Chapter 2 - Safe Work Procedure / Risk Assessment: Service Manual

Service Manual
Chapter 2 - Safe work procedure / Risk assessment

Safe work procedures....................................................................................................................................... 2-3
Safe work procedures SWP 001 - Safety check list ......................................................................... 2-5
Safe work procedures SWP 002 - Basic R 9250 machine isolation ................................................. 2-6
Safe work procedures SWP 003 - R 9250 Isolate for hydraulic repair ............................................. 2-7
Safe work procedures SWP 004 - remove R 9250 engine ............................................................... 2-8
Safe work procedures SWP 005 - Isolate machine for track component repairs ............................. 2-10
Safe work procedures SWP 006 - Isolate machine for welding repairs............................................ 2-11
Safe work procedures SWP 007 - Remove and replace hydraulic cylinder ..................................... 2-12
Safe work procedures SWP 008 - Removal of bucket levers and links............................................ 2-14
Safe work procedures SWP 009 - Repair / replacement of suction valve ........................................ 2-15
Safe work procedures SWP 010 - Remove and replace load rollers................................................ 2-16
Safe work procedures SWP 011 - Remove and replace track chain................................................ 2-18
Safe work procedures SWP 012 - R 9250 track drive sprocket change out..................................... 2-20
Safe work procedures SWP 013 - Remove counterweight............................................................... 2-23
Safe work procedures SWP 014 - Remove boom ............................................................................ 2-24
Safe work procedures SWP 015 - Remove stick.............................................................................. 2-26
Safe work procedures SWP 016 - Change splitterbox input shaft assembly.................................... 2-28
Safe work procedures SWP 017 - Remove idler and replace .......................................................... 2-29
Safe work procedures SWP 018 - Change carrier roller................................................................... 2-30
Safe work procedures SWP 019 - Bucket change out...................................................................... 2-31
Safe work procedures SWP 020 - Change out work pump .............................................................. 2-33
Safe work procedures SWP 021 - Change cabin ............................................................................. 2-35
Safe work procedures SWP 022 - R 9250 remove and replace engine ........................................... 2-36
Safe work procedures SWP 023 - Remove and replace swing box ................................................. 2-38
Safe work procedures SWP 024 - Change main valve bank............................................................ 2-40
Safe work procedures SWP 025 - Change swing pump................................................................... 2-41
Safe work procedures SWP 026 - Change splitterbox ..................................................................... 2-42
Safe work procedures SWP 027 - Change splitterbox Gears........................................................... 2-44
Safe work procedures SWP 028 - Change splitterbox input shaft assembly.................................... 2-45
Safe work procedures SWP 029 - Hy-torc operation........................................................................ 2-46
Safe work procedures SWP 030 - Remove and replace centre girder and side frames .................. 2-47
Safe work procedures SWP 031 - Fit stick assembly to boom ......................................................... 2-52
Safe work procedures SWP 032 - Assemble uppercarriage ............................................................ 2-54
Safe work procedures SWP 033 - Assemble undercarriage ............................................................ 2-56
Safe work procedures SWP 034 - Assemble boom, faceshovel or backhoe.................................... 2-58
Safe work procedures SWP 035 - Assemble stick, faceshovel or backhoe ..................................... 2-59
Safe work procedures SWP 036 - Fit boom assembly to uppercarriage .......................................... 2-60
Safe work procedures SWP 037 - Assemble LIEBHERR R 9250 .................................................... 2-62
Risk assessment............................................................................................................................... 2-66
LFR/en/version: 08 / 2007
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
1.17
1.18
1.19
1.20
1.21
1.22
1.23
1.24
1.25
1.26
1.27
1.28
1.29
1.30
1.31
1.32
1.33
1.34
1.35
1.36
1.37
1.38
R 9250 from 13466
MJFCIFSS
2 -1
Service Manual
2-2
MJFCIFSS
R 9250 from 13466
Service Manual
Safe work procedures
2 Safe work procedures
R 9250 from 13466
MJFCIFSS
2 -3
Service Manual
Safe work procedures
2-4
MJFCIFSS
R 9250 from 13466
LHB/de/02/Ausgabe: 08 / 2007
Check service vehicle
Report to supervisor
Check if excavator is on a blast area
Ensure that you have a "danger out of service" and informations tags, plus biro
Establish radio contact with excavator operator before approaching
Be aware of others working on the machine
Outside work in general
R 9250 from 13466
Wear safety glasses, boots and hard hat at all times and iridescent vest if applicable
Exposure to sunlight and heat

Exposure to wet weather and
cold
Personal injury or equipment damage
Personal injury
Forget to take tags with you
Steep ramps
Large equipment traffic
Hazards identified
Sunblock SPF15, clothing SPF50 full length, hard hat

brim and shaded safety glasses
Wear wet weather clothing
Inform others of your intentions. Completa appropriate tags

and tie to isolation point
Keep safe distance from excavator before embarking
Keep extra tags and biro in service vehicle
Check blast time before disabling
Sign contractor book
Check brakes
Two radio, revolving light and flag
Precautions to be taken
Safe work procedures SWP 001 - Safety check list
MJFCIFSS
2-5
Note!
The LIEBHERR equipment is large and heavy. It is mandatory that all work be done in a safe manner. If you are in doubt about a procedure,
always check with your supervisor before proceeding.
Work procedure
Step
2.1 Safe work procedures SWP 001 - Safety check list
Service Manual
Put attachment in rested position and service trap down
Turn off isolators for powerpack, batteries, electrical behind

the cab and maintenance
Pull apart sentry plugs on the engine
2-6
Park machine on level flat ground
Isolator sticking in
Attachment could creep
Injury to personnel while machine is

moving
Hazards identified
Rest position should be where the attachment can not

creep down
Stand clear
Service Manual
MJFCIFSS
R 9250 from 13466
Note!
Follow SWP 001
Work procedure
Step
2.2 Safe work procedures SWP 002 - Basic R 9250 machine isolation
Safe work procedures SWP 002 - Basic R 9250 machine isolation
Safe work procedures SWP 003 - R 9250 Isolate for hydraulic repair
Evacuate air from hydraulic tank
Install personal danger tag on isolation point and isolate
After the job is finished
Remove danger tags and turn on isolator
Check repair and test operation
R 9250 from 13466
Slippery
Oil leaks, hydraulic pressure and volume
All persons have completed work
Flying dirt, dust and oil
Servo accumulators not functioning,

unfamiliar personnel
Potential hydraulic pressure
Injury to personnel, damage to light

vehicles when moving
Hazards identified
Be careful
Stand clear of repair area
Ensure that all work is complete
One danger tag per person
Keep personnel away from outlet
Repair circuit so cylinder stored energy can be evacuated,

ensure hydraulic pressure is exhausted
Position attachment so mechanical stops are supporting

weight and / or bucket is flat on ground
Park a safe distance away from the machine.

Establish radio contact with operator before approaching
MJFCIFSS
2-7
Note!
Notify supervisor that job is finished
Turn ignition key on, safety lever down and activate joysticks in all direction to expel stored energy in cylinders and
servo accumulators
11
Ensure attachment is in a rested position
Clean affected area
Ensure machine is parked on flat surface
10
Follow safety check list SWP 001
Work procedure
Step
2.3 Safe work procedures SWP 003 - R 9250 Isolate for hydraulic repair
Service Manual
If necessary area is to be pressure cleaned
Drain coolant from radiator
Drain engine oil from engine
Disconnect all electrical wiring from the job area as necessary
Remove all fire system from around the work area
Remove inlet and exhaust systems and all covers for engine removal
Remove all hydraulic components and hoses necessary for

engine removal
Start undoing the engine bolts necessary for the removal
Prepare splitterbox for engine removal
10
2-8
Ensure that the machine is fully isolated
Work procedure
Step
MJFCIFSS
Splitterbox is back heavy and may fall

back. The box may fall and crush personal
Slips and trips
Potential stored hydraulic pressure.

Large volumes of oil may be losted
Sharp edges. Rusted and tight bolts.

Awkward body positionig
If system activates, possible personal

injury
Tripping on loose wiring
Oil on skin or clothing. Oil temp
Coolant may be hot. Splash coolant

in eyes or on the skin
Personal injury from highpressure

water and any cleaning fluid used
Personal injury. Electrical and hydraulic energy
Hazards identified
2.4 Safe work procedures SWP 004 - remove R 9250 engine
Safe work procedures SWP 004 - remove R 9250 engine
R 9250 from 13466
Block under the back of the splitterbox to prevent it falling

back
Use correct tooling and block any unstable components.

Ask for assistance where necessary
See SWP 003. Have drain containers to catch oil and blanking plates as necessary
PPE. Correct tooling and have second person to assist.
Remove system charge canister and isolate fire system
Rool up all loose wiring and store out of the work area if
possible
Allow oil to cool if necessary. Wear correct PPE
Check coolant temperature and allow cooling if necessary.

