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R1600G LOAD HAUL DUMP

OPERATOR FAMILIARIZATION

STUDENT MATERIALS

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 Student Materials

R1600G Load Haul Dump Operator Familiarization

Module Objectives

1. Safety Section.
Describe the basic safety precautions associated with the machine. Locate
and identify the warning signs and labels used on the machine.

2. Product Information Section.

Locate and identify the major machine components of the machine. Explain the
function of the engine, power train, steering, braking and hydraulic systems.

3. Operation Section.
Locate, identify and explain the function of the gauges, switches and machine
controls. Describe the Caterpillar Monitoring System and the required responses
to the warning levels. Explain the correct procedures for checking, starting,
operating and stopping the machine. Describe the operating techniques for the
machine.

4. Given class notes and all reference material, the students are to undertake
the Theory Exercise.

5. Identify and locate components.

6. Perform the pre-start checks and inspections.

7. Operate the machine within a defined area.

8. Perform the techniques of loading, hauling and dumping.

9. Operate the machine via remote control (if equipped).

10. Given a machine and the machines Operation and Maintenance Manual,
the students are to perform the Practical Exercise.

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 Student Materials

R1600G Load Haul Dump Operator Familiarization

Theory Assessment

Directions: Multiple Choice. The student is to achieve at least 75% in the following questions
in order to demonstrate the necessary competence.
NAME: _________________________________________
Read each statement carefully and circle the letter(s) of the correct answer(s)
* Students may reference notes and the machine Operation and Maintenance Manual.

Q.1. The R1600G Load Haul Dump is:

A. Front wheel drive.

B. Rear wheel drive.
C. Four wheel drive.
D. Hydrostatically driven.

Q.2. The R1600G Load Haul Dump engine is a Caterpillar:

A. 3406E E.U.I.A.T.A.A.C.
B. 3306 P.C.T.A.
C. 3176C.
D. 3408 D.I.T.A.

Q.3. The parking brake is:

A. Hydraulically disengaged and spring engaged.

B. Air released and air applied.
C. Spring released and hydraulically applied.
D. Manually applied.

Q.4. What is the is the function of the center foot pedal:

A. Throttle.
B. Service brake.
C. Service brake and transmission neutralizer.
D. Fire suppression system.

Q.5.
.5. In which document would you find rrefer
eference to detailed walk-ar
eference ound inspection information:
walk-around

A. Operation and Maintenance Manual.

B. Caterpillar marketing flyer.
C. Daily newspaper.
D. Caterpillar specification sheet.

Continued

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 Student Materials

R1600G Load Haul Dump Operator Familiarization

Theory Assessment (continued)

Q.6. What do you check for on the dash when you tur
turnn the key start switch to the ON position :

A. That the gauges read normal pressures and temperatures.

B. The dash lights are illuminated.
C. That the engine diagnostic light is ON.
D. Caterpillar Monitoring System self test is performed.

Q.7. The rreason

eason an engine should be idled down for 3 minutes before stopping is:
before

A. To reduce and stabilize the internal engine temperature and turbocharger speed.
B. To enable the valve to seat correctly prior to being shutdown.
C. To ensure engine oil pressure drops low enough.
D. To let the operator have a rest before the end of shift.

Q.8. What rresponse

esponse is rrequir
equired by the operator for a Category 2 W
equired ar
War ning on the Caterpillar Monitoring
arning
System:

A. Immediate shutdown of operation to prevent severe damage to the system or machine.

B. It requires the operator to be aware that a machine system needs attention.
C. It requires a change in machine operation to reduce excessive temperature in one or more of the machines
systems.
D. Cover the dash so the flashing indicators stop bothering you, keep operating the machine in the same manner.

Q.9. What is a good rule to rremember

emember in rrelationship
elationship to gear selection when driving down a decline:

A. Select the gear which you would use for driving up the decline.
B. Select the highest gear.
C. Select neutral.
D. Select reverse and drive down backwards.

Q.10. The tachometer indicates the:

A. Machines ground speed in kilometres per hour.

B. Tailshaft speed in revolutions per hour.
C. Engine speed in revolutions per minute.
D. Torque converter output speed in revolutions per minute.

