02 safe work procedure
TRANSCRIPT
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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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7/24/2019 02 Safe Work Procedure
2/70
2 - 2
Service Manual
R 9250 from 13466
LFR/en/version:08/2007
MJFCIFSS
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7/24/2019 02 Safe Work Procedure
3/70
Service Manual
R 9250 from 13466 2 -3
Safe work procedures
LFR/en/version:08/2007
MJFCIFSS
2 Safe work procedures
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Safe work procedures
2 - 4
Service Manual
R 9250 from 13466
LFR/en/version:08/2007
MJFCIFSS
-
7/24/2019 02 Safe Work Procedure
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.
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2-6
ServiceManual
Safeworkprocedure
sSWP002-BasicR9250machineisolat
ion
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.2SafeworkproceduresS
WP002-BasicR9250machineisola
tion
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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.
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ServiceManual
R9250from
13466
S
afeworkproceduresSWP003-R92
50Isolateforhydraulicrepair
2-7
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.3SafeworkproceduresSWP003-R925
0Isolateforhydra
ulicrepair
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
RRequipmentislargeandheavy.Itismandatorythatallworkbedo
neinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayschec
kwithyoursupervisorbeforeproceeding.
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2-8
ServiceManual
Safeworkprocedure
sSWP004-removeR9250engine
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.4SafeworkproceduresS
WP004-removeR
9250engine
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
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ServiceManual
R9250from
13466
SafeworkproceduresSWP
004-removeR9250engine
2-9
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
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
RRequipmentislargeandheavy.Itismandatorythatallworkbedo
neinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayschec
kwithyoursupervisorbeforeproceeding.
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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2-10
ServiceManual
Safeworkprocedure
sSWP005-Isolatemachinefortrackcom
ponentrepairs
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.5SafeworkproceduresS
WP005-Isolatem
achinefortrackcomponentrepairs
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
uipmentislargeandheavy.Itism
andatorythatallworkbedoneinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayscheckwith
yoursupervisorbeforeproceeding.
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ServiceManual
R9250from
13466
Sa
feworkproceduresSWP006-Isolatemachineforweldingrepairs
2-11
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.6SafeworkproceduresSWP006-Isolatemachineforweldingrepairs
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
RRequipmentislargeandheavy.Itismandatorythatallworkbedo
neinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayschec
kwithyoursupervisorbeforeproceeding.
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2-12
ServiceManual
Safeworkprocedure
sSWP007-Removeandreplacehydrauliccylinder
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.7SafeworkproceduresS
WP007-Remove
andreplacehydrauliccylinder
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
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ServiceManual
R9250from
13466
Safew
orkproceduresSWP007-Removeandreplacehydrauliccylinder
2-13
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
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
RRequipmentislargeandheavy.Itismandatorythatallworkbedo
neinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayschec
kwithyoursupervisorbeforeproceeding.
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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2-14
ServiceManual
Safeworkprocedure
sSWP008-Removalofbucketleversandlinks
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.8SafeworkproceduresS
WP008-Removalofbucketleversa
ndlinks
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
uipmentislargeandheavy.Itism
andatorythatallworkbedoneinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayscheckwith
yoursupervisorbeforeproceeding.
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ServiceManual
R9250from
13466
Safe
workproceduresSWP009-Repair/replacementofsuctionvalve
2-15
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.9SafeworkproceduresSWP009-Repa
ir/replacementof
suctionvalve
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
RRequipmentislargeandheavy.Itismandatorythatallworkbedo
neinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayschec
kwithyoursupervisorbeforeproceeding.
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2-16
ServiceManual
Safeworkprocedure
sSWP010-Removeandreplaceloadrollers
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.10SafeworkproceduresS
WP010-Remove
andreplaceloadrollers
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
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ServiceManual
R9250from
13466
SafeworkproceduresSWP010-Removeandreplaceloadrollers
2-17
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
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
RRequipmentislargeandheavy.Itismandatorythatallworkbedo
neinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayschec
kwithyoursupervisorbeforeproceeding.
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
-
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18/70
2-18
ServiceManual
Safeworkprocedure
sSWP011-Removeandreplacetrackchain
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.11SafeworkproceduresS
WP011-Remove
andreplacetrackchain
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
1
Follow
safetylist-SWP001
Requireminimumof2people
2
Alarg
eflatworkingarea
Cranesandforkliftsmayhavetrouble
withuneven
groundduringtrackre-
moval
Ensur
eworkareaisflat,freeofholesan
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
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19/70
ServiceManual
R9250from
13466
SafeworkproceduresSWP011-Re
moveandreplacetrackchain
2-19
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
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
RRequipmentislargeandheavy.Itismandatorythatallworkbedo
neinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayschec
kwithyoursupervisorbeforeproceeding.
