//UNCLASSIFIED// OPERATOR/SUPERVISOR PMCS BRIEF //UNCLASSIFIED// //UNCLASSIFIED// TERMINAL LEARNING OBJECTIVE ACTION: To understand Operator and Supervisor responsibilities and how to properly fill out a DA Form 5988-E and DA Form 2404 IAW DA PAM 750-8 (TAMMS). CONDITIONS: Given a classroom environment, a 5988-E, a 2404, an extract from DA PAM 750-8, and motivated Paratroopers willing to learn. STANDARDS: Soldiers will understand their responsibilities as operators and be able to properly fill out a DA Form 5988-E or DA Form 2404 while conducting PMCS. //UNCLASSIFIED// //UNCLASSIFIED// OPERATOR AND CREW RESPONSIBILITIES To have a successful field maintenance program that supports mission accomplishment, leaders must start with their operators and crews. Operators and crews must know how to detect and report malfunctions as well as operate equipment properly and safely. An atmosphere of “pride” and “ownership” on the part of operators and crews for equipment enables that to happen. A disciplined routine and a self-motivated pursuit of excellence help to ensure operators and crews performing PMCS achieve the Army Maintenance Standard. //UNCLASSIFIED// //UNCLASSIFIED// OPERATOR AND CREW RESPONSIBILITIES Do operators and crews… a. Know their responsibility in achieving the Army Maintenance Standard for their assigned equipment and, on a teamwork basis, for all unit equipment? b. Have appropriate TMs on hand and in use during PMCS and scheduled services? c. Ensure that all equipment faults are identified and corrected? If faults identified are beyond operator and crew capabilities, do crews report them to field maintenance personnel? d. Understand the fault-reporting process? e. Verify that all ASIOE are on hand or on order? f. Follow TM safety procedures when operating and maintaining the equipment? g. Have up-to-date licenses to operate all assigned equipment? h. Keep the equipment in a clean and secured condition? i. Have the necessary facilities, manuals, tools, and time for maintenance? j. Participate with field maintenance personnel during services? k. Have adequate supervision by technically competent leaders? //UNCLASSIFIED// //UNCLASSIFIED// OPERATOR AND CREW RESPONSIBILITIES As a vehicle operator, YOU are responsible for the following: • Safely operating your vehicle and complying with applicable federal, state, local, and HN laws and regulations. • Conducting before-, during-, and after-operation inspections of your vehicle. • Following all operator maintenance outlined in the appropriate vehicle technical manual(TM) (Army) or technical order (TO) (Air Force). • Caring for and cleaning your vehicle and its equipment at all times. • Ensuring the safety and comfort of your passengers (includes ensuring that seat and shoulder belts are fastened). The senior occupant will ensure that passengers comply. • Ensuring the security of the vehicle and cargo entrusted to you. • Exercising common sense. • Notifying your supervisor or noncommissioned officer (NCO) of any change in your status (for example, inability to drive due to physical condition or withdrawal of your state operator's license). • Remember, you are subject to corrective action by your commander/squadron commander for incidents of abuse, misuse, and damage to unit-assigned vehicles. FROM TC 21-305-20 – MANUAL FOR THE WHEELED VEHICLE OPERATOR //UNCLASSIFIED// //UNCLASSIFIED// 5988-E BREAK DOWN //UNCLASSIFIED// //UNCLASSIFIED// EQUIPMENT DATA. ADMIN NUM, EQUIP MODEL, EQUIP NOUN, EQUIP NSN, EQUIP SERIAL NUM, and REGISTRATION NUM (See note) is retrieved from the equipment data file. No entries from the operator/crew chief are needed in these areas. The operator/crew chief must ensure that data contained in these areas are correct prior to performing PMCS. If any fields are not current, notify the ERPS Clerk so they can update the data fields through the GCSS-A process. *Registration Number no longer required to track. //UNCLASSIFIED// //UNCLASSIFIED// SERVICE DATA. SERVICE TYPE. Reflects