NCCCO Overhead Crane

A maintenance lock and tag are still attached to the crane disconnect at the start of shift. What should the operator do?

• AEnergize the crane if the previous shift says repairs are done
• BOperate only at slow speed until maintenance returns
• CDo not energize the crane until authorized lockout/tagout removal is completed
• DRemove the lock if the crane is needed for production

When checking the emergency stop during pre-operation inspection, what result should the operator expect?

• AIt immediately prevents powered motion when activated
• BIt increases horn volume for travel warnings
• CIt resets the upper and lower limit devices
• DIt allows motion only at slow speed

The lettering on a pendant station is worn off and two motion buttons are hard to distinguish. What is the safest action?

• AKeep using the crane if the motions seem familiar
• BRemove the crane from service until the controls are clearly identified
• CMark the buttons with tape after the first lift
• DAsk a coworker to stand nearby and shout directions

Before handling a load with an unfamiliar pendant, why should the operator briefly verify each motion with no load?

• ATo confirm each control matches its labeled direction
• BTo warm up the motors for full-capacity lifts
• CTo test whether the runway is perfectly level
• DTo determine if the hook can be side loaded

Which hook condition is a clear reason to remove the crane from service?

• APaint worn off the hook body
• BA noticeable increase in throat opening from deformation
• CA swivel that turns freely under no load
• DA latch spring that feels stiffer than normal

During inspection, the wire rope shows birdcaging near the drum. What should the operator do?

• ARotate the rope by hand and continue if it looks better
• BLubricate it and make one test lift
• CRemove the crane from service and report the defect
• DUse only lighter loads until maintenance can inspect it

An electric hoist load chain has a visible twist and kink. What is the proper response?

• AStraighten it under light tension
• BContinue using it if the hook block is empty
• CRemove the hoist from service until corrected
• DOperate only in the lowering direction

What is the main purpose of an upper travel limit device on a hoist?

• ATo serve as the normal stopping point for every lift
• BTo prevent overtravel of the hook block into the hoist
• CTo measure exact load weight during hoisting
• DTo compensate for poor rigging angles

The hoist brake lets the empty hook drift several inches after the control is released. What should the operator conclude?

• AThe brake is functioning normally because no load is attached
• BThe crane can be used if the lift height is short
• CThe brake may be defective and the crane should be removed from service
• DThe trolley brake should be adjusted instead

In a noisy fabrication bay with more than one crane operating, what should be established before the first lift if voice commands are unreliable?

• AA designated communication method understood by everyone involved
• BA faster travel speed so the lift finishes quickly
• CPermission for any nearby worker to direct motions
• DA rule that the operator moves whenever the horn sounds

Why should an operator review capacity markings, warning placards, and operating labels during pre-operation inspection?

• AThey confirm current operating limits and required precautions
• BThey replace the need to inspect the hook and rope
• CThey allow small overloads when the load is balanced
• DThey are only important for maintenance personnel

A supervisor says production is behind schedule and tells the operator to run a crane that still has a lockout device applied. What is the correct response?

• AOperate only under the supervisor's observation
• BUse the crane for one lift and then relock it
• CDo not operate until the authorized lockout/tagout procedure is completed
• DRemove the device if the supervisor accepts responsibility

Why inspect sheaves and reeving before the shift begins?

• ATo ensure the rope is seated correctly and not crossed or damaged
• BTo verify the hook latch opens wider under load
• CTo determine the maximum sling angle for the day
• DTo increase the crane's rated capacity

If the crane's audible warning device is required by site practice for travel alerts but does not work, what should the operator do?

• AUse hand signals only and continue normally
• BOperate only when no one is looking
• CReport the condition and follow site procedure before operating
• DSubstitute the emergency stop for warning purposes

After a pendant station has been replaced, what is the BEST pre-operation verification?

• AStart with a full-capacity lift to prove the repair
• BTest each motion, direction, and emergency stop with no load from a safe position
• CAssume the replacement matches the old unit if the wiring is complete
• DSkip testing if maintenance signed the work order

When determining whether a lift is within capacity, what load weight must the operator use?

• AOnly the weight of the item being picked
• BThe total suspended weight including rigging and any below-the-hook device
• CThe weight listed by the last operator for a similar lift
• DOnly the portion of the load above waist height

A beam clamp and spreader bar will be used on a lift. Which rating rule applies?

• AThe crane's rated capacity automatically overrides accessory limits
• BOnly the spreader bar rating matters because it carries the load
• CEvery below-the-hook device used must be rated for the load, and the lowest applicable ra…
• DBelow-the-hook devices do not need rated capacity if inspected daily

A fabricated steel load has sharp edges. Which sling setup is MOST appropriate?

• AA bare synthetic web sling directly over the sharp corner
• BA sling suited to the load with proper edge protection at contact points
• CAny sling as long as two workers hold taglines
• DA fiber rope sling because it grips better on corners

What is a true vertical lift?

