Operators Manual 946-393 En

acLean Engineering

Mining Division

Operator’s Manual 946-393 SAN RAFAEL - Proyecto Minera el Escobal, Guatemala, SA FOR INFORMATION OR ASSISTANCE Toll Free 1-866-856-3626 • International +1-705-445-5707 • www.macleanengineering.com

Manufactured by MacLean Engineering & Marketing Co. Limited

PROPRIETARY NOTICE The proprietary information contained in this document is the property of Maclean Engineering and Marketing Company Ltd (MEMCO) and shall be limited in distribution to MEMCO’s customers, resellers and subcontractors as required to fulfill the terms of the relevant contract. Distribution outside of these terms requires the express written permission of MEMCO.

946-393 SAN RAFAEL

Proyecto Minera El Escobal, Guatemala, SA

MEM-946-393 – SAN RAFAEL Proyecto Minera El Escobal, Guatemala, SA Scissor Bolter Operator’s Manual Module #

Revision

Date

Topic

Safety OM-BLT-S1 OM-BLT-S2 OM-BLT-S3 OM-BLT-S4

B D B A

07/28/2008 10/28/2008 10/20/2008 08/28/2008

General Safety Operating Safety Servicing Safety Fire Prevention Safety

C E A A B A

06/11/2010 06/11/2010 10/23/2008 10/23/2008 03/03/2001 08/22/2008

Overview & Safety Systems Operator’s Compartment Layout Scissor Platform Layout ECO Boom Assembly Layout Main Electrical Layout Other Components Layout

OM-BLT-O1 OM-BLT-O2 OM-BLT-O3 OM-BLT-O4-ECO OM-BLT-O5 OM-BLT-O6 OM-BLT-O7 OM-BLT-O8 OM-BLT-O9 OM-BLT-O10 OM-BLT-O11 OM-BLT-O12-ECO OM-BLT-O13 OM-BLT-O14-ECO OM-BLT-O15-ECO

D D Original A E C Original Original Original Original Original A Original Original Original

Scissor Bolter Control & Interlocks Starting, Driving, Parking and Shutdown Brake Test Procedure ECO Deck Control Panel Operation Remote Pendant Operation Drilling Procedure Screen Handling Procedure RockBolt Installation Rebar Installation Split Set Installation Swellex Bolt Installation Bolting Options and Operations Drill Lubrication System Radio Remote Pendant Operation Remote Drill Operation

OM-BLT-M 1028339.dwg 1010422.dwg

D Original AC

04/08/2001 06/11/2010 12/07/2012 10/03/2008 02/06/2013 09/17/2013 08/16/2001 08/16/2001 08/16/2001 08/16/2001 08/16/2001 07/24/2002 08/16/2001 01/13/2004 08/29/2007 02/11/2013 10/21/1999 06/14/2013

Layout OM-BLT-V1 OM-BLT-V2 OM-BLT-V3-ECO OM-BLT-V4-ECO OM-BLT-V5 OM-BLT-V6

Operations

Daily Operator’s Maintenance Lube Chart, Chain Feed Daily Lube, Boom 928/946 Dolly Matrix Variations

Training T-001 T-001-TESTQ_ECO Revision: 0

G

08/15/2002

A

10/11/2005

Operator TrainingTopics and Checklist MEM-928/946 ECO Bolter Operator Training Test

Revision Date: 24-APR-2014

By: JPB

Title: Number: Machine Model(s) Affected: Revision: Creation Date: Written By: Checked By: Approved By:

GENERAL SAFETY OM-BLT-S1 928-946 Scissor Bolters B Revision Date: Revised By: Checked By: Approved By:

07/28/2008

J. Earl Graham

GENERAL SAFETY FOLLOW MINE SPECIFIC RULES AT ALL TIMES! MACLEAN ENGINEERING’s tradition has been to produce products that are safe and reliable. However, even when using equipment engineered for safe operation, there is always an element of risk in equipment operation. WHEN IT COMES TO SAFETY, NOTHING WILL EVER TAKE THE PLACE OF A SAFE AND CAREFUL OPERATOR. Therefore, study the following safety measures carefully and apply them on the job. •

Operate the Scissor Bolter only when you are fully trained and qualified.

•

Get to know the capabilities and limitations of the equipment. Use this manual as a basis to become an efficient operator.

•

Know all safety symbols on bolter and their meaning.

•

Use recommended safety devices and personal protective equipment, i.e. gloves, safety boots, hard hats, glasses/goggles and ear protection, and protective clothing when and where required.

•

Operate the equipment only when physically fit and not under the influence of alcohol or drugs.

•

Keep floors, steps and running boards clean and free of oil, ice, mud and loose objects.

•

Carry no passengers unless the vehicle proper authority has been obtained.

•

Never remove any elements of the engine’s exhaust system or any supplied guards and safety covers when the machine is in operation.

•

Follow the recommended daily inspection procedure outlined in this manual as well as on the Pre-op card.

•

Comply with the instructions in this manual, all applicable laws, and your company’s regulations for the operation of this vehicle.

•

NEVER operate a machine that has been tagged “Out of Service”.

OM-BLT-S1

Page 1 of 2

Title: General Safety Number: OM-BLT-S1 Revision: B

If any questions or problems arise, please contact MacLean Engineering Technical Service for assistance. Phone: 1-866-856-3626 Email: [email protected]

Page 2 of 2

OM-BLT-S1

Title: Number: Machine Model(s) Affected: Revision: Creation Date: Written By: Checked By: Approved By:

10/28/2008

J. Earl Graham

OPERATING SAFETY OM-BLT-S2 928/946 Scissor Bolters D Revision Date: Revised By: Checked By: Approved By:

OPERATING SAFETY Before starting the Scissor Bolter, make certain that the transmission gear selector and the emergency/parking brake control are positioned as specified in the starting instructions in the Scissor Bolter Operation section of this manual. FOLLOW MINE SPECIFIC RULES AT ALL TIMES! •

Adhere strictly to all regulations at the work site pertaining to the operation of this equipment including all local mining regulations.

•

Prior to commencing work, check all equipment controls and ensure that the machine responds correctly.

•

Whenever possible, test the functionality of the machine controls when standing at the control console on the scissor deck or when sitting in the driver’s seat. This will help to ensure that the operator is in a safe position away from moving parts.

•

Whenever possible, operate all boom and drill functions from the control console on the scissor deck. This will help to ensure that the operator is as far as possible from the boom.

•

Maintain a safe operating distance between the equipment and other personnel. Use only approved signaling practices.

•

Follow all instructions from the mining equipment manufacturer when operating the rock drills.

•

Never use the Emergency/Parking brake to slow down or stop the vehicle unless it is an emergency situation.

•

When operating the machine, ensure that the articulation area is clear. Do not allow personnel between pinch points.

•

NEVER place yourself under the scissor deck while the deck is in the raised position without first engaging the Scissor Lock Mechanism.

•

Always ensure that excess grease and oil accumulation, including spillage, are cleaned up immediately.

•

Always face the equipment when entering or leaving the operator’s compartment. Use three-point contact with handrails and steps. Do not use control levers or the steering joystick as a handle.

OM-BLT-S2

Page 1 of 4

Title: OPERATING SAFETY Number: OM-BLT-S2 Revision: D • •

Always use the outriggers to level and stabilize the Bolter prior to raising the scissor and / or working from the deck. Always raise the outriggers and lower the Scissor Bolter deck when leaving the bolter.

•

Keep hands and feet inside the driver’s compartment at all times when driving.

•

Keep head, hands, feet and loose clothing away from rotating parts.

•

Always ensure all safety chains/cables and guardrails are installed and in good working condition when operating the machine. The scissor deck openings and wings have safety chains/cables that must be set-up in their operating positions before work can begin.

•

Possible pinch points exist in the area of the boom and handrails. Keep clear of the boom and handrail area when operating any of the Bolter’s boom or drill functions and the deck extension function.

•

Test all Emergency Stop switches at the beginning of each shift to ensure that they are functioning correctly.

•

When parking the machine and shutting down the engine, set the Master Disconnect Switch to the “OFF” position.

•

If connecting a mine air line to the Bolter, properly secure the air line with a whip check.

•

Ensure all hoses, and the Bolter’s trailing cable are disconnected and properly secured before driving the Bolter.

•

Always remove the drill steel from the rock drill before driving the Bolter. Remove the drill steel from the drill and drill feed before placing the boom into the tramming position (tilted into the deck). The drill steel should not be reinstalled onto the drill feed until the boom is positioned into a safe operating position. In this way, the advancement of a drill steel into the driver’s compartment will not be possible.

•

Use the boom support post when driving the Bolter in order to reduce boom movement during driving. This will help prevent possible damage to deck or boom components.

•

Ensure drill feed and rotation lock are engaged only while drilling (i.e. – Disengaged whenever the machine is not drilling). In this way, the advancement of a drill steel into the driver’s compartment will not be possible.

•

Never use the hydraulics to aid you in removing the drill steel. A drill steel can be uncoupled with the percussive force of the drifter, however never hold the steel with your hands and rotate it with hydraulic pressure.

Page 2 of 4

OM-BLT-S2

Title: OPERATING SAFETY Number: OM-BLT-S2 Revision: D •

One person typically operates the Scissor Bolter. However when a second person is required both operators must be properly trained. They must be in constant communication with each other and be aware of each others location at all times when working on or around the Scissor Bolter.

OM-BLT-S2

Page 3 of 4

Title: OPERATING SAFETY Number: OM-BLT-S2 Revision: D

If any questions or problems arise, please contact MacLean Engineering Technical Service for assistance. Phone: 1-866-856-3626 Email: [email protected]

Page 4 of 4

OM-BLT-S2

Title: Number: Machine Model(s) Affected: Revision: Creation Date: Written By: Checked By: Approved By:

10/20/2008

J. Earl Graham

SERVICING SAFETY OM-BLT-S3 928/946 Scissor Bolters B Revision Date: Revised By: Checked By: Approved By:

SERVICING SAFETY Before performing maintenance or repair work on any equipment stop and think; “Are you qualified to carry out these repairs?” Know YOUR limits. Consult the maintenance bulletins provided and follow the recommended procedures. •

Follow the mine site’s lock out and tagging procedures.

•

When servicing or repairing the equipment, use proper wheel chocks and shut down the engine and AC power unless they are required to be running for adjustment purposes.

•

Whenever possible, test the functionality of the machine controls when standing at the control console on the scissor deck or when sitting in the driver’s seat. This will help to ensure that the operator is in a safe position away from moving parts.

•

NEVER place yourself under the Scissor Deck while the deck is in the raised position without first engaging the Scissor Lock Mechanism. This mechanism will prevent the deck from falling in the event that there is a loss of hydraulic pressure. Failing to do so could cause severe injury or death.

•

NEVER place yourself under the boom when the machine is running. Failing to do so could cause severe injury or death.

•

Proper supports should be used whenever servicing the boom or when working under a suspended load such as the boom or scissor.

•

Always use the proper tools for the job. Repair or replace any broken or damaged tools, including lifting equipment, immediately.

•

Keep your head, hands, feet and loose clothing away from power-driven parts. (i.e. engine alternator, feed, bolt dolly, drill steel, etc…)

•

Pressure can be maintained in the hydraulic circuits long after the power source and hydraulic pump have been shut down. Relieve ALL trapped pressures before performing any service work to the hydraulic components. Some valves are used to hold components in place. Removal of these valves or hosing could result in the load dropping or coming down onto yourself or others. Ensure that there is a zero energy situation before work commences by supporting all such components.

•

When troubleshooting a hydraulic system for leaks, use a piece of cardboard or other material as detector, NEVER use your hand. Pressurized hydraulic fluid escaping from a faulty component can penetrate the skin and cause serious injury.

OM-BLT-S3

Page 1 of 2

Title: SERVICING SAFETY Number: OM-BLT-S3 Revision: B •

Do not change the pressure setting of any hydraulic valves unless authorized instruction has been obtained.

•

Use caution when draining hot fluids from the machine. Splashing hot fluid can cause serious injury.

•

Ensure that all tire and rim parts are undamaged and correctly assembled before inflating the tires. (Applicable only to pneumatics)

•

Use an inflation cage, safety cables or some other safety device when inflating the tires. Do not exceed the tire manufacturer’s recommended maximum pressure. (Applicable only to pneumatics) ALWAYS FOLLOW MINE SPECIFIC REGULATIONS WITH REGARDS TO TIRE INFLATION.

If any questions or problems arise, please contact MacLean Engineering Technical Service for assistance. Phone: 1-866-856-3626 Email: [email protected]

Page 2 of 2

OM-BLT-S3

Title: Number: Machine Model(s) Affected: Revision: Creation Date: Written By: Checked By: Approved By:

08/28/2008

J. Earl Graham

FIRE PREVENTION SAFETY OM-BLT-S4 928/946 Scissor Bolters A Revision Date: Revised By: Checked By: Approved By:

FIRE PREVENTION SAFETY Fires can create severe emergencies where both human life and property may be lost. Even when confined, a fire may cause very expensive damage to your equipment. Fire can strike at any time, not only when the equipment is used, but also when left unattended between work shifts and nobody is around to fight it. When working in a confined environment, it is impossible to prevent combustive dust from collecting in tight corners of the machine. This dust, in itself, may not cause a fire however, when mixed with fuel, oil or grease in a hot and confined place, it can become a fire hazard. Always follow mine specific regulations and procedures pertaining to fires. To reduce the chances for a fire to break out, follow the preventive instructions listed below: •

Inspect the machine daily for potential fire hazards and make any necessary repairs immediately.

•

Always ensure that excess grease and oil accumulation, including spillage, are cleaned up immediately.

•

Set up, and follow a wash schedule. Use only non-flammable cleaning agents for cleaning the machine or machine components.

•

Discard oily rags and other combustible materials in the proper designated location; do not store them on the machine.

•

Before performing repair work such as welding, the area surrounding the repair location should be cleaned and a fire extinguisher positioned close by.

•

Ensure that you are familiar with the location of the machine’s fire suppression system actuators and KNOW HOW TO USE THEM.

•

Maintain a charged fire extinguisher on or near the machine at all times and KNOW HOW TO USE IT.

•

Follow the mine site’s procedures for transporting and loading explosives.

OM-BLT-S4

Page 1 of 2

Title: FIRE PREVENTION SAFETY Number: OM-BLT-S4 Revision: A

If any questions or problems arise, please contact MacLean Engineering Technical Service for assistance. Phone: 1-866-856-3626 Email: [email protected]

Page 2 of 2

OM-BLT-S4

Title: Number: Machine Model(s) Affected: Revision: Creation Date: Written By: Checked By: Approved By:

OVERVIEW & SAFETY SYSTEMS

OM-BLT-V1 MEM-928/946 C Revision Date: Revised By: Checked By: Approved By:

06/11/2010 Chris Wismer Jan Paul Brenner Darren Bowins

DESCRIPTION & OVERVIEW Description The MacLean MEM-928/946 Scissor Bolter is a complete ground support system for underground hard rock mines. It has been designed to facilitate ease of bolting and screening and to enable the work to be carried out by one person. Overview The layout of the MacLean Engineering and Marketing Co. Limited MEM-928/946 Scissor Bolter unit is as follows: •

Bumper / Power-pack

•

Driver’s Compartment

•

Working Platform

•

Control Dash

•

Boom Assembly

•

The machine’s general layout is shown in Figure 1.

OM-BLT-V2

Page 1 of 16

Title: OVERVIEW & SAFETY SYSTEMS Number: OM-BLT-V1 Revision: C BUMPER/ POWER-PACK

WORKING PLATFORM

CONTROL DASH

DRIVER’S COMPARTMENT

BOOM ASSEMBLY

Figure 1 – Typical Scissor Bolter Layout

Page 2 of 16

OM-BLT-V2

Title: OVERVIEW & SAFETY SYSTEMS Number: OM-BLT-V1 Revision: C Figure 2 below illustrates the overall envelope for the MEM-928/946 Scissor Bolter.

Figure 2 – Envelope of MEM-928/946 Scissor Bolter

OM-BLT-V2

Page 3 of 16

Title: OVERVIEW & SAFETY SYSTEMS Number: OM-BLT-V1 Revision: C Figure 3 illustrates the maximum articulation of the vehicle along with the related turning radius.

Figure 3 – MEM-928/946 Turning Radius

Page 4 of 16

OM-BLT-V2

Title: OVERVIEW & SAFETY SYSTEMS Number: OM-BLT-V1 Revision: C The MEM-928/946 Scissor Bolter has a gross vehicle weight of approximately 50,000 lbs (22680 kg) with a MAXIMUM deck load capacity of 2,000 lbs (905 kg). Do not exceed the maximum deck load capacity of 2,000 lbs (905 kg). The MEM-928/946 Scissor Bolter is equipped with one of the following three engines: •

Deutz BF4M1013C engine produces 152hp (113kW). Ontario OHSA regulations require minimum ventilation of 14,400 cubic feet per minute (6.79 cubic meters per second). MSHA regulations require minimum ventilation of 8,500 cubic feet per minute (4.01 cubic meters per second).

•

Mercedes 904 engine produces 147hp (109kW). Ontario OHSA regulations require minimum ventilation of 14,700 cubic feet per minute (6.6 cubic meters per second). MSHA regulations require minimum ventilation of 6,500 cubic feet per minute (3.06 cubic meters per second).

•

Caterpillar C6.6 engine produces 156hp (116kW). Ontario OHSA regulations require minimum ventilation of 15,600 cubic feet per minute (7.4 cubic meters per second). MSHA regulations require minimum ventilation of 8,700 cubic feet per minute (4.1 cubic meters per second). Maximum speeds for traveling on level grade are as follows: Mercedes / Clark / New Holland Power Train 1st gear on flat – 2 mph (3 km/h) 2nd gear on flat – 4 mph (6 km/h) 3rd gear on flat – 7 mph (11 km/h) Deutz / Clark / New Holland Power Train 1st gear on flat – 2 mph (3 km/h) 2nd gear on flat – 4 mph (6 km/h) 3rd gear on flat – 7 mph (11 km/h) CAT / Clark / New Holland Power Train 1st gear on flat – 2 mph (3 km/h) 2nd gear on flat – 4 mph (6 km/h) 3rd gear on flat – 7 mph (11 km/h)

OM-BLT-V2

Page 5 of 16

Title: OVERVIEW & SAFETY SYSTEMS Number: OM-BLT-V1 Revision: C

SAFETY SYSTEMS For each MEM-928/946 Scissor Bolter, there are a few safety points which every operator must be aware of. These safety points include the location of the fire extinguisher and fire suppression system, the location and usage of the articulation lock, the location and usage of the scissor lock, the location and usage of the Emergency Stop buttons, and the location and usage of the Master Disconnect Switch. The location of certain safety items may vary from unit to unit. Be sure to make yourself familiar with the location of the safety items on your particular bolter. Fire Extinguisher and Fire Suppression System The MEM-928/946 is equipped with a portable fire extinguisher and has a dedicated fire suppression system installed around the engine and drive train. It is the operator’s responsibility to be familiar with the fire safety systems present on their specific machine. The hand held fire extinguisher is accessible both from the driver’s compartment and from the ground, see Figure 4. It is the machine operator’s responsibility to know how to use the fire extinguisher properly. A daily visual inspection of the fire extinguisher must be performed to ensure that it is fully charged and has not been damaged.

Portable Fire Extinguisher Location

Figure 4 – Portable Fire Extinguisher Location (Typical Installation) •

Page 6 of 16

If your unit is equipped with a Deutz engine, the charge cylinder for the fire suppression system is located on the engine end outrigger, on the air compressor side of the unit as shown in Figure 5.

OM-BLT-V2

Title: OVERVIEW & SAFETY SYSTEMS Number: OM-BLT-V1 Revision: C •

If your unit is equipped with a Mercedes or Cat engine, the charge cylinder for the fire suppression system is located on the engine end outrigger, on the operator’s compartment side of the unit as shown in Figure 6.

Fire Suppression System Charge

Fire Suppression System Manual Palm Actuator

Figure 5 - Deutz Engine

OM-BLT-V2

Figure 6 – Mercedes/CAT Engine

Page 7 of 16

Title: OVERVIEW & SAFETY SYSTEMS Number: OM-BLT-V1 Revision: C Fire Suppression Charge Cylinder and Manual Palm Actuator Location There are three (3) manual palm actuators for the fire suppression system. A manual palm actuator is located near the charge cylinder as shown in Figures 5. A second manual palm actuator is located inside the operator’s compartment, to the right of the driver’s instrument panel as shown in Figure 7. A third manual palm actuator is located on the front of the deck control panel, as shown in Figure 8. If the unit you are operating has a fully enclosed cab, it has a fourth manual palm actuator located outside the cab, towards the engine end of the unit, mounted near the brake system accumulators (not shown).

Fire Suppression System Manual Palm Actuator

Figure 7 – Fire Suppression System Manual Palm Actuator Location Fire Suppression System Manual Palm Actuator

Figure 8 – Fire Suppression System Manual Palm Actuator Location

Page 8 of 16

OM-BLT-V2

Title: OVERVIEW & SAFETY SYSTEMS Number: OM-BLT-V1 Revision: C In order to use the palm actuators to activate the fire suppression system, the safety pin must first be pulled from the actuator’s stem and then the actuator depressed (pushed in/down). The typical fire suppression system installation on a Scissor Bolter is an Ansul system and has nozzles at following six points on the machine: • • • • •

In the battery box Near the engine fuel filter Two (2) at the transmission compartment Engine compartment Hydraulic pumps

Ansul Checkfire System™ (if equipped) A Checkfire® fire detection system (optional) may be installed on your machine. It provides automatic fire detection for designated areas of the machine. The Checkfire® fire detection system is integrated with the existing fire suppression system and activates the existing system, if initiated. The Checkfire® fire detection system utilizes an explosive “Squib”. Units built in September 2009 or later use a non-explosive Protracting Actuation Device (PAD). When equipped with Checkfire®, these devices are usually located in the operator’s compartment manual palm actuator. The “Squib” is an explosive device used to activate the fire suppression system. Do not inspect or attempt any maintenance on the Fire Suppression system or any of its components unless you are fully trained and qualified. For more information see maintenance bulletin MB-FIR1013. If the Fire Suppression system has been activated contact the appropriate mine personnel. Scissor Lock The scissor beneath the MEM-928/946 deck presents a possible pinch point. The machine operator must ensure that the scissor area is clear when operating the deck and must also ensure that the scissor lock (see Figure 8) is used whenever work is carried out in the scissor area. The scissor lock consists of handle (painted red) and bracket that pivots under at the deck frame. The bracket has a 90° channel which engages the sides of a cross member within the scissor assembly. The lock then acts as a deck support between the deck and scissor frames. The handle for the scissor lock is located on the entry side of the machine, midway down the length of the deck. To use the scissor lock properly, the following steps should be followed: NEVER place yourself under the scissor deck or boom while the deck is in the raised position without first engaging the Scissor Lock Mechanism

OM-BLT-V2

Page 9 of 16

Title: OVERVIEW & SAFETY SYSTEMS Number: OM-BLT-V1 Revision: C Use the outriggers of the bolter to level and stabilize the unit before raising the scissor. Locking Procedure: 1. Ensure that there is sufficient clearance around the bolter for the deck to be raised and the boom extended. 2. Unfasten the scissor lock handle. 3. Start unit diesel engine or electric power-pack. Ensure that the unit is in AUXILIARY mode. 4. From driver’s compartment, raise the platform with scissor toggle switch (press the Tilt Unlock switch if the boom is tilted in past 55º) and observe the scissor lock engage the scissor assembly cross member. 5. Once the scissor lock has dropped into the locked position, lower the platform. The scissor lock should now be supporting the platform. (Figure 9).

Figure 9 – Typical Scissor Lock Location (Engaged)

Page 10 of 16

OM-BLT-V2

Title: OVERVIEW & SAFETY SYSTEMS Number: OM-BLT-V1 Revision: C Unlocking Procedure: 1. Place the boom in the drill position. 2. Raise the platform to a point slightly higher than the locked position. 3. Rotate the scissor lock handle to the unlocked position and fasten it. (Figure 10)

Figure 10 – Scissor Lock Location (Unlocked) Articulation Lock The articulation point for the MEM-928/946 lies in the mid-ship of the machine and presents a possible pinch point. The machine operator must ensure that the articulation area is clear when operating the machine and must also ensure that the articulation lock is used whenever work is carried out in the articulation area. The articulation lock consists of a bar and pins (painted red), which are installed across lugs welded to the machine’s frame on either side of the articulation. When not in use the articulation lock is stored on the deck end of the machine, on the diesel/hydraulic tank side, just below the deck’s control panel. The articulation lock is shown in Figure 11.

Figure 11 – Articulation Lock Location When Tramming

OM-BLT-V2

Page 11 of 16

Title: OVERVIEW & SAFETY SYSTEMS Number: OM-BLT-V1 Revision: C With the engine running, the steering controls are active. A pinch-point exists at the Scissor Bolter’s articulation. Ensure that the articulation is clear before starting. Emergency/Park Brake Button The MEM-928/946 is equipped with an Emergency/Park Brake button. The Emergency /Park Brake button is located on the driver’s instrument panel. Figure 12 illustrates the typical location of the Emergency Brake/Park Brake button. By pushing this button in, the operator applies the emergency/park brakes (axle brakes and driveline brake simultaneously) and should be used whenever parking the machine or in the event of an emergency stopping situation. Emergency/Park Brake Button

Figure 12 – Typical Emergency/Park Brake Button Location

Page 12 of 16

OM-BLT-V2

Title: OVERVIEW & SAFETY SYSTEMS Number: OM-BLT-V1 Revision: C Emergency Stop System The Emergency Stop buttons present on the machine are located on the AC main panel, the remote pendant and the Remote Drive System (RDS) control console on the deck. These Emergency Stop buttons are shown in Figures 13, 14 and 15. When engaged, the Emergency Stop buttons trip the machine’s ground check detection circuit and interrupt the machine’s 24VDC control system. Tripping the machine’s ground check detection circuit in turn shuts down the high voltage power to the unit. It also interrupts the 24VDC control system that shuts down the diesel engine, and all 24V DC control circuits. In order to restore power to the unit, all Emergency Stop buttons must be disengaged. If an Emergency Stop button has shut off the AC power, then the AC power must be reset at the AC main panel or at the electrical sub-station. On some machines, if applicable, the remote pendant and RDS emergency stops do not trip the ground check circuit. The AC main panel emergency stop on all Scissor Bolters trips the ground check circuit, shutting down the AC power.

Emergency Stop Button

Figure 14 – Emergency Stop Button Location Main Panel

OM-BLT-V2

Page 13 of 16

Title: OVERVIEW & SAFETY SYSTEMS Number: OM-BLT-V1 Revision: C Typical Emergency Stop Button Locations

Figure 14 – Remote Pendant Emergency Stop Button Location The Master Disconnect Switch must be used to disconnect the batteries from the control system and engine circuit for complete machine shutdown.

Page 14 of 16

OM-BLT-V2

Title: OVERVIEW & SAFETY SYSTEMS Number: OM-BLT-V1 Revision: C Master Disconnect Switch The batteries, battery charger and alternator used on the MEM-928/946 can be isolated from the rest of the machine’s electrical circuitry by use of the Master Disconnect Switch and lockout. The Master Disconnect Switch is located near the operator’s compartment, above the battery box as shown in Figure 16. To “lock-out” the Master Disconnect Switch, turn the switch to the OFF position and attach your personal lock and tag on the bracket provided.

Master Disconnect Switch

Figure 16 – Typical Master Disconnect Switch Location If applicable, on some Scissor Bolters, the strobe light circuit is not disconnected by the Main Disconnect switch. This allows the strobe light to operate while the Scissor Bolter is parked, and shut down. Emergency Steering Systems (optional) As an option, a MEM-928/946 can be fitting with an emergency steering system. This system provides hydraulic pressure and flow to the steering system if the unit looses main hydraulic pressure and normal operation of the steering is not possible. This system is designed and tested to conform to SAE Standard J1511. The system is completely automatic and requires no input from the operator to activate. It does alert the operator that the system has been activated via an indicator on the Driver’s Instrument Panel (DIP). This light also self-tests when the ignition is turned on, but the engine is not running. See Section OM-Bolter-V2 in this Operator’s Manual for a description. A pressure gauge (not shown), is also provided on the brake gauge cluster to indicate the charge pressure in the emergency steering system. Fully charged, the gauge should read approximately 3000 PSI. When the gauge reads approximately 1000 - 1200 PSI, the emergency steering system reserve is empty and steering is no longer possible.

OM-BLT-V2

Page 15 of 16

Title: OVERVIEW & SAFETY SYSTEMS Number: OM-BLT-V1 Revision: C Safety Interlocks The Scissor Bolter is equipped with operator and machine safety interlocks. Please refer to the Safety Interlocks section of this manual for further details of these systems. NEVER DISABLE ANY SAFETY INTERLOCK. DOING SO MAY PUT YOURSELF AND OTHERS AT RISK OF PERSONAL INJURY OR DEATH.

