CAT BUCYRUS GENERAL START-UP & OPERATING INSTRUCTIONS RB1-85L Roof Bolter BI000931 - PDF DOWNLOAD

BI000931

BI000931

BI000931

Maintenance_____________________________ Fig. 20 (continued): Lubrication chart

Bucyrus Model

26,28

25

Roof Bolter RB1-85L General Start-up and Operating Instructions

© BUCYRUS AMERICA, INC.

24

Doc. No.: A6474X305 39

34 35

42

37

33

38 36

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Bucyrus - Model RB1-85L Roof Bolter

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

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

Internet: www.bucyrus.com

BI000931

_______________________________________

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 operation 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 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.

Fig. 20: Lubrication chart 30

30

29

32

41

16

54

55

31

19,49,51,52

54

10

40

5 17 © BUCYRUS AMERICA, INC.

This manual is intended to provide GENERAL product information for the Model RB1-85L 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.

____________________________ Maintenance

21

33

13, 14, 15

18 21

27

12

22 11,50

© BUCYRUS AMERICA, INC. ALL RIGHTS RESERVED

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BI000931

Maintenance_____________________________

________________________ Table of Contents

Table 4 (continued): Lubrication and maintenance schedule

Table of contents

43 44 45 46 47 48 49 50 51 52 53 54

© BUCYRUS AMERICA, INC.

Description Weekly Pump suction hose Electrical system permissibility Trailing cable Cable reel drive chain Cable reel drive chain tension Explosion proof housings (inspect) Tire/wheel mounting bolts (check) Drill box oil (change) Torque hub to chassis frame mounting bolts (check) Every three months Torque hubs Blower (gear end) Electric motor Every six months Hydraulic oil and suction strainer Cable reel

55 56

Places Inspect Check Inspect 2 Check 3 4 1 8 per hub

Lubricant

Spec.

Pre-start inspection..................................................................... 1 Operation .................................................................................... 2 How to operate the Roof Bolter ............................................. 2 Who is allowed to operate the Roof Bolter? .......................... 2 When can operation be started? ........................................... 2

Good quality chain lube

40W non-detergent

Controls and indicators............................................................... 3 Operator’s compartment........................................................ 3 Controller switches ................................................................ 8 Drill station controls ..............................................................11

4 1 2

Spec. 100-8 Spec. 100-14

Change Inspect

Spec. 100-1

© BUCYRUS AMERICA, INC.

Item

Hazard Zone..............................................................................20 Starting procedure .....................................................................21 Shutdown procedure .................................................................22 Towing procedure......................................................................23 Tramming procedure .................................................................25 Inch tramming............................................................................27 Drilling procedure ......................................................................28 Drilling with extension steels ................................................31 Drill options and adjustments ...............................................33 Installation of mechanically anchored roof bolts...................33 Installation of fully grouted resin bolts ..................................35 Drill thrust and torque settings..............................................37 Maintenance ..............................................................................38

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Table of Contents_________________________

____________________________ Maintenance Table 4: Lubrication and maintenance schedule

© BUCYRUS AMERICA, INC.

______________________________________ Bucyrus - Model RB1-85L Roof Bolter

Places

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Cable reel spooler bearing Cable reel stub shaft Cable reel drive gear King pin Lift arm pin (drill boom) Leveling bracket pin Lift arm pin (stab shoe) Radius arm/ATRS pin Stab cylinder (rod and base end) Feed cylinder pin (rod and base end) Blower belts Blower (drive end) Sliding surfaces for leveling bracket

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

4

Description Every shift Clean machine Electrical cables, conduits, glands Hydraulic hoses and fittings Panic strips (check) Tires (inspect) Lights (inspect) Switches Warning tags, labels and reflectors Hydraulic controls Hydraulic oil level Drill box oil Cradle, stab shoe, and boom Dust system - collected dust Dust system - door gasket Dust system - door gasket Cable reel Every other shift Pin pivot bracket to chassis Boom swing cylinder (rod and base end) Torque hub (check) Fasteners (nuts, bolts, and screws) Hydraulic oil filter Hydraulic oil tank breather Fire suppression Drill box carrier pins Drill box grease fitting Drill box slide bearings Sliding surfaces for canopy tubes Sumping drill box Cable reel spooler shaft

Inspect Inspect 4 4 7 Inspect Inspect Check Check Check Inspect Empty Inspect Inspect Inspect 2 2 4 Check Check Inspect Inspect 4 1 2

1

Lubricant

Spec 100-1 40W Non-Detergent.

