Atlas Copco

Boomer 104
Maintenance schedules

PM No. 9852 1529 01

2004-01
 SAFETY INSTRUCTIONS
Before starting, read all instructions carefully.

Special attention must be paid

to information alongside
this symbol.

Only use genuine Atlas Copco parts.

1250 0071 04

© Copyright 2004, Atlas Copco Rock Drills AB, Sweden

Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.

Atlas Copco Rock Drills AB

SE-70191 Örebro, Sweden
Table of Content

Safety ............................................................................................................. 5

Maintenance schedules ............................................................................... 7

3
4
Safety

5
6
Maintenance schedules
1. Introduction ............................................................................................................ 11
Interval................................................................................................................... 11
Division............................................................................................................. 11
Percussion hours ............................................................................................... 11
Diesel engine hours........................................................................................... 11
Lubricant................................................................................................................ 11
Tightening torques................................................................................................. 11

2. Percussion hours..................................................................................................... 12
Measures every 10 percussion hours..................................................................... 12
Feeder ............................................................................................................... 12
10-hour interval............................................................................................ 12
Boom................................................................................................................. 13
10-hour interval............................................................................................ 13
Hydraulic systems............................................................................................. 14
10-hour interval............................................................................................ 14
Compressor ....................................................................................................... 15
10-hour interval............................................................................................ 15
Water system..................................................................................................... 15
10-hour interval............................................................................................ 15
Cable reeling unit.............................................................................................. 16
10-hour interval............................................................................................ 16
Measures every 50 percussion hours..................................................................... 17
Feeder ............................................................................................................... 17
50-hour interval............................................................................................ 17
Boom................................................................................................................. 19
50-hour interval............................................................................................ 19
Hydraulic systems............................................................................................. 20
50-hour interval............................................................................................ 20
Cable reeling unit.............................................................................................. 20
50-hour interval............................................................................................ 20
Actions every 250 percussion hours...................................................................... 21
Feeder ............................................................................................................... 21
250-hour interval.......................................................................................... 21
Boom................................................................................................................. 22
250-hour interval.......................................................................................... 22
Hydraulic systems............................................................................................. 23
250-hour interval.......................................................................................... 23
Cable reeling unit.............................................................................................. 24
250-hour interval.......................................................................................... 24
Measures every 500 percussion hours................................................................... 24
Compressor ....................................................................................................... 24
500 hours...................................................................................................... 24
Actions every 1000 percussion hours.................................................................... 25
Boom................................................................................................................. 25
1000-hour interval........................................................................................ 25
Hydraulic systems............................................................................................. 26
1000-hour interval........................................................................................ 26

7
 Cable reeling unit.............................................................................................. 27
1000-hour interval........................................................................................ 27
Annual inspection .................................................................................................. 27
Fire fighting system, option .............................................................................. 27

3. Diesel engine hours ................................................................................................ 28

Measures every 10 diesel engine hours ................................................................. 28
Signs.................................................................................................................. 28
10-hour interval............................................................................................ 28
Emergency stops ............................................................................................... 28
10-hour interval............................................................................................ 28
Fire extinguishers.............................................................................................. 29
10-hour interval............................................................................................ 29
Diesel engine..................................................................................................... 30
10-hour interval............................................................................................ 30
Brake system..................................................................................................... 31
10-hour interval............................................................................................ 31
Cable reeling unit.............................................................................................. 31
10-hour interval............................................................................................ 31
Exhaust filtering................................................................................................ 32
10-hour interval............................................................................................ 32
Fire fighting system, option .............................................................................. 33
10-hour interval............................................................................................ 33
Measures every 50 diesel engine hours ................................................................. 34
Diesel engine..................................................................................................... 34
50-hour interval............................................................................................ 34
Transmission ..................................................................................................... 35
50-hour interval............................................................................................ 35
Cable reeling unit.............................................................................................. 36
50-hour interval............................................................................................ 36
Fire fighting system, option .............................................................................. 36
50-hour interval............................................................................................ 36
Measures every 100 diesel engine hours ............................................................... 37
Diesel engine..................................................................................................... 37
100-hour interval.......................................................................................... 37
Measures every 250 diesel engine hours ............................................................... 38
Transmission ..................................................................................................... 38
250-hour interval.......................................................................................... 38
Brake system..................................................................................................... 39
250-hour interval.......................................................................................... 39
Cable reeling unit.............................................................................................. 39
250-hour interval.......................................................................................... 39
Measures every 500 diesel engine hours ............................................................... 40
Diesel engine..................................................................................................... 40
500-hour interval.......................................................................................... 40
Brake system..................................................................................................... 41
500-hour interval.......................................................................................... 41
Cable reeling unit.............................................................................................. 42
500-hour interval.......................................................................................... 42
Measures every 1000 diesel engine hours ............................................................. 43
Diesel engine..................................................................................................... 43

