6102429707.1.6102511883 en-US Boomer S2 BUT S - Maintenance

Boomer S2
Maintenance
Original Instructions
2018-03-19 | No: 6102429707.1.6102511883 en-US
Boomer S2 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
1.5 Feedback and Contact Information ........................................................................................ 11
2 About Maintenance Management ...................................................................... 13

2.1 Maintenance Management and Hour Meters ......................................................................... 13
2.2 Maintenance Records .............................................................................................................. 13
2.3 Oil Analysis............................................................................................................................... 13
3 Specifications...................................................................................................... 15
3.1 Tightening Torques for Bolted Joints .................................................................................... 15
3.2 Type Designation Signs for Ordering Spare Parts ............................................................... 15
4 Machine Isolation and Lock-Out........................................................................ 17

4.1 Safe and Ergonomic Machine Positioning ............................................................................ 17
4.2 Electrical Isolation and Lock-Out ........................................................................................... 17
4.2.1 Battery Isolation Switch Lock-Out and Tag-Out ..................................................................... 17
4.2.2 Main Electric Switch Lock-Out and Tag-Out........................................................................... 17
4.3 Releasing Stored Energy......................................................................................................... 18
5 General Machine Condition................................................................................ 19

5.1 Wash Machine Externally ........................................................................................................ 19
5.2 Check Condition of Signs ....................................................................................................... 19
5.3 Check Condition of Hatches and Locks ................................................................................ 19
6 Fire Fighting Equipment..................................................................................... 21

6.1 Fire Inspection after Modification of the Machine ................................................................ 21
6.2 Check Ansul Firefighting System........................................................................................... 21
6.3 Replace Protracting Actuation Device ................................................................................... 21
6.4 Replace Ansul Fire Fighting System Protective Caps.......................................................... 21
6.5 Check Forrex Firefighting System.......................................................................................... 21
6.6 Loosen up Powder in Handheld Fire Extinguisher ............................................................... 21
7 Operator Environment ........................................................................................ 23

7.1 Check FOPS and ROPS Approved Cab ................................................................................. 23
7.2 Check the Seat Swivel Arm ..................................................................................................... 24
7.3 Check Electric Heater .............................................................................................................. 25
7.4 Checking Heater Pump Rotor ................................................................................................. 26
7.5 Check Fresh Air Filter and Recirculation Filter..................................................................... 27
7.6 Check Air Conditioning Unit ................................................................................................... 27
7.7 Adjusting Operating Panel ...................................................................................................... 28
7.8 Adjusting Air Conditioning Unit Compressor Speed ........................................................... 29
7.9 Troubleshooting Air Conditioner............................................................................................ 29
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7.10 Troubleshooting Climate Control Unit ................................................................................... 30

7.10.1 Error Messages ...................................................................................................................... 31
8 Boom Unit ............................................................................................................ 33

8.1 Boom Overview BUT S ............................................................................................................ 33
8.2 Using a New or Reconditioned Boom .................................................................................... 34
8.3 Hoisting the Boom ................................................................................................................... 35
8.4 Check Tightening Torques on Boom BUT S ......................................................................... 36
8.5 Check Bearing and Lubrication Points Boom BUT S ........................................................... 38
8.6 Checking Boom Extension Play ............................................................................................. 40
8.7 Checking Keys on Telescope Device..................................................................................... 41
8.8 Checking Slide Rails on Telescope Device ........................................................................... 42
8.9 Disassembling Boom Extension ............................................................................................ 42
8.10 Disassembling Expander Shafts ............................................................................................ 44
8.11 Assembling Expander Shafts ................................................................................................. 45
8.12 Check Hoses, Cylinders, Valves, and Valve Plates .............................................................. 46
8.13 Check Hydraulic Pressure....................................................................................................... 47
9 Feed Unit.............................................................................................................. 49
9.1 Safety Precautions before Working on Feed Unit................................................................. 49
9.2 Feed Unit 2700.......................................................................................................................... 50
9.3 Technical Data Feed Unit 2700 ............................................................................................... 51
9.4 Check Pull and Return Rope on Feeder ................................................................................ 51
9.5 Check Drill Steel Bushings on Feeder .................................................................................. 53
9.6 Check Slide Rails on Feeder .................................................................................................. 53
9.7 Check Dowel on Feeder .......................................................................................................... 55
9.8 Check Slide Pieces on Feeder ................................................................................................ 56
9.9 Check Tightening Torque on Feeder...................................................................................... 57
9.10 Special Tightening Torque on Spacer.................................................................................... 58
9.11 Clean Feed Unit ........................................................................................................................ 59
9.12 Installing Rock Drill and Rotation Unit................................................................................... 60
9.12.1 Safety Check of Rock Drill or Rotation Unit Installation.......................................................... 61
9.13 Replace Rock Drill Retaining Bolts ........................................................................................ 62
9.14 Replacing Slide Pieces in the Holder ..................................................................................... 63
9.15 Replacing Slide Rails............................................................................................................... 64
9.16 Adjusting Cradle on Feed Beam............................................................................................. 65
9.17 Replacing Pull Rope ................................................................................................................ 66
9.18 Adjusting Pull and Return Ropes ........................................................................................... 68
9.19 Adjusting Tension of Return Rope......................................................................................... 69
9.20 Adjusting Different Drill Rods Lengths for the Telescope Feed.......................................... 70
9.21 Adjusting Feed Beam on Telescope Feed ............................................................................. 71
9.22 Check Limit Switches .............................................................................................................. 71
9.23 Check Hydraulic Cylinder on Feeder ..................................................................................... 72
9.24 Check Pulleys and Hose Drum ............................................................................................... 72
9.25 Lubricate Pulleys and Hose Drum.......................................................................................... 74
9.26 Location of Drill Hoses ............................................................................................................ 75
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9.27 Disassembling Feeder from Boom......................................................................................... 78

9.28 Disassembling Feed Cylinder ................................................................................................. 79
9.29 Disassembling Tension Bushing for Spacer......................................................................... 82
9.30 Assembling Tension Bushing for Spacer.............................................................................. 83
10 Drill Rod Support ................................................................................................ 85

10.1 BSH-XS...................................................................................................................................... 85
10.2 Check Jaw Function BSH-XS.................................................................................................. 85
10.3 Replacing Jaws ........................................................................................................................ 85
10.4 Adjusting the Drill Rod Support ............................................................................................. 86
10.5 Pressure Setting....................................................................................................................... 87
11 Hydraulic System ................................................................................................ 89

11.1 Safety Precautions before Working on Hydraulic System................................................... 89
11.2 About Working on Hydraulic Components............................................................................ 89
11.3 Hydraulic Workshops .............................................................................................................. 89
11.4 Replacing Hydraulic Hoses..................................................................................................... 90
11.5 Check Hydraulic Hoses and Couplings ................................................................................. 90
11.6 Hydraulic Oil ............................................................................................................................. 91
11.6.1 Oil Sampling ........................................................................................................................... 91
11.6.2 Oil Monitoring ......................................................................................................................... 91
11.6.3 Check Oil Level in Carrier Hydraulic Tank.............................................................................. 93
11.6.4 Filling Hydraulic Oil................................................................................................................. 94
11.6.5 Drain Condensate from Hydraulic Oil Tank ............................................................................ 95
11.6.6 Emptying Hydraulic Oil Tank .................................................................................................. 96
11.6.7 Clean Hydraulic Tank ............................................................................................................. 97
11.7 Hydraulic Filters ....................................................................................................................... 98
11.7.1 Replace Return Oil Filter ........................................................................................................ 98
11.7.2 Replace Remote Return Oil Filter........................................................................................... 99
11.7.3 Check Hydraulic Tank Breather Filter................................................................................... 100
11.7.4 Replace Water Separator Particle Filter ............................................................................... 100
11.7.5 Replace Breather Filter......................................................................................................... 102
11.7.6 Bleeding Water Separator Particle Filter .............................................................................. 103
11.8 Hydraulic Pumps.................................................................................................................... 104
11.8.1 Overview of Power Unit Pumps............................................................................................ 104
11.8.2 Location of Hydraulic Valves, Sensors and Test Outlets ..................................................... 105
11.8.3 Starting New or Reconditioned Pump .................................................................................. 106
11.8.4 Checking Pump Rotation Direction....................................................................................... 106
11.8.5 Bleeding Hydraulic Pump ..................................................................................................... 107
11.9 Hydraulic Functions............................................................................................................... 108
11.9.1 Bleeding Hydraulic System................................................................................................... 108
11.9.2 Bleeding Hydraulic Motor ..................................................................................................... 108
11.9.3 Adjusting Maximum Pressure and Speed of Reeling Unit.................................................... 109
12 Diesel Engine..................................................................................................... 111

12.1 Safety Precautions before Working on Diesel Engine ....................................................... 111
12.2 Diesel Engine Data Plate ....................................................................................................... 111
12.3 Commissioning New or Overhauled Diesel Engine............................................................ 112
12.4 EMR ......................................................................................................................................... 113
12.5 Clean Diesel Engine............................................................................................................... 113
12.6 Check Engine Monitoring System ........................................................................................ 114
12.7 Replace Engine Oil................................................................................................................. 114
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12.8 Replace Engine Oil Filter....................................................................................................... 116

12.9 Filling Fuel Manually.............................................................................................................. 118
12.9.1 Fuel Quality .......................................................................................................................... 118
12.10Drain Fuel Tank ...................................................................................................................... 119
12.11Bleeding the Fuel System ..................................................................................................... 120
12.12Annual Replacement of Primary Filter ................................................................................. 121
12.13Replace Fuel Primary Filter................................................................................................... 121
12.14Replace Fuel Secondary Filter.............................................................................................. 122
12.15Check Belt Wear..................................................................................................................... 124
12.16Replace Multi-belt .................................................................................................................. 125
12.17Check Engine Pads................................................................................................................ 126
12.18Check Tightening Torque on Engine Suspension Bolts .................................................... 127
12.19Replace Engine Pads............................................................................................................. 128
12.20Check Hoses for Fuel and Air Intake Systems.................................................................... 129
12.21Air System .............................................................................................................................. 129
12.21.1 Every Second Year Replacement of Air Filter Cartridge ...................................................... 130
12.21.2 Replace Air Filter Cartridge .................................................................................................. 130
12.21.3 Replace Air Filter Safety Cartridge ....................................................................................... 131
12.21.4 Check Air Filter Indicator Lamp Function ............................................................................. 132
13 Cooling System ................................................................................................. 133

13.1 Safety Precautions before Working on Cooling System.................................................... 134
13.2 Check Coolant Concentration............................................................................................... 134
13.3 Adding Coolant ...................................................................................................................... 134
13.4 Replace Coolant ..................................................................................................................... 135
13.5 Draining Coolant .................................................................................................................... 136
13.6 Drain Charge Air Cooler ........................................................................................................ 137
13.7 Clean Flanges of Cooling Elements .................................................................................... 138
13.8 Clean Fan Housing................................................................................................................. 139
13.8.1 Disassembling Cooling Elements from Fan Housing ........................................................... 140
13.8.2 Assembling Cooling Elements to Fan Housing .................................................................... 141
13.9 Clean Cooling System Exterior............................................................................................. 141
14 Exhaust System ................................................................................................ 143

14.1 Exhaust Gas Aftertreatment System.................................................................................... 143
14.2 Diesel Particulate Filter ......................................................................................................... 144
14.3 Selective Catalytic Reduction ............................................................................................... 144
14.4 Passive Regeneration of Diesel Particulate Filter............................................................... 145
14.5 Heat Mode ............................................................................................................................... 145
14.6 Start Standstill Regeneration................................................................................................ 146
14.7 Power Reduction.................................................................................................................... 148
14.8 Interrupting Standstill Regeneration.................................................................................... 148
14.9 Replacing Diesel Particulate Filter ....................................................................................... 149
14.10Fill Diesel Exhaust Fluid (DEF) Tank.................................................................................... 150
14.11Location of DEF Tank ............................................................................................................ 152
14.12Diesel Exhaust Fluid (DEF) .................................................................................................. 152
14.13Cleaning Diesel Exhaust Fluid (DEF) Tank.......................................................................... 153
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14.14Every Second Year Replacement of DEF Supply Pump Filter Cartridge.......................... 154
14.15Replace Diesel Exhaust Fluid (DEF) Supply Pump Filter Cartridge.................................. 154
15 Electrical System, IEC ...................................................................................... 155

15.1 Safety Precautions before Working on Electrical System ................................................. 155
15.2 Cable Marking......................................................................................................................... 155
15.3 Electrical Component Marking ............................................................................................. 155
15.4 Low-Voltage Circuit ............................................................................................................... 155
15.5 Extra Low-Voltage Circuit ..................................................................................................... 155
15.6 Before Troubleshooting Electrical System.......................................................................... 156
15.7 Electrical Distribution Cabinet, High-Current...................................................................... 156
15.7.1 Checking Voltage, Current, and Percussion Running Hours................................................ 156
15.7.2 Electrical Distribution Cabinet A10 Y/D-Start IEC (1000V)................................................... 157
15.7.3 Electrical Distribution Cabinet A10 DOL-Start IEC (1000 V) ................................................ 158
15.7.4 Battery Charger ................................................................................................................... 158
15.8 Electrical System Protection................................................................................................. 159
15.8.1 Main Switch Q01 .................................................................................................................. 159
15.8.2 Setting Overload Protection.................................................................................................. 159
15.8.3 Setting Phase Sequence Relay............................................................................................ 160
15.8.4 Resetting Phase Sequence Alarm........................................................................................ 161
15.8.5 Ground Fault Equipment ...................................................................................................... 161
15.9 Motor Protection .................................................................................................................... 161
16 Electrical System, Canada ............................................................................... 163

16.1 Cable Marking......................................................................................................................... 163
16.2 Electrical Component Marking ............................................................................................. 163
16.3 Low-Voltage Circuit ............................................................................................................... 163
16.4 Extra Low-Voltage Circuit ..................................................................................................... 163
16.5 Before Troubleshooting Electrical System.......................................................................... 163
16.6 Electrical Distribution Cabinet, High-Current...................................................................... 164
16.6.1 Electrical Distribution Cabinet A10 Soft Start Canada (575V).............................................. 164
16.6.2 Setting Up Soft Start............................................................................................................. 165
16.6.3 Battery Charger .................................................................................................................... 165
16.7 Electrical System Protection................................................................................................. 166
16.7.1 Main Switch Q1 .................................................................................................................... 166
16.7.2 Setting Short-Circuit Protection ............................................................................................ 166
16.7.3 Setting Overload Protection.................................................................................................. 167
16.7.4 Setting Phase Sequence Relay............................................................................................ 168
16.7.5 Resetting Phase Sequence Alarm........................................................................................ 168
16.7.6 Ground Fault Switch ............................................................................................................. 169
16.7.7 Circuit Breaker...................................................................................................................... 169
17 Extra Low Voltage Battery................................................................................ 171

17.1 Alternator ................................................................................................................................ 171
17.2 Check the Extra Low Voltage Battery .................................................................................. 171
17.3 Lubricate Battery Connections............................................................................................. 171
17.4 Charging Maintenance-Free Battery .................................................................................... 171
17.5 Charging Battery Using External 24V Charger.................................................................... 172
17.6 Charging Battery Using External 12V Charger.................................................................... 173
17.7 Starting with Auxiliary Battery.............................................................................................. 174
18 Pneumatic System ............................................................................................ 177
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18.1 Safety Precautions before Working on Pneumatic System ............................................... 177

18.2 Drain Condensate from Air Tank .......................................................................................... 177
18.3 Check Cables and Plugs of Compressor............................................................................. 178
18.4 Check Hoses and Connections of Compressor.................................................................. 178
18.5 Check Compressor ................................................................................................................ 178
18.6 Check Safety Valve of Compressor...................................................................................... 179
18.7 Check Air Filter of Compressor ............................................................................................ 179
18.8 Clean Air Filter of Compressor ............................................................................................. 180
18.9 Clean Compressor ................................................................................................................. 181
18.10Membrane Dryer..................................................................................................................... 181
18.10.1 Safety Precautions Before Working on Membrane Dryer..................................................... 182
18.10.2 Check Membrane Dryer SDR6............................................................................................. 182
18.10.3 Replacing Membrane Dryer SDR6 ....................................................................................... 183
18.10.4 Check Membrane Dryer SDR6 Particle Filter....................................................................... 184
18.10.5 Replacing Membrane Dryer SDR6 Particle Filter ................................................................. 184
18.10.6 Setting Pressure Regulator for Membrane Dryer SDR6....................................................... 185
19 Water System .................................................................................................... 187

19.1 Safety Precautions before Working on Water System ....................................................... 187
19.2 Draining Water Pump............................................................................................................. 187
19.3 Checking Pressure Sensor B136.......................................................................................... 188
19.4 Checking Pressure Sensor B188:1....................................................................................... 189
19.5 Setting Water Flow Switch .................................................................................................... 189
19.6 Checking Water Pump Rotation Direction........................................................................... 190
19.7 Check Water Pump Shaft Seal .............................................................................................. 191
19.8 Replacing Water Pump Shaft Seal - Hydraulic Drive .......................................................... 191
19.9 Disassembling Water Pump Shaft Seal ............................................................................... 193
19.10Assembling Water Pump Shaft Seal .................................................................................... 194
19.11Adjusting Water Pump Speed............................................................................................... 196
19.12Water Mist System ................................................................................................................. 196
19.12.1 Check Water Mist Pump for Leaks ....................................................................................... 196
19.12.2 Draining Water Mist Pump.................................................................................................... 197
19.12.3 Checking Flow Switch for Water Mist ................................................................................... 198
20 Power Train........................................................................................................ 199

20.1 Safety Precautions before Working on Power Train .......................................................... 199
20.2 Power Train Overview............................................................................................................ 199
20.3 Checking Condition of Transmission Cooling System ...................................................... 200
20.4 Check Oil Level in Central Housing ..................................................................................... 200
20.5 First Replacement of Oil in Central Housing....................................................................... 201
20.6 Replace Oil in Central Housing............................................................................................. 201
20.7 Check Oil Level in Planetary Gear........................................................................................ 202
20.8 First Replacement of Oil in Planetary Gear ......................................................................... 203
20.9 Replace Oil in Planetary Gear ............................................................................................... 203
20.10Check Carrier Central Lubrication........................................................................................ 204
20.11Lubricate Carrier Joints......................................................................................................... 204
20.12Lubricate Cardan Shafts........................................................................................................ 205
20.13Lubricate Cardan Shaft Spline.............................................................................................. 206
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20.14Check Articulated Joint ......................................................................................................... 206

20.15Check Tightening Torque on Wheel Bolts and Nuts .......................................................... 207
20.16Check Tire Pressure .............................................................................................................. 207
20.17Checking Tires and Rims ...................................................................................................... 208
20.18Replace the Tramming Pump Filter...................................................................................... 209
20.19Towing..................................................................................................................................... 209
20.19.1 Safety Precautions before Towing........................................................................................ 209
20.19.2 Preparing for Towing ............................................................................................................ 210
20.19.3 Restoring after Towing ......................................................................................................... 212
21 Brake System .................................................................................................... 213

21.1 Safety Precautions before Working on Brake System ....................................................... 213
21.2 Check Service Brake Pressure ............................................................................................. 213
21.3 Bleeding Service Brake ......................................................................................................... 214
21.4 Check Parking Brake Pressure............................................................................................. 215
21.5 Bleeding Parking Brake......................................................................................................... 217
21.6 Check Brake Discs................................................................................................................. 218
21.7 Checking Brake Pressure Control Valve ............................................................................. 219
21.8 Checking Accumulator Charge Pressure ............................................................................ 221
21.9 Replacing Accumulator ......................................................................................................... 223
21.10Check after Working With Brake System............................................................................. 224
21.10.1 Check Service Brake ............................................................................................................ 224
21.10.2 Check Parking Brake............................................................................................................ 225
22 Reeling Unit ....................................................................................................... 227

22.1 Power Supply Cable............................................................................................................... 227
22.2 Check Tightening Torque of Cable Reeling Unit Collector ................................................ 227
22.3 Check Cable Reeling Unit Collector .................................................................................... 228
22.4 Clean Cable Reeling Unit Collector ...................................................................................... 229
22.5 Check Reeling Unit Drum ...................................................................................................... 230
22.6 Check Reeling Unit Drive Chain ........................................................................................... 230
22.7 Adjusting Reeling Unit Drive Chain...................................................................................... 230
22.8 Adjusting Limit Switch .......................................................................................................... 231
23 Lubrication System........................................................................................... 233

23.1 Automatic Central Lubrication System (CLS) ..................................................................... 233
23.2 Test Central Lubrication System .......................................................................................... 234
23.3 Lubrication Pump Safety Valve ............................................................................................ 234
23.4 Pause Time and Running Time Settings.............................................................................. 235
23.5 Fill Lubricant........................................................................................................................... 236
24 Welding .............................................................................................................. 237

24.1 About Welding........................................................................................................................ 237
24.2 Electrode Recommendations................................................................................................ 238
25 Downtime ........................................................................................................... 239

