engineer maintenance and operations

MCI 1326

MARINE CORPS INSTITUTE

ENGINEER MAINTENANCE AND OPERATIONS

MARINE BARRACKS WASHINGTON, DC

UNITED STATES MARINE CORPS MARINE CORPS INSTITUTE 912 CHARLES POOR STREET SE WASHINGTON NAVY YARD DC 20391-5680

IN REPLY REFER TO:

1550 Ser 1326 11 Feb 08 From: Director To: Marine Corps Institute Student Subj: ENGINEER MAINTENANCE AND OPERATIONS (MCI 1326) 1. Purpose. MCI 1326, Engineer Maintenance and Operations provides instruction on to all Marines having supervisory leadership duties in the engineering field. 2. Scope. This course addresses the operation, maintenance, and management of engineer equipment used in the Marine Corps. This course also discusses engineer equipment employment and planning for equipment operations. 3. Applicability. This course is intended for instructional purposes only. It is designed for use by Marines in the ranks of staff sergeant through master gunnery sergeant who are assigned the MOS of 1316, 1341, 1345, 1349, or 1391. 4. Recommendations. Comments and recommendations on the contents of the course are invited and will aid in subsequent course revisions. Please complete the course evaluation questionnaire at the end of the final examination. Return the questionnaire and the examination booklet to your proctor.

M.SCOTT REICHENBAUGH By direction

“THIS DOCUMENT IS UNCLASSIFIED”

(This page intentionally left blank.)

Table of Contents Page Contents ............................................................................................................................

i

Student Information ..........................................................................................................

iii

Study Guide ......................................................................................................................

v

Study Unit 1

Maintenance Operations ...............................................................

1-1

Administration .............................................................................. Engineer Equipment MOS Training ............................................. MIMMS/AIS................................................................................. Records and Forms ......................................................................

1-3 1-31 1-41 1-61

Maintenance Related Programs ....................................................

2-1

Programs ....................................................................................... Supervise Publications .................................................................. Supply Support Program............................................................... Engineer Equipment Licensing.....................................................

2-3 2-19 2-31 2-41

Maintenance..................................................................................

3-1

Corrective Maintenance ................................................................ Preventative Maintenance............................................................. Load Testing of Engineer Equipment ........................................... Engineer Equipment Employment................................................

3-3 3-21 3-31 3-43

Equipment Characteristics ............................................................

A-1

Review Lesson ..................................................................................................................

R-1

Lesson 1 Lesson 2 Lesson 3 Lesson 4 Study Unit 2 Lesson 1 Lesson 2 Lesson 3 Lesson 4 Study Unit 3 Lesson 1 Lesson 2 Lesson 3 Lesson 4 Appendix A

MCI Course 1326

i

(This page intentionally left blank.)

MCI Course 1326

ii

Student Information

Number and Title

MCI 1326 ENGINEER MAINTENANCE AND OPERATIONS

Study Hours

12

Course Materials

Text

Review Agency

Commanding Officer, Engineer School Marine Corps Detatchment Ft. Leonard Wood, MO 65473

Reserve Retirement Credits (RRC)

4

ACE

Not applicable to civilian training/education

Assistance

For administrative assistance, have your training officer or NCO log on to the MCI home page at www.mci.usmc.mil. Marines CONUS may call toll free 1-800-MCI-USMC. Marines worldwide may call commercial (202) 6857596 or DSN 325-7596.

MCI Course 1326

iii

(This page intentionally left blank.)

MCI Course 1326

iv

Study Guide Congratulations

Congratulations on your enrollment in a distance education course from the Distance Learning and Technologies Department (DLTD) of the Marine Corps Institute (MCI). Since 1920, the Marine Corps Institute has been helping tens of thousands of hard-charging Marines, like you, improve their technical job performance skills through distance learning. By enrolling in this course, you have shown a desire to improve the skills you have and master new skills to enhance your job performance. MCI Course 1326, Engineer Maintenance and Operations, prepares Marines for the job of engineer equipment chief.

Your Personal Characteristics

•

YOU ARE PROPERLY MOTIVATED. You have made a positive decision to get training on your own. Self-motivation is perhaps the most important force in learning or achieving anything. Doing whatever is necessary to learn is motivation. You have it!

•

YOU SEEK TO IMPROVE YOURSELF. You are enrolled to improve those skills you already possess, and to learn new skills. When you improve yourself, you improve the Corps!

•

YOU HAVE THE INITIATIVE TO ACT. By acting on your own, you have shown you are a self-starter, willing to reach out for opportunities to learn and grow.

•

YOU ACCEPT CHALLENGES. You have self-confidence and believe in your ability to acquire knowledge and skills. You have the selfconfidence to set goals and the ability to achieve them, enabling you to meet every challenge.

•

YOU ARE ABLE TO SET AND ACCOMPLISH PRACTICAL GOALS. You are willing to commit time, effort, and the resources necessary to set and accomplish your goals. These professional traits will help you successfully complete this distance learning course. Continued on next page

MCI Course 1326

v

Study Guide, Continued

Beginning Your Course

Before you actually begin this course of study, read the student information page. If you find any course materials missing, notify your training officer or training NCO. If you have all the required materials, you are ready to begin. To begin your course of study, familiarize yourself with the structure of the course text. One way to do this is to read the table of contents. Notice the table of contents covers specific areas of study and the order in which they are presented. You will find the text divided into several study units. Each study unit is comprised of two or more lessons and lesson exercises.

Leafing Through the Text

Leaf through the text and look at the course. Read a few lesson exercise questions to get an idea of the type of material in the course. If the course has additional study aids, such as a handbook or plotting board, familiarize yourself with them.

The First Study Unit

Turn to the first page of study unit 1. On this page, you will find an introduction to the study unit and generally the first study unit lesson. Study unit lessons contain learning objectives, lesson text, and exercises.

Reading the Learning Objectives

Learning objectives describe in concise terms what the successful learner, you, will be able to do as a result of mastering the content of the lesson text. Read the objectives for each lesson and then read the lesson text. As you read the lesson text, make notes on the points you feel are important.

Completing the Exercises

To determine your mastery of the learning objectives and text, complete the exercises developed for you. Exercises are located at the end of each lesson, and at the end of each study unit. Without referring to the text, complete the exercise questions and then check your responses against those provided. Continued on next page

MCI Course 1326

vi

Study Guide, Continued

Continuing to March

Continue on to the next lesson, repeating the above process until you have completed all lessons in the study unit. Follow the same procedures for each study unit in the course.

Preparing for the Final Exam

To prepare for your final exam, you must review what you learned in the course. The following suggestions will help make the review interesting and challenging. •

CHALLENGE YOURSELF. Try to recall the entire learning sequence without referring to the text. Can you do it? Now look back at the text to see if you have left anything out. This review should be interesting. Undoubtedly, you’ll find you were not able to recall everything. But with a little effort, you’ll be able to recall a great deal of the information.

•

USE UNUSED MINUTES. Use your spare moments to review. Read your notes or a part of a study unit, rework exercise items, review again; you can do many of these things during the unused minutes of every day.

•

APPLY WHAT YOU HAVE LEARNED. It is always best to use the skill or knowledge you’ve learned as soon as possible. If it isn’t possible to actually use the skill or knowledge, at least try to imagine a situation in which you would apply this learning. For example make up and solve your own problems. Or, better still, make up and solve problems that use most of the elements of a study unit.

•

USE THE “SHAKEDOWN CRUISE” TECHNIQUE. Ask another Marine to lend a hand by asking you questions about the course. Choose a particular study unit and let your buddy “fire away.” This technique can be interesting and challenging for both of you!

•

MAKE REVIEWS FUN AND BENEFICIAL. Reviews are good habits that enhance learning. They don’t have to be long and tedious. In fact, some learners find short reviews conducted more often prove more beneficial. Continued on next page

MCI Course 1326

vii

Study Guide, Continued

Tackling the Final Exam

When you have completed your study of the course material and are confident with the results attained on your study unit exercises, take the sealed envelope marked “FINAL EXAM” to your unit training NCO or training officer. Your training NCO or officer will administer the final examination and return the examination and the answer sheet to MCI for grading. Before taking your final examination, read the directions on the DP-37 answer sheet carefully.

Completing Your Course

The sooner you complete your course, the sooner you can better yourself by applying what you’ve learned! HOWEVER--you do have 2 years from the date of enrollment to complete this course.

Graduating!

As a graduate of this distance education course and as a dedicated Marine, your job performance skills will improve, benefiting you, your unit, and the Marine Corps. Semper Fidelis!

MCI Course 1326

viii

STUDY UNIT 1 MAINTENANCE OPERATIONS Overview

Introduction

As the engineer chief, it is your duty to make sure the shop is well-organized and functions effectively. Though most decisions are made at the command level about how a shop is put together, sometimes you will have to make these decisions. You must be able to set up and manage an effectively functioning maintenance facility that will achieve the best results under any conditions.

References

Information that prescribes field site selection is found in the current edition of FMFM 3-1, Command and Staff Action.

Scope

This study unit includes the initial set up of maintenance administration and the elements and resources that are used in this process. Engineer equipment MOS training, how to reconcile and manage the MIMMS/AIS system, and the importance of supervising maintenance records and forms will be discussed as well.

In This Study Unit

This study unit contains the following lessons: Lesson Administration Engineer Equipment MOS Training MIMMS/AIS Records and Forms

MCI Course 1326

1-1

See Page 1-3 1-31 1-41 1-61

Study Unit 1

(This page intentionally left blank.)

MCI Course 1326

1-2

Study Unit 1

LESSON 1 ADMINISTRATION Introduction

Scope

This lesson will introduce you to the planning, organization, layout, and overall structure of the maintenance shop.

Learning Objectives

At the end of this lesson, you will be able to •

Identify the two authorization documents.

•

Identify the four elements that make up maintenance administration.

•

Identify the seven maintenance resources.

•

Identify the purpose of internal inspections.

•

Identify two types of internal inspection.

•

Identify the purpose of the inspection checklist.

•

Identify the four functional shop sections with their functions.

•

Identify the four physical characteristics evaluated when selecting a site in the field for maintenance operations.

•

Identify the four factors considered when selecting a maintenance site.

•

Identify the 13 application principles when laying out a maintenance area.

•

Identify the individuals responsible for site selection of the maintenance area for major and force level commands. Continued on next page

MCI Course 1326

1-3

Study Unit 1, Lesson 1

Introduction, Continued

In This Lesson

This lesson contains the following topics: Topic Introduction Authorization Documents Maintenance System Resources Internal Inspections Shop Sections Field Site Selection Area Layout Lesson 1 Exercise

MCI Course 1326

1-4

See Page 1-3 1-5 1-6 1-9 1-13 1-17 1-21 1-23 1-26

Study Unit 1, Lesson 1

Authorization Documents

Important Documents

Every unit has a specific mission it must perform, and each unit is allocated the necessary assets based upon their mission. The two documents listed below lay out and dictate the unit’s organizational mission requirements, structure, and the authorizations for personnel and equipment: • Table of organization • Table of equipment

Table of Organization (T/O)

The table of organization (T/O) is established by Headquarters Marine Corps (HQMC). The T/O outlines a unit’s mission requirements, a description of the organizational structure, the manpower resources, and the echelons of maintenance. T/Os indicate the maintenance authority of each unit based on the capabilities, personnel and equipment rated, and careful consideration of the unit’s wartime mission. All organizations shall perform only those maintenance actions that are authorized by their T/O.

Table of Equipment (T/E)

HQMC also establishes the table of equipment (T/E). The T/E is a document that lists the tools and equipment the unit is authorized and required to possess to accomplish its mission: • • • • •

MCI Course 1326

Engineer equipment assets Logistical assets Test kits Tool kits Tool boxes

1-5

Study Unit 1, Lesson 1

Maintenance System

Managing the System

The engineer chief is normally involved in numerous administrative matters pertaining to the management of the shop. As the maintenance manager, you must always be aware what is going on. Keeping your resources in mind and readily available is the best way to manage your maintenance system.

The Four Elements

There are four elements that make up the maintenance administration system: • • • •

Command Resource Information Production

The table below is a basic breakdown of some common resources and where they fall under the acronym CRIP: Command Organization

Time

Resource

Information Records

Policies

Personnel

Reports

Procedures

Parts and Supplies

MIMMS/AIS

Supervision Funds

Tools and Equipment Facilities

Readiness Reporting Publications

Production Preventive Maintenance Corrective Maintenance Maintenance Related Programs Fabrication

Continued on next page

MCI Course 1326

1-6

Study Unit 1, Lesson 1

Maintenance System, Continued

The Command Element

The command element represents the best interest of the unit organization as it establishes and defines • • • •

Command policy letters Command procedures for specific functions Subordinate supervision Funds

Commanders cannot be expected to have the same expertise as the technicians and mechanics in all shops, but they should demonstrate enthusiasm and a willingness to learn to keep the maintenance machine running efficiently.

The Resource Element

The engineer chief is responsible for planning, organizing, coordinating, supervising, and evaluating resources. Along with the maintenance management officer (MMO), the engineer chief provides input for T/O and T/E revisions and recommended changes. Resources are the key element for any shop supervisor, although all the elements of the maintenance system are important. Without resources, nothing would get accomplished, i.e. you cannot fix equipment without tools.

The Information Element

An engineer chief needs the necessary information to carry out and accomplish the mission. There are several reports that are produced on a daily basis that contain this information. However, the engineer chief relies heavily on two types of information: • Equipment Records. By analyzing equipment’s record, the chief can learn the equipment’s history of past problems and major maintenance required. This allows the chief to predict future serviceability. • Reports. All the activity and transactions from the previous day’s work is captured on various reports. The chief looks at these reports each day to track the maintenance progression and to identify any negative trends in the maintenance cycle. The Marine Corps Integrated Maintenance Management System/Automated Information System (MIMMS/AIS) generates these reports as a basis for entering and tracking equipment in the maintenance cycle. Continued on next page

MCI Course 1326

1-7

Study Unit 1, Lesson 1

Maintenance System, Continued

The Production Element

MCI Course 1326

Production involves the actual physical performance of various maintenance functions. This element includes activities such as equipment repair, troubleshooting, equipment recovery, quality control and equipment inspection, etc. Though most production is performed by organizational and field level maintenance units, some production functions are performed only at the depot level, such as major overhauls and chassis rebuilds.

1-8

Study Unit 1, Lesson 1

Resources

Management

The key to any successful operation is how well management plans, coordinates, and organizes the functional areas of maintenance resources. Management consists of those continuing actions of planning, organizing, directing, coordinating, controlling, and evaluating the use of personnel, money, materials, and facilities to accomplish mission and tasks. As the engineer chief, you will spend most of your time managing your resources.

Seven Areas

The seven maintenance resources are • • • • • • •

Time Personnel Parts and supplies Tools and equipment Facilities Funds Publications

Time

A mechanic's loss of production time can double or triple when they lack the necessary tools, publications, parts, or skills to perform a job. It is the engineer chief’s job to make sure that shortfalls do not interfere with the mechanic’s ability to accomplish the mission or increase the time required to do the job.

Personnel

Personnel are your most precious asset! As the engineer chief, it is your responsibility to make sure they are properly trained. You must decide which approach to training is most appropriate for your mission. Your training choices include the following: • • • •

On-the-job training (OJT) Formal schools Mobile training teams (MTTs) MCIs (Marine Corps Institute occupational distance training courses)

The MMO is responsible for ensuring that maintenance management training is included in the annual training plan. Continued on next page MCI Course 1326

1-9

Study Unit 1, Lesson 1

Resources, Continued

Parts and Supplies

Replacement and repair parts are crucial to the mission. Without these, you cannot fix the equipment. Equipment that is sitting in short parts or awaiting parts status for extended periods of time hurts unit readiness and prevents mission accomplishment. Secondary repairables are considered as well, including parts such as engines, transmissions, starters, and pumps that are repaired by a higher echelon of maintenance and returned to the supply system for use by field units. For parts replacement, use an NAVMC 10925, Equipment Repair Order Shopping/Transaction List (EROSL), commonly referred to as a 4-card to requisition all repair/replacement parts and secondary repairables. The pre-expended bin (PEB) is another source for parts replacement. It stocks only high usage, fast moving items. The mechanic can draw parts such as filters and other common hardware from the shop’s PEB, rather than having to order them and wait for the supply system to deliver. Continued on next page

MCI Course 1326

1-10

Study Unit 1, Lesson 1

Resources, Continued

Tools and Equipment

Another key maintenance resource is the support equipment and test measurement diagnostic equipment (TMDE), including tool sets, kits, chests, hoists, jacks, stands, and multimeters. Part Tool Control

Function • The MMO establishes tool control by way of a policy letter to ensure proper inventories and maintenance. • Each shop must maintain and inventory numerous tools and tool kits. • Tool kits and boxes will have their own record jackets. • Each tool room issues out the following items on a daily basis: • • • • •

General mechanics tool boxes Equipment specific tools kits Common #2 tools Other special tools

Each receiving individual must sign for each tool in a log book or on an Equipment Custody Record (ECR) card.

• Calibration

Periodic tool inspections must be performed for the safety of personnel and equipment. • The MMO establishes calibration control.

• Each shop ensures a calibration program is properly worked and maintained. Calibration includes two steps: • •

Facilities

Establish a schedule for induction of each item into the maintenance cycle for calibration. Assign a calibration status to each item.

The MMO is responsible for the location and size of shop facilities whether in garrison or in the field. The size and location of the shop will depict how the shop is laid out. Most of the time, you will walk into a shop that is already established. Continued on next page

MCI Course 1326

1-11

Study Unit 1, Lesson 1

Resources, Continued

Publications

The S-1/adjutant, supply officer, and the MMO are in charge of publications control. In a commodity area, the supervisor is responsible for publications: ordering, inventory control, and maintenance. For publications control, the supervisor uses two types of inventories: • Wall-to-wall inventory. Every publication is inventoried using the PL and SL-1-2 to ensure all required publications are on hand to meet the mission. • Update inventory. Superseded publications, changes, etc., are checked and properly updated; library continues with proper updating and maintenance of publications.

Funds

In terms of hard dollars, budgets, or operating targets, the MMO and the maintenance sections do not “see” funds directly; they submit a cost plan and expenditures to the supply officer. The amount of funding for a unit is determined when planning the fiscal year budget for parts, tools, and other maintenance-related supplies.

MCI Course 1326

1-12

Study Unit 1, Lesson 1

Internal Inspections

Introduction

Internal inspections are inspections conducted by the maintenance management supervisor within each commodity to determine if the maintenance and maintenance management programs are running effectively. These inspections provide real-time feedback of the maintenance effort within the unit and are used to identify and correct deficiencies that are uncovered within any facet of the maintenance management program. The reference that you will need to be familiar with to perform internal inspections is the MCO P4790.2_.

Purpose

An internal inspection is a valuable tool to determine your unit’s effectiveness in its maintenance and maintenance management programs. An internal inspection ensures the following: • • • • •

There is an acceptable state of material readiness. Planning and organization are sound. Staffs are functioning effectively. Directives are clear and understood. Standards are established to measure performance.

Directives

Inspections are also a good tool to identify and educate your commodity sections on the correct orders and directives that govern the maintenance and maintenance management programs. It is imperative that each commodity has a clear understanding of these orders and directives so the job is performed correctly.

Inspection Characteristics

Inspections may be conducted in a variety of manners to accomplish different objectives. However, the following are characteristics common to good inspections: • • • •

Constructive Critical Objective Realistic and measurable standards Continued on next page

MCI Course 1326

1-13

Study Unit 1, Lesson 1

Internal Inspections, Continued

Constructive

Since you are the expert, you will have to provide education/training when the opportunity exists to those you are inspecting. Just telling a commodity section what their discrepancies are will not help the situation. In most cases, maintenance and maintenance management personnel will be eager to display their best.

Critical

Procedures and areas that appear to be without defect must be scrutinized carefully so that accomplishment may be recognized and to determine if the procedures could be useful elsewhere. The more critical your inspection is, the more effective your unit will become.

Objective

The inspection must be free of emotion and the interplay of personalities, whether favorable or adverse, should not affect the outcome of the inspection. Inspect each commodity section the same way. By conducting yourself in this manner, you will always be seen as fair, consistent, and objective.

Realistic and Measurable Standards

The inspected commodity section must comprehend the weight given to the inspection evaluation. These measurable standards are usually in the form of a checklist that you will provide to your commodities prior to the inspection. This will allow you and your section to keep track during the inspection of exactly what is being measured and to what standard. Most standards that can be set will deal with performance in the different areas of the maintenance management program.

Two Types

There are two types of inspections that can be conducted within your unit: • Formal • Informal Continued on next page

MCI Course 1326

1-14

Study Unit 1, Lesson 1

Internal Inspections, Continued

Formal

Formal inspections are announced in advance and a standard procedure for the conduct of the inspection disseminated. A checklist will be prescribed that can be used by the inspection team and the inspected unit to prepare for the inspection. Such an inspection routine assures the commander of the correction of many small faults or omissions that could otherwise fail to get accomplished during normal operations. Formal inspections become the primary activity of the inspected unit during the inspection, with personnel and equipment being made available to the fullest extent. An example of a formal inspection would be a Logistics Modernization Team (LMT) inspection. LMTs were formerly called a Marine Corps Logistics Chain Analysis Team (MCLCATs), which were also called Field Supply and Maintenance Analysis Office (FSMAO) inspections.

Informal

Informal inspections may examine the unit or certain areas (commodity section) of the unit’s activity to the same extent as a formal inspection or to any lesser extent. The depth of this inspection will be up to you, the maintenance manager. A spot-check inspection of equipment or personnel in the conduct of routine operations is an example of the simplest of the informal inspections. The helpful instructional aspect of the inspection process may be more readily achieved when the informal inspection aspect is stressed. Inspection checklists may be prescribed, either written or oral reports may be rendered. Informal inspections, though previously announced, are frequently conducted simultaneously with and not in lieu of normal unit operations.

References

When conducting internal inspections, review the following references: • MMSOP • Maintenance-related MCOs • Maintenance management policy letters Continued on next page

MCI Course 1326

1-15

Study Unit 1, Lesson 1

Internal Inspections, Continued

MMSOP

Your MMSOP will be one of the driving forces reviewed prior to inspecting. It should include information on the standards and guidelines that your commodity sections must adhere to when performing their job.

MaintenanceRelated MCOs

If your unit does not utilize a thorough MMSOP, always use the MCO P4790.2 that will outline guidance on what should be inspected in each commodity area.

Policy Letters

Maintenance management policy letters are those letters that further define certain aspects of things listed within your MMSOP. An example of a policy letter is the establishment of the unit’s ERO matrices for each commodity section. This additional information provides clarity to each section when completing their job.

Inspection Checklist

A commander must routinely prepare and use the inspection checklist during the inspection of maintenance sections. An inspection checklist is useful both for normal operations and in preparation for an inspection. The inspection checklist is used by maintenance personnel to make a final check on preparedness and to correct unresolved details.

Sources

A good source for an inspection checklist is the Logistics Modernization Teams (LMT) or higher headquarters. The LMT is the old MCLCAT/FSMAO teams and would have the most up-to-date checklists that are being used.

Uniformity

A good inspection checklist ensures the uniform appraisal by all members of an inspection team. The inspection checklist becomes the skeleton for the inspection report, represents a logical sequence of facts, and provides information for an analysis of the inspected unit.

MCI Course 1326

1-16

Study Unit 1, Lesson 1

Shop Sections

Functional Areas

A maintenance shop's actual layout varies from mission to mission, shop to shop, size, and location. Every maintenance shop is divided into four functional sections: • • • •

Shop Office Operations Section

The shop office operations section manages the overall conduct of maintenance and the various other functions within the shop: • • • • • • •

Issue Point

Administrative/Operations Administrative Section Services Section Maintenance Section

Assign personnel in the shop. Maintain and schedule the flow of equipment. Ensure the economy of resources and the proper use of maintenance float. Ensure maintenance operations interface with maintenance programs. Establish and execute the shop safety program. Supervise and maintain training in the shop. Ensure proper MIMMS (Marine Corps Integrated Maintenance Management System) transactions are submitted, and current and correct statuses are entered in the MIMMS system via EROs.

Many shops incorporate a parts storage/issue point. The issue point is vital part of every shop. • A required section for any functioning maintenance shop • Located in a small shop or centralized in a larger command—for this reason, it is not attached in the organizational flow chart on the next page. • Controls parts issue and storage Continued on next page

MCI Course 1326

1-17

Study Unit 1, Lesson 1

Shop Sections, Continued

Administrative Section

The administrative section performs the following tasks: • • • •

Shipping and Receiving

Shipping and receiving of the administration section does the following: • • • • • • •

Organizational Flow Chart

Receives and transfers equipment Researches technical data and issues tools Controls shop property Records and reports completed maintenance actions

Performs equipment receipt and inspections Performs acceptance inspections Issues parts requests Stores parts Maintains equipment security Issues equipment to the using unit Returns equipment to the customer

An organizational flow chart of the various shop sections is shown below:

Shop Office Operations Section

Layettes/ PEB Issue Point

Administrative Section

Services Section

Maintenance Section Continued on next page

MCI Course 1326

1-18

Study Unit 1, Lesson 1

Shop Sections, Continued

Technical Library

Tool Room

The technical library of the administration section does the following: •

Identifies and controls the technical publications for each piece of equipment in the unit. These publications cover maintenance, parts, and modifications of the equipment.

•

Updates publication library listings, providing direct assistance to maintenance personnel researching parts.

The tool room of the administration section does the following: • • •

Shop Supply

Issues, repairs, and replaces tools and test equipment Keeps up-to-date inventories on all tools and test equipment Provides security for all tools and test equipment

The shop supply of the administration section does the following: • •

Maintains equipment repair order (ERO) bins (layette bins) and preexpended bins Requisitions lubricants, rags, and other consumables Continued on next page

MCI Course 1326

1-19

Study Unit 1, Lesson 1

Shop Sections, Continued

Maintenance Section

The maintenance section performs the actual maintenance. You should organize this section as dictated by your heaviest mission. The most common way to organize a shop is by function and equipment: • Function. Separate into preventative maintenance, corrective maintenance, and modifications sections, etc. • Equipment. Separate by equipment type i.e. tracked, cranes, and forklifts.

Contact Teams

Sometimes you cannot deliver equipment to a central shop for maintenance. Perhaps the equipment is too large or set up in a distant location, such as generators and cranes. For such cases, it is more practical to send a maintenance team, known as a contact team, to the equipment. Contact teams are useful because they • Bring mechanics and parts to the inoperable equipment/job site more quickly than the equipment could be brought to a maintenance facility. • Save time that would be required to transport the equipment to the maintenance facility. • Increase equipment readiness.

