Oversized Cargo M-Series Truck Vehicle Management Codes: K212, K237, K248, K251, K460 K471 QUALIFICATION TRAINING PACKAGE

Transcription

1 DEPARTMENT OF THE AIR FORCE Headquarters US Air Frce Washingtn, D.C QTP24-3-K February 2017 Oversized Carg M-Series Truck Vehicle Management Cdes: K212, K237, K248, K251, K460 K471 QUALIFICATION TRAINING PACKAGE

2 CONTENTS SECTION 1 OVERVIEW Overview... 3 SECTION 2 RESPONSIBILITIES Respnsibilities SECTION 3 INTRODUCTION Objectives Desired Learning Outcmes Lessn Duratin Instructinal References Instructinal Training Aids and Equipment SECTION 4 TRAINEE PREPARATION Licensing Requirements Required Reading SECTION 5 KNOWLEDGE LECTURE AND EVALUATION Knwledge Overview Overview f Training and Requirements Vehicle Inspectin Vehicle Safety and Equipment Driving Safety and Precautins Vehicle Operatin Maintenance Prcedures SECTION 6 EXPLANATION AND DEMONSTRATION Instructr s Preparatin Safety Prcedures and Equipment Operatr Maintenance Demnstratin Operatin Demnstratin SECTION 7 TRAINEE PERFORMANCE AND EVALUATION Trainee Perfrmance Perfrmance Evaluatin Attachment 1 GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION 90 Attachment 2 VEHICLE INSPECTION GUIDE 91 Attachment 3 PERFORMANCE TEST 95 Attachment 4 SEVEN-STEP INSPECTION PROCESS 100

3 Sectin 1 OVERVIEW 1.1. Overview Send cmments and suggested imprvements n Air Frce (AF) Frm 847, Recmmendatin fr Change f Publicatin, thrugh Air Frce Installatin and Missin Supprt Center (AFIMSC) functinal managers via at AFIMSC.IZSL.VehicleOps@us.af.mil Hw t use this plan: Instructr: Prvide verview f training, Sectin 2 and Sectin Instructr s lessn plan fr trainee preparatin, give classrm lecture, Sectin Instructr s lessn plan fr knwledge training, Sectin Instructr s lessn plan fr demnstratin, Sectin Instructr s lessn plan fr perfrmance and evaluatin, Sectin Trainee: Reads this entire lessn plan prir t starting lecture Fllws alng with lecture using this lessn plan and its attachments Uses Attachment 2 and Attachment 4 as guides fr vehicle inspectin Takes perfrmance test. Sectin 2 RESPONSIBILITIES 2.1. Respnsibilities The trainee shall: Ensure the trainer explains the Air Frce Qualificatin Training Plan (AFQTP) prcess and the respnsibilities Review the AFQTP/Mdule/Unit with the trainer.

4 The trainee shuld ask questins if he/she des nt understand the bjectives fr each unit Review missed questins with the trainer Instructr shall: Review the AFQTP with the trainee Cnduct knwledge training with the trainee using the AFQTP Grade the review questins using the answer key Review missed questins with the trainee t ensure the required task knwledge has been gained t cmplete the task Sign-ff the task(s) The Certifier shall: Evaluate the Airman s task perfrmance withut assistance Sign-ff the task(s). Sectin 3 INTRODUCTION 3.1. Objectives Given lectures, demnstratins, hands-n driving sessin and a perfrmance test, trainees will be able t perfrm peratr s inspectin and cmplete the perfrmance test with zer instructr assists Train and qualify each trainee in safe peratin and preventive maintenance f the varius versized carg M-series trucks This training will ensure the trainee becmes a qualified versized carg M-series truck peratr; an peratr wh has the knwledge and skills t perate an versized carg M-series truck in a safe and prfessinal manner Desired Learning Outcmes Understand the safety precautins t be fllwed pre-, during-, and st- peratin f the versized carg M-series truck Understand the purpse f the versized carg M-series truck and its rle in the missin.

5 Knw the prper peratr maintenance prcedures f the versized carg M-series truck, in accrdance with (IAW) applicable technical rders (TOs) and use f AF Frm 1800, Operatr s Inspectin Guide and Truble Reprt Safely and prficiently perate the versized carg M-series truck Lessn Duratin Recmmended instructinal and hands n training time is 25 hurs: Figure 3.1. Recmmended Training Time fr Training Activities. Training Activity Trainee s Preparatin Instructr s Lecture and Demnstratin Trainee s Written Evaluatin Trainee s Persnal Experience (t build cnfidence and prficiency) Perfrm Operatr Maintenance Operate the Vehicle Trainee s Perfrmance Evaluatin Training Time 2 Hurs 5 Hurs 1 Hur 15 Hurs 2 Hurs Nte: This is a recmmended time; training time may be mre r less depending hw quickly a trainee learns new tasks Instructinal References Risk Management (RM) and Safety Principles IAW AFPAM , Risk Management (RM) Guidelines and Tls Applicable TOs r Manufacturer s Operatr s Manual T.O. 36A12 series Air Frce Manual (AFMAN) , Operatin f Air Frce Gvernment Mtr Vehicles, Chapters 1-5 and AFI , Air Frce Cnslidated Occupatinal Safety Instructin AF Frm Special references based-ff type f vehicle Instructinal Training Aids and Equipment Oversized Carg M-Series Truck Lessn Plan.

6 Oversized carg M-series truck Applicable TO r manufacturer s peratr s manual AF Frm Vides (if lcally prduced) Suitable training area Traffic cnes. Sectin 4 TRAINEE PREPARATION 4.1. Licensing Requirements Trainee must have in his/her pssessin a valid state driver s license AF Frm 171, Request fr Driver s Training and Additin t U.S. Gvernment Drivers IAW Air Frce Instructin (AFI) , Vehicle Operatins Applicable lcal licensing jurisdictin requirements Required Reading Read this entire lessn plan Read AFMAN , Chapters 1-5, and Read manufacturer s peratr s manual fr the vehicle being trained n Read recmmended references: T.O. 36A12 series Sectin 5 KNOWLEDGE LECTURE AND EVALUATION 5.1. Knwledge Overview The AF uses a variety f versized carg M-series trucks. The primary purpse varies by vehicle type.

7 The primary purpse f the 2-1/2 tn 6 x 6 versized carg M-series truck is primarily airdrp recvery prcedures that require the use f vehicles built fr adverse terrain. Other versized carg M-series truck serve a variety f purpses (passenger mvement, carg mvement, emergency services supprt, etc.) 5.2. Overview f Training and Requirements Training bjectives: Given lectures, demnstratins, hands-n driving sessin and a perfrmance test, trainees will be able t perfrm peratr s inspectin and cmplete the perfrmance test with zer instructr assists Train and qualify each trainee in safe peratin and preventive maintenance f the varius versized carg M-series trucks This training will ensure the trainee becmes a qualified versized carg M-series peratr an peratr wh has the knwledge and skills t perate an versized carg m- series truck in a safe and prfessinal manner Desired learning utcmes: Understand the safety precautins t be fllwed pre-, during-, and pstperatin f the versized carg M-series trucks Understand the purpse f the versized carg M-series truck and its rle in the missin Purpse varius based n vehicle type (carg mvement, passenger mvement, emergency services supprt, etc.) Rle in the missin (Unit/Base/Cmmunity (during natural disasters)/air Frce) Oversized Carg M-Series Truck Design. The design f an versized carg M-series truck varies depending n the vehicle type. Refer t the manufacturer s peratr s manual fr additinal infrmatin n the specific versized carg M-series truck being perated, and t the data plate fr safe lad capacity guidance. The versized carg M-series truck nrmally can be identified by the fllwing characteristics: /2 and 5 Tn Trucks: tn r 5 tn refers t the maximum paylad the vehicle can carry under the wrst crss-cuntry cnditins. Under ideal highway cnditins, it can carry twice as much.

8 The 6X6 designatin means the vehicle has six wheel ends and all six are capable f driving The truck bdy prvides 270 cubic feet f carg space. The side racks have built-in trp s seats fr trp transprt Use either diesel r JP-8 fr fuel. JP-8 shuld nly be used in an emergency and shuld be mixed with diesel as sn as pssible Tire pressure is checked and adjusted autmatically by the CTIS (Central Tire Inflatin System) Cntrls and indicatrs. See Table 5.1. Table /2 and 5 Tn Oversized Carg M-Series Truck Cntrls and Indicatrs. Cntrl/Indicatr Engine Stp Cntrl Accessry Pwer Switch Light Switch Engine Start Buttn Air Cleaner Indicatr Defrster Knb Windshield Wiper Cntrl Knb Damper Cntrl Knb Heater Blwer Switch Manifld Heater Switch Hand Thrttle Cntrl Oil Pressure Gauge Descriptin Stps flw f fuel frm fuel pump t shut dwn the engine. Rutes pwer t starter system, instrument panel gauges, fuel pump and lw pressure warning buzzer. Cntrls peratin f vehicle lights. Pressed t rute electrical current t the starter t crank the engine. Shws red when engine air cleaner filter needs servicing. Pulled ut t direct flw f ht air nt windshield t prevent frsting. Turns windshield wipers n/ff. Pulled ut all the way t prvide maximum amunt f heat t persnnel cmpartment. Psitined in high r lw psitin t cntrl flw f frced air int persnnel cmpartment. Turns manifld heater n/ff. Manifld heater is used t warmup and help start engine in cld weather (+20 F r belw). Sets engine speed at desired revlutins per minute (rpm) withut maintaining pressure n acceleratr pedal. Thrttle cntrl lcks in desired psitin when pulled ut. Rtating cntrl handle clckwise r cunterclckwise unlcks it. Indicates il pressure when engine is running. Nrmal pressure is punds per square inch (psi).

