CAT Operation Manual BUCYRUS LRB-15AR Roof Bolter (A6474X231) - PDF DOWNLOAD

Operation Manual BUC Model

Roof Bolter LRB-15AR

Doc. No.:

A6474X231

Bucyrus America, Inc. ________________________________________ 4041 Wurno Road Pulaski, VA 24301

Telephone: 540-980-4530 Fax: 540-994-3763

Internet: www.bucyrus.com

__________________________________________________________

This manual is intended to provide GENERAL product information for the Model LRB-15AR Roof Bolter . The illustrations, descriptions and procedures contained in this publication apply only to this machine.

Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.

This Roof Bolter was manufactured under the guidelines, procedures and requirements of the U. S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines, and other applicable non-U.S. regulatory agency standards.

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 Bucyrus America, Inc., and these regulatory agencies, or any repair or replacement of parts contrary to Bucyrus America, Inc.'s instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all Federal and State Mining 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 Bucyrus America, Inc. 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.

© BUCYRUS AMERICA, INC.

ALL RIGHTS RESERVED

________________________________________________ Table of contents

Table of contents 1. About this manual About this manual .................................................................. 1.3 Before starting to work ......................................................... 1.3 Who is this operating manual intended for? ........................ 1.3 What is the purpose of this operating manual? ................... 1.4 Characters and symbols ...................................................... 1.5

2. Your safety

© BUCYRUS AMERICA, INC.

Your safety .............................................................................. 2.3 Personnel............................................................................. 2.4 Operation ........................................................................ 2.4 Installation and repair...................................................... 2.4 Operating conditions ............................................................ 2.5 Intended use ................................................................... 2.5 Unauthorized use............................................................ 2.5 Safety instructions................................................................ 2.7 General rules: ................................................................. 2.7 Storage and transport ..................................................... 2.8 Pre-start inspection ......................................................... 2.8 Installation and start-up................................................... 2.9 Operation ........................................................................ 2.9 Stopping .........................................................................2.10 Maintenance and repair .................................................2.10 Overview of the safety instructions .....................................2.15 Chapter 3: Storage and transport ..................................2.15 Chapter 4: Installation ....................................................2.15 Chapter 5: Operation .....................................................2.16 Chapter 6: Technical data..............................................2.21

3. Storage and transport Storage and transport ............................................................ 3.3 Storage ................................................................................ 3.3 Storage of the machine and spare parts......................... 3.3 Transport.............................................................................. 3.4 Before transport .............................................................. 3.5

4. Installation Installation ............................................................................... 4.3 Points to observe prior to installation................................... 4.3 Who is allowed to carry out installation?......................... 4.3 Which tools are required for installation?........................ 4.3 Notes on installation........................................................ 4.4 Pre-installation check list ................................................ 4.5 Safety features ................................................................ 4.6

________________________________________________________________ A6474X231

VSVI / 03

Table of contents _________________________________________________

Operation ................................................................................. 5.3 General information.............................................................. 5.3 How to operate the roof bolter ............................................. 5.3 Who is allowed to operate the roof bolter ....................... 5.3 When can operation be started? ..................................... 5.3 Controls and indicators ........................................................ 5.4 Operator’s compartment ................................................. 5.4 Drill positioning ................................................................ 5.6 Drill station....................................................................... 5.7 Coontroller....................................................................... 5.9 Hazard zone........................................................................5.10 Starting procedure...............................................................5.11 Shutdown procedure ...........................................................5.13 Towing ................................................................................5.14 Tramming ............................................................................5.15 Drive assembly....................................................................5.16 Drilling .................................................................................5.17 Extension steel selection.....................................................5.19 Drilling with extension steels ...............................................5.20 Drill options and adjustments ..............................................5.22 Installation of mechanically anchored rock bolts ................5.22 Installation of fully grouted resin bolts.................................5.24 Electrical system overview ..................................................5.27 Instructions on the maintenance .........................................5.33 Important notes ..............................................................5.33 Before maintenance .......................................................5.33 Critical torque values......................................................5.35 Lubricants, fluids and capacities ....................................5.35 Specific lubrication and maintenance instructions ..............5.39 Every shift.......................................................................5.39 Every other shift .............................................................5.45 Weekly............................................................................5.52 Every three months ........................................................5.56 Replacement of wear parts .................................................5.61 Tire/wheel installation procedure ...................................5.61 Recommended wheel mounting procedures .................5.63

6. Technical data Technical data ....................................................................... 6.3 Components of the LRB-15AR Roof Bolter ....................... 6.3 Tightening torques ............................................................. 6.5 Permissible data..................................................................6.13 Lubrication fluids and greases .......................................6.13

7. For your information For your information............................................................. 7.3 Our service ......................................................................... 7.3 Service address ............................................................ 7.3 Rebuild facility address ................................................. 7.4

_________________________________________________________________ Bucyrus America, Inc. – Model LRB-15AR Roof Bolter ®

© BUCYRUS AMERICA, INC.

5. Operation

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1

About this manual

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________________________________________________________________

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_______________________________________ Before starting to work

About this manual This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols and characters used.

Before starting to work applicable operating manual machine type

Take care to ensure that the operating manual available to you is applicable for the type of equipment or machine used.

This operating manual is intended for: Bucyrus America, Inc. Serial No.

Model LRB-15AR Roof Bolter N/A

and is only permitted to be used for equipment of this type. © BUCYRUS AMERICA, INC.

new operation manual

The operating manual must be accessible at all times to all persons working on or with the machine. It should, if possible, always be available at the place of operation.

Send for a new operation manual immediately if the present manual is no longer complete or has become illegible.

Who is this operating manual intended for?

This operating manual is intended for those persons who work with or on the machine. Every person working on the face or in the intersection between face and entry or in the entry must read this operating manual.

This includes persons who: ■

are in charge of transport

■

perform assembly / disassembly work

■

operate the machine

■

eliminate faults

■

perform daily routine work on the face or in the entry

■

perform maintenance work

■

perform repair work

supervisory personnel who: ■

initiate and/or

■

supervise the activities just indicated

______________________________________________________________ A6474X231 VSVI / 03 1.3

Before starting to work ________________________________________ What is the purpose of this operating manual? cost-effectiveness

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the machine.

Read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

If any details are not clearly understood, please contact our service department. Our service address is given in the chapter titled “For your information”.

safety

Read the chapter “For your safety” with special attention. The chapter contains important information indicating possible hazards. Observe the information given and follow the procedural instructions.

© BUCYRUS AMERICA, INC.

service

_________________________________________________________________ 1.4 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter ®

_______________________________________ Before starting to work Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual.

Try to memorize the symbols and their meanings.

DANGER! Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.

WARNING! These points contain information on dangerous situations. Possible consequences are: very serious injury or even death.

© BUCYRUS AMERICA, INC.

CAUTION! This symbol draws attention to dangerous situations. Possible consequences are: light to moderately serious injuries and machine damage.

NOTICE! Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: damage to the machine or damage in the immediate vicinity.

IMPORTANT! Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations.

■

Items in lists are marked with bullets.

–

Points in sub-lists are marked with a long dash at the start of the line.

 Points in text marked in this way describe individual operations.

Follow these instructions step by step. They will help you carry out your work faster and more importantly, safer.

______________________________________________________________ A6474X231 VSVI / 03 1.5

© BUCYRUS AMERICA, INC.

Before starting to work ________________________________________

_________________________________________________________________ 1.6 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter ®

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2

Your safety

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________________________________________________________________

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__________________________________________________ Personnel

Your safety This chapter provides vital information for your safety. Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible. state of the art

The machine has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations.

You and others can nevertheless be exposed to dangerous situations e.g. as a result of environmental influences, machine damage, or operator errors.

Do not make any alterations or modifications which could impair the safety of the machine. All modifications and changes must be approved by Bucyrus America, Inc.

© BUCYRUS AMERICA, INC.

Use only original spare parts from Bucyrus America, Inc. Note that the use of parts from other manufacturers will void the guarantee.

In addition to this operating manual, be sure to also observe the respective legal provisions and regulations in your country.

Observe the safety and accident prevention regulations

further operating manuals

■

of the mine,

■

of the mine inspector, and

■

of the mining supervisory authorities.

Please also read the operating manuals of the components required for operation, e.g. of gearboxes, electric motors, etc., carefully and thoroughly. Clarify any questions before starting work.

______________________________________________________________ A6474X231 VSVI / 03 2.3

Personnel ___________________________________________________ Personnel Operation training

The machine may only be operated by qualified, trained personnel.

The machine is only allowed to be operated by qualified personnel who can provide proof of having been trained on this unit. Reading of the operation manual, especially the chapter on safety, shall constitute a part of this training.

You must have adequate knowledge of the ■

mechanics,

■

hydraulics, and

■

control engineering

Installation and repair As a fundamental rule, installation and repair work may only be carried out by personnel who have been adequately trained for these particular requirements.

Installation and repair work on ■

safety components (pressure relief valves, extinguishers, etc.),

■

the electrics (motors, controllers, etc.), and

■

the hydraulics (controls, cylinders, etc.)

may only be carried out by service engineers from Bucyrus America, Inc. or by specially qualified personnel of the mine.

_________________________________________________________________ 2.4 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter ®

© BUCYRUS AMERICA, INC.

and must be able to prove this knowledge.

_________________________________________ Operating conditions Operating conditions Intended use The Roof Bolter has been designed and manufactured purely for the installation of roof bolts.

Intended uses include: ■

the installation of roof bolts.

Unauthorized use Applications not expressly listed as intended uses are unauthorized uses and are not allowed to be performed with the machine.

■

any application other than the installation of roof bolts.

© BUCYRUS AMERICA, INC.

Bucyrus America, Inc. accepts no liability for any damage resulting from any such unauthorized use.

______________________________________________________________ A6474X231 VSVI / 03 2.5

© BUCYRUS AMERICA, INC.

Operating conditions __________________________________________

_________________________________________________________________ 2.6 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

___________________________________________ Safety instructions Safety instructions General rules general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

Always wear your personal protective equipment. This also includes ear protectors as the noise emitted by other equipment in the area may at times exceed 85 db(A).

© BUCYRUS AMERICA, INC.

Inform your colleagues of:

safety equipment

■

your exact location,

■

the work you are performing, and

■

the time that you will probably require.

Start the machine only when it is in a good and safe operating condition and all protective devices, e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.

Observe the acoustic and optical start-up warnings of the machine.

symbol plates emergency stop (panic strip)

cordon off working area moving parts

Observe the symbol plates on the machine.

Press the emergency stop (panic strip) immediately in the event of fault or irregularities in operation. Report any peculiarity to your superior so that necessary measures can be taken immediately.

Cordon off your working area widely for the machine.

Never allow parts of your body to come between parts which could move, such as: ■

ATRS system

■

pivot points

■

drill

______________________________________________________________ A6474X231 VSVI / 03 2.7

Safety instructions ____________________________________________ Storage and transport Maintain the prescribed storage periods and observe the instructions for storage.

Do not store materials or parts in the travel way or in your working area.

Inform the persons involved about the intended transport route and the anticipated duration of the transport. transport safety device

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

means of attachment

Connect the lifting equipment only to the points of attachment provided for that purpose. Observe the different load limits of the attachment points. Also observe the instructions on the transport sheet.

For round components, use only transport straps. Never use chains or steel cables for this purpose.

Do not damage the treated or polished surfaces of shafts, sealing surfaces, etc. mobile handling equipment

When using mobile handling systems for transport make sure that the center of gravity is as low as possible.

Pre-start inspection operation

Read this entire guide before attempting to operate this machine.

inspection

Inspect the machine and have any malfunctioning, broken or missing parts corrected or replaced before use.

maintenance instruction and safety operator’s compartment canopy

Verify that all maintenance has been performed.

Verify that all instruction and safety tags are in place and readable.

These are as important as any other equipment on the machine.

Clean any foreign material from the operator’s compartment.

This machine was shipped from the factory equipped with a protective canopy. The canopy must be securely in place before operating the unit.

_________________________________________________________________ 2.8 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Only use means of attachment which are in good condition and have been designed for the loads to be handled.

___________________________________________ Safety instructions Installation and start-up inclined face

environmental acceptability

On inclined faces secure all component parts by chains, e.g. to the support.

When working with oils, greases, and other chemical substances, observe the safety regulations applicable to the product.

Dispose of cleaning rags, etc. which have been soiled with oil, grease or other chemical substances in an environmentally safe manner.

controls

When starting up machine, do not operate any controls located inside the operator’s compartment from outside the compartment.

starting procedures

Follow the starting procedure instructions in Chapter 5 of this manual.

hazard zone

Do not operate any levers, pedals or controls if anyone is in the hazard zone. (See Hazard zone in Chapter 5 of this manual)

© BUCYRUS AMERICA, INC.

Operation training

Operate the machine only if you have a profound knowledge of the control elements and their functions. It is necessary that you have been task trained on the respective Roof Bolter.

before start-up

Before start-up, ensure that there are no persons or obstructions in your line of travel or in the articulation area when steering the unit.

protective devices

Check that all protective devices are installed on the machine and function properly.

operator’s compartment

Clean the operator’s compartment at regular intervals. Ensure that the operating symbols are legible in order to avoid any operator errors and resulting accidents.

Never climb onto out of the machine while it is in motion.

traveling

Use extreme caution when traveling in close quarters or in congested or blind-travel areas. The warning gong should be sounded to alert personnel of your movement.

passengers

Never carry passengers. Passengers can be thrown off of the machine or crushed between the machine and outside objects.

safety rules

Always follow all safety rules of each particular mine when operating the machine.

problems and malfunctions

If problems or malfunctions are encountered while operating the unit, it must be properly shutdown and the problem corrected immediately.

______________________________________________________________ A6474X231 VSVI / 03 2.9

Safety instructions ____________________________________________ Stopping operator’s compartment

Do not leave the operator’s compartment with the unit running. Always properly shutdown the unit before leaving the operator’s compartment.

parking

Always park the unit on solid, level ground. If this is not possible, park the unit at a right angle to the slope to prevent accidental movement of the machine.

Use proper flags, warnings, or barriers when parking in areas of traffic.

Chock all four (4) wheels in both directions whenever possible.

Maintenance and repair Be sure to observe the prescribed maintenance and inspection intervals.

securing

Secure your working area over a wide range, in order to avoid endangering other persons.

Disconnect the power from the machine to prevent unauthorized and unintentional restarting.

Protect your work area against falling rocks.

replacing components

Disconnect the power from machine to prevent from restarting before replacing any defective components.

Pass on defective components removed for servicing without delay in order to prevent these parts being reinstalled elsewhere.

original parts

lifting

handling of hydraulic fluids

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original Bucyrus America, Inc. spare parts.

Please refer to the spare parts lists for the order numbers.

For raising the Roof Bolter use only: ■

crib blocks with adequate load-holding capacity.

■

hoists, jacks, or cranes with adequate load-carrying capacity.

Avoid direct contact between the skin and hydraulic fluids. Hydraulic fluid can penetrate the skin and cause serious infection.

Never use hydraulic fluid for rinsing or cleaning. Hydraulic fluid represents a very serious danger to health.

_________________________________________________________________ 2.10 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Inform the supervisory personnel and the face crew of any maintenance and repair operations. Give them information on the intended operations and the anticipated duration.

___________________________________________ Safety instructions maintenance, repair

Only persons who have and can demonstrate a special knowledge of hydraulics are allowed to work on the hydraulic system.

Avoid, whenever possible, servicing, cleaning, or examining the machine in congested areas.

Avoid, whenever possible, servicing or providing maintenance to the unit unless the wheels are chocked to prevent accidental movement of the unit.

Do not alter the electrical or hydraulic settings from that indicated in this manual or as set at the factory.

Always replace damaged or lost decals and metal instruction plates.

© BUCYRUS AMERICA, INC.

Always follow all safety procedures of each particular mine when performing maintenance.

It is important that any procedure not specifically recommended in this guide be thoroughly evaluated from the standpoint of safety before it is implemented.

Some illustrations in this manual show guards or cover panels removed for purposes of clarity. Never operate unit without guards or cover panels in place.

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular check that ■

the hoses are not pinched or trapped,

■

the hoses have no bubbles or blisters,

■

the hoses or outer sheaths of the hoses are not abnormally rigid or hard,

■

the outer sheaths of the hoses are not damaged,

■

the connectors are securely inserted into the sockets, and

■

the connections are leak-tight.

Ensure that no dirt enters the hydraulic system during repair work. Dirt in the hydraulic system can cause serious damage to the whole system! Flush out the hydraulic lines thoroughly before connecting.

______________________________________________________________ A6474X231 VSVI / 03 2.11

Safety instructions ____________________________________________ If hydraulic hose couplers are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized. Be sure to depressurize the line before disconnecting couplers.

