Service Truck Learner Guide

Service Truck
Operation
LEARNER GUIDE
NQF Level 2
OPERATE A SERVICE TRUCK
NQF LEVEL : 2 SAQA UNIT STANDARD ID – 262790 NQF CREDITS : 8
LEARNER GUIDE
SUBJECT DETAILS OF UNIT STANDARD

Unit Standard Title Operate service truck
SAQA US ID 116085
N.Q.F. Level 2
Credits 8
Field Physical Planning and Construction
Sub-Field Civil Engineering Construction
PURPOSE
The purpose of this module is to enable you to safely operate Service Trucks
in accordance with manufacturers, company and regulatory instructions.
By the end of this module you will be able to:
1. Demonstrate knowledge of the functions of Service Trucks.

2. Start and shut down Service Trucks.
3. Operate Service Trucks.
4. Document Service Trucks use.
The Essential Embedded Knowledge required to perform successfully in the

above Outcomes are:
 The service truck operation procedures and main functions of all major
components
 The maximum operating capacities of the designed service trucks
capabilities.
 Statutory requirements including the Relevant Code of practice and Safety,
Health & Environmental legislation
 Worksite procedures
VERSION : 01 GREENRIM TRAINING PAGE 2

LEARNER GUIDE
CRITICAL CROSS FIELD OUTCOMES

Critical cross-field outcomes have the following meanings:
Identify and Solve Problems
Outcomes marked with this icon refer to the ability to recognise

possible difficulties that will prevent successful achievement of the
goal and obtaining a solution that will remove the obstruction.
Work Effectively With Others
Outcomes marked with this icon refer to the ability to co-operate

successfully with other members of the team to achieve the same
objective.
Employ Self Management

Outcomes marked with this icon refer to the ability of the learner to
organise and control his/her time and efforts efficiently.
Manage Information
collect, analyse and evaluate important information relevant to
achieving the objective.
Communicate Effectively
transfer and receive messages effectively with other people ensuring
that the meaning and purpose is maintained.
Demonstrate Scientific And Technological Competence
utilise technological systems and methods in the successful
achievement of the goal.
Understand Contextual World Systems
comprehend the situation in a global context and how to deal with it
in a universal manner.

LEARNER GUIDE
CONTENTS
Critical Cross Field Outcomes
Introduction
Learning Activity 1 Functions of Service Trucks

1.1 The Main Functions of Service Trucks
1.2 Service Trucks Main Components and Their Functions
1.3 Service Trucks Safety Features and Warning Devices
1.4 Maximum Operating Capacities of Service Trucks
1.5 Service Trucks Warning Indicators And Gauges
1.6 Corrective Actions To Neutralize Service Trucks Warnings
Learning Activity 2 Start And Shut Down Service Trucks

2.1 Pre-Operational Checks
2.2 Operator Maintenance
2.3 Compliance With Manufacturer’s Specifications
2.4 Start-Up And Shutdown Procedures
2.5 Parking Service Trucks
Learning Activity 3 Operate Service Trucks

3.1 The Purpose Of The Controls
3.2 The Functions Of The Controls
3.3 Using The Controls To Manoeuvre Service Trucks
3.4 Safe Working Procedures
3.5 Monitoring Service Trucks Performance
3.6 Safe Operation Of Service Trucks
3.7 Minimizing Service Trucks Hazards
Learning Activity 4 Document the Use of Service Trucks

4.1 Documenting Service Trucks Hours
4.2 Service Trucks Maintenance And Fault Reporting

LEARNER GUIDE
INTRODUCTION
Why Do I Need Training?
The different types of plant machines and attachments available make them extremely versatile
and effective worksite tools. But even the most experienced operators can find themselves in
potentially dangerous situations. Serious accidents can and do occur without proper training.
Training is a legal requirement in terms of the Occupational Health and Safety Act, which
requires employers to ensure that machines are operated by employees who have received the
appropriate training in their safe use, which will improve machine care and production.
An Overview of the NQF

(National Qualifications Framework)
National (throughout the whole of South Africa)
Qualifications (recognition of meeting a set of learning requirements)
Framework (ladder of learning on which the unit standards / qualifications are registered
The NQF is a framework on which standards and qualifications are registered. The NQF is a set
of principles and guidelines by which records of your achievements are registered to enable
national recognition of acquired knowledge and skills, thereby ensuring an integrated system
that encourages life-long learning.
Meaning, Origin and Value of a Unit Standard

Unit Standards are the building blocks for national qualifications.
They are the smallest unit or part that can be credited.
They can stand alone (like a brick) or be part of a qualification (like a
wall).
Level is the level at which the unit standards and/or qualification is registered
on the NQF.
Credit is the value given to the unit standard.
1 credit equals 10 notional hours of learning that it would take an
average learner to meet the outcomes laid out in the unit standard.
The notional hours of learning are made up of the learning spent
undergoing theoretical training, practical application and the experiential
time spent on the job.
Purpose Statement tells you why the unit standard exists and how it fits into the
qualification.
Specific Outcomes states the end result required to be achieved by you.
Assessment indicate the steps and actions that you need to carry out. It also
Criteria indicates the complexity and performance of each outcome.
These assessment criteria will determine if the specific outcome has
been achieved or not.
Range indicates the various conditions under which the assessment must take
place. It indicates the level, scope and context which you must undergo
during the assessment
Embedded is the knowledge and understanding required by you in order to carry
Knowledge out the steps and actions competently.
This embedded knowledge is assessed via questioning.
Critical Cross-Field are life skills needed by you to be used in your working and personal
Outcomes lives. These skills are integrated into the unit standard and are not
required to be assessed in isolation.
These skills are expressed as critical cross-field outcomes in the
qualifications eg. problem solving, team work, use of science and
technology
Activity Tasks are probably the most important learning step.
We want you to understand the Learning Activities and be able to

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explain what you have learnt.
How to Use this Manual

This manual serves three purposes for you:
1. Learning
During class lessons you will use the manual to complete your Activity Tasks
2. Review
You can use the manual to review material you learned in class.
3. Reference
You can use the manual to help you find specific information.
Word Find
As you work through this training material you will probably find words that are difficult for you to
understand. These words are listed in alphabetical order, i.e. from A -Z.
ABNORMAL ● not normal
ACTIVITY ● another word for job
ADVANTAGEOUS ● something that puts one in a favourable position
ANALOGUE ● electronic information or signals
ANTICIPATE to prepare for something before it happens
AUGER ● a tool resembling a large corkscrew for boring holes
CORRECTIVE ● to correct something undesirable
DEPRESSED ● pushed or pulled down
DETENT ● a hinged catch that fits into a notch of a ratchet to move a wheel forward or prevent
it from moving backward
DISSIPATION ● breaking up and scattering by dispersion
FUNCTION ● the purpose of a thing
GRUB ● dig shallowly in soil
HYDRAULIC ● operated by liquid moving in a confined space under pressure to provide
mechanical force
MANOEUVRE ● a movement or series of moves requiring skill and care
MIRED ● become stuck in mud or be in difficulties
PAYLOAD ● goods carried by a large vehicle
PERMIT ● give permission to someone or for something
PIVOT ● central point, pin or shaft on which mechanism turns or is balanced
PROCURED ● obtained
RACKING ● stretch to the limits
RATED ● give a standard or value to something according to a particular scale
RESISTANCE ● the impeding effect exerted by one thing to another
RETARDER ● hold back the progress
RIGID ● unable to bend or be forced out of shape
RUT ● a long deep track made by the repeated passing of the wheels of vehicles
SYSTEMATICALLY ● done or acting according to a system
TRACTION ● the grip of a tyre on a road, pulling a thing along a surface
TRANSMISSION ● the mechanism by which power is transmitted from an engine to the axle in
a vehicle
VERNIER ● a small movable graduated scale for indicating fractions of the main scale on a
measuring device

LEARNER GUIDE
LEARNING ACTIVITY 1
Functions of Service
Trucks
The purpose of this Learning Activity is to enable you to demonstrate
knowledge of the functions of Service Trucks.
Specific Outcome 1
After completing this Learning Activity you will be able to:
■ Explain the main functions of Service Trucks in terms of the

manufacturer’s instructions.
■ Explain the operation of all major components of Service Trucks in terms
of their functions.
■ Identify and explain all safety features and warning devices on Service
Trucks in accordance with manufacturer’s instructions.
■ Explain the maximum operating capacities of Service Trucks in terms of
the designed machine capabilities.
■ Explain the warnings from Service Trucks indicators and gauges
according to manufacturer’s instructions.
■ Describe or demonstrate corrective actions in terms of neutralizing
warnings received from Service Trucks.

LEARNER GUIDE
1.1 Service Trucks Main Functions

Equipment maintenance is the servicing, adjusting and repairing of
equipment. All too frequently operators and supervisors attempt to
increase production by operating equipment under load conditions
greater than the equipment was designed to handle. The result is
premature breakdown with accompanying delays and cost increases.
Proper preventative maintenance procedures and an efficient repair
system will minimize equipment failures and their consequences.
Learning Activity Outcome

1.1 Explain the main functions of Service Trucks in terms of
manufacturer’s specifications
The function of the Service Truck is to provide grease and oil to all vehicles on
site. To ensure there is an artisan and assistance on site during working hours.
1.2 Service Trucks Main Components

1.2 Explain the operation of all major components of Service Trucks in terms of
their functions.
We know that each machine may have similar components, but they also have
special attachments that make them different from the other machines. It is very
obvious to see the difference in machines like dozers and dump trucks. The
dozer is designed and made to push loads, while the dump truck is made to
transport or haul a load.
In other cases the difference between the machines is not so obvious at first
glance. For example tipper trucks and dump trucks. If an experienced person
was asked to look at a tipper truck and a service truck, they would only see the
difference in size and very few of the other differences.
The service truck has all the components as with any earthmoving machine,
such as an engine, cab, transmission, differential, etc., and is basically a truck.
Engine
Provides power to drive
 The engine provides power to propel the machine forward or backward.
 Converts heat energy into mechanical energy to perform work.
 It is the heart of the machine - enables other systems like the power steering and hydraulic
system to work.
 Engines come in different configurations with different kilowatt ratings that are suited for
different tasks and loads.

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 Most large machine manufacturers make use of a diesel engine, which is robust and
powerful. As the name suggest, the diesel engine uses diesel fuel to operate and makes
use of diesel injectors, as opposed to spark plugs found in petrol engines.
Transmission or Gearbox
Transmits power from the engine to the final drives
 A unit that enables the operator to select different gears, which allows different speeds and
load carrying abilities.
 Lower gears are more powerful than the higher gears and they propel the machine slower
than the higher gears.
Machine manufacturers use two types of transmissions: Manual and Automatic:
1. Manual Transmissions
Have to be selected one at a time and shifted up through the gears, as the speed and engine
revolutions increase, to prevent the engine from over revving and damage occurring. A clutch
is used to disconnect the drive as the gear is shifted up or down.
2. Automatic Transmissions
Work on oil pressure and once the machine is placed in gear, the operator only has to release
the parking and service brake and apply pressure to the accelerator, at which time the
machine will start to move forward or backward as selected. As the engine revs increase, the
automatic transmission will select the correct gear for the groundspeed, load and gradient. The
automatic transmission therefore automatically shifts up and down through the gear range as
required.
Final Drives
Transmit power from the engine to the final drives
 Units that provide the power or drive to the
tracks or wheels.
 On machines equipped with a differential, the
outer wheel is able to rotate at a faster speed
than the inner wheel, in order to reduce wear
on tyres.
 The outer wheel on an axle actually travels
further than the inner wheel when the axle goes
around a corner. If the differential was not
there, the wheels would drag at certain stages
of the turn, which would increase tyre wear and
place enormous stresses on the wheel bearings and other parts.
Hydraulic System
This provides pressure for the hydraulic system and cylinders.
Hydraulics are extremely powerful and are usually used to operate the many different types of
attachments we find on machines. Always exercise extreme caution when working with
hydraulics as they operate at extremely high oil pressures. The basic components of a
hydraulic system consist of a reservoir, strainer and filters, pump, control valves, hydraulic
cylinders, hoses, couplers, accumulators, and on some systems, a hydraulic motor
Hydraulic  The hydraulic reservoir is the fluid storehouse for the hydraulic system. It
Reservoir contains enough fluid to supply the normal operating needs of the
hydraulic system and an additional supply to replace fluid lost through
minor leaks.
 Additionally, the reservoir allows the settling of any impurities and
separation of air from the fluid before reuse in the system. The basic
hydraulic reservoir has a space above the fluid even when they are full.
This space allows the fluid to foam, and thus purges itself of air bubbles
that normally occur as the fluid flows from the reservoir, through the
system, and back to the reservoir.
 The air vent allows the air to be drawn in and pushed out of the reservoir

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by the ever-changing fluid level. An air filter is attached to the air vent to
prevent drawing atmospheric dust into the system. Because it is essential
that the fluid in the reservoir be kept at the correct level at all times, the
sight gauge is provided to allow the normal fluid level to always be seen
 The baffle plate segregates the outlet fluid from the inlet. This allows the
fluid time to dissipate air bubbles, contaminants to settle, and the return
fluid to cool before it is picked up by the pump.
 The proper hydraulic fluid level must be maintained. In some systems low
fluid level causes overheating because the fluid does not have enough
time to cool in the reservoir before it gas back into the pump.
 Also, some systems will not work at all because the fluid is so low in the
reservoir that air gets into the pump. Before adding hydraulic fluid, know
what type to use and make sure it is clean. Clean around the filler cap or
tube so there is less chance that dirt can get into the system.
Strainers  Hydraulic systems have a strainer and one or more filters that remove the
And Filters impurities that would eventually contaminate the hydraulic fluid. The
strainer is normally located in the reservoir or in the inlet line to the pump.
 The filter is normally located so only a small amount of fluid is lost when
the element is changed. The filter is equipped with a valve that allows the
fluid to bypass the filter element should it become clogged.
 The filter element is usually of the paper cartridge, canister, or edge type
and is similar to those used in engine lubrication systems. Regular filter
maintenance is necessary to prevent contaminated fluid from being
recirculated in the system.
Hydraulic  The hydraulic pump creates the flow of fluid within the hydraulic system.
Pumps The pressure in a hydraulic system is caused by a restriction placed in the
path of the fluid as it leaves the pump. Because of the resulting
mechanical drive and positive displacement, the pump merely moves the
fluid regardless of the restriction.
 When enough pressure is built up, movement of the restriction occurs or a
relief valve placed in the system opens, allowing the fluid to return to the
reservoir or the suction side of the pump.
 When the pump operates, hydraulic fluid is trapped between the gear
teeth and the pump housing and is carried to the outlet side of the pump.
As the teeth mesh, a seal is freed by the mating surfaces that prevent the
oil from leaking back to the inlet side of the pump. The sealing action
causes the oil to be forced out of the pump and into the system.
Control Control valves are valves accessible to the operator for directing the flow of
Valves fluid within the system to operate the machine or its attachment. By skillful
use of the control valves, the operator can regulate the speed and operation
of the hydraulic cylinders.
NOTE: Hydraulic controls should be operated smoothly to eliminate the
jerking motion that causes rapid wear and failure of the mechanical parts of
the machine.
Hydraulic  Hydraulic cylinders are used to transmit motion in relation to the volume of
Cylinders fluid directed into the cylinder. The force created by the cylinder is
determined by the pressure of the fluid and the area of the piston
contacted by the fluid. Thus the larger the piston, the more force
generated.
 Hydraulic cylinders used on heavy equipment are either single- or double-
acting cylinders.
Single-Acting Cylinders Single-acting cylinders, are used to exert force in
only one direction. This means the weight or resistance moved must be
located so it causes the cylinder to return to its original position when
pressure is relieved from the piston. A common use of this type of cylinder is

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in a hydraulic jack.
Double-Acting Cylinders Double-acting cylinders are used on equipment
where force is needed in two directions. Unlike the single-acting cylinder, the
double-acting cylinder contains seals at both ends of the piston where the
piston rod passes through the end of the cylinder. With the use of this
cylinder, fluid can be directed to either side of the piston and cause the piston
rod to extend or retract under pressure. The double-acting cylinder, is called
an unbalanced cylinder. This means that the cylinder can exert more force in
one direction than in the other. This is due to the piston rod preventing fluid
from acting on the full area of the piston on one side.
Flexible Flexible hoses are used in a hydraulic system to allow movement between
Hoses mechanical parts of the rams on the equipment and attachments should be
coated in grease.
NOTE: Wipe off all foreign material from hydraulic rams with a clean rag
during pre- and post-operations to prevent damaging seals and wiper seals.
Before you store equipment, a very important procedure to remember is that
the exposed hydraulic rams on the equipment and attachments should be
coated in grease. This action protects the surface of the hydraulic ram and is
critical in storage locations where corrosive environmental conditions, such as
salty air, strong winds, or blowing sand, exist.
Remember: Wipe off the grease before using the equipment when it is
removed from storage.
Fuel System
Provides fuel to the engine for combustion
 Ensures a quantity of clean fuel is delivered to
the fuel intake of an engine.
 The system must provide both safe fuel storage
and transfer.
 Fuel tanks store fuel in liquid form.
 The tank may be located in any part of a vehicle
that is protected from flying debris, shielded from
collisions, and not likely to bottom out.
 Most wheeled vehicles use removable fuel tanks.
The walls of fuel tanks are manufactured with
ridges to give them strength and internal baffles
that increase internal strength and prevent the
fuel from sloshing.
 The filler pipe offers a convenient opening to fill the tank and prevent fuel from being spilled
onto the passenger, engine, or cargo compartments.
 The fuel outlet pipe is located inside the tank and its opening is about one-half inch above
the bottom. This location allows sediment to fall to the bottom of the fuel tank without being
drawn into the fuel system.
 Most fuel tanks have a position on top to install a fuel gauge sending unit. This is usually a
flanged hole.
 A threaded drain plug is normally located at the bottom of the tank and is used for draining
and cleaning of the tank.
Electrical System
The electrical system generates power for the electrical system eg gauges, lights, batteries,
etc. It is a major component designed to perform a variety of functions that support the
operation of the equipment. The electrical and hydraulic systems control the starting,
charging, braking, steering, lifting, and movement of all attachments. The basic components of
the electrical system are: Storage Battery, Charging System and Lighting System

LEARNER GUIDE
Storage  The storage battery is the heart of the

Battery charging circuit. The type used in automotive,
construction, and weight-handling equipment
is a lead-acid cell type of battery. This type of
battery stores energy in a chemical form. It is
not a storage tank for electricity.
 It acts as a stabilizer for the voltage of the
electrical system and may, for a limited time,
furnish current when the electrical demands
of the vehicle exceed the generator output.
 Part of your pre-start and operator maintenance responsibilities are
checking the battery water level and ensuring the battery terminals are
tight and free from corrosion.
 The battery produces a flow of direct current when lights, starter motor, or
other current-consuming devices are connected to the battery posts. This
current is produced by a chemical reaction between the active materials of
the plates and the sulfuric acid of the electrolyte.
 Proper performance of pre- and post-operational checks and operator
maintenance requires a basic understanding of the electrical systems
used on construction equipment.
Charging  Performs two jobs: recharges the battery and generates current during
System operation.
 During peak operation, the battery helps the generator supply current; and
during normal operation, the generator supplies all current and recharges
the battery.
 In both electrical systems, the battery starts the electrical circuit that
supplies the spark to start the engine.
 The engine then drives the generator or alternator that produces current to
take over the operation of the ignition, lights, and accessory loads.
 The battery also supports the generator or alternator during peak
operation when the electrical loads are excessive. But once the engine is
started the generator or alternator is the “work horse,” providing current to
the ignition and accessory circuits.
 The generator supplies current as long as the engine is at speed and
running. When the engine slows down or stops, the battery takes over part
or the entire load.
 The two types of charging systems used on construction equipment are dc
charging system and ac charging system. Both systems generate an
alternating current, however, the difference is the way they rectify the ac
current to direct current for charging the battery.
Lighting  Lighting system on construction equipment includes the lamps and bulbs,

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System clearance lights, reflectors, taillights and brake lights, auxiliary lights, and
fuses.
 The manufacturer provides equipment with an electrical system that
supports the lighting circuits.
 Part of your pre-start responsibility is to ensure the lights on your
equipment work and is clean of dust and dirt. These lights outline the
length, height, and width of the vehicle.
 Each group of lights in a branch circuit of the lighting system is protected
by a fuse or circuit breaker and is provided with a switch.

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Braking System
Slows down and stops the vehicle
 The brake system applies to all machines. Braking systems must not only stop the unit but
also must stop it in a smooth, uniform motion.
 In nearly all brake systems, the brake drums provide the moving surface, and the brake
shoes provide the stationary surface.
 Good brakes are a critical element for ensuring the safe operation of equipment.
 Friction is the resistance in relative motion between two surfaces in contact with each other.
When a stationary surface is forced into contact with a moving surface, the rubbing action
between the two surfaces slows down the moving surface.
 The friction between the brake drum and the brake shoes slows the drum and wheel; and
the friction between the tyre and the road surface slows and stops the vehicle.
Cooling System
Cools the engine, transmission and hydraulic system to prevent overheating. All internal
combustion engines are equipped with some type of cooling system because of the high
temperatures they generate during operation.
Air Cooled  The simplest type of cooling is the air-cooled or direct method, in which
the heat is drawn off by moving air in direct contact with the engine.
 The rate of the cooling is dependent upon the area exposed to the cooling
air, the heat conductivity of the metal used, the volume of the metal or its
size in cross section, the amount of air flowing over the heated surfaces,
and the difference in temperature between the exposed metal surfaces
and the cooling air.
 Air-cooled engines generally operate at a higher temperature than liquid-
cooled engines, whose operating temperature is largely limited by the
boiling point of the coolant used.
 The temperature in the combustion chamber during the burning of fuel is
much higher than the melting point of iron. Therefore, if nothing is
available to cool the engine during operation, valves burn and warp,
lubricating oil breaks down, and bearings and pistons overheat resulting in
engine seizure.
 At the same time, the engine must not be allowed to run too cold.
 An engine running cold does not burn all the fuel taken into the
combustion chamber, causing carbon deposits to form that reduce fuel
mileage, increase wear, and reduce engine power.
 Three functions of the cooling system provide a satisfactory temperature
operating range for the engine:
1. The system removes the unwanted heat.
2. It regulates the engine temperature to keep it just right during all
operating conditions.
3. When the engine is first started, the cooling system assists the engine in
warming up to its normal operating temperature as soon as possible.
The two types of cooling methods are liquid cooling and air cooling.
1. The liquid-cooling system is the most popular for automotive use,
because it provides the most positive cooling and it maintains an even
engine temperature.
2. Air cooling is used for small vehicles and equipment; however, air cooling
is not used if water cooling is practical. This is because air-cooled
engines do not run at even temperatures and require extensive use of
aluminum to dissipate heat.
Other means of heat dissipation for the engine, in addition to the cooling

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system:
 The exhaust system dissipates as much, if not more, heat than the cooling
system, although that is not its purpose.
 The engine oil removes heat from the engine and dissipates it to the air
from the sump.
 The fuel provides some engine cooling through vaporization.
 A measurable amount of heat is dissipated as the air passes over the
engine.
Liquid-  A simple liquid-cooled cooling system consists of a radiator, water pump,
Cooling hoses, fan and shroud, thermostat, and a system of jackets and passages
System in the cylinder head and cylinder block through which the coolant
circulates.
 Cooling of the engine parts is accomplished by keeping the coolant
circulating and in contact with the metal surfaces to be cooled.
 The pump draws the coolant from the bottom of the radiator, forces it
through the jackets and passages, and ejects it into the upper tank on top
of the radiator.
 The coolant then passes through a set of tubes to the bottom of the
radiator from which the cooling cycle begins again.
 The radiator is situated in front of a fan that is driven either by the water
pump or an electric motor. The fan ensures an air flow through the radiator
at times when there is no vehicle motion.
Radiator  Most radiators have two tanks with a heat exchanging core between them.
The upper tank contains an outside pipe, called an inlet, and on top is the
filler neck.
 Attached to the filler neck is an outlet to the overflow pipe. The overflow
pipe provides an opening from the radiator for escape of coolant or steam
if pressure in the system exceeds the regulated maximum. This prevents
rupture of cooling system components.
 The lower tank contains an outside pipe that serves as the outlet for the
radiator.
 The radiator is usually mounted in the front of the engine compartment so
cool air can pass freely through the core. The outlet on the bottom radiator
tank is connected to the water pump inlet.
 The top tank inlet of the radiator is connected to the outlet at the top of the
engine. Rubber hoses and hose clamps are used to make these
connections to prevent engine vibrations from being transferred to the
radiator.
Radiator  The radiator pressure cap is used on nearly all modern engines.
Pressure Cap  The pressure cap closes off the overflow pipe and prevents loss of coolant
during normal operation. It also allows a certain amount of pressure to
develop within the cooling system.
 The pressure cap contains two spring-loaded valves. The larger valve is
called the pressure valve and the smaller one is called the vacuum valve.
 The pressure valve acts as a safety valve to relieve extra pressure within
the system. The vacuum valve opens only when the pressure within the
cooling system drops below the outside air pressure as the engine cools
down. This automatic action of the vacuum valve prevents collapse of the
hoses and the radiator.