Notes:

If any questions or problems arise, please contact MacLean Engineering Technical Service for assistance. Phone: 1-866-856-3626 Email: [email protected]

Page 16 of 16

OM-BLT-V2

Title: Number: Machine Model(s) Affected: Revision: Creation Date: Written By: Checked By: Approved By:

OPERATOR’S COMPARTMENT LAYOUT OM-BLT-V2 MEM-928/946 E Revision Date: 06/11/2010 Revised By: Chris Wismer Checked By: Jan Paul Brenner Approved By: Darren Bowins

OPERATOR’S COMPARTMENT LAYOUT This section of the MEM-928/946 Scissor Bolter Operator’s Manual is the first of the sections providing a general review of the machine’s layout, key components and their locations. It is the operator’s responsibility to be familiar with their machine; its layout and functions. The operator’s compartment of the MEM-928/946 Scissor Bolter contains a driver's instrument panel, stick steer handle, throttle and service brake foot pedals, a transmission gear/direction shifter, and various pressure gauges. The machines stick steer handle, transmission gear/direction selector switches, throttle and service brake pedals are located central to the driver’s instrument panel. Figure 1 shows the layout of a typical operator’s compartment. The brake system pressure gauges are located on the firewall next to the driver as shown in Figure 1.

Driver’s Instrument Panel Stick Steer Handle

Brake System Pressure Gauges

Throttle Pedal

Transmission Gear/Direction Selector Switches

Service Brake Pedal

Figure 1 – Typical Operator’s Compartment

OM-BLT-V2

Page 1 of 12

Title: OPERATOR’S COMPARTMENT LAYOUT Number: OM-BLT-V2 Revision: E Enclosed Cab (optional) Your particular unit may be equipped with either a canopy, or a fully enclosed cab as shown in Figure 2. The enclosed cab helps to protect the operator from the elements. Additional features that may be included with an enclosed cab are: •

Emergency removal ready, AS2 certified clear glass with ¼ inch laminate

•

Two windshield wipers with windshield washer fluid reservoir

•

Cab heater (optional A/C)

•

Interior light

•

Sliding rear window

•

Sliding entry/exit door (optional) interlocked with the Emergency/Park Brake Fully Enclosed Cab

Entry/Exit Door

Windshield Wiper

Figure 2 – Fully Enclosed Cab The enclosed cab is fitted with an emergency exit. The glass facing towards the engine end of the unit has a sealed insert around the perimeter of the window that is designed so that it may be quickly removed in an emergency situation. A red handle on the end of the sealed insert can be pulled to break the seal of the window. The window can then be pushed outwards, allowing the operator to exit the cab. If it is necessary to break the glass, a hammer designed for this purpose is also provided. Figure 3 shows the emergency exit and hammer.

Page 2 of 12

OM-BLT-V2

Title: OPERATOR’S COMPARTMENT LAYOUT Number: OM-BLT-V2 Revision: E The windshield wiper ON/OFF switches are maintained switches, and are located on each individual windshield wiper motor as shown in figure 3. Emergency Exit Handle

Hammer

Windshield Wiper Motor

Figure 3 – Emergency Exit & Hammer The cab heater (and optional A/C) controls and vents are located directly behind the operator’s seat as shown in Figure 4. The temperature and fan speed can be adjusted by turning the two knobs located on the heater vent faceplate. The interior light located in the operator’s compartment (shown in Figure 4) has an ON/OFF switch located on the light itself. The windshield washer fluid switch (shown in Figure 4) is a momentary style switch. It is located above the operator’s head when he is seated in the Operator’s compartment. Interior Light

Windshield Washer Fluid Switch

Heater Fan &Temperature Controls (Optional A/C) Figure 4 – Enclosed Cab Features

OM-BLT-V2

Page 3 of 12

Title: OPERATOR’S COMPARTMENT LAYOUT Number: OM-BLT-V2 Revision: E Driver’s Instrument Panel

Figure 5 –Typical Driver’s Instrument Panel Layout A typical layout for the 928/946 bolter driver’s instrument panel shown in Figure 5 is as follows: 1. Ignition Switch, On/Off – This is a two position maintained switch that allows 24VDC Power supply to the driver’s instrument panel ignition circuit. It acts as an electric shut-off switch. 2. Power On Indicator Light – This visual reference allows the operator to determine if the Master Disconnect switch (battery power) has been turned to the ON position. If any Emergency Stop buttons are in the OFF position, the Power ON Indicator light does not illuminate.

Page 4 of 12

OM-BLT-V2

Title: OPERATOR’S COMPARTMENT LAYOUT Number: OM-BLT-V2 Revision: E 3. Engine Start Push Button / Grid Heater Indicator Light – The Engine Start push button/Grid Heater Indication light is an illuminated momentary push button style switch. •

Engine Start Push Button – Depressing the Engine Start push button cranks the engine over to start. As soon as the engine starts, release the Engine Start push button. Before the engine can start, the Emergency/Park Brake switch must be in the Applied position and the Transmission Direction Selector switch must be in the neutral position. All interlocks must be satisfied. (For a more detailed explanation, refer to OM-BLT-O2 Scissor Bolter starting section of Operator’s Manual).

•

Grid Heater Indication Light (optional) – If equipped, the Grid Heater Indication light illuminates momentarily after the Ignition switch is turned to the ON position. The time duration of the illumination is dependent upon the ambient temperature around the engine. Do not attempt to start the engine until the Grid Heater Indication light has turned OFF. If the Fire Suppression System has been activated, a pressure switch automatically shuts down the engine. The Manual Fire Suppression switch must only be reset by trained personnel to ensure that all fire suppression safety systems are operable, and that the unit is safe to operate.

4. Check Engine / Stop Engine Indicator Lights – These two indicator lights are part of the engine protection system. The engine protection system monitors all of the engine sensors and electronic components and recognizes system malfunctions. •

Check Engine Indicator Light – This Indicator light is tied into the engine electronics and illuminates whenever an engine warning fault is detected. If the Indicator light illuminates during operation, contact the maintenance department. The Check Engine Indicator light also illuminates when there is a low engine coolant level fault detected.

•

Stop Engine Indicator Light – This Indicator light is tied into the engine electronics and illuminates whenever an engine alarm fault is detected. If the Indicator light illuminates during operation, shut down the machine and contact the maintenance department. This warning device is interconnected with the horn. Therefore, the horn sounds when the Stop Engine Indicator light illuminates.

OM-BLT-V2

Page 5 of 12

Title: OPERATOR’S COMPARTMENT LAYOUT Number: OM-BLT-V2 Revision: E The resulting engine protection is at the discretion of the operator. It is the operator’s responsibility to take action to avoid engine damage. 5. Throttle Lock Switch •

Mercedes (optional) – If equipped, this is a maintained switch used in AUXILIARY mode. Engaging the switch clockwise raises and locks the engine speed to a preset amount.

•

CAT (optional) – If equipped, this is a momentary switch used in AUXILIARY mode. Engaging the switch clockwise raises and locks the engine speed to a preset amount. Engaging the switch counter-clockwise disengages the throttle lock. The Throttle Lock is only available in AUXILIARY mode. When the unit is switched back to DRIVE mode, the Emergency/Park Brake switch is pulled up, or the unit is switched out of neutral, the throttle lock is disabled.

6. Engine Monitor Display – This monitor displays engine data in various formats. Additionally, various diagnostic screens are available. The operator is able to switch between various displays using the soft push buttons located on the bottom of the display. If at any time during operation the engine electronics detect a fault, the operator is warned by means of a flashing alarm displayed on the screen. 7. Cable Reel Switch – This momentary switch allows the operator to use the cable reel while travelling in the engine end direction of the machine. 8. Last Wind Warning / Brake Override – This indicator light illuminates when the cable reel has reached the 3rd last wind of the trailing cable. The push button allows the operator to bypass the cable reel’s last wind brake interlock. Only travel in the engine end direction is available during this operation. If the emergency/ park brake is automatically applied, it is necessary to reset the emergency / park brake to release. 9. Outrigger/Deck Left Switch – This momentary switch allows deck end left side outrigger function (viewed from operators compartment). When the switch is engaged to the Up position, the outrigger rises. When the switch is engaged to the Down position, the outrigger lowers. 10. Outrigger/Deck Right Switch – This momentary switch allows deck end right side outrigger function (viewed from operator’s compartment). When the switch is engaged to the Up position, the outrigger rises. When the switch is engaged to the Down position, the outrigger lowers.

Page 6 of 12

OM-BLT-V2

Title: OPERATOR’S COMPARTMENT LAYOUT Number: OM-BLT-V2 Revision: E 11. Outrigger/Engine Right/Left Switch – This momentary switch allows engine end left and right side outrigger function (side designation based upon viewing engine end outriggers from the operator’s compartment). When the switch is engaged to the Up position, the outriggers rise. When the switch is engaged to the Down position, the outriggers lower. 12. Tilt Switch (optional) – If equipped, the Tilt switch allows for control of the boom’s tilt function. It is a momentary switch that allows the operator to tilt the boom Out, or In to the working platform. It only functions while in AUXILIARY mode and in conjunction with the Tilt Unlock switch. However, if the boom is in the Operating position beyond 55° from the working platform, the Tilt switch can be utilized without depressing the Tilt Unlock switch. 13. Brake Test Push Button – Follow the specific instructions on the Brake Test label located on the firewall of your unit. • Axle – When depressed, this push button allows the axle brakes to be tested. • Driveline – When depressed, this push button allows the driveline brake to be tested. 14. Scissor Switch – This momentary switch allows operator to raise and lower the scissor platform. It must be used while in AUXILIARY mode in conjunction with the Tilt Unlock switch. However, if the boom is in the Operating position beyond 55° from the working platform, the switch can be utilized without depressing the Tilt Unlock switch. 15. Scissor Up Brake Overide Switch (optional) – If equipped, this switch illuminates if the scissor is not completely lowered. This push button switch allows the operator to override the scissor interlock. This is used for driving the unit from the operator’s compartment while the scissor is raised. For more information on the scissor interlock, refer to section OM-BOLTER-O1 of the Operators Manual. •

Emergency Steer Active (optional) – If equipped with an optional emergency steer system and the unit is not equipped with an optional Scissor Up Brake Override switch, this amber indicator alerts the operator that the emergency steer system is automatically activated because of a loss of hydraulic system pressure. If the unit is equipped with the Scissor Up Brake Override Switch, this indicator light is usually mounted next to the Engine Monitor Display. See Section OM-BOLTER-V1 for more information.

16. Tilt Unlock Switch – If the boom is within 55° from the working platform, the operator must press and hold the Tilt Unlock button while engaging the Tilt switch. It must be used while in AUXILIARY mode. For more information on the tilt interlock, refer to section OM-BOLTER-O1 of the Operators Manual. 17. Drive Indicator Light – This indicator light illuminates when DRIVE mode is active.

OM-BLT-V2

Page 7 of 12

Title: OPERATOR’S COMPARTMENT LAYOUT Number: OM-BLT-V2 Revision: E 18. Drive / Auxiliary Mode – This switch allows the operator to select between both DRIVE and AUXILIARY modes. In order to change modes, it is essential that all safety interlocks are satisfied. To change modes it is necessary to: I. Apply the emergency / park brake. II. Select Neutral on the transmission shifter. •

DRIVE Mode - Used for operation of all driving functions such as, steering, service brakes and allows park brakes to release. The Drive Mode Indicator light illuminates when this mode is active. The Selector switch must be in DRIVE mode to start the diesel engine from the driver’s instrument panel. • AUXILIARY Mode - Used for boom manipulation, drilling, bolting, use of pendant, RDS and outriggers. If the interlocks are not satisfied, switching the selector into another mode does not occur and the current mode remains active.

19. Cable Reel Last Wind Warning – This alarm sounds when the cable reel has reached the 3rd last wind of the trailing cable. This alarm is interlocked with the Last Wind Warning Light/ Brake Override button. 20. Transmission Gear Selector Switch – This maintained switch is used to select a transmission gear range. Turning the switch allows the operator to select between first, second, and third gears. First gear is low range moving up to third gear being high range. Some units may have the third gear locked out! 21. Transmission Direction Selector Switch – This maintained switch is used to select tramming direction. Turning the switch allows the operator to select between forward, neutral and reverse directions. 22. Transmission Oil Pressure – This gauge reflects transmission oil pressure. Normal operating pressure varies from 240-300 PSI (16–20 Bar). The emergency/park brakes do not release until the pressure rises above 60 PSI (4 Bar). If the pressure ever falls below the minimal operating pressure of 60 PSI (4 Bar) during travel, the emergency/park brakes are automatically applied. 23. Transmission Oil Temperature – This gauge reflects transmission oil temperature. 24. Hour Meter – The hour meter indicates how many hours the diesel engine has been utilized. This reading must be taken at the end of each work shift to allow maintenance personnel to carry out carrier preventative maintenance at scheduled intervals.

Page 8 of 12

OM-BLT-V2

Title: OPERATOR’S COMPARTMENT LAYOUT Number: OM-BLT-V2 Revision: E 25. Circuit Breakers – Circuit breakers protect the driving lights circuits, the instrument panel, and accessories from excess current draw. If a circuit breaker trips, it must be depressed in order to reset. 26. Engine End Light Switch – This is a maintained switch. Engaging the Switch Up turns the engine end driving lights ON. Toggling the switch Down turns them OFF. 27. Strobe Light Switch (optional) – If equipped, the Strobe Light switch is a maintained switch. Engaging the switch Up turns the strobe light ON. Engaging the switch Down turns it OFF. 28. Deck End Driving Light Switch – This is a maintained switch. Engaging the switch Up turns the deck end driving lights ON. Engaging the switch Down turns them OFF. 29. Brake Impending Indicator – This indicator light illuminates to warn the operator that hydraulic, or transmission pressure has dropped below the acceptable values. This serves as a warning prior to the emergency / park brakes being automatically applied. 30. Brake On Indicator – This indicator light illuminates when the emergency / park brakes are applied. 31. Brakes Emergency / Park Switch – This illuminated, three position (Push /Pull /Reset) switch allows the operator to apply and release the emergency / park brakes. (Figure 6) DO NOT use emergency / park brake for normal stopping of unit. • Indicator Light – This light illuminates when the axle brakes are applied. • Push – Depressed position. Allows the operator to apply the brakes for parking the unit, or in an emergency stop situation. • Pull – Maintained position. Allows the brakes to stay released after a reset function is used. • Reset – Momentary position (pulled out past maintained position). Allows energizing of the Emergency Brake Relay (EBR) circuit. This circuit verifies that all operating conditions are adequate before allowing the brakes to stay released. These conditions are: I.

Drive / Auxiliary mode selector switch is in the DRIVE position; Drive Indicator light is illuminated. II. Transmission clutch pressure is above 60 PSI. III. Service brake hydraulic accumulator pressures are above 1350 PSI.

OM-BLT-V2

Page 9 of 12

Title: OPERATOR’S COMPARTMENT LAYOUT Number: OM-BLT-V2 Revision: E IV. (optional) Scissor is in its lowest position. Indicator light in SCISSOR UP BRAKE OVERRIDE is illuminated when the scissor is in the raised position (i.e. - scissor is not fully down). V. Cable reel trailing cable is not on its last wind.

Figure 6 – Emergency / Park Brake Switch Positions . Engine End Service Brake Accumulator Pressure

Engine End Service Brake Pressure

Drill End Service Brake Accumulator Pressure

Drill End Service Brake Pressure

Axle Park Brake Pressure

Driveline Brake Pressure

Figure 7 – Typical Scissor Bolter Brake Pressure Gauges Drill End Service Brake Accumulator Pressure Gauge – This gauge indicates the accumulator pressure in reserve for the drill end service brake application. Pressure is available for a period of time, even after the diesel engine is shut down.

Page 10 of 12

OM-BLT-V2

Title: OPERATOR’S COMPARTMENT LAYOUT Number: OM-BLT-V2 Revision: E Engine End Service Brake Accumulator Pressure Gauge – This gauge indicates the accumulator pressure in reserve for the engine end service brake application. Pressure is available for a period of time, even after the diesel engine is shut down. Drill End Service Brake Pressure Gauge – This gauge indicates the hydraulic pressure being applied to the drill end service brakes. When applying the service brake pedal, a reading from 0 psi (0 Bar) to 1500 psi (103 Bar) is read on the gauge. The more pressure that is applied to the service brake pedal, the more pressure is sent to the service brakes for stopping. Engine End Service Brake Pressure Gauge – This gauge indicates the hydraulic pressure being applied to the engine end service brakes. When applying the service brakes, a reading from 0 psi (0 Bar) to 1500 psi (103 Bar) is read on the gauge. The more pressure that is applied to the service brake pedal, the more pressure is sent to the service brakes for stopping. Driveline Brake Pressure Gauge – This gauge indicates the hydraulic pressure being applied to release the driveline brake. It is also used as a visual reference to indicate that the driveline brake is applied (0 psi) (0 Bar), when isolation testing the driveline brake. The pressure should read 0 psi (0 Bar) when the brake is applied and 500 psi (34 Bar) when the driveline brake is released. Axle Brake Pressure Gauge – This gauge indicates the hydraulic pressure being applied to release the axle park brakes. When pressure is applied to the axle park brakes they must release. Also used as a visual reference that the axle brakes are applied (0 psi) (0 Bar) when isolation testing the axle brakes. Pressure should read 0 psi (0 Bar) when the brakes are applied and 2000 – 2500psi (138 – 172 Bar) when they are released. 32. Horn Push Buttons – These momentary push buttons control the horn. The On push button allows the operator to activate the horn when required. The Off push button allows the operator to bypass the horn, sounding the engine protection warning during initial start-up of the diesel engine

OM-BLT-V2

Page 11 of 12

Title: OPERATOR’S COMPARTMENT LAYOUT Number: OM-BLT-V2 Revision: E

Notes:

If any questions or problems arise, please contact MacLean Engineering Technical Service for assistance. Phone: 1-866-856-3626 Email: [email protected]

Page 12 of 12

OM-BLT-V2

Number: Revision: Revision Date: By: Topic:

OM-BLT-V3-ECO A 10/23/08 JEG ECO SCISSOR DECK LAYOUT

ECO SCISSOR DECK LAYOUT This section of the MEM-928/946 Scissor Bolter Operator’s Manual outlines the Scissor Deck layout of the machine. When on the deck the working end, or boom end, of the machine becomes the front. This is important to realize, as all function directions will follow this criteria when operating or testing is carried out. Figure 1 illustrates a typical Scissor Deck for a 928/946 Scissor Bolter. The Scissor Deck consists of a Deck Ladder, Control Panel, Bolt Rack, Fold Out Wings, Boom Support (not shown) and Screen Hooks. The Scissor Deck is designed to allow the operator to control functions from a safe location, which is withdrawn from the bolter boom’s working area. This way the operator is never underneath unsupported ground. The Scissor Deck is capable of extending three feet (3’) towards the boom assembly in order to allow for bolt installation. CONTROL PANEL

SCREEN HOOKS

TILT UNLOCK BUTTON

BOLT RACK

DECK LADDER

FOLDOUT WING WITH WING POSTS AND SAFETY CHAINS INSTALLED

Figure 1 – Typical Scissor Bolter ECO Scissor Deck

OM-BLT-V3-ECO

Page 1 of 4

Number: OM-BLT-V3-ECO Revision: A Deck Ladder - One section of the Deck Ladder is connected to the Scissor Deck (Figure 1). The remaining section of the Deck ladder is attached to the Articulation deck plate. The ladder is used for entry and exit to the Scissor Deck and should not be used as a storage area or place to stand. Figure 2 illustrates the entrance to the Scissor Deck. The Articulation Deck Plate acts as an access to the Deck Ladder. A possible pinch point exists at the ladder. The Deck Ladder moves with the deck when raising and lowering the scissor. No one should climb the ladder or enter the deck area without notifying the operator. Serious injury may occur. The Articulation Deck Plate should not be used as a place to stand or store material. The Deck Ladder and Articulation Deck Plate area should be kept clear at all times so as to prevent possible injury and to provide a way out in the event of an emergency.

DECK LADDER

ARTICULATION DECK PLATE

Figure 2 – Typical Scissor Deck Ladder and Articulation Deck Plate

OM-BLT-V3-ECO

Page 2 of 4

Number: OM-BLT-V3-ECO Revision: A Always use the safety chains and ensure that the handrail assemblies are correctly installed and in place when operating the scissor Bolter from the deck. This will help to prevent the possibility of a fall resulting in personal injury. ECO Scissor Deck Control Panel - The ECO Scissor Deck Control Panel includes numerous control levers, buttons and indicator lights for operation of the machine in Auxiliary Mode. Operating the machine using the Scissor Deck Control Panel helps to ensure the operator is working away from the boom. A typical ECO Scissor Deck Control Panel is illustrated in Figure 3.

Figure 3 – Typical ECO Scissor Deck Control Panel Tilt Unlock Button – A Tilt Unlock (Override) button is located on the ladder end of the control panel as illustrated in Figure 1. The Tilt Unlock button is an illuminated momentary pushbutton. The pushbutton will illuminate when the button is being pressed or when the boom is tilted out past the angle of the Tilt Interlock System (TIS). Refer to section OM-BLT-O1 of this operator’s manual for more information regarding the Tilt Interlock System. Bolt Rack – The Bolt Rack is located opposite the Control Panel on the platform (Figure 1). It provides storage for necessary bolting equipment and supplies. A small toolbox is integrated into the bolt rack and provides storage for hand tools, etc... Screen Hooks – The Screen Hooks are located on either side of the Scissor Deck (Figure 1). These hooks allow for the hanging of sheets of wire mesh screen used in the bolting and screening process of the Bolter. The capacity of the hooks is approximately ten sheets of screen per side.

OM-BLT-V3-ECO

Page 3 of 4

Number: OM-BLT-V3-ECO Revision: A Foldout Wings – The Foldout Wings are attached to both sides of the Scissor Deck to allow better access when installing wall bolts. Wing posts and safety chains, or the optional solid handrail assembly, must be installed whenever the Foldout Wings are being used to prevent the possibility of a fall resulting in personal injury. BOOM SUPPORT POST The Boom Support acts as a cradle for the boom when it is lowered onto the Scissor Deck (Figure 3). The Boom Support Post will reduce the movement of the boom when tramming which will reduce possible damage to the Scissor Deck or boom components. When in use the post is placed into a socket in the Scissor Deck floor near the entrance to the Scissor Deck. The safety chain is to be attached over the boom pivot assembly when travelling from location to location. When the Boom Support Post is not in use it can be stored on the deck in a location at the end of the bolt rack away from the work area of the Scissor Deck.

Figure 3 – Typical Boom Support

OM-BLT-V3-ECO

Page 4 of 4

Number: Revision: Revision Date: By: Topic:

OM-BLT-V4-ECO A 10/23/2008 JEG ECO BOOM ASSEMBLY LAYOUT

ECO BOOM LAYOUT This section of the MEM-928/946 Electric Control Option (ECO) Scissor Bolter Operator Manual outlines the boom assembly of the machine, outlining typical boom assembly components and their function. The following picture depicts the boom assembly for a 928/946 ECO Scissor Bolter. Included in the boom assembly are components for both drilling and bolting, a stinger, hydraulic valves and components used for boom manipulation. •

Whenever possible, operate all boom and drill functions from the control console on the scissor deck. This will help to ensure that the operator is in the safest possible location.

Figure 1 – Typical ECO Boom Assembly

OM-BLT-V4-ECO

Page 1 of 4

Number: OM-BLT-V4-ECO Revision: A Always use the outriggers of the bolter to level and stabilize the unit before raising the scissor or moving the boom. 1. DRILL CENTRALIZER – The Drill Centralizer is located at the end of the drill feed (Figure 1). A fixed and / or hydraulic style centralizer will be on the drill feed. A brief description follows of each follows; > Fixed Centralizer – This centralizer assembly has a fixed bushing that is used to guide the drill steel in single pass bolting applications when collaring the hole. It is important to maintain a close proximity to the surface being drilled to help eliminate drill steel from deviating during the collaring process. If the drill steel deviates from the desired location the boom may have to be repositioned in order to reduce the risk of the striker bar from breaking. Refer to section OM-BLT-O7 for more details on Drilling. > Hydraulic Centralizer – This centralizer has bushings that can be opened and closed hydraulically. The Hydraulic centralizer is used for Longhole drilling applications. The centralizer provides a guide for the drill steel when collaring the hole. When the drill string approaches the centralizer jaws the hydraulic centralizer must be opened in order for the coupling to go through. It is important to maintain a close proximity to the surface being drilled to help eliminate drill steel from deviating during the collaring process. If the drill steel deviates from the desired location the boom may have to be repositioned in order to reduce the risk of breaking the striker bar. Refer to section OM-BLT-O7 for more details on Longhole Drilling. A possible pinch point exists between the bushings of the hydraulic centralizers when they are being used. Keep hands away from area. 2. PIVOT ASSEMBLY With STINGER – Used to maintain boom position during the drilling cycle. The Pivot assembly allows the bolt feed to index into the Drill Feeds’ position after drilling for insertion of required ground support. Also acts as a screen pusher when installing screen. Refer to section OM-BLT-O8 for more details on Screen Handling. 3. DRILL FEED CROWD - The Drill crowd is used for moving the Drill feed. It is used to maintain a close proximity to the surface being drilled and for retracting the drill feed before indexing if uneven ground is encountered. 4. BOOM CROWD – The boom crowd is used for moving the Drill feed, Bolt feed and Pivot assembly (stinger) close to the work surface.

Page 2 of 4

OM-BLT-V4-ECO

Number: OM-BLT-V4-ECO Revision: A 5. HYDRAULIC VALVE – This Hydraulic Valve is mounted on the cradle mount of the boom assembly (Figure 1). Protective covers are installed over the valves. The functions controlled by this valve are as follows: • DRILL CROWD • BOOM CROWD • BOLT FEED • BOLT CENTRALIZER • HYDRAULIC DRILL CENTRALIZER • BOOM PIVOT Should the protective covers over the valves be missing or damaged do not use Bolter until repaired. Contact Maintenance personnel. Use of the machine with damaged boom mounted valves or wiring will lead to possible unwanted boom movement, personal injury or death. 6. C-ARM – Is the support through which the boom pivots between drilling and bolting positions. The boom assembly extends or crowds through the c-arm. 7. BOLT FEED – Used to insert the ground support into the drilled hole. A feed motor moves the Bolt dolly or Split-Set driver along the entire length of the feed. 8. BOLT DOLLY / SPLIT-SET DRIVER – Depending on Ground support being used two options are available: • Bolt Dolly – Used to provide rotational torque when installing various types of ground support. A swellex adapter may be installed directly onto the dolly when required. A Bolt dolly is shown in Figure 1. • Combi Head – Combination of hydraulic drill that provides percussion for installing Split Sets and a rotation head to torque various types of ground support. The swellex adapter can be installed directly into the Combi head when required. Reference section OM-BLT-O13 of Operator’s Manual for Bolting Options and Operations. Never come into contact with Combi head for any reason while in operation. The Combi Head is equipped with charged gas accumulators. Always shut down Bolter before servicing Combi head. Only properly trained personnel should service Combi Head. Personal injury may result. 9. BOLT CENTRALIZER – Used during insertion of ground support. Allows operator to install bolts in hard to reach places. Insert bolt onto dolly and into centralizer before manipulating boom into hard to reach areas. Use the resin injector tool provided for insertion of resin into hard to reach holes.

OM-BLT-V4-ECO

Page 3 of 4 4

Number: OM-BLT-V4-ECO Revision: A 10. DRILL FEED – Direct Drive Chain Feed is used to maintain a constant force on Drill string while drilling. Refer to section OM-BLT-O7 for more details on Drilling. 11. ROCK DRILL – Provides Percussion and Rotation for drill string. Operating pressures of rotation and percussion should be kept within specification when drilling. Never come into contact with the Rock Drill for any reason while in operation. Rock Drill is equipped with charged gas accumulators. Always shut down Bolter before servicing Rock drill. Only properly trained personnel should service Rock Drill. Personal injury may result. Personal injury may result. 12. ROLLOVER – Allows for boom manipulation. The Rollover assembly provides rotational movement of the boom assembly about the Tilt Actuator and allows for angle adjustment from bolting the back to bolting the wall. 13. TILT ACTUATOR – Allows for boom manipulation. The Tilt actuator provides rotational movement of the boom assembly about the transverse tube, allowing movement of the boom in towards and away from the Bolters’ working platform. 14. TRANSVERSE – Allows for boom manipulation. The transverse assembly allows lateral or side-to-side movement of the boom across the width of the Bolter. 15. HYDRAULIC VALVE – This hydraulic valve is located under a protective cover on the Rollover Mount (Figure 1). The functions controlled by this valve are as follows: • TRANSVERSE • TILT ACTUATOR • ROLLOVER Should the protective covers be missing or damaged do not use Scissor Bolter until repaired. Contact Maintenance personnel. Use of the machine with damaged boom mounted valves or wiring will lead to possible unwanted boom movement, personal injury or death.

Page 4 of 4

OM-BLT-V4-ECO

aclean Canada – MEM-928/946 SCISSOR BOLTER OPERATOR MANUAL Number: Revision: Revision Date: By: Topic:

OM-BLT-V5 B 03/03/01 SJC SCISSOR BOLTER HYDRAULIC & ELECTRICAL LAYOUT

This section of the MEM-928/946 Scissor Bolter Operator Manual outlines some of the more important hydraulic and electrical components on the machine. On the MEM-928/946 Scissor Bolter, the operator should beware of three important hydraulic block assemblies. One block assembly is the pump manifold block, which contains three pressure filters for the machine’s oil supply. The block assembly is located on the hydraulic oil tank side of the engine end bumper (below the engine’s air intake) as shown in Figure 1.

Figure 1 – Hydraulic Pump Manifold Blocks

The second hydraulic block assembly to be aware of is the throttle/brake block assembly. This block is located in the compartment under the throttle and brake foot pedals, below the driver’s compartment. Figure 2 illustrates this hydraulic block assembly.