9 Speedmeter/Odmeter Tachmeter Engine Clant Temperature Gauge Map Cmpartment Air Pressure Gauge Battery/Generatr Gauge Frnt Wheel Drive Lever Frnt Wheel Drive Indicatr Light Fuel Lever Gauge High Beam Indicatr Transfer Case Shift Lever Slave Receptacle Indicates vehicle speed and ttal mileage. Indicates engine speed in revlutins per minute (rpm) and peratin time in hurs and tenths f hurs. Indicates temperature f engine clant. Nrmal perating temperature is 180 t 200 F. Prvides strage fr manuals, frms and maps. Indicates pressure in air reservir tanks. Nrmal pressure is 85 t 120 psi. Indicates when the battery is charging r discharging. Engages/disengages frnt wheel drive pwer. Shws when frnt wheel drive is perating. Indicates fuel level in fuel tank. Shws when headlights are n high beam. Pushed dwn t Lw range fr heavy lad peratins, and pulled up t High range fr light lad peratins. Lcated n the right rear side f the cab, it is the plug-in pint fr an external pwer service required t slave start vehicle when batteries have becme discharged The 6x6 System (if applicable). A vehicle equipped with six wheel drive (6x6) has the ability t use all six wheels t pwer itself. This increases tractin which may enable the peratr t safely drive ver terrain and rad cnditins that a cnventinal tw wheel drive (2x2) r fur wheel drive (4x4) drive vehicle cannt Pwer is supplied t all six wheels thrugh a transfer case r pwer transfer unit. 6x6 vehicles allw the peratr t select different drive mdes as necessary Refer t the manufacturer s peratr s manual fr infrmatin n shifting prcedures and maintenance On sme 6x6 mdels, the initial shift frm 2x2/4x4 t 6x6 while the vehicle is mving can cause a mmentary clunk and ratcheting sund. These sunds are nrmal as the frnt drivetrain cmes up t speed and is nt cause fr cncern Vehicle Inspectin Pre-trip vehicle inspectin test. Use Attachment 2 as a walk arund guide alng with AF Frm The fllwing items must be checked when the vehicle is picked up:

10 Ensure all crrect dcumentatin is in the package when the vehicle is picked up AF Frm 1800 Frm. Ensure the fllwing are anntated n it: Reg. Number f vehicle matches what is n the AFTO Frm Signatures fr Tire Pressure Check/Stencil verificatin Miles/Hurs f Vehicle/Date. Recrd ff-base mileage slip (Write dwn mileage when leaving/returning frm base). Off base fuel is taxed) N pen write-ups Nte any discrepancies fund n the space prvided inside Frm 1800 and ntify Vehicle Maintenance persnnel Ensure that the fire extinguishers have been signed ff fr the mnth Waiver Card Vehicle Accident Reprt Accident ID Card A Seven-Step Inspectin Methd will help ensure the inspectin is the same each time it is cnducted, and that nthing is left ut. See Attachment 4 fr the Seven-Step Inspectin Methd Types f Vehicle Inspectin. If discrepancies are fund they must be reprted t the Vehicle Cntrl Officer/Vehicle Cntrl Nn Cmmissined Officer (VCO/VCNCO), the supervisr, and/r vehicle maintenance: Pre-trip inspectin find items/prblems that culd cause accident r breakdwn Vehicle maintenance t authrize cntinued use fr all ther maintenance discrepancies Cleanliness/damage/missing items Leaks (fuel/il/clant/hydraulic/air) Fluid Levels; ensure level is within limits:

11 Engine il Clant Pwer steering fluid Transmissin fluid Antifreeze Battery; security, fluid, damage and crrsin All wheel rims (cracks, splits, etc.); check fr lse r missing lug nuts All tires Prper inflatin. Nte: Ntify VCO/VCNCO, the supervisr, and/r vehicle maintenance if split rim is cmpletely flat Tread t include depth Cuts and abrasins Transmissin Drive belts; tensin and fraying Air restrictin gauge Hydraulic hses/cylinder (damage) All hses and wiring Differential, shcks and brakes fr leaks Suspensin and springs Twing cnnectin Fuel dr and fuel cap; intact, nt brken r damaged Hrn peratin Cntrl panel Heater/defrster.

12 Wiring/lights/reflectrs (interir and exterir) Mirrrs Windshield and windshield wipers/washers Drs Windws Hd latches Seatbelts Fire Extinguisher During-peratin All gauges and warning lights fr prper peratins Warning lights Gauges (il pressure, fuel gauge, water temperature, vltage) Indicatrs Listen fr exhaust and air leaks. Listen fr any unusual sunds Stay alert fr any unusual smells r drs Stay alert fr any abnrmal vibratins r handling prblems Cntrls fr prper peratin: Steering wheel Steering wheel tilt cntrl Directin cntrl lever Parking brake cntrl Off/n/enrich knb Battery discnnect switch.

13 Acceleratr cntrl pedal Ignitin switch Service brakes Selectr switch After-trip inspectin and reprt Ensure vehicle and cmpnents are cleaned Equipment is prperly stwed Refueled Parked Apply brakes Place transmissin in neutral (park fr an autmatic) Vehicle Safety and Equipment Hazards and Human Factrs: Traffic due t size and weight Carg lads beynd the vehicle s capability Jerky starts and stps Traveling t fast and turning t sharply Cutting crners t sharply Nt prperly securing the carg Overhead clearance Rllver risk Safety Clthing and Equipment: Safety steel-ted bts must be wrn.

14 Glves will be wrn during carg lading and unlading (take ff rings/jewelry first First aid kit Raingear, cld weather gear, etc Reflective belt during hurs f reduced visibility and n flight line Tire gauge Fire extinguisher Shvel, tw chains and cables Material fr under wheels (sft areas) Hearing prtectin Hand prtectin, if required (using pneumatic tls) Eye prtectin, if required AF Frm Driving Safety and Precautins Never use the versized carg M-series truck fr anything ther than its intended purpse Rllver risk warning. The ptential fr a vehicle t rllver increases fr vehicles with a high grss weight (20,000 lbs. r mre) r a high center f gravity. Check the vehicle s data plate t determine if the vehicle is at higher risk fr rllver General safety guidelines: Safe peratin f the carg truck is the respnsibility f the peratr Never start the carg truck frm any place ther than the driver s psitin Never drive the carg truck up t anyne standing in frnt f an bject Always keep all parts f the bdy in the peratr s area when the vehicle is in mtin.

15 The peratr and all passengers must wear seatbelts when the vehicle is in peratin Place wheel chcks (if required) when truck is parked Remve all jewelry and identificatin tags Pay particular attentin t the cautin and warnings listed in the peratr s manual Recmmended speed limits: On the flight line: 10 miles per hur (mph) Within 50 ft. f an aircraft: 5 mph All ther areas: Obey psted speed limits When driving during hurs f darkness, always turn-n lights Always face in the directin f travel Never carry passengers unless they are in the cab with seatbelts fastened r integrated seats in the bed f the truck Always cme t a cmplete stp befre changing directins Never use ether t start a vehicle that is equipped with glw plugs Always turn-ff engine when refueling N recap tires n frnt Tire Changing Safety Ensure the fllwing tls/equipment are used while changing the damaged/flat tire: Vehicle jack w/jack handle Lug wrench Jack stand Wheel chcks.

16 Hand/eye/hearing prtectin (if pneumatic tls are ging t be used), safety/steel-ted bts/shes Lsen, d NOT remve, lug nuts Jack the vehicle up until the tire clears the grund with n mre than an extra inch t allw replacement f the tire Place the jack stand under the frame f the vehicle t supprt the vehicle in case the jack s hydraulics shuld leak and/r fail Remve the vehicle s lug nuts Remve the vehicle s flat/damaged tire. Cautin Studs/spacers can stick and are under pressure causing them t becme prjectiles. This may result in persnal injury r damage t equipment. Nte: If the inside dual tire is flat and/r damaged the peratr must remve the separatin ring and remve the inside wheel studs/spacers (if equipped) in rder t remve the damaged/flat tire. Cautin studs/spacers can stick and are under pressure causing them t becme prjectiles during remvals. Lsen the nut but nt remve it fully, hit the spacer with the lug wrench r hammer t lsen it and then remve the nut Place replacement tire nt the vehicle s axle Replace the vehicle s lug nuts t hand tightness Jack the vehicle up and remve the jack stand Lwer the vehicle until it makes cntact with the grund Tighten vehicle s lug nuts in a start pattern Off-rad driving. Fr mre infrmatin n ff-rad driving and safe vehicle peratin guidance, refer t AFMAN Carg lading and tie-dwn prcedures. Fr mre infrmatin n safely lading, transprting and unlading carg, refer t AFMAN and the manufacturer s peratr s manual fr the specific vehicle type Hazardus carg. Fr mre infrmatin n transprting hazardus carg, refer t the Hazardus Carg Lessn Plan.

