Comprehensive SWMS for Heavy Vehicle Servicing and Maintenance Operations

Heavy Vehicles Service Maintenance Safe Work Method Statement

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Heavy vehicle service and maintenance operations are critical for ensuring the safe and reliable performance of trucks, semi-trailers, and heavy transport equipment used across Australian construction sites. This SWMS addresses the comprehensive safety requirements for conducting routine servicing, scheduled maintenance, breakdown repairs, and component replacement on heavy vehicles, covering mechanical systems, hydraulic equipment, electrical components, and structural repairs in accordance with Australian WHS legislation and heavy vehicle safety standards.

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Overview

What this SWMS covers

Heavy vehicle service and maintenance encompasses all routine and scheduled work performed on trucks, semi-trailers, tipper bodies, rigid vehicles, and specialised heavy transport equipment operating in construction environments. This work includes oil and filter changes, brake system inspections and repairs, suspension component replacement, hydraulic system servicing, electrical system diagnostics and repair, tyre changing and rotation, cooling system maintenance, and structural repairs to vehicle bodies and chassis. The maintenance may be performed in dedicated workshop facilities with proper equipment and infrastructure, or as field maintenance at construction sites, breakdown locations, or temporary service areas with portable equipment. Heavy vehicles used in construction operations are subject to harsh operating conditions including rough terrain, heavy loads, extended operating hours, dust and debris exposure, and frequent starting and stopping. These demanding conditions accelerate wear on mechanical components and require more intensive maintenance than vehicles operating in standard road transport applications. Preventative maintenance programmes based on manufacturer specifications and operational demands are essential to prevent mechanical failures that could compromise safety, cause project delays, or result in catastrophic component failures. Maintenance intervals are typically based on operating hours, distance travelled, or calendar periods, with critical safety systems including brakes, steering, and tyres receiving heightened attention. The complexity of modern heavy vehicles requires technicians to work with high-pressure hydraulic systems operating at 2000-3000 psi, electrical systems including 12V and 24V circuits with high amperage loads, pneumatic brake systems, engine components operating at extreme temperatures, rotating driveline components, and structural elements supporting multi-tonne loads. Service work often requires technicians to work beneath raised vehicles, inside confined spaces such as fuel tanks or chassis cavities, at height when accessing truck bodies or trailers, and with heavy components requiring mechanical lifting assistance. Chemical exposures include engine oils, hydraulic fluids, coolants, brake fluids, fuels, degreasers, and battery acids. Maintenance activities require coordination between workshop supervisors, qualified mechanics and technicians, apprentices under supervision, parts procurement personnel, and vehicle operators who report defects and performance issues. Work is performed using specialised equipment including vehicle hoists, jack stands and supports, hydraulic jacks rated for heavy vehicle loads, brake testing equipment, diagnostic computers, pressure testing equipment for hydraulic and pneumatic systems, and a comprehensive array of hand and power tools. Safety-critical maintenance including brake repairs, steering system work, and structural welding requires appropriate trade qualifications and experience. Australian heavy vehicle safety legislation, Chain of Responsibility requirements, and workplace health and safety regulations establish overlapping compliance obligations that maintenance operations must satisfy to ensure legal operation and worker protection.

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Why this SWMS matters

Heavy vehicle maintenance operations present serious injury and fatality risks that are well-documented in Australian workplace incident data. Safe Work Australia statistics identify vehicle maintenance activities as high-risk operations, with incidents including workers crushed when vehicles fall from jacks or hoists, serious injuries from high-pressure hydraulic fluid injection, burns from hot engine components, chemical exposures to oils and solvents, and traumatic injuries from rotating components or component failures under load. The consequences of inadequate maintenance extend beyond worker safety to include vehicle failures causing road crashes, load spills, environmental contamination, and project disruptions. Under the Work Health and Safety Act 2011, persons conducting a business or undertaking have primary duty of care to ensure the health and safety of workers performing maintenance operations and others who may be affected including vehicle operators and the public. This duty requires provision of safe systems of work, properly maintained tools and equipment, appropriate training and supervision, and effective risk controls following the hierarchy of control. The Heavy Vehicle National Law adds specific requirements for vehicle roadworthiness and maintenance documentation under Chain of Responsibility provisions, making all parties in the transport supply chain including maintenance providers potentially liable for safety breaches. Penalties for WHS violations can include substantial fines exceeding $600,000 for corporations and $300,000 for individuals, plus potential imprisonment for serious breaches. Proper SWMS implementation for heavy vehicle maintenance establishes systematic hazard identification and control for work that varies substantially between routine servicing and complex repairs. Documentation ensures technicians understand the specific hazards of working under raised vehicles, with high-pressure systems, on electrical circuits, and with heavy components, while providing clear procedures for isolation, testing, and verification before work commences. Lock-out tag-out procedures prevent unexpected vehicle movement or component activation during maintenance. Pre-work risk assessments identify job-specific hazards that may not be evident from standard procedures, such as modifications to vehicles, unfamiliar equipment types, or work in non-standard locations. The dynamic nature of maintenance work, where technicians encounter different defects, vehicle configurations, and working conditions daily, makes documented safe work procedures essential for consistent safety outcomes. Unlike production work with repetitive tasks, maintenance requires ongoing problem-solving and adaptation, increasing the risk that safety shortcuts may be taken under time pressure or when facing unexpected complications. Comprehensive SWMS provides the framework for safe work regardless of variations in tasks, supporting technicians to make safe decisions when confronting novel situations or complex repairs. This documentation also demonstrates due diligence in the event of incidents, provides the foundation for training programmes, and enables effective incident investigation and continuous improvement of safety systems.

