Attachment_0005_-_M1077_Flatrack_TM_9-3990-206-10.pdf

*TM 9-3990-206-10

TECHNICAL MANUAL

OPERATOR'S MANUAL

FOR

PALLETIZED LOAD SYSTEM (PLS) FLATRACK

M1077/M1077A1

NSN 3990-01-307-7676

ISO COMPATIBLE PALLETIZED FLATRACK

(IPF)

M1

NSN 3990-01-406-1340

*SUPERSEDURE NOTICE - This TM supersedes TM 9-3990-206-14&P dated 2 June 2006. All maintenance, troubleshooting, and parts information formerly located in this TM can now be found in the PLS IETM (TM 9-2320-364-14&P).

DISTRIBUTION A - Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY

30 APRIL 2009

WARNING SUMMARY

GENERAL SAFETY CAUTION/WARNING SUMMARY

• This list summarizes critical warnings. They are repeated here to let you know how important they are.

• Study these warnings carefully.

• They can save your life and the lives of personnel you work with.

• If there is any doubt about handling tools, materials, equipment, and procedures, see TB 43-0216, Safety and Hazard Warnings for Operation and Maintenance of TACOM Equipment.

FOR INFORMATION ON FIRST AID:

Reference FM 4-25.11. (WP 0034)

WARNING

MODIFICATION HAZARD

• Unauthorized modifications to, alterations to, or installations on this equipment are prohibited and are in violation of AR 750-10.

• Failure to comply may result in injury or death to personnel or damage to equipment.

WARNING

HIGH-PRESSURE HYDRAULIC SYSTEM

• Hydraulic systems can cause serious injuries if high-pressure lines or equipment fails.

TM 9-3990-206-10

a

• Never work on hydraulic systems or equipment unless there is another person nearby who is familiar with the operation and hazards of the equipment and can give first aid.

• Never disconnect any hydraulic hose or part while the engine is running. Allow several minutes to elapse after shutting off engine, to allow pressure to relieve itself, before attempting to remove hoses.

Failure to comply may result in injury to personnel.

• The PLS vehicles contain hydraulic systems operating at oil pressures up to 3,700 psi (25,512 kPa). Never disconnect any hydraulic line or fitting without first dropping the pressure to zero.

Failure to comply may result in serious injury or death to personnel.

• Be sure to wear eye protection when working around hydraulic pressurized systems. Failure to comply may result in serious injury or death to personnel.

WARNING

ELECTRICAL SYSTEM

• Remove all jewelry, such as rings, ID tags, bracelets, etc. If jewelry or tools contact electrical circuits, a direct short may result. Failure to comply may result in serious injury or death to personnel.

• Do not smoke, use open flame, make sparks or other ignition sources around batteries. A battery giving off gas could explode. Failure to comply may result in serious injury or death to personnel.

• Be careful when working on or with electrical equipment. Do not be misled by the term "low voltage". Voltages as low as 50 volts can cause death. For artificial respiration, refer to FM 4-25.11.

• When working inside the vehicle with power off, be sure to ground every capacitor likely to hold a dangerous voltage potential.

• Never work on electronic equipment unless there is another person nearby who is familiar with the operation and hazards of the equipment.

b

WARNING

SOLVENT CLEANING COMPOUND

• Solvent cleaning compound MIL-PRF-680 Type II and III may be irritating to the eyes and skin. Use protective gloves and goggles. Use in a well-ventilated area. Use respirator as needed. Accidental ingestion can cause irritation of digestive tract and respiratory tract, may cause lung and central nervous system damage. Can be fatal if swallowed. Inhalation of high/massive concentrations can cause coma or be fatal. First aid for ingestion: do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove contaminated clothing. Wash skin thoroughly with soap and water. If symptoms persist, seek medical attention. First aid for eye contact:

flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention. Keep away from open flames and other sources of ignition. Failure to follow this warning may result in injury or death to personnel.

• The flashpoint for Type II solvent cleaning compound is 141-198°F (61-92°C), and Type III is 200-241°F (93-116°C).

• Improper cleaning methods and use of unauthorized cleaning solvents may injure personnel and damage equipment.

• Fire extinguishers should be placed nearby when using solvent cleaning compound. Failure to follow this warning may result in injury or death.

• Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures. Failure to follow this warning may result in injury.

• Eye shields must be worn when cleaning with a wire brush. Flying rust and metal particles may cause injury.

c

POLYURETHANE COATING (CARC)

• Eye and hearing protection must be worn at all times when using power tools for grinding, cutting, sawing, and drilling. Failure to do so may result in injury to personnel. Chemical Agent Resistant Coating (CARC) paint contains isocyanate which is highly irritating to skin and respiratory system. High concentrations of isocyanate can produce symptoms of itching and reddening of skin, a burning sensation in the throat and nose, and watering of the eyes. In extreme concentrations, isocyanate can cause cough, shortness of breath, pain during respiration, increased sputum production, and chest tightness. First aid for ingestion: do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove contaminated clothing.

Wash skin thoroughly with soap and water. If symptoms persist, seek medical attention. First aid for eye contact: flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention.

