Advanced Shovels Debut at Safford

March 2, 2026 - The heavy equipment fleet at the company’s Safford, Arizona, site recently received some much-anticipated reinforcement as the site added two new larger shovels.

The massive scoopers – P&H 4100XPC models - are Safford's first brand-new shovels, breaking a practice of refurbishing used machines from other Freeport properties. But these are not merely newer, cleaner, shinier versions of what’s already on the site.

“One of the biggest differences with these new models is their AC (alternating-current) motors,” said Mike Guttierez, Supervisor, Mine Maintenance-Safford. “Our older 4100s have DC (direct-current) motors.”

The AC system affords tighter shovel performance, resulting in improved operational efficiency.

“AC motors provide smoother and more precise torque control than the DC machines,” said Michael Ryan, Supervisor, Technical/Electrical-Safford. “They are noticeably faster, and the control seems to have better response.”

AC motors also provide an economic advantage over their DC counterparts. DC motors come equipped with consumable brushes, which transfer electric current from the stationary part of the motor to the rotating part. AC motors do not need this piece of equipment, which must be replaced periodically, thus reducing the cost of motor maintenance, Ryan said.

The components and parts for the first shovel started arriving at Safford in April last year. Assembly began in early May and was completed in under four months, just in time to put that machine into service by early fall. Assembly of the second shovel took a little longer, lasting from September through most of December.

The newest of the two 4100XPCs, commissioned in late December 2025, also is the first-ever 4100 with a direct-drive crowd motor for the boom and dipper. The direct-drive crowd replaces the belt-driven mechanisms of earlier shovels and gives operators finer control of movement. That and increased load capacity significantly improve efficiency.

“Each shovel has a 74-cubic-yard bucket, which can fill a haul truck with only two to three scoops, vs. three to four with the older shovels,” Guttierez said. “It can complete a loading cycle up to 9 percent faster than our older 4100s.”

Another positive feature Guttierez noted is a new roller latch system on the dipper door.

"It takes away the need for adjustment and lasts a whole lot longer, which helps reduce shovel downtime,” he said.

The two new 4100XPCs will replace three of Safford’s older, smaller, 2800 models, parts for which have become increasingly hard to obtain. The new machines’ improved serviceability and load capacity will be advantageous for Safford as it expands the Lone Star pit, Guttierez said.

Photo (top right to bottom): Roy Vidales, Senior Supervisor Shovel/Drill Maintenance-Safford Operations, shows one of Safford’s new shovels during its assembly; one of Safford’s new shovels loads a haul truck in the Lone Star pit.