caterpillar performance handbook, january 2014, · pdf filecaterpillar is the global market...

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Caterpillar® Performance

Handbook Edition 44

UNDERGROUND MINING

EQUIPMENTPART B

Edition 44 20-29

20

CONTENTSLONGWALL

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29Roof Supports: Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31 Special Applications . . . . . . . . . . . . . . . . . . . . 20-32AFC Systems: Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37 Conveying Performance . . . . . . . . . . . . . . . . . 20-41Beam Stage Loaders (BSL): Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44CST Drive Systems: Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 20-48 Rated Power P/Gearbox Ratio i [–] . . . . . . . . 20-54Shearers: Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-56 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 20-57 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64 Optional Accessories . . . . . . . . . . . . . . . . . . . . 20-74Automated Plow Systems: Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-75 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 20-76 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-77

Programmable Mining Controls: PMC-R: Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 20-90 PMC-D and PMC-V: Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-94 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 20-94 MCU2: Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-98 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 20-98Roof Support Carriers: Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 20-101 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 20-102 Tractive Effort vs. Speed — Loaded. . . . . . . 20-104 % Grade vs. Speed — Loaded. . . . . . . . . . . . 20-105 Lift Capability . . . . . . . . . . . . . . . . . . . . . . . . 20-107Shield Trailers: Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-109 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 20-110 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111 SH150 Load Setting Table . . . . . . . . . . . . . . 20-112

INTRODUCTIONCaterpillar is the global market leader and supplier

of complete longwall systems. All over the world, our equipment and systems are meeting the demands of underground mining under the most stringent condi-tions. Adapted to the mining challenges faced by our customers today, Cat customized systems range from hydraulic roof supports, automated plow systems, shear-ers, face conveyors and drive systems to automation and roof support carriers. Caterpillar delivers your system of choice, from low to high seam heights, for the longest longwalls and highest production demands.

LONGWALLRoof-Supports

AFC SystemsBeam Stage Loaders (BSL)

CST Drive SystemsShearers

Automated Plow SystemsProgrammable Mining Controls

Roof Support CarriersShield Trailers

PHB-Sec20-Longwall(pg029-114).indd 29PHB-Sec20-Longwall(pg029-114).indd 29 12/20/13 9:01 AM12/20/13 9:01 AM

20-30 Edition 44

Longwall Roof Supports● Features

ROOF SUPPORTS

Features

Customized Design

● Seamless range for mining heights from 0.55 m to 7.5 m (1.8 to 24.6 ft) with support capacities of up to 1750 metric tonnes (1929 tons).

● Advanced design of critical parts prevents major fail-ures, costly underground repairs and unscheduled downtime.

● Easy maintenance, long intervals between overhaul and very long service life.

Equipment You Can Rely On

● Availability typically 98% on average.

● Extensive tests on all structural, hydraulic and control components.

● Sophisticated PMC®-R electro-hydraulic controls for full face automation.

● Down to 4-second advance cycles thanks to powerful hydraulics.

● Shield design in 3D, FEM integrated.


Edition 44 20-31

Longwall

20

Roof Supports● Specifications

Cat Roof SupportsHeight Closed 500-2900 mm 19.7-114.2"

Height Extended 1100-6100 mm 43.3-240.2"

Shield Centers 1500-2050 mm 59-80.7"

Nominal Leg Forces 2 × 800-2 × 7156 kN 2 × 90-2 × 805 ton

Shield Density Up to 111 tonne/m2 Up to 12.5 ton/ft2

Hydraulic Leg Up to 500 mm Up to 19.7"

Canopy Rigid design (with telescopic flipper)

Canopy Length 2997-8000 mm 118-315"

Forepole Length 1980-4520 mm 78-178"

Rear Projection 850-1448 mm 33.5-57"

Base Split design OR rigid designwith telescopic relay bar/pusher cylinder

Relay Bar

Direct Mounted OR Reverse Mounted 650-1067 mm effective web 25.6-39.4" effective web

Shifting Cylinder (with Reedrod) 700-1080 mm 27.6-42.5"

Shield Pull Force 185-565 kN/315/320/350 bar

20.7-63.3 ton/4568/4640/5076 psi

Conveyor Push Force 89-815 kN/315/320/350 bar

10.0-91.5 ton/4568/4640/5076 psi

Side Seals-on Canopy, Caving Shield (and rear lemniscates):

Both Sides Fixed/One Side Fixed, One Side Movable, Rehandable/Not Rehandable

Up to 300 mm stroke Up to 11.8" stroke

Materials High strength steel

Test EN 1804, different test program with up to 90,000 cycles

Weight 6.5-63.5 tonne 7.15-70 ton

Roof Support Specifications

Side View

Top View

Example High Seam Roof Support

Side View

Top View

Example Low Seam Roof Support

Front View

Front View


20-32 Edition 44

Longwall Roof Supports● Special Applications

Special Applications

Specifically designed roof supports are available for the following mining applications:

● Steep-seam Mining

● Conventional Sublevel Caving

● Longwall Top Coal Caving (LTCC)


Edition 44 20-33

Longwall

20

AFC Systems● Features

AFC SYSTEMS

Features

Moving Mountains

● For use in longwalls of up to 500 m (1640 ft) long.

● Up to 3 × 1800 kW (3 × 2413 hp) installed power.

● Capacities of up to 6200 tonnes/hr (6834 tons/hr).

● Intelligent CST drive system available.

● High system availability, long service life, low operat-ing costs.

● Various shearer haulage systems with rack bar or chain.

● Main drive: Cross-frame, side discharge, overhead discharge.

● Rigid or automated tensionable tail drive.


20-34 Edition 44

Longwall

AFC Line Pan Specifications — PF3Model PF3/722 PF3/822 PF3/922Line Pan Width 722 mm 28.42" 822 mm 32.36" 922 mm 36.30"

Flightbar Width 582 mm 22.91" 682 mm 26.85" 782 mm 30.78"

Deck Plate Thickness 30 mm 1.18" 30 mm 1.18" 30 mm 1.18"

Profile Height 244 mm 9.60" 244 mm 9.60" 244 mm 9.60"

Bottom Plate Thickness 20 mm 0.78" 20 mm 0.78" 20 mm 0.78"

Dogbone Breaking Strength 2000 kN 224.80 tonf 2000 kN 224.80 tonf 2000 kN 224.80 tonf

Dogbone Housing FoS 1.5 times 1.5 times 1.5 times

Shear Strength 3000 kN 337.21 tonf 3000 kN 337.21 tonf 3000 kN 337.21 tonf

Vertical Articulation Up to ± 6° Up to ± 6° Up to ± 6°

Horizontal Articulation 0.8°-1.2° 0.8°-1.2° 0.8°-1.2°

Chain Strands DKB 26×29DKB 30×108DKB 34×126DKB 38×137

DKB 26×29DKB 30×108DKB 34×126DKB 38×137

DKB 26×29DKB 30×108DKB 34×126DKB 38×137

Conveying Capacity 0.18 m² 1.93 ft² 0.26 m² 2.80 ft² 0.36 m² 3.87 ft²

AFC Line Pan Specifications — PF4Model PF4/832 PF4/932 PF4/1032Line Pan Width 832 mm 52.44" 932 mm 36.69" 1032 mm 40.62"

Flightbar Width 688 mm 46.77" 788 mm 31.02" 888 mm 34.96"