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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20/70
2-20
ServiceManual
Safeworkprocedure
sSWP012-R9250trackdrivesprocketchangeout
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.12SafeworkproceduresS
WP012-R9250tr
ackdrivesprocketchangeout
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
1
Follow
safetychecklist-SWP001
Requireminimumof2people
2
Alarg
eflatworkingarea
Cranesandforkliftsmayhavetrouble
withuneven
groundduringtrackre-
moval
Ensur
eworkareaisflat,freeofholesan
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
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21/70
ServiceManual
R9250from
13466
Safew
orkproceduresSWP012-R9250trackdrivesprocketchangeout
2-21
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
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
Precautionstobetaken
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22/70
2-22
ServiceManual
Safeworkprocedure
sSWP012-R9250trackdrivesprocketchangeout
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
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
uipmentislargeandheavy.Itism
andatorythatallworkbedoneinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayscheckwith
yoursupervisorbeforeproceeding.
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
-
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23/70
ServiceManual
R9250from
13466
SafeworkproceduresSWP
013-Removecounterweight
2-23
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.13SafeworkproceduresSWP013-Remo
vecounterweight
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
RRequipmentislargeandheavy.Itismandatorythatallworkbedo
neinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayschec
kwithyoursupervisorbeforeproceeding.
-
7/24/2019 02 Safe Work Procedure
24/70
2-24
ServiceManual
Safeworkprocedure
sSWP014-Removeboom
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.14SafeworkproceduresS
WP014-Remove
boom
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
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7/24/2019 02 Safe Work Procedure
25/70
ServiceManual
R9250from
13466
SafeworkproceduresSWP014-Removeboom
2-25
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
14
Liftboomawayfrommachine
Suspendedload,fallingobjects
Keepallpersonnelclearofsuspe
ndedloadandfalling
shims
Note!
TheLIEBHE
RRequipmentislargeandheavy.Itismandatorythatallworkbedo
neinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayschec
kwithyoursupervisorbeforeproceeding.
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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2-26
ServiceManual
Safeworkprocedure
sSWP015-Removestick
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.15SafeworkproceduresS
WP015-Remove
stick
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
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7/24/2019 02 Safe Work Procedure
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ServiceManual
R9250from
13466
SafeworkproceduresSWP015-Removestick
2-27
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
Note!
TheLIEBHE
RRequipmentislargeandheavy.Itismandatorythatallworkbedo
neinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayschec
kwithyoursupervisorbeforeproceeding.
-
7/24/2019 02 Safe Work Procedure
28/70
2-28
ServiceManual
Safeworkprocedure
sSWP016-Changesplitterboxinputsha
ftassembly
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.16SafeworkproceduresS
WP016-Changesplitterboxinputshaftassembly
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
Handlecarefully,keepareaclean
8
Follow
SWP004tofinishjob
Note!
TheLIEBHERReq
uipmentislargeandheavy.Itism
andatorythatallworkbedoneinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayscheckwith
yoursupervisorbeforeproceeding.
-
7/24/2019 02 Safe Work Procedure
29/70
ServiceManual
R9250from
13466
SafeworkproceduresSWP01
7-Removeidlerandreplace
2-29
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.17SafeworkproceduresSWP017-Remo
veidlerandreplace
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
Keepinvisualcontactwithopera
torandclearoftheload
7
Useloadertojibtopushidlerbackintoplace
Crush
ingorflyingobjects
Keepclearandinvisualcontactwithoperator
8
RefertoSWPtoreplacetrackch
ain
Note!
TheLIEBHE
RRequipmentislargeandheavy.Itismandatorythatallworkbedo
neinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayschec
kwithyoursupervisorbeforeproceeding.
-
7/24/2019 02 Safe Work Procedure
30/70
2-30
ServiceManual
Safeworkprocedure
sSWP018-Changecarrierroller
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.18SafeworkproceduresS
WP018-Changecarrierroller
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
uipmentislargeandheavy.Itism
andatorythatallworkbedoneinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayscheckwith
yoursupervisorbeforeproceeding.
-
7/24/2019 02 Safe Work Procedure
31/70
ServiceManual
R9250from
13466
SafeworkproceduresS
WP019-Bucketchangeout
2-31
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.19SafeworkproceduresSWP019-Buck
etchangeout
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
Keepinvisualcontactwithopera
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
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2-32
ServiceManual
Safeworkprocedure
sSWP019-Bucketchangeout
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
15
Notify
supervisorthatjobiscomplete
Note!
