10,000-LB ROUGH-TERRAIN FORKLIFT OPERATIONS PHASE I

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1 10,000-LB ROUGH-TERRAIN FORKLIFT OPERATIONS PHASE I POI FILE NUMBER: LESSON UNIT TITLES/TASK NUMBERS METHOD TIME Start the 10,000-lb. Rough-Terrain Forklift Stop and Shutdown the 10,000-lb. Rough-Terrain Forklift Put the 10,000-lb. Rough-Terrain Forklift in Motion Handle Palletized Load with 10,000-lb. Rough-Terrain Forklift Deposit Palletized Load with 10,000-lb. Rough-Terrain Forklift Handle and Deposit Palletized Load with 10,000-lb. Rough-Terrain Forklift Enter and Exit Surf with 10,000-lb. Rough-Terrain Forklift C/PE1 C/PE1 C/PE1 C C PE1 C 14.0 Hr 9.75 Hr Hr 1.25 Hr.75 Hr 16.0 Hr.75 Hr SUMMARY TEST TOTAL.50 Hr 2.0 Hr Hr 1

2 I. INTRODUCTION Attention Motivator Introduce self and lesson Show viewgraph VG01 As a cargo specialist, you may be required to operate a 10,000-lb. Rough-Terrain Forklift (RTFL). The RTFL is capable of operating over all types of terrain, and may be used as a forklift or a towing truck. In order to successfully operate the RTFL, you will have to know how to start, put into motion, handle and deposit palletized loads, and stop and shutdown the forklift. In addition you will also need to know how to enter and exit the surf with the forklift. (Stress the importance of the lesson through personal experience or a related story.) Terminal Learning Objective At the completion of this lesson, you (the student) will demonstrate the knowledge and basic skills required to operate a 10,000-lb. Rough-Terrain Forklift to load, move, and discharge general cargo. II. Transition BODY We will now begin by discussing the procedures to start the 10,000-lb. Rough- Terrain Forklift. 2

3 A. START THE 10,000-LB ROUGH-TERRAIN FORKLIFT TN: Introduction Motivator In operating the 10,000-lb. Rough-Terrain Forklift, you are required to know how to start the forklift. During this lesson unit, you will learn how to start the forklift and actually perform the procedures with a forklift. Inform the students of the following learning objective requirements. Objectives ACTION: CONDITIONS: STANDARD: At the completion of this lesson unit, the student will be able to start the 10,000-lb. Rough-Terrain Forklift Given references, class notes, Student Guide, check on learning questions, and a practical exercise To receive a GO for this lesson unit, the student must answer all check on learning questions correctly and start the 10,000-lb. Rough-Terrain Forklift IAW STP 55-88H1- SM and TM Safety Instructions There are no Force Protection Safety considerations for this lesson unit. Facility Requirements Classroom with a power source. Tools, Equipment and Materials Instructor: Students: Overhead Projector, Viewgraphs, Instructor Guide, and Training Support Package. Student Guide, Examination Book (IDT) and Notepad. References STP 55-88H1-SM TM

4 2. Learning Step/Activity 1: Conference Method of instruction: C Instructor to student ratio is 1:class. Time of instruction:.75 hour. Media: Instructor presentation and viewgraphs (VG01 - VG04). Refer students to the Student Guide to review Student Handout #1 on safety in the motorpool area and at the training site. a. Pre-Operational Checks Before starting the engine and operating the forklift, perform the beforeoperator/crew Preventive Maintenance Checks and Services (PMCS) according to TM Refer students to Student Guide to follow along while you explain the procedures for starting the forklift engine. b. Procedures for Starting the Engine Check the log book to determine the period of non-operation. If the engine has been idle for 30 days or more, the turbocharger must be primed before starting the engine. Notify organizational maintenance. Show viewgraph VG02 1) Turn the master disconnect switch ON. Before entering the cab of the forklift, you must turn the master disconnect switch to the ON position. The location of this switch will depend on the type of forklift being operated; however it is usually located externally on the left-hand side of the hydraulic reservoir. Only the S/N 2000 and below model is key-operated for protection against theft and vandalism when the forklift is left unattended. Do not use your foot to turn the master disconnect switch ON as this may damage the switch. Show viewgraph VG03 for steps 2 through 5 2) Ensure the parking brake is applied. The parking/emergency brake is a drum-type, spring-engaged, airdisengaged brake used for parking and emergency stopping situations. 4

5 3) Place the transmission directional lever in the NEUTRAL position. The lever is located to the left of the steering wheel on the dashboard. It is used to select the movement direction or neutral position of the forklift. To prevent accidental movement of the forklift, the parking brake must be applied and the transmission directional lever in lock position before starting the engine. 4) Press the accelerator pedal one-third of the way down. Depress the accelerator to the one-half engine speed position for temperatures above +50 degrees F or to the full speed position for temperatures below +50 degrees F. 5) Turn the ignition/starting switch to the START position, and release it the instant the engine starts. Caution: After 30 seconds of cranking, allow two minutes for the starting motor to cool if the engine does not start. 6) If the engine fails to start: Check to ensure the engine shutoff is pushed down and the cable is activating the governor control. Check to ensure the emergency shutoff is in the START position. Check the fuel tank and fuel filters for contamination. Inspect the air cleaner for obstructions. Show viewgraph VG04 7) Check instrument panel readings. Caution: If the engine oil pressure gage does not register within 10 seconds, stop the engine by turning the starting switch to OFF. Notify organizational maintenance. 8) Remove foot from accelerator. 9) Ensure the engine (radiator) fan switch is in the ON position when not in the surf. The engine (radiator) fan must be operating when engine is running or the engine will overheat. 5