8
 1000-hour interval........................................................................................ 43
Transmission ..................................................................................................... 44
1000-hour interval........................................................................................ 44
Brake system..................................................................................................... 45
1000-hour interval........................................................................................ 45
Cable reeling unit.............................................................................................. 45
1000-hour interval........................................................................................ 45
Measures every 2000 diesel engine hours ............................................................. 46
Diesel engine .................................................................................................... 46
2000-hour interval........................................................................................ 46
Transmission ..................................................................................................... 47
2000-hour interval........................................................................................ 47
Cable reeling unit.............................................................................................. 47
2000-hour interval........................................................................................ 47

9
10
1. Introduction

Interval

Division
The maintenance intervals for various rig components are based on
percussion hours and diesel engine hours.

Percussion hours
Percussion hours apply to components that are mainly in operation
during drilling. Examples; rock drill, feeder and boom.

Percussion hours can be read on the hour counter in the electric

cabinet.

For information on rock drill maintenance intervals, see separate

documentation for the rock drill in question.

Diesel engine hours

Diesel engine hours apply to components that are primarily in
operation when the rig is moved, e.g. diesel engine, transmission
and brake system.

Diesel engine hours can be read on the control panel from the hour
counter.

Lubricant
For information on recommended lubricants, see maintenance
instructions Lubricants, coolants and propellants.

Tightening torques
The tightening torques specified in the Atlas Copco standard apply
to most bolted joints. See maintenance instructions General. For
bolted joints requiring special tightening torques, these torques are
specified in the maintenance instructions for the component in
question.

11
2. Percussion hours

Measures every 10 percussion hours

Feeder
10-hour interval

4 6
14 7 10 8
6

1250 0065 07 3 12
6 13
10 7 15
BMHE BMH, BMHS

11 6 11 6

Figure 2.1. Check points, feeder BMH, BMHE, BHMS 2000

12
 4 6
14 10 8

6
10

1250 0065 06 12
6 3
15 7 13

11 6

11

Figure 2.2. Check points, feeder BMHT 2000

Table 2.1. Action, feeder

Check point Control object Action
Sliding surfaces Lubricate (if water lubrication is not satisfactory
when drilling).
Hoses Check for leaks and damage.

Boom
10-hour interval

3,7 4

1
6
1250 0096 56

9
5
2,8 1

Figure 2.3. Check points, boom BUT 4

13
 Table 2.2. Action, boom BUT 4
Check point Control object Action
- Entire boom Check and rectify any damage and leaks.

Hydraulic systems
10-hour interval

Figure 2.4. Check points, hydraulic system

Table 2.3. Action, hydraulic system

Check point Control object Action
1 Hydraulic oil reservoir Check the oil level through the sight glass.
2 Return oil filter Check for blockage.
3 Breather filter Check for blockage.
- Hydraulic hoses Check for leaks.

14
Compressor
10-hour interval

AF

1250 0071 26

SG

Figure 2.5. Compressor LE22, LE55, LE75

Table 2.4. Action, compressor

Check point Control object Action
SG Compressor Check oil level. Top up as necessary.

Water system
10-hour interval

4
5
1
1250 0099 68

Figure 2.6. Check points, water system

15
 Table 2.5. Action, water system
Check point Control object Action
5 Water strainer Clean the strainer. See maintenance instructions
Water system: Cleaning the water strainer.

