Safe Work Method Statement for Hydraulic System Assembly, Maintenance and Repair

Hydraulics Fluid Assemblies

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Hydraulics fluid assemblies involve the assembly, maintenance, and repair of hydraulic systems and components used in construction equipment and machinery. This work encompasses connecting hydraulic hoses, fittings, cylinders, pumps, and valves under high pressure conditions. Workers assembling or maintaining hydraulic fluid systems face significant risks including high-pressure fluid injection injuries, burns from hot fluids, crushing hazards from system failures, and exposure to hazardous hydraulic fluids. These systems operate at pressures up to 20,000 PSI, making proper isolation, depressurization, and safety procedures critical. Australian WHS regulations require comprehensive risk assessment and control measures for hydraulic work, with specific attention to fluid injection hazards that can cause severe injuries or fatalities.

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Overview

What this SWMS covers

Hydraulics fluid assemblies encompass the assembly, maintenance, and repair of hydraulic systems and fluid power components in construction equipment and machinery. This work involves connecting hydraulic hoses, installing fittings, assembling cylinders and actuators, and performing pressure testing on completed systems. Hydraulic systems operate with incompressible fluids under high pressures, typically 1,000-20,000 PSI, creating significant hazards including fluid injection injuries, burns, crushing incidents, and system failures. Workers must follow strict isolation procedures, use proper tools and equipment, and wear appropriate personal protective equipment. The assembly process requires systematic approaches to component selection, torque specifications, seal installation, and leak testing to ensure system integrity and worker safety. Environmental considerations include proper containment of hydraulic fluids and spill response procedures.

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Why this SWMS matters

Hydraulic fluid assembly work presents extreme safety risks due to high-pressure systems that can cause catastrophic injuries if not properly controlled. High-pressure fluid injection injuries can penetrate skin and cause severe tissue damage, amputation, blindness, or death - even through small cuts or under fingernails. Australian construction sites frequently involve hydraulic equipment including excavators, loaders, cranes, and hydraulic tools, making this a common high-risk activity. The Work Health and Safety Act 2011 requires specific controls for high-risk construction work, with hydraulic systems falling under this category due to their potential for stored energy release and rapid failure modes. Without proper SWMS procedures, workers risk fluid injection from pinhole leaks, burns from hot fluids exceeding 80°C, crushing injuries from sudden actuator movements, and environmental contamination from fluid spills. NSW Resources Regulator MDG guidelines and AS 2671 standards provide specific requirements for hydraulic safety, emphasizing isolation, depressurization, and personal protective equipment. This SWMS ensures systematic hazard identification and implementation of engineering controls, administrative procedures, and PPE to prevent incidents and maintain compliance.

Reinforce licensing, insurance, and regulator expectations for Hydraulics - Fluid Assemblies Safe Work Method Statement crews before they mobilise.

Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

High-pressure fluid injection injuries

high

Hydraulic fluid under pressure can penetrate skin through pinhole leaks or damaged hoses, causing severe tissue damage, infection, amputation, or death. Injection can occur through small cuts, under fingernails, or directly through skin. Pressures as low as 100 PSI can cause injury.

Consequence: Permanent disability, amputation, blindness, or fatality. Medical treatment often requires surgical intervention.

Burns and scalds from hot hydraulic fluid

high

Hydraulic systems operate with fluids that can exceed 80°C, particularly after extended operation. Leaking hot fluid can cause severe burns when contacting skin or splashing during hose disconnection.

Consequence: Severe burns requiring medical treatment, permanent scarring, or infection from contaminated fluid.

Crushing injuries from hydraulic system failure

high

Unexpected movement of hydraulic actuators, cylinders, or attachments due to system failure, contamination, or improper assembly can cause workers to be crushed or struck by moving components.

Consequence: Fractures, amputation, internal injuries, or death from being crushed by heavy equipment components.

