Rigid Body Dump Truck Learner Guide

OPERATE A RIGID DUMP TRUCK
UNIT STANDARD: 262731

CREDITS: 10
LEVEL: 2
VERSION : 01 GREENRIM TRAINING PAGE 1

NQF LEVEL : 2 SAQA UNIT STANDARD ID – 262731 NQF CREDITS : 10
LEARNER GUIDE
Index PG
Training Programme Introduction 3
Rigid Dump Truck Familiarisation and Functions 4
Rigid Dump Truck Checks, Starting and Shutting Down 16
General Rigid Dump Truck Safety 38
Operating the Rigid Dump Truck 51
Document the Machine Use, Report and Communicate Information 69
Transporting the Rigid Dump Truck 72
Professional Operators Attitude 75
VERSION : 01 GREENRIM TRAINING. PAGE 2

LEARNER GUIDE
Workbook Guidelines
How to use your work book
The following icons will be used throughout this work book.
Fact file
Read the information follows this icon
Group activity
Discuss the information with your peers
Individual tasks
Write your awnsers in you work book
Peer assessment
Check your peer’s work
Self assessment
Check your own work
Glossary
Video’s/Posters

LEARNER GUIDE
Training Programme Introduction:
Welcome to the training programme for Operate a Rigid Dump Truck. This
programme has been developed specifically for the Qualification: National
Certificate in Construction: Plant Operation.
Who is the training programme for?:
This training programme is designed for both novice and experienced learners who
may be expected to operate a RDT while performing their daily duties.
It also makes good business sense that anyone who is expected to supervise
employees related to these activities should know what the correct methods and
procedures are so that they are competent to identify good or bad practices during
the course of their supervision day / shift.
Training Programme Purpose

The qualifying learner is capable of:
Operating Rigid Dump Trucks and demonstrating knowledge of the
functions of RDT’s and starting, shutting down and operating procedures
for the machine.
LEARNERS’ ROLE & RESPONSIBILITIES:

During the training, the learner is expected to:
 Take part in the activities
 Ask questions
 Enter into discussions that have meaning to the topic.
The training is meant to enable the learner to master the skills, and this can only be
done by the learner making the effort to learn.
The facilitator’s purpose is to guide and assist the learners on the path to
competency. While the training is not necessarily a part of the productive work place,
learners will be expected to behave in a manner required in the work place e.g. to
wear the prescribed site specific Personal Protective Equipment (PPE) where
necessary.

LEARNER GUIDE
Module 1
RIGID DUMP TRUCK FAMILIARISATION AND FUNCTIONS
MODULE LEARNING OUTCOMES
At the end of this module the learner will be able to…
 Explain why you need to be a professional Rigid Dump Truck

operator
 Explain the functions of a rigid Dump Truck
 Identify Rigid Dump Truck components and explain their function
and purpose
 Explain what personal protective equipment a Rigid Dump Truck
operator may be required to use
1.1. Introduction:
The Rigid Dump Truck or RDT as it is more commonly referred to, is a purpose
designed haul truck which has a rigid chassis and is not able to articulate.
There are many different makes and models of RDT available, all with their own
advantages or disadvantages. All are designed to perform a similar function, but may
have a special application or capability, which may be better suited for a particular
situation or application, which may enable that particular model or make to perform
better than another make or model. All of these have different features and capacitiy.
Some of the more common makes of RDT are:
 Komatsu
 Terrex
 Cat
As with all plant and equipment, the RDT is no safer than the person operating it or

LEARNER GUIDE
the personnel maintaining it.

Given the design of the RDT, the “horse” cannot be unhitched from the rear load bin.
The RDT is usually fitted with high floatation tyres enabling the RDT to work in all
sorts of terrain from mud to highway conditions.
The RDT is certainly an extremely versatile machine, well suited for most haul
operations.
1.2. Rigid Dump Truck Function:

The function of the RDT is to haul material from the load site to the dump site.
The RDT is a very mobile haul truck that is able to travel between the load and dump
site relatively fast, and is capable of hauling large loads.
Trucks used for hauling on public roads are limited by transportation regulations with
regard to maximum width, gross weight and axle loads.
On larger sites, RDT are preferred as they can be larger and heavier and carry loads
up to several hundred tons.
The RDT is used for a variety of purposes from general site use up to the 300 Ton
versions in quarrying operations.
These RDT need to be very strong and robust.
RDT are usually loaded by:
 Excavators
 Front End Loaders
 Face Shovels

LEARNER GUIDE
1.3. Types of RDT’s:

Most RDT are very similar in design and appearance.
We do however get different configurations such as:
 2 wheel drive
 4 wheel drive
 standard load body
 extended load body
 exhaust heated load body
 rock body
1.4.RDT Main Components:

RDT’s have many components that a plant operator must check on a daily basis
during the pre – operating checks.
RDT operators spend most of their working day on the machine they are operating.
It therefore stands to reason that they are the ones who can look after the machine or
abuse it.
RDT operators are expected to carry out pre-operating and other inspections to
ensure that the machine is safe to use and will not place him/her or others in danger.
For a RDT operator to be able to perform the checks and inspections correctly, the
operators must know what they are looking at, what the components function is and
whether it is serviceable or defective.
If the operator identifies a component that is not serviceable, then they must also
know what the correct action to rectify the situation is.
The operator must know whether the component will affect or influence the safety of
the operator or others, or whether the fault can just be reported so that the
mechanical staff can prepare to attend to it at a later stage when production will not
be disrupted.
Most RDT’s have similar components which often operate on the same principles.
Any learner attempting to operate a RDT will have to master the components section
for that particular machine.

LEARNER GUIDE
If you know all the components, their function and how to check them, you will be a
professional operator who will be able to check the machine in a meaningful way and
correctly and accurately report any defects or potential problems.
So let us spend sometime familiarising ourselves with your RDT components.
The main RDT components are shown below.
Note: Every make and model of RDT is different in design and construction
however all have very similar components. Your facilitator will work through
the components found on your specific RDT.
RDT’s have many components that a plant operator must check on a daily basis
during the pre – operating checks.
It must be noted that a unit standard addressing all the components found on
earthmoving machines, their functions and how they work has also been generated,
“Demonstrate Mechanical Awareness And Plant Appreciation”, which is highly
recommended for all operators to achieve. Operators that have successfully
completed this unit standard will have a definite advantage over operators that have
not.

LEARNER GUIDE
RDT Main Components
2
1
5
4 3
1. Load body / bin 2. operator compartment / cab

3. Engine compartment 4. Front tyre
5. Rear tyre
Engine compartment
Cab
Articulation point Front tyre
Load body
Rear tyre

LEARNER GUIDE
PRACTICAL EXERCISE
Identify and name the relevant components on your RDT.
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DO YOU KNOW …
Where it is? How does it work? How do you have to check it?
1 Engine
2 Electrical System
3 Cooling System
4 Lubrication System
5 Fuel System
6 Transmission and Final Drive Systems
7 Tyres, rims, etc.
8 Hydraulic System
9 Braking Systems
10 RDT body and chassis

LEARNER GUIDE
11 RDT cab instruments and warning devices
1.5. Placards/Warning signs:
Important points to remember during operation are provided at the control stations by
DANGER, WARNING, CAUTION, IMPORTANT and INSTRUCTION placards. This
information is placed at various locations for the express purpose of
alerting personnel of potential hazards constituted by the operating
characteristics and load limitations of the machine.
1.6. Personal Protective Clothing and Equipment:

Operator safety is an aspect that we must always consider when
performing our daily tasks. Let us take a look at what Personal
Protective Equipment we may come across.
Personal Protective Equipment or PPE is the primary control measure, where
engineering controls are passive control measures.
When using Personal Protective Equipment, the hazards are still present in the
environment. The protective device merely provides a barrier between the hazard
and the worker.
The personal protective equipment supplied to you is for your personal safety and
should be used by you only.
It is the responsibility of the workers to look after the safety equipment provided and
to use it where required to by safety signs, and management ruling.
It is your responsibility to report any defects of your safety equipment to your
supervisor immediately.
By law no person will be allowed to move around on site or do any work without the
correct PPE
1.6.1. Body Protection:

Plant operators must wear overalls when carrying out their site
activities. The overall may be a two-piece overall or a one
piece. The two-piece overall is usually preferred.
1.6.2. Head Protection:

Hard hats are designed to:

LEARNER GUIDE
 Shield the wearer's head from the impact and penetration of falling objects or
flying particles.
1.6.3. Eye Protection:

Safety glasses and face shields must be worn at all times when working with tools
that could cause particles to shoot into your eyes.
Eye protection is used for protection against:
a) Air borne dust, sand, etc.
b) Flying objects.
1.6.4.Foot Protection:
Safety boots afford good protection:
a) Against falling objects
b) Against the hazards of accidentally kicking sharp objects
c) They must be worn at all times.
1.6.5.Hand Protection:
Gloves or other hand protection should be capable of giving protection:
a) From identified hazards.
b) Fit the users hands comfortably.
It is vital to protect the hands from any external agents, i.e., chemical, physical or
radiation.
1.6.6.Ear Protection:
Ear protection is divided into two parts:
Ear inserts and ear muffs.

