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Longwall Shearers
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Taking the Shearer to the Next Level
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 rening our successful
range of shearers. We started by reviewing and analyzing
all more recent shearer installations and setting goals to
improve productivity, availability and reliability. This was
not a redesign, but an evolution – keeping the best triedand-tested features of the existing design while using the
latest ndings 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 5 000 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. The mainframe is
available as a split unit in the event of transportation
limitations. Featuring the superior Jumbotrack shearer
haulage system, the shearer also offers advanced
integrated automation and communication options.
®
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Key Improvements
Cat shearers incorporate numerous new features and
benets. These are presented in the following pages by
category. The key improvements include:
• Extremely powerful PMC
state-of-the-art Ethernet communication
• Improved innovative downdrive design
• Ranging arm with longer service life
• Further development of the modular haulage and
electrical control box
™
Evo-S control system with
• Enhanced power pack with easy access
• Online vibration monitoring with VibraGuard
• Clear wiring and use of plug and play for easy
™
maintenance
• Trapping Shoe Ix (Insert Exchange) for longer service
life, safe and easy to replace
• Future-proof design allowing upgrades – such as
stronger ranging arms and haulage units or addition of
coal sizer – during rebuild
• Mainframe designed to handle 1 200 kW (1,930 hp)
ranging arms and 200 kW (320 hp) haulage units –
EL3000 only
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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 retrot of 1 200 kW (1,930 hp) ranging arms and
200 kW (320 hp) haulage units. A split mainframe is
available in case of transportation limitations.
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Benefits:
• High structural integrity and absorption of all cutting
and haulage forces, providing maximum protection for
all major units
• Maximum protection of electrical boxes, providing the
highest level of ameproof integrity
• Improved access for maintenance and ease of overhaul
and repair
• Versatility of application due to fully modular
construction
• Flexible and cost-effective equipment
management
• Independent unit exchange and selective overhaul
• Long service life
• Low operational costs
• High reliability
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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. A new
type of trapping shoe developed by Caterpillar – the
Trapping Shoe Ix – offers numerous advantages over the
conventional design:
• Greater safety and ease of handling during replacement
• Faster replacement
• Greater exibility
• Longer service life
• Lower operating costs
The patent-pending Trapping Shoe Ix continues the
Caterpillar principle of designing products with separate
structural and wear parts to allow quick and easy
replacement of surfaces subject to wear. The new design
cuts the weight that has to be handled during replacement
from more than 500 kg to less than 50 kg per insert, and
cuts the time required for exchange to a fraction of the
previous time. Because the weight handled is so much
lower, changeout can take place anywhere along the face
– previously this work had to be done at the gate ends,
where heavy lifting equipment was available.
Trapping Shoe Ix offers longer service life, greater flexibility,
faster replacement, and greater safety and ease of handling
during replacement.
Extended Service Life
The inserts have the same wear area as conventional shoes
and are articulated. This – combined with the fact that
the shoe does not have to exert as much pressure, resulting
in a lower point load – means less wear. Field tests of the
Trapping Shoe Ix showed its service life to be 50 percent
longer than conventional trapping shoes.
The robust mainframe protects the electrical boxes from cutting
and haulage forces; door handling system for easy access to the
electrical compartments.
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Power for the Toughest Mining
Conditions
Our shearers cover a wide range of cutting heights and
mining conditions. They have installed cutting power to
provide world-class production in the toughest mining
conditions: The EL3000 with a cutting power of up to
860 kW (1,380 hp) and the EL2000 with up to 750 kW
(or 1,200 hp). A new 1 200 kW (1,930 hp) ranging arm
is under development and can be retrotted to existing
EL3000 shearers during rebuild.
• High levels of installed power available in each class
• Cutting depth of 0.85 m and 1.0 m
• A range of cutter motors available to suit all mining
conditions
• Compact design for optimum coal-loading performance
• Fast and accurate positioning of the ranging arm
through two-speed technology and a more powerful
lifting cylinder
• Modularity allows fast in-situ maintenance and repair
• Improved lubrication results in lower operating
temperatures
• New, more robust cowl drives
Strong Arm
The safety factor for the ranging arm has been further
increased. Gear rating, bearing life and redundancy have
also been increased, leading to longer overhaul intervals
based on typical usage.
Downdrive
An innovative downdrive design results in longer bearing
life, increased gear rating and greater modularity for
simplied maintenance. Height adjustment of the shearer
is relatively easy and is achieved with replacement of
the downdrive to allow adaption to changing seam
conditions. Every mainframe is designed to take the full
range of downdrive arrangements to t a wide range of
seam heights.
