Professional Documents
Culture Documents
24 April 1998
FOREWORD
1. PURPOSE
2. SCOPE
MCWP 4-24 sets forth essentials of the Marine Corps’ equipment maintenance sys-
tem from the perspective of the unit commander. It provides a practical approach to
understanding maintenance management of ground equipment that can be applied
without any significant technical background. Maintenance policies and procedures
for aircraft and other Navy-procured equipment are outlined in OPNAVINST
4790.2, The Naval Aviation Maintenance Program (NAMP).
3. SUPERSESSION
J. E. RHODES
Lieutenant General, U.S. Marine Corps
Commanding General
Marine Corps Combat Development Command
Page
iii
MCWP 4-24
Appendices
Works Cited
iv
Chapter 1
Maintenance Overview
“It is a command responsibility to ensure that assigned materiel is maintained in operating condi-
tion to perform designated functions effectively.”1—Marine Corps Manual
MCDP 4, Logistics, indicates that “the complexity Our Service policy (MCO P4790.2, MIMMS
of the tasks involved in supporting a high technol- Field Procedures Manual) also considers efforts
ogy force also increases as the sophistication of its to update and upgrade the capability of materiel
weapons and equipment increases.”2 Quite simply, as a maintenance function.
the more advanced the equipment, the harder it is
to fix. Couple this with the notion of generating
ever-increasing tempo in reduced response time 1002. Maintenance Subfunctions
over greater distances and maintenance becomes a
significant challenge. To meet this challenge and a. Inspection and Classification
ensure combat readiness, commanders must be Inspection and classification are the first and last
maintenance oriented and have a basic under- tasks that a user and maintenance activity perform
standing of the Marine Corps’ maintenance sys- on equipment.
tem. The purpose of maintenance is simple and
direct—to keep equipment in service. Accord- Inspection is the checking or testing of an item
ingly, commanders must emphasize maintenance against established standards. The inspection pro-
at every level of command. cess determines maintenance requirements and
satisfactory maintenance performance. It deter-
mines if something is wrong with the equipment.
1001. Maintenance Definition All echelons of maintenance include inspections.
Inspections are most effective when the inspector
Maintenance is one of the six functional areas of is not the person who performs the maintenance.
logistics. It consists of—
Classification is the assignment of an item to a
“1. All action taken to retain materiel in a serv- maintenance category based on established proce-
iceable condition or to restore it to serviceabil- dures. The assigned classification determines who
ity. It includes: inspection, testing, servicing, repairs the item and where the repairs are made.
classification as to serviceability, repair, re-
building, and reclamation. 2. All supply and re- When an item is evacuated to a higher echelon,
the higher echelon’s repair organization also
pair action taken to keep a force in condition to
inspects and classifies equipment for service-
carry out its mission. 3. The routine recurring
ability/failure using tools and techniques unavail-
work required to keep a facility (plant, building, able to the lower echelon. This re-checking by the
structure, ground facility, utility system, or higher echelon confirms the results of the lower
other real property) in such condition that it echelon’s inspection. The higher echelon also per-
may be continuously utilized, at its original or forms a final inspection and classification before
designed capacity and efficiency, for its in- returning the equipment to the lower echelon.
tended purpose.”3 This confirms that the appropriate repairs were
1-2 MCWP 4-24
completed. The owning unit’s maintenance or- equipment. These are often referred to as “secon-
ganization performs the final equipment inspec- dary reparables,” “secreps,” or “line replacement
tion and classification before placing the item units.” See chapter 3 for more information on sec-
back in service. ondary reparables.
b. Servicing, Adjustment, and Tuning Two repair techniques are cannibalization and se-
lective interchange. Maintenance by cannibaliza-
Servicing, adjustment, and tuning tasks do not tion or selective interchange is considered to be
have precise definitions. Servicing may include all
an exceptional procedure. It is authorized only
repairs or maintenance, including adjustment and
when an operational commitment is imminent and
tuning. Tuning is a process of adjusting equipment the required part or reparable component may not
to achieve precise functioning. For example, tun- be available from stock or obtained in time. Main-
ing often refers to engine adjustments; however, tenance by cannibalization and selective inter-
engines are not the only components that need ad-
change is decided case-by-case. It can only be
justments. Regardless of precise definitions, the authorized by the Commandant of the Marine
terms have one thing in common: they refer to Corps, DC/S Installations and Logistics, Logistics
maintenance performed on operable equipment, Plans Policy and Strategic Mobility Division
including equipment that the maintenance activity
(HQMC code: LP); a major subordinate com-
has just repaired.
mand commander, and commanders of any unit
authorized third echelon repairs.
c. Testing and Calibration
Testing and calibration are terms that apply to the (1) Cannibalization. Cannibalization is the re-
maintenance of precision instruments. These in- moval of serviceable parts from an unserviceable
struments may be components of larger items, or item of equipment and installing it on another un-
they may be maintenance test equipment. Testing serviceable item to make it serviceable. Cannibali-
compares the accuracy of the instrument to an es- zation does not address the replacement of the
tablished standard. Calibration is the adjustment removed serviceable repair part/component; how-
of precision instruments that have deviated from ever selective interchange does.
their standards.
(2) Selective Interchange. Selective inter-
d. Repair change is the exchange of selected serviceable
parts/components from a deadlined item of equip-
Repair is the return of an item to serviceable con- ment for unserviceable repair parts/com- ponents
dition through correction of a specific failure or from a like item. The maintenance activity is re-
unserviceable condition. The repair cycle starts quired to immediately reuse or requisition the
when the maintenance activity removes an unserv- parts to repair other items of equipment. Selective
iceable part or reparable component. It ends when interchange can decrease the time to repair an
the maintenance activity reinstalls the replacement item and return it to the user. Selective inter-
part or reparable component and places the equip- change is commonly recognized as a lesser degree
ment back in service. of cannibalization.
Joint Pub 1-02 defines a reparable item as “an
item that can be reconditioned or economically re- e. Modification
paired for reuse when it becomes unserviceable.” Modification changes the design or assembly
A maintenance activity reconditions or repairs a characteristics of systems, end items, components,
reparable component after its removal and keeps assemblies, subassemblies, or parts. A modifica-
it in stock for reuse when the same type of com- tion’s purpose is to improve equipment function-
ponent becomes unserviceable on another item of ing, maintainability or reliability (usually issued as
Maintenance Operations 1-3
a normal modification), or its safety characteris- support element (CSSE). Evacuation is the re-
tics (typically seen as urgent modifications). sponsibility of the combat service support
Maintenance activities routinely apply normal element.
modifications to upgrade otherwise operable
equipment. However, in circumstances that re-
quire urgent modification, the item may be placed 1003. Categories of Maintenance
in an administrative deadline status, pending appli-
cation, to prevent possible damage or unsafe op- Three categories of maintenance exist within the
eration. Extensive modifications are referred to as Marine Corps’ ground equipment maintenance
product improvements and are managed sepa- system: organizational, intermediate, and depot.
rately from modifications. See chapter 2 for addi- Within these three categories are five echelons of
tional information. maintenance. Each category and echelon is
authorized to perform certain maintenance func-
f. Rebuilding and Overhauling tions on certain commodity area items of equip-
ment (e.g., communications, ordnance, motor
Rebuilding restores items to like new condition.
transport). This capability is normally listed in a
The rebuilt item’s appearance, performance, and
unit’s table of organization (T/O) mission state-
capabilities are the same as originally manufac-
ment. Maintenance units are not restricted to per-
tured. Overhauling restores items to a serviceable
forming only one echelon of maintenance. For
condition under maintenance serviceability stan-
example, a unit may be authorized to perform first
dards. Rebuilding is a depot maintenance func-
and second echelon maintenance or even third or
tion. Depending on the item, overhauling may be
fourth. To manage maintenance effectively, com-
either a depot or intermediate maintenance func-
manders must understand their maintenance re-
tion. When rebuilding or overhauling an item, the
sponsibilities and the maintenance responsibilities
maintenance activity also performs required mod-
of those units in support.
ifications that were not previously applied.
a. Organizational Maintenance
g. Reclamation
The using unit performs organizational mainte-
Reclamation is action taken to restore con-
nance on its assigned equipment. All units within
demned, scrapped, abandoned, or damaged mate-
the Marine division, force service support group
riel, parts, and components. Reclamation actions
(FSSG), and aircraft wing possess the organiza-
include repair, refabrication, or renovation. The
tional capabilities to maintain their organic equip-
maintenance activity returns reclaimed items to
ment. Organizational maintenance focuses on the
the supply system. Reclamation is a depot
operator and crew preventive/corrective measures
function.
required by technical publications, equipment fail-
ure, and service schedules. Organizational mainte-
h. Recovery and Evacuation nance phases normally consist of inspecting,
Recovery is the process of retrieving or freeing servicing, lubricating, adjusting, and replacing
immobile, inoperative, or abandoned materiel. It parts, minor assemblies, and subassemblies. Or-
includes returning it to operation or taking it to a ganizational maintenance includes first and second
collection point for repair, evacuation, or dis- echelon maintenance responsibilities.
posal. Recovery is the responsibility of the owning
unit. Evacuation moves materiel from one combat First echelon maintenance is performed by the
service support (CSS) maintenance activity to an- user or equipment operator. This maintenance in-
other for repair or disposal. It includes moving cludes the proper care, use, operation, cleaning,
equipment between the owning unit’s mainte- preservation, lubrication, adjustment, minor re-
nance site and the supporting combat service pair, testing, and parts replacement prescribed by
1-4 MCWP 4-24
(reverse blank)
Chapter 2
Maintenance Management
“Equipment is manufactured at great expense. It is shipped 5000 miles by train, ship, and truck. It
is issued to the troops and eventually, with great labor, carried to the top of a mountain in Korea.
How many times, at the last point, has the whole enormous effort been thrown away, as carelessly
as a burnt match, by the happy-to-lucky negligence of the very people whose lives depend on
keeping the stuff in shape?”1—FMFRP 12-14
Maintenance management is the systematic ap- commodity area have maintenance management
proach to the maintenance of organizational officers. If a maintenance management officer is
equipment. There are four principal concerns in not identified in organizational structure, com-
maintenance management: command, resources, manders should assign, in writing, maintenance
production, and information. The ability to plan, management officer responsibilities as an addi-
organize, staff, direct, and control a command’s tional duty. The maintenance management officer
ground equipment maintenance program is the coordinates and integrates command efforts in the
foundation for sustainment in combat. maintenance management functional areas listed
in figure 2-1.
When these items are not available at the work specialty training as well as operator and
site, time is wasted. supervisor training.
(2) Mechanic. Optimally, mechanics should Personnel safety is also a constant concern. Con-
spend their time maintaining and repairing equip- tinuous vigilance by all maintenance personnel is
ment to a combat-ready status. Realistically, me- required to ensure that operating procedures and
chanics could spend a majority of their time on work methods do not expose personnel to injury
maintenance training, administrative duties, and or equipment to damage or loss.
other miscellaneous requirements. Therefore, ef-
fective time management demands that these non- c. Repair Parts
maintenance requirements be consolidated into In this publication, repair parts refer to consum-
blocks and coordinated with the appropriate cog- able repair parts and secondary reparables. Com-
nizant staff officers, subordinate commanders, and manders must ensure that repair parts and
noncommissioned officers in charge in order to maintenance-related supplies are requisitioned
reduce the impact of these nonmaintenance, yet when required, properly accounted for, and safe-
related, activities to a mechanic’s primary duty. guarded.
