About Working on Hydraulic Components

The hydraulic system is sensitive to contamination. The environment where the machine is used is usually an incorrect area for repairing hydraulic components. Avoid repairing hydraulic systems outside workshops.

Observe the following points to minimize interruptions in operation because of dirty hydraulic oil:

• Keep the machine clean.

• Use a degreasing additive for washing.

• Before opening any hydraulic connection, clean the area around 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 applicable protective plugs installed.

• Spare parts for hydraulic components must always be kept in sealed plastic bags.

• Change filter cartridges when filters are clogged.

Hydraulic Workshops

Workshops that are used for the repair of hydraulic components must include:

• A clean environment to avoid dust and particles

• Applicable washing equipment for component repair

• Applicable tools for working on hydraulic systems

• Adequate ventilation system

Replace Hydraulic Hoses

Load, vibration, and mechanical stresses have many requirements 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 correctly tightened.

Check Hoses and Couplings

Oil Sampling

An oil sample gives a good indication of how well the hydraulic system has been maintained.

Fill Hydraulic Oil Manually

Hydraulic Oil Change

The hydraulic oil does not need to be changed as long as filter replacements have been carried out as directed and oil cooling has been working satisfactorily. If oil samples show signs of oxidation or high water content, change the oil.

Hydraulic Tank

Check Hydraulic Tank

1. •
   1.
   Replace the return oil filter (A) and breather filter if the needle on the pressure gauge (D) is in the red zone.
2. •
   2.
   Check connections for signs of leakage on the tank (B).
3. •
   3.
   Check that the oil level (C) is not in the red zone. The rig must be positioned horizontally to give a correct reading.

Drain Condensate from Hydraulic Oil Tank

Precondition

• The machine has been standing for eight hours before the water can be drained.

1. •
   1.
   Place a container under the hydraulic oil drain plug on the left-hand side of the machine.
2. •
   2.
   Remove the plug and let the water drain out.
3. •
   3.
   Replace the plug when the water turns to pure oil.

Drain Hydraulic Oil

1. •
   1.
   Place a container under the hydraulic oil drain plug (A). There is a drain point on the left-hand side of the machine.
2. •
   2.
   Remove the drain plug (A and let the oil drain out.
3. •
   3.
   Position a container under the drain point (B) and drain the system of the last oil.
4. •
   4.
   Close the drain point (B) when the oil has stopped running out.

Replace Oil in Hydraulic Oil Tank

Precondition

• The machine must be positioned horizontally.

1. •
   1.
   Change oil on the hydraulic oil tank (A).

Check Lubrication Tank Level

NOTE

Bleeding of the lubrication system is necessary if all the oil is drained out of it.

NOTE

The level must not be below 40 mm (1.6 in.).

1. •
   1.
   Check the lubrication tank (A) and connections for signs of leakage.
2. •
   2.
   Check the lubricant level in the lubrication tank (A). Fill lubricant, if necessary.

   NOTE

   Always use a funnel with strainer when filling lubricant.

Drain Lubrication Tank

1. •
   1.
   Drain off water from the lubrication tank (A).

Hydraulic Filters

Return Oil Filter

The return oil filter cleans the oil before it returns to the tank. The filter cartridges should be replaced according to the maintenance schedule. If the return filter pressure gauge on the operator display indicates a clogged filter, all return oil filters must be changed immediately.

Replace Return Oil Filter

The filter inserts are located in the hydraulic tank.

1. •
   1.
   Clean on and around the filter cap. Loosen and remove the nuts (A).
2. •
   2.
   Lift off the cap (B) and replace the O-ring (C) if damaged.
3. •
   3.
   Lift out the filter cannister (D).
4. •
   4.
   Remove the nut (E). Lift out and clean the magnetic rod (F).
5. •
   5.
   Remove filter cartridge (G) from the cover (H) and replace with a new filter cartridge.

   NOTE

   Only the filter cartridge is replaced. The filter cover is reused.

6. •
   6.
   Install all parts.

Replace Breather Filter

Replace the filter as per the maintenance schedule or if the tank is overfilled and the filter gets covered in oil.

1. •
   1.
   Clean thoroughly on and around the filter housing (A).
2. •
   2.
   Remove the cover plate by turning it counterclockwise.
3. •
   3.
   Replace with a new filter.
4. •
   4.
   Apply a little hydraulic oil to the sealing surface and threads.
5. •
   5.
   Install the cover.