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R1600G Load Haul Dump Operator Familiarization

Practical Assessment

Note: Each learning outcome must be “initialled” as it is satisfactorily performed.

Certificates of Achievement may only be granted upon successful completion of all the
learning outcomes.
STUDENT NAME __________________________

Competent
Learning Outcome Practical A
YES NO
1. Location of Instruct the student to identify and locate the following components on the machine.
Components : General
Arrangement - Rear Lights

- Fire system activation points (if applicable)

- Battery disconnect switch

- Fuel filler cap

- Engine oil dipstick

- Engine oil filler cap

- Coolant level sight glass

- Engine oil filter

- Hydraulic tank guard

- Hydraulic tank sight glass

- Hydraulic tank filler cap

- Transmission oil sight glass or dipstick

- Steering frame lock

- Front work lights

- Bucket control safety pins

- Steering neutralizer valves and steering stops

- Steering cylinder

- Air cleaner and precleaner

- Swing out grille and hydraulic oil cooler

Continued

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 Student Materials

R1600G Load Haul Dump Operator Familiarization

Practical Assessment (continued)

Competent
Learning Outcome Practical A
YES NO
2. Instruments and Instruct the student to identify the location, function and operation of the following instruments
Controls and controls.

- Engine start switch

- Parking brake control

- Front and rear light switches

- Remote control switch (if equipped)

- Action lamp

- Circuit breakers

- Service hour meter

- Transmission oil pressure indicator

- Front and rear brake gauges (if equipped)

- Service brake pedal and throttle pedal

- Horn button

- Joystick control

- Transmission direction and speed control

- Steering control

- Steering and transmission lock control (STIC steering)

- Transmission neutral lock control (wheel steering)

- Safety signs and labels

- Autodig controls (if equipped)

- Lift arm positioner switch

- Operator mode scroll switch

Continued

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R1600G Load Haul Dump Operator Familiarization

Practical Assessment (continued)

Competent
Learni ng Outcome Practical A
YES NO
3. Caterpillar Monitoring Instruct the student to briefly explain the operation and show the location of the following.
System
- Engine tachometer

- Speedometer

- Transmission speed/direction indicator

- Service code indicator

- Warning level 1 - Operator response

- Warning level 2 - Operator response

- Warning level 2-S - Operator response

- Warning level 3 - Operator response

- Fuel level gauge

- Engine coolant temperature gauge

- Transmission oil temperature gauge

- Hydraulic oil temperature gauge

4. Caterpillar Monitoring Insruct the student to explain the operation and location of the following alert indicators on the
System Alert Indicators dash

- Engine oil pressure indicator

- Parking brake indicator

- Brake accumulator oil pressure indicator

- Electrical system indicator

- Maintenance required indicator

- Air filter restriction indicator

- Air intake heater indicator

- Transmission oil pressure indicator

- Axle oil temperature indicator

- Engine coolant level indicator

- Impending Brake Application (IBA) indicator

Continued

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R1600G Load Haul Dump Operator Familiarization

Practical Assessment (continued)

Competent
Learning Outcome Practical A
YES NO
5. Basic Mechanical Instruct the student to briefly explain and show the location of the following mechanical
Appreciation components.

- Engine

- Torque converter

- Transmission

- Drive axles

- Service brake

- Parking brake

Continued

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R1600G Load Haul Dump Operator Familiarization

Practical Assessment (continued)

Competent
Learning Outcome Practical B
YES NO
6. Pre Start Checks and Instruct the student to demonstrate the necessary pre start checks and inspection required on
Inspections the machine.

- Ensure the machine is parked on a level surface with the parking brake
engaged

- Check for Danger/Out of Service Tags on machine controls

- Check the engine coolant level sight gauge

- Check the engine oil level

- Check the fuel tank level

- Check the gauge on the fire suppression system (if applicable)

- Check the hydraulic tank oil level

- Check the transmission oil level

- Check for oil leaks and machine damage

- Check the wheels and tires

Continued

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R1600G Load Haul Dump Operator Familiarization

Practical Assessment (continued)

Competent
Learning Outcome Practical C
YES NO
7. Start Up Procedure Instruct the student to demonstrate the start up procedure on the machine.