TheLIEBHERReq
uipmentislargeandheavy.Itism
andatorythatallworkbedoneinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayscheckwith
yoursupervisorbeforeproceeding.
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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ServiceManual
R9250from
13466
SafeworkproceduresSWP
020-Changeoutworkpump
2-33
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.20SafeworkproceduresSWP020-Chan
geoutworkpump
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
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2-34
ServiceManual
Safeworkprocedure
sSWP020-Changeoutworkpump
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
Note!
TheLIEBHERReq
uipmentislargeandheavy.Itism
andatorythatallworkbedoneinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayscheckwith
yoursupervisorbeforeproceeding.
-
7/24/2019 02 Safe Work Procedure
35/70
ServiceManual
R9250from
13466
Safeworkprocedu
resSWP021-Changecabin
2-35
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.21SafeworkproceduresSWP021-Chan
gecabin
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
Notifysupervisorthatjobiscomp
lete
Note!
TheLIEBHE
RRequipmentislargeandheavy.Itismandatorythatallworkbedo
neinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayschec
kwithyoursupervisorbeforeproceeding.
-
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36/70
2-36
ServiceManual
Safeworkprocedure
sSWP022-R9250removeandreplaceengine
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.22SafeworkproceduresS
WP022-R9250removeandreplace
engine
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
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ServiceManual
R9250from
13466
Sa
feworkproceduresSWP022-R925
0removeandreplaceengine
2-37
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
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
RRequipmentislargeandheavy.Itismandatorythatallworkbedo
neinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayschec
kwithyoursupervisorbeforeproceeding.
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
-
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2-38
ServiceManual
Safeworkprocedure
sSWP023-Removeandreplaceswingb
ox
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.23SafeworkproceduresS
WP023-Remove
andreplaceswing
box
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
Highpressurehydraulics,enginerun-
ning
Usein
structionsinmaintenancemanual,wearPPE,stand
clearofmovingcomponents
14
Clean
area
15
Notify
supervisorthatjobiscomplete
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ServiceManual
R9250from
13466
SafeworkproceduresSWP023-Removeandreplaceswingbox
2-39
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
Note!
TheLIEBHE
RRequipmentislargeandheavy.Itismandatorythatallworkbedo
neinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayschec
kwithyoursupervisorbeforeproceeding.
-
7/24/2019 02 Safe Work Procedure
40/70
2-40
ServiceManual
Safeworkprocedure
sSWP024-Changemainvalvebank
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.24SafeworkproceduresS
WP024-Changemainvalvebank
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
Highpressurehydraulics,enginerun-
ning
Usein
structionsinmaintenancemanual,wearPPE,stand
clearofmovingparts
10
Clean
area
11
Notify
supervisorthatjobiscomplete
Note!
TheLIEBHERReq
uipmentislargeandheavy.Itism
andatorythatallworkbedoneinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayscheckwith
yoursupervisorbeforeproceeding.
-
7/24/2019 02 Safe Work Procedure
41/70
ServiceManual
R9250from
13466
SafeworkproceduresSW
P025-Changeswingpump
2-41
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.25SafeworkproceduresSWP025-Chan
geswingpump
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
Notifysupervisorthatjobiscomp
lete
Note!
TheLIEBHE
RRequipmentislargeandheavy.Itismandatorythatallworkbedo
neinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayschec
kwithyoursupervisorbeforeproceeding.
-
7/24/2019 02 Safe Work Procedure
42/70
2-42
ServiceManual
Safeworkprocedure
sSWP026-Changesplitterbox
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.26SafeworkproceduresS
WP026-Changesplitterbox
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
supervisorthatjobiscomplete
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ServiceManual
R9250from
13466
SafeworkproceduresS
WP026-Changesplitterbox
2-43
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
Note!
TheLIEBHE
RRequipmentislargeandheavy.Itismandatorythatallworkbedo
neinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayschec
kwithyoursupervisorbeforeproceeding.
-
7/24/2019 02 Safe Work Procedure
44/70
2-44
ServiceManual
Safeworkprocedure
sSWP027-ChangesplitterboxGears
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.27SafeworkproceduresS
WP027-ChangesplitterboxGears
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
supervisorthatjobiscomplete
Note!
TheLIEBHERReq
uipmentislargeandheavy.Itism
andatorythatallworkbedoneinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayscheckwith
yoursupervisorbeforeproceeding.