Reinforce licensing, insurance, and regulator expectations for Heavy Vehicles Service Maintenance 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

Vehicle Instability and Collapse During Maintenance Under Raised Vehicles

High

Working beneath heavy vehicles raised on jacks, hoists, or ramps presents extreme crush hazard if the vehicle becomes unstable and collapses onto workers. Heavy vehicles can weigh 15-40 tonnes depending on configuration, creating catastrophic forces if structural failure occurs. Instability can result from inadequate jack capacity or incorrect jack placement, failure to use appropriate jack stands after raising vehicle, working on soft or uneven ground that allows jack settlement, vehicle movement due to inadequate wheel chocking, component removal that shifts vehicle centre of gravity, hydraulic hoist failure or power loss during servicing, and impact loading from using hammers or applying force to seized components. The confined space beneath raised vehicles limits escape options if collapse warnings are detected. Many serious injuries and fatalities occur when workers are trapped beneath vehicles during suspension work, differential repairs, or chassis maintenance. Using single-point jacking without supplementary supports, working under vehicles supported only by hydraulic jacks without mechanical locks, and inadequate inspection of hoist equipment all contribute to collapse risk.

Consequence: Fatal crushing injuries when workers are trapped beneath collapsed vehicles, permanent disability from crush injuries to limbs and torso, and traumatic injuries requiring emergency response and extended medical treatment.

High-Pressure Hydraulic Fluid Injection Injuries

High

Heavy vehicle hydraulic systems for tipping bodies, tailgate lifts, crane attachments, and brake boosters operate at pressures between 2000-3500 psi, sufficient to penetrate skin and inject hydraulic fluid deep into tissue. Injection injuries occur when technicians are exposed to hydraulic fluid under pressure during hose replacement, when probing for leaks with hands or fingers, during pressure testing of repaired systems, or when hydraulic lines fail catastrophically due to wear or damage. Even pinhole leaks can create high-velocity fluid streams invisible to the naked eye but capable of penetrating skin. The initial wound may appear minor, resembling a small puncture, but hydraulic fluid spreading through tissue causes severe inflammation, tissue death, and potential amputation if not treated immediately with surgical debridement. Common scenarios include checking for hydraulic leaks by running hands along hoses while system is pressurised, insufficient depressurisation of systems before disconnecting hoses, using incorrect replacement hoses or fittings that fail under pressure, and working on hydraulic systems without understanding pressure relief procedures.

Consequence: Severe tissue damage requiring emergency surgery, potential amputation of affected limbs, permanent disability, long-term pain and loss of function, and psychological trauma from serious injury events.

Tyre Inflation Explosive Failure and Split Rim Hazards

High

Heavy vehicle tyres and particularly split rim wheels present explosion hazard during inflation or when servicing damaged tyres. Truck tyres are inflated to 100-120 psi, storing tremendous energy that is released explosively if tyre or rim fails during inflation. Split rim wheels use multi-piece rims with locking rings that can separate violently if incorrectly assembled or if rim components are damaged, corroded, or mismatched. Explosive failures occur when overinflating tyres, inflating tyres with damaged sidewalls or internal structural damage, incorrectly seating tyre beads during inflation, using damaged or mismatched split rim components, failure to use safety cage during inflation, and standing in trajectory zone beside tyre during inflation. The explosive force can propel rim components and rubber fragments at high velocity, causing severe injuries to anyone in the immediate area. Technicians may underestimate stored energy in pneumatic tyres or may take shortcuts during tyre changing to save time. Working with unfamiliar wheel types or attempting to repair tyres that should be replaced increases risk.

Consequence: Fatal injuries from being struck by rim components during explosive failure, severe traumatic injuries including lost limbs, crush injuries, and penetrating wounds, hearing damage from explosive decompression, and secondary injuries from falls or impact with structures.

Contact with Hot Components and Thermal Burns

Medium

Heavy vehicle engines, exhaust systems, brake components, and hydraulic systems operate at extreme temperatures, creating burn hazards during maintenance work. Engine coolant systems operate at 100°C or higher under pressure, exhaust manifolds and turbochargers reach 400-600°C during operation, brake drums and rotors can exceed 200°C after extended braking, and hydraulic oil in systems under load can reach 80-100°C. Technicians suffer burns when draining hot coolant or oil, contacting exhaust components when working in engine compartments, handling brake components immediately after vehicle operation, and from pressurised coolant system failures causing hot coolant spray. Adequate cooling time before commencing work is often not provided due to time pressures or emergency repairs. Protective equipment may be inadequate for extreme temperature exposures. Burns are exacerbated when hot fluids are trapped against skin by clothing or when workers instinctively grab hot components. Coolant system pressures can propel boiling coolant significant distances if radiator caps are removed before systems cool adequately.

Consequence: Severe burns requiring medical treatment, permanent scarring, infection risk from contaminated fluids entering wounds, extended recovery periods affecting ability to work, and long-term sensitivity to temperature extremes in affected areas.

Exposure to Hazardous Substances Including Oils, Solvents, and Battery Acid

Medium

Heavy vehicle maintenance involves extensive exposure to hazardous chemicals including engine oils, transmission fluids, hydraulic oils, diesel fuel, brake fluids, coolants containing ethylene glycol, battery acid, degreasers and solvents, and refrigerants in air conditioning systems. Prolonged or repeated skin contact with petroleum products causes dermatitis, chemical burns, and increases cancer risk from polycyclic aromatic hydrocarbons. Inhalation of solvent vapours in poorly ventilated workshops causes respiratory irritation and potential long-term health effects. Battery acid causes severe chemical burns on contact with skin or eyes. Absorption of chemicals through skin can cause systemic health effects including liver and kidney damage. Technicians often work with bare hands to maintain dexterity when handling small components, increasing skin contact with contaminants. Inadequate washing facilities or time pressures result in extended contact periods. Waste oils and fluids accumulate in workshops creating slip hazards and ongoing exposure risks. Improper storage of chemicals and lack of safety data sheets prevents workers from understanding exposure risks and emergency procedures.