Storage and Issue

The storage and issue of repair parts if controlled by the maintenance section. A secured area is required to control the actual issue of parts. Large parts, such as exhaust systems, belly pans, and drive shafts, can be tagged and stored in a designated location if space is limited. Functions of the issue point include • Maintaining a copy of the EROSL for each ERO in a tub file • Personnel who are issued parts must sign for them by the EROSOL part(s) number • Picking up parts, following-up on part orders, returning parts not used to supply (rollback), and validating with supply

MCI Course 1326

1-20

Study Unit 1, Lesson 1

Field Site Selection

Four Physical Characteristics

Now that your shop sections are organized, the next process is to select a site for field maintenance operations. Selecting a field maintenance site requires evaluation of four physical characteristics: • • • •

Terrain and environment Tactical situation Size and mission of the unit Maintenance requirements dictated by the mission

S-1 Responsibility

In the using units, the maintenance area is normally within the limits of the unit's command post. The S-1, which is responsible for selecting all sites in the compound, determines the location of a unit's maintenance facilities.

G-3/S-3 Responsibility

The unit's G-3/S-3, assisted by the MMO (maintenance management officer), selects the maintenance area for major and force level commands within the logistics areas. Note: The logistics/maintenance areas are normally separated from the major or force level command post.

Four Factors

There are four factors pertinent to selecting a command post site when you are selecting a maintenance field site: • • • •

Space requirements Terrain Accessibility Location Continued on next page

MCI Course 1326

1-21

Study Unit 1, Lesson 1

Field Site Selection, Continued

Space Requirements

Congestion in a maintenance area impairs efficiency and safety. A maintenance area should be large enough to permit safe dispersion of equipment and provide adequate space for repairs.

Terrain

The terrain for a maintenance field site should • • • • •

Accessibility

When considering the accessibility of a field maintenance site, consider access routes that • • • • •

Location

MCI Course 1326

Offer concealment from ground and air observation. Favor defense against air and ground attacks. Facilitate local security. Have a hard stand. Have access to roads and water for vehicles and equipment.

Avoid congested areas. Are convenient to users of the maintenance facilities. Easily accessible to supported units. Provide the most effective means of safe evacuation. Allow resupply to occur efficiently.

A maintenance area should be positioned to allow each maintenance section to effectively perform its mission. A maintenance area of support maintenance units should be located far enough from supported combat elements to allow continuity of maintenance operations. Also it should be located in close proximity to other logistic elements of the unit to enable the use of common facilities and services.

1-22

Study Unit 1, Lesson 1

Area Layout

Advising

The maintenance management officer (MMO) advises the commander and the staff on the following: • • • •

Assignment of facilities Placement of shops Distribution of utilities Priority of installation within the maintenance area

The MMO also establishes a position of common services, such as welding, avoiding duplication of effort when possible.

Responsibilities

The MMO, commander, and staff play key roles in establishing the overall layout. Maintenance management will coordinate the organization of the maintenance area with unit staff officers applying thirteen principles. The engineer officer and the engineer chief manage their respective facilities. Continued on next page

MCI Course 1326

1-23

Study Unit 1, Lesson 1

Area Layout, Continued

Thirteen Principles

Apply the following 13 principles when laying out a maintenance area: Principle Facilities Working Areas

Centralize Services

Defensive Positions Hardstands Lighting Security Issue Points POL Fire Plan Accessibility Hazardous Areas Protect Personnel

Description Assign facilities according to equipment size, density, and anticipated work load. Decide which equipment to position inside and outside the compound—tracked vehicle maintenance should be performed outside the compound to cause less damage to the maintenance area. Take into consideration compound drainage when assigning outside work and storage areas. Conserve utilities by centralizing services. Think about the needs of your shops as you lay out the maintenance area. For example, locate shops with common requirements for extensive electrical power so that a minimum number of generators will meet their need. Make sure wash racks are positioned so they can serve several users at once. Make defensive positions accessible to the workplace. Install required hardstands where needed. Place lighting so it does not jeopardize tactical soundness. Locate necessary secure areas away from the perimeter of the unit. Centrally locate common issue points to serve more than one shop at a time. Centrally locate the storage area for fuel and other petroleum products. Design and implement a fire plan. Position all fire extinguishers properly. Locate access points to and from the maintenance area and inside the work areas according to regulations. Label hazardous work areas clearly, such as “Welding Shop-Hazardous” and “Battery Shop-Hazardous.” Design the maintenance area to provide cover and concealment to protect personnel and equipment in tactical situations. Continued on next page

MCI Course 1326

1-24

Study Unit 1, Lesson 1

Area Layout, Continued

Maintenance

Below is an example of a basic engineer equipment field maintenance site: Primary Road

Vehicle Wash

Maintenance Operations

Fuel Storage

Tracked Vehicles

Motor transport Maintenance

Traffic Flow

Traffic Flow

Issue point

Hardstand Engineer Maintenance

Supply Area

MCI Course 1326

1-25

Power Distribution

Study Unit 1, Lesson 1

Lesson 1 Exercise

Directions

Complete exercise items 1 through 10 by choosing the correct answer. Check your responses against those listed at end of this lesson.

Item 1

The table of organization (T/O) is the document that outlines a unit's a. b. c. d.

Item 2

The table of equipment (T/E) is the document that lists a. b. c. d.

Items 3 Through 6

equipment authorization. special tool allowances. chain of command. mission requirements.

special tool allowances. tools and equipment required for a unit to perform its mission. commodity manager's additional maintenance authorizations. equipment assigned to the commodity manager's account.

Matching: For items 3 through 6, match each shop section in column 1 with its corresponding shop function in column 2. Place your responses in the spaces provided. Column 1

Column 2

Shop Section

Function

___ 3. ___ 4. ___ 5. ___ 6.

a. Manages the overall conduct of maintenance b. Performs the function associated with receipt and transfer of equipment, researches technical data and tool issue, and records and reports completed maintenance actions in the shop c. Performs the actual maintenance on equipment d. Controls parts issue and storage

Maintenance Administration Shop Operations Issue Point

Continued on next page

MCI Course 1326

1-26

Study Unit 1, Lesson 1 Exercise

Lesson 1 Exercise, Continued

Item 7

To select a maintenance site in the field, what are the four physical characteristics you must evaluate? a. Weather, condition of personnel, logistical capabilities, and time factors b. Resources, environmental factors, weather, and condition of personnel c. Terrain and environment, tactical situation, size and mission of the unit, and maintenance requirements dictated by the mission d. Time allowance, enemy troop strength, tactical placement, and availability of supplies

Item 8

When setting up a shop in a field environment, what four factors should you consider? a. Supply location, fire protection, water for reverse osmosis process, and mess hall b. Defensive position, POL site, conservation of utilities, and supply location c. Command post, exchange location, chapel, and mess hall d. Space requirements, terrain, accessibility, and location

Item 9

Who is responsible for the site selection of the maintenance area for major and force level commands? a. b. c. d.

G-3/S-3 assisted by the MMO The equipment officer and chief Company 1stSgt and SgtMaj Executive officer and company commander Continued on next page

MCI Course 1326

1-27

Study Unit 1, Lesson 1 Exercise

Lesson 1 Exercise, Continued

Item 10

There are 13 principles you should apply when laying out a maintenance area. List 10 of the 13 principles in any order. 1.

________________________________________________________

2.

________________________________________________________

3.

________________________________________________________

4.

________________________________________________________

5.

________________________________________________________

6.

________________________________________________________

7.

________________________________________________________

8.

________________________________________________________

9.

________________________________________________________

10.

________________________________________________________ Continued on next page

MCI Course 1326

1-28

Study Unit 1, Lesson 1 Exercise

Lesson 1 Exercise, Continued

Answers

The table below lists the answers to the lesson exercise. If you have any questions about these items, refer to the reference page. Item Number 1 2 3 4 5 6 7 8 9 10

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Answer d b c b a d c d a Facilities Working areas Centralize services Defensive positions Hardstands Lighting Security Issue points POL Fire plan Accessibility Hazardous areas Protect personnel

Reference 1-5 1-5 1-20 1-18 1-17 1-17 1-21 1-21 1-21 1-24

Continued on next page

MCI Course 1326

1-29

Study Unit 1, Lesson 1 Exercise

(This page intentionally left blank.)

MCI Course 1326

1-30

Study Unit 1, Lesson 1 Exercise

LESSON 2 ENGINEER EQUIPMENT MOS TRAINING Introduction

Scope

The purpose of Marine Corps training is to attain and maintain the state of operational readiness required to conduct combat and other operations in accordance with assigned missions. To accomplish this, training must prepare individual Marines, teams, and units to perform assigned tasks and other duties at the desired level of proficiency. This lesson covers individual training requirements, individual training standards, components of an ITS, elements of training, and training records.

Realism in Training

Ideally, training should be as realistic as possible, conducted under simulated combat conditions. To achieve this, use simulated scenarios with full 782 gear and small training areas to conduct this type of training. Remember, the peacetime mission of the Marine Corps is to prepare for war!

Learning Objectives

At the end of this lesson, you will be able to • Define the components of individual training standards (ITS). • Identify the four essential elements of a training program.

In This Lesson

This lesson contains the following topics: Topic Introduction Training Requirements Individual Training Standard (ITS) Components of an ITS Elements of Training Individual Training Record (ITR) Lesson 2 Exercise

MCI Course 1326

1-31

See Page 1-31 1-32 1-33 1-34 1-36 1-38 1-39

Study Unit 1, Lesson 2

Training Requirements

Criteria

The Marine Corps establishes training requirements that set criteria for each individual Marine. These training requirements are stated in the form of a task statement known as an individual training standard (ITS). The ITS prescribes the individual tasks a Marine must perform for the unit to successfully perform its mission. They are derived from the Marine Corps Combat Readiness and Evaluation System Mission Performance Standards (MCCRES MPSs).

Reference and Guidance

All individual and collective training conducted by units in the operating forces and supporting establishments must be according to the training management (TM) principles established by Unit Training Management Guide, FMFM 0-1 and FMFM 0-1A.

MCI Course 1326

1-32

Study Unit 1, Lesson 2

Individual Training Standard (ITS)

Purpose

The individual training standard (ITS) establishes the training standards for all Marines in the same occupational field (OccFld), military occupational specialty (MOS), or billet. They provide a foundation upon which unit commanders, functional learning center (FLC) directors, and distance learning (DL) developers build training packages for individual Marines as part of unit training plans or formal courses of instruction. Note: The ITS represents the skills that contribute to the unit mission as expressed in the mission performance standards (MPS).

Unit Commanders

The ITS is used by unit commanders, FLC directors, and DL developers to design, develop, conduct, and evaluate the individual training of Marines. Unit commanders are responsible for the sustainment of all individual tasks that have been deemed, through analysis, to support the unit’s mission essential task list (METL). Therefore, unit commanders can use the tasks contained in this order as the basis of individual training through managed on-the-job training (MOJT), instruction in unit-level schools, or incorporation in their training plans. FLC directors and DL developers will derive terminal learning objectives (TLO) and enabling learning objectives (ELO) from the tasks, conditions, standards, and performance steps of each associated ITS. Task lists reported on course descriptive data (CDD) submissions will consist of tasks contained in this order that are designated for training at the appropriate level in the FLC. Task lists reported on distance learning descriptive data (DLDD) submissions will consist of tasks contained in this order that are designated for DL training at the appropriate level. Unit commanders and FLC directors are responsible for reviewing their training programs per reference and making interventions that reduce risk to acceptable levels.

MCI Course 1326

1-33

Study Unit 1, Lesson 2

Components of an ITS

Elements

There are six elements of an ITS—five of which are mandatory: • • • • • •

Task

Task Condition Standards Performance steps References Administrative instruction (optional)

Task describes a specific and necessary behavior expected of a Marine in a particular MOS or billet. It is a clearly stated, performance-oriented action requiring a learned skill. Skills that make a Marine or qualify that Marine for an MOS are designated as “core.” Those advanced skills that are mission, grade, or billet specific are designated as “core plus.” Example: Provided a Preventative Maintenance Roster (NAVMC 10561), descriptive date—with the aid of references, review the NAVMC 10561 for accuracy IAW the references.

Condition

Condition describes the equipment, manuals, assistance/supervision, special physical demands, environmental conditions, and location affecting a Marine’s performance of the task under real-world circumstances. Example: Provided a Preventative Maintenance Roster (NAVMC 10561), descriptive date—with the aid of references, review the NAVMC 10561 for accuracy IAW the references.

Standards

Standards describe the level of proficiency to which the individual must perform the task. Example: Provided a Preventative Maintenance Roster (NAVMC 10561), descriptive date—with the aid of references, review the NAVMC 10561 for accuracy IAW the references. Continued on next page

MCI Course 1326

1-34

Study Unit 1, Lesson 2

Components of an ITS, Continued

Performance Steps

Performance steps represent the logical sequence of actions required of the Marine to perform the task to standard. These actions are typically detailed in the references.

References

References are doctrinal publications, technical manuals, and other publications upon which the ITS and its performance steps are based. They should be readily available and provide detail to the procedures that are only summarized in the performance steps.

Administrative Instructions (Optional)

Administrative instructions provide the trainer/instructor with special required or recommended circumstances, including safety precautions, relating to the training or execution of the task. These instructions may also clarify the meaning of the task.

MCI Course 1326

1-35

Study Unit 1, Lesson 2

Elements of Training

Formal Schools

Training for engineer operator and maintenance billets are usually based on course materials issued by the formal schools. Although these materials do a good job of reinforcing skills Marines learned at the formal school, they often become outdated as new engineer items are introduced into the fleet. Until the formal schools can update their course materials to reflect the latest equipment, you must fill this gap with training at your level.

Essential Elements

The four essential elements of training are listed below: • • • •

Personnel

Personnel Equipment Area and facilities Imagination

Routinely, you will have your Marines performing other mission essential tasks during training times, so don't despair when only half of your strength falls out for the training. Do the best you can with those who can attend! Train all personnel who are present. Make it the best training possible. This benefits those present and makes others want to be trained in the future. Remember that lack of personnel is not an excuse for inadequate training. Many battles have been won without full strength platoons.

Equipment

Break out your equipment at every opportunity. Make your training as realistic as possible. Make sure your Marines get plenty of training experience on their equipment.

Area and Facilities

Some units have much better locations than others. The key is to use what you have available. Network to find areas you can use for training. Good places to start are your battalion S-3 and the range control. For convenience, keep training areas within walking distance. Make the field your classroom. When possible carry the chalkboard with you and make the training realistic by using several means of delivery. Continued on next page

MCI Course 1326

1-36

Study Unit 1, Lesson 2

Elements of Training, Continued

Imagination

Structure challenging training for your Marines by using all the elements; your Marines, the equipment, the training area, and imagination. Marines want a challenge! Make sure to give them one or they will seek it elsewhere. Stop talking and do it! Use your imagination to select training areas and situations that pose realistic problems for your Marines to overcome. For instance, train at night when visibility is a challenge or train in the mud when recovery becomes a necessity. Under such realistically challenging conditions, your Marines will learn and become better at operations and maintenance. Such exercises make them solve problems under pressure and develop leadership skills

MCI Course 1326

1-37

Study Unit 1, Lesson 2

Individual Training Record (ITR)

Purpose

The individual training record (ITR) is used to document all individual training completed by the each Marine in the section/unit. It contains essential training data such as weapons training, battle skills testing, physical fitness testing and education.

Monitoring

Ideally, the Marine’s squad leader makes the entries in each Marine’s ITR because he is in daily contact with the Marine. The platoon sergeant or training NCO supervises the accuracy and timeliness of the entries in the ITR and keeps the engineer chief informed. The engineer chief should screen the ITR on a quarterly basis to gather information on training and performance shortfalls. Then, the chief can schedule future training.

Training

Marines can be trained in different ways. Setting up a simple training program “by the book” can help the efficiency of your shop. • Consider using ITRs in your training program. • Assign a training NCO in writing. • Provide your training NCO with proper references and guidance.

MCI Course 1326

1-38

Study Unit 1, Lesson 2

Lesson 2 Exercise

Directions

Complete exercise items 1 through 6 by choosing the correct answer. Check your responses against those listed at end of this lesson.

Items 1 Through 4

Matching: For items 1 through 4, match each component of an ITS in column1 with its definition in column 2. Place your responses in the spaces provided.

Item 5

Column 1

Column 2

Component

Definition

___ 1. ___ 2. ___ 3. ___ 4.

a. Performance-oriented action that requires a learned skill b. Equipment, manuals, and location c. Proficiency and performance of a task d. Logical sequence of actions

What are four essential elements of a good training program? a. b. c. d.

Item 6

Condition Standards Task Performance Steps

Time, equipment, tools, and location Funds, personnel, tools, and location Imagination, time, personnel, and area Personnel, area and facilities, equipment, and imagination

The purpose of an ITR is to a. b. c. d.

help track performance of the Marine. document the individual Marine’s training throughout his or her career. help in planning unit training. document all individual training completed by Marines. Continued on next page

MCI Course 1326

1-39

Study Unit 1, Lesson 2 Exercise

Lesson 2 Exercise, Continued

Answers

The table below lists the answers to the lesson exercise. If you have any questions about these items, refer to the reference page. Item Number 1 2 3 4 5 6

MCI Course 1326

Answer b c a d d d

1-40

Reference 1-34 1-34 1-34 1-35 1-36 1-38

Study Unit 1, Lesson 2 Exercise

LESSON 3 MIMMS/AIS Introduction

Scope

As an engineer chief, knowing how to read and analyze MIMMS/AIS reports is essential. It provides insight on your unit’s maintenance efforts and will affect the overall readiness of your unit’s equipment. This lesson will introduce you to each report as well as give you some good guidelines on how to catch and correct deficiencies found during your analysis. Following this plan will ensure you have a successful maintenance management program at your unit.

Learning Objectives

In This Lesson

After completing this lesson, you will be able to •

Identify the header information on the daily processing report.

•

Identify the purpose of the daily transaction listing.

•

Identify the purpose of the weekly owning unit TAM report.

•

Identify the purpose of the weekly maintenance exceptions report.

This lesson contains the following topics: Topic Introduction Daily Processing Report Daily Transaction Listing Weekly Owning Unit TAM Report Weekly Maintenance Exceptions Report Lesson 3 Exercise

MCI Course 1326

1-41

See Page 1-41 1-42 1-48 1-52 1-55 1-57

Study Unit 1, Lesson 3

Daily Processing Report

Purpose

The purpose of the daily processing report (DPR) is to provide a complete history of an item in the maintenance cycle. This will be the most analyzed report by the engineer chief. It will allow you to track and verify all maintenance actions that are taking place within your shop.

Description

The DPR provides maintenance managers at all levels visibility of active equipment repair orders (EROs) in their shops. EROs that have had action taken will be indicated by two asterisks (**) to the left of the ERO number. This will enable the user to identify items in the maintenance cycle that have had work performed on the day prior from those that do not have work performed.

Trends

Some of the common trends found on the DPR are listed below: • • • • • • • • •

Header

Category code does not coincide with the priority (i.e. category code M with PRI 13) Priority of the ERO does not match any of the part requisitions Category codes and priorities do not match current F/AD Match defect codes against equipment ordered Excessive days in shop without upgrading/downgrading ERO open and no parts on order Incorrect job status listed Too high of priority used to order routine parts Incorrect category code used

The header information on the DPR is read from left to right and is broken down into three lines and several columns. The table that follows provides information on the description of those lines and columns. Remember, the DPR lists only equipment that is undergoing maintenance. Continued on next page

MCI Course 1326

1-42

Study Unit 1, Lesson 3

Daily Processing Report, Continued

Example

Below is an example of a DPR excerpt:

ZZ400 E0980 02498A 1234567 M 11001 5104-RPR PRGS 0.00 2 1 5101-SHT PART 5061-INS PRGS R-5101 99999-5096-7010 EA R-5101 99999-5096-7015 EA 99999-5108-7011 EA 99999-5108-7012 EA 99999-5108-7013 EA 99999-5108-7014 AY 99999-5108-7009 EA 99999-5109-7011 EA 99999-5109-7012 EA 99999-5109-7013 EA 99999-5109-7014 AY ZZ419 E1762 09081B US123456 P 11001 5074-INS PRGS 0.00 2 1 ZZ477 NL232 05538C 6654321 N 11001 5110-PCKP HECH 0.00 2 1 5101-INS PRGS

06 1005-00-322-9715 MACH GUN 50 CA 5061 5061 LC-M2/5104 WPNS-CBB 49 49

1 1 1 1 1 1 1 1 1 1 1

06 06 06 06 06 06 06 06 06 06 06 06

1005-00-556-4305 5315-00-600-8784 1005-01-141-1235 1005-01-453-9289 5360-00-726-6134 1005-00-550-4082 1005-02-122-6754 1005-01-141-1235 1005-01-453-9289 5360-00-726-6134 1005-00-550-4082 1005-01-371-5639

13 1005-00-674-1425 R4B80

ROD ASSEMB 9 PIN,SPRING 9 BUFFER ASS BUFFER,REC SPRING,FLA EXTENSION SPRING BUFFER ASS BUFFER,REC SPRING,FLA EXTENSION SHOTGUN WPNS-MINR M1 30CAL RIFLE WPNS-MINR

097 097

AS1 AS1 REJ REJ REJ REJ AE1 E E E E

D

MC1 MC1

AT AT AT AT AT AT 2B AT AT AT AT

S9G

5070 40 5101 9

D

Continued on next page

MCI Course 1326

1-43

Study Unit 1, Lesson 3

Daily Processing Report, Continued

First Line Information

The table below provides the items listed on the daily processing report and a description of each: Line ERO TAM ID SERIAL #

JON CAT CODE RDD

PRI NSN NOMEN DCD DRIS JOB-ID ORF

EOT

CLOS

Description The equipment repair order number. Table of authorized material control number. The identification number of the equipment. The USMC/manufacturer’s serial number of the equipment. Note: A serial number of 0 is entered on batched EROs only. If a piece of equipment does not have a serial number, the supply officer will assign a local serial number. The account number to be billed for the cost of maintenance. A code that identifies the equipment's category of maintenance priority. The required delivery date. A date entered in this field indicates the equipment is critical to the unit, requiring a date be set when the unit must have the equipment. If this date cannot be set, an ORF exchange may be required or requested. The priority of need for the equipment according to proper assignment under the urgency of need designation. The national stock number (NSN) of the equipment. The noun name of the equipment. The deadline control date. The date on which the equipment was actually deadlined. The date received in shop. The date on which the equipment was received in the shop that is doing the repairs. A code that best describes the maintenance action being performed. Operational readiness float indicator. A Y code in this field indicates the unit desires an ORF replacement item. If an ORF exchange is required, the RDD must also have been entered. An N code indicates an ORF replacement item is not desired. The equipment operational time code. The code, extracted from the ID standards file, identifies the primary operating mode for the item of equipment, such as miles, hours, days, or rounds. The close flag. A code of NO indicates that the ID number/serial number of the record did not match an NSN/serial number on the SASSY reporting unit allowance file (RUAF). The record cannot be closed until the NO flag is removed by corrective action. Blanks indicate either a match or no edit. Continued on next page

MCI Course 1326

1-44

Study Unit 1, Lesson 3

Daily Processing Report, Continued

Second Line Information

The table below provides the items listed on the DPR and a description of each: Line Description AWTG-STAT The status of the equipment prior to being inducted into the maintenance cycle or once maintenance has been completed. DEST-ACC The destination account activity code (AAC) to which the equipment is being evacuated for repairs. JOB-STATUS Reflects the actions that occurred on the equipment and the date each action was initiated. PARTS The accumulated parts charges for those parts which have been CHARGE obtained. Non-system parts charges are input via the 9 transaction. SASSY parts computed during system processing. ECH The echelon of maintenance. These codes indicate the echelon performing the required maintenance such as 1 or 2 (organic) 3 or 4 (intermediate). QTY The quantity of equipment. X-EROS Displays two intershop/interechelon EROs for an item of equipment. These ERO numbers reference EROs of different maintenance activities. MARES/DAT The MARES logistics readiness indicator. A machine generated E code which identifies the type of LM-2 readiness transaction that has been prepared for an ERO and the date of the transaction. DEFECT The interpretation of the defect code used in the input transaction. The first part of the interpretation relates to the first character of the defect code, and the second part of the interpretation relates to the second and third characters of the defect code. DDL Displays days deadlined. The total number of days the equipment has been in a deadline status. This is the sum of the current processing date minus the DCD or the accumulated category M days deadlined. DIS Days in shop. The total number of days the equipment has been in the maintenance shop. This is the sum of the current processing date minus the DRIS. OWNER The activity address code of the unit that owns the equipment. Continued on next page

MCI Course 1326

1-45

Study Unit 1, Lesson 3

Daily Processing Report, Continued

Third Line Information

The table below provides the items listed on the daily processing report and a description of each: Line RCVD

Description This column serves two purposes: •

When an item is received and the receipt is processed, the date of receipt is posted.

•

When a cancellation request has been inducted for an item, the letters CANC are posted. If the column is blank, it indicates the parts record is open. DOCUMENT # The unit document number used for repair parts requisitioned or the applicable modification instruction number. When a secondary reparable is issued over the counter to the customer by the maintenance float, the document number of the maintenance float is reflected. When a secondary reparable is back-ordered to the customer by the maintenance float, the document number of the using unit is reflected. U/I The unit of issue of the item requisitioned. QTY The quantity of material requisitioned. PRI The priority of the requisition. The priority of the requisition may not exceed the priority of the ERO; however, parts may be requisitioned on a lower priority. PART-NSN The national stock number (NSN) or local stock number (LSN) of the part requisitioned. PART-NAME The nomenclature of the item requisitioned. STAT The current status on the requisition. The status code is a two-digit code that indicates the status of the requisition at the supply source. When shipping status has been provided to the unit, the mode of shipment code is reflected. The mode of shipment code is a onedigit code that identifies the means by which the item is being shipped to the unit. Supply status and mode of shipment codes are contained in the UM 4790-5. DATE The date on which the status was posted to the unit's records at the SASSY Management Unit (SMU). DIC/EXPT The type of status being provided. The type of status is identified (TYPE) by a document identifier code (DIC). DICs are contained in UM4400-123. An exception is generated when a transaction processes against the unit's loaded unit balance file and conditions are present that caused the exception to be created. Exception codes are contained in UM-4400-123. When a transaction fails to pass the master edit process in SASSY and is reflected from processing, the letters “REJ” are entered in the “TYPE” column. Continued on next page MCI Course 1326

1-46

Study Unit 1, Lesson 3

Daily Processing Report, Continued

Third Line Information, continued Line NMCS

Description Not mission capable supply indicator. When the item undergoing repairs is readiness-reportable, or, in the opinion of the commander, it is mission essential impacting unit readiness, and the item being requisitioned is required to move the equipment from deadline or anticipated deadline, enter the NMCS indicator as follows: • • •

LKH

ADV

MCI Course 1326

N is for a NMCS requisition. E is for (anticipated) NMC. 9 is for expedited action (the code for a NMCS “999” entry).

Note: These codes are reflected on the 4-Cards submitted for the item being requisitioned in card columns 67–68. The last known holder of the transaction. The routing identifier codes for the last known holders are contained in the current edition of UM-4400-123. When LKH is identified as “FLT,” this indicates the maintenance float is the supply source for the item. Note: An additional guide to assist in referencing codes is available from MCLB Albany. Request a customer assistance handbook, eleventh edition, 1993. Advice code. MIMMS advice codes tell the MIMMS system information which is relative to the processing of the requisition.

