TIS0003768.002 en-US Boomer 282 - Maintenance

Maintenance
Boomer 282
Original Instructions
2021-03-17 | No: TIS0003768.002 en-US
Boomer 282 Table of Contents
Table of Contents
1 Introduction .......................................................................................................... 11
1.1 Safety First .............................................................................................................................. 11
1.2 The Purpose of This Publication ........................................................................................... 11
1.3 Target Group ........................................................................................................................... 11
1.4 Product Warranty .................................................................................................................... 11
2 About Maintenance Management....................................................................... 13

2.1 Maintenance Management and Hour Meters ........................................................................ 13
2.2 Maintenance Records ............................................................................................................. 13
3 General Machine Condition ................................................................................ 15

3.1 Wash Machine Externally ....................................................................................................... 15
3.2 Check Condition of Signs ...................................................................................................... 15
4 Fire Fighting Equipment ..................................................................................... 17

4.1 Check Fire Extinguishers ....................................................................................................... 17
4.2 Check and Lubricate Reset Plunger ..................................................................................... 17
4.3 Check Fire Fighting System................................................................................................... 18
4.4 Check Fire Fighting System Actuators ................................................................................. 19
4.5 Loosen up Powder in Handheld Fire Extinguisher .............................................................. 19
5 Operator Environment......................................................................................... 21
5.1 Technical Data......................................................................................................................... 21
5.2 Check Fresh Air Filter............................................................................................................. 21
5.3 Adjusting Belt Tension ........................................................................................................... 22
5.4 Troubleshooting Air Conditioner .......................................................................................... 22
6 Boom Unit............................................................................................................. 25
6.1 Safety Precautions before Working on Boom Unit.............................................................. 25
6.2 Boom Overview ....................................................................................................................... 26
6.3 BUT 28 G Technical Data ....................................................................................................... 27
6.4 Hose Location in Bulkhead Connection ............................................................................... 27
6.5 Check Boom Condition .......................................................................................................... 28
6.6 Check Boom ............................................................................................................................ 28
6.7 Check Special Tightening Torque on Boom BUT 28 ........................................................... 29
6.8 Lubricate Boom....................................................................................................................... 31
6.9 Check Bearing Points ............................................................................................................ 32
6.10 Using a New or Reconditioned Boom ................................................................................... 32
6.11 Hoisting the Boom .................................................................................................................. 33
6.12 Disassembling Feeder from Boom........................................................................................ 35
6.13 Disassembling Boom Body ................................................................................................... 36
6.14 Disassembling Expander Shafts ........................................................................................... 36
6.15 Assembling Expander Shafts ................................................................................................ 37
6.16 Disassembling Boom Extension ........................................................................................... 39
6.17 Checking Bushings in Bearing Housing .............................................................................. 39
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6.18 Checking Keys on Telescope Device.................................................................................... 41

6.19 Checking Slide Rails on Telescope Device .......................................................................... 41
6.20 Adjusting Tilt Cylinder............................................................................................................ 42
7 Feed Unit .............................................................................................................. 45

7.1 Safety Precautions before Working on Feed Unit ............................................................... 45
7.2 Feed Unit 2000-Series............................................................................................................. 45
7.3 Feed Unit 2000-series Technical Data................................................................................... 47
7.4 Lubricate Sliding Surfaces on Feed Unit .............................................................................. 48
7.5 Check Hoses on Feed Unit..................................................................................................... 48
7.6 Check Drill Rod Support BSH 110 ......................................................................................... 48
7.7 Lubricate Drill Rod Support BSH 45 ..................................................................................... 49
7.8 Lubricate Pulleys and Hose Drum......................................................................................... 49
7.9 Clean Feed Unit ....................................................................................................................... 50
7.10 Check Wear and Damage on Feed Unit ............................................................................... 51
7.11 Replace Parts on Drill Rod Support BSH 110 ...................................................................... 52
7.12 Check Drill Rod Support BSH 45 ........................................................................................... 52
7.13 Check Wear on Bearings........................................................................................................ 52
7.14 Check Hydraulic Cylinder ..................................................................................................... 53
7.15 Check Limit Switches ............................................................................................................. 53
7.16 Replace Rock Drill Retaining Bolts ....................................................................................... 53
7.17 Installing Rock Drill and Rotation Unit ................................................................................. 55
7.17.1 Checking Rock Drill and Rotation Unit after Four Hours ...................................................... 56
7.18 Location of Drill Hoses ........................................................................................................... 56
7.19 Adjusting Hoses on Rock Drill .............................................................................................. 59
7.20 Replacing the Haul Rope........................................................................................................ 60
7.21 Adjusting Haul and Return Ropes......................................................................................... 61
7.22 Adjusting Tension of Return Rope........................................................................................ 61
7.23 Adjusting Cradle on Feed Beam............................................................................................ 62
7.24 Adjusting Feed Beam on Telescope Feed ............................................................................ 64
7.25 Replacing Slide Pieces in the Holder .................................................................................... 65
7.26 Replacing Slide Rails.............................................................................................................. 65
7.27 Adjusting Different Drill Rods Lengths for the Telescope Feed ........................................ 67
7.28 Disassembling Feed Cylinder ................................................................................................ 67
7.29 Disassembling Tension Bushing for Spacer........................................................................ 70
7.30 Assembling Tension Bushing for Spacer............................................................................. 71
7.31 Dismantling Upper Feed Beam .............................................................................................. 72
7.32 Dismantling Lower Feed Cylinder ......................................................................................... 73
8 Rotation Unit ........................................................................................................ 75

8.1 Safety Precautions before Working on Rotation Unit ......................................................... 75
8.2 Rotation Unit ........................................................................................................................... 75
8.3 Function of Rotary Actuators ................................................................................................ 76
8.4 Removing Rotary Actuator from Boom ................................................................................ 77
8.5 Disassembling Rotary Actuator ............................................................................................ 79
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8.6 Assembling Rotary Actuator ................................................................................................. 82

8.7 Reinstalling Rotary Actuator onto Boom ............................................................................. 85
9 Hydraulic System................................................................................................. 89
9.1 Safety Precautions before Working on Hydraulic System.................................................. 89
9.2 Technical Data......................................................................................................................... 89
9.3 About Working on Hydraulic Components .......................................................................... 90
9.4 Hydraulic Workshops ............................................................................................................. 90
9.5 Replacing Hydraulic Hoses.................................................................................................... 90
9.6 Check Hoses and Couplings ................................................................................................. 91
9.7 Hydraulic Oil ............................................................................................................................ 91
9.7.1 Oil Sampling ......................................................................................................................... 91
9.7.2 Check Oil Levels................................................................................................................... 91
9.7.3 Drain Water Condensation from Hydraulic Oil Tank............................................................. 92
9.7.4 Emptying Hydraulic Oil Tank ................................................................................................ 93
9.7.5 Filling Hydraulic Oil Manually ............................................................................................... 93
9.8 Hydraulic Filters ...................................................................................................................... 94
9.8.1 Check Return Oil Filter ......................................................................................................... 94
9.8.2 Replace Return Oil Filter ...................................................................................................... 94
9.8.3 Check Hydraulic Tank Breather Filter................................................................................... 96
9.8.4 Replace Breather Filter......................................................................................................... 96
9.9 Hydraulic Pumps..................................................................................................................... 98
9.9.1 Overview of Power Unit Pumps............................................................................................ 98
9.9.2 Starting New or Reconditioned Pump .................................................................................. 98
9.9.3 Checking Pump Rotation Direction....................................................................................... 99
9.9.4 Replace Coupling Set for Electric Motor............................................................................. 100
9.9.5 Bleeding Hydraulic Pump ................................................................................................... 102
9.9.6 Circulating Hydraulic Pump ................................................................................................ 103
9.10 Settings .................................................................................................................................. 104
9.10.1 Safety Precautions before Pressure Setting....................................................................... 104
9.10.2 Pressure Settings and Rotation speeds ............................................................................. 104
9.10.3 Main Pump ......................................................................................................................... 106
9.10.4 Rotation Pump.................................................................................................................... 109
9.10.5 Feed Pressure .................................................................................................................... 117
9.10.6 Anti-jamming Protection ..................................................................................................... 124
9.10.7 ECL Lubricating System Adjustment .................................................................................. 130
10 Diesel Engine ..................................................................................................... 133

10.1 Safety Precautions before Working on Diesel Engine ...................................................... 133
10.2 Technical Data....................................................................................................................... 133
10.3 Check Glow Plugs................................................................................................................. 134
10.4 Check Pipe Connections ...................................................................................................... 134
10.5 Check Tightening Torque on Engine Suspension Bolts ................................................... 134
10.6 Lifting Engine Package ........................................................................................................ 135
10.7 Fuel System ........................................................................................................................... 135
10.7.1 Drain Water Condensation from Fuel Tank ........................................................................ 135
10.7.2 Replace Fuel Filter ............................................................................................................. 136
10.7.3 Clean Primary Fuel Filter.................................................................................................... 137
10.7.4 Bleeding Fuel System ........................................................................................................ 138
10.7.5 Draining Water Separator................................................................................................... 138
10.7.6 Filling Water Separator....................................................................................................... 139
10.8 Air System ............................................................................................................................. 140
10.8.1 Check Air Filter ................................................................................................................... 140
10.8.2 Replace Air Filter Cartridge ................................................................................................ 140
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10.8.3 Replace Air Filter Safety Cartridge ..................................................................................... 141

10.8.4 Cleaning Dust Valve ........................................................................................................... 142
10.9 Oil System ............................................................................................................................. 142
10.9.1 Check Engine Oil Level ...................................................................................................... 142
10.9.2 Replace Engine Oil............................................................................................................. 143
10.9.3 Replace Engine Oil Filter.................................................................................................... 144
10.10 Belts ....................................................................................................................................... 145
10.10.1 Check Belt Tension ............................................................................................................ 145
10.10.2 Adjust Alternator Belt.......................................................................................................... 145
10.10.3 Replace Cooling Fan Belt................................................................................................... 146
10.10.4 Replace Alternator Belt....................................................................................................... 146
10.10.5 Check Valve Clearance ...................................................................................................... 147
10.11 Alternator ............................................................................................................................... 148
10.12 Engine Diagnostics............................................................................................................... 148
11 Exhaust System ................................................................................................. 149

11.1 Safety Precautions before Working on Exhaust System .................................................. 149
11.2 Replacing Catalytic Converter ............................................................................................. 149
12 Electrical System ............................................................................................... 151

12.1 Lubricate Battery Connections............................................................................................ 151
13 Electrical System, IEC and Australia ............................................................... 153

13.1 Safety Precautions before Working on Electrical System ................................................ 153
13.2 Safety Precautions before Working on Lighting................................................................ 153
13.3 Before Troubleshooting Electrical System ........................................................................ 153
13.4 Cable Marking ....................................................................................................................... 154
13.5 Electrical Component Marking ............................................................................................ 154
13.6 Low-Voltage Circuit .............................................................................................................. 154
13.7 Extra Low-Voltage Circuit .................................................................................................... 154
13.8 Electrical Distribution Cabinet............................................................................................. 155
13.8.1 Electrical Distribution Cabinet IEC, AUS (380–690 V) ....................................................... 155
13.8.2 Electrical Distribution Cabinet IEC, AUS (1000V) .............................................................. 156
13.8.3 Overview of Voltmeter and Ammeter.................................................................................. 156
13.8.4 Hour Counter ...................................................................................................................... 157
13.8.5 Checking Voltage, Current, and Percussion Running Hours.............................................. 157
13.8.6 Setting Up Soft Start........................................................................................................... 158
13.9 Electrical System Protection ............................................................................................... 158
13.9.1 Main Switch Q01 ................................................................................................................ 158
13.9.2 Resetting Phase Sequence Alarm...................................................................................... 159
13.9.3 Ground Fault Equipment .................................................................................................... 159
13.10 Motor Protection Relay Fanox ............................................................................................. 160
13.10.1 Overview of Electronic Motor Protection Relay .................................................................. 161
13.10.2 Checking if Motor Protection is Triggered .......................................................................... 162
13.10.3 Checking if Motor Protection Is Triggered (for 360–690 V) ................................................ 162
13.10.4 Setting Rated Current......................................................................................................... 163
13.10.5 Fuses for Carrier................................................................................................................. 163
14 Electrical System, Canada and USA ................................................................ 165

14.1 Safety Precautions before Working on Electrical System ................................................ 165
14.2 Safety Precautions before Working on Lighting................................................................ 165
14.3 Before Troubleshooting Electrical System ........................................................................ 165
14.4 Cable Marking ....................................................................................................................... 166
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14.5 Electrical Component Marking ............................................................................................ 166

14.6 Low-Voltage Circuit .............................................................................................................. 166
14.7 Extra Low-Voltage Circuit .................................................................................................... 166
14.8 Electrical Distribution Cabinet, High-Current .................................................................... 167
14.8.1 Electrical Distribution Cabinet............................................................................................. 167
14.8.2 Electrical Distribution Cabinet Direct Start.......................................................................... 168
14.8.3 Electrical Distribution Cabinet Soft Start............................................................................. 169
14.9 Electrical System Protection ............................................................................................... 170
14.9.1 Main Switch ........................................................................................................................ 170
14.9.2 Setting Short-Circuit Protection .......................................................................................... 170
14.9.3 Resetting Phase Sequence Alarm...................................................................................... 170
14.9.4 Ground Fault Equipment .................................................................................................... 170
14.10 Motor Protection ................................................................................................................... 170
14.10.1 Thermal Overload Protection.............................................................................................. 170
14.10.2 Cabinet with Soft Start USA ............................................................................................... 171
14.10.3 Alignment Form, Soft Start ................................................................................................. 171
14.10.4 Diagnostics ......................................................................................................................... 172
15 Water System ..................................................................................................... 173

15.1 Safety Precautions before Working on Water System ...................................................... 173
15.2 Clean Water Strainer............................................................................................................. 173
15.3 Replacing Water Pump Shaft Seal - Hydraulic Drive ......................................................... 174
15.4 Replacing Water Pump Shaft Seal - Electric Drive ............................................................ 176
15.5 Setting Water Flow Switch ................................................................................................... 177
15.6 Draining Water System......................................................................................................... 178
15.7 Thermostat ............................................................................................................................ 179
16 Pneumatic System............................................................................................. 181
16.1 Safety Precautions before Working on Pneumatic System .............................................. 181
16.2 Overview of Compressor ..................................................................................................... 181
16.3 Check Oil Level ..................................................................................................................... 182
16.4 Check Air Filter ..................................................................................................................... 182
16.5 Draining Condensation from Air Tank ................................................................................ 183
16.6 Adjusting Compressor Unloading Pressure ...................................................................... 183
16.7 Adjusting Compressor Loading Pressure .......................................................................... 184
16.8 Adjusting Lubrication Air Pressure .................................................................................... 185
17 Water Mist System............................................................................................. 187

17.1 Technical Data....................................................................................................................... 187
17.2 Checking Water Mist Pump.................................................................................................. 187
17.3 Check Water Mist Pump for Leaks ...................................................................................... 189
17.4 Check Water Mist Pump Oil Level ....................................................................................... 189
17.5 Replace Oil in Water Mist Pump .......................................................................................... 189
18 Power Train ........................................................................................................ 191

18.1 Safety Precautions before Working on Power Train ......................................................... 191
18.2 Power Train Overview .......................................................................................................... 191
18.3 Steering System .................................................................................................................... 192
18.4 Technical Data....................................................................................................................... 192
18.5 Check Tire Pressure ............................................................................................................. 193
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18.6 Check Oil Level in the Transmission .................................................................................. 194

18.7 Check Oil Level in the Axle Differential .............................................................................. 194
18.8 Check Oil Level in Planetary Gears..................................................................................... 195
18.9 Check Tightening Torque on Wheel Bolts and Nuts ......................................................... 196
18.10 Check Central Lubrication Hoses and Nipples .................................................................. 196
18.11 Check Spider Joints ............................................................................................................. 196
18.12 Replace Transmission Oil Filter .......................................................................................... 197
18.13 Replace Transmission Oil .................................................................................................... 198
18.14 Replace Oil in Planetary Gears............................................................................................ 198
18.15 Replace Oil in Axle Differential ............................................................................................ 200
18.16 Check Articulated Joint ........................................................................................................ 201
18.17 Checking Tires and Rims ..................................................................................................... 201
18.18 Lubricating Cardan Shafts ................................................................................................... 202
18.18.1 Filling Central Lubrication System ...................................................................................... 203
19 Brake System ..................................................................................................... 205

19.1 Safety Precautions before Working on Brake System ...................................................... 205
19.2 Technical Data....................................................................................................................... 205
19.3 Check Service Brake Pressure ............................................................................................ 205
19.4 Check Parking Brake Pressure............................................................................................ 207
19.5 Check Brake Discs................................................................................................................ 208
19.6 Checking Accumulator Charge Pressure ........................................................................... 209
19.7 Checking Brake Pressure Control Valve ............................................................................ 209
19.8 Checking Accumulators ....................................................................................................... 211
19.9 Replacing Accumulator ........................................................................................................ 212
19.10 Bleeding the Service Brake and Parking Brake ................................................................. 213
20 Reeling Unit ........................................................................................................ 215

20.1 Power Supply Cable ............................................................................................................. 215
20.2 Reeling Unit RAC 612/RAC 614 ........................................................................................... 216
20.3 Reeling Unit RAC 611 ........................................................................................................... 216
20.4 Rotate Reeling Unit ............................................................................................................... 217
20.5 Check Hose Connections..................................................................................................... 217
20.6 Check Cable Reeling Unit Collector ................................................................................... 217
20.7 Lubricate Drive Chain and Bearings ................................................................................... 218
20.8 Check Oil Level in Reeling Unit Gear .................................................................................. 218
20.9 Adjust Reeling Unit Slip Clutch ........................................................................................... 218
20.10 Adjust Reeling Unit Drive Chain ......................................................................................... 219
20.11 Replace Oil in Reeling Unit Gear ......................................................................................... 219
20.12 Adjusting Reeling Unit Speed.............................................................................................. 220
20.13 Adjusting Limit Switch ......................................................................................................... 220
21 Automatic Central Lubrication System CLS ................................................... 223

21.1 Central Lubrication System ................................................................................................ 223
21.2 Central Lubrication System Power Supply ........................................................................ 224
21.3 Central Lubrication System Circuit Diagram ..................................................................... 225
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21.4 Lubrication Pump Safety Valve ........................................................................................... 226

21.5 Lubrication Return Connection ........................................................................................... 226
21.6 Fill Lubricant ......................................................................................................................... 227
21.7 Test Central Lubrication System ......................................................................................... 228
21.8 Setting Lubrication Pause and Running Time ................................................................... 228
22 Component Locations ....................................................................................... 231

22.1 Pressure Gauges, Test Outlet and Flow Switch ................................................................ 231
22.2 Modules and Fuse Boxes ..................................................................................................... 232
22.3 Sensors .................................................................................................................................. 232
22.4 Hydraulic Controlled Valves ................................................................................................ 233
Maintenance table.............................................................................................. 235
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Boomer 282 1 Introduction
1 Introduction
1.1 Safety First

Always read the information in the Safety document before starting to use the product or
starting maintenance work.
1.2 The Purpose of This Publication

The objective of these maintenance instructions is to detect and correct the faults at an
early stage so that breakdowns, costly secondary damage, and accidents can be pre-
vented.
Regular maintenance is a precondition for planning necessary interruptions in operation
such as reconditioning and repairs.
The publication allows maintenance to be carried out when most suitable regarding pro-
duction instead of causing a complete breakdown.
1.3 Target Group

The information in this publication is intended for everyone involved in the application, op-
eration, and maintenance of the machine and related equipment. All readers are expected
to possess basic competence regarding mining methods, construction methods, and the
machines used for that kind of operation.
1.4 Product Warranty

The product warranty relies on correct use, maintenance, and repair of the machine and its
components at all times.
• Use only Epiroc original parts. Any damage or operational interruptions caused by us-
ing spare parts of other manufactures than Epiroc will not be covered by warranty.
• Epiroc is not liable for any damage caused by unauthorized modification to the ma-
chine and its equipment.
• Epiroc is not liable for damage caused by inappropriate use.
• Overloading the machine can result in damage to the structure which is not noticed
during normal usage. Such damage is not covered by the warranty.
• Damage that occurs as a result of inadequate maintenance, substandard repairs, or
damage to equipment that is attributable to older unrepaired damage, is not covered
by the warranty.
• Read Epiroc policy warranty.
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Boomer 282 1 Introduction
12 No: TIS0003768.002 en-US

