Cat CM235 Continuous Miner Operation and Maintenance Manual A6474X378

A6474X378 February 2012

Operation and Maintenance Manual CM235 Continuous Miner A6474X (Mechanical - Gathering Head/Conveyor)

SAFETY.CAT.COM

__________________________________________________________ This manual is intended to provide GENERAL product information. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Caterpillar reserves the right to revise models and designs without prior notice.

This machine was manufactured under the guidelines, procedures and requirements of the appropriate government regulatory agencies.

At the completion of the manufacturing process, this unit was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of Caterpillar and these regulatory agencies, or any repair or replacement of parts contrary to the instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

While this manual attempts to anticipate the most important operations and maintenance needs for this unit, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your service representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

© CATERPILLAR 2012.

ALL RIGHTS RESERVED

_______________________________________________________________

Table of contents Safety Instructions............................................................................. 4 Preliminary Instructions ..................................................................... 6 Torque Values ................................................................................... 7 Component Weights.......................................................................... 9 Gathering Head Assembly ................................................................ 10 Gathering Head Drive Motor ............................................................. 16 Gathering Head Gear Case .............................................................. 23 Foot Shaft.......................................................................................... 30 Gathering Head Cylinder................................................................... 33 Centrifugal Loading Arm (CLA) ......................................................... 37 Swivel Pin Assembly ......................................................................... 42 Tail Roller .......................................................................................... 46 Conveyor Chain................................................................................. 49

________________________________________________________________ A6474X378

REV 1

Safety Instructions _______________________________________________ Safety Precautions

The following safety precautions should be observed whenever operating or performing any maintenance, repair, or adjustment procedure on this machine.

Additional precautions may appear in each section of this book. All precautions listed applicable to this machine, as well as all applicable regulatory agency rules and regulations must be followed at all times.

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

!

WARNING Failure to follow all applicable lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

!

WARNING Stand clear of the blocked cutter head and gathering head assemblies during the contraction of the gathering head lift cylinders.

!

WARNING When separating the gathering head from the tractor frame, ensure that the disconnected ends of the conveyor chain smoothly slide out of the gathering head.

!

WARNING When tramming the miner toward the gathering head, be careful that the conveyor chain and gathering head lift cylinders do not become pinched between the tractor frame and the gathering head.

!

WARNING Insert the pin far enough to avoid obstructing the placement of the pin retaining bar.

!

WARNING Use caution when using the lift cylinders and stabilizer to adjust the alignment of the clevis and pivot pins.

!

WARNING The pin must be inserted far enough so that it does not obstruct positioning of the retaining plate flat against the tractor frame.

!

WARNING While the power cable is detached from the motor, the trailing cable should not be reconnected to the miner. Damage to the machine or injury or death to personnel could result.

!

WARNING

The gathering head drive motor is extremely heavy. Be prepared to support this weight before performing the following steps.

!

WARNING

The bottom ports on the high speed input cases are the fill lines. The top ports on the high speed input cases are the check lines.

!

WARNING Improper conveyor chain tension can lead to excessive wear, mechanical problems, and miner downtime. Always keep the conveyor chain at proper tension.

IMPORTANT

Position the foot shaft so its sprocket will engage the conveyor chain links when the chain is reconnected.

________________________________________________________________ 4 CM235 Mechanical - Gathering Head and Conveyor

_______________________________________________ Safety Instructions !

WARNING Stand clear of the blocked cutter head and gathering head assemblies during gathering head lift cylinder contraction.

!

WARNING When aligning the cylinder end bearings within their clevises to allow for insertion of the retaining pins, do not test alignment with your fingers. Shifting parts could cause serious injury.

IMPORTANT

Insert the pin so that its retaining channel remains outside of the bushing.

IMPORTANT

Hog rings should be installed so that their sharp points are directed clockwise.

______________________________________________________________ A6474X378 REV 1 5

Preliminary Instructions ___________________________________________ Introduction

The following general guidelines, in addition to specific procedural instructions, should be followed whenever performing maintenance on this machine.

The procedures for the removal and installation of components are for a typical machine and conditions. Tools available, work conditions, or other factors may require procedures to vary from those given.

Tools

It is the responsibility of the mine operator or the employee to provide the necessary tools required for routine maintenance. If a procedure requires a specialty tool or material, it will be identified in the procedure.

Illustrations

The illustrations used in this manual are for a typical machine and may vary from your machine. If repair work is required, always refer to the specific drawing in the parts book supplied with your machine.

Before Maintenance

Before performing maintenance on this machine, observe the following: 1. Shutdown the machine on level ground.

2. Turn circuit breaker to the "OFF" position and disconnect the trailing cable.

Follow all applicable lockout/tagout procedures.

3. Only work on the miner in an area where the roof is properly supported.

4. Block any and all elevated assemblies before working under them. Make sure that the blocking can support the weight of the assembly without slipping or failing.

Important Notes

1. Use only suitable and approved tools for maintenance work.

2. Use only original spare parts when replacing components.

3. All electrical work must be supervised and inspected by a certified electrician.

4. Anyone performing maintenance on this equipment must be trained on machine operation.

5. Always refer to the appropriate engineering drawing when replacing components.

________________________________________________________________ 6 CM235 Mechanical - Gathering Head and Conveyor

___________________________________________________ Torque Values Introduction

The following charts list the recommended torque values for common fasteners used on the Continuous Miner. Use these torque values unless the drawing or instructional material states otherwise.

Do not use these tables for any bolt grades except those specifically listed.

Use a calibrated torque wrench for accuracy.

