BlueSafe
Electrical and Diagnostics Risk Assessment

Electrical and Diagnostics Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
  • • Pre-filled Content – Ready to Deploy Immediately
  • • Customisable – Easily Add Your Logo & Site Details
  • • Includes 2 Years of Free Compliance Updates

Electrical and Diagnostics Risk Assessment

Product Overview

Identify and control organisational risks associated with Electrical and Diagnostics activities using this management-level Risk Assessment, focused on governance, planning, systems, and resourcing rather than task-by-task work instructions. Strengthen WHS Risk Management, demonstrate executive Due Diligence under the WHS Act, and reduce operational liability exposure across your electrical and diagnostics functions.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • WHS Governance, Policies and Legal Compliance: Assessment of organisational WHS responsibilities, policy frameworks, consultation arrangements, and verification of compliance for electrical and diagnostics operations.
  • Electrical Safety Management and Isolation Systems: Management of electrical risk controls, lock-out/tag-out procedures, testing before touch, and selection of compliant electrical equipment and protective devices.
  • Airbag and Supplementary Restraint Systems (SRS) Management: Controls for handling live SRS components, deactivation protocols, storage, transport, and training requirements for working around undeployed airbags.
  • Dynamometer (Chassis and Engine) Safety Management: Assessment of plant safety, guarding, restraints, ventilation, noise, and emergency shutdown systems for chassis and engine dynamometer use.
  • Diagnostic Software, Data Security and Configuration Control: Management of software licensing, access control, cybersecurity, configuration changes, and protection of customer and vehicle data.
  • Competency, Licensing and Training for Electrical and Diagnostics: Systems for verifying qualifications, electrical authorisations, supervision levels, refresher training, and competency assessment for diagnostic work.
  • Workshop Layout, Plant, and Infrastructure for Diagnostics: Planning of safe workshop design, traffic flow, ventilation, lighting, power supply, and segregation of diagnostic bays from other high-risk activities.
  • Equipment Procurement, Maintenance and Inspection Systems: Processes for selecting compliant diagnostic and electrical equipment, scheduled inspections, calibration, and defect reporting and rectification.
  • Safe Systems for Vehicle Diagnostics and Test Procedures: Development and control of standard diagnostic procedures, test drive protocols, key and ignition control, and verification steps before and after testing.
  • Hazardous Energy, Heat and Emission Exposure Management: Controls for exposure to high voltage, rotating components, hot surfaces, exhaust emissions, noise, and other hazardous energies during diagnostics.
  • Contractor, Visitor and Customer Vehicle Management: Protocols for induction, access control, parking, vehicle handover, and communication of diagnostic risks to third parties.
  • Emergency Preparedness, Incident Response and First Aid: Planning for electrical shock, fire, chemical exposure, and mechanical incidents, including emergency equipment, drills, and post-incident review processes.
  • Fatigue, Workload and Human Factors in Diagnostics: Management of scheduling, complexity of diagnostic tasks, supervision, and human error risks associated with high-cognitive-load work.
  • Documentation, Records and Continuous Improvement: Systems for maintaining service records, test reports, training evidence, risk registers, and implementing corrective actions and safety improvements.

Who is this for?

This Risk Assessment is designed for Business Owners, Automotive Electrical Managers, Workshop Controllers, and Safety Officers responsible for planning, resourcing, and overseeing Electrical and Diagnostics operations across their organisation.

