Maintaining construction equipment is necessary to keep machines running safely, but maintenance work itself can expose workers to serious hazards. Unexpected machine movement, stored hydraulic pressure, hot components, and moving parts can cause severe injuries if proper precautions are not taken. Many maintenance incidents happen when workers assume equipment is fully shut down or safe to work on.
This talk focuses on safe practices crews must follow when performing equipment maintenance or repairs. Proper shutdown procedures, controlling stored energy, and staying aware of pinch points are critical to preventing injuries during maintenance work.
Why This Matters
- Unexpected startup or machine movement can crush or pin workers.
- Hydraulic systems may still hold pressure even after the engine is shut off.
- Hot engines, exhaust components, and fluids can cause burns.
- Moving parts such as belts, fans, and pulleys can catch clothing or hands.
- Improper maintenance can lead to equipment failure later on the jobsite.
Common Hazards
- Working on equipment without shutting down and isolating the power source.
- Stored hydraulic pressure causing parts or attachments to move unexpectedly.
- Working under raised buckets, blades, or attachments without proper support.
- Contact with hot engines, fluids, or exhaust systems.
- Pinch points around moving components or access panels.
- Slips caused by oil, grease, or fluid leaks around the machine.
- A worker removing a hydraulic hose while pressure remains in the system.
Safety Checklist
Before Work Begins
- Park equipment on level ground and set the parking brake.
- Shut down the engine and remove the key.
- Follow lockout/tagout procedures when required.
- Lower all attachments fully to the ground or secure them with proper supports.
- Allow engines and components to cool before working near them.
- Release stored hydraulic pressure according to manufacturer procedures.
- Wear proper personal protective equipment such as gloves and eye protection.
During Work
- Use the correct tools and follow manufacturer maintenance procedures.
- Keep hands clear of pinch points and moving parts.
- Never bypass guards or safety devices during maintenance.
- Clean up oil or fluid spills immediately to prevent slips.
- Ensure attachments and components are properly supported before working beneath them.
- Maintain clear communication if more than one worker is performing maintenance.
- Stop work if equipment behaves unexpectedly or parts begin to shift.
Crew Talking Points
- What maintenance tasks are scheduled for equipment today?
- Who is responsible for performing and documenting maintenance?
- What lockout or shutdown procedures apply to the equipment being serviced?
- Where are the major pinch points or pressure hazards on this machine?
- What PPE should be used during maintenance work?
- Does anyone see a hazard related to the maintenance tasks planned today?
Stop Work If
- The equipment has not been properly shut down or isolated.
- Hydraulic pressure or stored energy has not been released.
- Attachments are raised without proper supports.
- Guards or safety devices are missing or damaged.
- Workers are exposed to moving parts or unexpected machine movement.
- The task requires tools, parts, or procedures that are not available.
Final Reminder
Maintenance keeps equipment running safely, but only when the work itself is done safely. Shut down the machine, control stored energy, and never rush maintenance tasks.
| Crew Member Name | Signature | Date |
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