CAT Operation Manual RB220 Roof Bolter (A6474X175) - PDF DOWNLOAD

A6474X175 May 2012

Operation and Maintenance Manual RB220 Roof Bolter

__________________________________________________________ This manual is intended to provide GENERAL product information. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. The manufacturer reserves the right to revise models and designs without prior notice.

This machine was manufactured under the guidelines, procedures and requirements of the appropriate government regulatory agencies.

At the completion of the manufacturing process, this unit was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of the manufacturer and these regulatory agencies, or any repair or replacement of parts contrary to the manufacturer’ s instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

While this manual attempts to anticipate the most important operations and maintenance needs for this unit, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

© 2012 ALL RIGHTS RESERVED

_________________________________________________Table of contents

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

2. Your safety Your safety............................................................................... 2.3 Personnel ............................................................................. 2.4 Operation......................................................................... 2.4 Installation and repair ...................................................... 2.4 Operating conditions ............................................................ 2.5 Intended use.................................................................... 2.5 Unauthorized use ............................................................ 2.5 Safety instructions ................................................................ 2.7 General rules ................................................................... 2.7 Storage and transport...................................................... 2.8 Pre-start inspection ......................................................... 2.8 Installation and start-up ................................................... 2.9 Operation......................................................................... 2.9 Stopping ........................................................................ 2.10 Maintenance and repair................................................. 2.10

3. Storage and transport Storage and transport............................................................. 3.3 Storage................................................................................. 3.3 Storage of the machine and spare parts ......................... 3.3 Long-term storage of spare components ........................ 3.4 Transport .............................................................................. 3.5 Before transport............................................................... 3.5

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

________________________________________________________________ A6474X175

REV 07

Table of contents _________________________________________________ 5. Operation Operation ................................................................................. 5.3 How to operate the roof bolter.............................................. 5.3 Who is allowed to operate the roof bolter........................ 5.3 When can operation be started? ..................................... 5.3 Controls and indicators......................................................... 5.4 Operator’ s compartment.................................................. 5.4 Controller ....................................................................... 5.10 Drill station controls ....................................................... 5.12 Hazard zone ....................................................................... 5.20 Starting procedure.............................................................. 5.21 Shutdown procedure .......................................................... 5.22 Towing a disabled machine................................................ 5.23 Tramming the roof bolter .................................................... 5.25 Tramming from the Operator’ s compartment ................ 5.25 Inch tramming................................................................ 5.26 Drilling ................................................................................ 5.27 Extension steel selection............................................... 5.30 Drilling with extension steels ......................................... 5.30 Drill options and adjustments ........................................ 5.33 Installation of mechanically anchored roof bolts ........... 5.34 Installation of fully grouted resin bolts ........................... 5.36 Drill thrust and torque settings....................................... 5.38 Electrical systems............................................................... 5.

Hydraulic systems .............................................................. 5.

Mechanical systems ........................................................... 5.

Instructions on the maintenance ........................................ 5.

Important notes ............................................................. 5.

Before maintenance ...................................................... 5.

Critical torque values..................................................... 5.

Lubricants, fluids and capacities ................................... 5.

Specific lubrication and maintenance instructions ............. 5.

Every third shift.............................................................. 5.

Weekly........................................................................... 5.

Monthly .......................................................................... 5.

Every three months ....................................................... 5.

Instructions on the adjustment procedures ........................ 5.

Main relief - primary (main implement) pump section ... 5.

Main relief - accumulator pump section ........................ 5.

Unloader valve .............................................................. 5.

Relief valve - brake cooling manifold ............................ 5.

Pressure reducing valve - HRC pilot control circuit....... 5.

Troubleshooting procedures .............................................. 5.

Hydraulic system (general)............................................ 5.

Brakes ........................................................................... 5.

Hydraulic cylinders ........................................................ 5.

Hydraulic pump ............................................................. 5.

Valves............................................................................ 5.

________________________________________________________________ Model RB220 Roof Bolter

_________________________________________________Table of contents 6. Technical data Technical data ......................................................................... 6.3 Tightening torques................................................................ 6.9 Permissible data................................................................. 6.15 Lubrication fluids and greases ........................................... 6.15

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

________________________________________________________________ A6474X175

REV 07

Table of contents _________________________________________________

________________________________________________________________ Model RB220 Roof Bolter

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1

About this manual

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____________________________________________Before starting to work

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

Before starting to work applicable operating manual machine type

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

This operating manual is intended for: Model RB220 Roof Bolter Serial No. N/A and is only permitted to be used for equipment of this type.

new operation manual

The operating manual must be accessible at all times to all persons working on or with the machine.

It should, if possible, always be available at the place of operation.

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

Who is this operating manual intended for?

This operating manual is intended for those persons who work with or on the machine.

Every person working on the face or in the intersection between face and entry or in the entry must read this operating manual.

This includes persons who: ■

are in charge of transport

■

perform assembly / disassembly work

■

operate the machine

■

eliminate faults

■

perform daily routine work on the face or in the entry

■

perform maintenance work

■

perform repair work

supervisory personnel who: ■

initiate and/or

■

supervise the activities just indicated.

______________________________________________________________ A6474X175 REV 07 1.3

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

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

service

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

safety

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

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

________________________________________________________________ 1.4 Model RB220 Roof Bolter

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

Try to memorize the symbols and their meanings.

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

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

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

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

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

______________________________________________________________ A6474X175 REV 07 1.5

Before starting to work ____________________________________________

________________________________________________________________ 1.6 Model RB220 Roof Bolter

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2

Your safety

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______________________________________________________ Personnel

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

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

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

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

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

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

Observe the safety and accident prevention regulations

further operating manuals

■

of the mine,

■

of the mine inspector, and

■

of the mining supervisory authorities.

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

______________________________________________________________ A6474X175 REV 07 2.3

Personnel _______________________________________________________ Personnel Operation training

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

The machine is only allowed to be operated by qualified personnel who can provide proof of having been trained on this unit.

Reading of the operation manual, especially the chapter on safety, shall constitute a part of this training.

You must have adequate knowledge of the ■

mechanics,

■

hydraulics, and

■

control engineering

and must be able to prove this knowledge.

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

Installation and repair work on: ■

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

■

the electrics (motors, controllers, etc.)

■

the hydraulics (controls, cylinders, etc.)

may only be carried out by qualified service engineers or by specially qualified personnel of the mine.

________________________________________________________________ 2.4 Model RB220 Roof Bolter

_____________________________________________ Operating conditions Operating conditions Intended use The roof bolter has been designed and manufactured purely for the installation of roof bolts.

Intended uses: ■

the installation of roof bolts

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

Unintended uses: ■

any operation other than the installation of roof bolts

The mnaufacturer accepts no liability for any damage resulting from any such unauthorized use.

______________________________________________________________ A6474X175 REV 07 2.5

Operating conditions _____________________________________________

________________________________________________________________ 2.6 Model RB220 Roof Bolter

_______________________________________________ Safety instructions Safety instructions General rules general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

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

Inform your colleagues of:

safety equipment

■

your exact location,

■

the work you are performing, and

■

the time that you will probably require.

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

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

symbol plates emergency stop (panic strip)

lock-out

cordon off working area moving parts

steering lockout

Observe the symbol plates on the machine.

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

Lock-out and disconnect the power system while performing: ■

maintenance work

■

inspection work

■

repair work

Cordon off your working area widely for the machine.

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

boom arms and drill stations

■

pivot points

■

“T”bar / ATRS Support / Articulation

Connect the steering lockout device before performing maintenance or repairs on the machine.

______________________________________________________________ A6474X175 REV 07 2.7

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

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

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

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

means of attachment

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

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

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

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

mobile handling equipment

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

Pre-start inspection operation

Read the entire guide before attempting to operate this machine.

inspection

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

maintenance instruction and safety tags

operator’s compartment cab/canopy

Verify that all maintenance has been performed.

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

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

Clean any foreign material from the operator’ s compartment.

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

________________________________________________________________ 2.8 Model RB220 Roof Bolter

_______________________________________________ Safety instructions Installation and start-up inclined face

environmental acceptability

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

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

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

controls

starting procedures hazard zone

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

Follow the starting procedure instructions in the operations manual.

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

Operation training

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

before start-up

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

protective devices

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

operator’s compartment

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

Never climb onto, 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 .

traveling

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

passengers

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

safety rules

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

problems and malfunctions

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

______________________________________________________________ A6474X175 REV 07 2.9

Safety instructions _______________________________________________ Stopping operator’s compartment

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

parking

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

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

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

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

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

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

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

Protect your work area against falling rocks.

replacing components

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

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

original parts

lifting

handling of hydraulic fluids

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original spare parts. Please refer to the spare parts lists for the order numbers.

For raising the roof bolter use only: ■

crib blocks with adequate load-holding capacity.

■

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

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infection.

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

________________________________________________________________ 2.10 Model RB220 Roof Bolter

_______________________________________________ Safety instructions maintenance, repair

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

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

Avoid, whenever possible, servicing or providing maintenance to the unit unless the wheels are chocked and steering lockout device is connected to prevent accidental movement of the unit.

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

Always replace damaged or lost decals and metal instruction plates.

Disconnect the power when working with the electrical system, or when welding on the unit to prevent electrical shock.

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

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

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

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

the hoses are not pinched or trapped,

■

the hoses have no bubbles or blister,

■

the hose or outer sheath of the hose is not abnormally rigid or hard,

■

the outer sheath of the hose is not damaged,

■

the connectors are securely inserted into the sockets, and

■

the connections are leak-tight.

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

______________________________________________________________ A6474X175 REV 07 2.11

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

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

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

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

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

installing hydraulic hoses

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

Always install hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Installing hydraulic hoses, slack Right

Wrong

________________________________________________________________ 2.12 Model RB220 Roof Bolter

_______________________________________________ Safety instructions

■

are not twisted.

Fig. 2: Installing hydraulic hoses, twisting Right

■

Wrong

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

Fig. 3: Installing hydraulic hoses, bending Right

■

Wrong

always have a little slack.

Fig. 4: Installing hydraulic hoses, crossing Right

Wrong

______________________________________________________________ A6474X175 REV 07 2.13

Safety instructions _______________________________________________

■

are not kinked.

■

do not have to withstand tensile strains.

■

are protected against thermal radiation.

■

are accessible at all times.

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

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

torn out,

■

kinked,

■

crushed,

■

driven over or

■

twisted by movement of the machine.

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

Wrong

________________________________________________________________ 2.14 Model RB220 Roof Bolter

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3

Storage and transport

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____________________________________________ Storage and transport

Storage and transport This chapter contains important information on the correct storage and transport of the roof bolter. Observance of the instructions and tips will increase the service life and availability of the machine. You will also be able to carry out the transport work quicker and more safely. Careful attention to the points in this chapter will help you to simplify your day-to-day work.

Storage corrosion protection

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

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

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

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

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

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

short-term storage

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

long-term storage

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

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

■

Completely fill the hydraulic oil tank with oil

■

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

■

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

■

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

______________________________________________________________ A6474X175 REV 07 3.3

Storage and transport _____________________________________________ random sample inspection

After a storage period of approximately two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage.

natural aging

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

HFA fluids

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

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

Long-term storage of spare components

hydraulic components

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

miscellaneous components

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

motors

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

plastic deformation

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

________________________________________________________________ 3.4 Model RB220 Roof Bolter

____________________________________________ Storage and transport Before transport temperatures below freezing

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

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

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

electronic components

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

______________________________________________________________ A6474X175 REV 07 3.5

Storage and transport _____________________________________________

________________________________________________________________ 3.6 Model RB220 Roof Bolter

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4

Installation

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______________________________________________________ Installation

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

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

Work on: the safety components (pressure relief valves, fire extinguishing equipment etc.), the electrical equipment (control units, signaling devices, etc.), and the hydraulic equipment (cylinders, directional control valves, hoses etc.) should only be carried out by service engineers or by specially trained personnel.

Which tools are required for installation? tool box

No special tools are required to put the roof bolter into service.

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

These include: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock

■

jacks with adequate lifting capacity

______________________________________________________________ A6474X175 REV 07 4.3

Installation ______________________________________________________ Notes on installation CAUTION! Serious damage can be caused to the roof bolter as a result of incorrect installation. The unit should therefore only be installed under the instruction of specialists. installation plan

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

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

________________________________________________________________ 4.4 Model RB220 Roof Bolter

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

However, to ensure that no transit damage has occurred, the following pre-startup checks should be performed: ■

visually inspect all cylinders, gear boxes, tanks, and hydraulic components for leaks or damage

■

check the hydraulic oil tank and the gear boxes for correct fluid levels

■

visually inspect all electric motors and electrical components for signs of damage

■

check the full length of the trailing cable for damage

■

ensure that the trailing cable is properly suspended across intersections and that the trailing cable clamp at the roof bolter is secure

■

start up the machine and check for correct operation of all stop switches

■

perform daily maintenance

■

visually inspect all hydraulic hoses and electrical cables for damage

■

clean any foreign material from the operator’ s compartment

■

check safety provisions for operational condition on fire suppression system

■

start up the machine and check for correct operation of panic switch (s) which are located inside the operator’ s compartment

■

check that all covers and guards are in place and secure

■

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

■

check that operator’ s canopy is secure and in place

■

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

■

check hydraulic system pressures (refer to the hydraulic schematic supplied for your particular machine for pressure settings)

■

check and operate all control handles and remote switches to ensure all machine functions are operating properly and are in neutral position

______________________________________________________________ A6474X175 REV 07 4.5

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

Safety features include (reference Fig.6): panic strip (s)

The machine is equipped with five (5) panic strips. One is located inside the operator’ s compartment, to the right of the operator beside the controller assembly while sitting in the operator’ s seat. There are two (2) panic strips located on the left boom and two (2) panic strips on the right boom. The panic strip (s) are used to break the control circuit only in emergency situations, stopping all motors. Striking with a small amount of force will actuate the panic strip.

canopy/cab (s)

The machine was shipped from the factory with a protective canopy/cab over the operator’ s compartment and a canopy over the drill station.

Ensure that both the canopies are in place and secure at all times to protect the operator from falling debris.

fire suppression

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

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

guards and covers

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

DANGER! Do not operate the machine with any of the guards or covers removed. You or other personnel could be seriously injured from moving or rotating parts.

steering lockout

The machine is equipped with a steering lockout. The lockout should be connected and secure during shutdown and while performing maintenance on the machine.

circuit breaker reset

The machine is equipped with a circuit breaker reset located inside the operator’ s compartment. The circuit breaker reset may be used to shutdown the machine in emergency situations.

