02 Safe Work Procedure

7/24/2019 02 Safe Work Procedure

1/70

Service Manual

R 9250 from 13466 2 -1

LFR/en/version:08/2007

MJFCIFSS

Chapter 2 - Safe work procedure / Risk assessment

Safe work procedures....................................................................................................................................... 2-3

1.1 Safe work procedures SWP 001 - Safety check list ......................................................................... 2-5

1.2 Safe work procedures SWP 002 - Basic R 9250 machine isolation ................................................. 2-6

1.3 Safe work procedures SWP 003 - R 9250 Isolate for hydraulic repair ............................................. 2-71.4 Safe work procedures SWP 004 - remove R 9250 engine............................................................... 2-8

1.5 Safe work procedures SWP 005 - Isolate machine for track component repairs ............................. 2-10

1.6 Safe work procedures SWP 006 - Isolate machine for welding repairs............................................ 2-11

1.7 Safe work procedures SWP 007 - Remove and replace hydraulic cylinder ..................................... 2-12

1.8 Safe work procedures SWP 008 - Removal of bucket levers and links............................................ 2-14

1.9 Safe work procedures SWP 009 - Repair / replacement of suction valve ........................................ 2-15

1.10 Safe work procedures SWP 010 - Remove and replace load rollers................................................ 2-16

1.11 Safe work procedures SWP 011 - Remove and replace track chain................................................ 2-18

1.12 Safe work procedures SWP 012 - R 9250 track drive sprocket change out..................................... 2-20

1.13 Safe work procedures SWP 013 - Remove counterweight............................................................... 2-23

1.14 Safe work procedures SWP 014 - Remove boom............................................................................ 2-24

1.15 Safe work procedures SWP 015 - Remove stick.............................................................................. 2-261.16 Safe work procedures SWP 016 - Change splitterbox input shaft assembly.................................... 2-28

1.17 Safe work procedures SWP 017 - Remove idler and replace .......................................................... 2-29

1.18 Safe work procedures SWP 018 - Change carrier roller................................................................... 2-30

1.19 Safe work procedures SWP 019 - Bucket change out...................................................................... 2-31

1.20 Safe work procedures SWP 020 - Change out work pump .............................................................. 2-33

1.21 Safe work procedures SWP 021 - Change cabin ............................................................................. 2-35

1.22 Safe work procedures SWP 022 - R 9250 remove and replace engine ........................................... 2-36

1.23 Safe work procedures SWP 023 - Remove and replace swing box ................................................. 2-38

1.24 Safe work procedures SWP 024 - Change main valve bank............................................................ 2-40

1.25 Safe work procedures SWP 025 - Change swing pump................................................................... 2-41

1.26 Safe work procedures SWP 026 - Change splitterbox ..................................................................... 2-42

1.27 Safe work procedures SWP 027 - Change splitterbox Gears........................................................... 2-44

1.28 Safe work procedures SWP 028 - Change splitterbox input shaft assembly.................................... 2-45

1.29 Safe work procedures SWP 029 - Hy-torc operation........................................................................ 2-46

1.30 Safe work procedures SWP 030 - Remove and replace centre girder and side frames .................. 2-47

1.31 Safe work procedures SWP 031 - Fit stick assembly to boom......................................................... 2-52

1.32 Safe work procedures SWP 032 - Assemble uppercarriage ............................................................ 2-54

1.33 Safe work procedures SWP 033 - Assemble undercarriage ............................................................ 2-56

1.34 Safe work procedures SWP 034 - Assemble boom, faceshovel or backhoe.................................... 2-58

1.35 Safe work procedures SWP 035 - Assemble stick, faceshovel or backhoe ..................................... 2-59

1.36 Safe work procedures SWP 036 - Fit boom assembly to uppercarriage.......................................... 2-60

1.37 Safe work procedures SWP 037 - Assemble LIEBHERR R 9250.................................................... 2-62

1.38 Risk assessment............................................................................................................................... 2-66
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2/70

2 - 2

Service Manual

R 9250 from 13466


MJFCIFSS


3/70

Service Manual

R 9250 from 13466 2 -3

Safe work procedures


MJFCIFSS

2 Safe work procedures


4/70

Safe work procedures

2 - 4

Service Manual

R 9250 from 13466


MJFCIFSS


5/70

ServiceManual

R9250from

13466

SafeworkproceduresSWP001-Safetychecklist

2-5

LHB/de/02/Ausgabe:08/2007

MJFCIFSS

2.1SafeworkproceduresSWP001-Safet

ychecklist

Step

Workprocedure

Hazardsidentified

Precautionstobetaken

1

Wearsafetyglasses,bootsandhardhatatalltimesandiri-

descentvestifapplicable

2

Checkservicevehicle

Steepramps

Largeequipmenttraffic

Checkbrakes

Tworadio,revolvinglightan

dflag

3

Reporttosupervisor

Signcontractorbook

4

Checkifexcavatorisonablasta

rea

Checkblasttimebeforedisabling

5

Ensurethatyouhavea"dangeroutofservice"andinfor-

mationstags,plusbiro

Forge

ttotaketagswithyou

Keepextratagsandbiroinservic

evehicle

6

Establishradiocontactwithexcavatoroperatorbeforeap-

proaching

Perso

nalinjury

Keepsafedistancefromexcavatorbeforeembarking

7

Beawareofothersworkingonth

emachine

Perso

nalinjuryorequipmentdamage

Informothersofyourintentions.C

ompletaappropriatetags

andtietoisolationpoint

8

Outsideworkingeneral

Exposuretosunlightandheat

Exposuretowetweatherand

cold

SunblockSPF15,clothingSPF50fulllength,hardhat

brimandshadedsafetyglas

ses

Wearwetweatherclothing

Note!

TheLIEBHE

RRequipmentislargeandheavy.Itismandatorythatallworkbedo

neinasafemanner.Ifyouareindoubtaboutaprocedure,

alwayschec

kwithyoursupervisorbeforeproceeding.


6/70

2-6

ServiceManual

Safeworkprocedure

sSWP002-BasicR9250machineisolat

ion

R9250from13466

MJFCIFSS


2.2SafeworkproceduresS

WP002-BasicR9250machineisola

tion

Step

Workprocedure

Hazardsidentified


1

Follow

SWP001

2

Parkmachineonlevelflatground

Injurytopersonnelwhilemachineis

moving

Stand

clear

3

Putattachmentinrestedpositionandservicetrapdown

Attachment

couldcreep

Restp

ositionshouldbewheretheattac

hmentcannot

creep

down

4

Turno

ffisolatorsforpowerpack,batterie

s,electricalbehind

theca

bandmaintenance

Isolatorstickingin

5

Pullapartsentryplugsontheengine

Note!

TheLIEBHERReq

uipmentislargeandheavy.Itism

andatorythatallworkbedoneinasafemanner.Ifyouareindoubtaboutaprocedure,

alwayscheckwith

yoursupervisorbeforeproceeding.


7/70

ServiceManual

R9250from

13466

S

afeworkproceduresSWP003-R92

50Isolateforhydraulicrepair

2-7

MJFCIFSS


2.3SafeworkproceduresSWP003-R925

0Isolateforhydra

ulicrepair

Step

Workprocedure

Hazardsidentified


1

FollowsafetychecklistSWP001

2

Ensuremachineisparkedonflat

surface

Injury

topersonnel,damagetolight

vehicleswhenmoving

Parkasafedistanceawayfromthemachine.

Establishradiocontactwithoperatorbeforeapproaching

3

Ensureattachmentisinarested

position

Poten

tialhydraulicpressure

Positionattachmentsomechanic

alstopsaresupporting

weightand/orbucketisflatong

round

4

Turnignitionkeyon,safetylever

downandactivatejoys-

ticksinalldirectiontoexpelstoredenergyincylindersand

servoaccumulators

Servo

accumulatorsnotfunctioning,

unfam

iliarpersonnel

Repaircircuitsocylinderstorede

nergycanbeevacuated,

ensurehydraulicpressureisexhausted

5

Evacuateairfromhydraulictank

Flying

dirt,dustandoil

Keeppersonnelawayfromoutlet

6

Installpersonaldangertagoniso

lationpointandisolate

Onedangertagperperson

7

Afterthejobisfinished

8

Removedangertagsandturnon

isolator

Allpe

rsonshavecompletedwork

Ensurethatallworkiscomplete

9

Checkrepairandtestoperation

Oilleaks,hydraulicpressureandvo-

lume

Standclearofrepairarea

10

Cleanaffectedarea

Slippery

Becareful

11

Notifysupervisorthatjobisfinish

ed

Note!

TheLIEBHE



alwayschec



8/70

2-8

ServiceManual

Safeworkprocedure

sSWP004-removeR9250engine

R9250from13466

MJFCIFSS



WP004-removeR

9250engine

Step

Workprocedure

Hazardsidentified


1

Ensurethatthemachineisfullyisolated

Personalinjury.Electricalandhy-

draulicenergy

SeeS

WP001andSWP003

2

Ifnecessaryareaistobepressureclea

ned

Personalinjuryfromhighpressure

waterandanycleaningfluidused

Usea

ppropriatePPE.Facemaskandg

loves

3

Drain

coolantfromradiator

Coolantmaybehot.Splashcoolant

ineyesorontheskin

Checkcoolanttemperatureandallowco

olingifnecessary.

