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Create a life Energy wheel checklist for pressure performing a line break

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Life Energy Wheel Checklist for Line Break Pressure Performance

This checklist is designed to ensure safety when performing line breaks, focusing on hydraulic systems and related equipment. It covers pre-operation, during operation, and post-operation checks to minimize risks.

Instructions: Complete this checklist before, during, and after performing any line break on hydraulic systems. Mark each item as complete or incomplete. If incomplete, note the corrective action taken.

I. Pre-Operation Checks

A. Planning and Preparation
  • [ ] Job Safety Analysis (JSA): Conducted and reviewed for the specific line break task.
  • [ ] Communication: Hand signals and communication methods are understood by all workers [1].
  • [ ] "DO NOT OPERATE" Tag: Machine is properly tagged out to prevent accidental start-up during maintenance [1].
  • [ ] Ventilation: Ensure proper ventilation in the working area, especially when working indoors [2].
B. Equipment and Tools
  • [ ] Proper Tools: Correct tools are available and in good condition for the task [1].
  • [ ] Support Equipment: Proper support equipment (blocks, stands) are available and ready for use under the boom, arm, or bucket/attachment [3].
  • [ ] Fire Extinguisher: A fire extinguisher is readily available and inspected [4].
C. Personal Protective Equipment (PPE)
  • [ ] Required PPE: Approved safety glasses or face shield, gloves, hard hat, safety shoes, and work clothes are worn [2].
D. Hydraulic System Checks
  • [ ] Pressure Release: Hydraulic pressure in the system and attachment circuits has been properly released [5].
  • [ ] Hydraulic Tank Pressure: Internal pressure of the hydraulic tank has been released [6].
  • [ ] Line Inspection: Lines, tubes, and hoses are checked for damage (chafing, cuts, swelling, leaks) [4].

II. During Operation Checks

  • [ ] No Hot Surfaces: Avoid contact with hot surfaces; allow the machine to cool down before maintenance [1].
  • [ ] Leak Check: Use a piece of cardboard, wood, or metal to check for hydraulic leaks [2].
  • [ ] Component Condition: Ensure all clamps, guards, clips, and straps are correctly reinstalled to prevent vibration and rubbing [4].
  • [ ] Ether Usage (if equipped): Use ether in ventilated areas and follow proper cold engine starting procedures [4].

III. Post-Operation Checks

  • [ ] Area Clean Up: The working area is organized and cleaned up; all tools and parts are removed 4, 6.
  • [ ] Leak Verification: Verify no leaks are present after the line break is completed.
  • [ ] Machine Operation: After maintenance, operate the machine to ensure proper functionality and check for any issues.

IV. Corrective Actions

  • [ ] Record any corrective actions taken for incomplete items:

__________________________________________________________________________

__________________________________________________________________________

V. Signatures

  • Inspector: _________________________ Date: ____________
  • Supervisor: _________________________ Date: ____________
6 source record(s)

Sources used for this answer

[1] Kobelco SK235SR-2, SK235SRLC-2 Operation Manual

Page 178

Open source document

Source excerpt

## S. HYDRAULIC TANK PRESSURE Always release the internal pressure of the hydraulic tank before performing inspection or maintenance procedures. - 1. Remove cap (A) and push "DOWN" valve (B) to release air pressure in the reservoir. <!-- image --> Gasses from hydraulic tank may be hot. Wear safety equipment to avoid injury. ## T. WELDING SAFETY - 1. Turn starter key switch to "OFF" position. Wait 4 seconds for electrical power to disconnect. - 2. Remove negative (-) cable from battery terminal. - 3. Attach welder ground cable with 1 m {3'3"} away from component being welded. - 4. Make sure welder ground is not located at a seal or bearing. Do not locate welder ground at seal or bearing. - 5. Make sure that no bearings or seals separates the welder ground and the weld area. <!-- image --> <!-- image -->