Fluid contamination and system failure

medium

Dirt, water, or incorrect fluids entering hydraulic systems during assembly can cause valve sticking, component wear, or catastrophic failure. Metallic particles from damaged components can contaminate the system.

Consequence: Unplanned equipment movement, reduced system performance, or sudden failure during operation.

Manual handling injuries during component installation

medium

Heavy hydraulic components, hoses, and tools require manual lifting and positioning, particularly when working in confined spaces or elevated positions on construction equipment.

Consequence: Back strain, muscle injuries, or falls when handling heavy components above shoulder height.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

System isolation and depressurization

Engineering

Complete isolation of all energy sources including hydraulic pumps, accumulators, and gravity-fed systems before commencing work. This prevents stored energy release during component removal or installation.

Implementation

1. Shut down prime mover (engine/diesel power) 2. Isolate electrical power supply to hydraulic pumps 3. Close manual isolation valves in hydraulic circuit 4. Depressurize system by opening bleed valves 5. Verify zero pressure with pressure gauge 6. Lock out isolation points with personal locks 7. Install warning tags on all isolation points 8. Test system to confirm effective isolation

High-pressure injection prevention

Engineering

Implementation of barriers and relief systems to prevent fluid injection injuries, which are among the most severe hydraulic hazards.

Implementation

1. Use whip checks or hose restraints on all pressurized lines 2. Install pressure relief valves set to manufacturer specifications 3. Use shielded fittings and connectors where possible 4. Implement double-block-and-bleed systems for high-pressure work 5. Use pressure testing equipment rated above system pressure 6. Install check valves to prevent reverse flow 7. Use burst-disc type relief devices as secondary protection

Fluid contamination control

Administrative

Prevention of dirt, water, and foreign material entering hydraulic systems during assembly and maintenance work.

Implementation

1. Work in clean, designated assembly areas 2. Use manufacturer-approved hydraulic fluids only 3. Install new filters during assembly 4. Cap all open ports immediately when not in use 5. Use clean tools and equipment for assembly 6. Implement fluid cleanliness testing procedures 7. Store components in clean, sealed containers 8. Clean work area before and after assembly

Personal protective equipment requirements

PPE

Specialized PPE for hydraulic work including fluid-resistant clothing and eye protection rated for high-pressure environments.

Implementation

1. Safety glasses with side shields (AS/NZS 1336) 2. Face shield for overhead work 3. Fluid-resistant gloves (note: high pressure can penetrate gloves) 4. Long-sleeved shirt and long pants 5. Steel-capped safety boots (AS/NZS 2210.3) 6. Hearing protection if working near operating equipment 7. Hard hat for overhead work 8. High-visibility vest for site work

Competency and training requirements

Administrative

Ensuring workers have appropriate qualifications and training for hydraulic system assembly and maintenance.

Implementation

1. Certificate III in Engineering - Mechanical Trade or equivalent 2. Hydraulic system training specific to equipment being serviced 3. Annual refresher training on hydraulic hazards 4. Competency assessment for pressure testing procedures 5. Training in lockout/tagout procedures 6. Emergency response training for fluid injection injuries 7. Familiarization with specific equipment manufacturer's procedures

Pressure testing and commissioning

Engineering

Systematic pressure testing and commissioning procedures to verify assembly integrity before returning equipment to service.

Implementation

1. Hydrostatic pressure testing to 1.5x working pressure 2. Functional testing with gradual pressure increase 3. Leak testing with appropriate detection methods 4. Temperature monitoring during testing 5. Performance verification against manufacturer specifications 6. Documentation of all test results 7. Independent verification for critical systems

Environmental controls for fluid spills

Administrative

Containment and cleanup procedures for hydraulic fluid spills to prevent environmental contamination.

