Compressor

Component Removal and Installation Instructions

SmartROC D65

Epiroc Australia Pty Ltd

 Compressor Contents

Contents
1 Revision History ..........................................................................................................................3

2 Introduction .................................................................................................................................4
2.1 Safety First .........................................................................................................................................................4
2.2 Terms ..................................................................................................................................................................4

3 Preparations and Prerequisites .................................................................................................5

3.1 Technical Data....................................................................................................................................................5
3.2 Spare Parts .........................................................................................................................................................5
3.3 Reference Documentation ................................................................................................................................5
3.4 Job Safety and Environmental Analysis (JSEA).............................................................................................5
3.5 Personal Protective Equipment (PPE) .............................................................................................................5

4 Before Starting the Task.............................................................................................................6

4.1 Machine Set-up ..................................................................................................................................................6
4.2 Isolate Machine ..................................................................................................................................................6
4.3 Pre-conditions ....................................................................................................................................................6

5 Removing Compressor...............................................................................................................7

6 Installing Compressor ..............................................................................................................16

6.1 Post Conditions ...............................................................................................................................................22

7 After the Installation..................................................................................................................23

©Copyright 2019, Epiroc

All product names in this publication are trademarks of Epiroc. Any unauthorised use or copying of the contents or
any part thereof is prohibited. Illustrations and photos may show equipment with optional extras.
No warranty is made regarding specifications or otherwise. Specifications and equipment are subject to change
without notice. Consult your Epiroc Customer Centre for specific information.

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 Compressor Revision History

1 Revision History

Rev No. Date Description

A 15/04/19 Issued for review

1.0 17/05/19 Approved

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 Compressor Introduction

2 Introduction
This instruction has been developed with the intention of providing the step-by-step sequence to
conduct the task mentioned on the front cover, on the machine/s also mentioned on the front cover.
Where applicable, safety warnings and messages are used in the instruction to point out potential
hazards however, this instruction must be used in conjunction with a local Job Safety and
Environmental Analysis (or equivalent) in order to identify and manage hazards and risks.
This task serves numerous customer jurisdictions. Should a particular instruction or clause conflict
with the site-specific occupational health and safety standards, the responsibility rests on the user to
amend those instructions or clauses, as applicable.

! NOTE: This instruction is derived from OEM assembly. Variation of local options,
modifications, machine systems and layout can differ from these instructions.

2.1 Safety First

The person or persons performing work according to instructions in this manual must be qualified for
the work according to local regulations and requirements. It is the duty of all personnel that are
involved in performing the tasks to read and understand the machine-specific Safety, Operation,
Maintenance and Isolation manuals and any other documentation specifically referenced to in this
document before commencing any work on the machine.
The instructions include specific safety messages that are marked with Danger, Warning, Caution,
or Note. Pay extra attention to these messages as they are additional to instruction text. Comply with
any local safety rules specific to the work location.

2.2 Terms
Term Definition
Job Safety and Local job risk observation tool, used for job hazard identification and
Environmental Analysis determination of how to manage the risk through appropriate control
measures.
Technician Person who is qualified to perform the work according to local
regulations and requirements.
Machine Operator Person who is qualified and approved to operate the machine according
to local regulations and requirements.
Spotter Person who oversees machine operation within the surrounding
environment to assist and communicate with the machine operator to
make sure safe and precise movement of the machine.
Crane/lifting device Person who is qualified and approved for operating the crane or lifting
operator device according to local regulations and requirements.
Approved lifting device Device that is connected to, or applied on, a component for the purpose
of lifting it. The device must fulfil local regulations and requirements for
the lifting operation. The illustrations in this instruction show principal
examples for information purpose only.
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.
Local regulation Regulation, specification, or instruction that is valid for the local site and
that can complement or override the instructions in this document.
Thread locking Applied to the threads of fasteners to prevent loosening, leakage and
compound corrosion. Use a locally approved product.
Anti-seize compound Applied to the threads of fasteners to prevent seizing and disassembly
of a mechanical joint. Use a locally approved product.

