Heavy Vehicles Service Maintenance Safe Work Method Statement

The Work Health and Safety Regulations 2011 require persons conducting businesses to eliminate or minimise risks from plant and structures, which includes implementing isolation procedures for stored energy during maintenance. While Australian regulations do not use the specific term 'lockout-tagout' (which originates from US OSHA standards), the requirements are equivalent. Regulation 214 requires that plant must be isolated from all energy sources before maintenance work commences where there is a risk of injury from unexpected startup or release of stored energy. This includes electrical, hydraulic, pneumatic, mechanical, and potential energy. Each worker performing maintenance must apply a personal lock to isolation points, ensuring equipment cannot be energized while they are working. The isolation device must only be removable by the worker who applied it, and must remain in place until that worker's task is complete and they are clear of the equipment. Danger tags must be attached identifying what work is being performed and who applied the isolation. Employers must document isolation procedures specific to each type of equipment, train workers in correct isolation procedures, provide appropriate lockout devices, and supervise compliance. Failure to implement proper isolation procedures that results in serious injury or death can lead to significant penalties including fines exceeding $1 million for organisations and potential jail terms for officers under Category 1 offences in the WHS Act.

Hydraulic pressure relief is critical for preventing injection injuries and violent hose whip incidents. Begin by shutting down the equipment and isolating the battery to prevent accidental engine start. With the engine off, operate all hydraulic controls through their full range of motion multiple times - raise and lower booms, extend and retract buckets, operate steering if hydraulic, and cycle any other hydraulic functions. This vents pressure from cylinders and lines back to the tank. Wait 5 minutes after cycling controls as some systems have accumulators that store hydraulic pressure and release it slowly. After waiting, connect a pressure gauge to a hydraulic test port (if equipped) and verify pressure reads zero PSI. When removing hydraulic hoses, slowly loosen the fitting approximately one-quarter turn while holding absorbent material to contain any residual fluid. If you feel resistance or see fluid pressure, stop immediately - there is still trapped pressure. Use a hydraulic pressure relief tool to safely vent the remaining pressure. Never use your hands or body to check for hydraulic leaks - even small pinhole leaks at 3,000 PSI create fluid jets that penetrate skin causing injection injuries requiring emergency surgery. Use cardboard or paper held near suspected leak points to detect spray. When working on hydraulic cylinders, position them in the retracted position before disconnecting as this minimizes trapped fluid volume. After repairs, reconnect hoses and torque fittings to manufacturer specifications. When initially operating the system after repair, use low throttle to pressurize gradually while monitoring for leaks - this allows any issues to be identified before full operating pressure is applied.

Heavy vehicle maintenance workers must hold appropriate trade qualifications or be working toward them under supervision. Qualified mechanics typically hold a Certificate III in Mobile Plant Technology, Heavy Commercial Vehicle Mechanical Technology, or equivalent automotive trade qualifications. These qualifications are obtained through apprenticeships combining workplace training with formal technical education. Certain high-risk maintenance activities require additional licensing beyond trade qualifications. For example, performing electrical work on vehicle electrical systems (as opposed to simple component replacement) may require electrical licensing depending on jurisdiction and voltage levels involved. Working with refrigerant gases in air conditioning systems requires refrigerant handling licences. High-risk work such as working at heights above 2 metres using fall arrest systems may require specific tickets. Employers must verify qualifications by sighting original certificates or trade papers and maintaining copies in worker records. Apprentices and trainees may perform maintenance work but only under direct supervision of qualified mechanics, and must not perform high-risk tasks beyond their competency level. Employers must provide site-specific induction covering workplace hazards, location of emergency equipment, and site-specific procedures such as lockout-tagout protocols and chemical handling requirements. Even qualified mechanics must receive training in equipment-specific service procedures when working on specialized equipment they have not previously serviced. Continuing professional development is recommended to maintain currency with evolving vehicle technology, new safety standards, and updated manufacturer procedures. Workers should maintain records of training completed including dates, topics covered, and issuing organization to demonstrate ongoing competency.

