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#### CHAPTER 8

#### LESSON OUTLINES FOR MATERIAL-HANDLING CRANE AND
SELF-RECOVERY WINCH OPERATIONS

LESSON TITLE: | OPERATE AN M1074 PLS CRANE
TASK NUMBER: | 551-721-1407 (Operate an M1074 PLS Crane) and 551-721-1352 (Perform Vehicle Preventive Maintenance Checks and Services [PMCS])

A. TRAINING OBJECTIVE.

| TASK: | Operate and perform operator preventive maintenance checks and services (PMCS) on the M1074 PLS crane.
| CONDITIONS: | Given instruction, a suitable training area, an M1074 PLS truck with BII, an M1077 flatrack, several palletized loads of differing weights, DA FORM 2404 , pencil, TM 9-2320-364-10, equipment records folder, rags, and a requirement to inspect the truck crane components according to the PMCS tables in TM 9-2320-364-10 and to operate the crane using both manual and remote controls; prepare the crane for use, set up the outriggers, raise the boom to its operating position, rotate and telescope the boom, load/off-load palletized cargo to/from a flatrack, shut down the crane, and stow the outriggers.
| STANDARD: | Without causing damage to the truck and flatrack or injury to personnel, operate the crane in the correct sequence according to TM 9-2320-364-10 . Correct all faults within the operator's level of maintenance, and record all others legibly on DA FORM 2404 . If no faults are found, make necessary entries on DA FORM 2404 . Students will be graded on a Go/No-Go basis. See enclosed training evaluation checklist.

B. INTERMEDIATE TRAINING.

Intermediate Training Objective 1
| TASK: | Operate the crane on the M1074 PLS truck.
| CONDITIONS: | Given instruction, a suitable training area, an M1074 PLS truck with BII, an M1077 flatrack, several palletized loads of differing weights, and a requirement to operate the crane using both manual and remote controls; prepare the crane for use, set up the outriggers, raise the boom to its operating position, rotate and telescope the boom, load/off-load palletized cargo to/from a flatrack, shut down the crane, and stow the outriggers.
| STANDARD: | Without causing damage to the truck and flatrack or injury to personnel, operate the crane in the correct sequence according to TM 9-2320-364-10 . Students will be graded on a Go/No-Go basis.
Intermediate Training Objective 2
| TASK: | Perform operator preventive maintenance checks and services (PMCS) on the M1074 PLS crane.
| CONDITIONS: | Given instruction, DA FORM 2404 , pencil, TM 9-2320-364-10 , equipment records folder, rags, an M1074 PLS truck with BII, and a requirement to inspect the truck crane components according to the PMCS tables in TM 9-2320-364-10 .
| STANDARD | Correct all faults within the operator's level of maintenance, and record all others legibly on DA FORM 2404 . If no faults are found, make necessary entries on DA FORM 2404 .

C. ADMINISTRATIVE INSTRUCTIONS.

1. Training time: As scheduled.

2. Training location: Classroom and training area as scheduled.

3. Training type: Conference, demonstration, and practical exercise.

4. Students: Scheduled personnel.

5. Principal and assistant instructors required: One primary instructor for the conference and one assistant instructor for each two students for the demonstration and practical exercise.

6. Training aids and equipment: Television, VCR, and videotape TVT 55-36 (PIN: 710046DA), Part 3, "PLS Crane Operations." Hearing protection and work gloves are required for all personnel. DA FORM 2404 , pencil, rags, TM 9-2320-364-10 , equipment records folder, an M1074 PLS truck with BII, an M1077 flatrack, and several palletized loads of differing weights for every two students.

7. References: AR 385-55, DA Pamphlet 738-750, and TM 9-2320-364-10 .

D. SEQUENCE OF ACTIVITY.

1. Introduction:

a. Interest device.

b. Tie-in.

c. Lesson objective (paragraph A).

d. Procedures:

(1) Explanation and demonstration.

(2) Practical exercise.

(3) Summary.

