Standard Operating Procedure

Main Hydraulic Pump

Removal and Installation
Boomer S1 D

Original Instructions
2021-06-08 | No: TIS0001207.002 en-US
Main Hydraulic Pump Removal and Installation Table of Contents

Table of Contents
1 Customer Acknowledgment ................................................................................. 5

2 General Information............................................................................................... 7
2.1 Introduction ............................................................................................................................... 7
2.2 Qualifications / Licenses Required ......................................................................................... 7
2.3 Terms and Abbreviations ......................................................................................................... 7
2.4 Manufacturer's Information...................................................................................................... 8

3 Safety ...................................................................................................................... 9
3.1 Safety First ................................................................................................................................ 9
3.2 Job Safety and Environmental Analysis (JSEA) .................................................................... 9
3.3 Risk Factors .............................................................................................................................. 9
3.4 Safety Precautions Before and During the Work ................................................................. 10
3.5 Personal Protective Equipment ............................................................................................. 10

4 Preparations and Prerequisites.......................................................................... 11

4.1 Labor Resource (People/Skills) ............................................................................................. 11
4.2 Technical Data......................................................................................................................... 11
4.3 Machine Technical Data ......................................................................................................... 11
4.4 Component Technical Data.................................................................................................... 11
4.5 Tools ........................................................................................................................................ 11
4.6 Support Equipment................................................................................................................. 12
4.7 Consumables .......................................................................................................................... 12
4.8 Spare Parts .............................................................................................................................. 12
4.9 Suggested Time Required (Standard Planning Hours) ....................................................... 13
4.10 Reference Documentation ..................................................................................................... 13

5 Removing the Main Hydraulic Pump ................................................................. 15

6 Installing the Main Hydraulic Pump ................................................................... 29

7 Testing the Main Hydraulic Pump Operation .................................................... 39

8 Procedure Compliance........................................................................................ 43
8.1 Procedure Acknowledgement ............................................................................................... 43
8.2 Adherence and Compliance................................................................................................... 43

9 Procedure Report ................................................................................................ 45

9.1 Machine / Component Details ................................................................................................ 45
9.2 Task Specifications ................................................................................................................ 45

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Main Hydraulic Pump Removal and Installation Table of Contents

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Main Hydraulic Pump Removal and Installation 1 Customer Acknowledgment

1 Customer Acknowledgment

Use only Epiroc original parts. Damage or breakdown that is caused by non-original spare
parts are not covered by the warranty or product liability.
Epiroc is not held responsible for damages that are caused by unauthorized modification of
the machine and its associated equipment.
The manufacturer is not liable for damage that is caused by inappropriate use.
The following damages are not covered by the customer warranty policy:
• Damage from substandard repairs,
• Injury to personnel from unresolved repairs,
• Damage to equipment from unresolved repairs.
Always refer to the customer warranty policy.
Performance specifications are based on maximum computed values and are subject to re-
visions without notification. Nothing in this instruction extends any warranty or representa-
tion expressed or implied, regarding the products described. Any such warranties or other
terms and conditions shall be in accordance with Epiroc standard terms and conditions of
sale for such products, which are available upon request.
Specifications represented herein are calculated values at 100% efficiency. Epiroc is con-
stantly striving for product improvements and enhancements. Accordingly, Epiroc reserves
the right to make such changes in specifications and design as the company considers in
conformity with this policy or due to unavailability of materials or assemblies.

© 2021 Epiroc Rock Drills AB. All rights reserved.

Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in partic-
ular to trademarks, model denominations, text, illustrations, and photographs.

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Main Hydraulic Pump Removal and Installation 1 Customer Acknowledgment

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Main Hydraulic Pump Removal and Installation 2 General Information

2 General Information

2.1 Introduction
This SOP provides an administrative control to help manage the hazards and risks of doing
the task of Component Removal and Installation.
As a preface to using this SOP, all other types of controls, such as elimination, substitution,
isolation, and engineering must be considered and implemented.