OM-BLT-V5

Page 1 of 6

aclean Canada – MEM-928/946 SCISSOR BOLTER OPERATOR MANUAL Number: OM-BLT-V5 Revision: B

Figure 2 – Throttle/Brake Manifold Block

Figure 3 – Drill/Boom/Deck Control Valves The third hydraulic block assembly of importance on the Scissor Bolter is actually a group of valve banks that are located in the same general area on the machine. These valve banks are located on the deck of the machine behind the operator’s control console. These valves control the drill, boom, deck, scissor and outrigger functions. Figure 3 illustrates the location of a couple of these valve banks.

Page 2 of 6

OM-BLT-V5

aclean Canada – MEM-928/946 SCISSOR BOLTER OPERATOR MANUAL Number: OM-BLT-V5 Revision: B

One of the important electrical boxes that the operator must be aware of is the main electrical panel (600V panel) for the machine. This electrical panel is located on the driver’s dash side of the engine end bumper as shown in Figure 4. It is in this panel that the 600VAC supply voltage is converted to 24VDC for use on the carrier and rest of the Scissor Bolter. This panel also supplies 120VAC to the machine’s battery charger and possibly a 120VAC scissor deck receptacle (option on some machines). Note: Only qualified personnel should enter the 600VAC panel in order to prevent injury.

Figure 4 – Typical 600VAC Main Electrical Panel A typical 600VAC panel on a MEM-928/946 Scissor Bolter contains the following: Voltmeter and Phase Selector – Used to measure the voltage level for each supply phase to the 600 VAC panel. Ammeter and Phase Selector – Used to measure the current level for each supply phase to the 600 VAC panel. Powerpack Hourmeter – Records the usage of the Scissor Bolter’s powerpack unit.

OM-BLT-V5

Page 3 of 6

aclean Canada – MEM-928/946 SCISSOR BOLTER OPERATOR MANUAL Number: OM-BLT-V5 Revision: B Main Power Disconnect – used to disconnect the 600 VAC panel from electrical supply. Note: Even with the main power to the panel disconnected with this disconnect, power will be live on the line side of the disconnect and back to through the cable reel. Power On Indicator – indicates that supply power is available to the 600 VAC panel. 120VAC receptacle – receptacle to allow for the use of power tools, etc. Start Button – used to turn ‘on’ power within the 600 VAC panel. Emergency Stop Button – used to stop the powerpack and/or diesel engine in the event of an emergency. Voltage Monitor Trip Indicator – used to indicate that a problem with the voltage supply to the Scissor Bolter exists. Motor Start Button - used to start the Scissor Bolter’s power pack. The powerpack consists of a large electric motor and hydraulic pumps that will provide hydraulic power for the operation of the machine. Motor Stop Button – used to stop the power pack. Motor Run Indicator – indicates that machine’s electric motor has been powered. Circuit Breakers – the typical 600VAC panel contains circuit breakers for the 24VDC Remote Drive System, 24VDC control circuit and the 24VAC drill lighting. In addition, overload resets for the water pump, compressor and hydraulic pump are located on the face of the panel. Note: Some MEM-928/946 Scissor Bolters which have been equipped with an airpowered greaser may have a selector switch located on the main electrical panel. This selector switch can be used to limit electrical function to run only the air compressor and water pump for servicing the unit. This helps to prevent hydraulic oil supply to the boom assembly during servicing. Another important electrical panel on the Scissor Bolter is the Battery Charger. The battery charger charges the machine’s batteries from the 600VAC supply used by the Powerpack. Figure 5 illustrates a typical battery charger.

Page 4 of 6

OM-BLT-V5

aclean Canada – MEM-928/946 SCISSOR BOLTER OPERATOR MANUAL Number: OM-BLT-V5 Revision: B

Figure 5 – Typical Battery Charger

The battery charger has an input voltage of 120VAC and output voltage of 24VDC. Note: To avoid injury, only qualified personnel should enter the battery charger. Located in the Driver’s (Operator’s) Compartment is the Operator’s Compartment Junction Box. This electrical enclosure can be mounted on the face of the firewall or on top of the engine cowling above the firewall. This electrical enclosure typically houses a Tilt Unlock pushbutton, Tilt toggle switch and a Last Wind Interlock indicator light. The Tilt toggle switch can be used to tilt the boom in towards and out from the deck platform. The Tilt Unlock button can be used to override the Tilt Interlock discussed later in this manual. The Last Wind Indicator light notifies the operator when the high voltage trailing cable for the Scissor Bolter is close to its last wind on the cable reel. Figure 6 illustrates a typical Operator’s Compartment Junction Box.

OM-BLT-V5

Page 5 of 6

aclean Canada – MEM-928/946 SCISSOR BOLTER OPERATOR MANUAL Number: OM-BLT-V5 Revision: B

Figure 6 – Typical Operator’s Compartment Junction Box Finally, the electrical panel located behind the operator’s control panel on the deck should be noted. This panel is typically called the Deck Relay Panel and this panel provides power to and receives signals from the remote pendent as well as houses the boom’s Tilt Interlock System (described later in manual).

If any questions or problems arise, please contact MacLean Engineering Technical Service for assistance. Phone: 1-866-856-3626 Email: [email protected]

Page 6 of 6

OM-BLT-V5

Number: Revision: Revision Date: By: Topic:

OM-BLT-V6 A 08/22/08 JEG OTHER COMPONENTS LAYOUT

VARIOUS COMPONENTS This section of the MEM-928/946 Scissor Bolter Operator Manual outlines the location of components on the machine not previously shown.

HYDRAULIC OIL/WATER COOLER HYDRAULIC OIL RETURN FILTER HYDRAULIC OIL RESERVOIR HYDRAULIC OIL TEMPERATURE DIESEL FUEL RESERVOIR

HYDRAULIC MANIFOLD BLOCK AND HIGH PRESSURE FILTER HYDRAULIC FILTER ELEMENTS

ENGINE AIR INTAKE FILTER

HYDRAULIC OIL RESERVOIR SHUT-OFF VALVES

Figure 1 –Typical Hydraulic Tank Side, Engine End of Bolter

OM-BLT-V6

Page 1 of 4

Number: OM-BLT-V6 Revision: A

HYDRAULIC OIL RESERVOIR MAXIMUM OIL LEVEL SIGHT GLASS

HYDRAULIC OIL RESERVOIR MINIMUM OIL LEVEL SIGHT GLASS

HYDRAULIC OIL RESERVOIR FILL PUMP CONTROL HYDRAULIC OIL RESERVOIR FILLER PUMP WAND TYPICAL DIESEL FUEL RESERVOIR FILL POINT DIESEL FUEL RESERVOIR MAXIMUM LEVEL SIGHT GLASS DIESEL FUEL RESERVOIR MINIMUM LEVEL SIGHT GLASS

Figure 2 – Right Side of Engine End of Bolter

Page 2 of 4

OM-BLT-V6

Number: OM-BLT-V6 Revision: A

CABLE REEL WATER HOSE REEL (OPTIONAL)

AC MAIN PANEL

ENGINE END DRIVE LIGHTS ENGINE END OUTRIGGERS TOW HOOK-UPS Figure 3 – Engine End View of Bolter

OM-BLT-V6

Page 3 of 4

Number: OM-BLT-V6 Revision: A SCREEN HOOKS

DRILLING LIGHTS

BOOM ASSEMBLY BOLT RACK

FOLD OUT WING

DECK END DRIVE LIGHTS

SCISSOR TOOL BOX RIGHT SIDE OUTRIGGER

LEFT SIDE OUTRIGGER Figure 4 – Deck End View of Bolter

Always use the outriggers to level and stabilize the Bolter prior to raising the scissor and / or working from the deck. Whenever possible, test the functionality of the machine controls when standing at the control console on the scissor deck or when sitting in the driver’s seat. This will help to ensure that the operator is in a safe position. Possible pinch points exist in the area of the boom and handrails. Keep clear of the boom and handrail area when operating any of the Bolter’s boom or drill functions and the deck extension function. Always ensure all safety chains/cables and guardrails are installed and in good working condition when operating the machine. The scissor deck openings and wings have safety chains/cables that must be set-up in their operating positions before any work can begin.

Page 4 of 4

OM-BLT-V6

Number: Revision: Revision Date: By: Topic:

OM-BLT-O1 D 04/08/01 SJC SCISSOR BOLTER CONTROL & INTERLOCKS

TILT INTERLOCK SYSTEM (TIS) The Tilt Interlock System (TIS) is designed to prevent the boom assembly from being ‘tilted’ onto the working platform while the operator may be standing in its path. The TIS requires the operator to be located in a safe position when bringing the boom closer onto the deck. The TIS is an operator safety system and as such must be inspected and tested at the beginning of each shift. Failure to do so could result in injury. Refer to the Daily Operator’s Maintenance Section of this manual and Maintenance Bulletin MB-ELE1182 for testing details. The TIS consists of one proximity switch that is located on the machine’s tilt actuator. This proximity switch is used to determine whether the boom has been moved into a position where it will clear the deck area, making it safer for the machine operator. The boom will only be allowed to tilt in towards the deck only to an angle of approximately 55° from the deck regardless of the angle at which it is “rolled” to (see Figure 1). At this point the boom tilt function will be interrupted. The operator will then have to go to a Tilt Unlock (Override) button located at a position on the Bolter out of the path of the boom to be able to further tilt the boom onto the deck and place it in its tramming position. One of the Tilt Unlock (Override) buttons is located on the operator’s compartment (with optional tilt function toggle) and the other is located on the ladder end of the scissor deck’s control panel. In order to bring the boom in closer to the deck, the operator must press and hold one of the Tilt Unlock buttons while engaging the tilt toggle on the hardwired pendant or the optional tilt toggle at the operator’s compartment junction box. Alternately, in order to raise the boom into the working position from the tramming position, the operator must use a Tilt Unlock button and a tilt toggle switch to override the interlock. The Tilt Unlock button at the end of the deck has been positioned such that when the operator uses it to move the boom into or out of the tramming position, the operator will be positioned away from the boom as much as possible on the deck.

Page 1 of 6

Number: OM-BOLTER-O1 Revision: D

Figure 1 - TIS Angle Illustration The Tilt Unlock buttons are illuminated pushbuttons. These pushbuttons will illuminate when the boom has been tilted out past 55° from the deck platform or if the Tilt Unlock button is being pressed to override the interlock. Alternately, the pushbuttons will not be illuminated if the boom has been placed within 55° of the deck. Any deviation from this should be noted and the machine immediately “tagged out” for inspection.

DRILL IMPACT, FEED AND ROTATION INTERLOCKS The Drill Impact, Drill Feed and Rotation Locks are interlocked in three ways. The first interlock is with the TIS and is an operator safety interlock. The second interlock is with the drill lubrication system and is a machine safety. The third interlock is with the electrical power pack and is a machine safety. 1 – DRILL IMPACT, DRILL FEED AND ROTATION LOCK INTERLOCK WITH TIS The Drill Impact, Drill Feed and Rotation Locks are located in the deck’s control console. Drill impact, drill feed and rotation locks are interlocked with the Tilt Interlock System so that they are functional only if the boom is tilted out past 55° from the working platform.

Page 2 of 6

Number: OM-BOLTER-O1 Revision: D

IF THE MACHINE’S TIS IS COMPROMISED, THE DRILL IMPACT, FEED AND ROTATION LOCK INTERLOCK WILL ALSO BE COMPROMISED AND THE RESULT MAY BE THE ADVANCEMENT OF THE DRILL STEEL INTO THE OPERATOR’S COMPARTMENT WHEN THE BOOM IS IN THE TRAMMING POSITION. Inspection of the TIS and removal of the drill steel during tramming will prevent drill steel advancement into the operator’s compartment from occurring. 2 – ROCKDRILL LUBE PUMP INTERLOCK The Scissor Bolter is equipped with an interlock to prevent insufficient lubrication to damage the rock drill. This interlock is called the Rockdrill Lube Pump Interlock and works with the rockdrill lubrication pump and the Drill Impact, Feed and Rotation Lock buttons. The Drill Impact, Feed and Rotation Locks are wired through an oil level sensor and air pressure switch (see Figure 2) such that if one or both of the air pressure or oil level for the front head is too low then the Drill Impact, Feed and Rotation Locks will not function. Also, the rockdrill lubricator pump will stop functioning, which can be seen by its paddle remaining stationary.

Figure 2 - Rockdrill Lubrication Pump System

Page 3 of 6

Number: OM-BOLTER-O1 Revision: D Because the air pressure switch and oil level sensor are wired into the drill impact, feed and rotation locks with the Rockdrill Lube Pump Interlock, and the daily inspection of the Scissor Bolter’s TIS must be carried out with the electrical powerpack powering the Bolter, the operator must ensure that the rockdrill lubrication pump is operational before testing the TIS. This will help ensure that the drill impact, feed and rotation locks are non-functional due to the safety of the TIS and not because there is a lack of oil or air. The inspection of the TIS includes testing of the drill impact, feed and rotation locks to ensure that they are non-functional when the boom is tilted in close to the platform. Please refer to the Tilt Interlock System Inspection Maintenance Bulletin for more information. 3 - ELECTRICAL POWERPACK INTERLOCK The electrical powerpack cannot be started if the Drill Impact, Feed or the Rotation Locks are engaged. The operator will only be able to start the electrical powerpack if the feed, impact and rotation locks are disengaged. This prevents the drill feed, impact and rotation from functioning during starting.

DECK EXTENSION INTERLOCK Another safety system designed into the Scissor Bolter is the Deck Extension Interlock. This interlock is designed to prevent possible damage to the scissor deck if it is extended out too far towards the boom. If the deck is extended out too far towards the boom, a limit switch will be tripped and the rollover clockwise and tilt ‘in’ functions will be interrupted until the deck is sufficiently retracted. When the deck is extended out far enough, the Deck Extension indicator light at the deck’s control panel will illuminate indicating the deck is extended into the area where it may be damaged by rollover movement or tilting the boom back in towards the deck. Once the deck has been retracted such that the Deck Extension light is no longer illuminated, the rollover and tilt functions will be regained.

Page 4 of 6

Number: OM-BOLTER-O1 Revision: D

CABLE REEL LAST WIND INTERLOCK The cable reel holding the electrical trailing cable has an interlock built into it. The cable reel Last Wind Interlock is designed to prevent damage to the Scissor Bolter or electrical sub-station to which it is connected. It warns when the electrical trailing cable is getting close to being completely spooled out and it trips the brakes when the cable is completely spooled out. The Last Wind Interlock will illuminate the Last Wind indicator light located in the Operator’s Compartment when three (3) or less layers of trailing cable are left on the cable reel. The Interlock will trip the emergency/park brakes and prevent brake release for tramming when one (1) layer of trailing cable is left on the cable reel. At this point the operator will have to use the Last Wind Override pushbutton in order to tram in the forward direction only and reel in trailing cable. This interlock exists while tramming either in Drive Mode or while using Remote Drive System. The operator must use the Last Wind Override button on the Driver’s Instrument Dash to tram the unit and reel in some of the trailing cable. In order to tram the unit, the operator follows all steps required to start and drive the unit under diesel power as is done normally but the operator must press and hold the Last Wind Override pushbutton in order to get the brakes to release. The operator must ensure that he travels in the direction towards the trailing cable and is able to reel in some of the trailing cable otherwise damage to the cable, the cable reel or electrical substation could occur. The operator should drive slowly and ensure that the cable is not run over.

SCISSOR UP BRAKE INTERLOCK (OPTIONAL) The Scissor assembly used to raise the working platform and boom assembly has an interlock built into it. The Scissor Up Brake Interlock is designed to prevent the Scissor Bolter’s Emergency / Park Brakes from being released when the working platform isn’t in its lowest position. If the working platform has been raised to allow clearance of the boom’s hosing over large pieces of debris it is possible to use the Scissor Up Brake Override switch located in the operator’s compartment. In order to tram the unit, the operator follows all steps required to start and drive the unit under diesel power as is done normally but the operator must press and hold the Scissor Up Brake Override button in order to get the Emergency / Park Brakes to reset and release.

Page 5 of 6

Number: OM-BOLTER-O1 Revision: D

Notes:

If any questions or problems arise, please contact Maclean Engineering Technical Service for assistance. Phone: 1-866-856-3626 Email: [email protected]

Page 6 of 6

Title: Number: Machine Model(s) Affected: Revision: Creation Date: Written By: Checked By: Approved By:

STARTING, DRIVING, PARKING & SHUTDOWN OM-BLT-O2 MEM-928/946 & MEM-SSB D Revision Date: 06/11/2010 Revised By: Chris Wismer Checked By: Jan Paul Brenner Approved By: Darren Bowins

STARTING The following procedure is a guide for mines that do not have a standard starting procedure. FOLLOW MINE SPECIFIC RULES AT ALL TIMES. •

Follow ALL pre-operational checks before starting the Scissor Bolter.

•

The Master Disconnect switch (battery power) must be turned to the “ON” position.

•

Verify that all Emergency Stop buttons are reset (pulled out). On the Main AC Panel, the All Emergency Stops / Closed indicator lights must be illuminated.

•

Make sure the Emergency/Park Brake switch is applied (pushed in all the way), and that the Transmission Selector switch is in Neutral and that the Drive/Auxiliary selector switch is in Drive mode.

•

Ensure that no personnel are located in the articulation area of the unit.

•

Turn the Ignition switch to the ON position. The horn sounds, indicating low engine oil pressure, (engine protection 5 second test-beep with Mercedes/CAT engines) and to alert nearby personnel that the engine is about to be started.

Once the engine is started and the engine oil pressure increases to a sufficient operating level, the horn stops sounding (Deutz units). The unit typically requires approximately 5 seconds before the engine oil pressure reaches the minimal level required to de-activate the horn. •

Press and hold the Horn Off switch to silence the horn (if required).

•

The following indicator lights must be illuminated: > > > > > > > >

OM-BLT-O2

Power On Brake On Brake Impending Drive Fuel Enable (Deutz engine only) Glow Plugs (Deutz engine only) – indicator light automatically shuts off when the engine is ready to start. Wait to Start (Mercedes/CAT engines as applicable) – indicator light automatically shuts off when the engine is ready to start. Engine Warning and Engine Alarm (Mercedes and CAT engines)

Page 1 of 8

Title: STARTING, DRIVING, PARKING & SHUTDOWN Number: OM-BLT-O2 Revision: D It is recommended to wait until the Glow Plugs / Wait To Start indicator light goes OUT before starting the engine. •

To start the engine, push and hold the start button until the engine starts. As soon as the engine starts, release the Engine Start button. DO NOT crank the engine for more than 30 seconds at a time. If the engine does not start, wait two minutes and then try starting the engine again. If your unit is equipped with a CAT engine, and you release the start button before the engine starts, you may possibly need to reset the engine ECM prior to attempting to start the engine again. To do this from the operator’s compartment, turn the key switch OFF for 10 seconds then turn it back ON. If your Scissor Bolter has the diesel drill option installed, you may press and hold the Engine Stop button on the deck control console for 10 seconds. Some engine starter motors are equipped with overheat protection devices. These devices automatically prevent start motor over cranking/overheating. It is recommended that you still follow the above procedure to prevent damage.

If the engine does not start after several attempts, inform the appropriate maintenance personnel. If the horn does not stop sounding after 5 seconds, stop the unit. Inform the appropriate Maintenance personnel to correct the problem. Failure to correct the problem may result in serious damage to the unit. Although current model MacLean Engineering Scissor Bolters have an interlock circuit preventing the starter motor from cranking while the engine is running. It is recommended that the Engine Start push button not be engaged while the engine is running. After the engine is running, the following lights should NOT be illuminated: 

Glow Plugs (Deutz engine only)



Wait to Start (Mercedes/CAT engines as applicable)



Engine Low Oil Pressure (Deutz engines only) For Scissor Bolters using a Deutz 1013C model engine, a glow plug module is installed for the engine that includes a light in the driver’s instrument panel. This light may illuminate on the dash when the Ignition switch is turned ON, but does indicate that the engine pre-heat system is being energized prior to start-up. Once the light turns OFF, the engine should start.

Page 2 of 8

OM-BLT-O2

Title: STARTING, DRIVING, PARKING & SHUTDOWN Number: OM-BLT-O2 Revision: D For Mercedes equipped units. If the Wait to Start indicator begins to flash at any time, stop the unit immediately, shut down the engine and turn off the Master Disconnect switch. A flashing Wait to Start indicator light indicates a malfunction of the grid heater control circuit that can lead to engine damage, or fire.

DRIVING Once the low engine oil pressure warning alarm is stopped, all gauges are checked, and the vehicle is checked for any possible leaks that may be present with the vehicle running, the vehicle is ready for operation. Only operate the vehicle if properly trained, or under the direct supervision of a trained operator. Before driving, ensure that the area around the unit is clear of personnel and equipment. Ensure that the drill steel has been removed from the drill feed in order to help prevent the advancement of the drill steel into the operator’s compartment. Also, ensure that the boom support post is installed onto the deck and that the boom is resting on the support post. This helps prevent damage to the deck, or boom components during tramming. The unit must be in Drive mode in order to release the emergency/park brakes. Apply the service brakes before releasing the emergency/park brakes. Emergency/Park Brakes The emergency/park brakes are released using the Emergency/Park Brake button on the driver’s instrument panel. The Emergency/Park Brakes button as shown in Figure 1 has three positions: • • •

a maintained pushed-in position a pulled-out maintained position a momentary pulled-out reset position

Pushing the Emergency/Park Brake button in applies the emergency/park brakes. Pulling it out releases the emergency/park brakes, as long as the proper sequence is followed. In order to release the brakes, the button must be pulled up past the pulled (released) position to the reset position. The reset position is a momentary position and once the operator releases the button the button automatically goes back to the maintained release position. The emergency/park brakes must release.

OM-BLT-O2

Page 3 of 8

Title: STARTING, DRIVING, PARKING & SHUTDOWN Number: OM-BLT-O2 Revision: D

Figure 1 – Emergency/Park Brake Push/Pull/Reset Switch If the Emergency/Park Brake button is already in the released position when attempting to release the brakes, the brake button has to be reset to release the brakes. This situation occurs if the Scissor Bolter was previously shutdown without first applying the emergency/park brakes, or the EBR circuit was engaged. The following may engage the EBR circuit: > Low hydraulic pressure > Low transmission pressure > Cable reel interlock > Scissor interlock > Bolter cab door switch (if equipped with an enclosed cab option) Emergency Stopping In the event of an emergency, the emergency/park brakes can be applied. The emergency/park brakes are applied by pressing the Emergency/Park Brake button on the driver’s instrument panel as explained in the previous DRIVING section. If the emergency/park brakes must be applied in the event of an emergency, be prepared for the unit to come to sudden stop. Do not use the emergency/park brakes to slow down or stop the unit in a normal braking situation. To do so could cause unnecessary damage to the braking system and the machine.

Page 4 of 8

OM-BLT-O2

Title: STARTING, DRIVING, PARKING & SHUTDOWN Number: OM-BLT-O2 Revision: D Service Brakes The service brakes are applied using the service brake foot pedal. Pressing the service brake foot pedal applies hydraulic pressure to the axle brakes. Two pressure gauges are used to indicate drill end service brake pressure and engine end service brake pressure. In the event of an emergency, or to park the unit, the emergency/park brakes can be applied. The emergency/park brakes are applied by pressing the Emergency/Park Brake button on the driver’s instrument panel. A brake test should be carried out at the beginning of each shift or prior to travel in a ramp in order to test the service and emergency/park brakes and whenever else specified by the mine. Failure to do so could result in serious injury to you or others. Steering The Scissor Bolter is articulated left and right using a stick steer valve in the operator’s compartment. Sitting in the driver’s seat, move the stick steer valve handle in the direction you want to steer. Refer to Figure 2 below and Figure 3 on the following page.

Push stick steer valve handle away from operator.

Figure 2 – Steering Handle Away From Operator

OM-BLT-O2

Page 5 of 8

Title: STARTING, DRIVING, PARKING & SHUTDOWN Number: OM-BLT-O2 Revision: D

Pull stick steer valve handle towards operator

Figure 3 – Steering Handle Towards Operator A pinch-point exists at The Scissor Bolter’s articulation when the bolter is running. Ensure that the articulation area is clear before starting or moving the Scissor Bolter. Tramming Forward/reverse direction of travel is determined by turning the Transmission Direction Selector switch (see Figure 4). The arrow selected indicates the machine direction as the driver is sitting in the seat facing the driver’s instrument panel. Gear changes are made by selecting the appropriate gear on the Transmission Gear Selector switch. Shifts between forward and reverse must only be made once the unit has come to a complete stop.

Figure 4 - Direction Convention in Tram Mode

Page 6 of 8

OM-BLT-O2

Title: STARTING, DRIVING, PARKING & SHUTDOWN Number: OM-BLT-O2 Revision: D

PARKING AND SHUTDOWN The following procedure is a guide for mines that do not have a standard parking procedure. FOLLOW MINE SPECIFIC RULES AND REGULATIONS AT ALL TIMES. Mine specific rules must be followed when parking the scissor bolter. Wheel chocking requirements and parking location rules are specified by the mine, and should be followed by the operator. Normal Shutdown Procedure: 1. Park the unit in a designated area on firm level ground. If the Scissor Bolter is to be parked on an incline where bolting a heading is not completed, the unit must be turned into the wall with the wheel chocks applied, or the outriggers lowered, depending on mine specific regulations. 2. Apply the emergency/park brakes and then place the transmission in neutral 3. Allow the engine to idle for a few minutes before shutting down the Scissor Bolter. 4. Walk around the scissor bolter to check for any fuel, oil, exhaust leaks, broken hoses or any other visible damage. If any repairs are needed, inform the appropriate maintenance personnel. 5. Turn the Ignition switch to the OFF position. 6. To complete shutdown, disconnect the battery power supply to the Scissor Bolter by turning OFF the Master Disconnect switch.

OM-BLT-O2

Page 7 of 8

Title: STARTING, DRIVING, PARKING & SHUTDOWN Number: OM-BLT-O2 Revision: D

Notes:

If any questions or problems arise, please contact MacLean Engineering Technical Service for assistance. Phone: 1-866-856-3626 Email: [email protected]

Page 8 of 8

OM-BLT-O2

Title: Number: Machine Model(s) Affected: Revision: Creation Date: 07-DEC-2012 Written By: Donna Umlah Checked By: JanPaul Brenner Approved By: Darren Bowins

BRAKE TEST PROCEDURE OM-BLT-O3 ALL APPLICABLE Original Revision Date: Revised By: Checked By: Approved By:

BRAKE TEST PROCEDURE IF THE VEHICLE MOVES DURING ANY BRAKE TEST SHUT IT DOWN, DECOMMISSION IT IMMEDIATELY FOLLOWING MINE SPECIFIC LOCKOUT AND TAG-OUT PROCEDURES. INFORM THE APPROPRIATE PERSONNEL TO CORRECT THE PROBLEM. FAILURE TO CORRECT THE PROBLEM MAY RESULT IN EQUIPMENT AND/OR PROPERTY DAMAGE, SERIOUS INJURY, OR DEATH. As a minimum, a brake test must be carried out on the vehicle at the beginning of each shift. Mine requirements may require more frequent brake tests. A complete brake test consists of testing ALL braking systems on the vehicle. For an explanation of the operator’s compartment layout, refer to section titled Operator’s Compartment Layout of this Operator’s Manual. Start the vehicle following the startup procedure explained in section titled Starting, Driving, Parking and Shutdown of this Operator’s Manual. Follow the instructions as outlined by the Brake Test label located in the operator’s compartment. See example of a typical Brake Test label shown in Figure 1. Ensure that you follow the specific brake test label instructions on your particular vehicle.

OM-BLT-O3

Page 1 of 4

Title: BRAKE TEST PROCEDURE Number: OM-BLT-O3 Revision: Original

SERVICE BRAKE TEST 1. APPLY SERVICE BRAKES 2. RELEASE EMERGENCY/PARK BRAKES 3. PLACE TRANSMISSION IN 2ND GEAR FORWARD 4. INCREASE ENGINE SPEED TO FULL THROTTLE 5. UNIT SHOULD NOT MOVE

EMERGENCY/PARK BRAKE TEST 1. APPLY EMERGENCY/PARK BRAKES 2. PLACE TRANSMISSION IN 2ND GEAR FORWARD 3. ENSURE SERVICE BRAKES ARE RELEASED 4. INCREASE ENGINE SPEED TO FULL THROTTLE 5. UNIT SHOULD NOT MOVE

Figure 1 - Example of a Typical Brake Test Label SERVICE BRAKE TEST IF THE VEHICLE MOVES, SHUT IT DOWN AND DECOMMISSION IT IMMEDIATELY. INFORM THE APPROPRIATE PERSONNEL TO CORRECT THE PROBLEM. FAILURE TO COMPLY MAY RESULT IN EQUIPMENT AND/OR PROPERTY DAMAGE, SERIOUS INJURY OR DEATH. 1. Apply the service brakes by firmly pressing down on the service brake pedal. 2. Release the emergency/park brake by pulling the EMERGENCY/PARK BRAKE button up to the Reset position. 3. Place the TRANSMISSION DIRECTION selector switch into the Forward position. 4. Place the TRANSMISSION GEAR selector switch to 2nd gear. 5. Gently press down on the accelerator pedal to raise the engine RPM to the RPM stated on the Brake Test label. 6. The vehicle must not move. 7. Release the accelerator pedal. 8. Apply the emergency/park brakes by pressing the EMERGENCY/PARK BRAKE button. 9. Place the TRANSMISSION DIRECTION selector switch into the Neutral position. 10. Release the service brake pedal. 11. If the vehicle did not move then carry on to next test.

