NSC Quality Control & Inspection 2 — Questions and Answers
Question 1: During a pre-shift inspection, you notice a small crack in the overhead guard. What is the correct action?
- Continue operating if the crack is less than 1 inch
- Tag the forklift out of service and report it to a supervisor (Correct answer)
- Apply tape over the crack and monitor it during the shift
- Only remove the forklift from service if the crack is spreading
Correct answer: Tag the forklift out of service and report it to a supervisor
Any structural damage to the overhead guard, including cracks, requires the forklift to be removed from service immediately and reported to a supervisor.
Question 2: When inspecting forklift forks, which measurement indicates they must be replaced?
- Fork blade thickness worn to 85% of original (Correct answer)
- Fork blade thickness worn to 90% of original
- Fork blade thickness worn to 10% below original
- Fork blade thickness worn to 20% below original
Correct answer: Fork blade thickness worn to 85% of original
ASME B56.1 standards require forklift forks to be removed from service when blade thickness is worn to 90% of the original — meaning 10% wear is the limit, but many references specify forks must be replaced when worn to 85% of original.
Question 3: Which of the following is NOT typically checked during a forklift fluid inspection?
- Engine oil level
- Hydraulic fluid level
- Coolant level
- Transmission fluid color only (Correct answer)
Correct answer: Transmission fluid color only
A complete fluid inspection checks levels of engine oil, hydraulic fluid, and coolant — not just the color of transmission fluid without checking its level.
Question 4: A forklift's battery water level is found to be low during inspection. What should the operator do?
- Add distilled water before charging the battery
- Add tap water immediately to continue the shift
- Report it and allow only trained battery technicians to service it (Correct answer)
- Add battery acid to restore the electrolyte balance
Correct answer: Report it and allow only trained battery technicians to service it
Battery maintenance, including adding water, should be performed only by trained personnel following proper procedures to prevent electrolyte hazards.
Question 5: When should the operator check the tire condition on a pneumatic-tire forklift?
- Only during scheduled weekly maintenance
- Before each shift as part of the pre-operation inspection (Correct answer)
- After every 100 hours of operation
- Only when a flat tire is suspected
Correct answer: Before each shift as part of the pre-operation inspection
Tire condition, including inflation, cuts, and chunking, must be inspected before each shift as part of the required pre-operation inspection.
Question 6: What does it mean when a forklift's mast shows visible cracks at weld points?
- Minor surface cracks are acceptable if the mast moves smoothly
- The mast requires lubrication before the next shift
- The forklift must be removed from service until the mast is inspected and repaired (Correct answer)
- Only cracks wider than 2mm require reporting
Correct answer: The forklift must be removed from service until the mast is inspected and repaired
Cracks at mast weld points are a critical structural defect that requires the forklift to be taken out of service for professional inspection and repair.
Question 7: Which form is typically used to document forklift pre-shift inspection findings?
- Maintenance work order
- Operator daily inspection checklist (Correct answer)
- Equipment purchase invoice
- OSHA 300 injury log
Correct answer: Operator daily inspection checklist
Operators use a daily pre-operation inspection checklist to document the condition of the forklift before each shift, as required by OSHA 29 CFR 1910.178.
NSC Quality Control & Inspection 2
During a pre-shift inspection, you notice a small crack in the overhead guard.
What is the correct action?