Attachment S1 - Erection Procedure 2800XPB
Attachment S1 - Erection Procedure 2800XPB
Attachment S1 - Erection Procedure 2800XPB
2800XP Series B
DC ELECTROTORQUE® MINING SHOVEL
DUAL PLANETARY PROPEL & SWING
ERECTION PROCEDURE
The P&H service advisor is not authorized to approve modifi- SAFETY: All safety related equipment requirements and
cations to the machine that are not covered by the machine procedures are the responsibility of the Purchaser
data sheet, nor will P&H Mining Equipment accept any back- and or designated Erection Contractor and should
charge for any unauthorized modifications made. be in accordance with all applicable MSHA,
Local Mine, State Authorities and regulations.
The purchaser or the purchaser’s erection contractor
should contact the nearest P&H Mining Equipment regional NOTE: The purchaser is to supply all necessary start-up
office to schedule the P&H service advisor. We ask the lubrication materials, oils, greases, etc., per P&H
purchaser, prior to the arrival of P&H service advisor, to specifications.
issue a purchase order covering the P&H service advisor.
The first 50 normal working days will be on a no charge
basis. Any days beyond the first 50 days will be charged ERECTION SITE AND MATERIAL LOCATION
against the purchase order at established service rates.
Erection site preparation is the responsibility of the Purchaser
The normal working day for the P&H service advisor is and should be a flat leveled area, with good drainage, and
eight hours on site per day. The normal work week is stable under footing to support the lifting equipment and their
five days per week (Monday through Friday excluding floats or outriggers during any lift to be made.
holidays). Time spent on site beyond the normal work week
or day will be charged against the purchase order at The area required is approximately 300 feet (91.4 m) square,
established service overtime rates. with a tool shed.
1
BASIC RIGGING MATERIAL REQUIREMENTS BASIC HAND TOOLS (continued)
Cranes 2—wire brushes
3—each tapered drifts, 12” long, 5/8” and 3/4” dia.
One truck crane with 100-ton* (90,720 kg.) capacity and
one truck crane with 140-ton* (127,008 kg.) capacity. One 2—1/2” drive socket wrench sets, including two extensions,
truck crane will be required for 45 working days for each ratchet and sockets, from 7/16” to 1-1/4”, in 1/8”
machine during the erection period. The second truck crane increments
will only be required for the first 20 working days of the 1—3/4” drive socket wrench set, including two extensions,
erection for each machine. ratchet and sockets, from 1” to 3”, in 1/8” increments
6—3-ton P&H hoists
One 20-30-ton* (18,144-27,216 kg.) rough terrain crane 2—standard bolt tap set—1/4” to 1-1/2” in 1/8” increments
Cables 2—drill bit set—3/16” to 5/8” in standard increments
1—set of rotary files for pencil grinder
4—1-3/4” x 20’ 4—1” x 12’
1—torque wrench
2—1-1/2” x 20’ 4—3/4” x 10’
1—torque multiplier (2,500 ft.-lbs. capacity)
2—1-1/4” x 20’ 2—5/8” x 20’
10—smaller cables (1/2” and 3/8”, 15’ long) to handle the Basic Power Tools
miscellaneous material, such as brakes, blower
motors, boxes, cab sections, etc. 1—1/2” drive reversible electric drill motor 110 vac
1—pneumatic air wrench, 1/2” drive, with sockets from
Shackles 1/2” to 1-1/4”, in 1/8” increments
4—2-3/4” (with 5” throat opening and 12 deep) for 1—spray paint gun
lifting revolving frame 1—air powered grinder, 9” right angle disc
6 ea. 1/4”, 3/8”, 1/2”, 3/4”, 1” 1—air powered 1/4” pencil grinder
1—air powered chipping hammer
Blocking (Hardwood)
1—welding machine, 400 amp capacity (portable gasoline
40 ea. 8” x 8” or 10” x 10” in 6’, 4’, and 2’ lengths or diesel driven), including 100’ long welding cables
1—bag wooden wedges 1—portable air compressor, 150 CFM capacity, with 2 ea.
