CAT OPERATION PREVENTIVE MAINTENANCE & SERVICE GUIDE Bucyrus RB2-52A ROOF BOLTER (A6474X175) - PDF

OPERATION, PREVENTIVE MAINTENANCE AND SERVICE GUIDE MODEL RB2-52A ROOF BOLTER

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

A6474X175

NOTICE THIS GUIDE IS NOT INTENDED TO BE A COMPLETE OPERATING OR SERVICE MANUAL OR GUIDE. IT IS PREPARED ON THE BASIS THAT THE INDIVIDUAL OPERATING THIS UNIT IS TRAINED IN THE OPERATION OF UNITS OF THIS TYPE AND HAS HAD SPECIAL TRAINING TO OPERATE THIS UNIT. FURTHER, IT IS ASSUMED THAT THE INDIVIDUAL WILL TAKE NECESSARY PRECAUTIONS TO ENSURE SAFE OPERATION FOR HIMSELF AND FOR OTHERS. THE TEXT IN NO WAY COVERS ALL POSSIBLE CONTINGENCIES OR OPERATING PROCEDURES. THIS GUIDE IS DESIGNED TO BE OF GENERAL ASSISTANCE. IF PROCEDURES OR CONDITIONS ARE ENCOUNTERED WHICH ARE NOT INCLUDED IN THIS GUIDE, THE OPERATOR SHOULD GET EXPERT ASSISTANCE BEFORE ATTEMPTING TO OPERATE OR REPAIR THE MACHINE. FOR THE BUCYRUS AMERICA, INC. SERVICE DEPARTMENT, CALL (540) 980-4530.

BUCYRUS AMERICA, INC. ASSUMES NO RESPONSIBILITY FOR THE PERFORMANCE OR OPERATION OF THIS UNIT IF IT IS ALTERED IN ANY MANNER.

NOTICE SOME ILLUSTRATIONS IN THIS GUIDE MAY SHOW GUARDS OR COVERS REMOVED FOR PURPOSES OF CLARITY. NEVER OPERATE UNIT WITHOUT ALL GUARDS AND COVERS IN PLACE. SOME ILLUSTRATIONS IN THIS GUIDE MAY SHOW UNITS WITH OPTIONAL EQUIPMENT INSTALLED. THIS OPTIONAL EQUIPMENT MAY BE PURCHASED FROM YOUR LOCAL BUCYRUS AMERICA, INC. DEALER. SOME ILLUSTRATIONS IN THIS MANUAL MAY BE OF PROTOTYPE MODELS. PRODUCTION MODELS MAY VARY IN SOME DETAIL. CONTINUING IMPROVEMENT AND ADVANCEMENT OF PRODUCT DESIGN MAY CAUSE CHANGES TO YOUR MACHINE WHICH MAY NOT BE INCLUDED IN THIS PUBLICATION. EACH PUBLICATION IS REVIEWED AND REVISED, AS REQUIRED, TO UPDATE AND INCLUDE THE CHANGES IN LATER ADDITIONS. BUCYRUS AMERICA, INC. RESERVES THE RIGHT TO MODIFY OR MAKE CHANGES WITHIN A SPECIFIC MODEL GROUP WITHOUT NOTICE AND WITHOUT INCURRING ANY LIABILITY TO RETROFIT UNITS PREVIOUSLY SHIPPED FROM THE FACTORY. CONTACT YOUR BUCYRUS AMERICA, INC. DEALER FOR MAINTENANCE THAT IS NOT COVERED IN THIS PUBLICATION.

OPERATION, PREVENTIVE MAINTENANCE AND SERVICE GUIDE MODEL RB2-52A FOOF BOLTER

A6474X175 Revision 4 December, 2007 Bucyrus America, Inc. 4041 Wurno Road Pulaski, VA 24301

THIS GUIDE IS TO BE USED ONLY WITH THE MODEL RB2-52A ROOF BOLTER. OTHER MODELS IN THIS SERIES MAY HAVE OPERATING FEATURES UNLIKE THE MODEL RB2-52A.

TABLE OF CONTENTS Page IMPORTANT SAFETY INSTRUCTIONS..................................................................................... 1 MAJOR HAZARDS .................................................................................................................... 2 SAFETY PRECAUTIONS AND GUIDELINES .......................................................................... 4 OVERVIEW ................................................................................................................... 4 PRE-START INSPECTION ........................................................................................... 4 STARTING ..................................................................................................................... 4 OPERATION ................................................................................................................. 4 STOPPING .................................................................................................................... 5 MAINTAINANCE ........................................................................................................... 5 INTRODUCTION ........................................................................................................................ 7 GENERAL INFORMATION ........................................................................................................ 9 CONTROLS AND INDICATORS ............................................................................................. 17 OPERATOR’S COMPARTMENT ...................................................................................... 17 FIRE SUPPRESSION ACTUATORS .......................................................................... 18 PANIC STRIP .............................................................................................................. 18 TRAM CONTROL PEDAL ........................................................................................... 19 TRAM/STEERING CONTROL LEVER (Joystick) ....................................................... 19 VALVE BANK CONTROL LEVERS ............................................................................ 20 VERTICAL ARTICULATION CONTROL LEVER ........................................................ 20 POWER FILL CONTROL LEVER ............................................................................... 20 HYDRAULIC P.T.O. CONTROL LEVER ..................................................................... 20 GAUGE BLOCK .......................................................................................................... 20 CABLE REEL FOOT PEDAL ....................................................................................... 21 CONTROLLER ............................................................................................................ 21 LIGHT SWITCH ........................................................................................................... 21 CIRCUIT BREAKER RESET SWITCH ....................................................................... 22 PUMP START BUTTON .............................................................................................. 22 PUMP STOP BUTTON ................................................................................................ 22 OPERATOR’S SEAT ................................................................................................... 22 OUTSIDE OPERATOR’S COMPARTMENT ..................................................................... 23 OIL SIGHT GAUGE ..................................................................................................... 24 TORQUE HUB ............................................................................................................. 24 BOOM ARM CONTROLS ............................................................................................ 25 TRAM DIVERSION VALVE LEVER ............................................................................ 25 INCH TRAM/STEERING CONTROL VALVE LEVER ................................................. 26 PANIC STRIPS ............................................................................................................ 26 START BUTTON ......................................................................................................... 27 FIRE SUPPRESSION ACTUATORS .......................................................................... 27 INTEGRATED VALVE (ROTATION FUNCTIONS) .................................................... 28 ROTATION FLOW CONTROL .................................................................................... 28 ROTATION CHECK VALVE ........................................................................................ 28 BOOM FLOW CONTROL ........................................................................................... 28 DUAL RELIEF CONTROL ........................................................................................... 28

