Automotive Mechanical Repair SWMS
General automotive mechanical repair — vehicle hoist operation, jack and stand protocol, battery disconnection, air-con refrigerant handling, oil/fuel management and brake-dust exposure (pre-2003 vehicles may contain chrysotile asbestos).
SWMS variants reference your state’s WHS legislation. Instant download after payment.
This SWMS covers general automotive mechanical repair work including vehicle hoist operation, jack and axle stand procedures, battery disconnection, air-conditioning refrigerant handling, oil and fuel management, and brake servicing. Under the Model WHS Regulations 2025 Chapter 4 Part 4.5 (Plant) and Part 7.1 (Hazardous Chemicals), PCBUs must document control measures for powered mobile plant and chemical exposures. Pre-2003 vehicles may contain chrysotile in brake and clutch friction materials, triggering Part 8.7 asbestos duties.
Hazards identified
8 hazards covered, sorted by priority.
Crush fatality or catastrophic injury to worker beneath vehicle.
Worker crushed by falling vehicle causing fatal or serious injury.
Long-term mesothelioma, asbestosis or lung cancer from inhaled fibres.
Cryogenic burns, asphyxiation in confined areas and ozone-depleting emissions.
Acid burns, arc flash injury or explosion causing eye and facial damage.
Second-degree thermal burns to hands, arms and face.
Flash fire or explosion causing burns and workshop property damage.
Acute back, shoulder and knee musculoskeletal injuries.
Control measures
Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.
- 1Inspect hoist daily, verify SWL, use manufacturer lift points and engage safety locks before working under vehicle.
- 2Always pair hydraulic jacks with rated axle stands; never rely on jack alone — chock opposite wheels.
- 3Treat all pre-2003 friction material as asbestos; use enclosed brake washer, P2 RPE and wet methods per Code of Practice.
- 4Recover refrigerant with licensed ARC equipment; wear face shield and cryogenic gloves; ventilate workshop bay.
- 5Disconnect negative battery terminal first, use insulated tools, and prohibit ignition sources within 1 m of batteries.
- 6Allow exhaust and cooling systems to cool before service; depressurise fuel rail and capture fuel in approved containers.
- 7Use trolley jacks, wheel dollies and mechanical lifters for loads over 16 kg per Hazardous Manual Tasks COP.
Applicable Codes of Practice
Direct guidance for hoist inspection, maintenance, isolation and operator competency required under Part 4.5.
Applies to brake and clutch dust on pre-2003 vehicles containing chrysotile friction materials.
Covers oils, coolants, solvents and refrigerants used in mechanical repair under Part 7.1.
High-Risk Construction Work triggered
Vehicle hoists are powered mobile plant; operator competency, daily pre-start checks and documented SWMS are mandatory before lifting.
Conducting HRCW without a compliant SWMS attracts Category 2 penalties up to $1.8M (body corporate) under WHS Act s32.
Who this is for
- →Independent automotive workshops and franchised dealer service departments
- →Mobile mechanics and roadside repair operators
- →Heavy vehicle, fleet and government depot maintenance teams
What you receive
- ✓Editable DOCX SWMS tailored to automotive mechanical repair
- ✓State-specific WHS legislation and Code of Practice schedule
- ✓Hazard register with risk matrix scoring
- ✓Worker sign-on register for site induction and review
Worked example
A suburban Sydney workshop services a 1998 Toyota HiLux requiring brake pad replacement. The mechanic identifies pre-2003 manufacture, applies the asbestos control pathway: enclosed brake washer with HEPA vacuum, P2 half-face respirator, disposable coveralls and double-bagged waste to a licensed asbestos disposal site. Hoist pre-start verifies SWL 4000 kg, lift points engaged and safety locks dropped before work commences. The SWMS is signed by both technicians prior to start.
Related legislation
- Work Health and Safety Act 2011 (Model)
- Work Health and Safety Regulations 2025 — Chapter 4 Part 4.5 (Plant)
- Work Health and Safety Regulations 2025 — Chapter 7 Part 7.1 (Hazardous Chemicals)
- Work Health and Safety Regulations 2025 — Chapter 8 Part 8.7 (Asbestos)
- Ozone Protection and Synthetic Greenhouse Gas Management Act 1989 (Cth)