Product Overview

Summary: This SOP provides clear, step-by-step guidance for safely inspecting, setting up and adjusting harvesting equipment in Australian agricultural operations. It helps workers optimise machine performance while controlling the significant crush, entanglement and mechanical hazards associated with adjustment and maintenance tasks.

Incorrectly adjusted harvesting equipment can lead to serious injuries, machine failures, crop losses and costly downtime. This Harvesting Equipment Adjustment Safe Operating Procedure sets out a structured, repeatable process for safely isolating, inspecting and adjusting harvesters, headers, pickers and associated implements in line with Australian WHS expectations. It walks operators and supervisors through pre-adjustment checks, lock-out and tag-out, safe access to adjustment points, verification of settings and post-adjustment testing under controlled conditions.

Designed specifically for Australian farming and contracting operations, this SOP addresses the real-world risks of working around moving parts, sharp components and high‑inertia systems in paddocks, orchards and vineyards. It helps businesses demonstrate due diligence under WHS legislation, supports consistent operator training across seasonal and contract labour, and reduces the likelihood of incidents caused by ad‑hoc, undocumented adjustment practices. By implementing this procedure, agricultural businesses can improve harvest quality and throughput while protecting workers, contractors and bystanders from preventable injuries.

Key Benefits

• Reduce the risk of crush, entanglement and amputation injuries during harvesting equipment adjustment.
• Ensure consistent, documented adjustment practices across permanent, seasonal and contract operators.
• Improve harvest quality and machine efficiency through correctly set clearances, speeds and configurations.
• Demonstrate compliance with Australian WHS duties for plant, maintenance and isolation procedures.
• Minimise unplanned downtime, mechanical damage and crop losses caused by incorrect machine settings.

Who is this for?

• Farm Owners and Managers
• Harvesting Supervisors
• Farm Machinery Operators
• Agricultural Contractors
• Maintenance Technicians (Agricultural Equipment)
• WHS Advisors in Agriculture
• Production and Operations Managers (Grain, Horticulture, Viticulture)
• Safety and Compliance Officers

Hazards Addressed

• Entanglement in moving or rotating parts (belts, chains, shafts, augers, reels, pick-up fronts)
• Crush injuries from raised or unsupported components, headers and attachments
• Amputation and laceration risks from cutting blades, knives and sharp edges
• Unexpected start-up or movement of machinery during adjustment or inspection
• Struck-by hazards from moving components, ejected material or falling parts
• Hydraulic system failures, sudden release of stored energy and hose bursts
• Noise exposure when testing equipment after adjustments
• Manual handling injuries from lifting or repositioning heavy components and guards
• Slips, trips and falls when accessing adjustment points, ladders and platforms
• Contact with hot surfaces, exhausts and engine components during or after operation

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Types of Harvesting Equipment
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Required PPE, Tools and Adjustment Aids
• 6.0 Pre-Adjustment Planning and Risk Assessment (JSA/SWMS)
• 7.0 Isolation, Lock-out and Tag-out Procedure for Harvesting Equipment
• 8.0 Safe Access, Guard Removal and Verification of Zero Energy State
• 9.0 General Adjustment Principles (Clearances, Speeds, Heights and Tensions)
• 10.0 Step-by-Step Adjustment Procedure – Headers and Fronts
• 11.0 Step-by-Step Adjustment Procedure – Threshing, Separating and Cleaning Systems
• 12.0 Step-by-Step Adjustment Procedure – Pickers, Shakers and Specialty Harvesters
• 13.0 Reassembly, Guard Replacement and Pre-Start Safety Checks
• 14.0 Post-Adjustment Testing and Verification Under Controlled Conditions
• 15.0 Hazard Identification and Control Measures (Crush, Entanglement, Stored Energy)
• 16.0 Working with Contractors and Seasonal Workers
• 17.0 Environmental and Property Considerations (Dust, Spillage, Fire Risk)
• 18.0 Emergency Procedures and Incident Response
• 19.0 Training, Induction and Competency Assessment Requirements
• 20.0 Inspection, Maintenance and Recordkeeping
• 21.0 Review, Audit and Continuous Improvement of the SOP

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulation 2011 (Cth and relevant state/territory variants) – Plant and Maintenance of Plant
• Safe Work Australia – Code of Practice: Managing the Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace (where lubricants and fuels are used)
• Safe Work Australia – Code of Practice: How to Manage Work Health and Safety Risks
• AS 4024 series: Safety of machinery
• AS/NZS 4024.1603: Safety of machinery – Design of controls, interlocks and guards
• AS 2550 series: Cranes, hoists and winches – Safe use (relevant principles for lifting and supporting loads/components)
• AS/NZS 1891 series: Industrial fall-arrest systems and devices (for work at height on machinery)
• AS/NZS 1319: Safety signs for the occupational environment