TABLE OF CONTENTS (Continued) Page BOOM CONTROL VALVE BANK (RIGHT BOOM) ..................................................... 29 BOOM CONTROL VALVE BANK (LEFT BOOM) ....................................................... 30 STAB SHOE CONTROL LEVER ................................................................................ 30 BOOM SWING CONTROL LEVER ............................................................................. 30 CANOPY CONTROL LEVER ...................................................................................... 30 DRILL BOX SUMP CONTROL LEVER ....................................................................... 31 DRILL FEED CONTROL LEVER ................................................................................ 31 FAST FEED CONTROL LEVER ................................................................................. 31 ROTATION CONTROL LEVER .................................................................................. 31 T-BAR/ARTICULATION VALVE BANK ....................................................................... 31 T-BAR CONTROL LEVER .......................................................................................... 32 VERTICAL ARTICULATION CONTROL LEVER ........................................................ 32 OPERATION ............................................................................................................................ 33 PRELIMINARY CHECKS ............................................................................................ 33 BEFORE OPERATING MACHINE .............................................................................. 33 TO OPERATE MACHINE ............................................................................................ 34 DRILLING .......................................................................................................................... 37 EXTENSION STEELS SELECTION ........................................................................... 39 DRILLING WITH EXTENSION STEELS ..................................................................... 40 DRILL OPTIONS AND ADJUSTMENTS .......................................................................... 42 INSTALLATION OF MECHANICALLY ANCHORED ROCK BOLTS .............................. 43 INSTALLATION OF FULLY GROUTED RESIN BOLTS ................................................. 45 SHUTDOWN PROCEDURE .............................................................................................. 47 SAFETY PRECAUTIONS FOR UNDERGROUND OPERATION .................................... 48 GENERAL DRILLING AND BOLTING SAFETY ......................................................... 48 TRAMMING SAFETY RULES ..................................................................................... 48 SHUTTING DOWN THE ROOF BOLTER .................................................................. 49 HAZARD ZONE ........................................................................................................... 50 TOWING A DISABLED MACHINE ................................................................................... 51 GENERAL MAINTENANCE INSTRUCTIONS ........................................................................ 53 BEFORE MAINTENANCE INSTRUCTIONS .............................................................. 53 MAINTENANCE CHECK LIST .......................................................................................... 54 PERIODIC MAINTENANCE PROCEDURES ................................................................... 55 EVERY SHIFT ............................................................................................................. 55 EVERY OTHER SHIFT ............................................................................................... 59 WEEKLY ...................................................................................................................... 62 EVERY THREE MONTHS ........................................................................................... 64 EVERY SIX MONTHS ................................................................................................. 65

TABLE OF CONTENTS (Continued) Page LUBRICATION CHART ..................................................................................................... 67 LUBRICANT SPECIFICATIONS ....................................................................................... 69

RB2-52A ROOF BOLTER

BUCYRUS AMERICA, INC.

IMPORTANT SAFETY INSTRUCTIONS This guide provides important information to familiarize you with safe operating and maintenance procedures for the Model RB2-52A FOOF BOLTER. Even though you may be familiar with similar equipment, you MUST read and understand this guide before operating this unit.

Safety is everyone's business and must be one of your primary concerns. Knowing the guidelines covered in the following paragraphs will help provide for your safety, for the safety of those around you, and for the machine's proper operation.

LOOK FOR THESE SYMBOLS WHICH POINT OUT ITEMS OF EXTREME IMPORTANCE TO YOU AND YOUR CO-WORKERS’ SAFETY. READ AND UNDERSTAND THOROUGHLY. HEED THE WARNING AND FOLLOW THE INSTRUCTIONS.

WARNING WARNING SAFETY NOTES MUST BE FOLLOWED. YOUR MISTAKE MIGHT RESULT IN SERIOUS INJURY OR DEATH TO YOURSELF OR OTHERS.

CAUTION CAUTION SAFETY NOTES ARE ALSO VERY IMPORTANT. THEY POINT OUT TO YOU WHERE YOUR MISTAKES COULD CAUSE PHYSICAL HARM TO YOU OR OTHERS, OR DAMAGE TO THE MACHINE.

NOTICE NOTICE IS USED TO NOTIFY PEOPLE OF INSTALLATION, OPERATION, OR MAINTENANCE INFORMATION WHICH IS IMPORTANT BUT NOT HAZARDRELATED.

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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 30). Use extreme caution when moving machine. The machine should be properly shutdown (see page 47) 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.

Turning 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 47) before servicing and securely supported before working around or under the drill boom.

OPERATOR’S AREA (Drilling ControIs)

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, hands, under protective canopy at alI times during bolting or drilling operations.

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BUCYRUS AMERICA, INC.

MAJOR HAZARDS 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 53).

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, motors 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. Have any malfunctioning, broken or missing parts corrected or replaced before use.

VERIFY that all maintenance has been performed.

VERIFY that all the instruction and safety labels are in place and readable. important as any other equipment on the machine.

These are as

CLEAN any foreign material from the operator's compartment.

THIS Model RB2-52A 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 33) when the machine is to be used.

DO NOT operate any levers or pedals if anyone is in the Hazard Zone (page 50).

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.

USE extreme caution and be observant when working in close quarters or in congested or blindtravel areas.