2.2 Qualifications / Licenses Required

THIS PROCEDURE IS ONLY FOR EPIROC-CERTIFIED TECHNICIANS.
Service technicians/workers doing this maintenance procedure must have a Service Level
1 or Service Level 2 certification.
This task serves numerous customer jurisdictions. If a particular procedure or clause con-
flicts with the site-specific requirements or a particular country’s occupational health and
safety standards, the responsibility rests on the user to amend those procedures or
clauses, as applicable.

2.3 Terms and Abbreviations

Term Definition

Job Safety and Environmental Local job risk observation tool, used for job hazard identification
Analysis and determination of how to manage the risk through appropriate
control measures.

Technician A person who is qualified to do the work according to local regula-

tions and requirements.

Approved lifting device A device that is connected to, or applied on, a component for the
purpose of lifting it. The device must fulfil local regulations and re-
quirements for the lifting operation. All lifts must be assessed and
calculated by an approved person inclusive of rigging selection
and placement on the load to determine the safe lifting methods
that are applied.

Machine The complete Epiroc machine that the component is located

within.

Equipment Auxiliary equipment to assist task operations, including but not

limited to Lifting Devices, Compressors, Tooling.

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Main Hydraulic Pump Removal and Installation 2 General Information

Abbreviation Definition

JSEA Job Safety and Environmental Analysis

PPE Personal Protective Equipment

psig pounds per square inch gauge

2.4 Manufacturer's Information

Sweden USA
Epiroc Rock Drills AB Epiroc Drilling Solutions, LLC
Klerkgatan 21 2100 North First Street
Örebro, 701 91 Garland, Texas 75040 - USA

India India
Epiroc Mining India Limited Epiroc Mining India Limited
Phoenix Market City, Viman Nagar 90, MIDC, Satpur
Pune, 411014 Nashik, 422007

China Japan
Epiroc (Nanjing) Construction and Mining Equipment Epiroc Japan K.K.
Limited 50-1, Kawawa-cho, Tsuzuki-ku
2, Hengtai Road Yokohama 224-0057, Japan
Nanjing Economic and Technological Development
Zone
Nanjing, 210033

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Main Hydraulic Pump Removal and Installation 3 Safety

3 Safety

3.1 Safety First

The person or persons doing the tasks contained in this document must be qualified in ac-
cordance with local regulations and requirements. It is the duty of all personnel involved in
doing the tasks to read and understand the machine-specific Safety, Operation, Mainte-
nance, and Isolation manuals and any other documentation specifically referenced in this
document before starting any work on the machine.
The instructions include specific safety messages that are marked with Danger, Warning,
Caution, Notice, or Note. Give extra attention to these messages, as they contain addi-
tional information to the instruction text. Comply with any local safety rules that are specific
to the work location.
Use this instruction in conjunction with a local Job Safety and Environmental Analysis (or
equivalent) to identify and manage hazards.

3.2 Job Safety and Environmental Analysis (JSEA)

Job Safety and Environmental Analysis provides job hazard identification, potential risk as-
sessment, and suggested controls for the tasks that are described in this instruction. All
persons involved in the task must create a JSEA for the job or task on the physical objects
in front of them, and consider any local conditions, environmental hazards, and risks.
Remove or minimize all of the hazards that are identified before you begin work.
If hazards cannot be reduced to an acceptable level of risk, do a complete review of the
site-specific JSEA.

NOTE: Refer to local or site-specific regulations and the JSEA or equivalent type of
! job-risk-assessment documentation.

3.3 Risk Factors

• Hot fluids or components
• High-pressure system
• Slipping hazard
• Environmental contaminant
• Energized equipment
• Crushing hazard
• Heavy components
• Pinch points

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Main Hydraulic Pump Removal and Installation 3 Safety

3.4 Safety Precautions Before and During the Work

¡ All the persons who are involved in this task must be aware of hazards on and
around the machine.

¡ Refer to the machine-specific safety manual.

