100K Reach Stacker Vehicle Management Code: E985 QUALIFICATION TRAINING PACKAGE

Transcription

1 DEPARTMENT OF THE AIR FORCE Headquarters US Air Frce Washingtn, D.C QTP24-3-E May K Reach Stacker Vehicle Management Cde: E985 QUALIFICATION TRAINING PACKAGE Accessibility: Publicatins and frms are available n the e-publishing website at fr dwnlading r rdering. Realeasability: There are n releasability restrictins n this publicatin.

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 Overview f Training and Requirements Vehicle Inspectin Vehicle Safety and Equipment Driving Safety and Precautins Vehicle Operatin 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 25 Attachment 2 VEHICLE INSPECTION GUIDE 26 Attachment 3 PERFORMANCE TEST 30 Attachment 4 SEVEN-STEP INSPECTION PROCESS 33

3 Sectin 1 OVERVIEW 1.1. Overview Send cmments and suggested imprvements n 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 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 Package (AFQTP) prcess and the respnsibilities Review the AFQTP/Mdule/Unit with the trainer They trainee shuld ask questins if he/she des nt understand the bjectives fr each unit Review missed questins with the trainer.

4 Trainer 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, 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 100K reach stacker This training will ensure the trainee becmes a qualified 100K reach stacker; an peratr wh has the knwledge and skills t perate a 100K reach stacker in a safe and prfessinal manner Desired Learning Outcmes Understand the purpse f the 100K reach stacker and its rle in the missin Lcate infrmatin cntained in the applicable technical rder (TO) and explain terminlgy used in the TO and peratr guide Identify and perate the cntrls fr the 100k reach stacker Understand the safety precautins t be fllwed pre-, during-, and pst- peratin f the 100 K-reach stacker.

5 Knw the prper peratr maintenance prcedures f the 100K reach stacker, IAW applicable TOs and use f Air Frce (AF) Frm 1800, Operatr s Inspectin Guide and Truble Reprt Safely and prficiently perate the 100K reach stacker 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 Instructr s Demnstratin Trainee s Persnal Experience (t build cnfidence and prficiency) Perfrm Operatr Maintenance Operate the Vehicle Trainee s Perfrmance Evaluatin 2 Hurs 2 Hurs 5 Hurs 15 Hurs 1 Hur Training Time 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 Air Frce Pamphlet (AFPAM) , Risk Management (RM) Guidelines and Tls AFI , Air Frce Cnslidated Occupatinal Safety Instructin, Chapters 4, 8, 14 and AFI , The U.S. Air Frce Traffic Safety Prgram, Chapter Applicable TOs r manufacturer s peratr s manual (Hyster peratr manuals). See Vehicle Management fr TO number fr vehicle being used in training Air Frce Manual (AFMAN) , Operatin f Air Frce Gvernment Mtr Vehicles, Chapters 1-5 and AF Frm Special references based-ff type f vehicle.

6 3.5. Instructinal Training Aids and Equipment K Reach Stacker Lessn Plan K reach stacker Cntainers, if applicable Applicable TO r manufacturer s peratr s manual AF Frm Cmmercial training curse slide shws and vides, if available Vides (if lcally prduced) Suitable training area. 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. Sectin 5 KNOWLEDGE LECTURE AND EVALUATION 5.1. Overview f Training and Requirements Training bjectives: Given lectures, demnstratins, hands-n driving sessin, and a perfrmance and written test, trainees will be able t perfrm peratr s inspectin and cmplete the perfrmance test with zer instructr assists.

7 Train and qualify each trainee in safe peratin and preventive maintenance f the 100K reach stacker This training will ensure the trainee becmes a qualified 100K reach stacker peratr, an peratr wh has the knwledge and skills t perate a 100K reach stacker in a safe and prfessinal manner Desired learning utcmes: Understand the safety precautins t be fllwed befre-, during-, and afterperatin f the 100K reach stacker Understand the purpse f the 100K reach stacker and its rle in the missin. The purpse f the 100K reach stacker is t handle cntainers in rder t achieve maximum space utilizatin Rle in the missin (Unit/Base/Cmmunity (during natural disasters)/air Frce) K reach stacker design (varies by manufacturer/mdel) Dimensins Overall length: 38 feet Overall width: 20 feet Overall height: 15.5 feet Fluid levels Diesel fuel: # Engine il: 34 liters (10w20 fr -28 t 20, 14w40 fr -18 C and up) Hydraulic reservir: 605 liters (JDM-J20) Cling system: 40 liters (50/50 mixture) Transmissin: 62 liters (ATF Dextrin 4 r SAE 10w) Service weight: 152,944 lbs Tire pressure Frnt/rear: 145 punds per square inch (psi).

