Product Overview

Summary: This Tyre and Wheel Alignment Safe Operating Procedure sets out a clear, safe and consistent method for inspecting, removing, fitting and aligning tyres and wheels on light and heavy vehicles. It helps Australian workplaces control high-risk tasks such as working with jacking equipment, handling heavy wheels and operating alignment machinery, while supporting WHS compliance and high-quality vehicle performance.

Tyre and wheel alignment work combines high forces, heavy components and specialised equipment, making it a significant WHS risk area in Australian automotive and fleet maintenance environments. This Safe Operating Procedure provides a structured, step‑by‑step method for safely lifting vehicles, removing and fitting tyres, torquing wheel nuts, and carrying out wheel alignment checks and adjustments. It covers both light vehicles and, where applicable, heavy vehicles, ensuring that operators understand the correct sequence of tasks, the control measures required and the verification checks needed before a vehicle is returned to service.

The procedure is designed to help businesses reduce the likelihood of serious incidents such as vehicle falls from jacks or hoists, wheel separation on-road, eye and impact injuries from pneumatic tools, and musculoskeletal injuries from manual handling of wheels. It also addresses operational issues such as inconsistent alignment results, uneven tyre wear, customer complaints and rework. By implementing this SOP, workshops and fleets can demonstrate due diligence under Australian WHS laws, standardise training for new and existing staff, and deliver safer, more reliable vehicles to workers and customers alike.

Key Benefits

• Reduce the risk of vehicle falls, wheel separation and tool-related injuries through clearly defined safe work steps.
• Ensure consistent, manufacturer-compliant tyre fitting and wheel alignment that extends tyre life and improves vehicle handling.
• Standardise training for technicians, reducing variability in work quality across shifts, sites and contractors.
• Demonstrate compliance with WHS legislation, Australian Standards and manufacturer requirements for lifting, tyre work and alignment.
• Minimise costly rework, customer complaints and downtime by embedding quality checks and sign-off points into the process.

Who is this for?

• Automotive Workshop Managers
• Tyre Technicians
• Motor Mechanics
• Fleet Maintenance Supervisors
• Heavy Vehicle Mechanics
• Service Advisors
• WHS Managers and Safety Officers
• Dealership Service Managers
• Mining and Civil Fleet Managers
• Local Government Workshop Coordinators

Hazards Addressed

• Vehicle instability and falls from jacks, stands or hoists
• Crush injuries to hands, feet and body during lifting and wheel handling
• Manual handling injuries from lifting and moving heavy tyres and wheels
• Eye and impact injuries from use of rattle guns and tyre changing equipment
• Noise exposure from pneumatic tools and workshop equipment
• Pinch points and entanglement in rotating alignment and balancing machinery
• Slips, trips and falls around hoses, tools and waste tyres
• Exposure to hazardous chemicals such as tyre lubricants, brake dust and cleaning agents
• Burns or contact injuries from hot brake components and wheels
• On-road incidents due to incorrect torqueing, wheel fitment or alignment

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology (Tyre Types, Alignment Angles, Equipment)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Required Tools, Equipment and Calibration Requirements
• 5.0 Personal Protective Equipment (PPE) Requirements
• 6.0 Pre-Task Planning and Risk Assessment (JSA/SWMS Reference)
• 7.0 Vehicle Reception, Identification and Initial Safety Checks
• 8.0 Safe Vehicle Lifting, Support and Lowering Procedures
• 9.0 Tyre and Wheel Removal, Inspection and Fitting Procedure
• 10.0 Wheel Nut Torqueing and Re-Torque Verification
• 11.0 Wheel Alignment Setup, Measurement and Adjustment Steps
• 12.0 Quality Control Checks, Road Test and Documentation
• 13.0 Hazard Identification and Control Measures (Plant, Manual Handling, Chemicals)
• 14.0 Housekeeping, Waste Tyre Management and Environmental Considerations
• 15.0 Emergency Procedures (Equipment Failure, Vehicle Instability, Injury)
• 16.0 Training, Induction and Competency Assessment
• 17.0 Inspection, Maintenance and Tag-Out of Hoists and Alignment Equipment
• 18.0 Recordkeeping, Version Control and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts
• Work Health and Safety Regulations 2011 and state/territory equivalents
• Safe Work Australia – Code of Practice: Managing risks of plant in the workplace
• Safe Work Australia – Code of Practice: Hazardous manual tasks
• AS/NZS 4024 series: Safety of machinery
• AS 2550.9: Cranes, hoists and winches – Safe use – Vehicle hoists
• AS/NZS 1891 series: Industrial fall-arrest systems and devices (where under-vehicle access is required)
• AS/NZS 1269 series: Occupational noise management
• AS/NZS 2210.1: Safety, protective and occupational footwear
• Manufacturer service manuals and OEM specifications for tyre pressures, torque settings and alignment angles