Table 1: Imperial Bolts

Grade 8 Imperial Bolts Torque Recommendations (calculated at 75% proof load) Bolt size Dry Lubricated (inches) ft-lbs ft-lbs 1/4 12 6 5/16 25 12 3/8

44

22

7/16

70

35

1/2

107

53

9/16

154

77

5/8 3/4

212 376

106 188

7/8

606

303

1

909

454

1-1/8

1287

644

1-1/4

1875

938

1-3/8

2382

1191

1-1/2

3161

1581

1-3/4

4988

2494

2

7500

3750

2-1/4

10969

5484

2-1/2

15000

7500

2-3/4 3

17794 23507

8897 11753

3-1/4

30286

15143

3-1/2

38266

19133

3-3/4

47545

23773

4

58100

29085

______________________________________________________________ A6474X378 REV 1 7

Torque Values ___________________________________________________ Table 2: Metric Bolts

Metric Bolts Torque Recommendations (calculated at 75% proof load) Property Class

8.8

10.9

12.9

M6 - M16: 800 M20 - M30: 830

1040

1220

Minimum Tensile Strength (MPa) Nominal Size and Thread Pitch

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

M5 X 0.80 M6 X 1.00

(54) (92)

(41) (69)

(78) (133)

(59) (99)

(91) (156)

(68) (116)

M7 X 1.00

(156)

(116)

(222)

(167)

(260)

(195)

M8 X 1.25

(2250

(169)

(333)

(242)

(377)

(284)

M10 X 1.50

37

28

53

40

62

47

M12 X 1.75

65

49

93

69

108

81

M14 X 2.00

104

78

148

111

173

130

M16 X 2.00

161

121

230

172

269

202

M18 X 2.50

222

167

318

238

372

279

M20 X 2.50

314

235

449

337

525

394

M22 X 2.50

428

321

613

460

716

537

M24 X 3.00

543

407

776

582

908

681

M27 X 3.00

796

597

1139

854

1331

998

M30 X 3.50

1079

809

1543

1158

1804

1353

M33 X 3.50

1468

1101

2101

1576

2455

1842

M36 X 4.00

1886

1415

2699

2024

3154

2366

________________________________________________________________ 8 CM235 Mechanical - Gathering Head and Conveyor

______________________________________________ Component Weights Component Weights

Following are the approximate weights of the major components of the gathering head and conveyor systems. Be certain that adequate lifting and blocking is available whenever a component is being removed or installed as serious injury or death can result from falling loads. Never work under a component that is not adequately and correctly supported.

Table3: Component Weights Component

Approximate Weight

Foot Shaft Gathering Head Cylinder Gathering Head Assembly Gathering Head Motor Centrifugal Loading Arm Gathering Head Gear Case Conveyor Swing Cylinder Conveyor Lift Cylinder Conveyor Discharge Assembly Conveyor Assembly (without chain or cylinders)

66 lbs (30 kg) 163 lbs (74 kg) 23,515 lbs (10,666 kg) 900 lbs (408 kg) 472 lbs (214 kg) 985 lbs (447 kg) 217 lbs (98 kg) 166 lbs (75 kg) 4,700 lbs (2,132 kg) 14,000 lbs (6,350 kg)

______________________________________________________________ A6474X378 REV 1 9

Gathering Head Assembly _________________________________________ Introduction

The following procedure is for the removal and installation of the gathering head assembly. The foot shaft is coupled to the gathering head gear cases and drives the conveyor chain.

Tool Set

Basic Tool Set Pry Bar

Safety

When removing or installing the gathering head assembly, observe the following safety precautions:

Slide Hammer Blocking

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

!

WARNING Failure to follow all applicable lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

!

WARNING Stand clear of the blocked cutter head and gathering head assemblies during the contraction of the gathering head lift cylinders.

!

WARNING When separating the gathering head from the tractor frame, ensure that the disconnected ends of the conveyor chain smoothly slide out of the gathering head.

!

WARNING When tramming the miner toward the gathering head, be careful that the conveyor chain and gathering head lift cylinders do not become pinched between the tractor frame and the gathering head.

!

WARNING Use caution when using the lift cylinders and stabilizer to adjust the alignment of the clevis and pivot pins.

________________________________________________________________ 10 CM235 Mechanical - Gathering Head and Conveyor

_________________________________________Gathering Head Assembly Gathering Head Assembly

To remove the gathering head assembly: 1. Lower the conveyor tail section until it is level with the floor. Lower the gathering head (Fig. 1) until it rests on the floor. Place blocking under the rear of the gathering head to stabilize its position during and after removal of the pivot pins and disconnection of the lift cylinders.

2. Raise the cutter head to its highest point and place blocking underneath it.

Lower the cutter head onto the blocking.

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

Fig. 1: Gathering head assembly Foot shaft

CLA Gear case (under CLA)

CLA key

______________________________________________________________ A6474X378 REV 1 11

Gathering Head Assembly _________________________________________

4. Double check that the cutter head is securely blocked.

5. Separate the conveyor chain and remove the foot shaft (see Foot shaft removal procedure in this chapter).

6. Remove the retaining pin that secures each of the front rub rails to the tractor frame and open both front rub rails.

7. Remove the electrical power cables from the gathering head.

8. Disconnect, tag, and cap the motor cooling water and scrubber spray water hoses from the gathering head.

9. Remove the 2 (two) 1” hex head capscrews and lockwashers that secure the right gathering head pivot pin retaining plate to the tractor frame (Fig. 2).

10. Remove the 2 (two) 1” hex head capscrews and lock washers that secure the pin retaining plate to the gathering head pivot pin and remove the retaining plate.

Fig. 2: Gathering head pivot pin

Gathering head pivot pin Lockwashers Pivot pin retaining plate Hex head capscrews

11. Using a slide hammer, pull the pivot pin.

12. Repeat the previous three (3) steps for the left gathering head pivot pin.

13. Remove the 2 (two) 1/2” hex head capscrews and lock washers that secure the piston pin retaining bar on the right gathering head lift cylinder to the gathering head side panel and remove the retaining bar (Fig. 3).

14. Repeat the previous step for the left gathering head lift cylinder.

________________________________________________________________ 12 CM235 Mechanical - Gathering Head and Conveyor

_________________________________________Gathering Head Assembly Fig. 3: Gathering head lift cylinder piston pin retaining bar

Retaining bar Lockwashers pin cylinder

Hex head capscrews

Piston end pin 15. Connect the trailing cable to energizer the miner.