2. Explanation and demonstration:

NOTE: | The classroom must be near the training area where crane operations are to be practiced. This allows the student to view the videotape and put into practical application these operational procedures with a minimum loss of learned skills. Explain safety precautions and warnings, followed by the videotape, and then demonstrate PMCS, loading, and off-loading. PMCS on the crane is performed in conjunction with monthly crane operation.

a. Explain all safety precautions for this exercise and review warnings. Attention should be drawn to all warnings in vehicle operator's manual with particular attention given the warnings and note below.

WARNING Do not operate crane unless outriggers are set up. Vehicle could turn over causing serious injury or death.

NOTE: | If outrigger pads do not stay in firm contact with ground, crane functions will not operate. During operation, if controls do not work, check outriggers. Outriggers must take some load off the truck, even if outrigger pads sink into the ground.

WARNING Do not raise vehicle tires off ground with outrigger jack cylinders. Vehicle could roll causing serious injury or death.

WARNING Keep boom clear of all electrical lines and other obstacles while operating crane. Serious injury or death could result upon contact.

WARNING Be sure that area is clear of personnel before moving swing control lever. Boom should be swung slowly enough so crane operator has complete control. If operator cannot see load during operation, operate crane from remote control unit. Failure to control the boom could cause serious injury or death.

WARNING Operator must keep control of load at all times. If necessary, attach cargo tie-downs to load for use as a control tether. Failure to control load while it is moving could cause serious injury or death. Make sure remote control/emergency stop/on/off power switch is in off position and switch guard closed before connecting remote control unit. Crane moving out of control could cause serious injury or death.

b. Show videotape TVT 55-36, Part 3, "PLS Crane Operations."

c. Demonstrate crane PMCS and loading/off-loading the load from a flatrack using PLS crane with both manual and remote controls.

NOTE: | The flatrack must be unloaded from the truck using the LHS and the truck positioned so that all loading and off-loading can be accomplished without further moving the truck. This is the only safe method to load and off-load the flatrack. Do not try to load or off-load with a flatrack on the truck.

3. Practical exercise:

a. Assign students to vehicles and crane operation area. Issue work gloves, TM 9-2320-364-10 , pencils, DA FORM 2404 , and equipment records folder. Tell students where rags are located.

b. Students practice operating the crane to load/off-load palletized cargo to/from the flatrack. PMCS of the crane is also performed at this time.

NOTE: | Do not allow the students to perform any unsafe acts. Crane operations must be closely supervised because of the potential for injury or death.

4. Evaluate: Check each student's performance of crane operations to include PMCS.

5. Summary:

a. Recap main points.

b. Allow for questions.

c. Clarify questions.

d. Give closing statement.

6. Retraining: Retrain No-Gos and slow learners. All students must receive a Go in all areas of the attached training evaluation checklist.

E. SAFETY RESTRICTIONS.

1. Ensure that all chock blocks are in place when PLS trucks are parked or maintenance is to be performed.

2. Ensure the transmission is in neutral, the parking brake is set, and the engine is shut off before leaving the truck, when the truck is parked, or maintenance is being performed.

3. Ensure students remove all watches, jewelry, and identification tags before working in or around the PLS truck.

4. Ensure all personnel pay particular attention to the cautions and warnings listed in the operator's manuals.

5. Ensure ground guide(s) are used when backing.

6. Ensure all personnel wear hearing protection when working in or around a running PLS truck.

7. Ensure all occupants wear seat belts while the truck is in motion.

8. Ensure the driver and ground guides know and understand the hand and arm signals as outlined in FM 21-305.

9. Ensure all backing is conducted at a speed of 5 MPH or less.

10. Ensure personnel maintain at least three points of contact to mount or dismount the PLS truck (to include performing PMCS).

11. Use the PLS ladder when performing maintenance. Install the two hooks on the ladder in the holes located on top of the fender before use. Using the ladder for other applications could result in serious injury to personnel.

12. Ensure all personnel are clear of truck before engine start is attempted. Operator must visually check to see that all areas of the truck are clear of personnel before attempting to start the engine. Failure to do so could result in serious injury or death to personnel.

