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Overview

Highly productive longwalls count on Cat® Shearers to meet production goals.

Specifications

Units:
Typical Machine Length 55.8 ft 17.0 m Less
Installed Power 3680.0 hp 2295.0 kW Less
Haulage System AC inverter drive AC inverter drive Less
Applicable Minimum Pan Width 52.8 in 1342.0 mm Less
Available Cutting Power 2 × 750 kW; 2 × 860 kW 2 × 750 kW; 2 × 860 kW Less
Available Haulage Motors 2 × 150 kW (2 × 240 hp) 2 × 150 kW (2 × 240 hp) Less
Body Height 42.0 in 1070.0 mm Less
Coal Sizer 320.0 hp 200.0 kW Less
Cutting Drum Diameter Up to 3.50 m (Up to 138 in) Up to 3.50 m (Up to 138 in) Less
Haulage Pull Up to 1075 kN (Up to 120 tons) Up to 1075 kN (Up to 120 tons) Less
Haulage Speed Up to 31.1 m/min (Up to 102.03 ft/min) Up to 31.1 m/min (Up to 102.03 ft/min) Less
Height Range 4.00-7.00 m (158-276 in) 4.00-7.00 m (158-276 in) Less
Machine Weight Approx. 130 tonnes (Approx. 143 tons) Approx. 130 tonnes (Approx. 143 tons) Less
Operating Voltages 3,300V; 4,160V 3,300V; 4,160V Less
Pump Motor 120.0 hp 75.0 kW Less

Machine @ 50 Hz

Available Cutting Power 2 x 860 kW (2 x 1,153 hp); 2 x 750 kW (2 x 1,006 hp) 2 x 860 kW (2 x 1,153 hp); 2 x 750 kW (2 x 1,006 hp) Less
Body Height 42.0 in 1070.0 mm Less
Coal Sizer 268.0 hp 200.0 kW Less
Cutting Drum Diameter Up to 3500 mm (Up to 138 in) Up to 3500 mm (Up to 138 in) Less
Cutting Drum Speed 30.8, 35 and 43 rpm 30.8, 35 and 43 rpm Less
Haulage Motor 2 x 150 kW (2 x 201 hp) 2 x 150 kW (2 x 201 hp) Less
Haulage Pull Up to 1075 kN (110 tons) Up to 1075 kN (110 tons) Less
Haulage Speed Up to 31.1 m/min (102.03 ft/min) Up to 31.1 m/min (102.03 ft/min) Less
Haulage System AC inverter drive AC inverter drive Less
Installed Power Up to 2295 kW (Up to 3,078 hp) Up to 2295 kW (Up to 3,078 hp) Less
Machine Weight (approximate) 128.0 tons 130.0 tonnes Less
Minimum Pan Width 52.8 in 1342.0 mm Less
Operating Voltage 3300.0 volts 3300.0 volts Less
Pump Motor 101.0 hp 75.0 kW Less
Seam Range 4.0-7.0 m (158-276 in) 4.0-7.0 m (158-276 in) Less
Typical Machine Length (drum centers) 55.8 ft 17008.0 mm Less

Machine @ 60 Hz

Available Cutting Power 2 x 1029 kW (2 x 1,380 hp); 2 x 895 kW (2 x 1,200 hp) 2 x 1029 kW (2 x 1,380 hp); 2 x 895 kW (2 x 1,200 hp) Less
Body Height 42.0 in 1070.0 mm Less
Coal Sizer 320.0 hp 239.0 kW Less
Cutting Drum Diameter Up to 3500 mm (Up to 138 in) Up to 3500 mm (Up to 138 in) Less
Cutting Drum Speed 37, 42 and 51.6 rpm 37, 42 and 51.6 rpm Less
Haulage Motor 2 x 179 kW (2 x 240 hp) 2 x 179 kW (2 x 240 hp) Less
Haulage Pull Up to 1177 kN (120 tons) Up to 1177 kN (120 tons) Less
Haulage Speed Up to 30.1 m/min (98.7 ft/min) Up to 30.1 m/min (98.7 ft/min) Less
Haulage System AC inverter drive AC inverter drive Less
Installed Power Up to 2744 kW (Up to 3,680 hp) Up to 2744 kW (Up to 3,680 hp) Less
Machine Weight (approximate) 143.0 tons 145.0 tonnes Less
Minimum Pan Width 52.8 in 1342.0 mm Less
Operating Voltage 4160.0 volts 4160.0 volts Less
Pump Motor 120.0 hp 89.0 kW Less
Seam Range 4.0-7.0 m (158-276 in) 4.0-7.0 m (158-276 in) Less
Typical Machine Length (drum centers) 55.8 ft 17008.0 mm Less

