12 Aug Mobile Equipment Inspection – JSA

Mobile Equipment Inspection Job Safety Analysis (JSA)

Job / Task

Pre-use, pre-shift, periodic, and post-operation inspection of mobile equipment such as loaders, excavators, backhoes, dump trucks, forklifts, skid-steer loaders, aerial equipment, and similar powered equipment.

Purpose

This Job Safety Analysis (JSA), also known as a Job Hazard Analysis (JHA), identifies hazards associated with inspecting mobile equipment and establishes controls to prevent unexpected movement, struck-by and caught-between injuries, falls, burns, hydraulic injection injuries, and operation of defective equipment.

Personnel Qualifications

Mobile equipment inspections shall be performed by employees who are trained to recognize equipment defects and understand the inspection requirements for the specific equipment. Inspection does not authorize an employee to perform repairs or enter hazardous areas unless separately trained and authorized.

Inspectors shall:

• Know the manufacturer’s inspection requirements and applicable company procedures.
• Understand the equipment controls, warning devices, safety systems, and common defect indicators.
• Inspect equipment before operation at the frequency required for the specific equipment.
• Keep clear of moving parts, pinch points, suspended components, and traffic.
• Never place any part of the body beneath raised equipment or attachments unless properly blocked and hazardous energy is controlled.
• Report defects immediately and prevent unsafe equipment from being operated.
• Perform only those adjustments or repairs for which they are trained and authorized.
• Stop the inspection when conditions cannot be evaluated safely.

Required PPE

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

• Hard hat where construction or overhead hazards exist.
• Safety glasses with side protection.
• Safety footwear.
• High-visibility apparel when exposed to vehicle or equipment traffic.
• Work gloves appropriate for inspection activities.
• Hearing protection where noise exposure requires it.
• Additional task-specific PPE identified by the hazard assessment.

JSA – Job Steps, Hazards, and Controls

Step 1 – Prepare for the Inspection

Potential Hazards

• Wrong inspection criteria.
• Unrecognized hazards.
• Exposure to active operations.

Required Controls

• Identify the equipment and the required inspection checklist or manufacturer criteria.
• Review known defects, maintenance tags, or previous inspection findings when available.
• Select a safe inspection location away from unnecessary traffic and active operations.
• Ensure adequate lighting and visibility.
• Use required PPE before entering the equipment area.

Step 2 – Secure the Equipment

Potential Hazards

• Unexpected movement.
• Runaway equipment.
• Caught-between injury.

Required Controls

• Park equipment on firm, level ground where practical.
• Place transmission and controls in the required neutral or parked condition.
• Set the parking brake.
• Lower buckets, forks, blades, booms, platforms, and attachments to a safe resting position.
• Shut down and remove or control the key when the inspection requires personnel to approach hazardous areas.

Step 3 – Conduct a 360-Degree Walkaround

Potential Hazards

• Struck-by.
• Slip or trip.
• Contact with sharp or hot surfaces.

Required Controls

• Walk around the equipment before entering the cab or starting it.
• Check for personnel, obstructions, leaks, loose parts, debris, and signs of damage.
• Watch for uneven ground, mud, ice, cords, hoses, and other trip hazards.
• Maintain clearance from nearby moving equipment.
• Do not touch components that may be hot until they have cooled sufficiently.

Step 4 – Inspect Tires, Wheels, or Tracks

Potential Hazards

• Tire failure.
• Crushing.
• Sharp-object injury.

Required Controls

• Inspect tires for damage, excessive wear, cuts, exposed cords, and obvious underinflation.
• Inspect wheels, rims, lug nuts, hubs, and visible fasteners for damage or looseness.
• Inspect tracks, rollers, sprockets, and undercarriage components where applicable.
• Do not position the body beneath the equipment while inspecting.
• Do not attempt tire or wheel repairs unless trained, authorized, and equipped for the task.

Step 5 – Inspect for Fluid Leaks

Potential Hazards

• Slip hazard.
• Burn.
• Hydraulic injection injury.
• Environmental release.