[2] Kobelco SK235SR-2, SK235SRLC-2 Operation Manual

Page 48

Open source document

Source excerpt

## H. HYDRAULIC PRESSURE Under normal conditions, all circuits of the hydraulic system are under extreme pressure. When inspecting for leaks, use a small piece of cardboard, wood or metal to locate leaks. Small (pinhole) leaks can be dangerous if contact with skin or eyes is made. Wear approved safety glasses or face shield, gloves, hard hat, safety shoes and work clothes during all inspection and maintenance procedures. Seek immediate medical assistance if injury occurs. <!-- image --> ## I. RELIEVE THE HIGH PRESSURE IN FUEL LINE The engine fuel line generates high pressure in operation. In checking and servicing the fuel line, wait for 30 seconds to start checking and servicing until the internal pressure is released. ## J. STOP ENGINE Do not attempt any MAINTENANCE with engine running. Always stop the engine and allow machine to cool to avoid injury. Otherwise, there is a possibility of danger that your hand may be caught in the cooling fan or fan belt resulting injury. If it is unavoidable to operate the engine for inspection or maintenance, carry out the work with two people. The person seated in the operator's seat should be ready to stop the engine at any time while watching for a signal from the other person. ## K. VENTILATION PRECAUTIONS Operation of the machine indoor or in a place with poor ventilation may cause poisoning by gas. Ventilate any exhaust gas, fuel, cleaning oil, paint or similar articles. Make sure there is proper ventilation in the working area when the machine is operated indoors. Provide a ventilating fan, if required. <!-- image --> <!-- image --> <!-- image -->

[3] Kobelco SK235SR-2, SK235SRLC-2 Operation Manual

Page 49

Open source document

Source excerpt

## L. REMOVING AND INSTALLING ATTACHMENTS, AND STORING ATTACHMENTS - ・ Remove and install attachments after appointing a man to supervisor in advance. - ・ The attachment in danger of falling should be stored in the stable condition where supported in order not be fallen. And entry into the stored area of person other than the person concerned is prohibited. <!-- image --> ## M. USE SUPPORT EQUIPMENT DURING SERVICE - ・ When machine inspection or maintenance is done under the boom, arm or under the bucket/attachment use proper equipments or blocks to secure the attachment. - ・ The work in the condition where the crawler is floated by arm and boom causes the danger of falling of the machine if the control lever is shifted unexpectedly or the piping is broken. - No one is admitted to enter under the unstable machine. ## N. WORKING ABOVE GROUND There is a danger of falling when working on areas above ground. - ・ Do not approach edges. - ・ Use the appropriate equipment, such as ladders or platform when working above ground. In addition, strap yourself to the proper equipment accordingly. - ・ Avoid spillage of any oil or grease. - ・ Do not leave any tools around the working area. - ・ Use extreme caution to avoid slipping while walking. - ・ Do not jump on or from the machine. Use the steps and handrails and securely maintain a three point contact while mounting or dismounting at all times. <!-- image --> ## O. DO NOT DROP OFF TOOLS AND PARTS Dropping of any tools and parts in the working area may cause injury or faulty machine operation. Do not leave any tools or articles in the working area or component compartment. Store all tools properly when the work is completed. <!-- image --> １

[4] Kobelco SK235SR-2, SK235SRLC-2 Operation Manual

Page 47

Open source document

Source excerpt

## 1.6 INSPECTION &amp; MAINTENANCE SAFETY ## A. READ CAREFULLY OPERATING/MAINTENANCE PROCEDURES Incorrect maintenance may cause not only damages on the machine, but also injury. Read and fully understand the maintenance procedures and safety precautions described in the operation and maintenance manual before performing any maintenance in this machine. ## B. CONFIRM UNDERSTANDING OF HAND SIGNALS AND COMMUNICATION USED ON JOB SITE Have a meeting before starting work on the job site. Confirm all workers understand all hand signals, flag signals and other means of communication used on the job site to avoid any accidents or injuries. ## C. ORGANIZE AND CLEAN UP WORKING AREA Organize and clean up the working area. Remove any obstacles and also remove any grease, oil, paint, broken pieces, etc., from the working area to avoid injury. ## D. "TAG-OUT" MACHINE Before performing any inspection or maintenance procedures to the machine, fill out and post to the operator's controls a "DO NOT OPERATE" tag to warn persons not to start the machine. Also inform the supervisor and all operators that the machine is under inspection or maintenance and they will be informed when the machine is ready for normal operation. <!-- image --> ## E. TOOLS &amp; EQUIPMENT Use the proper tools and equipment for the task at hand. Know the proper use of the tools and equipment before starting any inspection or maintenance procedures. ## F. PRESSURIZED FLUIDS &amp; LUBRICANTS Always release pressure from hydraulic reservoir, engine coolant, fuel system and all systems containing pressure before removing any caps or components. Be cautious of hot fluids and gasses from systems on machines that have just been stopped. Allow sufficient time for systems to cool before performing any inspection or maintenance procedures. ## G. AVOID HOT SURFACES &amp; AREAS Immediately after the machine is operated, the temperature and pressure of the engine coolant, engine oil and hydraulic oil are ver…

