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CHAPTER IV

MAINTENANCE

SITUATION: A Bradley vehicle crew was occupying a guard post. The vehicle was overlooking the lodgment area perimeter and had the TOW launcher erected. During the course of normal operations, the crew shut down vehicle power. When the turret power was turned back on, both TOW missiles accidentally launched.

DISCUSSION: No mechanical problem with the weapon system was detected; however, this type of incident happened in the past. Obviously it can be very dangerous to have an accidental missile launch.

TTP!!! Apply the following techniques when turning your BFV (M2 or M3) power on or off:

1. Do not turn off the turret power with the TOW launcher erected.

2. If you must keep the launcher erected, ensure you select a gun system (25mm or COAX) before powering down the turret.

NOTE: The mechanical problem that caused the TOW missile misfire was identified. It had the potential to happen on any Bradley Fighting Vehicle. Until a repair can be made to the system, the original lesson applies:

TTP!!! When the launcher is loaded, leave it in the down position. Erect it only for operational or maintenance reasons, and do not turn your turret power off with the launcher erected and loaded.

SITUATION: While conducting routine maintenance on the TOW2A missile using TM 9-2350-284-10-2, soldiers from an ADA unit identified that the humidity indicator in the missile had changed from blue to light blue in color. A completely white or pink indicator would mean the TOW is unserviceable. The soldiers took the initiative to order dessicant, humidity indicator cards, sealant, and lubricant. The unit also reported the condition to the Quality Assurance Surveillance Ammunition Specialist (QASAS). This action also helps TFE respond to higher command levels and management agencies on disposition and maintenance of the TOW.

DISCUSSION:

• Ammunition is not manufactured for prolonged exposure to the environment. Ideally, ammunition should be kept in containers when not in use (although this is not always possible because some ammunition, such as the TOW2A, must remain uploaded for operational purposes). However, this often results in ammunition damage. Some types of ammunition rusts and others are dented. The TOW2A has parts that react to moisture in the air.

• The humidity indicator on the TOW2A alerts operators that there is moisture in the missile. The TM directs operators to replace the dessicant, lubricant, and seals to perform a validation check on the serviceability of the missile.

• The ADA personnel followed the correct procedure in identifying the problem, researching the solution in the TM, and notifying the experts. However, it is safe to say that some units are not aware of the problem and the proper procedures for rectifying it.

TTP!!! When the TOW2A remains uploaded for extended periods of time, it is exposed to moisture in the air and may become damaged. This is not a situation to learn at the "moment of truth" when all of the missile's capabilities are needed.

SITUATION: The following actual events illustrate that proper maintenance and PMCS must be performed by operators and that leaders must provide the time and resources to support this effort:

• A HMMWV driver reported a vibration he noticed to his mechanics. When he was told it would take time to troubleshoot the problem, the driver responded that he didn't have time; his mission had priority over the needed maintenance. Soon after leaving the motor pool, the vehicle's front wheel fell off.

• A broken-down HMMWV on a convoy resulted in a prolonged halt to the entire convoy along with the loss of precious shop time for the numerous mechanics who had to accompany the vehicles of the recovery convoy. The cause of this tremendous waste of resources - a burned-out transmission that had been allowed to leak dry.

DISCUSSION: Vehicles in a mobility intensive mission are critical. OPTEMPO is in overdrive, but there is no reason why vehicles should not be able to maintain the pace. The events described above are merely representative of the vehicle problems occurring within the U.S. sector. Regular PMCS and proper maintenance procedures cannot eliminate all of the problems that are experienced, but they may keep a piece of equipment running at that critical time.

TTP!!! The above situations need not occur. The old lesson is still valid, "that you will always have to make time to maintain, a little now, or a lot later."

SITUATION: Some very valuable lessons were learned on maintenance from the D-Rear at Lukavac. Although the specifics of the lessons may not pertain to a particular unit (not everyone is assigned a Palletized Loading System), the theme applies to every soldier who performs Preventive Maintenance, Checks and Services. Read the Technical Manuals carefully and perform the maintenance to standard. Pay attention to where the manuals fall short in providing guidance. If you see something that does not make sense, bring it up to your supervisor.

TTP!!! The Palletized Loading System (PLS). The PLS was fielded to units just as TFE deployed. With its haul capacity of over 33,000 pounds, it became the champion prime mover for ammunition, MREs and various containerized retrograde loads. Like so many other high tech workhorses, the PLS presents an indestructible support asset, but to the contrary, it is maintenance intensive. This particular vehicle has over 100 grease points. It is especially important as the OPTEMPO increases with the redeployment that operators and supervisors follow proper Lubrication Orders (LOs).

