News
SafeAdjust: Built for Mining’s Harshest Conditions
September 10, 2025
General News
Traditional hydraulic tuning on heavy equipment doesn’t happen in clean, controlled environments! Extreme temperatures, vibrations, oil and hydraulic fluid, noise, dust and water…
What if we could take the technician out of the danger zone during the tuning itself, keeping them clear of live pressure while still delivering precise, reliable results from a safe distance?
SafeAdjust has been expertly engineered and field-tested to cope with these exact conditions. Developed by our founder, Shane Lewis, who spent decades on the tools as a mobile maintenance fitter, SafeAdjust is engineered to perform in extreme conditions.
Take the SafeAdjust tablet, featuring the SafeAdjust App – an industrial-grade tablet that keeps running in extreme temperatures, dust and water ingress seals on every port, shock and vibration proof, and a high-strength / zero latency Bluetooth connection to the actuator that stays solid up to 100m (330ft).
Take the next step towards safer, more efficient hydraulic maintenance with HydraTune!
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The New Way in Hydraulic Maintenance:
The HydraTune Ecosystem
August 28, 2025
Blogs
Anyone who has worked around heavy machinery knows what hydraulic maintenance really looks like. The heat radiates from steel, dust clings to every surface and machines vibrate with stored energy even when idle. To keep production moving, technicians have often been forced to crawl into cramped spaces, adjust pressure valves by hand and hope nothing shifts or leaks while they are standing there. These tasks carry very real risks, such as high-pressure fluid injection, sudden machine movement or unexpected releases of stored energy.
The toll of these tasks is not just physical. Days spent working under these conditions create stress and fatigue, and they push skilled people into hazardous situations that feel unsafe by default. That’s why HydraTune developed SafeAdjust. A new way of approaching hydraulic maintenance that puts elimination of live work first, protecting technicians, improving productivity and efficiency and helping entire sites run with greater confidence.
SafeAdjust: Taking Technicians Out of Harm’s Way
Traditional hydraulic tuning has always meant standing too close to danger during maintenance. Adjustments required direct access to relief valves and control settings buried inside machines, forcing technicians to operate on live work and remain in hazardous zones during the process. SafeAdjust changes that.
With SafeAdjust, technicians can tune hydraulic systems wirelessly from up to 100 metres away. The adjustment accuracy is precise to 1 degree, allowing teams to achieve levels of performance that match or exceed manual tuning. Instead of crouching beside high-pressure lines, a technician can stand in a safe location with a tablet in hand, watching live system feedback as adjustments are made in real time.
This shift transforms tuning from a high-stress, hands-on job into a controlled, predictable process. Safety improves, accuracy improves, and the technician can focus on performance instead of exposure to risk. It is not only about removing danger, but also about making the task feel more manageable and professional.
HydraTune Tablet and the SafeAdjust App
A solution is only as good as the tools that support it and HydraTune’s tablet and app are built with the site in mind. Crews need something that works where they work, not a delicate device that falters under pressure.
The rugged tablet arrives ready to use, built to handle vibration, dust, water, drops and the punishing conditions of heavy industry. Technicians can carry it onto site with confidence, knowing it will hold up to the reality of their day. The interface is designed to be clear and simple. No clutter, no confusing layers of data, just the essential diagnostics, performance readings and tuning tools presented in a way that makes sense.
Connectivity is also reliable even in the most remote pits. The system pairs directly with SafeAdjust through high-fidelity Bluetooth, removing the need for internet access. That means tuning can continue in underground drifts, remote desert sites or any other environment where connections are unreliable. Over-the-air updates keep the system current, so new features and security improvements arrive automatically without interrupting work.
Together, the tablet and app create a platform that technicians can depend on. They reduce the stress of troubleshooting, cut down wasted time and give teams the confidence that every adjustment is logged, accurate and secure.
FlexAdjust: The Universal Adapter for Hydraulic Maintenance
FlexAdjust is built to fit where other tools can’t. As a universal adapter, it extends SafeAdjust into tight, obstructed or awkward spaces, making hydraulic maintenance accessible anywhere. With FlexAdjust, hard-to-reach adjustments become simple, safe and efficient.
What This Means for Mining Operations
The HydraTune ecosystem is more than a set of devices. Together, SafeAdjust, the app and tablet and FlexAdjust change how maintenance feels for crews and how reliability looks for operations.
For technicians, it means a safer, more professional environment where their skills are put to use without unnecessary risks. For safety managers, it means fewer exposure hours for technicians in hazardous zones and stronger compliance with the principles of Elimination of Live Work. For maintenance planners, it means faster turnaround times, fewer shutdowns and more reliable data to build predictive programs. For site leadership, it means machines running at peak efficiency with less downtime, more uptime and less costs tied up in unplanned repairs.
The cultural impact is just as important. A job once seen as dangerous, dirty and draining becomes a process carried out with modern digital tools, clear data and higher confidence. That shift changes not only the results on paper but also the way people feel about their work at the end of the day.