Secure the connectors of the hydraulic elements only the proper coupling clamps. Always fasten the clamps completely and with both sides. Never use nails, wire, or similar materials for securing.

After finishing repair work, check all connectors and connections for leaks before pressurizing the system again. permissible hoses

Use only hydraulic hoses approved for the prevailing pressures.

Do not use any hydraulic hoses with damaged connectors or worn orings.

Never try to hold a jumping hydraulic hose. Depressurize the line in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage. laying hydraulic hoses

Lay the hydraulic hoses properly behind the brackets and clamps provided for them.

Always lay hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Laying hydraulic hoses, slack Right

Wrong

_________________________________________________________________ 2.12 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Replace hydraulic hoses only with hoses of the same or a higher quality.

___________________________________________ Safety instructions ■

are not twisted.

Fig. 2: Laying hydraulic hoses, twisting Right

© BUCYRUS AMERICA, INC.

■

Wrong

are not bent directly behind the connections. (distance min. 1.5 x nominal diameter).

Fig. 3: Laying hydraulic hoses, bending Right

■

Wrong

always have a little slack.

Fig. 4: Laying hydraulic hoses, crossing Right

Wrong

______________________________________________________________ A6474X231 VSVI / 03 2.13

Safety instructions ____________________________________________

■

are not kinked.

■

do not have to withstand tensile strains.

■

are protected against thermal radiation.

■

are accessible at all times.

Push hydraulic hoses into the sockets only by hand. Never try to drive the hydraulic hoses in with a tool as this will damage the connections.

■

torn out,

■

kinked,

■

crushed,

■

driven over or

■

twisted by movement of the machine.

Fig. 5: Laying hydraulic hoses, connections on moving parts Right

Wrong

_________________________________________________________________ 2.14 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

When installing the hydraulic hoses, ensure that they cannot be:

________________________________ Overview of safety instructions Overview of the safety instructions This is a summary of all the safety instructions which have to be observed in the following chapters. This summary is intended only to give you an overview of all the instructions. In some cases, there is no logical relationship between the individual instructions.

Chapter 3: Storage and transport Instructions on the storage of concentrates for hydraulic fluids can be found, if required, in Chapter 6 in this operating manual.

© BUCYRUS AMERICA, INC.

IMPORTANT! Take care to insure that new supplies are stored separately from existing stock and that removal takes place on the “first in, first out” principle.

WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads. You could be seriously injured or even killed by falling loads. Use only suitable load handling devices.

Chapter 4: Installation CAUTION! Serious damage can be caused to the roof bolter as a result of incorrect installation. The unit should therefore only be installed under the instruction of specialists from Bucyrus America, Inc. IMPORTANT! The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established NOTICE! The machine was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

However, to ensure that no transit damage has occurred, a prestartup check should be performed.

NOTICE! The operator must become familiar with all the safety features and their location on the machine prior to installation or operation.

WARNING! If either of the fire suppression actuators is actuated, the system must be completely recharged with dry chemicals and expellants.

______________________________________________________________ A6474X231 VSVI / 03 2.15

Overview of safety instructions _________________________________ DANGER! Do not operate the machine any of the guards or covers removed.

You or other personnel could be seriously injured from moving or rotating parts.

Chapter 5: Operation

WARNING! When operating the roof bolter from the positioning controls on the left side of the machine, never pass beyond the last row of permanent supports. Operate the roof bolter from inside the tram station (operator’s compartment) for place change or other long distance moves.

WARNING! The roof bolter’s inch tram/steering is for maneuvering the machine between holes only. The roof bolter must be operated from inside the tram station for place change or other long distance moves.

NOTICE! Once either of the inch tram/steering control levers is released by the operator, the control lever automatically returns to the centered (neutral) position.

NOTICE! The LRB-15AR roof bolter has skid type steering, it is capable of turning within its own length.

WARNING! Do not operate roof bolter without drill station canopy in place.

Operating with drill station canopy can result in severe injury or death.

WARNING! Exposing any part of your body from under the drill staion canopy during drilling or bolting operations can cause severe injyury or death. Keep arms, legs, and head under drill station cannopy.

WARNING! Electrical power must be disconnected at the main power center before removing the cover from the electrical controller or before performing any work inside the controller.

_________________________________________________________________ 2.16 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

DANGER! Incorrect operation endangers yourself and others!

Incorrect operation of the machine is often the cause of very serious accidents! Operate the unit only when you have been sufficiently trained on the machine and have read and understood this operating manual. Should anything be unclear, please contact your immediate supervisor.

________________________________ Overview of safety instructions WARNING! Failure to read and understand all operating instructions before starting the roof bolter could result in serious injury or death to the operator or personnel around the machine or could cause damage to the machine.

Read all instructions carefully before attempting to start or operate the roof bolter.

Understand the function(s) of all controls before starting the roof bolter. Read and follow the instructions on all warning tags on the machine. Observe all regulations and safety precautions.

Never operate a roof bolter which has been damaged or is not operating properly. any part of the roof bolter which does not function properly can be a hazard. Immediately report all hazards to your supervisor.

© BUCYRUS AMERICA, INC.

Make sure no one is in the hazard zone (Fig. 12) before starting the roof bolter.

WARNING! Never operate any levers or pedals located inside the operator’s compartment from outside of the operator’s compartment.

WARNING! The machine is equipped with a canopy. Be careful not to hit your head when entering or leaving the operator’s compartment.

WARNING! Do not operate machine if all panic strips are not operational.

WARNING! Do not operate the roof bolter with any part of your body outside the operator’s compartment. Failure to follow this warning could result in injury due to body parts getting caught between the machine and outside objects.

Be sure no one is in the hazard zone (Fig. 12) before operating any levers or pedals.

The inch tram and steering controls located on the left side of the machine are for maneuvering the machine between bolt holes only. Long distance moves must be made from inside the operator’s compartment.

NOTICE! The roof bolter can be stopped at any time by striking the panic strip. Be prepared for a sudden stop when the panic strip is struck.

CAUTION! Do not permit the build-up of mud or other material to collect under or around the cable reel.

______________________________________________________________ A6474X231 VSVI / 03 2.17

Overview of safety instructions _________________________________ WARNING! When the torque hubs are in the disengaged position, the roof bolter must be chocked at all four wheels in both directions to prevent the machine from rolling away uncontrolled.

CAUTION! Never exceed the drill rod manufacturer’s recommendations for drill torque and thrust. Excessive torque and thrust can cause the drill rod to buckle or break, thereby creating a hazard for personnel in the vicinity of the roof bolter.

CAUTION! During drilling and bolting operations, operator must watch drill rod and regulate boom feed control to prevent drill rod buckling.

NOTICE! If you are not sure how much dust is in the dust collector tank, empty the tank. Do not overload the dust collector capacity.

CAUTION! The spotter drill is the only drill which may be safely rotated completely out of the hole. Stop rotation on all other drilling before coming out of the hole.

CAUTION! Examine drill rod for defects. Do not use a drill rod that is bent or damaged.

WARNING! Never grasp any object when it is rotating in the drill box.

WARNING! It is important to stop rotation before the drill is out of the hole to avoid whipping of the drill rod as it rotates clear of the hole. The drill chuck will prevent the drill rod from being hurled, but if you are not standing clear, you could be struck by the whip circle of the drill rod. Also, the whipping drill rod may be cut or scored by the whipping motion. Scoring will make a weak spot on the drill rod.

WARNING! Do not use machine power to rotate driver into alignment with lead extension.

NOTICE! Bit sizing is important. The following information on bit sizing is provided only as a general guide. Specific requirements will vary with mine conditions. Be sure to check with MSHA and staff officials to be sure that your bolting operation is permissible.

_________________________________________________________________ 2.18 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

WARNING! During drilling and bolting operations, operator must remain under drill station canopy at all times.

________________________________ Overview of safety instructions CAUTION! Be careful of your hands! Drill steel extensions are heavy. Do not put your hands or fingers between the end of the extensions in the hole and the top end of the driver. If steels hang in the hole, they can release and drop at any time.

NOTICE! Be sure your roof bolter is set up and adjusted for your conditions.

© BUCYRUS AMERICA, INC.

NOTICE! Immediately after the first bolt is installed, check for required torque reading with an approved calibrated torque wrency. Reading should be within limits of approved roof control plans. Check every fourth bolt. If torque limits cannot be obtained, or if bolt anchorage is different than normal, notify your supervisor immediately.

WARNING! Never use the roof bolter drill box rotation to join threaded bolt extensions.

IMPORTANT! When long plates or boards are used with the bearing plate as part of the bolt assembly, stop boom feed with the plate or board just short of the roof. Turn the plate or board to desired direction, remove your hand completely, then push on up solid with the roof.

WARNING! Never place your fingers between the bearing plate or board and the roof.

NOTICE! The bolt tightening wrench is retained at the base by the drill chuck. The top of the wrench is retained firmly against the roof by the contact with the roof bolt head. There is no need to hold the wrench while tightening the bolt.

NOTICE! The rotation flow control limits rotation torque to the preset value required for your conditions.

NOTICE! Hole depth is very critical with resin bolts. The depth must be longer than the bolt but no more than 1 to 2 inches longer.

CAUTION! Resin may cause skin irritation. Wear long sleeve clothing, gloves, and a face shield in addition to safety glasses with side shields.

______________________________________________________________ A6474X231 VSVI / 03 2.19

Overview of safety instructions _________________________________ WARNING! A resin bolt, usually made from concrete reinforcing rod material, has projections along its length. These are required for efficient resin mixing and for an effective bond between the resin and the bolt. Under no circumstances attempt to hold a rotating bolt.

Sever injury or death could occur.

WARNING! Special care should be exercised when working with bendable resin bolts used in low coal. Be sure to follow bolt and resin manufacturer’s recommendations.

CAUTION! This unit is equipped with a tram station canopy. Be careful not to hit your head when entering or exiting the operator’s compartment.

WARNING! It is not possible within the scope of this guide to anticipate all possible arrangements for towing a disabled unit. Before attempting to tow any vehicle, you must take all possible precautions to protect the operators and anyone around both vehicles from being injured by the towing vehicle, the towing devices, or the vehicle being towed. The primary towing devices used (cables, bars, etc.) and the towing vehicle (scoop, tractor, etc.) must be strong and heavy enough to maintain control of both vehicles through all bottom conditions to be encountered at all times. Safety chains or other safety devices must be used in case of failure of the primary towing device. All operators must be alert at all times to prevent either unit from “running away” or “running out of control” during towing.

WARNING! At no time during towing should anyone ride in or on the vehicle being towed or stand between the towing vehicle and the disabled vehicle.

WARNING! Failure to chock all four wheels on the disabled vehicle before removing the towing device could allow the disabled vehicle to roll away uncontrolled.

WARNING! Before performing maintenance on the machine, disconnect the electrical power. The machine circuit breaker must be in the "OFF" position. If work is to be done inside the electrical controller, the power cable should be disconnected. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

_________________________________________________________________ 2.20 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

WARNING! Always check before lowering the stab foot, boom, and the ATRS to make sure no one has any part of their body near moving parts of the machine.

________________________________ Overview of safety instructions WARNING! Do not move any hydraulic control lever unless you are certain that everyone is completely clear of any machine movement. Accidental machine movement can cause serious injuries or even death to you or the maintenance person.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers.

WARNING! Be sure the machine circuit breaker is in the “OFF” position before removing the inspection cover.

© BUCYRUS AMERICA, INC.

WARNING! Do not install or remove tire/wheel assemblies from a machine without proper training.

WARNING! Check wheel components periodically for cracks or broken parts.

Replace all cracked, badly worn, damaged or severely rusted components. When in doubt replace.

WARNING! Do not, under any circumstances, attempt to rework, weld, heat or braze any wheel components that are cracked, broken or damaged. Replace such components with new OEM parts of the correct size and type.

WARNING! Mixing wheel parts of different design or from a variety of sources is potentially dangerous.

WARNING! Replace broken studs and each unbroken stud next to the broken one.

WARNING! Replace all damaged wheel studs or bolts.

Chapter 6: Technical data IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled.

The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

______________________________________________________________ A6474X231 VSVI / 03 2.21

Overview of safety instructions _________________________________

© BUCYRUS AMERICA, INC.

NOTICE! Use only lubrication fluids and greases approved by Bucyrus America, Inc.! These fluids and greases have been tested at Bucyrus America, Inc. and guarantee reliable operation of the mechanical and hydraulic functions of the machine.

_________________________________________________________________ 2.22 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

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3

Storage and transport

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________________________________________ Storage and transport

Storage and transport This chapter contains important information on the correct storage and transport of the Roof Bolter. Observance of the instructions and tips will increase the service life and availability of the machine. You will also be able to carry out the transport work quicker and more safely.

Careful attention to the points in this chapter will help you to simplify your day-to-day work.

Storage corrosion protection

Components coated with temporary corrosion inhibitor are protected for approximately six months.

© BUCYRUS AMERICA, INC.

Before delivery, the hydraulically operated equipment is operated and all axles, gear boxes, hydraulic oil tank, etc. are filled to their maximum fill point.

Storage of the machine and spare parts no direct exposure to sunlight dirt and moisture

Store the equipment indoors or cover with a tarpaulin to protect against direct exposure to sunlight.

Protect the equipment and all spare parts stored outdoors against moisture and dirt, e.g. using tarpaulins.

Protect the hydraulic plug connectors and the connectors of electrical cables with the caps and plugs supplied.

short-term storage

During short-term storage (approximately 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must be particularly protected against excessive temperatures, dirt and moisture.

long-term storage

If the equipment is to be stored more than six months, the following lubrication and corrosion inhibiting procedures must be followed: ■

If the cylinder rods are explsed, the rods must be coated with a corrosion inhibiting fluid.

■

Completely fill the hydraulic oil tank with oil

■

Fill the gear case(s) to the maximum fill level. The gear case(s ) must be rotated monthly to ensure that the interior fo the gear case (s) remains lubricated.

■

Lubricate all grease points (see Maintenance section in Chapter 5 of this manual).

■

Store the equipment in a well ventilated, dry room. Do not store outdoors.

______________________________________________________________ A6474X231 VSVI / 03 3.3

Storage and transport _________________________________________ random sample inspection

After a storage period of approximately two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage. On request, the inspection can be carried out by Bucyrus America, Inc.

natural aging

Even with proper storage, seals and hoses are subject to natural ageing. Do not use these parts if they have been stored for more than two years.

HFA fluids

Instructions on the storage of concentrates for hydraulic fluids can be found, if required, in chapter 6 in this operating manual.

IMPORTANT! Take care to insure that new supplies are stored separately from existing stock and that removal takes place on the “first in, first out” principle.

hydraulic components

If a component is to be stored more than six months, the hydraulic component must be completely filled with a corrosion inhibiting fluid. fill the hollow areas of the hydraulic components (e.g. the piston chambers) in horizontal position (ports facing upwards) until they start to overflow, then seal the ports with plastic or steel plugs.

miscellaneous components

Store the electrical equipment, electronic components, spare parts of rubber or plastic (such as seals and hoses), and hydraulics fluids only in closed rooms at temperatures of 60 °F to 77 °F (15 °C to 25 °C).

motors

Refer to the motor manufacturer’s storage procedure guide located in your Bucyrus America, Inc. parts manual supplied with your machine.

plastic deformation

In order to prevent plastic deformation of the seal elements, cylinders must be stored in an upright position. some cylinders must be removed so that they can be stored upright.

_________________________________________________________________ 3.4 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter ®

© BUCYRUS AMERICA, INC.

Long-term storage of spare components

________________________________________ Storage and transport Before transport temperatures below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic components operated with emulsion (HFAE or HFAS) must be completely drained and then filled with a corrosion inhibitor/frostproofing fluid.

Transport of equipment at temperatures between -6° F (-21° C) and -40° F (-40° C) is only permissible when certain measures were taken to meet these conditions at the design and manufacture stages. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and may only be loaded statically or quasi-statically.

© BUCYRUS AMERICA, INC.

During transport of this equipment with floor-mounted vehicles at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads. At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to a maximum of 15 mph (25 kph) for truck transport. electronic components

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors unless these components or the complete equipment is protected against harmful environmental influences by a suitable packaging. The electrical cables remain in the equipment. They must be carefully protected against transport damage and soiling of the connections.

______________________________________________________________ A6474X231 VSVI / 03 3.5

© BUCYRUS AMERICA, INC.

Storage and transport _________________________________________

_________________________________________________________________ 3.6 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter ®

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4

Installation

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__________________________________________________Installation

Installation Points to observe prior to installation Who is allowed to carry out installation?

Installation is only allowed to be carried out by personnel having received adequate training to perform this task.

Work on the safety components (pressure relief valves, fire extinguishing equipment etc.),

© BUCYRUS AMERICA, INC.

the electrical equipment (control units, signaling devices, etc.), and the hydraulic equipment (cylinders, directional control valves, hoses etc.) should only be carried out by Bucyrus America, Inc. service engineers or by specially trained personnel.