16. Slowly retract the lift cylinders until the piston ends come free from their gathering head clevises.

17. Lift the cutter head off the blocking and slowly tram the miner in reverse until the cutter head clears the backboard of the gathering head.

______________________________________________________________ A6474X378 REV 1 13

Gathering Head Assembly _________________________________________ Gathering Head Assembly Installation

To install the gathering head assembly: 1. Position the gathering head assembly at the front of the tractor frame. Block up the rear of the gathering head so that it’s pivot points are at the level of the tractor frame clevises.

2. Raise the cutter head assembly to its highest point.

3. Slowly tram the miner forward until the gathering head pivot points are inserted into the tractor frame clevises.

4. Place blocking underneath the cutter head and lower the cutter head onto the blocking.

5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

6. Thread the lower end of the conveyor chain into the gathering head assembly return pan so that the end appears on the foot shaft return plate. Place the upper end of the conveyor chain down the front of the gathering head entrance pan.

7. Connect the trailing cable to energize the miner.

8. Extend the gathering head lift cylinders so that the piston end bearings can be inserted into the gathering head lift cylinder clevises.

9. Disconnect the trailing cable to de-energize the miner.

10. Insert the piston end clevis of the right gathering head lift cylinder into the gathering head clevis.

11. Using the hammer, insert the piston end pin through the aligned clevis bushings and the rod end bearing.

!

WARNING Insert the pin far enough to avoid obstructing the placement of the pin retaining bar.

12. Place the pin retaining bar over the end of the pin and insert and tighten the two (2) 1/2 X 1 1/2” hex head capscrews and lock washers that secure the piston pin retaining bar to the gathering head side panel and torque to 114 ft-lbs (156 Nm).

13. Repeat the previous three steps for the left gathering head lift cylinder.

________________________________________________________________ 14 CM235 Mechanical - Gathering Head and Conveyor

_________________________________________Gathering Head Assembly

14. Use the gathering head lift cylinders and tractor frame stabilizer to align the tractor frame clevis and the gathering head pivot points to make inserting pivot pins easier.

15. Gently tap the right gathering head pivot pin through the aligned tractor frame clevis and gathering head pivot bushings. !

WARNING The pin must be inserted far enough so that it does not obstruct positioning of the retaining plate flat against the tractor frame.

16. Place the pivot pin retaining bar (Fig. 3) so that edge with two cutouts located in the corners is positioned against the backup strip. The edge of the plate with two cutouts and a hole for the pin’s grease fitting must be positioned over the pivot pin.

17. Insert and tighten the two (2) 1 X 2 1/4” hex head capscrews and lock washers to secure the pivot pin retaining plate to the gathering head pivot pin, and torque to 970 ft-lbs.

18. Insert and tighten the two (2) 1 X 2 1/4” hex head capscrews and lock washers to secure the pivot pin retaining plate to the tractor frame, and torque to 970 ft-lbs.

19. Repeat the previous three steps for the left gathering head pivot pin.

20. Replace the motor cooling water and scrubber spray water hoses onto the gathering head assembly.

21. Replace the electrical power cables onto the gathering head assembly.

22. Close the front rub rails and insert and tighten a hex head capscrew and lock washer to secure the front rub rail closed against the tractor frame.

23. Replace the foot shaft into the gathering head (see foot shaft removal and installation procedure in this chapter) and reconnect the conveyor chain.

______________________________________________________________ A6474X378 REV 1 15

Gathering Head Drive Motor________________________________________ Introduction

The following procedure is for the removal and installation of the gathering head drive motor.

Tool Set

Basic Tool Set Pry Bar

Safety

When removing or installing a gathering head motor, observe the following safety precautions:

Blocking Retaining Ring Pliers

Slide Hammer

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

!

WARNING Failure to follow all applicable lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

!

WARNING While the power cable is detached from the motor, the trailing cable should not be reconnected to the miner. Damage to the machine or injury or death to personnel could result.

!

WARNING

The gathering head drive motor is extremely heavy. Be prepared to support this weight before performing the following steps.

________________________________________________________________ 16 CM235 Mechanical - Gathering Head and Conveyor

________________________________________Gathering Head Drive Motor Gathering Head Drive Motor Removal

To remove the gathering head drive motor: 1. Lower the gathering head completely until it touches the floor. Lower the conveyor tail assembly until it is level with the floor.

2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly. Lower the cutter head assembly onto the blocking.

3. Disconnect the trailing cable to de-energize the miner.

4. If necessary, remove the CLA to allow access to the motor (See CLA removal and installation procedure in this chapter).

5. Remove the three (3) M12 hex head capscrews and lock washers that secure the upper deck cover (Fig. 4) to the gathering head assembly.

6. Remove the upper deck cover. The gear case and drive shaft end of the motor should be exposed.

7. Locate the side cover of the gathering head motor and remove the six (6) M20 X 50 hex head capscrews and lock washers that secure the side cover to the gathering head assembly.

8. Remove the cover to expose the end of the motor.

9. Remove the square-head pipe plug on the end of the gathering head motor.

10. Remove the retaining ring that secures the shaft end plug inside the motor housing (Fig. 4).

11. Using a slide hammer, pull the drive shaft end plug out.

12. Pull the drive shaft from the motor and store in safe place.

13. Use the adjustable wrench to replace the pipe plug into the end of the motor.

14. Remove the four (4) 1/2” hex head capscrews and lock washers that secure the motor junction box cover 15. Remove the cover and its o-ring (Fig. 5).

16. Locate the three tapped power connections inside the junction box and strip the tap covering each lug connection.

17. Tag each connection and remove the 3/8 X 7/8” hex head capscrew, flat washer, lock washer, and hex head nut that secures each of the power cable lugs. .

