CAT Operation Preventive Maintenance & Service Guide Bucyrus LRB-15AR Roof Bolter - PDF DOWNLOAD

OPERATION, PREVENTIVE MAINTENANCE, AND SERVICE GUIDE

MODEL LRB-15AR ROOF BOLTER

THIS GUIDE CONTAINS IMPORTANT OPERATION AND SAFETY INFORMATION AND SHOULD BE KEPT AVAILABLE TO THOSE PERSONNEL INSTALLING AND OPERATING THIS EQUIPMENT.

P/N A6474X231 Revision 2, December 2007  BUCYRUS AMERICA, INC. 2007 ALL RIGHTS RESERVED

Bucyrus America, Inc. ________________________________________________________________ 4041 Wurno Road Telephone: 540-980-4530 Pulaski, VA 24301 Fax: 540-994-3763 Internet: www.bucyrus.com

Bucyrus America, Inc.

TABLE OF CONTENTS Page PREFACE ............................................................................................................................................... 1 SYMBOLS AND SPECIAL NOTATIONS ................................................................................................ 2 MAJOR HAZARDS ................................................................................................................................. 4 SAFETY PRECAUTIONS AND GUIDELINES ......................................................................................... 6 OVERVIEW ......................................................................................................................................... 6 PRE-START INSPECTION .................................................................................................................. 6 STARTING .......................................................................................................................................... 6 OPERATING........................................................................................................................................ 6 STOPPING .......................................................................................................................................... 7 MAINTENANCE................................................................................................................................... 7 INTRODUCTION ..................................................................................................................................... 8 GENERAL INFORMATION ..................................................................................................................... 9 PURPOSE OF THIS GUIDE ................................................................................................................. 9 OPERATION - FAMILIARZATION ........................................................................................................ 9 CONTROLS AND INDICATORS ........................................................................................................... 10 OPERATOR’S COMPARTMENT CONTROLS AND INDICATORS ..................................................... 10 DRILL POSITIONING CONTROLS AND INDICATORS ...................................................................... 15 DRILL STATION CONTROLS AND INDICATORS .............................................................................. 17 CONTROLLER SWITCHES ............................................................................................................... 19 DRIVE ASSEMBLY ............................................................................................................................ 20 OPERATION ......................................................................................................................................... 21 PRELIMINARY CHECKS ................................................................................................................... 21 BEFORE OPERATING MACHINE...................................................................................................... 21 TO OPERATE MACHINE ................................................................................................................... 22 DRILLING ............................................................................................................................................. 25 DRILLING INSTRUCTIONS ............................................................................................................... 25 EXTENSION STEELS SELECTION ................................................................................................... 27 DRILLING WITH EXTENSION STEELS ............................................................................................. 28 DRILL OPTIONS AND ADJUSTMENTS ............................................................................................. 30 INSTALLATION OF MECHANICALLY ANCHORED ROCK BOLTS .................................................... 31 INSTALLATION OF FULLY GROUTED RESIN BOLTS ...................................................................... 33 SHUTDOWN PROCEDURE .................................................................................................................. 35 SAFETY PRECAUTIONS FOR UNDERGROUND USE ........................................................................ 36 GENERAL DRILLING AND BOLTING SAFETY .................................................................................. 36 TRAMMING SAFETY RULES ............................................................................................................ 36 SHUTTING DOWN THE ROOF BOLTER ........................................................................................... 37 TOWING A DISABLED MACHINE ........................................................................................................ 38 MAINTENANCE .................................................................................................................................... 39 I

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GENERAL MAINTENANCE INSTRUCTIONS..................................................................................... 39 BEFORE MAINTENANCE OR SERVICING: ....................................................................................... 39 MAINTENANCE CHECK LIST .............................................................................................................. 40 PERIODIC MAINTENANCE PROCEDURES......................................................................................... 41 EVERY SHIFT ................................................................................................................................... 41 EVERY OTHER SHIFT....................................................................................................................... 46 WEEKLY............................................................................................................................................ 49 EVERY THREE MONTHS .................................................................................................................. 52 EVERY SIX MONTHS ........................................................................................................................ 54 LUBRICANT SPECIFICATIONS ........................................................................................................... 58

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PREFACE 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 Model LRB-15AR Roof Bolter. Bucyrus America reserves the right to revise models and designs without prior notice.

This Model LRB-15AR 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 Model LRB-15AR Roof Bolter 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 Model LRB-15AR Roof Bolter, without the consent of Bucyrus America, and these regulatory agencies, or any repair or replacement of parts contrary to Bucyrus America's instructions, may invalidate these approvals and render this Model LRB-15AR Roof Bolter 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 Model LRB-15AR Roof Bolter.

While this manual attempts to anticipate the most important operations and maintenance needs for this Model LRB-15AR Roof Bolter, unforeseen circumstances may arise

that have not been addressed in this manual. If any concerns or questions arise, please contact your Bucyrus America 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 nontransferable. 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. 2007 All rights reserved.

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SYMBOLS AND SPECIAL NOTATIONS Throughout this manual there are specific notations that are either UPPERCASE BOLD, UNDERLINED or ITALICIZED for the primary purpose of emphasis. Please pay special attention to such statements as they regard safety or critical maintenance installation information.

You will also see the following:

NOTICE: THIS NOTATION DENOTES A REFERENCE TO PREVIOUSLY STATED INSTRUCTIONS.

IMPORTANT: THIS SYMBOL DENOTES THAT SPECIAL ATTENTION MUST BE ADHERED TO IN THE ATTACHED STATEMENT.

CAUTION: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A CUT, BRUISE OR ABRASION.

WARNING: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A LOST TIME ACCIDENT.

DANGER: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A SERIOUS INJURY OR FATALITY.

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DANGER ONLY TRAINED AUTHORIZED PERSONNEL SHOULD OPERATE OR PERFORM MAINTENANCE ON THE MODEL LRB-15AR ROOF BOLTER. FAILURE TO ADHERE TO DANGERS, WARNINGS AND CAUTIONS, NOTED IN THIS MANUAL, COULD RESULT IN SERIOUS INJURY OR DEATH. FAILURE TO OPERATE OR MAINTAIN THIS LRB-15AR ROOF BOLTER IN STRICT ADHERENCE TO THESE INSTRUCTIONS AND WARNINGS IN THIS MANUAL COULD VOID THE WARRANTY.

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MAJOR HAZARDS AREA WHERE HAZARD CAN OCCUR

HAZARD WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED

SAFEGUARDS HOW TO AVOID THE HAZARD

ENTIRE MACHINE

Movement of machine can run over or crush body parts between machine and other objects and cause irreparable injury or death.

Keep alI people out of Hazard Zone (Figure 16). Use extreme caution when moving machine. The machine should be properly shutdown (see page 35) before the operator leaves the operator's compartment.

OPERATOR'S AREA (Cab)

Operation of machine with head, arms, or hands outside of operator's compartment could cause irreparable injury or death if body parts strike or are crushed between machine and outside objects.

Keep head, arms, hands, inside operator's compartment at alI times.

Keep the machine’s protective canopy securely in place at all times.

OPERATOR'S AREA (Positioning Controls)

Movement of machine can run over or crush body parts between machine and other objects and cause irreparable injury or death.

Boom positioning controls are for maneuvering machine between bolt holes only, never pass beyond last row of permanent supports. Machine must be operated from tram station for long distance moves.

DRILL BOOM ASSEMBLY

Drill boom could crush persons, hands, feet, or legs in between drill boom and face or rib of mine.

Rotating drill box could catch clothing, belts, tools, etc., pulling persons into the drilling assembly.

Keep alI persons, hands, feet, or Iegs away from drilling assembly during drilling operation. Machine must be properly shutdown (see page 35) before servicing and securely supported before working around or under the drill boom.

OPERATOR’S AREA (Drilling Controls)

Operation of drilling controls with head, feet, arms, or hands outside of protective canopy area, could cause irreparable injury or death if body parts are struck or crushed by falling debris.

