SUBCOURSE MM0160

EDITION A

AMMUNITION MAINTENANCE

AMMUNITION MAINTENANCE Subcourse Number MM0160 EDITION A
Missile and Munitions United States Army Combined Arms Support Command Fort Lee, Virginia 23801-1809

3 Credit Hours Edition Date: August 1992

SUBCOURSE OVERVIEW This subcourse is designed to teach you the planning for care, preservation, and maintenance of ammunition. Care stresses protection, and is performed at the serviced unit (the using unit), the Magazine Storage Area (MSA) or the Ammunition Supply Point (ASP). Preservation, while it includes protection, emphasizes maintenance and is also performed at the MSA or ASP. The subcourse is intended to train those personnel who are tasked to plan for the proper care and preservation of munitions at the respective storage location(s). Care and preservation of ammunition is essential to ensure world-wide stocks are serviceable for training and combat missions. There are no prerequisites for this subcourse. This subcourse reflects the doctrine which was current at the time it was prepared. In your own work situation, always refer to the latest official publications. Unless otherwise stated, the masculine gender of singular pronouns is used to refer to both men and women. TERMINAL LEARNING OBJECTIVE ACTION: You will learn the four levels of conventional ammunition maintenance, their functions and scopes of operations, and the authorizing document for conventional ammunition maintenance, including preparation and approval. You will cover Depot Maintenance Work Requirements (DMWR); planning considerations for ammunition maintenance; and procurement, control, use, and safe operation of Ammunition Peculiar Equipment (APE). You will require only the material contained in this subcourse. To demonstrate competency of this task, you must achieve a minimum of 70% on the subcourse examination.

CONDITION: STANDARD:

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TABLE OF CONTENTS Section Page

Subcourse Overview........................................................................................................................... ................i Lesson: Planning For Care, Preservation, and Maintenance of Ammunition..................................................1 PART A: Levels of Maintenance.................................................................................. ......................2 PART B: Safety..................................................................................................... .............................3 PART C: Maintenance Planning......................................................................................... ................4 Practice Exercise.................................................................................................... ..........................25 Answer Key and Feedback................................................................................................. ..............26

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LESSON AMMUNITION MAINTENANCE MQS II Critical Task: 03.4010.01-0008 OVERVIEW LESSON DESCRIPTION: In this lesson you will learn the basic requirements of planning for the care, preservation, and maintenance of ammunition. TERMINAL LEARNING OBJECTIVE: ACTION: CONDITION: STANDARD: You will be able to describe maintenance levels, determine scopes of maintenance required, formulate a maintenance line SOP, and design a maintenance line layout. You will require only the material contained in this subcourse. Evaluate the planning of the care, preservation and maintenance of conventional ammunition.

REFERENCES: The material contained in this lesson was derived from the following publications: DA PAM 738-50, SB 742-1, TM 9-1300-206, TM 9-1300-250, and TM 43-0001-47. INTRODUCTION The Ammunition Stockpile Reliability Program, as well as reports of ammunition problems received from the field, result in ammunition that must be suspended or restricted. Permanently suspended ammunition requires some action before it can be released. The repair equipment, as well as requirements for modification, conversion, or demilitarization, make it necessary to establish an ammunition maintenance program. Care and preservation is the term commonly used to describe that portion of Direct Support maintenance that includes such functions as repalletizing, repackaging, and minor rust removal. This is normally a function that can be accomplished prior to issue of the item. Care and preservation would not require the addition of a lot suffix or change in the National Stock Number. Care stresses protection, and is performed at the serviced unit (the using unit) and the Magazine Storage Area (MSA) or Ammunition Supply Point (ASP). Ammunition is one of the basic commodities used by the Army, and while its maintenance is addressed in several Army maintenance publications, there are some aspects of the process which set it apart from other commodities. There are two primary reasons to perform ammunition maintenance: environmental deterioration and obsolete material. Munitions can be rendered unserviceable due to environmental conditions such as excessive heat, cold, or moisture. If so, proper care and preservation may be as simple as removing rust, cleaning the items, repacking them, and/or repalletizing the packaged or repackaged items. Obsolete materiel may require more extensive maintenance such as fuze replacement, propellant and cartridge case replacement, or reboostering. 1 MM0160

