On Site Repair and Service for Forklift Risk Assessment

Product Overview

This risk assessment covers on-site forklift repair and service activities, from arrival and work area control through isolation, maintenance, testing and return to service. It supports planning by identifying hazards associated with plant movement, stored energy, access, tools, electrical and hydraulic work.

Activities & Risks Covered

This assessment addresses activities and risks including:

• Assess site conditions, access, lighting, weather, work rules and emergency arrangements before starting.
• Control traffic and establish a repair area to manage interaction with pedestrians, forklifts, vehicles and other plant.
• Isolate and shut down the forklift to manage unexpected movement and stored energy.
• Access mast, carriage, overhead guard and elevated components while managing falls, dropped objects and slip hazards.
• Handle tools, parts and heavy components with attention to lifting, crush and awkward-posture risks.
• Carry out electrical and battery work while managing shock, burns, short circuits, acid and battery-gas hazards.
• Release hydraulic pressure and inspect hoses or fittings while managing fluid, movement and oil-contact hazards.
• Use hand tools, power tools, hot work and substances while managing cuts, sparks, fumes, fire and noise.
• Functionally test, reinstate and return the forklift to service while managing movement, bystander access and incomplete reinstatement.

Who is this for?

Suitable for contractors, workers, supervisors and businesses carrying out on-site forklift repair and service work.

Activities & Hazards Covered

Legislation & References

The template records model guidance used to inform the documented controls. Applicable WHS/OHS laws and adopted Codes vary by state or territory, so confirm the current local requirements when tailoring the assessment:

• Model guidance: Model Code of Practice: Hazardous manual tasks — 4.1 The hierarchy of control measures; p. 31.
• Model guidance: Model Code of Practice: Managing risks of plant in the workplace — Plant hazard identification — Traffic movements in the workplace; p. 17.
• Model guidance: Model Code of Practice: Managing the work environment and facilities — 2. The work environment; p. 13.
• Model guidance: Model Code of Practice: Managing electrical risks in the workplace — 5. Isolation, locking off and access; p. 34.
• Model guidance: Model Code of Practice: First aid in the workplace — 3. First aid equipment, facilities and training; p. 12.
• Model guidance: Model Code of Practice: Managing noise and preventing hearing loss at work — 5. Controlling the risks; p. 29.
• Model guidance: Model Code of Practice: Welding processes — 1.3 What is involved in managing risks associated with welding processes?; p. 10.

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Standard Risk Assessment Features (Click to Expand)

• Activity-specific hazard identification and control measures
• Initial and residual risk ratings
• Assigned responsible persons for each activity
• Risk matrix and assessment classification
• Review, monitoring and sign-off fields
• Site-specific customisation before use