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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 canopies 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 47) 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

RB2-52A ROOF BOLTER FIGURE 1

The BUCYRUS AMERICA, INC. Model RB2-52A 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 RB2-52A Roof Bolter, study the illustration (Figure 8, page 17 and Figure 18, page 23) 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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SECTION 1 - GENERAL INFORMATION PURPOSE OF THIS GUIDE This guide provides operating and maintenance information for operators of the Model RB252A 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. The guide is divided into three (3) sections:

SECTION 1 - GENERAL This section contains general information about the roof bolter.

SECTION 2 - OPERATION This section explains pre-operation, start-up, and basic operating procedures.

SECTION 3 - MAINTENANCE This section explains the periodic maintenance procedures; it also includes lubrication requirements.

OPERATION - FAMILIARIZATION 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 his assistant move to the front (cradle) controls. An "inch tram” control at the front of the machine, used in conjunction with the cradle swing controls, allows for accurate final positioning of the machine. Once the machine is properly positioned, the operators raise the “T” bar to the mine roof. They then lower the cradle stab foot to the mine floor and begin operating.

The operator then moves from the cradle controls to the drilling controls, which are located under the drill station canopies leaving the dual relief valve in the "OFF' position (or turning it “ON” for resin bolting), each operator drills a starter hole, using a pilot bit. Operators then complete 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) each operator installs a bolt and torque’s it into place.

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NOTICE THROUGHOUT THIS GUIDE THE TERMS RIGHT-HAND AND LEFT-HAND (OR RIGHT AND LEFT) ARE USED TO DESCRIBE THE LOCATION OF COMPONENTS, THEY REFER TO POSITION RELATIVE TO AN OPERATOR SEATED IN THE TRAM CAB AND FACING FORWARD (SEE ILLUSTRATION BELOW.)

FIGURE 2

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BUCYRUS AMERICA, INC.

GENERAL MACHINE LAYOUT FIGURE 3

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GENERAL HAZARD LABEL PLACEMENT FIGURE 4

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HAZARD LABELS FIGURE 5

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HAZARD LABELS FIGURE 6

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HAZARD LABELS FIGURE 7

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BUCYRUS AMERICA, INC.

CONTROLS AND INDICATORS OPERATOR'S COMPARTMENT

WARNING BEFORE OPERATING ANY PEDALS OR LEVERS ON THE ROOF BOLTER, ALWAYS MAKE SURE THAT NO ONE IS IN THE HAZARD ZONE (FIGURE 30, PAGE 50). 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 8). These include: the fire suppression actuator, panic strip, tram/steering control (joystick), valve bank control levers (vertical articulation, power fill and optional hydraulic P.T.O.), gauge block, tram control pilot valve, cable reel pilot control valve and controller (light switch, circuit breaker reset switch, pump start switch and pump stop switch).

OPERATOR’S COMPARTMENT FIGURE 8

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FIRE SUPPRESSION ACTUATORS - The two fire suppression (remote) actuators (Figure 9) are located to the front of and to the operator's left while sitting in the operator’s seat and on the right boom assembly. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the fire suppression system from either of the two actuators, pull the safety pin and strike the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine.

FIRE SUPPRESSION ACTUATORS FIGURE 9

WARNING BE PREPARED FOR A SUDDEN STOP WHEN THE PANIC STRIP IS ACTUATED DURING NORMAL TRAMMING OF THE MACHINE. PANIC STRIP (Operators Compartment) - The panic strip (Figures 8 and 10) is located to the operator's right on top of the controller assembly while sitting in the operator’s seat. The panic strip is used to break the control circuit only in emergency situations, stopping all motors. The panic strip can be actuated by striking with a small amount of force (minimum of 7 lbs. nominal force).

PANIC STRIP (Operator’s Compartment) FIGURE 10

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RB2-52A ROOF BOLTER

BUCYRUS AMERICA, INC.

NOTICE THE ROOF BOLTER'S TRAM/STEERING VALVE (JOYSTICK) WILL NOT OPERATE WITHOUT FIRST DEPRESSING THE TRAM CONTROL PEDAL AND HOLDING IT IN THIS POSITION UNTIL TRAMMING AND STEERING IS COMPLETED. TRAM CONTROL PEDAL - The tram control pedal (Figure 8) is located in front of and to the operator’s left while sitting in the operator’s seat. The pedal activates the pilot control valve which in turn activates the tram/steering control valve (joystick). The pedal must be depressed and held in the depressed position before the tram/steering control lever can be actuated.

NOTICE THE ROOF BOLTER'S TRAM AND STEERING SPEED IS VARIABLE. THIS MEANS THAT THE FARTHER THE TRAM HANDLE IS ACTUATED THE FASTER THE ROOF BOLTER WILL TRAVEL OR TURN.

NOTICE ONCE THE TRAM/STEERING CONTROL LEVER IS RELEASED BY THE OPERATOR THE CONTROL LEVER AUTOMATICALLY RETURNS TO THE CENTERED (NEUTRAL) POSITION. TRAM/STEERING CONTROL LEVER (Joystick) - The tram/steering control lever (Figure 11) is used to steer and regulate the speed of the roof bolter. It is operated by the right hand while sitting in the operator’s seat. To tram “FORWARD” push the lever towards the front the machine and to tram in “REVERSE” pull the lever towards the rear of of the machine. To steer “RIGHT” push the control lever towards the right side of the machine and to steer “LEFT” pull the control lever towards the left side of the machine. The roof bolter may also be trammed and steered at the same time by moving the tram/steering control lever simultaneously to the desired direction.

TRAM/STEERING CONTROL LEVER FIGURE 11

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NOTICE ONLY SPRING CENTERED VALVE SECTIONS ARE USED ON THE RB2-52A ROOF BOLTER. THIS MEANS THAT ONCE THE CONTROL LEVER IS RELEASED BY THE OPERATOR THE CONTROL LEVER AUTOMATICALLY RETURNS TO THE CENTERED (NEUTRAL) POSITION. VALVE BANK CONTROL LEVERS (Operator's Compartment) - In the operator's compartment located to the right of the operator is a group of control levers (Figures 8 and 12). These levers control the vertical articulation, power fill and optional hydraulic P.T.O.

