03 Appendix 8_UAH Training POI.pdf

Program of Instruction Instructor Lesson Guide

Operator/Operator Maintenance

M1151A1 Armored Expanded Capacity Utility Truck

TACOM - LCMC

“Standards Start Here”

04 January 2008

Appendix 8

Instructor Guide Operation/Operator Maintenance

New Equipment Training

COURSE TITLE: Operation/Operator Maintenance of the M1151A1

Armored Expanded Capacity Utility Truck

COURSE LENGTH: 24 Hours

PURPOSE: Operator and Key Personnel Training

SCOPE: This instructor’s guide covers all lessons depicted in the New Equipment Training Program of Instruction for Operator and Key Personnel Training.

PREREQUISITES: Students attending this course must have a HMMWV

(any series) driver’s license.

INSTRUCTORS 1 Primary and 1 Assistant Instructors

STUDENTS Maximum of 12 students (1 to 6 Student Instructor

Ratio)

LESSON PLANS: SUBJECT HOURS

LP-1 Welcome/Orientation/Registration 1.0

LP-2 General Safety Guidelines 1.0

LP-3 Introduction to the M1151A1 Armored Expanded

Capacity Utility Truck 2.0

LP-4 Description and Use of Operator’s Controls and

Indicators 2.0

LP-5 Operator Preventive Maintenance Checks and

Services (PMCS) 1.0

LP-6 Emergency Procedures 8.0

LP-7 Basic Driving Techniques 8.0

LP-8 Class Completion/Student Critiques 1.0

Total: 24 Hours

Operator Training Schedule

NOTE: This a basic schedule that can be tailored to unit requirements

DAY 1

1. Welcome and orientation.

2. General Safety Guidelines.

3. Introduction, Characteristics, Capabilities and Features of the M1151A1 Armored

Expanded Capacity Utility Truck.

4. Description and use of Operator Controls and Indicators.

5. Operator Preventive Maintenance Checks and Services (PMCS).

• PMCS Intervals

• PMCS Procedures

• Fluid Leak Classification

• Lubrication Intervals

DAY 2

1. Emergency Procedures.

• Emergency Rescue Wrench

• Roll Over Drills

• Water Egress

• Hasty Evacuation

DAY 3

1. Basic Driving Techniques.

2. Class Completion/Student Critiques.

Lesson Plan 1

LESSON TITLE: Welcome/Orientation/Registration

METHOD OF INSTRUCTION: Conference

TIME ALLOTTED: 1.0

PERSONNEL REQUIRED: One Primary Instructor One Assistant Instructor

CLASS PRESENTED TO: Operators and Key Personnel

MATERIALS: Instructor Lesson Plan, Class roster, Class Sign in

Sheet, Laptop Computer, A/V Projector and Screen, note taking material and student guide.

REFERENCES: NONE

STUDENT UNIFORM: Military - BDU Civilian – Work Clothes

Show Slide 1-1 Course Introduction

1. Students to assembled in the classroom.

2. Instructor to welcome students to course and introduce instructors.

3. Instructors to extend a welcome and then proceed with outline of program of instruction, and registration.

Show Slide 1-2 Course Outline

Instructor’s Note

This slide is interactive. Click on all 3 bullets and discuss each with class.

1. Class Objectives

2. General coverage of course to include time allocation.

3. Emphasize importance of student participation during practical exercises.

Show Slide 1-3 Administrative Information

Discuss the following:

1. Daily schedule (reporting, break periods, lunch hour, and departure time).

2. Reporting procedures in case of absences.

3. Excused absences.

Student Registration

Show Slide 1-4 Complete

Lesson Plan 2

LESSON TITLE: General Safety Guidelines

METHOD OF INSTRUCTION: Conference

TIME ALLOTTED: 1.0

PERSONNEL REQUIRED: One Primary Instructor One Assistant Instructor

CLASS PRESENTED TO: Operators and Key Personnel

MATERIALS: Instructor Lesson Plan, Class roster, Class Sign in

Sheet, Laptop Computer, A/V Projector and Screen, note taking material and student guide.

REFERENCES: TM 9-2320-387-10

Civilian – Work Clothes

Show Slide 2-1 Instructional Lead in, Action, Conditions and Standards.

• Instructor to read Instructional Lead in, Action, Conditions and Standards to the class.

Instructional Lead In

This lesson re-emphasizes Army's commitment to safety of personnel and equipment.

During this lesson, you will become familiar with the safety guidelines for M1151A1 Armored Expanded Capacity Utility Truck in accordance with TM 9-2320-387-10.

Training Scope

ACTION: Identify M1151A1 Armored Expanded Capacity Utility Truck, General Safety Guidelines.

CONDITION: Utilizing classroom presentation and hands-on instruction, operator's manual TM 9-2320-387-10, student lesson guide and truck, students become familiar with all M1151A1 Armored Expanded Capacity Utility Truck safety related statements.

STANDARDS: The student will read, understand and observe all Warnings, Cautions and Notes as required when operating the M1151A1 Armored Expanded Capacity Utility Truck.

Show Slide 2-2 Warnings/Cautions and Notes

This slide is interactive. Click on all three bullets and discuss each with class

• A "Warning" signifies a potentially hazardous situation exists for a person on or near the equipment. If the recommended precautions are not followed, death or serious injury could result.

• A "Caution" signifies that damage to the equipment may occur if the recommended precautions are not followed.

• A "Note" signifies helpful information.

Show Slide 2-3 General Safety Requirements

NOTE

The following statements are general safety related warnings. It is the operator’s responsibility of read and understand all Warnings, Cautions and notes.

• Your safety and the safety of others depends on you using proper judgment during all operation and maintenance procedures.

• Be aware of unexpected vehicle movement at all times.

• Ground guides are required during any vehicle movement in motor pools or congested areas.