Wear

PPE

4

Drain

engineoilfromengine

Oilonskino

rclothing.Oiltemp

Allow

oiltocoolifnecessary.WearcorrectPPE

5

Disconnectallelectricalwiringfromthe

jobareaasneces-

sary

Trippingonloosewiring

Roolu

pallloosewiringandstoreoutoftheworkareaif

possib

le

6

Remo

veallfiresystemfromaroundthe

workarea

Ifsystemactivates,possiblepersonal

injury

Remo

vesystemchargecanisterandisolatefiresystem

7

Remo

veinletandexhaustsystemsand

allcoversforengi-

neremoval

Sharpedges.Rustedandtightbolts.

Awkwardbo

dypositionig

PPE.Correcttoolingandhavesecondpersontoassist.

8

Remo

veallhydrauliccomponentsandhosesnecessaryfor

engineremoval

Potentialsto

redhydraulicpressure.

Largevolum

esofoilmaybelosted

SeeS

WP003.Havedraincontainersto

catchoilandblan-

kingp

latesasnecessary

9

Startundoingtheengineboltsnecessaryfortheremoval

Slipsandtrips

Usecorrecttoolingandblockanyunsta

blecomponents.

Askfo

rassistancewherenecessary

10

Prepa

resplitterboxforengineremoval

Splitterboxisbackheavyandmayfall

back.Theboxmayfallandcrushper-

sonal

Block

underthebackofthesplitterboxtopreventitfalling

back


9/70

ServiceManual

R9250from

13466

SafeworkproceduresSWP

004-removeR9250engine

2-9

MJFCIFSS


11

Liftouttheenginewhenupperde

ckissuspendedonjac-

kingequipment

Machinemaybebumpedwhileon

thejacks.Fallingobjects.Personal

mayb

ecomecaughtbetweenmoving

objects

Therewillbenootherworkcarriedoutonthemachinewhi-

leliftingouttheengine.Noperson

willbearoundtheupper

deckwhilelifting.Therewillbeno

personalonthemachine

unlesstheyareinvolvedwiththelift.Ariggerwillsupervise

theliftatalltimes.

12

Theriggerwillhaveradiocontactwiththecranedriveratall

times.Allpersonalthatareinside

theworkareawillbeno-

tifiedbeforetheliftcommences

13

Engineontheground

Engin

emayfallcausingpersonalin-

jury

Theenginewillbesatonlevelgro

undandonsolidpacking

Note!

TheLIEBHE



alwayschec


Step

Workprocedure

Hazardsidentified



10/70

2-10

ServiceManual

Safeworkprocedure

sSWP005-Isolatemachinefortrackcom

ponentrepairs

R9250from13466

MJFCIFSS



WP005-Isolatem

achinefortrackcomponentrepairs

Step

Workprocedure

Hazardsidentified


1

Follow

SWP001

2

Ensuremachineisparkedonflatsurfac

e

Mobilelifting

devicesmayhavetrou-

blewithune

vengroundduringcom-

ponentremoval

Ensur

eworkareaisflat,freeofholesan

drocks.Gradepe-

rimete

rifnecessary,minimumareais4

0mx40m

3

Ensureattachmentisinrestedposition

Attachment

creep

Bucke

tisflatontheground,orthemechanicalstopsare

suppo

tingtheweight

4

Installdangertags

Onetagperperson

5

Evacu

ateoilfromtracktensioncircuitu

singleftandright

pump

valvesandcloseoffsupplyshuto

ffvalve

Ifengineisstartedsomeoilmayget

passed.Shu

toffvalve,usecorrect

dumpvalve.Maycauseconfusion

duetouppercarriageposition

Activa

tebothtovisuallycheck,whichiscorrect.Makesure

tapis

turnedonwhenmachinereturnstowork

6

Afterjobisfinished

7

Remo

vedangertags

Allpersonne

lhavecompletedwork

Ensur

ethatallworkiscomplete

8

Checkrepairandtestoperation

Movingparts,hydraulicpressure

Stand

clearofrepairareaandmovingp

arts

9

Clean

affectedarea

Slippery

Becareful

10

Notify

supervisorthatjobiscomplete

Note!

TheLIEBHERReq



alwayscheckwith



11/70

ServiceManual

R9250from

13466

Sa

feworkproceduresSWP006-Isolatemachineforweldingrepairs

2-11

MJFCIFSS


2.6SafeworkproceduresSWP006-Isolatemachineforweldingrepairs

Step

Workprocedure

Hazardsidentified


1

Wearsafetyglasses,boots,hat,iridescentvest

2

FollowSWP001

3

Parkmachineonlevelflatground

Injury

topersonnelwhilemachineis

movin

g

Standclear

4

Putattachmentinrestedposition

andservicetrapdown

Attachmentcouldcreep

Restpositionshouldbewhereattachmentcannotcreep

down

5

Turnoffisolatorsforpowerpack,b

atteries,electricalbehind

thecabandmaintenance

Isolatorstickingin

Checkthatisolatorbuttonpopso

utasyouturnitoff

6

Pullapartsentryplugsonbothengines

Note!

TheLIEBHE



alwayschec



12/70

2-12

ServiceManual

Safeworkprocedure

sSWP007-Removeandreplacehydrauliccylinder

R9250from13466

MJFCIFSS



WP007-Remove

andreplacehydrauliccylinder

Step

Workprocedure

Hazardsidentified


1

Follow

SWP001

2

Follow

SWP003

3

Remo

vecylinderpinendcaps

Weightofca

ps,usingrattlegun,pin-

chedfingers

Safety

pinonairlinesandsocket,ensuresocketsingood

condition,leaveoneboltholdingthecap

andcarefullypivot

theca

poutofthepinpath,usescissorlift

4

Hook

cranetocylinder,andtakeweightofcylinder

Pinchedfing

ers,slippingring,height

Usecorrectliftingequipmentandprocedures

5

Remo

verodendcylinderpins

Crushing,weight,shimsfallingout,

stabilityofth

ecylinder

Usea

pprovedpinpullingtool,connectFrannacranewith

rhinohook,usecorrectliftingequipmen

tandprocedures

keeppersonnelclear

6

Remo

vedangertagsandturnisolation

switcheson

7

Startengineandretractcylinders

Crushing

Stand

clear,keepvisualcontactwithop

erator

8

Turnignitionkeyon,safetyleverdownandactivatejoys-

ticksinalldirectionstoexpelstoredenergyincylindersand

servo

accumulators

Servoaccum

ulatorsnotfunctioning,

unfamiliarpersonnel

Repaircircuitsocylinderstoredenergycanbeevacuated,

ensurehydraulicpressureisexhausted.

9

Evacu

ateairfromhydraulictank

Flyingdirt,d

ustandoil

Keep

personnelawayfromoutlet

10

Installpersonaldangertagonisolation

pointandisolate

Oned

angertagperperson

11

Remo

vehosesfromcylinder

Oilloss,rod

extending,height

Capa

llhoses,keepareaclean,secure

rodendwitha

chain

12

Remo

vebarrelendpin

Weightofpin,shimsdislodging,wei-

ghtofcylind

er

Usea

pprovedpinpullingtool,connectFrannacranewith

rhinohook,usecorrectliftingequipmen

tandprocedures,

keeppersonnelclear,keepincontactw

ithbothcraneope-

rators


13/70

ServiceManual

R9250from

13466

Safew

orkproceduresSWP007-Removeandreplacehydrauliccylinder

2-13

MJFCIFSS


13

Removecylinder

Overh

eadload

Keeppersonnelclear,keepincontactwithcraneoperator

14

Sitcylinderontheground,remov

esling

Cylinderrolling,pinchedfingers

Securewithwedgesor"VEES",b

ecarefulwithsling

15

Liftreplacementcylinderinplace

Crush

ingoverheadlift

Usecorrectliftingproceduresandsling,keeppersonnel

clear

16

Installbarrelendpin

Weight,height,crushing

UseFrannatoliftpin,handlecarefully

17

Installhydraulichoses

Weight,slippery

Handlecarefully,keepareaclean

18

Removedangertagsandturniso

lationswitcheson

19

Startengine,extendcylinders,installrodendpins

Crush

ing

Standclear,keepvisualcontactw

ithoperator,useFranna

toliftpins,handlecarefully

20

Shutenginedown,isolate,installdangerstags

Onetagperperson

21

Installendcaps

Weight

Liftcarefully,usescissorlift

22

Installgreaselines

23

Cleanarea

24

Testoperation

Leaks

Keeppersonnelclear

25

Notifysupervisorthatjobiscomp

lete

Note!