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Proximity of Other Machines

Always be aware of your surroundings to  Uneven/unstable terrain
prevent hazards associated with:
 Trees
 Overhead service lines
 Bridges
 Surrounding buildings
 Obstructions Structures
 Facilities
 Dangerous materials
 Recently filled trenches
 Other machines
 Bystanders
Self Test …
1. What common components do most machines have?
2. What is the purpose of the engine?
3. What do you use the transmission or gearbox for?
4. What is the difference between manual and automatic transmissions?
5. What do the differentials and final drives do?
6. What is a hydraulic system?
7. What is the function of the fuel system?
8. What does the electrical system generate?
9. What does the battery produce?
10. What two jobs does the charging system perform?
11. What two types of charging systems are used on construction equipment?
12. What does the lighting system on construction equipment include?
13. Why are good brakes a critical element for ensuring the safe operation of equipment?
14. What are the three functions of the cooling system in order to provide a satisfactory
temperature operating range for the engine?
15. What are the two types of cooling methods?
16. Name other means of heat dissipation for the engine.
17. What does the liquid cooling system consist of?
18. Where is the radiator normally mounted?
19. What does the radiator pressure cap do?
1.3 Safety Features & Warning

Devices
So far you have learnt the chief purpose of Service Trucks and have
a general overview of the main parts and their purpose. This section
is very important as you will learn to identify the safety and warning
parts of Service Trucks.

1.3 Identify all safety features and warning devices on Service Trucks and
explain their purposes in accordance with manufacturer’s specifications

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Instruments, gauges and controls are put on machines and vehicles to tell you
how the machine is working. Each instrument or gauge measures something
(temperature, pressure, level, etc.) and shows it to you (or any other person
who reads it) in a way that the operator can easily understand it and take action,
if it is needed, before a problem develops.
Even if everything checks out okay during the prestart operation does not mean
it will stay that way throughout the workday. You must continually monitor
certain conditions, to ensure the equipment is running correctly.
You monitor them by watching the indicator (warning lights or gauges) on your
equipment. On equipment, you may see an analog type of gauge or color-coded
indicators.
Warning Devices
Water  When operating a piece of WARNING Use extreme caution when
Temperature equipment, you must monitor removing a hot radiator cap. Steam
Gauge the water or coolant coming from the radiator will cause
temperature gauge. severe burns.
 If your machine has an analog CAUTION Do not add cold water to a hot
type of gauge, you must know engine when it is not running. Rapid
the correct operating cooling of an overheated engine will
temperature. cause severe damage to the cylinder
head and block. To cool an overheated
 Refer to the operator’s manual
engine down, leave the engine running
to determine the operating
and add water slowly. Watch for the
temperature.
steam that may be produced when
 Anytime the temperature adding water. Should a radiator hose
reading on the gauge starts to burst, secure the engine before the
rise, stop and determine the temperature gets too high.
reason. Do not wait until the
gauge is in the red zone to
investigate.
Oil Pressure  The oil pressure indicator is one of, if not, the most important gauges to
Gauge watch. Every vehicle or equipment has an oil pressure warning light or a
gauge. Should you start to lose oil pressure and the warning light comes on,
secure the engine immediately.
 Operating equipment without proper oil pressure causes severe damage to
the engine.
 Check the oil level in the engine. If the oil level is low, add oil until it is at the
proper level.
 Start the engine; if oil pressure does not register on the gauge or the light
stays on for 30 seconds, secure the engine. Then document and report the
problem.
 Should the oil level be correct and no pressure registers on the gauge or the
warning light stays on, secure the engine. Then document and report the
problem.
NOTE: A rule of thumb is that after starting an engine, the oil pressure gauge
should show 15kgs of oil pressure after the engine runs for 30 seconds. Should
the oil level be correct but no pressure registers on the gauge, secure the
engine. Then document and report the problem.
Air Pressure  There is an air pressure gauge on each WARNING Do not operate
Gauge vehicle equipped with an air-brake system. any equipment with air brakes
 The air pressure must be maintained within if there is an air leak. With the
a range of 100 pounds per square inch engine at operating rpm, he

LEARNER GUIDE
(psi) to 120 psi. air pressure system should

 A warning light or buzzer should come on if build from 85 to 100 psi within
the air pressure drops below 60 psi. 45 seconds in ual-air
systems. In single-air systems
 If there is a rapid loss of air pressure, an air (pre-1975), the pressure
unit may have burst. A slow leak may should build up from 50 to 90
sometimes be repaired by tightening a psi within 3 minutes.
fitting.
Hydraulic  Most types of construction equipment are equipped with hydraulic pressure
Pressure gauges.
Gauge  When operating this equipment, you must watch for leaks.
 Consult the operator’s manual for the pressure at which the equipment
should be operated.
 Should the pressure not reach the operating range or should you detect a
leak, be sure to document and report either or both.
Hydraulic  Most types of construction equipment are also equipped with hydraulic
Temperature temperature gauges.
Gauge  In most cases, if the hydraulic temperature exceeds the recommended
temperature, it is because the fluid level is low.
 Should the fluid level be correct and the equipment overheats, you are
overworking the hydraulic system.
 Stop your machine and check the hydraulic fluid level. Be careful because
the hydraulic fluid is hot and the hydraulic system may be pressurized.
 If the fluid level is normal, let the machine sit at idle to cool the hydraulics.
Fuel Level  When prestart inspecting a piece of equipment, you should visually check
Gauge the fuel.
 During the day, watch the fuel gauge to ensure it shows a slow depletion of
fuel. Should the fuel gauge not move in a reasonable amount of time,
assume the fuel gauge is broken. In this case, check the fuel visually from
time to time to ensure that you do not run out of fuel.
By looking at the instruments now and again, you will discover abnormal values
in time, which means measures can be taken to prevent the occurrence of
major damage.
If red lamps light up or are lit, stop the vehicle at once and take suitable
measures. If you do not, your safety could be endangered or the vehicle could
be damaged.
If a yellow lamp lights up, you have to take action as this shows that there is an
abnormal situation. Other lamps indicate a connected function.
The main current must be connected with the battery isolator and the starting
lock in position 1, for you to be able to check the function of instruments and
controls.
Warning Signals
When something is wrong with any of the components on your machine, warning lights will
come on and a buzzer will sound, depending on the severity of the problem.
Level 3 Level 2 Level 1
The indicator and the fault The indicator and the fault Indicator comes on for
light will come on and the light come on. operator awareness
fault alarm will sound. The problem will be rectified To be rectified at next weekly

LEARNER GUIDE
Machine is not to be at the next daily service. service

operated. Report this to your Supervisor Examples of Level 1
Stop on safe spot and shut who is then responsible to Warnings:
down organize the Service truck to Fuel Level, Charge List, Park
Examples of Level 3 implement. Brake
Warnings: Change operating procedure
Engine Oil Pressure, Air Examples of Level 2
Leaks, Transmission Oil Warnings:
Pressure, Water Temperature Transmission Oil
Temperature, Hydraulic Oil
Temperature
Warning Operation
Warning Indications (1)
Alert Action The Required Action
Warning Possible Result (2)
Indicator Light Action from the Operator
Category
Flashes Flashes Alarm
(3) (4) Sounds
1 X No immediate action No harmful effects or
is required. The damaging effects will
system needs occur.
attention soon.
2 X X Change machine Damage to machine
operation or perform components will occur.
maintenance to the
system.
2-S X X X (5) Immediately change Severe damage to
machine operation. machine components
will occur.
3 X X X (6) Immediately perform Injury to the operator or
a safe engine severe damage to
shutdown. components will occur.
(1) The active warning indications are marked with an X

(2) If the required action is not carried out, the following results will occur
(3) The alert indicator flashes 10 times per second
(4) The action light flashes once per second
(5) The action alarm will sound at a steady rate
(6) The action alarm will sound 1 time per second
Safety Features
Safety Messages There are several specific safety messages on your machine. You must
take the time to familiarize yourself with them.
Fire Extinguisher Make sure that a fire extinguisher is available. Be familiar with the
operation of it. Obey the recommendations on the instruction plate.
Horn The horn is hooted to warn people nearby.
Parking Brake The parking brake is engaged to prevent the machine from moving.
Rotating lights The amber flash of the rotating lights increases visibility of the machine in
low light conditions and shows people the vehicle is on its way.
Safety Belts Always check the condition of the seat belt and mounting hardware before
operating the machine.

LEARNER GUIDE

LEARNER GUIDE
Self Test …
1. What do instruments, gauges and controls tell the operator?
2. What do they measure?
3. What happens when there is a level 3 warning?
6. Name five safety features?
Electronic Monitoring System (EMS)

The EMS was designed to assist the operator to monitor any faults in the
machine. It does not relieve the operator from performing their responsibility of
looking for changes regularly, checking the components and watching out for
any new defects while operating.
It is imperative that the basic EMS symbols are studied and understood –
embedded in your mind so that they are easily identified.
Basic EMS Symbols

The Pushing the top of the switch releases a pre-measured amount of
Starting ether into the air intake.
Aid (if Inject ether ONLY while cranking the engine. Use the ether sparingly
equipped) as excessive ether can cause piston and ring damage. Only use
when temperatures are below 0°C (32°F) for cold weather starting
purposes.
Engine The engine start switch must be turned ON to supply electrical power
Start to the operator’s compartment for the EMS to function.
Switch
Panel Test  With the engine stopped, move the test switch up.
Switch  All indicators should come on and the fault light should blink until
the switch is released.
 Release the switch.
 It will return to the OFF position
EMS Warning Categories

The EMS provides 3 warning categories. The first category requires only
operator awareness. The second warning category needs operator response.
The third warning level requires immediate shutdown of the machine systems.
Warning Category/Level 1
Parking / Indicates the parking / secondary brake is engaged and transmission
Secondary is in NEUTRAL.
Brake The indicator should come on during start-up.It should go out when
the parking / secondary brake is released.

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Alternator Indicates the alternator is malfunctioning.

If this indicator comes on, pull to a convenient stop.
Investigate the cause (loose or broken belt etc).
Fuel Level The indicator will light up when the fuel level NOTE: do not
reaches 10% of tank capacity. operate the
To avoid being stranded without fuel, refuel as machine until the
soon as possible within the hour. cause has been
corrected
At this category, the indicator and the fault light will come on. It requires a change in machine
operation to reduce excessive temperature in one or more of the systems.
Coolant Indicates excessive coolant Do not operate the
Temperature If this indicator comes on, pull the machine if the
machine to a convenient stop and indicator stays on
investigate the cause. and the fault light
blinks
Transmission Indicates excessive converter/transmission oil temperature.
Oil If this indictor comes on, reduce load on the machine.
Temperature
If the indicator temperaturestays on, pull to a convenient stop.
Investigate the cause.
Hydraulic Oil Indicates excessive hydraulic oil temperature.
Temperature If the indicator lights up, reduce the load on the system.
If the indicator stays lit, pull the machine to a convenient stop.
Do not operate the vehicle if the indicator stays lit and the fault
light flashes.
At this category, the indicator and the fault light will come on and the fault alarm will sound.
It requires immediate shut down of operation to prevent injury to the operator and/or severe
damage to the system and/or machine.
Brake Oil Indicates low oil pressure to the brakes. Do not operate
Pressure If the indicator comes on, stop the machine the machine
immediately. until the cause
has been
Engage the parking/secondary brake and stop
corrected
the engine.
Investigate the cause.
Engine Oil Indicates low oil pressure. Do not operate
Pressure If the indicator comes on, top the machine the machine
has been
Stop the engine and investigate the cause.
corrected
Coolant Flow Indicates no coolant flow in the engine. Do not operate
If this indicator comes on, stop the machine the machine
has been
corrected
Transmission Indicates that the transmission oil filter should be changed.
Oil Filter Change the transmission oil filter.

LEARNER GUIDE
Other Gauges & Indicators on the Instrument Panel

Parking / Indicates parking/secondary brake is engaged. Do not
Secondary If the indicator comes on during operation, stop operate the
Brake the machine immediately. machine until
the cause has
Stop the engine.
been
Investigate the cause. corrected
Shift the transmission lever to NEUTRAL to stop
the fault alarm.
If the parking/secondary brake and the
transmission is engaged during engine start-up,
the indicator will come on, the fault light will blink
and the fault alarm will sound.
Supplemental Indicates the primary steering has failed and Do not
Steering supplemental steering is being used. If this operate the
Light indicator comes on during operation, the fault machine until
light should blink and the fault alarm should the cause has
sound. been
Steer the machine immediately to a safe location corrected
and stop.
Supplemental steering only works while the
machine is moving.
When the machine operates under supplemental
steering, no directional changes can be made.
Temperature Gauges
Engine Indicates the temperature of the engine coolant.
Coolant Normal operating temperatures are between 75°C (165°F) and
Temperature 93°C.
Maximum allowable temperature is 107°C (225°F) with the cooling
system pressurized.
x Torque Indicates the temperature of the torque converter oil.
Converter Oil The maximum temperature is 130°C (265°F).
Temperature
If the coolant or torque converter exceeds maximum operating
temperatures, the respective indicators will come and the fault
light will blink.
Hydraulic Oil Indicates the temperature of the hydraulic oil.
Temperature Operating temperature is between 80°C - 100° C (176°F - 212°F)
Service Hour Indicates the total operating hours of the engine.

Meter It should be used to determine service intervals.

LEARNER GUIDE
Light Switches
Panel, Tail Move switch to the up position to turn on the panel
and Running lights, tail and running lights
Lights
Flood Lights Move the switch to the top position to turn on both the front and
(Front & Rear) rear flood lights
Flood Lights Move the switch to the top position to turn on cab flood lights.
(Cab)
Auxiliary Flood Move the switch to the top position to turn on auxiliary flood
Lights lights.
Interior Dome Move the switch back to turn the light on

Light
Windshield Wiper / Washer

Front Turn the knob clockwise to turn on the windshield wiper.
Windshield Push the knob to activate the windshield washer.
Wiper & Washer
Spring force will return the knob when released.
Rear Windshield Turn the knob clock wise to turn on the windshield wiper.
Wiper & Washer Push the knob to activate the windshield washer.
Spring force will return the knob when released.
Horn Push the knob down to sound the horn.

Use the horn to alert or signal personnel.
Back-up Alarm The alarm will sound when the transmission control lever is in
the reverse position.
It is used to alert people behind the machine that is backing up.
The back-up alarm is located on the rear of the machine.
Heating & Air Conditioning Controls

Floor Heater The floor heater fan control switch is located on top of the floor heater.
Low Move the switch to the centre to turn the fan off.
Off Move the switch to the centre to turn the fan off.

LEARNER GUIDE
High Move the switch to the right for high fan speed.
Floor Heater The floor heater temperature control switch is located on the side of the floor
Control Switch heater.
Off Move the switch to this position to turn the heater off.
On Move the switch in a clockwise direction to turn the heater on.
Warm Turn the switch clockwise until the desired amount of heating is
achieved.
Off The switch can be set at any position to obtain the desired amount
of heating.
Fan Control
Heat & Air This switch controls the heating and air conditioning three speed
Conditioning blower fan motor.
Fan Speed
Switch
OFF Move the switch to the top position to stop the blower fan.
Move the switch to the right to operate the heating system.
High – H Move the switch to this symbol for highest fan speed.
Medium – M Move the switch to this symbol for a medium fan speed.
Low – L Move the switch to this symbol for lowest fan speed.
Move the switch to the left to operate the air conditioning system.
Low – L Move the switch to this symbol for lowest fan speed.
Medium – M Move the switch to this symbol for a medium fan speed.
High – H Move the switch to this symbol for the highest fan speed.
Temperature Control
Heater – Turn the knob anywhere between OFF (left) and
Temperature MAXIMUM (right) cool.
Variable
Air Turn the knob anywhere between OFF (left) and

Conditioning MAXIMUM (right) cool.
Temperature
Variable
Heating & Air Conditioning System Operation
Heating Turn the blower fan switch to LOW, MEDIUM or HIGH speed.
Adjust the temperature variable control for the desired temperature.
Cooling Turn the blower fan switch to LOW, MEDIUM or HIGH speed.
Adjust the temperature variable control for the desired temperature.

LEARNER GUIDE
Pressurizing Pressure inside the cab will help keep dust out when not cooling.
Turn the temperature variable controls OFF.
Turn heating fan to either LOW, MEDIUM or HIGH speed,
depending on the volume of air needed to keep out dust.

LEARNER GUIDE
De-Fogging Turn the air conditioning fan to LOW, MEDIUM or HIGH speed,
depending on volume of air needed to remove moisture from the air
in the cab.
This will prevent moisture from forming on the windshield and
windows.
Turn on the blower fan.
Adjust temperature controls until moisture level is lowered.
Adjust temperature controls until it is comfortable and windshield
and side windows are free of moisture.
Self Test …
1. What is the purpose of the EMS?
2. How many warning levels are them on the EMS?
3. What action must be taken by the operator for a level 1 warning?
6. How will the operator know it is a level 1 warning?
1.4 Operating Capacities of Service

Trucks

1.4 Explain the maximum operating capacities of Service Trucks in
terms of the designed machine capabilities
Know the capacity and limits of your machine! Before operating your machine
read all plates and instructions which are fitted on the machine and given in the
Operator’s Instruction Manual. Each of the instructions contains important
information about safety, handling and service of the machine.
The maximum operating capacities in terms of the designed machine
capabilities depends on the make and type of machine.
Look for the label which indicates the maximum kgs and tons.

LEARNER GUIDE
Self Check 1
To help to reinforce your learning so far, take 40 minutes to complete this
Self Check. When you have finished, refer to your notes for the answers.
Should you require assistance, your practitioner will discuss the
suggested outcomes with you.
1. Explain the main function of the Service Trucks
2. List all the main components applicable to your machine
3. Describe the function of each of the following components:

Engine
Fuel system
Hydraulic system
Electrical system
Braking system
Cooling system
Final Drives
Proximity of other machines
4. Describe the corrective action you would take once you have received a warning from the
EMS

LEARNER GUIDE

LEARNER GUIDE
Learning Self-Check 1
Having completed this learning activity and signed off this learning self check, you are now
able to:
YES NO
1.1 Explain the main functions of Service Trucks in terms of the
1.2 Explain the operation of all major components of Service Trucks in
terms of their functions.
1.3 Identify and explain all safety features and warning devices on
Service Trucks in accordance with manufacturer’s instructions.
1.4 Explain the maximum operating capacities of Service Trucks in
terms of the designed machine capabilities.
1.5 Explain the warnings from Service Trucks indicators and gauges
according to manufacturer’s instructions.
1.6 Describe or demonstrate corrective actions in terms of neutralizing
warnings received from Service Trucks.
Learner’s signature: Date:
Practitioner’s signature: Date:

LEARNER GUIDE
LEARNING ACTIVITY 2
Start and Shut Down

Service Trucks
The purpose of this Learning Activity is to enable you to prepare for on-site
operations by starting and shutting down Service Trucks
Specific Outcome 2
■ Conduct pre-operational checks of Service Trucks according to

appropriate checklist.
■ Perform daily and weekly operator maintenance on Service Trucks in
accordance with post-operational checklists.
■ Complete checklists according to worksite procedures and take corrective
action if required, ensuring compliance with manufacturer’s instructions.
■ Start up and shut down Service Trucks according to manufacturer’s
instructions.
■ Park Service Trucks according to manufacturer’s and company
requirements.

LEARNER GUIDE
2.1 Pre-operational Checks

In order to make sure that all components on the Service Truck are
100% operational and everything is safe to start operation, it is
necessary to perform a pre-start inspection and record what you find
on the checklist.

2.1 Conduct pre-operational checks of Service Trucks according to the Pre-
Start Inspection Checklist
Walk Around Checks

Before you can be sure that the machine is safe to operate, you must do a walk
around inspection of the machine. This walk around inspection enables the
operator to ascertain exactly what is right and what is wrong with the machine
before he starts up and proceeds to site. If this walk around inspection is carried
out correctly, it will save the operator and fellow workers from potential danger.
The walk around inspection should highlight defects such as low oil levels,
radiator leaks, worn or cut tyres, loose nuts and bolts, chaffed hoses, worn
ground engaging equipment and many more aspects. Walk around checks must
be carried out daily before each shift or days start of work. If operators are
changed during a shift, for whatever reason, the operator taking over the
machine, must perform a walk round check.
These walk round checks must be done systematically, starting at one end of
the machine, moving around the machine and ending up where the check
started. Because it is extremely easy to forget or overlook a certain point or
points during the check, it is recommended that a walk round check-list be
used.
The check-list should incorporate all the points and components that should be
checked and these points are then marked off as having been checked and
either found serviceable or unserviceable. These check lists should be filed and
kept for a certain period in case of an accident. The history can then be
retrieved to high-light any negligence on the part of the servicemen or operator,
should an investigation be called for.
Walk Around Checks

Standards The following five specified standards that must be applied when performing a
walk round check on any machine:
1. Use the prescribed check-list
2. Inspect all the items listed on the check sheet
3. Report the defects according to the prescribed standards
4. Complete the walk round check within 15 minutes
5. Follow the sequence of the check-list
Component When checking the different components on the check-list the operator has to:
Checking

LEARNER GUIDE
 Use the prescribed form to do this check (see PRE-SHIFT CHECKLIST)

 Check the six views namely front, left side, rear end, right side, underneath
and the top of the machine.
 Check all components listed on the inspection sheet.
 Complete the appropriate box.
Testing for After checking the components on the checklist, get into the operators
function compartment.
 Test and ensure that all machine functions like the EMS, supplementary
steering, all brake systems and hydraulic systems are working as required
and specified.
 Mark the appropriate box.
Reporting At the end of the inspection, report the findings to the supervisor or pit
controller.
 Report the faults, if any, or report conditions O.K.
 When you finish the inspection sign the inspection sheet and hand it to the
supervisor immediately.
Consequences of  Machine failure
Failing to Carry  Loss of production
Out a Walk
Around  Cost - Replacement, Repair, Down-time, Increased production cost
Inspection  Loss of productivity
 Reduced profitability leads to loss of employment opportunities, lower
increases or bonuses
Establishing Your At the start of each shift the operator must check with his supervisor to
Work establish exactly what his work requirements are for the day.
Requirements for There are certain questions that the operator should ask the supervisor to
the Day ensure that he understands exactly what is expected of him for they are :
1. Which machine he should use for the day?
2. On which site and where on the site he should work for the day?
3. Where he can find the check list for the machine that he has to
operate?
4. Whether any faults were reported about the machine from the
previous shift?
5. Is the machine due for any scheduled maintenance during his shift?
6. Who he should report to on site when he gets there?
Self Test …
1. Why is the walk around check important?
2. What are the 5 walk around standards?
3. What six views must you check when component checking?
4. What questions should the operator ask the supervisor to ensure
that he understands exactly what is expected of him?.
5. Why are walk around checks important?
6. What are the consequences if you don’t do the walk around checks?
Pre-start Checks
As the operator, you are responsible for the roadworthiness and handling safety
aspects as soon as the Service Truck is handed over to you.

