Maintenance
Maintenance is limited to the replacement of missing or damaged components.
12.3.8.4 Replace Hoist Limit Switch Assembly
Refer to Figure 12-46 and replace the resolver as follows:
1. Remove locking screws (08) and cover (09) from the sensor assembly.
2. Remove locking screws (10), lock washers (16), nuts (15) and coupling guard (11).
3. Remove coupling connection hardware.
4. Mark and disconnect the resolver wiring.
5. Straighten the ends of locking plates (07). Remove nuts (08), locking plates (07), retainer plate (06), rubber pad
(05) and resolver (02).
6. Remove coupling (01) from the resolver shaft.
7. Install the new resolver with coupling as follows:
A. Measure the free length of coupling (01) and record.
B. Install the coupling on the resolver shaft leaving a 0.20" (5.1 mm) gap between the end of the coupling and
the end of the resolver housing.
C. Install new resolver (02) with coupling into mounting bracket (14) making sure that the coupling slides onto
the extension shaft properly.
D. Measure the length of the coupling. Make sure that the length of the coupling is within 0.020" (0.5 mm) of
the length measured in Step A.
8. Install rubber pad (04), retainer plate (05) and locking plates (06). Thread nuts (07) on rod bolts (19) and
tighten securely. Do not overtighten.
9. Bend the ends of locking plates (06) over the flat of each nut (07).

10. Tighten the coupling hardware.
11. Connect the resolver wiring.
12. Install coupling guard (11) with locking screws (10), lock washers (16) and nuts (15).
13. Install cover (09) with locking screws (08).
12.3.8.5 Replace Hoist Limit Switch Sensor
Refer to Subtopic 12.3.8.5 and remove the limit switch sensor from the assembly as follows:
1. Remove locking screws (10), lock washers (16), nuts (15) and coupling guard (11) from the sensor assembly.
3. Remove coupling connection hardware from the crowd gear case side of the coupling.
4. Remove socket head cap screws (13) and lock washers (12), then remove the remainder of the sensor assem-
bly from the side of the gear case using care not to damage coupling (01).
5. Remove coupling (01) from the resolver shaft. Measure and record the free length of the coupling.
6. Install the coupling on the resolver shaft leaving a 0.20" (5.1 mm) gap between the end of the coupling and the
end of the resolver housing. Lift the sensor assembly into place on the side of the crowd gear case making
sure that the coupling slides onto the extension shaft properly.
7. Install socket head cap screws (13) with lock washers (12). Tighten the cap screws to the torque specified in
the torque table in Topic 3.3.
8. Install the coupling cap screw on the crowd gear case side of the coupling.
9. Measure to confirm that the length of the coupling is within 0.020" (0.5 mm) of the length measured in Step 5.
12.3.9 Hoist Drum Shaft R58153
12.3.9.1 Inspection
Inspect the hoist drum every 750 hours checking the following:
• Check the hoist drum visually for wear and overall drum surface condition.
• Check the hoist drum sidestand for cracks.
• Check the hoist drum sidestand bearing block for cracks. Check bolts for security.
• Check hoist drum oil seal for leaks.
• Check the hoist drum spur gear inside the hoist gear case. If the gear is worn on only one side of the teeth,
the gear can be reversed.

Figure 12-48: Hoist Drum Shaft Assembly R58153

LEGEND 17. Hex Nut 34. Drilled Head Cap Screw

01. Shim 18. Spacer 35. Conical Lock Washer
02. Shim 19. Hoist Gear 36. Hex Head Cap Screw
03. Shim 20. Hoist Drum 37. Lube Fitting
04. Bearing Retainer Plate 21. Coupling Bolt 38. Cover
05. Tie Wire 22. Hardened Washer 39. Gasket
06. Drilled Head Cap Screw 23. Hex Nut 40. Super Nut
07. Hardened Washer 24. Seal 41. Bearing Block
08. Shim 25. Green Rubber Strip 42. Shim
09. Shim 26. Oil-Split Seal 43. Shim
10. Shim 27. Oil Seal Spacer 44. Shim
11. Bearing Retainer 28. Pipe Cap 45. Rod Bolt
12. Spherical Bearing 29. Shim 46. Hardened Washer
13. Spacer 30. Shim 47. Hex Nut
14. Split Collar 31. Shim 48. Spherical Bearing
15. Hex Head Cap Screw 32. Bearing Retainer Plate 49. Spacer
16. Hardened Washer 33. Hardened 50. Hoist Drum Shaft
Figure 12-49: Legend for Figure 12-48
Refer to Figures 12-49, and 12-48 and disassemble the hoist drum shaft as follows:
1. Remove lockwire (05), cap screws (06), retainer (04) and shims (08-10) from the gear end of the drum shaft.
2. Using a suitable puller, remove bearing (12).
3. Remove spacer (13), split collar (14) and spacer (18) from the end of the drum shaft.
! WARNING
Falling hoist drum gear (19) can crush causing severe personal injury or death. Use a
suitable lifting device and/or blocking to support the hoist drum gear before removing
gear mounting hardware.
4. Use a suitable lifting device and/or blocking to support the hoist drum gear (19) when removing gear mounting
hardware.
5. Nuts (23), washers (22) and coupling bolts (21) must be removed to remove the gear (19). The nuts are welded
to the coupling bolts. These coupling bolts must be cut to be removed. New coupling bolts and nuts must be
used for assembly.
6. Remove cap screws (36), washers (35), cover plate (38) and gasket (39) from bearing block (41).
7. Remove lockwire (05), cap screws (36), retainer (32) and shims (29-31) from the end of the shaft.
! WARNING
Falling hoist drum shaft bearing block (35) can crush causing severe personal injury or
death. Use a suitable lifting device and/or blocking to support the bearing block before
removing it from the shaft.

8. Use a suitable lifting device and/or blocking to support the hoist drum shaft bearing block when removing it
from the shaft.
9. Using a suitable puller, remove bearing (42) from the end of the shaft.
10. Remove spacer (43) from the drum shaft.
11. Using a suitable press, remove drum (20) from shaft (44).
12.3.9.3 Repair
Contact your local MinePro Services representative for information on repairing the hoist drum lagging.
12.3.9.4 Assembly
Refer to Figures 12-49, and 12-48 and assemble the hoist drum shaft as follows
1. Using a suitable press, press drum shaft (50) into the hoist drum. Insert the shaft from right to left. The right
side of the drum is opposite the gear end. Make sure that the drum is seated against the shoulder on shaft.
NOTICE
The bolts that secure the hoist gear to the drum are fitted bolts, and must be frozen prior to
assembly.
2. Obtain new body fitted coupling bolts (21) and freeze them (P&H recommends using dry ice) prior to assembly.
NOTICE
Body fit coupling bolts are specified as P&H P/N 20Z1940D24. These are ASTM Grade A490,
1½" (6UNC) X 8¾". Do not use bolts that do not meet these specifications.
Figure 12-50: Hoist Drum Gear Bolt, 20Z1940D24
3. Install gear (19) on the hoist drum (20). Make sure the bores in the gear and drum flange are properly aligned
and the gear is fitted tightly against the hoist drum.
4. Carefully, install two freeze-treated bolts (21) 180° apart, followed by two more 90° displaced from the first two.
Install the associated nuts and tighten the nuts snug tight. Continue to install the rest of coupling bolts and nuts,
using the same alternating steps until all coupling bolts are installed.
5. Torque the coupling bolts (21) to 2370 ft-lbs (3213 N·m) using the same pattern used in the previous step.
Then weld the nuts (23) to the coupling bolts (21). Do not weld on the gear!

6. Install spacer (18) and split collar (14) on the gear end of shaft (50).
CAUTION
Bearing (12) must be preheated prior to installation on the shaft. Extreme care must be
taken to assure bearings are never heated over 300°F (148°C).
7. Heat and install bearing (12) on the gear end of shaft (50).
8. To determine the thickness of shim pack to be installed under the bearing retainer plate (04), proceed as fol-
lows:
A. Install the bearing retainer plate (04) on the gear end of shaft (50) with cap screws (06). Tighten the cap
screws finger tight.
B. Measure the gap between retainer (04) and the end of shaft (44).
C. The thickness of shim pack is equal to the measured gap less 0.010".
9. Remove cap screws (06) and retainer (04).
10. Use shims (08-10) to prepare a shim pack with a thickness as determined in Step 8. Install shim pack, retainer
(04) and cap screws (06). Torque the cap screws to 840 ft-lbs (1,139 N·m).
11. Secure cap screws (06) with lock wire (05).
12. Install spacer (49) on the bearing block end of shaft (50) with the beveled surface on the inside diameter of the
spacer facing the shoulder on the shaft.
13. Install heated bearing (48) on the bearing block end of shaft (50).
14. To determine the thickness of shim pack to be installed under the bearing retainer plate (32), proceed as fol-
lows:
A. Install retainer (32) on the bearing block end of shaft (50) with cap screws (34). Tighten the cap screws fin-
ger tight.
B. Measure the gap between retainer (32) and the end of shaft (50).
C. The thickness of shim pack is equal to the measured gap less 0.010".
15. Remove cap screws (34) and retainer (32).
16. Install shim pack (10) with a thickness as determined in Step 8, retainer (04) and cap screws (06). Torque the
cap screws to 840 ft-lbs (1,139 N·m).

17. Secure the cap screws with lock wire (05).
Figure 12-51: Secure the Bearing Block to the Drum
18. Using a suitable lifting device, install bearing block (41) on bearing (48). Install a temporary holding rod similar
to that shown in Figure 12-51 to secure the bearing block.
19. Install gasket (39) and cover (38) with cap screws (36) and washers (35).
Technician Tip
The hoist drum shaft assembly must be aligned to the gear case by installing the proper amount
of shims under and/or in front of the bearing block at the hoist drum side stand. If the gear case
is being reassembled without changing major internal components, make sure to install the
same shims as were removed during removal of the assembly. If major internal components
have been changed, the mesh between the intermediate shaft pinions and the hoist drum gear
must be checked before securing the hoist drum sidestand bearing block. Refer to Subtopic
12.3.9.6, and contact your local P&H MinePro Service Representative for further assistance.
! WARNING
lifts for the hoist drum shaft installation procedures could cause the item being lifted to
fall causing severe personal injury or death. Be sure the lifting device has a rated capac-
ity equal to or exceeding the weight of the item being lifted.
2. If necessary, remove the gear case cover as described in Subtopic 12.3.5.5.

Technician Tip
If the hoist drum seals are to be partially installed at this time and installation completed during
the gear case cover installation procedure, proceed to Step 3. If the hoist drum seals are to be
installed after the hoist gear case cover is back in place, proceed to Step 5.
3. Install the lower sections of the split seal ring and seal retainer onto the hoist gear case base. Leave the seal
retainer cap screws loose.
4. With the hoist drum shaft assembly on blocks, install the two oil seals on the hoist drum as follows:
A. Check the diameter of the hoist drum and the length of the seal springs. If the drum is on the small side of
the specified limits and the spring length is of nominal length, shorten the spring as necessary. Do Not trim
the ends of the seal, or problems will result with the seal.
NOTICE
New drum seals are cut to a specific length for a hoist drum seal area diameter. The seal man-
ufacturer recommends that the seal spring length be shortened to adjust the seal for a tighter
seal.
B. Ensure the hoist drum seal surface is thoroughly clean and free from nicks and scratches.
C. Lubricate the hoist drum seal surface and the seal lips with a light coat of multipurpose grease. Do not
grease the outer part of the seal.
D. Lubricate the v-ring seal sealing surface on the inside of the hoist gear case cover with multipurpose grease.

E. Separate the ends of one of the split oil seals and place the seal around the hoist drum shaft with the butt
joint 45° from the top of the hoist drum. Ensure the seal spring cavity will face into the gear case when fully
seated.
NOTICE
The two oil seals are split with the butt joints positioned 90° apart from each other, and both
F. Lubricate the seal spring and install the spring around the hoist drum shaft. Connect the spring ends and
G. Install the seal spacer.
H. Repeat Steps 4D through 4E for the remaining hoist drum seal and spring. Position the butt joint of the sec-
ond seal 90° from the first seal.
I. After the hoist gear case cover is installed, insert the hoist drum seals by starting the butt end joint of the
inner seal into the cavity, and carefully working the rest of the seal into the cavity by working in small incre-
ments around the circumference of the drum. The lip of the seal should compress and allow the entire seal
to seat without trimming the ends of the seal. Seat the outer seal in the same way.
5. Using a suitable lifting device, lift the hoist drum shaft assembly into position on the hoist gear case and side
stand bearing blocks. The hoist drum shaft assembly weighs approximately 53,000 lbs (24,040 kg).
NOTICE
As the hoist drum is being lowered into the gear case, insure the oil seals are aligned properly
with the seal cavities in the hoist gear case (refer to Figure 12-52). Make sure the lip of the V-
ring seal is not pinched or damaged.
6. Secure the bearing block to the side stand with rod bolts. Supernuts™ are used for the top nuts and standard
nuts for the bottom. Refer to Subtopic 3.3.7.2 for the correct Supernut installation procedure.
7. Weld the bearing block to the side stand. Be sure the welder ground strap is attached to the side stand.

12.3.9.6 Alignment
After installation, the hoist drum must be aligned to the transmission to minimize end loading of the gear teeth and
pitting on the mating pinions. Pitting typically results on one end of the gear teeth on one of the pinions and on the
other end on the opposite pinion.
Figure 12-53: Hoist Drum Shaft Bearing Block Shim Locations
Alignment of the hoist drum gear requires shimming under and in front of the side stand bearing block. The objec-
tive of this procedure is to achieve equal backlash across the gear face and to obtain acceptable contact patterns
in the front and rear gear mesh.
Materials Required
• Solder (~.125" diameter solid - for best results, do not use hollow core solder)
• Dykem Hi-Spot Blue 107, Prussian Blue or PT-650 Tooth Marking Grease
• 3M Scotch-brand #845 Book Tape (2 ½ - 3" wide)
• Duct tape
• Degreaser
• Rags
Machine Conditions
To ensure clarity, the photographs in this section were taken with the gear case cover removed. The ideal circum-
stance to perform the alignment, however, is on a fully assembled machine. If this is not practical in any given situ-
ation, be aware and take note of machine conditions that can affect the outcome of this procedure. For example:
• Is the machine complete?
• Is the boom pinned and raised?
• Is all of the counterweight installed?

• Is all cribbing removed from under counterweight?
When all components (boom, counterweight, gear case cover) are in place, remove the hoist gear case inspection
covers from over the second reduction pinions. Sufficient space exists to reach into the gear case to position the
solder with duct tape about 1½" from each end of the gear. Roll the solder through the gear mesh far enough to
provide compression of the solder, then roll the gearing back and remove the solder pieces (be careful to note
which way they were placed on the gearing) and measure them with a micrometer. Also conduct the gear contact
inspection at this time. Use the results of these inspections to determine the need to shim under the hoist drum
shaft bearing block or shim in front of the shear ledge on the side stand (moving the bearing block toward the rear
of the shovel) to properly align the hoist drum gear with the hoist gear case. Consult your local P&H MinePro Ser-
vices representative for assistance if required.
Checking Backlash
04 02
03 01 LEGEND
01. Front Inboard
02. Front Outboard
03.Rear Inboard
05
04. Rear Outboard
05. Toward Front of
Machine
ES04868a01
Figure 12-54: Measurement Location
Prior to taking any measurements, if the gear case cover is not installed or torqued down, make sure all bearings
are properly seated in the gear case bores. This can be visually checked with feeler gages.
Measure total backlash in the front and rear pinion/gear mesh. Two solder samples will be taken for the front mesh
and two for the rear mesh (refer to Figures 12-55, and 12-56). Samples 1 and 2 will be front inboard and outboard,
respectively. Samples 3 and 4 will be rear inboard and outboard, respectively. Proceed as follows:
1. Attach solder to the front pinion 1.50" from each end. Position the solder in the pinion tooth as shown in Figure
12-55 with ends attached to adjacent teeth with duct tape.

Figure 12-55: Applying Solder to Front Pinion
2. When checking the front mesh, rotate the rear pinion by turning the rear input coupling, and vice versa. Rotate
the input coupling clockwise (while facing gear case) until the 2nd reduction pinion rotates one complete turn.
Figure 12-56: Measuring Solder Thickness on Front Pinion
3. Carefully remove and measure each solder sample from the pinion, making sure not to mix up locations. Mea-
sure the thickness near the pitch line using a micrometer or vernier caliper as shown in Figure 12-56.

1st Backlash Measurements
Front Pinon 2300XPA 2300XPB 2800XPA/XPB 4100/4100A 4100TS/BOSS 4100XPB
Load Side NON-Load Side Shim Sidestand Horizontally By:
Outboard Inboard Outboard Inboard (Greater Than Zero = Towards Front, Less Than Zero = Towards Rear)
Sec12Hoist.fm
Table 12-2.
A B C D
Rear Pinon 2300XPA 2300XPB 2800XPA/XPB 4100/4100A 4100TS/BOSS 4100XPB
Load Side NON-Load Side Shim Sidestand Vertically By:
Outboard Inboard Outboard Inboard (Greater Than Zero = Up, Less Than Zero = Down)
E F G H Note: Shim sidestand bearing block to the nearest .005"
2nd Calculation
2nd Backlash Measurements (after adjustment of sidestand)
ES41157 Mechanical Systems Manual
Front Pinon 2300XPA 2300XPB 2800XPA/XPB 4100/4100A 4100TS/BOSS 4100XPB

Load Side NON-Load Side Shim Sidestand Horizontally By:
Outboard Inboard Outboard Inboard (Greater Than Zero = Towards Front, Less Than Zero = Towards Rear)
Copyright © 2007 P&H Mining Equipment, Inc.

A B C D
Rear Pinon 2300XPA 2300XPB 2800XPA/XPB 4100/4100A 4100TS/BOSS 4100XPB
Load Side NON-Load Side Shim Sidestand Vertically By:
Outboard Inboard Outboard Inboard (Greater Than Zero = Up, Less Than Zero = Down)
5. Repeat steps 1 through 4 for the rear pinion/gear mesh.

E F G H Note: Shim sidestand bearing block to the nearest .005"
-12.71-
Distance Which Solder Nominal Actual Avg.
Factors is to Be Placed From Backlash in Backlash in
Model Horizontal Vertical Edge Of Pinion Face Pinion Gear in Gear Mesh Front Mesh
2300XPA 8.00 2.94 1.25" 1N1111 1N1165 .019" - .032" *(A + B + C + D) / 2
2300XPB 8.00 2.94 1.25" 1N1617 1N1616 .026" - .048"
2800XPA/XPB 7.50 2.75 1.25" 1N1035 1N1526 .048" - .064" Actual Avg.
4100/4100A 7.00 2.50 1.50" 1J329 1J199 .023" - .038" Backlash in
4100TS/BOSS 5.00 2.63 1.50" R37179 R32245 .026" - .048" Rear Mesh
4100XPB 5.25 2.72 1.50" R37179 R32245 .026" - .048" *(E + F + G + H) / 2
Table 12-2: Backlash Measurements and Calculations

Formulas for hand calculations: Final Check of Lead Error Across Gear Face (Load Side):
Maximum Permissible
Shim Sidestand Horizontally By: (- A + B - C + D + E - F + G - H) x Horizontal Factor Model Lead Error **
(Greater Than Zero = Towards Front) 2300XPA .003" Actual Lead Actual Lead
(Less Than Zero = Towards Rear) 2300XPB .003" Error (front) Error (rear)
2800XPA/XPB .004" *[ A - B ] *[ E - F ]
4100/4100A .004"
Shim Sidestand Vertically By: (A - B - C + D - E + F + G - H) x Vertical Factor 4100TS/BOSS .004"
(Greater Than Zero = Up) 4100XPB .004"
(Less Than Zero = Down) * Note: Use 2nd BL measurements
** If unobtainable contact Engineeri
4. Record the thickness measurements for the load and non-load side for the inboard and outboard locations in
Section 12, Version 00 - 06/07

Peak Services
Hoist System
6. Use the formulas in Table 12-2 to calculate the amount of shimming required. If you have the spreadsheet pro-
gram, simply enter the values in the boxes, and the program will automatically perform the calculations. If not,
hand calculations will be required using the formulas and factors provided.
7. Install the proper amount of shims and repeat steps 1 through 6 until proper alignment is achieved. Shim the
sidestand bearing block to the nearest .005".
Checking Contact Pattern
1. After final assembly of the gear set, rotate the pinions so that the drum gear makes at least one complete rev-
olution.
Thoroughly clean the teeth of the pinions and drum gear with degreaser.
03 LEGEND
01 02 01. (Green Arrow)
Load Side of Tooth
02. (Red Arrow)
Unload Side of Tooth
03. (Yellow Arrow)
Torque Direction when
Under Load
03 03
ES04870a01
02 01
Figure 12-57: Gearing Arrangement
2. Apply a thin layer of bluing compound to the load side of one tooth on the front pinion (refer to Figure 12-57).
[Note: Load side faces front of the machine on both pinions]. A thin film is defined as .0003" (.008 mm) to
.0005" (.012 mm) thick. A thin film is best accomplished by wiping the compound on the tooth and then using a
rag or finger to remove any excess. Excessive film thickness will result in false contact readings. The pinion
teeth are crowned; therefore full contact across the gear face width should not be seen.
3. Roll the gear mesh by turning the input coupling clockwise (while facing gear case) until the blue pinion tooth
comes in contact with a gear tooth to transfer the bluing compound from the pinion tooth onto the gear tooth.
4. Apply 3M book tape of proper width (2 ½ - 3") to cover the face of the gear tooth. The purpose of this is to
transfer the bluing impression on the gear tooth to the book tape.

Figure 12-58: Applying Bluing Compound
5. Use a sheet of 11" x 17" paper to prepare a sheet similar to the one shown in Figure 12-59 (permission to pho-
tocopy this page is hereby expressly granted). The rectangles on the sheet should measure approximately 3" x
15½". Paste the book tape with the bluing impression on the sheet. Record the gear and pinion part numbers.
Figure 12-59: Gear Tooth Contact Patterns

6. Check for acceptable contact pattern. Refer to Figure 12-60.
1 2 3
4 5 6
ES0619b01
LEGEND 03. Cross Bearing Misalignment - Cen-
ACCEPTABLE CONTACT ter Crown
01. Ideal Center Contact - Center Crown
02. Parallel Misalignment - Center Crown UNACCEPTABLE CONTACT
04. Unacceptable Contact - Center Crown
Figure 12-60: Acceptable and Unacceptable Gear Contact Patterns
7. Repeat steps 1 through 7 for the rear pinion/gear mesh.
8. Deviation: If contact patterns other than those shown in the upper section of Figure 12-60 are observed, or
contact patterns similar to those shown in the lower section of Figure 12-60 are observed, assembly personnel
must further evaluate and determine what is causing the alignment problem. If contact patterns are acceptable,
secure the hoist drum bearing block as described in Subtopic 12.3.9.7.
12.3.9.7 Securing the Hoist Drum Shaft Bearing Block
Once alignment shimming is completed, secure the bearing block as follows:
Figure 12-61: Side Stand Bearing Block

1. Secure the bearing block to the side stand with rod bolts.
2. Supernuts™ are used for the top nuts and standard nuts for the bottom. Refer to Subtopic 3.3.7.2 for the cor-
rect Supernut installation procedure.
3. Weld the bearing block to the side stand. Be sure the welder ground strap is attached to the side stand.
12.3.10 Hoist Ropes R23421D49
Figure 12-62: Hoist Rope Inspection
12.3.10.1 Inspection
NOTICE
Rope replacement criteria are not based on regulatory requirements, but are provided as a
guide. Experience may indicate that in addition to physical condition replacement criteria, ropes
should be replaced based on operating hours or total accumulated load hoisted, and those cri-
teria may vary based on loading conditions and material. Local policies may be more or less
restrictive.
Inspect the hoist ropes and related structures every 250 hours, checking the following items:
• Check the ropes for damage, particularly broken strands. Replace ropes that have more than 6 broken wires
in any one rope lay, or any broken wires in the valley between the strands.
• Check the hoist rope mounting hardware and the hoist drum for excessive wear, proper rope retention, or
fatigue cracks.
• Check the hoist rope equalizer blocks on the dipper bail for fatigue cracks.
• Check the rubber liners in the hoist cable guides for wear and retention.

12.3.10.2 Repair
Repair of hoist ropes is limited to replacement only. Ropes must be replaced in matched sets only.
12.3.10.3 Replacement
Each matched set consists of two lengths of cable from the same master reel with a ferrule becket on each end of
each length. Each reel of the same matched set will have a tag that includes the part number (R23421D49), the
P&H Purchase Order Number, and the marking for either “Piece 1 of 2” or “Piece 2 of 2”. Cables are hairpin wound.
NOTICE
Due to the differences in hoist rope attachment options, equipment (cranes, rope tuggers), skills
of personnel available and conditions in which hoist ropes are installed, it is difficult to define a
“factory recommended” hoist rope attachment procedure; however, the following instructions
are likely to apply to a majority of field operations. Steps in this section should be modified to
adapt to local policies and conditions.
Step 1: Refer to Subtopic 12.3.2 and confirm completion of preliminary maintenance procedures.
! WARNING
A falling load can crush, resulting in severe personal injury or death. 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. Each cable weighs approxi-
mately 5400 pounds (2450 kg).
Step 2: Remove the ferrule beckets from the hoist drum brackets. Secure the ropes against unplanned move-
ment.
Step 3: Attach tugger cables to the ends of the ropes and remove both hoist cables.

08
07
02
06
05
01
02
01
04
03
LEGEND
01. Rope #1 05. Right Sheave Outside Groove
02. Rope #2 06. Right Sheave Inside Groove
03. Inside Equalizer Groove 07. Left Sheave Inside Groove
04. Outside Equalizer Groove 08. Left Sheave Outside Groove
Figure 12-63: Hoist Rope Reeving
Figure 12-63 shows how the ropes will be reeved onto the shovel. Steps to achieve this configuration follow.
Figure 12-64: Hoist Cable Layout
Step 4: Refer to Figure 12-64. Arrange the new cables so that one end of each rope will be reeved over the right
sheave and one end of each rope will be reeved over the left sheave. Attach tugger cables to the ends
both hoist cables.

Figure 12-65: Attach New Cables
Step 5: As shown in Figure 12-63, Rope #1 will be reeved over the right groove of each sheave and Rope #2 will
be reeved over the left groove of each sheave. Refer to Figure 12-65 and rig the lines such that the rope
end to be attached to the drum first (the ropes on the inside sheave grooves) will be offset by about 3 feet
(1 meter). Secure the new cables to the tugger lines
Figure 12-66: Pull Cables In
Step 6: Refer Figure 12-63. Secure one end of each rope in the socket.
Step 7: Secure the left end of the rope and attach the right end to the bracket on the hoist drum.
Step 8: Rotate the drum 180° in the take-up direction.
Step 9: Attach the remaining rope ends to the brackets on the hoist drum.
12.3.10.4 Hoist Rope Break-In Procedures
The hoist ropes are subject to significant stresses of compression and tension as the rope bends over the boom
point sheaves and when the dipper is being hoisted through the bank. In order to prepare a new rope for this work
and to prolong useful rope life, break in new rope as follows:

1. Slowly raise and lower the empty dipper three times.
2. Fill the dipper to approximately one-half capacity. Slowly raise and lower the dipper three times.
3. Fill the dipper to capacity. Slowly raise and lower the dipper three times.
12.3.11 Hoist Cable Tuggers R26969D5
01. 02. 03.
ES1189_01
LEGEND 02. Transmission

01. Motor 03. Drum
Figure 12-67: Electric Tugger
12.3.11.1 General
Two electric tuggers are mounted on brackets behind the hoist drum to assist in changing hoist ropes. Each tugger
consists of a 3HP motor, a transmission, and a drum. The tuggers are equipped with disc brakes. Tugger ropes are
1/2" x 160 ft (6x37, Preformed, Right Regular Lay, IWRC, Extra Improved Plow Steel grade). Rated capacity is
3000 lbs (1360 kg). 50-foot remote pendant controllers are attached to the control panel mounted on the wall of the
right-hand room to the front and to the right of the hoist drum.
12.3.11.2 Wear Adjustment
Adjustment is necessary if either or both of the following conditions are observed:
• A decrease in braking torque. Adjustment is recommended when braking torque drops to approximately
80% of its static rating.
• Complete lack of disengagement (dragging), or motor stalled.
! WARNING
Contact with hazardous current will shock, and could cause death or severe personal
injury. This equipment is at line voltage when AC power is connected. Disconnect power
and follow lockout and tagout procedures.

! WARNING
pinch or crush, causing severe personal injury or death. Read and understand Topic 5.3,
A Warning About Stored Mechanical Energy, before releasing the tugger brake for main-
tenance. Be prepared for movement of the tugger rope. The brake must be de-energized
before attempting wear adjustment. Be certain that the tugger is not connected to any
load before starting the adjustment.
Before attempting any adjustment to the brake, be sure the power is turned off and there is no possibility of motor
start-up.
01 02
05
03
ES02504b01
04
LEGEND 04. Manual Release Lever

01. Pilot Plate (set position)
02. Pan Head Screw 05. Brake Manual Release Lever
03. Adjusting Bolt (released position)
Figure 12-68: Hoist Rope Tugger
Refer to Figure 12-68 and adjust to compensate for wear as follows:
1. Turn the 3 smaller hex head bolts (Items 03) clockwise (CW) progressively to 50 lb-in.
2. Turn each of the bolts back counter clockwise (CCW) 1/2 of a full turn (180 degrees). This resets the air gap to
the proper amount.
3. Turn power back on and check for normal operation.
Technician Tip
When adjustment intervals become more frequent, brake friction disc is nearing the end of its
normal life. Refer to Friction Disc Replacement procedures below.

12.3.11.3 Friction Disc Replacement
! WARNING
Contact with hazardous current can cause death or severe personal injury. This equip-
ment is at line voltage when AC power is connected. Disconnect power and follow lock-
out and tagout procedures.
! WARNING
Stored Mechanical Energy, before releasing the tugger brake for maintenance. Be pre-
pared for movement of the tugger rope. The brake must be de-energized before attempt-
ing wear adjustment. Be certain that the tugger is not connected to any load before
starting the procedure.
2. Confirm that each new friction disc is clean and free of any grease, oil or other contaminants which might result
in a loss of torque.
3. Disconnect and lock out all electrical power to the motor and brake.
4. Remove brake from motor.
5. Refer to Figure 12-68 and proceed as follows:
A. Remove pilot plate on brake input by removing the four (4) #6-32 pan head screws (Item 02).
B. Alternately turn counterclockwise (CCW) but do not completely remove the adjustment bolts (Items 03) until
the pressure plate is free and can be removed from the brake assembly.
Technician Tip
It is important to alternately turn these bolts so as not to cock the pressure plate. No more than
1-2 revolutions per bolt, then move to the next bolt. Continue until the plate is free.
C. After pressure plate is out, remove the old friction disc. For double disc units, remove disc 1, floating plate
and disc 2. Replace both discs and inspect floating plate.
D. Use dry, filtered compressed air to blow out any loose wear particles from the brake housing.
E. Visually inspect the steel wear surfaces of both the clapper and pressure plates.
F. Place the new friction disc onto the clapper plate with the 3" diameter boss facing up, away from the clapper.
For double disc units, install thinner disc onto clapper plate, followed by floating plate and thicker disc. Fric-
tion discs on double disc unit should be installed with 3" diameter boss facing up, away from clapper.

12.3.11.4 Manual Release Adjustment
The manual release levers (Items 04, Figure 12-68) need adjusting if:
• Levers will not stay in the brake released position (i.e., 90 degrees from housing).
• Levers will not rotate back to the full engage position when the brake is energized.
If levers will not stay in the brake released position, remove power to the brake and manually hold the lever out (90
degrees from the housing). Insert a 7/64" hex key into the hex socket head cap screw in the release lever. Slowly
turn clockwise (CW) until the lever will maintain this position by itself. Repeat this procedure for the other lever.
Rotate both levers simultaneously to the brake released position; they should maintain this position. If not, repeat
the procedure. Next, supply power to the brake. The levers should snap back to their original position.
If levers will not rotate back, start with the levers in the brake released position. With power supplied to the brake,
insert a 7/64" hex key into the hex socket head cap screw in the release lever. Slowly turn counterclockwise (CCW)
until the lever snaps back to the housing. Repeat this procedure with the other lever. To test, with power off to the
brake, use the manual release levers to release the brake. Then supply power to the brake; both levers should
snap back to the housing. If not, repeat procedure.
12.3.12 Hoist Lube Pump Assembly R57213D1
12.3.12.1 Removal
Remove the lubrication pump as follows:
1. Confirm that the preliminary maintenance procedures described in Subtopic 12.3.2 have been completed.
2. Turn the shutoff cock to the off position.
3. Place a pan under the pipe union, which is located between the shutoff cock and the strainer, to catch the
excess oil.
4. Remove the pump as follows:
A. Remove the coupling guard and remove the piping to the pump.
B. Disconnect the coupling between the gear reducer and the pump.
C. Remove the four cap screws that secure the foot (14) to the pump mounting plate.
12.3.12.2 Replacing The Shaft Seal
Replace the shaft seal (16, Figure 12-17) as follows:
1. Grip the pump firmly across the ports and the opposite side of the housing in a vice, with the shaft end up.
2. Remove all burrs from the rotor shaft (06).
3. Remove cap screws (20).
4. Slide housing plug (18) off the shaft and remove key (07). Remove any nicks of burrs at the keyway.

5. Slide the seal assembly (16) off the shaft and remove O-ring (17).
6. Polish the rotor shaft and clean the seal chamber thoroughly with a piece of clean lint-free cloth. This makes
seal damage unlikely and eases the installation of a new seal.
7. Install a new O-ring (17) on housing plug (18).
8. Place a new seal (16) on the rotor shaft (06) and slide it into place.
9. Install key (07) in the keyway on the shaft of rotor (06).
10. Place housing plug (18) on the shaft and slide it into place. Align the key with the slot in the plug for proper
location.
11. Position the mounting holes and install cap screws (20).
To completely disassemble the pump, refer to Figure 12-17 and proceed as follows:
1. Remove key (07) from the rotor shaft (06).
3. Remove bolts (01) and nuts (11) and remove foot (14) from housing (10).
4. Match mark cover (03) and bracket (12) to housing (10).
5. Remove screws (02), cover (03), gasket (08), shims (09), pin (04), and idler gear (05).
NOTICE
Keep shims (09) together as a set to maintain correct end clearance.
6. Remove screws (20) and remove housing plug (18). Bushing (19) and O-ring (17) will come off with the hous-
ing plug.
7. Remove O-ring (17) from the housing plug.
8. Press bushing (19) from the housing plug, if necessary.
9. Pull rotor (06) and bracket (12) from housing (10).
10. Pull the rotor from the bracket assembly.
11. Remove seal assembly (16) and snap ring (15) from the bracket (12).
12. If necessary, press bushing (13) from the bracket.

Clean all parts with a suitable solvent. Inspect the pump components for damage and excessive wear. Repair is
limited to replacing worn or damaged parts.
12.3.12.5 Assembly
Refer to Figure 12-17 and assemble the lubrication pump as follows:
1. Install bushing (13) into the bore in bracket (12). It may be necessary to soak the bushing in dry ice to aid the
installation of the bushing.
2. Install snap ring (15), and seal assembly (16) into bracket (12).
3. Lubricate the rotor shaft (06) with a light coating of grease and insert it into the bracket (12).
4. Install the bracket assembly with gasket (08) on housing (10).
5. Coat pin (04) and idler gear (05) and install the cover (03).
6. Install shim pack (09), gasket (08) and cover (03) on housing (10). Align the four holes in cover (03), housing
(10), bracket (12) and foot (14) so that the inlet and outlet ports on the pump housing are facing up. Secure
with screws (01) and nuts (11).
7. Install and tighten screws (02).
8. Install bushing (19) into the bore in plug (18). It may be necessary to soak the bushing in dry ice to aid the
9. Install a new O-ring (17) on plug (18).
10. Install plug (18) in bracket (12). Secure with screws (20).
To install the lubrication pump, refer to Figure 12-17 and proceed as follows:
1. Install the flexible coupling half on the pump rotor shaft. Align the pump rotor shaft flexible coupling half and the
gear reducer flexible coupling half with the elastic spider installed.
2. Install the pump foot mounting bolts.
3. Align the shafts and coupling halves.
4. Install the piping to the pump.
6. Open the shutoff cock.
7. Use lockout and tagout procedures to return the mining shovel to service checking the hoist lubrication system
for problems such as leaks, misalignment, or noisy operation.

12.3.12.7 Troubleshooting
Problem Probable Cause Remedy
Pump does not pump. Pump lost its prime. Check for air leak or low level in
transmission.
Motor not up to speed. Check motor’s rpm and coupling.
Relief valve set too low. Clean relief valve, reset pressure to
125 PSI (8.625 bars).
Pump worn out. Repair pump as necessary.
Pump starts, then loses its Low oil level in transmission. Check level and add oil as neces-
prime. sary.
Pump worn out. Repair or replace pump.
Pump is noisy. Coupling is worn or broken. Remove guard and inspect cou-
pling.
Loose piping or pump mounting base. Check all mounting hardware.
Foreign object in pump inlet. Remove inlet line and check suc-
tion port.
Pump is not up to capacity. Filter partially plugged. Remove and clean or replace the
filter.
Air leak in suction line or along the pump Repair lines, check and tighten
shaft. packings.
Motor turning below rated rpm’s. Check motor and wiring.
Pump takes too much Oil is too heavy for pump. Change the oil in the transmission
power. to suit conditions. See lubricant
specifications.
Packing gland drawn down too much. Loosen up packing gland. See
repair Subtopic.
Coupling misaligned. Repair the coupling.
Table 12-3: Lube Pump Troubleshooting

12.3.13 Hoist Lube System Bypass Valve R57221D1
Inspect every 250 hours for leaks. Test for correct setting and operation.
12.3.13.2 Adjustment
Adjust to 100 psi by removing the cover and adjusting the adjusting screw.
12.3.13.3 Repair
Repair is limited to replacement of a damaged or inaccurate valve.
Remove the valve from the line and install a new valve.
12.3.14 Oil Strainer Assembly (46Q108D3)
12.3.14.1 General Description
The basket strainer provides protection for the pumping system preventing solids or relatively large (greater than
0.075 inch diameter) foreign materials from entering the pump. The strainer assembly is similar to the one pictured
in Figure 12-70. The body of the strainer and the lid are aluminum. Simple lid rotation disengages the lid permitting
easy top removal of the basket for cleaning. An o-ring seals the lid. The inner basket has a stainless steel screen
that can be removed and cleaned. This strainer assembly also includes magnetic inserts for trapping ferrous parti-
cles, which should also be cleaned when serviced. The oil strainer is located between the shutoff cock at the gear-
case and the pump intake as shown in Figure 12-70. A union is located next to the strainer assembly in case it
must be removed. A drain plug is located in the bottom of the strainer housing.

NOTICE
The strainer housing must be installed with the flow arrows on the strainer housing pointing in
the direction of oil flow, i.e. toward the pump.
Figure 12-70: Strainer Assembly - Photo Typical

The oil strainer should be cleaned every 500 hours as follows:
1. Lockout and tagout the pump motor supply breaker to prevent start-up while working on the strainer.
2. Turn off the shutoff valve located in the pump input (03, Figure 12-70) just before the strainer.
3. Refer to Figure 12-71 and service the strainer as follows:
A. Make sure the plug located under the filter assembly is installed in the drip pan to catch any spilled oil.
Figure 12-71: Servicing Gearcase Oil Strainer
B. Remove the cover thumb screw from the top of the strainer.

C. Turn the cover counterclockwise until it stops. Lift the cover from the strainer body.
D. Remove the strainer basket as shown.
E. Clean the magnets (see Figure 12-72). The magnets are attached to the handle by spring clips, allowing
easy removal.
LEGEND
01. Spring Clips
02. Magnets
03. Strainer Basket
Figure 12-72: Magnet Locations - Typical
F. Clean the basket, using a small brush. Do not strike basket to clean as this might deform the basket.
G. Re-install the magnets and spring clips back into the basket.
H. Replace the basket with magnet assemblies.
I. Inspect the cover o-ring for cracks, splits, cuts, or permanent set. Replace the o-ring if there is the slightest
indication that it might not seal properly. Lubricate o-ring with a small amount of multi-purpose grease.
NOTICE
An o-ring that does not seal properly can cause the pump to cavitate and lead to pump damage.
J. Lower the cover into position, making sure that the cover screw holes will line up after the lid is rotated.
Avoid pinching the o-ring during cover installation. Press down on the cover firmly and evenly until it pops
into place.
NOTICE
Do not attempt to install the cover if the strainer has filled up with liquid. Drain before installing
the cover.
K. Rotate the cover clockwise until the two holes line up. Secure the cover with the cover screw.

! CAUTION
Before opening shut-off valve, be sure cover is turned to proper position and thumb-
screw is installed to prevent lid from turning.
L. Open the shutoff valve.
M. Following lock-out/tag-out procedures, return the pump to operation and start the pump.
N. Check the strainer cover for leaks.
O. Check the pump for any signs of cavitation such as excessive noise.
P. Drain the drip pan by removing the drain plug.
Q.
12.3.15 Oil Filter Assemblies (46U110D3)
12.3.15.1 General Description
Oil filter assembly 46U110D3 (Figure 12-73) is used on the hoist, drag, and swing lubrication systems. The filter
assembly has a single 40 micron wire mesh element which can be cleaned and re-used. The oil filter operates on
the principle of pressure drop as the filter gets dirty. The filter is equipped with an automatic bypass valve that
opens when the pressure drop across the filter reaches 241 kPa (35 PSI). When this occurs, oil is no longer pass-
ing through the filter and the filter element must be cleaned (see Subtopic 12.3.15.2).
DL0026a01
Figure 12-73: Oil Filter (46U110D3)

NOTICE
The filter should be cleaned or replaced before the filter indicator enters the red area to avoid
pumping unfiltered oil into the bearings and gear meshes.
A maintenance indicator (Figure 12-74) is included in the filter assembly. An indication in the red area means that
an excessive pressure drop exists and the filter should be serviced.
DL0027a01
Figure 12-74: Filter Indicator
NOTICE
In cold conditions, the indicator may give a reading in the red area because the oil is cold and is
not flowing through the filter well. Operate the pump for a while to warm up the oil and check the
indicator again. Be sure to use the proper oil viscosity for temperature conditions, see Section 8
of this manual for more information.
Figure 12-75 shows an exploded view of the filter assembly.
12.3.15.2 Filter Maintenance
Filter maintenance includes: filter element cleaning or replacing, cleaning magnets, and replacing damaged com-
ponents. This should be done every 500 hours.
The following removal procedure is provided to perform filter element cleaning or replacement and does not require
the entire filter assembly to be disassembled and removed from the lubrication piping.
12.3.15.3 Filter Removal
To remove the oil filter, proceed as follows:
1. Lock-out/tag-out the pump motor supply breaker to prevent motor from being energized.
2. Close the shut-off valve located just before the strainer.
3. Make sure the plug located under the filter assembly is installed in the drip pan to catch any spilled oil.


!
#
"

#
LEGEND
$ 01. Screw
&
02. Name Plate
03. Capscrew
' $ 04. Cover
% 05. O-Ring
06. Magnet
07. By-Pass Valve
08. Tube
! 09. Handle
10. O-Ring
11. Head
! 12. Grommet
13. Flange Assembly
14. O-Ring
15. Bowl
16. Filter Element
! 17. Not Used
' 18. Plug

" # 19. Washer
! 20. Gasket
& 21. Screw
22. Filter Indicator
23. Seal
DL0028a01
Figure 12-75: Filter Assembly (46U110D3)
4. Loosen filter cover capscrews (03, Figure 12-75). Figure 12-76 shows a photo of the cover capscrews.
5. Turn cover (04, Figure 12-75) counterclockwise and remove it from the filter assembly. Figure 12-77 shows a
photo of the cover removal.
6. Remove bypass valve assembly (07, Figure 12-75) from filter head (11). Filter element (16) will come out with
the bypass valve assembly. Figure 12-78 shows a photo of the bypass valve and filter element being removed.
7. The bypass valve assembly (07, Figure 12-75) can be separated from the grommet (12) and filter element (16)
as shown in Figure 12-79. The filter element has no grommet on the bottom.
8. Magnets (06, Figure 12-75) can be removed from the bypass valve assembly.

Figure 12-76: Loosening Cover Capscrews
Figure 12-77: Removing Cover

Figure 12-78: Removing Bypass Assembly
Figure 12-79: Removing Filter

12.3.15.4 Filter Cleaning or Replacement
To service the filter, refer to Figure 12-75 and proceed as follows:
1. Clean or replace the filter element. It is possible to clean a wire mesh element. To clean the element, soak the
element in an ultrasonic cleaner for 15 minutes. If an ultrasonic cleaner is not available, soak the elements in a
solution of hot soapy water and ammonia for 15 minutes.
2. Clean magnet assemblies (06) of all accumulated particles.
3. Inspect o-rings (05 and 10) and grommet (12) for cracks or other damage. Replace as necessary.
12.3.15.5 Filter Installation
To install the oil filter, refer to drawing (Figure 12-75) and photos (Figures 12-76, to 12-79) proceed as follows:
1. Replace element (16) and grommet (12) on the bypass valve as shown in Figure 12-75.
2. Replace magnets (06), if removed.
3. Install o-ring (10). Insert the filter element and bypass valve in the filter bowl and head. Make sure the notches
on the filter head and the bypass valve are aligned.
4. Install o-ring (05). Replace the cover (04) and twist it clockwise. Tighten screws (03).
5. Open the shut-off valve located just before the strainer.
6. Using lock-out/tag-out procedures, energize the pump motor.
7. Check the system for leaks. Repair any that are found.
8. Check the oil filter indicator. It should indicate in the green area.
9. Drain the drip pan under the filter assembly when finished.


ES41157 Mechanical Systems Manual Attachment
Section 13
Attachment
13.1 General
Figure 13-1: Attachment (typical)
The attachment components include the gantry, boom suspension cables, boom assembly, boom limit resolver
assembly, the dipper, and the dipper trip assembly (see Figure 13-1).
NOTICE
While the crowd machinery is physically part of the boom assembly, the crowd system is cov-
ered separately in Section 14 of this manual.

Sec13Attach.fm -13.1- Section 13, Version 00 - 06/07
Attachment ES41157 Mechanical Systems Manual
13.2 Components
04 05
03
06
07
08
09 TC1601c
10
LEGEND
01. Gantry 06. Dipper
02. Suspension Cables 07. Dipper Door
03. Hoist Rope Guard 08. Boom
04. Hoist Rope 09. Dipper Trip Motor
05. Boom Point Assembly 10. Boom Foot Pin
Figure 13-2: Attachment Components

Section 13, Version 00 - 06/07 -13.2- Sec13Attach.fm
13.2.1 Gantry R39787F1
Figure 13-3: Gantry R39787F1
The gantry assembly, shown in Figure 13-3, includes a compression member, two tension members, two suspen-
sion cable equalizers, and various pin assemblies. The compression member is a single unit weldment that has a
set of lugged feet that pin to the forward end of the revolving frame. Four other lugs are welded into the upper end
of the compression member structure. These upper lugs provide connections for the boom suspension cable
equalizers, and the upper lugs of the gantry tension members.

13.2.2 Boom Assembly R52773F2
Figure 13-4: Boom Assembly R52773F2
The boom assembly (Figure 13-4) consists of the boom weldment, the crowd machinery, the boom foot pin assem-
blies, the boom platform and catwalk assemblies, the boom point sheave assembly, and the boom point lugs and
equalizers.
NOTICE
ered separately in Section 14 of this manual
The boom weldment is 66’ 2" long. It uses box girder construction with diaphragms to provide torsional strength.
The crowd machinery, which provides the machine with the crowd and retract digging motions, is mounted on the
boom to provide efficient machine operation. The crowd gear case base is an integral part of the boom.

13.2.3 Boom Wear Boxes
Figure 13-5: Boom Wear Box
The boom wear boxes are the part of the boom that the inside of the dipper handles rub against. As the handles
are crowded and retracted and hoisted and lowered, they contact a large part of the length of the boom wear
boxes. The wear boxes (Figure 13-5) are the lowest portion of each side of the boom, and stretch from near the
boom point sheaves at the top to almost directly under the crowd transmission. The wear boxes are the widest part
of the boom weldment.
13.2.4 Boom Point Assembly R42014F1
Figure 13-6: Boom Point Assembly
The boom point assembly (Figure 13-6) provides a pair of sheaves to help control movement of the hoist ropes. It
is mounted at the point of the boom and retained in position by a retaining plate welded to the boom. The assembly
is mounted in split bearing blocks on the boom point, thus allowing removal as an assembly.
The boom point assembly is lubricated by means of the automatic lubrication system.

13.2.5 Boom Suspension Cables 30U254D5
Figure 13-7: Boom Suspension Cables
Four boom suspension cables support the weight of the boom and maintain the boom at the proper 45° angle.
Each cable is 62’ 6" (19.05 meters) long and 4" (10.2 cm) in diameter. Each cable has an open wire rope socket
attached at each end with pins in the same plane.
13.2.6 Cable Guide R42917F1
Figure 13-8: Cable Guide
The cable guide, shown in Figure 13-8, helps to guide, support and control the hoist cables during digging opera-
tions. It consists of two rollers in a boom-mounted frame.

13.2.7 Boom Resolver Assembly R43964F1
Figure 13-9: Boom Resolver Assembly
13.2.7.1 General
A linear position transducer is mounted inside the machinery house at the front right corner of the machinery deck.
An extension protrudes through the forward wall of the machinery house and connects to the boom to sense boom
movement.
The function of this boom resolver assembly is to sense a backward movement of the boom (called “jacking”) and
prevent a possible unsafe condition if the boom is raised during digging operations. Such movement can occur
when the crowd motion is opposed by the material being dug to such an extent that the boom point pivots back and
up, rather than the dipper moving forward.
Boom jacking may occur, for example, if the operator attempts to crowd the dipper into a rock shelf. When the
jacked up boom falls back into operating position, it creates a heavy shock load, which may damage the mining
shovel. Figure 13-10 illustrates boom jacking.
The boom resolver assembly consists of a cover, linkage, actuator link, linear resolver, and mounting brackets.
The boom resolver assembly, shown in Figure 13-9, is mounted behind the machinery house front wall. The actua-
tor link protrudes from the forward wall, and is pinned to a bracket that is bolted to the base of the boom. The clamp
link is connected to the actuator link. The linear resolver is connected to the clamp link by two nuts and washers.
The clamp link can be slid on the actuator link, and the clamp link can be moved with respect to the linear resolver
by moving the nuts and washers. It is critical to correct operation to make sure that the clamp link is firmly attached
so it cannot move with respect to the actuator link.
Each of the out of limit conditions are created by the same linear resolver. No measurements are required for this
system; the shovel control system is programmed to recognize the position of the boom from the input from the lin-
ear resolver and react accordingly. Once set up there should be no need for field adjustments to the linear resolver.
13.2.7.3 Boom Jacked (stage 1)
The system is set up so that if the boom is jacked, the first stage of the boom resolver will actuate. This first out-of-
limit stage will cause the crowd motor to stop the crowd motion of the mining shovel. The crowd motor will then
retract automatically at a 10% rate until the boom is back at rest.

LEGEND
01: Boom in its normal position
02: Boom Suspension Cables are slack
because the boom is jacked.
Figure 13-10: Jacking the Boom
13.2.7.4 Boom Jacked (stage 2)
If the boom is jacked severely, the second stage of the boom resolver assembly will actuate and set all brakes,
stopping all crowd or retract motion.
CAUTION
Manually releasing the crowd brake using air system components while the boom is
jacked will cause the boom to drop violently and stop hard when the suspension cables
draw tight. This can cause severe damage to suspension cables, gantry and boom com-
ponents and could cause the boom to crack. Never manually release the crowd brake
using air system components while the boom is jacked.
Once the crowd system has been placed in a Stage 2 condition, the crowd brake will not release in the normal way.
To return the crowd system to the normal operating range it will be necessary to manually override the crowd
brake.

02 03
01
ES04891a01
LEGEND
01. Crowd Brake 02. Horn Button
Release Button 03. Hoist Brake Switch
Figure 13-11: Crowd Joystick Controller and Crowd Brake Release Button
To return the boom to its normal operating position, refer to Figure 13-11 and proceed as follows:
CAUTION
Further crowding can cause the boom to be pushed back into the machinery house,
causing significant property damage. Be sure to retract by pulling the joystick toward
the operator’s seat; do not crowd further.
Press and hold the crowd brake release button while gently pulling backward on the joystick controller, slowly
retracting the dipper and allowing the boom to gently return to its normal position. When the crowd system is
returned to its normal operating range the crowd brake will stay released and it will no longer be necessary to hold
down the crowd brake release button.

13.2.8 Dipper Trip Assembly

D
Figure 13-12: Dipper Trip Assembly
The dipper trip motor drives the dipper trip transmission, which drives the drum. The assembly, shown in Figure 13-
12, is attached to the side of the boom by means of a bracket.
13.2.9 The function of the motor and drum assembly is to maintain a slight tension on the dipper trip cable during
normal operation of the shovel, except for the dumping phase at which time the motor torque is increased to actu-
ate the dipper trip mechanism.
13.2.10 Dipper Trip Cable R17556D2
Figure 13-13: Dipper Trip Cable R17556D2
The dipper trip cable is a 7 flex IWRC PFV or similar 7X19 plastic enhanced preformed, right regular lay, IWRC,
extra improved plow steel wire rope, ¾" (19 mm) in diameter and 90’ 0" (27.43 m) long. It comes with a ferrule
sleeve attached to one end that is inserted into the ferrule becket socket in the dipper trip drum.When the operator
trips the dipper, extra torque applied to the dipper trip motor is transmitted through the cable to the dipper trip
mechanism on the dipper, and the dipper door opens.

13.3 Maintenance
13.3.1 Part Numbers
NOTICE
to be lowered.

! WARNING

13.3.3 Gantry R39787F1
04
05
LEGEND
01. Tension member
02
03 02. Link Pin
02
03. Equalizer Link
04. Lift Point
05. Equalizer
06. Compression mem-
ber
07. Installation Struts
(ordered separately)
01
06
07
TC1682a
Figure 13-15: Gantry R39787F1
The tension members are I-beam weldments that have double lugs at both ends. The upper lugs are pinned to the
compression member and the lower lugs are pinned to the revolving frame. The compression member weighs
approximately 19,265 lbs (8,740 kg), and each of the tension members weighs approximately 7,750 lbs (3,515 kg).
The suspension cable equalizers, mounted to the two upper compression member lugs facing the boom assembly,
each consist of two equalizer links, one equalizer, and two pin assemblies.

13.3.3.1 Inspection
! WARNING
Shovel movement can shake or bounce the gantry causing people to fall resulting in
severe injury or death. Shut down the shovel and use lockout/tagout procedures before
performing inspection, maintenance or service on gantry. Always use personnel fall pro-
tection equipment and follow tie off procedures while on the gantry.
Inspect the gantry assembly every 250 hours as follows:
• Check the suspension cable pins for wear, retention, and proper lubrication.
• Check the compression and tension member pin assemblies (top and bottom) for wear and security.
• Check the suspension cable equalizer pin assemblies and bushings (if used) for wear and security.
• Check the equalizer and equalizer links for fatigue cracks.
• Check the tension and compression members for fatigue cracks.
• Check the gantry mounting lugs (welded to the revolving frame) for fatigue cracks.
• Check all platforms, ladders, and railings for security.
NOTICE
Any minor cracks should be repaired immediately (refer to Subtopic 13.3.3.2). If transverse
welds or major weld repair is required, contact your P&H MinePro Services representative.
13.3.3.2 Repair
Repair of the gantry assembly is limited to replacing worn or damaged parts and welding repairs of minor fatigue
cracks.
Welding repairs to the gantry assembly must be done using proper preheat and welding practices. All weld ends
should be ground and blended.
All welding on the gantry tension and compression members must be done using AWS recommended preheats
with AWS E7018 electrodes. Make sure that no undercut welds, or notches are made, and grind all welds smooth.