Consequence: Chemical burns and dermatitis requiring medical treatment, long-term health effects including respiratory disease and cancer from chronic exposure, environmental contamination from spills and improper disposal, and acute toxicity from inhalation of concentrated vapours.

Entanglement with Rotating Components and Power Take-Off Drives

High

Heavy vehicles include numerous rotating and moving components that present entanglement and entrapment hazards during maintenance and testing operations. Power take-off (PTO) drives for auxiliary equipment, exposed driveshafts and universals joints, cooling fans and belts, rotating wheels during brake testing, and hydraulic motors all present catch points that can entangle clothing, gloves, hair, or body parts. Incidents occur during running repairs where engines are operated while technicians work nearby, when testing drive systems or PTO equipment after repair, when guards are removed for access and not replaced before test running, and when loose clothing or jewellery contacts rotating components. The extreme torque of heavy vehicle drivelines can cause severe injuries before operators can disengage power. Cooling fans can sever fingers even when engines are switched off if fans rotate due to airflow or are activated by electric thermostatic controls. Workers may develop complacency around familiar equipment and fail to recognise changing hazards when guards are removed or during non-standard testing procedures.

Consequence: Severe traumatic injuries including degloving, amputations, fractures, and entanglement injuries requiring emergency extraction, permanent disability, psychological trauma, and potential fatalities from entanglement in high-torque driveline components.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Comprehensive Vehicle Support and Stability Procedures

Engineering

Ensuring heavy vehicles are properly supported during maintenance work beneath or around raised vehicles requires engineering controls that provide mechanical stability independent of hydraulic systems or single-point support. This includes using appropriately rated vehicle hoists with mechanical safety locks, supplementing hydraulic jacks with rated jack stands placed at manufacturer-specified jacking points, working on level concrete surfaces capable of supporting concentrated loads, and implementing wheel chocking and parking brake protocols. All lifting equipment must be inspected before use and rated for the actual vehicle weight plus safety margin. Multiple support points distribute loads and provide redundancy if single support fails. Ground surfaces must be assessed for load-bearing capacity, with soft or uneven areas prepared with load-spreading plates. This systematic approach eliminates the primary cause of crushing injuries during vehicle maintenance by ensuring vehicles cannot collapse onto workers regardless of single-point failures or vehicle movement.

Implementation

1. Verify vehicle weight and ensure all lifting equipment including hoists, jacks, and stands are rated for at least 1.5 times actual vehicle weight. 2. Inspect hoists before each use checking lifting mechanism, safety locks, hydraulic systems, and load-bearing structural components for damage or deterioration. 3. Position vehicles on level concrete surfaces, avoiding soft ground, asphalt that may deform under load, or areas with underground services that could collapse. 4. Apply parking brakes and use rated wheel chocks on all wheels remaining on ground before raising vehicle, with chocks placed both ahead and behind wheels. 5. Use multiple support points when raising vehicles, never relying on single jack or hoist point regardless of rated capacity. 6. Place mechanical jack stands at manufacturer-specified support points immediately after raising vehicle and before any work beneath vehicle commences. 7. Lower vehicle onto jack stands so weight is fully supported by mechanical means rather than hydraulic pressure before workers enter beneath vehicle. 8. Verify stability by attempting to rock vehicle before commencing work beneath it, checking all supports remain firmly in contact under load. 9. Prohibit any work beneath vehicles supported only by hydraulic jacks or hoists without mechanical locks engaged and verified. 10. Maintain exclusion zone preventing other workers from approaching raised vehicles, with barriers and warning signs during extended maintenance periods.

Hydraulic System Depressurisation and Isolation Procedures

Administrative

Preventing high-pressure injection injuries requires rigorous procedures for depressurising and isolating hydraulic systems before commencing any work on hydraulic components. This administrative control establishes mandatory steps including shutting down engines and hydraulic pumps, operating all hydraulic controls through full range of movement to dissipate stored pressure, verifying pressure relief before disconnecting lines, using cardboard or wood to check for invisible high-pressure leaks, and wearing appropriate protective equipment. Workers must be trained to understand that hydraulic systems can remain pressurised even after shutdown due to trapped pressure in accumulators or check valves. Lock-out tag-out procedures prevent unexpected system activation during maintenance. Pressure testing after repairs must be conducted with all personnel clear of potential failure zones, using remote controls where possible. This systematic approach ensures technicians never expose themselves to pressurised hydraulic fluid.

Implementation

1. Develop written procedures for each type of hydraulic system worked on, specifying depressurisation steps specific to system configuration and components. 2. Train all technicians on hydraulic injection injury risks, showing examples of tissue damage and emphasising that apparent minor injuries require immediate emergency medical treatment. 3. Establish mandatory shutdown and depressurisation sequence: switch off engine, operate all hydraulic controls to dissipate pressure, wait specified time for accumulator discharge, verify zero pressure before disconnecting lines. 4. Provide pressure gauges or test equipment allowing verification that systems are fully depressurised before commencing work. 5. Implement lock-out tag-out procedures isolating hydraulic pump power supplies and preventing vehicle starting during hydraulic system maintenance. 6. Prohibit checking for hydraulic leaks by hand, requiring use of cardboard or wood to detect high-pressure spray from pinhole leaks. 7. Require long-sleeved protective clothing, face shields, and impermeable gloves during any work on hydraulic systems to provide barrier protection. 8. Establish first aid procedures specifying immediate hospital referral for any suspected hydraulic injection injury regardless of apparent severity. 9. Use hydraulic hoses and fittings rated for system operating pressure with appropriate safety factors, maintaining stock of correct parts to prevent improvised repairs. 10. Conduct pressure testing of repaired systems remotely with all personnel clear of components, using minimum pressure necessary to verify integrity before returning to full operating pressure.