¡ Person maneuvering the machine must be a competent operator.

¡ Follow the machine specific operating instructions whenever maneuvering the ma-
chine or machine functions.

¡ Use the correct personal protective equipment.

¡ Use lifting equipment that is in correct condition and with adequate lifting capacity
at all times.

¡ Do not lift heavy objects above your personal capability.

¡ Be careful when you attach and secure the lifting device to the individual parts and
to the large assemblies being moved for replacement purposes to avoid the risk of
accidents.

¡ Do not work or stand below suspended loads at any time.

¡ Be careful of machine movement that can cause personal injury or death.

¡ Do not let used oil drain onto the ground.

¡ Obey all local standards and regulations for discarding the used oil.

¡ Plug the hoses when you replace a pump.

¡ Replace a pump with the same size and type.

¡ Use the correct adapters when installing a pump.

3.5 Personal Protective Equipment

Make sure that all necessary personal protective equipment (PPE) is available and prop-
erly used when doing this procedure, including:
• Head – Hard hat
• Ears – Hearing protection
• Eyes – Safety glasses
• Hands – Applicable gloves
• Feet – Safety shoes with steel toes
• Safety devices
Obey all site-specific standard PPE requirements, mandatory area PPE regulations, and
any other PPE requirements identified in the risk assessment.

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Main Hydraulic Pump Removal and Installation 4 Preparations and Prerequisites

4 Preparations and Prerequisites

4.1 Labor Resource (People/Skills)

Service Technicians x 2
Crane Operator x 1

4.2 Technical Data

To select correct lifting devices, stands, and tools, refer to the technical data as detailed
throughout the instruction sections.

NOTE: Due to the variation of machine options and components, actual values can dif-
! fer from data. Data is for reference only.

4.3 Machine Technical Data

See machine-specific manuals for weight, dimensions, and other data relevant to bringing
the machine to the work area and doing the task.

4.4 Component Technical Data

Description Data Remarks

Main hydraulic pump 56 kg (123 lb)

Gear pump 19 kg (42 lb)

Valve block 25 kg (55 lb)

4.5 Tools

Description Specification

Standard mechanic toolkit

Torque wrench, calibrated 3/4-in drive, capacity up to 76 N⋅m (56 ft⋅lb)

Pressure gauge 0-400 bar (0-5,802 psig)

Tags As required

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Main Hydraulic Pump Removal and Installation 4 Preparations and Prerequisites

4.6 Support Equipment

Description Specification

Crane As required

Lifting equipment As required

Container 60 L (16 gal)

Container (for hydraulic tank) 205 L (54 gal)

Vacuum pump As required

Wheel chocks As required

Maintenance stands As required

Oil drain hose assembly As required

4.7 Consumables

Description Specification Quantity

Covers - As required

JIC female plugs 3/8 in (10 mm) 7

JIC male plugs 3/8 in (10 mm) 7

JIC female plugs 1/2 in (13 mm) 4

JIC male plugs 1/2 in (13 mm) 4

JIC female plugs 3/4 in (19 mm) 2

JIC male plugs 3/4 in (19 mm) 2

JIC female plugs 1 in (25 mm) 1

JIC female plugs 1 in (25 mm) 1

JIC male plugs 5/8 in (16 mm) 2

JIC male plugs 5/8 in (16 mm) 2

Hose clamps HD suction hose clamps 4

Oil absorbent materials - As required

4.8 Spare Parts

NOTE: To create an order list request for the spare parts, refer to the Spare Parts Cat-
! alog for your specific machine model and serial number.

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Main Hydraulic Pump Removal and Installation 4 Preparations and Prerequisites

Description Specification Quantity

O-rings - As required

4.9 Suggested Time Required (Standard Planning Hours)

Ref. Section Description Planned Time (HH:MM)

5,6,7 Main Hydraulic Pump Removal and Installation 06:00

4.10 Reference Documentation

The following list of reference material relates to this instruction. Additional specific docu-
mentation is referenced at each applicable step.