Page 2 of 4

OM-BLT-O3

Title: BRAKE TEST PROCEDURE Number: OM-BLT-O3 Revision: Original EMERGENCY/PARK BRAKE TEST IF THE VEHICLE MOVES, SHUT IT DOWN AND DECOMMISSION IT IMMEDIATELY. INFORM THE APPROPRIATE PERSONNEL TO CORRECT THE PROBLEM. FAILURE TO COMPLY MAY RESULT IN EQUIPMENT AND/OR PROPERTY DAMAGE, SERIOUS INJURY OR DEATH. 1.

Apply the emergency/park brakes by pressing the EMERGENCY/PARK BRAKE button.

2.

Apply the service brakes by firmly pressing down on the service brake pedal.

3.

Place the TRANSMISSION DIRECTION selector switch into the Forward position.

4.

Place the TRANSMISSION GEAR selector switch to 2nd gear.

5.

Release the service brakes.

6.

Gently press down on the accelerator pedal to raise the engine RPM to the RPM stated on the Brake Test label.

7.

The vehicle must not move.

8.

Release the accelerator pedal.

9.

Place the TRANSMISSION DIRECTION selector switch into the Neutral position.

10. If the vehicle did not move, proceed with the inspection or operation of the vehicle as necessary.

OM-BLT-O3

Page 3 of 4

Title: BRAKE TEST PROCEDURE Number: OM-BLT-O3 Revision: Original

Notes:

If any questions or problems arise, please contact Maclean Engineering Technical Service for assistance. Phone: 1-866-856-3626 Email:[email protected]

Page 4 of 4

OM-BLT-O3

Title: Number: Machine Model(s) Affected: Revision: Creation Date: 10/03/2008 Written By: Checked By: Approved By: JEG

ECO DECK CONTROL PANEL OPERATION OM-BLT-O4-ECO ALL APPLICABLE A Revision Date: Revised By: Checked By: Approved By:

ECO DECK CONTROL PANEL OPERATION This section of the 928/946 Scissor Bolter operator manual outlines the function and usage of the scissor deck’s control panel with Electric Control Option (ECO). Always use the outriggers to level and stabilize the bolter prior to raising/lowering the scissor, working from the deck and/or moving the boom. Failure to ensure that outriggers are extended onto stable ground can cause machine damage and possible injury.

The control panel is the main control station for the bolters drill; boom, bolt and remote drive functions. The control panel allows the operator to control functions from a safe location, which is withdrawn from the boom’s working area. (Figure 1 illustrates a typical layout of the controls of the scissor bolter.)

Drill Control Panel

Deck Control Console

Remote Drive System Joystick

Figure 1 – Typical ECO Deck Control Panel Whenever possible, operate all boom and drill functions from the control console on the scissor deck. This will help to ensure that the operator is in the safest possible location.

OM-BLT-O4-ECO

Page 1 of 26

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A

DRILL CONTROL PANEL The typical ECO Scissor Bolter Drill Control Panel consists of a number of control levers, pressure gauges and regulators used to operate the unit efficiently. (Figure 2 illustrates a typical Drill Control Panel layout)

Figure 2 – Drill Control Panel Layout

Page 2 of 26

OM-BLT-O4-ECO

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A

1.

Drill Rotation – Control lever allows manual operation of rock drill rotation. Displacing the drill Rotation valve handle in the upward direction will rotate the drill’s striking bar in the counter-clockwise direction as indicated in Figure 3 (viewed from the rear of rock-drill). Displacing the valve handle in the downward direction will rotate the drill’s striking bar in the clockwise direction. Rotation pressure is indicated on the Drill Rotation Pressure Gauge (see Item 2).

Figure 3 – Drill Rotation Function 2.

Drill Rotation Pressure – Gauge shows the hydraulic pressure of the rock drill’s rotation circuit. Drill Rotation pressure is relevant to the drill feed force applied to drill string. If the drill feed force is increased the drill rotation pressure will increase. Normal drill rotation pressure values will depend upon the specific rock-drill being used. Typical normal operating range is 300 >700 psi (20 > 48 Bar).

3.

Drill Feed – Control lever allows manual operation of rock drill feed function. Displacing the Drill Feed valve handle in the upward direction will move the rockdrill in the forward direction as indicated in Figure 4. Displacing the valve handle in the downward direction will retract the rock-drill. Drill Feed pressure is indicated on the gauge (see item 4). The operator can regulate the drill feed pressure by using the Drill Feed Regulator (see item 5).

OM-BLT-O4-ECO

Page 3 of 26

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A

Figure 4 – Drill Feed Function 4.

Drill Feed Pressure – Gauge shows the hydraulic pressure being applied to move the drill. The Drill Feed pressure will increase once drill string comes in contact with rock surface. Drill Feed pressure will vary depending on the type of rock being drilled. Normal drilling pressure may be different depending on the drill option.

5.

Drill Feed Regulator – Valve allows control of the drill feed force being applied to the rock drill while drilling. The handle can be turned in the clockwise direction to increase drill feed pressure and counter-clockwise to decrease drill feed pressure (Figure 5). The hydraulic pressure that is being applied is indicated on the Drill Feed Pressure Gauge. Lower the regulated drill feed pressure before engaging the drill feed lock due to various drilling conditions that may exist with ground support and rock conditions. Once drill feed lock is engaged adjust the drill feed regulator for optimum performance. Failure to follow these steps will increase the chance of the drill steel bending due to higher than required drill feed pressure or the drill string running loose because of to little drill feed pressure.

Page 4 of 26

OM-BLT-O4-ECO

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A

Figure 5 – Drill Feed Regulator 6.

Drill Impact – Control lever allows impact operation of the rock drill and, if equipped, the impact operation of the combi-head drill used for installing split sets. Displacing the lever in the upward direction will activate the rock drill percussion for drilling. If equipped, displacing the valve handle in the downward direction will activate the Combi-head percussion used for installing split sets (Figure 6). Both pressures can be monitored on the impact pressure gauge (item 7).

Figure 6 – Impact Function The rock-drill is equipped with a Low Pressure Collaring circuit which will automatically reduce the Drill Impact pressure when the drill feed is in a “no load” situation. When drill feed pressure rises above a preset amount or when the drill string bit comes in contact with the rock surface to be drilled the impact pressure will rise to the rock-drills preset optimum working pressure.

OM-BLT-O4-ECO

Page 5 of 26

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A 7.

Impact Pressure Gauge – Indicates hydraulic pressure of rock drill percussion or, if equipped, Combi-head percussion.

8.

Bolt Rotation – The Scissor Bolter will be equipped with either a Bolt Rotation Head or a Combi-Head assembly. The Bolt Rotation Valve allows manual operation of the installed components rotation as described in the following.

Figure 7 – Bolt Rotation Function • Bolt Rotation Head (If equipped) - Displacing the Bolt Rotation valve handle upward will rotate the Bolt Rotation Heads dolly tube in the counter-clockwise (CCW) direction. Displacing the handle downward will rotate the dolly tube in the clockwise (CW) direction (Figure 7). NEVER use the bolt rotation function when Swellex adapter is installed! Equipment damage will occur. Never come into contact with Bolt Rotation head for any reason while in operation. Always shut down Bolter before servicing Bolt Rotation head. Only properly trained personnel should service Bolt Rotation. Personal injury may result.

Page 6 of 26

OM-BLT-O4-ECO

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A

CCW

Combi-Head Assembly Impact Figure 8 – Combi-Head Function • Combi-Head (If Equipped) - Displacing the Bolt Rotation Valve handle upward will rotate the dolly in the counter-clockwise (CCW) direction. Displacing the handle downward will rotate the dolly in the clockwise (CW) direction (Figure 8). Never come into contact with Combi head for any reason while in operation. The Combi Head is equipped with charged gas accumulators. Always shut down Bolter before servicing Combi head. Only properly trained personnel should service Combi Head. Personal injury may result. 9.

Bolt Rotation Pressure – Gauge used to monitor hydraulic pressure of bolt rotation in both clockwise and counterclockwise rotation. Maximum pressure is indicated when bolt dolly stalls during bolt torque process.

10. Bolt Rotation Counterclockwise Torque Regulator – Valve is used to limit bolt rotation torque in the counterclockwise rotation (Figure 9). The pressure setting will determine the amount of torque that is applied to the ground support being used. Refer to section OM-BLT-O12 for more information on adjusting torque.

OM-BLT-O4-ECO

Page 7 of 26

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A

Figure 9 – Bolt Rotation Counterclockwise Torque Regulator 11. Bolt Rotation Clockwise Torque Regulator – Valve is used to limit bolt rotation torque in the clockwise rotation (Figure 10). The pressure setting will determine the amount of torque that is applied to the ground support being used. Refer to section OM-BLT-O12 for more information on adjusting torque.

Figure 10 – Bolt Rotation Clockwise Torque Regulator 12. Air Pressure Gauge – Gauge is used to monitor the regulated air pressure entering the drill lube pump. A minimum of 25 psi is required for the drill lube system to work properly. 13. Water Pressure Gauge – Gauge is used to monitor water pressure used for flushing hole when drilling. A minimum of 35psi water pressure is required for water pump to work. 14. Water Flush Shutoff Override – Valve is used to shut off water if water flush solenoid valve fails. 15. Swellex Pressure Gauge (If equipped) – Gauge is used to determine operational pressure of Swellex system if so equipped.

Page 8 of 26

OM-BLT-O4-ECO

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A

CONTROL CONSOLE LAYOUT 1

2

3

4

5

6

7

Figure 11 – Control Console Layout – Indicator Lights 1.

Auxiliary Mode – Indicator light (Figure 11) illuminates when mode selector switch (Drivers Compartment, Console) is in the Auxiliary Mode. When Illuminated all controls on platform will be available.

2.

Hydraulic Filter Bypass – Warning indicator light (Figure 11) illuminates when a hydraulic filter assembly is bypassing indicting the filter is dirty or plugged. To determine which filter is contaminated a visual indicator is present on each filter.

3.

Hydraulic Oil Level – Warning indicator light (Figure 11) illuminates when hydraulic oil level in reservoir is below normal operating level. Unit should be shutdown immediately and reservoir filled. Unit should be cured of hydraulic leaks at this time. If reservoir oil drops below the minimum oil level the bolter will automatically shutdown.

4.

Hydraulic Oil Temperature – Indicator light (Figure 11) warns of excessive heat build up in the hydraulic system. Unit should be shutdown immediately and

OM-BLT-O4-ECO

Page 9 of 26

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A appropriate personnel consulted to determine the cause of overheating. If hydraulic oil temperature climbs above maximum operating temperature the bolter will automatically shutdown. 5.

Deck Extended – Indicator light (Figure 11) illuminates when working platform has extended beyond the operations threshold. When platform is moved towards boom an interlock disables the rollover clockwise and tilt in functions. Refer to section MB-GEN1184 for an explanation of the deck extension interlock.

6.

Drill Flushing Pressure – Indicator light (Figure 11) illuminates when water flow is sufficient for drilling. Light indicates when water pressure is above 35psi flushing pressure on the outlet side.

7.

Drill Lube – Indicator light (Figure 11) illuminates when drill lubricator is functional. If the drill lubricator is not functional the operator’s deck console locks will be disabled. Refer to section OM-BLT-O14 for a more detailed explanation of the Drill Lubrication System. 9

8

17

18

10

19

11

12

20

14

13

21

22

15

23

16

24

Figure 12 – Control Console Layout – Switches

Page 10 of 26

OM-BLT-O4-ECO

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A 8.

Drill Rotation Lock – Illuminated push/pull switch allows operator to maintain the drill rotation lock function without having to hold lever (Figure 12). When the switch is pulled out the switch will illuminate, the drill’s striking bar will rotate in the counterclockwise direction as indicated in Figure 3 (viewed from the rear of the rock drill) and the water flushing will automatically start. By pushing the switch the drill rotation counterclockwise function will stop and the water flushing will stop. The Drill rotation lock should only be used when drilling. Drill feed lock should only be used after the hole is collared and the drill feed manual lever has been pulled “UP” all the way to determine if the drill feed pressure is properly regulated. This will help prevent excessive feed force from being applied when drilling.

9.

Drill Feed Lock – Illuminated push/pull switch allows operator to maintain the drill feed lock function without having to hold lever (Figure 12). When the switch is pulled out the switch will illuminate, the rock-drill will move in the forward direction. By pushing the switch the rock-drill will stop moving along the feed.

10.

Drill Impact Lock – Illuminated push/pull switch allows operator to maintain the drill impact function without having to hold the lever (Figure 12). When switch is depressed drill impact will engage and light will illuminate. The function will be maintained until switch is depressed. Drill impact lock should only be used after hole is collared and drill impact lever has been pulled up all the way. Item 8 Drill Rotation Lock, item 9 Drill Feed Lock and item 10 Drill Impact Lock will only work when the following conditions are met: 1. Master Disconnect Switch is turned on 2. Power Pack or Diesel engine is energized (hydraulic pumps running) 3. Units selector switch is in the auxiliary Mode 4. Deck control console is energized 5. Boom is in the safe working position 6. Drill lubrication system is working. Air pressure is within specification and lube oil reservoir is full

OM-BLT-O4-ECO

Page 11 of 26

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A 11.

Console Power – Illuminated push button switch allows operator to energize all functions in console (Figure 12). When switch is depressed all console functions should be active. The console power switch will only operate if unit is in the auxiliary mode. Once switch is activated there is no need to use the switch unless unit’s drive/auxiliary mode selector switch is put into drive mode. Interlocks may cause some functions to be disabled ex: tilt interlock, deck extension…

12.

Engine Start (Diesel Bolting Option Only) – Push button switch allows operator to start diesel engine from the working platform (Figure 12).

13.

Emergency Stop – Button interrupt all 24 V power to the engine and to the Scissor Bolter control circuit. In the event of an emergency, push the Emergency Stop button and all power to the Scissor Bolter will be interrupted. To reset the Emergency Stop, twist the button clockwise and it will release.

14.

Engine Stop (Diesel Bolting Option Only) – Push button switch allows shutdown of the diesel engine (Figure 12).

15.

Throttle Lock (Diesel Bolting Option Only) – Selector switch allows the operator to raise engine speed for boom manipulation while operating on diesel engine (Figure 12).

16.

Outriggers – Engine end, left deck and right deck momentary toggle switches control raising /lowering the outriggers (Figure 12). Pushing up on the toggle will raise the outrigger (lowers the machine) and pushing down on the toggle switch will lower the outrigger (will raise the machine). Ensure that proper work bed material is supporting the unit. Failure to ensure that outriggers are on stable ground can cause serious injury. The engine end outriggers are connected hydraulically in parallel and are designed to be self leveling while the deck end outriggers are controlled independently and therefore leveling the deck end is the duty of the operator.

17.

Drill Control – Three-position selector switch allows the operator to select between deck control or remote control of the drilling functions (Figure 12). •

Off position turns off all drilling functions.

•

Remote position allows the operator to use the Hardwired Remote Drilling pendant, if equipped, at the engine end of the machine.

Page 12 of 26

OM-BLT-O4-ECO

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A • 18.

Deck position allows the operator to use the deck controls including the standard hardwired pendant used for boom and drill functions.

Drill Rod Clamp (If equipped) – Three-position selector switch. Figure 12 shows the switch location if equipped. •

Centre position drill rod clamp “off”.

•

Counterclockwise position drill rod “unclamp” – This is a momentary function. The switch will return to its centre position once released. Turning the switch in this direction will open the Drill Centralizer as indicated in Figure 13.

•

Clockwise position drill rod “clamp” – This is used to hold the drill steel coupling during long hole drilling. When using the drill rod clamp leave it in the “CW” clamp position to hold the drill steel in position for insertion of the next steel as indicated in Figure 13.

Figure 13 – Function of Drill Rod Clamp 19.

Drill Rod Rattle – Push button used for uncoupling drill steel (Figure 12). Activates rock drill impact and low-pressure collaring disable valve.

20.

Powerpack Start – Push button used to start electric power pack (Figure 12). The hydraulic pumps, water pump and compressor will start.

21.

Powerpack Reset (If equipped) – Push button used to reset mines power supply (Figure 12). Press and hold switch until the “PMR” relay is energized. Once “PMR” relay is energized switch can be released and power supply to unit will be maintained.

OM-BLT-O4-ECO

Page 13 of 26

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A 22.

Powerpac Stop – Push button used to shutdown the power pack (Figure 12). The hydraulic pumps, water pump and compressor will stop.

23.

Bolt Feed Speed – Illuminated push/pull switch (Figure 12) allows reduction of bolt feed function rate of travel after use with short bolts or cone bolts.

24.

Bolt Impact – Illuminated push/pull switch allows for Combi-head splitset installation (Figure 12). If switch is pulled up indicator light is illuminated and the Bolt Impact function will be available from the Bolt Rotation joystick (item 34).

23

24

25

26

27

28

29

30

31

32

33

34

Figure 14 – Control Console Joystick Controls 25.

Drill Feed Crowd – The Drill Feed crowd joystick (Figure 14) is used for moving the Drill feed. It is used to maintain a close proximity to the surfaced being drilled and for retracting the drill feed before indexing if uneven ground is encountered. Figure 14 illustrates movement of function.

Page 14 of 26

OM-BLT-O4-ECO

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A 26.

Boom Crowd – The Boom crowd joystick (Figure 14) is used for moving the boom assembly (Drill feed, Bolt feed and Pivot assembly). Figure 15 illustrates movement of function.

Figure 15 – Drill Feed and Boom Crowd Direction Control 27.

Rollover – Joystick (Figure 14) is used to rotate the Rollover assembly. The Rollover assembly provides rotational movement of the boom assembly (Figure 16) about the Tilt Actuator and allows for angle adjustment from bolting the back to bolting the wall.

OM-BLT-O4-ECO

Page 15 of 26

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A

Figure 16 – Rollover (Top View) Direction Control 28.

Transverse – Joystick (Figure 14) moves the Transverse assembly. The Transverse assembly allows lateral or side-to-side movement of the boom across the width of the Bolter as indicated in Figure 17.

Figure 17 – Transverse (Top View) Direction Control 29.

Scissor – Joystick (Figure 14) allows for raising and lowering of work platform and boom assembly as indicated in Figure 18.

Page 16 of 26

OM-BLT-O4-ECO

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A Always check above, below and the surrounding area before moving the scissor joystick handle to ensure that area is clear.

Figure 18 – Scissor, Direction Control 30.

Tilt Actuator – Joystick (Figure 14) allows rotational movement of the boom assembly in towards and away from the Bolters’ working platform about the transverse tube as indicated in Figure 19. When the boom is placed in the horizontal position (folded in on the deck) over the working platform it is said to be in tramming position.

Figure 19 – Tilt Actuator Direction Control

OM-BLT-O4-ECO

Page 17 of 26

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A 31.

Deck Extension – Joystick (Figure 14) allows for extending and retracting of platform as indicated in Figure 20. Deck extension allows operator access to working area. When deck is extended beyond 10” the deck extension interlock will disable the rollover clockwise and tilt in functions to protect the work platform. Refer to section MB-GEN1184 for more information on interlocks.

Figure 20 – Deck Extension Direction Control 32.

Drill Centralizer; •

Fixed Centralizer (not shown) – Used in single pass bolting application the centralizer provides a guide for the drill steel when collaring the hole. It is important to maintain a close proximity to the surface being drilled to help eliminate drill steel from deviating during the collaring process. If the drill steel deviates from the desired location the boom may have to be repositioned in order to reduce the risk of the drills striker bar from breaking. Refer to section OM-BLTO7 for more details on Drilling.

•

Hydraulic Centralizer (Figure 21) – Used for Longhole drilling application the centralizer provides a guide for the drill steel when collaring the hole. When the drill string approaches the centralizer jaws the hydraulic centralizer must be opened in order for the coupling to go through. It is important to maintain a close proximity to the surface being drilled to help eliminate drill steel from deviating

Page 18 of 26

OM-BLT-O4-ECO

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A during the collaring process. If the drill steel deviates from the desired location the boom may have to be repositioned in order to reduce the risk of breaking the drills striker bar. Refer to section OM-BLT-O7 for more details on Longhole Drilling.

Figure 21 – Hydraulic Centralizer (Top View) Function 33. Pivot Assembly - The Pivot assembly allows the bolt feed to index into the Drill Feeds’ position after drilling for insertion of required ground support as indicated in Figure 22.

Figure 22 – Boom Pivot/Index Function

OM-BLT-O4-ECO

Page 19 of 26

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A 34.

Bolt Centralizer – Used during insertion of ground support. Allows operator to install bolts in hard to reach places. Insert bolt onto dolly and into centralizer before manipulating boom into hard to reach areas. Use the resin injector tool provided for insertion of resin into hard to reach holes. (Figure 23 illustrates bolt centralizer motion).

Figure 23 – Bolt Feed and Centralizer Function 35.

Bolt Feed – Used to insert the ground support into the drilled hole. A feed motor moves the Bolt dolly or Split-Set driver along the entire length of the feed as indicated in Figure 23.

36.

Bolt Rotation – Used to Rotate Bolt dolly or activate Combi-head impact function when Bolt Impact selector (item 24) is energized.

Page 20 of 26

OM-BLT-O4-ECO

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A

REMOTE DRIVE SYSTEM (RDS) The Remote Drive System (RDS) is the scissor bolters system that allows for tramming of the machine while on the working platform. Figure 24 illustrates a typical RDS control.

Figure 24 – RDS Control Function The RDS can be engaged while operating with either the electrical powerpack or the diesel engine running. RDS controls consist of a proportional tramming/steering joystick, a RDS Enable switch and a Cable Reel switch. A warning alarm must be audible and both ends driving lights must illuminate when the brakes are released. It should be noted that the machine may ‘lurch’ or ‘jerk’ as the brakes release or reapply when tramming and/or bringing the unit to a stop from a high tram rate. The operator should be safely and securely positioned in order to prevent possible injury due to the braking action. Proportional Joystick – Hydraulic pilot control lever is used to tram and steer the machine while under RDS control. The joystick allows for forward, reverse, left

OM-BLT-O4-ECO

Page 21 of 26

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A and right directional controls. For RDS tramming, the control of tram direction and steering should be proportional to joystick displacement (the steering displacement and tramming speed will increase the more the joystick is displaced). The RDS control directions (Figure 25) are as follows: Forward = travel in the direction of the boom end Reverse = travel in the direction of the engine end Left = travel in the direction of the deck control panel side of the machine Right = travel in the direction of the bolt rack side of the machine In general, the machine will travel in the direction that the RDS joystick is moved.

Figure 25 – RDS Control Directions Convention The brakes will not release until tramming pressure is present after the joystick is moved. In

The machine operator has control of the brakes at all times. The unit’s brakes can be reapplied at any time by releasing either the joystick trigger or Brake Release switch or by bringing the joystick to the neutral position.

RDS Enable – Trigger switch is used to enable the RDS systems indicated in Figure 26. The tram and steering functions will be disabled until the trigger switch is depressed.

Page 22 of 26

OM-BLT-O4-ECO

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A

Figure 26 – RDS Control Trigger Switch Cable Reel – Thumb switch is used to engage the cable reel as indicated in Figure 27. The cable reel will rotate when the button is pushed such that the trailing cable will spool onto the reel.

Figure 27 – Cable Reel Thumb Switch Using the RDS Drive System: The following procedure outlines the recommended use of the RDS Drive System: • Initial set-up will have the Scissor Bolter in Auxiliary mode and the electric power-pack or diesel engine running.

OM-BLT-O4-ECO

Page 23 of 26

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A • Ensure that the work area of the Scissor Bolter is clear and that there is no debris, personnel or obstacles around it. The operator must ensure that the articulation area is clear. • Ensure that the machine’s outriggers are fully retracted. If not, use the outrigger toggle switches on the control console to retract them. Prior to and during tramming ensure that the trailing cable and water hose will not be run over with the machine. Engage the cable reel thumb switch to ensure any slack in the trailing cable is taken up. The brakes will automatically apply if trailing cable reaches its last wind on the cable reel. The length of the water hose must be sufficient to allow tramming the required distance. • Depress the RDS enable trigger and slowly move the RDS joystick in the direction you wish to travel. In

In order to release the brakes for tramming the following conditions must be met: 

With powerpack or diesel engine operating, mode selector switch must be in the auxiliary mode



Boom must be in the working position



Deck control console power must be enabled



The joystick trigger must be engaged (IN)



The joystick must be displaced in the direction of forward or reverse tram



Trailing cable must have more than 1 wrap left on spool

If any one of the above conditions is not met, then the unit’s emergency/park brakes will not be released. • Once the machine has been moved to its new working position, release RDS Enable trigger and allow the joystick to return to its center, or neutral, position. It should be noted that the machine may ‘lurch’ or ‘jerk’ as the brakes release and reapply when tramming and bringing the unit to a stop from a high tram rate. The operator should be safely and securely positioned in order to prevent possible injury due to the braking action.

Page 24 of 26

OM-BLT-O4-ECO

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A • Using the outrigger control toggle switches, place the outriggers on the ground and level the machine. When extending the outriggers ensure that the outriggers are placed on solid ground.

OM-BLT-O4-ECO

Page 25 of 26

Title: ECO DECK CONTROL PANEL OPERATION Number: OM-BLT-O4-ECO Revision: A NOTES:

If any questions or problems arise, please contact MacLean Engineering Technical Service for assistance. Phone: 1-866-856-3626 Email: [email protected]

Page 26 of 26

OM-BLT-O4-ECO

Title: Number: Machine Model(s) Affected: Revision: Creation Date: 08/16/2001 Written By: SJC Checked By: Approved By:

REMOTE PENDANT OPERATION OM-BLT-O5 928/946 All ECO/HCO Scissor Bolter’s E Revision Date: 02/06/2013 Revised By: JanPaul Brenner Checked By: Doug Ward Approved By: Bruce Mackereth

REMOTE PENDANT OPERATION This section of the 928/946 Scissor Bolter Operator’s Manual outlines the function and usage of the remote pendant. The operator must keep clear, and be very cautious of the boom, scissor deck, handrail and wing areas whenever operating the remote pendant. This helps to ensure that possible pinch points are avoided. The remote pendant and its cable must be inspected at the beginning of each shift to ensure they are free of damage and that the proper functions are provided and are working properly. Refer to remote pendant maintenance information for pre-operational inspection information. The remote pendant is used as an alternative to using the deck control console and aids the operator in handling the screen. The remote pendant provides flexibility in the operation of the vehicle. It must be noted that whenever possible, the controls for the boom and drill functions at the deck control console must be used to ensure that the operator is as far away from the boom as possible. Figure 1 illustrates a typical remote pendant. For vehicles equipped with the ‘two hand’ operated remote pendant, see Figure 2. Function Toggles Bolt/Off/Boom Toggle Switch

Emergency Stop

Figure 1 – Typical Bolt/Boom Manual Remote Pendant

OM-BLT-O5

Page 1 of 6

Title: REMOTE PENDANT OPERATION Number: OM-BLT-O5 Revision: E Function Toggles Bolt/Off/Boom Toggle Switch

Emergency Stop

Figure 2 – Typical Bolt/Boom Two Hand Operation Remote Pendant The remote pendant consists of an EMERGENCY STOP button, a BOLT/OFF/BOOM toggle switch and seven function toggle switches, which can be used to control boom, bolt, deck and scissor functions. The remote pendant or dummy plug must be installed to operate the vehicle. The dummy plug can be found on a short chain beside the remote pendant receptacle. See Figure 3.

Remote Pendant (in stored position) Remote Pendant Dummy Plug

Figure 3 – Typical Remote Pendant Dummy Plug

Page 2 of 6

OM-BLT-O5

Title: REMOTE PENDANT OPERATION Number: OM-BLT-O5 Revision: E Emergency Stop Button - In the event of an emergency situation, the EMERGENCY STOP button is pressed to shutdown the following: •

Mine supplied three phase electrical supply to the main AC electrical panel.

•

Electrically driven power pack.

•

The 24Vdc control system supply.

•

The vehicle’s engine.

To reset the EMERGENCY STOP button, twist the button clockwise and it must then pop up and return to its released position. Bolt/Off/Boom Toggle Switch This switch is used to select between BOLT and BOOM mode, as well as to turn the remote pendant OFF. Once a mode is selected, only the function switches available for that mode active. There are two configurations available for this switch. They are explained below. •

Maintained – This configuration allows the operator to operate the remote pendant with one hand, as the toggle switch remains in the selected position. See Figure 1. The BOLT/OFF/BOOM toggle switch must always be placed in the OFF position unless the operator is using the remote pendant. This helps to prevent inadvertent boom movement which could cause injury, or death.

•

Momentary – This configuration requires the operator to operate the remote pendant with two hands, as the toggle switch returns to the OFF position once released. See Figure 2.

Function Toggle Switches – The seven function toggle switches on the remote pendant are used to control the bolt/boom functions. These switches are momentary, meaning they must return to their Central, or Neutral positions when not pressed. The switches must be pressed in the desired direction for the function to be activated.

OM-BLT-O5

Page 3 of 6

Title: REMOTE PENDANT OPERATION Number: OM-BLT-O5 Revision: E While in the BOLT function control mode, the following seven functions can be controlled with the pendant: •

Bolt Feed (fwd/rev)

•

Bolt Rotation (clockwise/counter-clockwise) If equipped, the BOLT ROTATION toggle switch on the remote pendant may control the bi-directional split set driver option.