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 Compressor Preparations and Prerequisites

3 Preparations and Prerequisites

3.1 Technical Data

To select correct lifting devices, stands and tools, refer to the technical data as detailed throughout
the instruction sections. Refer to machine-specific manuals for weight, dimensions and other relevant
data.

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

3.2 Spare Parts

To create an order list request for the spare parts, refer to the Spare Parts Catalogue for your
specific machine model and serial number.

3.3 Reference Documentation

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

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

Manual Reference
Safety Instructions Machine-Specific (per serial number)
Operator Instructions Machine-Specific (per serial number)
Maintenance Instructions Machine-Specific (per serial number)
Mining and Rock Excavation Torque Specification No 1185028747
Spare Parts Catalogue Machine-Specific (per serial number)
Isolation Procedure Machine-Specific (per serial number)

3.4 Job Safety and Environmental Analysis (JSEA)

Job Safety and Environmental Analysis provides job hazard identification, potential risk assessment
and suggested controls for the tasks that are described within this instruction. The technician 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.

! NOTE: Refer to local regulation and JSEA or equivalent type of job risk assessment
documentation.

3.5 Personal Protective Equipment (PPE)

You must adhere to all site-specific standard PPE requirements, mandatory area PPE regulations
and any other PPE requirements identified as a result of a risk assessment. Additional specific PPE
relating to this instruction will be detailed at applicable steps. Therefore we recommend before
starting the task, you read through the entire instruction and ensure you have all required PPE before
commencing this task.

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 Compressor Before Starting the Task

4 Before Starting the Task

Before starting the task, it is important that you read through this document in its entirety and all reference
material. Refer to the isolation procedure for detailed safety instructions.

NOTE: Safety warnings are inserted at first occurrence but are applicable
! throughout the entire instruction. Please ensure you are aware and adhere to these
warnings throughout the whole process.

4.1 Machine Set-up

 General machine set-up, refer to AU - SmartROC D65 - SOP - 001, section 8.
 Vertical feed position, refer to AU - SmartROC D65 - SOP - 001, section 8.

4.2 Isolate Machine

1. Release machine stored energy sources according to local regulations.
2. Confirm there is no pressure left in the system/s specific to this task, refer to the isolation
procedure AU - SmartROC D65 - SOP - 001, section 6.

WARNING
High System Pressure
There is a risk of personal injury when working with pressurised systems.
 Do not perform maintenance work while the machine is running.
 Check that the hydraulic, water and air systems are depressurised before
starting to work on these systems.
 Wear suitable gloves.

3. Isolate the machine using the battery isolation switch.

a. Apply the necessary Lockout-Tagout procedure, refer to the isolation procedure
AU - SmartROC D65 - SOP - 001, section 6.

! NOTE: Refer to local regulations, extra requirements can apply.

4.3 Pre-conditions
 Exhaust Set removed, refer to AU - SmartROC D65 - CRI - 011.

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 Compressor Removing Compressor

5 Removing Compressor
1. Place a suitable receptacle under the right side rear of machine (A Figure 1) and drain the oil
from the compressor element drain point (B Figure 1).

Figure 1

2. Place a suitable receptacle under the left side rear of machine (A Figure 2) and drain oil from
the compressor receiver tank drain point (B Figure 2).

A
B

Figure 2

3. Disengage roof panel fasteners (A Figure 3) and remove roof panels (B Figure 3).

CAUTION

Heavy Objects Lifted by Hand

Can cause body or muscle strains.
 Position the body accordingly to support the weight.
 Use the two person lift technique as required.

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 Compressor Removing Compressor

Figure 3

4. Remove the feed rest (B Figure 4).

5. Remove the three (3) rear roof panels (A Figure 4).

CAUTION
Pinch Points
Can cause severe injury.
 Keep hands clear of mating surfaces during removal and installation.
 Wear suitable gloves.