6 Do not move the vehicle until the air pressure warning buzzer has stopped and the pressure gage reads in the operation range. Ask students if they have any questions before transition to check on learning. Check on Learning Distribute copies of the check on learning #1 (master is located in the Training Support Package) to the students and have them complete the questions. Allow the students 15 minutes to complete all the questions and then review the questions individually. Conduct a check on learning and summarize the learning activity. a. What must be done prior to starting the engine of the 10,000-lb. Rough- Terrain Forklift? (The before-operator/crew PMCS must be performed according to TM ) b. How can accidental movement of the forklift be prevented prior to starting the engine? (To prevent accidental movement, the parking brake must be applied and the transmission directional lever should be in NEUTRAL or lock position.) c. At what position should the accelerator pedal be pressed for temperatures +50 degrees F? (Depress the accelerator to the one-half engine speed position.) d. Why is it important to check the instrument panel, once the engine is started? (Important to ensure that the engine oil pressure gage registers within 10 seconds.) e. When should the engine (radiator) fan be in the ON position? (The engine fan must be operating when the engine is running and the forklift is not in the surf.) Transition Ask students if they have any questions. Now we will complete a Practical Exercise by actually starting a 10,000-lb. Rough-Terrain Forklift. 6

7 3. Learning Step/Activity 2: Practical Exercise Method of instruction: PE1. Instructor to student ratio is 1:class. Time of instruction: 13.0 hours. Instructional Lead-in An actual demonstration will first be given on the starting procedures for the 10,000-lb. Rough-Terrain Forklift. All steps covered in the instruction will be reviewed at this time. You will then have the opportunity to perform the starting procedures in order to complete this practical exercise. Resource Requirements First, demonstrate all the steps to perform the starting procedures. 10,000-lb. Rough-Terrain Forklift Safety Clothing Special Instructions For this practical exercise, each student will be required to perform the starting procedures in sequence on the 10,000-lb. Rough-Terrain Forklift. Refer to the check on learning for steps. In order to receive a GO for this lesson unit, each of you must successfully perform the steps for starting a 10,000-lb. Rough-Terrain Forklift. Feedback Requirements Score the soldier GO if all steps are passed. Score the soldier NO-GO if any step is failed. If the soldier fails any step, show what was done wrong and how to do it correctly. Check on Learning The following steps must be completed in sequence to receive a GO for this lesson unit: a. Perform before- operator/crew PMCS on the forklift. b. Turn the master disconnect switch ON. c. Ensure the parking brake is applied. d. Place the transmission directional lever in the NEUTRAL position. e. Press the accelerator pedal one-third of the way down. 7

8 f. Turn the starting switch to the START position, and release it the instant the engine starts. g. If the engine fails to start, perform the troubleshooting steps. h. Check instrument panel readings. i. Remove foot from accelerator pedal. j. Ensure the engine (radiator) fan switch is in the ON position when not in the surf. Critique students performance on practical exercise and summarize the learning activity. Transition This completes the instructions and practice on how to start the 10,000-lb. Rough-Terrain Forklift (RTFL). Now we will learn how to stop and shutdown the 10,000-lb. RTFL 8

9 4. Summary Method of instruction: C Instructor to student ratio is 1:class. Time of instruction:.25 hour. Review/ Summarize Lesson Unit In summary, we will now review the key points covered during this lesson unit. a. Always perform before- PMCS prior to starting the engine of the forklift. b. Procedures for starting the engine: 1) Turn the Electrical Master Disconnect switch ON. 2) Ensure the parking brake is applied. 3) Place the transmission directional lever in the NEUTRAL position. 4) Press the accelerator pedal one-third of the way down. 5) Turn the starting switch to the START position, and release it the instant the engine starts. 6) If the engine fails to start, perform the troubleshooting steps. 7) Check instrument panel readings. 8) Remove foot from accelerator pedal. 9) Ensure the engine (radiator) fan switch is in the ON position when not in the surf. Check on Learning Determine if students have learned the material presented by: a. Soliciting student questions and explanations. b. Asking questions and getting answers from the students. c. Correcting any student misunderstandings. Transition This completes the instruction and practice on how to start the 10,000-lb. Rough-Terrain Forklift (RTFL). Now we will learn how to stop and shutdown the 10,000-lb. RTFL. B. STOP AND SHUT DOWN THE 10,000-LB ROUGH-TERRAIN FORKLIFT 9

10 TN: Introduction Motivator In operating the 10,000-lb. Rough-Terrain Forklift, you are required to know how to park, stop and shut down the forklift. During this lesson unit, you will learn how to stop and shut down the forklift and actually perform the procedures with a forklift. Inform the students of the following learning objective requirements. Objectives ACTION: CONDITIONS: STANDARD: At the completion of this lesson unit, the student will be able to stop and shut down the 10,000-lb. Rough-Terrain Forklift (RTFL) Given references, class notes, Student Guide, check on learning questions, and a practical exercise To receive a GO for this lesson unit, the student must answer all check on learning questions correctly and park the RTFL following normal stopping and shutdown procedures and perform after-operations PMCS IAW STP 55-88H1-SM. Safety Instructions Facility Requirements There are no Force Protection Safety considerations for this lesson unit. Classroom with a power source. Tools, Equipment and Materials Instructor: Students: Overhead Projector, Viewgraphs, Instructor Guide, and Training Support Package. Student Guide, Examination Book (IDT) and Notepad. References STP 55-88H1-SM TM