8 Engine Cummins QSM 11 engine (Tier 3) Turbcharged aspiratin, diesel, 6 cylinder line; 10.8 liters Electrical: 24 vlt, negative grund Transmissin TE27 TE32 Pwer shift transmissin Fur frward and fur reverse Neutral Advanced systems Braking System Prvides hydraulic pressure fr brakes, hydraulic reservir, and pressure indicatin gauge Persnnel cab Designed fr high visibility, except in rear All cntrls fr peratins are lcated within easy reach f the peratr Fr cab perating instrument and cntrls, refer t Cmmercial Manual and slide shws Vehicle Inspectin Pre-trip vehicle inspectin test/peratinal checks. During each shift, the peratr must perfrm all peratinal checks. Befre peratin, during peratin, and after peratin. Any equipment r vehicle faults shuld be reprted immediately t vehicle maintenance persnnel Use the vehicle s TO in cnjunctin with AF Frm 1800 and Attachment 2 as a walk arund guide 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.

9 Types f Vehicle Inspectin. If discrepancies are fund they must be reprted t Vehicle Cntrl Officer/Vehicle Nn Cmmissined Cntrl 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 Parking brake set/wheels chcked if n an incline, attachment is fully lwered Cleanliness/damage/missing items All machine safety/peratin decals are in place and legible Leaks (fuel/il/clant/hydraulic/air) Lubricatin. Lubricatin intervals are fr nrmal climate cnditins. Times and lubricants must be adjusted when perating in extreme heat, cld, dust, r humidity. Check all carriage and lift pints Engine area Check air filter indicatr. Red indicates dirty filter. Ntify Vehicle Management Check air intake fr bstructin r damage Check alternatr and fan belt fr cracks r frays and belt play Check belts, hses and verall appearance f the engine Check all hydraulic and fuel lines fr leaks, dry rt and cracks Fluid Levels; ensure level is within limits: Fuel tank Engine il Check fluid level in radiatr, als fr annual stenciling Clant. Check the engine clant level at the reservirs. CAUTION: DO NOT check clant level if engine is ht.

10 Transmissin fluid Antifreeze Hydraulic fluid level Brake fluid (master cylinder) Check site gauge n hydraulic reservir. If verfilled damage culd be cause t seals, due t expansin f il when ht Windshield washer fluid level Battery; security, fluid, damage and crrsin Check battery terminals fr tightness and crrsin. Visually check fluid All wheel rims (cracks, splits, etc.); check fr lse r missing lug nuts All tires Prper inflatin Sidewalls, tread Cuts and abrasins Lug nuts Transmissin Drive belts; tensin and fraying All hses and wiring Differential, shcks and brakes fr leaks Suspensin, springs and shcks Check brake canister assembly fr damage Fuel dr and fuel cap; intact, nt brken r damaged Hrn peratin.

11 Cntrl panel Cylinders. Nt leaking r damaged Lift Bm extensin Expansin Steering Damping Sideshift Twistlcks Pile slpe (if equipped) Cab raise (if equipped) Electrical cnnectrs, wires, cables and junctin bxes are nt lse r damaged Hydraulic hses and cnnectrs are nt leaking r damaged Bm, attachment and frame. Free f cracks, brken welds, lse blts, dents, and bvius damage Attachment linkages, twistlcks, guide blcks, plungers, switches, expansin pads, etc Engine cmpartment hd-lck in place and functinal Operatr cab structure, braces, machine structure. N breaks, cracks r brken welds Heater/defrster Wiring/lights/reflectrs (interir and exterir) Mirrrs Windshield and windshield wipers/washers.

