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.
• Static discharge during refuelling — Use anti-static cans and bond container to the machine; avoid decanting between plastics in dry, windy conditions. Keep the nozzle in contact with the filler neck. Do not refuel inside vehicles or on trailers. Wear natural-fibre clothing; avoid synthetic layers that build charge.
• Hydraulic pressure release — Lower implements to ground, chock and support; apply pressure dump controls. Use rated hose caps and a card-edge test for pinhole leaks—never hands. Replace damaged hoses with like-for-like; torque to spec. Wear face shield and gauntlets when cracking joints; keep a spill tray in place.
• Compressed air misuse — Limit pressure at the gun; never use for cleaning skin or clothing. Wear eye protection and guard against flying debris. Use safety nozzles with relief ports; check hoses for damage and whip-checks at couplings. Depressurise before disconnecting; secure cylinders upright and cap when stored.
• 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.