Changing out a hydraulic hose
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Published by SALUSPre-Task Plan: Hydraulic Hose Replacement
Date: [DATE] Work Area: [WORK AREA] Task Supervisor: [SUPERVISOR NAME]
1. Task Description
Replacement of a hydraulic hose on the excavator.
2. Task Duration
Estimated Start: [START TIME] Estimated Completion: [END TIME]
3. Personnel Involved
- Mechanic
- Spotter
4. Task-Specific Hazards and Controls
| Hazard | Risk | Control Measures |
|---|---|---|
| Hydraulic pressure | Personal injury from pressurized oil | Release pressure in the hydraulic system before disconnecting any lines 2, 5, 6, 7, 14. Lower work tools to the ground 2, 5, 6, 7, 14. Use purge screws to release remaining pressure [1]. Slowly loosen fill/vent plug on hydraulic tank to release pressure [1]. |
| Hot oil and components | Burns | Allow the oil and components to cool before starting work 2, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 18, 19. Wear appropriate PPE. |
| Fluid spillage | Environmental contamination, slips | Use suitable containers to collect any spilled fluid 2, 5, 6, 7, 14, 17, 18, 19. Have spill kits readily available. Dispose of fluids according to local regulations 2, 18, 19. |
| Heavy equipment operation | Crushing, struck-by injuries | Ensure equipment is stable and on level ground 4, 10, 12, 13, 18, 19. Use hydraulic lockout control 4, 5, 6, 7, 11, 12, 13, 14, 20. Maintain a safe working distance from the machine. |
| Pinch points | Hand and finger injuries | Be aware of pinch points when handling hoses and tools. Use appropriate tools and gloves. |
| Contamination | System damage | Use plugs and caps to seal hoses and fittings to prevent contamination [2]. Keep work area clean. |
5. Required PPE for Today's Task
- Safety glasses
- Gloves
- Safety shoes [2]
6. Tools and Equipment Needed
- Hand tools for hydraulic lines [2]
- Torque wrench [2]
- Plugs and caps for hoses [2]
- Collection containers for oil
- Shop rags [2]
7. Pre-Start Checklist
Area Preparation
- [ ] Ensure the work area is clear of obstructions.
- [ ] Position the machine on level ground 4, 10, 12, 13, 18, 19.
- [ ] Identify and mark any potential hazards in the area.
Equipment Checks
- [ ] Inspect the new hydraulic hose for any damage.
- [ ] Check that all tools are in good working condition [2].
- [ ] Verify that the correct replacement hose is available.
Communication
- [ ] Review hand signals to be used during the task.
- [ ] Confirm emergency shutdown procedures.
8. Task Steps Overview
- Position the machine and lower the work tool to the ground 2, 5, 6, 7, 14.
- Release hydraulic pressure from the system 2, 5, 6, 7, 14.
- Disconnect the old hydraulic hose [1].
- Connect the new hydraulic hose 1, 2.
- Check and refill hydraulic oil if necessary 1, 4.
9. Emergency Response for This Task
- Hydraulic oil spray in eyes → Flush eyes with water for 15 minutes and seek medical attention.
- Large oil spill → Stop work, contain the spill, and notify the supervisor.
10. Task-Specific Precautions
- Do not allow hot oil or components to contact skin 1, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 18, 19.
- Ensure all connections are tightened to the correct torque [2].
- Dispose of used hoses and fluids properly 2, 18, 19.
Pre-Task Briefing Confirmation
All workers understand the task, associated hazards, and required controls.
Team Lead Initials: [___] Date: [DATE] Time: [TIME]
Safety powered by SALUS
Sources used for this answer
[1] CAT 374F Excavator Operation and Maintenance Manual
Page 226
Open source documentSource excerpt
## Transportation Information i02067410 ## Disconnecting Hydraulic Hoses and Lines SMCS Code: 5057 Release the pressure in the implement hydraulic circuits (boom, stick and bucket) before any hydraulic lines or components are disconnected or removed. <!-- image --> Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. ## NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, 'Dealer Service Tool Catalog' for tools and supplies suitable to collect and contain fluids on Cat ® products. Dispose of all fluids according to local regulations and mandates. - 1. Fully retract the stick cylinder rod. - 2. Adjust the position of the bucket so that the bucket is parallel to the ground. - 3. Lower the boom until the bucket is flat on the ground. - 4. Stop the engine. - 5. Turn the engine start switch to the ON position without starting the engine. - 6. Place the hydraulic lockout (lever) in the UNLOCKED position. - 7. Move the joysticks and pedals to FULL STROKE position in all directions. This will release any pressure that might be present in the pilot system. - 8. Turn the engine start switch to the OFF position. - 9. Slowly loosen the fill/vent plug on the hydraulic tank and release the pressure. - 10. Tighten the fill/vent p…
[2] Kobelco SK235SR-2, SK235SRLC-2 Operation Manual
Page 303
Open source documentSource excerpt
If a hydraulic hand pump is not available, and the contamination can be controlled easily, then proceed to the next page for specific instructions on a different alternative to release the swing parking brake. <!-- image --> Use safety protection such as: hard hat, working gloves, safety shoes and safety glasses when needed to perform this job. ## A. Tools &amp; Equipment Required - 1. Handtools required for removal of hydraulic tubes, hoses and fittings. - 2. Plugs and caps for tubes, hoses and fittings. - 3. 10 mm allen wrench. - 4. 5 mm allen wrench. - 5. Two M12-1.75 x 26 mm lifting eye. - 6. Overhead lifting device capable of lifting and holding 100 kg (220 lb). - 7. Plenty of clean, dry shop rags and/or paper towels. - 8. 14 mm allen wrench. - 9. 441 N-m {325 lbf-ft} torque wrench. ## B. Procedures - 1. Lower attachment to ground. Refer to previous page for proper procedures in lowering the attachment. - 2. Remove all hoses and tubes from the swing motor top plate and swing valve to gain access to the top plate mounting bolts. See Fig. 8-10. - 3. Install the proper plugs and caps onto hoses, tubes and fittings to avoid the possibility of contamination entering the hydraulic system. See Fig. 8-12. <!-- image --> <!-- image --> Use only plugs and caps designed to properly seal the specific hose, tube or fitting they are to be installed on. ８
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