PART A: LEVELS OF MAINTENANCE 1. There are four levels of maintenance for conventional ammunition performed in the field: Organizational, Direct Support (DS), General Support (GS), and Depot level. These levels encompass the full scope of ammunition maintenance to be performed in the Theater of Operations (TO). 2. These maintenance responsibilities are as required in the Department of the Army (DA) Technical Manuals (TMs), related publications and regulations. These levels of maintenance are detailed in the Maintenance Allocation Chart (MAC) published in the Organizational Maintenance TM for specific materiel. The levels of maintenance are briefly described below. a. Organizational Maintenance. (1) Organizational maintenance is performed by all activities having conventional ammunition on hand, to include using units. (2) It is performed to prevent deterioration of ammunition due to rough handling and exposure. (3) Organizational units may call upon DS units for technical advice, assistance and support. (4) This level of maintenance involves cleaning, removal of minor rust and corrosion, repair and replacement of boxes, repalletizing, and repacking. b. Direct Support (DS) Maintenance. (1) DS maintenance is performed by conventional ammunition companies providing support directly behind the divisions. DS maintenance includes surveillance with limited maintenance. (2) This category of maintenance includes the functions of inspections, tests, care and preservation, and service and repair (as authorized), on all types of conventional ammunition under the control of ammunition storage and issue facilities. (3) DS maintenance includes repairing, restenciling, or replacing packing materials; and declipping, reclipping, and changing ratio linkage of small arms ammunition. (4) Replacing readily removable parts and components, removing exudation from artillery projectiles, and performing electrical circuit continuity testing on rocket ammunition are other examples of DS operations. c. General Support (GS) Maintenance. (1) Basic procedures: All GS ammunition renovation operations have essentially five main actions: unpack, disassemble, perform the required work, reassemble, and repack. (2) General support maintenance consists of, but is not limited to: (a) Removal of exterior rust and corrosion. (b) Painting and stencilling. MM0160 2

(c) Major repairs or fabrication of boxes, containers, and crates. (d) Repair and renovation of ammunition. (e) Replacing unserviceable cartridge cases, primers, propellant, base detonating fuzes, or tracer units on artillery ammunition. (f) Replacing unserviceable boosters, fuzes, primers and igniters on all conventional ammunition. (3) GS maintenance units are responsible for accomplishing that part of the maintenance mission that is beyond the capability or capacity of the DS ammunition company. d. Depot Level Maintenance (1) All conventional ammunition depot level maintenance is performed by contract labor. (2) Depot maintenance includes modification, explosive component replacement, and complete renovation performed at a large, fixed depot complex. PART B: SAFETY 1. The ammunition and explosive safety standards of DOD 6055.9-STD, TM 9-1300-206, and AMC-R 385-100, as applicable, must be followed. 2. All personnel engaged in operations involving explosives and/or other hazardous material will be trained in safety, and will be thoroughly knowledgeable of the applicable standing operating procedures (SOPs). They will be capable of recognizing hazardous situations and conditions. Thinking safety, working safety, and attention to detail must become a habit when working with or near items that can create a hazard due to their explosive, flammable, or toxic fillers. 3. Explosive Safety. a. Ammunition and explosives are relatively safe to handle as long as due consideration is given to the characteristics of each type of explosive involved, the method in which each is assembled, and the nature of the operation being performed. Personnel must adhere to prescribed normal safety precautions and to any specific precaution in the applicable publication for the item. b. TM 9-1300-206 contains safety requirements covering the following topics and other topics concerning ammunition: (1) Fire-fighting procedures and symbols. (2) Handling and storage of ammunition. (3) Operational precautions. (4) Quantity-distance requirements. (5) Barricades. 3 MM0160