Only after a mechanic’s productivity has been
maximized can the command determine if ade- (1) Requisitioning. Repair parts must be placed
quate time has been allocated for equipment main- on requisition as soon as possible after a require-
tenance and repair. ment is identified. The need must be consistent
with the urgency and submission standards stated
Note: If mechanics are still unable to perform in MCO 4400.16, Uniform Material Movement
repair/maintenance activities within the alloca- and Issue Priority System. Units use the equip-
ted time, then either the available maintenance ment repair order shopping/transaction list
time must be increased, the workload reduced, or (EROSL) to requisition all repair parts and
a degraded level of readiness accepted. Some maintenance-related supplies for units supported
techniques for making these tradeoffs include ad- by the Field Maintenance Subsystem (FMSS). Use
ministrative storage, split shifts, and reduced op- of the EROSL or DD Form 1348 is optional for
erations. non-FMSS supported units. Reconciliation of
supply requisitions between the maintenance sec-
b. Personnel tion and its supply source must occur at least
The success of a unit’s maintenance effort is heav- every 2 weeks to review the status of repair part
ily influenced by its quantity and quality of per- requisitioning.
sonnel. The maintenance management officer
coordinates an annual review of the table of or- (2) Accounting. Repair parts are accounted for
ganization by the equipment commodity section by an equipment repair order (ERO) parts bin,
and recommends changes to the commanding offi- sometimes referred to as a layette. A copy of the
cer and G-1/S-1. Additionally, the table of organi- EROSL must be maintained in the layette. Parts
zation should be reviewed whenever the logistic for a pending job are placed in an ERO bin that is
capabilities statement, concepts of employment, designated for that specific job until all parts are
or capability statements change. received and maintenance personnel are available
to effect repairs. All parts for the same equipment
The maintenance management officer also ensures repair order are kept together in the same bin and
that maintenance and maintenance management the location is normally indicated by ERO num-
training requirements are included in the unit’s an- bers. Large parts may not fit into a bin and must
nual training plan. The annual training plan must be kept in another area; these parts are stored to-
address both mission and military occupational gether and must be marked with the applicable
2-4 MCWP 4-24
ERO number. The EROSL must indicate the al- Staff functioning affects site selection, shop lay-
ternate storage location. out, and shop organization. See chapter 6 and ap-
pendix A for more information.
Materiel stored in ERO bins must be inventoried
and validated at least every 2 weeks. EROSLs are f. Publications
annotated to indicate all repair parts, receipts
Publications control system operations are nor-
from supply sources, removal from the bin, trans-
mally managed by the S-1/adjutant, supply officer,
fers, and application to the equipment.
and maintenance management officer. Publica-
tions control is divided into four functional areas:
Another method of accounting and stocking re- automatic distribution control, internal distribu-
pair parts is a pre-expended bin. Pre-expended tion control, inventory control, and order control.
bins ensure adequate stockage of fast-moving
items resulting in an across the counter issue (1) Automatic Distribution Control. The auto-
rather than a back order. Pre-expended bins can matic distribution control system is managed via
save commanders time and money, and they can the publications listing. The publications listing
maintain readiness. MCO P4400.150, Consumer identifies all publications automatically distributed
Level Supply Policy Manual, gives specific guid- to an activity from the publications stock control
ance on establishing and maintaining pre- point at Marine Corps Logistics Base, Albany,
expended bins. Georgia. The activity’s S-1/adjutant, with the ad-
vice and assistance of the maintenance manage-
d. Tools and Support Equipment ment officer, maintains and reviews the
Tools and support equipment refer to tool sets, publications listing and ensures that all necessary
kits, chests, hoists, jacks, and stands. Loss of publications are listed. An outdated publications
tools slows maintenance and increases costs. listing can cause the activity to go without essen-
Therefore, proper inventory procedures and effec- tial information and/or receive publications that
tive control measures must be employed to reduce are no longer required. MCO P5600.31, Marine
loss of tools. Defective tools and equipment are Corps Publications and Printing Regulations,
also a safety hazard, and they are detrimental to contains procedures concerning the publications
the unit’s equipment readiness. Tools and support listing. The UM-MCPDS, Marine Corps Publica-
equipment are often classified and referred to as tions Distribution System (MCPDS) Users Man-
support equipment and test, measurement, and di- ual, provides detailed guidance on the automated
agnostic equipment. Marine Corps Publications Distribution System.
managers must understand the internal distribu- If a maintenance section is adequately funded, it
tion control system in order to properly manage has the necessary repair parts, tools, and other
publications and recommend timely changes to the maintenance-related supplies available. Funds
internal distribution control form and the publica- (dollars, budgets, or operating targets) are not di-
tions listing. rectly seen by the maintenance management offi-
cer or maintenance sections. Even though the
(3) Inventory Control. The inventory control impact of funding is indirect, the role of the main-
system manages publications libraries. An effec- tenance management officer is vital. The mainte-
tive inventory control system must ensure the nance management officer’s main funding
adequacy of two elements: publications conditions responsibility is to establish a budget and control
and on-hand quantities. Publications conditions fund outflow.
relate to the status of directives and publications
on the library shelf. Publications must be up-to- (1) Budgeting. The maintenance management
date with all changes properly entered. On-hand officer’s first task in the budgeting process is to
quantities must match the total quantities shown collect and evaluate previous expenditure infor-
in the “location of copy” column on the internal rmation. The maintenance management officer
distribution control form. The UM-PLMS, Ma- uses automated information systems to obtain ex-
rine Corps Publications Library Management penditure information. A review of the historical
System (PLMS) Users Manual, provides guidance expenditure information must include a check for
regarding the Marine Corps Publications Library correctness and consider expenses that are not
Management System (PLMS). covered on automated information system re-
ports. Past expenditures will not indicate future
There are two types of inventory methods used: needs unless the past expenditure is compared to
wall-to-wall and update inventories. Wall-to-wall future operations, logistic commitments, and new
inventories are conducted when libraries are in ex- equipment receipts. Once all information is gath-
treme disrepair. Update inventories are conducted ered, the maintenance management officer can as-
when either an updated NAVMC 2761, Catalog sist commodity and maintenance sections in
of Publications, SL-1-2 that contains an index of forecasting funding requirements.
authorized publications for equipment support, or
SL-1-3 that contains an index of publications (2) Control. Funds must be controlled once they
authorized and stocked by the Marine Corps is are allocated. The maintenance management offi-
received. cer provides staff advice on internal allo- cation of
money. The maintenance management officer en-
(4) Order Control. The order control system is sures that funds obligated for maintenance re-
an outgrowth of the inventory control system. sources are applied in the best manner and that
When publications become worn out or on-hand periodic fiscal reviews are conducted. The mainte-
quantities do not match total quantities, units nance management officer provides control by co-
must replace damaged or missing publications. ordinating with supply and fiscal officers and
Units order publications through the Marine presenting the commander with the information
Corps Publications Distribution System. An effec- needed to determine reallocation of funds, to can-
tive requisition control system depends on the cel requisitions, or to request additional funds. To
regular reconciliation of individual libraries with facilitate the control of funds, the maintenance
the unit publication control point. management officer, in conjunction with the unit’s
supply and fiscal officer and in coordination with
g. Funds the command’s comptroller, develops a unit’s job
2-6 MCWP 4-24
order number structure. This structure allows eas- required maintenance service (e.g., operator main-
ier information collection and sound decisionmak- tenance was performed and equipment was
ing because expenditures are listed by cleaned). Equipment that is incomplete (missing
maintenance commodity area (e.g., motor trans- equipment parts or records) or not properly pre-
port, engineer). pared by the unit or activity requesting mainte-
nance should not be accepted into the
maintenance cycle until discrepancies are cor-
2003. Production rected.
Production is the physical performance of various Once equipment is accepted it is given a work pri-
maintenance functions. These functions include ority based on the ERO priority, operational re-
preventive maintenance checks and services quirements, and available maintenance resources.
(PMCS), corrective maintenance, modification, Based on the assigned priority, the equipment is
calibration, conversion, modernization, overhaul, then scheduled to arrive at the maintenance facil-
and rebuild. Some of the functions are generally ity at, or immediately before, the time mainte-
performed only by depots, while others are per- nance resources are available. The equipment is
formed by field units (see table 2-1). Actions re- held by the owning unit in a unit recall status until
lated to maintenance production (recovery, facilities/personnel are available to conduct main-
quality control, and equipment inspection) are tenance actions and the unit is contacted. Until
also discussed in the following subparagraphs. that time, operationally safe equipment is returned
These functions are embedded within the four to the using unit, which gives the owner maximum
phases of the maintenance process. use and avoids congestion at maintenance sites.
The assignment of equipment to a specific mainte-
a. Maintenance Phases nance shop within the maintenance section occurs
upon completion of the acceptance inspection and
The maintenance process consists of four mainte-
scheduling.
nance phases. These phases include the accep-
tance of equipment, equipment induction, active
(2) Equipment Induction Phase. Induction is
maintenance, and maintenance closeout.
the physical commitment of an ERO and its asso-
ciated equipment to a specific shop. Delivery of
(1) Acceptance of Equipment Phase. The ac-
the equipment from the owning unit is requested
ceptance of equipment phase is the initial step of
once the maintenance shop is capable and ready to
the maintenance process. It consists of an accep- perform maintenance actions. This request should
tance inspection, scheduling, and assignment. The be given to the using unit or appropriate coordi-
purpose of the acceptance inspection is to verify nator as soon as possible. Induction of equipment
that equipment is complete and prepared for the into a specific shop is determined by the priority
Preventive Maintenance
Checks and Services Corrective Overhaul Rebuild
Calibration Modification Conversion Modernization
Field Functions Depot Functions
1. Preventive maintenance checks and services. 1. All field functions.
2. Corrective maintenance. 2. Overhaul.
3. Calibration. 3. Conversion.
4. Modification. 4. Rebuild.
5. Fabrication. 5. Modernization.
Maintenance Operations 2-7
assigned during the equipment acceptance phase positive indication that the action has been
in accordance with the priority requested by the successfully completed.
owning unit.
(d) Quality Control. Quality control requires a
(3) Active Maintenance Phase. Production ac- complete equipment check to determine proper
tions performed following induction of the ERO completion of maintenance actions and that equip-
and its associated equipment into a maintenance ment records are completed per TM 4700-15/1,
shop constitute the active maintenance phase and Ground Equipment Record Procedures. Equip-
the beginning of the repair process. This phase is ment not performing satisfactorily is rejected and
performed in a sequence of logical steps designed recommendations are made for further mainte-
to ensure that the required services are conducted nance actions. Acceptable performance results in
in an efficient and effective manner. Continual the completion of the active maintenance phase
emphasis is placed on the quality control of the and the movement of the equipment to the
actions and tasks performed. The frequency of closeout phase. Quality control should be per-
quality control inspections depends on the skill formed by experienced maintenance personnel
and experience of the individual technicians or since this is the last opportunity to catch any defi-
mechanics and the overall complexity of the ac- ciencies before equipment is returned to
tions. The following steps are conducted during operation.
active maintenance.
