22 Hazards, Refueling & Battery Charging Practice Questions & Answers

1. 1. A sit-down counterbalanced forklift starts to tip over sideways. What should the operator do?

   • A.Turn the steering wheel sharply in the opposite direction
   • B.Stand up and climb out over the overhead guard
   • C.Jump clear of the machine in the direction it is falling
   • D.Stay in the seat, hold on tight, brace your feet, and lean away from the fall✓ Answer

   Jumping puts the operator in the path of the descending overhead guard, which can crush them; staying belted in the seat and leaning away keeps the body inside the protected zone formed by the overhead guard and frame.

   Source: OSHA Powered Industrial Trucks eTool — Tipover procedures; 29 CFR 1910.178Report a problem with this question

2. 2. During a sideways tip-over, which way should a belted operator lean?

   • A.It makes no difference as long as the seat belt is fastened
   • B.Toward the direction of the fall so they can jump free
   • C.Straight forward over the mast
   • D.Away from the point of impact✓ Answer

   Leaning away from the impact keeps the operator's head and torso within the overhead guard's protective envelope and away from the ground and crush point.

   Source: OSHA Powered Industrial Trucks eTool — Tipover procedures; 29 CFR 1910.178Report a problem with this question

3. 3. Why does OSHA training tell forklift operators NOT to jump during a tip-over?

   • A.It is physically impossible to jump fast enough
   • B.The operator can be thrown down and pinned or crushed by the overhead guard as it hits the ground✓ Answer
   • C.Jumping is only dangerous on electric forklifts
   • D.Jumping voids the machine's warranty

   A tipping forklift falls faster than a person can jump clear, so a jumping operator typically lands where the heavy overhead guard comes down, causing fatal crush injuries.

   Source: OSHA Powered Industrial Trucks eTool — Tipover procedures; 29 CFR 1910.178Report a problem with this question

4. 4. What is the primary way a seat belt (operator restraint) protects a forklift operator in a tip-over?

   • A.It reduces fuel consumption
   • B.It prevents the engine from stalling
   • C.It keeps the operator inside the overhead guard's protective zone instead of being thrown out and crushed✓ Answer
   • D.It is required only for driving on public roads

   The restraint holds the operator in the seat within the survival space created by the overhead guard, so the body is not thrown into the path of the falling machine during a tip-over.

   Source: OSHA Powered Industrial Trucks eTool — Tipover procedures; 29 CFR 1910.178Report a problem with this question

5. 5. Before a forklift is driven into a parked highway trailer to load or unload, OSHA requires that:

   • A.The trailer's brakes be set and wheel chocks be placed under the rear wheels✓ Answer
   • B.The trailer's brakes be released so it can flex
   • C.The trailer doors be closed
   • D.The dock lights be turned off

   Setting the brakes and chocking the rear wheels stops the trailer from rolling away from the dock while the forklift's weight enters and exits it.

   Source: 29 CFR 1910.178(k)(1)Report a problem with this question

6. 6. Under 1910.178, before a forklift is driven over a dockboard or bridge plate, the operator must ensure it is:

   • A.Properly secured, driven over slowly, and not loaded beyond its rated capacity✓ Answer
   • B.Made of aluminum
   • C.Painted safety yellow
   • D.At least 10 feet long

   A secured, slowly crossed dockboard cannot shift or flip under the truck, and staying within its rated capacity prevents structural failure and a fall into the gap.

   Source: 29 CFR 1910.178(n)(11)Report a problem with this question

7. 7. When loading a trailer that is NOT coupled to a tractor, what precaution helps keep the trailer from tipping or moving?

   • A.Deflate the trailer tires
   • B.Remove the wheel chocks so it can settle
   • C.Support the front of the trailer with fixed jack stands to prevent nose-dive or landing-gear collapse✓ Answer
   • D.Load the trailer from front to back only

   An uncoupled trailer can nose-dive or its landing gear can collapse under the forklift's weight; fixed jack stands under the front support the load and keep the trailer level.

