12 Aug Equipment Inspection – JSA

Equipment Inspections Job Safety Analysis (JSA)

Job / Task

Pre-use, routine, periodic, and post-use inspection of construction equipment, vehicles, powered equipment, tools, attachments, and related safety devices to identify defects or unsafe conditions before operation or continued use.

Purpose

This Job Safety Analysis (JSA), also known as a Job Hazard Analysis (JHA), identifies hazards associated with equipment inspection and establishes safe work practices and controls to prevent unexpected movement, hazardous-energy exposure, falls, struck-by and caught-between injuries, burns, cuts, and equipment-related incidents.

Personnel Qualifications

Equipment inspections shall be performed by employees who are trained, competent, qualified, or authorized as required for the specific equipment and inspection being performed.

Employees shall:

• Understand the equipment, inspection requirements, manufacturer instructions, and applicable site procedures.
• Perform only inspections for which they have been trained or authorized.
• Know the location and function of controls, safety devices, guards, emergency stops, and energy-isolating devices.
• Use lockout/tagout or other hazardous-energy controls when an inspection requires entry into a danger zone, removal of guards, or exposure to hazardous energy.
• Use appropriate access equipment rather than climbing on equipment in an unsafe manner.
• Document and report defects as required.
• Remove unsafe equipment from service or prevent its use until the defect is corrected.
• Stop the inspection when conditions cannot be safely controlled.

Required PPE

PPE shall be selected based on the equipment, inspection activity, and work environment and may include:

• Safety glasses with side protection.
• Safety footwear with appropriate toe protection and slip-resistant soles.
• Work gloves appropriate for the inspection task.
• Hard hat where overhead or falling-object hazards exist.
• High-visibility apparel where vehicles or mobile equipment are operating.
• Hearing protection where noise exposure requires it.
• Face protection where fluid release, flying particles, or similar hazards exist.
• Electrical protective equipment when required for qualified electrical inspection.
• Fall protection where required by the work condition.
• Additional PPE required by the equipment, task, or site.

PPE does not replace equipment shutdown, hazardous-energy control, blocking, guarding, safe access, or other required protective measures.

JSA – Job Steps, Hazards, and Controls

Step 1 – Review Inspection Requirements

Potential Hazards

• Incomplete inspection.
• Unknown equipment hazards.
• Incorrect inspection criteria.
• Missed safety-critical components.

Required Controls

• Review the applicable inspection checklist, manufacturer instructions, operating manual, and site requirements before beginning.
• Determine whether the inspection is pre-use, periodic, post-repair, or otherwise required.
• Identify components requiring specialized inspection or qualified personnel.
• Do not perform adjustments, repairs, or testing beyond the employee’s training or authorization.

Step 2 – Inspect the Surrounding Area

Potential Hazards

• Vehicle or equipment traffic.
• Uneven ground.
• Poor lighting.
• Overhead hazards.
• Slips, trips, and falls.

Required Controls

• Perform the inspection in a safe location whenever practical.
• Park or position equipment on firm, stable ground.
• Maintain separation from traffic and operating equipment.
• Provide adequate lighting.
• Keep the inspection area clear of debris and unnecessary personnel.

Step 3 – Secure the Equipment

Potential Hazards

• Unexpected movement.
• Rollaway.
• Equipment startup.
• Caught-between or crushing injuries.

Required Controls

• Place equipment in the manufacturer’s recommended inspection or parked condition.
• Lower attachments to the ground when practical.
• Place controls in neutral or the appropriate safe position.
• Set parking brakes and use wheel chocks or other securement when required.
• Shut down the engine or power source before inspecting areas where movement could cause injury.

Step 4 – Perform an External Walk-Around

Potential Hazards

• Sharp edges.
• Hot surfaces.
• Leaks.
• Loose or damaged components.
• Slips on fluids or debris.

Required Controls

• Walk around the equipment systematically.
• Inspect for visible damage, missing parts, loose hardware, cracks, corrosion, leaks, and abnormal conditions.
• Avoid direct contact with hot surfaces and leaking fluids.
• Do not use bare hands to check for pressurized hydraulic leaks.
• Correct or barricade spilled fluids and report leaks.

Step 5 – Inspect Tires, Wheels, Tracks, and Undercarriage

Potential Hazards

• Crushing or pinch points.
• Damaged tires or wheels.
• Stored pressure.
• Unexpected movement.
• Cuts from damaged components.

Required Controls

• Keep hands and body parts clear of pinch and crush points.
• Inspect tires, wheels, tracks, lug hardware, and undercarriage from a safe position.
• Do not place any part of the body beneath unsupported equipment.
• Do not loosen, inflate, disassemble, or service multi-piece or damaged wheel assemblies unless trained and authorized.
• Report excessive wear, damage, or missing components.

Step 6 – Inspect Guards, Covers, and Safety Devices

Potential Hazards

• Exposure to moving parts.
• Missing guards.
• Defective alarms or interlocks.
• Pinch points.

Required Controls

• Verify required guards, covers, shields, and protective devices are present and secure.
• Inspect steps, handholds, railings, seat belts, alarms, horns, lights, mirrors, cameras, and other safety devices applicable to the equipment.
• Do not operate equipment with missing or defective safety-critical devices unless specifically permitted by an approved procedure.
• Do not bypass interlocks or safety devices.

Step 7 – Inspect Fluid Levels and Engine / Power Components

Potential Hazards

• Hot fluids.
• Burns.
• Chemical exposure.
• Unexpected startup.
• Rotating components.

