The Jumbos were required to develop two drifts for a new underground coal project in the Hunter Valley, working through a mix of siltstone geology and coal seams.
Traditionally used in hard rock drill and blast mining, Jumbo drills are rarely applied in coal environments due to stringent compliance requirements. This project broke new ground by fully modifying the machines for safe operation in coal, ensuring they could navigate challenging geology efficiently and meet all regulatory standards.
The result was two highly capable machines that performed reliably over 16 months of continuous operation, achieving impressive advance rates and showcasing Cougar’s engineering and problem-solving expertise.
The scope of work demanded significant structural and functional changes to adapt the hard rock equipment to coal industry standards. Cougar’s engineering team undertook:
Electronic Control System Redesign – to align with coal compliance and safety requirements.
Flameproofing of Motors – replacing all electric motors with flameproof models.
Hydraulic and Braking Systems Upgrades – including a revised hydraulic circuit and a new registered braking system.
Structural Frame Modifications – to accommodate the redesigned systems and maintain machine integrity underground.
Rather than fitting a flameproof diesel powertrain, Cougar engineered a solution using electric motors paired with the existing mechanical drivetrain. This innovation reduced maintenance, eliminated emissions, and lowered noise levels during tramming – critical advantages in the confined spaces of drift development.
All design and modification work was completed at Cougar’s Tomago, NSW facility by their specialist engineering team.
This project was the result of a strong partnership between Cougar and PYBAR. Cougar provided the full engineering design, modification, and compliance expertise, while PYBAR managed the drift development on-site in the Hunter Valley.
The collaboration demonstrated the strengths of both companies – Cougar’s innovation and technical capability, and PYBAR’s operational excellence in hard rock and coal environments. Together, they delivered a solution that set a new benchmark for cross-industry collaboration and equipment adaptation.
The converted Jumbos exceeded expectations, achieving outstanding reliability and productivity over the course of the project. This case study highlights Cougar’s ability to solve complex engineering challenges and support clients with tailored, innovative solutions.