NOTE: The listed documentation must be available in valid version at the location
! where the job is being done.

Manual Reference

Safety Manual Model Specific

Operation Manual Model Specific

Service/Maintenance Manual Model Specific

Mining and Rock Excavation Torque Specification No. 1185028747

Spare Parts Catalog Machine Specific (per serial number)

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Main Hydraulic Pump Removal and Installation 4 Preparations and Prerequisites

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Main Hydraulic Pump Removal and Installation 5 Removing the Main Hydraulic Pump

5 Removing the Main Hydraulic Pump

1. Position the machine for the task as follows:

a. Align the machine in position.

b. Apply the parking brake.

c. Stop the machine.

d. Attach safety locks and tags to the machine in accordance with the site-specific
procedures.

e. Install the articulation lock bar onto the load frame and power frame pins.

f. Insert the cotter pins to secure the articulation lock bar (A, Figure 1) with the
load frame and power frame pins.

Figure 1

WARNING
Energized Machine
Can cause serious injury.
u The machine must be fully energized and the engine must be
switched on to complete this procedure.
u Be careful around moving parts and pinch points.

g. Inform the supervisor, lead hand, and all other persons who are concerned of
the intent to restart the machine.

NOTE: Make sure that all personnel and bystanders are clear
! of the machine before start-up.

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Main Hydraulic Pump Removal and Installation 5 Removing the Main Hydraulic Pump

h. Remove the safety locks and tags from the machine in accordance with the
site-specific procedures.

i. Start the machine.

WARNING
Accidental Movements
Can cause serious injury or death.
u Make sure that no one is at danger or hazard zone before you
start or operate the machine.

j. Place the boom in center position as low as possible (Figure 2).

Figure 2

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Main Hydraulic Pump Removal and Installation 5 Removing the Main Hydraulic Pump

k. Raise the machine with the machine jacks at front (Figure 3A) and rear (Figure
3B).

Figure 3A

Figure 3B

l. Stop the engine.

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Main Hydraulic Pump Removal and Installation 5 Removing the Main Hydraulic Pump

m. Attach safety locks and tags to the machine according to the site-specific proce-
dure.

WARNING
Heavy Components
Lifting the heavy components by hand can cause body or
muscle strains.
u Position the body accordingly to support the weight of the
component.

n. Put maintenance stands in the approved area (Figure 4).

Figure 4

WARNING
Energized Machine
Can cause serious injury.
u The machine must be fully energized and the engine must be
switched on to complete this procedure.
u Be careful around moving parts and pinch points.

o. Inform the supervisor, lead hand, and all other persons who are concerned of
the intent to restart the machine.

NOTE: Make sure that all personnel and bystanders are clear
! of the machine before start-up.

p. Remove the safety locks and tags from the machine in accordance with the
site-specific procedures.

q. Start the machine.

WARNING
Accidental Movements
Can cause serious injury or death.
u Make sure that no one is at danger or hazard zone before you
start or operate the machine.

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Main Hydraulic Pump Removal and Installation 5 Removing the Main Hydraulic Pump

NOTE: Make sure that the machine jacks are still in contact
! with the ground.

r. Lower the machine onto the maintenance stands and do the check for the ma-
chine stability.

s. Stop the engine and isolate the machine with the battery isolation switch.

t. Attach safety locks and tags to the machine according to the site-specific proce-
dure.

WARNING
High-Pressure System
Working with pressurized systems can cause personal injury.
u Do not do the maintenance work when operating the ma-
chine.
u Make sure that the hydraulic, water, and air systems are de-
pressurized before you start to work on these systems.
u Put on applicable gloves.

u. Release the stored energy from the hydraulic brake system.

! NOTE: Make sure that there is no pressure in the system.

v. Release the stored energy from the hydraulic tank and system.

! NOTE: Make sure that there is no pressure in the system.

w. Release the stored energy from the air tank and system.

! NOTE: Make sure that there is no pressure in the system.