12 Steps, walkways and handhlds. Free f il, grease, hydraulic fluid, ice, snw, debris, etc. Anti-slip pads are in place. Free f any damage Drs Windws Hd latches Seatbelts Fire extinguisher Cmplete AF Frm 1800 dcument deficiencies and reprt all safety items immediately t Vehicle Management During-peratin Mnitr all gauges and warning lights fr prper peratins Warning lights Flashing beacns Camera system, if equipped Gauges (air pressure, il pressure, fuel gauge, water temperature, battery vltage, hydraulic il temperature) Indicatrs Reach stacker functins check: Attachment expansin Pile slpe Attachment rtatin Side shift Bm lift Bm extensin Twistlcks.

13 Cab psitining system Observe fr jerky mvement during peratin f hydraulic functins Listen fr any unusual sunds Stay alert fr any unusual smells r drs Stay alert fr any abnrmal vibratins r handling prblems Pst-peratin inspectin and reprt Set parking brake Shut dwn engine Chck wheels Walk arund the vehicle and check fr fluid leaks r unusual cnditins 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: Overall size Clearance Safety clthing and equipment: Safety ted bts must be wrn.

14 Glves will be wrn during carg lading and unlading (take ff rings/jewelry first Hearing prtectin Hard hat Eye prtectin Fall prtectin First aid kit. Inspect fr cntents and serviceability Raingear, cld weather gear, etc Reflective belt during hurs f reduced visibility and n flightline Fire extinguisher AF Frm Driving Safety and Precautins Operatrs are required t becme familiar with the safety precautins and lcatin and use f cntrls, accessries, indicatrs and handling characteristics f the 100K reach stacker prir t attempting any peratin r service prcedures. General safety precautins include: Lwering r blcking hydraulically perated cmpnents befre servicing units Ensuring unit is n level grund befre wrking under it Keeping transmissin in lw gear when ging dwnhill Never freewheeling n a dwngrade. Keep in gear fr maximum cntrl Never perating with the parking brake engaged Ensuring adequate ventilatin under all cnditins. Exhaust fumes can cause severe injury r death t persnnel Keeping persnnel at a minimum f 50 ft. away frm the vehicle while in peratin N riders, except during training (instructr must wear safety harness and secure it t the vehicle).

15 Ensuring all cntrls are clean and fee f il Never leaving a running unit unattended Never using steering wheel r cntrls as hand hlds fr munting and dismunting Transmissin may be up shifted. D nt verrun the engine by dwnshifting. Ensure the speed is nt t great befre attempting t dwnshift (5 miles per hur (mph)) Avid idling engine fr lng perids Never allwing thers t wrk n r under suspended lads Never exceeding lad capacity Being aware f pwer lines while traveling Operatr may refuse t lift r mve any lad that exceeds capacity, any unsafe lad, r any lad nt designated t be lifted by this machine Ensuring grund crews are qualified in all hand signals Never attempting t fllw mre than ne grund crew member. CAUTION: Grund crews will be used fr all lifting, psitining, and fr transprtatin f lads that restrict the peratrs visin D nt lift cntainer if all lift lcks are nt fully engaged and indicatr lights d nt shw engaged Be aware f steep inclines and declines Ensure chcks are psitined, as required Never stack cntainers during times f high winds (ver 28 mph) r when the wind exceeds the peratr s skill level r cmfrt zne Off-rad driving. Drive carefully n uneven, wet r slippery surfaces. 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.

16 Hazardus carg. Fr mre infrmatin n transprting hazardus carg, refer t AFMAN and the Hazardus Carg Lessn Plan Observe all flightline traffic rules Freign Object Damage (FOD). Vehicle peratrs will remve FOD frm tires during 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 n 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 t help eliminate aircraft damage Sptter safety Always use a sptter. The peratr shuld maintain visual cntact with the sptter at all times. If visual cntact is lst, the peratr must immediately stp the vehicle. See AFMAN fr additinal guidance n sptter safety and standard AF sptter hand signals Vehicle Operatin Cntrl familiarizatin. T ensure quick respnse time under nrmal r emergency cnditins, a thrugh familiarizatin f cntrls, lcatins, and functins will be prvided by the trainer. Students will be given enugh time t build familiarity in cntrl lcatin and use prir t perating the vehicle and being licensed n the vehicle Engine starting. Turn master switch t the ON psitin Be sure all cntrls and gear levers are in neutral (vehicle is equipped with a neutral switch and will nt start in gear) Engage parking brake Turn ignitin switch t start the vehicle.