11 2. Learning Step/Activity 1: Conference Method of instruction: C Instructor to student ratio is 1:class. Time of instruction:.50 hour. Media: Instructor presentation and viewgraphs (VG05 and VG06). Refer students to the Student Guide to review Student Handout #1 on safety in the motorpool area and at the training site. Show viewgraph VG05 for steps 1 through 5 Refer students to Student Guide to follow along while you explain the procedures for stopping the forklift. a. Procedures to Stop and Shut down the Forklift 1) Remove foot from accelerator. 2) Apply the service brake or the brake/transmission disconnect pedal until the forklift comes to a gradual stop. The brake/transmission disconnect pedal acts as a brake and also stops clutch pressure in the transmission. Do not use the brake/transmission disconnect pedal at a speed over 5 mph or when going downhill. Do not fan or pump the brake by repeatedly depressing and releasing the brake pedal. This reduces air pressure necessary for braking. 3) Place the transmission directional lever (FORWARD-NEUTRAL- REVERSE control lever) in NEUTRAL position. The transmission directional lever selects machine direction or the neutral position. 4) Lower the forks to the ground. Using the lift control lever, push the lever forward to lower the forks of the forklift to the ground. 5) Apply the parking/emergency brake. Warning: If the parking/emergency brake must be used to stop a forklift in motion, prepare for a sudden stop and brace yourself to prevent serious head, neck, and back injuries. 11

12 6) In parked position, operate the engine at low idle for five minutes. Caution: Stopping the engine immediately after the forklift has been under a load could result in overheating and accelerated wear. Show viewgraph VG06 7) Turn ignition switch to the OFF position. If equipped, pull up on the engine shutoff handle. Once the engine stops, push in the handle. 8) Turn the master disconnect switch to the OFF position. The location of this switch will depend on the type of forklift being operated, however it is usually located externally on the left-hand side of the hydraulic reservoir. Only the S/N 2000 and below model is key operated for protection against theft and vandalism when the forklift is left unattended. 9) Perform after-operations PMCS. After stopping the engine, perform the after-operator/crew Preventive Maintenance Checks and Services (PMCS) according to TM Ask students if they have any questions before transitioning to check on learning. Check on Learning Distribute copies of the check on learning #2 (master is located in the Training Support Package) to the students and have them complete the questions. Allow the students 15 minutes to complete all the questions and then review the questions individually. Conduct a check on learning and summarize the learning activity. a. What is the purpose of the brake/transmission disconnect pedal? (The brake/transmission disconnect pedal acts as a brake and also stops clutch pressure in the transmission.) b. Up to what speed can the brake/transmission disconnect pedal be applied? (The brake/transmission disconnect pedal should not be applied at a speed over 5 mph.) 12

13 c. What are the positions that the transmission directional lever can be placed? (The lever can be placed in the FORWARD, NEUTRAL, or REVERSE position.) d. What is used to lower the forks to the ground? (The lift control lever is used to lower the forks to the ground.) e. When in the parked position, how long should the engine idle to cool down? (Operate the engine at low idle for five minutes.) Transition Ask students if they have any questions. Now we will complete a Practical Exercise on performing stop and shutdown procedures using a 10,000-lb. Rough-Terrain Forklift. 13

14 3. Learning Step/Activity 2: Practical Exercise Method of instruction: PE1. Instructor to student ratio is 1:1. Time of instruction: 9.0 hours. Instructional Lead-in An actual demonstration will be given on performing the stop and shutdown procedures for the 10,000-lb. Rough-Terrain Forklift. All steps covered in the instruction will be reviewed at this time. You will have the opportunity to perform the procedures in order to complete this practical exercise. Resource Requirements First, demonstrate all the steps to perform the stop and shutdown procedures. 10,000-lb. Rough-Terrain Forklift Safety Clothing Special Instructions For this practical exercise, each student will be required to perform the stop and shutdown procedures in sequence on the 10,000-lb. Rough-Terrain Forklift. Refer to the check on learning for steps. In order to receive a GO for this lesson unit, each of you must successfully perform the stop and shutdown procedure steps on the 10,000-lb. Rough- Terrain Forklift. Feedback Requirements Score the soldier GO if all steps are passed. Score the soldier NO-GO if any step is failed. If the soldier fails any step, show what was done wrong and how to do it correctly. 14

15 Check on Learning The following steps must be completed in sequence to receive a GO for this lesson unit: a. Remove foot from accelerator. b. Apply service brake or brake/transmission disconnect pedal until forklift comes to a gradual stop. c. Place the transmission directional lever in NEUTRAL position. d. Lower the forks to the ground. e. Apply the parking/emergency brake. f. In parked position, operate the engine at low idle for five minutes. g. Turn ignition switch to OFF position. h. Turn master disconnect switch to OFF position. i. Perform after-operator/crew PMCS. Critique students performance on practical exercise and summarize the learning activity. 15

16 4. Summary Method of instruction: C Instructor to student ratio is 1:class. Time of instruction:.25 hour. Review/ Summarize Lesson Unit In summary, we will now review the key points covered during this lesson unit. a. Procedures to stop and shutdown the forklift: 1) Remove foot from accelerator. 2) Apply service brake or brake/transmission disconnect pedal until forklift comes to a gradual stop. 3) Place the transmission directional lever in NEUTRAL position. 4) Lower the forks to the ground. 5) Apply the parking/emergency brake. 6) In parked position, operate the engine at low idle for five minutes. 7) Turn ignition switch to OFF position. 8) Turn master disconnect switch to OFF position. 9) Perform after-operator/crew PMCS. Check on Learning Determine if students have learned the material presented by: a. Soliciting student questions and explanations. b. Asking questions and getting answers from the students. c. Correcting any student misunderstandings. Transition This completes the instruction and practice on how to stop and shut down a 10,000-lb. Rough-Terrain Forklift (RTFL). Now we will learn how to put the 10,000-lb. RTFL in motion. 16