17 Freign Object Damage (FOD). Vehicle peratrs will remve FOD frm tires during the daily vehicle inspectin. Befre entering the airfield, a physical check fr lse/unsecured bjects and an inspectin f the tire treads fr FOD will be accmplished, with the exceptin f emergency vehicles respnding t actual situatins Any vehicle which has been driven n an unpaved surface will have a tire FOD inspectin accmplished prir t re-entering the airfield area. Vehicles that frequent the flight line will be equipped with a FOD picker and a cvered FOD cntainer FOD picker will be etched with the vehicle number painted in red r range (r have a red streamer attached) FOD picker will be anntated n vehicle inspectin frm FOD cntainers will be identified with the letters "FOD" and will be emptied daily FOD checks are perfrmed s that aircraft damage can be kept at a minimum Vehicle Operatin Vehicle peratin review: Engine starting prcedures fr diesel and gasline mdels Using slave receptacle t start the engine Psitin the right side f the slaving (recharging) vehicle t the right side f the disabled vehicle Shut-ff slaving vehicle engine. Cautin Always cnnect slave cable t disabled vehicle first. Imprperly cnnecting cable may result in damage t batteries r cable Make sure electrical switches n bth vehicles are in the OFF psitin Remve cver frm slave receptacle and cnnect slave cable t slave receptacle n the disabled vehicle. Repeat prcedure n slaving vehicle Start slaving vehicle engine and set idle speed at 1,000 t 1,100 rpm Start slaved vehicle engine After engine starts and is running smthly, discnnect slave cable frm bth vehicles.

18 Put cvers back n receptacles Clean and stw slave cable Observe battery/generatr indicatr n slaved vehicle. If indicatr des nt reach green area, ntify maintenance persnnel Understanding and bserving gauges. Perfrming peratinal checks Use f the CTIS Shifting transfer case frm high r lw range Use f sptters. The peratr must maintain visual cntact with the sptter(s) at all times. If the peratr lses visual cntact, the vehicle must be stpped immediately. See AFMAN fr additinal guidance n sptter safety and standard sptter hand signals Frnt-wheel drive engagement Explain what fuels can be used in the 5 tn truck Use f engine starting aid Prcedures fr parking and shutting dwn vehicle n and ff the flight line On the flight line: Place transmissin in neutral, set parking brake, turnff engine. Explain tactical start t student using the TO as guide Off the flight line: Place transmissin in neutral, set parking brake, turnff engine Operating the vehicle in adverse cnditins. Fr additinal infrmatin n ffrad driving and cntingency peratins, see AFMAN Prcedures fr stwing and un-stwing the munted carg area seats. See Figure 5.1.

19 Figure 5.1. Stwing/Un-stwing Munted Carg Area Seats/Bws/Tarps Use f the truck fr twing. Nte: The peratr must be aware f the lad capacity and twing capacity limitatins f the vehicle being perated Vehicle Cntrls Overview Main instrumental panel. The fllwing Figure 5.2. and Table 5.2. describe cmmn functins n an versized carg M-series truck. Refer t the vehicle s manufacturer s peratr s manual fr the additinal infrmatin. Figure 5.2. Main Instrument Panel.

20 Table 5.2. Main Instrument Panel. Key Gauge/Cntrl/Instrument Descriptin 1 Deep Water Frding Switch Disables the radiatr fan fr deep water frding. 2 Ether Start Switch Injects ether int engine intake system t assist with cld weather starting. 3 Frnt Brake Air Pressure Shws air pressure (psi) available t perate the frnt Gauge brakes. Nrmal air pressure range is psi. 4 Lighted Indicatr Display Indicatrs light t indicate perating characteristics f the vehicle. 5 Oil Pressure Gauge Shws engine il pressure (in psi). Nrmal il pressure range is psi. 6 Speedmeter/Odmeter Speedmeter shws vehicle speed in mph and kilmeters per hur (kph). Odmeter indicates number f miles the vehicle has traveled. 7 Vlts Gauge Shws battery utput vltage when engine is nt running and alternatr utput vltage when engine is running. 8 Master Pwer Switch Cntrls electrical pwer fr engine starting and/r electrical system peratin. 9 Warning Light Switch Operates warning light n cab rf (if installed). 10 Hazard Lights Switch Operates hazard lights. Left and right turn signals and indicatrs flash when switch is n. 11 Manual Thrttle Lever Adjusts engine speed t assist with engine warm-up and set engine rpm when using the Pwer Take-ff (PTO). Nte: D NOT use manual thrttle lever while driving the vehicle. It is nt t be used as a cruise cntrl. Failure t cmply may cause lss f cntrl resulting in an accident and injury r death t persnnel r damage t prperty. 12 Air Filter Restrictin Gauge Indicates when the air filter is restricted. Diaphragm enters red zne when air filter is clgged and needs servicing. RESET buttn n face f gauge can be pressed t reset gauge after air cleaner is serviced. 13 Dimmer Switch Cntrls brightness f instrument panel lighting. Turn left t increase brightness, right t decrease brightness. 14 Light Selectr Switch Cntrls service and blackut (BO) lights. 15 Starter Pushbuttn Starter pushbuttn perates nly when master pwer switch is in the ON psitin. 16 Water Temperature Gauge Shws engine clant temperature in F. 17 Audible Alarm Sunds when air pressure is belw apprximately 65 psi r when STOP light illuminates n the lighted indicatr display. 18 Rear Brake Air Pressure Shws air pressure (psi) available t perate the rear Gauge brakes. Nrmal air pressure range is psi. 19 Fuel Gauge Shws fuel level in the tank.

21 20 Electrnic Cntrl Unit (ECU) Pushbuttn Shift Selectr Used t select frward r reverse range, t set highest gear range, t switch frm highway t ff-rad mde, and t mnitr transmissin peratin Lighted Indicatr Display: Figure 5.3. Lighted Indicatr Display.

22 Table 5.3. Lighted Indicatr Display. Key Gauge/Cntrl/Instrument Descriptin 1 Left Turn Signal Flashes (green) when left turn signal is n. 2 STOP Indicatr Lights (red) when a serius engine malfunctin r lss f air pressure ccurs. 3 High Beams ON Indicatr Lights (green) when high beam headlights are n. 4 PARK BRAKE Indicatr Lights (amber) when parking brake is applied. 5 EMERGENCY BRAKE Lights (amber) when service braking is prvided by a Indicatr twing vehicle. 6 Right Turn Signal Flashes (green) when right turn signal is n. 7 VAN DOOR OPEN Indicatr N/A 8 9 FRONT BRAKE AIR Indicatr Engine Oil Pressure Indicatr Lights (red) when air pressure fr frnt service brakes drps belw 65 psi. Alarm sunds and STOP indicatr lights when FRONT BRAKE AIR Indicatr is n. Lights (red) when engine il pressure drps belw 12 psi. STOP indicatr lights when engine il pressure indicatr is n. 10 High Engine Temperature Indicatr 11 PTO ON Indicatr Lights (green) when PTO is engaged. Lights (red) when engine clant temperature is greater than 230 F. 12 CTIS OVERSPD Indicatr Lights (amber) when speed exceeds safe limit fr selected tire inflatin pressure. 13 Fan OFF Indicatr Lights (amber) when radiatr fan is turned-ff REAR BRAKE INDICATOR ENGINE OIL LEVEL Indicatr 16 TRANS OIL TEMP Indicatr 17 CHEM DETECT Indicatr N/A Light Selectr Switch: Lights (red) when air pressure fr the rear service brakes drps belw 65 psi. Alarm sunds and STOP indicatr lights when REAR BRAKE AIR indicatr is n. Lights (red) t indicate lw engine il level when master pwer switch is psitined t ON and the engine is nt running. Lights (red) when transmissin il temperature is greater than 225 F.

23 Figure 5.4. Light Selectr Switch. Table 5.4. Light Selectr Switch. Key Gauge/Cntrl/Instrument Descriptin 1 Main Selectr Lever Cntrls peratin f service and blackut lights. All blackut lights perate when main selectr is psitined t BO DRIVE. Blackut marker lights perate when main selectr lever is psitined t BO MARKER. Stplights perate when main selectr switch is psitined t STOP LIGHT and brake pedal is depressed. All service drive lights perate when main selectr lever is psitined t SER DRIVE. N exterir lights perate when main selectr lever is psitined t OFF. 2 UNLUCK Lever Lcks light selectr switch. UNLOCK Lever must be lifted and held in rder t place main selectr lever in any psitin except BO MARKER.