(e) Cleanup of Maintenance Area. Time and re-
(a) Inspection of Equipment. The initial step in- sources must be allocated to cleanup the mainte-
volves a detailed inspection of equipment by nance area. Support, test, measurement, and
maintenance personnel. This inspection is the diagnostic equipment, (including tools) must be
foundation of the maintenance process and in- cleaned, serviced, and inventoried to facilitate fu-
cludes locating and identifying equipment mal- ture maintenance actions. Technical publications
functions, inventorying the equipment and its must be returned to their proper locations. Defec-
contents, and verifying that all equipment records tive parts and other residue must be removed
associated with the required service are prepared from the maintenance area using proper disposal
in accordance with current publications. procedures.
(b) Preparation for Maintenance Actions. Prepa- (4) Maintenance Closeout Phase. The close-
ration for maintenance actions includes the assem- out phase of the maintenance process commences
bly of the appropriate technical publications and when equipment has been repaired and the serv-
other technical information; support equipment; iceable item is returned to the owner or when a
and test, measurement, and diagnostic equipment decision has been made to evacuate or dispose of
to perform the required services. Adequate prepa- the equipment. Maintenance personnel must en-
ration reduces the actual time required to perform sure that the closeout process is accurate, com-
the maintenance and avoids initiating maintenance plete, and coordinated. This includes ensuring that
actions if resources are not available. the ERO and equipment records are correctly
completed. The closeout phase requires close co-
(c) Performance of Maintenance. Performance ordination with owning unit personnel to ensure
of all maintenance actions is per the appropriate that they are notified as soon as the equipment is
technical publication. Maintenance actions in- ready for pickup. This reduces vehicle congestion
clude performance of preventive maintenance at the maintenance facility and allows the using
checks and services, corrective maintenance, ap- unit to employ all of its assets. The using unit
plication of modifications, and calibration. Once must make every effort to pick up their repaired
maintenance actions are completed, the equipment equipment promptly. Any special packaging, pres-
is given final adjustments. Bringing the equipment ervation, transportation, and shipping require-
performance to within specified tolerances is a ments are addressed during this phase.
2-8 MCWP 4-24
knowledge of their equipment and increases main- safe, reliable service until the next scheduled pre-
tenance productivity. ventive maintenance checks and services. The op-
erator or crew of the equipment should provide
If a unit is operating under adverse climatic or ter- maintenance personnel with first- hand informa-
rain conditions, commanders are authorized to tion on irregularities or indications of equipment
conduct second echelon PMCS actions more fre- malfunction.
quently than scheduled. Preventive maintenance
checks and services may also be deferred or inter- (c) Annual PMCS. The normal interval for annual
vals extended if equipment is placed in an admin- PMCS is 12 months, but it may be advanced when
istrative storage program or equipment is placed the operating criteria specified in equipment tech-
on administrative deadline (see MCO P4790.2 for nical publications are achieved earlier. Equipment
specific criteria). There are certain items that, due technical publications provide the requirements
to technological advances, use different criteria for annual PMCS and other less frequent preven-
for scheduling second echelon PMCS (see the ap- tive maintenance checks and services. Annual
propriate technical publication for preventive PMCS is greater in scope than semiannual PMCS
maintenance checks and services requirements). and additional time is required to accomplish an-
The different classifications of second echelon nual PMCS requirements. The operator or crew
PMCS are discussed below. of the equipment should provide maintenance per-
sonnel with firsthand information on irregularities
(a) Quarterly PMCS. The normal interval be- or indications of equipment malfunction.
tween quarterly PMCS is 3 months. Economy of
operation demands that, within sound practices of (d) Biennial PMCS. The normal interval for bien-
safety and reliability, maximum useful life is ob- nial PMCS is 24 months, but it may be advanced
tained from materiel resources. Worn parts and when the operating criteria specified in the equip-
materials are replaced during preventive mainte- ment’s technical publications are achieved earlier.
nance checks and services. Equipment technical publications provide the re-
quirements for biennial PMCS and other less fre-
Note: The life expectancy of the part/material quent preventive maintenance checks and
and the nature of the anticipated operations must services. Biennial PMCS is greater in scope than
be taken into consideration. annual PMCS and additional time is required to
accomplish the maintenance requirements.
When possible, the operator or crew of the equip-
ment should be asked by maintenance personnel (e) Special PMCS. Special PMCS procedures are
to obtain first-hand information on irregularities necessary when equipment has been exposed to
or indications of equipment malfunctions. harsh environments (e.g., salt water, fresh water,
operations conducted in loose sand or mud).
(b) Semiannual PMCS. The normal interval for Equipment exposed to harsh conditions should be
semiannual PMCS is 6 months. Equipment techni- checked thoroughly for contamination, washed
cal publications provide the requirements for thoroughly with fresh water, and have appropriate
semiannual PMCS and other less frequent preven- services performed per the applicable technical
tive maintenance checks and services. Economy publication/instruction. In most instances, a spe-
of operation demands that, within sound practices cial PMCS will resemble a semiannual, annual, or
of safety and reliability, maintenance personnel biennial service. The commander may authorize
extract the maximum useful life from materiel re- the modification of the PMCS schedule to reflect
sources. Worn parts and materials are replaced the preventive maintenance checks and services
during preventive maintenance checks and serv- performed and reschedule existing preventive
ices only when it is determined, after considering maintenance checks and services.
life expectancy and the nature of anticipated op-
erations, that they cannot be expected to provide c. Corrective Maintenance
2-10 MCWP 4-24
Corrective maintenance actions are performed to used, should be maintained within each shop to
restore a defective item to a specified condition. ensure that selected items are readily available.
The detection of defective equipment may occur
during routine preventive maintenance checks and (3) Correcting Equipment Faults. Fault cor-
services or through operational failure of the rection is the goal of all corrective maintenance
equipment. Corrective maintenance is a very time- actions. Proper maintenance techniques are em-
consuming process and therefore requires close ployed to ensure that repair parts are installed
coordination of the maintenance workload and correctly. Reassembly is accomplished in se-
available resources. quence, including the proper servicing and the use
of test and measurement devices at the appropri-
If a required piece of equipment is unusable due ate stages of equipment reassembly. Major com-
to a failed part, then the equipment must be re- pleted maintenance actions are recorded on the
paired. However, since corrective maintenance is ERO, this provides information for future man-
very time consuming, the urgency of repair is rela- agement decisions and appropriate entries on
tive to the unit’s mission. To repair equipment equipment records.
that requires an echelon of maintenance higher
than that authorized at the owning/using unit, it d. Modification
must be evacuated to the support activity author-
Equipment modifications are maintenance actions
ized to perform the maintenance. Excessive delays
performed to change the configuration of equip-
in evacuation postpone corrective action and
ment systems, end items, components, assemblies,
therefore must be avoided.
subassemblies, or parts to improve equipment
functioning, maintainability, reliability, and/or
There are three basic stages of corrective main-
safety characteristics. Primary sources of modifi-
tenance.
cation requirements are manufacturer’s engineer-
ing change proposals and comments and
(1) Isolating Equipment Malfunctions. During
suggestions made by using units via the Product
this stage, maintenance personnel attempt to iso-
Quality Deficiency Report. Complaints regarding
late the equipment’s malfunction so that
equipment malfunction or poor design should be
corrective action can begin. Personnel use the
appropriate support equipment; test, measure- channeled to agencies responsible for procure-
ment, and diagnostic equipment; and the proper ment/development of Marine Corps equipment.
step-by-step procedures described in the applica-
(1) Modification Responsibility. It is the re-
ble technical publication to isolate the cause of
equipment malfunctions. Once the cause is iso- sponsibility of the using unit to determine which
lated and fault diagnosis confirmed, personnel modifications have been issued for their assigned
estimate the cost of the required maintenance and equipment and to take the necessary action for
determine if the equipment is economically repair- compliance. The modification instruction identi-
able. If the equipment is determined not to be fies the resources, skills (to include echelon of
economically reparable, personnel stop active maintenance), and time necessary to perform the
maintenance, and request disposition instructions. modification. If the application is to be applied by
the unit, it is scheduled and performed at that
(2) Obtaining Required Repair Parts. The level. For higher echelon modifications, the using
requisition of repair parts must be accurate to en- unit must arrange to evacuate the equipment to
sure the receipt of intended items in a timely man- the appropriate echelon of maintenance.
ner. Inaccurate requisition procedures (i.e., using
outdated publications and improperly completed (2) Modification Control. Equipment modifica-
forms) result in receipt of unneeded repair parts, tions must be controlled to ensure safe equipment
delays in maintenance production, and wasted operations. TM 4700-15/1 outlines unit responsi-
maintenance funds. Pre-expended bin levels, when bilities in establishing a modification control
Maintenance Operations 2-11
program. It also provides instructions for the ranges and functions tested and found within ap-
completion and disposition of the records main- plicable tolerances. The calibration label indicates
tained by the unit. The maintenance management the limitations (e.g., clockwise).
officer prepares periodic unit modification con-
trol program reports for the commander. There (3) Inactive. Inactive applies to instruments that
are two classifications of modifications: normal will not be used in the foreseeable future. Equip-
and urgent. ment is not allowed to be in an inactive status for
more than 3 years at a time. If equipment is inac-
Modifications classified as normal are usually tive for 3 years, the unit should re-evaluate the
completed during regular maintenance activities need for the equipment. If the equipment is still
such as preventive or corrective maintenance required, personnel request a new inactive label
services. Normal modifications comprise the ma- from the supporting calibration laboratory.
jority of modifications and generally do not re-
strict the operation of the equipment. Typically, (4) Calibration Not Required. Calibration not
the unit has 1 year from the date of the modifica- required applies to instruments that are used to
tion instruction to complete the actions required make measurements of a noncritical nature or for
by a normal modification. instructional purposes. However, some instruc-
tional equipment will require calibration or special
Modifications classified as urgent (printed at the calibration.
top of the modification instruction) are issued to
prevent serious injury to personnel and/or major f. Fabrication
equipment damage. Urgent modification instruc-
Fabrication is the process of constructing or
tions specify a date that the actions must be com- manufacturing parts or components that are not
pleted by and dictate any restrictive operating available through the normal supply system. It
conditions until the modification is completed. For should not be used to circumvent the normal sup-
example, an urgent modification instruction might ply system. Fabrication is primarily performed at
be issued to correct a faulty condition concerning the intermediate maintenance activity. However,
the 5-ton trucks’ fuel tanks. A leaking fuel tank units may find themselves in situations where it is
could result in serious injury to operators and necessary to perform fabrication. Fabrication is
transported troops/cargo. Based on this safety generally accepted when it is within the unit’s
hazard, the modification instruction would state authorized echelon of maintenance. Once a deci-
that the truck is not to be operated (deadlined) sion to fabricate an item is made, the unit must
until corrective actions are completed. consider safety and installation requirements. Per-
sonnel safety and damage to equipment must be
e. Calibration addressed. Fabricated items are intended to re-
Calibration is the process of adjusting items so place a like item, not create a new item. Fabri-
that they measure within a standard deviation. cated items that change the performance of
This applies to equipment submitted for repair; equipment or require changes in structure (e.g.,
maintenance tools and equipment; and test, meas- drilling additional holes) are not authorized.
