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newSchoolWorks.com › VoTechWorks › Building & Construction › Heavy Equipment Operation › Loader Operation › Lesson 2
BLD-HEAV08-03 · Lesson 2 · 10 clock hours · demo

Controls Familiarization, Startup/Shutdown, and Basic Machine Movement

Objective. Students will correctly identify and operate all cab controls, execute a safe engine startup and shutdown sequence, and travel the loader through a defined course at low speed without striking cones or exceeding posted travel speed.

⚠ Pending professional review

This lesson, its worked examples and its practice questions has not yet been verified by a licensed professional engineer or master tradesperson or by a certification or approval body. It is a study draft and may contain errors. Do not use it as instructions for work on a job site or on live equipment. Always follow your instructor, your supervising professional, and current official references and regulations.

VoTechWorks program approval and accreditation are still in progress. Credentials are issued only by the certifying bodies named in each program, after their own exams.

Why Controls Familiarization Comes First

Before you move a wheel loader an inch, you must know exactly what every control does and where it is. A loader weighs tens of thousands of pounds and can cause fatal injuries in a fraction of a second. Reaching for the wrong lever at the wrong moment is how accidents happen. This lesson builds the habit of knowing your cab the way you know your own living room—by feel, without looking down.

The Cab Layout

Modern wheel loaders use either a joystick (single-lever) hydraulic control or traditional pilot levers, depending on manufacturer. Regardless of style, the functions are the same.

Hydraulic (bucket) controls raise and lower the boom and tilt the bucket forward (dump) or back (curl/rollback). Always curl the bucket back and raise to carry position—roughly 12 to 18 inches off the ground—before traveling. Traveling with a full, raised bucket shifts the machine's center of gravity dangerously high.

Transmission direction and gear selector chooses Forward, Neutral, or Reverse (F-N-R) and sets the gear range. For yard travel and the cone course, stay in first gear. Never shift direction under heavy load or at speed.

Differential lock improves traction on slippery ground by locking the axle differentials. Engage it only when needed and disengage before turning—turning with the diff lock engaged can stress drivetrain components and reduce steering control.

Parking brake must be set any time you leave the seat or shut down the engine. It is a critical step; releasing it before the machine is ready to move is a common cause of runaways.

Secondary steering test Many loaders have an emergency or secondary steering system. Your OEM manual will specify how and when to test it—typically at low speed during pre-shift. Follow that procedure every shift.

Work lights and horn Know their locations so you can activate them instantly. The horn is your first warning device to alert ground workers. Work lights keep you and others visible during low-light conditions.

Pre-Operation Walkaround

Before you sit down, walk around the entire machine. Check for fluid leaks under the machine, tire condition and inflation, bucket cutting edge wear, mirror adjustment, and that no one is in the machine's swing path. This walkaround is not optional—it is required by OSHA standards for powered industrial equipment and is evaluated on the NCCER checklist.

Safe Startup Sequence

Follow your OEM checklist every time. The general sequence for most wheel loaders is:

1. Adjust seat and fasten seatbelt before touching any controls.

2. Set the parking brake (confirm indicator light or feel the detent).

3. Engage the hydraulic lockout lever or switch—this prevents accidental bucket movement during startup.

4. Place the transmission in Neutral.

5. Turn the key to ON; allow glow plugs to cycle if the machine is diesel and conditions require it.

6. Start the engine; do not crank for more than the time specified in your OEM manual.

7. Allow oil pressure to build—watch the gauges before moving any controls.

8. Test horn, lights, backup alarm, and brakes at low speed before leaving the immediate area.

Skipping steps—especially the parking brake and hydraulic lockout—are critical errors that will fail your scored checklist.

Safe Shutdown Sequence

1. Travel to a flat, clear area.

2. Lower the bucket fully to the ground.

3. Shift transmission to Neutral.

4. Set the parking brake.

5. Engage the hydraulic lockout.

6. Allow the engine to idle for the time specified in your OEM manual (typically a few minutes) so turbochargers cool down.

7. Turn the key to OFF.

8. Remove the key if leaving the machine unattended.

Traveling the Machine

For the cone course, you will travel in first gear only. Keep your bucket in carry position (12–18 inches off the ground). This low height gives you clearance over rough ground while keeping your center of gravity low enough for safe maneuvering.

Mirror use is mandatory. Check your mirrors before every reverse movement. The backup alarm will sound automatically, but mirrors let you see ground workers, equipment, or obstacles that the alarm cannot protect against. Look in the direction of travel—always look back when reversing.