the type of the service that is due next. SERVICE DUE. Reflects the date the next service is due. READING DUE. Reflects the reading type (m - miles, k - kilometers h - hours) and the number when the next service is due. (If applicable) Operators must verify any upcoming services and coordinate completion at the appropriate level. *If equipment is past the service late date, it must be placed in an Admin Deadline status until resolved IAW DA Pam 750-8, Section II. //UNCLASSIFIED// //UNCLASSIFIED// DA FORM 5988-E WITH NO FAULTS //UNCLASSIFIED// //UNCLASSIFIED// 1 2 1. Use the same worksheet for more than 1 day. If no faults are found during the BEFORE OPERATION checks in the PMCS, write the calendar date under the fault description column and initial in the far right box. 2. When no faults are found, this worksheet can be used for more than 1 day even if the worksheet was used for concurrent PMCSs; that is, W/M. Just place the first letter of the type of PMCS performed (W/M) under the corrective action column by that day’s date in the fault description column. //UNCLASSIFIED// //UNCLASSIFIED// DA FORM 5988-E WITH FAULTS //UNCLASSIFIED// //UNCLASSIFIED// CHECK HISTORICAL FAULTS PRIOR TO ANNOTATING NEW FAULTS. FAULTS MAY ALREADY BE CAPTURED. //UNCLASSIFIED// //UNCLASSIFIED// PARTS REQUESTED. The system checks the Document Control Register and prints any parts that have already been ordered against the admin number on the worksheet. Operator/crew chiefs and supervisors review this section and take appropriate action as required. //UNCLASSIFIED// //UNCLASSIFIED// Notification Number. The notification number under which the required part has been ordered. Notif Date. The date a fault was created. Fault Description Description of the fault. Tech Status. Indicates whether a fault is a deficiency or a deadline. //UNCLASSIFIED// For Maintenance use. //UNCLASSIFIED// FAULT. The fault number for which the part is requested. Pri. The priority for item ordered. Material Description Description of the part NIIN. ordered. Requested National Item Date. Identification The date a Number. repair part was ordered. //UNCLASSIFIED// QTY Ord/Iss. Due-in quantity for the part on order or the quantity received. Issued Date The date that all parts were received for document number listed or transaction closed. //UNCLASSIFIED// ANNOTATING A NEW FAULT //UNCLASSIFIED// //UNCLASSIFIED// 1 1. ITEM NUM. Write the PMCS item number that applies to the fault listed in this column. If the PMCS has no item numbers, list the page, paragraph, or sequence number. //UNCLASSIFIED// //UNCLASSIFIED// TECHNICAL STATUS X Equipment is “not ready/available” or “Not Mission Capable.” / Indicates a material defect other than a deficiency that must be corrected to make the item completely serviceable. - Inspection or check that is due, but not yet accomplished. X Indicates a deficiency. However, equipment may be operable under specific limitations as directed by the commander until corrective action can be accomplished. This is a one time use and can only annotated by the commander or commander’s representative. The commander or commander’s representative verifies the deficiency on a daily or mission basis, whichever is more frequent. A circle X is ALWAYS temporary and will go back to an X status when the daily or mission dispatch is over. E Indicates a safety deficiency. Also requires to be “circle X’d” by the commander in order to be operated. This fault is entered on the DA Form 5988-E by the ERPS clerk. //UNCLASSIFIED// //UNCLASSIFIED// 1 2 FAULT DESCRIPTION. 1. If a fault can be repaired, stop the PMCS and correct the fault. Do not enter faults that have been repaired or already listed on the worksheet. Continue the PMCS to make sure no other faults exist. 