Which tools are required for installation? tool box

No special tools are required to put the Roof Bolter into service.

Various items of auxiliary equipment and machines may be required at the point of installation.

These include: ■

hoists with adequate lifting capacity

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means of attachment with adequate lifting capacity

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unloading dock

■

jacks with adequate lifting capacity

______________________________________________________________ A6474X231 VSVI / 03 4.3

Installation___________________________________________________ Notes on installation CAUTION! Serious damage can be caused to the Roof Bolter as a result of incorrect installation. The unit should therefore only be installed under the instruction of specialists from Bucyrus America, Inc. installation plan

The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established.

© BUCYRUS AMERICA, INC.

IMPORTANT! The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established

_________________________________________________________________ 4.4 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

__________________________________________________Installation Pre-installation check list NOTICE! The machine was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

However, to ensure that no transit damage has occurred, a prestartup check should be performed.

© BUCYRUS AMERICA, INC.

The pre-startup check should include: ■

perform daily maintenance

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visually inspect all hydraulic hoses and electrical cables for damage

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clean any foreign material from the operator’s compartment

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check safety provisions for operational condition on fire suppression system

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start up the machine and check for correct operation of panic switch (s) which are located inside the operator’s compartment, at the drill positioning station, and at the drilling station

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check that all covers and guards are in place and secure

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check that all tags and instruction labels are in place and secure

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check that operator’s canopy is in place and secure

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check that the drilling station canopy is in place and secure

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start the machine and allow the hydraulic system to warm up for five (5) to ten (10) minutes

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check hydraulic system pressures (see spare parts manual for proper hydraulic schematic)

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check all control handles and switches to ensure all machine functions are operating properly

______________________________________________________________ A6474X231 VSVI / 03 4.5

Installation___________________________________________________ Safety features NOTICE! The operator must become familiar with all the safety features and their location on the machine prior to installation or operation.

Safety features include: (Reference Fig. 6)

canopies

fire suppression

The machine is equipped three (3) panic strips: one is located inside the operator’s compartment, to the right of the operator while sitting in the operator’s seat; one is located above the positioning control valve handles on the left side of the machine; and the third is located on the left front of the machine at the drilling controls. The panic strip is used to break the control circuit in emergency situations, stopping the motor.

The panic strip is struck with a small amount of force (a minimum of 7 lbs. nominal) to actuate.

The machine was shipped from the factory with two protective canopies: one located over the operator’s compartment and one over the drill station. Ensure that the canopies are in place and secure at all times during operation to protect the operator from falling debris.

The machine is equipped with two (2) fire suppression (remote) actuators. One is located to the operator’s left inside the operator’s compartment and the other is located on the left front of the machine at the drill station. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from either of the two (2) actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

WARNING! If either of the fire suppression actuators is actuated, the system must be completely recharged with dry chemicals and expellants.

guards and covers

The machine is equipped with guards and covers to reduce the possibility of personnel coming in contact with rotating or moving parts. All guards and covers must be installed and securely fastened during operation.

DANGER! Do not operate the machine any of the guards or covers removed.

You or other personnel could be seriously injured from moving or rotating parts.

circuit breaker reset (s)

The machine is equipped with two circuit breaker reset push-buttons and one main circuit breaker reset switch located on the front cover of the controller. The circuit breaker reset push-buttons enable the operator to reset either of the circuit breakers inside the controller without removing the cover. The circuit breaker reset switch is used to reset the circuit breaker when it has tripped.

_________________________________________________________________ 4.6 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

panic strip (s)

__________________________________________________Installation warning gong

The warning gong is located to the operator’s right in the operator’s compartment. It is sounded by striking the lever located on the side of the gong. The warning gong should be used in accordance with the safety standards at the mine where the roof bolter is being used.

ground monitor test button (optional)

The ground monitor test push-button is located on the front cover of the controller and is used to test ground from the main power center. Depressing the push-button will break the ground circuit and will trip the circuit breaker at the main power center.

Fig. 6: Safety features on the roof bolter

Circuit breaker reset push-button, controller

Circuit breaker reset push-button, controller

© BUCYRUS AMERICA, INC.

Ground monitor test button (optional)

Main circuit breaker reset switch, controller

Canopy, operator’s compartment Fire suppression actuator

Panic strip

Warning gong

Canopy, drill station

Panic strip, drill position controls

Panic strip, drill station

Fire suppression actuator, drill station

______________________________________________________________ A6474X231 VSVI / 03 4.7

Installation___________________________________________________ Fig. 7: Overview of the Roof Bolter

ATRS

Operator’s compartment

Drill position controls

Drill box

Drill station

_________________________________________________________________ 4.8 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Drill station canopy

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5

Operation

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___________________________________________________Operation

Operation This chapter contains important information on the operation and maintenance of the machine. It also includes instructions on the replacement of wear parts. Read this chapter carefully and thoroughly. In particular, observe the safety instructions in Chapter 2 “Your safety”.

General information

© BUCYRUS AMERICA, INC.

In operation, the roof bolter is trammed to the bolting location from the relative safety of the tramming cab (operator’s compartment). When the intended location of the first row of bolt holes is reached, the operator and assistant move to the drill positioning controls. “INCH TRAM” controls located on the left side of the machine are used for accurate final positioning of the machine. Once the machine is properly positioned, the operator lowers the stab foot to the mine floor. The operator then raises the ATRS to the mine roof and begins operation.

The operator then moves from the drill positioning controls to the drilling controls, which are located under the drill station canopy. Leaving the dual relief valve in the "OFF' position (or turning it “ON” for resin bolting), the operator drills a starter hole using a pilot bit. The operator then completes the drilling with a longer bit and extensions as necessary. Switching the dual relief to the “ON” position (or turning it “OFF” for resin bolting) the operator installs a bolt and torque’s it into place.

How to operate the roof bolter DANGER! Incorrect operation endangers yourself and others! Incorrect operation of the machine is often the cause of very serious accidents! Operate the unit only when you have been sufficiently trained on the machine and have read and understood this operating manual. Should anything be unclear, please contact your immediate supervisor.

Who is allowed to operate the roof bolter?

The roof bolter is only allowed to be operated by persons with adequate knowledge of the complete machine. This includes ■

what safety devices are installed on the machine,

■

where these safety devices are located, and

■

how these safety devices are to be operated.

When can operation be started?

Operation must not be started until the safe condition and proper function of the complete machine has been checked and the daily maintenance operations have been carried out.

______________________________________________________________ A6474X231 VSVI / 03 5.3

Operation____________________________________________________ Controls and indicators Operator’s compartment The controls and indicators used in the normal operation of the machine are located in the operator’s compartment (Fig. 8), at the drill position controls (Fig. 9), and at the drill station (Fig. 10).

Panic strip

Fire suppression actuator (not shown)

System main pressure gauge

Drill positioning and drill station controls pressure gauge

Cable reel

Start button

Fast tram, left

Front/rear light switch

Warning gong

Fast tram, right

_________________________________________________________________ 5.4 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Fig. 8: Operator’s compartment

___________________________________________________Operation

© BUCYRUS AMERICA, INC.

Operator’s compartment (continued) panic strip

The panic strip is located to the operator’s right while sitting in the operator’s compartment. The panic strip is used to break the control circuit in emergency situations, stopping the motor. The panic strip is actuated by striking with a small amount of force (minimum 7 lbs. force).

fire suppression actuator

The fires suppression actuator is located to the operator’s right while sitting in the operator’s compartment. The fire suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the fire suppression system, pull the safety pin and strike the plunger Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine.

warning gong

The warning gong is located to the operator’s right while sitting in the operator’s compartment. The warning gong should be used in accordance with the safety standards at the mine where the roof bolter is used.

front/rear light switch

The light switch, located to the operator’s right while sitting in the operator’s compartment, turns on either of the roof bolter’s headlights. It has three (3) positions: “FRONT”, “REAR”, and “OFF”. To activate the front headlight, turn the switch to the “FRONT” position. To activate the rear headlight, turn the switch to the “REAR” position. The “OFF” position turns both headlights off.

start button

The start button, located in the front of the operator’s compartment, is used to start the hydraulic pump’s electric motor. To start the electric motor, depress the start button and release once the motor has started.

system main pressure gauge

Located in the front of the operator’s compartment, the system main pressure gauge provides a means of monitoring the hydraulic oil pressure of the main hydraulic system.

drill position/drill controls pressure gauge

Located in the front of the operator’s compartment, the drill position/drill controls pressure gauge provides a means of monitoring the hydraulic oil pressure of the drilling controls.

tram/steering control levers

The tram/steering control levers, located in front of the operator’s compartment, are used to steer and regulate the speed of the roof bolter during normal tramming operations. To tram forward, push both levers toward the front of the machine and to tram in reverse, push both levers toward the rear of the machine.. To steer right, push the left control lever towards the front of the machine and leave the right control lever in the neutral position: for tighter turns, pull the right control lever towards the rear of the machine while pushing the left control lever towards the front of the machine. To steer left, push the right control lever towards the front of the machine and leave the left control lever in the neutral position: for tighter turns, pull the left control lever towards the rear of the machine while pushing the right control lever towards the front of the machine.

cable reel control lever

The cable reel control lever, located in the front of the operator’s compartment, is used to pick up trailing cable during reverse tramming operations. To actuate the cable reel, push the control lever toward the front of the machine and hold in this position until the desired amount of cable is retrieved.

______________________________________________________________ A6474X231 VSVI / 03 5.5

Operation____________________________________________________ Drill positioning controls Fig. 9: Drill position controls

Inch tram left control lever Inch tram right control lever

Stab foot control lever

ATRS control lever

WARNING! When operating the roof bolter from the positioning controls on the left side of the machine, never pass beyond the last row of permanent supports. Operate the roof bolter from inside the tram station (operator’s compartment) for place change or other long distance moves.

WARNING! The roof bolter’s inch tram/steering is for maneuvering the machine between holes only. The roof bolter must be operated from inside the tram station for place change or other long distance moves.

NOTICE! Once either of the inch tram/steering control levers is released by the operator, the control lever automatically returns to the centered (neutral) position.

NOTICE! The LRB-15AR roof bolter has skid type steering, it is capable of turning within its own length.

_________________________________________________________________ 5.6 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Panic strip

© BUCYRUS AMERICA, INC.

___________________________________________________Operation inch tram/steering control levers

The inch tram/steering control levers (Fig. 9), located on the left side of the machine, are used for final positioning and maneuvering the roof bolter between bolt holes during drilling operations only. To tram forward, push both levers toward the front the machine. To tram in reverse, pull both levers toward the rear of the machine. To steer right, push the left control lever towards the front of the machine and leave the right control lever in the neutral position or for tighter turns, pull the right control lever towards the rear of the machine. To steer left, push the right control lever towards the front of the machine and leave the left control lever in the neutral position or for tighter turns, pull the left control lever towards the rear of the machine.

ATRS control lever

The ATRS control lever (Fig. 9), located on the left side of the machine, is used for raising and lowering the ATRS (Automatic Temporary Roof Support) during drilling operations. To raise the ATRS push the lever toward the front the machine and to lower the ATRS pull the lever toward the rear of the machine.

stabilizer foot control lever

The stabilizer (stab) foot control lever (Fig. 9), located on the left side of the machine, is used to raise or lower the stab foot. To lower the stab foot, push the lever toward the front the machine and to raise the stab foot, pull the lever toward the rear of the machine.

panic strip

The panic strip (Fig. 9) is located above the positioning control valve handles on the left side of the machine. The panic strip is used to break the control circuit only in emergency situations, stopping the motor. The panic strip can be actuated by striking with a small amount of force (minimum of 7 lbs. nominal force).

Drill station controls and indicators WARNING! Do not operate roof bolter without drill station canopy in place.

Operating with drill station canopy can result in severe injury or death.

WARNING! Exposing any part of your body from under the drill station canopy during drilling or bolting operations can cause severe injyury or death. Keep arms, legs, and head under drill station cannopy. drill feed control lever

The drill feed control lever (Fig. 10)) is used for raising and lowering the elevation of the boom. To raise the boom push the control lever away from the operator and to lower the boom pull the control lever towards the operator. When the desired elevation is met, release the control lever and it will automatically return to the neutral position.

rotation control lever

The rotation control lever (Fig. 10) is used to control the rotation of the drill box. To start the drill box rotating in clockwise (CW) direction, push the control lever away from the operator and to start the drill box rotating in counterclockwise (CCW) direction pull the control lever towards the operator. To stop the rotation of the drill box release the control lever and it will automatically return to the neutral position.

______________________________________________________________ A6474X231 VSVI / 03 5.7

rotation flow control

To adjust hydraulic flow for the rotation circuit (Fig. 10), turn the adjustment knob counterclockwise (CCW) to increase RPM and turn the adjustment knob clockwise (CW) to decrease RPM.

torque flow control

To adjust hydraulic flow for the torque circuit (Fig. 10), pull the adjustment knob out to decrease torque and push the adjustment knob in to increase torque.

start button

The start button (Fig. 10), located on the left front of the machine is used to start the hydraulic pump’s electric motor. To start the electric motor, depress the “START” button and release once the motor has started.

panic strip

The panic strip (Fig. 10) is located on the left front of the machine. The panic strip is used to break the control circuit in emergency situations, stopping the motor. The panic strip can be actuated by striking with a small amount of force (minimum of 7 lbs. nominal force).

fire suppression actuator

The fire suppression actuator (Fig. 10) is located on the left front of the machine. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the fire suppression system, pull the safety pin and strike the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine.

Fig. 10: Drill station controls and indicators

Rotation flow control (RPM)

Rotation control lever

Feed control lever

Panic strip Fire suppression actuator (not shown)

Torque flow control (bolting torque) Start button

_________________________________________________________________ 5.8 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Operation____________________________________________________

___________________________________________________Operation

© BUCYRUS AMERICA, INC.

Controller switches circuit breaker “RESET” switch

The circuit breaker “RESET” switch (Fig. 11), located on the front cover of the controller box, is used to reset the circuit breaker when it has tripped. If the circuit breaker has tripped, the reset lever must be moved to the “RESET” position first, and then to the “ON” position.

“AREA LIGHT” switch

The “AREA LIGHT” switch (Fig. 11), located on the front cover of the controller assembly, turns on the area lighting system. To activate the area lighting system, rotate the switch clockwise (CW) to the “ON” position and to deactivate the area lighting, rotate the switch (CCW) counter clockwise to the “OFF” position.

circuit breaker “RESET” button (s)

The controller has two (2) circuit breaker “RESET” push-buttons (Fig. 11) located on the front cover of the controller. These push-buttons enables\ the operator to reset either of the circuit breakers inside the controller without removing the cover.

“GROUND MONITOR TEST” button (optional)

The “GROUND MONITOR TEST” push-button (Fig. 11) (optional), located on the front cover of the controller is used to test ground from the main power center. Depress the push-button to break ground circuit which will trip the circuit breaker at main power center.

WARNING! Electrical power must be disconnected at the main power center before removing the cover from the electrical controller or before performing any work inside the controller.

Fig. 11: Controller switches

Circuit breaker “RESET” push button

Circuit breaker “RESET” push button

Main circuit breaker “RESET” switch

“GROUND MONITOR TEST” button (optional)

“AREA LIGHT” switch

______________________________________________________________ A6474X231 VSVI / 03 5.9

Operation____________________________________________________ Hazard zone The hazard zone exists unless ■

the power cable is disconnected or

■

the machine circuit breaker is in the “OFF” or “TRIPPED” position.

© BUCYRUS AMERICA, INC.

Fig. 12: Hazard zone

_________________________________________________________________ 5.10 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

___________________________________________________Operation Start-up procedure After reading the previous descriptions and locating each control, the operator is ready to operate the roof bolter. An experienced operator should monitor a new operator’s indoctrination to the starting procedure.

WARNING! Failure to read and understand all operating instructions before starting the roof bolter could result in serious injury or death to the operator or personnel around the machine or could cause damage to the machine.

Read all instructions carefully before attempting to start or operate the roof bolter.

© BUCYRUS AMERICA, INC.

Understand the function(s) of all controls before starting the roof bolter. Read and follow the instructions on all warning tags on the machine. Observe all regulations and safety precautions.

Never operate a roof bolter which has been damaged or is not operating properly. any part of the roof bolter which does not function properly can be a hazard. Immediately report all hazards to your supervisor.

Make sure no one is in the hazard zone (Fig. 12) before starting the roof bolter.  Inspect machine completely and repair all defects before proceeding.  Clear machine operating area of personnel.  Check power rating: this information can be found on plate located on the control box cover and on the serial number plate.  Check control valve positions: all valve levers must be in the neutral position before starting machine.  Follow trailing cable back to power source, inspect the condition of the trailing cable and make sure cable is correctly identified at breaker, fuse, or nips connection. Make sure all connections are secure.  Turn machines circuit breaker switch to the "ON” position and turn light switch "ON” to the intended direction of travel.