TheLIEBHE



alwayschec


Step

Workprocedure

Hazardsidentified



14/70

2-14

ServiceManual

Safeworkprocedure

sSWP008-Removalofbucketleversandlinks

R9250from13466

MJFCIFSS



WP008-Removalofbucketleversa

ndlinks

Step

Workprocedure

Hazardsidentified


1

Follow

SWP001

2

Follow

SWP003-Isolatemachineforh

ydraulicrepair

3

Remo

vegreaselinesandpinendcaps

Heights

Usescissorliftorworkplatformandharness

4

Remo

vepinsfromlinks

Weightoflin

ks,loosebucketcylin-

ders,suspendedload

Usecorrectcraneandslings.Startmac

hineandsuckrod

in.Securecylinderwithchains.DONOT

POWEROUTCY-

LINDE

RSWHILERODISCHAINED.K

eeppersonnel

away

fromloadatalltimes

5

Remo

velinks

Weightoflin

ks,fallingobjects

Usecorrectcraneandslings.Checkconditionofslingsbe-

forestartinglift.Keeppersonnelawayfromloadatalltimes

6

Storedremovedcomponents

Personneltrippingoverpartsonthe

ground

Store

partsinasecurelocationawayfromtheworkarea.

Isolatewithconesorflags

Note!

TheLIEBHERReq



alwayscheckwith



15/70

ServiceManual

R9250from

13466

Safe

workproceduresSWP009-Repair/replacementofsuctionvalve

2-15

MJFCIFSS


2.9SafeworkproceduresSWP009-Repa

ir/replacementof

suctionvalve

Step

Workprocedure

Hazardsidentified


1

Followsafetychecklist-SWP00

1

2

Determinewhichsuctionvalvere

quiresrepair

Perso

nalinjury

Requireminimumoftwopeople

3

Seetroubleshootingguideifrequ

ired

4

Followisolatemachineforhydraulicrepair-SWP002

Ensureavailabilitytorepairmen

5

Remove/repair/replacesuction

valve

Hotcomponent,hotoil,storedhy-

draulicpressure

Wearrubberglovesandensureh

ydraulicpressureisex-

hausted

6

Cleanaffectedarea

Slippery

Becareful

7

Removedangertagandturnonisolator

Allpe

rsonshavecompletedwork

Ensurethatallworkiscomplete

8

Operateandtestoperation

Hydra

ulicpressureandvolume

Standclearofrepairarea

9

Notifysupervisorthatjobisfinish

ed

Note!

TheLIEBHE



alwayschec



16/70

2-16

ServiceManual

Safeworkprocedure

sSWP010-Removeandreplaceloadrollers

R9250from13466

MJFCIFSS



WP010-Remove

andreplaceloadrollers

Step

Workprocedure

Hazardsidentified


1

Follow

safetylist-SWP001

Requireminimumof2people

2

Using

machinelift-appropriateendofmachinetobefar

enoug

hoffthegroundtoaccommodate

safetystands

Injuriesmay

occur

Keeppersonnelawayfrommachine,kee

peyecontactwith

operator

3

Relea

setracktensionpressureandisolatetracktension

system

Ifthestands

arenotstandingupright,

themachine

maycomedownontop

ofyou

Make

sureoperatorknowswhatyouaredoing

4

Place

safetystandsunderrollers-soastherolleryouare

workingonisfreefromobstruction

Weightofstands,dirt,dust,sharped-

ges

Usefo

rklifttoplacestandsandbartomo

vestandsaround.

Handlecarefully

5

Lowermachinebackdownontostands.Makingsurebuc-

ketstaysontheground

Standsmay

ejectoutandinjureper-

sons

Make

suremachineisgoingtositonstandscorrectlyand

forkliftoperatorisclear

6

Turnmachineoff-isolateandinstallda

ngertag

Oned

angertagperperson

7

Using

Hy-torccrack-tensionoffall4bolts

Weightofunit,hydraulicpressure

Wear

personalprotectionandliftcorrectly.InspectHy-torc

carefu

llybeforeusing

8

Remo

ve2boltsonlowersideofrollerw

hichbecomeinac-

cessible-duetoliftingdevice

Weight,sharpedges

Becareful

9

Using

approvedliftingtoolandliftapparatus-placetoolun-

derro

llerandtaketheweightoftheroller

Weight,fingers

Keepoutofpathofmachineandkeepin

visualcontactwith

theop

erator,handlecarefully

10

Remo

veremaining2bolts

Rollermayfall

Ensur

erollerisproperlyseatedonsupp

ort

11

Remo

vetheroller

Weight,fork

liftoperation

Keepasafedistancefrommachineasrollerisbeingremo-

ved


17/70

ServiceManual

R9250from

13466

SafeworkproceduresSWP010-Removeandreplaceloadrollers

2-17

MJFCIFSS


12

Re-fitnewroller

Rollerfallingoffsupport,weight,fin-

gers

Keepvisualcontactwithoperatoranddontstandonma-

chinepath.Ensurerollerseatedcorrectlyonthesupport.

Becareful

13

Fit2boltsthatareaccessibleandtightenmostoftheway

up

Finge

rs,sharpedges,hydraulicpres-

sure

Wearpersonalprotectiveequipm

ent,becareful

14

Removeliftingtool

Forkliftoperation,weight

Keepasafedistancefrommachine

15

Replaceremainingboltsandhy-torqueallboltstocorrect

tension

Weight,hydraulicpressure,sharped-

ges

Wearpersonalprotection,lifthy-torquecorrectly,becare-

ful

16

Removedangertagsandturniso

latoron

Allwo

rkcompleted

Ensureallworkisdone

17

Liftmachineandremovestands

Weight,forkliftoperation

Keepallpersonnelclearandkeep

invisualcontactwiththe

operator

18

Placemachinebackontothegro

undandretensiontrack

adjustersystem

Hydra

ulicpressure

Keeppersonnelclearandkeepin

visualcontactwiththe

operator

19

Testoperation

Perso

nalinjury

Keeppersonnelclearandkeepin

visualcontactwiththe

opertor

20

Cleanarea

21

Notifysupervisor

Note!

TheLIEBHE



alwayschec


Step

Workprocedure

Hazardsidentified



18/70

2-18

ServiceManual

Safeworkprocedure

sSWP011-Removeandreplacetrackchain

R9250from13466

MJFCIFSS



WP011-Remove

andreplacetrackchain

Step

Workprocedure

Hazardsidentified


1

Follow

safetylist-SWP001


2

Alarg

eflatworkingarea

Cranesandforkliftsmayhavetrouble

withuneven

groundduringtrackre-

moval

Ensur


drocks.Gradepe-

rimete

rifnecessary.Minimumareais4

0x50meters

3

Turnthetracktensiontapoff,movethelevertoreleasethe

tracktensionpressureforthesideyouareworkingon

Ifmachineisstartedwhilethetapis

on,trackwillpumpup

Make

surethatthetapisturnedoff

4

Chooseanyoneofthetrackbolts,useH

y-Torquetoremo-

vebolt-knockingthepinout

Noisefromthehightorque,when

knockingthe

pinoutapieceofmetal

willflyout.M

akesureeveryoneis

clearofthetracks,removetrackpin

fromsideof

machine.

Hydraulicpr

essure

Wear

safetyglassesandearplugs.Kee

pclearofthe

tracks

.Liftcarefully,inspectHy-Torque

beforeusing

5

Tosplitthetrack,startmachineup.Movethemachine

slowly

torolltrackout

Trackcould

rollawayquickly

Make

surethatthetracktensiontapist

urnedoff,keep

clearofthetrackwhenmoving.Ensure

eyecontactwith

operator,standclearoftrack

6

Liftsideofmachine,usingatractortop

ulltrackout,clear

frommachine

Whilepullingtrack,slingscouldsnap

andflythrou

ghtheair

Stand

clearofmachinewhileliftingand

movingtrackout

7

Installsupportsunderthemachine,lowermachineonto

suppo

rts

Weight,fingers

Useforklift,require3plates50mmx1meterx1meter.

Maintaineyecontactwithoperator

8

Installoutofservicetag

9

When

readytoreplacetrackchain

10

Remo

veoutofservicetag


19/70

ServiceManual

R9250from

13466

SafeworkproceduresSWP011-Re

moveandreplacetrackchain

2-19

MJFCIFSS


11

Startengineandliftmachine

Movin

gparts

Ensureallpersonnelareclearof

thearea

12

Dragtrackundermachine

While

pullingtrack,slingscouldsnap

andflythroughair

Standclearofmachinewhileliftin

gandmovingtrack

13

Lowermachineontracksandpositioncorrectly

Perso

nalinjury

Standclearandmaintaineyecon

tactwithoperator

14

Installdangertagandisolate

Onetagforeachperson

15

Liftchainoveridlerwithaloader

Sling

couldslip

Standclear,maintaineyecontactwithloaderoperator

16

Lifttheotherendofthechainove

rthesprocketwithano-

therloader

Sling

couldbreak

Standclear,maintaineyecontactwithloaderoperator

17

Position2remainingpadsinalignmentandinsertjoining

pin

Weight,fingers

Liftwithforklift,handlecarefully

18

Insertretainingboltsandtorque

Weight,sharpedges,hydraulicpres-

sure

Handlecarefully

19

Opentracktensionvalve

Injury

toheadandbackwhileunder

machine

Becareful

20

Removedangertag,turnonisola

tor

Perso

nnelstillworkingonmachine

Ensureallworkiscomplete

21

Startengine,allowmachinetopu

mptracks,testoperation

bytravel

Perso

nalinjury

Standclear,watchoperator

22

Cleanarea

Weight,slippery

Becareful

23

Notifysupervisor

Note!