LEARNER GUIDE
Ear inserts
The following should be taken into consideration before any ear inserts are used:
a) Make sure the earplugs sit comfortably in your ears.
b) Make sure you keep the earplugs as clean as possible.
Earmuffs
a) Make sure that the earmuffs cover you ears.
b) Make sure that they sit comfortably over your ears.
REMEMBER …No Personal Protective Equipment …NO
WORK
SELF ASSESSMENT
Answer the following questions.
1. What does PPE stand for?
2. Who should supply the relevant PPE for an employee?
3. Who is responsible for the care and safe keeping of your PPE?
4. List three items regarded as PPE?
Module 2
RIGID DUMP TRUCK CHECKS, STARTING, SHUTTING DOWN AND

PARKING

 Identify the different checks an operator must do on a Rigid Dump

Truck
 Explain the different gauges we find on RDT’s
 Explain how to perform the checks and why

LEARNER GUIDE
 Demonstrate how to perform the checks

 Demonstrate how to start and shut down a RDT
 Demonstrate how to park a RDT
 Discuss RDT maintenance
2.1. RDT Checks:

One of the first tasks a RDT operator needs to perform when arriving at his / her
machine is the Pre – Operation Checks.
There are six checks and procedures that an operator must perform during the day or
shift.
These six checks / procedures are:
 THE WALK AROUND INSPECTION
 THE PRE – STARTING CHECKS
 THE PRE –OPERATING CHECKS
 THE OPERATING CHECKS
 THE PARKING PROCEDURE
 THE SHUT DOWN PROCEDURE
Before we proceed with the checks let us first discuss gauges.
2.2. Gauges and Warning Devices:

As a RDT operator we also need to be sure that when we start the RDT and operate
it that we are familiar with gauges. We find them in every RDT we come across.
Gauges are fitted onto machines to keep us in touch and well informed at all times of
what is happening in different sections of our machine.
Without these gauges, we would either have to stop and check the different
machines from time to time, or take a chance and only be made aware of potential
problems once it is too late to rectify them.
We find all types of gauges which all give us different information.
We get...

LEARNER GUIDE
 TEMPERATURE GAUGES
 PRESSURE GAUGES
 FUEL TANK LEVEL GAUGES
 ELECTRICAL SYSTEM CHARGING GAUGES
 HOUR METER GAUGES
 Etc.
All these gauges are there to assist us with the care and correct use of our machine.
2.2.1. Temperature Gauges:

The function of a temperature gauge is to measure the temperature of the oil or water
in a specific component and warn the operator if there is a problem.
For example, the temperature gauge monitoring the coolant (water) in the engine
radiator, will measure the coolant temperature once the engine is started.
The coolant temperature gauge will enable the plant operator to check when the
machine engine has warmed up from the cold starting temperature, to the correct
operating temperature.
The plant operator will be able to keep monitoring whether the machine is operating
in the correct temperature range, by simply looking at the temperature gauge.
If there is a problem with the machines cooling system, and the engine temperature
starts to increase, then the temperature gauge will indicate that the machine is
starting to over heat, and the plant operator will be able to see that there is a problem
just by watching the temperature gauge throughout the operation period.
If the temperature gauge needle moves into the overheating range, the operator will
be able to stop the machine immediately, before any major damage occurs to the
engine components.
Temperature gauges usually have three colours on the indication section, and a
needle which points to the relative colour.
The colours are usually:
 WHITE
 GREEN
 RED

LEARNER GUIDE
The WHITE section indicates the temperature it is monitoring, is still warming up and
has not yet reached the correct operating temperature.
The GREEN section indicates that the temperature has reached the correct operating
range and it is safe to operate at all times while the needle
is pointing in the green range of the gauge.
The RED section indicates that there is a problem and
over heating is occurring and the machine should be
brought to a safe and gradual stop, in a safe spot, and
switched off until the temperature has decreased
sufficiently to start the engine again or investigate the
cause of the over heating.
Sometimes colours are not used, but actual figures such as 400 or 700.
We get temperature gauges that monitor...

 ENGINE WATER OR COOLANT TEMPERATURE
 TRANSMISSION OIL TEMPERATURE
 HYDRAULIC OIL TEMPERATURE
2.2.2. Pressure Gauges:

The function of a pressure gauge is to measure the pressure in a specific system,
such as:
 the air brake system
 the hydraulic system
 the transmission system, etc.
Should the pressure become to high or drop too low, the gauge will register the
pressure and the plant operator will be able to see that a problem has occurred and
take the appropriate corrective action.
Pressure gauges like temperature gauges usually have the same three colours:

LEARNER GUIDE
 WHITE
 GREEN
 RED
Once again the WHITE indicates the operating
pressure has not yet been reached and may be too
low to safely operate a system.
The GREEN indicates the operating pressure is
correct as long as the indicating needle or pointer stays in the green range.
The RED indicates that a problem has occurred, that the pressure is to high and the
machine should be brought to a safe stop and the problem investigated.
Once again colours are not always used and we may find other methods of indicating
the pressures.
We get pressure gauges that monitor…

 LOW ENGINE OIL PRESSURE
 LOW TRANSMISSION OIL PRESSURE
 LOW BRAKE PRESSURE
2.2.3.Fuel Tank Level Gauge:

The function of the fuel tank level gauge indicates the level of the
diesel available in the machines fuel tank.
This enables us to plan ahead as to whether we can reach our
next destination, whether we need to consider returning to our
base camp for re-fuelling purposes and so on.
The gauge usually indicates
 E for Empty
OR
 F for full.

LEARNER GUIDE
There are however different types of gauges, some of which indicate when you are
operating in the reserve section of the tank.
Others have a warning light that comes on once the tank reaches a pre-determined
level and you should consider re-fuelling.
Some fuel level gauges show the estimated litres of diesel left in the fuel tank.
2.2.4. Electrical System Charging Gauges:

The function of the electrical system charging gauge is to indicate whether the
alternator system is charging and keeping the battery fully
charged at all times.
 The gauge needle points to the centre of the gauge
when the electrical system is not being charged or
discharged.
 As the system charges the needle moves right
towards the "+".
 As the system discharges it moves left towards the
"-".
2.2.5.Hour Meter Gauge:

The function of the hour meter gauge is to record the number of hours a particular
machine has worked.
If we know how many hours a machine has worked, we are able to determine when
preventative maintenance and servicing should be scheduled.
If we know that the machine has worked for 250 hours since the last service, then we
know it is time to schedule a service.
At certain predetermined hour meter readings, the mechanical staff will know what
type of service is required and what parts to order in advance, such as fuel and oil
filters.
The hour meter also enables the manufacturers or machine owners to calculate what
the machines running cost is etc.

LEARNER GUIDE
There are different types of hour meters.

 ELECTRICAL hour meter (operates off the electrical system once the ignition
is switched on
 MECHANICAL hour meter (operates when the engine is running)
 VIBRATION hour meter (operates as the machine vibrates)
Some types are more reliable than others, but at the end of the day they measure the
same thing and that is how long that machine has worked.
It should be remembered that from time to time these hour meters do cease working
and replacement hour meters have to be fitted.
If a replacement hour meter is fitted, do not lose the previous hours accumulated, but
keep adding those hours to the hours displayed on the new hour meter.
The problem is that new hour meters are not set to
the hours that the last meter stopped recording at,
and the operators sometimes start submitting the
new hour meter reading displayed, which starts at
zero again, even though the machine may have
completed a few thousand hours previously.
This oversight can cause havoc with any plant
records system, rendering the information and
projections useless.
A possible solution is to neatly paint the old hours above the new meter, or make a
neat plate that can be fixed there which states the amount of hours that must be
added to the hours displayed on the new meter before submitting the machines total
hours worked figure.
We have now looked at a few of the more common gauges we will find on the
different types of plant we may operate.
Depending on the machine type, make and model, we may find all these gauges,
less gauges or new gauges.
We must remember that gauges are not always used, and just indicating lights on a
dashboard may be our only assistance.
Whatever system, gauge or light is used, familiarise yourself with it and always pay
attention to it.
2.2.6. Warning Systems:

LEARNER GUIDE
All machines have some sort of warning system to alert the operator when a
problem, such as overheating is occurring.
These warning systems are usually gauges we are all familiar with, such as:
 Oil pressure light
 Temperature gauge
 Fuel gauge
 etc.
On larger machines there is usually a bigger red or orange light that will flash when
things are going wrong and if it is really important that the machine be stopped, the
red light will flash and an alarm will sound.
2.2.7. Warning Lights:

As safety is the primary concern of everyone operating heavy plant, many machines
are fitted with orange beacon lights.
The function of the beacon light is to make heavy plant more visible and draw others
attention to the machine, which:
 Is slow moving
 Is larger than normal vehicles
 Is wider than most vehicles
 Is obstructing the free flow of traffic
In some instances it is legislation that construction machines must have orange

beacon light fitted.
On some machines we find electronic monitoring systems (EMS) or computer
monitoring systems (CMS).
These systems have three levels of warning.
LEVEL ONE –
 The small red or orange light flashes on and off. This warns the operator that
something is wrong but requires no immediate action.