Keep head, feet, arms, and hands, under protective canopy at alI times during bolting or drilling operations.

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MAJOR HAZARDS (Continued) AREA WHERE HAZARD CAN OCCUR

HAZARD WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED

SAFEGUARDS HOW TO AVOID THE HAZARD

UNDERNEATH DURING SERVICE

Machine raised for service could fall, crushing persons body, hands, feet, or legs underneath.

If machine must be raised for service, it must be securely blocked so that all wheels may safely turn (see maintenance page 39).

ELECTRICAL (Trailing Cable, Controller, Motors, Etc.)

Electrical shock could cause severe injury or death.

The electrical system should be maintained by certified electricians. The power should be disconnected and locked out at the power center before servicing the trailing cable, motor or controller.

HYDRAULIC

If part of a hydraulic circuit is removed while there is a load on a cylinder in the circuit, the cylinder could drop the load.

Securely block or remove any load from the cylinder before disconnecting the hose or circuit.

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SAFETY PRECAUTIONS AND GUIDELINES OVERVIEW Before you operate, maintain or in any other way, use this unit READ and STUDY this guide. KNOW how to safely use the unit's controls and what you must do for safe maintenance.

ALWAYS wear or use the proper safety items required for your personal protection.

KNOW and follow the safety procedures of each mine when operating this unit.

If you have ANY QUESTIONS about the safe use or maintenance of this unit: ASK YOUR SUPERVISOR - NEVER GUESS - ALWAYS CHECK

PRE-START INSPECTION Read this entire guide BEFORE attempting to operate this unit. You should be familiar with the controls and their functions before the unit is energized.

INSPECT your machine by doing a pre-operational inspection. missing parts corrected or replaced before use.

Have any malfunctioning, broken or

VERIFY that all maintenance has been performed.

VERIFY that all the instruction and safety labels 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 Model LRB-15AR Roof Bolter was shipped from the factory equipped with protective canopies.

These canopies MUST be securely in place before operating the unit.

STARTING DO NOT operate any levers or pedals (located inside the operator’s compartment) from outside the operator's compartment to keep the machine from hitting you or other personnel.

FOLLOW the instructions in the OPERATION section of this guide (page 21) when the machine is to be used.

DO NOT operate any levers or pedals if anyone is in the Hazard Zone (page 37).

BE familiar with the operation of the Panic Strips and be prepared for the sudden stop when the panic strips are struck.

OPERATING ALWAYS make sure that no person or obstruction is in your line of travel BEFORE starting the unit into motion.

NEVER climb onto, or climb out of the machine while it is in motion.

DO NOT operate the machine with any part of your body outside of the operator's compartment in order to prevent body parts from being crushed between the machine and outside objects.

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USE extreme caution and be observant when working in close quarters or in congested or blind-travel areas.

NEVER carry passengers to prevent the passengers from being thrown off or crushed between the machine and outside objects.

NEVER grasp any object when it is rotating in the drill box.

ALWAYS look in all directions BEFORE changing your direction of travel.

ALWAYS use the automated temporary roof support assembly during drilling and bolting operations.

ALWAYS remain under drill station canopy during drilling and bolting operations.

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

If problems or equipment malfunctions are encountered while operating the unit, it must be properly shutdown (see page 36) and the problem repaired. Continuing to use malfunctioning equipment can not only be unsafe for the operator and other personnel, but can lead to further damage to the unit as well.

STOPPING DO NOT leave the operator's compartment with the unit running. ALWAYS properly shutdown the unit (page 47) before leaving the operator's compartment.

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 wheels in both directions whenever possible.

MAINTENANCE 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 adequately chocked to prevent accidental movement of the unit.

DO NOT alter the electrical or hydraulic settings from that indicated in this operation guide or as set at the factory.

ALWAYS replace damaged or lost decals or metal instruction plates. Refer to the Parts Manual for the proper location and part number of decals and plates.

DISCONNECT and lock out power at the power center before performing service or maintenance to prevent electrical shock or accidental start-up or movement of machine.

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.

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INTRODUCTION

FIGURE 1 – MODEL LRB-15AR ROOF BOLTER

The BUCYRUS AMERICA Model LRB-15AR Roof Bolter can be one of the most useful and safe machines found underground today, IF IT IS OPERATED CORRECTLY BY A PROPERLY TRAINED OPERATOR. Before operating the Model LRB-15AR Roof Bolter, study the Controls and Indicators section of this manual to become familiar with the controls and read the description of each control. If a word is in quotation marks and capital letters, such as "OFF" or "ON," that word is found as a label on the machine.

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GENERAL INFORMATION PURPOSE OF THIS GUIDE This guide provides operating and maintenance information for operators of the Model LRB-15AR Roof Bolter. Maintenance and lubrication procedures are those normally performed by maintenance personnel. The techniques of roof bolting are beyond the scope of this guide and no such information is included.

OPERATION - FAMILIARZATION In operation, the roof bolter is trammed to the bolting location from the relative safety of the tramming cab. 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 is 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 A.T.R.S. to the mine roof and begins operating.

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. 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.

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CONTROLS AND INDICATORS OPERATOR’S COMPARTMENT CONTROLS AND INDICATORS BEFORE OPERATING ANY PEDALS OR LEVERS ON THE ROOF BOLTER, ALWAYS MAKE SURE THAT NO ONE IS IN THE HAZARD ZONE (FIGURE 16, PAGE 37). DO NOT OPERATE ANY LEVERS OR PEDALS (LOCATED INSIDE THE OPERATOR’S COMPARTMENT) FROM OUTSIDE THE OPERATOR'S COMPARTMENT. In the operator's compartment are the controls and indicators used in the normal operation of the machine (Figure 2). These include: the fire suppression actuator, panic strip, tram/steering controls, pressure gauges, cable reel control, light switch, warning gong and start button.

FIGURE 2 – OPERATOR’S COMPARTMENT CONTROLS AND INDICATORS

PANIC STRIP (See page 11)

FIRE SUPPRESSION ACTUATOR (See page 11)

SYSTEM MAIN PRESSURE GAUGE (See page 14) DRILL POSITIONING AND DRILL STATION CONTROLS PRESSURE GAUGE (See page 14)

FRONT/REAR LIGHT SWITCH (See page 12)

WARNING GONG (See page 12) CABLE REEL (See page 14)

FAST TRAM (RIGHT) (See page 13)

START BUTTON (See page 13) FAST TRAM (LEFT) (See page 13)

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FIRE SUPPRESSION ACTUATOR (Operator’s Compartment) The fire suppression actuator (Figure 3) is located to the operator's right while sitting in the operator’s compartment of the roof bolter. 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.

FIGURE 3 – FIRE SUPPRESSION ACTUATOR

PLUNGER ACTUATOR PIN

CO2 CARTRIDGE BOMB

PANIC STRIP (Operator’s Compartment) The panic strip (Figure 4) 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 can be actuated by striking with a small amount of force (minimum of 7 lbs. nominal force).

BE PREPARED FOR A SUDDEN STOP WHEN THE PANIC STRIP IS ACTUATED DURING NORMAL TRAMMING OF THE ROOF BOLTER.

FIGURE 4 – PANIC STRIP

PANIC STRIP REACTS TO SIDE AND FRONT THRUST (7 LBS. NOMINAL FORCE)

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WARNING GONG The warning gong (Figure 5) is located to the operator's right. It is sounded by striking the lever located on the side of the gong. This warning gong should be used in accordance with the safety standards at the mine where the roof bolter will be used.

FIGURE 5 – WARNING GONG

WARNING GONG

LIGHT SWITCH The light switch (Figure 6), located to the operator's right, turns on either of the roof bolters headlights. It has three positions (3) “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.

FIGURE 6 – LIGHT SWITCH “OFF”

“FRONT”

“REAR”

START BUTTON The start button (Figure 7, page 13), located in 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.