VALVE BANK CONTROL LEVERS (OPERATOR’S COMPARTMENT) FIGURE 12 VERTICAL ARTICULATION CONTROL LEVER - The vertical articulation control lever (Figure 12) is used to control the ground clearance of the machine during tramming operations. To raise the center of the machine, push the control lever towards the front of the machine. To lower the center of the machine, pull the control lever toward the rear of the machine.

POWER FILL CONTROL LEVER - The power fill (Figure 12) provides the operator with an automatic controlled hydraulic oil replenishing system. To activate the power fill pull the control lever towards the rear of the machine and to deactivate release the lever and it will automatically return to its original position.

HYDRAULIC P.T.O. CONTROL LEVER (Optional) - The hydraulic P.T.O. (Figure 12) provides the roof bolter operator or other qualified individual in the work area with optional capability to power accessory equipment within the work area. To activate the P.T.O. push the lever towards the front of the machine and to deactivate release the lever and it will automatically return to its original position.

GAUGE BLOCK - The gauge block (Figures 8 and 13) is located to the operator's right while sitting in the operator’s seat. The gauge block consists of (4) four pressure gauges which provides a means of measuring oil pressure in individual circuits.

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BUCYRUS AMERICA, INC.

GAUGE BLOCK FIGURE 13 CABLE REEL FOOT PEDAL - The cable reel foot pedal (Figure 8), located in front of the operator’s seat and is normally operated by the right 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.

CONTROLLER - The controller (Figures 8 and 14) located inside the operator’s compartment has (4) four control switches. These include; light switch, circuit breaker reset, pump start and pump stop.

CONTROLLER ASSEMBLY FIGURE 14 LIGHT SWITCH - The light switch (Figures 14 and 15), located on the front cover of the controller assembly, 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.

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HEADLIGHT SWITCH FIGURE 15 CIRCUIT BREAKER RESET SWITCH - The circuit breaker reset switch (Figures 14 and 16), 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.

CIRCUIT BREAKER SWITCH FIGURE 16 PUMP START BUTTON - The pump start button (Figure 14), located on the front cover of the controller box 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.

PUMP STOP BUTTON - The pump stop button (Figure 14), located on the front cover of the controller box 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.

CAUTION BE SURE OPERATOR’S SEAT IS ADJUSTED FOR MAXIMIUM VISIBILITY AVAILABLE WITHIN YOUR OPERATING LIMITS BEFORE THE ROOF BOLTER IS PUT INTO MOTION. OPERATOR’S SEAT - The operator’s seat (Figures 8 and 17) has (4) four height adjustments.

To adjust the operator’s seat, lift the back and insert the adjustment rod into the desired adjustment slot.

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SEAT ADJUSTMENT FIGURE 17 OUTSIDE OPERATOR’S COMPARTMENT

CONTROLS AND INDICATORS (Located Outside Operator’s Compartment) FIGURE 18

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OIL SIGHT GAUGE - The oil sight gauge (Figures 18 and 19), located behind the left rear wheel of the roof bolter 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.

OIL SIGHT GAUGE FIGURE 19

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. TORQUE HUB - The roof bolter is equipped with torque hubs (Figures 18 and 20) 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.

TORQUE HUBS FIGURE 20

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WARNING WHEN OPERATING THE ROOF BOLTER FROM CONTROLS ON 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. BOOM ARM CONTROLS - On the outside of both right and left booms are the controls and indicators (Figure 18) for drilling operations and maneuvering machine between bolt holes. These include; the inch tram/steering control valve, tape switches, start buttons, fire suppression actuator, integrated valve (rotation functions), integrated valve (A.T.R.S. functions), t-bar valve bank, articulation control, fast feed diversion valve, boom control valve bank (right boom) and boom control valve bank (left boom).

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.

NOTICE 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. TRAM DIVERSION VALVE LEVER - The tram diversion lever (Figures 18 and 21) is located on the left boom assembly, in front of the inch tram. steering control valve. The tram diversion lever 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 before the inch tram/steering control lever can be actuated.

TRAM DIVERSION VALVE LEVER FIGURE 21

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INCH TRAM/STEERING CONTROL VALVE LEVER – The inch tram/steering control lever (Figures 18 and 22) is located on the outside of the left boom assembly. The lever is used for maneuvering the roof bolter between bolt holes during drilling operations only. To tram “FORWARD” push the lever towards the front the machine and to tram in “REVERSE” pull the lever towards the rear of of the machine. To steer “RIGHT” push the control lever towards the right side of the machine and to steer “LEFT” pull the control lever towards the left side of the machine. The roof bolter may also be trammed and steered at the same time by moving the tram/steering control lever simultaneously to the desired direction.

INCH TRAM/STEERING CONTROL VALVE FIGURE 22 PANIC STRIPS - The roof bolter is equipped with (4) four individual panic strips (Figures 18 and 23) on both right and left booms (two per boom). 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).

PANIC STRIPS FIGURE 23

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START BUTTON - The roof bolter is equipped with (2) start buttons (Figure 24), one on each boom assembly. The “START” button is used to start the roof bolter’s electric motor from either boom. To “START” the electric motor, depress the “START” button and release after the electric motor has started.

START BUTTON FIGURE 24 FIRE SUPPRESSION ACTUATOR - The two fire suppression (remote) actuators (Figure 25) are located to the front of and to the operator's left while sitting in the operator’s seat and on the right boom assembly. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the fire suppression system from either of the two actuators, pull the safety pin and strike the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine.

FIRE SUPPRESSION ACTUATORS FIGURE 25

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INTEGRATED VALVE (ROTATION FUNCTIONS) - The integrated valves (Figure 26) for both right and left booms operate in the same manner. They give the operator of each boom a means of limiting the flow of hydraulic oil to the boom and rotation circuits.

INTEGRATED VALVE (ROTATION FUNCTIONS) FIGURE 26 ROTATION FLOW CONTROL - To adjust hydraulic flow for the rotation circuit (Figure 26), turn the adjustment knob clockwise (CW) to increase torque and turn the adjustment knob counterclockwise (CCW) to decrease torque.

ROTATION CHECK VALVE - The rotation check valve (Figure 26) is preset at the factory and does not require any adjustment.

