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Question 1Site Setup and Inspection
Where should the operator find the maximum allowable ground slope for setting up a specific lattice boom crawler crane?
- In the rigging plan approved by the lift director
- In the crane's most recent periodic inspection report
- On the project's site grading and drainage plan
- In the manufacturer's operator's manual Correct answer.
Explanation
Leveling tolerances are machine-specific and are published by the manufacturer; the load chart is valid only when the crane is set up within that tolerance. Site drawings and lift plans must be consistent with the manufacturer's value but do not establish it.
Question 2Site Setup and Inspection
What must be done before a crawler crane is set up on ground that may contain buried utilities?
- Lay steel plates over the area to spread the track load
- Have the utilities located and marked before setup Correct answer.
- Backfill the area with compacted gravel to protect the buried lines
- Set up the crane and watch the ground for movement during the lift
Explanation
Buried gas, electric, water, and sewer lines can be crushed or ruptured by concentrated track loads, so they must be located and their position verified before the crane is placed. Covering the area does not establish where the lines run.
Question 3Site Setup and Inspection
What is the primary purpose of placing timber or steel mats under crawler tracks?
- To protect the track shoes from abrasive ground
- To spread the load and reduce ground bearing pressure Correct answer.
- To raise the crane so the boom can be assembled more easily
- To keep the tracks level when the ground is sloped
Explanation
Ground bearing pressure equals weight divided by contact area, so increasing the contact area with mats lowers the pressure the soil must carry. Mats do not correct a slope; the crane still has to be leveled within the manufacturer's tolerance.
Question 4Site Setup and Inspection
During a walk-around of a proposed setup location, the operator finds a patch of standing water and deep wheel ruts left by a previous crew. What is the appropriate action?
- Set up on the firm side and keep the boom over that track
- Treat the area as unsuitable and relocate the crane Correct answer.
- Proceed with setup and add extra timber mats under both tracks
- Set up and limit the load to 75 percent of chart capacity
Explanation
Standing water and ruts indicate soft soil whose bearing capacity is unknown and likely inadequate; the load chart assumes a firm, level surface. Mats cannot be sized without knowing the soil capacity, and no load reduction substitutes for suitable ground.
Question 5Site Setup and Inspection
When a crane is set up on a site where other trades are working nearby, what is required around the rotating superstructure?
- A barricade or controlled access marking the swing radius Correct answer.
- A six-foot chain link fence around the whole site
- A warning sign posted at the operator's cab door
- Nothing, as long as the operator sounds the horn before swinging
Explanation
The swing radius must be barricaded or controlled so that personnel cannot be struck or crushed between the rotating superstructure, counterweight, and fixed objects. A sign or horn does not physically prevent someone from entering the hazardous area.
Question 6Site Setup and Inspection
Who performs the required daily inspection of a crawler crane at the start of each shift?
- The lift director
- The manufacturer's field service technician
- The operator assigned to the crane Correct answer.
- The site safety officer
Explanation
The crane must be inspected at the start of each shift by the operator or another designated person before it is used. The inspection covers the items that could affect safe operation that day, such as the boom, wire rope, tracks, and safety devices.
Question 7Site Setup and Inspection
Why must a crawler crane be level before making a lift?
- It side-loads the boom and invalidates the load chart Correct answer.
- An unlevel crane consumes more hydraulic oil
- It is needed only to keep the operator's seat comfortable
- It keeps the boom from contacting the ground while the crane travels
Explanation
Rated capacities assume the crane is level within the manufacturer's tolerance. When the machine is tilted, the boom and load induce side loading and the actual radius and capacity no longer match the chart.
Question 8Site Setup and Inspection
What is a basic requirement for the area where a lattice boom will be assembled on the ground?
- It must be at least 100 feet from the crane
- It must be firm, level, and clear overhead Correct answer.
- It must be paved with reinforced concrete
- It must be sloped so that water drains toward the crane
Explanation
Boom sections are laid out and pinned on the ground before being raised, so the assembly area must support the sections and the assist equipment and be free of power lines and other overhead obstructions. It must also be level enough that sections are not side-loaded during assembly.
Question 9Site Setup and Inspection
A crawler crane and its load total 240,000 lb, carried equally on two tracks. Each track is 3 ft wide and 20 ft long. What is the approximate average ground bearing pressure under each track?