100’ long hoses with inline oilers
This material is used for setting the various components 1—portable light plant or electric power supply if needed
on the ground. The carbody is blocked approximately 48” high
for side frame clearance with shoes on. 1—electric heated rod oven
2—oxygen acetylene burning sets with 75’ hose
Optional Time Saving Equipment 2—50-ton hydraulic jacks
One 10-ton* (9.072 kg.) forklift. Basic Miscellaneous Items
3—tarpaulins, 30’ x 30’
BASIC TOOL REQUIREMENTS 2—15’ step ladders
2—24’ extension ladders
Basic Hand Tools 2—barrels of cleaning solvent
2—6” screwdrivers 1/4” face 20—rolls masking tape 1”
2—8” screwdrivers 3/8” face 50—sheets of fine emery cloth
2—12” screwdrivers 1/2” face 50—sheets of medium emery cloth
2—15” adjustable open end wrenches 2—wooden stairway with railing for boarding
2—12” adjustable open end wrenches 25—rolls black plastic electrical tape
4—12” long bastard files 25—rolls of friction tape
6—4” paint brushes for use with cleaning solvent 5—anti-seize lubricant (cans)
1—crosscut saw 5—dye check kits for checking welds
3—36” wrecking bars 6—fire extinguishers—20 lb. dry chemical type
2—20 lb. sledge hammers 100---lbs. each---3/16” and 3/32” weld rod---hydrogen (pre-dried)
4—2 lb. ball peen hammers 300—feet manila rope
6—putty knives 3” wide 100—lbs. cleaning rags
2000-lbs. (approx.) dry ice (the exact quantity required will depend
upon location of source and ambient temperature)
Data Codes
*1 ton = 2,000 pounds (907.2 kg)
10’ = 10 feet (305 cm) 10” = 10 inches (25.4 cm)
2
2800XPB LIFTING OR HITCHING POINTS AND APPROXIMATE WEIGHTS* OF MAJOR ITEMS
72,100 lbs. 86,700 lbs.
(32,704 kg.) (39,326 kg.)
CL Rotation
10'-10"
6'-6" (3.30 m)
(1.98 m)
6'-10"
(2.08 m)
9’-0”
(2.74 m)
31’-0”
Width 12’-3” (3.738 m)
House Pressurization
Crawler shoes 56" (1.42 m) Wide
51 Shoes each Belt-Weight: 99,000 Lbs.
43,250 lbs. 43,250 lbs. (44,906 Kg.)
(19,618 kg.) (19,618 kg.)
5'-4"
(1.63 m)
84,000 lbs.
84,000 lbs.
(38,102 kg.)
30’-10” (38,102 kg.)
(9.39 m)
Counterweight Box 80,000 lbs.
Width: 14’-4” (4.37 m) (36,287 kg.)
128,100 lbs.
(58,105 kg.) Weight: 86,500 (39,236 kg.) 125,000 lbs.**
(56,699 kg.) 7'-9"
(2.36 m) Width: 22’-6” (6.86 m)
Weight: 168,000 lbs.
(76,204 kg.)
5’-11” (1.80 m)
Dry ice to freeze center gudgeon (shown below) for field installation into carbody.
The quantity will depend on location of supplier, and ambient temperature.
111.6" (2835mm)
*Weights are ± 10%. For actual weight of each component, refer to packing list.
3
Figure 1 U.S. AND CANADIAN SHIPMENTS
95
Figure 1 depicts the recommended placement of
DIPPER
parts at the erection site. Each item shown is
numbered and refers to the Component List
67
90 (Table 1) which gives the approximate weights of
the components. For the actual weights, refer to
68 the machine packing list. The item numbers
shown in Figure 1 and Table 1 correspond to the
85 66 66 machine packing list, items 1 through 63. Items
beyond 63 are randomly applied.