Hazards & Risks Covered

Hazard Risk Description
1. WHS Governance, Policies and Legal Compliance
  • • Absence of a documented WHS management system referencing WHS Act 2011 and WHS Regulations for electrical and diagnostic work
  • • Inadequate integration of electrical safety, plant and hazardous chemicals requirements into workshop policies
  • • Lack of procedures covering high‑risk activities such as airbag system work, ignition diagnostics and dynamometer operation
  • • Poor consultation with workers and health and safety representatives on changes to diagnostic procedures and equipment
  • • No formal process to review incidents, near misses or regulatory changes related to electrical and diagnostic work
2. Electrical Safety Management and Isolation Systems
  • • Inadequate lock‑out/tag‑out system for isolating vehicle electrical systems, batteries and mains‑powered diagnostic equipment
  • • Uncontrolled exposure to live circuits during ignition system diagnostics and repair
  • • Unsafe practices when testing and adjusting alternator settings, including working on energised systems
  • • Lack of standardised procedures for de‑energising vehicles prior to diagnostics or software connection
  • • No system for managing risks from jump‑starting, booster packs or auxiliary power sources
  • • Inadequate labelling and segregation of high‑voltage or hybrid systems (where applicable)
3. Airbag and Supplementary Restraint Systems (SRS) Management
  • • Incorrect or absent procedures for airbag removal and refit leading to unintentional deployment
  • • Inadequate training on working with airbag systems and SRS control modules
  • • Failure to follow manufacturer de‑energisation and wait‑time requirements before handling SRS components
  • • Poor tracking and storage of removed airbag modules and pyrotechnic devices
  • • No system to verify that vehicles with disabled or removed airbags are not released to customers without documentation and warnings
4. Dynamometer (Chassis and Engine) Safety Management
  • • Absence of a formal risk assessment and operating procedure for chassis and engine dynamometer testing
  • • Inadequate guarding, barriers or exclusion zones around moving parts and rotating components
  • • Uncontrolled vehicle movement or detachment from the chassis dynamometer under load
  • • Noise, exhaust emissions and heat build‑up not adequately managed during dynamometer operation
  • • Insufficient controls for electrical and data connections between vehicle and dynamometer systems
  • • Inadequate emergency stop systems and response procedures for dynamometer faults or test failures
5. Diagnostic Software, Data Security and Configuration Control
  • • Use of unlicensed or unverified diagnostic software leading to incorrect diagnostic codes or unsafe configurations
  • • Software updates or coding changes that unintentionally disable safety systems such as airbags, ABS or stability control
  • • Poor management of access rights to diagnostic systems, allowing unqualified staff to change critical parameters
  • • Lack of documented procedures for reading diagnostic codes, clearing faults and verifying repairs
  • • Cybersecurity vulnerabilities in connected diagnostic equipment that could compromise system integrity
6. Competency, Licensing and Training for Electrical and Diagnostics
  • • Workers performing electrical and diagnostic work without appropriate trade qualification or competency verification
  • • Insufficient training in ignition system diagnostics, diesel engine diagnostics and alternator testing methods
  • • Lack of ongoing training in new vehicle technologies, complex electronic systems and diagnostic platforms
  • • No formal induction to workshop‑specific risks such as dynamometer testing, SRS handling and use of diagnostic software
  • • Supervision systems that do not adequately monitor apprentices and new starters during high‑risk diagnostic tasks
7. Workshop Layout, Plant, and Infrastructure for Diagnostics
  • • Poor workshop layout causing vehicle movement conflicts around diagnostic bays and dynamometers
  • • Inadequate segregation of high‑risk diagnostic areas (e.g. dynamometer cell, SRS workbench) from general workshop activities
  • • Insufficient electrical supply design, leading to overloading circuits used for diagnostic equipment and test rigs
  • • Trip and crush hazards from poorly routed diagnostic leads, exhaust hoses and test equipment
  • • Inadequate lighting and ventilation in diagnostic areas, increasing the risk of error and exposure to fumes
8. Equipment Procurement, Maintenance and Inspection Systems
  • • Use of outdated, damaged or non‑calibrated diagnostic tools, multimeters and oscilloscopes
  • • Inadequate maintenance regime for dynamometers, alternator test rigs and engine test stands
  • • Failure of safety interlocks or guards on diagnostic and test equipment due to lack of inspection
  • • No test and tag program for portable electrical equipment used in diagnostics
  • • Poorly managed repair and replacement of defective diagnostic leads, probes and adapters
9. Safe Systems for Vehicle Diagnostics and Test Procedures
  • • Lack of standardised procedures for performing vehicle diagnostics and reading diagnostic codes
  • • Uncontrolled cranking or engine running during diagnostics, creating risks of entanglement, noise and fumes
  • • Inconsistent approaches to diesel engine diagnostics that may involve exposure to high‑pressure fuel systems or hot components
  • • No formal risk assessment for non‑standard diagnostic tasks, performance tuning or fault replication on the road
  • • Failure to manage risks when replacing directional indicators, vehicle heating system components or other safety‑related parts under diagnostic conditions
10. Hazardous Energy, Heat and Emission Exposure Management
  • • Exposure to exhaust gases during engine and dynamometer testing due to inadequate extraction
  • • Burns from hot engine, exhaust and heating system components during diagnostics and repair
  • • Unmanaged battery charging, discharging and jump‑starting leading to explosion, acid exposure or fire
  • • Prolonged exposure to noise from test engines and dynamometers exceeding exposure standards
  • • Accumulation of flammable vapours or combustible materials near hot surfaces and ignition sources
11. Contractor, Visitor and Customer Vehicle Management
  • • Contractors undertaking electrical or diagnostic work without induction into workshop‑specific WHS procedures
  • • Visitors or customers entering diagnostic or dynamometer areas without awareness of hazards
  • • Insufficient controls over customer‑supplied or modified vehicles that may have unknown electrical or safety system alterations
  • • Lack of clear communication with customers about limitations or risks when safety systems (e.g. airbags, indicators, heating/defogging) are inoperative
  • • Inadequate verification of contractor qualifications and insurances for specialist diagnostic services
12. Emergency Preparedness, Incident Response and First Aid
  • • No specific emergency response procedures for electrical shock, SRS misfire or dynamometer failure
  • • Inadequate first aid equipment and training relevant to burns, electrical injuries and crush injuries
  • • Staff uncertainty about emergency shutdown of dynamometers, test engines and mains‑powered diagnostic equipment
  • • Incomplete investigation of electrical and diagnostic‑related incidents, leading to repeated systemic failures
  • • Lack of coordination with emergency services regarding workshop‑specific hazards such as airbags and test cells
13. Fatigue, Workload and Human Factors in Diagnostics
  • • Complex diagnostic tasks undertaken when workers are fatigued, increasing risk of error and unsafe decision‑making
  • • Production and time pressures leading to bypassing of isolation, verification or test procedures
  • • Cognitive overload when using multiple diagnostic systems, software platforms and reference materials simultaneously
  • • Inadequate break scheduling during prolonged investigations or repetitive testing sessions
  • • Poor reporting culture where workers feel unable to raise concerns about rushed or unsafe diagnostic practices
14. Documentation, Records and Continuous Improvement
  • • Incomplete or inaccurate recording of diagnostic procedures, software changes and test outcomes
  • • Loss of historical diagnostic data that could inform future risk assessments or maintenance planning
  • • No formal process to review and improve diagnostic and electrical safety procedures following incidents or new technology introduction
  • • Poor integration of WHS documentation with workshop management and job control systems
  • • Difficulty demonstrating compliance with WHS and regulatory requirements during audits or inspections