- 1,000 psf
- 4,000 psf
- 2,000 psf Correct answer.
- 8,000 psf
Explanation
Each track carries 240,000 divided by 2, or 120,000 lb. The contact area of one track is 3 ft times 20 ft, or 60 sq ft, so the average pressure is 120,000 divided by 60, or 2,000 psf.
Question 10Site Setup and Inspection
A track carries 150,000 lb and the soil can support 2,500 psf. The track itself covers 40 sq ft. What minimum mat area is required under that track?
- 75 sq ft
- 60 sq ft Correct answer.
- 120 sq ft
- 45 sq ft
Explanation
Required bearing area equals load divided by allowable soil pressure: 150,000 divided by 2,500 equals 60 sq ft. Because the track alone provides only 40 sq ft, the mats must present at least 60 sq ft of contact area under that track.
Question 11Site Setup and Inspection
A crawler crane must be set up near an open excavation that is 12 ft deep in firm clay. Which setup is acceptable?
- Tracks set back at least the excavation depth Correct answer.
- Tracks at the edge with the spoil pile on the far side
- Tracks 3 ft from the edge with timber mats under them
- Tracks 6 ft from the edge with timber mats under them
Explanation
An adjacent excavation removes lateral support, and the crane's surcharge can trigger a slope failure; common practice is to set back a distance at least equal to the depth, confirmed by a competent person or geotechnical evaluation. Matting does not compensate for an unstable excavation wall.
Question 12Site Setup and Inspection
After two days of heavy rain, a crew returns to a site where the crane was set up on graded fill. What should be done before lifting?
- Nothing needs to be done as long as the mats are still in place
- Increase the counterweight to compensate for soft ground
- Inspect the ground and mats for settlement and washout Correct answer.
- Reduce the load to 50 percent for the first lift
Explanation
Water softens fill and can wash soil from beneath mats, causing settlement that takes the crane out of level. The setup must be re-inspected and corrected before the load chart applies again.
Question 13Site Setup and Inspection
Why is setting a crawler crane over a buried foundation, septic tank, or old basement a concern?
- The crane's load chart is reduced when the ground is paved
- The structure can collapse under the track load and drop the crane Correct answer.
- Concrete rubble will damage the track shoes
- The buried structure will interfere with the crane's electrical system
Explanation
Hidden voids and buried structures give no surface indication of their presence and can fail suddenly under concentrated track loads, tilting or overturning the crane. Such areas must be identified and either avoided or bridged with engineered matting.
Question 14Site Setup and Inspection
A geotechnical report shows the soil at a setup location can support 1,200 psf, but the crane will impose 3,000 psf. What is the appropriate response?
- Spread 6 inches of loose gravel over the setup area
- Use mats sized to reduce pressure to 1,200 psf or less Correct answer.
- Set up anyway and limit swing and travel speeds
- Keep the boom positioned over the stronger track at all times
Explanation
The imposed pressure must be brought below the soil's allowable capacity, which is done by increasing the bearing area with properly sized mats or crane pads (or by improving the soil under engineering direction). Operating techniques and loose gravel do not increase soil capacity.
Question 15Site Setup and Inspection
Before reusing timber crane mats under the tracks, what should be checked?
- That each mat is at least 12 inches thick
- That they are laid with gaps between them for drainage
- That they are sound and laid so that they cannot shift Correct answer.
- That they are painted and marked with the owner's name
Explanation
Mats must transmit load without crushing or displacing; decayed or split mats crush under track loads, and poorly fitted mats shift and create point loading. Sound mats laid tightly together provide a continuous bearing surface.
Question 16Site Setup and Inspection
Under OSHA's crane standard, what minimum clearance must be maintained between a crane and an energized power line rated 120 kV?
- 20 ft
- 10 ft
- 15 ft Correct answer.
- 25 ft
Explanation
OSHA's Table A requires 15 ft of clearance for lines rated over 50 kV up to 200 kV. The 10-ft distance applies only to lines of 50 kV or less, and greater clearances apply above 200 kV.
Question 17Site Setup and Inspection
Which condition most directly affects whether a crawler crane can be walked to a new location on the same site?