Safe Tyre Inflation Procedures and Safety Cage Requirements

Engineering

Eliminating explosive tyre failure risks during inflation requires engineering controls including safety cages that contain rim components and tyre fragments in event of failure, remote inflation equipment allowing technicians to inflate tyres from safe distance, pressure limiting equipment preventing overinflation, and proper tyre and rim inspection before inflation. Safety cages are steel structures surrounding tyre during inflation, designed to contain explosive energy and direct any failure effects away from operators. Remote inflation allows technicians to control inflation from behind barriers while monitoring pressure gauges. This control also includes using tyre manufacturers' specifications for correct inflation pressures, inspecting tyres for damage before inflation, ensuring rim components are correctly assembled and undamaged, and inflating in incremental steps while checking bead seating. These measures prevent both overinflation failures and split rim component separation during the inflation process.

Implementation

1. Install permanent tyre safety cage in workshop constructed to AS/NZS standards for containing explosive tyre failures, with open side facing wall or barrier. 2. For mobile operations, provide portable tyre inflation cage or restraining equipment preventing rim component trajectory toward operators. 3. Inspect all tyres before inflation checking for sidewall damage, exposed cords, bulges, or internal damage that could cause failure under pressure. 4. For split rim wheels, verify all rim components match manufacturer specifications, check for corrosion, cracks, or damage, and ensure locking rings are correctly seated. 5. Lubricate tyre beads and ensure tyre is correctly positioned on rim before commencing inflation. 6. Use remote inflation equipment with pressure gauges visible from safe position, allowing operator to monitor inflation from behind barrier. 7. Inflate to seating pressure first (typically 30-40 psi), verify both beads have seated correctly around rim, then deflate slightly before continuing to operating pressure. 8. Never exceed maximum tyre pressure marked on sidewall, using inflation equipment with pressure limiting valves preventing overinflation. 9. Stand behind cage or barrier during entire inflation process, never standing in line with rim or alongside tyre regardless of equipment used. 10. Wait for pressure stabilisation and conduct final inspection of bead seating and rim component position before removing tyre from safety cage.

Hot Work Protocols and Thermal Hazard Management

Administrative

Preventing thermal burns requires administrative controls mandating cooling periods before commencing work on hot components, testing temperatures before contact, providing appropriate PPE for thermal protection, and establishing emergency procedures for burns. This includes requiring minimum cooling periods based on component type and operating conditions, providing non-contact infrared thermometers for temperature verification, ensuring coolant system pressure is released safely before draining, and training workers to recognise symptoms of thermal burns and provide appropriate first aid. Procedures must address both conductive heat from hot surfaces and convective/radiant heat from exhaust systems and engine compartments. Where work cannot be delayed for adequate cooling, appropriate heat-protective gloves and clothing must be provided and time limits imposed to prevent heat stress. Clear marking of hot components and warning systems alert workers to thermal hazards.

Implementation

1. Establish minimum cooling periods before work commences on different component types: engines 30 minutes, exhaust systems 60 minutes, brake components 20 minutes after vehicle operation. 2. Provide infrared thermometers allowing technicians to verify component temperatures before contact, with maximum safe temperature thresholds specified for different work types. 3. Train workers in safe coolant system depressurisation, requiring systems to cool below 60°C before removing radiator caps or opening pressurised coolant lines. 4. Install coolant drain equipment allowing controlled drainage without exposing workers to splash hazards from residual pressure. 5. Provide heat-resistant gloves rated for temperatures encountered when work cannot wait for complete cooling, with clear instruction on safe contact durations. 6. Establish hot work areas with appropriate signage warning other workers of thermal hazards during and immediately after work on hot components. 7. Require long-sleeved clothing and full-length trousers preventing hot fluid contact with skin if spills or splashes occur during oil and coolant drainage. 8. Train all workers in thermal burn first aid including immediate cooling with running water for minimum 20 minutes and medical referral for burns larger than coin size. 9. Schedule maintenance during cool parts of day in summer months to reduce starting temperatures and improve cooling rates. 10. Provide shaded or climate-controlled work areas reducing ambient temperatures and improving comfort during unavoidable work on hot components.

Hazardous Substance Management and Exposure Minimisation

Administrative

Controlling chemical exposures during vehicle maintenance requires comprehensive hazardous substance management including provision of appropriate PPE, spill containment equipment, washing facilities, proper ventilation, waste disposal procedures, and maintenance of safety data sheets. Administrative controls include requiring glove use during all work involving chemicals, providing chemical-resistant barrier creams, ensuring adequate washing facilities with soap and clean water, implementing spill response procedures, and training workers on chemical hazards. Substitution of less hazardous alternatives where possible, such as water-based degreasers instead of solvent-based products, reduces exposure. Proper workshop ventilation disperses vapours and fumes. Waste oil and chemical disposal through licensed contractors prevents environmental contamination and reduces ongoing exposure from stored wastes.

