Standard Operating Procedure

Rotation Pump Removal and

Installation
DML E, DML D, DM50, DM45SP, DM45, DML/SP

Original Instructions
2021-04-23 | No: TIS0000413.003 en-US
Rotation Pump Removal and Installation Table of Contents

Table of Contents
Revision History .................................................................................................... 5

1 Customer Acknowledgment ................................................................................. 7

2 General Information............................................................................................... 9
2.1 Introduction ............................................................................................................................... 9
2.2 Qualifications / Licenses Required ......................................................................................... 9
2.3 Terms and Abbreviations ......................................................................................................... 9
2.4 Manufacturer's Information.................................................................................................... 10

3 Safety .................................................................................................................... 11
3.1 Safety First .............................................................................................................................. 11
3.2 Job Safety and Environmental Analysis (JSEA) .................................................................. 11
3.3 Risk Factors ............................................................................................................................ 11
3.4 Safety Precautions Before and During the Work ................................................................. 11
3.5 Personal Protective Equipment ............................................................................................. 12

4 Preparations and Prerequisites.......................................................................... 13

4.1 Labor Resource (People/Skills) ............................................................................................. 13
4.2 Technical Data......................................................................................................................... 13
4.3 Machine Technical Data ......................................................................................................... 13
4.4 Component Technical Data.................................................................................................... 13
4.5 Tools ........................................................................................................................................ 13
4.6 Support Equipment................................................................................................................. 13
4.7 Consumables .......................................................................................................................... 14
4.8 Spare Parts .............................................................................................................................. 14
4.9 Suggested Time Required (Standard Planning Hours) ....................................................... 14
4.10 Reference Documentation ..................................................................................................... 14

5 Removing the Rotation Pump ............................................................................ 15

6 Installing the Rotation Pump .............................................................................. 21

7 Testing the Rotation Pump Operation ............................................................... 25

8 Procedure Compliance........................................................................................ 27
8.1 Procedure Acknowledgement ............................................................................................... 27
8.2 Adherence and Compliance................................................................................................... 27

9 Procedure Report ................................................................................................ 29

9.1 Machine / Component Details ................................................................................................ 29
9.2 Task Specifications ................................................................................................................ 29

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Rotation Pump Removal and Installation Table of Contents

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Rotation Pump Removal and Installation Revision History

Revision History

Revision No. Date Revision

001 June 2019 Original release

002 November 2019 Format changes

003 April 2021 Editorial changes for Live Work Elimination

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Rotation Pump Removal and Installation Revision History

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Rotation 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 Drilling Solutions, LLC

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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Rotation Pump Removal and Installation 1 Customer Acknowledgment

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Rotation 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 and
Analysis 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 pur-
pose of lifting it. The device must fulfil local regulations and require-
ments for the lifting operation. All lifts must be assessed and calcu-
lated by an approved person inclusive of rigging selection and place-
ment on the load to determine the safe lifting methods that are ap-
plied.

Machine 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.

Abbreviation Definition

JSEA Job Safety and Environmental Analysis

PPE Personal Protective Equipment

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Rotation Pump Removal and Installation 2 General Information

Abbreviation Definition

PTO Power Take-off

rpm revolutions per minute

2.4 Manufacturer's Information

Epiroc Drilling Solutions, LLC
2100 North First Street
Garland, Texas 75040, USA

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Rotation 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

• Energized equipment
• Crushing hazard
• High pressure
• Hot fluids or components
• Environmental contaminant
• Mast obstruction
• Overhead load

3.4 Safety Precautions Before and During the Work

! NOTE: Obey all warning statements in this procedure.

¡ Plug the hoses when a pump is replaced.

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Rotation Pump Removal and Installation 3 Safety

¡ Replace a pump with the same size and type.

¡ Use the correct adapters when a pump is installed.

¡ Make sure that all of the hydraulic hoses are connected in the same locations as
they are disconnected.

¡ Release all of the pressure in the hydraulic system before you disconnect hoses or
open any of the components.

¡ Clean spilled or leaked fluids before you start the machine.

¡ Use lifting devices that have inspections up to date and are approved and in com-
pliance with local regulations.

¡ Use lifting devices for lifting heavy components.