Implementation

1. Place drip trays under work areas 2. Have spill kits readily available 3. Use absorbent materials for cleanup 4. Proper disposal of contaminated materials 5. Secondary containment for bulk fluid storage 6. Spill reporting procedures 7. Environmental monitoring for large spills

Download complete control procedures

Personal protective equipment

Safety glasses with side shields

Requirement: AS/NZS 1336 - Medium impact resistance

When: All hydraulic assembly and maintenance work

Face shield

Requirement: Full face coverage for high-pressure work

When: Working with pressurized systems or overhead

Fluid-resistant gloves

Requirement: Nitrile or PVC coated - rated for hydraulic fluids

When: Handling hydraulic components and fluids

Long-sleeved shirt and long pants

Requirement: Cotton or synthetic blend, fluid-resistant if possible

When: All hydraulic work to protect against fluid contact

Steel-capped safety boots

Requirement: AS/NZS 2210.3 - Class 1 or higher

When: Working around heavy equipment and tools

Hard hat

Requirement: AS/NZS 1801 - Type 1 or 2

When: Working under or around equipment

High-visibility vest

Requirement: AS/NZS 4602 - Class D or higher

When: Working on construction sites

Inspections & checks

Before work starts

✓Verify system is fully depressurized and isolated
✓Inspect all components for damage or wear
✓Check hydraulic fluid level and condition
✓Confirm correct tools and equipment available
✓Verify PPE is available and in good condition
✓Check weather conditions for outdoor work
✓Confirm emergency equipment accessible
✓Review work procedures with team

During work

✓Monitor pressure gauges during testing
✓Check for leaks during pressure testing
✓Verify proper torque on fittings
✓Monitor fluid temperature
✓Check component alignment
✓Verify seal installation
✓Monitor for unusual noises or vibrations
✓Check work area for slipping hazards

After work

✓Complete functional testing of assembled system
✓Document all test results and pressures
✓Clean work area and dispose of waste properly
✓Return tools to storage
✓Report any incidents or near misses
✓Update maintenance records
✓Verify system is safe for operation

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready

System Preparation and Isolation

Prepare the work area and completely isolate the hydraulic system before commencing any assembly work. This critical first step prevents accidental system pressurization and protects workers from stored energy hazards.

Safety considerations

Never assume a system is depressurized - always verify with pressure gauges. Lockout/tagout procedures must be followed by authorized personnel only.

Component Inspection and Preparation

Thoroughly inspect all hydraulic components including hoses, fittings, seals, and adapters for damage, contamination, or wear. Clean components using appropriate methods and verify correct part numbers match equipment specifications.

Safety considerations

Damaged components can fail catastrophically under pressure. Never use components that show signs of cracking, bulging, or excessive wear.

Fluid Compatibility Verification

Verify hydraulic fluid type matches manufacturer specifications and system requirements. Check fluid condition, cleanliness, and absence of contamination before system filling or charging.

Safety considerations

Incorrect fluids can cause seal degradation, component failure, and system contamination. Always use manufacturer-approved fluids.

Hose and Fitting Assembly

Assemble hydraulic hoses and fittings following manufacturer torque specifications and procedures. Install seals properly, ensure correct orientation, and use appropriate thread lubricants. Mark hose routing to prevent kinking or abrasion.

Safety considerations

Improper assembly can cause leaks or hose failure under pressure. Always use calibrated torque wrenches and follow assembly sequences precisely.

System Pressurization and Testing

Gradually pressurize the system while monitoring for leaks and proper function. Start with low pressure testing, then progress to working pressure and proof pressure testing. Document all test results and pressures achieved.

Safety considerations

Stand clear during pressurization. Never exceed manufacturer pressure ratings. Stop immediately if unusual noises or vibrations occur.

Functional Testing and Commissioning

Perform full functional testing of the hydraulic system including all actuators, valves, and control functions. Verify smooth operation, proper sequencing, and absence of binding or sticking. Adjust as necessary to meet performance specifications.

Safety considerations

Test in a controlled environment away from personnel. Use barriers or remote operation where possible. Never place hands or body in pinch points during testing.

System Documentation and Handover

Document all assembly work, test results, and system configuration. Update equipment maintenance records and provide handover documentation to operators. Clean work area and properly dispose of waste materials.