25.1 Preparations before Long Period of Downtime................................................................... 239
25.1.1 Preparing Electrical System for Long Time Storage............................................................. 239
25.1.2 Preparing Water Mist System for Long Time Storage .......................................................... 239
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25.2 Restoring after Long Period of Downtime ........................................................................... 239

25.3 Inspection and Maintenance during Period of Downtime .................................................. 240
26 Start-Up .............................................................................................................. 241

26.1 About Special Start-Up .......................................................................................................... 241
26.2 Performing Special Start-Up ................................................................................................. 241
27 RCS Options ...................................................................................................... 243

27.1 Service Tool Bag RCS ........................................................................................................... 243
27.2 Checking CAN Network ......................................................................................................... 244
27.3 Checking CAN Power Supply ............................................................................................... 245
27.4 Checking CAN Cable ............................................................................................................. 247
27.5 Checking Digital Inputs on I/O Module ................................................................................ 248
27.6 Checking Digital Outputs Voltage on I/O Module ............................................................... 249
27.7 Checking Digital Outputs Current on I/O Module ............................................................... 250
27.8 Checking PWM Outputs Current on I/O Module.................................................................. 251
27.9 Checking Analog Inputs on I/O Module ............................................................................... 251
27.10Encoder Inputs ....................................................................................................................... 252
27.11Checking Resolver Module Resolver Inputs ....................................................................... 253
27.12Checking Resolver Module Encoder Inputs ........................................................................ 253
27.13Checking Resolver Module Analog Inputs .......................................................................... 254
27.14Replacing RCS Module.......................................................................................................... 255
28 Component Locations ...................................................................................... 257

28.1 Overview ................................................................................................................................. 257
28.2 Front Module .......................................................................................................................... 258
28.3 Rear Module............................................................................................................................ 261
28.4 Power Module, Middle Module.............................................................................................. 263
28.5 Cab Module............................................................................................................................. 265
29 Maintenance Schedule ..................................................................................... 267

Calendar Time ........................................................................................................................ 267
Diesel Engine Hours First Service........................................................................................ 268
Diesel Engine Hours .............................................................................................................. 268
Drilling Hours ......................................................................................................................... 269
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Boomer S2 1 Introduction
1 Introduction
1.1 Safety First

Always read the information in the Safety manual before starting to use the machine 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.
1.5 Feedback and Contact Information

Epiroc works actively to develop and continuously improve its products and associated
documentation. Provide your feedback on products and documentation by contacting your
local supplier at https://www.epiroc.com, under "Contact us."
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Boomer S2 1 Introduction
12 No: 6102429707.1.6102511883 en-US

Boomer S2 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.
2.3 Oil Analysis

Epiroc recommends the establishment of an oil analysis program. A program with regular
oil analysis can discover problems and the approach of maximum wear limits and the sys-
tem performance checks.
The objective of a preventative maintenance program is diagnosis and repair before failure.
Good sampling techniques and independent laboratory analysis are considered primary el-
ements of a good program.
NOTE: Oil analysis must not be used to determine if oil can be reused after the recom-
! mended service life. Replace oil within the recommended service intervals even if the
oil analysis shows that the oil remains within the set requirements. An extensive analy-
sis program can help to identify the optimum service intervals.
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Boomer S2 2 About Maintenance Management
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Boomer S2 3 Specifications
3 Specifications
3.1 Tightening Torques for Bolted Joints

Bolts on the equipment are tightened to either Normal, Special, or Joint-Specific torque de-
pending on what is stated in the instruction. It is important to understand the differences.
• Normal torque: Degree of Utilization (DOU) is 75% and torque tolerance is ± 25% for
the bolt type and dimension.
• Special torque: Degree of Utilization (DOU) is 90% and torque tolerance is ± 10% for
the bolt type and dimension. Special torques are specified in the maintenance or in-
stallation instruction for the unit
• Joint-Specific torque: The joint-specific torque differs from Normal or Special torque
value for the bolt type and dimension due to the design of the mechanical joint. Joint-
specific torques are specified in the maintenance or installation instruction for the unit
See Reference Documentation
Mining and Rock Excavation Torque Specifications
3.2 Type Designation Signs for Ordering Spare Parts

Type designation signs are posted on the larger components. The type designation and se-
rial number must always be stated when ordering spare parts or making inquiries regarding
the machine. Type designations and serial numbers are also specified in a separate docu-
ment, Machine Identification (MI). Spare parts can be ordered from Epiroc.
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Boomer S2 3 Specifications
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Boomer S2 4 Machine Isolation and Lock-Out
4 Machine Isolation and Lock-Out
Follow all the procedures in this section to make sure that the machine is technically in a
safe state before starting any work. Start functions must be isolated and locked-out.
NOTE: These instructions only cover technical procedures based on the design of the
! machine. Be aware that local regulations apply and workplace procedures must be fol-
lowed. Adapt both technical and workplace procedures to fulfill local requirements for
safe machine lock-out and tag-out.
4.1 Safe and Ergonomic Machine Positioning

Position the machine units as ergonomic as possible for the work to be performed. Make
sure that units can be accessed from floor level, or from approved work platforms available
at the workplace. Safe state and ergonomic positioning may include (adapt to local regula-
tions):
• raising the machine onto jacks
• lowering the booms onto approved stands
• supporting the feeders with stands so they cannot move, tip, or rotate during work
• apply articulation lock
4.2 Electrical Isolation and Lock-Out
! NOTE: Local regulations apply and can complement or override this instruction.
4.2.1 Battery Isolation Switch Lock-Out and Tag-Out
! NOTE: This will block battery electric power, but main electric power can still be
present in the machine.
1. Turn OFF the engine.
2. Turn OFF the battery isolation switch.
3. Lock the battery isolation switch in OFF position using an approved locking device.
4. Place a lock-out information tag according to local regulations.
4.2.2 Main Electric Switch Lock-Out and Tag-Out
! NOTE: This will block main electric power, but battery power can still be present in the
machine.
17 No: 6102429707.1.6102511883 en-US

Boomer S2 4 Machine Isolation and Lock-Out
1. Turn off all machine functions.
2. Turn OFF the main switch.
3. Lock the main switch in OFF position using an approved locking device.
4. Place a lock-out information tag according to local regulations.
4.3 Releasing Stored Energy

Stored energy is a common term for forces that remain in the machine systems when
power supply and functions are turned off. Stored energy forces are potentially dangerous
when working on the machine. Especially when unplugging hoses or cables, opening up
system connections, or loosening load-bearing joints.
Present in drill rigs are different forms of stored energy. Determine the appropriate stored
energy to be released or controlled in the relevant system for the task about to be per-
formed, some examples follows.
• Weight of booms and feeders – Weight in the hydraulic circuit may act like an accumu-
lator, care must be taken when removing hose connections. Use blocks or support
stands to rest the moveable units and remove the risk of unwanted movement.
• Brake Accumulator – verify that hydraulic pressure has been dissipated in the brake
circuit before work commencement, even if the unit is equipped with automatic accu-
mulator bleed down.
• Air Pressure in Tires – (appropriate when working under a machine, or removing tires)
it may not be necessary to remove the air pressure. However, work should not be per-
formed under a machine that is only supported by tire pressure. Machine stands must
be used to provide a stop point if there is tire failure.
• Hydraulic Tank Pressure – Relieve header pressure in Hydraulic tank.
• Emergency Steer Accumulators – verify accumulator hydraulic pressure has been dis-
sipated before opening the steering circuit.
• SAHR Brake Assemblies – SAHR Brake assemblies contain many heavily com-
pressed springs. Mandatory that adequate training competence is achieved before
working on SAHR brake assemblies, follow SAHR maintenance procedures.
• Batteries – They contain an electrolyte which contains dilute sulfuric acid. Sulfuric acid
may cause severe chemical burns. During the charging process or during operation,
they might develop hydrogen gas and oxygen, which under certain circumstances may
result in an explosive mixture. They can contain a considerable amount of energy,
which may be a source of high electrical current and a severe electrical shock in the
event of a short circuit.
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Boomer S2 5 General Machine Condition
5 General Machine Condition
5.1 Wash Machine Externally

Disconnect fire-fighting equipment if steam washing or high-pressure washing.
n Rinse the machine with water at least once a day to remove drill cuttings, mud, and
dirt.
5.2 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 defect or missing signs.
5.3 Check Condition of Hatches and Locks

Check the condition of hatches and the locks on enclosures, cabinets, and service points.
1. Check the condition of the closing, locking, and opening mechanisms of all hatches.
2. Check that the seals are positioned correctly and that they are intact.
3. Lubricate hinges. Apply universal grease to grease nipples.
4. Lubricate lock mechanisms with Teflon-based lock lubricant or equivalent.
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Boomer S2 5 General Machine Condition
20 No: 6102429707.1.6102511883 en-US

Boomer S2 6 Fire Fighting Equipment
6 Fire Fighting Equipment
6.1 Fire Inspection after Modification of the Machine

The automatic fire suppression system is an option.
Precondition p The machine has been modified.
n Contact an authorized service company to inspect over the automatic fire suppression
system.
Contact Epiroc
Contact an Epiroc local customer center for further information.
6.2 Check Ansul Firefighting System

n Contact an authorized service company for inspection of the firefighting system.
Contact Epiroc
6.3 Replace Protracting Actuation Device

n Replace the protracting actuation device on the Ansul fire suppression system.
6.4 Replace Ansul Fire Fighting System Protective Caps

n Replace all nozzles protective caps in the Ansul fire fighting system.
6.5 Check Forrex Firefighting System

n Contact an authorized service company for inspection of the firefighting system.
Contact Epiroc
6.6 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.
21 No: 6102429707.1.6102511883 en-US

Boomer S2 6 Fire Fighting Equipment
n Tap the fire extinguisher canister carefully with a rubber mallet in order to loosen-up
the powder.
22 No: 6102429707.1.6102511883 en-US

Boomer S2 7 Operator Environment
7 Operator Environment
7.1 Check FOPS and ROPS Approved Cab

New ROPS bolts must be installed with thread locking adhesive: Loctite 243 or equivalent.
1. Check the damper elements (A) for drying cracks, damage, or defects.
If any damage on one damper, all dampers must be replaced.
2. Check the retaining bolts (D) for the dampers.
3. Clean the cab brackets thoroughly.
4. Check frame brackets for cracks (J).
NOTE: If cracks or other defects are identified in one or more cab

! brackets, then Epiroc must be contacted for remedial action. Incor-
rect or incorrectly done action results in the invalidation of the
ROPS certification.
5. Check tightening bolts (E, G) for damage, if applicable
6. Check tightening torque on ROPS bolts (E, F, G, H).
23 No: 6102429707.1.6102511883 en-US

If any of the ROPS bolts move during check tightening, replace all ROPS bolts in all
cab brackets.
NOTE: The ROPS bolts, inspection torque, and tightening torque are adapted so that
! the joint must withstand high instantaneous loads. The torques for the ROPS bolts
must not be mixed up with the general tightening torques for the bolt dimensions. Too
much tightening torque causes structural damage. Inadequate tightening torque
causes the ROPS joint to loosen. Defect result in the invalidation of the ROPS certifica-
tion.
Position Cab ROPS Bolt Inspection Tightening New Bolt Tightening

Bracket Torque Torque
Nm lbf.ft Nm lbf.ft
E Front height- M42 180 ± 45 132.8 ± 33.2 200 ± 50 147.5 ± 36.9

ening
F Front M36 180 ± 45 132.8 ± 33.2 200 ± 50 147.5 ± 36.9

bracket
G Rear height- M30 180 ± 45 132.8 ± 33.2 200 ± 50 147.5 ± 36.9

ening
H Rear bracket M36 180 ± 45 132.8 ± 33.2 200 ± 50 147.5 ± 36.9
7.2 Check the Seat Swivel Arm
WARNING
Rotating Component
If the swing arm lock mechanism is not properly locked or if the belt tension is not cor-
rect, it can cause severe personal injury and machine damage.
u Be accurate when adjusting the lock mechanism swing arm to ensure that the mecha-
nism locks properly.
u Make sure the belt tension is correct.
24 No: 6102429707.1.6102511883 en-US

1. Check the belt (E).
2. Use belt tensioner (F) to tension the belt.
3. Tighten the belt tensioner to 10º at a time until there is no play between the belt and
the gears.
4. Check that the lock pin (B) is inserted into the lock slot (A).
5. Adjust the lock pin with the lock nut (D).
6. Lubricate the nipple (C) with the grease to make sure that the lock pin is functional.
7. Check the wear on the edges of the lock slot.

The edges must appear as in (J).
8. Replace the swivel arm (G) if the edges appear as in (H).
7.3 Check Electric Heater
n Check if automatic circuit breaker has been tripped.
25 No: 6102429707.1.6102511883 en-US

If it is tripped, reset with button (A).
n Check if output is 3 kW.

Correct output can be set using the knob (B).
n Check that the pump rotor is not jammed by using the control screw (C).
n Check for damage or wear in the connecting line.
n Check that the ground connection is intact.
7.4 Checking Heater Pump Rotor

The pump rotor gets jammed, if the heater is not used for a long time.
1. Loosen the control screw (A).
2. Pull out the screw and turn.
3. When the screw enters the pump rotors groove, turn and check if the pump rotor
turns.
If the pump rotor does not turn, remove the capsule and loosen te pump rotor with an
appropriate tool.
4. Connect the heater and check if the pump rotor rotates.

Replace the heater, if the pump rotor is still jammed.
5. Reset the control screw with the capsule and tighten it in the pump again.
26 No: 6102429707.1.6102511883 en-US

7.5 Check Fresh Air Filter and Recirculation Filter
1. Remove screws (B).
2. Remove metal plate (C).
3. Remove fresh air filter (A) and recirculation filter (D).
4. Check filters.
è Clean filters if necessary.
Replace filters if efficiency becomes impaired despite cleaning the filter regu-
larly.
7.6 Check Air Conditioning Unit
WARNING
Refrigerant Under Pressure
Can cause serious injury.
u Service of refrigerant system must be carried out by authorized personnel.
NOTICE
Damage to Compressor for air conditioning unit
Risk of compressor breaking down.
u Do not use the system with too little refrigerant, leakage, or any other fault until it is rec-
tified.
1. Check the drain for evaporator on air conditioning unit.
27 No: 6102429707.1.6102511883 en-US

2. Check that the condenser element airways are free from dirt and clean it often.
3. Check hoses and couplings for damage, wear, and leaks.
4. Check sight glass (A).
There must be no bubbles, except when compressor comes ON and OFF.
5. Check compressor attachment for damage and wear.
7.7 Adjusting Operating Panel
Gas spring in the operating panel attachment supports the height adjustment.
1. Pull lever (A) to adjust the height for the operating panel.
2. Leave the lever to lock the height.
28 No: 6102429707.1.6102511883 en-US

7.8 Adjusting Air Conditioning Unit Compressor Speed

n Adjust the compressor speed of the air conditioning unit to 1500 rpm using the flow
valve under Y156.
7.9 Troubleshooting Air Conditioner
WARNING
Refrigerant Under Pressure
Can cause serious injury.
u Service of refrigerant system must be carried out by authorized personnel.
Fault Symptom Action
No heating Check for air in the diesel engine cooling system.
No cooling at all Check the fuses, electrical connections, compressor ground, electromagnets,
switches, and pressure switches.
Check the expansion valve and temperature control valve.
Check the coolant hoses.
Poor cooling Check the fresh air fan.
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.
Check that the expansion valve capillary tube is firmly tightened against the evap-
orator 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 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
29 No: 6102429707.1.6102511883 en-US

Fault Symptom Action
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.
7.10 Troubleshooting Climate Control Unit
An error indicator (A) appears on the main screen if the temperature sensor, heater valve,
or the air-conditioning system malfunctions.
n To access the error message from the main screen, press the button until the
error screen appears.
n Press or buttons to scroll between the errors.
Temperature Sensor Error
Air Condition System Error
Heater Valve Error
NOTE: Heater valve position, and temperature sensor readings can

! also be accessed by pressing and hold buttons.
30 No: 6102429707.1.6102511883 en-US

7.10.1 Error Messages
Error Message Cause
Open Open circuit error for temperature sensors or

heater valve position sensor
Short Short circuit error for temperature sensors or

heater valve position sensor
Stuck Heater Valve failure to rotate
A/C System Air-condition system is disabled due to pressure

switch opening four times consecutively
This error locks out the air-conditioning system
until the operator manually resets
Power down, and return to the error screen, then
push the button to reset the error
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32 No: 6102429707.1.6102511883 en-US

Boomer S2 8 Boom Unit
8 Boom Unit
8.1 Boom Overview BUT S
Boom BUT S
A Feed extension cylinder
B Feed holder
C Tilt cylinder
D Rotary actuators
E Telescopic unit
F Rear boom cylinders
G Attachment plate
33 No: 6102429707.1.6102511883 en-US

8.2 Using a New or Reconditioned Boom
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.
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 in-
hibitor.
3. Check and install all bolted joints and expander shafts at least once every shift during
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.
34 No: 6102429707.1.6102511883 en-US

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.
8.3 Hoisting the Boom
WARNING
Risk of Crushing
Crushing can cause serious personal injury or death.
u Use extreme caution when slinging and hoisting heavy objects.
u Hoisting must take place at the center of gravity.
u Only use slings that are intact and designed for the load they will carry.
u Fasten the straps to lifting eyes, if available.
u Do not approach a suspended load.
WARNING
WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
35 No: 6102429707.1.6102511883 en-US

1. Run the boom to the end position.
2. Position the feed holder parallel with the boom body.
3. Apply the slings.
4. Hoist carefully.
! NOTE: Make sure that the boom does not start to swing and that
the slings do not start to slide off.
BUT S Weight, including hoses
Complete boom, including hydraulic hoses 1814 kg (3999 lb)
! NOTE: The weight are excluding feeder and rock drill.
8.4 Check Tightening Torques on Boom BUT S

Mining and Rock Excavation Torque Specifications
WARNING
36 No: 6102429707.1.6102511883 en-US

WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
n Check tightening of screws using a calibrated torque wrench.
è If any screw moves during torque check, remove old screws and replace with new
ones. Use specified lubrication and installation torques for new screws.
Position Bolted Joints Thread Quality Torque Quantity
A Attachment M24 12.9 881±220 Nm 12

plate - boom (650±162 lb-ft)
bracket
B Bolt, rear boom M20 8.8 365±36 Nm 1

link (269±27 lb-ft)
C Expander M16 8.8 156±39 Nm 2

shaft, rear (115±29 lb-ft)
boom link
37 No: 6102429707.1.6102511883 en-US

Position Bolted Joints Thread Quality Torque Quantity
D Expander M16 8.8 156±39 Nm 2

shaft, rear lift (115±29 lb-ft)
cylinder
E Bolt, rear boom M20 8.8 365±36 Nm 1

body (269±27 lb-ft)
F Boom exten- M12 8.8 63±16 Nm 1

sion (47±12 lb-ft)
G Expander M16 8.8 156±39 Nm 2

shaft, rear lift (115±29 lb-ft)
cylinder
H Boom exten- M20 12.9 513±128 Nm 12

sion, flange (378±94 lb-ft)
bolts
J Bolt, rotary ac- M20 12.9 513±128 Nm 11

tuator (378±94 lb-ft)
K Bolt, rotary ac- M20 12.9 513±128 Nm 8

L Bolt, rotary ac- M20 12.9 513±128 Nm 16

M Feed extension M16 8.8 156±39 Nm 2

cylinder lock (115±29 lb-ft)
nut
N Bolt, rotary ac- M20 12.9 513±128 Nm 12

P Bolt, feed M16 8.8 156±39 Nm 1

holder (115±29 lb-ft)
8.5 Check Bearing and Lubrication Points Boom BUT S
WARNING
38 No: 6102429707.1.6102511883 en-US

WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
n Check bearing points (A) for wear and damage and lubricate at lubrication points (A).
39 No: 6102429707.1.6102511883 en-US

8.6 Checking Boom Extension Play
WARNING
WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
40 No: 6102429707.1.6102511883 en-US

1. Extend boom extension tube (A).
2. Remove the washer (G) and seal (H) and then undo the cover (B).
3. Measure the distance between the extension tube (A) and the two upper bushings
(C).
è If the play (G) is greater than 1 mm, the bushings must be replaced.
8.7 Checking Keys on Telescope Device
n Check the keys (A).