17 Idle engine under 1000 revlutins per minute (rpm) fr 5-10 minutes Check all lights and wipers Check all hydraulic cntrls fr prper peratin Smth terrain With lad: travel with the bm and the spreader raised nly enugh fr visibility. Keep the lad upgrade fr maximum cntrl. Ensure center f gravity f the lad is t the center f gravity t the truck N lad: travel with the bm and spreader raised nly enugh fr visibility Rugh terrain With lad: travel with the bm and the spreader raised nly enugh fr visibility. Keep the lad upgrade fr maximum cntrl. Ensure center f gravity f the lad is t the center f gravity t the truck N lad: travel with the bm and spreader raised nly enugh fr visibility Put transmissin int first gear and test ft brake Sund hrn if ging arund blind crners After all checks are cmpleted, sign apprpriate frms. Crrect any discrepancies Pst peratin Park n level grund, set parking brake, gear in neutral Fully retract and lwer the bm Retract the spreader t the 20 ft. psitin Idle engine dwn fr 5-10 minutes T shut ff mtr, turn ignitin switch t the OFF psitin Ensure vehicle is secure by lcking the steering wheel, and clsing the windws Make a final walk-arund inspectin.

18 Check fr leaks Check fr cuts n tires Check fr damage t the vehicle Make sure it is clean with plenty f fuel befre turning it back t dispatch supprt. 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 the vehicle is parked Remve all jewelry and identificatin tags Persnal prtective equipment and equipment items Safety ted bts must be wrn Glves will be wrn during carg lading and unlading First aid kit Hearing prtectin Hard hat Fall prtectin Eye prtectin Raingear, cld weather gear, etc.

19 Reflective belt during hurs f reduced visibility r n the flightline The trainer and trainee shuld walk arund vehicle t becme familiar with all warning labels and signs Ensure trainee wears seat belts Prperly adjust driver s seat and all mirrrs, if available Thrughut demnstratin, practice 100K reach stacker safety Practice basic RM prcess during demnstratin: Identify hazards 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 100K reach stacker are cvered in additin t the Operatin Demnstratin guidelines prvided belw Operatin Demnstratin Thrughut demnstratin: Allw fr questins Repeat demnstratins as needed Fr the 100K reach stacker, within the training area, demnstrate and explain the fllwing. Nte: Use infrmatin cntained n the data plate and/r the peratr s manual: Specific 100K reach stacker capacities: Explain parking brake as they apply t 100K reach stacker being used K reach stacker levers and cntrls.

20 Pint ut the items t be inspected during peratins Describe and demnstrate the fllwing 100K reach stacker peratins (use trained sptter when backing) Describe the different types f lads and hw t handle each Describe the minimum levels fr il and air pressure Describe the prper shutdwn techniques Demnstrate backing prcedures. Always use a sptter Demnstrate prper parking prcedures Shw trainee the after peratin inspectin and reprt Ensure vehicle is cleaned Refuel vehicle Fllwing manufacturer s shut-dwn prcedures Park Apply brakes Place transmissin in neutral (park r an autmatic) Perfrm a pst-peratin 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).

21 Chck wheel (if required) when 100K reach stacker 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 and ther items: Safety ted bts must be wrn Fall prtectin/safety harness Glves will be wrn during carg lading and unlading First aid kit Hearing prtectin Eye prtectin Reflective belt during hurs f reduced visibility r n the flightline Raingear, cld weather gear, etc Pay particular attentin t the cautins and warnings listed in the peratr's manual and this lessn plan Ensure trainee wears seat belts Prperly adjust driver s seat and all mirrrs K reach stacker 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.

22 During-inspectin Ensure AF Frm 1800 is prperly dcumented Fr the 100K reach stacker, within the training area, demnstrate and explain the fllwing. Nte: Use infrmatin cntained n the data plate and/r the peratr s manual: Specific 100K reach stacker capacities: Explain parking brake as they apply t 100K reach stacker being used K reach stacker levers and cntrls Describe and demnstrate the fllwing 100K reach stacker peratins (use sptter when backing) Different types f lads and hw t handle each Minimum levels fr il and air pressure Prper shutdwn techniques Demnstrate backing prcedures. Always use a sptter Demnstrate prper parking prcedures Cntinue until trainee can shw prficiency in perating Perfrm pst-peratin inspectin Ensure vehicle cleaned Refueled Fllwing manufacturer s shut-dwn prcedures Park Apply brakes Place transmissin in neutral (park r an autmatic) Reprt any discrepancies fund n AF Frm 1800.