13. Always place transmission in neutral and set parking brake before operating crane.

14. Always wear heavy work gloves when handling cable. Never let cable run through your hands. A frayed cable may cut you severely.

15. Position the truck on level ground if possible. If the ground is not level, the outriggers can be used to level the truck from side to side on up to a 7 degree side slope. If outrigger pads do not stay in firm contact with the ground, crane functions will not operate.

16. Be careful when handling outrigger pads. Sharp edges can injure hands.

17. Always use outrigger control valve on the same side of the truck as the outrigger being extended or serious personal injury or death may result.

18. Keep hands and feet away from outrigger jack cylinders and outrigger pads while operating levers to avoid injury.

19. Outrigger cylinders must be extended to remove enough weight from the suspension so that the tires do not bulge, or truck could roll over, causing serious injury or death.

20. Do not operate crane unless both outriggers are set up. Truck could turn over causing serious injury or death.

21. Do not raise truck tires off ground with outrigger jack cylinders. Truck could roll causing serious injury or death.

22. Keep boom clear of all electrical lines and other obstacles while operating crane. Serious injury or death could result upon contact.

23. Operator should be stationed to be able to see load at all times during crane operation. Operate crane from left-hand or right-hand remote control station if load is not visible from main crane control panel. Failure to control boom and load could cause serious injury or death.

24. Operator must keep control of load at all times. If necessary, attach cargo tie-downs to load for use as a control tether. Failure to control load could cause serious injury or death.

25. Be sure area is clear of personnel before moving swing control lever. Boom should be swung slow enough so crane operator has complete control. If operator cannot see load during operation, operate crane from remote control unit. Failure to control boom could cause serious injury or death.

26. When operating two control levers at the same time, if one function is held wide open and "dead-headed," that is, cylinder is fully extended, and another function is operated, the second function can operate at a greater than normal speed, which can cause loss of control and serious injury or death to personnel.

27. Be sure there are at least two wraps of cable on hoist drum at all times. Serious injury or death could result if cable comes off hoist drum while lifting load.

28. Make sure remote control/emergency stop/on/off power switch is in the off position before connecting remote control unit. Failure to control crane could cause serious injury or death.

29. If electrical power fails during crane operation, move switch on remote control unit to shutdown position. Serious injury could result from uncontrolled moving parts.

F. ADDITIONAL COMMENTS AND INFORMATION. Recommended instructional time is 4 hours (.5 conference, .5 demonstration, and 3 hours practical exercise [PMCS is integrated]).

TRAINING EVALUATION
OPERATE THE CRANE ON THE M1074 PLS TRUCK

LESSON TITLE: | PERFORM SELF-RECOVERY ON A PLS TRUCK USING THE WINCH
TASK NUMBER: | 551-721-1390 (Perform Self-Recovery on a HEMTT Using a Winch) and 551-721-1352 (Perform Vehicle Preventive Maintenance Checks and Services [PMCS])

A. TRAINING OBJECTIVE.

| TASK: | Perform self recovery on a PLS truck using the winch and operator preventive maintenance checks and services (PMCS) on the winch.
| CONDITIONS | Given instruction, suitable training area, suitable anchor, a PLS truck with operational winch and BII, DA FORM 2404 , pencil, TM 9-2320-364-10 , equipment records folder, rags, and a requirement to inspect the truck winch according to the PMCS tables in TM 9-2320-364-10 , and a requirement to and recover the truck.
| STANDARD: | Recover the truck in the correct sequence so that it is free to move under its own power without causing damage to the vehicle or injury to personnel. Correct all faults within the operator's level of maintenance, and record all others legibly on DA FORM 2404 . If no faults are found, make necessary entries on DA FORM 2404 . You must perform this task as both the driver and assistant driver. Students will be graded on a Go/No-Go basis. See enclosed training evaluation checklist.