________________________________________________________________ 4.6 Model RB220 Roof Bolter

______________________________________________________ Installation Fig. 6: Safety features on the roof bolter Panic strip, fire suppression actuator, circuit breaker reset, cab/canopy

Fire suppression actuator Panic strip

Panic strip

Steering lock, installed location

Steering lock, stored location

Panic strip Panic strip Drill station canopy

______________________________________________________________ A6474X175 REV 07 4.7

Installation ______________________________________________________ Fig. 7: Overview of roof bolter Rear frame

Drill station canopy Front frame Drill box

Operator’ s compartment

“T”bar Drill station

________________________________________________________________ 4.8 Model RB220 Roof Bolter

_______________________________________________________________

5

Operation

________________________________________________________________

_______________________________________________________________

________________________________________________________________

_______________________________________________________ Operation

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

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

Who is allowed to operate the roof bolter?

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

This also includes: ■

what safety devices are installed on the machine.

■

where these safety devices are located.

■

how these safety devices are to be operated.

When can operation be started?

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

______________________________________________________________ A6474X175 REV 07 5.3

Operation _______________________________________________________ Controls and indicators Operator’s compartment The primary controls for the machine are located in the operator’ s compartment (Fig. 8). These controls and indicators include the fire suppression actuator, panic strips, tram/steering control (joystick), valve bank control levers: vertical articulation, power fill and optional hydraulic PTO, the pressure gauge block, tram control pilot valve/pedal, cable reel pilot control valve/pedal and controller (light switch, circuit breaker reset switch, pump start switch and pump stop switch).

Fig. 8: Operator’s compartment Pressure gauge panel Controller

Panic strip

Tram/steering control lever

Valve bank control levers

Actuator Cable reel foot pedal

Tram control pedal

Operator’ s seat

________________________________________________________________ 5.4 Model RB220 Roof Bolter

_______________________________________________________ Operation

operator’s seat

The operator’ s seat (Fig. 9) has (4) four height adjustments. To adjust the operator’ s seat, lift the back and insert the adjustment rod into the desired adjustment slot.

CAUTION! Be sure the operator’s seat is adjusted for maximum visibility available within your operating limits before the roof bolter is put into motion.

Fig. 9: Operator’s seat

pressure gauge panel

Located to the right of the operator’ s seat are four (4) pressure gauges (Fig. 10) that provides the operator with a continuous reading of the pressures in individual circuits.

Fig. 10: Pressure gauges Cable reel/left hand boom rotation gauge

Steering/right hand boom function gauge

Rear tram/right hand rotation gauge

Front tram/left hand rotation gauge

______________________________________________________________ A6474X175 REV 07 5.5

Operation _______________________________________________________ fire suppression actuators

The machine is equipped with two (2) fire suppression (remote) actuators (Fig. 11). One is located to the operator’ s left inside the operator’ s compartment behind the operator’ s seat and the other is located on the right boom assembly. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from either of the two (2) actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

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

Fig. 11: Fire suppression actuator location (typical)

Plunger

Pin

CO2 cartridge (bomb) Actuator

Typical actuator

Actuator

________________________________________________________________ 5.6 Model RB220 Roof Bolter

_______________________________________________________ Operation operator’s compartment panic strip (s)

The roof bolter is equipped with a panic strip (Fig.12) located in the operator’ s compartment. The panic strip is located to the operator’ s right beside of the controller assembly while sitting in the operator’ s seat.

The panic strips are used to break the control circuit only in emergency situations, stopping all motors. Striking with a small amount of force can actuate the panic strip.

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

Fig. 12: Panic strip

Panic strip

tram control pedal

The tram control pedal (Fig.13) 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.

IMPORTANT! 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.

______________________________________________________________ A6474X175 REV 07 5.7

Operation _______________________________________________________ cable reel foot pedal

The cable reel foot pedal (Fig.13), 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.

Fig. 13: Tram control pedal location

Tram control pedal

Cable reel foot pedal

Control levers In the operator's compartment located to the right of the operator is a group of control levers (reference Fig. 14). tram/steering control lever

The tram/steering control lever (joystick) , located to the right of the operator and controls the following: forward tram, reverse tram, right steer, left steer. The tram/steering control lever will not function if the tram control foot pedal is not engaged. To tram forward, push the joystick away from the operator and to tram in reverse, pull the joystick toward the operator. To steer left while going forward, push the joystick to the left and to steer right while going forward, push the joystick to the right.

IMPORTANT! 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.

IMPORTANT! Once the tram/steering control lever is released by the operator the control lever automatically returns to the centered (neutral) position.

________________________________________________________________ 5.8 Model RB220 Roof Bolter

_______________________________________________________ Operation 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. vertical articulation control lever

The vertical articulation control lever 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

The power fill 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 PTO (optional)

The hydraulic PTO (optional ) provides the roof bolter operator or other qualified individual in the work area with the capability to power accessory equipment within the work area. To activate the PTO, push the lever towards the front of the machine and to deactivate, release the lever and it will automatically return to its original position.

Fig. 14: Control levers

Vertical articulation control lever

Power fill control lever

Tram/steering control lever

Hydraulic PTO control lever

______________________________________________________________ A6474X175 REV 07 5.9

Operation _______________________________________________________ Controller The controller is located to the right of the operator (Fig.15) and is used to reset the circuit breaker when it has tripped. It has four (4) control switches: light switch, circuit breaker reset, motor start, motor stop, low oil light (optional), and ground check (optional).

Fig. 15: Controller “HEADLIGHT SWITCH”

“GROUND CHECK” (optional)

“CIRCUIT BREAKER” reset switch

“LOW OIL” light (optional)

Pump “STOP” switch

Pump “START” switch

“START”button

The “START”button (Fig. 15) is used to start the hydraulic pump’ s electric motor. To start the electric motor, depress the “START”button and release once the motor has started.

“STOP”button

The “STOP”button (Fig. 15) is used to stop the hydraulic pump’ s electric motor. To stop the electric motor, depress the “STOP”button and release once the motor has stopped.

“LOW OIL”light indicator

The optional “LOW OIL”light (Fig. 15) is normally illuminated but will turn off when the oil level in the hydraulic oil tank reaches an unsafe operating level.

“GROUND CHECK”button

The “GROUND CHECK”button (Fig. 15) (optional) is used to test the ground from the main power center. Depressing the push button will break the ground circuit and will trip the circuit breaker at the main power center.

________________________________________________________________ 5.10 Model RB220 Roof Bolter

_______________________________________________________ Operation “CIRCUIT BREAKER” reset switch

The circuit breaker reset switch (Fig.16) 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.

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

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

Fig. 16: “CIRCUIT BREAKER”reset switch “ON”

“TRIPPED”

“OFF”

“RESET”

The circuit breaker trips when one of the following occurs: ■ The electrical system is overloaded or shorted.

■ Panic strip (s) is struck.

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

■ The battery is disconnected.

To reset the circuit breaker proceed as follows:  Move the selector to “RESET”position and operate hand pump to move the circuit breaker to full “OFF”position.  Move the selector to the “SET”position and operate hand pump to move the circuit breaker to the full “ON”position.

______________________________________________________________ A6474X175 REV 07 5.11

Operation _______________________________________________________ “HEADLIGHT SWITCH”

The “HEADLIGHT SWITCH”(Fig.17) 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.

Fig. 17: “HEADLIGHT SWITCH”

“REAR”lights

“FRONT”lights

“AREA”lights

Drill station controls On the outside of both right and left booms are the controls and indicators for drilling operations and maneuvering machine between bolt holes (Fig. 18). These include: the inch tram/steering control valve, panic (tape) switches, start buttons, fire suppression actuator, integrated valve (rotation functions), integrated valve (A.T.R.S. functions), tbar valve bank, articulation control, fast feed diversion valve, boom control valve bank (right boom) and boom control valve bank (left boom).

Fig. 18: Drill station locations

Right drill station

Left drill station

________________________________________________________________ 5.12 Model RB220 Roof Bolter

_______________________________________________________ Operation man-in-position switch

The man-in-position switch (Fig. 19) is located on the left boom assembly, in front and to the left of the inch tram/steering control valve lever.

The man in position switch activates the pilot control valve, which in turn activates the inch tram/steering control valve. The lever must be pushed away from the operator and held in this position before the inch tram/steering control lever can be actuated.

Inch tram/steering control valve lever

The inch tram/steering control lever (Fig. 19) is located on the outside of the left boom assembly. This lever cannot be activated unless the man-in-position switch is held in position. The inch tram/steering lever is used for maneuvering the roof bolter between bolt holes during drilling operations only. To tram “FORWARD”push the lever towards the front the machine and to tram in “REVERSE”pull the lever towards the rear 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.

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

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

Fig. 19: Man-in-position and inch tram/steering control levers

Inch tram/steering control valve lever

Man-in- position switch

______________________________________________________________ A6474X175 REV 07 5.13

Operation _______________________________________________________ panic strip (s)

The roof bolter is equipped with (4) four individual panic strips (Fig. 20) 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).

start button

The roof bolter is equipped with (2) start buttons (Fig. 20), 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.

Fig. 20: Panic strips and start button

Panic strip Panic strip

Start button

Integrated valve (rotation functions) The integrated valves (Fig. 21) 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. rotation flow control

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

rotation check valve

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

boom flow control

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

dual relief control

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

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

________________________________________________________________ 5.14 Model RB220 Roof Bolter

_______________________________________________________ Operation Fig. 21: Integrated valves

Rotation flow control

Rotation check valve

Boom flow control

Dual relief control

Boom control valve bank The boom control valve bank located on the right and left boom (Fig. 21) includes the stab shoe, boom swing, canopy, drill box sump, drill feed, fast feed, and rotation control levers.

WARNING! Do not operate roof bolter without drill station canopies. Operating without drill station canopies can result in severe injury or death.

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

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

______________________________________________________________ A6474X175 REV 07 5.15

Operation _______________________________________________________ stab shoe control lever

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

boom swing control lever

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

canopy control lever

The canopy control lever is used to raise or lower the canopy for that particular boom. To raise the canopy, pull the control lever toward the operator and to lower the canopy, push the control lever away from the operator.

drill box sump control lever

The drill box sump control lever provides the operator with the ability to correct misalignment of drill box. To move the drill box forward, push the control lever away from the operator and to move the drill box backward, pull the control lever towards the operator. When the control lever is released it will automatically return to the neutral position.

drill feed control lever

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

fast feed control lever

The fast feed control lever 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 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.

________________________________________________________________ 5.16 Model RB220 Roof Bolter

_______________________________________________________ Operation Fig. 22: Boom control valve bank

“STAB” shoe control lever

“BOOM “CANOPY” SWING” control lever control lever

Drill box “SUMP” control lever

Drill “FEED” control lever

“FAST FEED” control lever

Drill “ROTATION” control lever

ATRS support/T-bar/Articulation valve bank The ATRS support/T-bar and Articulation valve bank (Fig. 23) is located on the left boom assembly. The valve bank consists of the T-bar control lever and the articulation control lever.

ATRS support/t-bar control lever

The ATRS Support/T-bar control lever 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 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.

rocker arm sump lever

The rocker arm sump lever (optional) is located to the left of the “ATRS SUPPORT”control lever. The rocker arm sump lever is used to slide the arms in and out on the T-bar.

______________________________________________________________ A6474X175 REV 07 5.17

Operation _______________________________________________________ Fig. 23:

Tram diversion valve, ATRS support/T-bar, and vertical articulation control levers

Rocker arm sump location (if equipped)

oil sight gauge

“ATRS SUPPORT” control lever

“ARTICULATION” control lever

The oil sight gauge (Fig. 24), 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.

Fig. 24: Oil sight gauge

Oil sight gauge

________________________________________________________________ 5.18 Model RB220 Roof Bolter

_______________________________________________________ Operation torque hub

The roof bolter is equipped with torque hubs (Fig. 25) 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.

WARNING! When the torque hubs are in the disengaged position, the roof bolter must be chocked at all four (4) wheels in both directions to prevent the machine from rolling away uncontrolled.

Fig. 25: Torque hub Torque hub, 4 places

steering lockout device

The roof bolter is equipped with a steering lockout device (Fig. 26).

The steering lockout device is painted red for quick, visual identification. The steering lockout device should be connected and secure during shutdown and while performing maintenance on the machine.

Fig. 26: Steering lockout device

Steering lock, storage location

Steering lock, installed

______________________________________________________________ A6474X175 REV 07 5.19

Operation _______________________________________________________ Hazard Zone The hazard zone exists unless:  the trailing cable is disconnected or  the machine circuit breaker is in the “OFF”or “TRIPPED”position.

Fig. 27: Hazard zone

________________________________________________________________ 5.20 Model RB220 Roof Bolter

_______________________________________________________ Operation Starting procedure After reading the previous descriptions and locating each control, the operator is ready to operate the roof bolter. an experienced operator should moniotr a new operator’ s indoctrination to the starting procedure.

IMPORTANT! Before start-up, check that daily maintenance has been performed on the machine.

1. Disconnect the steering lockout device.

2. Get in the operator’ s compartment and adjust the seat.

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

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

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

WARNING! Be sure no one is in the hazard zone (Fig. 27) before operating any levers or pedals.

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

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

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

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

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

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

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

9. Press the pump “START”switch.

The roof bolter is now ready to operate.

______________________________________________________________ A6474X175 REV 07 5.21

Operation _______________________________________________________ Shutdown procedure The roof bolter must be properly shutdown before leaving the area or before performing any maintenance or service. Some maintenance or service procedures may require additional steps to insure the safety of the maintenance personnel working on or around the machine and will be listed in the maintenance section of this guide.

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 a machine.

CAUTION! This unit is equipped 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. Push the pump “STOP”switch.

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

________________________________________________________________ 5.22 Model RB220 Roof Bolter

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

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

To tow the roof bolter proceed as follows: 1. Couple the towing vehicle securely to the disabled vehicle.

2. Chock all four wheels in both directions.

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

3. Rotate the torque hub end caps on both right and left sides of the roof bolter to the free position (Fig. 28) as follows: a. Remove the two bolts that retain the end cover to the center of the torque hub. b. Rotate the cover and reinstall with the two bolts to disengage the torque hub. Torque bolts to 70 to 80 ft-lbs.