Show Slide 2-4 Environmental Safety Warnings

• Ensure all POL products and antifreeze are properly covered and marked. Never mix oil and antifreeze.

• Ensure that a proper size drip pan or container is used. Drip pans will be used to prevent leakage on concrete, pavement or ground.

• All drip pans and containers will be properly cleaned after each use.

• Proper precautions will be taken to prevent oil or antifreeze from coming in contact with the ground, pavement or whatever surface you are working on.

• Clean up any minor spill or leak immediately. Place clean-up materials in appropriately marked containers.

Show Slide 2-5 Operators Responsibility

Remember! It is your responsibility to read and understand all Warnings, Cautions and Notes associated with the M1151A1 Armored Expanded Capacity Utility Truck. These Warnings, Cautions and Notes are listed in TM 9-2320-387-10, Pages A through D.

Have students read all below listed warnings (TM 9-2320-387-10, Pages A through D)

WARNING

EXHAUST GASES CAN KILL

Brain damage or death can result from heavy exposure. Precautions must be followed to ensure crew safety when the personnel heater or engine of any vehicle is operated for any purpose.

1. Do not operate your vehicle engine in enclosed areas.

2. Do not idle vehicle engine with windows closed.

3. Be alert at all times for exhaust odors.

4. Be alert for exhaust poisoning symptoms. They are:

• Headache

• Dizziness

• Sleepiness

• Loss of muscular control

5. If you see another person with exhaust poisoning symptoms:

• Remove person from area

• Expose to open air

• Keep person warm

• Do not permit physical exercise

• Administer artificial respiration, if necessary*

• Notify a medic

*For artificial respiration, refer to FM 21-11.

6. BE AWARE, the field protective mask for Nuclear, Biological, or Chemical (NBC) protection will not protect you from carbon monoxide poisoning.

THE BEST DEFENSE AGAINST EXHAUST POISONING IS ADEQUATE

• Do not attempt to operate cargo shell door forward latch. The cargo shell door is not to be opened from inside the vehicle. Opening cargo shell door from inside the vehicle may cause damage to equipment or injury to personnel.

• Dry cleaning solvent is flammable and will not be used near an open flame.

• A fire extinguisher will be kept nearby when the solvent is used. Use only in well ventilated places. Failure to do this may result in injury to personnel and/or damage to equipment.

• Protective gloves, clothing, and/or respiratory equipment must be worn whenever caustic, toxic, or flammable cleaning solutions are used. Failure to do this may result in injury to personnel.

• Do not perform fuel or battery system checks, inspections, or maintenance while smoking or near sparks. Fuel may ignite and batteries may explode, causing damage to vehicle and injury or death to personnel.

• Never use transmission shift lever in place of parking brake. Set parking brake, Ensure transmission shift lever is in P (park) position and transfer case shift lever is NOT in N (neutral) position. Damage to equipment and injury to personnel may occur if these instructions are not followed.

• Ensure all slack from three-point seatbelt adjusting strap or three-point seatbelt is removed. Three-point seatbelt retracts and will lock only during sudden stops or impact. Injury to personnel may result if an accident occurs and seatbelts are not in use or adjusted properly.

• This vehicle has been designed to operate safely and efficiently within the limits specified in this TM. Operations beyond these limits are prohibited IAW AR 750-1 without written approval from the Commander, U.S. Army Tank-automotive and Armaments Command, ATTN: AMSTA-CM-S, Warren, MI 48397-5000.

• Use extreme caution when transporting personnel. Although certain design characteristics of the vehicle, such as vehicle width, ground clearance, independent suspension, etc., provide improved capabilities, accidents can still happen.

• Operators are reminded to observe basic safe driving techniques/skills when operating the vehicle, especially when transporting personnel. Vehicle speed must be reduced consistent with weather and road/terrain conditions. Obstacles such as stumps and boulders must be avoided. Failure to use basic safe driving techniques/skills may result in loss of control and an accident or rollover resulting in injury or death to personnel and damage to equipment. Since the troop/cargo area has minimal overhead protections and does not have seatbelts, personnel seated here are at greater risk of serious injury.

• Prior to towing vehicle with rear wheels up, secure steering wheel to prevent front wheels from turning.

• Wear leather gloves when handling winch cable. Do not handle cable with bare hands. When fully extending winch cable, ensure that four wraps of winch cable remain on drum at all times. Direct all personnel to stand clear of winch cable during winch operation. Failure to do this may cause damage to vehicle and injury or death to personnel.

• Avoid using fire extinguisher in unventilated areas. Prolonged inhalation exposure to extinguishing agent or fumes from burning material may cause injury to personnel. Using fire extinguisher in windy area will cause rapid dispersal of extinguishing agent and reduce effectiveness in fire control.

• Vehicle operation in snow is a hazardous condition. Operator must travel at reduced speeds and be prepared to meet sudden changes in road conditions.

Pump brakes gradually when stopping vehicle on ice or snow. Sudden braking will cause wheels to lock and vehicle to slide out of control, causing damage to vehicle and injury or death to personnel.

• Do not rely on wet service brakes. Keep applying brakes until they dry out and uneven braking ceases. Failure to do this may cause damage to vehicle and injury or death to personnel.

• Exhaust components are hot after prolonged vehicle use. Ensure exhaust system components are cool before removing/installing exhaust assembly. Failure to do this may result in injury to personnel.

• Do not use hand throttle as an automatic speed or cruise control. The hand throttle does not automatically disengage when brake is applied, resulting in increased stopping distances and possible hazardous and unsafe operation.

Injury to personnel or damage to equipment may result.

• To ensure opening of hood is accomplished safely and effectively, always maintain the proper lifting posture, with legs bent and back straight. When raising and securing hood, ensure hood prop rod is secured to hood support bracket.