• The following precautions must be taken whenever using CARC paint:

• Protective equipment (gloves, goggles, ventilation mask) must be worn when using CARC paint.

• NEVER cut CARC-coated materials without high-efficiency, air-purifying respirators in use.

• DO NOT grind or sand painted equipment without high-efficiency, air-purifying respirators in use.

• BE AWARE of CARC paint exposure symptoms; symptoms can occur a few days after initial exposure. Seek medical help immediately if symptoms are detected.

• Use only in well-ventilated area. Check with local environmental office for methods and locations approved for painting in accordance with local and state environmental regulations.

• Always use air line respirators when using CARC paint unless air sampling shows exposure to be below standards. Use chemical cartridge respirator if air sampling is below standards.

d

ADHESIVE

• Adhesive, solvents and sealing compounds can burn easily and are harmful causing immediate bonding on contact with eyes, skin, or clothing and gives off harmful vapors.

• If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

• If adhesive gets in your eyes, try to keep them open; flush them with water for 15 minutes and get immediate medical attention.

• Wear protective goggles and use in a well-ventilated area.

• Keep away from open fire and use in well-ventilated area to avoid injury or death.

WARNING

FLAMMABLE LIQUID AND COMBUSTIBLE VAPOR

• Gasoline, fuel oil, lubricating oil, grease, paint, paint thinner, cleaning solvents, and other combustible liquids present a serious fire hazard.

• Combustible liquids must ALWAYS be stored in their approved containers and designated compartments or deck storage locations.

• Ensure exhaust and ventilation fans are operating while using cleaning solvents or paint products.

• Never store or charge batteries in a confined space without ventilation or near electrical equipment.

• Fuel is very flammable and can explode easily.

• To avoid serious injury or death, keep fuel away from open fire and keep fire extinguisher within easy reach when working with fuel.

e

• Do not work on fuel system when engine is hot. Fuel can be ignited by hot engine.

• When working with fuel, post signs that read NO SMOKING WITHIN

50 FEET OF VEHICLE.

• Starting fluid is toxic and flammable. Do not store in cab and do not breathe fumes. Do not puncture or burn containers. Dispose of container following manufacturer’s recommendations on the container.

WARNING

LIFTING OPERATIONS

• All personnel must stand clear during lifting operations. A swinging or shifting load may cause injury or death to personnel.

• Never crawl under equipment when performing maintenance unless equipment is securely blocked. Failure to comply may cause injury or death to personnel.

• Keep clear of equipment when it is being raised or lowered. Failure to comply may cause injury or death to personnel.

• Do not work on any item supported only by lift jacks or hoist. Always use blocks or proper stands to support the item prior to any work.

Failure to comply may result in injury or death to personnel.

• Do not lift a load greater than the rated load capacity of the crane or materiel handling equipment. Failure to comply may result in injury or death to personnel or damage to equipment.

• Do not allow heavy components to swing while hanging by lifting device. Failure to comply may cause injury or death to personnel.

• Any part or component that weighs between 50 lbs (23 kg) and 75 lbs (34 kg) must be removed with the aid of an assistant. Any part or component that weighs over 75 lbs (34 kg) must be removed with the aid of an assistant and a lifting device. Failure to comply may cause injury or death to personnel.

• Ensure all chains, hooks, and slings are in good condition and are of correct capacity. Ensure hooks are positioned correctly. Failure to comply may result in injury or death to personnel.

f

MOVING MACHINERY

• Use extreme care when operating or working near moving machinery including running engine, rotating shafts, and other moving parts.

Failure to comply may result in injury or death to personnel.

• Use extreme care when measuring voltage while engine is running around rotating fan blade and hot engine parts. Failure to comply may result in injury or death to personnel.

WARNING

HEAVY-DUTY WINCH OPERATION

• All personnel must stand clear during winching operations from possible snapping cable or shifting load. Failure to comply may result in injury or death to personnel.

• When hooking up for winching operations, position throat (open part) of hook upward in case overloading straightens out hook. Failure to comply may result in injury or death to personnel.

• The cable drum requires a minimum of three or four wraps of wire rope (cable) for safety. Failure to comply may result in injury or death to personnel.

• Be careful when handling the winch cable. Ensure cut ends are taped.

Ensure cut ends of cable on winch assembly are securely fastened down. Failure to comply may result in injury or death to personnel.

• Always wear leather gloves when handling winch cable. Failure to comply may result in injury or death to personnel.

g

LOAD HANDLING SYSTEM OPERATION

• Check for overhead power lines, ground condition for firmness, and other obstructions before attempting LHS operation.

• LHS hook maximum lifting height is 18 ft (5.5 m). Failure to comply can result in injury or death to personnel.

WARNING

PARTS UNDER PRESSURE

• Wear safety goggles and use caution when removing or installing springs, snap rings, retaining rings, and other parts under spring tension. These parts can act as projectiles. Failure to comply may result in injury or death to personnel.

• The radiator is very hot and pressurized during vehicle operation. Let radiator cool before removing cap. Failure to do so can result in serious burns.