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

The machine is now ready to begin towing.

______________________________________________________________ A6474X175 REV 07 5.23

Operation _______________________________________________________ 4. Once the destination is reached, stop both machines and chock all four wheels in both directions to prevent accidental movement.

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

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

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

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

Fig. 28: Torque hub normal tram position(typical all four wheels)

Retaining bolts (2)

End cap button pointing outward

________________________________________________________________ 5.24 Model RB220 Roof Bolter

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

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

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

The operator must be positioned fully within the confines of the operator’ s compartment to avoid getting caught between the machine and the rib, or other obstacle.

■

Alert other workers of intentions.

■

Maintain adequate clearance between machine and rib.

■

Know the physical conditions of the route of travel.

■

Be especially cautious when turning corners.

■

Be careful not to damage the trailing cable while tramming.

The trailing cable should pay out when traveling forward.

When traveling in reverse, press the cable reel foot pedal to pick up cable.

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

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

2. Ensure that the stabilizer feet are raised and the booms and T-bar are in position for tramming.

3. Depress the tram control pedal and hold in during tramming operations.

IMPORTANT! The roof bolter’s tram/steering valve functions will not operate without the tram control pedal being fully depressed and held in position. Releasing the tram control pedal will stop tramming functions.

______________________________________________________________ A6474X175 REV 07 5.25

Operation _______________________________________________________ 4. With the tram control pedal held in, operate the tram/steering control handle. a. To tram forward, push the joystick away from the operator. The farther the joystick is pushed, the faster the roof bolter will travel. b. To tram in reverse, pull the joystick toward the operator. The farther the joystick is pulled, the faster the roof bolter will travel. c.

To steer left (the front of the machine will go to the left while travelling forward and the rear of the machine will go to the left while travelling in reverse), push the joystick to the left.

d. To steer right (the front of the machine will go to the right while travelling forward and the rear of the machine will go to the right while travelling in reverse), push the joystick to the right.

5. To stop tramming, release the tram/steering control lever or the tram control pedal.

________________________________________________________________ 5.26 Model RB220 Roof Bolter

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

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

2. Position the stabilizer feet for tramming.

3. Push the man-in-position switch located to the left of the inch tram/ steering control lever at the drill station forward (away from the operator) and hold in position.

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

4. With the man-in-position engaged, operate the inch tram/steering control handle. a. To tram forward, push the joystick away from the operator.

IMPORTANT! The cable reel should freely pay out cable when traveling in the forward direction. b. To tram in reverse, pull the joystick toward the operator.

IMPORTANT! To avoid cable damage while traveling in reverse, press the cable reel foot pedal to reel in the cable. c.

To steer left (the front of the machine will go to the left while travelling forward and the rear of the machine will go to the left while travelling in reverse), push the joystick to the left.

d. To steer right (the front of the machine will go to the right while travelling forward and the rear of the machine will go to the right while travelling in reverse), push the joystick to the right.

5. To stop tramming, release the tram/steering control lever or the man-in-position switch.

______________________________________________________________ A6474X175 REV 07 5.27

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

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

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

IMPORTANT! 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. Next raise “T”bar until it comes in contact with mine roof, swing drilling assemblies to the desired position, and lower cradle stab feet to mine floor.

4. Lower drill boom to floor.

5. Insert the 12”spotter drill 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.

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.

________________________________________________________________ 5.28 Model RB220 Roof Bolter

_______________________________________________________ Operation 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. Then insert 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.

18. 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.

19. 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.

20. 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.

21. 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”.

______________________________________________________________ A6474X175 REV 07 5.29

Operation _______________________________________________________ 22. Another symptom of too high a feed rate in soft rock, beyond the collection capability of the dust system, is called “plastering”. In this condition, the drill cuttings not pulled into the drill rod are packed or plastered against the wall of the hole under the bit. With the "plastered”hole under the bit smaller than the bit, it can be very difficult to remove the drill rod from the hole. It is very particularly difficult to remove extensions.

23. 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.

24. 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.

25. 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.

________________________________________________________________ 5.30 Model RB220 Roof Bolter

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

■ Lead Extension - The section which has provision for bit attachment. At the end opposite the bit, the lead extension has a coupling arrangement which connects to the driver.

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

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

IMPORTANT! 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.

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

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

■ Driver length - recommended driver length to be 6”less than starter length.

■ 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 of the lead extension clears the top of the driver.

base

3. Line up and couple lead extension and driver.

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

______________________________________________________________ A6474X175 REV 07 5.31

Operation _______________________________________________________ WARNING! 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.

4. 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.

5. 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.

6. 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.

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

8. 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.

9. 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.

10. 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.

11. 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.

________________________________________________________________ 5.32 Model RB220 Roof Bolter

_______________________________________________________ Operation 12. Proceed with drilling as described previously.

13. 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.

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

15. 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.

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

17. 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 extensions are heavy. Do not put your hands or fingers between the and 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!

18. 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.

______________________________________________________________ A6474X175 REV 07 5.33

Operation _______________________________________________________ Drill options and adjustments IMPORTANT! 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, it is recommended 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. A 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 is provided.

This 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.

________________________________________________________________ 5.34 Model RB220 Roof Bolter

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



Roof bolts support mine roof in two principle ways: –

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

–

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

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

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

–

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

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

–

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

IMPORTANT! 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.

1. 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.

2. 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.

______________________________________________________________ A6474X175 REV 07 5.35

Operation _______________________________________________________

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.

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

3. Once 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.

IMPORTANT! 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.

4. 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.

IMPORTANT! 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.

5. 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.

________________________________________________________________ 5.36 Model RB220 Roof Bolter

_______________________________________________________ Operation 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.

2.

Resin bolt systems have proven to be effective in many mine roof conditions where mechanical bolts have failed.

3.

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.

4.

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

5.

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.

6.

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.

7.

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.

8.

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.

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

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

IMPORTANT! 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.

______________________________________________________________ A6474X175 REV 07 5.37

Operation _______________________________________________________ IMPORTANT! 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. An overall wrench length of 12 inches is recommended.

10. Insert necessary resin cartridges into the hole.

11. 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 rest on top of the bolt.

12. 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.

13. 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.

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

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

16. 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.

________________________________________________________________ 5.38 Model RB220 Roof Bolter

_______________________________________________________ Operation Table 1: Drill thrust and torque settings Drill thrust at various pressure settings

Pump flow to drill (gpm)

Drill speed (rpm)

Bolt torque (ft-lb)

Drill (rotation) hydraulic pressure setting (psi)

Drill feed hydraulic pressure setting (psi)

Boom low position (lbs)

Boom high position (lbs)

Standard hydraulic drill motor, part number 4010018019 30

440

150

1,010

900

3,556

5,539

30

440

160

1,075

1,000

3,951

6,154

30

440

170

1,140

1,100

4,346

6,770

30

440

180

1,210

1,200

4,741

7,385

30

440

190

1,275

1,300

5,137

8,001

30

440

200

1,345

1,400

5,532

8,616

30

440

210

1,410

1,500

5,927

9,232

30

440

220

1,475

1,600

6,322

9,847

30

440

230

1,540

1,750

6,915

10,771

30

440

240

1,600

Optional hydraulic drill motor, part number 4010018022 30

530

150

1,210

30

530

160

1,285

30

530

170

1,365

30

530

180

1,450

30

530

190

1,525

30

530

200

1,610

30

530

210

1,690

30

530

220

1,765

30

530

230

1,850

30

530

240

1,930

______________________________________________________________ A6474X175 REV 07 5.39

Operation _______________________________________________________

________________________________________________________________ 5.40 Model RB220 Roof Bolter

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

The machine receives electrical power through a heavy duty trailing cable. Be sure that the box connector is correctly identified and is securely connected. Also, check that the cable entrance is in good mechanical condition. Walk along the trailing cable from the power center to the roof bolter and check the condition of the trailing cable. Give special attention to points most apt to cause damage such as corners, intersections, and anywhere the cable may be run over by moving equipment. Never use trailing cable with exposed wires or splices, which heat up or spark under load.

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

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

Fig. 29: Major electrical component locator Tape switch

Start switch

Tape switch Cable reel assembly

Controller Tape switch

Start switch

Motor

Tape switch

Tape switch

______________________________________________________________ A6474X175 REV 07 5.41

Electrical system _________________________________________________ Controller The controller (Fig. 30), located to the right of the operator inside the operator’ s compartment, houses the primary electrical control components.

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

Fig. 30: Controller

Controller cover

Inside panel

________________________________________________________________ 5.42 Model RB220 Roof Bolter

________________________________________________ Electrical system Controller cover The cover of the controller (Fig. 31) consists of switches and a low oil indicator light (see Controls and indicators section in the Operation section of this chapter). The cover also contains a selector handle for turning the main circuit breaker “ON”and “OFF”. This allows the main power to the machine from the section power supply to be disconnected.

Fig. 31: Controller cover “HEADLIGHT SWITCH”

“GROUND CHECK” (optional)

“CIRCUIT BREAKER” reset switch

“LOW OIL” light (optional)

“STOP”switch

“START”switch

______________________________________________________________ A6474X175 REV 07 5.43

Electrical system _________________________________________________ Inside cover The inside cover of the controller (Fig. 32) is accessed by opening the cover of the enclosure. Located on the inside cover are relays, push buttons, the control transformer, fuses, and the main circuit breaker.

Fig. 32: Inside cover Light switch

“R1’relay

“C1” contactor

“OL”overload relay “F1”fuse

“F2”fuse “F3”fuse “F4”fuse “F5”fuse “F6”fuse

IS relay

Control transformer

Stop pushbutton

Start pushbutton

Safe-Pak relay (optional) (not shown)

light switch

The light switch is controlled by a handle located on the controller cover. The switch is used to energize the area lights or the front or rear headlights.

IS and “R1”

The “R1”relay works in conjunction with the (intrinsically safe) relay.

These relays are for the tape switches. If either relay is open, the machine will shutdown.

“C1”

The “C1”contactor is the contactor for the motor. “C1”must be energized before the motor will start.

circuit breaker

The circuit breaker reset switch is located on the front cover of the controller and is used to control the circuit breaker when the starter enclosure cover is in place.

When looking directly at the circuit breaker, the circuit breaker is on when the black switch is all the way to the left and is off when the black switch is all the way to the right. To reset the circuit breaker, push the switch to the right, past the off position, and then left to on.

________________________________________________________________ 5.44 Model RB220 Roof Bolter

________________________________________________ Electrical system “OL”

The “OL”overload relay is the overload for the motor. If the current to the motor exceeds the maximum rated current for the motor, the relay will shutdown the motor.

control transformer

The control transformer reduces the voltage supplied to the machine from the main power supply to 120V and 12V.

stop push button

The stop push button is used to stop the electric motor.

start push button

The start push button is used to start the electric motor.

“F1”and “F2”

“F1”and “F2”are 115V control fuses.

“F3”and “F4”

“F3”and “F4”are 115V fuses for the area lights.

“F5”and “F6”

“F5”and “F6”are 12V fuses for the front and rear headlights.

safe-pak relay (optional)

The safe-pak relay is the relay for the optional low oil level switch. If the oil level in the hydraulic tank drops below a preset level, the relay will turn off the “LOW OIL”indicator light located on the controller cover.

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

Remote “START”switches The roof bolter is equipped with two remote “START”switches, one on each boom assembly, located at the drill station controls. Either “START”switch can be used to start the electric motor from the drill station.

Panic strips There are five panic strips located on the roof bolter: two at each drilling station (on the right and left boom assemblies) and one in the operator’ s compartment. The roof bolter can be shutdown at any time by striking any one of the panic strips.

______________________________________________________________ A6474X175 REV 07 5.45

Electrical system _________________________________________________

________________________________________________________________ 5.46 Model RB220 Roof Bolter

________________________________________________ Hydraulic system Hydraulic system The following pages contain a brief description of the hydraulic components and assemblies that are on the roof bolter.

The hydraulic system for this machine has been designed to provide hydraulic power for the tram, steering, and drilling functions.

WARNING! This section is intended to familiarize the user with the hydraulic components of the roof bolter. All hydraulic maintenance should be preformed by a qualified technician with knowledge of the functions of the components involved.

WARNING! Never disconnect a hydraulic hose if the circuit it pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized, or when a load is on the circuit, the load will fall, resulting in damage to the machine or serious injury or death to you or other personnel. primary power source

All of the roof bolter's functions are hydraulically powered with the exception of lighting and dust collection. This hydraulic power is supplied by a multiple section (tandem type) hydraulic pump. The pump is of four sections and is driven from the front end of the electric motor.

Dust collection blowers are belt driven and mounted at the back ends of these motors.

tram system

The RB220 model roof bolter is equipped with four wheel drive hydraulically controlled front wheel steering. The system uses four tram motors (one for each wheel). These motors drive the wheels through planetary reducers at a ratio of about 25:1 or 30:1. The front drive assemblies are mounted to the front chassis and include multiple disc parking brakes between the tram motors and reducers. These brakes are applied by spring tension and released by hydraulic pressure.

While pressure is present in the tram circuit (during tramming), the brakes are released: while pressure is absent (when parked or when drilling and bolting) the brakes are applied. The rear drive assemblies are mounted to the rear chassis and do not have parking brakes, but are equipped with motion control valve to prevent machine run away.

Flow limiters are used in the machine's tram circuits. One set of these limiters reduces wheel spin while allowing some differential action at each axle. The other set regulates flow through the inch tram circuit (providing a consistent slow speed).

steering system

Steering of the machine is controlled by two hydraulic steering cylinders mounted between the front and rear frames. Fluid to the ends of the cylinders is metered by the steering control valve (joystick).

______________________________________________________________ A6474X175 REV 07 5.47

Hydraulic system_________________________________________________ drilling rotation

Rotational force for drilling is supplied by the gear type drilling rotation motors. These motors are mounted directly to the drill boxes. Each drill box serves to multiply torque while providing a chuck for driving a drill steel or wrench. The torque available at the chuck is determined by hydraulic pressure to the rotation motor. A system of relief valves allows chuck torque to be varied to suit conditions. Drill chuck speed is determined by rate of hydraulic oil flow; this can be controlled by the operator by means of the rotation flow control valve.

________________________________________________________________ 5.48 Model RB2-52A Roof Bolter

________________________________________________ Hydraulic system Fig. 33: Hydraulic component loca4

4

34

34

3

2

1

1

5

5 7

6

8

9 32 10

32 33 33 12

11 28

13

29 27

14

26 32 25 16

16 19

15

24

17

23

18 20 22 21

1.