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Main Hydraulic Pump Removal and Installation 5 Removing the Main Hydraulic Pump

2. Remove the breather filter (A, Figure 5) from the hydraulic tank.

Figure 5

3. Drain the oil from the hydraulic tank as follows:

WARNING
Slipping Hazard
Fluid leaks or spills can cause personal injury.
u Cover all of the open ports.
u Wipe off any spilled fluid immediately.

a. Put a container below the hydraulic tank to collect oil while draining.

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Main Hydraulic Pump Removal and Installation 5 Removing the Main Hydraulic Pump

b. Remove the plug from the ball valve (A, Figure 6) and connect a hose to collect
the oil in the container.

Figure 6

WARNING
Hot Fluids or Components
Hot fluids or components can burn.
u Fluids must be at a safe working temperature when you drain
it.
u Do not touch hot fluids or components.

c. Open the ball valve (A, Figure 6) and drain the oil from the tank.

NOTE: Make sure that the oil has been drained completely
! from the hydraulic tank.

d. Close the ball valve.

e. Remove the hose and install the plug onto the ball valve.

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Main Hydraulic Pump Removal and Installation 5 Removing the Main Hydraulic Pump

f. Put a tag on the battery isolation switch notifying that the oil has been drained
from the hydraulic tank.

CAUTION
Environmental Contaminant
Oil is an environmental contaminant and must be discarded
correctly.
u Do not let the used oil drain onto the ground.
u Discard the used oil in accordance with local environmental
regulations.

g. Remove the container and discard the used oil in accordance with local envi-
ronmental regulations.

4. Remove the bolts (A, Figure 7) that secure the protection plate (B, Figure 7), if
equipped.

Figure 7

5. Disconnect the hoses from the pump assembly as follows:

WARNING
Slipping Hazard
Fluid leaks or spills can cause personal injury.
u Cover all of the open ports.
u Wipe off any spilled fluid immediately.

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Main Hydraulic Pump Removal and Installation 5 Removing the Main Hydraulic Pump

a. Put a container or absorbent materials below the main hydraulic pump to collect
the oil spill while disconnecting the hoses.

WARNING
High Pressure
Residual pressure can cause personal injury.
u Loosen the fittings carefully to release the pressure fully be-
fore you disconnect and cap the hoses.

b. Clean, label, and disconnect all of the hoses (A, Figure 8) that are connected to
the valve block. Plug the hoses and cap the fittings immediately.

! NOTE: Leave the valve block with the main pump.

Figure 8

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Main Hydraulic Pump Removal and Installation 5 Removing the Main Hydraulic Pump

c. Clean, label, and disconnect the hoses (A, Figure 9) that are connected to the
hydraulic pump. Plug the hoses and cap the fittings immediately.

Figure 9

d. Clean, label, and disconnect the hoses (A, Figure 10) that are connected to the
main hydraulic pump. Plug the hoses and cap the fittings immediately.

Figure 10

CAUTION
Environmental Contaminant
Oil is an environmental contaminant and must be discarded
correctly.
u Do not let the used oil drain onto the ground.
u Discard the used oil in accordance with local environmental
regulations.

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Main Hydraulic Pump Removal and Installation 5 Removing the Main Hydraulic Pump

e. Remove the container or absorbent materials from below the main hydraulic
pump and discard the used oil in accordance with local environmental regula-
tions.

6. Remove the pump assembly from the machine as follows:

WARNING
Crushing Hazard
Can cause personal injury.
u Lifting equipment must be adequately sized, have the correct lift-
ing capacity, and be in good condition.
u Be careful when you lift heavy components.

a. Secure the pump assembly with an approved lifting device and support the
weight (Figure 11).

Figure 11

WARNING
Accidental Movements of Pump
Accidental movements when removing the bolts engaging the
pump can cause serious personal injury.
u Examine the unwanted pump movement with a spotter while
removing the bolts.
u Remove all of the bolts only when the pump is secured and
does not move.

