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#### CHAPTER 4

#### LESSON OUTLINES FOR TRUCK OPERATIONS

LESSON TITLE: | DESCRIBE VEHICLES, COMPONENTS, AND SPECIFICATIONS
TASK NUMBER: | 551-721-1352 (Perform Vehicle Preventive Maintenance Checks and Services [PMCS])

A. TRAINING OBJECTIVE.

| TASK: | Describe vehicles, components, and specifications.
| CONDITIONS: | Given instruction on the PLS truck, trailer, and flatrack and a requirement to describe vehicles, components, and specifications.
| STANDARD: | Correctly describe vehicles, components, and specifications.

B. INTERMEDIATE TRAINING. None.

C. ADMINISTRATIVE INSTRUCTIONS.

1. Training time: As scheduled.

2. Training location: Scheduled classroom.

3. Training type: Conference.

4. Students: Scheduled personnel.

5. Principal and assistant instructors required: One primary instructor.

6. Training aids and equipment: Overhead projector, transparencies, and screen.

7. Reference: 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) Summary.

2. Explanation:

NOTE: | This lesson is being presented so the student will become familiar with all PLS configurations and vehicles. The instructor will present vehicle information including vehicle capabilities, limitations, and data plates.

Transparency PLS 1-1

a. PLS truck configurations.

(1) Truck without crane - model M1075.

(2) Truck with crane - model M1074.

b. Description of vehicles.

Transparency PLS 1-2

(1) Components on right side of truck.

(a) Self-recovery winch [1] (optional). Winch can be used to pull vehicle forward or rearward. It is controlled in the cab and at the winch itself with a manual control lever.

(b) Stowage box [2] for BII items.

(c) Hydraulic oil reservoir [3] for the main hydraulics such as load-handling system (LHS) and material-handling crane (MHC) systems.

(d) Muffler [4].

(e) Spare tire [5] with the davit.

(f) Collapsible ladder [6]. Ladder is used by driver to check coolant, check oil, or perform other tasks requiring access to parts of truck out of normal reach.

Transparency PLS 1-3

(2) Components on left side of truck.

(a) Air filter [1] - two-stage.

(b) Battery box with removable cover [2]. It houses and protects four batteries.

(c) Control box (LHS) [3]. This box contains valves for the LHS.

(d) Air dryer system [4]. This system contains two air dryers, a prefilter, and a precooler.

(e) Fuel tank [5] with a fuel/water separator mounted in front of the tank. The fuel tank capacity is 100 gallons.

(f) Fuel/water separator [6]. It removes water and large solid particles from the fuel.

Transparency PLS 1-4

c. Trailer (PLST) M1076.

(1) Two position drawbar [1] that can be changed to shorten the length of trailer to make overall length of truck and trailer legal in certain areas.

(2) Steering axle [2] (turntable style) that uses a large bearing for rotation.

(3) Spare tire [3] with winch for dismounting from trailer.

(4) Stowage box [4] for stowing trailer BII.

(5) Data plates [5].

Transparency PLS 1-5

d. Flatrack M1077.

(1) Storage compartment [1] (one on each side) is used for storing the tie-down straps furnished with the flatrack. The stowage boxes are hinged and have provisions for locking.

(2) Hook bar [2] couples with the LHS hook arm to lift and pull the flatrack onto the PLS.

(3) Visual markers [3] are used to align the hook arm.

(4) Cargo tie-down rings [4] are in 29 locations to secure payloads.

(5) Pockets [5] for forklift are used to move flatrack when not on truck.

(6) ISO locks/fittings [6] are at the four corners for 20-foot ISO containers or are secured on any equipment capable of locking down a 20-foot ISO container, including ships and trailers.

(7) Rollers [7] at the rear are used for loading/unloading flatrack onto the trailer or docks. Rollers are removable and stored on brackets under storage boxes.

(8) Side boards [8] are an available option for the flatracks.

e. Specifications.

Transparency PLS 1-6

(1) PLS truck - weights and dimensions. Total curb weight is 51,090 pounds.

(a) Total loaded weight is 87,340 pounds. Actual load capacity is 33,000 pounds or 16.5 tons.

(b) The front axle loaded weight is 33,290 pounds and the rear group of axles weight is 54,050 pounds. To avoid overloading the truck components, these weights should not be exceeded.

(c) Overall height is 157.48 inches at the top of the hook in the stowed position. The cargo will increase this height.

(d) Overall width is 96 inches.

(e) Overall length is 441.65 inches (with flatrack and ISO container).

Transparency PLS 1-7

(2) PLS truck and trailer weights and dimensions. Total curb weight is 65,265 pounds.

(a) Total loaded weight is 137,715 pounds.

(b) Overall length is either 60 or 62 feet, depending on the position of the drawbar.

Transparency PLS 1-8

f. Capabilities of truck and trailer.

(1) Ascend and descend a 30 percent grade.

(2) Operate on a 20 percent side slope.

(3) Park on a 30 percent grade.

(4) Ford to a depth of 48 inches.

(5) Sustain a speed of 55 MPH.

(6) Travel approximately 225 miles without refueling.

Transparency PLS 1-9

g. Turning capability.

(1) Proper turning procedure with the trailer is very important.

(2) To make a turn on a 30-foot roadway, the start of the turn must be as shown. Notice the front wheel is at the start of the intersection.

(3) If turn is done properly, the actual width of the turn is about 26.5 feet.

NOTE: | For a complete listing of the PLS specifications, refer to the vehicle operator's manual, TM 9-2320-364-10, paragraph 1-11.

Transparency PLS 1-10

h. Description of driveline components and power flow.

(1) Engine - DD 8V92TA at 500 horsepower.

(2) Transmission - Allison CLT-755 (5-speed, fully automatic).

(3) Transfer case - Oshkosh model 55,000 with a planetary differential. Power is applied at all times.

(4) Axles - all are Rockwell Model 5 MR with planetary hub reduction and differential lockup. Note the front two and rearmost axles steer.

(5) Power flows from engine through transmission, into transfer case, then is split to front and rear. The split at the transfer case is 30 percent torque to the front with 70 percent going to the rear.

i. Location of data plates.

Transparency PLS 1-11

(1) Front/left data plates.

(a) Vehicle data.

(b) Shipping data.

(c) LHS electrical lowering override.

(d) Preoperation maintenance.

(e) Cold tire pressure.

(f) Parts data.

Transparency PLS 1-12

(2) Inside cab data plates.

(a) Warranty data.

(b) Rustproofing data.

(c) STE-ICE zero offset.

(d) Crane instructions.

(e) Caution hydraulic selector.

(f) Emergency engine shutdown.

(g) Transfer shift pattern.

(h) Vehicle data.

(i) Circuit breaker identification.

(j) Ether cold weather start.

(k) Caution trailer drawbar.

Transparency PLS 1-13

(3) Left side data plates.

(a) LHS manual override.

(b) Warning MHC.

(c) Warning fan.

(d) LHS hydraulic slave.

(e) Warning flatrack.

(f) Multilift data.

(g) Hardlift installation instructions.

(h) Emergency trailer air coupling.

(i) Service trailer air coupling.

Transparency PLS 1-14

(4) Right side data plates.

(a) MHC remote control.

(b) Warning self-recovery winch.

(c) Caution crane procedures.

(d) Warning outriggers.

(e) Danger electrocution.

(f) Danger machine familiarization.

(g) Caution electronic equipment.

Transparency PLS 1-15

(5) Superstructure data plates.

(a) MHC capacity.

(b) MHC boom angle indicator.

(c) Warning electrocution hazard.

(d) Caution outrigger.

(e) Left side MHC remote control hookup.

Transparency PLS 1-16

(6) Right side superstructure data plates.

(a) Crane stowage procedure.

(b) MHC right side remote control hookup.

(c) Caution material-handling system (MHS) system (electric) manual override.

(d) Caution MHS system (arctic warm-up manual override.

(e) High idle, power, and latch switch.

3. Practical exercise: None.

4. Evaluation: Students are evaluated daily during driving tasks and are tested during the end of course comprehensive test (EOCCT).

5. Summary:

a. Recap main points.

b. Allow for questions.

c. Clarify questions.

d. Give closing statement.

6. Retraining: Training is reinforced during daily driving tasks.

E. SAFETY RESTRICTIONS. None.

F. ADDITIONAL COMMENTS AND INFORMATION. Recommended instructional time is 0.5 hour conference.

#### LESSON TITLE: | IDENTIFY CAB CONTROLS, INSTRUMENTS, AND INDICATORS
TASK NUMBER: | 551-721-1352 (Perform Vehicle Preventive Maintenance Checks and Services [PMCS])

A. TRAINING OBJECTIVE.

| TASK: | Identify cab controls, instruments, and indicators.
| CONDITIONS: | Given instruction on the M1074/M1075 PLS truck and a requirement to identify and explain the function of cab controls, instruments, and indicators.
| STANDARD: | Correctly identify and explain the function of the cab controls, instruments, and indicators.

B. INTERMEDIATE TRAINING. None.

C. ADMINISTRATIVE INSTRUCTIONS.

1. Training time: As scheduled.

2. Training location: Scheduled classroom.

3. Training type: Conference.

4. Students: Scheduled personnel.

5. Principal and assistant instructors required: One primary instructor.

6. Training aids and equipment: Overhead projector, transparencies, and screen.

7. Reference: 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) Summary.

2. Explanation:

NOTES: | The instructor points out the use of international symbols to identify dash components as a way to avoid differences and confusion.
| The instructor will emphasize the importance of safety getting into and out of the cab (maintain three points of contact), observing all warnings, and using seat belts.

Transparency PLS 2-1

a. Foot pedals and lower window.

(1) Service brake pedal [1] applies the service brakes. If the truck is properly coupled to a trailer, the trailer service brakes will also operate when the truck service brakes are applied.

(2) Throttle control (accelerator pedal) [2] controls the engine speed.

(3) Floor window [3], for overcrest visibility, enables the driver to see what is on the down side of a crest. Also the metal horizontal bar across the center of the window is 48 inches, the maximum fording depth for the PLS.

Transparency PLS 2-2

b. Steering wheel and adjacent controls.

(1) Emergency flasher control [1] is used to turn hazard warning flashers on and off. To turn on the hazard warning flashers, push button in. To turn the hazard warning flashers off, pull button out.

(2) Steering wheel [2] is used to control the direction of the vehicle. Grasp the steering wheel at the three o'clock and nine o'clock positions with palms facing inward.

(3) Horn button [3] sounds the electric horn when pressed.

(4) Turn signal lever [4] is used to signal turns. Push up to signal a right turn and pull down to signal a left turn. When the turn is completed, the lever will self-cancel (return to the off position).

(5) Trailer hand brake control (johnson bar or trailer hand valve) [5] is used to apply and release the trailer brakes separate from the vehicle service brakes. It should only be used to test the trailer brakes. Using it when driving will cause the trailer to skid. It can be used for coupling and uncoupling trailers without spring brakes.

(6) Dimmer button [6] is located at the end of the turn signal arm. Press the button to raise or lower headlight beams. High beam indicator light will light blue when high beams are on.

Transparency PLS 2-3

c. Dash indicator lights.

(1) Left turn indicator [1] flashes green when left turn signal is on.

(2) Engine brake [2] indicator lights green when the engine brake on/off switch is in the on position.

(3) High beam indicator [3] lights blue when the vehicle headlights are on high beam.

(4) Trailer flatrack unlocked [4] indicator lights red when the trailer flatrack is not locked (only if load lock status line on trailer is connected to truck).

(5) Engine low oil pressure [5] indicator lights red when the engine oil pressure is below 5 psi.

(6) Transmission check [6] indicator lights yellow when the transmission fluid temperature is above 270°F.

(7) High water temperature [7] indicator lights red when the engine coolant temperature is above 230°F.

Transparency PLS 2-4

d. Dash indicator lights and gauges.

(1) LHS no transit [1] indicator lights red when the load-handling system is not correctly stowed on the truck.

(2) LHS overload [2] indicator lights yellow to warn operator that the load-handling system is overloaded. Maximum payload is 34,500 to 35,000 pounds.

(3) LHS [3] indicator lights green when the load-handling system is activated and in automatic, manual hook arm, and manual main frame mode.

(4) Auxiliary hydraulic [4] indicator lights green when auxiliary hydraulic is in use.

(5) Hydraulic oil [5] indicator lights red and buzzer sounds when the auxiliary (main) hydraulic fluid level is below 25.75 gallons.

(6) Emergency steer [6] indicator lights red when emergency steering system is activated.

(7) Oil pressure gauge [7] shows engine oil pressure (in psi and kPa).

(8) Water temperature gauge [8] shows engine coolant temperature in degrees Fahrenheit and degrees Celsius.

(9) Trans. temperature gauge [9] shows transmission fluid temperature in degrees Fahrenheit and degrees Celsius.

(10) Fuel gauge [10] shows level of fuel in the fuel tank.

Transparency PLS 2-5

e. Dash gauges and buzzers.

(1) Tachometer/hourmeter [1] shows the engine operating speed (RPM x 100) and total operating time in hours.

(2) Speedometer/odometer [2] shows vehicle traveling speed in MPH and KMPH and total miles traveled.

(3) Low air alarm/low hydraulic oil alarm [3] sounds an intermittent buzzer sounds when system air pressure drops below 60 psi or hydraulic oil level is below 25.75 gallons.

(4) Kilometer/odometer [4] shows total kilometers traveled.

(5) Oil/water alarm [5] sounds a steady buzzer sounds when engine oil pressure is below 5 psi or when engine coolant temperature is above 230°F.

(6) Voltmeter (12V) [6] shows state of charge of batteries and voltage level in the 12-volt system. Correct charge is 12-14 volts.