23 7.2. 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 100K reach stacker is parked, Remve all jewelry and identificatin tags Persnal prtective equipment and ther items Safety ted bts must be wrn Glves will be wrn during carg lading and unlading First aid kit Hearing prtectin Eye prtectin Reflective belt during hurs f reduced visibility r n the flightline Pay particular attentin t the cautins and warnings listed in the peratr's manual Ensure trainee wears seat belts Prperly adjust driver s seat and all mirrrs (if available) K reach stacker safety items/prcedures Explain driving techniques Establish a 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).

24 Different types f lads and hw t handle each Minimum levels fr il and air pressure Prper shutdwn techniques Demnstrate prper parking prcedures Demnstrate backing prcedures Cnduct after-actin reviews with the trainee Trainee is nt allwed any instructr assists t pass perfrmance evaluatin Evaluatin checklist prvided in Attachment Perfrm after-peratin inspectin. Anntate any discrepancies fund n AF Frm Retraining; retrain N-G s Re-demnstrate N-G items Have trainee re-perfrm until they shw prficiency in perating, critique weaknesses as bserved Re-evaluate.

25 Attachment 1 GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION References AFI , Vehicle Operatins, 5 May AFI , Air Frce Cnslidated Occupatinal Safety Instructin, 15 June 2012 AFI , The U.S. Air Frce Traffic Safety Prgram, 16 February 2017 AFMAN , Operatin f Air Frce Gvernment Mtr Vehicles, 9 December 2017 AFPAM , Risk Management (RM) Guidelines and Tls, 11 February 2013 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 f Publicatin, 22 September 2009 AF Frm 1800, Operatr s Inspectin Guide and Truble Reprt, 1 April 2010 Abbreviatins and Acrnyms AF Air Frce AFI Air Frce Instructin AFIMSC Air Frce Installatin Missin Supprt Center AFQTP Air Frce Qualificatin Training Package AFMAN Air Frce Manual FOD Freign Object Damage IAW In Accrdance With MPH Miles per Hur PSI Punds per Square Inch RM Risk Management RPM Revlutins per Minute VCNCO Vehicle Cntrl Nn Cmmissined Officer VCO Vehicle Cntrl Officer

26 Attachment 2 100K REACH STACKER 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 Hd Latches Oil Level Clant Level Pwer Steering Fluid Windshield Washer Fluid Hydraulic Fluid Battery Fluid Level, Cnnectins & Tie-dwns Autmatic Transmissin Fluid Level Engine Cmpartment Belts Air Filter/Air Intake Antifreeze Level

27 STEP 3. ENGINE START/CAB CHECK (LEFT/FRONT/RIGHT) Safe Start Gauges Oil Pressure Gauge Temperature Gauge (Clant/Engine Oil) Ammeter/Vltmeter Warning Lights, Beacns & Buzzers Mirrrs & Windshield Wipers/Washers Emergency & Safety Equipment Red Reflective Triangles Prperly Charged & Rated Fire Extinguisher Optinal (Chains/Tire Changing Equip, Emergency Phne List) 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 Running Lights Backing Lights Turn Signals Fur-Way Flashers Brake Lights Sptlight Deck Lights Red Reflectrs & Amber Reflectrs Reflective Tape Cnditin Hrn Heater/Defrster Brakes Parking Brake Check Hydraulic Brake Check Service Brake Check Safety Belt (TURN-OFF ENGINE/TURN-ON HEADLIGHTS *LOW BEAM* AND FOUR-WAY FLASHERS)