B. INTERMEDIATE TRAINING.

Intermediate Training Objective 1
| TASK: | Perform self-recovery on a PLS truck using the winch.
| CONDITIONS: | Given instruction, suitable training area, suitable anchor, a PLS truck with operational winch and BII, and a requirement to recover the truck.
| STANDARD: | Recover the truck in the correct sequence so that it is free to move under its own power without causing damage to the vehicle or injury to personnel. You must perform this task as both the driver and assistant driver. Students will be graded on a Go/No-Go basis. See enclosed training evaluation checklist.
Intermediate Training Objective 2
| TASK: | Perform operator preventive maintenance checks and services (PMCS) on the PLS winch.
| CONDITIONS: | Given instruction, DA FORM 2404 , pencil, TM 9-2320-364-10 , equipment records folder, rags, a PLS truck with BII, and a requirement to inspect the truck winch according to the PMCS tables in TM 9-2320-364-10 .
| STANDARD: | Correct all faults within the operator's level of maintenance, and record all others legibly on DA FORM 2404 . If no faults are found, make necessary entries on DA FORM 2404 .

C. ADMINISTRATIVE INSTRUCTIONS.

1. Training time: As scheduled.

2. Training location: Classroom and training area as scheduled.

3. Training type: Conference, demonstration, and practical exercise.

4. Students: Scheduled personnel.

5. Principal and assistant instructors required: One primary instructor for the conference, one assistant instructor for each six students for the demonstration, and one assistant instructor for each two students for the practical exercise.

6. Training aids and equipment: Television, VCR, and videotape TVT 55-37 (PIN: 710336DA), Part 5, "PLS Winch Operations." Hearing protection and work gloves are required for all personnel. DA FORM 2404 , pencil, rags, TM 9-2320-364-10 , equipment records folder, and a winch equipped PLS truck with BII and anchor for every two students.

7. References: AR 385-55, DA Pamphlet 738-750, FM 21-305, FM 20-22, and TM 9-2320-364-10 .

D. SEQUENCE OF ACTIVITY.

1. Introduction:

a. Interest device.

b. Tie-in.

c. Lesson objective (paragraph A).

d. Procedures:

(1) Explanation.

(2) Practical exercise.

(3) Summary.

2. Explanation and demonstration:

NOTE: | The classroom must be near the training area where recovery operations are to be practiced. This allows the student to view the tape and apply the self-recovery procedures with a minimum loss of learned skills. Explain safety precautions and warnings, followed by the videotape, and then demonstrate PMCS of the winch and self-recovery. PMCS on the winch is performed in conjunction with monthly winch operation.

a. Explain all safety precautions for this exercise and review warnings. Attention should be drawn to all warnings in vehicle operator's manual with particular attention given the warnings below.

WARNING Always wear heavy gloves when handling cables. Never let cable run through hands; frayed cables can cut. Never operate winch with less than five wraps of cable on winch drum. Serious injury or death could result if cable comes off drum while winching

WARNING Avoid quick, jerking winch operation. Keep other personnel well away from truck involved in winching operation. A snapped cable or shifting load can cause serious injury or death.

WARNING Do not operate winch while personnel are working on or around cable guides. Severe injury to arms, hands, and fingers may result if cable moves while working with cable and cable guides

WARNING Keep all personnel clear of area near cable when tension is on cable. If cable breaks, it can cause severe injury or death.

WARNING Do not use winch to reel clevis end of cable through roller guides. Clevis may catch on roller guide and cause cable or roller guide to break. Broken cables or roller guides can cause serious injury or death.

WARNING Keep all personnel clear of winch area when winch is reeling in cable. If hands are caught in winch or cable or if cable breaks under tension, severe injury or death could occur.

WARNING Never let moving cable slide through hands, even when wearing gloves. A broken cable could cut through glove and cut hand.

WARNING Do not reel in cable too tightly. Injury to personnel may occur if too much tension is applied to eyelet.

b. Show videotape TVT 55-37, Part 5, "PLS Winch Operations."

c. Demonstrate hand and arm signals required for this exercise.

d. Demonstrate self-recovery of a PLS to include winch PMCS.

NOTE: | The PLS will be winched forward for this exercise . The students will also winch the vehicle forward. Winching the PLS rearward is similar.

3. Practical exercise:

a. Assign students to vehicles and recovery location. Issue work gloves to each student.

b. Students practice self-recovery of the PLS and winch PMCS. Ensure the students practice as both the driver and the assistant driver.