Implementation

1. Conduct hazardous substance risk assessments for all chemicals used in maintenance operations, maintaining register of hazardous substances with safety data sheets readily accessible. 2. Provide chemical-resistant gloves appropriate for substances being handled, with different glove types for oils, solvents, acids, and other chemicals based on manufacturer compatibility charts. 3. Install parts washing stations with biodegradable degreasers and water-based cleaning solutions reducing reliance on solvent degreasing. 4. Ensure workshop ventilation provides minimum 10 air changes per hour, with local exhaust ventilation for areas where concentrated vapours may accumulate. 5. Provide spill kits containing absorbent materials, barriers, and disposal bags at strategic locations throughout workshop, training all staff in spill response. 6. Install eye wash stations near battery charging areas and any locations where corrosive chemicals are used, with emergency shower for large spills. 7. Require workers to wash hands and exposed skin before breaks and at end of shifts, providing adequate washing facilities with hot water and appropriate soaps. 8. Implement waste oil and chemical segregation systems with appropriately labelled containers for different waste streams, arranging collection by licensed waste contractors. 9. Prohibit eating, drinking, or smoking in workshop areas where chemical contamination of food and cigarettes could occur. 10. Provide laundry services for work clothing heavily contaminated with oils or chemicals, preventing workers from taking contaminated clothing home.

Machine Guarding and Lock-Out Tag-Out for Rotating Components

Engineering

Preventing entanglement injuries requires engineering controls ensuring all rotating components have appropriate guarding that prevents access during operation, combined with lock-out tag-out procedures preventing unexpected activation during maintenance. Guards must fully enclose driveshafts, PTO drives, fan belts, and other rotating components, with interlocked access panels that disconnect power when opened. Where guards must be removed for maintenance access, lock-out tag-out procedures isolate energy sources including electrical disconnection and mechanical immobilisation. Testing of drive components after repair must follow protocols ensuring all personnel are clear before activation, with incremental testing starting at low speeds. Clear signage and warning devices alert workers when rotating equipment is operating. This control eliminates the opportunity for contact with rotating components during operation and ensures they cannot activate unexpectedly during maintenance.

Implementation

1. Inspect all vehicle drive components, PTO equipment, and auxiliary systems verifying appropriate guards are installed preventing access to rotating components during operation. 2. Develop lock-out tag-out procedures for each type of maintenance work, identifying all energy sources requiring isolation including electrical, hydraulic, pneumatic, and mechanical. 3. Provide lock-out devices including electrical circuit lockouts, mechanical immobilisation equipment, and standardised danger tags identifying who has applied lockout and reason. 4. Train all technicians on lock-out tag-out procedures specific to equipment types worked on, with competency assessment before authorising independent work. 5. Establish procedures requiring individual locks for each worker involved in maintenance task, ensuring equipment cannot be re-energised until all workers have removed their locks. 6. Verify effectiveness of isolation by attempting to start equipment after lock-out applied, confirming power is isolated and mechanical components are immobilised. 7. For testing of drive components after repair, establish area clearance procedures ensuring all personnel are behind barriers or at safe distances before power activation. 8. Implement graduated testing protocols starting with brief low-speed activation, observing for abnormal vibration or noise before extended or high-speed testing. 9. Prohibit wearing of loose clothing, jewellery, or gloves when working near rotating components even when isolated, requiring removal of items that could become caught. 10. Install emergency stop controls for equipment with remotely operated components, ensuring workers can immediately disconnect power if entanglement occurs.

Download complete control procedures

Personal protective equipment

Steel Toe Cap Safety Boots with Oil-Resistant Soles

Requirement: Certified to AS/NZS 2210.3 with steel toe protection and oil-resistant slip-resistant soles

When: Required at all times in workshop and maintenance areas to protect feet from crushing injuries from dropped components, penetration from sharp objects, and slips on contaminated floors.

Chemical-Resistant Gloves for Oil and Solvent Protection

Requirement: Nitrile or neoprene gloves rated for petroleum product resistance per AS/NZS 2161.10

When: Mandatory during all work involving engine oils, hydraulic fluids, solvents, degreasers, and other chemicals to prevent skin contact and dermatitis.

Impact-Resistant Safety Glasses with Side Shields

Requirement: Impact-rated to AS/NZS 1337 with side protection and anti-fog coating

When: Required during all maintenance activities to protect against flying particles, fluid spray, and debris during component removal and installation.

Face Shield for Grinding and High-Pressure Work

Requirement: Full-face shield to AS/NZS 1337 worn over safety glasses

When: Required during grinding operations, pressure testing of hydraulic systems, battery maintenance, and any work with splash or spray hazards.

Heat-Resistant Gloves for Hot Component Work

Requirement: Leather or aramid gloves rated to 200°C minimum temperature resistance

When: Required when handling exhaust components, recently operated engines, brake components after testing, or draining hot fluids that cannot be delayed for complete cooling.

High-Visibility Vest or Shirt

Requirement: Class D Day/Night compliant with AS/NZS 4602.1 with reflective stripes

When: Mandatory in workshop areas where vehicles are moving, during roadside breakdown repairs, and when working in construction site vehicle movement areas.

Hearing Protection for Impact Tools and Compressed Air

Requirement: Class 4 or 5 earplugs or earmuffs per AS/NZS 1270 providing minimum 25dB attenuation

When: Required when using impact wrenches, air tools, grinding equipment, or working in workshop areas with sustained noise above 85dB(A).