WARNING! Never operate any levers or pedals located inside the operator’s compartment from outside of the operator’s compartment.

WARNING! The machine is equipped with a canopy. Be careful not to hit your head when entering or leaving the operator’s compartment.

______________________________________________________________ A6474X231 VSVI / 03 5.11

Operation____________________________________________________  Get into the operator’s compartment in proper position.  Depress electrical start button and check to see that electric motor is running in proper direction - this information is marked near the blower clutch control. If the motor is running in wrong direction, shutdown machine at once.  If the machine is not equipped with blowers, test the stabilizer shoe or ATRS function to see if the pump is building pressure. The pressure at idle is too low to read from the pressure gauge.

WARNING! Do not operate machine if all panic strips are not operational.

 Observing all safety precautions, carefully test each hydraulic circuit controlled from the valve banks except the tram circuit. Visually check machine for proper operation and loose parts. Note any unusual noises.  Check dust collection system for proper suction. If necessary empty canister and replace filters.  Before tramming machine from the rear tram area (operator’s compartment), the stab foot must be completely elevated to provide ground clearance. Also, check to see that the ATRS and drill boom are in their completely collapsed position.

WARNING! Do not operate the roof bolter with any part of your body outside the operator’s compartment. Failure to follow this warning could result in injury due to body parts getting caught between the machine and outside objects.

Be sure no one is in the hazard zone (Fig. 12) before operating any levers or pedals.

The inch tram and steering controls located on the left side of the machine are for maneuvering the machine between bolt holes only. Long distance moves must be made from inside the operator’s compartment.  Get into the operator's compartment in proper position.  Move the tram/steering control levers slowly back and forth to get the feel of how the machine will steer.

The roof bolter is now ready to tram.

_________________________________________________________________ 5.12 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

 Strike the panic strips to confirm that they are operational. When any one of the three panic strips is struck the circuit breaker should trip-out.

___________________________________________________Operation Shutdown procedure The roof bolter must be properly shutdown before leaving the area or before performing any maintenance or service. Some maintenance or service procedures may require additional steps to insure the safety of the maintenance personnel working on or around the machine and will be listed in the maintenance section of this guide.  Park the roof bolter in its designated parking area out of traffic, on flat, solid ground. If it is not possible to park the machine on flat ground, park the machine at a right angle to the slope.

© BUCYRUS AMERICA, INC.

WARNING! Always check before lowering the stab foot, boom, and the ATRS to make sure no one has any part of their body near moving parts of the machine.

CAUTION! This unit is equipped with a tram station canopy. Be careful not to hit your head when entering or exiting the operator’s compartment.  Completely lower stab foot and boom to the bottom.  Completely lower ATRS.  Properly tend to trailing cable.  Turn circuit breaker lever to "OFF” position.  Turn power "OFF” at main distribution box. Immediately report any defects or unsafe conditions to your supervisor.

______________________________________________________________ A6474X231 VSVI / 03 5.13

Operation____________________________________________________ Towing a disabled machine WARNING! It is not possible within the scope of this guide to anticipate all possible arrangements for towing a disabled unit. Before attempting to tow any vehicle, you must take all possible precautions to protect the operators and anyone around both vehicles from being injured by the towing vehicle, the towing devices, or the vehicle being towed. The primary towing devices used (cables, bars, etc.) and the towing vehicle (scoop, tractor, etc.) must be strong and heavy enough to maintain control of both vehicles through all bottom conditions to be encountered at all times. Safety chains or other safety devices must be used in case of failure of the primary towing device. All operators must be alert at all times to prevent either unit from “running away” or “running out of control” during towing.

 Rotate all four torque hubs on the roof bolter to the free wheeling position.

WARNING! At no time during towing should anyone ride in or on the vehicle being towed or stand between the towing vehicle and the disabled vehicle.  Begin towing the vehicle  Once the destination is reached, stop both vehicles and chock in both directions at all four wheels of the disabled vehicle for additional stability. Rotate all four torque hubs back to the drive position.

WARNING! Failure to chock all four wheels on the disabled vehicle before removing the towing device could allow the disabled vehicle to roll away uncontrolled.

_________________________________________________________________ 5.14 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

 Couple the towing vehicle securely to the disabled vehicle.

___________________________________________________Operation Tramming  Slowly move the tram/steering control levers in the intended direction of travel. To tram forward, push both levers toward the front of the machine and to tram in reverse, push both levers toward the rear of the machine. To steer right, push the left control lever towards the front of the machine and leave the right control lever in the neutral position: for tighter turns, pull the right control lever towards the rear of the machine while pushing the left control lever towards the front of the machine. To steer left, push the right control lever towards the front of the machine and leave the left control lever in the neutral position: for tighter turns, pull the left control lever towards the rear of the machine while pushing the right control lever towards the front of the machine.

© BUCYRUS AMERICA, INC.

NOTICE! The roof bolter can be stopped at any time by striking the panic strip. Be prepared for a sudden stop when the panic strip is struck.

The following precautions should be observed while tramming: ■

Operator must be positioned fully within the confines if the cab in order not to take the risk of getting caught between the machine and rib or other obstacle.

■

Trailing cable must be handled with care.

■

Alert other workers of intentions.

■

Maintain adequate clearance between machine and rib.

■

Know the physical conditions of the route of travel.

■

Be especially cautious when rounding corners.

■

Be careful not to damage the trailing cable while tramming. Push the cable reel control lever towards the front of the machine when picking up cable; release cable reel control lever when paying cable out.

CAUTION! Do not permit the build-up of mud or other material to collect under or around the cable reel.

______________________________________________________________ A6474X231 VSVI / 03 5.15

Operation____________________________________________________ Drive Assembly WARNING! When the torque hubs are in the disengaged position, the roof bolter must be chocked at all four wheels in both directions to prevent the machine from rolling away uncontrolled. torque hubs

The roof bolter is equipped with torque hubs (Fig.13) that will allow the operator or service technician to engage or disengage the drive assemblies.

To disengage the drive assembly:  Remove the four locking bolts that secure the torque hub in the engaged position and rotate 180°.  Reinstall the locking bolts.

© BUCYRUS AMERICA, INC.

Fig. 13: Torque hubs

Locking bolts (4 places)

..

Torque hub (typical 4 places)

_________________________________________________________________ 5.16 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

___________________________________________________Operation Drilling CAUTION! Never exceed the drill rod manufacturer’s recommendations for drill torque and thrust. Excessive torque and thrust can cause the drill rod to buckle or break, thereby creating a hazard for personnel in the vicinity of the roof bolter.

CAUTION! During drilling and bolting operations, operator must watch drill rod and regulate boom feed control to prevent drill rod buckling.

WARNING! During drilling and bolting operations, operator must remain under drill station canopy at all times.

© BUCYRUS AMERICA, INC.

NOTICE! If you are not sure how much dust is in the dust collector tank, empty the tank. Do not overload the dust collector capacity.  Be sure the dust collection system is operating efficiently before proceeding to drill.  Position machine for drilling/bolting cycle.  Raise the ATRS until it comes in contact with mine roof.  Position drilling assembly to the desired position.  Lower stab foot to mine floor.  Lower drill boom to floor.  Insert the 12” spotter drill into the drill chuck by grasping drill just below the bit.  Release your hold on the spotter drill.  Place one hand on the drill feed control lever. Raise the drill to contact mine roof using the drill feed control lever.  Move your hand to the rotation lever and start rotation.  Drill a “spotter” or pilot hole two or three inches deep then reverse the boom feed lever to lower the drill out of the hole.  When the spotter drill clears the hole, stop rotation.

CAUTION! The spotter drill is the only drill which may be safely rotated completely out of the hole. Stop rotation on all other drilling before coming out of the hole.

______________________________________________________________ A6474X231 VSVI / 03 5.17

Operation____________________________________________________  Continue the boom's downward travel until the drill box is nearly touching the floor. Remove hands from control levers.  Remove the spotter drill.

CAUTION! Examine drill rod for defects. Do not use a drill rod that is bent or damaged.  Examine drill rod for defects; do not use a drill rod that is bent or damaged. Insert drill rod in drill chuck.

 Continue to feed very slowly until the bit reaches the top of the pilot hole. Do not jam the bit. Center the feed control lever. The drill rod is now retained at both ends: the base in the drill chuck and the bit end in the pilot hole.  With one hand on the feed control lever and the other hand on the rotation control lever, you are now ready to start drilling in a normal, safe fashion.

WARNING! Never grasp any object when it is rotating in the drill box.

Judging the proper feed rate requires some experience. Too little feed rate can cause rapid bit wear by permitting the bit to be ground by the rock rather than the bit penetrating and cutting the rock.

Too high a feed force, with relief pressures to high, can cause the drill rod to buckle. Remember, buckling is most likely to occur when drilling is started with most of the full length of the drill rod exposed. As the drill penetrates into the roof, the wall of the hole stabilizes the drill rod, and a gradual increase in feed force can safely be provided to achieve maximum drilling rates.

Too high a feed force in soft rock can cause the bit to bite too deeply; if relief pressure is set to high, the bit shank or drill rod may be twisted off.

With rotation relief set properly, the drill rotation will stall when feed is too high.

In soft rock, too high a feed rate may permit the drill penetration to run ahead of the dust collector. This condition is easy to diagnose. You will notice intermittent bursts of dust around the drill rod at the hole.

This condition is called "puffing”.

_________________________________________________________________ 5.18 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

 Guide the drill rod while slowly elevating the drill boom. As the bit nears the roof, reduce the boom elevating speed to a very slow rate so you can easily guide the bit into the pilot hole. BE VERY CAREFUL OF YOUR HANDS AT ALL TIMES.

___________________________________________________Operation Another symptom of too high a feed rate in soft rock, beyond the collection capability of the dust system, is called “plastering”. In this condition, the drill cuttings not pulled into the drill rod are packed or plastered against the wall of the hole under the bit. With the "plastered” hole under the bit smaller than the bit, it can be very difficult to remove the drill rod from the hole. It is particularly difficult to remove extensions.  When the drill penetration nears the boom feed stops, or when the desired drill depth is reached, reverse feed direction. Maintaining rotation while lowering the drill boom helps to clean the hole. However, stop rotation before the drill rod is completely out of the hole.

© BUCYRUS AMERICA, INC.

WARNING! It is important to stop rotation before the drill is out of the hole to avoid whipping of the drill rod as it rotates clear of the hole. The drill chuck will prevent the drill rod from being hurled, but if you are not standing clear, you could be struck by the whip circle of the drill rod. Also, the whipping drill rod may be cut or scored by the whipping motion. Scoring will make a weak spot on the drill rod.

It is good practice to reverse drill feed just short of the boom stops. If the drill feed is stopped by the boom stops, the continued rotation will dull the bit by grinding against the back of the hole.  With rotation stopped, grasp the drill with one hand while continuing to lower the drill boom. Continue the down travel of the boom to provide all available clearance for installing extension sections or the roof bolt.

Extension steel selection Extension steels, two or more sections, are required when the desired drilling depth exceeds the available feed length of one section of the drill. The extension sections consist of the following: ■ Driver - The section which has the 1-1/8” square base to fit the roof bolter drill box chuck.

■ Lead Extension - The section which has provision for bit attachment.

At the end opposite the bit, the lead extension has a coupling arrangement which connects to the driver.

■ Middle Extension - One or more used when desired drilling depth exceeds the depth which can be obtained with driver and lead extension. This piece has a coupling arrangement, one end male, the other end female, to connect driver to lead extension.

Where extension steels are required, it is important to use the longest extension section lengths which will clear within the hole length obtained with the starter and the top of the roof bolter drill box.

Use of the longest lengths of sections which will clear may eliminate the need for an additional middle extension to obtain the desired drilling depth. ______________________________________________________________ A6474X231

VSVI / 03

5.19

Operation____________________________________________________ When planning for drill steel lengths to be used with the Bucyrus roof bolter, several factors should be considered.

■

Starter length - Mining height minus 12”. The 12” allows for the height of the standard drill box, length of drill drive shank, and working clearance.

■

Driver length – Bucyrus recommends the driver length to be 6” less than starter length.

■

Lead and Middle Extension Length - Mining height less 18” is recommended.

Drilling with extension steels  Insert “driver” into drill chuck.  Insert “lead extension” into hole and push upward until the base of the lead extension clears the top of the driver.

WARNING! Do not use machine power to rotate driver into alignment with lead extension.

NOTICE! Bit sizing is important. The following information on bit sizing is provided only as a general guide. Specific requirements will vary with mine conditions. Be sure to check with MSHA and staff officials to be sure that your bolting operation is permissible.

To facilitate manual insertion and removal of extensions, it is common practice to use a larger bit on the starter steel than is used on the lead extension. For 1-3/8” expansion shells used with mechanical bolts, it is generally permissible to use 1-1/2” starter steel bit (or starter bit). For 1” resin bolts, it is usually permissible to use 1-1/32” starter bit.

Bit suppliers usually paint the starter bit and lead extension bit (finisher bit) different colors. In addition, the bit size is usually forged into the bit body. Another identification required by MSHA is provided at the base of the bit shank. The starter bit has a flat shank base; the finisher has a pyramid at the shank base.

It is important to use only the finisher bit for the upper portion of the hole because the anchorage provided by either expansion shells or resin is dependent on the proper size hole. Even though resin bolts usually anchor over the full length, the upper anchorage is considered the most important.

Where one or more middle extensions are required, bit sizing is very important to the ease of removal of the middle and lead extensions.

Worn bits drill smaller holes than new bits. If you have drilled a portion of the hole with a worn bit and it is necessary to change for the remainder of the desired hole depth, be sure to ream the “worn bit hole” with the new bit. The worn bit hole can be reamed with the new bit by providing full rotation speed and feeding slowly to the back of the hole. _________________________________________________________________

5.20

Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

 Line up and couple lead extension and driver.

___________________________________________________Operation

You can force the new bit to the back of the hole with machine power, but you cannot force the bit out of the hole since extensions do not couple rigidly. Therefore, be sure to ream the hole first.

It may be permissible to use three bit sizes where multiple extensions are required. Consult your bit supplier for advice in this matter. They may recommend 1-5/8” starter, 1-1/2” intermediate, and finally 1-3/8” for the finisher when standard expansion shells are used with long bolts.  With expansion and driver coupled, move your hands back to the feed and rotation controls. As instructed previously, ease both controls in starting both rotation and feed.

You will be elevating the drill steels through a few inches of previously drilled hole, so approach the back of the hole with the bit gradually - Do not jam the bit.

© BUCYRUS AMERICA, INC.

Proceed with drilling as described previously.  As was described with the starter steel, when extension drills near the boom feed stops, or when the desired drill depth is reached, reverse feed direction. Maintain rotation while lowering the drill boom until the extension coupling joint is out of the hole several inches.  Stop rotation and stop boom down travel. Grasp the extension with one hand and grasp boom feed control with the other hand.  Lower the drill boom pulling the driver out of the extension coupling.

■ If the desired hole depth has been drilled, maintain your grip of the extensions with one hand while removing the driver from the drill chuck with the other hand.

■

If additional hole depth is required, maintain your grip of extensions with one hand while picking up and coupling middle extension with other hand.

With both hands, lift drill string up into the hole until base of middle extension clears the top of the driver.

Release one hand and line-up driver with extensions. Ease extensions down out of the hole, engaging coupling with driver.

CAUTION! Be careful of your hands! Drill steel extensions are heavy. Do not put your hands or fingers between the end of the extensions in the hole and the top end of the driver. If steels hang in the hole, they can release and drop at any time.

If you have problems with hanging steels, review the instructions previously presented. The more common causes and remedies have been outlined to keep the drill sections free from hanging in the hole. However, if water and voids are encountered in your roof drilling conditions, additional steps may be required to keep the drill steels free.

______________________________________________________________ A6474X231 VSVI / 03 5.21

Operation____________________________________________________ Drill options and adjustments NOTICE! Be sure your roof bolter is set up and adjusted for your conditions.

Since conditions vary extensively from mine to mine, or even between mine sections, Bucyrus recommends that you contact your Service Supervisor to be sure the roof bolter hydraulic pressures correspond safely to the ratings or specifications of your drilling tools.

Bucyrus standard speed and feed force limits provide a range which suits most conditions where 1-3/8” holes are drilled in rock strata which vary in hardness. Most mining conditions require drilling through soft to medium-hard shales for several feet with about 2’ of harder rock to be drilled for good expansion steel anchorage. The operators usually develop skills to achieve maximum penetration rates with reasonable bit wear.

If your conditions are consistently very soft drilling, your Service Supervisor may recommend replacement of the hydraulic drive unit for the drill rotation to provide higher speed.

Installation of mechanically anchored rock bolts Important factors toward successful mine roof support with rock or roof bolts should be remembered and practiced by the roof bolter operators.