1-47

Study Unit 1, Lesson 3

Daily Transaction Listing

Purpose

The daily transaction listing (DTL) is a tool that assists the chief in troubleshooting the print DPR quickly. It provides high visibility of input transactions that were accepted or rejected into MIMMS/AIS.

MIMMS/AIS Feedback

The DTL is divided into three sections: • • •

Transactions processed with no errors Transactions processed with non-critical errors Transactions that did not process

When your MIMMS clerk or supply clerk (maintenance person designated) inputs the information into the system, the transactions will be printed in one of these sections.

Identifying Information

Remember, a transaction is made of 80 characters commonly known as card columns (CCs). The DTL depicts these CCs across the top of each page. For instance, the first card column always identifies the type of transaction, such as “0,” “3,” “4,” or “9.” The last CC identifies whether it is an add or change transaction, such as “A” or “C.” Computer-generated transactions are also depicted in the last CC. The ERO number (five characters) is always placed in CCs 2–6 for any type of transaction. Therefore, it is very easy to identify and locate a transaction on the DTL. Continued on next page

MCI Course 1326

1-48

Study Unit 1, Lesson 3

Daily Transaction Listing, Continued

Example

Under the section of transactions that did not process, the third transaction, 8ZZF12, had an error code of 032. This error code describes the document number on the input transaction did not match an existing document number for the associated ERO. Corrective action would be to validate the document number and resubmit the transaction. As the engineer chief, make sure that these types of validations occur for all transactions that do not process. Below are examples of the three sections that a transaction can process under:

PROGRAM A4150D31 MIMMS FIELD MAINTENANCE SUBSYSTEM FOR 1STMARDIV (ORGANIC) DAILY TRANSACTION LISTING ON 07 FEBRUARY 05 (5038) FOR 9th MARDIV

PAGE 001

1 2 3 4 5 6 7 8 ERROR CODES 12345678901234567890123456789012345678901234567890123456789012345678901234567890**************************** ----------------------------TRANSACTIONS PROCESSED WITH NO ERRORS-------------------------0ZZC840000N 0000 05 0000 56 13 B C 9ZZC84 50380002415 D 1550010001 560010001 9ZZK81 0ZZY660000N 9ZZY89

50380037215 05

D

S550010007T550010020 560010156

0000

25

50380000715 D

C

4550010001 560010001

0ZZ8025038N 1 001070560501000000107 3ZZ8025180012441290 MK-2569/P TOOLA7900D 3ZZ8025180012441290 MK-2569/P TOOLA7900D

641209015AS25

C XA A B

0ZZ8035038N 1 001070700501000000107 3ZZ8035180012441290 MK-2569/P TOOLA7900D 3ZZ8035180012441290 MK-2569/P TOOLA7900D

641209015AS25

C XA A B

------------------TRANSACTIONS PROCESSED WITH NON-CRITICAL ERRORS------------------0ZZY890000N 05 0000 5612 N13 B C 011 ------------------------------TRANSACTIONS THAT DID NOT PROCESS-------------------------------7ZZQ38 8ZZF04 6230012253931

0027350327251 00140114350246381A

S6

8ZZF12 4130013498564

00220114350117340A

S6

8ZZF20 6625011210510 8ZZF20 5120002886468 8ZZF20 6230006354998 8ZZF20 6230001631856 8ZZF20 6625011210510

00040114350117347A 00040114350117349A 00720114350246375A 00720114350246376A 00720114350246377A

S6 S6 S6 S6 S6

000B16 BK

B 003 083

5038

BK

032

CANC CANC CANC

BK BK BK BK BK

083 083 032 032 032

Continued on next page

MCI Course 1326

1-49

Study Unit 1, Lesson 3

Daily Transaction Listing, Continued

First Section

Transactions that processed with no errors appear in this section.

Second Section

If there is a non-critical error, the transactions appear under the section “Transactions Processed With Noncritical Errors.” This means the transaction processed, but there was a minor mistake on the input.

Third Section

If the transaction had a critical error, it appears under “Transaction That Did Not Process.” These transactions were not allowed to process and were completely rejected.

Identify Error Codes

An error code is printed to the immediate right of the transaction under the column labeled “Error Codes.” Error codes are described in chapter 24 of the UM 4790-5. From the error codes, the MIMMS or supply clerk knows the specific elements where the error exists and the type of error within that field. Continued on next page

MCI Course 1326

1-50

Study Unit 1, Lesson 3

Daily Transaction Listing, Continued

Correcting Errors

The MIMMS clerk must submit the necessary changes/corrections for input errors as soon as possible. The maintenance chief will ensure that this is being accomplished. The table below provides a breakdown of the three types of transactions on the Daily Transaction Listing and the corrective procedures: If the transactions were… Processed with no errors Processed with non-critical errors Not processed. These transactions were not allowed to process. They were rejected completely.

Then you need to... Do nothing. Correct a noncritical error by following the corrective action measure provided in UM 4790-5 and submit a “0/C” transaction. Identify the error code and follow the corrective action provided in the UM-4790-5 and resubmit immediately. Remember, in some cases you may be required to submit another type of transaction based on the corrective action procedures provided.

Note: If any associated transactions are submitted at the same time of an “O/A” (O/Add) or an “O/T” (O Transfer) transaction that had critical errors, it will also be rejected. Additionally, a "4 card" transaction rejected for an incorrect ERO number, document number, or NSN will cause rejections for associated “5,” “7,” or “8” transactions submitted at the same time.

Use

MCI Course 1326

The DTL is used to validate input to MIMMS/AIS. The MIMMS clerk matches the previous day’s input transactions to the DTL. You must monitor this report to ensure a corrected transaction is promptly resubmitted. In addition to constant monitoring, you must also train your Marines to minimize processing errors. Remember, the ideal DTL is the one that reads “Processed With No Errors.”

1-51

Study Unit 1, Lesson 3

Weekly Owning Unit TAM Report

Purpose

The weekly owning unit table of authorized materials (TAM) report identifies trends by commodity, echelon, days on deadline, and job status.

Description

The TAM report is produced weekly. It groups TAMs, serial numbers, and all active EROs within a unit as well as organizational maintenance with the latest job status displayed.

Use

The information concerning EROs at intermediate maintenance allows you to view the status of your equipment: If… ERO indicates the job status “EVC HECH” No higher echelon ERO exists

Then check to see if A higher echelon ERO exists • • • •

Trends

Job status is wrong Difficulty getting the equipment to the higher echelon shop Higher echelon refused it Higher echelon possibly ran an “O/A” transaction instead of an “O/T” transaction

Trends that can be found on the TAM report are listed below: • • • • •

Excessive days deadlined by the TAM report Category code M to days deadlined Category code to priority incorrect Defect code misuse Use of defect code to identify trend of defect by the TAM report Continued on next page

MCI Course 1326

1-52

Study Unit 1, Lesson 3

Weekly Owning Unit TAM Report, Continued

Example

Below is an example of a weekly owning unit TAM report excerpt:

MIMMS FIELD MAINTENANCE SUBSYSTEM FOR 1ST MARINE BRIGADE SVCBN 9TH MARDIV WEEKLY OWNING UNIT MAINTENANCE TAM REPORT ON 20 APR 2005 PAGE 0001 TAM OWNER SRL-NO ID-NO

NOMEN

QTY PRI CAT ECH DEFECT

JOB-STATUS

DDL DIS ML-IND ERO

A0499 A1935 A1957 A1957 A1957

TSQ-227 DTC MRC138/TBD1 AN/MRC-145 AN/MRC-145 MRC145/TBD2

01 01 01 01 01

5090-ITRS REP 5013-SHT PART 5103-UNIT RCL 5098-ITRS REP 5026-SHT PART

0 155 0 0 155

99999 99999 99999 99999 99999

00005 A0092 S0229 S0229 S0235

10664A 07743B 09730A 09730A 09730A

06 06 13 13 06

X M C N M

2 2 2 2 2

ELEC-INOP COMP-RPLC BODY-RPLC BODY-RPLC COMP-RPLC

62 155 LCS2 13 12 155 LCS2

ZZR09 ZZB15 ZZA28 ZZB23 ZZB17

Continued on next page

MCI Course 1326

1-53

Study Unit 1, Lesson 3

Weekly Owning Unit TAM Report, Continued

Table

The table below describes the meaning of the terms in the weekly owning unit maintenance TAM report. Header TAM OWNER SERIAL-NO ID NO NOMENCLATURE QTY PRI CAT

ECH DEFECT JOB STATUS RDD DDL

DIS

ML-IND

ERO

Description The table of authorized materiel control number of the equipment undergoing maintenance. The activity address code of the unit that owns the equipment. The USMC/manufacturer's serial number of the equipment undergoing maintenance. The item identification number of the equipment undergoing maintenance. The item name of the equipment undergoing maintenance. The quantity of items undergoing maintenance on the ERO. The priority of need of the equipment undergoing maintenance. A code that identifies the category of the equipment undergoing maintenance. This code is used in the production of equipment readiness transactions. Echelon of maintenance. The code that indicates the echelon performing the required maintenance. The specific maintenance problem of the equipment undergoing repair. Reflects the latest event and the date this event was initiated. Required delivery date. Days deadlined. The total number of days the equipment has been deadlined. This is the sum of the current processing date minus the deadline control date, or Cat Code "M" accumulated days deadlined. Days in shop. The total number of days the equipment has been in the maintenance shop. This is the sum of the current processing date minus the date received in shop (DRIS). MIMMS logistics readiness indicator. A code that identifies the type of LM2 transaction that has been prepared for the ERO. The maintenance shop's equipment repair order number under which equipment is undergoing maintenance. The equipment repair order number for organization and intermediate maintenance for the same item of equipment can simultaneously be displayed. Continued on next page

MCI Course 1326

1-54

Study Unit 1, Lesson 3

Weekly Maintenance Exceptions Report

Purpose

The weekly maintenance exceptions (EXC) report gives a detailed evaluation of the current active EROs. This report locates discrepancies, trend actions, and pinpoints specific ERO numbers and supply documents when problems exist.

Description

The EXC report provides information in the narrative form. It will pinpoint specific ERO numbers and supply documents where problems exist. A weekly comparison of two or three consecutive reports can help determine personnel and procedural problems and aid in determining the necessary corrective action.

Trends

This report will provide a narrative of any EROs that fall within a trend, allowing you to work with those commodity sections whose EROs are deficient. Continued on next page

MCI Course 1326

1-55

Study Unit 1, Lesson 3

Weekly Maintenance Exceptions Report, Continued

Example

Below is an example of a EXC report excerpt: A4150W25

WEEKLY EXCEPTION REPORT FOR MAJCMD 1ST MARDIV UNIT 9TH MARDIV ERO PREFIX = ZZ 08 MAR 05 (5067) PAGE: 1

1. EROS IN JOB STATUS 02 (INS PRGS) OVER 10 DAYS: 2. EROS IN JOB-STATUS 24 (UNIT-RCL) OR 25 (SHT PART) WITHOUT VALID SUPPLY DOCUMENTS: ZZ419-25-4281 ZZ611-25-5004 ZZ694-25-4257 3. EROS/SUPPLY DOCUMENTS WITH SASSY EXCEPTIONS/REJECTIONS: 4. EROS WHICH EXCEED THE CRITERIA FOR DEADLINED DAYS: ZZ694-4156 5. SECONDARY-REPARABLE EROS WHICH EXCEED THE CRITERIA FOR DEADLINED DAYS: 6. EROS WHICH EXCEED THEIR RDD: 7. EROS WHICH EXCEED THE ORF EXCHANGE DATE: 8. EROS COMPLETED MORE THAN 10 DAYS: 9. EROS AWAITING DISPOSITION INSTRUCTIONS IN JOB-STATUS 37 (WIR SUB) OVER 30 DAYS: 10. EROS IN JOB-STATUS 13 (RPR COMP) OR 37 (WIR SUB) WITH OUTSTANDING SUPPLY DOCUMENTS: 11. EROS WHICH ARE CAT CODE M OR PRIORITY 06 AND IN ONE OF THE FOLLOWING JOB-STATUSES FOR OVER 10 DAYS: 02 (INS PRGS), 12 (RPR PRGS), 23 (SHT TEST), 26 (SHT SPAC), 27 (SHT TECH), OR 40 (SHT FUND): 12. EROS WHICH ARE NOT CAT CODE M OR PRIORITY 06 AND IN ONE OF THE FOLLOWING JOBSTATUSES FOR OVER 30 DAYS: 02 (INS PRGS), 12 (RPR PRGS), 23 (SHT TEST), 26 (SHT SPAC), 27 (SHT TECH), OR 40 (SHT FUND): ZZ615-12-5025 13. EROS WITH DISPOSITION INSTRUCTIONS EXCEEDING COMPLETION CRITERIA (30 DAYS CONUS/60 DAYS NON-CONUS): 14. EROS WITH A NO CLOSE FLAG:

MCI Course 1326

1-56

Study Unit 1, Lesson 3

Lesson 3 Exercise

Directions

Complete exercise items 1 through 5 by choosing the correct answer. Check your responses against those listed at end of this lesson.

Item 1

The header information on the DPR is read from left to right and broken down into ____ lines and several columns. a. b. c. d.

Item 2

The DTL is divided into how many sections? a. b. c. d.

Item 3

two three five seven

The purpose of the DTL is to a. b. c. d.

Item 4

one two three four

give the chief another report to look at. provide answers for the MMO. provide high visibility of input transactions. give the weekly transactions that processed or did not process.

What does the weekly owning unit TAM report do? a. b. c. d.

Groups serial numbers for easy access Groups TAM numbers by ERO priority Groups TAMs, serial numbers, and all active EROs within a unit Lists all active EROs in intermediate and depot maintenance facilities Continued on next page

MCI Course 1326

1-57

Study Unit 1, Lesson 3 Exercise

Lesson 3 Exercise, Continued

Item 5

The EXC report quickly pinpoints specific _____ numbers and supply documents numbers when problems exist. a. b. c. d.

ERO DTL SASSY EROSOL Continued on next page

MCI Course 1326

1-58

Study Unit 1, Lesson 3 Exercise

Lesson 3 Exercise, Continued

Answers

The table below lists the answers to the lesson exercise. If you have any questions about these items, refer to the reference page. Item Number 1 2 3 4 5

MCI Course 1326

Answer c b c c a

1-59

Reference 1-42 1-48 1-48 1-52 1-55

Study Unit 1, Lesson 3 Exercise

(This page intentionally left blank.)

MCI Course 1326

1-60

Study Unit 1, Lesson 3 Exercise

LESSON 4 RECORDS AND FORMS Introduction

Scope

“The job is not finished until the paper work is done.” Since this is an expression that you have probably heard before, this lesson will discuss basic records and forms—references, engineer equipment and maintenance records, and forms used when supervising an engineer maintenance section or shop.

Learning Objectives

At the end of this lesson you, will be able to • Identify the proper references for engineer equipment records and forms. • Identify the forms maintained in the NAVMC 696D. • Identify the information contained on the NAVMC 10524. • Identify the purpose of the NAVMC 10523. • Identify the purpose of the NAVMC 10560. • Identify the purpose of the NAVMC 10245. • Identify the purpose of the NAVMC 10925. • Identify the use of the NAVMC 10561. Continued on next page

MCI Course 1326

1-61

Study Unit 1, Lesson 4

Introduction, Continued

In This Lesson

This lesson contains the following topics: Topic Introduction References Equipment Records NAVMC 696D NAVMC 10524 NAVMC 10523 NAVMC 10560 NAVMC 10245 NAVMC 10925 NAVMC 10561 Lesson 4 Exercise

MCI Course 1326

1-62

See Page 1-61 1-63 1-64 1-65 1-68 1-71 1-74 1-76 1-79 1-81 1-84

Study Unit 1, Lesson 4

References

MCO P4790.2_

MCO P4790.2 _, MIMMS Field Procedures Manual, sometimes called the bible, is the main reference for setting up a shop or section. This reference describes and charts basic shop layout and the necessary paper work.

TM 4700-15/1_

TM 4700-15/1_, Ground Equipment Records Procedures, is a technical manual that describes how to complete records and forms. To help you with proper record keeping, this manual shows how to complete all records and forms pertaining to ground equipment operation and maintenance.

UM-4790-5

UM 4790-5, MIMMS (AIS) Field Maintenance Procedures, describes how to complete forms and records. It provides problem-solving and troubleshooting procedures for each form.

MCI Course 1326

1-63

Study Unit 1, Lesson 4

Equipment Records

Introduction

On a weekly basis, the engineer chief should review the preparation and disposition of various records and forms to ensure entries are valid.

Record Jackets

Each major end item of equipment must have a record jacket to provide a basis for neat and orderly record keeping. Most Marine Corps units use a standard bi-fold or tri-fold folder for setting up equipment record jackets.

Required Elements

Include the items listed below in the record jacket: • NAVMC 696D, Motor Vehicle and Engineer Record Folder • NAVMC 10524, Consolidated Engineer Equipment Operational Log and Service Record, also referred to as “con log” • NAVMC 10523, Engineer Equipment Operational Record, also referred to as “trip ticket” • NAVMC 10560, Worksheet for Preventive Maintenance and Technical Inspection for Engineer Equipment, also referred to as “LTI”

MCI Course 1326

1-64

Study Unit 1, Lesson 4

NAVMC 696D

Purpose

The NAVMC 696D, Motor Vehicle and Engineer Equipment Record Folder is used to maintain a historical record of the equipment’s transfer, receipts, modifications, and major assembly replacements. It also serves as a file folder for completed forms and records.

Responsibilities

Maintain a NAVMC 696D on each item of motor transport, engineer, and garrison mobile equipment. In cases where items of equipment are under one TAM control number, but are associated with standard items of other commodity equipment, maintain a separate record folder for that specific commodity item IAW TM 4700-15/1_. However, both records will reflect the Marine Corps registration number, chassis serial number, TAM control number, NSN, and ID number of the TAM as a single entity.

Establishment

The Marine Corps Logistic Base (MCLB) that first receives the item of equipment will establish the NAVMC 696D. MCLB will enter the descriptive data and any modifications accomplished while the equipment is under their cognizance and control. When units other than the MCLB receive the item of equipment direct from the manufacturer or the NAVMC 696D is lost, that unit will be responsible for establishing the NAVMC 696D. When establishing or reconstructing a NAVMC 696D, use the establishment or reconstruction date in a five-digit Julian date (YYDDD). The custodian is responsible for keeping the entries in the NAVMC 696D upto-date while the item of equipment is in the custodian’s custody. Note: When engineer equipment has more than one power plant, maintain NAVMC 10523 and 10524 on each power plant. Continued on next page

MCI Course 1326

1-65

Study Unit 1, Lesson 4

NAVMC 696D, Continued

Components

Preparation Instructions

The following forms must be maintained inside the equipment record jacket, NAVMC 696D: •

NAVMC 10245, Equipment Repair Order (ERO) once it is completed and closed out of the MIMMS system.

•

Load test results until the completion of the next successful load test. Maintain only the most recent load test results.

•

Condition inspection record until the successful completion of the next inspection. Maintain only the most recent inspection results.

•

NAVMC 10523, Engineer Equipment Operational Record for a minimum of 30 days.

•

One current NAVMC 10524, Engineer Equipment Operation Log and Service Record. When the form is full, transfer cumulative totals to the replacement form.

•

Any other pertinent information that might need to be referenced in the future for that particular item of equipment.

The descriptive data of the item of equipment will appear on the top of the NAVMC 696D when it is received by the using unit. Make entries in the transfer, modification, and major unit assembly replacement record portion each time the item is received, transferred from one reporting unit allowance file (RUAF) to another, modified, or a major assembly was replaced. The account serial number column refers to the owning unit activity code of the unit having custody of the item of equipment when the entry is made. Tactical wreckers and garrison mobile equipment (GME) wreckers require an annual condition inspection per MCO PI 1262.2, and the results must be filed inside the NAVMC 696D. Note: For a detailed description on how to fill out the NAVMC 696D, refer to TM4700-15/1_, page 2-14-1. Continued on next page

MCI Course 1326

1-66

Study Unit 1, Lesson 4

NAVMC 696D, Continued

Filing

Maintain the NAVMC 696D in the administrative office of the custodian of the item of equipment concerned or as designated by the commanding officer. When the face of the NAVMC 696D becomes full, initiate a new one and retain the full one inside the new NAVMC 696D.

Disposition

When the item of equipment is transferred, forward the NAVMC 696D by certified mail with the invoice (not forwarded with the item of equipment) upon each change of custody of the item of equipment. When both shipping and receiving units are in the same vicinity, the NAVMC 696D may be handdelivered. When the item of equipment is determined unserviceable and a letter of unserviceable property (LUP) is received, destroy all records.

Sample

Below is a sample NAVMC 696D:

MCI Course 1326

1-67

Study Unit 1, Lesson 4

NAVMC 10524

Purpose

The purposes of the NAVMC 10524, Engineer Equipment Operation Log and Service Record are listed below: • Authority for an operator to operate engineer equipment on an assigned mission. A duplicate NAVMC 10524 may be prepared and issued to the operator instead of a daily NAVMC 10523, Engineer Equipment Operational Record when equipment is operated at a project site for extended periods; e.g. a well drill, generator, or an air compressor. • The operator with a checklist for conducting before, during, and after preventive maintenance checks and services (PMCS). • A means for recording mileage and hours for equipment operation so that PMCS may be scheduled and petroleum, oil, and lubrications (POL) consumption determined. • A template for indicating required operator daily PMCS listed on the NAVMC 10523. Note: A NAVMC 10524 does not need to be prepared on equipment when an ERO/SRO has been submitted and equipment is operated from local equipment pool area to the maintenance shop.

Responsibilities

The engineer chief is responsible for the following: • Section A is updated after completion of a second echelon of maintenance or higher scheduled or unscheduled PMCS. • NAVMC 10561, Preventive Maintenance Checks and Services Roster is updated after completion of a second echelon of maintenance or higher scheduled or unscheduled PMCS. • Any required PMCS is accomplished before the equipment is dispatched. • Any required corrective maintenance is accomplished before the equipment is dispatched. Continued on next page

MCI Course 1326

1-68

Study Unit 1, Lesson 4

NAVMC 10524, Continued

Preparation Instructions

For a detailed description on how to fill out the NAVMC 10524, refer to TM4700-15/1_, page2-21-1.

Front Side

The front side of the NAVMC 10524 contains a • Schedule of upcoming PMCS • List of POL • Log of hours of operation of the equipment

Back Side

The back side of the NAVMC 10524 is • A template for the dispatcher to use • Self-explanatory • Identical to the back of NAVMC 10523 Note: Use the back of NAVMC 10524 to complete NAVMC 10523 (trip ticket).

Filing and Disposition

File the NAVMC 10524 in the NAVMC 696D, Motor Vehicle and Engineer Equipment Record Folder. When the sheet is filled, the accumulated totals and other data are transferred to a new NAVMC 10524. Retain only the last completed or filled NAVMC 10524. Continued on next page

MCI Course 1326

1-69

Study Unit 1, Lesson 4

NAVMC 10524, Continued

Sample

Below is a sample front side of a NAVMC 10524 form:

Continued on next page

MCI Course 1326

1-70

Study Unit 1, Lesson 4

NAVMC 10523

Purpose

The NAVMC 10523, Engineer Equipment Operational Record provides • An operator the authority to operate a piece of equipment to complete a mission. NAVMC 10524, Engineer Equipment Operation Log and Service Record may be prepared and issued to the operator instead of a daily NAVMC 10523 when equipment is operated at a project site for extended periods; e.g. a well drill, generator, or an air compressor. • The operator with a checklist for conducting daily PMCS. • A means for recording mileage and hours for equipment operation so that PMCS may be scheduled and POL consumption determined. Note: This form need not be prepared on equipment when an ERO/SRO has been submitted and equipment is operated from local equipment pool area to the maintenance shop. Continued on next page

MCI Course 1326

1-71

Study Unit 1, Lesson 4

NAVMC 10523, Continued

Front Side Sample

Below is a sample front side of a NAVMC 10523 form:

15 JAN 99

LRT 110 7 ½ TON CRANE

JONES,JOHN P.

275119

1100

112es

0700

109

4.0

3es

Alvin J.

2ND CEB DET. A

SSgt. Mimms

BLDG. 520

John P.

25

25

25

25

John P. 5.) HOUR METER J. P.

Continued on next page

MCI Course 1326

1-72

Study Unit 1, Lesson 4

NAVMC 10523, Continued

Back Side Sample

Below is a sample back side of a NAVMC 10523 form:

JPJ JPJ JPJ JPJ JPJ JPJ JPJ JPJ JPJ JPJ JPJ JPJ JPJ JPJ JPJ JPJ JPJ JPJ JPJ

MCI Course 1326

1-73

JPJ JPJ JPJ JPJ

C

JPJ JPJ JPJ JPJ JPJ JPJ JPJ JPJ

JPJ JPJ JPJ

Study Unit 1, Lesson 4

NAVMC 10560

Purpose

The NAVMC 10560, Worksheet for Preventive Maintenance and Technical Inspection is a worksheet for preventive maintenance and technical inspection for engineer equipment. It provides a checklist for performing and recording PMCS and limited technical inspections (LTIs), to include acceptance LTIs, LTIs prior to major repair, and LTIs at the discretion of the engineer equipment officer/chief on tactical engineer equipment and GME fleet manager on garrison mobile engineer equipment. The NAVMC 10560 is also used as a guide when performing an annual safety/condition check.

Preparation Instructions

The engineer chief is responsible for preparing the worksheet for the PMCS. Prepare a template indicating the required PMCS for each item of equipment. In preparing the template, refer to the appropriate services listed in the TMs, Army technical bulletins, and other publications applicable to the equipment. By laying the template for a specific item of equipment on a blank NAVMC 10560, non-applicable portions of the form may be readily blanked out. The worksheet, which indicates the required services, is then transmitted to the maintenance unit. The maintenance unit, with the assistance of the operator, performs the required services and signs the worksheet indicating the service has been completed. The engineer chief will also ensure that equipment requiring repairs is inspected and the results of the inspection are recorded on the NAVMC 10560 before the equipment is repaired. The preparing activity may be the equipment owner or the equipment user. For example, the equipment is on temporary loan or the equipment custodian in the maintenance section is evacuating to the next higher EOM. The preparing activity is responsible for initial preparation of the NAVMC 10560. For a detailed description on how to fill out the NAVMC 10560, refer to TM4700-15/1_, page 2-22-1. Note: An LTI performed by maintenance personnel upon receipt of equipment prior to the unit placing the equipment in service to determine the overall condition is called an acceptance LTI. Continued on next page

MCI Course 1326

1-74

Study Unit 1, Lesson 4

NAVMC 10560, Continued

Filing and Disposition

MCI Course 1326

When the engineer officer/chief has verified that all requirements listed in section B of the worksheet have been transferred to an ERO/SRO, the NAVMC 10560 will be destroyed. Retain any NAVMC 10560 used in conjunction with an investigation until released from investigation. Treat a NAVMC 10560 released from investigation as corrective maintenance (CM).