Required Controls

• Look for evidence of fuel, oil, coolant, brake-fluid, and hydraulic leaks.
• Never use bare hands to locate a suspected pressurized hydraulic leak.
• Use cardboard, wood, or another safe method when leak detection is required and permitted.
• Avoid contact with hot fluids and pressurized systems.
• Report significant leaks and remove unsafe equipment from service.

Step 6 – Inspect Hydraulic Hoses and Cylinders

Potential Hazards

• Hydraulic hose rupture.
• Injection injury.
• Unexpected component movement.

Required Controls

• Inspect visible hoses, fittings, cylinders, and connections for abrasion, cracks, bulges, leakage, or damage.
• Keep hands and body away from suspected pinhole leaks.
• Do not inspect beneath raised hydraulically supported components unless positively blocked.
• Do not loosen fittings or hoses during a routine inspection.
• Refer damaged hydraulic components for qualified repair.

Step 7 – Inspect Buckets, Forks, Blades, and Attachments

Potential Hazards

• Crushing.
• Attachment detachment.
• Falling component.

Required Controls

• Ensure attachments are lowered and stable before close inspection.
• Inspect attachment structure, cutting edges, forks, teeth, pins, retainers, couplers, and locking devices.
• Check for cracks, deformation, excessive wear, or missing components.
• Verify quick-coupler locking mechanisms appear fully engaged.
• Do not enter pinch points between the attachment and machine.

Step 8 – Inspect Guards and Protective Structures

Potential Hazards

• Contact with moving parts.
• Operator injury during rollover or falling-object event.

Required Controls

• Inspect guards, shields, covers, ROPS, FOPS, cab structures, doors, and protective screens.
• Check for missing bolts, obvious cracks, unauthorized modifications, or structural damage.
• Do not operate equipment with required guards removed.
• Report damaged protective structures for evaluation.
• Do not drill, weld, cut, or modify ROPS/FOPS unless specifically authorized by the manufacturer or qualified authority.

Step 9 – Inspect Steps, Ladders, and Handholds

Potential Hazards

• Slip or fall while mounting or dismounting.

Required Controls

• Inspect steps, ladders, platforms, and handholds for damage and secure attachment.
• Remove mud, grease, ice, oil, and debris.
• Confirm walking surfaces provide adequate traction.
• Report missing or damaged access components.
• Do not use tires, buckets, controls, or improvised surfaces as access points.

Step 10 – Inspect the Operator Restraint System

Potential Hazards

• Operator ejection.
• Injury during rollover.

Required Controls

• Inspect the seat, seat mounting, seat belt, buckle, latch, and retracting mechanism where provided.
• Check webbing for cuts, fraying, chemical damage, or excessive wear.
• Verify the buckle latches and releases correctly.
• Report damaged or nonfunctional restraints.
• Do not operate equipment when a required restraint system is defective.

Step 11 – Inspect the Operator Station

Potential Hazards

• Poor visibility.
• Control interference.
• Fire hazard.

Required Controls

• Remove loose tools, trash, and materials that could interfere with pedals or controls.
• Inspect windows, windshield, mirrors, and camera lenses for cleanliness and damage.
• Check doors, latches, and emergency exits where applicable.
• Verify labels and safety decals needed for operation are legible.
• Confirm the cab is free of excessive combustible debris.

Step 12 – Inspect Controls and Instruments Before Startup

Potential Hazards

• Unexpected movement.
• Control malfunction.

Required Controls

• Verify controls are in the required startup position.
• Check pedals, levers, switches, and steering components for obvious damage or obstruction.
• Inspect gauges and instrument panels for visible damage.
• Ensure emergency controls and shutdown devices are identifiable.
• Do not start equipment when controls are damaged or obstructed.

Step 13 – Inspect the Battery and Electrical System

Potential Hazards

• Electrical shock.
• Battery acid.
• Fire or explosion.

Required Controls

• Inspect batteries and electrical components only to the extent required by the routine inspection.
• Look for loose or damaged cables, exposed wiring, corrosion, or damaged covers.
• Keep sparks, flames, and smoking materials away from batteries.
• Do not place conductive tools across battery terminals.
• Refer electrical or battery defects to qualified personnel.