¡ Make sure that only approved personnel lift, install, and connect the equipment.

¡ When fitting, removing, or changing the installation position of equipment or compo-

nents, use approved lifting device or support devices to secure equipment or com-
ponents against unintentional movement.

3.5 Personal Protective Equipment

Make sure that all necessary personal protective equipment (PPE) is available and cor-
rectly 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 that are identified in the risk assessment.

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Rotation Pump Removal and Installation 4 Preparations and Prerequisites

4 Preparations and Prerequisites

4.1 Labor Resource (People/Skills)

Service Technician x 3
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

Rotation pump 77 kg (170 lb)

4.5 Tools

Description Specification

Standard mechanic toolkit

Torque wrench, calibrated Capacity up to 406 N·m (300 ft-lb)

Pry bar

Tags As required

4.6 Support Equipment

Description Specification

Crane As required

Lifting equipment As required

Container 19 L (5 gal)

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Rotation Pump Removal and Installation 4 Preparations and Prerequisites

4.7 Consumables

Description Specification Quantity

Oil absorbent paper As required

Caps and plugs 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 the specific machine model and serial number.

Description Specification Quantity

Pump 1

O-ring 1

Cap screws Pump mounting 2

Washers Pump mounting 8

Cap screws Pump fitting mounting 16

4.9 Suggested Time Required (Standard Planning Hours)

Ref. Description Planned Time (HH:MM)

5,6,7 Rotation Pump Removal and Installation 04:00

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 done.

Description Reference

Safety Manual Model specific

Operation Manual Model specific

Service/Maintenance Manual Model specific

Spare Parts Catalog Machine specific (per serial number)

Safety Locks and Tags Minimum Requirements Model specific Maintenance Manual

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Rotation Pump Removal and Installation 5 Removing the Rotation Pump

5 Removing the Rotation Pump

1. Park the machine on a dry level surface.

DANGER
Electrocution Hazard
Operating near or contacting a power line with any part of the ma-
chine can cause electrocution, causing death.
u Do not raise or lower the mast or operate the machine near elec-
tric power lines.
u Keep at least 3 meters (10 feet) away from power lines.
u If there appears any danger of wind or other obstruction decreas-
ing the distance, do not drill in that area.

2. Raise the mast to the vertical position and lock it in place.

3. Stop the engine/motor.

4. Set the main switch to OFF.

5. Attach safety locks and tags to the machine in accordance with the site-specific
procedures or refer to Safety Locks and Tags Minimum Requirements in the Main-
tenance manual.

6. Put blocks at the tracks, as applicable

WARNING
High Pressure
High-pressure cleaning with compressed air, water jets, or steam
cleaning methods can cause personal injury.
u Put on applicable personnel protective clothing to protect eyes
and uncovered parts of the body.
u Maximum air pressure at the nozzle must be less than 207 kPa
(30 psig) for cleaning purposes.

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Rotation Pump Removal and Installation 5 Removing the Rotation Pump

7. Use a pressure washer to clean the main pumps of any dirt, oil, and grease.

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

8. Put an absorbent paper and a container below the pump.

9. Label and disconnect the cables from the coils (Figure 1, item A).

Figure 1

A Coils

WARNING
Hot Fluids or Components
Hot fluids or components can burn.
u Make sure that the fluids are at a safe working temperature when
you service the machine.
u Do not touch hot fluids or components.

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Rotation Pump Removal and Installation 5 Removing the Rotation Pump

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

10. Find and disconnect the quick-coupling connection (Figure 2, item A) that reaches
the pump.

Figure 2

A Quick-coupling connection

WARNING
Hot Fluids or Components
Hot fluids or components can burn.
u Make sure that the fluids are at a safe working temperature when
you service the machine.
u Do not touch hot fluids or components.

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Rotation Pump Removal and Installation 5 Removing the Rotation Pump

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

11. Clean, label, and disconnect the hoses (Figure 3, item A) on the rotation pump.
Plug the hoses and cap the ports immediately.

Figure 3

A Hoses

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Rotation Pump Removal and Installation 5 Removing the Rotation Pump

12. Remove the fittings (Figure 4, item A) and store them in a safe location, if applica-
ble.

Figure 4

A Fittings

13. Discard the hydraulic fittings mounting cap screws.

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.