13.3.4 Boom Assembly R52773F2
04
03
02
01
05
06
07
TC0431b
08
09
LEGEND 05. Boom Point Assembly Bearing Block
01. Crowd Motor Mount 06. Access Hatches
02. Crowd Transmission mounting 07. Boom Wear Box
03. Suspension Cable Connections 08. Shipper Shaft Bushing
04. Rigging Point 09. Boom Foot Pin Pushing
Figure 13-16: Boom Assembly R52773F2
NOTICE
ered separately in Section 14 of this manual.
The boom feet are wide spread heavy steel fabrications welded to the body of the boom. Machined bores in the
boom feet receive pins, as shown in Figure 13-17, which fasten the boom base to the front of the revolving frame.
Metal shims are inserted between the revolving frame lugs and the outer face of each of the boom foot lugs, as
shown in Figure 13-17. They are installed in equal quantities to each boom foot, to center the boom and to elimi-
nate lateral movement of the boom on the boom foot pins during swing and plugging motion.
Platform and catwalk assemblies are mounted on the boom to provide access to the crowd machinery and boom
point assembly for maintenance purposes.
The boom point sheave assembly pin is straddle mounted in bearing blocks on the front end of the boom. The
boom point bearing blocks are split for easy installation and removal of the boom point sheave assembly.

11 10
09
01 02
05
05
06
06 08 07
TC0419b
01
02
04
03
TC0411
LEGEND 06. Bushing
01. Boom Foot Pin 07. Bushing
02. Split Collar 08. Boom Foot
03. Washer 09. Revolving Frame Lug
04. Cap Screw 10. Revolving Frame Lug
05. Thrust Washer 11. Shims
Figure 13-17: Boom Foot Pin Assembly (R43475)F1
The boom has a set of lugs and equalizer plates located near the boom point, to which the ends of four suspension
cables are connected. These suspension cables run from the boom point equalizers to the gantry and provide sup-
port for the boom.

! WARNING
Unexpected shovel movement can shake or bounce boom, causing personnel to fall and
resulting in serious personal injury or death. Shut down the mining shovel and use lock-
out and tagout procedures before conducting inspection, maintenance, or service on the
boom. Always use personal fall protection equipment and follow tie-off procedures while
on the boom.
Periodic inspections of the boom assembly are recommended to check for unsafe conditions, structural cracks,
tightness of mounting bolts, and operational condition of machinery mounted on the boom. Repair of the boom
assembly is limited to replacing worn or damaged parts. This manual does not cover repairs for the boom structure.
If a problem arises with the boom, contact your P&H MinePro representative.
Inspect the boom assembly periodically as follows:
• Check the boom foot pin assemblies for wear, retention, and proper lubrication.
• Check the boom point equalizer pins for wear, retention, and proper lubrication.
• Check the suspension cable pins for wear, retention, and proper lubrication.
• Check the boom point assembly for wear, retention, and proper lubrication.
• Check all platforms, catwalks, and railings for security.
• Check the boom wear boxes for wear (refer to subsection 13.3.5).

13.3.5 Boom Wear Boxes
2 2
ES1075A_01
LEGEND
01. Boom Assembly
02. Boom Wear Box (1 Each Side of Boom)
Figure 13-18: Boom Wear Boxes
The wear boxes will experience wear over time because they form the widest portion of the boom and are the
areas that rub against the dipper handles. This wear will allow lateral movement of the dipper handles as it
becomes greater. This lateral movement must be controlled or the shipper shaft, pinions, and the saddle blocks
could experience rapid wear or damage. The boom wear boxes should be inspected at every major boom inspec-
tion, especially when the boom has been in service for an extended period of time.
The outermost plate of the boom wear box (the plate that rubs against the dipper handles) is the part that will expe-
rience the wear. It is the part that needs to be inspected. This plate is said to be worn and in need of replacement
when it has lost a depth of 1/2 inch of its surface in any area. This loss may or may not correspond to a loss of a
depth of 1/2 inch of surface of the opposite wear box (directly across the boom) from the worn area. For a simple
measurement, if the boom has lost 1/2 inch total of its original width, it should receive a detailed inspection.
The original width of the boom from wear box to wear box is 89-1/2 inches. If in question, the original width of the
boom can be easily obtained by measuring across the bottom of the boom at an area where the wear boxes have
experienced little or no wear, which would usually be at the top or bottom end of the wear boxes. Normally the area
of most wear is somewhere in the center of the wear box, where the dipper handles contact it most of the time. So
the boom should receive a detailed inspection if its width measures 89 inches from wear box to wear box.
NOTICE
At the extreme top and bottom ends of the wear boxes, the boom wear box width tapers off. Do
not make any measurements in this tapered area.
A detailed inspection of the boom wear boxes should be made using measurements from a reference point on the
side of the boom. The reference point to be used is the machined surface of the boom where the shipper shaft

bushing retainer is installed. Use straight edges from this machined surface to measure the distance that the wear
box extends out from the side of the boom. A loss of 1/2 inch from the original measurement should be considered
significant wear.
Once it has been determined that the wear boxes have significant wear, the outer plate of each wear box should be
replaced. This involves cutting off the old plate and welding a new plate in place. For detailed information on per-
forming this repair, contact your P&H MinePro Services representative.

13.3.6 Boom Point Assembly R58150F1/F2/F3
LEGEND 12. Sleeve 24. Cap Access Cover

01. Connector 13. Retainer 25. Flange Locking Screw
02. Elbow 14. Tapered Roller Bearing 26. Conduit
03. Nipple 15. Sheave 27. Hose Clamp
04. Drilled Head Cap Screw 16. Spacer 28. Hex Head Cap Screw
05. Tie Wire 17. Pin 29. Lock Washer
06. Hardened Washer 18. Elbow 30. Mounting Pad
07. Retainer Plate 19. SuperNut 31. Strain Gauge Cabinet
08. Shim 20. Boom Point Pin Cap 32. Connector
09. Shim 21. Cap Body 33. Cable
10. Shim 22. Cable Cleat 34. Hex Head Cap Screw
11. Shim 23. Socket Head Cap Screw 35. Elbow
Figure 13-19: Boom Point Assembly R58150F1/F2/F3

13.3.6.1 Removal
Refer to Figure 13-19 and remove the boom point assembly as follows:
1. Confirm that preliminary maintenance procedures as described in Subtopic 13.3.2 have been completed.
2. Remove the hoist ropes from the boom point sheaves.
3. Disconnect the lubrication lines from each end of the boom point pin.
4. Remove the pin access cover (24) from the cap at the right end of the pin and disconnect the electric cable.
! WARNING
lowering or moving components with lifting equipment. The boom point assembly
5. Support the boom point assembly using a suitable crane. The boom point assembly weighs approximately
14,050 lbs (6,373 kg).
CAUTION
SuperNut removal requires strict adherence to procedures! Jack screws must be
unloaded gradually. If most of the jackscrews are fully unloaded prematurely, the
remaining jackscrews will carry the entire load and will be difficult to turn. At the
extreme, a jack screw tip can deform, making removal difficult.
6. Remove the SuperNuts from the boom point bearing block studs using the SuperNut removal procedure. Refer
to Subtopic 3.3.7 for this procedure.
7. Remove the boom point sheave bearing blocks.
8. Using suitable lifting equipment, lift the boom point sheave assembly from the boom.
Refer to Figure 13-19 and disassemble the boom point assembly as follows:
1. Place the boom point assembly on suitable blocking.
2. Remove the retainer (07) by removing cap screws (04) and tie wire (05) and shims (08-11) beneath the plate.
Save the shims for use during reassembly.
3. Remove sleeve (12) and retainer (13). Keep bearings (14) in place in the sheave hub and pull sheave (15) with
bearings (14) in place 17 from the pin (11). Each sheave assembly weighs approximately 5,500 lbs (2,495 kg).
4. Remove the spacer (16) and retainer (13), and then remove the second sheave in the same manner.

5. Remove the remaining retainers and bearings from the sheaves.
6. Remove the boom point pin cap (20) by removing the socket head cap screws (23)
7. Inspect and replace components as necessary.
13.3.6.3 Inspection
The sheave bores and boom point pin should be checked for wear when the assembly has been disassembled.
13.3.6.4 Assembly
Refer to Figure 13-19 and assemble the boom point assembly as follows:
1. Lubricate the cap screws (23) and attach the boom point pin cap (20) to the right end of the pin. Torque the cap
screws to 840 ft-lbs (1,139 N·m).
2. Install the cups of bearings (14) in the bores of sheaves (15). The heels of the cups should be seated in the
inside of the sheave hub so that the bearing cones fit properly into the bearing cup.
3. Using a suitable lifting device, position and block sheave (15) in an upright position.
CAUTION
All bearing cones must be preheated prior to installation. Extreme care must be taken to
assure that the bearings are not heated over 300°F (148°C) or damage to the bearings
may result. Freezing of the bearing cups is acceptable to aid in their installation. Refer to
Topic 3.4 for more information.
4. Install retainer (13) on pin (17). Install the cone of bearing (14) on pin (17). Ensure that the heel side of the
bearing cone is seated against retainer (13) and the taper is away from the retainer.
5. Install the sheave (15) on the pin (17), being careful to guide bearing (14) together. While supporting the
sheave (15), install the cone of second bearing (07) on the shaft and guide into its cup.
6. Install retainer (13) and sleeve (16) on the pin (17). Repeat steps 3 and 4 above for the remaining sheave.
Install bearings and sheave similar to first sheave.
7. Install sleeve (12) on the pin (17).
8. Place the boom point assembly on a saddle so it can be rotated.
9. Shim the retainer (07) as follows:
A. With no shims in place, loosely install the retainer (07) on pin (17) using two cap screws (04) installed 180°
apart.
B. Gradually tighten the two opposing cap screws while rotating both sheaves.

NOTICE
Rotation is necessary to allow tapered roller bearings to seat properly.
C. Continue rotating the sheaves and tightening the bolts until light resistance is felt. This indicates a light pre-
load on the bearings.
D. Measure the gap between the end of pin (17) and the retainer (07).
E. Using shims (08 - 11), prepare and install a shim pack of a thickness equal to the measured gap +0.000 to
0.005 inches (0.13 mm) . If possible, stay on the low side of the tolerance.
F. Lubricate drilled head cap screws (04) with an anti-seize compound and torque them to 1,365 ft-lbs (1,851
N·m).
G. Check sheaves for free turning. They should turn no harder than when they were turned with two opposing
cap screws tightened.
H. Secure cap screws (04) with tie wire (05).
! WARNING
lowering or moving components with lifting equipment. The boom point assembly
1. Using a suitable crane, position the boom point assembly on the boom point bearing blocks (see Figure 13-10).
Make sure the slot in the boom point pin engages the retaining plate on the right side of the boom point. The
assembly weighs approximately 13,375 lbs (6,070 kg).
2. Install the boom bearing cap blocks and install the SuperNuts. Refer to Subtopic 3.3.7 for this procedure.
3.
4. Install the lubrication lines on the boom point pin.
Application Super- Initial Final Number Dia. of Size of Qty Bolts Lubri-
Nut™ Dia. Target Target of Jack- Jack- Socket per cant
& P/N Torque (ft-lbs) screws screws Required Shovel Req’d for
(ft-lbs) per Jack-
Super- screws
Nut™
Boom Point 0.625-

2.5-12UN 0.5625"
Bearing Block 125 250 12 18UNF 4 JL-G
(R25192D1) (9/16")
Studs (5/8")
Table 13-1: Boom Point SuperNut Information
5. Cycle the automatic lubrication system until lube reaches the boom point and flows out of the bearing.

6. Install the hoist ropes.
13.3.7 Boom Suspension Cables 30U254D5
Figure 13-20: Boom Suspension Cable Lubrication Fitting
Every 90 days, apply multi-purpose grease through the fitting in the cable pendant (refer to Figure 13-20. There are
eight fittings total, one at each pendant) until grease is visible between the strands at the point where the cable
joins the pendant.
13.3.7.2 Inspection
! WARNING
Unexpected shovel movement can shake or bounce the boom causing personnel to fall,
resulting in serious personal injury or death. Shut down the mining shovel and use lock-
out and tagout procedures before conducting inspection, maintenance, or service on the
boom. Always use personal fall protection equipment and follow tie off procedures while
on the boom.
Confirm that preliminary maintenance procedures as described in Subtopic 13.3.2 have been completed.
Inspect the suspension cables every 250 hours as follows:
• Check the suspension cable pins for wear, retention, possible fatigue, and proper lubrication. There is a
manual grease fitting in each socket of the cables.
• Check the suspension cable equalizer pin assemblies for wear and security.
• Check the equalizer and equalizer links for fatigue cracks and broken pin retainers.
• Check suspension cables mainly for broken wires. Replace them, at the latest, when 25% of outer wires are
broken. Refer to Subtopic 13.3.7.4.
13.3.7.3 Repair
Repair is limited to replacing the suspension cables.

The replacement criteria for bridge strand suspension cables is 25% of the outer wires broken.
Boom suspension cables should be replaced in sets of four. If this is not possible, it is permissible to replace only
two ropes. If replacing only two ropes, install one new rope on one side and one on the other side (the new ropes
should not both be installed on the same side because there is no side-to-side equalization). The new rope may be
installed on either the top or the bottom, since the ropes are equalized vertically.
Replace the boom suspension cables as follows:
! WARNING
lowering or moving components with lifting equipment. The complete boom assembly
weighs approximately 330,000 lbs (150,000 kg); however, it is pinned to the revolving
frame at its base.
ES04885a01
Figure 13-21: Support the Boom
2. Refer to Figure 13-21 and attach a suitable crane to the boom lifting points to support the boom and allow the
boom suspension cables to go slack.
! WARNING

lowering or moving components with lifting equipment. Each boom suspension cable
weighs approximately 4056 lbs (1840 kg)
Figure 13-22: Remove the Boom Suspension Cable

Replace one cable at a time.
1. Using a suitable crane, support the cable to be removed near the pendant attached to the gantry.
2. Remove the pins from the cable pendants at the gantry. Place the pendant on the ground.
3. Support the cable near the pendant attached to the boom point.
4. Remove the pin from the pendant at the boom point. Place the cable on the ground.
5. Support one pendant on the replacement cable and lift it into place at the boom point. Install the support cable
pin in the boom point equalizer.
Figure 13-23: Line Stripes on Suspension Cables
6. Support the other pendant and lift it into place at the gantry. Observe the line stripe (refer to Figure 13-23) to
confirm that the pins are in line and that the cable is not twisted. Install the mounting pin.

7. Continue in like manner until all suspension cables have been replaced.
8. Carefully lower the crane that is supporting the boom until the boom suspension cables are supporting the full
weight of the boom. Confirm that all cables are supporting the boom equally and that all pendants and mount-
ing hardware are secure.
9. Remove the crane from the boom.
13.3.8 Cable Guide R42917F1
LEGEND
01. Guide Brace
02. Guide Roller
03. Roller Tube
04. Tube Roller Bracket
05. Guide Frame
06. Cotter Pin
07. Slotted Hex Nut
08. Flat Washer
09. Pin
10. Cap Screw
F6596A 11. Flat Washer
12. Hex Nut
Figure 13-24: Cable Guide Assembly
13.3.8.1 Inspection
The cable guide, shown in Figure 13-24, should be inspected at the same time that the suspension cables are
inspected.

• Inspect the roller guides (02) for wear and replace as necessary.
• Check the roller tubes (03) and tube roller brackets (04) for wear.
• Inspect the hoist rope guide braces (01) and frame (05) for wear and damage.
13.3.8.2 Repair
Repair is limited to the replacement of worn or broken parts.
Replace components as needed by removing the mounting hardware and replacing the component.
Replacing the frame requires the hoist ropes to be removed. Proceed as follows:
2. Remove hoist ropes as described in Subtopic 12.3.10.3.
! WARNING
lowering or moving components with lifting equipment. The cable guide weighs approxi-
! CAUTION
Unexpected component movement can pinch or crush, resulting in personal injury. Stay
clear of potential movement as mounting hardware is removed.
3. Attach a suitable lifting device to the frame of the hoist rope guide.
Figure 13-25: Cable Guide

4. Remove mounting hardware from the mounting lugs.
5. Remove the frame from the boom.
6. Using a suitable lifting device, lift the replacement frame into place on the boom and install the mounting hard-
ware.

13.3.9 Boom Resolver Assembly R43964F1
LEGEND
01. Cover 03. Actuator Link
02. Resolver Linkage 04. Linear Resolver
Figure 13-26: Boom Resolver Assembly
13.3.9.1 General
The boom limit switch resolver is mounted inside the machinery house at the front right corner of the machinery
deck. An extension protrudes through the forward wall of the machinery house and connects to the boom to sense
boom movement.
13.3.9.2 Inspection
Inspect the boom resolver assembly every 750 hours as follows:

• Check the operational condition of the assembly.
• Check to make sure that the resolver hardware is secure.
• Check the link wiper on the outside of the machinery house to make sure it is contacting the top of the link
evenly.
13.3.9.3 Repair
Repair of the boom resolver assembly is limited to replacing worn or damaged parts.
13.3.9.4 Adjustment
To connect the linear resolver (04, Figure 13-26) to the actuator link (03) proceed as follows:
2. With the boom at rest, slide linear resolver to the center of its travel.
3. Being careful to not move the linear resolver position, connect the clamp link to both the actuator link and linear
resolver. Tighten clamping hardware.
When the shovel starts up, the control system will reset itself to the resolver’s new position. No other adjustment
should be necessary.
13.3.9.5 Supplemental Information
Zero boom jack reference is the position of the boom when the boom suspension ropes are supporting the weight
of the boom (at rest position).
Setting the zero boom jack reference does not set the resolver input signal to 0 volts but will set a binary value in
the Centurion Control System to the value of the resolver input signal when the boom is in an at rest position. This
is now the zero point value in the Centurion Control System.
The Anti-Boomjack Soft Setdown (ABSS) logic will auto set the zero boom jack position when: the shovel is started
with the dipper set on the pit floor and the bail is lowered so that the hoist resolver count is within 100 counts of the
lower hoist limit.
The desired Stage 1 and Stage 2 levels can be adjusted via the appropriate GUI screen when the program key
switch is in the program position. From the TABLE OF CONTENTS screen the ABSS LIMITS screen can be
accessed.
13.3.9.6 ABSS Warning Screens
The following GUI screen warnings are associated with the boom limit switch:
1. WARNING! - ABSS SYSTEM DISABLED
• If the ABSS system is disabled from the touch panel, a warning will be displayed each time the shovel is
started.
• The ABSS system can only be enabled/disabled when the LUBE/PLS key located on the control cabinet
door is in the program mode.

2. ABSS AUTO RETRACT - BOOM LIMITS FAULT
• This message will be displayed if the system is in a Stage 1 or Stage 2 condition and the boom profile or
retract limits are exceeded.
3. ABSS GLIDE HIGH LIMIT EXCEEDED FAULT
• This message will be displayed if the glide of the linear resolver is moved forward toward the boom from the
zero point position. The glide may be loose or the system may have been tampered with. The system should
be checked and reset.
4. ABSS GLIDE OUT OF RANGE FAULT
• This message will be displayed if the glide is too far forward or too far back on the linear resolver. The glide
should be set up in the center of its travel - halfway point on the aluminum slide body.
Disconnect linear resolver from the actuator link before raising the boom or lowering the boom for maintenance.
Failure to do this could move the linear resolver past its maximum travel and damage it.
13.3.10 Dipper Trip Assembly R54947F2
01
02 03 02 04
TC0416a
LEGEND
01. Dipper Trip Assembly 03. Dipper Trip Cable
02. Dipper Trip Sheave 04. Dipper Latch Mechanism
Figure 13-27: Dipper Trip Assembly R54947F2
Inspect the dipper trip assembly components every 250 hours as follows:

• Check the dipper trip motor mounting cap screws for security. There are six large cap screws that attach the
motor bracket to the large mounting bracket. These cap screws should be torqued to 266 ft-lbs (360 N·m)
There are also two cap screws that attach the motor feet to the base. These cap screws should be torqued
to 75 ft-lbs (102 N·m). The mounting bracket is attached to the boom by four cap screws. These cap screws
should be torqued to 910 ft-lbs (1234 N·m).
• Check for proper slack take-up.
• Check the condition of the trip cable. Refer to Subtopic 13.3.12 to replace dipper trip cable.
• Check for loose or damaged components.
• Check the dipper trip drum guard to verify that it is firmly fastened and still functional.
Repair to the dipper trip assembly components is limited to replacing worn or damaged parts.

13.3.11 Dipper Trip Motor and Drum Assembly R54946F2
LEGEND
01. Dipper Trip Drum Guard
03. Hex Nut
04. Dipper Trip Drum
05. Dipper Trip Transmission
06. O-Ring
07. Set Screw
08. Motor
09. Dipper Trip Bracket
10. Lock Washer
11. Shims
12. Hex Nut
13. Hardened Washer
16. Set Screw
17. Hardened Washer
19. Lock Washer
Figure 13-28: Dipper Trip Motor and Drum R54946F2

13.3.11.1 Removal
Refer to Figure 13-28 and remove the dipper trip drum and motor assembly as follows:
! WARNING
Contact with energized circuits can cause severe injury or death. Disconnect power to
the dipper trip circuits before removing electrical connections to the motor. Use lockout
and tagout procedures before servicing.
2. Open and lock open electrical power to the dipper trip motor. Tag and disconnect the electrical input leads from
the motor.
3. Remove the dipper trip cable from the drum.
NOTICE
To ease the turning of the drum by hand, the transmission can be disengaged. This will allow
the drum to free wheel. Refer to subsection 13.3.11.2 for details.
! WARNING
lowering or moving components with lifting equipment.
4. Remove the cable guard. The guard weighs approximately 135 lbs (61 kg).
5. Attach a suitable lifting device to the dipper trip motor and drum assembly. This assembly weighs approxi-
mately 700 lbs (318 kg) without the cable.
6. Remove the mounting bolts (18 and 19, Figure 13-27) and lift the assembly from its mount.
13.3.11.2 Transmission Disengagement
The dipper trip transmission can be disengaged to allow the drum to free wheel and ease turning it by hand. A
small cap (manual disengage cap) on the side of the transmission opposite the motor has a protrusion in the mid-
dle. By removing this manual disengage cap, inverting it (so that the protrusion is now internal to the transmission),
and re-installing the cap the transmission is disengaged.
The manual disengage cap will press in a rod, which will disengage the transmission. To disengage the transmis-
sion manually, refer to Figure 13-29 and proceed as follows:
1. Remove four cap screws on manual disengage cap.
2. Invert manual disengage cap.

AA
A
01
02
A
03 05
06
C
TC0451c
02 04
LEGEND 05. Motor Assembly

01. Dipper Trip Motor and Drum 06. Brake
02. Manual Disengage Cap
03. Transmission Assembly B. Transmission Engaged
04. Dipper Trip Drum C. Transmission Disengaged
Figure 13-29: Dipper Trip Motor and Drum Assembly (R59556F2)

3. Replace four cap screws and tighten.
To engage the transmission invert the manual disengage cap and install so that protrusion is again facing out.
To disassemble the dipper trip motor and drum (Figure 13-28) proceed as follows:
1. If the assembly was removed from the machine, secure the dipper trip motor and drum on a sturdy base.
2. Support guard assembly and remove (if not removed earlier). To remove the guard assembly, remove socket
head cap screw (02) and four cap screws (23) and washers (24). Lift guard assembly clear. Guard assembly
weighs approximately 135 lbs (61 kgs).
3. Support drum assembly and remove nuts (03) from transmission studs, and remove drum (05) from transmis-
sion (06). Drum assembly weighs approximately 150 lbs (68 kgs) without cable.
4. Match mark transmission and motor before removal. Support transmission assembly (06). Remove eight cap
screws (22) and washers (21). Remove transmission (06) and o-ring (07) from motor.
5. Support the motor (09) and remove six mounting cap screws (19), nuts (16) and hardened washers (17).
Remove four cap screws (19), nuts (12) and washers (11). Lift motor clear of the bracket.
Clean and inspect all parts visually for cracks, damage, or excessive wear.
Check gear oil level in transmission and inspect transmission for leaks. There are two pipe plugs on the front of the
transmission. Rotate the drum until the pipe plugs are oriented as seen in Figure 13-30. The lower plug is the level
plug. Remove this plug to check level, and fill at the top plug until gear oil just begins to spill out of level plug.
Transmission oil should be replaced with the oil recommended in the Air and Lube Systems Manual every 1000
hours of operation.
13.3.11.5 Repair
Repair of the drum and motor assembly is limited to replacing worn or damaged parts. Replace O-ring (09) when
disassembled.
13.3.11.6 Assembly
To assemble the dipper trip motor and drum assembly (Figure 13-28) proceed as follows:
1. Assemble flange of motor (09) to large mounting bracket (10) with six cap screws (19), nuts (16), and hardened
washers (17). Torque cap screws to 266 ft-lbs (360 N·m). Install two cap screws (18), nuts (12), and four wash-
ers (12) that attach the motor feet to the base. Torque cap screws (18) to 75 ft-lbs (102 N·m). The mounting
bracket is attached to the boom by sixteen cap screws (13), nuts (15), and thirty-two hardened washers (14).
Torque cap screws (13) to 910 ft-lbs (1,234 N·m).
2. Have transmission disengaged (see Transmission Disengagement above). Lubricate O-ring (07) with a light
coating of multi-purpose grease and install on transmission. Seal four setscrews (08) and two setscrews (20)
with silicone and install in transmission.

Figure 13-30: Dipper Trip Transmission (R53914D2)
3. Assemble transmission (06), with O-ring (07) and setscrews (08) and (20), to motor with eight cap screws (22)
and washers (21). Torque cap screws to 150 ft-lbs (205 N·m). Splines on motor shaft must be aligned with
internal splines in transmission when assembling.
4. Assemble drum (05) to transmission (06) with ten nuts (03) on transmission studs. Torque nuts (03) to 332 ft-
lbs (450 N·m).
5. Fill the transmission with oil as instructed in Section 17.
6. Rotate drum assembly (05) to ensure that the drum assembly rotates freely.
7. Engage transmission.
8. Install the cable guard assembly.
To install the dipper trip motors and drum assembly (Figures 13-28, and 13-29) proceed as follows:
1. Position the motor and drum assembly on the mounting bracket, which is attached to the side of the boom.
1. The mounting bracket is attached to the boom by four cap screws (22), nuts (20), and eight hardened washers
(21). Torque cap screws (22) to 680 ft-lbs (925 N·m).

2. Attach the dipper trip cable to the drum. The drum has two connections for cable attachment. One is a ferrule
becket socket. The other is a bracket for a cable wedge. Either connection can be used.
3. Connect the electrical wiring to the motor.
13.3.11.8 Motor Brake Adjustment
! WARNING
Unexpected machine movement could cause striking, pushing or crushing, resulting in
serious personal injury or death.Do not manually release the brake before blocking over-
hauling loads to prevent unexpected machine movement.
01 02
05
03
ES02504b01
04
LEGEND 04. Manual Release Lever
01. Pilot Plate (set position)
02. Pan Head Screw 05. Brake Manual Release Lever
03. Adjusting Bolt (released position)
Figure 13-31: Manual Brake Release
The manual brake release levers are located on the back of the brake, opposite the input hub. Refer to Figure 13-
28. If it is necessary to manually release the brake, simultaneously turn the two levers counterclockwise approxi-
mately 90 degrees to their stop positions. The manual release levers will automatically reset the next time the
brake is energized. The levers may also be moved to the reset position manually.
13.3.11.9 Motor Break Wear Adjustment Procedure
Air gap adjustment is necessary if either or both of the following conditions are observed:

• A decrease in braking torque is observed. Adjustment is recommended when braking torque drops to
approximately 80 percent of its static rating.
• Complete lack of disengagement (dragging), or if the motor stalls.
In either case, proceed as follows:
! WARNING
Contact with energized circuits can cause serious injury or death.T his equipment is at
line voltage when ac power is connected. Disconnect and lock out all ungrounded con-
ductors of the ac power line.
1. Disconnect line voltage to the machine and perform lockout/tagout procedures to assure that electric power to
the motor is off and that the brake is deenergized.
2. Turn the three smaller hex bolts (see Figure 13-31) clockwise progressively to 50 in-lbs. Then turn the bolts
counterclockwise 1/2 of a full turn (180°). This will reset the air gap to the proper value.
3. Turn the electrical power on and check for normal operation. If adjustment intervals become frequent, the
brake friction disc may require replacement. In this case, contact your local P&H MinePro service representa-
tive,
13.3.11.10 Manual Brake Release Adjustment
The manual brake levers (see Figure 13-31) require adjustment if either of the following conditions are observed:
1. The levers will not stay in the brake released position; i.e., 90 degrees from the housing.
2. The levers do not rotate back to the fully engaged position when the brake is energized.
For the first condition, the levers will not stay in the brake released position, proceed as follows:
! WARNING
Contact with energized circuits can cause serious injury or death. This equipment is at
line voltage when ac power is connected. Disconnect and lock out all ungrounded con-
ductors of the ac power line.
! WARNING
Unexpected machine movement could cause serious injury or death. Do not manually
release the brake before blocking over-hauling loads to prevent unexpected machine
movement.
1. With power to the brake off, manually hold the lever out 90 degrees from the housing and insert a 7/64” hex
key into the hex head cap screw in the release lever.
2. Slowly turn the cap screw clockwise until the lever maintains this position by itself.

3. Repeat this procedure for the other lever.
4. Rotate both levers simultaneously to the brake released position. They should maintain this position. If not,
repeat the procedure.
5. Apply electric power to the brake. The levers should snap back to their original set position.
For the second condition, the levers do not rotate back to the fully engaged position when the brake is energized,
proceed as follows:
! WARNING
Unexpected machine movement could cause serious injury or death. Block over-hauling
loads to prevent unexpected machine movement. before manually releasing the brake.
1. Start with the levers in the released position. With electric power supplied to the brake, insert a 7/64” hex key
into the hex head cap screw in the release lever.
2. Slowly turn the cap screw counterclockwise until the lever snaps back to the housing. Repeat this procedure
with the other lever.
3. To test, with power to the brake off, use the manual release levers to release the brake. Apply electric power to
the brake. Both levers should snap back to the housing. If not, repeat the procedure.

13.3.12 Dipper Trip Cable R17556D2
01
02 03 02 04
TC0416a
LEGEND
01. Dipper Trip Assembly 03. Dipper Trip Cable
02. Dipper Trip Sheave 04. Dipper Latch Mechanism
Figure 13-32: Dipper Trip Cable Reeving
The dipper trip cable is reeved from the dipper trip drum through the dipper trip sheaves, and attaches to the dipper
latch mechanism. During normal digging, the dipper trip cable is maintained at minimal tension by the dipper trip
motor. When the operator trips the dipper, extra torque applied to the dipper trip motor is transmitted through the
cable to the dipper latch mechanism on the dipper, and the dipper door opens.
No regulatory requirements apply to the dipper trip cable. Replace the cable when it has excessive broken wires. It
is generally more cost effective to change the rope before it breaks rather than waiting for total failure.
! WARNING
Unexpected machine movement could cause serious injury or death. Do not manually
release the brake before blocking over-hauling loads to prevent unexpected machine
movement.
2. Disconnect the dipper trip cable from the dipper latch mechanism and from the dipper trip drum. If necessary,
refer to Subtopic 13.3.11.2 and disconnect the dipper trip transmission to permit the dipper trip drum to turn.

Figure 13-33: Attach Dipper Trip Cable to Dipper Trip Drum
3. Install the ferrule sleeve into the ferrule becket socket with the free end of the rope feeding outward from the
drum.
4. Reeve the free end of the cable through the sheaves on the boom.
5. Remove approximately 2” (5 cm) from the free end of the cable.
6. Attach the end of the cable to the dipper latch mechanism on the dipper.
! CAUTION
When the shovel starts, the dipper trip drum will begin to turn in the takeup direction. Be
certain no persons are in the vicinity of the slack dipper trip cable. Persons straddling
the cable could be upended, resulting in personal injury.
7. Remove locks and tags and start the shovel.
8. Observe the dipper trip cable as it winds onto the drum. Re-wind if the cable winds unevenly.


ES41157 Mechanical Systems Manual Crowd System
Section 14
Crowd System
Figure 14-1: Crowd System
14.1 General
The crowd system components, as shown in Figure 14-2, are mounted on the boom. The crowd components con-
sist of the crowd drive system, the crowd gear case and transmission, shipper shaft and pinions, the saddle blocks,
the dipper handles, the crowd brake assembly, and the crowd limit switch sensor. The crowd drive system includes
the crowd motor, the crowd motor base, the Power Band® (multiple belt) drive assembly, and the crowd belt ten-
sioning system.
When the mining shovel is in the crowd mode of operation and the crowd controller is actuated, the crowd motor
drives clockwise or counterclockwise depending on the direction of controller movement.

Sec14Crowd.fm -14.1- Section 14, Version 00 - 06/07
Crowd System ES41157 Mechanical Systems Manual
02
01
03
TC1601B
06 04
05
07
LEGEND 04. Saddle Block
01. Crowd Motor 05. Shipper Shaft and Pinion
02. Crowd Transmission 06. Crowd Brake (on opposite side)
03. Dipper Handle 07. Power Band® Cover
Figure 14-2: Crowd System Components (Side View)
The drive power from the motor is transmitted through the Power Band belt drive assembly to the crowd machinery.
The crowd machinery transmits the drive power through two gear reductions to the shipper shaft and pinions. The
shipper shaft pinions engage the racks on the dipper handles, and drive the dipper handles out (crowd) or in
(retract) depending on the positioning of the controller.
The saddle blocks, which are mounted on the shipper shaft, hold the dipper handles on the shipper shaft pinions
and distribute the loads from the dipper handles.
The crowd brake is a spring-set, air released, disc type holding brake. The crowd brake is used to hold the dipper
when the machine is idle.
The crowd limit switch sensor provides an electrical signal which is used to limit the travel of the dipper handle and
prevent the dipper handle from being crowded or retracted too far.

Section 14, Version 00 - 06/07 -14.2- Sec14Crowd.fm
The crowd system machinery is lubricated by various methods, including single point grease fittings, bath and
splash, and pressure feed from the automatic lubrication system. Refer to Section 17 for details.
14.2 Components
14.2.1 Crowd Drive Assembly R42119F1
04 04
03
05
02
01
06
ES04895a01
LEGEND
01. Crowd Motor 04. Shipper Shaft
02. Crowd Brake 05. Crowd Limit Switch
03. Crowd Gear Case 06. Power Band Cover
Figure 14-3: Crowd Drive System
Refer to Figure 14-3. The crowd drive assembly includes a horizontally mounted fast response DC motor (01) and
a Power Band® drive assembly (06).
The motor provides drive power and the Power Band drive assembly couples the drive power to the crowd trans-
mission (03) first reduction shaft. The motor is mounted on a pivotable base that permits adjustment of the Power
Band belt tension using a hydraulic cylinder, brake, and pump.

The crowd motor is kept cool and relatively clean by a motor and blower assembly that is mounted in the machin-
ery house. This blower assembly draws clean air from the machinery house and blows the air through ducting to
the crowd motor.
The Power Band drive assembly includes a case, the Power Band belts, and the belt drive sheaves. The case
completely encloses the belt drive system and has access covers for inspection and belt maintenance. The case
can be opened for motor removal.
14.2.2 Automatic Tensioning System
The belt tensioner system provides correct belt tension. It can be programmed (through the Centurion Control Sys-
tem) to performs automatic belt tensioning as specified intervals. It also has features to tension the belts on
demand, as well as to move the crowd motor mounting table to permit belt replacement.
14.2.2.1 Power Unit R45023
Figure 14-4: Hydraulic Power Unit R44023
The hydraulic power unit (refer to Figure 14-4) is mounted in the lubrication room. The power unit comes com-
pletely assembled and includes the following equipment:
• 1.5 GPM fixed vane pump
• 5 gallon heavy gauge steel reservoir with clean-out access
• 3 phase, 230/460 VAC, 50 Hz, 1800 RPM, totally enclosed, fan cooled motor with C-face mount
• Motor/pump adapter
• Filler/breather
• Oil level sight gauge
• Pressure gauge
• Single station manifold with unloading valve and adjustable relief valve set at 1700 psi
• Return-line spin-on filter (5 micron)

• Pressure and return line check valve
14.2.2.2 Hydraulic Solenoid Manifold With Electrical Panel
LEGEND
01. Electrical Panel 03. Hydraulic Cylinder
02. Hydraulic Solenoid Manifold 04. Test Ports
Figure 14-5: Hydraulic Solenoid Panel and Electrical Panel
The hydraulic solenoid manifold and electrical panel (Figure 14-5) are a part of the tensioning assembly, which is
mounted on the boom and attached to the crowd motor mounting base.
Visible from the outside on the hydraulic solenoid manifold assembly are the test ports, the proximity switch, and
the electrical panel. Test ports PG, RG, and LG are accessible using a quick release connection. A test gauge is
stored in the electrical box on a dummy port.

LEGEND
01. Brake Proximity Switch
02. PVD Card
03. Pressure Gauge Stored on
Dummy Port
04. Solenoid 2A
05. Solenoid 4A
06. Transducer
07. Solenoid 3A
08. Brake Air Filter
09. H1 and H2 are Threaded Holes
in the Manifold for Optional
Heaters (H2 Shown)
10. Terminal Block
Figure 14-6: Electrical Panel Interior
Inside the electrical panel (refer to Figure 14-6) are the solenoids 2A, 3A and 4A; also the PVD card, the brake air
filter, and pressure transducer.
Solenoid 2A is the rod lock (brake) release valve. Solenoid 3A is the regen valve used to direct pressure to the rod
end when it is off or drain the rod end pressure back to tank when it is on. Both of these solenoids have an amber
LED, when the LED is on it indicates that the coil is energized.
Refer to Figure 14.2.2.3 for a description of Solenoid 4A and the PVD card.
The transducer reads the pressure applied to the cylinder, it will read 815 psi at the Centurion Control System
when the RAISE or LOWER functions are activated.
14.2.2.3 Hydraulic PVD Signal Card and Associated Components
Figure 14-7: PVD Signal Card
The control of all solenoids, timing functions and operational protection is performed in the shovels’s programma-
ble logic controller (Centurion Control System) located in the right hand room. An output of 5 volts DC will be sup-

plied to the PVD card when the RAISE or LOWER functions are activated and the pump is running. The PVD card
is shown as item 02 in Figure 11-11. A closer view is shown in Figure 11-12.
The PVD card is adjusted to give a fixed current signal to the proportional solenoid valve 4A to achieve 815 psi out-
put pressure at 5 volts input to the card and 230 psi at 0 volts input to the card. The 5 and 0 volts are a function of
the Centurion Control System.
The power supply to the card is 24 volts DC; the PWR LED will be red (on) if the power supply voltage is greater
than 10.5 volts DC.
The PWM% LED indicates the duty cycle of the voltage to the coil by going from pure red, always off, through pure
green, always on at full current. The ratio of red to green gives a relative indication of the current flow through the
coil and is helpful when troubleshooting. In the crowd belt tensioning application, the PWM% LED will only switch
from a dark red to a light red when the RAISE or LOWER functions are activated with the pump running, and dark
red when they are not - regardless of whether the pump is running or not.
The MAX potentiometer is factory set to clamp the output pressure of solenoid valve 4A to 815 psi at 5 volts DC
input to the PVD card.
The MIN potentiometer is factory set to clamp the output pressure of solenoid valve 4A to 230 psi at 0 volts DC
input to the PVD card. The directional solenoid 1A shuts off with the proportional solenoid 4A, therefore you will
never see the 0 volt or 230 psi min setting.
DITHER AMPLIFICATION, RAMP UP, and RAMP DOWN are not used and should be set to the max CCW posi-
tion.
Proportional solenoid valve 4A has a maximum pressure of 5000 psi (350 BAR). This is an electro-hydraulic, pro-
portional valve and is a screw in cartridge style. It is a pilot operated, sliding spool, high pressure reducing and
relieving control valve.

14.2.2.4 Hydraulic Cylinder
Figure 14-8: Hydraulic Cylinder
The hydraulic cylinder used in the belt tensioning system is shown in Figure 11-13. Some specifications of the cyl-
inder are:
• Bore Diameter: 5.0 in.
• Rod Diameter: 2.0 in.
• Stroke: 11.0 in.
• Max Operating Pressure: 1700 psi
• Base Rod Connection: Clevis
• Oil Requirements: SAE 10, SAE 20
• Rate of travel 0.29 inch per second (extend), 0.35 inch per second (retract)
• Extend Force 16000 lbs.
• Retract Force 1650 lbs.
14.2.2.5 Hydraulic Rod Lock (Brake)
The rod lock or brake is a spring set, hydraulic release brake which provides clamping of the cylinder when the
power is off. It is released by hydraulic pressure when the 2A solenoid is energized. As pressure falls, the brake will
be set by the springs. The brake consists of an alloy steel housing with the locking mechanism actuated by disk
springs.
• Holding Force: 17000 lbs.

• Min Release Pressure: 1400 psi
• Min Set Pressure: 500 psi
• Proximity Switch: Is supplied with 24 VDC, when the brakes are released it will illuminate an LED which is
amber in color.
14.2.2.6 Control Panel R44918F1
CROWD
BELT
CHANGE
CONTROL
WARNING
TC0424b
Figure 14-9: Control Panel R44918F1
The control panel (Figure 14-9) is located outside the operator's cab and contains a selector switch and push but-
tons to control the crowd belt tensioner.
Controls and Indicator Description
• Selector Switch
• Hand - Manual control
• Off - No manual or automatic control can occur

• Auto - Automatic tensioning will occur at timed intervals
• Pump Start - Will start the pump in the lube room
• Raise - Once the pump is running pushing this button this will extend the cylinder to raise the motor
• Lower - Once the pump is running pushing this button this will retract the cylinder to lower the motor
• Pump Stop - Will stop the pump in the lube room
NOTICE
The shovel can only be started when the selector switch is in the OFF or AUTO position.
14.2.3 Crowd Belt Tensioning System Operation
Adjustment of Crowd belt tension is a function of the Centurion Control System, and is achieved by either a manual
or automatic control. Manual control is described in subsection 11.5.3.2, and auto control is described in subsec-
tion 11.5.3.3. Figure 11-15 shows a hydraulic schematic for the Crowd Belt Tensioning System.
14.2.3.2 Manual Control
! WARNING
Unexpected shovel operation can result in injury or death. Turning the selector switch to
HAND while the shovel is running will result in an immediate shovel shut-down. Turning
the selector switch to HAND must only be done while the shovel is shut down and the
dipper is on the ground. The shovel will not start while the selector switch is in HAND.
If the maintenance personnel wish to manually raise or lower the motor, the shovel must first be shut down. The
selector switch (see Figure 11-14) needs to be in the HAND position.
NOTICE
The hydraulic reservoir, the electric motor, the hydraulic pump and directional valve 1A are
located in the lube room. Hydraulic fluid is pumped from the lube room to the belt tensioning cyl-
inder when required.
Manual operation will occur only if the shovel is shut down and the switch is in the HAND position. Heavy springs in
the rod lock are set, preventing the cylinder from moving. The brake proximity switch, mounted on the brake, will
activate when the brake is released, the Centurion Control System will then allow raising and lowering of the cylin-
der.

03 05
04
SOL 2A
06
SOL 3A
LG
#4 07
P
SOL 4A SAE
PG
RG
02
08
09
T
SOL 1A A
A B
B
P 1700
PSI
TC0430a_02
01
LEGEND
01. Motor and Pump (in lube room) 06. Vent Line
02. Cylinder 07. Pressurized to Unclamp
03. Transducer 08. Rod Lock
04. Breather 09. Proximity Switch
05. Electrical Enclosure SOL = Solenoid
Figure 14-10: Crowd Belt Tensioning System Schematic (R43711)

NOTICE
The shovel’s inclinometer will inhibit the operation of the crowd belt tensioning system if the
incline or decline is more than 5 degrees. Ensure the shovel is parked on a level surface and
that the inclinometer is functioning properly or improper belt tensioning may occur.
! CAUTION
Moving components can pinch or crush, resulting in personal injury. Stay clear of the
motor base, motor, belt case, and cylinder while the tensioning system is functioning.

03 05
04
SOL 2A
06
SOL 3A
LG
#4
07
P
SOL 4A SAE
PG
RG
02
08
09
T
SOL 1A A
A B
B
P 1700
PSI
ES1251_03
01
LEGEND 05. Electrical Enclosure
01. Motor and Pump 06. Vent Line
(in lube room) 07. Pressurized to Unclamp Supply
02. Cylinder 08. Rod Lock Return
03. Transducer 09. Proximity Switch Drain
04. Breather SOL = Solenoid
Figure 14-11: Schematic: Pump Started
The schematic in Figure 14-11 shows the tensioner started but in an unloaded condition. The pump starts when the
START push button has been pressed. Directional Control Valve 1A is not energized, so oil will revert back to tank
and no pressure will build up in the system.

1.
03 05
04
SOL 2A
06
SOL 3A
LG
#4 07
P
SOL 4A SAE
PG
RG
02
08
09
T
SOL 1A A
A B
B
P 1700
PSI
ES1251c_03
01

01. Motor and Pump 06. Vent Line Supply
(in lube room) 07. Pressurized to Unclamp Return
02. Cylinder 08. Rod Lock Drain
03. Transducer 09. Proximity Switch
Figure 14-12: Schematic: Raise
The schematic in Figure 14-12 shows the tensioner in the “RAISE” condition. Valves 1A, 2A and 3A are energized.
In this condition, system pressure settings can be verified. Refer to the adjustment procedure in Subtopic 14.3.6.2.

Actuating valve 1A supplies pressure to the manifold on the crowd belt tensioning cylinder located under the crowd
motor base.
Actuating valve 2A applies pressure to release the rod lock (brake release).
Actuating valve 3A allows the pressure in the cylinder rod end to drain back to tank (allows motor to raise rapidly).
The brake proximity switch will activate, indicating a brake release. A light emitting diode (LED) located on the back
of the proximity switch will indicate that it is activated.
At the same time, the Centurion Control System sends 5 VDC to the PVD amplifier, which in turn sets a fixed pres-
sure on the cylinder cap end through the proportional valve 4A. On the 4100XPC 5 VDC = 815 PSI.
The motor base will now raise, and will continue to raise, until the cylinder reaches it's maximum extend position or
until the RAISE push button is released.
Releasing the RAISE push button will de-activate valves 1A, 2A, 3A and 4A. De-energizing the solenoids will
cause the rod lock to set and the brake proximity switch to de-activate. Pressure to the system is shut off, cylinder
motion stops. The pump will continue to run as described under Figure 14-11.

03 05
04
SOL 2A
06
SOL 3A
LG
#4 07
P
SOL 4A SAE
PG
RG
02
08
09
T
SOL 1A A
A B
B
P
1700
PSI
ES1251d_03
01

01. Motor and Pump 06. Vent Line Supply
(in lube room) 07. Pressurized to Unclamp Return
02. Cylinder 08. Rod Lock Drain
03. Transducer 09. Proximity Switch
Figure 14-13: Schematic: Lower
When the LOWER push button is pressed and held, solenoids 1A, 2A, and 4A will activate.
Actuating valve 1A supplies pressure to the manifold on the crowd belt tensioning cylinder located under the crowd
motor base.
Actuating valve 2A applies pressure to release the rod lock (brake release).

The brake proximity switch will activate, indicating a brake release. A light emitting diode (LED) located on the back
of the proximity switch will indicate that it is activated.
At the same time, the Centurion Control System sends 5 VDC to the PVD amplifier, which in turn sets a fixed pres-
sure on the cylinder cap end through the proportional valve 4A, AND in this case, will also apply the same fixed
pressure to the cylinder rod end, on the 4100XPC 5 VDC = 815 PSI.
The weight of the motor and base is enough to overcome the pressure in the cylinder. The motor and base will
lower, tightening the belt, and will continue to do so until the belt takes up enough of the pressure causing the base/
belt/cylinder pressures to equalize.
NOTICE
If it is desired to tighten the belt fully to the correct operating tension, continue to hold the
LOWER push button until the motor and base have stopped. At this point the belts are adjusted
and you can release the LOWER push button. Note: there will be 815 psi at RG and the trans-
ducer during the entire raise and lower cycle.
2. Releasing the LOWER push button will de-activate 1A, 2A, and 4A. De-energizing the solenoids will cause the
rod lock to set, the brake proximity switch will de-activate, and shut off any pressure to the system.
3. Press the PUMP STOP push button to stop the pump. Turn the switch to the AUTO position. The switch must
be in the AUTO or OFF position in order for the shovel to start.
! WARNING
The crowd belts should be carefully tested before returning to operation whenever belt
adjustment or maintenance has occurs. Do not assume the belts are tensioned until after
they have been tested.
NOTICE
Anytime the switch is in the HAND position, even momentarily, then turned to AUTO, this will
reset the Auto Tensioning time intervals. The Auto Tensioning time intervals are 0, 10, 100,
1000 and then every 1000 hours after. The auto tensioning will only occur at shovel start-up
when all brakes are set, the selector switch is in the AUTO position, and the shovel is level.
14.2.3.3 Auto Control
The Auto Tensioning time intervals are 0, 10, 100, 1000 hours and then every 1000 hours after. The auto tension-
ing will only occur at shovel start-up when all brakes are set, the shovel is level within 5 degrees, and the selector
switch is set to AUTO.
An automatic tensioning cycle occurs similar to this:
1. When the appropriate interval has passed, the Centurion Control System will prepare for an automatic tension
to occur.

2. The next time the shovel START button is pressed and other parameters (shovel level, selector switch in
AUTO position, brakes set) are met, automatic tensioning will take place. A touch panel screen will appear indi-
cating that the auto adjust has begun and telling the operator to wait until it is complete.
3. The pump in the lube room will start. Five seconds later the base will begin to raise, and will do so for 12 sec-
onds. After the 12 seconds of raise time, the base will then begin to lower. The tensioning will stop once the
pressure transducer reaches the value of the setting in the Centurion Control System program. This pressure
should be field set to 25 psi higher than the value of the transducer, which should be 815 PSI. Ten seconds
after reaching this pressure, the automatic tensioning system will shut off. The belts should now be tensioned.
4. Once the automatic tensioning cycle is complete the touch panel screen will shut off and the shovel will start.
14.2.4 Crowd Gear Case R43474F2
Figure 14-14: Crowd Gear Case R43474F2
The crowd gear case, shown in Figure 14-14, is a modular assembly that can be removed in one piece. The crowd
transmission shaft assemblies are supported in bearing housings that are machined into the sides of the crowd
gear case cover. Both the first reduction shaft and the second reduction shaft are straddle-mounted in bores in the
gear case cover and can be removed with the cover for service or repair purposes. The shipper shaft is straddle
mounted in the boom assembly.
The base of the gear case holds approximately 110 gallons (416 liters) of gear oil for lubrication of the crowd trans-
mission gear teeth and bearings. The crowd gear case uses the bath and splash method of lubrication. It is vented
to the atmosphere through a breather cap to prevent pressure build up in the gear case and to prevent contami-
nants from entering the gear case.
14.2.5 Crowd First Reduction Shaft R41571F1
The first reduction shaft mounts in the crowd gear case cover. The shaft assembly is supported by a double row
tapered roller bearing and a straight roller bearing. Retainers, at each end of the shaft assembly, hold the shaft
assembly in place and provide seals for the crowd gear case cover.
The first reduction shaft has a sheave pulley mounted on one end and a brake hub mounted on the other. This
shaft assembly is driven by the crowd drive assembly and transmits power, through a spur-cut pinion, to the sec-

ond reduction shaft. The crowd brake mounts on the first reduction shaft. When the brake is set, the shaft and
crowd transmission are prevented from free wheeling.
The first reduction shaft bearings are splash lubricated from the crowd transmission.
14.2.6 Crowd Second Reduction Shaft R40476F2
The second reduction shaft is straddle-mounted in the crowd gear case cover. The second reduction shaft consists
of a pinion shaft with an integrally machined spur cut pinion, a spline-fit spur gear, a spacer, a double row tapered
roller bearing, a straight roller bearing, and bearing retainer plates.
The second reduction shaft is driven by the first reduction pinion and transmits the crowd drive power to the shipper
shaft gear mounted on the shipper shaft. Rotation of the second reduction shaft is monitored by a crowd limit
switch resolver which has a built in speed reducer assembly and is connected to the end of the second reduction
shaft by a flexible coupling.
The bearings and gears on the second reduction shaft assembly are splash and bath lubricated with gear oil con-
tained in the crowd gear case.
14.2.7 Shipper Shaft R54042F1
Figure 14-15: Shipper Shaft
The shipper shaft is a large machined shaft that extends out both sides of the boom. The crowd second reduction
gear, mounted on the shipper shaft, is driven by the pinion on the second reduction shaft. It is mounted within the
portion of the crowd gear case that is integral with the boom.
The shipper shaft assembly consists of an input spur gear, and two shaft-mounted pinions that mate with the dipper
handle racks to drive the dipper handles. The spur gear and the two pinions are splined to the shipper shaft.

14.2.8 Saddle Blocks R54373F3/F4
Figure 14-16: Saddle Block
The shipper shaft assembly also includes adjustable saddle blocks, which maintain the alignment of the dipper
handles with the pinions and the boom. The saddle blocks are a single piece design. They are adjusted by means
of detachable hydraulic rams and a hand-operated hydraulic pump.
Figure 14-17: Crowd Second Reduction Gear
The shipper shaft gear (crowd second reduction gear) is splash lubricated by gear oil in the crowd gear case. An
external filtration system features a pump and filter mounted between the forward swing transmissions and to filter
the gear oil. The shipper shaft bushings, as well as the saddle block bushings and wear plates, are lubricated by
the automatic lubrication system.

14.2.9 Crowd Disc Brake R41760D1
Figure 14-18: Crowd Disc Brake R41760D1
The crowd system has a single disc brake mounted on the left end if the first reduction shaft.
been consolidated into one comprehensive discussion. Refer to Section 5 for information concerning all disc
brakes.
14.2.10 Crowd Limit Switch Sensor 979J249F1
Figure 14-19: Crowd Limit Switch Sensor 979J249F1
The limit switch sensor is coupled to the crowd intermediate shaft. It consists of a resolver and mounting assembly
as shown in Figure 14-19. The resolver contains a speed reducer and a variable transformer. The speed reducer
allows the transformer adjustment to rotate less than one full turn. As it turns, the output of the transformer
changes. The control unit monitors the output of the resolver. When the output of the transformer reaches one of
the programmed limits for either the crowd or retract function, that function is shut down. The other function will still
be operational.

14.2.11 Dipper Handles R52465F1
Figure 14-20: Dipper Handles
The dipper handles (Figure 14-20) consist of two handle legs joined at the dipper end by a torsion box. The dipper
handle rack sections are welded to each of the handle legs. One greenhorn assembly is attached to each handle at
the end of the rack section.
The handles rest on the shipper shaft pinions and are held in position by the saddle blocks that are mounted on
each end of the shipper shaft.

14.2.12 Dipper R47768F5
Figure 14-21: Dipper (typical)
The dipper originally assigned this electric mining shovel is an Optima dipper with a capacity of 82 cubic yards
(62.7 cubic meters).
The body of the dipper is fabricated of abrasion resistant, high-strength steel plate. The dipper body has excellent
welding properties for repair in the field using standard welding procedures.
Figure 14-22: Dipper Identification Plate (typical)
Each P&H dipper has an identification plate welded on its side (Figure 14-22). This plate includes the dipper serial
number, which should be referenced for all correspondence concerning the dipper.