Wear PPE
Use appropriate PPE. Face mask and gloves
See SWP 001 and SWP 003
Service Manual
R 9250 from 13466
MJFCIFSS
2-9
Note!
Engine may fall causing personal injury
The engine will be sat on level ground and on solid packing
Engine on the ground
There will be no other work carried out on the machine while lifting out the engine. No person will be around the upper
deck while lifting. There will be no personal on the machine
unless they are involved with the lift. A rigger will supervise
the lift at all times.
13
Machine may be bumped while on

the jacks. Falling objects. Personal
may become caught between moving
objects
The rigger will have radio contact with the crane driver at all
times. All personal that are inside the work area will be notified before the lift commences
Lift out the engine when upper deck is suspended on jacking equipment
11
Hazards identified
Safe work procedures SWP 004 - remove R 9250 engine
12
Work procedure
Step
Service Manual
Ensure attachment is in rested position
Install danger tags
Evacuate oil from track tension circuit using left and right
pump valves and close off supply shutoff valve
After job is finished
Remove danger tags
Check repair and test operation
Clean affected area
Notify supervisor that job is complete
10
2 - 10
Ensure machine is parked on flat surface
Slippery
Moving parts, hydraulic pressure
All personnel have completed work
If engine is started some oil may get

passed. Shut off valve, use correct
dump valve. May cause confusion
due to upper carriage position
Attachment creep
Mobile lifting devices may have trouble with uneven ground during component removal
Hazards identified
Be careful
Stand clear of repair area and moving parts
Activate both to visually check, which is correct. Make sure

tap is turned on when machine returns to work
One tag per person
Bucket is flat on the ground, or the mechanical stops are

suppoting the weight
Ensure work area is flat, free of holes and rocks. Grade perimeter if necessary, minimum area is 40 m x 40 m
Service Manual
MJFCIFSS
R 9250 from 13466
Note!
Follow SWP 001
Work procedure
Step
2.5 Safe work procedures SWP 005 - Isolate machine for track component repairs
Safe work procedures SWP 005 - Isolate machine for track component repairs
Safe work procedures SWP 006 - Isolate machine for welding repairs
Park machine on level flat ground
Put attachment in rested position and service trap down
Turn off isolators for powerpack, batteries, electrical behind

the cab and maintenance
Pull apart sentry plugs on both engines
R 9250 from 13466
Follow SWP 001
Isolator sticking in
Attachment could creep

moving
Hazards identified
Check that isolator button pops out as you turn it off
Rest position should be where attachment cannot creep

down
Stand clear
MJFCIFSS
2 - 11
Note!
Wear safety glasses, boots, hat, iridescent vest
Work procedure
Step
2.6 Safe work procedures SWP 006 - Isolate machine for welding repairs
Service Manual
Follow SWP 003
Remove cylinder pin end caps
Hook crane to cylinder, and take weight of cylinder
Remove rod end cylinder pins
Remove danger tags and turn isolation switches on
Start engine and retract cylinders
Turn ignition key on, safety lever down and activate joysticks in all directions to expel stored energy in cylinders and
servo accumulators
Evacuate air from hydraulic tank
Install personal danger tag on isolation point and isolate
Remove hoses from cylinder
Remove barrel end pin
10
11
12
2 - 12
Follow SWP 001
Work procedure
Step
MJFCIFSS
Weight of pin, shims dislodging, weight of cylinder
Oil loss, rod extending, height
R 9250 from 13466
Use approved pin pulling tool, connect Franna crane with

rhino hook, use correct lifting equipment and procedures,
keep personnel clear, keep in contact with both crane operators
Cap all hoses, keep area clean, secure rod end with a
chain
Keep personnel away from outlet
Repair circuit so cylinder stored energy can be evacuated,

ensure hydraulic pressure is exhausted.
Servo accumulators not functioning,

unfamiliar personnel
Flying dirt, dust and oil
Stand clear, keep visual contact with operator
Use approved pin pulling tool, connect Franna crane with

rhino hook, use correct lifting equipment and procedures
keep personnel clear
Use correct lifting equipment and procedures
Safety pin on airlines and socket, ensure sockets in good

condition, leave one bolt holding the cap and carefully pivot
the cap out of the pin path, use scissor lift
Service Manual
Crushing
Crushing, weight, shims falling out,

stability of the cylinder
Pinched fingers, slipping ring, height
Weight of caps, using rattle gun, pinched fingers
Hazards identified
2.7 Safe work procedures SWP 007 - Remove and replace hydraulic cylinder
Safe work procedures SWP 007 - Remove and replace hydraulic cylinder
Lift replacement cylinder in place
Install barrel end pin
Install hydraulic hoses
Remove danger tags and turn isolation switches on
Start engine, extend cylinders, install rod end pins
Shut engine down, isolate, install dangers tags
Install end caps
Install grease lines
Clean area
Test operation
15
16
17
18
19
20
21
22
23
24
25
R 9250 from 13466
Sit cylinder on the ground, remove sling
14
Leaks
Weight
Crushing
Weight, slippery
Weight, height, crushing
Crushing overhead lift
Cylinder rolling, pinched fingers
Overhead load
Hazards identified
Keep personnel clear
Lift carefully, use scissor lift
One tag per person
Stand clear, keep visual contact with operator, use Franna

to lift pins, handle carefully
Handle carefully, keep area clean
Use Franna to lift pin, handle carefully
Use correct lifting procedures and sling, keep personnel

clear
Secure with wedges or "VEES", be careful with sling
Keep personnel clear, keep in contact with crane operator
Safe work procedures SWP 007 - Remove and replace hydraulic cylinder
MJFCIFSS
2 - 13
Note!
Remove cylinder
Work procedure
13
Step
Service Manual
Remove grease lines and pin end caps
Remove pins from links
Remove links
Stored removed components
2 - 14
Follow SWP 003 - Isolate machine for hydraulic repair
Personnel tripping over parts on the

ground
Weight of links, falling objects
Weight of links, loose bucket cylinders, suspended load
Heights
Hazards identified
Store parts in a secure location away from the work area.

Isolate with cones or flags
Use correct crane and slings. Check condition of slings before starting lift. Keep personnel away from load at all times
Use correct crane and slings. Start machine and suck rod
in. Secure cylinder with chains. DO NOT POWER OUT CYLINDERS WHILE ROD IS CHAINED. Keep personnel
away from load at all times
Use scissor lift or work platform and harness
Service Manual
MJFCIFSS
R 9250 from 13466
Note!
Follow SWP 001
Work procedure
Step
2.8 Safe work procedures SWP 008 - Removal of bucket levers and links
Safe work procedures SWP 008 - Removal of bucket levers and links
Safe work procedures SWP 009 - Repair / replacement of suction valve
See troubleshooting guide if required
Follow isolate machine for hydraulic repair - SWP 002
Remove / repair / replace suction valve
Clean affected area
Remove danger tag and turn on isolator
Operate and test operation
Notify supervisor that job is finished
R 9250 from 13466
Determine which suction valve requires repair
Hydraulic pressure and volume
All persons have completed work
Slippery
Hot component, hot oil, stored hydraulic pressure
Personal injury
Hazards identified
Stand clear of repair area
Be careful
Wear rubber gloves and ensure hydraulic pressure is exhausted
Ensure availability to repairmen
Require minimum of two people
MJFCIFSS
2 - 15
Note!
Follow safety check list - SWP 001
Work procedure
Step
2.9 Safe work procedures SWP 009 - Repair / replacement of suction valve
Service Manual
Using machine lift - appropriate end of machine to be far

enough off the ground to accommodate safety stands
Release track tension pressure and isolate track tension

system
Place safety stands under rollers - so as the roller you are

working on is free from obstruction
Lower machine back down onto stands. Making sure bucket stays on the ground
Turn machine off - isolate and install danger tag
Using Hy-torc crack - tension off all 4 bolts
Remove 2 bolts on lower side of roller which become inaccessible - due to lifting device
Using approved lifting tool and lift apparatus - place tool under roller and take the weight of the roller
Remove remaining 2 bolts
Remove the roller
10
11
2 - 16
Follow safety list - SWP 001
Work procedure
Step
MJFCIFSS
Weight, forklift operation
Roller may fall
Weight, fingers
Weight, sharp edges
Weight of unit, hydraulic pressure
Stands may eject out and injure persons
Weight of stands, dirt, dust, sharp edges
If the stands are not standing upright,

the machine may come down on top
of you
Injuries may occur
Hazards identified
Service Manual
R 9250 from 13466
Keep a safe distance from machine as roller is being removed
Ensure roller is properly seated on support
Keep out of path of machine and keep in visual contact with

the operator, handle carefully
Be careful
Wear personal protection and lift correctly. Inspect Hy-torc

carefully before using
Make sure machine is going to sit on stands correctly and

forklift operator is clear
Use forklift to place stands and bar to move stands around.

Handle carefully
Make sure operator knows what you are doing
Keep personnel away from machine, keep eye contact with

operator
Require minimum of 2 people
2.10Safe work procedures SWP 010 - Remove and replace load rollers
Safe work procedures SWP 010 - Remove and replace load rollers
Remove lifting tool
Replace remaining bolts and hy-torque all bolts to correct

tension
Remove danger tags and turn isolator on
Lift machine and remove stands
Place machine back onto the ground and retension track

adjuster system
Test operation
Clean area
Notify supervisor
14
15
16
17
18
19
20
21
R 9250 from 13466
Fit 2 bolts that are accessible and tighten most of the way
up
13
Personal injury
Hydraulic pressure
Weight, forklift operation
All work completed
Weight, hydraulic pressure, sharp edges
Forklift operation, weight
Fingers, sharp edges, hydraulic pressure
Roller falling off support, weight, fingers
Hazards identified
Keep personnel clear and keep in visual contact with the

opertor
Keep personnel clear and keep in visual contact with the

operator
Keep all personnel clear and keep in visual contact with the
operator
Ensure all work is done
Wear personal protection, lift hy-torque correctly, be careful
Keep a safe distance from machine
Wear personal protective equipment, be careful
Keep visual contact with operator and dont stand on machine path. Ensure roller seated correctly on the support.
Be careful
Safe work procedures SWP 010 - Remove and replace load rollers
MJFCIFSS
2 - 17
Note!
Re-fit new roller
Work procedure
12
Step
Service Manual
A large flat working area
Turn the track tension tap off, move the lever to release the
track tension pressure for the side you are working on
Choose any one of the track bolts, use Hy-Torque to remove bolt - knocking the pin out
To split the track, start machine up. Move the machine

slowly to roll track out
Lift side of machine, using a tractor to pull track out, clear

from machine
Install supports under the machine, lower machine on to

supports
Install out of service tag
When ready to replace track chain
Remove out of service tag
10
2 - 18
Follow safety list - SWP 001
Work procedure
Step
MJFCIFSS
Weight, fingers
While pulling track, slings could snap

and fly through the air
Track could roll away quickly
Noise from the high torque, when

knocking the pin out a piece of metal
will fly out. Make sure everyone is
clear of the tracks, remove track pin
from side of machine.
Hydraulic pressure
If machine is started while the tap is

on, track will pump up
Cranes and forklifts may have trouble

with uneven ground during track removal
Hazards identified
Service Manual
R 9250 from 13466
Use forklift, require 3 plates 50 mm x 1 meter x 1 meter.