BOOM FLOW CONTROL - To adjust hydraulic flow for the boom circuit (Figure 26), turn the adjustment knob clockwise (CW) to increase flow and turn the adjustment knob counterclockwise (CCW) to decrease flow.

DUAL RELIEF CONTROL - The dual relief control (Figure 26), 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.

NOTICE IF RESIN BOLTS ARE BEING INSTALLED, THE DUAL RELIEF CONTROL MUST BE PUSHED IN.

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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 DRILL STATION CANOPY.

WARNING DO NOT OPERATE ROOF BOLTER WITHOUT DRILL STATION CANOPIES. OPERATING WITHOUT DRILL STATION CANOPIES CAN RESULT IN SEVERE INJURY OR DEATH. BOOM CONTROL VALVE BANK (RIGHT BOOM) - The boom control valve bank located on the right boom (Figures 18 and 27) includes the stab shoe, boom swing, canopy, drill box sump, drill feed, fast feed and rotation control levers.

BOOM CONTROL VALVE BANK (RIGHT BOOM) FIGURE 27

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BOOM CONTROL VALVE BANK (LEFT BOOM) - The boom control valve bank located on the left boom (Figures 18 and 28) includes the stab shoe, boom swing, canopy, drill box sump, drill feed, fast feed and rotation control levers.

BOOM CONTROL VALVE BANK (LEFT BOOM) FIGURE 28 STAB SHOE CONTROL LEVER - The stab shoe control levers (Figures 27 and 28) for both right and left booms operate in the same manner. They are used to raise or lower the stab shoe for that particular 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 levers (Figures 27 and 28) for both right and left booms operate in the same manner. They control the swing of both booms individually inward and outward. To swing the boom in the outward direction, pull the control lever for that particular boom towards the operator and to swing the boom inward, push the control lever for that particular boom away from the operator.

CANOPY CONTROL LEVER - The canopy control levers (Figures 27 and 28) for both right and left booms operate in the same manner. They are used to raise or lower the canopy for that

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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 (Figures 27 and 28) 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.

DRILL FEED CONTROL LEVER - The drill feed control lever (Figures 27 and 28) 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.

FAST FEED CONTROL LEVER - The fast feed control lever (Figures 27 and 28) provides the operator with the ability of increasing the speed (beyond normal speed delivered by the drill feed control lever) of the boom elevation. 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 (Figures 27 and 28) 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.

T-BAR/ARTICULATION VALVE BANK - The T-bar/articulation valve bank (Figures 18 and 29) is located on the left boom assembly. The valve bank consists of the T-bar control lever and the articulation control lever.

T-BAR/ARTICULATION VALVE BANK FIGURE 29

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T-BAR CONTROL LEVER - The T-bar control lever (Figure 27) is used to raise or lower the Tbar assembly. To raise the T-bar push the control lever away from the operator and to lower the T-bar pull the control lever toward the operator.

VERTICAL ARTICULATION CONTROL LEVER - The vertical articulation control lever (Figure 27) is used to control ground clearance of the machine during inch tramming operations. To raise the center of the machine, push the control lever away from the operator. To lower the center of the machine, pull the control lever toward the operator.

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SECTION 2 - OPERATION WARNING FAILURE TO READ AND UNDERSTAND ALL OPERATING INSTRUCTIONS BEFORE STARTING THE ROOF BOLTER COULD RESULT IN SERIOUS INJURY OR DEATH TO THE OPERATOR OR 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 30, PAGE 50) 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 45, page 67): 1. HYDRAULIC OIL LEVEL - Check level in sight gauge.

2. BLOWER - Check oil level.

3. DRILL BOXES - Check oil level.

4. HYDRAULIC FILTERS - 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.

WARNING NEVER OPERATE ANY LEVERS OR PEDALS (LOCATED OPERATORS COMPARTMENT) FROM OUTSIDE THE COMPARTMENT.

INSIDE THE OPERATORS

THIS MACHINE IS EQUIPED WITH A CANOPY. BE CAREFUL NOT TO HIT YOUR HEAD WHEN ENTERING OR LEAVING THE OPERATORS COMPARTMENT. THIS MACHINE MUST NOT BE OPERATED WITHOUT THE CANOPY IN PLACE. 6. Get into the operators 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 each blower clutch control. If the motor is running in wrong direction, shutdown machine at once.

WARNING 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 canisters and replace filters.

11. Before tramming machine from the rear tram area (operator’s compartment), the cradles stab feet must be completely elevated to provide ground clearance. Also, check to see that the “T” bar is in it’s completely collapsed position and that the “T” bar foot is completely elevated.

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WARNING 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 30, PAGE 50) BEFORE OPERATING ANY LEVERS OR PEDALS.

WARNING THE INCH TRAM AND STEERING CONTROLS LOCATED ON THE LEFT BOOM 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 lever slowly back and forth to get the feel of how the machine will steer.

NOTICE THE ROOF BOLTER’S TRAM/STEERING CONTROL LEVER IS VARIABLE. THIS MEANS THAT THE FARTHER THE TRAM HANDLE IS ACTUATED THE FASTER THE ROOF BOLTER WILL TRAVEL OR TURN.

CAUTION WHILE TRAMMING MACHINE TRAILING CABLE MUST BE HANDLED WITH CARE.

WARNING MAKE SURE NO ONE IS IN THE HAZARD ZONE (FIGURE 30, PAGE 50). BEFORE TRAMMING MACHINE. 14. The roof bolter is now ready to tram. Slowly move the tram/steering control lever in the intended direction of travel.

NOTICE 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.

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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.

CAUTION DO NOT PERMIT THE BUILD-UP OF MUD OR OTHER MATERIAL TO COLLECT UNDER OR AROUND THE CABLE REEL. 15. Be careful not to damage trailing cable while tramming. Depress cable reel foot pedal when picking up cable; release cable reel foot pedal when paying out cable.