• During pressure tests, ensure air pressure is drained to 0 psi (0 kPa) before taking off any components. If pressure is not released, plates or line could blow off and harm personnel. Do not drain air from tank with any part of body in air spray path. Skin embolisms and/or debris in eyes can occur from released pressure.

• High air pressure may be released from valve stem when valve core is removed. Stay clear of valve stem after core is removed. Ensure all personnel wear suitable eye protection. Failure to comply may result in injury to personnel.

• Stand clear of trajectory area during deflation or personal injury or death may result.

h

• Lock-ring is under tension. If lock-ring breaks loose it could cause injury to personnel. Keep hands and fingers away from lock-ring when removing.

• Never adjust relief valve so that personnel must stand on strongback to operate latch.

• If there is any residual pressure in tank when relief valve is open, personnel may lose their balance and fall. Failure to comply may result in injury or death to personnel.

• Use extreme care when removing or installing spring retainers.

Spring retainers are under tension and can act as projectiles when released suddenly. Ensure proper eye protection is worn to prevent injury to personnel.

• Use extreme care when removing or installing springs. Springs are under tension and can act as projectiles when released. Ensure proper eye protection is worn to prevent injury to personnel. Eye protection is required during all grinding operations. Failure to comply may result in serious injury to personnel.

• Failure to relieve tank pressure may result in sudden, unexpected loss of pressure. Failure to comply may result in personal injury or death.

• Do not remove the radiator cap when the engine is hot, as steam and hot coolant can escape. Failure to comply may result in personal injury or death.

WARNING

HEAVY PARTS

Any part or component that weigh over 50 lbs (23 kg) must be removed with the aid of an assistant and a lifting device. Failure to comply may result in personal injury or death.

i

CRANE SYSTEM

• Always refer to the range diagram BEFORE making any lift. It is extremely important that the crane is properly leveled to prevent overstressing.

• Do not operate crane unless outriggers are set up. Always chock front wheels when using outriggers. Failure to comply may result in injury or death to personnel.

• When using crane on any vehicle, park vehicle clear of all overhead powerlines. If operating crane under power lines, do not allow vehicle to contact high-voltage connections. Failure to comply will result in death to personnel.

• Do not stand under crane. Failure to comply may result in injury or death to personnel.

• Refuse to work with worn, frayed, or damaged wire rope. Always wear heavy gloves when handling winch cables; never let cable run through hands. Frayed cables can cut. Never operate winch with less than five wraps of cable on winch drum. Failure to comply may result in injury or death to personnel.

• When using crane on any vehicle, park vehicle clear of all overhead power lines. Do not operate crane near overhead power lines. Failure to comply may result in injury or death to personnel.

• Boom has a 370 degree rotation and is mechanically stopped at five degrees on either side of the left outrigger beam. Swing operations must be slowed no later than 15 degrees prior to contacting the stop.

• Keep boom clear of electrical powerlines and other obstacles. Do not operate crane near overhead powerlines. Failure to comply will result in death to personnel.

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

• If possible, keep one hand away from equipment to reduce the hazard of current flowing through vital organs of the body.

j

• Keep fingers clear of top of lift-hook. Failure to comply could result in personnel injury.

WARNING

CARBON MONOXIDE (EXHAUST GAS) CAN CAUSE DEATH

• Carbon monoxide does not have color or smell and can cause death.

• Breathing air with carbon monoxide produces symptoms of headache, dizziness, loss of muscular control, a sleepy feeling and coma. Brain damage or death can result from heavy exposure.

• Carbon monoxide is in exhaust fumes of fuel-burning heaters and internal combustion engines.

• Carbon monoxide can become dangerously concentrated under conditions of no ventilation.

• Precautions must be taken to ensure crew safety when the personnel heater or engine of any vehicle is operated for any purpose. Failure to comply may result in injury or death to personnel.

• DO NOT operate vehicle engine in a closed place unless the place has proper ventilation. Failure to comply may result in injury or death to personnel.

• DO NOT drive any vehicle with inspection plates, cover plates, or engine compartment covers removed unless necessary for maintenance purposes. Failure to comply may result in injury or death to personnel.

• BE ALERT at all times during vehicle operation for exhaust odors and exposure symptoms. If either odor or exposure symptoms are present, IMMEDIATELY VENTILATE personnel compartments. If symptoms continue, remove affected crew to fresh air and keep warm. DO NOT PERMIT PHYSICAL EXERCISE. If necessary, give artificial respiration and get immediate medical attention. For artificial respiration, refer to FM 4-25.11 . Failure to comply may result in injury or death to personnel.

• BE AWARE that the gas particulate filter unit or the field protection mask for nuclear-biological-chemical protection WILL NOT offer safety from carbon monoxide poisoning.

k

EXTREME HEAT

If required to remain inside the vehicle during extreme heat, occupants should follow the water intake, work/rest cycle, and other heat stress preventive medicine measures contained in FM 21-10, Field Hygiene and Sanitation.

WARNING

CABLES

• Always wear heavy gloves when handling winch cables; never let cable run through hands. Frayed cables can cut. Failure to comply may result in injury or death to personnel.