The New Way Forward with SafeAdjust
Hydraulic maintenance does not need to look the way it always has. HydraTune proves that safer, smarter and more efficient methods already exist:
SafeAdjust removes technicians from harm’s way. The rugged tablet and app keep teams connected and in control, no matter the environment. FlexAdjust is your hydraulic universal adapter.
Together, these innovations set a new standard for hydraulic maintenance in mining and heavy industry. They deliver precision, safety and reliability, while making day-to-day work more sustainable for the people who do it.
If your operation is ready to leave behind the risks of traditional hydraulic maintenance and embrace a new way of working, HydraTune can help. Contact us today to learn how SafeAdjust can transform hydraulic maintenance at your site.
Take the next step towards safer, more efficient hydraulic maintenance with HydraTune!
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Elimination of Live Work in Mining
August 15, 2025
Blogs
Wireless Hydraulic Maintenance Helping Set New Safety Benchmarks
Hydraulic maintenance has long required technicians to perform live work in mining, often close to operating machinery, in heat, under pressure and near moving components. Live work refers to any work on plant, equipment or system where the energy cannot be fully isolated in a practical manner, posing risk or injury due to uncontrolled energy within the hazard exposure zone. These conditions increase the risk of serious incidents like high-pressure fluid injection, equipment failures and impact injuries due to unexpected releases of stored energy.
To address these risks, the mining industry is steadily moving toward Elimination of Live Work in mining (ELW). The idea is straightforward. You take people out of situations where they could be exposed to hazards if something goes wrong. The ELW movement is having a significant impact on hydraulic maintenance, and addressing related risks has become a priority for mining operations. It’s changing the way machines are built, the way maintenance is scheduled and the way safety is measured on site.
Why Eliminating Live Work Matters
The most obvious driver for ELW is safety. Working in the “footprint” of live machinery exposes technicians to hazards such as: High-pressure fluid release causes injection injuries or burns. Unexpected machine movement during testing or adjustment. Stored energy is released from accumulators, springs, or elevated loads. Trips and falls caused by restricted access in tight machinery zones.
Each of these hazards can potentially cause life-altering injuries. Eliminating live work removes the need for technicians to be in proximity, radically improving safety. According to Safe Work Australia’s guidelines on managing the risks of plant in the workplace, eliminating live work is considered one of the most effective controls for reducing hazardous energy exposure.
But ELW is also about productivity and reliability. Reducing the risk of incidents helps avoid unplanned shutdowns, lost time and costly investigations. Remote-capable maintenance tools also allow work to be completed faster, reducing downtime and getting machines back to production sooner.
What’s Making ELW in Mining Possible Now
For years, the main barrier to the elimination of live work in mining was the lack of reliable technology that could replace hands-on adjustments without sacrificing precision. Hydraulic tuning, for example, has traditionally required physical access to pressure relief valves or control settings, often located deep inside a machine’s structure.
That is changing. Advances in wireless control, ruggedised digital interfaces, and compact actuators are making it possible to achieve the same, or even better results without entering hazardous zones. Industry leaders are now incorporating ELW principles into new equipment design, while maintenance teams are retrofitting existing fleets with safer, remote-enabled solutions.
At the same time, cultural change is taking place. Mining safety managers, operations teams and frontline technicians are increasingly aligned in recognising that “the way it’s always been done” is no longer acceptable when other alternatives exist, prioritising safety over productivity.
What Eliminating Live Work Looks Like in Practice
Putting ELW into practice means rethinking how maintenance is carried out so crews can complete tasks without entering high-risk areas. In hydraulic systems, that could mean moving pressure adjustments to accessible locations, integrating sensors that provide live diagnostics from outside the machine footprint or using remote and wireless tools to handle tuning and calibration.
Redesigning the process in this way keeps people out of danger and creates a smoother, more efficient workflow that reduces delays and unnecessary steps. When technicians can see precise data in real time and make adjustments from a safe position, they spend less time navigating tight spaces or working around moving parts. When done correctly, operations will experience more uptime, faster turnaround on maintenance, fewer unplanned stoppages, and all while meeting higher safety standards.
How SafeAdjust Supports the Elimination of Live Work in Mining
Eliminating live work is not about simply adding a single piece of equipment. It’s about applying a layer of controls that include design improvements, engineering barriers, robust procedures and user-centred technology. By eliminating the need for manual adjustments in hazardous conditions, SafeAdjust prioritises operator safety without compromising system performance.
HydraTune’s SafeAdjust puts the controls where they should be: in the hands of the technician, outside of the danger zone. Using a rugged industrial tablet, teams can make precise adjustments from a safe distance (up to 100m away) while seeing every change in real time. The high-fidelity Bluetooth connection stays stable even in remote or dusty sites, and over-the-air updates keep the system performing at its best without taking equipment offline.
Because SafeAdjust integrates with existing isolation procedures and barriers, it complements, not replaces, other risk management measures. With SafeAdjust, you keep your technicians out of harm’s way and provide them with the comprehensive data they need to perform thorough verification and planning.