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DRILLING CAUTION NEVER EXCEED THE DRILL ROD MANUFACTURER'S RECOMMENDATIONS FOR DRILL TORQUE AND THRUST. EXCESSIVE TORQUE AND THRUST CAN CAUSE THE DRILL ROD TO BUCKLE OR BREAK, THEREBY CREATING A HAZARD FOR PERSONNEL IN THE VICINITY OF THE ROOF BOLTER.

CAUTION DURING DRILLING AND BOLTING OPERATIONS OPERATOR MUST WATCH DRILL ROD AND REGULATE BOOM FEED CONTROL TO PREVENT DRILL ROD BUCKLING.

WARNING DURING DRILLING AND BOLTING OPERATIONS OPERATOR MUST REMAIN UNDER DRILL STATION CANOPY AT ALL TIMES.

NOTICE IF YOU ARE NOT SURE HOW MUCH DUST IS IN THE DUST COLLECTOR TANKS, EMPTY THE TANKS. 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.

A. Raise “T” bar until it comes in contact with mine roof.

B. Swing drilling assemblies to the desired position.

C. Lower cradle stab feet to mine floor.

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. Place other hand on the fast feed control lever.

Raise the drill to about one foot from mine roof using the fast feed. Then raise the drill to contact with the roof using slow feed.

8. Move your hand from the boost lever 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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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. 11. While maintaining the downward travel of the boom, shift your hand from the rotation control lever to the fast feed control lever.

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

13. Remove the spotter drill.

CAUTION EXAMINE DRILL ROD FOR DEFECTS; DO NOT USE A DRILL ROD THAT IS BENT OR DAMAGED. 14. Examine drill rod for defects; do not use a drill rod that is bent or damaged. lnsert drill rod in drill chuck.

15. 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. 16. 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.

17. With one hand on the feed control lever and the other hand on the rotation control lever, you are now ready to start drilling in a normal, safe fashion.

WARNING NEVER GRASP ANY OBJECT WHEN IT IS ROTATING IN THE DRILL BOX. Judging the proper feed rate requires some experience. Too little feed rate can cause rapid bit wear by permitting the bit to be ground by the rock rather than the bit penetrating and cutting the rock.

Too high a feed force, with relief pressures to high, can cause the drill rod to buckle.

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

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

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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 sympton 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 very particularly difficult to remove extensions.

17. 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.

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 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.

18. 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.

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3. When planning for drill steel lengths to be used with the BUCYRUS AMERICA, INC. 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, INC. recommends the driver length to be 6” less than starter length.

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

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.

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

NOTICE BIT SIZING IS IMPORTANT. THE FOLLOWING INFORMATION ON BIT SIZING IS PROVIDED ONLY AS A GENERAL GUIDE. SPECIFIC REQUIREMENTS WILL VARY WITH MINE CONDITIONS. BE SURE TO CHECK WITH MSHA AND STAFF OFFICIALS TO BE SURE THAT YOUR BOLTING OPERATION IS PERMISSIBLE. To facilitate manual insertion and removal of extensions, it is common practice to use a larger bit on the starter steel than is used on the lead extension. For 1-3/8” expansion shells used with mechanical bolts, it is generally permissible to use 1-1/2” starter steel bit (or starter bit). For 1” resin bolts, it is usually permissible to use 1-1/32” starter bit.

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

It is important to use only the finisher bit for the upper portion of the hole because the anchorage provided by either expansion shells or resin is dependent on the proper size hole.

Even though resin bolts usually anchor over the full length, the upper anchorage is considered the most important.

Where one or more middle extensions are required, bit sizing is very important to the ease of removal of the middle and lead extensions. Worn bits drill smaller holes than new bits. If you have drilled a portion of the hole with a worn bit and it is necessary to change for the remainder of the desired hole depth, be sure to ream the “worn bit hole” with the new bit. The worn bit hole

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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 1-3/8” 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.

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.

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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DRILL OPTIONS AND ADJUSTMENTS NOTICE BE SURE YOUR ROOF BOLTER IS SET UP AND ADJUSTED FOR YOUR CONDITIONS. Since conditions vary extensively from mine to mine, or even between mine sections, BUCYRUS AMERICA, INC. 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, INC. 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, INC. 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.

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. 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.

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 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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WARNING 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, pull out on the dual relief 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. 5. With the dual relief in the "ON” position (pushed in), 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.

NOTICE THE INTEGRATED VALVE (ROTATION FUNCTIONS) PROVIDES TWO FUNCTIONS. IT LIMITS ROTATION TORQUE TO THE PRESET VALUE REQUIRED FOR YOUR CONDITIONS. SECOND, IT LIMITS THE BOOM FORCE ON THE WRENCH TO A CONSISTENT LOW FORCE PROVIDED TO MAINTAIN FIRM CONTACT OF THE WRENCH AND BOLT HEAD. 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, INC. 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. provided by your resin supplier.

Specific instructions must be

A. 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 OR 2 INCHES LONGER.

NOTICE 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, INC. RECOMMENDS AN OVERALL WRENCH LENGTH 12 INCHES.

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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 reat on top of the bolt.

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.

CAUTION 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.

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. SEVERE INJURY OR DEATH COULD OCCUR.

WARNING 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.

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 MACHINE.

CAUTION THIS UNIT IS EQUIPED WITH A TRAM STATION CANOPY. BE CAREFUL NOT TO HIT YOUR HEAD WHEN ENTERING THE TRAM STATION. 2. Completely lower stab feet and booms to the bottom.

3. Completely lower “T” bar.

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 OPERATION 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 immedately 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.

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 DRILL STATION CANOPY.

WARNING DO NOT OPERATE ROOF BOLTER WITHOUT DRILL STATION CANOPIES. OPERATING WITHOUT DRILL STATION CANOPIES 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 feet, booms, and “T” bar for tramming.

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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.

7. Be especially careful when tramming for long distances, through intersections, in narrow intries, 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 macninery 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 47).

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HAZARD ZONE FIGURE 30

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TOWING A DISABLED MACHINE WARNING IT IS NOT POSSIBLE, WITHIN THE SCOPE OF THIS GUIDE, TO ANTICIPATE ALL POSSIBLE ARRANGEMENTS FOR TOWING A DISABLED UNIT. BEFORE ATTEMPTING TO TOW ANY VEHICLE, YOU MUST TAKE ALL POSSIBLE PRECAUTIONS TO PROTECT THE OPERATORS AND 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.

