Heavy Vehicle / Truck Servicing SWMS
SWMS template for heavy vehicle / truck servicing. Covers Tyres, brakes, drive train under raised vehicle.. 8-state AU coverage, CIH-reviewed editable DOCX delivered within 24 hours of payment.
SWMS variants reference your state’s WHS legislation. Instant download after payment.
Heavy vehicle and truck servicing exposes mechanics to a unique set of high-consequence hazards that go well beyond those encountered in light vehicle workshops. Working under raised prime movers, rigid trucks and trailers — typically supported by hydraulic hoists, column lifts or vehicle stands — places technicians directly in the crush zone of loads weighing 8 to 40 tonnes. Tasks such as tyre changes on multi-piece rims, brake chamber servicing on spring-applied air-released (SAAR) systems, and drive train work involving hot transmission and differential oils each carry their own catastrophic failure modes that must be controlled through documented safe work procedures.
Under the model Work Health and Safety Act 2011 and WHS Regulation 2025, a Person Conducting a Business or Undertaking (PCBU) must manage risks to health and safety so far as is reasonably practicable (s.19). Where the work meets the definition of High Risk Construction Work under r.291 — including work where there is a risk of a person falling more than 2 metres, work on or adjacent to energised installations, or work involving the use of powered mobile plant — a Safe Work Method Statement is mandatory before work commences (r.299). Heavy vehicle servicing routinely triggers HRCW categories through the use of vehicle hoists and the risk of being struck by stored mechanical or pneumatic energy.
This SWMS has been prepared and reviewed by a Certified Industrial Hygienist and aligns with the Safe Work Australia Model Code of Practice: Managing the Work Environment and Facilities, the Code of Practice for Managing Risks of Plant in the Workplace, and AS/NZS 2550 (Cranes, hoists and winches). It provides the documented risk assessment and control framework required to demonstrate compliance with WHS duties and to satisfy principal contractor and insurer requirements.
Hazards identified
6 hazards covered, sorted by priority.
Fatal crush injury — heavy vehicles can weigh 8–40 tonnes and survival under a falling load is unlikely
Fatal or severe blunt force trauma from rim component projectiles travelling at high velocity
Severe lacerations, fractures or fatality from ejected spring assembly under tonne-force load
Second and third degree burns to hands, arms and face; oils may exceed 90°C immediately after operation
Acute musculoskeletal injury, crush injuries to feet and hands, cumulative back and shoulder disorders
Long-term respiratory disease including occupational asthma, lung cancer and mesothelioma from pre-2003 components
Control measures
Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.
- 1Inspect hoist daily before use against AS/NZS 2550.9 requirements; verify current statutory inspection certificate is displayed and within 12-month interval
- 2Identify and use only manufacturer-designated lift points; consult OEM service manual for each vehicle make and model and confirm hoist arm pad placement before raising
- 3When working under a vehicle, install rated mechanical safety stands with a Working Load Limit (WLL) clearly stamped and exceeding the axle load; never rely on hydraulic hoist alone as primary support
- 4Cage all multi-piece rim assemblies during inflation using a tyre inflation safety cage compliant with the Code of Practice for Tyre Servicing; stand outside the trajectory zone during inflation
- 5Cage or mechanically restrain spring brake chambers before disassembly; use only manufacturer-supplied caging tools and follow the SAAR brake servicing procedure
- 6Allow drive train components to cool to below 40°C before draining oils; wear chemical-resistant gauntlets (AS/NZS 2161) and face shield when draining hot fluids
- 7Use mechanical lifting aids — tyre dollies, transmission jacks, component cranes — for any component over 20 kg; conduct two-person lifts where mechanical aids are not practicable
- 8Provide local exhaust ventilation at brake servicing bays and use HEPA-filtered vacuum (not compressed air) for brake dust removal in accordance with the Code of Practice: How to Manage and Control Asbestos in the Workplace
- 9Implement Lockout/Tagout (LOTO) on the vehicle ignition, battery isolator and air system before commencing work under the vehicle
- 10Ensure all technicians hold relevant competency — heavy vehicle mechanic trade qualification — and have been trained and assessed in this SWMS prior to work commencement
- 11Maintain workshop ventilation to control diesel exhaust emissions; never run engines indoors without connected tailpipe extraction
- 12Wear minimum PPE: safety footwear (AS/NZS 2210.3), safety glasses (AS/NZS 1337.1), hearing protection (AS/NZS 1270) when air tools in use, and oil-resistant nitrile gloves
Applicable Codes of Practice
Defines High Risk Construction Work and mandates SWMS preparation, review and availability before commencement
Provides guidance on safe use, inspection and maintenance of vehicle hoists and lifting equipment
Specifies inspection, maintenance and operation requirements for two-post and four-post vehicle hoists
Mandates use of inflation cages and procedures for multi-piece rim assemblies common on heavy vehicles
Applies to brake and clutch friction materials in heavy vehicles manufactured prior to December 2003
Risk management framework for handling heavy tyres, drums, gearboxes and tailshafts
High-Risk Construction Work triggered
Vehicle hoists are powered mobile plant under the WHS Regulation. Operation, including raising and lowering of heavy vehicles, brings workers into proximity with stored hydraulic and mechanical energy where failure presents a fatality risk.
