Product Overview

Summary: This Hydraulics Systems Safety Safe Operating Procedure provides clear, practical guidance for the safe installation, operation, inspection and maintenance of hydraulic equipment in Australian workplaces. It helps businesses control high-risk hazards such as high-pressure fluid injection, stored energy release and component failure, while demonstrating due diligence under WHS legislation.

Hydraulic systems are integral to plant, machinery and mobile equipment across construction, mining, manufacturing, agriculture and logistics. They also present significant risks when not managed correctly, including high-pressure fluid injection, uncontrolled movement of plant, hose bursts and environmental contamination. This Hydraulics Systems Safety SOP sets out a structured, step-by-step approach for safely working with hydraulic systems, from pre-start inspections and isolation through to depressurising, fault-finding, hose replacement and recommissioning.

Developed for Australian workplaces, the procedure supports compliance with WHS legislation and relevant Australian Standards by embedding risk assessment, isolation and verification of zero-energy as routine practice. It clarifies who does what on site, specifies mandatory PPE and tools, and details safe work methods for tasks such as connecting and disconnecting hoses, working under raised loads, bleeding systems and responding to leaks or failures. By implementing this SOP, businesses can reduce the likelihood of serious injuries, equipment damage and environmental spills, while improving consistency of maintenance practices and providing a defensible framework for training, supervision and incident investigation.

Key Benefits

• Reduce the risk of high-pressure fluid injection injuries and uncontrolled equipment movement.
• Ensure consistent, safe methods for inspection, maintenance and repair of hydraulic systems across all sites.
• Demonstrate compliance with Australian WHS legislation and plant safety requirements.
• Minimise unplanned downtime and costly damage arising from hose failures and component misuse.
• Strengthen induction, refresher training and contractor management with a clear, documented procedure.

Who is this for?

• Maintenance Supervisors
• Mechanical Fitters
• Plant Operators
• Mobile Plant Operators
• Workshop Managers
• WHS Managers and Advisors
• Site Supervisors and Leading Hands
• Engineering Managers
• Fleet and Asset Managers

Hazards Addressed

• High-pressure hydraulic fluid injection injuries to skin and eyes
• Sudden release of stored hydraulic energy causing crush or impact injuries
• Uncontrolled movement or collapse of raised loads, booms or attachments
• Hose bursts, whip and component failure during operation or testing
• Contact with hot hydraulic components and fluids causing burns
• Slips and falls due to hydraulic oil leaks and contaminated surfaces
• Fire and environmental contamination from hydraulic fluid spills
• Manual handling strains during hose replacement and component change-out
• Exposure to moving parts and pinch points on hydraulic plant

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Definitions and Abbreviations
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Description of Hydraulic Systems and Typical Applications
• 5.0 Hazard Identification and Risk Assessment for Hydraulic Work
• 6.0 Required PPE, Tools and Safety Equipment
• 7.0 Pre-Start Checks and System Inspection
• 8.0 Isolation, Lockout/Tagout and Verification of Zero Energy
• 9.0 Safe Work Method for Operating Hydraulic Systems
• 10.0 Safe Procedures for Inspection, Testing and Fault-Finding
• 11.0 Safe Procedures for Hose, Fitting and Component Replacement
• 12.0 Working Under Raised Loads and Support Requirements
• 13.0 Managing Leaks, Spills and Environmental Protection
• 14.0 Emergency Response to Hydraulic Failures and Injection Injuries
• 15.0 Post-Maintenance Recommissioning and Functional Testing
• 16.0 Training, Competency, Supervision and Contractor Management
• 17.0 Inspection, Maintenance, Tagging and Recordkeeping
• 18.0 Review, Audit and Continuous Improvement of the SOP

Legislation & References

• Work Health and Safety Act 2011 (Cth and harmonised state and territory legislation)
• Work Health and Safety Regulations 2011 – Part 5.1: Management of risks to health and safety associated with 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 (for hydraulic oils and fluids)
• AS 4024.1 Series: Safety of machinery
• AS/NZS 4024.1603: Safety of machinery – Design of controls, interlocks and guards
• AS 2671: Hydraulic fluid power – General requirements for systems
• AS/NZS 3760: In-service safety inspection and testing of electrical equipment (where electro-hydraulic systems are used)
• AS/NZS 4801 / ISO 45001: Occupational health and safety management systems