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Main Hydraulic Pump Removal and Installation 5 Removing the Main Hydraulic Pump

b. Remove the two bolts (A, Figure 12) and the washers (B, Figure 12) that secure
the pump assembly to the clutch case.

Figure 12

WARNING
Crushing Hazard
Unexpected movement of parts can cause personal injury or
death.
u Do not put any part of your body on the object when lifting,
moving, or lowering it.
u Do not go in, reside, or put body parts below unsecured,
moveable, or lifted parts.
u Do not put hands and fingers in the pinch point areas when
installing or tightening the parts.
u Stay away from moving parts.

c. Lower the pump assembly from the clutch case and put it on to the pallet.

d. Remove the attached lifting device from the pump assembly.

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Main Hydraulic Pump Removal and Installation 5 Removing the Main Hydraulic Pump

7. Transfer the shaft coupling (A, Figure 13) and disc (B, Figure 13) from the old pump
to the new pump.

Figure 13

8. Remove the hydraulic pump from the main pump assembly as follows:

WARNING
Crushing Hazard
Can cause personal injury.
u Lifting equipment must be adequately sized, have the correct lift-
ing capacity, and be in good condition.
u Be careful when you lift heavy components.

a. Secure the hydraulic pump with an approved lifting device (Figure 14).

Figure 14

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Main Hydraulic Pump Removal and Installation 5 Removing the Main Hydraulic Pump

b. Remove the bolts (A, Figure 15) that secure the hydraulic pump (B, Figure 15)
to the main pump assembly (C, Figure 15).

Figure 15

c. Remove the hydraulic pump (B, Figure 15) and put it in a safe location for rein-
stallation.

d. Remove the attached lifting device from the hydraulic pump and secure it
safely.

NOTE: Plug all the open ports on the main pump to avoid oil
! leaks.

9. Attach a notifying tag on the battery isolation switch stating that the main pump as-
sembly is removed from the machine.

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Main Hydraulic Pump Removal and Installation 6 Installing the Main Hydraulic Pump

6 Installing the Main Hydraulic Pump

1. Make sure that the machine is isolated and, if necessary, isolate the machine with
the battery isolation switch.

2. Prepare the main pump assembly for installation as follows:

a. Clean and examine all of the parts. Replace them, if necessary.

b. Install the fittings and valve block (A, Figure 1) to the main pump.

Figure 1

WARNING
Crushing Hazard
Can cause personal injury.
u Lifting equipment must be adequately sized, have the correct
lifting capacity, and be in good condition.
u Be careful when you lift heavy components.

NOTE: Make sure that the coupling seal and the oil ring are
! intact on the new pump.

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Main Hydraulic Pump Removal and Installation 6 Installing the Main Hydraulic Pump

c. Attach an approved lifting device to the hydraulic pump and align it with the
main pump (Figure 2).

Figure 2

d. Install the bolts (A, Figure 3) to secure the hydraulic pump (B, Figure 3) to the
main pump (C, Figure 3).

Figure 3

e. Torque the bolts to 76 Newton meters (56 foot-pounds) lubricated.

f. Remove the attached lifting device from the hydraulic pump.

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Main Hydraulic Pump Removal and Installation 6 Installing the Main Hydraulic Pump

g. Install the disc (B, Figure 4) and the shaft coupling (A, Figure 4) on to the main
pump shaft.

Figure 4

WARNING
Crushing Hazard
Can cause personal injury.
u Lifting equipment must be adequately sized, have the correct
lifting capacity, and be in good condition.
u Be careful when you lift heavy components.

h. Attach an approved lifting device to the pump assembly.

3. Secure the main pump assembly on to the machine as follows:

WARNING
Pinch Points
Can cause serious injury.
u Keep hands and fingers away from the moving parts during re-
moval and installation of the component.
u Put on the applicable Personal Protective Equipment (PPE).

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Main Hydraulic Pump Removal and Installation 6 Installing the Main Hydraulic Pump

a. Remove the bolt (A, Figure 5) from the cover and push the cover to one side to
prepare for alignment of coupling during installation.