Cable reeling unit

10-hour interval

2 1 3

1250 0135 03

1 Collector
2 Grease nipples
3 Drive chain
Figure 2.7. Check points, cable reeling unit

Table 2.6. Action, cable reeling unit

Check point Control object Action
1 Collector In order to avoid short circuits in the cable reeling
unit collector caused by oxide formation, the reeling
unit should be rotated at least once per shift.

16
Measures every 50 percussion hours

Feeder
50-hour interval

4 6
14 7 10 8
6

1250 0065 07 3 12
6 13
10 7 15
BMHE BMH, BMHS

11 6 11 6

Figure 2.8. Check points, feeder BMH, BMHE, BHMS 2000

17
 4 6
14 10 8

6
10

1250 0065 06 12
6 3
15 7 13

11 6

11

Figure 2.9. Check points, feeder BMHT 2000

Table 2.7. Action, feeder

Check point Control object Action
3 Haul rope pulleys Lubricate
4 Water-hose drum Lubricate
Complete feeder Clean.
6 Bolted joints Check tightness.
7 Haul and return rope Check wear and tension.
8 Drill steel bushings Check wear.
10 Slide pieces Check play and wear.
11 Slide rails Check wear and other damage.
12 Dowel Check wear.

18
Boom
50-hour interval

3,7 4

1
6
1250 0096 56

9
5
2,8 1

Figure 2.10. Check points, boom BUT 4

Table 2.8. Action, boom BUT 4

Check point Control object Action
1 Cylinder shafts Grease (6 nipples)
2 Cylinder links Grease (2 nipples)
3 Boom link Grease (1 nipple)
4 Bearing housing Grease (1 nipple)
5 Boom telescope Top up with oil
6 Feed holder shaft Grease (1 nipple)
- Hoses, cylinders, valves, valve Check and rectify any damage and leaks
blocks
- Grease nipples Check and rectify any damage
Replace damaged nipples
- Hydraulic pressure Check the pressure setup.
- Threaded joints Check tightening torques, see maintenance instruc-
tions Boom: Bolted joints
9 Boom body Check oil level, top up as necessary

19
Hydraulic systems
50-hour interval

D
1250 0094 26

Figure 2.11. Check points, hydraulic system

Table 2.9. Action, hydraulic system

Check point Control object Action
D Hydraulic oil reservoir Drain condensation.

Cable reeling unit

50-hour interval

2 1 3

1250 0135 03

Figure 2.12. Check points, cable reeling unit

Table 2.10. Action. Cable reeling unit

Check point Control object Steps to take
1 Collector Clean and tighten bolted joints and replace dam-
aged parts

20
Actions every 250 percussion hours

Feeder
250-hour interval

4 6
14 7 10 8
6

1250 0065 07 3 12
6 13
10 7 15
BMHE BMH, BMHS

11 6 11 6

Figure 2.13. Check points, feeder BMH, BMHE, BHMS 2000

21
 4 6
14 10 8

6
10

1250 0065 06 12
6 3
15 7 13

11 6

11

Figure 2.14. Check points, feeder BMHT 2000

Table 2.11. Action, feeder

Check point Control object Action
13 Haul rope pulley bearings Check wear.
14 Water-hose drum bearings Check wear.
15 Hydraulic cylinder Check for leaks
Limit switches Check function and for leaks

Boom
250-hour interval

3,7 4

1
6
1250 0096 56

9
5
2,8 1

Figure 2.15. Check points, boom BUT 4

22
 Table 2.12. Action, boom BUT 4
Check point Control object Steps to take
7 Boom link bushings Check for wear
8 Cylinder link bushings Check for wear

Hydraulic systems
250-hour interval

Figure 2.16. Check points, hydraulic system

Table 2.13. Action, hydraulic system

Check point Control object Action
3 Breather filter Replace filter

23
Cable reeling unit
250-hour interval

2 1 3

1250 0135 03

Figure 2.17. Check points, cable reeling unit

Table 2.14. Action. Cable reeling unit

Check point Control object Action
- Gearbox, cable reeling unit Check the oil level

Measures every 500 percussion hours

Compressor
500 hours

AF

1250 0071 26

SG
Figure 2.18. Compressor LE22, LE55, LE75

24
 Table 2.15. Action, compressor
Check point Control object Action
AF Compressor Check air filter. See maintenance instructions Air
system: Air filter.