• AA lift made with the hook directly over the load's center of gravity
• BA lift started with the bridge moving first
• CA lift that uses two slings of the same color
• DA lift where the hook is one foot ahead of the load

If the hook is not positioned directly over the load before hoisting, what hazard is most likely when tension comes on the rigging?

• AThe crane will gain extra capacity
• BThe load may swing or side load the hoist
• CThe lower limit switch may fail
• DThe hook latch will lock automatically

During a planned lift, who normally gives directions to the operator?

• AAny employee who is closest to the load
• BThe designated signal person, except that anyone may give a stop signal
• CThe rigger only after the load leaves the floor
• DThe forklift operator working nearby

A shipping document lists a machine at 8,000 lb, but the rigging and lifter add 1,200 lb. What weight should be used for the lift decision?

• A8,000 lb because rigging is not part of the load
• B8,600 lb because some rigging weight is offset by the hook
• C9,200 lb because total suspended weight includes attachments
• D10,000 lb because overhead cranes require a 25% margin

The center of gravity of a load is uncertain after it was partially disassembled. What is the BEST next step after rigging appears correct?

• AMake a full-speed lift so any imbalance becomes obvious quickly
• BRaise the load just clear of support, check balance, and lower to re-rig if needed
• CAdd extra sling length so the load can find its own center
• DProceed if two workers say it looks level

Aisles below the intended travel path are open to foot traffic. What should happen before moving the load?

• AMove quickly so pedestrians have less time underneath
• BControl or barricade the area and communicate the lift path
• CCarry the load higher so people can walk under it
• DRely on the hook latch to protect pedestrians

Why is sling angle important during lift planning?

• ASmaller sling angles increase tension in each sling leg
• BSmaller sling angles decrease the need to know load weight
• CLarge sling angles eliminate the need for edge protection
• DSling angle only matters for chain slings

The operator loses sight of the signal person and the radio stops working just before the load is lifted free. What should the operator do?

• AContinue if the intended motion seems obvious
• BStop operations until communication is restored
• CMake the lift only halfway and reassess
• DUse a coworker who is not briefed as a backup signal person

The crane is rated for 10 tons, but a vacuum lifter attached to the hook is rated for 8 tons in the planned configuration. What is the maximum allowable lift?

• A10 tons because the crane rating is higher
• B9 tons if the load is compact and balanced
• C8 tons because the lowest applicable rated component governs
• DWhatever the operator has lifted successfully before

A long load may pass close to a column during travel. What is the BEST pre-lift action?

• APlan the path, assign needed spotters, and use control measures such as taglines when app…
• BTravel with the load at maximum height so the column is cleared
• CTell the signal person to give faster commands
• DReduce the number of sling legs to shorten the load

The identification tag on a synthetic sling is missing and its capacity cannot be verified. What should be done?

• AUse it for light loads only
• BUse it only in a basket hitch
• CRemove it from service until its rating is known
• DDouble it with another sling to compensate

A long unbalanced load uses two pick points and one end is heavier. To make the initial pick as close to vertical as possible, where should the hook block be positioned?

• ADirectly above the midpoint between the pick points regardless of weight
• BDirectly above the load's center of gravity as rigged
• COver the lighter end so the heavy end rises first
• DAs far from the operator as possible

Before traveling with a load, how can an operator quickly verify the hoist brake is holding?

• ARaise the load slightly and stop to confirm it holds without drifting
• BLower the load rapidly and watch the drum
• CUse the upper limit device as a brake test
• DAsk the signal person if the brake sounds normal

A fault light or overload alarm activates while the load is suspended. What is the BEST response?

• AContinue carefully if the load is already off the floor
• BStop, keep the load controlled, and follow the crane's procedure for alarms or faults
• CSilence the alarm and finish the lift before investigating
• DIncrease hoist speed so the alarm clears sooner

What is the safest general rule for the load path during travel?

• AKeep the load as low as practical while maintaining clearance and never over people
• BAlways raise the load to the highest available clearance
• CTravel with the hook block tight to the upper limit
• DMove the load at eye level so it is easier to watch

How should bridge and trolley motions usually be started and stopped when a load is suspended?

• AAbruptly, to keep the load from drifting
• BSmoothly, to minimize load swing and shock loading
• COnly with both motions applied at the same time
• DAt full speed first, then immediately to slow speed

A suspended load begins to pendulum after a sudden start. What should the operator do?

• AMake sharp opposite motions to cancel the swing immediately
• BReduce or stop motion and regain control before continuing
• CRaise the load higher so it swings less
• DHave workers steady it by hand while it is moving

During the initial pick, how high should a load normally be raised to check balance and rigging?

• AOnly high enough to clear the support surface
• BAt least halfway to the final height
• CTo the full travel height before stopping
• DAs high as the sling angle allows

When working near another crane's operating zone, what is the safest practice?

• AAssume the other operator will stay clear
• BCoordinate movements and maintain clear separation between cranes and loads
• CRace through the area before the other crane arrives
• DUse the horn only after the two loads are close