2.

3.

4.

5.

6.

7.

8.

9.

Rotation valve (2) Control valve (RH) Control valve (LH) Fast feed diversion valve (4) Stab shoe valve (2) Boom swing cylinder (2) Oil filter (2) control valve Hand valve

10.

11.

12.

13.

14.

15.

16.

17.

18.

Inch tram joy stick Dual relief valve (2) Front wheel control valve Steering cylinder (2) Vert. articulation cylinder (2) Breather Tram valve Rear wheel & steer valve Steering valve

19. Reel motor 20. Flow control valve 21. Power fill/vert. articulation valve bank 22. Fast tram joy stick 23. Cable reel valve bank 24. 2-way foot valve 25. Shuttle manifold 26. Shuttle valve

27.

28.

29.

30.

31.

32.

33.

34.

Shuttle valve Oil tank Tram control valve Pilot operated check valve Pump Tram motor (4) Brake (2) Feed cylinder (2)

______________________________________________________________ A6474X175 REV 07 5.49

Hydraulic system_________________________________________________

________________________________________________________________ 5.50 Model RB2-52A Roof Bolter

_______________________________________________ Mechanical system Mechanical assemblies The following pages contain a brief description of the major mechanical assemblies that are on the roof bolter.

WARNING! This section is intended to familiarize the user with the major mechanical assemblies of the roof bolter. All mechanical maintenance should be performed by a qualified technician with knowledge of the functions of the assemblies involved. frame (chassis) assembly

The model RB220 frame (Fig. 34) incorporates two major subassemblies which includes the front and rear sections. These two sections are connected at the center of the machine by a center section assembly which allows the machine to articulate while tramming over uneven terrain.

The roof bolter’ s rear section also articulates vertically just in front of the rear wheels. The articulation of the rear frame provides the operator with additional front and rear ground clearance as well as mid-machine ground clearance if needed during tramming operations. Articulation of the rear frame is supplied by two hydraulic cylinders which must be actuated from the operator’ s compartment or the left boom assembly.

Fig. 34: Frame assembly Center section

Rear frame

Front frame

______________________________________________________________ A6474X175 REV 07 5.51

Mechanical system _______________________________________________ boom assemblies

The boom assemblies (Fig. 35) are mounted to the front frame section of the machine with king pins. The drill boom arms incorporate slider and hinge linkages to provide vertical motion for the drill boxes and sumping drill box carriers. The stab foot incorporates a simple pivot to stabilize the machine during drilling and bolting functions. Individual portions of these assemblies are described on the following pages.

Fig. 35: Boom assemblies

Boom assembly

Boom assembly

________________________________________________________________ 5.52 Model RB220 Roof Bolter

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

Important notes Please observe the following: ■

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

■

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

■

Use only suitable and approved tools for maintenance work.

■

Use only original spare parts when replacing components.

■

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

■

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

Before maintenance Please observe the following: ■

Shutdown the machine on level ground

■

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

WARNING! Before performing maintenance on the machine, disconnect the electrical power. If work is to be done inside the electrical controller, the power should be disconnected. Follow all Federal and mine rules for lockout/tagout procedures. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

______________________________________________________________ A6474X175 REV 07 5.53

Maintenance_____________________________________________________ ■

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

■

Chock all four (4) wheels in each direction.

■

Connect steering lockout device.

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

■

During maintenance or servicing, if drive motors are to be run, the machine must be jacked clear of the ground and securely blocked.

All four wheels must be free to rotate.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

■

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

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

■

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

■

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

■

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

________________________________________________________________ 5.54 Model RB220 Roof Bolter

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

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

Table 2: Critical torque values Location

Bolt size

Grade

Dry

Lubricated

Tire-wheel mounting nuts

5/8”

SAE 8

225 ft-lbs

170 ft-lbs

Center section retaining nuts

3/4”

SAE 8

395 ft-lbs

280 ft-lbs

Lubricants, fluids and capacities Table 3: Lubricants, fluids and capacities Location Hydraulic oil tank

Specification Spec. 100-1

Approximate capacity 150 gals. (600 liters)

Notes 1

Lubrication points

Spec. 100-3

As Required

3

Hypoid gear oil SAE 90W

6.8 qts. (6.5 liters)

2

Planetary wheel ends

Notes: 1. With booms lowered and ATRS lowered.

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

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

When filling the planetary wheel ends, allow enough time for the lubricant to fill the various cavities and around component parts in each assembly. Continue adding oil into each assembly until the required oil level is reached.

3.

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

______________________________________________________________ A6474X175 REV 07 5.55

Maintenance_____________________________________________________ Table 4: Lubrication and maintenance schedule Item

Description

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

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

31 32 33 34 35 36 37 38 39 40 41 42 43

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

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

Places

Inspect Inspect 5 4 2 Inspect Inspect Check Check Check Inspect Empty Inspect Inspect Inspect

Lubricant

Spec. 100-1 40W Non-Detergent.

2 4 4 Check Check Inspect Inspect Inspect 8 2 4

1

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

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

2

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

4 4 8 4 4

Inspect 2 4

Specification

NLGI EP2

Spec 100-3 Spec 100-3

________________________________________________________________ 5.56 Model RB220 Roof Bolter

____________________________________________________ Maintenance Table 4 (continued): Lubrication and maintenance schedule Item

Description

Places

Lubricant

Specification

44

Hydraulic pressure settings

Check

45

Pump suction hose

Inspect

46

Electrical system permissibility

Check

47

Trailing cable

Inspect

48

Cable reel drive chain

49

Cable reel drive chain tension

50

Explosion proof housings (inspect)

3

51

Tire/wheel mounting bolts (check)

4

52

Drill box oil (change)

2

53

Torque hub to chassis frame mounting bolts (check) Every three months

54

Torque hubs

4

55

Blower (gear end)

2

Spec. 100-8

56

Electric Motor

1

Spec. 100-3 Spec. 100-1

Weekly

2

Good quality chain lube

Check

40W non-detergent

8 per hub

Spec. 100-6

Every six months 57

Hydraulic oil and suction strainer

Change

58

Cable reel

Inspect

______________________________________________________________ A6474X175 REV 07 5.57

Maintenance_____________________________________________________ Fig. 36: Lubrication chart 42,55

41

42,55

31

30

31

32 33

16

10 22 19

17

17

24 18 18 19 12

34 12

34 34 18 18 13,14

28

13,15

11

11

________________________________________________________________ 5.58 Model RB220 Roof Bolter

____________________________________________________ Maintenance Fig. 36 : Lubrication chart (continued) 26

27,29

27,29

35 25 34

36

43

40

38

39

40

37

40

______________________________________________________________ A6474X175 REV 07 5.59

Maintenance_____________________________________________________

Specific lubrication and maintenance procedures Every shift general cleaning

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

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.

panic strips and switches

Check the operation and condition of all switches and panic strips.

(Fig. 37) .

Fig. 37: Panic strips and switches “LOW OIL” (optional)

“HEADLIGHT SWITCH”

“CIRCUIT BREAKER “START" switch

Panic strip

“GROUND CHECK”switch (optional)

Panic strip “STOP” switch

Panic strip

Start switch

Panic strip

Start switch

Panic strip

________________________________________________________________ 5.60 Model RB220 Roof Bolter

____________________________________________________ Maintenance electrical cables and conduits

Inspect all electrical cables and conduits for signs of wear or damage.

Repair or replace any found damaged.

hydraulic hoses and fittings

Inspect all hydraulic hoses and fittings for signs of wear or damage.

Repair or replace any found damaged.

tires

Inspect all tires for signs of wear or damage. Repair or replace any found damaged.

lights

Inspect all lights for signs of wear, damage or burnt out bulbs. Repair or replace any found damaged.

warning tags, labels, and reflectors

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

fasteners (nuts, bolts, and screws)

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

hydraulic oil level

Check the hydraulic oil level (Fig. 38) 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.

Fig. 38: Hydraulic oil level

Site glass

______________________________________________________________ A6474X175 REV 07 5.61

Maintenance_____________________________________________________ hydraulic controls

Check the operation and condition of all hydraulic controls (Fig. 39).

Fig. 39: Hydraulic controls Vertical articulation control lever

Power fill control lever

Tram/steering control lever

PTO control lever (optional)

Inch tram/steering control lever

“ATRS SUPPORT” control

“ARTICULATION” control lever

“TRAM DIVERSION” control lever

“STAB” shoe “BOOM SWING “BOOM FLOW CONTROL”

“CANOPY”

“DUAL RELIEF” control

“ROTATION FLOW CONTROL”

Drill box “SUMP”

“ROTATION” Drill “FEED”

“FAST FEED”

Valve bank typical, both drill stations

Controls typical, both drill stations

________________________________________________________________ 5.62 Model RB220 Roof Bolter

____________________________________________________ Maintenance hydraulic oil filters

Check the hydraulic oil filter indicators (Fig. 40). 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.

Fig. 40: Hydraulic oil filters

Oil filter indicator

Oil filter indicator

Oil filter

Oil filter

drill box

Visually inspect drill boxes for excessive wear or oil leakage and check oil level (Fig. 41).

1. Remove the oil level fill/check plug. The oil level should be kept at the level of the fill/ check plug.

2. Should it be necessary to add oil, add oil (40W non detergent) through the fill/check plug hole slowly until oil flows from the hole.

Do not overfill the drill box.

3. Replace the fill/check plug.

Fig. 41: Drill box

Grease fitting

Oil level fill and check plug

Drain

______________________________________________________________ A6474X175 REV 07 5.63

Maintenance_____________________________________________________ cradle, stab shoe, and boom

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

Fig. 42: Cradle, stab shoe, and boom T-bar Support arm assembly

Boom Stab shoe

Boom Cradle

cable reel

Stab shoe

Open the cover on top of the machine and inspect the cable reel (Fig. 43) for build-up of mud or other material under or around the reel.

Fig. 43: Cable reel

Cover

Cable reel

________________________________________________________________ 5.64 Model RB220 Roof Bolter

____________________________________________________ Maintenance dust system

Inspect the dust system (Fig. 44) ■ Visually inspect dust system hosing for signs of wear or damage.

Repair or replace as required.

■ 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.

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

To rake out dust: 1. Shutdown the machine (see Shutdown procedure in this chapter).

2. Disconnect the trailing cable from the power supply following all Federal and mine lockout/tagout procedures.

WARNING! Expected start up of the machine during maintenance could result in serious injury or death or in damage to the equipment. Always follow all Federal and mine lockout/tagout procedures when deenergizing the machine.

3. Pull the rubber handles to unlatch the door and swing the door open.

4. Use the rake, supplied with your machine, to remove excess dust.

5. Inspect the door seal and sealing flange. The seal should be intact and free of defects that may cause a leak. The seal and sealing flange should be clean and free of accumulated dirt/dust to ensure a good seal.

6. Close the door and latch by pushing the rubber handles.

______________________________________________________________ A6474X175 REV 07 5.65

Maintenance_____________________________________________________ Fig. 44: Dust system

Filter element

Door sealing surface

Door gasket

Dust collection area Rake

________________________________________________________________ 5.66 Model RB220 Roof Bolter

____________________________________________________ Maintenance Every Other Shift blower belts

The blowers are located under a cover at the back of the machine. Inspect the condition and tension of blower belts (Fig. 45) for wear. Replace worn belts and adjust tension as required. Tension should be adjusted to a maximum of 1 inch deflection.

To adjust the tension of a belt:  Shutdown the machine (see Shutdown procedure in this chapter).  Disconnect the trailing cable from the power supply following all Federal and mine lockout/tagout procedures.

WARNING! Expected start up of the machine during maintenance could result in serious injury or death or in damage to the equipment. Always follow all Federal and mine lockout/tagout procedures when deenergizing the machine.  Loosen the six bolts on the blower slide plate.  Turn the adjustment screw clockwise to tighten or counterclockwise to loosen the belt to achieve the 1 inch deflection.  Tighten the six bolts.

Fig. 45: Blower belt tension

Cover

Belt tension: 1”deflection here

Blower

Adjustment screw

Blower slide plate retaining bolts (6)

Adjustment screw

Blower slide plate retaining bolts (6)

Belt tension: 1”deflection here

Motor

Blower belt

______________________________________________________________ A6474X175 REV 07 5.67

Maintenance_____________________________________________________ blower (drive ends) bearings

Lubricate the blower drive end bearings with an non-lithium based grease (NLGI EP2, Spec. 100-3) through the four fittings located on the lubrication block mounted behind the seat in the operator’ s compartment (Fig. 46). Note: Special button head type grease fittings are used and grease can only be added with a hand gun.

IMPORTANT! Use a non-lithium based grease only. Lithium based grease is not approved for any ROOTS blowers.

Fig. 46: Blower lubrication

Blower drive end lubrication fittings (4)

________________________________________________________________ 5.68 Model RB220 Roof Bolter

____________________________________________________ Maintenance cable reel

Lubricate cable reel stub shaft, flange bearing, drive gear and spooler (Fig. 47) with Spec. 100-3 .

Fig. 47: Cable reel lubrication

Stub shaft Flange bearing

Spooler

Drive gear

cradle, stab shoe, and boom

Lubricate cradle, boom, and stab shoe (Fig. 48) with Spec. 100-3.

Fig. 48: Cradle, boom, and stab shoe lubrication

Boom

Cradle Stab shoe

______________________________________________________________ A6474X175 REV 07 5.69

Maintenance_____________________________________________________ drill box and sliding surfaces

Lubricate grease fitting located on top of drill box (Fig. 49) and sliding surfaces with Spec. 100-3 .

Fig. 49: Drill box and sliding surface lubrication (typical both drills)

Sliding surfaces

Grease fitting

center section pins and nuts

Check center section pins and nuts (Fig. 50) for looseness or wear.

Tighten or replace worn parts where necessary. Lubricate points as indicated on lubrication chart with Spec. 100-3.

Fig. 50: Center section lubrication Grease fitting

Lubrication block (not shown)

Grease fitting

Grease fitting

________________________________________________________________ 5.70 Model RB220 Roof Bolter

____________________________________________________ Maintenance torque hubs

Inspect all 4 torque hubs (Fig. 51) for wear or damage and check oil level.

1. Park the roof bolter on solid level ground.

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

3. Chock all four wheels in both directions.

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

5. 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.