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FIGURE 7 – START BUTTON

START BUTTON

TRAM/STEERING CONTROL LEVERS ONCE EITHER OF THE TRAM/STEERING CONTROL LEVERS ARE RELEASED

BY THE OPERATOR THE CONTROL LEVER AUTOMATICALLY RETURNS TO THE CENTERED (NEUTRAL) POSITION.

THE LRB-15AR ROOF BOLTER HAS SKID TYPE STEERING; IT IS CAPABLE OF TURNING WITHIN ITS OWN LENGTH. The tram/steering control levers, (Figure 8) 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 the machine and 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.

FIGURE 8 – TRAM/STEERING CONTROL LEVERS

FAST TRAM (RIGHT)

FAST TRAM (LEFT)

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CABLE REEL CONTROL LEVER The cable reel control lever (Figure 9), located in 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.

FIGURE 9 – CABLE REEL CONTROL LEVER

CABLE REEL CONTROL LEVER

PRESSURE GAUGES The LRB-15AR Roof Bolter has two (2) pressure gauges (Figure 10) located in the front of the operator’s compartment. They provide a means of monitoring hydraulic oil pressure to the main hydraulic system and drill positioning/drill station controls.

FIGURE 10 – PRESSURE GAUGES MAIN SYSTEM PRESSURE GAUGE

DRILL POSITIONING AND DRILL STATION PRESSURE GAUGE

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DRILL POSITIONING CONTROLS AND INDICATORS WHEN OPERATING THE ROOF BOLTER FROM THE POSITIONING CONTROLS ON THE LEFT SIDE OF ROOF BOLTER, NEVER PASS BEYOND 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. THE ROOF BOLTER’S INCH TRAM/STEERING IS FOR MANEUVERING MACHINE BETWEEN BOLT HOLES ONLY. MACHINE MUST BE OPERATED FROM INSIDE TRAM STATION FOR PLACE CHANGE OR OTHER LONG DISTANCE MOVES.

ONCE EITHER OF THE INCH TRAM/STEERING CONTROL LEVERS ARE RELEASED BY THE OPERATOR THE CONTROL LEVER AUTOMATICALLY RETURNS TO THE CENTERED (NEUTRAL) POSITION.

THE LRB-15AR ROOF BOLTER HAS SKID TYPE STEERING; IT IS CAPABLE OF TURNING WITHIN ITS OWN LENGTH.

INCH TRAM/STEERING CONTROL LEVERS The tram/steering control levers, (Figure 11, page 16) 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 and 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.

A.T.R.S. CONTROL LEVER The A.T.R.S. control lever, (Figure 11, page 16) located on the left side of the machine is used for raising and lowering the A.T.R.S. (Automatic Temporary Roof Support) during drilling operations. To raise the A.T.R.S. push the lever toward the front the machine and to lower the A.T.R.S. pull the lever toward the rear of the machine.

STAB FOOT CONTROL LEVER The stab foot control lever (Figure 11, page 16) 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.

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PANIC STRIP (Positioning Controls) The panic strip (Figure 11) 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).

FIGURE 11 – DRILL POSITIONING CONTROLS AND INDICATORS

INCH TRAM (LEFT) CONTROL LEVER

INCH TRAM (RIGHT) CONTROL LEVER A.T.R.S. CONTROL LEVER

PANIC STRIP REACTS TO SIDE AND FRONT THRUST (7 LBS. NOMINAL

STAB FOOT CONTROL LEVER

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DRILL STATION CONTROLS AND INDICATORS EXPOSING ANY PART OF YOUR BODY FROM UNDER THE DRILL STATION CANOPY DURING DRILLING OR BOLTING OPERATIONS CAN CAUSE SEVERE INJURY OR DEATH. KEEP ARMS, LEGS AND HEAD UNDER DRILL STATION CANOPY.

DO NOT OPERATE ROOF BOLTER WITHOUT DRILL STATION CANOPY. OPERATING WITHOUT DRILL STATION CANOPY CAN RESULT IN SEVERE INJURY OR DEATH. DRILL FEED CONTROL LEVER The drill feed control lever (Figure 12, page 18) 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 (Figure 12, page 18) is used to control the rotation of the drill box. To start the drill box rotating in (CW) clockwise direction, push the control lever away from the operator and to start the drill box rotating in (CCW) counterclockwise 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.

ROTATION FLOW CONTROL To adjust hydraulic flow for the rotation circuit (Figure 12, page 18), turn the adjustment knob counterclockwise (CCW) to increase RPM’s and turn the adjustment knob clockwise (CW) to decrease RPM’s.

TORQUE FLOW CONTROL To adjust hydraulic flow for the torque circuit (Figure 12, page 18), pull the adjustment knob out to decrease torque and push the adjustment knob in to increase torque.

START BUTTON The start button (Figure 12, page 18), 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 (Drilling Controls) The panic strip (Figure 12, page 18) 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).

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FIGURE 12 – DRILL STATION CONTROLS

ROTATION FLOW CONTROL (RPM)

ROTATION CONTROL LEVER FEED CONTROL LEVER

FIRE SUPPRESSION ACTUATOR

PANIC STRIP REACTS TO SIDE AND FRONT THRUST (7 LBS. NOMINAL FORCE) BOLTING TORQUE

START BUTTON

FIRE SUPPRESSION ACTUATOR (Drill Station) The fire suppression actuator (Figure 13) 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.

FIGURE 13 – FIRE SUPPRESSION ACTUATOR

PLUNGER ACTUATOR PIN

CO2 CARTRIDGE BOMB

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CONTROLLER SWITCHES CIRCUIT BREAKER RESET SWITCH The circuit breaker reset switch (Figure 14), 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.

AEREA LIGHT SWITCH The area light switch (Figure 14), 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 de activate the area lighting; rotate the switch (CCW) counter clockwise to the “OFF” position.

CIRCUIT BREAKER RESET PUSH-BUTTON The controller has two (2) circuit breaker reset push-buttons (Figure 14) 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 PUSH-BUTTON (Pennsylvania Use Only) The ground monitor test push-button (Figure 14), located on the front cover of the controller is used to test the ground from the main power center. Depress the push-button to break ground circuit which will trip the circuit breaker at main power center.

ELECTRICAL POWER MUST BE DISCONNECTED AT THE MAIN POWER CENTER BEFORE REMOVING COVER FROM THE ELECTRICAL CONTROLLER OR PERFORMING ANY WORK INSIDE THE CONTROLLER.

FIGURE 14 – CONTROLLER SWITCHES

CIRCUIT BREAKER RESET PUSH-BUTTON

CIRCUIT BREAKER RESET PUSH-BUTTON

MAIN CIRCUIT BREAKER RESET HANDLE

AREA LIGHT SWITCH

GROUND MONITOR TEST PUSH-BUTTON

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DRIVE ASSEMBLY TORQUE HUBS WHEN THE TORQUE HUBS ARE IN THE DISENGAGED POSITION, THE ROOF BOLTER MUST BE CHOCKED AT ALL FOUR (4) WHEELS IN BOTH DIRECTIONS TO PREVENT THE MACHINE FROM ROLLING AWAY UNCONTROLLED. The roof bolter is equipped with torque hubs (Figure 15) that will allow the operator or service technician to engage or disengage the drive assemblies. To disengage the torque hub, remove the two (2) locking bolts that secure the hub in the engaged position and rotate 180. After rotating the hub to the disengaged position re-install the locking bolts.

FIGURE 15 – TORQUE HUBS

LOCKING BOLTS (4 PLACES)

TORQUE HUB (TYPICAL 4 PLACES)

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OPERATION FAILURE TO READ AND UNDERSTAND ALL OPERATING INSTRUCTIONS BEFORE STARTING THE ROOF BOLTER COULD RESULT IN SERIOUS INJURY OR DEATH TO THE OPERATOR OR PERSONS AROUND THE MACHINE OR CAUSE DAMAGE TO THE MACHINE. READ ALL INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO START OR OPERATE MACHINE. 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. REPORT IT IMMEDATELY TO YOUR SUPERVISOR. MAKE SURE THAT NO ONE IS IN THE HAZARD ZONE (FIGURE 16, PAGE 37) BEFORE STARTING THE ROOF BOLTER.

