This represents DBT’s first US order for the new shearer and is part of a complete AFC package that has been purchased to operate with Joy Mining Machinery roof supports.

“The shearer has a ‘thin body’, designed for lower US coal seams, but still packs a high amount of horsepower,” said material handling and shearer division vice president Al Hefferan.

“The shearer package includes 2 x 135 horsepower AC haulage units, and 2 x 600 HP cutter motors on the shearer (not 800 HP which is normally used on a wider conveyor).

“The package includes more extensive monitoring than is usually supplied to American mines,” Hefferan said.

“Other than roof supports and the AFC being included in the data platform, the shearer has also been incorporated. DBT’s new control system, Compact, is replacing the previous generation control system and provides the ability for the shearer to communicate with headgate and link to supports. All data flow will be transmitted to the surface for monitoring purposes.

“The automation capability of the shearer was particularly attractive to Monterey for improvements in face horizon control,” he said.

Using DBT’s mimic and program differential cut shearer functions will require only one shearer operator per shift. Monterey’s roof conditions are extremely sensitive to variations in horizon control. A thinning area of the current reserve requires extracting up to 2 feet of roof rock material to provide machine clearance of 72 inches.

Monterey is anticipating a reduction in cutting height, better overall face conditions and an improvement in clean coal recovery as the result of the automation features.

“In the US, very few mines operate with shearer automation and only one operator. Managing the cutting horizon has been an ongoing problem at many mines," he said.

“Automation will enhance consistency among shifts, improve face conditions and result in less reject material to be handled which leads to improvements in profitability. In Australia there’s a dependency on automation and a willingness to use it.

“Senior management in America is interested in automation and it is coming slowly.”

It is a big step for DBT to get back into the shearer market in the US, Hefferan added.

The AFC has twin 42mm chain and 3 x CSTs with 800 HP motors and incorporates a narrow PF5 1042 conveyor.

The 1332mm wide stageloader has twin 34mm chain 400 HP drives and the crusher is a V-Belt style, not used in Australia.

Monterey produced 3.3 million clean tons in 2002 and will produce 3.5 million tons in 2003.