28 STEP 4. WALK-AROUND INSPECTION 4A Steering Steering Bx/Hses Steering Linkages Tie Rd Steering Plate Steering Arm Blts and Pins 4B Suspensin Springs/Air/Trque Munts Shck Absrbers 4C Brakes Slack Adjustrs & Pushrds Brake Chambers Brake Hses/Lines Brake Linings Brake Canister 4D Wheels Rims Tires Hub Oil Seals/Axle Seals Lug Nuts Prper Inflatin 4E Cylinders SIDE OF VEHICLE 4F Drs 4F Mirrrs 4F Fuel Tank/Fuel Dr/Fuel Cap 4F Steps/Walkways/Handhlds REACH STACKER COMPONENTS 4G Bm 4G Attachment Linkages/Twistlcks/Guide Blcks 4G Plungers/Switches/Expansin Pads 4G Frame 4G Reach Stacker Functins REAR OF VEHICLE

29 Figure A K Reach Stacker Vehicle Inspectin Guide.

30 A3.1. Desired Learning Outcme. Attachment 3 PERFORMANCE TEST A Understand the safety precautins t be fllwed befre-, during-, and afterperatin f the 100K reach stacker. A Understand the purpse f the 100K reach stacker and its rle in the missin. A Knw the prper peratr maintenance prcedures f the 100K reach stacker, in accrdance with (IAW) applicable TOs and use f AF Frm A Safely and prficiently perate the 100K reach stacker. A3.2. Instructins. Befre beginning the perfrmance test, the trainer will brief trainee n the scenari he/she will need t accmplish. They will be given additinal directins and instructins as needed while prceeding thrugh the scenari. A3.3. Scring. A The trainer examiner will be scring n 100K reach stacker peratins and als the general safe driving practices. The examiner will give directins and instructins t the trainee in sufficient time t execute a driving maneuver. He/she will nt be asked t drive in an unsafe manner. A The examiner will be making varius marks n the perfrmance test checklist. This des nt necessarily mean the trainee has dne anything wrng. It is in the best interest t cncentrate n the peratin f the 100K reach stacker. The trainer will explain the test results at the cnclusin f the perfrmance test. A Tasks being graded are listed n the fllwing page; the trainee will be required t successfully pass all items. A The instructr will stp the test at any time safe 100K reach stacker peratins are nt being fllwed r as deemed necessary fr safety cncerns.

31 Figure A3.1. Perfrmance Test Checklist: PERFORMANCE TEST Trainees Name: Date: Event G N G Ntes 1. PRE, DURING, AND POST- OPERATION INSPECTION 1.1. Operatr has required Persnal Prtective Equipment Fllws general pattern f preperatin and pst-peratin checklist Perfrms brake cmpnent check 1.4. Signs AF Frm 1800 t signify accmplishment f cmplete inspectin Inspects all emergency equipment n the 100K reach stacker Inspects all levers, cntrls and fluid levels Cleans windshield, windws, mirrrs, lights and reflectrs Cntinues during peratins inspectin checks Perfrms pst trip inspectin and reprts malfunctins t Vehicle Management. Event G N G Ntes 2. ON-ROAD DRIVING TEST 2.1. General - safety belt is used; beys all traffic signs, signals, and laws; cmpletes test withut an accident r mving vilatin. Prperly uses all necessary safety equipment. Prhibits persnnel frm cming within 50 feet f the vehicle while in peratin Operating the starter fr the crrect amunt f time Operating all cntrls Different types f lads and hw t handle each Obeying speed limits.

32 2.6. Demnstrating prper parking prcedures Demnstrating prper backing prcedures. Uses sptter Demnstrate shutdwn prcedures. CERTIFIER COMMENTS:

33 Figure A4.1. Seven-Step Inspectin Prcess. Attachment 4 SEVEN-STEP INSPECTION PROCESS Seven-Step Inspectin Prcess Step Prcedure 1. Vehicle Overview Review the AF Frm Ensure any discrepancy has been crrected. Vehicle Management anntated the discrepancy was cmpleted. Appraching the vehicle. Damage r vehicle leaning t ne side. Fresh leakage f fluids. Hazards arund vehicle. 2. Check Engine Cmpartment Nte: Check that the parking brakes are n and/r wheels chcked. The peratr may have t raise the hd, tilt the cab (secure lse things s they dn't fall and break smething), r pen the engine cmpartment dr. Check the fllwing: Engine il level. Clant level in radiatr; cnditin f hses. Pwer steering fluid level; hse cnditin (if s equipped). Windshield washer fluid level. Battery fluid level, cnnectins and tie-dwns (battery may be lcated elsewhere). Autmatic transmissin fluid level (may require engine t be running). Check belts fr tightness and excessive wear (alternatr, water pump, air cmpressr)--learn hw much "give" the belts shuld have when adjusted right.