PRELIMINARY CHECKS Before applying power to the machine, make a visual inspection for components or assemblies which may have been damaged during shipping.

Remove blocks, chains, tools, etc. which may have been left on or around the machine.

Check the fluid and lubricant levels at the following points (see Lubrication Chart, Figure 36, page 56): 1. HYDRAULIC OIL LEVEL - Check oil level.

2. BLOWER - Check oil level.

3. DRILL BOX - Check oil level.

4. HYDRAULIC FILTER - Check indicator.

5. TORQUE HUBS - Check oil level.

BEFORE OPERATING MACHINE 1. Inspect machine completely and repair all defects before proceeding.

2. Clear machine operating area of personnel.

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TO OPERATE MACHINE 1. Inspect machine for any damage.

2. Check power rating. This information can be found on plate located on the control box cover and on the serial number plate.

3. Check control valve positions. All valve levers must be in the neutral position before starting machine.

4. 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.

5. Turn machines circuit breaker switch to the "ON” position and turn light switch "ON” to the intended direction of travel.

NEVER OPERATE ANY LEVERS OR PEDALS (LOCATED INSIDE THE OPERATORS COMPARTMENT) FROM OUTSIDE THE OPERATORS COMPARTMENT. THIS MACHINE IS EQUIPED WITH A CANOPY. BE CAREFUL NOT TO HIT YOUR HEAD WHEN ENTERING OR LEAVING THE OPERATOR’S COMPARTMENT. THIS MACHINE MUST NOT BE OPERATED WITHOUT THE CANOPY IN PLACE. 6. Get into the operator’s compartment in proper position.

7. 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.

DO NOT OPERATE MACHINE IF ALL PANIC STRIPS ARE NOT OPERATIONAL.

8. Strike the panic strips to confirm that they are operational.

NOTE: By striking either panic strip the circuit breaker should trip-out.

9. 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.

10. Check dust collection system for proper suction. If necessary - empty canister and replace filters.

11. 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 A.T.R.S. and drill boom are in their completely collapsed position.

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DO NOT OPERATE THE ROOF BOLTER WITH ANY PART OF YOUR BODY OUTSIDE THE OPERATOR'S COMPARTMENT TO PREVENT HAVING BODY PARTS CAUGHT BETWEEN THE MACHINE AND OUTSIDE OBJECTS. BE SURE NO ONE IS IN THE HAZARD ZONE (FIGURE 16, PAGE 37) BEFORE OPERATING ANY LEVERS OR PEDALS. THE INCH TRAM AND STEERING CONTROLS LOCATED ON THE LEFT SIDE OF THE MACHINE ARE FOR MANEUVERING MACHINE BETWEEN BOLT HOLES ONLY. LONG DISTANCE MOVES MUST BE MADE FROM INSIDE THE OPERATOR'S COMPARTMENT. 12. Get into the operator's compartment in proper position.

13. Move the tram/steering control levers slowly back and forth to get the feel of how the machine will steer.

THE ROOF BOLTER’S TRAM/STEERING CONTROL LEVERS ARE VARIABLE. THIS MEANS THAT THE FARTHER THE TRAM HANDLES ARE ACTUATED THE FASTER THE ROOF BOLTER WILL TRAVEL OR TURN. MAKE SURE NO ONE IS IN THE HAZARD ZONE (FIGURE 16, PAGE 37).

BEFORE TRAMMING MACHINE.

WHILE TRAMMING MACHINE TRAILING CABLE MUST BE HANDLED WITH CARE. 14. The roof bolter is now ready to tram. Slowly move the tram/steering control levers in the intended direction of travel.

THE ROOF BOLTER CAN BE STOPPED AT ANY TIME IN CASE OF AN EMERGENCY BY STRIKING THE PANIC STRIP. BE PREPARED FOR A SUDDEN STOP WHEN THE PANIC STRIP IS STRUCK. NOTE: While tramming the following precautions should be observed.

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

B. Trailing cable must be handled with care.

C. Alert other workers of intentions.

D. Maintain adequate clearance between machine and rib.

E. Know physical conditions of route.

F. Be especially cautious when rounding corners.

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

DO NOT PERMIT THE BUILD-UP OF MUD OR OTHER MATERIAL TO COLLECT UNDER OR AROUND THE CABLE REEL.

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DRILLING DRILLING INSTRUCTIONS 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. DURING DRILLING AND BOLTING OPERATIONS OPERATOR MUST WATCH DRILL ROD AND REGULATE BOOM FEED CONTROL TO PREVENT DRILL ROD BUCKLING. DURING DRILLING AND BOLTING OPERATIONS OPERATOR MUST REMAIN UNDER DRILL STATION CANOPY AT ALL TIMES.

IF YOU ARE NOT SURE HOW MUCH DUST IS IN THE DUST COLLECTOR TANK, EMPTY THE TANK. DO NOT OVERLOAD THE DUST COLLECTOR CAPACITY. 1. Be sure the dust collection system is operating efficiently before proceeding to drill.

2. Position machine for drilling/bolting cycle.

3.

C. Lower stab foot to mine floor.

B. Position drilling assembly to the desired position.

A. Raise A.T.R.S. until it comes in contact with mine roof.

4. Lower drill boom to floor.

5. Insert the 12” spotter drill, provided with your machine, into the drill chuck by grasping drill just below the bit.

6. Release your hold on the spotter drill.

7. Place one hand on the drill feed control lever. Raise the drill to contact mine roof using the drill feed control lever.

8. Move your hand to the rotation lever. Start rotation.

9. 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.

10. When the spotter drill clears the hole, stop rotation.

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

12. Remove the spotter drill.

EXAMINE DRILL ROD FOR DEFECTS; DO NOT USE A DRILL ROD THAT IS BENT OR DAMAGED. 13. Examine drill rod for defects; do not use a drill rod that is bent or damaged. Insert drill rod in drill chuck.

14. 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. 15. 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.

16. 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.

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 to 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”.

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

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the bit, it can be very difficult to remove the drill rod from the hole. It is very particularly difficult to remove extensions.

16. 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.

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 PROVIDE 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.

17. 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 STEELS SELECTION 1. 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: A. Driver - The section which has the 1 -1/8” square base to fit the roof bolter drill box chuck.

B. 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.

C. 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.

2. 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.

Note: 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.

3. When planning for drill steel lengths to be used with the Bucyrus America Roof bolter, several factors should be considered.

A. 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.

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

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

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DRILLING WITH EXTENSION STEELS 1. Insert “driver” into drill chuck.

2. Insert "lead extension” into hole and push upward until the base of the lead extension clears the top of the driver.

3. Line up and couple lead extension and driver.

DO NOT USE MACHINE POWER TO ROTATE DRIVER INTO ALIGNMENT WITH LEAD EXTENSION.

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.

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 13/8” for the finisher when standard expansion shells are used with long bolts.

4. 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.

Proceed with drilling as described previously.

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5. 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.

A. 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.

B. 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.

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.

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DRILL OPTIONS AND ADJUSTMENTS

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 America 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.

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 America 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.

Bucyrus America standard speed and feed force limits provides 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.

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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.

1. Roof bolts support mine roof in two principle ways: A. 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.

B. 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.

2. In order for roof bolts to be effective roof support: A. The cut must be bolted as soon as possible after mining. The greater the delay the greater the roof layers have an opportunity to sag and separate.

B. 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.

C. 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.

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. 3. 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.

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.

WHEN LONG PLATES OR BOARDS ARE USED WITH THE BEARING PLATE AS PART OF YOUR 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.

