Army Maintenance: A Comprehensive Guide to Equipment, Processes, and Safety
What is an MTOE?
An authorization document that prescribes the modification of a basic TOE necessary to adapt it to the needs of a specific unit or type of unit. This includes personnel and equipment.
Types of Fluid Leaks
Class II: Leakage great enough to form drops, but not enough to cause drops to drip from the item being checked/inspected.
PMCS Process
- Operator/Crew: Performs PMCS, enters faults, and updates.
- Squad Leader/Immediate Supervisor: Spot checks PMCS, faults, corrections, and updates.
- Maintenance Supervisor: Prioritizes, assigns, and inspects work by checking repairs, parts, and maintenance actions.
- Mechanic: Diagnoses faults, corrects faults, determines parts required, and performs maintenance tasks.
- Clerk: Adds/modifies fault data, requests parts, requests evacuation job orders, indicates receipt and installation of parts, and updates 5988-E.
MEL (Maintenance Expenditure Limit)
The total acceptable one-time cost to repair an end item or repairable component to a fully serviceable condition.
MAC (Maintenance Allocation Chart)
Designates overall authority and responsibility for the performance of maintenance functions on an item of equipment.
Controlled Exchange
The removal of serviceable components from unserviceable, economically repairable end items for immediate reuse in restoring a like item or weapon system to an FMC condition.
Cannibalization
The authorized removal of components from material designated for disposal (uneconomically repairable piece of equipment). Commanders may authorize cannibalization ONLY to facilitate the repair of other equipment for return to combat – NOT FOR STOCKAGE.
Battle Damage Assessment and Repair (BDAR)
BDAR uses emergency expedient repairs to return an item to a fully or partially mission-capable status.
Standard Army Maintenance System–Enhanced (SAMS-E)
Manages maintenance and supply (CL II, CL III(P), CL IV, CL IX). Produces work order numbers, orders parts, and tracks labor hours. Interfaces with SAMS-2E and SARSS-1. Collects and retrieves maintenance and supply information from SAMS-1E. Produces information on work orders, shop backlogs, and inoperative equipment statuses.
Standard Army Retail Supply System (SARSS)
SARSS is an automated, multi-echelon, supply management and stock control tool. SARSS-1 receives and processes supply requisitions from SAMS-1E.
The Army Maintenance Management System (TAMMS)
Records used to assist commanders at all levels in managing equipment use and operations, equipment maintenance, and repair operations and to maintain equipment to the Army standard. Types of records used in maintenance are:
- Operational Records: Give the information needed to control equipment.
- Maintenance Records: Control maintenance schedules and services.
- Historical Records: Track equipment history.
Two Level Maintenance Actions
- Field Maintenance Actions: On-system replacement.
- Sustainment Maintenance Actions: Off-system repairing.
Fair Wear and Tear
Damage caused by normal and customary use.
Other Than Fair Wear and Tear
Damage that has been caused through negligence or willful misconduct.
Stryker Brigade Support Battalion
Attached to the Stryker BCT. Mission: Provides distribution-based, centrally-managed, sustainment support to the SBCT to sustain its operational employment.
Field Maintenance Company
Mission: Provide Field Maintenance Support to a Stryker Brigade Combat Team (SBCT).
Maintenance Control Office (MCO)
- MNT CTL/PLT HQ: Nerve center for SBCT maintenance operations.
- CRT: Deploy to forward locations of infantry and field artillery battalions to conduct field maintenance operations. Controlled by the MCO who coordinates with supported battalion S4 or XO.
Forward Maintenance Company Maintenance Platoons
- Wheeled Vehicle Repair: Provides field maintenance for organic wheeled vehicles in the SBCT and all supported units in the BSA. Work is loaded by the Maintenance Control Section. Provides backup support to the forward CRTs. Employs a replace forward/repair rear maintenance philosophy.
- Armament Repair: Provides field maintenance on all armament-related equipment including turrets, fire control systems, small arms, sight units, & artillery.
- Ground Support Equipment: Provides field maintenance for all non-vehicular environmental control, power generation, water purification, POL, & engineer equipment.
- Missile Electronics: Provides field maintenance for the SBCT’s missile & electronic equip/weapon systems. Two distinctly separate missions: missile weapon maintenance, and communications-electronics maintenance.
Brigade Support Battalion (BSB)
Mission: Provide logistics and field maintenance to a specific Brigade. Organized and equipped to sustain the BCT for 72 hours.
Field Maintenance Company
Mission: Provide field maintenance to the BCT and specifically to the BSB and the BTB. It also provides limited reinforcing/back-up support to the FSCs.
Forward Support Company (CAB)
Mission: Provides sustainment (less class VIII) to the maneuver Battalion from the CABSA.
Oil Analysis
Periodic, analytical evaluation of oil and lubricant samples. Samples provide information on:
- Oil and lubricant condition/changes
- Component wear and tear
- Improve Operational Readiness
- Detect Impending Component Failures
- Conserve lubricating and hydraulic oils by applying on-condition oil changes
Oil analysis is required on:
- Aeronautical
- Ground Combat Equipment
- Locomotives
- Watercraft Components
- Support Equipment
AOAP Monitor Responsibilities
- Enrollment of unit equipment
- Timely submission of Samples
- Train personnel on proper sampling techniques
- Oil changes and re-samples conducted properly
- Monitor the Unit AOAP Program
Tools
- Authorized by MTOE/TDA
- Mechanic’s tool kits
- Common tools
- Sets, kits, and outfits (SKO)
- Special tools
- Expendable/durable
- Tool rooms
Test Measurement and Diagnostic Equipment (TMDE)
Any system or device capable of being used to evaluate the operational condition of equipment. Identifies or isolates actual or potential malfunctions.
