Pre-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

1. Position the machine and lower the work tool to the ground 2, 5, 6, 7, 14.
2. Release hydraulic pressure from the system 2, 5, 6, 7, 14.
3. Disconnect the old hydraulic hose [1].
4. Connect the new hydraulic hose 1, 2.
5. 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]

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