Maintain eye contact with operator
Stand clear of machine while lifting and moving track out
Make sure that the track tension tap is turned off, keep
clear of the track when moving. Ensure eye contact with
operator, stand clear of track
Wear safety glasses and ear plugs. Keep clear of the

tracks. Lift carefully, inspect Hy-Torque before using
Make sure that the tap is turned off
Ensure work area is flat, free of holes and rocks. Grade perimeter if necessary. Minimum area is 40 x 50 meters
2.11Safe work procedures SWP 011 - Remove and replace track chain
Safe work procedures SWP 011 - Remove and replace track chain
Lower machine on tracks and position correctly
Install danger tag and isolate
Lift chain over idler with a loader
Lift the other end of the chain over the sprocket with another loader
Position 2 remaining pads in alignment and insert joining

pin
Insert retaining bolts and torque
Open track tension valve
Remove danger tag, turn on isolator
Start engine, allow machine to pump tracks, test operation

by travel
Clean area
Notify supervisor
13
14
15
16
17
18
19
20
21
22
23
R 9250 from 13466
Drag track under machine
12
Weight, slippery
Personal injury
Personnel still working on machine
Injury to head and back while under

machine
Weight, sharp edges, hydraulic pressure
Weight, fingers
Sling could break
Sling could slip
Personal injury

and fly through air
Moving parts
Hazards identified
Be careful
Stand clear, watch operator
Ensure all work is complete
Be careful
Handle carefully
Lift with forklift, handle carefully
Stand clear, maintain eye contact with loader operator
One tag for each person
Stand clear and maintain eye contact with operator
Stand clear of machine while lifting and moving track
Ensure all personnel are clear of the area
Safe work procedures SWP 011 - Remove and replace track chain
MJFCIFSS
2 - 19
Note!
Start engine and lift machine
Work procedure
11
Step
Service Manual
A large flat working area
Turn the track tension tap off, move the lever to release the
track tension pressure for the side you are working on
Choose any one of the track bolts, use Hy-Torque to remove bolt. Use hydraulic press to push pin out, or knock the
pin out with a hammer
To split the track, start machine up. Move the machine

slowly to roll track out
Lift side of machine, using a tractor to pull track out, clear

from machine
Install supports under the machine, lower machine on to

supports
Install danger tags
Clean rocks and debris, remove travel motor guards
Remove travel motors
10
2 - 20
Follow safety check list - SWP 001
Work procedure
Step
MJFCIFSS
Oil spillage, weight
Crane accessibility, weight falling objects
Weight, fingers

Track could roll away quickly
Noise from the high torque, when

knocking the pin out a piece of metal
will fly out.
Hydraulic pressure
If machine is started while the tap is

on, track will pump up
Cranes and forklifts may have trouble

with uneven ground during track removal
Hazards identified
Service Manual
R 9250 from 13466
Leave hoses attached and support motors at ground level,

lift carefully
Position attachment to facilitate crane accessibility, be careful
One tag per person
Use forklift, require 3 plates 50 mm x 1 meter x 1 meter.

Maintain eye contact with operator
Stand clear of machine while lifting and moving track out
Make sure that the track tension tap is turned off, keep
clear of the track when moving. Ensure eye contact with
operator, stand clear of track
Wear safety glasses and ear plugs. Keep clear of the

tracks. Lift carefully, inspect Hy-Torque before using. Make
sure everyone is clear of the tracks. Remove track pin from
side of machine
Make sure that the tap is turned off
Ensure work area is flat, free of holes and rocks. Grade perimeter if necessary. Minimum area is 40 x 50 meters
2.12Safe work procedures SWP 012 - R 9250 track drive sprocket change out
Safe work procedures SWP 012 - R 9250 track drive sprocket change out
Remove sprocket bolts with Hy-Torque
Release sprocket from final drive ready for removal
Secure lifting device to final drive
Remove final drive bolts
Remove final drive
Remove sprocket
Clean mating surfaces of all components
Install new sprocket
Install final drive
Install inner and outer plate
Remove danger tags
Start engine and lift machine
Drag track under the machine
Lower machine on tracks and position correctly
Install danger tag and isolate
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
R 9250 from 13466
Remove final drive inner and outer plates
Work procedure
11
Step
Service Manual
MJFCIFSS
Personal injury

Moving parts
Personnel working
Weight
Weight, personal injury
Component support and stability
Sanding and grinding generating debris
Weight
Sudden movement of component
Rattle gun noise, airlines
Device damage through use or transit, weight
Sprocket drop
Hydraulic pressure
Oil spillage, weight
Hazards identified
One tag for each person
Stand clear and maintain eye contact with operator
Stand clear of machine while lifting and moving track
Ensure all personnel are clear of the area
Ensure all personnel accounted for
Lift carefully
Use correct tools to torque bolts
2 - 21
Chock the sprocket upright and correct height or suspend

with second crane
Face shield and hearing protection
Personnel to stand clear
Hearing protection, hose clips
Inspect condition
Chock sprocket with wooden blocks or support with second

crane. All personnel to be clear of suspended loads unless
stabilising
Check Hy-Torque carefully, lift and handle carefully
Leave hoses attached and support motors at ground level,

lift carefully
Position 2 remaining pads in alignment and insert joining

pin
Insert retaining bolts and specified torque
Open track and tension valve
Remove danger tag, turn on isolator
Start engine, allow machine to pump tracks, test operation

by travel
Clean area
Notify supervisor
29
30
31
32
33
34
35
2 - 22
Lift the other end of the chain over the sprocket with another loader
28
Weight, slippery
Personal injury
Personnel still working on machine
Injury to head and back while under

machine
Weight, sharp edges, hydraulic pressure
Weight, fingers
Sling could break
Sling could slip
Hazards identified
Be careful
Stand clear, watch operator
Ensure all work is complete
Be careful
Handle carefully
Lift with forklift, handle carefully
Stand clear maintain eye contact with loader operator
Service Manual
MJFCIFSS
R 9250 from 13466
Note!
Lift chain over idler with a loader
Work procedure
27
Step
Remove handrails, lights from counterweight
Attach crane to counterweight and remove bolts
Lift counterweight off
R 9250 from 13466
Follow SWP 002
Weight, swinging
Breaking sling, restricted area, weight, flying objects
Weight, height
Hazards identified
Keep clear while lifting, attach rope to prevent swinging
Use correct lifting gear and crane, wear PPE, use ACRU
PROP to support Hy-Torque while undoing bolts
Lift correctly, use correct PPE, tape off area
Safe work procedures SWP 013 - Remove counterweight
MJFCIFSS
2 - 23
Note!
Follow SWP 001
Work procedure
Step
2.13Safe work procedures SWP 013 - Remove counterweight
Service Manual
Isolate per SWP 003
Remove stick per SWP 015
Drive boom down as far as possible
Remove all grease lines between boom and upper deck.

Plug all grease lines
Remove all electrical wiring
Remove and plug hydraulic lines between boom and stick
Remove cover plate from bottom of boom cylinder and

boom
Use chains to secure boom cylinders to boom, so they

wont hang when the boom is removed
Set crane to front of boom to take weight
Connect crane to boom cylinder pins and remove
Lift boom level and attach another crane to rear
Take some weight on the cranes and remove boom cylinder base pins
10
11
12
13
2 - 24
Isolate per SWP 001
Work procedure
Step
MJFCIFSS
Crushed fingers, restricted space,

height
Suspended load, crushed fingers
Height, weight, crushing, suspended

load
Weight
Chains slipping, pinched fingers
Crushed fingers and hands
Stored pressure
Heights
Working at heights, slippery
Falling objects
Hazards identified
2.14Safe work procedures SWP 014 - Remove boom
Safe work procedures SWP 014 - Remove boom
R 9250 from 13466
Keep clear when pins are removed, keep clear of load
Keep clear
Keep fingers clear, keep away from load
Ensure cranes and slings are in good condition use correct

lifting procedures
Put bite on chains, keep fingers clear
Wear hand protection, keep hands clear, use correct lifting

techniques
Be careful when breaking lines, cover with rags
Use safety harness or scissor lift or work platform. Operators must have tickets
Use safety harness or scissor lift or work platform
Ensure nothing is left on top after stick removal
Service Manual
Work procedure
Suspended load, falling objects
Hazards identified
Keep all personnel clear of suspended load and falling

shims
Safe work procedures SWP 014 - Remove boom
MJFCIFSS
2 - 25
Note!
Lift boom away from machine
R 9250 from 13466
14
Step
Service Manual
Remove bucket SWP 019
Lay boom down with stick out
Isolate per SWP 003
Remove grease lines between boom and stick. Plug all

lines
Remove bucket cut-out wiring between boom and stick
Remove and plug hydraulic lines between stick and boom
Remove end caps from stick cylinders and boom to stick

pins
Remove stick pins using mobile crane
Restart machine and suck slick cylinders in
Locate crane in suitable position to support stick, connect

to stick
Remove pins securing stick to boom with crane
Remove stick from machine
10
11
12
13
2 - 26
Follow SWP 001
Work procedure
Step
MJFCIFSS
Falling objects suspended load
Height, pinched fingers, suspended

load
Height, pinched fingers
Oil spillage, machine moving
Falling objects such as shims, suspended load
Crushing of fingers or hands, height
Stored pressure, height
Height
Working at heights, pinched fingers

moving
Hazards identified
2.15Safe work procedures SWP 015 - Remove stick
Safe work procedures SWP 015 - Remove stick
Keep clear
R 9250 from 13466
Use correct lifting gear and techniques, use safety harness,

keep clear
Use correct lifting gear and techniques, use safety harness,

keep fingers clear
Ensure bucket hoses capped correctly, keep personnel

clear
Keep all personnel clear
Keep clear, use safety harness or scissor lift. Use correct

lifting techniques
Be careful when breaking lines, cover with rags, use safety

harness and scissor lift when required
Use safety harness and scissor lift as required
Use safety harness and scissor lift as required. Keep fingers clear
Keep clear and erect barricades, one person to direct operator
Service Manual
R 9250 from 13466
Service Manual
MJFCIFSS
2 - 27
Note!
Safe work procedures SWP 015 - Remove stick
Follow SWP 004
Install lifting device on input shaft assembly and remove