The Calibration Program
The Calibration coordinator is the Calibrations NCO. The Calibration Program maintains the accuracy of torque wrenches, multi-meters, and other diagnostic equipment. Why calibrate TMDE?
- To properly maintain the sophisticated systems found in today’s Army.
- To ensure that it is working properly for comprehensive troubleshooting.
Phases of the Licensing Process
- Select: Screen records and personnel. Interview prospective personnel.
- Train: Proper equipment operation and PMCS. Safety and accident reporting. Local and national laws.
- Test: Written examination and physical examination (eye exam). Operational proficiency test (mechanical knowledge).
- License: DA Form 348-E, Driver Qualification Record. OF 346, Driver’s License.
Operator Records
The road test examiner (Master Driver) should be the most qualified individual, appointed by the commander. Operator license number consists of the first letter of the last name / last four of the SSN. Permit is valid for five years or expiration of civilian license.
Recognition of Operators and Mechanics
Commanders are responsible for establishing/maintaining the program for awarding drivers and mechanics badges.
Appurtenances (badges)
- Driver-W: For wheeled vehicles.
- Driver-T: For tracked vehicles.
- Driver-M: For motorcycles.
- Driver-A: For amphibious vehicles.
- Mechanic: For automotive or allied vehicles.
- Operator-S: For special mechanical equipment.
Purpose of the Army Safety Program
Provide a safe and healthy environment at all times for all Army personnel and others exposed to Army operations. Reduce and keep to a minimum accidental manpower and monetary losses.
Key Duties & Responsibilities
Commanders
- Protect personnel, equipment, and facilities.
- Set and enforce safety practices.
- Integrate risk management into all unit activities.
Supervisory Personnel
- Maintain a safe and healthy workplace.
- Ensure personnel follow instructions and wear personal protective equipment.
- Evaluate and correct reported hazards.
- Use risk management process.
Unit Safety Officer
Additional duty. SSG or higher at unit level / Officer at Bn level. Complete a unit safety officer course. Monitor unit safety practices. Advise the commander on safety concerns.
Everyone
- Practice safety awareness.
- Follow safe operating procedures.
- Use risk assessments.
OSHA’s Hazard Communication Standard
Goal: Reduce the risk of injury or illness caused by hazardous chemicals by transmitting key information. Establishes requirements for communicating information about chemical hazards to personnel in the workplace. The standard has four requirements:
- Local Hazard Communication Program
- Hazard Warning Labels
- Material Safety Data Sheets
- Training
Inspection Policy: Hazardous Material in stored drums or containers should be inspected weekly.
Logistics Information Warehouse Applications (LIW)
LIW is the merger of all LIDB and ILAP capabilities to create a single authoritative source for logistics information.
Types of Inspections
Initial Inspection: Normally done before equip enters shop, Location depends on item, Ensures compliance with SOPs
Determines: Extent of repairs/level of work, Estimated man-hours to complete work, Type/quantity of repair parts required, Tasks required to complete work.
Classification: Determines economical reparability of an unserviceable item
Considerations: Age, Mileage, Expenditure limits IAW Applicable TM/TB
In-Process Inspection: Done during shop processing, Pertains to task at hand, Technical assistance to maintenance shops, Performed by repair section chief
Final Inspection: Performed after equipment is repaired, Determines adequacy of repairs, Must meet established requirements IAW applicable TM’s, When possible, final inspector should be different from initial inspector
Why Evacuate:
TIME:Equipment will be evacuated based on the amount of time the unit has to repair the equipment fault
CAPACITY:The ability of the unit to perform the repair based on the amount of repair workload at the facility
CAPABILITY:Lack of personnel, equipment, etc. of the unit to repair the equipment fault
Maintenance equipment within a maintenance unit
Standard Automotive Tool Set (SATS)- Provides a common tool set with the capability to perform field maintenance of military vehicles and ground support equipment.
Base replaces Common #1, Common #2, Suppl #1 tool kits
FMM1 replaces Heavy DS Set T24660
FMM2 replaces Heavy Suppl T25619
Rapid inventory system, reducing time from 40+ hrs to 2 hrs
10 kw Tactical Quiet Generator
C130 Deployable
Forward Repair System (FRS)- A maintenance shop on wheels equipped to provide field maintenance of combat systems in the Forward Battle Area.
Secure enclosure mounted on PLS or HEMTT LHS flat rack
Operational within 5 minutes, allocated one per FMT/CRT
30 kw Tactical Quiet Generator and 175 PSI compressor
SPORT, IETM, FBCB2 and SINCGARS equipped
Equipped with a 5.5 ton crane that can lift/replace FUPPs
Electric and pneumatic power tools
Full ARC/MIG welding
Shop Equipment, Contact Maintenance (SECM)- Provides maintenance repair teams with the necessary tools and equipment to repair disabled combat equipment in the field.
Mounted on the HMMWV (M1097) chassis
Secure enclosure with accessible tool cabinets
Industrial quality hand tools/enhanced power tools
5 kw of electrical power supplied by the HMMWV’s generator
ARC and MIG welding with propylene brazing/cutting
Increased payload for parts, spares, and tools
Utility air compressor Tool Kit, General Mechanics (GMTK): A Soldier-portable tool kit designed for use by any repairperson requiring basic automotive-type hand tools.It is also a component in the Forward Repair System and the base kit for the Multi-capable Maintainer Tool Kit.
Used by all maintainers in CMF 63
Consists of 136 tools
Toolbox has wheels and a retractable handle
Drawers have foam liners with tool cutouts
Rapid inventory capability (