• Fully modular design
• Easy maintenance access
• Fully articulating shoe
• High pull and maximum life
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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. The fully modular haulage gearbox is
located in the shearer mainframe and does not form part
of the shearer structure. The haulage system offers:
• Simple construction, improved reliability and longer
service life
• Fully proven load-sharing system
• Reduced cost
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 difcult mining conditions. The coalsizer can be
ordered separately for installation during rebuild
or overhaul.
Packing More Power
The power pack has been reengineered to provide
increased functionality, optimized performance and better
access to ltration units via simplied layout. Both of the
following units are modular, with drawer units providing
easy access and upgrade.
Transformer Box
• Features closed-loop control with measurement of
speed, not power
• Transforms to 600 V for haulage units’ frequency
converter motors
• Connectorized cables for reduced wiring and quick,
clear installation
• Temperature monitoring and water cooling
Control Box
• Plug and play
• Easy to maintain
• Quick and easy troubleshooting
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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. That’s why each shearer design – which
is optimized for maximum availability – is subjected
to rigorous in-house testing to ensure that there are no
unpleasant surprises when units are in service. Shearer
production quality assurance falls into three main
categories: lubrication verication, endurance block load
testing and production load testing.
Lubrication Verification
Haulage unit in testing to ensure highest reliability
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. A suite
of tests is performed with a range of different gradients
and arm positions to represent even the most severe
mining conditions. The units are operated until stable
temperatures are achieved at all gradients. This establishes
the minimum, maximum and optimum oil quantities
for all conditions.
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 purposedesigned test rigs in a back-to-back conguration driven
by a suitable test motor. The endurance block load test
imposes loads from 100% to 175% to ensure that the
ranging arm design meets the requirements of the most
demanding applications. Input torque, losses and output
torque are monitored during the test, as are bearing,
gear and shaft temperatures. Vibration is monitored by
dedicated sensors. Oil samples are collected at intervals
for analysis, as the presence of metal in the oil can
indicate excessive component wear. On completion
of the endurance test, units are dismantled for a full
internal and external inspection to verify that the
design is t for purpose.
Lubrication test under the most extreme conditions
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Shearer in the last manufacturing stage getting tested before delivery to customer site
Production Load Testing Proven Productivity
After successful endurance block load testing, the same This extensive range of tests ensures the highest possible
test rigs are used to carry out production load testing of availability of shearers in service and maximum return
all ranging arms and haulage units. The test gradually on investment for your longwall installation. Nothing
increases the load up to full load. All temperatures and is left to chance in ensuring that our shearers are
vibration points are monitored during the test, and oil unsurpassed in reliability.
samples are again collected for analysis.
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Unparalleled Control
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 congured to meet individual control needs, from
basic monitoring and protection to advanced automation
and data transmission. The PMC
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. In 2002, StateBased Automation was invented and launched. Using this
technology, Caterpillar now offers a comprehensive range
of automation products as shown on page 15.
Power and Flexibility
With extensive computer power installed and simple
upgrade to new features, Cat shearer automation is t
for the future. Components connect into the network
rather than directly to a central computer, simplifying
installation, wiring, maintenance and troubleshooting.
The shearer is equipped with a state-of-the-art industry
PC in a ame-proof housing with plenty of computing
power, allowing exibility to upgrade to future features
such as condition monitoring.
™
Evo-S control system
Integrated end station display
A Programmable Logic Controller (PLC) takes care of
basic machine control tasks, ensuring that coal is mined.
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. In other words, integrated
automation does not prevent control via individual PLCs
in order to keep production up and running.
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Color display
Three shearers at different stages in the manufacturing process: From the
shearer on the left which is ready for equipping to the one on the right
which has successfully completed all test procedures and is being prepared
for shipping.
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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 exibility. There are no interfacing problems, as
equipment connected to the network only needs to be able
to communicate via Internet Protocol. Commissioning,
maintenance, upgrades and troubleshooting are much
easier and faster, and equipment is self-conguring. The
few cables that are used are standard Ethernet cables
rather than application-specic cables – cutting costs and
simplifying spare parts inventories.
Flameproof housings are no longer required, simplifying
installation and speeding up maintenance. New modules
are based on standardized CIOS™ modules (congurable
input output system), resulting in a plug and play
approach to upgrades. No reprogramming is necessary.
Remote control and diagnosis are also possible for
all components. And because of the Ethernet-based
approach, the failure of one component does not impact
the whole system.