HANDLE
DIPPER
80
75
50 52
70
53
65
70
60 71
COUNTER WEIGHT
34 BOX 72 46 26
73
55
47 49 32
20
44 71 74
50
21 REVOLVING
38 FRAME
39 22
45 HOIST
27 RING CASE
29
31 14 S S 17 GEAR
41 30 36 I I 1
D D
40 37 E CARBODY E 12
40 2 HOIST
63 15 F F 18
11 7 DRUM
R R
TOOL A A 23
CONTAINER M M ROLLER
35 16 E E 19 CARRIER
69 69
LUNCH
ROOM
13 6 13 PROPEL 62
MOTOR 25
30 45 BASE 8 9 10
5 33
48 24 28 51
54 BOOM
35
25 55
56 59 60 61 59 GANTRY
57
20 GANTRY LEGS
64
65
3 58
15
43
NOTE
Electrical cabinets, transformers, BOOM
10 AC & DC motors, etc. must be POINT
stored under cover until required.
0 5 10 15 20 25 30 35 40 45 50 55 60 65
METERS
4
Table 1 2800XPB COMPONENT LIST - U.S. & CANADA
BOX or APPROX. WEIGHT BOX or APPROX. WEIGHT
CRATE # DESCRIPTION OF CONTENTS LBS. KG. CRATE # DESCRIPTION OF CONTENTS LBS. KG.
1 Kit #1 Hardware for Revolving Frame 855 388 59 Shipper Shaft Pinions 2,350 1,066
2 Kit #2 Hardware for Carbody 1,170 531 60 Shipper Shaft Retainer w/Washer 650 295
3 Kit #3-If this is packed inside of the boom 61 Shipper Shaft Retainer w/Washer 650 295
hardware box, then the boom hardware
box will be box #3 300 136 62 Lower Disconnect Switch 900 406
4 Contains Kit #4 Hardware for Cab & Upper 1,205 546 63 House Heaters 150 68
5 Contains Kit #5 Hardware for Catwalk &
Railing 515 234
Assemblies without Pre-Assigned
6 Corduroy Bolt Box 6,000 2,721 Box or Crate Numbers
7 Lower Assembly Parts 4,000 1,814
8 House Rollers 2,150 975 APPROX. WEIGHT
DESCRIPTION OF CONTENTS LBS. KG.
9 House Rollers 2,150 975
10 House Rollers 2,150 975 Air Tugger Bracket 950 431
11 Assembly Tools 950 431 Auxiliary & Field Transformer 4,200 1,905
12 High-Voltage Guards 1,550 703 Auxiliary Control Cabinet 1,200 544
13 Crawler Shoe Pin and Hardware 8,125 3,685 Boom 130,900 59,375
14 Crawler Shoe Pin and Hardware 8,125 3,685 Boom Point Sheave Assembly 13,900 6,304
Shoe Size 4.5” Pins 4.5” Pins Carbody with Lube and Collector Shoes 168,000 76,204