Used oils, filters, coolants, solvents, and other maintenance wastes are classified as hazardous waste under environmental protection legislation and must be handled and disposed of according to strict requirements. Never pour used oil, hydraulic fluid, coolant, or solvents down drains, onto ground, or into general waste bins - this is illegal and carries significant penalties. In the workshop, provide designated waste oil collection containers (typically 200-litre drums) for storing used engine oil, hydraulic oil, transmission fluid, and gear oil. These must be clearly labeled identifying contents, kept in bunded storage providing 110% containment capacity to control spills, and kept away from ignition sources. Used oil filters must be drained of free-flowing oil before disposal (typically 12 hours drain time puncturing filters to release trapped oil) and then stored in designated containers for disposal. Coolant waste must be stored separately from waste oils as mixing prevents recycling - use separate labeled containers. Used solvents must be stored in their original containers or compatible sealed containers marked with contents. Batteries must be returned to suppliers or battery recyclers - never dispose of batteries in general waste as they contain lead and acid. Tyres must be disposed of through tire recycling programmes. Engage licensed waste contractors to collect and dispose of all hazardous wastes - verify contractors hold appropriate waste transport and disposal licenses. Maintain waste disposal records showing quantities disposed of, contractor details, disposal dates, and waste tracking documentation. Some jurisdictions require environmental authority approvals for businesses generating threshold quantities of hazardous wastes. Implement spill response procedures including provision of spill kits containing absorbent materials, neutralizers for battery acid, disposal bags, and PPE. Clean all spills immediately containing fluid with absorbent materials, disposing of contaminated absorbents as hazardous waste. Train all maintenance staff in proper waste handling, segregation, storage, and emergency spill response procedures.

Hydraulic injection injuries are medical emergencies requiring immediate action to prevent amputation and save the affected limb. If a worker experiences injection injury from high-pressure hydraulic fluid (typically appearing as a small puncture wound but with fluid injected beneath skin), implement emergency response immediately. Call emergency services (000) immediately stating 'hydraulic injection injury' and requesting ambulance transport to hospital with hand surgery or plastics surgery capability. Do not wait to see how serious it appears - hydraulic injection injuries that seem minor initially become catastrophic within hours as injected fluid destroys tissue. While waiting for ambulance, keep the injured worker calm and still, elevate the affected limb to reduce swelling, and do not apply tourniquets which worsen tissue damage. Do not attempt to squeeze out injected fluid or clean the wound beyond gentle washing - this causes additional tissue damage. Keep the worker warm as they may go into shock. Note what fluid was injected (hydraulic oil, grease, diesel, etc.) as this information assists medical treatment. The injured worker requires immediate surgical intervention - surgeons must cut into the affected tissue to remove injected fluid and dead tissue before infection develops. This must occur within 6-8 hours of injection for best chance of saving the limb. Delayed treatment almost always results in amputation. Prevention is far more effective than treatment. Maintain comprehensive hydraulic pressure relief procedures as specified in lockout-tagout protocols. Never check for hydraulic leaks using hands - use cardboard or paper to detect spray. Always verify zero pressure using gauges before disconnecting hydraulic lines. Wear appropriate gloves and eye protection when working on hydraulic systems. Ensure all maintenance workers understand hydraulic injection injury risks and emergency response procedures. Post emergency contact numbers prominently in workshop and field service vehicles. Consider providing first responder training to senior maintenance staff so immediate appropriate response can be initiated while waiting for emergency services. Include hydraulic injection injury scenarios in emergency drills and safety training. Maintain records of emergency contact numbers for nearest hospitals with surgical capabilities and brief ambulance dispatcher on exact location and best access route to minimize response time.

Working at heights on earthmoving equipment to access elevated service points requires implementation of fall protection controls according to the hierarchy of control. First, assess whether the task can be performed from ground level eliminating the height risk - for example, using extendable oil drain pumps to drain engine oil from ground level rather than climbing onto equipment. If work at height is unavoidable, provide collective fall protection in preference to personal fall protection. Use mobile work platforms with guardrails, or equipment-specific access stairs with handrails to provide safe access to service points. Position platforms to allow technicians to work with guardrails protecting them from falling. Many equipment manufacturers supply purpose-designed service platforms that attach to specific equipment models - use these where available. For work above 2 metres where platforms cannot be used, conduct a specific fall hazard assessment and implement appropriate controls. This typically requires use of personal fall arrest systems including full-body harnesses, energy-absorbing lanyards, and anchorage points rated for fall arrest loads (15kN minimum). Before using equipment structures as anchorage points, verify they are designed and rated for fall arrest use - many equipment components are not suitable anchors. Where suitable anchorage points do not exist, consider installing permanent fall arrest anchorage points on frequently serviced equipment. All workers using fall arrest equipment must hold appropriate training and be competent in donning harnesses correctly, inspecting equipment before use, selecting appropriate anchorage points, and understanding fall clearance distances. Fall arrest equipment must be inspected before each use and maintained according to manufacturer requirements - damaged or shock-loaded equipment must be removed from service. Prohibit climbing on equipment tyres, tracks, or fuel tanks as these provide unstable footing. Require three-point contact (two hands and one foot, or two feet and one hand) when climbing equipment access ladders. For field servicing, position service vehicles to allow technicians to work from vehicle trays or elevated platforms on service trucks reducing climbing on equipment. Document height access procedures in site-specific SWMS for high-risk equipment service tasks. Ensure supervisors monitor compliance with height access controls during site observations. Report any near-miss incidents involving height access including slips or near-falls to enable investigation and implementation of improved controls.