-
7/24/2019 02 Safe Work Procedure
45/70
ServiceManual
R9250from
13466
SafeworkproceduresSWP028-Changesp
litterboxinputshaftassembly
2-45
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.28SafeworkproceduresSWP028-Chan
gesplitterboxinpu
tshaftassembly
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
Handlecarefully,keepareaclean
9
FollowSWP022tofitengine
Note!
TheLIEBHE
RRequipmentislargeandheavy.Itismandatorythatallworkbedo
neinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayschec
kwithyoursupervisorbeforeproceeding.
-
7/24/2019 02 Safe Work Procedure
46/70
2-46
ServiceManual
Safeworkprocedure
sSWP029-Hy-torcoperation
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.29SafeworkproceduresS
WP029-Hy-torco
peration
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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
uipmentislargeandheavy.Itism
andatorythatallworkbedoneinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayscheckwith
yoursupervisorbeforeproceeding.
-
7/24/2019 02 Safe Work Procedure
47/70
ServiceManual
R9250from
13466
SafeworkproceduresSWP030-Removeandreplace
centregirderandsideframes
2-47
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
2.30SafeworkproceduresSWP030-Remo
veandreplacecentregirderandsideframes
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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.
Wearprotectiveglovesandusec
orrectliftingprocedures.
7
Jackupmachine
Machinemayfalloffjacks
Supervisortokeepallpersonnelclearexceptthoseactual-
lyengagedinjackingprocedures
.Supervisortomonitor
progressofliftandbeawareofanydangers
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2-48
ServiceManual
Safeworkprocedure
sSWP030-Removeandreplacecentregirderandsideframes
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
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
visortokeepallpersonnelclearexceptthoseactual-
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
visortokeepallpersonnelclearexceptthoseactual-
lyeng
agedinguidingcraneoperators.
Wear
protectiveglovesandusecorrect
liftingprocedures.
Wear
protectiveglovesandtakecare
13
Liftne
wcentregirderintoposition
Heavyparts
swingingfromcranedu-
ringtransfer
.
Slingsorchainsfailingorloadbeing
unbalanced
andfalling
Useo
fguideropesfromsuspendedpar
tstocontrolswing.
Check
conditionofchainsetcandensureloadbalanced.
Super
visortokeepallpersonnelclearexceptthoseactual-
lyeng
agedinguidingcraneoperators
14
Halfb
oltnewcentregirderandsideframestogether
Weightofbolts
Wear
protectiveglovesandusecorrect
liftingprocedures
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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ServiceManual
R9250from
13466
SafeworkproceduresSWP030-Removeandreplace
centregirderandsideframes
2-49
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
15
Transferrotaryjointandbracket,
andfitnewhosekit
Press
ureinhosesSlippingorfalling
onpla
tformaroundrotaryjoint.
Fallin
toholebelowrotaryjoint.
Weightofjoint.
Confinedworkareacouldproduce
unsafeconditions.
Heavypartsswingfromcraneduring
transfer
ExpelstoredenergyinhydraulicsystemasperSWP003.
Cleanallgreaseoutfromaround
rotaryjointandplatform.
Personnelontheplatformtowea
rsafetyharness.
Wearprotectiveglovesandusec
orrectliftingprocedures.
Ensurethoseworkingtherearefullyawareofeachother.
Useofguideropesfromsuspend
edpartstocontrolswing
16
Transferfinaldrivesandhosing
Failur
eofhosesorfittingsonHy-Tor-
queWeightofHy-Torque.
Heavypartsswingingformcranedu-
ringtransfer.
Slingsorchainsfailingorloadbeing
unbalancedandfalling
Checkconditionofhosesandensurefittingscorrect.
Wearprotectiveglovesandusec
orrectliftingprocedures.
Useofguideropesfromsuspendedpartstocontrolswing.
Checkconditionofchainsetc.an
densureloadbalanced.
Supervisortokeepallpersonnelclearexceptthoseactual-
lyengagedinguidingcraneoperators
17
Transferidlers
Finge
rorhandinjurieswhileadjus-
tingorfittingidlers.
Heavypartsswingingfromcranedu-
ringtransfer.
Slingsorchainsfailingorloadbeing
unbalanced
Wearprotectiveglovesandtakecare.
Useofguideropesfromsuspend
edpartstocontrolswing.
Checkconditionofchainsetc.an
densureloadbalanced.
Supervisortokeepallpersonnelclearexceptthoseactual-
lyengagedinguidingcraneoperators
18
Transfertracktensionvalves,accumulatorsandhoses
Weightofaccumulatorsandother
components
Wearprotectiveglovesandusec
orrectliftingprocedures
19
Transfercarrierrollers
Finge
rorhandinjurieswhileadjus-
tingorfittingrollers.Heavyparts
swing
ingfromcraneduringtransfer.