When releasing hood prop rod, do not pull rod at hook end. Damage to equipment or injury to personnel may occur if hood is not raised, secured, and lowered properly.

• If NBC exposure is suspected, all air filter media should be handled by personnel wearing protective equipment. Consult your unit NBC officer or NBC NCO for appropriate handling or disposal instructions.

• Due to tire load ratings and vehicle load carrying capabilities, only the load range

D radial tire can be used.

• Hearing protection is required for driver and passengers when engine is running.

• Noise levels produced by these vehicles exceed 85 dBA, which may cause injury to personnel.

• Do not operate the vehicle without windshield assembly positioned upright and the B-pillar securely attached. Operation of vehicle without these structures in place may result in injury to personnel and damage to equipment.

• Chock blocks shall be used when parking a vehicle with inoperative parking brakes, operating in extreme cold conditions, parking on inclines, or whenever and wherever maintenance is being performed. Failure to do so may result in injury to personnel or damage to equipment.

• Do not operate the vehicular heater in a closed area without proper exhaust evacuations. Damage to heater or injury to personnel may result.

• Do not operate the vehicular heater when refueling. Damage to heater or injury to personnel may result.

• Use care when opening and closing doors. Do not rest fingers in door opening.

Personnel injury may result.

• Do not operate heater when ventilation system is on. Damage to heater or injury to personnel may result.

• Communication shelters AN/GRC-122 and AN/GRC-142 RATT may overload vehicle by up to 500 pounds. Use caution when driving to avoid damage to equipment or injury to personnel.

End of Warning Statements

Show Slide 2-6 Standard Ground Guide Signals

To safely operate the M1151A1 Armored Expanded Capacity Utility Truck in a built up or congested area, the driver and assistant driver must understand key ground guide hand signals. In the examples we will be showing you, the ground guide will be in front of truck.

This slide is interactive and has 4 buttons. Click on buttons and discuss each ground guide signal with class.

1. Pull Truck Forward

2. Back Truck Up

3. Stop Truck

4. Turn Truck Left/Right

Show Slide 2-7 M1151A1 Safety Video

• Click on play button to display Safety video.

• Discuss video with class.

Show Slide 2-8 Safety Guidelines Complete

• Remember! It is operator’s responsibility to read, understand and observe all Warnings, Cautions and Notes. Whenever working with M1151P1 HMMWV.

• Questions or Comments?

Lesson Plan 3

LESSON TITLE: Introduction to the M1151A1 Armored Expanded Capacity Utility Truck

METHOD OF INSTRUCTION: Conference/Practical Exercise

TIME ALLOTTED: .50 Hr. Conference

1.5 Hr. Practical Exercise

PERSONNEL REQUIRED: One Primary Instructor Three Assistant Instructors

OBJECTIVE: This lesson will familiarize operators with the

Characteristics, Capabilities, Features and Principles of Operation for the M1151A1 Armored Expanded Capacity Utility Truck.

CLASS PRESENTED TO: Operators and Key Personnel

MATERIALS: Instructor Lesson Plan, Student Guide, Computer, A/V Projector, Screen, and 2 each M1151A1 trucks.

REFERENCES: TM 9-2320-387-10 and student lesson guide.

Civilian - Work Clothes

Show Slide 3-1 Instructional Lead in, Action, Conditions and Standards.

Instructor to read Instructional Lead in, Action, Conditions and Standards to the class.

To properly operate M1151A1 Armored Expanded Capacity Utility Truck, you must understand its characteristics, capabilities, features and basic principles of operation.

ACTION: Describe the M1151A1 Armored Expanded Capacity Utility Truck’s characteristics, capabilities, features and principles of operation.

Conditions: Utilizing classroom presentation and hands-on instruction, operator's manual TM 9-2320-387-10, student lesson guide and truck, students will receive a general overview of the M1151A1 Armored Expanded Capacity Utility Truck.

Standards: Each student will be able to identify and describe the information covered in this lesson without error.

Show Slide 3-2 M1151A1 Characteristics/Capabilities/Introduction

This slide is interactive, click on the 3 bullets and discuss each with class.

• Characteristics: The 1-1/4 ton, 4x4, M1151A1, is a tactical vehicle designed for use over all types of roads, as well as cross-country terrain, in all weather conditions. The vehicle has four driving wheels, powered by a V-8 liquid cooled, turbocharged diesel engine. Four-wheel hydraulic service brakes and a mechanical parking brake are standard. All vehicles are equipped with a pintle hook for towing. Tiedowns and lifting eyes are provided for air, rail, or sea shipment.

• Capabilities: Fully-loaded M1151A1 armament carriers will climb road grades as steep as 60% (31°) and traverse a side slope of up to 40% (22°). The vehicles ford hard bottom water crossings up to 30 inches (76 centimeters) without a deep water fording kit and 60 inches (152 centimeters) with the kit.

• Introduction: Click on and show this video. It is an introduction to the HMMWV program. This film is approximately 6 minutes long

Show Slide 3-3 M1151A1 Armor

• The M1151A1 Armored Expanded Capacity Utility Truck incorporates the latest in removable armor protection providing U.S. war fighters a tactical advantage.

• The armor of this new M1151A1 Armored Expanded Capacity Utility Truck may be installed or removed by soldiers in the field. The armor of the M1151P1 is installed at AM General's manufacturing facility in Mishawaka, Indiana. The armor comprises 2 kits, an "A" kit and "B" kit which, when combined, provide gapless mine and ballistic protection. The armor can later be removed, to provide greater flexibility for missions that do not require additional protection.