TheLIEBHE



alwayschec


Step

Workprocedure

Hazardsidentified



20/70

2-20

ServiceManual

Safeworkprocedure

sSWP012-R9250trackdrivesprocketchangeout

R9250from13466

MJFCIFSS



WP012-R9250tr

ackdrivesprocketchangeout

Step

Workprocedure

Hazardsidentified


1

Follow

safetychecklist-SWP001


2

Alarg

eflatworkingarea

Cranesandforkliftsmayhavetrouble

withuneven

groundduringtrackre-

moval

Ensur


drocks.Gradepe-

rimete

rifnecessary.Minimumareais4

0x50meters

3

Turnthetracktensiontapoff,movethelevertoreleasethe

tracktensionpressureforthesideyouareworkingon

Ifmachineisstartedwhilethetapis

on,trackwillpumpup

Make

surethatthetapisturnedoff

4

Chooseanyoneofthetrackbolts,useH

y-Torquetoremo-

vebolt.Usehydraulicpresstopushpin

out,orknockthe

pinou

twithahammer

Noisefromthehightorque,when

knockingthe

pinoutapieceofmetal

willflyout.

Hydraulicpr

essure

Wear

safetyglassesandearplugs.Kee

pclearofthe

tracks

.Liftcarefully,inspectHy-Torqueb

eforeusing.Make

suree

veryoneisclearofthetracks.Rem

ovetrackpinfrom

sideo

fmachine

5

Tosplitthetrack,startmachineup.Movethemachine

slowly

torolltrackout

Trackcould

rollawayquickly

Make

surethatthetracktensiontapist

urnedoff,keep

clearofthetrackwhenmoving.Ensure

eyecontactwith

operator,standclearoftrack

6

Liftsideofmachine,usingatractortop

ulltrackout,clear

frommachine

Whilepullingtrack,slingscouldsnap

andflythrou

ghtheair

Stand

clearofmachinewhileliftingand

movingtrackout

7

Installsupportsunderthemachine,lowermachineonto

suppo

rts

Weight,fingers

Useforklift,require3plates50mmx1meterx1meter.

Maintaineyecontactwithoperator

8

Installdangertags

Onetagperperson

9

Clean

rocksanddebris,removetravelm

otorguards

Craneaccessibility,weightfallingob-

jects

Positionattachmenttofacilitatecraneaccessibility,beca-

reful

10

Remo

vetravelmotors

Oilspillage,

weight

Leave

hosesattachedandsupportmoto

rsatgroundlevel,

liftcar

efully


21/70

ServiceManual

R9250from

13466

Safew

orkproceduresSWP012-R9250trackdrivesprocketchangeout

2-21

MJFCIFSS


11

Removefinaldriveinnerandouterplates

Oilsp

illage,weight

Leavehosesattachedandsupportmotorsatgroundlevel,

liftcarefully

12

RemovesprocketboltswithHy-T

orque

Hydra

ulicpressure

CheckHy-Torquecarefully,liftan

dhandlecarefully

13

Releasesprocketfromfinaldrive

readyforremoval

Sproc

ketdrop

Chocksprocketwithwoodenblocksorsupportwithsecond

crane.Allpersonneltobeclearof

suspendedloadsunless

stabilising

14

Secureliftingdevicetofinaldrive

Devic

edamagethroughuseortran-

sit,weight

Inspectcondition

15

Removefinaldrivebolts

Rattle

gunnoise,airlines

Hearingprotection,hoseclips

16

Removefinaldrive

Suddenmovementofcomponent

Personneltostandclear

17

Removesprocket

Weight

18

Cleanmatingsurfacesofallcomponents

Sandingandgrindinggeneratingde-

bris

Faceshieldandhearingprotectio

n

19

Installnewsprocket

Comp

onentsupportandstability

Chockthesprocketuprightandc

orrectheightorsuspend

withsecondcrane

20

Installfinaldrive

Weight,personalinjury

Usecorrecttoolstotorquebolts

21

Installinnerandouterplate

Weight

Liftcarefully

22

Removedangertags

Perso

nnelworking

Ensureallpersonnelaccountedfor

23

Startengineandliftmachine

Movin

gparts

Ensureallpersonnelareclearof

thearea

24

Dragtrackunderthemachine

While

pullingtrack,slingscouldsnap

andflythroughtheair

Standclearofmachinewhileliftin

gandmovingtrack

25

Lowermachineontracksandpositioncorrectly

Perso

nalinjury

Standclearandmaintaineyecon

tactwithoperator

26

Installdangertagandisolate

Onetagforeachperson

Step

Workprocedure

Hazardsidentified



22/70

2-22

ServiceManual

Safeworkprocedure

sSWP012-R9250trackdrivesprocketchangeout

R9250from13466

MJFCIFSS


27

Liftch

ainoveridlerwithaloader

Slingcouldslip

Stand

clearmaintaineyecontactwithlo

aderoperator

28

Lifttheotherendofthechainoverthes

procketwithano-

therlo

ader

Slingcouldbreak

Stand

clear,maintaineyecontactwithloaderoperator

29

Position2remainingpadsinalignment

andinsertjoining

pin

Weight,fingers

Liftwithforklift,handlecarefully

30

Insert

retainingboltsandspecifiedtorque

Weight,sharpedges,hydraulicpres-

sure

Handlecarefully

31

Open

trackandtensionvalve

Injurytohea

dandbackwhileunder

machine

Becareful

32

Remo

vedangertag,turnonisolator

Personnelstillworkingonmachine

Ensur

eallworkiscomplete

33

Startengine,allowmachinetopumptra

cks,testoperation

bytravel

Personalinjury

Stand

clear,watchoperator

34

Clean

area

Weight,slippery

Becareful

35

Notify

supervisor

Note!

TheLIEBHERReq



alwayscheckwith


Step

Workprocedure

Hazardsidentified



23/70

ServiceManual

R9250from

13466


013-Removecounterweight

2-23

MJFCIFSS


2.13SafeworkproceduresSWP013-Remo

vecounterweight

Step

Workprocedure

Hazardsidentified


1

FollowSWP001

2

FollowSWP002

3

Removehandrails,lightsfromco

unterweight

Weight,height

Liftcorrectly,usecorrectPPE,tapeoffarea

4

Attachcranetocounterweightan

dremovebolts

Break

ingsling,restrictedarea,wei-

ght,flyingobjects

Usecorrectliftinggearandcrane

,wearPPE,useACRU

PROPtosupportHy-Torquewhileundoingbolts

5

Liftcounterweightoff

Weight,swinging

Keepclearwhilelifting,attachropetopreventswinging

Note!

TheLIEBHE



alwayschec



24/70

2-24

ServiceManual

Safeworkprocedure

sSWP014-Removeboom

R9250from13466

MJFCIFSS



WP014-Remove

boom

Step

Workprocedure

Hazardsidentified


1

IsolateperSWP001

2

IsolateperSWP003

3

Remo

vestickperSWP015

4

Drive

boomdownasfaraspossible

Fallingobjects

Ensur

enothingisleftontopafterstickremoval

5

Remo

veallgreaselinesbetweenboom

andupperdeck.

Plugallgreaselines

Workingatheights,slippery

Usesafetyharnessorscissorliftorworkplatform

6

Remo

veallelectricalwiring

Heights

Usesafetyharnessorscissorliftorwor

kplatform.Opera-

torsm

usthavetickets

7

Remo

veandplughydrauliclinesbetwe

enboomandstick

Storedpressure

Becarefulwhenbreakinglines,coverw

ithrags

8

Remo

vecoverplatefrombottomofboo

mcylinderand

boom

Crushedfingersandhands

Wear

handprotection,keephandsclear

,usecorrectlifting

techniques

9

Usec

hainstosecureboomcylindersto

boom,sothey

wont

hangwhentheboomisremoved

Chainsslipp

ing,pinchedfingers

Putbiteonchains,keepfingersclear

10

Setcranetofrontofboomtotakeweight

Weight

Ensur

ecranesandslingsareingoodco

nditionusecorrect

lifting

procedures

11

Connectcranetoboomcylinderpinsan

dremove

Height,weig

ht,crushing,suspended

load

Keep

fingersclear,keepawayfromload

12

Liftbo

omlevelandattachanothercranetorear

Suspended

load,crushedfingers

Keep

clear

13

Takesomeweightonthecranesandre

moveboomcylin-

derbasepins

Crushedfingers,restrictedspace,

height

Keep

clearwhenpinsareremoved,kee

pclearofload


25/70

ServiceManual

R9250from

13466

SafeworkproceduresSWP014-Removeboom

2-25

MJFCIFSS


14

Liftboomawayfrommachine

Suspendedload,fallingobjects

Keepallpersonnelclearofsuspe

ndedloadandfalling

shims

Note!