Figure 5

WARNING
Crushing Hazard
Unexpected movement of parts can cause personal injury or
death.
u Do not put any part of your body on the object when lifting,
moving, or lowering it.
u Do not go in, reside, or put body parts below unsecured,
moveable, or lifted parts.
u Do not put hands and fingers in the pinch point areas when
installing or tightening the parts.
u Stay away from moving parts.

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Main Hydraulic Pump Removal and Installation 6 Installing the Main Hydraulic Pump

b. Lift and put the pump assembly onto the clutch housing (Figure 6).

Figure 6

NOTE: Take extra care not to damage the disc while aligning
! the couplings.

c. Align the couplings between the main electric motor and the main pump through
the access hole in the clutch housing.

WARNING
Crushing Hazard
Unexpected movement of parts can cause personal injury or
death.
u Do not put any part of your body on the object when lifting,
moving, or lowering it.
u Do not go in, reside, or put body parts below unsecured,
moveable, or lifted parts.
u Do not put hands and fingers in the pinch point areas when
installing or tightening the parts.
u Stay away from moving parts.

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Main Hydraulic Pump Removal and Installation 6 Installing the Main Hydraulic Pump

d. Lift the pump assembly and secure it with the washers (B, Figure 7) and the
bolts (A, Figure 7).

Figure 7

e. Torque the bolts to 187 Newton meters (140 foot-pounds) lubricated.

f. Remove the attached lifting device from the pump assembly.

g. Install the cover and secure it with bolt (A, Figure 8).

Figure 8

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Main Hydraulic Pump Removal and Installation 6 Installing the Main Hydraulic Pump

4. Connect the hoses to the pump assembly as follows:

WARNING
Slipping Hazard
Fluid leaks or spills can cause personal injury.
u Cover all of the open ports.
u Wipe off any spilled fluid immediately.

a. Put a container or absorbent materials below the main pump to collect the oil
spill while connecting the hoses.

b. Connect the hoses (A, Figure 9) to the main pump as they were labeled.

Figure 9

c. Connect the hoses (A, Figure 10) to the hydraulic pump as they were labeled.

Figure 10

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Main Hydraulic Pump Removal and Installation 6 Installing the Main Hydraulic Pump

NOTE: Examine all of the O-rings on the suction lines and re-
! place them, if necessary.

d. Connect the hoses (A, Figure 11) to the valve block on the main pump as they
were labeled.

Figure 11

CAUTION
Environmental Contaminant
Oil is an environmental contaminant and must be discarded
correctly.
u Do not let the used oil drain onto the ground.
u Discard the used oil in accordance with local environmental
regulations.

e. Remove the container or absorbent materials from below the main hydraulic
pump and discard the used oil in accordance with local environmental regula-
tions.

WARNING
Pinch Points
Can cause serious injury.
u Keep hands and fingers away from the moving parts during
removal and installation of the component.
u Put on the applicable Personal Protective Equipment (PPE).

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Main Hydraulic Pump Removal and Installation 6 Installing the Main Hydraulic Pump

5. Install the protection plate (B, Figure 12) and secure it with bolts (A, Figure 12), if
equipped.

Figure 12

6. Torque the bolts 76 Newton meters (56 foot-pounds) lubricated.

WARNING
High-Pressure System
Working with pressurized systems can cause personal injury.
u Do not do the maintenance work when operating the machine.
u Make sure that the hydraulic, water, and air systems are depres-
surized before you start to work on these systems.
u Put on applicable gloves.

7. Install the breather filter (A, Figure 13) on to the hydraulic tank.

Figure 13

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Main Hydraulic Pump Removal and Installation 6 Installing the Main Hydraulic Pump

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Main Hydraulic Pump Removal and Installation 7 Testing the Main Hydraulic Pump Operation

7 Testing the Main Hydraulic Pump

Operation

NOTE: After completing the installation section of this instruction, the component is in-
stalled but possibly not ready to operate. A trained machine specialist must proceed
! with a commissioning start-up procedure to make sure that the machine system status
is correct for start-up and all machine safety and functional requirements are met. Refer
to the machine-specific manuals for information about machine start-up requirements.

