Obtain headgate drive from the track entry with duck bill scoop and tram to headgate entry
Load with shield side toward operator
This task requires a ground man
Secure the drive with scoop winch rope
Obtain four crib blocks
Align headgate drive with walkway side of stageloader on center line of belt entry and with the face side 2' inby the longwall face
See diagram
Place crib blocks under drive at all four corners
Lower the drive onto the crib blocks
Back the duck bill scoop out
Remove sprocket access door from headgate
Remove the six Allen socket head bolts with the 19mm wrench
Lift and remove the door with lo-trac
Place door against rib
Push 35' sling through the access door opening under the sprocket until you see the end of the cable on the opposite side of the headgate drive
CAUTION: No standing between pan line joints when scoop is operating
Remove all debris and material
2. Duty 15: Install Headgate Specials
Conduct exam
Obtain and examine tools and materials
Chisel
Hammer
Anti-seize
Wire brush
Rags
Ladies slipper
Punch
Screw driver
Crib blocks
3/4" socket set
3/4" drive air impact
3/4" metric Allen sockets
1" wire rope slings (25 and 35 feet)
Rock bars
Install grade pan
Obtain grade pan and tram to face
Place the handrail on the off side of duck bill scoop operator
This task requires a ground man
Position the pan line on the duck bill scoop so that the operator can see the sigma on the face side of the pan
Secure the pan line on the duck bill scoop with winch rope
Align pan line and install four dog bones
See diagram/photo(s)
Use sigma as a guide to align the pan line with the sigma on the headgate drive
Pull cable sling until the eye is at the headgate sprocket access door
Obtain a box of face conveyor chain with the duck bill scoop
Secure the chain box with the winch cable
Place the box of chain directly in front of sprocket access door
E-bolts must be up so when the chain is pulled in bottom of pan line the flight is upside down
You may have to turn box
Attach 35' sling cable to the first links of face conveyor chain using connecting links
Tram the duck bill scoop to the last pan installed
Hook the 35' sling cable to the duck bill scoop
Pull until the connecting links are at the end of the last installed pan
Pull the sling cable up into the grade pan for storage while still hooked to the connecting links
See photo(s)
Set headgate special pans
Tram to the pan line storage area
Load two pans on the duck bill scoop
Position the pan line on the duck bill scoop so that the operator can see the sigma on the spill pan side
Use sigma as a guide to align the pan line with the sigma on the grade pan
Tram back to pan line
Align pan
Stop 2' away from pan
Lower pan to bottom
Turn duck bill scoop off
Push 35' cable through pan line and flap back over toward headgate
Have ground man keep tension on the sling pulling slack back as pans are put into place
Pick up pan
Push pan into final position
Shut duck bill scoop off
Install the two dumb bells and keeper and one accu-trac pin and keeper
Repeat this process to the headgate side of the notch in face
Remove all debris and materials
3. Duty 16: Install Shearer
Conduct exam
Obtain and examine tools and materials
Chisel
Hammer
Anti-seize
Wire brush
Rags
Ladies slipper
Punch
Screw driver
Crib blocks
3/4" socket set
3/4" drive air impact
3/4" metric Allen sockets
Rock bars
2 Duck bill scoops
Torches
Spotter
Burning permit
Rock dust
Fire Extinguisher
Cutting goggles
Welding gloves
Striker
Torque multiplier
Hand cleaner/spray silicon
Lubricant
Obtain shearer from the track with duck bill scoop
Position two duck bill scoops, one on each side of track, with the bills facing the track
Instruct the motorman to position the shearer so that the end of the shearer is even with the outby corner of the crosscut
Set torches up
See cutting and welding plan
Cut shearer free of transport car
Place duck bill under the shearer trapping shoe and sprocket near the outby end
When this shearer is being unloaded, the control panel covers must be on the inby side when taken to the face
Instruct the motorman to tram toward scoop at the same time the scoop will tram into the crosscut
This will swing the shearer to the position for transport
Stop the motorman and scoop operator when the shearer is parallel with crosscut