TheLIEBHE



alwayschec


Step

Workprocedure

Hazardsidentified



26/70

2-26

ServiceManual

Safeworkprocedure

sSWP015-Removestick

R9250from13466

MJFCIFSS



WP015-Remove

stick

Step

Workprocedure

Hazardsidentified


1

Follow

SWP001

2

Remo

vebucketSWP019

3

Layboomdownwithstickout

Injurytopersonnelwhilemachineis

moving

Keep

clearanderectbarricades,onepe

rsontodirectope-

rator

4

IsolateperSWP003

5

Remo

vegreaselinesbetweenbooman

dstick.Plugall

lines

Workingatheights,pinchedfingers

Usesafetyharnessandscissorliftasre

quired.Keepfin-

gersc

lear

6

Remo

vebucketcut-outwiringbetween

boomandstick

Height

Usesafetyharnessandscissorliftasre

quired

7

Remo

veandplughydrauliclinesbetwe

enstickandboom

Storedpressure,height

Becarefulwhenbreakinglines,coverwithrags,usesafety

harnessandscissorliftwhenrequired

8

Remo

veendcapsfromstickcylindersa

ndboomtostick

pins

Crushingof

fingersorhands,height

Keep

clear,usesafetyharnessorscissorlift.Usecorrect

lifting

techniques

9

Remo

vestickpinsusingmobilecrane

Fallingobjectssuchasshims,sus-

pendedload

Keep

allpersonnelclear

10

Resta

rtmachineandsuckslickcylindersin

Oilspillage,

machinemoving

Ensur

ebuckethosescappedcorrectly,

keeppersonnel

clear

11

Locatecraneinsuitablepositiontosupportstick,connect

tostic

k

Height,pinchedfingers

Usecorrectliftinggearandtechniques,u

sesafetyharness,

keepfingersclear

12

Remo

vepinssecuringsticktoboomwithcrane

Height,pinchedfingers,suspended

load

Usecorrectliftinggearandtechniques,u

sesafetyharness,

keepclear

13

Remo

vestickfrommachine

Fallingobjectssuspendedload

Keep

clear


27/70

ServiceManual

R9250from

13466

SafeworkproceduresSWP015-Removestick

2-27

MJFCIFSS


Note!

TheLIEBHE



alwayschec



28/70

2-28

ServiceManual

Safeworkprocedure

sSWP016-Changesplitterboxinputsha

ftassembly

R9250from13466

MJFCIFSS



WP016-Changesplitterboxinputshaftassembly

Step

Workprocedure

Hazardsidentified


1

Follow

SWP001

2

Follow

SWP003

3

Follow

SWP004

4

Installliftingdeviceoninputshaftassem

blyandremove

bolts

Weight,slingslipping,slipperysurfa-

ce,overbala

ncing

Usecorrectslingsandliftingprocedures

,keepliftingappa-

ratusbalanced,keepareaclean

5

Remo

veinputshaftassemblingincludin

gthegear

Weight,not

visibletocraneoperator

Keep

incontactwithoperator

6

Refitnewinputshaftassembly

Weight,pinc

hedfingersorhands,not

visibletocra

neoperator

Keephandsandfingersclear,keepinco

ntactwithoperator

7

Installboltsandremoveliftdevice

Slipperyare

a,pinchedfingers


8

Follow

SWP004tofinishjob

Note!

TheLIEBHERReq



alwayscheckwith



29/70

ServiceManual

R9250from

13466

SafeworkproceduresSWP01

7-Removeidlerandreplace

2-29

MJFCIFSS



veidlerandreplace

Step

Workprocedure

Hazardsidentified


1

FollowSWP001

2

FollowSWP011,removaloftrac

kchain

3

Layoutchain,donotremovefromunderloadrollers

Chain

mayrolloffunderownmomen-

tum

Keepclear,barricadeareawhere

trackcouldfall

4

Attachslingtoidleranduseaload

er/tractortotowtheidler

outonthetrackchain

Heavymachinery,slingcouldbreak,

idlerc

ouldrolloutonthechaincau-

sings

evereinjury

Keepinvisualcontactwithopera

tor,useapprovedtow

slings,keepclearatalltimes

5

Removeidlerfromchainandreplace

Heavypartsswingingfromcraneare

dangerous

Slingcorrectlywithapprovedslings,keepclearoftheload

6

Usecranetoholduptherearsec

tionoftheidler

Crush

edlimbsandfingers


torandclearoftheload

7

Useloadertojibtopushidlerbackintoplace

Crush

ingorflyingobjects

Keepclearandinvisualcontactwithoperator

8

RefertoSWPtoreplacetrackch

ain

Note!

TheLIEBHE



alwayschec



30/70

2-30

ServiceManual

Safeworkprocedure

sSWP018-Changecarrierroller

R9250from13466

MJFCIFSS



WP018-Changecarrierroller

Step

Workprocedure

Hazardsidentified


1

Follow

SWP001

2

Follow

SWP005

3

Using

loaderorjack,lifttrackchaininto

appropriateposi-

tionandblockup

Crushingha

ndsandfingers,weight

ofblocksan

dchain

Keep

handsandfingersclear,haveapp

ropriateblocks,

andliftcarefully

4

Remo

veboltsfromroller

Slipping,sm

allarea,crushedfingers

Have

adequateworkplatform,keepfing

ersclear

5

Using

loaderforks,removerollerfromthemachine

Rollerfalling

offforks

Lashrollertoforks,standclear

6

Repla

cerolleronmachineandinstallbolts

Crushedfingers,rollerfallingoffforks

Lashrollertoforks,keepinvisualconta

ctwithoperator,

keepclear

7

Jackorlifttracksandremoveblocks

Weightofblocks,tracksslipping

Liftblockscarefully,keepclearoftracks

andloader

8

Lowertracksbackontorollersandremovejacks

Tracksfallin

g

Keep

clearandinvisualcontactwithloaderoperator

9

Follow

SWP005tocompletejob

Note!

TheLIEBHERReq



alwayscheckwith



31/70

ServiceManual

R9250from

13466

SafeworkproceduresS

WP019-Bucketchangeout

2-31

MJFCIFSS


2.19SafeworkproceduresSWP019-Buck

etchangeout

Step

Workprocedure

Hazardsidentified


1

FollowSWP001

2

Ensurelevelpositionforbucketfloortorest

Ifareanotlevel,moredifficultandha-

zardo

ustoalignpins

Prepareareawithagraderordozer

3

Isolatemachinewithmaintenanceisolationswitch

4

Removegreaselines,halfclampsandpinendcaps

Weightofendcaps,height

Liftcarefullywithassistanceora

crane,useascissorlift

5

Putbucketinuprightpositionand

removepinsfromendof

thebellcranks

Weight,crushing,striking

Keepclearofbellcranksswinging

,slingingofpins

6

Startmachineandretractbucket

cylinders

Crush

ing

Keepclear,andvisualcontactwithoperator

7

Removebuckettostickpins

Crush

ingorstriking

Keepclearofpinsdroppingorbu

cketrolling,slingingof

pins

8

Liftstickoutofbucketandaligninnewbucket

Crush

ing


tor

9

Placesealsaroundbushingsinn

ewbucket

Crush

ing

Keepfingersclearwheninstalling

sealsintobushes

10

Alignsticktobucketbushingsandfitbucketpins

Heavyequipment,slingsslipping

Havecorrectslings,keepclearofcrane,liftpinscarefully

11

Alignbellcrankstobucketandfit

pins

Weight,slingsslipping,bellcranks

movin

gandcrushing

Becareful,mayhavetotieupon

ebellcranks

12

Isolatemachinewithmaintenanceisolationswitch

13

Installhalfclamps,endcoversan

dgreaselines

Crush

ingandfingers,heightandwei-

ght

Ensureattachmentisinthecorre

ctposition,keepfingers

clearwheninstallingcovers,liftcoverscarefully,usescis-

sorlift

14

Cleanarea


32/70

2-32

ServiceManual

Safeworkprocedure

sSWP019-Bucketchangeout

R9250from13466

MJFCIFSS


15

Notify


Note!