Spec 100-3 Spec 100-3 Spec 100-6

Spec 100-3 Spec 100-3 Spec 100-3 Spec 100-3 Spec 100-3 Dri-Slide or similar dry-lube

2

2 2 4 2 2 2 2 Inspect 1 4

Spec.

Spec 100-3 Spec 100-3 Spec 100-3 Spec 100-3 Spec 100-3 Spec 100-3 Spec 100-3 Spec 100-3 Spec 100-3 Spec 100-3 NLGI EP2

Spec 100-3 Spec 100-3

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Item

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Maintenance_____________________________

______________________________ Operation

Critical torque values

Pre-start inspection

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, antiseize or thread-locking compounds. Dry thread torque values should be used when threads are completely clean and dry.

Operation Read this entire guide before attempting to operate this machine.

Inspection

Table 2: Critical torque values Location

Size

Grade

Dry

Lubricated

Tire-Wheel mounting nuts

5/8”

8

225 ft-lb

170 ft-lb

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

Maintenance Verify that all maintenance has been performed.

Table 3: Lubricants, fluids and capacities Location Specification

Instruction and safety tags

Hydraulic oil tank

Spec. 100-1

Approximate capacity 168 Gallons

Lubrication points

Spec. 100-3

As Required

Electric motor lubrication

Spec. 100-14

As Required

Hypoid gear oil SAE 90W

6.8 quarts

Planetary wheel ends

Notes

3

1

2

Notes: 1.

2.

3.

Verify that all instruction and safety tags are in place and readable. These are as important as any other equipment on the machine.

Operator’s compartment Clean any foreign material from the operator’s compartment.

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

With boom lowered and ATRS (if equipped) lowered.

The planetary wheel end assemblies do not have a common oil source. Each assembly must be filled separately.

Make sure the level and fill hole in the planetary wheel end cover are in the proper positions. Rotate the wheel end as required to bring the fill hole to either the 3 o’clock or 9 o’clock position.

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

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Lubricants, fluids and capacities

BI000931

Operation _______________________________

____________________________ Maintenance

Operation

■

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

This manual contains important information on the operation of the machine. You must not operate this machine unless you are qualified by training and experience in its safe operation. Read the Operation and Maintenance Manual for this machine, Bucyrus America, Inc. part number A6474X298,before operating the machine.

■

Chock all four (4) wheels in each direction.

■

© BUCYRUS AMERICA, INC.

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.

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.

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.

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.

This also includes: ■

what safety devices are installed on the machine.

■

where these safety devices are located.

■

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.

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IMPORTANT! Before operating this machine, you must read the complete Operation and Maintenance manual supplied with your machine, part number A6474X298. This is a supplemental manual that contains basic operating procedures only.

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.

BI000931

Maintenance_____________________________

______________________________ Operation

Instructions on the maintenance

Controls and indicators

Maintenance at regular intervals increases the operational safety and prolongs the service life of the machine.

Operator’s compartment

Please observe the following:

© BUCYRUS AMERICA, INC.

■

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.

Fig. 1: Operator’s compartment

ATRS lift lever location (if equipped)

Controller

Panic strip

Fire suppression actuator location (if equipped)

Pressure gauge panel

© BUCYRUS AMERICA, INC.

Important notes

The following controls and indicators are located in the operator’s compartment (Fig. 1): ATRS lift (if equipped), controller (light switch, circuit breaker reset switch, and pump start and stop switches), panic strip, tram control levers, pressure gauge panel, fire suppression actuator, operator’s seat, man-in-position switch, rear lift lever, and cable reel foot pedal.

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.

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Bucyrus - Model RB1-85L Roof Bolter

Cable reel foot pedal

Rear lift lever

Man-in-position switch

Operator’s seat

Tram control levers

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Operation _______________________________

________________________Drilling procedure

Operator’s seat

Table 1: Drill thrust and torque settings

The operator’s seat (Fig. 2) has four (4) height adjustments. To adjust the operator’s seat, lift the back and insert the adjustment rod into the desired adjustment slot.

CAUTION! Adjust the operator’s seat for maximum visibility before the roof bolter is put into motion.