(7) Voltmeter (24V) [7] shows state of charge of batteries and alternator voltage output in the 24-volt system. Correct charge is 24 to 28 volts.

Transparency PLS 2-6

f. Dash indicator lights and switches.

(1) Engine check [1] indicator lights orange to show engine problem such as low oil pressure or high coolant temperatures.

(2) Drive line lock [2] indicator lights yellow to show drive line lockup when the transfer case is in low range and the CTIS is set at emergency position.

(3) Right turn indicator [3] flashes green when right turn signal is on.

(4) Check gauges [4] light orange when a problem exists in the engine that may cause damage. If the light comes on, check gauges. If gauges read normal, proceed. If gauge readings are abnormal, shut down and check coolant and lubricant levels in the engine.

(5) Low air [5] indicator lights red when system air pressure is below 60 psi.

(6) Parking brake [6] indicator lights red when the parking brake is on.

(7) Rheostat switch [7] controls the brightness/ dimness of the instrument panel lights.

(8) Headlight/clearance light switch [8] turns headlights and clearance lights on and off.

(9) Dome light switch [9] turns the dome light on and off.

Transparency PLS 2-7

g. Dash switches. These are rocker type with international symbols.

(1) Work light switch [1] turns work light on and off.

(2) Beacon light switch [2] turns beacon light on and off.

(3) Blackout light selector [3] selects between normal and blackout mode for night driving under blackout conditions. It locks out service drive lights and automatically deactivates the vehicle's backup alarm. The blackout lock selector (at the upper part of this switch) must be pushed down to turn this switch on.

(4) Blackout drive switch [4] turns blackout drive lights on and off.

(5) Blackout marker switch [5] turns blackout marker lights on and off.

(6) Engine brake switch [6] turns on or shuts off electric power to the engine brake. Center position is low and down position is high.

(7) Windshield washer switch [7] controls spray of cleaning fluid on windshield.

(8) Windshield wiper switch [8] controls operation of windshield wipers.

(9) Engine on/off/start switch [9] is straight up for the off position. On position operates electrical system and start position operates engine cranking circuit.

(10) Ether start button [10] is pressed to supply engine with a measured shot of ether for cold weather starts.

Transparency PLS 2-8

h. CTIS control panel.

(1) Rotary selector switch [1] selects one of four tire pressures for maximum traction and minimum tire wear under various conditions and speed limits. A green LED (light-emitting diode) at each of the four positions will stay lit continuously if the CTIS and drive line lockup are in the proper operating mode. Slow flashing indicates acceptable change. Rapid flashing indicates unacceptable operating parameters and requires corrective action by the operator. Speed limits are as follows:

(a) Highway - 55 MPH.

(b) Cross country - 40 MPH.

(c) Mud, sand, and snow - 12 MPH.

(d) Emergency - 5 MPH.

(2) Overspeed indicator [2] lights amber when the truck average speed for one minute exceeds the speed limit for the rotary selector switch setting.

(3) Low air indicator [3] lights red to warn of low pressure in the vehicle air system. This condition causes the CTIS to shut down giving the truck brake system priority to the available air pressure. The CTIS will automatically resume operation when the air pressure builds up to about 110 psi.

(4) Start switch [4] is pressed (and held for one second) to start operation of the CTIS.

(5) Shutdown switch [5] is turned to the on position for normal CTIS operation. Drive line function will still operate with switch in the off position. It is also used as emergency shutdown switch, to turn off CTIS if there is an air leak in the CTIS.

Transparency PLS 2-9

i. Air gauges and brake controls.

(1) Air pressure gauge [1] shows air pressure in psi and kPa in both sections of the air brake system. Green needle shows the front section air reservoir pressure. Red needle shows the rear section air reservoir pressure.

(2) Air filter restriction indicator [2] shows the condition of the air filter. Vacuum inches H20 window shows degree of restriction. Indicator should read less than 20 inches for normal operation. If indicator latches at 20 inches during operation, truck may continue to operate until mission is completed. Air filter must be serviced before next mission. Push the button to reset.

(3) Parking brake control [3] is pushed to release the truck brakes and pulled to apply truck brakes. It also automatically applies the parking brakes if air pressure goes below 35 psi (spring brakes).

(4) Trailer air supply control [4] is pushed to supply air to trailer brake system and pulled to shut off and exhaust trailer air.

Transparency PLS 2-10

j. Transmission shift control.

(1) Use R (reverse) [1] to move truck backwards.

(2) Use N (neutral) [2] to--

(a) Start engine.

(b) Park vehicle.

(c) Shift transfer case.

(d) Operate the load-handling system.

(e) Operate ancillary equipment (crane and/or winch).

(3) Use D (drive) [3] to--

(a) Drive in normal conditions.

(b) Move forward from a stop.

(c) Shift the transmission up and down automatically.

NOTE: | Transmission will start in second gear (transfer in low range only) or first gear (transfer in high range only).

(4) Use 4 or 3 (fourth or third range) [4] to--

(a) Drive in off-road conditions.

(b) Drive in city traffic.

(c) Drive in certain conditions. Refer to engine brake operation.

(d) Restrict up shifts to no higher than third fourth gear depending on selection.

(5) Do not shift [5]. Indicator lights red to show operating condition under which shifting would cause damage to the equipment. If in this mode and you shift gears, the transmission will shift to neutral. If this occurs while driving, pull over and stop as soon as it is safe to do so.

(6) Use 1 (first) when greatest traction and maximum engine braking is needed (also called low gear hold) [6].

(7) Use 2 (second) gear when pulling through mud or snow and climbing or descending steep grades (also called second gear hold) [7].

Transparency PLS 2-11

k. STE/ICE-R - transfer shift - LHS.

(1) STE/ICE-R receptacle [1] is used to connect the simplified test equipment/internal combustion engine-reprogrammable (STE/ICE-R).

(2) STE/ICE-R zero offset switch [2] is used to reset instrument connected to the STE/ICE-R receptacle switch to zero.

(3) Transfer case shift lever [3] is used to select high (HI) or low (LO) range. Center position is neutral.

NOTE: | The trick to shifting the transfer is to stop the truck, take your right hand and apply pressure to the transfer case shift lever, while at the same time pushing N on the transmission range selector with your left hand. Do not force the transfer case shift lever as this will only cause damage to the shift collars. The collars must be aligned before the transfer case will go in gear. If the transfer case shift lever is hard to move, push the D on the transmission range selector, then back to N. If the transfer case will not shift, select R then N and try to shift the transfer case lever again. If the transfer case will still not shift, select D, then back to N.

(a) Set the transfer case shift lever to high (HI) for highway driving and secondary roads.

(b) Set the transfer case shift lever to low (LO) for adverse off-road driving and steep grades.

(4) LHS load/unload joystick [4] is used to control the loading and unloading of flatracks.

Transparency PLS 2-12

l. Hydraulic mode selector.

(1) LHS mode selector. Use to select mode of operation for load-handling system.

CAUTION During driving operations, LHS mode selector must be placed in the off position or hydraulic system overheating will result.

(2) Modes.

(a) O = off. LHS is turned off. If not turned off when driving, it will cause the hydraulic oil to heat up and the engine to overheat. The reason for this is that when the LHS mode selector is in the 1 through 3 and 5 positions, the engine fan runs at half speed.

(b) 1 = automatic position. This setting activates the hydraulic circuit. The system will automatically respond to joystick movement by the operator.

(c) 2 = manual hook arm (MAN HA) position. Use this setting when automatic sequencing is not operating. This setting bypasses the automatic sequencing circuit to manually operate the hook arm only.

(d) 3 = manual main frame (MAN MF) position. Use this setting when the automatic sequencing is not operating. It bypasses the automatic sequencing circuit to manually operate the main frame only.

(e) 4 = manual transport (MAN TRANS) position. Use this setting if the automatic sequence has an electrical failure. This position must be selected if truck is to travel with this failure.

(f) 5 = crane/self-recovery winch (SRW). This setting energizes the auxiliary hydraulic circuit for the crane and/or self-recovery winch when the vehicle is equipped with either kit.

Transparency PLS 2-13

m. Side panel switches.

(1) Engine emergency stop switch [1] is used to shut down the engine only if the ignition switch will not shut off the engine.

(2) SRW/crane switch [2] allows operator to select SRW or crane individually when the vehicle is equipped with both kits.

(3) SRW in/out switch [3] controls self-recovery winch operation when truck is equipped with SRW kit.

(4) Gas particulate filter switch [4] turns gas particulate filter on or off when the truck is so equipped.

(5) Chemical alarm switch [5] activates chemical alarm when the truck is so equipped.

(6) Transfer case lockup indicator [6] lights (amber) when the transfer case is in the locked position.

(7) Transfer case lockup [7] locks or unlocks transfer case.

Transparency PLS 2-14

n. Circuit breakers.

(1) Circuit breakers are manual reset type.

(2) Each circuit breaker is labeled for its function.

Transparency PLS 2-15

o. Heater/defroster controls.

(1) Air control [1] controls amount of outside air entering cab through fresh air vent.

(2) Fan control [2] controls speed of heater fan.

(3) Heat control [3] controls amount of hot air entering cab.

(4) Defrost control [4] controls amount of air blown on windshield.

Transparency PLS 2-16

p. Operator's seat.

(1) Seat belt/shoulder harness [1] secures personnel in seat.

(2) Seat connector strap [2] secures seat to cab frame.

(3) Height adjustment control [3] is used to adjust seat height.

(4) Forward/backward adjustment control [4] is used to move seat forward or backward on slides.

(5) Ride adjustment control [5] is used to adjust seat tension and ride firmness.

NOTE: | Controls on operator's and passenger's seats are the same.

Transparency PLS 2-17

q. Rifle stowage mount.

(1) Lower rifle mount [1] holds the butt of the rifle.

(2) Rifle mount handle [2] secures upper hand guard of rifle.

(3) Top rifle mount [3] holds hand guard of rifle.

Transparency PLS 2-18

r. Machine gun mount.

(1) Machine gun operator platform [1] supports machine gun operator.

(2) Machine gun mount [2] secures the machine gun to the machine gun ring.

(3) Machine gun ring [3] allows machine gun to turn 360°.

3. Practical exercise: None.

4. Evaluation: Students are evaluated daily during driving tasks and are tested during the EOCCT.

5. Summary:

a. Recap main points.

b. Allow for questions.

c. Clarify questions.

d. Give closing statement.

6. Retraining: Training is reinforced during daily driving tasks.

E. SAFETY RESTRICTIONS. None.

F. ADDITIONAL COMMENTS AND INFORMATION. Recommended instructional time is 1 hour conference.

LESSON TITLE: | KNOW ENGINE START AND SHUTDOWN PROCEDURES
TASK NUMBER: | 551-721-1366 (Drive Vehicle with Automatic Transmission)

A. TRAINING OBJECTIVE.

| TASK: | Know engine start-up and shutdown procedures.
| CONDITIONS | Given instruction on the M1074/M1075 PLS truck and a requirement to locate the controls and explain the engine start-up and shutdown procedures.
| STANDARD: | Correctly locate the controls and explain the engine start-up and shutdown procedures.

B. INTERMEDIATE TRAINING. None.

C. ADMINISTRATIVE INSTRUCTIONS.

1. Training time: As scheduled.

2. Training location: Scheduled classroom.

3. Training type: Conference.

4. Students: Scheduled personnel.

5. Principal and assistant instructors required: One primary instructor.

6. Training aids and equipment: Overhead projector, transparencies, and screen.

7. Reference: 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) Summary.

2. Explanation:

NOTE: | This lesson will emphasize correct engine start-up and shutdown techniques to be used with the PLS vehicle. The instructor will review special cautions which will increase vehicle and component longevity.

Transparency PLS 3-1

a. Start engine.

(1) Pull out parking brake control [1].

(2) Turn engine on/off/start switch [4] to on. When switch is positioned to on, check gauges and check engine indicators will light and warning alarm will sound for about five seconds.

(3) Set transmission range selector [2] to neutral (N).

(4) To use the ether push button [3], press for five seconds; wait five seconds more before using it again or turning the engine on/off/start switch [4] to start. If outside temperature is above 45°F, go to step (5). Press ether push button as indicated below:

(a) One time for temperatures between +45°F to +10°F.

(b) Two times for temperatures between +10°F to -10°F.

(c) Three times for temperatures between -10°F to -25°F.

CAUTION Do not press ether start push button more than three times in a single starting attempt. Failure to observe this caution could cause severe engine damage.

CAUTION Do not turn engine start switch to start position while motor is running. Engine damage could result

NOTE: | Check engine light turns on for failures that are not potentially damaging to the engine. It is used as a warning lamp to tell a driver a problem has occurred. PLS truck should be serviced as soon as possible.

(5) Turn engine on/off/start switch [4] to start for about 15 seconds or until engine starts. If truck fails to start, wait 15 seconds before next attempt to allow starter to cool. Release switch. Switch will spring back to the on position. Low air indicator [13] will light and alarm [6] will sound.

NOTE: | Repeat steps (4) and (5) up to four times. If the engine fails to start after four tries, refer to Troubleshooting, Chapter 3, TM 9-2320-364-10.

CAUTION If oil pressure gauge does not show engine oil pressure within 10 to 15 seconds after starting engine, shut down immediately. Notify organizational maintenance. Lack of lubrication may damage engine.

CAUTION Do not operate engine above 1,000 RPM during warm-up until oil pressure gauge indicates 25 to 30 psi at 800 to 1,000 RPM. Oil pressure gauge should indicate 50 to 70 psi when engine operates at 1,800 to 2,000 RPM. Lack of lubrication may damage engine.

NOTE: | Check that oil pressure gauge reads 5 to 10 psi at idle and 40 to 60 psi during normal operation.

Transparency PLS 3-2

(6) Press accelerator pedal [5] until tachometer [7] indicates 800 to 1,000 RPM.