TheLIEBHERReq



alwayscheckwith


Step

Workprocedure

Hazardsidentified



33/70

ServiceManual

R9250from

13466


020-Changeoutworkpump

2-33

MJFCIFSS


2.20SafeworkproceduresSWP020-Chan

geoutworkpump

Step

Workprocedure

Hazardsidentified


1

FollowSWP001

2

FollowSWP003-Isolateforhyd

raulicrepair

3

Removeenoughsidelouvrestoprovideadequateaccess

topumparea

Weight

Liftcarefullywithassistance

4

Turnoffmainhydraulictaptosuc

tionmanifold

5

Arrangepumptopumpfromsuctionmanifoldbackinto

maintank

Slipping

Checkoilisntrunningfromhoseswhilehookingup

6

Removeallhosesandretainingb

oltsfrompumpexcept

onebolttoholdit

Crush

ing

Beawareoffingersasthetherearemanyobjectsinthe

way,becareful

7

Attachedapprovedliftingdevice,

removeremainingbolt

andliftout

Slipping,falling,drippingoilslippe-

ringconditions,height

Handlecarefully,keepclearofwindow,keepincontact

withcranedriver

8

Changeoveranyrequiredfittings

tonewpump

Lifting

devicefallingover

Usecorrectliftingdevice,handle

carefully

9

Liftinnewpump

Slipping,falling,drippingoilslippery

conditions,height

Handlecarefully,keepclearofwindow

10

Fitallboltsandhoses,removelif

tingbracket

Crush

ing

Bracketmayswingout,handlecarefully

11

Removesuctionmanifoldpumpa

ndturnon

Crush

ing

Handlecarefully

12

Replacesidelouvres

Weight,height,crushing

Liftcarefullywithassistance,keepfingersclear

13

Startupandtuning

Highpressurehydraulics,enginerun-

ning

Refertomaintenancemanualfor

startupinstructionsand

proceduresfortuning


34/70

2-34

ServiceManual

Safeworkprocedure

sSWP020-Changeoutworkpump

R9250from13466

MJFCIFSS


Note!

TheLIEBHERReq



alwayscheckwith



35/70

ServiceManual

R9250from

13466

Safeworkprocedu

resSWP021-Changecabin

2-35

MJFCIFSS



gecabin

Step

Workprocedure

Hazardsidentified


1

FollowSWP001

2

FollowSWP002

3

Disconnectallelectricalwiringan

dharnesses

Tripping,darkness,restrictedarea

Usetorch,leadlight,becareful

4

Disconnectairconditininghoses

Gasp

ressure

Haveairconditioningsystemdrainedorensurevalvesare

closed

5

Unboltcabin,hookupslingsand

crane,liftoff,placeina

safearea

Heigh

t,crushingoffingers,connec-

tedwiringorhoses

Ensureallhosesandwiringisdis

connected,usecorrect

slingsandprocedures,becarefulintherestrictedarea

6

Liftnewcabinin,alignandtorquebolts

Crush

ingoffingers,workinginares-

tricted

area

Keepincontactwithcraneoperator,becareful

7

Connectallwiringandhoses

Tripping,restrictedworkarea,

darkn

ess

Usetorchorleadlight,beawareofbulkheads

8

Changeairconditioningsystem

Airco

nditioninggas

Wearglasses,becareful

9

Turnonisolators,startmachineandtestsystems

Crush

ing

Keepareaclearwhiletesting

10

Cleanarea

11


lete

Note!

TheLIEBHE



alwayschec



36/70

2-36

ServiceManual

Safeworkprocedure

sSWP022-R9250removeandreplaceengine

R9250from13466

MJFCIFSS



WP022-R9250removeandreplace

engine

Step

Workprocedure

Hazardsidentified


1

Ensurethatthemachineisfullyisolated

Personalinjury.Electricalandhy-

draulicenergy

SeeS

WP001andSWP003

2

Ifnecessaryareaistobepressureclea

ned

Personalinjuryfromhigh-pressure

waterandanycleaningfluidused

Usea

ppropriatePPE.Facemaskandg

loves

3

Drain

coolantfromradiator

Coolantmaybehot.Splashcoolant

ineyesoronthesking

Checkcoolanttemperatureandallowco

olingifnecessary.

Wear

PPE

4

Drain

engineoilfromengine

Oilonskino

rclothing.Oiltemp

Allow

oiltocoolifnecessary.WearcorrectPPE

5

Disconnectallelectricalwiringfromthe

jobareaasneces-

sary

Trippingonloosewiring

Rollupallloosewiringandstoreoutoftheworkareaif

possib

le

6

Remo

veallfiresystemfromaroundthe

workarea

Ifsystemactivates,possiblepersonal

injury

Remo

vesystemchargecanisterandisolatefiresystem

7

Remo

veinletandexhaustsystemsand

allcoversforengi-

neremoval

Sharpedges.Rustedandtightbolts.

Awkwardbo

dypositioning

PPE.Correcttoolingandhavesecondpersontoassist

8

Remo

veallhydrauliccomponentsandhosesnecessaryfor

engineremoval

Potentialsto

redhydraulicpressure.

Largevolum

esofoilmaybelost

SeeS

WP003.Havedraincontainersto

catchoilandblan-

kingp

latesasnecessary

9

Startundoingtheengineboltsnecessaryfortheremoval

Slipsandtrips

Usecorrecttoolingandblockanyunsta

blecomponents.

Askfo

rassistancewerenecessary

10

Prepa

resplitterboxforengineremoval

Splitterboxisbackheavyandmayfall

back.Theboxmayfallandcrushper-

sonal

Block

underthebackofthesplitterboxtopreventitfalling

back

11

Liftou

ttheengine

Fallingobjects

Arigg

erwillsupervisetheliftatalltimes


37/70

ServiceManual

R9250from

13466

Sa

feworkproceduresSWP022-R925

0removeandreplaceengine

2-37

MJFCIFSS


12

Engineontheground

Engin

emayfallcausingpersonalin-

jury

Theenginewillbesatonlevelgro

undandonsolidpacking

13

Liftreplacementengineintomac

hine

Fallingobjects,weight,chainsbrea-

king

Usecorrectslingsandliftingproc

edures,ensurenoloose

objectsontheengine,keepinco

ntactwithcraneoperator

14

Fitenginetosplitterboxwhileeng

ineissuspendedbythe

crane

Crush

edfingers,restrictedarea

Keepfingersclear,keepcontactwithcraneoperator

15

Lowerengineandfitmountingbo

lts,removecraneand

chains

Crush

edorpinchedfingers,chains

gettingtangledduringretraction

Keepfingersclear,usebarstoalignholes,keepslings

clearwhenretracting

16

Re-fithydraulicandenginecomp

onents

Weight,oildripping,restrictedarea

Usecorrectliftingtechniques,keepworkareaclean

17

Re-fitelectricalwiring,enginecoversandfiresystem

Falling,tripping,slippery

Beawareofthe"hole"whilefitting

enginecovers,usehelp

whenlifting

18

Fillallfluidlevels

Slippery

Cleanasyouwork

19

Removedangertags,startenginesandtestoperation

Noise

,dust,movingobjects

WearPPE,ensureallpersonnela

reclear,testaccordingto

maintenancemanual

20

Cleantheworkarea

21

Notifysupervisorthatthejobiscomplete

Note!

TheLIEBHE



alwayschec


Step

Workprocedure

Hazardsidentified



38/70

2-38

ServiceManual

Safeworkprocedure

sSWP023-Removeandreplaceswingb

ox

R9250from13466

MJFCIFSS



WP023-Remove

andreplaceswing

box

Step

Workprocedure

Hazardsidentified


1

Follow

SWP001

2

Follow

SWP003

3

Drain

oilfromswingboxtoberemoved

Ensurecorrectboxisdrained

Connectionsuctionhosetothecorrectoutlet

4

Remo

vevalvebankcovers

Falling,weig

ht

Usetw

opeopletoliftcovers

5

Remo

veservocontrolvalveandHPhoses

Weight,falling,slippingonoil

Useh

elptoliftvalves,cleanupanyoilasyouwork

6

Slingswingmotorandremove

Weight,slingsslipping,restricted

area

Usecorrectslingsandcranetoliftmoto

r,standclear

7

Remo

veswingboxboltsandpinioncov

er

Restricteda

rea,noise,slipping

Wear

earmuffs,cleanareawhileworking

8

Jackoutswingboxandremove

Weightonja

ck

Keep

clearwhilejacking,usecorrectslings,standclear

9

Refitswingbox,pumpoffswingbrakea

ndalignboxwith

dowels

Crushing,re

strictedarea

Keep

fingersclear,keepincontactwith

craneoperator

10

Boltb

oxinandfitpinioncover

Nose,weigh

t

UseP

PE,use2peopletoliftcover

11

Fithydswingmotor,HPhosesandservovalvebanks

Weight,restrictedarea,slipperywith

oil

Usecorrectslingsandprocedure,dont

standunderthe

load,use2peopletoliftvalvebanks

12

Refitvalvebankcovers

Weight,fallingdownthehole

Use2

peopletoliftcovers,beawareof

thehole

13

Comm

issionnewswingbox


ning

Usein

structionsinmaintenancemanual,wearPPE,stand

clearofmovingcomponents

14

Clean

area

15

Notify



39/70

ServiceManual

R9250from

13466

SafeworkproceduresSWP023-Removeandreplaceswingbox

2-39

MJFCIFSS


Note!