   Source: OSHA Powered Industrial Trucks eTool — Dock safety; 29 CFR 1910.178Report a problem with this question

8. 8. To avoid running off the edge of a loading dock, an operator should:

   • A.Rely on the horn to warn of the edge
   • B.Raise the forks high to see the edge better
   • C.Travel at full speed to cross the dock quickly
   • D.Stay aware of the dock edge, keep a safe distance, and never back over an unprotected edge✓ Answer

   Driving off a dock edge is a leading cause of forklift fatalities; maintaining edge awareness and a safe buffer, and never reversing over an open edge, prevents the truck from falling.

   Source: OSHA Powered Industrial Trucks eTool — Dock safety; 29 CFR 1910.178Report a problem with this question

9. 9. Before traveling with a raised mast or entering a doorway, the operator must check for:

   • A.Adequate overhead clearance for sprinkler pipes, lights, and door headers✓ Answer
   • B.The tire pressure
   • C.The radio volume
   • D.The color of the floor markings

   A raised mast or load can strike overhead obstructions such as sprinkler lines, lights, and door headers, causing damage, falling objects, or a snagged-load tip-over; the operator must confirm clearance first.

   Source: 29 CFR 1910.178(m); OSHA Powered Industrial Trucks eToolReport a problem with this question

10. 10. What is the purpose of the overhead guard on a forklift?

    • A.To shade the operator from sunlight
    • B.To provide a place to store tools
    • C.To improve fuel economy
    • D.To protect the operator from falling objects✓ Answer

    OSHA requires an overhead guard so that, if the load or other material falls, the guard absorbs and deflects it away from the operator; it is also what makes staying in the seat survivable in a tip-over.

    Source: 29 CFR 1910.178(e)(1)Report a problem with this question

11. 11. Running an LPG- or diesel-powered forklift inside an enclosed building without adequate ventilation is dangerous mainly because the exhaust contains:

    • A.Helium
    • B.Only harmless water vapor
    • C.Carbon monoxide (CO)✓ Answer
    • D.Oxygen

    Internal-combustion engines produce carbon monoxide, a toxic gas that binds to hemoglobin and starves the body of oxygen; enclosed areas need ventilation to keep CO from accumulating to dangerous levels.

    Source: 29 CFR 1910.178; OSHA carbon monoxide guidanceReport a problem with this question

12. 12. OSHA's permissible exposure limit (PEL) for carbon monoxide in general industry is:

    • A.500 ppm as an 8-hour average
    • B.5,000 ppm as an 8-hour average
    • C.50 ppm as an 8-hour time-weighted average✓ Answer
    • D.5 ppm as an 8-hour average

    OSHA sets the general-industry PEL for carbon monoxide at 50 ppm as an 8-hour time-weighted average; sustained exposure above this level can cause headache, dizziness, and eventually loss of consciousness.

    Source: 29 CFR 1910.1000 Table Z-1 (carbon monoxide, 50 ppm)Report a problem with this question

13. 13. Carbon monoxide from forklift exhaust is especially hazardous because it is:

    • A.Bright red and easy to see
    • B.Colorless and odorless, so it can build up undetected✓ Answer
    • C.Only produced by electric forklifts
    • D.Heavier than water and pools on the floor visibly

    Because carbon monoxide has no color, odor, or taste, workers get no natural warning as it accumulates, so it can reach toxic concentrations before anyone notices symptoms.

    Source: OSHA carbon monoxide guidance; 29 CFR 1910.178Report a problem with this question

14. 14. How should an operator check for a leak at an LP-gas cylinder connection on a forklift?

    • A.Apply a soapy-water solution and watch for bubbles✓ Answer
    • B.Sniff directly at the valve
    • C.Hold a lighted match near the fitting
    • D.Feel for cold with a bare hand

    LP gas is highly flammable, so an ignition source like a match could ignite a leak; soapy water safely reveals escaping gas as bubbles without any flame or spark.

    Source: 29 CFR 1910.110 / 1910.178 LP-gas safe practiceReport a problem with this question

15. 15. Before disconnecting an LP-gas cylinder from a forklift to replace it, the operator should first:

    • A.Lay the cylinder on its side with the valve pointing down
    • B.Puncture the cylinder to vent the gas
    • C.Close the cylinder service (shut-off) valve✓ Answer
    • D.Remove the pressure-relief valve

    Closing the service valve stops fuel flow so the coupling can be disconnected with only the small amount of gas trapped in the line escaping, minimizing the release of flammable gas.