15 Crawler Shoe 52” (132 cm) Center Gudgeon Assembly 9,350 4,240
16 Crawler Shoe 55” (140 cm) 1,865 846 Control Cabinet 2,000 907
17 Crawler Shoe 70” (178 cm) Converter 10,950 4,966
18 Crawler Shoe 72” (183 cm) 2,100 952 Counterweight Box 86,500 39,236
19 Crawler Shoe 84” (213 cm) 3,470 1,574 Counterweight Cast Assembly-4 pcs.
Crawler Shoe 96” (244 cm) 4,565 2,070 Crowd Motor Assembly 6,800 3,084
20 House Cab Parts 450 204 Crowd Motor Base 2,200 998
21 House Panels 3,800 1,723 Crowd Motor Cover 8,100 3,673
22 Boarding Stairway/Ladder 2,630 1,193 Crowd Transmission
23 Spherical Washer 400 181 Dipper (See Packing List for Weight)
24 Low-Voltage Collector 1,200 544 Gantry Compression Member Assembly 23,000 10,431
25 Air Compressor 2,100 952 Gantry Tension Members 11,950 5,420
26 Troughs and False Floor 2,550 1,156 Handle 78,500 35,607
27 Swing Shafts 8,450 3,832 High Voltage Cabinet 2,100 952
28 Gantry Parts 2,100 952 Hoist Cable Reels (each) 4,300 1,950
29 Paint 450 204 Hoist Drum Assembly 41,500 18,824
30 Carbon Dioxide Cylinders 250 113 Hoist Motor Base, Front 3,600 1,633
31 Upper Assembly Parts 700 317 Hoist Motor Base, Rear 3,600 1,633
32 Air Duct Kit “Bleed Rear Roof” 350 159 Hoist Motor Front 6,150 2,789
33 Not Applicble Hoist Motor Rear 6,150 2,789
34 Left Hand and Right Hand Platforms 12,990 5,892 Hoist Transmission Assembly 25,600 11,612
35 Boom Electrical 400 181 Left Hand Elevated Section 12,800 5,806
36 Miscellaneous-Electrical 1,500 680 Main Transformer & Supp. Cabinet 16,700 7,575
37 Miscellaneous-Wire 1,200 544 Operator’s Coop 12,100 5,488
38 Floodlights 400 181 Propel Motor Base 23,300 10,568
39 Heaters “Portable” 500 227 Propel Motor 6,000 2,721
40 House Lighting Kit 850 385 Rear Enclosures 14,100 6,395
41 Buss Bars 3,500 1,587 Rear Roof Section 12,243 5,553
42 Boarding Ladder Material 200 91 Revolving Frame (Including Sidestand) 158,800 72,030
43 Shipper Shaft Adjusters 450 204 Right Hand Elevated Section 12,600 5,715
44 Remaining Floodlight Assy. & Hard. 600 272 Right Hand Platforms 11,117 5,042
45 Air Conditioner Parts 150 68 Roller Carrier Ring 2,584 1,172
46 Logo Letters 1,175 533 RPC Cabinets 15,000 6,803
47 Counterweight Box Reinforcement RPC Switching Cabinet 2,700 1,224
48 Boom-Sealtite-4” 500 227 Saddle Blocks (each) 9,525 4,320
49 Mounting Bolts-Cast Counterweight 300 136 Shipper Shaft 8,000 3,628
50 Canopy Arch 11,250 5,102 Shipper Shaft Gear 5,600 2,540
51 Hoist Cable Hoods 4,700 2,132 Sideframe Left with Transmission 149,600 67,857
52 Hatch Covers 4,380 1,986 Sideframe Right with Transmission 149,600 67,857
53 Side Beams 3,250 1,474 Suspension Cables (each) 9,600 4,354
54 Railing Crate 3,400 1,542 Swing Gear 18,000 8,163
55 Catwalks #1 1,850 839 Swing Motor Front 8,800 3,991
56 Catwalks #2 3,650 1,655 Swing Motor Rear 8,800 3,991
57 Catwalks #3 4,400 1,995 Swing Transmission/Front Motor 14,300 6,486
58 Boom Platforms 7,200 3,265 Swing Transmission/Rear Motor 14,300 6,486
Transfer Cabinet 1,750 794
*Weights are + 10%. For actual weight of each component, refer to packing list.
5
PLFA
igCuEre
ME2NT OF ITEMS FOR ERECTIOEN
XP-O
ERXT
POSR
HTIPMENTS
95
Figure 2 depicts the recommended placement of
DIPPER
parts at the erection site. Each item shown is
numbered and refers to the Component List
90 (Table 2) which gives the approximate weights of
the components. For the actual weights, refer to
23 the machine packing list. The item numbers
85
shown in Figure 2 and Table 2 correspond to the
42 43
machine packing list.
