Case Studies Archives | Cougar Group

Heavy Lift Fleet Build: Underground Giants Headed to Queensland

Ryan.Hartwell — Thu, 25 Sep 2025 04:40:14 +0000

Heavy Lift Fleet Build: Underground Giants Headed to Queensland

Three of the largest underground coal mobile machines head to work after being manufactured by Cougar Group in Tomago.

Two Longwall Chock Carriers (LWC) and one Dozer were recently manufactured by Cougar Group and shipped to an Australian customer. All three machines have a payload capacity of 70 tonnes, making the machines some of the largest payload capacity mobile plant in underground coal mines.

The machines were purchased by a valued customer to conduct installation of their Longwall system from the surface to underground and will be subsequently used for future Longwall moves underground forming a vital part of their equipment fleet.

The 2x LWC and 1x Dozer builds demonstrate Cougar Group’s skill at manufacturing some of the largest, heavy-duty gear in underground coal."

Cougar’s IP Depth: The Critical Link to Productivity

Manufacturing the largest payload capacity machines in their class demonstrates Cougar’s ingenuity with key features that include:

Hydrostatic Drive – for optimal power efficiency and tractive effort.
Track-Type Dozer – low ground pressure.
Heavy Payload Capacity – IP designed structures and hydraulics.

Rounding Out the Fleet

The LWCs and Dozer were the final machines shipped in a large purchase that also included:

10x MK8 Minecruiser Troops
2x MK8 Minecruiser Utes
1x M4H Grader

Cougar Group also supplies mine services FRAS pipe and multiple underground in-seam (UIS) gas drainage drill rigs to the same mine site.

The large purchase of equipment and services on-site demonstrate Cougar Group’s ability to provide complete lifecycle solutions for mining customers.

More Insights

Discover the latest news, insights, and updates from Cougar Group.

Heavy Lift Fleet Build: Underground Giants Headed to Queensland

Engineering Services Case Study: Converting Hard Rock Jumbos for Underground Coal

Cougar Capital: Delivering a Flexible Finance Solution for Mining Operations

Innovation in Grader Operator Protection

Cougar Strengthens Hire Fleet With New Grader Investment

Cougar CEO Chad Dillinger Joins Dirt and All Podcast

Engineering Services Case Study: Converting Hard Rock Jumbos for Underground Coal

ryan — Tue, 01 Jul 2025 21:39:06 +0000

Engineering Services Case Study: Converting Hard Rock Jumbos for Underground Coal

Cougar Group was engaged by PYBAR Mining Services to deliver a unique engineering solution – converting two Sandvik DD420 Jumbo Drills for safe and compliant use in underground coal operations.

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.

This project is a great example of how Cougar works with customers to solve unique challenges. By adapting the Jumbos for underground coal, we delivered a solution that exceeded expectations in reliability and performance."

Cougar's Engineering Advantage: Redesigning the Jumbo for Coal Compliance

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.

Cougar and PYBAR: A Collaborative Approach to a Unique Challenge

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.

More Insights

Discover the latest news, insights, and updates from Cougar Group.

Heavy Lift Fleet Build: Underground Giants Headed to Queensland

Engineering Services Case Study: Converting Hard Rock Jumbos for Underground Coal

Cougar Capital: Delivering a Flexible Finance Solution for Mining Operations

Innovation in Grader Operator Protection

Cougar Strengthens Hire Fleet With New Grader Investment

Cougar CEO Chad Dillinger Joins Dirt and All Podcast

Cougar Capital: Delivering a Flexible Finance Solution for Mining Operations

ryan — Thu, 17 Jul 2025 22:42:14 +0000

Cougar Capital Unlocks Ownership Flexibility for Hunter Valley Mining Customer

When a Hunter Valley mining customer needed to acquire four new pieces of equipment to support their mine development project, Cougar Capital provided a tailored financing solution that enabled a smooth transition into the production phase of operations.

For a cost not much more than a weekly hire, Cougar Capital offered a pathway to new machine ownership without the burden of upfront capital expenditure. This approach gave the customer immediate access to the latest technology and the benefits of lower maintenance costs, all within a manageable two-year payment structure.

In a market where fewer OEMs now offer lending solutions, Cougar’s ability to bridge this gap highlights its commitment to solving customer challenges. From technical support to financial flexibility, Cougar Capital is helping operators unlock new opportunities and maintain productivity with minimal financial strain.

Cougar Capital gave us a clear path to ownership without tying up capital. We had brand-new machines on site when we needed them most, and the flexible terms kept our project moving."

Delivering flexible ownership solutions for mining

A Hunter Valley mining customer needed four new machines to transition from development to production but faced challenges with upfront capital and limited OEM finance options. Cougar Capital provided a tailored solution offering new equipment for only slightly more than weekly hire rates, with a clear two-year pathway to ownership.

Unlocking operational and financial benefits

This approach gave the customer access to the latest technology, reduced maintenance costs, and ownership security – all while maintaining cashflow flexibility. The result was a strengthened fleet, uninterrupted project momentum, and a finance model that supported long-term operational success.

More Insights

Discover the latest news, insights, and updates from Cougar Group.