Boomer 282 2 About Maintenance Management
2 About Maintenance Management
2.1 Maintenance Management and Hour Meters

Maintenance management is organized in scheduled intervals.
Scheduled intervals supplement each other. A longer interval comprises maintenance
tasks supplementary to tasks from a shorter interval. Maintenance management must be
done regularly at the shortest interval of the unit or function (whichever comes first during
operation of the machine).
Operational maintenance is planned based on the following hour meters:
• Hour meters for the rock drill operation system
• Hour meter for the engine
• Hour meter for the electric motor
• Time-based maintenance is vital for:
– All rubber components
– Lubricants that are at risk of breaking during standstills
– Pressure vessel corrosion and wear
– Substance regression
– Environmental exposure
! NOTE: Local conditions can affect the scheduled intervals.
2.2 Maintenance Records

Correct record keeping enables maintenance personnel to identify the correct maintenance
records and to evaluate problems and high-cost areas. All maintenance procedures must
be checked off as each inspection or procedure is completed. Quantities of replenished lu-
bricants and fluids, and pressure and flow readings, must be recorded. Any faults or devia-
tions must be recorded irrespective of whether they have been rectified or are waiting for
rectification.
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Boomer 282 2 About Maintenance Management
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Boomer 282 3 General Machine Condition
3 General Machine Condition
3.1 Wash Machine Externally

¡ Rinse the machine with water at least once a day to remove drill cuttings, mud and
dirt.
3.2 Check Condition of Signs

• Make sure that all signs are in place.
• Make sure that all signs are intact, clean, and fully readable.
• Always replace the defect or missing signs.
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Boomer 282 3 General Machine Condition
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Boomer 282 4 Fire Fighting Equipment
4 Fire Fighting Equipment
4.1 Check Fire Extinguishers
¡ Check that the indicator is in the green zone.
Replace the fire extinguisher if the indicator is in the red zone.
¡ Check the seals for damage.
Replace if necessary.
¡ Check the fire extinguisher body and holder for damage.
4.2 Check and Lubricate Reset Plunger
¡ Check that the reset plunger (A) on the pressure switch is easy to press.
¡ Lubricate the reset plunger (A) with grease.
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4.3 Check Fire Fighting System
¡ Check that the nozzles (A) are clean and the protective caps are fitted.
¡ Check that all couplings (B) on the hoses are tightened.
¡ Check that all hoses are intact and that all hose attachments are securely bolted or
welded.
¡ Check the service card (C) to verify that the service has been carried out within the
specified time.
¡ Check that the holder (D) is not damaged.
¡ Check for any signs of corrosion (E).
¡ Check the pneumatic system connections (F) for leaks.
¡ Check that the lamp (J) on the pneumatic system is ON.
¡ Check the electric lines (H) for damage.
¡ Check that the indicator on the pressure gauge (G) is not in the red zone.
¡ Check that the nylon clamps (K) are tightened.
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¡ Check for cuts (L) and chafing (M) on the detector valve.
4.4 Check Fire Fighting System Actuators
¡ Check that the actuator lock pin (A) is secured in the proper position.
4.5 Loosen up Powder in Handheld Fire Extinguisher

The powder in a fire extinguisher can settle to the bottom of the canister over time. This re-
duces the effectivity of the extinguisher.
¡ Tap the fire extinguisher canister carefully with a rubber mallet in order to loosen-up
the powder.
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Boomer 282 5 Operator Environment
5 Operator Environment
5.1 Technical Data
Air Conditioning Unit
Refrigerant R134a
Amount of refrigerant 1.1 kg (2.42 lbs)
Refrigerating capacity (27°C, RH 30%) 4.8 kW (6.43 hp)
Heating capacity, from diesel engine 1.2 kW (1.6 hp)
Air flow 470 m3/h
5.2 Check Fresh Air Filter
1. Remove the rubber plugs (A).
2. Remove the screws (B).
3. Remove the metal plate (C) from the air filter (D).
4. Check the air filter (D).

Clean the air filter or replace as necessary.
5. Reinstall the metal plate, screws, and rubber plugs.
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5.3 Adjusting Belt Tension
1. Remove the cover (A) from the condenser unit.
2. Turn the screws (B) until the required tension between the fan drive belt (C) and the
electric motor (D) is achieved.
3. Turn the screw (E) until the required tension between the compressor belt (F) and
the electric motor (D) is achieved.
4. Reinstall the cover (A) on the condenser unit.
5.4 Troubleshooting Air Conditioner
Fault Symptom Action
No cooling at all Check the fuses, electrical connections, compressor ground, electro-
magnets, switches, and pressure switches.
Check the V-belt and compressor.
Check the expansion valve and temperature control valve.
Check the coolant hoses.
Poor cooling Check the fresh-air fan and V-belt tension.
Check whether the air is passing the evaporator in the unit.
Check that the evaporator and condenser are not clogged and that the
filter in the air intake is not dirty.
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Fault Symptom Action
Check that the expansion valve capillary tube is firmly tightened against
the evaporator outlet pipe.
Check that the thermostat does not cut out too early.
Uneven cooling Check that the connections to switches, magnetic coupling, or pressure
switch are not loose.
Check that the expansion valve is not clogged.
Check that the system is filled and that the thermostat is working.
Abnormal noise Check that the multi-V-belt to the compressor is properly tightened and
that the compressor retaining bolts are tightened.
Check that the system is filled sufficiently and not overfilled.
Check that the expansion valve is in working order.
Check that the airflow across the evaporator is sufficient.
Check that the condenser is clean and the airflow is sufficient.
• Abnormal system noise is often related to incorrectly assembled

components. If the compressor is noisy at a certain speed and the
noise disappears when the speed increases or decreases, there is
probably nothing wrong with the compressor itself. The difference
between the pressure on the suction side and the pressure side
also affects the level of noise. A compressor with low suction
makes more noise than a compressor with high suction. Likewise,
a compressor with high pressure makes more noise because it
puts more load on bearings and other components.
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Boomer 282 6 Boom Unit
6 Boom Unit
6.1 Safety Precautions before Working on Boom Unit
WARNING
Disassembling and Assembling Components
Can cause personal injury.
u Components that could move or fall down must be securely supported or strapped in
place during service and maintenance work.
WARNING
Heavy Objects
Can cause crushing injury or death.
u Do not stand under the heavy object being lifted.
u Use adequate lifting equipment.
WARNING
Moving Parts
u Shut off the machine and lock the battery isolation switch before starting any work.
u Make sure that the hydraulic pump is off and that the system is depressurized before
starting work.
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6.2 Boom Overview
A Attachment Plate
B Rear Boom Cylinders
C Front Boom Cylinders
D Telescopic Unit
E Boom Head
F Rotary Actuator
G Tilt Cylinder
H Feed Holder
J Feed Extension Cylinder
The hydraulic boom is a telescopic boom with 360 degrees feed rotation. It features three-
point suspension at front and rear. Each three-point suspension unit includes two hydraulic
cylinders which, through series connection in pairs, provide parallel feed both vertically and
horizontally.
A tilt cylinder enables the feed to be positioned for roof and cross-cut drilling.
The rotary motion is obtained by a hydraulic rotary actuator and transferred through a stub
shaft to the feed.
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6.3 BUT 28 G Technical Data
Weight
Boom including positioning hose, feed (BMH 2300 kg (5070.63 lbs)

2343), rock drill (COP 1238), and assembly set
Length
Telescope Extended 6726 mm (264.8 in)
6.4 Hose Location in Bulkhead Connection
Position Description
A Bulkhead lead-through without RAS
B Bulkhead lead-through with RAS
AF Air flushing
AL Air lubrication
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Position Description
DS Hydraulic drill-steel support, option
F Feed
FE Feed extension
FL Tilt cylinder
FR Feed rotation
F2X Feed cylinder, telescope feeder
HD Percussion drain
HDP Reflex damper, drill
HP Percussion In
HT Percussion tank
LS Automatic rock drill return, option
M Electric cable, option RAS
RA Rod handling arm, option RAS
RG Gripper claw, option RAS
RGF Front gripper claw, rod handling, option RAS
RGR Rear gripper claw, rod handling, option RAS
RRL Rotation left, drill
RRR Rotation right, drill
SR Stinger feed lock cylinder, option
WAM Water mist, option
WC Water lubrication feeder, option
WF Water flushing
6.5 Check Boom Condition

¡ Check and rectify any damage and leaks on the boom.
6.6 Check Boom

¡ Check and rectify any damage and leaks on hoses, cylinders, valves, and valve
blocks.
¡ Check grease nipples.
Replace damaged nipples.
¡ Check hydraulic pressure setup.
¡ Check tightness on threaded joints.
28 No: TIS0003768.002 en-US

6.7 Check Special Tightening Torque on Boom BUT 28
The following bolted joints require a special tightening torque. Other bolted joints on this
unit can be tightened to the torque specified in Epiroc standard K4369.
Precondition p All bolted joints must be lubricated with Molykote 1000 or corresponding thread lubricant
with a coefficient of friction 0.11 μ.
¡ Check bolted joints.
Position Bolted Thread Quality Torque Toler- Quantity

Joints (Nm) ance +/ -
(Nm)
A Boom M20 8.8 304 76 1

link
B Boom M20 8.8 304 76 1

link
C Rear M16 8.8 156 39 2

boom link
D Rear lift M16 8.8 156 39 2

cylinder
E Boom ex- M12 8.8 63 16 1

tension
29 No: TIS0003768.002 en-US


(Nm)
F Bearing M12 12.9 128 13 16

housing -
tele-
scope,
bolts
G Boom ex- M16 12.9 263 66 10

tension,
flange
H Front M20 8.8 304 76 1

boom link
J Front M16 8.8 156 39 1

boom link
K Front lift M16 8.8 156 39 2

cylinder
L Front M16 8.8 156 39 2

cylinder
link
M Rotary M16 12.9 263 66 12

actuator
rear joint
N Cylinder M12 8.8 63 16 2

link, tilt
cylinder
P Cover M12 12.9 107 27 4
Q Feed ex- M24 8.8 522 131 1

tension
cylinder,
rear
R Rotary M16 12.9 263 66 12

actuator
front joint
S Feed M16 8.8 156 39 8

holder
T Swivel M16 8.8 315 32 1
30 No: TIS0003768.002 en-US


(Nm)
U Tilt cylin- M10 8.8 30 3 2

der, lock
screw
V Attach- M24 12.9/8.8 627 63 18

ment
plate -
boom
bracket
6.8 Lubricate Boom
Boom BUT 28 G and BUT 28 SL
¡ Lubricate front and rear cylinders (A).
¡ Lubricate boom extension cylinder (B).
¡ Lubricate feed extension cylinder (C).
¡ Lubricate feed lookout cylinder (D).
¡ Lubricate boom link (E).
¡ Lubricate cylinder link (F).
¡ Lubricate telescope bearing (G).
! NOTE: Operate telescope while lubricating.
31 No: TIS0003768.002 en-US

¡ Lubricate attachment shaft (H).
¡ Lubricate rotation unit (J).
6.9 Check Bearing Points
Boom BUT 28 G and BUT 28 SL
¡ Check bearing points (A) for damage and leakage.
6.10 Using a New or Reconditioned Boom
WARNING
WARNING
Heavy Objects
32 No: TIS0003768.002 en-US

WARNING
Moving Parts
starting work.
WARNING
Moving Parts
Causes serious personal injury
u Air in hydraulic system can cause unexpected movements.
Follow the steps when starting to use a new or reconditioned boom, or the one that has
been out of service for a long period:
1. Lubricate the boom as described in the maintenance schedule.
2. Thoroughly clean all piston rods and sliding surfaces that is treated with corrosion
inhibitor.
3. Check and install all bolted joints and expander shafts at least once every shift dur-
ing the first week the boom is in use.
4. Check the pressure in the hydraulic circuits is correctly adjusted.

The pressure must be 230 bar (3335 psi) in the high-pressure circuit and 40 bar
(580 psi) in the pilot circuit.
5. Check all operating movements to make sure that all hydraulic cylinders travel to
their end positions and that the air bleeds from hydraulic cylinders.
6. Check no hoses can be caught up or pinched.
7. Check for oil leakage.
6.11 Hoisting the Boom
WARNING
Heavy Objects
Slinging and hoisting heavy objects can cause personal injury.
u Lift at the center of gravity.
u Only use slings which are intact and designed for the load that is to be carried.
u Fasten the straps to lifting eyes when available.
u Do not stand under the object being hoisted.
33 No: TIS0003768.002 en-US

1. Run the rock drill and feed to their rear end positions.
2. Rotate the feed so that it is positioned directly above the boom.
3. Position the feed so that it is parallel with the boom body.
4. Apply the slings and hoist carefully.

Make sure the boom does not start to swing and that the slings do not start to slide
off.
Boom With feed Boom Without feed
TP 2100 mm 2100 mm
L1 2600 mm 1350 mm
L2 2070 mm 1500 mm
34 No: TIS0003768.002 en-US

6.12 Disassembling Feeder from Boom
WARNING
WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
Precondition p Feeder is secured with slings before disassembling.
1. Disconnect all hoses from the feed hose retainer.
2. Seal disassembled hoses and nipples.
3. Remove the feed extension cylinder from the feeder.
35 No: TIS0003768.002 en-US

4. Remove the holders (A) from the feed holder.
6.13 Disassembling Boom Body

First read: Safety Precautions before Working on Boom Unit [} 25]
The boom can be shortened by splitting it between the telescope tube and the adapter on
the rear rotary actuator in the rotation unit.
1. Install a sling round the rotation unit or support it on stands.
2. Disconnect the hydraulic hoses from the cylinders.
3. Plug hoses and nipples.
4. Disconnect the sensor cables.
5. Remove the bolts (A) and washers.
6.14 Disassembling Expander Shafts
WARNING
Heavy Objects
u Use adequate lifting device.
WARNING
Moving Parts
starting work.
36 No: TIS0003768.002 en-US

Precondition p The part of the boom that is held by the expander shaft is secured with slings or rests
on stands.
1. Remove nut (A).
2. Pull out bolt (B).
3. Install a bolt appropriate to threads in the bushings (C) and tighten it until one of the
bushings loosens.
4. Remove the other bushing.
5. Remove shaft (D).
6.15 Assembling Expander Shafts
WARNING
Heavy Objects
37 No: TIS0003768.002 en-US

WARNING
Moving Parts
starting work.
Play can be eliminated by tightening the lead-through bolt.
1. Lubricate the shaft (D).
2. Install the shaft (D) in the cylinder lug or link.
3. Attach bushings (C).
NOTE: Make sure that the bushings are located symmetrically at

! the attachment point.
4. Install the bolt (B) and nut (A) in the expander shaft and tighten to recommended
special tightening torques.
NOTE: If the play cannot be eliminated, replace or repair is nec-

! essary. If it is tightened too much, the attaching lug could crack.
38 No: TIS0003768.002 en-US

6.16 Disassembling Boom Extension
CAUTION
Dismantling Boom Extension
u Observe great care when dismantling the boom extension.
u Support rotary actuators and front boom member securely before removing the boom
extension.
1. Extend the telescope to its front-end position.
2. Rotate the feed beam up and down.
3. Lower the boom until the feed beam rests on the ground.
4. Position supports correctly below the rotation unit, front cylinder bracket, and feed
beam before removing the telescope.
5. Remove the bolts (A) from the adapter on the rear rotary actuator in the rotation
unit.
6. Retract the telescope to its rear end position.
7. Install slings round the bearing housing.

Use an overhead traveling crane or hoist or similar.
8. Remove the bearing housing bolts (B).
9. Disconnect the hydraulic hoses (C).
10. Remove the expander shaft (D).
11. Remove entire telescope assembly, extension tube, cylinder, and bearing housing
carefully.
6.17 Checking Bushings in Bearing Housing

Inspect the telescope device for signs of damage and wear.
39 No: TIS0003768.002 en-US

1. Extend the extension tube (A).
2. Remove the washer (E) and seal (F), then remove the cover (B).
3. Measure the play between the extension tube (A) and the two upper bushings (C).
If the play (G) is greater than 1 mm, remove the bearing housing (D) and change
the worn bushings.
40 No: TIS0003768.002 en-US

6.18 Checking Keys on Telescope Device
¡ Check the keys (A).
If the keys are deformed, the damaged area must be ground smooth to avoid dam-
age to the slide rails (B) and bearing housing (C).
6.19 Checking Slide Rails on Telescope Device
1. Remove the washer (A) and seal (B), and then the cover (C).
41 No: TIS0003768.002 en-US

2. Place the feed on a support and rotate the boom until the load is taken up on only
one side of the keys.
3. Remove the slide rails (D) from the bearing housing.

Replace the slide rails if they are worn or scratched.
6.20 Adjusting Tilt Cylinder
42 No: TIS0003768.002 en-US

NOTE: When installing the tilt cylinder, start from the basic setting of 782 mm (30.8 in)
! (A) between the expander shaft centers.
1. Position the boom horizontally.
2. Position the rotary actuator bearing housing horizontally using a spirit level.
The spirit level is placed vertically on the rotary actuator flange.
3. Operate the rotary actuator to bring the feed holder into a horizontal position.
4. Dump the feed holder with the tilt cylinder.

è When the tilt cylinder piston rod is all the way inside the cylinder, the feed
holder becomes horizontal.
If the feed cylinder still requires adjusting, loosen the locking screws (B). Screw the piston
rod in or out using an open-end wrench on the piston rod flats (C) until the feed holder is
horizontal.
43 No: TIS0003768.002 en-US

44 No: TIS0003768.002 en-US

Boomer 282 7 Feed Unit
7 Feed Unit
7.1 Safety Precautions before Working on Feed Unit
WARNING
WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
7.2 Feed Unit 2000-Series
BMH 2000
45 No: TIS0003768.002 en-US

BMHS 2000 (with side-mounted hose drum)
BMHT 2000 (telescope feeder)
BMH 2700
46 No: TIS0003768.002 en-US

BMHT 2700 (Telescope Feeder)
The hydraulic feed units in the 2000 series are primarily intended for drift and tunnel
drilling. They are fitted on hydraulic booms of type BUT 4, BUT 28, and BUT 29. The feed
units are available in different versions depending on the rock drill being fitted on them.
The different numbers are explained, for example, BMH 2337 and BMHT 2628/21.
The first number states the type of feed: 2 = 2000 series.
The second number states the type of rock drill for which the feed is intended:
• 4 = COP 1132 / RR11 / 1435 / RR14
• 7 = COP MD20
• 8/ X = COP 1638/1838/2238/1238
The third and fourth number states the length of drill rod in dm.
The fifth and sixth numbers only apply to telescope feed unit (BMHT) and state the length
of the short drill rod in dm.
7.3 Feed Unit 2000-series Technical Data

Length
The total length of the feed depends on the type of rock drill and the length of the drill rod
for which it is intended. By adding the following length to the length of the drill rod (XX)
(XX/XX), it is possible to obtain the overall length of the feed.
Type Length
BMH 28XX 1587mm
BMHT 28XX/XX 1597mm
Weight
47 No: TIS0003768.002 en-US

NOTE: Only the weight of the shortest and longest standard feed is specified for each
! type of feed
Type Weight
BMH 2825 - BMH 2849 290 - 370kg
BMHT 2831/19 - BMHT 2843/25 410 - 440kg
7.4 Lubricate Sliding Surfaces on Feed Unit

¡ Lubricate sliding surfaces if water lubrication is not satisfactory when drilling.
7.5 Check Hoses on Feed Unit

¡ Check hoses for leakage and damage.
7.6 Check Drill Rod Support BSH 110
¡ Check bushing halves (A) and dampeners for damage.
48 No: TIS0003768.002 en-US

¡ Check grease nipples (B) and lubricate if necessary.
¡ Check pipes, nipples, and hoses (C) for damage and leakage.
7.7 Lubricate Drill Rod Support BSH 45
1. Clean the drill rod support assembly.
2. Lubricate grease nipples, sliding surfaces, and piston rod end.
7.8 Lubricate Pulleys and Hose Drum
WARNING
WARNING
Heavy Objects
49 No: TIS0003768.002 en-US

WARNING
Moving Parts
starting work.
Feeder BMHT
Feeder BMH
¡ Lubricate the hose drum (A) and pulleys (B).
7.9 Clean Feed Unit

¡ Clean the complete feed unit.
50 No: TIS0003768.002 en-US

7.10 Check Wear and Damage on Feed Unit
Feeder BMHT 2000
Feeder BMH, BMHE, BHMS 2000
¡ Check wear and damage on drill steel bushings (B), slide rails (C), and dowel (D).
¡ Check wear and tension on pull and return rope (A).
¡ Check play and wear on slide pieces (E).
51 No: TIS0003768.002 en-US

¡ Check tightness on bolted joints (F).
7.11 Replace Parts on Drill Rod Support BSH 110

¡ Replace worn or damaged parts on the drill rod support.

