Product Overview

This Safe Work Method Statement (SWMS) provides a structured, step-by-step approach to managing hazards and risks associated with on site repair and service of forklifts, helping you maintain strong WHS compliance. It is a comprehensive document that covers multiple aspects of On Site Repair and Service for Forklift activities, from job set-up and isolation through to testing, commissioning and demobilisation.

Activities & Specific Tasks Covered

This document includes specific risk controls for:

• Planning and preparation of on site forklift repair and servicing works, including pre-start checks and work area assessment
• Safe parking, isolation, and lock-out/tag-out (LOTO) of forklifts prior to inspection or repair
• Inspection and servicing of forklift mast assemblies, lift chains, forks and attachments
• Maintenance and replacement of hydraulic hoses, fittings, cylinders and associated components
• Servicing of engines, transmissions, cooling systems and drive components on internal combustion forklifts
• Inspection, testing and maintenance of electric forklifts, including batteries, chargers and electrical systems
• Safe use of jacks, axle stands, lifting equipment and support stands when raising or supporting forklifts
• Use of hand tools, power tools and portable electrical equipment during repair and servicing tasks
• Management of fire and explosion risks when working with fuels, oils, LPG, diesel and other flammable substances
• Manual handling and ergonomics when lifting, carrying, or positioning parts, components and tools
• Control of slips, trips, falls and mobile plant interactions in busy warehouse, yard or loading dock environments
• Environmental controls for spills, waste oils, coolant and contaminated rags, including clean-up and disposal
• Post-maintenance functional testing, commissioning and return-to-service verification of forklifts
• Emergency response procedures for injuries, fires, spills, equipment failure and uncontrolled movement

Who is this for?

This SWMS is designed for mobile forklift technicians, mechanical service contractors, material handling equipment providers, and site supervisors responsible for overseeing on site repair and service of forklifts across warehouses, logistics hubs, manufacturing plants and construction sites.

Specific Job Steps & Hazards Covered

Legislation & References

This document was researched and developed to align with:

• Model Code of Practice: How to Manage Work Health and Safety Risks – Guidance on identifying, assessing and controlling risks associated with forklift servicing tasks
• Model Code of Practice: Managing Risks of Plant in the Workplace – Requirements for the safe inspection, repair and maintenance of plant, including forklifts
• Model Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace – Controls for fuels, oils, coolants, solvents and cleaning agents used during service work
• Model Code of Practice: Hazardous Manual Tasks – Risk management for lifting, carrying and handling forklift components and tools
• AS 2359 Powered industrial trucks – General requirements for the safe operation, inspection and maintenance of forklifts
• AS/NZS 3012 Electrical installations – Construction and demolition sites – Safe use of portable electrical equipment and tools where applicable
• Work Health and Safety Act 2011
• Work Health and Safety Regulations 2017