If the keys are deformed, the damaged area must be ground smooth to avoid damage
to the slide rails (B) and bearing housing (C).
41 No: 6102429707.1.6102511883 en-US

8.8 Checking Slide Rails on Telescope Device
1. Remove the washer (A) and seal (B), and then the cover (C).
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.
8.9 Disassembling Boom Extension
WARNING
42 No: 6102429707.1.6102511883 en-US

WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
1. Extend the boom extension to its front-end position.
2. Rotate the feed holder 90º.
3. Position supports on the ground.
4. Lower the boom until the feed holder and the rotary actuator rests on supports.
5. Remove the bolts (B) from the adapter on the rear rotary actuator in the rotation unit.
6. Retract the boom extension to the rear end position.
7. Attach slings round the boom body. Use an overhead tramming crane or hoist or simi-
lar.
8. Remove the screws (C) that hold the front cover for the boom extension.
43 No: 6102429707.1.6102511883 en-US

9. Remove the seal and the two covers.
10. Remove the screws (D).
11. Remove the hydraulic hoses and nipples for the boom extension cylinder.
12. Remove the expander shaft for the boom extension cylinder (A).
13. Carefully withdraw the entire extension assembly, extension tube, cylinder, and boom
body.
8.10 Disassembling Expander Shafts
WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
44 No: 6102429707.1.6102511883 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).
8.11 Assembling Expander Shafts
WARNING
Heavy Objects
45 No: 6102429707.1.6102511883 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 spe-
cial tightening torques.
! NOTE: If the play cannot be eliminated, replace or repair is neces-

sary. If it is tightened too much, the attaching lug could crack.
8.12 Check Hoses, Cylinders, Valves, and Valve Plates

n Check for damage and leaks.
46 No: 6102429707.1.6102511883 en-US

8.13 Check Hydraulic Pressure

n Check the pressure setup.
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48 No: 6102429707.1.6102511883 en-US

Boomer S2 9 Feed Unit
9 Feed Unit
9.1 Safety Precautions before Working on Feed Unit
WARNING
WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
49 No: 6102429707.1.6102511883 en-US

9.2 Feed Unit 2700
BMH 2700
BMHT 2700 (telescope Feeder)

The hydraulic feeders in the 2000 series are primarily intended for drift and tunnel drilling.
They are fitted on hydraulic booms of type BUT S, BUT 4, BUT 28, and BUT 29. The feed-
ers are available in different versions depending on the drill being fitted on them. The differ-
ent numbers are explained, for example, BMH 2337 and BMHT 2628/21.
50 No: 6102429707.1.6102511883 en-US

The first number states the type of feed: 2 = 2000 series.

The second number states the type of drill for which the feeder is intended:
• 7 = COP MD20
• 8 = COP 1638/1838/2238
The third and fourth number states the length of drill rods in dm.
The fifth and sixth numbers only apply to telescope feeders (BMHE and BMHT) and state
the length of the short drill rods in dm.
9.3 Technical Data Feed Unit 2700

Length
The total length of the feed depends on the type of rock drill and the length of the drill rods
for which it is intended. By adding the following length to the length of the drill rods (XX)
(XX/XX), it is possible to obtain the overall length of the feed.
Type Length
BMH 27XX 1500 mm
BMHT 27XX/XX 1500 mm
Weight
! NOTE: Only the weight of the shortest and longest standard feed is specified for each
type of feed
COP MD20
Type Weight
BMH 2724 - BMH 2740 474–579 kg
BMHT 2731/19 - BMH 2749/30 585–660 kg
COP 1638/1838
Type Weight
BMH 2824 - BMH 2840 474–578 kg
BMHT 2831/19 - BMH 2849/30 584–659 kg
9.4 Check Pull and Return Rope on Feeder
WARNING
51 No: 6102429707.1.6102511883 en-US

WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
Feeder BMH
Feeder BMHT
n Check wear and tension on pull and return rope (A).
52 No: 6102429707.1.6102511883 en-US

9.5 Check Drill Steel Bushings on Feeder
Feeder BMHT
Feeder BMH, BMHE, BHMS
n Check wear on drill steel bushings (A).
9.6 Check Slide Rails on Feeder
WARNING
WARNING
Heavy Objects
53 No: 6102429707.1.6102511883 en-US

WARNING
Moving Parts
starting work.
Feeder BMHT
54 No: 6102429707.1.6102511883 en-US

n Check wear and damage on slide rails (A).
9.7 Check Dowel on Feeder
Feeder BMHT
n Check wear on dowel (A).
55 No: 6102429707.1.6102511883 en-US

9.8 Check Slide Pieces on Feeder
WARNING
WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
Feeder BMHT
56 No: 6102429707.1.6102511883 en-US

n Check play and wear on slide pieces (A).
9.9 Check Tightening Torque on Feeder
WARNING
WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
57 No: 6102429707.1.6102511883 en-US

Feeder BMHT
n Check tightness on bolted joints (A).
9.10 Special Tightening Torque on Spacer

First read: Safety Precautions before Working on Feed Unit [} 49]
58 No: 6102429707.1.6102511883 en-US

The following bolted joints require a special tightening torque. Other bolted joints on this
unit can be tightened to the torque specified in Atlas Copco 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.
1. Make sure that no bolt is missing or loose.
2. Tightening in circles from 1 to 8 until the bolts set.
3. Check the tightening torque of all bolts on spacer (A).
Position Size Torque Nm Tolerance Nm
A M6 18 ±0
9.11 Clean Feed Unit
WARNING
59 No: 6102429707.1.6102511883 en-US

WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
n Clean the complete feed unit.
9.12 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
60 No: 6102429707.1.6102511883 en-US

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.
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.
Rock drill instruction manual
9.12.1 Safety Check of Rock Drill or Rotation Unit Installation
WARNING
61 No: 6102429707.1.6102511883 en-US

WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
Perform this safety check four hours after fitting the rock drill or rotation unit.
1. Check and tighten torque on all bolted joints.

è Replace damaged or defect screws.
2. Check and adjust the tension of the ropes.
3. Check all hoses for leaks.
4. Adjust the tension of the hoses.
5. Check and adjust the slide rail alignment on the feed beam.
9.13 Replace Rock Drill Retaining Bolts

First read: Safety Precautions before Working on Feed Unit [} 49]
62 No: 6102429707.1.6102511883 en-US

1. Position the feeder 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.
9.14 Replacing Slide Pieces in the Holder
WARNING
WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
If the wear allowance for any of the slide pieces is less than 1 mm, replace all the slide
pieces.
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 install it to the holder.
5. Install new keys.
6. Adjust the cradle on the feed beam.
63 No: 6102429707.1.6102511883 en-US

9.15 Replacing Slide Rails
WARNING
WARNING
Heavy Objects
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.
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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.
9.16 Adjusting Cradle on Feed Beam
WARNING
WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
The cradle plates for the rock drill, intermediate drill rod support, and water hose drum are
guided along the feed beam by 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 rod is installed in the rock 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.
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è Shank adapter is set at the correct height.
3. Shift the lower holders lengthways until a clearance of 1 mm is attained between the
lower holder and feed beam.
4. Install the bolts (B).
5. Check by running the cradle along the entire beam.

The cradle runs forward within the maximum pressure with the hydraulic oil at operat-
ing temperature. If the pressure exceeds the maximum value, 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)
9.17 Replacing Pull Rope
WARNING
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WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
1. Operate the drill to about half its length of travel.
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2. Slacken the tension on the ropes, bolt (A), and nut (B).
3. Remove the pull rope from its front attachment on the rock drill cradle.
4. Remove the scraper plate (C) from the intermediate drill steel support.
5. Loosen the intermediate drill steel support holder (E) so that the intermediate drill
steel support can be lifted.
6. Remove the rope from the rope tensioner (D) in the rear part of the beam.
! NOTE: Make sure that the new rope is fitted in the same hole as
the old one.
7. Install the new rope and reinstall the scraper plate.
8. Adjust the ropes.
9.18 Adjusting Pull and Return Ropes
WARNING
WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
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Precondition p The cradle position on the feed beam is in its rear position.
p Drill steel with drill bit is installed on the rock drill.
1. Adjust the pull rope with bolt (A) and the return rope with nut (B).
2. Adjust the ropes so that the bit is behind the dowel.
3. Adjust the position measurement (M1).
Measurement for current feeder is specified in the feed measurement drawing that is
supplied in the machine documentation.
9.19 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.
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.
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è There is a couple of centimeters of slack remaining when the return rope is correctly
tensioned.
9.20 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.
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9.21 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).
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 be-
tween 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 hy-
draulic oil at operating temperature. If the pressure exceeds maximum pressure, the
holders are too tight and must be adjusted.
9.22 Check Limit Switches

n Check limit switches function.
n Check for leaks.
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9.23 Check Hydraulic Cylinder on Feeder
Feeder BMHT
n Check function of hydraulic cylinder (A).
n Check for leaks.
9.24 Check Pulleys and Hose Drum
WARNING
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WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
Feeder BMHT
Feeder BMH
n Check bearing hose drum (A) for wear.
n Check pull rope pulley bearings (B) for wear.
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9.25 Lubricate Pulleys and Hose Drum
WARNING
WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
Feeder BMHT
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Feeder BMH
n Lubricate the hose drum (A) and pulleys (B).
9.26 Location of Drill Hoses

Depending on the drill that is fitted on the feeder, the hoses must be positioned in the water
hose drum and the feed hose retainer.
Hose Designations Description
AL1 Air Lubrication
HPD1 Damper
HP1 Hammer Pressure
HT1 Hammer Tank
RRL1 Rotation Left
RRR1 Rotation Right
WF2 Flushing
Table 1: Drill Hose Designations

Drill Hose Locations:
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Water Hose Drum COP MD20
Feed Hose Retainer COP MD 20
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Hose Drum COP 1838/1638/2238
Feed Hose Retainer COP 1838/1638/2238
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Hose Drum COP 1838/1638/2238 (feeder with bulkhead connection)
Feed Hose Retainer COP 1838/1638/2238 (feeder with bulkhead connection)
9.27 Disassembling Feeder from Boom
WARNING
WARNING
Heavy Objects
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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.
4. Remove the holders (A) from the feed holder.
9.28 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.
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.
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WARNING
WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
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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).
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! 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.
9.29 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.
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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 bushing
are separated.
9.30 Assembling Tension Bushing for Spacer
WARNING
WARNING
Heavy Objects
WARNING
Moving Parts
starting work.
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! 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)
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Boomer S2 10 Drill Rod Support
10 Drill Rod Support
10.1 BSH-XS
Drill Rod Support BSH-XS
10.2 Check Jaw Function BSH-XS
For safety reasons, the jaws are always equipped with a lug to support the drill string.
1. Check that the jaws of this type are fitted correctly for example, for drilling upwards or
downwards respectively.
2. Check for jaw wears regularly and replace worn jaws.
10.3 Replacing Jaws

1. Open the drill rod support fully.
2. Loosen the bolts (A).
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3. Move the control plate (B) to one side to release the jaw on the opposite side.
4. Extract the loose jaw (C).
5. Install the new jaw in place.
6. Repeat steps 3–5 for the second jaw.
7. Return the control plate to the center to lock both jaws.
8. Install the bolts (A).
10.4 Adjusting the Drill Rod Support
Distance between feed beam and shank adapter

The drill rod support must be adjusted so that the smallest possible play is obtained be-
tween the drill rods and the jaws when the drill rod support is closed. This adjustment only
needs to be carried out after major repairs after removing the drill rod support or rock drill
cradle from the feeder.
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1. Check that the rock drill shank adapter is in the center of the drill rod support. Mea-
sure the distance between the top edge of the feed beam and the center of the shank
adapter. If the distance is not correct, the rock drill cradle must be adjusted.
2. Position the feeder vertically with the front of the feeder pointing down.
3. Open the drill rod support.
4. Thread a drill rods onto the shank adapter.
5. Move the rock drill so that the drill rods bypasses the jaws.
6. Close the drill rod support.
7. Check the play between the jaws and the drill rods.
8. Loosen the bolts holding the drill rod support.
9. Adapt the drill rod support position until the play is around 1 mm.
10. Fasten the bolts.
11. Open the drill rod support.
12. Close the drill rod support.
13. Check the play between the jaws and the drill rods.
10.5 Pressure Setting

1. Connect a pressure gauge to the test outlet at the valve (Y350).
2. Start the pumps and close the drill rod support.
3. Adjust maximum pressure to approx. 80 bar.
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Boomer S2 11 Hydraulic System
11 Hydraulic System
11.1 Safety Precautions before Working on Hydraulic

System
WARNING
WARNING
11.2 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.
11.3 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
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• Adequate ventilation system
11.4 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
• 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.
11.5 Check Hydraulic Hoses and Couplings
WARNING
WARNING
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n Inspect all hydraulic hoses and connections thoroughly with respect to cracking and
swelling that indicates an external or internal leak. Inspect the hose location and clips.
n Inspect the hose casing with respect to any swelling that indicates inner hose or cord
breakage.
n Inspect the hydraulic couplings with respect to leaks, indentations, and adapters. The
couplings should be fastened securely if they have screw flanges. If there are any
signs of connection leaks, replace the seals or the complete coupling.
n Check that all hose attachments and clamps are intact.
n Inspect all pressed couplings for signs of cracks or damage to compression sleeves.
Replace any defective hoses with new ones.
11.6 Hydraulic Oil
11.6.1 Oil Sampling

An oil sample gives a good indication of how well the hydraulic system has been main-
tained.
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 hydraulic pumps. The nipples can
also be used as pressure outlets for the pressure gauge.
Replacing Contaminated Oil

Hydraulic oil must be replaced if the oil sample show that the oil is oxidized, contains much
water, or many particles.
11.6.2 Oil Monitoring

If the machine is equipped with oil monitoring, there are sensors that are installed for mea-
suring moisture in the oil and the cleanliness of the oil. The sensors are connected to the
RCS system to provide continuous information about the oil condition.
• The moisture sensor shows a percentage value relative to the oil saturation value. The
oil begins to precipitate out water and is no longer able to bind moisture when the per-
centage value reaches 100%.
• Cleanliness measurement is made by obtaining the numbers of particles in the oil by
passing the oil through a particle counter.
Oil Moisture Measurement

When a new sensor is started, a reference phase runs for approximately 100 hours. The
sensor adjusts itself to the type of oil that is used and its properties. Measurements that are
made are relative and represent the differences of the values that the sensor adjusts itself
to during the reference phase.
The different values that are registered by the moisture sensor are displayed in the RCS
system.
If the moisture level in the hydraulic oil increases and reaches preset levels, the RCS sys-
tem gives warnings or an alarm.
• Warning 1 and warning 2 are displayed as yellow symbols in the information row in the
RCS system. The symbols are displayed as information for the operator only.
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• The alarm level is displayed as a red symbol in the information row in the RCS system.
After reaching this level the drilling function of the rig is canceled until the oil moisture
problem has been fixed.
Oil Cleanliness Measurement

The particle counter that is installed on the machine can be read in two ways.
• The instantaneous values of the quantity of particles can be read from the sensor dis-
play.
• The values from the particle counter are also registered in the RCS system as an aver-
age value over time.
NOTE: The values that are displayed on the RCS system can differ slightly with the
! values shown on the sensor display. This is due to the differences in average values
over time and instantaneous values.
The quantity of particles is measured in three different particle sizes (4-6-14 µm) and is
shown as an ISO rating for each size. The ISO rating represents the quantity of particles
according to the table.
Class More than Up to (and in- Class More than Up to (and in-
cluding) cluding)
0 0 1 15 16000 32000
1 1 2 16 32000 64000
2 2 4 17 64000 130000
3 4 8 18 130000 250000
4 8 16 19 250000 500000
5 16 32 20 500000 1000000
6 32 64 21 1000000 2000000
7 64 130 22 2000000 4000000
8 130 250 23 4000000 8000000
9 250 500 24 8000000 16000000
10 500 1000 25 16000000 32000000
11 1000 2000 26 32000000 64000000
12 2000 4000 27 64000000 130000000
13 4000 8000 28 130000000 250000000
14 8000 16000
Table 2: Quantity of particles / 100 ml
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11.6.3 Check Oil Level in Carrier Hydraulic Tank
Precondition p Service platform in transport position.
n Check oil level through the sight glass (A).
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11.6.4 Filling Hydraulic Oil
Location of button and sight glass on hydraulic tank differs on machines.
! NOTE: The position of the cylinders affects the level in the tank.
! NOTE: If the tank is overfilled, the breather filter is destroyed and needs a replace-
ment.
! NOTE: Fill new oil only with the filler pump installed on the machine.
The oil must be filtered before reaching the tank. It is achieved automatically if the filler
pump is used.
Precondition p All the cylinders are retracted (piston rod in).
p All couplings and hoses to be filled with hydraulic oil are clean.
1. Check if the return oil filter is clogged.

A symbol on the control system display warns if the filter is clogged.
2. Remove the protective cap from the suction hose.
3. Place the suction hose into the tank with new oil.
4. Press button A81 to activate pump (A) to start filling.
5. Check the oil level in the sight glass (D).
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The correct level is reached when the oil level is 20 mm (0.87 in) below the upper
edge of the oil sight glass.
6. Release button A81 when the correct level is reached.
7. Remove the suction hose from the tank.
8. Install the protective cap.
Hydraulic Oil Tank Volume
250 litres (66 gallons)
11.6.5 Drain Condensate from Hydraulic Oil Tank
WARNING
WARNING
95 No: 6102429707.1.6102511883 en-US

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.
11.6.6 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.
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11.6.7 Clean Hydraulic Tank
WARNING
WARNING
The hydraulic tank is cleaned manually through the access hatch at the top.
Precondition p The oil is drained from hydraulic tank.
1. Remove the access hatch.
2. Clean inside the tank completely.
3. Wipe all sides, the top, and the bottom of the tank using only lint-free rags.
Clean thorough especially in corners, edges, and, around connecting holes.
NOTE: Make sure that no pieces of dirt or foreign body is stuck in

! suction hoses or left in the tank. It results in damage or failure of
hydraulic pump.
4. Reattach the access hatch as fast as possible after cleaning to prevent any particles
from entering.
! NOTE: Make sure that the access hatch is closed tightly.
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11.7 Hydraulic Filters
11.7.1 Replace Return Oil Filter
WARNING
WARNING
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).
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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.
11.7.2 Replace Remote Return Oil Filter
Remote return oil filter is optional.
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1. Remove the bolt (B) from the cap (D).
2. Remove and discard the preformed packing (C) and (E) from the cap (D).
3. Replace the filter (F) with a new filter and install it to the housing (G).
4. Lubricate the new preformed packing (C), (E) and install them to the cap (D).
5. Install the cap (D) to the filter housing (G).
6. Tighten the bolt (B).
11.7.3 Check Hydraulic Tank Breather Filter

First read: Safety Precautions before Working on Hydraulic System [} 89]
The breather filter equalizes the pressure differences in the tank that would otherwise arise
when the level in the tank changes.
! NOTE: If the hydraulic tank is overfilled, hydraulic oil covers the breather filter and ru-
ins it. Breather filter must be replaced if it is clogged or found contaminated.
n Check breather filter (A) for clogging.
n Inspect that the breather filter is intact.
11.7.4 Replace Water Separator Particle Filter

First read: Safety Precautions before Working on Hydraulic System [} 89]
100 No: 6102429707.1.6102511883 en-US

NOTE: The particle filter must be replaced according to the maintenance interval, and
! if the filter pressure is greater than 1.5 bar (21.75 psi). The pressure is read on the
pressure gauge above the particle filter.
Precondition p The hydraulic pumps are switched off.
1. Remove the nut (G).
2. Remove the cap (H).
3. Loosen the two screws (J).
4. Remove the cover (A) from the filter housing (B).
5. Remove and discard the preformed packing (D).
6. Remove the filter assembly from the housing (B)
7. Remove and discard the preformed packing (E).
8. Disconnect the nipple assembly (L) from the filter housing.
9. Remove and discard the preformed packing (F).
10. Replace the filter (C) with the new filter.
11. Lubricate the preformed packing (F) and install it to the nipple (K).
12. Install the nipple assembly (L) to the filter housing (B).
13. Lubricate the preformed packing (E) and install them to the filter (C).
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14. Install the filter assembly to the housing (B).
15. Install the cover (A) to the filter housing (B).
16. Tighten the screws (J).
17. Install the cap (H) to the cover (A).
11.7.5 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.
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.
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4. Apply a little hydraulic oil to the sealing surface and threads.
5. Install the cover.
11.7.6 Bleeding Water Separator Particle Filter
WARNING
WARNING
1. Plug the pump to the electrical socket on the machine, or to an external electrical
socket.
2. Loosen the bleed screw (A).
3. Start the pump to run until oil without air bubbles runs out.
4. Retighten the bleed screw (A).
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5. Check for leaks.
11.8 Hydraulic Pumps
11.8.1 Overview of Power Unit Pumps
A Percussion and positioning
B Water pump (right side)
C Rotation
D Compressor (left pump)
E Damper
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11.8.2 Location of Hydraulic Valves, Sensors and Test Outlets
A Bleeding plug
B Stand by pressure
C Damper adjustment
D B268 pump pressure
E B268 damper pressure
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11.8.3 Starting New or Reconditioned Pump
WARNING
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.
11.8.4 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.
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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.
11.8.5 Bleeding Hydraulic Pump
WARNING
WARNING
If a major intervention has been made in the system, such as replacing or reconditioning
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.
Top up if necessary.
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.
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11.9 Hydraulic Functions
11.9.1 Bleeding Hydraulic System

Air in the hydraulic system can be detected if one or more hydraulic cylinders give or oper-
ate jerkily.
Precondition p Air has entered the system.
1. Check the oil level in the hydraulic oil tank.
2. Operate the cylinders several times between their end positions.