Inspections & checks

Before work starts

  • ✓Verify workshop hoists, jacks, and jack stands are within current inspection dates and display load rating tags showing capacity adequate for vehicle being serviced
  • ✓Check work area is clean, well-lit, and free from trip hazards, with adequate space around vehicle for safe access to all service points
  • ✓Confirm vehicle service history and identify any known defects or previous maintenance issues relevant to planned work
  • ✓Review manufacturer service specifications for torque values, fluid specifications, and safety warnings specific to vehicle model
  • ✓Verify all required tools, replacement parts, fluids, and safety equipment are available before commencing work
  • ✓Check fire extinguishers are in place and within service dates, with clear access for emergency use
  • ✓Ensure first aid kit is stocked and accessible, with eye wash stations operational in areas where chemicals are used
  • ✓Confirm all workers hold appropriate trade qualifications for safety-critical work including brake repairs and steering systems

During work

  • ✓Monitor vehicle stability on hoists or jack stands before working beneath vehicles, checking supports remain firmly in contact under load
  • ✓Verify hydraulic and pneumatic systems are fully depressurised before disconnecting lines, using pressure gauges to confirm zero pressure
  • ✓Check work area remains clean with waste oils and fluids properly contained, cleaning spills immediately to prevent slip hazards
  • ✓Monitor for signs of heat stress when working in confined engine compartments or during hot weather, ensuring workers take adequate breaks
  • ✓Verify guards are reinstalled on rotating components before test running equipment, with area clear of personnel during activation
  • ✓Ensure proper ventilation is maintained when running engines in workshop, with exhaust extraction connected to prevent carbon monoxide accumulation
  • ✓Monitor workers for signs of chemical exposure including skin irritation or respiratory symptoms, providing immediate first aid if exposure occurs

After work

  • ✓Conduct final inspection verifying all work completed per service specifications with appropriate torque values applied to critical fastenings
  • ✓Check all guards, covers, and panels removed for access are reinstalled and secured before vehicle is returned to service
  • ✓Test all systems worked on including brakes, steering, hydraulics, and electrical circuits confirming proper operation before releasing vehicle
  • ✓Document all work completed, parts replaced, and any defects identified for future service reference in vehicle maintenance logbook
  • ✓Dispose of waste oils, fluids, filters, and parts through appropriate waste contractors with disposal documentation retained for compliance verification
  • ✓Clean work area and tools, returning all equipment to storage and ensuring workshop is left safe for following shift
  • ✓Report any equipment defects, tool damage, or safety concerns identified during work to workshop supervisor for rectification

Step-by-step work procedure

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

Field ready
1

Conduct Pre-Service Vehicle Inspection and Risk Assessment

Before commencing any maintenance work, perform comprehensive inspection of the vehicle to identify existing damage, modifications, or conditions that may affect service procedures or present additional hazards. Review vehicle service history to understand previous maintenance, known defects, and any recurring issues. Examine vehicle for fluid leaks, structural damage, damaged components, or modifications from standard specifications. Check tyre condition and inflation pressures, inspect brake components for wear or damage visible without disassembly, examine steering and suspension for obvious defects, and look for hydraulic leaks or damaged hoses. Document any additional defects found beyond the scheduled maintenance items. Assess working conditions including whether work will be performed in workshop with proper equipment or as field maintenance with portable equipment. Identify required resources including special tools, lifting equipment capacity needed, replacement parts and consumables, and any specialist expertise required for safety-critical repairs. Complete job safety analysis identifying specific hazards for the actual work to be performed rather than relying solely on generic procedures.

Safety considerations

Unfamiliar vehicle types or configurations may have hazards not evident from standard service procedures. Modifications including PTO equipment, auxiliary hydraulic systems, or non-standard bodies require additional assessment. Field repairs lack the safety infrastructure of workshop facilities including proper lighting, hoists, and parts access. Never commence work without understanding specific hazards of actual vehicle configuration and work location.

2

Position Vehicle Safely and Establish Secure Support

Position vehicle on level concrete surface with adequate space around perimeter for safe access to all service points. For workshop-based maintenance, position vehicle on hoist following manufacturer load distribution recommendations, ensuring hoist arms contact vehicle at approved jacking points. Check vehicle weight against hoist capacity rating, applying safety factor of at least 1.5:1. Engage parking brake and place transmission in park position. For larger vehicles or when hoist is unavailable, use multiple hydraulic jacks rated for vehicle weight, again at manufacturer-specified jacking points. Block wheels remaining on ground with rated chocks placed both ahead and behind wheels. Raise vehicle to required height, immediately placing mechanical jack stands at approved support points. Lower vehicle onto jack stands so full weight is supported mechanically rather than by hydraulic pressure. Verify stability by attempting to rock vehicle, confirming all supports remain in firm contact. Establish exclusion zone around raised vehicle preventing other workers from approaching or working nearby. Install warning signs and barriers during extended maintenance periods. Never work beneath vehicles supported only by hydraulic jacks or hoists, regardless of rated capacity or apparent stability.

Safety considerations

Vehicle centre of gravity changes as components are removed, potentially causing instability on marginal supports. Always use multiple support points distributed along vehicle length. Verify ground surface is capable of supporting concentrated loads without settlement. Never trust hydraulic systems alone to support vehicles during maintenance work beneath or around raised vehicles.

3

Implement Lock-Out Tag-Out and System Isolation

Before commencing work on electrical, hydraulic, or mechanical systems, implement comprehensive isolation procedures preventing unexpected activation or energy release. For electrical work, disconnect battery negative terminal and install lock-out device preventing reconnection, tagging with personal lock and danger tag identifying worker and reason for isolation. For hydraulic systems, shut down engine, operate all hydraulic controls through full range to dissipate stored pressure, and verify zero pressure using gauges before disconnecting lines. For work on drive components, engage park brake, place transmission in neutral, install mechanical immobilisation preventing driveline rotation, and lock out starting circuits. Where work involves multiple technicians, each worker must apply personal lock ensuring system cannot be re-energised until all workers have completed their tasks and removed locks. Test effectiveness of isolation by attempting to start vehicle or activate systems after lock-out applied, verifying power is truly isolated. Maintain communication with other workers ensuring everyone understands which systems are isolated and for what purpose. Document isolation in workshop lock-out register showing date, time, equipment isolated, and worker responsible.

