Machinery Maintenance & Refuelling Risk Assessment Template

Typical hazards & measures

• 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.
• 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.
• 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.
• 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.
• 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.