34 Leaks in the engine cmpartment (fuel, clant, il, pwer steering fluid, hydraulic fluid, battery fluid). Cracked, wrn electrical wiring insulatin. 3. Start Engine and Inspect Inside the Cab Get in and start engine. Make sure parking brake is n. Put gearshift in neutral (r park if autmatic). Start engine; listen fr unusual nises. If equipped, check the Anti-lck Braking System (ABS) indicatr lights. Light n dash shuld cme n and then turn-ff. If it stays n the ABS is nt wrking prperly. Nte: Fr trailers nly, if the yellw light n the left rear f the trailer stays n, the ABS is nt wrking prperly. Lk at the gauges. Oil pressure. Shuld cme up t nrmal within secnds after engine is started. Air pressure. Pressure shuld build frm 50 t 90 psi within 3 minutes. Build air pressure t gvernr cut-ut (usually arund psi. Knw the vehicle s requirements. Ammeter and/r vltmeter. Shuld be in nrmal range(s). Clant temperature. Shuld begin gradual rise t nrmal perating range. Engine il temperature. Shuld begin gradual rise t nrmal perating range. Warning lights and buzzers. Oil, clant, charging circuit warning, and antilck brake system lights shuld g ut right away. Check cnditin f cntrls. Check all f the fllwing fr lseness, sticking, damage, r imprper setting: Steering wheel. Clutch.

35 Acceleratr (gas pedal). Brake cntrls. Ft brake. Parking brake. Transmissin cntrls. Hrn(s). Windshield wiper/washer. Lights. Headlights. Dimmer switch. Turn signal. Fur-way flashers. Parking clearance identificatin marker switch (switches). Check mirrrs and windshield. Inspect mirrrs and windshield fr cracks, dirt, illegal stickers, r ther bstructins t seeing clearly. Clean and adjust as necessary. Check emergency equipment. Check fr safety equipment: Spare electrical fuses (unless vehicle has circuit breakers). Three red reflective triangles, 6 fuses r 3 liquid burning flares. Prperly charged and rated fire extinguisher. Check fr ptinal items such as: Chains (where winter cnditins require). Tire changing equipment. List f emergency phne numbers Accident reprting kit (packet). Check safety belt. Check that the safety belt is securely munted, adjusts; latches prperly and is nt ripped r frayed. 4. Turn-ff Engine Make sure the parking brake is set, turn-ff the engine, and take the key with. Turn-n headlights (lw beams) and fur-way emergency flashers, and get ut f the vehicle.

36 5. D Walk-Arund Inspectin General. G t frnt f vehicle and check that lw beams are n and bth f the fur-way flashers are wrking. Turn-ff headlights and fur-way emergency flashers. Turn-n parking, clearance, sidemarker, and identificatin lights. Turn-n right turn signal, and start walk-arund inspectin. Walk arund and inspect. Clean all lights, reflectrs, and glass as while ding the walk-arund inspectin. Left frnt side. Driver's dr glass shuld be clean. Dr latches r lcks shuld wrk prperly. Left frnt wheel. Cnditin f wheel and rim-- missing, bent, brken studs, clamps, lugs, r any signs f misalignment. Cnditin f tires--prperly inflated, valve stem and cap OK, n serius cuts, bulges, r tread wear. Use wrench t test rust-streaked lug nuts, indicating lseness. Hub il level OK, n leaks. Left frnt suspensin. Cnditin f spring, spring hangers, shackles, U-blts. Shck absrber cnditin. Left frnt brake. Cnditin f brake drum r disc. Cnditin f hses. Frnt. Cnditin f frnt axle. Cnditin f steering system. N lse, wrn, bent, damaged r missing parts. Must grab steering mechanism t test fr lseness. Cnditin f windshield. Check fr damage and clean if dirty.