NOTE: | Do not allow the students to perform any unsafe acts. Recovery operations must be closely supervised because of the potential for injury or death.

4. Evaluate: Check each student's performance of self-recovery and winch PMCS as both the driver and assistant driver.

5. Summary:

a. Recap main points.

b. Allow for questions.

c. Clarify questions.

d. Give closing statement.

6. Retraining: Retrain No-Gos and slow learners. All students must receive a Go in all areas of the attached training evaluation checklist.

E. SAFETY RESTRICTIONS.

1. Ensure that all chock blocks are in place when PLS trucks are parked or maintenance is to be performed.

2. Ensure the transmission is in neutral, the parking brake is set, and the engine is shut off before leaving the truck, when the truck is parked, or maintenance is being performed.

3. Ensure students remove all watches, jewelry, and identification tags before working in or around the PLS truck.

4. Ensure all personnel pay particular attention to the cautions and warnings listed in the operator's manuals.

5. Ensure ground guide(s) are used when backing.

6. Ensure all personnel wear hearing protection when working in or around a running PLS truck.

7. Ensure all occupants wear seat belts while the truck is in operation.

8. Ensure the driver and ground guides know and understand the hand and arm signals as outlined in FM 21-305. Winching hand and arm signals are contained in FM 20-22.

9. Ensure all backing is conducted at a speed of 5 MPH or less.

10. Ensure personnel maintain at least three points of contact to mount or dismount the PLS truck (to include performing PMCS).

11. Use the PLS ladder when performing maintenance. Install the two hooks on the ladder in the holes located on top of the fender before use. Using the ladder for other applications could result in serious injury to personnel.

12. Ensure all personnel are clear of truck before engine start is attempted. Operator must visually check to see that all areas of the truck are clear of personnel before attempting to start the engine. Failure to do so could result in serious injury or death to personnel.

13. Always wear heavy leather-palmed work gloves when handling winch cable. Never let cable slide through hands, even when wearing gloves. Winch cable can become frayed or contain broken wires. Frayed or broken wires can cut through gloves and cut hands.

14. Never walk between the vehicle and anchor.

15. The driver must have a clear view of the assistant driver at all times.

16. Do not operate winch while personnel are working on or around cable guides or tensioning device. Severe injury to arms, hands, and fingers may result if cable moves while working with the cable and the cable guides or tensioning device.

17. Do not bend winch cable at sharp angles.

18. Keep all personnel clear of winch area when winch is reeling in cable. If hands are caught in winch or cable or if cable breaks under tension, severe injury or death could occur.

19. Keep all personnel clear of area near cable when tension is on cable (at least one cable length away from and opposite the angle of pull). If cable breaks, it can cause severe injury or death.

20. Never operate winch with less than five wraps of cable on winch drum. If load is applied with less than five wraps of cable on winch, cable may come loose on drum.

21. The winch is equipped with an overload protection relief valve which prevents the winch from pulling beyond 110 percent of the rated pull.

22. When attaching self-recovery winch cable to another truck, that truck must be used only as an anchor point or damage to equipment may result.

23. Self-recovery winch is not designed to winch mired truck by itself. Truck drive system power must always be used with winch to self-recover truck or damage to equipment can result.

24. If winch does not move the truck, stop using winch. Overheat damage may occur.

25. Keep winch cable tight at all times so cable does not get tangled with truck.

26. Do not use winch to reel clevis end of winch cable through roller guides. Clevis may catch on roller guides and cause cable or roller guides to break. Broken cables or roller guides can cause serious injury or death.

27. Do not reel in winch cable too tightly or injury to personnel may occur if too much tension is applied to cable retainer.

F. ADDITIONAL COMMENTS AND INFORMATION. Recommended instructional time is 4 hours (.5 conference, .5 demonstration, and 3 hours practical exercise [PMCS is integrated]).

TRAINING EVALUATION
PERFORM SELF-RECOVERY ON A PLS, USING TRUCK-MOUNTED WINCH (FORWARD)