______________________________________________________________ A6474X378 REV 1 17

Gathering Head Drive Motor________________________________________ 18. Remove the socket head capscrews and lock washers that secure the stuffing box’s half-moon clamp to the junction box.

19. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.

20. To prevent damage to the power cable lugs, stuffing box, and gland assembly, cover and secure the power cable to the miner in a safe location.

21. Replace the junction box o-ring and cover and secure with the eight (8) 1/4 X 5/8” hex head capscrews and lock washers to protect the motor’s electrical connections.

22. Tag, disconnect, and cap the two cooling water hoses (with elbow and adapter) from the two motor cooling water fittings on the gear case end of the motor.

23. Remove the two motor cooling water fittings from the motor and store in a clean place.

24. Plug the two motor cooling water ports to keep them clean.

25. Remove the four (4) M20 X 50 socket head capscrews that secure the motor to the gear case adapter plate.

26. The gathering head drive motor should now be detached from the gear case and able to be removed from the gathering head assembly through the motor side cover opening.

________________________________________________________________ 18 CM235 Mechanical - Gathering Head and Conveyor

________________________________________Gathering Head Drive Motor Fig. 4: Upper deck cover

Upper deck cover Lower deck cover

Fig. 5: Drive shaft and end plug removal

Drive shaft O-ring Drive shaft End plug

Retainer ring

______________________________________________________________ A6474X378 REV 1 19

Gathering Head Drive Motor________________________________________ Gathering Head Drive Motor Installation

To install the gathering head drive motor: 1. Insert the gathering head motor through the slide cover opening, attachment bolt holes first. The junction box of the motor should be positioned toward the front of the gathering head.

Fig. 6: Gear case to motor seal installation

Gear case adapter plate

Motor

2. Position the motor against the gear case adapter plate and align the four attachment bolt holes on the gear case side of the motor with the four holes on the corners of the adapter plate.

3. Insert and tighten the socket head capscrews to secure the motor to the gear case adapter plate.

4. Using an adjustable wrench, insert the two motor cooling water fittings into the gathering head drive motor’s cooling water ports, which are located on the gear case end of the motor.

5. Attach the two motor cooling water hoses (with elbow and adapter) to the fitting.

6. Remove the four (4) 1/2” hex head capscrews and lock washers that secure the junction box cover.

7. Remove the cover and its o-ring.

8. Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.

9. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.

________________________________________________________________ 20 CM235 Mechanical - Gathering Head and Conveyor

________________________________________Gathering Head Drive Motor

10. Insert and tighten the two (2) 3/8” socket head capscrews and lock washers to secure clamp to the junction box.

11. Locate the motor’s lug connections inside the junction box and match the motor lug connections to the corresponding power cable lugs.

12. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the power cable lug, through the motor lug, through a flat washer, and through a lock washer. Secure the capscrew with a hex nut.

13. Repeat this step with the other two power cable and motor lugged connections.

14. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of electrical (black) tape, and finally a layer of glass tape.

15. Replace the junction box o-ring and junction box cover and secure the cover with four (4) 1/2” hex head capscrews and lock washers to secure the junction box cover.

16. Remove the pipe plug from the end of the motor (Fig. 7).

17. Slide the drive shaft through the gathering head motor and into the gathering head gear case (the drive shaft end without the threaded hole should be inserted first). The shaft may require some adjustment so that its end fits into the gear case.

18. Install the o-ring into the channel on the shaft end plug.

19. Insert the drive shaft end plug into position in the center of the motor.

20. Insert the retaining ring to secure the shaft end plug inside the motor housing.

21. Replace the pipe plug into the end of the motor.

______________________________________________________________ A6474X378 REV 1 21

Gathering Head Drive Motor________________________________________ Fig. 7: Drive shaft installation

Drive shaft O-ring Retainer ring Pipe plug

24. Replace the gathering head motor side access cover. Secure the cover to the gathering head by inserting and tightening the hex head capscrews.

25. Replace the upper deck cover and secure to the gathering head by inserting and tightening the three (3) M12 hex head capscrews.

26. If removed, install the CLA over the motor (see CLA removal and installation procedure in this chapter).

________________________________________________________________ 22 CM235 Mechanical - Gathering Head and Conveyor

________________________________________ Gathering Head Gear Case Introduction

The following procedure is for the removal and installation of the gathering head gear case. The gathering head gear case turns the CLAs and drives the foot shaft which powers the conveyor chain.

Tool Set

Basic Tool Set Torque Wrench

Safety

When removing or installing a gathering head gear case, observe the following safety precautions:

Blocking Slide Hammer

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

!

WARNING Failure to follow all applicable lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

!

WARNING Improper conveyor chain tension can lead to excessive wear, mechanical problems, and miner downtime. Always keep the conveyor chain at proper tension.

______________________________________________________________ A6474X378 REV 1 23

Gathering Head Gear Case _________________________________________ Gathering Head Gear Case Removal

To remove the gathering head gear case: 1. Lower the conveyor tail section until it is level with the floor. Lower the gathering head until it touches the floor.

2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly. Lower the cutter head assembly onto the blocking.

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

4. Remove the gathering head motor’s side cover by removing the hex head capscrews and lock washers that secure the side cover to the gathering head assembly.

5. Remove the cover to expose the end of the motor.

6. Remove the square-head pipe plug on the end of the gathering head motor.

7. Remove the retaining ring that secures the shaft end plug inside the motor housing (Fig. 7).

8. Using a slide hammer, pull out the drive shaft end plug.

9. Pull the drive shaft from the motor and store in a safe place.

10. Replace the pipe plug into the end of the motor.

11. Remove the CLA to expose the gathering head gear case (see CLA removal and installation procedure in this chapter).

12. Remove the three (3) M12 X 30 hex head capscrews and lock washers that secure the upper deck cover (Fig. 8) to the gathering head assembly. Remove the upper deck cover to expose the gear case and the drive shaft end of the motor.

13. Remove the five (5) M12 X 30 hex head capscrews and lock washers that secure the lower deck cover (Fig. 8) to the gathering head assembly and remove the lower deck.

