Using Propane Safely e-learning reference material

Guide Book Series

Fork lift trucks

Fork Lift Trucks Key safety issues

A full fork lift truck cylinder weighs approximately 36kgs. The manual handling aspect of the cylinder changeover must be risk assessed and it is advisable that two trained operators are available to undertake the removal of the ‘empty’ cylinder and the lifting and securing of the new ‘full’ cylinder into the cradle on the rear of the vehicle. The cylinder must be loaded so that the arrow on the base of the cylinder is pointing downwards (towards 6 o’clock). This ensures that the dip tube inside the cylinder points downwards and will work effectively. The cylinder must be restrained with a strap that is in good condition. The operator should check that there is an ‘O’ ring washer inside the hose connector and that it is in good condition. The hose may be screwed onto the cylinder valve outlet. This connection is usually secured ‘hand-tight’. The cylinder valve may then be slowly opened to avoid a sudden rush of liquid into the hose. The valve may be opened fully and then turned back half a turn. After the valve has been opened the operator should now leak test the connection between the valve outlet and the hose with an approved leak test soluion or spray. If any bubbles are visible the valve should be closed and the leak corrected.

This information is for guidance only. Operators should always follow the vehicle manufacturer’s instructions as well as an authorised standard operating procedure for the cylinder change-over. The cylinder changeover must only be undertaken in a safe, well ventilated area by trained operators who are wearing the correct personal protective equipment. Safety glasses are essential when working with pressurised propane cylinders that contain very cold liquid

Propane cylinders for use on fork lift trucks are designed to be used horizontally. The gas pressure above the liquid forces the liquid through a dip tube, down the hose and into the engine. Unlike ‘standard’ propane cylinders which have left hand connections, the majority of the cylinders that are designed for fork lift trucks have right hand connections. When the ‘in-use’ cylinder has ‘run-out’ operators should ensure that they have a tight hold on the hose when they unscrew the connection with the cylinder as there may be some residual gas inside the hose. Before changing the cylinder operators must ensure that they have a full cylinder that not only contains the correct gas (reference must be made to the cylinder label or stencilling on the side of the cylinder) but is also designed for use on a fork lift truck. After removing the valve protector, the operator should visually inspect the valve for damage and/or contamination. If either is found the cylinder must not be used. If niether is found then the cylinder can be loaded onto the cylinder cradle.

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