¡ Check tightness on all bolted joints.
¡ Check the drill center, and adjust if necessary.
¡ Check the jaws for wear, and replace if necessary.
7.13 Check Wear on Bearings
Feeder BMHT 2000
¡ Check wear on water hose drum bearings (A).
¡ Check wear on pull rope pulley bearings (B).
52 No: TIS0003768.002 en-US

7.14 Check Hydraulic Cylinder
Feeder BMHT 2000
¡ Check hydraulic cylinder (A) for leakage.
7.15 Check Limit Switches

¡ Check limit switches function.
¡ Check for leaks.
7.16 Replace Rock Drill Retaining Bolts
WARNING
53 No: TIS0003768.002 en-US

WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
1. Position the feed horizontally with the rock drill upwards.
2. Remove and replace the retaining bolts (A) one at a time.
3. Torque-tighten the retaining bolts alternately.
See Reference Documentation
Rock drill instruction manual
54 No: TIS0003768.002 en-US

7.17 Installing Rock Drill and Rotation Unit
CAUTION
Heavy Object
The rock drill is a heavy object and can cause serious injury if it tips over or fall down.
u Do not remove all attachment screws at the same time without having the rock drill sup-
ported.
u Do not leave the rock drill unsupported if it needs to be disassembled from the feeder.
u Mount the rock drill on a folding plate for stability when performing work.
WARNING
WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
NOTE: The procedure describes the installation of rock drill only but can also be ap-
! plied to the rotation unit.
1. Clean the corrosion inhibitor from the feed unit.
2. Remove burrs, paint, or coatings from the cradle and the contact surfaces on the
rock drill.
3. Remove the attaching bolts from the cradle.
55 No: TIS0003768.002 en-US

4. Position the rock drill with shims on the cradle and reinstall the bolts, and make
sure that the rock drill is installed firmly in place.
5. Tighten the bolts alternately to the proper torque.
6. Connect and attach the hoses to the rock drill.
7. Adjust slide rails and hoses.
8. After four hours, perform a safety check of the rock drill or rotation unit installation.
Tightening Torque
200 Nm (147.5 lbf.ft)
7.17.1 Checking Rock Drill and Rotation Unit after Four Hours
¡ Check and tighten all bolted joints.
¡ Check and adjust the tension of the ropes.
¡ Check all hoses for leakage.
¡ Tighten and adjust the tension of the hoses if necessary.
¡ Check and adjust the slide rail alignment on the feed beam.
7.18 Location of Drill Hoses

Depending on the rock drill fitted on the feed unit, the hoses should be positioned in the
water hose drum and the feed hose retainer as described below.
Drill Hose Designations
New Hose Designations Old, Existing Hose Designa- Description

tions
AL1 L1 Air Lubrication
D1 D1 Drainage
HPD1 PD1 Damper
HP1 S1 Hammer Pressure
HT1 TS1 Hammer Tank
RRL1 R1 Rotation Left
RRR1 R2 Rotation Right
WF2 V1 Flushing
Drill Hose Locations:
56 No: TIS0003768.002 en-US

Water Hose Drum - COP 1838/1638/2238
Feed Hose Retainer - COP 1838/1638/2238
57 No: TIS0003768.002 en-US

Water Hose Drum - COP 1838/1638/2238 (feed with bulkhead connection)
Feed Hose Retainer - COP 1838/1638/2238 (feed with bulkhead connection)
Water Hose Drum - COP MD20
58 No: TIS0003768.002 en-US

Feed Hose Retainer - COP MD20
7.19 Adjusting Hoses on Rock Drill
WARNING
Dismantling and Assembling Components
WARNING
Heavy Objects
59 No: TIS0003768.002 en-US

WARNING
Moving Parts
Can cause personal injury!
u Shut off the machine and lock the electric main power switch before starting any work.
u Ensure that the hydraulic pump is off and that the system is depressurized before start-
ing work.
1. Check that the feed hoses are not crossed.
2. Tension the hoses as following:

Alternative step a. Loosen the bolts on the hose retainer slightly and adjust the hose tension.
Alternative step b. Loosen the nuts on the bulkhead union fittings and adjust the hose tension.
7.20 Replacing the Haul Rope
1. Operate the rock drill to about half its length of travel.
2. Slacken the tension on the ropes, bolt (A) and nut (B).
3. Remove the haul rope from its front attachment (F) on the rock drill cradle.
4. Remove the scraper plate (C) from the intermediate drill rod support.
5. Loosen the intermediate drill rod support holder (E) so that the intermediate drill rod
support can be lifted.
6. Remove the rope from the rope tensioner (D) in the rear part of the beam.
NOTE: Make sure the new rope is fitted in the same hole as the
! old one.
7. Fit the new rope and refit the scraper plate.
60 No: TIS0003768.002 en-US

8. Adjust the ropes.
7.21 Adjusting Haul and Return Ropes
Precondition p The cradle position on the feed beam is in its rear position.
p Drill rod with drill bit is fitted on the rock drill.
1. Adjust the haul rope with bolt (A) and the return rope with nut (B).
2. Adjust the ropes so that the bit is behind the spike.
3. Adjust the position measurement (M1).
Measurement for current feed unit is specified in the feed measurement drawing
supplied in the machine documentation.
7.22 Adjusting Tension of Return Rope

1. Position a plank between the rock drill cradle and the intermediate drill rod support.
2. Run the cradle forward until it stops against the plank and keep the feed force ap-
plied.
61 No: TIS0003768.002 en-US

3. Tension the return rope so there is no risk of it jumping out of the cable drum.
! NOTE: Do not tension the return rope too tightly.
è There is a couple of centimeters of slack remaining when the return rope is correctly
tensioned.
7.23 Adjusting Cradle on Feed Beam
WARNING
Dismantling and Assembling Components
WARNING
Heavy Objects
WARNING
Moving Parts
Can cause personal injury!
u Shut off the machine and lock the electric main power switch before starting any work.
u Ensure that the hydraulic pump is off and that the system is depressurized before start-
ing work.
62 No: TIS0003768.002 en-US

The cradle plate are guided along the feed beam by means of holder (A). Each pair of
holders is locked in position with bolts (B). The bolt holes in the holders are in the form of
angled grooves. The cradle can be adjusted on the feed beam by shifting the holders
lengthways.
Precondition p Feed is in the horizontal position and the drill steel is fitted in the drill.
p Holders are turned the same way as in the illustration so that the outer part of the an-
gled grooves is facing to the rear of the beam.
1. Remove the bolts (B).
2. Adjust the upper holders so the cradle is lying straight on the beam and is 5–7 mm
(0.19–0.27 in.) above the beam.
è Shank adapter is set at the correct height.
3. Shift the lower holders lengthways until a clearance of 1 mm (0.039 in.) is attained
between the lower holder and feed beam.
4. Install the bolts (B).
63 No: TIS0003768.002 en-US

5. Check by running the cradle along the entire beam.

The cradle runs forward within the maximum pressure with the hydraulic oil at oper-
ating temperature. If the pressure exceeds the maximum value, this means that the
holders are too tight and must be readjusted.
6. Install the rock drill straight on the cradle.
7. Replace damaged hoses and tighten leaking connections.
NOTE: The hoses are correctly adjusted as they do not hang

! down when the feeder is in the horizontal position.
Maximum Pressure 15 bar (217 psi)
7.24 Adjusting Feed Beam on Telescope Feed
The upper beam is guided on the lower beam by similar holders to the ones used for the
cradle.
Precondition p Holders are turned so that the outer part of the angled groove is facing to the rear.
p Feed is in the horizontal position.
1. Run the upper beam along the lower beam to about half its length of travel.
2. Remove the bolts (B) that attach the holders (A).
64 No: TIS0003768.002 en-US

3. Adjust the upper holders so that the upper beam is positioned straight on the lower
and the measurement is 5–7 mm (0.19–0.27 in.).
4. Shift the lower holders lengthways until a clearance of 1 mm (0.039 in.) is attained
between the lower holder and feed beam.
5. Install the bolts (B).
6. Run the beam along its entire length of travel.

The beam runs forward within the maximum pressure of 30 bar (435 psi) with the
hydraulic oil at operating temperature. If the pressure exceeds maximum pressure,
the holders are too tight and must be adjusted.
7.25 Replacing Slide Pieces in the Holder
Precondition p Replace the slide pieces if there is less than 1 mm of wear allowance. Replace all slide
pieces at the same time.
1. Remove the bolts (B) to remove the holder (A) from the cradle (E).
2. Remove the keys (D). Each slide piece is kept in place by three keys.
3. Remove the slide pieces (C) from the holder.
4. Slide a new slide piece into the holder track and fit it to the holder.
5. Fit new keys.
6. Adjust the cradle on the feed beam.
7.26 Replacing Slide Rails
WARNING
65 No: TIS0003768.002 en-US

WARNING
Heavy Objects
u Use adequate lifting device.
WARNING
Moving Parts
starting work.
Replace side rails if they are worn or severely scratched.
1. Remove the rock drill cradle, the intermediate drill rod support, and the water hose
drum from the beam.
2. Remove the old slide rails (A).

Press the lower edges of the bar outwards.
3. Clean the beam surfaces thoroughly.
4. Install the new slide rails with the larger edge on the slide rail facing upwards.
The rails are pressed in a place by hand.
5. Reinstall the rock drill cradle, intermediate drill rod support, and the water hose
drum.
6. Adjust the cradle on the feed beam.
7. Check the feed idling pressure.
66 No: TIS0003768.002 en-US

7.27 Adjusting Different Drill Rods Lengths for the

Telescope Feed
The use of different drill rods lengths is made possible by moving a mechanical stop mech-
anism on the lower feed cylinder.
1. Run the lower feed cylinder backwards towards the mechanical stop mechanism.
2. Remove socket head cap screws (A) and move one of the screws to the top of the
mechanical stop mechanism.
3. Operate forward or reverse to required drill rods length.

The drill bit must be behind the rubber dowel.
4. Replace the socket head cap screws (A) to its original position and tighten the me-
chanical stop mechanism.
7.28 Disassembling Feed Cylinder
WARNING
High Hydraulic Oil Pressure
Working on the hydraulic system involves a high risk of personal injury.
u Make sure that the system is de-pressurized before starting any work.
67 No: TIS0003768.002 en-US

WARNING
Hydraulic Oil and Water Pressure
u Do not replace high pressure hoses with hoses of lower quality than the originals.
u Do not replace high pressure hoses with hoses installed with removable couplings.
WARNING
WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
68 No: TIS0003768.002 en-US

Precondition p Hydraulic system is depressurized.
1. Operate the rock drill cradle to about half the feed length.
2. Relieve the tension from pull and return ropes with bolt (A) and nut (B).
3. Remove the bolts from the center of the water hose drum and lift the entire drum.
4. Disconnect the hoses at the hose retainer.
5. Loosen bolts (C) and (D) on cradle plates (E) and (F).
6. Remove bolt (A) from the end piece (G).
7. Remove the end plate (H).
8. Pull the cylinder and fork backwards, out of the beam.
9. Remove the pin (K).
10. Remove the fork (J) from the spacer (L).
69 No: TIS0003768.002 en-US

NOTE: Avoid removing the spacer (L). If the spacer must be removed, first measure
! (SP) so the spacer can be replaced in the same position.
! NOTE: Measurement (SP) is specified in the Spare Parts Catalog.
7.29 Disassembling Tension Bushing for Spacer
WARNING
WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
! NOTE: Measurement (SP) is specified in the Spare Parts Catalog.
The spacer at the front of the cylinder is held in place with an expanding bushing. In order
for the feeder to function correctly, the spacer measurement (SP) must be correct. This
measurement varies depending on the feed length and type of feeder.
70 No: TIS0003768.002 en-US

Precondition p Spacer measurement (SP) is noted, so the bushing can be replaced in the same posi-
tion.
1. Remove the plastic plugs (A).
2. Remove the bolts (B) from the bushing.
3. Place the bolts (B) into the threaded holes and pull them alternately until the bush-
ing are separated.
7.30 Assembling Tension Bushing for Spacer
WARNING
WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
71 No: TIS0003768.002 en-US

NOTE: The (SP) measurement is noted before disassembling and is also specified in
! the Spare Parts Catalog.
The spacer at the front of the cylinder is held in place with an expanding bushing. For the
feeder to function correctly, the spacer measurement (SP) must be correct. This measure-
ment varies depending on the feed length and type of feeder.
1. Assemble the bushing and the bolts (B). Do not tighten the bolts (B).
2. Install the spacer and bushing into the sleeve.
3. Tightening the bolts (B) in circles from 1–8 until the bolts set.
4. Install the plastic plugs (A).
Tightening Torque
18 Nm (13 lbf.ft)
7.31 Dismantling Upper Feed Beam
WARNING
Heavy Objects
Slinging and hoisting heavy objects can cause personal injury.
u Lift at the center of gravity.
u Only use slings which are intact and designed for the load that is to be carried.
u Fasten the straps to lifting eyes when available.
u Do not stand under the object being hoisted.
Make sure that the lifting attachments are intended for the load they are to carry and they
are not damaged.
72 No: TIS0003768.002 en-US

1. Remove any drill rods.
2. Run the rock drill to the center of the upper feed beam.
3. Reverse the upper feed beam so that the rear attachment (A) of the lower cylinder
is accessible.
4. Remove the rear cylinder attachment (A) from the upper feed beam.
Optional step Detach the water hoses from the rock drill cradle, if the feed is equipped with water
lubrication of the sliding surfaces.
Make sure to plug the hoses and unions.
5. Attach lifting slings to the upper feed beam.

Make sure to hoist from directly above the center of gravity.
6. Remove the four holders (B).
7. Hoist the upper feed beam.

Make sure that the feed does not start to swing and the slings do not slide off.
7.32 Dismantling Lower Feed Cylinder
WARNING
73 No: TIS0003768.002 en-US

Precondition p Hydraulic system is depressurized.
1. Detach the two hoses (A) from the limit switch.
2. Plug the hoses and unions.
3. Detach the front drill rod support (B) from the lower feed beam.
4. Remove the cotter pin and bolt (C) in the front cylinder attachment.
5. Remove the screws for the brace (D).
6. Detach the hoses (E) at both ends of the cylinder, then plug the hoses and unions.
è The cylinder can now be lifted out of the feed beam.
74 No: TIS0003768.002 en-US

Boomer 282 8 Rotation Unit
8 Rotation Unit
8.1 Safety Precautions before Working on Rotation Unit
WARNING
Dismantling Rotation Unit
u Observe great care when dismantling the rotation unit.
u Support the feed unit securely so that it is stable.
8.2 Rotation Unit
A Feed holder
B Attachment shaft
C Rotary actuator
D Bearing housing
E Tilt cylinder
The rotation unit consists of a rotary actuator and a bearing housing that is attached to the
feed holder attachment shaft.
75 No: TIS0003768.002 en-US

8.3 Function of Rotary Actuators
The rotary actuator for boom rotation, which is attached to the front of the telescope unit,
converts the linear movement of piston (B) into a rotary movement. The rotary actuator for
feed swing, which is mounted at right angles on the rear rotary actuator, has the equivalent
function.
The rotary actuator consists of a housing (A) with a ring gear (C) and two moving parts: a
piston (B) and a shaft (D). The shaft has splines that engage with the internal splines of the
piston. The external splines of the piston engage with the ring gear splines. The piston
moves back and forth in the housing and the splines rotate the shaft.
76 No: TIS0003768.002 en-US

8.4 Removing Rotary Actuator from Boom
Precondition p Supports are positioned firmly under the feed.
1. Rotate the feed 90º until the feed and the rock drill are under the boom.
2. Disassemble the expander shaft (A) for the tilt cylinder.
3. Remove the bolts (B) and protection (C).
4. Remove the bolts (D) and sensor (E).
NOTE: Applies only to machines with the RCS electronic control

! system and one of the ABC Regular or ABC Total options.
5. Remove the bolts (F) and the outer cover (G).
6. Remove the bolts (H), the inner cover (J), and the shim (K).
7. Disconnect the hydraulic hoses that are connected to the feed.
8. Plug all hoses and connections.
9. Lift the boom straight, without damaging the sliding bearings (L) in the bearing
housing.
77 No: TIS0003768.002 en-US

10. Rotate the bearing housing (M) so it reaches its original position.
11. Attach slings around the bearing housing (M).
12. Remove the bolts (N), hose retainer (P) and cover (Q).
13. Remove the bolts (R) and remove the bearing housing.
14. Remove the hydraulic hoses from the overcenter valve.
15. Plug the hoses and connections.
16. Attach slings around the rotary actuator.
17. Remove the bolts (S).
18. Remove the rotary actuator from the boom head.
78 No: TIS0003768.002 en-US

8.5 Disassembling Rotary Actuator
Permanent Marking Piston-Ring Gear
Permanent Marking Shaft-Piston
There are two permanent position marks, one mark for piston-ring gear and one mark for
shaft-piston. Assembly of the rotary actuator is facilitated if more positioning marks are
made during disassembling.
When assembling the component parts of the rotary actuator, the splined parts (shaft and
piston) must be remounted in their original positions.
1. Place the rotary actuator on a clean workbench.
2. Remove all hydraulic connections.
3. Remove the overcenter valve and associated components.
79 No: TIS0003768.002 en-US

4. Mark the relative positions of the retaining ring (F), cover (A) and shaft (B) using a
scriber or pen.
5. Remove the bolts (C) and plugs (D). Screw two of the bolts (C) in the threaded
holes of the retaining ring (B). With the bolts, remove the retaining ring from the
shaft splines (ring gear).
6. Screw two bolts with washers or sleeves in the cover (A) and use a tommy bar or
similar to remove the cover from the shaft.
In, certain cases the cover must be screwed in hard. An iron bar can then be
welded to the cover to provide greater leverage.
7. Screw two bolts in the shaft (B) flange. These bolts enable the shaft to be turned
with the aid of a tommy bar or similar. Turn the shaft clockwise. It starts to rotate
out of the housing.
8. Mark the position of the shaft relative to the piston. For example, mark one of the
shaft splines and the corresponding groove in the piston with a pen. See example
in figure.
9. Remove the shaft out of the housing.
80 No: TIS0003768.002 en-US

10. Use a plastic drift and hammer to drive the piston (J), including piston skirt (H), out
of the housing (G).
è After marking, the piston can be removed from the housing. Exercise care to
avoid damaging the piston and housing.
Optional step Remove the piston and piston skirt when it is suspected that the O-ring is dam-
aged.
11. Mark the relative positions of the piston and piston skirt if the o-ring must be re-
placed, and then remove the wear rings.
12. Press out the locking pins and remove the piston from the piston skirt.
13. Replace the O-ring and reassemble piston and piston skirt.
14. Remove the grease nipples and valves.
15. Remove all seals and bearings.
81 No: TIS0003768.002 en-US

8.6 Assembling Rotary Actuator
Precondition p Blow dried compressed air to clean all parts.

p All position marks are visible.
1. Inspect the threads on the shaft (B) and the lock ring (E) and rub down any burrs
with abrasive cloth.
2. Inspect the cover (D).
3. Install the cover (D) and the lock ring (E) on the shaft (B).
4. Check that the cover and lock ring do not jam in the ring gear and thread.
82 No: TIS0003768.002 en-US

5. Lubricate all seals and contact surfaces with hydraulic oil.
NOTE: Always change the seals and bearings when assembling

! rotary actuators. Never use sharp tools when installing seals.
6. Install the seals (V, S, R, Q, and M) and the wear rings (J and W) on the piston
sleeve (C).
7. Position the housing (A) upright with the flange upwards.
8. Install the piston sleeve in the housing, using the guide markings to make sure that
it is in the right position.
9. Place the housing down in a horizontal position when the piston has engaged with
the ring gear.
10. Check at the other end of the housing that the position of the piston coincides with
the permanent markings.
11. Install the piston in until the piston skirt bottoms against the ring gear.
Permanent Markings on Piston-ring Gear
12. Grease the washers (L).
13. Install the seals (N, M) and wear washers (J, K, and L) on the shaft (B) as well as
seals (V, N, and M) on the cover (D).
14. Stick masking tape on the ring gear of the shaft to avoid damage of the piston seals
when the shaft (B) is installed.
Shaft Ring Gear and Threads
83 No: TIS0003768.002 en-US

15. Install the shaft in place so that its marking is opposite the piston skirt marking.
16. Remove the masking tape.
17. Apply grease on the cover (D) ring gear and its surfaces and install the cover.
18. Use a Tommy bar to turn the piston ring gear clockwise, in towards the correspond-
ing ring gear in the cover (D).
NOTE: Be careful not to damage the ring gear or the cover, and
! make sure that they do not make contact with the piston ring gear
19. Turn the piston to its end position after the ring gear is aligned.
20. Install the seals (F, G) on the lock ring (E).
21. Apply grease on the threads and contact surfaces on the cover (D), the shaft (B),
and the lock ring (E).
22. Install two SAE #4 adapters opposite each other into the lock ring.
23. Use a Tommy bar to install lock ring in clockwise and tighten to 200ft lbs (271 Nm)
24. Rotate the lock ring (E) counterclockwise to install the lock pins (T) in the cover (D).
25. Apply sealing compound to the screw plugs (U) and tighten.
26. Pump grease into the grease nipples (H) to remove any impurities and to check
that they are in working order.
27. Install the grease nipples (H) and valves (P).
28. Install the hydraulic connections and over-center valve.
84 No: TIS0003768.002 en-US

8.7 Reinstalling Rotary Actuator onto Boom
1. Apply slings round the rotary actuator and mount it on the boom head using the
bolts (F).
2. Connect the hydraulic hoses to the over-center valve.