Fig. 2: Operator’s seat

Drill thrust at various pressure settings

Pump flow to drill (gpm)

Drill speed (rpm)

Bolt torque (ft-lb)

Drill (rotation) hydraulic pressure setting (psi)

Drill feed hydraulic pressure setting (psi)

Boom low position (lbs)

Boom high position (lbs)

Pressure gauge panel Located to the right of the operator’s seat are three (3) pressure gauges (Fig. 3) that provides the operator with a continuous reading of the pressures in individual circuits.

The cable reel pressure gauge should read less than 900 psi and the left and right tram should read less than 2,800 psi.

Fig. 3: Pressure gauges Right tram pressure gauge

Left tram pressure gauge

Cable reel pressure gauge

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Bucyrus - Model RB1-85L Roof Bolter

35

514

150

1,010

35

514

160

1,075

900

4,733

4,775

35

514

170

1,140

1,000

5,259

5,306

35

514

180

1,210

1,100

5,784

5,837

35

514

190

1,275

1,200

6,310

6,367

35

514

200

1,345

1,300

6,836

6,898

35

514

210

1,410

1,400

7,362

7,428

35

514

220

1,475

1,500

7,888

7,959

35

514

230

1,540

1,600

8,414

8,490

35

514

24

1,600

1,750

9,203

9,286

Optional hydraulic drill motor, part number 208292 35

614

150

1,210

35

614

160

1,285

35

614

170

1,365

35

614

180

1,450

35

614

190

1,525

35

614

200

1,610

35

614

210

1,690

35

614

220

1,765

35

614

230

1,850

35

614

240

1,930

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Standard hydraulic drill motor, part number 210424

BI000931

Drilling procedure ________________________

______________________________ Operation

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

Fire suppression actuator (if equipped)

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.

The fire suppression (remote) actuator (if equipped) (Fig. 4) is located to the operator’s right inside the operator’s compartment behind the operator’s seat. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from the actuator, 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 the fire suppression actuator is actuated, the system must be completely recharged with dry chemicals and expellants.

Panic strip The roof bolter is equipped with a panic strip (Fig. 4) located in the operator’s compartment. The panic strip is located to the operator’s right beside of the controller assembly while sitting in the operator’s seat. The panic strips are used to break the control circuit only in emergency situations, stopping all motors. Striking with a small amount of force can actuate the panic strip.

WARNING! Be prepared for a sudden stop when the panic strip is actuated during normal tramming of the machine.

Fig. 4: Fire suppression actuator (if equipped) and panic strip locations

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

Panic strip

Plunger

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

Pin

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.

CO2 cartridge (bomb)

Typical actuator

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.

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

BI000931

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

Tram levers There are two control levers located to the operator’s right inside the operator’s compartment (Fig. 5). The left lever controls left tramming and the right lever control right tramming.

NOTICE! The man-in-position switch must be pushed in and held while tramming. Releasing the man-in-position switch will stop all tramming functions.

To tram in a straight direction towards the drill box, push both tram controls levers away from the operator, toward the drill box. To tram in a straight direction towards the back of the machine, pull both levers back towards the operator.

© BUCYRUS AMERICA, INC.

To steer left in the direction of the drill box, push the right tram lever forward while the left tram control lever is in the neutral position or, for tighter turns, pull the left tram lever back towards the operator.

To steer right in the direction of the drill box, push the left tram lever forward while the right tram lever is in the neutral position or, for tighter turns, pull the right tram lever back towards the operator.

NOTICE! The roof bolter has skid type steering. It is capable of turning within its own limits.

Man-in-position switch The man-in-position switch (Fig. 5) is a foot operated switch. This foot switch must be depressed and held during tramming.

Fig. 5: Tram levers and man-in-position switch Tram levers

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.

Installation of fully grouted resin bolts 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.

Man-in-position switch

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Operation _______________________________

BI000931

–

–

The proper torque must be applied to the bolt (within a narrow range) to pretension 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.

______________________________ Operation Cable reel foot pedal The cable reel foot pedal (Fig. 6), located in front of the operator’s seat, is normally operated by the left foot. The pedal is used to pick-up trailing cable during reverse tramming operations. To actuate the cable reel, depress the foot pedal and hold in this position until the desired amount of cable is retrieved.

Fig. 6: Cable reel foot pedal location

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.



Cable reel foot pedal

“ATRS LIFT” lever (if equipped) There are two control levers located above the foot pedals (Fig. 14): the “ATRS LIFT” is the lever on the right and the “REAR LIFT” lever is on the left.