Intrinsically safe CIOS™ block with state-of-the-art Ethernet communication
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.
Changes to the system only require commissioning
changes – such as mounting and connection of sensors.
No replacement of control software is required. Remote
control and diagnosis are also possible for all components.
And because of the Ethernet-based approach, the failure
of one component does not impact the whole system.
This not only supports the unique “fault- tolerant” mode,
which allows the longwall to continue to operate when
there is a problem with the overall automation system, but
also, through systematic isolation, allows faulty units to be
identied while production continues.
PMC™ Evo-S offers reliability from day one
• Robust cables and plugs
• Minimized cabling due to network approach
• Vibration-tested components
• Designed for the working environment
Consistent performance using advanced automation
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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. Visualization gives operators a better understanding
of the overall system, allowing them to further optimize
operations. VLongwall provides a system overview and
access to the dedicated visualization modules VShield,
VDrive, VPlow and VShearer. It also gives access to
VTrend for trend analysis and VGraph3D for waterfall
plots of the entire longwall.
VShearer allows parameter-setting and visualization of operational
parameters and status of a Cat® shearer.
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.
• Permanent online monitoring and protection of
equipment instead of sporadic ofine measurements
• Assists in the prediction of machine component wear
• Alarms warn the operator if monitored components are
at risk of damage
• When utilized by trained personnel, VibraGuard
™
makes
repairs predictable and helps avoid unplanned downtime
• Repair work can be done largely without stress
• Allows timely procurement of spare parts
• Transfers data to a surface control center PC for detailed
analysis and evaluation
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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.
As shown in the table on page 15, automation systems match
your needs – from basic to highly sophisticated – while
remaining easy to install, operate and maintain.
The modular control concept is:
Intrinsically safe CIOS™ block with remote access down to I/O level
• Easily expandable based on modular design
• Ready for integration of highly sophisticated technologies
and devices
• Equipped for XML-based interfaces to third- or fourth-
party systems
Making it Easy
• Cat self-conguring controls and standard interfaces
such as Ethernet allow quick and easy system
conguration changes with no programming effort
• Ready for future technologies such as high-quality
condition monitoring, including vibration monitoring
• Easy and exible adaptation to existing data environments
• Greater use of Ethernet, standard connectorization and
PMC™ control family mean greater simplicity, reduced
spares inventories and shorter downtimes
• Standardization and modularization allow quick and easy
customization of components and systems
Fast Troubleshooting
Less Maintenance Effort
• Widespread use of intrinsically safe components in
PMC™ Evo-S reduces time-consuming opening of
ame-proof housings in the event of faults.
• Quick and easy exchange of modules.
Modularity is Strength
Modularity is a key feature of the Cat shearer. It results in
independent major units, each driven by its own dedicated
electric motor and housed within or attached to a robust
mainframe unique to the Cat range. Control systems are
also modular.
This modular design offers maximum availability –
through “fault-tolerant” mode operation – and the
exibility to meet even the most demanding customer
requirements by upgrading components such as the
ranging arm.
• Widespread use of intrinsically safe components
allows large-scale fault diagnosis under power
• Remote access to most components down to I/O level
• Diagnosis from surface or by Cat Mine Control Center
• Managed switches and eld bus coupler (FBC) allows
selective routing:
- Permits sequential disable and enable of �
components and/or communication routes �
- Isolation of faulty units until next repair shift
allowing production to continue �
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EL2000
EL3000
The Cat
®
Shearer Product Line
EL2000
The EL2000 incorporates all the features and benets
that have been established with the Cat shearer range in a
compact, rugged machine designed to meet the demands
of high productivity in low- to medium-seam applications
from 1.80 to 4.50 m (70 to 177 in.). High installed power is a
feature of the EL2000 shearer, with up to 750 kW (1,200 hp)
in a compact design. The haulage system is tailored to the
needs of high-productivity medium-seam applications with
up to 125 kW (200 hp) AC drives.
Benefits:
• High level of structural integrity provided by the unique
Cat shearer mainframe design
• High-powered ranging arms with up to 750 kW (@ 50 Hz)
of cutting power in a compact design
• Maximized coal cutting and coal clearance ability
• AC haulage system with up to 125 kW (200 hp) per
haulage unit providing the necessary haulage force and
speed for high-productivity medium seam applications
• Advanced automation for optimized performance and
improved face management
EL4000
EL3000
The EL3000 shearer has been developed for medium to high
seams to meet the requirements of the most demanding
longwall installations in the world. World-class performance
has demonstrated the practical capabilities of this machine.