Electrical Material

Type This model of shearer is available with headlights, cameras, methane monitoring, end displays and audible alarms. This model of shearer is available with headlights, cameras, methane monitoring, end displays and audible alarms. Less
Type All electrical material is designed and certified to IEC standards and also complies with other regional and national standards. All electrical material is designed and certified to IEC standards and also complies with other regional and national standards. Less

Hydraulic Material

Type All hose and hosing is in compliance with guideline MDG 41 and MSHA regulations. All hose and hosing is in compliance with guideline MDG 41 and MSHA regulations. Less
Type The hoses are assembled to Hose Assembly Standard DIN20066:201-10. The hoses are assembled to Hose Assembly Standard DIN20066:201-10. Less
Type All hose assemblies are to ISO 6805 and proof tested to EN ISO 1402. All hose assemblies are to ISO 6805 and proof tested to EN ISO 1402. Less

Water Material

Type All hose assemblies are to ISO 6805 and proof tested to EN ISO 1402. All hose assemblies are to ISO 6805 and proof tested to EN ISO 1402. Less
Type This shearer is available with onboard filtration, dust suppression spray bars, shearer clearers and ranging arm spray rings. This shearer is available with onboard filtration, dust suppression spray bars, shearer clearers and ranging arm spray rings. Less
Type All hose and hosing is in compliance with guideline MDG 41 and MSHA regulations. All hose and hosing is in compliance with guideline MDG 41 and MSHA regulations. Less
Type The hoses are assembled to Hose Assembly Standard DIN20066:201-10. The hoses are assembled to Hose Assembly Standard DIN20066:201-10. Less

Health Monitoring

Type This system monitors oil levels and temperatures, flows, pressures and vibration. This system monitors oil levels and temperatures, flows, pressures and vibration. Less
Type A comprehensive health monitoring system is available. A comprehensive health monitoring system is available. Less

Machine Automation and Communication

Levels of Automation State-based shearer automation “Navigator 2” State-based shearer automation “Navigator 2” Less
Levels of Automation Zone-based automation “Navigator 1” Zone-based automation “Navigator 1” Less
Levels of Automation “Longwall Navigator” for improved face alignment and horizon control “Longwall Navigator” for improved face alignment and horizon control Less
Levels of Automation Integrated longwall automation with “Navigator 2 + 3” Integrated longwall automation with “Navigator 2 + 3” Less
Type PMC Evo-S control system allows the shearer to be operated even if the overall control system is not functioning. PMC Evo-S control system allows the shearer to be operated even if the overall control system is not functioning. Less
Type The shearer is equipped with a state-of-the-art industry PC in a flame-proof housing with plenty of computing power. The shearer is equipped with a state-of-the-art industry PC in a flame-proof housing with plenty of computing power. Less
Type State-of-the-art industry PC allows flexibility to upgrade to future features such as condition monitoring. State-of-the-art industry PC allows flexibility to upgrade to future features such as condition monitoring. Less
Type Unlike competitor systems, modularity of the longwall system & control allows the longwall to operate in “fault-tolerant” mode. Unlike competitor systems, modularity of the longwall system & control allows the longwall to operate in “fault-tolerant” mode. Less
Type In other words, integrated automation does not prevent control via individual PLC’s in order to keep production up and running. In other words, integrated automation does not prevent control via individual PLC’s in order to keep production up and running. Less
Type PMC Evo-S control system with state-of-the-art Ethernet communication and backup functionality. PMC Evo-S control system with state-of-the-art Ethernet communication and backup functionality. Less
Type This shearer has a state-of-the-art distributed automation system for the control, monitoring and protection of the shearer. This shearer has a state-of-the-art distributed automation system for the control, monitoring and protection of the shearer. Less
Type A Programmable Logic Controller (PLC) takes care of basic machine control tasks, ensuring that coal is produced. A Programmable Logic Controller (PLC) takes care of basic machine control tasks, ensuring that coal is produced. Less
Type Industry-leading Automation from the Pioneer of State-based Automation. Industry-leading Automation from the Pioneer of State-based Automation. Less
Type Its modular design allows it to be configured to meet individual control needs. Its modular design allows it to be configured to meet individual control needs. Less