(6) Operational shields. (7) Personnel and explosive limits. (8) Safety tools and equipment. 4. Safety requirements for renovation. Renovation operations require a thorough knowledge of the activities involved, hazards to be guarded against, and precautionary methods necessary for greatest protection to personnel and property. Before starting any operation involving ammunition or explosives, an adequate SOP shall be developed and approved by the commander of the establishment or by a qualified member of his staff to whom the commander has delegated the responsibility for review of, and authority for approval of the SOP. Controlled tests may be necessary in order to establish SOPs for certain operations. This SOP shall include, as a minimum, such items as safety requirements, personnel and explosive limits, equipment designation, and location and sequence of operations. No deviation from this procedure shall be made without approval of the commander or his designated representative. 5. Prompt action will be taken to control any hazard. If a dangerous item or situation is encountered, all operations in the immediate area will shut down. Personnel will be evacuated to a safe site. The incident will be reported immediately through the proper chain of command. Explosive Ordnance Disposal (EOD) or other authorized personnel will be called for help in eliminating the hazard. Operations will not be resumed until the hazard has been eliminated. PART C: MAINTENANCE PLANNING 1. The Technical Support Section in a using unit receives notice of necessary maintenance by receiving a work authorization from the chief of the operations section. There are two primary reasons an authorization has been generated. Either an inspector at any level has found a substandard lot, or a using unit turns in what it considers unserviceable ammunition. The inspector issues a DA Form 2415 (Ammunition Condition Report) (ACR) (Figure 1), and the using unit submits a DA Form 2407 (Maintenance Request) (Figure 2, page 6). 2. Before maintenance on any item can be started, however, each operation (step) to be performed must be thoroughly planned. Most of the technical data necessary to the planning at any maintenance level is in the depot maintenance work requirements (DMWRs). The Technical Support Section obtains the DMWRs and any other necessary documents, such as specific technical manuals and packaging drawings, from the operations and surveillance sections. 3. The Technical Support Section then studies all reference material along with the work request. Vitally important in this study are safety requirements, which must be included in the planning and be in force throughout the maintenance operation. Upon completion of the study, there should be enough information to fill out a process flow sheet. If not, more references may be requested from the operations and surveillance sections. a. Ammunition Condition Report (ACR) (DA Form 2415). (1) The condition of ammunition is determined through inspections conducted by ammunition surveillance inspectors, who will identify the degree of serviceability using ammunition condition codes. MM0160 4

Figure 1. DA Form 2415 (Ammunition Condition Report) authorizing ammunition maintenance 5 MM0160

Figure 2. DA Form 2407 (Maintenance Request) authorizing ammunition maintenance MM0160 6

(2) Ammunition surveillance inspectors are required to submit DA Form 2415, Ammunition Condition Report (ACR), to provide data for control and management of unserviceable and permanently suspended ammunition items. (3) The DA Form 2415 is used to report unserviceable repairable ammunition items which are in condition codes E, F, G, and N. This form will also be used to report unserviceable, uneconomically repairable ammunition items in condition code H, and permanently suspended ammunition in condition code J. (4) An individual DA Form 2415 will be prepared for each line item reported; however, more than one lot of identical items can be reported on the same form. (5) The ACR will be prepared in sufficient copies, as prescribed by local standing operating procedures (SOP), and forwarded through command channels for disposition. (6) The processed report will normally be returned through command channels. The report with endorsement will constitute the authority for disposition of the reported item. b. Depot Maintenance Work Requirement (DMWR). (1) Depot Maintenance Work Requirements (DMWRs) are prepared by AMCCOM for a variety of installations operating on a comparatively large production basis. (2) DMWRs are composed of a series of sheets in the form of a pamphlet. They are used for renovation, repair, or demilitarization of ammunition. Each sheet is an operation study of the technical features of the operation to be accomplished. See Figure 3, page 8 for an example of a DMWR. (3) The DMWR shall be approved by the commanding officer, or by a qualified/authorized member of his staff who has been delegated the responsibility for review and approval of the DMWR. (4) The sequence of operations may not be applicable to a DS or GS facility. The manner in which the field unit does a job probably will be different from the manner in which an established depot does the same job. (5) A DMWR received in the field will serve as a guide to the ammunition officer in making up the maintenance SOP. (6) When a work authorization has been received, with or without an assignment sheet, the unit will prepare the details and procedures for doing the work. c. Operational Planning. (1) The proper performance of a maintenance operation depends primarily upon thorough planning. A thorough study should be conducted to determine the specific operations required, and at what point they should be accomplished. Safety requirements are very important in this study-they must be included in all phases throughout the operation. Additional planning factors include: 7 MM0160