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NEVER PLACE YOUR FINGERS BETWEEN THE BEARING PLATE OR BOARD AND THE ROOF. 4. 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.

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. 5. 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.

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.

6. 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.

7. Remove wrench.

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INSTALLATION OF FULLY GROUTED RESIN BOLTS 1. 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 America Service Supervisor should be called in to assist in a safe transition from mechanical bolts to resin.

2. 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.

3. 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.

4. Following are general procedures for installing resin bolts. Specific instructions must be provided by your resin supplier.

A. After hole has been drilled, insert wrench in drill chuck.

HOLE DEPTH IS VERY CRITICAL WITH RESIN BOLTS. THE DEPTH MUST BE LONGER THAN THE BOLT BUT NO MORE THAN 1 OR 2 INCHES LONGER.

THE WRENCH USED FOR RESIN BOLT INSTALLATION SHOULD BE NO LONGER THAN NECESSARY TO CLEAR WITHIN THE DRILL CHUCK, AND THE WRENCH SURFACE MUST REACH THE ROOF LINE. BUCYRUS AMERICA RECOMMENDS AN OVERALL WRENCH LENGTH 12 INCHES. B. Insert necessary resin cartridges into the hole.

C. 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.

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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.

D. 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.

E. Rotate the bolt for fifteen to twenty seconds at about half rotation speed (200 to 250 RPM).

F. Stop rotation; push the bolt upward solid against the roof and hold for the time specified by the resin manufacturer.

G. Lower the boom; remove the wrench; turn dual relief to "ON” position ready for drilling the next hole.

RESIN MAY CAUSE SKIN IRRITATION TO SOME PEOPLE. YOU MIGHT CONSIDER THE USE OF LONG SLEEVE CLOTHING, GLOVES, AND A FACE SHIELD IN ADDITION TO SAFETY GLASSES WITH SIDE SHIELDS. 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. SEVERE INJURY OR DEATH COULD OCCUR. SPECIAL CARE SHOULD BE EXERCISED WHEN WORKING WITH THE BENDABLE RESIN BOLTS USED IN LOW COAL. BE SURE TO FOLLOW BOLT AND RESIN MANUFACTURER'S RECOMMENDATIONS.

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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.

1. 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.

ALWAYS CHECK BEFORE LOWERING THE STAB FOOT, BOOM, AND THE A.T.R.S. TO MAKE SURE NO ONE HAS ANY PART OF THEIR BODY NEAR MOVING PARTS OF MACHINE.

THIS UNIT IS EQUIPED WITH A TRAM STATION CANOPY. BE CAREFUL NOT TO HIT YOUR HEAD WHEN ENTERING OR EXITING THE OPERATOR COMPARTMENT. 2. Completely lower stab foot and boom to the bottom.

3. Completely lower A.T.R.S. 4. Properly tend to trailing cable.

5. Turn circuit breaker lever to "OFF” position.

6. Turn power "OFF” at main distribution box.

7. Immediately report any defects or unsafe conditions to your supervisor.

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SAFETY PRECAUTIONS FOR UNDERGROUND USE In addition to the preceding instructions for operating the roof bolter, observe the following special precautions after the roof bolter is taken underground.

1. Communication is a key element in maintaining safety. Exact instructions and warnings should be given to, and thoroughly understood by each workman. Good communications between the entire crew must be maintained throughout the shift.

2. Check the condition of the trailing cable before turning power on at the power source.

3. This machine must be maintained in a permissible condition, following all state and federal laws.

4. Make a visual check of the roof bolter before energizing. Look for loose bolts, covers, locking devices, damaged parts, and cracked or broken lenses. Any part of the machine which does not function properly is a hazard. Report it immediately to your immediate supervisor.

5. Prior to operation, make sure the working area is safe. Make a visual inspection of roof and ribs and take all steps necessary to insure safety.

GENERAL DRILLING AND BOLTING SAFETY 1. Before beginning the drilling or bolting operation, carefully pay out the trailing cable and provide enough slack in the cable to allow adequate clearance and safe maneuverability.

EXPOSING ANY PART OF YOUR BODY FROM UNDER THE DRILL STATION CANOPY DURING DRILLING OR BOLTING OPERATIONS CAN CAUSE SEVERE INJURY OR DEATH. KEEP ARMS, LEGS, AND HEAD UNDER DRILL STATION CANOPY. DO NOT OPERATE ROOF BOLTER WITHOUT DRILL STATION CANOPY. OPERATING WITHOUT DRILL STATION CANOPY CAN RESULT IN SEVERE INJURY OR DEATH.

TRAMMING SAFETY RULES 1. Communicate your intentions to the workmen affected by the movement of the roof bolter.

2. Check the position of the trailing cable to be sure there is sufficient slack to finish the operation.

3. Note the condition of the roadways and physical surroundings of the route.

4. Position the stab foot, boom, and A.T.R.S. for tramming.

5. Position your body completely inside the operator's compartment, facing the intended direction of travel.

6. Position the roof bolter in the center of the roadway to allow maximum safe clearance. Consistently maintain clearance, which is critical to the safe movement of the roof bolter.

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7. Be especially careful when tramming for long distances, through intersections, in narrow entries, or over uneven bottoms.

8. Remember that careless operation of a roof bolter can lead to roof falls or accidents.

9. Always stop and check behind before passing through ventilation curtains to avoid hitting other machinery or workmen on the other side of the curtain.

10. Because of limited visibility, be especially careful when turning corners.

SHUTTING DOWN THE ROOF BOLTER 1. At the end of the shift, park the roof bolter at a designated parking area. Provide sufficient clearance and avoid parking the roof bolter near ventilation curtains where collisions with workmen or other equipment might result.

2. Properly shutdown the roof bolter (see Shutdown Procedure, Page 35).

FIGURE 16 – HAZARD ZONE

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Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

TOWING A DISABLED MACHINE 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 ANY ONE AROUND BOTH VEHICLES FROM BEING INJURED BY EITHER THE TOWING VEHICLE, THE TOWING DEVICES OR THE VEHICLE BEING TOWED. THE PRIMARY TOWING DEVICE 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. 1. Couple the towing vehicle securely to the disabled vehicle.

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

AT NO TIME DURING TOWING SHOULD ANYONE RIDE IN OR ON THE VEHICLE BEING TOWED OR STAND IN BETWEEN THE TOWING VEHICLE AND THE DISABLED VEHICLE. 3. Begin towing the vehicle 4. 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.

FAILURE TO CHOCK ALL FOUR WHEELS ON THE DISABLED VEHICLE BEFORE REMOVING THE TOWING DEVICE COULD ALLOW THE DISABLED VEHICLE TO ROLL AWAY UNCONTROLLED.

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Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

MAINTENANCE GENERAL MAINTENANCE INSTRUCTIONS Long reliable service and the safety of those working with this Roof Bolter can only be ensured by conscientious periodic maintenance of the machine.

Anyone performing maintenance on this machine should be trained to operate it and must be familiar with this BUCYRUS AMERICA Guide.

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

BEFORE MAINTENANCE OR SERVICING: 1. SHUTDOWN the roof bolter on level ground (see Shutdown Procedure, page 36).

2. Disconnect the power. The circuit breaker must be in the "OFF" position. If work is to be done inside the electrical connection box, the power should be disconnected.

3. Test the controls to be sure that the roof bolter will not operate.

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

During maintenance or servicing, if the drive motors are to be run, the roof bolter must be jacked clear of the ground and securely blocked. All four wheels must be free to rotate.

DO NOT perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity. The maintenance area should be as clean as possible.

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

CLEANLINESS cannot 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.

DO NOT MOVE ANY HYDRAULIC CONTROL LEVER UNLESS YOU ARE CERTAIN THAT NO ONE COULD BE HURT BY THE MACHINE'S MOVEMENT. DO NOT DISCONNECT A HYDRAULIC CIRCUIT FROM A CYLINDER WHILE THERE IS LOAD ON THE CYLINDER. DISCONNECT THE POWER BEFORE WORKING ON ANY PART OF THE ELECTRICAL SYSTEM.