14. Loosen tension on the conveyor chain as much as possible.

15. Separate the conveyor chain and remove the gathering head foot shaft (see the Foot shaft removal and installation procedure in this chapter).

16. Connect the trailing cable to energize the miner.

17. Raise the gathering head to its highest position. Place blocking underneath the gathering head and lower the gathering head onto the blocking.

________________________________________________________________ 24 CM235 Mechanical - Gathering Head and Conveyor

________________________________________ Gathering Head Gear Case Fig. 8: Deck covers

Upper deck cover

Lower deck cover

18. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

19. Remove the drain plugs from the underside of the gathering head gear case and completely drain the gear case lubricant. Follow all local, state and Federal regulations for the catching and disposal of lubricant. In the event the miner will be serviced by a technician, leave the gear case lubricant intact.

20. Replace the drain plugs into the underside of the gear case.

21. Connect the trailing cable to energize the miner.

22. Raise the gathering head off the blocking, remove the blocking, and lower the gathering head until it touches the floor.

______________________________________________________________ A6474X378 REV 1 25

Gathering Head Gear Case _________________________________________ 23. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

24. Disconnect, tag, and cap the four lubrication connections from the gathering head gear case.

25. Remove the four (4) 3/4 X 4” socket head capscrews (Fig. 9) that secure the motor to the gear case.

26. Remove the motor and clean out the cavity.

27. Remove the twelve (12) M24 X 80 hex head capscrews that secure the gathering head gear case pot to the mounting plate.

28. The gathering head gear case is now unattached and can be removed from its position in the gathering head.

Fig. 9: Gear case removal

Adapter plate Hex head capscrews

Socket head capscrews

Gear case to mounting plate

________________________________________________________________ 26 CM235 Mechanical - Gathering Head and Conveyor

________________________________________ Gathering Head Gear Case gathering head gear case installation

To install the gathering head gear case: 1. Insert a new gear case-to-motor seal between the adapter plate and the gear case (Fig. 10). When the gear case is inserted into the gathering head and the transfer case is positioned against the gathering head motor, the seal should be located between the surfaces of the motor and the gear case.

2. Carefully insert the gathering head gear case into position in the gathering head assembly.

3. Insert and tighten the twelve (12) M24 X 80 hex head capscrews and lock washers to secure the gear case pot to its mounting plate, and torque to 776 ft-lb.

Fig. 10: Gear case mounting Gear case adapter plate

Hex head capscrews

4. Install the motor and align the four holes on the corners of the adapter plate with the four attachment bolt holes on the gear case side of the motor.

Tighten outside wedge blocks until the gear case is snug against the inside wall. Tighten front wedge blocks until the case is snug against the front wall.

5. Insert and tighten the four (4) 3/4 X 4” socket head capscrews to secure the gear case adapter plate to the motor, and torque to 416 ft-lb.

6. Torque wedge blocks to 432 ft-lbs.

7. Attach the four lubrication connections to the gathering head gear case. ______________________________________________________________ A6474X378 REV 1 27

Gathering Head Gear Case _________________________________________ 8. Attach the rose gun to the lower ports located adjacent to the gathering head side cover and fill the gathering head gear case to the proper level with lubricant. Check the gear case lubricant level at the sight glass adja cent to the gathering head side cover. !

WARNING

The bottom ports on the high speed input cases are the fill lines. The top ports on the high speed input cases are the check lines.

9. Examine the gathering head gear case in various places for signs of leaking lubricant that identify improper installation or gear case damage.

10. Install the gathering head foot shaft and reconnect the conveyor chain (see Foot shaft installation procedure in this chapter).

11. Tighten the conveyor chain to the proper tension (see Conveyor chain ad justment procedure in the Maintenance section of this manual 12. Replace the lower deck cover (Fig. 8) onto the gathering head assembly and secure to the gathering head assembly by inserting and tightening the hex head capscrews and washers.

13. Replace the upper deck cover (Fig. 8) onto the gathering head assembly and secure by inserting and tightening the hex head capscrews and washers.

14. Install the CLA onto the gathering head gear case turntable (see CLA removal and installation procedure in this chapter).

15. Remove the pipe plug from the end of the motor.

16. Slide the drive shaft through the gathering head motor and into the gathering head gear case (the drive shaft end without the threaded hole should be inserted first.) The shaft may require some adjustment so that its end fits into the gear case.

17. Install the o-ring into the channel on the shaft end plug (Fig. 11).

18. Insert the drive shaft end plug into position in the center of the motor.

19. Insert the retaining ring to secure the shaft end plug inside the motor housing.

20. Replace the pipe plug into the end of the motor.

21. Replace the side cover onto the gathering head assembly.

22. Insert and tighten the hex head capscrews and lock washers to secure the side cover to the gathering head assembly.

________________________________________________________________ 28 CM235 Mechanical - Gathering Head and Conveyor

________________________________________ Gathering Head Gear Case Fig. 11: Drive shaft installation

Drive shaft O-ring Retainer ring Pipe plug

______________________________________________________________ A6474X378 REV 1 29

Foot Shaft_______________________________________________________ Introduction

The following procedure is for the removal and installation of the conveyor foot shaft. The foot shaft is coupled to the gathering head gear cases and drives the conveyor chain.

Tool Set

Basic Tool Set Pry Bar

Safety

When removing or installing the foot shaft, observe the following safety precautions:

Blocking

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

!

WARNING Failure to follow all applicable lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

IMPORTANT

Position the foot shaft so its sprocket will engage the conveyor chain links when the chain is reconnected.

________________________________________________________________ 30 CM235 Mechanical - Gathering Head and Conveyor

______________________________________________________ Foot Shaft Gathering Head Foot Shaft Removal

To remove the gathering head foot shaft (Fig. 12): 1. Lower the gathering head until it touches the floor.