■

■

Roof bolts support the mine roof in two principle ways: –

With the expansion shield anchored in a firm rock, the bolt suspends weaker rock layers which rest on the bearing plate and cap (header, half header, scab board, etc.) board.

–

With the expansion shell anchored in a firm rock and the bearing plate drawn against the rock at the roof line, the weaker rock layers are bound together to serve as a solid laminated beam.

In order for roof bolts to be effective roof support: –

The cut must be bolted as soon as possible after mining. The greater the delay the greater opportunity the roof layers have to sag and separate.

_________________________________________________________________ 5.22 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Soft drilling usually requires high rotation speed and low feed force.

Hard drilling conditions require just the opposite: slower rotation speed and higher feed force. Bucyrus provides as standard a rotation speed of approximately 514 RPM and feed hydraulic pressure relief set to limit the feed force on the drill to about 2,000 pounds.

___________________________________________________Operation –

The proper torque must be applied to the bolt (within a narrow range) to pre-tension the bolt and compress the rock layers.

The torque applied to the bolt is prescribed by experience in your mining condition. The torque is usually determined by the quality of the anchorage rock.

–

All bolts must be torqued consistently. Otherwise, the high torqued bolts will carry all the loading. Consistent torque distributes the roof load over all the bolts evenly.

NOTICE! Immediately after the first bolt is installed, check for required torque reading with an approved calibrated torque wrench. Reading should be within limits of approved roof control plans. Check every fourth bolt. If torque limits cannot be obtained, or if bolt anchorage is different than normal, notify your supervisor immediately.

© BUCYRUS AMERICA, INC.

 Roof bolts are inserted into the hole manually. Always use a bolt wrench which fits the drill chuck properly. Push the bolt into the hole manually far enough to insert the bolt head into the drill chuck.

WARNING! Never use the roof bolter drill box rotation to join threaded bolt extensions.  While pushing the bolt toward the roofline, watch carefully to try to detect any side flexing which would indicate the shell is jamming and the bolt is about to buckle.

IMPORTANT! When long plates or boards are used with the bearing plate as part of the bolt assembly, stop boom feed with the plate or board just short of the roof. Turn the plate or board to desired direction, remove your hand completely, then push on up solid with the roof.

WARNING! Never place your fingers between the bearing plate or board and the roof.  Now that the bearing plate and bolt head are firmly contacting the mine roof, rotate the torque flow control knob to apply the correct amount of torque to the bolt.

NOTICE! The bolt tightening wrench is retained at the base by the drill chuck. The top of the wrench is retained firmly against the roof by the contact with the roof bolt head. There is no need to hold the wrench while tightening the bolt.  With the rotation flow control adjusted correctly, push in feed lever with one hand and with the other hand push in rotation lever to torque the bolt. Keep rotation engaged until the rotation stalls.

______________________________________________________________ A6474X231 VSVI / 03 5.23

Operation____________________________________________________ NOTICE! The rotation flow control limits rotation torque to the preset value required for your conditions.

The boom force applied to the wrench is controlled so that the rotation torque is not absorbed in friction between wrench, bolt head, and bearing plate. Without the thrust control, it is nearly impossible to maintain consistency in bolt torques. With the bolt installed, center rotation control and reverse feed control to "DOWN' direction. With the drill boom lowered to about level position, center boom feed control.  Remove wrench.

Resin bolt systems operate much as was discussed for mechanical bolts. However, resin bolts do not depend solely upon anchorage at a single point because the resin forms a bond between the bolt and all of the surrounding strata.

Resin bolt systems have proven to be effective in many mine roof conditions where mechanical bolts have failed. However, procedures differ somewhat as specified by the various resin manufacturers. Principle differences between resin manufacturers' procedures usually involve mixing time and the amount of time thrust is held on the assembly to permit setup.

Your resin supplier and your Bucyrus Service Supervisor should be called in to assist in a safe transition from mechanical bolts to resin.

Drilling procedures provided previously apply to drilling for resin bolt installation. However, drill thrust and rotation torque must be set with relief limits within the mine tool suppliers recommendations. The small diameter drill steels commonly used for resin installation are very easily buckled.

Drilling thrust for drilling the one inch resin hole is often lower than thrust required to push the resin bolt into the resin cartridges. Likewise, rotation torque for drilling is often less than the torque required for mixing the resin after the bolt is inserted.

Your service supervisor can assist in setting up your roof bolter so that resin hole drilling is done with the dual relief on. The dual relief (normally used for mechanical bolt installation) can be set for boom thrust and rotation torque limits corresponding to limits of your drilling tools.

When installing the resin bolt, turn the dual relief "OFF”. Higher boom thrust and rotation torque (provided by system relief settings) is then available for inserting the pin and then mixing the resin.

_________________________________________________________________ 5.24 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Installation of fully grouted resin bolts

___________________________________________________Operation Following are general procedures for installing resin bolts. Specific instructions must be provided by your resin supplier.  After hole has been drilled, insert wrench in drill chuck.

NOTICE! Hole depth is very critical with resin bolts. The depth must be longer than the bolt but no more than 1 to 2 inches longer.  Insert necessary resin cartridges into the hole.  Insert the resin bolt head into the wrench. It is helpful if the boom elevation is preset so that there is just enough clearance to insert the resin bolt. The upper end of the resin bolt is then positioned under the hole, and you can permit the resin cartridge to slip out of the hole and sit on top of the bolt.

© BUCYRUS AMERICA, INC.

Guide the bolt with one hand while slowly elevating the boom.

When the bolt end is started in the hole, release your hold on the bolt. Push the bolt into the hole. Watch for any indication of bowing of the bolt which is a warning of buckling. If no bowing is observed, continue pushing the bolt to a point with the bearing plate 1/2” to 1” below the roof line. Center boom elevation control. Rotate the bolt for fifteen to twenty seconds at about half rotation speed (200 to 250 RPM).  Stop rotation; push the bolt upward solid against the roof and hold for the time specified by the resin manufacturer.  Lower the boom; remove the wrench; turn dual relief to "ON” position ready for drilling the next hole.

CAUTION! Resin may cause skin irritation. Wear long sleeve clothing, gloves, and a face shield in addition to safety glasses with side shields.

WARNING! A resin bolt, usually made from concrete reinforcing rod material, has projections along its length. These are required for efficient resin mixing and for an effective bond between the resin and the bolt. Under no circumstances attempt to hold a rotating bolt.

Sever injury or death could occur.

WARNING! Special care should be exercised when working with bendable resin bolts used in low coal. Be sure to follow bolt and resin manufacturer’s recommendations.

______________________________________________________________ A6474X231 VSVI / 03 5.25

© BUCYRUS AMERICA, INC.

Operation____________________________________________________

_________________________________________________________________ 5.26 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

____________________________________ Electrical system overview Electrical system The following pages contain a brief description of the major electrical components and assemblies that are on the roof bolter.

The machine receives electrical power through a heavy-duty trailing cable. Be sure that the box connector is correctly identified and is securely connected. Check that the cable entrance is in good mechanical condition. Walk along the trailing cable from the power center to the roof bolter and check the condition of the trailing cable. Pay special attention to points most apt to cause damage such as corners, intersections, and where the cable may be run over by moving equipment.

Never use trailing cable with exposed wires or splices which can heat up or spark under load.

© BUCYRUS AMERICA, INC.

WARNING! This section is intended to familiarize the user with the major electrical components of the roof bolter. All electrical maintenance should be performed by a qualified electrician with knowledge of the function of the components involved.

WARNING! Before removing the cover from the starter enclosure and attempting any maintenance or troubleshooting on the machine, the main power must be disconnected and locked and tagged out at the main power center.

Fig. 14: Major electrical component locator Electric motor

Cable reel

Controller

Start switch

Tape switch

Start switch

Tape switch

Lights

Tape switch

______________________________________________________________ A6474X231 VSVI / 03 5.27

Electrical system overview _____________________________________ Controller The controller (Fig. 15), located on the right hand side of the machine, houses the primary electrical control components.

WARNING! Before removing the cover from the controller and attempting any maintenance or troubleshooting on the roof bolter, the main power must be disconnected and locked out at the main power center.

Controller cover

Controller panel board

_________________________________________________________________ 5.28 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Fig. 15: Controller

____________________________________ Electrical system overview Controller cover On the cover of the controller (Fig. 16) are the circuit breaker reset switches, the area light switch, and the ground monitor test button (if equipped). The main circuit breaker reset switch allows the main power to the roof bolter from the section power supply to be disconnected. For a detailed description of how to operate these switches, see the Controls and indicators section of this chapter.

Fig. 16: Controller cover Circuit breaker “RESET” push button

Main circuit breaker “RESET” switch

© BUCYRUS AMERICA, INC.

Circuit breaker “RESET” push button

“GROUND MONITOR TEST” button (optional)

“AREA LIGHT” switch

______________________________________________________________ A6474X231 VSVI / 03 5.29

Electrical system overview _____________________________________ Controller panel board The controller panel board (Fig. 17) houses the circuit breakers, relays, and fuses. The controller panel board is accessed by removing the controller cover.

There is a control transformer (Fig. 17) mounted inside the box, in front of the panel board.

Fig. 17: Controller panel board and control transformer “CB4”

“R1”

“CB5”

Starter

Main circuit breaker, “CB1”

© BUCYRUS AMERICA, INC.

IS relay

Control transformer

circuit breaker “CB1”

Fuse (2)

“CB2”

“CB3”

“CB1” is a 100 amp circuit breaker and is the main circuit breaker for the roof bolter. The circuit breaker reset switch on the front cover of the controller is used to control the circuit breaker when the controller cover is in place.

When looking directly at the circuit breaker, the circuit breaker is off when the black switch is in the down position and is on when the black switch is in the up position. If the circuit breaker has tripped, the switch will be in the middle, between off and on. After the circuit breaker has tripped, the switch must be moved down, past off, then up to the on position.

_________________________________________________________________ 5.30 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

____________________________________ Electrical system overview starter

The size 3 starter is located on the middle of the panel and includes an overload protection.

IS relay

The IS relay is an intrinsically safe relay for the tape switches.

fuses

The two 2 amp fuses protect the IS relay.

Turk relay, “R1”

The Turk relay, “R1”, will engage, allowing the electric motor to start, when the safety circuit is OK and the motor start button is engaged.

“CB2” and “CB3”

“CB2” and “CB3” are single pole, 10 amp circuit breakers for the lights.

“CB4” and “CB5”

“CB4” and “CB5” are single pole, 10 amp circuit breakers are on the control circuit. If anything in the control circuit gets shorted or overloaded, the circuit breakers will trip.

control transformer

The control transformer reduces the 440 volts coming into the machine to 12 volts and 120 volts.

© BUCYRUS AMERICA, INC.

Cable reel assembly Power is supplied to the roof bolter from the mine through the trailing cable. The trailing cable is connected to the roof bolter at the cable reel assembly. The cable is wound around the reel is and the reel is controlled by a foot pedal located in the operator’s compartment. During reverse tramming operations, the cable is picked up by depressing the foot pedal and holding until the desired amount of cable has been reeled in.

Remote “START” switches The roof bolter is equipped with two “START” switches, one in the operator’s compartment and one at the drill station controls. Either “START” switch can be used to start the electric motor from the drill station.

Panic strips There are three panic strips located on the roof bolter: one at the drilling station, one ate the drill positioning controls, and one in the operator’s compartment. The roof bolter can be shutdown at any time by striking any one of the panic strips.

Electric motor The roof bolter is equipped with a 40 hp, 440 VAC motor that drives the hydraulic pump and blower.

______________________________________________________________ A6474X231 VSVI / 03 5.31

© BUCYRUS AMERICA, INC.

Electrical system overview _____________________________________

_________________________________________________________________ 5.32 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

________________________________________________ Maintenance Instructions on the maintenance Maintenance at regular intervals increases the operational safety and prolongs the service life of the machine. In particular, observe the safety instructions in Chapter 2 “Your safety”.

Important notes

© BUCYRUS AMERICA, INC.

Please observe the following: ■

In order to avoid individual components not being serviced or being only inadequately serviced during maintenance work on the machine as a whole, we recommend that a general maintenance plan be drawn up. You can, for example, draw up a checklist using this operation manual and the manuals of the other components.

■

Inadequate maintenance can result in machine damage which leads to considerable costs.

■

Use only suitable and approved tools for maintenance work.

■

Use only original Bucyrus America, Inc. spare parts when replacing components.

■

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

■

Anyone performing maintenance on this equipment must be trained to operate it and be familiar with this Bucyrus America, Inc. guide.

Before maintenance Please observe the following: ■

Shutdown the machine on level ground.

■

Disconnect the electrical power. The machine circuit breaker must be in the "OFF" position. If work is to be done inside the electrical controller, the power cable should be disconnected and locked out.

WARNING! Before performing maintenance on the machine, disconnect the electrical power. The machine circuit breaker must be in the "OFF" position. If work is to be done inside the electrical controller, the power cable should be disconnected. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

______________________________________________________________ A6474X231 VSVI / 03 5.33

Maintenance _________________________________________________ ■

Test the controls to ensure that the unit will not move.

■

Chock all four (4) wheels in each direction.

WARNING! Do not move any hydraulic control lever unless you are certain that everyone is completely clear of any machine movement. Accidental machine movement can cause serious injuries or even death to you or the maintenance person.

Do not perform maintenance on a circuit while there is a load resting on the hydraulic cylinder. Booms must be securely blocked if maintenance is to be performed with the boom in the raised position.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers.

■

Do not perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity.

■

Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that it be corrected immediately by a qualified maintenance technician.

■

Cleanliness can not be overemphasized as the essential ingredient of a good maintenance program. Machines should be kept as free as possible of dirt and debris which could impede performance or infiltrate systems and cause premature wear or failure.

_________________________________________________________________ 5.34 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

■

________________________________________________ Maintenance Critical torque values Torque values are expressed in lubricated and dry thread values. Lubricated thread torque values should be used any time the bolt threads are covered with oil, grease, anti-seize or thread-locking compounds.

Dry thread torque values should be used when threads are completely clean and dry.

Table 1: Critical torque values Location

Size

Grade

Dry

Lubricated

Tire-Wheel mounting nuts

5/8”

8

225 ft-lb

170 ft-lb

© BUCYRUS AMERICA, INC.

Lubricants, fluids and capacities Table 2: Lubricants, fluids and capacities Location Hydraulic oil Torque hubs Multi-Purpose grease Blower gear housing Level wind and stabilizer shaft Drill box

Specification Spec. 100-1 Spec. 100-6 Spec. 100-3 Spec. 100-8 Dri-Slide or similar dry lube 40W non-detergent oil

Approximate capacity 55 Gallons

Notes 2

As Required

1 2 2

Notes: 1. Pump grease into fitting until old grease can be observed coming out of component.

2. Slowly fill with oil until oil is observed coming out of the check hole.

______________________________________________________________ A6474X231 VSVI / 03 5.35

Maintenance _________________________________________________ Table 3: Lubrication and maintenance schedule Item

Description

Places

Lubricant

Specification

Every shift 1 2

Panic strips (Check) Electrical cables, conduits, and glands

3 Inspect

3 4

Hydraulic hoses and connections Fasteners (nuts, bolts, screws)

Inspect Check

5 6

Tires (Inspect) Lights (Inspect)

7 8

Switches Reflectors and warning tags

Inspect Inspect

9 10

Warning gong Hydraulic oil level (Check)

Check 1

11 12 13 14

Hydraulic oil filter indicator Drill box oil Cradle, boom, and support arm assembly Dust system - collected dust (if equipped)

Check Check Inspect Empty

15 16

Dust system - door gasket (if equipped) Dust system - filter element (if equipped)

Inspect Inspect

17 18

Cable reel Hydraulic controls

Inspect Check

19

First bolt installed

Inspect

4 4

Spec. 100-1

Every other shift 20

Level wind shaft bearing

21 22

Cable reel index pin Level wind and stabilizer shaft

1

Spec. 100-3 Spec. 100-3

23 24

Cable reel bearing Cable reel drive chain

Spec. 100-3 Spec. 100-3

25 26

Blower gear housing oil level (if equipped) Torque hub

27 28

ATRS lift arm pivot guide bar Stabilizer foot pin

Spec. 100-3 Spec. 100-3

29 30 31

Drill head lift arm pin Drill head face plate ATRS lift arm center pivot

Spec. 100-3 Spec. 100-3 Spec. 100-3

32

ATRS roof support pivot

Spec. 100-3

33 34

Thrust (feed) cylinder pins Stab foot cylinder pins

Spec. 100-3 Spec. 100-3

35 36

Lift arm center pivot Crank arm front pivot

Spec. 100-3 Spec. 100-3

37

ATRS oscillating link front pivot

Spec. 100-3

Check Check

Spec. 100-3

Spec. 100-8 Spec. 110-6

_________________________________________________________________ 5.36 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

40W non-detergent oil

________________________________________________ Maintenance Table 3 (continued): Lubrication and maintenance schedule

© BUCYRUS AMERICA, INC.

