AG-002 · Free microlearning

Machinery, PTO & Guarding

Awareness learning for people who use, maintain or work around tractors, PTO-driven equipment and other farm or horticultural machinery in New Zealand.

What you will learn

  • why rotating and moving machinery can cause catastrophic harm
  • how PTO and entanglement hazards arise
  • why guards must be present, suitable and maintained
  • why stopping a machine is not always the same as making it safe
  • when isolation, competent maintenance and supervision are required.
This is awareness learning, not machinery-operation or isolation certification. Practical competence must be established for the actual machine, task and workplace.
Lesson 2

Where this learning fits

Under the Health and Safety at Work Act 2015 and the General Risk and Workplace Management Regulations, PCBUs must identify and manage work risks and provide the information, training, instruction or supervision workers need to work safely.

  • eliminate machinery risks where reasonably practicable; otherwise minimise them using effective controls
  • maintain and review controls so they continue to work
  • guarding is an important control, but should not replace elimination where elimination is reasonably practicable
  • work under raised objects also requires specific risk controls
  • young people have additional legal restrictions around machinery and some vehicles.

Always apply current law, WorkSafe guidance, manufacturer instructions and your farm or workplace procedures.

Lesson 3

PTOs and entanglement

A PTO shaft can rotate at high speed. Clothing, hair or other material can be caught before a person has time to react.

  • keep well clear of rotating shafts, couplings, belts, chains, rollers and other moving parts
  • never step over, reach across or work close to an operating PTO shaft
  • do not rely on being careful around an exposed rotating shaft
  • secure loose clothing and hair as required for the work
  • do not approach machinery to clear, adjust or repair it until the required safe shutdown and isolation process has been completed.
Distance and guarding matter. A missing guard turns normal work around a PTO into exposure to a severe entanglement hazard.
Lesson 4

Guards and pre-start checks

  • check required guards are present, correctly fitted and in serviceable condition before use
  • include guarding in the workplace's documented or required pre-start process
  • report cracked, damaged, loose, missing or unsuitable guards
  • do not operate machinery where a safety-critical guard or control is missing or defective
  • repair or replace defective guarding before the machinery is returned to use
  • never bypass or defeat an interlock or protective device.

WorkSafe's 2026 PTO prosecution showed why a rule on paper is not enough: guarding checks and maintenance processes have to work in practice.

Lesson 5

Stop, isolate and control stored energy

Pressing stop, switching off the tractor or using an emergency stop does not automatically make every machine safe for maintenance or clearing.

  • follow the workplace's authorised isolation procedure for the actual machine
  • prevent unexpected start-up or movement before entering a danger zone
  • consider electrical, hydraulic, pneumatic, mechanical, spring, pressure and gravitational energy
  • support raised equipment with suitable engineered supports where required — do not rely on hydraulics alone
  • verify the safe state in accordance with the workplace procedure before work begins
  • only authorised and competent people should perform isolation or maintenance where the task requires it.
Stopped ≠ isolated. Stored energy or another person restarting equipment can still cause serious harm.
Lesson 6

Maintenance, communication and competence

  • maintain machinery and safety controls to manufacturer and workplace requirements
  • remove unsafe machinery from service until defects are dealt with
  • make sure everyone affected knows when machinery is being inspected, cleared or maintained
  • do not assume another worker can see you or knows you are near the machine
  • use competent people for repairs, guarding changes and safety-critical maintenance
  • provide machine-specific practical training and supervision appropriate to the worker and task.

AG-002 gives general awareness. It does not authorise a learner to repair, modify, isolate or operate machinery they are not competent and authorised to work with.

Lesson 7

Stop · Think · Act

Scenario: During a pre-start check you notice the PTO guard on a feed mixer is cracked and part of the rotating shaft is exposed. The job is already behind schedule.

What is the best response?

Lesson 8

Knowledge check

Answer all four correctly to complete this awareness module.

1. A PTO guard is missing. What is the safest response?

2. Why can switching a machine off be insufficient before maintenance?

3. What should a pre-start check include where relevant?

4. What does AG-002 completion demonstrate?