Eliminate Live Work in Mining with HydraTune
The elimination of live work in mining presents challenges, but the tools to achieve it already exist. SafeAdjust is one example of how remote, field-ready digital technology can reduce exposure, improve data quality, and support safer, smarter maintenance practices. Sites that still depend on manual tuning in hazardous zones have a clear opportunity to move toward safer operations and stronger maintenance performance.
Take the next step towards safer, more efficient hydraulic maintenance with HydraTune!
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SafeAdjust Replaces Dangerous Hydraulic Tuning Methods
August 7, 2025
Product Updates
SafeAdjust handheld kits replace the work of dangerous, outdated processes. By eliminating live work and the need for manual adjustments in hazardous conditions, it helps prioritise safety without compromising system performance.
SafeAdjust helps technicians: Keep out of harm’s way with remote tuning Access and log accurate data in real-time at their fingertips, up to 100m (330ft) away Reduce maintenance downtime by predicting and preventing failures before they become an issue
Safety can start with a compact tool. You don’t need bulky gear to make a big difference!
Take the next step towards safer, more efficient hydraulic maintenance with HydraTune!
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Remote Hydraulic Tuning that Adapts to the Job
July 31, 2025
Product Updates
Hydraulic maintenance is high-risk, so it needs to be precise and informed.
HydraTune helps technicians fine-tune flow and pressure based on how the machine is actually used. By adapting to real working conditions like load and terrain, HydraTune ensures the hydraulic system performs at its best, whatever the environment.
That means smoother operation, better fuel efficiency, and less wear and tear over time. It’s the upgrade that gives you long-term gains in performance and reliability.
Take the next step towards safer, more efficient hydraulic maintenance with HydraTune!
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Stay One Step Ahead – Live Data from SafeAdjust
July 17, 2025
Product Updates
Technicians shouldn’t have to guess.
The SafeAdjust app provides real-time feedback during every tuning session so your team can see what’s happening inside the system as it happens. Pressures, positions, and trends are all logged automatically for more valuable insights and improved outcomes.
This data helps identify faults before they become failures. Over time, the system builds a history of valve performance, helping you make informed maintenance decisions, reducing costs and downtime.
Take the next step towards safer, more efficient hydraulic maintenance with HydraTune!
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Precision from a Distance
July 4, 2025
Product Updates
The SafeAdjust app, used on the HydraTune tablet, gives technicians the live data they need to make informed adjustments without being physically near the machine.
Pressure, temperature, and fine-tuned system readings are all captured and logged digitally, streamlining maintenance, performance and safety. Combined with SafeAdjust’s wireless functionality, the app allows for 1-degree accuracy, all delivered at a safe distance.
Take the next step towards safer, more efficient hydraulic maintenance with HydraTune!
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NSW Safety Bulletin Highlights Why SafeAdjust Matters
June 26, 2025
General News
Hydraulic systems, while essential in heavy machinery operations, can pose significant risks when not properly managed.
A safety bulletin from the NSW Resources Regulator highlights several incidents where high-pressure fluid releases led to serious injuries. In one case, a maintenance worker was struck in the face by high-pressure fluid due to a failure in isolating stored pressure in a hydraulic accumulator. Another incident involved a worker being sprayed with hydraulic oil when a hose failed during pressure testing.
These incidents highlight the importance of stringent safety protocols and the adoption of advanced technologies to mitigate risks.
With HydraTune, you can prevent incidents before they happen, eliminate live work, and keep your technicians out of the line of fire. When safety and reliability matter most, HydraTune is your smart solution.
Take the next step towards safer, more efficient hydraulic maintenance with HydraTune!
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From Lived Experience to Industry Innovation: The HydraTune Story
June 10, 2025
Announcements
HydraTune began with a question many in the field have asked but few have answered: Why are we still tuning hydraulics by hand under live conditions?
In his 18 years working across WA mine sites, Shane Lewis, an Indigenous entrepreneur and experienced diesel mechanic, had seen the risks of live hydraulic maintenance up close. That experience led to a turning point – one where safety, innovation, and firsthand knowledge came together to solve a critical industry problem.
Today, HydraTune is revolutionising hydraulic tuning through wireless technology, eliminating live work to protect technicians, whilst improving precision, safeguarding equipment and cutting downtime.
Take the next step towards safer, more efficient hydraulic maintenance with HydraTune!
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Introducing SafeAdjust with FlexAdjust Adapter
May 29, 2025
Product Updates
The SafeAdjust system from HydraTune is changing the game!
SafeAdjust prioritises technician safety whilst maximising efficiency. With digital-wireless testing, it allows technicians to tune hydraulic systems remotely, eliminating direct exposure to the inherent risks associated with live work.
Real-time data ensures precise, consistent tuning, significantly cutting downtime and keeping machines running at peak performance. And with the new FlexAdjust attachment included in every kit, even the toughest-to-reach tuning points are no longer a challenge.