Place the duck bill of the second scoop under the trapping shoe and sprocket on the opposite end
When this shearer is being unloaded, the control panel covers must be on the inby side when taken to the face
Lift shearer off the car with both scoops
Secure the shearer body with scoop winch rope
Instruct motorman to transport car from under the shearer
Tram scoops with the shearer to pan line, push the shearer and lead scoop with the trailing scoop
These two operators have to work together
Communication between the two operators is critical
The lead scoop is only to assist as needed
Stop at notch
Shut scoops down
Crib the headgate end of the shearer with six crib blocks about 18" off the bottom
Lower the shearer on to the cribbing
Unhook the scoop winch line
Install ranging arms, cutter drum, and water spider
See Duty No. 17
Install shearer on pan line
Install piece of accu-trac onto the existing pan line leaving one end loose
This is to be use as a guide pin
Set duck bill scoops
One scoop on the headgate end
One scoop on the tailgate end of shearer
Lift the headgate end of the shearer off the bottom
Tram the scoop forward toward the head drive until the trapping shoe is aligned with accu-trac
You may have to lower or raise the scoop to engage the trapping shoe onto the accu-trac
Use tailgate scoop to push the entire shearer toward the headgate engaging the trapping shoe on both ends
You may have to lower or raise the scoop to engage the trapping shoe onto the accu-trac
Install tailgate ranging arm, cutter drum, and water spider
See Duty No. 17
Remove all debris and materials
4. Duty 17: Install Ranging Arms, Headgate Cutter Drum, and Water Spider
Conduct exam
Obtain and examine tools and materials
Chisel
Hammer
Anti-seize
Wire brush
Rags
Ladies slipper
Punch
Screw driver
Crib blocks
3/4" socket set
3/4" drive air impact
3/4" metric Allen sockets
Rock bars
2 Duck bill scoops
Torches
Spotter
Burning permit
Rock dust
Fire Extinguisher
Cutting goggles
Welding gloves
Striker
Torque multiplier
Hand cleaner/spray silicon/lubricant
Come-a-long
Tacky stuff
Install ranging arms
Tram the scoop back to the notch and pick up the headgate ranging arm
Position the ranging arm so that the cutter drum hub is toward the operator and cutter motor facing the scoop operator's side
Tram the scoop with the ranging arm back to the shearer body
Remove the ranging arm pins
Align arm into position
Raise arm into position with scoop
Ground man will instruct scoop operator as needed
CAUTION: Ground man must stay clear of ranging arm and scoop until arm is in position and scoop is shut down
Install pins and keepers
Follow the manufacturer's guidelines
If you do not have the manufacturer's guidelines, do not install the keepers
Install pin in shearer jack
Raise or lower with scoop for adjustment
Insert pin
Bolt keeper plate to ranging arm
Install headgate cutter drum
Obtain headgate cutter drum from notch with scoop
Attach winch cable to the hanging eye on the drum
Pull drum with the winch cable so that it is standing with the shallow side toward the face and comes in contact with the front of the duck bill and wedges itself
Tram headgate cutter drum to ranging arm
Align drum with shaft
Use the duck bill to maneuver the drum onto the shaft
Release the winch cable
Install starter pull bolts through the drum into the drive until drum is flush
Remove starter bolts, one at a time
Replace with drum bolts
Torque drum bolts to 1200 foot pounds
Use torque multiplier
Install water spider
Obtain water spider with duck bill scoop
Obtain O-rings
Two large and four small
Tram scoop with spider to headgate ranging arm
Install large O-rings on water manifold on ranging arm
Lubricate O-rings with hand cleaner
Install small O-rings in spider
Hold in place with something tacky
Install two 19mm all thread about 18' long into the drum
Lift with come-a-long
Loop come-a-long chain through bit holder
Loop a chain through the spider
Lift into place
Slide onto 19mm all thread guide bolts
Slide in as far as possible
Install nuts onto the guide bolts then remove come-a-long
Draw spider into place using the guide bolt nuts
Install spider mounting bolts
Remove guide bolts
Torque to manufacturer's specification
Repeat this process for the tailgate ranging arm, drum, and spider after the shearer is on the pan line
