Theory Questions & Answers

Most special attachments increase the effective load centre distance, reducing the machine's rated capacity. Always refer to the attachment's load chart and the machine's data plate when fitting attachments.

For public highway travel, two-wheel high range mode is correct. Four-wheel drive modes and differential locks are designed for off-road or site conditions — using them on the road can damage drivetrain components and is not appropriate for normal highway use.

The SLI indicates the machine's stability condition and alerts the operator when they are approaching a condition of instability. It does not display exact weight — it is a stability warning device to prevent tip-over.

A continuous audible warning means the machine is approaching or has reached an unstable condition. STOP all movement immediately, then take corrective action — retract the boom, lower the load, or reduce the load weight to restore stability.

Extending the boom moves the load centre further from the machine, dramatically reducing stability. The rated capacity at extended reach is much lower than at fully retracted position — always consult the load chart.

On inclines with a load, always travel with the load facing uphill. This keeps the load on the uphill side preventing it slipping off the forks and maintaining the machine's stability. If vision is restricted going up, use a guide.

Approach as close as safely possible, then raise the boom to the required height, and only then extend over the stack. This minimises the time the machine is in a potentially unstable extended/raised configuration.

When travelling with a load, keep the load as close to the ground as possible with the boom fully retracted and sufficient back tilt applied. This keeps the centre of gravity as low and as far back as possible, maximising stability.

Forks should be adjusted centrally so that the load weight is distributed equally on each fork/attachment. This ensures load stability and prevents uneven stress on the fork arms and carriage.

If the load obscures forward vision, travel in reverse so you are looking in the direction of travel. If this is not possible due to the operation, use a banksman/guide to direct you safely.

Before travelling under any overhead obstruction, always verify that there is sufficient headroom for both the machine AND the load. Account for the full height including any elevated portion of the attachment or load.

Raising the load on an incline dramatically raises the centre of gravity and increases the risk of the machine tipping over sideways. Always keep the load at travel height or lower when on any incline.

When parked, the heel of the forks should be as low as possible with the tips touching the ground and the boom fully retracted. This presents no trip hazard and the machine is in the most stable resting position.

If a fault occurs, park the machine as safely as possible immediately and report the fault to your supervisor straight away. Never attempt repairs yourself and never continue to use a machine with a known fault.

The primary purpose of the pre-use inspection is to ensure the vehicle is in a safe operating condition before it is used. This protects the operator, other workers, and the public from risks caused by defective equipment.

Before loading any lorry, the lorry's engine must be stopped, the parking brake applied, and the wheels chocked. This prevents the lorry moving during the loading operation, which could cause a serious accident.

Turning with a load held high raises the centre of gravity and creates serious risk of the truck overturning sideways. Always lower the load to travel position before turning. This is one of the most common causes of forklift accidents.

Increasing the load centre (moving the load's centre of gravity further from the heel of the forks) reduces the machine's safe load carrying capacity. Always check the load chart for the actual capacity at the specific load centre distance.

A rating of 2500kg at 500mm load centre means the machine can safely lift up to 2500kg provided the boom is fully retracted AND the centre of gravity of the load is no more than 500mm from the heel of the forks. Extending the boom or increasing the load centre will reduce this figure.

The parking brake should always be applied when using hydraulic controls to ensure and maintain the truck's stability during hydraulic operations. When hydraulic functions are in use, the load and mast movement can cause the truck's center of gravity to shift, making it essential that the truck remains stationary and secure before raising, lowering or extending any load.

Operators must check the crane at the start of each shift, or whenever they take over a crane that has not already been inspected that day. This ensures any defects or faults are identified before the crane is used.

Park the crane safely and report the fault immediately. Never continue operating a crane with a known fault — faults must be assessed and repaired by a competent person before work can resume.

A lifting accessory is any item used to connect a load to the crane. This includes: slings (chain, wire rope, fibre), shackles, eyebolts, spreader beams, and lifting beams. All must be marked with their SWL and be in good condition.

The crane's maximum SWL (Safe Working Load) is the maximum load weight the crane is rated to handle safely. This must never be exceeded. Special attachments may reduce the effective SWL — always check the attachment's own rating.

Under Section 2 of the Health and Safety at Work Act 1974, the duty to ensure employees receive adequate training rests with the employer. Employers must provide information, instruction, training and supervision to ensure health and safety.

Most special attachments decrease the crane's effective load handling capacity because they add weight and/or change the effective load centre. Always check the attachment's specific SWL rating and subtract its weight from the crane's available capacity.

Section 7 of HSWA 1974 places a duty on every employee (and person at work) to take reasonable care for the health and safety of themselves AND of other persons who may be affected by their acts or omissions at work.

TRUE. Sudden crane movements generate dynamic (shock) loads that can be significantly higher than the static load weight. These shock loads can exceed the SWL of the lifting equipment and cause catastrophic failure. Always operate smoothly and avoid sudden movements.

All new multi-purpose slings use the Uniform load rating method (also known as the mode factor system). This provides a single SWL marking on the sling that covers its capacity in various configurations (straight pull, choker, basket etc.).

You should ALWAYS avoid lifting loads over people. If a load falls from height, it presents an immediately life-threatening risk to anyone below. Clear all personnel from the lift zone before any lifting operation begins.

NEVER operate the crane controls if the slinger/banksman is out of sight. If you lose visual contact, stop the crane immediately. Either the slinger must regain line-of-sight or a secondary communication/signalling system must be in place before proceeding.

If a 3-leg sling rated at 6 tonnes is used with only 2 legs, the SWL to apply is 4 tonnes. The SWL is proportional to the number of legs actually in use. Never assume a 3-leg SWL applies when using fewer legs.

'Stowed away' means: no tackle on the hooks, the hook raised above head height (out of pedestrian's reach), and the pendant stored to one side or the cab returned to the park position. This is the safe parked configuration for an overhead crane.

TRUE. As the angle between sling legs increases, the tension in each leg increases dramatically. Beyond 60° from vertical the SWL must be de-rated. Beyond 90° the forces can exceed the weight of the load itself — this is why sling angles must always be calculated.

The normal safe working angle from vertical for multi-leg chain slings is 0–45 degrees. Beyond 60° the load on the sling legs increases sharply and the SWL must be significantly reduced. The SWL marked on slings is typically rated at 0–45° from vertical.

FALSE. Unmarked slings must NEVER be used for lifting. All lifting accessories must be clearly marked with their SWL (Safe Working Load). If the SWL is unknown, the sling cannot be used safely — it must be removed from service.

The correct action when a load starts to swing is to wait until it stops swinging naturally. Do NOT try to counteract the swing by moving the crane — this can increase the swing amplitude and generate additional shock loads. Let the load settle, then continue carefully.

The crane operator should vary speed according to working conditions. Speed must be reduced near obstructions, other workers, or when manoeuvring in confined spaces. A constant or unnecessarily slow speed is not always appropriate — the key is safe and controlled movement at all times.

Under LOLER (Lifting Operations and Lifting Equipment Regulations 1998), lifting accessories (slings, shackles, etc.) must be thoroughly examined by a competent person at least every 6 months. Records of all examinations must be kept.

Overhead cranes should not approach within 10 feet (approximately 3 metres) of people working at height. This exclusion zone protects workers from the risk of being struck by the crane structure or suspended loads. Always maintain the exclusion zone.