Smart cable management for safer, more efficient mining operations
Our client, Eurasian Machinery LLP, was approached by a major mining operator in Kazakhstan seeking a reliable solution to manage the high-voltage trailing cable on its new electric-powered Hitachi EX2600E-6 excavators. The goal was clear: improve safety, keep machines moving, and ensure consistent uptime in one of the harshest operating environments in the industry.
The challenge
Managing a trailing cable on a 250-tonne electric excavator is no small task. The client needed a system that would be both reliable and highly efficient, while also protecting the excavator’s chassis from unnecessary reaction loads. The system had to function in rough terrain, offer enough capacity for extended cable runs, and reduce the risks associated with manual cable handling. Ultimately, the solution needed to combine safety, durability, and manoeuverability—without compromising the machine’s stability and productivity.
Our solution
IHC Mining delivered a fully engineered, turnkey trailing cable reeler system designed specifically for the EX2600E-6 platform. The underlining design philosophy and engineering approach focused on creating a solution with inherent adaptability, ensuring that the cable reeler can be seamlessly configured to suit a wide range of other OEM mining excavators.
The scope included complete design, fabrication, corrosion protection, assembly, FAT, delivery, and on-site support.
Key features of the reeler system
- Lightweight, cost-effective frame that minimises loads on the excavator
- 620 mm ground clearance and a large departure angle for improved mobility
- 250 m live-cable capacity for extended operational range
- Robust mechanical design including heavy-duty drum, planetary gearbox, induction motor, and spooling system
- Manual and automatic modes, with joystick control and auto operation
- Safety and monitoring functionality, including over/under-wind warnings, E-stop, and system health indicators
This end-to-end approach ensured smooth integration with the client's new electric excavator fleet.
Delivering direct benefits
The new cable reeler system now allows the excavator to operate with far less manual intervention around the cable—significantly improving operator safety, while also increasing operational uptime. The operational uptime has increased because cable-related stoppages and damage have been minimised. The cable reeler’s 620 mm ground clearance and large departure angle ensure that, when mounted to the chassis, it does not hinder the excavator’s ability to manoeuvre effectively across the mining bench or during repositioning. With robust construction, corrosion protection, operator training, and a full set of documentation and spares, the solution is designed for long-term, low-maintenance performance.
This solution now forms a crucial part of the customer’s strategy to enable safe, productive, and more sustainable mining—powered by smart and reliable engineering.
At IHC Mining, we design, build, and supply mining equipment that delivers improved operational uptime while supporting a reduced environmental impact for our clients.
Mark Du Preez - Project Engineer Manager
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