LEARNER GUIDE
 This level will indicate things like low fuel level, alternator not charging
correctly or park brake still applied.
 On level one the operator must just make a note of the problem and report it at
the first opportunity.
LEVEL TWO –
 the small red or orange light will flash and the big red light known as the
master fault light will also flash.
 This level warns the operator that if he doesn't change his working procedure,
the machine may overheat.
 The operator should at this stage check if the underfoot conditions are poor
and the machine is battling or whether his ripper is too deep into the ground and so
on. Basically there is too much load on the machine that leads to overheating.
LEVEL THREE –
 the small light flashes, the master fault light flashes and an alarm sounds.
 This indicates that something is very wrong and the operator must bring the
machine to a safe stop out of the traffic's way and immediately switch off the
machine, until the mechanic has repaired the problem.
 Level three usually indicates low oil pressure, no coolant flow, low air brake
pressure etc.
2.2.8. Hooters:
Most machines are supplied from the manufacturers with a hooter or horn fitted.
The hooter is fitted so that the plant operator can press the hooter to warn others in
the vicinity that:
 they are about to move forward with the machine
 they are about to reverse with the machine
 they are about to start the machine
 they are approaching with the machine
 there is an emergency
The hooter is a safety and warning device and should not be used if it is not required,
such as to call or greet a friend.

LEARNER GUIDE
If we use the hooter often when it is not required, others will not respond when there
is really an emergency. They may assume that we are greeting a friend again, and
someone could get injured or killed.
2.2.9. Buzzers:
Some machines are fitted with warning buzzers.
The warning buzzer is fitted to warn the plant operator if something is not right or
ready.
A warning buzzer may warn an operator that:
 the brake air pressure is not at operating pressure
 an attachment, such as the load body, is not fully down
2.2.10. Back – up alarms:

Some of the latest machines are fitted with back – up alarms.
The function of the back – up alarm is to warn others that the machine is about to
reverse.
Since some machines are large and wide, the operator may not be able to see all
around the back of the machine when reversing.
As the plant operator selects reverse gear, the back – up alarm is activated, making
a loud warning sound that warns others that the machine is about to reverse.
NEVER IGNORE A GAUGE
OR
WARNING LIGHT
2.2.11. Electronic/Computer Monitoring System:

The symbols used on EMS and CMS systems are illustrated in the next section.
We normally find a Test Button on the EMS or CMS system, which enables the plant
operator to check whether the system is working correctly.
To test the system, press the “TEST” button and check that the lights on the EMS
do light up, indicating that the system is working correctly.

LEARNER GUIDE
The “TEST” button
Cooling Agent Temperature pilot lamp.
Engine Oil Pressure pilot lamp.
Air Filter pilot lamp.
Parking Brake pilot lamp.
Brake Pressure pilot lamp.
Hydraulic Oil Temperature pilot lamp.

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Minimum Hydraulic Fluid Level pilot lamp.
Return Line Filter Controller pilot lamp.
High Pressure Filter Controller pilot lamp.
Automatic Greasing System pilot lamp.
Transmission Overspeed pilot lamp.
Engine Oil Pressure / Clutch Pressure pilot lamp.
Alternator pilot lamp.
Let us now look at the checks specific to a RDT.

Remember each and every company or organisation may have their own checklists
and particular systems and procedures specific to their operations.

LEARNER GUIDE
When starting to work for a new or different company or

organisation ask for their specific checklists and get to
know their systems and procedures.
The following check list is a generic checklist that may be
used on most RDT’s.
2.3. Walk Around Inspection Check List:

CHECK…(if applicable) YES NO
1 Radiator water level, cap and cap seal
2 Engine oil level
3 Transmission oil level and breathers
4 Hydraulic oil level and breathers
5 Battery electrolyte level
6 Battery terminals and hold down clamps
7 All lights are secure, clean and crack free
8 Turbo charger condition
9 Air cleaner system
10 All number plates are secure and clean
11 Radiator core is clean & clear of leaves / grass
12 Tyre condition and pressures
13 Rims, wheel studs and nuts
14 Engine fan belts tension, cracks or cuts
15 All engine hoses, pipes, clamps and bolts
16 All electrical wiring and connections
17 For signs of oil and water leaks
18 Fuel system, pipes, filters, injectors etc.
19 Water has been drained from fuel water trap
20 Cab steps & grab handles are clean (no grease)
21 Machine frame for cracks or damage
22 Hydraulic pipes for leaks

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23 Hydraulic cylinders condition and leaks

24 Mirrors, windscreens & cab floor are clean
25 All machine attachments
26 Service or hour-meter reading
27 Fuel tank full
28 Other
After we have completed the walk around inspection, we need to start the pre-start
checks.
2.4.THE PRE-START CHECKS:

1 Report/record any defects found in the walk around
inspection
2 Ensure you are wearing all the required safety
equipment
3 Switch the master isolator switch on (if applicable)
4 Climb up to the operator’s compartment facing the
machine and using the three points of contact method
5 Adjust the seat
6 Ensure that the seat belt is fitted and adjusted
7 Ensure that the transmission lock lever is applied
8 Ensure that the appropriate implements controls are in
the hold position
9 Ensure that the transmission gear select lever is in the
park position
10 Ensure the transmission directional select lever is in
neutral position
11 Check for loose items on the floor
12 Check if all persons are well clear of the machine
13 Do a 360 degree check for any potential hazards
14 Record start of trip hour metre reading

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15 Turn the ignition switch / key to the on position

16 Check that all the gauges are functioning correctly
17 Sound the hooter (if fitted) once to warn anyone in the
immediate vicinity that you are about to start the
machine
After we have completed the pre-start checks, we need to start the pre-operating
checks.
2.5.THE PRE-OPERTAING CHECKS:

1 Use starting fluid sparingly if the engine is cold (if
applicable)
2 Start the engine
3 Do not allow the starter to turn longer than 10 seconds
without allowing the starter to cool for two minutes
4 Once the engine starts, warm up the engine
5 Check the engine oil pressure indicator to be sure that
pressure develops within ten (10) seconds after start-
up
6 Allow the engine to idle for approximately 5 minutes
7 Do not rev the engine before the correct engine
operating temperature has been reached
8 Operate the implements during warm up
9 Test operate the controls, brakes, steering, travel
controls, machine controls
10 Test operate the controls with the engine idling and
the engine not revved, until the correct operating
temperature has been reached
11 Observe the machines gauges

LEARNER GUIDE
12 Check that all the different systems are operating to

standard
13 Listen very carefully for any strange noise that may
come from the engine or other parts of the machine
14 Check lights, indicators, brake lights, back-up alarms
After we have completed the pre-operating checks, we need to start the operating
checks.
2.6.THE OPERATING CHECKS:

1 The gauges are all working and indicating in the safe
operation range
2 Monitor all gauges at all times
3 The warning indicators
4 Listen for warning device alarms
5 Listen for any unusual engine noise
6 Watch for fluid leaks
7 Observe changes in the machines handling
After we have completed our work for the day and we are ready to park the machine
for the night, we need to follow the parking and shutting down procedures.
2.7.THE PARK AND SHUT DOWN PROCEDURES:

1 Select a safe area with solid, level ground to park the
machine
2 Reduce the engine speed
3 Stop a reasonable distance from other machines
4 Apply the parking brake (if applicable)
5 Place the transmission range selector in the correct
park position
6 Allow the engine to idle for five minutes

LEARNER GUIDE
7 Ensure that all the lights are off

8 Bring the implements to the “park” position
9 Shut down the engine correctly
10 Turn the ignition switch off
11 Remove the ignition key
12 Record the hour meter reading on the checklist
13 Dismount by facing the machine and use the three
points of contact method
14 Switch the master isolator switch to “off”
15 Fill the fuel tank to avoid water condensation
16 Record any changes or problems on the operator’s
daily check list that may have developed during the
operating period
17 Report any serious problems to his supervisor
18 Hand in the operator’s daily checklist to his supervisor
at the end of the operating period
19 Mark the machine parked in a traffic pattern with
warning flags, flashing beacons or flares if broken
down
2.8.Shutting Down and Parking the RDT:

After we have done our days work and operated the machine safely, we can finally
return to the machine parking site for the evening.
2.8.1.Stopping the RDT:

How to stop the RDT:
 Release the accelerator.
 Brake, and when the machine has stopped, put the gear selector in neutral.
 Apply the parking brake.
2.8.2.Parking:

LEARNER GUIDE
When you park the RDT, follow the instructions below:

 Ensure the machine is on level and firm ground
 Ensure all switches are in the off or neutral positions
 Ensure that the park brake is applied
 Switch off the isolator or master switch if applicable
2.8.3.Stopping the Engine:

Let the engine idle for a few minutes before stopping it (approximately 5 minutes), to
ensure that the turbo charger gets sufficient lubrication, and for the turbo charger and
engine to cool down.
Pull the stop control out. Keep the control pulled out until the engine has stopped
entirely. Turn the ignition key anti-clockwise until the indication lamps go out.
Always use a three-point stance, i.e. two hands and one foot or one hand and two
feet for climbing and descending. - Do not jump!
To shut down the engine, follow this procedure:

1. Switch off all lights and warning devices.
2. Shut down the engine.
3. Turn the ignition key to the OFF position.
4. Record the hour meter reading on you checklist and/or logsheet.
5. Close all windows and lock all the cab doors.
6. Do not jump off the machine. Use the steps and handholds provided.
Face the machine when you dismount.
7. Place chocks in front and at the back of the machines wheels to prevent
it rolling forwards or backwards.
8. Switch the Master Isolator switch to the “Off “ position.
9. Drain sediment and water from the water separator and fuel tank.
10. Carry out a final check and make sure that:
a) All lights are off.
b) There are no fluid or air leaks.
c) The tyres are roadworthy.
d) All doors are closed and secure.
11. Mark any defects and problems on the Operator’s Daily Checklist.
12. Hand in your Operator’s Daily Checklist to your Supervisor. Inform him of
any critical problems. This includes any damage or operating problems.
Note - It is your duty to note and report any problems during your shift. This
includes any damage or operating problems. Report all incidents to your
Supervisor immediately when they occur.

LEARNER GUIDE
REMEMBER
OUR RESPONSIBILITY IS TO ENSURE THAT THE MACHINE IS SAFE TO
USE
PRACTICAL EXERCISE
Practice the checks on the RDT.
 the walk around inspection

 the pre – starting checks
 the pre –operating checks
 the operating checks
 the parking procedure
 the shut down procedure
2.9.Engine Maintenance:
As the engine is the heart of the machine, we need to ensure that the engine is
always maintained correctly.
Most companies and organisations practice “preventative maintenance”.
Preventative maintenance means maintaining the engine every day so that the
engine is always in good condition and hopefully we will be able to prevent an engine
failure and expensive repairs.
We have a role to play in maintaining the engine.
Since we check and operate the machine daily, we are able to check the important
aspects on a daily bases.
The aspects that we need to check and maintain daily are:
 Keeping the engine clean, so that we can detect leaks or cracks
 Keeping the engine compartment free of trash, that could cause a fire
 Ensuring that there is no mud or other material accumulating between the
engine sump and any belly plates, as this could cause the sump to
crack, the sump oil to overheat, etc.

LEARNER GUIDE
 Check engine oil levels

 Check engine oil colour (white colour indicates water is mixing in the oil)
 The fan belt tensions and conditions
 The condition of the engine cooling system, to prevent the engine overheating
 The condition of the fuel system
 The condition of the air filter system
 Keeping the area around any breathers clean and free of sand, dust, mud, etc.
 Keeping the area around the engine oil level dip stick clean, to prevent dirt
falling directly into the sump oil
 The security of all components such as the alternator, etc.
There are also other checks and maintenance that is scheduled for machines, such
as weekly greasing of certain components and the 250 hour oil change or 1000 hour
major service.
Machines are usually scheduled for services every 250 hours.

This means that a machine will be serviced after:
 250 hours
 500 hours
 750 hours
 1 000 hours
This cycle continues throughout the life of the machine, such as:
 1 250 hours
 1 500 hours
 1 750 hours
 2 000 hours
The mechanical staff will carry out these services.

LEARNER GUIDE
Module 3
GENERAL RIGID DUMP TRUCK SAFETY
 Explain the general operating safety aspects

 Explain the general site rules
 Demonstrate the brake and steering tests
 Discuss defensive RDT operating
3.1.Operator Compartments:
The RDT operator compartment or cab as it is more commonly referred to, is where
the operator will “manage” his / her machine from.
It is in the cab that all the controls and levers will be within easy reach of the
operator’s hands or feet.
The very first thing a RDT operator must do when he gets into the cab, is to adjust
the seat and his posture, so that he can reach all levers and pedals without
stretching.
If the RDT operators seating position is incorrect, he will be exhausted at the end of a
shift and find his body has certain aches and pains from repeatedly stretching or
twisting throughout the shift while operating the machine.
All RDT’s are designed differently and the position of their control levers may also be
different.
NEVER assume that because you know one type of machine very well, that the next
machine will be the same. Always double check and the best time to double check is

LEARNER GUIDE
during the pre-operating period, once you have started the machine and are ready to
warm-up the hydraulics system.
Very important is to always keep the operator cab clean and tidy. Make sure no oil,
grease or mud is on the levers or pedals, as it may cause your foot or hand to slip
and it could lead to someone getting injured.
REMEMBER
YOUR CAB IS YOUR OFFICE
THIS IS WHERE YOU MANAGE YOUR MACHINE
AND WORK AREA FROM
SO KEEP IT CLEAN, NEAT AND TIDY
3.2.General RDT Safety:

You must always be concerned with the safety of yourself, your co-workers, the
machine, the load, personnel in the operations area and property in the operations
area.
That mass you are moving can cause tremendous damage, injury or even death if
you run into, or over, something.
A RDT is no safer than the person operating it or the personnel maintaining it.
Travelling to the actual site where the RDT is to work sometimes entails travelling
along public roads etc. The RDT operator must therefore observe all the rules and
signs of the road.
If travelling on a public road the RDT operator must ensure that he / she is licensed
for that type and size of machine.
The RDT operator must also ensure that he / she is carrying his / her driving licence
as required by law.
Below are some rules the RDT operator should adhere to while travelling to site.
3.3.Safety Rules:
a) Obey all road signs.
b) Keep on established haul roads.
c) Keep left unless overtaking a standing machine or vehicle.

LEARNER GUIDE
d) Do not exceed the speed limit.

e) Keep a safe following distance away from the machine or vehicle ahead of you.
f) Do not drive over electrical cables.
g) Do not squash barricading drums.
h) Look out for pedestrians.
i) Wear your seat belt at all times.
j) Do not enter any closed off areas.
k) Travel at a speed to suit conditions.
l) Never free-wheel the machine down a ramp/haul road.
m) Use the emergency brake only in case of emergency.
n) Do not reverse at high speed. Control and visibility is less than when travelling
forward, always face the direction of travel.
o) Do not operate the machine while observing in the other direction.
p) Do not stand between the front and rear tyres of the machine while the engine is
operating.
Once on site, there are additional rules and regulations that the RDT operator must
adhere to.
These rules differ from site to site due to circumstance.
The RDT operator must however know what site rules apply, and this must be taught
to him / her before being allowed on site, at the site induction training course.
3.4.Site Rules:
Some site rules that must be known are:
 All the road and general safety warning signs used on site, and what they
mean.
 The machines traffic direction around the site.
 Who has right of way?
 What hand signals are used on that site?
By whom?
When?

LEARNER GUIDE
What they mean and what action to take?

 What emergency sirens/horns are used?
What they sound like?

When they are sounded?
What action to take?
Where the first aid stations are?
 Who of the staff are first aiders?
 What the fire safety rules are?
 Where the fire fighting equipment is stored?
 How to use the fire fighting equipment.
The majority of operating accidents are caused by unsafe operating practices,

operating too fast, operating without due care and attention and operating a machine
that is in a faulty condition.
RDT operators are required to:

a) Carry out the correct pre start-up inspection.
b) Tell the maintenance supervisor when there is a fault that requires immediate
attention.
c) Ensure that lights, windows and mirrors are clean.
d) Ensure that tyres are at correct pressure.
e) Ensure that the reversing lights, reversing buzzer, sirens and horns are
working properly.
f) Not exceed the site speed limit or the safe speed for the activity being
undertaken.
g) Always mount and dismount the machine using three points of contact on the
handrails, grab irons and steps, and always face the machine.
h) Be constantly aware of trips and falls and never jump down from mobile
equipment.
i) Always be aware of the presence of pedestrians. Sound the machine hooter
to make sure pedestrians are aware of your machine.