(7) Run engine at 800 to 1,000 RPM for about three minutes.

(8) Check that oil pressure gauge [8] reads 25 to 30 psi at 800 to 1,000 RPM. A cold engine may read above 30 psi, while a hot engine may read as low as 5 psi at idle.

NOTE: | If red and green needles on air pressure gauge do not read 60 to 125 psi after warm-up, shut off engine. Notify organizational maintenance.

(9) Check that air pressure gauge [14] reads 60 to 125 psi. Low air indicator [13] will light and alarm [6] will sound until both needles reach above 60 psi.

(10) Check that fuel gauge [10] shows enough fuel to complete the mission.

(11) Check that water temperature gauge [9] does not read over 210°F.

NOTE: | The water temperature gauge may not show a reading until after extensive operation.

(12) Check that 12-volt battery gauge [11] reads between 13 and 14 volts.

(13) Check that 24-volt battery gauge [12] reads between 26 and 28 volts.

(14) Check that air filter restriction indicator reads less than 20 inches H20.

Transparency PLS 3-3

b. Engine shutdown.

(1) Bring vehicle to a complete stop.

(2) Shift transmission to neutral (N) [1].

(3) Apply the parking brake [2]. Pull to apply.

(4) Run engine at 800 to 1,000 RPM for three to five minutes. This continues oil circulation to turbocharger which is turning at about 67,000 RPM.

(5) Idle engine for 30 seconds.

(6) Shut off all accessories.

(7) Turn engine on/off/start (ignition) switch [4] to off position.

3. Practical exercise: None.

4. Evaluation: Students are evaluated daily during driving tasks and are tested during the EOCCT.

5. Summary:

a. Recap main points.

b. Allow for questions.

c. Clarify questions.

d. Give closing statement.

6. Retraining: Training is reinforced during daily driving tasks.

E. SAFETY RESTRICTIONS. None.

F. ADDITIONAL COMMENTS AND INFORMATION. Recommended instructional time is 0.5 hour conference.

LESSON TITLE: | OPERATE ENGINE BRAKE (JAKE BRAKE)
TASK NUMBER: | 551-721-1366 (Drive Vehicle with Automatic Transmission)

A. TRAINING OBJECTIVE.

| TASK: | Operate the engine brake.
| CONDITIONS | Given instruction on the M1074/M1075 PLS truck and a requirement to locate the controls and explain the operation of the engine brake.
| STANDARD: | Correctly locate the controls and explain the operation of the engine brake.

B. INTERMEDIATE TRAINING. None.

C. ADMINISTRATIVE INSTRUCTIONS.

1. Training time: As scheduled.

2. Training location: Scheduled classroom.

3. Training type: Conference.

4. Students: Scheduled personnel.

5. Principal and assistant instructors required: One primary instructor.

6. Training aids and equipment: Overhead projector, transparencies, and screen.

7. Reference: 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) Summary.

2. Explanation:

Transparency PLS 4-1

a. How the engine brake (Jake brake) works. The principle behind the engine brake is very simple. It is a hydraulically operated device that converts a power-producing diesel engine into a power-absorbing retarding mechanism. To understand how the engine brake provides its strong retarding power, compare the engine cycles with and without an engine brake. For this purpose, the illustrations pertain to a four-cycle engine. However, the engine brake is effective on both two- and four-cycle diesels.

(1) During the intake stroke--

(a) Without engine brake [1], the intake valve is opened and air is pulled into the cylinder.

(b) With engine brake [1A], same action occurs as above.

(2) During the compression stroke--

(a) Without engine brake [2], air is compressed to between 500 and 1,000 psi and heat rises to about 1,000°F. Fuel is injected and combustion occurs, resulting in a pressure rise to some 1,500 psi, with a corresponding increase in temperature.

(b) With engine brake [2A], air is compressed with corresponding increases in pressure and temperature. Near top dead center, the engine brake's slave piston opens the exhaust valve, and the compressed air mass (representing potential energy) is released through the exhaust system. (Note black arrows in illustrations [2A] and [3A]). No combustion occurs since the engine brake operates only when the engine is in a no fuel (foot completely off accelerator) mode.

(3) During the power stroke--

(a) Without engine brake [3], the high pressures resulting from the combustion of the fuel/air mixture force the piston down, imparting power to the drivetrain.

(b) With engine brake [3A], no positive power is produced since the compressed air mass was released via the exhaust system during the modified compression stroke. The energy required to return the piston to its bottom position is now derived from the momentum of the vehicle. It is this two-step process, elimination of the compressed air and use of vehicle momentum to move the piston, that develops the engine brake's retarding capabilities.

(4) During the exhaust stroke--

(a) Without engine brake [4], upward motion of the piston forces exhaust gases out of the cylinder.

(b) With engine brake [4A], any remaining air is forced out of the cylinder.

b. How the engine brake is controlled. Discuss the system briefly. DDEC (Detroit Diesel Electronic Control) controls the brake. There are three basic parts:

(1) DDEC control, an electronic sensor that responds to the activation switch to control the exhaust valves.

(2) Engine device that works the exhaust valve.

(3) Three-position activation switch.

Transparency PLS 4-2

c. When and how to use the engine brake.

NOTE: | The engine must be warmed before using or checking the operation of the engine brake. The engine brake uses engine oil to operate. The oil must be warmed enough to flow through the tiny orifices and valves that cause the engine brake to operate.

(1) Location of control and how to operate.

(a) The engine brake switch has three positions: off (top position), low (center position), and high (bottom position). Set the engine brake switch [1] to low. Indicator light [2] will come on.

(b) Lift foot off throttle treadle (accelerator pedal). Engine brake will automatically slow vehicle.

(c) Optimum braking occurs with engine between 1,650 and 2,100 RPM [3]. Select appropriate transmission range and engine brake setting to maintain desired effect. Do not over rev engine during braking.

(d) If more braking is required, set the engine brake switch [1] to high.

WARNING Apply engine brake only when vehicle tires have good traction. Use of the engine brake on slick surfaces can cause the vehicle to skid and cause injury or death.

NOTE: | Service (wheel) brakes must be used in addition to engine brake for maximum braking. The engine brake supplements the service brakes. The engine brake is a vehicle-slowing device, not a vehicle-stopping device.

Transparency PLS 4-3

d. When to use engine brake.

(1) Do not use the engine brake until the engine has warmed.

(2) Select proper transmission gear to keep engine speed high, but not beyond governed speed (1,650 to 2,100 RPM).

(3) Always be aware of control switch position.

(4) Use proper brake position for existing road condition.

(5) Get acquainted with braking feel to make best use of the system.

(6) Note that the gear used going up grade is usually good for going down.

(7) Always shut off control switch after use.

3. Practical exercise: None.

4. Evaluation: Students are evaluated daily during driving tasks and are tested during the EOCCT.

5. Summary:

a. Recap main points.

b. Allow for questions.

c. Clarify questions.

d. Give closing statement.

6. Retraining: Training is reinforced during daily driving tasks.

E. SAFETY RESTRICTIONS. None.

F. ADDITIONAL COMMENTS AND INFORMATION. Recommended instructional time is 0.5 hour conference.

#### ENGINE BRAKE (JAKE BRAKE) INFORMATION SHEET

1. Each M1074/M1075 PLS truck is equipped with a retarder system that enables the engine to act as a brake. Use the engine brake for descending grades or in any situation where slowing is required. Do not use it on slippery road surfaces (rain, snow, sleet, or ice). Using the engine brake on slippery surfaces can cause the vehicle to skid. The engine brake is most effective between 1,650 to 2,100 RPM.

2. Never allow the engine speed to drop below 1,650 RPM with the engine brake applied. This will cause serious transmission damage.

CAUTION The engine brake loses effectiveness in controlling engine |RPM and vehicle speed when being pushed by a load down a grade. Use service brakes and manually downshift range selector as necessary on long grades to keep vehicle speed under control and engine RPM at 1,650 to 2,100.

3. Use the following procedures when the vehicle tires have good traction:

a. Select a gear that will allow the engine with the engine brake applied to control the truck speed with the engine at or below 2,100 RPM and service brakes not applied. This means as you approach a downgrade, progressively select a gear which when combined with the engine brake will allow you to maintain an engine speed of 1,650 to 2,100 RPM.

b. As engine speed exceeds 2,100 RPM, apply the service brakes one time to slow the engine speed, turn off the engine brake, and downshift one gear. (If you are in 4, downshift to 3 and reapply the engine brake.) Repeat this procedure until the engine speed can be maintained between 1,650 to 2,100 RPM.

c. If the engine overspeeds (above 2,100 RPM), apply the service brakes one time to slow the vehicle speed and regain control.

WARNING Failure to follow the downhill driving procedures may cause you to lose vehicle control and result in severe injury or death to personnel.

CAUTION Excessive use of the service brake to control downhill speed will result in the loss of braking power because of heat buildup.

WARNING Rapid operation repeatedly of service brakes will consume compressed air supply and cause automatic spring brake application. Failure to follow proper service brake operating procedures may cause serious injury or death to personnel.

4. The instructor must emphasize and reemphasize the importance of the proper downhill braking procedures and the use of the engine brake, especially on slippery surfaces, as outlined above. He must instill in the drivers that if these procedures are not followed, death or serious injury can result.

5. Also, the instructor must explain to the students that braking ability and braking techniques are different when loaded. The driver must think and plan ahead, increasing following distance and reducing speed consistent with road and traffic conditions.

LESSON TITLE: | OPERATE THE PLS CENTRAL TIRE INFLATION SYSTEM (CTIS)/DRIVELINE LOCKUP
TASK NUMBER: | 551-721-3361 (Operate the PLS Central Tire Inflation System [CTIS]/Driveline Lockup)

A. TRAINING OBJECTIVE.

| TASK: | Operate the PLS central tire inflation system (CTIS)/driveline lockup.
| CONDITIONS | Given instruction on the M1074/M1075 PLS truck and a requirement to locate the controls and explain the operation of the CTIS/driveline lockup.
| STANDARD: | Correctly locate the controls and explain the operation of the PLS central tire inflation system (CTIS)/driveline lockup.

B. INTERMEDIATE TRAINING. None.

C. ADMINISTRATIVE INSTRUCTIONS.

1. Training time: As scheduled.

2. Training location: Scheduled classroom.

3. Training type: Conference.

4. Students: Scheduled personnel.

5. Principal and assistant instructors required: One primary instructor for the class.

6. Training aids and equipment: Screen, overhead projector, and transparencies.

7. Reference: 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) Summary.

2. Explanation:

a. General. The PLS CTIS is designed to improve traction under different driving conditions and to maximize mobility without sacrificing tire life. It will automatically adjust the pressure in all tires to correspond to the rotary switch position selected and activated by the operator.

Transparency PLS 5-1

b. CTIS and driveline lockup controller.

(1) Rotary selector switch [1] selects one of four tire pressures for maximum traction and minimum tire wear under various conditions and speed limits as follows: highway, 55 MPH; cross-country, 40 MPH; mud, sand, and snow, 12 MPH; emergency, 5 MPH. A green LED at each of the four positions will stay lit continuously if the CTIS is in the proper operating mode. Slow flashing indicates acceptable change. Rapid flashing indicates unacceptable operating parameters and requires corrective action by the operator. In switch position 3 and 4, the switch also changes axle lockup conditions.

NOTE: | Changing the rotary switch positions engages a new driveline lockup mode; however, it does not activate the CTIS. The operator must always depress the start button on the controller module to initiate a change in CTlS setting.

(2) Overspeed indicator [2] lights (amber) when the vehicle average speed for one minute exceeds the speed limit for the rotary selector switch setting.

(3) Low air indicator [3] lights (red) to warn that air pressure in the vehicle air system is below 90 psi. This condition causes the CTIS to shut down, giving priority to the vehicle brake system for available air pressure. The CTIS will automatically resume operation when the air pressure builds up to about 110 psi.

(4) Start switch [4] is pushed to start operation of the CTIS.

(5) Disable (on/off) switch [5] disables the entire CTIS system. When this toggle switch is moved to the off position, the system is disabled and tire pressure or CTIS setting cannot be changed until the unit is switched back on. When this switch is off, overspeed protection is also disabled. Driveline function will still operate with the switch in the off position.

Transparency PLS 5-2

c. Explanation of axle lockup modes.

NOTE: | The transfer case is not locked up in any of the CTIS modes. This must be done with a separate switch on the side panel.

(1) Highway operation. Limit speed to 55 MPH [1]. Tire pressure is 65 psi front and 75 psi rear. The driveline remains in normal 10-wheel drive (no driveline lockup).

(2) Cross-country. Limit speed to 40 MPH [2]. Tire pressure is 34 psi front and 38 psi rear. The driveline remains in normal 10-wheel drive (no driveline lockup).

(3) Mud, sand, and snow. Limit speed to 12 MPH [3]. Tire pressure is now 20 psi front and 23 psi rear. Interaxle differentials will lock causing axles one and two to turn at the same rate and axles three, four, and five to turn at the same rate. (Tires on each axle may rotate individually.)

(4) Emergency. Limit speed to 5 MPH [4]. Tire pressure is 15 psi front and 18 psi rear. Now interaxle differentials are locked and side-to-side differentials are locked if the transfer case lever is set to low range. (This causes the tires on each axle to rotate at the same rate.)

Transparency PLS 5-3

CAUTION Do not move the rotary switch to the third or fourth position while the wheels are slipping or vehicle is turning a corner. Damage to the driveline may result.

CAUTION Before operating off-road, mud flaps need to be pinned on storage hook located on mud flap bracket. If a steep slope is encountered and mud flaps are not pinned, damage can result

NOTE: | Select the proper CTIS setting before entering an area where poor traction conditions are likely to occur.

d. Operating procedures. If truck is stopped during CTIS mode change, an increase in engine RPM is required to provide adequate air supply. An increase in RPM is generally not required during normal operation.