14.2.12.1 Ground Engaging Teeth (GET)
Figure 14-23: Ground Engaging Teeth
The dipper includes eight ground engaging teeth (referred to as GET) with adapters, as well as protective plating,
which includes corner shroud protectors, lip protectors, and wear plate packages.
The tooth assembly consists of a system of interlocking components that include the tooth point, tooth adapter, a
wedge, and ‘C’ clamp or spool, and a pin to hold the tooth to the adapter (Figure 14-24). For hard and abrasive dig-
ging conditions, the assembly usually also includes a wear cap.
Tooth assemblies are offered in a variety of sizes or classes. Typically WH6, WH8, WH10, WH11, and WH12 are
available, depending on the dipper type and size. Tooth adapters are mechanically attached to the dipper lip.
The “WH,” or Whisler®, sizes were developed to help standardize the fit between tooth adapters and dipper lips.
Generally, dipper lip thickness, and therefore the Whisler® fit, increases with dipper capacity.
A precise fit between the lip and tooth adapter is essential to minimize or eliminate lip rework and grinding that is
sometimes necessary to fit up tooth hardware. If the tooth adapter fit is too loose, resulting adapter movement will
damage the lip fit and cause the adapter to break prematurely.
NOTICE
Ground-engaging equipment should be installed using a systems approach. Avoid mixing
equipment from different manufacturers, even though the replacement tooth points may fit on
the standard adapters.
The fit between each manufacturer’s tooth points and adapters is proprietary. Therefore, it is generally not possible
to mix one manufacturer’s tooth points with another manufacturer’s adapters.
Tooth adapters of the same size from any supplier (for example, the WH10) are designed to fit any manufacturer’s
dipper lip of the corresponding thickness.
Points are made in a variety of shapes and lengths to fit particular adapters and applications. General purpose
points often have a slim penetration profile, combined with other design features, for use in applications ranging
from easy to hard digging. Appropriate applications may include road building, overburden removal, and mining of
various materials. General purpose points may also incorporate features such as self-sharpening designs.

04
03
02
01
05
ES0676_01
LEGEND 03. Wear Cap

01. Tooth Point 04. Wedge
02. Pin 05. Tooth Adapter
Figure 14-24: Dipper Tooth Components (Typical)
Points designed for digging rock provide high strength and long wear properties with materials, construction, and
sizes tailored to specific applications.
Point life depends largely on the application and hardness of material. For example, an 18" (457 mm) point used in
copper mining may last for weeks, while the same point used in taconite may last only eight hours.

14.2.12.2 Dipper Mounting
Figure 14-25: Dipper Mounting
Dipper attachment lugs with pins and pin retainers fasten the dipper to the dipper handle. Pitch braces, used to
hold the dipper at a set digging angle on the end of the dipper handle, connect the top of the dipper to the dipper
handles. This shovel features patented P&H adjustable pitch braces, which allow adjustment of the pitch brace
length to alter the dipper angle. Fixed, non-adjustable pitch braces are also available.
The dipper door is pin-mounted to the dipper body. Two identical pins are used to pin the back of the dipper to the
dipper handles.
The bail is pinned to the dipper for the hoist ropes. D-rings are used to retain the ropes, with pivoting rope retainers
on either side of each D-ring to keep the rope engaged.
Dual hydraulic snubber assemblies mount on the dipper to slow (or dampen) the closing of the dipper door, and to
eliminate unrestrained swinging.
The dipper trip system features a single latch bar mechanism mounted on the door. The dipper trip components
include adjusting washers and replaceable wear plates to adjust or correct for wear.
Pitch Brace Length, Tooth Angle, and Rake Angle
Dipper tooth angle and rake angle are major factors in determining how the dipper fills and how much power is con-
sumed in the filling process. The rake angle is defined as the angle formed between the level ground line from the
leading edge of the dipper lip to the point at which an individual rack pinion tooth contacts the dipper handle rack
(see Figure 14-26). As the rake angle is adjusted up or down, the tooth angle adjusts with it (see Figure 14-26).
Essentially, the idea is to have the largest tooth angle possible for maximum cutting action, balanced with reason-
able heel band clearance for acceptable wear. If the tooth angle is too high for an application, the dipper will heel
out early and heavy wear will occur on the heel band and bottom of the tooth adapters. If the tooth angle is too low,
the dipper will not fill properly and will “rake” instead of “cut” the bank, and heavy wear will occur on the top of the
tooth adapters.

The greatest influence on the size of the rake angle is the length of the pitch braces, along with proper placement
of the shovel relative to the bank.
Increasing the length of the braces tilts the dipper further forward and lifts the rear of the dipper away from the floor
and the bank during normal digging.
NOTICE
The tooth angle is not the same as the rake angle (see Figure 14-26). Thus, for a particular
application, the recommended rake angle may be 59° while the recommended tooth angle is
48°.
Pitch Brace Too Long. Indications that the pitch braces are too long (heavy penetration) include:
• Excessive material carried back on the dipper lip after dumping.
• Greater wear on the top legs of the tooth adapters than on the bottom legs.Excessive wear on the inside of
the lip.
ES0679_01
Figure 14-26: Dipper Versus Tooth Angle
Dipper Rake Versus Tooth Angle. Indications that the pitch braces incorrectly adjusted include:
• Excessive heel band and latch keeper clearance with the material as the dipper cuts through the bank.
• Difficulty holding the grade.

03
02
04
01
05
ES0680_01
LEGEND 03. Tooth Angle
01. Ground Reference 04. Rake Angle
02. Pitch Brace 05. Tooth Radius
Figure 14-27: Dipper Rake Versus Tooth Angle
• Excessive hoist motion; stalling in the bank.
Pitch Brace Too Short. Indications that the pitch braces are too short (lack of penetration) include:
• Rapid heel band and latch keeper wear with a short interval between heel band and/or latch keeper rebuild
or replacement.
• Excessive latch keeper maintenance due to increased loading on the dipper heel with little or no heel band
clearance from the bank.
• Greater wear on the bottom legs of the tooth adapters than on the top legs.
• Poor shovel operation and difficulty holding a level floor when standing back from the bank; the shovel will
not want to penetrate the bank due to lack of heel band clearance pitch. Excessive hoist and crowd motion
are required to make the dipper dig.
When the pitch braces are at their optimum length, a level floor grade can be held without difficulty. The dipper will
penetrate and slice through the bank easily and fill in about 2-1/2 lengths of the dipper front. Filling will be fastest at
the bottom (toe) of the bank, and the dipper will be full well before the time it reaches the dump height.
At the optimum pitch-brace length, the latch keeper and heel band clearances will be about 3 - 6" (8 - 15cm) from
the face as the dipper slices through the bank. The dipper handle should extend about 3 ft (1 m) above the shipper
shaft when it is in the vertical position. With this configuration the dipper will also dump loads cleanly, with little or
no carryback of material on the dipper lip.

Optimizing Rake Angle. Some manufacturers use computer modeling to determine the approximate rake angle
and pitch brace length for a given shovel and dipper configuration, and the digging conditions at the mine. The rake
angle may need adjustment or fine tuning, however, after a few weeks of operation. Field alterations to the dipper
with new fronts or lips, or both, or the use of tooth adapters with downward-pitched adapter noses, may also neces-
sitate fine-tuning of the rake angle.
The best way to check and adjust the rake angle is to use a certified land surveyor, because the needed adjust-
ment is frequently quite small, requiring precision instruments. Although the adjustment may be only a fraction of
1°, the effect on performance is well worth the effort.
If one or more operators are satisfied with a particular shovel’s digging performance, the surveyor can determine
that shovel’s rake angle and check to determine whether other shovels of the same model have the same angle.
NOTICE
To properly measure rake angle, the shovel must be on level ground. To assure that the dipper
is level, the dipper latch keeper and tooth adapters must also be resting on the ground.
As a starting point, the rake angle in hard digging conditions should be between 57° and 59°; in medium digging,
the starting point should be between 59° and 61° (see Tables 14-1). The rake angle can then be fine tuned for opti-
mum performance according to the material density and the quality and consistency of blasting. It is important to
consider that the degree of variance between the tooth angle and the rake angle may vary with dipper style.
To adjust the rake angle, disconnect the pitch braces at one end. Propel the shovel forward or backward as needed
until the desired angle is achieved. It will then be necessary to adjust or modify the length of the pitch braces to
reconnect them.
For shovels equipped with P&H patented adjustable pitch braces, lengths can be easily adjusted 3" (76.2 mm) in
either direction for a total of 6" (152.4 mm). (For shovels without adjustable pitch braces, it will be necessary to cut
and/or weld the pitch braces or replace them.) Changing pitch brace length 1" (25.4 mm) is roughly equivalent to
changing the rake angle 1°. Remember that adjustments are often just fractions of a degree and seldom exceed 2
or 3 degrees. Accordingly, pitch brace length adjustments seldom exceed 2 or 3 inches.
Changing the length from 55" (139.7 cm) to 44" (111.7 cm), for example, is a drastic change and should be a clear
indication that either the starting pitch brace angle or the adjusted angle is seriously inadequate.
Referring to Table 14-1, the optimum rake angle will vary according to the density of the material being mined, and
the thoroughness and consistency with which it is blasted. Also note that the size of the tooth angle relative to the
rake angle may vary from one dipper style to another: for example, a dipper designed for taconite versus one used
for coal or overburden removal.
Hard Rock Digging Medium Digging
Tooth Angle 46° - 48° 48° - 50°
Rake Angle 57° - 59° 59° - 61°
Table 14-1: Suggested Starting Points for Adjusting the Tooth and Rake Angle

14.2.12.3 SnubRite® Hydraulic Snubbers R52182
Figure 14-28: SnubRite® Hydraulic Snubber
SnubRite is a registered trademark that identifies a hydraulic snubber used to control (dampen) the closing of the
door of a shovel dipper. The SnubRite Hydraulic Snubber is modeled after the proven operating principles of
hydraulic door closers used in many public buildings. It is used to slow (or dampen) the closing speed of the door
and to eliminate unrestrained swinging.
Being totally enclosed, the SnubRite Hydraulic Snubber virtually eliminates periodic maintenance and adjustments.
Two snubbers are required on the dipper, one on each side. Control of the unit is provided through the entire range
of door closing with balanced loading between snubbers.
After 12,000 hours of operation, SnubRite Hydraulic Snubbers should be exchanged through P&H Mining Equip-
ment’s ENCORE component exchange program. During the ENCORE rebuild, wear items and hydraulic fluid are
replaced to ensure continued operation. Rebuilding the Snubber should not be attempted in the field.
Serial Number Plate. The SnubRite serial number plate is located on the back side of the snubber body (refer to
Figure 14-29). The serial number plate is tack welded to the snubber housing. The serial number and part number
should be included with all correspondence regarding the unit.
PART NO.
DOOR SIDE
SERIAL NO.
APPLICABLE PATENTS
CANADIAN & FOREIGN PATENTS PENDING
US PATENT NO. 8735067
MADE IN USA R46565D1
ES0497b01
Figure 14-29: SnubRite Serial Number Plate

14.3 Maintenance
14.3.1 Part Numbers
NOTICE
to be lowered.
Uncontrolled movement resulting from the release of mechanical stored energy may cause
severe personal injury or death. Read and understand Topic 5.3, A Warning About Stored

Mechanical Energy, and Subtopic 5.8.1, Releasing Propel Brakes for Maintenance, before releas-
ing any brake for maintenance. Be prepared for movement of major shovel components con-
trolled by the various brakes that may occur when performing maintenance procedures. Ensure
that all personnel are clear of the major motions affected by the brake to be released. In any situ-
ation where there is doubt regarding mechanical stored energy, do not begin work until you have
contacted a person who is qualified and authorized to assist in making such determinations.
Contact your local P&H MInePro Services representative whenever such assistance is appropri-
ate.

14.3.3 Crowd Motor R41837F1
LEGEND 07. Nut 14. Button Head Capscrew

01. Crowd Motor 08. Hex Head Capscrew 15. Washer
02. Crowd Motor Base 09. Nut 16. Belt Sheave
03. Bushing 10. Washer 17. Pin
04. Bushing 11. Hardened Washer 18. Pin
05. Bolt 12. Crowd Motor Spacer 19. Pin Retainer
06. Bolt 13. Hardened Washer 20. Bushing Retainer Plate
Figure 14-31: Crowd Motor and Motor Mounting Base
14.3.3.1 Inspection
Inspect the crowd drive assembly every 500 hours as follows:
• Check for cleanliness of the blower assembly. Check for loose, broken, or missing hardware. Check the
integrity of the blower wheel and integrity of the blower ducting.
• Check for proper lubrication of the motor in accordance with motor lubrication procedures in Subtopic
17.2.2.

• Check the crowd motor mounting for security. Check all pins for retention. Check crowd tensioning cylinder
mounting and the clevis and pin where it connects to the motor base.
• Check for cracks in the crowd motor base and its mounting lug on the boom weldment.
14.3.3.2 Removal
2. Remove the PowerBand belts (refer to Subtopic 14.3.5.5).
! WARNING
Contact with energized circuits can cause severe injury or death. Use lockout/tagout pro-
cedures and test before disconnecting electrical connections.
3. Mark and disconnect the electrical connections and conduit.
4. Attach slings to the motor.
! WARNING
Unexpected machine movement could cause an uncontrolled component to fall from its
mounting area and crush, resulting in severe personal injury or death. Always attach an
appropriate lifting device with a lifting capability exceeding the weight of the motor to the
crowd motor prior to removing the mounting hardware. The crowd motor weighs approx-
imately 12,500 lbs (5,670 kg).
5. Remove the bolts holding motor to the base.
Technician Tip
Bring the motor alignment jackscrews in contact with the motor base. This will provide a means
to set the motor back in correct alignment. The alignment must always be verified.
6. Using appropriate lifting equipment, lift the motor off the base.
7. Remove crowd motor sheave using a suitable puller.
Installation procedures for the crowd motor or the motor base are not covered in detail in this manual due to the
number of methods that can be used. In case a problem occurs with the crowd motor, contact your P&H MinePro
2. Inspect the motor base support pin bores and replace the bushings if they are excessively worn.
3. Apply a generous coat of multi-purpose grease to the motor base support pins.

CAUTION
P&H Mining Equipment designs and builds electric motors specifically for use in its min-
ing equipment. Since any specific model of motor may be used in more than one applica-
tion, plates are included to allow direction of air flow required for the application. After
any crowd motor service, the air flow through the motor must be checked to ensure the
arrangement of plates is correct and that air flow is present and proper; otherwise, prob-
lems may result from overheating. Refer to notes taken at motor removal and confirm
that the plates are configured in the same manner as for the motor that was removed. If
such notes are not available, contact your local P&H MinePro Services representative for
assistance. The crowd motor should be sealed with solid covers.The expansion duct and
all connections should be checked so that forced air can flow through the motor hous-
ing. Figure 14-32 shows the Crowd Motor Ventilation Plate.
! CAUTION
MOTOR MAY OVERHEAT IF NOT PROPERLY
VENTILATED. THIS MOTOR IS USED IN
MANY APPLICATIONS, THEREFORE, IT IS
EXTREMELY IMPORTANT THAT THE PROPER
COVERS BE REMOVED WHILE THE OTHERS
REMAIN IN PLACE TO ASSURE PROPER
COOLING. ANY QUESTIONS SHOULD BE
DIRECTED TO THE P&H DISTRICT
PARTS/SERVICE OFFICE. 32Q2031
TC2074
Figure 14-32: Crowd Motor Ventilation Plate (32Q2031)
! WARNING
lowering or moving components with lifting equipment. The crowd motor weighs
4. Using appropriate lifting equipment, lift the motor into place.
When installing the crowd motor it is important that the drive belt sheaves on the motor and the first reduction
(input) shafts are aligned. Sheave alignment is accomplished by placing a straight edge on the faces of the
sheaves and adjusting the motor alignment cap screws (Figure 14-31) until the sheaves are aligned.
It is important that the belts be installed and tensioned properly. Refer to Subtopic 14.3.5.4.
Torque motor mounting cap screws to 2200 ft-lbs (2983 N·m).

14.3.4 Crowd Motor Sheave
Remove crowd motor sheave using a suitable puller.
CAUTION
Using excessive or hard-to-control force to install the sheave can result in dislocating
the armature shaft and must be avoided.
The construction of the motor is such that there is a nominal 0.30 inch clearance (+/- 0.120 inch tolerance) between
the end of the brush boxes and the risers on the commutator (see circled area of Figure 14-33). The bearing on the
drive end (where the sheave is mounted) is fixed, but the bearing on the commutator end is floating.
! " # $
& %
ES1699_01
LEGEND
01. Clearance 05. Nut and Bent Washer
02. Motor 06. Sheave
03. Motor Shaft (Bare) 07. Pressure Applied for Sheave Installation
04. Motor Shaft (With Sheave Installed) 08. Bearing Retainer Cap
Figure 14-33: Sheave Installation
This means that a force on the armature shaft on the sheave end can result in movement of the shaft through the
interference fit of the drive end bearing. The straight roller bearing on the floating end moves within the outer race
as the entire armature (shaft, commutator, and windings) moves. The movement stops when the commutator risers
contact the brush boxes. However, under these circumstances, proper rotation of the motor is impossible. There-
fore, never use lateral force to install sheaves on crowd motor shafts.
Refer to Figure 14-33 and install the sheave as follows:
1. Inspect the motor shaft (03) and sheave (06). Look for and repair any nicks, gouges, interrupted sharp edges,
and damaged keys.
2. Lubricate the motor shaft, sheave, and keys. Use of assembly paste R20429D1 or grease conforming to P&H
spec 469 is recommended.
3. Remove bearing retainer cap (08) from the motor (02).

4. With the end of the motor shaft exposed, block the commutator end of the shaft (opposite the drive end) to pre-
vent movement.
5. Pressure can now be applied to the hub to be pressed onto the shaft.
NOTICE
Use a hydraulic press to apply even pressure to the sheave when it is being installed as shown.
14.3.5 PowerBand™
14.3.5.1 General
It is important to maintain proper PowerBand tension for best operation of the crowd system. The crowd motor is
mounted on a pivoted motor table. The weight of the motor forces the pivoted motor table downward, putting ten-
sion on the PowerBand.
The crowd motor weighs approximately 12,500 lbs (5,670 kg). This weight, if not controlled, would over-tension the
Power Band. Therefore, part of the weight of the crowd motor and associated parts is relieved from the Power
Band by a hydraulic cylinder and brake assembly which extends upward to lift the motor table and partially relieve
belt tension. The cylinder is powered by electronic control and an electric pump.
Raising the motor will loosen the belts and produce a higher hydraulic pressure. Lowering the motor will tighten the
belts and produce a lower hydraulic pressure.
The crowd belt case cover is equipped with a support rod (similar to an automotive hood support rod) which is used
to prop the case cover up during inspection and maintenance.
A support chain is provided in a box welded to the rear of the crowd belt case. This chain is used to hold the crowd
module (motor and associated parts) in the raised position while replacing crowd belts or performing other mainte-
nance.
Even though there is an automatic tensioning system, belt tension is not monitored between tensioning cycles and
belts can loosen. If at any time the belts squeal or smoke, or if there is other evidence of loose belts, the belts
should be adjusted immediately. Refer to Subtopic 14.3.5.4.
NOTICE
The final criteria for correct belt adjustment is that the belt must be kept tightened just enough to
prevent belt slippage under maximum motor torque. Slight, occasional slippage under higher
impulse loads is acceptable.

14.3.5.2 Inspection
04
05
03
02
01
06
07
12
08
09
TC1630a
11 10
LEGEND
01. Crowd Motor 07. First Reduction Shaft Sheave
02. Location of Chain Support 08. Motor Sheave
03. Belt Case Cover 09. Belt Tensioning Cylinder
04. Crowd Gear Case Cover 10. Belt Tensioning Manifold
05. Power Band 11. Electrical Enclosure
06. Support Rod 12. Motor Mount
Figure 14-34: Power Band Inspection
! WARNING
A falling cover can pinch or crush, resulting in severe personal injury or death. The
crowd belt case cover weighs approximately 110 lbs (50 kg). Use care when lifting and
securing the belt case cover. Make sure the support rod is firmly in place and the cotter
pin is installed to prevent the support rod from coming loose.

The belt case cover weighs approximately 110 lbs (50 kg) and is equipped with a support rod (similar to an automo-
bile hood support rod) which is used to prop the case cover up when performing maintenance to the belt. A cotter
pin is used to hold the support in position to prevent it from falling out. Two people may be required to lift the cover.
The front covers can be removed once the top cover is propped up.
Every 500 hours, check the Power Band Drive Belts for signs of wear, glazing, and/or damage. Even though there
is an automatic tensioning system, belt tension is not monitored between tensioning cycles and belts can loosen.
Confirm that belts are properly tensioned and actuate a manual tensioning cycle (refer to Subtopic 14.3.5.4) if belt
tension is not correct.
14.3.5.3 Automatic Adjustment
! WARNING
Unexpected movement of parts or components can hit, pinch or crush resulting in seri-
ous personal injury or death. Before adjusting the Power Bands, inspect hydraulic cylin-
der, pump, hoses and Power Bands for signs of wear or damage which could fail while
performing this procedure.
Automatic belt tensioning occurs when the following parameters are all satisfied:
• The interval required by the Centurion Control System settings has been met.
• The crowd brake is set.
• The shovel is level within 5° as indicated by the inclinometer.
• The selector switch on the automatic tensioner control panel is in the AUTO position.
• The shovel is started.
Interval settings required by the Centurion Control System are 0 hours, 10 hours, 100 hours, and 1000 hours. The
timer resets to 0 whenever the selector switch on the control panel is switched to the HAND position (such as when
a new Power Band has been installed). The next time the shovel starts, the Centurion Control System will confirm
that all other parameters have been met; if so, the automatic tensioning system activates to provide the correct ten-
sion to the belts. The process will repeat after 10 hours of production, after another 100 hour of operation, and then
after 1000 more hours, and every 1000 hours thereafter.
14.3.5.4 Manual Adjustment
! WARNING
Unexpected movement of parts or components can hit, pinch or crush resulting in seri-
ous personal injury or death. Before adjusting the Power Bands, inspect hydraulic cylin-
der, pump, hoses and Power Bands for signs of wear or damage which could fail while
performing this procedure.
1. Confirm that the shovel is within 5° of level; that the crowd brake is set; and that the shovel is shut down.
2. Place the selector switch on the automatic tensioner control panel to the HAND position.

! WARNING
Stay clear of the motor base, motor, belt case, and cylinder while tensioning system is
moving motor.
3. Press the START push button to start the pump. At this time, oil will revert back to tank and no pressure will
build up in the system
4. Press and hold the RAISE push button until the crowd motor mounting base rotates slightly upward.
5. Press and hold the LOWER push button. Continue to hold the LOWER push button until the motor and base
have stopped. At this point the belts are adjusted and you can release the LOWER push button.
6. Press the PUMP STOP push button to stop the pump. Turn the switch to the AUTO position.
! WARNING
The crowd belts should be carefully tested before returning to operation whenever belt
adjustment or maintenance has occurs. Do not assume the belts are tensioned until after
they have been tested.
NOTICE
Placing the selector switch is in the HAND position, even momentarily, resets the Auto Tension-
ing time intervals. The Auto Tensioning time intervals are 0, 10, 100, 1000 and then every 1000
hours after. The auto tensioning will only occur at shovel start-up when all brakes are set, the
shovel is level to within 5°, and the selector switch is in the AUTO position.
Three people are required for this procedure:
A. A qualified operator must be at the controls of the mining shovel.
B. Two maintenance people are required.
A means of communication must be available to allow personnel to communicate with each other.
Proceed as follows:
! WARNING
Moving the dipper can shake or bounce the boom, causing people or tools on the boom
to fall. This can result in severe personal injury or death. Always use personnel harness
with lanyards and tie off when performing service or maintenance on the boom. Do not
allow tools to lie loose on the boom.

Figure 14-35: Automatic Tensioner Control Panel
2. Place the selector switch on the automatic tensioner control panel (Figure 14-35) in the HAND position.
! WARNING
Unexpected downward motor pivot movement can hit, pinch or crush resulting in seri-
ous personal injury or death. Stay clear of the motor base and belt case while tensioning
system is moving the motor.
3. Instruct the shovel operator to monitor the work site from the operator's cab and to inform the maintenance per-
sonnel of any potential hazard. Inform the operator that the belt replacement is about to begin.
4. Press the START push button in the control panel. This will start the motor and pump in the lube room.
5. Press and hold the RAISE push button until the motor mounting base stops moving. This should take between
30 and 60 seconds. The cylinder is now at maximum extension.
Figure 14-36: Support Chain
6. Remove the support chain from the box on the rear of the belt case.

LEGEND
01. Crowd Motor 03
02. Motor Lifting Clevis
03. Crowd Gear Case
Lifting Clevis
02
01
TC2075
Figure 14-37: Crowd Motor Support Chain
CAUTION
Note how the chain in Figure 14-37 is shown doubled as it was installed. Do not install
chain as one circle through the clevises, as that could produce unwanted side pull on
the crowd gear case clevises. Installing the chain doubled as shown will produce only
forward pull on the clevises, which is what they are designed to support.
7. Place the chain through the two rear lifting shackles on the crowd gear case cover and the forward lifting lug of
the crowd motor. Hook the grab clevis onto the loose end of the chain. Make sure the chain is as tight as pos-
sible. Figure 15-31 shows how chain should be threaded through the motor lug and gear case clevis.
8. Press and hold the LOWER push button until the chain is tight. Release the push button when all slack is
removed from the chain.
9. Press the STOP push button to stop the pump. Make sure the selector switch is still in the HAND position.
Close the control panel cover and lock it closed.

04
05
03
02
01
06
07
12
08
09
TC1630a
11 10
LEGEND
01. Crowd Motor 07. First Reduction Shaft Sheave
02. Location of Chain Support 08. Motor Sheave
03. Belt Case Cover 09. Belt Tensioning Cylinder
04. Crowd Gear Case Cover 10. Belt Tensioning Manifold
05. Power Band 11. Electrical Enclosure
06. Support Rod 12. Motor Mount
Figure 14-38: Power Band Replacement
! WARNING
A falling cover can pinch or crush, resulting in severe personal injury or death. The
crowd belt case cover weighs approximately 110 lbs (50 kg). Use care when lifting and
securing the belt case cover. Make sure the support rod is firmly in place and the cotter
pin is installed to prevent the support rod from coming loose.

10. Remove the necessary hardware and open the crowd belt case cover. The belt case cover weighs approxi-
mately 110 lbs (49.9 kg) and is equipped with a support rod (similar to an automobile hood support rod) which
is used to prop the case cover up when performing maintenance to the belt. A cotter pin is used to hold the
support in position to prevent it from falling out. Two people may be required to lift the cover. The front covers
can be removed once the top cover is propped up. A pin is used in the hinge for the top cover. On newer
machines the pin may have been replaced by a removable bolt. Lift the cover and prop it in the open position
using the support rod (Item 06, Figure 14-38). Make sure the cotter pin is in place to prevent the rod from dis-
engaging. Then slide the two face plate covers off to gain front access to belts. The belt case should now look
11. Remove old belts and install the new matched set of P&H belts.
NOTICE
The 4100XPC belt automatic tensioning system automatically calculates the correct tension for
the P&H Power Band belts. This assumes the use of the correct P&H-supplied belts. Belts sup-
plied by other sources may not be of consistent materials, and may not perform well at the cal-
culated tensions. P&H recommends the use of P&H-supplied belts only. Contact your local P&H
MinePro representative for more information.
12. Close the crowd belt case securely. Make sure that all personnel are clear of the motor and motor base.
13. Remove lock and open the cover of the automatic tensioner control panel.
14. Press the START push button in the control panel to start the hydraulic pump.
15. Press and hold the RAISE push button until the chain is slack. Remove the chain and return it back to its stor-
age box on the back of the belt case.
16. Press and hold the LOWER push button to lower the crowd motor and base. The belt will be properly tensioned
when the crowd motor stops moving. You can release the push button.
17. Press the STOP push button to shut down the hydraulic pump.
18. Turn the selector switch to the AUTO position. Close and lock the control box.
NOTICE
Leaving the selector switch in the HAND position will prevent the shovel from starting. Leaving
the selector switch in the OFF position will prevent the automatic tensioning system from
cycling. The selector switch should be left in the AUTO position.

14.3.6 Automatic Tensioning System
14.3.6.1 Inspection
Figure 14-39: Cylinder Mounting Pin Bore
Every 250 hours:
• Visually inspect the pin connections of the cylinder and the clevis that attaches the cylinder to the motor
base.
LEGEND
01. Pump
02. Reservoir
03. Sight Gauge
04. Filter
Figure 14-40: Automatic Tensioner Pump Unit
Check oil level and add oil as necessary to maintain the level between the two black lines on the sight gauge (item
03, Figure 14-39).

Oil level should be checked regularly and should be maintained between the two black lines on the sight gauge.
Fill the reservoir through the filler/breather with a good quality hydraulic oil. Fill to the top of the oil level gauge on
the reservoir and maintain the oil level so oil always shows in the sight gauge. Do not overfill. Recommended oil
depends on the ambient temperature:
• Ambient temperature 0° to 160°F (-18° to 71°C), use SAE 10 grade
• Ambient temperature 32° to 200°F (0° to 93°C), use SAE 20 grade
After the first 50 hours of operation, change the oil and oil filter after about 50 hours of operation. Afterwards,
change the filter every 250 hours of unit operation.
At least once a year:
• Drain and clean the reservoir.
• Replace the suction strainer on the pump inlet.
• Replace the breather filter.
• Change the oil and oil filter.
• Grease the motor bearings.
• Check the entire system.
14.3.6.2 Adjustment
With the RAISE push button pressed and held, pressure readings at ports PG and LG on the crowd belt tensioner
manifold should be 1700 psi (refer to Figure 14-12). Pressure at port RG should be the equalizing pressure (815
psi). The transducer should be reading 815 PSI at the Centurion Control System.
Adjust the relief valve as necessary to ensure it is set at the desired 1700 PSI set point. Check pressure at the
gauge. The adjustment screw for the relief valve is located directly below the gauge. Follow these steps to check
relief valve:
1. Turn pump on.
2. Extend cylinder to raise motor and loosen belts.
3. Extend cylinder to full stroke so oil is going over relief valve.
4. Check pressure gauge to observe relief valve setting.
5. Loosen lock nut on relief valve adjustment screw.
6. Turn the adjustment socket head (allen head) screw:
A. Clockwise (CW) to increase pressure setting.
B. Counterclockwise (CCW) to decrease pressure setting.

7. When desired pressure is reached on pressure gauge, tighten lock nut.
14.3.7 Crowd Gear Case R43474F2
14.3.7.1 Inspection
Confirm that all preliminary maintenance procedures described in Subtopic 14.3.2 have been completed.
Inspect the crowd gear case and transmission every 1,000 hours checking the following:
• Check the gear case for leaks.
Figure 14-41: Crowd Gear Case Dipstick
• Check oil level at dipstick, which is located on the right side of the gear case cover between the first and
second reduction shafts (refer to Figure 14-41).
Figure 14-42: Crowd Gear Case Breather
• Check the gear case breather cap (Figure 14-42) for cleanliness. There is an indicator to show when it is
restricting. Replace if necessary.

• Check the gear case cover for cracks. If cracks are found, consult with MinePro Services for weld repair pro-
cedures designed to minimize bore distortion and to avoid welding up bores.
• Check all gear case cover and retainer bolts for tightness. Torques are shown in subsection 11.7.4.2.
! CAUTION
When releasing brake and turning gearing to inspect, stay clear to avoid injury.
• Check the gearing visually for cracks, unusual wear, and/or galling, scoring or spalling of gear teeth. The
gears can be viewed by removing inspection covers on the crowd gear case cover.
14.3.7.2 Repair
Repairs of the crowd transmission are limited to the replacement of worn or damaged components. To replace
components, remove them as described in Subtopic 14.3.7.4, and install the new components as described in Sub-
topic 14.3.9.1. If repair of the gear case is required, contact your area P&H MinePro Services representative.
14.3.7.3 Crowd Gear Case Removal
1. Remove the dipper handles from the shovel. Refer to Subtopic 14.3.13.3.
2. Remove or position the hoist cables to gain access to the crowd gear case. If necessary, remove the hoist
cable support assembly from the boom.
1. Remove the Power Band belts. Refer to Subtopic 14.3.5.5
2. Remove the Power Band cover/guard assembly if necessary.
! WARNING
before performing maintenance work on P&H Mining Shovels. Review subtopic 5.3
before proceeding.
3. Release stored mechanical energy as described in Subtopic 5.3.2.2
4. If necessary, remove the crowd brake as described in Subtopic 5.10.6. If the brake is not to be removed,
release the brake using an external air supply as described in Subtopic 5.9.3 to allow the gears to move while
the gear case cover is being removed.
5. Drain the oil from the gear case. The gear case capacity is approximately 110 gallons (416 liters).
6. Remove the crowd limit switch sensor assembly as described in Subtopic 14.3.8.2.

02
03
09 01
08 10 01
06 02
04
05
04
05
TC1631b
07
06 04 04
05 05 06
01
LEGEND 04. Hex Head Cap Screw 1.5" 08. Coupling Dowel Pin
01. Coupling Dowel (8 places) 05. Hardened Washer, 1.5" 09. Tack Weld 8 places (typ)
02. Hex Head Cap Screw, 1" 06. Locator Dowel Pin (3 places) 10. Gear Case Cover
03. Hardened Washer, 1" 07. Boom Top Plate
Figure 14-43: Gear Case Cover Bolt Arrangement
7. Remove all the gear case cover bolts. Refer to Figure 14-43.

Figure 14-44: Prepare Blocking to Support Gear Case
8. Prepare suitable blocking to support each end of the crowd gear case cover in its normal position as illustrated
in Figure 14-44. The blocking must be arranged to allow the first reduction gear to hang beneath the cover
without touching the floor or ground. Gear diameter is approximately 7 ft (2.1 m).
NOTICE
Coupling dowels (item 1 on Figure 14-43) may come off with cover, but could fall out of cover as
cover is removed. Exercise caution to avoid losing the dowels. Retain coupling dowels for
installation.
! WARNING
Failure to use an adequate lifting device or using improper lifting techniques during
removal of the crowd gear case could cause the gear case to fall, resulting in crushing
and causing severe personnel injury or death. Be sure the lifting device is adequate to
lift the gear case assembly, which weighs approximately 12,000 lbs (5,443 kg).
9. Attach suitable lifting equipment to the lifting clevises and lift the assembly (consisting of the crowd gear case
cover and the first and second reduction shafts) out of the crowd gear case (boom) as a unit.
10. Set the assembly on the blocking previously prepared, being careful to ensure that the blocking is adequate
and secure to prevent the gear case from toppling.
14.3.7.4 Crowd Gear Case Disassembly
The crowd gear case is not disassembled as a unit. Rather, the first reduction shaft assembly, the second reduction
shaft assembly, the crowd brake, and the Power Band sheave, are disassembled in order to remove them from the

gear case. Completing all of these individual component disassemblies will completely disassemble the crowd gear
case.
Refer to Subtopic 14.3.8 to remove the crowd limit switch resolver.
Refer to Subtopic 14.3.10 to remove and disassemble the first reduction shaft assembly.
Refer to Subtopic 14.3.11 to remove and disassemble the second reduction shaft assembly.
Refer to Section 5 to remove the crowd brake.
14.3.8 Crowd Limit Switch Resolver
01
02
05 09
06 10
07
08
03
04
11
12
13
14
15
20
19
18
17 16
LEGEND 07. Locking Plate 14. Cap Screw
01. Coupling 08. Nut 15. Mounting Bracket
02. Resolver 09. Locking Screw 16. Nut
03. Bushing 10. Cover 17. Lock Washer
04. Conduit Connector 11. Locking Screw 18. Lock Washer
05. Rubber Pad 12. Coupling Guard 19. Cap Screw
06. Retainer Plate 13. Lock Washer 20. Rod Bolt
Figure 14-45: Crowd Limit Switch Resolver
14.3.8.1 Resolver Replacement
Refer to Figure 14-45 and replace the resolver as follows:
1. Remove locking screws (09) and cover (10) from the sensor assembly.

2. Remove locking screws (11), lock washers (17), nuts (16) and coupling guard (12).
3. Remove coupling connection hardware.
5. Straighten the ends of locking plates (07). Remove nuts (08), locking plates (07), retainer plate (06), rubber pad
(05) and resolver (02).
6. Remove coupling (01) from the resolver shaft.
7. Install the new resolver with coupling.
8. Measure the free length of coupling (01) and record.
A. Install the coupling on the resolver shaft leaving a 0.20 inch (5.08 mm) gap between the end of the coupling
and the end of the resolver housing.
B. Install new resolver (02) with coupling into mounting bracket (15) making sure that the coupling slides onto
the extension shaft properly.
C. Measure the length of the coupling. Make sure that the length of the coupling is within 0.020 inch (0.508
mm) of the length measured in Step 8A.
9. Install rubber pad (05), retainer plate (06) and locking plates (07). Thread nuts (08) on rod bolts (20) and
tighten securely. Do not overtighten.
10. Bend the ends of locking plates (07) over the flat of each nut (08).
11. Tighten the coupling hardware.
12. Connect the resolver wiring.
13. Install coupling guard (12) with locking screws (11), lock washers (17) and nuts (18).
14. Install cover (10) with locking screws (09).
14.3.8.2 Limit Switch Sensor Removal
Refer to Figure 14-45 and remove the limit switch sensor from the second reduction shaft as follows:
1. Remove locking screws (11), lock washers (17), nuts (16) and coupling guard (12) from the sensor assembly.
3. Remove coupling connection hardware from the crowd gear case side of the coupling.
4. Remove socket head cap screws (14) and lock washers (13), then remove the remainder of the sensor assem-
bly from the side of the gear case using care not to damage coupling (01).
14.3.8.3 Limit Switch Sensor Installation
Refer to Figure 14-45 and install the limit switch sensor as follows:

1. Remove coupling (01) from the resolver shaft. Measure and record the free length of the coupling.
2. Install the coupling on the resolver shaft leaving a 0.20” (5.08 mm) gap between the end of the coupling and
the end of the resolver housing.
3. Lift the sensor assembly into place on the side of the crowd gear case making sure that the coupling slides
onto the extension shaft properly.
4. Install socket head cap screws (14) with lock washers (13). Tighten the cap screws to the torque specified in
the torque table (Table 3-2).
5. Install the coupling cap screw on the crowd gear case side of the coupling.
6. Measure the length of the coupling. Make sure that the length of the coupling is within 0.020” (0.508 mm) of the
length measured in Step 1.
14.3.9 Crowd Gear Case Assembly and Installation
14.3.9.1 Crowd Gear Case Assembly
The crowd gear case is not assembled as a unit. Rather, the first reduction shaft assembly, the second reduction
shaft assembly, the crowd brake, and the Power Band sheave, are assembled in order to install them into the gear
case. Completing all of these individual component assemblies will completely disassemble the crowd gear case.
Refer to Subtopic 14.3.10 to assemble and install the first reduction shaft assembly.
Refer to Subtopic 14.3.11 to assemble and install the second reduction shaft assembly.
Refer to Subtopic 14.3.8 to install the crowd limit switch resolver.
Refer to Section 5 to install the crowd brake.
14.3.9.2 Crowd Gear Case Installation
Refer toFigure 14-43 and install the crowd gear case as follows:
1. Remove welds from holes where coupling dowels (item 01) were. This is necessary so that dowels can be re-
installed.
2. Install locator dowels (item 06) into holes in boom.
NOTICE
Ensure that mating surfaces of the gear case cover are free from burrs and other damage.
Replace the gear case O-ring gasket. Lubricate parts as required during assembly.
! WARNING
Failure to use an adequate lifting device or using improper lifting techniques during
installation of the crowd gear case could cause the gear case to fall, resulting in crush-

ing and causing severe personnel injury or death. Be sure the lifting device is adequate
to lift the gear case assembly, which weighs approximately 12,000 lbs (5,443 kg).
3. Lift the gear case assembly and position it on the gear case base. Use an auxiliary air line to release the brake
while lowering the gear case into position. Regulate the air line to 100 PSI.
4. Apply a circular bead of oil-resistant silicone sealant to the parting face of all 1½” and 1” bolt holes (43 places).
5. Press coupling dowels (1) into the gear case cover. These dowels are used to align the gear case cover.
NOTICE
Coupling dowels are not a press fit. They are installed in special bores located around the gear
case cover flange as shown in Figure 14-43.
6. Install the cap screws and hardened washers in the gear case flange. Tighten the cap screws in steps, alternat-
ing from one side of the gear case to the other until all cap screws are tightened as follows:
• Torque all 1" cap screws (item 3) to 650 ft-lbs (881 N·m).
• Torque all 1½" cap screws (item 4) to 1950 ft-lbs (2644 N·m).
7. Apply weld bead around coupling dowel hole as shown in Figure 14-43.
8. Install belt case if it was removed.
9. Install and adjust the Power Band belts as described in Subtopic 14.3.5.4.
10. Install the crowd limit switch sensor assembly on the end of the second reduction shaft as described in Sub-
topic 14.3.8.3
11. Install and adjust the crowd brake assembly as described in Section 5.

14.3.10 Crowd First Reduction Shaft R41571F1
21
20
19
18
17
13
11 12
09 10
07 08
06
04 05
03
02
01
16 31
15 15
14
30
29
28
27
26
25
24
22
32
23 13
37
TC0412a 09
33 10
38
39
36
35
34
LEGEND
01. Cap Screw 14. Cap Screw 27. O-Ring
02. Disc Brake 15. Washer 28. Shim
03. Tie Wire 16. Bearing Retainer 29. Bearing Retainer
04. Cap Screw 17. Shim 30. Crowd Belt Guard Plate
05. Retainer Plate 18. O-Ring 31. Cap Screw
06. Disc Brake Hub 19. Bearing 32. Oil Seal
07. Bearing Spacer 20. Bearing Capsule 33. Seal Retainer
08. O-Ring 21. O-Ring 34. Spacer
09. Cap Screw 22. Pinion 35. Sheave
10. Lock Washer 23. Key 36. Retainer Plate
11. Seal Retainer 24. O-Ring 37. Tie Wire
12. Oil Seal 25. Bearing Capsule 38. Cap Screw
13. Set Screw 26. Bearing 39. Washer
Figure 14-46: First Reduction Shaft Components

14.3.10.1 Removal/Disassembly
After removal of the crowd gear case (Subtopic 14.3.7.3), remove the first reduction shaft from the cover as follows
(refer to Figure 14-46):
1. Remove retainer plate (05) by removing cap screws (04) and tie wire (03), then remove brake hub (06) from
the end of shaft (22). Disc brake (02) was removed during the gear case cover removal procedure.
2. Using a suitable puller, remove spacer (07) and o-ring (08). Remove o-ring (08) from the inside diameter of the
spacer.
3. Remove bearing retainer (16) by removing cap screws (14) and hardened washers (15). Seal (12), seal
retainer (11), cap screws (09), lock washers (10) and setscrew (13) will come off with the retainer.
4. Remove cap screws (09), lock washers (10), seal retainer (11) and seal (12) from bearing retainer (16).
5. Remove shims (17).
6. At the opposite end of the shaft, remove cap screws (31) and washers (15).
7. Support pinion shaft (22) while pushing from the left (brake) end of the shaft to remove the shaft from the gear
case cover. The shaft with bearing capsule weighs approximately 1000 lbs (454 kg).
8. Remove tie wire (37) and cap screws (38) and remove sheave retainer (36).
9. Pull sheave (35) off shaft (22).
10. Remove bearing retainer (29).
11. Remove cap screws (09), lock washers (10), seal retainer (33) and seal (32) from bearing retainer (29).
CAUTION
The cups, cones and spacers of bearing (26) are matched and must be kept together if
they are to be re-installed.
12. Pull spacer (34) and the outer cone of bearing (26) from shaft (22).
13. Remove bearing capsule (25). The cup of bearing (26) will come off with the capsule. Remove O-ring (24) from
the outside diameter of the bearing capsule.
14. Remove the spacer and inner cone of bearing (26) from the shaft.
15. Remove bearing capsule (20) from the bore in the gear case cover. Remove bearing (19) from capsule (20).
Clean and inspect all parts. Check parts visually for cracks, breaks or excessive wear and replace any question-
able parts.

14.3.10.3 Assembly/Installation
Refer to Figure 14-46 and assemble the first reduction shaft as follows:
1. Install new oil seals (32 and 12) in retainers (16 and 29) with the lips toward the inside.
2. Install cap screws (09), lock washers (10) and seal retainer (11 and 53) in each bearing retainer.
3. Lubricate the seal with multipurpose grease.
Technician Tip
All bearing cones must be preheated prior to installation on the shaft. Freezing of bearing cups
is acceptable to aid in installation. Refer to Topic 3.5 for further information regarding the han-
dling and installation of double tapered roller bearings.
4. Assemble bearing capsule (25) and install double tapered roller bearing (26) as follows:
A. Preheat and install a cone of bearing (26) on the keyed end of first reduction shaft (22).
B. Install the spacer of bearing (26) against the installed cone.
C. Install the cup of bearing (26) in capsule (25).
D. Install a new lubricated O-ring (24) on capsule (25) and install capsule (25) with the cup of bearing (26) over
the cone of bearing (26) already installed on the shaft. Ensure bearing parts match.
E. Preheat and install the remaining cone of bearing (26) onto the shaft. Seat this bearing cone into the cup.
5. Heat spacer (34) and slide it on the end of the first reduction shaft. The internal chamfer of the spacer should
be against the inner bearing race of bearing (26).
NOTICE
Spacer (34) must be allowed to cool before installing bearing retainer (29). Care must be taken
that the oil seal in bearing retainer (29) is not damaged during retainer installation.
6. Check bore of gear case for nicks and burrs on both ends where the two bearing capsules (20 and 25) will be
installed. Lubricate bore with a light coating of oil to receive the capsule’s o-ring.
7. Carefully support the partially assembled shaft so it can not fall and insert it into the gear case bore from right
to left.

01 02 03
TC0193_02
LEGEND 02. Setscrew
01. Capsule 03. Flat Side of Capsule
Figure 14-47: Bushing Capsule and Setscrew
8. Carefully align the shaft with to the bore, keeping the flat side of the capsule down (refer to Figure 14-47), and
press the shaft into position until the installed bearing capsule (25) presses firmly against the gear case bore
surface. Make sure the O-ring (24) stays in position.
9. At the opposite end of the shaft, lubricate and install a new O-ring (21) on bearing capsule (20). Then install
bearing (19) in capsule (20) and install the capsule and bearing on shaft (22), pressing the capsule firmly
against the gear case bore surface. Confirm the flat side of the capsule is down (refer to Figure 14-47). Make
sure the O-ring (21) stays in position.
10. Lubricate and install O-rings (18) on bearing retainer (16) and install the bearing retainer over the end of the
shaft. Support the retainer so the seal is not damaged. Align the capsule and retainer by installing setscrew
(13), making sure the setscrew fits against the flat spot of the capsule (20) correctly ((refer to Figure 14-47).
Secure the retainer with cap screws (14) and hardened washers (15). Torque the cap screws to 150 ft-lbs (203
N·m) to seat the bearings.
11. Lubricate and install O-ring (27) on bearing retainer (29) and install the bearing retainer on each end of the
shaft. Support the retainer so the seal is not damaged. Align the capsule and retainer by installing setscrew
(13), making sure the setscrew fits against the flat spot of the capsule (25) correctly (refer to Figure 14-47).
Support plate (30) in place and align holes with the holes in the retainer. Rotate the plate until the tapped hole
is located on top. Secure the plate and retainer with cap screws (31) and hardened washers (15). Torque the
cap screws to 150 ft-lbs (203 N·m) to seat the bearings.
12. Shim the retainers (16 and 29) as follows:
CAUTION
Over-shimming the retainer could allow outer race of bearing to spin in the bore. Under
shimming the retainer could allow the retainer to flex slightly, which would allow the
shaft seal to leak. It is critical to measure and install shims correctly.
A. Loosen cap screws (14 and 31) and then re-torque to 35 ft-lbs (47.5 N·m). This torque will be used for mea-
surements purposes only.

B. Measure the gaps between the bearing retainers and the gear case bore surface at four points located 90
degrees apart (at each end of the shaft) and find the average of the four gap measurements.
C. Remove cap screws (14 and 31) and install shims (17 and 28) equal to the average measured gap + 0.000"
to -0.002" (.05 mm).
D. Reinstall the bearing cap screws and tighten to 150 ft-lbs (204 N·m).
13. Install new O-ring (08) in spacer (07). Lubricate the o-ring with oil to ensure that the o-ring is not stretched or
pinched during installation.
14. Install spacer (07).
15. Install brake hub (06) and secure it in place with plate (05), cap screws (04) and tie wire (03). Torque cap
screws to 150 ft-lbs (204 N·m).
16. Install belt sheave as follows:
A. Install key (23) in shaft (23). Lubricate shaft, key, and bore of sheave with a light coating of anti-seize com-
pound.
B. Install sheave (35) on shaft making sure it contacts spacer (34).
C. Install retainer plate (36), washers (39), and cap screws (38). Torque cap screws to 266 ft-lbs (362 N·m).
14.3.11 Crowd Second Reduction Shaft R40476F2
Inspect the second reduction shaft during periodic (6 month) inspections and when the crowd gear case is
overhauled. Repair of the second reduction shaft assembly is limited to the replacement of damaged or exces-
sively worn parts.

14.3.11.2 Removal/Disassembly
LEGEND 09. Shim 18. O-Ring

01. Hex Head Cap Screw 10. Shim 19. Bearing Capsule
02. Hardened Washer 11. Shim 20. Cylindrical Roller Bearing
03. Bearing Retainer 12. Tapered Roller Bearing 21. Bearing Retainer
04. Tie Wire 13. Bearing Capsule 22. O-Ring
05. Drilled Head Cap Screw 14. O-Ring 23. Bearing Retainer
06. Hardened Washer 15. 2nd Reduction Pinion 24. Hex Head Cap Screw
07. O-Ring 16. 1st Reduction Gear 25. Oil Seal
08. Bearing Retainer Plate 17. Bearing Spacer 26. Self Locking Set Screw
Figure 14-48: Second Reduction Shaft
Refer to Figure 14-48 and remove/disassemble the second reduction shaft assembly as follows:

NOTICE
The crowd limit switch resolver was removed during the removal of the crowd gear case cover.
1. Remove cap screws (01), washers (02), and retainer (04).
2. Remove tie wire (06) and cap screws (05) and remove retainer (08).
3. At the opposite end of the shaft, remove cap screws (23) and washers (02) and then remove retainer (26). Seal
(24) and setscrew (25) will come off with the retainer.
4. Remove retainer (21), setscrew (20), and shaft (19) by removing tie wire (06) and cap screws (05).
5. Support the pinion (12) and first reduction gear (13) so they cannot fall, and remove bearing capsule (10) and
bearing (09) by removing the attaching cap screws and washers (01 and 02). O-ring (11) will come off with the
capsule.
6. Remove bearing carrier (16) with o-ring (15) and bearing (17).
! WARNING
Failure to use a suitable lifting device or to use proper lifting procedures could cause the
pinion or gear to fall, resulting in substantial property damage or serious personal injury
or death. The gear weighs approximately 2,450 lbs (1,111 kg) and the pinion weighs
7. Support gear (13) and push pinion (12) out of the gear case, making sure that neither item is allowed to fall.
Clean and inspect all parts of the shaft assembly. Check parts visually for cracks, breaks or excessive wear. Repair
of the second reduction shaft assembly is limited to the replacement of worn or damaged parts.
14.3.11.4 Assembly/Installation
Refer to Figure 14-48 and assemble and install the second reduction shaft into the crowd gear case as follows:
Technician Tip
Refer to Topic 3.5 for further information regarding the handling and installation of
roller bearings.
1. Install the cup of bearing (09) in capsule (10). Freeze the cup if necessary.
2. Install bearing (17) in capsule (16). Heat the capsule if necessary.
3. Lubricate and install new O-ring (11) in capsule (10) and o-ring (15) in capsule (16) after capsule has cooled if
it was heated.

4. Preheat the cones of bearing (09) and install one cone on pinion (12). Hold the cone in place until it seizes.
Install the bearing spacer.
5. Slide capsule (10) with bearing cup and o-ring over inner cone of bearing (09).
6. Install heated outer cone of bearing (09) onto shaft, sliding it inside bearing cup and capsule (10).
7. Install bearing retainer (08) and cap screws (05). Shim gap between retainer and pinion shaft as follows (refer
to Topic 3.9 for more information on shimming procedures):
A. Snug up cap screws (05).
B. Measure gap between retainer plate (08) and pinion shaft (12).
C. Install shims equal to .010" (.25 mm) less than measured gap.
D. Install shims, retainer plate, and cap screws. Torque cap screws to 266 ft-lbs (362 N·m). Tie wire the cap
screws.
Technician Tip
Rotating the gearbox on its side will make it easier to install the gear and pinion for the next
step.
! WARNING
pinion or gear to fall, causing crushing and resulting in serious personal injury or death.
The gear weighs approximately 2,450 lbs (1,111 kg) and the pinion shaft weighs approxi-
8. Support gear inside gear case. Lower pinion into place while aligning the splines of the gear and pinion. Bear-
ing capsule (10) will be installed into gear case bore. Make sure the O-ring is not damaged as the capsule goes
into the gear case.
9. Install spacer (14) on pinion. Then install bearing (17) and capsule (16). The bearing should slide over the pin-
ion and the capsule should slide into the gear case bore. A slight press may be needed for the bearing due to
a tight fit. Make sure the O-ring is not damaged as the capsule goes into the gear case. The capsule should be
rotated so that the flat area of the capsule will be on the bottom (refer to Figure 14-47).
10. Install shaft (19) into bearing retainer (21) if it was removed. Install cap screws (05). Torque cap screws to 266
ft-lbs (362 N·m). Tie wire the cap screws.
11. Lubricate and install a new O-ring (07) on retainer (04). Install retainer (04) and secure with cap screws (01)
and washers (02). Lubricate cap screws (01) and torque to 200 ft-lbs (261 N·m).
12. Lubricate a new o-ring (22) and install it on retainer (26). Install new seal (24) in retainer (26). Install retainer
(26) on shaft (19), do not damage seal (24). Turn retainer (26) so that setscrew (25) lines up as shown in Fig-
ure 14-47. Install cap screws (23) and washers (02) and tighten cap screws (23) to 200 ft-lbs (261 N·m).

NOTICE
The crowd limit switch resolver will be mounted on the end of the second reduction shaft.
Replacement of the limit switch resolver is described in Subtopic 14.3.8.
14.3.12 Shipper Shaft And Saddle Blocks (R54042F1)
01 02
08 07 06 05 04 03
ES05010a01
LEGEND
01. Dipper Handle 05. Shipper Shaft
02. Saddle Block 06. Inner Saddle Block Bushing
03. Adjusting Collar 07. Shipper Shaft Bushing
04. Outer Saddle Block Bushing 08. Crowd Second Reduction Gear
Figure 14-49: Shipper Shaft and Saddle Blocks
14.3.12.1 General
Proper adjustment of the 4100XPC shipper shaft axial play and of saddle block clearances are very important.
Even though this is a large machine, adjustment tolerances must be maintained to ensure proper meshing
between the dipper handle rack and the shipper shaft pinion, thereby enhancing crowd rack and pinion life.
The saddle blocks are intended to limit the lateral and vertical movement of the dipper handles in crowd and
retract. Together with the boom wear boxes, the saddle block lateral adjustment ensures that the handle racking
meshes correctly with the shipper shaft pinions.

