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CAT Longwall Shearer EL1000

Your shearer is the most critical part of your longwall production process. That's why high-performance longwall operations demand shearers that deliver the highest productivity, availability and reliability. Cat shearers were always designed to meet these demands. But Caterpillar has taken them to the next level.

SURVIVAL OF THE FITTEST - To do this, we invested heavily in refining our successful range of shearers. We started by reviewing and analyzing all more recent shearer installations and setting goals to improve productivity, availa¬bility and reliability. This was not a re design, but an evolution – keeping the best tried-and tested features of the existing design while using the latest findings from science and technology to improve features and add new ones.

SHEAR PERFORMANCE - With high-powered ranging arms and haulage units, Cat shearers cut and load up to 5000 tons (5,500 tons) per hour and more, depending on mining conditions. The unique, one-piece mainframe design offers maximum structural integrity and service life. The mainframe is available as a split unit in the event of transportation limitations. Featuring the superior Jumbo track shearer haulage system, the shearer also offers advanced integrated automation and communication options.

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Overview

Your shearer is the most critical part of your longwall production process. That's why high-performance longwall operations demand shearers that deliver the highest productivity, availability and reliability. Cat shearers were always designed to meet these demands. But Caterpillar has taken them to the next level.

SURVIVAL OF THE FITTEST - To do this, we invested heavily in refining our successful range of shearers. We started by reviewing and analyzing all more recent shearer installations and setting goals to improve productivity, availa¬bility and reliability. This was not a re design, but an evolution – keeping the best tried-and tested features of the existing design while using the latest findings from science and technology to improve features and add new ones.

SHEAR PERFORMANCE - With high-powered ranging arms and haulage units, Cat shearers cut and load up to 5000 tons (5,500 tons) per hour and more, depending on mining conditions. The unique, one-piece mainframe design offers maximum structural integrity and service life. The mainframe is available as a split unit in the event of transportation limitations. Featuring the superior Jumbo track shearer haulage system, the shearer also offers advanced integrated automation and communication options.

Specifications

Typical Machine Length
13.6 m
Installed Power
1429 kW
Haulage System
AC inverter drive
Haulage System
AC inverter drive
Installed Power
Up to 1230 kW (Up to 1,649 hp)
Haulage System
AC inverter drive
Installed Power
Up to 1429 kW (Up to 1,916 hp)

Ripper

Type
This flameproof module contains the majority of the shearer electrical control and power distribution components.
Type
High current carrying capacity of 400 amps and can accommodate trailing cables up to 185 mm2 (2.9 in2).
Type
All internal chassis can be ‘bench built,’ tested and stored.
Type
Box contains various LV circuit breakers which can be reset through the FLP cover, reducing downtime.
Type
An extremely powerful PMC Evo-S control system with state-of-the-art Ethernet communication and backup functionality, this allows the shearer to be operated even if the overall control system is not functioning.
Type
This unit also contains cutter motor contactors, circuit breakers, control transformer, current monitoring, HV fuses, earth leakage and a visible disconnect.
Type
A comprehensive health monitoring system is available, including oil levels and temperatures, flows, pressures and vibration analysis.
Type
Maximum power rating 100 kW (134 hp)
Type
Transmission reduction of 132.6:1
Type
Available with Machine Position Encoder
Type
Available with Machine Parking Brake
Type
Integral monitoring transducers
Type
Quillshaft transmission protection
Type
Online vibration monitoring
Type
All hose assemblies are to ISO 6805 and proof tested to EN ISO 1402.
Type
The hoses are assembled to Hose Assembly Standard DIN20066:201-10.
Type
All hose and hosing is in compliance with guideline MDG 41 and MSHA regulations.
Type
This model of shearer is available with onboard filtration, dust suppression spray bars, shearer clearers and ranging arm spray rings.
Type
Industry-leading Automation from the Pioneer of State-based Automation.
Type
This shearer has 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 a
Type
The PMC Evo-S control system with state-of-the-art Ethernet communication and backup functionality allows the shearer to be operated even if the overall control system is not functioning.
Type
The shearer is equipped with a state-of-the-art industry PC in a flame-proof housing with plenty of computing power, allowing flexibility to upgrade to future features such as condition monitoring.
Type
A Programmable Logic Controller (PLC) takes care of basic machine control tasks, ensuring that coal is produced.
Type
Unlike competitor systems, the modularity of the longwall system and control allow the longwall to operate in “fault-tolerant” mode, even when there is a problem with the overall automation system.
Type
In other words, integrated automation does not prevent control via individual PLC’s in order to keep production up and running.
Type
This flameproof module contains the main 253 kVA haulage transformer, power supplies, auxiliary transformer, drive system circuit breaker and one 250 kW (335 hp), 600V AC inverter drive, with integrated regenerative braking.
Type
This model of shearer is available with headlights, cameras, methane monitoring, end displays and audible alarms.
Type
All electrical material is designed and certified to IEC standards and also complies with other regional and national standards, such as MSHA, GOST, MA, ATEX and DGMS, as well as Australia’s New South Wales and Queensland regulations.
Type
Innovative and unique downdrive design
Type
Transmission rating of 100 kW (134 hp)
Type
Maximum haulage pull of 732 kN (82 tons)
Type
Fully removable, rehandable, modular gearbox
Type
Removable modular top drive wheel assembly
Type
Downdrive ratio 17T—23T—10T (two wheel configuration)
Type
Trapping shoe with replaceable wear inserts, safe and easy to replace (unique to Caterpillar)
Type
Suitable for all current rack type systems
Type
Fixed displacement pump, with a capacity of 50 L/min (13 gal/min)
Type
Operating system pressure of 210 bar (3,046 psi)
Type
Robust hydraulic reservoir of 190 L (50 gal) capacity
Type
Integral monitoring transducers
Type
For use with ISO 68 or ISO 100 hydraulic oils
Type
Available with 6 section valve bank
Type
This unit has a pump motor rating of 30 kW @ 50 Hz (48 hp @ 60 Hz)
Type
High structural integrity and absorption of all cutting and haulage forces, providing maximum protection for all major units
Type
Maximum protection of electrical boxes, providing the highest level of flameproof integrity
Type
Improved access for maintenance and ease of overhaul and repair
Type
Versatility of application due to fully modular construction
Type
A split mainframe is available in case of transportation limitations
Type
All hose assemblies are to ISO 6805 and proof tested to EN ISO 1402.
Type
The hoses are assembled to Hose Assembly Standard DIN20066:201-10.
Type
All hose and hosing is in compliance with guideline MDG 41 and MSHA regulations.