HANDLE
DIPPER
80
104 105
75
50 52
70
53
65
63
82
60 COUNTER WEIGHT 64
BOX
34 16 65 46 26
66
55
47 49 83
20
44 71 112
50
21 REVOLVING
38 FRAME
15 74
39 22
4 75 HOIST
45 27 24 CASE
29 CRAWLER CRAWLER RING
31 SHOES S S SHOES GEAR
41 30 36 I I
D D
40 37 E CARBODY E 12
40 113 HOIST
87 F 1 F
11 7 DRUM
R R
TOOL A A 73
CONTAINER M M ROLLER
35 E 2 3 E CARRIER
5 18
76 77
LUNCH
ROOM
14 6 13 PROPEL 62 17
110 MOTOR 25
30 45 BASE 8 9 10
61 94 48
72 28 51
54 108 BOOM
19 35
25 55
56 59 60 60 59 32 GANTRY
57
20 33 GANTRY LEGS 114
69 90
70
93 58 106 107
95
15
NOTE
Electrical cabinets, transformers,
AC & DC motors, etc. must be BOOM
10 POINT
stored under cover until required. 67
0 5 10 15 20 25 30 35 40 45 50 55 60 65
METERS
6
Table 2 2800XPB COMPONENT LIST - EXPORT
BOX or APPROX. WEIGHT BOX or APPROX. WEIGHT
CRATE # DESCRIPTION OF CONTENTS LBS. KG. CRATE # DESCRIPTION OF CONTENTS LBS. KG.
1 Carbody with Lube and Collector Shoes 168,000 76,204 57 Catwalks #3 4,400 1,995
2 Sideframe (Left) with Transmission 149,600 67,857 58 Boom Platforms 7,200 3,265
3 Sideframe (Right) with Transmission 149,600 67,857 59 Shipper Shaft Pinions 2,350 1,065
4 Swing Gear 18,000 8,163 60 Crowd Motor Blower 750 340
5 Propel Motor Base 23,300 10,568 61 Dipper Trip Motor 950 431
6 Corduroy Bolt Box 6,000 2,721 62 Lower Disconnect Switch 900 408
7 Lower Assembly Parts 4,000 1,814 63 Counterweight Cast Assembly - 4 pcs.
8 House Rollers 2,150 975 64 Counterweight Cast Assembly - 4 pcs.
9 House Rollers 2,150 975 65 Counterweight Cast Assembly - 4 pcs.
10 House Rollers 2,150 975 66 Counterweight Cast Assembly - 4 pcs.
11 Assembly Tools 7,500 3,401 67 Boom Point Sheave Assembly 13,900 6,304
12 High-Voltage Guards 1,550 703 68 Center Beams 3,500 1,587
13 Crawler Shoe Pin and Hardware 8,125 3,685 69 Catwalks #4 1,350 612
14 Crawler Shoe Pin and Hardware 8,125 3,685 70 Catwalks #5 2,500 1,134
15 Revolving Frame (Including Sidestand) 158,800 72,030 71 Right Hand Elevated Section 12,600 5,714
16 Counterweight Box 86,500 39,236 72 Left Hand Elevated Section 12,800 5,805
17 Air Receiver Tank Box (Optional) 1,100 499 73 Hoist Drum Assembly 41,500 18,824
18 Center Gudgeon Assembly 9,350 4,240 74 Hoist Motor Base, Front 3,600 1,633
19 Boom 130,900 59,375 75 Hoist Motor Base, Rear 3,600 1,633
20 House Cab Parts 950 431 76 Swing Transmission/Front Motor 14,300 6,485
21 House Panels 3,800 1,723 77 Swing Transmission/Rear Motor 14,300 6,485
22 Boarding Stairway/Ladder 2,630 1,193 78 Hoist Motor Front 6,150 2,789
23 Handle 78,500 35,607 79 Hoist Motor Rear 6,150 2,789
24 Low-Voltage Collector (Part of Box 11) 80 Swing Motor Front 8,800 3,991
25 Air Compressor 2,100 952 81 Swing Motor Rear 8,800 3,991
26 Troughs and False Floor 2,550 1,156 82 Pressurization System 21,000 9,524
27 Swing Shafts 8,450 3,832 83 Air Duct Kit “Bleed Rear Roof” 1,900 862
28 Gantry Parts 84 Air Duct Kit “Bleed Rear Roof” 1,900 862
29 Paint 450 204 85 Air Conditioner 2,600 1,179
30 Carbon Dioxide Cylinders 250 113 86 Right Hand Boom Extension 4,600 2,086
31 Upper Assembly Parts 7,000 3,175 87 Operator’s Coop 12,100 5,488
32 Gantry Compression Member 22,500 10,206 88 Boom Catwalk #1 3,000 1,361