• Never operate winch with less than five wraps of cable on winch drum. Frayed cables can cut. Failure to comply may result in injury or death to personnel.

l

BATTERY

• Battery acid is harmful to skin and eyes. Be careful not to short out battery terminals. Failure to comply may result in injury or death to personnel.

• Do not smoke or use open flame near batteries. Batteries may explode from a spark. Failure to comply may result in injury or death to personnel.

WARNING

NBC

• NBC-contaminated air filters must be handled and disposed of only by authorized and trained personnel.

• The unit commander or senior officer in charge of maintenance personnel must ensure that prescribed protective clothing (FM 3-11.4) is used, and prescribed safety measures and decontamination procedures (FM 3-11.5) are followed.

• The local unit SOP is responsible for final disposal of contaminated air filters. Failure to comply may cause severe injury or death to personnel.

m

TIRE OPERATION

• Operating a vehicle with a tire in an overinflated or underinflated condition, or with a questionable defect, may lead to premature tire failure. Ensure tire has proper tire pressure. Failure to comply may result in injury or death to personnel.

• When inflating tires mounted on the vehicle, all personnel must remain out of trajectory of the side ring and lock-ring as shown by the areas indicated. Failure to follow proper procedures may result in serious injury or death to personnel.

• Cracked, broken, bent or otherwise damaged rim components shall not be reworked, welded, brazed, or otherwise heated or damage or personal injury or death may result.

• No heat shall be applied to a multi-piece wheel or wheel component or damage or injury or death may result.

• Failure to place wheel/tire assembly in safety cage prior to initial inflation could result in serious injury or death to personnel.

• When a wheel/tire is in a restraining device, do not rest or lean any part of body or equipment on or against the restraining device, or injury or death could result.

• While changing tires or while performing tire maintenance, stay out of the trajectory path. Failure to comply may result in injury or death to personnel.

• Always use an inflation hose with an in-line gauge and a clip-on chuck when inflating tires. The gauge and valve must be mounted a minimum of 10 feet (3.10 m) away from air chuck.

• High air pressure may be released from valve stem when valve core is removed. Stay clear of valve stem after core is removed. Ensure all personnel wear suitable eye protection. Failure to comply may result in injury to personnel.

• Tire is heavy. Brace tire to ensure tire will not fall over on you or on others.

n

VEHICLE OPERATION

• Speed limits posted on curves reflect speeds that are considered safe for automobiles. Heavy trucks with a high center of gravity can roll over at these speed limits. Use caution and reduce your speed below the posted limit before entering a curve. Failure to comply may result in vehicle crash and injury to personnel.

• Use caution and reduce your speed below the posted limit before entering a curve. Failure to comply may result in vehicle crash and injury to personnel.

• Always use seatbelts when operating vehicle. Failure to use seatbelt can result in serious injury or death in case of accident.

• Operation at speeds over 15 mph (24 kph) on paved roads can be achieved when the operator determines that the vehicle being towed and the terrain allow safe operation.

• Under no condition can speeds over 35 mph (55 kph) on paved road and 15 mph (24 kph) off-road be allowed. Loss of control can cause serious injury or death. Excessive speed can cause damage to vehicle being towed.

WARNING

BRAKES

• Ensure all personnel are clear from front of truck before performing brake stall check. Be ready to apply service brake. Operator must remain in cab while performing this check. Failure to comply could result in personnel injury.

• Never use parking brake for normal braking or wheels will lock up causing severe skid. Skidding vehicle may result in serious personal injury or death.

o

• Do not use trailer brakes as a parking brake. Trailer brakes may not hold loaded vehicle and trailer on a grade. A runaway vehicle may cause severe personal injury or death.

• Engine must be shut OFF and parking brake set before performing PMCS walkaround. Failure to comply may result in injury or death to personnel.

WARNING

BURNS

The exhaust pipe and muffler can become very hot during vehicle operation. Be careful not to touch these parts with bare hands, or allow body to come in contact with exhaust pipe or muffler. Exhaust system parts can become hot enough to cause serious burns.

WARNING

HEARING PROTECTION

• Excessive noise levels are present any time the heavy-duty winch or crane is operating.

• Wear single hearing protection (earplugs or equivalent) while working around equipment while it is running. Failure to do so could result in damage to your hearing.

• Seek medical aid should you suspect a hearing problem.

p

COMPRESSED AIR

• Brake shoes may be coated with dust. Breathing this dust may be harmful to your health.

• Do not use compressed air to clean brake shoes. Wear a filter mask approved for use against brake dust. Failure to comply may result in injury or death to personnel.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa).

• Use only with effective chip guarding and personal protective equipment, goggles, shield, and gloves.

q

LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE:

*This TM supersedes TM 9-3990-206-14&P dated 2 June 2006. All maintenance, troubleshooting, and parts information formerly located in this TM can now be found in the PLS IETM (TM 9-2320-364-14&P). Zero in the "Change No." column indicates an original page or work package.

Date of issue for the original manual is:

Original 30 APRIL 2009

TOTAL NUMBER OF PAGES FOR FRONT AND REAR

MATTER IS 40 AND TOTAL NUMBER OF WORK PACKAGES

IS 36, CONSISTING OF THE FOLLOWING:

Page/WP No.