urement, and diagnostic equipment. Test, meas-
urement, and diagnostic items are identified with
labels that classify their category of calibration. 2004. Information
There are four categories of calibration:
Maintenance information provides the basis for
(1) Calibrated. Calibrated applies to instruments
managing a unit’s equipment maintenance pro-
gram. Maintenance information is comprised of
with all ranges and functions tested and found
records, reports, and an automated information
within applicable tolerances.
system. Proper upkeep and use of maintenance in-
(2) Special Calibration. Special calibration ap-
formation are invaluable tools for analyzing and
plies to instruments with only a portion of the
evaluating maintenance performance. The
2-12 MCWP 4-24
maintenance performance analysis and evaluation Maintenance reports contain information that
are generally expressed in the form of equipment commanders use to determine policy, to plan, to
readiness. establish controls, to evaluate operations and per-
formances, and to prepare other reports. They are
a. Records generally summarized and may be transmitted on
a recurring, one time, or occasional basis. Mainte-
Preparing and maintaining records consumes both nance reports fall into one of the following classi-
personnel and materiel resources. Therefore, re- fications that reflect who generated the request.
cords must be kept to the minimum consistent
with required Marine Corps directives and publi- (1) Headquarters, Marine Corps Reports. Re-
cations. Commanders should ensure that records ports submitted to Headquarters, Marine Corps
originating within the unit are not prepared and include maintenance reports required by both Ma-
used in lieu of or in addition to those required by rine Corps directives and other forms of commu-
Marine Corps directives and publications. Mainte- nication. They may be produced by either manual
nance records are classified as equipment, re- or automated means and normally contain a report
source, and local records. TM 4700-15/1 contains control symbol. Reports currently required on a
instructions for the preparation, use, and disposi- recurring basis are listed in the MCBul 5214 se-
tion of the required forms and records for the op- ries, Information on Requirements Management
eration and maintenance of Marine Corps ground
in the Marine Corps. MIMMS is the primary
equipment.
source for maintenance reports required by Head-
quarters, Marine Corps.
(1) Equipment Records. Equipment records
are maintained for a specific item of equipment.
(2) Field Reports. Field reports list a unit’s spe-
Equipment records are an integral part of the
cial field requirements that Headquarters, Marine
equipment because they contain historical data
Corps reports do not address. Using these reports
concerning repairs performed, maintenance sched-
should be kept to a minimum so that units are not
ules (i.e., PMCS schedule), and modifications. To
overburdened with administrative work. When-
ensure this information is available to maintenance
ever a requirement for a field-originated report is
personnel, equipment records must accompany
established on a recurring basis, it must be for-
equipment when it is evacuated for maintenance,
warded to the Commandant of the Marine Corps
transferred, or temporarily loaned to another unit.
for nomination as a standard report.
(2) Resource Records. Resource records doc-
(3) External Agency Reports. At times, a unit
ument the unit’s maintenance efforts (e.g., modifi-
may be required to submit reports to an activity
cations, preventive maintenance checks and serv-
outside of the Marine Corps. Requests for reports
ices, calibration). These records contain historical considered invalid should be referred to the next
information and provide the basis for evaluation senior unit in the administrative chain of com-
of past performance and planning for future mand.
efforts/requirements.
(3) Local Records. Local records are discour- c. Automated Information Systems
aged. Local records should not be initiated unless Automated information systems were developed
a definite requirement has been established and it to assist the field user by automating manual ad-
has been determined that records required by ministrative work. These systems provide com-
higher headquarters will not satisfy the require- manders at all levels with excellent, up-to-date
ment. information and management tools. MIMMS is
the current automated system for the maintenance
b. Reports
field and is discussed in appendix B.
Maintenance Operations 2-13
Headquarters, Marine Corps (HQMC code LP) ment normally considered mission-essential at the
encourages the use of automated systems to cap- battalion level; for example, M16A2 rifles are not
ture, track, and schedule maintenance actions/in- included due to their high density. However, the
formation. As the system sponsor for all Class I list is sufficiently representative to provide an ade-
supply and maintenance systems, Headquarters, quate measure of the equipment readiness of the
Marine Corps (HQMC code LP) intends to inte- operating forces.
grate both maintenance and supply under a single
system with the fielding of Asset Tracking Logis- (2) Table of Equipment Deficiencies. Table of
tics and Supply System Phase II+. equipment deficiencies are items that are author-
ized but not on-hand. To remain a force in readi-
ness, the Marine Corps plans, programs, and
d. Readiness Reporting budgets annually for the modernization of its
As prescribed in MCO 3000.11, Marine Corps equipment and capabilities. The modernization of
Ground Equipment Resource Reporting mission-essential equipment could have a substan-
(MCGERR), commanders are required to report tial effect on MCGERR reporting. Accordingly, a
the level and condition of MCGERR-reportable replacement item and the item it is replacing may
equipment. Table 2-2 identifies categories of be excluded from MCGERR reporting during the
ground equipment readiness. MCGERR- modernization (phase in/phase out) of equipment.
reportable equipment is identified in MCBul 3000,
Table of Marine Corps Ground Equipment Re- (3) Equipment Deadlines. Equipment dead-
source Reporting (MCGERR) Equipment. Equip- lines are items that are not capable of performing
ment included in this bulletin must be a principal their designed combat missions due to their need
end item that is 85-percent fielded Marine Corps- for critical repairs. Ground equipment readiness
wide (including the Reserves), nominated by ei- reporting begins at maintenance shops with the
ther the field commands or Headquarters, Marine
Corps, and accepted for inclusion (or deletion) by
the Commandant of the Marine Corps (Logistics). Table 2-2. Categories of Ground
Equipment Readiness.
Note: The term “fielded Marine Corps-wide”
Percentage of
means that the system’s manager, in coordination Mission-Essential Equipment
with the project manager for the principal end Category That Is Operationally Ready
items, has verified to the Commandant of the
Marine Corps that sufficient quantities are dis- C-1 90-100
tributed throughout the Fleet Marine Force and C-2 70-89
Reserves to meet the 85-percent criteria. C-3 60-69
C-4 0-59
Readiness reporting for Marine Corps supplies
and equipment has three components: mission- Notes:
1. MCBul 3000 lists mission-essential equipment
essential equipment, table of equipment deficien- and provides an adequate measure of the
cies, and equipment deadlines. equipment readiness of the operating forces.
2. Per Joint Pub 1-02, operationally-ready equip-
(1) Mission-Essential Equipment. Mission- ment is “the status of an item of equipment in
essential equipment is governed by MCBul 3000. the possession of an operating unit that indi-
cates it is capable of fulfilling its intended mis-
This bulletin lists selected items of mission- sion and in a system configuration that offers a
essential equipment required to be reported to high assurance of an effective, reliable, and
higher headquarters. The items that appear in this safe performance.”
bulletin do not represent a complete list of equip-
2-14 MCWP 4-24
determination of deadline status. Table 2-2 identi- mission rests with the commander. Excessive de-
fies categories of ground equipment readiness. lays in evacuation postpone corrective action and
Deadline status is entered into MIMMS at the therefore must be avoided.
maintenance shop level via the ERO input. Dead-
line status is normally determined by commodity
managers/shop officers. However, final authority
for determining whether or not a piece of equip-
ment is capable of performing its assigned combat
Chapter 3
Maintenance-Related Programs
“If field operations continue for a considerable length of time, it may be necessary to reinforce the
cartridge belts, magazine carriers, and other web equipment with leather. This has been done in
the past by local artisans in the theater of operations.”1—FMFRP 12-15
Marine Corps by cyclically rebuilding items before 3003. Recoverable Item Program
they become unreparable. TI-4710-14/1, Replace-
ment and Evacuation Criteria, USMC Equip- Equipment not included in the Replacement and
ment, lists the equipment administered by this
Evacuation Program is disposed through the Re-
program. It also contains specific criteria for
selecting/nominating equipment for rebuilding. coverable Item Program, also known as the WIR
Program. This program is outlined in MCO
P4400.82, Marine Corps Unified Materiel Man-
a. Equipment Nomination agement System (MUMMS) Control Item Man-
Organizations nominate equipment for rebuilding agement Manual. The WIR Program provides for
and replacing to the Commandant of the Marine the recovering, reporting, and managing of equip-
Corps through the chain of command and the lo- ment that cannot be repaired within the resources
cal Replacement and Evacuation Program coordi- of the field commander and for the disposal of
nator, in the supporting FSSG. Nominations are
items that are beyond economical repair. Com-
made each year for the next 3 years. The Com-
mandant then uses unit nominations and the manders replace unserviceable items through the
workload of the depot maintenance activities to supply system.
establish yearly allowances for Marine Forces.
Marine Forces then allocate allowances to their
major subordinate commands. Once allocations 3004. Corrosion Prevention and
are physically made available, nominating units Control Program
are authorized to turn in items to the force service
support group and receive replacements. Marine Corps tactical ground and ground support
equipment are particularly susceptible to corro-
b. Selection sion and other types of moisture damage due to
When a unit is directed to turn in equipment for their material composition and assigned missions
replacement and evacuation they must select the in moisture-laden environments. Compounding
items that are in the worst condition, yet still re- the problem is the fact that a significant portion of
pairable. Equipment that is not repairable does not Marine Corps ground equipment is stored out-
qualify for the Replacement and Evacuation doors without shelter and subject to the direct,
Program. corrosive effects of the environment. The Corro-
sion Prevention and Control Program was estab-
c. Equipment Exchange lished to extend the useful life of Marine Corps
tactical ground and ground support equipment. Its
When units turn in equipment they should ensure intent is to reduce maintenance requirements and
that all collateral (e.g., SL-3 gear) equipment re-
associated costs through the identification, imple-
quired by higher headquarters accompanies the
turn-in. Generally, a requirement exists for miss- mentation, and development of corrosion preven-
ing collateral equipment to be noted on the limited tion procedures and corrective corrosion control.
technical inspection of an item. The unit should The Corrosion Prevention and Control Program
indicate if responsibility for the loss is known or seeks ways to use technologies and processes that
what action is ongoing to determine responsibil- will repair existing corrosion damage and prevent,
ity. Before accepting a replacement item, the unit or retard, future corrosion damage to Marine
should inspect and ensure that the item is in con- Corps ground and ground support equipment.
dition code A as defined in the applicable supply MCO 4790.18, Corrosion Prevention and Con-
directives. If not, the unit should either refuse the trol Program, and TM-3080.12, Corrosion Con-
item or note the deficiencies on the acceptance in- trol G/Equipment, address the Corrosion
spection sheet. Prevention and Control Program in detail.