LEARNER GUIDE
Part of your pre-start and operator maintenance responsibilities consist of

Measuring engine oil level, Measuring transmission oil level, Measuring final
drive oil level, Measuring hydraulic oil level, Reporting faults according to
procedure, Take appropriate action if any instrument panel warning light or EMS
lights up.
Measuring Oil Levels

The most important aspects to check on any vehicle or machine are the oil, fuel and other fluid
levels of the different components.
 In most instances, as long as the oil in the compartment is still good and at the correct level,
damage will be avoided, or at least reduced.
 Every compartment that contains oil, be it engine, transmission or hydraulics, will have some
method to check the level inside.
 Usually, a dip stick or sight glass is used to check the oil level. It is extremely important that
the operator knows exactly how to read and interpret the level indicated on the dip stick or in
the sight glass. DO NOT GUESS how to check the oil levels - rather ask for assistance and
additional training. Too much oil in a compartment will also cause problems such as
overheating or burst oil seals.
 The operator must ensure that they know which type of oil must go into each compartment,
as the incorrect oil grade will not have the right viscosity and additives to protect that system
sufficiently – approach the mechanic or manufacturer is in doubt.
 Your supervisor or mechanic will rather show you again, as a mistake can be extremely
costly. Do not be embarrassed to ask, because you will be even more embarrassed if
something goes wrong.
Oil Level Dip Sticks Sight Glass
Checking All motor cars, trucks, earthmoving The sight glass method is sometimes
Methods plant and practically any engine, used to check oil levels in
There are a few have dip sticks so that the oil level in compartments that do not have dip
different the engine can be checked. sticks.
methods of The dip stick has markings on it A sight glass is usually a round see-
checking oil which usually indicate low oil level, through glass eye located on the oil
levels in sate oil level and oil compartment full compartment tank, through which the
different level. oil level can be clearly seen.
compartments
As the name suggests, the dip stick The sight glass is located at a pre-
of machines:
is literally a metal rod, which is found determined height on the
Dip Stick or
on the side of an engine, usually in compartment. The exact height is
Observing a
an easily seen and easy to get to determined by the manufacturers
Sight Glass
position, which extends down into the
engine sump.
after tests and calculations as to

what volume of oil is used by that
particular system and exactly how
much oil the tank should hold.
The manufacturers have also
determined what the oil level in the
tank should be when all the
attachments are in a certain position.

LEARNER GUIDE
In most cases, the oil we see in the

sight glass should only be halfway
when all the attachments are lowered
and the control levers are in the
neutral position.
Oil compartments on which we
usually find sight glasses are:
 Transmission systems
 Hydraulic systems
The rod is marked by the engine

manufacturer after testing what
quantity of oil should be in that
engine sump.
The markings on the dip stick always
indicate the lowest oil level that
should that should be in the engine
sump, as well as the highest oil level,
if the engine is to be started.
Some manufacturers place additional
markings on the dip stick to assist the
person checking the oil level. These
additional markings sometimes
indicate the safe oil level to start the
engine and others indicate the safe
engine operating oil level.
Oil Level The correct method of checking oil levels:

Checking  Ensure the machine is parked on a level surface
 Clean around the dip stick socket.
 Remove the dip stick.
 Check which side of the dip stick has the correct markings for checking
the oil level prior to starting the engine.
 Check where there is evidence of oil on the dip stick.
 Note whether the oil clinging to the dip stick is within the safe ranges
marked on the dip stick.
 Check the oil colour is correct, and not white, which indicates that water.
 Has penetrated the oil system
 Once the oil level has been established in relation to the markings on the
dip stick, wipe the dip stick with a clean rag, and replace the dip stick hack
carefully.
If the oil level is found to be too low, then add additional oil of the same type
to that compartment until the desired oil level is reached.
Oil The following oil compartments must be checked:
Compartments  engine
That Must Be
Checked  transmission

LEARNER GUIDE
 hydraulic
 differential and final drives
Tyre Maintenance
Tyres are an extremely expensive component of machine maintenance and if not correctly
maintained can be even more costly.
One very important factor to consider at  One of the biggest causes of tyre wear and
all times is the actual amount of tyre damage is the incorrect tyre inflation pressure.
rubber actually on the road at any one  If the tyre is under-inflated or over-inflated, we find
time. On a normal passenger vehicle, certain damage does occur to the tyre and the
the amount of tyre rubber in actual tyre sidewalls.
contact with the road is approximately
the size of your palm, per wheel. So you  The actual tyre tread wear pattern usually
can see there is very little rubber indicates whether the tyre has been utilized under
controlling your safety, especially at or over inflated over a period of time.
high speeds.  The most important thing an operator can do to
It is extremely important that the prevent excessive tyre wear or damage, is to
machines tyres are maintained and check the tyre inflation pressure regularly and to
cared for correctly. do it correctly.
Care is often one of the most neglected  Incorrect tyre inflation pressures do affect the
aspects of machine care, and yet the handling or control of a machine, and must
actual maintenance is relatively simple therefore he regarded as a safety hazard.
and easy, once the operator has been  In most companies and organizations, it is the
trained, knows how to do the required responsibility of the operator to check the tyre
checks, knows how to perform the inflation pressures of the machine he / she
corrective action and is more aware of operate.
the vehicle machines tyres.
 The tyre pressure should be checked with a
gauge that is calibrated correctly and therefore
accurate when the Ire is cold. Test the tyre
pressure gauge against another gauge from time
to time just to ensure that the gauge is still
accurate.
 Tyre pressures should ideally he checked while
the tyre is still cold, as the increase in tyre heat
causes the air inside the tyre to expand, resulting
in an increase in tyre pressure and eventually an
over-inflated tyre, which causes excessive tyre
wear.
 Manufacturers specified tyre inflation pressure is
usually specified for a cold tyre, unless otherwise
stated in their machine maintenance manual.
 If the tyre pressure seems low and has to be
checked while the tyre is hot, first check the tyre
pressure of another tyre on the same machine
that seems correct, to establish the air pressure
inside that particular “hot” tyre, and inflate the
problem tyre to the same air pressure. As this is
not the most ideal method, but more a “quick fix”
to a particular problem.
 Remember to re-check all the tyre pressures later
when the conditions are better.
On some machines. (especially trucks) we often find
that the rear axle is fitted with grip or off-road tyres
while the front axle is fitted with hi-way or on road
tyres, depending on the particular function and tasks
of that particular machine.
Tyre Air Tyre air pressure gauges come in many different types, shapes, sizes, makes

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Pressure and models, but all perform the same function.

Checking The function of the air pressure checking gauge is to measure the air pressure
Gauges inside the tyre being checked.
The main types of tyre air pressure checking gauges are:
 the dial type gauge
 the linear “blow out” type gauge
 the combined air pressure gauge and inflation chuck type
Dial Type Linear “Blow Out” Type Combined Air Pressure Gauge
The dial type tyre air  The linear “blow out” tyre and Inflating Chuck
pressure gauge usually air pressure gauge is  The combined air pressure
has a stem that usually a round hollow gauge and inflating chuck type,
attaches to the valve of cylinder with an inner combines the two functions and
the vehicle / machine cylinder that is marked with enable the driver / operator to
and a round dial at the air pressure readings. check tile tyre air pressure and
other end of the stem. easily and conveniently inflate
 The inner cylinder the tyre should it require
The round dial gauge is resembles a ruler and is inflating.
marked with the able to move in and out
different air pressures within the outer cylinder.  This model is extremely
and once the end of the convenient and popular and is
 When the one end of the used on service trucks and other
stem is attached to then
gauge is attached to the locations where air compressors
valve, the lyre air
tyre valve, the air pressure are available.
pressure is indicated on
inside the tyre forces the
the dial with the aid of inner cylinder to move  As the air pressures inside a
an indicating needle. outwards and the air normal passenger vehicle and a
pressure marking that line large earthmoving machine
up with the end of the outer differ vastly, it is not always
cylinder indicates the actual possible to use the same air
air pressure inside that tyre. pressure checking gauge on
both vehicles and machine, as
the range of the gauge may not
come the smaller and large
spectrum of air pressures. It is
due to this fact that the driver /
operator should always establish
whether he / she is using the
correct gauge.
Tyre Air Pressure The correct procedure to check the tyre air pressure is as follows
 Establish the correct specified air pressure for that particular tyre
 Remove the valve caps from the valve
 Reset the air pressure checking gauge
 Attach the air pressure gauge to the valve
 Check the reading on the air pressure gauge
 Compare the air pressure gauge reading with the manufacturers spec.
If the air pressure inside the tyre is correct according to the manufacturer’s
specification then:
 Remove the air pressure checking gauge
 Replace the valve cap
Inflating the Tyre Should the driver / operator have checked the tyre air pressure and found
that the tyre is under -inflated, the following procedure should be followed
 Attach the air pressure inflating chuck to the valve
 All persons must stand next to the tyre and NOT in front of the tyre,
before and during the process of pumping air into the tyre
 Press the air pressure inflating lever for a short period depending on

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how much the tyre air pressure needs to be increase by and then
release the lever
 Re-check the tyre air pressure with the appropriate gauge as instructed
in the section on “checking the tyre air pressure” above.
 If more air inflation is required. repeat the inflating and checking
procedure until the desired tyre air pressure is obtained
If over-inflation has occurred, depress the valve pin so that air escapes via
the valve, until the specified lyre air pressure has been obtained.
Tyre Inflation with  In some companies and in certain
Nitrogen Gas circumstances and applications, tyre are
inflated using Nitrogen gas, instead of
normal compressed air. Proper Nitrogen inflation
 Tyre Inflation with Nitrogen (N2) gas for equipment and training in
both tyre inflation, and tyre pressure using the equipment are
adjustments on all rubber tired necessary to avoid over
machines. Nitrogen is an inert gas and inflation.
will not support combustion inside the
tyre. Use a self attaching
 A tyre blow out or rim failure can result inflation chuck and stand
from improper or misused equipment behind the tread when
and serious personal injury or death can inflating a tyre, to prevent
occur. possible personal injury.
 Because a fully charges nitrogen
cylinders pressure is approximately NOTICE set the tyre
15000 kPa 2200 (psi) inflation equipment
 A tyre blow out and rim failure can occur regulator at no more than
if the inflation equipment is not used 140 kpa (20 psi) over tile
correctly. recommended tyre
pressure.
 In addition to reducing the risk of an
explosion, using nitrogen to inflate tyres
lessens the slow oxidation of the rubber
and the accompanying gradual tyre
deterioration.
 This is especially important for tyres that
have an expected long service life - four
or more years.
 It also reduces the corrosion of rim
components and the resultant
disassembly problems.
Cab Inspection
You begin the cab inspection by ensuring the parking brake is on and the transmission is in
neutral or park, if automatic. Start the engine and listen for unusual noises. Allow the engine to

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warm up properly. This takes between 3 to 5 minutes.

Gauges Check the condition of the following for looseness, sticking, damage, or
Controls improper setting:
 Steering wheel
 Clutch Accelerator pedal
 Brake controls, such as foot brakes, trailer brakes, parking brakes, and
retarder controls
 Transmission controls Inner axle differential lock (if so equipped)
 Horn(s) Windshield wiper/washer
 Lights, such as headlights, dimmer switch, turn signals, four-way flashers,
clearance, identification, and marker lights
Mirrors And Inspect mirrors for cracks, dirt, looseness, and obstructions. Clean, tighten,
Windshield and adjust as necessary.
Emergency Check for safety equipment, such as:
Equipment  Spare electrical fuses (unless the vehicle has circuit breakers)
 Three red reflective triangles
 A properly charged and rated fire extinguisher
 Tyre changing equipment
 Accident reporting package
Brake Test If your vehicle is equipped with hydraulic brakes, perform the following test to
check the brake system:
 Pump the brakes three times, then apply firm pressure to the pedal and
hold for 5 seconds.
 The pedal should not move. If it does, there may be a leak or other
problems.
 To test the parking brake, you should allow the vehicle to move forward
slowly and then apply the parking brake.
 To test the service braking action, you should proceed at about 5 mph,
then push the brake pedal firmly. A pull of the vehicle to one side or the
other or any delay in stopping action is an indication of brake trouble.
Any brake problems that occurred during this testing must be documented
and repaired before operating the piece of equipment.
Air Brakes Air brakes use compressed air to make the brakes work. They provide a safe
way to stop large vehicles when maintained and used correctly. The air brake
system is composed of three combined braking systems, the service
brake system, the parking brake system, and the emergency brake system.
 The service brake system applies and releases the brakes when you use
the brake pedal during normal driving.
 The parking brake system applies and releases the parking brakes when
you use the parking brake control.
 The emergency brake system uses parts of the service and parking brake
system to stop the vehicle in the event of a brake system failure
Self Test …
1. What are the most important things to check on a vehicle or machine?
2. What will reduce wear and damage?
3. Name two ways of checking oil levels
4. What will happen if too much oil is in a compartment?
5. What is the correct oil level in a sight glass?

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6. Where must the attachments be when checking the oil levels?

7. How must a machine be parked when checking the oil level?
8. What can be done to minimize tyre costs?
9. List two things drivers and operators must know how to perform.
10. Name the two incorrect tyre inflates we get.
11. Who is responsible for checking tyres?
12. What can incorrect tyre inflation pressures affect?
13. When is the ideal time to check tyre pressures?
14. When inflating tyres, what type of chuck should you use?
15. When inflating a tyre, where should the person stand?

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PRE-SHIFT CHECKLIST – RIGID SERVICE TRUCK

All items to be checked for condition and function
Date Shift D A N Equipment No
Entry in ‘GO’ = vehicle can move Operator Coy No

Entry in ‘NO GO’ = vehicles does not move
All Systems Operating GO NO GO Artisans Report
Brakes
Steering/
Supplementary
Steering
A HAZARDS
Engine Oil
Transmission Oil
Seat Belts
Reverse Hooter
Rotating Light
Entry in ‘GO BUT’ Notify Foreman

Components GO GO BUT Remarks
Tyres
Hydraulic Oil
Service Compartment
Oil Leaks
Radiator
Fire Extinguisher
B & C HAZARDS
Front Lights
Tail Lights
Filter Indicator
EMS/CMS Check
Handrails/Steps
Seat
Lock-out
Stop Blocks
PPE
Suspension
SMR Reading
Operator’s Signature Production Foreman’s Signature

Engine Foreman’s Signature
Time Stopped Time Returned
Artisan’s Signature

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PRE-SHIFT CHECKLIST – ADT SERVICE TRUCK

All items to be checked for condition and function
Date Shift D A N Equipment No
Entry in ‘GO’ vehicle moves Operator Coy No

Entry in ‘NO GO’ vehicle does not move
All Systems Operating GO NO GO Artisans Report
Brakes
Steering
A HAZARDS
Engine Oil
Transmission Oil
Seat Belts
Reverse Hooter
Rotating Light
GO
Components GO Entry in ‘GO BUT’ Notify Foreman Remarks
BUT
Tyres
Hydraulic Oil
Service Compartment
Oil Leaks
Radiator
Fire Extinguisher
B & C HAZARDS
Front Lights
Tail Lights
Filter Indicator
EMS/CMS Check
Rails/Steps
Seat
Lock-out
Stop Blocks
PPE
Suspension
SMR Reading
Operator’s Signature Production Foreman’s Signature

Engine Foreman’s Signature
Time Stopped Time Returned
Artisan’s Signature
Comments

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2.2 Daily & Weekly Maintenance

Doing regular maintenance inspections is a very important for many
reasons:
1. to check for and repair defects on the earthmoving equipment or
plant early (eg cut or worn hydraulic hoses, damaged fuel lines, loose
bolts or nuts).
2. to identify the need to make repairs to plant or equipment before
defects get worse and become expensive (eg oil leaks, lubrication oil
or hydraulic oil and v-belts)
3. to replace critical parts and components that have a known life
expectation. The parts or components are replaced (eg oil filters, oil
seals etc.) before they fail and cause major damage
4. to help make the plant or equipment last longer before it must be
replaced
5. to help keep down maintenance costs
6. to follow manufacturer’s maintenance instructions to protect
warranties and guarantees.

2.2 a) Perform daily and weekly operator maintenance on Service Trucks in
accordance with post-operational checklists b) Complete checklists according
to worksite procedures and take corrective action if required, ensuring compliance
with manufacturer’s instructions.
Personal Development
This section will assist you with preparing yourself whenever you are about to
embark on a task or project, at work or in your personal life. Once mastered,
you will realize that by applying these basic steps before starting a task, and not
just attacking it blindly, the day and the task will be less disrupted, and seem to
pass more smoothly. These basic steps of thinking ahead can be applied every
day where ever we are and what ever we are doing. The more use we make of
this technique, the more it will become second nature, and we will find that we
are applying without thinking about it.
Receiving Instruction
When the operator reports for The types of questions that the operator should ask are:
his daily work or shift, he must 1. What his task for the day is?
first stop and check with his
2. Which machine he should use for the day?
supervisor as to the days work
requirements. The supervisor 3. At which site he is to work and where on the site
should advise him of the 4. Where the check list is for the machine that he is to
requirements for the day, in operate
case they have changed from 5. If any faults were reported about the machine from the
the day before, due to previous shift?
circumstances.
6. Is the machine due for any scheduled maintenance that
day?

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7. Who is he to report to on site when he gets there?
These questions, if answered correctly by the supervisor, will give the operator
all the information he needs to perform his daily task, with the least disruption.
Should the operator forget to ask these type of question, and simply gets into
the machine and sets off to the same site and location where he worked the day
before, he might find that work has stopped at that particular location, due to
safety or other reasons and place himself in extreme danger. He will also have
wasted a lot of production time etc.
If he just takes the same machine he always uses, without checking whether
the previous shifts operator reported any defects, he might realize too late that
the machine is not serviceable and have an accident that may injure him or his
fellow workers
These are just some of the many possible situations that might occur, should
the operator decide to ignore the basics of preparing to drive or operate
vehicles and plant.
Maintenance Inspection Information

Before you begin any maintenance inspection you must first obtain all the information about that
particular maintenance inspection that you need. What sort of information will you need?
Answer these 1. What piece of equipment or plant must you service?
questions for 2. Which service must you do (10, 250, 500, 750, or 1000 hour service?)?
yourself each time
3. For when (date and time) has this service been booked?
you prepare for a
new maintenance 4. Who is assigned to carry out the service? Is he available?
inspection. By 5. Do you have service cards for the planned service? Are they the right
answering these ones? Where are the service cards kept?
questions, you will 6. Has the operator of that equipment or plant given you (or your
create a list of all of department) any complaints about the equipment or plant, which could
the information you (or must) be attended to during the planned service?
will need.
7. Are these complaints in writing? Are they clear, understandable and
specific? If they are verbal, have you written them down and confirmed
that what you have written down is the same as what the operator or
originator said to you? Do you need to get any more information from
the operator or originator, or from anyone else?
8. Where (in the workshop, in the mine, in the bush) will the earthmoving
equipment be serviced? Can you reach it safely there? Can it be or has
it been positioned for servicing? Is there a better way?
9. Do you have all the safety related information you need to complete
the service? Have all procedures been followed?
Is there anything else that you must know before you begin to service the
piece of earthmoving equipment or plant? Make sure that there are no
last minute instructions from your mechanics or fitters.
Prepare the Service Truck
The second step in You prepare the service truck before doing a maintenance inspection for
the process of several reasons:
preparing to service 1. To check for, and if necessary obtain, the equipment (tools, jacks,
a piece of power tools) necessary for you to do the planned (scheduled)
earthmoving maintenance inspection and service expertly
equipment or plant is
2. to check for, and if necessary obtain, the materials (oils, lubricants
to prepare the
etc) necessary for you to do the planned (scheduled) maintenance
service truck. You

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have already inspection and service effectively

collected all the 3. to check for, and if necessary obtain, the consumables (filters,
information that you cleaning materials etc) necessary to do the planned maintenance
need. This was what inspection and service professionally.
you were asked to
4. to check for, and if necessary obtain, the personal protective
identify in the work
equipment [PPE] (hard hat, safety shoes, gloves) necessary to do
that you have just
the planned maintenance inspection and service safely.
completed. Now it is
time for you to move 5. to ensure that the tools and equipment are serviceable (ready for
on. use) and in good condition
6. to ensure that the service truck itself is ready for safe use (fuelled,
cleaned, repaired and operational)
There are 4 critical tool and equipment checks that you must carry out:
 Is the oil sample kit in the truck?
1  Is it clean, in good working order and useable? is there a spare kit?
Oil Sample Kit
 Are there enough sample bottles for the day?
 Do whatever needs to be done to make the oil sample kit fit for use (clean,
replace, repair, find etc.)
 Are all the tools and equipment in the service truck and in their correct
2 positions?
Tools and  Find and/or replace missing tools and equipment if it is necessary to do so.
Equipment
 Are there any special tools and equipment required for the planned
(scheduled) services? Can they be used in the location of the planned
service? If not what other arrangements must be made?
 Confirm these with your mechanic or fitter. If there are special tools or
equipment needed find them, check them and load them. If special
arrangements need to be made for the equipment, make these
arrangements.
 Are specialized equipment items loaded on the service truck (grease guns,
special applications greases etc)?
 Are there sufficient greases, oils, and lubricants to do all the planned work?
 Are there sufficient supplies of the standard spares (oil filters, air filters etc)?
3  Are specialized spare items required and have they been loaded on the
Spares service truck?
 Confirm these with your mechanic or fitter. If there are special spares
needed, requisition them, check that they have been correctly issued and
load them.
 CHECK YOUR LIST OF SPARES, TOOLS AND ANCILLARY EQUIPMENT
TO BE LOADED ONTO THE SERVICE TRUCK.
 Are there sufficient supplies of the standard lubricants (oil, torque fluid,
4 brake fluid etc)?
Oils  Are specialized lubricants (special applications) required and have they
been loaded on the service truck?
 Confirm these with your mechanic or fitter. If special lubricants are needed,
requisition them, check that they have been correctly issued and load them.
 CHECK YOUR LIST OF GREASES, OILS, ETC.
Check the Service Truck
There are 5 critical checks that you must carry out on the service truck itself:
 Are the oil pumps working?
1  Are there any signs of oil leaks?
Oil Pumps
 Are the oil hoses in good condition?
 Is the oil pump area clean & safe?