- The number of boom sections currently pinned in
- The distance to the nearest concrete batch plant
- The number of personnel working in the area
- The bearing capacity and slope of the travel route Correct answer.
Explanation
Manufacturers limit the ground slope and ground condition on which a crawler may travel, and the travel path must be able to carry the track loads. Boom configuration is addressed in the travel chart, but ground slope and capacity are the controlling site conditions.
Question 18Site Setup and Inspection
Why is a setup on frozen ground potentially unsafe as the weather warms?
- The crane's hydraulic oil will freeze and stop flowing
- Frozen ground always has lower bearing capacity than thawed ground
- Thawing soil can lose strength and let the crane settle unevenly Correct answer.
- Track shoes lose traction only below zero degrees Fahrenheit
Explanation
Frozen soil can be strong while frozen but becomes soft and compressible as it thaws, especially under the crane's weight and vibration. Differential settlement under one track can tilt the crane outside its leveling tolerance.
Question 19Site Setup and Inspection
During a lift, the operator notices one track sinking into the ground and the level indicator moving off center. What should the operator do?
- Finish the lift quickly and then inspect the ground
- Ask the signal person to watch the sinking track
- Continue the lift but reduce the swing radius
- Stop, land the load, and shut down until the ground is corrected Correct answer.
Explanation
Progressive settlement means the crane is losing level and stability, which can lead to a tipping failure. The lift must be stopped and the load set down before the setup is repaired and re-verified.
Question 20Site Setup and Inspection
Who should determine whether a filled or graded area can support a crawler crane?
- A geotechnical engineer using soil data or testing Correct answer.
- The crane operator, using the bubble level on the crane
- The signal person, using the load chart
- The rigging crew, using visual inspection of the surface
Explanation
Bearing capacity depends on soil type, moisture, and compaction, which require engineering evaluation or field testing. Visual inspection and the crane's level indicator show surface conditions but cannot quantify capacity.
Question 21Site Setup and Inspection
A crane is set up on a 1.5 percent cross slope because the site plan calls for drainage in that direction. The manufacturer's limit is 1 percent. What is the correct action?
- Do not lift until the crane is within tolerance Correct answer.
- Lift only loads under 50 percent of the chart rating
- Lift at 90 percent of the chart rating to account for the slope
- Lift only with the boom pointed downhill
Explanation
The rated load chart is valid only when the crane is level within the manufacturer's stated tolerance. Exceeding that tolerance introduces side loading and invalidates the ratings; no arbitrary derating formula substitutes for bringing the crane within the limit.
Question 22Site Setup and Inspection
Why can ground pressure under a crawler track be much higher than the average calculated from total weight and track area?
- The load chart already includes a ground pressure allowance
- The load concentrates under rollers and shifts with boom position Correct answer.
- Track shoes are made of high-strength steel
- The counterweight is always carried over one track
Explanation
Average pressure assumes uniform distribution, but track loading is non-uniform: the center of gravity shifts as the boom and load move, and peak pressures occur under rollers and near track ends. Pads and mats must be evaluated for these peak pressures, not the average.
Question 23Site Setup and Inspection
A crawler crane will be set up next to a retaining wall that supports a roadway. What must be done before setup?
- Nothing, because the wall carries its own load
- Assign a worker to watch the wall during the lift
- Place mats against the wall to brace it
- Have the wall's capacity evaluated for the crane's surcharge load Correct answer.
Explanation
Crane loads near a retaining wall add surcharge that increases lateral earth pressure behind the wall. The wall must be evaluated for that additional load before the crane is placed; an observer is not a substitute for an engineering assessment.
Question 24Site Setup and Inspection
Before the first lift at a new setup, which set of items best confirms that the setup has been verified?
- Ground evaluated, mats sized, crane leveled, inspection completed Correct answer.
- The site is fenced and the load is rigged
- The boom is assembled and the counterweight is installed
- The crane is level and the operator is certified
Explanation
Setup verification is a series of independent requirements: ground bearing capacity confirmed, mats or pads sized to the load, the crane leveled within the manufacturer's tolerance, and the pre-lift inspection completed. No single item satisfies the others.