17 C. PUT THE 10,000-LB ROUGH-TERRAIN FORKLIFT IN MOTION TN: Introduction Motivator In operating the 10,000-lb. Rough-Terrain Forklift, you are required to know how to drive and maneuver the forklift. During this lesson unit, you will learn how to drive and maneuver a forklift without a load along a designated course. Inform the students of the following learning objective requirements. Objectives ACTION: CONDITIONS: STANDARD: At the completion of this lesson unit, the student will be able to drive and maneuver the 10,000-lb. Rough-Terrain Forklift (RTFL) without a load along a designated course. Given references, class notes, Student Guide, check on learning questions, and a practical exercise To receive a GO for this lesson unit, the student must answer all check on learning questions correctly and drive and maneuver the RTFL without a load and perform beforeand during-operations PMCS IAW STP 55-88H1-SM. Safety Instructions Facility Requirements There are no Force Protection Safety considerations for this lesson unit. Classroom with a power source. Tools, Equipment and Materials Instructor: Students: Overhead Projector, Viewgraphs, Instructor Guide, and Training Support Package. Student Guide, Examination Book (IDT) and Notepad. References STP 55-88H1-SM TM

18 2. Learning Step/Activity 1: Conference Method of instruction: C Instructor to student ratio is 1:class. Time of instruction:.75 hour. Media: Instructor presentation and viewgraph (VG07). Refer students to the Student Guide to review Student Handout #1 on safety in the motorpool area and at the training site. Refer students to Student Guide to follow along while you explain the procedures for. a. Preparation for Movement Before starting the forklift, ensure all personnel are clear of the area and your seat belt is securely fastened. 1) Perform before-operations PMCS according to TM ) Start the engine according to TM After starting engine, operate at low idle speed until the hydraulic oil is warm. When the temperature is below 35 degrees, move all hydraulic controls slowly to warm them up. Move each cylinder several times to warm it. Test the hydraulic controls. Allow extra warm-up time if controls are sluggish. Caution: The air pressure gage must be in the green range. If it is not, stop the engine and notify organizational maintenance of the problem. b. Procedures to Put 10,000-lb. Rough-Terrain Forklift in Motion 1) Perform during-operations PMCS according to TM Show viewgraph VG07 for steps 2-8 2) Pull the lift control lever to raise the forks 12 to 18 inches above the operating surface. 3) Place the drive selector lever in two-wheel drive position (this lever may be located in various positions, depending on the type of forklift). 4) Disengage the parking brake and at the same time apply the service brake. 18

19 Brake damage can occur if the machine is moved with the brake applied. 5) Place the transmission gear range lever in the LOW (1), MEDIUM (2), or HIGH (3) position. The transmission has three forward gear ranges, three reverse gear ranges, and a neutral range, which are manually selected with the transmission gear range and directional levers. First gear (1) is the lowest and main working gear range. Second gear (2) can be used for working and roading the machine. Third gear (3) is used to road the machine for longer distances at the maximum machine speeds. The transmission gear range lever can be changed only under the following conditions: Down-shifting. Down shifting from 3 to 2 or 2 to 1 or 3 to 1 can be made at any time to maintain an efficient engine speed. Up-shifting. Up shifting from 1 to 2 or 2 to 3 or 1 to 3 can be made at any time. The most efficient use of each gear range is achieved when maximum engine rpm is reached in the gear range before an up-shift is made. 6) Place the transmission directional lever (FORWARD-NEUTRAL- REVERSE) in either the forward or reverse position. The forklift must come to a complete stop before changing forward or reverse direction. Warning: Never shift transmission into neutral when traveling downhill. This could cause loss of control or damage to the drive train upon shifting back into gear. 7) Slowly release the service brake. 8) Gradually depress the accelerator pedal and proceed. Ask students if they have any questions before transitioning to check on learning. Distribute copies of the check on learning #3 (master is located in the Training Support Package) to the students and have them complete the questions. Allow the students 15 minutes to complete all the questions and then review the questions individually. 19

20 Check on Learning Conduct a check on learning and summarize the learning activity. a. Once the forklift engine is started, what must be done? (The engine must be operated at low idle speed until the hydraulic oil is warm.) b. What should be done if the temperature is below 35 degrees? (All hydraulic controls need to be moved slowly to warm them up.) c. How high should the forks be raised above the operating surface when preparing to put the forklift in motion? (The forks should be raised 12 to 18 inches above the operating surface.) d. Under what conditions can the transmission gear range lever be changed? (The transmission gear range lever can be changed while down-shifting or up-shifting.) e. What does the transmission directional lever control? (The transmission directional lever controls the forward and reverse movement of the forklift and also the neutral position.) Transition Ask students if they have any questions. Now we will complete a Practical Exercise on procedures to put the 10,000-lb. Rough-Terrain Forklift in motion. 20