While mounting the bearing housing, it is important to ensure that the stop position
for feed rotation is correct. The bearing housing in horizontal position (A) and the
bearing housing rotated under the boom to stop position (B) is shown.
3. Rotate the rotary actuator to the stop position and then rotate it in the opposite di-
rection so that the pattern of holes on the rotary actuator's shaft flange is displaced
two holes.
With the rotary actuator rotated to this position it is possible to fit the bearing hous-
ing (G) hanging vertically.
85 No: TIS0003768.002 en-US

4. Fit the cover (C) and hose retainer (D) using the screws (E).
5. Mount the feeder by rotating the bearing housing by 90 degrees.
6. Lower the boom against the feed holder's attachment shaft.

Take care to avoid damaging the sliding bearings (J) in the bearing housing.
86 No: TIS0003768.002 en-US

7. Fit shim (K) and inner cover (L).
8. Fit the inner cover (M) using the screws (N).
9. Mount the sensor (P) using the bolts (Q).
NOTE: Applies only to rigs with the RCS electronic control sys-
! tem and one of the ABC Regular or ABC Total options.
10. Mount the protection (R).
11. Fit the tilt cylinder using the expander shaft (H).
87 No: TIS0003768.002 en-US

12. Lift the boom and rotate the feeder through 90 degrees.
13. Refit the hydraulic hoses.
88 No: TIS0003768.002 en-US

Boomer 282 9 Hydraulic System
9 Hydraulic System
9.1 Safety Precautions before Working on Hydraulic

System
WARNING
WARNING
u Do not replace high-pressure hoses with hoses of lower quality than the originals.
u Do not replace high-pressure hoses with hoses installed with removable couplings.
9.2 Technical Data
Main Pump (Positioning and Percussion Unit)
Type Axial Plunger Pump
Model RX A10VO100
Displacement 100 cm3 / turn
Rotation and Damper Pump (Twin Pump), 2-Boom
Type Gear Pump
Model Parker 620/511
Displacement, Rotation 50 cm3 / turn
Displacement, Damping 11 cm3 / turn
Hydraulic Oil Tank
Volume Maximum 188 L (0.26417 gal)
89 No: TIS0003768.002 en-US

9.3 About Working on Hydraulic Components

The hydraulic system is sensitive to contamination. The environment where the machine is
normally used is generally an unsuitable place for repairing hydraulic components. Avoid
repairing hydraulic systems outside workshops.
Observe the following points to minimize interruptions in operation due to contaminated hy-
draulic oil:
• Keep the machine clean.
• Use a degreasing additive for washing.
• Before opening any hydraulic connection, clean the area round it.
• Use clean tools and work with clean hands.
• Always plug hydraulic connections immediately after they are disengaged.
• Use clean protective plugs.
• Hydraulic components, like hoses, valves, and motors, must always be stored with
suitable protective plugs are installed.
• Spare parts for hydraulic components must always be kept in sealed plastic bags.
• Change filter cartridges when filters indicate clogging.
9.4 Hydraulic Workshops

Workshops that are used for the repair of hydraulic components must include:
• A clean environment to avoid dust and particles
• Suitable washing equipment for component repair
• Suitable tools for working on hydraulic systems
• Adequate ventilation system
9.5 Replacing Hydraulic Hoses
WARNING
WARNING
Load, vibration, and mechanical stresses place many demands on hydraulic hoses. When
replacing, check that replacement hoses have:
• The correct crimped couplings
• The correct quality class
90 No: TIS0003768.002 en-US

• The correct dimensions

All pressurized components must be purchased from Epiroc. The grades and dimensions
of hoses are specified in the spare part catalog. Make sure that hose couplings are clean,
undamaged, and properly tightened.
9.6 Check Hoses and Couplings

¡ Check hydraulic hoses for leaks.
9.7 Hydraulic Oil
9.7.1 Oil Sampling

An oil sample gives a good indication of quality of maintenance of the hydraulic system.
The system is equipped with nipples that are used together with special equipment to take
oil samples. The nipples are on the delivery line from the percussion pump and positioning
pump.
Replacing Contaminated Oil

Hydraulic oil must be replaced if the oil sample show that the oil is oxidized, contains much
water, or many particles.
9.7.2 Check Oil Levels
1. Check the oil level in the hydraulic oil reservoir sight glass (A).
Top up if necessary.
2. Check the oil level in the lubricating oil tank.

91 No: TIS0003768.002 en-US

9.7.3 Drain Water Condensation from Hydraulic Oil Tank
The ball valve (A) is used to drain water that can seriously damage components in the hy-
draulic system and cause corrosion. It is also used for emptying all hydraulic oil from the
tank.
Precondition p The hydraulic system has not been in operation for eight hours before draining the hy-
draulic oil tank.
1. Open the air breather filter in the top of the hydraulic oil tank.
2. Remove the plug on the ball valve (A) underneath the hydraulic oil tank.
3. Place a vessel below the ball valve (A).
4. Open the ball valve to drain the water.
5. Close the ball valve when oil starts to drain.
6. Install the plug.
7. Check and fill up oil level.
8. Close the air breather filter in the top of the hydraulic oil tank.
92 No: TIS0003768.002 en-US

9.7.4 Emptying Hydraulic Oil Tank
1. Open the breather filter in the top of the hydraulic oil tank.
2. Remove the plug from the ball valve (A) below the hydraulic tank.
3. Connect a hose to the ball valve and place the other end of the hose into a vessel.
4. Open the ball valve and empty the tank.
5. Close the ball valve after all oil is drained.
6. Disconnect the hose.
7. Close the breather filter.
8. Install the plug on the ball valve.
9.7.5 Filling Hydraulic Oil Manually
93 No: TIS0003768.002 en-US

Precondition p Connections and hoses used to fill oil has been cleaned.
p Return oil filter is checked.
1. Pump manually using hand pump (A).
2. Check the oil level in oil level glass (B).
3. Stop pumping when the oil is visible in the upper part of the oil level glass.
9.8 Hydraulic Filters
9.8.1 Check Return Oil Filter
¡ Check hydraulic return oil filter (A) for blockage.
9.8.2 Replace Return Oil Filter
WARNING
WARNING
94 No: TIS0003768.002 en-US

1. Clean on and around the filter cap.
2. Remove the nuts and washers (A).
3. Remove cap (B).
4. Remove the filter canister by the handle.
5. Replace with a new O-ring (C).
6. Remove the overflow valve (E) by pressing down and turning the handle counter-
clockwise.
7. Replace the filter cartridges (D) with new ones.
8. Install the overflow valve and filter canister.
9. Install cap (B) with nuts and washers (A) and tighten.
95 No: TIS0003768.002 en-US

9.8.3 Check Hydraulic Tank Breather Filter
¡ Check hydraulic tank breather filter (A) for blockage.
9.8.4 Replace Breather Filter
WARNING
WARNING
Replace the filter as per the maintenance schedule or if the tank is overfilled and the filter
gets covered in oil.
96 No: TIS0003768.002 en-US

1. Clean thoroughly on and around the filter housing (A).
2. Remove the cover plate by turning it counterclockwise.
3. Replace with a new filter.
4. Apply a little hydraulic oil to the sealing surface and threads.
5. Install the cover.
97 No: TIS0003768.002 en-US

9.9 Hydraulic Pumps
9.9.1 Overview of Power Unit Pumps
A Location on DCS 12, 2-boom
B Location on DCS 12, 1-boom, and DCS 14/18, all
C Main pump (positioning and percussion). Damper supply (only DCS 14/18, 1-boom)
D Rotation pump
E Damper pump (only DCS 14/18, 2-boom). Pump for water pump operation (only for DCS 14/18,
1-boom)
9.9.2 Starting New or Reconditioned Pump
WARNING
98 No: TIS0003768.002 en-US

WARNING
If a major intervention has been made in the system, such as replacing or reconditioning
components in the hydraulic system, the system must be bled.
1. Fill the pump housing with oil.
2. Bleed air from the pump housing.
3. Circulation-pump the system.
9.9.3 Checking Pump Rotation Direction
An arrow on the pump coupling housing indicates the correct direction of rotation.
1. Start the pump and stop it again at once so that it rotates only a few turns.
2. Check the direction in which the motor-pump coupling rotates.

è If the pump rotates in the wrong direction, an authorized electrician must re-
verse two of the phase leads in the electric motor connection cable.
99 No: TIS0003768.002 en-US

9.9.4 Replace Coupling Set for Electric Motor
A Electric motor shaft
B Set screw
C Upper coupler
D Disc
E Set screw
F Washer
G Lower coupler
H Pump shaft
1. Remove the coupling part from the electric motor.
a. Remove the set screw (B) from the upper coupler (C).
b. Remove the upper coupler (C) from the electric motor shaft with a suitable
puller.
! NOTE: Do not hit the coupler half with a hammer.
! NOTE: Heat the coupler half if it is stuck.
2. Remove the disc (D), set screw (E), washer (F), and lower coupler (G) from the
pump shaft (H).
100 No: TIS0003768.002 en-US

3. Install the new coupling part to the electric motor.
a. Heat the upper coupler (C) using a suitable heater.
b. Install the set screw (B) and upper coupler (C) to the electric motor shaft (A).
NOTE: Apply grease to the surface and threads of upper cou-

! pler.
è The bottom end of the upper coupler is aligned (2 mm) with the chamfer of
the electric motor shaft.
4. Install the lower coupler (G), washer (F), set screw (E), and the disc (D) to the
pump shaft (H).
5. Install the electric motor to the coupling housing.

è The clearances of both sides of two couplers are 3.5 mm.
101 No: TIS0003768.002 en-US

9.9.5 Bleeding Hydraulic Pump
WARNING
WARNING
Precondition p All hoses are connected to the pump.
1. Check the level of the hydraulic oil in the oil sight glass on the hydraulic oil tank.
2. Remove plug (B).
3. Install plug when oil starts to run out of the plug hole.
4. Loosen drain hose (A).
5. Tighten the drain hose (A) when clean oil with no air bubbles runs out.
102 No: TIS0003768.002 en-US

9.9.6 Circulating Hydraulic Pump
Principles for Circulating the Pump
Circulation pumping must be carried out to check if any contaminants are collected in the
filter.
1. Connect the machine to water supply.

This step does not apply for diesel hydraulic machines.
2. Connect the delivery and return hoses for the percussion unit with suitable unions.
3. Connect the delivery and return hoses for the rotation motor with suitable unions.
4. Connect the feeder delivery and return hoses for the hydraulic cylinder with suitable
unions.
5. Start the hydraulic pump.
6. Start drilling.
7. Allow oil to circulate in the hoses for at least five minutes.
8. Stop the hydraulic pump.
9. Reconnect the hoses to their designated positions.
103 No: TIS0003768.002 en-US

9.10 Settings
9.10.1 Safety Precautions before Pressure Setting
CAUTION
Hazardous Hydraulic Oil Pressure
u Always exercise the greatest caution.
u Pressure settings must only be performed by trained personnel.
9.10.2 Pressure Settings and Rotation speeds
Pressure Settings and Rotation Speeds
Setting Valve / Valve Plate Value Read From
Percussion pressure for V10 130-140 bar (1885.5 to Pressure gauge for per-
collaring 2030.53 psi) cussion unit Gh
Percussion pressure for full drilling
Rock drill COP 1238 V11 180-220 bar (2610 to Pressure gauge for per-
3190.83 psi) cussion unit Gh
Rock drill COP 1638 Vhp/V11 180-200 bar (2610 to

2900.75 psi)

3335.87 psi)

3335.87 psi)
Positioning pressure
DCS 12 Vsb 210-230 bar (3045.8 to Pressure gauge outlet

3335.87 psi) G5
DCS 14/18 CT4/VB1 210-230 bar (3045.8 to Pressure gauge outlet

3335.87 psi) G1
Rotation speed V3a Depends on type of drill Drill steel rev counter
bit and its diameter
Rock drill damper pressure
Rock drill COP 1838/ Vdp 40 bar (580.15 psi) Pressure gauge for
1638 damper pressure Gdp
Rock drill COP 1432 Vdp 15 bar (217.55 psi)
Rock drill COP 1532 Vdp 30 bar (435.11 psi)
Percussion return pressure for:
104 No: TIS0003768.002 en-US

Rock drill COP 1432 Vhr 14-20 bar (203 to 290 Pressure gauge outlet
psi) G4
Rock drill COP 1532 Vhr 6-12 bar (87 to 174 psi)
Maximum feed pressure Vfm DCS 12: 80 bar (1160.3 Pressure gauge for feed
psi) Gf
DCS 14/18: 100 bar
(1450.38 psi)
Feed pressure for col- Vfl DCS 12: 35 bar (507.63 Pressure gauge for feed
laring psi) Gf
DCS 14/18: 40 bar
(580.15 psi)
Feed pressure for full Vfh DCS 12: 40-80 bar Pressure gauge for feed
drilling (580.15 to 1160.3 psi) Gf
DCS 14/18: 65-100 bar
(942.74 to 1450.38 psi)
Anti-jamming protection, RPCF
DCS 12 C5A 20-25 bar (290 to 362.6 Pressure gauge for ro-
psi) above normal rota- tation Gr
DCS 14/18 V1a
tion pressure during
drilling
Anti-jamming protection, feed return movement
DCS 12 C5C 40 bar (580.15 psi) Pressure gauge outlet

above normal rotation fitting G3
DCS 14/18 Vaj
pressure during drilling
Settings for Reaming Hole (Option)
Rotation speed V3b Depends on type of drill Drill steel rev counter
bit and its diameter
Feed pressure for full V6 50-70 bar (725.2 to Pressure gauge Gf

drilling 1015.26 psi)
Anti-jamming protection, RPCF
DCS 12 V1b 20-25 bar (290 to 362.6 Pressure gauge Gr

psi) above normal rota-
DCS 14/18 V1b
tion pressure during
drilling
105 No: TIS0003768.002 en-US

Settings for Telescope Feeder (Option)
Maximum feed pressure Vfm 140 bar (2030.53 psi) Pressure gauge Gf
Feed pressure, differ- V8 45 bar (652.67 psi) Pressure gauge outlet

ence between upper fitting G2
and lower cylinder
Feed pressure, reverse V17 120 bar (1740.45 psi) Pressure gauge outlet
G8
9.10.3 Main Pump
Adjusting Stand-By Pressure for Main Pump

Normally the stand-by pressure does not need to be checked or adjusted. The pressure is
set by the pump supplier. Check and adjust the pressure only if the pump is not supplying
a sufficient flow to the system.
1. Disconnect the anti-inductive protection (Y156).

è Pump has been unloaded (stand-by mode).
2. Remove screw (A) and pull out the connector.
3. Start the pump.
4. Connect a pressure gauge to pressure test outlet (G1).
5. Remove the cover (B).
106 No: TIS0003768.002 en-US

6. Loosen the lock nut (C).
Valve Vsb
7. Adjust the screw (D) until the pressure is between 16 bar-20 bar (232 psi-290 psi).
Screwing in the screw (D) increases the pressure.
Read the pressure from the pressure gauge connected to the pressure test outlet
(G1).
8. Tighten the lock nut (C).
9. Reinstall the cover (B).
10. Reinstall the connector.
11. Reinstall the anti-inductive protection (Y156) and screw (A).
Adjusting Percussion Pressure for Main Pump

This procedure applies only to the DCS 14/18.
Precondition p All control levers on the operator panel are in neutral position.
2. Start the pump.
107 No: TIS0003768.002 en-US

3. Remove cover (A).
Valve Vsb
4. Loosen the lock nut (B).
5. Adjust the screw (C) until the pressure is between 210-230 bar (3045-3335 psi).
(G5).
Screwing in the screw (C) increases the pressure.
6. Tighten the lock nut (B).
7. Refit cover (A).
Adjusting Positioning Pressure for Main Pump

This procedure applies only to DCS 14/18.
Precondition p All drilling levers are in neutral position.
108 No: TIS0003768.002 en-US

2. Loosen the lock nut (A) on the valve (CT4).
3. Adjust the screw (B) until the pressure is 210 bar (3045 psi).
(G1).
Screwing in the screw (B) increases the pressure.
4. Tighten the lock nut (A).
9.10.4 Rotation Pump
Adjusting Rotation Speed for Small Hole Bit

1. Set lever (A) to small hole position.
NOTE: Applies if the machine is equipped with a reaming hole

! kit.
2. Start the pump.
109 No: TIS0003768.002 en-US

3. Set the rotation lever (B) to its forward position.
4. Measure the rotation speed with a rev counter on the drill steel.
The ideal rotation speed depends on the drill bit and the diameter.
5. Use the knob (C) and (D) on the valve for any adjustment in speed.
Valve V3a
a. Loosen knob (C).
b. Adjust the speed using knob (D).

Screwing in the knob (D) reduces the speed.
c. Tighten the knob (C).
Adjusting Rotation Speed for Reaming Hole Bit

This procedure is optional for the machine.
1. Set lever (A) to reaming hole position.
2. Start the pump.
3. Set the rotation lever (B) to its forward position.
110 No: TIS0003768.002 en-US

4. Measure the rotation speed with a rev counter on the drill steel.
The ideal rotation speed depends on the drill bit and the diameter.
5. Use the locknut (C) and screw (D) on the valve for any adjustment in speed.
Valve V3b
a. Loosen the lock nut (C).
b. Adjust the speed using the adjustable screw (D).