Question 25Site Setup and Inspection
A lattice boom crawler crane will be set up in an open area where high winds are forecast overnight and the crane will stand unattended. What is the primary concern?
- Wind matters only when a load is suspended on the hook
- Wind cools the hydraulic oil, which reduces lifting capacity
- The boom's exposed area can catch wind and overturn the crane Correct answer.
- Wind has no effect on a crawler crane because the tracks rest on the ground
Explanation
A lattice boom presents a large sail area, and wind can overturn or damage an unattended crane even with no load on the hook. Manufacturers publish out-of-service wind procedures, such as lowering the boom, that must be followed.
Question 26Site Setup and Inspection
What is the primary purpose of barricading the swing radius of a crawler crane at a setup?
- To mark the site property line for the customer
- To designate where rigging is staged during the shift
- To prevent the operator from swinging over the site fence
- To keep people out of the path of the rotating counterweight Correct answer.
Explanation
The rotating upperworks and counterweight create a crush zone that extends beyond the tracks, so access to that area must be controlled during operation. Barricading the swing radius is a setup requirement aimed at personnel protection, not property marking or material storage.
Question 27Site Setup and Inspection
Before a crawler crane is set up on a site where buried utilities may exist, what should be done first?
- Assume that buried utilities run only in the street
- Ask the client whether any lines are buried on the site
- Probe the ground with a bar across the setup area
- Have the utility owners locate and mark the buried lines Correct answer.
Explanation
Buried lines must be located and marked by the utility owners or a qualified locating service so the crane is not set up or walked over them. Verbal assurances and manual probing are not accepted substitutes and can result in a strike.
Question 28Site Setup and Inspection
What fire protection is required on a crawler crane at a setup?
- A fire blanket stored in the toolbox
- A charged extinguisher rated for the hazard, kept within reach Correct answer.
- A charged water hose connection located within 50 ft of the crane
- A fire watch posted at the crane during all lifting
Explanation
Cranes must carry a fire extinguisher that is rated for the hazards present, maintained in a charged condition, and accessible to the operator. Site hoses, fire watches, or blankets are not substitutes for the on-board extinguisher.
Question 29Site Setup and Inspection
What is the purpose of the anti-two-block device on a lattice boom crane?
- It locks the swing brake whenever the crane is out of level
- It prevents the boom from being lowered below a set angle
- It limits the load to the crane's rated capacity
- It stops hoisting before the load block reaches the boom tip Correct answer.
Explanation
The device senses when the load block approaches the boom tip and interrupts the hoist function before contact occurs. Two-blocking shock-loads the boom hoist rope and reeving and can cause serious damage.
Question 30Site Setup and Inspection
What does the level indicator on a crawler crane tell the operator?
- Whether the boom is at the radius shown on the load chart
- Whether both tracks carry equal shares of the crane's weight
- Whether the crane is level within the manufacturer's tolerance Correct answer.
- Whether the load on the hook is balanced front to back
Explanation
The level indicator shows whether the upperworks is within the out-of-level tolerance allowed by the manufacturer, which must be satisfied before lifting. It does not measure load balance, track loading, or operating radius.
Question 31Site Setup and Inspection
A crawler crane will make lifts after dark. What must be provided?
- A handheld flashlight carried by the signal person
- Reflective tape applied to the counterweight
- Flashing amber beacons mounted on the boom tip
- Lighting that covers the load path, the landing area, and the controls Correct answer.
Explanation
Night operations require lighting sufficient for the operator to see the load, the landing area, and the machine controls. Marking the crane with reflective material or beacons improves visibility of the machine but does not illuminate the work.
Question 32Site Setup and Inspection
What is the purpose of placing timber or steel mats under a crawler crane's tracks?
- To reduce the crane's overall weight on the ground
- To protect the track pads from abrasive soil
- To spread the track load over a larger soil area Correct answer.
- To raise the crane's center of gravity
Explanation
Mats increase the area over which the track load is distributed, lowering the pressure applied to the soil to a level it can support. They do not change the crane's weight or improve stability by raising the center of gravity.
Question 33Site Setup and Inspection
What condition must a crane hook's latch be in before lifting?
- It must be painted a contrasting color
- It must be wired open so slings can be attached quickly
- It must be removed whenever slings are used in the hook bowl
- It must close the throat opening and work freely Correct answer.