Show Slide 3-4 M1151A1 Features

• The M1151A1 Armored Expanded Capacity Utility Truck provides mounting and firing of the MK19 automatic grenade launcher, M2, caliber .50 machine gun;

M60, 7.62 mm machine gun; M240B, 7.62 mm machine gun; and M249, 5.56 mm Squad Assault Weapon (SAW); ring-mounted with a 360° arc of fire, with armor protection for crew, weapon components, and ammunition. The M1151A1 comes equipped with Integrated Armor Protection (IAP) that provides added ballistic protection for armament components, crew, and ammunition.

• For higher payload capacity, the M1151A1 Armored Expanded Capacity Utility Truck is equipped with a reinforced frame, cross members, lifting shackles, heavy-duty variable rate rear springs, shock absorbers, reinforced control arms, heavy-duty tires and rims, and a transfer case and differential with a modified gear ratio.

• The M1151A1 vehicles have a total payload, including crew, of 1,800 pounds.

Show Slide 3-5 M1151A1 Objective Gunner Protection Kit

Discuss each bullet with class

• Reduces ballistic vulnerabilities

• Enhances situational awareness while gunner maintains cover

• Uses Battery Powered Motorized Traversing Unit (BPMTU)

Show Slide 3-6 M1151A1 Objective Gunner Protection Kit

Discuss each bullet with class

• Magnetic Base Joystick

• Battery Box

• Ballistic Glass (AP)

• Motor and Drive Assembly ring

• Rearview Mirrors

Take students out to trucks and discuss the following information

Operation of Battery Powered Motorized Traversing Unit (BPMTU) .

1. Motorized turret rotation:

a. Ensure motor engagement control is in the horizontal position.

Push in (“OFF” position) emergency stop switch before joystick or other components are replaced.

b. Magnetically attach joystick assembly in desired position. See photos for location options.

c. To move joystick assembly, push in emergency stop switch, grab the joystick assembly box (not the joystick), and tilt downward to break magnetic hold. Place joystick assembly in desired position.

d. Pull out emergency stop switch to “ON” position.

e. Push joystick to direction indicated on joystick assembly to rotate turret left and right.

f. Break-away connector should stay connected when operating vehicle to allow constant charging of system.

Turret rotation causes break-away connection to separate. The system is designed to continue functioning on its own power. As soon as mission allows, the break-away connectors should be re-connected to continue charging.

g. When turret rotation is no longer necessary, depress emergency stop switch to “OFF” position.

h. Re-charge system after every mission.

i. Push in emergency stop switch to “OFF” position when BPMTU is not charging or in use.

2. Manual turret rotation:

CAUTION

Turret has no brake when motor engagement control is in the “NEUTRAL” position.

a. Push in and turn motor engagement control to the vertical position to place motor and drive assembly in “NEUTRAL”.

b. Manually rotate turret as desired.

c. When manual turret rotation is no longer needed, lock turret in place by turning the motor engagement control in the horizontal “DRIVE” position.

3. Checking charge level of turret batteries:

Emergency stop switch must be in the “ON” position to charge batteries.

a. Battery status indicator is normally off – “lights out”. Pushing battery status indicator button will turn LED display, of battery status indicator, “ON” for ten seconds. Holding battery status indicator button down will keep LED display on, until ten seconds after button is released.

b. Seven LED segments are provided for battery capacity indication. When all seven segments are illuminated, battery is fully charged. As battery discharges, fewer LED segments will be illuminated. When battery is low, only one LED segment will be illuminated and will be flashing. There may still be significant battery life remaining when flashing low, but running below this point will degrade battery life.

c. The battery status indicator button can be used at any time to indicate battery capacity, but to get the most accurate indication, perform the following test:

1) First disconnect break-away connector.

2) In order to reset system, push in the emergency stop switch to the “OFF” position; pull out emergency stop switch to the “ON” position.

3) Activate the turret motor by moving the joystick (either right or left) rotating turret for approximately five seconds.

4) Press battery status indicator button and read the capacity from the LED display.

Absorbed glass mat batteries have more capacity when warm than when cold.

Absorbed glass mat batteries have more capacity when new than when old.

d. Charge batteries whenever possible to maintain capacity. Batteries left sitting around not on charge will sulfate, which increases the internal resistance of the cells and reduces the life of the batteries.

4. Charging the system using vehicle power system:

a. Rotate turret so that the break-away connectors are aligned and able to be fully engaged when connected.

b. Depress emergency stop switch to “OFF” position.

c. Connect two break-away connector halves connecting the vehicle buss bar cable to the system control assembly.

d. Pull out emergency stop switch to the “ON” position.

e. Start vehicle.

Vehicle system must be above 25 amps to allow BPMTU charging to external batteries.

f. Ensure all unnecessary electrical equipment in vehicle is turned off.

g. Allow vehicle to idle at high RPM by pulling throttle lock until LED display shows batteries are fully charged.

h. Full charge allows approximately ten continuous hours of motorized traversing unit usage.

5. Operating the Manual Traversing Unit:

a. Turn handle to manually rotate turret.

b. When not using manual traversing unit, disengage by pulling drive bar in an out and downward motion until drive bar locks. This prevents handle from spinning.

c. When not using manual traversing unit, pull locking pin and remove handle.

Place in provided pouch.

Maintenance of the Battery Powered Motorized Traversing Unit (BPMTU) for M1114.

Turn emergency stop switch to the off position prior to plugging in the joystick cable. Failure to do so may result in damage to equipment.

1. Daily battery maintenance:

a. Check battery for loose or corroded connections.

b. Ensure battery remains charged during storage.

Allowing absorbed glass mat batteries to fully discharge greatly reduces life span and recharge ability of battery. To prolong battery life, recharge when single bar flashes on the battery status indicator.

2. Daily joystick maintenance:

a. Ensure joystick has free motion by moving joystick forward and backwards.

3. Daily motor and drive assembly maintenance:

a. Inspect and adjust motor and drive assembly chain monthly. A properly adjusted chain has no slack.

