Question 1

According to OSHA, how often must a forklift be inspected?

Accepted Answer

OSHA 1910.178(q)(7) requires that industrial trucks be examined before being placed in service. If used on a round-the-clock basis, they must be examined after each shift.

Question 2

If a safety-related defect is found during the pre-operation inspection (e.g., the horn doesn't work), the operator must:

Accepted Answer

Any vehicle in need of repair, defective, or in any way unsafe shall not be driven. It must be taken out of service immediately.

Question 3

When inspecting pneumatic tires, you should check for:

Accepted Answer

Pneumatic tires rely on air pressure for stability. Low pressure, damage, or missing hardware can cause instability or tire failure.

Question 4

For solid cushion tires, a common removal criteria is 'chunking'. This means:

Accepted Answer

Chunking causes uneven travel and vibration, potentially destabilizing a load. Tires with significant missing rubber chunks must be replaced.

Question 5

When inspecting the forks, you are looking for:

Accepted Answer

The heel of the fork takes the most stress.  Cracks, bends, or wear >10% reduce the safe lifting capacity significantly.

Question 6

The lift chains should be checked for:

Accepted Answer

Chains must be lubricated and hang with equal tension. If one is loose, the other takes all the load, risking breakage.

Question 7

If the hydraulic system is leaking oil on the floor, the operator should:

Accepted Answer

Leaks create slip hazards and indicate a failure in the lifting or braking systems. The truck is unsafe to operate.

Question 8

When checking the propane (LPG) tank, the relief valve cap must be pointed:

Accepted Answer

The relief valve must communicate with the vapor space of the tank, not the liquid fuel. The tank's locating pin ensures proper orientation.

Question 9

Which of the following is an 'Engine On' inspection item?

Accepted Answer

Brakes, steering, lift/tilt controls, and gauges require the engine/motor to be running to verify proper function.

Question 10

The overhead guard must be inspected for:

Accepted Answer

The overhead guard is critical safety equipment for falling object protection. Structural damage compromises its ability to protect the operator.

Question 11

Fork latch pins (locking pins) must be:

Accepted Answer

Latch pins prevent the forks from sliding sideways loosely on the carriage. If missing, a fork could slide off during a turn.

Question 12

If the brake pedal goes all the way to the floorboard when pressed:

Accepted Answer

This indicates master cylinder failure, a leak, or air in the lines. The truck has no reliable stopping power.

Question 13

On an electric forklift, checking the battery includes:

Accepted Answer

Visual inspection of cables for fraying and checking water levels (after charging) ensures the power source is safe.

Question 14

Why must the seatbelt be inspected?

Accepted Answer

Seatbelts are the primary life-saving device in a tip-over. If damaged/non-functional, the truck is unsafe to operate.

Question 15

If you hear a hissing sound coming from the LPG tank connection:

Accepted Answer

Hissing indicates a gas leak. If hand-tightening the coupler doesn't stop it, the O-ring or valve is defective. Do not operate.

Question 16

When checking the mast operation, you should verify:

Accepted Answer

The inspection includes testing the full range of hydraulic functions to ensure smooth, leak-free operation.

Question 17

For Internal Combustion trucks, checking the engine oil level should be done:

Accepted Answer

Engine oil is checked with the engine off (and ideally cool) to get an accurate dipstick reading.

Question 18

Excessive 'play' (looseness) in the steering wheel:

Accepted Answer

Excessive play indicates worn steering components (tie rods, steering gear), which can lead to loss of control.

Question 19

Sparks or flames coming from the exhaust (internal combustion) indicate:

Accepted Answer

Sparks violate fire safety standards, especially in hazardous locations. The truck requires maintenance.

Question 20

If a forklift is found to be overheating during the shift, the operator must:

Accepted Answer

Overheating indicates a mechanical failure. Continuing to operate risks engine seizure or fire.

Question 21

Checking the 'Data Plate' (Capacity Plate) during inspection is important to:

Accepted Answer

If the plate is unreadable or doesn't list the current attachment, the operator cannot safely determine lifting capacity.

Question 22

The parking brake must be capable of holding the truck:

Accepted Answer

The parking brake must be verified to hold the truck on the steepest slope it operates on.

Question 23

Are you required to inspect the lights?

Accepted Answer

If the truck has lights (headlights, taillights, warning lights), they must be functioning. If working in low light (less than 2 lumens/sq ft), lights are mandatory.

Question 24

Inspection of the fork 'heel' typically requires replacement if wear exceeds:

Accepted Answer

ANSI B56.1 (incorporated by reference) states that 10% wear reduces the lifting capacity by 20% and requires fork replacement.

Question 25

What should you check regarding the battery plug connection?

Accepted Answer

Damaged connectors can cause arcing, overheating, or loss of power.

Question 26

If a pneumatic tire looks low on air:

Accepted Answer

Visual estimation is inaccurate. A gauge must be used to verify it meets the psi listed on the tire/data plate.

Question 27

The Load Backrest must be checked to ensure:

Accepted Answer

The backrest prevents the load from falling on the operator. It must be secure and undamaged.

Question 28

When inspecting hoses and lines (hydraulic), look for:

Accepted Answer

Damaged hoses can burst under pressure, dropping the load or spraying hot fluid.

Question 29

A 'spongy' feel in the brake pedal usually indicates:

Accepted Answer

Air is compressible; hydraulic fluid is not. Air in the lines delays braking action and is a safety defect.

Question 30

If the forklift emits excessive smoke (internal combustion):

Accepted Answer

Excessive exhaust/smoke indicates poor combustion, increasing CO hazards for indoor workers.

Question 31

Documentation of daily inspections is:

Accepted Answer

OSHA 1910.178(q)(7) requires exams to be *made*, but does not explicitly state a *written* record is required (unlike cranes). However, nearly all corporate policies require written logs.

Question 32

The horn must be tested to ensure:

Accepted Answer

The horn is a critical warning device for intersections and blind spots.

Question 33

Checking for 'drift' in the lift cylinder involves:

Accepted Answer

Drift indicates internal seal leakage in the hydraulic cylinder or valve, which can cause a load to drop unexpectedly.

Question 34

If a forklift has been modified with a hole drilled in the overhead guard:

Accepted Answer

Modifications affecting strength or safety require manufacturer approval.

Question 35

Before operating a forklift found to be safe, the operator should also:

Accepted Answer

The final step of pre-op prep before moving is securing the restraint system.

Pre-Operation Inspection Practice Questions

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