LEARNER GUIDE
j) Keep to designated routes or haul roads.

k) Always observe all road signs and signals.
l) Always wear the correct personal protective equipment.
m) Always clear up spilled debris on haul roads.
n) Do not carry passengers on the machine.
REMEMBER
SAFETY IS YOUR RESPONSIBILITY
3.5.Operating the RDT:

RDT’s may be used for a variety of tasks. As an operator, you should be able to
perform all the tasks that your machine is capable of. It may occur that your specific
operation or task only requires a specific task, but as a competent operator you
should be aware of the other RDT functions.
Let us discuss some of the more common RDT tasks.
Your facilitator will ensure that your specific tasks are
covered in more depth during the practical sessions on
your RDT in your working environment.
Remember …always read and understand the instruction
book before you begin to operate the machine.
REMEMBER…
 You must wear personal safety equipment, for safe
operation.
 Never operate the machine if you are under the
influence of alcohol, medicines or other drugs.
 Use the lap belt during all operations if provided.
 The cab is the operator’s protection and
conforms to the requirements for roll-over protection,
specified in the testing standard for this, (ROPS). The
prerequisite for providing protection is that the operator

LEARNER GUIDE
remains in the cab. So keep a firm hold of the steering controls if the machine tips
over. Do not jump!
Before moving the machine the operator should first signal with the hooter.
If moving off, signal with one (1) blast of the hooter

When moving in REVERSE, signal with two (2) blasts of the hooter.
3.6.Mounting and Dismounting:

a) Mount and dismount the machine only where steps and/or handholds are
provided.
b) Inspect, and when necessary, clean and have repairs made to steps and
handholds before mounting and dismounting.
c) Face the machine when mounting and dismounting.
d) Maintain a three-point
e) Never get on or off a moving machine.
f) Never jump off the machine.
g) Do not try to climb on or off the machine when carrying
tools or supplies. Use a hand line to pull equipment up onto the platform.
h) Do not use any controls as handholds when entering or leaving the operator’s
station.
3.7.Preliminary tests:
There are two preliminary tests the operator should perform before proceeding with
his / her daily operating tasks. These tests are…
1. The Preliminary Brake Test.
2. The Preliminary Steering Test.
IMPORTANT

LEARNER GUIDE
The Preliminary Tests should always be carried out with complete safety in
mind. Always consider the safety of other persons and property in and
around your area of operation. Also make sure that you do not put yourself
in danger.
The Preliminary Brake Test:
The purpose of the Preliminary Brake Test is to check that the Service Brake and the
Park Brake on the machine are functioning to standard (Serviceable).
The Service Brake (Footbrake) is designed to slow down and stop the machine within
a prescribed distance.
The Park Brake is designed to hold the machine stationary after it has stopped.
Note – The brakes should be checked as soon as the machine is put into
operation. They should be checked before starting any operating duties.
Do not just go through the motions.
To carry out the Preliminary Service Brake Test, follow this procedure:
1. Drive to the test area.
2. Accelerate to 15 kph.
3. Keep a straight course and brake progressively (gently but firmly).
4. Bring the machine to a complete stop.
5. Apply the Parking Brake.
6. Move the Gear Shift Lever into the neutral position.
The Service Brakes are SERVICEABLE if:
1. The machine does not pull to the left or to the right when braking.
2. None of the wheels skid when braking.
3. The machine stops within the prescribed stopping distance.
4. The brake pedal operation is firm (no pumping of the brake pedal and the
brake pedal does not go all the way to the floor).
WARNING:
THE SERVICE BRAKE IS DEFECTIVE IF ANY CONDITION ABOVE FAILS.
IF THE SERVICE BRAKE IS DEFECTIVE, IMMEDIATELY STOP THE
MACHINE AND REPORT THE FINDINGS TO YOUR SUPERVISOR. THE
MACHINE MUST NOT BE USED UNTIL THE DEFECT HAS BEEN

LEARNER GUIDE
CORRECTED.
The Preliminary Park Brake Test is carried out immediately after the Preliminary
Service Brake Test.
Note – The test area should include a road slope with sufficient gradient to test the
parking brake.
To carry out the Preliminary Park Brake Test, follow this procedure:
1. Ensure that the Park Brake is applied (ON).

2. Ensure that the gear shift lever is in the “neutral” (N) position.
3. Remove your foot from the footbrake (Service Brake).
The Park Brake is SERVICEABLE if:

1. The machine remains stationary. In other words, it does NOT move from
the position it came to rest.
Warning - The Park Brake is DEFECTIVE if the condition above fails.
The Preliminary Steering Test
The purpose of the Preliminary Steering Test is to check that the steering system of
the machine is functioning to standard (Serviceable).
The Steering System is designed to turn the machine within a prescribed turning
radius.
The steering is checked immediately the machine is put into operation.
WARNING - Do not check the steering while the machine is stationary (standing still).
The Steering must be checked before starting any operating duties.

Do not just go through the motions.
To carry out the Preliminary Steering Test, follow this procedure:
1. Drive to the test area.

2. Keep a straight course and travel at approximately 10 kph.
3. Move the steering wheel to the left of centre so that the machine turns
fully left.
4. Move the steering wheel back to centre to straighten.
5. Move the steering wheel to the right of centre so that the machine turns
fully right.

LEARNER GUIDE
6. Move the steering wheel back past centre to straighten.
The Preliminary Steering is SERVICEABLE if:

1. The machine turns fully to the left.
2. The machine turns fully to the right.
3. The steering wheel is free moving.
4. There is no unusual noise.
WARNING:
THE STEERING IS DEFECTIVE IF ANY CONDITION FAILS.
IF THE STEERING IS DEFECTIVE, IMMEDIATELY STOP THE MACHINE AND
REPORT THE FINDINGS TO YOUR SUPERVISOR. THE MACHINE MUST
NOT BE USED UNTIL THE DEFECT HAS BEEN CORRECTED.
3.8.Operating Defensively:
You have a great deal to think about when operating a machine.
Ever changing operating ‘hazards’ demand ongoing changes in course and speed.
What is a hazard? A hazard is anything that contains an element of actual or possible
danger.
Hazards include stationary objects such as buildings, walls, gates, traffic lights, lamp
posts, bridges, potholes, etc.
Hazards also include moving objects such as other road users.
There are hazards created by changes in the environment.
These hazards include rain, hail and mist.
Finally, hazards also include variations in the road surface, such as stones, rocks,
sand, gravel, leaves, etc.
It is your duty to operate the machine in a defensive manner.
This means that you operate in a protective manner.
Operating the machine in a protective manner ensures that you protect your life as
well as those working around you.
The more knowledge and confidence you have at your disposal, the greater will be
your ability for operating defensively.
3.9.RDT Operation:

LEARNER GUIDE
a) Ensure that no one is working on or near the RDT to prevent injury. Keep the
machine under control at all times to prevent injury.
b) Reduce engine speed when manoeuvring in tight quarters or when breaking over
a rise.
c) Select the gear speed necessary before starting a downgrade. Do not change
gears while going downhill.
d) A good practice is to use the same gear speed going downgrade that would be
used to go up the grade.
e) Do not allow the engine to over speed downhill. Use
the brake pedal to reduce engine over speed going
downhill.
f) When the load will be pushing the machine, put the
transmission gear in FIRST speed before starting downhill.
3.10.Lifted Load Body:

Avoid driving with the load body lifted on surfaces where
there is a risk of turning over, for example on a steep
incline or where ground conditions do not permit this.
You must not go beneath the lifted load body unless it is secured by the load body
lock.
Beware of a lifted load body close to an overhead power line.
(Exposed high voltage cables)

The distance between the RDT and the live conductor must be at least 2 m (6.4 ft) for
low voltage, 4 m (12.9 ft) for high voltage up to 40 kV (power lines which normally
have support insulators) and 6 m (19.3 ft) for high voltage above 40 kV (power lines
which normally have hanging insulators).
When the RDT is underneath the live power line, the vertical distance between the
highest point of the vehicle and the lowest part of the power line must be at least 2 m
(6.4 ft) for low voltage. At high voltage the distance must be at least 4 m (12.9 ft).
Note: Power line refers to lines consisting of posts or other supports, single
conductors suspended separate from each other plus associated material, such as
insulators, hooks and battens.
PRACTICAL EXERCISE

LEARNER GUIDE
Practice the following tasks.
 Mounting and dismounting

 Starting an warming up the RDT
 Monitoring of the gauges
 The brake test
 The steering test
 Pulling off
 Stopping
 Driving the RDT forward, backwards and through a “figure 8”
 Parking and shutting down the RDT
Module 4
OPERATING THE RIGID DUMP TRUCK
 Demonstrate operating the RDT

 Explain good operating practices
4.1.Operating the RDT:

Operating the RDT is what the RDT operator is primarily employed to do.