2. Briefly describe fault. Skip one or two lines between faults. This gives maintenance room to note actions they take. 3. When more than one TM covers the equipment, draw a line under the last entry for one TM. Under the line, write the TM number of the manual to be used next. After the PMCS is finished and all faults that could not be fixed are listed, give the form to the maintenance supervisor. //UNCLASSIFIED// //UNCLASSIFIED// 1 2 3 4 1. Corrective Action. Explain corrective actions taken. 2. Initial. Initials are only used when faults are corrected. 3. If 5988-E is used for changing “X” condition (Circle X): Print “Cleared for Limited Operations”. Provide the specific limits under which equipment can be operated. For example: limits may involve speed, type of mission, distance, weather, or time. • Deficiencies changed to a circle X return to an X status at the end of the day or mission. • Circle X conditions are for one-time operation or mission (common sense must be used). 4. When a deficiency is corrected or changed to a circle X, enter the miles and calendar date in the corrective action column at the end of the dispatch or operation. //UNCLASSIFIED// //UNCLASSIFIED// 2 1 12345678910 1. INSPECTOR’S LIC #, SIGNATURE and TIME. When a deficiency or shortcoming is found, the time and signature of supervisor and rank are required. This signature keeps the form from being used past current dispatch. 2. The person performing the inspection inputs their personnel number into the “Inspector Lic #” block. //UNCLASSIFIED// //UNCLASSIFIED// QUESTIONS? //UNCLASSIFIED// //UNCLASSIFIED// 2404 BREAK DOWN //UNCLASSIFIED// //UNCLASSIFIED// //UNCLASSIFIED// //UNCLASSIFIED// 1 2 4a 4b 3 4c 4d 5 6 1. Enter the name of the unit to which the equipment belongs. 2. a. Enter the noun abbreviation and the model of the equipment. b. For watercraft, use the noun abbreviation and Hull Design Number. 3. REGISTRATION/SERIAL/NSN. a. Enter the serial or registration number. Enter the NSN when no serial or registration number is available. b. For watercraft, enter the DA Hull Number. 4 a. MILES. When a deficiency or a shortcoming is found, enter the miles or kilometers on the equipment’s odometer at the end of operation. Round to the nearest mile or kilometer. Enter the letter K before the number if the reading is kilometers. Leave blank if the item does not have an odometer or if no faults are found. b. HOURS. When a deficiency or a shortcoming is found, enter the hour meter reading at the end of operation. Leave blank if hours do not apply to the equipment or if no faults are found. c. ROUNDS FIRED. Leave blank. d. HOT STARTS. Leave blank. 5. DATE. Enter the calendar date the deficiency or shortcoming was found. 6. TYPE INSPECTION. Enter PMCS. a. Use the same DA Form 2404 for more than 1 day. If no faults are found during the BEFORE OPERATION checks in the PMCS, enter the date in column c. If no faults are found DURING or AFTER OPERATION, initial in column e. b. When no faults are found, this form can be used for more than 1 day even if form was used for concurrent PMCSs, for example, W/M. Just place the first letter of the type of PMCS performed (W/M) in column d, by the days date in column c after the PMCS was performed. //UNCLASSIFIED// //UNCLASSIFIED// 7 7. APPLICABLE REFERENCE. TM NUMBER, TM DATE. a. Enter the number and date of the PMCS TM. When two TMs cover an item, enter the second TM number and date in the second number and date block. b. When the manual has changes, print W/C and the latest change number after the TM number. Then, enter the latest change date in the TM date block. //UNCLASSIFIED// //UNCLASSIFIED// 8a 9a 8 a. SIGNATURE (Person(s) performing inspection). When a deficiency or shortcoming is found, the operator or supervisor signs and enters rank. A signature in this block keeps the form from being used past current dispatch. 8 b. TIME. Leave blank or use as needed locally. 9 a. SIGNATURE (Maintenance Supervisor). Maintenance supervisor or the commander’s designated representative signs when corrective action is taken. 