06 LEGEND
01. Dipper Handle
05 02. Dipper Handle Top Plate
04 03. Upper Gap
03 06
04. Upper Wear Plate
02 05. Upper Wear Plate Shims
07 06. Saddle Block
01 07. Lateral Wear Plate Shims
08
08. Lateral Wear Plate
09 09. Lateral Gap
ES05012a01
Figure 14-50: Saddle Block Adjustment
250-hour PM Inspection
Every 250 hours, Inspect the saddle block shimming and shipper shaft adjustment.
to be lowered.
• Place barricades around the area in front of the shovel to prevent other personnel from working near or
under the work area while maintenance activities are taking place.
• Raise the dipper to the carry position (dipper directly under the boom point sheaves with the dipper door
open). Set the hoist and crowd brakes.
• Station an individual in the operator’s station to ensure that all personnel remain clear of the area under-
neath the dipper handles, boom, and dipper.
Refer to Figure 14-50 and inspect gaps.
1. Prepare for measurement as follows:

A. Place the dipper handles in the carry position.
B. Swing the shovel to the left and stop the motion by plugging. Observe the motion of the saddle blocks and
the shipper shaft.
C. Swing the shovel to the right and stop the motion by plugging. Observe the motion of the saddle blocks and
the shipper shaft.
D. Run the dipper handles in and out using the crowd motion and observe the motion of the saddle blocks and
the shipper shaft.
E. Manipulate the dipper handles to the best position to unload the shipper shaft as much as possible.
F. Press the STOP button on the operator’s console. CLock out and tag out the operator controls as prescribed
by applicable regulations and by local policy.
1. Measure the upper gap (03) between the upper plate of the dipper handles and the saddle block upper slide
plates. Each saddle block has two upper slide plates. The minimum gap between the wear plate and the dipper
handle is .125" (1/8" or 3.2 mm). These gaps must be kept at less than .250" (¼" or 6.3 mm).
2. Measure the lateral gap (09) between the side of the dipper handles and the saddle block lateral wear plates.
Each saddle block has two upper slide plates. The minimum gap between the wear plate and the dipper handle
is .125" (1/8" or 3.2 mm). These gaps must be kept at less than .250" (¼" or 6.3 mm).
Adjustment before maximum gap is reached is preferred; do not wait until the maximum gap is reached to adjust.
Frequent adjustments will keep the gaps closer to the minimum and will keep tooth loading low, reducing possibili-
ties of tooth damage. In addition, consider that both saddle blocks must be adjusted at the same time. If one goes
out of adjustment it will cause one side of the racking to take a larger load and raise the possibility of tooth failure.
To adjust saddle block clearances, refer to Subtopic 14.3.12.
500-hour Inspection
Inspect the shipper shaft and related components every 500 hours as follows:
• Check the lube pattern on the dipper handle rack and crowd pinions.
• Check all crowd transmission gears for wear and proper lubrication.
• Check shipper shaft for correct adjustment
• Check the saddle blocks for proper vertical and lateral adjustment.
• Check the saddle blocks for cracking.
• Check the operation of the crowd limit switch resolver.
14.3.12.2 Shipper Shaft Axial Adjustment
NOTICE
Saddle block lateral wear plates can interfere with the shipper shaft clearances during axial
clearance adjustment. For that reason, shipper shaft axial clearance must be adjusted before

the saddle block adjustments are made. The left hand side of the shipper shaft must be
adjusted first.
Adjust the shipper shaft axial clearances as follows:
1. Move the shovel away from the high wall to a solid and level area.
2. Position the shovel so that the revolving frame is in position with the crawler side frame to allow the stairway to
be lowered.
3. Place barricades around the area in front of the shovel to prevent other personnel from working near or under
the work area while maintenance activities are taking place.
4. Place the dipper handles in the horizontal or carry position to unload the shipper shaft as much as possible.
5. Press the STOP button on the operator’s console. Lock out and tag out operator controls as prescribed by
06 LEGEND
05 01. Dipper Handle
04 02. Dipper Handle Top Plate
03 06
03. Upper Gap
02
07 04. Upper Wear Plate
05. Upper Wear Plate Shims
01 08 06. Saddle Block
09 07. Lateral Wear Plate Shims
08. Lateral Wear Plate
09. Lateral Gap
ES05012a01
Figure 14-51: Remove Shims
6. Refer to Figure 14-51. On both ends of the shipper shaft, remove shims (07) from behind the lower saddle
block wear plates 08) to provide a gap (09) between the lower wear plates (08) and the dipper handle (01).
NOTICE
Enough shims must be removed from the saddle blocks so that the lateral slide plates do not
come in contact with the dipper handles as the shaft is tightened. If it cannot be determined how
many shims must be removed, remove all shims.

08
03
07 05 04
06
02
ES05035a01
01
LEGEND
01. Adjusting Collar 05. Nuts (2)
02. Mounting Plate 06. Hardened Washer
03. Mounting Bolts (2) 07. Threaded Rod
04. Hydraulic Ram 08. Jack Stand
Figure 14-52: Install Hydraulic Ram
7. Refer to Figure 14-52 and install hydraulic ram (04) on mounting plate (02) with cap screws (03) and washers
on the left end of the shipper shaft. Attach the threaded rod (07), nuts (05) and washer (06) as shown.
! WARNING
The threaded rod could be pulled out of the shaft, resulting in severe injury or death.
Thread the threaded rod fully into the shaft before using the ram to extract the shipper
shaft.

Figure 14-53: Locking Keys
8. Remove the cap screws and locking keys from each end of the shaft. Loosen the adjusting collar ½ turn on
each end.

B
A A
LEGEND
A: Gaps MUST EXIST
between the dipper han-
dles and the saddle
block lateral wear plates.
B: Gaps MUST NOT EXIST
between the shipper
shaft pinions and their
thrust washers.
C: Adjust the gap to .090"
(2.3 mm) between the
adjusting collar and the
flange of the outer ship-
ES05010a01
per shaft bushing.
D: Shipper shaft gear thrust
washer is pressed
against the steel wear
plate inside the boom
D (this is inside the crowd
transmission and is not
.090”
(2.3 mm) normally visible).
Figure 14-54: Shipper Shaft Appearance After Pulling to the Left
Over the next several steps, the hydraulic ram will pull the shipper shaft to the left. Refer to Figure 14-54 to confirm
that the conditions indicated exist.
! WARNING
The threaded rod could be pulled out of the shaft, resulting in severe injury or death.
Confirm that the threaded rod is fully threaded into the shipper shaft. Stay clear of the
rod path during pulling operation.
9. Apply hydraulic pressure to hydraulic ram mounted to the left end of the shipper shaft until the plunger comes
in contact with the nuts. Continue to apply pressure until the left saddle block and pinion are tight against the
boom hub (Item B, Figure 14-54).
10. Inspect the saddle block lower slide plate and confirm that there is a gap between the handle and lower slide
plate (Item A, Figure 14-54). If no gap exists, release the hydraulic pressure and remove the lower slide plate
shims. If all shims have been removed, remove the lower slide plate. Repeat Step 9 until the left saddle block
and the pinion are tight against the boom hub.

11. Tighten the adjusting collar until a gap of .090" (2.3mm) is obtained between the adjusting collar and the bush-
ing flange on the left hand saddle block (Item C, Figure 14-54)
12. Secure the adjusting collar by install the two locking keys (Figure 14-53) with cap screws and tie wire. If no
slots align, turn the adjusting collar outward rather than inward to the nearest slot. Torque the cap screws to 56
ft-lbs (76 N·m).
NOTICE
This assembly was originally shipped with only one key for each adjusting collar. P&H Mining
Equipment recommends that two keys be installed in each locking collar. If only one key is cur-
rently installed on each locking collar, contact your local P&H MinePro Services representative.
08
03
07
04 05
06
02
ES05035c01
01
LEGEND
01. Adjusting Collar 05. Nuts (2)
02. Mounting Plate 06. Hardened Washer
03. Mounting Bolts (2) 07. Threaded Rod
04. Hydraulic Ram 08. Jack Stand
Figure 14-55: Install Hydraulic Ram on Right Side
13. Refer to Figure 14-55 and install hydraulic ram (04) on mounting plate (02) with cap screws (03) and washers
on the left end of the shipper shaft. Attach the threaded rod (07), nuts (05) and washer (06) as shown.

LEGEND
A: Gaps MUST EXIST
B between the dipper han-
A A
dles and the saddle
block lateral wear plates.
B: Gaps MUST NOT EXIST
between the shipper
shaft pinions and their
thrust washers.
C: Gap is closed.
D: Shipper shaft gear end
play is between .060"
and .090" (1.2 mm and
2.3 mm) (this is inside
the crowd transmission
and is not normally visi-
ble).
E. Adjust the gap to .060"
(1.2 mm) between the
adjusting collar and the
D flange of the outer ship-
per shaft bushing.
ES05010e01
C E
Figure 14-56: Shipper Shaft Appearance After Pulling to the Right
14. Apply hydraulic pressure to the hydraulic ram, allowing the plunger to come into contact with the nut (05) and
washer (06). Continue to apply pressure to the ram until the .090" (2.3 mm) gap on the left side of the shaft is
closed. Refer to Item C, Figure 14-56.
15. Tighten the adjusting collar on the right side of the shipper shaft until a gap of .060" (1.5 mm) is obtained
between the adjusting collar and the bushing flange of the right hand saddle block. Refer to Item E,
Figure 14-56.
16. Secure the adjusting collar by installing the two locking keys (Figure 14-53) with cap screws and tie wire. If no
slots align, turn the adjusting collar outward rather than inward to the nearest slot. Torque the cap screws to 56
ft-lbs (76 N·m).
17. Remove the jack stands, hydraulic rams, and threaded rods.
18. Actuate the automatic lubrication system sufficient cycles until grease appears at the bushing flanges.
The shipper shaft axial adjustment provides a total shaft end play of .060" (1.2 mm), and the shipper shaft gear’s
total movement is .090" (2.3 mm) within the crowd gear case. Readjust the shipper shaft when the total end play
exceeds .190" (4.8 mm). Replace worn bushings when the gap between the saddle block and the pinion is .190"
(4.8 mm) or less. Limit wear on the shipper shaft gear thrust washer to .190" (4.8 mm) or less.

NOTICE
Monitor temperature of the bushings during initial break-in. If high temperature condition exists
on any thrust surface, back off the adjusting collar ¼ turn.
14.3.12.3 Upper Saddle Block Wear Plate Adjustment
With the shipper shaft axial clearance properly adjusted, adjust the upper (vertical) wear plates as follows:
1. Move the shovel away from the high wall to a solid and level area.
2. Position the shovel so that the revolving frame is in position with the crawler side frame to allow the stairway to
be lowered.
3. Place barricades around the area in front of the shovel to prevent other personnel from working near or under
the work area while maintenance activities are taking place.
4. Raise the dipper to the carry position (dipper directly under the boom point sheaves with the dipper door open).
Set the hoist and crowd brakes.
NOTICE
If the dipper handle racks or the dipper handle top slide area has significant wear, adjustments
must be made in the area having the least wear. Place the dipper handles in the carry position
for the initial adjustment if the dipper handles are new.

5. Press the STOP button on the operator’s console. Lock out and tag out operator controls as prescribed by
03
D D
04
A A
02 02
B B
05
01 01 TC1632A
LEGEND
01. Shear Block A: Jacking Screws
02. Wear Plate B: Retaining Bolts
03. Wear Plate C: Retaining Bolts
04. Hydraulic Ram D: Jacking Screws
05. Dipper Handle Rack
6. Loosen eight retaining cap screws.
7. Insert the two small hydraulic rams from the hydraulic tool kit into the holders on the saddle block.
Figure 14-58: Hydraulic Control Valve

8. Connect the hydraulic pump in the tool kit to the control valve in the tool kit (refer to Figure 14-58). Connect the
control valve to the two rams.
9. Using the hydraulic pump, apply hydraulic pressure to the front and rear rams until the ram plungers come into
contact with the top of the dipper handle. Use the control valve to alternate the flow of hydraulic fluid to the front
or rear ram. Continue to pump fluid to the rams until the saddle block is evenly lifted from the dipper handle.
NOTICE
Use the control valve to maintain parallelism between the saddle block and the top of the dipper
handle.
10. Pry down the two upper wear plates until the wear plates rest on the top of the handle.
11. Measure the gap between the wear plates and the saddle block. Install shims to equal the measurement minus
0.120″ (3 mm). This should leave .120” (3 mm) clearance (gap) when completed.
NOTICE
The shims are made of sheet metal of 11 gauge (.1196" or 3.04 mm) thickness.
12. Loosen inner screws and insert the correct thickness of shims.
13. Lubricate the eight retaining cap screws and torque them to 1460 ft-lbs (1980 N·m).
14. Use the control valve to release the pressure from both of the rams. Make sure ram cylinders retract fully to
prevent ram from contacting handle when in operation.
CAUTION
The cylinder ram may need to be manually retracted. Visually confirm that it is fully
retracted. Otherwise, the ram will be damaged when the shovel begins operation.
15. Use these reference measurements for the upper saddle block adjustments:
• Maintain the clearance between the wear plate and handle between 0.120″ (3.048 mm) and 0.250″ (6.350
mm).
• Replace slide plates when clearance exceeds 0.380″ (9.650 mm) and all shims are in place. Five shims are
provided for each wear plate.
NOTICE
The standard slide plate is 1½" thick. A plate that is 1-7/8" thick (R52536D6) is available. Refer
to this shovel’s up-to-date LinkOne electronic parts manual to confirm current availability and
applicability.

LEGEND 09. Shim

01. Saddle Block 05. Inboard Bushing 10. Shim
02. Hardened Washer 06. Dowel Pin 11. Wear Plate
03. Drilled Head Cap Screw 07. Wear Plate 12. Outboard Bushing
04. Tie wire 08. Shear Block 13. Drilled Head Cap Screw

14.3.12.4 Lower Saddle Block Wear Plate Adjustment
NOTICE
The lower saddle block adjustment should be done after the axial shipper shift clearance is
adjusted. If the saddle block lower shims are too tight, the shipper shaft axial adjustment can
not be done correctly, and shims will have to be removed.
With the shipper shaft axial clearances properly adjusted, adjust the lower (lateral) slide plates. Note that measure-
ments must be taken at the widest point on the dipper handle and that adjustments are made on both sides to help
compensate for any wear that the handles may have experienced. Place the dipper handles in the carry position,
with handles parallel to the ground and hoist ropes straight up and down.
NOTICE
Dipper handles should be centered so there are equal gaps between the handle and lower wear
plate on both sides. It may be necessary to use the shovel swing motion to center the handles.
There should not be a large difference in the number of shims on each saddle block when this
adjustment is concluded.
Refer to Figure 14-57 and adjust the saddle block lateral wear plates as follows:
1. Loosen four retaining bolts (B). Back off on the upper two of these bolts until they are flush with the saddle
block plate.
NOTICE
Do not back off on the two bottom retaining bolts (B) more than is required to remove the shims.
If the bottom bolts are removed, the wear plate will drop slightly and become very difficult to
hold up to re-install the bolts.
2. Screw the four jacking screws (A) against the wear plate until the wear plate contacts the side of the dipper
handle leg. Turn all jacking screws equally to maintain parallelism between the wear plate and the handle leg.
NOTICE
Refer to Section A-A on Figure 14-59. The shear blocks on front and back of the wear plate will
control the amount of shims that can be installed for the wear plate. It is possible that the wear
plate will contact the shear blocks before it contacts the side of the handle. Measure the gap
between the wear plate and the dipper handle, as well as the gap between the wear plate and
the saddle block.
3. Turn four jackscrews (A) until wear plate has firmly contacted the dipper handle or, if it cannot go that far, with
the shear blocks both front and back.
4. Measure gap between lower wear plate and handle. If gap is smaller than .120" (3 mm) go to Step 4A. If larger
go to Step 4B.

A. Measure gap between the wear plate and the saddle block and existing shims. Add this to gap measured
above in Step 4. Subtract the minimum gap of .120" (3 mm) from this total. Add this amount of shims to this
saddle block. Go to Step 5 below.
B. If gap measured in Step 4 above is larger than .120" (3 mm) and smaller than .380" (9.6 mm), insert enough
shims between wear plate and saddle block to fill gap completely. Go to Step 5 below.
NOTICE
If gap measured in Step 4 above is larger than .380" (9.6 mm) at both saddle blocks, the lower
slide plates have exceeded maximum wear and should be replaced.
5. Lubricate the four retaining cap screws and torque them to 1460 ft-lbs (1980 N·m). Tie wire jacking screws (A).
6. Readjust when clearance exceeds 0.250″ (6.350 mm).
14.3.12.5 Shipper Shaft Removal
Confirm that preliminary maintenance procedures have been performed as described in Subtopic 14.3.2.
Prepare to remove the shipper shaft by removing the following components.
1. Remove the dipper handles. Refer to Subtopic 14.3.13.3.
2. Remove the crowd gear case cover. Refer to Subtopic 14.3.7.3.

LEGEND
01. Jack Stand 11. Adjusting Collar 21. Thrust Washer
02. Hex Head Cap Screw 12. V Ring Seal 22. Gear
03. Hardened Washer 13. Pinion 23. Shipper Shaft
04. Dowel Pin 14. Self Locking Screw 24. Socket Head Cap Screw
05. Stand Cover Plate 15. Thrust Washer 25. Hardened Washer
06. Stand Support Plate 16. Bushing Assembly 26. Socket Head Cap Screw
07. Stand Support Plate 17. Bushing 27. Lock Washer
08. Drilled Head Cap Screw 18. Oil Seal 28. Threaded Rod
09. Wire Tie 19. Snap Ring 29. Hardened Washer
10. Locking Key 20. O-ring 30. Hex Nut
Figure 14-60: Shipper Shaft Removal

Refer to Figure 14-61 and remove the shipper shaft as follows:
3. Remove the locking keys (10) from the two shipper shaft adjusting collars (11).
4. Each adjusting collar (11) weighs approximately 710 lbs (322 kg). Using a suitable lifting device, remove the
shipper shaft adjusting collars from the ends of the shipper shaft.
! WARNING
The saddle block assembly weighs approximately 11,700 lbs (5307 kg).
5. Each saddle block (Figure 14-61) weighs approximately 11,700 lbs (5307 kg). Using a suitable lifting device,
remove the saddle blocks from the ends of the shipper shaft.
6. Each shipper shaft pinion (13) weighs approximately 2,200 lbs (959 kg). Remove the shipper shaft pinions (13)
from the ends of the shipper shaft.
7. The shipper shaft gear (22) with thrust washer (21) weighs approximately 7,000 lbs (3,175 kg). The shipper
shaft weighs approximately 13,800 lbs (6,260 kg). Using a suitable lifting device, support the shipper shaft gear
to prevent the shipper shaft and gear from dropping during disassembly.
8. Remove bushing assembly (16) at the right end of the shaft as follows:
A. Remove cap screws (24) and washers (25).
B. Insert four 1½”-6UNC cap screws in the four threaded holes in the bushing flange. The cap screws should
be long enough to push the bushing away from the boom when tightened against the side of the boom.
C. Tighten each of the cap screws in equal alternating steps until the bushing breaks free of the boom.
D. The shipper shaft bushing weighs approximately 860 pounds (390 kg). Using a suitable lifting device, sup-
port the bushing. Continue to tighten the cap screws until the bushing can be pulled from the bore in the
boom and removed from the shipper shaft.

NOTICE
Support the shipper shaft on the right end after the bushing has been pulled free.
! WARNING
The shipper shaft weighs approximately 13,800 lbs (6,260 kg).
9. The shipper shaft (23) weighs approximately 13,800 lbs (6,260 kg). Using a suitable lifting device, push or pull
the shipper shaft (23) out of the hub of gear (22) and out of the right side of the gear case.
NOTICE
Shipper shaft must be removed out the right side. The central hub on the shaft is a larger diam-
eter than the gear ID and will not go through the gear if pushed to the left. Leaving the left bush-
ing and retainer in place while removing the shaft will provide support for the shaft on the left
side.
! WARNING
The shipper shaft gear with thrust washer weighs approximately 7,000 lbs (3,175 kg).
10. The shipper shaft gear (22) with thrust washer (21) weighs approximately 7,000 lbs (3,175 kg). Using a suit-
able lifting device, lift gear with thrust washer attached out of the gear case.
11. Remove bushing assembly (16) from the left side of the boom as follows:
A. Remove cap screws (24) and washers (25).
B. Insert four 1½”-6UNC cap screws in the four threaded holes in the bushing flange. The cap screws should
be long enough to push the bushing away from the boom when tightened against the side of the boom.
C. Tighten each of the cap screws in equal alternating steps until the bushing breaks free of the boom.
D. The shipper shaft bushing weighs approximately 860 pounds (390 kg). Using a suitable lifting device, sup-
port the bushing. Continue to tighten the cap screws until the bushing can be pulled from the bore in the
boom and removed.

14.3.12.6 Saddle Block Disassembly and Assembly
LEGEND 09. Shim

01. Saddle Block 05. Inboard Bushing 10. Shim
02. Hardened Washer 06. Dowel Pin 11. Wear Plate
03. Drilled Head Cap Screw 07. Wear Plate 12. Outboard Bushing
04. Tie wire 08. Shear Block 13. Drilled Head Cap Screw
Figure 14-62: Saddle Block Disassembly and Assembly

Refer to Figure 14-62 and disassemble saddle blocks as follows:
1. Cut and remove inner and outer bushings (01 and 12) from the bore in the saddle blocks.
2. Remove dowel pins (11) from the inner and outer faces of the bore in the saddle block.
3. Remove lockwire (02), cap screws (03) and lock washers from the side of the saddle block.
4. Remove wear plate (10) and shims (08) from the inner side of the saddle block.
5. Remove lockwire (07), cap screws (06) and lock washers (05) from the top end of the saddle block. Remove
wear plates (14) and shims (13).
Refer to Figure 14-62 and assemble saddle blocks as follows:
1. Freeze inner and outer bushings (01 and 12) as described in Topic 3.6.
2. Install bushings into the bores in the saddle block. Note that the shorter bushing goes toward the outside.
3. install dowel pins (11) in the inner and outer faces of the bore in the saddle block.
4. Install wear plate (10) without shims to the inner side of the saddle block. Secure with lockwire (02), cap
screws (03) and lock washers from the side of the saddle block.
5. Install two wear plates (14) without shims to the upper structure of the saddle block. Secure with lockwire (02),
cap screws (03) and lock washers from the top of the saddle block.
Repair of the shipper shaft is limited to replacement of worn or damaged parts.
14.3.12.8 Shipper Shaft Assembly and Installation
NOTICE
In this subtopic, discussion will include directional information (“right” and “left”) as it applies to
the shipper shaft, the shipper shaft gear, and the boom. This directional information is written as
though the observer is in the operator’s seat.
LEGEND
01. Left
02. Right
Figure 14-63: Right and Left

LEGEND
01. Jack Stand 11. Adjusting Collar 21. Thrust Washer
02. Hex Head Cap Screw 12. V Ring Seal 22. Gear
03. Hardened Washer 13. Pinion 23. Shipper Shaft
04. Dowel Pin 14. Self Locking Screw 24. Socket Head Cap Screw
05. Stand Cover Plate 15. Thrust Washer 25. Hardened Washer
06. Stand Support Plate 16. Bushing Assembly 26. Socket Head Cap Screw
07. Stand Support Plate 17. Bushing 27. Lock Washer
08. Drilled Head Cap Screw 18. Oil Seal 28. Threaded Rod
09. Wire Tie 19. Snap Ring 29. Hardened Washer
10. Locking Key 20. O-ring 30. Hex Nut
Figure 14-64: Shipper Shaft Assembly and Installation

Confirm that preliminary maintenance procedures have been performed as described in Subtopic 14.3.2.
Confirm that the following components are not installed on the mining shovel:
1. Dipper handles. If they are present, remove them as described in Subtopic 14.3.13.3.
2. Crowd gear case cover. If it is present, remove it as described in Subtopic 14.3.7.3.
Refer to Figure 14-64 and assemble and install the shipper shaft assembly as follows:
! WARNING
component being lifted to fall, striking or crushing persons and resulting in serious per-
sonal injury or death. Ensure the lifting capacity exceeds the weight of the component
being lifted.
1. Clean the two boom bushings (17).
2. Install new thrust washers (15) on each bushing (17) with self-locking socket head screws (14) and torque to
610 ft-lbs (827 N·m).
ES05066a01
Figure 14-65: Lip Seal Orientation
3. Refer to Figure 14-65. Lubricate and install lip seals (18), with the lips facing away from each other, in the seal
seats.

4. Lubricate and install the O-rings (19) in the O-ring grooves. Clean the boom bores.
! WARNING
The bushing assembly weighs approximately 860 pounds (390 kg).
5. The bushing assembly (16) weighs approximately 860 pounds (390 kg). Using a suitable lifting device, support
and install a bushing assembly into the bore on the left side of the boom.
01
02
LEGEND
01. Locking Compound
02. Bolt
Figure 14-66: Apply Sealing and Locking Compound
6. Apply sealing and locking compound, P&H Part Number 21Z772D5, to the threads of socket head cap screws
(24).
7. Secure the bushing assembly to the boom using socket head cap screws (24) and hardened washers (25).
Torque cap screws to 3160 ft-lbs (4284 N·m).
NOTICE
Do not install a bushing assembly into the right side of the boom at this time.

8. Install a new thrust washer (21) to shipper shaft gear (22) using cap screws (26) and lock washers (27).
LEGEND
01. Boom Structure 04
02. Shipper Shaft
03. Thrust Washer 02
03 05
04. Shipper Shaft Gear
05. Shaft Step
01
ES05010b01
Figure 14-67: Components Are Not Symmetrical
NOTICE
When the system is viewed looking from the machinery house to the boom point, as depicted in
Figure 14-67, note that the shipper shaft gear (04) has only one thrust washer. That thrust
washer (03) is on the left side of the gear. Notice also that the shipper shaft (02) is not symmet-
rical: a step (05) to the right of center requires that the shipper shaft be installed from right to left
(as viewed from the operator’s cab), and that the bushing on the right side of the boom cannot
be installed until after the shipper shaft is in place.

Figure 14-68: Position the Shipper Shaft Gear
! WARNING
The shipper shaft gear with thrust washer weighs approximately 7,000 lbs (3,175 kg). The
shipper shaft weighs approximately 13,800 lbs (6,260 kg).
9. The shipper shaft gear (22) with thrust washer (21) weighs approximately 7,000 lbs (3,175 kg). Using a suit-
able lifting device, support the shipper shaft gear to prevent the shipper shaft and gear from dropping during
installation.
Figure 14-69: Install Shipper Shaft
10. The shipper shaft (23) weighs approximately 13,800 lbs (6,260 kg). Using a suitable lifting device, position the
shipper shaft so that the shaft step is to the right of the center splined portion of the shaft. Lift the shipper shaft
and install it into the right side of the boom.

11. Apply a generous coating of multi-purpose grease to the center splines on the shipper shaft and on the splines
inside the hub of the shipper shaft gear.
12. Lower the shipper shaft gear into the crowd gear case so that the shipper shaft can be inserted into the gear
hub.
Figure 14-70: Meshing Splines
13. Install the shipper shaft into the gear hub. Maneuver the shaft so that the splines mesh with the gear splines.
Figure 14-71: Install Bushing Assembly
14. Install the bushing assembly (refer to Steps 1 through 7 in this subtopic) on the right side of the boom.

15. Refer to Figure 14-64. Install the V-ring seals (12) into the recesses in the thrust washers (15) on the boom
assembly.
16. Apply a generous coat of multi-purpose grease to the seal (12), to the face of the thrust washer (15), and to the
splines on the shipper shaft (23) that are on either side of the boom.
17. Lubricate the splines inside the shipper shaft pinion with Never Seez.
Figure 14-72: Install Shipper Shaft Pinion
! WARNING
The shipper shaft pinion weighs approximately 2,200 lbs (959 kg).
18. Each shipper shaft pinion (13) weighs approximately 2,200 lbs (959 kg). Using a suitable lifting device, Lift and
position the shipper shaft pinion for assembly.

01 02
LEGEND
01. Shipper Shaft Timing Mark 02. Pinion Timing Marks
Figure 14-73: Timing Marks
The shipper shaft pinions must be timed. Refer to Figure 14-73. A grinder mark is applied to one of the shipper
shaft splines (01), and two grinder marks are applied to two splines inside the shipper shaft pinion (02). Install the
pinions such that the two marked pinion splines are straddling the marked shipper shaft spline.
19. Position the shipper shaft pinion so that the two chamfer marks in the pinion straddle the chamfer mark on the
shipper shaft splines.
20. install the shipper shaft pinions (13) on the ends of the shipper shaft.
.
Figure 14-74: Install Seal and Lubricate Bushing
21. Install the V-ring seal (12) onto the flange of the inner saddle block bushing and lubricate the surfaces of the
inner and outer saddle block bushings with a generous coat of multipurpose grease.

! WARNING
Each saddle block weighs approximately 11,700 lbs (5307 kg). Each adjusting collar (11)
weighs approximately 710 lbs (322 kg).
22. Each saddle block (Figure 14-75) weighs approximately 11,700 lbs (5307 kg). Using a suitable lifting device, lift
the saddle blocks and install over the ends of the shipper shaft.
23. Lubricate the threads of the adjusting collars with Never Seez.
Figure 14-76: Adjusting Collar
24. Each adjusting collar (11) weighs approximately 710 lbs (322 kg). Using a suitable lifting device, lift the shipper
shaft adjusting collars onto the ends of the shipper shaft and use a bar to thread the collars onto the shaft.
25. Adjust components as follows:
A. Perform shipper shaft axial adjustment as described in Subtopic 14.3.12.2.
B. Perform saddle block upper wear plate adjustment as described in Subtopic 14.3.12.3.
C. Perform saddle block lower wear plate adjustment as described in Subtopic 14.3.12.4.

14.3.13 Dipper Handles R52465
LEGEND
01. Dipper
Handles
02. Racking
03. Greenhorn
Assemblies
04. Bushings
(4 Pairs or
8 Total)
Figure 14-77: Dipper Handles
Visual Inspection
Visually inspect the dipper handle during Preventive Maintenance to ensure that:
• Tooth wear is not excessive.
• There are no broken teeth.

Weld Inspection
Welds should be inspected at 1,000 hour intervals to detect small cracks before they develop into larger ones. The
welds can be inspected with the handle on the mining shovel or with it removed. Use dye penetrant rather than
magnetic particle. This handle has manganese steel racks and stainless steel welds, both of which are non-mag-
netic. Visually inspect the following welds on the dipper handles:
• The joint between the rack and the termination plate.
• The joint between the front end of the termination plate and the handle leg.
• The rack splice joints.
• The longitudinal welds joining the rack to the handle leg.
• The joint between the torsion box and the handle legs.
• The joints between the dipper lugs and the structure of the handle.
When repairing welds, remove all paint and foreign material before welding.
14.3.13.2 Repair
Repair in the field is limited to replacing the greenhorns. If the handle needs more complex repair, it should be
removed from the shovel (refer to Subtopic 14.3.13.3) and repaired in a permanent facility. Contact your local P&H
MinePro Services representative for assistance.
LEGEND
01. Hex Head Cap Screw 03. Greenhorn
02. Lock Washer 04. Greenhorn mounting Plate
Figure 14-78: Greenhorn
Refer to Figure 14-78 and replace the greenhorn (03) as follows:
1. Confirm that all preliminary maintenance procedures have been completed as described in Subtopic 14.3.2.

! WARNING
being lifted. The greenhorn weighs approximately 420 lbs (190 kg).
2. The greenhorn weighs approximately 420 lbs (190 kg). Using a suitable lifting device, support the greenhorn so
that it will not fall when the bolts are removed.
3. Remove hex head cap screws (01) and lock washers (02).
4. The greenhorn weighs approximately 420 lbs (190 kg). Using a suitable lifting device lift and position the new
greenhorn.
5. Attach the greenhorn to the greenhorn mounting plate (04) using hex head cap screws (01) and lock washers
(02).
14.3.13.3 Removal
Remove dipper handles as follows:
NOTICE
There are several ways to remove the dipper handles, depending on the equipment available
and on what maintenance tasks are to be performed. The technique described here is appropri-
ate for many maintenance tasks, and can be modified based on local requirements.
1. Post a qualified operator at the controls of the shovel while removing the dipper handles. The hoist and crowd
motions will be used to position the dipper and handles. The propel motion and the swing motion will also be
needed to move the shovel as the handles are being removed.
2. Position the mining shovel on level ground.

LEGEND
01. Shipper Shaft Pinion
02. Dipper Handles
03. Dipper
Figure 14-79: Place the Loaded Dipper on the Ground
3. Partially fill the dipper. The material in the dipper will help to anchor the dipper and the dipper handles when the
machine is moved. Put the dipper on the ground. A dozer can be used to push material against the sides of the
dipper (but not against the door) to help keep the dipper from moving.
! WARNING
With the hoist limits disabled, the torsion box can be brought into contact with the boom
structure, the hoist equalizer could be brought into contact with the boom point
sheaves, or the hoist ropes could be slacked. With the crowd limits disabled, the green-
horns or the rack front termination plates may contact the crowd pinions. Any of these
situations could cause severe damage. Be very careful when making any movements
with the hoist or crowd when the limits are disabled.
4. Disable the hoist and crowd limits as follows:
A. Log on to the GUI screen as MAINTENANCE or higher.
B. Select the Setup push button in the Control Bar. Refer to Figure 14-80.
Figure 14-80: Setup Push Button - Control Bar

C. Select the Boom Limits push button in the Navigation Bar. Refer to Figure 14-81.
Figure 14-81: Boom Limits Setup - Navigation Bar
D. Confirm that the Boom Limits Selection Setup screen is displayed, as shown in Figure 14-82.
Figure 14-82: Boom Limits Selection Setup Screen

E. On the display panel (center section of screen), select the four point setup push button. Refer to Figure 14-
83.
Figure 14-83: Four Point Setup Push Button Indicator
F. Confirm that the Four Point Boom Limit Setup screen is displayed. Refer to Figure 14-84.
Figure 14-84: Four Point Boom Limit Setup Screen

G. Confirm that the Lube/PLS keyswitch is in the Program position. Refer to Figure 14-85.
Figure 14-85: Lube/PLS Keyswitch
H. Press the Disable Limits push button.
! WARNING
Moving the dipper can shake or bounce the boom, causing people or tools on the boom
to fall. This can result in serious personal injury or death. Use a personnel harness and
lanyard and tie off following applicable safety guidelines as established at the mine. Do
not allow tools to lie loose on the boom.
5. Disconnect the dipper equalizer from the dipper bail or dipper, or remove the hoist cables. Disconnect the dip-
per trip cable from the latch bar.
6. Remove lubrication lines from the saddle blocks and gear case as necessary.
7. Remove the saddle blocks from each end of the shipper shaft as follows:
A. Remove the locking keys (10) from the two shipper shaft adjusting collars (11).

8. Each adjusting collar (11) weighs approximately 710 lbs (322 kg). Using a suitable lifting device, remove the
shipper shaft adjusting collars from the ends of the shipper shaft.
! WARNING
being lifted. Each saddle block weighs approximately 11,700 lbs (5307 kg).
9. Each saddle block (Figure 14-61) weighs approximately 11,700 lbs (5307 kg). Using a suitable lifting device,
remove the saddle blocks from the ends of the shipper shaft.
Technician Tip
Two different methods of removing the dipper handles are described below. Either method can
be used, depending on the reason why the handles are being removed. If the dipper handles
are being removed to get them out of the way for a procedure on the shovel, and for only a
short length of time, there is no reason to disconnect them from the dipper (Step 10). If the dip-
per handles will be removed from the dipper, refer to Step 11.
NOTICE
If the dipper handles will be left off the machine for more than a brief period of time, disconnect
them from the dipper as described in Step 11. Do not leave the handles in the air for extended
periods
10. Follow lockout and tagout procedures prior to starting the mining shovel. Carefully propel the machine in
reverse until the dipper handles clear the shipper shaft pinions. It may also be necessary to use the swing
motion to slightly rock the boom as the handles are removed. A qualified operator should be at the controls of
the shovel throughout the removal procedure (refer to Figure 14-87).

LEGEND
01. Shipper Shaft Pinion
02. Dipper Handles
03. Dipper
Figure 14-87: Dipper Handle Position
11. To remove the dipper handles from the shipper shaft pinions, and then to remove the handles from the dipper,
proceed as follows:
! WARNING
Dropping a raised load can crush, resulting in serious personal injury or death. Be sure
the rated capacity of the lifting equipment exceeds the weight of the dipper handles, and
always follow approved rigging and lifting procedures. The dipper handles weigh
A. Support the pitch braces so that they do not rotate downward when the mounting pins are removed.
Remove pitch brace pins from the dipper handles. The pitch braces will stay with the dipper.
B. Follow lockout and tagout procedures prior to starting the mining shovel. Support the dipper handle with a
suitable crane and carefully propel the machine in reverse until the dipper handles clear the shipper shaft
pinions. It may also be necessary to use the swing motion to slightly rock the boom as the handles are
removed. A qualified operator should be at the controls of the shovel throughout the removal procedure.
C. Lower the dipper handle ends to the ground.
D. Remove the dipper handles from the dipper by supporting the dipper handles with suitable lifting equipment
and removing the dipper handle pins. The dipper handle weighs approximately 95,100 lbs (43,137 kg).
E. Have blocking ready to set the dipper handles on. Lift the dipper handle clear from the dipper and place the
dipper handle on blocks with the racks up.

LEGEND 01.Spacer Bar 02.Steel Flats
Figure 14-88: Spacer for Dipper Handles
12. Place heavy spacer bars or pipes between the dipper legs as close to the open end as possible (refer to
Figure 14-88). Construct the spacer bar as follows:
A. Determine the length of the spacer bar by measuring the distance of the handle spread directly behind the
front torsion box (handle front).
B. Cut the spacer bar one inch shorter than the actual dimension measured between the handles.
C. Supply four steel flats with the following dimensions: 6 x 1/2 x 6" (152.4 x 12.7 x 152.4 mm). Weld one steel
flat on each end of each spacer bar. The spacer bar with the flats must be installed close to the open end of
the handle. The spacer bar must be tack welded into place. Use horizontal welds only (parallel to the handle
leg), no vertical welds (across the handle leg) are permitted.
Just as there are several ways to remove the dipper handles, there are also several ways to install them depending on the equip-
ment available. One method of installing the handles is shown here.
Reattach Dipper Handles to Dipper
If the dipper handles have been removed from the dipper, they should be re-attached as follows:
NOTICE
All dipper pins should be shimmed tight (all gaps filled) to prevent movement of the dipper or
dipper components. Steel shims should be used, and an attempt should be made to install
equal amounts of shims on each side to center the components. The shims should be retained
by using a few solid shims and attaching slotted shims to them, or by tack welding shims. This
includes bail pins and pitch brace pins. The shims will also help to prevent material from pack-
ing into the bushing and becoming a wear material. Also if the door is shimmed too far to one
side the latch mechanism in the door will not line up with the latch hole in the dipper body. Have
shims prepared before starting the job.

NOTICE
It is assumed that the dipper is still filled with material and packed on the sides, to prevent the
dipper from moving, as the handles are re-attached to it.
! WARNING
Dropping a raised load can cause serious personal injury, death, and equipment dam-
age. Be sure the rated capacity of the crane exceeds the weight of the dipper handles
and crane hoist rope is securely attached to the dipper handle. The dipper handles weigh
1. Lift the dipper handles using a suitable crane. Lower the handles down onto the dipper while lining up the dip-
per door/handles to dipper pins. Insert these two pins and attach the pin retainers. Shim pins tight (see Notice
above).
2. Raise the dipper handles and line up the pitch brace to dipper handle pins. Install these two pins and attach the
pin retainers. Shim pins tight (see Notice above). The handles should now be in the air and the dipper weight
should hold them up so the crane is not needed.
Saddle Blocks Not Installed
The rest of the dipper handle installation procedures are written assuming that the saddle blocks are not installed,
the dipper handles are supported in the vertical position and are connected to the dipper.
Refer to Figure 14-87 and install the dipper handles as follows:
! WARNING
Moving the shovel can shake or bounce the boom, causing people or tools on the boom
to fall. This can result in serious personal injury or death. Use a personnel harness and
lanyard and tie off following applicable safety guidelines as established at the mine. Do
not allow tools to lie loose on the boom.
1. Follow lockout and tagout procedures prior to starting the mining shovel. With the boom aligned between the
vertical ends of the dipper handles, propel the shovel forward until the handles rest squarely against the ship-
per shaft pinions. It may also necessary to use the swing motion to slightly rock the boom as the handles are
engaged to keep from binding. A qualified operator should be at the controls of the shovel throughout the
installation procedure.
NOTICE
Make sure the pinion teeth engage the same tooth on the dipper handle racks. Failure to do this
will cause the handles to bind.
2. Shut down the shovel.

! WARNING
lifts for the saddle block installation procedures could cause the item being lifted to fall
causing serious personal injury or death. Be sure the lifting device has a rated capacity
exceeding the weight of the item being lifted.
3. Using a suitable lifting device, install the saddle blocks (01, Figure 14-49) on the shipper shaft. One assembled
saddle block weigh approximately 11,400 lbs (5171 kg).
4. Lubricate threads on end of shipper shaft with P&H 469 aluminum complex grease and install sleeve retainers
(06). Tighten the sleeve retainers until they are seated firmly against the saddle blocks.
5. If they were removed, install end plates (02) with drilled head capscrews (19) (P/N 20P1872D615). Tighten
capscrews to 1820 ft-lbs (2463 N·m) torque. Secure the capscrews with lockwire.
6. Align two channels in the sleeve retainer (06) with the channels in end plate (02) by rotating the sleeve retainer.
7. Install two locking keys (07) at each end of the shaft. Torque locking key capscrews (09) (P/N 20P1858D492)
to 430 ft-lbs (582 N·m). Secure the capscrews with lockwire (08).
8. Install spacers (21) and capscrews (22) (P/N 20Q260D492) in the outer hole in each slot in sleeve retainer (06)
which does not contain a locking key (07).
NOTICE
Failure to install spacers and capscrews in these holes could allow lubricant to escape and
cause the bushing to wear prematurely.
9. Install mounting plate (12) and spacers (18) on each of the saddle blocks with capscrews (16) (P/N
20P1858D510) and washers (17) (P/N 18Z694D9). Tighten the capscrews to 180 ft-lbs (244 N·m). Secure the
capscrews with tie wire.
10. Install all lubrication and hydraulic lines removed during disassembly.
11. Connect the dipper equalizer, hoist ropes, or the bail depending on which was disconnected.
12. Connect the dipper trip cable to the dipper latch bar.
! WARNING
With the hoist limits disabled, the torsion box can be brought into contact with the boom
structure, the hoist equalizer could be brought into contact with the boom point
sheaves, or the hoist ropes could be slacked. With the crowd limits disabled, the green-
horns or the rack front termination plates may contact the crowd pinions. Any of these
situations could cause severe damage. Be very careful when making any movements
with the hoist or crowd when the limits are disabled.
13. Enable the hoist limits once the dipper handles are installed. Follow the procedures in the Operator’s Manual.

14. Do the shipper shaft axial adjustment and the upper and lower saddle block adjustments as described in Sub-
topic 14.3.12.
14.3.14 Dipper
01 02 03 04 05 06
11
07
10 08
09
ES05033a01
LEGEND 06. Dipper Bail

01. Door/Body Pin 07. Bail Pin
03. Hydraulic Snubber 08. Wing Shroud
03. Pitch Brace Pin 09. Tooth Point and Adapter
04. Adjustable Pitch Brace 10. Dipper Door
05. Front Rock Guard 11. Identification Plate
Figure 14-89: Dipper
Inspect the dipper every 250 hours as follows:
1. Visually inspect the dipper body for structural wear and cracks.
2. Confirm that pin retainers are in place. Check that pins and bushings are not walking out.
3. Check pins, bushings, and trip mechanisms, for excessive wear. Repair, replace, or adjust these mechanisms
as needed, according to P&H specifications. As a guideline, excessive wear can be defined as follows:
• Wear plate worn through to the parent metal over 10% or more of the area covered.

• Bushings worn through to the parent structural bore.
• Pins worn to half their original diameter or to 3/4" (19 mm) or less.
4. Operate and inspect the latch bar to verify that it engages properly with the latch keeper. Engagement should
be between 3/4" (19 mm) and 1" (25 mm).
• The dipper door latch mechanism includes latch adjusting washers (commonly called latch shims) on the
latch bar to allow adjustment of the door latch assembly. As the latch bar wears, latch adjusting washers
must be removed to provide engagement within the range specified above.
• Check the latch keeper insert and the latch bar tip insert for wear. These parts can be removed and rotated,
or replaced.
• Check the latch bar wear plate for clearance (see Figure 14-97). The nominal clearance between the latch
bar and wear plate should be 1/4" (6.35 mm). If the clearance reaches the maximum allowable tolerance, or
if the latch bar starts rubbing on the dipper door, replace the wear plates.
14.3.14.2 Ground Engaging Equipment Maintenance
Ground engaging equipment is designed specifically for a given digging application. The equipment includes the
dipper teeth, adapters, lips, shrouds, and related hardware. Your MinePro Services representative is the best
source of specific equipment recommendations. Accordingly, the following discussion presents only generalized
descriptions and instructions.
Tooth Points
Removal and installation of tooth points and adapters demand adherence to all appropriate safety precautions to
avoid personal injury.
Wear the appropriate personal protective equipment including a hard hat, safety glasses, steel-toed work shoes,
and work gloves. Perform a pre-work tool inspection, and use only tools that are in proper working order. Keep
non-essential people out of the work area.
Adapters and Wedges
When a mechanically attached tooth adapter is first installed, the wedge must be driven in tight with a hammer.
After approximately 6 to 12 hours of operation, inspect and re-tighten the wedge. This procedure should be
repeated again after 48 to 72 hours of additional operation, or as instructed by the manufacturer (refer to
Figure 14-90). Verify that all clearances and bearing surfaces are within the manufacturer's prescribed limits.
As the wedge is driven in, the bottom edge will protrude beyond the bottom of the lip. Burn off any excess after
each re-tightening, or heat and bend the tang back to secure it in place. If the top of the wedge is flush with the top
of the lip, replace the wedge with the next larger size.
Bearing surfaces of adapter noses and dipper lips eventually wear from the digging forces placed on them. Gradu-
ally, the parts loosen, increasing the contact forces on the adapter and lip. Unless preventive maintenance proce-
dures are followed, parts can break or fall off.

ES0677_01
Figure 14-90: Dipper Tooth Wedge
NOTICE
A broken tooth that falls into the dipper and finds its way to the crusher can cause significant
crusher damage. To avoid loss of points in extreme work conditions, match the pin type to the
point. Always use new pins with new points.
Wear Caps and Shrouds
Wear caps (Figure 14-91) are designed to bear the brunt of the high wear that occurs when the leading edge of the
tooth adapter meets the base of the tooth. Some adapters are designed to have wear caps on both the top and the
bottom sides of the adapter, while other styles may use a cap only on the top side.
ES0678_01
Figure 14-91: Dipper Tooth Wear Caps (Circled Area)
Wear shrouds protect the lip and wing base metal from abrasive wear.
Wing shrouds (Figure 14-91) may be used in the upper, midpoint, and lower part of the wing. Common shroud
types include ‘C’ clamp or spool-and-wedge styles, and pin-and-plug designs.

Lip shrouds (Item 05, Figure 14-92)should be replaced before they wear through completely to ensure adequate
protection of the lip and wing shroud bearing surfaces. When replacing lip shrouds, all shroud locking devices
(worn ‘C’ clamps, spools, wedges, etc.) should also be replaced.
14.3.14.3 Dipper Maintenance
Component Weights – R47768F5
WEIGHT – LBS (KG)
DIPPER PART TOTAL DIPPER

CAPACITY (Including typical DIPPER BODY DOOR BAIL
NUMBER
ground engaging (Without wear (Without (Without
equipment and wear package) hardware and hardware)
package) wear package)
R47768F5 73 yd3 171,450 93,110 24,350 17,850

(77768) (42233) (11045) (8097)
(55.8 m3)
Primary Wear Areas
09
08
07
01
02 ES0681a_01
03 04 05 06
LEGEND 05. Lip Shroud
01. Heel Band 06. Adapter
02. Upper Band 07. Corner Shroud
03. Door Wear Plates 08. Wing and Wing Shroud
04. Tooth Point 09. Dipper Wear Plates
Figure 14-92: Primary Wear Areas
Primary wear areas should be inspected regularly, and repaired or replaced as needed. Figure 14-92 shows a
generic dipper with colored tint of high wear areas. These include the leading edge of the dipper shell, the outside
corners of the lip and front, and the leading edge of the protective wings. Each of these high wear areas can be
protected with wear-resistant bars or any easily welded material.

Maintain the shroud fit areas of the lip by weld build-up of the bearing pads. Use templates as a guide for welding
repairs.
General Outside Wear Plate
ES0682_01
Figure 14-93: Replaceable Outside Wear Plates
A replaceable wear plate is normally added to the corners of the dipper body and upper band (box section under
the lip on most dippers). This plate only needs to protect the high wear areas and be thick enough to last from one
dipper relining or restoration on the next (see Figure 14-93).
Heel bands are available to protect the corners and intermediate sections of the dipper heel. In highly abrasive and
high impact materials, the heel band is covered with a thick replaceable casting or plate. In the case of high abra-
siveness, the preferred heel band thickness is approximately 3 to 5 inches (76 to 127 mm).
In less abrasive conditions, the heel band may vary from a heavy, through-hardened casting or plate, to carbide
over a layer of weld-clad wear plate. In many mines with high-impact material, heavy plate or cast heel bands are
preferred. All heel bands are welded in place.
Heel shrouds should be checked routinely and replaced before wear occurs to the parent metal of the front. It is
often more efficient to install the shrouds with the dipper upside down.
Different operating conditions will produce differing wear patterns and wear rates on the corner heel bands. In
some digging conditions, corner heel band service life may be extended by adding a piece of wear plate to the high
wear area.
If the heel band wears rapidly when a new dipper goes to work, the pitch brace length needs adjustment, as
described in Subtopic 14.2.12.2.

Inside Wear Liners
ES0683a_01
Figure 14-94: Inside Wear Plate (Typical)
Replaceable wear liners are normally added to the lower inside of the dipper, but coverage may extend from the
lower one-third to the top of the dipper depending on the type of material being mined, its abrasiveness and its
level of impact on the dipper (refer to Figure 14-94).

Dipper Door
LEGEND
01 -09: Wear Plates
Figure 14-95: Dipper Door Wear Package
The door usually includes protective wear plate (Figure 14-95) on the area of the door that drags through the mined
material, as the dipper leaves the truck to return to the bank. This normally encompasses the lower one-third of the
door. This plate only needs to be thick enough to last from one rebuild to the next. Any excess weight will increase
loads on the snubber and add to snubber maintenance. Excess weight also increases loads on the entire machine
and reduces swing speeds.
There are several grades of wear plate hardness used inside a dipper. If wear abrasiveness is not a factor, but
impact to the liners is great, a through-hardened alloy plate of 360 to 500 BHN should be used. If digging produces
both high abrasion and high impact, it is best to use high hardness through-hardened alloy plate.
Where there is mostly high abrasion, carbide overlay weld-clad material of approximately 600 BHN should be
used. Also, when there is a weight restriction on the number of liners that can be used, higher values of hardness
are better.
Wear patterns on plates being replaced can be used to guide the installation of replacement plates so that all
plates will wear out at the same time. Use thicker plate where wear is greatest, and less thickness where less wear
occurs.

For example, if there is more wear on the inside liner by the door, make the liner thicker in that area. If the sides
don’t wear as much, make the plate thin enough so that it will wear through at the same time as the rest of the
plates.
Using thinner plate where possible will help keep suspended load weights to a minimum, and will allow easier
swing motion and easier cutting through the bank. It will also allow for more efficient wear plate maintenance and
replacements.
LEGEND 45. Hex Slotted Nut

01. Dipper Door 23. Cotter Pin 46. Cotter Pin
02. Snubber Lug 24. Latch Bar 47. Hex Head Cap Screw
03. Bumper Bracket 25. Cotter Pin 48. Thrust Washer
04. Latch Lever Bracket 27. Latch Adjusting Washer 49. Latch Lever Sheave Bolt
05. Latch Wear Plate Weldment 28. Latch Adjusting Washer 50. Sheave Pin
06. Bumper Bracket 29. Latch Bar Retainer 51. Hex Nut
07. Not Used 30. Drilled Pin 52. Rope Clamp
08. Not Used 31. Bumper Pin 53. Rope Wedge and Socket
09. Bushing 32. Door Bumper 54. Latch Lever
10. Door Bushing 33. Flat Washer 55. Bushing
11. Flat Head Cap Screw 34. Cotter Pin 56. Deflector Sheave Bracket
12. Wear Bar 35. Dipper Trip Mechanism Assembly
13. Lock Washer 36. Sheave Bracket 57. Deflector Sheave Bracket
14. Hex Nut 37. Retainer Block 58. Hex Nut
15. Hex Nut 38. Hex Head Cap Screw 59. Sheave Pin
16. Lock Washer 39. Conical Lock Washer 60. Hex Head Cap Screw
17. Bumper 40. Sheave Frame 61. Sheave
18. Hex Head Cap Screw 41. Thrust Washer 62. Snap Ring
19. Hex Drilled Shank Screw 42. Latch Lever Sleeve 63. Bearing
20. Plain Washer 43. Roller Bearing 64. Sleeve
21. Slotted Hex Nut 44. Retaining Ring 65. Roll Pin
Figure 14-96: Legend for Dipper Door Exploded Drawing (Figure 14-97)

14.3.14.4 Dipper Door Maintenance
Figure 14-97: Dipper Door (refer to legend at Figure 14-96)
Figure 14-97 shows an exploded view of a typical dipper door. These components will be covered in the latch sec-
tions that follow.

14.3.14.5 Latch Lever
When the latch bar does not engage properly and all shims have been used, it indicates that the latch lever has
worn away at the pivot point and fulcrum point. Proper engagement can be restored with welding build-up and
grinding.
The hole at the end of the lever where the cable attaches will elongate over time, but it can be restored.
NOTICE
When cracks appear along the edges of the lever, it’s time to replace the lever.
Dipper Door Latch Mechanism
After the dipper is installed, adjust the trip cable.
Latch Bar. Manganese latch bar ends can be restored by welding and grinding them smooth. Alloy steel latch bars
can be restored with welding; however, proper pre-heating is essential, and considerable skill is required to do the
job successfully. The latch bar wear plate (see item 24, Figure 14-97) is replaceable, and its weldment (item 05,
Figure 14-97) can be restored by welding and grinding.
Latch Keeper. The latch keeper supports and holds the latch keeper insert in place. Most latch keeper breakage
occurs when the latch keeper strikes the crawler shoes. Latch keeper damage may also occur if the operator hits a
large rock when cleaning up the pit floor around the machine.
In all types of material, the latch keeper area is typically protected with through-hardened alloy plate.
Inserts must maintain square edges (90°) for continued satisfactory latch operation. Maintain the clearance
between the door and the bottom of the dipper with the latch bar engaged in the keeper to ensure that the latch
mechanism will work properly.
Latch Keeper Insert. The latch keeper insert (Item 1, Figure 14-98) is held in place by two bolts with lock washer
and nut. It is important to torque bolts to 100% of the recommended 2,740 ft-lbs (3715 N·m). Keep spare bolts on
hand and replace them frequently.
When the latch keeper insert is worn on one side, it may be removed, rotated, and reinstalled with the unworn end
providing a new engagement surface with the latch bar insert. The latch keeper insert must be supported at the
bottom opposite side of the latch bar or the insert will break from repeated strikes with the latch bar.
NOTICE
When changing the latch keeper insert, be sure to clean its surfaces and torque the bolts prop-
erly. Replace the bolts when changing the latch keeper.
Latch Adjustment. Periodic adjustment of the dipper door latch assembly is required to compensate for wear.
Adjustment is accomplished through the removal of latch adjusting washers (also known as latch shims) from the
latch mechanism (see Figure 14-97).