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 Report any defects to your mechanic or fitter.

 Take housekeeping actions if needed.
Make sure that you comply with all safety precautions and use your personal
protection equipment
 Is the hose reel operating smoothly?
2  Are there any signs of wear?
Hose Reel
Operation  Are there any other defects beginning to show?
 Report any defects to your mechanic or fitter.
protection equipment.
 Is the power washer working?
3  Is the power washer operating at its correct pressure? Are gauges working?
Power Washer
 Is the power washer water tank full?
 Are there any signs of water leaks? Hydraulic oil leaks?
 Have you noticed any unusual sounds or vibrations?
 Report any defects, especially unusual noises and vibration, to your
mechanic or fitter.
protection equipment
 Is the compressor working?
4  Is the compressor reaching its correct operating pressures? Is its pressure
Compressor gauge working?
 THE OPERATING PRESSURE IS …….
 Are there any signs of air leaks?
 Have you noticed any unusual sounds or vibrations?
 Is the compressor oil level correct?
 Report any defects, especially unusual noises and vibration, to your
mechanic or fitter.
 Take housekeeping action if needed.
protection equipment.
 Is your service truck operationally safe?
5  Tyres are correctly inflated and meet legal tread specifications (including
Safety spares)
 Head, tail and indicator lights all work as designed
 Windscreens and windows are clean and wipers work effectively
 All safety systems (hooter, reverse siren, hand brake, fire extinguisher(s),
etc. are in place, have been tested and are working
 All loose equipment and material is securely tied down to prevent
movement while the truck is in motion
 First aid/medical supplies meet with legislation standards and are easy to
reach in an emergency
 Flammable liquids and materials are contained in fire- proof containers.
Prepare Vehicles or Plant before Maintenance

So far you have studied how you must collect all the information that you need
and how you must prepare the Service Truck before doing the maintenance

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inspection/service. The third step in the process of preparing to service a piece

of earthmoving equipment or plant is to prepare the earthmoving vehicle or the
plant that must be serviced.
You prepare the vehicle or plant before servicing it for several reasons:
 To check for, and to ensure that, the vehicle(s) or the plant that your team
will service is made available and can be reached conveniently.
 To check for, and to ensure that, the vehicle(s) or the plant that your team
will Service is safe to work on.
 To check for, and to ensure that, suitable housekeeping type actions have
been performed on the vehicle(s) or the plant that your team will service.
Preparing Machine Before Maintenance

You must complete three main activities when preparing the vehicle or plant:
Position the  Is the vehicle on level ground? Is there a better position for this vehicle?
Machine  Can the plant be moved to a more convenient position for the service to be
done on it?
 Are Mines Health and Safety Act regulations being kept? Are these
regulations available to you?
 Are you authorized/licensed to position (drive, move, maneuver) the
vehicle(s) to be prepared for servicing
Complete Pre-  Is the pre-service safety checklist the correct one for the vehicle or plant to
service Safety be serviced? Is it up to date?
Checks  Are all the checklist items easy to identify and check? Are you authorized to
make any adjustments to the vehicle or plant required by the pre-service
safety checklist?
 Is the vehicle or the plant a safe distance from electric power sources
(power lines, extension cables, hi-walls, sidewalls etc)?
 Are standard health and safety requirements for the vehicle in place?
- Vehicle is on level ground
- Chocks have been placed in front and behind vehicle wheels and vehicle
- Hand brake is engaged
- Ground engaging hydraulic tools are grounded
- Transmission is in neutral
- Safety warnings and “do not start/operate” tags are placed on vehicle/plant.
 Are the bucket & articulation locking devices in place?
 Are Mines Health and Safety Act regulations and site safety rules being
adhered to?
 Are standard safety requirements for the plant in place (including site safety
rules)?
- Plant is supported to prevent toppling
- All safety features are “ON” (stop button)
- All power sources are isolated (electrical-mechanical drives, gearboxes etc)
- Plant is protected from dust, moisture, insects etc.
Ensure  Are all heavy/moving vehicle parts (buckets, hinges, hydraulic tools etc
Personal anchored or isolated?
Safety  Is personal protective equipment available for all workers on the vehicle?
 Is medical/first aid/fire fighting equipment easily available in an
emergency?
10 Hour or Daily Service
Air Tank The primary air tank is located on the right hand side of the platform.

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Moisture & The secondary air tank is located to the right of the operator’s compartment.
Sediment – 1. Open drain valves for the air tanks
Drain
2. Check for moisture and sediment in the air tanks. Drain the moisture and
the sediment from the air tank into a suitable container.
3. Close drain valves for the air tanks.
Backup Alarm Make sure the parking brake is engaged
Test Turn the engine switch to the ON position in order to perform the test.
Make sure that the area behind the machine is clear of personnel and clear of
obstacles.
Move the transmission direction and speed control lever to the REVERSE
position.
The backup alarm should sound immediately. The backup alarm should sound
immediately. The backup alarm should continue to sound until the
transmission direction and speed control lever is moved to the NEUTRAL
position or to the FORWARD position.
Brakes, Test for Proper Function
Indicators Look for broken gauge lenses or indicator lights, switches, etc.
and Gauges
Start the engine.
Look for inoperative gauges.
Turn all machine lights on. Check for proper operation.
Sound the forward horn.
Move the machine forward and test the service and parking/secondary brakes.
If the brakes do not function properly refer to ‘Brakes’ in ‘250 Hours or Monthly
Service’ section.
Stop the engine
Make any needed repairs before operating.
Differential & Use sight gauge to check the oil level for the differential
Final Drive Oil Maintain the proper oil lever at the bottom of sight gauge
Level
If necessary, add oil. Clean the area around the cover. Clean the cover. Install
the cover.
Engine Air Start the engine
Filter Service Run the engine at torque converter stall speed.
Indicator
If the yellow piston in air filter service indicator enters the red zone, service the
air cleaner
Stop the engine
Engine Oil Check the Oil Level
Level NOTICE: Do not overfill the crankcase. Engine damage can result
Wipe covers and surfaces around openings before checking or adding oil.
1. Open the access cover on the right side of the machine.
2. Maintain the oil level between ADD and FULL marks on the dipstick with
the engine running. Maintain the oil level between the LOW and FULL
marks on the engine stopped side of the dipstick with the engine stopped.
3. Remove the oil plug and add oil if necessary.
4. Clean and install the fill plug.
5. Close the access cover.
Hydraulic Check the Oil Level
Tank Oil Wipe covers and surfaces around openings before adding oil.
The hydraulic oil tank is located on the right side of the machine.
Maintain the oil level above the ADD COLD mark on the sight gauge

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Remove the oil fill cap and add oil, if necessary, through the fill tube
Clean and install the fill cap
Radiator Look at the coolant level
The coolant level sight gauge is located on the right side of the engine
compartment.
Check the sight gauge for the coolant level.
ADDING COOLANT
The radiator cap is located in the top hood of the machine at the right rear.
1. Open the access cover in the hood.
2. Remove the radiator cap slowly to relieve pressure.
3. Maintain the coolant level to within 1cm of the bottom of the fill pipe. If it is
necessary to add coolant daily, check for leaks
4. Inspect the cap and cap seal for damage, deposits or foreign material.
Clean the cap with a clean cloth or replace the cap if it is damaged.
5. Install the cap. Close the access cover.
6. Inspect the radiator core for debris and clean if necessary.
Compressed air is preferred, but high pressure water or steam can be used to
remove dust, leaves and general debris from a radiator. Clean as required by
condition of radiator.
Seat Belt Inspect for Wear and Damage
Seat belt and mounting hardware must be inspected for wear or damage
before operating the machine. Replace the belt or mounting hardware if worn
or damaged.
Transmission Check the Oil Level
System Oil Wipe covers and surfaces before checking the or adding oil
1. Open the access cover located on the platform behind the operator’s
compartment
2. Maintain the oil between the ADD and FULL marks on the dipstick at LOW
IDLE
3. Remove the oil fill cap and add oil if necessary.
4. Clean and install the fill cap. Replace the filter element if the cab
transmission oil filter indicator comes on during operation. Refer to
‘Transmission Filter’ in 500 or 3 Months Service.
Walk-around Inspect Machine
Inspection NOTICE: Accumulated grease and oil on a machine is a fire hazard. Remove
this debris with steam cleaning or high pressure water, at least every 1000
hours or each time any significant quantity of oil is spilled on a machine.
NOTE: Keep a close watch for leaks. If leaking is observed, find the source
and correct the leak. Check the fluid levels more frequently than the
recommended periods if leaking is suspected or observed.
1. Inspect the engine pre-cleaner bowl for dirt buildup. Remove dirt from bowl
when any dirt has accumulated close to the full line on the bowl.
2. Inspect the bucket and linkage for damage or excessive wear. Repair if
damaged.
3. Inspect the light for broken bulbs and lenses. Replace if broken.
4. Inspect and remove any trash buildup in the engine compartment.
5. Inspect the cooling system for leaks, faulty hoses and trash buildup.
Correct any leaks and remove any trash from the radiator.
6. Inspect the hydraulic system for leaks. Inspect the tank, cylinder rod seals,
hoses, tubes, plugs, joints and fittings. Correct any leaks.

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7. Inspect the differentials and final drives (front and rear) under the machine
for leaks.
8. Inspect tyres (front and rear) for damage and proper inflation. Replace any
missing valve caps.
9. Inspect transmission for leaks.
10. Be sure the covers and guards are firmly in place, Inspect for damage.
11. Inspect the steps, walkways and handholds for their condition and
cleanliness. Inspect the Rollover Protective Structure (ROPS) (if equipped)
for damage. Tighten any loose ROPS bolts.
12. Inspect the operator’s compartment for cleanliness. Keep it clean.
13. Adjust the rear view mirrors for best vision.
Window Use commercially available window cleaning solutions to clean the windows.
Cleaning Clean the outside windows from the ground, unless handrails are available.
50 Hour or Weekly Service
Brake 1. Remove drain plugs from the bottom of the
Cooling Oil housings of hydraulic filters fro brake cooling. Drain
Filter the oil into a suitable container. Clean the drain Hot oil and hot
plugs and install the drain plugs. components can
2. Remove covers. cause personal
injury. Do not allow
3. Remove filter elements
hot oil or hot
4. Discard filter elements into a suitable container components to
5. Remove screens from the filter housings contact skin.
6. Wash the filter housings in clean nonflammable
solvent. NOTE: Removing
7. Inspect the cover seals. If the seals are damaged, the drain plug from
replace the seals with new seals. the bottom of the
8. Install clean screens and new filter elements in the brake cooling oil
filter housing. Install covers. filters may not drain
all of the oil from the
9. Start the engine and operate the engine at low idle.
housings. When you
Check for leaks and make any necessary repairs.
remove the filter
10. Observe the oil level. The transmission must be housings and the
kept in NEUTRAL position and the parking brake filter elements, be
must be engaged. careful to avoid
11. Maintain the oil level to the FULL mark in upper contact with hot oil.
sight gauge.
12. If necessary, add oil. NOTICE: Care must
Parking Brake 1. Remove drain plug from the bottom of filter be taken to ensure
Release Oil housing. Drain the oil into a suitable container. that fluids are
Filter Clean drain plug and install the drain plug. contained during
NOTE: Removing drain plug from the bottom of filter performance
housing may not drain all of the oil from the filter. inspection,
maintenance,
2. Remove filter housing and the filter element. testing, adjusting
Discard the used filter element. and repair of the
3. Wash filter housing in clean, nonflammable solvent. product. Be
4. Inspect the seal in the housing base. If the seal is prepared to collect
damaged, replace the seal with a new seal. the fluid with suitable
containers before
5. Install the new element in the filter housing.
opening any
6. Install filter housing compartment or
7. Start the engine and operate the engine at low idle. disassembling any
Check for leaks and make any necessary repairs. component
8. Observe the oil level. The transmission must be in containing fluids.
the NEUTRAL position and the parking brake must

LEARNER GUIDE
be engaged.
Rear Axle Oil 1. Remove the filter housing drain plug. Drain the oil
Filter into a suitable container. Clean drain plug and
install the drain plug.
2. NOTE: Removing drain plug from the bottom of
filter housing may not drain all of the oil from the
filter.
3. Remove filter housing and the filter element.
Discard the used filter element.
4. Wash filter housing in clean, nonflammable solvent.
5. Inspect the seal in the filter base. If the seal is
damaged, replace the seal with a new seal.
6. Install the new filter element in the filter housing.
8. Observe the oil level. The transmission must be in
the NEUTRAL position and the parking brake must
be engaged.
9. Maintain the proper oil level for the differential to
the bottom of the sight gauge.
10. If necessary, add oil.
Steering 1. Push the button on the breaker relief valve. The breaker relief valve is
Pump Case located on top of the steering hydraulic tank.
Drain Filter 2. Slowly remove the cap on the steering hydraulic tank in order to relieve the
pressure.
3. Remove filter from the base. Discard used filter.
4. Clean the base of the filter housing. Make sure that all of the former seal is
removed.
5. Lubricate the sealing surface with clean oil
6. Install new filter by hand until the sealing surface contacts the base.
Tighten filter for an additional ¾ of a turn.
7. Start the engine and operate the machine for a few minutes. Inspect the
machine for leaks.
Steering Park the machine on level ground and engage the
System Oil parking brake. Stop the engine.
Filter 1. Push the button on the breaker relief valve. The Hot oil and hot
breaker relief valve is located on top of the steering components can
hydraulic tank. cause personal
injury. Do not allow
2. Slowly loosen the filler cap on the steering hydraulic
hot oil or hot
tank in order to relieve the pressure.
components to
3. Remove filter cover. contact the skin.
4. Loosen the nut. Pull filter assembly out of the tank.
5. Remove the filter element. Discard the used filter
element.
6. Remove the filter screen.
7. Clean the cover and the filter screen in a clean,
nonflammable solvent. Inspect the cover seal. If the
seal is damaged, use a new seal.
8. Install the clean filter screen and the new filter
element. Put filter assembly in the tank. Tighten the
nut.
9. Install the cover. Tighten the cover bolts.

LEARNER GUIDE
10. Start the engine and operate the machine for a few
minutes. Check the machine for leaks. Install the
filler cap.
Torque 1. Remove the drain plug from the bottom of the filter
Converter Oil housing and drain the oil into a suitable container.
Filter 2. Clean drain plug and install the drain plug. Hot oil and hot
components can
3. Remove cover.
cause personal
4. Remove filter element. Discard the used element into injury. Do not allow
a suitable container. hot oil or hot
5. Remove screen from the filter housing. components to
6. Clean the filter housing in clean nonflammable contact the skin.
solvent.
7. Inspect the cover seal. If the seal is damaged,
replace the cover seal with a new cover seal.
8. Install screen and a new filter element
9. Install the cover.
11. Observe the oil level when the oil is warm and the
transmission is in the NEUTRAL position. Make sure
that the parking brake is engaged.
12. Maintain the oil level to the FULL mark in upper sight
gauge.
13. If necessary, add oil.
Transmission 1. Remove drain plug for filter housing. Drain the oil
Oil Filter into a suitable container. Clean drain plug and
install the drain plug. Hot oil and hot
NOTE: Removing drain plug from the bottom, the components can
filter housing may not drain all of the oil from the cause personal injury.
filter. Do not allow hot oil or
hot components to
2. Remove filter housing and the filter element.
contact the skin.
Discard the used filter element.
NOTICE: Care must
3. Wash filter housing in clean nonflammable
be taken to ensure
solvent.
that fluids are
4. Inspect the seals in the filter base. If the seals contained during
are damaged, replace seals with new seals. performance of
5. Install the new filter element in the housing. inspection,
Install the housing. maintenance, testing,
6. Start the engine and operate the engine at low adjusting and repair of
idle. Check for leaks and make any necessary the product. Be
repairs. prepared to collect the
fluid with suitable
7. Observe the oil level when the oil is warm and
containers before
the transmission is in the NEUTRAL position. opening any
Make sure that the parking brake is engaged. compartment or
8. Maintain the oil level to the FULL mark in upper disassembling any
sight gauge. If necessary, add oil. component containing
fluids.
Maintenance When Required
Engine Air Clean the Air Intake
Intake System Empty the pre-cleaner bowl whenever the dirt reaches the full mark
Loosen the wing nut on cover and remove cover. Empty and wash the bowl
and cover.

LEARNER GUIDE
Install the bowl and cover. Tighten the wing nut finger tight only. Do not use a
tool.
Service the NOTICE: Service the air cleaner with the engine stopped. Engine damage
Filter could result.
Elements Service the air cleaner if the yellow piston in the filter element indicator moves
into the red zone with the engine running at high idle. Stop the machine.
Service the 1. Open the access cover.
Primary 2. Remove the air cleaner cover (1)
Element
3. Remove the primary filter element (2) from
the air cleaner housing.
4. Clean the inside of the air cleaner housing.
5. Clean and inspect the primary element.
6. Install a clean primary element.
7. Clean and install the cover. Tighten the cover bolts finger tight. Do not use
a tool to tighten the bolts.
8. Close the access door.
If the yellow piston in the filter element indicator moves
into the red zone after starting the engine, or the exhaust
smoke is still black after installation of a clean primary
filter element. Install a new primary filter element.
The primary element should be replaced after being
cleaned a maximum of 6 times. Replace the element
once a year even though it has not been cleaned 6 times.
Change the NOTICE: Always replace the secondary filter element.
Secondary Never attempt to reuse it by cleaning.
Element The secondary filter element should be replaced at the
time the primary element is serviced for the 3rd time.
The secondary filter element should also be replaced if
the yellow piston in the filter element indicator enters the
red zone after installation of a clean primary element, or
if the exhaust smoke is still black.
1. Open the access cover
2. Remove the housing cover and the primary element.
3. Remove the bolts that hold the secondary filter element to housing.
Remove the secondary element.
4. Cover the air inlet opening. Clean the inside of the air cleaner housing.
5. Inspect the gasket between the air inlet pipe and the housing. Replace it if
it is damaged.
6. Uncover the air inlet opening. Install a new secondary element.
7. Install the nuts and washers on the studs. Torque the nuts to 27 ± 7 N•m
8. Install the primary element. Install the cover. Tighten the cover bolts finger
tight only. Do not use a tool to tighten the cover bolts.
Cleaning NOTICE: Do not clean the filter elements by bumping or tapping them. Engine
Primary damage could result.
Elements Filter elements can be cleaned with pressure air – 205 kPa (30 psi) maximum,
pressure water – 280 kPa (40 psi) maximum, or detergent washing.
1. Direct air or water along the pleats inside and outside of filter element.

LEARNER GUIDE
The element can be washed in warm

water and nonsudsing household
detergent. Rinse inside and outside the
pleats and air dry fully.
2. Inspect the filter elements after
cleaning. Do not use a filter element
with damaged pleats, gaskets or
seals.
3. Wrap and store the clean filter
elements in a clean dry place.
Ether Starting Installing the Cylinder
Aid Cylinder 1. Open the engine access cover located behind the operator compartment of
the machine. The ether cylinder is mounted on the right side of the
compartment.
2. Loosen the cylinder retaining clamp, unscrew and remove the empty ether
cylinder
3. Remove the used gasket. Install the new gasket provided with each new
cylinder.
4. Install the new cylinder. Tighten the cylinder hand tight. Tighten the cylinder
clamp securely.
5. Close the access door.
Radiator Clean or Replace Pressure Cap
The radiator cap access door is located on the top rear of the machine.
Open the radiator cap access door.
Remove the radiator cap slowly to relieve pressure.
Inspect the cap for damage, deposits or foreign material. Clean the cap with a
clean cloth or replace the cap as necessary.
Install the cap
Close the access door.
Clean Outside of Radiator Core
Open the radiator guard on the rear of the machine.
Compressed air, high pressure water or steam can be used to remove dust,
leaves and general debris from a radiator. Clean as required by condition of
radiator.
The use of compressed air is preferred.
Fuses & Replace Fuses
Circuit Fuses protect the electrical system from damage caused by overloaded
Breakers circuits. Change a fuse if the element separates. If the element of a new fuse
separates, have the circuit checked and repaired.
NOTICE: Replace fuses with the same type and size only. Otherwise electrical
damage can result. If it is necessary to replace fuses frequently, an electrical
problem may exist. Notify your supervisor.
Reset Circuit Breaker
Push the button in to reset the circuit breakers. If working properly,
button will stay depressed. If the button does not stay in, or comes out
shortly after being reset, have appropriate electrical circuit checked.
Circuit breaker is located at the right side of the operator’s compartment.
Windshield Inspect / Replace
Wipers and Inspect the front and rear windshield wiper blades. Replace if it is worn or
Washer damaged, or if streaking occurs.
Fill Washer Bottle
NOTICE: When operating in freezing temperatures, use nonfreezing window

LEARNER GUIDE
washer solvent. System damage can result from freezing.

Filters
Oil Filter  Use a filter cutter to cut the filter element
open. Spread apart the pleats and
inspect the element for metal and other
debris. An excessive amount of debris in
the filter element can indicate a possible
failure.
 Small amounts of debris may be found in
the filter element. This could be caused
by normal wear. Small amounts of
material will be especially noticeable
during the first 500 hours of operation.
 If metals are found in the filter element, a magnet can be used to
differentiate between ferrous metals and nonferrous metals. Ferrous
metals can indicate wear on steel parts and on cast iron parts. Nonferrous
metals can indicate wear on aluminum or on other nonferrous parts.
Cab Filter  Clean, inspect or replace the cab air filters more often in dusty conditions.
 Remove the filter cover in the rear of the cab behind the seat.
 Remove the filter element.
 The filter element can be cleaned by using pressure air (maximum 205
kPa (30 psi). Direct the air from the clean side to the dirty side.
 Look through the filter toward a bright light. Inspect the element for
damage. Inspect the gaskets for damage. Replace damaged filters.
 Install the filter element.
Service Summary
Preparing the Service Truck is done 1. Checking the Tools and Equipment
in two parts: 2. Checking the Service Truck itself
There are 4 critical tool and 1. Oil Sample Kit
equipment checks that you must 2. Tools and Equipment
carry out:
3. Materials and Spares
4. Oils and Lubricants
Confirm all deviations from “normal” practice with your mechanic or fitter.
If there are special tools, equipment, materials etc needed you must find or requisition them,
check to see if they have been correctly issued and load them.
If special arrangements need to be made for any equipment, make these arrangements.
There are five critical service truck 1. Oil Pumps
checks that you must carry out: 2. Hose Reel Operation
3. Power Washer
4. Compressor
5. Safety - is your Service Truck operationally safe?
You must report all defects to your mechanic or fitter. You must take whatever housekeeping
actions are needed. And most importantly, you must make sure that you comply with all safety
precautions and use your personal protection equipment.
Preparing the Machine is done to: 1. Position the vehicle or plant ready for servicing
2. Complete the pre-servicing safety checks
3. Ensure personal: safety at the servicing site
Confirm all deviations from “normal” practice with your mechanic or fitter. If there are special
circumstances, which must be managed, get assistance from an authorized person. If special
arrangements need to be made for any equipment, make them.

LEARNER GUIDE
Servicing vehicles on site means that all personnel at the site must obey the Site Safety Rules
as well as the Mines Health and Safety Act Regulations. You can be made to suffer severe legal
penalties if you ignore or disobey these rules.
Self Test …
1. List 6 reasons for doing regular maintenance inspections
2. What is the first step in the process of preparing to do a maintenance inspection?
3. What are the four critical tool and equipment checks that you must carry out?
4. What are the five critical checks that must be carried out on the service truck?
5. Why do you prepare the vehicle or plant before servicing it?
6. What three main activities must be done when preparing the vehicle or plant?