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Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

MAINTENANCE CHECK LIST (For Specific Instructions, See Page 41) (For Lubricant Specifications, See Pages 58 & 59) (For Lubrication Chart, See Page 56)

ITEM OR LOCATION

INSPECT

EVERY SHIFT Electrical Cables And Conduits; Hydraulic Hoses And Fittings; Tires; Lights; Warning Tags; Reflectors Operation Of All Switches, Panic Strips And Hydraulic Controls Hydraulic Oil Level Hydraulic Oil Filter Indicators Drill Box Cradle, Boom And Support Arm Assembly Dust System Cable Reel First Bolt Installed

ADJUST

CHANGE

LUBRICATE



EVERY OTHER SHIFT Blower Belt Hinge Pins, Jack Pins, Jack Anchors And Sliders Entire Machine (Nuts And Bolts) Blower (Gear End) Cable Reel Cradle, Boom And Support Arm Assembly Drill Box Torque Hubs Fire Suppression



A/R

      

A/R

 

A/R

      

WEEKLY Hydraulic Pressure Settings Electrical System Trailing Cable Cable Reel (Drive Chain) Drill Box Explosion Proof Housings Hydraulic Oil Filter Tire And Wheel Mounting Bolts Torque Hub and Ground Clearance Bolts

       

EVERY THREE MONTHS Blower (Drive End) Torque Hubs Electric Motor

A/R A/R A/R A/R

A/R A/R 

A/R A/R A/R A/R

A/R A/R A/R

A/R  A/R

A/R  A/R A/R

 

EVERY SIX MONTHS Hydraulic Oil And Suction Strainer Pump Electric Motor Cable Reel

   

  

    A/R 

A/R - Perform service as required.

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Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

PERIODIC MAINTENANCE PROCEDURES EVERY SHIFT DO NOT ALLOW WATER TO ENTER THE ELECTRICAL CONTROLLER AT ANY TIME DURING SERVICE OR MAINTENANCE, THE CONTROLLER COVER SHOULD BE IN PLACE AND SECURED.

DO NOT DISCONNECT A HYDRAULIC CIRCUIT FROM A CYLINDER WHILE THERE IS LOAD ON THE CYLINDER. DISCONNECT THE POWER BEFORE WORKING ON ANY PART OF THE ELECTRICAL SYSTEM.

1. Wash down the roof bolter and remove all foreign material from the operator's compartment and drill station work area.

2. Inspect all electrical cables, conduits, hydraulic hoses, fittings, tires, and lights for signs of wear or damage. Repair or replace any found damaged.

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

4. Check the hydraulic oil level (Figure 17) 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. (For Fluid Specifications, see pages 58 & 59).

FIGURE 17 – HYDRAULIC OIL LEVEL

FILL CAP BREATHER

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Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

5. Check the operation and condition of all switches, warning gong and panic strips (Figure 18). Start the roof bolter, but do not tram. Strike the tape switches to be certain that they are operating properly, tripping the machine circuit breaker and shutting down the roof bolter.

FIGURE 18 – PANIC STRIPS AND SWITCH LOCATIONS

CIRCUIT BREAKER RESET HANDLE CIRCUIT BREAKER RESET PUSH-BUTTON

CIRCUIT BREAKER RESET PUSH-BUTTON

GROUND MONITOR TEST PUSH BUTTON

AERIAL LIGHT SWITCH

CONTROL STATION

TAPE SWITCH

START BUTTON TAPE SWITCH FRONT/REAR LIGHT SWITCH BUTTON

TAPE SWITCH START BUTTON

42

WARNING GONG

Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

6. Check the operation and condition of all hydraulic controls and gauges (Figure 19).

FIGURE 19 – HYDRAULIC CONTROLS SYSTEM MAIN PRESSURE GAUGE

ROTATION CONTROL

FEED CONTROL

DRILL POSITIONING AND DRILL CONTROLS PRESSURE GAUGE

FAST TRAM (LEFT)

CABLE REEL CONTROL

FAST TRAM (RIGHT)

BOLTING TORQUE INCH TRAM (RIGHT) INCH TRAM (LEFT) A.T.R.S .

STAB FOOT

7. Visually inspect the condition of cradle, stab foot, boom, and A.T.R.S. for cracks or excessive wear.

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

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Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

9. Check the hydraulic oil filter pressure indicator gauge (Figure 20). If the gauge is reading in the red zone, filter element should be replaced.

FIGURE 20 – HYDRAULIC OIL FILTER

PRESSURE INDICATOR

ELEMENT

TIGHTEN TO 20 FT-LB TORQUE

10. Visually inspect drill box for excessive wear or oil leakage and check oil level (Figure 21).

A. Remove the oil level fill/check plug (Figure 21). The oil level should be kept at the level of the fill/check plug.

B. Should it be necessary to add oil, (Spartan EP 460) add oil through the fill/check plug hole slowly until oil flows from the hole. Do not overfill the drill box.

C. Replace the fill/check plug.

FIGURE 21 – DRILL BOX OIL LEVEL

FILL/CHECK PLUG

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Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

11. Inspect the dust system (Figure 22).

A. Visually inspect dust system hosing for signs of wear or damage. Repair or replace any found damaged.

B. Inspect filter elements located inside 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.

C. Inspect dust collection area of dust box. If excess dust has accumulated, it must be removed with the rake.

FIGURE 22 – DUST COLLECTION SYSTEM

FILTER ELEMENTS

DUST COLLECTION AREA

12. On non-resin bolting applications, check torque on installed bolts with a torque wrench of known accuracy. If torque is consistently too high or too low, reset the dual relief valve. If torque varies erratically, check dual relief valve for proper operation and cleanliness. Also make sure hydraulic system oil is clean.

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Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

EVERY OTHER SHIFT 1. Inspect the condition and tension of blower belt (Figure 23) for wear. Replace belt if worn and adjust tension as required. Tension should be adjusted to a maximum of 1/2” deflection. Also, check oil level in blower and lubricate blower drive end with spec 100-3 until clean grease flows from operation relief valve.

A. Remove the oil level fill/check plug (Figure 23). The oil level should be kept at the level of the fill/check plug.

B. 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. (For Lubricant Specifications see pages 58 & 59).

C. Replace the fill/check plug.

FIGURE 23 – BELT TENSION AND BLOWER OIL LEVEL ½ INCH DEFLECTION

GREASE FITTING

MOTOR

BLOWER

GREASE FITTING

OIL FILL/CHECK PLUG ADJUSTMENT BOLTS TYPICAL 4 PLACES

2. Inspect all hinge pins, jack pins, jack anchors, and sliders for excessive wear or cracks. Lubricate points as indicated on lubrication chart with spec 100-3. (For Lubricant Specifications, see pages 58 & 59).

3. Visually inspect the entire machine, checking for loose nuts or bolts. Pay particular attention to high stress areas.

4 Lubricate cable reel stub shaft, drive gear and spooler. Lubricate points as indicated on lubrication chart with spec 100-3. (For Lubricant Specifications, see pages 58 & 59).

5. Lubricate cradle, boom, and A.T.R.S. assemblies. Lubricate points as indicated on lubrication chart with spec 100-3. (For Lubricant Specifications, see pages 58 & 59).

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Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

6. Lubricate grease fitting located on top of drill box with spec 100-3 (Figure 24). (For Lubricant Specifications, see pages 58 & 59).

FIGURE 24 – DRILL BOX GREASE FITTING

GREASE FITTING

7. Inspect torque hubs for wear or damage and check oil level (Figure 25).

A. Park the roof bolter on solid level ground.

B. Rotate wheel unit until check and fill plugs are at 3 o’clock and 9 o’clock positions.

C. Remove check plug. Oil should just barely flow out of the check plug hole.

D. Should it be necessary to add oil, add oil (spec 100-6) through the fill plug hole slowly, just until it starts to run out of the check plug hole slowly (Figure 37). (For Lubricant Specifications, see pages 58 & 59).

