Product Overview

Summary: This Suspension System Adjustment SOP sets out a clear, safe and repeatable process for inspecting and adjusting vehicle suspension systems in Australian workplaces. It helps technicians minimise the risk of component failure, lifting incidents and road safety hazards while maintaining compliance with WHS and roadworthiness requirements.

Suspension system adjustments are routine in workshops, depots and field service operations, yet they involve significant safety risks if not carried out in a controlled, methodical way. This Suspension System Adjustment Safe Operating Procedure provides a structured process for assessing, adjusting and verifying suspension components on light vehicles, heavy vehicles and off‑road plant. It covers pre-work checks, safe lifting and support of vehicles, selection and use of tools, adjustment techniques, post-adjustment verification and documentation requirements.

By implementing this SOP, businesses can reduce the likelihood of suspension-related failures that lead to loss of control, rollovers or load instability on Australian roads and worksites. It supports compliance with WHS obligations, heavy vehicle roadworthiness and chain of responsibility requirements by standardising how technicians manage hazards such as crush risks, stored energy in springs and airbags, and exposure to moving plant. The procedure also promotes consistent ride height, handling and load-carrying performance across fleets, improving driver confidence, customer satisfaction and asset life while providing a defensible, auditable process for regulators and insurers.

Key Benefits

• Reduce the risk of crush injuries and vehicle instability during suspension inspection and adjustment.
• Ensure consistent, compliant suspension adjustment across all technicians and sites.
• Improve vehicle handling, braking performance and load stability, enhancing on-road safety.
• Support compliance with Australian WHS laws and heavy vehicle roadworthiness requirements.
• Streamline technician training with a clear, step-by-step process and defined safety controls.

Who is this for?

• Automotive Technicians
• Heavy Vehicle Mechanics
• Fleet Maintenance Supervisors
• Workshop Managers
• Service Advisors
• Agricultural and Earthmoving Equipment Mechanics
• WHS Managers in Transport and Logistics
• Light Vehicle Mechanics
• 4WD and Suspension Upgrade Specialists

Hazards Addressed

• Crush injuries from vehicle or plant falling due to inadequate lifting or support
• Release of stored energy from coil springs, leaf springs, torsion bars and air suspension components
• Pinch and entanglement injuries when working near moving suspension and steering parts
• Manual handling injuries from handling wheels, suspension components and heavy tools
• Slips, trips and falls in and around the workshop or service area
• Exposure to hazardous substances such as lubricants, solvents and cleaning agents
• Noise exposure from rattle guns, impact tools and workshop equipment
• Vehicle roll-away due to inadequate chocking or failure to secure the vehicle
• Fire risk from hot components, welding or grinding near flammable materials

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Standards and Legal Obligations
• 3.0 Definitions and Types of Suspension Systems
• 4.0 Roles, Responsibilities and Competency Requirements
• 5.0 Required Tools, Equipment and Personal Protective Equipment (PPE)
• 6.0 Pre-Work Checks and Vehicle Identification
• 7.0 Hazard Identification and Risk Controls
• 8.0 Safe Vehicle Lifting, Support and Isolation Procedures
• 9.0 Suspension Inspection and Assessment Criteria
• 10.0 Step-by-Step Suspension Adjustment Procedure (Coil, Leaf, Torsion Bar, Air and Heavy Vehicle Systems)
• 11.0 Post-Adjustment Verification, Road Test and Quality Checks
• 12.0 Documentation, Records and Customer/Driver Communication
• 13.0 Emergency Procedures and Incident Response
• 14.0 Training, Supervision and Competency Assessment
• 15.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS legislation
• Work Health and Safety Regulations 2011 and state/territory equivalents
• Safe Work Australia – Model Code of Practice: Managing risks of plant in the workplace
• Safe Work Australia – Model Code of Practice: Hazardous manual tasks
• Safe Work Australia – Model Code of Practice: Managing risks of hazardous chemicals in the workplace
• AS 2550 series: Cranes, hoists and winches – Safe use (relevant where lifting equipment is used)
• AS/NZS 1891 series: Industrial fall-arrest systems and devices (where work at height is involved)
• AS/NZS 4024 series: Safety of machinery (for workshop plant and equipment)
• Heavy Vehicle (Vehicle Standards) National Regulation and related roadworthiness guidelines
• National Heavy Vehicle Regulator (NHVR) – Heavy Vehicle Inspection Manual (for heavy vehicles)