2. Position the conveyor tail section directly behind the miner so that it is level with the floor.

3. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly and lower the cutter head assembly onto the blocking.

4. Slowly advance the conveyor chain until a connecting link appears on the gathering head entrance pan.

5. Disconnect the trailing cable to de-energize the miner.

6. Loosen tension on the conveyor chain as much as possible (see Conveyor chain adjustment procedure in the Maintenance section of this manual).

7. With conveyor chain tension removed, remove the connecting link pins and the connecting link.

8. The conveyor chain should now be separated. Move the two pieces of the conveyor chain out of the way to allow for easier removal of the gathering head foot shaft.

9. Remove the hex head capscrews and lock washers that secure the foot shaft cover to the gathering head and remove the foot shaft cover.

10. Locate the two collars on the foot shaft and remove the eight (8) M12 X 60 hex head capscrews that secure each of the collars to the foot shaft. When the capscrews are removed, the flex lock nuts will fall free from the other side of the collar. Hand tighten new nuts onto their capscrews. Remove both collars from the foot shaft.

11. Slide the foot shaft couplings from the ends of the foot shaft toward the sprocket in the center. Once the couplings have been moved, the foot shaft is disconnected from the gear case bevel pinions.

12. The foot shaft can now be removed from the gathering head.

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Foot Shaft_______________________________________________________ Fig. 12: Foot shaft removal

Foot shaft collar Foot shaft coupling

Hex head capscrews Gathering Head Foot Shaft Installation

To install the gathering head foot shaft (Fig. 12): 1. Slide a coupling onto each end of the foot shaft.

2. Insert the gathering head foot shaft into position between the two gathering head gear case bevel pinions.

3. Align the foot shaft splines with the bevel pinions’ splines.

4. Slide the right coupling over the foot shaft spline onto the bevel pinion splines until it touches the gear case seal carrier. Repeat with the left coupling.

5. Place a collar onto each end of the foot shaft so that the collars keep the couplings secure against the gear case seal carriers, bridged between the foot shaft and bevel pinion.

6. Insert and tighten the eight (8) M12 X 60 hex head capscrews through both halves of each collar and into new flex lock nuts to secure the collars to the foot shaft, and torque to 75 ft-lb.

7. Replace the foot shaft cover.

8. Insert and tighten the hex head capscrews and lock washers to secure the foot shaft cover to the gathering head.

9. Reattach the two ends of the conveyor chain by replacing the connecting link. Secure the link.

10. Tighten the conveyor chain to the proper tension.

________________________________________________________________ 32 CM235 Mechanical - Gathering Head and Conveyor

__________________________________________ Gathering Head Cylinder Introduction

The following procedure is for the removal and installation of a gathering head cylinder.

Tool Set

Basic Tool Set Sling or Chain Slide Hammer

Safety

When removing or installing a gathering head cylinder, observe the following safety precautions:

Blocking Pry Bar Puller Bolts

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

!

WARNING Failure to follow all applicable lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

!

WARNING Stand clear of the blocked cutter head and gathering head assemblies during gathering head lift cylinder contraction.

!

WARNING When aligning the cylinder end bearings within their clevises to allow for insertion of the retaining pins, do not test alignment with your fingers. Shifting parts could cause serious injury.

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Gathering Head Cylinder __________________________________________ Gathering Head Lift Cylinder Removal

To remove a gathering head lift cylinder: 1. Lower the conveyor tail section so that it is level with the floor.

2. Completely raise the cutter head and gathering head assemblies.

3. Place blocking under the cutter head and gathering head assemblies and lower the assemblies onto the blocking.

4. Disconnect the trailing cable to de-energize the miner.

5. Remove the two (2) M16 X 35 hex head capscrews and lock washers that secure the lift cylinder piston pin retaining bar to the gathering head side panel and then remove the retaining bar (Fig. 13).

Fig. 13: Gathering head lift cylinder piston pin retaining bar

Retaining bar Lockwashers Piston pin

Hex head capscrews

6. Use a slide hammer to pull the pin from the clevis bushings.

7. Connect the trailing cable to energize the miner.

8. Slowly retract the lift cylinder until the piston end comes free from its clevis.

9. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

10. Check the blocking that supports the cutter head and gathering head assemblies.

________________________________________________________________ 34 CM235 Mechanical - Gathering Head and Conveyor

__________________________________________ Gathering Head Cylinder 11. Move the gathering head lift cylinder control lever up and down to release any pressure from the gathering head lift cylinders.

12. Disconnect and plug the hydraulic hose from the gathering head lift cylinder’s hydraulic fitting.

13. Remove the hydraulic fitting from the gathering head lift cylinder and store it in a clean place.

14. Attach a lifting device to the gathering head lift cylinder. Take up any slack in the lift device so that the weight of the cylinder rests on the left device.

15. Remove the two hex head capscrews and lock washers that secure the pin retaining plate (Fig. 14) on the gathering head lift cylinder to the tractor frame and remove the retaining plate.

16. Using a slide hammer, remove the rod end pin (Fig. 14) from the frame clevis bushing. The cylinder should now be able to be removed from the miner.

Fig. 14: Gathering head lift cylinder piston pin retaining bar Retaining plate

Hex head capscrews

Rod end pin

______________________________________________________________ A6474X378 REV 0 35

Gathering Head Cylinder __________________________________________ Gathering Head Lift Cylinder Installation

To install the lift cylinder: 1. Insert the piston end bearing of the gathering head lift cylinder into the gathering head assembly clevis.

2. Insert the piston end through the aligned clevis bushings and piston end bearing.

3. Place the pin retaining bar (Fig. 13) over the piston end pin and secure to the gathering head side panel with the two (2) M16 X 35 hex head capscrews and lock washers.