Change No.

Front Cover 0 Warning Summary 0 i-xii 0 Chp 1 - General Information, Equipment Description, and Theory of Operation 0 WP 0001 (20 pages) 0 WP 0002 (6 pages) 0 WP 0003 (6 pages) 0 WP 0004 (2 pages) 0 WP 0005 (2 pages) 0 Chp 2 - Operator Instructions 0 WP 0006 (4 pages) 0 WP 0007 (2 pages) 0 WP 0008 (4 pages) 0 WP 0009 (16 pages) 0 WP 0010 (18 pages) 0 WP 0011 (2 pages) 0 WP 0012 (2 pages) 0 WP 0013 (6 pages) 0 WP 0014 (4 pages) 0 WP 0015 (4 pages) 0 WP 0016 (2 pages) 0 WP 0017 (2 pages) 0 WP 0018 (4 pages) 0 WP 0019 (10 pages) 0

Page/WP No.

Change No.

WP 0020 (4 pages) 0 WP 0021 (4 pages) 0 WP 0022 (2 pages) 0 WP 0023 (4 pages) 0 WP 0024 (6 pages) 0 Chp 3 - Troubleshooting Procedures 0 WP 0025 (2 pages) 0 WP 0026 (4 pages) 0 WP 0027 (4 pages) 0 Chp 4 - Preventive Maintenance Checks and Services (PMCS) 0 WP 0028 (4 pages) 0 WP 0029 (2 pages) 0 WP 0030 (4 pages) 0 WP 0031 (24 pages) 0 Chp 5 - Maintenance Instructions 0 WP 0032 (4 pages) 0 WP 0033 (4 pages) 0 Chp 6 - Supporting Information 0 WP 0034 (4 pages) 0 WP 0035 (6 pages) 0 WP 0036 (8 pages) 0

A/(B blank)

HEADQUARTERS

DEPARTMENT OF THE ARMY

WASHINGTON, DC, 30 APRIL 2009

TECHNICAL MANUAL

PALLETIZED LOAD SYSTEM (PLS) FLATRACK

M1077/M1077A1

NSN 3990-01-307-7676

ISO COMPATIBLE PALLETIZED FLATRACK (IPF)

M1

NSN 3990-01-406-1340

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is https://aeps.ria.army.mil. The DA Form 2028 is located under the Public Applications section in the AEPS Public Home Page. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LC-LMPP / TECH PUBS, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The e-mail address is tacomlcmc.daform2028@us.army.mil.

The fax number is DSN 793-0726 or Commercial (309) 782-0726.

*SUPERSEDURE NOTICE - *This TM supersedes TM 9-3990-206-14&P dated 2 June 2006. All maintenance, troubleshooting, and parts information formerly located in this TM can now be found in the PLS IETM (TM 9-2320-364-14&P).

DISTRIBUTION A - Approved for public release: distribution is unlimited.

*TM 9-3990-206-10

i/(ii blank)

TABLE OF CONTENTS

WP Sequence No.

Page No.

Warning Summary

How to Use this Manual

Chapter 1 - General Information, Equipment Description, and Theory of Operation

GENERAL INFORMATION.......................................................................... WP 0001

Table 1. Nomenclature Cross-Reference List..................... 0001-4

Table 2. List of Abbreviations.............................................. 0001-5

Table 3. Warning Icons Used In This Manual..................... 0001-10

Table 4. Approximate Conversion Factors.......................... 0001-17

Figure 1. ............................................................................. 0001-18

Figure 2. ............................................................................. 0001-20

EQUIPMENT DESCRIPTION AND DATA................................................... WP 0002

Figure 1. ............................................................................. 0002-2

Figure 2. ............................................................................. 0002-3

Figure 3. ............................................................................. 0002-4

Table 1. Flatrack Equipment Data....................................... 0002-4

EQUIPMENT DESCRIPTION AND DATA................................................... WP 0003

Figure 1. ............................................................................. 0003-3

Figure 2. ............................................................................. 0003-4

Figure 3. ............................................................................. 0003-5

Table 1. M1 Flatrack Equipment Data................................. 0003-6

THEORY OF OPERATION.......................................................................... WP 0004 iii

TABLE OF CONTENTS - Continued

Page No.

Figure 1. ............................................................................. 0004-1

THEORY OF OPERATION.......................................................................... WP 0005

Figure 1. ............................................................................. 0005-1

Chapter 2 - Operator Instructions

ASSEMBLY AND PREPARATION FOR USE.............................................. WP 0006

Figure 1. ............................................................................. 0006-2

Figure 2. ............................................................................. 0006-3

DECALS AND INSTRUCTION PLATES...................................................... WP 0007

Figure 1. ............................................................................. 0007-1

Figure 2. ............................................................................. 0007-2

SIDEBOARD KIT.......................................................................................... WP 0008

Figure 1. ............................................................................. 0008-2

Figure 2. ............................................................................. 0008-3

FLATRACK STACKING AND LOADING ON PLS....................................... WP 0009

Figure 1. ............................................................................. 0009-2

Figure 2. ............................................................................. 0009-3

Figure 3. ............................................................................. 0009-5

Figure 4. ............................................................................. 0009-5

Figure 5. ............................................................................. 0009-6

Figure 6. ............................................................................. 0009-7

Figure 7. ............................................................................. 0009-8

Figure 8. ............................................................................. 0009-8 iv

Page No.

