Machinery Maintenance & Refuelling Risk Assessment Template

Typical hazards & measures

• 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.
• Yard traffic and plant interface — Set a separated maintenance bay with barriers; use hi-vis and site speed limits. Appoint a banksman for movements; extinguish engines before approaching. Mark pedestrian routes; apply reversing alarms and beacons. Schedule fuelling away from peak movements; communicate on radios.
• 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.
• Engine exhaust and carbon monoxide — Avoid indoor testing; if unavoidable, duct exhaust outdoors and monitor CO. Open doors and use fans to create flow-through ventilation. Limit run time; never idle in enclosed vans. Brief on CO symptoms; stop work and evacuate if monitors alarm or symptoms present.
• Rotating parts during test runs — Agree a test area and set exclusion zones; secure loose clothing and tie hair. Use remote start where available; keep hands and tools outside guards. Stand clear of belts, PTOs and fans; confirm guards refitted before running. Stop and isolate before any adjustments between runs.