bolts
Remove input shaft assembling including the gear
Refit new input shaft assembly
Install bolts and remove lift device
Follow SWP 004 to finish job
2 - 28
Follow SWP 003
Slippery area, pinched fingers
Weight, pinched fingers or hands, not

visible to crane operator
Weight, not visible to crane operator
Weight, sling slipping, slippery surface, overbalancing
Hazards identified
Keep hands and fingers clear, keep in contact with operator
Keep in contact with operator
Use correct slings and lifting procedures, keep lifting apparatus balanced, keep area clean
Service Manual
MJFCIFSS
R 9250 from 13466
Note!
Follow SWP 001
Work procedure
Step
2.16Safe work procedures SWP 016 - Change splitterbox input shaft assembly
Safe work procedures SWP 016 - Change splitterbox input shaft assembly
Lay out chain, do not remove from under load rollers
Attach sling to idler and use a loader / tractor to tow the idler
out on the track chain
Remove idler from chain and replace
Use crane to hold up the rear section of the idler
Use loader to jib to push idler back into place
Refer to SWP to replace track chain
R 9250 from 13466
Follow SWP 011, removal of track chain
Crushing or flying objects
Crushed limbs and fingers
Heavy parts swinging from crane are

dangerous
Heavy machinery, sling could break,

idler could roll out on the chain causing severe injury
Chain may roll off under own momentum
Hazards identified
Keep clear and in visual contact with operator
Keep in visual contact with operator and clear of the load
Sling correctly with approved slings, keep clear of the load
Keep in visual contact with operator, use approved tow

slings, keep clear at all times
Keep clear, barricade area where track could fall
Safe work procedures SWP 017 - Remove idler and replace
MJFCIFSS
2 - 29
Note!
Follow SWP 001
Work procedure
Step
2.17Safe work procedures SWP 017 - Remove idler and replace
Service Manual
Using loader or jack, lift track chain into appropriate position and block up
Remove bolts from roller
Using loader forks, remove roller from the machine
Replace roller on machine and install bolts
Jack or lift tracks and remove blocks
Lower tracks back onto rollers and remove jacks
Follow SWP 005 to complete job
2 - 30
Follow SWP 005
Tracks falling
Weight of blocks, tracks slipping
Crushed fingers, roller falling off forks
Roller falling off forks
Slipping, small area, crushed fingers
Crushing hands and fingers, weight

of blocks and chain
Hazards identified
Keep clear and in visual contact with loader operator
Lift blocks carefully, keep clear of tracks and loader
Lash roller to forks, keep in visual contact with operator,

keep clear
Lash roller to forks, stand clear
Have adequate work platform, keep fingers clear
Keep hands and fingers clear, have appropriate blocks,

and lift carefully
Service Manual
MJFCIFSS
R 9250 from 13466
Note!
Follow SWP 001
Work procedure
Step
2.18Safe work procedures SWP 018 - Change carrier roller
Safe work procedures SWP 018 - Change carrier roller
Place seals around bushings in new bucket
Align stick to bucket bushings and fit bucket pins
10
R 9250 from 13466
Clean area
Lift stick out of bucket and align in new bucket
14
Remove bucket to stick pins
Install half clamps, end covers and grease lines
Start machine and retract bucket cylinders
13
Put bucket in upright position and remove pins from end of

the bellcranks
Isolate machine with maintenance isolation switch
Remove grease lines, half clamps and pin end caps
12
Isolate machine with maintenance isolation switch
Align bellcranks to bucket and fit pins
Ensure level position for bucket floor to rest
11
Follow SWP 001
Work procedure
Step
MJFCIFSS
Crushing and fingers, height and weight
Weight, slings slipping, bellcranks

moving and crushing
Heavy equipment, slings slipping
Crushing
Crushing
Crushing or striking
Crushing
Weight, crushing, striking
Weight of end caps, height
If area not level, more difficult and hazardous to align pins
Hazards identified
2.19Safe work procedures SWP 019 - Bucket change out
Service Manual
2 - 31
Ensure attachment is in the correct position, keep fingers

clear when installing covers, lift covers carefully, use scissor lift
Be careful, may have to tie up one bellcranks
Have correct slings, keep clear of crane, lift pins carefully
Keep fingers clear when installing seals in to bushes
Keep in visual contact with operator
Keep clear of pins dropping or bucket rolling, slinging of

pins
Keep clear, and visual contact with operator
Keep clear of bellcranks swinging, slinging of pins
Lift carefully with assistance or a crane, use a scissor lift
Prepare area with a grader or dozer
Safe work procedures SWP 019 - Bucket change out
2 - 32
15
Step
Hazards identified
Service Manual
MJFCIFSS
R 9250 from 13466
Note!
Work procedure
Safe work procedures SWP 019 - Bucket change out
Lift in new pump
R 9250 from 13466
Start up and tuning
Changeover any required fittings to new pump
13
Attached approved lifting device, remove remaining bolt

and lift out
Replace side louvres
Remove all hoses and retaining bolts from pump except

one bolt to hold it
12
Arrange pump to pump from suction manifold back into

main tank
Remove suction manifold pump and turn on
Turn off main hydraulic tap to suction manifold
11
Remove enough side louvres to provide adequate access

to pump area
Fit all bolts and hoses, remove lifting bracket
Follow SWP 003 - Isolate for hydraulic repair
10
Follow SWP 001
Work procedure
Step
MJFCIFSS
High pressure hydraulics, engine running
Crushing
Crushing
Slipping, falling, dripping oil slippery

conditions, height
Lifting device falling over
Slipping, falling, dripping oil slippering conditions, height
Crushing
Slipping
Weight
Hazards identified
2.20Safe work procedures SWP 020 - Change out work pump
Service Manual
2 - 33
Refer to maintenance manual for start up instructions and

procedures for tuning
Lift carefully with assistance, keep fingers clear
Handle carefully
Bracket may swing out, handle carefully
Handle carefully, keep clear of window
Use correct lifting device, handle carefully
Handle carefully, keep clear of window, keep in contact

with crane driver
Be aware of fingers as the there are many objects in the

way, be careful
Check oil isnt running from hoses while hooking up
Lift carefully with assistance
Safe work procedures SWP 020 - Change out work pump
2 - 34
Service Manual
MJFCIFSS
R 9250 from 13466
Note!
Safe work procedures SWP 020 - Change out work pump
Disconnect all electrical wiring and harnesses
Disconnect air conditining hoses
Unbolt cabin, hook up slings and crane, lift off, place in a

safe area
Lift new cabin in, align and torque bolts
Connect all wiring and hoses
Change air conditioning system
Turn on isolators, start machine and test systems
Clean area
10
11
R 9250 from 13466
Follow SWP 002
Crushing
Air conditioning gas
Tripping, restricted work area,

darkness
Crushing of fingers, working in a restricted area
Height, crushing of fingers, connected wiring or hoses
Gas pressure
Tripping, darkness, restricted area
Hazards identified
Keep area clear while testing
Wear glasses, be careful
Use torch or leadlight, be aware of bulkheads
Keep in contact with crane operator, be careful
Ensure all hoses and wiring is disconnected, use correct

slings and procedures, be careful in the restricted area
Have air conditioning system drained or ensure valves are

closed
Use torch, leadlight, be careful
Safe work procedures SWP 021 - Change cabin
MJFCIFSS
2 - 35
Note!
Follow SWP 001
Work procedure
Step
2.21Safe work procedures SWP 021 - Change cabin
Service Manual
If necessary area is to be pressure cleaned
Drain coolant from radiator
Drain engine oil from engine
Disconnect all electrical wiring from the job area as necessary
Remove all fire system from around the work area
Remove inlet and exhaust systems and all covers for engine removal
Remove all hydraulic components and hoses necessary for

engine removal
Start undoing the engine bolts necessary for the removal
Prepare splitterbox for engine removal
Lift out the engine
10
11
2 - 36
Ensure that the machine is fully isolated
Work procedure
Step
MJFCIFSS
Falling objects
Splitterbox is back heavy and may fall

back. The box may fall and crush personal
Slips and trips
Potential stored hydraulic pressure.

Large volumes of oil may be lost
Sharp edges. Rusted and tight bolts.

Awkward body positioning
If system activates, possible personal

injury
Tripping on loose wiring
Oil on skin or clothing. Oil temp
Coolant may be hot. Splash coolant

in eyes or on the sking
Personal injury from high-pressure

water and any cleaning fluid used
Personal injury. Electrical and hydraulic energy
Hazards identified
Service Manual
A rigger will supervise the lift at all times
R 9250 from 13466
Block under the back of the splitterbox to prevent it falling

back
Use correct tooling and block any unstable components.

Ask for assistance were necessary
See SWP 003. Have drain containers to catch oil and blanking plates as necessary
PPE. Correct tooling and have second person to assist
Remove system charge canister and isolate fire system
Roll up all loose wiring and store out of the work area if
possible
Allow oil to cool if necessary. Wear correct PPE
Check coolant temperature and allow cooling if necessary.