Maintenance Operations 3-3
(reverse blank)
Chapter 4
Maintenance Organizations
“There is no area of military activity where so many departures from the theoretical ideal are re-
quired by circumstances as in organization. Yet the fact that compromises which produce defects
are inevitable should not lead us to ignore them. Instead we have the task of recognition and
compensation.”1—FMFRP 12-14
Task organization is a quantitative and qualitative over a large geographic area. The FSSG is the
process used to best structure available assets to Marine expeditionary force’s combat service sup-
support a specific mission and concept of opera- port element. It supports the Marine expedition-
tions. It is applicable whether commanders are ary force command element; surveillance,
building combat power or maintenance capability. reconnaissance, and intelligence group; ground
Within this context, the CSSE is the Marine air- combat element comprised of one Marine divi-
ground task force (MAGTF) element that pro- sion; and aviation combat element comprised of
vides the task-organized intermediate ground one Marine aircraft wing.
maintenance capability to support requirements
beyond the organic capabilities of the supported b. Combat Service Support Group
elements. Combat service support elements vary The combat service support group is the task-
in size from temporary, task-organized combat organized combat service support element of a
service support detachments (CSSD) to perma- unit with less than the full spectrum of capability
nent organizations such as the FSSG. Normally, normally afforded a Marine expeditionary force.
there is only one combat service support element For example, a combat service support group cur-
in a MAGTF. rently supports Marine units stationed in Hawaii.
Personnel and equipment are assigned to the com-
bat service support group from permanent battal-
4001. Types of MAGTF Combat ions of the FSSG. This support group provides
Service Support Elements general and direct combat service support to des-
ignated units. If required, it may be augmented by
The designation, size, and composition of the assets from the division and/or wing.
MAGTF combat service support element is deter-
mined by the mission, size, and composition of the c. Marine Expeditionary Unit Service
MAGTF it supports. There are five basic types of Support Group
combat service support elements.
The MEU service support group (MSSG) is a
task-organized combat service support element
a. Force Service Support Group that provides combat service support to all ele-
The FSSG is a permanently structured command. ments of the Marine expeditionary unit. Like the
Its mission is to provide combat service support combat service support group, the MEU service
to the Marine expeditionary force. The FSSG nor- support group draws its personnel and equipment
mally has eight permanent battalions, but task or- from the organic battalions of the FSSG. The
ganizations can be created from these battalions MSSG may also contain assets from the division
to support Marine expeditionary force operations and/or the wing.
4-2 MCWP 4-24
support area may expand to include the full spec- combat service support area deliver directly to the
trum of combat service support functions or it users at the forward repair and replenishment
may be designated as a CSSA. Also, it may even- points.
tually be dissolved or become the force combat
service support area. In some situations, the beach
support area may be the only combat service sup- 4003. Permanent Organizations
port installation ashore. In other situations, it may
be one of several combat service support installa- Permanent organizations are established with ta-
tions. The CSSE commander determines the bles of organization and tables of equipment.
beach support area’s composition (e.g., dumps, Each unit’s table of organization establishes its
issue points, etc.) based on the MAGTF concept structure and mission. Its table of equipment es-
of operations. tablishes the quantity and type of authorized
equipment required to perform the unit’s assigned
d. Landing Zone Support Area mission. By table of organization and table of
equipment, 11 MAGTF units of battalion and
The landing zone support area (LZSA) is a com- squadron size or larger possess organic mainte-
bat service support area established to support nance capabilities. There are two permanent com-
helicopterborne operations. It is normally devel- bat service support organizations within the
oped from an existing helicopter landing zone that Marine expeditionary force that provide inter-
was established by a helicopter support team. A mediate ground maintenance support to the
helicopter landing zone is established when a MAGTF: the force service support group and the
combat service support buildup beyond the heli- Marine wing support group. These organizations
copterborne unit’s basic load of supplies and am- possess most of the assets required to task-
munition or organic CSS capabilities is required. organize the combat service support element.
When a combat service support buildup begins in Normally, the FSSG is the primary source of in-
a helicopter landing zone, control of the helicop- termediate maintenance support for the ground
ter landing zone normally transitions from the combat element.
helicopterborne unit’s helicopter support team to
a designated combat service support unit and the a. Maintenance Battalion, FSSG
helicopter landing zone is redesignated an LZSA.
Although the landing zone support area can be
(1) Mission. The maintenance battalion provides
expanded into a CSSA, it is most often a short-
intermediate (third and fourth echelon) mainte-
term installation with limited capabilities. Typi-
nance for Marine Corps-furnished tactical ground
cally, an LZSA only contains dumps for rations, equipment of a Marine expeditionary force.
fuel, ammunition, and water.
(2) Concept of Employment. The battalion es-
e. Repair and Replenishment Point tablishes and operates intermediate level, direct
A CSSD normally establishes a temporary repair and general support maintenance facilities in sup-
and replenishment point to support mechanized or port of the Marine expeditionary force or any
rapidly moving units. Repair and replenishment smaller combination of MAGTF. If the mainte-
points are either a pre-established point or a hast- nance battalion is supporting MAGTFs smaller
ily selected point to rearm, refuel, or provide re- than a Marine expeditionary force, it forms pla-
pair services to the supported unit. Depending on toon detachments from each of the functional
the mission, a combat service support detachment companies (while maintaining unit integrity) as-
may establish multiple repair and replenishment signed to the supporting combat service support
points. Although the main body of the CSSD usu- element. The detachments are task-organized to
ally follows the advancing unit, repair and replen- provide all second and third echelon and limited
ishment points are normally located in forward fourth echelon secondary reparables capabilities.
areas near the supported unit’s trains. To mini- Maintenance support of major end items is
mize the handling of supplies, vehicles from a
4-4 MCWP 4-24
Maintenance
Battalion
Maintenance Planning
“The factors and methods which give great economy in a stable situation may not be adequate for
the changing situation.”1—FMFRP 12-14
“. . . Mere size is no suitable object; rather, the efficiency of the logistic support rendered is the
true aim.”2—FMFRP 12-14
MCDP 4 shows that common to all logistic sys- determining support requirements, assigning pri-
tems are a distribution system and command and orities, and allocating resources.
control. The distribution system is made up of
bases (sources sized and located in accordance a. Determining Support Requirements
with need and capability) and distribution proce-
Supported unit commanders must determine and
dures (means, parameters, and criteria to distrib-
identify combat service support mission require-
ute). Command and control provides the ability to
ments that are beyond their organic capabilities.
administer, monitor, and adjust the distribution
To accurately determine the type and amount of
system as required. Therefore, planning efforts
external service support, the supported com-
must focus on developing a distribution system
mander’s staff must calculate the exact quantities
with the command and control appropriate to the
of needed supply categories. The following fac-
mission and scheme of maneuver.
tors should be considered when calculating need:
Planning expeditionary maintenance to support
MAGTF operations must start early and be ad- MAGTF mission.
justed, as necessary, with the receipt of the initiat- Characteristics of the objective area, inclu-
ing directives and other planning documents. Both ding available resources, climate, weather,
the supported and supporting units must know and terrain.
each other’s responsibilities if a unit commander is Enemy capabilities.
to receive timely and appropriate combat service
Characteristics of operations to be sup-
support. While maintenance and supply are sepa-
ported.
rate functions, maintenance support planning must
parallel and interface with supply planning efforts. Duration of the operation.
It is also essential to make maximum use of the Capability and dependability of the transpor-
FSSG’s major base/ installation facilities to pre- tation system (outside and inside the objec-
pare equipment prior to deployment. tive area).
Tasks requiring special supplies and equip-
ment.
5001. Supported Unit
Experience in similar operations.
Responsibilities
Supported unit commanders, through the coordi- b. Assigning Priorities
nated efforts of the G-3s/S-3s and G-4s/S-4s, ini- Units assign priorities based on their assigned
tiate combat service support detailed planning. force activity designator (FAD) and urgency of
Combat service support planning begins by need designators as outlined in MCO 4400.16.
5-2 MCWP 4-24
Units upgrade force activity designators based on and be informed of changes as they occur. Close
changes to the unit’s mission. Commanders must coordination between the supporting CSSE and
be keenly aware of their FAD and when it the supported unit prevents support short- falls.
changes. A unit’s FAD directly translates to
whose equipment is fixed first. The assignment of b. Procuring Assets
priorities affects the supporting CSSE’s concept
of combat service support and must be coordi- The supporting combat service support element
nated by the supported unit and the combat serv- procures assets based on the requirements needed
to sustain the supported unit. To prevent unnec-
ice support element to ensure that adequate
combat service support is available during the essary logistical burdens, the CSSE planner
early stages of an operation. Ultimately, the carefully reviews requirements to avoid overes-
MAGTF commander oversees assignment of pri- timating requirements.
orities.
c. Distributing Assets
c. Allocating Resources The distribution of assets is the actual perform-
Supported unit commanders allocate available or- ance of the supported service. The distribution of
assets has the most critical impact on responsive-
ganic CSS resources, including the assets they
ness, flexibility, and economy of combat service
retain as a reserve, to subordinate elements within
support. Assets distribution can be successfully
their organization. These allocations must support
achieved only by coordinated predeployment
and complement the MAGTF’s concept of opera-
planning, which anticipates and provides for unex-
tions and reflect previous decisions concerning re-
pected replenishment opportunities, surge require-
quirements and priorities. Like supported unit
ments, and alternate delivery means.
commanders’ assignment of prior- ities, their allo-
cation of combat service support resources also
affects the supporting CSSE’s concept of combat
service support.
5003. Combat Service Support
Planning References
5002. Supporting Unit Combat a. Table of Authorized Materiel
Service Support Responsibilities The table of authorized materiel (TAM) provides
general information and instruction on the supply
The supporting combat service support planner system; specific information on classes I, II, III,
can be an important asset to the supported unit. IV, and VII; and replacement factors needed to
The supporting combat service support planner project anticipated losses or consumption rates.
can advise and assist the unit in refining require- This source document is the one most used by
ments, procuring the resources to meet those re- Marine Corps personnel with regards to logistic
quirements, and planning for the distribution of planning.
assets to support the mission and concept of
operations. b. Mechanized Allowance List and
Table of Equipment
a. Determining Requirements The mechanized allowance list (MAL) and table
Requirements are based on the supported com- of equipment (T/E) identify the equipment that a
manders concept of operations and the situation. unit rates and the total of what it has on-hand or
The identified requirements must address each on order. The table of equipment is primarily con-
CSS functional support area. The CSSE must cerned with class VII items. It also assists in the
know the requirements early in the planning phase determination of class V because it identifies the
Maintenance Operations 5-3
availability are causing common safety prac- personnel. The following factors should be con-
tices, procedures, and regulations to be sidered during repair parts block determination:
violated?
Type and density of equipment to be sup-
ported.
5007. Maintenance and Supply Level of maintenance to be performed by the
Interface organizational and CSSE maintenance
elements.