9 b. TIME. Leave blank or use as needed locally. For a missile system and missile subsystems reported under AR 700–138, chapter 4, enter the time when item was found to be NMC. 10. MANHOURS REQUIRED. Leave blank or use as needed locally. //UNCLASSIFIED// //UNCLASSIFIED// a b TM ITEM NO. a. a. Enter the PMCS item number that applies to the fault listed in column c. If the PMCS has no item numbers, list the page, paragraph, or sequence number. Circle the number if the fault is listed in the Equipment is not ready/available if column or Not Mission Capable if column of the PMCS. If the PMCS has no ready/available or NMC column, circle the TM item number, page, paragraph number of any fault that makes the equipment NMC. b. Pubs or TM section other than PMCS may be required for safety faults or local dispatching. For example, AR 385–10 lists safety checks that may not be in the PMCS. Those faults are not counted as NMC for DA Form 2406 (Materiel Condition Status Report) unless they are in the PMCS not ready column or the NMC column. But, list them if a problem is found with one of them. c. For those faults not covered by the PMCS, leave this column blank. STATUS b. Enter the status symbol that applies to the fault or deficiency. //UNCLASSIFIED// //UNCLASSIFIED// c d e DEFICIENCIES AND SHORTCOMINGS c. a. If a fault that can be repaired is found, stop the PMCS and correct the fault. Do not enter faults that have been repaired on DA Form 2404. Continue the PMCS to make sure no other faults exist. b. Briefly describe the fault. Skip one or two lines between faults. This gives maintenance room to note actions they take. c. When more than one TM covers the equipment, draw a line under the last entry for one TM. Under the line, write the TM number of the manual to be used next. After the PMCS is finished and all faults that could not be fixed are listed, give the form to the maintenance supervisor. d. When using one DA Form 2404 for more than one item of equipment, enter the serial number or administration number for the item with the fault. Write the fault on the line below the serial number. When faults not covered by the PMCS are listed, add the pub that covers them; for example, SOP or AR 385–10. CORRECTIVE ACTION d. Explain corrective actions taken. INITIAL WHEN CORRECTED e. The mechanic initials any faults that have been fixed. The initials go on the last line for the entry in column d. The maintenance supervisor reviews the faults corrected and those still not fixed to decide what other action is needed. For quality control, the inspector or a designated representative checks all corrected status symbol X faults. The inspector then initials the status symbol. //UNCLASSIFIED// //UNCLASSIFIED// //UNCLASSIFIED// //UNCLASSIFIED// SUMMARY •UNDERSTAND OPERATOR AND SUPERVISOR RESPONSIBILITIES DURING THE PMCS PROCESS IAW DA PAM 750-1 AND DA PAM 750-3 •KNOW HOW TO PROPERLY FILL OUT A DA FORM 5988-E AND A DA FORM 2404 IAW DA PAM 750-8 //UNCLASSIFIED// //UNCLASSIFIED// QUESTIONS? //UNCLASSIFIED// //UNCLASSIFIED// PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) //UNCLASSIFIED// //UNCLASSIFIED// PREVENTIVE MAINTENANCE CHECKS AND SERVICES THE APPLICATION OF SYSTEMATIC PROCEDURES FOR THE INSPECTION, DETECTION, AND CORRECTION OF BEGINNING FAILURES BEFORE THEY DEVELOP INTO MAJOR DEFECTS. THE CORNERSTONE OF A SOUND UNIT MAINTENANCE PROGRAM IS THE OPERATOR/CREW PERFORMING THE PMCS FROM THE APPLICABLE -10 SERIES TECHNICAL MANUALS. //UNCLASSIFIED// //UNCLASSIFIED// TWO LEVELS OF MAINTENANCE: FIELD MAINTENANCE (-10/-20/-30) SUSTAINMENT MAINTENANCE //UNCLASSIFIED// //UNCLASSIFIED// There are five primary PMCS intervals we are concerned with for the purposes of this class: BEFORE DURING AFTER WEEKLY MONTHLY //UNCLASSIFIED// //UNCLASSIFIED// BEFORE checks and services are performed prior to the equipment leaving its containment area or performing its intended mission. DURING checks begin when the equipment is being used for its intended mission. AFTER checks and services begin when the equipment is taken out of its mission mode or returned to its containment area. WEEKLY checks and services are performed once per week, normally during