21 3. Learning Step/Activity 2: Practical Exercise Method of instruction: PE1. Instructor to student ratio is 1:class. Time of instruction: hours. Instructional Lead-in An actual demonstration will first be given on performing the procedures to put the 10,000-lb. Rough-Terrain Forklift in motion. All steps covered in the instruction will be reviewed at this time. You will then have the opportunity to perform the procedures in order to complete this practical exercise. Resource Requirements First, demonstrate all the steps to put the forklift in motion. 10,000-lb. Rough-Terrain Forklift Safety Clothing Special Instructions For this practical exercise, each student will be required to perform the procedures in sequence on the 10,000-lb. Rough-Terrain Forklift. Refer to the check on learning for steps. In order to receive a GO for this lesson unit, each of you must successfully perform the procedure steps to put the 10,000-lb. Rough-Terrain Forklift in motion. Feedback Requirements Score the soldier GO if all steps are passed. Score the soldier NO-GO if any step is failed. If the soldier fails any step, show what was done wrong and how to do it correctly. Check on Learning The following steps must be completed in sequence to receive a GO for this lesson unit: a. Perform before-/during-operations PMCS according to TM b. Start engine according to TM c. Pull lift control lever to raise forks 12 to 18 inches above the operating surface. d. Place drive selector lever in two-wheel drive position. 21

22 e. Disengage parking brake and apply service brake. f. Place transmission gear range lever in LOW, MEDIUM, or HIGH position. g. Place transmission directional lever (FORWARD-NEUTRAL-REVERSE) in either forward or reverse. h. Release service brake. i. Depress accelerator pedal and proceed. Critique students performance on practical exercise and summarize the learning activity. 22

23 4. Summary Method of instruction: C Instructor to student ratio is 1:class. Time of instruction:.25 hour. Review/ Summarize Lesson Unit In summary, we will now review the key points covered during this lesson unit. a. Preparation for movement: 1) Perform before-operations PMCS according to TM ) Start the engine according to TM b. Procedures to put 10,000-lb. Rough-Terrain Forklift in motion: 1) Perform during-operations PMCS according to TM ) Pull lift control lever to raise forks 12 to 18 inches above operating surface. 3) Place drive selector lever in two wheel-drive position. 4) Disengage parking brake and apply service brake. 5) Place transmission gear range lever in LOW, MEDIUM, or HIGH. 6) Place transmission directional lever (FORWARD-NEUTRAL- REVERSE) in either forward or reverse position. 7) Slowly release the service brake. 8) Gradually depress the accelerator pedal and proceed. Check on Learning Determine if students have learned the material presented by: a. Soliciting student questions and explanations. b. Asking questions and getting answers from the students. c. Correcting any student misunderstandings. Transition This completes the instruction and practice on how to put the 10,000-lb. Rough-Terrain Forklift (RTFL) in motion. Now we will learn how to handle palletized loads with the 10,000-lb. RTFL. D. HANDLE PALLETIZED LOADS WITH 10,000-LB ROUGH-TERRAIN FORKLIFT 23

24 TN: Introduction Motivator Given instructions from your supervisor, you will be tasked to use the 10,000- lb. RTFL to handle palletized loads. During this lesson unit, you will learn about hand signals used during forklift operations, and how to transport a palletized load using a 10,000-lb. RTFL. Inform the students of the following learning objective requirements. Objectives ACTION: CONDITIONS: STANDARD: At the completion of this lesson unit, the student will have the knowledge of how to transport a palletized load to a designated storage area, either indoors or outdoors using the 10,000-lb. Rough-Terrain Forklift (RTFL) and give proper hand signals. Given references, class notes, Student Guide, and check on learning questions. To receive a GO for this lesson, the student must answer all check on learning questions IAW STP 55-88H1-SM. Safety Instructions Facility Requirements There are no Force Protection Safety considerations for this lesson unit. Classroom with a power source. Tools, Equipment and Materials Instructor: Students: Overhead Projector, Viewgraphs, Instructor Guide, and Training Support Package. Student Guide, Examination Book (IDT) and Notepad. References STP 55-88H1-SM TM

25 2. Learning Step/Activity 1: Conference Method of instruction: C Instructor to student ratio is 1:class. Time of instruction: 1.0 hour. Media: Instructor presentation and viewgraphs (VG08 - VG16). Refer students to the Student Guide to review Student Handout #1 on safety in the motorpool area and at the training site. Show viewgraph VG07 for steps 2 through 8 Refer students to Student Guide to follow along while you explain hand signals used during forklift operations. a. Hand Signals Used During Forklift Operations The forklift operator must be able to interpret the hand signals given by the signalman. The following are basic hand signals given by the signalman during forklift operations. Show viewgraph VG08 1) Stop or Disregard Last Command: The right arm is raised above the head with the forearm bent at elbow and fist clenched. The forklift operator must take foot off accelerator and apply brake pedal. This is the most important hand signal to remember. Show viewgraph VG09 2) Slow Down: The right arm is lowered to waist level with forearm being swept right to left, turning several times in a wave motion. The forklift operator must take foot off accelerator and proceed slowly. Show viewgraph VG10 25

26 3) Lift Load: The right arm is raised above head with arm bent at elbow and forefinger pointing upward. The forklift operator must place the transmission directional lever in neutral, pull the lift control lever back, and accelerate while lifting the load. Show viewgraph VG11 4) Lower Load: The right arm is extended and bent at elbow with forefinger pointing downward. The forklift operator must place the transmission directional lever in neutral, push the lift control lever forward, and accelerate while lowering the load. Show viewgraph VG12 5) Tilt Load Back: The right arm is raised above the head with arm bent at elbow and forefinger and middle fingers pointing upward. Forklift operator pulls the tilt control lever back until the desired upward tilt angle is reached. Show viewgraph VG13 6) Tilt Load Forward: The right arm is extended and bent at elbow with forefinger and middle finger pointing downward. Forklift operator pushes the tilt control lever forward until the desired downward tilt angle is reached. Forklift operator pulls the tilt control lever back until the desired upward tilt angle is reached. 26