The EL3000 shearer mines seams of up to 5.50 m (216 in).
It offers 2 x 860 kW (1,150 hp) of cutting power combined
with haulage motors of up to 2 x 150 kW, with a 75 kW
(100 hp) pump motor to provide a total installed power in
excess of 2 000 kW and a production capacity of over 5 000
tonnes per hour. Some of the highest-producing longwall
installations in the USA and Australia utilize Cat shearers.
Benefits:
• High level of installed power provides high level of
performance in the most arduous mining conditions
• AC haulage system capable in excess of 100 tonnes
haulage force
• Heavy-duty, high mass for maximum stability and
reliability in the most demanding applications
EL4000
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The EL4000 is designed for maximum production in high
seams. It is based on the EL3000, but has a cutting drum
diameter of up to 3.50 m and ranging arms that allow mining
up to heights in excess of 7 meters.
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Optional Accessories
Model Series EL2000 EL3000 EL4000
Height range 1.80 m – 4.50 m 2.50 m – 5.50 m 4.00 m - 7.00 m
Typical 13.75 m 15.20 m 16.70 m
machine length 45.1 ft 49.9 ft 54.8 ft
Installed power 1 900 kW (3,040 hp) 2 295 kW (3,680 hp) 2 295 kW (3,680 hp)
Available 2 x 500 kW 2 x 650 kW 2 x 750 kW
cutting power 2 x 620 kW 2 x 750 kW 2 x 860 kW
Cutting drum 1.40 m – 2.30 m Up to 2.70 m Up to 3.50 m
diameter 55 – 91 in Up to 106 in Up to 138 in
Haulage system AC AC AC
Available
haulage motors
Haulage Up to 32 m/min Up to 32 m/min Up to 32 m min
speed Up to 105 ft/min Up to 105 ft/min Up to 105 ft/min
Haulage pull Up to 920 kN Up to 1 075 kN Up to 1 075 kN
Coal sizer 100 kW (160 hp) 200 kW (320 hp) 200 kW (320 hp)
Pump motor 50 kW (80 hp) 75 kW (120 hp) 75 kW (120 hp)
Machine
weight Approx. 77 tons Approx. 116 tons Approx. 154 tons
Body height 520 mm (20.5 in) 685 mm (27.0 in) 1 050 mm (41.3 in)
Operating 2300 V
voltages 3300 V 3300 V 3300 V
Applicable min.
pan width 40.6 in 44.6 in 52.8 in
71 – 177 in 98 – 217 in 158 – 276 in
2 x 750 kW 2 x 860 kW
2 x 125 kW 2 x 150 kW 2 x 150 kW
2 x 200 hp 2 x 240 hp 2 x 240 hp
Up to 100 tons Up to 120 tons Up to 120 tons
Approx. 70 tonnes Approx. 105 tonnes Approx. 140 tonnes
1 032 mm 1 132 mm 1 342 mm
4160 V 4160 V 4160 V
Model Series EL2000 EL3000 EL4000
Multi-piece
mainframe
Cowl
Spall guards
Coal sizer
Trapping Shoe Ix
(Insert exchange)
Shearer clearer
Spray bars
Central lubrication
system
™
PMC
Evo-S
Gate end data
connection
IPC
Zone-based
automation
“Navigator 1”
State-based
shearer automation
“Navigator 2”
Integrated longwall
automation with
“Navigator 2 + 3”
“Longwall Navigator”
for improved face
alignment and
horizon control
incorp. LASC Tech.
100 kW
200 kW
Powerline
Fibre optics
WLAN
O O O
O O O
O O O
O
–
•
O
O O O
O
•
•
•
–
•
O O O
O O O
O O O
O* O* O*
O* O* O*
O
O
•
O
O
•
•
•
O
•
O
O
•
O
O
•
•
•
O
•
Specialized Shearers
Caterpillar also supplies shearers for specialized applications:
• Single- and double-drum low-seam shearer
• Three-drum shearer for selective mining
These shearers utilize the key feature of modular mainframe
construction and are proven for coal and non-coal applications.
VibraGuard
Cameras
Condition
monitoring
=Standard equipment, O =Available equipment,
•
O*=Only with Cat longwall equipment
™
O O O
O O O
O O O
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Longwall Shearers �
For more complete information on Cat products, dealer services, and industry solutions,
visit us 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 the “Power Edge” trade
dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and
may not be used without permission.
AEXQ0603-01
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