| Step | Potential Hazard | Control |
|---|---|---|
| Assess work area | Equipment movement, poor lighting, slips from leaking fluid | Park equipment on level ground; shut down engine; set parking brake; use wheel chocks; ensure adequate lighting; place absorbent pads under leak area |
| Inspect tools and replacement hose | Wrong hose rating, damaged fittings, improper tools | Verify hose matches OEM specifications for pressure and temperature; inspect fittings; use correct wrenches and caps |
| Don required PPE | High pressure fluid exposure, eye injuries, hand lacerations | Wear safety glasses or face shield and cut resistant gloves; avoid loose clothing |
| Release hydraulic pressure | High pressure injection injury, fluid spray | Shut off equipment; cycle controls to release stored pressure; confirm system is fully depressurized before loosening fittings |
| Cap or plug hydraulic lines | Spills, contamination entering system | Use clean caps and plugs; prevent dirt and debris from entering open ports; place absorbent pads beneath hose ends |
| Remove damaged hose | Contact with hot surfaces, slipping on spilled fluid, pinch points | Allow components to cool; maintain stable footing; use wrenches carefully; keep hands clear of pinch points |
| Install new hose | Cross threading, twisting hose, improper routing | Align fittings properly; hand tighten first; avoid twisting hose; route according to OEM diagrams; secure with clamps or guards |
| Tighten fittings | Stripped threads, overtightening, trapped debris | Use proper torque if specified; ensure fittings are clean; tighten until snug without overtightening |
| Inspect routing and clearance | Hose rubbing on edges, potential future failure, contact with moving parts | Verify hose is not kinked; ensure clearance from pinch points, heat sources, and abrasion points; reinstall guards |
| Repressurize hydraulic system | Sudden hose failure, leaks spraying onto workers | Start equipment at idle; activate hydraulics slowly; keep body away from hose during pressurization; inspect for leaks with cardboard or wood, never hands |
| Clean spills and dispose materials | Slip hazard, environmental contamination | Wipe residual fluid; use absorbent pads; dispose of contaminated materials in accordance with regulations |
| Final test and inspection | Hidden leaks or improper function | Operate equipment through full motion; recheck hose and fittings; verify proper function of hydraulics |
| Remove traffic or equipment control | Worker exposure to moving machinery | Remove cones or lockout devices only when equipment is fully operational and work area is safe |
Safety glasses or face shield
Cut resistant gloves
Steel toe boots
High visibility vest if working outdoors or near other equipment
Long pants and long sleeves
Hearing protection if equipment is running nearby
Always have a complete, well-stocked first aid kit available.
JSA Category: General Maintenance and Shop Operations
* The steps, hazards, and controls displayed above may be incomplete or not suit your department's needs. All job safety analyses should be a completed with frontline worker input to ensure that each potential hazard is identified and mitigated.
Please read about The Essentials Elements of a Solid Job Safety Anaylsis here.
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| Step | Potential Hazard | Control |
|---|---|---|
| Assess work area | Equipment movement, poor lighting, slips from leaking fluid | Park equipment on level ground; shut down engine; set parking brake; use wheel chocks; ensure adequate lighting; place absorbent pads under leak area |
| Inspect tools and replacement hose | Wrong hose rating, damaged fittings, improper tools | Verify hose matches OEM specifications for pressure and temperature; inspect fittings; use correct wrenches and caps |
| Don required PPE | High pressure fluid exposure, eye injuries, hand lacerations | Wear safety glasses or face shield and cut resistant gloves; avoid loose clothing |
| Release hydraulic pressure | High pressure injection injury, fluid spray | Shut off equipment; cycle controls to release stored pressure; confirm system is fully depressurized before loosening fittings |
| Cap or plug hydraulic lines | Spills, contamination entering system | Use clean caps and plugs; prevent dirt and debris from entering open ports; place absorbent pads beneath hose ends |
| Remove damaged hose | Contact with hot surfaces, slipping on spilled fluid, pinch points | Allow components to cool; maintain stable footing; use wrenches carefully; keep hands clear of pinch points |
| Install new hose | Cross threading, twisting hose, improper routing | Align fittings properly; hand tighten first; avoid twisting hose; route according to OEM diagrams; secure with clamps or guards |
| Tighten fittings | Stripped threads, overtightening, trapped debris | Use proper torque if specified; ensure fittings are clean; tighten until snug without overtightening |
| Inspect routing and clearance | Hose rubbing on edges, potential future failure, contact with moving parts | Verify hose is not kinked; ensure clearance from pinch points, heat sources, and abrasion points; reinstall guards |
| Repressurize hydraulic system | Sudden hose failure, leaks spraying onto workers | Start equipment at idle; activate hydraulics slowly; keep body away from hose during pressurization; inspect for leaks with cardboard or wood, never hands |
| Clean spills and dispose materials | Slip hazard, environmental contamination | Wipe residual fluid; use absorbent pads; dispose of contaminated materials in accordance with regulations |
| Final test and inspection | Hidden leaks or improper function | Operate equipment through full motion; recheck hose and fittings; verify proper function of hydraulics |
| Remove traffic or equipment control | Worker exposure to moving machinery | Remove cones or lockout devices only when equipment is fully operational and work area is safe |
Safety glasses or face shield
Cut resistant gloves
Steel toe boots
High visibility vest if working outdoors or near other equipment
Long pants and long sleeves
Hearing protection if equipment is running nearby