27 Show viewgraph VG14 7) Side Shift the Load: Both arms are bent at the elbows and extended forward at the waist level. Either left or right hand is extended with fingers joined. Using the other hand, point with forefinger toward the open palm in the direction which load is to be shifted. Forklift operator puts mode selector switch in back position, and pulls or pushes the fork positioner control lever to move the fork carriage. Show viewgraph VG15 8) Oscillate Load to the Side: Hands are placed on hips and body is tilted in the direction load should be tilted. Forklift operator puts mode selector switch in center position and pulls or pushes fork positioner control lever to rotate carriage in direction which load is to be tilted. b. Procedures to Handle Palletized Loads with 10,000-lb. Rough-Terrain Forklift 1) Secure the lock assemblies in the chain. 2) Place the special lock handles in the lock position. Caution: Do not overload the 10,000-lb. Rough-Terrain Forklift. 3) Approach the load squarely with lift forks at the correct height. Adjust the forks to align with the slots in the pallet. Mode selector switch in the forward position; pull fork positioner lever back to move forks toward each other, or push fork positioner lever forward to move forks away from each other. 4) Move forward until forks are completely under the load. Show viewgraph VG16 for steps 5 through 8 27

28 5) Neutralize the transmission by depressing the disconnect pedal. The disconnect pedal slows and stops the forklift while disconnecting the transmission, to allow full power to the forklift hydraulics. 6) Accelerate the engine to approximately 1,500 rpm or not more than half the throttle. 7) Pull back the forklift control lever to lift the load. Lift the load approximately 12 inches above the pick-up point. The lift control lever is the first lever to the right of the operator s seat. It has three control positions: RAISE, HOLD, and LOWER. 8) Pull back the fork tilt control lever to tilt the load. The tilt control lever is the second lever to the right of the operator s seat. It has three control positions: TILT BACK, HOLD, and TILT FORWARD. 9) Pull back the fork extension control lever to retract the load to the carrying position. 10) Perform after-operations PMCS upon completion of the mission. Ask students if they have any questions before transitioning to check on learning. Check on Learning Distribute copies of the check on learning #4 (master is located in the Training Support Package) to the students and have them complete the questions. Allow the students 15 minutes to complete all the questions and then review the questions individually. Conduct a check on learning and summarize the learning activity. a. Which hand signal is the most important to remember? (Stop or disregard last command ) 28

29 b. What must the forklift operator do when the lift load hand signal is given? (The forklift operator must place the transmission directional lever in neutral, pull the lift control lever back, and accelerate while lifting the load.) c. What should be done when approaching the load with the forklift? (The forks should be adjusted to align with the slots in the pallet.) d. How can the forklift transmission be neutralized? (Depressing the disconnect pedal will neutralize the transmission.) e. What procedure must be performed to lift a load? (The forklift control lever must be pulled back to lift a load.) Ask students if they have any questions. 29

30 3. Summary Method of instruction: C Instructor to student ratio is 1:class. Time of instruction:.25 hour. Review/ Summarize Lesson Unit In summary, we will now review the key points covered during this lesson unit. a. The forklift operator must be able to interpret the hand signals given by the signalman during operations. 1) Basic hand signals used during forklift operations: Stop or disregard last command Slow down Lift load Lower load Tilt load back Tilt load forward Side shift the load Oscillate load to the side b. Procedures to handle palletized loads with 10,000-lb. Rough-Terrain Forklift: 1) Secure the lock assemblies in the chain. 2) Place the special lock handles in the lock position. 3) Approach the load squarely with lift forks at the correct height. 4) Move forward until forks are completely under the load. 5) Neutralize the transmission by depressing the disconnect pedal. 6) Accelerate the engine to approximately 1,500 rpm or not more than half the throttle. 7) Pull back the forklift control lever to lift the load. 8) Pull back the fork tilt control lever to tilt the load. 9) Pull back the fork extension control lever to retract the load to the 30

31 carrying position. 10) Perform after-operations PMCS upon completion of the mission. Check on Learning Determine if students have learned the material presented by: a. Soliciting student questions and explanations. b. Asking questions and getting answers from the students. c. Correcting any student misunderstandings. Transition This completes the instruction on forklift hand signals and how to handle palletized loads with the 10,000-lb. Rough-Terrain Forklift (RTFL). Now we will learn how to deposit palletized loads with the 10,000-lb. RTFL. 31

32 E. DEPOSIT PALLETIZED LOADS WITH 10,000-LB ROUGH-TERRAIN FORKLIFT TN: Introduction Motivator Given instructions from your supervisor, you will be tasked to use the 10,000- lb. RTFL to deposit palletized loads. During this lesson unit, you will learn how to deposit a palletized load using a 10,000-lb. RTFL. Inform the students of the following learning objective requirements. Objectives ACTION: CONDITIONS: STANDARD: At the completion of this lesson unit, the student will have the knowledge of how to deposit a palletized load in a designated storage area, either indoors or outdoors using the 10,000-lb. Rough-Terrain Forklift (RTFL). Given references, class notes, Student Guide, and check on learning questions. To receive a GO for this lesson unit, the student must answer all check on learning questions correctly IAW STP 55-88H1-SM. Safety Instructions There are no Force Protection Safety considerations for this lesson unit. Facility Requirements Classroom with a power source. Tools, Equipment and Materials Instructor: Students: Overhead Projector, Viewgraphs, Instructor Guide, and Training Support Package. Student Guide, Examination Book (IDT) and Notepad. References STP 55-88H1-SM TM