LEARNER GUIDE
CHECK-LIST (DAILY)
Site Plant No Flat, Water & Crane Trucks, Diesel
Bowsers + Personnel Carriers
LEGEND When item is checked = CH Date
When item is drained = DR
MON TUE WED THU FRI SAT SUN
1 Check and Sign Operators Checklist
2 Check all Gauges for Correct Operation
3 Check all Lights and Back-up Alarm
4 Check Indicators, Stop Lights and Hooter
5 Check Air Induction System
6 Check Chevron Plate, Reflectors and Triangles
7 Check all Warning Devices
8 Check Hand/Parking Brake Operation
9 Check Foot Brakes for Correct Operation
10 Check Brake Bocks & Brackets
11 Check Windscreen Wiper Blades and Arms
12 Check Power Steering Oil Level
13 Check all V-Belts
14 Check Engine Mountings and Bolts
15 Check Air Cleaner Service Indicators
16 Clean Air Dust Bowl
17 Check Battery Water Level, Terminals, Hold-down
Bolts and Clean
18 Check for Air, Water, Oil or Fuel Leaks
19 Check that Tyre Valves are not Leaking
20 Check Condition of all Tyres & Spare Wheel
21 Check Tyre Pressures & Jack/Tools
22 Check that all Valve Caps are Fitted
23 Check all Wheel Nuts and Studs
24 Drain Air Tanks
25 Check Propshaft Centre Bearing & “U” Joints
26 Check all Spring, Centre + “U” Bolts & Nuts
27 Check Hanger Brackets, Shackle Pins & Brushes
28 Check Front & Rear Suspension and Steering
29 Check P.T.O. Operation
30 Check Body for Wear &/or Damage
31 Tighten &/or Replace Loose/Missing Bolts & Nuts
32 Check Vehicle for Cracks
33 Grease Vehicle as Required
34 Check Radiator Water Level (Engine Cold)
35 Check Engine Oil Level (when Engine is Off)
36 Use Pressure Washer to Clean Vehicle
37 Check Number Plates, Licence & F.E. Date
38 Road Test
Operator’s /Drivers Signature Supervisor’s Signature
Foreman’s Signature Plant Foreman’s Signature

LEARNER GUIDE
NOTE: Refer to Back of Page for DEFECT LIST Use Engen Oil Spec List

LEARNER GUIDE
250 HOUR SERVICE CARD

750 HOUR SERVICE CARD
Site Plant No Flat Trucks, Crane Trucks, Water
Trucks, Diesel Bowsers + Personnel
Carriers
Kilometer Reading (SMR)
Carry out 10 Hour Service
Drain Engine Oil and Charge Filter - Sample
Replace Vee Belts if Necessary
Check Alternator Bearings
Check Gear Box Oil
Check Transfer Box Oil
Check Differential Oil
Check Rear Hub Oils
Check Steering Box Oil
Change Fuel Filters
Check Steering Shaft “U” Joints
Check Brake Lining and Drum Wear
Adjust Brake Lining and Drum Wear
Adjust Brakes to Specs
Check and Adjust Clutch Pedal Free Play
Renew Air Cleaner Elements (when Necessary)
Check Radiator Hoses
Road Test
Operator’s /Drivers Signature
Supervisor’s Signature
Foreman’s Signature
Plant Foreman’s Signature

LEARNER GUIDE
2.3 Start-up and Shutdown

Procedures
The start-up and shutdown procedures are very important for the
operator to master. Most accidents involving plant operation are
caused by failure to observe basic safety rules and precautions when
using the equipment. Accidents can often be avoided by operators
who recognize the importance of using the machine to specific safety
and operating standards.

2.3 Start up and shut down Service Trucks according to manufacturer’s
instructions.
Personal Protective Equipment (PPE)

There are certain legal requirements that have to be adhered to when working on site and with
machines. These legal requirements are stipulated in different Acts such as the Occupational
Health and Safety Act & Code of practice
The following personal protective equipment must be worn on site:
 Overalls must be worn
 Safety shoes or boots must be worn
 Safety reflector vests must be worn over an
overall that does not have reflective strips on
the back or front
 Construction hard hats must be worn
Other types of personal protective equipment
that may be required in certain circumstances
and applications are: Safety glasses, Safety
face shields, Ear muffs, Respirators, Kidney
belts, Gloves
If these items are required for certain tasks, the
supervisors will be made aware of this by
management and the equipment will be
supplied to you.
Hard Hats  Falling objects and obstructions at height are major hazards and can cause
serious injury. Helmets must be worn whenever these hazards exist. In
practice that means in most locations work is going on overhead or nearby.
 Workers, who need to move between different locations, some of which
may be hazardous, must wear safety helmets at all times.
 Safety helmets must be adjusted to fit the wearer's head snugly, and each
worker should have his own helmet. Someone else's helmet may not fit
properly and so fail to provide the necessary level of protection

LEARNER GUIDE
Eye There are different types of eye protectors, make sure NOTE:
Protection you have the right type for the job. You Have Only
The hazard involved in particular operations and One Pair Of Eyes
processes will be identified during training and you will - Guard Them
learn whether goggles are needed to withstand impact, Well! An Eye
shield the eyes from glare, keep out dust or gases; or be Cannot Be
of the general purpose type. Replaced!
Safety lenses A safety lens is a lens which does not form sharp slivers when shattered but
forms granules under impact and does not constitute a serious hazard to the
eye. They can be either made of laminated glass or plastic.
The following types of eye protection are available:
 Safety Goggles fitted with lenses of safety glass, laminated glass, hard
plastic, wire mesh or coloured (filter) plastic.
 Spectacles with specially toughened glass or plastic lenses - with or
without side shields.
 Face shields that are made of toughened plastic or wire mesh.
Protective goggles, glasses or other eye protection must be worn when there
is any foreseeable risk of injury to the eyes. Common sense will usually
suggest when eyes need protection. If for example a power tool is used to cut
hard material, particles of material will be thrown off at high speed. The
particles 'will be at arm's length away from the users head and eyes. It should
be obvious to anyone that the eyes need protection in these circumstances.
Hearing The use of tools and machinery often creates a great deal of noise. Excessive
Protection noise can cause annoyance and irritation, loss of hearing for short periods
and, unless something is done about it, permanent deafness. There are
various ways of tackling the problem of noise: engines can be silenced,
machines can be placed behind barriers or screens which reduce the noise
levels or machines can be sited further away from where people are working.
Where possible this should always be done, but in most cases at least one
person, the operator, will still be exposed to the noise and must be equipped
with the proper protection.
Ear Muffs and  Ear muffs are designed to cover and seal ears from excessive noise. They
Ear Plugs should be worn at all times by those operating plant and machinery or
using equipment such as hammer drills, concrete breakers, etc., and by
anyone else likely to be exposed to harmful levels of noise. Ear muffs must
fit properly. If they are loose they will not give full protection to the wearer.
 Ear plugs should not be confused with ear muffs. Ear plugs fit inside the
ear and may be disposable. They are not suitable for plant operators. It is
important to ensure that the ear protection used is the correct type for the
job you have to do
Respirators  Harmful dust can be released during demolition work when for example
for Dust and power tools or machinery are used to work wood, metal or plastic.
Fumes  Fumes and vapours can be produced by heating of metals, i.e. welding and
flame cutting, and by the use of solvents, adhesives and other substances.
Fumes are especially hazardous in confined spaces.
 Always ensure what protection is needed before starting a job. Dust masks
or dust respirators are not suitable for use with spray painting and with the
handling or use of hazardous chemicals that give off harmful vapours such
as acids, etc. Proper chemical respirators with the correct type or filters
must be used.
 Dust and fumes can enter the eyes, mouth and nose and may also damage
the skin and lungs. The degree for protection needed, depends on the job

LEARNER GUIDE
to be done: Stripping asbestos requires full body protection and breathing

apparatus, sand and shot blasting also requires full protection.
 Nobody should perform these tasks without understanding the hazards
involved and the use of protective equipment required.
Hand and  The hands and feet of workers also need protection in most instances on a
Foot building site.
Protection  Workers on a building site should wear safety shoes or boots at all times.
The danger or objects dropping on a foot is real.
 Safety boots and shoes are manufactured with a steel toe cap
Safety Boots  Where your employer provides items of protection equipment, he should
make sure you know when and how to use them (if not, ask before you
commence the work).
 It is your responsibility to use the equipment provided for your safety and to
take care of it.
 Failure to do so may mean you are breaking not only company safety rules,
but the law thereby resulting in an accident and jury to yourself and others
Walk Around Check
Maximum service life of the machine, make a thorough walk-around inspection before mounting
the machine or starting the engine. The starting of the machine engine must only be done after
the walk around-check has been completed and the operator is satisfied that the machine is safe
to start.
Before  Look around and under the machine for
starting, the items such as loose or missing bolts, trash
following build-up, oil, coolant or fuel leaks. Inspect
must be the condition and inflation of tyres. Diesel engine exhaust
done:  Remove any trash and debris. Adjust tyre contains products of
inflation as needed. Have any necessary combustion which may be
repairs made, loose connections and parts harmful to your health.
tightened to their specified torques and any Always start and operate
missing arts replaced before starting the the engine in a well-
engine or operating the machine. ventilated area and if it is
in an enclosed area, vent
 Any defects that were detected during the the exhaust to the outside.
walk-around check must be repaired or
NOTE: If equipped with a
corrected if they are vital defects and can
block heater, be sure to
affect the machine operation.
connect the power source
 The operator must ensure that he has on line to the heater on the
the correct personal safety equipment machine first, then to the 240
 The operator must check that everyone is volt source. Before starting or
well clear of the machine moving the machine,
 The operator must ensure that he is aware disconnect the power source
of the surrounding area and any potential line from the 240 volt source
hazards such as electric cables, etc. first, then the machine.
 Check all oil, coolant and fuel levels
Access and Exit Procedures
Access to the  Use the suspended step, bumper step, NOTE: There is a switch located
operator’s ladder and appropriate handholds, face above the bumper at the left hand
compartment the machine and use both hands when ladder side. Use this during hours
is provided at mounting the machine. of darkness. The light will light up
the front of the  Upon entering the cab, caution should the ladder and walkway areas.
machine. be taken to avoid hitting your head on The light can also be turned on or
off by a second switch located in

LEARNER GUIDE
the canopy side guard. the cab overhead console.

Exit  Move the engine start switch key to OFF and ENGAGE the parking brake.
 Move the light switch, located on the overhead console to ON. During the
hours of darkness this will light up the walkway and ladder areas.
 When leaving the machine cab, caution should be taken to avoid hitting
your head on the canopy side guard
 Use the steps and handholds, face the machine and use both hands when
dismounting the machine.
Secondary  Turn the engine start switch key to the NOTE: A ladder is located on the
Exit OFF position. Apply the parking brake left side of the radiator. This
 When you are stepping around the ladder can be used to exit the
centre console, care should be taken in machine. Use the handholds.
order to avoid injury. When you are Face the machine and descend to
stepping up to the hood, avoid the door the ground
opening or the canopy.
 Use the hand rail and handholds, face
the machine and descend to the
ground
Seat Adjustment
The seat position can be
adjusted forward or
backward, upward or
downward and seat back tilt.
Select the desired position to Seat adjustment should be
allow full pedal and lever checked at the geginning of each
travel shift or when changing operators.
Always use the seat belt when
operating the machine.
Adjust seat to allow full pedal
travel with operator’s back against
seat back.
Mirrors Adjust the two cab rear view mirrors for best operator vision before operating
the machine or when operators change.
Seat Belt
Always check the condition of the seat belt and the condition of the mounting hardware before
you operate the machine
Inspect for worn or frayed webbing
Check for worn or damaged buckle, retractor,
extrusion and mounting hardware. Replace
them if they are worn or damaged.
Always check the
If the bolts and nuts of the mounting hardware condition of the seat
are not correctly installed, the seat belt can belt and mounting
separate from its mounting. Make certain bolts hardware before
and nuts are corretly installed. operating the
If a bolt and not are not correctly installed, machine.
remove them and install a new bolt and nut.

LEARNER GUIDE
Retractable To fasten the belt: With the

Seat Belt gripper (2) held, extend the seat
belt from retractor (1) and insert
extrusion (3) into buckle (4) until
correctly latched. Use care to
avoid twisting the webbing.
To unfasten seat belt: Push in
button (5) of buckle (4) and
extrusion (3) will be released from
buckle (4). Then allow the seat
belt to slowly retract into retractor
(1).

LEARNER GUIDE
Starting a Machine
When starting a machine, you must remember the engine is cold and this is one of the most
dangerous times for the engine, as there are sudden extreme stresses and strains on the
engine. These extreme stresses and strains occur while the engine systems are not functioning
at their peak performance. An example of this is that the engine oil has not reached certain
sections of the engine to protect it. The oil filters may not be filtering oil correctly yet
To start a 1. Switch the master switch on (usually situated outside the operators
machine the compartment.
operator 2. Climb up into the operators compartment, using the ‘3 points of contact’
needs to principle and ensuring the steps and grab handles are clean and free from
follow grease, oil or mud, etc.
certain
3. Sit correctly in the operators seat
steps:
4. Move the transmission selector lever to NEUTRAL. Engage the parking
brake.
5. Observe the body down indicator. The body should be down and the hoist
lever in FLOAT position.
6. Ensure that the transmission gear select lever is in neutral or in the park
position
7. Check that no loose items are on the floor of the operators compartment that
may be able to roll under the control pedals and cause the operator to lose
control of the machine
8. Turn the ignition key to the on position
9. Check all the gauges/indicators are registering
10. Press the hooter once to warn people you are about to start the machine
engine and check once again visually
11. In some situations and low temperatures, you may be required to heat the
engine piston cylinders with the aid of glow plugs before actually trying to
start the engine. Starting aids are also fitted on some machines to assist
with difficult starting.
12. Turn the ignition key to the start position (or press the start button)
13. If the engine does not start after trying for 30 seconds continuously, then
release the starter key or button and allow the starter motor to cool for 2
minutes before trying again.
Use of When auxiliary start receptacles are not available, use the following procedure:
Jumper 1. Make initial determination of malfunction of the amchine to crank.
Cables
2. Move the transmission selector level into NEUTRAL position on the stalled
machine. Engage the parking brake. Lower the attachment to the ground.
Move hoist lever to HOLD position.
3. On stalled machine, move the engine start switch key to OFF. Turn off all
accessories.
4. On stalled machine, move the battery disconnect switch to ON position.
5. Move boost start machine near enough to stalled machine for the jumper
cables to reach. DO NOT ALLOW MACHINES TO TOUCH.
6. Stop the engine on the boost machine or, if using an auxiliary power source,
turn off the charging system.
7. Make sure the battery caps are all in place and tight on both machines and
that batteries in the stalled machine are not frozen or low on electrolyte.
8. Connect positive (+) jumper able (red) to positive (+) cable terminal of
discharged battery or battery set on stalled machine. Do not allow positive
(+) cable clamps to touch any metal other than battery terminals.
9. Connect the other end of the positive (+) jumper cable (red) to positive (+)
terminal of boost battery. Use procedure of step 8 to determine correct

LEARNER GUIDE
terminal.
10. Connect one end of the negative (-) jumper cable to the negative (-) boost
battery terminal (connected to the battery disconnect switch) in the same
battery set as used in step 9.
11. Make final connection of negative (-) cable to frame of the stalled machine
(not battery negative (-) post) away from battery, fuel or hydraulic lines, or
moving parts.
12. Start the enigne on the boost machine or energize the charging system of
the auxiliary power source.
13. Wait a minimum of 2 minutes for the batteries in the stalled machine to
charge.
14. Attempt to start the stalled engine. Refer to the engine starting section.
15. Immediately after starting the stalled engine, disconnect the jumper cables in
reverse order.
16. Conclude failure analysis on starting/charging sysgtem of stalled machine as
required, now that engine is operating and charging system is in operation.
After 1. Follow cold engine idle procedure. NOTICE:
Starting the 2. The low air pressure alarm will sound until the service air Keep engine
Engine reservoir is charged to approximately ½ maximum speed low until
operating pressure. If alarm sounds and air pressure is at the engine oil
½ max operating pressure, the coolant flow alarm sounds. pressure
Stop the engine immediately and check coolant level. registers on
3. The alternator aleert indicator should be off. It it stays on the gauge. If it
after enigne is operating, stop the engine and investigate. does not
register within
4. If the transmission, torque converter and hoist filtering
10 seconds,
system alert indicator is on continously, stop the engine
stop the
and service the transmission and torque converter filters
engine and
and screens.
investigate the
5. If the steering indicator is on, stop the amchine and check cause before
the system before putting the machine to work. To provide starting aain.
maximum sound suppression on machines equipped with Failure to do
sound suppressed cabs, keep all doors and windows so, can cause
closed. engine
6. Check the engine oil, steering tank, transmission, hoist, damage.
converter and brake oil levels with the engine at low idle
and the oil at normal operating temperature.
7. Observe all gauges, warning and service lights frequently
during operation. All gauges should indicate in the green
range and all warning and service indicators should be off.
Secondary Engine rpm beginning of machine movement, with
Brake secondary brake applied, should be compared with the
System engine rpm your specific machine was able to hold on a
Testing prior test.
Test operation of
1. Start the engine and allow the air system pressure to
secondary brake
build-up to maximum operating pressure.
system daily or at
2. Apply the secondary brake the beginning of
3. Move the transmission shift lever to 1st gear range each shift.
forward WARNING!
4. Release the parking brake Personal injury
5. Accelerate the engine to 1200 rpm could result from
6. The machine should not move forward the sudden stop of
the machine. The
7. Stop the engine
secondary
8. If the secondary brake does not function properly,

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report it to your supervisor.

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Warming up the Engine

Once the engine starts, the operator must allow it to warm up sufficiently before placing it under
tremendous load. The engine should be allowed to idle for approximately 5 minutes and must
not be revved until the correct engine operating temperature has been reached and is indicated
on the engine temperature gauge.
The reasons  The oil viscosity (thickness) of cold oil is not good
why the  Not enough oil can pass through the oil filter
engine must
not be  The oil by pass valve opens and allows unfiltered oil through
revved  Unfiltered oil causes more wear at high engine revolutions
during the  Turbo chargers have very close tolerances and due to their high revolution
warm-up speed, the revolutions of the turbo charger should be kept as low as possible
period are: until the engine oil is warm and being filtered correctly.
 Additives to the oil only work at the correct operating temperature
 During the warm-up period, while the engine is at low idle, the air pressure
required for the machines brake system should build up to the correct
operating pressure and only once the air pressure in the air tanks is at the
manufacturers specified pressure, will the park brakes be able to release.
 The air pressure for the brakes must be allowed to build-up to the correct
pressure before trying to move the machine because if the air pressure is not
correct, the park brakes will not release fully and the machine will be used
with only partially released brakes, which will increase brake lining wear and
also cause brake over-heating.
 While the engine oil and water is warming up to the correct operating
temperatures, the air is also building up to the correct operating pressure.
 The operator should also operate the hydraulics during this warm-up period,
which will assist with warming the hydraulic oil in the system and indicating if
there are any leaks in the system once the hydraulic oil system is placed
under pressure.
 The above attachment operation must be carried out while the engine is idling
and the engine must not be revved until the correct operating temperature has
been reached.
 While all the above is taking place, the operator must observe the machines
gauges and indicators and check that all the different systems are operating
as they are supposed to.
 The operator must also listen very carefully for any strange noises, smells or
vibrations that may be coming from the engine or other parts of the machine.
During this warm-up period other functions can be checked such as indicators,
brake lights, etc., with the aid of an assistant if one is available.
Leaving It is good safety practice NOT to leave the operating position once the engine
Machine has been started, although this is not always possible, as some machines oil
when levels can only be checked once the machine has started. Park brake must be
Engine is applied
Running  Transmission gear select lever is in neutral
Requires
Extreme  All attachment levers are in the float position
Care  Control lever lock devices are in position
 That you do not bump any levers while climbing in and out of the machine.
 That you do not bump the steering wheel, especially if it is a machine which
can articulate.
 That all your personal protection equipment is on and correctly tied up, with
no loose cords or shod laces that can get caught up in the machines moving
parts

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 That you are aware of what you are doing at all times and do not get
distracted.

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Moving Off & Operational Checks

Once the engine has reached the correct operating temperature, the brake air pressure is
correct and the other systems are ready for operation, according to all the gauges, you are
ready to move off and proceed to site.
Moving off  Make sure you are seated correctly in the operating IMPORTANT
The position with the seat and steering adjusted correctly to once the correct
operator suit you speed has been
must  Adjust and secure the seatbelt reached and it is
proceed as safe to do so, the
 Ensure everyone and everything is clear of the
follows: Brake Test must be
machine
carried out.
 Lift all the attachments off the ground and place in
travel position
 Press the hooter to indicate you are moving off
 Engage the clutch
 Depress the foot brake
 Engage the transmission gear and direction selection
lever
 Check all round the machine for people or hazards
 Check the mirrors
 Release the park brake
 Release the foot brake
 Accelerate slightly, releasing the clutch and maintaining
good pedal balance
 If the brake test is successful and the machine is safe
to operate, the operator may proceed. Should there be
some problem or defect, the operator must return and
report the defect or take any corrective action you are
capable of.
Operational The operational checks are the checks that need to be carried out while the
Checks machine is in motion and actually operating. They must be carried out all day
are basically while the machine is working and not only at the start of a shift.
monitoring  Check the gauges at all times
the machine  Monitor the EMS at all times
performance
and  Check for warning lights
checking for  Listen for warning device alarms
any faults or  Listen to the engine sounds
problems
that may  Watch for fluid leaks in the rear view mirrors
occur during  Be observant to changes in machine handling
the shift.\
Shutting Down Procedures
At the end of the shift the machine must be switched off correctly and safely. The machine has
been operating all day under extreme stresses and conditions and a good operator will not just
switch off without following the correct procedures. These shutting down procedures enable the
conditions in the engine to normalize. These checks are carried out before the machine is
actually switched off.
The correct procedure is: REMEMBER
1. Stop the machine in a safe, level spot. always let the
2. Reduce the engine speed and revs to idle engine idle for at
least 3 minutes
3. Engage the park brake

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4. Place the gear select lever in neutral before switching

5. Lower all attachments off the engine.
6. Check all the gauges
7. Listen to the engine noise, vibration or smell for possible indications
that something is wrong
8. Place all safety locks and devices in position
9. Note the end of shift mileage or hour meter reading
10. Clean up the operators cab
11. Close windows
12. Collect your personal items
13. Wait while the engine idles for at least 3 minutes
14. Switch off the engine
15. Remove the key from the ignition
16. Switch off the master switch
17. Lock the cab
18. Hand the keys to your supervisor
19. Report any defects or problems that may have occurred during your
shift
Start-Up Summary Shut Down Summary
1. Ensure you have the correct PPE (boots, overall, hearing 1. Reverse into area
protection, reflective vest, hard hat, safety shoes 2. Ensure no other vehicles or
2. Walk around check: look and feel first on carriage items can be damaged
(bottom) section of machine 3. Lower implements
3. Open bonnet and check oil, battery, water and fuel levels (if applicable)
4. Move up to cabby section and undergo the same check 4. Place gear into neutral
i.e.: loose material, seating 5. Idle machine for 5 mins
5. Start engines and wait 5 mins to check all gauges 6. Apply parking brakes
(pressure points)
7. Switch engine off
6. Remove stop blocks (if applicable)
8. Close all windows
7. Ensure no person under machine
9. Exit & take keys
8. Sound an alarm (hooter or rev engine or whistle) to
10. Close all doors and lock
indicate movement
11. Insert stop blocks (where
9. Check brakes by using brake test: ramp (procedure
applicable)
attached?)
12. Hand in keys
10. Check implements lifted from ground
11. Sound alarm again
12. Reverse vehicle (where applicable)
Safety Summary
Certain legal requirements governed by the different Acts, stipulate that certain personal safety
equipment must be worn by the operator onsite.
The following personal ■ Overalls
protective equipment ■ Safety shoes or boots
must be worn by
■ Safety vests must be worn over an overall that does not have
operators:
reflective strips on the back and the front
■ Construction hard hats
The items listed above are supplied by the company and must always be worn while on site.
These items must be neatly and securely tied up to prevent any loose cords or laces being
caught up in rotating engine or machine parts.
Other types of ■ Safety glasses

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personal protective ■ Safety face shields

equipment that may be ■ Ear muffs
required in certain
■ Respirators
circumstances and
applications are: ■ Kidney belts
■ Gloves
At the start of each shift the operator must check with his supervisor to establish exactly what his
work requirements are for the day.
There are certain ■ Which machine he should use for the day?
questions that the ■ On which site and where on the site he should work for the day?
operator should ask
■ Where he can find the check list for the machine that he has to
the supervisor to
operate?
ensure that he
understands exactly ■ Whether any faults were reported about the machine from the
what is expected of previous shift?
him for they are : ■ Is the machine due for any scheduled maintenance during his shift?
■ Who he should report to on site when he gets there?
Certain types of ■ Diesel engine
components are found ■ Transmission
on most machines and
■ Differential and final drives
they are:
■ Hydraulic system
Walk around checks are extremely important for safety and machine care purposes.
The walk around should highlight defects that, could cause accidents or, minor defects with the
potential of turning into major defects, so that corrective action can taken.
Walk around checks must be performed by all operators at the start of each shift.
Walk round checks must be performed systematically and with the aid of a check-list to ensure
that no important points are over looked.
Self Test …
1. Who stipulates that certain personal safety equipment must be worn on site?
2. What PPE must be worn by operators?
3. Who supplies the PPE?
4. What must the operator do at the start of each shift?
5. What questions must the operator ask the supervisor?
6. What components are found on most machines?
7. Why are walk around checks important?
8. Who must perform walk around checks
9. What must you remember when starting the machine?
10. How long must you warm up the engine?
11. Is it good safety practice to leave the machine when it is running?
12. What must you do if you need to leave the machine when it is running?
13. What position must the attachments be in when moving off?
14. What operation checks must you do while the machine is in motion?
15. How long must you let the engine idle before switching off the engine?