Figure 9. ............................................................................. 0009-9

Figure 10. ........................................................................... 0009-10

Figure 11. ........................................................................... 0009-11

Figure 12. ........................................................................... 0009-12

Figure 13. ........................................................................... 0009-13

Figure 14. ........................................................................... 0009-14

Figure 15. ........................................................................... 0009-14

Figure 16. ........................................................................... 0009-15

Figure 17. ........................................................................... 0009-15

Figure 18. ........................................................................... 0009-16

FLATRACK STACKING AND LOADING ON PLS TRAILER....................... WP 0010

Figure 1. ............................................................................. 0010-2

Figure 2. ............................................................................. 0010-3

Figure 3. ............................................................................. 0010-4

Figure 4. ............................................................................. 0010-6

Figure 5. ............................................................................. 0010-7

Figure 6. ............................................................................. 0010-8

Figure 7. ............................................................................. 0010-9

Figure 8. ............................................................................. 0010-11

Figure 9. ............................................................................. 0010-12

Figure 10. ........................................................................... 0010-13

Figure 11. ........................................................................... 0010-14 v

Page No.

Figure 12. ........................................................................... 0010-16

Figure 13. ........................................................................... 0010-17

ASSEMBLY AND PREPARATION FOR USE.............................................. WP 0011

UNLOCK AND LOCK TWIST LOCKS.......................................................... WP 0012

Figure 1. ............................................................................. 0012-1

LOWER AND RAISE FRONT AND REAR WALL........................................ WP 0013

Figure 1. ............................................................................. 0013-2

Figure 2. ............................................................................. 0013-3

SIDEBOARD KIT.......................................................................................... WP 0014

Figure 1. ............................................................................. 0014-2

Figure 2. ............................................................................. 0014-3

CARGO TARP.............................................................................................. WP 0015

Figure 1. ............................................................................. 0015-2

Figure 2. ............................................................................. 0015-3

NUCLEAR, BIOLOGICAL, AND CHEMICAL (NBC)

DECONTAMINATION PROCEDURES........................................................ WP 0016

LOADING SINGLE FLATRACK ON PLS VEHICLE OR TRAILER.............. WP 0017

STACKING/LOADING TWO FLATRACKS ON PLS VEHICLE OR

TRAILER...................................................................................................... WP 0018

Figure 1. ............................................................................. 0018-1

Figure 2. ............................................................................. 0018-3

STACKING/LOADING THREE FLATRACKS ON PLS VEHICLE OR

TRAILER...................................................................................................... WP 0019 vi

Page No.

Figure 1. ............................................................................. 0019-2

Figure 2. ............................................................................. 0019-3

Figure 3. ............................................................................. 0019-4

Figure 4. ............................................................................. 0019-6

Figure 5. ............................................................................. 0019-7

Figure 6. ............................................................................. 0019-9

STACKING/UNSTACKING LOADED FLATRACKS.................................... WP 0020

Figure 1. ............................................................................. 0020-2

Figure 2. ............................................................................. 0020-3

PREPARATION FOR STORAGE OR SHIPMENT...................................... WP 0021

DECALS AND INSTRUCTION PLATES...................................................... WP 0022

Figure 1. ............................................................................. 0022-2

PREPARATION FOR RAIL TRANSPORT................................................... WP 0023

Figure 1. ............................................................................. 0023-1

Figure 2. ............................................................................. 0023-3

STOWAGE AND SIGN GUIDE.................................................................... WP 0024

Table 1. Flatrack Front and Passenger Side Exterior......... 0024-1

Table 2. Flatrack Rear Exterior........................................... 0024-2

Table 3. ISO Flatrack Front and Driver Side Exterior.......... 0024-3

Table 4. ISO Flatrack Rear Side Exterior............................ 0024-4

Chapter 3 - Troubleshooting Procedures

PIN ASSEMBLIES WILL NOT TURN........................................................... WP 0025 vii

Page No.

Figure 1. ............................................................................. 0025-1

FRONT OR REAR WALL IS DIFFICULT TO LIFT (TOO HEAVY).............. WP 0026

Figure 1. ............................................................................. 0026-2

FRONT OR REAR WALL LOWERS TOO RAPIDLY................................... WP 0027

Figure 1. ............................................................................. 0027-2

Chapter 4 - Preventive Maintenance Checks and Services (PMCS)

INTRODUCTION - OPERATOR'S PREVENTIVE MAINTENANCE............ WP 0028

Figure 1. ............................................................................. 0028-3

Figure 2. ............................................................................. 0028-4

OPERATOR'S PMCS - BEFORE................................................................. WP 0029

Table 1. OPERATOR'S PMCS - BEFORE......................... 0029-1

Figure 1. ............................................................................. 0029-2

OPERATOR'S PMCS - DURING................................................................. WP 0030

Table 1. OPERATOR'S PMCS - DURING.......................... 0030-1

Figure 1. ............................................................................. 0030-2

Figure 2. ............................................................................. 0030-3

OPERATOR'S PMCS - AFTER.................................................................... WP 0031

Table 1. OPERATOR'S PMCS - AFTER............................ 0031-1

Figure 1. ............................................................................. 0031-2

Figure 2. ............................................................................. 0031-3

Figure 3. ............................................................................. 0031-4

Figure 4. ............................................................................. 0031-6 viii

Page No.