1) To adjust chain, loosen six bolts holding the motor and drive assembly to the drive housing. Slide motor and drive assembly over until there is no slack in the drive chain. Tighten bolts to 6 LB-FT (8.13 N·m).

MOTOR AND

The motor and drive assembly requires no lubrication on chain or bearing.

b. Check motor and drive assembly for proper engagement with traversing stop ring.

c. Check motor engagement control functionality. Change positions and make sure motor is disengaged and the turret can be manually spun.

4. Daily system control assembly maintenance:

a. Check system control assembly break-away connectors are not damaged and are free of debris.

b. Check swivel connector where it mounts with the system control assembly for loose or damaged connection.

c. Check swivel connector for free motion.

d. Check emergency stop functionality. Turret should shut down when emergency stop button is pressed.

5. Daily general maintenance:

a. Check for loose bolts, retighten if necessary.

b. Check for loose cable connections and secure.

c. Check for damage to cables.

d. Check electrical connections to the buss bar.

Show Slide 3-7 Frag Kit 5

• Frag Kit 5 provides additional integrated protection against IEDs. It includes new doors and additional overlay to protect against IED fragments.

Improvements to the new doors include:

1. Reduction of behind armor debris

2. External Opening windows

3. Elimination of automotive latches

Practical Exercise

• Take students out to trucks and point out all previously discussed information.

Students should be able to identify all information.

1. Roof Blast Protection

2. Additional Steel Protection

3. Additional Aluminum Armor

4. Additional Protection

5. “A” Pillar Aluminum Armor

6. Exterior Windows

7. Roof Blast Shield

8. Door Seam Protection

9. Rescue Wrench Access

10. Door Handles

11. Crew Extraction Shackle

12. Improved “B” Pillar

13. Improved Hinges

14. Mirrors

15. Window Handle

16. Window Latch

17. Door Pull Strap

18. Door Support Bracket

19. Door Latch

20. Internal Rescue Wrench Access

21. Rescue Wrench Release Pin

22. Door Handle

23. Combat Lock Bracket

24. Door Limiter Strap

• The instructor must point out and discuss each of the below listed safety items with class.

• Instructor must conduct and question and answer session with class to verify all students understand below listed safety items.

1. Risk Level = Low

• Several occurrences of inadvertent door openings were experienced early in testing. The cause of the inadvertent openings was attributed to poor door installation/adjustment and an unnecessary bevel cut into the back-side of the door jam where the slam latches engage. The Frag 5 door design was modified to eliminate the interior bevel cut and provide more latch engagement. It is imperative that the Frag 5 doors are installed properly and alignment is maintained to avoid inadvertent opening of the doors during road operations.

2. Risk Level = Medium

• Installation of the incorrect limit strap on the rear door can create a sequencing issue with the front and rear Frag 5 doors. This could potentially trap the front seat occupant in the vehicle. Installation of the correct limit strap eliminates this hazard. The correct limit strap for the rear doors should be clearly marked and inspected by to operations. These straps are currently part of production vehicles.

3. Risk Level = HIGH Risk

• The front axle is overloaded by 440 pounds when the M1151A1 with B1 Kit, with Frag Kits is at vehicle curb weight (VCW) and is overloaded by 660 pounds when the vehicle is at a representative gross vehicle weight of 14,900 pounds. The rear axle is overloaded by 1,920 pounds when the vehicle is at a representative gross vehicle weight of 14,900 pounds. Rear axle wheel loads also exceed the wheel/tire capacity of 3,850 pounds per wheel/tire. The maximum sustained speed of the vehicle on a paved surface should be restricted to 35 miles per hour (MPH). Operations at speeds in excess of 35 mph could result in failure of the tire/wheel assembly and loss of vehicle control. Overloading the front axle by 660 pounds has the potential to cause premature and unexpected failure of critical front-end components affecting vehicle control and stability. Likewise, for the rear overload condition to cause premature wheel/tire wheel failure. This risk can be mitigated to MEDIUM by limiting speed of continuous operation to 35 mph or reduce payload or by ensuring the Preventative Maintenance Checks and Services (PMCS) are completed as scheduled, paying particular attention to critical front end components (wheel studs, lugs, wheel half bolts, ball joints, steering links, suspension components and half shafts). Tire pressure of 50 psi front and 50 psi rear must be maintained for normal operation to support the expected axle loads

• Steering/handling characteristics of the M1151A1 with Frag kits at a representative GVW of 14,900 pounds are similar to those of the M1151A1 with B1 kit only at GVW of 12,100. During left steer portion of the test, the vehicle exhibited a constant understeer condition at lateral acceleration levels between 0 and .45g’s. During the right steer portion of the test, the vehicle exhibited a slight understseer at low levels of lateral acceleration, then transitioned to slight oversteer at moderate and high lateral accelerations. Understeer characteristics are desirable because it is easier to control the vehicle. Oversteer characteristics are undesireable because it requires the driver to vary the throttle application and countersteer. Wheel lift-off was never observed during steering/handling tests.

In contrast M1114’s maintains an understeer condition during both left and right steer directions. Operators should be alerted to the degraded handling characteristics with respect to the M1151A1. It is recommended that operators be alerted to exercise caution during cornering.

4. Risk = Medium

• The M1151A1 with Frag Kits installed does not meet the requirements for a lateral Field of View (FOV) of 180 degrees and ground view capability at all distances beyond 10 feet in the forward direction. Operators should be aware of the potential for blind spots. Visibility to the right rear side of the vehicle is poor due to the limited view of the right rear-view mirror from the driver’s seat.

Operators should be made aware of reduced visibility and ground guide should be used at all times when operating the vehicle in reverse.