24 3 Auxiliary Lever Cntrls peratin f parking lights. Operates parking lights when auxiliary lever is psitined t PARK and main selectr lever is psitined t SER DRIVE. PANEL BRT and DIM psitins have n functin n the FMTVs. Use dimmer switch instead ECU Pushbuttn Shift Selectr: Figure 5.5. ECU Pushbuttn Shift Selectr. Table 5.5. ECU Push Buttn Shift Selectr. Key Gauge/Cntrl/Instrument Descriptin 1 Shift Selectr Display Windw Displays the fllwing: Frward gear selected (shwn in left side f windw). Operating mde (blank fr highway mde, MODE ON displayed when ff-rad mde is selected). Current frward gear (shwn in right side f windw). Service messages (cdes will appear in display windw if Electrnic Cntrl Unit (ECU) detects an abnrmal cnditin. 2 MODE Select Buttn Switches transmissin between highway and ff-rad mdes. 3 Up Arrw Buttn Switches transmissin t the next higher frward gear r t select maximum frward gear. 4 Dwn Arrw Buttn Switches transmissin t next lwer frward gear r t dwnshift t first gear.

25 5 D Range Buttn Switches transmissin int Drive. Autmatically selects seventh gear maximum frward gear. Secnd gear is the lwest gear available. First gear is available nly as a manual selectin. 6 N Range Buttn Switches transmissin int Neutral. 7 R Range Buttn Switches transmissin int Reverse Trailer Brakes Cntrl Figure 5.6. Trailer Brakes Cntrl (1) TRAILER AIR SUPPLY Cntrl: Cntrls air supply t trailer brakes. Air is supplied t trailer when cntrl is pushed in (2) SYSTEM PARK Cntrl: Applies and releases the parking brakes and trailer parking brakes (if equipped). Parking brakes are applied when cntrl knb is pulled Fan/Heat/Vent/Defrst Cntrls.

26 Figure 5.7. Fan/Heat/Vent Defrst Cntrls. Table 5.7. Fan/Heat/Vent Defrst Cntrls. Key Gauge/Cntrl/Instrument Descriptin 1 Fan Switch Fur-psitin switch cntrls the peratin and speed f the heater fan. 2 HEAT Cntrl Cntrls temperature f air that heats the cab interir and defrsts the windshield. Pull ut t increase temperature. 3 VENT Cntrl Cntrls flw f air int cab. When cntrl is pulled, fresh air is vented int cab. 4 DEFR (Defrst) Cntrl Cntrls windshield defrsting. Air is ruted frm the heater t defrst the windshield when cntrl is pulled CTIS Electrnic Cntrl Unit

27 Figure 5.8. CTIS Electrnic Cntrl Unit. Table 5.8. CTIS Electrnic Cntrl Unit. Key Gauge/Cntrl/Instrument Descriptin 1 HWY (Highway) Mde Pressed t set CTIS in highway mde. Indicatr Buttn and Indicatrs illuminates steady when tire pressure is 55 psi. 2 X-C (Crss Cuntry) Mde Buttn and Indicatr Pressed t set CTIS in crss-cuntry mde. Indicatr illuminates steady when tire pressure is 33 psi. 3 SAND (Sft Terrain) Mde Buttn and Indicatr 4 EMER (Emergency) Mde Buttn and Indicatr 5 RUN FLAT Mde and Indicatr CTIS Operatin Nrmal CTIS Operatin. Maximum speed at this setting is 40 mph. Pressed t set CTIS in sft terrain mde. Indicatr illuminates steady when tire pressure is 20 psi. Maximum speed at this setting is 12 mph. Pressed t set CTIS in emergency mde. Indicatr lights steady when tire pressure is 14 psi. Maximum speed is 5 mph in EMER mde. Mde used t maintain tire pressure in the event f a leak.

28 Figure 5.9. Nrmal CTIS Operatin. Table 5.9. Nrmal CTIS Operatin. 1 2 Step Descriptin Start engine. Nte: If vehicle is stpped when CTIS mde is changed, it may be necessary t increase engine speed t prvide adequate air supply t tires. CTIS will autmatically shut-ff when air system pressure drps belw 74 psi *510 Kpa) r when CTIS malfunctin ccurs. Slwly press dwn n acceleratr pedal (1) if FRONT BRAKE AIR pressure gauge (2) and REAR BRAKE AIR pressure gauge (3) read less than 100 psi (690 kpa). Mde light n CTIS ECU will flash when tire pressure is changing t air pressure setting fr that mde. Mde light will illuminate steady when tire reaches air pressure setting fr that mde.

29 3 4 Press apprpriate CTIS mde buttn (4) fr vehicle speed and terrain cnditins (Refer t the TO r manufacturer s peratr s manual fr tire pressures and restrictins). If average speed f vehicle exceeds speed limit f selected CTIS mde fr ne minute, CTIS OVRSPD indicatr will flash. If average speed f vehicle exceeds speed limit f selected CTIS mde fr tw minutes, CTIS will autmatically inflate tires t pressure setting f next higher mde. If CTIS OVRSPD indicatr (5) flashes, reduce vehicle speed until CTIS OVRSPD indicatr ges ut. Check that CTIS mde light (6) illuminates steady. Steady illuminatin f CTIS mde light indicates vehicle speed is crrect fr CTIS mde selected Reset CTIS. Figure Reset CTIS If all five CTIS ECU mde lights flash, perfrm steps (1) thrugh (4): (1) Psitin master pwer switch (1) t ff (2) Psitin master pwer switch (1) t n (3) Press RUN FLAT mde buttn (2) n CTIS ECU (3) (4) Start engine.

30 CTIS RUN FLAT Mde CTIS peratin in RUN FLAT mde is limited t 10 minutes. T cntinue perating CTIS in RUN FLAT mde after 10 minutes, RUN FLAT mde buttn must be pressed again r CTIS will shut dwn cmpletely. Failure t cmply may result in damage t equipment CTIS is perated in RUN FLAT mde when tire(s) have been punctured, RUN FLAT mde causes CTIS t check tire pressure every 15 secnds (nrmal interval is every 15 minutes). If lw air pressure is sensed, CTIS will supply air in wet tank t leaking tire(s) every 15 secnds. Figure CTIS RUN FLAT Mde. Table CTIS RUN FLAT Mde. Step Descriptin 1 Press RUN FLAT mde buttn (1). RUN FLAT mde light (2) will illuminate when CTIS is perating in RUN FLAT mde. 2 If perating CTIS in RUN FLAT mde is n lnger required, press RUN FLAT mde buttn (1) again. RUN FLAT mde light (2) will g ut. 3 Change leaking tire(s) as sn as pssible Additinal Cntrls.

31 Figure Additinal Cntrls. Table Additinal Cntrls. Cntrl Descriptin 1 Hrn Buttn Sunds hrn when pressed. 2 Windshield Activates windshield washer when pushed in. Washer Switch 3 Windshield Wiper Switch Fur psitin switch used t perate and cntrl the speed f the windshield wipers. Windshield wipers perate at lw r high speed 4 Turn Signal/Headlight Dimmer Cntrl 5 Steering Wheel Tilt/Telescpe Cntrl when switch is placed in the I r II psitin respectively. Operates turn signals and cntrls headlight dimming. Right turn signal and indicatr will flash when cntrl is mved up. Left turn signal and indicatr will flash if cntrl is mved dwn. Headlight dimming is cntrlled by pulling the cntrl tward the peratr. High Beam Indicatr illuminates when high beam headlights are n. Adjusts angle and height f steering wheel Hydraulic Cntrl Manifld is lcated n the right side f the vehicle adjacent t the tlbx. The Backup Pump frward f the tlbx is used if air is nt available in the vehicle air system.

32 Figure Hydraulic Cntrl Manifld. Table Hydraulic Cntrl Manifld. Cntrl 1A Cab TILT Knb 2A SPARE TIRE Knb 3A SUSPENSION Knb 4A FUNCTION SELECT Knb 5A PUMP Knb 6A CAB Knb 1B XMSN (Transmissin) DIP STICK 2B NATO Receptacle 3B Hydraulic Reservir Gauge 4B Engine Oil Dipstick 5B Radiatr Overflw Tank Sight Glasses 6B Pwer Steering Dipstick Descriptin Allws the peratr t select t raise r lwer the cab. Allws the peratr t select t raise r lwer the spare tire. Allws the peratr t raise r lwer the suspensin. Selectin determines which cmpnent will receive the hydraulic pressure. Pushing in and hlding PUMP Knb will activate selected system. Pull ut and turn left t deflate cab air springs. Push and turn knb t the right t inflate cab air springs. Indicates il level in the transmissin. Receptacle used fr starting the vehicle using external pwer. (if applicable) Only used n vehicles with a winch. Indicates il level in the engine. Tp sight glass indicates safe clant level with the engine nt running. Indicates il level in the pwer steering reservir Air/Hydraulic Pwer Unit is lcated behind the cab t the left f the spare tire. This is the pump which raises the cab, lwers the spare tire, etc. The dipstick fr checking hydraulic il level is lcated n the bdy f the pump husing.