[5] CAT 349F, 352F Excavators Operation and Maintenance Manual

Page 35

Open source document

Source excerpt

- · Cuts on insulation - · Other damage Make sure that all clamps, guards, clips, and straps are reinstalled correctly. This will help to prevent vibration, rubbing against other parts, and excessive heat during machine operation. Attaching electrical wiring to hoses and tubes that contain flammable fluids or combustible fluids should be avoided. Consult your Cat dealer for repair or for replacement parts. Keep wiring and electrical connections free of debris. ## Lines, Tubes, and Hoses Do not bend high-pressure lines. Do not strike highpressure lines. Do not install any lines that are bent or damaged. Use the appropriate backup wrenches in order to tighten all connections to the recommended torque. <!-- image --> Illustration 62 g00687600 Check lines, tubes, and hoses carefully. Wear Personal Protection Equipment (PPE) in order to check for leaks. Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury. Replace the affected parts if any of the following conditions are present: - · End fittings are damaged or leaking. - · Outer coverings are chafed or cut. - · Wires are exposed. - · Outer coverings are swelling or ballooning. - · Flexible parts of the hoses are kinked. - · Outer covers have exposed embedded armoring. - · End fittings are displaced. Make sure that all clamps, guards, and heat shields are installed correctly. During machine operation, this will help to prevent vibration, rubbing against other parts, excessive heat, and failure of lines, tubes, and hoses. Do not operate a machine when a fire hazard exists. Repair any lines that are corroded, loose, or damaged. Leaks may provide fuel for fires. Consult your Cat dealer for repair o…

[6] CAT 374 Excavator Operation and Maintenance Manual

Page 309

Open source document

Source excerpt

- 4. Release hydraulic system pressure in the attachment circuits, if equipped. - a. Start the engine to charge pilot accumulator. - b. Shut off the engine. Note: Perform Step 4c through Step 4e immediately after the engine is shut off to insure adequate pilot system pressure is available to release the pressure in the hydraulic circuits. - c. Turn the engine start switch to the ON position without starting the engine. - d. Place the hydraulic activation control lever in the UNLOCKED position. - e. Activate the switch or pedal for the attachment circuit. - f. Place the hydraulic activation control lever in the LOCKED position. - g. Repeat Step 4a through Step 4f for each attachment circuit. - 5. After releasing the hydraulic pressure in each of the desired hydraulic circuits, place the hydraulic activation control lever in the LOCKED position. - 6. Turn the engine start switch to the OFF position. <!-- image --> Illustration 484 ## Filler cap (A) LOCK position - (B) PRESSURE RELEASE - START position - (C) PRESSURE RELEASE - END position - (D) OPEN position - 7. Release the pressure that may be present in the return hydraulic circuit with the following procedure. Refer to Illustration 484 for filler cap positions. - a. Turn the filler cap counterclockwise and move the arrow from position (A) to position (B). - b. Release the pressure for a minimum of 45 seconds by moving the arrow from position (B) to position (C). - c. Push the filler cap down and move the arrow from position (C) to position (D). Note: The travel hydraulic circuit is open to the hydraulic tank. Pressure from the travel circuit is released by releasing pressure from the return circuit. Note: If a hydraulic line for the boom, the stick or the bucket must be disconnected, utilize the purge screws. Refer to Purge Screws (Boom, Stick and/or Bucket Hydraulic Circuits). ## Purge Screws (Boom, Stick and/or Bucket Hydraulic Circuits) If a hydraulic line for the boom, the stick or the bucket must b…

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