Dimensions (Approximate)

AFC Pan Width 53.0 in 1342.0 mm Less
Clearance from Drum to AFC Toeplate 15.0 in 380.0 mm Less
Cutting Drum Overall Width 43.0 in 1100.0 mm Less
Diameter of Shearer Cutting Drum 126.0 in 3200.0 mm Less
Distance between Drums with Arms Horizontal 670.0 in 17008.0 mm Less
Distance between Ranging Arm Hinge Points 378.0 in 9600.0 mm Less
Distance between Trapping Shoe Centers 272.0 in 6910.0 mm Less
Height to Top of Machine Main Body 105.0 in 2656.0 mm Less
Machine Height over Main Body 133.0 in 3366.0 mm Less
Maximum Cutting Height for Seam 283.0 in 7188.0 mm Less
Ranging Arm Cutting Drum Diameter 126.0 in 3200.0 mm Less
Ranging Arm Length (hinge to drum) 153.0 in 3893.0 mm Less
Shearer Drum Undercut of Floor 24.0 in 621.0 mm Less
Top Guard Height over Main Body 24.0 in 620.0 mm Less
Vertical Tunnel Clearance 50.0 in 1277.0 mm Less

Ranging Arms – RA860

Type Transmission rating of 860 kW @ 30.8 rpm and above Transmission rating of 860 kW @ 30.8 rpm and above Less
Type Maximum drum diameter of 3500 mm (138 in) Maximum drum diameter of 3500 mm (138 in) Less
Type Choice of drum speeds Choice of drum speeds Less
Type Complete with 32 mm (1.3 in) bore, through shaft PFF/PBF wet cutting Complete with 32 mm (1.3 in) bore, through shaft PFF/PBF wet cutting Less
Type Available cutter motors – 750 kW and 860 kW @ 50 Hz (1,200 hp and 1,380 hp @ 60 Hz) Available cutter motors – 750 kW and 860 kW @ 50 Hz (1,200 hp and 1,380 hp @ 60 Hz) Less
Type Maximum oil capacity of 45 L (11.88 gal) in high speed compartment and 60 L (15.85 gal) in the epicyclic Maximum oil capacity of 45 L (11.88 gal) in high speed compartment and 60 L (15.85 gal) in the epicyclic Less
Type Integral monitoring transducers Integral monitoring transducers Less
Type Quillshaft transmission protection Quillshaft transmission protection Less
Type Square drum hub (630 mm [24.8 in] across flats) Square drum hub (630 mm [24.8 in] across flats) Less