Step 14 – Check Fuel and Fluid Levels

Potential Hazards

• Burn.
• Chemical exposure.
• Fire.
• Slip hazard.

Required Controls

• Check fluid levels according to manufacturer procedures.
• Allow pressurized or hot systems to cool before opening caps where required.
• Use proper funnels and containers when adding fluids.
• Clean spills promptly.
• Keep ignition sources away from fuel and flammable liquids.

Step 15 – Inspect Fire Extinguisher and Emergency Equipment

Potential Hazards

• Unavailable emergency equipment.
• Delayed emergency response.

Required Controls

• Verify required fire extinguishers are present, charged, secured, and accessible.
• Check first-aid kits, spill kits, wheel chocks, warning triangles, or other required equipment as applicable.
• Replace missing or defective emergency equipment.
• Do not obstruct emergency equipment with tools or materials.
• Document deficiencies as required.

Step 16 – Start the Equipment for Operational Checks

Potential Hazards

• Unexpected movement.
• Exhaust exposure.
• Noise.

Required Controls

• Ensure personnel are clear before startup.
• Start equipment from the designated operator position.
• Do not start or idle internal-combustion equipment in inadequately ventilated enclosed areas.
• Check gauges and warning indicators immediately after startup.
• Stop the engine if abnormal warnings, noises, smoke, or conditions are observed.

Step 17 – Test Horns, Alarms, Lights, and Warning Devices

Potential Hazards

• Pedestrian exposure.
• Inadequate warning.

Required Controls

• Test the horn, backup alarm, lights, strobes, turn signals, brake lights, and other required warning devices.
• Verify cameras and proximity devices function where installed.
• Clean lenses and sensors as needed.
• Do not rely on cameras or alarms as substitutes for safe operating practices.
• Remove equipment from service when required warning devices are defective and cannot be safely compensated for under applicable procedures.

Step 18 – Test Steering and Travel Controls

Potential Hazards

• Loss of control.
• Collision.
• Unexpected movement.

Required Controls

• Conduct operational checks in a clear, controlled area.
• Verify steering and travel controls respond normally.
• Operate at low speed during testing.
• Keep personnel outside the test area.
• Stop immediately if steering, transmission, or travel response is abnormal.

Step 19 – Test Service and Parking Brakes

Potential Hazards

• Runaway equipment.
• Collision.

Required Controls

• Test brakes at low speed in a clear area.
• Verify service brakes stop the equipment effectively.
• Verify the parking brake holds as intended under appropriate test conditions.
• Do not continue operating equipment with questionable braking performance.
• Report brake defects immediately.

Step 20 – Test Hydraulic and Attachment Functions

Potential Hazards

• Unexpected movement.
• Crushing.
• Dropped attachment.

Required Controls

• Ensure the operating area is clear before cycling hydraulic functions.
• Operate booms, buckets, blades, forks, stabilizers, outriggers, and attachments slowly.
• Watch for drift, abnormal movement, leaks, noises, or binding.
• Keep personnel outside the equipment’s movement envelope.
• Lower attachments after testing.

Step 21 – Check Backup Visibility

Potential Hazards

• Backing collision.
• Pedestrian struck-by.

Required Controls

• Verify mirrors and cameras provide the intended field of view.
• Check for blind spots specific to the equipment.
• Ensure backup alarms operate where required.
• Determine whether a spotter will be necessary for the planned work.
• Correct visibility problems before operation.

Step 22 – Inspect Equipment-Specific Safety Devices

Potential Hazards

• Failure of safety system.
• Unexpected movement or overload.

Required Controls

• Inspect interlocks, limit switches, load indicators, outriggers, stabilizers, emergency lowering devices, fork locks, couplers, or other equipment-specific systems as applicable.
• Follow manufacturer test procedures.
• Do not bypass, disable, or defeat safety devices.
• Report any device that fails its test.
• Remove equipment from service when required safety systems are defective.