è The aerated oil forces back to the hydraulic tank where the air can be sepa-
rated.
11.9.2 Bleeding Hydraulic Motor
WARNING
WARNING
If a major intervention has been made in the system such as replacing or reconditioning
1. Remove the plug (A) and fill the hydraulic motor with oil.
2. Reinstall and tighten the plug (A).
3. Run the hydraulic motor for a few minutes.
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4. Bleed the hydraulic motor by carefully opening the plug (A), a few turns.
5. Tighten the plug (A) when oil without air flows out.
11.9.3 Adjusting Maximum Pressure and Speed of Reeling Unit
In situations where it is not possible for the slip clutch on the reel gear to unwind the hose
or cable, the hydraulic motor for the reel can be used.
During normal operation, do not operate the cable and hose reels hydraulically when un-
winding.
Precondition p The cable and hose are pulled out through the gear friction coupling.
1. Connect a pressure gauge, 0–250 bar (0–3626 psi), to the pressure reducing valve
(A).
2. Adjust the pressure to 200 bar (2900 psi) with the pressure reducing adjustment
screw (C).
3. Start the reeling unit for winding and unwinding.
4. Adjust the speed for winding to 10–12 rpm (one revolution per 5–6 seconds) and un-
winding to 5–6 rpm (one revolution per 10–12 seconds) with the adjustment screw
(B).
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Boomer S2 12 Diesel Engine
12 Diesel Engine
12.1 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.
12.2 Diesel Engine Data Plate
A Type plate
B Engine type
C Engine number
D Engine number stamped on the crankcase.
! NOTE: Engine type and engine number must be designated if ordering spare parts.
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12.3 Commissioning New or Overhauled Diesel Engine

The following maintenance must be done when commissioning a new diesel engine.
! NOTE: To perform the following maintenance points, see respective maintenance in-
structions in the Maintenance manual.
n Bleed the fuel system.
n Check the Pre fuel filter and secondary fuel filter and replace if necessary.
n Check diesel engine oil level.
n Check diesel engine oil quality.
n Check for engine oil leaks.
n Check the coolants concentration.
n Check coolant level and add if necessary.
n Replace diesel engine air filter cartridge and safety cartridge.
n Drain any condensation or oil from the charge air cooler.
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12.4 EMR
A EMR
The engine is installed with a control unit which is designated EMR. Some sensors are
connected to the EMR which detect engine functions. In the event of a fault, one or more
sensors signal to the EMR. These signals are also sent further to the summation alarm on
the control panel. In addition, the EMR ensures that the engine operates optimally from an
environmental point of view.
12.5 Clean Diesel Engine

Precondition p The engine is not running.
1. Remove engine cover and cooling air cover if present.
2. Clean the engine using degreasing agent and a high-pressure water jet.
3. Warm up the engine so that the water residues evaporate.
4. Remount engine cover and cooling air cover.
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12.6 Check Engine Monitoring System

n Check the engine monitoring system.
! NOTE: Only an authorized specialist must carry out the checking.
12.7 Replace Engine Oil
WARNING
Burning Hazard
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Placement of drain plug, filling, and dipstick can differ depending on brand and model.
! NOTE: Only use engine oil that the engine manufacturer approves for engine and type
of operation.
! NOTE: Always replace oil filter when replacing oil.
Precondition p Machine is placed on flat surface.

p Oil temperature is 80 ºC/176 °F.
1. Switch off the engine.
2. Allow the oil to drain down from the internal parts for a few minutes.
3. Place a vessel under the drain hose.
4. Remove the oil drain plug (B) from the hose and drain all oil.
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5. Reinstall the oil drain plug to the hose.
6. Replace oil filter (D).
7. Fill oil in the filler hole (A) with recommended amount.
8. Check oil level on the dipstick (C).

Oil level must be close to top mark.
9. Start the engine.
10. Allow the engine to be idle for about two minutes.
11. Check that the engine oil pressure indication lamp goes out.
12. Check for leakage.
13. Stop the engine.
14. Check oil level.

Top up if necessary.
Oil Drain Plug Tightening Torque
100Nm (73.75 ft)
Engine Oil Volume
8 L (2.1 gal)
Diesel engine instruction manual
12.8 Replace Engine Oil Filter
WARNING
Burning Hazard
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Placement of oil filter can differ depending on brand and model.
! NOTE: Only use engine oil that the engine manufacturer approves for engine and type
of operation.
Precondition p Always replace oil filter when replacing oil.

p The engine oil has been drained.
1. Place a vessel under the oil filter (A).
2. Remove the oil filter (A).
3. Clean the surface of the filter holder.
4. Apply clean oil to the gasket of the new oil filter.
5. Turn the filter by hand until the gasket makes contact with the filter base.
6. Tighten the filter (A).
Tightening Torque on Engine Oil Filter
15 - 17 Nm (11 - 12.5 lb-ft)
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12.9 Filling Fuel Manually
WARNING
Flammable and Toxic Liquid
Fuel is toxic and can cause injury. Fuel is flammable and causes burns, serious per-
sonal injury, or death.
u Shut off the engine.
u Do not handle flammable fluids near hot surfaces, sparks, or flames.
u Clean up fuel spills.
NOTICE
Damage to Diesel Engine or Particle Filter
The use of fuel of a lower quality other than that recommended by the diesel engine
manufacturer, damages the diesel engine and particle filter.
u Always use the recommended fuel.
Avoid filling fuel if there is a risk of contamination, for example, in windy or wet weather, or
when there is dust in the air.
Precondition p The diesel engine is turned off.

p Tank and tank cover are clean.
1. Remove the filler cap (A).
2. Fill with fuel.
Diesel Tank Volume
95 L (25 gal)
12.9.1 Fuel Quality

• Fuel that is stored must not have contact with air. Fuel must be stored in a closed and
clean vessel, that is approved for its purpose.
• Only use manufacturer approved fuel for the engine and type of operation.
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Fuel Quality Sulphur Grade
Ultra Low Sulfur Diesel (ULSD) Maximum 5000 PPM
12.10 Drain Fuel Tank
WARNING
Burning Hazard
1. Place a vessel under the drain plug (A).
2. Loosen the plug (A) about one turn and allow the fuel to run out.
3. Tighten the plug (A) to avoid fuel leakage.
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12.11 Bleeding the Fuel System
WARNING
Burning Hazard
The fuel system must be drained when the engine is started for the first time or when the
fuel tank runs dry.
The ignition key must be switched ON when the fuel system is bled so that the solenoid
valve (Y226) on the fuel tank remains open and the fuel pump operates.
Precondition p Ignition key is switched ON.
1. Put a suitable receptacle under the fuel filter.
2. Loosen the air bleeder screws (A) on the fuel filters.

Allow them to remain open until only fuel fills with out any air bubbles.
3. Tighten the air bleeder screws (A).
4. Start the engine and run it at idling speed or at low load for approximately five min-
utes.
5. Check the sealing integrity of the filters.

Allow the engine to run at idling speed until it runs evenly.
Bleed Nipples Tightening Torque Tolerance
Primary fuel filter (B) 6.5 Nm (4.8 lb-ft) ±1.3 Nm (0.96 lb-ft)
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Bleed Nipples Tightening Torque Tolerance
Secondary fuel filter (C) 6.5 Nm (4.8 lb-ft) ±1.3 Nm (0.96 lb-ft)
Table 3: Tightening Torque Fuel Filter Bleed Nipples
12.12 Annual Replacement of Primary Filter

First read: Safety Precautions before Working on Diesel Engine [} 111]
! NOTE: Replace the primary filter annually irrespective of how many hours the diesel
engine has been running.
12.13 Replace Fuel Primary Filter
WARNING
Burning Hazard
Precondition p The diesel engine is turned off.
1. Disconnect the electrical connection from the water level sensor.
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2. Place a vessel under the primary filter.
3. Drain the primary filter (A) by removing the drain plug (B).
4. Remove the filter.
5. Clean the filter holder.
6. Moisten the sealing surface with fuel.
7. Install the new filter and hand tighten it until the gasket makes contact with the sur-
face of the filter holder.
8. Install the drain plug (B) and tighten.
9. Reconnect the electrical connection to the water level sensor.
! NOTE: The system has to be bled after filter replacement.
Tightening Torque Primary Fuel Filter
17–18 Nm (12.5–13.3 lbf.ft)
Table 4: Tightening Torque Primary Fuel Filter
Tightening Torque Tolerance
1.6 Nm (1.2 lbf.ft) ±0.3 Nm
Table 5: Tightening Torque Primary Fuel Filter Drain Plug
12.14 Replace Fuel Secondary Filter
WARNING
Burning Hazard
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1. Remove the secondary fuel filters (A) with a suitable tool.
2. Collect any residual fuel.
3. Clean the surface of the filter holder.
4. Lubricate the rubber seal of the new fuel filter sparingly with a little oil.
5. Install the new filter and hand tighten it until the gasket makes contact with the sur-
face of the filter holder.
6. Check that the fuel filter does not leak.
! NOTE: Bleed the system after filter replacement.
7. Bleed the fuel system.
Engine Type Tightening Torque
Deutz TCD/TD 3.6 Diesel Engine 10 - 12 Nm
Table 6: Tightening Torque Secondary Fuel Filter
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12.15 Check Belt Wear
WARNING
Burning Hazard
n Check belt wear by inspecting the wear indicator for the belt tensioner.
Replace the belt If the distance (A) is less than 3 mm (0.11 in.).
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12.16 Replace Multi-belt
WARNING
Burning Hazard
Drive Belt Replacement for Deutz TCD/TD 3.6

Precondition p Diesel engine is switched off.
1. Press tension pulley (A) with key (B) in the direction of the arrow.
2. Place the lock pin (C) in the installing hole.

è The tension pulley is attached.
The belt is tension free.
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3. Pull the belt (D) from the smallest roller or from the tension pulley (A) and then re-
move the entire belt.
4. Install the new belt.
5. Turn the wrench (B) in the direction of the arrow.

è Lock pin (C) comes loose.
6. Remove the lock pin (C).
7. Lower the tension pulley (A) slowly against the direction of the arrow until the belt (D)
pulls tight.
8. Check and align the belt correctly.
12.17 Check Engine Pads
n Check the engine pads (A) for wear and damage.

Replace the engine pads (A), if necessary.
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12.18 Check Tightening Torque on Engine Suspension Bolts
WARNING
Burning Hazard
n Check that no engine bolts (A) are missing or loose.
n Check the engine bolts (A) for damage.
n Check the tightening torque of the engine bolts (A).
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12.19 Replace Engine Pads
WARNING
Burning Hazard
If it is difficult to remove the engine pads, the entire engine pad bracket can be disassem-
bled and then the engine pad can be removed.
Precondition p Engine is attached with a suitable lifting device.
1. Remove the bolts from the engine pads (A).
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2. Remove the engine pads (A).
3. Install the new engine pads (A).
4. Replace the bolts.
5. Tighten the bolts to the correct tightening torque.
12.20 Check Hoses for Fuel and Air Intake Systems
WARNING
Burning Hazard
n Check hoses and couplings for wear and leakage.
12.21 Air System
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! NOTE: Location and shape of air filter differs depending on brand and model.
The air filters consist of a filter housing (F) with cover (A), clamps (B), main cartridge (D),
safety cartridge (E), and evacuation valve (C). Air filtration is done in two stages. The first
stage comprises a cyclone and the second stage a normal filter. Both filtration stages take
place in the filter housing. The filter performance improves right up until it becomes
clogged. There is an indicator that is on the filter housing to advise when the filter cartridge
is clogged. The indicator is connected to the display in the cab. A warning symbol comes
on in the status bar at the bottom of the display if a filter is starting to clog.
It is important to keep the air filter and air cleaner in good condition so that the exhaust
gases are as clean as possible. Repeated disassembling and assembly can damage the
gasket between the insert and the filter housing. Smoke and poor engine performance can
be an indication of clogged filters.
12.21.1 Every Second Year Replacement of Air Filter Cartridge
! NOTE: Replace air filter cartridge every second year irrespective of how many hours
the diesel engine has been running.
12.21.2 Replace Air Filter Cartridge
Air filter cartridge also needs a frequent replacement depending on the operating environ-
ment.
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! NOTE: Do not clean the filter cartridge.
1. Remove the clamps (A).
2. Remove the cover (B).
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.
7. Install the cover (B).
8. Fasten the clamps (A).
12.21.3 Replace Air Filter Safety Cartridge
1. Loosen the clamps (A).
3. Pull out the safety cartridge (C).
4. Cover the air outlet with adhesive tape.
5. Clean inside the cover (B), and evacuation dust valve (D).
6. Install the new safety cartridge.
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7. Install the cover (B) again.
8. Fasten the clamps (A).
12.21.4 Check Air Filter Indicator Lamp Function
! NOTE: Check that no dirt or other particles enter the filter housing.
1. Remove the air intake cover on the filter housing.
2. Allow the engine to idle.
3. Use a piece of board or similar to cover part of the air intake.
4. Check that the alarm indicator lamp is turned on.

è The alarm indicator lamp is turned on.
NOTE: If an alarm indicator lamp is not turned on, check ca-

! ble connections. If there are no problems with the connec-
tions, then the alarm indicator lamp (A) is faulty and must be
replaced.
5. Stop the engine and reset the alarm indicator lamp (A) by pressing the button on the
indicator lamp.
6. Install the air intake cover.
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Boomer S2 13 Cooling System
13 Cooling System
Cooling system removes the heat that is generated in different system during the machine
run.
There are three different coolers in the cooling system:
• Oil cooler (A)
• Intercooler (B)
• Engine cooler (C)
Oil cooler remove the heat from the circulated oil and cools the hydraulic oil in the hydraulic
system.
Intercooler cools the air that is compressed by the turbocharger, reducing its temperature
and increasing the density of the air that is supplied to the engine.
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Engine Cooler cools the engine with an engine coolant which passes through the passages
inside the engine castings and the heads.
The expansion tank (D) acts as an overflow reservoir for the coolant mix that is forced from
radiator as it heats and builds pressure in the system.
13.1 Safety Precautions before Working on Cooling

System
13.2 Check Coolant Concentration

Precondition p Engine is cooled down.
n Check coolant concentration with test kit.
13.3 Adding Coolant
WARNING
High System Pressure
High system pressure with high temperatures can cause personal injury.
u Shut off the diesel engine and wait for it to reach room temperature.
u Release the pressure in the system before starting any work.
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1. Open the expansion tank filler cap (A).
2. Fill coolant until the level is approximately in the centre of the level glass (B).
3. Close the expansion tank filler cap (A).
4. Start the engine and warm up til the thermostat opens.

This is to circulate the coolant through the system.
5. Stop the engine.
6. Check the coolant level when the engine is cold.

Top up coolant if necessary.
! NOTE: Bleeding is performed automatically while coolant is being

filled.
13.4 Replace Coolant

1. Drain the coolant.
2. Add new coolant.
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Diesel Engine Coolant Volume
Litre Gallon
Coolant for diesel engine Deutz 27.0 7.13

TCD 4.1
Coolant for diesel engine Deutz 35.3 9.32

TCD 6.1
Coolant for diesel engine, Deutz 29.0 7.66

2013 L04
Coolant for diesel engine, Deutz 35.0 9.24

2012 L06
13.5 Draining Coolant
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! NOTE: If the drain plug cannot be accessed then the system can also be drained from
the coolant line on the engine oil cooler.
1. Open the lid (A) on the expansion tank.
2. Place a vessel under the coolant drain plug (C) on crankcase.
3. Remove the coolant drain plug on crankcase.
4. Place a vessel under the cooler.
5. Open the drainage tap (B).
6. Let all the coolant run out.
7. Close the drainage tap and reinstall the drain plug on crankcase.
8. Reinstall the lid on the expansion tank.
13.6 Drain Charge Air Cooler

First read: Safety Precautions before Working on Cooling System [} 134]
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1. Place a vessel under the drain plug (A).
2. Remove the drain plug (A).
3. Allow any condensation and/or lubricating oil to run out.
4. Install the drain plug.
13.7 Clean Flanges of Cooling Elements
WARNING
Dangerous Voltage
Risk of personal injury.
u Disconnect the power source from the engine/motor before cleaning.
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Direction of high pressure water jets

Clean the cooling elements frequently to maintain the system cooling capacity.
1. Blow the flanges of the cooling elements clean with compressed air.
Use degreaser and high pressure water jet if dirt remains.
NOTE: High pressure water jets must be directed parallel to the

! flanges according to the image (straight ahead or from behind).
There is a risk of damaging components and cables when using
high pressure water jets. The fire-fighting system must be discon-
nected to avoid activation.
2. Blow the fan blades clean with compressed air.
3. Remove the fan grille and wipe away the dirt from the fan blades.
4. Clean the inside of the fan grille.
13.8 Clean Fan Housing

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WARNING
Dangerous Voltage
1. Disassemble the cooling elements from the fan housing.
2. Clean inside the fan housing with compressed air.

Use degreasing agent if necessary.
3. Blow compressed air through the fan grill from the hydraulic motor side.
13.8.1 Disassembling Cooling Elements from Fan Housing

1. Turn off the system.
2. Disconnect the power source to the engine.
3. Check that the system is depressurized.
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4. Close oil, charge air, and coolant connections.
5. Remove hydraulic hose, charge air hose, and coolant hose from the cooling element.
6. Remove the bolts that hold the cooling elements to the fan housing.
7. Lift away the cooling elements.
13.8.2 Assembling Cooling Elements to Fan Housing

1. Lift the cooling elements in place.
2. Reinstall the bolts that hold the cooling elements to the fan housing.
3. Connect the hydraulic hoses, charge air hoses, and coolant hoses to the cooling ele-
ments.
4. Open oil, air, and coolant connections.
5. Connect the power source to the engine.
6. Turn on the system.
7. Check the cooler components for damage.
8. Check that the cooler is connected correctly.
9. Check that the fan is rotating freely using manual power.
10. Check that all couplings are tightened.
11. Check that the inside the fan housing is free from objects that can be thrown out and
cause injury or damage.
12. Check that the direction of the fan rotation and air flow agrees with the indicator decal
on the fan housing.
13. Check for abnormal noise and vibrations.
14. Check the cooler for leaks.
13.9 Clean Cooling System Exterior
WARNING
Dangerous Voltage
Precondition p Engine is switched off.

p Electrical power source is switched off.
p Cooling system is at room temperature.
n Clean the outside of the cooling system with water.
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Boomer S2 14 Exhaust System
14 Exhaust System
Exhaust system is optional.
14.1 Exhaust Gas Aftertreatment System
B Selective Catalytic Reduction converter (SCR)
C Diesel Particulate Filter (DPF)
D Reduction agent (DEF fluid)
The exhaust gas aftertreatment system cleans the exhaust gas to reduce bad emissions.
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14.2 Diesel Particulate Filter
• The combustion of diesel fuel results in soot. The soot is separated in the diesel partic-
ulate filter.
• The filter must be regenerated as the contamination with soot increases. That means
that the soot in the diesel particulate filter is burned. The regeneration is done by an
automatic passive regeneration or, if necessary, by a standstill regeneration.
• The diesel particulate filter must be replaced after a high filter running time as non-
combustible residues and ash accumulate in the filter.
NOTE: The soot and ash level is monitored and displayed in the control system as per-
! centage values.
NOTE: The ash lamp and a symbol in the menu status bar indicates when the fil-
ter must be replaced.
14.3 Selective Catalytic Reduction

The SCR system reduces NOx (Nitric oxides) emissions continuously from the engine.
A reduction agent (DEF fluid) is injected into the exhaust system. The DEF fluid reacts in
the SCR catalytic converter with the NOx emissions to reduce them to nitrogen and water.
! NOTE: The SCR function lamp on the operators panel indicates different prob-
lems that are related to the SCR system. Depending on the type of problem to be indi-
cated the SCR function lamp comes on separately or together with the engine warning
lamp and symbols or messages on the menu status bar.
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14.4 Passive Regeneration of Diesel Particulate Filter
WARNING
Burning Hazard
Cause service personal injury as the exhaust gases and exhaust system becomes hot
during regeneration.
u Do not touch the exhaust system.
u Do not cover the exhaust system.
u Do not expose the exhaust system to any flammable materials.
Regeneration cleanses the diesel particulate filter of the exhaust gas system. That means
that the soot in the diesel particulate filter is burned.
The regeneration process called passive regeneration starts automatically when the ex-
haust temperature of 250 °C (482 °F) is exceeded. This temperature is exceeded in normal
operating conditions. The passive regeneration process is continuous and keeps the filter
contamination with soot in a permissible range. This type of regeneration does not affect
the performance of the machine.
If the exhaust temperature is not exceeded due to reasons like short operating time or low
engine workload, Heat mode raises the temperature.
! NOTE: The engine control unit monitors the contamination of soot in the filter and the
control system displays it.
14.5 Heat Mode
WARNING
Burning Hazard
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Heat mode raises the exhaust gas temperature to achieve passive regeneration with a
throttle valve, automatically controlled through the engine control unit. This is necessary if
the normal use of the machine does not entail an exhaust gas temperature >250 °C (482
°F). Reasons for this can be short operating time or low engine workload.
NOTE: A certain soot level of the diesel particle filter requires a standstill regeneration
! requested in the operators panel and a symbol in the menu status bar.
14.6 Start Standstill Regeneration

This equipment is optional.
WARNING
Very High Exhaust Temperatures
Can cause serious personal injury and damage to property.
u Park the machine in the open air during regeneration.
u Never cover the exhaust system.
u Never let flammable materials come in contact with the exhaust system.
A certain soot level of the diesel particulate filter requires a standstill regeneration. The
Standstill regeneration cleanses the diesel particulate filter of the exhaust gas system. That
means that the soot in the diesel particulate filter is burned.
Standstill regeneration is done as soon as possible when requested. Otherwise power re-
duction starts. Request is done by a flashing regeneration lamp on the operators panel and
a regeneration symbol in the menu status bar.
When regeneration is in progress, the symbol high exhaust temperature is shown as a

warning in the menu status bar.
! NOTE: Ignoring of the standstill regeneration leads to conditions to be solved by Deutz

service.
146 No: 6102429707.1.6102511883 en-US

! NOTE: Short intervals (<10 hours) between standstill regenerations is signs of engine
failure.
NOTE: The number of standstill regenerations is monitored. When indicated by the en-
! gine warning lamp on the operators panel and a symbol on the menu status bar,
the engine oil and engine oil filter must be replaced and the EMR must be reset by
Deutz or Epiroc service.
! NOTE: The control system displays remaining standstill regeneration time and time
since last standstill regeneration.
! NOTE: Do not use the machine during the standstill regeneration. The regeneration
lasts for 35–40 minutes.
Precondition p The regeneration lamp is flashing.

p The machine is parked safely by fulfilling the interlocks with activated parking brake, the
gear in neutral and the diesel positioning knob in OFF position.
1. Position the machine on open terrain at a safe distance to flammable objects.
2. Warm up the engine.