1-75

Study Unit 1, Lesson 4

NAVMC 10245

Purpose

The purpose of the NAVMC 10245, Equipment Repair Order (ERO) is to request modification, calibration, corrective maintenance (CM), preventive maintenance checks and services (PMCS), and limited technical inspection (LTI) on all ground equipment within the unit’s organic maintenance capability. The ERO is used for transmitting work to higher echelons of maintenance (EOM) and for recording and reporting the maintenance performed. Maintenance personnel will use an ERO in all instances where maintenance resources, repair parts, or secondary repairable items are required to perform requested maintenance.

Use

An ERO is required when •

Requesting maintenance for second through fourth EOM

•

In conjunction with the equipment repair order shopping list (EROSL) to requisition SL-3 components

•

Reporting an end item of equipment sent to depot level maintenance (fifth EOM)

•

Transmitting test measurement diagnostic equipment (TMDE) into the calibration lab

However, do not use of an ERO when •

Total labor hours are less than 0.3 hours

•

Total parts cost is less than $25 and the parts do not have to be requisitioned

•

Requesting or recording either operator maintenance (first EOM) or depot level maintenance (fifth EOM)

Note: All units, whether preparing a second EOM ERO or not, are required to establish a second EOM record in MIMMS/AIS for TMDE transmitted work for calibration or third EOM. Continued on next page

MCI Course 1326

1-76

Study Unit 1, Lesson 4

NAVMC 10245, Continued

Preparing Activity

Maintenance Section

The preparing activity responsibilities are •

Completing the ERO in accordance with TM 4700-15/1_

•

May be the equipment owner, the equipment user; e.g. the equipment is on temporary loan or the equipment custodian as in the case of the maintenance section evacuating to the next higher EOM

•

Initial preparation of an ERO to include completion of the heading and description of work to be performed

•

Filling out the “Description of Work” block by both the preparing activity and maintenance section

The maintenance section will receipt for the equipment by completing the “Accepted By,” “Date” (DRIS), and “ERO No.” blocks and those other blocks as indicated in the instructions. The maintenance section will enter information on work performed as maintenance actions are completed and close out the ERO. •

When the maintenance section needs to evacuate the equipment to the next higher EOM, the maintenance section will prepare a new ERO, completing those items required of the preparing activity and using its ERO number as the request number.

•

When an end item of equipment requires second EOM or higher, the equipment owner will prepare a second EOM ERO completing those items required of the preparing activity.

•

When an end item of equipment requires repair beyond second EOM, the maintenance section providing second EOM will prepare a third EOM ERO completing those items required of the preparing activity.

•

When an end item of equipment requires repair beyond third EOM, the maintenance section providing third EOM will prepare a fourth EOM ERO completing those items required of the preparing activity.

•

When a secondary reparable item requires repair, the maintenance section requesting the repair will prepare a third EOM ERO completing those items required of the preparing activity. When the ERO is prepared, the maintenance section will evacuate the item to the maintenance section providing third EOM via the reparable issue point (RIP). Continued on next page

MCI Course 1326

1-77

Study Unit 1, Lesson 4

NAVMC 10245, Continued

Preparation Instructions

For a detailed description on how to fill out the NAVMC 10245, refer to TM4700-15/1_, page 2-2-1.

Sample

Below is a sample NAVMC 10245 form:

MCI Course 1326

1-78

Study Unit 1, Lesson 4

NAVMC 10925

Purpose

The NAVMC 10925, Equipment Repair Order Shopping List (EROSL) is a dual purpose form. It serves as the ERO shopping list and a MIMMS data input form. Use the EROSL in conjunction with the ERO to requisition, receipt for, cancel, and record partial issues and credits of repair parts and secondary repairable items associated with ground equipment undergoing repair. To simplify data input, all required MIMMS input transactions may be placed on the EROSL.

Header Section

The procedures below are for processing a “4” card transaction for a parts requisition. There are other maintenance-related cards, but this one accompanies your ERO. Consult the UM-4790-5 to find out how to properly complete the other cards used for maintenance transactions. The table below shows how to complete the header section of the EROSL: Step 1 2 3 4 5

6

Action Write in ERO number Write in your unit/section Write the date submitted Sign and date the maintenance block Supply issue point

7

Data clerk initials after checking the DTL Material usage code

8

Source reference

Comment Get the ERO number from your ERO matrix logbook. The submitting unit/section. Date delivered to MIMMS clerk. The chief initials and dates here. Person receiving EROSL initials to indicate date it was received for processing. Make sure the part(s) actually entered the system. • 6 is for SL-3 components. • 7 is for corrective maintenance. • 8 is for modifications. • 9 is for preventive maintenance. Enter on any line A–R, depending on local SOP. Continued on next page

MCI Course 1326

1-79

Study Unit 1, Lesson 4

NAVMC 10925, Continued

Header Section, continued Step 9

Action 80 card column (CC)

Comment Requires several entries by the ERO holder as follows: (a) CC 1: For repair parts, a “4” stands for a parts request card (b) CC 2–6: ERO number (c) CC 11–23: NSN (d) CC 24–26: Quantity of parts (e) CC 28–40: Document number divided into three groups: • AC (CCs 28–32) • Date (CC 33–36) • Document serial number (CC 37– 40): The first digit in CC 37 reflects the material usage code 6, 7, 8, or 9. (f) CC 41: Signal code: Where part will be shipped to and who pays the bill (g) CC 42–43: Priority of the part according to the ERO (h) CC 49–50: Unit of issue (i) CC 51–64: Job order number (JON): The paying unit’s account number (j) CC 66: Demand code • R is for recurring. • N is for nonrecurring. (k) CC 67: Not mission capable supply (NMCS) • 9 is for high priority, deploying overseas. • N is for priority CONUS. • E is for anticipating a priority. (l) CC 68–69: Advise code • SC is for scrounged. • PB is for preexpended parts. • 99 is for non-SASSY parts. (m) CC 77: Shop section (n) CC 70–79: Nomenclature/Part name (o) CC 80: Transaction type • A is for add. • C is for change. Continued on next page

MCI Course 1326

1-80

Study Unit 1, Lesson 4

NAVMC 10561

Purpose

The NAVMC 10561, Preventive Maintenance Checks and Services (PM Roster) is used to systematically schedule and record second EOM and higher preventive maintenance checks and services (PMCS) on Marine Corps ground equipment. Units are authorized to schedule PMCS via locally developed automated programs, providing it duplicates the information on the NAVMC 10561.

Responsibilities

The responsibility for scheduling all required second EOM and higher PMCS rests with the engineer officer, engineer chief, or appointed individual or individuals. The chief ensures all equipment is scheduled for PCMS at least annually.

Scheduling

Each roster has instructions on the back how to fill it out. Make all permanent entries in ink and all temporary entries in pencil. The following are some examples on how to schedule PCMS: • Schedule second EOM and higher PMCS per the equipment commodity chapter of TM 4700-15/1_. This does not relieve the unit from its responsibility to conduct first EOM PMCS. In preparing rosters, care must be taken to ensure the workload is staggered so that all items of one type of equipment are not scheduled for PMCS at the same time. • Schedule PMCSs at least monthly. • Maintain at least one active scheduled interval and one interval under preparation (used to schedule the next PMCS). Upon completion of a PMCS, schedule the next PMCS. Schedules for current and the upcoming year may be maintained. Note: Schedule required second EOM and higher PMCS per the appropriate commodity chapter of TM 4700-15/1_. Continued on next page

MCI Course 1326

1-81

Study Unit 1, Lesson 4

NAVMC 10561, Continued

Filing

Maintain current (active) copies in the administrative office. Retain the NAVMC 10561 that has all required PMCS completed for a minimum of 1 year. For equipment requiring a biennial PMCS, retain the NAVMC 10561 for 2 years. Units possessing a limited quantity of equipment may list items for subsequent years on the same NAVMC 10561. Note: Units using an automated system may retain printouts in place of the NAVMC 10561. Continued on next page

MCI Course 1326

1-82

Study Unit 1, Lesson 4

NAVMC 10561, Continued

Sample 8

Below is a sample NAVMC 10561 roster:

199

LRT-

199

199

A

275119

a

275119: Received on 21 DEC 98, Performed

Note: Capitalized letters indicate PMCS was completed, lower case letters indicate PMCS is scheduled.

MCI Course 1326

1-83

Study Unit 1, Lesson 4

Lesson 4 Exercise

Directions

Complete exercise items 1 through 8 by choosing the correct answer. Check your responses against those listed at end of this lesson.

Item 1

Which reference is often referred to as the bible in establishing a shop with money, personnel, facilities, and material? a. b. c. d.

Item 2

MCO P4790.2, MIMMS Field Procedures Manual MCO P6100, MC Fitness Test and Body Composition Program Manual NAVMC 10524, Engineer Equipment Operator Log and Service Record UM 4790-5, MIMMS (AIS) Field Maintenance Procedures

Which form is maintained inside the equipment record jacket NAVMC 696D? a. NAVMC 10245, Equipment Repair Order (ERO) b. NAVMC 10925, Equipment Repair Order Shopping List (EROSL) c. NAVMC 10560, Worksheet for Preventive Maintenance and Technical Inspection d. NAVMC 10561, Preventive Maintenance Checks and Services (PM Roster)

Item 3

The schedule of upcoming PMCS can be found on the ______ of the NAVMC 10524. a. b. c. d.

back front top left top right Continued on next page

MCI Course 1326

1-84

Study Unit 1, Lesson 4 Exercise

Lesson 4 Exercise, Continued

Item 4

The purpose of the NAVMC ________ is to give the operator the authority to operate a piece of equipment to complete a mission. a. b. c. d.

Item 5

The NAVMC 10560 is a worksheet for preventative maintenance and technical inspection for _________ equipment. a. b. c. d.

Item 6

all MARES repaired engineer

The NAVMC 10245 (ERO) is used to request a. b. c. d.

Item 7

10524 10523 10560 10561

annual leave. parts. modifications. tool boxes.

The purpose of the NAVMC ______ is to order parts and change inputs status in the MIMMS/SASSY system. a. b. c. d.

10955 10925 10560 10561 Continued on next page

MCI Course 1326

1-85

Study Unit 1, Lesson 4 Exercise

Lesson 4 Exercise, Continued

Item 8

The form used to systematically schedule and record PMCS performed on all ground equipment is the NAVMC a. b. c. d.

10560. 10561. 10925. 10546. Continued on next page

MCI Course 1326

1-86

Study Unit 1, Lesson 4 Exercise

Lesson 4 Exercise, Continued

Answers

The table below lists the answers to the lesson exercise. If you have any questions about these items, refer to the reference page. Item Number 1 2 3 4 5 6 7 8

MCI Course 1326

Answer a a b b d c b b

1-87

Reference 1-63 1-66 1-69 1-71 1-74 1-76 1-79 1-81

Study Unit 1, Lesson 4 Exercise

(This page intentionally left blank.)

MCI Course 1326

1-88

Study Unit 1, Lesson 4 Exercise

STUDY UNIT 2 MAINTENANCE RELATED PROGRAMS Overview

Introduction

This study unit discusses how to keep the shop functioning and working proficiently. There are numerous programs that you must monitor according to the appropriate references and directives. Most of these programs are paper-based and are filed for future reference. As the supervisor, it is your duty to monitor these programs—they could make or break your maintenance mission.

Scope

This study unit includes a look at the supervision and coordination of programs that relate to the maintenance system—procedures for supervising publications, the supply support program, and the licensing program.

In This Study Unit

This study unit contains the following lessons: Lesson Programs Supervise Publications Supply Support Program Engineer Equipment Licensing

MCI Course 1326

2-1

See Page 2-3 2-19 2-31 2-41

Study Unit 2

(This page intentionally left blank.)

MCI Course 1326

2-2

Study Unit 2

LESSON 1 PROGRAMS Introduction

Scope

This lesson will cover the programs associated with the engineer maintenance field. Maintenance-related programs contribute to the maintenance cycle mission. You must constantly monitor these programs. For example, if you do not keep your calibration program current, your mechanics may not be able to conduct a test, perform a calibration, or torque an item to the specifications required for that piece of gear. You will find maintenance related programs under production control. These programs do not fall directly under the maintenance cycle (MIMMS).

Learning Objectives

At the end of this lesson, you will be able to • Define maintenance-related programs. • Identify the correct procedure in a modification program. • Identify the procedure for supervising the TMDE program. • Identify when to complete a product quality deficiency report (PQDR). • Identify the purpose of the recoverable items program (WIR). • Identify the purpose of the joint oil analysis program. Continued on next page

MCI Course 1326

2-3

Study Unit 2, Lesson 1

Introduction, Continued

In This Lesson

This lesson contains the following topics: Topic Introduction Modification Program Calibration Program Warranty Items Product Quality Deficiency Report Recoverable Items Program Joint Oil Analysis Lesson 1 Exercise

MCI Course 1326

2-4

See Page 2-3 2-5 2-8 2-11 2-12 2-13 2-14 2-15

Study Unit 2, Lesson 1

Modification Program

Definition of Modification

Modifications are maintenance actions performed to improve the operation and safety of equipment by changing the actual design of the item.

Procedures

You will receive modification instructions if a defect is discovered by the manufacturer or if a fellow Marine sends in a SF 368, Product Quality Deficiency Report (PQDR). Requests for modification are sent to the item manager, who determines whether the modification is URGENT or NORMAL in Albany, Georgia. • An URGENT modification is necessary because the equipment is in danger of being damaged. For urgent modifications, the equipment is deadlined until the modification is applied. • A NORMAL modification improves the equipment. You have 1 year to apply a normal modification to equipment. Note: Once the item manager approves the modification, the required instructions and materials are assembled and fielded to the Operational Forces. Continued on next page

MCI Course 1326

2-5

Study Unit 2, Lesson 1

Modification Program, Continued

Description

Descriptions for many of the modification instructions are listed in the table below: Block Description TIME COMPLIANCE Normally found on an urgent modification PARAGRAPH instructions. It gives the time frame in which the modification must be completed. If the modification is completed within the directed time frame, there is no cost to the unit. However, if the modification is not completed by the time directed (one year for normal modifications), then the cost of the modification is incurred by the unit unless the modification materials are still on the shelf at the depot. INFORMATION Describes the modification instructions. MAJOR END ITEM Describes the NSN and/or part number, TAMCN, AFFECTED and ID number of the affected end item. COMPONENT Provides the same information as “Major End Item AFFECTED Affected,” except it is for a component. MATERIAL Describes the NSN and/or part number, quantity of AFFECTED the material required and material discarded. SKILL AND TIME MOS and man hours required to accomplish the REQUIRED modification. MODIFICATION Details information, pictures, and drawings of how PROCEDURES the modification is to be performed. RECORDING AND Provides the specific instructions on how to record REPORTING THE and report modification instructions. Additional MODIFICATION information on recording modifications can be found in TM-4700-15/1. Note: Descriptions not listed are self-explanatory. Continued on next page

MCI Course 1326

2-6

Study Unit 2, Lesson 1

Modification Program, Continued

Responsibilities

The engineer chief is responsible for tracking modifications. When modification is performed on an item of equipment, use the forms listed below: • NAVMC 11053 (Form A) • NAVMC 11054 (Form B) Note: Use form B when you have a large amount of equipment requiring modifications. Both forms give you a readily available means of accurately determining the modification(s) status of assigned equipment.

MCI Course 1326

2-7

Study Unit 2, Lesson 1

Calibration Program

Definition of Calibration

Calibration is the adjustment of precision instruments that deviate from the standard.

Responsibilities

As directed by the calibration cards, the engineer chief must perform an annual inventory and calibration of all test, measurement, and diagnostic equipment (TMDE). During the annual inventory, make sure the following items are identified:

Calibration Not Required

•

T/E items—components of sets, chests, or kits: torque wrenches, pressure gauges, micrometers, etc.

•

Calibration control records—electronic, mechanical, engineer, and motor transport TMDE

Items designated calibration not required (CNR) and inactive receive annual status review and validation. The annual TMDE inventory provides an excellent opportunity to do the following: • • • •

Identify TMDE that is eligible for designation as CNR/Inactive Verify current status Validate records Reschedule calibrations

At the end of a 3-year inactive period, units will reevaluate the following: • •

Need to retain the equipment Requirement to calibrate the equipment Continued on next page

MCI Course 1326

2-8

Study Unit 2, Lesson 1

Calibration Program, Continued

Reference Table

The name and description of relevant publications is listed in the table below: Short Title Long Title MCO P4790.2_ MIMMS Field Procedure Manual MCO 4733.1_

I-4733-15/1_

Marine Corps Test, Measurement, and Diagnostic Equipment (TMDE) Calibration and Maintenance Program (CAMP) Technical Instructions on the TMDE of Calibrated Equipment

Description Provides step-by-step procedures to establish and maintain calibration control • Establishes policy •

Provides guidance and general information

•

Promulgates responsibilities relative to the MC,TMDE, and CAMP Provides instruction on the following: •

Calibration of TMDE

•

Identification of TMDE that requires calibration

•

Identification of calibration labels and tags

•

Determination of extent of calibration required for TMDE ML-MC Marine Corps Data Provides the operational test code Management List for all equipment TM-4700-15/1_ Ground Equipment Record Provides purpose and instructions Procedures to prepare calibration control records MSC MMSOP Major Subordinate • Designates which technique Command SOPs to use for calibration control. •

States the procedure for opening an ERO Continued on next page

MCI Course 1326

2-9

Study Unit 2, Lesson 1

Calibration Program, Continued

Tracking Systems

There are three systems for tracking calibration equipment: System Chart Card index Automated or locally produced control card

Control Chart

As the chief, you must screen the EROs for TMDE turn-in, ensure the proper information was submitted, and screen the records on the TMDE items. A control chart will help to simplify the process as shown below: Step 1

2

3

4 5

MCI Course 1326

Function The calibration control record is maintained on a wall chart or on standard-sized paper. The calibration control record is maintained on 5×8 inch cards. The automated method is the most accurate means to record and track your information. It is fast becoming the way to do business. If your unit does not have a computer, you can produce a local form.

Action Perform an annual inventory to make sure all items are accounted for and to verify CNR and inactive items are properly labeled. Make sure items are staggered in your PMCS system to avoid putting all like items in the maintenance cycle at the same time. Screen all EROs to ensure proper entries. Be sure to load the ERO into the MIMMS system at least 5 days before the scheduled turn-in date. Make sure proper calibration is being performed and stickers are affixed to the items when they are returned. Make sure that items are kept in a secure area and all components are clean and serviceable.

2-10

Study Unit 2, Lesson 1

Warranty Items

Definition

Warranty items are end items that are fielded by the Marine Corps and have a manufacturers' warranty.

Purpose

Periodically manufacturers issue updates and recalls that may affect your equipment. By keeping the warranty for end items, the manufacturer will pick up the cost of updating or fixing the item.

Procedures

If you possess an item with a manufacturer's warranty, follow the steps listed below:

Notification of Warranty Defect

MCI Course 1326

•

Keep warranty records for the item.

•

Indicate the warranty period in the remarks section of the record jacket.

•

Maintain the warranty record in the item’s record jacket (NAVMC 696D) for the period the equipment is in the system.

The procedures used to notify units of a warranty defect are within this block. The using unit will immediately notify the warranty coordinator when a warranted item has failed. The warranty coordinator at the designated command/area shall notify the warranty administrator immediately thereafter. Such notification may be either telephonic or in writing. Any telephone notification will be followed by an SF 368 prepared per the current edition of MCO 4855.10. An information copy of the written notification, SF 368, will be provided to the Operational Forces warranty coordinator. When repair is being accomplished by the Marine Corps, it will be so stated on the SF 368.

2-11

Study Unit 2, Lesson 1

Product Quality Deficiency Report

Purpose

SF 368, Product Quality Deficiency Report (PQDR) notifies activities that develop, procure, and manage equipment about deficiencies in the equipment.

Function

A PQDR enables activities to initiate action to correct reported deficiencies. Proper use of PQDRs ensures correction of deficiencies. Corrections may be in several forms. The equipment may be modified by the Marine Corps or if the equipment is under warranty, the manufacturer may repair it or be held responsible for its repair. If the equipment has not been received from the manufacturer, it will be corrected prior to being sent to the Marine Corps.

Responsibility

The individual who discovers the deficiency initiates the PQDR and submits it to the originating point—battalion, squadron, or company. The originating point submits the PQDR to the Marine Corps PQDR screening point. Per the current edition of MCO 4855.10, all deficient material must be secured, segregated, and tagged with a completed DD Form 1575, Suspended Material Tag and a DD Form 2332, Product Quality Deficiency Report Exhibit.

Categories of Reports

There are two PQDR categories of reports: Report Category I

Description Deficiencies that may cause • • •

Category II

Death or injury Severe occupational illness Major damage to a weapon system

When an urgency exists, you may first transmit Category I PQDRs orally; however you must follow up by sending a priority electronic message using the SF 368 or an electronic facsimile of the SF 368 according to MCO-4855.10. Deficiencies that do not meet category I criteria.

Note: The instructions for completing a PQDR are self-explanatory, but may be found in TM-4700-15/1_.

MCI Course 1326

2-12

Study Unit 2, Lesson 1

Recoverable Items Program

Purpose

The recoverable items (WIR) program establishes policy and procedures for the recovery, reporting, and management of recoverable items in three situations: • Cannot be repaired with current resources available to the field commander • Excessive to a command’s allowances • Beyond economical repair

Responsibility

Skilled maintenance personnel determine the condition of equipment nominated for recovery.

Disposition

Recoverable items that cannot be repaired with the resources available to the unit or that are suspected of being beyond economical repair will be inducted into the supporting intermediate maintenance shop for an LTI and disposition.

Intermediate Maintenance Facility

The intermediate maintenance facility will report the item via a WIR to the MCLB Albany, Georgia requesting disposition instructions.

Guidance

MCO P4400.82 outlines submission of reports, repairs of recoverable items, salvage of repair parts, replacement of unserviceable recoverable items, and accounting instructions.

MCI Course 1326

2-13

Study Unit 2, Lesson 1

Joint Oil Analysis

Definition of Oil Analysis

Oil analysis is a term used to describe scientific tests and evaluations performed on used oil. It is used to • •

Determine whether the oil may be retained or must be changed Provide information on the internal condition of engines, transmissions, and other oiled components

Through testing, the lab can detect the various wear of metals. Oil analysis also detects whether the viscosity of the oil has changed due to fuel dilution or water content.

How to Sample Oil

Sample the equipment without warming the component to the operating temperature if the equipment has been operated within the last 30 days or ambient temperatures allow. Sometimes the ambient temperature is too low; if so, warm the item just long enough to obtain the sample. If new oil has been added recently, allow the oil to mix before taking an oil sample. Take samples every 180 days or 250 hours of operation.

Guidance

TI-44731-14/1_ provides guidance for whichever equipment is tested.

MCI Course 1326

2-14

Study Unit 2, Lesson 1

Lesson 1 Exercise

Directions

Complete items 1 through 7 by performing the action required. Check your answers against those listed at the end of this lesson.

Item 1

Maintenance-related programs can be defined as a. b. c. d.

Item 2

When a modification is performed on an item of equipment, you a. b. c. d.

Item 3

must log it in a modification log book. must log it on a 3×5 inch card and file it. must log it on a NAVMC 11053/4. just perform it and forget about it.

When should you perform a TMDE inventory? a. b. c. d.

Item 4

shop items such as tools. an easy way to administer MIMMS and SASSY. items that contribute to the maintenance cycle mission. a publications and tool room filing system.

Biannually Annually Semiannually Monthly

While under the manufacturer's warranty period, you are required to maintain ________________ for the length of the warranty. a. b. c. d.

a NAVMC 696D the manufacturer’s serial number warranty records in the NAVMC 696D folder an acceptance ERO Continued on next page

MCI Course 1326

2-15

Study Unit 2, Lesson 1 Exercise

Lesson 1 Exercise, Continued

Item 5

A PQDR is initated when a. b. c. d.

Item 6

The recoverable item program (WIR) is used for a. b. c. d.

Item 7

the PMCS needs to be performed. a discrepancy is found on a item of equipment. the MMO gives the direction to complete one. the CO directs.

an item that cannot be repaired at the second echelon level. an item that is beyond economical repair. a way to cut your T/E. a convenience for the CO.

The joint oil analysis program is used to determine a. b. c. d.

what weight oil to use. how old the oil is. which oil company has better oil products. the internal condition of parts lubricated by oil. Continued on next page

MCI Course 1326

2-16

Study Unit 2, Lesson 1 Exercise

Lesson 1 Exercise, Continued

Answers

The table below lists the answers to the lesson exercise. If you have any questions about these items, refer to the reference page. Item 1 2 3 4 5 6 7

MCI Course 1326

Answer c c b c b b d

2-17

Reference 2-3 2-7 2-8 2-11 2-12 2-13 2-14

Study Unit 2, Lesson 1 Exercise

(This page intentionally left blank.)

MCI Course 1326

2-18

Study Unit 2, Lesson 1 Exercise

LESSON 2 SUPERVISE PUBLICATIONS Introduction

Scope

This lesson will cover the functional area of publications, focusing on the supervisors areas of responsibility. There will be an emphasis on publication requirements, inventory procedures, and publication control. You may have to request an increase in publications when your unit is tasked with a deployment of some of its assets or when some of your Marines are deployed and need to take publications with them.

Learning Objectives

In This Lesson

At the end of this lesson, you will be able to •

Identify the key documents used to establish a publications library.

•

Identify two types of inventories in a publications library.

•

Identify the purpose of the publications control form.

•

Identify the purpose of the NAVMC 10772.

This lesson contains the following topics: Topic Introduction Publications Library Types of Publications Inventory Procedures Controlling Publications NAVMC 10772 Lesson 2 Exercise

MCI Course 1326

2-19

See Page 2-19 2-20 2-21 2-23 2-25 2-27 2-28

Study Unit 2, Lesson 2

Publications Library

Key Documents

The three key documents needed to establish a publications library are • T/O • T/E • Publications listing

Importance of T/O and T/E

In study unit 1, you were provided a breakdown of the T/O and T/E (TO/TE) and their purposes. The TO/TE are building blocks for your unit. From the TO/TE, you can do the following: • Get a clear understanding of which publications needed to support your equipment and mission. • Determine the quantity of those publications needed to carry out your mission. • Identify your mission statement and echelon of maintenance. • Identify what type of equipment you rate.

Publications Listing

Once you have located the TO/TE and you know their contents, you need to acquire the publication listing (PL), which is an electronic display of all publications in the Marine Corps Publications Directive System (MCPDS) designated for a particular unit.

Category Components

The PL is produced in a computer-generated format by standard subject identification code (SSIC) and ID groups, followed by applicable publication control numbers (PCNs).

Additional Components

The short and long title of the publication, the quantity, and a remarks column are also on the PL to help you determine the publications needed.

