Machinery Maintenance & Refuelling Risk Assessment Template

Typical hazards & measures

• Support failure of jacks and stands — Raise on level, firm ground; chock wheels and isolate drives. Use rated stands at manufacturer lift points; never rely on a jack alone. Place spreader pads on soft ground. Shake-test stability before crawling under; keep body clear of pinch points and use mechanical locks where fitted.
• Competence, supervision and briefings — Authorise maintainers/refuelers by role; verify competence on the specific model. Deliver a pre-task brief covering hazards, isolation points, torque specs and test procedures. Supervise new staff; use checklists, sign-off sheets and stop-work authority to catch errors before release.
• Slips and trips from oils and tools — Keep a clean floor policy: lay absorbent mats under work, wipe spills immediately, and bin oily rags. Route leads and hoses overhead or with covers; maintain clear walkways. Use anti-slip footwear and good lighting. Store tools in trays, not on the floor; mark wet areas.
• Electrical isolation and lockout — Apply lockout/tagout to battery, spark, mains, and auxiliary feeds; verify zero energy by test-for-dead. Bleed capacitors and isolate chargers. Keep keys in a lockbox; attach personal locks and tags. Record isolation points on a permit and perform a controlled re-energisation check.
• Fuel handling and storage — Store petrol/diesel in approved, labelled containers within a ventilated, bunded cabinet; segregate from oxidisers and ignition. Keep quantities to task need. Inspect cans and hoses for damage. Provide spill kits, extinguishers, no-smoking signage, and update the chemical inventory.