5. Risk = Medium

• The Frag 5 doors are heavy and difficult to open and close. With the vehicle parked on level ground the average force required to push open a door from the inside of the vehicle was 124 pounds and the average force required to pull open a door from outside the vehicles was 85 pounds. Both of these efforts exceed the recommended maximum door opening effort of 25 pounds. The doors are even more difficult to control when opening/closing with the vehicle on sloped terrain. The average force required to pull open the door on the uphill side of a 20 percent side slope was 129 pounds. In addition, there is no mechanism to hold the door open and the only method to limit the door opening is a nylon restraining strap. Failure to control the opening/closing force of the door could result in personnel injury and/or equipment damage.

• The M1151A1 with Frag Kits loaded to the representative GVW of 14,900 was capable of stopping within the criteria specified in the FMVSS 105 Hydraulic and Electric Brake System. All the brake stops met the individual criteria for a vehicle with a GVW of greater than 10,000 pounds. The service brakes were also capable of stopping the vehicle straight and without any of the tires sliding on a 60 percent longitudinal grade at VCW and representative GVW. The parking brake was able to hold the vehicle stationary on the 40 percent grade for at least two minutes without any tire slide or roll; however, the force required to apply the parking brake lever exceeded the specified limit of 90 pounds in FMVSS 105 (actual force required was 100 pounds).

Show Slide 3-8 Introduction to the M1151A1 Armored Expanded Capacity Utility Truck - Complete

Questions? Comments?

Lesson Plan 4

LESSON TITLE: Description and Use of Operator Controls and Indicators

METHOD OF INSTRUCTION: Conference/Practical Exercise

TIME ALLOTTED: 1.0 Hr. Conference

1.0 Hr. Practical Exercise

PERSONNEL REQUIRED: One Primary Instructor Three Assistant Instructors

OBJECTIVE: This lesson will familiarize operators with the Operator

Controls and Indicators located on the M1151A1 Armored Expanded Capacity Utility Truck.

MATERIALS: Instructor Lesson Plan, Student Guide, Computer, A/V Projector, Screen and two M1151A1 Trucks.

REFERENCES: TM 9-2320-387-10 and student lesson guide.

Show Slide 4-1 Action, Conditions and Standards

1. Instructor to read Instructional lead in, Action, Conditions and Standards to students.

In this lesson, we will become familiar with the location, description and use of the operator controls and indicators used to operate the M1151A1 Armored Expanded Capacity Utility Truck. We must know the location and proper use of every control and indicator before operating the vehicle.

ACTION: Locate, identify and describe the function of the M1151A1 Operator Controls and Indicators.

CONDITIONS: Utilizing classroom presentation and hands-on instruction, operators will be able to locate, Identify and describe the function of each Operator Control and Indicator.

STANDARDS: Each student will locate, identify and describe the function of the each Operator Control and Indicator without error.

Show Slide 4-2 Operator Controls and Indicators – Introduction

2. Because of the amount of controls and indicators located inside the M1151A1 Armored Expanded Capacity Utility Truck, we will break them down into four separate parts.

1. Left Front

2. Main Instruments

3. Right Front

4. Trans/Transfer Control Panel

Show Slide 4-3 Operator Controls and Indicators – Left Front

• Located to the left and front of the operator are five controls and indicators.

These controls and indicators are:

This slide is interactive. Click the five bullets and discuss each with class.

1. Engine Rotary Switch: The Engine Rotary switch has ENG STOP, RUN, and START positions. When positioned to RUN, the glow plugs are activated to heat the engine pre-combustion chambers. When positioned to START, starter will engage and crank engine.

2. Wait to Start Lamp: The Wait-to-start lamp illuminates when glow plugs are activated and goes out when engine is ready to be started.

3. Brake Warning Lamp: The Brake Warning lamp illuminates if the parking brake is applied or if a hydraulic imbalance (leak, etc.) exists between the front and rear brake systems.

4. Air Filter Restriction Gauge: The Air Filter Restriction Gauge signals the operator that a restriction exists in the air cleaner.

5. Main Vehicle Light Switch: The Main Vehicle Light Switch controls the operation of all service drive and Black Out operations.

Show Slide 4-4 Operator Controls and Indicators – Main Instruments

Located in front of the operator is the Main Instrument controls and indicators. These controls and indicators are:

This slide is interactive. Click on the seven bullets and discuss each with class.

1. Oil Pressure Gauge: Engine oil pressure gauge indicates oil pressure when engine is running. Normal operating pressure is 30 to 50 PSI.

2. Fuel Gauge: The fuel gauge indicates the amount of fuel in the main fuel tank.

3. Coolant Temperature Gauge: The Coolant temperature gauge indicates the engine coolant temperature. Normal operating temperature is 190 to 230 Degrees.

4. Voltmeter: The voltmeter indicates the charging level and activity of the battery charging system.

5. Speedometer/Odometer: The Speedometer/Odometer indicates the vehicle speed in MPH and KPH and it's accumulated mileage.

6. High Beam Lamp: The High Beam Lamp illuminates when the front headlights are switched to the HIGH Beam position.

7. Instrument Panel Lights: The Instrument panel lights illuminate the instrument panel gauges.

Show Slide 4-5 Operator Controls and Indicators – Right Front

Located to the Right and front of the operator are two additional controls. These controls are:

This slide is interactive. Click on the two bullets and discuss each with class.

1. Fan Hi/Low Switch: The Fan Hi/Low Switch controls the blower motor fan speed.

2. AC/Heat Switch: The AC/Heat Switch controls the temperature of air output.

Show Slide 4-6 Operator Controls and Indicators – Trans/Transfer Control Panel - Introduction

Located to the Right of the operator is the Trans/Transfer Control Panel.

Show Slide 4-7 Operator Controls and Indicators – Transfer Case Controls

There are four controls and one indicator we must understand before operating the vehicle, they are:

This slide is interactive. Click on the five bullets and discuss each with class.