•

Drill Centralizer (open/close – hydraulic only)

•

Pivot (in/out or Drill/Bolt)

•

Drill Feed (fwd/rev)

•

Drill Rotation (clockwise/counter-clockwise)

•

Bolt Centralizer (open/close), (or Bolt Crowd extend/retract, if equipped) If equipped, the Combi-Head bi-rotation valve changes the functionality of the BOLT FEED toggle switch on the remote pendant. Ensure that the Combi-Head bi-rotation valve is in the correct position for the type of bolt being used.

While in BOOM function control mode, the following functions can be controlled with the pendant: •

Drill Crowd (fwd/rev)

•

Transverse (left/right)

•

Boom Crowd (fwd/rev)

•

Rollover (clockwise/counter-clockwise)

•

Scissor (raise/lower)

•

Tilt (in/out)

•

Deck (extend/retract)

Page 4 of 6

OM-BLT-O5

Title: REMOTE PENDANT OPERATION Number: OM-BLT-O5 Revision: E Whenever the pendant is not in use, it must be stored either on the hangers provided on the deck’s hand railings, or on the hanger on the side of the deck’s control console. The remote pendant can be unplugged from the deck’s control console and a dummy plug installed in its place. The dummy plug must be connected to the deck control panel whenever the remote pendant is not connected, or the vehicle does not function. If the remote pendant is unplugged from the deck control panel, it must be stored in a safe and dry place to prevent damage. See Figure 3. The remote pendant may be used while operating in AUXILIARY mode under the power of the diesel engine, or the electric power pack.

OM-BLT-O5

Page 5 of 6

Title: REMOTE PENDANT OPERATION Number: OM-BLT-O5 Revision: E

Notes:

If any questions or problems arise, please contact MacLean Engineering Technical Service for assistance. Phone: 1-866-856-3626 Email: [email protected]

Page 6 of 6

OM-BLT-O5

Title: Number: Machine Model(s) Affected: Revision: Creation Date: 03/21/2004 Written By: ATH Checked By: Approved By:

DRILLING PROCEDURE OM-BLT-O6 928/946 All ECO/HCO Scissor Bolter’s C Revision Date: 09/17/2013 Revised By: JanPaul Brenner Checked By: John Huggins Approved By: Bruce Mackereth

DRILLING SET-UP FAILURE TO ADHERE TO THE RECOMMENDATIONS AND WARNINGS OF THIS MANUAL AND THE MACHINE LABELING COULD LEAD TO EQUIPMENT DAMAGE, PERSONAL INJURY, OR DEATH. ALWAYS READ AND UNDERSTAND ALL LABELS BEFORE OPERATING THE SCISSOR BOLTER. This section of the Operator’s Manual is only an outline of the steps to be considered prior to drilling. Always follow all mine specific rules and regulations when preparing the work site. PERFORM NECESSARY PRE-OPERATION INSPECTION CHECKS If the bolter must be trammed to the work area, all applicable pre-operation inspection checks in order to start-up and tram the bolter must first be performed. Refer to Daily Operator’s Maintenance section of this manual for more details. Once the bolter is at the work area, all remaining pre-operation checks must be performed prior to commencing drilling. POSTING OF SIGNS AND MARKERS Once the Scissor Bolter is driven to its work area, proper signs and markers in accordance with mine procedures must be posted. (Example: CAUTION Trailing Cable. DANGER Remote Operated Equipment.) See Figure 1.

Figure 1 - Typical Signs and/or Markers

OM-BLT-O6

Page 1 of 22

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C GATHER NECESSARY SUPPLIES Ensure that you have all supplies required for the job at hand. Supplies required may include bolts, screen, plates/washers, resin cartridges, plastic resin birdies/spiders, threaded nuts, rock drill oil etc. ONLY LOAD THE REQUIRED AMOUNT OF SUPPLIES FOR THE JOB AT HAND ONTO THE SCISSOR BOLTER DECK. FOR REFERENCE, A LABEL INDICATING THE APPROXIMATE WEIGHTS OF VARIOUS MATERIALS IS AFFIXED TO THE FRONT OF THE BOLT RACK. SEE FIGURE 2. DO NOT EXCEED THE DECK LOAD CAPACITY OF 2000 LBS (905 KG).

Figure 2 – Typical Label showing Material Weights (Approximate) VENTILATION If drilling is to be performed using the diesel engine, ensure that the work area is adequately ventilated. The Bolter is equipped with a required ventilation tag in the operator’s compartment, which states how many cubic feet per minute (CFM) the engine requires to safely operate the Bolter on diesel power. See Figure 3.

Figure 3 - Example of CFM tag

Page 2 of 22

OM-BLT-O6

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C TRAILING CABLE HOOK UP With all pre-operational set-ups and checks complete, shutdown the diesel engine. Unwind the trailing cable and plug it into the mine’s power supply. The trailing cable must be retained from pulling on the plug with the proper cable support and anchor. Also ensure that the trailing cable is identified to other operators and it is not in the path of other equipment. See Figure 4.

Figure 4 – Typical Trailing Cable Hook Up

OM-BLT-O6

Page 3 of 22

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C INSPECT THE WORK AREA FOR HAZARDS IF THE BOLTER DOES NOT HAVE A FIRM WORK SURFACE, UNINTENDED DROPS COULD OCCUR WHEN THE OUTRIGGERS SUPPORTING THE BOLTER ARE LOWERED ONTO UNSTABLE ROCKBED MATERIAL. Visually inspect the work area for potential hazards that could pose a danger when tramming the Scissor Bolter into the work area, and hazards that could pose a danger while working in the area. Examples of such hazards are: • • • • • • • •

Potentially hazardous ground conditions including loose rock on the walls, back and face. Always scale and scale well! Large pieces of rock in the roadway. Uneven roadbed. Air and water pipes/hoses. Equipment, tools and supplies on the ground. Ventilation tubing. Un-detonated explosives. Bolts and screen protruding from the walls and back. BE AWARE OF POTENTIAL HAZARDS AND WHEN NECESSARY TAKE ACTION TO REMOVE OR CORRECT SUCH HAZARDS, OR INFORM THE APPROPRIATE PERSONNEL AS PER MINE STANDARDS AND REGULATIONS.

Page 4 of 22

OM-BLT-O6

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C STARTING THE POWER PACK

Main Disconnect Switch Indicator Lights

Voltmeter

Emergency Stop Button Main Power Reset Button Figure 5 – Typical Main AC Electrical Panel 1. Turn the MAIN DISCONNECT switch to the ON position. 2. Ensure that all EMERGENCY STOP buttons are pulled out. When all EMERGENCY STOP buttons are pulled out, the ALL E-STOPS CLOSED indicator light located on the main AC electrical panel illuminates. 3. Because the main AC electrical panel is not yet supplied with the mines voltage supply, the VOLTAGE MONITOR indicator light illuminates to indicate a problem with the required voltage supply. 4. Turn the MAIN DISCONNECT switch to the ON position and press and hold the MAIN POWER RESET button. 5. The mines voltage power supply must now appear on the volt meter and the R1 ENABLED indicator light must be illuminated. 6. If the required voltage supply is adequate, the VOLTAGE MONITOR indicator light turns OFF. 7. The power pack is ready to start. The DRIVE/AUXILIARY selector switch must be in the AUXILIARY mode when operating Bolter functions. Refer to section OM-BLT-V5 for the main AC electrical panel layout and to Section OMBLT-O1 for a detailed explanation of the Bolter’s interlocks)

OM-BLT-O6

Page 5 of 22

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C DIESEL BOLTING SETUP (OPTIONAL) 1. Hook up the mine water supply as outlined in this section of the Operator’s Manual under headings Inlet Water Hook-Up. 2. Turn the MAIN DISCONNECT switch to the ON position. 3. Ensure that all EMERGENCY STOP buttons are pulled out. 4. On the main AC electrical panel the ALL E-STOPS CLOSED indicator light illuminates. 5. From the operator’s compartment instrument panel, the POWER ON indicator lights illuminate. 6. From the operator’s compartment instrument panel, turn the IGNITION switch ON. The horn sounds for about 5 seconds. For bolter’s equipped with a Deutz engine, the FUEL ENABLE indicator light illuminates. 7. Ensure that the emergency/park brakes are applied and that the transmission is in the Neutral position. 8. Select AUXILIARY mode. 9. The AUXILIARY MODE indicator light on the control console illuminates to indicate that the vehicle is in AUXILIARY mode. 10. Start the diesel engine by pressing the ENGINE START push button located on control console. 11. The Throttle lock is only engaged when the rock drill is drilling the hole. All boom movements are done at engine idle speed. 12. Continue on to heading titled Working Platform Setup. The DRIVE/AUXILIARY selector switch must be in AUXILIARY mode when operating Bolter functions. To shut down the diesel engine from deck platform, first disengage the throttle lock. Once engine returns to idle, press and hold the ENGINE STOP push button, located on control console, until engine shuts OFF. FAILURE TO DISENGAGE THE THROTTLE LOCK PRIOR TO STOPPING THE ENGINE COULD RESULT IN SERIOUS ENGINE DAMAGE. Refer to section OM-BLT-O1 for a detailed explanation of the Bolter’s interlocks, section OM-BLT-O2 for a detailed explanation of diesel engine operation and to section OMBLT-O4-ECO/HCO for control console layout.

Page 6 of 22

OM-BLT-O6

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C INLET WATER HOOK-UP Before hooking up the water hose flush it in order to eliminate large pieces of rust or scale that may have accumulated in the mine’s water supply. Hook up the water supply and open the Y-strainer flushing valve to clean the screen filter inside strainer. See Figure 6.

Figure 6 – Inlet Water Regulator 1. Water Pressure Gauge - Shows the regulated water pressure. 2. Water Regulator - Regulates mine water pressure to 50 PSI. Turning adjustment IN, decreases the water pressure. Turning the adjustment OUT, increases the water pressure. 3. Ball Valve - Used to clean, or flush the Y-strainer before allowing the mine water supply into the system. A plugged Y-strainer inhibits the water pumps performance and may cause the water pumps overload circuit to trip. 4. Y- Strainer - Used to filter large pieces of rust, or scale from the mine water supply. Inside the unit, a wire mesh screen must be flushed at the beginning of shift.

OM-BLT-O6

Page 7 of 22

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C INLET WATER HOOK-UP (DIESEL BOLTING) During diesel bolting operations, the electric water pump, or booster does not aid the Bolter’s flushing system. For this reason, it is necessary to increase the regulated mine water inlet pressure back to the full mine water pressure, we do this by using the water selector valve. The mine water selector valve is located in the Bolter’s front bumper (see Figure 7 and Figure 8).

Figure 7 – Mine Water Selector

Mine Water Selector

Figure 8 – Mine Water selector location

Page 8 of 22

OM-BLT-O6

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C MINE AIR HOOK-UP (DIESEL BOLTING) During diesel bolting operations, the Bolter’s main electrically driven compressor is not available for the lubrication circuits. For this reason, there is an engine mounted compressor that feeds the drill lubrication system with the required compressed air. There is another alternative setup that allows the use of the mine’s compressed air supply to supply the bolter with compressed air. This setup is used if neither of the on board compressors are available. See Figure 9.

Figure 9 – Mine Air inlet

OM-BLT-O6

Page 9 of 22

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C WORKING PLATFORM SETUP ALL HANDRAILS MUST BE PROPERLY INSTALLED AND SECURED IN PLACE. ALL SAFETY CHAINS MUST BE PROPERLY PLACED ACROSS THE DECK OPENINGS, AND IN GOOD CONDITION. IF CHAIN, LINKS, HOOKS OR ANCHORS APPEAR TO BE WORN STRETCHED OR CRACKED REPAIRS MUST BE COMPLETED BEFORE ANY WORK IS PERFORMED. THE HOOKS MUST BE EQUIPPED WITH A LATCH TO PREVENT INADVERTENT REMOVAL OF SAFETY CHAIN The boom must first be tilted into the vertical position, in order to clear the deck and allow access to the deck wing extensions. Ensure that the wing posts are in position with locks in place and that all safety chains are in place across the openings. See Figure 10. Top Chain

Wing Posts Middle Height Chain

Chains, Links and Hooks

Retaining Pins

Deck Wing

Figure 10 – Deck Extension Wing Assembly POSSIBLE PINCH POINTS EXIST IN THE AREA OF THE BOOM AND HANDRAILS. KEEP CLEAR OF THE BOOM AND HANDRAIL AREA WHEN OPERATING ANY OF THE SCISSOR BOLTER’S BOOM, OR DRILL FUNCTIONS AND THE DECK EXTENSION FUNCTION. Re-arrange any materials on the scissor bolter deck that may have shifted while tramming to the worksite. Good housekeeping will enable you to perform your job in a safe and efficient manner and help to reduce trip hazards on the scissor deck.

Page 10 of 22

OM-BLT-O6

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C DRILL STRING Choose a suitable drill steel and drill bit for the bolting operation to be carried out and install them onto the rockdrill. Our experience has been that threaded button bits work better. For normal rock bolting applications, we recommend the use of 1 1/4" (33mm) button bits with 1" rope (R25) thread. In soft rock, threaded cross bits may also work. The usual drill steel is 1" hex with 1" rope (R25) thread on the bit end and 1 1/4" inch rope (R32) thread on the coupling end. The length varies according to the required length of the drill hole. Some common steel lengths used are 6'10", 7' 9", and 8’ 6". BOOM POSITIONING Using the remote drive system (RDS) the Bolter can be trammed into the working area. Always follow a safe sequence, stay under bolted ground, and start by bolting the back. The scissor deck can now be raised to a comfortable working height (generally 6 to 7 feet from the back) for drilling. Use the TRANSVERSE FEED, TILT, ROLLOVER and CROWD controls to place the drill feed into position for drilling. Depending on the mine’s specific ground control requirements, screen may be required for the back and walls during the drilling and bolting operations. The outriggers must be placed on the ground to level and stabilize the Bolter during drilling and bolting operations. Sting the rubber stinger to the face of the rock to be drilled using the BOOM CROWD control, crowd the drill steel close the rock face using the drill crowd. Refer to section OM-BLT-O4-ECO/HCO for details on the boom controls and to section OM-BLT-07 for details on screen handling.

OM-BLT-O6

Page 11 of 22

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C DRILLING PROCEDURE The actual drilling procedure depends on the ground conditions where the Bolter is used, but MacLean Engineering & Marketing Co. Limited recommends the following basic procedure. With the stinger ‘stung’ to the back: 1. Engage the ROTATION LOCK switch and allow water to flow out of drill bit (ECO). HCO requires the water to be turned on and off manually. 2. Pull up the DRILL IMPACT lever (HCO), or engage the DRILL IMPACT LOCK button (ECO) until the drill percussion starts to hammer. 3. Slowly pull up on the DRILL FEED lever to bring the drill bit in contact with the rock. 4. Feather the DRILL FEED lever to collar the hole. 5. Once the drill bit completely enters the rock, engage the DRILL FEED LOCK button. 6. Assess drill penetration. 7. If required, adjust the feed pressure regulator for optimum performance (generally between 1100 to 1800 psi depending on ground conditions, type of rock drill used and type of feed used, see Table of Hydraulic Drill Settings later in this section). 8. If a hydraulic centralizer is used, open it before drill coupling makes contact. 9. When the hole is finished, shut OFF the DRILL FEED LOCK and DRILL IMPACT functions, and close the hydraulic centralizer. 10. Using the DRILL FEED lever, retract the drill steel from the hole. 11. Return the drill head to the bottom of the drill feed and shut OFF the DRILL ROTATION LOCK function. The drill feed pressure, impact pressure and rotation pressure can all be checked at the operator’s dash. The gauges are located on the main control panel on the deck. Refer to section OM-BLT-O4-ECO/HCO for control panel layout and operation.

Page 12 of 22

OM-BLT-O6

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C Always try to drill perpendicular to the rock face. Ensure that water flow exists before drilling occurs. Failure to have water flow during drilling can cause the drill steel to plug with drill cuttings, and stick in the hole. Ensure lubrication of the front head of the drill is ON while drilling. In badly fractured ground, it is a good idea to run the drill steel up the hole a few times with the drill rotation ON, to clear it. Always keep the drill steel lined up with the shank adaptor (striking bar) of the drill. Drilling off-line causes excess wear on drill string and decreases penetration rate. To loosen the drill string, shut OFF the drill rotation function and let the impact mechanism hammer for about 5 seconds. After a while, you are able to tell that the bit is loose by the change in frequency of the sound. NEVER ROTATE THE DRILL STEEL WHILE HOLDING THE BIT WITH YOUR HAND.

OM-BLT-O6

Page 13 of 22

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C ROCKDRILL 1 2 3 4

Figure 11 – Typical Hydraulic Rockdrill 1. Accumulators - The high and low-pressure accumulators are comprised of nitrogen gas on one side of a rubber diaphragm. They act as shock absorbers for the hydraulic system. The rubber diaphragms tend to rupture on a periodic basis and may need to be replaced and recharged with nitrogen. If you notice the drill impact hoses vibrating violently, the high-pressure accumulator may need recharging. As you gain experience with the drill, you start to notice when this occurs. The accumulators must be checked on regular intervals by using the impact hour meter as a reference. Recharging of accumulators must be done by qualified mechanical personnel only. 2. Water Flushing Seals - Always monitor the drill to ensure that the water seals are in good shape. If there is water coming out of the drill at its front head (flushing cover), this is usually an indication that these seals are defective and must be replaced. 3. Rubber Cap/Protector - Covers the front head of the rock drill. The rubber cap/protector helps to keep cuttings out of the drill thereby lengthening its service life. The rubber protector is necessary to prevent debris/cuttings from entering the unit. DO NOT RUN THE DRILL PERCUSSION (HAMMER) WITHOUT TOUCHING THE DRILL BIT FIRMLY AGAINST THE ROCK, UNLESS TAKING OFF A DRILL BIT. SEVERE DAMAGE TO THE DRILL PISTON MAY OCCUR. 4. Lubrication - Ensure that the drill’s oil lubrication is functional when the drill rotation is engaged. Failure to have the drill’s oil lubrication may cause premature wear of the drill and significantly reduce the useful life of the drill. Refer to section OM-BLT-O13 if the Bolter is equipped with a drill lubrication system.

Page 14 of 22

OM-BLT-O6

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C PRESSURE SETTINGS When drilling, the pressure settings of the drilling equipment must be checked to ensure that they are set for optimum drill performance. Every model of drill has different pressure and flow requirements. The following table is subject to manufacturer’s changes and is for reference only.

TABLE OF HYDRAULIC DRILL SETTINGS SIG HBM 50

SIG HBM 120

ATLAS COPCO 1032

ATLAS COPCO 1238ME

MONTABERT HC-40

Impact Pressure (PSI)

3000

3000

3000

3000

1500 - 1700

Maximum Rotation Pressure (PSI)

2000

2000

2000

2000

2000

YES

NO

YES

YES

YES

NO

YES

NO

NO

NO

TAMROCK HL-538

TAMROCK HL-500

SECOMA HYDRASTAR 200

SECOMA HYDRASTAR 300

FURUKAWA HD30

Impact Pressure (PSI)

2500

2500

2350

2350 – 2600

2400

Maximum Rotation Pressure (PSI)

2000

2000

2000

2000

2000

Independent Rotation

YES

YES

YES

YES

YES

Internal Anti-Jam

NO

NO

NO

NO

NO

FURUKAWA HD90

FURUKAWA HD150

BOART HD65

ATLAS COPCO 1432

GARDNERDENVER HPR-H

Impact Pressure (PSI)

2200

2600

2200

2600

3000

Maximum Rotation Pressure (PSI)

2000

2000

2000

2000

2000

Independent Rotation

YES

YES

N/A

YES

N/A

Internal Anti-Jam

NO

NO

N/A

NO

N/A

ITEM

Independent Rotation

Internal Anti-Jam

ITEM

ITEM

N/A = Not Available

OM-BLT-O6

Page 15 of 22

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C

ANSWERS TO SOME COMMON DRILLING QUESTIONS Q - The Rockdrill hoses are vibrating badly and the drill seems to be drilling slower. A - The accumulator diaphragms may have ruptured. They must be replaced and recharged. Q - The Rockdrill is drilling slowly. A - Make sure that the bit, and threads on drill steel, coupling and shank adapter are in good shape before checking anything else. A - Check the hydraulic drill comparison chart to make sure the correct impact and rotation pressures are met. The feed pressure must be enough so that the drill does not bounce but not so much as to bind the steel and slow down the rotation. Q – Rockdrill penetration stops suddenly. The hammer and rotation are working proper. I have checked the bit, steel and shank adapter. What could be the problem? A - Check that drill feed chain is adjusted properly. Too much slack here can cause it to jam between the sprocket and idler wheel. Also check to ensure that the feed rail is not bent, causing excess friction. Ensure that the hydraulic hoses going to the drill are not pinched as this partially cuts off oil flow to the drill. Check for loose, or jammed rock cuttings in the feed’s rail. Q - The drill impact, feed and rotation locks do not function. The drill impact, feed and rotation functions do function manually (with the hydraulic valve handles) but the functions do not work when the push buttons are used. A - Check to see whether the lubricator pump is operating. If it is not functioning then there is likely insufficient air pressure, or insufficient oil level in the lubricator. If the boom is tilted in towards 55° of the deck platform, then the tilt interlock system is interlocking the drill feed and rotation locks. Attempt to reposition the Scissor Bolter so that the boom is angled out from the deck greater than 55°.

Page 16 of 22

OM-BLT-O6

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C

LONGHOLE DRILLING PROCEDURE MacLean Engineering & Marketing Co. Limited recommends the following procedure for longhole drilling with the MEM-928/946 ECO/HCO Scissor Bolters. Mine specific regulations and procedures may vary. Always follow mine specific regulations and procedures with regards to longhole drilling. Some MEM-928/946 Scissor Bolters have an optional longhole centralizer to facilitate drilling holes for cable bolting applications.

Centralizer Jaws

Figure 12 – Typical Hydraulic Centralizer DO NOT ATTEMPT TO DRILL THESE LONGER HOLES WITHOUT THIS SPECIAL CENTRALIZER, AS IT CAN BE VERY DANGEROUS TO DO SO. ALWAYS INSPECT AND ENSURE THAT THE HYDRAULIC CENTRALIZER IS WORKING PROPERLY, FREE OF HYDRAULIC LEAKS AND ENSURE THAT THE JAWS ARE IN GOOD CONDITION. Prior to setting up to drill long holes with the 928/946 Scissor Bolter, the operator must do a complete initial inspection of the bolter to ensure that it is in good operating condition. The operator must then do an initial inspection of the work area to ensure it is safe to work in the area to be drilled. The operator can now set up the bolter for drilling doing so as he would for standard operations of the bolter. 1. We highly recommend the use of male/female “M/F” type drill rods. These are easier to use and give better penetration than standard drill rods and couplings. The initial drill rod on the bolter is recommended to be an 8 foot length. The rest of the drill string rods can be 6 feet lengths. 2. Install the correct striking bar on the drill to match the thread size of the M/F drill rods.

OM-BLT-O6

Page 17 of 22

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C 3. If there is a fixed drill centralizer on the bolter as well as a hydraulic centralizer, the insert on the fixed centralizer must be removed to allow the coupling end of the M/F rods to pass through it when drilling the longer holes. See Figure 13. Fixed Centralizer Insert

Fixed Centralizer

Figure 13 – Typical Fixed Centralizer 4. Raise the drill tower into the drilling position. 5. To install the drill steel onto the drill: a) Select the correct size drill bit and screw it counter-clockwise onto the drill steel. b) Open the hydraulic centralizer jaws from the console controls. See Figure 16. c) Advance the sliding deck to the drill tower. d) Place the drill steel onto the striker bar and manually screw the drill steel counter-

clockwise onto the drill. e) Using the remote pendant, close the hydraulic centralizer jaws around the drill

steel. f) Retract the sliding deck away from the drill tower.

NEVER HOLD THE DRILL STEEL WITH YOUR HAND WHILE IT IS ROTATING. ALSO, WHEN CHANGING BITS, REMOVE THE USED ONE BY HAND AND PUT ON A NEW ONE ON BY HAND. 6. Lower the outriggers to stabilize the vehicle. Adjust the drill boom and slide to the desired position for drilling. 7. Sting the boom to the back, collar the drill hole about 4 – 5 inches, then open the hydraulic centralizer jaws. This prevents premature wearing of the centralizer jaws. 8. Drill the length of the steel, allowing the coupling of the M/F rod to enter the centralizer so it can be clamped in the jaws to allow for adding additional rods. See Figure 14. Following the Drilling procedure as outlined in the Operator’s Manual.

Page 18 of 22

OM-BLT-O6

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C

Figure 14 – Typical M/F Rod Coupling 9. Stop the drill feed, drill impact, and drill steel rotation functions. 10. To loosen the striker bar from the drill rods: •

On the ECO model, activate the rod rattle by pushing the DRILL ROD RATTLE button on the drill dash for about 5 seconds. See Figure 15.

•

On the HCO model, activate the drill impact lever for about 5 seconds. You will hear the sound of the drill rod loosening. See Figure 15.

Rod Rattle Button (ECO)

Drill Impact Lever (HCO)

Figure 15 – Typical ECO/HCO Drill Rod Release Functions 11. Close the hydraulic centralizer jaws over the coupling using the DRILL ROD CLAMP switch on the drill console. See Figure 16. Turning the switch to the right locks the centralizer jaws, and provides constant hydraulic pressure to the jaws. This also disables the centralizer toggle switch on the remote pendant. Turning the switch to the left releases the constant pressure from the jaws and unlocks the centralizer jaws.

Figure 16 – Typical Drill Rod Clamp Button

OM-BLT-O6

Page 19 of 22

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C 12. To disconnect the drill from the rods. a) Rotate the drill steel clockwise and slowly retract the drill feed. b) Once the drill steel is disconnected from the drill rod in the centralizer jaws,

lower the drill to the bottom of the slide. c) Advance the deck to the drill tower.

13. Screw the new drill rod on to the steel in the centralizer jaws by hand. 14. Using the remote pendant, bring the drill up slowly until it comes in contact with the drill rod. 15. Retract the deck away from the drill tower. NEVER USE THE DRILL ROTATION FUNCTION WHILE HOLDING THE DRILL STEEL. PERSONAL INJURY, OR DEATH MAY OCCUR. 16. Return to the drill console and rotate the drill steel counter-clockwise using the drill rotation, to thread on the new drill rod. 17. Turn the DRILL ROD CLAMP switch to the left to unlock the drill rod clamp and open the hydraulic centralizer. 18. Start the drill rotation function and wait for water to start coming out of the drill hole. 19. Start the IMPACT and DRILL FEED function to continue drilling the next rod. 20. Continue adding drill rods as necessary to get the drill hole to the required depth. 21. When the drill hole is completed, stop the drill feed, rotation and impact functions. 22. Lower the drill rods a couple of inches, and activate the DRILL ROD RATTLE switch (for ECO models), or the DRILL IMPACT lever (for HCO models) and rattle the drill string for about 5 seconds. You will hear the rods loosen by the sound change. See Figure 15. 23. Lower the drill string until the coupling between the first two drill rods enters the hydraulic centralizer jaws. 24. Stop the drill feed and clamp the coupling in the centralizer using the DRILL ROD CLAMP switch. See Figure 16. 25. Rotate the drill clockwise and lower the drill using the drill feed to disconnect the drill from the drill rods. Lower the drill away from the rods. 26. Advance the deck to the drill tower, go to the drill, and manually unscrew the drill rod from the drill string. The remote pendant is not required for this function. 27. Place the removed drill rod in a safe place and return to the drill console.

Page 20 of 22

OM-BLT-O6

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C 28. Retract the deck and advance the drill up to the coupling in the centralizer and rotate the striker bar counter-clockwise to attach to the drill string. Do not screw the striker bar all the way into the coupling. 29. Open the centralizer by turning the DRILL ROD CLAMP switch to the left. 30. Lower the drill string to the next coupling on the string and close the centralizer jaws using the DRILL ROD CLAMP switch. Continue doing this step-by-step until the drill string is retracted from the drill hole.

Notes:

OM-BLT-O6

Page 21 of 22

Title: DRILLING PROCEDURE Number: OM-BLT-O6 Revision: C

Notes:

If any questions or problems arise, please contact MacLean Engineering Technical Service for assistance. Phone: 1-866-856-3626 Email: [email protected]

Page 22 of 22

OM-BLT-O6

Number: Revision: Revision Date: By: Topic:

OM-BLT-O7 ORIGINAL 08/16/01 ELL/IFL SCREEN HANDLING PROCEDURE

SCREEN HANDLING PROCEDURE The MEM-928/946 Scissor Bolters handling design is such that one person can handle and install sheets of welded wire screen. Both guardrails have screen hooks that can carry approximately 10 sheets of 5’ by 11’ welded wire mesh screen. Once the rig is set up in the workplace, we recommend the following basic procedure for installing screen: •

Position Boom in the area for drilling the next hole.

•

Position stinger close to the rock face but leave enough room to slip the screen in behind.

•

Remove the next sheet of screen from the hangers.

•

Place screen halfway across the stinger, between the back and the stinger face. The screen should now be draped over the rubber stinger. Extend the drill crowd until the drill steel protrudes through the screen, acting as a second hand. The screen can now be rotated into position.

•

Keeping one hand on the screen to stabilize it, use the pendent to manipulate the Boom to the exact position and adjust screen. Use the pivot ‘crowd’ (pendent control) to press the stinger against the back; this will hold the screen in position until ground support is installed.

CAUTION: Avoid possible pinch point with hand when pushing screen against back. •

Drilling may now be carried out Use caution when positioning the drill. Ensure that the drill steel will move through one of the openings of the wire mesh.