Required Controls

• Follow manufacturer instructions for checking fluid levels.
• Allow equipment to cool before opening pressurized cooling systems or contacting hot components.
• Keep hands, clothing, and tools away from belts, fans, shafts, and other moving parts.
• Use appropriate gloves and eye protection.
• Clean spills and replace caps or covers securely.

Step 8 – Inspect Hydraulic and Pneumatic Systems

Potential Hazards

• High-pressure fluid injection.
• Stored pressure.
• Hose failure.
• Unexpected movement of attachments.

Required Controls

• Inspect hoses, fittings, cylinders, and lines for wear, leakage, abrasion, or damage.
• Never use hands or fingers to locate a suspected high-pressure leak.
• Lower or mechanically support raised components before entering a potential crush zone.
• Relieve stored pressure before disconnecting or servicing components.
• Remove equipment from service when defects could affect safe operation.

Step 9 – Inspect Electrical Systems

Potential Hazards

• Electrical shock.
• Arc hazards.
• Damaged wiring.
• Battery chemical exposure.
• Short circuits.

Required Controls

• Inspect accessible wiring, cables, connectors, batteries, and terminals for visible damage.
• Do not contact exposed energized conductors.
• Use insulated or rated equipment where required and only when qualified for the task.
• Keep conductive tools away from battery terminals.
• Follow manufacturer precautions for batteries and charging systems.
• Refer electrical defects requiring repair to qualified personnel.

Step 10 – Access the Operator Station

Potential Hazards

• Slips and falls.
• Poor access.
• Damaged steps or handholds.
• Unexpected control activation.

Required Controls

• Use designated steps and handholds.
• Maintain three points of contact while climbing when practical.
• Do not climb using controls, steering wheels, hoses, or other unsuitable components.
• Keep steps and access surfaces clean and free of oil, mud, ice, and debris.
• Face the equipment when climbing on or off.

Step 11 – Inspect Operator Controls and Safety Features

Potential Hazards

• Unexpected equipment movement.
• Control malfunction.
• Defective brakes or steering.
• Personnel in danger zone.

Required Controls

• Ensure personnel are clear before energizing or starting equipment for functional checks.
• Verify controls, gauges, indicators, warning devices, seat belts, brakes, steering, horn, lights, backup alarms, and other required features operate as intended.
• Conduct functional tests in a controlled area.
• Do not continue testing when abnormal operation or a safety-critical defect is identified.

Step 12 – Inspect Attachments and Work Equipment

Potential Hazards

• Falling or shifting attachments.
• Damaged pins or locking devices.
• Crushing hazards.
• Unexpected movement.

Required Controls

• Lower attachments before inspection whenever practical.
• Inspect attachment points, pins, retainers, locking devices, hoses, couplers, buckets, forks, blades, and other components.
• Verify attachments are properly secured.
• Use blocking or manufacturer-approved supports before inspecting beneath raised components.
• Do not place body parts between components that could move.

Step 13 – Identify and Control Defects

Potential Hazards

• Unsafe equipment returned to service.
• Unauthorized repair.
• Unexpected failure.
• Miscommunication.

Required Controls

• Immediately report defects affecting safe operation.
• Tag, lock, barricade, or otherwise identify unsafe equipment to prevent use in accordance with company procedures.
• Do not operate equipment with a safety-critical defect until repaired and released for service.
• Repairs shall be performed only by trained and authorized personnel.
• Reinspect or function-test repaired equipment as required before return to service.

Step 14 – Complete Inspection Documentation

Potential Hazards

• Incomplete records.
• Missed defects.
• Equipment released without verification.

Required Controls

• Complete the required inspection form or electronic record accurately.
• Document defects, corrective actions, and equipment status as required.
• Submit or retain inspection records according to applicable procedures.
• Communicate unresolved defects to supervision and affected operators.
• Do not sign or indicate that an inspection is complete unless the required inspection has actually been performed.

General Safe Work Requirements

• Inspect equipment at the frequency required by the applicable standard, manufacturer, site, or company procedure.
• Use a consistent inspection sequence to reduce the likelihood of missed items.
• Do not crawl beneath, reach into, or enter equipment danger zones unless hazardous movement and energy are controlled.
• Never rely solely on hydraulic pressure to support raised equipment or attachments.
• Do not use bare hands to check for hydraulic leaks.
• Keep guards and safety devices in place except when removal is necessary for an authorized inspection and appropriate energy controls are applied.
• Remove equipment from service when a defect could affect safe operation.
• Do not make unauthorized repairs or modifications during an inspection.
• Maintain inspection records when required.
• Stop work whenever the inspection cannot be performed safely.

Training

Employees shall receive training appropriate to the equipment they inspect and the level of inspection they perform. Training shall include manufacturer inspection requirements, hazard recognition, hazardous-energy awareness, safe access, fluid and pressure hazards, safety-device inspection, defect reporting, equipment removal from service, and required documentation. Specialized inspections shall be performed by personnel meeting applicable qualification or competency requirements.

References

• OSHA 29 CFR 1910.147 – The Control of Hazardous Energy (Lockout/Tagout).
• OSHA 29 CFR 1910.178 – Powered Industrial Trucks.
• OSHA 29 CFR 1926.20 – General Safety and Health Provisions.
• OSHA 29 CFR 1926.21 – Safety Training and Education.
• OSHA 29 CFR 1926 Subpart O – Motor Vehicles, Mechanized Equipment, and Marine Operations.
• Applicable manufacturer inspection, operation, and maintenance instructions.

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