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. 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.

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

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SECTION 3 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, INC. 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 47).

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.

WARNING 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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MAINTENANCE CHECK LIST (For Specific Instructions See Page 55) (For Lubricant Specifications See Pages 69 & 70) (For Lubrication Chart See Page 67)

ITEM OR LOCATION 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 EVERY OTHER SHIFT Blower Belts 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 Center Section WEEKLY Hydraulic Pressure Settings Electrical System Trailing Cable Cable Reel (Drive Chain) Drill Box Explosion Proof Housings Tire And Wheel Mounting Bolts EVERY THREE MONTHS Blower (Drive End) Torque Hubs Electric Motor Hydraulic Oil Filters EVERY SIX MONTHS Hydraulic Oil And Suction Strainer Pump Electric Motor Cable Reel

INSPECT

ADJUST

CHANGE

LUBRICAT E

• •

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

A/R A/R

• •

• • • •

• • • •

A/R - Perform service as required.

54

• • •

• A/R •

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BUCYRUS AMERICA INC.

PERIODIC MAINTENANCE PROCEDURES EVERY SHIFT

CAUTION 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.

WARNING 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 areas.

2. Check the operation and condition of all switches and panic strips (Figure 31).

SWITCHES AND PANIC STRIPS FIGURE 31

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

4. Visually inspect the condition and readability of all warning tags, labels, and reflectors.

Replace any found missing or damaged.

5. Check the operation and condition of all hydraulic controls (Figure 32).

HYDRAULIC CONTROLS FIGURE 32 6. Check the hydraulic oil level (Figure 33) by looking at the sight glass located on the frame behind the left rear wheel. The oil level should be kept within 1/2” of the full level. If hydraulic oil is needed, fill with spec.100-1. (For Fluid Specifications see pages 69 & 70).

HYDRAULIC OIL LEVEL FIGURE 33

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7. Check the hydraulic oil filter indicators (Figure 34). The hydraulic oil filters are located on the front frame assembly. The filter indicator, located on top of the filter housing, remains clear as long as the element is not restricted. Once the element becomes restricted, the indicator will turn red, indicating the element is clogged and requires changing. After changing the elements, the indicator button must be reset by pushing in on the button.

HYDRAULIC OIL FILTER INDICATORS FIGURE 34 8. Visually inspect drill boxes for excessive wear or oil leakage and check oil level (Figure 35).

A. Remove the oil level fill/check plug (Figure 35). The oil level should be kept at the level of the fill/check plug.

B. Should it be necessary to add oil, (40W non detergent) 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.

DRILL BOX OIL LEVEL FIGURE 35

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9. Visually inspect cradles stab feet, booms, and “T” bar, condition for cracks or excessive wear.

10. Inspect the dust system.

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

B. Inspect filter element located inside both dust boxes. If the element is not damaged, it can be cleaned by briskly shaking out excess dust or with air pressure. If element is damaged, it must be replaced.

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

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

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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EVERY OTHER SHIFT 1. Inspect the condition and tension of blower belts (Figure 36) for wear. Replace worn belts and adjust tension as required. Tension should be adjusted to a maximum of 1” deflection. Also, check oil level in both blowers (Figure 36).

A. Remove the oil level fill/check plug (Figure 36). 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 69 & 70).

C. Replace the fill/check plug.

BLOWER BELT TENSION AND OIL LEVEL FIGURE 36 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 69 & 70).

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

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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 69 & 70).

5. Lubricate cradle, boom, and “T” bar assemblies. Lubricate points as indicated on lubrication chart with spec 100-3. (For Lubricant Specifications see pages 69 & 70).

6. Lubricate grease fitting located on top of drill box and sliding surfaces with spec 100-3 (see Figure 35, page 57). (For Lubricant Specifications see pages 69 & 70).

7. Inspect torque hubs for wear or damage and check oil level (Figure 37).

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 69 & 70).

E. Replace plugs.

TORQUE HUB OIL LEVEL FIGURE 37 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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9. Check center section pins and nuts (Figure 38) for looseness or wear. Tighten or replace worn parts where necessary. Lubricate points as indicated on lubrication chart with spec 100-3. (For Lubricant Specifications see pages 69 & 70).

CENTER SECTION LUBRICATION FIGURE 38

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

WARNING 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 chain with a good quality chain lube (Figure 39).

CABLE REEL DRIVE CHAIN LUBRICATION FIGURE 39 5. Drain and replace oil in drill boxes (Figure 35, page 57).

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.

WARNING 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 53).

6. Remove covers on explosion proof housings (Figure 40). 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.

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EXPLOSION PROOF HOUSINGS FIGURE 40 7. Check tire condition and wheel mounting bolts (Figure 41). The mounting bolts should be torqued to 225 ft. lbs. If equiped with pneumatic tires, check tire pressure and condition.

WHEEL MOUNTING BOLTS FIGURE 41

NOTICE IF UNORDINARELY DIRTY OR DUSTY CONDITIONS ARE ENCOUNTERED, HYDRAULIC OIL FILTERS SHOULD BE REPLACED MORE FREQUENTLY. 8. Change hydraulic oil filter elements (see Figure 34, page 57).

9. Check torque hub to chassis frame mounting bolts (8 per hub) for tightness.

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EVERY THREE MONTHS 1. Lubricate blower drive end with spec 100-3 (see Figure 36, page 59) until clean grease flows from operation relief valve. (For Lubricant Specifications see pages 69 & 70).

2. Replace oil in the torque hubs (see Figure 37, page 60).

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. (see Figure 37, page 60). (For Lubricant Specifications see pages 69 & 70).

H. Replace plugs.

3. Lubricate the electric motor armature bearings with spec 100-3 (Figure 42). (For Lubricant Specifications see pages 69 & 70).

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.

ELECTRIC MOTOR LUBRICATION FIGURE 42

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EVERY SIX MONTHS 1. Change hydraulic oil and clean or replace the hydraulic oil strainer inside the hydraulic oil tank (Figure 43).