TheLIEBHE



alwayschec



40/70

2-40

ServiceManual

Safeworkprocedure

sSWP024-Changemainvalvebank

R9250from13466

MJFCIFSS



WP024-Changemainvalvebank

Step

Workprocedure

Hazardsidentified


1

Follow

SWP001

2

Follow

SWP003

3

Remo

veservocontrolhoses,returnhosesandHPfilters

Weightrestrictedarea,slipperywith

oil

Use2

peopletolifthoses,cleanareaasyouwork

4

Remo

vepipesandholdoutofway

Weight

Use2

peopleorcranetolift

5

Unboltvalvebankandliftout

Crushedfingers,chainsbreaking

Usecorrectliftprocedureandchains,keepincontactwith

crane

operator,standclearoflift

6

Refitnewvalvebank

Crushedfingers

Keep

fingersclearwhilepositioningnew

valvebank,dont

stand

underload,keepincontactwithc

raneoperator

7

Repla

cefrontpipes

Pinchedfing

ers,weight,slipperywith

oil

Use2

peopletolift,cleanasyouwork,beawareofrestric-

tedworkarea

8

Repla

ceHPfilters,returnhoseandservohose

Weight,slipperywithoil

Keep

workareaclean,use2peopletolift

9

Testn

ewvalvebank


ning

Usein

structionsinmaintenancemanual,wearPPE,stand

clearofmovingparts

10

Clean

area

11

Notify


Note!

TheLIEBHERReq



alwayscheckwith



41/70

ServiceManual

R9250from

13466

SafeworkproceduresSW

P025-Changeswingpump

2-41

MJFCIFSS



geswingpump

Step

Workprocedure

Hazardsidentified


1

FollowSWP001

2

FollowSWP003

3

Removesidecoversoffmachine

Weight,pinchedfingers

Use2peopletoliftcovers,keepfingersclear

4

Removeallhosesandboltsfrom

pump

Slipping

Usecorrecttools,keepareaclea

n

5

Liftpumpoutandinstallnewpum

p

Weight,restrictedarea,crushing,

slippe

ry

Usecorrectliftingtool,keepincontactwithcraneoperator,

lashpumpsecurelytoliftingtool,

keepareaclean

6

Refithosesandbolts

Crush

ing,slipperywithoil

Keepareaclean

7

Refitsidecovers

Weight,pinchedfingers

Use2peopletolift,keepfingersclear

8

Commisionperfactoryspecs

Noise

,movingparts

UsePPE,standclear,usemaintenancemanualinstruc-

tions

9

Cleanarea

10


lete

Note!

TheLIEBHE



alwayschec



42/70

2-42

ServiceManual

Safeworkprocedure

sSWP026-Changesplitterbox

R9250from13466

MJFCIFSS



WP026-Changesplitterbox

Step

Workprocedure

Hazardsidentified


1

Follow

SWP001

2

Follow

SWP003

3

Drain

splitterboxandturnoffhydsuctiontap

4

Remo

veexhaustsystemandalltopcovers

Weight,fallinginhole

Use2

peopletoliftoffcovers,beaware

ofhole,barricade

areaw

ithtape

5

Remo

veallhosesandelectricalwiring

Slippingonoil,crushing

Clean

asyouwork

6

Unboltcoupling,bellhousingandblock

engine

Restricteda

rea,crushingoffingers

Usecorrecttools,blockenginesoitcan

tmoveordrop

7

Unboltsplitterboxandliftoutsplitterbox

assy

Weight,slingsbreakingorslipping,

overbalancing

Slingcorrectlywithcorrectslings,keep

clear,keepincon-

tactw

ithcraneoperator

8

Changeoutallpumps

Weight

Liftca

refully,usecranewherenecessary,standclearof

load

9

Liftin

newsplitterboxandboltup

Weight,slingsbreakingorslipping,

overbalancing

Slingcorrectlywithcorrectslings,keep

clear,keepincon-

tactwithcraneoperator,keepareaclean,usecorrecttools

10

Installbellhousing,boltupcoupling

Restricteda

rea,pinchingfingers

Usecorrecttools

11

Installallhosesandwiring

Slippery

Keep

areaclean

12

Installtopcoversandexhaustsystem

Weight,fallinginhole

Use2

peopletoliftcovers,beawareof

hole

13

Refillsplitterboxandtest

Noise,engin

erunning

UseP

PE,standclear,commissionpermaintenancema-

nual

14

Clean

upworkarea

15

Notify



43/70

ServiceManual

R9250from

13466

SafeworkproceduresS

WP026-Changesplitterbox

2-43

MJFCIFSS


Note!

TheLIEBHE



alwayschec



44/70

2-44

ServiceManual

Safeworkprocedure

sSWP027-ChangesplitterboxGears

R9250from13466

MJFCIFSS



WP027-ChangesplitterboxGears

Step

Workprocedure

Hazardsidentified


1

Follow

SWP001

2

Follow

SWP003

3

Turnoffhydraulicsuctiontap

4

Remo

veallhoses

Slipperyand

oily

Block

allhosesandcleanareaasyoug

o

5

Remo

vebothpumps

Weight,rest

rictedarea,slippery

Usecorrectliftmethods,keepincontac

twithcraneopera-

tor,ha

ndlecarefully,keepareaclean

6

Remo

veandgearsandseals,replaceg

ears

Weight,restrictedarea,slippery

Handlecarefully,use2peopletoliftgears,keepareaclean

7

Refitgearcoverplateandnewseals

Weight,flyin

gobjects

Wear

PPE,use2peopletolift

8

Refitpumps

Weigth,pinc

hedfingers

Liftco

rrectly,keepincontactwithcrane

operator,keep

areac

lean,keepfingersclear

9

Refithoses

Slippery

Keep

areaclean

10

Turnhydraulicsuctionvalveon

11

Tests

ystem

Noise,movingcomponents

Wear

PPE,usemaintenancemanualin

structions

12

Clean

upworkarea

13

Notify


Note!

TheLIEBHERReq



alwayscheckwith



45/70

ServiceManual

R9250from

13466

SafeworkproceduresSWP028-Changesp

litterboxinputshaftassembly

2-45

MJFCIFSS



gesplitterboxinpu

tshaftassembly

Step

Workprocedure

Hazardsidentified


1

FollowSWP001

2

FollowSWP003

3

FollowSWP004

4

FollowSWP022toremoveengin

e

5

Installliftingdeviceoninputshaftassemblyandremove

inputshaftretainingbolts

Weight,slingslipping,slipperysurfa-

ce,ov

erbalancing

Usecorrectslingsandliftingprocedures,keepliftingappa-

ratusbalanced,keepareaclean

6

Removeinputshaftassemblingincludingthegear

Weight,notvisibletocraneoperator

Keepincontactwithoperator

7

Refitnewinputshaftassembly

Weight,pinchedfingersorhands,not

visibletocraneoperator

Keephandsandfingersclear,kee

pincontactwithoperator

8

Installboltsandremoveliftdevice

Slipperyarea,pinchedfingers


9

FollowSWP022tofitengine

Note!

TheLIEBHE



alwayschec



46/70

2-46

ServiceManual

Safeworkprocedure

sSWP029-Hy-torcoperation

R9250from13466

MJFCIFSS



WP029-Hy-torco

peration

Step

Workprocedure

Hazardsidentified


1

InspectHy-torcforphysicaldamage

Damagedhosesmayruptureathigh

pressure,toolcouldflyapartcausing

injury

Check

hosesandfittingsfordamage.C

hecktoolingfor

physic

aldamage

2

Inspectelectricpump

Electricfaultmaycausepersonalin-

jury

Check

toconfirmthatthepumphasbee

nelectricallyins-

pectedforthemonthofuse

3

Inspectsocketsforwearorphysicaldamage

Socketmay

sliporexplodeifinada-

magedstate

Anydamagedequipmentistobepresentedtothesupervi-

sorforreplacement

4

Fittoo

lingtotheboltheadandadjustth

ereactionarmto

theco

rrectposition

Socketorto

olmayslipandcause

personalinjury

Make

surethatthetoolingisinservicea

bleconditionand

thatth

ereactionarmisatthebestpositiontogivethetool

maxim

umsupport.Ifnecessaryasuppo

rtshouldbeused

toholdthetoolinposition

5

Setre

quiredpressureonpump/refertomanufactures

chart

Ifpressureisincorrecttheboltmay

snapandca

usepersonalinjuryand

damagetotoolingandequipment

Check

pressureonchartagainstboltdim

ensionandgrade

toobtaincorrecttorque

6

Comm

encetensioning

Toolslipping/hosedamage/perso-

nalinjury

Check

thatthehosesarenotjammedo

rtwistedandthat

thetoolissupported.Standwellcleara

talltimes

7

Tensioningcompleted

Storedhydraulicpressure/weightof

thetoolonremoval

Relea

seallhydraulicpressure.Ifnecessarygainassistan-

ceintheremovalofthetooling

Note!

TheLIEBHERReq



alwayscheckwith



47/70

ServiceManual

R9250from

13466

SafeworkproceduresSWP030-Removeandreplace

centregirderandsideframes

2-47

MJFCIFSS



veandreplacecentregirderandsideframes

Step

Workprocedure

Hazardsidentified


1

FollowSWP001

2

Setupmachineinposition

Perso

nnelinwayofmachine

Supervisortokeepallpersonnelclearexceptthoseactual-

lyinengagedinguidingmachineintoposition.Keepincon-

tactwithoperatoratalltimes

3

Removehoistcylinderlowerpins

andretractcylinders

Press

ureincylinders

Weightofcoverplatesandpins

Isolateandexpelstoredenergyin

hydraulicsystemasper

SWP003-Points1to6.