Wear PPE
Use appropriate PPE. Face mask and gloves
See SWP 001 and SWP 003
2.22Safe work procedures SWP 022 - R 9250 remove and replace engine
Safe work procedures SWP 022 - R 9250 remove and replace engine
Fit engine to splitterbox while engine is suspended by the

crane
Lower engine and fit mounting bolts, remove crane and

chains
Re-fit hydraulic and engine components
Re-fit electrical wiring, engine covers and fire system
Fill all fluid levels
Remove danger tags, start engines and test operation
Clean the work area
Notify supervisor that the job is complete
14
15
16
17
18
19
20
21
R 9250 from 13466
Lift replacement engine in to machine
13
Noise, dust, moving objects
Slippery
Falling, tripping, slippery
Weight, oil dripping, restricted area
Crushed or pinched fingers, chains

getting tangled during retraction
Crushed fingers, restricted area
Falling objects, weight, chains breaking
Engine may fall causing personal injury
Hazards identified
Wear PPE, ensure all personnel are clear, test according to

maintenance manual
Clean as you work
Be aware of the "hole" while fitting engine covers, use help

when lifting
Use correct lifting techniques, keep work area clean
Keep fingers clear, use bars to align holes, keep slings

clear when retracting
Keep fingers clear, keep contact with crane operator
Use correct slings and lifting procedures, ensure no loose

objects on the engine, keep in contact with crane operator
The engine will be sat on level ground and on solid packing
Safe work procedures SWP 022 - R 9250 remove and replace engine
MJFCIFSS
2 - 37
Note!
Engine on the ground
Work procedure
12
Step
Service Manual
Follow SWP 003
Drain oil from swing box to be removed
Remove valve bank covers
Remove servo control valve and HP hoses
Sling swing motor and remove
Remove swing box bolts and pinion cover
Jack out swing box and remove
Refit swing box, pump off swing brake and align box with
dowels
Bolt box in and fit pinion cover
Fit hyd swing motor, HP hoses and servo valve banks
Refit valve bank covers
Commission new swing box
Clean area
10
11
12
13
14
15
2 - 38
Follow SWP 001
Work procedure
Step
MJFCIFSS
Weight, falling down the hole
Weight, restricted area, slippery with

oil
Nose, weight
Crushing, restricted area
Weight on jack
Restricted area, noise, slipping
Weight, slings slipping, restricted

area
Weight, falling, slipping on oil
Falling, weight
Ensure correct box is drained
Hazards identified
Service Manual
R 9250 from 13466
Use instructions in maintenance manual, wear PPE, stand

clear of moving components
Use 2 people to lift covers, be aware of the hole
Use correct slings and procedure, dont stand under the

load, use 2 people to lift valve banks
Use PPE, use 2 people to lift cover
Keep fingers clear, keep in contact with crane operator
Keep clear while jacking, use correct slings, stand clear
Wear ear muffs, clean area while working
Use correct slings and crane to lift motor, stand clear
Use help to lift valves, clean up any oil as you work
Use two people to lift covers
Connection suction hose to the correct outlet
2.23Safe work procedures SWP 023 - Remove and replace swing box
Safe work procedures SWP 023 - Remove and replace swing box
R 9250 from 13466
Service Manual
MJFCIFSS
2 - 39
Note!
Safe work procedures SWP 023 - Remove and replace swing box
Remove servo control hoses, return hoses and HP filters
Remove pipes and hold out of way
Unbolt valve bank and lift out
Refit new valve bank
Replace front pipes
Replace HP filters, return hose and servo hose
Test new valve bank
Clean area
10
11
2 - 40
Follow SWP 003
Weight, slippery with oil
Pinched fingers, weight, slippery with

oil
Crushed fingers
Crushed fingers, chains breaking
Weight
Weight restricted area, slippery with

oil
Hazards identified
Use instructions in maintenance manual, wear PPE, stand

clear of moving parts
Keep work area clean, use 2 people to lift
Use 2 people to lift, clean as you work, be aware of restricted work area
Keep fingers clear while positioning new valve bank, dont

stand under load, keep in contact with crane operator
Use correct lift procedure and chains, keep in contact with

crane operator, stand clear of lift
Use 2 people or crane to lift
Use 2 people to lift hoses, clean area as you work
Service Manual
MJFCIFSS
R 9250 from 13466
Note!
Follow SWP 001
Work procedure
Step
2.24Safe work procedures SWP 024 - Change main valve bank
Safe work procedures SWP 024 - Change main valve bank
Remove side covers off machine
Remove all hoses and bolts from pump
Lift pump out and install new pump
Refit hoses and bolts
Refit side covers
Commision per factory specs
Clean area
10
R 9250 from 13466
Follow SWP 003
Noise, moving parts
Weight, pinched fingers
Crushing, slippery with oil
Weight, restricted area, crushing,

slippery
Slipping
Weight, pinched fingers
Hazards identified
Use PPE, stand clear, use maintenance manual instructions
Use 2 people to lift, keep fingers clear
Keep area clean
Use correct lifting tool, keep in contact with crane operator,

lash pump securely to lifting tool, keep area clean
Use correct tools, keep area clean
Use 2 people to lift covers, keep fingers clear
Safe work procedures SWP 025 - Change swing pump
MJFCIFSS
2 - 41
Note!
Follow SWP 001
Work procedure
Step
2.25Safe work procedures SWP 025 - Change swing pump
Service Manual
Follow SWP 003
Drain splitterbox and turn off hyd suction tap
Remove exhaust system and all top covers
Remove all hoses and electrical wiring
Unbolt coupling, bell housing and block engine
Unbolt splitterbox and lift out splitterbox assy
Change out all pumps
Lift in new splitterbox and bolt up
Install bell housing, bolt up coupling
Install all hoses and wiring
Install top covers and exhaust system
Refill splitterbox and test
Clean up work area
10
11
12
13
14
15
2 - 42
Follow SWP 001
Work procedure
Step
MJFCIFSS
Noise, engine running
Weight, falling in hole
Slippery
Restricted area, pinching fingers
Weight, slings breaking or slipping,

overbalancing
Weight
Weight, slings breaking or slipping,

overbalancing
Restricted area, crushing of fingers
Slipping on oil, crushing
Weight, falling in hole
Hazards identified
2.26Safe work procedures SWP 026 - Change splitterbox
Safe work procedures SWP 026 - Change splitterbox
R 9250 from 13466
Use PPE, stand clear, commission per maintenance manual
Use 2 people to lift covers, be aware of hole
Keep area clean
Use correct tools
Sling correctly with correct slings, keep clear, keep in contact with crane operator, keep area clean, use correct tools
Lift carefully, use crane where necessary, stand clear of

load
Sling correctly with correct slings, keep clear, keep in contact with crane operator
Use correct tools, block engine so it cant move or drop
Clean as you work
Use 2 people to lift off covers, be aware of hole, barricade

area with tape
Service Manual
R 9250 from 13466
Service Manual
MJFCIFSS
2 - 43
Note!
Safe work procedures SWP 026 - Change splitterbox
Turn off hydraulic suction tap
Remove all hoses
Remove both pumps
Remove and gears and seals, replace gears
Refit gear cover plate and new seals
Refit pumps
Refit hoses
Turn hydraulic suction valve on
Test system
Clean up work area
10
11
12
13
2 - 44
Follow SWP 003
Noise, moving components
Slippery
Weigth, pinched fingers
Weight, flying objects
Weight, restricted area, slippery
Weight, restricted area, slippery
Slippery and oily
Hazards identified
Wear PPE, use maintenance manual instructions
Keep area clean
Lift correctly, keep in contact with crane operator, keep

area clean, keep fingers clear
Wear PPE, use 2 people to lift
Handle carefully, use 2 people to lift gears, keep area clean
Use correct lift methods, keep in contact with crane operator, handle carefully, keep area clean
Block all hoses and clean area as you go
Service Manual
MJFCIFSS
R 9250 from 13466
Note!
Follow SWP 001
Work procedure
Step
2.27Safe work procedures SWP 027 - Change splitterbox Gears
Safe work procedures SWP 027 - Change splitterbox Gears
Safe work procedures SWP 028 - Change splitterbox input shaft assembly
Follow SWP 004
Follow SWP 022 to remove engine
Install lifting device on input shaft assembly and remove

input shaft retaining bolts
Remove input shaft assembling including the gear
Refit new input shaft assembly
Install bolts and remove lift device
Follow SWP 022 to fit engine
R 9250 from 13466
Follow SWP 003
Slippery area, pinched fingers
Weight, pinched fingers or hands, not

visible to crane operator
Weight, not visible to crane operator
Weight, sling slipping, slippery surface, overbalancing
Hazards identified
Keep hands and fingers clear, keep in contact with operator
Keep in contact with operator
Use correct slings and lifting procedures, keep lifting apparatus balanced, keep area clean
MJFCIFSS
2 - 45
Note!
Follow SWP 001
Work procedure
Step
2.28Safe work procedures SWP 028 - Change splitterbox input shaft assembly
Service Manual
Inspect sockets for wear or physical damage
Fit tooling to the bolt head and adjust the reaction arm to
the correct position
Set required pressure on pump / refer to manufactures

chart
Commence tensioning
Tensioning completed
2 - 46
Inspect electric pump
Stored hydraulic pressure / weight of

the tool on removal
Tool slipping / hose damage / personal injury
If pressure is incorrect the bolt may

snap and cause personal injury and
damage to tooling and equipment
Socket or tool may slip and cause

personal injury
Socket may slip or explode if in a damaged state
Electric fault may cause personal injury
Damaged hoses may rupture at high

pressure, tool could fly apart causing
injury
Hazards identified
Release all hydraulic pressure. If necessary gain assistance in the removal of the tooling
Check that the hoses are not jammed or twisted and that
the tool is supported. Stand well clear at all times
Check pressure on chart against bolt dimension and grade

to obtain correct torque
Make sure that the tooling is in serviceable condition and

that the reaction arm is at the best position to give the tool
maximum support. If necessary a support should be used
to hold the tool in position
Any damaged equipment is to be presented to the supervisor for replacement
Check to confirm that the pump has been electrically inspected for the month of use
Check hoses and fittings for damage. Check tooling for

physical damage
Service Manual
MJFCIFSS
R 9250 from 13466
Note!
Inspect Hy-torc for physical damage
Work procedure
Step
2.29Safe work procedures SWP 029 - Hy-torc operation
Safe work procedures SWP 029 - Hy-torc operation
Safe work procedures SWP 030 - Remove and replace centre girder and side frames
Remove hoist cylinder lower pins and retract cylinders
Set up powerpack of undercarriage
Set up jacks beneath machine
Remove nuts and studs from uppercarriage
R 9250 from 13466
Jack up machine
Set up machine in position
Follow SWP 001
Work procedure
Step
MJFCIFSS
Machine may fall off jacks
Fall from undercarriage

Confined work area could produce
unsafe conditions. Failure of hoses /
fittings on Hy-Torque / threadstretcher. Weight of Hy-Torque or
threadstretcher
Unstable jacks.
Heavy parts swinging from crane during positioning slings or chains or
load being unbalanced and falling
Failure of hoses or fittings
Pressure in cylinders
Weight of cover plates and pins
Personnel in way of machine
Hazards identified
2 - 47
Supervisor to keep all personnel clear except those actually engaged in jacking procedures. Supervisor to monitor
progress of lift and be aware of any dangers
Personnel on the undercarriage to wear safety harness.

