Fuelling, Battery Recharging and End-of-Shift Procedures
This domain tests the hazards that do not involve driving: flammable fuel, LPG under pressure, hydrogen from charging batteries, acid, and the handover routine that keeps the next shift safe.
Refuelling and LPG
Refuel only in the designated area with the engine off, no smoking and no ignition sources. Clean up spills with the spill kit and report them. LPG cylinder changes should be done in the open or in a well-ventilated area - LPG is cold and can cause cold burns, so wear gloves, check the seal and hose, secure the cylinder, and leak-test with soapy water, never a flame. Close the valve when the truck is not in use.
Battery charging
Charge only in a designated, ventilated area - charging releases hydrogen, which is explosive. No smoking, no naked flames, no tools laid across the terminals. Wear goggles and acid-resistant gloves, know where the eyewash is, and top up electrolyte with distilled water after charging, not before, and only to the manufacturer's level. Report acid spills and damaged leads; the Electricity at Work Regulations and COSHH both apply here.
End of shift
Park correctly, forks down and mast tilted forward, parking brake on, key off and handed to the authorised person, LPG valve closed, battery on charge, truck cleaned, defects reported and the checklist completed so the next operator knows the state of the machine.
Worked example
You smell gas as you walk up to an LPG truck. Stop, do not start it, move it only if that can be done safely, shut the cylinder valve, ventilate the area, tag the truck out of service, report it, and let a competent person find the leak with soapy water.
Traps
- Topping up electrolyte before charging.
- Smoking or using a phone charger near the charging bay.
- Leaving the key in the truck or the forks raised at handover.