33 Figure Air/Hydraulic Pwer Unit Carg Bed sides and tailgate may be remved and stred creating a flatbed truck. Strage is prvided in cmpartments belw the bed. (See belw). Figure Carg Bed Center stakes and rear stakes may als be remved and stred in a cmpartment at the frnt f the bed. (Requires a wrench t remve retaining blt).

34 Figure Stwage Cmpartments A ladder is available fr aiding in access t the bed. It is lcated between the frame rails at the rear f the bed. A lcking pin keeps it in the stred psitin. Tw rectangular hles are available in the bed int which t insert the hks n the ladder. The plugs are held in by a retaining pin under the rear f the bed. Figure Ladder and Lcking Pin Pintle Hk.

35 Figure Pintle Hk (1) Latch - lift t pen upper jaw (2) Upper Jaw (3) Lwer Jaw (4) Latch Pin. Mst pintle hks have just a ctter pin which must be safety wired t prevent it frm falling ut. We have supplied each pintle hk with a slid pin with a spring safety device t eliminate the safety wire Wear prtective glves while attaching/un-attaching the trailer frm the pintle hk. Nte: Be sure the latch (1) is cmpletely dwn befre installing pin, therwise it culd pen. Mre detailed infrmatin is available in the Operatr's Manual, TO 36Al2-1B-1095-l (M-1078) r 36A l 2-1C-1091 (M-1083) Maintenance Prcedures Tire changing prcedures Initial set-up Vehicle parked n level grund Engine shutdwn Wheels chcked Cab raised.

36 Tls Jack, hydraulic Wrench, scket Changing Lwer Spare Tire. Nte: Warning Ensure vehicle is parked n level grund befre changing flat tire. Vehicle may rll. Failure t cmply may result in serius injury r death t persnnel. Figure Changing Lwer Spare Tire (1 f 3) Step 1. Release latch (1) n ratchet (2) Step 2. Lift ratchet (2) and release strap (3) Step 3. Remve strap (3) frm ratchet (2) Step 4. Discnnect safety chain (4) frm spare tire retainer (5). Cautin Ratchet must be in the clsed psitin befre cab is lwered. Failure t cmply may result in damage t equipment.

37 Figure Changing Lwer Spare Tire (2 f 3) Step 5. Place ratchet (2) in clsed psitin. Figure Changing Lwer Spare Tire (3 f 3) Step 6. Remve strap (3) and safety chain (4) frm spare tire retainer (5) Step 7. Lwer cab.

38 Figure Spare Tire Functin Knb Step 8. Turn SPARE TIRE knb (6) t the LOWER psitin Step 9. Turn FUNCTION SELECT knb (7) t the SPARE TIRE psitin. Nte: WARNING Tire weighs apprximately 350 lbs (159 kgs). If treads f tire catch n tl bx during lwering, raise tire and pull tire away frm tl bx and cntinue lwering. Use extreme care when lwering r handling tire. Failure t cmply may result in injury t persnnel. Use cautin when lwering tire t prevent damage t CTIS wheel valve. Failure t cmply may result in damage t equipment. Use backup hydraulic pump if pressing PUMP knb des nt accmplish step (10) Step 10. Press and hld PUMP knb (8) t lwer spare tire (9) t grund.

39 Figure Lwer Spare Tire Step 11. Discnnect ne end f the chain (10) frm spare tire retainer lift arm (11) Step 12. Pull chain (10) thrugh hle in spare tire (9) Step 13. Hk chain (10) t spare tire retainer lift arm (11). Figure Hk Chain t Retainer.

40 Step 14. Remve nut (12), tw washers (13), and blt (14) frm CTIS hse (15). Figure Remve Nuts/Washers/Blts Tire Remval. Warning Place hydraulic jack n flat surface. D nt allw persnnel under vehicle when jacking. Failure t cmply may result in serius injury r death t persnnel. Figure Tire Remval Tl Bx.

41 Step 1. Remve hydraulic jack (1) and handle (2) frm tl bx. Nte: Perfrm steps (2) and (3) when remving frnt tire. Figure Psitin Hydraulic Jack Step 2. Psitin hydraulic jack (1) under saddle (3) f leaf spring (4) Step 3. Unscrew jack ram (5) until it tuches saddle (3). Nte: Perfrm steps (4) and (5) when remving rear tire Step 4. Psitin hydraulic jack (1) under inside blt head n shck munt (6). Figure Psitin Hydraulic Jack (cntinued) Step 5. Unscrew jack ram (5) until it tuches shck munt (6).

42 Nte: Bth frnt and rear tires are remved the same way. Rear tire shwn. Air will nt escape when CTIS hse is remved frm hllw wheel stud. Figure Remval f Blts/Washers Step 6. Remve banj blt (7), tw washers (8), and CTIS hse (9) frm hllw wheel stud (10). Nte: Studs and lug nuts n left side f vehicle have left-hand threads. Turn lug nuts t right t lsen, and turn left t tighten. Studs and lug nuts n right side f vehicle have right-hand threads. Turn lug nuts t left t lsen, and t right t tighten. Figure Lsen Lug Nuts Step 7. Lsen ten lug nuts (11).

43 Figure Raise Hydraulic Jack Step 8. Raise hydraulic jack (1) until tire (12) is ff grund. Warning Tire weighs apprximately 350 lbs (159 kgs). Use extreme care when handling tire. Failure t cmply may result in injury t persnnel. Figure Remval f Lug Nuts Step 9. Remve ten lug nuts (11) frm studs (13). Cautin D nt drag tire acrss studs during remval. Failure t cmply may result in damage t equipment Step 10. Remve tire (12) frm studs (13). Nte: This step requires the aid f an assistant Tire Installatin. Nte: Steps (1) thrugh (5) require the aid f an assistant.

44 Figure Tire Installatin Step 1. Rll tire (1) up t hub (2). Nte: Frnt and rear tires are installed the same way. Rear tire installatin is shwn Step 2. Align CTIS hse (3) with hllw wheel stud (4) Step 3. Align ten hles (5) in wheel (6) with studs (7). Cautin D nt drag tire acrss studs r crss thread lug nuts. Failure t cmply may result in damage t equipment. Figure Installatin f Wheel Step 4. Install wheel (6) n studs (7).

45 Figure Tightening Sequence. Nte: Warning Ntify Unit Maintenance that lug nuts must be tightened t lb-ft ( N m) as sn as pssible. Tire may cme lse if lug nuts are nt tightened t prper trque. Failure t cmply may result in serius injury r death t persnnel Step 5. Install ten lug nuts (8) n studs (7) in sequence shwn. Nte: Studs and lug nuts n left side f vehicle have left-hand threads. Turn lug nuts t right t lsen, and t left t tighten. Studs and lug nuts n right side f vehicle have right-hand threads. Turn lug nuts t left t lsen, and t right t tighten Step 6. Lwer vehicle t grund with hydraulic jack (9). Figure Psitin f Hydraulic Jack Step 7. Remve hydraulic jack (9) and handle (10) frm vehicle.

46 Figure Tlbx Step 8. Stw hydraulic jack (9) and handle (10) in tlbx. Figure Installatin f Nuts Step 9. Install CTIS hse (3) n hllw wheel stud (4) with tw washers (11) and banj blt (12). Cautin D nt ver tighten banj blt when installing CTIS hse n hllw wheel stud. Failure t cmply may result in damage t equipment.

47 Tire Stwage. WARNING: Handle tire with care. Tire may have expsed brken metal crds r sharp debris in it. Failure t cmply may result in injury t persnnel. Tire weighs apprximately 350lbs (159kgs). Use extreme care when handling tire. Failure t cmply may result in injury t persnnel. Figure Installatin f Lug Nuts Step 1. Install blt (1), tw washers (2) and nut (3) in CTIS hse (4) Step 2. Rll flat tire (5) under center f spare tire retainer lift arm (6) Step 3. Discnnect ne end f chain (7) frm spare tire retainer lift arm (6). Nte: The valve n tire must be psitined t the frnt f vehicle and at the 6 'clck psitin. Flat tire shuld be straight up and dwn when installing chain thrugh lug hle. Figure Hk Tire t Retainer Step 4. Rute chain (7) thrugh uppermst lug hle (8) in wheel (9).

48 Step 5. Cnnect chain (7) t spare tire retainer lift arm (6). Cautin Use cautin when raising tire t prevent damage t CTIS valve. Failure t cmply may result in damage t equipment. Figure Raise Tire Tl Bx Step 6. Raise cab Step 7. Turn SPARE TIRE knb (10) t the RAISE Psitin Step 8. Turn FUNCTION SELECT knb (11) t the SPARE TIRE psitin Cautin Tire must be stwed against back frame f spare tire retainer (fr all mdels except Air Drp vehicles). Failure t cmply may result in damage t equipment. Nte: Use backup hydraulic pump (para 2-41) if pressing PUMP knb des nt accmplish step (9).