Deck Plate Thickness 40 mm 1.57" 40 mm 1.57" 40 mm 1.57"

Profile Height 284 mm 11.18" 284 mm 11.18" 284 mm 11.18"


Dogbone Breaking Strength 3000-3600 kN

337.21-404.65 tonf

3000-3600 kN

337.21-404.65 tonf

3000-3600 kN

337.21-404.65 tonf

Dogbone Housing FoS 1.5 times 1.5 times 1.5 times

Shear Strength 4000 kN 449.61 tonf 4000 kN 449.61 tonf 4000 kN 449.61 tonf

Vertical Articulation Up to ± 6° Up to ± 6° Up to ± 6°

Horizontal Articulation 0.8°-1.2° 0.8°-1.2° 0.8°-1.2°

Chain Strands AKB FI30×108DKB 34×126

AKB FI30×108DKB 34×126

AKB FI30×108DKB 34×126DKB 42×146

Conveying Capacity 0.26 m² 2.80 ft² 0.36 m² 3.87 ft² 0.46 m² 4.95 ft²

AFC Systems● Specifications


Edition 44 20-35

Longwall

20

AFC Line Pan Specifications — PF4 (continued)Model PF4/1132 PF4/1332Line Pan Width 1132 mm 44.65" 1332 mm 52.44"

Flightbar Width 988 mm 38.89" 1188 mm 46.77"

Deck Plate Thickness 40 mm 1.57" 40 mm 1.57"

Profile Height 284 mm 11.18" 284 mm 11.18"

Bottom Plate Thickness 25 mm 0.98" 25 mm 0.98"

Dogbone Breaking Strength 3000-3600 kN 337.21-404.65 tonf 3000-3600 kN 337.21-404.65 tonf

Dogbone Housing FoS 1.5 times 1.5 times

Shear Strength 4000 kN 449.61 tonf 4000 kN 449.61 tonf

Vertical Articulation Up to ± 6° Up to ± 6°

Horizontal Articulation 0.8°-1.2° 0.8°-1.2°

Chain Strands DKB 34×126DKB 42×146

DKB 48×160/144

DKB 42×146DKB 48×160/144

Conveying Capacity 0.58 m² 6.24 ft² 0.85 m² 9.15 ft²

AFC Line Pan Specifications — PF5Model PF5/1142 PF5/1342Line Pan Width 1142 mm 44.96" 1342 mm 52.83"


Deck Plate Thickness 50 mm 1.96" 50 mm 1.96"



Dogbone Breaking Strength 4500 kN 505.82 tonf 4500 kN 505.82 tonf


Shear Strength > 6000 kN > 674.42 tonf > 6000 kN > 674.42 tonf



Chain Strands DKB 42×146DKB 48×160/144

DKB 42×146DKB 48×160/144

Conveying Capacity 0.58 m² 6.24 ft² 0.85 m² 9.15 ft²



20-36 Edition 44

Longwall

AFC Line Pan Specifications — PF6Model PF6/1042 PF6/1142Line Pan Width 1042 mm 41.02" 1142 mm 44.96"


Deck Plate Thickness 30 mm plus 25 mm 1.18" plus 0.98" 30 mm plus 25 mm 1.18" plus 0.98"








Chain Strands DKB 42x146DKB 48x160/144

DKB 42x146DKB 48x160/144

Conveying Capacity approx. 0.58 m² approx. 6.24 ft² approx. 0.58 m² approx. 6.24 ft²

Model PF6/1242 PF6/1342Line Pan Width 1242 mm 48.90" 1342 mm 52.83"


Deck Plate Thickness 30 mm plus 25 mm 1.18" plus 0.98" 30 mm plus 25 mm 1.18" plus 0.98"








Chain Strands DKB 42×146DKB 48×160/144

DKB 42×146DKB 48×160/144

Conveying Capacity approx. 0.72 m² approx. 7.75 ft² approx. 0.85 m² approx. 9.15 ft²



Edition 44 20-37

Longwall

20

AFC Line Pan Dimensions — PF3(All dimensions are approximate.)

A B

C

D

E

H

J

K

L

F

G

Model PF3/722 PF3/822 PF3/922

A 136 mm 5.35" 136 mm 5.35" 136 mm 5.35"

B 450 mm 17.72" 550 mm 21.65" 650 mm 25.59"

C 288 mm 11.33" 288 mm 11.33" 288 mm 11.33"

D 60 mm 2.36" 60 mm 2.36" 60 mm 2.36"

E 107 mm 4.21" 107 mm 4.21" 107 mm 4.21"

F 244 mm 9.6" 244 mm 9.6" 244 mm 9.6"

G 30 mm 1.18" 30 mm 1.18" 30 mm 1.18"

H 107 mm 4.21" 107 mm 4.21" 107 mm 4.21"

J 582 mm 22.91" 682 mm 26.85" 782 mm 30.78"

K 594 mm 23.38" 694 mm 27.32" 794 mm 31.26"

L 722 mm 28.42" 822 mm 32.36" 922 mm 36.30"

AFC Systems● Dimensions


20-38 Edition 44

Longwall


A B C

D

E

F

K

LM

N

G

J

H

Model PF4/832 PF4/932 PF4/1032 PF4/1132 PF4/1332

A 15 mm 0.59" 15 mm 0.59" 15 mm 0.59" 15 mm 0.59" 15 mm 0.59"

B 154 mm 6.06" 154 mm 6.06" 154 mm 6.06" 154 mm 6.06" 154 mm 6.06"

C 524 mm 20.62" 624 mm 24.56" 724 mm 28.50" 824 mm 32.44" 1024 mm 40.31"

D 341 mm 13.42" 341 mm 13.42" 341 mm 13.42" 341 mm 13.42" 341 mm 13.42"

E 105 mm 4.13" 105 mm 4.13" 105 mm 4.13" 105 mm 4.13" 105 mm 4.13"

F 122 mm 4.80" 122 mm 4.80" 122 mm 4.80" 122 mm 4.80" 122 mm 4.80"

G 284 mm 11.18" 284 mm 11.18" 284 mm 11.18" 284 mm 11.18" 284 mm 11.18"

H 40 mm 1.57" 40 mm 1.57" 40 mm 1.57" 40 mm 1.57" 40 mm 1.57"

J 122 mm 4.80" 122 mm 4.80" 122 mm 4.80" 122 mm 4.80" 122 mm 4.80"

K 12 mm 0.47" 12 mm 0.47" 12 mm 0.47" 12 mm 0.47" 12 mm 0.47"

L 676 mm 26.61" 776 mm 30.55" 876 mm 34.48" 976 mm 38.42" 1176 mm 46.29"

M 688 mm 27.08" 788 mm 31.02" 888 mm 34.96" 988 mm 38.89" 1188 mm 46.77"

N 832 mm 32.75" 932 mm 36.69" 1032 mm 40.62" 1132 mm 44.56" 1332 mm 52.44"



Edition 44 20-39

Longwall

20


A B

D

F

M

G H

J

K

L

C

E

Model PF5/1142 PF5/1342

A 164 mm 6.45" 164 mm 6.45"

B 24 mm 0.94" 24 mm 0.94"

C 134 mm 5.27" 134 mm 5.27"

D 50 mm 1.96" 50 mm 1.96"

E 140 mm 5.51" 140 mm 5.51"