The “ATRS LIFT” lever, if the machine is equipped with an ATRS, is used to raise and lower the ATRS. Push the lever up to raise the ATRS and push the lever down to lower the ATRS. “REAR LIFT” lever The “REAR LIFT” lever is used to raise or lower the rear frame of the roof bolter (including the operator’s compartment). To raise the rear frame, push the lever up. To lower the rear frame, push the lever down.

Fig. 7: ATRS and rear lift levers

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.

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Bucyrus - Model RB1-85L Roof Bolter

“REAR LIFT” lever

“ATRS LIFT” lever location (if equipped)

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Drilling procedure ________________________

BI000931

Operation _______________________________

________________________Drilling procedure

Controller

Drill options and adjustments

The controller is located to the right of the operator (Fig. 8) and is used to reset the circuit breaker when it has tripped. It has four (4) control switches: light switch, circuit breaker reset, motor start, motor stop, low oil light (optional), and ground check (optional).

Fig. 8: Controller “HEADLIGHT SWITCH”

“CIRCUIT BREAKER” reset switch

“LOW OIL” light (optional)

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 AMERICA, INC.

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 “GROUND CHECK” (optional)

Pump “STOP” switch

Pump “START” switch

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

■

“START” button

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.

The “START” button 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.

“STOP” button The “STOP” button is used to stop the hydraulic pump’s electric motor. To stop the electric motor, depress the “STOP” button and release once the motor has stopped.

“LOW OIL” indicator light (optional)

■

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

The optional “LOW OIL” light is normally illuminated but will turn off when the oil level in the hydraulic oil tank reaches an unsafe operating level.

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.

“GROUND CHECK” button (optional) The “GROUND CHECK” button (optional) is used to test the 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.

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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.

BI000931

Drilling procedure ________________________

______________________________ 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.

“CIRCUIT BREAKER” reset switch

WARNING! The machine circuit breaker de-energizes the electrical controller and motors. However, electrical power is still present inside the connection box to the circuit breaker. If the circuit breaker inside the connection box requires service, disconnect the machine from the power center following all applicable Federal and mine rules regarding lockout/tagout.

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.

WARNING! Once the breaker has tripped, it will not stay in the “ON” position without first being moved to the "RESET" position, and then to "ON".

© 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.

© BUCYRUS AMERICA, INC.

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.

The circuit breaker reset switch (Fig. 9) 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.

Fig. 9: “CIRCUIT BREAKER” reset switch “ON”

Stop rotation and stop boom down travel. Grasp the extension with one hand and grasp boom feed control with the other hand.

“TRIPPED”

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.

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“OFF”

“RESET”

The circuit breaker trips when one of the following occurs: ■

The electrical system is overloaded or shorted.

■

The disconnect switch is moved to the “OFF” position (if equipped).

■

The battery is disconnected.

To reset the circuit breaker proceed as follows: 

Move the selector to “RESET” position and operate hand pump to move the circuit breaker to full “OFF” position.



Move the selector to the “SET” position and operate hand pump to move the circuit breaker to the full “ON” position.



Move the selector to the “ON” position for normal operation.

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Operation _______________________________

________________________Drilling procedure

“HEADLIGHT SWITCH”

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

The “HEADLIGHT SWITCH” (Fig. 10) turns on either pair of the roof bolters headlights or the area lights. To activate the front headlight, turn the switch to the “FRONT” position.

To activate the “REAR” headlight, turn the switch to the “REAR” position. To activate the area lights, turn the switch to the “AREA” position.

■

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.

Fig. 10: “HEADLIGHT SWITCH”

“FRONT” lights

“REAR” lights

Drilling with extension steels Insert “driver” into drill chuck.

Line up and couple lead extension and driver.

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

“AREA” lights

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.

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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.

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

BI000931

Drilling procedure ________________________

______________________________ 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.

Drill station controls

Fig. 11: Drill station controls “ROTATION FLOW CONTROL”

© 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.

“BOOM FLOW CONTROL”

Panic strip

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.

“DUAL RELIEF”

Valve bank

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.

“DIVERTER KNOB” (fast feed two-hand operation)

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.

Start button

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.

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Man-in-position lever

Panic strip

Inch tram levers

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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.

The controls for drilling operations and maneuvering the machine between bolt holes are located at the drill station (Fig. 11). These controls include: the inch tram/steering control valve, panic (tape) switches, start button, rotation functions, boom functions, canopy lift, and stabilizer foot controls.