01
02
03
04
05
06
07
08
ES05068a01
LEGEND 04. Dipper Door

01. Latch Bar Retainer 05. Latch Bar
02. Latch Lever Bracket 06. Latch Bar Guide Insert
03. Latch Adjusting Washers 07. Latch Keeper
(aka Latch Shims) 08. Latch Keeper Insert
Figure 14-98: Latching Mechanism Wear Areas
As the latch bar wears, latch adjusting washers must be removed from the latch bar assembly to allow the latch bar
to engage 3/4" to 1" (19 mm to 25 mm) into the latch keeper. Less engagement can cause the bar to slip out. More
engagement can cause difficulty in adjusting and maintaining the door and trip mechanism.
Remove latch adjusting washers as follows:
1. To gain access to the dipper door, position the dipper on the ground with the dipper door perpendicular to the
ground.
! CAUTION
Unlatching the dipper door could cause the door to move or open slightly, striking per-
sons and causing personal injury. Be sure all personnel are clear of the dipper door
before moving the latch lever.
2. Raise the latch lever as far as it will go. This will disengage the latch bar and move the latch lever away from
the latch adjusting washers.

3. Block or otherwise support the latch bar in the raised position. If necessary, bend the end of the retaining pin
and remove the shim retaining bars.
4. Remove latch adjusting washers from the latch lever bracket as necessary to achieve the required engage-
ment of ¾ - 1" (19 to 25 mm) with the latch keeper. Each latch adjusting washer removed increases latch bar
engagement approximately 1/2 in (13 mm).
NOTICE
Do not remove all of the latch adjusting washers from the latch lever bracket. The final washer
is necessary to hold the maintain the assembly. The need to remove all the washers would be
evidence that latching mechanism components are due for replacement.

Latch
A A
LEGEND
01. Latch Bar Wear Plate
02. Latch Bar
05 03. Wear Plate Weldment
04. Dipper Door
05. Dipper Body
06. Latch Keeper Insert
07. Latch Keeper
01
06
02
07
4 cm
03 - 2.5
1.90
- 1”
04 3/4”
A-A
ES05069a01
Figure 14-99: Latch Bar Engagement
The latch bar wear plates and latch guide insert located in the door guides (refer to Figure 14-98) should be
checked for wear and replaced if they allow the latch bar to rub against the door itself. Insert and guide are loose
and held in place by fit, while insert is held in place by a welded-on keeper plate.

14.3.15 SnubRite® Hydraulic Snubbers R52182
02 03 01
01 03
21 06
05 LEGEND
07 01. Spacer
03 08
02. Link Arm
21 03. Bushing
04 04. Snubber Arm Pin
05. Split Collar
06. Hex Head Screw
20 07. Lock Washer
08. Hex Nut
09. Door Mounting Pin
10. Hex Head Screw
11
19 11. Split Collar
09 10 12. Lock Washer
12 13. Hex Nut
13 14. Snubber Mounting Pin
15. Split Collar
16. Hex Head Screw
17. Lock Washer
16 18. Hex Nut
15 19. Spacer
17 20. Snubber
14 18 21. Bushing
F7441B
Figure 14-100: SnubRite® Hydraulic Snubber (Right hand shown; left opposite)
Periodically, inspect the SnubRite Hydraulic Snubber to verify the following:
• The dipper door should open and close smoothly.
• All guards to protect the snubber should be in place.
• Link and snubber arm should move freely during door travel.
• All pins should be properly anchored.
• Check pins, bushings, and linkage for wear.
• Seals should not leak.

Some oil seepage at the shaft can be expected during normal operation. A “seep” is defined as a moist patch
around the shaft, and is typically identified by the dust that collects around the shaft opening. A “leak” would be
defined as a visible oil stream or channel cut through the dust that collects around the shaft area.
Whether the snubber should be immediately replaced when leaking or left to operate until the next regularly sched-
uled maintenance will be dependent upon two major factors:
• Severity of the leak.
• Date of next rebuild.
These are management decisions that must be addressed by the owner. Please contact your P&H MinePro Ser-
vices representative for assistance if appropriate.
14.3.15.2 Maintenance and Adjustment
No maintenance is prescribed for the snubbers other than a rebuild at 12,000 hours. The snubber is filled to the
correct level with hydraulic fluid at the factory.
! CAUTION
DO NOT OPEN!
PRESSURIZED
OIL INTERNALLY
CONTACT P&H MINEPRO
FOR MAINTENANCE AND
ADJUSTMENTS R46533D1
ES0498_01
Figure 14-101: Do Not Open Snubber
Do not attempt to add fluid, or to change fluid during the lifetime of the snubber.
No field adjustments are prescribed for the snubbers. Adjustments are preset at the factory. Field adjustments
should not be necessary and are not recommended for the life of the snubber.
NOTICE
If the dipper door does not open and close smoothly, contact your local P&H MinePro Services
representative.
After 12,000 hours of operation, SnubRite Hydraulic Snubbers should be exchanged through P&H Mining Equip-
ment’s ENCORE component exchange program. During the ENCORE rebuild, wear items and hydraulic fluid are
replaced to ensure continued operation. Rebuilding the snubber should not be attempted in the field.

14.3.15.3 Lifting
SnubRite Hydraulic Snubber installation is easier if the snubber is picked and suspended as level as possible.The
SnubRite Hydraulic Snubber will “hang level” only if it is picked up by the tapped holes diagonally across from each
other on the unit.
The two top holes on the front and rear of the snubber are not symmetrical. If the two front holes or the two rear
holes are used to lift the snubber, they will not allow it to hang level. However, if one hole from the front and one
hole from the rear are used, the snubber will hang level.
! WARNING
Failure to use an adequate lifting device to lift the SnubRite Hydraulic Snubber can
cause the snubber to fall, resulting in serious personal injury, death, or equipment dam-
age. Be sure the lifting device has a rated capacity exceeding the weight of the snubber.
The snubber weighs approximately 1,175 lbs (533 kg).
01
02 02
04
03
05
LEGEND
05
01. Crane Hook
05
02. Lift Sling
03. Threaded Eyebolt (Front)
04. Threaded Eyebolt (Rear)
05. Plug
TC2212a
Figure 14-102: Lifting the Snubber
Refer to Figure 14-102 and lift the snubber as follows:
1. Remove one plug from the top front and top rear of the snubber. The holes must be diagonally across from
each other to ensure the snubber will hang level.
2. Install the threaded eyebolts (03, 04) in the tapped holes. Attach the snubber to the lifting slings (02) and crane
hook (01).
3. Lift the SnubRite Hydraulic Snubber.


ES41157 Mechanical Systems Manual Air System
Section 15
Air and Lubrication Systems Manual
Air System
15.1 General
Figure 15-1: Air Panel
The shovel air system provides filtered, dried, and lubricated compressed air for the shovel brake systems (swing,
hoist, crowd, and propel) and the automatic lubrication system (air-driven pumps). Compressed air is also used for
the air horn, the boarding stairway (air cylinders), and the AirScrub Pro System (to clean the filters), and other
optional auxiliary devices, and to adjust the operator’s seat.

Sec15Air.fm -15.1- Section 15, Version 00 - 06/07
Air System ES41157 Mechanical Systems Manual

Figure 15-2 shows a schematic diagram of the basic air system
17
18
19
B A
B A
P
P
20
14 15
B A
16
06
.01
05 5
200 PSI
11 04
03
02
13
M
01
B A B A
P P 07
TC2071e
10 09 08
12
LEGEND
01. Air Compressor 08. to Aux Air 14. To Lube Pumps
02. Air Dryer 09. To Operator’s Seat 15. To Air Hose Reel
03. Air Receiver 10. Air Horns 16. Swing Brakes
04. Air System Lubricator 11. Air and Grease Swivel 17. Hoist Brakes
05. Air Manifold Assembly 12. Propel Brakes 18. Crowd Brake
06. System Transducer 13. Propel Brake 19. Air Horns
07. To Boarding Stairway Maintenance Valve 20. To Air Sprayers
Figure 15-2: Air System Schematic

Section 15, Version 00 - 06/07 -15.2- Sec15Air.fm
15.2.1 Air Compressor R36961D3
Figure 15-3: Air Compressor
15.2.1.1 General
NOTICE
The Sullair ES-8 compressor (Figure 15-3) is a special 30XH (30 HP extra high pressure) pack-
age. This compressor is capable of operating at higher pressures than the regular Sullair ES-8
compressor. If the compressor needs replacement, it must be replaced with a compressor of
similar pressure capability.
This rotary screw compressor has a 30 HP, 3-phase motor. A directional arrow is provided on the fan shroud
between the motor and the compressor so that correct motor rotation can be observed. The motor is direct-coupled
to the compressor with a flexible coupling.

15.2.1.2 Operation
03
04
07 08 09
02
05
06
01 TC0441A
LEGEND 05. Cooling Fan

01. Oil Filter 06. Compressor Unit
02. Air/Oil Separator 07. Air
03. Intake Air 08. Air/Oil
04. Inlet Control Valve 09. Oil
Figure 15-4: Compressor Operation
Refer to Figure 15-4. This compressor has an air filter for incoming air. Air (red arrows) will pass through an inlet
control valve (item 04) as it enters the compressor (06). The inlet control valve (item 04) is a pneumatically con-
trolled valve, controlled by air pressure entering the valve at a small control air line. At peak demand, this inlet con-
trol valve will be wide open. As the system pressure approaches the maximum set point, the inlet control valve will
gradually close. At the maximum set point, the inlet control valve will be in its fully closed position and will prevent
any further compression until demand lowers system pressure below the maximum set point.
The compressor unit consists of two screws, one male and one female. The male is turned by the motor and the
female is an idler. As these screws are turned past the inlet port they create a vacuum which draws air through the
filter and inlet control valve and into the compressor. Oil (blue arrows) is also introduced into the compressor to
keep the screws and bearings lubricated. There is no oil pump; the oil is pushed into the compressor by pressure in
the oil sump. As the screws rotate an air/oil mix is compressed between the screws and expelled out the outlet port
of the compressor into the sump area. Most of the heavy oil falls to the bottom of the sump due to gravity. A small
amount of oil remains in the air in the sump. As the air in the sump is pushed out the air outlet at the top of the
sump, the air passes through the separator, which removes the remaining oil. A minimum pressure/check valve at
the outlet ensures the pressure in the sump area stays above 60 PSI (4.2 bar), which is necessary for good oil flow.
The minimum pressure/check valve also ensures system pressure can not be forced back into the compressor
when the compressor motor is shut down.

Air exiting the compressor is directed through an after cooler and a moisture separator, and then on to the air sys-
tem main receiver.
! CAUTION
Opening the oil fill plug or opening the compressor to atmosphere in any other way
while the compressor contains air pressure will allow compressed air and possibly hot
oil to escape, which could cause severe personal injury. Do not open or remove any the
compressor components while the compressor contains air pressure. Refer to mainte-
nance procedures prescribed in Subtopic 15.3.3.4.
As the compressor begins operating, pressure in the sump forces oil to a temperature bypass valve. This valve will
allow cold oil to bypass the oil cooler, but as the oil warms, the bypass valve directs the oil through the oil cooler to
maintain proper oil temperature. The temperature bypass valve works similar to a thermostat on an automobile
cooling system. The oil continues on through the oil filter and into the compressor screws. The oil lubricates the
compressor, seals the small gaps between the screws, and also cools the compressor. A temperature sensor
located in the bottom of the oil sump will cut out the compressor motor power if the oil temperature rises above
235º F (113ºC).
NOTICE
In cold weather the temperature bypass valve must allow the oil to warm up before opening and
sending oil through the cooler. If the valve sticks open, the oil will remain cold and will load up
with moisture, which could cause the oil to froth and the separator to send oil through to the rest
of the air system.

15.2.2 Air Control Description
Description Keypad Display Recommended Setting
Unload Pressure UNLOAD 175 PSI
Load Pressure Differential LOAD 45 PSI
Maximum Sump Pressure P1 MAX 185 PSI
Wye to Delta Transition Timer WYE DELT See Note 1 Below
Restart Time RST TIME 10 seconds
Unload Stop Timer UNLD TIME 15 minutes
Language LANGUAGE English
Units UNITS English
Communication ID# COMM ID# 1
Baud Rate BAUD RATE 9,600
Modulation, Set @ Pressure Regula- Not on Keypad, physical set point 170 PSI
tor Valve
Note 1: Wye to Delta is used on 50Hz machines (5 seconds), it is disabled on 50Hz machines
Table 15-1: Programmed Set Points - Single Compressor
This compressor will operate through several pressure modes as it builds system air pressure. This description will
start with no system air pressure and progress to maximum system pressure.
As the compressor starts when the air system receiver has no pressure in it, the compressor will first pressurize its
own sump to ensure proper oil flow. The minimum pressure/check valve will contain exiting air in the sump until the
sump pressure exceeds 60 PSI (4.2 bar). As the sump pressure exceeds 60 PSI (4.2 bar) the minimum pressure/
check valve will open and allow air to exit into the receiver and the shovel’s air system.

15.2.2.1 Touchpad Operation
The touchback is used to control the machine as well as to display status and change set points. Refer to Figure
15-5 for following key descriptions:
!
P
P1 T1 P2

POWER ON AUTO
DISPLAY

PROG
6+"""
LEGEND 02. System Graphic Display

01. Keypads 03. Message Display
Figure 15-5: Compressor’s Touchpad and Display
STOP – used to put the compressor into manual stop. It is also used to clear alarm conditions.
CONTINOUS – Starts compressor if no alarm conditions are present. Also used to clear alarm conditions while the
compressor is running. Compressor will ignore unload stop timer.
AUTOMATIC RUN – Starts compressor and selects auto mode if no alarms are present. Also used to clear alarm
conditions when compressor is running.

DISPLAY – Used to display pressures, temperatures, and other status information.
DISPLAY
LOGO – Used for various functions. (Not described in detail here).
PROGRAM – Used to enter the parameter change mode where control parameters may be displayed and
changed.
PROG
UP ARROW – Used in Status Displays to change displays and in Parameter Setup Mode to increase a value.
DOWN ARROW – Used in Status Displays to change displays and in Parameter Setup Mode to decrease a value.
When in the default display the key will light all the lamps for three seconds.
15.2.2.2 Status Displays
By default, the line pressure (P2) and discharge temperature (T1) are shown on the bottom line of the display, and
compressor status on the top line. The following are the various machine status messages that indicate the state of
the compressor:
STOP - Compressor is off.
STANDBY - Compressor is off but armed to start. NOTE: The compressor may start at any time.
STARTING - Compressor is trying to start.
OFF LOAD - Compressor is running and is off loaded.
ON LOAD - Compressor is running and is loaded.
SEQ STOP - Compressor is off but is armed to start, if required. (Dual compressor packages only). The compres-
sor will start when the sequencing conditions meet the criteria to start.The compressor may start at any time.
The default display appears as follows (the 170 is the P1 pressure and the 195 is the T1 temperature):
STOP
170 195

If there are alarms active they will alternately be shown with the default display. For example:
T1 H1
170 235
To view other status press the DISPLAY key. All temperatures and pressures may be displayed as well as other
status information. To scroll through the displays press the UP ARROW or DOWN ARROW keys. UP ARROW
moves to the next display, DOWN ARROW moves to the previous display. To return to the default display press the
display key.
This display shows the separator differential pressure and the maximum limit. If the limit is exceeded, a separator
maintenance warning will be displayed.
dp1 4
MAX 10
Sump pressure and line pressure.
P1 160
P2 165
Compressor discharge temperature and the maximum limit. If the temperature exceeds the limit a T1 HI shutdown
will occur.
T1 210
MAX 235
Total hours that the compressor has been running.
HRS RUN
001000.0
Total hours that the compressor has been loaded.
HRS LOAD
000990.0
Last fault log. This shows the fault on the last line and the run hours when the fault occurred.
T1 H1
@1 300
Next to last fault log. This shows the fault on the first line and the run hours when the fault occurred.
T1 H1
@2 200

Lamp Indicators. These lamp indicators are embedded in the Touch Panel schematic below the display see Fig-
ure 15-5. Pressing the lamp test key will light all lamps for 3 seconds.
P1 - If lit steady, signifies that P1 is being displayed. If flashing it indicates an alarm.
P2 - If lit steady, signifies that P2 is being displayed. If flashing it indicates an alarm.
dP1 - If lit steady, signifies that dP1 is being displayed. If flashing it indicates the separator differential pressure is
high and the separator should be replaced.
T1 - If lit steady, signifies that T1 is being displayed. If flashing it indicates an alarm.
Motor - If flashing, it indicates that the motor overload contact has opened.
Power On - Lit if line power is present and applied to the compressor control unit.
On - If lit steady, the compressor is running. If flashing, indicates the compressor is armed but is stopped because
of restart timer not expired or because of a sequence stop. If flashing, the compressor could start at any time.
Auto - If lit steady, the compressor is running and is in auto mode. If flashing, indicates the compressor is armed
but is stopped because of restart timer not expired or because of a sequence stop. If flashing, the compressor
could start at any time.
15.2.2.3 Compressor Modulation
The compressor will continue to compress air at its maximum rate as it builds up system air pressure. As the sys-
tem pressure nears its maximum set point the compressor inlet control valve will begin to close and slow down the
rate of compression. This closing will begin to occur at about 160 PSI (11.2 bar).
As the system air pressure continues to rise the inlet valve will continue to close. At 170 PSI (11.9 bar) the inlet
control valve should be fully closed and compression should stop. The compressor will continue to run and as
demand drops the system air pressure below 170 PSI (11.9 bar), the inlet control valve will begin to open and more
compression will take place. This action will allow the compressor to modulate its compression and produce a
nearly constant system pressure of 170 PSI (11.9 bar) while not requiring the compressor to stop and unload then
start and reload.
The inlet control valve is controlled by pneumatic pressure in a small control line. As the control line air pressure
increases, the inlet control valve closes. As the control line pressure is decreased, the inlet control valve will open
proportionally to allow more air to enter the compressor. A pressure regulator valve, located on the right rear side
of the after cooler unit while facing the touch panel, modulates the pressure in the control line.
The pressure regulator valve (Figure 15-6) is supplied with system air pressure. As the system air pressure rises, it
overcomes the internal spring pressure and allows the diaphragm to open. This will allow a small amount of air
pressure to discharge from the pressure regulator valve into the control air line leading to the inlet control valve. As
the system air pressure rises further, more air pressure escapes the diaphragm and enters the inlet control valve.
The amount of air pressure entering the inlet control valve can be adjusted with the adjustment screw of the pres-
sure regulator valve, which adjusts spring tension on the diaphragm. The correct pressure adjustment will be to
make the inlet control valve fully close at 170 PSI (11.9 bar). And this adjustment should cause the diaphragm to

just begin to open at approximately 160 PSI (11.2 bar). Below 160 PSI (11.2 bar) the compressor will run at full
capacity.
!

"
6+$#&)
LEGEND
01. Orifice 03. Bell
02. Diaphragm Assembly 04. Adjustment Screw
Figure 15-6: Pressure Regulator Valve
The pressure regulator valve is shown in Figure 15-6. Next to the adjustment screw is a small orifice. As the dia-
phragm opens, air will be felt exhausting out the orifice.
The orifice on the pressure regulator valve must remain open so air can exhaust. When the diaphragm is closed
this will allow the control air line to bleed off pressure and allow the inlet control valve to open. If the orifice is
plugged the control air line will stay charged with air pressure, the inlet control valve will stay closed, and the com-
pressor will not be able to compress any air. To check this, hold your finger under the orifice. If the compressor is
running and will not compress air, and no air is escaping the orifice, the valve should be disassembled and
cleaned. Refer to maintenance procedures prescribed in Subtopic 16.3.1.
15.2.2.4 Compressor Unloading
If the Unload Pressure is reached the compressor will unload itself. A solenoid valve will open and allow air pres-
sure to do two things:
1. Air pressure will be directed to the inlet control valve to ensure it is fully closed
2. Air pressure will be directed to open a pilot operated blow-down valve.
When this blow-down valve opens, the sump pressure will be allowed to exhaust until it reaches a low pressure,
approximately 35 PSI (2.45 bar).

NOTICE
This is just the pressure in the sump, not the entire air system pressure.
The compressor will then run in an unloaded condition until the system air pressure drops to the load pressure dif-
ferential (45 PSI below the unload pressure, or 130 PSI, 9.1 bar) (refer to Table 15-1). At this pressure the solenoid
valve will close, the blow-down valve will close, the inlet control valve should open and compression should again
occur.
NOTICE
If the pressure regulator is working properly and stopping compression at 170 PSI (11.9 bar),
the unload pressure of 175 PSI (12.25 bar) should not be reached under normal conditions.
The Unload Stop Timer will monitor how long the compressor remains in the unloaded condition, and will turn off
the motor if it times out (Compressor Automatic Mode only). If the compressor turns off in automatic mode, it will
turn itself back on again when the system pressure reaches the load pressure of 130 PSI (9.1 bar). However, since
the compressor should not normally reach an unload condition, the compressor should not turn itself off automati-
cally.
To guard against the compressor reaching an air pressure that is too high for the system, the Maximum System
Pressure (P1 MAX) is set at 185 PSI (12.95 bar). At this pressure the power for the motor will be interrupted, and a
fault will occur. At 200 PSI (14 bar) the safety relief valves on the compressor and the air system receiver should
open to atmosphere.
15.2.2.5 Compressor Programmed Set Points
The compressor is equipped with a pressure transducer located on the exiting air line to monitor system air pres-
sure. All set point adjustments other than the pressure regulator are made using the compressor’s touchpad shown
in Figure 15-5. The programmed set points are shown in Table 15-1.
Single Compressor Set Points. A brief description of the set points in Table 15-1 follows:
1. Unload Pressure. This is the pressure where the compressor will unload.
2. Load Differential Pressure. Subtract this differential from the Unload Pressure and it gives the set point where
the compressor would reload after it has unloaded.
3. Maximum Sump Pressure. Reaching this pressure (P1 MAX), will result in the compressor shutting down on a
high pressure fault. This is protection against the compressor running away and producing a system pressure
higher than the rated capacities of other system components.
4. Wye to Delta Transition Timer. Wye to Delta transition is set to 5 seconds.
5. Restart Time. This is the time the compressor will wait after power up before starting. This is used to delay start
until other equipment has started.
6. Unload Stop Time. If the compressor is running in auto mode, this parameter specifies the amount of time that
the compressor will run unloaded before it will automatically shut down. This should not normally be set less
than 15 minutes.

NOTICE
Because the setup specified here should not allow the compressor to unload, it should never
shut itself down automatically.
7. Language Select. The default setting is English, it can be changed to other languages.
8. Units. English or Metric can be selected.
9. Communications ID#. For a single compressor it should always be 1.
10. Baud Rate. Select 9600.
11. The Modulation Point is set by turning the adjustment screw of the Pressure Regulator Valve. See Subtopic
15.2.2.3 for adjustment details.
15.2.3 Air Dryer R37969F2
Figure 15-7: Air Dryer
15.2.4 General
Figure 15-7 shows the membrane-type air dryer. The membrane dryer is plumbed between the air compressor and
the main air receiver. It is used to dry all the air required to operate the mining shovel air system. The membrane
dryer is preceded by three filters, to remove contaminants from the air before it reaches the membrane dryer. This
provides the receiver with dry air to reduce wet tank contamination and frozen drain valve problems.
The membrane dryer provides filtration to 0.01 microns and drying to a pressure dew point of -50 degrees F, when
properly maintained.

NOTICE
If a membrane dryer is used a deicer is not needed. This is important, since the combination of
deicers and lubricants in air systems may cause valve malfunctions.
15.2.5 Operation
The membrane dryer operates as follows (refer to Figure 15-8):
3 µ 1µ .01µ
E
170 PSI
200 PSI
ES0843d01
Figure 15-8: Air System Schematic With Membrane Air Dryer
Compressed air arrives at the inlet valve and passes through the system filter pack, which consists of three filters.
Note that the valve handles are shown in their normal operating positions. The first filter is designed to remove par-
ticles down to 3 microns, the second to 1 micron, and the third to 0.01 micron.
Air passes from the filters through the membrane dryer, where it is dried to a pressure dew point of -50°F (45.6°C)
when the dryer is properly maintained.
Dry air is discharged into the air system as shown in the schematic diagram (Figure 15-2)

15.2.6 Air Receiver
Figure 15-9: Air Receiver
The air exiting the dryer is routed to the main air system receiver.
The main air system receiver is a 240 gallon tank mounted in the lubrication room on the left front corner of the
machinery deck. It is mounted on brackets near the ceiling of the room. Safety relief valves on the air receiver limit
maximum receiver pressure to 200 psi (13.8 bar).
Figure 15-10: Reciever Automatic Drain
. An automatic drain removes sediment accumulated in the bottom of the receiver. This automatic drain is opened
by an adjustable timer/solenoid valve at regular intervals. After a short timed duration, the drain is automatically
closed.
Figure 15-11: System Transducer
A pressure transducer monitors the pressure in the receiver.

15.2.7 Lubricator 46Z405D1
Figure 15-12: Air System Lubricator
The air lubricator is mounted in the lube room between the lubricant tank and the air dryer. It conditions air passing
through it by metering a preset amount of oil into the air. The oil lubricates the moving parts of the air valves and
cylinders.
Oil is metered into the air line only when there is air flow through the lubricator. Variations in the air flow through the
lubricator vary the amount of oil metered into the air stream. For lubricator maintenance, refer to Subtopic 15.3.6.
15.2.8 Air Manifold Assembly (R42202F1)
Figure 15-13: Air Manifold Assembly
The air manifold assembly (Figure 15-13) is mounted on the forward wall of the left-hand room (lube room). The
supply inlet receives air pressure from the main system receiver. A gauge located at the manifold’s air inlet indi-
cates system air pressure as it enters the manifold.
A pressure transducer on the air manifold assembly in the lube room monitors main air pressure and sends that
signal to the main Centurion Control System. The Centurion Control System must receive a signal from the trans-
ducer indicating that system pressure is above 110 PSI (7.59 bar), or the shovel will not start. Any time the air pres-
sure drops below this setting, the shovel will shut down on a main air pressure fault.

07
08
AUX-AIR
06
09
LWR BRAKES
SPRAY 100 PSI
40 PSI MAX
MAX
10
AUX-AIR AUX-AIR
05
11
PUMPS AUX-AIR
80 PSI
MAX
04
AUX-AIR AUX-AIR
12
13 03
LWR COOP/
AIR PNL STAIR
02
INLET
14
TC0446c_02
01
LEGEND
01. Air Inlet 08. Pressure Regulator and Gauge (4)
02. Control Pressure Switch 09. To Lube Spray Valve
03. To Coop/Stair Circuit 10. Auxiliary Air Outlet (2)
04. Shut-off Valve (6) 11. To Lube Pump Valve Manifold
05. Auxiliary Supply 12. Auxiliary Air Outlet (2)
06. To Upper Brake Circuit 13. To Propel Brake Circuit
07. Auxiliary Supply (For Optional Left Air Horn) 14. Input Air Pressure Gauge
Figure 15-14: Air Manifold Assembly
The air manifold assembly has 6 outputs, each of which is equipped with a shut-off valve on the manifold. Refer to
Figure 15-14 for each of the 6 outputs below.
1. Item 03 shows an unregulated supply line for the Operator’s Coop and Boarding Stairway (refer to Subtopic
15.2.9).
2. Item 05 shows a regulated Auxiliary Supply this supply can be used for optional air-operated accessories. The
regulator adjustment will depend on the optional accessory
3. Item 06 shows a regulated Brake Air Supply (refer to Subtopic 15.2.13).

4. Item 09 shows a regulated supply for the Lube Spray Valves (refer to Subtopic 15.2.14).
5. Item 11 shows a regulated supply for the Lube Pumps (refer to Subtopic 15.2.12).
6. Item 13 shows an unregulated supply line for the Lower Air Control Panel (refer to Subtopic 15.2.10).
In addition to the six outputs equipped with shut-off valves, items 7, 10 and 12 show auxiliary air supply ports on
the manifold. These ports do not include shut-off valves or regulators on the manifold. If unused, these are
equipped with pipe plugs installed in the ports. They can be used to connect auxiliary devices.
15.2.9 Coop/Stair Circuit
The lower right port on the manifold assembly (item 03, Figure 15-14) provides compressed air to the following
components:
A. Boarding Stairway
B. Operator’s seat assembly
C. AirScrubPro house filtration system
D. Horn
E. auxiliary air devices

15.2.9.1 Boarding Stairway
Figure 15-15 is a schematic diagram of the boarding stairway air system.
07 08
06
12 12
04
51 3
05
14 14
LEGEND
01. Inlet Pressure
09
02. Handle Operated Valve
03. Pullcord Operated Valve
04. Vent
04 05. Flow Control Valves (down
1 3 1 3 speed)
02 03 06. Pilot Air Operated Valve
07. Pilot Air Operated Valve
08. Stairway Cylinders
09. Flow Control Valve (upward
speed)
3 4 3 4
1 2 1 2
1 3 1 3
TC0348
01
Figure 15-15: Boarding Stairway Air System Schematic (R15627)

The system has a pressure regulator/filter/oiler assembly. Refer to Figure 15-16.,
01 02 03 04
ES05042a01
LEGEND
01. Check Valve 03. Filter
02. Regulator 04. Lubricator
Figure 15-16: Regulator/Filter/Lubricator Assembly
The automatic drain air filter (03) removes contaminants and water before the air goes to the various air-operated
components.
Louvers guide air entering the filter into a downward swirling pattern. Liquid and coarse particles are thrown against
the bowl wall by centrifugal force and run down to the bottom of the bowl. The baffle at the bottom of the bowl cre-
ates a “quiet zone” to minimize entry of the separated liquid into the outgoing air stream. Air leaving the bowl
passes through the element where finer solid particles are removed and retained.
The air filter drains automatically using a float-operated mechanism at the bottom of the bowl, that opens when liq-
uid has accumulated above a certain level. The liquid is expelled through the drain. The automatic drain is normally
open during shutdown periods so that any liquid accumulated in the bowl may drain out.
At start-up, the automatic drain closes when the bowl pressure reaches approximately 5 PSI (0.34 bar). The mini-
mum operating pressure is 10 PSI (0.70 bar).
This air lubricator (Item 04) conditions air passing through it by metering a preset amount of oil into the air. This
lubricates the moving parts of air valves and cylinders. Oil is metered into the air line only when there is air flow
through the lubricator. The rate of flow is controlled by rotating the knob on the top of the lubricator.

Compressed air is available to the two manually operated valves (Figure 15-17) which operate the boarding stair-
way. The handle operated valve allows operation of the stairway from the shovel, and the pullcord operated valve
allows operation from the ground.
! "
6+$'$=
LEGEND
01. Valve (Pilot Air Actuator) 03. Valve (Pilot Air Actuator)
02. Pull Cords 04. Handle Actuator
Figure 15-17: Boarding Stairway Manually Controlled Valves
The handle-operated valve is located on the outside wall on the stairway side of the mining shovel. Two locations
are shown because the valve may be located on either right or left side of the mining shovel, depending on opera-
tor cab position.
The pullcord operated valve enables a person on the ground to raise or lower the boarding stairway. The pullcord
operated valve operates the system in the same manner as the handle operated valve.
When both of the manually operated valves are placed in the raise position, pilot air pressure is applied to one of
the pilot air operated directional control valves (DCV). The DCV then applies air pressure to the boarding stairway
cylinders (Figure 15-18) that raise the boarding stairway. When one of the manually operated valves is placed in

the down position, the air in the cylinders is vented, allowing the stairway to lower. The cylinder is controlled by two
pilot air operated valves (DCV), which will be discussed in detail in Subtopic 15.3.7.

53
LEGEND
01. Handle Operated
Valve
02. Air Cylinders
6+$'"=
Figure 15-18: Location of Air Cylinders
NOTICE
It is important to remember that there is no locking device that holds the stairway in the raised
position, only air pressure holds it up when it is raised. Shutting the shovel down has no imme-
diate effect on the stairway system, as it has no electrically operated components. However,
when the system air pressure is no longer strong enough to support the stairway, it will lower.
Pilot air pressure operated air valves (directional control valves or DCV’s) are used on the air supply for the board-
ing stairway. These valves physically resemble Type 1 solenoid air valves, but do not have an electric coil. Instead
they are completely operated by air pressure. The air valve manifold contains two valves, which work indepen-
dently to control the stairway.
An air line connects the valve manifold to each of the two stairway manually operated control valves (see sche-
matic, Figure 15-15). The schematic shows all valves in the raised position.
As one manually operated valve is turned to the lower position, it opens and supplies pilot air pressure to the air
supply valve manifold. The pilot air pressure entering the valve manifold is applied to one of the two pilot air oper-
ated valves (DCV). As the pilot air pressure is applied to the DCV it moves the valve’s main spool. As the spool

moves the valve’s input and output configuration changes, which will reverse the connections to the cylinders,
block the supply, and vent the cylinders, causing the stairway to lower. Note that one shifted DCV will actuate both
of the stairway cylinders, and that there are separate vent lines for each of the two pilot operated valves.
When the manually operated valve is returned to the raise position, the DCV will shift back and reverse the connec-
tions to the cylinders, again applying air pressure to the cylinders causing the stairway to raise.
There is no adjustment to be made to the DCV’s. The DCV’s have no push-button for manual operation.
There is a proximity switch which is actuated when the stairway is raised to its upright position. This proximity
switch informs the shovel control system of stairway position. If stairway air pressure is adjusted too low, the stair-
way will bounce, and the proximity switch will signal to the Centurion Control System that the stairway has lowered
when the stairway bounces low enough to exceed its range. This will cause the shovel controls to immediately set
the swing and propel brakes, as these brakes are set automatically when the Centurion Control System determines
the stairway is lowered.
The flow control valve in-line with the stairway cylinders is used to control upward speed of the stairway. The two
flow control valves in the vent lines from the pilot operated valves are used to control downward stairway speed:
one is used when the pull-cord operated manual valve is used, one when the handle operated manual valve is
used.
Figure 15-19: Boarding Stairway Cylinders
The boarding stairway cylinders (Figure 15-19) are air-operated cylinders that are used to raise or lower the board-
ing stairway. The cylinder is supplied with 1 rod clevis, 2 retaining pins, and 2 cotter pins. There are two cylinders
on the boarding stairway, one on each side of the stairway.
The boarding stairway is covered in detail in Topic 8.4.
15.2.9.2 AirScrubPro®
The air line that provides compressed air to the AirSrubPro system originates here. For a complete description of
that system and the role that compressed air plays, refer to Section 9.
15.2.9.3 Operator’s Seat
The seat assembly contains an air bladder that can be adjusted for the operator’s comfort. Refer to the Operator’s
Manual for a description of the adjustments for the operator’s seat. The air pressure for the operator’s seat should
be adjusted within the guidelines shown in Table 15-2.
Air Seat Pressure Settings
Recommended 120 PSI (8.28 bar)
Maximum 150 PSI (10.35 bar)
Minimum 90 PSI (6.21 bar)
Table 15-2: Recommended Air Pressures for Air Seat

15.2.9.4 Air Horns
Figure 15-20: Air Horn
There are two air horns mounted on the forward wall of the machinery house, one on the right and one on the left.
The regulator settings for the air horn assemblies should not exceed 100 PSI (6.9 bar).
15.2.10 Propel Brake Circuit
Air from lower left port on the manifold assembly (item 13, Figure 15-14) provides compressed air to the propel
brakes. The line is plumbed through the air swivel mounted above the high and low voltage collector assemblies in
front of the hoist drum.
Figure 15-21: Air Swivel

The air line goes through the center gudgeon and to the lower air control cabinet at the back of the carbody.
ES04331b01
Figure 15-22: Lower Air Control Cabinet
Inside the lower air control cabinet is a check valve. This prevents the air that is being used to release the propel
brakes from being stolen by some other system. The air pressure regulator is set to 105 psi (7.25 bar). There are
three air valves. The top and bottom air valves are for the left and right propel brakes. The air valve in the middle is
for a cable reel; if there is no cable reel, this valve acts as a spare.
From the lower air control cabinet, the air is plumbed to the quick release valve that is attached to the propel brake.
01
04
03
LEGEND
01. Inlet
02. Exhaust
03. Outlet
02

At the top of the brake, another air line is plumbed to the propel brake air panel mounted on the side of the motor
mounting base.
Figure 15-24: Propel Brake Air Panel (top) and Maintenance Panel (bottom)
from escaping through the valve and allows air pressure to build and cause the brake to release. When the brake
sets, the redundant air valve opens to provide an additional passage to exhaust air and ensure quick and sure
brake setting. The two redundant air valves are joined by a redundant exhaust line, so that if one of the valves
sticks in the closed position, both brakes will still have an exhaust path independent of the quick release valve.
Installed in this line is the maintenance valve. The maintenance valve, operated by controls on the Propel Brake
Maintenance Panel, causes the release of one of the propel brakes while the other brake remains set, permitting
inspection and maintenance of the propel brakes without losing control of the shovel.
15.2.11 Auxiliary Air Supply
Air from middle right port on the manifold assembly (item 05, Figure 15-14) provides regulated compressed air for
air powered tools or accessories.

15.2.12 Automatic Lubrication System Air Supply
Figure 15-25: Automatic Lubrication System Air Pressure Regulator
Air from middle left port on the manifold assembly (item 11, Figure 15-14) provides regulated compressed air for air
the Automatic Lubrication System. The regulator on the air manifold assembly is used to adjust the pressure for the
lube pumps to 60-80 PSI.
Figure 15-26: Auto Lube System Solenoid Valves
A solenoid valve manifold (Figure 15-26) is located near the pumps in the lube room. There is one air valve to sup-
ply each of the two pumps, and a valve to supply the spray valves. A fourth valve is provided as a spare.
An adjustable valve that is attached at the pump air inlet allows the air flow to the pump to be restricted. This will be
used to adjust pump speed. Refer to Topic 15.5 for more information.
When air pressure is supplied to the air motor, it drives the pump, which draws lubricant out of the tank and pumps
it to the vent valve or to the zone valve. Three zone systems typically have vent valves, while four zone systems
have a zone valve. The lube is then routed to the rest of the system. Refer to Subtopic 18.2.2 for more information.

15.2.13 Upper Brake System Air Supply
Air from upper right port on the manifold assembly (item 06, Figure 15-14) provides regulated compressed air for
air the upper system brakes. The regulator on the air manifold assembly is used to adjust the pressure for the
brake systems to 100 PSI.
Figure 15-27: Upper Brake System Air Valve Manifold
From the upper air control panel, the air is plumbed to the upper brake solenoid air valve manifold mounted on the
lube room wall just to the right of the upper air control panel. All three valves are labeled:
• The first valve (labeled CROWD) supplies air to the single crowd brake.
• The second valve (labeled HOIST) supplies air to the two hoist brakes.
• The first valve (labeled SWING) supplies air to the three swing brakes.
For each brake system, the air is plumbed from the air valve and out of the lube room.
• The line for the crowd brake goes out the front house wall and up the boom.
• The lines for the hoist brakes go under the machinery deck and up the side of the hoist gear case.
• The lines for the swing brakes go under the machinery deck and up the sides of the swing motors.

In each case, the line connects to the quick release valve that is attached to a port on each of the brakes.
01
04
03
LEGEND
01. Inlet
02. Exhaust
03. Outlet
04. Brake
ES04322a01
02
For the crowd brake, the line goes no farther. For the hoist and swing brakes, another air line is threaded into a port
on the opposite side of the brake cylinder from where the quick release valve is attached. This line goes to the
brake air control panel, which is mounted on the side of the hoist gear case or the side of the swing motor.
03
02
04 LEGEND
01. From Brake
04. Exhaust
ES04324a01
Figure 15-29: Brake Air Panel

The crowd brake has no brake air panel. The crowd brake pressure transducer is located near the air valve.
An additional air line, plumbed along the sides of the swing motors, connects the exhaust lines of all three swing
brakes. The purpose of this double-redundancy crossover line is to ensure that when the brakes are set, even if
two of the secondary solenoid valves fail to open, the air pressure from all three brakes will still have an exhaust
path. A similar setup provides double redundancy for the hoist brakes.
15.2.14 Automatic Lubrication System Sprayers Air Supply
Air from the upper left port on the air manifold assembly (item 09, Figure 15-14) provides regulated compressed air
for air the automatic lubrication system spray nozzles. The spray valves (Figure 15-64) used on mining shovels all
Figure 15-30: Automatic Lubrication System Air Valve Manifold
have two inlet ports, one for open gear lubricant pumped from the reservoir and the other for pressurized air from a
solenoid air valve mounted on the lube air control panel. The spray valve has a clean out assembly.
The open gear lubricant and air meet in the air nozzle of the spray valve and produce a spray.
At the end of the lubrication cycle, the air solenoid valve for the open gear lubricant pump is de-energized. The air
solenoid valve supplying air directly to the air valve to produce the spray remains open for a pre-determined time to
ensure that the lubricant is cleared from the valve.

15.3 Maintenance
15.3.1 Part Numbers
NOTICE
to be lowered.

15.3.3 Air Compressor
06
05
07
04
03
08
02
09
01
10
TC0442b
11
LEGEND 06. Moisture Separator
01. Oil Sight Tube 07. After Cooler
02. Pressure Relief Valve 08. Motor
03. Air/oil Separator Access 09. Inlet Control Valve
04. Air Filter 10. Cooling Fan
05. Oil Cooler 11. Oil Filter
Figure 15-32: Compressor Components
15.3.3.1 General
NOTICE
The Sullair ES-8 compressor used on P&H mining shovels is a special 30XH (30 HP extra high
pressure) package. This compressor is capable of operating at higher pressures than the regu-
lar Sullair ES-8 compressor. If the compressor needs replacement, it must be replaced with a
compressor of similar pressure capability. All pressure settings shown are for the 30XH pack-
age. The manufacturer’s manual will also give settings for other compressor packages using
lower settings; these must not be used for this compressor package.

CAUTION
If a rotary screw compressor is turned backwards due to a reverse phase condition
occurring because the shovel main power has been connected incorrectly, or due to the
motor leads being reversed, serious damage can be done in a very short period of time.
This rotary screw compressor has a 30 HP, 3-phase motor. Correct motor rotation must
be observed with all rotary screw compressors when changing a motor or when first
applying power. A directional arrow is provided on the fan shroud between the motor
and the compressor. The motor is direct-coupled to the compressor with a flexible cou-
pling. On motor change-out the correct motor rotation must be observed before con-
necting the coupling to the compressor. A phase monitoring relay is installed to protect
against compressor damage if the shovel main power is connected in reverse phase;
however, this reverse phase detection will not apply if the compressor wires are con-
nected incorrectly. It is recommended that the compressor circuit breaker be opened
while connecting power to the shovel until the correct phase connection is verified. Do
not allow a rotary screw compressor to be operated in the reverse direction.
15.3.3.2 Inspection
Check the oil level at every preventive maintenance inspection. A small clear sight tube is provided to check oil
level. Confirm that oil is visible in the oil level sight tube (Item 01, Figure 15-32) when the compressor motor is not
running, as the oil level will go down in the sight tube when the compressor is operating.
! CAUTION
oil to escape, which could cause severe personal injury. Do not open or remove any the
compressor components while the compressor contains air pressure. Refer to mainte-
nance procedures prescribed in Subtopic 15.3.3.4.
15.3.3.3 Adjustment
Air Control Settings
Refer to Compressor’s Touchpad and Display and set air controls as determined by local conditions and/or by
mine management. Factory recommended settings are indicated in Programmed Set Points - Single Compressor
Unload Pressure UNLOAD 175 PSI
Load Pressure Differential LOAD 45 PSI
Maximum Sump Pressure P1 MAX 185 PSI
Wye to Delta Transition Timer WYE DELT 5 seconds
Restart Time RST TIME 10 seconds

Unload Stop Timer UNLD TIME 15 minutes
Language LANGUAGE English
Units UNITS English
Communication ID# COMM ID# 1
Baud Rate BAUD RATE 9,600
Modulation, Set @ Pressure Regula- Not on Keypad, physical set point 170 PSI
tor Valve
Adjusting Modulation
!

"
6+$#&)
LEGEND
01. Orifice 03. Bell
02. Diaphragm Assembly 04. Adjustment Screw
Figure 15-33: Pressure Regulator Valve
Refer to Figure 15-33 and set the modulation as follows:
1. Turn the compressor off.
2. Back the adjustment screw (04) outward at least four turns to limit the maximum output pressure. The screw is
located upside down on the back right side of the after cooler unit as you are facing the touch panel.

3. Start the compressor and let it build system pressure.
4. Turn the regulator adjustment screw inward to increase system pressure up to the modulation point (170 PSI
[11.9 bar]). Turn the screw slowly in smaller increments when the pressure nears the modulation point. If the
screw is turned too far, the compressor will reach the unload point (175 PSI, 12.25 bar) and the compressor will
unload.
5. Shut the compressor off.
Add Oil as necessary
Refer to Figure 15-32. When oil is not visible in the sight tube with the compressor not running, add oil as follows:
! CAUTION
oil to escape, which could cause severe personal injury. Turn the compressor off and
use lockout and tagout procedures to prevent the compressor from starting before add-
ing or changing oil.
1. Turn off the compressor.
2. Remove the oil fill plug (Item 06,Figure 15-32).
CAUTION
Overfilling the compressor with oil can lead to discharge of oil at the air outlet, which
could damage the air dryer. Fill oil to the correct level and check the oil level when com-
pressor motor is not running.
3. Add oil of the type specified in the lubrication section until oil is visible approximately half-way up the sight tube.
Change Oil Filter
Change the oil filter every 90 days as follows:
! CAUTION
use lockout and tagout procedures to prevent the compressor from starting before add-
ing or changing oil.
2. Place a drip pan under the compressor drain to catch oil.

3. Remove the drain cap and allow the oil from the compressor to drain.
4. Remove the spin-on-type oil filter (Item 11, Figure 15-32).
5. Install the new oil filter.
6. Replace the drain cap.
7. Add oil as described in the subtopic titled Add Oil as necessary.
Change Oil Separator
LEGEND 02. O-ring

01. Separator Cap 03. Separator
Figure 15-34: Change Oil Separator
The separator is enclosed in the oil sump. Refer to Change Oil SeparatorFigure 15-34 and change the oil separator
every 6 months as follows:
! CAUTION
Removing the separator cap or opening the compressor to atmosphere in any other way
use lockout and tagout procedures to prevent the compressor from starting before
removing the separator cap.
2. Place a drip pan under the separator cap (01) to catch oil.
3. Remove the separator cap.
4. Pull out the separator (03).
5. Install a new O-ring (02) on the inboard stem of the new separator.
6. Insert the new separator into the compressor housing.
7. Remove the old O-ring (02) from the separator cap. Install a new O-ring (02) onto the separator cap.

8. Install the cap into the compressor housing.
15.3.4 Air Dryer R37969F2
01
02 09
03
AIR IN 36 16 .016
AIR OUT
04
05
10
06
07
11
08 TC0418b
LEGEND 06. Automatic Drain Valve

01. Terminal Strip 07. Dryer Outlet Swivel Hose End
02. System Filter Pack 08. Condensate Drain
03. Inlet Valve (N.O.) 09. Membrane Dryer
04. By-Pass Valve (N.C.) 10. Check Valve
05. Outlet Valve (N.O.) 11. Heater
Figure 15-35: Membrane Air Dryer
15.3.4.1 General
Proper maintenance of the air dryer is an absolute necessity. Failure to maintain the system as defined below will
cause system malfunctions and machine damage.
! CAUTION
Compressed air can propel contaminants at high speed. These contaminants can cause
severe eye injuries. Always wear protective goggles and clothing when opening com-

pressed air systems. Before servicing the dryer filter elements, close both the inlet and
outlet service ball valves (Figure 15-35). Drain air pressure and water from the filters by
depressing and holding the TEST button on the filter automatic drain valve. This relieves
air pressure within the dryer system and drains liquid from the filters prior to opening
the filter bowls (Figure 15-36). If the mining shovel is shut down for an extended period
of time in extremely cold weather, drain the filters in this manner to prevent freezing of
the water in the filter bowls.
01
02
03
TC0417a
LEGEND
01. O-Ring
02. Filter Bowl
03. Filter Element
Figure 15-36: Filter Assembly

15.3.4.2 Inspection
500 Hours
Filter Elements.
Figure 15-37: Filter Elements
Inspect differential pressure indicators (Figure 15-37). If any differential pressure indicator shows red, all filter ele-
ments must be changed. Refer to Subtopic 15.3.4.4.
CAUTION
Prolonged system operation after the filter indicators turn red results in low air flow and
air pressure, high dew points, and oil/water contamination in the membrane dryer.
Drain Valve.
LEGEND
01 01. Manual Push-To-Test Button
02. Interval Between Cycles
03. Duration of Cycles
02
03
TC1600b
Figure 15-38: Automatic Drain Valve (R41033D1)
The valve is equipped with two LED indicators. One indicates power is available at the valve. The other indicates
the solenoid is activated to open the valve. The power LED goes off when the solenoid indicator goes on. Do not
depend on the LED to indicate a faulty valve. Press the manual test button every 500 hours to verify operation.

As Necessary
If the filters are not inspected and serviced as recommended, contamination of the membrane air dryer may result.
If oil contamination is suspected, check as follows:
A. Turn the inlet and outlet valves to the closed position (Items 03 and 05, Figure 15-35) to isolate the dryer
from the air system.
B. Press the TEST button on the automatic drain valve (Item 01, Figure 15-7) to internally depressurize the
dryer system.
! CAUTION
Compressed air can propel contaminants at high speed. These contaminants can cause
severe eye injuries. Always wear protective goggles and clothing when opening com-
pressed air systems.
C. Disconnect the dryer outlet swivel hose end (Items 07, Figure 15-35) and direct the hose out of the dryer
unit.
Gradually open the inlet valve. If the air discharged from the membrane dryer is contaminated with oil or water, it is
necessary to replace the membrane dryer with a new dryer unit.
15.3.4.3 Adjustment
Drain Valve
Refer to Figure 15-38 and initially adjust the two timers on the automatic drain valve as follows:
1. Adjust the “Interval between Cycles” timer (Item 02) to 10 minutes.
2. Adjust the “Duration of Cycle” timer (Item 03) to 2 seconds.
These settings may be changed if experience indicates the need. For instance, if liquid is still being expelled from
the filters after two seconds have elapsed, it may be necessary to increase the time the valve is open or to
decrease the time interval between openings.
The valve is equipped with two LED indicators. One indicates power is available at the valve. The other indicates
the solenoid is activated to open the valve. The power LED goes off when the solenoid indicator goes on. Do not
depend on the LED to indicate a faulty valve. Check the valve every 500 hours to ensure proper valve operation. To
perform the test, press the manual test button to verify the valve cycle.
Filter Elements
The filter elements must be changed whenever any of the three differential pressure indicators registers in the red.
In addition, they must be changed at intervals not greater than every six months, regardless of the differential pres-
sure indicator readings.

01
02
03
ES05039a01
LEGEND 02. Bowl

01. Body 03. Element
Figure 15-39: Dryer Filter and Element (typical)
Refer to Figure 15-39 and replace the dryer filter element as follows:
1. Use lockout and tagout procedures to turn off the air compressor.
2. Turn the inlet and outlet valves to the closed position (Items 03 and 05, Figure 15-35) to isolate the dryer from
the air system.
3. Press the TEST button on the automatic drain valve (Item 01, Figure 16-17) to internally depressurize the dryer
system.
4. Disconnect the bowl (02) from the body (01) and lower it to expose the element (03).
5. Remove the old element and install the replacement element.
6. Exercising care to avoid twisting or pinching the O-ring, install the bowl onto the body.
7. Return the dryer to operating configuration by opening the valves and removing locks and tags from the com-
pressor.

Membrane Canister
01
02
LEGEND
01. Inlet
03
02. Sweep Air
03. Outlet
ES05040a01
Figure 15-40: Air Dryer Membrane Canister
Change the membrane canister every year, or whenever oil or water contamination is suspected.
Refer to Figure 15-40 and replace the air dryer membrane canister as follows:
1. Use lockout and tagout procedures to turn off the air compressor.
2. Turn the inlet and outlet valves to the closed position (Items 03 and 05, Figure 15-35) to isolate the dryer from
the air system.
3. Press the TEST button on the automatic drain valve (Item 01, Figure 16-17) to internally depressurize the dryer
system.
4. Tag and disconnect the inlet line (01), both sweep air lines (92), and the outlet line (03).
5. Remove the canister mounting brackets and remove the canister from the enclosure.
6. Paying attention to the AIR INLET and AIR OUTLET labels on the new canister, connect the inlet line (01), both
sweep air lines (92), and the outlet line (03).
7. Return the dryer to operating configuration by opening the valves and removing locks and tags from the com-
pressor.

15.3.5 Air Receiver R42570D1
Figure 15-41: Air Receiver
15.3.5.1 Inspection
During preventive maintenance sessions:
• pull the ring on the safety relief valve to verify that the stem has not seized.
• confirm tank pressure on the gauge. Pressure should be 185-190 psi.
• Confirm that the tank is structurally sound and no leaks are evident.

01
02
07
04 03
05
06
ES05041a01
LEGEND 04. Hardened Washer

01. Air Receiver 05. Self Locking Nut
02. Hex Head Cap Screw 06. Rebound Washer
03. Vibration Dampening Mount 07. Plain Washer
Figure 15-42: Air Receiver Mounting Hardware (four places)
• Refer to Figure 15-42 and inspect the integrity of the mounting hardware.

15.3.6 Lubricator 46Z405D1
LEGEND
01. Dome Assembly
02. O-Ring
03. O-Ring
04. Lubricator Body
05. Fill Plug
06. O-Ring
07. Flow Sensor
08. O-Ring
09. Check Valve
10. Siphon Tube
11. O-Ring
12. Adapter Gasket
13. Reservoir
14. Sight Gauge
15. Body Plug
16. Gasket
17. Strap
Figure 15-43: Air System Lubricator
15.3.6.1 Inspection
During preventive maintenance sessions:
• Observe the sight glass for oil level. If the fluid level is low, add sufficient oil to bring the oil to an acceptable
level. Refer to Lubricant Specifications for the type of lubricant required; refer to Subtopic 15.3.6.4 for filling
procedures.
• Check for leaks or damaged components.
15.3.6.2 Adjustment

Make drip rate adjustments only under a steady air flow condition. Once established, the lubricator automatically
adjusts the drip rate proportionally to variations in air flow. To adjust the drip rate, proceed as follows:
1. Fill the reservoir with the correct oil.
2. Open the air shut-off valve to the lubricator at the receiver.
3. With the air flowing at a normal rate, lift the lock ring and turn the adjusting knob counterclockwise to increase
the drip rate. Turn the knob clockwise to decrease the drip rate.
15.3.6.3 Push the lock ring downward to lock the setting after the final adjustment
Fill the lubricator as follows:
1. Shut off the air supply to the lubricator at the air receiver. The lubricator may still be pressurized even if the
supply lines to the lubricator are shut off.
! WARNING
Never remove the fill plug when the lubricator is under pressure. Doing so could cause
the fill plug and lubricator contents to be expelled under pressure, which could cause
serious injury or death. Compressed air in the air lubricator could cause oil to spray into
the eyes or to be injected into the skin resulting in severe personal injury. If either of
these situations occur, seek medical help immediately. Use extreme care when loosen-
ing the vent/fill plug.
2. Carefully loosen the reservoir fill plug (5) of the lubricator until the bleed orifice is exposed and air begins to
vent from the reservoir. Allow the lubricator reservoir to vent completely.
3. Remove the body fill plug (15) and fill the reservoir to the proper level on the sight glass. This reservoir holds
approximately 5 gallons (19 liters) of light oil. Refer to the lubrication chart, Table 17-1 for specifications. Do
not overfill.
4. Install the body fill plug with gasket and tighten securely.
5. Shut and tighten the reservoir fill plug (05).
6. Open the air supply to the air system. If necessary, adjust the lubricator drip rate. See Subtopic 16.
15.3.6.5 Repair
If desired, the working parts of the air lubricator may be removed without removing it from the air line. To repair or
overhaul the air lubricator, refer to Figure 15-43 and proceed as follows:
1. Shut off the air supply to the lubricator.
2. De-pressurize the lubrication reservoir.
3. Remove the reservoir mounting strap (17).