Travel speed should be slow enough that you can stop within the distance you can see. In a yard cone exercise, if you feel rushed, you are going too fast.

Communication and Ground Personnel

Never move the machine until you have confirmed no one is in your path. Use the two-way radio if your instructor is outside the cab. Hand signals between operator and spotter follow a standard set defined by industry practice—your instructor will review these. One clear signal to stop from any ground worker means you stop immediately, no questions asked.

PPE Requirements

At the machine: hard hat, high-visibility vest, safety-toed boots, and safety glasses. Hearing protection if you will be near the engine for extended periods outside the cab. These are non-negotiable on any active construction site and are enforced during all yard exercises.

What the Scored Checklist Looks For

You must score 90% or higher on the startup/shutdown checklist, and every critical step—parking brake set, hydraulic lockout engaged, correct key sequence—must be completed correctly. A missed critical step is an automatic unsatisfactory rating for that cycle regardless of your overall score. Three out-and-back cone passes without striking a cone, stalling, or raising the bucket above carry position completes the performance check.

Key terms8

Carry positionThe bucket height during travel—approximately 12 to 18 inches off the ground—that keeps the center of gravity low and provides ground clearance.
Hydraulic lockoutA lever or switch that disables hydraulic control movement so the bucket and boom cannot be raised or tilted accidentally during startup, shutdown, or when the operator leaves the seat.
Parking brakeA mechanical brake that holds the machine stationary when parked; must be set before shutdown and before the operator exits the cab.
Differential lockA drivetrain feature that locks the axle differentials together to improve traction on slippery surfaces; must be disengaged before turning.
Secondary steeringAn emergency steering system that operates independently of the primary hydraulic steering circuit; tested each shift at low speed per OEM procedure.
Backup alarmAn automatic audible device that sounds whenever the transmission is placed in reverse, warning ground personnel that the machine is moving rearward.
Pilot-lever hydraulic controlsTraditional separate levers that control boom lift and bucket tilt through low-pressure hydraulic pilot signals sent to the main control valve.
Pre-operation walkaroundA required visual inspection of the entire machine performed before each shift to identify leaks, damage, tire condition, and safety hazards before startup.
In class: Instructor demonstration in the cab: walk students through every control (joystick or pilot-lever hydraulic controls, transmission direction/gear selector, differential lock, parking brake, secondary steering test, work lights, and horn); students narrate back the function of each control from the observer position before rotating into the seat. · Supervised startup and shutdown practice—each student performs three consecutive startup-to-shutdown cycles following the OEM checklist sequence while the instructor evaluates against a scored checklist; errors are debriefed immediately. · Cone-course travel exercise on a flat, clear yard: students drive forward through a 10-cone slalom at first gear, stop at a marked line, reverse to start, and repeat; instructor times each run and debriefs bucket height (must remain in carry position, approximately 12–18 inches off ground) and mirror use.
Materials: Wheel loader with functioning backup alarm and mirrors; cone course materials (10 traffic cones, painted stop line); OEM operator's manual; NCCER Heavy Equipment Level 1 controls reference card; two-way radio for instructor-student communication; PPE as above
Check: Each student completes three out-and-back cone-course passes without striking a cone, stalling the engine, or raising the bucket above carry position; startup and shutdown checklist scored at 90% or higher (all critical steps—park brake, hydraulic lockout, key sequence—must be correct).

Practice check8

Answer each question, then check it. Nothing is recorded; this is your own practice.

Equipment Operation — NCCER Heavy Equipment Level 1
1. What is the correct bucket height while traveling a wheel loader across a yard?
Equipment Operation — NCCER Heavy Equipment Level 1
2. Which step must be completed immediately before turning the ignition key to the START position?
Equipment Operation — NCCER Heavy Equipment Level 1
3. Why must the differential lock be disengaged before turning the loader?
Safety — OSHA 10 / NCCER Heavy Equipment Level 1
4. A ground worker gives a clear hand signal to stop while you are reversing. What is the correct response?
Equipment Operation — NCCER Heavy Equipment Level 1
5. During the scored startup/shutdown checklist, a student completes all steps correctly but forgets to set the parking brake before shutdown. How does this affect the score?
Safety — OSHA 10
6. Which PPE combination is required when working at or near the loader during yard exercises?
Equipment Operation — NCCER Heavy Equipment Level 1
7. What is the primary purpose of performing a pre-operation walkaround before starting the loader?
Safety — OSHA 10 / NCCER Heavy Equipment Level 1
8. During the cone-course reverse run, a student notices the backup alarm is not sounding. What is the correct action?
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