Caterpillar® Product Information

Performance Report
May 1996

Caterpillar® 5230 ME

Job Purpose Evaluate productive capability of 5230 mass excavator

Job Site Western U.S. Coal Mine

Study Dates June 19-23, 1995

Material Overburden, virgin clay/rock mix. 3000 lbs/LCY (1.8 t/LCM),

3750 lbs/BCY (2.2 t/BCM)
Coal, blasted, 1500 lbs/LCY (0.9 t/LCM), 2000 lbs/BCY (1.2 t/LCM)

Loading Tools
5230 mass excavator 20.2 yd (15.4 m3) bucket - overburden
36.0 yd (27.5 m3) bucket - coal

For Dealer Sales Personnel

Haul Units 130 Ton Wabco Electric Drive

Observers Rick Miller, Large Mining Products, Caterpillar

Karl Weiss, Large Mining Products, Caterpillar
Kevin Thorlakson, Denver District Office, Caterpillar
Rob Hoenes, Large Mining Products/Corporate Mining Group, Caterpillar
Roger Rohr, Salesman, Tractor and Equipment
Lou Marcon, Tinaja Hills Training Center, Caterpillar

Written By Rob Hoenes, Large Mining Products/Corporate Mining Group, Caterpillar

2
1. The 5230 exceeded design productivity targets in overburden, Significant Results
swinging an average of 33 tons (30 tonnes) in less than 30 seconds.

2. Loader productivity into the combo body did not vary relative to
loading over the side or tailgate of the truck.

3. The 5230 reach was sufficient to maintain the floor on 11+ foot
(3.4 m) bench.

4. The 5230 worked a 20+ foot (6.1 m) coal bench with sufficient
reach for loading material, requiring some help maintaining the
floor at the front of the trucks.

5. The 36 yd3 (27.5 m3) coal bucket performed to acceptable levels

with 90% or higher bucket fills.

The 5230 mass excavator top loaded the 130 ton (118 tonne) Job Description - Overburden
Wabco trucks from a 10-14 foot (3.0-4.3 m) bench.

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Overburden -Truck Positioning
Straight Back

Trucks were first backed up perpendicular to the bench.

4
 Overburden -Truck Positioning
Modified Drive By

Next, a modified drive by system was evaluated, where drivers

passed along the bench and then backed into the cut area more
parallel to the bench.

5
Job Description - Coal The 5230 top loaded the same trucks from a 20-22 ft coal bench.

The trucks backed in perpendicular to the bench.

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 Summary of Results

5230 Mass Excavator loading overburden over truck tailgate (trucks modified drive by)

Load 0.160 min Avg. Truck load 134.8 tons 122.3 tonnes
Swing Loaded 0.120 min Avg. Bucket load 33.7 tons 30.6 tonnes
Dump 0.070 min Bucket Fill Factor 111%
Swing Empty 0.141 min
Total Cycle 0.491 min (29.5 sec)
Passes 4 Truck per 60 min 26.8
Truck Cycle w/ .7 exchange 2.24 min Truck per 50 min 22.3
Sys Prod per 60 min 3610 tons/60 min 3275 tonnes/60 min
Sys Prod per 50 min 3010 tons/50 min 2730 tonnes/50 min

5230 Mass Excavator loading overburden over truck side (trucks backing into bench)

(Segments not available) Avg. Truck load 135.6 tons 123.0 tonnes
Avg. Bucket load 33.9 tons 30.8 tonnes
Total Cycle 0.485 min (29.1 sec) Bucket Fill Factor 110%
Passes 4 Truck per 60 min 27.0
Truck Cycle w/ .7 exchange 2.22 min Truck per 50 min 22.5
Sys Prod per 60 min 3660 tons/60 min 3320 tonnes/60 min
Sys Prod per 50 min 3050 tons/50 min 2770 tonnes/50 min

5230 Mass Excavator loading coal over truck side (trucks backing into bench)

Load 0.198 min Avg. Truck load 121.4 tons 110.1 tonnes
Swing Loaded 0.107 min Avg. Bucket load 24.3 tons 22.0 tonnes
Dump 0.056 min Bucket Fill Factor 90%
Swing Empty 0.113 min
Total Cycle 0.474 min (28.4 sec)
Passes 5 Truck per 60 min 22.7
Truck Cycle w/ .7 exchange 2.65 min Truck per 50 min 18.9
Sys Prod per 60 min 2750 tons/60 min 2500 tonnes/60 min
Sys Prod per 50 min 2290 tons/50 min 2075 tonnes/50 min

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Discussion Rock Bucket
The material studied heaped well in the 5230 rock bucket resulting
in fill factors approaching 110%.

Coal Bucket
The coal bucket used was designed for coal density of
1600 lbs/LCY (1.0 t/LCM). Actual density was determined to be
1500 lbs/LCY 0.9 t/LCM) contributing to the lower than expected
payloads of 24.3 (22 T). This study also revealed that the tooth
spacing of the coal bucket was too wide resulting in excess
spilling. The bucket has been redesigned to address this.

Tons Payload — Tons/Tonnes Tonnes

50
40
40
30
30
20
20

10 10

0 0
Rock-Parallel Rock-Straight Coal

Bucket Fill
%
140
120
100
80
60
40
20
0
Rock-Parallel Rock-Straight Coal

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Rock Bucket Load

Coal Bucket Load

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Cycles The cycles from this study demonstrate the 5230 can 5 pass load in
2 minutes or less. “Splits” were not taken for the loader during the
portion of the test where the trucks backed straight into the bench.

Cycle — Minutes
0.7
0.6
0.491 0.485 0.474
0.5
0.4
0.3
0.2
0.1
0
Rock-Parallel Rock-Straight Coal
Swing Swing
Dump Load
Loaded Empty

Conclusion Truck positioning did not affect LOADER productivity between

backing straight into face and using the modified drive by. The
difference in sideboard and tailgate height was not enough to affect
productivity. However, SYSTEM productivity would be affected
due to decreased exchange times in a fully trucked situation using
the modified drive by setup.

In overburden the angle of repose varied along the rock/dirt face

from 30 to 60 degrees. The 5230 was able to keep material pulled
back and the floor clean for the trucks to come in.

In coal the machine successfully loaded material from the 20 foot

bench. The face was nearly vertical, but due bench height a
cleanup unit was required occasionally.

Productivity and performance expectations were met for this

particular application.

The information contained herein is intended for circulation only to Caterpillar and dealer employees whose duties require knowledge of such reports and is
intended exclusively for their information and training. It may contain unverified analysis and facts observed by various Caterpillar or dealer employees. However,
effort has been made to provide reliable results regarding any information comparing Caterpillar built and competitive machines. Effort has been made to use the
latest available spec sheet and other material in the full understanding that these are subject to change without notice.
Any reproduction of this release without the foregoing explanation is prohibited.

TEXR0240
May 1996

© 1996 Caterpillar
Printed in U.S.A.