Item

Description

Places

38 39 40 41 42

ATRS lift cylinder pins Lift arm rear pivot Carriage rollers Guide arm pin

Blower oil level (if equipped)

Check

43 44 45 46

Inspect Check

47

Blower drive belt (if equipped) Blower (gear end) (if equipped) Drill box Fire suppression (if equipped) Weekly Hydraulic pressure settings

48 49 50 51 52 53

Pump suction hose Electrical system Trailing cable Drill box Explosion proof housings (Inspect) Hydraulic oil filter

Inspect Check Inspect Change 4 Change

54 55 56

Tire and wheel mounting bolts Torque hub and ground clearance bolts Blower shaft bearing (if equipped) Every three months Blower (drive end) (if equipped) Torque hubs

Inspect Inspect

57 58 59 60 61 62

Electric motor bearing Every six months Hydraulic oil and suction strainer Pump Cable reel assembly

Lubricant

Specification Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-8 Spec. 100-3 Spec. 100-3

Inspect Check

40W non-detergent oil

Spec. 100-3

Change Inspect Inspect

______________________________________________________________ A6474X231 VSVI / 03 5.37

Maintenance _________________________________________________ Fig. 14: Lubrication chart

12,18,45,51

41

30

32,37

29 36 33 38

13

35 14,15,16

34 1,7,52

28

31

26,58

27,39

7,52 33 1 55

5,54

26 60

52

47 59

48 7

42,43,44, 56,57 61

1,46,52

25 24,52 9

A-A

20

62

17

23

21 22

A-A Level wind

_________________________________________________________________ 5.38 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

40

________________________________________________ Maintenance Specific lubrication and maintenance procedures Every shift panic strips

Check the three (3) panic strips located inside the operator’s compartment, at the drill positioning controls, and at the drilling controls (Fig. 15). Start the machine, but do not tram. Strike the panic strips to be certain that they are operating properly, tripping the machine circuit breaker and shutting down the machine.

Fig. 15: Panic strips

© BUCYRUS AMERICA, INC.

Panic strip

Panic strip Panic strip

fasteners (nuts, bolts and screws)

Loose fasteners will cause premature wear and failure to machine and components. Visually inspect for loose fasteners and tighten as required.

electrical cables, conduits and glands

Visually inspect all electrical cables, conduits and glands for signs of wear or damage.

hydraulic hoses and connections

Visually inspect all hydraulic hoses and connections for signs of wear, damage or leakage.

tires

Visually inspect all tires for signs of wear or damage.

headlights

Turn on headlights and visually inspect for bulbs that need replaced or for signs of damage.

reflectors and warning plates

Visually inspect the condition and readability of all warning tags, labels and reflectors for signs of wear or damage. Replace any found missing or damaged.

______________________________________________________________ A6474X231 VSVI / 03 5.39

Maintenance _________________________________________________ switches

Check the operation of all switches (Fig. 16) to be certain that they are operating properly.

warning gong

Check the warning gong (Fig. 16) for proper operation.

Fig. 16: Switches and warning gong Circuit breaker “RESET” push button

“CIRCUIT BREAKER RESET” handle

Circuit breaker “RESET” push button

“AREA LIGHT” switch

“GROUND MONITOR TEST” push button (PA only) © BUCYRUS AMERICA, INC.

Control Station

Drill station

Start button

Warning gong

Operator’s Station

Front/rear light switch

Start button

_________________________________________________________________ 5.40 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

________________________________________________ Maintenance hydraulic oil level

Check the hydraulic oil level (Fig. 17) by removing the fill cap. The oil level should be kept within 1 1/2” of the top of the tank. If hydraulic oil is needed, fill with Spec. 100-1 until oil level is within 1 1/2” from the top of the tank.

Fig. 17: Hydraulic oil level

© BUCYRUS AMERICA, INC.

Fill cap

hydraulic oil filter

Check the hydraulic filter (Fig. 18). If the pressure indicator gauge is reading in the red zone, replace the filter element.

Fig. 18: Hydraulic oil filter

Pressure indicator

Element

______________________________________________________________ A6474X231 VSVI / 03 5.41

Maintenance _________________________________________________ drill box oil level

Visually inspect the drill box (Fig. 19) for excessive wear or oil leakage and check oil level. Remove the oil level fill/check plug. The oil level should be kept at the level of the fill/check plug.  If it is necessary to add oil, slowly add 40W non-detergent oil through the fill/check plug hole until oil flows from the hole. Do not overfill the drill box.  Replace the fill/check plug.

Fill/check plug

cradle, boom, and support arm assembly

Inspect the cradle, boom, and support arm assembly for cracks and excessive wear.

cable reel

Inspect the cable reel for build-up of mud or other material under or around the reel.

dust collection system (if equipped)

Inspect the dust collection system (Fig. 20).  Inspect the hosing for signs of wear or damage. Repair or replace any found damaged.  Inspect door gasket for wear or damage. Replace as necessary.  Inspect filter elements located inside the dust box. If the elements are not damaged, they can be cleaned by briskly shaking out excess dust or with air pressure. If elements are damaged, they must be replaced.  Inspect dust collection area of dust box. If excess dust has accumulated, it must be removed with the rake.

_________________________________________________________________ 5.42 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Fig. 19: Drill box

________________________________________________ Maintenance Fig. 20: Dust collection system

© BUCYRUS AMERICA, INC.

Filter element

Dust collection area

Door gasket

______________________________________________________________ A6474X231 VSVI / 03 5.43

Maintenance _________________________________________________ hydraulic controls

Check the operation and condition of all hydraulic controls and gauges (Fig. 21).

Fig. 21: Hydraulic controls System main pressure gauge

Drill positioning and drill controls pressure gauges

Cable reel control

Fast tram (right) © BUCYRUS AMERICA, INC.

Fast tram (left)

Rotation control

Feed control

Bolting torque Inch tram (left) Inch tram (right) Stabilizer foot

ATRS

_________________________________________________________________ 5.44 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

________________________________________________ Maintenance Every other shift level wind shaft bearing

cable reel index pin

Lubricate the level wind shaft bearing (Fig. 22) with Spec. 100-3 through the grease fitting located on the bearing. Pump grease into the fitting until old grease can be observed coming out.

Lubricate the cable reel index pin (Fig. 22) with Spec. 100-3. Pump grease into the fitting until old grease can be observed coming.

level wind and stabilizer shaft

Inspect, clean, and lightly oil the level wind and stabilizer shaft (Fig. 22) with a light coat of Dri-Slide (or similar lubricant).

cable reel bearing

Lubricate the cable reel bearing (Fig. 22) with Spec. 100-3 through the grease fitting located on the bearing. Pump grease into the fitting until old grease can be observed coming out of the bearing.

© BUCYRUS AMERICA, INC.

Fig. 22: Level wind and cable reel maintenance

Level wind shaft bearing (not shown)

Cable reel index pin

Level wind and stabilizer shaft

Cable reel bearing (not shown)

______________________________________________________________ A6474X231 VSVI / 03 5.45

Maintenance _________________________________________________ cable reel drive chain

Inspect, clean, and lightly oil the cable reel drive chains (Fig. 23) with a good quality chain lube.

Cable reel drive chain

Cable reel drive chain

blower gear housing (if equipped)

Check the oil level in the blower gear housing (Fig. 24). If the oil is low, pour oil, Spec. 100-8, through the oil check/fill plug.

Fig. 24: Blower gear housing oil level

Oil fill/check plug

_________________________________________________________________ 5.46 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Fig. 23: Cable reel drive chain

________________________________________________ Maintenance

© BUCYRUS AMERICA, INC.

ATRS lift arm pivot guide bar

Apply a light coat of lubrication, Spec. 100-3, to the ATRS lift arm pivot guide bars (Fig. 25).

stabilizer foot pin

Lubricate the stabilizer foot pin (Fig. 25) with Spec. 100-3. Pump grease into the fitting until old grease can be observed coming out.

drill head lift arm pin

Lubricate the drill head lift arm pin (Fig. 25) with Spec 100-3. Pump grease into the fitting until old grease can be observed coming out.

drill head face plate

Lubricate the drill head face plate (Fig. 25) with Spec. 100-3 as required. Use one to two pumps of grease (1.5” (25 cc)).

ATRS lift arm center pivot

Lubricate the ATRS lift arm center pivot (Fig. 25) with Spec. 100-3.

Pump grease into the fitting until old grease can be observed coming out.

ATRS roof support pivot

Lubricate the ATRS roof support pivot (Fig. 25) with Spec. 100-3.

Pump grease into the fitting until old grease can be observed coming out.

ATRS oscillating link front pivot

Lubricate the ATRS oscillating link front pivot (Fig. 25) with Spec. 1003 . Pump grease into the fitting until old grease can be observed coming out.

ATRS lift cylinder pins

Lubricate the ATRS lift cylinder pins (Fig. 25) with Spec. 100-3. Pump grease into the fitting until old grease can be observed coming out.

lift arm rear pivot

Lubricate the lift arm rear pivot (Fig. 25) with Spec. 100-3. Pump grease into the fitting until old grease can be observed coming out.

carriage rollers

Lubricate the carriage rollers (Fig. 25) with Spec. 100-3. Pump grease into the fitting until old grease can be observed coming out.

guide arm pin

Lubricate the guide arm pin (Fig. 25) with Spec. 100-3. Pump grease into the fitting until old grease can be observed coming out.

stabilizer foot cylinder pin

Lubricate the stabilizer foot cylinder pin (Fig. 25) with Spec. 100-3.

Pump grease into the fitting until old grease can be observed coming out.

thrust (feed) cylinder pin

Lubricate the thrust (feed) cylinder pin (Fig. 25) with Spec. 100-3.

Pump grease into the fitting until old grease can be observed coming out.

lift arm center pivot crank arm (front) pivot

Lubricate the lift arm cylinder pin (Fig. 25) with Spec. 100-3. Pump grease into the fitting until old grease can be observed coming out.

Lubricate the crank arm (front) pivot (Fig. 25) with Spec. 100-3. Pump grease into the fitting until old grease can be observed coming out.

______________________________________________________________ A6474X231 VSVI / 03 5.47

Maintenance _________________________________________________ Fig. 25: Grease points

Drill head face plate

Stabilizer foot cylinder pin

ATRS lift cylinder pin

ATRS oscillating link front pivot

Crank arm front pivot

Thrust (feed) cylinder pin

Drill head lift arm pin

Lift arm center pivot

Stabilizer foot cylinder pin ATRS lift arm center pivot pin ATRS lift arm pivot guide bar Carriage rollers

Thrust (feed) cylinder pin

Lift arm rear pivot

Guide arm pin

_________________________________________________________________ 5.48 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Stabilizer foot pin

________________________________________________ Maintenance blower drive belt (if equipped)

Inspect the condition and tension of blower belt (Figure 26) for wear.

Tension should be a maximum of 1/2” deflection. If adjustment is required, is adjustment procedure in this chapter. Replace belt if worn

blower drive end (if equipped)

Lubricate blower drive end (Fig. 26) through the two (2) grease fittings with Spec. 100-3 until clean grease flows from operation relief valve.

blower oil level (if equipped)

Check oil level in blower:  Remove the oil level fill/check plug (Fig. 26). The oil level should be kept at the level of the fill/check plug. Should it be necessary to add oil, add oil (Spec 100-8) through the fill/check plug hole slowly until oil flows from the hole. Do not overfill the blower.  Replace the fill/check plug.

© BUCYRUS AMERICA, INC.

Fig. 26: Blower drive belt and blower lubrication

Belt tension: 1/2” deflection here

Grease fitting

Grease fitting

Blower

Motor

Oil fill/check plug

______________________________________________________________ A6474X231 VSVI / 03 5.49

Maintenance _________________________________________________ drill box

Lubricate the drill box (Fig. 27) through the grease fittings located on top of the drill box with Spec. 100-3.

Fig. 27: Drill box grease fitting Grease fitting

torque hubs

Inspect torque hubs for wear and damage and check oil level (Fig. 28).

To check oil level: Park the roof bolter on solid level ground. Rotate wheel unit until check and fill plugs are at 3 and 9 o’clock positions. Remove check plug. Oil should just barely flow out of the check plug hole.  Should it be necessary to add oil, slowly add oil (Spec. 100-6) through the fill plug hole, just until it starts to run out of the check plug hole slowly. Replace plugs.

Fig. 28: Torque hubs

Check plug

Fill plug

Torque hub (typical 4 places)

_________________________________________________________________ 5.50 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Grease fitting

________________________________________________ Maintenance fire suppression system (if equipped)

Check the fire suppression system (Fig. 29): Inspect the hoses, fittings, and nozzles and replace any found damaged. Check the extinguisher tanks for signs of damage or corrosion. Check the nozzle openings. The slot should be packed with silicone grease. If the nozzles are open or need to be repacked, the lines should be checked for blockage and blown clear before repacking them with silicone grease. Remove the fill cap. Check that the extinguisher is filled with free-flowing Ansul multipurpose ABC dry chemical to a point not more than 3” from the bottom of the fill opening.

© BUCYRUS AMERICA, INC.

Replace the fill cap, hand tight.

Fig. 29: Fire suppression system

Actuator

Nozzle (4 places)

Actuator

Chemical tank

______________________________________________________________ A6474X231 VSVI / 03 5.51

Maintenance _________________________________________________ Weekly hydraulic pressure settings

Check hydraulic pressure settings (Fig. 30) on the gauges located in the operator’s compartment.

Fig. 30: Hydraulic pressure settings

Drill positioning and drill station pressure gauge

pump suction hose electrical system trailing cable drill box

Check of the condition of the suction hose on the pump. Replace damaged or worn hose as necessary.

Check the electrical system for permissibility.

Unreel the trailing cable and carefully check its condition. Replace trailing cable is excessively worn or damaged.

Drain and replace oil in drill box (Fig. 31):  Fill drill box to level of fill plug with clean light mineral oil.  Run gear box for five minutes.  Drain and refill with 40W non-detergent oil.

Fig. 31: Drill box

Fill/check plug

_________________________________________________________________ 5.52 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Main system pressure gauge

________________________________________________ Maintenance WARNING! Extreme caution must be observed when working inside the electrical controller to prevent electrical shock. All safety procedures must be followed. Failure to follow safety procedures may lead to serious injury or death. explosion proof housings

Inspect the explosion proof housings (Fig. 32):  Remove the covers on the explosion proof housings . Make sure that all connections are tight and that the housing interiors are clan and dry.  Replace covers making sure to check for permissible fit.

© BUCYRUS AMERICA, INC.

Fig. 32: Explosion proof housings

Controller Light switch

Start switch

Start switch

______________________________________________________________ A6474X231 VSVI / 03 5.53

Maintenance _________________________________________________ hydraulic oil filter

Change the hydraulic oil filter element (Fig. 33).

Fig. 33: Hydraulic oil filter element

Element

tires and wheel mounting bolts

Check tire condition and wheel mounting bolts. The mounting bolts should be torqued to 225 ft-lbs. If equipped with pneumatic tires, check tire pressure and condition.

_________________________________________________________________ 5.54 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Dirt indicator

________________________________________________ Maintenance torque hub and ground clearance adjustment plate

Check torque hub to adjustment plate mounting bolts (8 per hub) and mounting plate to chassis frame mounting bolts (10 per plate) for tightness (Fig. 34).

Fig. 34: Torque hub and ground clearance adjustment plate

Torque hub mounting bolts (8 per hub)

© BUCYRUS AMERICA, INC.

Adjustment plate mounting bolts (10 per plate)

blower shaft bearing (if equipped)

Lubricate the blower shaft bearing with Spec. 100-3. Grease until clean grease flows from relief.

______________________________________________________________ A6474X231 VSVI / 03 5.55

Maintenance _________________________________________________ Every three months blower (drive end) (if equipped)

Lubricate the blower drive end (Fig. 35) with Spec. 100-3 until clean grease flows from the operation relief valve.

Fig. 35: Blower (drive end)

Grease fitting

Belt tension: 1/2” deflection here

© BUCYRUS AMERICA, INC.

Operation relief valve

Grease fitting

Blower

Motor

Oil fill/check plug

_________________________________________________________________ 5.56 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

________________________________________________ Maintenance torque hub

Replace oil in the torque hubs (Fig. 36): Park the roof bolter on solid level ground.  Rotate wheel unit until drain plug is at the 6 o’clock position.  Remove drain plug.  Allow oil to drain from hub. Replace drain plug.  Rotate wheel unit until check and fill plugs are at 3 o’clock and 9 o’clock positions. Remove check and fill plugs.  Add oil (Spec. 100-6) through the fill plug hole slowly, just until it starts to run out of the check plug hole slowly.

