Product Overview

Summary: This Hydraulic Systems Safe Operating Procedure sets out clear, practical steps for the safe operation, isolation, and maintenance of hydraulic equipment in Australian workplaces. It helps control the significant risks associated with stored energy, high-pressure fluid injection, and equipment failure, while supporting compliance with WHS legislation and industry standards.

Hydraulic systems are integral to mobile plant, fixed machinery, and production equipment across construction, mining, manufacturing, agriculture, and logistics. They also present serious hazards when not controlled correctly, including high-pressure fluid injection injuries, uncontrolled movement of plant, hose failures, and environmental contamination. This Hydraulic Systems Safe Operating Procedure provides a structured, step-by-step approach to planning, operating, isolating, depressurising, and maintaining hydraulic systems in line with Australian WHS expectations.

The document helps businesses translate complex technical risks into clear, everyday instructions that operators and maintenance personnel can follow. It covers pre-start inspections, leak detection, safe connection and disconnection of lines, lockout/tagout and isolation of stored energy, and verification of safe condition before work begins. It also addresses contractor interface, housekeeping, and incident response procedures specific to hydraulic failures. By implementing this SOP, organisations can demonstrate due diligence, standardise training, reduce unplanned downtime, and significantly lower the risk of serious injury and environmental harm from hydraulic system incidents.

Key Benefits

• Reduce the risk of high-pressure fluid injection injuries and uncontrolled plant movement.
• Ensure consistent, compliant hydraulic system practices across all shifts, sites, and contractors.
• Minimise equipment damage and unplanned downtime through structured inspections and maintenance steps.
• Support compliance with Australian WHS legislation and plant safety requirements.
• Improve incident readiness with clear guidance for hydraulic leaks, hose bursts, and system failures.

Who is this for?

• Maintenance Supervisors
• Mechanical Fitters
• Plant Operators
• Mobile Plant Operators
• Workshop Managers
• WHS Managers and Advisors
• Fleet Managers
• Engineering Managers
• Site Supervisors
• Apprentice Mechanics and Fitters

Hazards Addressed

• High-pressure fluid injection injuries from pinhole leaks or hose failures
• Uncontrolled movement or collapse of plant and attachments due to hydraulic failure
• Exposure to hot surfaces and hot hydraulic oil
• Crush and pinch point injuries during maintenance and adjustments
• Slips, trips, and falls caused by oil leaks and spills
• Fire risk from hydraulic fluid contacting hot surfaces or ignition sources
• Environmental contamination from hydraulic fluid spills and hose bursts
• Musculoskeletal injuries from incorrect handling of heavy hoses, components, and tools
• Electric shock when working on electro-hydraulic systems without proper isolation

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and System Overview
• 3.0 Roles and Responsibilities
• 4.0 Applicable Legislation, Standards and References
• 5.0 Required Competencies, Training and Authorisations
• 6.0 Required PPE, Tools and Equipment
• 7.0 Pre-Start Checks and System Inspection
• 8.0 Safe Operating Procedure – Normal Use of Hydraulic Systems
• 9.0 Safe Isolation, Lockout/Tagout and Depressurisation of Hydraulic Systems
• 10.0 Safe Work Practices for Inspection, Testing and Maintenance
• 11.0 Hose, Fittings and Component Replacement Procedures
• 12.0 Leak Detection, Spill Management and Environmental Controls
• 13.0 Hazard Identification and Risk Control Measures for Hydraulic Systems
• 14.0 Emergency Response – Hose Burst, Uncontrolled Movement and Injection Injuries
• 15.0 Contractor Management and Permit-to-Work Requirements (if applicable)
• 16.0 Housekeeping, Storage and Waste Disposal
• 17.0 Inspection, Testing, and Preventive Maintenance Schedules
• 18.0 Training, Induction and Competency Assessment
• 19.0 Incident Reporting, Investigation and Corrective Actions
• 20.0 Document Control and Review

Legislation & References

• Work Health and Safety Act 2011 (Cth and state/territory equivalents)
• Work Health and Safety Regulation 2011 (Cth and state/territory equivalents) – Plant and Structures
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing the Work Environment and Facilities
• AS 4024.1 Safety of machinery (series)
• AS 2671: Hydraulic fluid power – General requirements for systems
• AS/NZS 3760: In-service safety inspection and testing of electrical equipment (for electro-hydraulic components)
• AS/NZS 4801: Occupational health and safety management systems (superseded but still referenced in many systems)
• ISO 4413: Hydraulic fluid power – General rules and safety requirements for systems and their components (as a recognised international benchmark where adopted)