Transfer Case Warning Light: The Transfer Case Warning Light illuminates when the transfer case is in the "HL" or "L" position. This light should go out when the transfer case is shifted back into the "H" position. If the light does not go out, you have a driveline windup.

Click on the driveline windup button and discuss information with class.

1. Driveline Windup: Driveline windup can occur after shifting the transfer case into “HL” or “L”. This is when the transfer case WILL NOT disengage.

2. To correct this fault, place the vehicle in reverse and drive at least 10 feet. If it does not disengage, continue backing in 10’ increments until it does.

3. The Transfer Case Warning Light will go out.

• High Lock: The High Lock “HL” position provides full time four-wheel drive with both axles locked together. The Transfer Case Warning Light illuminates when the ”HL” position has been selected. “HL” is used when operating off road. The operator can shift from “H” to “HL” while moving. This drive range should be selected for off highway or hilly terrain or when continuous wheel slippage is evident such as mud, snow and/or loose sand or ice.

• High: High or “H” position permits the front and rear axles to operate independently and still maintain four-wheel drive whenever possible. The High range should be used on all primary, secondary and off road travel, where little or no wheel slippage exist. This range should also be used when encountering sharp, continuous turns on high traction surfaces.

• Neutral: Neutral “N” position is used when the vehicle is disabled or must be towed, for very short distances at low speeds (30 miles at 30 MPH), without removing the drive shafts. If the operator fails to make a smooth shift of the transfer case, it may get stuck in Neutral. DO NOT attempt to force the shifter out of neutral. Turn the vehicle off and allow the engine and torque converter to stop rotating. Shift the transfer case into the desired selection and restart the vehicle.

• Low: Low “L” provides full time four-wheel drive with both axles locked together.

The Transfer Case Warning Light will illuminate when the “L” position is selected.

Low provides an additional gear reduction to the drive train and is used when operating OFF Road, and rough terrain and the operator needs to maintain a constant slow speed. At the same time it provides lots of power to the wheels.

The operator must stop in order to shift for “HI” to “L”. This drive range shall be selected only when high ranges do not provide sufficient power to negotiate steep hills or downgrades. This range shall also be used when the vehicle is mired and cannot be extracted using the “HL” range.

Show Slide 4-8 Operator Controls and Indicators – Transmission Controls

The M1151A1 has a four-speed automatic transmission that includes a park and overdrive position. As with any vehicle, the combination of the transmission range selection and transfer case selection limit the maximum speeds the vehicle can be operated.

Only use Dextron III or higher when adding fluid to the transmission. Use of any other fluid will result in damage to the wiring inside of the transmission.

This slide is interactive. Click on the eight bullets and discuss each with class.

• Transmission Indicator Light: The Transmission Indicator Light illuminates whenever the vehicle ignition is turned on and goes off when the vehicle is started. It is also used by maintenance personnel to flash diagnostic codes when troubleshooting the transmission.

• Park: Park is used when the vehicle is parked, secured or unattended and when starting the vehicle when the parking brake is applied.

• Reverse: Used for backing up the vehicle. Always use a ground guide. Maximum speeds are:

1. H = 23 MPH

2. HL = 9 MPH

3. L = 9 MPH

• Neutral: Neutral is used when the vehicle is stopped and parked. Parking brake should be applied.

• Overdrive: Overdrive is used for normal driving and fording conditions.

Maximum speeds are:

1. H = 55 MPH

2. HL = 55 MPH

3. L = 21 MPH

• Drive: Drive is used for hilly terrain and during towing operations. Maximum

Speeds are:

1. H = 55 MPH

2. HL = 55 MPH

3. L = 21 MPH

• Second (2): Second is used for hill climbing and engine braking to slow the vehicle when descending steep hills. Maximum Speeds are:

1. H = 40 MPH

2. HL = 40 MPH

3. L = 15 MPH

• First (1): First is used for maximum engine braking and torque when descending or climbing very steep hills. It is also used in deep mud, sand or snow driving.

• Instructor will take students out to vehicles and cover all previously discussed information.

• Conduct a question and answer session with each student.

Show Slides 4-9 Lesson Complete

Lesson Plan 5

LESSON TITLE: Operator Preventive Maintenance Checks and Services (PMCS).

METHOD OF INSTRUCTION: Conference and Practical Exercise.

TIME ALLOTTED: .50 hr Conference .50 hr Practical Exercise

PERSONNEL REQUIRED: One Primary Instructor

Three assistant instructors

OBJECTIVE: To familiarize the operator with Before, During and

After PMCS and Lubrication requirements.

CLASS PRESENTED TO: Operators and Key Personnel

MATERIALS: Instructor Lesson Plan, Student Guide, Computer, A/V Projector, Screen and two M1151A1 Tucks.

REFERENCES: TM 9-2320-387-10 and student lesson guide.

Show Slide 5-1 Action, Conditions and Standards

Instructor must read Instructional lead in, Action, Conditions and Standards to students.

Instructional lead-in

To properly operate and maintain the M1151A1 Armored Expanded Capacity Utility Truck, you must be familiar with Operator Preventive Maintenance Checks and Services or PMCS and Lubrication of the vehicle.

ACTION: Perform Operator level PMCS.

CONDITIONS: Given classroom and hands on instruction, student lesson guide and a truck, students will perform Before, During, After Operator PMCS on the Truck.

STANDARDS: Students will perform Operator PMCS without violation of any Warnings, Cautions or Notes.

Show Slide 5-2 PMCS Intervals

This slide is interactive, Click on the six bullets and discuss each with class

1. Before (B) – Before checks and services must be performed prior to placing the vehicle or it’s components in operation

2. During (D) – During checks and services must be performed while the vehicle or it’s components are in operation.

3. After (A) – After checks and services must be performed at the completion of every mission.

4. Weekly (W) – Weekly checks and services must be performed once every seven days regardless of the operating time on the vehicle during this period.