LEARNER GUIDE
2.4 Parking Service Trucks

2.4 Park Service Truck according to manufacturer’s and company
requirements.
Safe Parking
Track machines remain on the work site. Tyre driven machines are parked in a secure vicinity.
When parking on public roads, provide fences, signs, flags or lights and put up any other
necessary signs to ensure that passing traffic can see the machine clearly and park the
machine so that the machine, flags and fences do not obstruct traffic.
1. Park on level ground where there is no danger of falling
rocks or landslides. When parking on low ground, park in a
place where there is no problem of flooding.
2. Release accelerator control pedal. Depress the service Personal injury or death can
brake control pedal. result from not engaging the
parking brake. If the parking
3. Move transmission control lever to the NEUTRAL position brake is not engaged, the
after the machine has stopped. machine may roll while
4. Move parking brake switch to the ON position in order to personnel are on or near the
engage the parking brake machine. Always engage the
NOTE: do not use retarder as a parking brake parking brake before leaving
the machine.
Engine Stopping
1. Operate the engine at low idle for 5 minutes to allow the engine to NOTE: Never move
cool gradually. the battery
2. Move the engine start switch key to OFF to stop the engine. disconnect switch
to OFF while the
3. Test the supplemental steering system using the procedure in
engine is operating.
Before Starting the Engine Section.
Serious damage to
4. After testing the supplemental steering circuit, turn the battery the electrical
disconnect switch OFF and remove the key. system can result.
5. If the machine is parked, block the wheels
6. Drain the water from the brake air start tank.
Leaving the Machine
1. Use the steps and the handholds when you get off the machine. NOTE: 3-point contact
Make sure that the steps are clear of debris before you dismount can be two feet and
2. Face the machine and maintain a 3-point contact with the steps one hand. 3-point
and with the handholds. contact can also be
one foot and two
3. Inspect the engine compartment for debris. Clean out any debris
hands.
and paper in order to avoid a fire.
4. Remove all flammable debris from the front bottom guard in
order to reduce the fire hazard. Dispose of the debris properly.
5. Turn the battery disconnect switch to the OFF position. Remove
the disconnect key and secure the lock on the cover plate. This
will help to prevent a battery short circuit. Removing the key will
also help to protect the battery from vandalism and from any
possible current draw by components over extended time
periods.

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6. Install all the covers and install all the vandalism protection locks.
7. Always close the door of the operator’s compartment.

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Self Check 2
1. Complete a Pre-operational checklist

2. Explain what you will do if you receive a level 3 warning
5. List the steps you must follow in the start-up procedure
6. List the steps you must follow in the shut down procedure
7. List the steps you must follow when parking a Service Truck

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able to:
YES NO
2.1 Conduct pre-operational checks of Service Trucks according to
appropriate checklist.
2.2 Perform daily and weekly operator maintenance on Service
Trucks in accordance with post-operational checklists.
2.3 Complete checklists according to worksite procedures and take
corrective action if required, ensuring compliance with
2.4 Start up and shut down Service Trucks according to
2.5 Park Service Trucks according to manufacturer’s and company
requirements.

LEARNER GUIDE
LEARNING ACTIVITY 3
Operate Service Trucks

The purpose of this Learning Activity is to enable you to manoeuvre and control
Service Trucks on site.
Specific Outcome 3
■ Explain the purpose of Service Trucks various controls in accordance with

their designed use.
■ Demonstrate the functions of Service Trucks various controls in
accordance with the manufacturer’s instructions.
■ Use various controls to effectively manoeuvre Service Trucks within
■ Follow safe working procedures according to manufacturer’s, company and
statutory requirements.
■ Monitor Service Trucks performance and take corrective action when
necessary, in accordance with manufacturer’s instructions.
■ Operate Service Trucks without risk of damage or loss to machine or
property, or injury to people.
■ Explain ways to minimize hazards specific to operating Service Trucks in
terms of potential damage to machine and property and injury to people.

LEARNER GUIDE
3.1 Service Truck Controls

3.1 a) Explain the purpose of Service Trucks various controls in accordance with
their designed use. b) Demonstrate the functions of Service Trucks various
controls in accordance with the manufacturer’s instructions. c) Use various controls
to effectively manoeuvre Service Trucks within manufacturer’s instructions
Machine Controls
Pneumatic The pneumatic control valve is operated from 2 switches which are
Control Valve situated inside the cab of the truck and toward the bottom right of the
steering wheel.
RIGHT HAND SWITCH operates the PTO
LEFT HAND SWITCH operates the bypass valve at the rear end of the
truck. This bypass valve enables the operator to switch the water flow to
the nozzles ON or OFF while the PTO is engaged.
Steering It is important that the drivers of Service Trucks are aware of the steering
wheel lock and steering wheel adjustment.
The steering lock on a Service Truck enables the steering wheel to be
locked in a certain position if required, but only once the key has been
removed from the ignition.
We find the following:
1. Neutral position (key can be inserted or removed)
2. Driving position
3. Starter engaged position
The steering is locked as the key is withdrawn, The key cannot be
removed from the steering lock if:
The engine is running
The electrical system has failed
Never remove the key from the steering lock while the vehicle is still
moving.
Steering Wheel In some Service Trucks the height and inclination of the steering wheel
Adjustment are adjustable.
The respective screw clamps must be loosed before the steering wheel
can be adjusted and tightened securely after adjustment.
The function of the park brake is to hold the machine SAFETY
stationary during the following conditions which may PRECAUTION:
arise on job site: Should the
(a) To park the machine overnight or at the end of a engine cut out
shift. or stop whilst
Parking Brake the vehicle is
(b) Whilst the operator leaves the cab, i.e. engine
Move the lever to running or engine stopped on a level plane. moving, the
the OFF position to brake will
(c) Waiting to enter the loading area, or to water a
release the parking gradually apply.
load.
brake. Move the The park brake
lever to the ON The parking brake is also an emergency brake. is spring applied
position to engage However, the use of the parking brake as a service and hydraulic
the parking brake. brake in regular operation will cause severe damage to pressure
the brake system. released.

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Service Brake During normal operation, depress the service brake control pedal to stop
or slow down the machine. The service brake pedal applies all four wheel
brakes. The pedal is fully variable. The amount of braking force depends
on the position of the pedal.
Depress the service brake pedal to stop or to slow the machine and to
keep the engine from over speeding on a downgrade.
Accelerator The accelerator pedal controls the fuel flow to the engine.
The further the pedal is pushed to the floor, the higher the rpm.
Clutch Pedal To change gears
Tipper Switch To dim and bright lights
Engine Shutdown Raise the guard and move the toggle switch up (OFF) to NOTE: The
Switch stop the engine. After the engine stops, lower the guard engine
(Normal shutdown and the toggle switch will be returned to the ON position. shutdown
is with engine key Use in emergencies only. switch does
start switch in the The engine shutdown switch does not discharge not deactivate
cab) pressure from the steering accumulators. Remove the the machine’s
steering system pressure from the steering accumulators electrical
before doing any work on the machine. To remove system.
steering accumulator pressure, do either of the following:
 Turn the steering wheel right and left as far as
possible in both directions until the machine front
wheels will not move. This discharges the pressure in
the steering accumulators.
 Enter the cab and move the engine key switch to
OFF.
Move the engine start switch key and the battery
disconnect switch key to the OFF position. Remove the
keys. (Remove the battery disconnect switch key only if
the machine is to be parked for an extended period of
time)
Tachometer When driving, constantly observe the engine speed and keep the needle
in the green (economy range) and not the red danger range.
A warning buzzer in the cab sounds when the engine’s maximum speed is
exceeded.
The governor on the injector pump limits the maximum speed. When
traveling downhill, the vehicle determines the engine speed and the
governor cannot limit it. The driver must then ensure that maximum
engine revolutions are not exceeded in the individual gears or damage to
the engine, injector pump or propeller shaft may occur.
Light Switch Every Service Truck must have lights to be roadworthy and pass the COF
test every year.
The following positions are found on all Service Truck light switches
 Lights switched OFF position
 Parking lights switched ON position
 Headlights switched ON position
Combination A combination switch is a switch which performs a few different functions.
Switch Switches of this type, which are found on all Service Trucks, are the levers
usually found on the steering column and operates the following functions:
1. Low beam
2. High beam
3. Headlight flasher
4. Turn signal lights RIGHT

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5. Turn signal lights LEFT

6. Hooter
7. Windscreen wiper switch:
O = OFF I = Intermittent wiper II = Low speed III = High speed
8. Windscreen washer
Heating & Most Service Trucks have some mechanism for heating or venting the
Ventilation drivers compartment. The exact layout and operation may differ from
make to make and model to model. However, the basics remain the same,
and will only require a few moments to figure out.
A typical heating and ventilating mechanism consists of:
1. Swivel ventilation and defrosting nozzles for windscreen and side
windows.
2. Ventilation nozzles for fresh air to footwell.
3. Adjustable fresh air vent in dashboard.
4. Control lever for blower motor. Push down to switch off and up to
switch on
5. Control lever for heater valve. Push down to OPEN and up to CLOSE
6. Control lever for windscreen and side window air nozzles (ventilation
or defrosting). Push down to CLOSE and up to OPEN
7. Control lever for foot well air flaps (ventilation or heating). Push down
to OPEN and up to CLOSE
8. Control lever for fresh air vent in dashboard (ventilation only). Push
down to OPEN and up to CLOSE
Self Test …
1. What is the main function of the parking brake?
2. What is the function of the service brake?
3. When do you use the secondary brake?
4. What happens when you use the accelerator?

LEARNER GUIDE
An example of a Service Truck Evaluation form used to test your ability to use
various controls to effectively maneuver the machine within manufacturer’s
instructions:
SERVICE TRUCK EVALUATION

NOTE: Instructor must tick all applicable boxes
Name Company No
ID
Rating NYC Competent Marks
1 Personal Safety 5
2 Walk Around Checks 5
3 Pre-start Checks 5
4 Mounting & Dismounting 5
5 Inside Cab Checks 5
6 Stacking and Placement 5
7 Starting & Warming Procedure 5
8 Brake Testing 5
9 Seating Position 2
10 Use of Foot Controls 2
11 Use of Gears 2
12 Use of Steering 2
13 Use of Mirrors 2
14 Safety Awareness 5
15 Use of Indicators 5
16 Reversing 3
17 Use of Hooter 3
18 Service Truck Sympathy 2
19 Overall Observation 2
20 Shut Down Procedures 5
21 Slippery Objects and Cleanliness 3
22 Violent Collision 2
23 Hazardous Handling 5
24 Operating Dangerously 5
25 Travelling and Parking 5
26 Awareness of Pedestrians 5
100
If +85% Operator is Trainable 100% Required for Competency
Is the Operator Competent YES NYC
Signature of Training Instructor
Re-Training done by Instructor

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Operating Techniques
Machine Operation
 Do not drive off until the pressure gauge and the brake pressure warning light in the
instrument cluster has gone out.
 Do not set off immediately after starting the engine. Let the engine idle at a moderate speed
for a short period, using the speed control knob.
 After driving off, warm up the engine smoothly at moderate engine speeds in the lower
gears. Demand full engine performance only after operating temperature (70-90°C) has been
reached.
 On level roads, or on minor gradients, an unloaded vehicle can be driven off in third gear.
First gear is required only when a loaded vehicle is driven off on a gradient or off the road.
 Immediately after setting off, test the brakes (hand and foot brakes) on a dry road affording
good traction(or brake ramp if available).
NOTE: The brakes are in good working order if the brake action is equal on all the wheels and if
sufficient deceleration is obtained. Your sound judgment will tell you whether the vehicle is
roadworthy.
If any deterioration of braking effect is experienced the vehicle should be stopped for immediate
inspection.
Shifting Gears
 Observe tachometer while driving.
 Stay within the economic operating range (green band)
 Drive in the highest gear possible.
 Skip gears if possible and shift only if necessary.
 Always disengage clutch fully.
 Shift gears without exerting force.
 Engage reverse gear only with the engine idling and the vehicle at a standstill.
 The engine should not be shut down at a coolant temperature above normal (90°C), but
should be allowed to idle for 1 to 2 minutes to enable the engine to cool down.
3.2 Safe Working Procedures

Safety concerns everybody! Before starting, operating or servicing a
machine for the first time, study the machines’ Operator’s Instruction
manual carefully. Many hours have been spent in designing and
producing the safest and most efficient machine possible. However,
all this time may be wasted if an individual does not read the safety
instructions or does not bother to follow them.
Machines rarely cause accidents, whereas people do. A safety
conscious person and a well maintained machine make a safe,
efficient and profitable combination.

LEARNER GUIDE

3.2 a) Follow safe working procedures according to manufacturer’s, company and
statutory requirements. b) Operate Service Trucks without risk of damage or loss
to machine or property, or injury to people.
Legal Requirements
People who are employed in a mining environment fall under laws that focus on the prevention
of occupational injuries, illness or death.
The Minerals Act and Mines Health and Safety Act

Operators should take specific note of the following points in the Mines Health and Safety Act:
Manufacturer’s 1 Any person who:
& Supplier's (A) Designs, manufactures, repairs, imports or supplies any article for use at a mine
Duty for Health must ensure, as far as reasonably, practicable:
& Safety (i) That the article is safe and without risk to health and safety when used properly;
(CHAPTER 2- and
SECTION 21)
(ii) That it complies with all the requirements in terms of this act;
(B) Erects or installs any article for use at a mine must ensure, as far as reasonably
practicable, that nothing about the manner in which it is erected or installed
makes it unsafe or creates a risk to health and safety when used properly; or
(C) Designs, manufactures, erects or installs any article for use at a mine must
ensure, as far as reasonably practicable, that ergonomic principles are
considered and implemented during design, manufacture, erection or
installation.
2 Any person who bears a duty in terms of subsection (1) IS RELIEVED OF
THATDUTYTO THE EXTENT THAT IT IS REASONABLE IN THE
CIRCUMSTANCES IF:
(A) That person designs, manufactures, repairs, imports or supplies an article for or
to another person; and
(B) That other person provides a written undertaking to take specified steps
sufficient to ensure, as far a reasonably practicable, that the article will be safe
and without risk to Health and safety when used properly and that it complies
with all prescribed requirements.
3. Any person who designs or constructs a building or structure, including a
temporary structure for use at a mine must ensure, as far a reasonably
practicable that the designer construction is safe and without risk to health and
safety when properly used.
4. Every person who manufactures imports or supplies any hazardous substance
for use at a mine must:
(A) Ensure as far as reasonably practicable, that the substance is safe and without
risk to health and safety when used, handled, processed, stored or transported at
a mine in accordance with the information provided in terms of paragraph (B);
(B) Provide adequate information about:
(i) The use of the substance
(ii) The risks to health and safety associated with the substance
(iii) Any restriction or control on the use, transport & storage of the substance,
including but not limited to exposure limits;
(iv) The safety precautions to ensure that the substance is without risk to health or
safety.
(v) The procedure to be followed in the case of an accident involving excessive
exposure to the substance or any other emergency involving the substance; and
(vi) The disposal of used containers in which the substance has been stored and
waste involving the substance; and
(C) Ensure that the information provided in terms of

LEARNER GUIDE
paragraph (b) complies with the Provisions of the Hazardous Substances Act, 1973
(Act No 15 of 1973).
Employee's 3. Every employee at a mine, whilst at that mine must:
Duties for (A) Take reasonable care to protect their own health and safety;
Health & (B) Take reasonable care to protect the health and safety of other persons who may
Safety he affected by any act or omission of that employee;
(CHAPTER 2-
SECTlON 22)
(C) Use and take proper care of protective clothing, and other health and safety
facilities and equipment provided for the protection, health or safety of that
employee and other employees;
(D) Report promptly to their immediate supervisor any situation, which, the
employee believes presents, a risk to the health or safety of that employee or
any other person and with which the employee cannot properly deal;
(E) Co-operate with any person to permit compliance with the duties and
responsibilities placed on that person in terms of this Act; and
(F) Comply with prescribed health and safety measures.
Employee's 1 The employee has the right to leave any working place whenever:
Right to Leave (A) Circumstances arise at that working place which, with reasonable justification
Dangerous appear to that employee, to pose a serious danger to the health & safety of that
Working Place employee; or
CHAPTER2- (B) The health and safety representative responsible for that working place directs
SECTION23
that employee to leave that working place.
2 Every manager, after consulting the health and safety committee at the mine,
must determine effective procedures of the general exercise of the rights
granted by sub-section 1, and those procedures must provide for:
(A) Notification of supervisors and health and safety representatives of dangers
which have been perceived and responded to in terms of subsection 1:
(B) Participation by representatives of management and representatives of dangers,
which are perceived and responded to in terms of sub-section 1
(C) Participation, where necessary, by an inspector or technical advisor to assist in
resolving any issue that may arise from the exercise of the right referred to in
sub-section 1;
(D) Where appropriate, the assignment to suitable alternate work of any employee
who left, or refuses to work in, a working place contemplated in sub-section
(1); and
(E) Notification to any employee who has to perform work or is requested to
perform work in a working place contemplated in sub-section 1 of the fact that
another employee has refused to work there and of the reason for that refusal.
3. If there is no health and safety committee at a mine, the consultation required in
sub-section 2 must be held with:
(A) The health and safety representatives; or
(B) If there is no health and safety representatives at the mine with the employees.
The Minerals 18.1.1 No person shall drive or cause or permit any other person to drive any self
Health & propelled mobile machine which is under the control of the manager in or on
Safety Act a mine or at a works or on private in or at such works, unless such person has
Chapter 18 been authorized thereto by the manager, mine overseer, engineer or
competent person appointed in terms of regulation 2.13.1
18.1.2 The manager, mine overseer, engineer or competent person appointed in
terms of Regulation2.13.2 may authorize any person to drive a self-propelled
mobile machine if he is satisfied that such person:
(A) Has attained the age of 18 years
(B) Does not suffer from defective sight or hearing or any other infirmity,
mental or physical, likely to interfere with the efficient discharge of his
duties;
(C) Has completed a satisfactory course of training; and
(D) Has been found competent to do so, by actual test, by the engineer or
competent person appointed in terms of regulation 2.13.2 or by some other
competent person to whom this duty has been delegated by the engineer:

LEARNER GUIDE
Provided that the provisions of paragraph (A), (C) and (D) shall not apply to a
person to whom:
(i) A drivers license has been issued by a provincial authority in respect of
the class of vehicle for which authorization must be granted; or
(ii) In the case of a locomotive, a locomotive drivers certificate has been
issued in terms of these regulations; or
(iii) Authorization has been granted to drive a self-propelled machine as a
learner driver under the immediate supervision and control of an authorized
driver.
18.1.7 Whenever a person who was authorized to drive a self-propelled mobile
machine has, for any reason whatsoever, not driven such machine for a period
of 180 days or longer, he may not be authorized to drive such machine;
Provided that the provisions of regulation 18.1.2 (d) are complied with.
18.2.1 No person operating a self-propelled mobile machine shall leave such
machine unattended unless he has taken reasonable precautions that it cannot
be set in motion by an unauthorized person.
18.3.4 No person shall board or alight from a self-propelled mobile machine, any
rolling stock or any other vehicle operated by machinery while it is in motion;
Provided that this regulation shall not apply to:
(A) Any person riding a man-trolley attached to an endless rope haulage; OR
(B) A trained or trainee shunter engaged in shunting operation on the
surface.
18.4.2.4 When any machine, rolling stock or vehicle is parked in or near a haulage
way, the minimum clearance between such parked machine, rolling stock or
vehicle and any moving machine, rolling stock or vehicle shall not be less
that 500 mm.
18.6.1 Where any self-propelled mobile machine operates at a place where it may
endanger the safety of persons, should it run out of control, such machine
shall in addition to the normal service braking system, be fitted with an
independent braking system capable of stopping such machine effectively
should it run out of control; Provided that the provisions of this regulation
shall not apply to a locomotive or to any motorcar, light delivery vehicle or
other passenger vehicle which is designed to carry not more than 12
passengers And which is registered with a local authority for use on a public
road.
18.6.2 If the vision of a driver of a self-propelled machine, excluding a locomotive,
is restricted in an direction of travel, the machine shall be equipped with a
clearly audible alarm, hooters, or a clearly visible flashing light installed in
such a manner that it operates whenever the machine moves in that direction.
18.6.3 Every self-propelled mobile machine shall be equipped with a suitable and
adequate fire extinguisher.
Safety 20.7.3.1 No person shall set a machine or machinery in motion unless he has taken
Precautions all. Reasonable precautions to ensure that no other person can be injured by the
Setting in motion thereof.
Safety of 20.7.3.2 Every reasonable precaution shall be taken in connection with the use of
Persons machinery to ensure that the safety of every person employed on or about such
machinery is not endangered.
Safety 20.7.3.3 No person shall conduct maintenance or repair work, and no person shall
Measures cause or permit such work to be done, until all reasonable precautions have been
During Repairs taken to ensure that the work can be done safely. A machine or part of a machine,
which may fall on the person conducting such work or on any other Person, shall be
adequately supported.
First Aid 20.7.3.4 At every mine where more that 300 persons are employed every person
Certificate under the age of 50 years, who is in charge of workmen and who is employed in the
Requirements workings or who is normally employed on surface where machinery is operated shall
within one year of his engagement on the mine be in possession of a valid First Aid
Certificate recognized by the Chief Inspector : Provided that any Person appointed in

