UK CPCS Forklift Theory Exam cheat sheet

Health and Safety at Work etc. Act 1974 places a general duty on employers to ensure, so far as is reasonably practicable, the health, safety and welfare of employees and others affected by the work.

The Management of Health and Safety at Work Regulations 1999 require suitable and sufficient risk assessment and the appointment of competent persons.

Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) require lifting equipment to be strong and stable, marked with safe working load, and thoroughly examined at statutory intervals.

Provision and Use of Work Equipment Regulations 1998 (PUWER) require work equipment to be suitable, maintained, inspected and used only by trained and authorised people.

The Approved Code of Practice L117 supports rider-operated lift trucks under PUWER and covers training, authorisation and supervision of operators.

LOLER thorough examination intervals: 6 months for equipment lifting people or with lifting accessories; 12 months for other lifting equipment, or as stated in the examination scheme.

The Control of Substances Hazardous to Health Regulations 2002 apply to fuel, battery acid, oils and exhaust emissions; diesel exhaust is a recognised occupational carcinogen.

Environmental duties include correct disposal of waste oil, batteries and filters, spill containment, and preventing fuel or hydraulic oil reaching drains or watercourses.

The Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 2013 (RIDDOR) require reporting of specified workplace incidents to the enforcing authority.

Operators must be trained, competent and specifically authorised in writing by their employer for each type of truck they use.

An operator is responsible for the pre-use inspection of the truck and must not use equipment found defective; defects must be reported and the truck taken out of service.

Operators must follow the site's safe system of work, including speed limits, one-way routes, pedestrian priority and designated parking areas.

An operator must never carry passengers unless the truck is designed and equipped with a suitable passenger seat.

Operators must not operate a truck while under the influence of alcohol, drugs or medication that impairs judgement or reaction.

Seat belts, where fitted, must be worn whenever the truck is in motion, unless a documented risk assessment justifies otherwise.

Operators must keep the load, forks and attachments within the truck's rated capacity and within the site's height and route restrictions.

Operators must report all accidents, near misses, damage and defects promptly, including to the next shift or supervisor at handover.

A safe system of work is a documented method of working that identifies hazards, controls and the sequence of operations for a task.

Site traffic management schemes separate pedestrians and vehicles using barriers, marked walkways, crossing points, mirrors and speed limits.

Pedestrians have priority in designated areas; the operator must make eye contact and receive acknowledgement before passing.

Permit-to-work systems are required for high-risk tasks such as working near overhead power lines, confined spaces or hot work.

Exclusion zones must be maintained around the truck's slewing or lifting area; a banksman is used where visibility is restricted.

Site speed limits, floor loadings, headroom clearances and bridge or ramp weight limits must be checked and obeyed.

Vehicles must be parked on level ground with forks lowered, mast tilted forward, controls neutralised, parking brake applied and keys removed.

Visitors and contractors must be inducted and escorted where required; unauthorised use of trucks is a disciplinary matter.

Counterbalance trucks lift loads outside the wheelbase and rely on rear counterweight; reach trucks use a moving mast to place loads inside the wheelbase.

Common truck types include counterbalance (diesel, LPG, electric), reach, order picker, pallet truck, side loader and telehandler.

Key controls: accelerator, brake, inching/clutch pedal, direction lever, hydraulic lift/tilt/auxiliary levers, parking brake and horn.

A pre-use check covers tyres and wheels, forks and heels, mast chains and tension, hydraulic hoses, fluid levels, battery, seat, seat belt, lights, horn, brakes and steering.

Fork heel wear limit: fork thickness at the heel should not be reduced by more than 10 percent of the original dimension.

Mast chain tension should be even on both chains; loose or damaged chains, or a stretched chain, require the truck to be taken out of service.

Battery charging areas must be ventilated to disperse hydrogen; no smoking or naked flames, and eyewash and spill kits must be available.

Any defect found in a pre-use check must be recorded, reported and the truck isolated until repaired and re-checked.

Stability is maintained when the combined centre of gravity of truck and load stays inside the stability triangle formed by the two front wheels and the steer axle pivot.

Load moment = load weight x distance from the front wheel (load centre); the rated capacity decreases as the load centre distance increases.

The load chart or capacity plate states rated capacity at a stated load centre, usually 500 mm or 600 mm, and at a stated lift height.

A truck's rated capacity is reduced when attachments such as clamps, rotators or extension forks are fitted; the attachment's own weight and increased load centre must be deducted.

Travelling with a load: keep it low, typically 100-150 mm above the floor, with the mast tilted back, and never travel with the load raised.

The forklift is least stable when unladen (rear-heavy) during fast turns, and when laden with the load raised or the mast tilted forward.

Loads must be stable, secured, within the truck's capacity, and the forks fully under the load with the load against the fork carriage.

Never lift people on forks; use a purpose-built access platform or order picker with a cage and restraint.

Travelling forward up a gradient with a load and in reverse down a gradient keeps the load on the uphill side; gradients are normally limited to about 10 percent unless the manufacturer permits more.

Travel with the load low and tilted back; look in the direction of travel and use mirrors where fitted; if the load obstructs forward vision, travel in reverse.

Reduce speed before turns; a laden truck turning at speed can tip over sideways because the centre of gravity moves outside the stability triangle.

Maintain a safe following distance of at least three truck lengths and never overtake another moving truck at a junction or blind corner.

Sound the horn at blind corners, doorways and crossings, and slow to walking pace where pedestrians may be present.

On ramps and inclines, drive straight up and down, not across; do not turn on a slope; keep the load on the uphill side.

Parking: level ground, forks flat on the floor, mast tilted forward, parking brake on, controls neutral, key removed and truck left in a designated area.

When leaving the truck unattended, even briefly, isolate the power source and remove the key to prevent unauthorised use.

Traffic management measures include speed limits, one-way systems, pedestrian barriers, marked crossings, mirrors and designated loading bays.

First actions after an incident: stop the truck safely, make the area safe, give first aid, call emergency services if needed, and preserve the scene.

Report the incident to the supervisor immediately and record it in the accident book; RIDDOR-reportable events include deaths, specified injuries, over-seven-day injuries and dangerous occurrences.

A tip-over in a counterbalance truck: stay in the seat, hold on, brace and lean away from the direction of the fall; do not jump out.

In a tip-over with a seat belt, keep the belt fastened and stay in the cab; jumping out is a leading cause of fatal crush injuries.

Fire: raise the alarm, switch off the ignition, use the correct extinguisher (CO2 or dry powder for electrical and fuel fires) and evacuate to the assembly point.

Battery acid spill: use the spill kit, neutralise with a suitable agent, avoid skin contact, and dispose of waste as hazardous waste.

Fuel or hydraulic oil spill: stop the leak, contain with absorbent material, prevent entry to drains, and report to the environmental responsible person.

Near misses must be reported and investigated; they are leading indicators and often precede serious incidents.

All incidents, damage and near misses must be recorded and investigated to identify root causes and prevent recurrence.