(1) Place on/off switch to the on position [1].

(2) Set rotary switch [2] on the CTIS for correct driveline lockup and tire pressure to match anticipated driving conditions.

NOTE: | CTIS may not engage properly if CTIS start button is pressed too quickly.

(3) Press and hold start button [3] on the controller for about one second to activate the CTIS system.

(4) Observe green LED lights [4] on controller to check system operation.

CAUTION The rotary switch setting should always correspond to the lighted setting. If the light and switch settings do not match, the operator must change the switch setting to correct the situation.

(a) A continuous green light indicates the CTIS and driveline lockup are both in proper operating mode and CTIS pressure check/ adjustment cycle has been completed.

(b) Flashing green light indicates the CTIS is in the process of checking/adjusting the tire pressure.

CAUTION The CTIS increases tire inflation pressure when vehicle speed exceeds the allowable speed for each setting. When an increase in speed is required, maintain the lower speed until the tires are reinflated to the correct pressure.

(c) A rapidly flashing green light indicates the rotary switch and tire pressure do not match and requires the operator to take corrective action (change the switch setting).

(5) The amber overspeed [5] light begins to flash when an overspeed condition has been present for one minute and continues to flash along with the green light until the new CTIS setting is reached.

(6) The red low air light [6] indicates the CTIS has turned off due to a low air pressure in the braking system. Flashing red light indicates a CTIS problem.

NOTES: | With CTIS manually disabled, the vehicle can still be operated normally (as if the vehicle were not CTIS- equipped) to complete the mission before repairs are made.
| Intermittent manual on/off operation of the CTIS system to inflate or deflate tires may still be available to the operator and can be used to complete mission before repairs are made.
| If it becomes necessary to disable the CTIS, the tires will have to be manually inflated or deflated.
| If a Class III oil leak develops from a wheel valve, turn CTIS on/off switch to off position and complete the mission. Notify organizational maintenance.

(7) If it becomes necessary to disable the CTIS, turn the on/off switch [1] to off. To start the CTIS, turn on/off switch [l] to on and press start button [3].

CAUTION When using emergency position on CTIS, top speed should not exceed 5 MPH and distance traveled should not exceed 5 miles. Care must be exercised as steering response is limited due to full driveline lockup. (The vehicle tries to go straight because of side-to-side lockup.)

(8) When changing setting from emergency to a lesser degree of driveline lockup, the vehicle must be stopped and driveline torque loading relieved.

(a) Stop truck.

(b) Set transmission range selector [7] to neutral.

(c) Turn CTIS rotary switch [2] to new position.

(d) Set transmission range selector [7] to reverse.

(e) Back up about 5 to 10 feet to relieve driveline loading and then bring truck to a stop.

(f) Press transmission range selector [7] to neutral and then to 3, 2, or 1, depending on ground conditions.

(9) The chart shows speed limits, lockup mode, and tire pressures for the four rotary switch [2] positions. For example, if the switch is set for cross-country, the speed of the truck should not exceed 40 MPH, no differentials lock up, and the tire pressure will adjust to 34 and 38 psi.

3. Practical exercise: The practical exercise for this lesson is integrated in the driving and off-road driving lessons.

4. Evaluation: Students are evaluated in the driving lessons and tested on the EOCCT.

5. Summary:

a. Recap main points.

b. Allow for questions.

c. Clarify questions.

d. Give closing statement.

6. Retraining: Training is reinforced during daily driving tasks.

E. SAFETY RESTRICTIONS. None.

F. ADDITIONAL COMMENTS AND INFORMATION. Recommended instructional time is .5 hour conference.

LESSON TITLE: | PERFORM OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
TASK NUMBER: | 551-721-1352 (Perform Vehicle Preventive Maintenance Checks and Services [PMCS])

A. TRAINING OBJECTIVE.

| TASK: | Perform operator PMCS on an M1074/M1075 PLS truck.
| CONDITIONS | Given instruction, DA Form 2404, pencil, TM 9-2320-364-10, equipment records folder, rags, lubricants, coolant, an M1074/1075 PLS truck with BII, and a requirement to inspect the PLS truck according to the PMCS tables listed in TM 9-2320-364-10.
| STANDARD: | Correct all faults within the operator's level of maintenance, and legibly record all others on DA Form 2404. If no faults are found, make necessary entries on DA Form 2404.

B. INTERMEDIATE TRAINING. None.

C. ADMINISTRATIVE INSTRUCTIONS.

1. Training time: As scheduled.

2. Training location: Classroom and motor pool.

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

4. Students: Scheduled personnel.

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

6. Training aids and equipment: Television, VCR, TVT 55-36 (PIN: 710046DA), Part 1, "PLS Truck PMCS," hearing protection, rags, lubricants, and coolant. DA Form 2404, pencil, TM 9-2320-364-10, equipment records folder, and an M1074/M1075 PLS truck with BII 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.

(2) Practical exercise.

(3) Summary.

2. Explanation and demonstration:

a. Show TVT 55-36, Part 1, "PLS Truck PMCS."

b. Demonstrate before-, during-, and after-operation PMCS to students.

3. Practical exercise:

a. Assign students to vehicles and issue TM 9-2320-364-10, pencils, DA Form 2404, and equipment records folder. Tell students where rags, lubricants, and coolant are located.

b. Students perform PMCS.

4. Evaluation: Check each student's PMCS performance.

5. Summary:

a. Recap main points.

b. Allow for questions.

c. Clarify questions.

d. Give closing statement.

6. Retraining: Students perform PMCS daily and are reinforced throughout the course. PMCS is tested on the EOCCT.

E. SAFETY RESTRICTIONS.

1. Ensure that all chock blocks are in place when the 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 manual.

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.

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.

F. ADDITIONAL COMMENTS AND INFORMATION. Recommended instructional time is 2.0 hours (.25 conference, .75 demonstration, and 1.0 practical exercise). The remaining PMCS is performed throughout the course in conjunction with driving tasks.

LESSON TITLE: | DRIVE THE PLS TRUCK
TASK NUMBER: | 551-721- 1366 (Drive Vehicle with Automatic Transmission)

A. TRAINING OBJECTIVE.

| TASK: | Drive an M1074/M1075 PLS truck.
| CONDITIONS | Given instruction, DD Form 1970, DA Form 2404, pencil, TM 9 2320-364-10, equipment records folder, rags, lubricants, coolant, a suitable driver training area, an M1074/M1075 truck with BII, and a requirement to operate the PLS truck, start the truck, put the truck in motion, read gauges, upshift and downshift the transmission, manipulate the controls, use correct braking procedures, perform basic driving maneuvers to include backing using ground guides, and shut down the engine.
| STANDARD: | Drive the truck correctly and safely without accident or injury.

B. INTERMEDIATE TRAINING. None.

C. ADMINISTRATIVE INSTRUCTIONS.

1. Training time: As scheduled.

2. Training location: Classroom, motor pool, 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 the demonstration, and one assistant instructor for each student for the practical exercise.

6. Training aids and equipment: Television, VCR, videotape TVT 55-36 (PIN: 710046DA), Part 2, "PLS Driving Techniques," hearing protection, rags, lubricants, coolant, and 40 traffic cones or empty POL drums. DA Form 2404, DD Form 1970, pencil, TM 9-2320-364-10, equipment records folder, and an M1074/M1075 truck with BII for each student.

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

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: | An instructor will be in the cab whenever a student is driving the PLS truck.

a. Show videotape TVT 55-36, Part 2, "PLS Driving Techniques."

b. Place vehicle in motion.

(1) Perform before-operation PMCS.

(2) Remove and stow wheel chocks in stowage box.

(3) Ensure MHC and outriggers are secured in their stowed position (M1074 only).

(4) Adjust each rearview mirror so back of truck and view of road can be seen.

(5) Adjust foot rest if required.

(6) Adjust seat as needed.

(7) Adjust seat belt as needed.

WARNING 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.

(8) Start engine and allow it to warm up.

CAUTION Hydraulic selector switch must be in off position before driving or hydraulic system could overheat causing damage to equipment

(9) Ensure hydraulic (LHS mode) selector switch is in the off position.

(10) Push CTIS on/off switch to the on position.

(11) Check all gauges and instruments. Ensure all are registering normal readings.

(12) Turn on lights as appropriate.

(13) Set the transfer case shift lever to the appropriate range.

(14) Set the CTIS rotary selector switch to the appropriate position. Press and hold CTIS start switch for about one second.

(15) Apply the service brake and press the transmission range selector button to the appropriate range.

(16) Push in the parking brake control to release the brakes.

(17) Release the service brake pedal and slowly press the accelerator pedal until the truck reaches the desired speed.

(18) Accelerate, brake, and steer as required.

CAUTION Do not hold steering wheel at full left or right position for longer than 10 seconds. Oil overheating and pump damage can result.

(19) Manually downshift the transmission range selector to match driving conditions.

c. Stop the truck.

(1) Release the accelerator pedal.

(2) Depress the brake pedal.

WARNING Apply brakes gradually when stopping. A panic stop will cause the vehicle wheels to lock, engine to stall, and power steering to fail. Failure to do this will result in injury or death.

WARNING Repeated rapid operation of service brakes will consume compressed air supply and cause automatic spring brake application. Failure to follow proper service brake operating procedures may cause serious injury or death to personnel.

(3) As the vehicle begins to reduce speed, decrease brake pedal pressure.

(4) Stop smoothly by releasing the brake pedal pressure gradually as the stopping rate increases.

(5) After stopping, apply the brake just enough to keep the truck stopped.

d. Avoid backing the truck. Since the driver cannot see directly behind his vehicle, backing is always a dangerous maneuver. Common sense therefore dictates that backing be avoided whenever possible. For example, if the vehicle must be parked, the driver parks so that he will be able to pull forward when leaving. Though planning ahead can reduce the need to back, almost everyone who drives will have to back on occasion. These four simple rules will help to back safely:

(1) Inspect your intended path.

(2) Back and turn toward the driver's side.

(3) Use four-way flashers and horn (backup alarm is activated whenever the transmission is in reverse and blackout lights are turned off).

(4) Use ground guide(s).

WARNING When backing up or going forward, ground guides should never stand directly in the vehicle's path. Keep 10 yards between the vehicle and ground guides at the front or rear and at the corners of the vehicle (never directly behind the vehicle). Ground guides must not position themselves between the vehicle being guided and another object where an inadvertent engine surge or momentary loss of vehicle control could cause injury. The vehicle driver will immediately stop the vehicle if he loses sight of ground guides or notes that the guide is dangerously positioned between the vehicle and another object. In such cases, the vehicle driver will secure his vehicle, dismount, and make an on-the-spot correction before commencing operations.

e. Park the truck and shut down the engine.

WARNING Do not park the truck on a steep grade. Serious injury to personnel could result.

(1) Align the front tires in a straight ahead position.

(2) Pull out the parking brake control.

(3) Press transmission range selector button to neutral.

(4) Chock wheels.

(5) Increase engine speed to 800 to 1,000 RPM and continue to run engine for three to five minutes.

(6) Release the accelerator pedal.

(7) Turn engine switch to off.

(8) Perform after-operation PMCS.

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

g. Demonstrate driving within the training area.

3. Practical exercise:

a. Assign students to vehicles and issue TM 9-2320-364-10, pencil, DA Form 2404, DD Form 1970, and equipment records folder. Tell students where rags, lubricants, and coolant are located.

b. Students perform before-operation PMCS.

c. Students practice maneuvering the PLS truck through the courses laid out in the training area(s). Sample training areas are in Chapter 6 (Figures 6-1 through 6-5). During-operation PMCS is also conducted at this time.

NOTE: | As each student practices driving, an assistant instructor rides in the right seat. The assistant instructor explains driving techniques, ensures the driver is aware of driving situations, and conducts after-action reviews with each driver. Now is the time to pass on valuable experience and correct any bad driving habits.

d. Students perform after-operation PMCS and ensure all operator entries required on DA Form 2404 and DD Form1970 are accurate, complete, and legible.

4. Evaluation: Check each student's performance of PMCS and driving.

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. This can be accomplished using the videotape TVT 55-36, Part 2, "PLS Driving Techniques." Students perform driving tasks daily and are tested on the EOCCT.

E. SAFETY RESTRICTIONS.

1. Ensure that all chock blocks are in place when the 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 manual.

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.

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 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. Apply brakes gradually when stopping. A panic stop will cause the vehicle wheels to lock, engine to stall, and power steering to fail. Failure to do this will result in injury or death.

14. Repeated rapid operation of service brakes will consume compressed air supply and cause automatic spring brake application. Failure to follow proper service brake operating procedures may cause serious injury or death to personnel.

15. Do not park the truck on a steep grade. Serious injury to personnel could result.

F. ADDITIONAL COMMENTS AND INFORMATION. Recommended instructional time is 11 hours (.5 conference, .5 demonstration, and 10.0 practical exercise including 1.5 PMCS).

LESSON TITLE: | DRIVE THE PLS TRUCK ON THE ROAD (PRIMARY AND SECONDARY)
TASK NUMBER: | 551-721-1366 (Drive Vehicle with Automatic Transmission)

A. TRAINING OBJECTIVE.

| TASK: | Drive a loaded and empty PLS truck on the road (primary and secondary).
| CONDITIONS | Given instruction, DD Form 1970, DA Form 2404, pencil, TM 9-2320-364-10, equipment records folder, rags, lubricants, coolant, designated driving route (improved surfaced and secondary roads), an M1074 or M1075 truck with BII, an M1077 flatrack with securely tied down palletized load, and a requirement to drive a designated route (to include make right and left turns, make gradual steering corrections, signal intentions in advance, pass oncoming vehicles, maintain vehicle interval, obey highway warning and regulatory signs, operate the lights as required, monitor gauges and indicator lights, upshift/ downshift the transmission through all gear ranges, manipulate the controls, and perform basic driving maneuvers to include downhill braking [using the engine brake] and backing using ground guides).
| STANDARD: | Operate the truck correctly and safely without accident or injury.

