Product Overview

Summary: This Axle Alignment Safe Operating Procedure sets out a clear, step-by-step method for safely inspecting, adjusting and verifying axle alignment on vehicles and mobile plant. It helps Australian businesses protect workers, prevent mechanical failures, and maintain compliance with WHS and roadworthiness requirements.

Incorrect axle alignment is more than just a wear-and-tear issue – it can compromise vehicle stability, braking performance and steering control, putting drivers, workshop staff and the public at risk. This Axle Alignment Safe Operating Procedure provides a structured, WHS-focused approach to carrying out axle alignment on cars, trucks, trailers and mobile plant. It covers the full workflow from pre-job planning and safety checks, through to the use of alignment equipment, verification of results and documentation of work performed.

Developed for Australian workshops and fleet operators, this SOP helps you integrate safety, quality and compliance into everyday maintenance tasks. It clarifies roles and responsibilities, specifies required tools and PPE, and embeds hazard controls for working around raised vehicles, rotating components and compressed air or hydraulic systems. By standardising axle alignment practices, you reduce the likelihood of mechanical failures, extend tyre life, and demonstrate due diligence under WHS legislation and heavy vehicle roadworthiness obligations.

Key Benefits

• Ensure axle alignment work is carried out safely, consistently and in line with Australian WHS expectations.
• Reduce the risk of vehicle instability, loss of control and on-road incidents linked to poor alignment.
• Extend tyre life and reduce fuel consumption by maintaining correct axle geometry across the fleet.
• Standardise training for mechanics and apprentices with a clear, step-by-step procedure and defined responsibilities.
• Provide defensible records of inspection, adjustment and verification to support compliance and audit requirements.

Who is this for?

• Workshop Managers
• Heavy Vehicle Mechanics
• Light Vehicle Technicians
• Fleet Maintenance Supervisors
• Automotive Service Managers
• Mobile Plant and Equipment Supervisors
• WHS Managers and Advisors
• Apprentice Mechanics

Hazards Addressed

• Crush injuries from vehicle or trailer collapse when working under raised vehicles
• Struck-by injuries from moving or rotating wheels and components during testing and adjustment
• Manual handling injuries from lifting wheels, alignment heads and heavy components
• Slips, trips and falls in congested workshop environments around hoists and pits
• Eye and hand injuries from use of hand tools, impact tools and compressed air equipment
• Noise exposure from workshop machinery and pneumatic tools
• Exposure to fumes from running engines during alignment checks
• Pinch and entanglement hazards from alignment equipment, jacks and stands

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Standards and Definitions
• 3.0 Roles and Responsibilities
• 4.0 Competency, Training and Authorisation Requirements
• 5.0 Tools, Equipment and Calibration Requirements
• 6.0 Personal Protective Equipment (PPE)
• 7.0 Pre-Job Planning and Risk Assessment
• 8.0 Vehicle Reception, Identification and Pre-Inspection Checks
• 9.0 Safe Vehicle Lifting, Supporting and Isolation Procedures
• 10.0 Axle Alignment Preparation (Tyres, Suspension, Steering)
• 11.0 Axle Alignment Measurement – Step-by-Step Process
• 12.0 Axle Alignment Adjustment – Step-by-Step Process
• 13.0 Verification, Road Test and Quality Checks
• 14.0 Hazard Identification and Control Measures Specific to Axle Alignment
• 15.0 Housekeeping, Workshop Layout and Traffic Management
• 16.0 Documentation, Records and Reporting Requirements
• 17.0 Non-Conformance, Defects and Escalation Procedure
• 18.0 Emergency Procedures and Incident Response
• 19.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts and Regulations
• Safe Work Australia – Code of Practice: Managing risks of plant in the workplace
• Safe Work Australia – Code of Practice: Managing the work environment and facilities
• AS/NZS 5732:2022 Heavy road vehicles – Safety requirements for maintenance and repair (or successor standard, where applicable)
• AS 2550 series: Cranes, hoists and winches – Safe use (relevant where vehicle hoists or lifting equipment are used)
• AS/NZS 1891 series: Industrial fall-arrest systems and devices (where work at height around vehicles is required)
• Manufacturer specifications and OEM service manuals for vehicle and axle alignment