14. Attach the pump with an approved lifting device and attach it to the crane.

! NOTE: Consider pump weighs of 77 kilograms (170 pounds).

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Rotation Pump Removal and Installation 5 Removing the Rotation Pump

15. Remove the two cap screws and washers (Figure 5, item A) that attach the pump to
the PTO. Discard the cap screws and washers.

Figure 5

A Cap screw and washer

WARNING
Pinch Points
Can cause serious injury.
u Be careful with the pinch points created by the two mounting sur-
faces.

16. Remove the pump from the PTO with a pry bar.

! NOTE: Consider pump weighs of 77 kilograms (170 pounds).

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Rotation Pump Removal and Installation 6 Installing the Rotation Pump

6 Installing the Rotation Pump

Precondition p The machine is OFF.

p All controls are in the OFF or neutral position.
p Tracks are blocked, as applicable.

1. Attach safety locks and tags to the machine in accordance with the site-specific
procedures or refer to Safety Locks and Tags Minimum Requirements in the Main-
tenance manual.

WARNING
Crushing Hazard
Can cause severe injury or death
u Do not stand in the working area of the work floor crane when it is
operating with an overhead load.

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.

2. Attach the pump with an approved lifting device and lift it with the crane.

! NOTE: Consider the pump weighs of 77 kilograms (170 pounds).

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Rotation Pump Removal and Installation 6 Installing the Rotation Pump

3. Install a new O-ring (Figure 6, item A) on the pump.

Figure 6

A O-ring

WARNING
Pinch Points
Can cause serious injury.
u Be careful with the pinch points created by the two mounting sur-
faces.

4. Align the pump and engage it into the PTO.

5. Insert the two cap screws with washers (Figure 5). Torque the cap screws to 298
Newton meters (220 foot-pounds) dry.

6. Release the pump from the lifting device and the crane.

7. Install the fittings onto the new pump if applicable. (Figure 4).

8. Insert the hydraulic fitting mounting cap screws into the pump.

9. Torque the fitting mounting cap screws to 298 Newton meters (220 foot-pounds)
dry.

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

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Rotation Pump Removal and Installation 6 Installing the Rotation Pump

10. Put an absorbent paper and a container below the pump.

11. Connect the hoses to the pump (Figure 3).

12. Connect the quick-coupling connection (Figure 2).

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

13. Remove the cap from the H port and the plug to let the air out. Insert the plug when
pure oil comes out.

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Rotation Pump Removal and Installation 6 Installing the Rotation Pump

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Rotation Pump Removal and Installation 7 Testing the Rotation Pump Operation

7 Testing the Rotation 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.

1. Remove all tools and trash from the work area.

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

2. Remove the containers and discard the used oil in accordance with local environ-
mental regulations.

3. Do an oil level check in the hydraulic tank. Add oil if necessary.

WARNING
Energized Machine
Can cause serious injury
u The machine must be fully energized and the engine/motor 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.

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Rotation Pump Removal and Installation 7 Testing the Rotation Pump Operation

5. Remove the safety locks and tags from the machine in accordance with the site-
specific procedures or refer to Safety Locks and Tags Minimum Requirements in
the Maintenance manual.

6. Turn the main switch to ON.

7. Start the machine.

8. Let the machine operate at low idle to reach normal operating temperatures.

9. Make sure that the maximum rotation pressure is 310 bar (4,500 psi).

10. Stop the machine.

11. Attach safety locks and tags to the machine in accordance with the site-specific
procedures or refer to Safety Locks and Tags Minimum Requirements in the Main-
tenance manual.

12. Do a leak check at the rotation pump and pump hoses. Make any needed correc-
tions.

13. Fill all of the PTO and the hydraulic fluids to their correct levels.

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Rotation 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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Rotation Pump Removal and Installation 8 Procedure Compliance

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Rotation 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 require 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 and Description Value

5 PTO cap screws

9 Pump fitting cap screws

Testing the Rotation Pump Operation

9 Maximum rotation pressure

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Rotation Pump Removal and Installation 9 Procedure Report

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Rotation Pump Removal and Installation 9 Procedure Report

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