4. Remove the reservoir and gasket from the lubricator body.
NOTICE
Some lubricators of this type have a reservoir charge (check) valve in the body. If necessary,
remove the check valve for cleaning. Do not remove the siphon tube unless replacement is nec-
essary.
5. Remove the dome assembly, seals, fill plug, and o-ring from the body.
6. The flow sensor should be removed only if it is obviously damaged. Remove the flow sensor as follows:
A. Insert an extra long needle nose pliers into the inlet port in the body and grasp the point of the sensor.
B. Rotate the sensor approximately one-quarter turn either direction and push it through the outlet port in the
body.
7. Clean all parts with soap and water.
! CAUTION
8. Dry the parts and blow out the internal passages in the body using clean, dry compressed air.
9. Make certain the siphon tube check ball in the body moves freely.
10. Inspect each part and replace any parts that are damaged.
11. Install the flow sensor if it was removed. The pointed end must face in the opposite direction to the flow arrow
on the body.
12. Install the dome assembly and the check valve. Torque them to 30 to 35 PSI (2.07 to 2.41 bar).
13. Apply a coat of grease to the reservoir gasket.
14. Attach the reservoir and gasket to the body.
15. Install the reservoir mounting strap.
16. Return air pressure to the lubricator.
15.3.7 Boarding Stairway Air System Components
15.3.7.1 Inspection
During Preventive Maintenance inspections, inspect the following:
• check air lines for leaks

• check the regulator for correct setting
• check for correct operation of the boarding stairway in both lower and raise functions.
15.3.7.2 Adjustment
! CAUTION
Lower stairway before adjusting or removing system pressure. If stairway is in raised
position and system air pressure is adjusted too low or removed, the stairway will lower.
01 02 03 04
ES05042a01
LEGEND
01. Check Valve 03. Filter
02. Regulator 04. Lubricator
Figure 15-44: Boarding Stairway Filter/Regulator/Lubricator Assembly
The air pressure regulator is part of the Filter/Regulator/Lubricator assembly (Figure 15-44). Adjust the air pressure
regulator to 150 PSI (10.35 bar).

With system air pressure properly adjusted, stairway lifting and lowering speeds can be adjusted to suit by adjust-
ing the three flow control valves shown in Figure 15-45. These valves will allow the air flow into and out of the cyl-
inders to be adjusted, but will not change the system pressure.

LEGEND
01. Air Supply (From Regulator)
! 02. Air Input From Front Hand Valve
03. Air Input From Rear Hand Valve
04. Left Air Valve
"
05. Right Air Valve
# 06. Air Line to Stairway Cylinders
07. Flow Control Valve (Raise Speed)
08. Exhaust #1
09. Flow Control Valve (Lower Speed #1)
10. Exhaust #2
11. Flow Control Valve (Lower Speed #2)
%
'
& $
6+$'!>
Figure 15-45: Boarding Stairway Air Valves
Technician Tip
There is a proximity switch which is actuated when the stairway is raised to its upright position.
This proximity switch informs the shovel control system of stairway position. If stairway air pres-
sure is adjusted too low, the stairway will bounce, and the proximity switch will signal to the
Centurion Control System that the stairway has lowered when the stairway bounces low
enough to exceed its range. This will cause the shovel controls to immediately set the swing
and propel brakes, as these brakes are set automatically when the Centurion Control System
determines the stairway is lowered.
The flow control valve in-line with the stairway cylinders is used to control upward speed of the stairway. The two
flow control valves in the vent lines from the pilot operated valves are used to control downward stairway speed:
one is used when the pull-cord operated manual valve is used, one when the handle operated manual valve is
used. The two downward speed control valves should be adjusted to the same setting to ensure consistent pres-
sure venting from the stairway cylinders while being lowered.

Use the following procedure to adjust the stairway raising and lowering speed:
! WARNING
Unexpected shovel shutdown can cause serious personal injury or death. Shut down
mining shovel and use lockout/tagout procedures before conducting inspection, mainte-
nance, or service on the shovel.
Before maintenance is performed the shovel should be parked and shut down. Follow procedures similar to this:
1. Back the shovel away from the bank or high wall.
2. Position the shovel in a level, water-free area.
3. Position the machine upper so that the boarding stairway can be safely lowered.
4. 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.
5. Set all brakes. Press the STOP button.
Adjust the stairway raising and lowering speed as follows:
1. Use the handle operated manual valve to lower the stairway completely to the fully lowered position.
2. Visually check the regulator to make sure it is set at 150 PSI (10.35 bar).
3. Identify the three flow control valves used for speed adjustment of the stairway (see Figure 15-45).
4. Adjust the raise speed first, as follows:
A. The flow control valve on the far right (raise speed) will be used to make the raise adjustment.
B. Use the handle operated manual valve to raise the stairway, while observing the speed it raises. Adjust the
raise flow control valve to adjust the speed. Turning the valve handle clockwise will close the valve more,
reducing the flow and the speed. If turned all the way in the clockwise direction the valve will fully close.
Turning the valve handle counter clockwise will open the valve more and increase the speed.
C. Lower the stairway and raise it again to observe the new speed. Repeat steps B and C until speed is satis-
factory.
5. Adjust the lowering speed with the handle operated valve as follows:
A. .Use the lower speed #2 flow control valve (item 11, Figure 15-45) to adjust lowering speed.
B. Use the hand operated valve to lower the stairway, while observing the lowering speed. Adjust the flow con-
trol valve to adjust the speed. Turning the valve handle clockwise will close the valve more, reducing the
flow and the speed. If turned all the way in the clockwise direction the valve will fully close. Turning the valve
handle counter clockwise will open the valve more and increase the speed.
C. Raise the stairway and lower it again to observe the new speed. Repeat steps B and C until speed is satis-
factory.
6. Adjust the lowering speed with the pull cord operated valve as follows:

A. Use the lower speed valve #1 flow control valve (item 9) to adjust lowering speed.
B. Use the pull cord operated valve to lower the stairway, while observing the lowering speed. Adjust the flow
control valve to adjust the speed. Turning the valve handle clockwise will close the valve more, reducing the
flow and the speed. If turned all the way in the clockwise direction the valve will fully close. Turning the valve
handle counter clockwise will open the valve more and increase the speed.
C. Raise the stairway and lower it again to observe the new speed. Repeat steps B and C until speed is satis-
factory.
15.3.7.3 Air Filter
! WARNING
Do not take apart air system fittings or components or open up air system components
to atmosphere in any other way while the compressor and/or components contain air
pressure. Attempting to take apart components while under pressure could result in the
parts flying apart violently and causing personal injury or property damage. Doing so
will allow compressed air and possibly hot oil or other liquids to escape, which could
cause personal injury and/or property damage. Be sure to lock-out/tag-out the compres-
sor to prevent accidental start-up. Isolate and depressurize the compressor or other
components, or drain all air system pressure, before attempting to take components
apart.
All parts of the filter can be disassembled without removal from the air line. The filter has a service life indicator. To
service the filter (Figure 15-46) proceed as follows:
! WARNING
Ensure that the bowl is depressurized before proceeding.
1. Shut off the air supply to the filter.
2. Unscrew and remove the bowl and gasket.
3. Remove the automatic drain from the bowl.
4. Unscrew and remove the baffle, element, and gaskets.
5. Pull the louver and o-ring out of the body assembly. Do not remove the center post stud from the body.
6. Clean the parts using warm water and soap.
! CAUTION
Compressed air can injure eyes and ears. Wear eye and ear protection when releasing or
spraying compressed air.
7. Blow air through the filter element from inside to outside to dislodge surface contaminants.
8. Dry all parts and blow the internal passage in the body using clean, dry air.

9. Inspect each part and replace any parts that are damaged.
10. Assemble the filter in reverse order of disassembly with the following additions:
A. Apply a wipe coat of grease to the o-rings.
B. Tighten the baffle to 10 to 12 lbs-in (1.13 to 1.36 N·m) torque (hand snug).
C. Tighten the automatic drain retaining nut to 20 to 25 lbs-in (2.26 to 2.82 N·m) torque.
D. Tighten the bowl by hand until the arrowhead on the bowl is in line or to the right of the arrowhead on the
body.
11. Open the air supply valve to the filter.
12. Unscrew and remove the element.
Inspect each part and replace any damaged parts
15.3.7.4 Air Lubricator
LEGEND
01. Reservoir
02. Siphon Tube
03. Fog Generator
04. Sight Feed Dome
05. Drip Rate Adjusting Knob
06. Needle Valve
07. Flow Sensor
08. Passage
09. Check Ball
Figure 15-46: Air Lubricator (46Q38D9)
! WARNING
Never remove the fill plug when the lubricator is under pressure. Doing so could cause
the fill plug and lubricator contents to be expelled under pressure, which could cause
serious injury or death. Compressed air in the air lubricator could cause oil to spray into
the eyes or to be injected into the skin resulting in severe personal injury. If either of

these situations occur, seek medical help immediately. Use extreme care when loosen-
ing the vent/fill plug.
1. Fill the reservoir with air lubricating oil.
2. Raise the boarding stairway, or operate the auxiliary device to be lubricated.
3. With the air flowing at a normal rate, lift the red lock ring and turn the adjusting knob counterclockwise to
increase the drip rate. Turn the knob clockwise to decrease the drip rate.
4. Repeat Steps 1 through 3 until the desired rate is achieved.
Push the lock ring downward to lock the setting after the final adjustment.
15.3.7.5 Air Pressure Regulator
LEGEND
01. Adjustment Knob 05. Valve
02. Regulating Spring 06. Relief Passage
03. Vent 07. Aspirator Tube
04. Diaphragm 08. Valve Spring
Figure 15-47: Air Regulators (typical)
When the adjusting knob is turned completely counterclockwise, there is no load applied to the regulating spring
and the valve is closed.
When the adjusting knob is turned clockwise, a force is applied to the regulating spring causing the diaphragm to
move downward and open the valve.

Disassembly
! WARNING
High pressure can cause injury. Always release system air pressure before disassem-
bling regulators. Shovel should be parked with the dipper on the ground, and lockout
and tagout procedures used before releasing air system pressure.
If desired, all the regulators may be disassembled without removing them from the air line. Disassemble the regu-
lator using the views in Figure 15-47 as a guide.
Inspection
Inspect each part carefully. Replace any damaged or worn parts. Check the diaphragm for holes or cracks by flex-
ing it.
Assembly
Assemble the regulator using Figure 15-47 as a guide. Apply a small amount of grease on the rubber valve seat.
Troubleshooting
Table 15-4 lists some causes of regulator problems. If the cause of the problem is identified, use the remedies sug-
gested.
Problem Possible Cause Remedy
Regular creep (increase in sec- Dirty or cut valve elastomers. Nick Replace or clean valve. If valve
ondary pressure due to leak from in valve seat. seat damaged, it can be replaced
primary). on most regulators. On others, it
may require replacing complete
regulator.
Excessive leak from relief hole in Damaged relief seat. Ruptured Replace diaphragm assembly.
bonnet. diaphragm. Leakage past valve Replace or disassemble and clean
causing secondary to increase valve.
somewhat and open relief seat.
Regulator chatter. A resonant condition. Reorientation of the regulating

spring helps.
Regulator difficult to adjust. Adjusting screw or knob locking Unlock locking device.
device in locked position. Remove adjusting screw, clean
Contaminants in adjusting screw threads and lubricate.
threads.
Table 15-4: Troubleshooting Air Regulators

15.4 Boarding Stairway Air Cylinder (R51982D1, 38Q136)
15.4.1 Description
The boarding stairway cylinders are air-operated cylinders that are used to raise or lower the boarding stairway.
The original cylinder used on 4100XPC’s was a 38Q136. This cylinder has been superseded by cylinder
R51982D1. This cylinder is supplied with 1 rod clevis, 2 retaining pins, and 2 cotter pins.
There are two cylinders on the boarding stairway, one on each side of the stairway.
The boarding stairway cylinders are illustrated in Figure 15-18.
15.4.2 Removal
Remove the boarding stairway air cylinder as follows:
! WARNING
Unexpected movement of the mining shovel can cause severe personal injury or death.
Use lockout/tagout procedures to prevent accidental movement of the mining shovel.
1. Use lockout/tagout procedures to prevent accidental movement of the mining shovel.
2. Lower the boarding stairway so that it is resting on its stops.
3. Disconnect the air piping from the cylinder to be removed. Remove the cotter pins and clevis pins from each
end of the cylinder.
4. Remove the cylinder from the boarding stairway. The cylinder weighs approximately 105 lbs (47.9 kg).

15.4.3 Disassembly
If the boarding stairway air cylinder (Figure 15-48) requires disassembly and repair, disassemble as follows. Repair
is limited to seal and gasket replacement.
LEGEND
01. O-Ring 09. Cylinder 17. Wiper
02. Adjusting Screw 10. Screw 18. Packing
03. Nut 11. Sleeve 19. Rod Bearing
04 Head 12. Piston 20. Spacer
05. Seal 13. Sleeve 21. Ring
06. O-Ring 14. Piston 22. Head
07. Seal 15. Plate 23. Tie Rod
08. O-Ring 16. Ring 24. Piston Rod
Figure 15-48: Boarding Stairway Air Cylinder (38Q137)
1. Remove the clevis and clevis jam nut (not shown).
2. Remove nuts (03) from one end of tie rods (23).
3. Pull cylinder head (04) from cylinder (09) and remove piston assembly (24) from the cylinder.
4. Remove cylinder (09) from head (04).

5. Remove o-rings (06) and seals (05) from heads (04 and 22).
6. Disassemble the piston assembly as follows:
A. Remove socket head cap screw (10), piston (12), o-ring (08), and sleeve (13) from piston rod (24).
B. Remove seals (07) from the piston.
7. Remove socket head cap screws (14) and plate (15) from the end of the cylinder.
8. Remove ring (16), packing (17), rod bearing (19) packing (18), spacer (20) from the head. Note how the pack-
ing comes out of the end ring (21) from cylinder head (22).
15.4.4 Inspection
Clean and inspect the disassembled parts as follows:
1. Discard all seals and o-rings. Clean all metal parts in a suitable cleaning solvent.
2. A seal repair kit is available for this cylinder. See the Parts Manual for this machine.
3. Inspect the piston, tube and heads for damage and excessive wear. Inspect the push rod for cracks or bends.
4. Replace parts as necessary.
15.4.5 Assembly
Assemble the boarding stairway air cylinder (Figure 15-48) as follows:
1. Coat the new o-rings and seals with a light grease prior to assembly.
2. Install seals (07) on piston (12).
3. Install seals (05) on heads (04 and 22).
4. Assemble the piston and rod assembly as follows:
A. Install rod bearing (19) and o-ring on piston rod (24).
B. Place piston (12) with seals on the piston rod.
C. Install sleeve (11) on the piston rod. Secure the piston rod assembled parts with socket head cap screw
(10).
The boarding stairway is covered in detail in Topic 8.4.
The right hand horn assembly is standard on 4100XPC shovels. A left hand horn can be added as an option to give
the shovel dual horn capabilities. The regulator setting for the air horn assembly should not exceed 100 PSI (6.9
bar).
A line from this supply is routed to the air pressure gauge located on the operator’s console.

NOTICE
The air pressure displayed by the gauge on the operator’s console will display the system air
pressure available at the main air system receiver, provided no restrictions occur before the
gauge. This air pressure will not be the same as that which is supplied to the brake systems or
any other system that has a regulator in its supply line.
The seat assembly contains an air bladder that can be adjusted for the operator’s comfort. Refer to the Operator’s
Manual for a description of the adjustments for the operator’s seat. The air pressure for the operator’s seat should
be adjusted within the guidelines shown in Table 15-2.
Auxiliary devices may also be connected to this supply line. Many of these auxiliary devices will have a remote air
panel which may be equipped with a filter, lubricator, regulator, and such other devices as may be required for the
application.
A pressure transducer on the air manifold assembly in the lube room monitors main air pressure for the shovel.
System pressure must be above the setting required by the Centurion Control System or the shovel will not start.
Any time the air pressure drops below this setting, the shovel will shut down on a main air pressure fault.
All set points for the air pressure regulators are shown on the system schematic and in Table 15-6. They will be
detailed in the individual system topics in the following sections.
Description Location Set Point Refer to This Topic for

More information
Upper Brake System Sup- Left Hand (Lube) Room 100 PSI (6.9 bar) - do not Subtopic 15.4.8.2
ply adjust
Lower Air Control Panel Lower Air Control Panel 105 PSI (7.25 bar) - do Subtopic 15.4.6.2
Supply not adjust
Air Horn Supply Right Hand Room 100 PSI (6.9 bar) Max. Subtopic 15.4.5.3
Left Hand (Lube) Room
Lube Pump Air Control Left Hand (Lube) Room 60-80 PSI (4.14-5.52 Subtopic 15.4.7
Panel bar)
Air Spray Valves Supply Left Hand (Lube) Room 40-60 PSI (2.76-4.14 Subtopic 15.4.7
bar)
Boarding Stairway Supply Right Hand Room 150 PSI (10.35 bar) - do Subtopic 15.2.9.1
not adjust
Air Seat Supply Right Hand Room 120 PSI (8.28 bar) Subtopic 15.4.5.2
Table 15-6: System Regulator Set Points

NOTICE
Regulator settings for the lube system are to be used as a starting basis. The air spray regulator
is used to adjust the air spray system, and the correct setting will depend on lubricants, location
of the spray nozzles, etc. The regulator for the lube pumps, air horns, and air seat may also be
adjusted according to system performance.
15.4.5.1 AirScrub Pro
wh03123a
Figure 15-49: AirSrub Pro
Inspection
During preventive maintenance sessions, inspect components for proper operation and correct air pressure set-
ting.
Adjustment
Adjust the AirScubPro air pressure regulator for 100 PSI (6.89 bar)
15.4.5.2 Operator’s Seat
Inspection
During preventive maintenance sessions, inspect components for proper operation and correct air pressure set-
ting.
Adjustment

The air pressure for the operator’s seat should be adjusted within the guidelines shown in Table 15-2.
15.4.5.3 Air Horns
Figure 15-50: Air Horn Air Pressure Regulator and Solenoid Valve
Inspection
The air pressure regulator and the solenoid valve for the right air horn are located in the right hand room (refer to
Figure 15-50). The air pressure regulator and the solenoid valve for the left air horn are located in the lubrication
room. During preventive maintenance sessions, inspect the control components for proper operation and correct
air pressure setting.
Adjustment
Adjust the air horn air pressure regulator for 100 PSI (6.89 bar). Do not exceed the recommended setting.
15.4.6 Propel Brake Air System Components
15.4.6.1 General
able.

Figure 15-51: Propel Brake Air Pressure Regulator
Inspection and Adjustment
The air pressure regulator for the propel brakes is located in the lower air control panel, which is mounted on the
left rear of the carbody (refer to Figure 15-51). Adjust the propel brake air pressure regulator to 105 psi. (7.24 bar).
Maintenance and Repairs
15.4.6.3 Air Valve Manifolds
Figure 15-52: Propel Brake Air Valve Manifold
Inspection

The air pressure regulator for the propel brakes is located in the lower air control panel, which is mounted on the
left rear of the carbody (refer to Figure 15-52). Inspect exhaust mufflers on the brake air valve manifolds for dam-
age and blockage due to contamination or icing. Inspect brake air supply lines for damage, deterioration due to age
or contamination, and blockage due to pinching. Repair or replace components as required.
Inspect brake valve exhaust air piping for damage and blockage due to pinching, contamination, or icing. Repair or
Repair and Replacement
Quick Release Valve
LEGEND
01. Body 03. Gasket
02. Diaphragm 04. Cover
Inspection
Repair

03
02
04 LEGEND
01. From Brake
04. Exhaust
ES04324a01
Inspection
Inspection of the pressure transducer is limited to operational observation. If the propel system fails to operate, the
transducer may not be reporting air pressure accurately.
Inspection
When the brake is released, this valve should close. If air continues to exhaust through the valve when the brake is
released, replace the valve.
replace the valve.

15.4.7 Automatic Lubrication System Air Supply
Figure 15-55: Automatic Lubrication System Air Valve Manifold
General
The automatic lubrication system’s air valve manifold (Figure 15-55) is mounted in the left-hand room (lubrication
room) on the forward wall of the shovel. The first two valves (labeled GREASE and OPEN GEAR) provide com-
pressed air to the air motors that power the two lubrication pumps. The third valve acts as a spare.
The fourth valve in the manifold provides air to the spray nozzles in the lower. It receives its air pressure from a dif-
ferent port on the air manifold, at a different pressure. Refer to Subtopic 15.4.9.
Inspection
Inspect exhaust mufflers on the automatic lubrication system air valve manifolds for damage and blockage due to
contamination or icing. Inspect automatic lubrication system air supply lines for damage, deterioration due to age
or contamination, and blockage due to pinching. Repair or replace components as required.
Inspect automatic lubrication system exhaust air piping for damage and blockage due to pinching, contamination,
or icing. Repair or replace components as required.
Adjustment
Adjust the pressure for the lube pumps to 60-80 PSI.

15.4.8 Upper Brake Air System Components
15.4.8.1 General
able.
The air pressure regulator for the upper brakes is located on the upper right corner of the air manifold in the left-
hand room (refer to Figure 15-56). Adjust the propel brake air pressure regulator to 100 psi. (6.89 bar).

15.4.8.3 Air Valve Manifold
Figure 15-57: Upper Brake Air Valve Manifold
Inspection
Inspect exhaust mufflers on the brake air valve manifold for damage and blockage due to contamination or icing.
Inspect brake air supply lines for damage, deterioration due to age or contamination, and blockage due to pinching.
Repair or replace components as required.
Inspect brake exhaust air piping for damage and blockage due to pinching, contamination, or icing. Repair or

Quick Release Valve
LEGEND
01. Body 03. Diaphragm
02. Cover 04. Gasket
Inspection
Repair

03
02
04 LEGEND
01. From Brake
04. Exhaust
ES04324a01
Inspection
Inspection of the pressure transducer (Item 02, Figure 15-59) is limited to operational observation. If the motion
associated with this brake fails to operate correctly, the transducer may not be reporting air pressure accurately.
Inspection
When the brake is released, this valve (Item 03, Figure 15-59) should close. If air continues to exhaust through the
valve when the brake is released, replace the valve.
replace the valve.

15.4.9 Lube Sprayers
15.4.9.1 General
able.
Figure 15-60: Lube Sprayer Pressure Regulator
The air pressure regulator for the lube sprayers is located on the upper left corner of the air manifold in the left-
hand room (refer to Figure 15-60). Adjust the spray valve air pressure regulator to 60 PSI. (4.14 bar).

15.4.9.3 Air Valve Manifold
Figure 15-61: Upper Brake Air Valve Manifold
Inspection
Inspect exhaust mufflers on the lube sprayer air valve manifold for damage and blockage due to contamination or
icing. Inspect air supply lines for damage, deterioration due to age or contamination, and blockage due to pinching.
Repair or replace components as required. Inspect exhaust air piping for damage and blockage due to pinching,
contamination, or icing. Repair or replace components as required.

15.4.9.4 Spray Nozzle
LEGEND 04. Fluid Cap Gasket

01. Retaining Ring 05. Body
02. Air Cap 06. Gasket
03. Fluid Cap 07. Cleanout Assembly
Inspection
Repair

15.4.10
Figure 15-63: Sprayer Air Pressure Regulator

15.5 Spray Valves (R5808F3, F6)
15.5.1 General
The spray valves (Figure 15-64) used on mining shovels all have two inlet ports, one for open gear lubricant
pumped from the reservoir and the other for pressurized air from a solenoid air valve mounted on the lube air con-
trol panel. The spray valve has a clean out assembly.
LEGEND
01. Retaining Nut
02. Air Cap
03. Fluid Cap
04. Fluid Cap Gasket
05. Body
06. Gasket
07. Cleanout Assembly
Figure 15-64: Spray Valve With Cleanout Assembly (R5808F3, F6)
15.5.1.1 Inspection
During Preventive Maintenance periods, confirm that the sprayer is functioning effectively either by direct observa-
tion while the sprayer is operating, or by confirming an appropriate coating of lubricant on the target area.
If the sprayer is clogged, press the button on the cleanout assembly and confirm that the blockage has been
removed. If using the cleanout assembly does not return the sprayer to satisfactory operation, clean or replace the
sprayer as described in the following paragraphs.
15.5.1.3 Removal
To remove the spray valve, proceed as follows:

! WARNING
High pressure oil or grease can spray and penetrate skin or eyes causing serious per-
sonal injury. Use extreme caution when working around operating lubrication system
and wear appropriate face and body protective devices. Shut down the mining shovel
using lockout and tagout procedures before performing inspection, service, and mainte-
nance of the lubrication system. Get medical aid immediately if the lube sprays into the
eyes or penetrates the skin.
2. Remove the oil and air supply lines from the spray valve.
3. Remove the spray valve from the spray valve mounting bracket.
15.5.1.4 Repair
Disassemble the spray valve per Figure 15-64. Use suitable non-flammable, non-toxic solvent to clean the spray
valve parts, then examine for wear. Repair is limited to replacing worn or damaged parts. Re-assemble the spray
valve and install per the following procedure.
1. Mount the spray valve in the mounting bracket.
2. Install the air and lubricant supply hoses in the spray valve. The ports on the spray valve are labeled air and liq-
uid and must be connected correctly.
3. Use lockout and tagout procedures to start the mining shovel.
Cycle the open gear lube system by pressing the button on the lube panel. While cycle is in process, check for
leaks.

ES41157 Mechanical Systems Manual Lubricant Specifications
Section 16
Lubricant Specifications
16.1 Description
This Section describes the P&H material specifications and selection of gear case oils. Grease versus open gear
lubricant, viscosity, and ISO grade oils are also covered.
NOTICE
A copy of the appropriate P&H lubricant specification, latest issue, must be supplied to the lubri-
cant suppliers. All lubricants must conform to the appropriate specification.
16.2 Selection of Lubricants
16.2.1 System Limitations
There is one pump for each of the three systems or zones of the automatic lubrication system. These zones are:
upper zone, lower zone, and open gear zone. There are two lubricant reservoirs or tanks. The lubricant tanks could
be used in different ways, depending on the type of lubricant desired for each of the three zones of the shovel. The
three different types of lubricant that could be used are:
• Multi-Purpose Grease, P&H Specification No. 472
• Open Gear Lubricant, P&H Specification No. 464
• Multi-Service Lubricant, P&H Specification No. 520
See Topics Step 16.4 to Step 16.10 of this manual for specific descriptions of the lubricant specifications.
Open gear lubricant or multi-service lubricant must be used for the open gear zone. Multi-purpose grease or multi-
service lubricant must be used for the upper and lower zones. However it is the customer’s choice to use multi-
service lubricant for one, two, or all three zones. Typical combinations would be:
1. Multi-purpose grease in tank 1, open gear lubricant in tank 2. The pumps supplying the upper and lower zones
would be in tank 1, and the pump supplying the open gear zone would be in tank 2.
2. Multi-purpose grease in tank 1, multi-service lubricant in tank 2.
A. The upper and lower zone pumps could be in tank 1, and the open gear zone pump could be in tank 2. This
would mean using grease for the upper and lower zones, but using multi-service lubricant instead of open
gear lube on the open gear zone.

Sec16LubeSpec.fm -16.1- Section 16, Version 00 - 06/07
Lubricant Specifications ES41157 Mechanical Systems Manual
B. The pump supplying the upper or lower zone could be moved to the multi-service lubricant tank 2. This
would mean using grease on one zone (upper or lower) and multi-service lubricant for the other two zones.
3. Multi-service lubricant could be used in both tanks and supplied to all three zones.
NOTICE
When changing lubricants for any particular zone, the old lubricant must be taken into account.
Just filling the tank with a different lubricant, or switching a pump and its zone from one lubri-
cant to another, without considering the compatibility of the two lubricants could cause prob-
lems with the components in the automatic lubrication system. If compatibility of lubricants is
questioned, it is recommended that the old lubricant be purged from the lines when a change is
made to a particular zone. Information on compatibility of lubricants must come from the lubri-
cant supplier.
16.2.2 P&H Lubricant Specifications
In the past, P&H Mining Equipment lubricant specifications included references to various lubricant manufacturer's
products as a guide to the selection of appropriate lubricants. The lubricant specifications have now been updated
and all references to lubricant manufacturer’s products have been removed. In the future, only the appropriate P&H
Mining Equipment lubricant specification number will be referenced.
NOTICE
Each P&H material specification pertaining to lubricants provides the shovel owner with the
minimum requirements for the lubricant. Conformance to these requirements does not consti-
tute the only basis of acceptance. Lubricants must be judged further on their satisfactory field
performance.
For proper equipment performance, it is the responsibility of the lubricant supplier and the shovel owner to deter-
mine if the type of lubricant being considered will meet P&H Mining Equipment lubricant requirements (that is,
specifications and performance). The shovel owner must rely upon the lubricant supplier to verify this.
16.2.3 Operating in Cold Conditions
Automatic lubrication systems can malfunction when the lubricant becomes too cold to flow smoothly or vent prop-
erly. This can cause the system cycle to end before lube points are properly lubricated.
16.2.3.1 Possible Effects of Excessively Cold Lubricant
• Improper venting after the cycle may prevent the injectors (Lincoln) from reloading. If pressure is not vented
back to the tank, the injector springs stay compressed and can not reload. The next cycle the injectors will
not output any lube if they have not recharged. As a result, the lube points may not receive proper lubrica-
tion.
• Cold grease can make it difficult to pump the lubricant. A restriction to flow in one area can cause a local
pressure drop to some components. The pressure switch (Lincoln) or reversing valve (Farval) on the lubri-
cation control panel may reach the set point pressure before it is high enough to cycle all the injectors or
measuring valves. The lube pump turns off prematurely before the lube points get the needed lubricant.

Section 16, Version 00 - 06/07 -16.2- Sec16LubeSpec.fm
NOTICE
If cold weather problems occur, contact your P&H MinePro Services representative to assist in
choosing which of the following solutions should be selected.
16.2.3.2 Possible Solutions
• Use a grease more appropriate for colder temperatures. Refer to the lubrication specifications in this Topic
of this manual for details.
• Slow the lubrication pump to allow more time for the cold grease to move through the lube piping. See Topic
19.2 [?] of this manual for more details.
16.3 Selection of Gear Case Oils

In addition to compliance with the material specifications, consideration must be given to viscosity requirements
and filtration when selecting gear case oils.
16.3.1 Viscosity
The viscosity is a critical parameter in determining film thickness under operating conditions. Too low viscosity will
allow tooth surfaces to contact each other. Viscosity varies exponentially with operating temperature.
The viscosity grade selection is dependent on the maximum and minimum operating temperatures. If the extreme
or peak operating sump temperatures are not known, measure the sump oil temperature during a period of
extreme or peak ambient temperature, after working the machine continuously for at least 1/2 a shift.
NOTICE
The minimum acceptable viscosity of gear case oils in the hoist, crowd, swing, and propel trans-
missions on P&H Model electric mining shovels is 400 centistokes (cSt) at the maximum oper-
ating sump temperature of the oil.
Maximum oil viscosity (and, therefore, its suitability for application in cold weather), is also temperature dependent
and is primarily determined by the pour point of the oil. Refer to minimum operating sump temperatures in Table
16-1.
Oil Grade P&H Viscosity (cSt) Max Operating Sump Min Operating Sump
Specification 40o C 100o C Temperature Temperature
Deg C Deg F Deg C Deg F
ISO 150 497 152 16 28 82 -24 -11
ISO 220 497 223 20 30 87 -21 -6
ISO 320 497 320 24 37 98 -18 -0
ISO 460 497 452 30 42 107 -15 5
Table 16-1: Gear Oil Operating Limits

Oil Grade P&H Viscosity (cSt) Max Operating Sump Min Operating Sump
Specification 40o C 100o C Temperature Temperature
Deg C Deg F Deg C Deg F
ISO 680 497 680 36 48 118 -12 10
ISO 1,000 497 1,070 55 55 131 -6 21
SYN 220 474 210 25 32 89 -37 -35
SYN 320 474 305 35 39 102 -34 -30
SYN 460 474 440 45 46 115 -29 -20
SYN 680 474 645 60 54 129 -26 -15
SYN 1,000 474 947 80 62 143 -31 -24
SYN 1,500 474 1,387 102 69 156 -26 -15
Table 16-1: Gear Oil Operating Limits
NOTICE
The maximum sump temperatures are based on a minimum allowable viscosity of 400 cSt.
Exceeding limits, especially the maximum limits for even short periods can result in progressive
surface deterioration. If maximum and minimum temperature limits cannot be met with any one
product, seasonal oil change outs should be considered. In cold environments exceeding lower
limits, drives should be run at no load to warm up the oil prior to operation. Sump temperatures
should be monitored in extreme ambient conditions.
The channel point of an oil is about 8-14o below the pour point. If the ambient temperature drops below the pour
point, the oil will not flow through a pump. This condition is unacceptable, even though some lubrication of gearing
might be possible if the gearing dips into oil in a sump. If the ambient temperature falls below the channel point, no
lubrication is possible as the oil will become semi-solid and will be displaced (channeled) as the gearing dips into
the sump. This condition will result in destruction of the gearing.
If it is desired to use a single grade of oil year round, users must be certain that at no time will either the maximum
or minimum operating sump temperature be exceeded for the grade of oil being used.
The minimum operating sump temperature represents the pour point of the oil, but it is still possible to operate the
machine if the ambient temperature drops below the pour point. Temperature below the pour point is mainly a con-
cern if the machine is not operating. If a machine has been shut down for an extended period of time, and the ambi-
ent temperature drops below the pour point during this time, before putting the machine to work, start the machine
and monitor the oil, while the motions are run slowly under no load, to warm up the oil to the point where it will flow.
This task is critical to avoid serious damage to gearing. If the sump temperature is still below the pour point, a
lighter grade of oil should be used.
Oil selection will affect filter performance. When selecting filter elements, the viscosity grade and operating temper-
ature range must be considered. The viscosity of the oil will change with temperature. Normally, a 10 PSI pressure
drop is permitted across filters. To ensure that the filter element type and mesh is appropriate for the oil viscosity at
the highest and lowest temperature, the oil temperature, oil viscosity at that temperature, and the flow through the
filter must be known. Generally, the curves for filter elements are available from filter suppliers. For example, for

the R36586 filter elements supplied by P&H for the 2800XPB and 4100A, the maximum allowable operating vis-
cosities that will result in a 10 PSI pressure drop across the filter are shown in Table 16-2.
R36586D_ Filter Length, Single Filter Media - Double Element Filtration Rating in
or Double microns
D1 Double Fiberglass 10
D2 Double Fiberglass 20
D3 Double Synthetic 40
D4 Double Woven Wire 40
D5 Double Woven Wire 74
D6 Single Fiberglass 10
D7 Single Fiberglass 20
D8 Single Synthetic 40
D9 Single Woven Wire 40
D10 Single Woven Wire 74
Table 16-2: R36586 Filter Elements
The selection of gear case oils must be made on the basis of conformance to P&H Specification 497 or 474, on the
minimum viscosity requirement of 400 cSt at maximum operating temperature, and on the pour point of the oil vs.
the minimum ambient temperature.
16.3.2 ISO Grades of Oil
It is recommended that only oils with an ISO grade designation be used. If a type of oil other than an ISO grade is
to be used, consult with the manufacturer. Oils of the same ISO grade will typically have similar viscosity and pour
point parameters. If unsure, compare proposed oil’s properties with those listed in Table 16-1. If significantly differ-
ent, consult the manufacturer regarding suitability.
16.4 Material Specification P&H No. 464
16.4.1 Open Gear and Wire Rope Lubricant, Issue No. 9, 4-20-93
16.4.1.1 Scope
This specification covers open gear lubricants with highly fortified blends of viscous oils combined with additives to
form a stable, long lasting, high load carrying and wear resistant film that lubricates under boundary conditions.
Materials furnished under this specification are intended to lubricate open gears, racks, bushings, rails, rollers, dip-
per handles, and walk mechanisms. These applications are subject to extreme contact pressures, reversing loads,
and peripheral speeds of up to 1,200 feet per minute (366 meters per minute), while operating under varied
weather conditions.
Materials furnished under this specification are intended to be dispensed intermittently by centralized lubrication
systems of the single line parallel, single line progressive series, and/or dual line progressive construction.

This specification covers all grades of open gear lubricants that are usable from -50o to 120o F (-46° to 49o C). The
particular grade selected must perform in the specific temperature range in which it is utilized.
Materials furnished under this specification may be semi-fluid asphaltic or non-asphaltic, grease or pastes. Specific
product selection will depend on climate, application, performance, and regulatory requirements.
Materials furnished under this specification are not intended for use in moderate to high anti-friction bearings.
16.4.1.2 Reference Documents
• ASTM D92/ISO 2592, Latest Issue: Flash Point, COC Method
• ASTM D1404, Latest Issue: Deleterious Particles Test
• ASTM D1743, Latest Issue: Rust Protection
• ASTM D2266, Latest Issue: Four Ball Wear Test
• ASTM D2596, Latest Issue: Four Ball EP Test
• ASTM D4048, Latest Issue: Copper Strip Corrosion Test
• Grease Pumpability, Lincoln Ventability (Ventmeter) Test, Latest Issue
16.4.1.3 Physical Characteristics
These open gear lubricants must have excellent adhesive and cohesive qualities, must not chip or throw off, and
must provide sufficient film thickness to prevent metal to metal contact between applications under all operating
conditions.
These open gear lubricants must have excellent water resistant and rust preventive qualities.
These open gear lubricants must have retarded dripping qualities for operation at various temperatures.
These open gear lubricants must be specifically formulated to protect surfaces, reduce wear, and provide normal
component service life under all anticipated operating conditions.
These materials shall meet applicable safety, health, and environmental regulations.

16.4.1.4 Performance Requirements
Property Requirement
Flash point, ASTM D92/ISO 2592, minimum °F(°C). 175 (79)
Four ball EP test, ASTM D2596, weld point, minimum kgf, Asphaltic 250
Compounds.
Non-asphaltic Compounds, Grease, Pastes. 400
Four ball wear test, ASTM D2266, 60 minutes @ 40 kgf, maximum 1.0
scar, mm.
Rust protection, ASTM D1743 Rating. Pass
Copper strip corrosion, ASTM D4048 Max. rating, 24 hrs @ 212°F 1b

(100°C).
Deleterious particles, ASTM D1404, Max. number of scratches. 20
Pumpability, Lincoln ventability test, maximum PSI (bar) @ lowest 400 (27.60) (1)
anticipated ambient temperature.
(1) Consult lubricant system components manufacturer regarding any deviations from this requirement.
Table 16-3: Performance Requirements - P&H Specification 464
16.4.1.5 Special Considerations
The material furnished under this specification must be dispensable through the distribution lines of a centralized
lubrication system to the most remote application point, at the lowest anticipated operating temperature. It must not
plate or plug components of the centralized lubrication system such as injectors, metering blocks, or spray nozzles.
When the material furnished under this specification is formulated with solid film additives, particle size must not
exceed 100 microns.
Should the material furnished under this specification contain a diluent to improve dispensability, special care must
be exercised to ensure its compatibility with all centralized lubrication system components (that is, gaskets, o-rings,
vent valves, and so on).
Diluent containing lubricants furnished under this specification must conform to the performance requirements pro-
vided in Subtopic 16.4.1.4 after the diluent has evaporated.
16.4.1.6 Identification and Packaging
Containers must be clearly identified by the supplier with the following information:
• Purchase Order Number
• Supplier’s Name and Product Trade Name
• P&H Material Specification Number followed by a brief description:
• P&H No. 464 - Asphaltic Type Open Gear Lubricant
or

• P&H No. 464 - Paste Type Open Gear Lubricant
• Material Safety Data Sheet (MSDS) - one (1) with each shipment
The lubricant furnished under this specification must be supplied in clean containers of the size(s) as specified on
the purchase order.
16.4.1.7 Inspection at Purchaser’s Works
Acceptance of material furnished under this specification shall be subjected to confirmation by Customer’s Quality
Assurance Department.
The purchaser shall have the option of accepting or rejecting any material failing to meet the requirements of this
specification.
16.4.1.8 Additional Criteria of Acceptance
Conformance to all specified requirements shall not constitute the sole basis of acceptance, since all lubricants
must be judged further on their satisfactory field performance in P&H Mining Equipment.
Re-lubrication volume and frequency can directly affect the performance of a lubricant and the economies of oper-
ation. Consult the equipment shop manual and lubricant supplier for the re-lubrication volume, and frequency for
each application.
The suitability of a lubricant is highly dependent upon environmental conditions. It is the consumer’s responsibility
to provide lubricant suppliers with the following:
• Actual application and copy of this specification.
• Environmental data - temperature range and weather conditions.
• Type of centralized lubrication system(s).
It is the responsibility of the consumer to verify that lubricants conform to applicable environmental and safety
codes governing their use and disposal.
16.5.1 Multi-Purpose Grease, Extreme Pressure, Aluminum Complex Soap Base, Liquilon
Solid Lubricant Additive, Issue No. 1, 1-80
16.5.1.1 Scope
Material furnished under this specification is a multi-purpose aluminum complex soap grease lubricant. It is charac-
terized by its excellent water resistance, thermal and shear stability, and compatibility with all other types of
greases.
This grease contains a derivative of polytetrafluoroethylene as a solid lubricant additive. This additive has the reg-
istered trade name of “Liquilon”.

This grease is intended for lubricating components during assembly. It can be used in equipment having grease fit-
tings and in centralized distribution systems. (Refer to Note (a) in Table 16-4.)
16.5.1.2 Physical Properties
This lubricant must be an Aluminum Complex Soap Base, Multi-Purpose Extreme Pressure Grease containing
“LIQUILON”. It must be formulated to resist oxidation and corrosion, oil separation, caking, and water washout.
Material furnished under this specification shall conform to the following physical requirements:
P&H Grade 469 469A
N.L.G.I. Consistency #2EP #1EP
Suggested Operating Temperature Range °F (°C) (a) 0 to 400 (18 to 204) -15 to 400 (-26 to 204)
Penetration at 77°F (25°C) Worked 60 Strokes 265 to 295 330 to 340
Dropping Point °F (°C) Minimum 475 (246) 475 (246)
Bomb Oxidation Stability Pressure Drop, 100 Hours ASTM 5 PSI (35 kPa) 5 PSI (35 kPa)
D942, Latest Issue
Oil Separation, 50 Hours at 210°F (99°C) 5.0% Maximum 7.0% Maximum
Extreme Pressure Properties:

Timken ok Load, lbs (kg) 75 (34) 75 (34)
Weld Point KG, Minimum 325 325
Mineral Oil Specifications:

Viscosity @ 100°F 800 to 1200 800 to 1200
Viscosity @ 210°F 75 to 90 75 to 90
Flash Point °F (°C) Minimum 425 (218) 425 (218)
Pour Point °F (°C) Maximum 0 (-18) 0 (-18)
(a) Consult manufacturer’s manual for correct consistency when used in centralized distribution systems.
Conformance to the above requirements shall not constitute the sole basis of acceptance, since all lubricants must
be judged further on their satisfactory field performance in P&H Mining Equipment.
16.5.1.3 Packaging
This grease lubricant is available in 400 lb (181 kg) drums, 120 lb (54 kb) kegs, 35 lb (15.9 kg) pails, and hand gun
cartridges. The container shall be specified on the purchase order to the supplier.
16.5.1.4 Identification

• P&H Material Specification Number as specified on the Purchase Order
Acceptance of material furnished under this specification shall be subject to confirmation by the P&H Materials
Engineering Department.
The Purchaser shall have the option to accept or reject material that fails to meet any of the requirements of this
specification.
In the event of rejection, the supplier will be notified, and the material will be returned at their expense.
16.6.1 Multi-Purpose Grease; Extreme Pressure (EP), Issue No. 11, 2-24-95
16.6.1.1 Scope
This specification covers premium multi-purpose, extreme pressure greases with essential properties and charac-
teristics that make them suitable for use in diversified applications through a wide range of ambient temperatures.
Both mineral and synthetic base oils may be used to formulate greases that comply with this specification.
Materials furnished under this specification are intended to lubricate bushings, plain and rolling element bearings,
and miscellaneous items on P&H Mining Equipment requiring grease.
Materials furnished under this specification may be applied by hand, hand pressure guns, pneumatic or electric
pressure guns, or centralized lubrication systems of the single line parallel, single line progressive series, and/or
dual line progressive construction.
P&H 472 (no suffix) from Issue No. 9 is the same as P&H 472C in this specification.
P&H 472D is primarily intended to lubricate bearings in Magnetorque® Assemblies, and bearings and gears in
hoists and cranes, where long life of lubricant is demanded, and high temperature operation may be expected, in
both intermittent and continuous duty. Other product uses include high speed electric motor bearings; ball, roller,
and journal bearings - medium to high temperature and high temperature applications; bearings subject to water,
steam, chemicals, and contaminants; and bearings subject to heavy thrust or shock loads.
• ASTM D217/ISO 2137, Latest Issue: Determination of Cone Penetration
• ASTM 0445/ISO 3104, 02161, Latest Issue: Kinematic Viscosity
• ASTM D566/ISO 2176, Latest Issue: Determination of Dropping Point
• ASTM 0942, Latest Issue: Oxidation Stability, Oxygen Bomb Method
• ASTM 01264, Latest Issue: Water Washout Resistance
• ASTM 01404, Latest Issue: Deleterious Particles Test

• ASTM 01743, Latest Issue: Rust Protection
• ASTM 01831, Latest Issue: Roll Stability Test
• ASTM 02265, Latest Issue: Determination of dropping point over a wide temperature range
• ASTM 02509, Latest Issue: Timken EP Test
• ASTM 02596, Latest Issue: Four Ball EP Test
• ASTM 04048, Latest Issue: Copper Strip Corrosion Test
• DIN 51 802/IP 220, Latest Issue: EMCOR Rust Protection Test
• Grease Pumpability, Lincoln Ventability (Ventmeter) Test, Latest Issue
These lubricating greases shall be manufactured with a lithium 12-hydroxystearate, lithium complex, or other thick-
eners, provided care is taken by the end user to avoid grease incompatibility in P&H Mining Equipment. Thickeners
such as clay base, polyurea, or calcium may result in incompatibilities. Always consult lubricant suppliers before
changing types or brands of grease.
These lubricating greases must contain extreme pressure additives, and be formulated to resist oxidation, corro-
sion, separation, and water washout.
These lubricating greases must have chemical and mechanical stability to maintain consistency and performance
characteristics throughout their intended service life.
The NLGI grade of the grease must be appropriate for the prevailing ambient temperature range. P&H 472C is the
preferred grade for all temperature ranges. However, at lower ambient temperature ranges, P&H 472A or 472B
may be recommended by the lubrication supplier.

P&H Grade 472A 472B 472C 472D
NLGI Grade * 0 1 2 2
Worked penetration ASTM D217/1SO 2137 @ 355-385 310-340 265-295 265-295

60 strokes, 77°F (25°C)
Dropping point, ATSM 0445/1SO 2176 or ATSM N/A 350 (177) 350 (177) 500 (260)
02265, Min. °F (°C)
Base fluid viscosity, ATCSM 0445/1SO 3104; 68 100 220 220

02161, Min. mm2/s @ 40C
Oxidation stability ATSM 0942, Max. pressure 5 (35) 5 (35) 5 (35) 5 (35)
drop @ 100 hrs., PSI (kPa)
Roll stability, ATSM 01831 Max. points change 30 30 30 30
Water washout, ATSM 01264, Max. % loss @ N/A 10 10 10

175°F (79°C)
Rust protection, ATSM 01743 rating Pass Pass Pass Pass
EMCOR Rust Protection DIN 51 802/1P 220, 0, 0 0, 0 0, 0 0, 0

Min. rating
Copper strip corrosion, ATSM 04048 Max. rat- 2 2 2 2

ing, 24 hrs @ 212°F (100°C)
Timken EP Test, ASTM D2509 Min OK value, 45 (20) 45 (20) 45 (20) 45 (20)
lbs (kg)
Four ball EP, ASTM D2596 - Weld load, Min. kgf 315 315 315 315
Load wear index, Min. kgf 45 45 45 45
Deleterious patches, ASTM D1404, Max. num- 20 20 20 20

ber of scratches
Pumpability**, Lincoln Ventability test, Normal 400 (2,758) 400 (2,758) 400 (2,758) 400 (2,758)
max. PSI (kPa) @ lowest anticipated ambient *** *** *** ***
temperature
*The preferred grade is NLGI #2. However, an NLGI #1 or #0 may be required for proper dispensing at low
temperature, or by centralized lubrication systems (see Topic 16.3).
**This is applicable for use only in centralized lubrication systems.
***Consult lubrication system component manufacturer regarding any deviations from this requirement.

• P&H Material Specification Number followed by a letter which will indicate a particular consistency grade in
accordance with the following:
• P&H Number 472A - NLGI #0 EP
• P&H Number 472B - NLGI #1 EP
• P&H Number 472C - NLGI #2 EP
• P&H Number 472D - NLGI #2 EP
• Material Safety Data Sheets (MSDS) - one (1) with each shipment.
The lubricant furnished under this specification shall be supplied in clean containers of the size(s) as specified on
the purchase order.
Acceptance of material furnished under this specification shall be subjected to confirmation by purchaser’s Quality
Assurance Department.
specification.
ation. Consult the equipment shop manual and lubricant supplier for the proper re-lubrication volume and fre-
quency for each application.
• Environmental data - ambient temperature range and weather conditions.
• Type of centralized lubrication system(s).

16.7.1 Synthetic Gear Oil; Extreme Pressure (EP), Issue No. 5, 2-24-95
16.7.1.1 Scope
This specification covers premium gear oils produced from synthetic or semi-synthetic base stocks and com-
pounded with extreme pressure additives for high load carrying ability.
• Materials furnished to Issue No. 3 of this specification had a single flash point requirement whereas this
issue now covers a variety of ambient temperatures.
Materials furnished under this specification are intended to lubricate gears, bushings, plain and rolling element
bearings, sprockets, chain drives, and other components enclosed in oil-tight housings, and operating under high
speed, high torque, high shock load, and/or high speed, low torque conditions.
! WARNING
Do not use oils containing EP additives or other friction modifiers in applications con-
taining internal mechanical load brakes, backstops or clutches. Additionally, certain EP
formulations may not be compatible with bronze gears as found in worm gear cases.
Materials furnished under this specification may be used in sump (splash), circulating, or total-loss applications.
Materials furnished under this specification may be used as replacements for P&H specification 496 or 498 gear
oils, when extremes in ambient temperatures require seasonal changes to different viscosities. Consult P&H Engi-
neering or P&H MinePro Services prior to making such a substitution.
Materials furnished under this specification are intended for use in applications where MIL-L-2105 (latest issue)
and/or API Service GL-5 gear oils are a requirement.
Materials furnished under this specification are not intended for use in applications where bulk oil operating tem-
peratures routinely range from 170° to 225°F (77° to 107°C).
• ASTM 097/ISO 3016, Latest Issue: Pour Point
• ASTM 0130/ISO 2160, Latest Issue: Copper Strip Corrosion Test
• ASTM 0665/ISO 7120, Latest Issue: Rust Test
• ASTM 0892, Latest Issue: Foam Stability
• ASTM 02270/ISO 2909, Latest Issue: Viscosity Index
• ASTM 02422/ISO 3448, Latest Issue: ISO Viscosity Classifications

• ASTM 02711, Latest Issue: Demulsibility
• ASTM 02893, Latest Issue: Oxidation Stability
• DIN 51 354, Latest Issue: FZG Test
These gear oils must be formulated with full synthetic or semi-synthetic base fluids.
NOTICE
Numerous types of synthetic and semi-synthetic fluid formulations may be applicable to this
specification, some of which may be chemically incompatible. Therefore, different brands or
types of synthetic or semi-synthetic fluids should not be intermixed such as during system top-
off, without consulting the lubricant supplier(s).
These lubricants may not contain viscosity or viscosity index enhancers that are subject to breakdown under
extended shearing conditions.
These lubricants must have chemical and physical stability to maintain viscosity and performance characteristics
throughout their intended service life.
Any EP or other friction modifiers used in the formulation of these lubricants must be fully oil soluble, and/or be in a
stable colloidal suspension.
16.7.1.4 P&H Identification Number and Viscosity Grade
• P&H No. 474A, ISO VG 32, AGMA 0 EP
• P&H No. 474B, ISO VG 46, AGMA 1 EP
• P&H No. 474C, ISO VG 68, AGMA 2 EP
• P&H No. 474D, ISO VG 100, AGMA 3 EP
• P&H No. 474E, ISO VG 150, AGMA 4 EP
• P&H No. 474F, ISO VG 220, AGMA 5 EP
• P&H No. 474G, ISO VG 320, AGMA 6 EP
• P&H No. 474H, ISO VG 460, AGMA 7 EP
• P&H No. 474I, ISO VG 680, AGMA 8 EP

• P&H No. 474J, ISO VG 1000, AGMA 8A EP
• P&H No. 474K, ISO VG 1500, AGMA 9 EP
Viscosity Grade 150 VG 32 - 1500, AGMA OEP - 9EP. In accordance with

ASTM 02422/150 3448
Viscosity In accordance with ASTM 0445/150 3104/02161
Viscosity Index, ASTM 02270 20111
Cleanliness Must be free of visible contaminants
16.8.1 Gear Oil - Single Viscosity Grade; Extreme Pressure (EP), Issue No. 11, 2-1-93
16.8.1.1 Scope
This specification covers premium single grade gear oils produced from refined mineral oil base stocks, and com-
pounded with extreme pressure additives for high load carrying ability. Synthetic lubricants are not covered in this
specification.
Materials furnished under this specification are intended to lubricate gears, bushings, plain and rolling element
bearings, sprockets, chain drives, and other components enclosed in oil-tight housings, and operating under high
speed, high torque, high shock load, and/or high speed, low torque conditions.
NOTICE
Do not use oils containing EP additives or other friction modifiers in applications containing
internal mechanical load brakes, backstops, or clutches. Additionally, certain EP formulations
may not be compatible with bronze gears as found in worm gear cases.
Materials furnished under this specification may be used in sump (splash) circulating, or total loss applications.
When extremes in ambient temperatures may dictate seasonal changes to different viscosity grades, or where
MIL-L-2105 oils are required, P&H specification 496 or 498 gear oils may be suitable substitutions for these single
grade EP gear oils. Consult P&H Engineering or P&H MinePro Services prior to making such a substitution.
The designations 497A and 497B are being reserved for lighter viscosities than ISO VG 68 if required in the future.
P&H 497A, B, and C from Issue No. 6 do not match the same designations in this specification.
Materials furnished under this specification are not intended for use in applications where MIL-L-2105 (latest
issues), and/or API Service GL-5 gear oils are a requirement.