E. Replace plugs.

FIGURE 25 – TORQUE HUBS

CHECK PLUG

FILL PLUG

TORQUE HUB (TYPICAL 4 PLACES)

47

Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

8. Check the fire suppression system.

A. Inspect the hoses, fittings, and nozzles and replace any found damaged.

B. Check the extinguisher tanks for signs of damage or corrosion.

C. 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.

D. Remove the fill cap.

E. Check that the extinguisher is filled with free-flowing Ansul multi-purpose A,B,C dry chemical to a point not more than 3” from the bottom of the fill opening.

F. Replace the fill cap, hand tight.

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Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

WEEKLY 1. Check hydraulic pressure settings and condition of suction hose on pump. Replace damaged or worn hoses and readjust pressure settings if necessary.

ELECTRICAL SYSTEM REPAIRS MUST BE PERFORMED OR SUPERVISED BY AN MSHA - CERTIFIED ELECTRICIAN.

2. Check electrical system for permissibility.

3. Unreel the entire trailing cable and carefully check its condition. Replace trailing cable if excessively worn or damaged.

4. Inspect, clean, and lightly oil cable reel drive chains and level wind shaft with a good quality chain lube (Figure 26).

FIGURE 26 – CABLE REEL DRIVE CHAINS CABLE REEL DRIVE CHAIN

CABLE REEL DRIVE CHAIN

LEVEL WIND SHAFT

5. Drain and replace oil in drill box (Figure 27).

A. B. C.

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.

FIGURE 27 – DRILL BOX OIL LEVEL

FILL/CHECK PLUG

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Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

EXTREME CAUTION MUST BE OBSERVED WHEN WORKING INSIDE THE ELECTRICAL CONTROLLER TO PREVENT ELECTRICAL SHOCK. YOU MUST FOLLOW THE SAFETY PROCEDURES LISTED AT THE BEGINNING OF THIS SECTION (PAGE 39).

6. Remove covers on explosion proof housings (Figure 28). Make sure that all connections are tight and that housing interiors are clean and dry. When replacing covers, be sure to check for permissible fit.

FIGURE 28 – EXPLOSION PROOF HOUSINGS

CONTROLLER

LIGHT SWITCH

START SWITCH

START SWITCH

7. 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.

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Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

IF UNORDINARELY DIRTY OR DUSTY CONDITIONS ARE ENCOUNTERED, HYDRAULIC OIL FILTER ELEMENT SHOULD BE REPLACED MORE FREQUENTLY. 8. Change hydraulic oil filter element (Figure 29).

FIGURE 29 – HYDRAULIC OIL FILTER ELEMENT

PRESSURE INDICATOR

ELEMENT

TIGHTEN TO 20 FT-LB TORQUE

9. Check torque hub to adjustment plate mounting bolts (8 per hub) and mounting plate to chassis frame mounting bolts (10 per plate) for tightness (Figure 30).

FIGURE 30 – TORQUE HUB AND GROUND CLEARENCE ADJUSTMENT PLATE

ADJUSTMENT PLATE MOUNTING BOLTS (10 PER PLATE)

TORQUE HUB MOUNTING BOLTS (8 PER HUB)

TYPICAL 4 PLACES

51

Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

EVERY THREE MONTHS 1. Lubricate blower drive end with spec 100-3 (Figure 31) until clean grease flows from operation relief valve. (For Lubricant Specifications, see pages 58 & 59).

FIGURE 31 – BLOWER LUBRICATION

BLOWER

GREASE FITTING GREASE FITTING OIL FILL/CHECK PLUG

2. Replace oil in the torque hubs (Figure 32).

A. Park the roof bolter on solid level ground.

B. Rotate wheel unit until drain plug is at the 6 o’clock position.

C. Remove drain plug.

D. Replace drain plug.

E. Rotate wheel unit until check and fill plugs are at 3 o’clock and 9 o’clock positions.

F. Remove check and fill plugs.

G. Add oil (spec 100-6) through the fill plug hole slowly, just until it starts to run out of the check plug hole slowly. (Figure 32) (For Lubricant Specifications, see pages 58 & 59).

H. Replace plugs.

FIGURE 32 – TORQUE HUBS CHECK PLUG

FILL PLUG

52

TORQUE HUB (TYPICAL 4 PLACES)

Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

3. Lubricate the electric motor armature bearings with spec 100-3 (Figure 33). (For Lubricant Specifications, see pages 58 & 59).

A. Locate lube fittings on each end of motor.

B. Use 1.5 cubic inches of grease per end.

C. Remove fittings and allow motor to run for at least 1 hour and reinstall fittings.

FIGURE 33 – ELECTRIC MOTOR LUBRICATION GREASE FITTING GREASE FITTING

53

Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

EVERY SIX MONTHS 1. Inspect cable reel collecting rings, contactor points, brushes, and bearings (Figure 34). Clean and repack bearings when reel is disassembled.

FIGURE 34 – CABLE REEL

GROUND BRUSH ASSEMBLY

DRIVE SPROCKET

MAIN SHAFT

CABLE

PACKING

OUTER BEARING INNER BEARING COLLECTOR RING

PACKING GLAND

2. Check flow on pump with flow meter.

3. Inspect the electric motor.

A. Be sure the machine circuit breaker is in the “OFF” position.

B. Remove the inspection cover.

C. Inspect the windings, commutators, brushes, armature, and terminal leads.

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Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

4. Change hydraulic oil and clean or replace the hydraulic oil strainer inside the hydraulic oil tank (Figure 35).

A. Remove drain plug and drain old oil from tank.

B. Replace drain plug.

C. Clean all dirt and debris from around the hydraulic tank cap and cover assembly.

D. Remove the bolts that secure the cover to the tank.

E. Reaching down into the tank, unscrew the suction strainer and remove it from the tank.

F. 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.

G. Replace strainer in tank and tighten hand tight.

H. Re-install the cap and cover assembly.

I. Refill the oil tank to the proper level with spec 100-1. (For Lubricant Specifications, see pages 58 & 59).

FIGURE 35 – HYDRAULIC OIL TANK STRAINER

FILL CAP

COVER BOLTS

OIL TANK

DRAIN PLUG

55

STRAINER

Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

FIGURE 36 – LUBRICATION CHART

ENLARGED VIEW OF LEVEL WIND

56

Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

Ref. 1 2 3 4 5

Location Level wind shaft bearing Cable reel index pin Level wind and stabilizer shaft Cable reel bearing Cable reel drive chain

6 7

Blower gear housing Blower shaft bearing

8

Electric motor bearing

9

Tram reducers

10

ATRS lift arm pivot guide bars Stabilizer foot pivot Drill head lift arm pin Drill head housing

11 12 13

14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

31 32 33

Drill head face plate ATRS lift arm center pivot ATRS roof support pivot Thrust (Feed) cylinder pins Stab foot cylinder pins Lift arm center pivot Crank arm (Front) pivot ATRS oscillating link (Front) pivot ATRS lift cylinder pins Lift arm rear pivot Carriage rollers Guide arm pin

LUBRICATION Lubricant Remarks Spec 100-3 * See Note Spec 100-3 * See Note Dri-Slide or Similar dry Light coat of lube lube Spec 100-3 * See Note Any good quality chain Light coat of lube lube Spec 100-8 Check oil level Spec 100-3 Grease until clean grease flows from relief Spec 100-3 Lube armature bearings through grease fitting on ends of motor.

Use 1.5 inch (25cc) per end.

Remove fittings allow to run for at least one hour, then re-install fittings.

