Underground Crushing

and Conveying Systems

Product Overview

Service Leader
Zero Harm
Highest Lowest Cost
Production Per Ton
World-Class
Mine Performance
Every customer is a reference
Delivering world-class
mine performance
At the core of our commitment to
customers is providing world-class
solutions through our unique direct
service network. This allows us to
collaborate with customers,
developing innovative parts,
products, consumables and systems
that lower their total cost of ownership
and maximize production without
impacting safety.
TM
Our commitment to quality and
reliability is supported by our focus
on Operational Excellence. We use
Joy OpEx principles to eliminate waste,
simplify the process, automate and
remove people from harm’s way.
2 | Joy Global | Underground crushing and conveying systems product overview
Crushing and conveying equipment from Joy Global is designed to work as an
integrated system for maximum availability and productivity. Single-source
supply allows us to provide crushing and conveying equipment designed to operate
as one system.
A material handling system, simple or complex, will perform only as well as its
component parts, the engineering that went into its design, and its installation.
At Joy Global, we strive to make sure that all of our products work together at the
highest levels.
Underground Feeder-Breaker
Joy feeder-breakers, designed for low-to-high seam applications, provide high productivity and reliability in the most rigorous of
conditions. Each feeder-breaker is designed to work as an integral part of your total mining operation. It allows mining, haulage and
conveying systems to work at their most efficient rates to maximize mine production.
Designed to work as
an integral part of The basic elements of each feeder-breaker are similar in design, following decades of
engineering design philosophies and field performance. Each machine begins with robust, all
your mining operation. welded frame construction. The conveyor deck is hard surfaced with chromium carbide overlay
The underground feeder-breaker is an integral part of this system providing efficient,
adding long deck life to the unit. All flights and shafting are made from alloy steel, allowing for smaller sized components at a high tensile
flexible sizing and surge capability, the interface between the batch haulage and the
strength. Controls and components are located for safety, ease of troubleshooting and maintenance.
conveyor belt. The feeder-breaker is the connection between the mining system and
material handling system, allowing both systems to operate at maximum efficiency
Designed to increase your mining efficiency
and productivity.
• Surge capacity allows the feeder-breaker to discharge mined material at the maximum capacity of the haulage equipment
Joy Global can custom design and build a crushing and conveying system to match
your specific mining requirements. • Material throughput is fully variable up to 2,000 TPH (1814 tonne)
• Powerful rotary pick breaker reduces mined material to a consistent, easily handled size
• Mined material is discharged at a steady rate, virtually eliminating spillage and reducing
belt wear
• Available with optional Integrated Continuous Tramming (ICT) crawlers. The heavy-duty frame construction includes a planetary
crawler drive with reversible cap for free wheeling capability
Underground crushing and conveying systems product overview | Joy Global | 3
 General Specifications
Total control
Th e l at e s t in V FD t ec h n o l o g y. . .
Processed material Run-of-mine coal with high percentage of rock content Intake end design Ram car
Various material types and belt 3-way dump
conveyor capacities require flexibility Conveyor width 50 and 56 in 1270 and 1422 mm
Hoppered with sideboards
in the feeder-breaker discharge rate. Overall length 396 - 460 in 10058 - 11684 mm
Available tractive effort Up to 142,000 lbs Up to 64,410 kg
The Optidrive AC variable frequency
Mobility High torque
drive (VFD) system offers variable Drawbar pull Up to 100,000 lbs Up to 45,359 kg
Free wheeling extreme duty crawlers
speed drive conveyor control from
Optional tram speeds 30, 42 and 50 fpm
25% to 100% of the rated throughput
(9.14, 12.8 and 15.2 mpm)
capacity. Water cooled and air cooled Available per customer requirements
drives are available to meet customer
machine and application preferences.

UFB-14 UFB-17 UFB-22

Designed for maximum mobility and performance
Each feeder-breaker has the same basic configuration - hopper, breaker, and conveyor. By Overall width (at intake end) 112 - 148 in 2844 - 3759 mm 108 - 142 in 2743 - 3606 mm 108 - 142 in 2743 - 3606 mm
varying these three aspects of the configuration, we can match our equipment with the
Weight 80,000 - 100,000 lbs 36,287 - 45,359 kg 75,000 - 90,000 lbs 34,000 - 40,823 kg 58,000 - 65,000 lbs 26,308 - 29,483 kg
application. We offer several options for increased mobility, lower ground pressure and
improved traction in varying bottom conditions. Seam height Greater than 65 in Greater than 1650 mm 48 - 64 in 1220 - 1625 mm Less than 48 in Less than 1220 mm

Throughput standard (variable) Up to 1,500 TPH Up to 1360 MTPH Up to 1,000 TPH Up to 900 MTPH 700 TPH 636 MTPH
Intake ends are designed to meet customer preferred haulage means. Ram car, swing gate
Special applications Up to 2,000 TPH Up to 1800 MTPH Up to 1,200 TPH Up to 1091 MTPH N/A N/A
and three-way dump intake ends can be custom-designed to accept discharge from specific
haulage equipment such as ram cars, scoops, shuttle cars and battery-powered haulers. Breaker diameter 21 - 34 in 533 - 864 mm 15 - 21 in 381 - 533 mm 15 - 17 in 381 - 432 mm
Staked or hinged sideboards are also available at various heights for additional capacity.
Breaker pick force (variable) Up to 130,000 lbs Up to 60,000 kg Up to 130,000 lbs 60,000 kg 60,000 lbs 27,200 kg

Unmatched in breaker strength at pick point, the breaker shaft, components and drives Material compressive strength Up to 30,000 PSI Up to 200 Mpa Up to 30,000 PSI 200 Mpa 7,000 PSI 48 Mpa
are designed and capable of fracturing material up to 33,000 PSI (220 MPa) unconfined
Ground clearance:
compressive strength. A direct drive breaker system is standard on most units, which 2 - 17 in 50 - 432 mm 0 - 8 in 0 - 203 mm 0 - 8 in 0 - 203 mm
Intake end
reduces maintenance time and spare parts stock by eliminating chain, sprockets and take-up
Discharge end 12 - 27 in 305 - 686 mm 6 - 21 in 152 - 533 mm 2 - 10 in 50 - 254 mm
on the breaker drive assembly.
Frame height 36 - 51 in 914 - 1295 mm 28 - 37 in 711 - 940 mm 26 in 660 mm
Both hydraulic and mechanical conveyors are available. Most models offer the customer a
Total horsepower (variable) Up to 300 hp Up to 225 kW Up to 250 hp Up to 190 kW 175 hp 130 kW
choice. Hydraulic conveyor drives are recommended for applications involving extremely
Flexibility of configuration High Moderate Minimal
hard materials. Mechanical conveyor drives are offered on most all other applications.

A "feedback" circuit enhances the performance of both hydraulic and mechanical conveyor
drives. The "feedback" circuit monitors loads seen by the breaker shaft and automatically
adjusts the conveyor speed to provide optimum operation and reduce potential overloads.

Quick disconnect for hydraulic pump (optional equipment)

Quick disconnect disengages hydraulic pump from the electric motor and idles
hydraulics when feeder-breaker is not tramming. Equipment life is extended and
operator hands are away from rotating parts for a safer working environment.

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Designed to reduce downtime and increase production Splined breaker shafts
Our splined breaker shafts reduce change-out time by up to 50%.
Operators benefit from our simplified and more robust connection,
fewer parts, less labor and less space needed for removal. With less
Enclosed tail shaft bearings option
downtime during change-out, the machine is put back in service
Feeder-breaker intake ends are available with our enclosed tail
more quickly and is therefore more productive. By moving to a
shaft bearings design.
splined connection versus a compression connection, assembly
• Extends bearing life up to four times longer
time is reduced up to 50%. Overall machine width is reduced by 18"
• Reduces downtime (457mm) at the drive. This increases available space for drive removal
• Increases production and installation, and make repairs easier. Actual splined connection is
25% stronger than previous connections, while maintaining ability to
disassemble when required.

Design includes alloy steel shafts, improved contact seals (three

degrees of separation from contaminants), a larger bearing and
several levels of bearing protection from water and contamination.
Field retrofit-kits are available to upgrade existing machines with
slight frame modifications
Optional bolt-on flights
Conveyor flight replacement is quicker and easier with our bolt-on,
alloy steel flight design. With this option, operators have the flexibility
to add additional flights and improve product sizing. Instead of the
welded flight end design, four bolts hold each flight in place. No
special conveyor chain links are included and there is no need to
remove chain covers. The new design also retrofits with standard
conveyor chain. Downtime to replace flights is reduced by up to 75%.
Additional UFB-14 options
Optional equipment for the UFB-14 includes a tail piece and impact
bed for smoother transfer of material to the belt conveyor system.
This built-in loading section option is used in lieu of a separate
conveyor tail loading section. Belt alignment can be improved by
adjusting the tail section training cylinders as required.
Belt moves are quicker and easier since the conveyor belt is pulled
by the feeder-breaker as it is trammed to a new location and re-
positioned. Operators should consult Joy Global personnel during
the mine planning process for maximum belt pull capabilities. The
requirement to bolt a separate tail loading section in place and
un-bolt during a belt move is eliminated. Machine-stabilizing roof
beams or cylinders are also part of the design for added stability
during operation.

Available equipment includes our conveyor belt lifter that can be

used to suspend the conveyor belt in place as sections of conveyor
structure are being added.
Optional hydraulic conveyor chain tensioning system
Chain take-up can easily be adjusted to the proper tension with
the push of a button. This means that you can easily adjust chain
tension without removing covers on the intake end and manually
adjusting the chain. With less downtime during change-out, the
machine is put back in service more quickly.
• More robust design with fewer parts to fail

• Tensioning is more accurate, leading to improved machine

performance and increased component life

• Under normal conditions, chain adjustment time is reduced from

two hours to two minutes

The system is capable of providing the optimal conveyor tension

without over-tensioning the chain under normal operating conditions.

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Engineering Typical structure arrangements Proven conveyor performance
The drive section is one of the most important terminal components in a conveyor
expertise Mine duty rigid conveyors system. It should be carefully selected to ensure that the arrangement is suited

Conveyor system to the application. There are three basic types: single pulley, adjustable boom and
With the introduction of high production longwall mining many years ago, the need
simulation software remote drive.
developed for a conveyor structure that was more sturdy, yet still portable enough
Successful underground conveyor to be installed quickly. The Joy mine duty rigid conveyor, with a structural channel The single pulley type drive is available for low horsepower conveyors. The adjustable
systeminstallations start with proper side-member with boltless construction, was designed to fill this need. boom type drive is highly portable and can be furnished as a head drive or a tandem
engineering. Joy Global utilizes pulley skid configuration.
proprietary conveyor simulation
Floor mounted rigid structure The remote drive is most frequently used on permanent installations. It is available
software to model system behavior 3048 mm (10')
with single, dual, triple, or quadruple drive trains. It is also available with tandem drive
under a wide variety of loading 762 mm (2' 6") 1524 mm (5') 762 mm (2' 6")
Channel Support stand Idler Idler Support stand pulleys or with our four pulley arrangement.
conditions before your c onveyor side rail assembly assembly

Belt travel
is installed. Each specification is designed and furnished to your requirements utilizing the most
Drop bracket
assembly
modern and up-to-date methods available. We have been the leader in high tension
conveyor terminals for many years and have designed conveyors with up to 10,000
connected horsepower.
Idler return roll 3048 mm (10') Idler return roll

Roof mounted rigid structure

Properly designed terminal equipment
FLOOR MOUNTED
RIGID STRUCTURE is at the heart of any conveyor system.
The correct application is key to a conveyor’s
Roof attachment
angle 762 mm (2' 6")
3048 mm (10')
1524 mm (5') 762 mm (2' 6")
performance and productivity.
Idler Idler

History
Rail connecting cuff assembly assembly

Tradition in
quality and pride
Joy Global, a leader in the materials
handling industry for decades, has
incorporated progressive design,
dependability and ruggedness into
our complete line of mining conveyor
equipment. Each year, hundreds
of miles of intermediate structure
are installed in mining applications.
These types of mining conveyors are
easily installed and can be quickly
extended or retracted.
Belt travel
Drive options
Proper drive selection varies depending on many factors including the operating
Bottom chain Channel Drop bracket
connecting bracket side rail assembly environment, maintenance expertise (hydraulic vs. electrical), overall horsepower
Idler return roll 3048 mm (10') Idler return roll
requirements, and the investment required to make the system perform at the
highest level. The goal when selecting a particular drive option is to provide a
Service and support
Catenary conveyors conveyor powering system that is controllable and friendly to the system from a
At Joy Global, we strive to make sure that all
Longwall mining requires conveyor structure that is extremely portable due to the rapid starting and load sharing standpoint, thereby protecting the conveyor belt and the
of our products work together and perform
rate of extraction during the longwall retreat. This structure must be very rugged in many components that make up the conveyor system. Too much stress on either
at the highest levels. We are committed to
order to withstand the heavy loading encountered in longwall mining. The Joy hinged can result in extended downtime and lost production. A system that allows a manufacturing technologically advanced
ROOF MOUNTED repeatable, linear time ramp during start-up and can balance load distribution during equipment backed by a dedication to service.
handle catenary structure is designed to meet this need. The design uses rigid side
RIGID
frames made of round tubing. In addition, the number of loose parts is minimized to operation (regardless of load) offers the most protection for your conveyor system.
reduce losses while moving from one mining panel to another. In today’s market, four of these systems have emerged as the best available options:
controlled clutch slip system, controlled fill fluid coupling, low-voltage VFD control
Catenary structure system, and medium-voltage VFD control system. Each has its advantages and

3048 mm (10')
disadvantages. We can supply all of these systems in addition to other drive options.
Side rail
762 mm (2' 6") 1524 mm (5') 762 mm (2' 6") We continually work with our customers to determine which system best fits their
Support stand Idler Idler Support stand
assembly Belt travel assembly particular requirements.

A Joy Global representative can assist you in determining the best technology for
your application and provide unparalleled expertise in the selection of conveyor
components or assist you with complete system design.

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CATENARY
STRUCTURE
Conveyor drives

(Alignment-free) drive/discharge section Large remote drives

LC drive (polychain design) Remote A-frame head drive

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Tripper booster drives Discharges
Tripper booster drives provide smooth start-up and shutdown operations with full A-frame remote discharge with boom discharge
tension control on extremely long single-flight panel conveyors. Joy tripper booster
drives are able to respond to varying load conditions while maintaining a stable
operating system.

These drives can have a significant impact on reducing downtime and improving
productivity on many operating conveyor systems.

4 Pulley

A-frame remote discharge with snub pulley

2 Pulley

Remote A-frame discharge

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Typical conveyor arrangements

Drive arrangement with adjustable boom

Adjustable boom drive Hydraulic take-up section Tail loading section

Drive arrangement with remote drive

Intermediate loading section

A-frame remote discharge Remote drive Hydraulic take-up section A-frame tail section

Drive arrangement with belt storage unit and All-electric winch

Remote drive Belt storage unit All-electric winch

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All-electric and Pony winches
Constant tension winches are an alternative to the traditional sheaved cylinder take-up
designs. Greater line pull and longer travel are the main advantages of the winch design.
Our first generation constant-tension winch employed a hydraulic power system. In the
fall of 1995, we revolutionized the high-tension take-up market with the introduction of
an all-electric constant tension winch. This technology enables us to furnish a take-up
system without sheaves, cylinders and hydraulic power units. With line pull ranging from
25,000 lbs. - 150,000 lbs., our constant tension winch take-up is capable of meeting
your belt tensioning requirements on lengthy, high-tension applications.
Hydraulic take-ups
Any conveyor system is only as productive as its take-up. Joy hydraulic cylinder
take-up sections are designed to pull slack out of the belt for a smooth conveyor start,
regardless of the loading conditions. Our take-up sections are designed to withstand
rigorous mining conditions with minimum downtime. Joy take-up sections are available
in standard arrangements ranging from 10 feet to 40 feet of travel.

All-electric Pony winch offers digital control

in a very small package
The Pony winch is designed for conveyor systems that do
not require extremely high take-up tensions. Pony winches
are available in 30, 40 and 50 horsepower configurations. The
standard configuration utilizes a non-grooved drum, gearbox,
electric motor, electric brake, encoder and a controller. The drum
can be grooved as an option.

Horizontal take-up unit (side mounted cylinder shown)

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Hydraulic power units
The Joy hydraulic take-up power unit provides an accurate, reliable system for proper
tensioning of your belt system. Improper tensions, whether high or low, are severely
damaging to the belt and components such as pulleys, shafts and bearings. A system
of pressure-sensing switches provides constant monitoring of the hydraulic circuit.
A low pressure switch starts the hydraulic pump when a minimum safe operating level
is reached. A high pressure switch stops pump action when the maximum level is
attained. This system provides an intermittent operating motor and pump as opposed
to a continuous system, resulting in a great reduction in maintenance problems. All
units are factory set and tested based on your tension requirements.
All hydraulic unit components, including the
accumulator, are integrally mounted on a
common welded steel skid type base. The
unit is designed to be compatible with either
standard hydraulic, synthetic, or water-in-oil
type fire-resistant fluids. Immersion heating
element and control circuits are available for
cold climate operations in 25, 40, 60, 100 and
125 horsepower units.
Controllers provided by Joy Global
Joy Global has long been the industry leader with its Smartveyor technology. This
technology is made possible through the use of PLC control systems. With controllers
for main and tripper drives, the overall conveyor control system is capable of handling
the most complex conveyor systems. With tried and proven start packages including
DC, VFD, and controlled fill fluid coupling, our systems are capable of providing start
times in excess of 120 seconds and optimal load sharing between main and multiple
tripper drives. Whether you have a short stacker belt or a long single-flight mainline
belt, we can provide a custom-designed control system to meet your conveying needs.
18 | Joy Global | Underground crushing and conveying systems product overview
Belt storage units
Increased production afforded by longwall mining systems has had a major impact on
the cost of material mined. However, the full potential of a longwall system cannot be
realized without the utilization of an effective, trouble-free belt storage unit.
The Joy belt storage unit consists of a bolted construction rail system, stationary pulley
assembly, rolling carriage assembly and a winch assembly. The rugged framework
and carriages are substantial enough to withstand rigorous mining conditions but also
portable enough for movement between installations. For relocation, the winch and
moveable carriage are removed and the frame is disassembled into sizes conducive to
your mining environment. After re-assembly, the wire rope is re-attached to the carriage
and the unit is ready to operate. Because of its modular design, no tedious reducer/
motor/winch realignment is necessary for the winch component.
The carriage and belt supports (drop-off carriages) are designed with vee-grooved
wheels. These wheels move along inverted angles that are secured to heavy-duty
I-beams and automatically drop return belt supports (drop-off carriages) at set
intervals along this unit as the rolling carriage adjusts and belt is stored.
The drop-off carriages are then automatically retracted as the
rolling carriage moves back.
As the longwall face retreats, the main haulage systems must be
shortened. This procedure is completely automatic and requires
no operator. All units have manual settings to facilitate belt
splicing and maintenance.
Joy belt storage units are available in single or multiple lap
configurations that can store up to 1,200 ft. of belt. Our units can
be designed to meet the specific needs of your conveyor system.
All-electric constant tension winches, used in conjunction
with belt storage units, provide carriage travel in excess of 1 ft.
per second.
Typical 6 lap belt storage unit
Typical 4 lap belt storage unit and CTW
Underground crushing and conveying systems product overview | Joy Global | 19
Engineered transfer systems Belt winders and pinch roll drives
and loading sections Belt winders simplify and improve the control of your belting when you
are adding belt to, or removing belt from your system. The belt winder
Engineered transfer systems incorporates a pinch-roll drive arrangement that delivers a constant winding
speed and pull to the belt roll. The pivotal spool arrangement allows the spool
Our engineered transfer systems include a discharge section,
of belt to be rotated 90 degrees in either direction. Lift cylinders make removal
loading section, and custom-designed transfer chute that are all
and installation operations significantly easier.
engineered and designed as one piece to help eliminate spillage
problems at the point of transfer.

Belt winding system typical layout

Tail loading section

Tail loading sections are designed to withstand the abusive conditions encountered
in conveyor loading. Tail sections of varying heights are available to fit your particular
requirements. Units are available with solid type pulley, lagged solid pulley, wing type
pulley and spiral type self-cleaning pulley arrangements.
All tail sections are available with hinged deck plates to help maintain both skirt rubber
and idlers. Designs incorporating either rubber disc impact idlers, steel roll idlers or
impact/slider beds are available. Special purpose tail loading sections may be furnished
to your exact specifications.

Pinch roll drives

Intermediate loading section
Although first developed to work in tandem with the
Intermediate loading sections are used in loading areas along the length of your belt
belt winder, the pinch roll drive can also be used with
line. These loading sections can be furnished with impact idlers, impact beds or a
numerous belt retrieval devices to introduce or remove
combination of the two. Sealing skirt boards are standard on all intermediate sections.
belt from your conveyor system at a constant rate of
speed and torque. An additional benefit of the pinch roll
drive, when used in conjunction with a belt clamp station,
is the improvement of belt splicing. The pinch roll drive will
allow you to easily spot splices for installation or repair.

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Pulley offerings Joy Global
MTD-pulley mine-duty turbo-disc pulley Joy Global Inc. is a worldwide mining machinery and services company. Through our
• Solid plate end-discs market-leading brands — P&H, Joy and Montabert — we manufacture and service

• Near full-penetration weld between end-discs and rim advanced original equipment and provide aftermarket parts for underground and
surface mining applications. We also manufacture, sell and service material handling
• B-LOC B106 or B106-IN keyless locking elements
systems and components for a variety of applications. Our integrated technology,
• Cold rolled shafting without turn-downs or hot rolled
material with turned and polished transitions services and solutions are a critical component of operations in a variety of
commodity markets including energy, hard rock and industrial minerals.
• Hot vulcanized and machined lagging
• Static balancing of pulley assembly

Customized training

• Training schools
TD-pulley engineered turbo-disc pulley
• Computer-based training
• One piece machined turbo-shaped end-discs
• Electronic parts books
• Near full-penetration weld between end-discs and rim
• B-LOC B106 or B106-IN keyless locking elements
• Hot rolled or forged shafting with turned and polished
transitions on turn-downs
• Machined pulley O.D. as required per application
• Hot vulcanized and machined lagging Safety first
• Static balancing of pulley assembly Personalized service
Our drive for zero harm
• Field service representatives Joy Global strives to provide
TB-pulley heavy-duty T-bottom pulley • Field sales engineers equipment that meets the highest
• One piece "T" shaped end-discs • Engineering specialists standard of safety. Employee
• 100% full-penetration weld between end-discs and rim and operator safety is always
• B-LOC B115 or B112 keyless locking elements taken into consideration when we
• Hot rolled or forged shafting with turned and polished design equipment.
transitions on turn-downs
• Machined pulley O.D. as required per application
• Hot vulcanized and machined lagging Comprehensive support
• Static balancing of pulley assembly • Quality OEM parts
• Scheduled and special deliveries
DS-pulley dead-shaft engineered pulley with internal bearings • 24-hour, 7-days-a-week customer service
• Cost effective and lighter pulley design possible • Terminal rebuilds
• Spherical roller bearings or bearing cartridges • Machine and parts warranties
• Through-Shaft lubrication • Computerized inventory system
• Alignment free installation • Repair and return program
• Support pedestals sized to replace pillow blocks
• Adjustable support centers
• Proven design for belt speeds up to 1,500 ft/min

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 Joy Global worldwide locations

Guards removed for photos. Equipment should be guarded while in operation to comply with local regulations.
Product designs, specifications and/or data in this document are provided for informational purposes only and are not warranties
of any kind. Product designs and/or specifications may be changed at any time without notice. The only warranties that apply to
sales of products and services are Joy Global’s standard written warranties, which will be furnished upon request.
Joy Global, Joy, Montabert, P&H, Pony, Smartveyor and related logos are trademarks
of Joy Global Inc. or one of its affiliates.
© 2017 Joy Global Inc. or one of its affiliates. All rights reserved.
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