Ensure those working there are fully aware of each other.
Check condition of hoses and ensure fittings are correct.
Wear protective gloves and use correct lifting procedures.
Ensure flat and properly compacted base beneath jacks.

Use of guide ropes from suspended parts to control swing.
Check condition of chains, etc. and ensure load is balanced. Supervisor to keep all personnel clear except those
actually engaged in guiding crane operators
Check condition of hoses and ensure fittings correct
Isolate and expel stored energy in hydraulic system as per

SWP 003 - Points 1 to 6.
Wear protective gloves and use correct lifting procedures
Supervisor to keep all personnel clear except those actually in engaged in guiding machine into position. Keep in contact with operator at all times
2.30Safe work procedures SWP 030 - Remove and replace centre girder and side frames
Service Manual
Breaks tracks and lay out
Crack tension on centre girder-to-side frame bolts per SWP

029
Remove half of the bolts centre girder to side frames
Lift new side frames on and fit feet to motor guard pins
Lift new centre girder into position
Half bolt new centre girder and side frames together
10
11
12
13
14
2 - 48
Drive undercarriage out from beneath machine
Work procedure
Step
MJFCIFSS
Weight of bolts
Heavy parts swinging from crane during transfer.

Slings or chains failing or load being
unbalanced and falling

unbalanced and falling.
Weight of support feet.
Finger or hand injuries while adjusting or fitting feet
Weight of bolts
Failure of hoses or fittings on Hy-Torc
Noise from hammer knocking pins

out
Hammer fracturing pins causing metal pieces to fly tracks falling and
crushing personnel as they are laid
out
Clearance to uppercarriage
Hazards identified
R 9250 from 13466

Check condition of chains etc and ensure load balanced.
Supervisor to keep all personnel clear except those actually engaged in guiding crane operators
Use of guide ropes form suspended parts to control swing.

Check condition of chains etc and endure load balanced.
Supervisor to keep all personnel clear except those actually engaged in guiding crane operators.
Wear protective gloves and take care
Use of correctly fitted ear muffs or ear plugs

Wear PPE-safety helmet and glasses and gloves
Supervisor to keep all personnel clear except those actually engaged in track laying out procedures
Ensure excess clearance exists when jacking complete.

Supervisor to keep all personnel clear except those actually engaged in operating powerpack for undercarriage
Service Manual
Transfer final drives and hosing
Transfer idlers
Transfer track tension valves, accumulators and hoses
Transfer carrier rollers
16
17
18
19
R 9250 from 13466
Transfer rotary joint and bracket, and fit new hose kit
Work procedure
15
Step
Service Manual
MJFCIFSS
Finger or hand injuries while adjusting or fitting rollers. Heavy parts

swinging from crane during transfer.
unbalanced and failing
Weight of accumulators and other

components
Finger or hand injuries while adjusting or fitting idlers.

unbalanced
Failure of hoses or fittings on Hy-Torque

Weight of Hy-Torque.
Heavy parts swinging form crane during transfer.
Pressure in hoses Slipping or falling

on platform around rotary joint.
Fall into hole below rotary joint.
Weight of joint.
Confined work area could produce
unsafe conditions.
Heavy parts swing from crane during
transfer
Hazards identified
2 - 49
Wear protective gloves and take care.

Check condition of chains etc. and endure load balanced.
Wear protective gloves and take care.

Check condition of chains etc. and ensure load balanced.
Check condition of hoses and ensure fittings correct.

Expel stored energy in hydraulic system as per SWP 003.

Clean all grease out from around rotary joint and platform.
Personnel on the platform to wear safety harness.
Ensure those working there are fully aware of each other.
Use of guide ropes from suspended parts to control swing
Remove rest of bolts centre girder-to side frames
Lift out centre girder
Complete bolting new centre girder to side frames
Torque up centre girder to side frame bolts
Fit extra track pads to each track chain
Lift tracks back into position and reconnect chains
Set up powerpack for undercarriage
Fit spacer ring into centre girder
21
22
23
24
25
26
27
28
2 - 50
Fit feet to motor guard pins to hold side frames
Work procedure
20
Step
MJFCIFSS
Heavy parts swinging from crane during fitting.

Sling or chains failing or load being
unbalanced and falling.
Finger or hand injuries while adjusting or fitting spacer
Failure of hoses or fittings
Noise from hammer knocking pins in.

Hammer fracturing pins causing metal pieces to fly. Slings snapping allowing tracks to fall and crush
personnel
Noise from hammer knocking pins in.

Hammer fracturing pins causing metal pieces to fly
Failure of hoses or fittings on Hy-Torque.

Weight of Hy-Torque
Weight of bolts
Heavy parts swinging form crane during transfer.

Weight of bolts
Weight of support feet

Finger or hand injuries while adjusting or fitting feet
Hazards identified
R 9250 from 13466
Use of guide ropes from suspended part to control swing.

Check condition of chains etc. and ensure load balance.
Use correctly fitted ear muffs or ear plugs.

Wear correct PPE-safety helmet and glasses, and gloves.
Check condition of slings and ensure correctly fitted.
Supervisor to keep all personnel clear except those actually engaged in track fitting procedures
Use correctly fitted ear muffs or ear plugs.

Wear correct PPE-safety helmet and glasses, and gloves
Check condition of hoses and ensure fittings correct.



Service Manual
Lower machin onto undercarriage
Fit studs and nuts and torque up
Reconnect hoist cylinder power pins
Remove powerpack and jacks and clean area
31
32
33
34
R 9250 from 13466
Drive undercarriage beneath machine and align
30
Heavy weights swinging from crane

during loading of jacks and powerpack.
unbalanced and failing
Weight of coverplates and pins
Machine may fall over off jacks
Clearance to uppercarriage
Hazards identified

Personnel on the undercarriage clear except those actually

engaged in jacking procedures. Supervisor to monitor progress of downlift and be aware of any dangers
Supervisor to keep all personnel clear except those actually engaged in jacking procedures. Supervisor to monitor
progress of downlift and be aware if any dangers
Ensure excess clearance still exists - no dropping

Supervisor to keep all personnel clear except those actually engaged in operating powerpack for undercarriage
Personnel on the undercarriage to wear safety harness
MJFCIFSS
2 - 51
Note!
Place studs into holes in undercarriage
Work procedure
29
Step
Service Manual
Follow SWP 002
Inspect stick assembly
Connect cranes to stick assembly
Move stick assembly to the excavator, and align the holes

with the boom
Fit shims into position
Once aligned, the stick pivot pins can be pushed into place
securing the stick to the boom. Install pin covers and
grease lines
Release lifting gear and cranes
Stick can be lowered to the ground or on timber packing.

Release lifting gear and cranes
2 - 52
Follow SWP 001
Work procedure
Step
MJFCIFSS
Crushing
R 9250 from 13466
Keep clear, use solid timber to keep stick out of mud and
dirt. Wear gloves, and keep fingers clear. Wear safety harness or use scissor lift for safe access. Keep clear when
equipment is moving
Wear gloves, and keep fingers clear. Wear safety harness

or use scissor lift for safe access. Keep clear when equipment is moving
Use suitable tooling to push pins. Wear harness or use

scissor lift to access work area. Work with another person
to assist you
Squashed fingers, height, weight
Pinched fingers, height, large moving

equipment
Use scissor lift to access underneath stick to fit shims in position
Stand clear of suspended load. Dogman must direct the

crane operators and be in visual contact. Use scissor lift or
boom lift as applicable. Keep fingers and hands clear of bores
Stand clear, dogman must direct the crane operators and

be in visual contact. Use correct lifting gear and techniques
Make sure all attached components including cylinders are

properly located and secured
Service Manual
Height, weight and slippery surfaces
Weight, height, crushing, suspended

load
Pinched fingers or crushing, moving

equipment
Falling objects, crushing, height
Hazards identified
2.31Safe work procedures SWP 031 - Fit stick assembly to boom
Safe work procedures SWP 031 - Fit stick assembly to boom
R 9250 from 13466
Service Manual
MJFCIFSS
2 - 53
Note!
Safe work procedures SWP 031 - Fit stick assembly to boom
Follow steps 2-9 in SWP 037
Fit hydraulic tank to left side of chassis
Fit powerpack to chassis
Fit fuel tank module to right side of chassis
Fit operators cabin above fuel tank assy
Fit cabin side walkway and handrail.

Fit emergency ladder to front of fuel tank
Fit service trap
2 - 54
Follow SWP 001
Work procedure
Step
MJFCIFSS
Weight, crushing
Height, weight, crushing
Hazards identified
Service Manual
R 9250 from 13466
Use correct lifting gear and procedures at all times. Stand

clear when moving the load. Use tools to locate holes.
Keep fingers clear

Keep fingers clear. Use boom and scissor lifts as applicable

clear when moving the load. Keep fingers clear. Use boom
and scissor lifts as applicable

clear when moving the load. Keep fingers clear. Use boom
and scissor lifts as applicable
Dogman to co-ordinate lift. Use correct lifting gear and procedures at all times. Stand clear when moving the load.
Dogman to co-ordinate lift. Use correct lifting gear and procedures at all times. Stand clear when moving the load.
2.32Safe work procedures SWP 032 - Assemble uppercarriage
Safe work procedures SWP 032 - Assemble uppercarriage
Connect hydraulic hoses and electrical cables to components installed in step 11-14
Connect remaining hydraulic hoses and eletrical cables
Fit correct lifting jigs to the front and rear of the assembly
Position cranes and connect to uppercarriage lifting jigs
10
11
12
13
R 9250 from 13466
Fit radiator, pump side cowlings and access ladder then fit
remaining walkways, handrails, lights and accessories
Pinched fingers, spilled oil, height
Pinched fingers, spilled oil, height
Weight, crushing
Hazards identified
Gross weight approximately 135 to 150 tonnes. Use correct

lifting gear and procedures at all times. Stand clear when
moving the load. Use tools to locate holes. Keep fingers
clear. Use boom and scissor lifts as applicable