Haulage Units – HU150

Maximum Machine Speed 98.77 ft/min 30.11 m/min Less
Pull at Maximum Speed 537.97 kN/120,940 lbf (55.07 tonnes/60.70 tons) 537.97 kN/120,940 lbf (55.07 tonnes/60.70 tons) Less
Speed at Maximum Pull 49.39 ft/min 15.06 m/min Less
Total Machine Pull 1075.94 kN/241,881 lbf (110.15 tonnes/121.42 tons) 1075.94 kN/241,881 lbf (110.15 tonnes/121.42 tons) Less
Type Available with Machine Parking Brake Available with Machine Parking Brake Less
Type Maximum oil capacity of 25 L (7 gal) Maximum oil capacity of 25 L (7 gal) Less
Type Integral monitoring transducers Integral monitoring transducers Less
Type Quillshaft transmission protection Quillshaft transmission protection Less
Type Available with Machine Position Encoder Available with Machine Position Encoder Less
Type This unit has a haulage motor rating of 150 kW (201 hp) This unit has a haulage motor rating of 150 kW (201 hp) Less
Type Integral water cooling @ 9 L/min (2 gal/min) Integral water cooling @ 9 L/min (2 gal/min) Less
Type Maximum power rating 150 kW (201 hp) Maximum power rating 150 kW (201 hp) Less
Type Transmission reduction of 137:1 Transmission reduction of 137:1 Less

Downdrive – DD150

Type Innovative and unique downdrive design Innovative and unique downdrive design Less
Type Transmission rating of 150 kW (201 hp) Transmission rating of 150 kW (201 hp) Less
Type Maximum haulage pull 1075 kN (123 tons) Maximum haulage pull 1075 kN (123 tons) Less
Type Suitable for all current rack type systems Suitable for all current rack type systems Less
Type Removable modular top drive wheel assembly (cartridge) Removable modular top drive wheel assembly (cartridge) Less
Type Downdrive ratio 22T – 27T – 31T – 11T (three wheel configuration) Downdrive ratio 22T – 27T – 31T – 11T (three wheel configuration) Less
Type Trapping shoe with replaceable wear inserts, safe and easy to replace (unique to Caterpillar) Trapping shoe with replaceable wear inserts, safe and easy to replace (unique to Caterpillar) Less
Type Fully removable, rehandable, modular gearbox Fully removable, rehandable, modular gearbox Less

Powerpack – PP3

Type Fixed displacement pump, with a capacity of 200 L/min (53 gal/min) Fixed displacement pump, with a capacity of 200 L/min (53 gal/min) Less
Type Operating system pressure of 210 bar (3,046 psi) Operating system pressure of 210 bar (3,046 psi) Less
Type Robust hydraulic reservoir of 300 L (79 gal) capacity Robust hydraulic reservoir of 300 L (79 gal) capacity Less
Type This unit has a pump motor rating of 75 kW @ 50 Hz (120 hp @ 60 Hz) This unit has a pump motor rating of 75 kW @ 50 Hz (120 hp @ 60 Hz) Less
Type For use with ISO 68 or ISO 100 hydraulic oils For use with ISO 68 or ISO 100 hydraulic oils Less
Type Available with 6 or 8 section valve bank (dependent on function requirement) Available with 6 or 8 section valve bank (dependent on function requirement) Less
Type Available with two speed ranging arm facility Available with two speed ranging arm facility Less
Type Integral monitoring transducers Integral monitoring transducers Less

Mainframe – MF4

Type High structural integrity and absorption of all cutting and haulage forces, providing maximum protection for all major units High structural integrity and absorption of all cutting and haulage forces, providing maximum protection for all major units Less
Type Maximum protection of electrical boxes, providing the highest level of flameproof integrity Maximum protection of electrical boxes, providing the highest level of flameproof integrity Less
Type Split mainframe, in case of transportation limitations Split mainframe, in case of transportation limitations Less
Type Versatility of application due to fully modular construction Versatility of application due to fully modular construction Less
Type Improved access for maintenance and ease of overhaul and repair Improved access for maintenance and ease of overhaul and repair Less

Hydraulically Activated Top Guards

Type This shearer can be equipped with hydraulically activated top guards This shearer can be equipped with hydraulically activated top guards Less