Figure 3. Depot maintenance work requirement (a) Complete rounds or items to be worked on must be inspected, to determine total materials required. (b) All tools and equipment used to do the job must be procured and distributed to the points where they will be used. Necessary replacement parts or components must be determined, then procured and stored. Supplies such as paint, varnish, steel wool, cardboard, and sealing compound must be obtained in the proper quantities. MM0160 8

(c) Personnel who are experienced in the operation must be assigned to various sections of the job. Inexperienced personnel must receive training so that they will be able to help when needed. (d) Technical information must be obtained so that the job will be performed correctly. Consideration must be given to safety so that each operation may be conducted with minimal possibility of injury to either the operator or the equipment. (e) Once operations are begun, provisions must be made for removing bottlenecks and increasing production, making operations more simple, and increasing safety. (f) Operational planning is used to plan jobs of other types by deciding in advance of starting the operation. Critical questions that must be considered are: What is to be done? How is the work to be done? Who is to do the work? Where is the work to be done? (2) These items apply themselves very well to maintenance. The paperwork applied, to be discussed later, is merely a step in answering these questions so as to build up to an official line layout. d. Renovation Facilities. (1) The maintenance building is a specially designed structure which provides the maximum degree of safety for operators, while at the same time facilitating production. See Figure 4, page 10. (2) The building is constructed with laced reinforced concrete dividing walls to prevent simultaneous detonation of the explosives in the building. They are not designed to provide complete protection for personnel. The dividing walls are a minimum of 12 inches thick (some buildings are constructed with twice this thickness so that completely separate operations can be conducted on both sides of the building). (3) The building walls and roof coverings should be of non-combustible material. The interior surfaces should be of fire retardant material and as free from cracks as possible. Seams should be taped over, and if painted, the paint should be a gloss to facilitate cleaning. The building is designed to vent an explosion. (4) The building is designed so that materials enter one end of the building and flow to the other. Conveyors and hoists are setup throughout the building along with larger items of machinery, electrical power, and compressed air. (5) The work is divided so that different operations are performed in each of the cubes. The building can be adapted for numerous jobs by installing or removing equipment and machinery. (6) Marking and color coding of areas and equipment, water lines, high pressure air lines, hazard areas, electrical lines, etc., contribute to safety. For example, color coding for identification of the different power lines, high pressure lines, and hazard areas could be as follows: (a) High pressure water lines ----- Red. (b) High pressure air lines -------- Green. 9 MM0160

Figure 4. Ammunition maintenance facility MM0160 10

(c) Electrical lines ------------------ Blue. (d) Marking of hazard areas ------- Black and yellow. (7) Normally, safety and hazard markings are established by the maintenance facility commander and published in local policies and/or SOPs. Different geographical areas could use systems which utilize different color coding and markings requirements; therefore, local safety policies must be checked prior to the marking of safety areas and equipment. (8) AMC Regulation 385-100 is the basis for establishing policies and procedures required for ammunition maintenance facilities. However, AMC publications are applicable to AMC facilities only. Each facility performing maintenance will comply with local policies. (9) In overseas commands, portions of AMC Regulation 385-100 may be extracted, or portions modified to establish local policies. e. Process Flow Sheets. (1) The first form to be completed will be a process flow sheet (Figure 5). A process flow sheet is a chart to plan and record, in a compact manner and in proper sequence, the operation found in an operating line. The chart begins with the ammunition to be processed coming from storage and follows it through each operation to the finished reworked item. Planning also includes use of applicable Ammunition Packaging Drawing. (2) Operations arranged in proper sequence fall naturally into five major groups. All types of ammunition to be processed must go through the following operations: (a) Unpacking. (b) Disassembly. (c) Replace/repair. (d) Reassembly. (e) Repacking. (3) In planning the flow sheets, the following questions should be considered: (a) Can any operation be eliminated? (b) Can any of the operations be combined? (c) Can any operation be performed better in a different order? (d) Can any of the operations be simplified? (4) To fill out the sheet, look at Figure 5, page 12. The first column is the number of the operation in the process. Each operation is described as an action in the next column. Then, each operation is noted as either primary or secondary. A primary operation is one that is essential for a smooth production flow. It is also called a main-line operation because it is on the main line of the 11 MM0160

layout. A secondary operation is one that is necessary for the completion of production, but may interrupt the smooth flow. A secondary operation may be routed from the main lines into branch lines, to be returned at a point further along the main line. The most common reasons for these detours are because of facility limitations, safety reasons, complicated or bulky operations, or operation exceptions that may result in delays (for example, it is discovered on the receiving dock that only one package out of 50 needs refurbishment). (5) Included in the flow sheet is a table listing the number of each operation, the personnel required, the tools to be used, and the materials needed. (a) Personnel. The number of workers assigned to each operation will be kept at an efficient operational minimum.