The supply system provides the MAGTF with the MAGTF objective and scheme of maneuver.
material it needs to support unit operations. The
Environmental impact.
needs of the supported unit must be the basis of
all supply efforts, especially that of the CSSE. The Projected length of operation and resupply
using unit level is where the supply cycle begins capability.
and ends. Therefore, supply related limitations Other resources in the MAGTF’s area of
that affect maintenance support operations must operation.
be minimized. Tailoring repair parts blocks to After-action reports of MAGTFs previously
support a MAGTF’s maintenance effort, collocat- deployed to the same region.
ing issue points and maintenance facilities, ware-
housing to support anticipated maintenance, and High demand national stock numbers.
using maintenance and supply automated informa- Embarkation and lift constraints.
tion systems are all part of the maintenance and
supply interface. The goal is to provide the using b. Repair Parts Issue Point
unit with sufficient expeditionary maintenance ca-
pabilities to support the scheme of maneuver Ideally, the CSSE commander locates the repair
parts issue point near the intermediate mainte-
without overtaxing embarkation/lift constraints.
nance area. At each forward issue point, the com-
bat service support detachment maintains a block
a. Repair Parts Block (Class IX Block) of repair parts tailored to the anticipated needs of
Composition the supported unit(s).
During the predeployment phase, a class IX block
is tailored to support MAGTF units. The process Note: The repair parts block, which the combat
of estimating the supply block begins with the service support detachment holds, has limited
SASSY Management Unit running a deployment range and depth (too large a supply block limits
support generator package (also known as a gen- mobility, too small a supply block reduces re-
pack.) This automated computer program esti- sponsiveness).
mates repair parts requirements based on historic
usage data (past demand for parts in support of The preponderance of class IX blocks arrive in
equipment by identification number). The SASSY the area of responsibility with the assault follow-
Management Unit runs the genpack against the on echelon. When they arrive, the combat service
equipment density list provided by the MAGTF to support element expands the primary issue point
estimate repair parts requirements for each type of in the force combat service support area.
equipment supported. Since this history does not
capture variable that influenced the demand (e.g., Forward issue points stock only those class IX re-
operating climates), the estimates usefulness is pair parts necessary to maintain combat-essential
mainly as a starting point to further develop and equipment. The MAGTF commander establishes
refine the class IX block. To further refine the es- the stockage objective for forward issue points
timate, commanders also consider the experience based on the CSSE commander’s recommen-
captured in lessons learned from previous opera- dation. The composition of the issue point is de-
tions and the input provided by their maintenance termined by the MAGTF scheme of maneuver and
Maintenance Operations 5-5
(reverse blank)
Chapter 6
Maintenance Execution
“Has all the money spent on what is now called ‘the tail’ been wasted?”1—FMFRP 12-14
The Marine Corps demands that its maintenance To perform maintenance as far forward as
plan is well directed, organized, staffed with suffi- possible, commanders must decentralize execution
cient materiel and trained personnel, and executed of essential tasks. As a general rule, the goal in
with its focus on the supported units mission and combat should be centralized control with decen-
the commander’s intent. Chapter 6 addresses the tralized execution unless the tactical circum-
impact of maintenance execution in the organiza- stances or resources demand a different
tion, embarkation, transit, offload, and employ- configuration. Similarly, the peacetime goal is
ment of personnel and materiels. centralized control with centralized execution.
This is more economical, although not as re-
sponsive. In peacetime, economy will frequently
6001. Ground Maintenance outweigh responsiveness in order to conserve
Control and Execution Options resources.
when properly coordinated with ship personnel. and/or ordnance repair personnel. The com-
The embarked MAGTF commander and staff mander determines the exact number of personnel
should be aware of the maintenance facilities and mix of skills in a maintenance contact team.
aboard ship and coordinate their use by MAGTF
personnel if needed. Positioning of maintenance contact teams depends
largely on the train option selected. If combat
trains are used, maintenance contact teams are
6003. Maintenance in Maritime forward, where they are more responsive to the
Prepositioning Force Operations tactical units they support. If unit trains are used,
maintenance contact teams are further to the rear
The maritime prepositioning force offload prepa- and are not as readily available to inspect, classify,
ration party is task-organized and composed of or repair damaged or inoperable items.
maintenance supervisors (i.e., officers and staff
noncommissioned officers), mechanics, techni- Figure 6-1, on page 6-4, shows the notional posi-
cians, and operators. The offload preparation tioning and relationship among various mainte-
party deploys prior to the MAGTF to prepare nance agencies in an expeditionary environment.
equipment for offload and receipt by the MAGTF. Ground combat element collection points repre-
Limited by size, capability, time, and workspace, sent the battalion and regimental trains. The ter-
its work is typically confined to first echelon rain and tactical situation dictate the locations of
maintenance and second echelon emergency field both tactical and combat service support ele-
expedient repairs. Therefore, corrective mainte- ments. Organizational maintenance elements are
nance requirements of a more significant nature generally forward of the division’s rear boundary.
are identified for resolution by maintenance units
at the point of offload. b. Intermediate Maintenance Concept
of Operations
6004. Maintenance Concepts There are three elements in the intermediate main-
tenance concept: the maintenance support team,
the forward support maintenance detachment, and
a. Organizational Maintenance Con- the CSSE maintenance element.
cept of Operations
All battalions and regiments have organizational (1) Maintenance Support Team. The mainte-
maintenance capabilities. Proper employment of nance support team is to intermediate mainte-
these elements is essential to sustain combat op- nance what the maintenance contact team is to
erations. The maintenance contact team is the key organizational maintenance. Maintenance support
element of organizational maintenance in combat. teams consist of intermediate maintenance repair-
Maintenance contact teams are essential to a suc- men, tools, test equipment, and repair parts.
cessful recovery, evacuation, and repair program. Maintenance support teams inspect, diagnose,
They determine whether an item is repairable at classify, and repair equipment at forward sites.
the recovery site. If so, they fix it themselves or The CSS commander forms maintenance support
obtain parts and additional personnel and tools teams from available intermediate maintenance as-
from the rear. If the equipment is not repairable at sets. Unlike maintenance contact teams, mainte-
or near the recovery site, they supervise evacua- nance support teams are not routinely forward
tion of the equipment. Maintenance contact teams with the tactical units. They usually work on
consist of organizational maintenance repairmen equipment in the CSSA until sent forward to re-
with tools, test equipment, and limited repair parts pair a specific item of equipment. This permits
to inspect, diagnose, classify, and repair equip- better use of maintenance and transportation as-
ment at forward sites. Depending on the organiza- sets while also permitting the maintenance team to
tion, maintenance contact teams can be composed draw and bring with them the needed repair parts.
of communications, engineer, motor transport,
6-4 MCWP 4-24
The CSS commander may position maintenance repair parts block must also be sent. When dis-
support teams forward; however, this is usually patched, the team remains forward only until the
only done when the commander anticipates that work is completed. Once the work is completed,
the team will have enough work to justify this op- they return to the CSSA where they are accessible
tion. If the commander sends the team forward, a for further missions. Combat service support
Maintenance Operations 6-5
combat service support element. Elements of elec- maximum number of operable and mobile weapon
tronics and general support maintenance compa- systems. Therefore, mechanics and technicians
nies can be positioned in the rear area to take working in forward areas must be able to meet the
advantage of captured facilities, security, and the increased demands for organizational (first and
establishment of semi-fixed facilities. second echelon) and intermediate (third and
fourth echelon) maintenance. Intermediate main-
d. Main Area Support tenance elements, in the form of maintenance sup-
In the vicinity of the FSSG’s main area, the main- port teams, may also operate in direct support of
tenance battalion is located in one of the combat lead units in the attack. Maintenance support
service support areas with its companies located teams must be properly configured (military occu-
in the same or in other combat service support ar- pational specialty and quantity), equipped (trans-
eas to provide dispersion. It is not effective to es- portation, common tools, special tools, and
tablish a full range of capabilities in each combat communications), and supplied (components, as-
service support area, but establishing complemen- semblies, and repair parts) to perform their mis-
tary capabilities facilitates reconstitution in the sions. Noncombat essential repair parts,
event of loss of a combat service support area or components, and assemblies should not be carried
redeployment. forward due to their adverse effects on mobility.
Assault elements of the landing force are in either unnecessary duplication of effort, and reduce dis-
scheduled or on-call waves. Assault units usually tance between train positions, which also reduces
have few organizational maintenance personnel. the transportation burden for both maintenance
The majority of their organizational maintenance and resupply.
capability follows in nonscheduled waves.
c. Maintenance During Subsequent
The initial maintenance capability, to include lim- Operations
ited recovery, evacuation, and repair, is provided
by the landing force support party (LFSP). The Only after the assault follow-on echelon arrives
does the combat service support element reach
LFSP maintenance detachment carries a small
full maintenance capability. When a maintenance
block of critical repair parts tailored to match the
unit cannot repair an item, it holds the item at the
quantity and type of equipment in the assault
maintenance collection point or evacuates the
waves. Due to the intense activity during the as-
item to the next higher level. As the situation con-
sault phase, the LFSP’s emphasis will be on re- tinues to mature, the landing force commander
placement of components and assemblies rather phases in additional CSSE units from the assault
than repairing them. The LFSP should be author- echelon and maintenance capabilities gradually in-
ized selective interchange and cannibalization to crease. When satisfied that adequate capability
offset the limited depth and breadth of the repair and command and control is established by the
parts block. Immediate tasks of the LFSP mainte- CSSE, the landing force commander will disestab-
nance detachment are to establish maintenance lish the LFSP, which will be subsequently ab-
and salvage collection points and aggressively im- sorbed into the CSSE.
plement the recovery and evacuation plan. Assault
elements must be made to understand the impor-
tance of recovering damaged equipment and re- 6007. Maintenance Support in
turning the equipment to the appropriate the Defense
collection point. Even extensively damaged items
may provide parts for repair of other combat-
The MAGTF maintenance effort’s primary thrust
essential equipment items. Equipment should only in the defense is to prepare the maximum number
be abandoned when the tactical situation leaves of combat-ready weapons. Once the defensive
no other options. When units are unable to re- battle begins, the priority shifts to repairing the
cover equipment, they should report the location maximum number of damaged/inoperable systems
to the LFSP for later recovery and evacuation. and returning them to the battle as fast as possi-
Assault elements are normally on unit distribution ble. This requires conduct of maintenance on site
for resupply and should place damaged equipment or as near as possible to the location where the
on resupply vehicles for return to the LFSP. system is employed. Commanders task-organize
personnel, equipment, and parts as required to
b. Maintenance During Transition provide responsive maintenance in the forward
Periods area. This organization should include trained per-
As the tactical situation stabilizes, assault element sonnel who are able to diagnose problems quickly,
commanders phase in their nonscheduled units make rapid repairs, or decide to evacuate equip-
that include their unit/battalion trains and their or- ment to the next level of maintenance.
ganizational maintenance elements. The primary Note: Consideration should also be given to pro-
responsibility for maintenance then shifts to the viding maintenance to covering force elements
unit owning the equipment. As the assault units’ when they return to the ground combat element’s
organizational maintenance capability expands, rear area so they may be returned more rapidly
the LFSP shifts its efforts to intermediate mainte- to a combat-ready condition.
nance. Assault units initially position their trains
near the LFSP to enhance mutual support, avoid
6-8 MCWP 4-24
Since the basic functions and tasks of a mainte- i.e., cover, concealment, and perimeter security.
nance shop are the same, its organization is fairly Other factors also include—
standard regardless of shop size or authorized
echelon of maintenance. The difference among (1) Space Requirements. Space limitations in
shops is mainly the workload associated with each a maintenance area can cause congestion that
function or task and the resources required. This could impair maintenance efficiency and safety. A
appendix addresses establishment of a basic main- maintenance area should be large enough to pro-
tenance shop applicable to a wide range of vide for the adequate dispersal of equipment and
scenarios. maintenance activities.
considerations. Since mobility normally is not a equipment resources should be used to the maxi-
major factor in garrison, restrictions on the mum extent practical to extend tactical equipment
amount of maintenance capability to collocate life. Proximity of the unit’s maintenance area to
with the commodity users are limited only by the dining, billeting, and administrative facilities re-
unit’s maintenance capabilities. Commercial duces time lost due to travel.