BI000931

Operation _______________________________

________________________Drilling procedure

Man-in-Position switch

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

Inch tram/steering control valve levers

© BUCYRUS AMERICA, INC.

The inch tram/steering control levers (Fig. 12) are located on the front left side of the machine. These levers cannot be activated unless the man-in-position switch is held in position. The inch tram/steering lever is used for maneuvering the roof bolter between bolt holes during drilling operations only. To tram forward, push both levers towards the front the machine and to tram in reverse, pull both levers towards the rear of the machine. To steer right, push the top control lever towards the back of the machine and the bottom control lever towards the front of the machine. To steer left, push the top control lever towards the front of the machine and the bottom control lever towards the rear fo the machine.

WARNING! 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.

IMPORTANT! The roof bolter’s inch tram/steering control will not operate without first pushing the tram diversion lever and holding it in this position until tramming and steering is completed.

Fig. 12: Man-in-position and inch tram/steering control levers

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.    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.  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.  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.

Man-in- position switch

Inch tram/steering control valve levers

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.

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The man-in-position switch (Fig. 12) is located on the front left of the machine, to the left of the inch tram/steering control valve levers. The man in position switch activates the pilot control valve, which in turn activates the inch tram/steering control valve. The lever must be pushed away from the operator and held in this position during inch tram/ steering operations.

BI000931

Drilling procedure ________________________

______________________________ Operation

Drilling

Panic strips

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

© BUCYRUS AMERICA, INC.

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

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.

WARNING! Before beginning the drilling or bolting operation, carefully pay out the trailing cable to provide enough slack in the cable to allow adequate clearance and safe maneuverability.

The roof bolter is equipped with (2) two individual panic strips (Fig. 13) at the drill station.

The panic strips are used to shutdown the machine, stopping all motors. Either panic strip can be actuated by striking with a small amount of force (minimum of 7 lbs. nominal force).

Start button The roof bolter is equipped with a start button (Fig. 13) located at the drill station controls.

The start button is used to start the roof bolter’s electric motor from the boom. To start the electric motor, depress the start button and release after the electric motor has started.

Fig. 13: Panic strips and start button

Panic strip

© BUCYRUS AMERICA, INC.

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.

Panic strip

Start button

 Be sure the dust collection system is operating efficiently before proceeding to drill.  Position machine for drilling/bolting cycle.

Integrated valve (rotation functions)

 Raise the ATRS until it comes in contact with mine roof.

The integrated valves (Fig. 14) give the operator a means of limiting the flow of hydraulic oil to the boom and rotation circuits.

 Position drilling assembly to the desired position.

“ROTATION FLOW CONTROL”

 Lower stab foot to mine floor.  Lower drill boom to floor.

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

 Insert the 12” spotter drill into the drill chuck by grasping drill just below the bit.

Rotation check valve

 Release your hold on the spotter drill.

The rotation check valve is preset at the factory and does not require any adjustment.

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

“BOOM FLOW CONTROL”

 Move your hand to the rotation lever and start rotation.

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

 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.

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_____________________ Tramming procedure

“DUAL RELIEF” control

Inch tramming

The dual relief control provides the operator with a means of limiting torque to the drill box during bolting or drilling operations. During drilling operations, the control must be pushed in to apply the correct amount of torque that has been set in the system pressure. During bolting operations, the control must be pulled out to apply the correct amount of torque that has been set on the dual relief valve.



Fig. 14: Integrated valves

 

Start the roof bolter (see start-up procedure in this chapter).



Position the stabilizer feet for tramming.



Push the man-in-position switch forward and hold in position. The man-in-position switch is located to the left of the inch tram/steering control levers.

© BUCYRUS AMERICA, INC.

IMPORTANT! The roof bolter’s inch tram/steering valve functions will not operate without the man-in-position switch lever being fully engaged and held in position. Releasing the man-in-position switch will stop tramming functions. 

With the man-in-position switch held in, operate the inch tram levers: 

To tram forward in a straight line, push both tram levers toward the front of the machine. The farther the tram levers are pushed, the faster the roof bolter will travel.

NOTICE! The cable reel should pay cable out while the machine is travelling forward.

 “ROTATION FLOW CONTROL”

Rotation check valve

“BOOM FLOW CONTROL”

“DUAL RELIEF” control

To tram in reverse, push both tram levers towards the rear of the machine. The farther the tram levers are pulled, the faster the roof bolter will travel.