NOTE: Make sure that the work area is clean, free of unwanted material, and tools are
! returned to the designated locations.

NOTE: The machine must be isolated when doing any repairs or adjustments during
! testing.

1. Fill the hydraulic tank with hydraulic oil.

2. Bleed the hydraulic pump by opening the bleeding port (A, Figure 1) on the pump to
escape the air while filling the oil into the tank.

Figure 1

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Main Hydraulic Pump Removal and Installation 7 Testing the Main Hydraulic Pump Operation

3. Close the bleeding port once the hydraulic oil starts coming out.

WARNING
Energized Machine
Can cause serious injury.
u The machine must be fully energized and the engine must be
switched on to complete this procedure.
u Be careful around moving parts and pinch points.

4. Inform the supervisor, lead hand, and all other persons concerned of the intent to
restart the machine for testing purposes.

NOTE: Make sure that all personnel and bystanders are clear of
! the machine before start-up.

5. Remove the safety locks and tags from the machine in accordance with the site-
specific procedures.

6. Set the battery isolation switch to the ON position.

7. Start the engine.

WARNING
Accidental Movements
Can cause serious injury or death.
u Make sure that no one is at danger or hazard zone before you
start or operate the machine.

8. Lower the jacks to raise the machine away from the maintenance stands.

9. Actuate the cable reel function to roll out the cable and connect it to the power
source.

10. Stop the engine.

11. Switch on the power from the main supply.

12. Start the power pack and stop it at once to rotate only few turns.

! NOTE: The rotation must be in clockwise direction.

13. Do the pressure check for the main hydraulic pump.

14. Set the stand-by pressure between 16 bar (232 psig) – 20 bar (290 psig), and the
pump pressure between 210 bar (3046 psig) – 250 bar (3626 psig).

15. Do a check for direction in which the motor pump coupling rotates.

16. Stop the power pack and isolate the machine with the battery isolation switch.

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Main Hydraulic Pump Removal and Installation 7 Testing the Main Hydraulic Pump Operation

17. Attach safety locks and tags to the machine in accordance with the site-specific
procedures.

WARNING
Heavy Components
Lifting the heavy components by hand can cause body or muscle
strains.
u Position the body accordingly to support the weight of the compo-
nent.

18. Remove the maintenance stands from the machine.

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Main Hydraulic Pump Removal and Installation 8 Procedure Compliance

8 Procedure Compliance

8.1 Procedure Acknowledgement

This procedure has been read and fully understood by the employee.

8.2 Adherence and Compliance

The employee acknowledges that they agree to obey the procedure and all safety require-
ments that are contained and referred here. This acknowledgment is given by virtue of the
signature below by the employee.

Employee (Name Printed) Employee (Signature) Date

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Main Hydraulic Pump Removal and Installation 8 Procedure Compliance

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Main Hydraulic Pump Removal and Installation 9 Procedure Report

9 Procedure Report

Use the report to document all of the installation specifications such as torques and pres-
sures.
The report must be completed, signed, and stored to use as a record, if settings or installa-
tion conditions requires verification. Include photos where necessary.

9.1 Machine / Component Details

Service Order Number:

Machine Model:

Machine Number:

Machine Serial Number:

Machine Hours:

Component Model:

Component Serial Number:

Technician Name:

Technician Signature:

9.2 Task Specifications

Use this section to record installation specifications such as torques and pressures.

Ref. Step Installation Step Description Value

2e Hydraulic pump mounting bolts

3e Pump Assembly mounting bolts

6 Protection plate mounting bolts (If equipped)

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Main Hydraulic Pump Removal and Installation 9 Procedure Report

Ref. Step Testing Step Description Value

14 Stand-by pressure and pump pressure

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