Electrical Control Box – ECB3

Type This flameproof module contains the majority of the shearer electrical control and power distribution components. This flameproof module contains the majority of the shearer electrical control and power distribution components. Less
Type High current carrying capacity of 500 amps and can accommodate trailing cables up to 240 mm2 (9.45 in2). High current carrying capacity of 500 amps and can accommodate trailing cables up to 240 mm2 (9.45 in2). Less
Type All internal chassis can be ‘bench built,’ tested and stored. All internal chassis can be ‘bench built,’ tested and stored. Less
Type This unit also contains HV fuses, earth leakage and both visible disconnects. This unit also contains HV fuses, earth leakage and both visible disconnects. Less
Type An extremely powerful PMC Evo-S control system with state-of-the-art Ethernet communication and backup functionality. An extremely powerful PMC Evo-S control system with state-of-the-art Ethernet communication and backup functionality. Less
Type This unit contains cutter motor contactors, circuit breakers, control transformer and current monitoring. This unit contains cutter motor contactors, circuit breakers, control transformer and current monitoring. Less
Type Box contains various LV circuit breakers which can be reset through the FLP cover, reducing downtime. Box contains various LV circuit breakers which can be reset through the FLP cover, reducing downtime. Less

Haulage Transformer Box – HTB3

Type Module contains drive system circuit breaker & two 200 kW (268 hp), 600V AC inverter drives, with regenerative braking module. Module contains drive system circuit breaker & two 200 kW (268 hp), 600V AC inverter drives, with regenerative braking module. Less
Type This flameproof module contains the main 350 kVA haulage transformer, power supplies and auxiliary transformer. This flameproof module contains the main 350 kVA haulage transformer, power supplies and auxiliary transformer. Less

Optional Machine Mounted Coalsizer – CS200

Type Transmission rating of 200 kW @ 50 Hz (320 hp @ 60 Hz) Transmission rating of 200 kW @ 50 Hz (320 hp @ 60 Hz) Less
Type Quillshaft transmission protection Quillshaft transmission protection Less
Type Drum speed of 200 rpm (240 @ 60 Hz) Drum speed of 200 rpm (240 @ 60 Hz) Less
Type Available motor rating 200 kW @ 50 Hz (320 hp @ 60 Hz) Available motor rating 200 kW @ 50 Hz (320 hp @ 60 Hz) Less
Type Integral water cooling for transmission and motor Integral water cooling for transmission and motor Less
Type Square drum hub drive for drum Square drum hub drive for drum Less
Type Complete with anti-shock lift mechanism (unique to Caterpillar) Complete with anti-shock lift mechanism (unique to Caterpillar) Less
Type Drum diameter 900 mm (35.5 in) over picks Drum diameter 900 mm (35.5 in) over picks Less

Shear Performance

With high-powered ranging arms and haulage units, Cat shearers cut and load up to 5000 tonnes (5,500 tons) per hour and more, depending on mining conditions. The unique, one-piece mainframe design offers maximum structural integrity and service life.


Key Improvements

Cat shearers incorporate numerous new features and benefits. These are presented in the following pages by category.


Mainframe Made for Muscle...

The unique mainframe of the Cat shearer is one of its key features. The fabricated structure of the mainframe with cast ranging-arm hinge points results in an extremely robust design not only to meet the toughest mining conditions and ensure reliability and long service life, but also to handle even higher cutting and haulage forces in the future. The mainframe of the EL3000 is designed to allow retrofit of 1200 kW (1,930 hp) ranging arms and 200 kW (320 hp) haulage units. A split mainframe is available in case of transportation limitations.


Innovative Trapping Shoe

Trapping shoes attach the shearer to the haulage rack system, part of the armored face conveyor, allowing the shearer to be hauled up and down the face.


Extended Service Life

The inserts have the same wear area as conventional shoes and are articulated.


Downdrive

An innovative downdrive design results in longer bearing life, increased gear rating and greater modularity for simplified maintenance. Height adjustment of the shearer is relatively easy and is achieved with replacement of the downdrive to allow adaption to changing seam conditions.


Modular Haulage System

Caterpillar has further developed its modular haulage concept with increased power rating, gear rating, bearing life and redundancy, leading to longer overhaul intervals based on typical usage. The haulage system is a simple design capable of achieving cutting speeds of up to 32 m/min (105 ft/min), with improved reliability and longer service life.