F 30 mm 1.18" 30 mm 1.18"

G 318 mm 12.52" 318 mm 12.52"

H 383 mm 15.07" 383 mm 15.07"

J 976 mm 38.42" 1176 mm 46.29"

K 988 mm 38.89" 1188 mm 46.77"

L 1142 mm 44.96" 1342 mm 52.83"

M 68 mm 2.67" 68 mm 2.67"



20-40 Edition 44

Longwall


A B

E

L

F

H

G

K

C D

J

M

Model PF6/1042 PF6/1142 PF6/1242 PF6/1342

A 92 mm 3.62" 92 mm 3.62" 92 mm 3.62" 92 mm 3.62"

B 1042 mm 41.02" 1142 mm 44.96" 1242 mm 48.90" 1342 mm 52.83"

C 77 mm 3.03" 77 mm 3.03" 77 mm 3.03" 77 mm 3.03"

D 164 mm 6.45" 164 mm 6.45" 164 mm 6.45" 164 mm 6.45"

E 350 mm 13.77" 350 mm 13.77" 350 mm 13.77" 350 mm 13.77"

F 134 mm 5.27" 134 mm 5.27" 134 mm 5.27" 134 mm 5.27"

G 30 mm 1.18" 30 mm 1.18" 30 mm 1.18" 30 mm 1.18"

H 130 mm 5.11" 130 mm 5.11" 130 mm 5.11" 130 mm 5.11"

J 30 mm 1.18" 30 mm 1.18" 30 mm 1.18" 30 mm 1.18"

K 25 mm 0.98" 25 mm 0.98" 25 mm 0.98" 25 mm 0.98"

L 50 mm 1.96" 50 mm 1.96" 50 mm 1.96" 50 mm 1.96"

M 888 mm 34.96" 988 mm 38.89" 1088 mm 42.83" 1188 mm 46.77"



Edition 44 20-41

Longwall

20

AFC Line Pan Conveying Performance — PF3 AFC Line Pan Conveying Performance — PF4

AFC Systems● Conveying Performance

PF3/722

600

700

800

900

1000

1100

1200

1300

1400

661

771

882

992

1102

1212

1323

1433

1543

1.0 1.2 1.4 1.6 1.8 2.03.28 3.93 4.59 5.25 5.90 6.56

Cap

acit

y

Speed

ton/hr

ft/sm/s

tonne/hr

PF4/832

800

1000

1200

1400

1600

1800

2000

882

1102

1323

1543

1763

1984

2204

1.0 1.2 1.4 1.6 1.8 2.03.28 3.93 4.59 5.25 5.90 6.56

Cap

acit

y

Speed

ton/hr

ft/sm/s

tonne/hr

PF3/822

800

1000

1200

1400

1600

1800

2000

882

1102

1323

1543

1763

1984

2204

1.0 1.2 1.4 1.6 1.8 2.03.28 3.93 4.59 5.25 5.90 6.56

Cap

acit

y

Speed

ton/hr

ft/sm/s

tonne/hr

PF4/932

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

1102

1323

1543

1763

1984

2204

2425

2645

2866

3086

1.0 1.2 1.4 1.6 1.8 2.03.28 3.93 4.59 5.25 5.90 6.56

Cap

acit

y

Speed

ton/hr

ft/sm/s

tonne/hr

PF3/922

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

1102

1323

1543

1763

1984

2204

2425

2645

2866

3086

1.0 1.2 1.4 1.6 1.8 2.03.28 3.93 4.59 5.25 5.90 6.56

Cap

acit

y

Speed

ton/hr

ft/sm/s

tonne/hr

PF4/1032

1000

1500

2000

2500

3000

3500

1102

1653

2204

2756

3307

3858

1.0 1.2 1.4 1.6 1.8 2.03.28 3.93 4.59 5.25 5.90 6.56

Cap

acit

y

Speed

ton/hr

ft/sm/s

tonne/hr


20-42 Edition 44

Longwall AFC Systems● Conveying Performance

AFC Line Pan Conveying Performance — PF4 AFC Line Pan Conveying Performance — PF5

PF4/1132

1000

1500

2000

2500

3000

3500

4000

4500

1102

1653

2204

2756

3307

3858

4409

4960

1.0 1.2 1.4 1.6 1.8 2.03.28 3.93 4.59 5.25 5.90 6.56

Cap

acit

y

Speed

ton/hr

ft/sm/s

tonne/hr

PF5/1142

1000

1500

2000

2500

3000

3500

4000

4500

1102

1653

2204

2756

3307

3858

4409

4960

1.0 1.2 1.4 1.6 1.8 2.03.28 3.93 4.59 5.25 5.90 6.56

Cap

acit

ySpeed

ton/hr

ft/s

m/s

tonne/hr

PF4/1332

2000

2500

3000

3500

4000

4500

5000

5500

6000

6500

2204

2756

3307

3858

4409

4960

5511

6062

6613

7165

1.0 1.2 1.4 1.6 1.8 2.03.28 3.93 4.59 5.25 5.90 6.56

Cap

acit

y

Speed

ton/hr

ft/sm/s

tonne/hr

PF5/1342

2000

2500

3000

3500

4000

4500

5000

5500

6000

6500

2204

2756

3307

3858

4409

4960

5511

6063

6614

7165

1.0 1.2 1.4 1.6 1.8 2.0

3.28 3.93 4.59 5.25 5.90 6.56

Cap

acit

y

Speed

ton/hr

ft/s

m/s

tonne/hr


Edition 44 20-43

Longwall

20

AFC Systems● Conveying Performance

AFC Line Pan Conveying Performance — PF6

PF6/1042

1000

1500

2000

2500

3000

3500

1102

1653

2204

2756

3307

3858

1.0 1.2 1.4 1.6 1.8 2.03.28 3.93 4.59 5.25 5.90 6.56

Cap

acit

y

Speed

ton/hr

ft/s

m/s

tonne/hr

PF6/1242

2000

3500

3000

2500

4000

4500

5000

5500

2205

2756

3858

3307

4409

4960

5512

6063

1.0 1.2 1.4 1.6 1.8 2.03.28 3.93 4.59 5.25 5.90 6.56

Cap

acit

y

Speed

ton/hr

ft/s

m/s

tonne/hr

PF6/1142

1000

1500

2000

2500

3000

3500

4000

4500

1102

1653

2204

2756

3307

3858

4409

4960

1.0 1.2 1.4 1.6 1.8 2.0

3.28 3.93 4.59 5.25 5.90 6.56

Cap

acit

y

Speed

ton/hr

ft/s

m/s

tonne/hr

PF6/1342

2000

2500

3000

3500

4000

4500

5000

5500

6000

6500

2204

2756

3307

3858

4409

4960

5511

6063

6614

7165

1.0 1.2 1.4 1.6 1.8 2.0

3.28 3.93 4.59 5.25 5.90 6.56

Cap

acit

y

Speed

ton/hr

ft/s

m/s

tonne/hr


20-44 Edition 44

Longwall

BEAM STAGE LOADERS (BSL)

The AFC is continuously running and conveys the coal mined by a shearer or plow to the head gate, where it is transferred onto the beam stage loader (BSL) with inte-grated crusher and then onto the main belt (eventually to the surface).

Main Functions of a BSL:

● Transportation of the coal from the AFC and hand-over to the belt conveyor.