NOTICE! To avoid trailing cable damage while traveling in reverse, push the cable reel lever forward to reel in cable.

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Bucyrus - Model RB1-85L Roof Bolter





To steer left (the front of the machine will go to the left while travelling forward and the rear of the machine will go to the left while travelling in reverse), push the top tram lever forward while the bottom tram lever is in the center (neutral) position. For tighter turns, push the top lever forward while pushing the bottom lever back.



To steer right (the front of the machine will go to the right while travelling forward and the rear of the machine will go to the right while travelling in reverse), push the bottom tram lever forward while the top tram lever is in the center (neutral) position. For tighter turns, push the bottom tram lever forward while pulling the top tram lever back.

To stop inch tramming, release the tram lever (s) or the man-in-position switch. _______________________________________

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IMPORTANT! If resin bolts are being installed, the dual relief control must be pushed in.

WARNING! The inch tram controls are for moving the roof bolter between holes only and should not be used to move the roof bolter long distances (ex. between crosscuts or entries). Tramming the roof bolter long distances from outside of the operator’s compartment may result in serious injury to the operator.

BI000931



With the man-in-position switch held in, operate the tram levers: 

To tram forward in a straight line, push both tram levers away from the operator. The farther the tram levers are pushed, the faster the roof bolter will travel.



To tram in reverse, pull both tram levers toward the operator. The farther the tram levers are pulled, the faster the roof bolter will travel.



To steer left (the front of the machine will go to the left while travelling forward and the rear of the machine will go to the left while travelling in reverse), push the right tram lever forward while the left tram lever is in the center, neutral, position. For tighter turns, push the right lever forward while pulling the left lever back.

© BUCYRUS AMERICA, INC.





To steer right (the front of the machine will go to the right while travelling forward and the rear of the machine will go to the right while travelling in reverse), push the left tram lever forward while the right tram lever is in the center, neutral, position. For tighter turns, push the left tram lever forward while pulling the right tram lever back.

To stop tramming, release the tram lever (s) or the man-in-position switch.

______________________________ Operation Drill station valve bank The valve bank (Fig. 15) includes the stab shoe, boom swing, canopy, drill box sump, drill feed, drill rotation, and fast feed levers.

WARNING! Do not operate roof bolter without drill station canopies. Operating without drill station canopies 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 injury or death. Keep arms, legs and head under the drill station canopy.

WARNING! When operating the roof bolter from controls on the boom arm, 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.

“STAB” shoe control lever The “STAB” shoe control lever is used to raise or lower the stab shoe on each boom. To raise the stab shoe, push the control lever away from the operator and to lower the stab shoe, pull the stab shoe toward the operator.

“BOOM SWING” control lever The “BOOM SWING” control lever controls the swing of the boom (left or right) inward and outward. To swing the boom out, pull the control lever towards the operator and to swing the boom in, push the control lever away from the operator.

“CANOPY” control lever The “CANOPY” control lever is used to raise or lower the canopy for that particular boom.

To raise the canopy, pull the control lever toward the operator and to lower the canopy, push the control lever away from the operator.

Drill box “SUMP” control lever The drill box “SUMP” control lever provides the operator with the ability to correct misalignment of drill box. To move the drill box forward, push the control lever away from the operator and to move the drill box backward, pull the control lever towards the operator.

When the control lever is released it will automatically return to the neutral position.

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Tramming procedure______________________

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_____________________ Tramming procedure

Drill “FEED” control lever

Tramming the Roof Bolter

The drill “FEED” control lever is used for raising and lowering the elevation of the boom at normal operating speed. 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.

The roof bolter can be trammed using the tramming controls in the operator’s compartment or by using the inch tram controls at the drill station. The inch tram controls are for moving the roof bolter between holes only and should not be used to move the roof bolter long distances (ex. between crosscuts or entries).

WARNING! The inch tram controls are for moving the roof bolter between holes only and should not be sued to move the roof bolter long distances (ex. between crosscuts or entries). Tramming the roof bolter long distances from outside of the operator’s compartment may result in serious injury to the operator.

“FAST FEED” control lever

 Tramming from the operator’s compartment The following precautions should be observed while tramming:

Rotation control lever The rotation control lever 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.

Fig. 15: Valve bank

  “BOOM SWING” control lever

“FAST FEED” control lever

“DIVERTER KNOB”

Drill “FEED” control lever

Drill box “SUMP” control lever

“CANOPY” control lever

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Bucyrus - Model RB1-85L Roof Bolter

The operator must be positioned fully within the operator’s compartment in order to avoid getting caught between the machine and the rib (or other obstacle).