Screwing out the screw (D) reduces speed.
c. Tighten the lock nut (C).
Adjusting Percussion Pressure for Collaring

The pressure is best adjusted during collaring.
1. Loosen the lock nut on restrictor (V10).
2. Start the pump.
111 No: TIS0003768.002 en-US

3. Set the percussion lever (A) to its middle position.
4. Adjust the screw on the restrictor (V10) until the pressure is between 130-140 bar
(1885–2030 psi).
Read the pressure on the percussion pressure gauge (B) on the operator panel.
Screwing in the screw on the restrictor (V10) reduces pressure.
5. Tighten the lock nut on restrictor (V10).
Adjusting Percussion Pressure for Full Drilling

The percussion pressure must be adjusted depending on the rock conditions and the pres-
sure is best adjusted during full drilling.
This procedure applies only to DCS 12 and to DCS 14/18 at percussion pressure below
210 bar (3045 psi).
1. Loosen the lock nut on restrictor (V11).
2. Start the pump.
112 No: TIS0003768.002 en-US

3. Set the percussion lever (A) to its forward position.
4. Adjust the screw on the restriction (V11) until the pressure is between 180-220 bar
(2610–3190 psi) (for DCS 12) or 180–210 bar (2610–3045 psi) (for DCS 14/18).
Screwing in the screw on the restriction (V11) reduces the pressure.
Read the pressure on the percussion pressure gauge (B) on the operator panel.
5. Tighten the lock nut on the restriction (V11).
Adjusting Percussion Pressure for Full Drilling

The pressure is best adjusted during full drilling.
This procedure applies only to DCS 14/18 at percussion pressure above 210 bar (3045
psi).
1. Loosen the lock nut on the restriction (V11) and pull the adjustment screw all the
way out.
113 No: TIS0003768.002 en-US

2. Tighten the lock nut on the restriction (V11).
3. Remove the cover (A) on the valve.
Valve Vhp
5. Start the pump.
6. Set the percussion lever (D) in its forward position.
7. Adjust the screw (C) until the pressure is between 210-230 bar (3045–3335 psi).
Read the pressure on the percussion pressure gauge (E) on the operator panel.
Screwing in the screw (C) increases the pressure.
114 No: TIS0003768.002 en-US

9. Reinstall the cover (A).
Checking Rock Drill Damper Pressure

This procedure applies only to DCS 14/18.
Precondition p All control levers on the operator panel are in neutral position.
1. Start the pump.
2. Check the rock drill damper pressure on pressure gauge (A) on the operator panel.
Adjusting Rock Drill Damper Pressure

Adjust the rock drill damper pressure if it is not 40 bar (580 psi) (DCS 18) or 30 bar (435
psi) (DCS 14 with COP 1532).
Precondition p Adapter on the rock drill is in the suspended position.
p All control levers on the operator panel are in neutral position.
1. Start the pump.
115 No: TIS0003768.002 en-US

2. Loosen the knob (C) on the valve.
Valve Vdp
3. Set the knob (B) until the correct pressure is obtained.

Read the pressure on the pressure gauge (A) on the operator panel.
4. Tighten knob (C).
Adjusting Percussion Return Pressure

This procedure applies only to rock drill COP 1532.
Adjust the percussion return pressure if the rock drill has been replaced or if the main
pump percussion pressure has been adjusted.
116 No: TIS0003768.002 en-US

1. Connect a pressure gauge to test outlet (G4).
2. Adjust the pressure using the return restrictor (Vhr) during full drilling.
The percussion pressure must be between 6-12 bar (87–174 psi).
Opening the return restrictor (Vhr) reduces the pressure.
NOTE: Do not open the return restrictor too far as it causes a

! drop in percussion pressure.
9.10.5 Feed Pressure
Setting Maximum Feed Pressure

Precondition p The pressure is not adjusted while drilling.
p All the control levers on the operator panel are in neutral position.
1. Place a wooden block (10-20 cm/4-8 inches wide) in the feeder in front of the for-
ward drill steel support.
2. Start the pump.
117 No: TIS0003768.002 en-US

3. Run the rock drill towards the wooden block using lever (A).
4. Screw the valve (B) clockwise until the valve is disengaged.
5. Loosen the lock nut from the valve.
Valve Vfm
6. Adjust the screw on the valve to 80 bar (1160 psi) for DCS12 or 100 bar (1450 psi)
for DCS 14 and DCS 18.
Read the pressure on the pressure gauge (C) on the operator panel.
7. Tighten the lock nut on the valve.
8. Reset valve (B).
9. Run the rock drill back to its rear end position.
10. Turn off the pump.
11. Remove the wooden block.
118 No: TIS0003768.002 en-US

Setting Feed Pressure for Collaring
1. Move percussion lever (A) to its middle position and feed lever (B) to its forward po-
sition.
2. Loosen the lock nut on valve (C).
3. Adjust the collaring feed pressure with an Allen key on valve (C) to 35 bar (507 psi)
(DCS 12) or 40 bar (580 psi) (DCS 14 and DCS 18).
Read the pressure on the pressure gauge (D) on the operator panel.
4. Tighten the lock nut on valve (C).
Adjusting Feed Pressure for Reaming Hole Bit

The procedure is optional for the machine.
119 No: TIS0003768.002 en-US

1. Move lever (A) to its reaming position.
2. Remove the cover (B) on the pressure control valve (C).
3. Adjust the screw on the pressure control valve (C) until the feed pressure is be-
tween 50-70 bar (725–1015 psi).
Turning the screw clockwise increases the feed pressure.
Read the pressure on pressure gauge (D) on the operator panel.
4. Refit the cover (B).
Adjusting Maximum Feed Pressure for Telescopic Feed

Precondition p The pressure is not adjusted while drilling.
p All the control levers on the operator panel are in neutral position.
2. Start the pump.
4. Screw the valve (B) clockwise until the valve is disengaged.
5. Loosen the lock nut from the valve.
Valve Vfm
6. Adjust the screw on the valve to 140 bar (2030 psi).

Read the pressure on a pressure gauge connected at the test outlet (G2).
120 No: TIS0003768.002 en-US

7. Tighten the lock nut on the valve.
8. Reset valve (B).
9. Run the rock drill back to its rear end position.
10. Turn off the pump.
11. Remove the wooden block.
Adjusting Pressure Difference between Upper and Lower Cylinders

The feed pressure of the upper cylinder should normally be 45 bar (652 psi) lower than the
feed pressure of the lower cylinder. If the telescope feeder is not operating satisfactorily, it
may be necessary to adjust the pressure difference.
Precondition p All the drilling levers are in neutral position.
121 No: TIS0003768.002 en-US

3. Start the pump.
122 No: TIS0003768.002 en-US

5. Adjust the pressure using the valve (V8).
Turning the valve knob clockwise increases the pressure difference.
Adjusting Reverse Feed Pressure

Precondition p All the drilling levers are in the neutral position.
2. Start the pump.
3. Activate reverse feed.
4. Check the pressure on the pressure gauge when the rock drill cradle and upper
feed beam are at their rear end positions.
123 No: TIS0003768.002 en-US

5. Adjust the screw on the valve (V17) until the pressure is 120 bar (1740 psi).
Screwing in the valve (V17) increases the pressure.
9.10.6 Anti-jamming Protection
Setting Anti-jamming Protection
1. Set the lever (A) in the small hole position, to set the small hole valve (B).
2. Open needle valve (F).
è The rock drill starts to move forward.
3. Close needle valve (F) until the rotation pressure reaches about 70 bar (1015 psi).
è The rock drill cradle stops.
124 No: TIS0003768.002 en-US

4. Close needle valve (F) until the rotation pressure reaches about 80 bar (1160 psi).
è Anti-jamming protection is activated and the rock drill cradle reverses direc-
tion.
5. Set the lever (A) in the reaming hole position, to set the reaming hole valve (C).
6. Repeat steps two to four.
7. Move the rotation lever (D) and feed lever (E) to their neutral positions.
Setting RPCF for DCS 14/18 during Drilling

A normal value for the rotation pressure during drilling is around 50 bar (725 psi).
The RPCF valve (B) must be activated if the normal rotation pressure rises by 20 bar (290
psi) during drilling.
Precondition p Hydraulic oil is at normal operating temperature.
1. Set the lever (A) in correct position if the machine is equipped with a special ream-
ing hole kit.
Alternative step a. Set the lever (A) in the small hole position to set the small hole valve (B).
Alternative step b. Set the lever (A) in the reaming hole position to set the reaming hole valve (C).
2. Screw in the adjustment screw that is used for the RPCF valve (B).
3. Collar the hole firmly and start full drilling at a suitable feed pressure.
125 No: TIS0003768.002 en-US

4. Check the rotation pressure during drilling from the rotation pressure gauge (D) on
the drilling and positioning panel.
5. Screw out the adjustment screw that is used for the RPCF valve (B) until the feed
pressure drops.
6. Screw in the adjustment screw about one turn to increase the pressure by minimum
of 20 bar (290 psi) for full drilling.
7. Tighten the RPCF valve (B) lock nut.
Setting Feed Return Movement

The feed return valve (A) for DCS 12 and (B) for DCS 14/18, is used to set the rotation
pressure at which the rock drill changes direction.
Precondition p The hydraulic oil is at normal operating temperature.
126 No: TIS0003768.002 en-US

1. Check the rotation pressure during normal drilling from the pressure gauge (C) on
the drilling and positioning panel.
2. Connect a pressure gauge to the pressure test outlet (G3).
3. Loosen the lock nut used for valve (B).
4. Adjust the set screw to 30-40 bar (435-580 psi) above the normal rotation pressure.
Read the pressure from the pressure gauge connected to pressure test outlet (G3).
5. Tighten the lock nut for valve (B).
Setting RPCF for DCS 14/18 in a Workshop

Normal rotation pressure settings for drilling are around 50 bar (725 psi) for small holes
and 40-50 bar (580-725 psi) for reaming holes.
The RPCF valve (A) must be activated, if the normal rotation pressure rises by 20 bar (290
psi) during drilling.
127 No: TIS0003768.002 en-US

Precondition p Hydraulic oil is at normal operating temperature.
1. Set the lever (A) in correct position if the machine is equipped with a special ream-
ing hole kit.
Alternative step a. Set the lever (A) in the small hole position, to set the small hole valve (B).
Alternative step b. Set the lever (A) in the reaming hole position, to set the reaming hole valve (C).
2. Run the drill to it's rear position on the feeder.
3. Screw out the adjusting screw from the RPCF valve (D).
4. Simulate jamming.
a. Disengage the drill rotation hoses (RRR4) and (RRL4).
b. Connect the hoses together with a cock/needle-valve (E).
128 No: TIS0003768.002 en-US

5. Set the rotation lever (F) to the forward position.
6. Screw in the needle valve (E) until the rotation pressure gauge (H) on the drilling
panel reads 70 bar (1015 psi).
7. Set the feed lever (G) in forward position.
8. Screw in the adjusting screw on the RPCF valve (D) until the rock drill cradle starts
moving forward on the feeder.
9. Screw out the adjusting screw on the RPCF valve (D) until the cradle stops.
10. Tighten the lock nut used for the RPCF valve (D).
11. Check the function of anti-jamming protection before making any further settings.
129 No: TIS0003768.002 en-US

9.10.7 ECL Lubricating System Adjustment
Metering Lubricating Oil
ECL Lubrication System
ECL Pulse relay
B LED on lubrication pump anti-inductive protection
Gl Pressure gauge for lubricant pressure. Located on

operator panel.
1. Start the pump.
2. Check that the LED (2) on the pulse relay in the electric cabinet.
It indicates that power is turned On.
ECL Pulse Relay
3. Adjust screw (T1) so that the LED (1) is on for approximately 0.5 second.
4. Set the correct lubricating oil dosage with screw (T2) including LED (1) to indicate
25 pulses/minute.
130 No: TIS0003768.002 en-US

5. Check the lubrication pump LED (B) after each shift to confirm that the correct
pulse frequency is obtained and that oil is emerging from the front section of the
rock drill.
131 No: TIS0003768.002 en-US

132 No: TIS0003768.002 en-US

Boomer 282 10 Diesel Engine
10 Diesel Engine
10.1 Safety Precautions before Working on Diesel Engine
WARNING
Burning Hazard
Hot components can cause serious personal injury.
u Turn off the machine before starting maintenance work.
u Be careful when draining hot oils and fluids.
u Use personal protective gear.
u Do not handle flammable fluids near hot surfaces, sparks, or open flames.
10.2 Technical Data
Deutz D914 L04
Rated Power at 2300 rpm 58 kW*
Normal maximum Torque at 1500 rpm 270 Nm*
Swept Volume 4.3 dm3
Idling Speed 700 rpm
Cooling Air-cooled
Fuel Injection Bosch
Alternator (Bosch) 55 A / 28 V
Engine Starter 4 KW / 24 V
Weight 320 kg
Deutz BF4L 914
Rated Power at 2500 rpm 72 kW*
Normal maximum Torque at 1600 rpm 355 Nm*
Swept Volume 4.3 dm3
Idling Speed 700 rpm
Cooling Air-cooled
Fuel Injection Bosch
Alternator (Bosch) 55 A / 28 V
133 No: TIS0003768.002 en-US

Deutz BF4L 914
Engine Starter 4 KW / 24 V
Weight 360 kg
10.3 Check Glow Plugs

¡ Check the glow plugs.
– Clean them as necessary.
10.4 Check Pipe Connections

¡ Check that pipe connections are intact and that they do not leak.
– Replace as necessary.
10.5 Check Tightening Torque on Engine Suspension Bolts
¡ Check that no engine bolts (A) are missing or loose.
¡ Check the engine bolts (A) for damage.
¡ Check the tightening torque of the engine bolts (A).
134 No: TIS0003768.002 en-US

10.6 Lifting Engine Package
1. Disconnect all the connections to the engine.
2. Adjust the lifting device for the engine center of gravity.
3. Remove the lifting eyes before the engine is taken into operation again.
10.7 Fuel System
10.7.1 Drain Water Condensation from Fuel Tank
1. Place a vessel under the drain plug (A).
2. Loosen the plug (A) about one turn and allow the water to run out.
3. Retighten the plug to avoid fuel leakage.
135 No: TIS0003768.002 en-US

10.7.2 Replace Fuel Filter
1. Close the fuel tap.
2. Remove the fuel filter (A) using a suitable tool.
3. Collect any residual fuel.
4. Clean the surface of the filter holder.
5. Lubricate the rubber seal of the new fuel filter sparingly with a little oil.
6. Refit on the filter by hand until the gasket makes contact with the surface of the fil-
ter holder.
7. Tighten the filter an extra half turn.
8. Open the fuel cock.
9. Check that the fuel filter does not leak.
136 No: TIS0003768.002 en-US

10.7.3 Clean Primary Fuel Filter
¡ Clean the primary fuel filter (A).
137 No: TIS0003768.002 en-US

10.7.4 Bleeding Fuel System
Manually bleed the fuel system, if it has been fully drained or if larger filters have been re-
placed.
Precondition p Engine is switched off.
p Water separation filter, if present is filled and bled.
1. Disconnect the pipe connections (A) to all injection nozzles.
2. Use the hand pump (B) to pump the fuel.

è Fuel mixed with air bubbles flow through the loose pipe connections.
3. Close and tighten the pipe connections when fuel, not mixed with air flows out.
Wipe any spilled fuel.
4. Run the engine at idling speed without load or throttle output for five minutes.
10.7.5 Draining Water Separator

The water separator is an optional function.
138 No: TIS0003768.002 en-US

1. Turn the valve (A) counterclockwise to drain the water.
2. Turn the valve clockwise to close.
10.7.6 Filling Water Separator

The water separator is an optional function.
1. Loosen the bleed screw (A).
2. Plug the tank's bleed.
3. Seal around the tank cap and air nozzle.
139 No: TIS0003768.002 en-US

4. Slowly add compressed air through the tank cap.
NOTE: Do not pressurize the tank more than required for the fuel
! to start filling into the filter's glass.
è Fuel and air bubbles start to emerge through the bleed screw.
5. Stop filling compressed air when fuel without air bubbles emerge through the bleed
screw.
6. Close the bleed screw.
7. Remove the air nozzle and the temporary seal.
8. Close the tank cap and reset the tank bleed.
9. Bleed the remaining fuel lines manually.
10.8 Air System
10.8.1 Check Air Filter

¡ Check air filter to make sure the air filter is clean.
10.8.2 Replace Air Filter Cartridge
! NOTE: Do not clean the filter cartridge.
1. Remove the clamps (A).
140 No: TIS0003768.002 en-US

3. Remove the filter cartridge (C).
4. Clean inside the filter housing and lid.
5. Check the evacuation valve (D).
6. Install a new filter cartridge (C).
7. Install the cover (B) and attach the clamps (A).
10.8.3 Replace Air Filter Safety Cartridge
1. Remove the clamps (A).
3. Pull out the safety cartridge (C).
4. Cover the air outlet with adhesive tape.
5. Clean inside the filter housing and the lid.
6. Install the new safety cartridge (C).
7. Install the cover (B) and attach the clamps (A).
141 No: TIS0003768.002 en-US

10.8.4 Cleaning Dust Valve

1. Empty the dust valve (A) by squeezing the slit together in the direction of the arrow.
Cleaning the Dust Valve
2. Clean the slit at regular intervals.
3. Remove any accumulation of dirt by squeezing the upper part of the valve.
10.9 Oil System
10.9.1 Check Engine Oil Level
WARNING
Burning Hazard
High oil temperature can cause serious personnel injury.
u Use working gloves, face shield, and cover your arms with long sleeves.
Precondition p Machine is parked on a flat and leveled surface.

p Parking brake is applied.
p Engine is stopped and has reached room temperature.
142 No: TIS0003768.002 en-US

¡ Check that the oil level is between the upper and lower mark on the dipstick (A).
Fill with new oil if necessary.
Diesel engine instruction manual
10.9.2 Replace Engine Oil

p The parking brake is applied.
p The engine oil is at temperature 80 °C (176 °F).
1. Shut down the engine.
2. Place a suitable container under the drain plug (C).
3. Remove the drain plug (C) and drain the oil.
4. Install the drain plug with a new gasket and tighten the drain plug.
5. Fill with new oil through the filler hole (A).
143 No: TIS0003768.002 en-US

6. Check oil level on the dipstick (B).
Correct oil level is between the two marks and close to the top mark. Top up if oil
level is low.
7. Start the engine and allow it to idle for about two minutes.
8. Check the engine oil pressure.
9. Check for leaks.
10. Stop the engine and recheck the oil level.

10.9.3 Replace Engine Oil Filter

p The engine is stopped.
1. Place a suitable container under the engine oil filter.
2. Loosen the engine oil filter using a suitable tool and unscrew it.
3. Clean the surface of the filter holder.
4. Apply oil to the gasket of the new filter.
5. Fill the new filter with new engine oil.
6. Screw in the new filter by hand until the gasket makes contact with the filter base.
7. Continue to screw in the filter half a turn.
8. Check the engine oil level.
9. Check the engine oil pressure.
10. Check for oil leaks.
144 No: TIS0003768.002 en-US

10.10 Belts
10.10.1 Check Belt Tension
1. Press down the arm (A) in the tensioning gauge.
2. Place the gauge (D) on the belt (E) between the two belt pulleys.
3. Press the button (C) at right angles to the belt (E).
4. Lift the gauge (D) without changing the position of arm (A).
5. Note the value at the intersection (arrow) of the scale (B) and the arm (A).
10.10.2 Adjust Alternator Belt
1. Loosen the bolts (B), (C) and (D).
2. Push alternator (A) outward, in the direction of arrow until the required belt-tension
is achieved.
3. Tighten the bolts (B), (C) and (D).
145 No: TIS0003768.002 en-US

10.10.3 Replace Cooling Fan Belt
1. Press the tensioning pulley (A) inwards using a suitable tool and remove the V-belt.
2. Fit the new V-belt.
10.10.4 Replace Alternator Belt
Precondition p Cooling fan belt is removed
1. Loosen the bolts (B), (C) and (D).
2. Push the alternator (A) inwards as indicated by the arrow.
3. Replace the old V-belt with a new V-belt.
146 No: TIS0003768.002 en-US

4. Pull the alternator (A) outwards as indicated by the arrow until correct belt tension
is achieved.
5. Tighten the bolts (B), (C) and (D).
6. Re-fit the cooling fan belt.
10.10.5 Check Valve Clearance
Precondition p Engine is cooled down and oil temperature is below 80oC/176oF.
1. Disconnect the ventilation valve and turn it to one side.
2. Remove the valve cover.
3. Adjust the crankshaft according to the adjustment schedule.
4. Check the valve clearance (A) between the rocker arm (B) and the valve (C) by us-
ing a feeler gauge (F).
5. Adjust the valve clearance, as necessary.
a. Loosen the lock nut (D).
b. Adjust the set screw (E) with an Allen key (G).

è Valve clearance is adjusted.
6. Fit the valve cover and change the gasket if necessary.
7. Turn back the ventilation valve into position and tighten.
Maintenance interval of 500 engine hours is only applicable for BF4L 914 engine. For the
D914 L04 engine, an interval of 1000 diesel engine hours is applicable.
147 No: TIS0003768.002 en-US

10.11 Alternator
¡ Do not break connections between battery, alternator, and regulator when the en-
gine is running.
¡ If the alternator must be started and run without the battery, the cable between the
regulator and alternator must be disconnected before starting the engine.
¡ Do not mix up the battery connections.
¡ The charge lamp must be replaced immediately if it is broken.
¡ Do not spray water directly on the alternator when cleaning the engine. Run the en-
gine warm afterward to evaporate excess water.
¡ The method of checking whether the alternator is energized by undoing one of the
contacts and grounding it must not be used under any circumstances! Sparks can
cause engine fires.
¡ When carrying out electric welding, connect the ground directly to the part being
welded.
10.12 Engine Diagnostics
Refer to Deutz instruction manual for more information.

Refer to Deutz Trouble Code List for actual diagnostics.
• Problems arise due to deficient operation and maintenance of the engine.