● Crushing of coal blocks to smaller sizes to suit belt capability.

Features● Stageloader and crusher completely matched to AFC,

both with higher capacity to prevent bottlenecks.

● Tailor-made belt tailpiece for required capacity and belt dimensions, allowing BTP to handle longitudinal and lateral entry gradients.

● Horizontal crusher for high throughput and low oper-ating costs due to double action impact elements.

● Automated chain tensioning system for enhanced chain and sprocket lifetime. As option SlackTronic available for superior chain tension management.

● Patented PowerChain technology available.

Beam Stage Loaders (BSL)● Features● Specifications

BSL Line Pan SpecificationsModel PF4 PF5 PF6Width Outside 932 mm

1132 mm1332 mm

36.69"44.56"52.44"

1342 mm1542 mm1742 mm

52.83"60.71"68.58"

1342 mm1542 mm1742 mm

52.83"60.71"68.58"

Typical Top Plate Thickness 40 mm 1.57" 50 mm 1.97" 30 mm (+ 25 mm)

1.18" (+ 0.98")


Dogbone Breaking Force 3600 kN 809,312 lbf 4500 kN 1,011,640 lbf 4500 kN 1,011,640 lbf

Production Average per Year 2000 tonnes3800 tonnes5500 tonnes

2204 tons4189 tons6063 tons

5500 tonnes6200 tonnes7000 tonnes


5500 tonnes6200 tonnes7000 tonnes



Edition 44 20-45

Longwall

20

BSL Crusher — Impact Roll Crusher SpecificationsModel SK0909 SK1111 SK1118Feed Size 875 × 500 ×

X mm34.4 × 19.7

× X"1050 × 600 ×

X mm41.3 × 23.6

× X"1750 × 600 ×

X mm68.9 × 23.6

× X"

Roll Diameter 910 mm 35.83" 1100 mm 43.31" 1100 mm 43.31"

Inlet Width 925 mm 36.42" 1100 mm 43.31" 1800 mm 70.87"

Maximum Passage Height 295 mm 11.61" 300 mm 11.81" 300 mm 11.81"

Type of Drive Gearbox or V-Belt Gearbox or V-Belt Gearbox or V-Belt

Maximum Installed Power V-Belt 132 kW 177 hp 315 kW 422 hp 500 kW 671 hp

Maximum Installed Power Gearbox 2 × 90 kW 2 × 121 hp 400 kW 536 hp 400 kW 536 hp

Throughput 1500 tonnes/hr 1653 tons/hr 3000 tonnes/hr 3307 tons/hr 5000 tonnes/hr 5511 tons/hr

Model SK1218 SK1422Feed Size 1750 × 650 × X mm 68.9 × 25.6 × X" 2150 × 750 × X mm 84.6 × 29.5 × X"

Roll Diameter 1200 mm 47.24" 1400 mm 55.12"

Inlet Width 1800 mm 70.87" 2200 mm 86.61"

Maximum Passage Height 300 mm 11.81" 300 mm 11.81"

Type of Drive Gearbox or V-Belt Gearbox or V-Belt

Maximum Installed Power V-Belt 750 kW 1006 hp 750 kW 1006 hp

Maximum Installed Power Gearbox 750 kW 1006 hp 750 kW 1006 hp

Throughput 6000 tonnes/hr 6614 tons/hr 8000 tonnes/hr 8818 tons/hr

Features● Horizontal crushing.

● Exchangeable impact elements as standard.

● Hydraulic height adjustment of crusher roll to match output size to belt capability.

● PMC® monitored overload protection causing BSL speed variation down to automatic stop.

● Spraying integrated into impact roll or spraying from the top cover for dust suppression available.

● Central lubrication system.

Tensionable Drive Frame SpecificationsModel SPR3 SPR5Available Widths 900 mm

1100 mm1300 mm1500 mm

35.43"43.31"51.18"59.06"

1100 mm1300 mm1500 mm1700 mm

43.31"51.18"59.06"66.93"

Sprocket Universal Sprocket Universal Sprocket

Installed Power Up to 400 kW Up to 536 hp Up to 500 kW Up to 671 hp

Stroke 350 mm 13.78" 500 mm 19.68"

Capacity Up to 6200 tonnes/hr Up to 6834 tons/hr Up to 7000 tonnes/hr Up to 7716 tons/hr

Beam Stage Loaders (BSL)● Specifications


20-46 Edition 44

Longwall Beam Stage Loaders (BSL)● Specifications

BSL Gearbox SpecificationsModel K-10 KP-25/30Maximum Output Torque for Short Duration (3 sec.) 100 000 N·m 73,756 lb-ft 300 000 N·m 221,269 lb-ft

Maximum Input Speed (Motor Speed) 1800 RPM 1800 RPM

Maximum Installed Power at:

i = 39:1 160 kW* 262 hp** 435 kW* 709 hp**

i = 33:1 x x 500 kW* 816 hp**

i = 28:1 200 kW* 326 hp** 500 kW* 816 hp**

i = 24,4:1 200 kW* 326 hp** 500 kW* 816 hp**

i = 21:1 200 kW* 326 hp** 500 kW* 816 hp**

i = 18:1 200 kW* 326 hp** 500 kW* 816 hp**

i = 16,94:1 200 kW* 326 hp** —

i = 16:1 — 500 kW* 816 hp**

Input Shaft D = 90 D=100 or W 100×4

Output Shaft W160/N190 N 220×10

Required Cooling Water Flow 5 L/min 1.32 gal/min 15-20 L/min 3.96-5.28 gal/min

Cooling Water Inlet Temperature 25° C 77° C 25° C 77° C

Oil Filling Quantities 120 L 31 U.S. gal 137 L 36 U.S. gal

Weight (without oil) 1910 kg 4211 lb 3200 kg 7055 lb

Dimensions:

Height 690 mm 27.16" 820 mm 32.28"

Length 1665 mm 65.55" 1419 mm 55.87"

Width 560 mm 22.05" 943 mm 37.13"

*Rated Power P [kW] (n = 1.485 RPM) (@ 50 Hz).**Rated Power P [hp] (n = 1.782 RPM) (@ 60 Hz).

Boot End Specifications

ModelSkid-Mounted

Boot End (SMB)Crawler-MountedBoot End (CMB)

Belt Width 1000 mm1200 mm1400 mm1600 mm

39.37"47.24"55.12"62.99"

1400 mm 55.12"

Advancing Mechanism:

Overlap Up to 3500 mm Up to 137.80" Up to 3000 mm Up to 118.11"

Recommendation Normal Floor Conditions Soft Floor


Edition 44 20-47

Longwall

20

CST DRIVE SYSTEMS

Features

The Drive for Productivity

● No-load motor start-up with modest energy demand on the electrical system.

● Soft start of the face conveyors which is gentle to all components, particularly the chain.

● Maximum total torque, available to facilitate heavy load start-up of the fully loaded conveyor.

● Accurate load sharing between the drives for full uti-lization of the installed power.

● Excellent overload protection in the event of sudden chain jams.

● Clutch delivers maximum efficiency with minimum operational slip of 0.2% with no wear.