SUPPLY
AREA
BILLETING/ADMINISTRATIVE
AREA
EL INT
GE UPP NA
M
M
S TE
A
AI
EC EN
NE OR NC
N
MAINTENANCE
OPERATIONS
T R AN
RA T E
O N CE
SECURE
L
POINT
ISSUE
AREA
IC
PRIMARY ROAD
TR INT
M
MO SP AN
MA
EN NTE
AN E N
A
TO OR CE
M
OR NT
I
GI NA
AI
R T
NE N
HA
DN E NA
HA
E R CE
RD
AN NC
RD
S
CE E
TA
ST
ND
AN
DISTRIBUTION
HARDSTAND
D
POWER
TRACKED VEHICLES
E WASH
VEHICL
AGE
FUEL STOR
CLEANING AREA
RECORDING
AND SHOP OFFICE
CLOSEOUT
TECHNICAL
LIBRARY WORK AREA
TOOL ISSUE
MAINTENANCE/
LUBE PIT HAZARDOUS
AREA
LUBE RACK
Repair parts and materials (shop stores and Support and test equipment (equipment used
pre-expended bins should be located in close primarily by one mechanic should be located
proximity to work areas). as close as possible to the mechanic’s place
A scrap collection point (a central collection of use; however, a central location for low-
point for scrap should be established to keep density, common-use tools facilitates tool
work areas clear and facilitate easy collection availability and is preferred).
and removal of refuse from the shop).
Maintenance Operations A-5
(reverse blank)
Appendix B
The Marine Corps Integrated Maintenance Man- Georgia and the other at Barstow, California. The
agement System is an automated management Depot Maintenance Subsystem provides materiel
system. Operating force commanders and sup- and production control information and cost and
porting establishment commanders use MIMMS labor accounting information.
to perform Marine Corps ground equipment
maintenance. It is organized into three subsys-
tems: the Headquarters Maintenance Subsystem, 3. Field Maintenance Subsystem
the Depot Maintenance Subsystem, and the Field
Maintenance Subsystem. The Field Maintenance Subsystem was developed
to improve and standardize equipment status re-
porting and management, while reducing and con-
1. Headquarters Maintenance solidating manual reporting requirements. It
Subsystem provides operating force commanders with timely
and accurate information concerning the status of
The Headquarters Maintenance Subsystem sup- equipment currently in the maintenance cycle.
ports commodity managers at Headquarters This system provides for the reporting of active
Marine Corps. It allows commodity managers maintenance and repair parts information, produc-
(i.e., motor transport, communications-electron- tion of selected SASSY transactions, collection of
ics, engineer, and ordnance) to enter standard historical costs, and tracking of maintenance engi-
data into the Marine Corps Integrated Mainte- neering and modification control information. Re-
nance Management System and to maintain a data ports and listings are generated from information
base of selected maintenance information. The generated by the Field Maintenance Subsystem on
Headquarters Maintenance Subsystem data base is both a scheduled and nonscheduled basis. See UM
comprised of information extracted from the Field 4790-5, MIMMS Automated Information System
Maintenance Subsystem. It facilitates selective Field Maintenance Procedures, for user
maintenance engineering analysis, logistic readi- instructions.
ness evaluation, and maintenance management for
specified functions required by the Headquarters a. Input Sources
Maintenance Subsystem user. The Field Maintenance Subsystem receives input
primarily from two source documents: NAVMC
Form 10245, Equipment Repair Order and
2. Depot Maintenance Subsystem NAVMC Form 10925, ERO Shopping/Transac-
tion List. NAVMC Form 10245 is commonly re-
The Depot Maintenance Subsystem supports the ferred to as the ERO, and NAVMC Form 10925
materiel functions of the two Marine Corps depot is commonly referred to as the ERO Shopping
maintenance activities: one located at Albany, List (EROSL).
B-2 MCWP 4-24
The ERO is used for all maintenance actions ap- maintenance ship performance using Field Mainte-
plied beyond the first echelon. Maintenance per- nance Subsystem output reports, and training per-
formed and requests for higher echelons of sonnel in all aspects of Field Maintenance
maintenance are recorded on the ERO. Subsystem operations.
The EROSL, often referred to as a shopping list, The FSSG’s information systems coordinator
is used to requisition, receipt for, cancel, and re- sponsors and coordinates Field Maintenance Sub-
cord partial issues and credits of repair parts and systems operations within a Marine expeditionary
secondary reparable items associated with equip- force. The information systems coordinator coor-
ment being repaired. It also serves as an excellent dinates and disseminates system changes or direc-
source document for unit supply input and pro- tives from higher headquarters; consolidates
vides a method for processing unit maintenance system changes, modification requests, and impact
input to the Field Maintenance Subsystem. statements from adjacent major commands to
higher headquarters; coordinates the schedule for
The ERO and EROSL are completed by mainte- submission/dissemination of daily input and out-
nance and supply personnel at the using unit and put reports; and prepares work requests for all
by the activity repairing the equipment. At the update cycles and reports.
battalion level, the appropriate maintenance shop
(e.g; motor transport, armory) or the supply sec-
tion completes the ERO and EROSL. Within the 4. Reports
force service support group, the appropriate
equipment maintenance company of the mainte- Report information is based on the input provided
nance battalion completes the ERO and EROSL. by technicians at the working level. Therefore,
TM 4700-15/1 contains instructions for complet- commanders must ensure that personnel are
ing both forms. trained, guided, and motivated to perform their
jobs effectively and to report relevant information.
b. Input to the Data Base These reports are used in two critical activities:
Each battalion inputs data into the data base. validation of requisitions and reconciliation of
Maintenance and supply information are con- readiness, maintenance, and supply reports. Vali-
verted into the appropriate input transaction type dation involves confirming that repair parts on or-
and transmitted to the supporting automated serv- der are still needed, and that cancellations,
ices center for entry into the Field Maintenance receipts, scrounges, and current statuses are prop-
Subsystem data base. The conversion is accom- erly reflected. Reconciliation of information
plished using source data automation equipment. among maintenance, supply, and readiness reports
Transactions are verified on machine media and is accomplished by the maintenance management
transferred to the automated services center for officer in concert with commodity and supply rep-
storage and production of Field Maintenance Sub- resentatives. Reconciliation is the means to moni-
system reports. tor the status of mission-essential deadlined
equipment and to identify any recurring errors or
c. Data Base Output trends in maintenance or requisitioning proce-
dures that could result in delay. While not all in-
Maintenance management officers at all levels are clusive, the following is a list of reports essential
responsible to their commanders for all aspects of to managing the maintenance effort:
their unit’s maintenance programs, which includes
Field Maintenance Subsystem operations. Their
Daily Process Report.
duties include establishing and disseminating pro-
cedures for the submission of information and the Field Maintenance Production Report.
dissemination of output reports, evaluating MIMMS LM2 Unit Report.
Maintenance Operations B-3
Weekly Maintenance Exception Report. TAM report is used to identify unfavorable trends
Weekly Materiel Report. in equipment defects, priority assignments, job
status, days deadlined, and days in shop. The
Weekly Owning Unit Maintenance TAM Re-
TAM report also provides ERO information from
port.
the intermediate maintenance level to determine
current status of equipment that was evacuated to
a. Weekly Maintenance Exception a higher echelon for repair.
Report
The Weekly Maintenance Exception Report is an c. Daily Process Report
effective tool that provides a summary of pending The Daily Process Report is used predominantly
supply and maintenance items and identifies dis- by leaders of organizational maintenance sections.
crepancies. A weekly comparison of two or three The Daily Process Report contains complete
consecutive reports can help determine procedural maintenance and repair parts information regard-
problems, developing trends, and aid in determin- ing each ERO opened by a section. Section heads
ing corrective action. Report information is use the Daily Process Report to track equipment
printed in narrative form and is very easy to repair performed by the respective unit repair
comprehend. ships.
b. Weekly Owning Unit Maintenance The Daily Process Report provides a presentation
TAM Report of both supply and maintenance data. The shop
The Weekly Owning Unit Maintenance TAM Re- chief generally uses the information in day-to- day
port, commonly referred to as the TAM report, operation. It is useful in the conduct of periodic,
provides the specific repair status of individual informal inspections to identify work stoppages
pieces of equipment within a unit’s maintenance and delays, outstanding parts requisition, disa-
cycle. This report is produced weekly in table of greements between maintenance and repair parts
authorized number sequence. It includes active priorities, added parts, and parts needed for dead-
EROs at intermediate and organizational main- lined equipment.
tenance activities and the latest job status. The
(reverse blank)
B-4 MCWP 4-24
Maintenance Operations B-5
B-6 MCWP 4-24
Maintenance Operations B-7
B-8 MCWP 4-24
Maintenance Operations B-9
B-10 MCWP 4-24
Appendix C
Maintenance Directives,
Technical Manuals, and Stock Lists
The Marine Corps establishes maintenance guide- maintained to ensure the effective perform-
lines so that all commanders can comply with pro- ance of mission requirements.
curement regulations and perform required The categories and echelons of maintenance
equipment maintenance. These guidelines are set to be performed are assigned to specific
forth in directives that establish maintenance levels of command as determined by the mis-
goals. These directives can contain broad guid- sion and resources assigned. This main-
ance or very specific instructions. Equipment tenance authority is prescribed in the unit’s
technical manuals and Marine Corps stock lists table of organization logistic capabilities
support these directives. This appendix introduces statement. Standard ground equipment poli-
some of the more widely used maintenance cies and procedures are followed at all levels
resources. of command, for all equipment commodity
areas, and all echelons of maintenance
throughout the Marine Corps. Maintenance
1. Basic Maintenance Directives and maintenance management procedures
and Policies and systems used when the unit is deployed
will not differ from those used in a garrison
There are numerous directives that provide poli- environment.
cies and procedures for every level of authorized Repairs are performed at the lowest, author-
maintenance required for MAGTF equipment. It ized echelon of maintenance and as far for-
is essential that all commanders and their staffs be ward as possible to enhance the tactical
aware of basic directives and key policies that ap- situation. The evacuation of equipment re-
ply to their organization. duces combat and combat support strength.