4. Insert the hydraulic fitting into the gathering head lift cylinder hydraulic port.

5. Attach the hydraulic hose to the gathering head cylinder hydraulic fitting.

6. Connect the trailing cable to energize the miner.

7. Slowly extend the cylinder so that its rod end bearing can be inserted into the gathering head cylinder frame clevis.

8. Disconnect the trailing cable to de-energize the miner.

9. Position the gathering head cylinder rod and bearing into the gathering head cylinder frame clevis.

10. Insert the rod end pin into the aligned clevis bushings and rod end of the cylinder.

IMPORTANT

Insert the pin so that its retaining channel remains outside of the bushing.

11. Insert the pin retaining plate in the pin’s channel to secure the pin in the clevis.

12. Insert and tighten the two two (2) M16 X 35 hex head capscrews and lock washers (Fig. 13) that secure the pin retaining plate to the tractor frame.

________________________________________________________________ 36 CM235 Mechanical - Gathering Head and Conveyor

__________________________________________ Centrifugal Loading Arm Introduction

The following procedure is for the removal and installation of a centrifugal loading arm (CLA). The gathering head gear case turns the CLAs and drives the foot shaft which powers the conveyor chain.

Tool Set

Basic Tool Set Torque Wrench

Safety

When removing or installing a CLA, observe the following safety precautions:

Blocking Slide Hammer

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

!

WARNING Failure to follow all applicable lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

IMPORTANT

Hog rings should be installed so that their sharp points are directed clockwise.

______________________________________________________________ A6474X378 REV 0 37

Centrifugal Loading Arm __________________________________________ To remove a CLA:

CLA Removal

1. Lower the conveyor tail section until it is level with the floor. Lower the gathering head until it touches the floor.

2. Raise the cutter head assembly to its highest position. Place blocking under the cutter head assembly. Lower the cutter head assembly onto the blocking.

3. Disconnect the trailing cable to de-energize the miner.

4. Use a screwdriver to pry out the hog rings (Fig. 14) from around each of the CLA’s socket head capscrews.

5. Remove the twelve (12) 1 X 2 3/4” socket head capscrews located where the arms meet the CLA hub.

6. Remove the capscrews located in the center of the CLA hub. The CLA should now be free and able to be removed.

Fig. 14: Centrifugal loading apparatus (CLAs)

Hog rings

CLA tip

CLA

Socket head capscrews

________________________________________________________________ 38 CM235 Mechanical - Gathering Head and Conveyor

__________________________________________ Centrifugal Loading Arm 7. Remove the four CLA alignment keys (Fig. 15) from the exposed gathering head gear case turntable and store the keys in a safe place.

Fig. 15: CLA alignment key removal

Alignment key

Inner hub

CLA installation

To install the CLA: 1. On the CLA exterior, mark the bolt hole (outer set of three holes) located directly adjacent to a key cut-out.

2. Place an alignment dowel (Fig. 16) in the gathering head gear case turntable bolt hole (outer set of three holes) that is directly adjacent to a key cutout.

3. Place the four keys into their cutouts on the gathering head gear case turntable.

4. Place the CLA onto the gear case turntable so that the dowel extends through the marked CLA hole. Adjust the CLA as necessary to fit the turntable keys into the CLA cut-outs.

5. Insert two socket head capscrews into the CLA outer holes not blocked by the dowel.

6. Remove the alignment dowel and insert the last socket head capscrew into the CLA hole.

______________________________________________________________ A6474X378 REV 0 39

Centrifugal Loading Arm __________________________________________ 7. Tighten the six capscrews to secure the CLA to the gear case turntable.

8. Use the hammer to install three hog rings into the counterbore around each of the three outer socket head capscrews of the CLA.. The rings should be tapped down until they are below the chamfer of the socket head capscrews.

9. Insert the twelve (12) 1 X 2 3/4” socket head capscrews into CLA hub bolt holes and tighten.

10 Use the hammer to install hog rings into the counterbore around each of the socket head capscrews of the CLA hub (Fig. 17). The rings should be tapped down until they are below the chamfer of the socket head capscrews.

Fig. 16: Alignment dowel placement Alignment dowel placement location

Inner hub

Alignment key

Gear case turn table

Fig. 17: Hog ring installation Hog ring

Capscrew chamfer

Bottom of Hog ring counterbore

________________________________________________________________ 40 CM235 Mechanical - Gathering Head and Conveyor

__________________________________________ Centrifugal Loading Arm CLA tip installation

To replace a CLA tip (Fig. 18): 1. Lower the conveyor tail section until it is level with the floor. Lower the gathering head until it touches the floor.

2. Raise the cutter head assembly to its highest position. Place blocking under the cutter head assembly, both on the floor and on the gathering head.

Lower the cutter head assembly onto the blocking.

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

4. Locate the CLA tip (Fig. 18) which requires replacement.

5. Remove the hex head capscrews (Fig. 18) and mounting plate that secure the tip to the CLA. 6. Use force as necessary to remove the tip from the CLA. 7. Slide the new tip onto the CLA. 8. Insert and tighten the hex head capscrews through the tip and the CLA.

Fig. 18: CLA tip installation

CLA CLA tip

Mounting plate

Hex head capscrews

______________________________________________________________ A6474X378 REV 0 41

Swivel Pin Assembly______________________________________________ Introduction

The following procedure is for the removal and installation of the swivel pin assembly.

Tool Set

Basic Tool Set

Safety

When removing or installing a swivel pin assembly, observe the following safety precautions:

Slide Hammer

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

!

WARNING Failure to follow all applicable lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

________________________________________________________________ 42 CM235 Mechanical - Gathering Head and Conveyor

_____________________________________________ Swivel Pin Assembly

swivel pin assembly removal

To remove the swivel pin assembly (Fig. 18): 1. Lower the cutter head and gathering head assemblies until they touch the ground.

2. Position the conveyor tail section to the extreme right or left of the miner so that the chain is drawn to one side as far as possible and the conveyor swivel pin is exposed.