Figure 5. ............................................................................. 0031-7

Figure 6. ............................................................................. 0031-9

Figure 7. ............................................................................. 0031-10

Figure 8. ............................................................................. 0031-11

Figure 9. ............................................................................. 0031-14

Figure 10. ........................................................................... 0031-15

Figure 11. ........................................................................... 0031-16

Figure 12. ........................................................................... 0031-18

Figure 13. ........................................................................... 0031-20

Figure 14. ........................................................................... 0031-22

Chapter 5 - Maintenance Instructions

ROLLER REPLACEMENT........................................................................... WP 0032

Figure 1. ............................................................................. 0032-1

Figure 2. ............................................................................. 0032-2

Figure 3. ............................................................................. 0032-2

Figure 4. ............................................................................. 0032-3

ROLLER REPLACEMENT........................................................................... WP 0033

Figure 1. ............................................................................. 0033-2

Figure 2. ............................................................................. 0033-2

Figure 3. ............................................................................. 0033-3

Figure 4. ............................................................................. 0033-3 ix

Page No.

Chapter 6 - Supporting Information

REFERENCES............................................................................................. WP 0034

COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS............ WP 0035

Table 1. Components of End Item...................................... 0035-2

Table 2. BASIC ISSUE ITEMS............................................ 0035-3

EXPENDABLE/DURABLE ITEMS LIST....................................................... WP 0036

Table 1. Expendable/Durable Supplies and Materials List........................................................................ 0036-2 x

HOW TO USE THIS MANUAL

USABLE ON CODE (UOC) INFORMATION

Usable On Code (UOC) - the user should be aware that the M1077/M1077A1 Palletized Load System (PLS) Flatrack UOC is "077" and the M1 ISO Compatible Palletized Flatrack (IPF) UOC is "IPF". Depending on the format used for printing this manual, the user may not see instructions printed in this manual stating what information is applicable to which model PLS series vehicle by UOC.

PRECEDENCE

The PLS Interactive Electronic Technical Manual (IETM) TM 9-2320-364-14&P takes precedence over this manual. The purpose of this manual is to give the operator a usable operator's manual in the absence of the IETM, NOT to take the place of the IETM.

Updates and revisions to this manual can be found within the PLS Interactive Electronic Technical Manual (IETM) TM 9-2320-364-14&P. Activities should regularly check the IETM for updates and revisions to this manual.

WARNINGS, CAUTIONS, AND NOTES

Read all WARNINGS, CAUTIONS, and NOTES before performing any procedure.

Warnings, cautions, notes, subject headings, and other essential information are printed in BOLD type, making them easier for the user to see.

GENERAL INFORMATION

This manual is designed to help operate and maintain the Palletized Load System (PLS) Flatrack and ISO Compatible Palletized Flatrack (IPF). Listed below are some features included in this manual to help locate and use the required information:

• Chapter 1 of this manual includes PLS Flatrack and IPF general information, theory of operation, differences between models, etc.

• Chapter 2 of this manual provides operating procedures for both the PLS Flatrack and IPF, and its accompanying operating systems.

• Chapter 3 of this manual provides operator troubleshooting procedures for both the PLS Flatrack and IPF, and its accompanying operating systems.

• Chapter 4 of this manual provides operator Preventive Maintenance Checks and Services (PMCS) for both the PLS Flatrack and IPF.

In addition to text, there are illustrations showing:

1. Components, controls, and indicators.

2. How to take a component off, and put it back on.

3. Cleaning and inspection criteria are also listed when necessary.

xi/(xii blank)

CHAPTER 1

GENERAL

INFORMATION,

EQUIPMENT

DESCRIPTION, AND

THEORY OF

OPERATION

OPERATOR MAINTENANCE

GENERAL INFORMATION

SCOPE

This manual is used for operation and operator-performed maintenance of Palletized Load System M1074 and M1075 series vehicles, M1076 PLS Trailers, M1077 Flatracks, and M1 ISO Compatible Flatracks. M1074 series vehicles are similar to M1075 except for the addition of a Material Handling Crane (MHC) and Self-Recovery Winch (SRW) kit. Models are as follows:

*** The following is applicable to model(s) 077 IPF. ***

MODEL DESCRIPTION

M1077 The M1077 flatrack is designed specifically for use with the Palletized Load System (PLS). The flatrack is used as a movable cargo bed for the vehicle and Palletized Load System Trailer

(PLST).

TM 9-3990-206-10 0001

0001-1

SCOPE - Continued

MODEL DESCRIPTION

M1 ISO Com-patible Flatrack

The M1 flatrack is a flat cargo body with folding end walls, designed specifically for use with the Palletized Load System (PLS). The flatrack is designed to be loaded on the PLS using the Load Handling System (LHS).