Copies

To increase the number of copies of publications, submit the changes to the S-1 using the individual activity code (IAC). The S-1, in turn, will submit the change to the CMC.

MCI Course 1326

2-20

Study Unit 2, Lesson 2

Types of Publications

Categories

Publications are grouped into two categories: • Technical (equipment-related) • Non-technical (not equipment-related)

Technical

Technical publications are divided into two areas: • Equipment associated: Publications that apply to a specific piece of equipment. • Non-equipment associated: Publications that apply to equipment in general, but not one specific piece of equipment. These manuals are categorized by an item designator (ID) number. Knowing the item designator number of each piece of equipment, you will be able to find all required publications for that item of equipment because the equipment and the publications share the same number.

Non-Technical

Non-technical publications are • Marine Corps Orders (MCOs) are permanent publications. • Marine Corps Bulletins (MCBuls) are temporary publications. These publications are numbered by a standard subject identification code (SSIC). These codes are listed in SECNAVINST 5210.11, Secretary Naval Instructions and in NAVMC 2671, Catalogue of Publications. Continued on next page

MCI Course 1326

2-21

Study Unit 2, Lesson 2

Types of Publications, Continued

Seven Types

The seven types of publications are listed in the table below: Publication Technical Manuals (TMs)

Description Furnish technical information, instructions, and procedures of a permanent nature on the operation, maintenance, and handling of equipment or material. Lubrication Instructions (LIs) Furnish technical information and instructions on the service, lubrication, and related preventive maintenance checks and services requirements for equipment or material. Modification Instructions (MIs) Authorize the modification of equipment or material and furnish technical instructions on how to accomplish the modification. Technical Instructions (TIs) Furnish technical advice or information on equipment or material. Support Concepts (SCs) Establish the support policies developed for the logistic support of specific items of equipment. Stock Lists (SLs) Furnish supply support information on specific supply problems or procedures for specific equipment or classes of material. User Manuals (UMs) Provide procedures for formatting and entering information into the AIS. Note: For more detailed information, refer to MCO 4790.2_ Appendix B.

MCI Course 1326

2-22

Study Unit 2, Lesson 2

Inventory Procedures

Inventory Control

The procedure established in the inventory control functional area must be thoroughly employed by your publications librarians on a day-to-day basis. This will ensure that Marines have up-to-date publications available to them for daily tasks as well as operational deployments. Guidelines for the inventory control procedure are listed below: Step 1 2 3 4 5 6

Types

Action Establish libraries and their locations. Arrange different types of publications within a library. Document procedures for embarkation to ensure deployment and contingency libraries are identified. Establish procedures for a publication control form that will be used to manage the publications control system. Keep track of publications checked in and out on a daily basis. Establish procedures for entering changes to the different types of publications and how to update records to reflect new publications, new changes, or requisitions already filled.

There are two types of inventory procedures: •

Wall-to-wall: Identify exactly what is on hand for the initial setup of a publications library.

•

Update: Required once you have identified all the discrepancies and ordered appropriate publications. Continued on next page

MCI Course 1326

2-23

Study Unit 2, Lesson 2

Inventory Procedures, Continued

Publications Lists

Librarian

MCI Course 1326

Conduct an update inventory quarterly to coincide with the arrival of the following new editions: •

NAVMC 2761: A catalog of publications to use when requisitioning Marine Corps directives.

•

SL-1-2: A listing of publications to use in the support and maintenance of equipment.

•

SL-1-3: A listing of Marine Corps publications stocked at MCLB Albany, Georgia.

The librarian performs another duty that is not listed as an inventory function, but which may be thought of as an on-going inventory. Whenever any additions, deletions, or changes to a publication occur, the librarian must make the changes as they are received.

2-24

Study Unit 2, Lesson 2

Controlling Publications

Importance of Procedures

The publications control procedure you set up is very important because your librarian must manage the publications daily.

Library Layout

The interior physical arrangement of the publications library is based on the type of publication: • Non-technical publications: Maintain according to MCO P5215.1 in the shop office. • Technical publications: Maintain in a working library for use by the mechanics and operators. These publications are arranged in one of two ways: •

Non-equipment: Arrange in short title numerical sequence and list in the SL-1-2 and SL-1-3, and the TIs in the 4700, 4790, and 5600 series. Example: TM 4700-15/1 PCN 18204600000

•

Equipment: Arrange by equipment type and list in the SL-1-2 under the ID number of the equipment or component. Example: ID NO. 08602A Roller, Motorized, Vibratory Compactor

S-1/Adjutant

The S-1/Adjutant maintains the electronic PL, procures required publications, monitors the backorder status, and distributes publications received through the MCPDS.

MMO

The MMO ensures adequate copies of maintenance management publications are listed on the PL. The MMO is the coordinating link between the commodity sections and the S-1/Adjutant in publications distribution and guidance. Continued on next page

MCI Course 1326

2-25

Study Unit 2, Lesson 2

Controlling Publications, Continued

Maintaining a Library

The table below lists the procedure to properly maintain and control a library: Procedure Deploy Control Track Requisition

Control Form

Action Make sure contingency libraries are documented, maintained, and supported with an embarkation plan. Ensure a filing system is in effect and each library has, at a minimum, a card system. Maintain a log book to check publications in and out. Establish procedures for updating, ordering, and making changes to publications.

A control form is used to identify the contents, quantity, and location of a shop library according to MCO P4790.2_, MIMMS Field Procedures Manual, Appendix B. It is one of the most important forms in the publications library that must be maintained. The publication control form can be a locally produced form or an automated form. The MMO SOP establishes the policy as to which form to use and what the form will contain. The publication control form will contain, at a minimum, the following information: Header Data Individual Activity Code/Activity Equipment Nomenclature PCN Short Title Publication Date Number of the Change (consecutive: 1, 2, 3, etc.)

MCI Course 1326

Reference Use the name or the seven digit IAC number of your activity. List the equipment nomenclature, item designator (ID No.), and TAMCN when the form is used for equipment related publications. Use the publication's PCN as listed in the NAVMC 2761 or the SL-1-3/1-2. Use the publication's short title as listed in the NAVMC 2761 or the SL-1-3/1-2. Use the date as listed in the NAVMC 2761 or the SL-1-3/1-2. Indicate the number of the change to the basic publication as listed in the NAVMC 2761 or SL-1-3/1-2. When SL-1-3/1-2 lists changes separately on the control form, list each change on a separate line.

2-26

Study Unit 2, Lesson 2

NAVMC 10772

Purpose

Once you have established the library, inventoried the contents, and set procedures for managing your publications, your Marines will begin asking questions about missing paragraphs and pages, outdated information, and misspelled words. What do you do? You will use the NAVMC 10772, Recommended Changes to Publications/Logistics–Maintenance Data Coding. NAVMC 10772 provides a means for accelerating information feedback. It gives you a way to submit changes, comments, and corrections to the publication at MCLB Albany, Georgia.

When to Submit

Completion of the NAVMC 10772 form is self-explanatory. Mailing instructions are also included. Your local SOP should cover the reporting process. Complete a NAVMC 10772 whenever an error is found in a publication. The person finding the error(s) submits the form. The corrections you submit can help many Marines beyond your unit. Spread the word! Note: For complete instructions on how to complete this form, refer to TM 4700-15/1_, Ground Equipment Records Procedures.

MCI Course 1326

2-27

Study Unit 2, Lesson 2

Lesson 2 Exercise

Directions

Complete items 1 through 4 by performing the action required. Check your answers against those listed at the end of this lesson.

Item 1

What three documents are key to establishing a publication library? a. b. c. d.

Item 2

Two types of inventory procedures are wall-to-wall and a. b. c. d.

Item 3

annual. update. semiannual. one according to the MMO SOP.

The purpose of the publications control form is to identify a. b. c. d.

Item 4

T/O, T/E, and PL T/O, PL, and TM 4700-15/1_ T/O, T/E, and MMO SOP TM 4700-15/1_, PL, and T/E

contents, quantity, and location of a shop library. ID, NSN, and location. quantity authorized, quantity on hand, and location. contents, location, and changes.

NAVMC 10772 is used to a. b. c. d.

report TO/TE changes. submit reports to S-1. submit changes to the MMO SOP. submit changes to publications. Continued on next page

MCI Course 1326

2-28

Study Unit 2, Lesson 2 Exercise

Lesson 2 Exercise, Continued

Answers

The table below lists the answers to the lesson exercise. If you have any questions about these items, refer to the reference page. Item 1 2 3 4

MCI Course 1326

Answer a b a d

2-29

Reference 2-20 2-23 2-26 2-27

Study Unit 2, Lesson 2 Exercise

(This page intentionally left blank.)

MCI Course 1326

2-30

Study Unit 2, Lesson 2 Exercise

LESSON 3 SUPPLY SUPPORT PROGRAM Introduction

Scope

As the engineer chief, you are not concerned with how the part is made or how it is warehoused. At the local level, you are concerned with how the part is shipped and how soon it will arrive. After all, you want the equipment up and performing its mission as soon as possible. This lesson covers budgeting, repair parts support, maintenance float, and validation procedures.

Learning Objectives

At the end of this lesson, you will be able to • Identify the requirements for assembling a budget. • Identify the definition of maintenance float items. • Identify the validation procedure for ERO layettes.

In This Lesson

This lesson contains the following topics: Topic Introduction Budgeting Repair Parts Support Maintenance Float Validating Layettes Lesson 3 Exercise

MCI Course 1326

2-31

See Page 2-31 2-32 2-33 2-34 2-35 2-38

Study Unit 2, Lesson 3

Budgeting

General Information

Budgeting starts with your input. Begin the budget process by scrutinizing the past year's maintenance records to determine how much money was spent and where it was spent. Such parts and supplies listed below may be needed on a continuous basis: • PM items, filters, and POLs • Shop overhead—rags, floor dry, tools, and office supplies • CM parts—tires, lights, brakes, seals, and bearings Note: The MMO must submit an annual budget for expenditures.

New Equipment

As you create a parts and supply budget based on current needs, keep in mind that new equipment fielding may be a factor: • Set aside a fixed amount for CM and PM. • Obtain the cost of items and parts from the manufacturer or dealer. • Submit a budget that includes your input. Remember, you are the first link in the budgeting process.

MCI Course 1326

2-32

Study Unit 2, Lesson 3

Repair Parts Support

Coordination

The proper functioning of a unit's maintenance program depends on the continuous coordination between maintenance and supply activities. Good coordination contributes significantly to the goal of unit equipment readiness. As the user, maintenance depends upon supply to provide the secondary reparables, repair parts, and other supplies when and where they are needed. Maintenance personnel must actively support the unit supply program by using proper procedures and providing timely feedback.

Unit Supply Activity

Supporting the unit supply activity is accomplished by providing timely information about normal and special needs: • • • • •

MCI Course 1326

Request required material only. Use the proper forms and procedures. Use material properly. Return material not used promptly to the issue point. Review outstanding requisitions frequently to validate the continued need for background material.

2-33

Study Unit 2, Lesson 3

Maintenance Float

Definition

Maintenance float, often referred to as secondary repairable items, are end items or components of equipment authorized for stockage at installations or activities for replacement of unserviceable items of equipment when immediate repair of unserviceable equipment cannot be accomplished.

Secondary Repairables

A secondary repairable is a repairable component/part other than the principal unit/end item. They are not functional by themselves, but are components of other items. They are items that can be repaired and put back into the supply system as shelf items for issue at the repairable issue point (RIP). Secondary repairable are often referred to as float items. The two types of secondary repairable items are listed below: • Field Repairables: Items that are fourth echelon terminal and identified with O, F, or H in the last position of the SMR code; for example: transmissions and engines. • Depot Repairables: Items that are fifth echelon terminal and identified with D or L in the last position by the SMR code; for example: radio set receivers, transmitters, and module printed circuit boards. Maintenance sections will maintain a current listing or catalog of secondary repairables managed by their supporting RIP. This will enable the maintenance section to determine what secondary repairables are available for exchange at the RIP. Note: These items are managed per MCO P4400.82.

Advantages

The advantages of having secondary repairables in a local supply warehouse are listed below: • Reduced costs • Readily available interchangeable parts • Less requisitioning time required

MCI Course 1326

2-34

Study Unit 2, Lesson 3

Validating Layettes

Definition of Validation

Validation is the process used to confirm repair part requirements. It involves confirmation of requirements that are still needed, cancellations, receipts, scrounges, and current status. When confirming needed requirements, the customer must ensure the items have been made known, still exist, and are resident in the supply system.

Purpose

The reason for validating your requests and receipts is to ensure the parts ordered for equipment get to the user in a proper and timely fashion. Every working day, there should be a validation based on the work load and amount of parts ordered by the unit. This will occur less in a second echelon unit compared to a third echelon unit.

Daily Procedures

Start by screening the DPR for parts received. Then, once the parts are identified and picked up from supply, put those parts in the correct ERO layette bin. The 4-card EROSL is initialed as parts are received and placed into the ERO layette bin. The parts stay in this bin until they are signed out by the mechanic for installation on the equipment. All parts for the same ERO are stored in the same bin. If a part is too large for the bin, tag it and store it in another suitable area. Continued on next page

MCI Course 1326

2-35

Study Unit 2, Lesson 3

Validating Layettes, Continued Bi-Weekly Validation

Material in the ERO bins must be validated at least biweekly. To do a biweekly validation, follow the steps listed in the table below: Step 1 2

Action Make sure all EROs cite the category codes that accurately reflect the actual condition and status of the equipment. Compare all EROs on the DPR in a short parts status with the ERO and EROSL: • • • •

Parts Issue

ERO job status is correct. ERO category and priority are valid. EROSL has been prepared, document numbers assigned, and transactions processed. Priorities assigned to the document number on an EROSL logically follow the priority and category assigned.

Once all parts are received and the layette is full, the parts can be issued to a mechanic for installation. There are instances when work will be performed prior to having a full layette. If critical parts are received, bring the item off deadline, place it into a noncritical status, and install them at that time. An example is a CAT CODE “M” ERO.

Down-Grading EROs

Once an ERO is down-graded because all of the “M” parts have been applied, it cannot be upgraded to “M” again. If a category code “M” exists again, that ERO must be closed completely out and a new ERO must be opened. • •

Make sure the problem is fixed before down-grading. Do a quality control check on CAT CODE “M” PRIORITY 02 or 03 EROs because only the CO can sign them. Continued on next page

MCI Course 1326

2-36

Study Unit 2, Lesson 3

Validating Layettes, Continued

Transfers

When opening a new ERO, you may want to transfer all parts to the new ERO by means of an “8-card” with authority code 9 in CC 27 and a new ERO number in CCs 55–59 on a EROSL. Note: All CAT CODE “M” parts must first be installed before closing the old ERO.

Monitoring Changes

MCI Course 1326

The chain of custody for parts is maintained by use of an EROSL. It is a simple process. Be sure to use it from start to finish because it makes life easier. Do not hesitate to write brief statements concerning the parts if it makes things easier for you. By all means, note on your DPR what up-grades and down-grades were done on your EROs.

2-37

Study Unit 2, Lesson 3

Lesson 3 Exercise

Directions

Item 1

Complete items 1 through 6 by performing the action required. Check your answers against those listed at the end of this lesson.

What is used to assist in assembling a budget? a. b. c. d.

Item 2

Past year’s maintenance records A calculator and paper The MMO Present EROSLs

To support the unit supply, maintenance personnel must a. review the DPR, submit requests, call supply once a week, and resubmit requests biweekly. b. read the UM 4790, submit EROSLs, call supply once a week, and resubmit missing documents. c. request only correct parts, use proper forms and procedures, properly use materials, return unused materials, and validate and reconcile. d. request required parts, use proper forms, use materials properly, return unused materials, review outstanding requisitions, and validate for continued need.

Item 3

Maintenance float items are a. b. c. d.

for deployments only. used only by MLG. referred to as secondary repairables. maintained for supply functions only. Continued on next page

MCI Course 1326

2-38

Study Unit 2, Lesson 3 Exercise

Lesson 3 Exercise, Continued

Item 4

Daily procedures for validating layettes involve screening and monitoring which of the following groups? a. b. c. d.

Item 5

In what situation(s) are parts issued from layettes for equipment installation? a. b. c. d.

Item 6

DPR, EROSLs, and parts Parts, EROs, EROSLs, and DPR POLs, EROSLs, and parts EROSLs, EROs, and POLs

Layettes bins are full or category “M” parts take an item off deadline As parts are received Whenever the floor chief needs something to do When category “X” or “P” parts are received

A key point to remember about up-grading and down-grading EROs and ordering new parts on an existing ERO is a. b. c. d.

once an ERO is opened, it cannot be up-graded. after an “M” ERO is opened, it cannot be down-graded. an “X” ERO cannot be up-graded or down-graded. an “M” ERO may not be up-graded after being down-graded. Continued on next page

MCI Course 1326

2-39

Study Unit 2, Lesson 3 Exercise

Lesson 3 Exercise, Continued

Answers

The table below lists the answers to the lesson exercise. If you have any questions about these items, refer to the reference page. Item 1 2 3 4 5 6

MCI Course 1326

Answer a d c b a d

2-40

Reference 2-32 2-33 2-34 2-35 2-36 2-36

Study Unit 2, Lesson 3 Exercise

LESSON 4 ENGINEER EQUIPMENT LICENSING Introduction

Scope

Remember that new Marines may have had only a few weeks of formal training on each item of engineer equipment. To become proficient, they must be provided the opportunity to continue training after they reach their first duty station. You can provide this opportunity by establishing and supervising a licensing program to further develop your Marines in their MOS. This program can include mechanics as well as operators. Incorporate this program into the training schedule and your unit and Marines will be able to accomplish the mission faster and more efficiently.

Learning Objectives

In This Lesson

At the end of this lesson, you will be able to •

Identify qualifications required for a licensing examiner.

•

Identify files relating to the engineer equipment licensing program.

•

Identify testable areas for license applicants.

•

Identify the disqualification criterion for an individual seeking an operator’s license.

This lesson contains the following topics: Topic Introduction Licensing Personnel Record Keeping Stages of Licensing Disqualification, Revocation, and Suspension Lesson 4 Exercise

MCI Course 1326

2-41

See Page 2-41 2-42 2-43 2-47 2-48 2-49

Study Unit 2, Lesson 4

Licensing Personnel

Designation

The unit commander must designate in writing the licensing officer and the licensing examiners who will establish the unit licensing program. New equipment and newly assigned personnel make the licensing program a necessity to ensure training is properly conducted and documented in the training records.

Licensing Officer

The licensing officer must hold a 1310, 3510, or 2110 MOS. He or she is responsible for properly conducting a licensing program that issues licenses only to those personnel who have met the proper licensing qualifications. The licensing officer is authorized to issue a license card validated by their signature to operators and mechanics having responsibility for equipment or having access to equipment.

Licensing Examiner

The licensing officer can assign a licensing examiner or make a recommendation to the OIC for a licensing examiner assignment. Specific qualifications for a licensing examiner are listed below: • A graduate of the formal school in the equipment MOS • Fully qualified as a licensed operator for tactical engineer equipment and serving in a supervisory status • Trained by qualified instructors in the administration, procedures, and evaluation of the various examinations for the tactical engineer equipment operator's and mechanics testing and licensing program Note: Use TM 11275-15/4 as the reference for administering the licensing program.

MCI Course 1326

2-42

Study Unit 2, Lesson 4

Record Keeping

Licensing Examiners

One licensing examiner can run the administrative part of the licensing program for a small unit. However, large units like Transportation Support Battalions (TSB) and Engineer Support Battalions (ESB) that have a lot of equipment and personnel may require several examiners to handle the administrative workload.

Records Files

Administrative procedures begin with establishing three record files: • History file • Action date file • Licensing logbook

History File

The history file is the most important licensing file. It must contain all documentation related to the licensing individual. Requirement Contents

• • • • •

Maintain File

• • • •

Action Completed license application Licensing examiner interview notes Complete test of equipment knowledge and skill performance Documentation of special action Copies of notification and other letters and forms (medical results, SRB entries, etc.) Enter documents chronologically. Enter date of the next required action on the front of the cover. Maintain history file information for 3 years after date of last entry. Release file to transferring Marine who takes it to the receiving unit. Continued on next page

MCI Course 1326

2-43

Study Unit 2, Lesson 4

Record Keeping, Continued

Action Date File

An action date file must be established to schedule the administrative requirements for licensing action. The action date file consists of fifty-two 3×5-inch note cards organized by the weeks in a year (1 through 52). Requirement Follow Rules

Maintain File

Action Monitor the action date file to contact individuals and remind them when they are eligible for • Renewal • Retesting • Upgrade • Other administrative actions The licensing examiner maintains this file as shown below: When First week of month

Action • Remove cards for current month. • Make list of individuals needing administrative action. • Submit a copy of the action date card information to the unit commander. Two weeks Coordinate with individuals to before testing develop test schedule. All actions for the Discard the action date cards. month initiated or completed End of month Resubmit a copy of the action date card information to the unit commander with names lined out of persons who completed the licensing process.

Continued on next page

MCI Course 1326

2-44

Study Unit 2, Lesson 4

Record Keeping, Continued

Action Date Card

Each card contains a list of applicants who need action on their licenses (OF-346) during a particular week. Each week the licensing examiner pulls the current card and follows through with the required tasks listed. Most of the information on these cards will be for licensing transactions that must be referenced from the Operator History File. An example of an 3×5-inch action date card during the week of 21–25 May 2007 is shown below: PFC BOWERS LCPL WRIGHT CPL BUDGET BLDG 2003

Licensing Activity Report

21–25 MAY License renewal; current license expires/070521 Upgrade testing for the EBFL/070522 Physical appointment @ 1030/070523 for explosive handling Class on the HSHMC load movement indicator 0730– 1030/070524

A sample of the licensing activity report is shown below: PFC BOWERS LCPL WRIGHT CPL BUDGET

Renewal EBFL upgrade Explosive physical

HSHMC CLASS

LMS instruction

21 May 07 22 May 07 Medical Appointment (Passed) 23 May 07 Sgt’s Class 24 May 07

Engineer Support Company LICENSING ACTIVITIES: WEEK OF: 21–25 MAY 07 From: SSGT McGruff To: CWO 2 Sprinter Continued on next page

MCI Course 1326

2-45

Study Unit 2, Lesson 4

Record Keeping, Continued

License Logbook

A licensing logbook is used to record all licensing issues—renewals, duplicates, and upgrades. Remember two rules about the logbook: • No two licenses may have the same number. • Retain the logbook for 3 years following the last entry. The licensing logbook is set up with the following required entries: date, card number, type of transaction, equipment item, applicant’s names and signatures, and the examiner’s signature. An example of the licensing logbook entries is shown below:

DATE

070515

CARD TYPE OF EQUIPMENT APPLICANT'S APPLICANT'S LICENSING NUMBER TRANSACTION ITEM(S) NAME SIGNATURE EXAMINER'S SIGNATURE 2345 Renewal D7, 1155, Welch, Jason Engineer, John DTC 8606, TRAM, EBFL

MCI Course 1326

2-46

Study Unit 2, Lesson 4

Stages of Licensing

Five Stages

Stage 1 2 3 4

5

The examiner establishes procedures for screening the Service Record Book of each newly joined Marine to determine if the Marine qualifies for initial or upgrade to an engineer equipment license. There are strict licensing procedures for issuance of the OF-346 license, including five stages to complete the licensing process. A licensing flow chart is shown below: Who Does It? What Happens? Applicant Completes application Licensing Examiner Recommends license and gives applicant physical examination form Applicant Proceeds to medical with evaluation form for physical exam Physically Qualified Takes test in three areas—new or reissue of revoked licenses: Applicant • Skill performance • Equipment knowledge • Safety procedures Licensing Examiner Makes sure all appropriate entries are made on both parts of the application and then issues license

Note: The four areas and reasons for disqualification are explained later in this lesson. The CO may grant a waiver of any disqualification. Issuance of License

If the Marine is recommended for licensing and the transaction is an initial license or renewed license, make an action date card with the applicant's name on it and file it in the week file that is 4 weeks prior to the expiration date of the new license. Once the license has been issued, you must ensure history files are established and proficiency tests are scheduled. Maintain the continuity that is prescribed by TM-11275-15/4, Engineer Equipment Operator Licensing Program.

Continuous Training

It is very important to continue training. During deployments and operations, it will not be you who operates the equipment. So, you must make sure your Marines are well-trained and prepared to operate heavy equipment proficiently. As the engineer chief, you must use planning and creativity. Use whatever resources are available, especially for earth-moving operations. Check with your S-3 and range control officer for available training sites. Training on forklifts and cranes can usually be performed in the local area of the equipment shop. Though time consuming, close supervision is required for all training operations. Plan your training according to your everyday mission workload. Do not neglect safety; it is a vital part of training.

MCI Course 1326

2-47

Study Unit 2, Lesson 4

Disqualification, Revocation, and Suspension

Introduction

Licensed operators sometimes act irresponsibly. It takes a qualified, safe, and responsible individual to properly operate engineer equipment. When individuals violate these standards, punitive action must be taken.

Disqualification

Applicants can be disqualified for the following reasons: • • • •

Revocation

Failure to pass physical exam Lack of operating skills Failure to pass the knowledge test Recklessness, an accident, or a poor attitude

Commanding officers are authorized to revoke OF-346 licenses held by personnel in their command for a period of 90 days or more. If the commanding officer revokes the license, “REVOKED UNTIL (DATE)” is written across the license and the license is filed in the individual’s engineer equipment history file. Licenses may be revoked for the following reasons: • Found to be under the influence of alcohol or controlled substances, other than those prescribed by a medical officer • Receives a citation or is found liable for causing a reportable accident/incident or for committing personnel/equipment safety violations while operating tactical engineer equipment Note: Complete retesting, including a new application, is required before the individual becomes eligible to hold an OF-346 license again.

Suspension

Commanding officers have the authority to suspend a license, for cause, for periods of up to 90 days. The CO confiscates the OF-346 license and holds it until the suspension has expired. The OF-346 license may be returned to the Marine without formal licensing processing. No retesting is necessary unless the CO requires it. If it is requested, the Marine is required to complete retesting. Note: All documents related to license status must be filed in the Marine's history file folder.

MCI Course 1326

2-48

Study Unit 2, Lesson 4

Lesson 4 Exercise

Directions

Complete items 1 through 4 by performing the action required. Check your answers against those listed at the end of this lesson.

Item 1

The _____________ should have a thorough knowledge of equipment operating techniques, be fully qualified as a licensed operator for tactical engineer equipment, and be trained by qualified instructors on administration, procedures, and evaluation. a. b. c. d.

Item 2

The records relating to the engineer equipment licensing program are the licensing logbook, history file, and the a. b. c. d.

Item 3

deed action file. card file. action date file. history file folder.

The areas that are testable for an individual seeking an engineer equipment license are a. b. c. d.

Item 4

shop chief operator commanding officer licensing examiner

academic, written, and skill. knowledge, academic, and awareness. skill performance, equipment knowledge, and safety procedures. verbal, written, and operating skills.