LEARNER GUIDE
terms of regulation 2.5.1 -2.6.1 - 2.12.1 -2.13.1 or 2.13.3 shall be exempted from
being the holder of such certificate. Every first aid certificate shall be renewed at
intervals of not more than three years. The provisions of this regulation shall not
apply to any person who is the holder of the gold medal of the South African Red
Cross Society, the medallion and two labels of the St John's Ambulance Association,
the highest diploma of Die Suid Afrikaanse Noodhulpliga or to any registered
medical, surgical or dental nurse.
Duties of an It is the employer's duty to consult with employees on health and safety
Employer matters. Regular analysis of and communication regarding existing hazards,
Control of hazards, acting on reported unsafe or unhealthy conditions, record
the findings of reported incidents, recommendations and actions taken by the
health and safety committee.
Duties of an  Taking care of your own health and safety
Employee  Ensuring responsible actions so that people are not affected by your
behaviour
 Co-operation with your employer and representatives
 Obeying lawful orders, rules and procedures
 Reporting unsafe or unhealthy conditions immediately
 Reporting injuries no later than the end of the shift
 Keeping safe protective equipment (e.g.) fire extinguishers, provided for
your Health and Safety.
Personal The regular washing of your body, clothing and eating utensils from an
Hygiene integral part of personal hygiene. The law is very specific about personal
hygiene, particularly regarding smoking, eating and drinking at work.
Hints and tips regarding personal hygiene:
 Wash your hands before and after using the toilet
 Wash your hands after working with food or toxic substances (including
fuels and oils)
 Cough or sneeze into your shoulder to prevent germs from being passed
on.
 Your locker must be clean, hygienic and free from rubbish
 If you contract any disease that could be transferred to fellow workers, tell
your supervisor or employer.
Emergency Plans
An emergency is an unexpected incident that requires urgent and immediate action:
Fires Hints and Tips on fire:
Follow the rules  Report the use of equipment to your health & safety representative as
and you will SOON as possible.
eliminate many of  If you detect fire or smoke, raise the alarm immediately
the dangers. If a
fire should occur,  If you are in a situation where help is not immediately at hand ensure
you must raise the that you are familiar with the use of fire fighting equipment in order to
alarm. There are help your self
people trained in  Flammable solvents should not be used to clean your hands or
how to use the fire clothing.
fighting appliances.  Panic and confusion are contagious, stay calm all the time.
 Fire equipment is for extinguishing fires, not for washing vehicles,
floors or for fun.
 Observe fire protection signs.
Emergency Make sure you know what emergency numbers are:
Numbers  Remember your rights
 Remember your duties

LEARNER GUIDE
 Make health and safety a way of life

Overturning The cab is for the protection of the operator and its meets the
requirements for roll over protection according to the adopted standards
(ROPS). A precondition for protection is that the operator uses the seat
belt and remains in the cab. Therefore, hold onto the steering wheel is the
machine should roll over.
Emergency Exits Do not jump! As an option the cab can be fitted to meet the requirements
for objects falling onto the cab roof according to the (FOPS) standard.
The cab has 2 emergency exits: the door and the open able side window.
The side window is opened by pulling the ring and the attached locking
strip out of the moulding and then pushing hard at one of the corners of
the window pane until it is forced out of the rubber moulding, thus
providing an exit.

LEARNER GUIDE
Self Test …
1. Who is the main person responsible for your safety?
2. Name two reasons incidents occur?
3. What is a hazard?
4. Which act focuses on the prevention of Occupational Health
and Safety in our Industry?
5. Name three rights of an employee?
6. Name four duties of an employee?
7. Name five important hints regarding personal hygiene?
Safety Rules
Rules For 1. Avoid overtaking when:
Manoeuvering  It is not necessary - The road is not clear
 Any faster machines are in front
2. When overtaking, ensure the following:
 The road is clear 75, ahead
 There is no fast moving vehicles coming from behind
 The road condition is good
Rules for  Reverse into area
Shutdown  Ensure no other vehicles or items can be damaged
 Maintain 4m distance between machines for fire hazard
 Lower implements
 Place gear into neutral
 Idle the machine for 5 minutes
 Apply parking brakes
 Switch off engine
 Close all windows
 Exit and take keys
 Close all doors
 Insert stop blocks (where applicable)
 Hand in keys
Rules for  Park the machine on a flat surface
Parking  Put the parking brake on -Lower all attachments onto the ground -Ensure
that the transmission lever is in the neutral position
 Park at least 15m away from the pit crest. highway and loading areas
 Park at least 5m in front of or behind any earthmoving vehicle
 Do not park on ramps (if it is unavoidable) -If it is unavoidable to park on a
ramp, the following steps must be taken
 Put transmission lever in the neutral position
 Engage the parking brake -Lower all attachments to the ground -Switch off
the engine
 Place wheel locks on to block the vehicle from rolling down hill
 Demarcate the machine with two white drums 5m in front and two drums
5m behind the machine
 Carry out the walk-around inspection

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Rules For  Obey all road signs -Keep on established roads

Operating  Keep left unless overtaking
 Do not exceed the speed limit
 Keep a safe following distance of at least 40m or 5 lengths of your machine
away from the vehicle in front of you.
 Give way to laden trucks
 Do not drive over electric cables
 Do not squash barricading drums
 Look out for pedestrians
 Wear your seat belt at all times
 Do not enter any closed of areas - Bulldozers must be 0.5m above the
ground
 Travel at speed to suit conditions -Never freewheel the machine down a
ramp
 Use neutralizer brake for dozing and service brake stop
 Use emergency brake only in case of emergency
 Do not reverse at a high speed, control and visibility, are less than when
travelling forward.
Hooter Signals Hooters signals are means of communication between all personnel in the
working area. The signals should take place least 5 seconds before moving the
machine.
For personnel safety and the safety of the machine, all operators must know
the meaning and understand the four hooters signals. It is very important to
know the appropriate response to each hooters signal.
Road Signs
STOP SIGN YIELD SIGN ONE WAY SIGN SPEED LIMIT
CHEVRON SHARP CURVE NO ENTRY

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NO PARKING FALLING KEEP LEFT

ROCKS
Safety Risk The objective of Safety/Risk Programme is:
Control  Prompt incident / accident information
 Effective incident / accident investigation and reporting
 Reducing Injuries
 Reducing property damage
 Reducing wastage of time and material
 Minimization of the risk of fire
 Ensuring a healthy working environment
Accident  Park the machine where the accident occurs
Reporting  Report the accident to the pit controller by means of two-way radio, stating
the location and time of accident.
 Apply first aid if necessary.
 Barricade the machine with some white drums.
 Help the foreman to complete the accident report forms.
Breakdown  Drive machine out of haul roads
 Park the machine according to procedure
 Put the wheel locks on and lock the wheels
 Barricade the machine with some white drums
 Check the machine for fault
 By means of two-way radio, report the breakdown to the Supervisor.
Swinging or Before operating the machine or the work equipment, always observe the
Changing following precautions in order to prevent serious injury or death:
Direction of  When changing direction of travel from forward to reverse or from reverse
Travel to forward, reduce speed early and stop the machine before changing
direction of travel.
 Sound the horn to warn people in the area
 Check that there is no one in the area around the machine. There are
blind spots behind the machine, so if necessary, swing the upper structure
to check that there is no one behind the machine before traveling in
reverse.
 When operating in areas that may be hazardous or have poor visibility,
designate a person to direct worksite traffic.
 Ensure that no unauthorized person can come within the turning radius or
direction of travel.
Be sure to observe the above precautions even if a travel alarm or mirrors are
installed.
Precautions  Never turn the starting switch to the OFF position when traveling. It is
When dangerous if the engine stops when the machine is traveling. It will be

LEARNER GUIDE
Traveling impossible to operate the steering.

 It is dangerous to look at other things when operating. Always concentrate
on your work.
 It is dangerous to drive too fast, start suddenly, stop suddenly, turn
suddenly, or snake when driving the machine.
 If any abnormality in the machine (noise, vibration, smell, abnormality in
gauges, leakage of air or oil, etc) is seen during operations, stop the
machine immediately at a safe place and look for the cause.
 Keep the work equipment at a height of 40-50cm from the ground level.
 When traveling, do not operate the work equipment control levers. If they
have to be operated, stop the machine first.
 Do not operate the steering suddenly. The work equipment may hit the
ground and cause the machine to lose its balance which may damage the
machine or structures in the area.
 When traveling on rough ground, travel at low speed and avoid sudden
changes in direction.
 Avoid traveling over obstacles as far as possible. If the machine has to
travel over an obstacle, keep the work equipment as close to the ground
as possible and travel at low speed. Never travel over obstacles which
make the machine tilt strongly (10 degrees or more).
 When traveling and during operations, always keep a good distance to
prevent contact with other machines and structures.
 Always keep to the permissible water depth.
 When traveling over bridges or structures on private land, check first that
the bridge or structure can withstand the weight of the machine. When
traveling on public roads, check with the local authorities and follow their
instructions.
Rules For  Obey all road signs
Operating  Keep on established roads
Service Trucks
Without Risk  Keep left unless over taking
Of Damage Or  Adhere to speed limits
Loss To  Keep safe following distance of at least 40 m or 5 lengths of your machine
Machine Or
Property, Or  Give way to laden trucks
Injury To  Do not drive over electric cables
People  Do not squash barricading drums
 Look out for pedestrians at all times
 Wear your seat belt at all times
 Be aware of the environment by being alert for small animals
 Do not enter any closed off areas
 Bull excavators must be 0.5m above the ground
 Never free wheel down a ramp
 Use neutralizing brake for dozing
 Service brake stop
 Use emergency brake in case of emergency
 Do not reverse at high speed
 Control and visibility are less when traveling forward

LEARNER GUIDE
Self Test …
1. When must you avoid overtaking?
2. Name two reasons incidents occur?
3. What is a hazard?
4. Which act focuses on the prevention of Occupational Health
and Safety in our Industry?
5. Name three rights of an employee?
6. Name four duties of an employee?
7. Name five important hints regarding personal hygiene?
Monitoring Service Trucks Performance

When the engine is running, respect the warning lamps. The red lamps require
immediate action or consideration.

3.3 Monitor Service Truck performance and take corrective action when necessary,
in accordance with manufacturer’s instructions.
Warning Indicators & Corrective Actions

LEVEL 3 LEVEL 2 LEVEL 1
The indicator and the fault The indicator and the fault Indicator comes on.
light will come on and the fault light come on to be rectified at To be rectified at next weekly
alarm will sound. next daily service. service
Machine not to be operated Report this to their supervisor
who is then responsible to
organize the service truck to
implement
3.4 Safety - Minimize Hazards

A hazard can be anything which causes you to change speed or
direction or both. Not all operators approach a hazard in the same
manner. This stems from the fact that very few operators in South
Africa receive formal driver training. The training that is given is not of
a uniform or standardized nature, with the result that one does not
know how other operators will react in any given situation. This
results in much confusion, frustration and general chaos on our
roads, as shown by the unacceptably high collision and fatality
statistics.
A vehicle can become a lethal weapon unless it is handled with great
care and attention. It will become apparent that operating a vehicle
can be a pleasure if the operator possesses certain knowledge and
can master certain specific actions. It is also possible that you could
someday save someone’s life (perhaps your own) if you were to

LEARNER GUIDE
practice and apply with care the knowledge contained in the next few
pages.

3.4 Explain ways to minimize hazards specific to operating Service Trucks in terms
of potential damage to machine and property and injury to people.
Types of Hazards
There are three types of hazards – moving, stationary and proximity
1. Stationary hazards Intersections, stop streets, turns, potholes, lampposts, driveways etc.
2. Moving hazards Other road users i.e. Fast-moving vehicles and slower moving
pedestrians and animals, whose behaviour is unpredictable.
Laden production vehicles always have the right of way.
3. Proximity hazards Varying ground and support conditions exist on sites where machines
operate. The operator must ensure that the machine is operated on
stable ground conditions.
Ground Hazards
The three likely ground hazards are:
Back filling Water logged soil Cable/Pipe Soft Ground
When trenches are When the soil is trenches Soft ground may be an indication
dug and refilled waterlogged, no The soil on top of underground services.
without being resistance exists may look Operators should be warned to
compacted and machines will stable, but watch out for manholes and or
sink into the wet sinking can be marker posts indicating
soil if the caused. underground services.
necessary steps
are not taken.
The System of Vehicle Control
In order to be a defensive driver / operator, you should be in control of the machine / vehicle.
This can be done by following a certain method of driving / operating – referred to as the
SYSTEM OF VEHICLE CONTROL.
The S I P D E Process SEARCH (for hazards)
The operator should continually be aware of
everything happening around him, so that he IDENTIFY (The type of hazard)
will be prepared to react in the correct
manner according to the System of Vehicle PREDICT (How one will be influenced by it)
Control. This involves an on going mental
process, which consists of the following DECIDE (What action to take)
actions:
EXECUTE (Executing the action)
Search ■ This means that we should continually be searching for anything, which
could cause us to change speed or direction. The search process should not
be restricted to forward vision only, but to the side and rear as well.
■ Hazards should be searched for 12 seconds ahead, meaning that from the
time we see a point to the time we reach it, should take 12 seconds, in order
to identify hazards.
■ You should not look at any hazard for longer than one second.
■ Allow eyes to scan continuously from one hazard to the other.
You must bring all your senses into action during the search for hazards,
BUT ESPECIALLY THE EYES.
■ Certain hazards or hazardous situations can be expected under certain

LEARNER GUIDE
circumstances. At an intersection in an urban area, there could be

pedestrians, cyclists, motorcyclists and other traffic arriving from several
directions in different lanes, which in tern may have various road markings,
and road signs which regulate our own and other’s movements.
■ With all these ‘persons’ you have to share the road safely. The same applies
to earth moving sites.
■ Generally, a point where traffic meets or crosses presents the greatest
danger.
■ There are various such inter sections, e.g. traffic circles, on-and-off ramps
on freeways, hidden entrances to houses, traffic-light-controlled
intersections, stop streets, junctions where one must yield and so on.
■ There are situations, such as lane - changing and overtaking where these
manoeuvres may be prohibited. When weather conditions are poor, you
must consider how these could cause restricted visibility and a slippery
surface and ensuing dangers, especially when the tyres are worn.
■ You must be aware of where the road narrows, e.g. where two lanes merge
and where vehicles are parked, someone may attempt to share the lane.
One must also realize the dangers, which may arise from these situations.
Identify ■ When a hazard has been identified during the search process, the following
question must be asked, “ Is it a stationary or moving hazard and how will it
affect my speed or direction or both? “
■ A school bus with children getting on and off, presents a far greater
possibility of being faced with a number of potential hazards than does a
blind man with his guide dog on the sidewalk.
Predict Once the hazard has been identified, it is necessary to predict how it could affect
us. Think of matters like the following:
■ If the hazard can move, what are all the possible ways in which it can affect
a person?
■ Is the hazard moving toward or away from you; at what speed and where
could a collision possibly occur?
■ What is the potential of the hazard for causing a collision?
■ How can your actions to avoid the collision influence other road users?
For example
- When a machine has stopped in front of you, what is the possibility of
someone alighting and walking in front of you whilst you are driving past?
- Could a vehicle coming toward you cross in front of you at an intersection?
- Could a machine behind you start to overtake?
- Might a dog, which you observed on the right hand side of the road run across
your path?
- Might a child follow a ball, which has rolled into the road?
Decide Depending on your prediction, you must now decide how to react to the
situation:
■ Are you going to warn of your presence simply by hooting or flicking the
lights?
■ Should you increase or decrease your speed?
■ Are you going to change direction only, or combine some of the above
actions?
Your decision will be influenced by the amount of clear space you need to create
between your vehicle and the hazard. Always remember that you must create as
much clear space around you as possible.
At this stage it is essential that you do not look at a hazard fixedly, but look
towards your escape route or the path that you need to follow.

LEARNER GUIDE
Execute Whatever decision you make on the road must be executed in accordance with
the System of Vehicle Control. This means that the execution of your decision
must be done in such a manner that your vehicle is at all times:
■ In the correct position on the road;
■ At a speed which is safe for prevailing conditions; and
■ In the correct gear for immediate future requirements
In order to meet these requirements, a series of actions must be considered
carefully in sequence, whenever a hazard is approached:
1. 1st Mirror Check
2. 1st Blind Spot Check
3. Signal
4. 2nd Mirror Check
5. Brake
6. Appropriate Gear Selection
7. 2nd Blind Spot Check
8. Steer
9. Accelerate
■ Using the horn will in many cases be sufficient to catch the attention of
1 certain hazards so that further avoiding action may not be necessary.
First Mirror ■ More often than not it will be necessary to change speed or direction and to
Check this end the next step of the System of Vehicle Control must be carried out,
namely to look in the mirrors in order to obtain a picture of the traffic situation
to the rear. You cannot afford to ignore what is happening behind you.
■ Traffic situations change continually and quickly, but by checking the mirrors
regularly, you can keep track of the situation behind and this will help
towards making a correct decision about how to negotiate a hazard ahead.
Remember Check the mirror regularly
■ For example, if you know someone is following too closely, you may decide
to avoid the hazard ahead by turning away from it rather than by trying to
brake and risk being hit by the car behind.
■ Frequent mirror checks to the left and right should be part of your normal
search routine for hazards.
■ As part of the ‘moving-off procedure, checks to the rear and sides must also
be made.
■ Many vehicles are fitted with rounded convex mirrors, especially the exterior
mirrors. These give you a wider view of the road behind than do flat mirrors.
However they also make cars seem farther away than they really are.
■ If you are not used to these mirrors, practice until you can judge distance
accurately when using them.
■ Park in a quiet side street and search in the side mirror for a vehicle
approaching from the rear.
■ Look quickly over the shoulder or in the flat centre mirror (if so equipped) to
ascertain exactly how far the vehicle actually is.
■ Practice in this way until you have mastered the situation.
■ All mirrors should be adjusted to give maximum vision to the rear.
■ If it was your decision to slow down and you have satisfied yourself that it is
safe to do so, you may then reduce speed.
■ If your decision was to change direction then the following essential action,
immediately following the mirror check, is to check the area, which is not
visible in either the interior or exterior mirrors.
■ This check is to ensure that the vehicle, which may be hidden in that area, is
not about to overtake you.
■ The purpose of the mirrors is to inform you of the traffic situation to the rear.
2 It is a fact that the interior mirror does not cover the situation to the sides.

LEARNER GUIDE
First Blind ■ The exterior mirrors are useful for checking the traffic situation on both sides
Spot Check to the rear. Unfortunately these exterior mirrors don’t give the full picture.
Even with the help of the exterior mirrors there is an area on each side of the
vehicle that is not visible to the driver. This area is called the Blind - spot.
■ The fact that drivers are not aware of this blind spot and that a vehicle may
be hidden there, is the cause of thousands of collisions annually.
■ The only way of ensuring that no vehicle is hidden in the blind spot is to look
over the appropriate shoulder, to left or right depending on the direction of
the turn. This quick look over the shoulder is an integral part of the search
process to identify a hazard.
■ You must take care not to look over the shoulder for too long a time. Also
make sure that the steering wheel is not turned inadvertently when doing this
check. You are inclined to steer in the direction that you are looking,
especially if the shoulders are twisted when the head is turned.
■ Before any direction change, a blind spot check in the required direction
must be made. This means that before signaling to the right, one needs to
check the blind spot to the right.
■ Mirrors and the blind spot should be checked before signaling to ensure that
there is no vehicle or other road user in the blind spot. Should you signal
before checking the blind spot, the driver of the vehicle next to you could be
startled, as often happens, swerve away from you to avoid a collision and
possibly become involved in another one. Ensure that no other vehicle is in
the blind spot before the signal is activated.
■ On a road with more than two lanes in the same direction, it is necessary to
check all the lanes to the right or left in case another vehicle is heading for
the same space as you are.
■ It often happens on a three-lane road that you want to move into the lane on
your right and the vehicle in the extreme right hand lane wants to move to
the left, which then places you both on a collision course.
■ When moving off from a stationary position, both blind spots and the interior
mirror should be checked. It is imperative to spot all the pedestrians and
cyclists who weave through the traffic. Remember … you should at all times
have a clear vision of everything around you, by observing correctly.
■ The blind spot should be checked when approaching a skew junction.
■ Both blind spots should be checked when intending to use an off-ramp on a
freeway.
■ Check to the left firstly, to ensure that it is safe to leave the freeway, then to
the right to ensure that no -one from the right hand lane is about to drive
across your path of travel in order to exit at the same off-ramp.
■ When about to drive past an off-ramp, a check to the right is still required for
the same reason as stated above.
■ Some drivers in the middle or extreme right hand lane decide at the last
moment to cut across the front of your car in a dangerous manner in order
not to miss the exit.
■ Extra care must be taken when checking the left blind spot. In the case of an
enclosed truck or cab, better use should be made of the left mirror to check
the blind spot by leaning forward.
■ So far, we have determined by checking mirrors and blind spots what the
traffic situation is and that it is safe to execute our decision. Only now can
we, by indicating, tell other road users what we intend doing.
■ The Road Traffic Act requires that we give a clear signal of our intention to
3 change direction or reduce speed. The vehicle’s stop - lights serve to
Signal indicate to our fellow road users that we intend slowing or stopping.
■ The use of the indicator is our means of communicating to other road users,
even though they may not be visible to us, our intention of changing

LEARNER GUIDE
direction.
■ The indicators must be activated timeously and long enough to warn other
road users of our intention.
■ Once your manoeuvre or action has been completed and you are in the
desired position, the signal must be cancelled.
■ Care should be taken not to cancel the signal too soon as this could give the
impression that you have decided not to complete the manoeuvre.
■ Care should also be taken not to cause confusion by signaling too soon e.g.
where two intersections are close together and your intention is to turn at the
second intersection.
■ In this case the signal should be given as you are leaving the first
intersection.
■ Additional hand signal may be considered necessary e.g. when turning into
driveway when it is close to an intersection.
■ It is preferable to operate the indicator switch with the fingers so that the
hand is no moved from the steering wheel.
■ Care should be taken not to inadvertently switch on the indicator when the
hand is removed from the steering wheel for some reason.
■ Direction indicators must also be used when parking the vehicle and even
when reversing for parallel parking and alley docking.
■ A means of remembering in which direction to operate the indicator switch
when reversing is to move the switch in the same direction that the rear of
the vehicle must move.
■ When leaving the parking bay, the indicator should be activated to inform
other road users that you intend to join the traffic flow or enter the road.
■ Often the indicators can be used as a request to other road users to allow
you to change lanes in order to turn at the next intersection. If someone
should create a gap for you it is a nice gesture to give him a smile and a
wave of thanks.
At this point we know:
■ How to observe traffic from the rear (first mirror check)
■ How to observe to the sides (first blind spot check).
■ How and when to signal to inform other road users of our intention which might involve a
reduction in speed, stopping, lane changing, or any other change in direction.
After all these actions have been executed, we can start thinking about reducing speed
■ Before the next action (which is speed reduction) is commenced, mirrors
4 must again be checked.
Second ■ Since we last checked the mirrors and blind spot and activated the signal,
Mirror some time has elapsed during which the traffic situation behind may have
Check changed.
■ Once again make sure that the traffic situation behind you is still of such a
nature that you can safely reduce speed.
■ If it is safe to brake, release the accelerator smoothly to ensure that the
5 vehicle does not jerk.
Brake ■ Depress the brake pedal smoothly and progressively.
■ Use may also be made of either the exhaust or engine brake if fitted.
■ The danger exists that when the brakes are applied suddenly and fiercely,
the wheels could lock and as a result, you could lose control of the vehicle.
■ When the brakes are locked the driver loses all ability to steer, thus
preventing him from steering safely round a hazard.
■ With locked wheels the vehicle will continue on a straight course even if the
steering wheel is turned.
VERSION : 01 GREENRIM TRAINING PAGE