the Command Maintenance period as annotated on the training schedule. MONTHLY checks and services are performed once per month, normally during the Command Maintenance period as annotated on the training schedule. //UNCLASSIFIED// //UNCLASSIFIED// OTHER SERVICES PERFORMED: Non Combat Operations Maintenance Plan (NCOMP) (Operator) HOURS BASED * QUARTERLY * (Bi)SEMI-ANNUAL * ANNUAL * BIENNIAL * *These services require a qualified equipment maintainer to perform. They are to be scheduled and placed on the training schedule. //UNCLASSIFIED// //UNCLASSIFIED// MAINTENANCE LIFECYCLE EQUIPMENT PUT BACK ON LINE GCSS-A DATA UPDATED BEFORE OPERATIONS PMCS FAULT IDENTIFIED/ FAULT VERIFIED BY MECHANIC QUALITY ASSURANCE TO 10/20 PARTS AND JOB HANDED TO MECHANIC TO INSTALL PARTS ORDERED BY ERPS CLERK INPUT INTO SAMS DATABASE DCR UPDATED PARTS RECEIVED BY ERPS CLERK GCSS-A UPDATED PARTS RECEIVED THRU SUPPLY SUPPORT ACTIVITY //UNCLASSIFIED// //UNCLASSIFIED// ARMY MAINTENANCE STANDARD The Army has one maintenance standard, TM xx-10/20 - Equipment is fully mission capable (FMC) if… A) Preventive Maintenance Checks and Services (PMCS) complete B) Services and repairs completed C) Parts and supplies needed on valid requisition D) Higher level valid support maintenance request E) All authorized BII and COEI present and serviceable //UNCLASSIFIED// //UNCLASSIFIED// The -10 Technical (Operators) Manual TM 9 - 2320 - 387 - 10 9 - Is the proponent issuing the equipment (9 is ordnance, 5 is engineer and etc.) 2320 - Is the type of equipment (2320 is wheeled, 2330 is trailer, 2350 is tracked, etc.) 387 - Is the model of the equipment (here the M1114, M1151etc.) 10 - is the level of maintenance covered (10 is operator, 20 is organizational maintenance, etc.) //UNCLASSIFIED// //UNCLASSIFIED// BASIC SECTIONS OF THE TECHNICAL MANUAL 1. TABLE OF CONTENTS 2. CAUTIONS AND WARNINGS 3. PMCS OR EQUIVALENT TABLE 4. OPERATING PROCEDURES 5 TROUBLESHOOTING PROCEDURES //UNCLASSIFIED// //UNCLASSIFIED// TABLE OF CONTENTS Self explanatory - tells the location of the topics covered in the manual. //UNCLASSIFIED// //UNCLASSIFIED// PRINCIPLES OF OPERATION Use these tables to gain an understanding of the operations of certain systems of the equipment. Understanding how it works will result in proper care and operation of the equipment. Topics can include, but are not limited to: 1. Drive train operation. 2. Fuel system operation. 3. Cooling system operation. 4. Starting system operation. 5. Generating system operation. 6. Battery system operation. 7. Service brake system operation. 8. Steering control system operation. //UNCLASSIFIED// //UNCLASSIFIED// OPERATING INSTRUCTIONS Before you attempt to operate your equipment (which is required as part of PMCS), make sure you are familiar with the location and function of all controls and indicators. The location and function of controls are described in this section. The equipment has been designed to operate safely and efficiently within the limits specified in the TM. Operations beyond these limits are prohibited IAW AR 70-1. Injury to personnel or damage to equipment may result. //UNCLASSIFIED// //UNCLASSIFIED// LUBRICATION INSTRUCTIONS Some of the newer manuals contain lubrication instructions in them. These show in detail where to perform certain lubricating operations, what POL products to use and the interval at which they are to be performed. If your -10 Manual does not contain these instructions, use the -12 Lubrication Order. //UNCLASSIFIED// //UNCLASSIFIED// TROUBLESHOOTING There are many troubleshooting steps that operators can perform to place their equipment back into the fight. These steps can be found in the operator manual. If all of these steps are performed, troubleshooting and repair time by unit maintenance can be reduced. //UNCLASSIFIED// //UNCLASSIFIED// MAINTENANCE PROCEDURES Just as there are troubleshooting steps at the operator level, there are many maintenance procedures that are to be performed at the operator level as well. These are included in the operators manual. Some are: Parking brake adjustment. Battery maintenance. Emergency procedures. Towing procedures. //UNCLASSIFIED// //UNCLASSIFIED// TROUBLESPOTS Even though covered in the manual, these areas are far too often overlooked as they are listed on the page before the PMCS tables begin. 