• Check that all maintenance instructions have been adhered to if a problem arises.
• If the cause of a problem not determined, contact Deutz service centre.
148 No: TIS0003768.002 en-US

Boomer 282 11 Exhaust System
11 Exhaust System
11.1 Safety Precautions before Working on Exhaust

System
WARNING
Hot Engine and Components
u Make sure that the engine is switched off for all maintenance work.
u Take care when draining hot oil and fluids.
11.2 Replacing Catalytic Converter
1. Loosen the clamps (A) around the catalytic converter.
2. Replace the catalytic converter.
149 No: TIS0003768.002 en-US

Boomer 282 11 Exhaust System
150 No: TIS0003768.002 en-US

Boomer 282 12 Electrical System
12 Electrical System
12.1 Lubricate Battery Connections

1. Clean all the battery terminals.
2. Lubricate the cable lugs at battery isolation switch, alternator, starter, and battery
poles with contact lubricant grease after the cables are connected.
151 No: TIS0003768.002 en-US

Boomer 282 12 Electrical System
152 No: TIS0003768.002 en-US

Boomer 282 13 Electrical System, IEC and Australia
13 Electrical System, IEC and Australia
13.1 Safety Precautions before Working on Electrical

System
WARNING
Dangerous Voltage
Can cause severe personal injury.
u Check that the electrical system is de-energized before starting to work.
u The electrical system must only be serviced by authorized electrician.
13.2 Safety Precautions before Working on Lighting
WARNING
Risk on Bulb Replacement
Hot surfaces can cause burns while replacing a bulb.
u Dirt on bulb glass is burned in and shortens the life of the bulb.
u Do not touch the glass on a bulb with fingers.
u Always use a clean cloth when installing the bulb or hold the bulb at its base.
u Wait until the bulb has cooled before replacing it.
WARNING
Xenon Bulbs
Working with high voltage can cause serious personal injury.
u The supply voltage to the xenon bulb must be switched off before replacing the bulb or
starting other work on the supply circuit.
u Only the authorized maintenance personnel can handle the xenon bulbs.
13.3 Before Troubleshooting Electrical System

Check the following before troubleshooting the electrical system:
¡ All fuses are intact and switched on.
¡ Correct power supply is connected (see voltmeter).
¡ All warning lamps on the electric cabinet are in working order (lamp test).
153 No: TIS0003768.002 en-US

13.4 Cable Marking

All the cables are marked with cable numbers corresponding to the external connection di-
agram.
13.5 Electrical Component Marking

When replacing a component, make sure the new component has the same Epiroc part
number as the old one. Mark new components with the same marking as the ones they re-
place.
13.6 Low-Voltage Circuit

Low voltage refers to an alternating current circuit with a voltage greater than 50 V but less
than or equal to 1000 V. The machines low-voltage circuit is a high-current circuit.
Low-voltage sources are:
• Cable on reeling unit and collector
• Electric cabinet
• Electric motors for hydraulic pumps
• Operating circuits
• Service outlet
• Battery charger for the carrier (also a source of extra low voltage)
• Indicator lamps on electric cabinet
• Electric motor for compressor
• Electric motor for water pump
13.7 Extra Low-Voltage Circuit

Extra low-voltage refers to an alternating current with a voltage less than or equal to 50 V
or a direct current with a voltage less than or equal to 120 V.
Examples of extra low-voltage sources:
• Monitors in the system
• Battery charger for the carrier (also a source of low-voltage)
• Lighting
154 No: TIS0003768.002 en-US

13.8 Electrical Distribution Cabinet
13.8.1 Electrical Distribution Cabinet IEC, AUS (380–690 V)
F131 Motor protection switch, water pump
F126 Motor protection switch, compressor
F19 Protection switch, T16
F20 Short circuit protection
F91 Ground fault switch
S13 Knob for selection of measuring range
P66 Hour counter
P12 Volt meter/amp meter
K10 Ground fault relay
K26 Phase sequence relay
F6 Protection switch, T50 and T11
F60 Motor protection, electric motor 1
F70 Motor protection, electric motor 2 (only Boomer 282)
Q7 Main switch
155 No: TIS0003768.002 en-US

13.8.2 Electrical Distribution Cabinet IEC, AUS (1000V)
F91 Ground fault switch
F6 Protection switch, T50 and T11
F6:1 Protection switch, T50 and T11
K26 Phase sequence relay
K10 Ground fault relay
P12 Volt meter/amp meter and hour meter
F126 Motor protection switch, compressor
F131 Motor protection switch, water pump
F60 Motor protection, electric motor 1
F70 Motor protection, electric motor 2 (only Boomer 282)
Q7 Main switch
13.8.3 Overview of Voltmeter and Ammeter
P12 Voltmeter and ammeter
S13 Knob for selection of measuring range
156 No: TIS0003768.002 en-US

13.8.4 Hour Counter

The electrical distribution cabinet (380–690 V) contains hour meters that register the num-
ber of percussion hours for each rock drill.
P66 Hour counter for rock drill 1
P76 Hour counter for rock drill 2 (only Boomer 282)
13.8.5 Checking Voltage, Current, and Percussion Running Hours
WARNING
Dangerous Voltage
The Meter (P12), on the electric cabinet, is a combined voltmeter, ammeter, and hour me-
ter. The light under the buttons indicates if button is activated.
¡ Press button (V) to check that the input voltage to the machine complies with the
rated voltage specified on the data plate of the machine.
¡ Check the current of the hydraulic pumps electric motors by pressing the buttons
(A1, A2, A3). The number of buttons (A1, A2, A3) that are functional varies depend-
ing on number of hydraulic pump units on the machine.
¡ Check that the hydraulic pumps electric motors are not overloaded in operation by
comparing the meter readings with the rated current specified on the data plates of
the electric motor.
157 No: TIS0003768.002 en-US

¡ Check the running hours of the percussion unit button (T).
Does not apply for machines with RCS.
13.8.6 Setting Up Soft Start
Operator Panel
The setup applies to type PSS 142/145-690F.
1. Set start ramp to 6 s.
2. Set stop ramp to 0 s.
3. Set U ini to 30%.
4. Set the DIP switch to up.
13.9 Electrical System Protection
13.9.1 Main Switch Q01

The main switch (Q01) is on the 3-phase circuit in the electric cabinet, and has built in pro-
tections. The main switch has a knob for on and off. If triggered by a protection, the switch
can be reset by turning the knob to position 0 (OFF) and then back to position 1 (ON).
158 No: TIS0003768.002 en-US

13.9.2 Resetting Phase Sequence Alarm
WARNING
Dangerous Voltage
The electrical system has a phase sequence monitor (K26) to prevent the electric motors
from starting if the power supply has the wrong phase sequence. If there is a phase se-
quence problem, an indicator lamp on the electric cabinet comes on.
If the phase sequence fault indicator lamp comes on, a qualified electrician must take ac-
tion.
1. Turn off the main power switch for the input cable and remove the plug.
2. Switch two of the phases in the consumer mains source.
3. Install the plug and turn on main power switch.
13.9.3 Ground Fault Equipment
WARNING
Dangerous Voltage
The electrical system has a ground fault relay (K10) and a ground fault breaker (F91).
• The purpose of the ground fault relay is to protect against fires in the main circuits.
This switch is set to 300 mA and 500 ms.
• The ground fault switch provides personal protection. When it trips, the supply to the
transformer circuit for service outlet 230 VAC and to the battery charger is discon-
nected. This switch is set to 30 mA and maximum 40 ms.
A qualified electrician must test the ground fault equipment regularly. The ground fault
equipment settings are checked before delivery and sealed.
159 No: TIS0003768.002 en-US

13.10 Motor Protection Relay Fanox
Each hydraulic pump motor has an electronic motor protection relay. The motor protection
has a green lamp (A) that indicates that the power supply is on and that the output relay is
in operating position. If the motor protection is triggered, the lamp goes off.
The motor protection has three lamps to indicate which type of fault has triggered the pro-
tection.
• Lamp (B) comes on if the permitted motor current is exceeded (over-current). Motor
protection trips because the motor is overloaded (thermal overload).
• Lamp (C) comes on in the event of a phase loss or a phase error. The electric motor
stops or cannot be started
• Lamp (D) comes on if the permitted motor temperature is exceeded (overheating). The
electric motor stops.
• The motor protection can be reset using the reset button (E).
The motor protection has a DIP switch for setting rated current (F) and a DIP switch for
phase sequence monitoring (H). It is possible to set the trip class (G). It also has a reset
button (E) to reset alarms.
160 No: TIS0003768.002 en-US

13.10.1 Overview of Electronic Motor Protection Relay
A Indicator for motor protection in operating position
B Indicator for over current and thermal overload
C Indicator for phase loss and phase error
D Indicator for overheating
E Reset button
F Setting rated current
G Setting the trip class
H Phase sequence monitoring
161 No: TIS0003768.002 en-US

13.10.2 Checking if Motor Protection is Triggered
Check which lamp is ON to analyze which protection is triggered.

¡ If lamp (A) is on: The motor current exceeds the set rated current and the motor
protection has tripped.
¡ If lamp (B) is on: Turn off the main power and pull out the plug from the wall socket.
Check the cables in the electric motor circuit and the electric motor.
¡ If lamp (C) is on: Check that the electric motor is properly cooled or if it has been
overloaded for a long time.
Check that the power supply complies with the rated voltage on the data plate. If
the voltage is correct, check the electric motor circuit.
Reset the motor protection with button (D) after the fault has been rectified.
13.10.3 Checking if Motor Protection Is Triggered (for 360–690 V)

The hydraulic pumps' electric motor includes motor protection that is triggered when the
motor is overloaded. The motor protection for the water pump and compressor electric mo-
tors is triggered due to overloading and short-circuiting. If any of these motor protection de-
vices are triggered, an indicator on the electric cabinet comes ON and the following actions
must be taken by an authorized electrician.
162 No: TIS0003768.002 en-US

1. Determine for which motor protection has been triggered and reset it.
2. Check that the voltage displayed on the combined voltmeter and ammeter corre-
sponds with the rated voltage on the electric motor data plate.
3. Set the correct motor protection setting value on the relevant motor.
Motor protection for compressor electric motor (F126) and the motor protection for
water pump electric motor(F131) must be set to the rated current shown on the re-
spective motor data plate.
Motor protection (F60 for Boom1 and F70 for Boom 2)for the hydraulic pump elec-
tric motor for 380-690 V must be set to the current in phase, which is 0.58 times
rated motor current.
13.10.4 Setting Rated Current

The motor protection has a basic setting of 4 A or 40 A that must be taken into considera-
tion when setting the value. The value must consequently be 4A or 40A lower than the
rated current or 4 A or 40 A lower than the rated current times the service factor (1.15 or
1.3). During Y/D start the value must be as above but times 0.58. Adjust settings using the
DIP switches on the motor protection.
The rated current and service factor are specified on the engine's data plate.
¡ If the service factor is 1.15, set the motor protection to a value 15% higher than the
rated current.
¡ If the service factor is 1.3, set the motor protection to a value 30% higher than the
rated current.
¡ Set Trip class to a value of 35.
13.10.5 Fuses for Carrier

The electrical system is protected by two 10 A automatic circuit breakers and three 16 A
automatic circuit breakers that are fitted inside the driving panel.
A main fuse of 50 A is fitted on the battery compartment next to the main power contractor.
There is also a 16 A fuse fitted next to the main fuse. This fuse protects the carrier electri-
cal system and battery if any fault arises in the electric cabinet.
163 No: TIS0003768.002 en-US

164 No: TIS0003768.002 en-US

Boomer 282 14 Electrical System, Canada and USA
14 Electrical System, Canada and USA
14.1 Safety Precautions before Working on Electrical

System
WARNING
Dangerous Voltage
14.2 Safety Precautions before Working on Lighting
WARNING
Risk on Bulb Replacement
Hot surfaces can cause burns while replacing a bulb.
u Dirt on bulb glass is burned in and shortens the life of the bulb.
u Do not touch the glass on a bulb with fingers.
u Always use a clean cloth when installing the bulb or hold the bulb at its base.
u Wait until the bulb has cooled before replacing it.
WARNING
Xenon Bulbs
Working with high voltage can cause serious personal injury.
u The supply voltage to the xenon bulb must be switched off before replacing the bulb or
starting other work on the supply circuit.
u Only the authorized maintenance personnel can handle the xenon bulbs.
14.3 Before Troubleshooting Electrical System

Check the following before troubleshooting the electrical system:
¡ All fuses are intact and switched on.
¡ Correct power supply is connected (see voltmeter).
¡ All warning lamps on the electric cabinet are in working order (lamp test).
165 No: TIS0003768.002 en-US

14.4 Cable Marking

All the cables are marked with cable numbers corresponding to the external connection di-
agram.
14.5 Electrical Component Marking

When replacing a component, make sure the new component has the same Epiroc part
number as the old one. Mark new components with the same marking as the ones they re-
place.
14.6 Low-Voltage Circuit

Low voltage refers to an alternating current circuit with a voltage greater than 50 V but less
than or equal to 1000 V. The machine low-voltage circuit is a high-current circuit.
Low-voltage sources are:
• Cable on reeling unit and collector
• Electric cabinet
• Electric motors for hydraulic pumps
• Lighting
• Service outlet
• Battery charger for the carrier (also a source of extra low voltage)
14.7 Extra Low-Voltage Circuit

Extra low-voltage refers to an alternating current with a voltage less than or equal to 50 V
or a direct current with a voltage less than or equal to 120 V.
• Monitors in the system
• Battery charger for the carrier (also a source of low-voltage)
• Lighting
• Oil level switch
166 No: TIS0003768.002 en-US

14.8 Electrical Distribution Cabinet, High-Current
14.8.1 Electrical Distribution Cabinet
Electrical Distribution Cabinet, Exterior
MCB Main switch
4PB Emergency stop
55LT Indicator lamp, main power
61LT Indicator lamp, phase sequence correct
63LT Indicator lamp, low hydraulic oil level
1HM Hour counter 1
2M Pump 2 on and off
1M Pump 1 on and off
56P Ground fault test

B
72P Indicator lamp, motor overload

BLT
25S Ammeter, on and off

S
VM Volt meter
2HM Hour counter 2
167 No: TIS0003768.002 en-US

2AM Battery charging
1AM Ammeter
14.8.2 Electrical Distribution Cabinet Direct Start
Electrical Distribution Cabinet, Interior
MCB Main switch
SEN Summated current transformer for ground fault
1M Contactor, electric motor, and hydraulic pump 1
1MP Thermal overload protection, electric motor, and hydraulic pump 1
4M Contactor, compressor
4MP Thermal overload protection, compressor
5M Contactor, water pump
5MP Thermal overload protection, water pump
GFR Ground fault relay
PRR Phase sequence monitor
168 No: TIS0003768.002 en-US

14.8.3 Electrical Distribution Cabinet Soft Start
Electrical Distribution Cabinet, Interior
MCB Main switch
SEN Summated current transformer for ground fault
4M Contactor, compressor
4MP Thermal overload protection, compressor
5M Contactor, water pump
5MP Thermal overload protection, water pump
GFR Ground fault relay
PRR Phase sequence monitor
1SS Soft start
2SS Soft start
169 No: TIS0003768.002 en-US

14.9 Electrical System Protection
14.9.1 Main Switch

The main switch (MCB) is on the 3-phase circuit in the electric cabinet. The main switch
has a knob for on and off. The main switch has as standard under-voltage protection, ther-
mal overload protection, and magnetic short-circuit protection.
If triggered by a protection, the switch can be reset by turning the knob to position 0 (OFF)
and then back to position 1 (ON).
14.9.2 Setting Short-Circuit Protection

¡ The short-circuit protection is set to 10 × the main switch rated current (In).
14.9.3 Resetting Phase Sequence Alarm

The electrical system has a phase sequence switch (PRR) to prevent starting the electric
motors if there is phase fault in the user power socket. In the event of a phase sequence
fault, the indicator lamp (61LT) on the electric cabinet goes out.
If the indicator lamp for the correct phase sequence does not come on, a qualified electri-
cian must carry out the following measures:
1. Turn off the main power contactor for the input cable and pull out the plug.
2. Switch two of the phases in the consumer mains source.
3. Refit the plug and turn on main power contactor.
14.9.4 Ground Fault Equipment

The electrical system has a ground fault relay (GFR).
• The purpose of the ground fault relay (GFR) is to protect the machine from fires in the
main circuits. The supplier sets this switch.
A qualified electrician should test the ground fault equipment regularly. The ground fault
equipment settings are checked before delivery and sealed.
14.10 Motor Protection
14.10.1 Thermal Overload Protection

Each of the hydraulic pump motors has its own thermal overload protection (1MP and 2MP
respectively). The motors for the compressor and water pump are also each equipped with
thermal overload protection (4MP and 5MP respectively).
The motor protection for the compressor motor and water pump motor must be set to their
rated current in accordance with each respective motor data plate.
The motor protection for the hydraulic pump motors must be set to each motor respective
rated current. The exception to set the rated current is when the motor has a service factor
(SF) of 1.15. Then the motor protection must be set to a particular value (1.15 x the rated
motor current). The rated current and service factor are specified on the motor data plate.
170 No: TIS0003768.002 en-US

Triggered overload protection is reset using the knob for the respective overload protec-
tion. These knobs are located inside the electric cabinet, except for the knobs for the over-
load protection for the hydraulic pump motors. These knobs are instead on the outside of
the cabinet, knobs (1M) and (2M).
If the overcurrent protection indicator lamp comes on, a qualified electrician must take the
following measures:
1. Determine the motor for which the motor protection has been triggered and reset it.
2. Make sure that the incoming voltage shown on the volt meter corresponds with the
rated voltage on the electric motor data plate.
3. Make sure that the motor protection setting is correct as specified.
4. If the reason for the motor protection being tripped cannot be found using the mea-
sures described in steps 2 and 3, then perform fault diagnosis on the electric motor
and the motor protection.
14.10.2 Cabinet with Soft Start USA

Parameter settings for soft start are made through the display. A form is enclosed contain-
ing the necessary settings that are to be made. For example, covering a 440-V system 60
Hz with 55-kW electric motor.
14.10.3 Alignment Form, Soft Start
! NOTE: Codes In and Uln must correspond with the rated plate on the motor.
Menu, Standard setting parameters: SEt
Code Factory Set- Customer Set- Code Factory Set- Customer Set-
ting ting ting ting
In (1) 88 dEC 15 s
ILt 400% 300% EdC 20%
ACC 15 s 10 s brC 50%
t90 20% 20% EbA 20%
Sty -F- F
Menu, Protection parameters: PrO
ting ting ting ting
tHP 10 10 PHr no no
ULL OFF OFF tbS 2s 2s
LUL 60% PHL 10% 10%
tUL 60% PtC OFF OFF
tLS OFF OFF ArS OFF OFF
OIL OFF OFF rtH no no
171 No: TIS0003768.002 en-US

ting ting ting ting
LOC 80%
tOL 10.0
Menu, Advanced setting parameters: drC
ting ting ting ting
tLI OFF OFF LSC 50% 50%
bSt OFF OFF tIG 40%
dLt OFF OFF CSC OFF
SSt OFF OFF Uln (1) 460
CLP ON ON Frc AUt AUt
Menu, Function allocation of inputs and outputs: IO
ting ting ting ting
L 13 LIA LIA r1 rII rIF
L 14 LIL LIL r3 m1 m1
IPr 0% AO OCr OCr
tPr 5s 04 020 020
L 01 tA1 tA1 ASC 200 200
L 02 m1 m1
Menu, Communication parameters: COP
ting ting ting ting
Add 0 0 tLP 10 s 5.0 s
tbr 19.2 kBits/s 19.2 kBits/s PCt OFF OFF
FOr 8n1 8n1
14.10.4 Diagnostics
Before starting fault finding, check that:
• All fuses are intact and turned on.
• The correct power supply is connected to the machine.
Check volt meter.
• All warning lamps on the electric cabinet are in working order.
Carry out lamp test.
172 No: TIS0003768.002 en-US

Boomer 282 15 Water System
15 Water System
15.1 Safety Precautions before Working on Water System
WARNING
High System Pressure
There is a risk of personal injury when working with pressurized systems.
u Do not perform maintenance work while the machine is operating.
u Check that the hydraulic, water, and air systems are depressurized and that the electri-
cal system is de-energized before starting to work on these systems.
15.2 Clean Water Strainer
WARNING
Clean the strainer regularly to maintain the proper flow.