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LEARNER GUIDE
■ If the brakes are locked due to injudicious braking, steering control can be
regained by reducing pressure on the brake pedal sufficiently in order to
allow the wheels to start rolling again (obtain traction).
■ Both hands must be on the steering wheel all the time while braking in order
to be in full steering control.
■ A lower gear should not be engaged to reduce speed or to replace braking.
■ When speed has to be reduced, the braking procedure should be completed
before the appropriate gear is engaged. Remember … Gears Are For Going
And Brakes Are For Slowing. Braking should, as far as possible, be
completed while the vehicle is moving in a straight line.
■ Just as the pressure on the brake pedal must be applied smoothly and
progressively at the beginning of the braking process, so should the
pressure on the pedal be reduced gradually at the end of the braking
process to avoid a jerk.
The Following Rule Applies To Braking:
STOPPING DISTANCE + REACTION TIME = BRAKING DISTANCE
■ Stopping distance (the distance needed to bring the vehicle to a stop after
the decision to stop has been taken) is the sum of the reaction time and
braking distance.
■ Reaction time is the time taken from the moment the decision to brake is
taken to the point where the foot is placed on the brake pedal. Reaction time
of a normal person can vary from one to one-and-a-half seconds.
■ Braking distance is the distance a vehicle takes to come to a standstill by
depressing the foot brake. Braking distance is greatly influenced by tyre
pressure, tyre tread depth, as well as the road surface.
■ The components of the System of Vehicle Control, which have been covered
thus far, are the checking of mirrors and blind spots, the signaling of your
intention, the second check of mirrors before braking and controlled braking
to reduce the speed of the vehicle.
■ As mentioned before, we need to place the vehicle in the correct position on
6 the road. At a safe speed for the circumstances and in the correct gear. We
Appropriate have covered the first two components, now we must discuss the third one,
Gear which concerns the selection of the appropriate gear.
Selection ■ Vehicles equipped with automatic transmission will automatically select the
correct gear for the acceleration required.
■ Effective acceleration depends on understanding the potential of the engine
and the gear ratios.
■ The selection of the gears must go hand in hand with the potential of the
vehicle.
■ One of the marks of a good driver is his ability to change gears smoothly and
to utilise the correct gear for that particular vehicle in the circumstances
existing at that time.
■ This ability will improve with practice.
■ The ability of the driver to match the correct gear smoothly with engine
revolutions and road speed depends on the precise use of the clutch,
accelerator and gears. After the correct gear has been selected for moving
off, the judicious use of the clutch and accelerator will allow you to move off
smoothly and to progress through the higher gear changes to build up your
speed.
■ Once the desired speed has been reached in a particular gear, acceleration
must be reduced just before the next higher gear is selected.
■ Gear changes must take place without jerking the vehicle and without
grating the gears whilst the eyes are continually on the road. Naturally by
this time the driver must be entirely familiar with the gear change pattern

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LEARNER GUIDE
before driving the vehicle.

■ As soon as the gear change has been completed, the hand must be placed
back on the steering wheel and the foot removed from the clutch pedal.
Where possible, gear changes should only be made while the vehicle is
moving straight ahead.
■ Maximum acceleration is seldom needed in the lower gear ratios and care
should he taken not to exceed the recommended engine revolutions.
■ A driver must therefore understand what the speed potential of his vehicle is
in each gear.
■ When ascending a steep gradient, a lower gear must be selected before the
road speed drops too low and the engine starts labouring.
■ When a reduction in speed is necessary, braking must be completed before
a lower gear is selected.
■ When driving down a steep decline, start braking at an early stage so that a
lower gear can be engaged in good time to prevent the vehicle gaining
speed, with the resultant excessive braking causing undue wear.
■ The use of mirrors and blind spot, signal, mirror and brakes, followed by the
selection of the appropriate gear, has ensured that the vehicle is in the
correct position on the road at a safe speed and in the correct gear to drive
round or away from a hazard.
■ Some time has elapsed since the last check of the blind spot. One must now
7 again check to ensure that nothing has moved into the blind spot in the
Second meantime.
Blind Spot ■ Remember that the first blind spot check was to see if it was safe to signal,
Check now we must see that it’s safe to steer. This second check is to ensure that it
is safe to steer -in other words to change direction.
■ Just as in the case of the first blind spot check, the second one may be
omitted if no change in direction is intended e.g. when we are going to stop
and then continue straight ahead.
After you have braked, changed down and checked the blind spot, you can now
8 start steering, concentrating on the steering action in case there should be some
Steer emergency in the traffic situation and keeping both hands on the steering wheel
for controlled rapid and safe steering action.
How to Hold and Handle the Steering Wheel
■ A safe method for holding the steering wheel is with both hands on the
wheel in the ten-to-two or quarter-to-three position, so that the pull-push
steering method comes naturally. The driver has a more balanced posture in
the vehicle when the hands are in a horizontal position opposite each other
on the steering wheel even while he is turning the wheel.
■ This means that the hands will not go past each other causing the arms to
cross when the steering is turned.
■ When turning left with the hands in the ten-to-two or quarter-to-three
position, the grip is tightened on the left hand, which pulls the wheel down,
the right hand also moving down along the rim and joining the left hand at
the six-thirty position at the bottom of the wheel. The grip is now changed so
that the right hand grips the wheel and pushes upwards while the left hand
moves along the rim towards the twelve o’clock position where both hands
meet. It may be necessary to repeat the process to complete the turn. To
straighten the wheel, exactly the same method is followed.
■ To turn to the right, the same method is used, hut the first action would be
for the right hand to grip the wheel and pull down to the six-thirty position,
followed by the left hand pushing upwards. This method is known as the
pull-push steering method.
Counter Steering

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LEARNER GUIDE
■ The steering must not be turned while the vehicle is stationary.

■ When parking and the maneuvers are executed, counter-steering must be
done in order to minimize strain on the steering mechanism and wear on the
tyres. It will facilitate completion of these maneuvers.
■ Counter steering means turning the steering wheel in the opposite direction
just before coming to a stop, in order to straighten the wheels while the
vehicle is still moving.
Smooth Steering Movements
■ Ensure that both hands do not turn the steering wheel at the same time,
which could cause jerky and uneven steering movements.
■ Smooth steering movements ensure that the vehicle is in a more balanced
attitude at all times. A vehicle is unbalanced when changing direction, so
making a smooth and gentle steering movement ensures that the imbalance
is not made worse.
■ Sudden and jerky steering movements are to be avoided when the road
surface is slippery e.g. when it has just started to rain or, in general when it
is wet.
■ At the completion of a turn the steering method should be applied again.
Allowing the steering wheel to spin back on it’s own is a dangerous practice
and can lead to severe imbalance of the vehicle.
Be Familiar with the Steering Characteristics of Your Vehicle
■ Just as it is important to be familiar with the gear change pattern, so is it
important to be familiar with the steering characteristics of your vehicle.
■ Different vehicles could have vastly different steering characteristics.
■ Knowledge of the steering characteristics of your vehicle will ensure that you
don’t cut the corner or run wide when negotiating a turn.
■ Vehicles equipped with power steering react more easily to steering input
than vehicles not so equipped and could respond more quickly than is
anticipated.
■ The hands should not be removed from the steering wheel unnecessarily.
The indicators can usually be activated using the fingers.
■ As soon as you commence the turn, accelerate gently and progressively
9 without jerking in order to maintain a constant speed.
Accelerate ■ When the wheels are straightened after the turn or, having gone around the
hazard, accelerate more progressively until the desired speed has been
achieved.
■ Once the desired speed has been reached iii a particular gear, acceleration
must be stabilized by decreasing the pressure on the accelerator pedal just
before the next higher gear is selected, to ensure a smooth gear change.
■ If acceleration is not done smoothly and progressively, there is a possibility
that the balance of the vehicle could be disturbed to such an extent that the
vehicle could go out of control.
■ As part of the continual “search and identify” process, the condition of the
road surface must be observed so that the appropriate amount of
acceleration may be applied.
■ After the turn or hazard has been negotiated and the wheels are
straightened, check the situation to the rear once more.
SIPDE
The importance of the SIPDE (Search, Identify, Predict, Decide, Execute) process as part of the
system of vehicle control, con not be over – emphasized. Pedestrians bump into each other and
apologize for not seeing each other. At the scene of a collision, one frequently hears one of the
drivers or operators say, “I did not see you”.
Many collisions could be avoided if drivers / operators would only search for hazards, identify

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LEARNER GUIDE
them, predict the worst that could possibly happen and then make the correct decision.
Many drivers approach a green light presuming that the red light for cross traffic will stop them.
Frequently, drivers do not obey the red robot! Continually strive to create as much clear space
as possible by adjusting speed or direction so that you have more time and space in which to
react to any hazard. Allow two hazards to separate, as it is easier to deal with one hazard at a
time.
When hazard cannot be separated, a compromise should be reached to create equal clear
space laterally between the hazards, e.g. the parked vehicles on the left hand side and the
oncoming vehicles create equal hazards, so one selects a middle path between them so that
one has equal clear space on either side of one’s vehicle.
Most collisions occur at intersections in urban areas and during lane changes. Single vehicle
collisions due to a failure on the part of the driver to search for hazards; collisions which occur
between a vehicle and a pedestrian or fixed objects and where the vehicle has overturned,
make up approximately one third of all collisions.
Rear-end collisions constitute the largest percentage, particularly in poor visibility situations,
such as in rain or misty weather. These collisions can be ascribed to two factors:
■ Insufficient sight distance in bad weather conditions; and
■ Too close a following distance

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LEARNER GUIDE
The Three-Second Following Distance Rule

Clear space is vitally important in the handling of hazards. Vehicles moving in the same
direction are also hazards. If there is insufficient following distance (clear space) behind you and
in front, this is also potentially dangerous. You should maintain a following distance of at least
three seconds at all times.
■ Note when the rear of the vehicle in front of you passes a fixed reference point on or near
the side of the road, e.g. a lamp past, road marking or shadow on the road, and then count
slowly “two thousand and one, two thousand and two, two thousand and three”.
■ At the completion of the count, the front of your vehicle should not have reached the
reference point or mark. In the event of your reaching the reference point before you have
completed the count, your following distance is insufficient and you must fall back to
increase it.
■ The three-second following distance rule also ensures that, the vehicle in front of you less
restricts your forward vision. This is one of the reasons for keeping a safe following distance
behind a large commercial vehicle when wanting to overtake. The closer you are, the more
your view ahead is restricted.
■ The three-second rule ensures that you have an adequate view of the road surface ahead,
which will enable you to avoid potholes and other objects.
■ The advantage of this rule is that, although the three-second-time span is constant, the
clear space increases with the increase in speed.
■ At 60 km/h the gap is 51 metres, but at 120 km/h the gap is now 102 metres, although three
seconds is applicable in both cases.
■ If someone drives too closely behind you, there is no sense in speeding up, as he will also
speed up.
■ The only way to overcome this problem is to increase your following distance. This will
ensure that, if the vehicle in front of you reduces speed suddenly, you will have more space
in which to reduce speed or stop, thus giving the driver behind you more space in which to
react, thereby avoiding a rear-end collision.
■ This also encourages him to overtake you when the opportunity arises. Bear in mind that
the sooner he passes, the less of a threat he is to your safety.
Summary
Let us summarize what we have learnt about Defensive Driving and the System of Vehicle
Control so far.
1. You must continually search for hazards.
2. When the hazard is identified you must predict what could happen and then decide how to
act.
3. The situation changes continually, which means that a decision that has just been taken may
be influenced by the identification of other hazards and that the whole process must be
repeated.
4. Remember that when reading this, all the above appears to take place over a long period,
but that it actually happens in a split second.
5. Drivers must frequently compensate for other people’s mistakes or reckless behaviour.
6. Becoming annoyed or angry in such circumstances benefits no one and in fact one could
add to the danger by acting irrationally.
7. Allow your fellow road user the opportunity to recover from his mistake rather than to make it
worse.
Self Test …
1. What are the 2 types of hazards?
2. Name the 3 likely ground hazards?
3. What does Search mean in the SIPDE process?
4. What is the purpose of the first mirror check?
5. What is the purpose of the blind spot checks?
6. Why is it important to signal?
7. What is a safe method of holding the steering wheel?

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LEARNER GUIDE
8. What is counter steering?

9. How is the 3 second following distance rule applied?
Self Check 3
1. Explain at least 6 of the potential hazards which could occur whilst operating your machine
4. 1. 2. Describe the ways to minimize the above mentioned hazards
3. What is the S I P D E process?
4. What are the series of actions that must be considered whenever a hazard is approached?

106
LEARNER GUIDE
able to:
YES NO
3.1 Explain the purpose of Service Trucks various controls in
accordance with their designed use.
3.2 Demonstrate the functions of Service Trucks various controls in
accordance with the manufacturer’s instructions.
3.3 Use various controls to effectively manoeuvre Service Trucks
within manufacturer’s instructions.
3.4 Follow safe working procedures according to manufacturer’s,
company and statutory requirements.
3.5 Monitor Service Trucks performance and take corrective action
when necessary, in accordance with manufacturer’s instructions.
3.6 Operate Service Trucks without risk of damage or loss to machine
or property, or injury to people.
3.7 Explain ways to minimize hazards specific to operating Service

Trucks in terms of potential damage to machine and property and
injury to people

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LEARNER GUIDE
LEARNING ACTIVITY 4
Document Service Truck

Use
The purpose of this Learning Activity is to enable you to accurately record the
use and maintenance of Service Truck.
Specific Outcome 4
■ Document the Service Trucks hours in accordance with company

requirements.
■ Report Service Trucks maintenance and faults in accordance with company
requirements.

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LEARNER GUIDE
4.1 Documenting & Reporting Service

Truck Status

4.1 a) Document Service Truck hours in accordance with company
requirements. b) Report Service Truck maintenance and faults in
accordance with company requirements
Servicing System
The servicing system is there to make sure that every piece of earthmoving
equipment or plant is serviced regularly. The system that you use has been
developed over a long period of time. It has changed as new technology has
been used and what you use today is the result of many years of experience
and operation.
The servicing system is a planned maintenance system. This means that the
servicing is done to a planned cycle. The plan is based on servicing a vehicle
every so many hours e.g. 10 hours, 250 hours, 500 hours, 750 hours and 1000
hours.
prevention - the need to replace certain components before they fail
interval - the calculated period of time between services based on past
experience of component failure rates and on OEM recommendations
accumulation - the need to deal with the cumulative effect of wear and tear
when servicing vehicles.
Servicing Procedures
The servicing procedures are made easy for you to follow. Each vehicle has a
service sheet for each kind of service. This means, for example, that there is a
service sheet for a D9L Dozer for each of its 10 hours, 250 hours, 500 hours,
750 hours and 1000 hours services. The service sheet is a check list which you
must use to make sure that you complete every activity that is required for a
particular service.
Deviation/Defect Reporting System

Every defect (or deviation) that you find on any piece of earthmoving equipment
or plant MUST be reported. The service sheets have 39 lines for you to report
defects that you find while you are servicing plant. When you report a defect
you must provide enough information for the mechanic or fitter to find and repair
it. It is not enough to say “bracket loose”. Which bracket ? which component ?
Why did you NOT tighten it while you were there ? (perhaps it was broken and
needs to be welded)
You must never ignore small defects. Also you must never wait for small defects
to get bigger (“worth” reporting) before you report them. If you cannot do
something about it while you are there, then you MUST report it for action. If it is

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LEARNER GUIDE
not repaired soon, you MUST report it again…and again…and again, until it is
repaired.
Corrective Actions for Rejected Components / Defects

What must you do if a component fails inspection or is not in good enough
working order to keep on being used on the machine until the next service of
the same interval? In some cases you know you must make the repair or
replacement yourself (e.g. you replace an air filter after it has been cleaned for
the third time). If the problem (defect) is one that you are authorized to repair,
then you can make the repair immediately. (e.g. tighten or replace loose or
missing bolts).
Finally, if the problem (defect) is one that you are not authorized to repair, you
must report the defect immediately so that the fitter or mechanic can make the
repair.
Typical Failures of Components

There are some things that usually seem to happen to components and cause them to fail. The
more common causes of failure of components are:
lubrication oil or grease is not provided (or the wrong lubricant is provided) to the
failure component and it wears out, seizes, over heats or breaks long before it should
do.
abrasion sand, grit, dust, iron filings etc get in between moving parts in a component
and cause it to wear out (fail) sooner than you would expect
vibration causes components to shake loose and function under stress. Too much
vibration will damage delicate equipment like electronic equipment
pressure
temperature
Cost of Failure
What does it really cost a company when a component fails?
Let’s say that a radiator hose is leaking. The serviceman does not have a spare
with him but he decides to go back to the workshop to get one. He is away for
one hour.
What did the hose cost the company?
1. the cost of the new radiator hose R???
2. plus, the cost of the operator waiting, thirty minutes for the service, one hour
waiting for the hose and thirty minutes to fit the hose and fill up the radiator.
That is two hours operator’s wages R???
3. plus, the cost of the serviceman making a trip to the workshop to fetch a
hose. That is one hour Serviceman’s time wasted R???. The service team is
also delayed by one hour. That is three hours total delays (3 people x 1 hour
each) R???
4. plus, the cost of lost production. In two hours the machine could have
produced ??? tonnes of coal or chrome ore etc. Those tonnes will not be
sold today. That means the company lost X tonnes @R/t = R???

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LEARNER GUIDE
You can see that the failure of a radiator hose, and the failure of the
Serviceman to plan his day caused the price to replace the radiator hose to
grow to R???.
Fitting It All Together

Everything that we do is part of a system. Whatever you do in one system has
an impact on another system. If you use the wrong oil in the “servicing system”
to lubricate a Service Truck motor, you could cause the Service Truck to fail. If
the Service Truck motor has to be overhauled it creates extra, and
unnecessary, work in the “maintenance system”. This could delay the repairs to
the brakes on a personnel carrier in the “transport system”.
On the way home the truck’s brakes could fail at a level crossing and cause an
accident on the “railway system”. Injuries will have to be treated in the “hospital
system”...and so on. You can see then that a simple action at work can cause
trouble at a national level.
Remember then that everything that you do affects someone, somewhere,
somehow!

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LEARNER GUIDE
CHECK-LIST (DAILY)
Site Plant No Flat, Water & Crane Trucks, Diesel
Bowsers + Personnel Carriers
MON TUE WED THU FRI SAT SUN
1 Check and Sign Operators Checklist
2 Check all Gauges for Correct Operation
3 Check all Lights and Back-up Alarm
4 Check Indicators, Stop Lights and Hooter
5 Check Air Induction System
6 Check Chevron Plate, Reflectors and Triangles
7 Check all Warning Devices
8 Check Hand/Parking Brake Operation
9 Check Foot Brakes for Correct Operation
10 Check Brake Bocks & Brackets
11 Check Windscreen Wiper Blades and Arms
12 Check Power Steering Oil Level
13 Check all V-Belts
14 Check Engine Mountings and Bolts
15 Check Air Cleaner Service Indicators
16 Clean Air Dust Bowl
17 Check Battery Water Level, Terminals, Hold-down
Bolts and Clean
18 Check for Air, Water, Oil or Fuel Leaks
19 Check that Tyre Valves are not Leaking
20 Check Condition of all Tyres & Spare Wheel
21 Check Tyre Pressures & Jack/Tools
22 Check that all Valve Caps are Fitted
23 Check all Wheel Nuts and Studs
24 Drain Air Tanks
25 Check Propshaft Centre Bearing & “U” Joints
26 Check all Spring, Centre + “U” Bolts & Nuts
27 Check Hanger Brackets, Shackle Pins & Brushes
28 Check Front & Rear Suspension and Steering
29 Check P.T.O. Operation
30 Check Body for Wear &/or Damage
31 Tighten &/or Replace Loose/Missing Bolts & Nuts
32 Check Vehicle for Cracks
33 Grease Vehicle as Required
34 Check Radiator Water Level (Engine Cold)
35 Check Engine Oil Level (when Engine is Off)
36 Use Pressure Washer to Clean Vehicle
37 Check Number Plates, Licence & F.E. Date
38 Road Test
Operator’s /Drivers Signature Supervisor’s Signature
Foreman’s Signature Plant Foreman’s Signature

112
LEARNER GUIDE

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LEARNER GUIDE
DEFECTS / FAULT REPORTING

Defect Action Taken
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
35
36
37
38
39
40

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LEARNER GUIDE
Self Check 4
1. What is the servicing system?
2. Why is it important to document the Service Truck hours?
4. 1.
3. Why is it important to report every defect (or deviation) that you find on any piece of
earthmoving equipment or plant?
4. What must you do if a component fails inspection?
5. What are typical failures of components?
6. What does it cost when a components fails?

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LEARNER GUIDE

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LEARNER GUIDE
able to:
YES NO
4.1 Document Service Truck hours in accordance with company
requirements.
4.2 Report Service Truck maintenance and faults in accordance with
company requirements.

117

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Service Truck

SUBJECT DETAILS OF UNIT STANDARD

By the end of this module you will be able to:

1. Demonstrate knowledge of the functions of Service Trucks.

The Essential Embedded Knowledge required to perform successfully in the

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CRITICAL CROSS FIELD OUTCOMES

Identify and Solve Problems

Outcomes marked with this icon refer to the ability to recognise

Work Effectively With Others

Outcomes marked with this icon refer to the ability to co-operate

Employ Self Management

Demonstrate Scientific And Technological Competence

Understand Contextual World Systems

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Learning Activity 1 Functions of Service Trucks

Learning Activity 2 Start And Shut Down Service Trucks

Learning Activity 3 Operate Service Trucks

Learning Activity 4 Document the Use of Service Trucks

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An Overview of the NQF

Meaning, Origin and Value of a Unit Standard

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explain what you have learnt.

How to Use this Manual

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■ Explain the main functions of Service Trucks in terms of the

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1.1 Service Trucks Main Functions

Learning Activity Outcome

1.2 Service Trucks Main Components

Learning Activity Outcome

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Storage  The storage battery is the heart of the

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Proximity of Other Machines

1.3 Safety Features & Warning

Learning Activity Outcome

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(psi) to 120 psi. air pressure system should

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Machine is not to be at the next daily service. service

(1) The active warning indications are marked with an X

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Electronic Monitoring System (EMS)

Basic EMS Symbols

EMS Warning Categories

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Alternator Indicates the alternator is malfunctioning.

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Other Gauges & Indicators on the Instrument Panel

Service Hour Indicates the total operating hours of the engine.

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Interior Dome Move the switch back to turn the light on