■

Handle the trailing cable with care.

■

Alert other workers of intentions.

■

Maintain adequate clearance between the machine and the rib.

■

Know the physical conditions of the route of travel.

■

Be especially cautious when traveling around corners.

■

Be careful not to damage the trailing cable while tramming. The cable reel will automatically pay out cable while the machine in traveling forward. Push the cable reel foot pedal when picking up cable (traveling in reverse).

IMPORTANT! Do not permit the build-up of mud or other material to collect under or around the cable reel.   Start the roof bolter (see start-up procedure in this chapter).

“STAB” shoe control lever

Drill “ROTATION” control lever

■

 

Ensure that the stabilizer feet are raised and the ATRS and T-bar (if equipped) are in position for tramming.

Depress the man-in-position switch and hold in during tramming.

IMPORTANT! The roof bolter’s tram valve functions will not operate without the manin-position switch being fully depressed and held in position. Releasing the man-in-position switch will stop tramming.

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The “FAST FEED” control lever requires two hands for operation. This lever provides the operator with the ability to increase the speed (beyond normal speed delivered by the drill feed control lever) of the boom elevation. To raise the boom, press and hold the “DIVERTER KNOB” (located below the valve bank) while pushing the “FAST FEED” control lever away from the operator. To lower the boom, press and hold the “DIVERTER KNOB” while pulling the control lever towards the operator. When the desired elevation is met, release the “DIVERTER KNOB” and the control lever, which will automatically return to the neutral position.

BI000931



Once the destination is reached, stop both machines and chock all four wheels in both directions to prevent accidental movement.

WARNING! Failure to chock all four wheels in both directions could allow uncontrolled movement of the roof bolter. Failure to chock all four wheels in both directions could result in serious injury or death to you or other personnel.



Rotate the torque hub end cap on both right and left sides of the roof bolter to the drive position.



Remove the two bolts that retain the end cap to the center of the torque hub.



Rotate the end cap and reinstall with the two bolts to engage torque hubs in the drive position. Torque bolts to 70 to 80 ft-lbs.

Fig. 19: Torque hub (typical all four wheels)

______________________________ Operation ATRS/Cable reel control station The ATRS/Cable reel control station (Fig. 23), is located on the left hand side of the machine. Located at this control station are a valve bank, a panic strip, a fire suppression actuator, and the hydraulic oil level sight gauge.

Valve bank The valve bank (Fig. 16) consists of the following controls: “JET FILL” control lever The first section from the left on the valve bank controls the jet fill function. Jet fill provides the operator with an automatically controlled hydraulic oil refilling system. To activate the jet fill, pull the control lever towards the operator. To deactivate, release the control lever and it will automatically return to the off position.

© BUCYRUS AMERICA, INC.

“SUPPORT POST” control lever (if equipped) The second section from the left on the valve bank is used to raise and lower support post (if equipped). To raise the support post, push the lever away from the operator. To lower the post, pull the lever toward the operator.

“ATRS” support control lever (if equipped) The third section from the left on the valve bank is used to raise and lower the ATRS support (if equipped). To raise the assembly, push the control lever away from the operator and to lower the assembly, pull the control lever towards the operator.

“ATRS LIFT” control (if equipped)

Retaining bolts (2)

End cap button pointing outward

Normal tram position

The fourth section from the left on the valve bank is used to raise and lower the T-bar (if equipped). To raise the T-bar, push the control lever away from the operator. To lower the T-bar, pull the control lever towards the operator.

“CABLE REEL” control lever The fifth section from the left on the valve bank is to activate the cable reel. The cable reel is used to pick up the trailing cable during reverse inch tramming operations. To start the cable reel, pull the lever towards the operator. To stop the cable reel, push the lever away from the operator.

IMPORTANT! The “CABLE REEL” control lever is detented so that the function can be active when the lever is released. The operator must return the lever to the off position, pushed away from the operator, to turn the cable reel off.

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Towing procedure ________________________

Operation _______________________________

________________________Towing procedure

Panic strip

Towing a disabled machine

The panic strip is located to the left of the valve bank and is used to break the control circuit only in emergency situations, stopping all motors. Striking with a small amount of force will actuate the panic strip.