Figure 5. Process flow sheet MM0160 12

(b) Equipment. In selecting equipment, refer to TM 43-0001-47 and TB 43-0195. The most appropriate equipment available will be selected and used in the operation. Improvised tools planned for use in this process should be approved by the appropriate commodity command. (c) Materials. A careful study will be made of the requirements for materials to go into the product. Materials include such items as new components, sealing compound, paint, etc. (6) The original flow sheet acts as a blueprint for the layout of the line. It is useful as a reference and as a guide for locating the various operating tables or operating rooms. Using the flow sheet, a clear picture of the job as a whole can be obtained. Changes probably will be made in methods, tools, personnel, and sequence of operations after work has begun. All the changes will be incorporated into the final flow sheet, and copies sent later to the next higher headquarters. f. Standing Operating Procedures (SOP). (1) An SOP is a step-by-step guide to be used for each maintenance operation. Figure 6, page 14 shows the SOP for one operation; there must be one prepared for each operation. Before writing an SOP the following questions should be answered: (a) What is to be done? Refer to DA Form 2407 or DA Form 2415. (b) Where can it be done? Check with personnel in the surveillance section. (c) How shall it be done? Refer to the process flow sheet. (d) With what shall it be done? Refer to the process flow sheet. (e) What safety precautions are necessary? Refer to the technical manuals for items being maintained, and to TM 9-1300-206. (2) SOPs must be clear, conclusive, and easily understood by the operators. They must tell exactly what the operation is to do, leaving nothing open to interpretation. The SOP for each operation should tie into the operations before and after, and should detail the identification characteristics of the operation (see items A through I in Figure 6). Each operation should also describe its activity, special requirements, equipment, etc. Finally, the SOP should have a cover sheet with information on it as shown in Figure 7, page 15. As a minimum, an SOP for an operation should contain the following: (a) Safety requirements. (b) Personnel. The fewest required to do the job efficiently and safely. (c) Explosive limits. Explosive limits are in the DMWR and are expressed in rounds. They are based on the net explosive weight (NEW) for the ammunition. The limits in the DMWR, however, are based on depot work flows and are usually too high for ASP operations. The senior ammunition NCO must consider safety, the size of the operation, and past experience to decide the explosive limits for a particular operation. (d) Equipment required for the operation. 13 MM0160

Figure 6. SOP information necessary for any ammunition maintenance operation MM0160 14

Figure 7. Information necessary for the cover of an ammunition maintenance SOP (e) Location and sequence of operation to maintain a smooth flow. This is usually a diagram of the line layout. (f) General. In developing detailed SOPs, the information contained therein must be clear, conclusive, and easily understood by all concerned. Great care must be exercised in use of the English terminology, taking into consideration the limited vocabulary of some workers that may be assigned to the operation. (g) In overseas commands where indigenous personnel are used, SOPs will be written bilingually, in English and the language of the host nation. (h) Minimum requirements. Experience has indicated that adequate, up-to-date SOPs will aid materially in the reduction of accidents. (i) When the best layout has been determined and tested, and the SOP has been written, the senior ammunition NCO submits the plan to the supervisor. The SOP will consist of: the 15 MM0160

work authorization (DA Form 2407 or DA Form 2415); the DMWR; the process flow sheet; the line layout; and the SOP. (j) Obtaining approval of the SOP. The SOP shall be approved by the commanding officer or by a qualified member of his staff, who has been delegated the responsibility for review and authority for approval. If the plan is disapproved, the senior ammunition NCO must correct the plan until it is acceptable and approved. g. Line Layouts. (1) The objective of all planning is construction of the maintenance line and actual processing of the item. The line is arranged on the basis of the flow sheet. Although it may take many forms, it will usually follow the U type line or the straight line. (2) The U line (Figure 8) is ordinarily employed when there is only one road available for use in supplying and removing processed items.