Servicing tasks on prime movers and B-double trailers frequently require accessing cab roofs, trailer tops and engine bays at heights exceeding 2 metres, particularly when raised on a four-post hoist.
Because this work meets the definition of High Risk Construction Work under WHS Regulation r.291, a SWMS must be prepared before work commences (r.299), kept available for inspection (r.302), and reviewed if controls are revised or an incident occurs (r.301). Failure to comply is a Category 3 offence under the WHS Act with penalties up to $63,450 for an individual or $317,250 for a body corporate.
Who this is for
- →Heavy vehicle mechanical workshops servicing prime movers, rigid trucks and trailers
- →Bus and coach maintenance depots
- →Mining and civil contractor in-house heavy vehicle workshops
- →Mobile heavy vehicle service technicians and field mechanics
- →Trailer manufacturing and repair facilities
- →Local government and council fleet workshops servicing heavy plant
What you receive
- ✓Fully editable Microsoft Word (DOCX) SWMS template, CIH-reviewed and ready to customise with your company details
- ✓State-specific legislation schedule covering NSW, VIC, QLD, WA, SA, TAS, ACT and NT WHS regulations and codes of practice
- ✓Comprehensive hazard register with risk ratings using a 5x5 matrix and residual risk after controls
- ✓Worker sign-on register with competency verification fields and SWMS acknowledgment
- ✓High Risk Construction Work declaration aligned with WHS Regulation r.291
- ✓Plant and equipment pre-start inspection checklist for vehicle hoists and stands
- ✓Emergency response procedures specific to vehicle fall, tyre explosion and burns incidents
- ✓Delivery within 24 hours of payment via secure email link
Worked example
Daniel is a heavy vehicle mechanic at a regional truck workshop in Wagga Wagga, NSW. A B-double prime mover arrives for a 100,000 km service including front tyre replacement, rear brake adjustment and a transmission oil change. Before commencing, Daniel reviews this SWMS at the workshop toolbox meeting with his apprentice and signs the worker sign-on register. He confirms the two-post hoist's most recent statutory inspection sticker (dated within the past 11 months) and conducts the daily pre-start inspection documented in the SWMS pack. Daniel positions the hoist arms at the OEM-marked lift points, raises the prime mover and immediately installs two 15-tonne rated mechanical stands under the chassis rails as documented in the SWMS control measures. For the front tyre work, he uses a tyre inflation cage during reseating of the multi-piece rim. Before draining the transmission oil he allows a 30-minute cooldown and dons gauntlets and a face shield. When the workshop manager later conducts a SafeWork NSW audit, the SWMS, signed sign-on register and hoist inspection records are produced on request, satisfying the inspector's requirements under WHS Regulation r.302.
Related legislation
- Work Health and Safety Act 2011 (Cth model) — duties of PCBUs (s.19) and workers (s.28)
- Work Health and Safety Regulation 2025 — Chapter 3 (General risk management), Chapter 5 (Plant), Chapter 6 (Construction Work)
- Dangerous Goods (Storage and Handling) Regulations — applicable to bulk oil and fuel storage
- Environment Protection Act 2017 (state equivalents) — used oil and waste tyre disposal
- Heavy Vehicle National Law — for roadworthiness obligations post-service
Frequently asked questions
Does heavy vehicle servicing always require a SWMS?
A SWMS is mandatory whenever the work meets the definition of High Risk Construction Work under WHS Regulation r.291. Heavy vehicle servicing typically triggers this through use of powered mobile plant (hoists) and work at heights exceeding 2 metres. Even where HRCW is not triggered, a documented risk assessment is still required under the general risk management duty in r.34–38, and most principal contractors and insurers require a SWMS as a contractual condition.
Is this SWMS valid in all Australian states and territories?
Yes. The template includes a state-specific legislation schedule covering all jurisdictions operating under the model WHS framework (NSW, QLD, SA, TAS, ACT, NT, WA, and the Commonwealth). Victoria operates under the OHS Act 2004 and OHS Regulations 2017 — equivalent clauses and Compliance Codes are referenced in the Victorian schedule.
How often must this SWMS be reviewed?
Under WHS Regulation r.301, a SWMS must be reviewed and, if necessary, revised if control measures are not effective, before any change to the work that may give rise to a new or different risk, or if a notifiable incident occurs. Best practice is to review at least every 12 months or whenever new equipment, vehicles or procedures are introduced into the workshop.
Does this SWMS cover work on multi-piece (split rim) tyre assemblies?
Yes. The hazard register and control measures specifically address multi-piece rim assemblies common on heavy vehicles, including mandatory use of inflation cages, exclusion zones during inflation, and references to the relevant state Code of Practice for Tyre Servicing.
Can the document be edited to include our company logo and procedures?
Absolutely. The SWMS is delivered as a fully editable Microsoft Word (DOCX) file. You can insert your company logo, ABN, project details, site-specific controls and additional hazards. The template uses structured headings and tables to make customisation straightforward while maintaining compliance with WHS Regulation r.300 content requirements.
Who has reviewed this SWMS?
This SWMS has been prepared and reviewed by a Certified Industrial Hygienist (CIH) with experience in heavy vehicle and mechanical workshop risk assessment. The content aligns with current Safe Work Australia model Codes of Practice and AS/NZS standards applicable to vehicle hoists, tyre servicing and asbestos management.