33 2. Learning Step/Activity 1: Conference Method of instruction: C Instructor to student ratio is 1:class. Time of instruction:.5 hour. Media: Instructor presentation and viewgraph (VG17). Refer students to the Student Guide to review Student Handout #1 on safety in the motorpool area and at the training site. a. Transporting Palletized Loads Transport loads using the following guidelines: 1) Perform all steering and shifting as smoothly as possible. 2) Use lower transmission gear range loading and transporting the load. 3) Terrain and route are the main factors that govern speed and carrying height. 4) Descending hills and ramps should be taken with extreme caution (normally in reverse). Show viewgraph VG17 for steps 1 through 6 b. Procedures to Deposit Palletized Loads with 10,000-lb. Rough-Terrain Forklift 1) Depress the disconnect pedal to stop the forklift and allow full power to the forklift hydraulics. 2) Put the mode selector switch in the forward position and extend the forks outward (apart) by pushing the fork positioner lever forward, or retract the forks (together) by pulling the fork positioner lever back. 3) Push the fork tilt control lever, the second lever to the right of the operator s seat, forward to tilt forks to a horizontal position. 4) Push the lift control lever, the first lever to the right of the operator s seat, forward allowing the load to be lowered to a resting place (ground, stack, vehicle, and so on). Adjust and level the forks in the slot of the pallet. 33

34 5) Place the transmission direction lever (FORWARD-NEUTRAL- REVERSE) in REVERSE position. Sound the horn twice before backing up to make sure the rear area of the forklift is clear. 6) Release disconnect pedal before backing up the forklift. Bring the forks out of the pallet and adjust the forks to the proper carrying position. Ask students if they have any questions before transitioning to check on learning. Distribute copies of the check on learning #5 (master is located in the Training Support Package) to the students and have them complete the questions. Allow the students 15 minutes to complete all the questions and then review the questions individually. Check on Learning Conduct a check on learning and summarize the learning activity. a. What transmission gear range should be used during loading and transporting? (Use lower transmission gear range.) b. What must be done to extend the forks on the forklift? (The mode selector switch must first be placed in the forward position, then the fork positioner lever must be pushed forward to extend the forks.) c. As a precaution, what must be done before backing up the forklift? (The horn must be sounded twice.) d. To lower the cargo load, what direction must the lift control lever be positioned? (Push the lift control lever forward to lower load.) Ask students if they have any questions. 34

35 3. Summary Method of instruction: C Instructor to student ratio is 1:class. Time of instruction:.25 hour. Review/ Summarize Lesson Unit In summary, we will now review the key points covered during this lesson unit. a. When transporting loads with a 10,000-lb. Rough-Terrain Forklift, always follow the safety guidelines. b. Procedures to deposit palletized loads with 10,000-lb. Rough-Terrain Forklift: 1) Depress the disconnect pedal. 2) Extend the forks outward by pushing the fork positioner lever forward, or retract forks inward by pulling back on the fork positioner lever. 3) Push the fork tilt control lever forward to tilt forks to a horizontal position. 4) Tilt forks by pushing the lift control lever forward, allowing the load to be lowered to a resting place (ground, stack, vehicle, and so on). 5) Place transmission directional lever (FORWARD-NEUTRAL- REVERSE) in REVERSE position. 6) Release disconnect pedal before proceeding. Check on Learning Determine if students have learned the material presented by: a. Soliciting student questions and explanations. b. Asking questions and getting answers from the students. c. Correcting any student misunderstandings. Transition This completes the instruction on how to deposit palletized loads with the 10,000-lb. Rough-Terrain Forklift (RTFL). Now you will practice how to handle and deposit palletized loads with the 10,000-lb. RTFL. 35

36 F. HANDLE AND DEPOSIT PALLETIZED LOADS WITH 10,000-LB ROUGH- TERRAIN FORKLIFT 1. Introduction Motivator Given instructions from your supervisor, you will be tasked to use the 10,000- lb. RTFL to handle and deposit palletized loads. Inform the students of the following learning objective requirements. Objectives ACTION: CONDITIONS: STANDARD: At the completion of this lesson unit, the student will perform the steps to handle and deposit a palletized load in a designated storage area, either indoors or outdoors using the 10,000-lb. Rough-Terrain Forklift (RTFL). Given references, class notes, Student Guide, and a practical exercise To receive a GO for this lesson unit, the student must complete the practical exercise IAW STP 55-88H1-SM. Safety Instructions Facility Requirements There are no Force Protection Safety considerations for this lesson unit. N/A Tools, Equipment and Materials Instructor: Students: Instructor Guide, and Training Support Package. Student Guide. References STP 55-88H1-SM TM