Connect the water supply to the hose reeling unit if the machine is equipped with it.
Precondition p Hose connection points are clean.
1. Connect a water supply to the water inlet (B) on the machine.
2. Open the main stop valve (A).
3. Open the valve (E) and let water run through the water strainer (C).
4. Remove the end piece (D) if the water strainer is damaged.
173 No: TIS0003768.002 en-US

5. Remove the strainer drum.
6. Clean the strainer drum or replace with a new one if necessary.
15.3 Replacing Water Pump Shaft Seal - Hydraulic Drive
Precondition p The water pump is removed from the machine.
1. Remove the plate protection (L) from the lantern piece.
2. Remove the hub's bolts (D and E) and associated lock tabs, and the remove lock-
ing pin (G), which is inside the lock tabs (F).
3. Undo the bolts that attach the hydraulic motor in flange (C) and lift off the hydraulic
motor together with the hub (B).
4. Remove the nuts (A) and the lift off the lantern piece (K).
5. Lift off the disk (J) and remove the upper part of the shaft seal (H) from the disk's
underside.
6. Wash the upper part of the new shaft seal with alcohol and fit it in place on the disk.
7. Pull off the lower part of the old shaft seal from the shaft.
174 No: TIS0003768.002 en-US

8. Wash the lower part of the new seal with alcohol and place on the shaft.
9. Fit the disk (J) with the upper part of the shaft seal in place.
10. Fit and attach the lantern piece (K) with the nuts (A).
11. Press in the fork-shaped shim (M) on the shaft.

If there is no shim then a fitting piece of 5 ± 0.1 mm can be used.
12. Lower the hub (B) over the shaft, fit the locking pin (G) in the shaft's hole, and fit the
lock tabs (F) and the hub's bolts (D and E).
13. Screw the hydraulic motor into the flange on the lantern piece.
14. Remove the fork-shaped shim and fit the plate protection (L).
175 No: TIS0003768.002 en-US

15.4 Replacing Water Pump Shaft Seal - Electric Drive
Precondition p The water pump is removed from the machine.
1. Remove the electric motor from the water pump.
a. Remove the plate protection (E).
b. Remove the coupling halves' fasteners (D, G and F) using a wrench (M).
c. Remove the screws (N) to remove the electric motor.
176 No: TIS0003768.002 en-US

2. Remove the coupling halves (C) and the locking pin (H).
3. Remove the fasteners (A and B) to lift the lantern piece (L).
4. Lift the disk (K) and remove the upper part of the shaft seal (J) from the disk's un-
derside.
5. Wash the upper part of the new shaft seal with alcohol and fit it in place on the disk.
6. Pull off the lower part of the old shaft seal from the shaft.
7. Wash the lower part of the new seal with alcohol and place on the shaft.
8. Fit the disk (K) with the upper part of the shaft seal in place.
9. Fit and attach the lantern piece (L) with the fasteners (A and B).
10. Press in the fork-shaped shim (P) on the shaft.
If there is no shim then a fitting piece of 5 ± 0.1 mm can be used.
11. Refit the coupling halves (C) and the locking pin (H).
12. Refit the electric motor on the lantern piece and tighten the coupling halves' fasten-
ers (D, G and F).
13. Remove the fork-shaped shim and fit the plate protection (E).
15.5 Setting Water Flow Switch
Flow Switch
1. Remove the black plastic cover from the guard.
2. Remove the screw on top of the switch.
177 No: TIS0003768.002 en-US

3. Adjust sensor body (A).
4. Set the flow switch (B141) as a making contact (B).

The filled red triangle (B) shows interval for making contact and white triangle (C)
for breaking contact.
5. Adjust the water flow switch so that just the tip of the red triangle is visible.
6. Tighten the screw and install the plastic cover.
7. Check that desired function is reached by turning ON and OFF the flow.
è The flow switch (B141) senses the water flow during drilling. The adjustment
of the sensor body determines the water flow value. If the flow is below the set
value, the water pump stops and the drilling is interrupted.
15.6 Draining Water System

Precondition p The electric motor of the water pump is disconnected.
1. Remove the drain plug (A) from the water pump.
2. Allow the water to drain out, and reinstall the drain plug (A).
178 No: TIS0003768.002 en-US

Optional step If the machine is equipped with an oil cooler with water as refrigerant, open the
drain tap (B) and allow the water to run out.
3. Connect an air supply to connector (D).
4. Open the valve (C).

Optional step If the machine is equipped with a water hose reeling unit, open the main stop valve
(E) to flush water out of the reel, and then close the valve (E).
5. On the operator panel, move the lever (F) forward and flush the water out of the
system.
15.7 Thermostat
This function is an option.
179 No: TIS0003768.002 en-US

Reducing Valve by the Hydraulic Oil Reservoir
At a certain hydraulic oil temperature (50 °C (122 °F)), a thermostat is located by the hy-
draulic oil tank opens, and releases the water to increase the flow of water through the oil
cooler.
The thermostat is set at 50 °C (122 °F) by turning the setting knob (C). The thermostat has
a scale graduated 1–5. The value 1 on the scale is equivalent to approximately 25 °C (77
°F) and the value 5 is equivalent to approximately 65 °C (149 °F). Check the setting on the
thermometer on the hydraulic oil tank.
Input water pressure to the thermostat can be read on the pressure test outlet that is con-
nected to test outlet (B). The pressure must be approximately 5 bar (72.5 psi) and is ad-
justed on the reducing valve (A). The thermostat input water pressure (C) must be a maxi-
mum of 16 bar (232.05 psi).
180 No: TIS0003768.002 en-US

Boomer 282 16 Pneumatic System
16 Pneumatic System
16.1 Safety Precautions before Working on Pneumatic

System
WARNING
16.2 Overview of Compressor
! NOTE: Only applies to compressor LE3 (LE22), LE5 (LE40), LE7 (LE55), LE10 (LE75).
A Air filter
B Sight glass
The compressor is an electric motor-driven piston compressor. It starts operating when the
hydraulic pumps are started.
181 No: TIS0003768.002 en-US

16.3 Check Oil Level
WARNING
High System Pressure and Voltage
Can cause serious personal injury
u Do not carry out maintenance while the machine is in operation.
u Make sure that the hydraulic, water and air systems are depressurized and the power
supply is switched off.
Precondition p The compressor is stopped by stopping all the hydraulic pumps.

¡ Check that the oil level is seen at the bottom half of the sight glass (A).
16.4 Check Air Filter
WARNING
High System Pressure and Voltage
u Do not carry out maintenance while the machine is in operation.
u Make sure that the hydraulic, water and air systems are depressurized and the power
supply is switched off.
182 No: TIS0003768.002 en-US

Precondition p The compressor is stopped by stopping all the hydraulic pumps.

¡ Remove the cover plate of air filter (A) and check the air filter (A).
16.5 Draining Condensation from Air Tank

The air tank is fitted only on machines with the air flushing option.
Precondition p Machine is parked in flat and leveled surface.
¡ Open the drain valve to drain the water in the air tank.
16.6 Adjusting Compressor Unloading Pressure
WARNING
High Air Pressure
u De-pressurize the pressure tank before adjusting the pressure.
The pressure can be adjusted on the control valve V19.
183 No: TIS0003768.002 en-US

2. Adjust the pressure using the screw (A).

Tightening the screw (A) into the valve seat (C) increases the pressure.
The pressure should be 6–9 bar (87–116 psi), depending on the depth and diame-
ter of the hole.
16.7 Adjusting Compressor Loading Pressure
WARNING
High Air Pressure
u De-pressurize the pressure tank before adjusting the pressure.
1. Remove the valve seat (B).
2. Adjust loading pressure by adding or removing shims (A).

Adding shims will increase the loading pressure.
The pressure difference between unloading pressure and loading pressure should
be 0.6 bar (8.7 psi).
184 No: TIS0003768.002 en-US

16.8 Adjusting Lubrication Air Pressure
The lubrication air pressure may need adjustment if the compressor pressure is high (up to
9 bar / 130.5 psi).
1. Loosen the screw (A).
2. Adjust the lubrication air pressure to 3 bar (43.5 psi), using the screw (B).
Read the pressure on the pressure gauge (C).
If the machine is used for rising drilling, set the pressure to 5 bar (72.5 psi).
3. Tighten the screw (A).
185 No: TIS0003768.002 en-US

186 No: TIS0003768.002 en-US

Boomer 282 17 Water Mist System
17 Water Mist System
17.1 Technical Data
Water Pump
Rpm, maximum 900 rpm
Speed, minimum (for adequate lubrication) 100 rpm
Drive pressure, hydraulic motor Approximately 150 bar (2175 psi)
Water flow at 900 rpm, maximum 49 l/min
Maximum water pressure 50 bar (725 psi)
Air-oil cooler (Option)
Rpm, maximum 1800 rpm
17.2 Checking Water Mist Pump
CAUTION
Hazardous Air Pressure
Pressure and flow settings made on a pressurized system can cause personal injury.
u Proceed with great care.
u Pressure and flow settings should only be carried out by personnel trained especially
for the system.
187 No: TIS0003768.002 en-US

1. Open the adjustment valve (A).
2. Connect a pressure gauge to the pressure test outlet on the pressure regulator un-
der the water pump control valve.
3. Press button (C) to start the hydraulic pump.
4. Press button (B) to activate water mist.
5. Check the water pump speed.

The speed must be 400 ± 10 rpm. Adjust if necessary using a flow regulator.
188 No: TIS0003768.002 en-US

6. Close the adjustment valve (A).
7. Check the pressure on the pressure gauge.

The pressure should be 13–15 bar (188–217 psi). Adjust if necessary using a flow
regulator.
8. Open the adjustment valve (A) a quarter of a turn and check that the pressure is
stable.
9. Press button (D) to turn off the hydraulic pump.
17.3 Check Water Mist Pump for Leaks

1. Check for water leaks.
2. Check for oil leaks.
3. Replace damaged or worn parts if necessary.
17.4 Check Water Mist Pump Oil Level
1. Check oil level in the sight gauge (A).
2. Top up if necessary.
17.5 Replace Oil in Water Mist Pump
189 No: TIS0003768.002 en-US

NOTE: The first replacement of oil in the water mist pump must only be performed the
! first time this maintenance interval is reached. Thereafter maintenance according to
other interval specified in maintenance table.
¡ Replace oil in water mist pump trough the opening (A).
190 No: TIS0003768.002 en-US

Boomer 282 18 Power Train
18 Power Train
18.1 Safety Precautions before Working on Power Train
WARNING
Burning Hazard
18.2 Power Train Overview
A Front axle
B Rear axle
C Hydraulic transmission
191 No: TIS0003768.002 en-US

18.3 Steering System
Hydraulic System for Steering
A Diesel engine
B Pump for steering
C Pump for positioning
D Return oil filter
E Test outlet
F Pressure control valve
G Control valve (orbitrol)
H Pressure control valve (pressure pulses)
J Steering cylinder
K Brake valve
18.4 Technical Data
Wheels
Tires (Boom and Engine Section) 12.00 x 20
Rims (Boom and Engine Section) 8.00 x 20
Tire Pressure 10 bar (145 psi)
Tightening Torque with Molykote, Wheel Nuts 470 Nm
Steering
Control Valve Danfoss OSPB 630 ON 150- 0048
Gear Pump Displacement 25.4 cm3/turn
192 No: TIS0003768.002 en-US

Steering
Maximum Working Pressure 140 bar (2030.53 psi)
Steering Cylinder VOAC 125/63-380
Steering Wheel Turns, lock-to-lock 6.0 turns from full left lock to full right lock
Drive Shafts
Axle Type, Front Axle Dana 123
Axle Type, Rear Axle Dana 123
Maximum Load Front Axle 15,500 kg (34171.65 lbs)
Maximum Load Rear Axle 6000 kg (13227.74 lbs)
Weight, Front Axle 530 kg (1168.45 lbs)
Weight, Rear Axle 530 kg (1168.45 lbs)
Transmission
Transmission Type Clark T12 000 Long Drop
18.5 Check Tire Pressure

¡ Check tire pressure on each wheel and adjust if necessary.
Tire Pressure
Wheel Tire Pressure (bar) Tire Pressure (psi)
Front wheel 10 145
Rear wheel 10 145
193 No: TIS0003768.002 en-US

18.6 Check Oil Level in the Transmission
Machine is parked on a flat and leveled surface.

The parking is applied.
The transmission oil has reached normal operating temperature (80-90 oC/176-194 oF).
¡ Check the transmission oil level through the sight glasses FULL (A) and LOW (B)
when the engine is running at idle speed around 800 rpm.
If the oil level falls below the sight glass "LOW (B), add new oil to the level of sight
glass FULL (A).
18.7 Check Oil Level in the Axle Differential
Precondition p The machine is on a flat surface.
194 No: TIS0003768.002 en-US

p The machine is turned off.

p The machine is cooled down for at least five minutes so that the oil is settled and at nor-
mal temperature.
1. Remove the oil level plug (A, B).
2. Check that the oil level is at the bottom of the plug hole. Add oil as recommended.
3. Install the oil level plug (A, B).
18.8 Check Oil Level in Planetary Gears
Precondition p The machine is parked on a flat and level surface.

p The machine is turned off.
p The oil level plug is horizontal with the centerline of the wheel.
1. Remove the oil level plug (A).
2. Check that the oil level is at the bottom of the plug hole and add oil if necessary.
3. Install the oil level plug (A).
4. Check the oil level for all the other planetary gears.
195 No: TIS0003768.002 en-US

18.9 Check Tightening Torque on Wheel Bolts and Nuts
NOTE: Tighten the nuts in a cross pattern.

! NOTE: Do not tighten two adjacent nuts consecutively.
! NOTE: Do not lubricate wheel bolts and nuts.
¡ Check that no bolt or nut is missing or loose.
¡ Check the tightening torque on wheel bolts and nuts.
Tightening Torque
470 Nm/346.65 lb-ft
18.10 Check Central Lubrication Hoses and Nipples

¡ Check hoses and nipples.
¡ Fill with grease.
18.11 Check Spider Joints

1. Check hoses and nipples.
196 No: TIS0003768.002 en-US

2. Fill with grease.
18.12 Replace Transmission Oil Filter

p The engine is switched off.
p The oil has reached normal operating temperature of 80-95 °C/176-203 °F.
1. Place a suitable container under the drain plug to receive the oil.
2. Remove the drain plug to drain the transmission oil.
3. Reinstall the drain plug once the oil has drained.
4. Remove the transmission oil filter (A) and replace it with a new one.
5. Fill oil into the transmission housing until it reaches the sight glass LOW (B).
6. Start the engine and let it idle (500-600 rpm) to fill the torque converter and lines.
7. Once the new oil reaches normal operating temperature (80-95 °C/176-203 °F),
check the oil level again.
Fill with oil as necessary until it reaches the sight glass LOW (B).
197 No: TIS0003768.002 en-US

18.13 Replace Transmission Oil

1. Place a suitable container under the drain plug to receive the oil.
2. Remove the drain plug to drain the transmission oil.
3. Reinstall the drain plug once the oil has drained.
4. Fill oil into the transmission housing until it reaches the sight glass LOW (B).
5. Start the engine and let it idle (500-600 rpm) to fill the torque converter and lines.
6. Fill up to the sight glass FULL (A) when new oil reaches normal operating tempera-
ture (80-95 °C/176-203 °F).
18.14 Replace Oil in Planetary Gears

198 No: TIS0003768.002 en-US

1. Move the machine back and forward until the oil level/drain/fill plug is at 6 o'clock
position (the draining position, shown as A).
2. Apply the parking brake and switch off the engine.
3. Place a suitable container under the oil level/drain/fill plug.
4. Remove the oil level/drain/fill plug, and drain the oil.
5. Reinstall the oil level/drain/fill plug.
6. Restart and reposition the machine, so that the oil level/drain/fill plug is at 9 o'clock
position (the checking/filling position, shown as B).
7. Apply the parking brake and switch off the engine.
8. Add new oil into the planetary gear box through the level/drain/fill plug (the check-
ing/filling position, shown as B).
The oil level must be up to the bottom of the oil level/drain/fill plug hole.
9. Repeat Steps 1-8 for all the other planetary gears.
199 No: TIS0003768.002 en-US

18.15 Replace Oil in Axle Differential
Change the oil immediately after operation while the oil is still hot.
1. Remove plugs (B) to drain oil and receive the oil with a suitable container.
Oil drains faster if plug (A) is also removed.
2. Refit the plugs (B).
3. Fill with new oil through the hole for plug (A) until the oil reaches this hole.
4. Refit the plug (A).
200 No: TIS0003768.002 en-US

18.16 Check Articulated Joint
WARNING
Burning Hazard
¡ Check the articulated joints (A) for wear or damage.

è Replace if necessary.
18.17 Checking Tires and Rims
DANGER
Explosion Risk
Incorrect maintenance may result in serious personnel injury or death.
u Maintenance should be performed by authorized personnel only.
201 No: TIS0003768.002 en-US

Check the following while assembling tires and rims:

¡ Check that the tires are inflated to the correct pressure.
¡ Check that the contact surfaces between the hub and rim are clean so that the cor-
rect tightening torque can be maintained.
¡ Check that the wheel nuts are tightened to the correct torque.
¡ Check that the replacement tires are filled with the same medium (air, liquid, or
foam) as the original tires.
Changing to tires that are filled with another medium can have a negative effect on
the stability of the machine.
¡ Check that the right volume of air, liquid, or foam (appropriate medium) is filled to
obtain stability and safety standpoints.
¡ Only authorized tire companies must fill liquid in tires with a salt solution in accor-
dance with the specifications on the drawing.
¡ Check that the correct mixture of liquid medium is obtained to remain in liquid form
down to temperatures of -20 °C (-4 °F).
18.18 Lubricating Cardan Shafts
1. Pump grease into the grease nipples in the center (A) of the universal joints.
2. Make sure the lubricating grease pass through the nipples.
202 No: TIS0003768.002 en-US

18.18.1 Filling Central Lubrication System

1. Turn on the valve (D) at the grease barrel (C).
è Grease is pumped forward to the manual lubrication reeling unit (A).
2. Press grease into the grease nipple (B) with the handle on the manual lubrication
reeling unit (A).
Make sure grease comes out at all positions (E).
3. Turn off the valve (D) at the grease barrel (C).
203 No: TIS0003768.002 en-US

204 No: TIS0003768.002 en-US

Boomer 282 19 Brake System
19 Brake System
19.1 Safety Precautions before Working on Brake System
WARNING
u Switch off the machine.
u Press the brake pedal repeatedly after the machine has been switched off to make sure
that the system is de-pressurized.
u Check a pressure gauge on both brake system accumulators to make sure that the
system is de-pressurized.
19.2 Technical Data
Drive Brake
System Dual independent circuits.

Hydraulic disk brakes in oil bath on all wheels.
Minimum Hydraulic Pressure 80 +5/-0 bar (1160.3 psi)
Parking or Emergency Brake
System SAHR (Spring Applied Hydraulic Released)
Minimum Hydraulic Pressure 35 bar (507.63 psi)
19.3 Check Service Brake Pressure
WARNING
Hydraulic Oil at High Pressure
Thin jets of hydraulic oil under high pressure can penetrate the skin and cause perma-
nent damage.
u Immediately consult a doctor if hydraulic oil has penetrated the skin.
u Never use your fingers to check for hydraulic fluid leaks.
u Keep your face away from any possible leaks.
205 No: TIS0003768.002 en-US


1. Connect a pressure gauge to the brake system pressure test outlet (A).
2. Start the diesel engine.
3. Push and hold the brake pedal and read the pressure on the pressure gauge.
The reading on the pressure gauge must be 80–85 bar (1160–1232 psi).
The pressure is factory set and cannot be adjusted.
4. Stop the diesel engine.
5. Remove the pressure gauge from the test outlet (A).
206 No: TIS0003768.002 en-US

19.4 Check Parking Brake Pressure
1. Connect the pressure gauge to the brake system pressure test outlet (B).
3. Release the parking brake.
4. Check the pressure on the pressure gauge.