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 secures 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 69 & 70).

HYDRAULIC OIL TANK STRAINER FIGURE 43 2. Check flow on pump with flowmeter.

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.

4. Inspect cable reel collecting rings, contactor points, brushes, and bearings (Figure 44). Clean and repack bearings when reel is disassembled.

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CABLE REEL ASSEMBLY FIGURE 44

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LUBRICATION CHART FIGURE 45

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BUCYRUS AMERICA INC.

Ref.

RB2-52A ROOF BOLTER

Location

Lubricant

No. Of Places

1 2 3

Pin Pivot Bracket To Chassis Cylinders Hydraulic oil Reservoir

Spec 100-3 Spec 100-3 Spec 100-1

2 4 1

4

---------------

1

5

Breather (Oil Reservoir) Torque hubs

Spec 100-6

4

6

Oil Filter

---------------

2

7

Blower (Drive End)

Spec 100-3

1

Grease Until Clean Grease Flows From Relief

Blower (Gear End) Electric motor

Spec 100-8

1

Check Oil Level

Spec 100-3

1

Spec 100-3

1

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 Reinstall Fittings.

See Note

Spec 100-3

4

Light Coat Of Grease On Sliding Surfaces.

Any Good Quality Chain Lube Dri-Slide Or Similar Dry Lube Spec 100-3

2

Light Coat Of Lube

1

Light Coat Of Lube

Every Other Shift

2

See Note

Every Other Shift Every Other

8

9

11

Grease Fitting On Cable Reel Flange Bearing Sliding Surfaces For Roof support Tubes And Sumping Drill Box Cable Reel Drive Chain

12

Cable Reel Spooler Shaft

13

Cable Reel Spooler Bearing

14

Drill Box

15

Drill Box Carrier Pins

16

Lift Arm Pin (Drill Boom) Leveling Bracket Pin

10

17 18 19 20 21 22 23 24

Lift Arm Pin (Stab Shoe) Radius Arm/ATRS Pin Stab Cylinder Pin (Rod End) Stab Cylinder Pin (Base End) Feed Cylinder Pin (Base End) Sliding Bearings For Drill Box Feed Cylinder Pin (Rod End)

Remarks

Frequency

See Note See Note 150 Gals. Check Sight Gauge And Add Fluid If Necessary.

Clean Filter When Required.

Every Shift Every Shift Every Shift

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) 25 Micron Element

40W Non Detergent Spec 100-3

1

Check Oil Level

4

See Note

Spec 100-3

2

See Note

Spec 100-3

4

See Note

Spec 100-3

2

See Note

Spec 100-3

2

See Note

Spec 100-3

1

See Note

Spec 100-3

1

See Note

Spec 100-3

1

See Note

Spec 100-3 Spec 100-3

4 1

-----------------------------See Note

68

-------------Every Other Shift

At least Every Week Or Sooner Every 250 Hrs. Of Operation Daily Every 3 Months

Every Other Shift Every Other Shift

Every Other Shift Every Other Shift Every Other Shift Every Other Shift Every Other Shift Every Other Shift Every Other Shift Every Other Shift Every Other Every Other Shift

RB2-52A 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

2. GULF OIL 3. MOBIL OIL CORP.

HARMONY 68 AW MOBIL DTE-16

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

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

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

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

8. CENTURY LUBRICATING OILS, INC. 9. ATLANTIC RICHFIELD CO.

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

69

BUCYRUS AMERICA INC.

RB2-52A ROOF BOLTER

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.

70

TERESSTIC 150 PENNZBELL RO 150 6405 MONOLEC TURBINE OIL

THE BUCYRUS AMERICA, INC. PRODUCT FOR WHOM THIS MANUAL WAS PREPARED WAS DESIGNED AND BUILT TO PROVIDE RELIABLE PERFORMANCE UNDER TYPICAL MACHINE OPERATING CONDITIONS. BUCYRUS AMERICA, INC. DESIGNERS AND ENGINEERS HAVE CAREFULLY DEVELOPED OR SPECIFIED EACH PART WITH MATERIAL COMPOSITION AND TOLERANCES APPROPRIATE TO THE PART'S INTENDED USE. THIS PRODUCTS' MSHA CERTIFICATION WAS GRANTED BASED ON THE INCORPORATION OF APPROVED BUCYRUS AMERICA, INC. PARTS. BUCYRUS AMERICA, INC. IS COMMITTED TO PROVIDING THE BEST SERVICE AND SUPPORT TO ITS CUSTOMERS. THAT IS WHY IT HAS:

• DEVELOPED, SELECTED AND MADE AVAILABLE TECHNICALLY CORRECT AND APPROVED REPLACEMENT PARTS FOR ITS PRODUCT LINES.

• ESTABLISHED AN EFFECTIVE NETWORK OF SALES AND SERVICE FACILITIES IN THE U.S. AND ABROAD.

• INSTALLED AND MAINTAINS A COMPUTERIZED PARTS STOCKING SYSTEM TO ENSURE HIGH AVAILABILITY LEVELS REPLACEMENT COMPONETRY AND SUBASSEMBLIES.

FOR

• ADOPTED A UNIQUE CHANGEOUT SYSTEM COVERING MAJOR COMPONENTS TO MINIMIZE CUSTOMER COSTS AND DOWNTIME.

WE RECOMMEND THAT YOU PURCHASE BUCYRUS AMERICA, INC. RENEWAL PARTS TO MAINTAIN YOUR EQUIPMENT IN ITS ORIGINALLY APPROVED CONDITION, A MANDATORY MSHA REQUIREMENT. SINCE MSHA REGULATIONS MAKE IT INCUMBENT UPON THE MINE OPERATOR TO MAINTAIN ALL PERMISSIBLE EQUIPMENT AND MACHINERY IN ITS APPROVED CONDITION, IT IS ESSENTIAL THAT PROPER PROCEDURES AND REPLACEMENT PARTS ARE USED DURING REPAIR OR REBUILDING OF APPROVED EQUIPMENT AND MACHINERY.