37 Check windshield wiper arms fr prper spring tensin. Check wiper blades fr damage, "stiff" rubber, and securement. Lights and reflectrs. Parking, clearance, and identificatin lights clean, perating, and prper clr (amber at frnt). Reflectrs clean and prper clr (amber at frnt). Right frnt turn signal light clean, perating, and prper clr (amber r white n signals facing frward). Right side. Right frnt: check all items as dne n left frnt. Right fuel tank(s). Securely munted, nt damaged, r leaking. Fuel crssver line secure. Tank(s) cntain enugh fuel. Cap(s) n and secure. Cnditin f visible parts. Rear f engine--nt leaking. Transmissin-- nt leaking. Exhaust system--secure, nt leaking, nt tuching wires, fuel, r air-lines. Frame and crss members--n bends r cracks. Right rear. Cnditin f wheels and rims--n missing, bent, r brken spacers, studs, clamps, r lugs. Cnditin f tires--prperly inflated, valve stems and caps OK, n serius cuts, bulges, tread wear, tires nt rubbing each ther, and nthing stuck between them. Tires same type, e.g., nt mixed radial and bias types. Tires evenly matched (same sizes). Wheel bearing/seals nt leaking. Suspensin. Cnditin f spring(s), spring hangers, shackles, and U-blts. Axle secure.

38 Pwered axle(s) nt leaking lube (gear il). Cnditin f trque rd arms, bushings. Cnditin f shck absrber(s). Cnditin f air ride cmpnents. Brakes. Brake adjustment. Cnditin f brake drum(s) r discs. Cnditin f hses--lk fr any wear due t rubbing. Lights and reflectrs. Side-marker lights clean, perating, and prper clr (red at rear, thers amber). Side-marker reflectrs clean and prper clr (red at rear, thers amber). Rear. Lights and reflectrs. Rear clearance and identificatin lights clean, perating, and prper clr (red at rear). Reflectrs clean and prper clr (red at rear). Right rear turn signal perating, and prper clr (red, yellw, r amber at rear). License plate(s) present, clean, and secured. Splash guards present, nt damaged, prperly fastened, nt dragging n grund, r rubbing tires. Left side. Check all items as dne n right side, plus: Battery (batteries) (if nt munted in engine cmpartment). Battery bx (bxes) securely munted t vehicle. Bx has secure cver. Battery (batteries) secured against mvement. Battery (batteries) nt brken r leaking. Fluid in battery (batteries) at prper level (except maintenance-free type).

39 Cell caps present and securely tightened (except maintenance-free type). Vents in cell caps free f freign material (except maintenance-free type). 6. Check Signal Lights Get in and turn-ff all lights. Turn-n stp lights. Turn-n left turn signal lights. 7. Start the Engine and Check Test fr Hydraulic Leaks Get ut and check lights. Left frnt turn signal light clean, perating and prper clr (amber r white n signals facing the frnt). Left rear turn signal light and bth stp lights clean perating, and prper clr (red, yellw, r amber). Get in vehicle. Turn-ff lights nt needed fr driving. Check fr all required papers, trip manifests, permits, etc. Secure all lse articles in cab (they might interfere with peratin f the cntrls r hit the peratr in a crash). Start the engine. Test fr hydraulic leaks. If the vehicle has hydraulic brakes, pump the brake pedal three times. Then apply firm pressure t the pedal and hld fr five secnds. The pedal shuld nt mve. If it des, there may be a leak r ther prblem. Brake system. Test parking brake. Fasten safety belt. Set parking brake (pwer unit nly). Place vehicle int a lw gear. Gently pull frward against parking brake t make sure the parking brake hlds. If it desn't hld vehicle, it is faulty; get it fixed. Test service brake stpping actin. G abut 5 miles per hur.

40 Push brake pedal firmly. "Pulling" t ne side r the ther can mean brake truble. Any unusual brake pedal "feel" r delayed stpping actin can mean truble. If the trainee finds anything unsafe during the Vehicle inspectin, get it fixed. Federal and state laws frbid perating an unsafe vehicle. Check vehicle peratin regularly: Instruments. Air pressure gauge (if the vehicle has air brakes). Temperature gauges. Pressure gauges. Ammeter/vltmeter. Mirrrs. Tires. Safety inspectin. Dcument any discrepancy n AF Frm Sign-ff AF Frm 1800 t signify accmplishment f inspectin.