Job Safety Analysis (JSA) Worksheet
Job Title:
Engine Overhaul – Installations / Assessment Date:
January 1, 2009 / New
Revision / Page 1 of 3
Company:
Reagan Equipment Company / Location:
Harvey, LA / Department:
MECHANICAL
Job Task: Installing: Liners / Pistons / Rings / Camshaft and Rollers
Tools and Equipment Required:
Hand tools, chain falls,
impacts, pulling tools, sockets and wrenches, and micrometer sets. / Material(s) Required:
Absorbent pads for spills and slippery floor,
parts cleaner and rags. / PPE Required:
Safety glasses, work gloves, steel toe work boots. Hard hat and hearing protection where applicable. / Risk Rating: R / Consequence Rating: C / Occurrence Rating: O
High Risk = 3 / Fatality/ Catastrophic Property Damage = 3 / Daily/ Frequently = 3
Medium Risk = 2 / Lost time Accident/ Major Property Damage = 2 / Monthly/ Occasionally = 2
Low Risk = 1 / Medical Aid/ Minor Property Damage = 1 / Quarterly/ Rarely = 1
Step# / Sequence of Basic Steps
/ Potential Hazards / Health / Safety / R / C / O / Priority Rating
(R + C + O) / Current Hazard Control / Hazard Control Required
Place X in appropriate column legend:
EO: Engineered Control
ADM: Administrative Control
PPE: Personal Protective Equipment
Other: Suitable Alternative Method / Hazard Control Description
Examples:
EO: install proper ventilation
ADM: written procedure
PPE: eye/ hearing protection
Other: contracting out job
EO / ADM / PPE / OTHER

Parts Cleaning & Re-Installation

/ NOTE: Watch for pinch points, heavy objects, air tools, etc. / H / Upon completion of the disassembly and all the inspections are completed, the parts will be cleaned and made ready for reassembly. Close attention must be paid in order to insure cleanness of parts and checking for damage to parts.
NOTE: Safety is a key part of these tasks due to multiple jobs going on at the same time. This can include: air tools (flying objects), hand cleaning (sharp edges or tools), chemicals, etc. / Use rubber gloves when washing parts w/Varsol.
Ventilation required.
1 /

Micrometer inspect the pistons and liners. Record readings.

/ sharp edges / S / 1 / 1 / 1 / 3 / Watch for sharp edges. / X / Watch for sharp edges.
2 / Install each ring in a new liner and check end gap and check ring side clearance on all pistons before installation. Record readings. / sharp edges / S / 2 / 1 / 1 / 4 / Watch for sharp edges. / X / Watch for sharp edges.
3 /

Re-check liner micrometer reading after installation to insure the liner is round.

/ sharp edges / S / 2 / 1 / 1 / 4 / Watch for sharp edges. / X / Watch for sharp edges.
4 /

After installation and using the correct torque procedure, check rod bearing clearance and rod side clearance.

/ 1) shaft can move before pistons are installed
2) heavy parts
3) straining
4) oily parts / S / 2 / 1 / 1 / 4 / THIS TASK IS A HIGH CAUTION TASK. Block the shaft from moving before installing pistons. Use correct lifting techniques… get help if needed. Use correct body positioning. / X / Supervisor shall insure all personnel are informed as to the seriousness of this task. Use correct tooling.
5 /

Install the camshaft, check all clearances, set thrust, install cover and rollers.

/ 1) pinch points
2) sharp edges
3) oily parts / S / 2 / 1 / 1 / 4 / THIS TASK IS A HIGH CAUTION TASK. Keep awareness high. / X / Supervisor shall insure all personnel are informed as to the seriousness of this task. Use correct tooling.

Note: Block the shaft from moving before installing pistons. Watch for sharp areas and pinch points. This task is a HIGH CAUTION area. All personnel must be informed to the seriousness of this task. Attention is needed with the liners and pistons. Watch for pinch points; this includes the camshaft installation.

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