The engine must reach normal operating temperature.
3. Operate the engine in idling.
4. Turn and release the standstill regeneration knob to the ON/OFF-position to the right.
è The knob returns to neutral-position automatically.

The standstill regeneration process starts.
The regeneration lamp lights constantly during the regeneration and goes off
when finished.
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14.7 Power Reduction

Power reduction is the automatic performance reduction process of the engine defined by
international law. This occurs if certain errors are not rectified in time. In general, all errors
that would cause the engine to produce more toxic exhaust lead to power reductions. The
power reduction reduces the engine performance in two stages.
Stage 1 Stage 2
Torque reduction Torque reduction + Engine speed limitation
14.8 Interrupting Standstill Regeneration

WARNING
Very High Exhaust Temperatures
Can cause serious personal injury and damage to property.
u Park the machine in the open air during regeneration.
u Never cover the exhaust system.
u Never let flammable materials come in contact with the exhaust system.
The standstill regeneration can be interrupted at any time. The regeneration lamp on the
operators panel keeps flashing until standstill regeneration has been done without interrup-
tion.
! NOTE: The control system displays time since last standstill regeneration.
Turn and release the standstill regeneration knob to the ON/OFF-position to the right.
148 No: 6102429707.1.6102511883 en-US

è The knob return to neutral-position automatically.

The standstill regeneration stops.
The regeneration lamp on the operators panel flashes.
Remove the interlocks and operate the machine.

è The standstill regeneration stops.
The regeneration lamp on the operators panel flashes.
14.9 Replacing Diesel Particulate Filter

WARNING
Burning Hazard
The diesel particulate filter requires replacement after a high filter running time as non-
combustible residues, ash, accumulate in the filter.
When the diesel particulate filter has reached a critical ash level and requires replacement,
the ash lamp lights up and a symbol in the menu status bar appears.
The machine can operate normally until the replacement is carried out. After a while power
reduction starts.
! NOTE: The soot and ash level is monitored and displayed in the control system as per-
centage values.
Precondition p The ash lamp is indicating.
n Contact Deutz service for replacement.
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14.10 Fill Diesel Exhaust Fluid (DEF) Tank
NOTICE
Damage to DEF System
The DEF system is extremely sensitive to contamination.
u Follow instructions and recommendations.
u Make sure all system components, tanks and new fluid are clean.
! NOTE: Always fill up with DEF when filling fuel.
! NOTE: The level of the DEF tank is monitored and displayed in the control system.
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Precondition p The engine is off.
1. Check that the DEF tank and funnel are clean.
2. Remove the filler cap (A).
3. Fill with DEF.
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14.11 Location of DEF Tank
A DEF tank
14.12 Diesel Exhaust Fluid (DEF)

• The DEF must fulfil the requirements specified in ISO 22241-1, DIN 70070 or ASTM D
7821.
• Store DEF in clean tanks resistant of DEF.
• Avoid storing DEF in the sun.
• DEF is affected by temperatures.
• Store DEF maximum one year. Storage time depends on storage conditions.
152 No: 6102429707.1.6102511883 en-US

14.13 Cleaning Diesel Exhaust Fluid (DEF) Tank
NOTICE
Damage to DEF System
The DEF system is extremely sensitive to contamination.
u Follow instructions and recommendations.
u Make sure all system components, tanks and new fluid are clean.
Precondition p The diesel engine is off.

p The control system is off.
1. Remove the hoses from the suction unit (B).
! NOTE: The coolant supply hose is pressurized. Cap it so the liquid

does not flow out during cleaning of the tank.
2. Remove the screws (A) from the clamp that holds the tank in the frame.
3. Remove the tank from the frame.
4. Loosen the hose clamp and remove the suction unit (B) from the tank.
5. Remove the screws that hold the filler neck (C).
6. Lift out the filler neck.
7. Clean the tank, neck filter (D), and suction filter (E) with deionized water, distilled wa-
ter, or DEF fluid.
153 No: 6102429707.1.6102511883 en-US

14.14 Every Second Year Replacement of DEF Supply Pump

Filter Cartridge
! NOTE: Replace DEF supply pump filter cartridge every second year irrespective of
how many hours the diesel engine has been running.
Also see about this

2 Replace Diesel Exhaust Fluid (DEF) Supply Pump Filter Cartridge [} 154]
14.15 Replace Diesel Exhaust Fluid (DEF) Supply Pump

Filter Cartridge
Precondition p Diesel engine is off.

p The control system is off.
1. Remove all electrical connections.
2. Place a vessel under the filter.
3. Remove the cover (A).
4. Remove filter cartridge (C) and compensation body (B).
5. Install new filter cartridge and compensation body.
6. Install cover.
7. Install all electrical connections.
Socket Wrench Insert Cover Tightening Torque
27 mm (1.06 in) 22.5 ±2.5 Nm (16.59 ±1.84 lbf-ft)
154 No: 6102429707.1.6102511883 en-US

Boomer S2 15 Electrical System, IEC
15 Electrical System, IEC
15.1 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.
15.2 Cable Marking

All the cables are marked with cable numbers corresponding to the external connection di-
agram.
15.3 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.
15.4 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
15.5 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:
155 No: 6102429707.1.6102511883 en-US

• Monitors in the system

• Battery charger for the carrier (also a source of low-voltage)
• Lighting
• RCS system
15.6 Before Troubleshooting Electrical System

Check the following before troubleshooting the electrical system:
n All fuses are intact and switched on.
n Correct power supply is connected (see voltmeter).
n All warning lamps on the electric cabinet are in working order (lamp test).
15.7 Electrical Distribution Cabinet, High-Current
15.7.1 Checking Voltage, Current, and Percussion Running Hours
WARNING
Dangerous Voltage
The Meter (P01), on the electric cabinet, is a combined voltmeter, ammeter, and hour me-
ter. The light under the buttons indicates if button is activated.
n 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.
n 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 depending on
number of hydraulic pump units on the machine.
n 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.
n Check the running hours of the percussion unit button (T).

Does not apply for machines with RCS.
156 No: 6102429707.1.6102511883 en-US

15.7.2 Electrical Distribution Cabinet A10 Y/D-Start IEC (1000V)
U40: Battery charger

1
U40: Battery charger

2
P01 Voltmeter and Ammeter
K51 Ground fault relay (fire protection)
F25 Ground fault breaker (personal protection)
K50 Phase sequence monitor
Q01 Main power switch
1F01 Motor protection relay (one relay for each hydraulic pump motor)
2F01 Motor protection relay (one relay for each hydraulic pump motor)
157 No: 6102429707.1.6102511883 en-US

15.7.3 Electrical Distribution Cabinet A10 DOL-Start IEC (1000 V)
U40:1 Battery charger
U40:2 Battery charger
P01 Voltmeter and Ammeter
K51 Ground fault relay (fire protection)
F25 Ground fault breaker (personal protection)
Q01 Main power switch
1F01 Motor protection relay (one relay for each hy-

draulic pump motor)
2F01 Motor protection relay (one relay for each hy-

draulic pump motor)
15.7.4 Battery Charger
WARNING
Dangerous Voltage
158 No: 6102429707.1.6102511883 en-US

The battery charger is integrated in the electrical distribution cabinet (A10) and supplies the
24-V system of the machine. The supply voltage to the battery charger must be 240 VAC,
45–65 Hz. The temperature sensor regulates the charging voltage. If this sensor is discon-
nected, the charge voltage is 28.8 V. Check regularly that the cooling fan in the power sup-
ply cubicle (A10) is working. If the fan ceases to work, there is a great risk of the cubicle
overheating and components ceasing to work.
The lamp (A) changes color depending on battery status.
• Orange color: Battery Charging.
• Green color: Battery fully charged.
• Red color flashing: No battery connected.
Use the reset button (B) to reset charger after overload.
15.8 Electrical System Protection
15.8.1 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).
15.8.2 Setting Overload Protection
WARNING
Dangerous Voltage
159 No: 6102429707.1.6102511883 en-US

DIP switches
The overload protection setting is dependent on the supply voltage and total electric motor
output. The setting is made with DIP switches (I1) on the main power switch. Next to the
DIP switches is a mark indicating the different setting alternatives.
Precondition p The duration (t1) must be set to 12 seconds.
n Setting overload protection on switches.
– The overload protection of the switch is set to the total rated current of the mo-
tors, multiplied by the current service factor plus the calculated transformer
value.
15.8.3 Setting Phase Sequence Relay
n Set the minimum voltage to 180 V.
n Set the delay to 10 seconds.
160 No: 6102429707.1.6102511883 en-US

15.8.4 Resetting Phase Sequence Alarm
WARNING
Dangerous Voltage
The electrical system has a phase sequence monitor (K50) 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.
15.8.5 Ground Fault Equipment
WARNING
Dangerous Voltage
The electrical system has a ground fault relay (K51) and a ground fault breaker (F25).
• 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.
15.9 Motor Protection
161 No: 6102429707.1.6102511883 en-US

162 No: 6102429707.1.6102511883 en-US

Boomer S2 16 Electrical System, Canada
16 Electrical System, Canada
16.1 Cable Marking

All the cables are marked with cable numbers corresponding to the external connection di-
agram.
16.2 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.
16.3 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
• Service outlet
• Battery charger for the carrier (also a source of extra low voltage)
• Electric motor for compressor
• Electric motor for water pump
16.4 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
• RCS system
16.5 Before Troubleshooting Electrical System

Check the following before troubleshooting the electrical system:
n All fuses are intact and switched on.
n Correct power supply is connected (see voltmeter).
163 No: 6102429707.1.6102511883 en-US

n All warning lamps on the electric cabinet are in working order (lamp test).
16.6 Electrical Distribution Cabinet, High-Current
16.6.1 Electrical Distribution Cabinet A10 Soft Start Canada (575V)
F25 Ground fault switch, 115V
F26 Ground fault switch, 230V
K53:1 Emergency stop relay master
K53:2 Emergency stop relay slave
Q01 Main switch
1Q02 Circuit breaker, electric motor 1
2Q02 Circuit breaker, electric motor 2
U40 Battery Charger
1V13 Soft start, electric motor 1
2V13 Soft start, electric motor 2
164 No: 6102429707.1.6102511883 en-US

16.6.2 Setting Up Soft Start
n The rig is equipped with soft start it must be set according to the tables.
Parameter Value
Start Method Current Limit Start
Soft Start Time 6 seconds
Initial Torque 30%
Table 7: Menu "Soft Start Config"
Parameter Value (55kW) Value (75kW)
Overld Trip Class 30 30
Overld trip FLA See data plate on electrical motor
Table 8: Menu " Oveload Config"
16.6.3 Battery Charger
WARNING
Dangerous Voltage
165 No: 6102429707.1.6102511883 en-US

The battery charger (U40) is integrated in the electrical distribution cabinet (A10) and sup-
plies the 24-V system of the machine. The supply voltage to the battery charger must be
115 V AC, 45–65 Hz. The temperature sensor regulates the charging voltage. Check regu-
larly that the cooling fan in the power supply cubicle (A10) is working. If the fan ceases to
work, there is a great risk of the cubicle overheating and components ceasing to work.
The lamp (A) changes color depending on battery status.
• Orange color: Battery charging.
• Green color: Battery fully charged.
• Red color: Battery discharged.
• Red color flashing: No battery connected.
16.7 Electrical System Protection
16.7.1 Main Switch Q1

The main switch (Q01) is on the 3-phase circuit in the electric cabinet. It has a knob for on
and off. The main switch has as standard shunt trigger, thermal overload protection and
magnetic short-circuit protection.
The switch can be reset after being triggered by turning the knob to position 0 (OFF) and
then back to position 1 (ON)
16.7.2 Setting Short-Circuit Protection
WARNING
Dangerous Voltage
166 No: 6102429707.1.6102511883 en-US

DIP Switches
The settings for the short-circuit protection depend on the method of starting. The setting is
made with DIP switches (I3) on the main power switch. Next to the DIP switches is a mark,
indicating the different setting alternatives.
n The short-circuit protection is set to 3.5 × the main power switch rated current (In) for
Y/D start or soft start.
16.7.3 Setting Overload Protection
WARNING
Dangerous Voltage
DIP switches
167 No: 6102429707.1.6102511883 en-US

The overload protection setting is dependent on the supply voltage and total electric motor
output. The setting is made with DIP switches (I1) on the main power switch. Next to the
DIP switches is a mark indicating the different setting alternatives.
Precondition p The duration (t1) must be set to 12 seconds.
n Setting overload protection on switches.
– The overload protection of the switch is set to the total rated current of the mo-
tors, multiplied by the current service factor plus the calculated transformer
value.
16.7.4 Setting Phase Sequence Relay
n Set the minimum voltage to 180 V.
n Set the delay to 10 seconds.
16.7.5 Resetting Phase Sequence Alarm
WARNING
Dangerous Voltage
The electrical system has a phase sequence monitor (K50) 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.
168 No: 6102429707.1.6102511883 en-US

16.7.6 Ground Fault Switch

The ground fault switch (F25) provides personal protection. When it trips, the supply to the
circuit for service outlet 115 VAC is disconnected.
The ground fault switch (F26) provides personal protection. When it trips, the supply to the
cabin heater outlet 230 VAC is disconnected.
The switches are set to 30 mA and maximum 40 ms. The ground fault switches should be
tested regularly by an authorised electrician.
16.7.7 Circuit Breaker

Each hydraulic pump motor has a circuit breaker (Q02).
The circuit breaker short-circuit current must be set to Min. The setting is applied with the
knob (A) in accordance with the figure (Min = 625 A) (Max = 1250 A).
An activated circuit breaker is reset by moving switch (B) to position 0.
The circuit breaker function can be tested with button C after it has been triggered and re-
set.
169 No: 6102429707.1.6102511883 en-US

170 No: 6102429707.1.6102511883 en-US

Boomer S2 17 Extra Low Voltage Battery
17 Extra Low Voltage Battery
17.1 Alternator
n Do not break connections between battery, alternator, and regulator when the engine
is running.
n 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.
n Do not mix up the battery connections.
n The charge lamp must be replaced immediately if it is broken.
n Do not spray water directly on the alternator when cleaning the engine. Run the en-
gine warm afterward to evaporate excess water.
n 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.
n When carrying out electric welding, connect the ground directly to the part being
welded.
17.2 Check the Extra Low Voltage Battery

Batteries are maintenance free under normal conditions. Compensating-charge can be
needed if the machine has not been used for a longer time.
1. Check that batteries are mounted correctly.
2. Check that battery connections are tightened and have no trace of corrosion.
3. Check all cables to the alternator, starter, and all the other electrical components for
damage and wear.
17.3 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.
17.4 Charging Maintenance-Free Battery

The battery is normally charged when the main power supply of the machine is on, by the
alternator and via built in charger in the electrical cabinet. If the battery is fully discharged
for some reason, it must be recharged using a battery charger. Batteries contains corrosive
fluid. Always turn off the charge current before disconnecting the clips. If the density has
not risen noticeably despite a number of hours of charging, the battery is probable ex-
pended. Rapid charging, when carried out correctly, will not damage the battery. Rapid
charging should not be undertaken too often and is not recommended for old batteries. Re-
171 No: 6102429707.1.6102511883 en-US

peated discharging for long periods will impair the service life of the battery. Avoid, for ex-
ample, leaving the tramming lights on while the engine is stationary. Discharging with high
current is not normally harmful.
Since the 24V electrical system is powered by two 12V batteries connected in series, ob-
serve:
• The batteries must have the same capacity (Ah).
• The batteries must be the same age. This is because the charging current required to
bring a battery up to a certain voltage changes with age.
• Series coupling maintains the same capacity but increases the voltage. For example,
when 2 x 12V 60Ah batteries are connected in series, the voltage will be 24V but the
capacity remains at 60Ah.
• Use a 24V charger when charging both batteries connected. Use a 12V charger when
charging each battery individually. Observe the voltage before connecting a battery
charger.
17.5 Charging Battery Using External 24V Charger
WARNING
Risk of Fire and Explosion
Gas that is formed in the battery during charging and discharging is explosive which
can cause serious personal injury and property damage.
u Avoid open flames and sparks.
u Make sure that the ventilation is good.
u Disconnect the negative terminal first, and connect it last.
u Disconnect the fire suppression system.
u Use protective safety glasses.
u Use protective gloves.
Precondition p The machine is switched off.

p The fire-fighting system is disconnected due to risk of damaging the electronics.
p The external charger is 24V.
1. Turn off battery isolation switch (S300).
172 No: 6102429707.1.6102511883 en-US

2. Connect the battery charger positive cable to the positive terminal on battery (B).
3. Connect the battery charger negative cable to the negative terminal on battery (A).
4. Start the battery charger.
5. Turn off the battery charger when batteries are fully charged.
6. Disconnect the battery charger negative cable from the negative terminal on battery
(A).
7. Disconnect the battery charger positive cable from the positive terminal on battery (B).
8. Turn on battery isolation switch (S300).
17.6 Charging Battery Using External 12V Charger
WARNING
Risk of Fire and Explosion
Gas that is formed in the battery during charging and discharging is explosive which
can cause serious personal injury and property damage.
u Avoid open flames and sparks.
u Make sure that the ventilation is good.
u Disconnect the negative terminal first, and connect it last.
u Disconnect the fire suppression system.

p The fire-fighting system is disconnected due to risk of damaging the electronics.
p The external charger is 12V.
1. Turn off the battery isolation switch (S300).
2. Disconnect the cable between batteries.
3. Connect the battery charger's positive cable to the positive terminal on battery (A).
Connect the battery charger's negative cable to the negative terminal on battery (A).
173 No: 6102429707.1.6102511883 en-US

4. Start the battery charger.
5. Turn off the battery charger when battery (A) is fully charged.
6. Disconnect the battery charger's negative cable from the negative terminal on battery
(A). Disconnect the battery charger's positive cable from the positive terminal on bat-
tery (A).
7. Repeat step 3 to 6 for battery (C).
8. Connect the cable between batteries (B).
9. Turn on battery isolation switch (S300).
17.7 Starting with Auxiliary Battery
WARNING
Risk of Explosion
There is a risk of personal injury if a charged battery is connected to a discharged bat-
tery.
u Use a well ventilated area.
u Fire extinguisher must be close at hand.

p The RCS system is switched off from the control system panel.
p The fire fighting system is disconnected due to risk of damaging the electronics.
1. Check that the auxiliary batteries (A) have the same voltage as the batteries that re-
quire to be charged (B).
2. Connect the positive terminal of the auxiliary batteries (A) to the positive terminal of
the batteries that require to be charged (B).
3. Connect the negative terminal of the auxiliary batteries (A) to ground on the chassis
(XII).
174 No: 6102429707.1.6102511883 en-US

NOTE: Do not connect the negative terminal of the auxiliary batter-

! ies (A) to the negative terminal of the batteries that require to be
charged (B).
4. Disconnect the cable from the chassis ground (XII) when the engine starts.
5. Disconnect the cable from the negative terminal on the auxiliary batteries (A).
6. Disconnect the cable between the positive terminal of the charged batteries (B) and
the auxiliary batteries (A).
175 No: 6102429707.1.6102511883 en-US

176 No: 6102429707.1.6102511883 en-US

Boomer S2 18 Pneumatic System
18 Pneumatic System
The function of the air system is to supply the rock drill with lubrication in the form of air
with an oil mixture. The air is compressed with a compressor (Atlas Copco GAR 5 or GAR
30). If the Air blowing option is installed, the air is also used for blowing clean holes when
drilling is finished and in this case there is normally one air tank.
Depending on the machine type, there are more systems that are connected to the air sys-
tem for example, cartridge unit, water cannon, cement unit and so on.
18.1 Safety Precautions before Working on Pneumatic

System
WARNING
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.
18.2 Drain Condensate from Air Tank

Air tank is installed on machine with the air flushing option.
Precondition p Machine is parked on a flat and level surface.
1. Open the drain tap on the air tank.
2. Close the drain tap when the flow of water stops.
Automatic drain water from air tank is an optional function.
177 No: 6102429707.1.6102511883 en-US

The valve opens when the air system gets depressurized.
18.3 Check Cables and Plugs of Compressor
WARNING
n Check cables and plugs.
Compressor instruction manual
18.4 Check Hoses and Connections of Compressor
WARNING
n Check hoses and hose connections of compressors and air receivers.
18.5 Check Compressor

Refer to separate instruction for maintenance.
See reference documentation
2920 7089 82 LE 7-20 Compressor instruction manual
178 No: 6102429707.1.6102511883 en-US

18.6 Check Safety Valve of Compressor
LE10-10
n Check the safety valve (A) for damages.
18.7 Check Air Filter of Compressor

First read: Safety Precautions before Working on Pneumatic System [} 177]
179 No: 6102429707.1.6102511883 en-US

LE10-10
1. Check condition of the air filter (A).
2. Replace if necessary.
18.8 Clean Air Filter of Compressor

First read: Safety Precautions before Working on Pneumatic System [} 177]
180 No: 6102429707.1.6102511883 en-US

LE10-10
n Clean coarse separator (A) in the air filter.