Figure 4

6. Disconnect the right side rear light cable (A Figure 5).

Figure 5

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 Compressor Removing Compressor

7. Disconnect the left side rear light cable (A Figure 6).

Figure 6

8. Disconnect and remove GPS attachment pole (A Figure 7).

Figure 7

9. Attach an approved lifting device to the right side handrail (B Figure 8) and support the weight.

! NOTE: Right side handrail weight: 72 kg (159 lbs)

WARNING
Heavy Objects Requiring Lifting Device
Can result in death or serious injury.
 Never work under a suspended load.
 Use a tag line to keep load clear of personnel and equipment.
 Do not attempt to lift heavy objects by hand.

10. Remove the handrail attaching bolts from the machine frame (A Figure 8).

WARNING
Working at Heights, Risk of Falling
Can cause severe or permanent injury when falling from machine or ladders.
 Control open edge hazards as per local/site working at height procedures.
 Use fall arrest or restraint equipment as required.
 Use approved task specific steps, ladders and work platforms.

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 Compressor Removing Compressor

11. Lift handrail away from machine, place onto a suitable surface and remove lifting device.

Figure 8

12. Attach an approved lifting device to the left side handrail (B Figure 9) and support the weight.

! NOTE: Left side handrail weight: 36 kg (79 lbs)

13. Remove the handrail attaching bolts from the machine frame (A Figure 9).
14. Lift handrail away from machine, place onto a suitable surface and remove lifting device.

Figure 9

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 Compressor Removing Compressor

15. Clean, label and disconnect all hoses from the coolant expansion tank (C Figure 10).

! NOTE: Immediately plug and cap the hoses and ports.

16. Remove coolant expansion tank attaching bolts (A Figure 10).

17. Remove the expansion tank (B Figure 10) from the machine and place on a suitable surface.

Figure 10

18. Attach an approved lifting device to the rear roof section and support the weight (Figure 11).

! NOTE: Roof assembly weight: 270 kg (595 lbs)

Figure 11

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 Compressor Removing Compressor

19. Remove the rear roof section attaching bolts from the machine frame (A Figure 12).
20. Lift roof section away from machine, place onto a suitable surface and remove lifting device.

Figure 12

21. Attach an approved lifting device to the rear ladder (B Figure 13) and support the weight.

! NOTE: Rear ladder weight: 16.5 kg (36.5 lbs)

22. Remove ladder attaching bolts (A Figure 13).

CAUTION

Pinch Points
Can cause severe injury.
 Keep hands clear of mating surfaces during removal and installation.
 Wear suitable gloves.

23. Lift ladder away from machine, place onto a suitable surface and remove lifting device.

Figure 13

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 Compressor Removing Compressor

24. Disconnect and remove compressor intake filter assembly (A Figure 14).

Figure 14

25. Remove the three (3) bottom plates (A Figure 15).

Figure 15

26. Label and disconnect the two (2) temperature sensors from the bottom of the compressor
(A Figure 16).

Figure 16

27. Place a suitable receptacle under the compressor hose connections.

28. Clean, label and disconnect all hoses and pipes from compressor.

! NOTE: Immediately plug and cap the hoses and ports.

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 Compressor Removing Compressor

29. Clean the two (2) compressor lifting points (A Figure 17) using a suitable tap, as required.

Figure 17

30. Attach an approved lifting device to the compressor and support the weight.

! NOTE: Compressor weight: 638 kg (1407 lbs)

31. Remove the 12 compressor to engine bell housing bolts (A Figure 18).

Figure 18

32. Remove the four (4) mounting bolts on both sides of the compressor (A Figure 19).

Figure 19

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 Compressor Removing Compressor

33. Lift compressor out of the machine, place onto a suitable surface and remove lifting device
(Figure 20).

Figure 20

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 Compressor Installing Compressor

6 Installing Compressor

First read ‘Before Starting this Task’

NOTE: Safety warnings are inserted at first occurrence but are applicable
! throughout the entire instruction. Please ensure you are aware and adhere to
these warnings throughout the whole process.