The pressure must be 35 bar (507.63 psi).
5. Stop the diesel engine.
6. Disconnect the pressure gauge from the pressure test outlet.
207 No: TIS0003768.002 en-US

19.5 Check Brake Discs
WARNING
NOTE: The check can be optimally carried out with an oil change in the central hous-
! ing.
! NOTE: This test procedure is not applicable on all axles.
Precondition p Service brake is applied.

p Diesel engine is running.
1. Remove level plugs in the central housing.
2. Check the distance (A) between the brake discs from both level plugs using a feeler
gauge or similar tool with a thickness of 5.2 mm (0.20 in).
Replace the brake discs If the distance (A) between the discs is less than 5.2 mm
(0.20 in).
3. Install the level plugs again in the central housing.
208 No: TIS0003768.002 en-US

19.6 Checking Accumulator Charge Pressure
WARNING
u Relieve the high accumulated brake pressure, which will be present even after the en-
gine/motor has been stopped, before opening the system.
1. Connect a pressure gauge to the test outlet (A) on the axle.
2. Depressurize the system by pressing the brake pedal about 40 times.
3. Pull out the stop control and run the starter motor.
è The pressure gauge shows a rapid rise in pressure up to the lowest charge
pressure in one of the accumulators.
The accumulators are charged to 50-55 bar (725-797 psi).
4. Replace the accumulator if the charge pressure is lower than 25 bar (362 psi).
19.7 Checking Brake Pressure Control Valve
WARNING
Hydraulic Oil at High Pressure
Thin jets of hydraulic oil under high pressure can penetrate the skin and cause perma-
nent damage.
u Immediately consult a doctor if hydraulic oil has penetrated the skin.
u Never use your fingers to check for hydraulic fluid leaks.
u Keep your face away from any possible leaks.
209 No: TIS0003768.002 en-US

WARNING
Accidental Movement During Maintenance of Brake System
Accidental movement of the machine can cause serious injury or death.
u Make sure that the machine wheels are blocked.
1. Connect a pressure gauge to pressure test outlet (DS2).
2. Start the engine and check that the “low brake pressure” lamp goes out at 105–115
bar and that the pressure rises to 145–155 bar.
3. Brake repeatedly with the engine idling.

è When the pressure drops to 120–130 bar, the brake system control valve is
engaged so that the maximum brake pressure 145–155 bar is achieved.
4. Stop the engine when maximum pressure is achieved.
5. “Brake hard” four times, i.e. depress the pedal fully and release completely each
time.
If the brake pressure drops below 90 bar after this step is performed, then there is a
fault in the brake system. This can be caused by air in the brake lines, no charge
pressure in the accumulator or low pressure.
210 No: TIS0003768.002 en-US

19.8 Checking Accumulators
Check the accumulators if there is no charge pressure or low pressure in one or more ac-
cumulators.
NOTE: The system may still be pressurized even when the brake pressure gauge indi-
! cates zero pressure.
Precondition p All relevant contact points are cleaned.

p Hoses and unions are protected with plugs and caps as they are detached.
1. Stop the engine.
2. Push and hold the brake pedal repeatedly until the fluid stops flowing through the
brake valve.
è Hissing sound that accompanies when the brake pedal is pushed ceases.
3. Connect a pressure gauge to the pressure test outlet (17) in the accumulator circuit
being checked.
4. Remove the connecting hoses on the accumulator block and plug them in all the
accumulator circuits except the one being checked first.
5. Pull out the stop control and crank the starter motor.
è The pressure gauge indicates a rapid increase in pressure to the lowest pres-
sure with which an accumulator is charged and then rises slowly.
Replace the accumulator if the charge pressure is lower than 35 bar (507 psi).
The system must be depressurized before the accumulator is replaced.
6. Depressurize the system.
7. Disconnect the hoses from the tested accumulator.
8. Repeat steps 4 to 6 on all the remaining accumulators.
9. Reconnect Y200.
10. Start the engine and let it run at high speed until the maximum brake pressure of
145–155 bar (2103–2248 psi) is achieved.
11. Reduce the engine speed to idling.
12. Bleed the brake system.
211 No: TIS0003768.002 en-US

19.9 Replacing Accumulator
WARNING
WARNING
Moving Cab
A moving cab can cause serious personal injury.
u Make sure that no personnel remain under the cab when it is operated.
u Make sure that the cab is secured with associated lockpins during all cab maintenance
work.
WARNING
Pressure Vessel
u A discarded accumulator must be rendered harmless.
u A discarded accumulator that has not been punctured must be handled as a pressure
vessel.
u Be careful when draining the accumulator.
u Work with pressure vessel must be carried out by personnel with prescribed training.
212 No: TIS0003768.002 en-US

1. Remove the protective cap at the top of the accumulator.
2. Loosen the plug (A) with an Allen wrench, one turn at a time to release any pres-
sure.
3. Disconnect the accumulator.
NOTE: A discarded accumulator that has not been punctured

! must be treated as a pressure vessel.
4. Install a new accumulator.
19.10 Bleeding the Service Brake and Parking Brake
213 No: TIS0003768.002 en-US


p Machine is standing on the jacks with the wheels suspended.
1. Attach plastic hoses to the nipples (A).
3. Open the nipples (A) about half a turn.
4. Press and hold the brake pedal (do not pump).
5. Tighten the nipples when there is no air in the fluid.
6. Switch off the diesel engine.
7. Remove the plastic hoses.
214 No: TIS0003768.002 en-US

Boomer 282 20 Reeling Unit
20 Reeling Unit
20.1 Power Supply Cable
WARNING
Risk of Short Circuit or Fire
Can cause serious injuries or death.
Can cause material damage.
u Make sure that you use a cable with sufficient area for the current ambient temperature
and power output of the machine.
u Make sure that the cable is intact before using the machine. Replace the cable in the
event of damage, discoloration, or deformation.
u Make sure that the cable is routed on the tunnel floor so that it is protected from being
driven over by other mobile machines.
u Unwind the whole cable for intensive operation.
u Make sure that the cable does not overheat during intensive use of the machine.
For intensive operation with short intervals for cooling down, there is a risk of the cable
overheating. For instance, during long drilling cycles with a short time between the cycles.
Many external factors affect the ability of the cable to cool down. For example:
• The number of layers on the reel.
• The ambient temperature.
• The air exchange.
• The dirt accumulation.
Therefore, make a habit of always unreeling the entire length of the cable during operation.
215 No: TIS0003768.002 en-US

20.2 Reeling Unit RAC 612/RAC 614
A Hydraulic motor
B Collector for cable reel
C Gears
RAC 612/RAC 614 is used as cable and hose reeling unit on machines equipped with both
cable and hose reeling unit.
20.3 Reeling Unit RAC 611
A Hydraulic motor
B Collector for cable reel
RAC 611 is used as cable reeling unit on machines which are only equipped with cable
reeling unit.
216 No: TIS0003768.002 en-US

20.4 Rotate Reeling Unit

¡ Rotate the reeling unit at least once per shift in order to avoid short circuit in the ca-
ble reeling collector due to oxidation.
20.5 Check Hose Connections

¡ Check all reeling unit hose connections for leaks.
20.6 Check Cable Reeling Unit Collector
WARNING
Dangerous voltage
u Keep away from high-voltage cables.
u Check that the system is de-energized before starting any maintenance work.
u The electrical system may only be serviced by an authorised electrician.
¡ Check that the collector housing (A), cables and collector rings are dry, clean, and
free from oil, copper deposits, and other impurities.
Use a vacuum cleaner, clean cloth, and a brush for cleaning.
! NOTE: Do not use water or compressed air.
217 No: TIS0003768.002 en-US

¡ Check that internal cables are attached and not rubbing against moving parts.
¡ Check all components for damage and replace if necessary.
¡ Check that the protective cable stocking is installed.
¡ Check tightening torque on all bolted joints.
¡ Check bolt tightening on electric cable attachment and electric joints.
¡ Check gaskets on covers and cable entry gaskets and that no water leaks into the
collector housing.
¡ Check that all carbons on the carbon brush are in correct position on the ring be-
fore closing the collector.
20.7 Lubricate Drive Chain and Bearings

¡ Lubricate reeling unit drive chain and all bearings.
20.8 Check Oil Level in Reeling Unit Gear
¡ Check the level of the gear oil through the sight glass (A).
Fill oil through the filler hole (B) if necessary.
20.9 Adjust Reeling Unit Slip Clutch
1. Remove the set key (A) and insert it upside down into the gearing housing.
218 No: TIS0003768.002 en-US

2. Rotate the drum slowly until the set key (A) is locked.
By turning the drum clockwise or counterclockwise, the torque can be increased or
decreased.
3. Adjust quarter of a turn at a time and tighten the set key (A).
4. Remove the set key (A) and refit to its original position.
5. Check the torque and repeat the procedure if further adjustment is required.
20.10 Adjust Reeling Unit Drive Chain
1. Remove the two bolts (C).
2. Move the hydraulic motor (A) along the adjustment grooves (B) maintaining the cor-
rect chain slack.
3. Tighten the hydraulic motor (A) in place with the bolts (C).
Chain Slack 1 - 2 mm
20.11 Replace Oil in Reeling Unit Gear
1. Open the drain plug (B) and drain the oil.
2. Seal the drain plug (B) when the flow of oil has stopped.
219 No: TIS0003768.002 en-US

3. Fill oil through filler hole (C) until it reaches up to the level in the level glass (A).
20.12 Adjusting Reeling Unit Speed

¡ Adjust the speed of reeling in and reeling out of the reeling unit with the two restric-
tion valves located by the reeling unit controls.
20.13 Adjusting Limit Switch
The limit switch contactors should be adjusted if the cable on the reel is changed or if the
contactor setting is inadvertently changed.
1. Remove the limit switch cover (F).
2. Loosen the locking screw (A).
3. Run the cable until three turns are left on the drum of the cable reeling unit.
220 No: TIS0003768.002 en-US

4. Adjust screw (C) until contactor (D) activates the cable reel warning lamp (H24) on
the electric control panel for the cable reeling unit.
5. Run the cable reeling unit until there is one turn on the drum.
6. Adjust screw (B) until contactor (E) activates the parking brake.
7. Press button (T15) to check that the parking brake indicator is deactivated.
8. Tighten locking screw (A).
9. Refit the limit switch cover (F).
221 No: TIS0003768.002 en-US

222 No: TIS0003768.002 en-US

Boomer 282 21 Automatic Central Lubrication System CLS
21 Automatic Central Lubrication

System CLS
21.1 Central Lubrication System

The CLS lubricates all joints in the rear boom body. The CLS is started by a pressure
switch, B186, in the hydraulic positioning circuit.
Lincoln Quicklub 203 Lubricating Pump
A Pump element
B Safety valve
C Plug (Timer for pause and running time)
D Filler nipple
E Reservoir
223 No: TIS0003768.002 en-US

21.2 Central Lubrication System Power Supply
Timer Terminal
A Ground
B Ignition switch
C Motor
D Low-Level Indication
E Extra lubrication
F Lamp in push button
• The timer receives power through the ignition switch and ground.
• Operating time and the lubrication system pause time are started and stopped when
the electric motor is started and stopped.
• The system stores the time setting when the voltage is switched off.
224 No: TIS0003768.002 en-US

21.3 Central Lubrication System Circuit Diagram
Automatic Lubrication System Circuit Diagram with Two Versions
A Pump housing
B Terminal 1
C Cable contact 1 (Black) with 2-core cable
D1 Pump without extra push button
D2 Pump with extra push button
E Ignition switch
F Fuse 6A
G Cable, black
H Cable, brown
J Terminal 2
K Cable contact 2 (Grey) with 3-core cable
L Push button with lamp
225 No: TIS0003768.002 en-US

21.4 Lubrication Pump Safety Valve
Location of Safety Valve on Lubrication Pump
The safety valve (A) is used to limit the pressure in the system. The valve opens at a pres-
sure of 350 bar (5076 psi).
If a hose, lubrication point, or nipple is blocked, the lubricant grease leaks out of the safety
valve. Troubleshooting is required when it happens.
21.5 Lubrication Return Connection
Excess lubricant after dosage to the primary distributor must be routed back to the pump
through the return connection (A).
226 No: TIS0003768.002 en-US

21.6 Fill Lubricant
The container is transparent for visual inspection of the level. One filler nipple is located
above the running lights on the left-hand side and one filler nipple is located directly on the
pump.
! NOTE: Use a filler pump to fill the lubricant.
1. Remove the protective cover on the nipple (A).
2. Fill through the nipple (A) to the MAX marking on the container.
! NOTE: Do not overfill.
3. Reinstall the protective cover.
See separate manual
Fluids and Greases
227 No: TIS0003768.002 en-US

21.7 Test Central Lubrication System
Lubrication System Timer
Precondition p Battery isolation switch is ON.

p One of the hydraulic pumps is ON.
1. Press the pushbutton (A) for two seconds.

è The lubrication system starts.
2. Check the indicator (B) to see if the lubrication pump follows the set pause time and
the running time.
Reset the pause time and running time if necessary.
3. Check that lubricant grease emerges from all lubrication points.
21.8 Setting Lubrication Pause and Running Time
228 No: TIS0003768.002 en-US

Integrated in the lubrication pump is a timer which controls pause and running times. To
access the timer, remove the plug from the lubrication pump.
Precondition p Battery isolation switch is ON.
p One of the hydraulic pumps is ON.
¡ Adjust the pause time in increments of 15 (1, 2, 3,......15 hours) with the blue rotary
switch (A).
! NOTE: Pause time is preset at six hours.
¡ Adjust running time in increments of 15 (2, 4, 6,......30 minutes) with the red rotary
switch (B).
! NOTE: Running time is preset at six minutes.
229 No: TIS0003768.002 en-US

230 No: TIS0003768.002 en-US

Boomer 282 22 Component Locations
22 Component Locations
Component locations may vary between machines depending on the options equipped.
22.1 Pressure Gauges, Test Outlet and Flow Switch
Location of Gauges, Test Outlet and Flow Switch
231 No: TIS0003768.002 en-US

22.2 Modules and Fuse Boxes
Location of Modules and Fuse Boxes on Directional Control Equipment
22.3 Sensors
Location of Sensors on the Boom
Location of Sensors on the Feeder (Option, Hole Length Measurement)
232 No: TIS0003768.002 en-US

22.4 Hydraulic Controlled Valves
Location of Valves
233 No: TIS0003768.002 en-US

234 No: TIS0003768.002 en-US

Boomer 282 Maintenance table
Maintenance table
Interval Type Interval Maintenance Task
Calendar Time Daily 3.1 Wash Machine Externally
3.2 Check Condition of Signs
4.1 Check Fire Extinguishers
4.3 Check Fire Fighting System
6.5 Check Boom Condition
7.4 Lubricate Sliding Surfaces on Feed Unit
7.5 Check Hoses on Feed Unit
7.7 Lubricate Drill Rod Support BSH 45
9.7.2 Check Oil Levels
10.3 Check Glow Plugs
10.4 Check Pipe Connections
10.9.1 Check Engine Oil Level
15.2 Clean Water Strainer
16.3 Check Oil Level
Diesel Engine Hours 10 10.8.1 Check Air Filter
20.5 Check Hose Connections
50 4.4 Check Fire Fighting System Actuators
9.7.3 Drain Water Condensation from Hydraulic Oil

Tank
18.5 Check Tire Pressure
18.6 Check Oil Level in the Transmission
20.6 Check Cable Reeling Unit Collector
20.7 Lubricate Drive Chain and Bearings
100 12.1 Lubricate Battery Connections
19.3 Check Service Brake Pressure
250 4.2 Check and Lubricate Reset Plunger
18.7 Check Oil Level in the Axle Differential
18.8 Check Oil Level in Planetary Gears
235 No: TIS0003768.002 en-US

18.9 Check Tightening Torque on Wheel Bolts and

Nuts
18.10 Check Central Lubrication Hoses and Nipples
18.11 Check Spider Joints
19.4 Check Parking Brake Pressure
20.8 Check Oil Level in Reeling Unit Gear
20.9 Adjust Reeling Unit Slip Clutch
20.10 Adjust Reeling Unit Drive Chain
21.6 Fill Lubricant
500 10.5 Check Tightening Torque on Engine Suspension

Bolts
10.7.1 Drain Water Condensation from Fuel Tank
10.8.2 Replace Air Filter Cartridge
10.8.3 Replace Air Filter Safety Cartridge
10.9.2 Replace Engine Oil
10.9.3 Replace Engine Oil Filter
10.10.1 Check Belt Tension
10.10.2 Adjust Alternator Belt
10.10.3 Replace Cooling Fan Belt
10.10.4 Replace Alternator Belt
10.10.5 Check Valve Clearance
18.12 Replace Transmission Oil Filter
19.5 Check Brake Discs
1000 4.5 Loosen up Powder in Handheld Fire Extinguisher
10.7.2 Replace Fuel Filter
18.13 Replace Transmission Oil
20.11 Replace Oil in Reeling Unit Gear
2000 10.7.3 Clean Primary Fuel Filter
18.14 Replace Oil in Planetary Gears
18.15 Replace Oil in Axle Differential
18.16 Check Articulated Joint
Drilling Hours 10 9.6 Check Hoses and Couplings
236 No: TIS0003768.002 en-US

9.8.1 Check Return Oil Filter
9.8.3 Check Hydraulic Tank Breather Filter
20.4 Rotate Reeling Unit
50 5.2 Check Fresh Air Filter
6.6 Check Boom
6.7 Check Special Tightening Torque on Boom BUT

28
6.8 Lubricate Boom
7.8 Lubricate Pulleys and Hose Drum
7.9 Clean Feed Unit
7.10 Check Wear and Damage on Feed Unit
7.11 Replace Parts on Drill Rod Support BSH 110
15.3 Replacing Water Pump Shaft Seal - Hydraulic

Drive
17.3 Check Water Mist Pump for Leaks
17.4 Check Water Mist Pump Oil Level
21.7 Test Central Lubrication System
250 6.9 Check Bearing Points
7.13 Check Wear on Bearings
7.14 Check Hydraulic Cylinder
7.15 Check Limit Switches
7.16 Replace Rock Drill Retaining Bolts
9.8.4 Replace Breather Filter
500 16.4 Check Air Filter
17.5 Replace Oil in Water Mist Pump
1000 9.8.2 Replace Return Oil Filter
237 No: TIS0003768.002 en-US

238 No: TIS0003768.002 en-US

239 No: TIS0003768.002 en-US

2021-03-17 | No: TIS0003768.002 en-US
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TIS0003768.002 en-US Boomer 282 - Maintenance

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TIS0003768.002 en-US Boomer 282 - Maintenance

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Maintenance

2 About Maintenance Management....................................................................... 13

3 General Machine Condition ................................................................................ 15

4 Fire Fighting Equipment ..................................................................................... 17

iii No: TIS0003768.002 en-US

6.18 Checking Keys on Telescope Device.................................................................................... 41

7 Feed Unit .............................................................................................................. 45

8 Rotation Unit ........................................................................................................ 75

iv No: TIS0003768.002 en-US

8.6 Assembling Rotary Actuator ................................................................................................. 82

10 Diesel Engine ..................................................................................................... 133

v No: TIS0003768.002 en-US

10.8.3 Replace Air Filter Safety Cartridge ..................................................................................... 141

11 Exhaust System ................................................................................................. 149

12 Electrical System ............................................................................................... 151

13 Electrical System, IEC and Australia ............................................................... 153

14 Electrical System, Canada and USA ................................................................ 165

vi No: TIS0003768.002 en-US

14.5 Electrical Component Marking ............................................................................................ 166

15 Water System ..................................................................................................... 173

17 Water Mist System............................................................................................. 187

18 Power Train ........................................................................................................ 191

vii No: TIS0003768.002 en-US

18.6 Check Oil Level in the Transmission .................................................................................. 194

19 Brake System ..................................................................................................... 205

20 Reeling Unit ........................................................................................................ 215

21 Automatic Central Lubrication System CLS ................................................... 223

viii No: TIS0003768.002 en-US

21.4 Lubrication Pump Safety Valve ........................................................................................... 226

22 Component Locations ....................................................................................... 231

ix No: TIS0003768.002 en-US

x No: TIS0003768.002 en-US

1.1 Safety First

1.2 The Purpose of This Publication

1.3 Target Group

1.4 Product Warranty

11 No: TIS0003768.002 en-US

12 No: TIS0003768.002 en-US

2 About Maintenance Management

2.1 Maintenance Management and Hour Meters

! NOTE: Local conditions can affect the scheduled intervals.

2.2 Maintenance Records

13 No: TIS0003768.002 en-US

14 No: TIS0003768.002 en-US

3 General Machine Condition

3.1 Wash Machine Externally

3.2 Check Condition of Signs

15 No: TIS0003768.002 en-US

16 No: TIS0003768.002 en-US

4 Fire Fighting Equipment

4.1 Check Fire Extinguishers

¡ Check that the indicator is in the green zone.

Replace the fire extinguisher if the indicator is in the red zone.

¡ Check the seals for damage.

¡ Check the fire extinguisher body and holder for damage.

4.2 Check and Lubricate Reset Plunger

¡ Lubricate the reset plunger (A) with grease.

17 No: TIS0003768.002 en-US

4.3 Check Fire Fighting System

¡ Check that all couplings (B) on the hoses are tightened.

¡ Check that the holder (D) is not damaged.

¡ Check for any signs of corrosion (E).

¡ Check the pneumatic system connections (F) for leaks.

¡ Check that the lamp (J) on the pneumatic system is ON.