CST Drive Systems● Features


20-48 Edition 44

Longwall

SpecificationsModel CST30Typical Application Chain Type Longwall Machinery like Armored Face Conveyors (AFC)

KP-30 CST P-30 CST

Maximum Output Torque (for 3 sec) Tmax [N·m] 300 000 N·m 221,269 lb-ft 300 000 N·m 221,269 lb-ft

Ratio i [–]: Rated Power P(n = 1485 RPM)

Rated Power P(n = 1782 RPM)



16 500 kW 816 hp 500 kW 816 hp

21 500 kW 816 hp 500 kW 816 hp

24.4 500 kW 816 hp 500 kW 816 hp

28 500 kW 816 hp 500 kW 816 hp

33 500 kW 816 hp 500 kW 816 hp

39 435 kW 710 hp 435 kW 710 hp

50 400 kW 653 hp 400 kW 653 hp

Dimensions:

Length 2280 mm 89.8" 1400 mm 55.1"

Width 1180 mm 46.5" 960 mm 37.8"

Height 900 mm 35.4" 900 mm 35.4"

Capacity:

Oil Quantity 500 L 132 U.S. gal 250 L 66 U.S. gal

Gearbox Weight (without oil) 5800 kg 12,783 lb 3900 kg 8596 lb

Requirements of Cooling Water:

Required Cooling Water 20 L/min 5.28 gal/min 20 L/min 5.28 gal/min

Maximum Water Inlet Temperature 25° C/298,15 K 77° F/298.15 K 25° C/298,15 K 77° F/298.15 K

Shaft Design:

Input Shaft (cylindrical) DIN 5480-W 100×4×30×24 DIN 5480-W 100×4×30×24

Output Shaft with Internal Toothing DIN 5480-N 220×10×30×20 DIN 5480-N 220×10×30×20

CST Drive Systems● Specifications


Edition 44 20-49

Longwall

20


KP-45 CST P-45 CST






24.5 800 kW 1305 hp 800 kW 1305 hp

28 800 kW 1305 hp 800 kW 1305 hp

33 800 kW 1305 hp 800 kW 1305 hp

39 700 kW 1142 hp 700 kW 1142 hp

45 540 kW 881 hp 540 kW 881 hp

50 500 kW 816 hp 500 kW 816 hp

Dimensions:

Length 2875 mm 113.2" 1697 mm 66.8"

Width 1401 mm 55.2" 1120 mm 44.1"

Height 1060 mm 41.7" 1060 mm 41.7"

Capacity:


Gearbox Weight (without oil) 9700 kg 21,385 lb 5900 kg 13,007 lb




Shaft Design:

Input Shaft (cylindrical) DIN 5480-W 120×4 DIN 5480-W 120×4




20-50 Edition 44

Longwall CST Drive Systems● Specifications

SpecificationsModel CST45 MTypical Application Chain Type Longwall Machinery like Armored Face Conveyors (AFC)

and Plow Systems

P-45 M CST

Maximum Output Torque (for 3 sec) Tmax [N·m] 450 000 N·m 331,858 lb-ft



16 800 kW 1305 hp

21 800 kW 1305 hp

28 800 kW 1305 hp

33 800 kW 1305 hp

39 700 kW 1142 hp

45 540 kW 881 hp

50 500 kW 816 hp

Dimensions:

Length 1697 mm 66.8"

Width 1120 mm 44.1"

Height 1060 mm 41.7"

Capacity:

Oil Quantity 320 L 85 U.S. gal

Gearbox Weight (without oil) 7200 kg 15,873 lb


Required Cooling Water 30 L/min 7.9 gal/min

Maximum Water Inlet Temperature 25° C/298,15 K 77° F/298.15 K

Shaft Design:

Input Shaft (cylindrical) DIN 5480-W 120×4

Output Shaft with Internal Toothing DIN 5480-N 260×10×30×24


Edition 44 20-51

Longwall

20

SpecificationsModel CST45 VTypical Application Chain Type Longwall Machinery like Armored Face Conveyors (AFC)

KP-45 V CST P-45 V CST






16 1050 kW 1713 hp 1050 kW 1713 hp

21 1050 kW 1713 hp 1050 kW 1713 hp

28 1050 kW 1713 hp 1050 kW 1713 hp

33 1050 kW 1713 hp 1050 kW 1713 hp

39 820 kW 1338 hp 820 kW 1338 hp

45 710 kW 1158 hp 710 kW 1158 hp

50 650 kW 1061 hp 650 kW 1061 hp

Dimensions:

Length 2875 mm 113.2" 1697 mm 66.8"

Width 1401 mm 55.2" 1120 mm 44.1"

Height 1060 mm 41.7" 1060 mm 41.7"

Capacity:


Gearbox Weight (without oil) 9700 kg 21,380 lb 5900 kg 13,000 lb




Shaft Design:





20-52 Edition 44

Longwall CST Drive Systems● Specifications


KP-65 CST P-45 CST






28 1200 kW 1958 hp 1200 kW 1958 hp

33 1200 kW 1958 hp 1200 kW 1958 hp

39 1000 kW 1632 hp 100 kW 1632 hp

45 900 kW 1468 hp 900 kW 1468 hp

50 800 kW 1305 hp 800 kW 1305 hp

Dimensions:

Length 2910 mm 114.6" 1887 mm 74.3"

Width 1530 mm 60.2" 1120 mm 44.1"

Height 1060 mm 41.7" 1060 mm 41.7"

Capacity:


Gearbox Weight (without oil) 10 880 kg 23,980 lb 7300 kg 16,094 lb




Shaft Design:


Output Shaft with Internal Toothing DIN 5480-N 320×10 DIN 5480-N 320×10


Edition 44 20-53

Longwall

20



KP-115 CST P-115 CST

Maximum Output Torque (for 3 sec) Tmax [N·m] 1 150 000 N·m 848,196 lb-ft 1 150 000 N·m 848,196 lb-ft





39 1800 kW 2937 hp 1800 kW 2937 hp

46 1800 kW 2480 hp 1800 kW 2480 hp

Dimensions:

Length 3600 mm 141.6" 2811 mm 110.6"

Width 2029 mm 79.8" 1400 mm 55.1"

Height 1300 mm 51.1" 1300 mm 51.1"

Capacity:


Gearbox Weight (without oil) 23 980 kg 52,851 lb 16 400 kg 36,145 lb




Shaft Design:


Output Shaft with Internal Toothing DIN 5480-N 360×10 DIN 5480-N 360×10


20-54 Edition 44

Longwall CST Drive Systems● Rated Power P/Gearbox Ratio i [–]

Rated Power P/Gearbox Ratio i [–]

CST30

500

700

600

400

300

200

816

1142

978

653

489

32616 24.4 33 50392821

RA

TE

D P

OW

ER

P

GEARBOX RATIO i [–]Rated Power P [hp] @ 60 Hz

Rated Power P [kW] @ 50 Hz

kW hp

CST45

500

700

600

400

816

1142

979

900

800

1468

1000 1632

1305

65324.5 28 33 504539

RA

TE

D P

OW

ER

P



kW hp

CST45 V

1100

700

600

1200

1793

1141

978

900

800

1467

10001630

1304

1956

13002119

16 28 39 50453321

PO

WE

R



hp kW

CST45 M

500

800

650

816

1305

1060

33 45 50392116 28

PO

WE

R



hp kW


Edition 44 20-55

Longwall

20

CST Drive Systems● Rated Power P/Gearbox Ratio i [–]

Rated Power P/Gearbox Ratio i [–]

CST65

1100

1200

1741

900

800

1468

10001632

1305

1955

13001958

28 39 504533

PO

WE

R



hp kW

CST115

1500

1400

2447

2251

1700

1600

2774

18002937

2573

40 464342 4539 41 44P

OW

ER



hp kW


20-56 Edition 44

Longwall

Shearers

Features

Taking the Shearer to the Next Level

● Cat shearers meet the demands of the world’s leading longwall operators in medium to high seam mining.