B. INTERMEDIATE TRAINING. None.

C. ADMINISTRATIVE INSTRUCTIONS.

1. Training time: As scheduled.

2. Training location: Motor pool and driver training route (built up and rural areas) as scheduled.

3. Training type: Conference 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 student for the practical exercise.

6. Training aids and equipment: Rags, lubricants, coolant, DA Form 2404, DD Form 1970, pencil, TM 9-2320-364-10, equipment records folder, an M1074/M1075 PLS truck with BII for each student, and one M1077 flatrack with securely tied down palletized load for each two trucks.

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

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:

NOTES: | An instructor will be in the cab whenever a student is driving the PLS truck.
| The students will be required to drive the truck loaded and empty. If two trucks are used, one truck should be loaded with the PLS flatrack (load should be as close to 16.5 tons as possible) and the other should be empty.
| To prevent loss of cargo or shifting en route, check cargo tie-downs or ISO locks for security before operation and repeatedly during operation.

a. Explain putting the vehicle in motion--

(1) On flat roadways.

(2) On upgrades.

(3) On downgrades.

(4) In sand and snow, and on ice.

b. Explain the procedures for braking--

(1) Using the engine brake (Jake brake).

NOTE: | For detailed information on the use of the engine brake refer to the lesson outline, Operate Engine Brake (Jake Brake).

(2) Using the service brakes (foot brake).

(3) Driving on flat roadways.

(4) Driving on sand, snow, ice, and wet surfaces.

(5) Using emergency braking procedures.

(6) Downshifting the transmission.

c. Explain procedures for hill climbing:

(1) The engine works hardest when moving a loaded truck up a grade. Proper use of gear ranges will shorten the time on hills.

(2) Unless the hill is extreme, begin in gear range D (drive), and depress the accelerator pedal all the way downward. Keep it there as the truck moves up the grade. If there is enough power to maintain a satisfactory road speed, remain in this gear range and allow the transmission to upshift and downshift automatically.

(3) As you progress up the hill count the number of downshifts.

NOTE: | The automatic transmission is equipped with a lockup clutch that automatically engages after the load is rolling and torque demand is low. This provides increased fuel economy at highway cruising speeds. It automatically releases at lower vehicle speeds. Lockup engagement, like range shifts, may be felt under some conditions and you may hear a slight change in engine sound as RPM drop. A little driving experience will enable you to tell the difference between gear range changes and lockup engagement/disengagement.

(4) When you reach the top of the hill, manually downshift the transmission to the gear that the transmission is in (this was the reason for counting the number of downshifts). This is normally the gear the truck should be in to descend the other side of the hill.

(5) For starting on maximum grades with maximum load (such as truck fully loaded), stop the truck and shift the transfer to low. Start in gear range 2, depress accelerator pedal to the floor, and manually upshift the lever one range at a time, shifting when engine speed approaches 2,000 RPM.

d. Explain procedures for downhill driving:

(1) Manually downshift the transmission into a lower gear before starting downgrade. (The general rule is to use the same gear to descend the grade that would be needed to climb the grade.)

(2) Check brakes before starting the downgrade.

(3) Set the engine brake switch to low. If more braking is needed, set the switch to high.

NOTE: | For detailed information on the use of the engine brake, refer to the lesson outline, Operate Engine Brake (Jake Brake).

(4) Pay attention to signs indicating location of escape ramps.

(5) Use steady brake applications as required to slow vehicle speed.

(6) If braking power diminishes, use pull off and allow brakes to cool.

CAUTION Excessive use of the service brake to control downhill speed will result in the loss of braking power because of heat buildup.

WARNING Repeated rapid operation of service brakes will consume compressed air supply and cause automatic spring brake application. Failure to follow proper service brake operating procedures may cause serious injury or death to personnel.

e. Explain following distances:

(1) Maintain one second for each 10 feet of vehicle length (40 MPH and less). The PLS truck is 36 feet long, so at speeds up to 40 MPH, allow four seconds following distance.

(2) Increase by one second for speeds over 40 MPH. At 45 MPH, with the PLS truck, allow five seconds following distance.

(3) Increase by several seconds for rain, fog, and winter conditions.

f. Explain maneuvering the vehicle--

(1) In curves.

(2) Through a constant curve.

(3) Through a U-turn.

(4) At intersections.

(5) At turns.

(a) Start to turn before reaching the intersection.

(b) Observe the rear of the truck through the mirrors. (Normally, the PLS will follow the front wheels with minimal off-tracking.)

(6) When steering the vehicle.

NOTE: | When driving the PLS truck at highway speeds, new drivers tend to hug the edge of the road and oversteer. The rear axle of the truck is a steering axle and generally drivers tend to work the steering wheel too much. This causes the truck to constantly wander or sway. To correct this, check the position of the truck in the rearview mirrors, keep the truck centered in its lane, and make minor steering corrections.

(7) When making gradual steering corrections.

(8) To avoid abrupt steering movements.

(9) When passing stationary and moving vehicles.

g. Explain lane changing:

(1) Signal intentions.

(2) Check mirrors.

h. Give safety briefing.

i. Explain ground guide safety precautions for backing the truck.

3. Practical exercise:

a. Assign students to vehicles and issue TM 9-2320-364-10, pencils, DA Form 2404, DD Form 1970, and equipment records folder. Instruct students on the location of rags, lubricants, and coolant.

b. Students perform before-operation PMCS.

c. Students practice driving the vehicle on the road (primary and secondary). During-operation PMCS is also conducted at this time.

NOTE: | As each student practices driving, an assistant instructor rides in the right seat. The assistant instructor explains driving techniques, ensures the driver is aware of driving situations, and conducts after-action reviews with each driver. Now is the time to pass on valuable experience and correct any bad driving habits.

d. Students perform after-operation PMCS and ensure all operator entries required on DA Form 2404 and DD Form 1970are accurate, complete, and legible.

4. Evaluation: Check each student's performance of PMCS and driving.

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. Students perform driving tasks daily and are tested on the EOCCT.

E. SAFETY RESTRICTIONS.

1. Ensure that all chock blocks are in place when the 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 when 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 manual.

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.

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. During driving operations, hydraulic selector switch must be placed in the off position or hydraulic system overheating will result.

14. Do not hold steering wheel at full left or right position for longer than 10 seconds. Oil overheating and pump damage can result.

15. Apply brakes gradually when stopping. A panic stop will cause the vehicle wheels to lock, engine to stall, and power steering to fail. Failure to do this will result in injury or death.

16. Repeated rapid operation of service brakes will consume compressed air supply and cause automatic spring brake application. Failure to follow proper service brake operating procedures may cause serious injury or death to personnel.

17. Excessive use of the service brake to control downhill speed will result in the loss of braking power because of heat buildup.

18. Do not park the truck on a steep grade. Serious injury to personnel could result.

19. Apply engine brake only when truck tires have good traction. Use of engine brake on slippery surfaces can cause the truck to skid and cause injury to personnel.

20. If emergency steer light illuminates when driving, immediately pull the truck over to the side of the road and stop or serious injury or death could result.

F. ADDITIONAL COMMENTS AND INFORMATION. Recommended instructional time is 12 hours (1.0 conference and 11.0 practical exercise, including 2.0 PMCS).

LESSON TITLE: | CHANGE TIRE ON PLS TRUCK USING TIRE DAVIT
TASK NUMBER: | 551-721-3371 (Change Tire on PLS Truck Using Tire Davit)

A. TRAINING OBJECTIVE.

| TASK: | Change a tire on the PLS truck using the tire davit.
| CONDITIONS | Given instruction, TM 9-2320-364-10, rags, heavy work gloves, hearing protection, an M1074 or M1075 truck with BII, and a requirement to change a simulated flat tire on the truck.
| STANDARD: | Perform task in the correct sequence according to TM 9-2320-364-10 and without damage to equipment or injury to personnel. Students will be graded on a Go/No-Go basis.

B. INTERMEDIATE TRAINING. None.

C. ADMINISTRATIVE INSTRUCTIONS.

1. Training time: As scheduled.

2. Training location: Training area or motor pool as scheduled.

3. Training type: Demonstration and practical exercise.

4. Students: Scheduled personnel.

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

6. Training aids and equipment: Rags, heavy work gloves, TM 9-2320-364-10, and an M1074 or M1075 truck with BII for every two students. Hearing protection is required for all personnel.

7. References: 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: | Changing a tire on the PLS truck is a two-soldier task. One soldier cannot safely do this task.

a. Review safety warnings.

b. Park the truck.

(1) Park the truck in a safe area, out of traffic, where there is no traffic danger to personnel changing the tire. Also, the truck must be parked on hard, level ground.

(2) Set the parking brake, press the transmission range selector button to neutral, turn the CTIS on/off switch to off, and shut off the engine.

(3) Turn on emergency flashers as dictated by traffic hazards.

(4) Position emergency reflective triangles as dictated by traffic hazards.

(5) Chock the wheels. It is best to chock a front wheel on the opposite side of the truck. For example, if the right front tire of axle one were flat, chock the left front tire of axle two, front and rear of the tire, to prevent movement in either direction.

c. Tools. Remove all necessary tools from truck stowage boxes (jack, jack handle extension, jack plate, winch handle, 7/8-inch by 3/4-inch open end wrench, 3/4-inch tube wrench, 8-inch adjustable wrench, air hose, air impact wrench, cargo strap, 33-mm socket, and 1 1/2-inch socket [extension wrench and sliding handle may be used in place of air impact wrench]).

NOTE: | If an air impact wrench is not available, a slide handle with extension handle can be used.

d. Remove spare tire and jack up truck.

(1) Install the winch handle to spare tire winch and turn counterclockwise about three turns (or until there is enough slack in winch cable to remove the hook).

(2) Remove hook from spare tire winch.

(3) Turn the winch handle counterclockwise until the winch cable hook touches the ground.

(4) Position the vehicle ladder on the left side of the truck, climb the ladder, and get in position by the tire davit.

WARNING Do not touch hot exhaust system with bare hands; injury to personnel will result.

NOTE: | There is a second hole drilled in the extension arm to allow the pin to be reinserted and lock the extension arm in the extended position.

(5) Remove the safety pin and pin from the tire davit extension arm and extend the extension arm to the second alignment hole. Install the pin and safety pin in the second alignment hole.

(6) Remove the safety pin and pin from the hoist (this allows the spare tire and davit to swivel, which will be accomplished later in this procedure).

WARNING Ensure all personnel wear protective gloves at all times during this procedure when handling the cable. The cable may fray and injury to personnel may result.

(7) Route the hook and cable through the mounting plate and around the spare tire. Be careful that the cable does not damage the CTIS fittings on the spare tire.

(8) Attach the hook to the cable above the spare tire ensuring that the hook is connected at a point where the rubber casing covers the cable. If the hook is attached to the bare cable, damage to the cable will result.

(9) Move the access ladder to the right side of the truck.

(10) Turn the spare tire winch handle clockwise to place tension on the cable.

(11) Connect the air hose to truck air coupling and connect the air impact wrench to the other end of the air hose.

NOTE: | Perform steps (12) and (13) if the flat tire is on axle three. The reason for doing these two steps is to relieve pressure on the air bags on axle three. If the pressure is not relieved, in some terrain situations the jack will not fit under the axle beam.

(12) Close the ball valve located on top of the crossmember behind the transfer case by turning the lever.

(13) Open the air tank drain valve petcocks on both sides of the truck (rear tanks). This isolates the system so that no air goes to the air bags and the vehicle still has three remaining air tanks to provide air for the air impact wrench.

NOTE: | Jack position will vary depending on location of flat tire.

(14) Position the jack base plate, jack, and handle under the truck axle beam nearest the flat tire. Unscrew the jack extension until it touches the truck axle beam.

(15) Raise the jack until the flat tire is slightly off the ground.

(16) Start the truck and build up the air pressure to above 120 psi. Air pressure must be maintained above 120 psi while using the air impact wrench.

WARNING Wear hearing protection during the tire-changing procedure while using the air impact wrench. Failure to do so may result in injury to personnel.

(17) Using the air impact wrench and 1 1/2-inch socket, remove the two nuts and plate from the spare tire mounting plate.

(18) Disconnect the ratchet strap from the spare tire hold-down strap.

WARNING Stand clear of tire when raising or lowering. Do not let the tire hang in midair for a long period of time. Place tire on carrier or on ground as soon as possible. Tire is very heavy (about 500 pounds) and could cause serious injury or death if it falls

(19) Hook the cargo strap to the rim and move the access ladder out of the way.

(20) Turn the spare tire winch handle clockwise to lift the spare tire just above the carrier.

(21) Pull on the cargo strap so the spare tire swings clear of the truck.

(22) Turn the winch handle counterclockwise to lower the spare tire to the ground.

(23) Remove the cargo strap and winch cable from the spare tire. With the aid of an assistant, rotate the spare tire so that the mounting plate is facing away from the truck and lean the spare tire against the truck, out of the way.

WARNING While changing tires or while performing tire maintenance, stay out of the trajectory of the wheel. The wheel trajectory area is the rim on both sides of the wheel. Under some circumstances, the trajectory may deviate from its expected path. Failure to follow proper procedures may result in injury or death to personnel.

CAUTION Be careful not to twist the CTIS plug tethering cables. Failure to comply may result in damage to equipment

(24) Using 7/8-inch by 3/4-inch open end wrench, remove the two plugs from the CTIS valves. Save these plugs to install in the CTIS valves in the flat tire.