Failure to pass physical and knowledge tests, lack of operating skills, and ________________________ are reasons to disqualify a licensing applicant. a. b. c. d.

obedience boisterousness lack of communication skills recklessness, an accident, or a poor attitude Continued on next page

MCI Course 1326

2-49

Study Unit 2, Lesson 4 Exercise

Lesson 4 Exercise, Continued

Answers

The table below lists the answers to the lesson exercise. If you have any questions about these items, refer to the reference page. Item 1 2 3 4

MCI Course 1326

Answer d c c d

2-50

Reference 2-42 2-43 2-47 2-48

Study Unit 2, Lesson 4 Exercise

STUDY UNIT 3 MAINTENANCE Overview

Introduction

To ensure that a shop is running properly and efficiently, be aware of all activity in and around your shop as much as possible. An engineer chief who does not stay engaged with the shop floor will not have a clear picture of what maintenance is being done, which will ultimately affect mission accomplishment. This study unit covers the fundamentals of maintenance, providing you the basic knowledge of the internal workings of your shop.

Scope

This study unit includes the corrective and preventative maintenance programs, policies and procedures used in the programs, load testing, and how to determine the availability and employment of engineer equipment.

In This Study Unit

This study unit contains the following lessons: Lesson Corrective Maintenance Preventative Maintenance Load Testing of Engineer Equipment Engineer Equipment Employment

MCI Course 1326

3-1

See Page 3-3 3-21 3-31 3-43

Study Unit 3

(This page intentionally left blank.)

MCI Course 1326

3-2

Study Unit 3

LESSON 1 CORRECTIVE MAINTENANCE Introduction

Scope

Corrective maintenance is defined as that action taken on material, as a result of a failure to restore equipment to a specific condition, which includes inspection, testing, servicing, and classification as to serviceability, repair, rebuilding, and reclamation. This lesson will discuss the definition of corrective maintenance and discuss the four phases of maintenance in detail. The assigning of key billets and reconciliation will also be covered.

Learning Objectives

At the end of this lesson, you will be able to • Identify the four phases of corrective maintenance. • Identify the key billets in a maintenance shop. • Identify the process of validation.

In This Lesson

This lesson contains the following topics: Topic Introduction Maintenance Phase Acceptance Phase Induction Phase Active Maintenance Phase Close-Out Phase Key Billets Quality Control MIMMS Personnel Supply Clerks Mechanics Validation Reconciliation Lesson 1 Exercise

MCI Course 1326

See Page 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 3-11 3-12 3-13 3-14 3-17 3-18

3-3

Study Unit 3, Lesson 1

Maintenance Phase

Process

The tasks comprising corrective maintenance vary. However, when performed, corrective maintenance will normally occur in the same sequence. The composite of these tasks is referred to as the corrective maintenance process and, for any specified maintenance action, consists of those tasks to restore the equipment to the specified condition. The corrective maintenance process starts when the equipment is reported as requiring corrective maintenance. It terminates when equipment is either restored to a serviceable condition, declared not reparable, or as otherwise determined by competent authority.

Four Phases

The corrective maintenance process consists of four phases: • • • •

MCI Course 1326

Acceptance Induction Active maintenance Close-out

3-4

Study Unit 3, Lesson 1

Acceptance Phase

Elements

The acceptance phase, also known as the initial phase, consists of the following elements: • • •

Inspection Scheduling Shop assignment

Inspection

The purpose of inspection is to verify the equipment is complete and prepared for the required maintenance service. Inspection is conducted upon initial receipt by the maintenance section.

Scheduling

The purpose of scheduling is to have equipment requiring maintenance arrive at the maintenance facility at or after the time the required maintenance resources are available. This procedure allows the equipment owner maximum operational use of this equipment while avoiding needlessly large concentrations of equipment awaiting maintenance at the maintenance facility. Acceptance scheduling normally applies to all PMCS, modification, calibration, or routine repairs. To be effective, close coordination between the equipment owner and the maintenance section is required.

Shop Assignment

The assignment of equipment to a specific maintenance shop within the maintenance section occurs upon completion of the acceptance inspection and scheduling, when appropriate. In maintenance sections comprised of only one maintenance shop, shop assignment occurs at the time of acceptance of the equipment during the acceptance inspection. In smaller shops, where the maintenance section handles all the corrective maintenance (CM) modifications, calibrations, and preventive maintenance (PM) functions, the assignment of equipment is based on the workload of the individual mechanics.

MCI Course 1326

3-5

Study Unit 3, Lesson 1

Induction Phase

Definition

The physical commitment of equipment and its ERO into the maintenance cycle is known as the induction phase. When the equipment is inducted and assigned to a specific section, it is worked on according to the priority in which it was inducted.

Deferred ERO

MCI Course 1326

If the equipment is inducted by a deferred ERO, the maintenance section calls for the equipment when the resources become available to work on it and according to the priorities of the ERO—category code of the ERO, date received in shop, equipment needs, and urgency of the equipment's mission.

3-6

Study Unit 3, Lesson 1

Active Maintenance Phase

Definition

The active maintenance phase, also known as the beginning of the repair process, is the induction of the ERO and its associated equipment into a maintenance shop for production actions. This phase is performed in a sequence of logical steps designed to ensure the required services are conducted in an efficient and effective manner. During the active maintenance phase, continual emphasis is placed on quality control of the actions and tasks performed. The frequency of quality control inspections will depend on the skill and experience of the individual technicians or mechanics and the overall complexity of the actions.

Repair Process

The repair process follows a sequence of logical steps designed to ensure required services are completed in an efficient and effective manner. Follow the steps listed in the table below: Step 1 2 3

Action Inspect the equipment. Prepare the Performance of Maintenance Actions. Perform the following maintenance actions: •

4 5 6

MCI Course 1326

Preventive Maintenance Checks and Services • Obtain required materials. • Complete a PMCS. • Corrective Maintenance • Isolate the cause of the equipment malfunction. • Obtain required repair parts and secondary repairables. • Correct the equipment fault. • Modification Control • Obtain required materials. • Apply modification. • Calibration Check the Completed Maintenance Actions on an ERO. Perform quality control. Clean up the maintenance area.

3-7

Study Unit 3, Lesson 1

Close-Out Phase

Definition

The close-out phase takes place when one of the two following decisions is made: • Equipment has been repaired and the serviceable item is to be returned to the owner. • Equipment is scheduled for evacuation or disposal.

Role

Maintenance personnel ensure the close-out process is accurate, complete, and coordinated.

Actions During Close-Out

The following actions are accomplished during the close-out phase: • Accurate completion of the ERO and equipment records according to TM-4700-15/1_, Ground Equipment Record Procedures, by maintenance personnel • Performance of any special packaging, preservation, transportation, and shipping requirements • Coordination between the owning unit and the maintenance section for receipt of equipment and records Note: If the EOM is beyond the unit's capability, the unit prepares a courtesy ERO and evacuates the equipment to the next higher EOM.

MCI Course 1326

3-8

Study Unit 3, Lesson 1

Key Billets

Importance of Sequence

Follow the orders and directives in the sequence they are laid out. Equally important is selecting the right Marine for the right billet.

Four Key Areas

There are four key maintenance areas that require assignment of personnel to perform specific maintenance-related tasks: • • • •

MCI Course 1326

Quality control MIMMS personnel Supply clerks Mechanics

3-9

Study Unit 3, Lesson 1

Quality Control

Importance

Quality control (QC) is an important link in the maintenance cycle, and a supervisor must place the correct Marine in that billet.

Requirements

The QC section must have a sound understanding of MIMMS, be able to supervise troubleshooting equipment and ensure all repairs are complete. If possible, the QC billet should be filled by a Marine in a supervisory role, who has worked in all areas of the shop, and can guide the equipment through the maintenance cycle.

MCI Course 1326

3-10

Study Unit 3, Lesson 1

MIMMS Personnel

Importance

Everyone looks at the DPR, DTL, LM-2, and TAM reports generated by your shop. The accuracy of these reports reflects on your supervisory skills and those of your MIMMS personnel. This job is an extremely important position. If it is not properly supervised, a multitude of problems could result. However, if your expertise in maintenance management is poor, the MMO will provide guidance to correct the deficient areas.

Requirements

MIMMS personnel who maintain your records and enter transactions are a vital link in the maintenance of the administration section:

MCI Course 1326

•

The Marine should be a school-trained 0411, maintenance management specialist.

•

The supervisor is responsible for training a Marine to do the job if this billet is not filled.

3-11

Study Unit 3, Lesson 1

Supply Clerks

Function

Supply clerks are another subsection of administration. They handle all parts requests for the shop, ranging from replacement parts to floor dry and rags for the shop.

Responsibilities

The responsibilities of the supply clerk are listed below:

Requirements

MCI Course 1326

•

Research parts.

•

Make sure the correct category codes and priorities are assigned to the EROSOLs.

•

Oversee the layette bins. These bins contain the parts that are received. The clerk must control these bins so that the right items go to the right piece of equipment.

•

Coordinate with supply follow-ups.

The Marine in the supply clerk billet must •

Understand MIMMS and Supported Activities Supply Support System (SASSY).

•

Know how to use the source maintenance and recoverability codes (SMRC) that are listed in SL-4s, making sure the correct information is being submitted.

3-12

Study Unit 3, Lesson 1

Mechanics

Importance

Maintenance personnel, mechanics, assigned to the floor are your money makers. Place your mechanics into sections where they are or can become proficient. Do not leave your mechanics in a particular section just because they are the duty expert. Move experienced mechanics to another section to spread their knowledge.

Mentoring

Mentor your mechanics in skill areas such as troubleshooting equipment, researching parts, and equipment operation: •

Assign tasks to your mechanics according to skill levels.

•

Train your mechanics in the basics of how paperwork is assigned and how it flows.

Marines differ from one another. Some need to be more closely supervised than others. It is your job to know how much supervision to give your Marines.

MCI Course 1326

3-13

Study Unit 3, Lesson 1

Validation

Importance

The engineer maintenance chief is held responsible for the efficient and effective work habits of personnel in the shop. The chief will use the validation process to measure the quality of work being performed in the shop. Validation and reconciliation are the means of checking, identifying, and correcting discrepancies found in either MIMMS or SASSY reports. The engineer maintenance chief must coordinate, dictate, and supervise these processes.

Definition

Validation is the process used to confirm repair part requirements. It involves confirmation of requests that are still needed, cancellations, receipts, scrounges, and current status. When confirming needed requests, the customer must ensure the items have been made known, still exist, and are resident in the supply system. Validations are conducted daily between the MIMMS/records section, the layette section, and the floor chief. Once every 2 weeks, validation is conducted by the commodity manager or engineer maintenance chief.

Source Document

The ERO is your source document. All of its information must be verified against your DTL and DPR. To ensure that this is being accomplished, you should verify by validating this information and reconciling it with the supply section accordingly. Continued on next page

MCI Course 1326

3-14

Study Unit 3, Lesson 1

Validation, Continued

Daily Procedures

Bi-Weekly Procedures

Each day the engineer maintenance chief, commodity manager, or engineer maintenance officer will ensure the following: •

When all critical parts have been received for a category code “M” ERO, but non-critical parts remain outstanding, make sure all critical parts are installed as well as the non-critical parts that are practical to install. Then the category code will be changed or a new ERO will be opened.

•

After opening a new ERO, make sure the following has been done: •

All pending parts have been transferred to new ERO via an “8” transaction with authority code “9” and with the assistance of the supply officer.

•

Any parts that have been received and could not be installed are placed in the newly assigned ERO bin.

•

An ERO is closed when category code “M” parts have been received and installed.

After completing the daily validation, the engineer maintenance chief, commodity manager, or engineer maintenance officer will complete the following validation bi- weekly: Step

Action

1 2

Review the daily validation procedures to ensure they are done properly. Make sure all EROs cite the category codes that accurately reflect the actual condition and status of the equipment. Compare all EROs on the DPR in a short parts status with the ERO and EROSL:

3

• • •

4

5

ERO job status is correct. ERO category codes and priority are valid. An EROSL has been prepared, document numbers assigned, and transactions processed. • The priorities assigned to document numbers on an EROSL follow the priority and category code assigned to the ERO. • The priorities assigned meet the criteria contained in MCO 4400.16. Inventory the ERO bins. Compare the EROSL to the material/parts in the bin. Annotate the EROSL with any changes required and make sure that corrective actions are entered into MIMMS/AIS. All of the repair parts in the ERO bin should be reflected as received on the DPR. Make sure all open EROs were prepared per TM-4700-15/1. Continued on next page

MCI Course 1326

3-15

Study Unit 3, Lesson 1

Validation, Continued

MMO Function

Every week the MMO will conduct a validation as listed in the table below: Step 1 2

3

4

Action Review the RM4 Remarks for accuracy and thoroughness. Reconcile the deadline status of equipment shown on the LM2 Unit Report against the Weekly Owning Unit Maintenance TAM Report and the DPR. Note: Units must manually input all active category code “M” EROs that are not listed on the LM2 Unit Report. Review the DPR and DTL for the purpose of identifying recurring input transaction errors and trends in input errors that should prompt a review of procedures or discussions with the Maintenance Information System Coordinator Office (MISCO). Identify the source of requisitioning delays by comparing the EROSL, the document date, and the “4 Parts” transaction run date.

Note: The MMO will also conduct a monthly validation by reconciling the LM2 Unit Report with the T/E, T/A, and a MCBul 3000 series to ensure all MARES reportable equipment is listed on the LM2 Report with the correct authorized quantity. This will also reconcile the mechanized allowance list (MAL) and the LM2 unit report with the equipment physically to ensure “possessed” quantities are reported correctly.

MCI Course 1326

3-16

Study Unit 3, Lesson 1

Reconciliation

Purpose

In the reconciliation process, the unit makes sure the validation requirements have been properly logged into the SASSY and MIMMS system and accurately reported on the output reports.

Bi-Weekly Procedures

After completing validation, reconciliation must be conducted every 2 weeks by the commodity manager or engineer maintenance chief:

Forms and Reports

•

All receipts, cancellations, and scrounges have been annotated on the EROSL and required transactions have been submitted and processed.

•

Supply status provided is current, acceptable, and understood. Request the supply office to clarify any status that is not understood or does not sufficiently respond according to priority.

•

DPR is annotated with the current and correct data and reconciled with supply against SASSY output reports. Prepare and submit the required transactions to correct invalid data reflected on the DPR.

The section MIMMS clerk picks up the required reports that are used on a daily basis. Validation of the DPR and DTL usually takes place on a daily basis. To conduct a reconciliation, you will need the following forms and reports: • • •

Documents

Supply must also furnish the following documents to assist in validation and reconciliation: • • •

MCI Course 1326

Open EROs EROSLs that correspond to the EROs MIMMS/AIS reports • DTL • DPR • TAM report

Listing from the due and status file (DASF) ERO DOC/NSN

3-17

Study Unit 3, Lesson 1

Lesson 1 Exercise

Directions

Complete items 1 through 13 by performing the action required. Check your answers against those listed at the end of this lesson.

Item 1

The four phases of corrective maintenance are a. b. c. d.

Item 2

Which of the following lists the four main key billet areas in a maintenance shop? a. b. c. d.

Items 3 Through 6

scheduling, inspection, induction, and ERO tub placement. induction, acceptance, assignment, and close-out. modifications, inspection, induction, and assignment. acceptance, induction, active maintenance, and close-out.

Tool room, MIMMS, battery shop, and supply QC, MIMMS, publications, and battery shop QC, MIMMS, supply, and mechanics Tool room, QC, MIMMS, and mechanics

Matching: For items 3 through 6, match the action performed in column 1 with the process name in column 2. Place your responses in the spaces provided. Column 2 answers may be used more than once. Column 1

Column 2

Action Performed

Name of Process

___ 3. Confirmation of supply requests ___ 4. Confirms current status ___ 5. Makes sure SASSY and MIMMS are logged ___ 6. Ensures requests are accurately reported on output reports

a. Validation b. Reconciliation

Continued on next page

MCI Course 1326

3-18

Study Unit 3, Lesson 1 Exercise

Lesson 1 Exercise, Continued

Items 7 Through 13

Matching: For items 7 through 13, match the action taken in column 1 with the frequency requirement in column 2. Place your responses in the spaces provided. Column 2 answers may be used more than once. Column 1

Column 2

Action Taken

Validation Required

___ 7. Verify the ERO against the DTL. ___ 8. Compare all EROs and EROLs in a short part. ___ 9. Make sure the category codes reflect actual conditions and current job status of the equipment. ___ 10. Submit corrections to update DPR. ___ 11. Inspect for recurring errors/trends in input errors. ___ 12. Identify the source of requisitioning delays. ___ 13. Review/discuss procedures.

a. Daily validation b. Bi-weekly validations c. Bi-weekly MMO validations

Continued on next page

MCI Course 1326

3-19

Study Unit 3, Lesson 1 Exercise

Lesson 1 Exercise, Continued

Answers

The table below lists the answers to the lesson exercise. If you have any questions about these items, refer to the reference page. Item 1 2 3 4 5 6 7 8 9 10 11 12 13

MCI Course 1326

Answer d c a a b b a b b a c c c

3-20

Reference 3-4 3-9 3-14 3-14 3-17 3-17 3-14 3-15 3-15 3-14 3-16 3-16 3-16

Study Unit 3, Lesson 1 Exercise

LESSON 2 PREVENTIVE MAINTENANCE Introduction

Scope

The objective of preventive maintenance (PM) is to reduce corrective maintenance. This lesson will cover the guidance to be followed to ensure proper lubrication, scheduling for preventive maintenance checks and services, and the forms that are used to schedule and record the preventive maintenance that was performed.

Learning Objectives

At the end of this lesson you will be able to

In This Lesson

•

Identify the three sources of information for the establishment of PMCS.

•

Identify the forms used to establish recordkeeping for PMCS.

This lesson contains the following topics: Topic Introduction References Scheduling and Forms NAVMC 10524 NAVMC 10523 NAVMC 10561 Lesson 2 Exercise

MCI Course 1326

3-21

See Page 3-21 3-22 3-23 3-24 3-25 3-26 3-27

Study Unit 3, Lesson 2

References

Requirements

Preventive maintenance schedules and lubrication requirements are outlined in three references. • • •

Lube orders and instructions TM-4700-15/1_ Equipment TMs

Lube Orders and Instructions

Lube orders and instructions, commonly referred to as LOs and LIs, serve as a quick reference guide to identify lubrication points. These charts are useful to the operators and mechanics to show time interval requirements when they are performing PMCS.

TM 4700-15/1_

TM 4700-15/1_ provides detailed instructions on how to fill out the various forms associated with PMCS. This manual also provides recordkeeping procedures and preventive maintenance guidance for engineer ground equipment.

Equipment TMs

The technical manual for each piece of equipment identifies lubrication and maintenance specifications and intervals. These specifications are set by the manufacturer and are adopted by the Marine Corps. These may be based on hours of equipment operation and calendar time: • • • • •

MCI Course 1326

Daily Weekly Monthly Semi-annually Annually

3-22

Study Unit 3, Lesson 2

Scheduling and Forms

Timing of Services

You may perform PM service before they are due in certain circumstances, such as extreme operating climates, unforeseen contamination, and adverse operating conditions; all of which can cause undue equipment wear. At times, you must make a common sense judgment call on PM service. Keep in mind that only in rare cases should lubrication interval extend beyond established schedules. Over lubricating and over filling often lead to leaking seals and protective joint covers. Not lubricating causes excessive wear on joints and other moving parts.

Forms

There are three forms used for PMCS: • • •

NAVMC 10524, Consolidated Engineer Equipment Log NAVMC 10523, Engineer Equipment Operational Record NAVMC 10561, Preventive Maintenance Checks and Services Roster

These forms serve as checklists and provide the means for tracking large numbers of equipment. Note: The NAVMC 10524 and 10523 forms provide a checklist for daily preventive maintenance.

MCI Course 1326

3-23

Study Unit 3, Lesson 2

NAVMC 10524

Purpose

On the front of the NAVMC 10524, you can record hours or miles for PMCS scheduling and POL consumption. The back of the form can be used as a daily checklist for PMCS in certain situations.

Section A

When setting up the schedule, first identify the hourly interval of PMCS listed in the equipments’ TM. On the bottom row of Section A, the hourly PCMS are entered in ink because they do not change. In the top row, enter the equipment’s hour meter readings or the estimated hours that PMCS will become due. Use a pencil for these entries because they will change when the hourly PMCS is performed as shown below: LAST SCHEDULED

NEXT SCHEDULED

LUBRICATION

PMCS

PMCS

DUE

(ENTER DATE PERFORMED)

(ENTER DATE DUE)

(ENTER TYPE)

PMCS DUE 1200

1200

1250

1200

1200

2000

2000

(USE PENCIL ONLY)

SCHEDULED PMCS 50

Scheduled Adjustment

100

250

300

500

1000

2000

When making adjustments to the PM schedule, you must remember two things: •

The ERO, if required, will always be written for the largest PMCS that is due.

•

When a PM service comes due, all lesser scheduled PMCS that can be evenly divided into the larger PMCS are also performed at this time. This should be reflected in Section A.

Example: If a 300-hour PM is due, then a 50-, 100-, and a 150-hour PM are performed, but a 250-hour is not. When a 500-hour PM is due, then a 50-, 100-, and 250-hour PM are done as well, but the 150- and 300-hour PM are not. Note: Only the performed PMCS are adjusted on the NAVMC 10524.

MCI Course 1326

3-24

Study Unit 3, Lesson 2

NAVMC 10523

Purpose

The NAVMC 10523, Engineer Equipment Operational Record, serves three purposes: • • •

Provides the operator the authority to operate and item of equipment Records the PMCS entries of petroleum, oil, and lubricants Lists equipment deficiencies

Responsibilities

The engineer equipment chief ensures that an ERO is prepared or if an ERO is already opened, makes sure the parts are requisitioned for any repairs noted.

Recording

NAVMC 10523 contains blocks 7 through 12 for recording PMCS. This information can be taken from NAVMC 10524, Section A. The dispatcher enters the information into these blocks, which lets the operator know to perform 1st echelon services according to the equipments’ TM. Note: Chapter 2 of TM-4700-15/1 gives further guidance on using this form.

MCI Course 1326

3-25

Study Unit 3, Lesson 2

NAVMC 10561

Scheduling

Use NAVMC 10561 to systematically schedule 2nd echelon or higher PMCS on a calendar basis. All equipment must have PMCS scheduled on this form for at least an annual PM. Stagger your like items of equipment on the PMCS roster to maintain enough equipment on hand and to support your unit’s daily and anticipated missions. Schedule and perform service on an end item and its components and attachments at the same time to eliminate equipment down time. You can schedule annual PMCS for load lifting equipment in conjunction with the annual condition inspection (ACI). Note: For specific entries, refer to TM 4700-15/1.

MCI Course 1326

3-26

Study Unit 3, Lesson 2

Lesson 2 Exercise

Directions

Complete items 1 through 7 by performing the action required. Check your answers against those listed at the end of this lesson.

Item 1

List the three resources, in any order, that establish the preventive maintenance interval requirements for an item of engineer equipment. (1) ______________________________________ (2) ______________________________________ (3) ______________________________________

Item 2

A quick reference guide for lubrication checks and points can be found on the a. b. c. d.

Item 3

LO/LI Trip ticket Consolidated Engineer Log Preventive Maintenance Service Roster

Which forms provide a checklist for daily preventive maintenance? a. b. c. d.

Engineer Equipment Operational Log and Service Record Preventive Maintenance Checks and Services Roster Lubrication Order and Lubrication Instructions Consolidated Engineer Equipment Log and Engineer Equipment Operational Record Continued on next page

MCI Course 1326

3-27

Study Unit 3, Lesson 2 Exercise

Lesson 2 Exercise, Continued

Items 4 Through 6

Matching: For items 4 through 6, match each shop section in column 1 with its corresponding shop function in column 2. Place your responses in the spaces provided. Column 1

Column 2

Reference/Form

Use

___ 4. Equipment TM ___ 5. TM 4700-15/1_ ___ 6. NAVMC 10524

a.

b.

c.

Item 7

Provides a means for recording hours or miles so PMCS can be scheduled and POL use determined Provides recordkeeping procedures and preventive maintenance guidance for engineer ground equipment Provides manufactures complete lubrication and maintenance specifications and intervals

Which echelon(s) of maintenance must be scheduled on the NAVMC 10561? a. b. c. d.

Fifth Second or higher First and second Third and fourth Continued on next page

MCI Course 1326

3-28

Study Unit 3, Lesson 2 Exercise

Lesson 2 Exercise, Continued

Answers

The table below lists the answers to the lesson exercise. If you have any questions about these items, refer to the reference page. Item 1

• • •

2 3 4 5 6 7

MCI Course 1326

3-29

Answer Equipment TM LO/LI TM 4700-15/1_ a d c b a b

Reference 3-22

3-22 3-23 3-22 3-24 3-26 3-26

Study Unit 3, Lesson 2 Exercise

(This page intentionally left blank.)

MCI Course 1326

3-30

Study Unit 3, Lesson 2 Exercise

LESSON 3 LOAD TESTING OF ENGINEER EQUIPMENT Introduction

Scope

This lesson discusses load testing and annual condition inspections (ACI) of engineer equipment. Due to the critical nature of load lifting and testing of cranes and aerial devices, it is important that correct information is published and used. Marine Corps Order P11262.2_ details the criteria pertaining to load testing and ACIs. The load testing standards come from regulations issued by the Department of Labor's Occupational Safety and Health Administration (OSHA). There are also Marine Corps directives, TMs, and other guidance that apply to equipment maintenance, testing, and inspecting of load-lifting equipment. For many years, the Marine Corps and Navy have applied much more stringent standards than OSHA requires regarding industrial safety when using load-lifting equipment. The reason for such stringent orders and standards is simple—accidents occur, people die.

Learning Objectives

At the end of this lesson, you will be able to •

Identify the types of equipment that require load testing.

•

Identify the procedures to conduct a maximum load test.

•

Identify the procedures to conduct a stability test.

•

Identify the purpose of the annual condition inspection.

•

Identify the procedures to conduct a no-load test.

•

Identify the MOS of a certifying officer. Continued on next page

MCI Course 1326

3-31

Study Unit 3, Lesson 3

Introduction, Continued

In This Lesson

This lesson contains the following topics: Topic Introduction Load Test Requirements Maximum Load Test Stability Test Annual Condition Inspection No-Load Test Load Test Certification Lesson 3 Exercise

MCI Course 1326

3-32

See Page 3-31 3-33 3-35 3-36 3-37 3-38 3-39 3-40

Study Unit 3, Lesson 3

Load Testing Requirements

Background

The Secretary of Defense requires all components, including the Marine Corps, to conform to OSHA’s regulations —with some exceptions predicated by Defense missions. Extracts of pertinent safety instructions set forth in OSHA-29 Code of Federal Regulations (CFR) 1910 have been consolidated into MCO P11262.2_.