Figure 8. A U-shaped layout, used when only one road is available MM0160 16

(3) The straight line (Figure 9) is more readily employed whenever two roads are availableone at the incoming end of the line and the other at the outgoing end of the line. (4) A clear, legible line layout must be forwarded with each SOP that is submitted for review. (5) Line layouts should show the structural material of the facility, fire protection, location of dividing walls, operational shields, and permanently installed equipment. (6) Operational shields must be detailed to show the type of material used, height, and thickness. (7) Permanently installed equipment must be listed whether or not it is used on the specific operation.

Figure 9. A straight-line layout, used when two roads are available 17 MM0160

(8) Each bay or room must be identified by a numeral or letter. (9) The operational sequence must be depicted by use of standardized symbols. (10) The location of pallets, tables, APE, etc., must be depicted where they will be used. A legend must be used to briefly explain the operations, inspections, and locations of pallets, tables, APE, etc. (11) A pilot run on a small sample may be tried out to determine if the initial SOP is sufficient and will provide a satisfactory end product. h. Production Control. (1) Production control should support the following objectives: (a) Estimates of man/machine/material requirements for new jobs, from past experience. (b) Maintenance and controlled inventories. (c) Production schedules on the basis of headquarters requirements and availability of all facilities of the line. (d) Availability of all facilities for production at the time the job is scheduled. (e) Maintaining production levels for the best utilization of trained personnel. (f) Keeping abreast of the current delivery dates of items to be renovated, special machinery needed for the particular job, and component items that will be needed. (g) Direction of the major flow of the item and component part transportation within the area. (h) Receipt of reports of work done and evaluation of performance. (i) Replacement when original plans are not carried out. Should the ongoing program be terminated or experience an inordinate delay, the next scheduled program should be readily available to commence operation, thereby minimizing production down time and maximizing utilization of the workforce and facilities. (j) Minimizing the idle time of men and machines. (k) Maximizing the quality and quantity of renovated items completed. (2) Production control charts can provide assistance in attaining maximum production performance. Charts kept posted with timely information in a neat manner can provide a ready, valuable source of information for answering questions from higher headquarters and for forecasting bottlenecks and schedule shippages. A chart is also used for posting expected deliveries of ammunition to be renovated, component parts to be used in the renovation, and special equipment needed for the particular job. The remoteness of several sections (lines), away from immediate control of the unit (section), necessitates the use of a computer driven or chart-type control device to indicate the progress each operation has made on assigned jobs. The type of chart utilized is dependent solely on the situation and the supervisor. MM0160 18

i. Scheduling. (1) Another important phase of production control is the scheduling of work to be performed. Scheduling establishes priorities, time of release to the line, and the sequence to be followed. A master schedule, designed to provide a convenient means of keeping a running total of production requirements, is used for scheduling purposes. A maintenance schedule is prepared for a particular operation indicating the name and number of products to be processed during a specified period. The manner in which this phase of production control is carried out must be adaptable to different types of installations and commands. Schedules should be established at GS level for 1 month and 6 months. The decision is influenced by workload, availability of equipment and personnel, and relative cost. (2) A widely used method of production scheduling is the control chart. It varies considerably as to type and scope of information. It may be in the form of a graph or mechanical device. The basic function of a control chart, regardless of its form, is to provide a quick, comprehensive, visual record of accomplishment against an established plan. Properly used, the control chart readily points out the need for investigation and correction of deficient accomplishment. j. Description and use of lot numbers. See Figure 10. (1) The purpose of lot numbering of ammunition is to provide the identification of materiel necessary to assure accurate control of item movements; to conserve and maintain surveillance records; and to provide a means of withdrawing from service any defective, deteriorated, hazardous, or obsolete ammunition and explosive materiel. (2) The old lot numbering system, which consisted of a manufacturer's identification symbol and a task and serial number, will be in the field until all items marked with this system are exhausted or destroyed. (a) The manufacturer's identification symbol consisted of one, two, or three letters assigned in a manner indicating the identity of the arsenal, plant, depot, or station.