Safety considerations

Unexpected activation of systems during maintenance causes severe injuries including electrocution, hydraulic injection, and crushing. Never assume others understand isolation status or rely on verbal communication alone. Physical locks and tags provide visible verification of isolation. Systems may have multiple energy sources requiring isolation including electrical, hydraulic, pneumatic, and mechanical stored energy.

4

Perform Scheduled Maintenance Tasks Following Manufacturer Specifications

Conduct scheduled maintenance items according to vehicle manufacturer service specifications and applicable Australian Standards. For oil and filter changes, ensure engine has cooled sufficiently to prevent burns from hot oil, position drain pan to contain full oil capacity, remove drain plug carefully controlling oil flow, and dispose of waste oil through licensed contractors. Replace oil filter and drain plug using new sealing washers, filling with manufacturer-specified oil grade to correct level. For brake system maintenance, inspect pad and shoe thickness, rotor and drum condition, hydraulic lines for leaks or damage, and brake fluid level and condition. Replace brake components as required using genuine or equivalent parts meeting Australian Design Rules. For suspension work, inspect bushings, shock absorbers, springs, and steering linkages for wear or damage, replacing worn components in pairs to maintain balance. Throughout all work, use calibrated torque wrenches for safety-critical fastenings, following manufacturer torque specifications. Keep work area organized with systematic component removal and installation sequences, preventing errors during reassembly. Document all work completed including parts replaced, fluid specifications used, torque values applied, and any additional defects identified requiring future attention.

Safety considerations

Safety-critical systems including brakes, steering, and suspension require qualified technicians and adherence to manufacturer specifications. Incorrect torque values can cause component failure under load. Using incorrect fluids affects system performance and safety. Mixing incompatible brake fluids causes seal deterioration and brake failure. Always verify parts are correct before installation and confirm proper operation before returning vehicle to service.

5

Conduct Component Testing and System Verification

After completing maintenance work, systematically test all systems worked on to verify correct operation before returning vehicle to service. For brake repairs, conduct stationary tests of brake pedal feel and response, check for hydraulic leaks under pressure, and perform controlled road test with graduated braking from low to high speeds, verifying straight-line stopping without pulling or pulsing. For electrical repairs, verify all circuits function correctly, check for proper voltage readings, and confirm no short circuits or abnormal current draws. For hydraulic systems, remove lock-out devices, start engine, and gradually pressurize systems while monitoring for leaks or abnormal operation. Test all hydraulic functions through full range of movement verifying smooth operation and adequate pressure. For drive component work, start testing at low speeds with short duration, monitoring for abnormal vibration, noise, or heating before extended operation. Verify all gauges and warning systems function correctly. Check fluid levels after test running, topping up as required. Conduct final walk-around inspection verifying all guards, covers, and panels are reinstalled and secured. Do not release vehicle until confident all systems operate safely and no defects remain unaddressed.

Safety considerations

Inadequate testing leads to failures in service potentially causing crashes or breakdowns in hazardous locations. Brake system failures are particularly dangerous requiring thorough testing before vehicle operates under load. Begin all testing at low speeds or pressures, gradually increasing to operating conditions while monitoring for problems. Ensure test area is clear of other workers and has adequate space for emergency shutdown if testing reveals defects.

6

Complete Documentation and Return Vehicle to Service

Complete comprehensive service documentation recording all work performed, parts replaced, fluids used, and systems tested. Document includes date, technician name and qualifications, odometer or hours reading, detailed description of work completed, parts with specifications and part numbers, torque values applied to critical fastenings, and results of all testing and verification procedures. Note any additional defects identified requiring future attention with severity assessment guiding urgency of repairs. Update vehicle maintenance logbook maintaining continuous history of all service and repairs. For commercial heavy vehicles, service records form part of Chain of Responsibility compliance demonstrating proper maintenance to prevent defects contributing to crashes. Provide copy of service documentation to vehicle operator or fleet manager. Brief operator on work completed, any changed operating characteristics, and scheduled next service interval. Reset service interval indicators where applicable. Store original documentation per business record-keeping requirements, typically minimum 7 years for commercial vehicles. Clean work area and dispose of all waste materials appropriately. Return all tools to storage and report any equipment defects or safety issues encountered during work to workshop supervisor for rectification before equipment is used again.

Safety considerations

Inadequate documentation prevents proper maintenance tracking leading to missed services and mechanical failures. Chain of Responsibility legislation makes all parties in transport chain potentially liable for vehicle defects including maintenance providers. Proper records demonstrate due diligence and provide evidence of compliance. Clear communication with operators ensures they understand vehicle condition and any limitations on use until additional repairs are completed.

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Frequently asked questions

What qualifications are required to perform heavy vehicle maintenance in Australia?

Automotive technicians performing heavy vehicle maintenance should hold relevant trade qualifications including Certificate III in Heavy Commercial Vehicle Mechanical Technology or equivalent recognised qualification. Safety-critical work including brake repairs, steering systems, and load-bearing structural repairs must be performed by qualified tradespeople with demonstrated competency in these systems. Apprentices may perform work under direct supervision of qualified technicians. Specialist systems including air conditioning require additional certification under Australian Refrigerant Handling Licence (ARC) requirements. Electrical work beyond basic component replacement may require electrical trade qualifications depending on complexity and voltage. Employers must verify qualifications and maintain training records. Under Chain of Responsibility legislation, maintenance providers can be held liable for defects resulting from inadequate repairs, making proper qualifications and competency essential. Ongoing professional development ensures technicians remain current with evolving vehicle technologies and safety requirements.

