Maintenance, Refueling/Recharging, and Equipment Care
This domain tests routine care and the high-risk tasks around energy: battery charging, LP cylinder exchange, refuelling, and planned maintenance. The exam expects lockout/tagout discipline, PPE, and ventilation awareness.
Maintenance and energy control
- Only trained and authorized people maintain trucks. Follow lockout/tagout: isolate the battery or ignition, disconnect the charger, and release stored hydraulic pressure before working on the mast or hoses.
- Inspect and report: hydraulic leaks, chafed hoses, chain wear, tyre condition, brake drift, and damaged guards. Do not modify the truck or fit unauthorised attachments.
- Keep the truck clean; remove combustible debris from the engine or motor compartment.
Charging and refuelling
- Charge lead-acid batteries in a ventilated area with no smoking, sparks, or open flame. Wear eye/face protection, gloves, and apron. Keep an eyewash and acid spill kit nearby.
- Turn the truck off, apply the brake, and follow the charger sequence. Add distilled water after charging to the specified level, not before, to avoid overflow.
- For LP: shut off the engine, exchange cylinders in a ventilated area, check seals and hoses for leaks, and never use a flame to test for gas.
- For diesel/petrol: refuel with the engine off, no smoking, and spill control.
Worked example
An operator notices the battery is low and wants to top it up before charging. The correct action is to charge first, then check electrolyte level and add distilled water to the marked level. Adding water to a discharged battery can cause overflow when the electrolyte expands during charging, creating an acid spill and reducing capacity.
Traps
Watering before charging; charging in an unventilated room; testing an LP leak with a lighter; bypassing interlocks; using water on an electrical fire.