6. Replace plugs.

Fig. 51: Torque hubs (typical four places)

Fill plug

Check plug

______________________________________________________________ A6474X175 REV 07 5.71

Maintenance_____________________________________________________ drill box carrier pins

Lubricate grease fitting located on side of drill box (Fig. 52) with Spec.

100-3. Pump grease into fitting until old grease can be seen coming out of the pins.

Fig. 52: Drill box carrier pins (typical both drill boxes)

Grease fitting

Grease fitting

________________________________________________________________ 5.72 Model RB220 Roof Bolter

____________________________________________________ Maintenance fire suppression

Check the fire suppression system (Fig. 53).  Inspect the hoses, fittings, and nozzles and replace any found damaged.  Check the extinguisher tanks for signs of damage or corrosion.  Check the nozzle openings. The slot should be packed with silicone grease. If the nozzles are open or need to be repacked, the lines should be checked for blockage and blown clear before repacking them with silicone grease.  Remove the fill cap.  Check that the extinguisher is filled with free-flowing Ansul multipurpose ABC dry chemical to a point not more than 3”from the bottom of the fill opening.  Replace the fill cap, hand tight.

Fig. 53: Fire suppression Actuator

Nozzle

Chemical tank

Nozzle

Nozzle Actuator

Nozzle

______________________________________________________________ A6474X175 REV 07 5.73

Maintenance_____________________________________________________ Reference Fig. 54 for the following lubrication points on pins: lift arm pin (drill boom)

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

leveling bracket pin

Lubricate the leveling bracket pin with Spec. 100-3. Pump grease into the fitting until the old grease can be observed coming out.

radius arm/ATRS pin

Lubricate the radius arm pin/ ATRS pin with Spec. 100-3. Pump grease into the fitting until the old grease can be observed coming out.

stab cylinder pin (rod end)

Lubricate the stab cylinder pin (rod end) with Spec. 100-3. Pump grease into the fitting until the old grease can be observed coming out.

stab cylinder pin (base end)

Lubricate the stab cylinder pin (base end) with Spec. 100-3. Pump grease into the fitting until the old grease can be observed coming out.

lift arm pin (stab shoe)

Lubricate the left arm pin (stab shoe) with Spec. 100-3. Pump grease into the fitting until the old grease can be observed coming out.

feed cylinder pin (base end)

Lubricate the feed cylinder pin (base end) with Spec. 100-3. Pump grease into the fitting until the old grease can be observed coming out.

feed cylinder pin (rod end)

Lubricate the feed cylinder pin (rod end) with Spec. 100-3. Pump grease into the fitting until the old grease can be observed coming out.

Fig. 54: Pin lubrication

Lift arm pin (drill boom)

Feed cylinder pin (rod end)

Leveling bracket pin

Radius arm/ ATRS pin

Stab cylinder pin (base)

Stab cylinder pin (rod end) Feed cylinder pin (base)

Leveling bracket pin

Lift arm pin (stab shoe)

________________________________________________________________ 5.74 Model RB220 Roof Bolter

____________________________________________________ Maintenance Weekly hydraulic pressure settings

Check hydraulic pressure settings (Table 5) on the gauges in the operator’ s compartment (Fig. 55). If adjustments are necessary, see the Adjustment section in this chapter.

Table 5: Pressure gauge readings Gauge

Pressure (psi)

“CABLE REEL/LH BOOM ROTATION” “STEERING/RH BOOM FUNCTION” “REAR TRAM/RH ROTATION” “FRONT TRAM/LH ROTATION”

Fig. 55: Hydraulic pressure

“REAR TRAM/RH ROTATION”

“CABLE REEL/LH BOOM ROTATION”

pump suction hose electrical system

“STEERING/RH BOOM FUNCTION”

“FRONT TRAM/LH ROTATION”

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

Check electrical system for permissibility.

IMPORTANT! Electrical system repairs must be performed or supervised by an MSHA certified electrician.

______________________________________________________________ A6474X175 REV 07 5.75

Maintenance_____________________________________________________ trailing cable

Unreel the entire trailing cable (Fig. 56) and carefully check its condition. Replace trailing cable if excessively worn or damaged.

Fig. 56: Trailing cable

Trailing cable

cable reel drive chain

Inspect, clean, and lightly oil cable reel drive chain (Fig. 57) with a good quality chain lube .

Fig. 57: Cable reel drive chain

Cable reel drive chain

________________________________________________________________ 5.76 Model RB220 Roof Bolter

____________________________________________________ Maintenance drill boxes

Drain and replace oil in both drill boxes (Fig. 58).

1. Remove drain plug and drain oil from drill box. Replace drain plug.

2. Remove check/fill plug and fill drill box to level of fill plug with clean light mineral oil. Replace check/fill plug.

3. Run gear box for five minutes.

4. Remove drain plug and drain mineral oil. Replace drain plug.

5. Remove check/fill plug and fill drill box with 40W non detergent oil.

Replace check/fill plug.

Fig. 58: Drill box lubrication change (typical both drill boxes)

Grease fitting

Oil level fill and check plug

explosion proof housings

Drain port

Remove covers on explosion proof housings (Fig. 59). 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.

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.

Fig. 59: Explosion proof housings Start button

Controller

Start button

______________________________________________________________ A6474X175 REV 07 5.77

Maintenance_____________________________________________________ tire condition and wheel mounting bolts

Check tire condition and wheel mounting bolts (Fig. 60) on all 4 tires.

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

Fig. 60: Tire condition and wheel mounting bolts

Tires and wheel mounting bolts

hydraulic oil filter element (2)

Change both (2) hydraulic oil filter elements (Fig. 61).

IMPORTANT! If unordinarily dirty or dusty conditions are encountered, hydraulic oil filters should be re placed more frequently.

Fig. 61: Hydraulic oil filter elements

Oil filter

Oil filter

________________________________________________________________ 5.78 Model RB220 Roof Bolter

____________________________________________________ Maintenance torque hub to chassis frame mounting bolts

Check torque hub to chassis frame mounting bolts (8 per hub) for tightness (Fig. 62) .

Fig. 62: Torque hub to chassis mounting bolts

Mounting bolts (8 per hub)

Every two months electric motor

Lubricate the electric motor with Spec.100-3 through the two plugs located on either end of the motor (Fig. 63). Pump only one or two pumps of grease into each fitting. Over greasing of the motor may cause serious damage to the electric motor.

Fig. 63: Electric motor Grease plug

Grease plug

______________________________________________________________ A6474X175 REV 07 5.79

Maintenance_____________________________________________________ Every three months blower oil level

Check the oil level in both blowers (Fig. 64).  Remove the oil level fill/check plug. The oil level should be kept at the level of the fill/check plug.  If necessary, slowly add oil (Spec. 100-8) through the fill/check plug hole until oil flows from the hole. Do not overfill the blower.  Replace the fill/check plug.

Fig. 64: Blower oil level

Oil check/ fill plug

Blower

________________________________________________________________ 5.80 Model RB220 Roof Bolter

____________________________________________________ Maintenance torque hubs

Replace oil in the torque hubs (Fig. 65).

1. Park the roof bolter on solid level ground.

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

3. Chock all four wheels in both directions.

4. Remove drain plug.

5. Replace drain plug.

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

7. Replace plugs.

8. Remove check and fill plugs.

9. Add oil (spec 100-6) through the fill plug hole slowly, just until it starts to run out of the check plug hole slowly.

Fig. 65: Torque hubs (typical, 4 places)

Fill plug

Check plug

______________________________________________________________ A6474X175 REV 07 5.81

Maintenance_____________________________________________________ Every Six Months hydraulic oil strainer

Change hydraulic oil and clean or replace the hydraulic oil strainer inside the hydraulic oil tank (Fig. 66).

1. Chock all four wheels in both directions.

2. Place an oil catch pan under the oil tank and remove drain plug, allowing oil to drain. Dispose of oil in accordance with all laws and regulations.

3. Replace drain plug.

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

5. Remove the bolts that secures the cover to the tank.

6. Unscrew the suction strainer and remove it from the tank. If the strainer is not torn or damaged, it can be cleaned using kerosene and a soft brush and dried thoroughly. If the strainer is damaged, it must be replaced.

7. Replace strainer in tank and tighten hand tight.

8. Manually add oil to the tank until the suction strainers are covered.

WARNING! If jet fill is employed, the tank must be filled manually until the suction strainer is completely flood with oil before the jet fill is employed. Failure to manually flood the suction strainer will result in premature wear or pump failure.

9. Re-install the cap and cover assembly.

10. Refill the oil tank to the proper level with spec 100-1 using the jet fill system.

Fig. 66: Hydraulic oil strainer Hydraulic oil tank

Oil sight glass

________________________________________________________________ 5.82 Model RB220 Roof Bolter

____________________________________________________ Maintenance cable reel

Inspect cable reel collecting rings, contactor points, brushes, and bearings (Fig. 67). Clean and repack bearings when reel is disassem-

Fig. 67: Cable reel

Inner bearing

Ground brush assembly

Collector rings

Packing

Packing gland location

______________________________________________________________ A6474X175 REV 07 5.83

Maintenance_____________________________________________________

________________________________________________________________ 5.84 Model RB220 Roof Bolter

________________________________________ Replacement of wear parts Tire/wheel installation procedure The following installation procedures are for general guidance when installing a tire/ wheel assembly (Fig. 61) on most underground mining machines. Any use made of the advisory information contained herein is entirely within the control and discretion of the user and is wholly voluntary.

Fig. 68: Tire/ wheel assembly

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

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

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

wheel mounting arrangements

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

______________________________________________________________ A6474X175 REV 07 5.85

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

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

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

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

wheel mounting tips

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

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

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

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

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

________________________________________________________________ 5.86 Model RB220 Roof Bolter

________________________________________ Replacement of wear parts Recommended wheel mounting procedures 

All steel mating surfaces must be free and clean of any dirt, corrosion, paint, etc. These areas include wheel/hub tapers and disc faces. NO PAINT should be present under bolt heads or nuts.



Fasteners should be in proper condition. Any fastener with damage, such as corrosion, bending or worn threads, should be replaced. Replace all broken wheel studs.



After positioning the wheel on the hub, tighten nuts down evenly.

Triangulate the bolt pattern tightening sequence as shown in the diagrams (Fig. 69 and 70).



After operating the machine for a short period of time, check the wheel-mounting bolts or nuts for proper torque.

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

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

Fig. 69: Triangular bolt pattern

Fig. 70: Torque patterns

______________________________________________________________ A6474X175 REV 07 5.87

Replacement of wear parts_________________________________________

________________________________________________________________ 5.88 Model RB220 Roof Bolter

___________________________________________ Adjustment procedures Instructions on the adjustment procedures It is essential that adjustments be made periodically, as otherwise damage can be caused to other parts of the machine. Inspect the adjustments at regular intervals.

WARNING! Failure to follow applicable guidelines described in Chapter 2, "Your Safety" before performing maintenance or service on this machine could result in severe personal injury or potential death.

Drill Feed Relief (located near front tires) Instructions to adjust the drill feed relief The drill feed relief set point is 700 psi If this setting is not at 700 psi, an adjustment should be made to bring the set point back to the recommended setting. (Fig. 71) IMPORTANT! The drill feed relief has a hex head screw type of adjustment.  1.

To increase the setting, break loose the 9/16”jam nut, then use a 1/2”open end wrench to adjust by turning clockwise.

Retighten the jam nut to keep the setting in place.

 2.

To decrease the setting, break loose the 9/16”jam nut, then use a 1/2”open end wrench to adjust by turning counter clock wise. Retighten the jam nut to keep the setting in place.

IMPORTANT! The dual relief is used only with conventional bolts.

Rotation Relief Instructions to adjust the rotation relief for the main torque relief setting (located near front tires) The rotation relief set point for the main torque relief setting is between 1100— 1750 psi If this setting is not between 1100-1750 psi, an adjustment should be made to bring the set point back to the recommended setting. (Fig. )  1.

To increase the setting, break loose the 9/16”jam nut, then use a 5/32”Allen wrench to adjust by turning clockwise. Retighten the jam nut to keep the setting in place.

 2.

To decrease the setting, break loose the 9/16”jam nut, then use a 5/32”Allen wrench to adjust by turning counter clockwise. Retighten the jam nut to keep the setting in place.

IMPORTANT! The rotation relief for the main torque relief setting has an Allen head screw type of adjustment.

IMPORTANT! The feed and rotation will also have to be fine tuned to meet the roof strata conditions.

______________________________________________________________ A6474X175 REV 07 5.89

Adjustment procedures ___________________________________________ Tram Valve Relief Instructions to adjust the tram valve relief The tram valve relief set point is 2150 psi. If this setting is not at 2150 psi., an adjustment should be made to bring the set point back to the recommended setting. (Fig. )  1.

To increase the setting, break loose the 9/16”jam nut, then use an open end wrench to adjust by turning clockwise. Retighten the jam nut to keep the setting in place.

 2.

To decrease the setting, break loose the 9/16”jam nut, then use an open end wrench to adjust by turning counter clockwise. Retighten the jam nut to keep the setting in place.

IMPORTANT! The tram valve is preset by the manufacturer.

Vacuum Control Instructions to adjust the vacuum control The vacuum control set point is 12. If this setting is not at 12, an adjustment should be made to bring the set point back to the recommended setting. (Fig. )  1.

To increase the setting, loosen the jam nut. By hand, adjust the knob clockwise. Retighten the jam nut to keep the setting in place.

 2.

To decrease the setting, loosen the jam nut. By hand, adjust the knob counter clockwise. Retighten the jam nut to keep the setting in place.

System Gauge Instructions to read the system gauge The system gauge set point is 1850 psi (S.Y.S.) / 900 psi (C.R.A.) and 15 gpm. If this setting is not at 1850 psi (S.Y.S.) / 900 psi (C.R.A.) and 15 gpm, an adjustment should be made to bring the set point back to the recommended setting. (Fig. )

Steer Gauge Instructions to read the steer gauge The steer gauge set point is 1850 psi and 15 gpm If this setting is not at 1850 psi and 15 gpm, an adjustment should be made to bring the set point back to the recommended setting. (Fig )

________________________________________________________________ 5.90 Model RB220 Roof Bolter

___________________________________________ Adjustment procedures Front Tram Gauge Instructions to read the front tram The front tram set point is 2150 psi and 30 gpm. If this setting is not at 2150 psi and 30 gpm, an adjustment should be made to bring the set point back to the recommended setting.