49 Figure Pump Knb Step 9. Press and hld PUMP knb (12) t raise spare tire retainer lift arm (6) t the stwed psitin. Nte: Cautin Tread engagers must be in slts f tire treads. A lse strap will allw tire t mve causing chafing f strap and pssible lss f tire. Failure t cmply may result in damage t equipment. Tread engagers must nt be snug at installatin fr prper fit, but strap must have a tight fit. Failure t cmply may result in damage t equipment.

50 Figure Tread Engager Step 10. Psitin tread engager (13) in third tread (14), tread engager (15) in sixth tread (16), and tread engager (17) in ninth tread (18) Step 11. Cnnect strap (19) t spare tire retainer (20). Figure Strap thrugh Ratchet Step 12. Feed ther end f strap (19) thrugh ratchet (21). Cautin Ensure that strap is wrapped arund ratchet at least three cmplete wraps after tightening. Failure t cmply may result in damage t equipment.

51 Step 13. Tighten strap (19) arund flat tire (5) with ratchet (21) and clse latch (22). Figure Safety Chain Step 14. Cnnect safety chain (23) t spare tire retainer (20). Cautin Ensure that safety chain is lse. If safety chain is tight then strap is nt tight enugh. Failure t cmply may result in damage t equipment Step 15. Rute ther end f safety chain (23) thrugh flat tire (5) and cnnect t spare tire retainer (20). Figure Safety Chain (cntinued) Step 16. Lwer cab.

52 Self Recvery Winch (SRW) Guidelines fr light medium tactical vehicle (LMTV) (if applicable) The SRW is lcated aft f the fuel tank n the passenger side, winch is fr frward r aft peratin and may be used 15 degrees left r right ff centerline as any additinal bend will affect pulling capability, winch peratin and can led t damage r injury if nt prperly fllwed Safety: Winch use is extremely hazardus and shuld nly be used by qualified and safety minded persnnel Mandates that the winch will be fully extended, checked fr fraying, cnditin, and prper peratin/mvement bi-annually (i.e. summer and winter ps changever) and befre any actual recvery peratins take place Spling Cable t Frnt f Vehicle. Nte: Warning Wear heavy leather-palmed wrk glves when handling cable. Cables can becme frayed r cntain brken wires. Never let mving cable slide thrugh hands, even when wearing glves. Failure t cmply may result in injury t persnnel Step 1. Shut dwn engine (WP 0019) Step 2. Remve retaining pin (1), pin (2), and rller (3) frm rear rller supprt (4). Figure Rller Supprt.

53 Step 3. Remve cable (5) frm rear rller supprt (4). Nte: Install Retaining pin s that clasping end is tward curbside f vehicle. Figure Spling Cable Retaining Pin Step 4. Install rller (3) in rear rller supprt (4) with pin (2) and retaining pin (1). Figure Rller Supprt Step 5. Remve cable (5) frm rear cable pulley (6).

54 Figure Cable Pulley Step 6. Remve cable (5) frm rear cable guide (7) n 15K SRW (8). Figure Cable Psitin Step 7. Psitin cable (5) tward frnt f vehicle Step 8. Install cable (5) thrugh frnt cable guide (9) n l5k SRW (8).

55 Figure Install Cable Step 9. Install cable (5) thrugh cable guide (10) behind fuel tank (11). Figure Install Cable (cntinued) Step 10. Install cable (5) thrugh frnt cable pulley (12).

56 Figure Retaining Pin Step 11. Remve retaining pin (13), pin (14), and rller (15) frm frnt rller supprt (16). Figure Remve Headlight Bracket Step 12. Install cable (5) thrugh frnt rller supprt (16). Nte: Install retaining pin s that clasping end is tward curbside f vehicle.

57 Figure Install Rller Step 13. Install rller (15) n frnt rller supprt (16) with pin (14) and retaining pin (13). Figure Spling Cable Spling Cable t Rear f Vehicle Step 1. Shut dwn engine (WP 0019).

58 Figure Headlight Bracket Retaining Pin Step 2. Remve retaining pin (13), pin (14), and rller (15) frm frnt rller supprt (16). Warning Wear heavy leather-palmed wrk glves when handling cable. Cables can becme frayed r cntain brken wires. Never let mving cable slide thrugh hands, even when wearing glves. Failure t cmply may result in injury t persnnel Step 3. Remve cable (5) frm frnt rller supprt (16). Nte: Install retaining pin s that clasping end is tward curbside f vehicle Step 4. Install rller (15) n frnt rller supprt (16) with pin (14) and retaining pin (13). Figure Remve Cable Step 5. Remve cable (5) frm frnt cable pulley (12).

59 Figure Cable Pulley Step 6. Remve cable (5) frm cable guide (10) behind fuel tank (11). Figure Frnt Cable Guide Step 7. Remve cable (5) frm frnt cable guide (9) n l5k SRW (8).

60 Figure Psitin Cable Step 8. Psitin cable (5) tward rear f vehicle Step 9. Install cable (5) thrugh rear cable guide (7) n 15K SRW (8). Figure Install Cable Step 10. Install cable (5) thrugh rear cable pulley (6).

61 Figure Rear Rller Supprt Step 11. Remve retaining pin (1), pin (2), and rller (3) frm rear rller supprt (4). Figure Rear Rller Supprt (cntinued) Step 12. Install cable (5) thrugh rear rller supprt (4).

62 Figure Rear Rller Supprt (cntinued) Step 13. Install rller (3) in rear rller supprt (4) with pin (2) and retaining pin (1). Warning Ensure line pull des nt exceed capacity f 15K SRW. Failure t cmply may result in serius injury r death t persnnel. Nte: Cautin Ensure that supply valve and return valve n M1083A1P2 are pen befre perating hydraulic equipment. Failure t cmply may result in damage t equipment. Figure Install Rller with Pin K SRW Operatin Step 1. Shut dwn engine (WP 0019).

63 Warning There must always be at least five wraps f cable n 15K SRW. If lad is applied with less than five wraps f cable n 15K SRW, cable may cme lse n drum. Failure t cmply may result in serius injury r death t persnnel. Nte: Cautin D nt attempt t pull lad ver 15K SRW capacity. Failure t cmply may result in damage t equipment SRW peratin is the same fr the frnt and rear. Frnt peratin is shwn Step 2. Psitin 15K SRW clutch cntrl lever (17) t DISENGAGED Wear heavy leather palmed wrk glves when handling cable. Cables can becme frayed r cntain brken wires. Never let mving cable slide thrugh hands, even when wearing glves. Failure t cmply may result in injury t persnnel. Nte: Cautin D nt attach cable t any bject mre than apprximately 15 degrees away frm a straight 15K SRW pull. Failure t cmply may result in damage t equipment. Figure Clutch Cntrl Lever Step 3. Pull ut cable (5) and attach t secure bject Warning Keep all persnnel clear f area when tensin is n cable. Failure t cmply may result in serius injury r death t persnnel.

64 Figure Cable Attach t Object Step 4. Psitin 15K SRW clutch cntrl lever (17) t ENGAGED Step 5. Start engine (WP 0019). Figure K Self Recvery Winch Step 6. Psitin PTO switch (18) t n Step 7. Psitin winch switch (19) t n.

65 Step 8. Hld WINCH IN/OUT switch (20) in the WINCH IN psitin until vehicle is recvered Step 9. Release WINCH IN/OUT switch (20) Step 10. Pull ut PARKING BRAKE cntrl (21). Figure Parking Brake Cntrl Step 11. Remve cable (5) frm secure bject.

66 Figure Reel Cable Step 12. Hld WINCH IN/OUT switch (20) in the WINCH IN psitin t reel in cable (5) until cable scket (22) cntacts rllers (3). Figure Reel Cable (cntinued) Step 13. Psitin winch switch (19) t ff Step 14. Psitin PTO switch (18) t ff Step 15. Shut dwn engine (WP 0019).

67 Figure Psitin Switch Rigging. Rigging is applying wire rpe in varius tackle cmbinatins t raise r mve lads. Rigging invlves installing the necessary equipment t use the available effrt (AE), and it may r may nt prduce MA Rigging Fundamentals Fall line A fall line is the winch line that runs frm the surce f effrt t the first blck in the tackle There is nly ne fall line in a simple tackle system. The amunt f frce that must be exerted n the fall line relative t the AE must be cnsidered in every prblem The fall line frce must be less than the capacity f the effrt t accmplish the recvery.

68 Figure Terminlgy f Simple Tackle Return line A return line is a winch line rigged between the blck r the winch line frm the sheave f a blck t the pint where the end f the line is attached. This frce is always the same as the fall line frce Dead line A dead line is a line used t attach blcks r ther equipment t the lad r t an anchr. T determine the dead line frce, multiply the fall line frce by the highest number f winch lines supprted by the dead line Fleet angle Achieving even winding f the winch cable n the drum is imprtant fr wire rpe life and winch peratins. This is best accmplished by wrking with the prper fleet angle Figure displays the wire rpe running frm a fixed sheave, ver flating sheaves, and then nt the surface f a smth drum. The fleet angle is defined as the included angle between tw lines One line is drawn thrugh the middle f the fixed sheave and the drum and perpendicular t the axis f the drum A secnd line is drawn frm the flange f the drum t the base f the grve in the fixed sheave.