Replace if necessary.
18.9 Clean Compressor
WARNING
n Clean the compressor.
18.10 Membrane Dryer

The membrane dryer is optional equipment.
181 No: 6102429707.1.6102511883 en-US

18.10.1 Safety Precautions Before Working on Membrane Dryer
WARNING
High Air Pressure
The air nipples can be warm and cause personal injury.
u Pressure settings must only be changed by personnel trained on the system.
18.10.2 Check Membrane Dryer SDR6

First read: Safety Precautions Before Working on Membrane Dryer [} 182]
A Drainage valve membrane dryer, Y117:2
B Water separator WSD
C Particle Filter
D Shut off valve, Y117:1
E Pressure regulator for incoming air to the membrane dryer
F Membrane dryer
Precondition p Compressors are OFF.
1. Check that the air system is depressurized.
2. Connect an air humidity meter after the pressure regulator (E).
3. Start one hydraulic pump.
4. Read the relative humidity on the air humidity meter.
182 No: 6102429707.1.6102511883 en-US

The air humidity must be 5–10 % with a brand new dryer.
è Replace the membrane dryer (F) if the measured humidity exceeds 40%.
18.10.3 Replacing Membrane Dryer SDR6

C Particle Filter
E Pressure regulator for incoming air to the mem-

brane dryer
F Membrane dryer
! NOTE: The membrane dryer (F) is replaced as a unit.
Precondition p Hydraulic pumps are OFF.
2. Remove the connections.
3. Remove the filter from the holder.
4. Connect the drainage valve (A) to the new membrane dryer.
5. Install the dryer in the holder.
183 No: 6102429707.1.6102511883 en-US

6. Install the connections.
18.10.4 Check Membrane Dryer SDR6 Particle Filter
WARNING
High Air Pressure
1. Check pressure drop indicator (A).
a. If indicator is green
è Filter is ok.
b. If indicator is red
è Replace filter.
18.10.5 Replacing Membrane Dryer SDR6 Particle Filter
WARNING
High Air Pressure
184 No: 6102429707.1.6102511883 en-US

Precondition p The indicator is red.

p Hydraulic pumps are OFF.
2. Remove the filter cap (A) from the filter housing (B).
3. Remove the filter (C) from the filter housing (B).
4. Install a new filter in the filter housing.
5. Reattach the filter cap.
6. Dispose of the old filter in accordance with local environmental regulations.
18.10.6 Setting Pressure Regulator for Membrane Dryer SDR6

C Particle filter
E Pressure regulator for incoming air to the mem-

brane dryer
185 No: 6102429707.1.6102511883 en-US

F Membrane dryer
1. Start one hydraulic pump.

Wait until the compressor fully built up pressure in the air tank.
2. Set pressure regulator (E) to 6 bar (87.02 psi) in the pressure gauge.
186 No: 6102429707.1.6102511883 en-US

Boomer S2 19 Water System
19 Water System
The water system is used to flush the borehole clean from cuttings and to cool the drill
string. The water is also used for cooling the hydraulic oil. A water pump increases the wa-
ter pressure.
19.1 Safety Precautions before Working on Water System
WARNING
19.2 Draining Water Pump
WARNING
187 No: 6102429707.1.6102511883 en-US

1. Open the water pump drain plug (A).
2. When the flow of water stops, close the drain plug.
19.3 Checking Pressure Sensor B136
If the sensor is replaced, it must be calibrated
1. Connect a pressure gauge to the sensor B136.
2. Make sure that the relevant system is depressurized.
188 No: 6102429707.1.6102511883 en-US

3. The sensor value on the display 0 bar must agree with the pressure reading from the
pressure gauge.
4. Start the pump and pressurize the sensor.
5. The sensor value on the display must agree with the pressure reading from the pres-
sure gauge.
If the values do not correspond, the sensor must be calibrated or replaced.
19.4 Checking Pressure Sensor B188:1
1. Connect a pressure gauge to the sensor in question.
2. Make sure that the relevant system is depressurized.
3. The sensor value on the display 0 bar must agree with the pressure reading from the
pressure gauge.
4. Start the pump and pressurize the sensor.
5. The sensor value on the display must agree with the pressure reading from the pres-
sure gauge.
If the values do not correspond, the sensor must be calibrated or replaced.
19.5 Setting Water Flow Switch
Flow Switch
1. Remove the black plastic cover from the guard.
2. Remove the screw on top of the switch.
3. Adjust sensor body (A).
189 No: 6102429707.1.6102511883 en-US

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.
19.6 Checking Water Pump Rotation Direction
Precondition p The rotation direction of the water pump is checked after working on the hydraulic cir-
cuit.
n Check the rotation direction of the water pump corresponds with the arrow (A).
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If the rotation direction is incorrect, the delivery and return hoses on the motor and
valve must be switched.
19.7 Check Water Pump Shaft Seal
n Check for leakage around the water pump shaft seal (A).
è Disassemble the pump and replace the seal if leakage occurs.
19.8 Replacing Water Pump Shaft Seal - Hydraulic Drive
191 No: 6102429707.1.6102511883 en-US

Precondition p The water pump is removed from the machine.
1. Remove the protection (L) from the lantern piece.
2. Remove the hub bolts (E) and associated lock tabs (F).
3. Remove locking pin (G), inside the lock tabs (F).
4. Remove the bolts that attach the hydraulic motor in flange (C).
5. Lift the hydraulic motor together with the hub (B).
6. Remove the plug (M).
7. Remove the nuts (A) and then lift the lantern piece (K).
8. Lift the disc (J) and remove the upper part of the shaft seal (H) from the bottom of
disc.
9. Wash the upper part of the new shaft seal with alcohol and install it in place on the
disc.
10. Remove the lower part of the old shaft seal from the shaft.
11. Wash the lower part of the new seal with alcohol and place on the shaft.
12. Install the disc (J) with the upper part of the shaft seal in place.
13. Install and attach the lantern piece (K) with the nuts (A).
14. Press in the fork-shaped shim (M) on the shaft.

If there is no shim, then a fitting piece of 5 ± 0.1 mm (0.19 ± 0.0039 in.) can be used.
15. Lower the hub (B) over the shaft, and install the locking pin (G) in the shaft hole.
16. Install the lock tabs (F) and the hub bolts (E).
17. Install the hydraulic motor into the flange (C) on the lantern piece.
18. Remove the fork-shaped shim and install the plate protection (L).
192 No: 6102429707.1.6102511883 en-US

19.9 Disassembling Water Pump Shaft Seal
! NOTE: A mechanical shaft seal usually requires no maintenance. It must never run
dry.
Precondition p Water pump is removed from the machine.
1. Remove the plate protection from the lantern piece (A).
2. Remove the screws (B) and lift the hydraulic motor away from the lantern piece.
3. Remove the coupling half (C) from the shaft and remove the wedge (D).
4. Loosen and fold, aside the discharge line (E) from shaft seal cover (F).
5. Remove the discharge line nipple (G) from the cover.
6. Remove the top V-ring (H) from the shaft and slide down the bottom V-ring (H).
193 No: 6102429707.1.6102511883 en-US

7. Loosen the upper and lower bearing covers (J), and remove the upper cover from the
shaft.
8. Remove the top lock ring (K) and the intermediate ring (L) from the shaft.
9. Loosen the four bolts (M) that attach the lantern piece in the pump housing.
A ring spanner with narrow handle or special tools are required.
10. Pull the lantern piece (N) and ball bearing (P) from the shaft with a puller.
11. Remove the two lock rings (Q) from the bearing housing.
12. Press the bearing (P) out from the bearing seat using a tube that supports the outer
ring of the bearing.
13. Remove the lower intermediate ring (L) and the lower lock ring (K) from the shaft.
14. Remove the bearing cover (J) and the lower V-ring (H) from the shaft.
15. Remove the shaft seal cover (F) from the shaft and remove the static ring, which is in-
stalled in the shaft seal cover.
16. Slide the seal (R) rotating ring off from the shaft.
19.10 Assembling Water Pump Shaft Seal
194 No: 6102429707.1.6102511883 en-US

! NOTE: A mechanical shaft seal usually requires no maintenance. It must never run
dry.
Precondition p Shaft seal remains in the original packaging.

p Paint from the pump shaft and bearing seat is removed.
p The work area is free of dust and the parts and tools are clean.
1. Install the adjustment ring (B), and lock it with the set screw (C) at the correct dis-
tance to the closest groove (A) in the shaft above the adjustment ring.
2. Check the grooves (A) for the lock rings lack sharp edges.
3. Lubricate the shaft with water mixed detergent.
4. Install the shaft on the rotating part of the shaft seal (D) with a slight right-hand turning
movement.
The sliding surface is turned upward.
5. Lubricate the seal cover seal chamber with water mixed with detergent.
6. Install the static ring on the shaft with the sliding surface turned downward.
7. Install the gasket (E) and the shaft seal cover (F) in the pressure seat, and move the
cover to the right way.
8. Install the lower lock ring (G) and bottom bearing cover (H) on the lantern piece (J).
9. Move the lower V-ring (K) over the pump shaft with the narrow opening turned to-
wards the inside of the pump.
10. Attach the lantern piece (J) on the pressure seat with the screws (L).
11. Install the lower lock ring (M) on the pump shaft in the lower of the two grooves.
12. Install the intermediate ring (N).
13. Lubricate the ball bearing with lubricant grease on both sides.
14. Install the bearing (P) over the pump shaft with suitable assembly sleeve, which sup-
ports the bearing outer ring.
15. Install the upper intermediate ring (N) and the upper lock ring (M) in the upper groove
of the pump shaft.
16. Install the upper lock ring (G) in the lantern piece.
17. Press the upper bearing cover and attach the upper V-ring (K) with the narrow open-
ing turned upwards.
18. Install the discharge line nipple (Q) in shaft seal cover (F) and connect the discharge
line (R).
! NOTE: Put the sliding rings down onto the sliding surfaces care-
fully. Do not touch sliding surfaces with your fingers.
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19.11 Adjusting Water Pump Speed
Precondition p Maximum rotation speed is 4000 rpm.
1. Start all the hydraulic pumps.
2. Adjust the flow regulator valve (Y162) until output water pressure is 15–20 bar (217–
290 psi).
! NOTE: Output water pressure must not exceed 30 bar (435 psi).
19.12 Water Mist System

Sometimes it is undesirable to use water as a flushing medium. Instead it is possible to use
air with a certain mixture of water. This form of flushing is called water mist. A common
reason for flushing with water mist is limited access to water or if the rock is sensitive to
water. The machines can also have a combination of water flushing and flushing with water
mist. The form of flushing most suitable for each type of drilling can then be selected. It is
also possible to drill with external air.
19.12.1 Check Water Mist Pump for Leaks

1. Check for water leaks.
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2. Check for oil leaks.
3. Replace damaged or worn parts if necessary.
19.12.2 Draining Water Mist Pump
1. Connect air to the water inlet (A).
2. Open the front water tap for the water mist pump.
3. Open the drain tap for water before the water mist pump.
4. Blow until no more water appears from the drain line.
5. Close the drain tap.
6. Open the drain tap connected to the water block after the water mist pump.
7. Start the control system.
8. Start one of the hydraulic pumps.
9. Activate the water mist pump ON/OFF function in the Settings menu under the ma-
chine tab.
10. Run the pump until no more water comes out of the drain line.
11. Deactivate the water mist pump ON/OFF function.
12. Close the water mist pump taps.
13. Remove the air connection from the water inlet (A).
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19.12.3 Checking Flow Switch for Water Mist
1. Go to the Settings/Drilling/Sensors screen view.
2. Test blow air through the drill rod and the drill bit that are used during drilling.
è The value of Air flow is obtained in the menu as 0 = no air flow or 1 = air flow. If
no air flow is obtained, investigation of the cause must be done.
198 No: 6102429707.1.6102511883 en-US

Boomer S2 20 Power Train
20 Power Train
20.1 Safety Precautions before Working on Power Train
WARNING
Burning Hazard
20.2 Power Train Overview
A Front axle
B Rear axle
C Hydraulic transmission
D Tramming motor
199 No: 6102429707.1.6102511883 en-US

20.3 Checking Condition of Transmission Cooling System
WARNING
Burning Hazard
A thermostat valve (A) controls the cooling of the transmission oil. The thermostat valve (A)
does not open the flow to the radiator before the oil has reached a temperature of 70 °C
(158 °F). Thermostat valve (A) location could vary slightly depending on type of engine/mo-
tor.
n Check for leaks and damage to heat exchanger, fan, and hoses.
n Check for leaks and damage to the thermostat valve (A).
n Check attachment of heat exchanger and fans.
20.4 Check Oil Level in Central Housing
WARNING
Burning Hazard
200 No: 6102429707.1.6102511883 en-US

Precondition p Machine is parked on a flat and leveled surface.
1. Remove plug (A).
2. Check that the oil reaches up to the hole.

Add if necessary.
3. Reinstall plug (A) and tighten.
See separate manual
Fluids and Greases
20.5 First Replacement of Oil in Central Housing

First read: Safety Precautions before Working on Power Train [} 199]
NOTE: The first replacement of oil in the central housing must only be performed the
! first time this maintenance interval is reached. Thereafter maintenance according to
other interval specified in maintenance table.
20.6 Replace Oil in Central Housing

1. Place a vessel under the central housing.
2. Remove the plug (B).
3. Drain the oil.
4. The oil drains faster if the plugs (A and C) are also removed.
201 No: 6102429707.1.6102511883 en-US

5. Install the plug (B) again and tighten it.
6. Fill with new oil through the plug (A) until oil reaches the hole for plug (C).
7. Install and tighten the plugs (A and C).
Oil Volume for Central Housing on Wheel Axle, Dana 123
13.5 Litres (3.57 gal)
See separate manual
Fluids and Greases
20.7 Check Oil Level in Planetary Gear
WARNING
Burning Hazard
1. Rotate the wheel until plug (A) on the planetary gear is at level with the gear center.
2. Remove plug (A).
3. Check that the oil reaches up to the hole.

Add if necessary.
4. Reinstall the plug (A) and tighten.
202 No: 6102429707.1.6102511883 en-US

See separate manual
Fluids and Greases
20.8 First Replacement of Oil in Planetary Gear

NOTE: The first replacement of oil in the planetary gear must only be performed the
! first time this maintenance interval is reached. Thereafter maintenance according to
other interval specified in maintenance table.
20.9 Replace Oil in Planetary Gear

1. Rotate the gear until plug (A) is brought to its lowest position.
2. Remove the plug (A).
3. Drain the oil into a suitable vessel.
4. Rotate the gear until plug (A) is at level with the gear center.
5. Fill new oil through the hole for plug (A).
6. Check that the oil is at level with the hole.
7. Reinstall plug (A) and tighten.
See separate manual
Fluids and Greases
203 No: 6102429707.1.6102511883 en-US

20.10 Check Carrier Central Lubrication
WARNING
Burning Hazard
n Check the central lubrication hoses and nipples for wear or other damage.
n Fill the central lubrication with grease if necessary.
20.11 Lubricate Carrier Joints
1. Pump grease into the lubrication point (B) using the lubricant gun on the manual lubri-
cation reeling unit (A).
2. Pump until grease comes out at all positions (C).
204 No: 6102429707.1.6102511883 en-US

See Separate Manual
Fluids and lubricants
20.12 Lubricate Cardan Shafts

n Lubricate the support bearing (A) on cardan shaft.
See separate manual
Fluids and Greases
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20.13 Lubricate Cardan Shaft Spline

n Lubricate the cardan shaft spline (A).
See separate manual
Fluids and Greases
20.14 Check Articulated Joint
WARNING
Burning Hazard
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n Check the articulated joints (A) for wear or damage.

è Replace if necessary.
20.15 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.
n Check that no bolt or nut is missing or loose.
n Check the tightening torque on wheel bolts and nuts.
Tightening Torque
550 Nm (405.7 lb-ft)
20.16 Check Tire Pressure

n Check tire pressure on each wheel and adjust if necessary.
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Wheel Tire Pressure (bar) Tire Pressure (psi)
Front wheel 10 145
Rear wheel 10 145
Table 9: Tire Pressure
20.17 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.
Check the following while assembling tires and rims:
n Check that the tires are inflated to the correct pressure.
n Check that the contact surfaces between the hub and rim are clean so that the correct
tightening torque can be maintained.
n Check that the wheel nuts are tightened to the correct torque.
n 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.
n Check that the right volume of air, liquid, or foam (appropriate medium) is filled to ob-
tain stability and safety standpoints.
n Only authorized tire companies must fill liquid in tires with a salt solution in accor-
dance with the specifications on the drawing.
n Check that the correct mixture of liquid medium is obtained to remain in liquid form
down to temperatures of -20 °C (-4 °F).
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20.18 Replace the Tramming Pump Filter
2. Remove and discard the preformed packing (C).
3. Remove the tramming pump filter (D).
4. Install the new pump filter (D) to the cover (B).
5. Lubricate the new preformed packing (C) and install it to the cover (B).
6. Install the cover (B) to the pump.
20.19 Towing
20.19.1 Safety Precautions before Towing
WARNING
Machine Movement
The machine has no working brakes when it is being towed which can cause serious
injury or death.
u Always attach a tow bar between the machine and the towing machine before releasing
the brakes or removing the cardan shafts.
u Make sure that the towing machine and the tow bar are suitable to pull the load.
NOTICE
Incorrect Towing
Starting the machine by towing could seriously damage the hydraulic transmission.
u Do not start the machine by towing.
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20.19.2 Preparing for Towing

First read: Safety Precautions before Towing [} 209]
Only tow the carrier, if necessary.
Do not tow the carrier more than 1 km (0.621 mile) or at a speed greater than 5 km/hr (3.10
miles/hr).
! NOTE: The brakes do not function while the machine is being towed.
1. Connect a tow bar between the machine and the towing machine.
2. Disable the parking brake mechanically.
3. Disassemble the cardan shaft from the drive train.

If the diesel engine is not working, disconnect the steering cylinder.
Disconnecting Parking Brake Mechanically
WARNING
Machine Movement
injury or death.
Precondition p A tow bar is connected between the machine and the towing machine.
1. Loosen the lock nuts (A).
2. Tighten the bolts (B) alternately until the brake is released.