LEARNER GUIDE
Good RDT operation starts with good basic training regarding all the safety issues,
getting to know and understand RDT’s and how to perform the first line maintenance
and care for the machine.
A good operator can save the company lots of money by doing the correct daily
checks and maintenance, as well as operating the machine correctly within the
manufacturers specifications.
The cost of RDT’s is extremely high and the financial allocation for new equipment
keeps being reduced annually.
It is for this very reason that we must care for the machine as best possible, to try
and make the machine last longer.
The care for the individual machine starts with the operator and is dependent on your
attitude to the machine and the job.
A machine that is in good condition and clean, indicates that the operator is positive
about his work and machine. It is an excellent indicator to the supervisors and
management that the operator is responsible and
can be relied upon.
In this module we will look at how we should
operate the RDT correctly applying the appropriate
operating techniques.
REMEMBER…
 Always ensure that the load bin is in the
correct travelling position
 When travelling down a steep incline always use a low gear to maintain at
least half maximum engine speed in order to maintain a constant air supply for the
brakes and also have enough hydraulic pressure for steering purposes.
 Always maintain the correct speed to suit the immediate

working conditions.
 Always bring the machine to a stop, de – accelerate

and then change direction.
4.2.RDT Brakes and Braking:

LEARNER GUIDE
Given the mass of the loads we haul as RDT operators we must be totally aware of
the braking capabilities of our machines.
Some makes and models of RDT are fitted with retarders.
If your RDT has a retarder always use the retarder in the first instance, especially
when driving downhill.
Retarder
The hydraulic retarder (brake) built into the gearbox. Retarder action depends on the
gear used i.e.Lower gear - greater retarder action (brake action) Higher gear - less
retarder action (brake action)
Service Brake
The service brake is divided up into two separate circuits. If a fault occurs on one of
the circuits, the vehicle can still brake with the intact circuit.
Avoid driving with the brakes applied for longer periods of time as it raises the
temperature of the linings and wears them out unnecessarily. Short, hard braking is
more effective and wears the brake linings less.
If braking effect is lost in both brake circuits, apply the retarder and parking brake,
and stop the RDT.
If there is a fault in the brakes: do not continue. Contact the mechanical staff or your
supervisor to have them mended.
Parking Brake
The parking brake should not be applied until the RDT is stationary.
4.3.Driving the RDT:

It is important that the correct operating techniques are used so that you can do your
work safely and efficiently.
Whenever you drive on public roads with reasonable inclines, use gear position D.
The transmission then changes gear automatically, depending on torque
requirements.
You can use the maximum speed, but you must do it with common sense, especially
on downgrades.
Always suit your speed to road grip and surface, and to traffic situations, so that you
drive safely and comfortably.

LEARNER GUIDE
Avoid going fast through bends, on bumpy ground and on down-grades.

When cornering, you must always remember that there is a risk of tipping over if you
drive too fast. The risk increases when the centre of gravity of the load is high or off-
centre, when bends are tight, on adverse camber or when the road is slippery.
Take measures to ensure that the load will not fall off during transport.
Do not forget to disconnect the fore-aft differential lock if you drive on a good road
(firm ground).
Do not use the differential locks unless the road conditions warrant it.
NOTE! Be careful of the load unit’s behaviour until you have got to know the RDT!
4.3.1.Driving uphill:
The automatic gearbox normally makes sure that you get the correct traction for
driving up hill.
In some circumstances, the RDT can begin to “hunt” between gears.
This means that the transmission shifts up and down at short intervals, between the
gears.
This is because there is not enough power for the higher gear, but it is sufficient on
the lower gear to permit an upshift.
When this happens, you must select the next lower gear position to prevent “hunting”
between gears, or use the lock-up switch.
Even in other situations, e.g. driving on difficult ground, it can be an advantage to
select another lever position. The transmission then automatically shifts up and
down to the selected gear.
4.3.2.Driving downhill:
In general, the retarder should be used before the service brakes in all braking, to
reduce brake wear.
Choose a suitable gear position, 1, 2 or 3 before the downwards slope begins, and
reduce speed so that the vehicle changes down to the speed chosen.
Rule: Use the same gear uphill and downhill.
Use the retarder and then the service brakes if necessary.

LEARNER GUIDE
4.3.3.Off-road driving:
Different types of ground require completely different types of driving techniques.
If you are unsure, you should always investigate the ground before you start driving,
so as to avoid getting stuck unnecessarily.
When driving on soft ground, where space permits, it is a good idea to use a different
line for each time you turn round.
You then avoid making unnecessarily deep ruts.
Avoid driving over steep sideways slopes and over sharp stones and tree stumps.
4.3.4.General RDT operations:

RDT’s are used on a variety of hauling jobs, from mine, overburden removal to dam
building. Every RDT operation, regardless of the type of job, can be divided into four
phases;
 loading,
 hauling,
 dumping and
 the empty return.
4.3.4.1.Loading:
 The most common methods of loading RDT’s are with hydraulic excavators,
rope shovels, and front-end loaders.
 For maximum material movement, the RDT operator must help the loading
machine operator hold loading time to a minimum.
 The fewer manoeuvres the RDT must make to get into loading position, the
sooner loading can start. And the shorter the distance the loading unit bucket must
travel between the stockpile and the RDT load body the more passes it can make in
a given period of time and the quicker the RDT can be loaded.
 Ideally, the hydraulic excavator or rope shovel should require a 90o pass swing
to dump into the RDT load body for best loading efficiency.
 Required turning and backing to position the RDT for loading should be held to
a minimum. A common leading method is to have RDT travel a semi-circle in the
loading area.
 Waiting machines should stay about two RDT lengths behind the on-being
load to avoid any spillage from the loading machine bucket or RDT load body.

LEARNER GUIDE
 The operator of the waiting RDT is also better able to judge the best spot of
his RDT when it is his turn to be loaded.
On some jobs, the loading machine might work most efficiently when RDT’s are
positioned on both sides of its loader. This way, while one RDT is being engaged,
another can move into position on the opposite side of the loader and the loading
machine can swing over to load the next RDT within a minimum of lost time.
Since the RDT is usually backed into the loading position with this method, the
operator must be alert and careful while backing.
 For fastest, most accurate loading when being loaded by a front end loader,
the RDT operator should spot his machine on the most level area and at an angle to
the face of the bank or stockpile.
 This minimizes loader travel time, particularly with a raised, full bucket.
 Where possible, the RDT should also locate downwind of the loader when
dusty-type material is being loaded on a windy day.
This practice improves both working conditions and visibility for the loader operator.
A cleanup dozer or a small loader is often working in conjunction with the main
loading machine to keep the area of bucket spillage for maximum efficiency of the
loading operation.
 The truck operator must always be alert to the position of the cleanup machine
when entering the loading area to avoid congestion, and for maximum safety.
The following precautions should be observed when approaching the loading area
and while being loaded -
 Avoid rocks and other shovel spillage that can needlessly damage tyres or
other RDT components.
 Allow the cleanup machine sufficient time to clear up such debris.
 Do not move the RDT into loading position with the shovel bucket swinging
overhead. Large rocks that might fall from the bucket can be dangerous to both the
RDT and operator.
 When the loader operator signals that the RDT is loaded, sound two blasts on
the hooter, release the brakes and shift the transmission to drive [ D ].
 Move out of the loading area and onto the haul road with the least possible
delay to allow any waiting RDT to move into the loading position as soon as possible.

LEARNER GUIDE
4.3.4.2.Loading Methods:
When being loaded by a front end loader or excavator, the RDT operator must
position the machine correctly for effective and efficient operation.
There are various methods that can be used, such as:
 V – Shape method.
 L – Shape method.
 T – Shape method.
The operators of the loading machine and the RDT must discuss which method they
are going to use as well as the communication signals.
V Shape Loading Method
V – Shape loading method

Stockpile
60°
L – Shape Loading Method (Cross Drive Loading)
L - Shape loading Stockpile

method

LEARNER GUIDE
T – Shape Loading Method
T – shape loading
Stockpile
method
4.3.4.3.Hauling:
 While travelling on the haul road, always maintain a safe speed for the haul
road conditions and grades.
 Never allow the machine to move or coast with the transmission in
“NEUTRAL“!
 When approaching downgrades, select the proper transmission range and use
the retarder and service brakes as required to maintain safe descent speed without
over-speeding the engine or going in excess of the site or safe travel speed.
Generally, the transmission range required for ascending is also correct for
descending a grade.
 Always remain a safe distance behind the machine ahead, particularly on
downgrades. A good rule-of-thumb to follow is to allow [ 2 ] RDT lengths between
machines to reach 15 km / h [ 0 mile/s ] of travel speed under normal operating
conditions. Under adverse conditions, allow more room for safe operation.
 On jobs on which minimum distance between machines is specified for the
haul road, be sure to observe the regulations at all times. Such regulations would be
established for the safety of everyone on the job.