Explanation
The latch must be present, close off the throat opening, and operate freely so slings and fittings cannot slip out when the line goes slack. Removing or disabling a latch is not permitted.
Question 34Site Setup and Inspection
A crawler crane cannot maintain the required clearance from an energized high-voltage line. What is the correct action?
- Lower the boom and travel beneath the line at reduced speed
- Have the line de-energized and visibly grounded at the site Correct answer.
- Hold the load away from the line with a fiber tag line
- Post a flagger under the line to warn the operator
Explanation
Where the required clearance cannot be maintained, the line must be de-energized and visibly grounded at the work site before the crane operates near it. Other measures do not remove the electrical hazard itself.
Question 35Site Setup and Inspection
A crawler crane must walk across a paved area that has a culvert beneath it. What should be done before crossing?
- Nothing, since pavement is designed to carry traffic loads
- Verify that the buried structure can carry the track loads Correct answer.
- Spread gravel over the pavement to cushion the crossing
- Cross quickly to limit the time spent over the culvert
Explanation
Buried structures such as culverts are often designed for distributed highway loads, not the concentrated pressure of a crawler track. Their capacity must be confirmed before the crane crosses or is positioned over them.
Question 36Site Setup and Inspection
During inspection, a running wire rope shows six randomly distributed broken wires within one rope lay. What is required?
- The rope must be removed from service Correct answer.
- The broken wires may be cut back and the rope returned to service
- The rope may be used only for lifts under half of rated capacity
- The rope may remain in service until the next annual inspection
Explanation
Six or more randomly distributed broken wires in one rope lay, or three broken wires in one strand in one lay, is a removal criterion for running wire rope. Cutting back wires or restricting the load does not restore the rope's integrity.
Question 37Site Setup and Inspection
Which condition on a lattice boom section requires it to be removed from service?
- Light surface rust on the lacings
- Faded paint on the boom identification plate
- A missing decal on the section
- A crack at a pin hole in the main chord Correct answer.
Explanation
Cracks at pin holes and similar structural damage in chords or lacings affect the boom's load-carrying ability and require the section to be taken out of service. Cosmetic conditions do not by themselves condemn the section.
Question 38Site Setup and Inspection
A lattice boom crawler crane is working on a day with gusty winds. How should wind speed be monitored?
- By checking the local forecast at the start of the shift
- By having the signal person estimate the wind by feel
- With an anemometer, compared against the manufacturer's limit Correct answer.
- By watching how much the load swings
Explanation
Wind speed must be measured at the crane and compared with the manufacturer's allowable wind speed for the boom configuration in use. Forecasts and subjective judgments do not capture the instantaneous gusts that affect a lattice boom.
Question 39Site Setup and Inspection
Before the crane is put to work at a new site, what should the operator confirm about the load chart?
- That it lists the crane's fuel consumption
- That it shows the crane's travel speed
- That it matches the crane's boom length and current configuration Correct answer.
- That it is printed in color and laminated
Explanation
The chart in use must correspond to the crane as actually configured, including boom length, jib, counterweight, and other installed options. A chart for a different configuration can show capacities the crane does not have.
Question 40Site Setup and Inspection
The rated capacity limiter on a crawler crane fails during the shift. What must the operator do?
- Continue lifting at 75 percent of rated capacity
- Continue lifting with a signal person watching the boom
- Stop lifting until the device is repaired and working Correct answer.
- Note the failure and finish the shift
Explanation
A rated capacity limiter that is not functioning properly makes the crane unserviceable for lifting until it is repaired. Operating at reduced capacity or with added spotters is not an acceptable substitute for the device.
Question 41Site Setup and Inspection
A setup area has standing water and soft, saturated soil. Why is this a concern for a crawler crane?
- Wet soil changes the hydraulic oil temperature
- Wet ground increases friction in the track bearings
- Standing water will short out the crane's electrical system
- Saturated soil may not support the tracks and the crane may settle Correct answer.
Explanation
Saturated soil loses bearing capacity and may allow the tracks to sink, which changes the crane's level and stability while lifting. The risk is ground failure under load, not the effects listed on the machine's systems.
