Forklift trucks are often run on liquid chemicals like diesel or gasoline and are therefore convenient to refuel. However, these liquid chemicals are also incredibly flammable, so the operator is at risk of explosion and fire when refuelling the tanks. Therefore, safety has to be the number one priority when you fuel up a forklift. To help with this, we’ve put together an in-depth guide that covers forklift fuel types and how to fuel forklifts safely.
What to remember before refuelling your forklift
• Never refuel with the engine running.
• Park the forklift following the safe parking procedure.
• No open flame, smoke, or possible sources of ignition can go near 10 metres of where the truck is being refuelled.
Parking a forklift
You need to consider the safety of your fellow workers as you park the forklift. In other words, never park in front of an exit or near stairways. You should also lower the forks on the forklift so there aren’t any tripping hazards.
When you leave the forklift unattended, set the vehicle controls to neutral, set the parking brake, and switch off your engine. To be on the safe side, you should also take the key with you.
Refuelling a forklift
First and foremost, you need to put on the appropriate protective equipment before you fuel any type of forklift. The re-fuelling process may differ depending on what type of forklift you are working with: propane-powered, liquid petroleum gas-powered, or gasoline/diesel-powered.
Refuelling a propane-powered forklift
- Close the fuel valve on the cylinder after you’ve parked.
- Turn off the ignition.
- Put on your protective gloves.
- Disconnect the holding straps and the hose.
- Lift the cylinder (that is now empty) free.
- Replace the cylinder. You need to put the locating pin through the hole on the cylinder handle. When it’s seated, the valve will point upwards.
- Re-connect the holding straps and tighten the nuts.
- Check for leaks by slowly opening the valve around halfway.
- If you notice that the valve is leaking, tighten the connecting nuts and check for the leaks again.
- Once you see that there are no leaks, you can fully open the cylinder.
Note: If the fuel system does have a leak, you need to report it straight away. The appropriate action needs to be taken to stop the truck from being used until the leak has been fixed.
Refuelling a liquid petroleum gas-powered forklift
- Fully close the (fuel line) valve on the cylinder.
- Turn off the ignition.
- Put on your protective gloves.
- Disconnect the holding straps and the hose.
- Lift the cylinder (that is now empty) free.
- Replace the cylinder. You need to put the locating pin through the hole on the cylinder handle. When it’s seated, the valve will point upwards.
- Re-connect the holding straps and tighten the nuts.
- Check for leaks by slowly opening the valve around halfway.
- If you notice that the valve is leaking, tighten the connecting nuts and check for the leaks again.
- Once you see that there are no leaks, you can secure the cylinder and start the engine.
Note: It is strongly suggested that you wear leather gloves when changing the cylinders to prevent injury.
Refuelling gasoline or diesel-powered forklifts
- Ensure you’ve got the correct fuel.
- Switch off the engine.
- Put on the parking brake.
- Fill the tank.
- Replace the fuel cap.
- Clean up spilt fuel.
Our final reminders when refuelling a forklift
Refuel at the designated location
You need to ensure that you only refuel at the designated location stated by the company. There should also be a ‘no smoking’ sign at this location.
Class B fire extinguishers
There should be Class B fire extinguishers next to the refuelling location. This fire extinguisher needs to be properly maintained so it remains in working condition should an accident take place.
The forklift operator needs to be properly trained
The operator needs to know how to properly operate the vehicle and how to follow the safety guidelines. It’s important to bear in mind that every powered forklift has its own safety procedures when it comes to refuelling, so always do what is recommended by the manufacturer.
Assign an operator for refuelling
We highly recommend that a company or organisation designates one or two operators to refuel to avoid accidents.
Don’t use your phone while refuelling
As with regular fuel stations, you shouldn’t be on your phone while refuelling as there is a risk of incendive sparking.
Remember: refuelling a forklift is a routine operation in the workplace. Never forget that refuelling is hazardous and dangerous. So, it needs to be done responsibly and safely to prevent any accidents from taking place.
As the No. 1 forklift hire and sales company for Telford, Coventry, and Birmingham, don’t hesitate to get in touch with our friendly and expert team at West Mercia Fork Trucks for all your forklift needs by giving us a call on 0121 522 22 11 (Birmingham), 02476 440 050 (Coventry), or 01952 680 368 (Telford).