Both the bolts must be tightened to the same extent.
3. Lock the bolts with the nuts.
4. Disable the brakes on both wheel axles.
210 No: 6102429707.1.6102511883 en-US

Removing Cardan Shafts
WARNING
Machine Movement
injury or death.
Precondition p A tow bar must be connected between the machine and the tractor.
1. Mark the flanges on the cardan shafts so they can be reinstalled in the same way.
2. Remove the bolts (A).
3. Remove the cardan shafts.
Disconnecting Steering Cylinder
First read: Safety Precautions before Towing [} 209]

If the diesel engine is not working during towing, the steering cylinder must be discon-
nected hydraulically.
Precondition p Unions on the cylinder are not plugged to allow oil to run out.
p The Unions are protected from dirt.
1. Remove both hoses from the steering cylinder.
2. Plug the hoses.
3. Protect the steering cylinder against dirt.
211 No: 6102429707.1.6102511883 en-US

20.19.3 Restoring after Towing
1. Install the cardan shafts and the hoses again to the steering cylinder.
2. Apply the parking brake.
3. Loosen the lock nuts (A) few turns.
4. Loosen the bolts (B) until the measurement of 34 mm (1.3 in.) is reached.
5. Lock the position of the bolts (B) with nuts (A).
6. Remove the tow bar between the chassis and the towing machine.
7. Check the service and parking brake.
212 No: 6102429707.1.6102511883 en-US

Boomer S2 21 Brake System
21 Brake System
21.1 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.
21.2 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.
213 No: 6102429707.1.6102511883 en-US

p Parking brake is applied.
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 maximum 80 bar (1160 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).
21.3 Bleeding Service Brake
WARNING
nent damage.

p Machine is standing on the jacks with the wheels suspended.
1. Attach plastic hoses to the nipples (B2).
214 No: 6102429707.1.6102511883 en-US

3. Press and hold the brake pedal.
4. Open the nipples (B2), about half a turn.
5. Use a vessel to collect the fluid residues.
6. Tighten the nipples when there is no air in the fluid.
7. Shutdown the engine and turn on the ignition key.
8. Press the brake repeatedly.
This must activate the once the pressure has dropped to 110 bar (1595 psi).
9. Press and hold the brake pedal completely and release.

Repeat this four times.
If the brake pressure drops below 90 bar (1305 psi) after this step is performed, re-
peat steps 1–6.
Repair the brakes if the service brakes do not work.
10. Switch off the diesel engine.
11. Remove the plastic hoses.
21.4 Check Parking Brake Pressure
WARNING
nent damage.
215 No: 6102429707.1.6102511883 en-US


p Wheels are chocked.
1. Connect a pressure gauge to the brake system test outlet (A)
3. Pull out the parking brake switch on the driving panel to release the parking
brake and read the pressure on the pressure gauge.
The reading on the pressure gauge should be 30 bar (435.11 psi).
The pressure can be adjusted on pressure regulator (3PR) under the operator station.
4. Stop the diesel engine.
5. Remove the pressure gauge from the test outlet (A).
216 No: 6102429707.1.6102511883 en-US

21.5 Bleeding Parking Brake
WARNING
Pressurized System
The parking brake is bled while the system is pressurized and the hydraulic oil in the
system can cause personal injury.
u Never unscrew the bleeder nipples fully when bleeding the parking brakes.
u Follow the instructions carefully.

p Machine is standing on the jacks with the wheels suspended.
1. Attach plastic hoses to the nipple (B1).
3. Release the parking brake.
4. Open the nipple (B1), about half a turn.
5. Use a vessel to collect the fluid residues.
6. Tighten the nipple when there is no air in the fluid.
! NOTE: Repeat bleeding several times to remove all the air from the
system.
7. Switch off the diesel engine.
217 No: 6102429707.1.6102511883 en-US

8. Remove the plastic hoses.
21.6 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.
218 No: 6102429707.1.6102511883 en-US


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.
21.7 Checking Brake Pressure Control Valve
WARNING
nent damage.
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.
219 No: 6102429707.1.6102511883 en-US

Precondition p Machine wheels are blocked.
1. Connect a pressure gauge to pressure test outlet (53) under the brake pedal and a
gauge on the diesel positioning test outlet ().
2. Start the diesel engine and brake repeatedly with the engine idling.
è When the pressure drops to 125 bar (1812.97 psi), the brake system control
valve is engaged so that the maximum brake pressure 150 bar (2175.56 psi) is
achieved.
3. When maximum brake pressure 150 bar (2175.56 psi) is attained, activate .
4. Release the parking brake, loosen the pump inner actuators until gauge that is
mounted on the position pump shows 40 bar (580.15 psi).
5. Brake repeatedly.
220 No: 6102429707.1.6102511883 en-US

è The indicator lamp , on the control panel comes on when the pressure
has dropped to 110 bar (1595.41 psi).
6. Press and hold the brake pedal completely and release. Repeat this four times.
If the brake pressure drops below 90 bar (1305.34 psi) 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.
7. Press the brake pedal several times so that the pressure in the brake system de-
crease and check that parking brake and parking brake indicator lamp activates
once the pressure drops to 80 bar (1160.30 psi).
è Parking brake gets engaged.
8. Insert the inner actuator on the diesel positioning pump and adjust the pump pressure
to 210 ± 3 bar (3045.8 ± 43.51 psi).
21.8 Checking Accumulator Charge Pressure
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
u Relieve the high accumulated brake pressure, which will be present even after the en-
gine/motor has been stopped, before opening the system.
The accumulator charge pressure is specified on each accumulator sign.

The system could still be pressurized even when the brake pressure gauge (where in-
stalled) indicates zero pressure.
221 No: 6102429707.1.6102511883 en-US

1. Connect a pressure gauge to pressure test outlet (A) on the accumulator block.
! NOTE: Check all accumulators one by one.
2. Start the diesel engine to build up pressure in the system.
3. Switch off the engine when the system is charged and the pressure rise on the
manometer has stopped.
4. Press the brake pedal a few times and watch the manometer.
! NOTE: Press carefully when the manometer pressure has passed

70 bar (1015 psi).
è When the accumulator is fully empty, the pressure suddenly drops. This pres-
sure, from which the pressure suddenly drops, is the same as the accumulator
pre-charge pressure. If the pre-charge pressure is less than 50 bar (725 psi),
the accumulator must be recharged according to the manufacturer instructions,
or replaced.
5. Repeat steps 1–4 with a pressure gauge on pressure test outlet (B).
222 No: 6102429707.1.6102511883 en-US

21.9 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.
223 No: 6102429707.1.6102511883 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 pressure.
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.
21.10 Check after Working With Brake System
21.10.1 Check Service Brake
NOTICE
Property Damage
Risk of overheating the transmission system.
u Do not perform the brake test for longer than four seconds.
Precondition p Machine is parked on a flat and level surface.

p The diesel engine is turned on.
1. Press the brake pedal and hold it down.
2. Release the parking brake.
3. Engage second gear.
224 No: 6102429707.1.6102511883 en-US

4. Gradually increase engine rpm to maximum.
5. Check the machine movement.

If the machine moves, then the brakes must be repaired or replaced before operating
the machine.
21.10.2 Check Parking Brake
NOTICE
Property Damage
Risk of overheating the transmission system.
u Do not perform the brake test for longer than four seconds.

1. Start the diesel engine and engage second gear.
2. Gradually increase engine rpm to maximum.
3. Check the machine movement.

If the machine moves, then the brakes must be repaired or replaced before operating
the machine.
225 No: 6102429707.1.6102511883 en-US

226 No: 6102429707.1.6102511883 en-US

Boomer S2 22 Reeling Unit
22 Reeling Unit
22.1 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.
22.2 Check Tightening Torque of Cable Reeling Unit

Collector
n Tighten the nuts on all cable terminals of the collector.
n Tighten the slip rings of the collector.
227 No: 6102429707.1.6102511883 en-US

22.3 Check Cable Reeling Unit Collector
WARNING
Dangerous voltage
Can cause serious personal injury
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.
n 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.
n Check that internal cables are attached and not rubbing against moving parts.
n Check all components for damage and replace if necessary.
228 No: 6102429707.1.6102511883 en-US

n Check that the protective cable stocking is installed.
n Check tightening torque on all bolted joints.
n Check bolt tightening on electric cable attachment and electric joints.
n Check gaskets on covers and cable entry gaskets and that no water leaks into the
collector housing.
n Check that all carbons on the carbon brush are in correct position on the ring before
closing the collector.
22.4 Clean Cable Reeling Unit Collector
n Clean the collector (A) thoroughly using a vacuum cleaner or lint free cloth.
Only use pure alcohol if liquid is needed, do not use industrial cleaning liquids.
229 No: 6102429707.1.6102511883 en-US

22.5 Check Reeling Unit Drum
n Check tightening torque on all bolted joints of the drum.
n Check the drum structure for mechanically damage and sharp edges that can dam-
age the cables.
22.6 Check Reeling Unit Drive Chain

1. Check the tension of the chain.
The slack must be 10–15 mm (0.4–0.6 in).
è Adjust the tension if necessary.
2. Remove the chain cover and check the lubrication of the chain and sprockets.
è Clean and lubricate if necessary.
22.7 Adjusting Reeling Unit Drive Chain
230 No: 6102429707.1.6102511883 en-US

1. Loosen the bolts (B) holding the gear.
2. Adjust the chain using the set screw (A).

The chain slack must be 10–15 mm (0.4–0.6 in).
3. Retighten the bolts (B).
22.8 Adjusting Limit Switch
Adjust the limit switch if the cable or cable reel has been changed, or of the limit switch set-
ting has unintentionally been changed.
1. Remove the limit switch cover (F).
2. Loosen the lock screw (A).
3. Run the cable until three turns are left on the drum of the cable reeling unit.
4. Adjust screw (C) until contactor (D) activates the cable reel warning lamp on the driv-
ing panel.
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.
è Parking brake lamp on the driving panel comes on.
7. Check the adjustment by running the cable in and out.
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è Repeat the procedures if further adjustment is required.
8. Tighten locking screw (A).
9. Reattach the limit switch cover (F).
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Boomer S2 23 Lubrication System
23 Lubrication System
23.1 Automatic Central Lubrication System (CLS)

The CLS is auxiliary equipment that lubricates all joints in the rear boom body. CLS is
started through a pressure switch (B186) in the hydraulic positioning circuit.
A Pump element
B Safety valve
C Plug (timer for pause and running time)
D Filler nipple
E Reservoir
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23.2 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.
23.3 Lubrication Pump Safety Valve
Location of Safety Valve on Lubrication Pump
234 No: 6102429707.1.6102511883 en-US

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.
23.4 Pause Time and Running Time Settings

Integrated in the lubrication pump is a timer which controls pause and running times. To
access the timer, remove the plug on the lubrication pump.
• Pause time can be adjusted to increments of 15 with the blue rotary switch (A). Pause
time is preset from factory.
• Running time can be adjusted to increments of 15 with the red rotary switch (B). Run-
ning time is preset from factory.
Rotary switch position 1 2 3 4 5 6 7 8 9
Hours 1 2 3 4 5 6 7 8 9
Rotary switch position A B C D E F
Hours 10 11 12 13 14 15
Table 10: Pause Time Rotary Switch
Rotary switch position 1 2 3 4 5 6 7 8 9
Minutes 2 4 6 8 10 12 14 16 18
Rotary switch position A B C D E F
Minutes 20 22 24 26 28 30
Table 11: Running Time Rotary Switch
235 No: 6102429707.1.6102511883 en-US

23.5 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
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Boomer S2 24 Welding
24 Welding
24.1 About Welding
WARNING
Risk of Poisoning
When heated, the paint forms substances that can cause eczema, eye irritation, respi-
ratory system difficulties, and in severe cases, asthma, or other health problems.
u Always use personal protection such as appropriate breathing apparatus, eye protec-
tion, and gloves.
u Always make sure that there is good ventilation when welding, grinding and other hot
work that involves heating the paint.
WARNING
Thermal Cracks
u Follow the instructions.
u Do not weld on the booms.
u Do not weld on the framework of the cab or mountings.
u Pay attention to special certification for FOPS and ROPS.
! NOTE: Unauthorized modification of the machine is not allowed.
! NOTE: Always keep a fire extinguisher for oil fires near during all types of welding, cut-
ting, and grinding. Screen off the work area from flammable materials.
Contact Epiroc before repair welding on components or frames, approval of welding

method and choice of electrodes.
• Qualified personnel must perform all welding.
• Turn off the current supply to the machine.
• Disconnect the cables from the alternator, the battery, the electronic modules, and the
firefighting equipment.
• Grind off rust and paint from the area to be welded and carefully prepare the joint.
• Welding equipment must be grounded correctly.
• Weld in a dry area.
• If repair welding is necessary, damaged units must preferably be removed and re-
paired separately.
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Boomer S2 24 Welding
• Framework, brackets, and load-carrying structures are made of special materials. Any
repair welding performed with incorrect materials or additives can weaken the struc-
ture.
• Avoid welding close to bearings and bushings.
• Do not weld on the boom, hydraulic tanks, hydraulic cylinders, valve blocks, com-
pressed air tanks, or pressure lines.
• Do not weld on a FOPS and ROPS approved cab. The certification would then be in-
valid.
• Protect hoses, cables, and electrical components.
• If possible, grind the surface of the weld smooth and treat it with anti-corrosion paint.
24.2 Electrode Recommendations

Use only intact and clean electrodes that have been stored in a dry place. The generally
recommended type of electrode is ESAB OK 48.00, ESAB OK 48.30 or the equivalent in
accordance with the standard below:
ISO 2560 E51 5B 120 20 H
SS 14 3211 H10
DIN 1913 E51 55 B10
AWS A/SFA 5.1 E 7018
Table 12: Electrode recommendations

The use of MIG welding equipment is perfectly acceptable. The generally recommended
type of electrode is ESAB-OK Autorod 12,51 or equivalent in accordance with the standard
below:
SS 14 3403 3423
DIN 8559 SG 2
AWS A/SFA 5.18 ER 70 S-6
Table 13: MIG electrodes

If in any doubt, contact Epiroc for advice.
238 No: 6102429707.1.6102511883 en-US

Boomer S2 25 Downtime
25 Downtime
25.1 Preparations before Long Period of Downtime

Protect the equipment from corrosion and storage damage if downtime is expected to last
three months or longer. If environment is, for example, corrosive or dusty, extra protection
is necessary.
• Wash the equipment thoroughly and wipe it dry. Use compressed air to blow any col-
lections of water out of cavities and pockets.
• Protect from rain, snow, and strong sunshine. Keep regulated temperature and ventila-
tion. Recommended storage environments must maintain a temperature of 10 °C to 20
°C (50 °F to 68 °F) and maximum 20–50% humidity. Storage site must be free from
severe vibration to avoid spot damage to the equipment.
• Apply corrosion inhibitor (For example, Tectyl 506) to machined surfaces.
• Apply touch-up paint to any scratches and damage on painted areas.
• Cover all equipment with plastic sheet.
• Clean old lubricant grease from lubrication points to prevent coke formation. Apply lu-
bricant grease into the lubrication nipples. Apply lubricant grease with a brush to slid-
ing surfaces and splines where it occurs. Use the correct lubricant grease for each
point.
• Observe the strictest cleanliness when disassembling hydraulic, compressed air, and
water flushing hoses. Immediately plug all hoses, nipples and hydraulic oil pipes, or
seal and protect them from dirt in some other suitable way.
• Mark hoses, pipes, and other connections to make reassembly easier and prevent
mix-ups.
• Hoses and rubber parts must be packed in air-tight plastic to reduce aging and drying.
Make sure that the components are dry before packing.
• Fill fuel tanks and oil tanks.
25.1.1 Preparing Electrical System for Long Time Storage

If the temperature falls below freezing point then the battery must be stored indoors.
n Disconnect the battery terminal connections.
n Clean and grease battery terminal connections.
25.1.2 Preparing Water Mist System for Long Time Storage

1. Drain the water mist system.
2. Rinse with anti-freeze.
3. Blow dry the water mist system with compressed air.
25.2 Restoring after Long Period of Downtime

• Change lubricant and hydraulic oil where appropriate.
• Change filter and drain water separators where appropriate.
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Boomer S2 25 Downtime
• Inspect joints, bushings, and splines for corrosion. Remedy any corrosion by cleaning
or replacing components.
• To remove any moisture binding from lubrication points: Pump new grease into the
grease nipples and apply grease with a brush to splines and sliding surfaces. Use the
correct grease for each point.
• Carry out special startup as instructed.
25.3 Inspection and Maintenance during Period of

Downtime
• Check levels for oils and coolants.
• Start the diesel engine and run until the normal operating temperature is reached.
• Operate the machine a few metres back and forth so that the tramming gears are lubri-
cated.
• Operate the tilt cylinders, boom, feeder, drill rod support, and rod handling until all
cylinders reach their end positions.
• Drain condensed water from the hydraulic oil tank and compressor oil tank.
• Rotate the electric motors a few turns at least every three months to avoid spot dam-
age on motor bearings.
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Boomer S2 26 Start-Up
26 Start-Up
26.1 About Special Start-Up

Special start-up is performed when commissioning the machine for the first time. An Epiroc
representative will perform a special start-up procedure.
Special start-up of the machine and associated equipment is also performed in the follow-
ing cases:
• After a long standstill (one month or more)
• After major change of components or repairs
Maintenance personnel or an Epiroc representative must take part when starting up or dur-
ing a test start-up after maintenance.
26.2 Performing Special Start-Up
DANGER
Work in Operating Zone
Risk of serious personal injury or death.
u Stay out of the machine operating zone.
1. Follow up on any installation or maintenance work that has been carried out and com-
ponents that have been changed. These require special attention during special start-
up.
2. The pumps must be primed before start if the circuits have been drained.
3. At the time of start-up, the operator and any personnel present must stay out of the
operating zone of the machine. Maintenance personnel can enter this zone later. Op-
erators must remain with the operating console or remote panel in the immediate
vicinity of the emergency stop.
4. Check that the handheld fire extinguisher and fire fighting system are fully functional.
5. Pay extra attention to any electrical work are performed.
6. Listen for any noise that indicates defects. Stop the machine immediately if these
noises occur.
7. Look for any signs of overheating or fire.
8. After a special start-up, the operator and maintenance personnel must carry out re-
maining checks as instructed.
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Boomer S2 26 Start-Up
242 No: 6102429707.1.6102511883 en-US

Boomer S2 27 RCS Options
27 RCS Options
27.1 Service Tool Bag RCS

The service tool bag is used for troubleshooting machines that are equipped with Epiroc
RCS.
A CAN tester
B Resolver tester
C Multimeter
D Encoder tester
E CAN open cable
F I/O tester
G Signal cable
H Test cables
J Test box
K Connectors
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L Torque tools
M Torque tools
N Contact
27.2 Checking CAN Network

The power supply for the module, the CAN power supply and the CAN communication can
be measured and checked using the CAN test equipment.
CAN Test Equipment

Connect the CAN tester (B) on the multimeter (A). Make certain the pins are positioned
correctly as indicated by the colour coding. The red pin goes to V/Ohm on the multimeter.
Always use the torque tools to tighten cable connections.
Pin Function
1 Screen/Shield
2 CAN +
3 CAN -
4 CAN Hi
5 CAN Low
Table 14: Pin Configuration, CAN Inputs and Outputs, I/O Modules
Pin Function
1 NC/Not Connected
2 CAN +
3 CAN -
4 CAN Hi
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Pin Function
5 CAN Low
Table 15: Pin Configuration, CAN Inputs and Outputs, Other Modules
1. Set the multimeter range to DC volt.
2. Connect the 5-pin connectors of the tester to the CAN network requiring measure-
ment:
a. Decoder: contact X3 or X4
b. Display, application, and master modules: connector X2, X3, or X4
c. I/O modules: contact X1 or X19
d. Resolver modules: contact X3 or X4
è Main power (supply voltage) 24–28 V (shines green)
CAN power (CAN power supply) 20–24 V (shines green)
CAN Hi (CAN communication), about 2.5 V (flashes green)
CAN Low (CAN communication), about 2.3 V (flashes green)
Table 16: Normal State
CAN Hi glows red constantly for short circuit to ground
CAN Hi glows green constantly for voltage above 3.5 V
CAN Low glows green constantly for short circuit to ground
CAN Low glows red constantly for voltage above 3.5 V
If neither CAN Hi nor CAN Low is lit, there is no communication even though power
is being supplied to CAN.
If any light is flashing red, then CAN communication is at the wrong level or is in-
verted.
Table 17: Fault Indication
27.3 Checking CAN Power Supply

245 No: 6102429707.1.6102511883 en-US

CAN Test Equipment

Pin Function
1 Screen/Shield
2 CAN +
3 CAN -
4 CAN Hi
5 CAN Low
Pin Function
1 NC/Not Connected
2 CAN +
3 CAN -
4 CAN Hi
5 CAN Low
1. Set the multimeter range to DC volt.
2. Connect the 5-pin connector of the tester to the power supply of the module.
a. I/O modules: contact X25. 7-pin contact. Use enclosed T-cross.
b. Other modules: connector X1. 4-pin connectors.