Actions every 1000 percussion hours

Boom
1000-hour interval

3,7 4

1
6
1250 0096 56

9
5
2,8 1

Figure 2.19. Check points, boom BUT 4

Table 2.16. Action, boom BUT 4

Check point Control object Action
9 Boom body Change oil

25
Hydraulic systems
1000-hour interval

Figure 2.20. Check points, hydraulic system

Table 2.17. Action, hydraulic system

Check point Control object Action
2 Return oil filter Change return oil filter.

26
Cable reeling unit
1000-hour interval

2 1 3

1250 0135 03

Figure 2.21. Check points, cable reeling unit

Table 2.18. Action. Cable reeling unit

Check point Control object Action
- Gearbox, cable reeling unit Change oil

Annual inspection

Fire fighting system, option

It is important that the fire fighting system is checked at least once
a year by an authorised service workshop. They will perform a
maintenance service on the system at the same time as its operation
is tested. For information on suitable service workshops, please
contact your local Atlas Copco representative.

27
3. Diesel engine hours

Measures every 10 diesel engine hours

Signs
10-hour interval

1250 0098 91

Figure 3.1. Examples of signs

Table 3.1. Measures, signs

Check point Control object Action
- Rig signs Make sure all signs are in place and fully legible.
Clean all signs as necessary. With regard to sign lo-
cations and part numbers, see applicable spare
parts catalogue.

Emergency stops
10-hour interval

1250 0102 10

Figure 3.2. Emergency stops

Table 3.2. Measures, emergency stops

Check point Control object Action
- Emergency stops Check the function of all the emergency stops on
the rig. Locations of emergency stops, see safety
Emergency stop.

28
Fire extinguishers
10-hour interval

OK
OK

0
0
1250 0098 88

Figure 3.3. Fire extinguishers

Table 3.3. Action, fire extinguisher

Check point Control object
- Fire extinguishers
- Fire extinguishers
- Fire extinguishers
Action
Make sure the indicator is in the green zone.
Check that none of the seals are broken and that
service has been carried out within the prescribed
time.
Check that the fire extinguisher and its holder are
not damaged.

29
Diesel engine
10-hour interval

1250 0088 46
4
2
7 D

Figure 3.4. Check points, Deutz 912W diesel engine

Table 3.4. Action, diesel engine

Check point Control object Action
4 Oil level Check oil level. See maintenance instructions En-
gine: Checking oil level.
A Air filter Check cleanness. See maintenance instructions
Engine: Air system.

30
Brake system
10-hour interval

1 Boom shaft
2 Engine shaft
3 Hydraulic transmission
Figure 3.5. Check points, brake system

Table 3.5. Action, brake system

Check point Control object Action
- Foot brake Check the foot brakes at low speed before starting
long transport.

Cable reeling unit

10-hour interval

2 1 3

1250 0135 03

Figure 3.6. Check points, cable reeling unit

31
 Table 3.6. Action, cable reeling unit
Check point Control object Action
- Hose connections Check for leaks

Exhaust filtering
10-hour interval

E A

D B

1250 0068 26
C
Figure 3.7. Check points, scrubber

Table 3.7. Action, scrubber

Check point Control object Action
Scrubber Fill with water. See maintenance instructions Ex-
haust filtering: Filling water in the scrubber.

32
Fire fighting system, option
10-hour interval

1 2
2.1

4 5
5.1
4.1

4.2 5.4

4.3

5.3

5.2

6 6.2

6.1
1250 0103 96

6.3

Figure 3.8. Check points, fire fighting system

Table 3.8. Action, fire fighting system

Check point Control object
1 Nozzles
2 Hose system
4 Powder container
Action
Check that nozzles are clean and the protective
caps are fitted and tight.
Make sure all couplings are tight (2.1). Make sure all
hoses are intact and that all hose attachments are
securely bolted or welded.
Make sure service has been carried out within the
prescribed time (4.1) and that the holder is not dam-
aged (4.2). Corrosion must not be present (4.3).

