Product Overview

Summary: This Radiator Maintenance Safe Operating Procedure sets out clear, step-by-step requirements for safely inspecting, servicing and maintaining radiators in vehicles, plant and fixed equipment. It helps Australian workplaces control overheating, burns, coolant exposure and environmental risks while keeping critical machinery running reliably and in line with WHS obligations.

Radiators are a critical control point in managing engine temperature for vehicles, mobile plant and fixed equipment. When they are not maintained correctly, the consequences can range from minor breakdowns and costly downtime through to engine fires, burns from hot coolant, environmental spills and serious on-road incidents. This Radiator Maintenance Safe Operating Procedure provides a structured, repeatable method for inspecting, servicing and testing radiators and associated cooling system components in an Australian WHS context.

The SOP guides workers through pre-maintenance checks, safe isolation and depressurisation, coolant handling, leak detection, cleaning, repair escalation and post-maintenance verification. It embeds WHS risk management into day-to-day maintenance activities, ensuring hazards such as hot surfaces, pressurised systems, chemical exposure and slips from spills are systematically controlled. For businesses operating fleets, workshops or plant, this document supports compliance with WHS legislation, extends asset life, and creates a defensible record of safe work practices that can be used for training, audits and contractor management.

Key Benefits

• Reduce the risk of burns, scalds and pressure-related injuries when working on hot or pressurised radiators.
• Improve reliability of vehicles and plant by standardising radiator inspection, cleaning and servicing practices.
• Ensure compliant handling, storage and disposal of engine coolant and associated chemicals in line with Australian environmental and WHS requirements.
• Minimise unplanned downtime, roadside breakdowns and costly engine damage caused by overheating or coolant loss.
• Strengthen training, onboarding and contractor control by providing a clear, documented radiator maintenance method aligned with WHS duties.

Who is this for?

• Fleet Maintenance Managers
• Heavy Vehicle Mechanics
• Automotive Technicians
• Plant and Workshop Supervisors
• WHS Managers
• Facilities and Maintenance Coordinators
• Light Vehicle Fleet Coordinators
• Mobile Plant Operators
• Workshop Leading Hands

Hazards Addressed

• Burns and scalds from hot coolant and radiator components
• Injury from sudden release of pressure when opening radiator caps or hoses
• Chemical exposure to engine coolant, corrosion inhibitors and cleaning agents
• Slips, trips and falls from spilled coolant or water in the work area
• Manual handling strains from removing and refitting radiators or heavy components
• Fire risk from coolant leaks contacting hot surfaces or electrical components
• Environmental contamination from improper disposal of waste coolant and residues

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations
• 3.0 Roles and Responsibilities
• 4.0 Applicable Legislation, Standards and References
• 5.0 Radiator Types and System Overview
• 6.0 Required Tools, Equipment and PPE
• 7.0 Pre-Maintenance Safety Checks and Isolation
• 8.0 Safe Depressurisation and Cooling Procedures
• 9.0 Coolant Draining, Handling and Disposal
• 10.0 Radiator Inspection and Leak Detection
• 11.0 Cleaning, Flushing and Minor Repairs
• 12.0 Reassembly, Refilling and Bleeding the System
• 13.0 Post-Maintenance Testing and Verification
• 14.0 Hazard Identification and Risk Controls
• 15.0 Emergency Procedures for Burns, Spills and Exposure
• 16.0 Housekeeping and Environmental Management
• 17.0 Training, Competency and Authorisation Requirements
• 18.0 Documentation, Records and Maintenance Schedules
• 19.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory WHS Regulations
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• AS/NZS 4024.1: Safety of machinery – General principles for design – Risk assessment and risk reduction
• AS 1940: The storage and handling of flammable and combustible liquids (for workshops handling related fluids)
• Environmental Protection (Waste Management) requirements as applicable in each state or territory