(25) With the aid of an assistant, rotate the tire, remove the three nuts from the mount plate, and retain for later use (when the flat is mounted in place of the spare tire).

(26) Remove the mount plate from the spare tire. Remember the position of the mount plate, so that when the flat tire is mounted, the plate will be in the same relative position to the CTIS valve.

e. Remove flat tire.

(1) Using air impact wrench and 33-mm socket, remove four wheel cover nuts from the studs and remove the wheel cover from the rim of the flat tire.

NOTE: | Note the location of the CTIS holes in the tire rim to aid in the installation of the spare tire.

(2) Using 8-inch adjustable wrench, 3/4-inch tube wrench, and 7/8-inch by 3/4-inch open end wrench, loosen two nuts and remove the two CTIS hoses from the flat tire.

(3) Install the two CTIS hoses removed from the flat tire on the spare tire CTIS wheel valve and tighten the nuts finger tight.

WARNING Crew member should steady the tire during removal. Falling tire may cause injury to personnel.

WARNING Do not loosen outer bolt circle nuts on wheel. Outer bolt circle holds wheel assembly together. Tire is under pressure and loosening these nuts can cause the tire to blow apart. Severe injury or death can occur.

(4) Studs and lug nuts on both sides of the truck have right-hand threads. Using air impact wrench and 1 1/2-inch socket, rotate the lug nuts counterclockwise to loosen and remove the 10 lug nuts.

WARNING Keep hands away from the inside of the rim while removing the tire or injury to personnel may result.

WARNING Tire should be kept upright during removal. Damage to the CTIS may result if the tire falls on the CTIS valve.

(5) With the aid of an assistant, remove the flat tire from the hub and lean the tire against the truck. Jack handle extension may be used under the tire to assist sliding or creeping wheel away from the hub.

f. Install spare tire and wheel.

(1) Roll the spare tire up to axle where flat tire was removed.

NOTE: | Make sure deep side of spare tire wheel dish is in the same position as the flat tire wheel dish when flat tire was removed.

(2) Line up the CTIS holes in spare tire with CTIS fittings in hub.

WARNING Tire assembly is very heavy (500 pounds). Do not try to lift or catch tire assembly. Injury to personnel could result.

(3) Lean top of spare tire against the studs and hub.

WARNING Jack is under heavy pressure. Keep hand, arm, and head clear while slowly raising or lowering the jack to avoid injury to personnel. Do not lower the jack too quickly as tire could fall causing serious injury or death.

CAUTION If the jack must be raised or lowered, shut off the truck before moving under the truck.

(4) Slide the spare tire onto the hub and studs. The jack may have to be raised slightly to accommodate the spare tire. The jack extension handle may be placed near the bottom of the tire to either side and raised up to move the tire forward on the hub and studs.

(5) Studs and lug nuts on both sides of the truck have right-hand threads. Rotate the lug nuts clockwise to tighten. Install the 10 lug nuts finger tight on the studs.

(6) If the truck was shut off, start the engine and build up air pressure to above 120 psi. Air pressure must be maintained above 120 psi while using the air impact wrench.

(7) Using the air impact wrench and 1 1/2-inch socket, tighten the 10 lug nuts using the sequence as shown.

(8) Allow the air pressure in the truck to reach 120 psi and repeat tightening of the 10 lug nuts using the same sequence.

(9) Install the two CTIS hoses to the CTIS fittings in the hub and tighten finger tight.

CAUTION When tightening the CTIS hose, be careful not to twist hoses. Use the adjustable wrench to hold the hose fitting in place.

(10) Using the 7/8-inch by 3/4-inch open end wrench and 3/4-inch tube wrench, tighten the two CTIS hose fittings.

(11) Install the wheel cover, ensuring that the hole in the wheel cover is aligned with the tire valve. Install the four wheel cover nuts and tighten finger tight.

CAUTION When using the air impact wrench to tighten the wheel cover nuts, be careful not to overtorque the nuts. Damage to the nuts and studs may occur if wheel cover nuts are overtightened.

(12) Tighten the four wheel cover nuts using the air impact wrench and 33-mm socket.

g. Stow tire using the tire davit.

NOTE: | Ensure the pointed end of the mounting plate is pointed to the third hole (left or right side) from the center of the wheel valve to prevent damage to the valve from the cable.

(1) Using air impact wrench and socket, install the mount plate and three nuts on the flat tire.

CAUTION Be careful not to twist the CTIS plug tethering cables. Failure to comply may result in damage to equipment.

(2) Install the two plugs to the CTIS valve using 7/8-inch by 3/4-inch open end wrench.

(3) Roll flat tire under hoist arm so deep side of wheel dish is facing out and away from truck.

NOTE: | Cable is routed through the smaller square hole in mount plate with single mounting stud facing up.

(4) Pull the cable and hook through small square hole in mount plate and around flat tire.

WARNING Ensure the cable is connected at a point where the rubber casing covers the cable or damage to the cable could result.

(5) Attach the hook to the cable above the flat tire.

WARNING Stand clear of tire when raising or lowering. Do not let the tire hang in midair for a long period of time. Place tire on carrier or on ground as soon as possible. Tire is very heavy (about 500 pounds) and could cause serious injury or death if it falls.

(6) Turn the hand crank clockwise to raise the flat tire just above the carrier.

NOTE: | Use the ladder to push the tire over the carrier.

NOTE: | If the tire will not move or is too hard to move, install ladder to the left side of truck and pull the hoist in.

(7) Swing the hoist arm so the flat tire is over the carrier and aligned with studs.

(8) Install the ladder to the right side of the truck.

(9) Turn the hand crank counterclockwise to lower the flat tire into the carrier.

CAUTION Before installing the plate, ensure that the CTIS plug tether cables are clear of the spare tire mounting surface to prevent damage to the CTIS tether cables.

(10) Install the plate with two nuts. Tighten the nuts using the air impact wrench and socket.

(11) Connect the ratchet strap to the hold-down strap and tighten securely.

(12) Shut off the truck.

h. Stow tire davit.

(1) Turn the hand crank three times counterclockwise to loosen the cable.

(2) Install the ladder to the left side of the truck.

(3) Remove the hook from the lift cable.

(4) Remove the lift cable from around the tire.

(5) Remove the safety pin and pin from the extension arm, second alignment hole.

(6) Push the extension arm in and reinstall the pin and safety pin in the first alignment hole.

WARNING Do not touch the hot exhaust system with bare hands; injury to personnel will result

(7) Install pin and safety pin in hoist.

(8) Attach cable hook to winch and wind up the cable.

i. Prepare truck for driving.

WARNING Jack is under heavy pressure. Keep hand, arm, and head clear while lowering jack slowly to avoid injury to personnel.

(1) Slowly lower truck to the ground.

(2) Remove jack, jack handle, and base plate from under the truck.

NOTE: | Perform steps (3) and (4) if the flat tire was on axle three, ball valve was closed, and air tank drain valves were opened. If steps (3) and (4) are not performed, air system pressure will not be adequate for CTIS and braking.

(3) Close the air tank drain valve petcocks on both sides of the truck (rear tanks).

(4) Open the ball valve located on top of the crossmember behind the transfer case by turning the lever.

(5) Disconnect air hose from the truck air coupler.

(6) Stow ladder.

(7) Return all tools and wheel chocks to stowage boxes.

(8) Stow highway safety markers in stowage boxes.

(9) Start truck, turn on CTIS, and continue with the mission.

(10) At the earliest opportunity, have unit maintenance torque all nuts/bolts that were loosened during the tire-changing procedure and repair/replace spare tire.

3. Practical exercise:

a. Assign two students to each truck and issue TM 9-2320-364-10.

b. Students practice changing simulated flat tires.

4. Evaluation: Check each student's performance.

5. Summary:

a. Recap main points.

b. Allow for questions.

c. Clarify questions.

d. Give closing statement.

6. Retraining: Retrain slow learners.

E. SAFETY RESTRICTIONS.

1. Ensure that all chock blocks are in place when the 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 manual.

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.

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. Stand clear of tire when raising or lowering. Do not let the tire hang in midair for a long period of time. Place tire on carrier or on ground as soon as possible. Tire is very heavy (about 500 pounds) and could cause serious injury or death if it falls.

14. Tire assembly is very heavy (500 pounds). Do not try to lift or catch tire assembly. Injury to personnel could result.

15. Crew member should steady the tire during removal. Falling tire may cause injury to personnel.

16. Do not loosen outer bolt circle nuts on wheel. Outer bolt circle holds wheel assembly together. Tire is under pressure and loosening these nuts can cause the tire to blow apart. Severe injury or death can occur.

17. Keep hands away from the inside of the rim while removing the tire or injury to personnel may result.

18. Ensure all personnel wear protective gloves at all times when handling the spare tire winch cable. The cable may fray and injury to personnel may result.

19. Wear hearing protection during the tire-changing procedure while using the air impact wrench. Failure to do so may result in injury to personnel.

20. Jack is under heavy pressure. Keep hand, arm, and head clear while slowly raising or lowering jack to avoid injury to personnel. Do not lower jack too quickly as tire could fall, causing serious injury or death.

21. If the jack must be raised or lowered, shut off the truck before moving under the truck.

22. Do not touch the hot exhaust system with bare hands; injury to personnel will result.

23. While changing tires or while performing tire maintenance, stay out of the trajectory of the wheel. The wheel trajectory area is the rim on both sides of the wheel. Under some circumstances, the trajectory may deviate from its expected path. Failure to follow proper procedures may result in injury or death to personnel.

F. ADDITIONAL COMMENTS AND INFORMATION. Recommended instructional time is 4.0 hours (1.0 demonstration and 3.0 practical exercise).

LESSON TITLE: | LOAD AND UNLOAD PLS TRUCK IN AUTOMATIC MODE
TASK NUMBER: | 551-721-3364 (Load Truck in Automatic Mode) and 551-721-3365 (Unload Truck in Automatic Mode)

A. TRAINING OBJECTIVE.

| TASK: | Load and unload the PLS truck in the automatic mode.
| CONDITIONS: | Given instruction, DA Form 2404, DD Form 1970, pencil, TM 9-2320-364-10, equipment records folder, rags, lubricants, coolant, an M1074/M1075 truck with BII, an M1077 flatrack with securely tied down palletized load, and a requirement to load/unload the flatrack onto/off the PLS truck.
| STANDARD: | Perform task in the correct sequence according to TM 9-2320-364-10 and without damage to equipment or injury to personnel. Students will be graded on a Go/No-Go basis. See enclosed training evaluation checklists.

B. INTERMEDIATE TRAINING. None.

C. ADMINISTRATIVE INSTRUCTIONS.

1. Training time: As scheduled.

2. Training location: : Classroom, motor pool, 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 every two students for the demonstration and practical exercise.

6. Training aids and equipment: Television, VCR, screen, overhead projector, transparencies, videotape TVT 55-37 (PIN: 710336DA), Part 4, "PLS Load-Handling System," rags, lubricants, and coolant. DA Form 2404, DD Form 1970, pen or pencil, TM 9-2320-364-10, equipment records folder, an M1074/M1075 truck with BII, and an M1077 flatrack with securely tied down palletized load 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.

(2) Practical exercise.

(3) Summary.

2. Explanation and demonstration:

a. Review safety warnings. Because we are dealing with heavy loads and much of the operation is not fully visible to the operator, it is important to review warnings that pertain to the load-handling system (LHS).

WARNING Check for overhead power lines or other obstructions before attempting LHS operation. LHS reaches a height of 17 feet 2 inches (5.22 meters) with ISO container. Serious injury or death could result from contact with electrical power lines.

WARNING Check ground conditions for firmness and extreme sideways inclination before picking up or off-loading a flatrack. Any ground instability beneath road wheels could cause serious injury or death to personnel.

WARNING Before and during any load or unload cycle, all personnel should stay clear of LHS and flatrack or serious injury or death could result to personnel.

WARNING Ensure that flatrack runners contact LHS rear rollers correctly. Failure to contact flatrack runners correctly could result in serious injury or death to personnel and damage to equipment.

WARNING When loading or unloading flatracks on uneven ground (side slope or downgrades up to 10 degrees), it may be necessary to apply truck service brakes to prevent truck roll away or severe injury or death could result.

WARNING Never drive with the LHS no transit light illuminated. An illuminated light means load locks are not engaged and LHS is not fully stowed.

b. Review slides of operating controls and techniques.

Transparency PLS 6-1

(1) Hydraulic mode selector control. Go through each mode briefly.

(a) 0 = off position. Joystick is not operational; there are no hydraulics. Use for transit mode.

(b) 1 = automatic position. This setting is used for normal pickup and off-loading sequence of the flatrack.

(c) 2 = manual hook arm (MAN HA) position. This setting is used for picking up and off-loading on trailers and docks and in the event of failure of automatic hook arm electronic circuits.

(d) 3 = Manual main frame (MAN MF) position. This setting is used for picking up and off-loading on trailers and docks and in the event of failure of automatic main frame electronic circuits.

(e) 4 = Manual transit (MAN TRANS) position. This setting is used when automatic circuits have failed and MAN HA and MAN MF are operated. This position must be selected if truck is to travel.

(f) 5 = Crane or self-recovery winch (CRANE/SRW). This setting is used to switch hydraulic power to either crane or winch. In this position, the LHS free flow valve is closed and the LHS section of the hydraulic system is isolated.

Transparency PLS 6-2

(2) LHS warning lights.

(a) LHS no transit [1] illuminates when LHS is not correctly stowed in transport position.

(b) LHS overload [2] light (yellow) is located on the driver's dash panel and illuminates whenever the main hydraulic relief valve is opened during loading or unloading. When the light illuminates, the driver will be warned that LHS has reached an overload condition or that hydraulic system is lifting very near maximum capacity. The LHS overload light will come on any time the main relief valve is cracked open. Load or unload operation may not come to a complete stop, but light will come on momentarily. This situation would indicate that the system is lifting near maximum capacity. If the load is overweight by 10 percent or greater, the light illuminates and the system is automatically blocked out. Stop operation and redistribute weight or reduce payload before attempting to load or unload.