Figure 10. Ammunition lot numbering systems 19 MM0160

(b) Each lot number had an interfix number between the manufacturer's identification symbols and the serial number. The interfix number indicated the lots made according to a specific design or manufacturing procedure. (c) The serial number identified the lot according to the sequence of production. A number was assigned to each lot. The serial number began with the number 1 and continued in sequence until production of the item was terminated or completed. (3) The new ammunition lot numbering system consists of a manufacturer's identification symbol, a numeric code depicting the year of production, an alpha code representing the month of production, a lot interfix number followed by a hyphen, and a lot sequence number. An alpha character may be used as an ammunition lot suffix to denote a reworked lot. The ammunition lot number is no longer than fourteen characters in length, with no characters separated by spaces. The minimum number of characters used is thirteen. The ammunition lot number for the new system is as illustrated in Figure 10, page 19. k. Description and use of lot numbers for maintenance operations. (1) The old lot numbering system for renovated, modified or regrouped operations, which are performed subsequent to acceptance of the munitions into the stockpile and to restore them to issuable condition, is as follows: (a) Ordinary maintenance, when new components replace like components, a lot suffix will be assigned by the responsible service. EXAMPLE: US Army, Korea, Special Ammunition Depot 200 replaces fuzes on complete rounds of lot LOP-1-8; the suffix furnished changes the lot number to LOP-1-8A, B, C, etc., as applicable.

(b) Extensive maintenance, where different components are added or work is extensive enough to warrant model number change. EXAMPLE: (1) Cartridge, 105mm HE, M1 changes to cartridge, 105mm HE, M1A1; (2) replacement Fuze; PD, M52 to M525 and; (3) replacement of Fuze; MTSQ, M5000A1 to M520A1.

(c) New lots will be formed in accordance with the requirements of the maintenance directive. Let numbers will be assigned in the normal manner except that the interfix number will start with 500 instead of 1, and the manufacturer's symbol will be that of the facility performing the work. (d) Lot numbers are furnished to the maintenance facility by AMCCOM. (2) The new lot numbering system for renovation and modification is basically the same as the old system: (a) Ordinary maintenance. When new components replace like components (same model number), a lot suffix will be assigned by the responsible service. Example is provided under paragraph 2.k.1(a) above. MM0160 20

(b) Extensive maintenance. Where components replace different components, components are added, or where work is extensive enough to warrant model number change. Example is provided under paragraph 2.k.1(b) above. (c) Maintenance regrouping. When numerous lots are regrouped to form one lot, regardless of whether or not ordinary or extensive maintenance is performed in conjunction with regrouping, a new lot number will be assigned. EXAMPLE: US Army, Fort Amador, Canal Zone regroups 81 mm mortar rounds lots MA-2-24, MA-2-26, and MA-2-28; etc. The new lot number CRV81A001G001 is assigned.

l. Ammunition Data Cards. (1) An Ammunition Data Card (DD Form 1650) (Figure 11, page 22) is an easily referenced record of the initial history of a lot of ammunition or explosive materiel, which contains all required data pertaining to each lot of ammunition. (2) When maintenance operations are performed, the facility performing the maintenance will prepare a new ammunition data card and attach it to the old card. m. Ammunition Peculiar Equipment (APE). (1) Ammunition peculiar equipment is equipment designed, fabricated, procured, tested, and adopted to standard items by respective commodity commands. The APE is then used to accomplish ammunition operations, including surveillance, maintenance, demilitarization, and storage functions. (2) Equipment requirements. To accomplish the required work, certain equipment must be available. The type of equipment will depend upon the complexity and type of work to be done, such as: (a) Deterioration. (b) Design changes. (c) Safety. (3) Safety design features. Design features that make ammunition effective must be taken into consideration in providing the tools and equipment necessary to perform ammunition operations. Explosives are sensitive to initiation by shock, flame, and electrostatic discharge. Therefore, equipment peculiar to ammunition operations must be designed to minimize these hazards. (4) Operational shields. When hazards cannot be minimized to a safe level, special shields or machines operated by remote control must be used. Operational shields are used to remove primers, boosters, base detonating fuzes, etc. (5) APE equipment is issued to all US Army installations (CONUS and overseas) on hand receipt from AMCCOM, IAW AR 700-20. 21 MM0160