Page 1 of 2

Number: OM-BLT-O7 Revision: Original

Page 2 of 2

Number: Revision: Revision Date: By: Topic:

OM-BLT-O8 ORIGINAL 08/16/01 ELL ROCKBOLT INSTALLATION

ROCKBOLT INSTALLATION PROCEDURE To install a mechanical rockbolt, MacLean Engineering & Marketing Co. Limited recommends the following basic procedure. Depending on the mine’s specific ground control requirements, screen may be required for the back and walls during the drilling and bolting operations (Reference section OM-BLT-O7 of Operator’s Manual for Screen Handling Procedure). Follow recommended Drilling Procedure (Reference section OM-BLT-O6 of Operator’s Manual for Drilling Procedure): 1. Use the ‘cradle pivot’ lever to move the bolt feed into position under the position for the hole. 2. Use the ‘bolt centralizer’ lever to swing the bolt holding centralizer into position. 3. Place one end of the rockbolt into the dolly and the other end into the clips of the centralizer. 4. Use the ‘cradle pivot’ lever to move the bolt feed out of position and move the drill feed into position. 5. Drill the hole to the proper depth as per the recommended Drilling Procedure. 6. Use the ‘cradle pivot’ lever to rotate the drill feed out of the way and to position rockbolt underneath the hole. 7. Use the ‘bolt feed’ lever to start pushing the rockbolt into the hole. 8. Use the ‘bolt centralizer’ lever to swing the bolt holding centralizer out of the way. 9. Use the ‘bolt feed’ lever to push the rockbolt firmly against the rock.

Page 1 of 2

Number: OM-BLT-O8 Revision: ORIGINAL 10. Release the ‘bolt feed’ lever and use the ‘bolt rotation’ lever to start tightening the rock bolt. As the rockbolt tightens, it may be necessary to “jog” the ‘bolt feed’ lever to ensure the bolt drive dolly remains engaged with the rockbolt. Never hold the ‘bolt feed’ lever while tightening the rockbolt. The friction created between the bolt drive dolly face and the rockbolt’s washer may not allow the rockbolt to be tightened to its necessary torque specification. 11. Once the rock bolt has been tightened (stalls the bolt rotation), release the ‘bolt rotation’ lever. 12. Engage the ‘bolt feed’ lever in the reverse direction to return the bolting head to the bottom of the bolt feed. 13. Continue this procedure for the next bolt to be installed.

WARNING: Always ensure that the rubber protector for the rotation head or combihead/split-set driver is in place on its shank rod. The rubber protector is necessary to prevent debris/cuttings from entering the unit. The rubber protector must be in place on the shank rod and in good condition otherwise damage to the rotation head or combi head/split-set driver will be incurred. Reference section OM-BLT-O12 of the Operator’s Manual for Bolting Options and Operations.

Page 2 of 2

Number: Revision: Revision Date: By: Topic:

OM-BLT-O9 ORIGINAL 08/16/01 ELL REBAR INSTALLATION

REBAR INSTALLATION PROCEDURE To install a rebar, MacLean Engineering & Marketing Co. Limited recommends the following basic procedure. Depending on the mine’s specific ground control requirements, screen may be required for the back and walls during the drilling and bolting operations (Reference section OM-BLT-O7 of Operator’s Manual for Screen Handling Procedure). Follow recommended Drilling Procedure (Reference section OM-BLT-O6 of Operator’s Manual for Drilling Procedure): 1. Use the ‘cradle pivot’ lever to move the bolt feed into position under the position for the hole. 2. Use the ‘bolt centralizer’ lever to swing the rebar holding centralizer into position. 3. Using rebar of proper length, place washer over rebar and place one end of the rebar into the dolly and the other end into the clips of the centralizer. 4. Use the ‘cradle pivot’ lever to move the bolt feed out of position and move the drill feed into position. 5. Drill the hole to the proper depth as per the recommended Drilling Procedure. 6. Use the ‘cradle pivot’ lever to pivot the drill feed away from the hole but stop the pivoting short of lining up the bolt feed under the hole. Having the feeds partially pivoted will allow access to the hole, which is required when loading the resin cartridges. 7. Load the required resin cartridge into the Resin Cartridge Installation Tool. The type of resin cartridges to be used and the order in which they are to be used is determined by the mine’s Ground Control office.

Page 1 of 4

Number: OM-BLT-O9 Revision: ORIGINAL 8. Place Resin Cartridge Installation Tool up to the rock face and line it up with the drilled hole. Using the plunger in the tool, push the resin cartridge as far into the hole as the plunger will allow. Be careful not to hook or catch the resin cartridge on any sharp surfaces (i.e. – screen), as this will tear open the cartridge, spill the contents and not allow full installation of the cartridge. The resin cartridges should have some sort of device on them to hold the cartridges in the hole. If not, an anchor device may have to be placed onto the cartridge prior to installation. 9. Install any remaining resin cartridges for the hole in the same manner. 10. Use the ‘cradle pivot’ lever to rotate the drill feed out of the way and to position the bolt feed underneath the hole. 11. Use the ‘bolt feed’ lever to start pushing the rebar into the hole. Some rebar installations may require rotation of the rebar while pushing up the hole through the resin cartridges. This requirement is determined by the mine’s Ground Control office. Rotation of the rebar can be carried out by engaging the ‘bolt rotation’ lever while pushing the rebar into the hole. 12. Use the ‘bolt centralizer’ lever to swing the rebar holding centralizer out of the way. 13. Use the ‘bolt feed’ lever to push the rebar properly into the hole, placing the rebar’s washer firmly against the rock, and then release the ‘bolt feed’ lever. 14. Once the rebar has been properly pushed into the hole, spin the rebar for the necessary length of time to mix the resin. The mine’s Ground Control office will determine the proper amount of mixing required. 15. Wait for the necessary length of time to allow the resin to harden.

The mine’s Ground Control office will determine the proper waiting period.

Page 2 of 4

Number: OM-BLT-O9 Revision: ORIGINAL 16. Use the ‘bolt rotation’ lever to start tightening the rebar nut. As the rebar nut tightens, it may be necessary to “jog” the ‘bolt feed’ lever to ensure the bolt drive dolly remains engaged with the rebar nut. Never hold the ‘bolt feed’ lever while tightening the nut. The friction created between the bolt drive dolly face and the rebar’s washer may not allow the rebar to be tightened to its necessary torque specification. 17. Once the rebar nut has been tightened (stalls the bolt rotation), release the ‘bolt rotation’ lever. 18. Engage the ‘bolt feed’ lever in the reverse direction to return the bolting head to the bottom of the bolt feed. 19. Continue this procedure for the next rebar to be installed.

WARNING: Always ensure that the rubber protector for the rotation head or combihead/split -set driver is in place on its shank rod. The rubber protector is necessary to prevent debris/cuttings from entering the unit. The rubber protector must be in place on the shank rod and in good condition otherwise damage to the rotation head or combi head/split-set driver will be incurred. Reference section OM-BLT-O12 of the Operator’s Manual for Bolting Options and Operation.

Page 3 of 4

Number: OM-BLT-O9 Revision: ORIGINAL

Page 4 of 4

Number: Revision: Revision Date: By: Topic:

OM-BLT-O10 ORIGINAL 08/16/01 ELL SPLIT SET INSTALLATION

SPLIT SET INSTALLATION PROCEDURE To install a split set, MacLean Engineering & Marketing Co. Limited recommends the following basic procedure.

Figure 1 – Split-Set Option

When installing spilt sets, the drive dolly used will be different than that used for rockbolt installation (Reference section OM-BLT-O7 of Operator’s Manual for Screen Handling Procedure). Follow recommended Drilling Procedure (Reference section OM-BLT-O6 of Operator’s Manual for Drilling Procedure): 1. Use the ‘cradle pivot’ lever to move the bolt feed into position under the position for the hole. 2. Use the ‘bolt centralizer’ lever to swing the bolt holding centralizer into position. 3. Place one end of the split set into the drive dolly and the other end into the clips of the centralizer. 4. Use the ‘cradle pivot’ lever to move the bolt feed out of position and move the drill feed into position. 5. Drill the hole to the proper depth as per the recommended Drilling Procedure. 6. Use the ‘cradle pivot’ lever to rotate the drill feed out of the way and to position split set underneath the hole.

Page 1 of 2

Number: OM-BLT-O10 Revision: ORIGINAL 7. Use the ‘bolt feed’ lever to start pushing the split set into the hole. 8. Use the ‘bolt centralizer’ lever to swing the split set holding centralizer out of the way. 9. Use the ‘bolt feed’ and ‘bolt impact’ levers to push the split set firmly into the rock. 10. Once the split set has been driven sufficiently into the rock, release the ‘bolt feed’ and ‘bolt impact’ levers. 11. Reverse the ‘bolt feed’ lever to return the drive head to the bottom of the bolt feed. 12. Continue this procedure for the next split set to be installed.

WARNING: Always ensure that the rubber protector for the combi-head/split -set driver is in place on its shank rod. The rubber protector is necessary to prevent debris/cuttings from entering the unit. The rubber protector must be in place on the shank rod and in good condition otherwise damage to the combi head/split-set driver will be incurred. Reference section OM-BLT-O12 of Operator’s Manual for Bolting Options and Operations.

Page 2 of 2

Number: Revision: Revision Date: By: Topic:

OM-BLT-O11 ORIGINAL 08/16/01 ELL SWELLEX BOLT INSTALLATION

SWELLEX BOLT INSTALLATION PROCEDURE To install Swellex bolts, MacLean Engineering & Marketing Co. Limited recommends the following basic procedure. Depending on the mine's specific ground control requirements, screen may be required for the back and walls during the drilling and bolting operations (Reference section OMBLT-O7 of Operator’s Manual for Screen Handling Procedure).

Figure 1 – Swellex Tool Follow recommended Drilling Procedure be as follows (Reference section OM-BLT-O6 of Operator’s Manual for Drilling Procedure): 1. Drill the hole to required depth to accommodate the bolt to be installed. 2. Once hole is drill to depth and during retraction it may be necessary to run drill steel back into the hole to ensure that it is free of any obstructions. Depending on the ground conditions. 3. Once the drill is retracted all the way back, it may be necessary to move drill crowd back in order to clear the screen prior to pivoting into bolt feed position.

Page 1 of 2

Number: OM-BLT-O11 Revision: ORIGINAL 4. Place Swellex bolt partially into the drilled hole before feeding Swellex dolly onto the head of the bolt. It is necessary to hold on to the bolt to help line up and to make sure that it is properly inserted into the Swellex chuck.

WARNING: Do not engage the Bolt Rotation function when installing Swellex bolts. 5. The bolt can then be fed all the way into the hole. Apply some bolt feed pressure to secure the screen as tight as possible to the rock face.

WARNING: Never use impact function in the case where a Combi-Head is in use, this will cause damage to the seals inside the Swellex chuck. 6. Start up Swellex pump to pump up maximum pressure required to allow for maximum advantage of the friction bolt. The minimum pressure to be applied into the swellex bolt will be determined by the mine’s Ground Control Office. In order to pump water into the Swellex bolt, the Swellex valve handle is pulled upwards. Releasing the valve handle and letting it drop to its lower position releases water.

WARNING: Always ensure that the rubber protector for the rotation head or combihead/split -set driver is in place on its shank rod. The rubber protector is necessary to prevent debris/cuttings from entering the unit. The rubber protector must be in place on the shank rod and in good condition otherwise damage to the rotation head or combi head/split-set driver will be incurred. Reference section OM-BLT-O12 of Operator’s Manual for Bolting Options and Operations.

Page 2 of 2

Number: Revision: Revision Date: By: Topic:

OM-BLT-012-ECO A 07/24/02 ELL Bolting Options & Operations

BOLTING OPTIONS The MEM-928/946 Scissor Bolter is equipped with one of two bolting options: a Rotation Head or a Combination Head. The Rotation Head allows for the installation of rockbolts, rebar and Swellex. The Combination Head allows for the installation of rockbolts, rebar, Swellex and split-sets. Both are controlled by the Bolt Feed valve handle for feeding along the bolt feed. Both are controlled by the Bolt Rotation valve handle for rotation or rotation and impact. Figure 1 illustrates the typical Rotation Head assembly and Figure 2 illustrates the typical Combination Head assembly. BOLT DOLLY / SPLIT SET DRIVER – Depending on Ground support being used two options are available: BOLT DOLLY – Used to provide rotational torque when installing various types of ground support. A swellex adapter may be installed directly onto the dolly when required. A Bolt dolly is shown in Figure 1.

Figure 1 – Rotation Head Assembly

Page 1 of 8

Number: OM-BLT-012-ECO Revision: A COMBI HEAD – Combination of hydraulic drill that provides percussion for installing Split Sets and a rotation head to torque various types of ground support. The swellex adapter can be installed directly into the Combi head when required. A Combi Head is shown in Figure 2.

Figure 2 – Combination Head Assembly 1. 2. 3. 4. 5. 6.

Hydraulic Motor Housing Rubber Umbrella Shank rod retainer Shank Rod Dolly

7. Dolly Extension 8. Swellex Adapter 9. Combi Head 10. Split-Set Driver 11. Bolt Dolly Assembly

WARNING: Never come into contact with the Bolt Dolly or Combi head for any reason while in operation. Always shut down Bolter before changing dolly option. Combi Head is equipped with charged gas accumulators.

Page 2 of 8

Number: OM-BLT-012-ECO Revision: A

WARNING: Always ensure that the umbrella (rubber protector) for the unit is in place on the shank rod. The umbrella is necessary to prevent debris/cuttings from entering the unit. The umbrella must be in place on the shank rod and be in good condition otherwise damage to the rotation head or combination head will be incurred.

BOLTING CONTROLS AND OPERATION Figures 3 and 4 illustrate the controls used for the installation of Ground Support. 1

3

4

2

5 6

Figure 3 – Deck Control Panel

Page 3 of 8

Number: OM-BLT-012-ECO Revision: A

Figure 4 – Control Console 1. DRILL IMPACT (LEVER DOWN) – Lever used for operating Combi Head option Impact function. The Impact pressure gauge (2) will indicate operating pressure. 2. DRILL IMPACT PRESSURE – Gauge indicates pressure for Impact function. Pressure gauge should read 3000psi when operating Combi Head for installing SplitSet. 3. BOLT ROTATION – Lever used to operate Bolt rotation Clockwise (Lever Down) and Bolt Rotation Counter Clockwise (Lever Up) functions. The Rotation Torque is adjusted by regulator (5) for CCW and (6) for CW rotation. The Rotation pressure gauge (4) will indicate operating pressure. 4. BOLT ROTATION PRESSURE – Gauge indicates Bolt Rotation pressure 5. BOLT ROTATION PRESSURE REGULATOR CCW – Regulator adjusts the maximum operating pressure used for the Bolt Rotation function CCW. Refer to TORQUE ADJUSTMENTS in this section of operators’ manual for pressure settings.

Page 4 of 8

Number: OM-BLT-012-ECO Revision: A 6. BOLT ROTATION PRESSURE REGULATOR CW - Regulator adjusts the maximum operating pressure used for the Bolt Rotation function CW. Refer to TORQUE ADJUSTMENTS in this section of operators’ manual for pressure settings. 7. BOLT CENTRALIZER – Joystick used to operate the Bolt Centralizer. “UP” on the Joystick will lift the centralizer out of the Bolt Dolly’s / Combi Head’s path. “Down” on the Joystick will Lower the Centralizer in preparation for inserting the next Bolt. 8. BOLT FEED – Joystick used to operate the Bolt feed function. “UP” on the joystick will feed the Rotation Head / Combi Head Forward.(Toward Bolt Centralizer) “DOWN on the Joystick will move the Bolt Dolly / Combi Head in the Backwards direction. (Away from Bolt Centralizer) 9. BOLT ROTATION – Joystick used to operate the Bolt Rotation Function. “UP” on the Joystick will rotate Bolt Dolly / Combi Head in a CCW direction. Down on the Joystick will rotate the Bolt Dolly / Combi Head in the CW direction. If the Bolt / Impact selector is energized the Bolt Rotation function will be used for Bolt Impact. (Refer to Section OM-BOLTER-O4 for more information on Functions 7, 8 and 9) Both the Rotation Head and Combination Head assemblies use shank rods and dollies for bolting tools, many variations of these tools exist. Refer to Dolly Matrix (#1010422) for a listing of these tools.

TORQUE ADJUSTMENT Both the Rotation Head and Combi Head can be calibrated using the "rotation pressure - torque charts" provided below. The following describes the adjustment process for the two bolting options: 1. Place the dolly on a pre-tightened bolt in the rock cut. 2. Engage the CCW Bolt Rotation by lifting the bolt rotation control handle. Bolt Feed must be released when the final torque is being applied to the bolt. Bolt feed pressure adds an element of friction between the dolly and the bolt washer plate that will lessen the achievable torque on the bolt, resulting in improper bolt torques. 3. Determine the correct pressure using the "rotation pressure-torque chart" (see Figure 5 and 6).

Page 5 of 8

Number: OM-BLT-012-ECO Revision: A

These values are approximate. Rotation Pressure (Psi)

Motor Torque (ft.lbs)

Rotation Pressure (Psi)

Motor Torque (ft.lbs)

250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000

32 63 95 127 158 190 221 253 285 317 349 380

250 500 750 1000 1250 1500 1750 2000

26 52 78 104 130 156 182 208

Figure 6 – Combi Head Motor

Figure 5 – Rotation Head Motor 4. While the ‘bolt rotation control’ is engaged, observe the ‘bolt rotation pressure gauge’ and adjust the ‘bolt rotation regulator’ to the required pressure. 5. Once the desired pressure has been set remove the bolting head from the bolt. 6. Check the torque on the bolt using a torque wrench. 7. Continue adjusting the Bolt Rotation pressure until the desired torque is achieved.

Ground Control will determine the torque specification for support.

Page 6 of 8

Number: OM-BLT-012-ECO Revision: A

WARNING: If the machine’s TIS is compromised, the drill impact, feed and rotation lock interlock will also be compromised and the result may be the advancement of the drill steel into the operator’s compartment when the boom is in the tramming position.

Inspection of the TIS and removal of the drill steel during tramming will prevent drill steel advancement into the operator’s compartment from occurring.

Page 7 of 8

Number: OM-BLT-012-ECO Revision: A

Page 8 of 8

Number: Revision: Revision Date: By: Topic:

OM-BLT-O13 ORIGINAL 08/16/01 SJC Drill Lubrication System

DRILL LUBRICATION SYSTEM The MEM-928/946 Scissor Bolter is equipped with a rock drill lubrication system which is used to lubricate the fronthead of the rock drill on the Scissor Bolter. The lubrication system is also used to lubricate the transverse feed’s chain and the Combination Head if the Scissor Bolter is equipped with the Combination Head option. This lubrication system is located at the end of the deck’s control console. The drill lubrication system supplies atomized oil to the fronthead of the rock drill. The system also provides a means of pressurizing the fronthead of the drill with air pressure to restrict drill cuttings and water from entering the fronthead. Air Pressure Switch

Reservoir and Filler/Breather

Pressure Regulator

Oil Level Sensor Switch

Capillary Tube

Figure 1 - Drill Lube Pump System The drill lubrication system works by pumping a metered supply of oil into the air stream leading to the fronthead of the drill. The amount of oil that enters the air stream is approximately 1/10th of a litre per hour. The air pressure for carrying the oil to the fronthead is generally regulated to 35 to 40 PSI. The pressure switch in the system monitors the air pressure; if the air pressure falls below 25 PSI, the drill feed and rotation locks (electrical detents) will be disabled, preventing the operator from drilling. If the drill fails to operate, make certain there is air pressure of at least 25 PSI from the regulator.

Page 1 of 2

Number: OM-BLT-O13 Revision: ORIGINAL

An oil level switch is also incorporated into the drill lube system. This switch is a capacity proximity sensor that if adjusted correctly, will determine if the oil in the pump reservoir has fallen below an acceptable level. If the oil level drops below that acceptable level, once again the drill feed and rotation locks will be disabled. Because the air pressure switch and oil level sensor are wired into the drill feed and rotation locks, the daily inspection of the Scissor Bolter’s Tilt Interlock System (TIS) must be carried out with the electrical powerpack powering the Bolter. The operator must ensure that the drill lubrication pump is operational before testing the TIS this will help ensure that the drill feed and rotation locks are non-functional due to the safety of the TIS and not because there is a lack of oil or air. The inspection of the TIS includes testing of the drill feed and rotation locks to ensure that they are non-functional when the boom is tilted in close to the deck. Please refer to the Control and Functional Modes section of this Operator’s Manual and the Tilt Interlock System Inspection Maintenance Bulletin for more information. The pump system (generally used in a grease application) has a paddle that revolves around inside the reservoir (to wipe the grease down from the sides of the bowl in a grease pumping application). The paddle provides a means to determine that the pump is operating; if the paddle is revolving, the pump is operating. As the pump piston reciprocates, rock drill oil is forced through a small capillary tube placed inside the airline for a distance. The air then picks up the oil from the output of the capillary tube and carries it to the fronthead of the rockdrill. The lubricator unit should be filled at the beginning of each shift with rock drill oil. For Scissor Bolters using a Rotation Head for the installation of rockbolts, rebar and Swellex, the lubrication is set to default to the rock drill. The lubrication will switch to the transverse feed chain when the transverse is operated. For units using a Combination Head for the installation of rockbolts, rebar, Swellex and splitsets, the lubrication is set to default to the Combination Head. The lubrication will switch to the rock drill whenever the rock drill is operated. The lubrication will switch to the transverse feed chain when the transverse is operated.

Page 2 of 2

Number: Revision: Revision Date: By: Topic:

OM-BLT-O14-ECO Original 01/13/2004 D_C SCISSOR BOLTER RADIO REMOTE PENDANT OPERATION

RADIO REMOTE PENDANT OPERATION This section of the 928/946 Scissor Bolter Operator Manual outlines the function and usage of the Radio Remote Pendant System. The Radio Remote Pendant System on the 928/946 Scissor Bolter is used as an alternative to the control panel on the deck control console or to an optional hardwired pendant. It allows for the bolting of the screen to be controlled from a position closer to the boom than the deck control console allows. Figures 1 & 2 illustrate a typical Radio Remote Pendant System. Transmitter Pendant

Radio Receiver Box

Radio Bypass Selector

Figure 1 – Typical Radio Remote Pendant System The Radio Remote Pendant System consists of a radio receiver box, a transmitter pendant and a radio bypass selector switch box. The transmitter pendant sends radio signal(s) to the radio receiver box that in turn controls the boom/bolt function(s). The radio bypass selector switch is used to bypass the transmitter pendant E-Stop and to disable functions in the “off” position when it is not being used, especially, when tramming on diesel to prevent machine E-Stop shutdown if the transmitter battery becomes discharged. The momentary ‘start’ position allows the transmitter pendant E-Stop to be bypassed while the radio receiver box powers up and until an ‘E-Stop

Page 1 of 4

Number: OM-BLT-O14-ECO Revision: Original pulled out’ signal is received from the transmitter pendant. During the maintained ‘on’ position the transmitter pendant E-Stop and other functions are operable. After the master-switch has been turned off, the radio bypass selector switch must be placed in the ‘off’ position before 24 VDC power can be turned on again. The transmitter pendant consists of an ‘E-Stop’ button, a ‘Bolt/Boom’ toggle switch and seven other toggle switches which can be used to control boom, bolt, deck and scissor functions. It also has a full length ‘safety bar’ located on the top edge of the transmitter. This is a push-to-operate (PTO) safety bar that electronically disconnects all toggle switches when it is released. Therefore, the PTO safety bar must be pressed in order to activate any function through the toggle switches. The ‘E-Stop’ button is used to shutdown the machine in the event of an emergency situation. To activate the ‘E-Stop’ button, simply depress the mushroom cap of the pushbutton. This pushbutton should ‘lock down’ into place and maintain the ‘E-Stop’ state. To de-activate the ‘E-Stop’, the mushroom cap pushbutton should be twisted clockwise and it should then ‘pop up’ and return to its ‘up’ position. E-Stop Button

Bolt/Boom Toggle PTO Safety Bar

Function Toggles

Figure 2 – Typical Transmitter Pendant The ‘Bolt/Boom’ toggle is a maintained style toggle switch, which allows the operator to place the Control System into Bolt or Boom mode. This toggle switch should remain in position once selected, for example, once placed in the ‘Boom’ position the switch should maintain this position unless the toggle is moved to the ‘Bolt’ position.

Page 2 of 4

Number: OM-BLT-O14-ECO Revision: Original The other seven toggle switches on the transmitter pendant are used to control the below-mentioned Bolt/Boom functions. These toggle switches are momentary style switches, meaning they should return to their central neutral position when not being pressed. The switches must be pressed in the desired direction for the function to be activated. While in Bolt mode, the following seven functions can be controlled with the pendant: • • • • • • •

Bolt Feed (fwd/rev) Bolt Rotation (clockwise/counterclockwise) Drill Centralizer (Open/Close – Hydraulic Only) Pivot (In/Out or Drill/Bolt) Drill Feed (fwd/rev) Drill Rotation (clockwise/counterclockwise) Bolt Centralizer (Extend/Retract)

While in Boom mode, the following functions can be controlled with the pendant: • • • • • • •

Drill Crowd (fwd/rev) Transverse (left/right) Boom Crowd (fwd/rev) Rollover (clockwise/counterclockwise) Scissor (Raise/Lower) Tilt (in/out) Deck (extend/retract)

Whenever the transmitter pendant is not in use it should be stored on the hangers provided on the deck’s hand railings. The radio receiver box can be unplugged from the deck control console and a ‘dummy’ plug be installed in its place. The ‘dummy’ plug must be connected to the deck control console whenever the radio receiver box is not connected. If the radio receiver box is unplugged from the deck console, it should be stored in a safe and dry place to prevent damage. The transmitter pendant must be inspected at the beginning of each shift to ensure that it is free of damage and that the proper functions are provided and are working properly. Please refer to Radio Pendant maintenance information for pre-operational inspection information. The operator should always maintain a safe distance from all moving parts and be very cautious around the boom, handrail and wing areas whenever operating with the Radio Remote Pendant System to ensure possible pinch points are avoided.

Page 3 of 4

Number: OM-BLT-O14-ECO Revision: Original

The Radio Remote Pendant System may be used while operating in Auxiliary mode under the power of the diesel engine or the electric power pack.

Page 4 of 4

Number: Revision: Revision Date: By: Topic:

OM-BLT-O15-ECO Original 08/29/07 JEG REMOTE DRILL OPERATION

INTRODUCTION This section of the 928/946 Scissor Bolter operator manual outlines the function and usage of the Remote Drilling package that has been fitted to an ECO (Electric Control Option) Bolter. The purpose of the Remote Drill package is to allow the operator to complete the drilling cycle while maintaining a safe distance from the Bolter should the area require additional precautionary measures. The operator should be very cautious whenever operating with the remote pendant to ensure possible injuries are avoided. The components will be discussed in the following order: 1. Remote Drill Hardwired Pendant 2. Remote Drill Dummy Plug 3. Drill Feed Speed Control 4. Remote Drill Selector Switch 5. Remote Drill Indicator 6. Interlocks Figure 1 illustrates a typical layout of the components used for this package.

Page 1 of 12

Number: OM-BLT-O15-ECO Revision: ORIGINAL

REMOTE/DRILL REMOTE/DECK

INDICATOR LIGHT

SELECTOR SWITCH

REMOTE DRILL PENDANT/DUMMY PLUG IN

DRILL FEED SPEED CONTROL

REMOTE DRILL PENDANT

Figure 1 – Remote Drill Components

Page 2 of 12

Number: OM-BLT-O15-ECO Revision: ORIGINAL

1 - REMOTE DRILL HARDWIRED PENDANT The Remote Drill Pendant on the 928/946 Scissor Bolter is used as an alternative to the control panel on the deck that allows the operator to complete the drilling cycle from a remote location. The remote pendant gives flexibility in the operation of the Scissor Bolter. Figure 2 illustrates a typical Remote Drill pendant. It should be noted that whenever possible, the manual controls for the boom and drill functions at the deck’s operator console should be used.

TOGGLE SWITCHES

EMERGENCY STOP

Figure 2 – Typical Remote Drill Pendant The Remote Drill pendant consists of an ‘Emergency Stop’ button and four other toggle switches which can be used to control Rotation/Water flushing, Drill Impact, Feed forward/reverse and Drill Centralizer open/close functions. Emergency Stop Button -– is used to shutdown the Scissor Bolter’s electric Powerpack and diesel engine in the event of an emergency situation. To engage the ‘Emergency Stop’ button, simply depress the mushroom cap of the pushbutton. This pushbutton should ‘lock’ down into place and maintain the ‘Emergency Stop’ state. To disengage the ‘Emergency Stop’, the mushroom cap pushbutton should be twisted clockwise and it should then ‘pop up’ and return to its upper position. Page 3 of 12

Number: OM-BLT-O15-ECO Revision: ORIGINAL

Drill Rotation / Water Flushing Switch – This is a maintained toggle switch. Pushing the toggle switch in the upward direction will turn “ON” the rock drill’s rotation in a counter clockwise (CCW) direction (viewed from the rear of rockdrill. See Figure 3) and turn “ON” the water flushing for the drill. Pushing the toggle switch in the downward direction will turn the Drill Rotation and Water flushing functions “OFF”.