33 Gantry Tension Members 11,950 5,420 89 Boom Catwalk #2 3,250 1,474
34 Left Hand and Right Hand Platforms 12,990 5,891 90 Shipper Shaft 8,000 3,628
35 Boom Electrical 400 181 91 Bearing Retainers
36 Gantry Platform 2,800 1,270 92 Crowd Motor Assembly 6,800 3,084
37 Miscellaneous - Wire 1,200 544 93 Crowd Case Cover 8,100 3,674
38 Floodlights 400 181 94 Crowd Motor Base 2,200 998
39 Platform Supports R/L Hand 3,000 1,361 95 Boom Hardware 1,050 476
40 House Lighting Kit 850 385 96 Load Center Panel 2,500 1,134
41 Buss Bars 3,500 1,587 97 Main Transformer & Supp. Cabinet 16,600 7,530
42 Saddle Blocks (each) 9,525 4,320 98 High Voltage Cabinet 2,100 952
43 Saddle Blocks (each) 9,525 4,320 99 Auxiliary & Field Transformer 4,200 1,905
44 Floodlight Assembly and Hardware 1,125 510 100 Converter 10,950 4,966
45 Air Tugger Bracket 950 431 101 Transfer Cabinet 1,750 794
46 Logo Letters 1,175 533 102 RPG Switching Cabinet 2,700 1,224
47 Counterweight Box Reinforcement 103 Dipper Trip Resistor Assembly 1,950 884
48 Boom-Sealtite - 4” 500 227 104 Reel Hoist Cable 4,300 1,950
49 Low Voltage Cover Guard 700 317 105 Reel Hoist Cable 4,300 1,950
50 Canopy Arch 11,250 5,102 106 Suspension Cables (each) 9,600 4,354
51 Hoise Cable Hoods 4,700 2,132 107 Suspension Cables (each) 9,600 4,354
52 Hatch Covers 4,380 1,986 108 Shipper Shaft Gear 5,600 2,540
53 Side Beams 3,250 1,474 109 Left Hand Boarding Ladder 1,750 794
54 Railing Crate 3,400 1,542 110 Kit Boxes
55 Catwalks #1 1,850 839 111 Air Conditioner Parts
56 Catwalks #2 3,850 1,746 112 Rear Enclosure Panels
*Weights are + 10%. For actual weight of each component, refer to packing list.
7
ELECTRICAL TEST EQUIPMENT REQUIREMENTS Recommended Maintenance/Commissioning Test
Equipment Available only through P&H
Basic Electrical Test Instrumentation Required by Customer To
Commission and Maintain Electrotorque Mining Excavator. Description P&H Part #
Recommended Maintenance Test Equipment Available Start-Up Resistor—200 Ohms, 6 kW 80Z984D1
through P&H and other Vendors. RPC/Step Reference Unit 89Z866
Reference/Pushbutton Unit 89Z833D1
Description P&H Part #
Capacitor Unit 89Z508D1
DMM (Digital MultiMeter) Voltage Divider R1192F1
Fluke Model 23 89Z514D12 SCR (Thyristor) Tester 89Z511D1
Alternate DMM—Fluke, Model 87 1089Z275 Test Probes w/Banana Plugs (6 Req’d.) 79Z2738D2
Oscilloscope
Tektronix Model THS710 (Handheld, Dual Trace,
Digital, Storage, Battery Powered, Soft Case) Scope
w/120V / 60Hz Adapter 89Z515D15
120V / 50 Hz AC Adapter (240V Adapters Available) 89Z515D30
Hard Carrying Case 89Z515D26
X10 Probe (1kV) 89Z515D17
Note: All designs, specifications and components of equipment described above are subject to change at manufacturer’s sole discretion at any time without advance notice. Data
published herein is informational in nature and shall not be construed to warrant suitability of machine for any particular purpose as performance may vary with conditions encountered.
The only warranty applicable is our standard written warranty for this machine. P&H Mining Equipment, Box 310, Milwaukee, Wisconsin 53201.
A Harnischfeger Industries Company.
XS1394 8 2CCI-1197