1. Check all bolts, nuts, and screws. If loose, bent, broken, or missing, either tighten or report conditions to unit maintenance. 2. Look for loose or chipped paint, and rust or cracks at welds. Remove rust and loose paint, and spot-paint as required. If a cracked weld is found, report situation to unit maintenance. 3. Inspect electrical wires and connectors for cracked or broken insulation. Also look for bare wires and loose or broken connections. Tighten loose connections. Report other problems to unit maintenance. 4. Check hoses and fluid lines for wear, damage, and leaks. Ensure clamps and fittings are tight. 5. Check hinges for security and operation. 6. Check data, caution, and warning plates for security and legibility. //UNCLASSIFIED// //UNCLASSIFIED// FLUID LEAKAGE Wetness around seals, gaskets, fittings, or connections indicates leakage. A stain also denotes leakage. If a fitting or connector is loose, tighten it. If broken or defective, report it. Use the following as a guide: Class I - Leakage indicated by wetness or discoloration, but not great enough to form drops. Class II - Leakage great enough to form drops, but not enough to cause drops to drip from item being checked/inspected. Class III - Leakage great enough to form drops that fall from the item being checked/inspected. CAUTION Operation is allowable with Class I or II leakage except for brake system (no, Class I or II diesel fuel leaks do not deadline the equipment). Any brake fluid leakage deadlines the equipment. When operating with Class I or II fluid leaks, check fluids more frequently. Class III leaks must be reported immediately to unit maintenance. //UNCLASSIFIED// //UNCLASSIFIED// PMCS TABLE These tables provide detailed step-by-step instructions on the performance of operator level Preventive Maintenance Checks and Services. //UNCLASSIFIED// //UNCLASSIFIED// ITEM NUMBER The item number is annotated on the DA Form 5988E when faults are found. This allows unit maintenance personnel to get a good idea about what the operator is identifying. This is important because operators aren’t very descriptive about faults. Some of this is due to time constraints and some is due to limited space on the DA Form 5988E. //UNCLASSIFIED// //UNCLASSIFIED// INTERVAL This is where you will find the interval at which the inspections are to be performed. //UNCLASSIFIED// //UNCLASSIFIED// In some manuals, the interval tables will look like this one. These are manuals belonging to older pieces of equipment. As manuals and equipment are updated, they will look like those on the previous slide. B = Before D = During A = After W = Weekly M = Monthly //UNCLASSIFIED// //UNCLASSIFIED// LOCATION OF ITEM TO CHECK/SERVICE This gives a short description of the general area that the check is to be made. Many times, photos will accompany the more complicated checks to assist in the identification of the components to be checked. //UNCLASSIFIED// //UNCLASSIFIED// PROCEDURE Here, you will find what exactly is to be performed. You will find the standards against which to measure your checks as well (tire pressures, tread depths, etc.). Also in this column, you will see numerous warnings and cautions. Ensure that your operators observe all warnings and cautions. They were put there for our own protection. //UNCLASSIFIED// //UNCLASSIFIED// NOT FULLY MISSION CAPABLE IF Here, you will find what will render the equipment Non-Mission Capable (NMC or deadlined). //UNCLASSIFIED// //UNCLASSIFIED// SUMMARY •2 LEVELS OF MAINTENANCE •UNDERSTAND THE CONTENTS OF THE -10 •KNOW HOW TO REFERENCE THE TM FOR LUBE ORDERS AND PMCS INTERVALS //UNCLASSIFIED// //UNCLASSIFIED// QUESTIONS? //UNCLASSIFIED//