Machine @ 50 Hz

Available Cutting Power
2 × 500 kW (2 × 671 hp)
Body Height
530 mm
Cutting Drum Diameter
1524 to 2000 mm (60 to 78 in)
Cutting Drum Speed
33.5, 38.8 and 43.8 rpm
Haulage Motor
2 × 100 kW (2 × 134 hp)
Haulage Pull
Up to 732 kN / 165,000 ibf (up to 75 tonnes/82 tons)
Haulage Speed
Up to 29.5 m/min (Up to 97 ft/min)
Machine Weight (approximate)
60 tonne
Minimum Pan Width
832 mm
Operating Voltage
3300 V
Pump Motor
30 kW
Seam Range
1.6-3.2 m (63-126 in)
Typical Machine Length (drum centers)
13635 mm
Available Cutting Power
2 × 597 kW (2 × 800 hp)
Body Height
530 mm
Cutting Drum Diameter
1524 to 2000 mm (60 to 78 in)
Cutting Drum Speed
40.2, 46.6 and 52.5 rpm
Haulage Motor
2 × 100 kW (2 × 134 hp)
Haulage Pull
Up to 732 kN/165 lbf (Up to 75 tonnes/82 tons)
Haulage Speed
Up to 29.5 m/min (Up to 97 ft/min)
Machine Weight (approximate)
60 tonne
Minimum Pan Width
832 mm
Operating Voltage
4160 V
Pump Motor
36 kW
Seam Range
1.6-3.2 m (63-126 in)
Typical Machine Length (drum centers)
13635 mm

Haulage Unit – HU100

Maximum Machine Speed
29.50 m/min
Pull at Maximum Speed
366.06 kN/82.3 lbf (37.48 tonnes/41.31 tons)
Speed at Maximum Pull
14.75 m/min
Total Machine Pull
732.11 kN/164.58 lbf (74.95 tonnes/82.62 tons)

Machine Automation and Communication

Levels of Automation
Zone-based automation “Navigator 1”
Levels of Automation
State-based shearer automation “Navigator 2”
Levels of Automation
Integrated longwall automation with “Navigator 2 + 3”
Levels of Automation
“Longwall Navigator” for improved face alignment and horizon control

Dimensions (Approximate)

AFC Pan Width (typical – as shown)
1142 mm
Clearance from Drum to AFC Toeplate
271 mm
Cutting Drum Overall Width
1142 mm
Diameter of Shearer Cutting Drum
1524 mm
Distance between Drums with Arms Horizontal
13635 mm
Distance between Ranging Arm Hinge Points
8125 mm
Distance between Trapping Shoe Centers
6124 mm
Height to Top of Machine Main Body (lowest version)
1200 mm
Machine Height over Main Body (< in lowest version)
1200 mm
Maximum Cutting Height for Seam (plus)
3200 mm
Ranging Arm Cutting Drum Diameter
1524 mm
Ranging Arm Length (hinge to drum)
2755 mm
Shearer Drum Undercut of Floor (>)
500 mm
Vertical Tunnel Clearance (approximate)
460 mm
Width across Picks
1067 mm

Ranging Arm

RA560
Designed and robustly tested – for longer service life.
RA560
Transmission rating of 500 kW @ 33.5 rpm and above (40 rpm @ 60 Hz)
RA560
Maximum drum diameter of 2000 mm (78 in)
RA560
Choice of drum speeds
RA560
Complete with 32 mm (1.3 in) bore, through shaft PFF/PBF wet cutting
RA560
Square drum hub (440 mm [17.3 in] across flats)
RA560
Integral monitoring transducers
RA560
Quillshaft transmission protection
RA560
A robust cowl drive mechanism is also available on this model
RA560
Available cutter motors – 500 kW @ 50 Hz (800 hp @ 60 Hz)

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