Product and service

Joy Compak Next Gen hydraulic control system helps improve performance of high production longwall systems

2 min read / May 4, 2022

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High-performance valve technology helps improve cycle times by up to 12%*

May 4, 2022 – When mining in challenging, unpredictable conditions, operators need confidence in their longwall systems, and building that confidence starts with the hydraulic functions in powered roof supports (PRS). Improve the performance of your high production longwall systems by equipping your PRS with the multifunctional Joy Compak Next Gen hydraulic control system, and help facilitate your shearer cutting rate with exceptional cycle time performance.

Engineered to be durable and reliable in rugged environments, the Joy Compak system features corrosion-resistant materials on valve block assemblies, components and the main body. With a reduced number of components to lessen wear and tear, the spool valve in the system is engineered to handle higher flow rates, to help reduce the risk of part failure and promote extended life. Providing flexibility to suit the individual needs of your operation, the Joy Compak Next Gen hydraulic system can be conveniently upgraded or retrofit to any PRS system (regardless of manufacturer).

Increase productivity
The high-performance valve technology of the Compak hydraulic control system helps improve cycle times by up to 12%, compared to the previous model. Designed with operators in mind, this hydraulic system's overall size is reduced by up to 27%** and weight by up to 30%**, making it easier to position, while improving accessibility. Hosing position has also been conveniently located for better access.

The reliable hydraulic valve system helps control modern automated longwall powered roof supports from the Faceboss electronic control system using solenoid control or through manual control with the solenoid push button override function. Ergonomically positioned for ease of access, operators can control the main override function easily and effectively through an integrated pushbutton within the solenoid.

High reliability
Seals play a crucial role in the functionality of the hydraulic spools that operate your roof supports’ functions, and Komatsu's innovative and proven seal technology helps prevent leakage in your hydraulic spools. A simplified, standardized hydraulic circuit design helps provide a reduction in the number of spool valves without impacting performance of the Compak hydraulic system. This design minimizes fitting and connecting hoses, to help reduce potential leak points.

Easily expand the system (over 16 functions) to increase functional requirements to suit your operation’s needs. For example, a standard 10-spool valve can be expanded with ease through separate two- and four-spool expansion modules.

Modular approach streamlines maintenance
To help reduce lead times for replacement parts and streamline maintenance, the hydraulic control system features a modular design incorporating a series of standard components. Easy to change cartridge-style construction makes replacement straightforward and manageable. Manifolds, valve assemblies, cartridge valves and fittings are all standard as part of the system's modular design. The modular approach also makes upgrades easy.

To learn more about Joy-engineered powered roof support (PRS) solutions, click here.

About Komatsu
Komatsu develops and supplies technologies, equipment and services for the construction, mining, forklift, industrial and forestry markets. For a century, the company has been creating value for its customers through manufacturing and technology innovation, partnering with others to empower a sustainable future where people, business and the planet thrive together. Front-line industries worldwide use Komatsu solutions to develop modern infrastructure, extract fundamental minerals, maintain forests and create consumer products. The company's global service and distributor networks support customer operations to enhance safety and productivity while optimizing performance.

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*Comparison based on previous model
**Comparison based on previous model (like-for-like designs) without extra add-ons

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