3. Lower the conveyor tail section until it is level with the floor.

4. Insert blocking between the conveyor tail section and the floor.

5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

6. Remove the six (6) 5/8 X 3” socket head capscrews from the upper swivel pin.

7. Remove the 5/8 X 7/8” center setscrew from the center of the upper conveyor swivel pin.

8. Use a slide hammer to remove the upper conveyor swivel pin.

9. Remove the 5/8 X 7/8” center setscrew from the center of the lower conveyor swivel pin.

10. Remove the six (6) 5/8 X 3” socket head capscrews from the lower conveyor swivel pin.

11. Use a slide hammer to remove the lower conveyor swivel pin.

12. Using a retrieval tool, retrieve both upper and lower swivel pin retainers from the conveyor chain return channel.

______________________________________________________________ A6474X378 REV 0 43

Swivel Pin Assembly______________________________________________ Fig. 18: Conveyor swivel pin

Dowel pins

________________________________________________________________ 44 CM235 Mechanical - Gathering Head and Conveyor

_____________________________________________ Swivel Pin Assembly swivel pin assembly installation

To install the swivel pin assembly (Fig. 18): 1. Working first on the upper swivel pin assembly, insert the dowel pin, 5/8 X 7/8” center setscrew, and the grease fitting into the swivel pin.

2. Lower the swivel pin into the hole in the conveyor bed making sure the dowel pin is positioned in the notch and the top of the swivel pin is flush with the top surface of the conveyor bed.

3. Holding the swivel pin retainer with the flanged side downward, using a retrieval tool, reach into the conveyor chain return channel and fit the swivel pin retainer into the hole.

4. Insert the six (6) 5/8 X 3” socket head capscrews and tighten.

5. Working on the lower swivel pin assembly, insert the dowel pin, 5/8 X 7/8” center setscrew and the grease fitting into the swivel pin.

6. Lift the swivel pin into the hole in the lower side of the conveyor making sure the dowel pin is positioned in the notch and the lower side of the swivel pin is flush with the lower surface.

7. Holding the swivel pin retainer with the flanged side upward, reach into the conveyor chain return channel and fit the swivel pin retainer into the hole.

8. Insert the six (6) 5/8 X 3” socket head capscrews and tighten.

______________________________________________________________ A6474X378 REV 0 45

Tail Roller _______________________________________________________ Introduction

The following procedure is for the removal and installation of the tail roller.

Tool Set

Basic Tool Set Pry Bar

Safety

When removing or installing the tail roller, observe the following safety precautions:

Blocking Puller Cable

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

!

WARNING Failure to follow all applicable lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

!

WARNING Improper conveyor chain tension can lead to excessive wear, mechanical problems and miner downtime. Always keep the conveyor chain at the proper tension.

________________________________________________________________ 46 CM235 Mechanical - Gathering Head and Conveyor

_______________________________________________________ Tail Roller Tail Roller Removal

To remove the tail roller (Fig. 19): 1. Lower the gathering head and cutter head assemblies until they rest on the floor.

2. Slowly advance the conveyor chain until a connecting link moves onto the conveyor tail section slide pan.

3. Loosen tension on the conveyor chain as much as possible.

4. Lower the conveyor tail section onto blocking so it is level with the floor.

5. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

6. With conveyor chain tension removed, remove the retaining rings from the connecting link.

7. Remove the connecting link and its strap. The conveyor chain should now be separated. Move the two pieces of the conveyor chain out of the way to allow for easier removal of the conveyor tail roller assembly.

8. Remove the four (4) M20 X 55 socket head capscrews that secure the tail roller assembly to the slide pan.

9. Remove the tail roller assembly from its location in the slide pan.

______________________________________________________________ A6474X378 REV 0 47

Tail Roller _______________________________________________________ Fig. 19: Tail roller

Tail roller Tail Roller Installation

Socket head capscrews

To install the tail roller (Fig. 19): 1. Insert the tail roller assembly into the proper location in the slide pan.

2. Insert and tighten the four (4) M20 X 55 socket head capscrews through the holes in the tail roller shaft and into the threaded holes in the slide pan.

3. Reattach the two ends of the conveyor chain by replacing the connecting link.

4. Secure the connecting link by replacing the side strap and the retaining rings onto the ends of its pins.

5. Tighten the conveyor chain to the proper.

________________________________________________________________ 48 CM235 Mechanical - Gathering Head and Conveyor

_________________________________________________ Conveyor Chain Introduction

The following procedure is for the removal and installation of the conveyor chain.

Tool Set

Basic Tool Set Pry Bar

Safety

When removing or installing the conveyor chain, observe the following safety precautions:

Blocking Puller Cable

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

!

WARNING Failure to follow all applicable lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

______________________________________________________________ A6474X378 REV 0 49

Conveyor Chain __________________________________________________ Conveyor Chain Replacement

To replace the conveyor chain (Fig. 20): 1. Lower the cutter head and gathering head assemblies until they touch the ground.

2. Position the conveyor tail section directly behind the miner and raise it. Insert the blocking under the tail section and lower the tail section onto the blocking.

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

4. Loosen the tension of the conveyor chain as much as possible.

5. Remove the two retaining rings from a connecting link located near the rear of the conveyor bed.

6. Remove the connecting link. The chain is now separated.

7. Connect the come-along to the end of the chain on the conveyor bed.

8. Connect the new chain to the end of the lower chain and allow the new chain to extend behind the miner on the floor.

9. Use the come along to pull the old chain out of the miner. The new chain will follow the old through the conveyor return channel around the gathering head foot shaft and out onto the conveyor tail section.

10. When the entire length of old chain has been pulled through the miner and the replacement chain is in position, disconnect the old chain from the new and remove the come along.

11. Connect both ends of the new chain by replacing the connecting link, pins and retaining rings (Fig. 20).

12. Tighten the conveyor chain.

________________________________________________________________ 50 CM235 Mechanical - Gathering Head and Conveyor

_________________________________________________ Conveyor Chain Fig. 20: Conveyor chain installation Retaining rings

Attach Come along

Attach New chain

Chain connecting link

Pins

Retaining rings

______________________________________________________________ A6474X378 REV 0 51