• ASTM 092/ISO 2592, Latest Issue: Flash Point, COC Method
• ASTM 097/ISO 3016, Latest Issue: Pour Point
• ASTM 0130/ISO 2160, Latest Issue: Copper Strip Corrosion Test
• ASTM 0892, Latest Issue: Foam Stability
• ASTM 0665/ISO 7120, Latest Issue: Rust Test
• ASTM 02270/ISO 2909, Latest Issue: Viscosity Index
• ASTM 02422/ISO 3449, Latest Issue: ISO Viscosity Classifications
• ASTM 02711, Latest Issue: Demulsibility
• ASTM 02893, Latest Issue: Oxidation Stability
• DIN 51 354, Latest Issue: FZG Test
These gear oils must be manufactured from highly refined mineral oil base stocks.
These lubricants may not contain viscosity or viscosity index enhancers that are subject to breakdown under
extended shearing conditions.
These lubricants must have chemical and physical stability to maintain viscosity and performance characteristics
throughout their intended service life.
Any EP or other friction modifiers used in the formulation of these lubricants must be fully oil soluble, and/or be in a
stable colloidal suspension.
16.8.1.4 Identification Number and Viscosity Grade
• P&H No. 497C, ISO VG 68. AGMA 2 EP, SAE 80W
• P&H No. 497D, ISO VG 100. AGMA 3 EP, SAE 80W
• P&H No. 497E, ISO VG 150. AGMA 4 EP, SAE 85W
• P&H No. 497F, ISO VG 220. AGMA 5 EP, SAE 90W

• P&H No. 497G, ISO VG 320. AGMA 6 EP, SAE 90W
• P&H No. 497H, ISO VG 460. AGMA 7 EP, SAE 140W
• P&H No. 497I, ISO VG 680. AGMA 8 EP, SAE 140W
• P&H No. 497J, ISO VG 1000. AGMA 8 A EP, SAE 250W
• P&H No. 497K, ISO VG 1500. AGMA 9 EP, SAE 250W
Viscosity Grade ISO VG 68 - 1500, AGMA 2EP-9EP,

In accordance with ASTM 02422/ISO 3448
Viscosity In accordance with ASTM 0445/ISO 3014/02161
Viscosity Index, ASTM 02270/ISO 2909 Min. 90
Cleanliness Must be free visible of contaminants
Additive Solubility Must be filterable to 25 microns (Beta 25 equals

200 filter rating) without loss of additive(s)
Pour Point, ASTM 097/ISO 3016 Max. 9°F (5°C) below the lowest anticipated ambient
temperature
Flash Point, ASTM 092/ISO 2592, Min. 400°F (204°C)
Rust test, ASTM 0665/ISO 7120

Procedure A Pass
Procedure B Pass
Copper strip corrosion, ASTM 0130/ISO 2160 1b

3 hrs @ 100C/212F, Max.
Oxidation stability, ASTM 02893, @ 250°F 6 (Viscosity grades 68 through 680)

(121°C) Max. % viscosity increase 10 (Viscosity grades 1,000 through 1,500)
Foam Suppression, Must be within these limits:

ASTM 0892
Max. volume of foam (ml) after:
Temperature 5 min blow 10 min blow
Seq. 1 75°F (24°C) 75 10

Seq. II 200°F (93.5°C) 75 10
Seq. III 75°F (24°F) 75 10
Table 16-8: Performance Requirements - P&H Specification 497 (Continued)

Demulsibility, ASTM Must be within these limits: Viscosity Grades

02711
68-460 680-1,500
Max % water in oil after 5 hr test 2.0 2.0

Max cuff after free centrifuging 1.0 mL 1.0 mL
Min total free water collected during entire test (start with 80.0 mL 50.0 mL
90 mL water)
Four ball EP test, ASTM 02783

Weld Load, Min. lbf (kgf) 551 (250)
Load wear index, Min. lbf (kgf) 121 (55)
Timken EP test, ASTM 02782

Min. OK value, lbs (kg) 60 (27)
FZG test, ASTM 05182 with A/8.3/90C >12

parameters, Min. fail stage
Table 16-8: Performance Requirements - P&H Specification 497 (Continued)
• P&H Material Specification Number followed by a letter which will indicate a particular viscosity grade in
accordance with the following:
• P&H No. 497C, ISO VG 68. AGMA 2 EP, SAE 80W
• P&H No. 497D, ISO VG 100. AGMA 3 EP, SAE 80W
• P&H No. 497E, ISO VG 150. AGMA 4 EP, SAE 85W
• P&H No. 497F, ISO VG 220. AGMA 5 EP, SAE 90W
• P&H No. 497G, ISO VG 320. AGMA 6 EP, SAE 90W
• P&H No. 497H, ISO VG 460. AGMA 7 EP, SAE 140W
• P&H No. 497I, ISO VG 680. AGMA 8 EP, SAE 140W
• P&H No. 497J, ISO VG 1000. AGMA 8 A EP, SAE 250W
• P&H No. 497K, ISO VG 1500. AGMA 9 EP, SAE 250W
• Material Safety Data Sheet (MSDS) - one (1) with each shipment

The lubricant furnished under this specification shall be supplied in clean containers of the size(s) as specified on
the purchase order.
Acceptance of material furnished under this specification shall be subjected to confirmation by the purchaser’s
Quality Assurance Department.
specification.
Lubricant change frequency, or re-lubrication volume and frequency, can directly affect the performance of the
lubricant and the economies of operation. Consult the equipment shop manual, and with the lubricant supplier, for
the proper change frequency, or re-lubrication volume and frequency, for each application.
• Environmental data - ambient temperature range and weather conditions.
• Type of centralized lubrication system(s), including pump, filtration, and reservoir data, when applicable.
Sealing Grease; Petroleum Resistant, Issue No. 2, 6-70
16.9.0.1 Scope
This specification covers a petroleum resistant sealing compound properly formulated to have oil sealant qualities.
16.9.0.2 Application
This sealing grease is intended for use in certain applications which require the use of a suitable sealant.
This sealing grease is primarily used as an oil seal on shafts, hubs, and other keyway assemblies. The compound
need not serve primarily as a lubricant but should not interfere with lubrication.
This sealing grease may also be used in other applications (as an oil seal) that are satisfied by a compound of this
type.

16.9.0.3 Physical Properties
The material furnished under this specification shall conform to the following characteristics, requirements, and
conditions:
• Insoluble in petroleum 011 and petroleum by-products.
• Have shelf life in excess of one year.
• Must retain insolubility and exhibit no dispersal in mineral oil when in contact with agitated or flowing oil
within a temperature range of -20° to 215°F (-29° to 107°C).
• Must retain the properties of a high viscosity paste without hardening in application to machinery with rotat-
ing parts and adjacent moving surfaces.
The above mentioned properties are not a complete description of the product required and stated only as refer-
ence material for descriptive purposes. Conformance to the physical properties shall not constitute the sole basis
of acceptance or application.
The accepted symbol used in the petroleum products industry to designate the standard is S.C.
16.9.0.5 Packaging
Sealing grease used for this purpose shall be supplied in cartons containing clean, one pound cans; unless other-
wise specified on the Purchase Order.
16.9.0.6 Identification
• Supplier’s Name and Trade Name
• P&H Material Specification Number
16.9.0.7 Rejection
The Purchaser shall have the option of accepting or rejecting material that fails to meet any of the requirements of
this specification.

16.10.1 Multi-Service Mining Lubricant, Issue No. 00, 3-97
16.10.1.1 Scope
Multi-service lubricants specified herein are partially or fully synthetic premium quality semifluid EP greases or
polymer/gel thickened, which are specifically formulated to provide the necessary load carrying and wear resisting
characteristics, required in a variety of applications, found in large surface mining equipment in continuous
operation.
These lubricants are intended to lubricate open gears, racks, bushings, rails, rollers, handles, walk mechanisms,
multi-row slewing bearings, and low to moderate speed plane and rolling element bearings. These applications are
subject to extreme contact pressures reversing loads that may dwell at zero velocity while loaded, gear peripheral
speeds over 2,000 feet per minute (610 meters per minute), and bearing speeds approaching 1,000 rpm.
Lubricants furnished under this specification are intended to be dispensed intermittently from centralized lubrication
systems of the single line parallel, single line progressive, and/or dual line progressive construction at the ambient
operational temperature at which the equipment operates.
Lubricants furnished under this specification are not intended to lubricate electric motor bearings, Magnetorque®
clutches, and other applications where there may be service requirements of the lubricant that differ from or are
beyond those described in this specification. Depending upon the consistency of semi-fluid products, they may not
be appropriate for use in couplings or with labyrinth seals.
• ASTM D445/ISO 3104/D2161, Latest Issue: Standard Test Method for Kinematic Viscosity
• ASTM D1743, Latest Issue: Rust Protection
• ASTM D2266, Latest Issue: Four Ball Wear Test
• ASTM D2509, Latest Issue: Timken EP Test, Grease
• ASTM D2596, Latest Issue: Four Ball EP Test, Grease
• ASTM D3279, Latest Issue: Heptane Insolubles Test
• ASTM D4048, Latest Issue: Copper Strip Corrosion Test
• US Steel Lubrication manual - Grease Mobility Test
• US Steel Lubrication manual - Timken Retention Test
• US Steel Lubrication manual - Lincoln Ventmeter Test

Multi-service lubricants specified herein must have the necessary adhesive and cohesive properties to resist chip-
ping, throw off, and run off, and provide the necessary film thickness and lubricating properties to prevent metal to
metal contact between application intervals under all operating conditions.
These lubricants must be specifically formulated to protect surfaces from wear, have excellent water resisting and
rust preventing properties, and have the necessary properties to provide exceptional service life of the components
which they lubricate under all operating conditions.
Multi-service lubricants specified herein must be dispensable through the distribution lines of a centralized lubrica-
tion system to the most remote application point at the lowest anticipated operating temperature. They must not
plate or plug components of the centralized lubrication system such as injectors, metering blocks, lines, or spray
nozzles.
When a lubricant furnished under this specification is formulated with a diluent to improve dispensability, the lubri-
cant must meet the performance requirements of Subtopic 16.10.1.4 both before and after the diluent has
evaporated.
Materials specified herein must meet the performance requirements when tested with samples taken from produc-
tion batches of the lubricant.
Materials specified herein shall meet all applicable safety, health, and environmental regulations.

Property Test Method Requirement
Flash Point ASTM 092/ISO 2592 266°F (130°C) minimum*
Copper Strip Corrosion ASTM 04048, 2 hrs @ 212°F (100°C) 1 b maximum
Rust Protection ASTM 01743 Pass
Four Ball Wear Test ASTM 02566, scar diameter, 0.7 mm maximum
60 Minutes at 40 k.Qf
Four Ball EP Test ASTM 02596, weld point 500kg minimum

Load Wear Index 70 minimum
Timken EP Test ASTM 02509, no score 50 lb minimum
US Steel Retention Test US Steel OM51 4 grams, no refill, pass

(Timken) 33 lbs for 30 minutes
Base Oil Viscosity ASTM 0445/ISO3104/02161 300 cSt minimum @ 725°F (400°C) **
Solid Lubricant Particle Size 20 micron maximum
Asphaltene Content ASTM 03279 less than 0.10%
Pumpability US Steel Mobility Test, OM 43, Test 0.30g/m minimum @ lowest operating
run at 150 PSI (10.4 bar) temperature
Lincoln Ventmeter Test VE-1, test 400 PSI (27.6 bar) maximum @ lowest
run for 30 seconds operating temperature
*Note for diluent containing lubricants: Although the flash point requirement applies to the mixture of
diluent and lubricant, it should be noted that the flash point of a diluent alone (that is, the flash point of the
diluent when it is not mixed with the lubricant) may be considerably lower than the flash point of the mixture
of lubricant and diluent.
**Note: While 300 cSt is the minimum viscosity required for most climates, it may be necessary to formu-
late products with slightly lower base oil viscosity for use in arctic conditions. In such cases, these products
should only be applied within their intended temperature range.
Containers must be clearly marked by the supplier with the product name and, if appropriate, the grade (that is,
“arctic”, “heavy”, “summer”, and so on)
Identification must remain legible upon outdoor storage of the containers.
If appropriate, a shelf life should be clearly marked on the container.
Any special considerations regarding the storage of the product such as protection of container openings, elimina-
tion of water buildup, etc. should be clearly communicated to the end user.
Material Safety Data Sheets (MSDS) must be supplied to the end user for each product delivered.

must be judged further on their satisfactory field performance on the type and model equipment which they are
intended to lubricate.
ation. Consult the equipment shop manual and lubricant supplier for the re-lubrication volume and frequency for
each application.
to provide the lubricant supplier(s) with the appropriate application data, material specification(s), environmental
data such as temperature and weather conditions, and type of centralized lubrication system.


ES41157 Mechanical Systems Manual Lubrication Requirements
Section 17
Lubrication Requirements
17.1 Overview
This shovel uses a combination of lubrication techniques and systems. They include:
1. Manual fittings for single lubrication points. The manual lube points are shown in the Lubrication Charts.
Refer to Subtopic 17.1.1.
2. Normal wear (service) points are shown in the Lubrication Charts, except for components not manufactured
by P&H Mining Equipment. For information concerning purchased component lubrication, see the applicable
manufacturer’s manual. Lubricate service points, such as linkages and pins not having grease fittings, with a
few drops of motor oil, or a thin layer of MPG or MS, to prevent corrosion.
3. Individual Gear Case Circulation. The hoist gear case lubricant circulation system (Subtopic 12.2.9) is a
pump-operated system that circulates hoist gear case oil, using an electric motor driven pump. The lubrication
system uses filters and strainers to maintain the quality of oil in the system. A similar lubricant circulation sys-
tem is used for the crowd transmission.
4. Bath and Splash Lubrication. Large gears and bearings in the hoist, crowd, swing, and propel transmissions
utilize bath and splash lubrication systems to circulate the gear oil.
5. Spray Lubrication. Some components of the swing system are equipped with air-operated lubricant spray
nozzles.
6. the shovel is equipped with a Centralized Automatic Lubrication System controlled by the Centurion Control
System. A touch panel is used to view the system set points or make changes.
17.1.1 Lubrication Charts
The lubrication charts for the Upper, Lower, and Attachment are shown in Figure 17-1, Table 17-1, Figure 17-2,
Table 17-2, and Table 17-3.

Sec17LubeReq.fm -17.1- Section 17, Version 00 - 06/07
Lubrication Requirements ES41157 Mechanical Systems Manual
! # &
" ' &

!
"
%
$
#

!
"

6+" ?
Figure 17-1: 4100XPC Upper Shovel Lubrication Diagram - Service Points

Section 17, Version 00 - 06/07 -17.2- Sec17LubeReq.fm
4100XPC MINING SHOVEL LUBRICATION CHART (UPPER)
TIME SERVICE IDENTIFICATION REQUIRED LUBRICANT NUMBER OF

INTERVAL POINT SERVICE SERVICE
SAE P&H POINTS
CODE NUMBER
Each Shift 01 Grease Tank Check And Fill MPG Or 472 Or Dipstick
MS 520
02 Oil Tank Check And Fill GL Or 464 Or Dipstick

MS 520
03 Air System Lubricator Check And Fill Mineral Oil (10w or less)
04 Air Compressor Check And Fill See Compressor Manufacturer’s Rec-

ommendations (Subtopic 15.3.3)
05 Swing Gear Cases Check And Fill GO 497 Dipstick
06 Hoist Gear Case Check And Fill GO 497 Dipstick
09 Hydraulic Tank Check and Fill HO 484C-F Sight Gauge
See Note 1 07 Hoist Drum Seals Lube MPG 472 2 Fittings
Inspect Auto-
lube System For
Broken Lines,
Faulty Injectors
See Note 2 08 All Pins W/o Grease Fit- Lube MO Or 451 Or All Wear
tings, All Levers, Hinges MPG Or 472 Or Points
And Linkages MS 520
Every 90 04 Air Compressor Drain And Refill See Compressor Manufacturer’s Rec-
Days Crankcase ommendations
Every 250 10 Electrical Cabinet Blow- Lube MPG 472 6 Fittings

Hours ers
Every 2000 11 Swing Motors See Motor Lubrication Plate 4 Fittings

Hours
12 Hoist Motors See Motor Lubrication Plate 4 Fittings
13 Swing Motor Couplings Lube MPG 472 Fill And Vent

Plugs
14 Hoist Motor Coupling Lube MPG 472 Fill And Vent

Plugs
Seasonally Or 06 Hoist Gear Case Drain And Refill, GO 497 Drain Plug
Semi-annu- Sample And And Dipstick
ally W/peri- Analyze Oil See
odic Oil 05 Swing Gear Case Note 3 GO 497 Drain Plug
Sampling And Dipstick
Every 5000 15 Transmission Lube Check Oil Level GO 497 Drain And Fill
Hours Pump Gear Reducers Plug
Annually 09 Hydraulic Tank Change Hydrau- HO 484C-F Drain and Fill

lic Oil
Table 17-1: 4100XPC Upper Shovel Lubrication Chart

4100XPC MINING SHOVEL LUBRICATION CHART (UPPER)
NOTES:
1. The time interval depends on the mining shovel operation and the corrosive and/or abrasive influences. Be care-
ful not to invert seals by over lubrication.
2. The time interval depends on the mining shovel operation and the corrosive and/or abrasive influences.
3. Refer to Subtopic 16.2.2, Lubrication Specifications.
Table 17-1: 4100XPC Upper Shovel Lubrication Chart

11
10
13
05
01
04
02 08
09
03
TC1595c
"
%
$
#
6+"!%@
"
Figure 17-2: 4100XPC Attachment and Lower Lubrication Diagrams - Service Points

MINING SHOVEL LUBRICATION CHART (ATTACHMENT AND LOWER)
INTERVAL SERVICE IDENTIFICATION REQUIRED LUBRICANT NUMBER OF

POINT SERVICE SERVICE
SAE P&H POINTS
CODE NUMBER
See Note 2 01 Dipper Trip And Latch Bar Lube MPG 472 All Wear Points
See Note 2 02 Dipper Trip Transmission Check Level GO 497 Level Plug
Semiannu- 03 Rollers (55) Lube MPG 472 55 Fittings

ally
See Note 2 04 Ladder Pulleys & Slides Lube MPG 472 At Wear Points
05 House Ventilation Blower Lube MPG 472 4 Fittings

Motors
06 Propel Motors See Motor MPG 472 4 Fittings

Plate
07 Propel Motor/blower See Motor Plate
08 Crowd Motor See Motor MPG 472 2 Fittings

Plate
09 Crowd Motor/blower See Motor Plate
See Note 2 10 Hoist Ropes See Rope Manufacturers Lubricant Length Of Rope &
Recommendation Attaching Points
See Note 2 11 Boom Suspension Ropes
100 Hours. 12 All Pins W/o Grease Fittings, Lube MO 451, 472 All Wear Points
Or Semi- Levers, Linkages MPG
Monthly
Seasonally 13 Crowd Gear Case Drain, Fill, GO 497 Drain Plug, Level
Sample & Pipe
Analyze Oil.
See Note 3
Seasonally 14 Propel Gear Case Drain, Fill, GO 497 Drain & Level Plug
Sample &
Analyze Oil.
See Note 3
2000 Hrs. 15 Propel Motor Couplings Lube MPG 472 Fill & Vent Plugs
NOTES:
1. The time interval depends on the mining shovel operation and the corrosive and/or abrasive influences. Be careful
not to invert seals by over lubrication.
2. The time interval depends on the mining shovel operation and the corrosive and/or abrasive influences.
3. Refer to Subtopic 16.2.2, Lubrication Specifications.
Table 17-2: 4100XPC Attachment and Lower Lubrication Chart

4100XPC MINING SHOVEL LUBRICANT IDENTIFICATION
SAE P&H SPECIFICATION LUBRICANT DESCRIPTION

CODE
GL 464 Open Gear Lubricant Refer to Section

16, Lubrication
MO 451 Motor Oil Specifications.
MPG 472 Multi-Purpose Grease
GO 474 Synthetic Gear Oil
GO 497 Gear Oil
HO 484 Hydraulic Oil
MS 520 Multi-Service Lubricant
Table 17-3: 4100XPC Shovel Lubrication Chart
! WARNING
High pressure oil or grease can spray and penetrate skin or eyes, causing serious per-
sonal injury. Use extreme caution when working around lubrication systems in use and
wear appropriate face and body protection. Shut down the system and follow lockout
and tagout procedures for inspection, service, and maintenance of the lubrication sys-
tem. Inspect for evidence of leaks, loose connections, or ruptured components during
shutdown periods. Get medical aid immediately if the lube sprays into the eyes or pene-
trates the skin.
17.1.2 Automatic Lubrication System General Description
A complete description of the automatic lubrication system is provided at Section 18.
17.2 Electric Motor Lubrication
17.2.1 General
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 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 shocks 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 lock nuts.
17.2.2 Motor 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 outlets are equipped with a pipe
plug.
NOTICE
Never attempt to pump grease into the bearings through the outlet.
Very few grease inlets and outlets on motor bearings have the grease fitting or the plug located at the end head of
the motor. For accessibility, most inlet and outlet points are fitted with a short length of pipe, and the grease fitting
or 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.
NOTICE
Ensure the flexible hose extensions to the grease inlet are filled with a compatible grease
before placing the shovel in operation.

17.2.3 Lubrication Intervals
Each motor is equipped with a metal tag similar to the one shown in Figure 17-3.
Figure 17-3: Typical Electric Motor Tag
The amount of grease to add and the frequency of re-lubrication depend on operating conditions. Generally, adding
a little grease at more frequent intervals is preferred to a larger amount of grease at infrequent intervals.
17.2.4 Lubrication Procedures
Prior to greasing each bearing, wipe the grease fittings using a clean dry cloth and thoroughly clean the grease gun
fitting. Remove the drain pipe plug and remove any hardened grease in the tubes with a pliable plastic stick or a
length of wire, if necessary.
NOTICE
Be careful to prevent breaking the stick or wire off in the pipe or hose.
! WARNING
Failure to exercise care while working around rotating equipment can result in serious
personal injury or death. Ensure that guards are in place. Establish a means of commu-
nication with the operator station and notify all personnel working inside and outside of
the shovel of the impending motion.
Grease should be added while the motor is warm and slowly turning. Pump the grease into the bearing slowly and
gradually with a hand-operated grease gun. Cartridge-type grease guns will expel approximately 0.05 cu. in. of
grease per stroke. Whether the “oz.” (ounce) unit of measure is volume or weight, the amount of grease expelled
by a “standard” grease gun in 20 strokes is about equal to 1/2 ounce. Add grease slowly either until grease is
expelled from the drain line or 20 strokes of the pump. Leave the outlet (drain) holes open and run the motor to
relieve pressure until no more grease is expelled (20 minutes or longer). Replace the drain plugs.

! CAUTION
Over-greasing the bearings in vertical applications may cause personal injury and pre-
mature bearing failure if grease should drip on the commutator and flashover occur (see
Figure 17-4). To avoid over-greasing when repacking bearings, fill the cavity 1/3 to 1/2
full.
#
" !
LEGEND
01. Bearing
02. Drain Plug
03. Bearing
04. Drain Plug
05. Grease Fitting

TC2210b
Figure 17-4: Swing Motor Bearing Lubrication
While it is important not to over-grease any bearing, it is especially important not to over-grease the top bearing of
vertical applications. In addition to causing premature bearing failure, excess grease can drip onto the commutator
and adjacent parts and cause a flash over.
Avoid contaminating the commutator and windings with grease during assembly and maintenance. When re-pack-
ing the bearings, also fill the cavity about 1/3 to 1/2 full. Do not pack the cavity completely full.

NOTICE
Make no attempt to “purge” motor bearings by pumping large volumes of grease into the bear-
ings. There are labyrinth passages within the motor end heads that will pass grease internally
without forcing it out of the drain. Purging results in over-greasing the bearing, which leads to
failure, and can lead to flashing as previously noted.
17.3 Grease Selection

The grease selected must be compatible with that used at manufacture. The grease must be an extreme pressure
(EP) compatible with P&H Specification 472A, 472B, or 472C, respectively. Refer to Section 16, Lubricant Specifi-
cationsfor details.
Under no circumstances can grease 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 grease will promote flash overs.
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 grease, using a suitable solvent.

17.4 Installing Replacement Motor

Although all the bearings in new motors 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 motor installation, especially for the swing motor.
The supply hose must be disconnected from the fitting at the head end of the motor. Grease must be pumped
through the grease fitting until clean lube comes out of the end of the hose. Reconnect the hose. This procedure is
necessary to make sure the hose has been filled. Do not continue to pump grease into the fitting and wait for it to
come out of the drain, this will only result in over greasing.
Follow the lubrication procedures described in Subtopic 17.2.4 and make sure to select a grease of the proper
NLGI grade. Also, refer to “Grease Selection” Topic 17.3.
NOTICE
In some cases, it may be necessary to move replacement motors inside (to a warmer ambient)
and run them for a few hours at no load. A welding machine can be used to perform this task.
17.5 Lubrication After Extended Storage

The grease used as a bearing lubricant gradually deteriorates when the motor is idle for extended periods. The
bearing grease could become contaminated during storage in dirty environments. The separation of 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 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 re-lubricated
with fresh clean grease. Refer to “Grease Selection” Topic 17.3.
Re-lubrication is also recommended following storage outdoors or in a contaminated environment for a period of 5
months or longer. However, P&H Mining Equipment recommends that motors never be stored outdoors.
Each bearing should be packed between 1/2 and 2/3 full of grease upon installation. (Bearings are greased com-
pletely at the factory). 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.

17.5.1 Hoist Gear Case Lubrication System R57234F1/F2
ES04430a01
Figure 17-5: Hoist Gear Case Lubrication System Overview
17.5.1.1 General
The hoist gear case lubrication system includes a pump, strainer, and filter. An oil cooler is mounted under the plat-
form. The cooler is equipped with an electric fan that will automatically be turned on and off as the system deems
necessary. The pump motor is controlled by a variable frequency drive. The drive will cause the pump to be turned
on or off and the pump speed varied to help control oil flow and temperature.
The pump output is directed to the bearings of the gear case. There are also pump output lines plumbed into each
end of the gear case (front and rear) at the location of the input pinion.
For a more detailed description of the system operation and components, refer to Subtopic 12.2.9.
17.5.2 Hoist Lube Pump Assembly R57213D1
17.5.2.1 Removal
Remove the lubrication pump as follows:
excess oil.

C. Remove the four cap screws that secure the foot (14) to the pump mounting plate.
LEGEND 07. Key 14. Foot

01. Screw 08. Gasket 15. Snap Ring
02. Screw 09. Shim 16. Seal
03. Cover 10. Housing 17. O-Ring
04. Idler Pin 11. Nut 18. Plug
05. Idler Gear 12. Bracket 19. Bushing
06. Rotor Shaft 13. Bushing 20. Screw
Figure 17-6: Lubrication Circulation Pump

5. Slide the seal assembly (16) off the shaft and remove O-ring (17).
7. Install a new O-ring (17) on housing plug (18).
location.
NOTICE
6. Remove screws (20) and remove housing plug (18). Bushing (19) and O-ring (17) will come off with the hous-
ing plug.
7. Remove O-ring (17) from the housing plug.

17.5.2.5 Assembly
9. Install a new O-ring (17) on plug (18).
3. Align the shafts and coupling halves.
6. Open the shutoff cock.

17.5.2.7 Troubleshooting
Problem Probable Cause Remedy
Pump does not pump. Pump lost its prime. Check for air leak or low level in
transmission.
Motor not up to speed. Check motor’s rpm and coupling.
Relief valve set too low. Clean relief valve, reset pressure to
125 PSI (8.625 bars).
Pump worn out. Repair pump as necessary.
Pump starts, then loses its Low oil level in transmission. Check level and add oil as neces-
prime. sary.
Pump is noisy. Coupling is worn or broken. Remove guard and inspect cou-
pling.
Loose piping or pump mounting base. Check all mounting hardware.
Foreign object in pump inlet. Remove inlet line and check suc-
tion port.
Pump is not up to capacity. Filter partially plugged. Remove and clean or replace the
filter.
Air leak in suction line or along the pump Repair lines, check and tighten
shaft. packings.
Motor turning below rated rpm’s. Check motor and wiring.
Pump takes too much Oil is too heavy for pump. Change the oil in the transmission
power. to suit conditions. See lubricant
specifications.
Packing gland drawn down too much. Loosen up packing gland. See
repair Subtopic.
Coupling misaligned. Repair the coupling.
Table 17-4: Lube Pump Troubleshooting

17.5.3 Hoist Lube System Bypass Valve R57221D1
17.5.3.1 Inspection
Inspect every 250 hours for leaks. Test for correct setting and operation.
17.5.3.2 Adjustment
Adjust to 100 psi by removing the cover and adjusting the adjusting screw.
17.5.3.3 Repair
Repair is limited to replacement of a damaged or inaccurate valve.
Remove the valve from the line and install a new valve.
17.5.4 Hoist Lube System Strainer 46Q108D2
The oil strainer (Figure 17-8) is located between the shutoff cock at the gear case and the pump intake. The
strainer is provided to collect any large particles which may be in the gear case before they enter the pump.
17.5.4.1 Servicing
2. Turn off the shutoff cock.

Figure 17-8: Oil Strainer
A. Place a catch pan under the strainer assembly.
B. Remove the cover retaining screw from the top of the strainer.
C. Turn the cover to the left until it stops. Lift the cover from the strainer body.
E. Clean the basket with a suitable solvent.
F. Inspect the cover O-ring checking for cracks, splits and cuts.
G. Replace the basket and install the cover. Avoid pinching the O-ring during cover installation.
H. Secure the cover with the cover screw.
I. Open the shutoff cock.
J. When starting the mining shovel, confirm that the strainer does not leak.

17.5.5 Hoist Lube System Filter 46U110D1
The 46U110D1double element filter features two elements stacked on top of one another.
The following disassembly procedure is provided to perform element cleaning or replacement and does not require
the filter to be removed from the lubrication piping.
LEGEND 08. Tube 16. Element

01. Screws 09. Handle 17. Grommet
02. Nameplate 10. O-Ring 18. Plug
03. Screws 11. Head 19. Washer
04. Cover 12. Grommet 20. Gasket
05. O-Ring 13. Flange Assembly 21. Screws
06. Magnet 14. O-Ring 22. Filter Indicator
07. Bypass Valve 15. Bowl 23. Seal
Figure 17-9: Oil Filter
Refer to Figure 17-12 and disassemble the oil filter assembly as follows:
1. Shut down the mining shovel to stop the pump. Lockout and tag the pump motor supply breaker to prevent
start-up while working on the filter.

3. Place a catch pan under the filter assembly.
4. Loosen filter cover screws (03). Turn cover (04) counterclockwise and remove it from the filter.
5. Remove bypass valve assembly (07) from filter head (11). Filter element (16) will come out with the valve
assembly.
Filter maintenance includes: replacing filter elements, cleaning magnets, and replacing damaged components.
Refer to Figure 17-12 and service the oil filter assembly as follows:
1. Replace elements.
3. Inspect O-rings (05 and 10) and grommets (12 and 17) for cracks or other damage. Replace as necessary.
17.5.5.3 Assembly
Refer to Figure 17-12 and assemble the oil filter assembly as follows:
1. Replace elements (16) and grommet (12) on the bypass valve.
3. Insert the element and bypass valve in the filter assembly. Make sure the notches on the filter head and the
bypass valve are aligned.
4. Replace the cover (04) and twist it clockwise. Tighten screws (03).
5. Open the shutoff cock. Allow time before system start up to inspect for leaks.
6. Remove the lockout and tag from the pump motor supply breaker and start up the mining shovel.
7. Check the oil filter indicator. It should indicate “Filter Clean”.

17.6 Crowd Gear Case Lubrication System (R48499F1)
17.6.1 Description
Figure 17-10 shows a crowd gear case lubrication system. The system is self-contained and provides filtered gear
oil (GO) to the components in the crowd transmission. This system is optional.
01
02
04
05
03
06
07
08
ES0512A_01
LEGEND
01. Gear Case 05. Strainer
02. Return Line 06. Filter
03. Drain Line/Supply Line 07. Pump Assembly
04. Valve 08. House Wall
Figure 17-10: Crowd Gear Case Lubrication System (Typical, 4100XPC Not Shown)

An electric motor-driven pump draws gear oil from the transmission through a strainer and discharges the oil
through an indicator type oil filter to provide filtered oil for transmission operation. The pump and filter are located
inside the machinery house.
NOTICE
A valve located just before the strainer provides a means of shutting off the oil supply to the
pump during maintenance.
17.6.2 Maintenance
17.6.2.1 General
Maintenance of the crowd gear case lubrication system consists of periodic inspections, adding or changing oil, fil-
ter maintenance, and lube pump and system troubleshooting and repair.
17.6.2.2 Inspection
Inspect the crowd gear case lubrication system every 250 hours as follows:
• Check the system for leaks and signs of improper operation. Refer to Table 17-4 for lube pump trouble-
shooting.
• Check the filter indicator for cleanliness. Replace the filter element if necessary.
• Check the transmission oil level, using the dipstick provided (see Figure 17-11).
TC2078
Figure 17-11: Crowd Gear Case Dipstick

• Check the gear oil for metal particles and obvious contamination.
• Service the strainer element every 500 operating hours as shown in Figure 17-13. The crowd transmission
strainer is of the same construction as the hoist gear case strainer.
• Replace the oil filter element every 500 operating hours. Refer to “Oil Filters” Subtopic 17.7.1. The crowd fil-
ter is of the same construction as the hoist gear case filter.
• If the lube pump fails, replace it with an identical unit.

17.7 Lubrication System Components
17.7.1 Oil Filters (46U110D1, D2) Description
The oil filters provide a bypass based on the principle of pressure drop as the filter gets dirty. The filter is equipped
with an automatic bypass valve that opens when the pressure drop across the filter reaches 35 PSI (2.42 bar).
When this occurs, oil is no longer passing through the filter and the filter element must be cleaned (if wire mesh fil-
ters are being used) or replaced (see Figure 17-12). Refer to the lubrication instruction plate located on the side of
the hoist gear case for filter element options.
LEGEND 08. Tube 16. Element

01. Screws 09. Handle 17. Grommet
02. Nameplate 10. O-Ring 18. Plug
03. Screws 11. Head 19. Washer
04. Cover 12. Grommet 20. Gasket
05. O-Ring 13. Flange Assembly 21. Screws
06. Magnet 14. O-Ring 22. Filter Indicator
07. Bypass Valve 15. Bowl 23. Seal
Figure 17-12: Oil Filter (46U110) - D1 Shown
P&H shovels may be equipped with single element (46U110D2) or double element (46U110D1) filter assemblies
(see Figure 17-12). The primary difference is that the double element filter assembly has two elements stacked on
top of one another. These are used on the hoist lubrication and the optional crowd lubrication system. The single

element filter assemblies have only one element which is twice the length of the double elements. These are used
on the optional swing lubrication system.
The following disassembly procedure is provided to perform element cleaning or replacement and does not require
the filter to be removed from the lubrication piping.
To disassemble the oil filter assembly, refer to Figure 17-12 and proceed as follows:
1. Shut down the mining shovel to stop the pump. Lockout and tag the pump motor supply breaker to prevent
start-up while working on the filter.
3. Refer to Figure 17-12 and service the filter as follows:
A. Place a catch pan under the filter assembly.
B. Loosen filter cover screws (03). Turn cover (04) counterclockwise and remove it from the filter.
C. Remove bypass valve assembly (07) from filter head (11). Filter element (16) will come out with the valve
assembly.
Filter maintenance includes: filter element cleaning or replacing, cleaning magnets, and replacing damaged com-
ponents.
To perform maintenance, refer to Figure 17-12 and proceed as follows:
1. If the element is disposable, replace it with a new element. Refer to the lubrication chart located on the side of
the hoist gear case.
2. If the element is wire mesh, soak the element in an ultrasonic cleaner for 15 minutes. If an ultrasonic cleaner is
not available, soak the elements in a solution of hot soapy water and ammonia for 15 minutes.
4. Inspect o-rings (05 and 10) and grommets (12 and 17) for cracks or other damage. Replace as necessary.
17.7.1.3 Assembly
To assemble the oil filter, refer to Figure 17-12 and proceed as follows:
1. Replace element (16) and grommet (12) on the bypass valve as shown in Figure 17-12.
3. Insert the element and bypass valve in the filter assembly. Make sure the notches on the filter head and the
bypass valve are aligned.
4. Replace the cover (04) and twist it clockwise. Tighten screws (03).

5. Open the shutoff cock. Allow time before system start up to inspect for leaks.
6. Remove the lockout and tag from the pump motor supply breaker and start up the mining shovel.
7. Check the oil filter indicator. It should read “Filter Clean”.
17.7.2 Oil Strainer (46Q108D2, D3)
The oil strainer (Figure 17-13) is located between the shutoff cock at the gear case and the pump intake. The
strainer is provided to collect any large particles which may be in the gear case before they enter the pump.
Figure 17-13: Oil Strainer (46Q108)
17.7.2.1 Servicing
1. Shut down the mining shovel to stop the pump.
2. Lockout and tagout the pump motor supply breaker to prevent start-up while working on the strainer.

A. Place a catch pan under the strainer assembly.
B. Remove the cover retaining screw from the top of the strainer.
C. Turn the cover to the left until it stops. Lift the cover from the strainer body.
E. Clean the basket with a suitable solvent.
F. Inspect the cover o-ring checking for cracks, splits and cuts.
G. Replace the basket and install the cover. Avoid pinching the o-ring during cover installation.
H. Secure the cover with the cover screw.
I. Open the shutoff cock.
J. When starting the mining shovel, check to see that the strainer does not leak.

17.7.3 Lubrication Pump (37Z331D2)
17.7.3.1 General
This Subtopic will describe the operation and removal, replacing the shaft seal, disassembly, inspection, reassem-
bly, and installation of the hoist gear case lubrication pump (see Figure 17-14).
LEGEND 07. Key 14. Foot

01. Screw 08. Gasket 15. Snap Ring
02. Screw 09. Shim 16. Seal
03. Cover 10. Housing 17. O-Ring
04. Idler Pin 11. Nut 18. Plug
05. Idler Gear 12. Bracket 19. Bushing
06. Rotor Shaft 13. Bushing 20. Screw
Figure 17-14: Lubrication Pump (37Z331D2)
Description
This is a gear-type pump. Power from the gear reducer is transmitted to the pump rotor. The rotor meshes with and
drives the idler gear (05).

The space between the outside diameter of the idler gear and the inside diameter of the rotor is sealed by the cres-
cent shaped flange on cover (03).
When the rotor and idler begin to turn, there is an increase in volume between the gear teeth on the suction side of
the pump as shown in Figure 17-15. This increase in volume tends to create a partial vacuum on the pump suction
side and oil is drawn into the area.
LEGEND
01. Idler
02. Suction Zone
03. Bushing
04. Pressure Zone
05. Housing
06. Crescent
07. Rotor
Figure 17-15: Pump Operation
Oil fills the spaces between the teeth of the idler and rotor, is trapped by the crescent, and is carried past the cres-
cent to the pressure side of the pump. When the teeth mesh on the pressure side, the oil is forced from the spaces
between the gear teeth and out through the discharge port.
Pump problems, and their causes and remedies, are shown in “Lube Pump Troubleshooting” (see Table 17-4).
Removal
To remove the lubrication pump, refer to Figure 17-14 and proceed as follows:
1. Use lockout and tagout procedures to shut down the pump.
excess oil.
C. Refer to Figure 17-14 and remove the four cap screws (not shown) which secure the foot (14) to the pump
mounting plate.

5. Slide the seal assembly (16) off the shaft and remove o-ring (17).
7. Install a new o-ring (17) on housing plug (18).
location.
NOTICE
6. Remove screws (20) and remove housing plug (18). Bushing (19) and o-ring (17) will come off with the housing
plug.
7. Remove o-ring (17) from the housing plug.

17.7.3.5 Assembly
9. Install a new o-ring (17) on plug (18).

3. Refer to the flexible coupling, Subtopic 17.7.4, below and align the shafts and coupling halves.
6. Open the shutoff cock (see Figure 17-14).

17.7.4 Hoist And Crowd Lube Pump Flexible Coupling (18Z3706D2, D3)
The flexible coupling (Figure 17-16) used to couple the hoist and crowd gear case lubrication pumps to the motor
driven reducers is an elastic spider type coupling consisting of two coupling halves, a spider and set screws to lock
the coupling half in place on the shaft.
LEGEND
01. 1/16” Clearance
02. 1/16” Clearance
03. Spider
04. Coupling Halves
Figure 17-16: Hoist and Crowd Lubrication Flexible Coupling (18Z3706D2,D3)
17.7.4.2 Alignment
The coupling requires no lubrication. Maintenance is limited to proper alignment and replacing worn or damaged
parts.
To align the coupling halves, refer to Figure 17-16 and proceed as follows:
1. With the pump mounting hardware installed but not tightened, make sure the motor is moved toward the gear
reducer enough so the inside base of both coupling halves contact the elastic spider equally without compress-
ing it. This should provide the 1/16 inch clearance shown in Figure 17-16.

2. Use a ruler to check that the shafts are axially aligned as shown in Figure 17-17.
LEGEND
01. Use straight edge.
These surfaces must
be parallel.
Figure 17-17: Aligning Coupling Halves (18Z3706 D2,D3)
3. Adjust the pump until the shafts are aligned, then tighten the pump mounting bolts.
17.7.5 Swing Lube Pump Flexible Coupling (18Z3706D4)
The flexible coupling, Figure 17-18, used to couple the swing gear case lubrication pumps to the motor driven
reducers is a grid type coupling consisting of two coupling hubs, a two piece grid, a two piece cover, and seals and
gasket. It also contains set screws to lock the coupling hubs in place on the shaft.

01 02
03
04
05
11
06
07
12
07 09
10
08
13 11
ES0733_01
LEGEND 07. Cover Seal

01. Motor 08. Gasket
02. Gear Reducer 09. Pump Side Hub
03. Lubrication Pump 10. Reducer Side Hub
04. Coupling 11. Grid Cover
05. Plug 12. Bolt
06. Flexible Grid 13. Nut
Figure 17-18: Swing Lubrication Pump Flexible Coupling (18Z3706D4)
The coupling requires lubrication. Maintenance is limited to proper alignment and replacing worn or damaged
parts.
17.7.5.2 Alignment
To align the coupling halves, refer to Figure 17-18 and proceed as follows:
1. With the pump mounting hardware installed but not tightened, make sure the motor is moved toward the gear
reducer enough so the grid will fit in the coupling correctly.
2. Use a ruler to check that the shafts are axially aligned.
3. Adjust the pump until the shafts are aligned, then tighten the pump mounting bolts.

17.7.6 Gear Reducer (53Z801)
The lubrication pump gear reducer is provided to increase the torque output of the motor and decrease the rotating
speed of the pump. The gear reducer is a three reduction transmission as shown in Figure 17-19.
LEGEND 09. Gasket 18. Gear Case 27. Bearing

01. Key 10. Bearing 19. Breather Plug 28. Key
02. Output Shaft 11. Snap Ring 20. Gasket 29. Pinion Shaft
03. Key 12. Spacer 21. Snap Ring 30. Bearing
04. Screw 13. Gear 22. Pinion 31. Shim
05. Lock washer 14. Bearing 23. Key 32. Snap Ring
06. Oil Seal 15. Spacer 24. Bearing 33. Shaft
07. Drain Plug 16. Shim 25. Snap Ring 34. Key
08. Cover 17. Snap Ring 26. Gear 35. Gear
Figure 17-19: Gear Reducer

Normal maintenance of the gear reducer consists of monitoring the lubricant level and the condition of the lubri-
cant.
Refer to Figure 17-19 and check the following items at the intervals described:
1. Check the oil level and visually inspect the oil quality every 5,000 hours as follows:
A. Remove plug (07) from the front cover of the gear reducer.
B. Check the level and quality of the oil. The level should be up to the level of the plug.
C. Check the quality of the oil. If the oil is waxed, burned, or contaminated, it must be changed. Refer to the
gear reducer nameplate and the manufacturer’s recommendation’s for the type of lubricant required.
2. Change the oil every 10,000 hours, under normal operating conditions.
3. Clean and repack the bearing every 10,000 hours. Fill the bearing to 1/3 capacity with grease. Refer to the
gear reducer nameplate and the manufacturer’s recommendations for the type of lubricant required.
17.7.6.3 Removal
To remove the gear reducer, refer to Figure 17-19 and proceed as follows:
1. Use lockout and tagout procedures to shut down the mining shovel.
2. Tag and disconnect the electrical wires to the lubrication motor.
3. Remove the coupling guard.
4. Remove the mounting hardware from the gear reducer.
5. Remove the motor and gear reducer from the mounting plate by lifting it away from the pump.
To disassemble the gear reducer, refer to Figure 17-19 and proceed as follows:
1. Drain the gear oil from the gear reducer into suitable containers.
2. Remove the four motor mounting screws and remove the motor from the gear reducer.
3. Remove the setscrew and coupling half from the output shaft.
4. Loosen and remove screws (04) and lock washers (05) from cover (08).
5. Pull cover (08) and the output shaft from gear case (18). Items 01 through 03, 06, and 11 through 17 will be
removed with the cover.
6. Disassemble the output shaft as follows:
A. Remove snap ring (17) and pull shims (16), spacer (15), bearing (14), gear (13) and spacer (12) from the
output shaft.

B. Remove snap ring (11) from the cover.
C. Remove the shaft and bearing (10) from the cover.
D. Remove bearing (10) from output shaft (02).
7. Remove snap ring (32) from gear case (18).
8. Remove the second reduction pinion shaft (29) from gear case (18). It will be necessary to remove bearing
(24), snap ring (25) and gear (26) from the back side of the gear case.
9. Disassemble the remaining parts of the second reduction pinion shaft (29) as follows:
A. Remove key (28) from the keyway on the second reduction shaft.
B. Remove snap ring (32), shims (31) and bearing (30) from the shaft.
10. Remove snap ring (32) from the gear case and pull the first reduction shaft assembly towards the front of the
gear case.
11. Remove shims (31) and bearing (30) from the end of the first reduction shaft.
12. Pull the remaining parts of the first reduction shaft from the gear case.
13. Remove bearing (24), gear (35) and key (34) from first reduction shaft (33).
Clean all the components with a suitable solvent. Inspect the components of the gear reducer for excessive wear or
damage. Check gears and pinions for chipped or cracked teeth. Check bearings for discoloration. Repair is limited
to replacing worn or damaged components.
17.7.6.6 Assembly
To assemble the gear reducer, refer to Figure 17-19 and proceed as follows:
1. Lubricate each of the bearings with gear oil prior to assembly.
2. Assemble and install the first reduction shaft as follows:
A. Place key (34) in the keyway in the first reduction shaft (33).
B. Slide gear (35) and bearing (24) onto the first reduction shaft.
C. Place the pinion end of the first reduction shaft and assembled parts into the inside bearing bore in the gear
case.
D. Place bearing (30), shim pack (31) on the pinion end of the first reduction shaft.
E. Slide the first reduction shaft so the bearings (24 and 30) are in the their bores.
F. Install snap ring (32) in the groove in the gear case.
3. Assemble and install the second reduction shaft as follows:

A. Install bearings (30 and 27) and shim pack (31) on second reduction shaft (29).
B. Coat the keyway in the shaft with grease and install key (28) in the keyway.
C. Place bearing (24) in its bore at the rear of the gear case.
D. Place gear (26) in the back of the gear case.
E. Insert the second reduction shaft through the bores in the front and center of the gear case.
F. Align the keyway in gear (26) and key (28) on the shaft.
G. Push the gear onto the shaft until it is seated against the inner race of the bearing (27). Secure the gear in
place with a snap ring (25).
H. Push the shaft into the gear box until the bearing race on the end of the shaft is in the bore (24).
I. Secure the shaft in place by installing snap ring (32) in the groove of the second reduction shaft bore at the
front of the gear case.
4. Assemble and install the front cover and output shaft as follows:
A. Install oil seals (06) in the bore in cover (08) with the lips of each seal facing away from each other.
B. Install bearing (10) into the bore in the cover. Secure the bearing in place with snap ring (11).
C. Lubricate the lips of seals (06) with gear oil.
D. Insert shaft (02) through the front of the cover. Rotate the shaft while inserting it to avoid inverting the lip of
the front seal. Make sure that the shoulder of the shaft is seated against the inner race of bearing (10).
E. Slide spacer (12) onto the shaft.
F. Place key (03) in the keyway on shaft (02).
G. Place gear (13) on the shaft, align the key way on the gear with the key on the shaft and slide the gear onto
the shaft until it is seated against spacer (12).
H. Slide spacer (15) and shim pack (16) on the shaft.
I. Install snap ring (17) in the groove on the end of the shaft.
J. Install the shaft and cover assembly by aligning bearing (14) on the end of the shaft with the bore on the
inside of the gear case.
K. Align the holes in the cover with the threaded holes in the gear case. Secure the cover in place with screws
(04) and lock washers (05).

17.8 Centralized Transmission Drain
Figure 17-20: Centralized Transmission Drain Line (typical)
The centralized transmission drain assembly provides a common drain point for the hoist transmission and all three
swing transmissions.
Figure 17-21: Centralized Transmission Drain
Each transmission (hoist and three swings) is equipped with a drain valve. Drain valves can be opened individually
or together, and the oil drains through lines to the terminal point at the front of the revolving frame.
Access to the drain valves may be through the access ports in the revolving frame.

17.9 Gear Case Capacities

Table 17-5 shows the gear case oil capacities for 4100XPC mining shovel.
Gear Case (Quantity) Capacity
CROWD GEAR CASE (1) 110 GALLONS (416.3 LITERS)
HOIST GEAR CASE (1) 145 GALLONS (549 LITERS)
PROPEL TRANSMISSION (2) 100 GALLONS (378 LITERS)
SWING GEAR CASE (3) 70 GALLONS (265 LITERS)
Table 17-5: Gear Case Capacities

ES41157 Mechanical Systems Manual Automatic Lubrication System
Section 18
Automatic Lubrication System
Figure 18-1: Automatic Lubrication System (typical)
18.1 General
This shovel is equipped with a Lincoln® centralized lubrication system. The system features two pumps, each with
two lubrication zones, and is referred to as a two-pump, four-zone system.
Automatic lubrication is controlled by the shovel’s Centurion Control System. The basic purpose of the control sys-
tem is to turn each of the lubricant pumps on at the required intervals, and to keep the pumps running for the
required period of time. System components are connected to either inputs or outputs of the shovel’s Centurion
Control System. Pressure transducers, level indicators, etc. also provide inputs to the Centurion Control System.
The Centurion Control System controls the system pumps by output signals that control the solenoid valves for the
air-operated pumps. Timers in the Centurion Control System program are set up for each pump to determine the

Sec18AutoLube.fm -18.1- Section 18, Version 00 - 06/07
Automatic Lubrication System ES41157 Mechanical Systems Manual
length of time between cycles. Other timers monitor pump operation and set system faults if the pump cycle runs
too long, or if the system pressure does not vent back to the tank correctly.
The automatic lubrication system is a two-pump, four-zone system. The four zones are:
A. The upper grease system, which supplies Multi-Purpose Grease (MPG) to the upper zone including the
revolving frame and boom.
B. The upper open gear system, which supplies Open Gear Lubricant (GL) to the zone including the dipper
handle rack teeth, shipper shaft pinions, and saddle block wear plates.
C. The lower grease system which supplies Multi-Purpose Grease (MPG) to the lower zone including the pro-
pel system.
D. The lower open gear system, which supplies Open Gear Lubricant (GL) to the zone including the ring gear,
roller circle, and swing pinions.
MultiService Lubricant, P&H Specification 520, may be used in either or both of these systems.

Section 18, Version 00 - 06/07 -18.2- Sec18AutoLube.fm
18.2 Lube Circuits

The block diagram at Figures 18-2, show the Grease system major components and their connections.

$
'
& #
%
"
%
"
! $ $
!

# #

LEGEND 11. Centurion Control Sys-

01. Lube Tank 06. Lube Injector temCenturion Control
02. Pump 07. Zone Control Valve System
03. Air Motor 08. Air Flow Control Valve 12. Pressure Transducer
04. Vent Valve 09. Air Regulator 13. Vent Line
05. Lube Point 10. Air Valve 14. Zone 2
Figure 18-2: Grease System Upper Zone and Lower Zone

The block diagram at Figure 18-3 show the Open Gear system major components and their connections.
19
13
10 11 12 14
15
09
09
17
18
08
07 06 06
03 16
04 05
02
04
01
LEGEND 07. Vent Valve

01. Lube Tank 08. Air Flow Control Valve 14. Air Valve
02. Pump 09. Zone Control Valve 15. Air Regulator
03. Air Pump 10. Air Valve 16. Vent Line
04. Lube Point 11. Centurion Control System 17. Zone 1
05. Spray Nozzle 12. Pressure Transducers 18. Zone 2
06. Lube Injector 13. Air Regulator 19. Air Supply
Figure 18-3: Open Gear Lube System Upper Zone and Lower Zone

18.2.1 Lincoln Four Zone System Pumping and Venting
NOTICE
There are four zone control valves (R56032D1). This valve is also used for the two vent valves,
making a total of 6 of these valves.
The schematic used for this description is R52900. In the system that is detailed on this schematic, a 1300PSI
accumulator is plumbed between the pump and the zone control valves. An electric solenoid vent valve is located
near the tank and will open at the end of each cycle and vent the pressure back to the tank. A pressure relief valve
is located in parallel to the vent valve to limit system pressure.
Figure 18-4 and Figure 18-5 show the schematic of a Lincoln pump and system vent including the vent valve
assembly. In Figure 18-4, the pump is pumping lube and one of the two zone control valves is open. In Figure 18-5
the pump has stopped, the zone control valve has closed, and the system is venting pressure back to the tank.
These schematics are the same for each of the four automatic lubrication zones.
The schematics are color coded to show air, lube suction, high pressure lube, and pressure return to the tank.

01 11
10
02 09
05
07
03 04 08
06
12
13
14
15
LEGEND
01. Lower Grease System
02. Lower Zone Control Valve
03. Accumulator COLOR CODE
04. Filter 12. High Pressure Grease
05. Hand Valve 13. Air
06. Pump 14. Grease Suction To Pump
07. Vent Valve 15. Grease Return To Tank
08. Pressure Relief Valve
09. Upper Zone Control Valve
10. Check Valves (2)
11. Upper Grease System
Figure 18-4: Lincoln Four Zone System Pump and Vent Valve, Pumping
In Figure 18-4, the air input is present signifying that the pump is running. The normally opened vent valve is
closed. This will prevent the lube from venting back into the tank while the cycle is running. Check valves (items 10)
prevent lube from flowing between the zones.
The air input enters the pump air motor and causes the pump to begin stroking. The air exits the pump air motor
through a muffler or exhaust line.

01 11
10 LEGEND
01. Lower Grease System
02. Lower Zone Control Valve
03. Accumulator
02 09 04. Filter
05. Hand Valve
06. Pump
07. Vent Valve
08. Pressure Relief Valve
09. Upper Zone Control Valve
10. Check Valves (2)
05 11. Upper Grease System
07 COLOR CODE
12. High Pressure Grease
13. Air
03 04 08 14. Grease Suction To Pump
06 15. Grease Return To Tank
12
13
14
15
Figure 18-5: Lincoln Four Zone System Pump and Vent Valve, Venting
At the end of the cycle, the supply solenoid valve closes and removes air pressure from the pump. The pump stops
running and the vent valve opens and vents system pressure back to the tank as shown in Figure 18-5.
One zone control valve is opened electrically during the cycle and closed at the end of the cycle.
18.2.2 Four Zone System Descriptions
Figures 18-6,, 18-7, 18-8, and 18-9 show complete schematics of the four Lincoln Lubrication System zones. Each
of these schematics are color coded, and show the system as the pump is running. The color code shows air, lube
input to the pump (suction), lube output from the pump at system pressure (high pressure), and lube output from
the injectors (low pressure). The lube lines between the injectors and the lube points are not shown, so in most
instances a line is drawn going out from the injector to show an injector output
Three sizes of Lincoln injectors are used: SL1, SL11, and SL-V. Each injector on the shovel is shown, along with its
lube point. The pump, vent valve, zone control valves, and pump air supply are also shown for each zone.