© BUCYRUS AMERICA, INC.

Fig. 36: Torque hub

Fill plug

Check plug

Torque hub (typical 4 places)

______________________________________________________________ A6474X231 VSVI / 03 5.57

Maintenance _________________________________________________ electric motor

Lubricate the electric motor armature bearings (Fig. 37) with Spec. 1003 through the two grease fittings located on each end of the motor.

Pump only one or two pumps of grease into each fitting.

NOTICE! Incorrect grease or over greasing may cause serious damge to the electric motor.

Fig. 37: Electric motor bearings

Grease fitting

_________________________________________________________________ 5.58 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Grease fitting

________________________________________________ Maintenance hydraulic oil and suction strainer

Change hydraulic oil and clean or replace the hydraulic oil strainer inside the hydraulic oil tank (Fig. 38): Remove drain plug and drain old oil from tank.  Replace drain plug.  Clean all dirt and debris from around the hydraulic tank cap and cover assembly.  Remove the bolts that secure the cover to the tank.  Reaching down into the tank, unscrew the suction strainer and remove it from the tank.  If the strainer is not torn or damaged, it can be cleaned using kerosene and a soft brush and dried thoroughly. If the strainer is damaged, it must be replaced.

© BUCYRUS AMERICA, INC.

 Replace strainer in tank and tighten hand tight.  Re-install the cap and cover assembly.  Refill the oil tank to the proper level with Spec 100-1.

Fig. 38: Hydraulic oil and suction strainer Fill cap

Cover bolts

Drain plug Strainer

______________________________________________________________ A6474X231 VSVI / 03 5.59

Maintenance _________________________________________________ cable reel assembly

Inspect the cable reel collecting rings, contactor points, brushes, and bearings (Fig. 41). Clean and repack bearings when reel is disassembled.

Fig. 41: Cable reel assembly

Drive sprocket

Ground brush assembly Main shaft

Packing

Outer bearing

Collector ring Inner bearing

Packing gland

_________________________________________________________________ 5.60 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Cable

____________________________________ Replacement of wear parts Tire/wheel installation procedure The following installation procedures are for general guidance when installing a tire/ wheel assembly (Fig. 42) on most underground mining machines. Any use made of the advisory information contained herein is entirely within the control and discretion of the user and is wholly voluntary.

© BUCYRUS AMERICA, INC.

Fig. 42: Tire/ wheel assembly

WARNING! Mixing parts of different design or from a variety of sources for wheels with pneumatic tires could cause severe injury or death. tire/wheel stresses

Rubber tired underground mining machinery is routinely subject to severe abuse due to the conditions in which it is operated. Whether a primary haulage or utility/support vehicle, all are subject to extreme shock, vibration, temperature change and various other loads and stresses that cause maintenance problems. One such problem is found in tire/wheel assemblies.

Many maintenance personnel view installing a tire/wheel assembly on a machine as a relatively simple task. However, if a few simple rules on proper installation are not followed, unnecessary difficulties may be experienced. Tires act like shock absorbers on haulage and support vehicles, transferring cushioned loads to the wheels. Even after proper installation, periodic checks need to be made to insure that tire/wheel assemblies do not loosen, causing wheel studs to break or damaging the mounting bolt pattern.

wheel mounting arrangements

Various mounting arrangements between the wheel and hub or wheel end are used by manufacturers. One of the more common is the taperlock. This arrangement requires a taper on both wheel and hub where the mating surfaces of the taper carry the loads. Incomplete seating of the taper will allow the wheel to loosen, resulting in stud or bolt shear and possible tire/wheel damage.

______________________________________________________________ A6474X231 VSVI / 03 5.61

Replacement of wear parts _____________________________________ Another mounting arrangement is based on holding a very close pilot fit where the tolerance between the wheel and hub is very tight, requiring a clamp-load force to hold the wheel securely in place. If the wheel studs or bolts are allowed to loosen, the load will be transmitted to them, resulting in sheared studs or bolts.

Periodic wheel inspection is critical to the life cycle of a tire/wheel assembly. A fractured wheel, broken bolt pattern and missing or broken wheel studs are all contributors to tire/wheel failures. Problems in these areas occur as the result of repeated cyclical loading as the tire/wheel unit rotates during machine travel. Haulage vehicles loaded unevenly, downhill hauls with high speed turns, or operating a vehicle with one tire of a dual assembly damaged or flat are some examples of conditions that produce damaging high stresses in wheel assemblies. Also, the effects of corroding or poorly fitted mating parts can produce surface irregularities that result in cracks and ultimate failure of a wheel.

A most common problem with tire/wheel installations is the incorrect tightening of wheel bolts or studs. Threaded fasteners perform there function of holding things together better when torque control is used in their tightening. Using an accurate torque wrench correctly is the best and most practical way of securing fasteners, Although torque value charts are available as a reference guide to proper tightening, OEM specifications should always be followed when tightening fasteners.

However, proper torque values are of little benefit if certain other factors are not considered. wheel mounting tips

All fasteners should be examined before use. Any fastener that is worn, bent or has damaged threads should be replaced. Fastener threads should also be lightly coated with a protective substance, such as residual oils, wax or loctite, because any oxidation or rust will upset the torque-to-tension relationship.

Mating surface conditions should also be considered. The tightening surface under the bolt or nut should be carefully inspected. A fastener, when tightened against a softer material, will gall under these conditions, and much of the applied torque may be lost through head friction.

It is very important when using higher strength fasteners to have a smooth, even surface under the bolt head. In some cases, hard flat washers and most lockwashers will provide a good tightening surface.

An other area of concern is cleanliness. All mating surfaces should be free of rust, dirt, oil, paint, etc. Also no paint of any kind should exist between a fastener and wheel disc surface. Any form of contamination between these surfaces will most likely lead to serious wheel problems.

WARNING! When torquing any wheel bolt pattern, always torque in a triangular pattern.

_________________________________________________________________ 5.62 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

problem areas

____________________________________ Replacement of wear parts Recommended wheel mounting procedures  All steel mating surfaces must be free and clean of any dirt, corrosion, paint, etc. These areas include wheel/hub tapers and disc faces. NO PAINT should be present under bolt heads or nuts.  Fasteners should be in proper condition. Any fastener with damage, such as corrosion, bending or worn threads, should be replaced. Replace all broken wheel studs.  After positioning the wheel on the hub, tighten nuts down evenly.

Triangulate the bolt pattern tightening sequence as shown in the diagrams (Fig. 43 and 44).  After operating the machine for a short period of time, check the wheel-mounting bolts or nuts for proper torque.

© BUCYRUS AMERICA, INC.

IMPORTANT! Wheel bolts or nuts “seat in” during normal vehicle operation.

Therefore, it is necessary to repeat torquing procedures as necessary to seat the wheel to the hub. Planned periodic checks will help maintain correct torque values. All bolts and nuts, regardless of type, should be regularly checked for tightness.

Fig. 43: Triangular bolt pattern

Fig. 44: Torque patterns

______________________________________________________________ A6474X231 VSVI / 03 5.63

Replacement of wear parts _____________________________________ PRECAUTIONS: WARNING! Do not install or remove tire/wheel assemblies from a machine without proper training.

WARNING! Check wheel components periodically for cracks or broken parts.

Replace all cracked, badly worn, damaged or severely rusted components. When in doubt replace.

WARNING! Do not, under any circumstances, attempt to rework, weld, heat or braze any wheel components that are cracked, broken or damaged. Replace such components with new OEM parts of the correct size and type.

WARNING! Replace broken studs and each unbroken stud next to the broken one.

WARNING! Replace all damaged wheel studs or bolts.

_________________________________________________________________ 5.64 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

WARNING! Mixing wheel parts of different design or from a variety of sources is potentially dangerous.

_______________________________________________________________

6

Technical data

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_______________________________________________ Technical data

Technical data This chapter contains the most important technical data on the Roof Bolter ®. Further data can be found in the spare parts lists. At the end of this chapter you will find information on the bolt tightening torques, HFA fluids, greases, etc. Read this chapter through carefully and pay particular attention in particular to the safety instructions.

The technical data listed in this chapter is for stock machines only. Customer specials may not be listed.

Components of the LRB-15AR Roof Bolter Technical data sheet

© BUCYRUS AMERICA, INC.

general

Overall length with ATRS: Chassis overall width: Drill boom feed: Minimum tramming height with 26X7-12 tires: ATRS reach with 26X7-12 tires: Ground clearance with 26X7-12 tires: Chassis height with 26X7-12 tires: Wheelbase: Tram speed (fast): Tram speed (slow): Drilling feed thrust (maximum): Drilling torque (variable): Bolt tightening torque (adjustable):

approx. 14’ 10” approx. 6’ 2” approx. 4’ 2” approx. 2”8” approx. 6’4” approx. 6” approx. 2’2 approx. 3’ 6” approx. 0-130 fpm approx. 0-60 fpm approx. 7,000 lbs approx. 280 ft-lbs approx. 200 ft-lbs

______________________________________________________________ A6474X231 VSVI / 03 6.3

© BUCYRUS AMERICA, INC.

Technical data ________________________________________________

_________________________________________________________________ 6.4 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

___________________________________________ Tightening torques Tightening torques IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled.

The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

Set screws

© BUCYRUS AMERICA, INC.

Table 2: Set screws (Socket long-lok) Nominal diameter

Recommended torque setting

#6

6 in-lbs

#8

9 in-lbs

#10

13 in-lbs

¼”

30 in-lbs

5/16”

5 ft-lbs

3/8”

8 ft-lbs

7/16”

11 ft-lbs

½”

16.7 ft-lbs

Table 3: Set screws (Socket standard steel) Nominal diameter

Recommended torque setting

#6

9 in-lbs

#8

16 in-lbs

#10

30 in-lbs

¼”

6 ft-lbs

5/16”

12 ft-lbs

3/8”

18 ft-lbs

7/16”

29 ft-lbs

½”

43 ft-lbs

5/8”

100 ft-lbs

¾”

146 ft-lbs

7/8”

199 ft-lbs

1”

262 ft-lbs

______________________________________________________________ A6474X231 VSVI / 03 6.5

Tightening torques ____________________________________________ Table 4: FSR hex bolts (SAE 5 and 325 steel) Recommended torque setting

¼”

9 ft-lbs

5/16”

18 ft-lbs

3/8”

31 ft-lbs

7/16”

50 ft-lbs

½”

75 ft-lbs

9/16”

110 ft-lbs

5/8”

150 ft-lbs

¾”

250 ft-lbs

7/8”

378 ft-lbs

1”

583 ft-lbs

1 1/8”

782 ft-lbs

1 ¼”

1,097 ft-lbs

1 3/8”

1,461 ft-lbs

1 ½”

1,748 ft-lbs

1 ¾”

3,114 ft-lbs

2”

4,504 ft-lbs

2 ¼”

6,497 ft-lbs

2 ½”

7,144 ft-lbs

2 ¾”

12,092 ft-lbs

3”

15,744 ft-lbs

Table 5: Socket, flat, & button head cap screws (Steel only) Nominal diameter #6 #8 #10 ¼” 5/16” 3/8” 7/16” ½” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½”

Recommended torque setting 26 in-lbs 52 in-lbs 6 ft-lbs 14 ft-lbs 30 ft-lbs 50 ft-lbs 81 ft-lbs 121 ft-lbs 240 ft-lbs 395 ft-lbs 629 ft-lbs 964 ft-lbs 1,523 ft-lbs 2,121 ft-lbs 2,843 ft-lbs 3,402 ft-lbs

_________________________________________________________________ 6.6 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Nominal diameter

___________________________________________ Tightening torques Table 6: Untreated screw, black finish (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M3 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.60

1.37

2.70

4.5

7.8

11

22

Ft-lbs

0.44

1.01

1.99

3.3

5.6

8.1

16

Nm

1.37

3.10

6.15

10.5

17.5

26

61

Ft-lbs

1.01

2.29

4.54

7.7

12.9

19

37

Nm

1.92

4.40

8.55

15

25

36

72

Ft-lbs

1.42

3.25

6.38

11

18.4

26

53

Nm

2.30

5.25

10.4

18

29

43

87

Ft-lbs

1.70

3.87

7.6

13

21.3

31

64

© BUCYRUS AMERICA, INC.

Table 6: Untreated screw, black finish (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M12 M14 M16

Nominal diameter M18

M20

M22

M24

Nm

39

62

85

130

184

250

315

Ft-lbs

28

45

70

95

135

184

232

Nm

89

141

215

295

420

570

725

Ft-lbs

65

103

158

217

308

420

634

Nm

125

198

305

420

690

800

1020

Ft-lbs

92

146

224

309

435

590

752

Nm

150

240

365

500

710

960

1220

Ft-lbs

110

177

269

368

523

708

899

Table 6: Untreated screw, black finish (Coarse thread, continued) Property class

Torque Ma

5.6 8.8 10.9 12.9

Recommended torque setting M27 M30

Nominal diameter M33

M36

M39

Nm

470

635

865

1111

1440

Ft-lbs

346

468

637

819

1062

Nm

1070

1450

1970

2630

3290

Ft-lbs

789

1069

1452

1885

2428

Nm

1510

2050

2770

3560

4620

Ft-lbs

1113

1511

2042

2625

3407

Nm

1810

2450

3330

4280

5550

Ft-lbs

1334

1606

2455

3156

4093

______________________________________________________________ A6474X231 VSVI / 03 6.7

Tightening torques ____________________________________________ Table 7: Untreated screw, black finish (Fine thread) Property class

Torque Ma

8.8 10.9 12.9

Recommended Nominal diameter torque setting M8 X 1 M10 X 1.25 M12 X 1.25

Nm

27

52

95

Ft-lbs

19

38

70

Nm

38

73

135

Ft-lbs

28

53

99

Nm

45

88

160

Ft-lbs

33

64

118

Property class

Torque Ma

8.8 10.9 12.9

Recommended Nominal diameter torque setting M14 X 1.5 M16 X 1.5 M18 X 1.5

Nm

150

225

325

Ft-lbs

110

165

239

Nm

210

315

460

Ft-lbs

154

232

339

Nm

260

380

550

Ft-lbs

184

280

405

Table 7: Untreated screw, black finish (Fine thread, continued) Property class

Torque Ma

8.8

Nm

Recommended Nominal diameter torque setting M20 X 1.5 M22 X 1.5 M24 X 2 399

Ft-lbs 10.9 12.9

610

780

449

575

Nm

640

860

1100

Ft-lbs

472

634

811

Nm

770

1050

1300

Ft-lbs

567

774

958

_________________________________________________________________ 6.8 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Table 7: Untreated screw, black finish (Fine thread, continued)

___________________________________________ Tightening torques Table 8: Electrically zinc plated (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M33 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.56

1.28

2.50

4.3

7.1

10.5

21

Ft-lbs

0.41

0.94

1.84

3.1

5.2

7.7

15

Nm

1.28

2.90

5.75

9.9

16.5

24

48

Ft-lbs

0.94

2.14

4.24

7.3

12.1

17.7

35

Nm

1.80

4.10

8.10

14

23

34

67

Ft-lbs

1.33

3.02

5.97

10.3

16.9

25

49

Nm

2.15

4.95

9.70

16.5

27

40

81

Ft-lbs

1.59

3.65

7.15

12.1

19.9

29

59

© BUCYRUS AMERICA, INC.

Table 8: Electrically zinc plated (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M12 M14 M16

Nm

36

Ft-lbs

26

42

Nm

83

132

Ft-lbs

61

97

58

Nominal diameter M18

M20

M22

121

171

230

54

89

126

169

200

275

390

530

147

202

287

390

88

Nm

117

185

285

390

550

745

Ft-lbs

86.2

136

210

287

405

549

Nm

140

220

340

470

660

890

Ft-lbs

103

162

250

346

486

656

Table 8: Electrically zinc plated (Coarse thread, continued) Property class 5.6

8.8

10.9

12.9

Torque Ma

Recommended torque setting M24 M27 M30

Nominal diameter

Nm

295

435

590

800

1030

1340

Ft-lbs

217

320

435

590

759

988

Nm

675

995

1350

1830

2360

3050

Ft-lbs

497

733

995

1349

1740

2249

Nm

960

1400

1900

2680

3310

4290

Ft-lbs

708

1032

1401

1902

2441

3163

Nm

1140

1680

2280

3090

3980

5150

Ft-lbs

840

1239

1661

2278

2935

3798

______________________________________________________________ A6474X231 VSVI / 03 6.9

Tightening torques ____________________________________________ Table 9: Electrically zinc plated (Fine thread) Property class 8.8 10.9 12.9

Torque Ma Nm Ft-lbs Nm Ft-lbs Nm Ft-lbs

Recommended torque setting M8 X 1 25 18 35 25 42 30

Nominal diameter M10 X 1.25 49 36 68 50 82 60

M12 X 1.25 88 84 125 92 150 110

Table 9: Electrically zinc plated (Fine thread, continued)

8.8 10.9 12.9

Torque Ma

Recommended torque setting M14 X 1.5

Nominal diameter M16 X 1.5

M18 X 1.5

Nm

140

210

305

Ft-lbs

103

154

224

Nm

195

295

425

Ft-lbs

143

217

313

Nm

235

350

510

Ft-lbs

173

258

376

Table 9: Electrically zinc plated (Fine thread, continued) Property class 8.8 10.9 12.9

Torque Ma

Recommended torque setting M20 X 1.5

Nominal diameter M22 X 1.5

M24 X 2

Nm

425

570

720

Ft-lbs

313

420

531

Nm

600

800

1000

Ft-lbs

442

590

737

Nm

720

960

1200

Ft-lbs

531

708

885

_________________________________________________________________ 6.10 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Property class

___________________________________________ Tightening torques Table 10: Hex and socket headcap screws, coarse thread (Grade 8)

© BUCYRUS AMERICA, INC.