Rear Tram Gauge Instructions to read the rear tram The rear tram set point is 2150 psi and 30 gpm . If this setting is not at 2150 psi and 30 gpm, an adjustment should be made to bring the set point back to the recommended setting.

Main Relief Instructions to adjust the main relief (located at the valve bank control levers in operator’s compartment) The main relief set point is 1850 psi. If this setting is not at 1850 psi, an adjustment should be made to bring the set point back to the recommended setting.  1.

To increase the setting, break loose the 9/16”jam nut, then place a flathead screwdriver in the slot to adjust by turning clockwise. Retighten the jam nut to keep the setting in place.

 2.

To decrease the setting, break loose the 9/16”jam nut, then place a flathead screwdriver in the slot to adjust by turning counter clockwise. Retighten the jam nut to keep the setting in place.

Main Relief Instructions to adjust the main relief (located at the bottom of the valve assembly) The main relief set point is 1850 psi, If this setting is not at 1850 psi, an adjustment should be made to bring the set point back to the recommended setting. To check system pressure, pull up the cable reel pedal and hold in position.  1.

To increase the setting, break loose the 9/16”jam nut, then place a flathead screwdriver in the slot to adjust by turning clockwise. Retighten the jam nut to keep the setting in place.

 2.

To decrease the setting, break loose the 9/16”jam nut, then place a flathead screwdriver in the slot to adjust by turning counter clockwise. Retighten the jam nut to keep the setting in place.

______________________________________________________________ A6474X175 REV 07 5.91

Adjustment procedures ___________________________________________ IMPORTANT! To check system pressure on main relief located at the bottom of the valve assembly, pull up the cable reel pedal and hold in position.

Cable Reel Relief Instructions to adjust the cable reel relief (located at the top of the valve assembly) The cable reel relief set point is 900 psi.. If this setting is not at 900 psi., an adjustment should be made to bring the set point back to the recommended setting.

IMPORTANT! Before adjusting, be sure the flow control is turned all the way clockwise.  1.

To increase the setting, break loose the 9/16”jam nut, then place a flathead screwdriver in the slot to adjust by turning clockwise. Retighten the jam nut to keep the setting in place.

 2.

To decrease the setting, break loose the 9/16”jam nut, then place a flathead screwdriver in the slot to adjust by turning counter clockwise. Retighten the jam nut to keep the setting in place.

Cable Reel Flow Control Instructions to adjust the cable reel flow control The cable reel flow control set point is set in the field . If this setting is not as desired, an adjustment should be made to bring the set point back to the desired setting. The cable reel flow control sets the speed of the cable take-up.  1. To increase the setting, use knob to loosen jam nut and turn counter-clockwise.  2. To decrease the setting, use knob to loosen jam nut and turn clockwise.

IMPORTANT! The cable reel flow control MUST be set in the field!

A.T.R.S. Pressure Reducing Valve Instructions to adjust the A.T.R.S. pressure reducing valve The A.T.R.S. set point is preset by the manufacturer and is protected by a safety tire/wire. If the set point must be adjusted, cut the safety wire/ tie and follow the instructions. ________________________________________________________________

5.92

Model RB220 Roof Bolter

___________________________________________ Adjustment procedures

 1.

To increase the setting, break loose the 9/16”jam nut and use a 5/32”Allen wrench to adjust by turning clockwise.

 2.

To decrease the setting, break loose the 9/16”jam nut and use a 5/32”Allen wrench to adjust by turning counter clockwise.

Pilot Relief Instructions to adjust the pilot relief The pilot relief set point is 500 p.s.i. If this setting is not at 500 p.s.i, an adjustment should be made to bring the set point back to the recommended setting.  1.

To increase the setting, break loose the 9/16”jam nut and use a 5/32”Allen wrench to adjust by turning clockwise.

 2.

To decrease the setting, break loose the 9/16”jam nut and use a 5/32”Allen wrench to adjust by turning counter clockwise.

Rotation Relief Instructions to adjust the rotation relief (located at the drill box control lever area) The rotation relief is set at the desired torque by using a torque wrench at the drill box. If this setting is not at the desired torque, an adjustment should be made to bring the set point back to the desired setting.  1.

To increase the setting, break loose the 9/16”jam nut and use a 5/32”Allen wrench to adjust by turning clockwise.

 2.

To decrease the setting, break loose the 9/16”jam nut and use a 5/32”Allen wrench to adjust by turning counter clockwise.

Inch Tram Flow Control Instructions to adjust the inch tram flow control The inch tram flow control set point is 60 - 80 ft/min. If this setting is not at the recommended setting , an adjustment should be made to bring the set point back to the recommended setting.  1.

To decrease the setting, break loose the 9/16”jam nut, then place a flathead screwdriver in the slot to adjust by turning clockwise. Retighten the jam nut to keep the setting in place.

 2.

To increase the setting, break loose the 9/16”jam nut, then place a flathead screwdriver in the slot to adjust by turning counter clockwise. Retighten the jam nut to keep the setting in place.

______________________________________________________________ A6474X175 REV 07 5.93

Adjustment procedures ___________________________________________ Stab Shoe Instructions to fine tune adjust the stab shoe The stab shoe is set at 500 psi. If this setting is not at 500 psi, an adjustment should be made to bring the set point back to the recommended setting. For fine tune adjustment, use shims.  1. To increase the setting, use more shims.  2. To decrease the setting, use less shims.

Canopy Instructions to fine tune adjust the canopy The canopy is set at 500 psi.. If this setting is not at 500 psi, an adjustment should be made to bring the set point back to the recommended setting. For fine tune adjustment, use shims.  1. To increase the setting, use more shims.  2. To decrease the setting, use less shims.

A.T.R.S. Instructions to fine tune adjust the A.T.R.S. The A.T.R.S. is set at 1100 psi. If this setting is not at 1100 psi, an adjustment should be made to bring the set point back to the recommended setting. For fine tune adjustment, use shims.  1. To increase the setting, use more shims.  2. To decrease the setting, use less shims.

Stab Shoe Pressure Reducing Valve Instructions to adjust the stab shoe pressure reducing valve The stab shoe pressure reducing valve is set at . If this setting is not at an adjustment should be made to bring the set point back to the recommended setting. (Fig. )  1.

To increase the setting, break loose the 9/16”jam nut and use a 5/32”Allen wrench to adjust by turning clockwise.

 2.

To decrease the setting, break loose the 9/16”jam nut and use a 5/32”Allen wrench to adjust by turning counter clockwise.

________________________________________________________________ 5.94 Model RB220 Roof Bolter

___________________________________________ Adjustment procedures Drill Feed Relief (on boom control valve bank) Instructions to adjust the drill feed relief The drill feed relief is set at 1550 psi If this setting is not at 1550 psi, an adjustment should be made to bring the set point back to the recommended setting. (Fig. )  1.

To increase the setting, break loose the 9/16”jam nut, then place a flathead screwdriver in the slot to adjust by turning clockwise. Retighten the jam nut to keep the setting in place.

 2.

To decrease the setting, break loose the 9/16”jam nut, then place a flathead screwdriver in the slot to adjust by turning counter clockwise. Retighten the jam nut to keep the setting in place.

NOTICE! The drill feed relief psi setting can range from a top setting of 1750 to 1250 psi according to the roof conditions.

NOTICE! Torque Button: Use only with conventional bolts.

NOTICE! The rotation flow control is used to slow drill to meet the roof strata conditions.

NOTICE! The drill flow control is used to slow feed to meet the roof strata conditions.

IMPORTANT! All pressures are pre-set at the plant to + or - 50 psi.

Torque Button Use only with conventional bolts.

Rotation Flow Control Used to slow drill to meet roof strata conditions.

Drill Flow Control Used to slow feed to meet roof strata conditions.

Drill Box Sump Loosen jam nut and set A port at 1000 psi and for B port, set at 650 psi.

______________________________________________________________ A6474X175 REV 07 5.95

Adjustment procedures ___________________________________________ Drill feed relief

Rotation relief

Fig. 64: Adjustments for RB2-52A Stab shoe Drill flow control

Canopy

Rotation flow control Torque button Drill feed relief

Stab shoe pressure reducing valve ATRS

Rotation Relief

Drill feed relief Rotation Relief

ATRS pressure reducing valve

Pilot relief

Inch tram flow control Tram valve relief setting Tram valve relief setting

Cable reel flow control

Cable reel relief

Main relief System gauge

Main relief valve bank

Vacuum control

Front tram Steer gauge Rear tram

Vacuum control

________________________________________________________________ 5.96 Model RB220 Roof Bolter

_________________________________________________ Troubleshooting Troubleshooting procedures The following section lists possible problems encountered when servicing the roof bolter and can aid in locating and correcting these problems.

This section covers basic hydraulic components, with each listed in a trouble-cause-remedy format.

For electrical instructions, troubleshooting, and maintenance procedures, refer to the “Dual Motor Controller Solid-State Troubleshooting Guide”.

WARNING! Some procedures must be carried out with the cover of the electrical controller removed and some procedures require the controller to be energized during the tests. It is extremely important that you take all necessary precautions to prevent accidental electrical shock while working within the controller. An MSHA-certified electrician must supervise and inspect all work performed.

For maintenance procedures and tests that DO NOT require the controller to be energized, these precautions include:  1. Before removing the controller cover, remove power from the system by unplugging the battery.  2. When the cover is removed, wait one minute for the capacitors to discharge before working inside the controller. To insure that the capacitors are discharged, connect an insulated 100ohm, 10-watt resistor between the center buss bar and the outer buss bar of the capacitor bank and hold for 30 seconds.  3. Use insulated gloves and tools where possible.  4. All connections must be tight and care must be taken to pre vent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

For procedures that DO require that the controller be energized while the cover is off:  5. At no time should you reach inside the controller while it is energized. If it becomes necessary to make adjustments or to replace parts inside the controller, the machine circuit breaker must be turned to the “OFF”position and the capacitor bank discharged (see above). Once the circuit breaker is in the “OFF”position and the capacitor bank discharged, adjustments or parts replacements can be made.  6. Use insulated gloves and tools where possible.

______________________________________________________________ A6474X175 REV 07 5.97

Troubleshooting _________________________________________________  7. All connections must be tight and care must be taken to pre vent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasten ers could cause electrical shorts inside the controller.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. If a hose is disconnected while the cylinder is supporting a load, the load will fall.

Hydraulic system (general) Table 4: Hydraulic system (general) troubleshooting Trouble, symptom or cause

Probable cause

dirty oil  Components not properly cleaned after servicing.  Air breather left off.

Test, check and/or remedy  Disassemble components and reclean parts.  Replace breather.

 Hose lines not properly covered  Clean hose lines after servicing. after servicing machine.  Filter elements not replaced at proper intervals or when indicated. foaming oil  Return of tank lines not below fluid level. Check oil level.

 Replace elements at proper intervals.  Replace broken hoses or lines.

 Oil contaminated with incompatible foreign matter.

 Drain out oil and replace with clean oil.

 Suction leak to pump aerating oil.

 Replace or tighten fittings and lines.

moisture in oil  Soluble oil solution splashing into poorly gasketed tanks or fill holes left open.  Moisture in cans or used replacement oil.

 Drain out and refill with clean oil. Check fill pipes to see if they are properly closed.  Replace with new cans of oil.

 Extreme temperature differential  Replace with recommended oil in certain geographical locafor correct temperature range. tions. overheating of system  Fluid viscosity too high.

 Check fluid specs.

 Excessive slippage or internal  Fluid viscosity too low. leakage past pump or cylinders.

________________________________________________________________ 5.98 Model RB220 Roof Bolter

_________________________________________________ Troubleshooting Table 4 (continued): Hydraulic system (general) troubleshooting Trouble, symptom or cause

Probable cause

Test, check and/or remedy

overheating of system  Improper air circulation around (continued) reservoir.

 Check to see if the area around the reservoir is clear.

 System relief valve set too high or too low.

 Reset the relief valve to specifications.

foreign matter sources  Sealing compound (pipe dope, in the circuit Teflon tape).

 Clean or replace seals.

 Burrs inside piping components.  Disassemble piping components and remove any burrs.  Tag ends of packing coming loose.

 Remove old packing and replace with new.

 Lines left unprotected and dirty, repaired components.

 Drain and replace oil.

 Repair parts not properly protected while stored.

 Clean parts thoroughly before installation.

Accumulator charging cycle  Leaking accumulator lines or repeats frequently when fittings. accumulator is not normally being discharged in service  Accumulator gas charge too low.

 Check lines and fittings for leaks and correct.  Check accumulator gas charge.

 Accumulator gas charge too high.

 Check accumulator.

 Line to accumulator plugged.

 Replace line.

Accumulator starts to charge but  No oil or low oil in tank. doesn’t reach high limit  Defective or worn pump (pump doesn’ t deliver full flow or pressure).

 Check oil level.  Check pump pressure and flow.

 Defective system relief valve  Check relief valve. (valve leaking or has low setting so full flow and pressure are not available).  Defective charging valve. accumulator charging time  No oil or low oil level in tank. too long  Relief valve setting too low.

 Replace valve.  Check oil level.  Check vaIve setting.

 Pump worn or defective and not  Check pump. delivering full flow or pressure.  Defective charging valve.

 Remove charging valve.

______________________________________________________________ A6474X175 REV 07 5.99

Troubleshooting _________________________________________________ Table 4 (continued): Hydraulic system (general) troubleshooting Trouble, symptom or cause

Probable cause

accumulator fails to start  No oil or low oil level in tank. charging  Worn or defective pump.

Test, check and/or remedy  Check oiI level.  Check pump pressure and flow.

 Defective relief valve.

 Check relief valve setting.

 Defective charging valve.

 Replace charging vaIve.

very rapid cycling of  Accumulator gas charge too charging valve low.

 Check gas charge.

 Accumulator gas charge too high.

 Check gas charge.

 No gas charge in accumulator.

 Check gas charge.

 Defective charging valve.

 Replace charging valve.

________________________________________________________________ 5.100 Model RB220 Roof Bolter

_________________________________________________ Troubleshooting Brakes Table 5: Brakes troubleshooting Trouble, symptom or cause

Probable cause

brakes slow to apply  Defective brakes.

Test, check and/or remedy  Check brakes.

