Forklift Test Questions 61–68 with Answers & Explanations

Quick answer: questions 61-68 of the forklift bank cover Inspection & Maintenance. The correct answer is marked under each question with the reasoning behind it — and the source for every fact. Watch items rated hard in this set: 2 of 8 trip test takers most.

Questions 61-68

Question 61: A warehouse wants to bolt on extra counterweight to raise a truck's rated capacity. Is this allowed?

• A. Yes, with a supervisor's sign-off
• B. Yes, if the weight is painted safety yellow
• C. No — trucks shall not be altered from the manufacturer's original configuration, and added counterweight requires the truck manufacturer's approval ✓
• D. Yes, as long as the total weight stays under 10,000 pounds

Answer: C — No — trucks shall not be altered from the manufacturer's original configuration, and added counterweight requires the truck manufacturer's approval. Trucks must not be altered so that parts change position from the original manufacturer configuration, nor by adding or eliminating parts — and additional counterweighting shall not be done unless approved by the truck manufacturer. Capacity is engineered, not improvised. Official outline

Question 62: A gasoline-approved truck is converted to run on liquefied petroleum gas. Under what condition may it be used?

• A. If the conversion kit cost more than $500
• B. If any mechanic confirms the fittings are tight
• C. Converted trucks may never be used again in any location
• D. If the complete conversion results in a truck embodying the features specified for LP or LPS designated trucks, with approved conversion equipment ✓

Answer: D — If the complete conversion results in a truck embodying the features specified for LP or LPS designated trucks, with approved conversion equipment. Gasoline-approved trucks may be converted to LP gas only when the complete conversion embodies the features specified for LP or LPS trucks, using approved conversion equipment. Properly converted, they may be used where G, GS, LP, and LPS designated trucks are specified. Official outline

Question 63: Where must battery charging installations be located?

• A. Anywhere near a dock door for ventilation
• B. In areas designated for that purpose ✓
• C. In the center of the warehouse for equal access
• D. Outdoors, uncovered, year-round

Answer: B — In areas designated for that purpose. Battery charging installations are located in areas designated for that purpose — dedicated spaces equipped for flushing and neutralizing spilled electrolyte, fire protection, protection of charging apparatus, and ventilation of gassing fumes. Smoking is prohibited in the charging area, and open flames, sparks, and electric arcs are guarded against. Official outline

Question 64: When replenishing electrolyte in a battery, the correct practice is:

• A. Pour acid into water — never water into acid ✓
• B. Pour water into acid to reduce splashing
• C. Mix acid and water simultaneously in a sealed drum
• D. Let the battery cool, then add dry acid crystals

Answer: A — Pour acid into water — never water into acid. When charging batteries, acid shall be poured into water; water shall not be poured into acid. Water into concentrated acid flash-boils and spatters electrolyte — a chemical-burn classic that this rule has prevented for a century. Official outline

Question 65: What equipment must be provided for handling batteries during change-out?

• A. Nothing — two workers can lift a battery by hand
• B. A conveyor, overhead hoist, or equivalent material handling equipment ✓
• C. A standard pallet jack
• D. Only insulated gloves

Answer: B — A conveyor, overhead hoist, or equivalent material handling equipment. A conveyor, overhead hoist, or equivalent material handling equipment shall be provided for handling batteries, and reinstalled batteries must be properly positioned and secured in the truck. Industrial batteries are far beyond manual-lift weight, and a shifted battery is both a crush hazard and an electrical one. Official outline

Question 66: Before changing or charging a battery on the truck, the operator must:

• A. Position the truck properly and apply the brake ✓
• B. Leave the engine idling to keep the lights on
• C. Park on a slight incline so electrolyte drains forward
• D. Remove the overhead guard for clearance

Answer: A — Position the truck properly and apply the brake. Trucks shall be properly positioned and the brake applied before attempting to change or charge batteries. Vent caps are checked to be functioning and battery compartment covers opened to dissipate heat — and tools and other metallic objects stay away from the top of uncovered batteries. Official outline

Question 67: Cleaning solvents for industrial trucks must have what flash point?

• A. Any flash point — solvents are rated by odor instead
• B. Low flash point, below 100 °F, for faster evaporation
• C. High flash point — at or above 100 °F; low flash point (below 100 °F) solvents shall not be used ✓
• D. Only water-based solvents of any kind

Answer: C — High flash point — at or above 100 °F; low flash point (below 100 °F) solvents shall not be used. Trucks are kept clean and free of lint, excess oil, and grease using noncombustible agents where possible; low flash point solvents (below 100 °F) are not used, while high flash point solvents (at or above 100 °F) may be used — with toxicity, ventilation, and fire precautions matched to the agent. Official outline

Question 68: A truck's exhaust starts emitting hazardous sparks or flames. What must happen?

• A. The truck continues working if it stays outdoors
• B. Reduce the load by half and continue to the end of the aisle
• C. Only the exhaust screen needs cleaning at the next weekly check
• D. The truck is immediately removed from service and not returned until the cause is eliminated ✓

Answer: D — The truck is immediately removed from service and not returned until the cause is eliminated. Any vehicle that emits hazardous sparks or flames from the exhaust system is immediately removed from service and not returned until the cause has been eliminated. The same immediate-stop rule applies to any part running above normal operating temperature in a way that creates a hazardous condition. Official outline

Answer key at a glance

Answer from memory first, then check the key — the fastest way to find which explanations you actually need to read in full.

Study notes for this set

If this set felt rough, drill the weak section directly: Inspection & Maintenance. When the explanations all read as "obviously", you are ready for the next block — everything is indexed in the Forklift Test question bank.