● Highest reliability due to own test center.

● Power for the toughest mining conditions.

● Robust design and unique mainframe concept.

● Unparalleled control with world-leading automation capabilities.

● Seam range: 1.8–7.0 m (5.9–23.0 ft).

● Installed power of up to 2295 kW (3078 hp), cutting speed up to 45 m/min (150 ft/min).

● Maximum capacity: 5000 tonnes/hr (6063 tons/hr).

Specialized Shearers

Caterpillar also supplies shearers for specialized appli-cations:

● Single- and double-drum low-seam shearer.

● Three-drum shearer for selective mining.

These shearers utilize the key feature of modular main-frame construction and are proven for coal and non-coal applications.

Shearers● Features


Edition 44 20-57

Longwall

20

SpecificationsModel EL2000 EL3000 EL4000

Machine @ 50 Hz

Machine @ 60 Hz

Machine @ 50 Hz

Machine @ 60 Hz

Machine @ 50 Hz

Machine @ 60 Hz

Seam Range 1.8-4.5 m 71-177" 2.5-5.5 m 98-217" 4.0-7.0 m 158-276"

Typical Machine Length (drum centers) 14 155 mm 46.2' 15 200 mm 49.9' 17 008 mm 55.8'

Installed Power Up to 1780 kW

Up to 2387 hp

Up to 2295 kW

Up to 3680 hp

Up to 2295 kW

Up to 3680 hp

Available Cutting Power: 2 × 500 kW2 × 620 kW2 × 750 kW

2 × 800 hp2 × 1000 hp2 × 1200 hp

2 × 860 kW2 × 750 kW

2 × 1380 hp2 × 1200 hp

RA860 Arms 2 × 860 kW 2 × 1380 hp

RA860 Arms 2 × 750 kW 2 × 1200 hp

RA750 Arms 2 × 620 kW 2 × 1000 hp

RA750 Arms 2 × 750 kW 2 × 1200 hp

Cutting Drum Diameter: 1600-2500 mm

63-98.5" Up to 3500 mm

Up to 138"

RA860 Up to 2750 mm

Up to 108"

RA750 Up to 2500 mm

Up to 98"

Cutting Drum Speed: 32.8, 37.4 and 45.2 RPM

39.4, 44.9 and 54.3 RPM

30.8, 35 and 43 RPM

37, 42 and 51.6 RPM

RA860 30.8, 35 and 43 RPM

37.42 and 51.6 RPM

RA750 32.8, 37.4 and 45.2 RPM

39.4, 44.9 and 54.3 RPM

Haulage System AC Inverter Drive AC Inverter Drive AC Inverter Drive

Haulage Motor 2 × 125 kW 2 × 168 hp 2 × 150 kW 2 × 240 hp 2 × 150 kW 2 × 240 hp

Haulage Speed Up to 30.1 m/min

Up to 98.5 ft/min

Up to 31.1 m/min

Up to 98.7 ft/min

Up to 31.1 m/min

Up to 98.7 ft/min

Haulage Pull Up to 945 kN

Up to 107 tons

Up to 1075 kN

Up to 123 tons

Up to 1075 kN

Up to 120 tons

Pump Motor 30 kW 40 hp 75 kW 120 hp 75 kW 120 hp

Body Height 600 mm 23.6" 685 mm 27" 1070 mm 42"

Machine Weight (approximate) 70 tonnes 77 tons 105 tonnes 116 tons 130 tonnes 143 tons

Operating Voltage 3300V 4160V 3300V 4160V 3300V 4160 V

Minimum Pan Width 1032 mm 40.6" 1132 mm 44.6" 1342 mm 52.8"

Coal Sizer — 200 kW 320 hp 200 kW 320 hp

Shearers● Specifications


20-58 Edition 44

Longwall

Ranging ArmsTwo types of ranging arm, both designed and robustly

tested, for longer service life.

RA750 RA860EL2000 ●

EL3000 ● ●

EL4000 ●

RA750

● Transmission rating of 750 kW @ 37.4 RPM and above

● Maximum drum diameter of 2500 mm (98 in)

● Choice of drum speeds

● Complete with 32 mm (1.3 in) bore, through shaft PFF/PBF wet cutting

● Square drum hub (440 mm [17.3 in] across flats)

● Maximum oil capacity of 28 L (7 gal) in high speed compartment and 30 L (8 gal) in the epicyclic

● Integral monitoring transducers

● Quillshaft transmission protection

● A robust cowl drive mechanism is also available on both models (EL2000, EL3000)

● Online vibration monitoring with VibraGuard

● Available cutting motors:EL2000 500 kW, 620 kW and 750 kW @ 50 Hz (800 hp, 1000 hp and 1200 hp @ 60 Hz)EL3000 620 kW and 750 kW @ 50 Hz

(1000 hp and 1200 hp @ 60 Hz)

RA860

● Transmission rating of 860 kW @ 30.8 RPM and above

● Maximum drum diameter:EL3000 2750 mm (108 in)EL4000 3500 mm (138 in)

● Choice of drum speeds

● Complete with 32 mm (1.3 in) bore, through shaft PFF/PBF wet cutting

● Square drum hub (630 mm [24.8 in] across flats)

● Maximum oil capacity of 45 L (12 gal) in high speed compartment and 60 L (15.85 gal) in the epicyclic



● A robust cowl drive mechanism is also available


● Available cutting motors — 750 kW and 860 kW @ 50 Hz (1200 hp and 1380 hp @ 60 Hz)



Edition 44 20-59

Longwall

20


Haulage Units

HU125 HU150EL2000 ●

EL3000 ●

EL4000 ●

Haulage Unit — HU125

Total Machine Pull 945.51 kN96.80 tonnes

212,559 lbf106.70 tons

Speed at Maximum Pull 14.28 m/min 46.83 ft/min

Maximum Machine Speed 28.56 m/min 93.66 ft/min

Pull at Maximum Speed 472.75 kN48.40 tonnes

106,278 lbf53.35 tons

● Maximum power rating 125 kW (168 hp)

● Integral water cooling @ 9 L/min (2 gal/min)

● Transmission reduction of 137:1

● Maximum oil capacity of 25 L (7 gal)



● This unit has a haulage motor rating of 125 kW (168 hp)

● Available with Machine Position Encoder

● Available with Machine Parking Brake

Haulage Unit — HU150

Total Machine Pull 1075.94 kN110.15 tonnes

241,881 lbf121.42 tons

Speed at Maximum Pull 15.06 m/min 49.39 ft/min

Maximum Machine Speed 30.11 m/min 98.77 ft/min

Pull at Maximum Speed 537.97 kN55.07 tonnes

120,940 lbf60.70 tons

● Maximum power rating 150 kW (201 hp)

● Integral water cooling @ 9 L/min (2 gal/min)

● Transmission reduction of 137:1

● Maximum oil capacity of 25 L (7 gal)