Need to add specific hazards for your workplace?

Don't worry if a specific hazard isn't listed above. Once you purchase, simply log in to your Client Portal and add your own custom hazards at no extra cost. We take care of the hard work—creating the risk ratings and control measures for free—to ensure your document is compliant within minutes.

Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • AS/NZS 3000:2018 (Wiring Rules): Electrical installations — Safety requirements for electrical work and installations.
  • AS/NZS 4836:2011: Safe working on or near low-voltage electrical installations and equipment.
  • AS 4024.1 (Series): Safety of machinery — Principles for risk assessment, guarding, and control systems for plant such as dynamometers.
  • AS/NZS ISO 45001:2018: Occupational health and safety management systems — Requirements with guidance for use.
  • Safe Work Australia Codes of Practice: Including “Managing electrical risks in the workplace”, “Managing risks of plant in the workplace”, and “Managing the work environment and facilities”.
  • Manufacturer and OEM Technical Bulletins: Guidance for safe use of diagnostic equipment, software, and vehicle-specific electrical systems.
Standard Risk Assessment Features (Click to Expand)
  • Comprehensive hazard identification for all activities
  • Risk rating matrix with likelihood and consequence analysis
  • Existing control measures evaluation
  • Residual risk assessment after controls
  • Hierarchy of controls recommendations
  • Action priority rankings
  • Review and monitoring requirements
  • Consultation and communication records
  • Legal compliance references
  • Sign-off and approval sections

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