è The power supply (main power) is between 24–28 V (lights green).
246 No: 6102429707.1.6102511883 en-US

27.4 Checking CAN Cable

CAN Test Equipment

Pin Function
1 Screen/Shield
2 CAN +
3 CAN -
4 CAN Hi
5 CAN Low
Pin Function
1 NC/Not Connected
2 CAN +
3 CAN -
4 CAN Hi
5 CAN Low
Precondition p The RCS is shut down.
1. Set the multimeter measuring range to ohms.
247 No: 6102429707.1.6102511883 en-US

2. Connect the 5-pin connectors of the tester to the CAN network requiring measure-
ment:
a. Decoder: contact X3 or X4
b. Display, application, and master modules: connector X2, X3, or X4
c. I/O modules: contact X1 or X19
d. Resolver modules: contact X3 or X4
3. Select cable test on the CAN tester.

è The multimeter reads about 60–65 Ohms if the cable is intact.
The multimeter reads 120 Ohms if the end plug is missing or there is a break in
a cable.
NOTE: Because of the internal resistance in the tester, the

! multimeter reads about 100 kOhm if the cables are not con-
nected or if there is an open circuit.
27.5 Checking Digital Inputs on I/O Module

Each designated contact has two digital inputs, A and B.
1. Connect the 5-position connector on the I/O tester between the input of interest on the
I/O model and the guard.
2. Connect the multimeter between ground and the signal A (+A) or signal B (+B) output
of interest.
3. Measure the voltage according to the table.
248 No: 6102429707.1.6102511883 en-US

è The signal is 0 V for an open contact and +24 V for a closed contact.
Pin Function
1 +24 V DC
2 Signal B
3 Ground
4 Signal A
5 Ground
Table 22: Pin Configuration
27.6 Checking Digital Outputs Voltage on I/O Module

Each designated contact has two digital outputs, A and B.
1. Connect the 5-position connector on the I/O tester between the output of interest on
the I/O module and the valve.
2. Connect the multimeter between ground and the signal A (+A) or signal B (+B) output
of interest.
3. Activate the function.
249 No: 6102429707.1.6102511883 en-US

è The multimeter reads 24 ±1 V.

If the valve is not activated, there can be an open circuit in the cable running to the
valve or in the coil in the valve.
Pin Function
1 +24 V DC
2 Signal B
3 Ground
4 Signal A
5 Ground
27.7 Checking Digital Outputs Current on I/O Module

Each designated contact has two digital outputs, A and B.
2. Connect the multimeter in series with the +A or +B output.
è The multimeter reads 1 A.

If the multimeter reads 0.00 A and the solenoid coil diode comes on, there could be
an open circuit in the valve coil.
250 No: 6102429707.1.6102511883 en-US

27.8 Checking PWM Outputs Current on I/O Module

Each designated contact has two PWM outputs, A and B.
2. Connect the multimeter in series with the +A or +B output that is of interest.
4. Check that the current corresponds with the actuated value on the display.
è Pin Function
1 Not Used
2 Out +B
3 Out -B
4 Out +A
5 Out -A
27.9 Checking Analog Inputs on I/O Module

Each designated contact has one analog input.
251 No: 6102429707.1.6102511883 en-US

1. Connect the 5-position connector on the I/O tester between the input of interest on the
I/O model and the sensor.
2. Measure the values according to the table.

è Pin Function
1 +24 V DC
2 0–5 V
3 Ground
4 4–20 mA
5 +5 V DC
27.10 Encoder Inputs

Each encoder connector has two signals, A and B.
There are two designated contacts, X12 and X18, for the pulse sensor.
Pin Function
1 +24 V DC
2 B
3 Ground
4 A
5 Ground
252 No: 6102429707.1.6102511883 en-US

27.11 Checking Resolver Module Resolver Inputs

For the inputsX6 - X9 there are designated contacts.
1. Connect the resolver tester to the relevant cable. Turn the test sensor slowly and
check that the angle shown on the sensor menu changes.
a. If the angle changes, the sensor on the boom is faulty.
b. If the angle does NOT change, the cable on the boom must be checked.
2. Connect the test sensor and test cable directly to the resolver module input. Turn the
test sensor slowly and check that the angle on the sensor menu changes.
a. If the angle changes, the cable on the boom is faulty
b. If the angle does NOT change, the resolver module is faulty.
Pin Function
1 Ref +
2 Ref -
3 Sine Signal
4 Sine Ground
5 Cosine Signal
6 Cosine Ground
27.12 Checking Resolver Module Encoder Inputs

There is a designated contact, X10, for the pulse sensor.
1. Connect the encoder tester to the relevant cable. Turn the test sensor slowly and
check that the length measurement shown on the sensor menu changes.
a. If the measured value changes, the sensor on the boom is faulty.
253 No: 6102429707.1.6102511883 en-US

b. If the measured value does NOT change, the cable on the boom must be
checked.
2. Connect the test sensor with test cable directly to the resolver module input. Turn the
test sensor slowly and check that the length measurement shown on the sensor menu
changes.
a. If the measured value changes, the cable on the boom is faulty.
b. If the measured value does NOT change, the resolver module is faulty.
Pin Function
1 + 15V
2 + 15V
3 Signal A
4 Ground
5 Signal B
6 Ground
27.13 Checking Resolver Module Analog Inputs

There are two designated connectors, X11 and X12, for analog input.
Pin Function
1 Ground
2 + 4.5-V DC power supply out
3 Signal in
4 Not Used
5 Not Used
Table 28: Pin Configuration for Input X11
Pin Function
1 Ground
254 No: 6102429707.1.6102511883 en-US

Pin Function
2 + 15-V DC power supply out
3 Signal in
4 Not Used
5 Not Used
Table 29: Pin Configuration for Input X12
1. Connect the resolver module connector X11 or X12 to test box connector (B).
2. Connect the multimeter to test box pins 2 and 3.
3. Set the multimeter to DC voltage.

It must read 4.5 V on connector X11 and 15 V on connector X12.
If the multimeter reading is 0 V, there could be a fault in the signal cable or resolver
module. Continue as follows:
a. Connect the cable (C) on the test box to resolver module input X11 or X12 and
measure 1 and 2.
b. Recheck the multimeter reading.

If it is 0 V, there is a fault on the resolver module input, X11 or X12.
27.14 Replacing RCS Module
! NOTE: Avoid starting the engine/motor while the program is being loaded.
! NOTE: Do not turn off the system while the program is being loaded.
Precondition p The electric power is present at the machine or that the engine/motor is running before
loading the program.
1. Make sure that the module has the correct address plug and that the end plug (if any)
is put in place.
2. Read the program into the system again when any of the application modules, I/O, or
resolver module is replaced.
3. Insert the USB memory stick with the program into the USB port.
4. Start the RCS.
5. Follow the instructions on the display.

è Remove card and restart the system! appears on the display when the pro-
gram is fully loaded.
6. Switch off the RCS.
7. Remove the USB memory stick.
8. Start the RCS.
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256 No: 6102429707.1.6102511883 en-US

Boomer S2 28 Component Locations
28 Component Locations
28.1 Overview
The component locations vary depending on the options with which the machine is
equipped.
A Feed Module
B Boom Module
C Front Module
D Middle Module
E Rear Module
F Power Module
G Cab Module
257 No: 6102429707.1.6102511883 en-US

28.2 Front Module
Location of Valves, Sensors, and Pressure Test Outlets - Front Module
Hydraulic Valve Description
Y101 Flow control percussion
Y102A Rotation left
Y102B Rotation right
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Y103 Feed pressure
Y104A Feed forward
Y104B Feed backward
Y106 Lubrication system ECL pump
Y110 Full water flow
Y112 Water injection
Y115 Full air flow
Y117 Lubrication air off
Y156 Air condition compressor
Y184A Main feed reverse
Y184B Main feed forward
Y411 Front jack (left)
Y412 Front jack (right)
Y423 Extension (front jacks)
Y436 Protective roof
Y450 Anti-parallel valve
Y451A Feed extension in
Y451B Feed extension out
Y452A Boom extension out
Y452B Boom extension in
Y453A Feed inclination cylinder out
Y453B Feed inclination cylinder in
Y455A Boom cylinder left rear out
Y455B Boom cylinder left rear in
Y456A Boom cylinder right rear out
Y456B Boom cylinder right rear in
Y457A Front left boom cylinder in
Y457B Front left boom cylinder out
Y458A Front right boom cylinder in
Y458B Front right boom cylinder out
Y459A Front feed rotation, clockwise
Y459B Front feed rotation, counterclockwise
259 No: 6102429707.1.6102511883 en-US

Y473A Basket cylinder out
Y473B Basket cylinder in
Y501 Air cooling hydraulic oil
Y608A Stair platform
Y608B Stair platform
Sensor Description
B100 Percussion pressure
B101 Rotation pressure
B121 Drill rod, drilling completed
B133 Feed pressure
B136 Water pressure
B141 Waterflow switch
B142 Flow switch, air
B250 Water flow sensor
B263 Main feed max forward
B264 Main feed position
B268 Pos. pressure pump
B300 Boom swing
B301 Boom lift
B302 Feed rotation
B303 Feed inclination
B305 Feed extension position
B306 Boom extension position
B307 Rock drill position
B309 Feed swing
B310 Feed lift
B312 Inclination Y
B313 Inclination X
B314:1 Barrier sensor left
B314:2 Barrier sensor right
B368 ECL oil pressure
B380 ECL oil level
260 No: 6102429707.1.6102511883 en-US

28.3 Rear Module
Valves - Rear Module
Y162 Water pump
Y162:2 Water mist pump (option)
Y171 Compressor GAR 30 on and off (option)
Y174 Water cooling hydraulic oil
Y189 Compressor boost (option)
Y226 Fuel flow shutdown
Y230 Cable reel guide (option)
261 No: 6102429707.1.6102511883 en-US

Y231 Hose reel guide (option)
Y410 Rear jacks
Y414 Cable reel
Y415 Hose reel (option)
Y501 Air cooling hydraulic (option)
Sensor Description
B139 Pressure switch, return filter
B325 Hydraulic pump overload
B326 Drain pump overload
B327 Incorrect phase sequence
B328 Drain pump ground fault
B329 Drain pump pilot damaged
B330 Drain pump started
B334 Water level fuel filter
B348:2 Fire suppression pressure switch
B352 Fuel level
B353 Diesel engine running
B358 Cable reel limit switch
B360 Air filter
B361 Coolant level
B366 Compressor temperature switch
B490 Drilling stop signal
B677 Current motor
B678 Voltage incoming
Electrical Cabinet and Fuse Box Description
A10 Electrical cabinet
A41 Emergency stop box with pilot test button
A50 Main connection box for carrier electrics
A300 Battery electric cabinet
262 No: 6102429707.1.6102511883 en-US

28.4 Power Module, Middle Module
Valves, Sensors, and Pressure Test Outlets - Power Module
Y117:2 Ventilation membrane dryer
Y172 Percussion, Position pump
Y210 Compressor loading
Y218 Gear change valve second gear
Y219 Gear change valve reverse
Y220 Gear change valve forward
Y221 Gear change valve third gear
Y233 Lubrication carrier
Sensor Description
B132 Damper pressure boom
263 No: 6102429707.1.6102511883 en-US

Sensor Description
B143 Hydraulic oil level
B188 Air pressure ECL lubricating air
B268 Pos. pressure pump
B324 Level sensor hydraulic oil
B350 Brake fluid pressure switch
B351 Parking brake pressure switch
B355 Transmission oil pressure indication switch
B362 Hydraulic oil temperature
B364 Brake light pressure switch
B381 Air condition pressure switch
B382 Foot throttle
Electrical Cabinet and Fuse Box Description
A48 Emergency stop connection box
A74 Connection panel in cab or canopy
264 No: 6102429707.1.6102511883 en-US

28.5 Cab Module
Valves, Sensors, and Pressure Test Outlets - Cab Module
Y203 Diesel pos valve
Y216 Parking brake valve
Sensor Description
B350 Brake fluid pressure switch
B351 Parking brake pressure switch
265 No: 6102429707.1.6102511883 en-US

Sensor Description
B364 Brake light pressure switch
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Boomer S2 29 Maintenance Schedule
29 Maintenance Schedule
Calendar Time
Maintenance Task Calendar Time
5.1 Wash Machine Externally Daily
5.2 Check Condition of Signs Daily
5.3 Check Condition of Hatches and Locks Daily
11.5 Check Hydraulic Hoses and Couplings Daily
11.6.4 Filling Hydraulic Oil Daily
12.9 Filling Fuel Manually Daily
14.10 Fill Diesel Exhaust Fluid (DEF) Tank Daily
18.5 Check Compressor Daily
21.10.1 Check Service Brake Daily
7.2 Check the Seat Swivel Arm Weekly
12.5 Clean Diesel Engine Monthly
6.2 Check Ansul Firefighting System Biannually
18.5 Check Compressor Biannually
6.4 Replace Ansul Fire Fighting System Protective Caps Annually
6.5 Check Forrex Firefighting System Annually
11.6.7 Clean Hydraulic Tank Annually
12.6 Check Engine Monitoring System Annually
12.12 Annual Replacement of Primary Filter Annually
12.13 Replace Fuel Primary Filter Annually
12.21.1 Every Second Year Replacement of Air Filter Cartridge Every Second Year
12.21.2 Replace Air Filter Cartridge Every Second Year
13.4 Replace Coolant Every Second Year
14.14 Every Second Year Replacement of DEF Supply Pump Filter Every Second Year
Cartridge
14.15 Replace Diesel Exhaust Fluid (DEF) Supply Pump Filter Car- Every Second Year
tridge
6.3 Replace Protracting Actuation Device Every Fifth Year
267 No: 6102429707.1.6102511883 en-US

Diesel Engine Hours First Service

Diesel Engine Hours First
Maintenance Task Service
12.3 Commissioning New or Overhauled Diesel Engine 4
12.15 Check Belt Wear 50
20.5 First Replacement of Oil in Central Housing 250
20.8 First Replacement of Oil in Planetary Gear 250
Diesel Engine Hours
Maintenance Task Diesel Engine Hours
6.6 Loosen up Powder in Handheld Fire Extinguisher 50
13.8 Clean Fan Housing 50
20.16 Check Tire Pressure 50
22.2 Check Tightening Torque of Cable Reeling Unit Collector 50
22.3 Check Cable Reeling Unit Collector 50
22.4 Clean Cable Reeling Unit Collector 50
13.7 Clean Flanges of Cooling Elements 100
13.9 Clean Cooling System Exterior 100
17.3 Lubricate Battery Connections 100
21.2 Check Service Brake Pressure 100
21.4 Check Parking Brake Pressure 100
11.9.3 Adjusting Maximum Pressure and Speed of Reeling Unit 250
20.4 Check Oil Level in Central Housing 250
20.5 First Replacement of Oil in Central Housing 250
20.7 Check Oil Level in Planetary Gear 250
20.8 First Replacement of Oil in Planetary Gear 250
20.10 Check Carrier Central Lubrication 250
20.13 Lubricate Cardan Shaft Spline 250
20.15 Check Tightening Torque on Wheel Bolts and Nuts 250
23.5 Fill Lubricant 250
12.7 Replace Engine Oil 500
12.8 Replace Engine Oil Filter 500
12.10 Drain Fuel Tank 500
268 No: 6102429707.1.6102511883 en-US

Maintenance Task Diesel Engine Hours
12.18 Check Tightening Torque on Engine Suspension Bolts 500
12.20 Check Hoses for Fuel and Air Intake Systems 500
12.21.2 Replace Air Filter Cartridge 500
12.21.3 Replace Air Filter Safety Cartridge 500
13.2 Check Coolant Concentration 500
14.6 Start Standstill Regeneration 500
14.15 Replace Diesel Exhaust Fluid (DEF) Supply Pump Filter Car- 500
tridge
20.18 Replace the Tramming Pump Filter 500
21.6 Check Brake Discs 500
22.5 Check Reeling Unit Drum 500
22.6 Check Reeling Unit Drive Chain 500
7.1 Check FOPS and ROPS Approved Cab 1000
11.7.2 Replace Remote Return Oil Filter 1000
12.13 Replace Fuel Primary Filter 1000
12.14 Replace Fuel Secondary Filter 1000
12.15 Check Belt Wear 1000
12.17 Check Engine Pads 1000
12.19 Replace Engine Pads 1000
12.21.4 Check Air Filter Indicator Lamp Function 1000
13.6 Drain Charge Air Cooler 1000
17.2 Check the Extra Low Voltage Battery 1000
20.6 Replace Oil in Central Housing 1000
20.9 Replace Oil in Planetary Gear 1000
12.16 Replace Multi-belt 2000
20.14 Check Articulated Joint 2000
Drilling Hours
Maintenance Task Drilling Hours
7.3 Check Electric Heater 50
7.5 Check Fresh Air Filter and Recirculation Filter 50
7.6 Check Air Conditioning Unit 50
269 No: 6102429707.1.6102511883 en-US

Maintenance Task Drilling Hours
8.12 Check Hoses, Cylinders, Valves, and Valve Plates 50
8.13 Check Hydraulic Pressure 50
9.4 Check Pull and Return Rope on Feeder 50
9.5 Check Drill Steel Bushings on Feeder 50
9.6 Check Slide Rails on Feeder 50
9.7 Check Dowel on Feeder 50
9.8 Check Slide Pieces on Feeder 50
9.9 Check Tightening Torque on Feeder 50
9.11 Clean Feed Unit 50
9.25 Lubricate Pulleys and Hose Drum 50
11.6.3 Check Oil Level in Carrier Hydraulic Tank 50
11.6.5 Drain Condensate from Hydraulic Oil Tank 50
11.7.3 Check Hydraulic Tank Breather Filter 50
18.2 Drain Condensate from Air Tank 50
18.7 Check Air Filter of Compressor 50
18.10.4 Check Membrane Dryer SDR6 Particle Filter 50
19.12.1 Check Water Mist Pump for Leaks 50
23.2 Test Central Lubrication System 50
19.7 Check Water Pump Shaft Seal 100
9.22 Check Limit Switches 250
9.23 Check Hydraulic Cylinder on Feeder 250
9.24 Check Pulleys and Hose Drum 250
11.7.5 Replace Breather Filter 250
18.4 Check Hoses and Connections of Compressor 500
18.6 Check Safety Valve of Compressor 500
18.8 Clean Air Filter of Compressor 500
18.9 Clean Compressor 500
11.7.1 Replace Return Oil Filter 1000
18.10.2 Check Membrane Dryer SDR6 1000
18.3 Check Cables and Plugs of Compressor 2000
270 No: 6102429707.1.6102511883 en-US

29 Maintenance Schedule
271 No: 6102429707.1.6102511883 en-US

2018-03-19 | No: 6102429707.1.6102511883
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Boomer S2

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

4 Machine Isolation and Lock-Out........................................................................ 17

5 General Machine Condition................................................................................ 19

6 Fire Fighting Equipment..................................................................................... 21

7 Operator Environment ........................................................................................ 23

iii No: 6102429707.1.6102511883 en-US

7.10 Troubleshooting Climate Control Unit ................................................................................... 30

8 Boom Unit ............................................................................................................ 33

iv No: 6102429707.1.6102511883 en-US

9.27 Disassembling Feeder from Boom......................................................................................... 78

10 Drill Rod Support ................................................................................................ 85

11 Hydraulic System ................................................................................................ 89

12 Diesel Engine..................................................................................................... 111

v No: 6102429707.1.6102511883 en-US

12.8 Replace Engine Oil Filter....................................................................................................... 116

13 Cooling System ................................................................................................. 133

14 Exhaust System ................................................................................................ 143

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15 Electrical System, IEC ...................................................................................... 155

16 Electrical System, Canada ............................................................................... 163

17 Extra Low Voltage Battery................................................................................ 171

18 Pneumatic System ............................................................................................ 177

vii No: 6102429707.1.6102511883 en-US

18.1 Safety Precautions before Working on Pneumatic System ............................................... 177

19 Water System .................................................................................................... 187

20 Power Train........................................................................................................ 199

viii No: 6102429707.1.6102511883 en-US

20.14Check Articulated Joint ......................................................................................................... 206

21 Brake System .................................................................................................... 213

22 Reeling Unit ....................................................................................................... 227

23 Lubrication System........................................................................................... 233

24 Welding .............................................................................................................. 237

25 Downtime ........................................................................................................... 239

ix No: 6102429707.1.6102511883 en-US

25.2 Restoring after Long Period of Downtime ........................................................................... 239

26 Start-Up .............................................................................................................. 241

27 RCS Options ...................................................................................................... 243

28 Component Locations ...................................................................................... 257

29 Maintenance Schedule ..................................................................................... 267

x No: 6102429707.1.6102511883 en-US

1.1 Safety First

1.2 The Purpose of This Publication

1.3 Target Group

1.4 Product Warranty

1.5 Feedback and Contact Information

11 No: 6102429707.1.6102511883 en-US

12 No: 6102429707.1.6102511883 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

2.3 Oil Analysis

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14 No: 6102429707.1.6102511883 en-US

3.1 Tightening Torques for Bolted Joints

See Reference Documentation

Mining and Rock Excavation Torque Specifications

3.2 Type Designation Signs for Ordering Spare Parts

15 No: 6102429707.1.6102511883 en-US