Coalsizer

Cat shearers can be supplied with an optional rugged coalsizer, currently with up to 200 kW (320 hp) of installed power for maximum productivity in high seams or difficult mining conditions.


Packing More Power

The power pack has been reengineered to provide increased functionality, optimized performance and better access to filtration units via simplified layout. Both of the following units are modular, with drawer units providing easy access and upgrade.


Tested for Reliability

Downtime is extremely expensive for operators – costs continue to add up while nothing is produced. This is why Caterpillar ensures that our superbly engineered shearers are up to the job.


Lubrication Verification

Ranging arms and haulage units are subjected to an intense test regime to establish the optimum oil-level requirements to suit all mining conditions. The units are mounted on purpose-designed test rigs that are positioned to simulate the gradient of the underground seam.


Endurance Block Load Testing

This test applies loads far in excess of those encountered during normal mining operations, ensuring that the shearer can operate reliably at the installed power ratings. Ranging arms or haulage units are mounted on purpose-designed test rigs in a back-to-back configuration driven by a suitable test motor.


Production Load Testing

After successful endurance block load testing, the same test rigs are used to carry out production load testing of all ranging arms and haulage units.


Proven Productivity

This extensive range of tests ensures the highest possible availability of shearers in service and maximum return on investment for your longwall installation.


Industry-leading Automation from the Pioneer of State-based Automation

Caterpillar has developed a state-of-the-art distributed automation system for the control, monitoring and protection of the shearer. Its modular design allows it to be configured to meet individual control needs, from basic monitoring and protection to advanced automation and data transmission.


Power and Flexibility

With extensive computer power installed and simple upgrade to new features, Cat shearer automation is fit for the future. Components connect into the network rather than directly to a central computer, simplifying installation, wiring, maintenance and troubleshooting.


The Net is the Control

The shearer control system uses a state-of-the-art Ethernet bus, resulting in a drastic reduction in wiring and a huge increase in flexibility. There are no interfacing problems, as equipment connected to the network only needs to be able to communicate via Internet Protocol.


Intrinsic Safety

More components designed to be intrinsically safe means simpler installation and speedier maintenance. New modules are based on standardized CIOS™ modules, resulting in a plug and play approach to upgrades.


Visualization

Visualization not only provides a graphical representation of current operating conditions, but can also display historical conditions and a graphic display of trends. An automated longwall is a highly complex system with many interacting components generating time-variant data.


VibraGuard™

VibraGuard™ allows trained personnel to predict machine component wear, avoid unplanned downtime and set alarms to warn the operator if monitored machine components run the risk of damage. This comprehensive protection backs long life and high availability of your valuable mining equipment.


Modular Control Offers Flexibility and Power

PMC™ Evo-S brings state-of-the art processor performance underground. Designed by the market leader in shearer automation, the advanced Cat automation package allows improved utilization of manpower in a safe environment; with increased yield from any given seam section, faster haulage speeds, improved face management and increased life of all longwall equipment, including AFC and shields.


EL4000 Standard Equipment

Trapping Shoe Ix

Central lubrication system

PMC™ Evo-S

Gate end data connection
  • Powerline
  • WLAN

EL4000 Optional Equipment

Multi-piece mainframe

Cowl

Spall guards

Coal sizer
  • 100 kW
  • 200 kW

Trapping Shoe Ix ((Insert exchange)

Shearer clearer

Spray bars

Gate end data connection
  • Fiber optics

IPC

Zone-based automation“Navigator 1”

State-based shearer automation “Navigator 2”

Integrated longwall automation with “Navigator 2 + 3” (only with Cat longwall equipment)

“Longwall Navigator” for improved face alignment and horizon control incorporates LASC Technology (only with Cat longwall equipment)

VibraGuard™

Cameras

Condition monitoring

A Commitment to the Mining Industry

As the demand for commodities grows, mining companies need a partner to support them in their efforts. Caterpillar is committed to being that partner.

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Mining Financial Services

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