REAR OF DRILL

Figure 3 – Counter Clockwise Drill Rotation Drill Impact Switch – This is a maintained toggle switch that allows rockdrill impact operation. Pushing the toggle switch in the upward direction will turn “ON” the rock drill percussion for drilling (impact). Pushing the toggle switch in the downward direction will turn the Drill Impact function “OFF”. For units equipped with Low Pressure Collaring the Drill Impact pressure will be such that if feed force isn’t pushing the drill string against the rock it will be diminished to avoid excessive breakage of the drill string components. The Low Pressure Collaring function also aids the operator during the collaring of the drill hole. After feed pressure has reached the optimum drilling pressure (preset) the drill percussion will rise to the drill’s maximum impact pressure setting.

Figure 4 – Drill Impact function Page 4 of 12

Number: OM-BLT-O15-ECO Revision: ORIGINAL

If the Drill Rotation/Water Flushing switch and/or the Drill Impact switch are left in the ‘ON’ position the electric Powerpack or diesel engine will not start. (Refer to Remote Pendant maintenance information MB-ELE1293 for pre operation inspection information.) Feed Switch – This is a momentary toggle switch that allows operation of the rockdrill’s direction on the feed. Pushing the toggle in the upward direction will move the rockdrill in the forward direction. Pushing the toggle switch in the downward direction will retract the rockdrill. See figure 5. The operator regulates drill feed pressure by using the feed regulator in the control panel on the deck. The drill feed pressure must be setup prior to using the Remote Drilling pendant.

Figure 5 – Drill Feed function Hydraulic Centralizer Switch – This is a momentary toggle switch used for opening and closing of the hydraulic centralizer. Pushing the toggle switch in the upward direction will open the hydraulic centralizer. Pushing the toggle switch in the downward direction will close the hydraulic centralizer. The Long hole drilling application requires the use of a hydraulic centralizer to provide a guide for the drill steel when collaring the hole and allow the operator to clamp onto the drill string when adding or removing additional rods. During single pass drilling, when the drill string approaches the centralizer jaws the hydraulic centralizer must be opened in order for the coupling to go through and avoid coming into contact with the centralizer jaws. Page 5 of 12

Number: OM-BLT-O15-ECO Revision: ORIGINAL

When Long hole drilling it is important to be in close proximity to the surface being drilled to help prevent the drill steel from deviating during the collaring process. If the drill steel deviates from the desired location the boom may have to be repositioned in order to reduce the risk of breaking the drill’s striking bar.

Figure 6 – Hydraulic Centralizer function The Remote Drill pendant and its cable must be inspected at the beginning of each shift to ensure they are free of damage and that the proper functions are provided and are working properly. (Refer to Remote Pendant maintenance information MB ELE-1293 for pre-operational inspection information. 2 - REMOTE DRILL DUMMY PLUG To help prevent inadvertent damage to the Remote Drill pendant and as a good operating practice the pendant should be unplugged from the main electrical panel when not being used and a Remote Dummy plug installed in its place. The Remote Dummy plug must be connected to the main electrical panel whenever the Remote Drill pendant is not connected. The electric Powerpac and the diesel engine will not run if the Dummy plug is not installed in its place. When the Remote drill pendant is unplugged from the main electrical box, it should be stored in a safe and dry place to prevent damage.

Page 6 of 12

Number: OM-BLT-O15-ECO Revision: ORIGINAL

Figure 7 – Remote Drill Dummy Plug 3 - DRILL FEED SPEED CONTROL The Drill Feed speed control can regulate the speed of the drill feed for collaring purposes. The speed should be set at the same speed that the drill will travel during the drilling cycle. If the speed is set too slow it will cause poor penetration and if it is set too fast it will be harder to properly collar the hole. The Drill feed speed control is only active while in the Remote Drilling mode. DRILL FEED SPEED REGULATOR

Figure 8 – Feed Speed Regulator 4 - REMOTE DRILL SELECTOR SWITCH The Remote Drill Selector Switch is a 3 position switch that allows the operator to select the following modes of operation: 1. DECK – Select for regular bolting. This allows the deck control panel, Radio remote pendant and hardwired pendant to operate from the work platform for regular Bolter operation. While in this mode the Remote Drill pendant is inoperative.

Page 7 of 12

Number: OM-BLT-O15-ECO Revision: ORIGINAL

2. REMOTE – Select to drill from a remote location. The Remote Drill pendant will allow the operator to control the drilling function from a remote distance. In this mode the deck control panel and Radio remote pendant are inoperative. When Remote mode is activated the Remote Drill indicator light located on the main panel will illuminate. 3. OFF – Selecting this switch position makes both the DECK mode functions and REMOTE mode functions inoperative.

REMOTE DRILL SELECTOR SWITCH

Figure 9 – Location of Remote Drill Selector Switch 5 - REMOTE DRILL INDICATOR The Remote Drill Indicator light is located in the Bolter’s main panel. When the light is illuminated it indicates that the Remote Drill Selector Switch is in the REMOTE position and that the Remote Drill pendant is ready for use.

Page 8 of 12

Number: OM-BLT-O15-ECO Revision: ORIGINAL

Figure 10 – Remote Drill indicator light 6 – INTERLOCKS Drill Impact, Feed and Rotation locks interlock with the Tilt Interlock System (TIS). The Drill Impact, Feed and Rotation Locks are located in the deck’s control console. Drill Impact, Feed and Rotation locks are interlocked with the Tilt Interlock System so that they are functional only if the boom is tilted out past 55° from the working platform.

If the machine’s ‘TIS’ is compromised, the Drill Impact, Feed and Rotation Lock interlocks will also be compromised and the result may be the advancement of the drill steel into the operator’s compartment when the boom is in the tramming position. Inspection of the ‘TIS’ and removal of the drill steel during tramming will prevent drill steel advancement into the operator’s compartment from occurring. Page 9 of 12

Number: OM-BLT-O15-ECO Revision: ORIGINAL

Figure 11 - Interlock of Drill Impact, Feed and Rotation Lock functions with TIS Remote Drill Pendant Interlocked with Tilt Interlock System (TIS) The Tilt Interlock System (TIS) will interlock the Remote Drill pendant. The Remote Drill pendant will not function if the ‘TIS’ is activated. The boom must be tilted out past 55° from the working platform.

Figure 12 - Remote Drill Pendant interlocked with TIS

Page 10 of 12

Number: OM-BLT-O15-ECO Revision: ORIGINAL

Powerpack and Diesel engine interlocked by Remote Drill Pendant maintained functions. If the Drill Impact and Drill Rotation/Water Flush switches located in the Remote Drill pendant are left in the ‘ON’ position the Powerpack will not start. This interlock is to prevent the inadvertent activation of the Drill Impact and/or Drill Rotation/Water Flush function(s) should they be left ‘ON’ and the Powerpack be started. Some units may also be equipped to interlock the diesel engine in this same way.

If the Powerpack and if equipped, Diesel Engine can be started when the Remote Drill Pendant’s Drill Impact and Drill Rotation/Water Flush toggles are in the “ON’ position then stop the machine immediately. Contact the appropriate maintenance personnel to correct the problem.

Figure 13 - Powerpack and Diesel engine interlocked by pendants Drill Lube Interlock. Ensure that the Drill Lube pump reservoir is full. If there is insufficient Drill Lube and/or air pressure the Remote Drill functions will not work.

Page 11 of 12

Number: OM-BLT-O15-ECO Revision: ORIGINAL

Notes:

If any questions or problems arise, please contact MacLean Engineering Technical Service for assistance. Phone: 1-866-856-3626 Email: [email protected]

Page 12 of 12

Title: Number: Machine Model(s) Affected: Revision: Creation Date: 03/03/2001 Written By: Steve Czerny Checked By: Steve Czerny Approved By: Steve Czerny

DAILY OPERATOR’S MAINTENANCE OM-BLT-M All MEMCO ECO/HCO & SSB BOLTER’S D Revision Date: 02/11/2013 Revised By: JanPaul Brenner Checked By: Darren Bowins Approved By: Bruce Mackereth

DAILY OPERATOR’S MAINTENANCE This section outlines the daily pre-operational maintenance that MacLean Engineering and Marketing Co. Limited recommends for Bolters. All items listed in the daily preoperation maintenance schedule must be performed without exception. The vehicle operator at the beginning of each shift must carry out the daily inspection maintenance. Daily maintenance includes a general inspection of the vehicle and lubrication of some systems. Included in this section, for reference (on the following pages) is a table of Recommended Lubricants and Fluids for the vehicle. For drive train components, please refer to the corresponding Maintenance Bulletin for further details.

OM-BLT-M

Page 1 of 28

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D

RECOMMENDED LUBRICANTS AND FLUIDS As customer requirements change, certain components listed in the table below may not be applicable to your particular vehicle. It is the operator’s responsibility to become familiar with their particular vehicle and its options. The following table is referenced throughout this Operator’s Manual section.

Location

Lubricant/Fluid

MacLean Part #

Capacity

Grease

Multi-purpose Molybdenum Grease EP2

1015699

N/A

Hydraulic System (MEM-928/946)

Mineral Oil (Tellus 46) Harmony or equivalent (AW46)

1012269

235 L 62 US Gallons

Hydraulic System (MEM-SSB)

Mineral Oil (Tellus 46) Harmony or equivalent (AW46)

1012269

190 L 50 US Gallons

Engine Oil (Mercedes 904)

CH-4 Caterpillar Diesel Engine Oil or equivalent (SAE 15W40)

CAT-155-6199

15 L 4 US Gallons

Engine Oil (Mercedes 906)

CH-4 Caterpillar Diesel Engine Oil or equivalent (SAE 15W40)

CAT-155-6199

22 L 5.8 US Gallons

Engine (Deutz 1013)

CH-4 Caterpillar Diesel Engine Oil or equivalent (SAE 15W40)

CAT-155-6199

15 L 4 US Gallons

Engine Oil (Deutz 2012 L04 T3)

CH-4 Caterpillar Diesel Engine Oil or equivalent (SAE 15W40)

CAT-155-6199

14 L 3.7 US Gallons

Engine Oil (Deutz 2012 L06 T3)

CH-4 Caterpillar Diesel Engine Oil or equivalent (SAE 15W40)

CAT-155-6199

20 L 5.3 US Gallons

Engine Oil (Caterpillar C6.6)

CH-4 Caterpillar Diesel Engine Oil or equivalent (SAE 15W40)

CAT-155-6199

16 L 4 US Gallons

Page 2 of 28

OM-BLT-M

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D

MacLean Part #

Capacity

ESSOTRANS 30 Transmission Oil or equivalent (SAE 30)

1037011

25 L 6.5 US Gallons

Transmission (Caterpillar C6.6)

TDTO/TO-4 CAT Transmission Oil and Drive Train Oil or equivalent (SAE 30)

CAT-9X-6466

34 L 9 US Gallons

Axles – New Holland (per axle)

HYDRAUL 56 (ESSO) Drive Train Oil or equivalent (SAE 30)

1005160

28 L 7 US Gallons

Axles (Dana 113 – Central Housing)

Oil, Synthetic SAE 75W90 (API GL5-MIL 2105-B), or equivalent

1121050

16.3 L 4.3 Gallons

Axles (Dana 113 – Left & Right Hub)

Oil, Synthetic SAE 75W90 (API GL5-MIL 2105-B), or equivalent

1121050

2.6 L (each) 0.7 Gallons

Axles (Dana 114 – Central Housing)

Oil, Synthetic SAE 75W90 (API GL5-MIL 2105-B), or equivalent

1121050

18 L 4.8 Gallons

Axles (Dana 114 – Left & Right Hub)

Oil, Synthetic SAE 75W90 (API GL5-MIL 2105-B), or equivalent

1121050

4.7 L (each) 1.2 Gallons

Engine Coolant (Mercedes 904)

CAT Extended Life Coolant or equivalent Pre-Mixed 50/50

CAT-101-2844

46 L 12.2 US Gallons

Engine Coolant (Mercedes 906)

CAT Extended Life Coolant or equivalent Pre-Mixed 50/50

CAT-101-2844

56 L 14.8 US Gallons

Engine Coolant (1013)

CAT Extended Life Coolant or equivalent Pre-Mixed 50/50

CAT-101-2844

14 L 3.7 US Gallons

Engine Coolant (Deutz 2012 L04 T3)

CAT Extended Life Coolant or equivalent Pre-Mixed 50/50

CAT-101-2844

46 L 12.2 US Gallons

Engine Coolant (Deutz 2012 L06 T3)

CAT Extended Life Coolant or equivalent Pre-Mixed 50/50

CAT-101-2844

56 L 14.8 US Gallons

Engine Coolant (Caterpillar C6.6)

CAT Extended Life Coolant or equivalent Pre-Mixed 50/50

CAT-101-2844

40 L 10.5 US Gallons

Location

Lubricant

Transmission (Clark 32000)

OM-BLT-M

Page 3 of 28

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D

MacLean Part #

Capacity

#2 Diesel Fuel

N/A

215 L 57 US Gallons

Fuel (MEM-SSB)

#2 Diesel Fuel

N/A

178 L 47 US Gallons

Driveline Brake

TDTO/TO-4 CAT Transmission Oil and Drive Train Oil or equivalent (SAE 30)

1060738 CAT-9X-6466

250 ml 0.06 US Gallons

Atlas Copco (LE22) Compressor Oil

Mineral Oil SAE 10W or equivalent

1018369 PAO Compressor 32

1.6 L 0.4 US Gallons

Hydrovane Compressor Oil

Hydrovane CS5000XL Synthetic

1013033

1.8 L 61 US oz

Mattei Compressor Oil

Mattei Rotoroil 8000 F2

1107256

Less Than 2.0 L 0.5 US Gallons

Rollover Brake

Mineral Oil AW46 or equivalent

1012269

3 oz 88.7 ml

Rollover Housing

Petro Canada Enduratex EP 680 (Ultima)

1074083

Fill to Centre of Hub

Generation 3 Rollover Worm Drive Gear Box

Light Grease (Esso EP6F Nebula)

1128064

As Required

Rock Drill Oil

SAE 10W Rock Drill Oil or equivalent (Ardee 32)

1010814

Fill as required at beginning of shift

Location

Lubricant

Fuel (MEM-928/946)

RDS Reduction Gear Box

80W90 Gear Oil or equivalent

1007124

22.5 oz 645 ml Total Gearbox and Clutch

Throttle Pedal Reservoir

Mineral Oil AW46 or equivalent

1012269

N/A

Cavotec Cable Reel Torque Unit

Esso GX 85W-90

N/A

As Required

*Consult MacLean Engineering’s Service Department for Cold Weather Fluid Recommendations. Page 4 of 28

OM-BLT-M

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D Scissor Bolter Daily Pre-Operational Maintenance Guide The following is a list of the daily checks required for the MEM-928/946 Scissor Bolter found in your Operator Pre-Op Guide. Always use the outriggers to level and stabilize the vehicle prior to raising/lowering the deck, working from the deck and/or moving the boom. Failure to ensure that the outriggers are extended onto stable ground can cause vehicle damage and possible operator injury.

Figure 1 – Pre-Op Guide Card

OM-BLT-M

Figure 2 – Pre-Op Guide Card (Reverse Side)

Page 5 of 28

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D DAILY PRE-OPERATION MAINTENANCE CHECKLIST The following checklist can be used for the both the MEM-928/946 Scissor Bolter and the MEM-SSB Bolter. 1. Walk around inspection. Check general condition of bolter. 2. Fill diesel fuel and hydraulic oil reservoir to the proper operating levels, inspect for leaks. 3. Inspect tires, wheel assemblies and visually inspect mounting bolts. 4. Engine checks include - engine oil level, engine coolant level, inspection of fuel lines, flexible coolant hoses, belts, and turbo and exhaust system. Check air filter indicator to ensure that intake air filter is in good condition. 5. Compressor, oil level, coupling, intake filter should be inspected. Empty the air reservoir and water separator (if applicable). 6. Cable reel, inspect condition of trailing cable and plug. 7. When making connection to the water circuit, flush the Y-strainer to clean out any debris that may be present. 8. Testing of mine power supply, ground check and emergency stop switch. Inspect general condition of electrical panels. 9. Driver’s Compartment - inspect hand held fire extinguisher, seat belt, oil level in throttle pedal reservoir (if equipped). 10. Start engine - check all instrument gauges, horn, drive lights and back-up alarm. 11. Perform brake tests, test steering controls, and check transmission oil level with engine running at operating temperature. 12. Raise scissor, install scissor lock and shut down unit. G. Grease all accessible lube points. 13. Lower scissor and take boom off of the deck if in the tram position. Test the tilt interlock system. 14. Test functions - start by testing emergency stops, pendant inspection and testing, Remote Drive System (RDS) inspection and testing. 15. Test all boom functions with control levers. Manipulate boom and check for excessive play in components. General inspection of the boom. G. Grease boom and all remaining lube points. 16. Inspect general condition of working platform, clean if necessary. Inspect condition of wings, safety posts, locking pins and safety chains. 17. Inspect general condition of rock-drill and bolting option. The pre-operational check procedures may vary slightly for a specific MacLean Bolter.

Page 6 of 28

OM-BLT-M

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D DAILY PRE-OPERATION MAINTENANCE PROCEDURES The following are procedural descriptions for each daily pre-operation check. If the vehicle, or any of its sub-systems are found to be damaged, or non-functional, decommission the vehicle immediately and inform the appropriate personnel to correct the problem. Failure to correct the problem may result in serious injury, or death. 1. Walk around inspection. Check general condition of bolter. 1. Inspect the bolter’s general condition and remove any debris that may be present. Check for leaks, loose fastener’s, and condition of all hosing and electrical 1. harnesses. Inspect all protective covers on the boom. 2. Fill diesel fuel and hydraulic oil reservoir to the proper operating levels, inspect for leaks. Diesel fuel level is checked by observing the sight gauges located on the side of the diesel tank (located opposite the driver’s compartment, below the hydraulic oil reservoir). It is recommended to fill the tank at the beginning of each shift. Hydraulic oil level is checked by observing the sight gauges located on the side of the hydraulic oil reservoir (located opposite the driver’s compartment, above the diesel tank). When looking at the sight gauges, it is recommended that the hydraulic oil level be between the minimum/maximum level marks. If the diesel fuel level, or hydraulic oil level is low, fill as required using the recommended fluids listed in the table of Recommended Lubricants and Fluids. Some vehicles may be equipped with an electrical hydraulic oil tank pump and switch. See Figure 3. Inspect the frame and ground below the diesel fuel tank and any fuel hoses connecting to the engine. No leaks, or wetness must be present.

OM-BLT-M

Page 7 of 28

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D Inspect all hydraulic hoses, fuel hoses, etc. No leaks, or wetness must be present.

Hydraulic Oil Tank Pump Hydraulic Oil Tank Hydraulic Oil Tank Sight Gauges Hydraulic Oil Tank Pump Switch

Diesel Fuel Tank

Diesel Fuel Tank Sight Gauges Figure 3 – Typical Diesel Fuel and Hydraulic Tank Inspect the condition of the main hydraulic system pressure filter and the drill rotation hydraulic system pressure filter. This is done by viewing the clear bubble on the filter housing. As long as the indicator inside the sight glass is not popped (typically red if it is), the hydraulic filter is good. See Figure 4.

Clear Bubble on top of Filter Housing

Clear Bubble on Filter Housings

Hydraulic Pressure Filter (Inside Housing)

Hydraulic Pressure Filters (Inside Housing, Behind Cover) Figure 4 – Typical Hydraulic Pressure Filter Indicators

Page 8 of 28

OM-BLT-M

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D 3. Inspect tires, wheel assemblies and visually inspect mounting bolts. Over inflation of pneumatic tires could result in serious injury, or death. Only qualified personnel must repair damaged wheels. The vehicle uses either pneumatic, or foam filled tires. Regardless of the type, all tires, treads, and sidewalls must be in good condition with no visible damage such as large pieces of tread missing. Each wheel rim must be in good condition with no visible damage such as dents, or cracks. The split rings on the wheels must be in place, and in good condition. Tire fasteners must be secure and in good condition. Refer to the Wheel Fastener Data label installed on the vehicle, or to mine site policy regarding wheel fastener and torque data. 4. Engine checks include - engine oil level, engine coolant level, inspection of fuel lines, flexible coolant hoses, belts, and turbo and exhaust system. Check air filter indicator to ensure that intake air filter is in good condition. Use care when working near the exhaust system. It may be extremely hot. If the oil level is constantly above normal and engine oil has not been added to the crankcase, consult with authorized personnel for the cause. Fuel or coolant dilution of engine oil can result in serious engine damage. If your vehicle is equipped with a high altitude kit, inspect the hydraulic tank air compressor and air filter, pressure gauge, air/water filter and canister and all associated hosing and fittings. Check for any signs of damage. Depending upon the vehicle, ensure that the air compressor turns ON when the IGNITION switch is turned ON, or the emergency stop circuit is reset.

OM-BLT-M

Page 9 of 28

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D •

Mercedes engine: The engine oil dipstick is located on the operator’s compartment side of the engine. The engine oil fill location is towards the front of the operator’s side of the engine. It is covered with a black screw style cap. There may be an optional oil fill location installed on the vehicle. See Figure 5. The engine coolant level is checked by observing a sight gauge located on the radiator expansion reservoir located on the operator’s compartment side of the engine. With the engine at operating temperature, coolant must be visible when looking into the sight gauge. This indicates a sufficient level. Engine Oil Fill Point Access Hole (top of shroud)

Coolant Filling Point Sight Gauge

Optional Engine Oil Fill Point

Radiator Expansion Reservoir

Engine Oil Dipstick

Figure 5 – Typical Mercedes Engine Check Points •

CAT engine: The engine oil dipstick is located on the operator’s compartment side of the engine. The engine has up to two oil fill locations. One is located on the front of the engine on the back side of the timing gear case on the operator’s compartment side. If the diesel bolting option is present, this fill point is partially obscured by the installed air compressor, or may not be installed. The other fill point is on the opposite side of the engine located on the lower half of the engine block below and forward of the turbocharger. Both fill points use screw type caps. The coolant fill point is identical to the Mercedes engine. See Figure 6.

Coolant Filling Point

Sight Gauge Radiator Expansion Reservoir

Engine Oil Fill Point Engine Oil Dipstick

Optional Engine Oil Fill Point (Behind Hoses) Figure 6 – Typical Cat Engine Check Points

Page 10 of 28

OM-BLT-M

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D •

Deutz engine: The engine oil dipstick is located on the passenger side of the engine. The engine has two oil filling points. One is located above the oil dipstick, on top of the engine. See Figure 7. The second fill point is located below the oil dipstick. Depending upon vehicle configuration, the second fill point may be located on a bracket close to the engine. For MEM-928/946 Bolters equipped with the Deutz 2012 engine, the engine coolant level is checked by observing the coolant level through the clear radiator expansion reservoir. See Maintenance Bulletin MBENG2048. For MEM-928/946 Bolters equipped with the Deutz 1013 engine, the engine coolant level is checked by observing the clear tube on the side of the radiator on the operator’s compartment side of the vehicle. See Figure 8. See also Maintenance Bulletin MB-ENG1049. For MEM-SSB Bolters equipped with the Deutz 2012 engine, the engine coolant level is checked by observing the coolant level through a sight glass located on the radiator expansion reservoir similar to the one shown in Figure 5. Depending upon vehicle configuration, it may also be located on the passenger side of the engine. With the engine running at operating temperature, the coolant level must be visible through the clear radiator expansion reservoir, or through the sight glass on the radiator expansion reservoir. Engine Oil Fill Point (Top of Engine)

Coolant Filling Point

Engine Oil Dipstick

Coolant Level

Secondary Oil Fill Point (Optional not Shown) Figure 7 – Typical Deutz 2012 Engine Check Points (MEM-928/946 shown)

Coolant Filling Point

Coolant Level Clear Tube

Figure 8 – Typical Deutz 1013 Engine (MEM-928/946 shown) OM-BLT-M

Page 11 of 28

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D If the engine oil or coolant level is low, add as required. See table of Recommended Lubricants and Fluids. Inspect the frame and ground below the engine. No leaks, or wetness must be present. Examine hoses for leaks and damage. Carefully check all hose fittings, clamps, and ties. Ensure that all hoses are not resting on, or touching shafts, couplings, heated surfaces including exhaust manifolds, any sharp edges or other hazardous area. Engine belts must be free of fraying, nicks, and cuts. Belts must be neither too tight, nor too loose (approximately ½ inch deflection in belt tension is acceptable). Mercedes engines have automatic belt tensioners. Ensure that the engine belt and engine fan guarding is installed and not damaged. Inspect the air filter assembly and the exhaust system for possible damage. Check the heat-insulating exhaust materials and shields for damage and/or missing sections. With the engine running (see Step 10 for details), inspect the air cleaner restriction indicator. This unit is typically located on a bracket attached to the air filter housing. See Figure 9. If the air cleaner restriction indicator contains a red band in the indicator ring area, notify the maintenance department. Reset Button (On Top) Air Cleaner Restriction Indicator Indicator Ring

Figure 9 – Typical Air Cleaner Restriction Indicator

Page 12 of 28

OM-BLT-M

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D 5. Compressor, oil level, coupling, intake filter should be inspected. Empty air reservoir and water separator (if applicable). Hydrovane Equipped - Visually inspect the Hyrdrovane air compressor for damage, loose fasteners and fittings, leaks and general wear. No leaks or wetness must be present. Check the Hydrovane motor oil level by viewing the sight gauge on the unit. Oil can be added by removing the nut and using a funnel to add oil into the compressor. Fill referencing the table of Recommended Lubricants and Fluids. The fill point is indicated in Figure 10. The cover must be removed in order to inspect the air filter. Replace as necessary. For maintenance, parts and service information on the Hydrovane air compressor refer to Maintenance Bulletin MB-PNE1598. Hydrovane Air Compressor Air Filter (Cover Must be Removed to Access) Fill Point Sight Gauge Water Separator

Air Filter (Remove Cover) Atlas Copco Air Compressor Fill Point Sight Gauge

Figure 10 – Typical Hydrovane and Atlas Copco Air Compressors (MEM-928/946) Atlas Copco Equipped - The air compressor oil level is inspected using a sight gauge located on the side of the compressor unit. A small red circle inscribed on the face of the sight glass indicates the acceptable oil level. The oil level must not be higher than the top of the circle, or lower than the bottom of the circle. Oil can be added by removing the plastic nut located on the top of the compressor and using a funnel to add oil through the pipe in the centre of the compressor. See Figure 10. Fill referencing the table of Recommended Lubricants and Fluids. The compressor coupling must be in good condition. A rubber insert must also be present with no excessive space existing between the couplings. The coupling halves must be close together with no gaps between them. The cover must be removed in order to inspect the air filter. Replace as necessary. The water separator empties itself. However, if for some reason the mechanism does not function, drain all air pressure from the system using the reservoir drain ball valve and take the bowl section off by twisting it 1/8” of a turn in the counterclockwise direction. Ensure that the o-ring is in good condition before reinstalling the bowl. OM-BLT-M

Page 13 of 28

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D For maintenance, parts and service information on the Atlas Copco air compressor, refer to Maintenance Bulletins MB-PNE1053, MB-ELE1054 and MB-ELE1106. Mattei Equipped - The air compressor oil level is inspected using a sight tube located on the side of the compressor unit. The oil level must not be higher than the max level, or lower than the min level. Oil can be added by removing the cover to access the nut located on the compressor housing and using a funnel to add oil. See Figure 11. Fill referencing the table of Recommended Lubricants and Fluids. The cover must be removed in order to inspect the air filter. Replace as necessary. For maintenance, parts and service information on the Mattei air compressor refer to Maintenance Bulletin MB-PNE1978. Fill Point (Cover Must be Removed to Access)

Mattei Air Compressor

Sight Tube

Air Intake Filter (Cover Must be Removed to Access)

Drain Plug (Cover Must be Removed to Access)

Figure 11 – Typical Mattei Air Compressor (MEM-SSB) The air reservoir may be under pressure. The air reservoir is located at the engine end, by the cable reel (if equipped). The drain line is located inside the power pack mount hydraulic compartment access door. The air reservoir must be drained before every shift to remove any residual water that may be present. See Figure 12. To drain water from the air reservoir: a. Open the power pack mount hydraulic compartment access door. b. Open the compressed air drain ball valve (the ball valve handle is parallel to the ball valve housing when open). c. When draining is complete, close the compressed air drain ball valve. d. Close the hydraulic compartment access door. Page 14 of 28

OM-BLT-M

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D 6. Cable reel, inspect condition of trailing cable and plug. Inspect the general condition of the cable reel as well as the electrical AC trailing cable and plug. All must be free of damage and debris. The electrical cable must not have any pinches, nicks or cuts. The cable reel spool must be in good condition and all rollers must be clean and turn freely. Depending upon the cable reel, there may be grease fittings on the guide rollers that require greasing. See Figure 12. Refer to Maintenance Bulletins MB-ELE1328 and MB-ELE1378. If your vehicle is equipped with a Cavotec cable reel, the cable reel torque unit oil level must be checked. Fill referencing the table of Recommended Lubricants and Fluids. The cable reel must also be inspected and maintained according to the maintenance labels on the unit. Refer also to Maintenance Bulletins MB-ELE1713. 7. When making connection to the water circuit, flush the Y-strainer to eliminate any waste that may be present. The location for the mine water Y-strainer drain ball valve can be seen in Figure 12. Mine Water Y-Strainer Drain Ball Valve

Cable Reel and Guide Rollers (if equipped)

Compressed Air Drain Ball Valve

Power Pack Mount Hydraulic Compartment Access Door

Drain Lines

Figure 12 – Typical Mine Air Drain and Mine Water Y-Strainer Locations (MEM-928/946 Shown) To flush the mine water Y-strainer: a. Open the power pack mount hydraulic compartment access door. b. With the mine water supply connected, open the mine water Y-strainer drain ball valve (the ball valve handle is parallel to the ball valve housing when open). c. When flushing is complete, close the mine water Y-strainer drain ball valve. d. Close the hydraulic compartment access door.