MAINTENANCE FORMS AND RECORDS

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA PAM 750-8, The Army Maintenance Management System (TAMMS) User Manual.

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

The quarterly TB 43-0001-62 (series) Equipment Improvement Report and Maintenance Digest contains valuable field information on equipment covered in this manual. Information in the TB 43-0001-62 (series) Equipment Improvement Report and Maintenance Digest is compiled from some of the Equipment Improvement Reports (EIR) that have been prepared

0001-2

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) - Continued on vehicles covered in this manual. Many of these articles result from comments, suggestions, and improvement recommendations that were submitted to the EIR program.

TB 43-0001-62 (series) Equipment Improvement Report and Maintenance Digest contains information on equipment improvements, minor alterations, proposed Modification Work Orders (MWOs), warranties (if applicable), actions taken on some of the DA Form 2028 (WP 0034) (Recommended Changes to Publications and Blank Forms), and advance information on proposed changes that may affect this manual. Refer to the TB 43-0001-62 (series) Equipment Improvement Report and Maintenance Digest periodically for the most current and authoritative information on the equipment. The information will help to do a better job and will advise of the latest changes to this manual. Also refer to DA PAM 25-30, Consolidated Index of Army Publications and Blank Forms at http://www.army.mil/usapa/ 2530.html, and reference section of this manual. If you have a change recommendation to this manual, submit a DA Form 2028 (WP 0034) (Recommended Changes to Publications and Blank Forms) via e-mail to: tacomlcmc.daform2028@us.army.mil.

You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Submit your DA Form 2028 (WP 0034) (Recommended Changes to Equipment Technical Publications and Blank Forms) through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is https://aeps.ria.army.mil. The DA Form 2028 (WP 0034) is located under the Public Applications section in the AEPS Public Home Page. Fill out the form and click on SUBMIT.

Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program. You may also mail, fax or e-mail your letter or DA Form 2028 (WP 0034) direct to: TACOM Life Cycle Management Command, ATTN:

AMSTA-LC-LMPP / TECH PUBS, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The e-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 793-0726 or Commercial (309) 782-0726.

HAND RECEIPT (HR) INFORMATION

The TM 9-2320-364-10-HR (Hand Receipt) is a companion document to this manual, which consists of preprinted hand receipts (DA Form 2062) that list end item related equipment (COEI, BII, (WP 0035) and AAL ) which must be accounted for. As an aid to property accountability, additional Hand Receipt (-HR) Manuals may be requisitioned from the following source in accordance with procedures in DA PAM 25-30, Consolidated Index of Army Publications and Blank Forms; Commander US Army Distribution Operation Facility, 1655 Woodson Road, St Louis, MO 63114-6181.

CORROSION PREVENTION AND CONTROL (CPC)

Corrosion prevention and control (CPC) of Army material is a continuing concern. It is important that any corrosion problems be reported so they can be corrected and improvements can be made to prevent problems in the future. While corrosion is typically associated with the rusting of metals, it can also include deterioration of other materials, 0001-3

CORROSION PREVENTION AND CONTROL (CPC) - Continued such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion problem.

If a corrosion problem is identified, it can be reported using SF 368 (WP 0034). The use of key words, such as "corrosion", "rust", "deterioration", and "cracking" will ensure that the information is identified as a CPC problem.

DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE

Command decision, according to the tactical situation, will determine when the destruction of the equipment will be accomplished. A destruction plan will be prepared by the using organization unless one has been prepared by a higher authority. Refer to TM 750-244-6, (WP 0034) Procedures for Destruction of Tank Automotive Equipment to Prevent Enemy Use, for general destruction procedures.

PREPARATION FOR STORAGE OR SHIPMENT

See information on preparing the PLS series vehicles, trailers, and flatracks for storage or shipment.

WARRANTY INFORMATION

The PLS is warranted by Oshkosh Truck Corporation for 12 months. For complete information covering this warranty refer to TB 9-2320-364-15, (WP 0034) Warranty Procedures for Vehicle, Tractor, M1074 and M1075, Palletized Load System (PLS) NSN 2320-01-304-2277 and 2320-01-304-2278. Trailer and flatrack warranty starts on the date found in block 23, DA Form 2408-9, (WP 0034) in logbook. Report all defects in materiel or workmanship to the supervisor, who will take appropriate action.

NOMENCLATURE CROSS-REFERENCE LIST

Table 1.

Common Name Official Nomenclature

Cable Wire rope

Cold Start System Ether quick start system

Engine Coolant Antifreeze, ethylene glycol mixture

Glad Hand Quick disconnect air coupling

Jackstand Trestle

0001-4

NOMENCLATURE CROSS-REFERENCE LIST - Continued

Table 1. - Continued

Common Name Official Nomenclature

Jake Brake Engine brake

Service Brake Pedal Brake pedal

Throttle Pedal Throttle control

Towing Eye Drawbar lunette

Towing Pintle Self-guiding coupler

LIST OF ABBREVIATIONS

Table 2.

AAL Additional Authorization List

AC…