LEARNER GUIDE
 Pay attention to haul road conditions to avoid rocks, cable or other obstacles.
Such obstacles not only present hazards to safe operation, but can needlessly
damage tyres and suspensions if not avoided.
 Be sure to reduce speed and come to a full stop, as required, at intersections,
rail-roads, public highways etc. Where a “ FLAGMAN “ is stationed to direct traffic,
always stay alert and follow his directions.
4.3.4.4.Dumping:
The dumping operation usually depends upon the material being hauled. For
instance, overburden and other waste material is usually dumped over a spoil back
or pilled into large mounds.
The dumping on a job of this type might be controlled by a dump “ SPOTTER “, “
FLAGMAN “ or “ BANKSMAN “ or second person who directs the RDT to its dumping
area.
The “ SPOTTER “ is needed due to the limited rear visibility the operator has with a
loaded RDT of this size.
 While backing to dump, the operator must watch the “ SPOTTER “ at all times
and follow his direction.
 Under no circumstances should the operator leave his seat to gain better
visibility while backing.
 Always remain seated to maintain maximum machine control.
 Mineral ores, blasted rock etc., are usually dumped into a hopper or crusher
where it is processed before shipment.
 When dumping into a hopper, the operator, in order to avoid excess wear on
the tyres, must avoid hitting the protecting rail at the hopper.
 If a DRIVE HOPPER is used, the operator must avoid rubbing the tyre inner
side walls.
 When hauling dirt or rock from a borrow pit into a fill area such as earth-fill
dam, the load is usually dumped in a string with other loads and the loads smoothed
out with a crawler tractor.
 When dumping on a fill of this type, the operator usually works alone and picks
his own dumping place.
 To save bulldozer work and cleaning up, the load should be dumped as close
as possible to the preceding load.

LEARNER GUIDE
 The operator should pull past the preceding load, turn in line with the string
and back his RDT until it is within a few feet of the last load. This assures that the
load will fall in the right place.
No matter what kind of job the operator is working, there are a few things which are
common to all jobs and which the operator should observe. -
 When dumping over a spoil bank without a “ SPOTTER “, know how close the
machine can safely approach the edge under all weather conditions.
 If in doubt as to dumping safety, dump the load a safe distance from the edge
so that it can be pushed over the edge later.
 Before raising the body, make sure the rear wheels are on firm level ground. If
one wheel is higher than the other a twisting strain is imposed upon the body hinge
pins, hoists and chassis.
 Stop the machine, allow the engine to slow to idle, shift the transmission to “
NEUTRAL “ and apply the brakes with the PARKING-Emergency Brake control to
hold the machine stationary.
 Pull the body control level up into the “ RAISE “ position and accelerate the
engine.
 Decelerate the engine to slow the raising speed as the hoists approach their
maximum extension or when the body has been raised to the desired height, release
the control level into the “ HOLD “ position until the body is to be lowered.
 Do not hold the wheel in the “ RAISE “ position when the hoists are fully
extended to prevent unnecessary hydraulic system relief operation.
 NEVER “ JUMP DUMP “ the machine by bouncing the rear tyres against a
stop block, otherwise jarring the body in its raised position to dislodge, stuck or
frozen material. The tremendous stress that this practice develops in the body pins,
chassis and hydraulic system can cause needless and extensive damage.
 Once the load has been dumped, push the control level down into the “
POWER “ position and power the body until it begins to lower by gravity. Then
release the control lever into the “FLOAT” position. The reason for this is that the
hydraulic pump must start the movement, before the operator can put the lever in the
“FLOAT” position, otherwise the load bin will stay in the air.
The load can be dumped in many ways.
The decisive factor for the choice of method used frequently depends on what the
dumping site looks like.
It is quickest to unload if the unloading site is large and the load is to be bulldozed
over a sharp edge.

LEARNER GUIDE
If there is no requirement that specifies that the unloading site has to be kept flat, and
the tip edge is quite high, the foreman can decide to not use a bulldozer mover. It is
fully possible to use the good stability of your vehicle and its off-road ability.
When you drive in to the unloading site, choose an aiming point that you then use for
guidance during reversing. Always keep an eye on the rear-view mirrors during
reversing. Do not stop until the wheels on the rear axle are at the tip edge. Avoid
driving in the same ruts, to reduce the risk of getting stuck. Save some of the load
and put this on the tip edge, to use as an aiming point and stop block when you
unload the next load.
4.3.4.5. Empty Return:

Make sure the body is completely lowered, the body control lever is in the
“ FLOAT “ position, and the transmission is shifted to the correct range before
releasing the brakes and moving away from the dump site.
Do not drive the RDT with the body up. Apart from effecting the
stability of the RDT, there can be severe danger from contacting
overhead electric cables, trees, or bridges over the haul route.
Except for the above, the procedure for returning empty to the loading area is the
same as that given earlier for “ HAULING “.
Intermittent Revving
There are also some very obvious "tell tale" signs that we can observe which can
indicate that things are not exactly correct with the operation of a particular machine.
One of these telltale signs is intermittent revving.
Intermittent revving should be avoided at all times as…
 Each time an engine is accelerated the engine oil pressure increases and
each time it is decelerated the pressure drops.
 This causes the turbo charger to break through the thin oil layer, causing
metal-to-metal contact and results in turbo charger failure.
 Sudden changes of engine speed / revolutions greatly increase wear of all
moving engine parts.
 Excessive revving could result in a type of over fuelling that may result in fuel
dilution, which causes abnormal wear.
 Excessive revving increases fuel consumption.

LEARNER GUIDE
4.3.4.6.Excessive Idling:
Excessive idling of a machine is another aspect that a plant operator should be
aware of and attempt to avoid as much as possible.
Idling an engine for longer than 5 minutes could result in an engine failure.
 If an engine is allowed to idle too long incomplete combustion occurs resulting in
partial over fuelling, which if allowed to continue, causes fuel dilution of the
lubricating oil.
 Fuel dilution causes the oil to become thin and the oil can no longer perform its
task.
 Fuel dilution causes the piston rings to break through the thin oil layer and starts
coming into contact with the cylinder liners, causing glazed cylinder walls.
 To overcome excessive idling switch off the machine, or if the batteries or starting
system isn't good, drive the machine around a bit.
4.3.4.7.Engine Exhaust Smoke Colour:

The different colours of exhaust smoke can be of great assistance to operators,
supervisors and mechanics.
Each different exhaust smoke colour indicates a few different clues as to what the
problem may be if any.
Below are the different colours of exhaust smoke we may come across and the
possible problems associated with that particular colour of exhaust smoke:
Excessive black smoke at full engine revs could indicate...
 Dirty air filters
 Too heavy a load
 Operating in too high a gear
 Over fuelling
 Faulty turbo charger
Black smoke indicates hot unburned fuel.
White smoke could indicate...
 Incorrect starting procedure
 Faulty injectors
 Low quality fuel

LEARNER GUIDE
 Incorrect fuel injection timing

 Leaking cylinder head gasket
 Cracked cylinder head
White smoke indicates fuel problems.
Blue smoke could indicate...

 Worn rings
 Worn cylinder liners
 Worn turbo charger seals
 Worn valve guides
Blue smoke indicates oil consumption.
4.3.4.8.Starting a Cold Engine:

We must always remember that starting a cold engine is one of the most dangerous
times for the engine, as there are suddenly extreme stresses and strains on that
engine.
These extreme stresses and strains occur while the engine systems are not
functioning at the 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 the oil correctly yet, and so on.
The following procedure should be adhered to when starting a cold engine:

 Check engine oil twice - before start up and once engine is at operating
temperature.
 Preheat the engine using the glow plugs.
Do not heat the engine if it is warm.
 Keeping the throttle in the shut-off position, crank the engine for approximately 5
to 10 seconds, to allow oil to reach the turbo charger and then move the throttle to
the open position, to allow the engine to start.
 If the machine is fitted with a starting aid, only use this system when the engine is
cold, and whilst cranking the engine.
 If the engine does not start after cranking for 5 to 10 seconds, allow the starter
motor to cool down for at least 2 minutes before trying again.

LEARNER GUIDE
ONCE THE ENGINE STARTS, DO NOT REV THE ENGINE,

LET IT IDLE FOR A MINIMUM PERIOD OF 5 MINUTES.
The reasons for this are:

1. The oil viscosity of cold oil is not good
2. Not enough oil can pass through the filter
3. The oil bypass valve opens and allows unfiltered oil through
4. Unfiltered oil causes more wear at high engine revolutions
5. Turbo chargers have close tolerances and due to their revolution speeds should
be kept as low as possible until the oil is warm and being filtered
6. Additives in the oil only work once the oil is at operating temp.
 Remember that during the first 5 to 10 minutes the wear of the internal engine
parts are greatly accelerated.
 During the 5-minute warm up period, operate the hydraulics to warm the oil as
well.
 During the 5 minute warm up period the air pressure will build up and eliminate
the possibility of operating the machine with only partially released brakes.
If an engine will not start, there could be many reasons for this.
Some of these reasons could be serious and require the advice or repairs from a
trained mechanic.
However, sometimes the reason the engine will not start is something simple that we
may have overlooked.
Consider the following before seeking help.