69 Figure Fleet Angle There are left and right fleet angles, measured t the left and right f the centerline f the sheave. The fleet angle shuld be restricted when wire rpe passes ver a fixed sheave and nt a drum Fr the mst efficient methd and best service, the angle shuld nt exceed 1½ degrees, fr mst vehicles. Refer t the equipment peratr s manual fr specific infrmatin n fleet angles. Nte: Althugh many vehicles have winches that can safely perate at higher fleet angles, maximum stability and perfrmance is achieved at lesser fleet angles Mechanical Advantage (MA) f tackle MA is needed whenever the lad resistance is greater than the AE. The amunt f MA needed is estimated by dividing the lad resistance by the AE. The MA f any simple tackle system is equal t the number f winch lines supprting the lad r the number f winch lines that becme shrter as pwer is applied t the winch (Figure 5.77.). The lines can be attached directly r indirectly thrugh a blck.

70 Placement f the blck is critical t gaining MA. The blck must be attached t the mvable lad and effrt applied in the ppsite directin t divide the effrt equally ver the tw lines. The arc ver the lines indicates lines that supprt the lad (Figure 5.77.). Nte: The 1-t-1 rati shwn has an arc ver nly ne line indicating the blck is simply changing the directin f effrt. N MA is gained in this cnfiguratin. Figure Winch Line(s) Mechanical Advantage Determine Line Frces: The fllwing example shws hw t cmpute varius line frces. A disabled vehicle had a lad resistance f 14 tns (28,000 punds). The AE is a winch with a maximum capacity f 5 tns (10,000 punds). What MA must be rigged t recver this vehicle? What are the line frces?

71 Figure Determine Line Frces.

72 Figure t-1 Mechanical Advantage. Nte: If field expedient slings are used as deadlines, refer t FM t determine sling leg frces. Field expedient slings are cnsidered slings that are cnstructed using materiel nt part f the recvery vehicle s BII Methds f Rigging: The rigging techniques used depend n terrain, the type f vehicle, and the distance between the recvery vehicle and the disabled vehicle. Manpwer, backup, and lead methds fr rigging techniques are discussed belw Manpwer methd. The manpwer methd is used when the winch cable and ther rigging equipment are lightweight and can be carried easily by the crewmembers t where they are needed. This methd depends cmpletely n Sldier manpwer Backup methd. The backup methd is used when the recvery vehicle can be safely psitined within 20 t 25 feet f the disabled vehicle Pull ut enugh main winch cable t attach t the disabled vehicle Place the main winch snatch blck in the lp f the cable and attach the blck t the disabled vehicle Back up the recvery vehicle, allwing the main winch cable t be spled frm the winch drum until sufficient cable is remved t btain maximum winch capacity Cab Raising/Lwering Guidelines fr the LMTV (if applicable).

73 Raising/lwering cab. Raising/lwering the cab shuld nly be perfrmed by qualified and safety minded persnnel befre prcedure. Nte: Warning Engine cmpartment and accessries may be extremely ht when engine is running r has been running recently. Use cautin arund engine when cab is raised. Failure t cmply may result in injury t persnnel. Engine cmpartment cntains a partially expsed fan blade. Use extreme cautin arund frnt f engine. Failure t cmply may result in injury t persnnel Raising Cab Step 1. Remve quick release pin (1) frm switch bx cver (2) Step 2. Open switch bx cver (2) n electric hydraulic switch bx (3). Figure Raising Cab Switch Bx Step 3. Psitin NORMAL OPERATION/AIR TRANSPORT switch (4) t NORMAL OPERATION. Nte: Switches must be held in perating psitin while cnducting the raise cab functin.

74 Figure Raising Cab Switch Bx (cntinued) Step 4. Psitin and hld CAB switch (5) t RAISE until cab is fully raised Warning Never raise cab while ccupied r when parked uphill n a steep grade. Failure t cmply may result in serius injury r death t persnnel. Ensure bth drs are securely clsed befre cab is raised D nt allw persnnel near cab when cab is being raised. Failure t cmply may result in serius injury r death t persnnel r damage t equipment Remve all lse bjects frm cab befre raising the cab. Failure t cmply may result in damage t equipment. Cab height is higher than nrmal when raised. Ensure area abve and in frnt f cab is adequate befre raising the cab. Nte: Use backup hydraulic pump if temperature is belw -25 F (-32 C) r if pressing CAB switch des nt accmplish step 4.

75 Figure Raising Cab Switch Bx (cntinued) Lwering Cab Step 1. Psitin NORMAL OPERATION/AIR TRANSPORT switch (4) t NORMAL OPERATION. Nte: Warning Ensure bth drs are securely clsed befre cab is lwered. D nt allw persnnel near cab when cab is being lwered. Failure t cmply may result in serius injury r death t persnnel r damage t equipment.

76 Figure Switch Bx Step 2. Psitin and hld CAB switch (5) t LOWER until cab is fully lwered. Nte: Switches must be held in perating psitin while cnducting the varius functins. If the NORMAL OPERATION/AIR TRANSPORT switch is n air transprt mde, the cab ride height limit switch is deactivated and the rear leveler cylinders will cmpletely retract. When the NORMAL OPERATION/AIR TRANSPORT switch is psitined in NORMAL OPERATION, the cab will raise autmatically t its preset ride height when the master pwer is ON r the engine is running. If the ignitin is n while lwering the cab, it will lwer but will autmatically raise up t its preset ride height. The rear cylinders will nt stay lwered cmpletely. Use backup hydraulic pump if temperature is belw -25 F (-32 C) r if pressing CAB switch des nt accmplish step 2.

77 Figure Switch Bx (cntinued) Step 3. Check buttn (6) psitin t cnfirm cab is latched Warning Cab hydraulic latch must be lcked befre driving vehicle. Failure t cmply may result in serius injury r death t persnnel r damage t equipment. Nte: Buttn n right end f cab hydraulic latch shws status f latch. Buttn pressed in shws cab is latched. Buttn ut shws cab is nt latched.

78 Figure Latch Cab Step 4. Clse switch bx cver (2) n electric hydraulic switch bx (3) Step 5. Install quick release pin (1) in switch bx cver (2). Figure Switch Bx (cntinued).

79 Sectin 6 EXPLANATION AND DEMONSTRATION Instructr s Preparatin Establish a training lcatin Obtain apprpriate vehicle peratr s manual Schedule/reserve a vehicle Ensure trainee cmpletes AF Frm Safety Prcedures and Equipment The fllwing safety items shuld be fllwed by bth the instructr and trainee Chck wheel (if required) when versized carg M-series truck is parked Remve all jewelry and identificatin tags Persnal prtective equipment and equipment items Safety steel-ted bts must be wrn Glves will be wrn during carg lading and unlading First aid kit Raingear, cld weather gear, etc Reflective belt during hurs f reduced visibility r n the flightline Hearing prtectin Walk arund vehicle t becme familiar with and t familiarize and the trainee with all warning labels and signs Ensure trainee wears seatbelts Prperly adjust driver s seat and all mirrrs, if available Thrughut demnstratin, practice versized carg M-series truck safety Practice basic RM prcess during demnstratin: Identify hazards.

80 Assess hazards Develp cntrls and make decisins Implement cntrls Supervise and evaluate Operatr Maintenance Demnstratin With trainee, accmplish vehicle inspectin using AF Frm The vehicle inspectin will fllw the seven-step methd as described in Attachment 4. An inspectin guide (Attachment 2) can be used t ensure all areas f the tractr and trailer are cvered in additin t the Operatin Demnstratin guidelines prvided belw Operatin Demnstratin Thrughut demnstratin: Allw fr questins Repeat demnstratins as needed Fr all versized carg M-series trucks, within the training area, demnstrate and explain the fllwing. Nte: Use infrmatin cntained n the data plate and/r the peratr s manual Specific versized carg M-series truck capacities: Explain parking brake as they apply t versized carg M-series truck being used Oversized carg M-series truck cntrls Shifting pattern Overdrive Pint ut the items t be inspected during peratins Instruments Air pressure gauge (if the vehicle has air brakes) Temperature gauges Pressure gauges.

81 Ammeter/vltmeter Mirrrs Tires Carg, carg cvers Demnstrate the fllwing versized carg M-series truck peratins (use sptter when backing) Frward stp (see fllwing example fr bundary setup) Drive frward between the tw rws Bring vehicles t a cmplete stp as clse t the bundary Backing Always use a sptter when backing The sptter and peratr must maintain visual cntact at all times. If visual cntact is lst, the peratr must immediately stp the vehicle See AFMAN fr additinal guidance n standard AF sptter hand signals and safety Parking Right turn (see fllwing example fr bundary set-up) Drive frward and make a right turn arund a cne Bring right rear wheel(s) f the vehicle as clse t the base f the cne as pssible withut hitting it Demnstrate securing carg (if applicable t vehicle type) Demnstrate twing peratin/winch peratin (if applicable) With the versized carg M-series truck, demnstrate driving n a rad curse Turns (Left/Right) Intersectins.