NOTE: | To reset LHS overload, return the load to start position and release the joystick switch.

CAUTION Overload protection system on PLS protects LHS and flatrack from structural damage during loading or unloading. This system does not protect truck chassis from being overloaded by means of a crane, forklift, or excessively loaded flatracks. Truck chassis is designed to carry an evenly distributed 16.5 tons payload. The operator is responsible to know what the payload weighs.

(c) "LHS" [3] illuminates when rotary hydraulic selection switch is in positions AUTO, MAN HA, or MAN MF.

(d) Flatrack [4] illuminates red when flatrack on trailer is not locked and trailer status line is connected to the truck.

Transparency PLS 6-3

(3) LHS joystick.

(a) The joystick controls the operation of loading and unloading of flatracks.

(b) The joystick has movement in only two directions: forward for (LOAD) and rearward for (UNLOAD).

Transparency PLS 6-4

(4) Alignment with flatrack. Stress the importance of proper alignment.

(a) Before starting any LHS operations, adjust extension mirror on driver's side to monitor LHS operations.

(b) Back into flatrack as straight as possible to assure the flatrack comes onto truck rollers properly and then sets in place on the truck.

(c) Slight misalignment (up to 10 percent) will not prevent the hook from attaching to the flatrack. If slightly misaligned, attach hook and lift 6 to 12 inches and attempt to drag flatrack forward until aligned with truck. If flatrack does not move freely, do not attempt to drag any further.

Transparency PLS 6-5

(5) Hook positions. Explain the hooking procedure.

(a) When backing into the flatrack loop, adjust the hook so it will contact in the area shown.

(b) Monitor the hook and loop in the extension mirror and back slowly until hook and loop contact. Hook will catch the loop as it is raised.

(c) Do not use reverse (R) to back up the truck while the hook arm is attached to the flatrack or damage to LHS will occur.

c. Review operating procedures. Show TVT 55-37, Part 4, "PLS Load-Handling System."

d. Demonstrate loading and unloading the flatrack onto and off the PLS truck using the LHS automatic mode.

3. Practical exercise:

a. Assign students to vehicles and issue TM 9-2320-364-10, pencils, DA Form 2404, DD Form 1970, and equipment records folder. Instruct students on the location of rags, lubricants, and coolant.

b. Students perform before-operation PMCS.

c. Students practice loading/unloading in the training area(s). During-operation PMCS is also conducted at this time.

d. Students perform after-operation PMCS and ensure that all operator entries required on DA Form 2404 and DD Form1970 are accurate, complete, and legible.

4. Evaluation: Check each student's performance on loading/unloading and PMCS.

5. Summary:

a. Recap main points.

b. Allow for questions.

c. Clarify questions.

d. Give closing statement.

6. Retraining: Retrain slow learners. LHS operation can be reinforced daily throughout the course. Students are tested on the EOCCT.

E. SAFETY RESTRICTIONS.

1. Ensure that all chock blocks are in place when the 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 manual.

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 inFM 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 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. The 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. Check for overhead power lines or other obstructions before attempting LHS operation. LHS reaches a height of 17 feet 2 inches (5.22 meters) with ISO container. Serious injury or death could result from contact with electrical power lines.

14. Check ground conditions for firmness and extreme sideways inclination before picking up or off-loading a flatrack. Any ground instability beneath road wheels could cause serious injury or death to personnel.

15. Before and during any load or unload cycle, all personnel should stay clear of LHS and flatrack or serious injury or death could result to personnel.

16. Ensure that flatrack runners contact LHS rear rollers correctly. Failure to contact flatrack runners correctly could result in serious injury or death to personnel and damage to equipment.

17. When loading or unloading flatracks on uneven ground (side slope or downgrades up to 10 degrees), it may be necessary to apply truck service brakes to prevent truck roll away or severe injury or death could result.

18. Never drive with LHS no transit light illuminated. An illuminated light means load locks are not engaged and LHS is not fully stowed.

19. Overload protection system on PLS protects LHS and flatrack from structural damage during loading or unloading. This system does not protect truck chassis from being overloaded by means of a crane, forklift, or excessively loaded flatracks. Truck chassis is designed to carry an evenly distributed 16.5 tons payload. Operator is responsible to know what the payload weighs.

20. Before starting any LHS operations, adjust extension mirror to monitor LHS operations or damage to equipment may result.

21. If terrain is deeply rutted, soft soil, and so forth, mud flaps must be pinned before beginning LHS operations or damage to mud flaps may result.

22. Engine speed must be at idle before using hydraulic selector switch, or damage to equipment may result.

23. Do not use reverse to back up truck while hook arm is attached to flatrack or damage to LHS will occur.

24. If LHS overload lamp illuminates but loading operation continues, operator is cautioned that LHS is nearing maximum capacity. In this situation, the operator should determine if the payload is evenly distributed on the flatrack or if the flatrack load exceeds 16.5 tons. If any of these conditions exist, the operator must redistribute or reduce the payload or damage to equipment may result.

25. Load must be evenly distributed on the pallet and flatrack. Uneven load distribution may cause LHS overload indicator to give false signals and cause LHS to operate incorrectly.

26. If LHS overload lamp illuminates and normal operation has stopped, return the load to original position and redistribute or reduce payload weight or equipment damage may occur.

27. Before starting load sequence, ensure that parking brake is not applied or damage to equipment may occur.

28. Reduce engine speed to idle before flatrack main rails contact rear rollers or damage to flatrack may result.

29. Hydraulic selector switch must be in off position before driving or hydraulic system could overheat.

30. Ensure parking brake is not applied during unload sequence or damage to equipment may result.

31. Ensure rail transport locking pins are disengaged before unloading flatrack. Rail transport locking pins are used for rail transport only. Failure to comply may result in damage to equipment.

32. Once truck's rear suspension has been relieved of flatrack load, do not continue in unload position as possibility of jacking up rear of truck with hook arm may occur and damage to equipment may result.

F. ADDITIONAL COMMENTS AND INFORMATION. Recommended instructional time is 8 hours (1.0 conference, .5 demonstration, and 6.5 practical exercise including 1.0 PMCS).

TRAINING EVALUATION
for
Load the Flatrack onto the PLS Truck in Automatic Mode
and
Unload the Flatrack onto the PLS Truck in Automatic Mode

LESSON TITLE: | DRIVE THE PLS TRUCK OFF ROAD
TASK NUMBER: | 551-721-1360 (Drive Cargo Vehicle on Side Roads and Unimproved Roads)

A. TRAINING OBJECTIVE.

| TASK: | Drive the PLS truck off road.
| CONDITIONS | Given instruction, DD Form 1970, DA Form 2404, pencil, TM 9-2320-364-10, equipment records folder, rags, lubricants, coolant, a suitable training area, an M1074/M1075 PLS truck with BII and a requirement to operate the truck off road (to include ditches, marshes, gullies, ravines, steep grades, woods, mud, rocky terrain, and shallow streams [48 inches or less]) during daylight hours.
| STANDARD: | Operate the vehicle safely at reduced speeds and over rough terrain without damaging the truck.

B. INTERMEDIATE TRAINING. None.

C. ADMINISTRATIVE INSTRUCTIONS.

1. Training time: As scheduled.

2. Training location: Classroom, motor pool, and off-road driver training area as scheduled.

3. Training type: Conference 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 student for the practical exercise.

6. Training aids and equipment: Television, VCR, videotape TVT 55-36 (PIN: 710046DA), Part 2, "PLS Driving Techniques." Rags, lubricants, coolant, DA Form 2404, DD Form 1970, pencil, TM 9-2320-364-10, equipment records folder, and an M1074/M1075 PLS truck with BII for each student.

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

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: | An instructor will be in the cab whenever a student is driving the PLS truck.

a. As an option, show videotape TVT 55-36, Part 2, "PLS Driving Techniques," to reinforce driving tasks. This step may be deleted because the students should have viewed this tape in earlier lessons.

b. Driving off road or over rough terrain basically requires good driving sense. Experience is the best teacher, but there are a few good rules to keep in mind when driving under these conditions.

(1) Before operating off road, mud flaps need to be pinned on the storage hook on the mud flap bracket. If a steep slope is encountered and mud flaps are not pinned, damage can result.

(2) Anticipate terrain and, before negotiating, take positive action to match CTIS, driveline lockup, engine brake selection, and gear selection to terrain features.

(3) Do not shift into any lower gear than is necessary to maintain headway.

(4) Do not shift the transmission into first gear or the transfer case while the truck is moving. Severe damage to the driveline will result.

(5) Allow CTIS ample time to adjust before encountering adverse terrain.

(6) Check for obstructions and clearances to include underneath and overhead.

(7) Preset the CTIS selector switch to the cross- country position for off-road driving. Remember to press and hold the CTIS start button for about one second. When encountering more difficult terrain, the CTIS setting/driveline lockup can be changed.

(8) Attempt to keep the vehicle's wheels from spinning. If the wheels start to spin, stop the truck and change the CTIS setting/driveline lockup. Lockup makes the vehicle drive train more vulnerable to damage. This is especially true when the wheels are slipping (100 percent of available torque could flow to the wheels that are not spinning).

(9) Drive slowly enough to prevent--

(a) Truck damage.

(b) Cargo from coming loose or shifting.

(c) Occupants from being injured (injuries associated with hard or excessive jolts).

CAUTION Do not engage the transfer case lockup while wheels are spinning or when turning a corner. Damage to the driveline may result.

c. Driving up steep grades requires these techniques:

(1) Ensure the CTIS rotary switch setting and transfer case shift lever settings match the terrain conditions.

(2) Engage the transfer case lockup (this is only required if the grade is steep or slippery) on approaching the grade and decelerate for about two seconds to allow transfer case lockup to engage.

CAUTION Do not move the transfer case shift lever when the truck is moving or when the transmission is in gear. Severe damage to the driveline may result.

(3) If operating the truck with a heavy load, stop the truck and shift the transfer case shift lever to low.

CAUTION Do not shift the transmission into first gear while the truck is moving. Severe damage to the driveline will result.

(4) Apply the service brake pedal and place the transmission selector in first gear if encountering an extreme grade (greater than 25 percent). If grades are less than 25 percent, all other gear selections are acceptable while climbing.

CAUTION Excessive wheel slippage while travelling up a steep upgrade could cause driveline damage. When wheel slippage is detected, immediately stop the truck.

(5) Proceed up the grade by releasing the service brake pedal and gradually applying the throttle as traction allows. If wheels start to slip, stop the truck and change the CTIS setting to a greater degree of driveline lockup.

CAUTION When the using emergency position on CTIS, top speed should not exceed 5 MPH and distance traveled should not exceed 5 miles. Care must be exercised as steering response is limited due to full driveline lockup or damage to equipment may result.

(6) If wheels are still slipping, stop the truck and turn the CTIS rotary selector switch to the emergency position. Do not press the start button. Pressing the start button will lower the tire air pressure. In this position, with the transfer case in low range, side-to-side axles are also locked up.

(7) Release the service brake pedal and gradually apply the throttle as traction improves.

(8) After reaching the top of the grade, stop the truck and unlock the transfer case. Select the appropriate transmission gear and CTIS setting for the terrain. (Remember, when changing CTIS setting from emergency to a lesser degree of driveline lockup, the vehicle must be stopped and driveline torque loading relieved.)

d. Driving down steep grades requires these methods:

(1) Ensure the CTIS rotary switch setting matches the terrain conditions.

(2) If operating the truck with a heavy load or the grade is steep, stop the truck and shift the transfer case shift lever to low.

CAUTION The engine brake operates best when the engine speed is between 1,650 and 2,100 RPM. Transmission torque converter lockup will disengage below 1,650 RPM resulting in loss of engine braking.

WARNING Apply engine brake only when vehicle tires have good traction. Use of the engine brake on slick surfaces can cause the vehicle to skid and cause injury or death.

(3) Set the engine brake switch to low or high depending on the amount of braking required.

NOTE: | Service (wheel) brakes must be used in addition to engine brake for maximum braking. The engine brake supplements the service brakes. The engine brake is a vehicle-slowing device, not a vehicle-stopping device.

(4) Adjust the transmission range selector to a gear that will allow the engine with the engine brake applied to control the truck speed with the engine at or below 2,100 RPM and service brakes not applied.

WARNING Repeated rapid operation of service brakes will consume compressed air supply and cause automatic spring brake application. Failure to follow proper service brake operating procedures may cause serious injury or death to personnel.

CAUTION Excessive use of the service brake to control downhill speed will result in the loss of braking power because of heat buildup.

(5) Use the service brakes as needed to control truck speed.

e. Crossing shallow ditches requires the following driving techniques:

(1) Stop the truck.

(2) Check the terrain for obstacles.

(3) Ensure the CTIS rotary switch setting matches the terrain conditions, and shift the transfer case shift lever as required.

(4) Adjust the transmission range selector as required (normally, first through third gear).

(5) Slowly approach the ditch at an angle.

(6) Steer the truck toward the ditch so that one wheel on an axle will leave the ditch as the other wheel on the same axle enters it.

f. Crossing deep ditches requires the following driving techniques:

(1) Stop the truck.

(2) Check the terrain for obstacles.

(3) Cut away both sides of the ditch if necessary.

(4) Ensure the CTIS rotary switch setting matches the terrain conditions, and shift the transfer case shift lever as required.

(5) Adjust the transmission range selector as required (normally, first or second gear).

(6) If necessary, engage the transfer case lockup and decelerate for about two seconds to allow transfer case lockup to engage.