33
Check point Control object Action
5 Check of pneumatic check-fire Check connections for leaks (5.1) and that the lamp
system, option is on (5.2). Inspect also electric lines for damage
(5.3) and make sure the pressure gauge is not
showing red (5.4).
6 Detector valve, option Make sure there are no signs of cuts (6.1) or chafing
(6.3). Make also sure that nylon clamps are tight
(6.2) and there are no leaking connections.

Measures every 50 diesel engine hours

Diesel engine
50-hour interval

1250 0088 46
4
2
7 D

Figure 3.9. Check points, Deutz 912W diesel engine

Table 3.9. Action, diesel engine

Check point Control object Action
Oil leak Check for oil leaks.
7 Engine oil Change engine oil. See maintenance instructions
Engine: Changing oil.
3 Oil filter Change oil filter. See maintenance instructions En-
gine: Changing oil filter.

34
Check point Control object
1 Fuel filter
Valve clearance
Engine suspension
B All belts
2 Preliminary fuel filter
Glow plugs
Tightening torques
Action
Change fuel filter. See maintenance instructions
Engine: Changing fuel filter.
Check valve clearance and adjust as necessary.
(See Deutz manual)
Check that all bolts are tightened to the correct
torque and retighten if necessary.
Make sure belts are not slack. See maintenance in-
structions Engine: Belts.
Clean the filter.
Check and clean as necessary.
Check that all bolts are tightened to the correct
torque. See maintenance instructions General:
Tightening torques.

Transmission
50-hour interval

Figure 3.10. Check points, transmission

Table 3.10. Action, transmission

Check point Control object
A Tyres, front axle
A Tyres, rear axle
2 Transmission
Action
Check air pressure (9 bar), adjust if necessary.
Check air pressure (9 bar), adjust if necessary.
Check oil level. See maintenance instructions
Transmission: Hydraulic transmission.

35
Cable reeling unit
50-hour interval

2 1 3

1250 0135 03

Figure 3.11. Check points, cable reeling unit

Table 3.11. Action, cable reeling unit

Check point Control object Action
- Drive chain Lubricate
- Bearings Grease (4 nipples)

Fire fighting system, option

50-hour interval

A
1250 0103 95

Figure 3.12. Check points, fire fighting system

Table 3.12. Action, fire fighting system

Check point Control object Action
A Trigger Check that actuator lock pins are in place.

36
Measures every 100 diesel engine hours

Diesel engine
100-hour interval

1250 0088 46
4
2
7 D

Figure 3.13. Check points, Deutz 912W diesel engine

Table 3.13. Action, diesel engine

Check point Control object Action
D Battery connections Clean and grease the terminals.

37
Measures every 250 diesel engine hours

Transmission
250-hour interval

Figure 3.14. Check points, transmission

Table 3.14. Action, transmission

Check point Control object Action
B Final drive Check oil level. Top up as necessary. See mainte-
nance instructions Transmission: Wheel axles.
C Hub gear Check oil level. Top up as necessary. See mainte-
nance instructions Transmission: Wheel axles.
D Wheel nuts Check tightening torque (350 Nm)
Central lubrication Check hoses and nipples. Fill with grease. See
maintenance instructions Transmission: Lubricating
the chassis.
E Spider joint Check hoses and nipples. Fill with grease. See
maintenance instructions Transmission: <Lubricat-
ing the chassis.

38
Brake system
250-hour interval

1 Boom shaft
2 Engine shaft
3 Hydraulic transmission
Figure 3.15. Check points, brake system

Table 3.15. Action, brake system

Check point Control object Action
- Parking brake Check functionality and adjust as necessary. See
maintenance instructions Brake system: Checking
the parking brake pressure.

Cable reeling unit

250-hour interval

2 1 3

1250 0135 03

Figure 3.16. Check points, cable reeling unit

39
 Table 3.16. Action, cable reeling unit
Check point Control object Action
- Gears, cable reeling unit Check oil level. See maintenance instructions Reel-
ing units: Reeling unit gear.
- Gears, cable reeling unit Check fasteners and cleanliness. See maintenance
instructions Reeling units: Adjusting the reeling unit
slip clutch.
3 Drive chain Check the tension. See maintenance instructions
Reeling units: Adjusting reeling unit drive chain.