Keep fingers clear. Get assistance when necessary. Maintain good house keeping. Beware of height
Keep fingers clear. Get assistance when necessary. Maintain good house keeping. Beware of height

Safe work procedures SWP 032 - Assemble uppercarriage
MJFCIFSS
2 - 55
Note!
Work procedure
Step
Service Manual
Lay out track pads
Install track pad pins
Install track pad pin retaining bolts
Mount track frames onto track pad assembly
Fit centre girder to track frames
Bolt centre girder to track frames and torque
Fit left and right idlers
2 - 56
Follow steps 1-8 of SWP 037
Work procedure
Step
MJFCIFSS
Heavy lifts, property damage, personal injury, CRUSHING, working area

congested

congested

congested

congested
Pinched fingers, hydraulic pressure,

weight

congested

congested
Hazards identified
Service Manual
R 9250 from 13466
Dogman to co-ordinate lifts. Use correct lifting gear and

procedures at all times. Do not walk under slung loads
Use correct lifting gear and procedures at all times. Do not

walk under slung loads. Use SWP 029
Use correct lifting gear and procedures at all times. Do not

walk under slung loads
Dogman to co-ordinate lifts. Use corrects lifting gear and

procedures at all times. Do not walk under slung loads the
frames need to be measured to ensure squareness, so the
centre girder will fit
Keep fingers clear, follow SWP 029 when using Hytorc tools. Wear PPE

procedures at all times

procedures at all times. Do not walk under slung loads. Ensure a gap of 15 metres from the front of the upper deck
assy. Start laying track pad assembles accurately to fit
track frames and centre girder
2.33Safe work procedures SWP 033 - Assemble undercarriage
Safe work procedures SWP 033 - Assemble undercarriage
Final inspection to ensure undercarriage is ready to install

under the uppercarriage
11
R 9250 from 13466
Connect hydraulic powerpack, and test operation
10
Slippery work area, Height
Property damage, personal injury,

CRUSHING, working area congested, hydraulic pressure

congested
Hazards identified
Stand clear, wear eye protection

procedures at all times. Do not walk under slung loads
Safe work procedures SWP 033 - Assemble undercarriage
MJFCIFSS
2 - 57
Note!
Lift tracks over the track frames and join together
Work procedure
Step
Service Manual
Fit stick cylinders to faceshovel boom. Install boom cylinders, pins and caps
Chain eyes of boom and stick cylinders with safety chains
Install handrails
Fit arch hoses to boom mounted distributor blocks
Install wiring and lights
Connect cranes to boom assembly
2 - 58
Place the boom assembly on certified stands approximately to 3 to 4 metres in front of the undercarriage. For faceshovel boom place boom approximately 2 metres off the
ground

equipment
Height
Pinched fingers or crushing height

and weight
Pinched fingers or crushing height

and weight
Pinched fingers or crushing
Height, weight, swinging load,

crushing
Personal injury working on or under

boom assembly. Some heavy man
handling is required, while working at
heights. Crushing
Hazards identified

be in visual contact
Get assistance as required. Use scissor lift or scaffold if required
Make sure the chained end of cylinder is secure. Keep fingers clear
Do not stand under swinging load. Use scissor lift or harness as required. Ensure that dogman or forklift operator
has visual contact with people under the boom.
Keep hands and fingers clear
Dogman to co-ordinate lift. Ensure the boom sits level.

Wear all PPE. Handle lifts carefully
Service Manual
MJFCIFSS
R 9250 from 13466
Note!
Follow SWP 001
Work procedure
Step
2.34Safe work procedures SWP 034 - Assemble boom, faceshovel or backhoe
Safe work procedures SWP 034 - Assemble boom, faceshovel or backhoe
Safe work procedures SWP 035 - Assemble stick, faceshovel or backhoe
Fit safety chain to shift levers and backhoe bucket cylinders
Install pipe-work and hoses for bucket circuit
Connect cranes to stick assembly
R 9250 from 13466
Position stick assembly approximately 5 to 7 metres in front

of undercarriage

equipment
Pinched fingers or crushing, height

and weight
Pinched fingers or crushing
Personal injury working on or under

boom assembly. Some heavy man
handling is required, while working at
heights. Crushing
Hazards identified

be in visual contact
Make sure the chain is secure. Keep fingers clear and

maintain visual contact with operator
Ensure that stands or timber is strong enough to support

the complete stick. Ensure the boom sits level. Wear all
PPE. Get assistance as required. Handle lifts carefully
MJFCIFSS
2 - 59
Note!
Follow SWP 001
Work procedure
Step
2.35Safe work procedures SWP 035 - Assemble stick, faceshovel or backhoe
Service Manual
Follow SWP 002
Inspect boom assembly
Connect cranes to boom assembly
Fit boom pivot pins and cylinder mounting pins to upper

deck
Move boom assembly to uppercarriage and align the holes

with the upper deck
Once aligned, the boom pivot pins and shims can be

pushed into place with the aid of a porta-power kit, securing
the boom to the upper deck. Install pin covers
Faceshovel : - release boom cylinders and lower into

mounting points using crane. Install pins and end caps.
Connect arch hoses to machine
Backhoe : - lower boom to stands 1 meter high. Connect
arch hoses to machine. Run up machine and use hydraulics to extend boom cylinder rod to machine
Connect all hydraulic hoses, grease tubes and wiring
2 - 60
Follow SWP 001
Work procedure
Step
MJFCIFSS
Height, falling objects, weight, slippery
R 9250 from 13466
Wear safety harness and use correct tooling. Get assistance with heavy lifts. Work in teams as required. Clean any
oil or lube spills as they occur
Stand clear while cylinders are being lowered. Good communication is necessary with crane operator. Use scissor
lift or other method for safe access. Use correct tooling to
push pins in. Get assistance as required. Keep fingers and
hands clear
Use hydraulic jack to push pins. Wear harness or use scissor lift to access work area. Work with another person to
assist you
Squashed fingers, height, weight
Crushing, weight, squashed fingers,

height
Stand clear of suspended load. Dogman must direct the

crane operators and be in visual contact. Use scissor lift or
boom lift as applicable. Keep fingers and hands clear of bores
Use a small crane to lift and locate pins. Use correct tooling. Keep fingers and hands clear.

be in visual contact. Use correct lifting gear and techniques
Make sure all attached components including cylinders are

properly located and secured
Service Manual
Weight, height, crushing, suspended

load
Weight, crushing

equipment
Falling objects, crushing, height
Hazards identified
2.36Safe work procedures SWP 036 - Fit boom assembly to uppercarriage
Safe work procedures SWP 036 - Fit boom assembly to uppercarriage
R 9250 from 13466
Inspect area for job completion
11
Height
Height, falling objects, weight
Hazards identified
Use safety harness if required
Safe work procedures SWP 036 - Fit boom assembly to uppercarriage
MJFCIFSS
2 - 61
Note!
Fit bucket cylinders to Faceshovel boom
Work procedure
10
Step
Service Manual
Find suitable assembly area
Locate suitable infrastructure
Mobilise equipment
Equipment inspection
Manpower
Unload and position components as close to the plan

layout as possible
2 - 62
Follow SWP 001
Work procedure
Step
MJFCIFSS
Heavy lifts, moving trucks, personal

injury
Personal injury
Personal injury, wrong tooling
Personal injury and congestion
Area to small, area inaccessable or

soft
Hazards identified
Service Manual
R 9250 from 13466
Dogman to co-ordinate lifts. Ensure that correct lifting

slings and practices are used
10 to 12 persons excluding crane operators
All equipment must be inspected and comply with relevant

regulations before being used on site
Mobile equipment : 3 or 4 cranes depending on size and

availability.
10 tonnes all terrain forklift.
Scissor lift with 15 metres reach.
Boom lift with 12 metres reach.
Generator with 415 and 240 volts power outlets.
Large air compressor with 3 outlets.
Hytorc kit and associated tooling.
Stud stretcher.
1 and 1 impact guns with hoses.
Electric grinders, sanders, drills, lights, leads and misc
Must be away from assembly area, but adjacent. Preferred

area is 50 x 25 metres
Minimum area is 75 x 50 metres. Area must be level with

good drainage and compacted well enough to support 250
tonnes in any weather conditions. Must be accessible for
semi-trailers and large cranes
2.37Safe work procedures SWP 037 - Assemble LIEBHERR R 9250
Safe work procedures SWP 037 - Assemble LIEBHERR R 9250
Position upper deck assy on certified stands. The deck

should be placed in the middle towards the rear of the assembly area
Assemble uppercarriage per SWP 032
Assemble undercarriage per SWP 033
Lift uppercarriage high enough to allow undercarriage to be

driven under the uppercarriage. Remove stands only when
height of uppercarriage is achieved and cranes are safe
with no need to lower uppercarriage
Use hydraulic powerpack to move the undercarriage under

uppercarriage
Once the undercarriage is in position, lower the uppercarriage until rotary connection locating ears just clear rotary
connection
2 men (LIEBHERR and dogman with radio) to climb into

undercarriage girder area to direct uppercarriage lowering
to undercarriage via rotary connection ears. Align holes initially at track frame sides and install all studs and nuts
lower uppercarriage so contact is made at all points
between upper and undercarriage. Tension four sets of six
studs at 90 degs intervals with Hytorc XLT10 to 300 Psi
Have cranes completely release the load, and disconnect

all cranes
Torque all studs according to SWP 029
10
11
12
13
14
15
16
17
R 9250 from 13466
Unpack containers and crates
Work procedure
Step
Service Manual
Dogman to co-ordinate complete lift. Use correct lifting

gear and lifting techniques, keep personnel clear of the lift.
Ensure work area is clean
Height, crushing
MJFCIFSS
Hydraulic pressure
2 - 63
Stand clear, keep fingers clear, get assistance if required
Use correct lifting gear and lifting techniques, keep personnel clear of the lift
Crushing, heavy lifts
Crushing, weight, pinched fingers
Stand clear
Coordinate lifts and traffic. Ensure that correact lifting

slings and practices are used.
Ensure stands are certified appropriately to handle the total

weight of 150 tonnes. All stands are to sit level
Use correct tools, remove timber and rubbish in a suitable

container or area.
Remove or fold all nails
Crushing, personal injury
Heavy lifts, moving trucks, personal

injury
Crushing, mobile equipment movements
Pinched fingers, nail punctures
Hazards identified
Lift and fit counterweight
Tension counterweight bolts with Hytorc
Hose up rotary connection and connect all wiring
Assemble boom per SWP 034
Connect boom to uppercarriage per SWP 036
Assemble stick per SWP 035
Install hydraulic oil, diesel fuel, engine oil, coolants and

greases in the correct tanks. Bleed all systems and pumps
as per service manual
Pre start checks
Connect stick to boom per SWP 031
Inspect boom and stick assembly
Fit bucket to stick
Fit bucket pins
Connect all lube piping
19
20
21
22
23
24
25
26
27
28
29
30
31
2 - 64
Disconnect hydraulic powerpack and fit counterweight
Work procedure
18
Step
MJFCIFSS
Height, difficult area to work, slippery
Crushing, pinched fingers, weight,

height
Height, weight, pinched fingers
Personal injury, property damage,

height, hydraulic pressure
Height, spilled lube on machine or

skin. Slippery
slippery
Height, weight
Weight
Hydraulic pressure
Hazards identified
Use boom lift to access work area
R 9250 from 13466
Use small crane to lift and locate pins. Use scissor lift or
scaffolding when working on the bucket. Keep hands clear
Drive excavator to the bucket. All personnel to stand clear.