Battling to start:
1. Insufficient fuel or frozen fuel
2. Battery or starting system faulty
3. Accelerator too wide open and causes flooding
4. Main switch not on

LEARNER GUIDE
5. Gear lever not in the neutral position

6. Park brake not applied
7. Implement control lever not in the hold position
PRACTICAL EXERCISE
Practice the above tasks with the RDT.
 Drive to the loading site

 Positioning the RDT correctly for loading using the “V” method
 Positioning the RDT correctly for loading using the “L” method
 Positioning the RDT correctly for loading using the “T” method
 Hauling a load
 Dumping a load
 Returning to the load site empty

LEARNER GUIDE
Module 5
DOCUMENT THE MACHINE USE, REPORT AND COMMUNICATE

INFORMATION
 Explain the importance of documenting the machine use

 Explain reporting faults and problems with the machine
 Discuss communicating information to other role-players
5.1.Introduction:
As with all work activities there is always a need for documenting what has occurred
during the shift.
As a RDT operator we need to …
 Document the hours the machine worked during the shift
 Report back and communicate about any faults or problems the machine may
have picked up during the shift to the relevant role-players
At the end of the shift we will need to complete the machine usage documentation.
We will record the hours worked by writing down the hour meter reading. By looking
at the end hours and start hours we will be able to determine hour many hours the
machine worked during that shift.
We will also have to complete the machine condition documents, by filling in any
faults or problems experienced during the shift that need to be taken care of.
It is important that we document the hour readings so that our supervisors can
determine whether the machine must be scheduled for maintenance or not.
If we document a fault that is not too serious our supervisor can alert the mechanical
staff and they can arrange to check it out before if becomes a major problem and
results in a breakdown and production loss.

LEARNER GUIDE
Remember if it is a serious problem then communicate immediately with your

supervisor so that immediate action can be taken and so that the next shift operator
does not go off with a defective machine.
All company’s have their own documentation, recording and reporting procedures.
During your induction to the company as a RDT operator you will have been told
what procedures to follow. Abide by these procedures.
We must also ensure that we communicate any relevant information to our
supervisor or the next shift operator, which could be important to them.
We may need to explain what we have done, how far we are and what hazards we
experienced during our shift with the machine, the site, etc.

LEARNER GUIDE
Module 6
TRANSPORTING THE RIGID DUMP TRUCK
 Explain the safety aspects a RDT Operator must consider when

loading the machine for transportation
 Explain how the correctly load and position the RDT on the
transporter
6.1.Transporting the Rigid Dump Truck:

Given the size and travel speed of RDT’s, it is often required that we load the
machine on to a low-bed transporter to take the RDT to a different site or to the
mechanical workshops.
To transport many of the larger machines, certain permits and documentation will be
required from the traffic authorities.
The paperwork will have been arranged by the office and the route that the
transporter must follow to ensure the bridges are not too low or any other traffic flow
obstructions are prevented, will have been communicated to the transporter driver.
As plant operators we will need to drive the RDT on to the low-bed transporter and
ensure the RDT is safe for transportation.
Remember…we know our RDT better than anyone else, and therefore we will know
how to drive it safely on to the low-bed and secure the machine.
Aspects we must pay attention to when loading or off-loading the RDT:
 Is the low-bed correctly positioned?
 Is the low-bed parked on level and firm ground?
 Is the low-bed horse and trailer park brakes applied?
 Are the low-bed wheels chocked?

LEARNER GUIDE
 Is the low-bed big and wide enough for our RDT?

 Are the ramps up to the low-bed stronger enough?
 Are the ramps securely fitted for loading and unloading?
 Are the ramps positioned correctly to avoid loading the RDT too much on one
side?
 Remove as much mud or other debris from the RDT as possible
 Drive the RDT on slowly
 Ensure the RDT is loaded in the middle of the trailer, so that there is not extra
load on the left or right hand side suspension and wheels
 Ensure the load body is lowered
 Engage the park brake
 Select neutral and engage the transmission lock
 Remove the key from the ignition and give it to the low-bed driver
 Place blocks in front and behind the tyres
 Secure the RDT with chains that are strong enough

LEARNER GUIDE
Module 7
PROFESSIONAL OPERATORS ATTITUDE

 Explain why a professional operator should have a positive attitude
to his / her work
 Explain what is considered a positive and good attitude.
 Explain why a professional operator must be a team player
 Explain why a professional operator should be able to identify and
solve problems
 Explain why a professional operator should be able to communicate
in the work place
7.1. Professional operator’s attitude in the work place:

As a professional operator you will have to abide by the company rules, regulations
and your employment conditions.
As a responsible, trained, competent professional operator you will always be
observed and your work performance monitored.
These are all aspects that make a good professional operator.
We must remember that there is no job (or very few) that requires you to work totally
alone and in isolation.
The very nature of a professional operator’s duties requires him / her to work and
communicate with others.
A PROFESSIONAL OPERATOR MUST
BE A TEAM PLAYER

BE ABLE TO COMMUNICATE

LEARNER GUIDE
BE ABLE TO IDENTIFY AND SOLVE PROBLEMS

HAVE THE CORRECT AND POSITIVE ATTITUDE
REMEMBER
AS A PROFESSIONAL OPERATOR YOU WILL NEED TO IMPLEMENT AND
APPLY ALL YOU HAVE LEARNT IN THESE TRAINING SESSIONS…
NOT ONLY WHEN YOU ARE BEING ASSESSED
YOU ARE NOW READY TO GO AND PRACTICE WHAT YOU HAVE BEEN
TAUGHT
REMEMBER …
SAFETY IS YOUR PRIMARY
CONCERN AND RESPONSIBILITY
ASSESSEMENT
Once all the course content has been successfully covered and your
facilitator feels confident that you are ready to attempt the knowledge
assessments, you will be prepared for the assessment and proceed with
the knowledge assessments.
Once the facilitator feels confident that you are ready to attempt the
performance assessment, you will be prepared for assessment and
proceeds with the performance assessments.

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OPERATE A RIGID DUMP TRUCK

UNIT STANDARD: 262731

VERSION : 01 GREENRIM TRAINING PAGE 1

VERSION : 01 GREENRIM TRAINING. PAGE 2

Read the information follows this icon

Discuss the information with your peers

Write your awnsers in you work book

Check your peer’s work

Check your own work

VERSION : 01 GREENRIM TRAINING. PAGE 3

Training Programme Introduction:

Who is the training programme for?:

Training Programme Purpose

LEARNERS’ ROLE & RESPONSIBILITIES:

VERSION : 01 GREENRIM TRAINING. PAGE 4

RIGID DUMP TRUCK FAMILIARISATION AND FUNCTIONS

MODULE LEARNING OUTCOMES

At the end of this module the learner will be able to…

 Explain why you need to be a professional Rigid Dump Truck

VERSION : 01 GREENRIM TRAINING. PAGE 5

the personnel maintaining it.

1.2. Rigid Dump Truck Function:

VERSION : 01 GREENRIM TRAINING. PAGE 6

1.3. Types of RDT’s:

1.4.RDT Main Components:

VERSION : 01 GREENRIM TRAINING. PAGE 7

The main RDT components are shown below.

VERSION : 01 GREENRIM TRAINING. PAGE 8

RDT Main Components

1. Load body / bin 2. operator compartment / cab

Articulation point Front tyre

VERSION : 01 GREENRIM TRAINING. PAGE 9

Identify and name the relevant components on your RDT.

VERSION : 01 GREENRIM TRAINING. PAGE 10

11 RDT cab instruments and warning devices

1.5. Placards/Warning signs:

1.6. Personal Protective Clothing and Equipment:

1.6.1. Body Protection:

1.6.2. Head Protection:

VERSION : 01 GREENRIM TRAINING. PAGE 11

1.6.3. Eye Protection:

VERSION : 01 GREENRIM TRAINING. PAGE 12

1. What does PPE stand for?

2. Who should supply the relevant PPE for an employee?

4. List three items regarded as PPE?

RIGID DUMP TRUCK CHECKS, STARTING, SHUTTING DOWN AND

MODULE LEARNING OUTCOMES

 Identify the different checks an operator must do on a Rigid Dump

VERSION : 01 GREENRIM TRAINING. PAGE 13

 Demonstrate how to perform the checks

2.1. RDT Checks:

2.2. Gauges and Warning Devices:

VERSION : 01 GREENRIM TRAINING. PAGE 14

2.2.1. Temperature Gauges:

VERSION : 01 GREENRIM TRAINING. PAGE 15

We get temperature gauges that monitor...

2.2.2. Pressure Gauges:

VERSION : 01 GREENRIM TRAINING. PAGE 16

We get pressure gauges that monitor…

2.2.3.Fuel Tank Level Gauge: