Machinery Maintenance & Refuelling Risk Assessment Template

Typical hazards & measures

• 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.
• Working at height on machinery — Use a podium step or mobile platform; avoid standing on tyres or buckets. Maintain three points of contact; fit guardrails on platforms. Keep surfaces dry; use tool lanyards. Exclude people below; never overreach. Descend to reposition rather than stretching; inspect access gear before use.
• 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.
• 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.
• Manual handling of heavy parts — Assess weight, shape and grasp; split assemblies where possible. Use hoists, dollies or two-person lifts; keep loads close, back neutral, and steps clear. Plan the path and set down points; wear cut-resistant gloves. Warm up before repetitive tasks and rotate duties to reduce fatigue.