 Pedal linkage out of adjustment.  Adjust Iinkage.  Damaged hydraulic brake lines.  Check lines for dents that restrict flow of oiI.  Defective brake pedal valve.

brakes won’t release  Pedal linkage out of adjustment or binding.

 Test individual valve performance and replace brake valve (s) as required.  Check for proper adjustment and binding.

 Brake release controls not func-  Inspect brake release solenoid, tioning properly. pilot valves and brake release hand pump.  Defective brakes.

 Check brakes.

 Defective brake pedal valve.

 Test individual valve performance and replace brake valve (s) as required.

insufficient brakes  No oil or low level in tank.

 Check oil level in tank.

 Pedal linkage out of adjustment.  Adjust linkage.  Brake line mashed.

 Check Iines and replace.

 No gas charge in accumulator.

 Check gas charge.

 Defective brakes.

 Repair or replace as required.

 Brake valve defective.

 Test valves performance and replace valve as required.

brakes will not release  Defective brakes. completely  Oil Level.

 Check brakes.  Check oil level and fill as required.

 Pedal linkage out of adjustment.  Adjust pedal linkage.  Air in brakes.

 Bleed brakes.

 Defective brake valve.

 Replace brake valve.

 Brake release controls not func-  Inspect brake release solenoid, tioning properly. pilot valves and brake release hand pump.

______________________________________________________________ A6474X175 REV 07 5.101

Troubleshooting _________________________________________________ Table 5 (continued): Brakes troubleshooting Trouble, symptom or cause

Probable cause

excessive braking  Defective brakes.  Defective brake valve.

Test, check and/or remedy  Check brakes.  Replace brake valve.

no brakes  Pedal Iinkage out of adjustment.  Adjust pedal linkage.  Broken or mashed brake line.

 Check Iines for breaks or mashed condition.

 Defective or worn brakes.

 Check brakes.

 Defective brake valve.

 Replace brake valve.

parking brakes will not release  Insufficient pressure. completely  Accumulator not properly precharged. excessive accumulator cycling  Damaged lines or connections when brakes are not being used in circuit.  Valve (s) in any branch of this circuit contaminated or damaged. insufficient brakes  Defective or worn brakes.

 Check lines and brake release control valves for proper operation.  Recharge accumulator.  Repair or replace as required.  Isolate circuits to locate the source of the leakage and clean or replace as required.  Replace or repair as required.

 Damaged lines or connections in circuit.

 Repair or replace as required.

 Valve (s) in any branch of this circuit contaminated or damaged.

 Isolate circuits to locate the source of the leakage and clean or replace as required.

brakes won’t release  Damaged lines or connections in circuit.  Valve (s) in any branch of this circuit contaminated or damaged.

Excessive accumulator leakage  Defective brake pedal valve (s) when brakes are applied

 Repair or replace as required.  Isolate circuits to locate the source of the leakage and clean or replace as required.  Replace as required.

________________________________________________________________ 5.102 Model RB220 Roof Bolter

_________________________________________________ Troubleshooting Hydraulic cylinders Table 6: Hydraulic cylinder troubleshooting Trouble, symptom or cause

Probable cause

cylinder drifts  Piston seal leak.

Test, check and/or remedy  Repair seals or replace cylinder.

 Control cartridge by-passing.

 Replace cartridge or cylinder as required.

 Other circuit leaks.

 Correct leaks.

cylinder fails to move the load  Pressure too Iow. when actuated

 Check pressure at cylinder to make circuit requirements.

 Piston seal leak.

 Repair seals or replace cylinder.

 Piston rod broken at piston end.  Repair as required or replace cylinder.  Contamination in hydraulic system resulting in scored cylinder bore. erratic or chatter in operation  Excessive friction due to misalignment and/or side loading.  Air in circuit.

 Replace cylinder.

 Correct cylinder to load alignment.  Cycle cylinder to full stop positions to purge air.

excessive or rapid piston  Excessive system pressure due  Correct pressure adjustment to seal wear to over adjustment. rated limits.  Excessive friction due to misalignment and/or side loading. cylinder body seal leak  Excessive pressure.

 Correct cylinder to load alignment.  Reduce pressure to rated limits.

 Seal is pinched or extruded.

 Replace cylinder body seal.

 Seal deterioration (soft or gummy).

 Check compatibility of seal material with operating fluid. Replace oil.

the piston is leaking  Dirt has scored the piston or the  Replace rod. rod. the piston freezes to the tube  Scoring in the piston.

Packing and gasket leaks  Excessive heat. develop

 Replace.  Replace packing and gasket.

______________________________________________________________ A6474X175 REV 07 5.103

Troubleshooting _________________________________________________ Hydraulic pump Table 7: Hydraulic pump troubleshooting Trouble, symptom or cause

Probable cause

pump makes excessive noise  Vacuum leaks in suction line.

Test, check and/or remedy  Check for leaks in fittings or damaged suction lines.

 Vacuum leaks in the pump shaft  Check pump. seal.  Poor alignment with drive mechanism.

 Align pump and pump motor.

 Incorrect fluid in system.

 Check fluid specs.

 Relief valve set too high.

 Check relief pressure.

 Seal deterioration (hard or loss of elasticity).

 Replace seal.

 Seal deterioration (loss of radial  Replace seal . squeeze due to flat spots or wear on O.D. or I. D.). seal leak  Torn or worn seaIs.

 Replace seal.

 Gland bearing worn.

 Replace gland and seals.

 Seal deterioration (soft or gummy).

 Replace seal.

 Seal deterioration (hard or loss of elasticity).

 Replace seal.

 Seal deterioration (flat spots on I.D.).

 Replace seal.

 Aeration of fluid in reservoir.

 Correct air leak.

 Worn or damaged gears and housing.

 Replace gears and housing.

 Worn or faulty bearing.

 Replace faulty bearing.

 Reversed rotation.

 Check pump motor wiring.

 Plugged or restricted suction line or suction strainer.

 Clean by removing the plugged area.

 Plugged reservoir filter breather .

 Clean reservoir. Clean breather.

________________________________________________________________ 5.104 Model RB220 Roof Bolter

_________________________________________________ Troubleshooting Table 7 (continued): Hydraulic pump troubleshooting Trouble, symptom or cause

Probable cause

seal leak (continued)  Oil viscosity too high or operating temperature too low.

Test, check and/or remedy  Replace with recommended oil.

 Air leak in suction line or fittings.  Replace lines or fittings if badly worn.  Loose or worn pump parts.

 Replace worn pump parts.

 Air leak at pump shaft seal.

 Replace pump shaft seals.

 Oil level too low and drawing air  Check oil level. in through inlet pipe opening.  Air bubbles in intake oil.

 Check oil level and tighten any loose fittings.

 Pump housing bolts loose or not  Tighten the housing bolts and properly torqued. re-torque bolts. pump failure to deliver oil  Low oiI Ievel in reservoir.

 Fill to proper level.

 Oil intake hose suction strainer plugged.

 Clean or replace strainer.

 Air leak in suction line and preventing priming.

 Tighten or replace suction lines.

 Pump shaft turning too slowly.

 Gears are worn and need replacing.

 Oil viscosity too high.

 Replace with recommended oil.

 Wrong shaft rotation.

 Check pump motor wiring.

 Pump shaft or parts broken.

 Replace shaft or broken parts.

 Dirt in pump.

 Clean pump .

oil leakage around pump  Shaft seal worn.

 Replace seals.

 Head of oil on suction hose con-  Tighten bolts. Tighten or renection leaking. place connections.  Pump housing bolts loose or improperly torqued.

 Tighten bolts.

______________________________________________________________ A6474X175 REV 07 5.105

Troubleshooting _________________________________________________ Table 7 (continued): Hydraulic pump troubleshooting Trouble, symptom or cause

Probable cause

excessive pump wear  Abrasive dirt in hydraulic oil being circulated through the system.

Test, check and/or remedy  Replace oil with clean hydraulic oil.

 OiI viscosity too Iow.

 Replace with recommended oil.

 System pressure exceeding pump rating.

 Relief valve out of adjustment.

 Pump misalignment.

 Realign pump.

pump parts inside the housing  Seizure due to lack of oil. are broken  Excessive system pressure above maximum pump rating.

 Check oiI level.  Relief vaIve out of adjustment.

 Excessive torqueing to housing bolts.

 Loosen bolts and then retorque.

 Solid matter being drawn in from reservoir and wedged in pump.

 Remove and clean clogged area.

Valves Table 8: Valve troubleshooting Trouble, symptom or cause

Probable cause

the operating pressure cannot be  Valve spring broken. changed  Open valve in the system.

Test, check and/or remedy  Replace the spring.  Find and close open valve.

the valve piston sticks  Dirt in the system.

 Remove the valve and clean it thoroughly; flush the system as necessary.

certain passages are blocked or  Dirt in the system. pressure fluctuates

 Remove the valve and clean it thoroughly; flush the system as necessary.

the pressure fluctuates and there  Air in the system. is extreme noise in the valve  Pressure or volume too high.

 Check for leaks.

the valve leaks internally  Valve piston and body worn. excessive leakage or sticking  Valve excessively hot. pistons occurs  Dirt in the system.

 Adjust the pressure or volume.  Replace the vaIve.  Remove the valve and clean it thoroughly; flush the system.  Replace oil.

________________________________________________________________ 5.106 Model RB220 Roof Bolter

_______________________________________________________________

6

Technical data

________________________________________________________________

_______________________________________________________________

________________________________________________________________

___________________________________________________ Technical data

Technical data This chapter contains the most important technical data on the RB252A roof bolter. Further data can be found in the spare parts lists. At the end of this chapter you will find information on the bolt tightening torques, HFA fluids, greases, etc. Read this chapter through carefully and pay particular attention in particular to the safety instructions.

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

Components of the RB2-52A roof bolter Technical data sheet general

Overall length with ATRS .......................................... approx. 25’2” Chassis overall width ................................................. approx. 9’½” Drill boom feed ........................................................... approx. 4’4” Maximum boom separation ........................................ approx. 16’2” Minimum boom separation ......................................... approx. 3’6” Minimum tramming height: with 28X12-15 tires .............................................. approx. 2' 8" with 32X12.5-15 tires ........................................... approx. 3’10 ½” with 35X15-15 tires .............................................. approx. 4’0” ATRS reach: with 28X12-15 tires .............................................. approx. 10’ with 32X12.5-15 tires ........................................... approx. 10’ with 35X15-15 tires .............................................. approx. 10’ Ground clearance: with 28X12-15 tires .............................................. approx. 6” with 32X12.5-15 tires ........................................... approx. 8” with 35X15-15 tires .............................................. approx. 9 ½” Chassis height: with 28X12-15 tires .............................................. approx. 2' 3" with 32X12.5-15 tires ........................................... approx. 2’5” with 35X15-15 tires .............................................. approx. 2’6 ½” Wheelbase ................................................................. approx. 6’7”

performance

Inside turn radius........................................................ approx. 9’6” Outside turn radius ..................................................... approx. 21’6” Steering articulation.................................................... approx. 80° (each direction) Tram speed: Fast ...................................................................... approx. 0-130 fpm Slow ..................................................................... approx. 0-65 fpm Drilling feed thrust (maximum .................................... approx. 10,000 lbs Drilling torque (variable) ............................................. approx. 310 ft-lbs Bolt tightening torque (adjustable) ............................. approx. 190 ft-lbs

______________________________________________________________ A6474X175 REV 07 6.3

___________________________________________________ Technical data

______________________________________________________________ A6474X175 REV 07 6.4

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

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

Set screws Table 9: Set screws (Socket long-lok) Nominal diameter

Recommended torque setting

#6

6 in-lbs

#8

9 in-lbs

#10

13 in-lbs

¼”

30 in-lbs

5/16”

5 ft-lbs

3/8”

8 ft-lbs

7/16”

11 ft-lbs

½”

16.7 ft-lbs

Table 10: Set screws (Socket standard steel) Nominal diameter #6

Recommended torque setting 9 in-lbs

#8

16 in-lbs

#10

30 in-lbs

¼”

6 ft-lbs

5/16”

12 ft-lbs

3/8”

18 ft-lbs

7/16”

29 ft-lbs

½”

43 ft-lbs

5/8”

100 ft-lbs

¾”

146 ft-lbs

7/8”

199 ft-lbs

1”

262 ft-lbs

______________________________________________________________ A6474X175 REV 07 6.5

Tightening torques _______________________________________________ Table 11: Hex and socket head capscrews (Grade 8) Nominal diameter 1/4”

Recommended torque setting (lubed) 8 ft-lbs

Recommended torque setting (dry) 13 ft-lbs

5/16”

16 ft-lbs

26 ft-lbs

3/8”

28 ft-lbs

47 ft-lbs

7/16”

45 ft-lbs

75 ft-lbs

1/2”

70 ft-lbs

115 ft-lbs

9/16”

99 ft-lbs

165 ft-lbs

5/8”

135 ft-lbs

225 ft-lbs

3/4”

240 ft-lbs

400 ft-lbs

7/8”

390 ft-lbs

645 ft-lbs

1”

545 ft-lbs

905 ft-lbs

1 1/8”

830 ft-lbs

1,380 ft-lbs

1 1/4”

1,160 ft-lbs

1,935 ft-lbs

1 3/8”

1,525 ft-lbs

2,540 ft-lbs

1 1/2”

2,030 ftj-lbs

3,380 ft-lbs

________________________________________________________________ 6.6 Model RB220 Roof Bolter

_______________________________________________ Tightening torques Table 13: Untreated screw, black finish (Coarse thread) Property Torque Recommended Nominal diameter class torque setting Ma M3 M4 M5 M6 M7 M8 M10 5.6 8.8 10.9 12.9

Nm

0.60

1.37

2.70

4.5

7.8

11

22

Ft-lbs

0.44

1.01

1.99

3.3

5.6

8.1

16

Nm

1.37

3.10

6.15

10.5

17.5

26

61

Ft-lbs

1.01

2.29

4.54

7.7

12.9

19

37

Nm

1.92

4.40

8.55

15

25

36

72

Ft-lbs

1.42

3.25

6.38

11

18.4

26

53

Nm

2.30

5.25

10.4

18

29

43

87

Ft-lbs

1.70

3.87

7.6

13

21.3

31

64

Table 13: Untreated screw, black finish (Coarse thread, continued) Property class