WARNING! It is not possible, within the scope of this guide, to anticipate all possible arrangements for towing a disabled vehicle, you must take all possible precautions to protect the operators and anyone around both vehicles from being injured by either the towing vehicle, the 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. The vehicle to be towed must be securely coupled to the towing vehicle before the brakes are released on the disabled unit. The operator of the towing vehicle must be in place in the towing vehicle with the brakes applied before the brakes of the disabled vehicle are released.  WARNING! 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.

WARNING! Be prepared for a sudden stop when the panic strip is actuated during tramming operations.

Fire suppression remote actuator

© BUCYRUS AMERICA, INC.

The fire suppression remote actuator is located to the right of the valve bank. The fire suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system, 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 the fire suppression system is actuated, the system must be completely recharged with dry chemicals and expellants.

To tow the roof bolter proceed as follows:

Oil level sight gauge The oil level sight gauge, located to the right of the valve bank, provides the operator with a convenient and quick check of the roof bolter hydraulic oil level. The oil level should be kept within 1/2” of the full level.



Couple the towing vehicle securely to the disabled vehicle.



Chock all four wheels in both directions.

WARNING! Failure to chock all four wheels in both directions could allow uncontrolled movement of the roof bolter. Failure to chock all four wheels in both directions could result in serious injury or death to you or other personnel.

Fig. 16: ATRS control station Panic strip

“JET FILL” control lever

“ATRS SUPPORT” control lever (if equipped)

“CABLE REEL” control lever



Rotate the torque hub end caps on both right and left sides of the roof bolter to the free position (Fig. 26) as follows: 

Remove the two bolts that retain the end cover to the center of the torque hub.



Rotate the cover and reinstall with the two bolts to disengage the torque hub.

Torque bolts to 70 to 80 ft-lbs.

WARNING! Do not exceed 5 mph during towing. Exceeding 5 mph could cause seriou injury or death to you or other workers or damage to the machine.

“SUPPORT POST” (optional) control lever

“ATRS LIFT” control lever (if equipped)

Fire suppression actuator location (if equipped)

Hydraulic oil level sight gauge

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Bucyrus - Model RB1-85L Roof Bolter



Begin towing.

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Shutdown procedure______________________

______________________________ Operation

Shutdown procedure

Torque hub

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.

WARNING! 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.

Fig. 17: Torque hub

CAUTION! This unit is equipped with a tram station canopy. Be careful not to hit your head when entering the tram station. 

Completely lower stab feet and ATRS (if equipped) to the bottom.



Completely lower “T” bar (if equipped).



Properly tend to trailing cable.



Push the pump “STOP” switch.



Turn circuit breaker lever to "OFF” position.

Retaining bolts (2)

© BUCYRUS AMERICA, INC.

© BUCYRUS AMERICA, INC.

WARNING! Always check before lowering the stab feet, booms, and the “T” bar to make sure no one has any part of their body near moving parts of a machine.

The roof bolter is equipped with torque hubs (Fig. 17) 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 90°. After rotating the hub to the disengaged position re-install the locking bolts.

End cap button pointing outward

Normal tram position

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Bucyrus - Model RB1-85L Roof Bolter

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Operation _______________________________

_______________________ Starting procedure

Hazard Zone

Starting procedure

The hazard zone exists unless:

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.

 the trailing cable is disconnected or 

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

Fig. 18: Hazard zone

IMPORTANT! Before start-up, check that daily maintenance has been performed on the machine.    Get in the operator’s compartment and adjust the seat.

© BUCYRUS AMERICA, INC.

WARNING! Never try to adjust the operator's seat while the roof bolter is in motion.

Check that all personnel are a safe distance from the machine.



WARNING! Be sure no one is in the hazard zone (Fig. 18) before operating any levers or pedals.

Operate the valve levers to ensure that they are in the center, neutral, position.



WARNING! Never operate any levers or pedals (located inside the operators compartment) from outside the operators compartment.

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



WARNING! This machine must not be operated without the canopy in place.  

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Bucyrus - Model RB1-85L Roof Bolter

Press the pump “START” switch located on the controller to the right of the operator.



Strike the panic strip, located to the right of the operator, to confirm that it is operational. Striking the panic strip should shutdown the pump motor immediately.



Reset the circuit breaker. The circuit breaker must first be turned to the “RESET” position, then to “ON”.



Press the pump “START” switch.

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The roof bolter is now ready to operate.

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WARNING! This machine is equipped with a canopy. Be careful not to hit your head when entering or leaving the operators compartment.