Question 42Site Setup and Inspection
What must be true of the ladder or steps used to get on and off a crawler crane?
- They may be removed during lifting to save weight
- They must be at least 24 inches wide
- They must be painted yellow for visibility
- They must be clean, dry, and free of loose material Correct answer.
Explanation
Steps, ladders, and walkways must be kept clean, dry, and free of oil, grease, and loose material to prevent slips and falls during access. They must remain in place and functional whenever the machine is in service.
Question 43Site Setup and Inspection
During assembly of a lattice boom, who may be inside the area beneath the boom sections being pinned?
- Only the person guiding the boom section into place
- No one; the area must be kept clear of personnel Correct answer.
- Only the oiler, who is watching for leaks
- Any crew member wearing a hard hat
Explanation
Handling boom sections creates a drop and pinch zone beneath the suspended component, and personnel must stay out of it. Sections are controlled with tag lines from outside the fall zone rather than by workers standing underneath.
Question 44Site Setup and Inspection
After boom sections are pinned together, what must be checked?
- That each pin is fully seated with its keeper installed Correct answer.
- That each pin can be turned freely by hand
- That grease has been wiped from each pin
- That each pin is painted to match the boom
Explanation
Each connecting pin must be driven fully home and secured with the correct keeper so it cannot walk out under load. A loose or unretained pin can release a boom section while the boom is being raised.
Question 45Site Setup and Inspection
Utility markings at a setup location are missing or unclear. What should the operator do?
- Refuse to set up until the utilities are located Correct answer.
- Probe the ground under each track with a steel bar
- Set up anyway and watch for signs of settlement
- Move to a slightly different spot without telling anyone
Explanation
If utility locations cannot be confirmed, the crane must not be set up until the lines have been located and marked. Unilateral relocation or probing risks a strike on an unknown line.
Question 46Site Setup and Inspection
An open utility trench crosses the path the crane must walk. What is the correct approach?
- Lay timber mats across the trench and proceed
- Use a bridge or cover designed and rated for the crane's loads Correct answer.
- Walk along the trench edge to keep the tracks on firm soil
- Fill the trench loosely with spoil and walk across
Explanation
Crossing an open trench requires a bridge or cover with engineered capacity for the crane's track loads. Mats, spoil, or travel along the edge provide no rated capacity and can collapse under the crane.
Question 47Site Setup and Inspection
What does a worn or undersized sheave groove do to a running wire rope?
- It increases the rope speed through the sheave
- It has no effect as long as the rope is lubricated
- It crushes and flattens the rope, accelerating wear Correct answer.
- It reduces the load carried by the rope
Explanation
A grooved or undersized sheave pinches the rope, crushing and flattening it and speeding up wear and broken wire development. Lubrication does not correct a groove that no longer matches the rope.
Question 48Site Setup and Inspection
During the pre-shift inspection, the operator finds the boom hoist brake slipping. What should happen?
- The lift proceeds with the boom at a low angle
- The crane is removed from service until the brake is repaired Correct answer.
- The lift proceeds if the load is kept small
- The operator adjusts the brake during the shift
Explanation
A slipping boom hoist brake is a load-holding failure, and the crane must be taken out of service until the brake is repaired. Brake adjustment is not an operator task during the shift, and reducing the load does not correct the defect.
Question 49Site Setup and Inspection
Site conditions change and the crane must be moved to a new pad a short distance away. What is required before lifting at the new location?
- The level indicator can be ignored for the first lift
- Lifting may begin immediately if the load is light
- A quick visual check of the ground is enough
- The setup must be re-verified as a new setup Correct answer.
Explanation
Each new position is a new setup, so ground conditions, level, clearances, and mat placement must be evaluated again before lifting. Proximity to the previous location does not carry over the earlier verification.
Question 50Site Setup and Inspection
A boom chord was damaged and repaired by welding in a shop. What must happen before the crane returns to service?
- A post-repair inspection by a qualified person before use Correct answer.
- Nothing, because the repair was made in a shop
- A load test at 50 percent of rated capacity
- A visual check by the operator at the start of the shift
Explanation
Repairs to critical structural members such as boom chords require inspection by a qualified person before the crane is returned to service, following the manufacturer's guidance. The location of the repair does not remove the inspection requirement.