Safety considerations

Incomplete documentation can lead to future maintenance issues. Always record pressure test results, torque values, and component replacements.

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Frequently asked questions

What are the most common causes of hydraulic fluid injection injuries?

High-pressure fluid injection injuries typically occur from pinhole leaks in hoses or fittings, damaged seals, or improper connection procedures. Even pressures as low as 100 PSI can cause severe injury if fluid penetrates skin through small cuts or under fingernails. Workers should never check for leaks by hand and must wear appropriate PPE during hydraulic work.

How do I safely depressurize a hydraulic system?

First isolate all energy sources (engine, electrical power). Close manual isolation valves, then carefully open bleed valves to release pressure. Use pressure gauges to verify zero pressure before opening the system. Lock out isolation points and install warning tags. Never assume a system is safe - always test for dead before working on pressurized components.

What PPE is most important for hydraulic assembly work?

Safety glasses with side shields are critical for eye protection against fluid injection. Face shields provide additional protection for overhead work. Fluid-resistant gloves help protect hands, though high pressure can penetrate most glove materials. Long clothing protects against fluid contact, and steel-capped boots protect feet from falling tools or components.

How often should hydraulic systems be inspected?

Daily pre-work inspections should check for visible leaks, damaged hoses, and proper fluid levels. Weekly inspections should include pressure testing of critical systems. Annual comprehensive inspections by qualified technicians should verify all components meet manufacturer specifications. Any unusual noises, vibrations, or performance issues require immediate inspection.

What should I do if I suspect hydraulic fluid contamination?

Stop work immediately and isolate the system. Do not operate contaminated equipment as it can cause catastrophic failure. Drain and flush the system using proper procedures, replace filters, and refill with clean manufacturer-approved fluid. Test system performance before returning to service. Document the incident and implement preventive measures.

Are there specific Australian standards for hydraulic safety?

Yes, AS 2671 provides guidelines for hydraulic systems in mining and construction. NSW Resources Regulator MDG guidelines (MDG 41) cover fluid power safety systems. WorkSafe Australia provides general guidance on high-risk construction work. Always follow manufacturer specifications and local WHS regulations for hydraulic equipment.

Overview

Hydraulic fluid assemblies involve working with high-pressure fluid power systems commonly found in construction equipment including excavators, loaders, cranes, and hydraulic tools. The work includes assembling new hydraulic circuits, replacing worn components, repairing leaks, and performing routine maintenance on hydraulic hoses, fittings, cylinders, pumps, motors, and valves. These systems operate with hydraulic fluids under extreme pressures, typically ranging from 1,000 to 20,000 PSI, creating significant potential for catastrophic failure if not handled correctly. Workers must be competent in hydraulic principles, pressure testing, isolation procedures, and emergency response. The complexity of hydraulic systems requires systematic approaches to assembly, testing, and commissioning to ensure safe operation and prevent environmental contamination from fluid leaks.

Why This SWMS Matters

Hydraulic fluid assembly work carries some of the highest risk profiles in construction due to the potential for high-pressure fluid injection injuries, which can penetrate skin and cause severe tissue damage, amputation, or death. Australian WHS statistics show hydraulic incidents frequently result in permanent disability or fatality when proper controls are not implemented. The Work Health and Safety Act 2011 requires PCBUs to identify hazards associated with high-risk construction work and implement control measures following the hierarchy of control. Hydraulic systems present unique challenges including stored energy in accumulators, thermal expansion of fluids, contamination sensitivity, and complex failure modes. Without proper SWMS procedures, workers risk fluid injection injuries that can occur even through small cuts or under fingernails, burns from hot fluids exceeding 80°C, crushing injuries from sudden movements, and environmental harm from hydraulic fluid spills. This SWMS ensures systematic hazard identification, risk assessment, and implementation of engineering and administrative controls to protect workers and maintain compliance with Australian standards including AS 2671 and NSW MDG guidelines.

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