(7) Slowly approach the ditch at an angle.

(8) Steer the truck toward the ditch so that one wheel on an axle will leave the ditch as the other wheel on the same axle enters it.

(9) Accelerate the truck enough to keep it rolling as it goes up the other side.

g. Crossing gullies and ravines requires these driving techniques:

(1) Stop the truck.

(2) Check the terrain for obstacles.

(3) Ensure the CTIS rotary switch setting matches the terrain conditions, and shift the transfer case shift lever as required.

(4) Set the transmission range selector to 1.

(5) If necessary, engage the transfer case lockup and decelerate for about two seconds to allow transfer case lockup to engage.

(6) Ease the front wheels over the edge and into the ravine or gully.

(7) Steer a straight course so both front wheels strike the bottom at the same time.

(8) Accelerate enough so that the truck can climb up the opposite bank.

h. Wooded area driving techniques include the following:

(1) Stop the truck.

(2) Check the terrain for obstructions.

(3) Ensure the CTIS rotary switch setting matches the terrain conditions, and shift the transfer case shift lever as required.

(4) Set the transmission range selector to 3, 2, or 1, depending on the condition of the ground.

(5) If necessary, engage the transfer case lockup and decelerate for approximately two seconds to allow transfer case lockup to engage.

(6) Maneuver around obstructions.

i. Rocky terrain requires these driving techniques:

(1) Stop the truck.

(2) Check the terrain for obstructions.

(3) Ensure the CTIS rotary switch setting matches the terrain conditions, and shift the transfer case shift lever as required.

(4) Set the transmission range selector to 3, 2, or 1, depending on the condition of the ground.

(5) If necessary, engage the transfer case lockup and decelerate for about two seconds to allow transfer case lockup to engage.

(6) Drive slowly, maneuver around large boulders, and choose route while under way.

j. Fording streams calls for these handling techniques:

(1) Ensure depth of fording site is not more than 4 feet and the water flow of the stream is not too swift.

WARNING Do not ford water unless depth is known. Water deeper than 4 feet may enter truck causing personnel injury or death.

(2) Ensure the bottom at the fording site is firm enough that 4 feet maximum fording depth will not be exceeded and truck will not become mired.

(3) Secure loose objects in the cab of the truck and check load security (past accidents have involved soldiers drowning because they were trapped by materials such as camouflage nets).

(4) Stop the truck at the edge of the water.

(5) If the brakes have been used heavily and are hot, allow drums and shoes to cool before entering the water if possible.

(6) Ensure the engine is operating correctly before entering the water.

(7) Set the transfer case shift lever to low.

(8) Set the CTIS rotary selector switch to the emergency position.

(9) Set the transmission range selector to 1.

(10) Drive truck slowly into water.

(11) If the engine stops, immediately attempt to restart the engine. If the truck will not start, tow or winch the truck from the water with another truck as soon as possible.

(12) Drive the truck at 3 to 4 MPH or less through water.

(13) Unless absolutely necessary, do not stop while in water.

(14) If the truck accidentally enters water deeper than 4 feet do the following (remember the height of the metal horizontal bar across the center of the floor window is 4 feet):

(a) Press on the service brake pedal and hold to stop the truck.

(b) Set the transmission range selector to reverse (R).

(c) Let up on the service brake pedal.

(d) Slowly back the truck out of deep water.

(15) After leaving the water, press the service brake pedal lightly and hold while driving slowly to dry out brake linings.

(16) When clear of the fording area, stop the truck, apply and release the parking brake several times to remove water from the brake components.

(17) Remove water and clean deposits from all truck parts as soon as possible.

(18) Lubricate and perform PMCS as soon as possible.

k. Mud and swamps require these driving techniques:

(1) Stop the truck and check the terrain for obstructions.

(2) Ensure the CTIS rotary switch setting matches the terrain conditions, and shift the transfer case shift lever as required.

(3) Set the transmission range selector to 3, 2, or 1, depending on the condition of the ground.

(4) If necessary, engage the transfer case lockup and decelerate for about two seconds to allow transfer case lockup to engage.

(5) Drive through area maintaining a steady speed.

l. Clean mud from wheels, brakes, axles, universal joints, steering mechanism, and radiator as soon as possible.

m. Give safety briefing, to include reinforcing ground guide safety precautions for backing the truck.

3. Practical exercise:

a. Assign students to vehicles and issue TM 9-2320-364-10, pencils, DA Form 2404, DD Form 1970, and equipment records folder. Instruct students on the location of rags, lubricants, and coolant.

b. Students perform before-operation PMCS.

c. Students practice driving the PLS truck off road. During-operation PMCS is also conducted at this time.

NOTE: | As each student practices driving, an assistant instructor rides in the right seat. The assistant instructor explains driving techniques, ensures the driver is aware of driving situations, and conducts after-action reviews with each driver. Now is the time to pass on valuable experience and correct any bad driving habits.

d. Students perform after-operation PMCS and ensure all operator entries required on DA Form 2404 and DD Form 1970 are accurate, complete, and legible.

4. Evaluation: Check each student's performance of PMCS and off-road driving.

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. This can be accomplished using the videotape TVT 55-36, "PLS Driving Techniques," and reinforced throughout the course. Students perform driving tasks daily and are tested on the EOCCT.

E. SAFETY RESTRICTIONS.

1. Ensure that all chock blocks are in place when the 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 manual.

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.

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. During driving operations, hydraulic selector switch must be placed in the off position or hydraulic system overheating will result.

14. Do not hold steering wheel at full left or right position for longer than 10 seconds. Oil overheating and pump damage can result.

15. Apply brakes gradually when stopping. A panic stop will cause the vehicle wheels to lock, engine to stall, and power steering failure. Failure to do this will result in injury or death.

16. Repeated rapid operation of service brakes will consume compressed air supply and cause automatic spring brake application. Failure to follow proper service brake operating procedures may cause serious injury or death to personnel.

17. Do not park the truck on a steep grade. Serious injury to personnel could result.

18. Apply engine brake only when truck tires have good traction. Use of engine brake on slippery surfaces can cause the truck to skid and cause injury to personnel.

19. If emergency steer light illuminates when driving, immediately pull the truck over to the side of the road (trail) and stop or serious injury or death could result.

F. ADDITIONAL COMMENTS AND INFORMATION. Recommended instructional time is 10 hours (1.0 conference and 9.0 practical exercise, including 3.0 PMCS).

LESSON TITLE: | OPERATE THE PLS TRUCK AT NIGHT
TASK NUMBER: | 551-721-1366 (Drive Vehicle with Automatic Transmission), 551-721-3364 (Load Truck in Automatic Mode), and 551-721-3365 (Unload Truck in Automatic Mode)

A. TRAINING OBJECTIVE.

| TASK: | Operate the PLS truck at night.
| CONDITIONS | Given instruction, DD Form 1970, DA Form 2404, pencil, TM 9-2320-364-10, equipment records folder, rags, lubricants, coolant, designated driving route (improved surfaced and secondary roads), an M1074/M1075 truck with BII, an M1077 flatrack with securely tied down palletized load, and a requirement to operate the PLS truck during the hours of darkness, drive a designated route and load and unload the flatrack onto and off the PLS truck.
| STANDARD: | Operate the PLS truck safely without accident, injury, or damage to equipment according to TM 9-2320-364-10.

B. INTERMEDIATE TRAINING. None.

C. ADMINISTRATIVE INSTRUCTIONS.

1. Training time: As scheduled.

2. Training location: Motor pool, training area, and driver training route (built-up and rural areas) as scheduled.

3. Training type: Conference 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 student for the practical exercise.

6. Training aids and equipment: Rags, lubricants, coolant, DA Form 2404, DD Form 1970, pencil, TM 9-2320-364-10, equipment records folder, an M1074/M1075 PLS truck with BII for each student, and one M1077 flatrack with securely tied down palletized load for each truck.

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

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: | Students practiced these lesson objectives during daylight and should be familiar with all operations.

NOTE: | An instructor will be in the cab whenever a student is driving the PLS truck.

NOTE: | Each student will be required to drive the designated route and load and unload the flatrack in the automatic mode onto and off the PLS truck.

a. Discuss the LHS operation.

(1) Stress the importance of alignment of truck to flatrack.

(2) Discuss the mode selections of the hydraulic selector switch.

(3) Explain the use of the work lights, required for night LHS operations. (One driver must act as assistant driver and hold the work lights so the driver can see the load, hook arm, and to position the truck.)

b. Discuss driving the truck at night.

(1) Point out the extra care that must be taken for night operation.

(2) Visibility is poorer, instruments and gauges are harder to read, and more attention must be given to driving.

c. Give safety briefing with emphasis on safety precautions for night operations. Stress that assistant driver must stay out of the path of the truck at all times, even while holding the work lights.

3. Practical exercise:

a. Assign students to vehicles and issue TM 9-2320-364-10, pencils, DA Form 2404, DD Form 1970, and equipment records folder. Instruct students on the location of rags, lubricants, and coolant.

b. Students perform before-operation PMCS.

NOTE: | This exercise can be conducted in a round robin. One truck is used for driving and one for LHS operations. An instructor must be at the LHS station to enforce standards, with another instructor in the cab of the other PLS for driving operations.

c. Students practice driving the vehicle on the road and LHS operations. During-operation PMCS is also conducted at this time.

NOTE: | As each student practices driving, an assistant instructor rides in the right seat. The assistant instructor explains driving techniques, ensures the driver is aware of driving situations, and conducts after-action reviews with each driver. Now is the time to pass on valuable experience and correct any bad driving habits.

d. Students perform after-operation PMCS and ensure all operator entries required on DA Form 2404 and DD Form1970 are accurate, complete, and legible.

4. Evaluation: Check each student's performance of PMCS, night driving, and LHS night operations.

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. Students are tested on the EOCCT.

E. SAFETY RESTRICTIONS.

1. Ensure that all chock blocks are in place when the 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 manual.

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.

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. Check for overhead power lines or other obstructions before attempting LHS operation. LHS reaches a height of 17 feet 2 inches (5.22 meters) with ISO container. Serious injury or death could result from contact with electrical power lines.

14. Check ground conditions for firmness and extreme sideways inclination before picking up or off-loading a flatrack. Any ground instability beneath road wheels could cause serious injury or death to personnel.

15. Before and during any load or unload cycle, all personnel should stay clear of LHS and flatrack or serious injury or death could result to personnel.

16. Ensure that flatrack runners contact LHS rear rollers correctly. Failure to contact flatrack runners correctly could result in serious injury or death to personnel and damage to equipment.

17. When loading or unloading flatracks on uneven ground (side slope or downgrades up to 10 degrees), it may be necessary to apply truck service brakes to prevent truck roll away or severe injury or death could result.

18. Never drive with LHS no transit light illuminated. An illuminated light means load locks are not engaged and LHS is not fully stowed.

19. Overload protection system on PLS protects LHS and flatrack from structural damage during loading or unloading. This system does not protect truck chassis from being overloaded by means of a crane, forklift, or excessively loaded flatracks. Truck chassis is designed to carry an evenly distributed 16.5 tons payload. Operator is responsible to know what payload weighs.

20. Before starting any LHS operations, adjust extension mirror to monitor LHS operations or damage to equipment may result.

21. If terrain is deeply rutted, soft soil, and so forth, mud flaps must be pinned before beginning LHS operations or damage to mud flaps may result.

22. Engine speed must be at idle before using hydraulic selector switch or damage to equipment may result.

23. Do not use reverse to back up truck while hook arm is attached to flatrack or damage to LHS will occur.

24. If LHS overload lamp illuminates but loading operation continues, operator is cautioned that LHS is nearing maximum capacity. In this situation, operator should determine if payload is evenly distributed on flatrack or if flatrack load exceeds 16.5 tons. If any of these conditions exist, operator must redistribute or reduce the payload or damage to equipment may result.

25. Load must be evenly distributed on the pallet. Uneven load distribution may cause LHS overload indicator to give false signals and cause LHS to operate incorrectly. Damage to equipment may result.

26. If LHS overload lamp illuminates and normal operation has stopped, return load to original position and redistribute or reduce payload weight or equipment damage may occur.

27. Ensure that parking brake is not applied before starting load sequence or damage to equipment may occur.

28. Reduce engine speed to idle before flatrack main rails contact rear rollers or damage to flatrack may result.

29. Hydraulic selector switch must be in off position before driving or hydraulic system could overheat.

30. Ensure parking brake is not applied during unload sequence or damage to equipment may result.

31. Ensure rail transport locking pins are disengaged before unloading flatrack. Rail transport locking pins are used for rail transport only. Failure to comply may result in damage to equipment.

32. Once truck's rear suspension has been relieved of flatrack load, do not continue in unload position as possibility of jacking up rear of truck with hook arm may occur and damage to equipment may result.

33. Do not hold steering wheel at full left or right position for longer than 10 seconds. Oil overheating and pump damage can result.

34. Apply brakes gradually when stopping. A panic stop will cause the vehicle wheels to lock, engine to stall, and power steering failure. Failure to do this will result in injury or death.

35. Rapid operation repeatedly of service brakes will consume compressed air supply and cause automatic spring brake application. Failure to follow proper service brake operating procedures may cause serious injury or death to personnel.

36. Excessive use of the service brake to control downhill speed will result in the loss of braking power because of heat buildup.

37. Do not park the truck on a steep grade. Serious injury to personnel could result.

38. Apply engine brake only when truck tires have good traction. Use of engine brake on slippery surfaces can cause the truck to skid and cause injury to personnel.

39. If emergency steer light illuminates when driving, immediately pull the truck over to the side of the road and stop, or serious injury or death could result.

F. ADDITIONAL COMMENTS AND INFORMATION. Recommended instructional time is 5 hours (.5 conference and 4.5 practical exercise, including 1.0 PMCS).