Figure 11. DD Form 1650. Ammunition Data Card MM0160 22

(6) Description of specific APE. It is not within the scope of this lesson to describe each piece of equipment that is presently available. For discussion of specific APE, see TM 43-0001-47. n. Profile and Alignment Gaging Operations. (1) Profile and alignment gages are devices which simulate the breech block or chamber of a weapon. These gages are precision-made instruments that are used to ensure the rounds will chamber in the weapon after reassembly. An example of the use would be after the propellant in a fixed round has been replaced, and the round has been reassembled and crimped. The gages then assure that the round is not offset, thus not allowing the round to properly chamber, which could cause serious damage to the weapon or cause the round to malfunction. (2) Each profile and alignment gaging operation, excluding small arms ammunition, should be so enclosed that adjacent operations are protected by operational shields complying with the requirements of TM 9-1300-206. The layout of the equipment and operational procedure will be developed with a view toward minimizing personal injury and property damage in the event of an incident. (3) During chamber gaging of major caliber fixed ammunition, the gage should be pointed toward a dividing wall or other barrier and the round inserted into the gage and removed by the same operator. In no case will the round be left in the gage. Rounds of mortar ammunition shall be gaged prior to attaching propellant increments, and, unless prohibited by design characteristics, prior to assembly of ignition cartridge. 4. You have completed the lesson. You will now take a Practice Exercise to use the knowledge you gained in the lesson. Once you complete the Practice Exercise satisfactorily, proceed to the subcourse Examination.

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PRACTICE EXERCISE The following items will test your grasp of the material covered in this lesson. There is only one correct answer for each item. When you complete the exercise, check your answers with the answer key that follows. If you answer any item incorrectly, study again that part of the lesson which contains the portion involved. 1. What are the four levels of ammunition maintenance? A. B. C. D. Unit Support, Organizational, Direct Support, General Support. General Support, Depot, Unit Support, Direct Support. Organizational, Direct Support, General Support, Depot. Depot, Unit Support, Direct Support, General Support.

2. What is one of the primary references that must be followed by personnel engaged in operations involving explosives and hazardous materials? A. B. C. D. TB 43-0195. TM 9-1300-250. TM 9-1300-206. TM 9-1300-214.

3. What does the proper performance of a maintenance operation primarily depend upon? A. B. C. D. Equipment. Planning. Personnel. Standing Operating Procedure (SOP).

4. Which of the following forms is used for authorizing care and preservation of ammunition? A. B. C. D. DA Form 2404. DA Form 2405. DA Form 2406. DA Form 2407.

5. Which form is used to report unserviceable repairable ammunition items that are in condition codes E, F, G, and N? A. B. C. D. DA Form 2406. DA Form 2407. DA Form 2415. DA Form 2496.

6. Which document, composed of a series of sheets in the form of a pamphlet, is used for renovation, repair, or demilitarization of ammunition? A. B. C. D. Ammunition Condition Report (DA Form 2415). Depot Maintenance Work Requirements (DMWR). Standing Operating Procedure (SOP). Maintenance Request (DA Form 2407). 25 MM0160

PRACTICE EXERCISE ANSWER KEY AND FEEDBACK Item 1. Correct Answer and Feedback C. Organizational, Direct Support, General Support, and Depot. There are four levels of maintenance for conventional ammunition performed in the field: Organizational, Direct Support (DS), General Support (GS), and Depot level (page 2, para 1). C. TM 9-1300-206, Ammunition and Explosives Standards. The ammunition and explosive safety standards of DOD 6055.9-STD, TM 9-1300-206, AMC-R 385-100, as applicable, must be followed (page 3, para 1). B. Planning. The proper performance of a maintenance operation depends primarily upon thorough planning (page 7, para 3.c.(1)). D. DA Form 2407 (Maintenance Request). … the using unit submits a DA Form 2407 (Maintenance Request) (page 4, para 1). C. DA Form 2415 (Ammunition Condition Report). The DA Form 2415 is used to report unserviceable repairable ammunition items which are in condition codes E, F, G, and N (page 7, para 3.a.(3)). B. Depot Maintenance Work Requirement (DMWR). DMWRs are composed of a series of sheets in the form of a pamphlet. They are used for renovation, repair, or demilitarization of ammunition (page 7, para 3.b.(2)).

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