5.6

8.8

10.9

12.9

Torque

Recommended torque setting

Nominal diameter

Ma

M12

M14

M16

M18

M20

M22

M24

Nm

39

62

85

130

184

250

315

Ft-lbs

28

45

70

95

135

184

232

Nm

89

141

215

295

420

570

725

Ft-lbs

65

103

158

217

308

420

634

Nm

125

198

305

420

690

800

1020

Ft-lbs

92

146

224

309

435

590

752

Nm

150

240

365

500

710

960

1220

Ft-lbs

110

177

269

368

523

708

899

Table 13: Untreated screw, black finish (Coarse thread, continued) Property class

5.6

8.8

10.9

12.9

Torque

Recommended torque setting

Nominal diameter

Ma

M27

M30

M33

M36

M39

Nm

470

635

865

1111

1440

Ft-lbs

346

468

637

819

1062

Nm

1070

1450

1970

2630

3290

Ft-lbs

789

1069

1452

1885

2428

Nm

1510

2050

2770

3560

4620

Ft-lbs

1113

1511

2042

2625

3407

Nm

1810

2450

3330

4280

5550

Ft-lbs

1334

1606

2455

3156

4093

______________________________________________________________ A6474X175 REV 07 6.7

Tightening torques _______________________________________________ Table 14: Untreated screw, black finish (Fine thread) Property class

Torque

Recommended torque setting

Nominal diameter

Ma

M8 X 1

M10 X 1.25

M12 X 1.25

8.8

Nm Ft-lbs

27 19

52 38

95 70

10.9

Nm

38

73

135

Ft-lbs

28

53

99

Nm

45

88

160

Ft-lbs

33

64

118

12.9

Table 14: Untreated screw, black finish (Fine thread, continued) Property class

Torque

Recommended torque setting

Nominal diameter

Ma

M14 X 1.5

M16 X 1.5

M18 X 1.5

8.8

Nm Ft-lbs

150 110

225 165

325 239

10.9

Nm

210

315

460

Ft-lbs

154

232

339

Nm

260

380

550

Ft-lbs

184

280

405

12.9

Table 14: Untreated screw, black finish (Fine thread, continued) Property class

Torque Ma

M20 X 1.5

M22 X 1.5

M24 X 2

8.8

Nm Ft-lbs Nm Ft-lbs

399 640 472

610 449 860 634

780 575 1100 811

Nm Ft-lbs

770 567

1050 774

1300 958

10.9 12.9

Recommended torque setting

Nominal diameter

________________________________________________________________ 6.8 Model RB220 Roof Bolter

_______________________________________________ Tightening torques Table 15: Electrically zinc plated (Coarse thread) Property class

5.6

8.8

10.9

12.9

Torque

Recommended torque setting

Nominal diameter

Ma

M33

M4

M5

M6

M7

M8

M10

Nm

0.56

1.28

2.50

4.3

7.1

10.5

21

Ft-lbs

0.41

0.94

1.84

3.1

5.2

7.7

15

Nm

1.28

2.90

5.75

9.9

16.5

24

48

Ft-lbs

0.94

2.14

4.24

7.3

12.1

17.7

35

Nm

1.80

4.10

8.10

14

23

34

67

Ft-lbs

1.33

3.02

5.97

10.3

16.9

25

49

Nm

2.15

4.95

9.70

16.5

27

40

81

Ft-lbs

1.59

3.65

7.15

12.1

19.9

29

59

Table 15: Electrically zinc plated (Coarse thread, continued) Property class

5.6

8.8

10.9

12.9

Torque

Recommended torque setting

Nominal diameter

Ma

M12

M14

M16

M18

M20

M22

Nm

36

58

88

121

171

230

Ft-lbs

26

42

54

89

126

169

Nm

83

132

200

275

390

530

Ft-lbs

61

97

147

202

287

390

Nm

117

185

285

390

550

745

Ft-lbs

86.2

136

210

287

405

549

Nm

140

220

340

470

660

890

Ft-lbs

103

162

250

346

486

656

Table 15: Electrically zinc plated (Coarse thread, continued) Property class 5.6

8.8

10.9

12.9

Torque Ma

Recommended torque setting M24 M27 M30

Nominal diameter

Nm

295

435

590

800

1030

1340

Ft-lbs

217

320

435

590

759

988

Nm

675

995

1350

1830

2360

3050

Ft-lbs

497

733

995

1349

1740

2249

Nm

960

1400

1900

2680

3310

4290

Ft-lbs

708

1032

1401

1902

2441

3163

Nm

1140

1680

2280

3090

3980

5150

Ft-lbs

840

1239

1661

2278

2935

3798

______________________________________________________________ A6474X175 REV 07 6.9

Tightening torques _______________________________________________ Table 16: Electrically zinc plated (Fine thread) Property class

Torque

Recommended torque setting

Nominal diameter

Ma

M8 X 1

M10 X 1.25

M12 X 1.25

8.8

Nm Ft-lbs

25 18

49 36

88 84

10.9

Nm Ft-lbs

35 25

68 50

125 92

12.9

Nm Ft-lbs

42 30

82 60

150 110

Table 16: Electrically zinc plated (Fine thread, continued) Property class

Torque

Recommended torque setting

Nominal diameter

Ma

M14 X 1.5

M16 X 1.5

M18 X 1.5

8.8

Nm Ft-lbs

140 103

210 154

305 224

10.9

Nm

195

295

425

12.9

Ft-lbs Nm Ft-lbs

143 235 173

217 350 258

313 510 376

Table 16: Electrically zinc plated (Fine thread, continued) Property class

8.8

10.9

12.9

Torque

Recommended torque setting

Nominal diameter

Ma

M20 X 1.5

M22 X 1.5

M24 X 2

Nm

425

570

720

Ft-lbs

313

420

531

Nm

600

800

1000

Ft-lbs

442

590

737

Nm

720

960

1200

Ft-lbs

531

708

885

________________________________________________________________ 6.10 Model RB220 Roof Bolter

_______________________________________________ Permissible media Permissible media Lubrication fluids and greases NOTICE! Use only approved lubrication fluids and greases approved!

These fluids and greases have been tested and guarantee reliable operation of the mechanical and hydraulic functions of the machine.

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

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

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

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

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

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

______________________________________________________________ A6474X175 REV 07 6.11

Permissible media________________________________________________ Approved suppliers: Table 17: Anti-wear hydraulic oil (Spec 100-1) Supplier

Brand name

1

Amoco Oil Company

Amoco AW Oil No.68

2

Gulf Oil

Harmony 68 AW

3

Mobil Oil Corporation

Mobil DTE-16

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Hydraulic Oil AW ISO 68 Sunvis 868

6

Unocal 76

Unax AW 68

7

Shell Oil Company

Shell Hydraulic Oil #33

8

Century Lubricating Oils, Inc.

Hydraulic AW 68

9

Atlantic Richfield Company

Duro AW S-315 Oil

10

Texaco Lubricants Company

Texaco Rando Oil HD 68

11

Exxon

Nuto 68

12

Pennzoil

Pennzbell AW 68 Hydraulic Oil

13

14

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

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

15

Conoco Inc.

Super Hydraulic oil 68

16

Hydrotex

Systems 5K 68

17

Phillips

Maginus A Oils 81350

18

Miners Oil

Hydraulic Oil 68AW

________________________________________________________________ 6.12 Model RB220 Roof Bolter

_______________________________________________ Permissible media Table 18: Extreme pressure gear oils (Spec. 100-2) Supplier

Brand name

1

Amoco Oil Company

Amoco Permagear EP 460

2

Gulf Oil

EP Lubricant HD 460

3

Mobil Oil Corporation

4

Chevron U.S.A.

5

Sun Oil Company

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

6

Unocal 76

7

Shell Oil Company

8

Century Lubricating Oils, Inc.

9

Texaco Lubricants Company

Hulbest EP-7 Powergear 460 Meropa 680

10

Exxon

Spartan EP 460

11

Pennzoil

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

12

Lubricating Engineers

13

Conoco Inc.

608 Almosal Vari-Purpose Gear Lubricant Gear Oil 460

14

Hydrotex

933 Industrial Gear Lubricant

15

Phillips

16

Miners Oil

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

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

______________________________________________________________ A6474X175 REV 07 6.13

Permissible media________________________________________________ Table 19: Extreme pressure motor bearing grease (Spec. 100-3) Supplier

Brand name

1

Amoco Oil Company

2 3 4

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

5 6 7 8

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

9 10 11 12

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers

13

Conoco Inc.

14 15 16

Hydrotex Phillips Atlantic Richfield

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

Table 20: Semi-fluid grease (Spec. 100-4)

1 2 3 4 5 6

Supplier Texaco Lubricants Company Century Oils Limited Hydrotex Pennzoil Unocal Exxon

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

________________________________________________________________ 6.14 Model RB220 Roof Bolter

_______________________________________________ Permissible media Table 21: Invert emulsion hydraulic fluid (Spec. 100-5)

1 2 3 4

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

5 6

Cincinnati –Vulcon Company Cities Service Oil Company

7 8

10 11

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

12 13 14 15 16 17

Century Lubricating Oils Imperial Oil and Grease Mobil Oil Corporation National Oil and Chemical Co. Pennzoil Quaker Chemical Company

18

Henery E. Sanson and Sons MFGE Company Southwest Grease and Oil Company, Inc. Southwest Petroleum Corp.

9

19 20 21

22 23

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

24 25

Wynn Oil Company Lubrication Engineers

26

Hydrotex

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

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

______________________________________________________________ A6474X175 REV 07 6.15

Permissible media________________________________________________ Table 22: Extreme pressure gear oil, SAE 90 (Spec. 100-6) Supplier

Brand name

1

Amoco Oil Company

Amoco Premagear EP 320

2

Gulf Oil

EP Lubricant HD 320

3

Mobil Oil Corporation

Mobil gear 632

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Gear Compound EP ISO 320 Sunep 320

6

Unocal 76

Extra Duty NL Gear Lube 6EP

7

Shell Oil company

Omala 75

8

Century Lubricating Oils, Inc.

Hulbest EP-6

9

Texaco Lubricants Company

Meropa 320

10

Exxon

Spartan EP 320

11

Pennzoil

Super Maxol EP 220 Gear Lube

12

Lubricating Engineers

13

Conoco Inc.

605 Almasol Vari-Purpose Gear Lubricant Gear Oil 320

14

Hydrotex

932 Industrial Gear Lube

15

Phillips

16

Atlantic Richfield

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

17

Cities Service

Citgo EP Compound 110

18

Pennzoil

Pen Gear #320

19

Miner Oil

Gear Oil EP220

20

Texaco, Lubricants Company

Texaco Multigear EP 80W-90

________________________________________________________________ 6.16 Model RB220 Roof Bolter

_______________________________________________ Permissible media Table 23: Hydraulic and general purpose oil medium-heavy/R&O inhibited (Spec. 100-7) Supplier Brand name 1

Amoco Oil Company

American Industrial Oil No. 68

2

Gulf Oil

Harmony 68

3

Mobil Oil Corporation

DTE Heavy –Medium

4

Chevron U.S.A.

5

Sun Oil Company

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

6

Unocal 76

7

Shell Oil Company

Unax RX68 or Turbine Oil 68 Turbo 68

8

Century Lubricating Oils, Inc.

Centraulic R&O 68

9

Texaco Lubricants Company

Regal Oil R&O N-68

10

Exxon

Tresstic 68

11

Pennzoil

Pennzbell RO 68

12

Lubricating Engineers

6120 Monolec Turbine Oil

13

Conoco Inc.

14

Hydrotex

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

15

Atlantic Richfield

Duro 5.315

16

Cities Service

Citgo Pacemaker A/W68

17

Miner Oil

Hydraulic Oil AW68

18

Texaco, Lubricants Company

TDH 1893

______________________________________________________________ A6474X175 REV 07 6.17

Permissible media________________________________________________ Table 24: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8) Supplier Brand name 1

Amoco Oil Company

American Industrial Oil No. 150

2

Gulf Oil

Harmony 150

3

Mobil Oil Corporation

DTE Oil EX. Heavy

4

Chevron U.S.A.

5

Sun Oil Company

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

6

Unocal 76

7

Shell Oil Company

Unax RX 700 or Turbine Oil 700 Turbo 150

8

Century Lubricating Oils, Inc.

Centraulic R&O 150

9

Atlantic Richfield Company

10

Texaco Lubricants Company

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

11

Exxon

Teresstic 150

12

Pennzoil

Pennzbell RO 150

13

Cities Service

Citgo Pacemaker 150

14

Lubrication Engineers

6405 Monolec Turbine Oil

15

Conoco Inc.

Dectol R&O 76

16

Hydrotex

System 1 150, System 5k 150

17

Phillips

Magnus Oils 700

18

Miner Oil

ISO 150

Table 25: Worm gear lubricant, compounded cylinder oil (Spec. 100-9) Supplier Brand name 1 Amoco Oil Company Cylinder Oil No. 1000 2 Mobil Oil Corporation Extra Hecla Super Cylinder Oil 3 Chevron U.S.A. Chevron Cylinder Oil W ISO 1000 4 Sun Oil Company Sun Steam Cylinder Oil 5 Unocal 76 Worm Gear Lube 250 or Stevalc 6 Century Lubricating Oils, Inc. Garwal 680 7 Atlantic Richfield Company Modoc 195 8 Texaco Lubricants Company 650 T Cylinder Oil 1000 9 Exxon Cylesstic TK-1000 10 Pennzoil Cylinder Oil #1000 11 Conoco Inc. Inca Oil 1000

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_______________________________________________ Permissible media Table 26: Light gear oil, SAE 40 motor oil (Spec. 100-10)

1 2 3 4

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

5 6 7

Sun Oil Company Unocal 76 Shell Oil company

8 9 10

Century Texaco Lubricants Company Exxon

11 12 13

Pennzoil Lubricating Engineers Conoco Inc.

14 15

Hydrotex Phillips

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

Table 27: Synthetic EP gear lubricants (Spec. 100-11)

1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

Table 28: Multi-purpose tractor hydraulic fluid (Spec. 100-12)

1 2 3 4

Supplier Exxon / Mobil Century / Fuchs Shell Chevron

Brand name Mobilfluid 424 Multitran Donax TD Tractor Hydraulic Fluid

5 6 7

BP Lubricants Quaker State Conoco

Tractran UTH Quaker State FCI HD Powertran Fluid

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Permissible media________________________________________________

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7

For your information

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_____________________________________________________ Our service

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

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

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

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

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

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

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

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

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

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

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

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

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

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