Ensure correct alignment
use scissor lift or boom lift. Work in 2 men teams. Use harness as applicable and correct tooling
A thorough inspection of all major components and sub assemblies should be completed prior to any start-up or testing. Use a checklist to ensure all assemblies are checked.
Ensure the operator has read and understood the operators manual. Ensure danger tags are removed by each
person
Have a plan and equipment in case of any spills to ensure

adequate clean up. Have MSDS for all fluids and chemicals. Wear appropriate PPE
Maintain good housekeeping at all times
Wear safety glasses, use sizzor lift and stand for XLT30
Hytorc tool
Dogman to co-ordinate complete lift
Wear safety glasses
Service Manual
Testing and commissioning
34
R 9250 from 13466
Cycle bucket
33
Personal injury, property damage,
height, hydraulic pressure
Personal injury, property damage
Height
Hazards identified
Use workshop manual for all testing and adjusting procedures. Wear hearing and eye protection
Clear area around machine and bucket before cycling.

Make sure pins are greased
Wear harness or use scissor lift as applicable
MJFCIFSS
2 - 65
Note!
Inspect boom, stick and bucket now that job is complete
Work procedure
32
Step
Service Manual
[x]
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Manual handling
Electrical
Noise
Gravity
Chemical
Manual handling
Electrical
Noise
Gravity
Chemical
Manual handling
Electrical
Noise
Remove R 9250 engine
Remove hydraulic cylinder
Remove bucket cylinder levers

and links
Repair / replace suction valve
2 - 66
[x]
[ ]
[x]
[ ]
[x]
Potential hazards involved
Gravity
Chemical
Manual handling
Electrical
Noise
Major activity
2.38Risk assessment
Risk assessment
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MJFCIFSS
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Consequences :
1:[ ]2:[ ]3:[ ]
Activity risk score

Likelihood :
1:[ ]2:[ ]3:[ ]
Job safety analysis required
No : [ ]
Yes : [ x ]
No : [ ]
Yes : [ x ]
No : [ ]
Yes : [ x ]
No : [ ]
Yes : [ x ]
Note : any activity that scores 1 or 2

in likelihood or consequences must
have a SWP
R 9250 from 13466
SWP 009
SWP 008
SWP 007
SWP 004
Safe work
procedure No.
Service Manual
[x]
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[x]
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[x]
[x]
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[x]
[x]
[x]
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Gravity
Chemical
Manual handling
Electrical
Noise
Gravity
Chemical
Manual handling
Electrical
Noise
Gravity
Chemical
Manual handling
Electrical
Noise
Gravity
Chemical
Manual handling
Electrical
Noise
Remove / replace load rollers
Remove and replace track

chain
Change R 9250 sprocket
Remove counterweight
Remove boom
R 9250 from 13466
[x]
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[x]
[x]
[x]
Gravity
Chemical
Manual handling
Electrical
Noise
Major activity
Service Manual
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MJFCIFSS
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1:[ ]2:[ ]3:[ ]
Activity risk score

Likelihood :
1:[ ]2:[ ]3:[ ]
No : [ ]
Yes : [ x ]
No : [ ]
Yes : [ x ]
No : [ ]
Yes : [ x ]
No : [ ]
Yes : [ x ]
No : [ ]
Yes : [ x ]

have a SWP
2 - 67
SWP 014
SWP 013
SWP 012
SWP 011
SWP 010
Safe work
procedure No.
Risk assessment
[x]
[ ]
[x]
[ ]
[x]
[x]
[ ]
[x]
[ ]
[ ]
[x]
[ ]
[x]
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[x]
[x]
[ ]
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[ ]
Gravity
Chemical
Manual handling
Electrical
Noise
Gravity
Chemical
Manual handling
Electrical
Noise
Gravity
Chemical
Manual handling
Electrical
Noise
Gravity
Chemical
Manual handling
Electrical
Noise
Remove stick
Remove and replace idler
Change out carrier roller
Bucket change out
Change out work pump
2 - 68
[x]
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[x]
[ ]
[x]
Gravity
Chemical
Manual handling
Electrical
Noise
Major activity
Risk assessment
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MJFCIFSS
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1:[ ]2:[ ]3:[ ]
Activity risk score

Likelihood :
1:[ ]2:[ ]3:[ ]
No : [ ]
Yes : [ x ]
No : [ ]
Yes : [ x ]
No : [ ]
Yes : [ x ]
No : [ ]
Yes : [ x ]
No : [ ]
Yes : [ x ]

have a SWP
R 9250 from 13466
SWP 020
SWP 019
SWP 018
SWP 017
SWP 015
Safe work
procedure No.
Service Manual
[x]
[ ]
[x]
[ ]
[ ]
[x]
[ ]
[x]
[ ]
[ ]
[x]
[ ]
[x]
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[x]
[ ]
[x]
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[ ]
Gravity
Chemical
Manual handling
Electrical
Noise
Gravity
Chemical
Manual handling
Electrical
Noise
Gravity
Chemical
Manual handling
Electrical
Noise
Gravity
Chemical
Manual handling
Electrical
Noise
Remove and fit cabin
Remove and replace engine
Remove and replace swingbox
Change out main valve bank
Change out swing pump
R 9250 from 13466
[x]
[ ]
[x]
[ ]
[ ]
Gravity
Chemical
Manual handling
Electrical
Noise
Major activity
Service Manual
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1:[ ]2:[ ]3:[ ]
Activity risk score

Likelihood :
1:[ ]2:[ ]3:[ ]
No : [ ]
Yes : [ x ]
No : [ ]
Yes : [ x ]
No : [ ]
Yes : [ x ]
No : [ ]
Yes : [ x ]
No : [ ]
Yes : [ x ]

have a SWP
2 - 69
SWP 025
SWP 024
SWP 023
SWP 022
SWP 021
Safe work
procedure No.
Risk assessment
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Gravity
Chemical
Manual handling
Electrical
Noise
Gravity
Chemical
Manual handling
Electrical
Noise
Gravity
Chemical
Manual handling
Electrical
Noise
Gravity
Chemical
Manual handling
Electrical
Noise
Change out splitterbox
Change out splitterbox gears
Change out splitterbox input

shaft
Replace center girder and track

frames using jacks
R 9250 machine assembly
2 - 70
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Gravity
Chemical
Manual handling
Electrical
Noise
Major activity
Risk assessment
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have a SWP
R 9250 from 13466
SWP 037
SWP 030
SWP 028
SWP 027
SWP 026
Safe work
procedure No.
Service Manual

Chapter 2 - Safe Work Procedure / Risk Assessment: Service Manual

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Copyright:

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Chapter 2 - Safe Work Procedure / Risk Assessment: Service Manual

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Copyright:

Verfügbare Formate

Service Manual

Chapter 2 - Safe work procedure / Risk assessment

R 9250 from 13466

R 9250 from 13466

Safe work procedures

2 Safe work procedures

R 9250 from 13466

Safe work procedures

R 9250 from 13466

Check service vehicle

Check if excavator is on a blast area

Establish radio contact with excavator operator before approaching

Be aware of others working on the machine

Outside work in general

R 9250 from 13466

Exposure to sunlight and heat

Personal injury or equipment damage

Forget to take tags with you

Sunblock SPF15, clothing SPF50 full length, hard hat

Inform others of your intentions. Completa appropriate tags

Keep safe distance from excavator before embarking

Keep extra tags and biro in service vehicle

Check blast time before disabling

Sign contractor book

Safe work procedures SWP 001 - Safety check list

2.1 Safe work procedures SWP 001 - Safety check list

Put attachment in rested position and service trap down

Turn off isolators for powerpack, batteries, electrical behind

Pull apart sentry plugs on the engine

Park machine on level flat ground

Attachment could creep

Injury to personnel while machine is

Rest position should be where the attachment can not

R 9250 from 13466

Follow SWP 001

Safe work procedures SWP 002 - Basic R 9250 machine isolation

Evacuate air from hydraulic tank

Install personal danger tag on isolation point and isolate

After the job is finished

Remove danger tags and turn on isolator

Check repair and test operation

R 9250 from 13466

Oil leaks, hydraulic pressure and volume

All persons have completed work

Flying dirt, dust and oil

Servo accumulators not functioning,

Potential hydraulic pressure

Injury to personnel, damage to light

Stand clear of repair area

Ensure that all work is complete

One danger tag per person

Keep personnel away from outlet

Repair circuit so cylinder stored energy can be evacuated,

Position attachment so mechanical stops are supporting

Park a safe distance away from the machine.

Notify supervisor that job is finished

Ensure attachment is in a rested position

Clean affected area

Ensure machine is parked on flat surface

Follow safety check list SWP 001

If necessary area is to be pressure cleaned

Drain coolant from radiator