18.2.2.1 Grease Upper Zone
Refer to Figure 18-6 on the next page. At the beginning of the cycle, the grease pump zone control valve opens.
This allows lube to flow from the pump to the upper zone, but prevents lube from flowing to the lower zone.
As the lube flows from the lube pump, it pushes the lube that is in the filled lines into the injectors. The lube enter-
ing the injector pushes on a spring-loaded piston. As the lube pressure on the piston overcomes the spring tension,
the piston is forced to move, and force out a measured amount of lube. When all the pistons in the injectors in one
zone have bottomed out, the lube no longer has anywhere to flow. The pressure will continue to build until it
reaches the system pressure set point and the cycle ends.
At the end of the cycle the vent valve opens as the pump stops. The vent valve allows system pressure to vent
back to the tank so the injectors can recharge for the next cycle.
The upper zone has four groups of injectors. The group numbered 16 - 24 are located inside the machinery house
on the lube room wall. There are two groups of large injectors numbered 03 - 07 and 10 - 14 that supply the shipper
shaft and saddle block bushings. One of these groups is located on each saddle block. And a group of 2 injectors
numbered 01 which are located on the boom near the boom suspension equalizers and supply the boom point
sheave assembly. There are four transducers in this zone. Transducer 02 is located on the upper middle of the
boom. Transducers 08 and 09 are located on the crowd gear case. Transducer 15 is located inside the machinery
house on the lube room wall.

01 01
02
28
27
26
25
03
04
05
06
07
08
09
13
12
11
10
14
15
24
23
22
21
20
18
17
16
19
LEGEND 11. Center Saddle Block Bushing 19. Front Swing Shaft Bearings
01. Boom Point Sheave 12. Inner Saddle Block Bushing 20. Rear Swing Shaft Bearing
02. Transducer, Boom 13. Inner Shipper Shaft Bushing 21. Hoist Drum Sidestand Bearing
03. Shipper Shaft Outer Bushing 14. Outer Shipper Shaft Bushing 22. R.H. Boom Foot Pin
04. Shipper Shaft Inner Bushing 15. Transducer, Machinery House 23. L.H. Boom Foot Pin
05. Inner Saddle Block Bushing 16. Center Gudgeon Bushing 24. Center Gudgeon Thrust
06. Center Saddle Block Bushing (Lower) Washer
07. Outer Saddle Block Bushing 17. Center Gudgeon Bushing COLOR CODE
08. Transducer, Crowd Gear Case (Upper) 25. Low Pressure Lube
09. Transducer, Crowd Gear Case 18. Center Gudgeon Spherical 26. High Pressure Lube
10. Outer Saddle Block Bushing Washer 27. Air Pressure
28. Lube Suction
Figure 18-6: Grease Pump Upper Zone

18.2.2.2 Grease Lower Zone
Refer to Figure 18-7 on the next page. At the beginning of the cycle, the grease pump zone control valve opens.
This allows lube to flow from the pump to the lower zone, but prevents lube from flowing to the upper zone.
The grease lower zone has four groups of injectors. The two groups numbered 02 are located near the front idler
on the inside of each of the side frames. There are two groups of large injectors numbered 03 - 13 and 14 - 24 that
supply the rest of the propel components. One of these is located on the inside of each side frame near the propel
transmission. There is one transducer in this zone, located on the left rear of the carbody.

03 04 05 06 07 08 09 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24
02
02
01
25
26
27
28
LEGEND 11. Lower Roller Bushing 21. Lower Roller Bushing

01. Transducer, Lower 12. Lower Roller Bushing 22. Lower Roller Bushing
02. Front Idler Bushings 13. Inboard Final Drive Shaft 23. Lower Roller Bushing
03. Rear Idler Bushing Thrust Washer 24. Inboard Final Drive Shaft
04. Outboard Final Drive Shaft 14. Rear Idler Bushing Thrust Washer
Bearing 15. Outboard Final Drive Shaft COLOR CODE
05. Lower Roller Bushing Bearing 25. Low Pressure Lube
06. Lower Roller Bushing 16. Lower Roller Bushing 26. High Pressure Lube
07. Lower Roller Bushing 17. Lower Roller Bushing 27. Air Pressure
08. Lower Roller Bushing 18. Lower Roller Bushing 28. Lube Suction
09. Lower Roller Bushing 19. Lower Roller Bushing
10. Lower Roller Bushing 20. Lower Roller Bushing
Figure 18-7: Grease Lower Zone

18.2.2.3 Open Gear Lube Upper Zone
Refer to Figure 18-8 on the next page. At the beginning of the cycle, the open gear lube pump zone control valve
opens. This allows lube to flow from the pump to the upper zone, but prevents lube from flowing to the lower zone.
The open gear lube upper zone supplies open gear lube to drip lines for the dipper handles and the mesh between
the shipper shaft pinions and the dipper handle rack. The injectors numbered 01 - 09 are located on the saddle
blocks. There is one transducer in this zone, located on the lower right of the boom.

05 06
04 07
03 08
02 09
01 01
01 01
10
11 ES02772a01
12
13
14
LEGEND 08. Top Slide Plate & Handle

01. Rack and Pinion Drip Lines 09. Vertical Slide Plate & Handle
02. Vertical Slide Plate & Handle 10. Transducer (Located on Boom)
03. Top Slide Plate & Handle COLOR CODE
04. Top Slide Plate & Handle 11. Low Pressure Lube
05. Top Slide Plate & Handle 12. High Pressure Lube
06. Top Slide Plate & Handle 13. Air Pressure
07. Top Slide Plate & Handle 14. Lube Suction
Figure 18-8: Open Gear Lube Upper Zone

18.2.2.4 Open Gear Lube Lower Zone
Refer to Figure 18-9 on the next page. At the beginning of the cycle, the open gear lube pump zone control valve
opens. This allows lube to flow from the pump to the lower zone, but prevents lube from flowing to the upper zone.
The open gear lube lower zone supplies open gear lube and air to spray valves. Four groups of injectors numbered
01 - 02 are located on the under side of the revolving frame and supply lube to the swing gear and roller circle. Air
lines also supply air to each spray valve. These injectors are the lower open gear zone. There is one transducer in
this zone, located on the under side of the revolving frame.

ES02773a01
" # $ %

!

LEGEND COLOR CODE
01. Roller Circle Spray Valves 04. Low Pressure Lube
02. Ring Gear Spray Valves 05. High Pressure Lube
03. Transducer (located under 06. Air Pressure
revolving Frame) 07. Lube Suction
Figure 18-9: Four Zone Lincoln System Swing Open Gear Zone Schematic

18.3 Component Operation
18.3.1 Lube Room I/O Cabinet
ES05056a01
01 02 03 04 05 06
LEGEND
01. Upper Grease System 04. Lower Open Gear
02. Lower Grease System 05. Alarm Silence
03. Upper Open Gear 06. Alarm Horn
Figure 18-10: Lube Room I/O Cabinet
A cabinet on the lube room wall provides input and output capability between the lube system control components
and the Centurion Control System. On the front panel of the cabinet are lighted push buttons that have several
functions, as follows:
• When power is applied to the cabinet, the lamps go through a lamp test sequence.
• When any lube system is functioning, the light in its push button illuminates.
• When any lube system registers a fault, the light in its push button flashes, the light in the ALARM SILENCE
push button flashes, and the alarm horn sounds.
• Pushing a system push button initiates a lube cycle. If the system is in a fault condition, pushing the system
push button also resets the fault.
• Pushing the ALARM SILENCE push button turns off the alarm horn, but does not reset the fault. The light in
the ALARM SILENCE push button will continue to flash until the fault is reset by pushing the system push
button.

18.3.2 Centurion Control System
Figure 18-11: Control Cabinet With Centurion Control System and Touch Panel
The Centurion Control System is programmed to energize the air valves at the appropriate time. Adjustable timers
in the Centurion Control System program set the intervals for opening the air valves. The Centurion Control Sys-
tem also receives an input signal from the system transducers when building system pressure signals the end of a
pump cycle. The Centurion Control System will then de-energize the air valve. The Centurion Control System will
also set system faults
Figure 18-11shows a typical control cabinet. The Centurion Control System is also located in the control cabinet.
The Centurion Control System program carries the programmed instructions that control the automatic lubrication
system components. Automatic lubrication components are connected to the Centurion Control System inputs or
outputs. The touch panels located in the control cabinet and in the operator’s cab can be used to monitor the status
of the inputs and outputs.

18.3.3 Touch Panel
Figure 18-12: Operations - Main Screen
The Operations Main screen is the screen that will normally be displayed during shovel digging operations. Icons
with white backgrounds are not active; icons with amber backgrounds are active.
Lubrication System icons are at the top of the screen. Pushing any of the lube icon buttons will initiate a lubrication
cycle in that system.
The controls and indications associated with the automatic lubrication system are described in Table 18-1.

Screen Control Description
Lube System Status/Diagnostics - Not Active

This push button/indicator informs the operator that the screen
being viewed is not for Lube System diagnostics. Pushing this
button will open the Lube System Status Screen screen.
Lube System Status / Diagnostics - Active

being viewed is for Lube system information.
Lube Time - Not Active

being viewed is not for Lube Cycle setup. Pushing this button
will open the Lube Time screen.
Lube Time - Active

being viewed is for setting up the lube cycle timers.
Upper Lube - Not Active

This indication informs the operator that the Upper Lube system
is not in operation (automatically or manually). Pushing this
button will initiate an Upper Lube System cycle.
Upper Lube - Active

This indication informs the operator that the Upper Lube system
is in operation (automatically or manually).
Upper Lube Fault

This indication alerts the operator that there is a fault associ-
ated with the Upper Lube system. Pushing this button will reset
the fault and initiate an Upper Lube cycle.
Lower Lube Not Active

This indication informs the operator that the Lower Lube system
button will initiate a Lower Lube System cycle.
Lower Lube Active

This indication informs the operator that the Lower Lube system
Table 18-1: Automatic Lubrication System Controls and Indications

Screen Control Description
Lower Lube Fault

ated with the Lower Lube system. Pushing this button will reset
the fault and initiate a Lower Lube cycle.
Open Gear Not Active

This indication informs the operator that the Open Gear system
button will activate an Open Gear lubrication cycle.
Open Gear Active

This indication informs the operator that the Open Gear system
Open Gear Fault

ated with the Open Gear system. Pushing this button will reset
the fault and initiate a Open Gear Lube cycle.
Propel Lube Not Active

This indication informs the operator that the Propel Lube system
button will initiate a Propel Lube cycle.
Propel Lube Active

This indication informs the operator that the Propel Lube system
is in operation (automatically or manually)
Propel Lube Fault

ated with the Propel Lube system. Pushing this button will reset
the fault and initiate a Propel Lube cycle.
Table 18-1: Automatic Lubrication System Controls and Indications

18.3.3.1 Lube System Status Screen
Figure 18-13: Operations - Shovel Lube System Status Screen
The Lube Screen provides a visual representation of the lubes levels of the shovel and of which lube zone is active.
Lubrication System icons are near the top of the screen. Pushing any of the lube icon buttons will initiate a lubrica-
tion cycle in that system, which will also reset the interval timer to 0.

18.3.3.2 Setup - Lube Cycle Setup Screen
Figure 18-14: Setup - Lube Cycle Setup Screen
The Lube Cycle Setup screen provides the operator with the ability to set the automatic lube cycles for the follow-
ing zones:
• Upper Lube (10 - 30 minute time limit)
• Open Gear Lube (10 - 30 minute time limit)
• Lower Lube (10 - 30 minute time limit)
• Propel Lube (3 - 6 minute time limit)
Air Supply and Air Regulator
The air pressure required to run the air-driven pumps comes from the shovel’s air system. The regulator is used to
adjust the pressure for the lube pumps to 60-80 PSI. A second air regulator is shown on the open gear system
block diagram. This is to regulate the pressure of the spray valves. Refer to Subtopic 15.2.12 for more information.
18.3.4 Air Valves
A bank of solenoid valves is located near the pumps in the lube room. There is one air valve to supply each of the
pumps, and a valve to supply the spray valves. Refer to Subtopic 15.2.12 for more information.

18.3.5 Lubrication Tanks
02
02
03
04
01
05
05
ES05052a01
06
LEGEND
01. Grease Tank 04. Open Gear Lube Tank
02. Sensor Tube 05. Pump Hole
03. Tiedown Ring 06. Tank Cover Panel
Figure 18-15: Lubrication Tanks
Figure 18-15 shows the lube tanks. The 620-gallon (2347-liter) tank (Item 01) holds multipurpose grease, while the
415-gallon (1571-liter) tank (Item 04) holds open gear lubricant. (If multiple service (MS) lubricant is used, both
tanks could contain MS. Refer to Section 16.) Each tank has two holes (Item 05) in the top cover that can be used
to insert lube pumps. Because this shovel uses a four zone system, there will be one pump in each tank. A spare
pump assembly may be stored in the remaining holes. Each tank is equipped with a breather assembly and a level
sensor (not shown).

18.3.5.1 Lube Level Sensor R54757D3
Figure 18-16: Lube Level Sensor
The lube level sensor (Figure 18-16) is an ultrasonic transducer mounted atop the sensor tube (Item 02, Figure 18-
15) on the upper portion of the lube tank. Its output is fed to the Centurion Control System, and can be monitored
on the touch panels located in the control cabinet or the operator’s coop. Refer to system schematics.
A Lube Tank Low Fault will be activated if the lube tank level drops too low.
18.3.5.3 Principle of Operation
An ultrasonic wave is pulse-transmitted from the base of the unit two times per second. The sound wave is
reflected from the surface of the lubricant in the tank and is received by the transducer. An internal microprocessor
measures the time of flight of the ultrasonic wave, i.e. between the time of transmission to the time of receipt, and
translates this time into a distance from the base of the transducer to the top of the lubricant level. The program-
ming procedures below will set up the transducer for the application. Level displays on the touch panel screen and
level alarm functions are contained in the Centurion Control System logic.
18.3.5.4 Breather
Figure 18-17: Lubrication Tank Breather
Each tank is provided with a breather to compensate for volume and temperature variations. The breather is
equipped with a spin-on filter with a visual indicator.

18.3.5.5 Flow Control Valve
Figure 18-18: Pump Flow Control Valve
An adjustable valve that allows the air flow to the pump to be adjusted is provided to adjust pump speed.
18.3.5.6 Air Motor and Pump R54687D1
Figure 18-19: Air Motor and Lubrication Pump
When air pressure is supplied to the air motor, the air motor drives the pump, which draws lubricant out of the tank
and pumps it to the lubrication panel. The lube is then routed to the rest of the system.

The pump has a 75:1 lubricant-to-air stall ratio.This means that 1 PSI of air pressure input to the pump should pro-
duce 75 PSI lube pressure output from the pump. It is important that the air pressure regulator for the pump supply
air pressure is not turned too low, or the pump will stall before the system develops the pressure necessary to end
the cycle.

18.3.6 Lubrication Panel R54840F3
11
10
12
09 13
14
08
07
06
05 15
04 16
03 17
18
02
19
01
20
21
24 23 22
LEGEND
01. From Grease Pump 13. Grease Header Manifold
Grease Flow
02. From Open Gear Lube (OGL) Pump 14. OGL Header Manifold
03. Grease Header Manifold 15. OGL To Boom
Open Gear Lube Flow
04. Grease System Accumulator 16. Grease To Revolving Frame
05. OGL Pressure Gauge 17. OGL Header Manifold
06. OGL Header Manifold 18. OGL to Lower
07. OGL System Accumulator 19. Grease Header Manifold
08. Grease Pressure Relief Valve 20. Grease to Lower
09. OGL Pressure Relief Valve 21. OGL Upper Zone Valve
10. OGL Vent Valve 22. OGL Lower Zone Valve
11. Grease Vent Valve 23. Grease Lower Zone Valve
12. Grease To Boom 24. Grease Upper Zone Valve
Figure 18-20: Lubrication Panel

18.3.6.1 General
The Lincoln Four Zone system uses two pumps to deliver lubricant to four zones. The controls for the four zones
are mounted on the Lubrication Control Panel. Both lubricant systems – Grease and Open Gear Lubricant (OGL) –
operate identically. The grease system will be discussed here; the OGL system works the same way. Refer to Fig-
ure 18-20.
18.3.6.2 Header Manifold R532540D2
Grease initially enters the panel at the header manifold (Item 03). Connected to the header manifold are the pres-
sure gauge (Item 02), the accumulator (Item 04), and the pressure relief valve (Item 09).
18.3.6.3 Accumulator R52405D1
The accumulator holds a small amount of grease under pressure (minimum 1300 PSI (89.63 bar)) to ensure
grease flow to the zone control valve as soon as the valve opens.
18.3.6.4 Pressure Relief Valve R54835D1
! CAUTION
If the system pressure rises beyond the rated capacity of the system components, a
component will fail and release pressure. This failure could produce a combination of
flying debris from the components and/or lubricant being expelled at high pressure,
which could cause injury to personnel.
If the system builds pressure in excess of 3000 PSI (206.8 bar), the pressure relief valve (item 02) will open and
relieve the lubricant supply line. The output of the pressure relief valve will allow lubricant passing through the
valve to return to the tank.
NOTICE
Only a replacement valve corresponding to the part number listed in the LinkOne electronic
parts manual provides the necessary relief pressure for the circuit and its components. Always
refer to the LinkOne electronic parts manual when replacing the relief valve.
18.3.6.5 Zone Control Valve R56032D1
The header manifold divides the grease into two lines, one line to each of the two zone control valves (items 23
and 24). Zone control valves are normally closed solenoid valves controlled by an output from the Centurion Con-
trol System. As each lubrication cycle begins, one of the two valves will open, permitting the grease to flow to the
appropriate delivery lines (either to the upper grease components or the lower grease components). The other
zone control valve will remain closed.
18.3.6.6 Electric Vent Valve R56032D1
The vent valve (Item 11) is a normally closed solenoid valve. The valve is de-energized when the pump is running
and it remains closed until the end of the lube cycle. When the air supply to the lubrication pump is shut off, the
vent valve is energized and opens. When the vent valve opens the pressure vents back to the tank. The vent valve

is located on the upper lubrication panel in the lube room. When all transducers in the lube system report pressures
less than 500 PSI (34.47 bar), the solenoid de-energizes and the vent valve closes.
18.3.6.7 Lube Injectors
Figure 18-21: SL-V Injectors
Lubricant injectors are mounted in varying quantities on manifolds, located in groups positioned around the mining
shovel. Each injector delivers a measured amount of lubricant to the lubrication point. Three styles of injectors are
used: SL-1, SL-11, and SL-V. The injectors all operate the same way, and they have dual outlets, allowing them to
be cross-ported to deliver increased amounts of lubricant to the lube point.

The Lincoln injectors are pressure operated and spring reset. Spring loaded valves measure the amount of lubri-
cant for each lube point during each cycle. Pressure from the pump pushes the lubricant into the injector, which
contains a measured amount of lube from the previous cycle. As the lube pressure builds and overcomes the
spring(s) in the injector, the measured grease is pushed out the exit line to the lube point. At the end of the cycle
the pressure is vented back to the tank through a vent valve, which allows the spring to return. The injector
recharges itself as pressure in the system drops below 600 PSI (41.37 bar) and the spring returns the injector pis-
ton to its normal position. A more detailed description follows:
LEGEND
01. Lubricant Supply
02. Passage
03. Measuring Chamber
04. Injector Piston
05. Discharge Chamber
06. Slide Valve
Pump Pressure
Figure 18-22: Injector Operation - Position 1
Refer to Figure 18-22.When the lubrication cycle starts, pressure from lubricant entering the injector (01) forces the
slide valve (06) off its seat and allows lubricant to enter the passage (02) leading to the measuring chamber (03).

LEGEND
02. Passage
03. Spring
05. Injection Piston
06. Outlet Port
07. Slide Valve
Pump Pressure
Figure 18-23: SL-1 and SL-11 Operation - Position 2
Refer to Figure 18-23. After the slide valve (07) opens, lubricant (01) is directed through the side passage (02) into
the measuring chamber (04) above the injector piston (05). As lubricant and pressure continue to enter the mea-
suring chamber, he injector piston is pushed down against spring (03) pressure, forcing lubricant from the dis-
charge chamber, through the outlet port (06) to the lube point.

LEGEND
02. Passage
04. Injector Piston
05. Slide Valve
Discharge Pressure
Refer to Figure 18-24. As the injector piston continues to move downward, it contacts the slide valve and forces it
downward against the pressure of the incoming lubricant. As the slide valve moves downward, the slide valve
blocks the passage to the measuring chamber.
The slide valve can no longer move downward against incoming lubricant pressure, and the injector piston cannot
move upward against the captured lubricant. The injector piston remains in this position until incoming pressure is
reduced below the pressure exerted by the spring. This happens only after all the injectors have finished the first
half of their cycle, the pressure transducers report a rise in system pressure, and the Centurion Control System
causes the air valve solenoid to de-energize to stop the pump.

LEGEND
02. Passage
03. Spring
05. Injector Piston
05. Slide Valve Port
06. Slide Valve
Refer to Figure 18-25. After all the injectors have cycled, movement of pistons and slide valves within the system
stops. As the pump continues to pump, pressure builds up until the pressure in the system reaches the designated
pressure. The Centurion Control System then de-energizes the air valve solenoid, stopping the lubrication pumps.
At the same time, the vent valve opens, venting the supply line pressure back to the reservoir.
Once the venting allows the pressure in the supply line to drop below the pressure of the injector spring (600PSI
(41.37 bar)), the spring in the injector begins to expand. When the slide valve returns to its seat, a port opens
between the measuring chamber and the delivery chamber. The spring continues to expand, forcing the injector
piston upward and forcing the lubricant in the measuring chamber to move through the side passage and into the
delivery chamber. When the injector piston’s indicator stem contacts the adjustment nut, the injector piston stops.
The spring then continues to expand, forcing the slide valve back into its seat. The injector cycle is complete and
the injector is ready for the next cycle.

18.3.6.8 Pressure Transducers R43284D1
The R43284D1 transducer is an analog device using a 4-20mA signal with a pressure range of 0 to 5000 PSI (see
Figure 18-26).
01
05
04
LEGEND
01. Enclosure
02. Transducer
02 03. Adapter
04. Terminal Block
05. Terminal Anchor
03
COVER REMOVED TO SHOW INSIDE
ES02460a01
Figure 18-26: Pressure Transducer (R43284D1)
After the injectors have all cycled, the lube has nowhere to flow. With no flow, the pump output will build up system
pressure. Pressure transducers in each zone monitor pressure. All transducers in a lube zone must reach the des-
ignated pressure before the cycle is stopped. This is done to prevent a pressure drop in one area of the zone.
When the cycle stops, the transducers continue to provide pressure data to the Centurion Control System, which
requires that input to control the vent valve.
The number and location of the transducers in the zones are as follows:
• The upper grease zone has four transducers:
• One in the machinery house on the outer lube room wall.
• Two on the crowd gear case, one om each side of the shipper shaft/saddle block assembly).
• One on the upper middle part of the boom.
• The lower grease zone has one transducer, located on the left rear of the carbody.

• The upper open gear zone has one transducer located on the lower right of the boom.
• The lower open gear zone has one transducer located on the underside of the revolving frame near the
swing gear.
The pressure transducer(s) monitor lubrication supply line pressure. After all of the injectors in that zone have
cycled, pressure in the supply line builds until it reaches the Centurion Control System’s preset pressure setting.
The pressure transducer(s) signal the Centurion Control System to de-energize the solenoid air valve. This will
cause the lubrication pump to stop and the lube zone to vent pressurized lubricant back into the reservoir.
If the lubrication zone has more than one transducer, they must all report the designated pressure before the cycle
is ended. If any one transducer in the zone fails to report the designated pressure (2400 PSI 165.5 bar)) before the
end of the fault timer dimension, that lube zone will produce a lube fault. The fault timer dimension is 3 minutes and
20 seconds.
The Lincoln system will also monitor the system pressure as it vents after a pumping cycle. The pressure must vent
back into the tank in order for the next cycle to operate the injectors. If the pressure does not vent, the injectors will
not be able to recharge. Each transducer in a zone must report pressure below 300 PSI within 3 minutes and 20
seconds. If there is over 300 PSI at any of the zone’s transducers after this interval, the lube system will fault.
18.4 Maintenance
18.4.1 Part Numbers
NOTICE

to be lowered.
! WARNING
18.4.3 General
Some basic inspection and adjustment procedures for the automatic lubrication system as a whole apply:
18.4.3.1 System Inspection
Inspect the automatic lubrication system every 1,000 hours making the following checks:
• Check the condition of lubricant supply piping, hoses and fittings. Tighten or replace as necessary.
• Check the condition of lubrication piping guards.
• Check the condition of lubrication components, hoses and piping mounting for security.
• Check all injectors for proper operation/movement.

• Check spray valves for proper operation and proper spray pattern on the component being lubricated.
• Service the lubricant filter located near each pump.
• Check pressure transducer operation by manually running a cycle for each system.
• Check for expelled lubricant and examine for viscosity, color, and impurities, possibly indicating lubricant
contaminated with air, etc. Check for excess wear or component damage, which could indicate lack of lubri-
cation or improper lubrication.
• Check amount of lubricant at each lube point. An unusually large amount of lubricant at one lube point could
indicate a bypassing injector.
Check supply lines between injectors and their lube points. Any leaks must be repaired.
18.4.3.2 Startup
When returning the mining shovel to operation after the shovel has been idle for an extended period, or after sys-
tem-wide inspections or repairs to the system have been accomplished, use the following procedures to ensure the
automatic lubrication system is functioning properly:
1. Check the adjustment intervals on the Centurion Control System to ensure that they are set properly. Adjust as
necessary.
2. Check the air pressure adjustments on the air manifold assembly. This adjusts pressure to all the lubrication
system air solenoid valves.
3. Manually cycle the individual lubrication systems using the push-buttons on the control panel and check the fol-
lowing for proper operation:
A. Observe the pressure gauges on the lube system (the Farval system has two pressure gauges on each
reversing valve) to verify proper adjustment. Normal adjustment is 2,250 PSI (155 bar). Check Farval
reversing valves twice, once for each supply line.
B. Observe injectors or measuring valves for proper operation. Check injector indicators for complete motion.
Lincoln injector indicators lower when the injector discharges lubricant, and raise to reset. On Farval mea-
suring valves, all the indicators move in only one direction and remain there after the reversing valve
switches. The Farval systems should be cycled twice to make sure valves function correctly when each sup-
ply line is pressurized.
18.4.3.3 Lubrication System Settings
NOTICE
The system set points in Table 18-2 are general recommendations. All these set points are
adjustable. Local conditions must be taken in to account when making adjustments. Weather,
type of lubricant, and other special circumstances will often dictate a need to fine tune or modify
these set points.
System Adjustment Location of Adjustment Recommended Set

Point
Table 18-2: Recommended Lubrication System Settings

Pump Air Pressure Air Regulator on Air Manifold Assembly 60-80 PSI
(see Subtopic 15.2.8)
Air Spray Pressure Air Regulator on Air Manifold Assembly 40 to 60 PSI range
(see Subtopic 15.2.8)
Pump Speed/ Length of Cycle Flow Control Valve on Lube Air Control Blue Band to Green
Panel (see Subtopic 15.2.8) Band on Valve Stem
Cycle Timer - Upper Zone Lube Cycle Times touch screen, control 15 minutes
cabinet touch panel (see Subtopic Maximum 30 minutes
18.3.3)
Minimum 2 minutes
Cycle Timers - Lower Zone Lube Cycle Times touch screen, control 25 minutes
18.3.3)
Minimum 2 minutes
Cycle Timers - Open Gear Zone(s) Lube Cycle Times touch screen, control 15 minutes
See Note 2 cabinet touch panel (see Subtopic Maximum 25 minutes
18.3.3)
Minimum 10 minutes
Cycle Timer - Propel Lube Cycle Times touch screen, control 2 minutes
18.3.3)
Minimum .5 minutes
Note:
1. The pressure setting for the Lincoln system is programmed into the Centurion Control System. There is
no physical adjustment required.
Table 18-2: Recommended Lubrication System Settings
18.4.4 Electrical and Electronic Components
The Centurion Control System controls the automatic lubrication system. Certain functions in the lubrication sys-
tem are available to operators and maintainers through the touch panels or other interface devices, and those func-
tions are discussed in this section. Other functions require different permissions and are not discussed here. For
any procedure not discussed in this section, consult with qualified and authorized electrical maintenance personnel
at the mine, or with your local P&H MinePro Services representative.
18.4.5 Air System Components
Air system components provide power for operation of the pumps. For detailed descriptions of maintenance proce-
dures regarding air pressure regulators, solenoid valves and other air system components, refer to Section 15.

18.4.6 Lubrication Tanks
02
02
03
04
01
05
05
ES05052a01
06
LEGEND
01. Grease Tank 04. Open Gear Lube Tank
02. Sensor Tube 05. Pump Hole
03. Tiedown Ring 06. Tank Cover Panel
Figure 18-28: Lubrication Tanks
18.4.6.1 Inspection
Check lubricant level every shift by observing the indicator on the Graphical User Interface panel at the operator’s
station.

During Preventive Maintenance inspections, check the filter assembly indicators mounted on the tank (refer to Fig-
ure 18-29). The upper assembly, consisting of four filters, is for the open gear lube tank. The lower assembly is for
the grease tank. There is a visual indicator for each pair of filters. Service the filters as required.
ES05060a01
Figure 18-29: Lubrication Tank Filter Assemblies

Fill the lube tank as necessary. The grease tank holds 620 gallons (2347-liter); the open gear lube tank holds 415
gallon (1571-liter) Refer to Section 16 for lubricant specifications.
01 02
03 04
ES05061ao1
LEGEND
01. Grease Quick Fill Fitting 03. Grease Tank
02. Open Gear Lube Quick Fill Pipe 04. Open Gear Lube Tank
Figure 18-30: Quick Fill Fittings
Quick Fill fittings for the grease and open gear lube tanks are located outside the lube room on the forward wall of
the shovel. Refer to Figure 18-30.

18.4.7 Lube Tank Breathers
Figure 18-31: Lubrication Tank Breather
18.4.7.1 Inspection
During Preventive Maintenance inspections, observe the visual indicator in the breather filter assemblies. Service
the breather when the indicator shows in the red area.
18.4.8 Flow Control Valve
Figure 18-32: Pump Flow Control Valve
18.4.8.1 Adjustment
The flow control valve attached to each pump is used to control pump speed. Slow pump operation, particularly
when the outside ambient temperature is low, helps to assure an even distribution of pressure throughout the sys-
tem.
Turning the adjustment knob clockwise slows the pump. Adjust pump speed so that each pump stroke takes about
one second.

18.4.9 Air Motor and Pump R54687D1
Figure 18-33: Air Motor and Lubrication Pump (typical)
The pump and motor assembly is bolted to a flange on the pumping tube. To replace the pump and motor assem-
bly, unbolt the studs from the flange and install the new pump on the flange.
18.4.10 Injectors
During Preventive Maintenance Inspections, check the injectors for leaks or damage. Check lubrication points for
excessive lubricant, which could indicate a bypassing injector. Check for insufficient lubricant, which could indicate
a leaking or disconnected lube line.

18.4.10.2 Adjustment
To adjust the lubrication injectors, refer to Figure 18-34 or Figure 18-35 and proceed as follows:
LEGEND
01. Output Adjusting Screw
02. Indicator Stem
03. Increase Output
04 Decrease Output
05. Manual Fitting
06. Female Outlet
07. Manifold
Figure 18-34: SL-1 Injector Adjustment
LEGEND
01. Decrease Output
02. Increase Output
03. Indicator Stem
04. Output Adjusting Screw
05. Locknut
06. Female Outlet
Figure 18-35: SL-11 Injector Adjustment

NOTICE
In addition to lubricating the various components in the lubrication system, the lubricant sup-
plied to the lube point flushes dirt and other impurities from the lube point (component). Reduc-
ing the amount of lubricant to the lube point can result in excessive wear and premature
component failure. Contact your P&H MinePro Services representative before changing (espe-
cially before reducing) the amount of lubricant being supplied to the lube point.
1. Loosen the output adjusting screw locknut.
2. Adjust the injector to deliver the desired amount of lubricant to the lube point. Refer to Table 18-3 and turn the
output adjustment screw outward (counterclockwise) to increase the amount of lubricant to the lube point, or
turn the output adjustment screw inward (clockwise) to decrease the amount of lubricant delivered to the lube
point.
Injector Adjustment Max. Vent Operating Pressure

Range Pressure
(Cubic Inches) Minimum Maximum
SL-1 0.008-0.08 300 PSI 1,850 3,000*
SL-11 0.050-0.5 600 PSI 1,850 3,000*
SL-V XL .015-0.305 1000 PSI 1,850 3,000*
* Do not exceed 3,000 PSI (207 bar). Published maximum pressures for the injec-
tors may be higher; however,lube piping will not permit higher pressures.
Table 18-3: Injector Adjustments
3. Tighten the output adjusting screw locknut to lock the adjusting screw in place.

18.4.10.3 SL-1and SL-V XL Removal
To remove an SL-1 or SL-V XL type injector, refer to Figure 18-36 and proceed as follows:
LEGEND
01. Feeder Lines
02. Manifold
03. Adapter Bolt
Figure 18-36: SL-1 Injector Removal/Installation
1. Position the mining shovel so that it is on level ground.
2. Place the dipper so it is resting on the ground.
! WARNING
Accidental shovel movement during service procedures can result in serious personal
injury or death. Always park the shovel on level ground, place the dipper on the ground,
set all brakes, and use lockout and tagout procedures to prevent accidental shovel start-
up and/or motion.
3. Use lockout and tagout procedures to prevent accidental shovel movement and to shut down the mining
shovel.
! WARNING
sonal injury. Use extreme caution when working around lubrication systems and wear
appropriate face and body protection. Shut down and depressurize the system and fol-
low lockout and tagout procedures for disassembly or assembly of the lubrication sys-
shutdown periods. Get medical aid immediately if lubricant sprays into the eyes or pene-
trates into the skin.
4. Remove the feeder line from the injector which is being removed.

5. Loosen and remove the adapter bolt.
6. Remove the injector and gasket from the injector manifold. Discard the gasket.
18.4.10.4 SL-1 and SL-V XL Disassembly
To disassemble an SL-1 or SL-V XL type injector, refer to Figure 18-37 and proceed as follows:
LEGEND
01. Adjusting Nut
02. Locking Nut
03. Piston Stop Plug
04. Gasket
05. Packing
06. O-Ring
07. Fitting Assembly
08. Slide Valve
09. Washer
10. Adapter Gasket
11. Adapter Bolt
12. Gasket
13. Manifold
14. Packing
15. Inlet Disc
16. Packing
17. Spring Seat
18. Injector Spring
19. Injector Piston
20. Injector Body
21. Washer
Figure 18-37: SL-1 Injector Disassembly/Assembly
1. Loosen locknut (02).
2. Loosen and remove adjusting nut (01) with locknut (02).
3. Loosen and remove piston stop plug (03) with packing (05) and washer (21).
4. Remove packing (05) and washer (21) from piston stop plug (03). Discard the packing.
5. Remove injector piston assembly (19) with o-ring (06). Remove the o-ring and discard.
6. Remove injector spring (18).
7. Remove spring seat (17) through the top of the injector body.
8. Remove washer (09), packing (14), inlet disc (15) packing (16) and slide valve (08) through the bottom of the
injector.
18.4.10.5 SL-1 and SL-V XL Repair
Repair of SL-1 or SL-V XL injector is limited to replacing worn or defective parts. Whenever an SL-1 or SL-V XL
injector is disassembled, all gaskets, o-rings, and packings should be replaced.

18.4.10.6 SL-1 and SL-V XL Assembly
To assemble an SL-1 or SL-V XL type injector, refer to Figure 18-37 and proceed as follows:
1. Install spring seat (17) in injector body (20) with the flat side of the seat flat against the bottom of the cylinder in
the injector body.
2. Place injector spring (18) into the cylinder bore in the injector body.
3. Lubricate a new o-ring (06) with a light coating of grease and install in the groove of injector (19).
4. Place piston assembly (19) with installed o-ring (06) into the cylinder bore of the injector body. Make sure that
the tapered portion on the piston assembly is pointed toward the top of the injector body
5. Place washer (21) and new packing (05) into the bore at the bottom of piston stop plug (03).
6. Place piston stop plug over injector piston (19) onto the injector body. Torque to 25-30 ft-lbs (33.9-40.7 N·m)
7. Install lock nut (02) onto adjusting nut (01). Install adjusting nut (01) over injector (19) into the threaded bore in
piston stop plug (03).
8. Install new packing (16) into the bore inside the bottom of the injector body.
9. Place slide valve (08) into the bore of packing (16).
10. Place inlet disc (15) in the bore at the bottom of the injector.
11. Place new packing (14) in the bore at the bottom of the injector.
18.4.10.7 SL-1and SL-V XL Installation
To install an SL-1 or SL-V XL type injector, refer to Figure 18-36 and proceed as follows:
1. Place the injector at the top of the manifold.
2. Install new gasket on the adapter bolt.
3. Install adapter bolt through the bottom of the manifold and thread into the bottom of the injector. Tighten the
adapter bolt to 45-50 ft-lbs (61-68 N·m).
4. Install the feeder line into the injector body.
5. Bleed the air from the affected system as follows:
A. Using lockout and tagout procedures, start up the mining shovel. Use the lockout and tagout procedures to
prevent anyone from operating the mining shovel while performing bleeding procedures.
B. Adjust the air flow control valve to reduce air pressure to the lubrication pump. Adjust the air flow as follows:
1). Press the manual lube button on the lube panel to initiate a lube cycle for the lubrication system being
bled.
2). Close the air flow control valve. Record the number of turns it takes to close the valve.

3). Open the valve so that the lube pump runs slowly.
LEGEND
01. Tee
02. Plug
Figure 18-38: Bleeding Air - Fittings
C. If there are fittings that could trap air, such as in Figure 18-38, start with the fitting closest to the lube pump,
removing each plug in order, and run the lube pump until lubricant flow is free of air or foreign matter. Install
and tighten the plug and move on to the next fitting.
LEGEND
01. Plug
02. Manifold
Figure 18-39: Bleeding Air - Manifolds
D. Remove the plug(s) at the injector (refer to Figure 18-39). Use a drain pan to collect the lubricant discharged
during the bleeding process.
E. Run the lubrication pump until lubricant flow is free of air or foreign matter.
F. Replace the plug or tighten the fitting.

LEGEND
01. Injector
02. Filler Fittings
03. Cap
04. Grease Gun Nozzle
05. Feeder Line to Lube Point
Figure 18-40: Bleeding Air From Feeder Lines
G. Disconnect the feeder line at the lube point.
H. Remove the cap from the filler fitting on the injector.
I. Using a grease gun, attach the nozzle and pump grease through the feeder line until clean grease, free of
dirt and contaminants, comes from the feeder line. Make sure the grease gun contains the same type of
grease used in the lubrication system.
J. Remove the grease gun, replace the cap on the filler fitting, and connect the feeder line at the lube point.
6. After all air is removed from the system, manually cycle the lubrication system and confirm proper operation.

18.4.10.8 SL-11 Removal
To remove and disassemble an SL-11 type injector, refer to Figure 18-41 and proceed as follows:
LEGEND
01. Adjusting Screw
02. Indicating Rod
03. Jam Nut
04. Bushing
05. O-Ring
06. Plunger Washer
07. Retainer
08. Piston
09. Stop Pin
10. Piston Retainer
11. Gasket
12. Injector Body
13. Spring
14. Spring Seat
15. Gasket
16. O-Ring
17. Plunger
18. Bushing
19. Fitting Assembly
20. Washer
21. Packing
22. Packing Retainer
Figure 18-41: SL-11 Injector Disassembly/Assembly
1. Position the mining shovel so that it is on level ground.
2. Place the dipper so it is resting on the ground.
! WARNING
Accidental shovel movement during service procedures can result in serious personal
injury or death. Always park the shovel on level ground, place the dipper on the ground,
set all brakes, and use lockout and tagout procedures to prevent accidental shovel start-
up and/or motion.
3. Use lockout and tagout procedures to prevent accidental shovel movement or to shut down the mining shovel.
! WARNING
sonal injury. Use extreme caution when working around lubrication systems and wear
appropriate face and body protection. Shut down and depressurize the system and fol-
low lockout and tagout procedures for disassembly or assembly of the lubrication sys-

shutdown periods. Get medical aid immediately if lubricant sprays into the eyes or pene-
trates into the skin.
4. Remove the feeder line from the injector which is to be removed.
5. Remove the injector from the pipe on which it is threaded.
18.4.10.9 SL-11 Disassembly
To disassemble an SL-11 type injector, refer to Figure 18-41 and proceed as follows:
1. Loosen jam nut (03).
2. Unthread adjusting nut (01) from bushing (04).
3. Loosen and remove bushing (04). When bushing (04) is removed from the injector body, piston parts including
items (2) and (7 thru 13) will be withdrawn with it.
4. Remove gasket (11).
5. Remove items (02) and (07 thru 13) from bushing (04).
6. Remove o-ring (05) from bushing (04) and discard.
7. Remove plunger washer (06), packing (21) and packing retainer (22) from bushing (04). Discard packing (21).
8. Remove washer (20) from piston retainer (10).
9. Remove piston retainer (10) from piston (08).
10. Remove retainer (07) and indicator rod (02) from piston (08). Slide retainer (07) from indicator rod (02).
11. Remove spring (13) and stop pin (09) from piston (08).
12. Unthread bushing (18) from the bottom of the injector body (12). Remove o-ring (16) from the bushing.
13. Remove spring seat (14) and plunger (17) from bushing (18). Unthread plunger (17) from spring seat (14).
14. Remove gasket (15) from the bushing. Discard the gasket.
18.4.10.10 SL-11 Repair
Repair of SL-11 injectors is limited to replacing worn or defective parts. Whenever an SL-11 injector is disassem-
bled, all gaskets, o-rings, and packings should be replaced.
18.4.10.11 SL-11 Assembly
To assemble an SL-11 injector, refer to Figure 18-41 and proceed as follows:
1. Thread plunger (17) into spring seat (14). Tighten firmly.
2. Lubricate o-ring (16) with a light coating of grease and install on bushing (18).

3. Place gasket (15) on bushing (18).
4. Lubricate plunger (17) with a light coating of grease and install in bushing (18).
5. Thread bushing (18) into the bottom of the injector body (12). Tighten to 150 ft-lbs (203.4 N·m).
6. Install new gasket (11) in the injector body.
7. Install spring (13) into the injector body.
8. Place stop pin (09) into the inside of spring (13).
9. Insert indicator rod (02) into retainer (07). Thread retainer into piston (08).
10. Place piston retainer (10) onto piston (08) with the tapered end of the piston retainer facing away from the indi-
cator rod.
11. Thread jam nut (03) on adjusting screw (01).
12. Thread adjusting screw (01) into bushing (04).
13. Install new o-ring (05) on bushing (04).
14. Install packing retainer (22), new packing (21), and plunger washer (06) into bushing (04).
15. Install indicator rod (02) into bushing (04).
16. Install bushing and assembled parts into the injector body. Make sure that spring (13) is properly seated inside
piston (08) and make sure that piston retainer (10) is seated on gasket (11) in the injector body. Tighten bush-
ing (04) to 150 ft-lbs (203.4 N·m).
18.4.10.12 SL-11 Installation
To install an SL-11 type injector, refer to Figure 18-41 and proceed as follows:
1. Thread the injector onto the pipe.
2. Install the feeder line into the injector body.
3. Bleed the air from the affected system as follows:
A. Using lockout and tagout procedures, start up the mining shovel. Use the lockout and tagout procedures to
prevent anyone from operating the mining shovel while performing bleeding procedures.
B. Adjust the air flow control valve to reduce air pressure to the lubrication pump. Adjust the air flow as follows:
1). Press the manual lube button on the lube panel to initiate a lube cycle for the lubrication system being
bled.
2). Close the air flow control valve. Record the number of turns it takes to close the valve.
3). Open the valve so that the lube pump runs slowly.

LEGEND
01. Tee
02. Plug
Figure 18-42: Bleeding Air - Fittings
C. If there are fittings that could trap air, such as in Figure 18-38, start with the fitting closest to the lube pump,
removing each plug in order, and run the lube pump until lubricant flow is free of air or foreign matter. Install
and tighten the plug and move on to the next fitting.
LEGEND
01. Plug
02. Manifold
Figure 18-43: Bleeding Air - Manifolds
D. Remove the plug(s) at the injector (refer to Figure 18-39). Use a drain pan to collect the lubricant discharged
during the bleeding process.
E. Run the lubrication pump until lubricant flow is free of air or foreign matter.
F. Replace the plug or tighten the fitting.

LEGEND
01. Injector
02. Filler Fittings
03. Cap
04. Grease Gun Nozzle
05. Feeder Line to Lube Point
Figure 18-44: Bleeding Air From Feeder Lines
G. Disconnect the feeder line at the lube point.
H. Remove the cap from the filler fitting on the injector.
I. Using a grease gun, attach the nozzle and pump grease through the feeder line until clean grease, free of
dirt and contaminants, comes from the feeder line. Make sure the grease gun contains the same type of
grease used in the lubrication system.
J. Remove the grease gun, replace the cap on the filler fitting, and connect the feeder line at the lube point.
4. After all air is removed from the system, manually cycle the lubrication system and confirm proper operation.
5. Install two mounting straps over injector to keep it from vibrating and breaking loose.
6. Start up the mining shovel using lockout and tagout procedures.
18.5 Troubleshooting
18.5.1 System Faults and Alarms
A lubrication fault turns on an audible alarm. Turn off the audible alarm by pressing the ALARM SILENCE push-
button on the control cabinet in the lube room. This enables troubleshooting without the alarm noise. The indicator
light on the RESET/MANUAL push-button for the zone that has faulted will flash, to indicate which zone has
faulted. When the fault is corrected, press the RESET/MANUAL push-button to clear the fault, initiate a manual
lube cycle, and enable the alarm.

If the pump runs a cycle and the actual problem has not been corrected, the fault will occur again and the alarm will
sound.
At the end of a normal lubrication cycle, the Centurion Control System de-energizes the solenoid and resets the
fault timer so it will start at 0 next cycle. If the pressure set point is not reached before the fault timer reaches its
setpoint, the fault timer will initiate the fault. A lube fault occurs to a zone when the pump is not able to produce the
pressure set point.
The fault dimension timer for a lube fault is typically set at 200 seconds (3 minutes and 20 seconds). This can not
be field adjusted at the touch panel. For more information on the system pressure settings in the system, see Table
18-2.
When a lube zone sets a fault, it does not immediately go into a shutdown mode. Because of the possibility of nui-
sance faults, a 15 minute timer has been programmed into the Centurion Control System program. If a lube zone
continues to fault for 15 minutes, it will initiate a 30 second delayed shutdown. This shut-down will shut the shovel
down, and it will have to be restarted after the fault is cleared. This fault could be produced either from a zone not
reaching the 2400 PSI pressure set point, or failing to vent the pressure back to the tank.
See Topic 18.5 for specific hydraulic troubleshooting information and causes of faults.
When a lube fault occurs to one of the four zones, the fault occurs for one of two reasons. The first reason would
be that the Centurion Control System did not receive a signal from the pressure transducers indicating that the sys-
tem reached the system pressure set point of 2400PSI within the fault timer dimension of 200 seconds. There are
a number of reasons why this may have occurred:
1. Empty tank. Check the tank and pump input. If the pump cannot draw lube from the tank, the system will not
build pressure. See Subtopic 18.3.5 for more information on the lube tanks.
2. Air pressure problems. Lack of air pressure, regulator set too low, flow control valve closed too much, etc. If the
pump is not supplied with the proper air pressure, the system will not build sufficient pressure. See Subtopic
18.3.6 for more information on the pump air supply.
3. Pump lost prime or not pumping. If the pump is not pumping correctly, the system will not build pressure. See
Subtopic 15.4.7 for more information on the lube pumps.
4. Zone control valve stuck closed. If the zone control valve blocks the lubricant from the pump, the injectors and
pressure transducer downstream will not receive pressure.
5. Vent valve stuck open. If the vent valve is stuck open and lube is venting back to the tank while the pump is
running, the system will not build pressure.
6. System leak. If a leak occurs anywhere in the green area of the schematics (high pressure), the lube will flow
through the leak instead of pressurizing the system and the system will not build pressure.
7. Bypassing injector. If an injector’s internal seals are leaking badly, the lube will bypass the piston and exit out to
the lube point. If the internal leak is severe enough, or if several injectors are bypassing, the system will not
build pressure. See Subtopic 18.4.10 for more information on injectors.
8. Pressure relief valve misadjusted or malfunctioning. The pressure relief valve should stay closed until the pres-
sure is greater then 3000 PSI. If the pressure relief valve allows lube to flow through at a lower pressure, it may
keep the system from building adequate pressure and cause a fault.
A lube fault may also occur because the pressure in the lube zone can not vent back to the tank properly at the end
of the cycle. At the end of the cycle the pump stops and the vent valve opens. The pressure should vent to the tank

and the transducers should monitor this pressure drop. If the pressure does not vent below the setpoint of 300 PSI
within 200 seconds of the end of the cycle, a fault will occur. There are a number of reasons why this may have
occurred:
1. The vent valve did not open. If the vent valve sticks closed the pressure will not vent back to the tank.
2. If the vent line back to the tank has a restriction, the pressure will not vent back to the tank. This could happen
in one of the lines between the injectors and the vent valve, in the line between the vent valve and the tank, or
in the elbow union or fitting where the line goes into the tank. The restriction could be caused by a pinched line
or lube contamination.
3. The check valve before the vent valve could have a restriction in it.
There can also be problems with the system which will not cause a fault to occur (these problems can only be
found with a visual inspection of the lube system and all the components, lines, and connections):
1. Stuck injector. If an injector does not cycle, the lube will not be output to the lube point. Because the system
pressure was still built up, the system will not set a fault. But the lube point from that injector will not get lube.
The injector can be checked by watching its indicator stem during a cycle. See Topic 18.4.10 for more informa-
tion on injectors. An injector can get stuck for several reasons:
A. Contamination in the injector may cause it to lock up.
B. The output line from the injector may be pinched or blocked.
C. The lube point may not be taking lube.
2. Broken line after the injector. If the (low pressure) line after the injector is broken, the system will not fault
because the injector will still build up the system pressure. But the lube point will get no lube, as the lube will
escape out the leak.
3. Injector bypassing. Often an injector which is bypassing will not have an internal leak large enough to cause
a fault. But the amount of lube which will be supplied to the lube point is much larger than the measured
amount the injector should be supplying. To spot this, look for one lube point that appears to be building up a
lot of lube around it. Check the injector to determine if the injector is bypassing. See Topic 18.4.10 for more
information on injectors.
A restriction in one of the supply lines between the pump and the injectors may or may not cause a system fault.
The 4100XPC lubrication system zones contain pressure transducers for monitoring system pressure. Each trans-
ducer is connected to the Centurion Control System.
If a restriction in a supply line between the pump and the injectors occurs, it will occur as one of the following con-
ditions:
1. All of the zone’s transducer(s) are located between the pump and the restriction.
• If this occurs, the pump will cycle as normal, no fault will occur, and the cycle duration will appear normal.
• Depending on the severity of the restriction, the injectors located downstream of the restriction may or may
not cycle. If the injectors do not cycle, their lube points will go dry.
• The restriction can be diagnosed by observing the injectors downstream to see if they are cycling. A pres-
sure gauge could be installed at the end of the line to check pressure at that point.

2. At least one of the zone’s transducer(s) are located downstream of the restriction.
• As system pressure builds, the pressure read by a transducer downstream of the restriction would indicate a
low system pressure if the pressure at that transducer does not reach the 2400 PSI setpoint within the 200
second fault timer dimension. If the lube zone is faulting out because pressure at that transducer is not
reaching the 2400 PSI setpoint, this could indicate a restriction.
• As system pressure builds, the transducer downstream of the restriction may not indicate a restriction, if the
restriction is not severe. In this case it could be causing a pressure drop, but the pump produces enough
pressure and flow through the restriction that the transducer reaches the 2400 PSI setpoint within the 200
second fault timer dimension. The difference in pressure on each side of the restriction may be minor or
more pronounced depending on the severity of the restriction and the pump speed or stroke rate. As a gen-
eral rule, as the pump speed or stroke rate increases, the chance of a pressure differential across a restric-
tion increases. Slowing the pump speed or stroke rate allows more time for the lube to flow through a
restriction and lessons the chance of a pressure differential.
NOTICE
If a pressure drop is occurring after the restriction, the pressure of the zone before the restric-
tion may rise to a level that is much greater than the 2400 PSI system setpoint. This could hap-
pen even if the lube zone is not setting a fault. This could result in component failure due to high
pressure, or the zone’s relief valve opening.
If a restriction is occurring in the lines, manifolds, or other components in a zone, check for the following:
1. A restriction in a supply line due to a pinched line or lube contamination which is causing a pressure drop
downstream.
2. A supply line plugged or restricted because the lube is too cold and will not flow. If cold weather is causing the
supply line restriction, see Subtopic 16.2.3.


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ES41157 Mechanical Systems Manual Preface

Copyright © 2007 P&H Mining Equipment, Inc. Peak Services

Peak Services Copyright © 2007 P&H Mining Equipment, Inc.

SECTION 1, Shovel Safety

Copyright © 2007 P&H Mining Equipment, Inc. Peak Services

Table of Contents (Continued)

SECTION 3, General Assembly Procedures

Peak Services Copyright © 2007 P&H Mining Equipment, Inc.

Table of Contents (Continued)

SECTION 4, General Inspection

SECTION 5, Disc Brakes

Copyright © 2007 P&H Mining Equipment, Inc. Peak Services

Table of Contents (Continued)

Peak Services Copyright © 2007 P&H Mining Equipment, Inc.

Table of Contents (Continued)

SECTION 6, Machine Lower Assembly

SECTION 7, Propel System

Copyright © 2007 P&H Mining Equipment, Inc. Peak Services

Table of Contents (Continued)

SECTION 8, Machinery House and Exterior Walkways

Peak Services Copyright © 2007 P&H Mining Equipment, Inc.

Table of Contents (Continued)

SECTION 10, Air Conditioning Units

SECTION 11, Swing System

Copyright © 2007 P&H Mining Equipment, Inc. Peak Services

Table of Contents (Continued)

SECTION 12, Hoist System

SECTION 13, Attachment

Peak Services Copyright © 2007 P&H Mining Equipment, Inc.

Table of Contents (Continued)

SECTION 14, Crowd System

Copyright © 2007 P&H Mining Equipment, Inc. Peak Services

Table of Contents (Continued)

SECTION 15, Air System

Peak Services Copyright © 2007 P&H Mining Equipment, Inc.

Table of Contents (Continued)

SECTION 16, Lubricant Specifications

SECTION 17, Lubrication Requirements

Copyright © 2007 P&H Mining Equipment, Inc. Peak Services

Table of Contents (Continued)

SECTION 18, Automatic Lubrication System

Peak Services Copyright © 2007 P&H Mining Equipment, Inc.

List of Figures (Continued)

Section 3: General Assembly Procedures

List of Figures (Continued)

Section 4: General Inspection

Section 5: Disc Brakes

List of Figures (Continued)

List of Figures (Continued)

List of Figures (Continued)

Section 6: Machine Lower Assembly

List of Figures (Continued)

Section 7: Propel System

List of Figures (Continued)

Section 8: Machinery House and Exterior Walkways

List of Figures (Continued)

Section 10: Air Conditioning Units

Section 11: Swing System

List of Figures (Continued)

Section 12: Hoist System

List of Figures (Continued)

List of Figures (Continued)

Section 13: Attachment