Step 23 – Identify Defects and Determine Equipment Status

Potential Hazards

• Unsafe equipment placed into service.
• Miscommunication.

Required Controls

• Evaluate inspection findings before operating the equipment.
• Immediately report safety-related defects to the appropriate supervisor or maintenance personnel.
• Do not operate equipment with defects that could affect safe operation.
• Use out-of-service tags, keys, locks, or other controls required by company procedure to prevent unauthorized use.
• Do not remove an out-of-service designation until authorized repairs and required verification are complete.

Step 24 – Document the Inspection

Potential Hazards

• Incomplete records.
• Uncorrected defect.

Required Controls

• Complete the required inspection form or electronic record accurately.
• Identify the equipment, date, inspector, and defects found as required.
• Clearly document conditions requiring repair or follow-up.
• Submit records according to company procedures.
• Do not mark defective items satisfactory without verification.

Step 25 – Post-Repair Verification

Potential Hazards

• Defect remains after repair.
• Unexpected movement during testing.

Required Controls

• Ensure repairs are performed by qualified and authorized personnel.
• Verify safety-critical repairs before equipment is returned to service.
• Repeat affected inspection or operational checks as necessary.
• Ensure guards and protective devices removed for repair are reinstalled.
• Remove out-of-service controls only when the equipment has been authorized for return to service.

Step 26 – Complete the Inspection

Potential Hazards

• Equipment left unsecured.
• Trip hazards.

Required Controls

• Lower attachments and place the equipment in a safe condition.
• Set the parking brake and shut down if the equipment will not immediately be operated.
• Remove inspection tools, rags, and materials.
• Clean spills and restore housekeeping.
• Communicate equipment status and outstanding defects to affected personnel.

General Safe Work Requirements

• Mobile equipment shall be inspected at the frequency required by the applicable equipment, manufacturer instructions, company procedures, and regulatory requirements.
• Inspections shall be performed by employees trained to recognize defects and hazards associated with the equipment.
• Equipment shall be secured against unintended movement before close inspection of hazardous areas.
• Raised buckets, booms, beds, platforms, forks, or attachments shall not be entered beneath unless positively supported and hazardous energy is controlled.
• Pressurized hydraulic leaks shall never be located with bare hands.
• Required guards, protective structures, seat belts, alarms, brakes, steering systems, and safety devices shall be maintained in serviceable condition.
• Operational tests shall be performed only in areas clear of personnel and obstructions.
• Inspectors shall maintain three points of contact when mounting and dismounting equipment.
• High-visibility apparel shall be worn when inspections expose employees to vehicle or mobile-equipment traffic.
• Safety-related defects shall be reported immediately.
• Equipment with defects that could affect safe operation shall be removed from service until repaired.
• Out-of-service tags or controls shall not be removed except in accordance with company procedures.
• Only trained and authorized personnel shall perform repairs, adjustments, or servicing.
• Inspection results and corrective actions shall be documented as required.
• Work shall stop whenever the equipment cannot be inspected safely because of traffic, unstable conditions, stored energy, inadequate lighting, or other uncontrolled hazards.

Training

Employees assigned to inspect mobile equipment shall receive training appropriate to the equipment and inspection duties. Training shall address inspection checklists, manufacturer requirements, defect recognition, tires or tracks, brakes, steering, hydraulics, attachments, guards, protective structures, seat belts, warning devices, visibility systems, fluid leaks, battery hazards, safe mounting and dismounting, equipment securement, stored-energy hazards, defect reporting, out-of-service procedures, and inspection documentation. Additional training and authorization are required before employees perform repairs or servicing.

References

• OSHA 29 CFR 1926.600 – Equipment.
• OSHA 29 CFR 1926.601 – Motor Vehicles, where applicable.
• OSHA 29 CFR 1926.602 – Material Handling Equipment.
• OSHA 29 CFR 1910.178 – Powered Industrial Trucks, where applicable.
• Applicable manufacturer inspection and operating manuals, company procedures, and client requirements.