Slingsorchainsfailingorloadbeing
unbalancedandfailing
Wearprotectiveglovesandtakecare.
Useofguideropesfromsuspendedpartstocontrolswing.
Checkconditionofchainsetc.an
dendureloadbalanced.
Supervisortokeepallpersonnelclearexceptthoseactual-
lyengagedinguidingcraneoperators
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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2-50
ServiceManual
Safeworkprocedure
sSWP030-Removeandreplacecentregirderandsideframes
R9250from13466
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
20
Fitfee
ttomotorguardpinstoholdside
frames
Weightofsu
pportfeet
Fingerorha
ndinjurieswhileadjus-
tingorfitting
feet
Wear
protectiveglovesandusecorrect
liftingprocedures.
Wear
protectiveglovesandtakecare
21
Remo
verestofboltscentregirder-tosideframes
Weightofbolts
Wear
protectiveglovesandusecorrect
liftingprocedures
22
Liftou
tcentregirder
Heavyparts
swingingformcranedu-
ringtransfer
.
Slingsorchainsfailingorloadbeing
unbalanced
andfalling
Useo
fguideropesfromsuspendedpar
tstocontrolswing.
Check
conditionofchainsetc.andensu
reloadbalanced.
Super
visortokeepallpersonnelclearexceptthoseactual-
lyeng
agedinguidingcraneoperators.
23
Comp
leteboltingnewcentregirdertos
ideframes
Weightofbolts
Wear
protectiveglovesandusecorrect
liftingprocedures
24
Torqu
eupcentregirdertosideframebolts
Failureofho
sesorfittingsonHy-Tor-
que.
WeightofHy-Torque
Checkconditionofhosesandensurefittingscorrect.
Wear
protectiveglovesandusecorrect
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
visortokeepallpersonnelclearexceptthoseactual-
lyeng
agedintrackfittingprocedures
27
Setuppowerpackforundercarriage
Failureofho
sesorfittings
Checkconditionofhosesandensurefittingscorrect
28
Fitspacerringintocentregirder
Heavyparts
swingingfromcranedu-
ringfitting.
Slingorchainsfailingorloadbeing
unbalanced
andfalling.
Fingerorha
ndinjurieswhileadjus-
tingorfitting
spacer
Useo
fguideropesfromsuspendedparttocontrolswing.
Check
conditionofchainsetc.andensu
reloadbalance.
Super
visortokeepallpersonnelclearexceptthoseactual-
lyeng
agedinguidingcraneoperators.
Wear
protectiveglovesandtakecare
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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ServiceManual
R9250from
13466
SafeworkproceduresSWP030-Removeandreplace
centregirderandsideframes
2-51
MJFCIFSS
LHB/de/02/Ausgabe:08/2007
29
Placestudsintoholesinunderca
rriage
Fallfr
omundercarriage
Personnelontheundercarriagetowearsafetyharness
30
Driveundercarriagebeneathmachineandalign
Clearancetouppercarriage
Perso
nnelinwayofmachine
Ensureexcessclearancestillexists-nodropping
Supervisortokeepallpersonnelclearexceptthoseactual-
lyengagedinoperatingpowerpackforundercarriage
31
Lowermachinontoundercarriage
Machinemayfalloveroffjacks
Supervisortokeepallpersonnelclearexceptthoseactual-
lyengagedinjackingprocedures
.Supervisortomonitor
progressofdownliftandbeawareifanydangers
32
Fitstudsandnutsandtorqueup
Fallfr
omundercarriage
Personnelontheundercarriageclearexceptthoseactually
engagedinjackingprocedures.S
upervisortomonitorpro-
gressofdownliftandbeawareofanydangers
33
Reconnecthoistcylinderpowerp
ins
Weightofcoverplatesandpins
Wearprotectiveglovesandusec
orrectliftingprocedures
34
Removepowerpackandjacksan
dcleanarea
Heavyweightsswingingfromcrane
duringloadingofjacksandpower-
pack.
Slingsorchainsfailingorloadbeing
unbalancedandfailing
Useofguideropesfromsuspend
edpartstocontrolswing.
Checkconditionofchainsetc.an
densureloadbalanced.
Supervisortokeepallpersonnelclearexceptthoseactual-
lyengagedinguidingcraneoperators
Note!
TheLIEBHE
RRequipmentislargeandheavy.Itismandatorythatallworkbedo
neinasafemanner.Ifyouareindoubtaboutaprocedure,
alwayschec
kwithyoursupervisorbeforeproceeding.
Step
Workprocedure
Hazardsidentified
Precautionstobetaken
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2-52
ServiceM