OM-BLT-M

Page 15 of 28

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D 8. Testing of mine power supply, ground check and emergency stop switches. Inspect general condition of electrical panels. High Voltage! Do not open electrical panels unless qualified to do so. Failure to comply can result in serious injury, or death. Inspect the main AC electrical panel’s general condition. All instrument gauges, indicator lights and buttons must be free of damage. All electrical enclosures must be closed and sealed. If any electrical panel is not closed and sealed properly, electrical panel component and wiring corrosion occurs. This eventually leads to vehicle malfunction. For MEM-SSB Bolters, the main AC electrical panel can be inspected in accordance to Maintenance Bulletin MB-GEN1903. Ensure that the vehicle is connected to mine power supply. The vehicle’s MAIN BATTERY (MASTER) DISCONNECT switch and the MAIN AC POWER DISCONNECT switch located on the main AC electrical panel must be in the ON position. If your system utilizes a power monitor relay (PMR), ensure that the MAIN POWER RESET button on the vehicle’s main AC electrical panel, or the mine AC electrical panel is pressed. At the main AC electrical panel, press and hold the GROUND CHECK TEST pushbutton (if equipped). AC power to the vehicle must be shut OFF (can be seen on the voltmeter on the main AC electrical panel). Release the GROUND CHECK TEST pushbutton and reset the main voltage. Start the power pack. With the electrical power pack running, test the EMERGENCY STOP button on the main AC electrical panel. When the EMERGENCY STOP button is pushed, the electrical power pack must stop. With the power pack stopped, and the EMERGENCY STOP button still engaged, attempt to restart the electrical power-pack. The power pack must not restart. With the diesel engine running, test the EMERGENCY STOP button on the main AC electrical panel. When the EMERGENCY STOP button is pushed, the 24Vdc control system power is interrupted and the diesel engine shuts down. With the 24Vdc control system power interrupted and the EMERGENCY STOP button still engaged, attempt to restart the diesel engine. The diesel engine must not start. Testing of the hardwired pendant, RDS control box (HCO Bolters) and console EMERGENCY STOP buttons must be completed as part of the pendant and console functional testing.

Page 16 of 28

OM-BLT-M

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D 9. Driver’s Compartment - inspect hand held fire extinguisher, seat belt, oil level in throttle pedal reservoir (if equipped). There must not be anything on the floor of the operator’s compartment that could possibly restrict the travel of the service brake, or throttle pedals, which could potentially cause an accident. See Figure 13. Ensure that the operator’s compartment, or cab is clear of any flammable materials, mud and debris. The hand held fire extinguisher located just outside the operator’s compartment must be fully charged and ready for use in case of an emergency. Some extinguishers have a sight gauge located on the neck of the extinguisher, which indicates its charge level. Others use charge bottles that use red coloured pop-up indicators after they are discharged. It is the operator’s responsibility to become familiar with the fire safety systems present on their specific vehicle. The seat belt must be in good condition. Visually inspect the seat belt material. No fraying, or cuts in the seat belt material are allowed. Test the latching mechanism for proper engagement and disengagement. The latching mechanism must function properly. If equipped, the throttle pedal reservoir must be within the operating level indicators. If the level is low check for leaks and repair as necessary. See Figure 13. Fill referencing the table of Recommended Lubricants and Fluids. Refer also to Maintenance Bulletin MB-HYD1018.

Throttle Slave Cylinder

Throttle Pedal Reservoir (Minimum and Maximum Level Marks on Housing)

Throttle Pedal Service Brake Pedal

Figure 13 – Typical Throttle Pedal Lubricator and Reservoir (MEM-928/946 only) Check all three-point contact handles and steps to enter/exit the operator’s compartment, or cab. They must be in good condition, free from oil, dirt and damage. They must be painted in accordance with mine site, or local policy regulations. OM-BLT-M

Page 17 of 28

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D If the vehicle has a canopy, or enclosed cab, visually inspect it for damage. Ensure that the structure is secure and that the mounting bolts are present and tight. Check the wipers (and all wiper accessories, if equipped), blower motor (if equipped) for functionality. Ensure that all controls are functioning properly and that the windshield washer reservoir is full (if equipped). Fill as required. Check all cab air filters and clean/replace as required. On the inside of the cab, inspect the emergency exit window (if equipped) to ensure that the emergency exit handle and the seal that secures the windshield in place, is present and secure. Ensure that the seat belt cutter is present and not damaged. See Figure 14. Refer to the vehicle labeling with regards to the use of the emergency exit procedure. See also Figure 15 for an illustration of a typical emergency exit procedure label. Emergency Exit Window

Seal Emergency Exit Handle

Emergency Exit Procedure Label

Seat Belt Cutter

Figure 14 – Typical Emergency Exit Window (MEM-928/946 shown)

Figure 15 – Typical Emergency Exit Procedure Label

Page 18 of 28

OM-BLT-M

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D 10. Start Engine - check all instrument gauges, horn, drive lights and back-up alarm. Refer to Operator’s Manual section OM-BLT-O2 titled Starting. If not already in the ON position, turn the MAIN BATTERY MASTER DISCONNECT switch to the ON position and ensure that all EMERGENCY STOP buttons reset. Activate the parking/warning light(s) (if equipped), drive lights and work lights. Walk around the vehicle to visually determine that each drive light, work light, tail lights (if equipped) and parking/warning lights (if equipped) are working. When the engine is running, the steering controls are active. Ensure that the articulation area is clear before starting as pinch-point exists. Ensure that the emergency/park brake is engaged and the transmission is in the Neutral position. Start the vehicle’s engine and test the horn by pressing the HORN ON switch. While the engine is running, monitor all gauges, warning indicators and alarm indicators. View the electronic display (see Figure 16) to verify that the engine RPM, oil pressure, coolant temperature and battery voltage are within their normal operating ranges.

Figure 16 – Typical Electronic Display If any gauge is out of normal operating range or a warning indicator or alarm indictor is activated, shut down the vehicle and contact maintenance personnel immediately. Place the transmission into the Reverse position. A loud audible alarm must be immediately heard. Place the transmission into Neutral and the audible alarm stops. OM-BLT-M

Page 19 of 28

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D With the engine running, visually inspect the exhaust mounting, intake and exhaust ducting and connections for leaks. Check for unusual noise or vibration and if excessive, stop the engine and do not operate until the cause is determined. Use care when working near the exhaust system. It may be extremely hot. With the engine running, activate a hydraulic function such as lowering the outriggers and inspect the condition of the hydraulic return filter inside the hydraulic tank. This is done by viewing the bypass indicator on top of the hydraulic tank. As long as the indicator is not red, the filter inside the tank is good. See Figure 17. Hydraulic Return Filter (Inside Tank) Bypass Indicator (Top of Hydraulic Oil Tank)

Figure 17 – Typical Hydraulic Filter Indicator

Page 20 of 28

OM-BLT-M

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D 11. Perform brake tests, test steering controls, and check transmission oil level with engine running at operating temperature. Refer to section OM-BLT-O2 titled Operating Instructions and to section OM-BLT-O3 titled Brake Test Procedure. A pinch-point exists at the vehicle’s articulation area. Ensure that the articulation area is clear before testing the steering. The operator must be sitting in the operator’s compartment seat to ensure operator safety. With the operator sitting in the driver’s seat, and the engine running and the transmission in the Neutral position, test that the articulation responds properly to the steer stick input. Refer to the Steering Controls section in OM-BLT-O2. With the engine running and the transmission in the Neutral position, inspect the transmission fluid level using the transmission dipstick. For MEM-928/946 Bolter’s, the dipstick is located under the operator’s compartment on the vehicle. Some vehicles have an access plate to the transmission dipstick located on the cowling beside the operator’s seat. For MEM-SSB Bolter’s, the dipstick is located beside the operator’s seat. The level is checked when sitting in the operator’s seat. Optionally, there may be a transmission level check point in front of the operator’s compartment. See Figure 18. Operator’s Seat

Operator’s Seat

MEM-SSB Check Point

MEM-928/946 Check Point (access cover raised)

Optional Check Point Figure 18 – Typical Transmission Fluid Check Points Do not stand in the articulation area when filling the transmission with fluid. A pinch-point exists at the vehicle’s articulation area.

If the transmission fluid level is low, fill as required with the recommended transmission fluid listed in the table of Recommended Lubricants and Fluids.

OM-BLT-M

Page 21 of 28

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D 12. Raise scissor, install scissor lock and shut down unit. Refer to section titled Machine Safety Systems. The scissor area is a potential pinch point. The operator must be sitting in the operator’s compartment seat, or standing in front of the scissor deck operator’s dash. This ensures that the scissor area is clear when testing the scissor function. See Figure 22. Always use the outriggers to level and stabilize the vehicle prior to raising/lowering the deck, working from the deck and/or moving the boom. For MEM-928/946 vehicles, raise the deck and install the scissor lock. Inspect the general condition of the scissor arms. Wash away excess mud and debris. Ensure that the upper and lower scissor channels are clean. Look for cracks and signs of stress. Visually inspect the scissor keeper bolts. Ensure that all bolts are secured, in place and in good condition. See Figure 19. Upper Scissor Channel

Scissor Lock

Keeper Bolts (Top Shown) Scissor Arms

Figure 19 – Typical Scissor Lift Keeper Bolts For MEM-SSB vehicle’s equipped with the deck lift and tilt arms, raise the deck and install the left and right deck lift and tilt lock pins. Inspect the general condition of the lift arms. Wash away excess mud and debris. Look for cracks and signs of stress. See Figure 20.

Page 22 of 28

OM-BLT-M

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D Look for any hydraulic leaks. There must be no leaks, or wetness present on the hoses, or cylinders.

Deck Lift and Tilt Arms

Deck Lift and Tilt Lock Pins (Operator Side)

Figure 20 – Typical Deck Lift Arms G. Grease all accessible lube points. Visually check the auto-lube reservoir (if equipped). Fill as required using the recommended fluid listed in the table of Recommended Lubricants and Fluids. If no auto lube system is present, manually grease at all manifolds. See Figure 21. Depending upon vehicle configuration, the auto lube system can be found in various locations around the engine end of the vehicle. It is the operator’s responsibility to become familiar with their particular vehicle and its configuration. Manifold by Rear Articulation

Manifold Front of Operator’s Compartment

Auto Lube System Manifold Left Side of Transverse Carriage

Manifold Right Side of Transverse Carriage

Remote Fill Grease Point – Do not Remove lid to fill.

Figure 21 – Typical Lube System (MEM-928/946 shown) For MEM-SSB Bolters, there is only one manual lubrication manifold and it is located in front of the operator’s compartment. OM-BLT-M

Page 23 of 28

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D 13. Lower scissor, move boom off of deck if in the tram position. Test the tilt interlock system. Inspect/test the tilt interlock system in accordance with: a. Maintenance Bulletin MB-ELE1182 for ECO Bolters. b. Maintenance Bulletin MB-ELE1114 for HCO Bolters. c. Maintenance Bulletin MB-ELE1814 for SSB Bolters. 14. Test functions - start by testing emergency stops, pendant inspection and testing, remote drive system (RDS) inspection and testing. Inspect the hardwired pendant in accordance with Maintenance Bulletin MBELE1008. This includes testing the EMERGENCY STOP button. Inspect the RDS control console’s general condition; the console must be free of damage and debris. Inspect the RDS controls in accordance with: a. Maintenance Bulletin MB-GEN1179 for ECO Bolters. b. Maintenance Bulletin MB-GEN1117 for HCO Bolters. c. Maintenance Bulletin MB-GEN1840, and MB-GEN2041 (Deutz equipped) for SSB Bolters. Always check the vehicle controls functionality when standing at the deck control console on the vehicle’s deck, or when sitting in the driver’s seat. This ensures that the operator is in a safe position away from moving parts. See Figure 22. Refer to section titled Deck Layout & (Auxiliary) Controls for further information. Driver’s Compartment Safe Area

Scissor Deck Safe Area

Figure 22 – Safe Areas for Functionality Testing Page 24 of 28

OM-BLT-M

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D 15. General inspection of boom. Test all boom functions with control levers. Manipulate boom and check for excessive play in components. When repairing hydraulic components, hydraulic pressure may be present. Ensure that there is no hydraulic pressure present in the system before repairing the part. Always use the outriggers to level and stabilize the vehicle prior to raising/lowering the deck, working from the deck and/or moving the boom. Inspect the boom and its components for good general condition. Inspect for any damage to the hydraulic hoses and electrical cables. All hoses and cables must be bundled. See Figure 23. Repair/release any hoses that are caught on the boom, drill, feed, etc. Remove any loose rock cuttings that may be present on the boom, or any of its components. The drill and bolt feeds and pivot assembly must be in good general condition.

Hoses Neatly Bundled and not Hung up on other Components (MEM-928/946)

Hoses Neatly Bundled and not Hung up on other Components (MEM-SSB)

Figure 23 – Typical Boom Hosing With the operator standing at the deck control console on the deck, or when sitting in the driver’s seat, use the manual boom controls to perform a drill functional test on all boom and drill functions possible in accordance with: a. Maintenance Bulletin MB-GEN1179 for ECO Bolters. b. Maintenance Bulletin MB-GEN1121 for HCO Bolters. c. Maintenance Bulletin MB-GEN1840 for SSB Bolters. There must only be minimal play when manipulating the boom. Any excessive play is a sign that the boom requires maintenance and that it must be carried out before the boom is to be used.

OM-BLT-M

Page 25 of 28

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D G. Grease boom and all remaining lube points. The vehicle’s drill and bolt feed assemblies must be lubricated daily! There can be many grease fittings located on a Bolter’s feed. They all require daily greasing. For chain feed units, ensure that all pins and bearings are greased. For cylinder feed units, ensure that all pins are greased. The recommended lubricant for greasing is listed in the table of Recommended Lubricants and Fluids. Two, or three pumps of grease using a hand-operated greaser can be added at each fitting. 16. Inspect general condition of working platform. Clean if necessary. Inspect condition of wings, safety posts, locking pins and safety chains. Inspect the general condition of the deck, and the control panel, including all instrument gauges and indicator lights. All must be free of damage and debris. Inspect the deck lights. They must be free of damage and debris. Refer to section titled Drilling and Bolting Set-Up. 17. Inspect general condition of rock-drill and bolting option. If the oil level is low, fill as required using the recommended oil specified in the table of Recommended Lubricants and Fluids. Fill rock-drill lubricator. Ensure that the drill lube oil is working. For ECO’s, see section OM-BOLTER-O13 titled Drill Lubrication System, For HCO’s, see section OMBLT-O14 titled Drill Lubrication System and for SSB’s, see section OM-SSB-O13 titled Drill Lubrication System. Check for loose or missing bolts/nuts. Replace with OEM parts as required and ensure that they are tightened to their proper torque specifications. Check the flushing head seals and rubber deflectors/protectors (for vehicles equipped with bolting options). See Operator’s Manual section titled Drill Lubrication System for more information. The rock drill oil reservoir must be filled prior to every work shift. The recommended lubricant for the rock drill is listed in the table of Recommended Lubricants and Fluids. The rubber deflectors/protectors (for vehicles equipped with bolting options) for the rock drill and the rotation head, or combo-head/split-set driver must be in place on the shank rods of their respective units. Failure to use the rubber deflectors/protectors may cause premature damage of the units. If the vehicle, or any of its sub-systems are found to be damaged, or non-functional, decommission the vehicle immediately and inform the appropriate personnel to correct the problem. Failure to correct the problem may result in serious injury, or death. Page 26 of 28

OM-BLT-M

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D

BOLTER MAINTENANCE SCHEDULE In addition to the daily pre-operation maintenance, a MacLean Bolter requires maintenance to ensure optimal vehicle performance. For non-MacLean manufactured systems or components, the maintenance intervals are based on the manufacturers’ recommendations. All maintenance requirements are divided into time intervals and are based upon the vehicles power pack hour meter. The power pack hours are displayed on a meter located on the main AC electrical panel. Figure 24 illustrates the typical location of the power pack hour meter for all Bolters.

Power Pack Hour Meter

Power Pack Hour Meter

Figure 24 – Example of Typical Main AC Electrical Panels Maintenance intervals include 60, 250, 1000, 2000 and 4000 power pack hours, where 60 power pack hours represents a week of operation, 250 hours a month of operation and 1000 hours four months of operation. These intervals are approximate. Maintenance periods vary depending on the vehicle’s operating conditions. Maintenance requirements are cumulative. In other words, carry out daily operator’s inspections during 60-hour inspections, etc. See Maintenance Bulletin MB-GEN1060 for further explanation of maintenance intervals.

OM-BLT-M

Page 27 of 28

Title: DAILY OPERATOR’S MAINTENANCE Number: OM-BLT-M Revision: D

Notes:

If any questions or problems arise, please contact MacLean Engineering Technical Service for assistance. Phone: 1-866-856-3626 Email: [email protected] Page 28 of 28

OM-BLT-M

aclean Canada MEM-928/946 Scissor Bolter OPERATOR TRAINING Number: Revision: Revision Date: By: Topic:

T-001 G 08/15/02 ELL Operator Training Topics and Checklist

SCISSOR BOLTER TRAINING TOPICS MEM 928/946 Scissor Bolter Operator Training should include, but may not be limited to, the following topics: 1. 2. 3. 4.

General Safety Operating Safety Servicing Safety Fire Prevention Safety

Review operator’s manual sections and discuss Safety points as outlined in Manual. Review all points with operator on Scissor Bolter unit to ensure he understands and can identify the Stabilizer, Articulation, Tilt, and Diesel A/C interlocks, as well as all other safety points discussed in Operator’s Manual. 5. 6. 7. 8.

General Layout and Safety Systems Operator’s Compartment Layout Boom Layout Main Electrical Layout

Review operator’s manual sections and discuss all points as outlined in Manual. Familiarize the operator with the Scissor Bolter’s Layout. Review all points with operator on Scissor Bolter unit to ensure he understands and can identify all safety points discussed in Safety systems section. 9. Control Interlocks and Alarms Review operator’s manual sections and discuss all points as outlined in Manual. Familiarize the operator with the Scissor Bolter’s Interlocks and Alarms by reviewing all points with operator on Scissor Bolter unit and demonstrate systems so he understands and can identify Interlocks and Alarms. 10. Driving

Page 1 of 6

aclean Canada MEM-928/946 Scissor Bolter Number: T-001 Revision: G

11. BRAKE TEST Review operator’s manual sections and discuss all points as outlined in Manual. Familiarize the operator with the Scissor Bolter’s drive system. Review all points with operator on Scissor Bolter unit and demonstrate systems so he understands and can identify all components pertaining to driving the unit. Operator should be comfortable with driving unit. 12. REMOTE DRIVE SYSTEM (RDS) Review operator’s manual sections and discuss all points as outlined in Manual. Familiarize the operator with the Scissor Bolter’s RDS system. Review all points with operator on Scissor Bolter unit and demonstrate systems so he understands and can identify all components pertaining to RDS. Operator should be comfortable with operating RDS. Highlight safety points of operating unit while on Platform. Training should be carried out in an area, which allows the operator to manipulate the unit without any confines. No persons other than the Trainer should be in close proximity with the unit during operation. 13. BOOM CONTROLS Review operator’s manual sections and discuss all points as outlined in Manual. Familiarize the operator with the Scissor Bolter’s Boom controls. Review all points with operator on Scissor Bolter unit and demonstrate systems so he understands and can identify all components pertaining to Boom manipulation. Operator should be comfortable with operating boom functions. Highlight safety points of operating unit while on Platform and potential pinch points. Training should be carried out in an area, which allows the operator to manipulate the unit without any confines. No persons other than the Trainer should be in close proximity with the unit during operation. 14. DRILLING AND BOLTING CONTROLS 15. DRILLING PROCEDURE Review operator’s manual sections and discuss all points as outlined in Manual. Familiarize the operator with the Scissor Bolter’s Drilling and Bolting controls. Review all points with operator on Scissor Bolter unit and demonstrate systems so he understands and can identify all components pertaining to Drilling and Bolting. Operator should be comfortable with operating Drill/Bolt mode functions. Highlight safety points of operating unit while on Platform and potential pinch points. Training should be carried out in an area, which allows the operator to manipulate the unit without any confines. No persons other than the Trainer should be in close proximity with the unit during operation. Page 2 of 6

aclean Canada MEM-928/946 Scissor Bolter Number: T-001 Revision: G

16. SCREEN HANDLING 17. GROUND SUPPORT INSTALLATION Review operator’s manual sections and discuss all points as outlined in Manual. Review all points with operator on Scissor Bolter unit and demonstrate systems so he understands and can identify all components pertaining to installation of Screen and various types of ground support. Operator should be comfortable with installation of screen and ground support. Highlight safety points and potential pinch points. No persons other than the Trainer should be in close proximity with the unit during operation. 18. HANDHELD PENDANT Review operator’s manual sections and discuss all points as outlined in Manual. Review all points with operator on Scissor Bolter unit and demonstrate. Highlight safety points and potential pinch points. No persons other than the Trainer should be in close proximity with the unit during operation. 19. DAILY MAINTENANCE Review operator’s manual sections and discuss all points as outlined in Manual. Review all points with operator on Scissor Bolter unit and demonstrate. Highlight safety points and importance of daily Scissor Bolter controls testing. 20. REVIEW Review of systems or operations that operator is not comfortable with. Training must include the documentation of all topics covered. The trainer and the trainee(s) must sign-off for each topic covered and the time spent in training. A training checklist is provided on the following page in which this information should be recorded. Notes regarding the trainee’s previous operating experience should be made (General previous experience - # years & type equipment, has the trainee operated MacLean Bolters or partial training in the past?) Any deviations or additions to the training agenda should be recorded either on the checklist sheet or in a Service Report Summary (record training related SRS #’s in the table following the checklist). All information must be copied to MacLean Engineering’s Technical Service department. Certification will only be issued once checklist has been completed and signed off by trainee and trainer.

Page 3 of 6

aclean Canada MEM-928/946 Scissor Bolter Number: T-001 Revision: G SCISSOR BOLTER OPERATOR CHECKLIST MINE SITE:

BOLTER #:

TRAINER:

DATE:

TRAINEE Print:

EMPLOYEE #:

Signature: SECTION

TOPIC

NOTES / COMMENTS

OM-BOLTER-S1

General Safety

OM-BOLTER-S2

Operating Safety

OM-BOLTER-S3

Servicing Safety

OM-BOLTER-S4

Fire Prevention Safety

OM-BOLTER-V1

Overview & Safety Systems

OM-BOLTER-V2

Operator’s Compartment Layout

OM-BOLTER-V3

Scissor Deck Layout

OM-BOLTER-V4

Boom Assembly Layout

OM-BOLTER-V5

Hydraulic & Electrical Layout

OM-BOLTER-V6

Other Components

OM-BOLTER-O1

Scissor Bolter Control & Interlocks

OM-BOLTER-O2

Starting, Driving, Stopping, Parking, Shutdown

OM-BOLTER-O3

Brake Test

OM-BOLTER-O4

Deck Control Panel

OM-BOLTER-O5

Remote Pendent

OM-BOLTER-O6

Drilling

OM-BOLTER-O7

Screen Handling

OM-BOLTER-O8

Rock Bolt Installation

OM-BOLTER-O9

Rebar Installation

OM-BOLTER-O10

Split Set Installation

OM-BOLTER-O11

Swellex Bolt Installation

OM-BOLTER-O12

Bolting Options

OM-BOLTER-O13

Drill Lubrication System

OM-BOLTER-M

Daily Operator’s Maintenance

Total # of Training Hours =__________

Page 4 of 6

COMPLETED Initial

aclean Canada MEM-928/946 Scissor Bolter Number: T-001 Revision: G

SCISSOR BOLTER TRAINING RECORDS PREVIOUS EXPERIENCE: Record the trainee’s previous operating experience below (general experience - # years & type equipment, has the trainee operated MacLean Bolters or received partial training in the past?)

SRS REFERENCES: Record the #’s of any Service Report Summaries relating to the training of the operator.

Page 5 of 6

aclean Canada MEM-928/946 Scissor Bolter Number: T-001 Revision: G

Page 6 of 6

aclean Canada – OPERATOR TRAINING Number: Revision: Revision Date: By: Topic:

T-001_TESTQ A 10/11/05 KBB MEM-928/946 Scissor Bolter Operator Training Test

MEM-928/946/914 - Scissor Bolter Training Test

Safety Systems: Q 1. Name the location of the fire suppression palm actuators and how to activate them if the need arose. A. ____________________________________________________________ ____________________________________________________________ Q 2. Name two Safety lock features on the MacLean 928/946/914 bolter. A. 1) __________________________________________________________ 2) ___________________________________________________________ Q 3. The MEM-928/946/914 is equipped with three emergency stop pushbuttons. What are their locations? A. 1) __________________________________________________________ 2) ___________________________________________________________ 3) ___________________________________________________________ Q 4. What is the load capacity of the deck on the 928/946/914 bolter? A. ____________________________________________________________ _______________________________________________________________ _______________________________________________________________

Page 1 of 6

aclean Canada – OPERATOR TRAINING Number: T-001_TESTQ Revision: A

Q 5. One of the key safety systems present on the MEM-928/946/914 Scissor Bolter is the Tilt Interlock System which was integrated into the boom assembly. Explain the purpose of this safety feature. A. ____________________________________________________________ _______________________________________________________________ _______________________________________________________________

Q 6. The 928/946/914 MacLean bolter is equipped with one or two proximity switches. (Depending on age.) What is their purpose and location? A. 1) __________________________________________________________ 2) ___________________________________________________________ Q 7. When should a brake test be conducted on the MacLean bolter? A. ____________________________________________________________ _______________________________________________________________ _______________________________________________________________ Q 8. What does a complete brake test consist of? A. ____________________________________________________________ _______________________________________________________________ _______________________________________________________________ Q 9. If the unit moves in any of the three-brake test what is the operator required to do? A. ____________________________________________________________ _______________________________________________________________ Page 2 of 6

aclean Canada – OPERATOR TRAINING Number: T-001_TESTQ Revision: A

Q 10. What is the purpose of the Remote Drive System? A. ____________________________________________________________ _______________________________________________________________ _______________________________________________________________ Q 11. What two warning devices are activated when the Brake Release button is pressed and the Joystick trigger is pulled? A. 1) __________________________________________________________ 2) ___________________________________________________________ Q 12. Describe conditions, which must be met in order to release the brakes when tramming using the RDS. A. ____________________________________________________________ _______________________________________________________________ _______________________________________________________________ Q 13. (True or False) When using the RDS the Scissor bolter should be in the Auxiliary mode and the electric power pack running. If unit has a standard transmission it must be placed in neutral and the forward reverse lever in the reverse position.  True

False

Page 3 of 6

aclean Canada – OPERATOR TRAINING Number: T-001_TESTQ Revision: A

DECK CONTROL VALVES AND GAGES Q 14. What are the three functions of the drill control valves? A. 1) __________________________________________________________ 2) ___________________________________________________________ 3) ___________________________________________________________ Q 15. What is the purpose of the drill hour meter located on the deck, or in some models on the 600 V panel? A. ____________________________________________________________ _______________________________________________________________ _______________________________________________________________ Q 16. What is the purpose of the bolt rotation valve? A. ____________________________________________________________ _______________________________________________________________ _______________________________________________________________ Q 17. When and why does the deck extension light illuminate? A. ____________________________________________________________ _______________________________________________________________ _______________________________________________________________ Q 18. Which two steps must be followed prior to removing lubricator cap? A. 1) __________________________________________________________ 2) __________________________________________________________ Page 4 of 6

aclean Canada – OPERATOR TRAINING Number: T-001_TESTQ Revision: A

REMOTE PENDANT OPERATION: Q 19. The remote Pendant on the 928/946/914 Scissor Bolter is used as an alternative to the control panel on the deck. What function is not available on the Pendant when in Drill mode? A. ____________________________________________________________ Q 20. (Fill in the blank) The Emergency Stop button will stop the Scissor Bolter’s electric power pack and on the newer models will shutdown the_________________ also. Q 21. The Remote Pendant has two modes of functions, which are? A. 1) __________________________________________________________ 2) __________________________________________________________ Q 22. (True or False) The Remote Pendant cannot be operated while the diesel engine is running.  True

False

Q 23. During the Pre-operation of the Pendant you notice that one toggle switch is malfunctioning, what is the operator expected to do? A. ____________________________________________________________ _______________________________________________________________ DRILLING SET UP: Q 24. When setting up bolter for drilling and bolting in a working heading what is a safe practice to follow prior to starting up? A. ____________________________________________________________ _______________________________________________________________

Page 5 of 6

aclean Canada – OPERATOR TRAINING Number: T-001_TESTQ Revision: A

Q 25. (True or False) these checks are not required as part of the daily Pre-Operational Maintenance.  True

 False

-- Condition of seat belts

 True

 False

-- Check back –up alarm.

 True

 False

-- Test ground fault.

 True

 False

-- Check turbocharger/exhaust system (general condition).

 True

 False

-- Check hydraulic return filter bypass.

 True

 False

-- Tilt Interlock System test.

 True

 False

-- Deck Limit Switch Test

Q 26. What is the purpose of the air compressor? A. ____________________________________________________________ _______________________________________________________________ _______________________________________________________________ Q 27. I have studied the operators manual provided by MacLean Engineering on the MEM 928/946/914  Yes

 No

______________________________ Trainee’s name (Print)

_____________________________ (Sign)

Page 6 of 6