Equipment

Only cranes and aerial personnel devices require load testing. Aerial personnel devices are defined as any mechanically, hydraulically, or electrically operated device used to lift a person in the air. Scheduled periodic load testing is not required. Prior to initial use, all are required to be load tested. The testing is to include • • •

Newly manufactured Extensively repaired Altered cranes/aerial personnel devices

Testing Standards

The load test consists of two parts: a maximum load test and a stability test. Although the different items of equipment have similarities in their performance, they have different testing standards. Each piece of equipment must be checked structurally for stress fractures, broken welds, bent members, etc. Any of these discrepancies automatically disqualifies the equipment from being operational. Any item with a problem must enter the maintenance cycle for correction of any deficiencies. Then that equipment is tested again. For any equipment that passes testing, if later it is found deficient, that equipment must be corrected and retested.

Equipment with Hooks

Hooks are inspected annually for wear in swivels and pins, cracks or gouges, and proper operation and condition of safety latches where installed. When normal wear or removal of cracks or gouges result in a reduction in the original sectional dimension of 10 percent or more, discard the hook. If the hook is visually bent or twisted, discard it. Make no attempt to • •

Straighten bent or twisted hooks. Correct hook deficiencies by use of heat or welding. Continued on next page

MCI Course 1326

3-33

Study Unit 3, Lesson 3

Load Testing Requirements, Continued

Hook Throat Spread

MCI Course 1326

Hooks are measured for hook throat spread upon receipt. A throat dimension base measurement is established by installing two tram points and measuring the distance between these tram points (+/-1/64 inch). This base dimension is retained in the “Remarks” section of the Record Jacket (form NAVMC 696D) for the life of the hook. The distance between tram points is measured quarterly. Hooks showing an increase in the throat opening by more than 15 percent from the base measurement is discarded.

3-34

Study Unit 3, Lesson 3

Maximum Load Test

Procedures

MCI Course 1326

There are two distinct procedures in the maximum load test: •

Position the crane with the boom at maximum prescribed lift angle, hook attached to the load lifting measuring device, with the position of the boom 90 degrees to the right or left of the lower carrier frame, outriggers must be at full horizontal extension and vertical jacks lowered to level the turntable bearing. Check level with carpenter’s level. Place level in direction of boom and at 90 degrees to direction of boom to establish a level turntable. Tires must be free of ground for test and the wire rope connecting the hook to the boom in a vertical configuration—check wire rope with carpenter’s level.

•

Exert 110 percent of the crane’s rated capacity on the load lifting measuring device and hold for 1 minute. Slowly decrease load until wire rope is barely slack. Repeat foregoing once. Hook will be inspected as in paragraph 2002.3 of MCO P11262.2_. This serves as the nondestructive hook test.

3-35

Study Unit 3, Lesson 3

Stability Test

Test Steps

To perform a stability test, follow the steps listed in the table below: Step 1

2 3

4

5

6

7

8 9

MCI Course 1326

Action Choose any load from the load chart not in the black (shaded) structural strength area of the rated load 360 degrees chart. Chosen test load must clear outriggers during full 360 degrees rotation. Position the lift to the right or left side at 90 degrees to the side of the lower carrier frame. Outriggers at full horizontal extension and vertical jacks lowered to level the turntable bearing. Check level with carpenter’s level. Place level in direction of boom and at 90 degrees to direction of boom to establish a level turntable. Tires must be free of ground for test. Position the hook block to obtain the appropriate operating test radius for test boom length. By actual measurement, confirm the operating radius to center of rotation. Adjustment may be necessary to obtain the specified radius. Mark the operating radius with a line of sufficient length to ensure its visibility when the load is suspended over it. The line should be on an arc about the axis of rotation for the tested radius. Position the test load inside the selected operating radius. The rated load is equal to the test weight plus the hook block weight (approximately 620 pounds) plus sling weights. Boom up 2 to 4 degrees to position the hook block over the load and to compensate for boom deflection. Lift the rated load. Make sure the boom is down while keeping the load close to ground until the rated load is hook block centered over the selected operating radius and suspends the rated load 2 to 4 inches above the ground. Swing the crane through the 360-degree rotation. Lower load.

3-36

Study Unit 3, Lesson 3

Annual Condition Inspections

Purpose

The purpose of the annual condition inspection is to ensure the overall structural, mechanical, hydraulic, and electrical components of the equipment that had been maintained in a safe and serviceable condition and are functioning properly. Each item of the load-lifting equipment should be certified as condition inspected at least once annually. Inspections forms are retained until the next inspection is complete.

Requirements

In addition to the inspections required by the load-lifting equipment TMs, the following discrepancies would require re-inspections before an ACI: •

All mechanical controls for proper adjustments and the entire control mechanism for excessive wear of components and contamination by leaking lubricants or foreign matter

•

Hydraulic system seals, hoses, lines, fittings, pumps, and valves for deterioration, leaks, and wear

•

Mast and lift carriage assemblies to include forks, and chains for cracks, broken welds, distortion, improper fit, and excessive wear

•

Brake and steering systems for excessively worn or defective moving parts to include seat switches, parking brakes, and brake interlock switches

•

Protective motor control circuit devices, battery cable connectors, battery compartment insulation, thermo protectors, compartment covers, filters, and emergency switches

•

Proper marking

•

Evidence of mishandling and/or damage

•

Excessive wear on brake and clutch system linings, pawls, and ratchets

•

Rope reeving for nonconformance with manufacturer’s specifications

•

Bends, distorted sections, broken welds, excessive corrosion, and loose bolts or rivets on the frame

Correct all deficiencies and repairs (if required) prior to load testing.

MCI Course 1326

3-37

Study Unit 3, Lesson 3

No-Load Test

Components

There are two components that require a no-load test: • Hoist • Boom

Hoist

The steps to test the hoist are listed in the table below: Step 1 2 3

Boom

The steps to test the boom are listed in the table below: Step 1 2

3 4 5 6

MCI Course 1326

Action Raise and lower the hook through the full working distance of hook travel. Run the hoist block into the limit switch(es), where installed, at slow speed. Run the hoist block beyond the limit switch(es), where installed by using the bypass switch.

Action Raise and lower the boom through the full working range. Raise the boom into the upper limit switch, where installed. Raise the boom past the boom upper limit switch, using the bypass switch. Test the lower limit switch, where installed, by the same procedure prescribed for testing the upper limit switch. Extend and retract the telescoping boom sections the full distance of travel. Check the radius indicator by measuring the radius at the minimum and maximum boom angle. Operate other motions, including swing, through one cycle— one full revolution of major components.

3-38

Study Unit 3, Lesson 3

Load Test Certification

Certifying Officer

The certifying officer is responsible for ensuring the safety and reliability of all load-lifting equipment. The officer is assigned in writing by the CG/CO. The certifying officer can be a Marine officer or a qualified civilian. Marine certifying officers are from MOS 1310 (engineer equipment officer), 3510 (motor transport maintenance officer), or 2110 (ordnance vehicle maintenance officer). The certifying officer designates the test directors and the inspection test personnel.

Certification Procedures

All items of equipment must be certified when initially put into service and an acceptance LTI must be performed. Once this is completed, the equipment is put on a schedule for an ACI. Although these items are certified annually, if there is maintenance to the major components, such as welding or new packing in the cylinders, the equipment must be retested. Forklifts must also be certified and a condition inspection performed annually. The inspection results are recorded in the same manner as they are for cranes.

MCI Course 1326

3-39

Study Unit 3, Lesson 3

Lesson 3 Exercise

Directions

Complete items 1 through 6 by performing the action required. Check your answers against those listed at the end of this lesson.

Item 1

What types of equipment require load testing? a. b. c. d.

Item 2

How many procedures are in a maximun load test? a. b. c. d.

Item 3

1 2 3 6

What type of discrepancy would require the reinspection of a crane before an ACI? a. b. c. d.

Item 4

Forklifts and dozers Cranes and forklifts Aerial devices and cranes Aerial devices and forklifts

Flat tire Broken weld Bent pintle hook Broken windshield

Each item of load-lifting equipment shall be certified as condition inspected at least once a. b. c. d.

weekly. monthly. annually. bi-weekly. Continued on next page

MCI Course 1326

3-40

Study Unit 3, Lesson 3 Exercise

Lesson 3 Exercise, Continued

Item 5

The two components that will be tested in a no-load test are the a. b. c. d.

Item 6

hoist and boom. outriggers and hoist. boom and hook. hoist and hook.

Certifying officers must have an MOS from which of the following? a. b. c. d.

1345, 2110, and 3510 3510, 2110, and 1349 2110, 3510, and 1310 1345, 1349, and 1310 Continued on next page

MCI Course 1326

3-41

Study Unit 3, Lesson 3 Exercise

Lesson 3 Exercise, Continued

Answers

The table below lists the answers to the lesson exercise. If you have any questions about these items, refer to the reference page. Item Number 1 2 3 4 5 6

MCI Course 1326

Answer c b b c a c

3-42

Reference Page 3-33 3-35 3-37 3-37 3-38 3-39

Study Unit 3, Lesson 3 Exercise

LESSON 4 ENGINEER EQUIPMENT EMPLOYMENT Introduction

Scope

This lesson briefly covers the operational employment of engineer equipment. You will learn about the general engineer equipment capabilities and characteristics, the supervisory aspects of employing and deploying various engineer equipment types, and about safety factors and areas of environmental concerns. Your own experiences will add to your knowledge of how to employ the equipment.

Learning Objectives

At the end of this lesson, you will be able to •

Identify the four things an equipment chief should know before employing engineer equipment.

•

Identify the six steps involved in the employment of engineer equipment.

•

Identify four things a supervisor should ensure before deploying loadlifting equipment.

•

Identify two types of engineer equipment items that are classified as materiel-handling equipment.

•

Define the term “general support” of engineer equipment.

•

Identify two job site factors the equipment chief must consider before employing equipment.

•

Identify which type of equipment operation usually involves more planning due to a variety of equipment requirements. Continued on next page

MCI Course 1326

3-43

Study Unit 3, Lesson 4

Introduction, Continued

In This Lesson

This lesson contains the following topics: Topic Introduction Supervising Equipment Employment Equipment Required by the Mission Controls and Considerations Operations Material-Handling Equipment Earth-Moving Equipment Employment General Support Engineer Equipment Lesson 4 Exercise

MCI Course 1326

3-44

See Page 3-43 3-45 3-46 3-47 3-48 3-49 3-50 3-51 3-52

Study Unit 3, Lesson 4

Supervising Equipment Employment Assigning Equipment

To assign equipment requires research. This research assists in the decisionmaking process: • •

Six Areas of Supervision

The areas of supervising the employment of engineer equipment are listed below: • • • • • •

MCI Course 1326

Makes equipment assignments that serve mission requirements Changes equipment assignments when the S-4 assigns equipment to support requests

Equipment required by the mission Environmental controls and natural resource considerations Engineer equipment operations Materiel-handling equipment Earth-moving equipment employment General support of engineer equipment

3-45

Study Unit 3, Lesson 4

Equipment Required by the Mission Identify the Mission

To determine equipment requirements, you must identify the mission. Many times this is done for you, such as when S-4 sends out a general support request. Consequently, sometimes the wrong equipment is requested and different equipment must be sent later to do the job. To avoid sending the wrong equipment, the chief should know the following: • • • •

MCI Course 1326

Equipment and personnel capability Mission requirements Operating standards and conditions Availability of your personnel and equipment

3-46

Study Unit 3, Lesson 4

Controls and Considerations Job Site Factors

Once you have all the information about a particular tasking, you need to consider the environmental controls and the use or misuse of natural resources for the task, particularly when it involves earth-moving operations. The following job site factors must be taken into consideration prior to employing equipment: •

Identify the mission and the environmental and natural resource considerations. Make personnel and equipment assignments. Brief the situation to your operators and NCOs who will supervise at the job site.

•

Be aware of the rules and regulations pertaining to removal of trees, digging below ground level, and use of soils from borrow pits. In some localities, if you remove trees one inch or larger, you are subject to large fines.

•

When dealing with bodies of water and hilly terrain, you may have erosion control (soil runoff) problems.

•

Check with range control and the natural resource environmental authority for the area before beginning earth-moving operations.

•

Digging below certain depths can endanger personnel.

•

Buried lines can be struck and cut.

Note: Contact the utility section for the area. They will come to the planned digging site. CAUTION: Check for buried lines and pipes before you dig!

Environmental Considerations

Destruction of any non-government property has to be compensated for by the government or by the individual Marine who does the damage, so be aware of damage made by heavy equipment and make sure your operators are aware at all times of the impact of the heavy equipment they operate. Heavy equipment simply moving across some surfaces can do extensive damage such as severing ground laid communication wires and damaging asphalt. Tracked vehicles easily place ruts in soft turf.

MCI Course 1326

3-47

Study Unit 3, Lesson 4

Operations Assignments

Employment

It is imperative that you know your operators’ proficiency levels and present physical condition. The procedure is listed below: •

Make sure personnel are licensed to operate a given item of equipment.

•

Assign operators missions that coincide with their proficiency or provide close on site proficiency supervisory personnel.

•

Ensure the physical alertness of your operators. In most cases, medications, hangovers, fatigue, etc. disqualify an individual from operating engineer equipment.

•

Know the equipment used by the Marine Corps and the equipment capabilities.

Equipment must be employed for specific tasks according to its operational capabilities. Equipment currently used by the Marine Corps, not including garrison mobile equipment (GME), are listed below: • • • • • • • • • • • • • • • • • •

Caterpillar D7G Dozer J.I. Case 1150E Dozer J.I. Case 1155E Tracked Loader Caterpillar 130G Grader Caterpillar 621B Scraper RAYGO 420C Vibratory Compactor John Deere 644EZ TRAM (Tractor Rubber Tired Articulated Steering Multipurpose) Caterpillar 988B RTCH (Rough Terrain Container Handler) J.I. Case 1085 Excavator M9 ACE. (Armored Combat Earthmover) Lorain LRT 110 7½-Ton Crane P&H 25-Ton HSHMC (High Speed High Mobility Crane) Ingersoll Rand 260CFM Compressor Tymco 600 Street Sweeper Engineer Equipment Trailer (EET) Model MT020 Caterpillar Backhoe 420D IT

Light Capability Rough Terrain Forklift (LCRTF) TX 51-19M SkyTrak-MMV

Note: Equipment characteristics are discussed further in Appendix A.

MCI Course 1326

3-48

Study Unit 3, Lesson 4

Material-Handling Equipment Definition

Material handling refers to picking up and moving raw materials, equipment, parts, supplies, finished materials, and maintenance items. Cranes and forklifts are classified as material handlers.

Safety Considerations

Continuous safety and training procedures for material-handling equipment should be conducted regularly at the operations section. Accidents are likely to occur more often with forklifts and cranes than with earth-moving equipment due to the mobility and diversity of the operating sites and the different conditions. As the equipment chief, you must stress safety awareness and hazard prevention:

OSHA Considerations

•

Use experienced personnel to establish a training program for your platoon.

•

Train your younger Marines so they develop into confident and proficient operators.

Material handlers that have a load-lifting chart can be operated only by school-trained personnel. Operators must ensure they do not exceed the machine’s lifting capacity because this could result in extensive equipment damage and possible personal injury. Material handlers now fall under the OSHA load test and certification requirements (see MCO P11262.2_, Inspection, Testing and Certification of Tactical Ground Load Lifting Equipment). The equipment chief must ensure all load-lifting equipment is properly load tested, certified, clearly marked, and safety inspected before it is operated.

MCI Course 1326

3-49

Study Unit 3, Lesson 4

Earth-Moving Equipment Definition

Earth-moving equipment refers to bulldozers, scrapers, graders, excavators, bucket loaders, and other types of similar equipment.

Special Requirements

Earth-moving operations involve cutting and filling earth to build and repair roads, runways, berms, emplacements, etc. You must plan, schedule, and coordinate all phases of construction for earth-moving operations. Usually, earth-moving operations require more time, planning, and coordination than material-handling operations because you must obtain a variety of equipment and make estimations for time and material requirements.

MCI Course 1326

3-50

Study Unit 3, Lesson 4

General Support Equipment Definition

General support engineer equipment is the equipment you have available to support requested tasks from your supported unit(s).

Reporting

According to the established SOP, an equipment availability report is normally submitted to the S-4 shop daily. This report shows the availability status of your equipment. Any equipment assigned for direct support should not be made available for general support requests. As the equipment chief, you must consider your own missions for your shop/section and any working projects at the time. Establish priorities with your OIC first so that you do not list needed equipment as available on this report. In so doing, the equipment that is left available is what is scheduled for general support by the S-4 or other assigned sections or individuals.

MCI Course 1326

3-51

Study Unit 3, Lesson 4

Lesson 4 Exercise

Directions

Complete items 1 through 7 by performing the action required. Check your answers against those listed at the end of this lesson.

Item 1

Before employing engineer equipment, the chief should know the a. equipment and personnel capability, mission requirements, operating standards and conditions, and availability of personnel and equipment. b. mission requirements, operating standards, equipment availability, and operators' physical condition. c. mission requirements, operating standards and conditions, availability of operators, and availability of equipment. d. mission requirements, operating standards and conditions, availability of personnel and equipment, and capabilities of equipment and personnel.

Item 2

Item 3

In the spaces below, list the two job site factors to be considered before equipment employment. (1)

________________________________________________________

(2)

________________________________________________________

Before assigning a Marine to operate equipment, the chief must know the operator’s a. b. c. d.

experience and time in service. skills and knowledge. proficiency and skill. proficiency level and present physical condition. Continued on next page

MCI Course 1326

3-52

Study Unit 3, Lesson 4 Exercise

Lesson 4 Exercise, Continued

Item 4

Before employing load-lifting equipment, the equipment chief ensures the a. operator is licensed, has a trip ticket, and knows where to go and whom to report to. b. operator is in good physical condition and has a license, a trip ticket, and fuel. c. equipment is load-tested, certified, clearly marked, and safety inspected. d. equipment is operational, load-tested, clearly marked, and lubricated.

Item 5

Item 6

In the space below, list the two types of equipment classified as materialhandling equipment. (1)

________________________________________________________

(2)

________________________________________________________

In the space below, identify which type of equipment operation usually involves more planning because you must obtain a variety of equipment and make estimations for time and material requirements. _________________________________________________________

Item 7

In the space below, define the term general support of engineer equipment. _________________________________________________________ _________________________________________________________ Continued on next page

MCI Course 1326

3-53

Study Unit 3, Lesson 4 Exercise

Lesson 4 Exercise, Continued

Answers

The table below lists the answers to the lesson exercise. If you have any questions about these items, refer to the reference page. Item 1 2

3 4 5 6 7

MCI Course 1326

Answer c • •

Mission Environmental and natural resources d c Cranes and forklifts Earth-moving Equipment available for your support units

3-54

Reference 3-45 3-47

3-48 3-49 3-49 3-50 3-51

Study Unit 3, Lesson 4 Exercise

APPENDIX A EQUIPMENT CHARACTERISTICS P&H HSHMC 25-Ton Crane

Characteristics

The P&H High Speed High Mobility Crane (HSHMC), TAMCN B0443 consists of the following characteristics: •

Overall. 25-ton capacity, diesel engine-powered V-8 Caterpillar with a 4-speed, full power, shift forward and reverse with a high and low transfer.

•

Crane. Equipped with front and rear planetary drive axles capable of 8wheel drive differential lock for improved traction when needed.

•

Boom assembly. Consists of a three-section, box-type with a minimum boom length of 32 feet and a maximum boom length of 80 feet.

Illustration

An illustration of the P&H HSHMC 25-ton crane is shown below:

Capabilities

For normal lifting operations, supervisors must ensure the crane is equipped with the proper length of wire rope and the correct parts according to the TM. HSHMC performs pick-and-carry operations according to load charts and the TM. Other capabilities of the HSHMC crane are listed below: • • • • •

Fit with a five-part line to lift the 50,000-pound maximum load Winch holds 500 feet of an ¾-inch wire rope Speed should not exceed 2.5 mph Hydraulic, fully revolving Performs normal lifting, cargo handling, pile driving, and clamshell operations Continued on next page

MCI Course 1326

A-1

Appendix A

P&H HSHMC 25-Ton Crane, Continued

Attachments

The three attachments that can be fitted for operations are listed below: •

Hook block. The hook block has almost unlimited use. A hook block may be used at, above, or below ground level. Some other uses are listed below: • • •

•

Pile driver model DA15B. This operation consists of a three-man crew— the crane operator, a signal man, and a hook-up man. The pile driver is primarily used to drive wooden piles for piers, seawalls, work pits, and loading ramps.

•

Clamshell bucket. The clamshell bucket is a vertically operated attachment capable of digging loose to medium soils at, above, or below ground level. Some other uses are listed below: • • •

Load Moment System (LMS)

Assists in bridge construction Loads and unloads ships and trucks during port operations Lifts any load rigged with slings or vehicles equipped with lifting eyes

Digs foundations, footings, pier holes, trenches, and cellars Fills charge bins above ground level Loads trucks and scrapers

The HSHMC is equipped with a load moment system (LMS) that allows the operator to dial in the load chart information that pertains to the anticipated load lift. When properly used, the LMS warns the operator when an unsafe lifting position has been reached. If the wrong information is installed into the LMS or if it is not checked for proper calibration, then it may fail to inform the operator of an unsafe position. Mechanical and personal injury could result. Continued on next page

MCI Course 1326

A-2

Appendix A

P&H HSHMC 25-Ton Crane, Continued

Components of the LMS

MCI Course 1326

Components of the LMS are illustrated below:

A-3

Appendix A

LRT 110 7½-Ton Crane

Characteristics

The LRT 110 7½-ton crane, TAMCN B0446 is a very versatile hydraulic crane powered by a diesel engine and designed to perform normal lifting operations. It is a wheel-mounted, self-contained, two- and four-wheel drive, two- and four-wheel steering crane. Other characteristics of the LRT 110 7½ton crane are listed below: •

Boom assembly is a two-section telescopic boom with a minimum length of 21¼ feet and a maximum length of 35¾ feet.

•

Winch is a single drum and hydraulically operated. It will hold 350 feet of ½-inch wire rope.

•

Lifting capacity is 15,000 pounds (7½ tons) when rigged with at least 180 feet of ½-inch cable on a three-part line.

Illustration

An illustration of the LRT 110 7½-ton crane is shown below:

Capabilities

The LRT 110 7½-ton crane has only two attachments—the hook block for lifting loads with slings at, above, and below ground level and a personnel basket. Various

lifting operations are listed below: • • •

MCI Course 1326

Installs and removes rotor blades on helicopters and assisting with engine maintenance on fixed-winged aircraft Loads generators and other trailer-mounted equipment onto trucks Performs extended reach maintenance services

A-4

Appendix A

The Rough Terrain Container Handler (RTCH) RT 240

Characteristics

The rough terrain container handler (RTCH) RT 420, TAMCN B0391 is designed to lift, move, stack, or unstack 20 and 40 feet by 8 feet wide ISO containers. It has a lift capacity of 53,000 pounds (24,062 kg) and operates on hard and/or unimproved surfaces, to include beach operations and can be utilized as a forklift with an operator-installed forklift kit. Additional features include the following: •

Electronically controlled 400 hp, 6-cylinder turbocharged engine.

•

Electronic semiautomatic shift controlled transmission with four ranges forward and three reverse. Operator selects range and ECM controls shift points.

•

Drive axles provide traction for two- or four-wheel drive.

•

Limited slip differentials and multi-disc-wet brakes are an integral part of the axle assemblies. Multi-disc-wet brakes are hydraulically cooled to prevent overheating. Accumulators store energy for the emergency braking system.

•

Steering system is capable of two-wheel, four-wheel, crab, and emergency modes of operation.

•

Parking brake is hydraulically released and spring-applied by disc brake assemblies mounted on the front and rear differentials.

•

The operator’s cab has a fully adjustable operator’s seat, fresh air (filtered) ventilation system, and heater/defroster/air conditioning systems.

•

Maximum speed is 23 mph (37 kph) on level ground without a load and 15 mph (24 kph) loaded.

•

Maximum fording depth is 60 inches (1.52 m).

•

Operates in temperatures from -25°F to +125°F (-32°C to +52°C) and to -40°F (-40°C) with an arctic kit installed. Continued on next page

MCI Course 1326

A-5

Appendix A

The Rough Terrain Container Handler (RTCH) RT 240, Continued

Illustration

An illustration of the RTCH RT 420 is shown below:

Capabilities

The container handler capabilities are listed below: • • • • • • • •

Forklift Kit

MCI Course 1326

Stacks or unstacks 8 feet high ISO containers stacked 3 high with a gross weight of 53,000 pounds (24,062 kg) in the first row Stacks or unstacks 8 feet high ISO containers stacked 3 high with a gross weight of 27,500 pounds (12,485 kg) in the second row Stacks or unstacks 4.3 feet high ISO containers stacked 7 high Adjusts to 20 or 40 feet ISO container lengths Oscillates 7 degrees left and right Rotates 195 clockwise and 105 counterclockwise Tilts 8 forward and 12 to the rear Side shifts ± 15 inches (± 400 mm) from the center

Forklift kit is operator-installed and attaches to the tophandler. •

Fork tines are adjustable from 24 inches (61 cm) center-to-center to 81.5 inches (207 cm) center-to-center.

•

Lift capacity is 44,000 pounds (19,976 kg).

A-6

Appendix A

644E Rubber Tired, Articulated Steering, Multipurpose (TRAM) Forklift

Characteristics

Manufactured by John Deere, the 644E Rubber Tired, Articulated Steering, Multipurpose (TRAM) Forklift, TAMCN B2567 is a fully hydraulic rough terrain articulating forklift/loader equipped with two attachments—forks and a 4-in-1 bucket. The TRAM is truly an all-terrain forklift. Other characteristics of the TRAM forklift are listed below:

• • • • •

Illustration

Equipped with a quick release disconnect for changing attachments Maximum lifting capacity is 10,000 pounds with forks A locking bar for transportation and maintenance A secondary steering system for emergencies if the TRAM loses power Equipped with a full-time, four-wheel drive, and a differential lock

An illustration of the TRAM forklift is shown below:

Continued on next page

MCI Course 1326

A-7

Appendix A

644E Rubber Tired, Articulated Steering, Multipurpose (TRAM) Forklift, Continued

Capabilities

Capabilities of the TRAM are listed below:

• • • • • • •

Maximum lifting capacity is 10,000 pounds with the fork attachment. Height is approximately 12 feet with the fork attachment. Loads and unloads trailers, air force pallets, aircraft, and ships in garrison or in the field. Most preferred item of equipment in port operations. A 4-in-1 multipurpose bucket with a 2½-cubic yard capacity. Lifting capacity is 7,500 pounds with the bucket. Fording depth is 60 inches.

Note: Although it is employed primarily as a loader or a forklift, the multipurpose bucket can be employed as a clamshell, a light dozer, or a scraper.