5. Monthly (M) – Monthly checks and services must be performed every thirty days regardless of the operation time of the vehicle.

Show Slide 5-3 PMCS Procedures

This slide is interactive, Click on the 4 bullets and discuss each with class

• Technical Manual – PMCS tables in your Technical Manuals must be followed step-by-step to ensure the checks are performed correctly and completely.

• DA Form 2404 – Use of DA Form 2404 is used to record discrepancies found while performing PMCS. Report discrepancies that you cannot correct to your field level maintenance at once.

• Tools – The tools included in your vehicle’s BII are to be used by you during

PMCS. Expendable supplies such as cleaning materials should be provided to you from your motor pool.

• Visual Inspection – An overall visual inspection of your vehicle is an extremely important part of PMCS. The following are some of the items to look for and correct if possible during a visual inspection:

1. Check all bolts, nuts and screws. If loose, bent, broken or missing, correct the condition.

2. Look for chipped paint and rust. Check for cracked welds and remove rust.

Repair chipped paint if possible and report cracked welds.

3. Inspect electrical wires and connectors for cracked or broken insulation.

Also look for bare wires and loose or broken connections. Tighten loose connections. Correct other problems as necessary.

4. Check hoses and fluid lines for wear, damage and leaks. Make sure clamps and fittings are tight. Repair damage and wear as necessary.

Show Slide 5-4 Fluid Leakage Classification

Wetness around the seals, gaskets, fittings or connections indicates fluid leakage. A stain also denotes leakage. There are 3 classifications for leakage. These are:

This slide is interactive, Click on the 3 bullets and discuss each with class

1. Class I – Leakage indicated by dampness or discoloration not great enough to form drops.

2. Class II – Leakage great enough to form drops, but not enough to cause drops to drip from the item being inspected.

3. Class III – Leakage great enough to form drops that fall from the item being inspected.

Show Slide 5-5 Lubrication Intervals

There are 3 intervals or situations we must consider when ever we lubricate the M1151A1 Armored Expanded Capacity Utility Truck. They are:

This slide is interactive and contains 3 buttons. Click on the buttons and discuss each with the class.

• Service Interval Under Normal Conditions: Service intervals listed are for normal operation in moderate temperatures, humidity, and atmospheric conditions. Hard time intervals may be shortened if your lubricants are contaminated or if you are operating the equipment under adverse conditions, including longer-than-usual operating hours. Hard time intervals may be extended during periods of low activity, though adequate preservation precautions must be taken. Perform semi-annual service intervals every six months, or 3,000 miles (4,827 km), whichever comes first.

• Service Interval Under Unusual Conditions: Increase frequency of lubricating service when operating under abnormal conditions such as high or low temperatures, prolonged high speed driving, or extended cross-country operations. Such operation can diminish lubricant's protective qualities. More frequent lubricating service intervals are necessary to maintain vehicle readiness when operating under abnormal conditions.

• Hard Time Intervals: Intervals shown in this appendix are based on mileage and calendar times. An example of mileage and calendar intervals is 3/S, in which 3 stands for 3,000 mi. (4,827 km), and S stands for semiannually (every six months). The lubrication for the vehicle is to be performed at whichever interval occurs first. For equipment under manufacturer's warranty, hard time oil service intervals shall be followed.

Practical Application

• After completion of this portion of the classroom instruction, take students out to the trucks and have students conduct PMCS AS REQUIRED.

• Bring students back into classroom for completion of class.

• Review as required

• There is no Check on learning for this lesson.

• Before, During and After PMCS will be conducted daily on all training vehicles.

• Have students refer to their student guides for PMCS tables.

Show Slides 5-6 Lesson Complete

Lesson Plan 6

LESSON TITLE: Emergency Procedures

METHOD OF INSTRUCTION: Practical Exercise

TIME ALLOTTED: 8.0 Hours Practical Exercise

PERSONNEL REQUIRED: One Primary Instructor

Three assistant instructors

OBJECTIVE: To familiarize operators with the emergency procedures required to safely operate the M1151A1

MATERIALS: Instructor Lesson Plan, Student Guide, and two

M1151A1Trucks.

REFERENCES: TM 9-2320-387-10, student lesson guide and the

Combined Safety Smart Card.

Action, Conditions and Standards

Instructional lead-in

To safely operate the M1151A1 Armored Expanded Capacity Utility Truck, you must understand several life saving emergency procedures. A thorough understanding of these procedures may save the lives of yourself and vehicle crew someday.

ACTION: Perform the following emergency procedures:

3. Emergency Rescue Wrench

4. Roll Over Drills

5. Water Egress

6. Hasty Evacuation

CONDITIONS: Given Hands on instruction, student lesson guide, Combined Safety Smart Card and a truck, students will become familiar with the Emergency Procedures required to operate this truck.

STANDARDS: Students will be able to perform emergency procedures safely and without error.

• The following emergency procedures will be demonstrated by the instructor and performed correctly by each student.

• Instructor will follow the checklist listed below or the Combined Safety Smart

Card.

Emergency Rescue Wrench

Procedures: You are removing the bolts

1. Remove emergency rescue wrench from storage position behind right rear passenger seat on the “C” partition.

2. Identify door that allows immediate access to conscious occupants.

3. Locate two groups of three bolts at the rear of each door.

Note: One bolt protrudes in each group

4. Remove countersunk bolts first then the protruding one. Complete one group at a time. Remove bolts by turning in a counterclockwise motion until the bolts back out.

Note: You should feel the lock fall after removing the third bolt from each group.

5. After removing the second group of bolts, open door with handle.

6. Proceed to next door.

Roll Over Drills

Never…