● This unit has a haulage motor rating of 150 kW (201 hp)

● Available with Machine Position Encoder

● Available with Machine Parking Brake


0 5 10 15 20 25 300 16.40 32.81 49.21 65.62 82.02 98.43

0100200300400500600700800900

1000

022,48144,96267,44389,924

112,404134,885157,366179,847202,328224,809

HA

UL

AG

E P

ULL

SPEED

HAULAGE PULL AND SPEEDlbf

ft/minm/min

kN

0 5 10 15 20 25 30 350 16.40 32.81 49.21 65.62 82.02 98.43 114.83

0

200

400

600

800

1000

1200

0

44,962

89,924

134,885

179,847

224,809

269,771

HA

UL

AG

E P

ULL

SPEED

HAULAGE PULL AND SPEEDlbf

ft/minm/min

kN


20-60 Edition 44

Longwall

Down Drives

DD125 DD150EL2000 ●

EL3000 ●

EL4000 ●

Down Drive — DD125/DD150

● Innovative and unique downdrive design

● Transmission rating:DD125 125 kW (168 hp)DD150 150 kW (201 hp)

● Maximum haulage pull:DD125 945 kN (107 tons)DD150 1075 kN (123 tons)

● Fully removable, rehandable, modular gearbox

● Removable modular top drive wheel assembly (cartridge)

● Downdrive ratio:DD125 17T-23T-10T (two wheel configuration)

EL3000: DD150 22T-31T-11T (two wheel configuration);

available with three wheel configuration (27T idler)

EL4000: DD150 22T-27T-31T-11T (three wheel configuration)

● Trapping shoe with replaceable wear inserts, safe and easy replace (unique to Caterpillar)

● Suitable for all current track-type systems

Powerpack

PP2 PP3EL2000 ●

EL3000 ●

EL4000 ●

Powerpack — PP2/PP3

● Fixed displacement pump, with a capacity of:PP2 50 L/min (13.21 gal/min)PP3 200 L/min (53 gal/min)

● Operating system pressure:PP2 260 bar (3770 psi)PP3 210 bar (3046 psi)

● Robust hydraulic reservoir; capacity:PP2 165 L (43.6 gal)PP3 300 L (79 gal)


● For use with ISO 68 or ISO 100 hydraulic oils

● Available with 6 (PP2, PP3) or 8 (PP3) valve bank (dependent on function requirement)

● Available with two speed ranging arm facility (EL4000)

● This unit has a pump motor rating of:PP2 30 kW @ 50 Hz (48 hp @ 60 Hz)PP3 75 kW @ 50 Hz (120 hp @ 60 Hz)



Edition 44 20-61

Longwall

20

Mainframe

MF2 MF3 MF4EL2000 ●

EL3000 ●

EL4000 ●

Mainframe — MF2/MF3/MF4

● High structural integrity and absorption of all cutting and haulage forces, providing maximum protection of all major units

● Maximum protection of electrical boxes, providing the highest level of flameproof integrity

● Improved access for maintenance and ease of over-haul and repair

● Versatility of application due to fully modular con-struction

● A split mainframe is available in case of transportation limitations

Hydraulically Activated Top Guards● EL3000 and EL4000 are equipped with hydraulically

activated top guards

Electrical Control Box

ECB2 ECB3EL2000 ●

EL3000 ●

EL4000 ●

Electrical Control Box — MF2/MF3/MF4

● This flameproof module contains the majority of the shearer electrical control and power distribution com-ponents

● High current carrying capacity of 400 amps (ECB2) or 500 amps (ECB3) and can accomodate trailing cables up to 185 mm² [ECB2] (2.9 in²) or 240 mm² [ECB3] (9.4 in²)

● All internal chassis can be ‘bench built,’ tested and stored

● Box contains various low voltage (LV) circuit break-ers which can be reset through the flameproof cover (FLP) cover, reducing downtime

● An extremly powerful PMC Evo-S control system with state-of-the-art Ethernet communication and backup functionality, this allows the shearer to be operated even if the overall control system is not functioning

● This unit also contains cutter motor contactors, cir-cuit breakers, control transformers, current monitor-ing, high voltage (HV) fuses, earth leakage and both visible disconnects



20-62 Edition 44

Longwall

Haulage Transformer Box

HTB2 HTB3EL2000 ●

EL3000 ●

EL4000 ●

Haulage Transformer Box — HTB2/HTB3

● This flameproof model contains the main 253 kVA (HTB2)/350 kVA (HTB3) haulage transformers, power supplies, auxiliary transformer, drive system circuit breaker and

HTB2 one 250 kW, 600 V AC inverter driveHTB3 two 200 kW, 600V AC inverter driveswith regenerative braking module

Electrical Material● All three models are available with headlights, cam-

eras, methane monitoring, end displays and audible alarms

● All electrical material is designed and certified to IEC standards and also complies with other regional and national standards, such as MSHA, GOST, MA, ATEX and DGMS, as well as Australia’s New South Wales and Queensland regulations

Hydraulic Material● All hose assemblies are to ISO 6805 and proof tested

to EN ISO 1402

● The hoses are assembled to Hose Assembly Standard DIN20066:201-10

● All hose and hosing is in compliance with guideline MDG 41 and MSHA regulations

Water Material● All hose assemblies are to ISO 6805 and proof tested

to EN ISO 1402

● The hoses are assembled to Hose Assembly Standard DIN20066:201-10

● All hose and hosing is in compliance with guideline MDG 41 and MSHA regulations

● All three models are available with onboard filtra-tion, dust surpression spray bars, shearer clearers and ranging arms spray rings

Health Monitoring● A comprehensive health monitoring system is avail-

able, including oil levels and temperatures, flows, pres-sures and vibration analysis



Edition 44 20-63

Longwall

20

Machine Automation and Communication● Industry-leading Automation from the Pioneer of State-

based Automation.

● The shearers have a state-of-the-art distributed auto-mation system for the control, monitoring and pro-tection of the shearers. Its modular design allows it to be configured to meet individual control needs, from basic monitoring and protection to advanced automa-tion and data transmission.

● The PMC Evo-S control system with state-of-the-art Ethernet communication and backup functionality allows the shearer to be operated even if the overall control system in not functioning.

● The shearer is equipped with a state-of-the-art indus-try PC in a flameproof housing with plenty of com-puting power, allowing flexibility to upgrade to future features such as condition monitoring.

● A Programmable Logic Controller (PLC) takes care of basic machine control tasks, ensuring that coal is produced.

● Unlike competitor systems, the modularity of the longwall system to operate in “fault-tolerant” mode, even when there is a problem with the overall automa-tion system.

● In other words, integrated automation does not pre-vent control via individual PLC’s in order to keep production up and running.

● Levels of automation:

– Zone-based automation “Navigator 1”

– State-based shearer automation “Navigator 2”

– Integrated longwall automation with “Navigator 2+3”

– “Longwall Navigator” for improved face alignment and horizon control

Optional Machine Mounted Coal Sizer —CS200 (EL3000 and EL4000)● Transmission rating of 200 kW @ 50 Hz (320 hp @

60 Hz)


● Drum speed of 200 RPM (240 @ 60 Hz)

● Drum diameter 900 mm (35.5 in) over picks

● Integral water cooling for transmission and motor

● Square drum hub drive for drum

● Complete with anti-shock lift mechanism (unique to Caterpillar)

● Available motor rating 200 kW @ 50 Hz (320 hp @ 60 Hz)



20-64 Edition 44

Longwall

EL2000 Longwall Shearer

Typical Machine Configurations (Machine Sketch)

Low

Mid-Low

Dimensions (All dimensions are approximate.)