82 Urban/rural straight Expressway Start/stp Curves Upgrades/Dwngrades Lcal ff-rad driving. Nte: curse must be apprved by Security Frces and the Installatin Occupatinal Safety Office Shw trainee the after peratin inspectin and reprt Ensure vehicle is cleaned Carg straps and chains are prperly stwed Refuel vehicle Fllwing manufacturer s shut-dwn prcedures Park Apply brakes Place transmissin in neutral (park r an autmatic) Perfrm a walk arund inspectin Anntate any discrepancies fund n AF Frm Cnclude by allwing time fr questins and any requested re-demnstratins. Sectin 7 TRAINEE PERFORMANCE AND EVALUATION 7.1. Trainee Perfrmance Instructr will: Ensure safety at all times. Nte: Stp training when safety items are vilated. Prceed nly when the trainee fully understands hw t avid repeating the safety infractin(s).

83 Chck wheel (if required) when versized carg M-series truck is parked Remve all jewelry and identificatin tags. Nte: If available, mark vehicle with magnetic sign indicating Driver-in-Training r Trainee Operatr Persnal prtective equipment (PPE) and ther items: Safety steel-ted bts must be wrn Glves will be wrn during carg lading and unlading First aid kit Reflective belt during hurs f reduced visibility r n the flightline Raingear, cld weather gear, etc Hearing prtectin Pay particular attentin t the cautins and warnings listed in the peratr's manual Ensure trainee wears seatbelts Prperly adjust driver s seat and all mirrrs Oversized carg M-series truck safety items/prcedures Ensure the driver is aware f driving situatins he/she is t perfrm Cnduct during/after-actin reviews with the trainee (demnstratin may need t be re-accmplished) Trainee Perfrmance Cnduct peratr maintenance (have trainee explain items being inspected). Nte: Allw trainee t use Attachment 2 as a guide while perfrming inspectin Pre-inspectin During-inspectin Ensure AF Frm 1800 is prperly dcumented.

84 Establish a rad curse that will have the fllwing: (if the curse des nt have ne f the fllwing, then the trainee shuld be able t explain the crrect driving techniques) Turns (Left/Right) Lane change maneuvers Intersectins Urban/rural straight Start/stp Curves Upgrades/Dwngrades Backing Serve as the trainee s sptter, r if available, have anther trainee be the sptter Parking Lcal ff-rad driving. Nte: Curse must be apprved by Security Frces and the Installatin Occupatinal Safety Office Cntinue until trainee can shw prficiency in perating Have trainee practice the versized carg M-series truck peratins listed belw (use sptter when backing) until they can safely and efficiently perfrm Securing carg, have trainees secure different types f carg, if applicable t vehicle type Demnstrate twing peratin/winch peratin (if applicable) Perfrm pst-peratin inspectin Ensure vehicle cleaned Carg straps and chains are prperly stwed Refueled.

85 Fllwing manufacturer s shut-dwn prcedures Park Apply brakes Place transmissin in neutral (park r an autmatic) Perfrm a walk arund inspectin Reprt any discrepancies fund n AF Frm Perfrmance Evaluatin Trainee will perfrm perfrmance evaluatin fund in Attachment Instructr and trainee will review Attachment Instructr will answer trainee s questins. Nte: If available, mark vehicle with magnetic sign indicating Driver-in-Training r Trainee Operatr Instructr will: Ensure safety at all times Place wheel chcks (if required) when versized carg M-series truck is parked, Remve all jewelry and identificatin tags PPE and ther items Safety steel-ted bts must be wrn Glves will be wrn during carg lading and unlading First aid kit Reflective belt during hurs f reduced visibility r n the flightline Hearing prtectin Pay particular attentin t the cautins and warnings listed in the peratr's manual.

86 Ensure trainee wears seatbelts Prperly adjust driver s seat and all mirrrs (if available) Oversized carg M-series truck safety items/prcedures Explain driving techniques Establish a rad curse that will have the fllwing: (if the curse des nt have ne f the fllwing, then the trainee shuld be able t explain the crrect driving techniques) Establish a rad curse that will have the fllwing: (if the curse des nt have ne f the fllwing, then the trainee shuld be able t explain the crrect driving techniques) Turns (Left/Right) Lane change maneuvers Intersectins Urban/rural straight Curves Upgrades/Dwngrades Backing Parking Lcal ff-rad driving. Nte: Curse must be apprved by Security Frces and the Installatin Occupatinal Safety Office Ensure the driver is aware f driving situatins Cnduct after-actin reviews with the trainee Trainee is nt allwed any instructr assists t pass perfrmance evaluatin Evaluatin checklist prvided in Attachment Retraining; retrain N-G s Re-demnstrate N-G items.

87 Have trainee re-perfrm until they shw prficiency in perating, critique weaknesses as bserved Re-evaluate.

88 Attachment 1 GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION References AFI , Vehicle Operatins, 5 May 2016 AFMAN , Operatin f Air Frce Gvernment Mtr Vehicles, X January 2017 AFPAM , Risk management (RM) Guidelines and Tls, 11 February 2013 AFI , Air Frce Cnslidated Occupatinal Safety Instructin, 12 June 2012 Adpted Frms AF Frm 171, Request fr Driver s Training and Additin t U.S. Gvernment Drivers, 15 March 2011 AF Frm 847, Recmmendatin fr Change in Publicatin AF Frm 1800, Operatr s Inspectin Guide and Truble Reprt Abbreviatins and Acrnyms AE Available Effrt AF Air Frce AFI Air Frce Instructin AFIMSC Air Frce Installatin and Missin Supprt Center AFMAN Air Frce Manual AFQTP Air Frce Qualificatin Training Plan BO Blackut CTIS Central Tire Inflatin System ECU Electrnic Cntrl Unit FOD Freign Object Damage IAW In Accrdance With KPH Kilmeters Per Hur LMTV Light Medium Tactical Vehicle MA Mechanical Advantage MPH Miles Per Hur PPE Persnal Prtective Equipment PSI Punds Per Square Inch PTO Pwer Take-ff RM Risk Management RPM Revlutins Per Minute SRW Self Recvery Winch TO Technical Order VCNCO Vehicle Cntrl Nn Cmmissined Officer VCO Vehicle Cntrl Officer

89 Attachment 2 OVERSIZED CARGO M-SERIES TRUCK INSPECTION GUIDE GENERAL STEP 1. VEHICLE OVERVIEW Paperwrk AF Frm 1800 Discrepancy Crrectin Cmplete (VM Anntatin) Vehicle Apprach Damage Vehicle Leaning Fresh Leakage f Fluids Hazards Surrunding Vehicle INTERNAL STEP 2. ENGINE COMPARTMENT Leaks/hses/Electrical Wiring Insulatin Oil Level Clant Level Pwer Steering Fluid Windshield Washer Fluid Battery Fluid Level, Cnnectins & Tie-dwns Autmatic Transmissin Fluid Level Engine Cmpartment Belts STEP 3. ENGINE START/CAB CHECK (LEFT/FRONT/RIGHT) Safe Start Gauges Oil Pressure Gauge Air Pressure Gauge Temperature Gauge (Clant/Engine Oil) Ammeter/Vltmeter Warning Lights & Buzzers Mirrrs & Windshield Wipers/Washers Emergency & Safety Equipment Red Reflective Triangles Prperly Charged & Rated Fire Extinguisher Optinal (Chains/Tire Changing Equip, Emergency Phne List)

90 3B Lights/Reflectrs/Reflectr Tape Cnditin (Frnt/Sides/Rear) (Dash Indicatrs fr:) Left Turn Signal Right Turn Signal Fur-Way Emergency Flashers High Beam Headlight Clearance Lights (Reflective Clean & Functinal Light & Reflectr Checks Include:) Headlights Taillights Backing Lights Turn Signals Fur-Way Flashers Brake Lights Red Reflectrs & Amber Reflectrs Reflective Tape Cnditin Hrn Heater/Defrster Brakes Parking Brake Check Hydraulic Brake Check Air Brake Check (if equipped) Service Brake Check Safety Belt (TURN-OFF ENGINE/TURN-ON HEADLIGHTS *LOW BEAM* AND FOUR-WAY FLASHERS) STEP 4. WALK-AROUND INSPECTION 4A Steering Steering Bx/Hses Steering Linkages 4B Suspensin Springs/Air/Trque Munts Shck Absrbers 4C Brakes Slack Adjustrs & Pushrds Brake Chambers Brake Hses/Lines Drum Brake Brake Linings

91 4D Wheels Rims Tires Hub Oil Seals/Axle Seals Lug Nuts Spacers & Budd Spacing 4D Twing Cnnectin/Winch (if applicable) SIDE OF VEHICLE 4E Drs 4E Mirrrs 4E Fuel Tank REAR OF VEHICLE

92 Figure A2.1. Oversized Carg M-Series Truck Inspectin Guide.