MCI Course 1326

A-8

Appendix A

TX51-19M, TEREX 5K (LCRTF)

Characteristics

The Light Capability Rough Terrain Forklift (LCRTF) TX51-19M, TAMCN B2566 is a diesel engine powered, self-contained, rough terrain forklift manufactured by TEREX Lift Trucks, a division of Terex American. Other characteristics of the TEREX are listed below: •

Smallest forklift in the Marine Corps with a gross vehicle weight of 13,500 pounds

•

Full time four-wheel drive and the front axle (limited slip differential) drives the rear axle (locked differential) thru a drive shaft

Illustration

An illustration of the TEREX TX51-19M is shown below:

Capabilities

The mission of the TEREX TX51-19M is to load and unload palletized cargo from trucks, trailers, aircraft, ships, and ISO containers. It is equipped with front (two-wheel), crab, or 4-wheel steer. A few other capabilities of the TEREX TX51-19M include having a maximum • • •

MCI Course 1326

Lifting capacity is 5,070 pounds. Lifting height is 18 feet and 9 inches. Reach forward is 10 feet and 9 inches (measured from the front tires).

A-9

Appendix A

Skytrak, Extended Boom Forklift (MMV)

Characteristics

The Skytrak, Extended Boom Forklift (MMV) is a diesel powered, fourwheel drive, rubber tired forklift that incorporates a three section telescoping boom. Other characteristics of the MMV are listed below: • • • • •

Load moment indicator (LMI) system that continually monitors the load on the rear axel Three steering selections—two-wheel, four-wheel, and crab steering Equipped with a quick disconnect system for the forklift attachments Two fork attachments—7k and an 11k fork carriage Maximum lifting height is 42 feet and 4 inches

Note: The 7k Carriage has a maximum capacity of 7,000 pounds at a 48-inch load center and the 11k carriage has a maximum capacity of 11, 000 pounds at a 24-foot load center.

Illustration

An illustration of the MMV is shown below:

Capabilities

The MMV is designed for loading and unloading trucks, ships, aircraft, and containers. It may also be used in warehouse operations. It can ford a depth of 30 inches and a maximum forward boom reach of 30 feet from the front tires.

MCI Course 1326

A-10

Appendix A

Caterpillar 130G Road Grader

Characteristics

The Caterpillar 130G Road Grader, TAMCN B1082 has a 12-foot moldboard that can be used for leveling, mixing, and spreading materials. It is also equipped with an 11-tooth scarifier that can be used for ripping light concrete, asphalt, and frozen ground.

Illustration

An illustration of the 130G Grader is shown below:

Capabilities

The grader performs a variety of different grading techniques. Some of these techniques are listed and described in the table below: Technique Right-Hand Leveling Left-Hand Leveling Bank Sloping Wet Ditch Cleaning Military Road Construction

Description Set the blade to cast material to the outside of the left rear wheels. Set the blade to cast the material to the outside of the right rear wheels. Adjust blade to the side of the machine in a vertically set position. Rotate with a forward pitch. Offset to a crab-steering position to keep the wheels away from softer material. A single lane road is 11½ feet wide from shoulder to shoulder with a 1-foot ditch. From ditch bottom to top shoulder, the edge is 4 feet on either side of the road.

Note: To avoid blade or machine structure damage, take special care when setting the blade to perform bank sloping operations.

MCI Course 1326

A-11

Appendix A

1150E Crawling Tractor

Characteristics

The MC1150E Crawling Tractor, TAMCN B2460 is manufactured by J.I. Case. It is a small dozer with many uses. Its six-way blade and easy transportability make this dozer very useful for smaller jobs. Other characteristics of the MC1150E are listed below: •

A full-tracked, low speed tractor that is practically identical to the MC1155E, except it has a blade instead of a bucket.

•

Attachments include an angle/tilt blade and a 30,000-pound winch.

Illustration

An illustration of the MC1150E is shown below:

Capabilities

Classified as a small dozer, capabilities of the 1150E are listed below: • • • •

MCI Course 1326

Light dozer work—clearing, grubbing, and stripping Removes small trees and brush Pushes and pulls loads Recovers mired vehicles

A-12

Appendix A

1155E Tracked Scooploader

Characteristics

The MC1155E Tracked Scooploader, TAMCN B2464 is also manufactured by J.I. Case. It has a 4-in-1 hydraulically controlled 1¾-cubic yard multipurpose bucket and a 30,000-pound capacity hydraulically operated winch.

Illustration

An illustration of the MC1155E is shown below:

Capabilities

The 4-in-1 bucket is designed to perform dozing, scraping, bucket, and clamshell operations. The winch provides 50 to 100 percent greater line pull than the tractor. Other capabilities of the MC1155E are listed below: • • • • • • •

MCI Course 1326

Designed mainly for use as a loader Loads scrapers using the clam to dump material A maximum height of 11 feet when using the clam Work area must be kept level when loading haul units Dump material placed in the bucket using the roll bucket or the open clam method Uproots trees and stumps, hoists and skids fallen trees, and frees mired equipment Well-suited for constructing field artillery positions due to its lifting and carrying capacity for placement of materials

A-13

Appendix A

D7G Crawling Tractor

Characteristics

Characteristics of the Caterpillar D7G Crawling Tractor, TAMCN B2462 are listed below: • • • •

Illustration

Largest, most powerful dozer employed by the Marine Corps Medium class, full-tracked dozer Weighs approximately 48,000 pounds Attachments include a blade, a winch, a ripper, and a drawbar

An illustration of the D7G is shown below:

Continued on next page

MCI Course 1326

A-14

Appendix A

D7G Crawling Tractor, Continued

Capabilities

The D7G is particularly well-suited for the operations listed in the table below: Operation Clearing

Description Consists of clearing all trees, brush, vegetation, and boulders. Due to its power and size, the D7G is ideal for tree removal: • Small trees (2 to 4 inches in diameter)—removal is easily performed. • Medium trees (4 to 10 inches in diameter)—removal requires a little more time and a few more steps. Average clearing time per tree is 2 to 9 minutes. • Large trees (10 inches or greater in diameter). Requires more time and three or four cuts. A ramp is built to push the tree over. Average clearing time per tree is 5 to 20 minutes.

Stripping

Grubbing Side Hill Excavation Ditching Back-Filling Winch

Ripping

MCI Course 1326

• Embedded boulders. Removal is similar to removing large trees. Consists of removing and disposing objectionable topsoil and sod. Topsoil is considered the first 2 to 4 inches of soil. The material removed is referred to as spoil. Stockpile good topsoil and sod for later use on bare areas for dust, erosion control, and camouflage purposes. Consists of uprooting and removing roots and stumps. It is best performed with the D7G dozer. Best performed with a dozer with an angle blade (MC1150E) or a tilt blade (D7G) for casting material to the side. Tilt and angle blade dozers will cut "V" ditches and flatbottomed ditches. Constructs culverts, bridge abutments, bunkers, and shelters of all kinds. A maximum pull of 80,000 pounds. (The one-inch rope installed has maximum pull strength of 89,800 pounds.) The winch can be spooled with 1- to 19-inch wire rope. The ripper attachment is equipped with three removable teeth and has a maximum penetration of 29 inches.

A-15

Appendix A

M9 Armored Combat Earthmover

Characteristics

Unfortunately the D7G and 1150 series dozers lack speed, mobility, and armor protection. To fill this gap, a new item of engineer equipment has come on line to overcome these shortcomings—the M9 armored combat earthmover (ACE). Other characteristics of the M9 ACE are listed below: • • • • •

Illustration

Bowl will carry 8.7 cubic yards of material. Powered by a Cummins 8-cylinder diesel engine with a Clark transmission and is equipped with a 35,000-pound line pull winch. A SINGARS radio provides communication onboard the vehicle. The torque and track design make this item less powerful than the standard bulldozer type where torque and traction are common features. Mobility and versatility are greatly improved.

An illustration of the M9 ACE is shown below:

Continued on next page

MCI Course 1326

A-16

Appendix A

M9 Armored Combat Earthmover, Continued

Capabilities

The ACE is designed as a multipurpose, mobile earthmover that can perform operations in somewhat more hostile environments without threat from small arms fire. Other capabilities of the ACE are listed below: • • • • • • • •

High speeds for an earthmover (30 mph) Air transportable in a C-130 aircraft Can “swim” 3 mph Maximum range of 230 miles on secondary roads on a full tank of fuel (134 gallon) A light-armored dozer Transports soils and other materials in the bowl In hostile areas due to its protection from small arms fire When increased mobility is required and decreased traction is acceptable (compared to a conventional dozer such as the 1150E)

The ACE performance depends largely on the level of experience of the operators. As an equipment chief, you must understand it will take a considerable amount of time to train your Marines to operate and maintain proficiency on this item of equipment. Use it as much as possible to learn its capabilities and features. Make sure experienced personnel are readily available to accept assignments using this unique item of equipment.

MCI Course 1326

A-17

Appendix A

420D IT Backhoe Loader

Characteristics

Illustration

Characteristics of the 420D IT Backhoe Loader (BHL), TAMCN B2483 are listed below:

•

Fully hydraulic, rough terrain backhoe/loader, manufactured by Caterpillar

•

Equipped with manually selected all wheel drive (AWD) components, taking 80W90

•

Front axle oscillates 11 degrees left or right from center, and the rear axle is rigid mounted

•

Critical asset that provides the ground combat element with a light multipurpose excavating capability

•

Can negotiate a grade up to 35 degrees and has a maximum ground clearance of 12 inches

•

Equipped with a roll over protective structure (ROPS)

An illustration of the 420D IT BHL is shown below:

Continued on next page

MCI Course 1326

A-18

Appendix A

420D IT Backhoe Loader, Continued

Capabilities

The primary mission of the 420D IT Backhoe Loader is to provide units with assistance in ditching, trenching operations, and dozing, scraping, clamshell, and bucket operations. Further description of the 420D IT capabilities are listed in the table below: Operation Flat Bottom Ditching

Loading and Clamshell Grading and Leveling

MCI Course 1326

• • • • • • •

A-19

Description Fighting positions Basic ditches for roads Footers Loading a haul unit Moving earth or other material Dozing or scraping operations Job site maintenance

Appendix A

621B Scraper

Characteristics

The 621B Scraper, TAMCN B1922 consists of a two-section tractor/scraper combination. The empty scraper weighs 66,590 pounds and has a maximum load capacity of 48,000 pounds. The total weight capacity is 114,590 pounds loaded. It is powered by a 6-cylinder diesel engine and has a maximum speed of 26 mph. The unit can ford a depth of 60 inches. The 621B Scraper is a self-loading haul unit used extensively in cut and fill operations.

Illustration

An illustration of the 621B Scraper is shown below:

Capabilities

Scrapers move a lot of soil materials and provide cut and fill for the base of construction surfaces. Finished slopes, smoother cuts, and ditches can be created using a grader that provides many angles of cut and fill by pushing and pulling smaller amounts of soil materials to a finished grade. Other capabilities of the scraper are listed below: • • •

An economical haul distance of 1,500 to 7,000 feet Spreads up to 9 inches of material Carries 14 cubic yards struck loaded and 18 cubic yard heap loaded Type Struck Heap

Definition Material is level with sides of the bowl Material is higher than sides of the bowl Continued on next page

MCI Course 1326

A-20

Appendix A

621B Scraper, Continued

Loading Methods

The 621B Scraper also employs various methods of loading. These methods are described in the table below: Method Flat Terrain Downhill Straddle Pump Push Bucket Loaders

MCI Course 1326

Description A common method—opens the bowl 12 to 18 inches and moves forward at a constant speed Increases the production Speeds production on the third pass Best method to use in sand Provides maximum production From material stockpiles

A-21

Appendix A

Engineer Equipment Trailer (EET)

Characteristics

Characteristics of the Engineer Equipment Trailer (EET), TAMCN B are listed below: • • • • • • •

Fulfills a requirement to equip forces with the required mobility resources The prime mover for the trailer is the medium tactical vehicle replacement (MTVR) family of 7-ton trucks Move/transport the backhoe loader (BHL), the light-capability rough terrain forklift (LRTF), or ammunition loads Highway payload 10 tons at 45 mph Improved road (graded gravel) payload 10 tons at 35 mph Off road payload 10 tons at 15 mph QUAD-CON container load bed configuration capable

Note: The LRTF is essential for the handling and movement of ammunition, small container, and cargo within artillery units.

Illustration

An illustration of the EET is shown below:

Continued on next page

MCI Course 1326

A-22

Appendix A

Engineer Equipment Trailer (EET), Continued

Capabilities

This trailer is designed to transport the BHL or the LRTF. The trailer is capable of hauling 10 tons on highways, improved roads (graded gravel), and off roads. Other capabilities of the EET are listed below: • • •

Reduces transit time and vulnerability to enemy action. Can be towed over improved roads (graded gravel) with loads up to 10 tons. Design, configuration, and capability of the trailer permits off-road use.

Note: Should be operated only after being serviced and equipped for existing climatic conditions.

MCI Course 1326

A-23

Appendix A

(This page intentionally left blank.)

MCI Course 1326

A-24

Appendix A

ENGINEER MAINTENANCE AND OPERATIONS REVIEW LESSON EXAMINATION Review Lesson

Introduction

The purpose of the review lesson examination is to prepare you for your final examination. We recommend that you try to complete your review lesson examination without referring to the text, but for those items (questions) you are unsure of, restudy the text. When you finish your review lesson and are satisfied with your responses, check your responses against the answers provided at the end of this review lesson examination.

Directions

Select ONE answer that BEST completes the statement or that answers the item. For multiple choice items, circle your response. For matching items, place the letter of your response in the space provided.

Item 1

What is the document that describes the unit's mission statement, organizational structure, the manpower resources, and the echelons of maintenance? a. b. c. d.

Item 2

Table of assets (T/A) Table of organization (T/O) Table of equipment (T/E) Table of mission (T/M)

The element that allows for the review of records and reports is a. b. c. d.

command. resources. information. production. Continued on next page

MCI Course 1326

R-1

Review Lesson Examination

Review Lesson, Continued

Item 3

Four of the seven maintenance resources are parts and supplies, tools and equipment, publications, and facilities. What are the remaining three resources? a. b. c. d.

Item 4

The two types of internal inspections are formal and a. b. c. d.

Item 5

commanding officers. informal. instructional. surprise.

By following ____________________, the unit will ensure that adequate preparation and normal operations are maintained. a. b. c. d.

Item 6

Funds, personnel, and time Funds, property, and time Funds, personnel, and supervisors Funds, personnel, and training

technical publications Marine Corps Orders inspection checklists internal inspection lists

A valuable tool to determine your unit’s effectiveness in its maintenance and maintenance management programs is a. b. c. d.

a. Mission Performance Standards Individual Training Standards Mission Accomplishment Internal Inspections Continued on next page

MCI Course 1326

R-2

Review Lesson Examination

Review Lesson, Continued

Item 7

Which shop section controls all parts issue and storage and may be located in a small separate shop? a. b. c. d.

Item 8

When selecting a site for field maintenance operations, which factor is considered when congestion in a maintenance area impairs efficiency and safety? a. b. c. d.

Item 9

Accessibility Location Space requirements Terrain

Which individual will establish a position of common services to avoid duplication of effort when possible? a. b. c. d.

Item 10

Administration Issue Point Maintenance Shop Office/Operations

Supply officer S-3 operations officer Executive officer Maintenance management officer

Which principle of layout for a maintenance area involves deciding which equipment to position inside and outside the compound? a. b. c. d.

Working area Protect personnel Centralize services Issue points Continued on next page

MCI Course 1326

R-3

Review Lesson Examination

Review Lesson, Continued

Item 11

What is the name of the component of the ITS that indicates how well a task should be performed? a. b. c. d.

Item 12

Which component, of the four essential elements of a training program, is the most important? a. b. c. d.

Item 13

Equipment Imagination Personnel Training area/facilities

On the DPR, the _______________ date indicates how critical the equipment is to the unit and specifies when the unit requires the equipment back. a. b. c. d.

Item 14

Condition Performance steps Standard Task

RCVD, received DCD, deadline control DIS, days in shop RDD, required delivery

The DTL is used to reconcile input into a. b. c. d.

SASSY. MUMMS. exceptions report. MIMMS/AIS. Continued on next page

MCI Course 1326

R-4

Review Lesson Examination

Review Lesson, Continued

Item 15

The weekly owning unit TAM report is produced weekly for unit performing ______________ maintenance. a. b. c. d.

Item 16

The weekly maintenance exceptions report quickly pinpoints specific __________ numbers and supply documents numbers when problems exist. a. b. c. d.

Item 17

ERO DTL SASSY EROSOL

What manual would you use to prepare, use, and maintain all forms pertaining to ground equipment operation and maintenance? a. b. c. d.

Item 18

intermediate depot field organizational

MCO P4790.2_ MCO P6100 TM 4700-15/1_ UM 4790-5

What form is maintained in the 696D Motor Vehicle and Engineer Record Folder for a minimum of 30 days, after which it may be destroyed? a. b. c. d.

NAVMC 10523, Engineer Equipment Operational Record NAVMC 10524, Engineer Equipment Operation Log and Service Record NAVMC 10560, Worksheet for Preventive Maintenance and Technical Inspection NAVMC10561, Preventive Maintenance Checks and Services (PM Roster) Continued on next page

MCI Course 1326

R-5

Review Lesson Examination

Review Lesson, Continued

Item 19

The _____ of the NAVMC 10524 is identical to the back of the NAVMC 10523. a. b. c. d.

Item 20

The NAVMC 10523 is held for ______ days and then discarded. a. b. c. d.

Item 21

10 20 30 45

One purpose of the NAVMC _______ is to serve as a guide for limited technical inspections, during both acceptance and repair of equipment. a. b. c. d.

Item 22

front top left back top right

10561 10560 10523 10524

The purpose of the NAVMC _______ is to request modification, calibration, corrective maintenance, PMCS and LTI on all ground equipment within a unit maintenance capability. a. b. c. d.

10560 10561 10245 10244 Continued on next page

MCI Course 1326

R-6

Review Lesson Examination

Review Lesson, Continued

Item 23

A NAVMC 10925 used to requisition parts is called a ____ card transaction. a. b. c. d.

Item 24

All permanent entries on the NAVMC 10561 will be made in what? a. b. c. d.

Item 25

Ink Pencil Marker Highlighter

Something that contributes to the maintenance cycle mission, is the definition of a a. b. c. d.

Item 26

“8” “P” “T” “4”

Modification program. MIMMS/AIS. Administrative program. Maintenance related program.

Which modification category is necessary because the equipment is in danger of being damaged? a. b. c. d.

NORMAL STANDARD URGENT ROUTINE Continued on next page

MCI Course 1326

R-7

Review Lesson Examination

Review Lesson, Continued

Item 27

This system has greatly increased with the advancement of technology and can be tailored to the needs of the unit and managing its Test Measuring Diagnostic Equipment (TMDE) program. What is the system called? a. b. c. d.

Item 28

What form is used to report deficiencies occurring in major weapon systems, secondary, consumable, repairable items, spare, and repair parts? a. b. c. d.

Item 29

LM2 Report Daily Process Report Product Quality Deficiency Report Table of Authorized Material Report

The recoverable item program is used when a. b. c. d.

Item 30

Mechanical system Chart system Card index system Automated system

items that cannot be repaired with current resources available to the field commander. an item that can’t be repaired at the second echelon level. a way to cut your T/E. a convenience for the CO.

TI-4473-14/1 is the reference that provides the guidance on which equipment to be tested under the a. b. c. d.

joint oil analysis program. preventive maintenance program. quality control program. warranted items program. Continued on next page

MCI Course 1326

R-8

Review Lesson Examination

Review Lesson, Continued

Item 31

The T/O, T/E and the ________ are the three key documents to establish a publications library. a. b. c. d.

Item 32

Which type of inventory is conducted when you have identified all the discrepancies and ordered appropriate publications? a. b. c. d.

Item 33

Annual Update Yearly As required

The purpose of the publication control form is for identifying the contents, quantity, and location of publications in a a. b. c. d.

Item 34

technical manual publication library publication listing priority listing

publications listing. publications library. table of authorization. table of equipment.

What form is completed to submit for a change or correction in a publication? a. b. c. d.

NAVMC 10523, Engineer Equipment Operational Record NAVMC 10524, Engineer Equipment Operation Log and Service Record NAVMC 10560, Worksheet for Preventive Maintenance and Technical Inspection NAVMC 10772, Recommended Changes To Publications/Logistics Continued on next page

MCI Course 1326

R-9

Review Lesson Examination

Review Lesson, Continued

Item 35

Items such as filters, corrective maintenance parts, and office supplies are items that are needed to a. b. c. d.

Item 36

A secondary repairable item is an item that can be repaired and put back into the supply system as a shelf item. This item is commonly referred to as which of the following? a. b. c. d.

Item 37

Low-cost item Maintenance float item Pre-expended bin item Preventive maintenance item

Validation and inventorying the ERO parts bin should be completed __________ to ensure the EROSL and the material/parts in each bin should be compared to ensure accuracy. a. b. c. d.

Item 38

assemble a budget. create a new shop. order material. review the LM2 report.

bi-weekly monthly quarterly semi-annually

The most important aspect of being a qualified licensing examiner is to be a graduate from a. b. c. d.

the formal school in the equipment MOS. motor transport or engineer equipment school. any Marine Corps MOS school. basic training. Continued on next page

MCI Course 1326

R-10

Review Lesson Examination

Review Lesson, Continued

Item 39

The _____________ is used to record all licensing issues, to include renewals, duplicates, and upgrades. a. b. c. d.

Item 40

What are the three areas that a licensing applicant must be tested on? a. b. c. d.

Item 41

display a poor attitude. recently had NJP. not have a military identification card. be color blind.

When equipment has been repaired and the serviceable item is to be returned to the owner, you are now in which phase of corrective maintenance? a. b. c. d.

Item 43

Earthmovers, cranes, and forklifts Awareness, equipment procedures, and equipment knowledge Safety, equipment knowledge, and skill performance Physical ability, equipment knowledge, and skill performance

One way to be disqualified from obtaining an operator’s license is to a. b. c. d.

Item 42

action date file license logbook action folder operator history file

Acceptance Induction Active-maintenance Close-out

Which billet is responsible for researching parts, overseeing the layette bins, receiving material and parts, and coordinating with supply? a. b. c. d.

Maintenance personnel MIMMS personnel Quality control Supply personnel Continued on next page

MCI Course 1326

R-11

Review Lesson Examination

Review Lesson, Continued

Item 44

Which process involves confirmation of supply requests still needed, receipts, cancellations, scrounges, and current statuses? a. b. c. d.

Item 45

Recordkeeping procedures and preventive maintenance guidance for engineer ground equipment are found in chapters 2 and 3 of which reference? a. b. c. d.

Item 46

MCO P4790.2_ MCO 4855.10 TM 4700-15/1_ UM-4790-5

Which form is used as the operational log to operate an item of equipment and also used to record the preventive maintenance checks and service entries of petroleum, oil, and lubricants (POL)? a. b. c. d.

Item 47

Validation Evaluation Inspection Examination

NAVMC 10780 NAVMC 10561 NAVMC 10524 NAVMC 10523

Aerial devices and ________________ are the types of equipment that require load testing to be accomplished. a. b. c. d.

bulldozers cranes forklifts winches Continued on next page

MCI Course 1326

R-12

Review Lesson Examination

Review Lesson, Continued

Item 48

During a maximum load test, the crane’s tires must be free from a. b. c. d.

Item 49

During a stability test, swing the crane through a ____ rotation. a. b. c. d.

Item 50

180º 90º 360º 270º

The purpose of an annual condition inspection is to ensure the overall a. b.

c. d.

Item 51

obstruction. the ground. inflation. debris.

electrical components of the equipment have been maintained in a safe and serviceable condition and are functioning properly. structural, mechanical, hydraulic, and electrical components of the equipment have been maintained in a safe and serviceable condition and are functioning properly. structural, mechanical, hydraulic, and electrical components of the equipment have been damaged or misused. structural, mechanical, and hydraulic components have been maintained in a safe and serviceable condition and are functioning properly.

During a no-load test, the ________________ are the main sections tested. a. b. c. d.

hook and ladder hoist and boom boom and outriggers hoist and cab Continued on next page

MCI Course 1326

R-13

Review Lesson Examination

Review Lesson, Continued

Item 52

To be a certifying officer, you must posses the MOS 3510, Motor Transport Officer; 2110, Ordnance Vehicle Maintenance Officer; or a. b. c. d.

Item 53

Before employing engineer equipment, what four things should the equipment chief know a. b. c. d.

Item 54

equipment and personnel capability, mission requirements, operating standards and conditions, and availability of personnel and equipment. mission requirements, operating standards, and operator’s physical condition. mission requirements, operating temperature and conditions, availability of operators, and availability of equipment. operating standards and conditions, availability of personnel and equipment, and capabilities of equipment and personnel.

Which of the following is one of the six areas of supervision? a. b. c. d.

Item 55

0303, Infantry Officer. 1120, Utilities Officer. 1310, Engineer Equipment Officer. 6102, Aircraft Maintenance Officer.

Supervise general support of engineer operations. Conduct engineer equipment operations. Supervise excavation. Determine the equipment required by the mission.

The chief ensures the ____________ is load tested, certified, clearly marked and safety inspected before it is employed. a. b. c. d.

load-lifting equipment trip ticket field operator Continued on next page

MCI Course 1326

R-14

Review Lesson Examination

Review Lesson, Continued

Item 56

What items of equipment are referred to as material handlers? a. b. c. d.

Item 57

Select the definition of “general support” of engineer equipment. a. b. c. d.

Item 58

Forklifts and cranes Cranes and excavators Dozers and graders Backhoes and excavators

Equipment available to support tasks that your mission requires Equipment not available to support tasks your supported units have requested Equipment your supported units would like to have Equipment available to support tasks your supported units have requested

Mission and environmental and natural resources are two a. b. c. d.

phases of corrective maintenance. stages of load test. two types of inventories. job site factors. Continued on next page

MCI Course 1326

R-15

Review Lesson Examination

Review Lesson, Continued

Solutions

The table below provides the answers to the review lesson examination items. If you have any questions, refer to the reference page listed for each item.

Item Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Answer b c a b c a c c d a c c d d d a c a c b b c d a d c d c a a

Reference Page 1-5 1-6 1-9 1-14 1-16 1-18 1-21 1-21 1-23 1-24 1-34 1-36 1-44 1-48 1-52 1-55 1-63 1-66 1-69 1-71 1-74 1-76 1-79 1-81 2-3 2-5 2-10 2-12 2-13 2-14 Continued on next page

MCI Course 1326

R-16

Review Lesson Examination

Review Lesson, Continued

Solutions, continued

Item Number 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58

MCI Course 1326

Answer c b b d a b a a b c a d d a c c b b c b b c a d a a d c

R-17

Reference Page 2-20 2-23 2-26 2-27 2-32 2-34 2-36 2-42 2-43 2-47 2-48 3-8 3-12 3-14 3-22 3-24 3-33 3-35 3-36 3-37 3-38 3-39 3-46 3-45 3-49 3-49 3-51 3-47

Review Lesson Examination