TTP!!! The 5-Ton Tractor. The 5-ton tractor, another prime mover for TFE, had its unique maintenance challenges. The 5-ton has fifth-wheel wedges that should be reversed to cushion heavy trailer loads over rough terrain or for "off-the-road" transport. Most tractor drivers following strict guidance of TMs were not reversing wedges since Bosnian roadways are paved. As a result, fifth-wheel mounting bolts were broken due to the numerous potholes in the main supply routes. The common-sense solution was and is to reverse the wedge allowing the cushioning movement under the heavily loaded trailers when not on smooth, paved roads.

TTP!!! The HMMWV. HMMWV passengers should have noticed a distinct difference between the smooth ride of one vehicle verses the rough ride of another. This difference may be attributed to the partial exchange of biased tread tires for radials. As several HMMWV drivers learned, when swapping out tires, keep the tread the same for the front or back axles. If not all of the tires are going to be changed simultaneously, change them in pairs.

DISCUSSION: Any experienced NCO knows that it is important to clean/wash vehicles as part of the unit maintenance program. Tactical operations make washing more difficult, but still important. Clean vehicles are easier to maintain.

Over time, dirt and road contaminants create an environment where moisture remains in crevices long after the remainder of the equipment has dried. Organisms, such as mold, mildew, and even grasses and mosses, can begin to grow. These growths contribute to the deterioration of surface coatings, rubber, and plastic. Accumulation of dirt and mud retains moisture longer than a clean surfaces and accelerates the corrosion process.

TTP!!!

• Despite the fact that vehicles will immediately be covered with mud during an operation, vehicles should be washed routinely to break the cycle of micro-biological growth which results in the destruction of paint/protective coatings and corrosion of metals.

• Prior to maintenance services, vehicles must be cleaned thoroughly. This will keep dirt, grit, and contaminants from entering bearings, fluid reservoirs or machined/close tolerance areas. In some cases, contamination can result in a repair that causes more damage than the original fault. Additionally, critical faults, such as worn suspension components, leaks, cracks and other damage, will be masked by dirt and accumulations of other contaminants.

• The few wash racks that exist are not necessarily located at or near high vehicle density areas or where equipment maintenance is routinely performed. Leaders need to plan PMCS convoys, allowing sufficient time and personnel to properly clean vehicles. Without proper PMCS convoys, vehicle cleaning is limited to headlights, windshields and a cosmetic wipedown of the exterior.

• During any deployment, leaders must establish vehicle-washing facilities at base camps where one or more organizational motorpools are established for more than two weeks. At a minimum, facilities must be collocated with DS maintenance facilities. Additionally, NBC training could be incorporated into the initial setup and operation of vehicle wash points as vehicle cleaning and decontamination require some of these same operations. NBC personnel are well versed on setting up vehicle-washing facilities. Chemical decontamination equipment can be used to facilitate the removal of mud from the undercarriage of vehicles.

SITUATION: Doctors at the DREAR in Slavonski Brod treated at least 67 soldiers who displayed the symptoms of food-borne gastroenteritis. Doctors confirmed at least nine cases of Salmonella based on positive lab results.

DISCUSSION: Salmonellosis is a bacterial disease. It is classified as a food-borne disease because contaminated food, mainly of animal origin, is the predominant mode of transmission. There are approximately 2,000 types of Salmonellosis, but the two most commonly reported are Salmonella typhimurium and Salmonella enteritidis.

Soldiers contract the disease by eating food that contains the Salmonella bacteria. Salmonella bacteria are commonly found in raw and undercooked eggs and egg products, raw milk and raw milk products, contaminated water, meat and meat products, and poultry and poultry products. Symptoms include the sudden onset of headache, abdominal pain, diarrhea, nausea and sometimes vomiting. Dehydration may be severe. Fever is almost always present. Deaths are uncommon.

The dining facility may be implicated in the outbreak. It was suspect because the dining facility recently changed from a tent location over to hard billet location. The new food service manager found eggs in an unrefrigerated conex. Cooks had used the eggs to prepare meals up until their discovery by the food service manager. He ordered the eggs to be thrown away. Chicken was also implicated in the incident. Many infected people had eaten chicken prior to developing symptoms.

Policy and standards were set, but not maintained.

TTP!!!:

The TFE policy on cooking eggs is that they will be cooked hard and not as a mass batch. Cooks should not batch-cook eggs. Eggs are to be fried hard or scrambled; hard is best. Boiled eggs are considered safe as long as the eggshell is not cracked. Soldiers should avoid consuming raw or undercooked meat, poultry, and egg products.

Food service managers need to educate their food handlers and cooks on the importance of sanitation, especially handwashing. This is especially true when local nationals are used instead of properly trained soldiers. Proper food storage is essential due to the extreme temperatures at this time of year. Cooks should be trained on the avoidance of possible cross-contamination during food preparation. Placing a food service NCO in the dining facility to supervise and ensure adherence to Army standards is also very beneficial. Note: There is an increased risk with contamination associated with moving to a new dining facility.

Chapter III: Safety

Acknowledgements