- Check that the area is clear and sound the machine horn

- Turn the key start switch until the engine starts

- Check all gauges and alert indicators for the appropriate response

- With warm oil and the engine at low idle recheck the transmission oil level

- Check that all hydraulic controls function before moving the machine

- Test service brake holding ability

- Test parking brake holding ability

- Test the operation of the steering mechanical lockout

- Test the operation of the implement and steering hydraulic lockout

8. Shutdown Procedure Insruct the student to demonstrate the shutdown procedure on the machine

- Stop only in locations which will not hinder traffic

- Do not rely on the parking brake to hold the machine on a grade, head the front
of the machine down the decline and steer the machine bucket to the wall

- Place the transmission in neutral. Move the steering and transmission lock
control to the locked position (STIC steering), or lock the transmission neutral
lock control (wheel steering)

- Engage the parking brake

- Idle down the engine

- Stop the engine

Continued

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Practical Assessment (continued)

Outcome Familiar
Practical C
Component YES NO
9. Operating Procedures Instruct the trainee to demonstrate (on the surface)the operation of moving the machine.

- Ensure the steering frame lock pin is removed and stowed in the correct
location

- Maintain a three point contact when entering the operator station

- Adjust the operators seat

- Fit and adjust the seat belt

- Check that the operating area is clear and sound the horn (before starting hte
machine)

- Start the machine

- Unlock the transmission control

- Check the area is clear and sound the horn (before moving the machine)

- Raise the bucket with the joystick control and place in the tramming position

- Increase the engine rpm to 1000 - 1500 until the brake accumulator oil
pressure indicator goes out

- Depress the service brake pedal (to hold the machine)

- Return the engine to idle and disengage the parking brake

- Select the desired direction and speed

- Release the service brake pedal

- Apply the throttle smoothly to move off

Outcome
Practical D
Component
10. Load Haul Dumping Instruct the trainee to demonstrate (on the surface).

- Mucking from a stockpile

- Simulated or actual truck loading

- Remote control of the machine (if equipped)

- Parking the machine on a decline

Continued

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R1600G Load Haul Dump Operator Familiarization

Practical Assessment (continued)

Competent
Learni ng Outcome Practical E (If Equipped)
YES NO
11. Operating Instruct the student to demonstrate (on the surface) the operation of the machine under remote
Procedures Remote control.
Control (if equipped)
- Before operating the machine by remote control - perform a walk-around
inspection of the machine

- Operate the machine manually to ensure that all controls operate normally and
that all brakes operate effectively

- Park the machine in a convenient and safe location to start remote control
operation

- Shift the transmission control to the NEUTRAL position

- Move the steering and transmission lock control to the locked position (STIC
steering), or lock the transmission neutral lock control (wheel steering)

- Engage the parking brake

- Lower the bucket and move the hydraulic controls to the HOLD position

- Stop the engine

- Turn the remote control switch on the dash to the ON position

- Turn the machine lights off

- Ensure the machine does not move. Leave the machine

- Connect a 12V power supply to the transmitter

- Move the parking brake switch on the transmitter to the ON position (brakes
engaged)

- Turn the transmitter on

- Ensure the amber light on the machine is illuminated

- Start the machine by remote control

- Operate the machine by remote control

- Stop the machine by remote control

- Lower the bucket and engage the parking brake

- Shutdown the engine with the transmitter

- Turn the transmitter off

- Mount the machine and turn off the remote control switch on the dash

Continued

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R1600G Load Haul Dump Operator Familiarization

Practical Assessment (continued)

Competent Not Yet Competent

Assessor............................................... Assessor...............................................
Participant............................................ Participant.............................................
Date...................................................... Date......................................................
Comments

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 Student Materials

R1600G Load Haul Dump Operator Familiarization

Course Evaluation

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Course Name: R1600G Load Haul Dump Operator Familiarization Date: ....................................

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