Surface Belt
Structure
CEMA C & D SERIES
Custom-Designed
Caterpillar has a full range of rugged and reliable belt systems and belt products unsurpassed in performance
and service life custom-designed solutions to handle the most demanding bulk-material handling applications,
both on the surface and underground.
Cat Steel Rolls
The Cat roll design is the result of over two years
of design and engineering effort and represents new
technology in idler designs.
A new shaft end configuration allows us to retrofit Cat
rolls into virtually any competitors frame with a unique
retrofit adaptor. Our end cap (bearing housing) has been
redesigned for increased strength and a close fit to the
deflector cap.
Our automated assembly process includes three separate,
metered grease inputs to ensure every roll has plenty of
grease for a lifetime of trouble-free operation.
The Idler PAL bearing cavity design
allows for extra lubricant capacity,
which is unmatched in the
industry and assures
that the grease
stays where you
need it: in the
bearing.
Idler PAL (Positive
Automatic Lubrication)
Grease moves due to taper of rolling
elements in the bearing
Grease expands due to increased bearing
temperatures in operation
The compensator disc moves outward,
compressing the wave spring
When rotation stops and grease
contracts, the wave spring exerts
slight pressure on the compensator
disc, ensuring no voids in the grease
Greased for Life: the Idler PAL
self-lubricating system
Electronic Quality Tracking: An Industry First
Each shaft end is coded at time of assembly with:
Day of the year
Production year
Individual serial number
Automatic data recording of rotational torque,
TIR (Total Indicated Runout) and bearing play
of each individual roll is tied to the serial number.
Caterpillar is the first idler manufacturer to offer
individual serialized rolls as a standard. Now you can
tell when the roll was manufactured, allowing accurate
monitoring of roll life. No other idler manufacturer checks
each roll for rotational torque, TIR and bearing play.
Plus, each roll is test run, ensuring complete grease
distribution throughout bearings and seals.
Cat steel rolls going through an automated five-stage assembly
and testing process.
For example, this roll was
assembled on the 85th day of
2005 and it was the 35th roll
assembled that day.
The computer panel of the roll assembly machine graphically
monitors and controls the five stages of the assembly process.
Surface Belt Structure
All Cat surface belt structure conforms to CEMA
(Conveyor Equipment Manufacturers Association)
standards. The intelligent design and manufacturing
technology provide long life, high reliability and
superior performance.
Carrying Idlers
Cat in-line carrying idlers are designed for the rugged
and sometimes adverse conditions that exist in all
surface mining industries. Multiple configurations and
roll material options provide maximum flexibility for all
surface mining belt conveyors.
Carrying idlers
Impact Idlers
Cat in-line impact idlers are ideal for loading and highimpact belt conveyor applications and conditions. Roll
technology utilizing two-piece tapered roller bearings and
a reliable sealing system provide excellent performance in
dirty and adverse mining conditions.
Impact idlers
Return Idlers
Cat return idlers are designed for the rugged and
sometimes adverse conditions that exist in all surface
mining industries. Multiple configurations and roll
material options provide maximum flexibility for all
surface mining belt conveyors.
Steel Rolls above ground applications
Diameters:
4", 5" and 6" CEMA C or D (load capacity,
30,000 60,000 hrs.)
6" and 7" CEMA E (load capacity, 60,000 hrs.)
Shell Thickness:
0.1793"
0.25"
Carrying Assembly Idler Styles
In-line
Single tube cross member
Belt Width
24", 30", 36", 42", 48", 54", 60", 72"
4
Return idlers
Rubber Disc Return Idlers
Rubber disc return idlers are ideal for critical return
belt conditions in conveyor applications.
The utilization of rubber dics provides additional wear
capacity to the idler and also protects the conveyor
belting in any mining conditions.
Replacement Steel, EXALON, and
Rubber Disc Rolls
Rubber disc return idlers
Roll material options provide superior performance in
any conditionswet, dry, clean, dirty, abrasive and
corrosive environments.
Steel rolls
EXALON rolls
Rubber disc rolls
Cat EXALON rolls are ideal for use in highly corrosive and abrasive above ground environments.
Cat EXALON Rolls
EXALON light-weight
polyethylene rolls.
Another Perfect Choice for Underground
Mining Operations
In addition to its world-class steel rolls, Caterpillar also
offers a highly successful range of CEMA C-, D- and
E- class rolls made of a proprietary high molecular
weight polyethylene (HMWPE) called EXALON.
While steel rolls are effective in most bulk-material
handling applications, some applications benefit from the
use of the EXALON roll product. Applications with
environments that are highly corrosive, abrasive, wet or
have a tendency for material buildup on the roller are
ideal for the EXALON roll and its additional features
and benefits.
Smooth Operators
EXALON inline idler
Tube-based, with higher concentricity further enhanced
by final machining (poly-body) for reduced belt wear,
the EXALON roll offers balanced, vibration-free
running. These fully conductive rolls are MSHA-certified
as safe for underground use. They have two certifications:
IC-56/1 flame-resistant and IC-56/2 flame-resistant
and static-dissipating.
EXALON inline idler
EXALON Benefits at a Glance
MSHA certified
Certified for underground use:
IC-56/1 flame resistant and
IC-56/2 flame resistant and static dissipating.
Longer shell life
EXALON rolls last two to three times longer
than steel rolls in highly corrosive and/or
highly abrasive environments.
Low maintenance
Cat Idler PAL ensures life-long grease management.
EXALON is a high molecular weight polyethylene conveyor roll constructed of
a proprietary formulation, which is fully conductive and MSHA approved.
Versatile, Low-Maintenance
EXALON rolls can be retrofitted to any frame even
those of competitors. Custom sizes can be ordered for
special applications. EXALON heads are installed using
a unique spin-welding method, creating a single-piece
roll construction. Cat Idler PAL ensures life-long grease
management, making them virtually maintenance-free.
Tested for Quality
All Cat EXALON and steel rolls are processed through
an automated assembly system, which tests and records
rotational torque, total indicator run-out and axial end
play. Upon acceptance, each idler roll is then permanently
marked with a serial number and date of manufacture.
By extending belt life and reducing downtime,
EXALON rolls deliver significant savings to
mine operators.
Reduced belt damage
The smooth PE surface minimizes belt friction
and wear and acts as a slider bar in the event of a
bearing seizure. The all-PE body means there are
no sharp pizza cutter edges.
Lighter weight
EXALON rolls are 20-30% lighter than equivalent
steel rolls.
Corrosion-proof
Being made of HMWPE, the EXALON roll is not
subject to corrosion.
Sound dampening
Reduce noise by up to 20%, particularly in
underground applications.
Resistance to material buildup
The smooth, non-adhesive HMWPE surface resists
material buildup.
Cost-efficient
EXALON offers cost savings through extended life,
reduced downtime, longer replacement intervals and
reduced belt damage.
Versatile
The entire EXALON product line can be produced
to fit any existing manufacturers top-side and return
frame assemblies.
Surface Belt Structure CEMA C & D Series
For more complete information on Cat products, dealer services, and industry solutions,
visitus on the web at mining.cat.com and www.cat.com
2011 Caterpillar Inc.
All rights reserved
Materials and specifications are subject to change without notice. Featured machines in
photos may include additional equipment. See your Cat dealer for available options.
CAT, CATERPILLAR, their respective logos, Caterpillar Yellow and thePower Edge trade
dress, as well as corporate and product identity used herein, aretrademarks of Caterpillar and
may not be used without permission.
AEXQ0592-01