Wearprotectiveglovesandusec

orrectliftingprocedures

4

Setuppowerpackofundercarriage

Failur

eofhosesorfittings

Checkconditionofhosesandensurefittingscorrect

5

Setupjacksbeneathmachine

Unsta

blejacks.

Heavypartsswingingfromcranedu-

ringp

ositioningslingsorchainsor

loadb

eingunbalancedandfalling

Ensureflatandproperlycompactedbasebeneathjacks.

Useofguideropesfromsuspendedpartstocontrolswing.

Checkconditionofchains,etc.andensureloadisbalan-

ced.Supervisortokeepallpersonnelclearexceptthose

actuallyengagedinguidingcrane

operators

6

Removenutsandstudsfromupp

ercarriage

Fallfr

omundercarriage

Confinedworkareacouldproduce

unsafeconditions.Failureofhoses/

fittingsonHy-Torque/threadstret-

cher.

WeightofHy-Torqueor

threadstretcher

Personnelontheundercarriagetowearsafetyharness.

Ensurethoseworkingtherearefullyawareofeachother.

Checkconditionofhosesandensurefittingsarecorrect.


orrectliftingprocedures.

7

Jackupmachine

Machinemayfalloffjacks


lyengagedinjackingprocedures

.Supervisortomonitor

progressofliftandbeawareofanydangers


48/70

2-48

ServiceManual

Safeworkprocedure

sSWP030-Removeandreplacecentregirderandsideframes

R9250from13466

MJFCIFSS


8

Drive

undercarriageoutfrombeneathmachine

Clearancetouppercarriage

Personnelin

wayofmachine

Ensur

eexcessclearanceexistswhenja

ckingcomplete.

Super

visortokeepallpersonnelclearexceptthoseactual-

lyeng

agedinoperatingpowerpackforundercarriage

9

Break

stracksandlayout

Noisefromhammerknockingpins

outHammerfracturingpinscausingme-

talpiecesto

flytracksfallingand

crushingpersonnelastheyarelaid

out

Useo

fcorrectlyfittedearmuffsorearp

lugs

Wear

PPE-safetyhelmetandglassesa

ndgloves

Super


lyeng

agedintracklayingoutprocedure

s

10

Crack

tensiononcentregirder-to-sideframeboltsperSWP

029

Failureofho

sesorfittingsonHy-Torc

Check

conditionofhosesandensurefittingscorrect

11

Remo

vehalfoftheboltscentregirdertosideframes

Weightofbolts

Wear

protectiveglovesandusecorrect

liftingprocedures

12

Liftne

wsideframesonandfitfeettom

otorguardpins

Heavyparts

swingingfromcranedu-

ringtransfer

.

Slingsorchainsfailingorloadbeing

unbalanced

andfalling.

Weightofsu

pportfeet.

Fingerorha

ndinjurieswhileadjus-

tingorfitting

feet

Useo

fguideropesformsuspendedpar

tstocontrolswing.

Check

conditionofchainsetcandendu

reloadbalanced.

Super


lyeng

agedinguidingcraneoperators.

Wear


liftingprocedures.

Wear

protectiveglovesandtakecare

13

Liftne

wcentregirderintoposition

Heavyparts


ringtransfer

.


unbalanced

andfalling

Useo

fguideropesfromsuspendedpar

tstocontrolswing.

Check

conditionofchainsetcandensureloadbalanced.

Super


lyeng

agedinguidingcraneoperators

14

Halfb

oltnewcentregirderandsideframestogether

Weightofbolts

Wear


liftingprocedures

Step

Workprocedure

Hazardsidentified



49/70

ServiceManual

R9250from

13466



2-49

MJFCIFSS


15

Transferrotaryjointandbracket,

andfitnewhosekit

Press

ureinhosesSlippingorfalling

onpla

tformaroundrotaryjoint.

Fallin

toholebelowrotaryjoint.

Weightofjoint.

Confinedworkareacouldproduce

unsafeconditions.

Heavypartsswingfromcraneduring

transfer

ExpelstoredenergyinhydraulicsystemasperSWP003.

Cleanallgreaseoutfromaround

rotaryjointandplatform.

Personnelontheplatformtowea

rsafetyharness.



Ensurethoseworkingtherearefullyawareofeachother.

Useofguideropesfromsuspend

edpartstocontrolswing

16

Transferfinaldrivesandhosing

Failur

eofhosesorfittingsonHy-Tor-

queWeightofHy-Torque.

Heavypartsswingingformcranedu-

ringtransfer.


unbalancedandfalling

Checkconditionofhosesandensurefittingscorrect.




Checkconditionofchainsetc.an

densureloadbalanced.


lyengagedinguidingcraneoperators

17

Transferidlers

Finge

rorhandinjurieswhileadjus-

tingorfittingidlers.

Heavypartsswingingfromcranedu-

ringtransfer.


unbalanced

Wearprotectiveglovesandtakecare.


edpartstocontrolswing.





18

Transfertracktensionvalves,accumulatorsandhoses

Weightofaccumulatorsandother

components



19

Transfercarrierrollers

Finge

rorhandinjurieswhileadjus-

tingorfittingrollers.Heavyparts

swing

ingfromcraneduringtransfer.


unbalancedandfailing

Wearprotectiveglovesandtakecare.



dendureloadbalanced.



Step

Workprocedure

Hazardsidentified



50/70

2-50

ServiceManual

Safeworkprocedure

sSWP030-Removeandreplacecentregirderandsideframes

R9250from13466

MJFCIFSS


20

Fitfee

ttomotorguardpinstoholdside

frames

Weightofsu

pportfeet

Fingerorha


tingorfitting

feet

Wear


liftingprocedures.

Wear


21

Remo

verestofboltscentregirder-tosideframes

Weightofbolts

Wear


liftingprocedures

22

Liftou

tcentregirder

Heavyparts

swingingformcranedu-

ringtransfer

.


unbalanced

andfalling

Useo

fguideropesfromsuspendedpar

tstocontrolswing.

Check

conditionofchainsetc.andensu

reloadbalanced.

Super


lyeng


23

Comp

leteboltingnewcentregirdertos

ideframes

Weightofbolts

Wear


liftingprocedures

24

Torqu

eupcentregirdertosideframebolts

Failureofho

sesorfittingsonHy-Tor-

que.

WeightofHy-Torque

Checkconditionofhosesandensurefittingscorrect.

Wear


liftingprocedures

25

Fitextratrackpadstoeachtrackchain

Noisefromhammerknockingpinsin.

Hammerfracturingpinscausingme-

talpiecesto

fly

Usecorrectlyfittedearmuffsorearplugs.

Wear

correctPPE-safetyhelmetandglasses,andgloves

26

Lifttra

cksbackintopositionandreconn

ectchains

Noisefromhammerknockingpinsin.

Hammerfracturingpinscausingme-

talpiecesto

fly.Slingssnappingal-

lowingtrackstofallandcrush

personnel

Usecorrectlyfittedearmuffsorearplugs.

Wear

correctPPE-safetyhelmetandglasses,andgloves.

Check

conditionofslingsandensureco

rrectlyfitted.

Super


lyeng

agedintrackfittingprocedures

27

Setuppowerpackforundercarriage

Failureofho

sesorfittings

Checkconditionofhosesandensurefittingscorrect

28

Fitspacerringintocentregirder

Heavyparts


ringfitting.

Slingorchainsfailingorloadbeing

unbalanced

andfalling.

Fingerorha


tingorfitting

spacer

Useo

fguideropesfromsuspendedparttocontrolswing.

Check

conditionofchainsetc.andensu

reloadbalance.

Super


lyeng


Wear


Step

Workprocedure

Hazardsidentified



51/70

ServiceManual

R9250from

13466



2-51

MJFCIFSS


29

Placestudsintoholesinunderca

rriage

Fallfr

omundercarriage

Personnelontheundercarriagetowearsafetyharness

30

Driveundercarriagebeneathmachineandalign

Clearancetouppercarriage

Perso

nnelinwayofmachine

Ensureexcessclearancestillexists-nodropping


lyengagedinoperatingpowerpackforundercarriage

31

Lowermachinontoundercarriage

Machinemayfalloveroffjacks


lyengagedinjackingprocedures

.Supervisortomonitor

progressofdownliftandbeawareifanydangers

32

Fitstudsandnutsandtorqueup

Fallfr

omundercarriage

Personnelontheundercarriageclearexceptthoseactually

engagedinjackingprocedures.S

upervisortomonitorpro-

gressofdownliftandbeawareofanydangers

33

Reconnecthoistcylinderpowerp

ins

Weightofcoverplatesandpins



34

Removepowerpackandjacksan

dcleanarea

Heavyweightsswingingfromcrane

duringloadingofjacksandpower-

pack.


unbalancedandfailing


edpartstocontrolswing.





Note!

TheLIEBHE



alwayschec


Step

Workprocedure

Hazardsidentified



52/70

2-52

ServiceM

Documents

02 Safe Work Procedure