    Source: 29 CFR 1910.110 / 1910.178 LP-gas safe practiceReport a problem with this question

16. 16. When an LP-gas cylinder is mounted on a forklift, it must be positioned (using the locating pin) so that the pressure-relief valve communicates with the:

    • A.Operator's seat
    • B.Liquid space at the bottom of the cylinder
    • C.Fill hose
    • D.Vapor space at the top of the cylinder✓ Answer

    The locating pin orients the cylinder so the relief valve vents from the vapor space; venting vapor rather than liquid propane discharges far less material and reduces the fire hazard if the valve opens.

    Source: 29 CFR 1910.110 / 1910.178(f) LP-gas cylinder mountingReport a problem with this question

17. 17. If an LP-gas cylinder is leaking and closing the valve does not stop it, the operator should:

    • A.Store it in a closed cabinet indoors
    • B.Keep operating the forklift to use up the gas
    • C.Move the cylinder to a safe, well-ventilated outdoor area away from ignition sources and report/tag it✓ Answer
    • D.Spray it with water and continue working

    Leaking LP gas is heavier than air and can pool and reach an ignition source and explode; moving the cylinder outdoors to a ventilated area away from ignition lets the gas disperse safely.

    Source: 29 CFR 1910.110 / 1910.178 LP-gas safe practiceReport a problem with this question

18. 18. Charging a lead-acid forklift battery requires good ventilation primarily because charging releases:

    • A.Hydrogen gas, which is explosive✓ Answer
    • B.Chlorine gas
    • C.Carbon monoxide
    • D.Nitrogen, which is inert

    Charging electrolyzes water in the electrolyte and liberates hydrogen gas, which is highly flammable and explosive in air, so 1910.178(g) requires adequate ventilation to disperse the fumes from gassing batteries.

    Source: 29 CFR 1910.178(g)(2)Report a problem with this question

19. 19. Under 1910.178(g), smoking in a battery charging area is:

    • A.Allowed once charging has finished
    • B.Allowed if the battery cover is closed
    • C.Prohibited✓ Answer
    • D.Allowed at least 10 feet from the charger

    Smoking is prohibited in charging areas because the hydrogen gas released during charging can be ignited by a lit cigarette or its spark, causing an explosion.

    Source: 29 CFR 1910.178(g)(10)Report a problem with this question

20. 20. Why should the charger be switched off before connecting or disconnecting the charging leads to a battery?

    • A.It is unnecessary; the order does not matter
    • B.To save electricity
    • C.To prevent an arc or spark at the connection that could ignite hydrogen gas✓ Answer
    • D.To reset the charge timer

    Making or breaking a live (energized) circuit produces an electrical arc or spark; 1910.178(g) requires precautions against sparks in charging areas because a spark can ignite the hydrogen released by the battery.

    Source: 29 CFR 1910.178(g)(11)Report a problem with this question

21. 21. OSHA requires battery-charging facilities to provide a means for:

    • A.Charging cell phones
    • B.Recycling cardboard
    • C.Storing propane cylinders
    • D.Flushing and neutralizing spilled electrolyte✓ Answer

    1910.178(g)(2) requires facilities for flushing and neutralizing spilled electrolyte because the electrolyte is sulfuric acid; prompt flushing (and eyewash for skin/eye contact) limits chemical burns and equipment corrosion.

    Source: 29 CFR 1910.178(g)(2)Report a problem with this question

22. 22. During battery charging, 1910.178(g) requires that vent caps be kept functioning and that the battery (or compartment) cover be:

    • A.Covered with a metal plate and tools
    • B.Sealed shut to keep out dust
    • C.Removed and thrown away
    • D.Kept open to dissipate heat and let gases escape✓ Answer

    Keeping vent caps working and the cover open lets built-up heat and hydrogen escape rather than accumulating; tools and metal objects must also stay off the battery top to avoid shorting cells and sparking.

    Source: 29 CFR 1910.178(g)(9) and (g)(12)Report a problem with this question

Practice questions modeled on the OSHA Powered Industrial Trucks standard (29 CFR 1910.178). Not affiliated with or endorsed by OSHA. Passing this practice test does not certify you to operate a forklift — federal law requires your employer to provide formal training and a hands-on evaluation. Always follow OSHA rules and your workplace procedures. Study the official standard at osha.gov. OSHA standard →