Measures every 500 diesel engine hours

Diesel engine
500-hour interval

1250 0088 46
4
2
7 D

Figure 3.17. Check points, Deutz 912W diesel engine

Table 3.17. Action, diesel engine

Check point Control object Action
7 Engine oil Change engine oil. See maintenance instructions
Engine: Changing oil.
3 Oil filter Change oil filter. See maintenance instructions En-
gine: Changing oil filter.

40
Check point Control object Action
Engine suspension Check that all bolts are tightened to the correct
torque and retighten if necessary.
B All belts Make sure belts are not slack and tension as neces-
sary. See maintenance instructions Engine: Belts.
Fuel tank Drain condensate from the tank. See maintenance
instructions Engine: Draining the fuel tank.

Brake system
500-hour interval

1 Boom shaft
2 Engine shaft
3 Hydraulic transmission
Figure 3.18. Check points, brake system

Table 3.18. Action, brake system

Check point Control object Action
- Brake system Check the brake pressure and adjust as necessary.
See maintenance instructions Brake system:
Checking service brake pressure.

41
Cable reeling unit
500-hour interval

2 1 3

1250 0135 03

Figure 3.19. Check points, cable reeling unit

Table 3.19. Action, reeling unit

Check point Control object Action
- Gears Check oil level. See maintenance instructions Reel-
ing units: Reeling unit gear.
- Gears Adjusting the reeling unit slip clutch. See mainte-
nance instructions Reeling units: Adjusting the reel-
ing unit slip clutch.
3 Drive chain Check the tension. See maintenance instructions
Reeling units: Adjusting reeling unit drive chain.

42
Measures every 1000 diesel engine hours

Diesel engine
1000-hour interval

1250 0088 46
4
2
7 D

Figure 3.20. Check points, Deutz 912W diesel engine

Table 3.20. Action, diesel engine

Check point Control object Action
1 Fuel filter Change fuel filter. See maintenance instructions
Engine: Changing fuel filter.
Glow plugs Check and clean as necessary.
Hoses and connections (on air check that hoses are sound and that the connec-
side) tions do not leak. Change as necessary.

43
Transmission
1000-hour interval

Figure 3.21. Check points, transmission

Table 3.21. Action, transmission

Check point Control object Action
F2 Transmission Change oil. See maintenance instructions Trans-
mission: Hydraulic transmission.

44
Brake system
1000-hour interval

1 Boom shaft
2 Engine shaft
3 Hydraulic transmission
Figure 3.22. Check points, brake system

Table 3.22. Action, brake system

Check point Control object Action
Brake pads Check wear and replace as necessary. See main-
tenance instructions Brake system: Checking brake
disc wear.

Cable reeling unit

1000-hour interval

2 1 3

1250 0135 03

Figure 3.23. Check points, cable reeling unit

45
 Table 3.23. Action, cable reeling unit
Check point Control object Action
Gears Change oil. See maintenance instructions Reeling
units:

Measures every 2000 diesel engine hours

Diesel engine
2000-hour interval

1250 0088 46
4
2
7 D

Figure 3.24. Check points, Deutz 912W diesel engine

Table 3.24. actions, diesel engine

Check point Control object Action
2 Preliminary fuel filter Clean the filter

46
Transmission
2000-hour interval

Figure 3.25. Check points, transmission

Table 3.25. Action, transmission

Check point Control object Action
B Final drive Change oil. See maintenance instructions Trans-
mission: Wheel axles.
C Hub gear Change oil. See maintenance instructions Trans-
mission: Wheel axles.
Articulated joint Check for wear. Change if necessary.

Cable reeling unit

2000-hour interval

2 1 3

1250 0135 03

Figure 3.26. Check points, cable reeling unit

47
 Table 3.26. Action, reeling unit
Check point Control object Action
- Gears Change oil. See maintenance instructions Reeling
units.

48