Spec 100-6 Turn wheel unit until check and fill plugs are at 3 and 9 o’ clock. Then remove plugs. Fill in one plug until oil flows from second. (Case is half full) Spec 100-3 Light coat of lube Spec 100-3 Spec 100-3 Castrol Molly Lube Alloy Graphite 80W – 90W Gear Oil Spec 100-3 Spec 100-3 Spec 100-3 Spec 100-3 Spec 100-3 Spec 100-3 Spec 100-3 Spec 100-3

Frequency Every other shift Every other shift Every other shift Every other shift Every other shift Every other shift Every 250 hours of operation Every Three Months

Every other shift

Every other shift

* See Note * See Note Check oil level

Every other shift Every other shift Every other shift

As required * See Note * See Note * See Note * See Note * See Note * See Note * See Note

Every other shift Every other shift Every other shift Every other shift Every other shift Every other shift Every other shift Every other shift

Spec 100-3 * See Note Every other shift Spec 100-3 * See Note Every other shift Spec 100-3 * See Note Every other shift Spec 100-3 * See Note Every other shift DUST COLLECTION SYSTEM Collected dust must be removed from storage area before capacity is reached.

Door gaskets – Inspect for leaks, repair or replace as needed.

Filter element – Should be changed regularly as they become plugged and performance is hampered.

Relief valve vacuum setting should be set at 12” mercury (HG) minimum. Use flow meter No. RDX0-5215, available from your Donaldson distributor to measure airflow. A minimum of 24 CFM is required for drill operation.

Blower drive belt – Must be maintained properly for maximum system airflow. Keep the belt adjusted properly and replace as needed.

HYDRAULIC SYSTEM Description Quantity Frequency Hydraulic fluid 55 Gallon Every six months Suction strainer 1 Every six months Filter element 1 Weekly

* Note: Pump grease into fitting until old grease can be observed coming out.

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Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

LUBRICANT SPECIFICATIONS SPEC. 100-1 - ANTI-WEAR HYDRAULIC OIL ASTM GRADE 315 SUPPLIER

BRAND NAME

SUPPLIER

BRAND NAME

1. AMOCO OIL CO.

AMOCO AW OIL NO. 68

10. TEXACO LUBRICANTS CO. 11. EXXON 12. PENNZOIL

TEXACO RANDO OIL HD 68 NUTO H 68 PENNZBELL AW 68 HYDRAULIC OIL

2. GULF OIL 3. MOBIL OIL CORP.

HARMONY 68 AW MOBIL DTE-16

4. CHEVRON U.S.A.

CHEVRON HYDRAULIC OIL AW ISO 68

13. STANDARD OIL CO. STD. OIL CO.OF OHIO BORON OIL CO BP OIL INC.

5. SUN OIL'COMPANY

SUNVIS 868

6. UNOCAL76

UNAX AW 68

14. LUBRICATION ENGINEERS 15. CONOCO INC.

7. SHELL OIL COMPANY 8. CENTURY LUBRICATING OILS, INC. 9. ATLANTIC RICHFIELD CO.

SHELL HYDRAULIC OIL #33 HULDRAULIC AW 68 CENTRAULIC AW 68

16. HYDROTEX

SUPER HYDRAULIC OIL 68 SYSTEMS 5K 68

17. PHILLIPS

MAGINUS A OILS 81350

DURO AW S-315 OIL

18. MINERS OIL

HYDRAULIC OIL 68AW

INDUSTRON 53 INDUSTRON 53 ENERGOL HLP-C68

6120 MONOLEC HYD. OIL

SPEC. 100-3 - EXTREME PRESSURE BEARING GREASE NLGI GRADE #2 1. AMOCO OIL CO

2. GULF OIL 3. MOBIL OIL CORP. 4. CHEVRON U.S.A. 5. SUN OIL COMPANY

6. UNOCAL 76 7. SHELL OIL COMPANY 8. CENTURY LUBRICATING OILS, INC.

AMOLITH GREASE 2 EP RYKON PREMIUM GREASE 2 EP GULFCROWN GREASE EP#2 MOBILUX EP-2

9. TEXACO, LUBRICANTS CO.

TEXACO MULTIFAK EP 2

10. EXXON

LIDOK EP 2

11. PENNZOIL

CHEVRON DURA-LITH GREASE EP-2 NLGI 2 SUN PRESTIGE 742EP

12. LUBRICATION ENGINEERS 13. CONOCO INC.

MULTIPLEX EP2 ALVANIA EP-2 HULLITH EP2 MULTIPURPOSE GREASE OR REPLEX 2 OR UNIWRL 2 OR UNIWRL EMB OR HULLITH GP 2 OR HULLITH EP 2

14. HYDROTEX 15. PHILLIPS 16. ATLANTIC RICHFIELD

PENNLITH EP 712 GREASE 3752 ALMAGARD VARIPURPOSE LUBRICANT EP CONOLITH GREASE NO. 2 OR SUPER STA GREASE NO. 2 LC-65 HYPLEX PHILUBE EP GREASE LITHOLINE H EP-2 GREASE

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Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER

Bucyrus America, Inc.

SPEC. 100-6 - EXTREME PRESSURE GEAR OIL (SAE 90) SUPPLIER

BRAND NAME

SUPPLIER

BRAND NAME

1. AMOCO OIL CO.

AMOCO AW PREMAGEAR EP 320

10. TEXACO LUBRICANTS CO.

2. GULF OIL 3. MOBIL OIL CORP.

EP LUBRICANT HD 320 MOBIL GEAR 632

11. EXXON 12. PENNZOIL

4. CHEVRON U.S.A.

CHEVRON GEAR COMPOUND EP ISO 320

13. LUBRICATION ENGINEERS

5. SUN OIL'COMPANY 6. UNOCAL76

SUNEP 320 EXTRA DUTY NL GEAR LUBE 6EP OMALA 75

14. CONOCO INC. 15. HYDROTEX

HULBEST EP-6

17. MINERS OIL

MEROPA 320 or TEXACO MULTIGEAR EP 80W-90 SPARTAN EP 320 SUPER MAXOL EP 220 GEAR LUBE or PEN GEAR #320 605 ALMASOL VARIPURPOSE GEAR LUBRICANT GEAR OIL 320 932 INDUSTRIAL GEAR LUBE PHILUBE ALL PURPOSE GEAR OIL 85W-90 GEAR OIL EP220

PENNANT NL S-1000

18. CITIES SERVICE

7. SHELL OIL COMPANY 8. CENTURY LUBRICATING OILS, INC. 9. ATLANTIC RICHFIELD CO.

16. PHILLIPS

CITGO EP COMPOUND 110

SPEC. 100-8 - HYDRAULIC AND GENERAL PURPOSE OIL HEAVY / R & O INHIBITED SUPPLIER

BRAND NAME

SUPPLIER

BRAND NAME

1. AMOCO OIL CO.

AMERICAN INDUSTRIAL OIL NO. 150 HARMONY 150 DTE OIL EX. HEAVY CHEVRON MACHINE OIL AW ISO 150M or CHEVRON MACHINE OIL R&O ISO 150 SUNVIS 961 UNAX RX 700 or TURBINE OIL 700 TURBO 150 CENTRAULIC R & O 150

10. TEXACO LUBRICANTS CO. 11. EXXON 12. PENNZOIL 13. LUBRICATION ENGINEERS

REGAL OIL R & O 150

14. CONOCO INC. 15. HYDROTEX 16. PHILLIPS 17. MINERS OIL

DECTOL R & O 76 SYSTEM 1 150, SYSTEM 5K 150 MAGNUS OILS 700 ISO 150

DURO 600 or S-100

18. CITIES SERVICE

CITGO PACEMAKER 150

2. GULF OIL 3. MOBIL OIL CORP. 4. CHEVRON U.S.A.

5. SUN OIL'COMPANY 6. UNOCAL76 7. SHELL OIL COMPANY 8. CENTURY LUBRICATING OILS, INC. 9. ATLANTIC RICHFIELD CO.

59

TERESSTIC 150 PENNZBELL RO 150 6405 MONOLEC TURBINE OIL

Revised 12 - 07 MODEL LRB-15AR ROOF BOLTER