! NOTE: During installation, torque all fasteners in accordance with the Mining and
Rock Excavation Torque Specification, No. 1185028747.

1. Verify that the machine is isolated and if necessary isolate the machine using the battery
isolation switch.
a. Apply the necessary Lockout-Tagout procedure, refer to the isolation procedure
AU - SmartROC D65 - SOP - 001, section 6.

! NOTE: Refer to local regulations, extra requirements can apply.

2. Transfer all necessary components and hoses to the replacement compressor.

CAUTION

Heavy Objects Lifted by Hand

Can cause body or muscle strains.
 Position the body accordingly to support the weight.
 Use the two person lift technique as required.

3. Attach an approved lifting device to the replacement compressor.

! NOTE: Compressor weight: 638 kg (1407 lbs)

WARNING
Heavy Objects Requiring Lifting Device
Can result in death or serious injury.
 Never work under a suspended load.
 Use a tag line to keep load clear of personnel and equipment.
 Do not attempt to lift heavy objects by hand.

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 Compressor Installing Compressor

4. Lift compressor into the machine and align to mounting points (Figure 1).

CAUTION
Pinch Points
Can cause severe injury.
 Keep hands clear of mating surfaces during removal and installation.
 Wear suitable gloves.

Figure 1

5. Install the four (4) mounting bolts on both sides of the compressor (A Figure 2).

Figure 2

6. Install the 12 compressor to engine bell housing bolts (A Figure 3).

Figure 3

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 Compressor Installing Compressor

7. Connect all hoses and pipes to the compressor, according to labels.

8. Connect the two (2) temperature sensors (A Figure 4) at the bottom of the compressor,
according to labels.

Figure 4

9. Install the three (3) bottom plates (A Figure 5).

Figure 5

10. Install and connect compressor intake filter assembly (A Figure 6).

Figure 6

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 Compressor Installing Compressor

11. Attach an approved lifting device to the rear ladder.

! NOTE: Rear ladder weight: 16.5 kg (36.5 lbs)

12. Lift ladder (B Figure 7) onto machine and install attaching bolts (A Figure 7).

Figure 7

13. Attach an approved lifting device to the rear roof section.

! NOTE: Roof assembly weight: 270 kg (595 lbs)

14. Lift roof section onto the machine and install the attaching bolts (A Figure 8).

WARNING
Working at Heights, Risk of Falling
Can cause severe or permanent injury when falling from machine or ladders.
 Control open edge hazards as per local/site working at height procedures.
 Use fall arrest or restraint equipment as required.
 Use approved task specific steps, ladders and work platforms.

Figure 8

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 Compressor Installing Compressor

15. Position coolant expansion tank (B Figure 9) and install attaching bolts (A Figure 9).
16. Connect all hoses to the coolant expansion tank (C Figure 9).

Figure 9

17. Attach an approved lifting device to the left side handrail.

! NOTE: Left side handrail weight: 36 kg (79 lbs)

18. Lift handrail onto machine and install attaching bolts (A Figure 10).

Figure 10

19. Attach an approved lifting device to the right side handrail.

! NOTE: Right side handrail weight: 72 kg (159 lbs)

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 Compressor Installing Compressor

20. Lift handrail onto machine and install attaching bolts (A Figure 11).

Figure 11

21. Install and connect the GPS attachment pole (A Figure 12).

Figure 12

22. Connect the left side rear light cable (A Figure 13).

Figure 13

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 Compressor Installing Compressor

23. Connect the right side rear light cable (A Figure 14).

Figure 14

24. Install the three (3) rear roof panels (A Figure 15) and feed rest (B Figure 15).

Figure 15

25. Install roof panels (B Figure 16) and lock panel fasteners (A Figure 16).

Figure 16

26. Replenish system fluids as required. Refer to the machine-specific instruction manual.

6.1 Post Conditions

 Exhaust set installed, refer to AU - SmartROC D65 - CRI - 011.

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 Compressor After the Installation

7 After the Installation

After completing the installation section of this instruction, the component is installed 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.

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