Low Mid-Low

A Distance between Drums with Arms Horizontal 14 155 mm 537" 14 155 mm 537"

B Distance between Ranging Arm Hinge Points 8525 mm 336" 8525 mm 336"

C Distance between Trapping Shoe Centers 6453 mm 254" 6056 mm 238"

D Cutting Heights:

Maximum 3930 mm 155" 4135 mm 163"

Minimum 1800 mm 71" 1900 mm 75"

E Height to Top of Machine Main Body 1444 mm 56.8" 1495 mm 58.8"

F Shearer Drum Undercut of Floor 619 mm 24" 718 mm 28.3"

G Ranging Arm Length (Hinge to Drum) 2815 mm 111" 2815 mm 111"

H Diameter of Shearer Cutting Drum 1600 mm 63" 1900 mm 75"

Shearers● Dimensions


Edition 44 20-65

Longwall

20



Mid-High

High


Mid-High High




D Cutting Heights:

Maximum 4360 mm 172" 4570 mm 180"

Minimum 2200 mm 87" 2500 mm 98"

E Height to Top of Machine Main Body 1571 mm 61.8" 1647 mm 64.8"

F Shearer Drum Undercut of Floor 793 mm 31.2" 866 mm 34"





20-66 Edition 44

Longwall


Typical Machine Configurations (Cross Section)

Low

Mid-Low


Low Mid-Low

A Machine Height over Main Body 1444 mm 56.8" 1495 mm 58.8"

B Ranging Arm Cutting Drum Diameter 1600 mm 63" 1900 mm 75"

C Vertical Tunnel Clearance 598 mm 23.5" 649 mm 25.5"

D Maximum Cutting Drum Overall Width 1150 mm 45.3" 1150 mm 45.3"

E Clearance from Drum to AFC Toeplate 300 mm 12" 300 mm 12"

F AFC Pan Width:

Maximum 1342 mm 53" 1342 mm 53"

Minimum 1032 mm 41" 1032 mm 41"



Edition 44 20-67

Longwall

20




Mid-High

High


Mid-High High

A Machine Height over Main Body 1571 mm 61.8" 1647 mm 64.8"

B Ranging Arm Cutting Drum Diameter 2200 mm 87" 2500 mm 98"

C Vertical Tunnel Clearance 725 mm 28.5" 801 mm 31.5"

D Maximum Cutting Drum Overall Width 1150 mm 45.3" 1150 mm 45.3"

E Clearance from Drum to AFC Toeplate 300 mm 12" 300 mm 12"

F AFC Pan Width:

Maximum 1342 mm 53" 1342 mm 53"

Minimum 1032 mm 41" 1032 mm 41"


20-68 Edition 44

Longwall Shearers● Dimensions



A

D

CF

E

H

B

G

Low

A

D

CF

EH

B

G

Medium


Low Medium




D Maximum Cutting Height for Seam 4400 mm 173" 4500 mm 177"

E Height to Top of Machine Main Body 1690 mm 67" 1950 mm 77"

F Shearer Drum Undercut of Floor 550 mm 22" 519 mm 21"




Edition 44 20-69

Longwall

20



A

D

CF

EH

B

G

High

A

D

CF

EH

B

G

Super-High


High Super-High




D Maximum Cutting Height for Seam 4500 mm 177" 5532 mm 218"

E Height to Top of Machine Main Body 2110 mm 83" 2240 mm 88"

F Shearer Drum Undercut of Floor 510 mm 20" 567 mm 22"





20-70 Edition 44

Longwall



EF

C

B

AD

H

G E

F

C

B

AD

H

G

Low Medium


Low Medium

A Machine Height over Main Body 1690 mm 67" 1950 mm 77"

B Top Guard Height over Main Body 1124 mm 44" 1124 mm 44"

C Ranging Arm Cutting Drum Diameter 2700 mm 106" 2700 mm 106"

D Vertical Tunnel Clearance 800 mm 32" 1000 mm 39"

E Cutting Drum Overall Width 1100 mm 43" 1100 mm 43"

F Clearance from Drum to AFC Toeplate 344 mm 14" 344 mm 14"

G AFC Pan Width 1142 mm 45" 1142 mm 45"

H CSA 0.57 m² 6.1 ft² 0.80 m² 8.6 ft²



Edition 44 20-71

Longwall

20



EF

C

B

AD

H

G E

F

C

B

AD

H

G

High Super-High


High Super-High

A Machine Height over Main Body 2110 mm 88" 2240 mm 88"

B Top Guard Height over Main Body 1124 mm 44" 1124 mm 44"

C Ranging Arm Cutting Drum Diameter 2700 mm 106" 2750 mm 108"

D Vertical Tunnel Clearance 1160 mm 45" 1300 mm 51"

E Cutting Drum Overall Width 1100 mm 43" 1100 mm 43"

F Clearance from Drum to AFC Toeplate 344 mm 14" 344 mm 14"

G AFC Pan Width 1142 mm 45" 1142 mm 45"

H CSA 0.95 m² 10.2 ft² 1.06 m² 11.4 ft²



20-72 Edition 44

Longwall



Model EL3000

A Distance between Drums with Arms Horizontal 17 008 mm 670"

B Distance between Ranging Arm Hinge Points 9600 mm 378"

C Distance between Trapping Shoe Centers 6910 mm 272"

D Maximum Cutting Height for Seam 7188 mm 283"

E Height to Top of Machine Main Body 2656 mm 105"

F Shearer Drum Undercut of Floor 621 mm 24"

G Ranging Arm Length (Hinge to Drum) 3893 mm 153"

H Diameter of Shearer Cutting Drum 3200 mm 126"



Edition 44 20-73

Longwall

20



Model EL3000

A Machine Height over Main Body 3366 mm 133"

B Top Guard Height over Main Body 620 mm 24"

C Ranging Arm Cutting Drum Diameter 3200 mm 126"

D Vertical Tunnel Clearance 1277 mm 50"

E Cutting Drum Overall Width 1100 mm 43"

F Clearance from Drum to AFC Toeplate 380 mm 15"

G AFC Pan Width 1342 mm 53"



20-74 Edition 44

Longwall

Optional AccessoriesModel EL2000 EL3000 EL4000Multi-piece Mainframe

Cowl

Spall Guards

Coal Sizer:

100 kW (134 hp)

200 kW (268 hp) —

Trapping Shoe Ix

(Insert Exchange)

Shearer Clearer

Spray Bars

Central Lubrication System

PMC™ Evo-S

Gate End Data Connection:

Powerline

Fiber Optics —

WLAN

IPC

Zone-based Automation “Navigator 1”

State-based Shearer Automation “Navigator 2”

Integrated Longwall Automation with “Navigator 2 + 3” * * *

“Longwall Navigator” for Improved Face Alignment and Horizon Control Incorporating LASC Technology * * *

VibraGuard™

Cameras

Condition Monitoring

= Standard equipment = Available equipment* = Only with Cat longwall equipment

Shearers● Optional Accessories


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