Nominal diameter ¼” 5/16” 3/8” 7/16” ½” 9/16” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½”

Recommended torque setting (lubed) 8 ft-lbs 16 ft-lbs 28 ft-lbs 45 ft-lbs 70 ft-lbs 99 ft-lbs 135 ft-lbs 240 ft-lbs 390 ft-lbs 545 ft-lbs 830 ft-lbs 1,160 ft-lbs 1,525 ft-lbs 2,030 ft-lbs

Recommended torque setting (dry) 13 ft-lbs 26 ft-lbs 47 ft-lbs 75 ft-lbs 115 ft-lbs 165 ft-lbs 225 ft-lbs 400 ft-lbs 645 ft-lbs 905 ft-lbs 1,380 ft-lbs 1,935 ft-lbs 2,540 ft-lbs 3,380 ft-lbs

______________________________________________________________ A6474X231 VSVI / 03 6.11

© BUCYRUS AMERICA, INC.

Tightening torques ____________________________________________

_________________________________________________________________ 6.12 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

___________________________________________ Permissible media Permissible media Lubrication fluids and greases

© BUCYRUS AMERICA, INC.

NOTICE! Use only lubrication fluids and greases approved by Bucyrus America, Inc.! These fluids and greases have been tested at Bucyrus America, Inc. and guarantee reliable operation of the mechanical and hydraulic functions of the machine.

IMPORTANT! The lubrication fluids and greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed fluids and greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases and fluids having the same specification base but different origins.

In case of doubt, the manufacturer of the lubrication to be used should be contacted as to the compatibility of the lubrication in question.

IMPORTANT! Bucyrus America, Inc. expressly point out that the approval of the listed products relates only to the pure technical use in our mechanical and hydraulic systems. The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

IMPORTANT! Be sure to use the manufacturer’s instructions for use.

NOTICE! When performing maintenance on the machine, all used oil and lubricants should be disposed of per your local EPA standards.

______________________________________________________________ A6474X231 VSVI / 03 6.13

Permissible media ____________________________________________ Approved suppliers:

Supplier

Brand name

1

Amoco Oil Company

Amoco AW Oil No.68

2

Gulf Oil

Harmony 68 AW

3

Mobil Oil Corporation

Mobil DTE-16

4

Chevron U.S.A.

5

Sun Oil Company

Chevron hydraulic Oil Aw ISO 68 Sunvis 868

6

Unocal 76

Unax AW 68

7

Shell Oil Company

Shell Hydraulic Oil #33

8

Century Lubricating Oils, Inc.

Hyldraulic AW 68

9

Atlantic Richfield Company

Duro AW S-315 Oil

10

Texaco Lubricants Company

Texaco Rando Oil HD 68

11

Exxon

Nuto 68

12

Pennzoil

Pennzbell AW 68 Hydraulic Oil

13

14

Standard Oil Company Standard Oil Co. of Ohio Boron Oil Company BP Oil Inc. Lubricating Engineers

Industron 54 Industron 53 Energol HLP-C68 6120 Monolec Hydraulic Oil

15

Conoco Inc.

Super Hydraulic oil 68

16

Hydrotex

Systems 5K 68

17

Phillips

Maginus A Oils 81350

18

Miners Oil

Hydraulic Oil 68AW

_________________________________________________________________ 6.14 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Table 11: Anti-wear hydraulic oil (Spec 100-1)

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 12: Extreme pressure gear oils (Spec. 100-2) Supplier

Brand name

1

Amoco Oil Company

Amoco Permagear EP 460

2

Gulf Oil

EP Lubricant HD 460

3

Mobil Oil Corporation

4

Chevron U.S.A.

5

Sun Oil Company

Mobil Gear 634 Mobil Gear 636 Chevron Gear Compound EP ISO 460 Sunep 460

6

Unocal 76

7

Shell Oil Company

8

Century Lubricating Oils, Inc.

9

Texaco Lubricants Company

Hulbest EP-7 Powergear 460 Meropa 680

10

Exxon

Spartan EP 460

11

Pennzoil

Super Maxol EP 460 Gear Lube Super Maxol EP 460 Gear Lube

12

Lubricating Engineers

13

Conoco Inc.

608 Almosal Vari-Purpose Gear Lubricant Gear oil 460

14

Hydrotex

933 Industrial Gear Lubricant

15

Phillips

16

Miners Oil

All Purpose Gear Oil 85W-90 5EP Gear Oil EP460

Extra Duty NL Gear Lube 7 EP Extra Duty NL Gear Lube 8 EP Shell Omala 680

______________________________________________________________ A6474X231 VSVI / 03 6.15

Permissible media ____________________________________________

Supplier

Brand name

1

Amoco Oil Company

2 3 4

Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6 7 8

Sun Oil Company Unocal 76 Shell Oil Company Century Lubricating Oils, Inc.

9 10 11 12

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers

13

Conoco Inc.

14 15 16

Hydrotex Phillips Atlantic Richfield

Amolith grease 2 EP Rykon Premium Grease 2 EP Gulfcrown grease EP#2 Mobilux EP-2 Chevron Dura-Lith Grease EP-2 NLGI 2 Sun Prestige 742EP Multiplex EP2 Alvania EP-2 Hullith EP2 Multipurpose Grease or Replex2 or Uniwrl 2 or Uniwrl EMB or Hullith GP 2 or Hullith EP 2 Texaco Multifak EP 2 Lidok EP 2 Pennlith EP 712 Grease 3752 Almagard Vari-Purpose Lubricant EP Conolith grease No. 2 or Super Sta Grease No. 2 LC-65 Hyplex Philube EP Grease Litholine H EP-2 Grease

Table 14: Semi-fluid grease (Spec. 100-4)

1 2 3 4 5 6

Supplier Texaco Lubricants Company Century Oils Limited Hydrotex Pennzoil Unocal Exxon

Brand name Novatex EP 000 Joy Loader Semi-Fluid grease MPD-60 Ultra E.P. 000 Semi-Fluid 760 Grease MM Grease Lidok E.P. 000

_________________________________________________________________ 6.16 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Table 13: Extreme pressure motor bearing grease (Spec. 100-3)

___________________________________________ Permissible media Table 15: Invert emulsion hydraulic fluid (Spec. 100-5)

1 2 3 4

Supplier Unocal 76 Conoco Inc. Atlantic Richfield Company Brooks Oil Company

5 6

Cincinnati – Vulcon Company Cities Service Oil company

7 8

Century Oils Limited Fiske Bros. Refining Company Getty Oil Company (Veedol, Tidewater) Gulf Oil Company E.F. Houghton

9

© BUCYRUS AMERICA, INC.

10 11 12 13 14 15 16 17 18 19 20 21

Century Lubricating Oils Imperial Oil and Grease Mobil Oil Corporation National Oil and Chemical Co. Pennzoil Quaker Chemical Company Henery E. Sanson and Sons MFGE Company Southwest Grease and Oil Company, Inc. Southwest Petroleum Corp.

22 23

Standard Oil Company of Ohio (Boron Sohio) Sun Oil Company Tower Oil Company

24 25

Wynn Oil Company Lubrication Engineers

26

Hydrotex

Brand name FR Fluid FR Hydraulic Fluid Duro FR-HD Brooks fire Resistant Hydraulic Fluid B Vulcon FR Fluid #1 Citgo Pacemaker Invert FR Fluid Aquacent Light Lubriplate HO-Retard Veedol Auburn FRH FR Fluid Houghto-Safe 5046 Houghto-Safe 5046W Hulsafe 600 Astrol 587 Pyrogard D Erifon 1, 2, and 3 Maxmul FRP/G Quintolubric 958 Series Quintolubric 958 Series Hydra-Mul Premium Emulsion Fluid Invert Emulsion fire resistant Hydraulic Fluid Swepco Fire Resistant Hydraulic oil #718 Staysol FR

Sunsafe F Safoil Anti-Wear Hydraulic Fluid Hydra-Safe heavy Medium 6455 Monolec Fire Resistant hydraulic Fluid HY-Guard

______________________________________________________________ A6474X231 VSVI / 03 6.17

Permissible media ____________________________________________

Supplier

Brand name

1

Amoco Oil Company

Amoco Premagear EP 320

2

Gulf Oil

EP Lubricant HD 320

3

Mobil Oil Corporation

Mobil gear 632

4

Chevron U.S.A.

5

Sun Oil Company

Chevron gear compound EP ISO 320 Sunep 320

6

Unocal 76

Extra Duty NL Gear Lube 6EP

7

Shell Oil Company

Omala 75

8

Century Lubricating Oils, Inc.

Hulbest EP-6

9

Texaco Lubricants Company

Meropa 320

10

Exxon

Spartan EP 320

11

Pennzoil

Super Maxol EP 220 Gear Lube

12

Lubricating Engineers

13

Conoco Inc.

605 Almasol Vari-Purpose Gear Lubricant Gear Oil 320

14

Hydrotex

932 Industrial Gear Lube

15

Phillips

16

Atlantic Richfield

Philube All Purpose Gear Oil 85W-90 Pennant NL S-1000

17

Cities Service

Citgo EP Compound 110

18

Pennzoil

Pen Gear #320

19

Miner Oil

Gear Oil EP220

20

Texaco, Lubricants Company

Texaco Multigear EP 80W-90

_________________________________________________________________ 6.18 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Table 16: Extreme pressure gear oil, SAE 90 (Spec. 100-6)

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 17: Hydraulic and general purpose oil medium-heavy/R&O inhibited (Spec. 100-7) Supplier Brand name 1

Amoco Oil Company

American Industrial Oil No. 68

2

Gulf Oil

Harmony 68

3

Mobil Oil Corporation

DTE Heavy – Medium

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Turbine Oil ISO 68 or Chevron Machine Oil R&O ISO 68 Sunvis 754

6

Unocal 76

7

Shell Oil Company

Unax RX68 or Turbine Oil 68 Turbo 68

8

Century Lubricating Oils, Inc.

Centraulic R&O 68

9

Texaco Lubricants Company

Regal Oil R&O N-68

10

Exxon

Tresstic 68

11

Pennzoil

Pennzbell RO 68

12

Lubricating Engineers

6120 Monolec Turbine Oil

13

Conoco Inc.

14

Hydrotex

Detol R&O 68 or Turbine Oil 68 Systems 1, System 5K 68

15

Atlantic Richfield

Duro 5.315

16

Cities Service

Citgo Pacemaker A/W68

17

Miner Oil

Hydraulic Oil AW68

18

Texaco, Lubricants Company

TDH 1893

______________________________________________________________ A6474X231 VSVI / 03 6.19

Permissible media ____________________________________________

1

Amoco Oil Company

American Industrial oil No. 150

2

Gulf Oil

Harmony 150

3

Mobil Oil Corporation

DTE Oil EX. Heavy

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Machine Oil AW ISO 150M or Chevron Machine Oil R&O ISO 150 Sunvis 961

6

Unocal 76

7

Shell Oil Company

Unax RX 700 or Turbine Oil 700 Turbo 150

8

Century Lubricating Oils, Inc.

Centraulic R&O 150

9

Atlantic Richfield Company

10

Texaco Lubricants Company

Duro 600 or S-700 Regal Oil R&O 150

11

Exxon

Teresstic 150

12

Pennzoil

Pennzbell RO 150

13

Cities Service

Citgo Pacemaker 150

14

Lubrication Engineers

6405 Monolec Turbine Oil

15

Conoco Inc.

Dectol R&O 76

16

Hydrotex

System 1 150, System 5k 150

17

Phillips

Magnus Oils 700

18

Miner Oil

ISO 150

Table 19: Worm gear lubricant, compounded cylinder oil (Spec. 100-9) Supplier Brand name 1 Amoco Oil Company Cylinder oil No. 1000 2 Mobil Oil Corporation Extra Hecla Super Cylinder Oil 3 Chevron U.S.A. Chevron Cylinder Oil W ISO 1000 4 Sun Oil Company Sun Steam Cylinder Oil 5 Unocal 76 Worm gear Lube 250 or Stevalc 6 Century Lubricating Oils, Inc. Garwal 680 7 Atlantic Richfield Company Modoc 195 8 Texaco Lubricants Company 650 T Cylinder Oil 1000 9 Exxon Cylesstic TK-1000 10 Pennzoil Cylinder Oil #1000 11 Conoco Inc. Inca Oil 1000

_________________________________________________________________ 6.20 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

© BUCYRUS AMERICA, INC.

Table 18: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8) Supplier Brand name

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 20: Light gear oil, SAE 40 motor oil (Spec. 100-10)

1 2 3 4

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6 7

Sun Oil Company Unocal 76 Shell Oil Company

8 9 10

Century Texaco Lubricants Company Exxon

11 12 13

Pennzoil Lubricating Engineers Conoco Inc.

14 15

Hydrotex Phillips

Brand name Amoco 300 SAE 40 Super Duty 40 Delvac 1340 Chevron RPM Heavy Duty Motor Oil 15W-40 Sunoco Super C 40 Guardol Motor Oil SAE 40 Rotella Oil 40 (Automotive) Turbo Oil 150 (Industrial) Rimula CT40 (Foreign) Rotela SX40 (Foreign) Flexe SAE 40 Ursa Super plus SAE 40 XD-3 Extra SAE 40 or XD-3 SAE 40 Long Life SAE 40 Motor Oil 8440 Monolex GFS Engine Oil Fleet Heavy Duty Motor Oil SAE 40 Hyfilm SAE 40 Super HD II Motor Oil SAE 15W-40

Table 21: Synthetic EP gear lubricants (Spec. 100-11)

1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

Table 22: Multi-purpose tractor hydraulic fluid (Spec. 100-12)

1 2 3 4

Supplier Exxon / Mobil Century / Fuchs Shell Chevron

Brand name Mobilfluid 424 Multitran Donax TD Tractor Hydraulic Fluid

5 6 7

BP Lubricants Quaker State Conoco

Tractran UTH Quaker State FCI HD Powertran Fluid

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Permissible media ____________________________________________ Table 23: Synthetic EP gear lubricants (Spec. 100-13) Brand name Powergear H680

© BUCYRUS AMERICA, INC.

1

Supplier Fuchs

_________________________________________________________________ 6.22 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter

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7

For your information

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_________________________________________________ Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

© BUCYRUS AMERICA, INC.

Service address Beckley, WV 200 George Street, Suite 4 Beckley, WV 25801 Phone: (304) 256-5927 Fax: (304) 256-5928

Craig, CO 400 Mack Lane Craig, CO 81625 Phone: (970) 824-3249 Fax: (970) 824-8851

Duffield, VA P.O. Box 847 6808 Fraley Avenue Duffield, VA 24244 Phone: (276) 431-7000 Fax: (276) 431-2464

Houston, PA 2045 West Pike Street Houston, PA 15342 Phone: (724) 743-1200 Fax: (724) 743-1201

Carrier Mills, IL 9580 State Route 13 West Carrier Mills, IL 62917 Phone: (618) 982-9000 Fax: (618) 982-9912

Oak Hill, WV P.O. Box 60 843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450

Paonia, CO P.O. Box 566 719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846

Washington, PA 255 Berry Road Washington, PA 15301 Phone: (724) 743-1200 Fax: (724) 228-2177

Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

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Our service __________________________________________________ Rebuild facility address Huntington, UT P.O. Box 1190 Route 10, 1Mile North Huntington, UT 84528 Phone: (435) 687-9831 Fax: (435) 687-2522

Norris City, IL 635 Illinois Highway 1 Norris City, IL 62869 Phone: (618) 378-3441 Fax: (618) 378-3106

© BUCYRUS AMERICA, INC.

Pearisburg, VA P.O. Box 463 222 Industrial Park Drive Pearisburg, VA 24134 Phone: (540) 921-2111 Fax: (540) 921-2711

_________________________________________________________________ 7.4 Bucyrus America, Inc. – Model LRB-15AR Roof Bolter