37 2. Learning Step/Activity 1: Practical Exercise Method of instruction: PE1. Instructor to student ratio is 1:class. Time of instruction: hours. Instructional Lead-in An actual demonstration will be given on performing the procedures to handle and deposit palletized loads with the 10,000-lb. Rough-Terrain Forklift. The appropriate hand signals will also be demonstrated. All steps covered in the instruction will be reviewed at this time. You will have the opportunity to perform the procedures and hand signals in order to complete this practical exercise. Resource Requirements First, demonstrate all the steps to handle the palletized load with the forklift. Then give a brief demonstration of the hand signals. 10,000-lb. Rough-Terrain Forklift Safety Clothing For this practical exercise, each student will be required to perform the procedures in sequence for handling and depositing a load using a 10,000-lb. Rough-Terrain Forklift and giving the proper hand signals. Divide class into pairs, assigning one student to be the forklift operator and the other student to be the signalman. Once all students have performed the practical exercise with their assigned roles, have students reverse roles (i.e., the forklift operator is now the signalman and vice versa) and perform the practical exercise. Refer to the check on learning for steps. Special Instructions In order to receive a GO for this lesson unit, each of you must successfully perform the procedure steps to handle and deposit a palletized load with the 10,000-lb. Rough-Terrain Forklift and perform the hand signals. As one student operates the forklift, another will be assigned to give the appropriate hand signals. Feedback Requirements Score the soldier GO if all steps are passed and the appropriate hand signals are given. Score the soldier NO-GO if any step is failed. If the soldier fails any step, show what was done wrong and how to do it correctly. 37

38 Check on Learning The following steps must be completed in sequence to receive a GO for this lesson unit: a. Procedures to handle palletized loads with 10,000-lb. Rough-Terrain Forklift: 1) Secure the lock assemblies in the chain. 2) Place the special lock handles in the lock position. 3) Approach the load squarely with lift forks at the correct height. 4) Move forward until forks are completely under the load. 5) Neutralize the transmission by depressing the disconnect pedal. 6) Accelerate the engine to approximately 1,500 rpm or not more than half the throttle. 7) Pull back the forklift control lever to lift the load. 8) Pull back the fork tilt control lever to tilt the load. 9) Pull back the fork extension control lever to retract the load to the carrying position. 10) Perform after-operations PMCS upon completion of the mission. b. Procedures to deposit palletized loads with 10,000-lb. Rough-Terrain Forklift: 1) Depress the disconnect pedal. 2) Extend the forks outward by pushing the fork positioner lever forward, or retract forks inward by pulling back on the fork positioner lever. 3) Push the fork tilt control lever forward to tilt forks to a horizontal position. 4) Tilt forks by pushing the lift control lever forward, allowing the load to be lowered to a resting place (ground, stack, vehicle, and so on). 5) Place transmission directional lever (FORWARD-NEUTRAL- REVERSE) in REVERSE position. 6) Release disconnect pedal before proceeding. 38

39 c. Hand signals for forklift operation: 1) Stop or disregard last command 2) Slow down 3) Lift load 4) Lower load 5) Tilt load back 6) Tilt load forward 7) Side shift the load 8) Oscillate load to the side Critique students performance on practical exercise and summarize the learning activity. 39

40 3. Summary Method of instruction: C Instructor to student ratio is 1:class. Time of instruction:.25 hour. Review/ Summarize Lesson Unit In summary, we will now review the key points covered during this lesson unit. a. Procedures to handle palletized loads with 10,000-lb. Rough-Terrain Forklift: 1) Secure the lock assemblies in the chain. 2) Place the special lock handles in the lock position. 3) Approach the load squarely with lift forks at the correct height. 4) Move forward until forks are completely under the load. 5) Neutralize the transmission by depressing the disconnect pedal. 6) Accelerate the engine to approximately 1,500 rpm or not more than half the throttle. 7) Pull back the forklift control lever to lift the load. 8) Pull back the fork tilt control lever to tilt the load. 9) Pull back the fork extension control lever to retract the load to the carrying position. 10) Perform after-operations PMCS upon completion of the mission. b. Procedures to deposit palletized loads with 10,000-lb. Rough-Terrain Forklift: 1) Depress the disconnect pedal. 2) Extend the forks outward by pushing the fork positioner lever forward, or retract forks inward by pulling back on the fork positioner lever. 3) Push the fork tilt control lever forward to tilt forks to a horizontal position. 4) Tilt forks by pushing the lift control lever forward, allowing the load to be lowered to a resting place (ground, stack, vehicle, and so on). 40

41 5) Place transmission directional lever (FORWARD-NEUTRAL- REVERSE) in REVERSE position. 6) Release disconnect pedal before proceeding. Check on Learning Determine if students have learned the material presented by: a. Soliciting student questions and explanations. b. Asking questions and getting answers from the students. c. Correcting any student misunderstandings. Transition This completes the practical exercise on how to handle and deposit palletized loads with the 10,000-lb. Rough-Terrain Forklift (RTFL). Now you will learn how to enter and exit the surf using the 10,000-lb. RTFL. 41

42 G. ENTER AND EXIT SURF WITH 10,000-LB ROUGH-TERRAIN FORKLIFT TN: H10 1. Introduction Motivator Given instructions from your supervisor, you will be tasked to load and unload cargo from a landing craft using a 10,000-lb. Rough-Terrain Forklift (RTFL). During this lesson unit, you will learn how to enter and exit the surf with 10,000-lb. RTFL. Inform the students of the following learning objective requirements. Objectives ACTION: CONDITIONS: STANDARD: At the completion of this lesson unit, the student will have knowledge of how to enter and exit the surf with a 10,000- lb. Rough-Terrain Forklift (RTFL). Given references, class notes, Student Guide, and check on learning questions. To receive a GO for this lesson unit, the student must answer all check on learning questions correctly IAW STP 55-88H1-SM. Safety Instructions Facility Requirements There are no Force Protection Safety considerations for this lesson unit. Classroom with a power source. Tools, Equipment and Materials Instructor: Students: Overhead Projector, Viewgraphs, Instructor Guide, and Training Support Package. Student Guide, Examination Book (IDT) and Notepad. References STP 55-88H1-SM TM

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