How do I safely work under a raised heavy vehicle?

Working beneath raised heavy vehicles requires multiple independent supports preventing collapse if any single support fails. Begin by positioning vehicle on level concrete surface capable of supporting concentrated loads. Use vehicle hoist rated for actual vehicle weight plus safety factor, engaging mechanical safety locks before any work beneath vehicle commences. Where hoists are unavailable, use multiple hydraulic jacks at manufacturer-specified jacking points, immediately supplementing with rated mechanical jack stands. Lower vehicle onto jack stands so full weight is supported mechanically rather than by hydraulic pressure. Verify stability by attempting to rock vehicle before entering beneath. Never rely solely on hydraulic jacks regardless of rated capacity as hydraulic systems can fail without warning. Block all wheels remaining on ground with rated chocks placed both ahead and behind. Engage parking brake and place transmission in park. Maintain exclusion zone preventing other workers from approaching raised vehicle or creating vibration that could disturb supports. Install warning signs and barriers during extended work. If vehicle must be moved or supports adjusted during work, ensure all workers exit from beneath before any support changes are made.

What are the specific hazards when working on hydraulic systems?

Hydraulic systems operating at 2000-3500 psi present extreme injection injury risk where pressurised fluid penetrates skin and spreads through tissue causing severe damage potentially requiring amputation. Even pinhole leaks create invisible high-velocity streams capable of penetrating skin. Always depressurise systems completely before disconnecting lines by shutting down pump, operating controls through full range, and verifying zero pressure with gauges. Never check for leaks by hand - use cardboard to detect spray. Wear long sleeves, face shield, and impermeable gloves when working on hydraulic systems. Seek immediate emergency medical treatment for any suspected injection injury regardless of apparent minor entry wound, as hydraulic fluid spreading through tissue causes rapid deterioration requiring surgical debridement within hours. Use only manufacturer-specified hoses and fittings rated for system pressure. Inspect hydraulic components for wear, damage, or deterioration before reassembly. Pressure test repaired systems remotely with all personnel clear of potential failure zones. Never use hands or body to check if hydraulic components are operating under pressure. Even small quantities of hydraulic fluid under high pressure can cause catastrophic injuries.

What are the requirements for tyre inflation safety?

Heavy vehicle tyre inflation presents explosion hazard requiring specific safety equipment and procedures. Always use tyre safety cage designed to contain explosive energy if tyre or rim fails during inflation, with open side facing wall or solid barrier. For split rim wheels, carefully inspect all rim components for damage, corrosion, or mismatch before assembly, as damaged components can separate explosively during inflation. Lubricate tyre beads and ensure correct seating on rim. Use remote inflation equipment allowing operator to monitor pressure gauges from behind barrier rather than standing beside tyre. Inflate incrementally - first to bead seating pressure (30-40 psi) while verifying both beads have seated correctly, then continue to operating pressure while monitoring from safe position. Never exceed maximum pressure marked on tyre sidewall. Never stand in line with rim or alongside tyre during inflation regardless of safety equipment used. Install pressure limiting valves preventing accidental overinflation. Inspect tyres before inflation for sidewall damage, exposed cords, or internal damage that could cause failure. Explosive tyre failures can propel rim components and rubber fragments with lethal force, making proper safety procedures and equipment non-negotiable for this high-risk activity.

How should hazardous substances be managed in vehicle maintenance workshops?

Vehicle maintenance involves extensive exposure to oils, solvents, coolants, battery acid, and other hazardous substances requiring comprehensive management. Maintain register of all hazardous substances with current safety data sheets readily accessible to all workers. Provide chemical-specific PPE including oil-resistant gloves for petroleum products, acid-resistant gloves for battery work, and solvent-resistant gloves for degreasing. Install adequate workshop ventilation providing minimum 10 air changes per hour with local exhaust for concentrated vapour sources. Provide spill kits and train workers in spill response and cleanup. Install eye wash stations near battery charging areas and where corrosives are used. Ensure workers have access to washing facilities with hot water and appropriate soaps for removing chemical contamination before breaks and end of shifts. Segregate waste oils, coolants, solvents, and other wastes in appropriately labelled containers, arranging collection by licensed waste contractors. Never dispose of chemicals through drains or with general waste. Prohibit eating, drinking, or smoking in areas where chemical contamination could occur. Provide laundry services for heavily contaminated work clothing. Conduct health monitoring for workers with sustained chemical exposure. Substitute less hazardous alternatives where possible such as water-based degreasers instead of solvent-based products.

What documentation is required for heavy vehicle maintenance compliance?

Heavy vehicle maintenance documentation serves both workplace health and safety compliance and Chain of Responsibility regulatory requirements. Maintain vehicle service logbooks recording all maintenance performed including date, technician name and qualifications, work completed, parts replaced with specifications, fluids used, torque values for critical fastenings, and test results verifying proper operation. Document pre-service vehicle condition and any additional defects identified. For commercial vehicles, these records form evidence of proper maintenance preventing defects contributing to crashes or load restraint failures. Under Chain of Responsibility legislation, all parties including maintenance providers can be liable for vehicle defects, making proper documentation essential to demonstrate due diligence. Retain service records for minimum 7 years as required for commercial vehicle operations. Maintain inspection and test records for workshop equipment including hoists, pressure testing equipment, and torque wrenches. Document worker qualifications and training completion. Record any incidents, near-misses, or equipment failures for incident investigation and continuous improvement. Maintain hazardous substance registers with safety data sheets. Keep records of waste disposal through licensed contractors. Comprehensive documentation demonstrates systematic safety management and provides legal protection in event of incidents or regulatory investigations.

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