Evacuation to a higher echelon of mainte-
a. The Marine Corps Manual nance is accomplished only after prescribed
The Marine Corps Manual is the capstone publi- fault diagnosis and isolation has been accom-
cation for policy statements issued by the Com- plished at the previous echelon of mainte-
mandant of the Marine Corps. It contains policies nance. Each echelon is authorized to perform
that supplement naval regulations established by lower echelon repair operation.
the Secretary of the Navy. The guidance con- Marine Corps equipment is modified only as
tained in The Marine Corps Manual is very broad directed or approved by the Commandant of
and it is amplified by other Marine Corps publica- the Marine Corps.
tions. The manual’s section devoted to mainte- Commanders order periodic inspections of
nance has five basic policies that commanders their materiel. The scope of the inspection
should be familiar with— shall conform generally to the authorized
echelon of maintenance. They must include a
Maintenance is a command responsibility. schedule of technical inspections that cover
Therefore, commanders are responsible for all pertinent areas performed by qualified
ensuring that assigned equipment is properly personnel.
C-2 MCWP 4-24
Mechanics should use the applicable technical Each part of an equipment technical manual is
manual to ensure that inspection and repair proce- identified by a basic number that identifies the
dures are effectively applied. The Marine Corps type of equipment and the echelon of mainte-
has a comprehensive technical publication system nance. For example, in the M198 howitzer series
Maintenance Operations C-3
Glossary
materiel control number (TAMCN) commodity technical assistance and performing that mainte-
designators are as follows: nance beyond their responsibility. Depot mainte-
(1) . . . . . Communications-Electronics (C&E). nance provides stocks of serviceable equipment
A, H, and T. by using more extensive facilities for repair than
(2) . . . . . . . . . . . . . Engineer (Eng). B, K, and U. are available in lower level maintenance activities.
(3) . . . . Motor Transport (MT). D, M, and W. (Joint Pub 1-02)
(4) . . . . . . . . . . . . . Ordnance (Ord). E, N, and X.
(5) . . . . . . . . . . . . . . . Garrison Mobile Equipment desk top procedures—Usually a file folder or
(GME). G. loose-leaf binder of instructions, procedures, ref-
(6) . . . . . . . . General Supply (GS). C, K, and V. erences, and notes pertaining to the everyday du-
(7) . . . . . Nuclear, Biological, Chemical (NBC). ties and operations of a personnel billet. Desk top
NBC equipment carries Eng, C&E, procedures should standardize requirements, ac-
and GS commodity designators. tions, and record keeping. See turnover folder.
(MCO P4790.2) (MCO P4790.2)
maintenance cycle time—That period of time command and structured to accomplish a specific
during which equipment is inoperative and re- mission. The Marine air-ground task force
quires repair. (MCO P4790.2) (MAGTF) components will normally include
command, aviation combat, ground combat, and
maintenance management—The retention or combat service support elements (including Navy
restoration of materiel to a serviceable condition Support Elements). Three types of Marine air-
through the efforts of other people. (MCO ground task forces which can be task organized
P4790.2) are the Marine expeditionary unit, Marine ex- pe-
ditionary force and special purpose Marine air-
maintenance management officer (MMO)— ground task force. The four elements of a Marine
An officer designated to perform the general du- air-ground task force are: a. command element
ties of a special staff officer under the staff cogni- (CE)—The MAGTF headquarters. The CE is a
zance of the G/S-4 and is the primary point of permanent organization composed of the com-
contact in maintenance management matters. mander, general or executive and special staff sec-
(MCO P4790.2) tions, headquarters section, and requisite
communications and service support facilities.
maintenance (materiel)—1. All action taken to The CE provides command, control, and coordi-
retain materiel in a serviceable condition or to re- nation essential for effective planning and execu-
store it to serviceability. It includes inspection, tion of operations by the other three elements of
testing, servicing, classification as to serviceabil- the MAGTF. There is only one CE in a MAGTF.
ity, repair, rebuilding, and reclamation. 2. All sup- b. aviation combat element (ACE)—The
ply and repair action taken to keep a force in MAGTF element that is task organized to provide
condition to carry out its mission. 3. The routine all or a portion of the functions of Marine Corps
recurring work required to keep a facility (plant, aviation in varying degrees based on the tactical
building, structure, ground facility, utility system, situation and the MAGTF mission and size. These
or other real property) in such condition that it functions are air reconnaissance, antiair warfare,
may be continuously used, at its original or de- assault support, offensive air support, electronic
signed capacity and efficiency for its intended pur- warfare, and control of aircraft and missiles. The
pose. (Joint Pub 1-02) ACE is organized around an aviation head-
quarters and varies in size from a reinforced heli-
maintenance resources—Maintenance resources copter squadron to one or more Marine aircraft
include: time, personnel, repair parts, tools and wing(s). It includes those aviation command (in-
equipment, facilities, funds, and publications. cluding air control agencies), combat, combat
(MCO P4790.2) support, and combat service support units re-
quired by the situation. Normally, there is only
maintenance status—1. A nonoperating condi- one ACE in a MAGTF. c. ground combat ele-
tion, deliberately imposed, with adequate person- ment (GCE)—The MAGTF element that is task
nel to maintain and preserve installations, organized to conduct ground operations. The
materiel, and facilities in such a condition that GCE is constructed around an infantry unit and
they may be readily restored to operable condition varies in size from a reinforced infantry battalion
in a minimum time by the assignment of additional to one or more reinforced Marine division(s). The
personnel and without extensive repair or over- GCE also includes appropriate combat support
haul. 2. That condition of materiel which is in and combat service support units. Normally, there
fact, or is administratively classified as, unservice- is only one GCE in a MAGTF. d. combat service
able, pending completion of required servicing or support element (CSSE)—The MAGTF element
repairs. (Joint Pub 1-02) that is task organized to provide the full range of
combat service support necessary to accomplish
Marine air-ground task force—A task organ- the MAGTF mission. CSSE can provide supply,
ization of Marine forces (division, aircraft wing maintenance, transportation, deliberate engineer,
and service support groups) under a single health, postal, disbursing, enemy prisoner of war,
D-6 MCWP 4-24
sense or to express a level or degree of readiness. either before they occur or before they develop
(Joint Pub 1-02) into major defects. (Joint Pub 1-02)
operational readiness float—A pool of mission- principal items—End items and replacement as-
essential, maintenance significant end items used semblies of such importance that management
to provide replacement items for unserviceable, techniques require centralized individual item
reparable end items which cannot be repaired in management throughout the supply system, to in-
time to meet an operational commitment. clude depot level, base level, and items in the
(FMFRP 0-14) hands of using units. These specifically include the
items where, in the judgment of the Services,
organizational maintenance—That maintenance there is a need for central inventory control, in-
which is the responsibility of and performed by a cluding centralized computation of requirements,
using organization on its assigned equipment. Its central procurement, central direction of distribu-
phases normally consist of inspecting, servicing, tion, and central knowledge and control of all as-
lubricating, adjusting, and the replacing of parts, sets owned by the Services. (Joint Pub 1-02)
minor assemblies, and subassemblies. (Joint Pub
1-02) principal end item—A Marine Corps-unique
term synonymous with principal item. (MCO
overhaul—The restoration of an item to a com- P4400.150)
pletely serviceable condition as prescribed by
maintenance serviceability standards. See rebuild; R
repair. (Joint Pub 1-02)
rebuild—The restoration of an item to a standard
P as nearly as possible to its original condition in
appearance, performance, and life expectancy.
part—An item forming part of an assembly or See overhaul; repair. (Joint Pub 1-02)
subassembly, which is not normally further broken
down. (Joint Pub 1-02, NATO definition) recoverable item—An item which normally is not
consumed in use and is subject to return for repair
part number—A combination of numbers, let- or disposal. (Joint Pub 1-02)
ters, and symbols assigned by a designer, a manu-
facturer, or vendor to identify a specific part or recoverable item program—The program that
item of materiel. (Joint Pub 1-02) establishes policy and procedures for the recov-
ery, reporting, and management of recoverable
petroleum, oils, and lubricants—A broad term
items which cannot be repaired within the re-
which includes all petroleum and associated prod-
ucts used by the Armed Forces. Also called POL. sources available to the field commander, become
(Joint Pub 1-02) excess to a command’s allowances, or which are
beyond economical repair and require disposal.
pre-expended bin—Low-cost, fast-moving con-
sumables held by maintenance shops that are re- repair—The restoration of an item to serviceable
plenished on a recurring basis and expended upon condition through correction of a specific failure
issue from the consumer inventory. (MCO or unserviceable condition. See overhaul; re-
P4400.150) build. (Joint Pub 1-02)
preventive maintenance—The care and servic- repair cycle—The stages through which a
ing by personnel for the purpose of maintaining reparable item passes from the time of its removal
equipment and facilities in satisfactory operating or replacement until it is reinstalled or placed in
condition by providing for systematic inspection, stock in a serviceable condition. (Joint Pub 1-02)
detection, and correction of incipient failures
D-8 MCWP 4-24
reparable item—An item that can be recondi- subassembly—In logistics, a portion of an as-
tioned or economically repaired for reuse when it sembly, consisting of two or more parts, that can
becomes unserviceable. See recoverable item. be provisioned and replaced as an entity. See as-
(Joint Pub 1-02) sembly; component; part. (Joint Pub 1-02)
requisition—1. An authoritative demand or re- supplies—In logistics, all materiel and items used
quest especially for personnel, supplies, or serv- in the equipment, support, and maintenance of
ices authorized but not made available without military forces. (Joint Pub 1-02)
specific request. 2. To demand or require services
from an invaded or conquered nation. (Joint Pub supply—The procurement, distribution, mainte-
1-02) nance while in storage, and salvage of supplies,
including the determination of kind and quantity
S
of supplies. a. producer phase—That phase of
military supply which extends from deter-
salvage—1. Property that has some value in ex-
cess of its basic material content but which is in mination of procurement schedules to accep-
such condition that it has no reasonable prospect tance of finished supplies by the Military Services.
of use for any purpose as a unit and its repair or b. consumer phase—That phase of military sup-
rehabilitation for use as a unit is clearly impracti- ply which extends from receipt of finished sup-
cal. 2. The saving or rescuing of condemned, dis- plies by the Military Services through issue for
carded, or abandoned property, and of materials use or consumption. (Joint Pub 1-02)
contained therein for reuse, refabrication, or
scrapping. (Joint Pub 1-02) T
(reverse blank)
Appendix E
4733-15/7 Procedural Publications Index for Marine Corps Measurement and Diagnostic
Equipment, Calibration and Maintenance Program
4733-15/10 Special Calibration of Torque Wrenches, Marine Corps Calibration Program
4733-35/5 Calibration Equipment Recommendations, Marine Corps Calibration Program
4733-35/6 Test, Measurement, and Diagnostic Equipment, Calibration and Maintenance
Program
4733-35/8 Marine Corps Standards Exchange Program, Calibration and Maintenance
Program
5600 Series Publication Information, Marine Corps Equipment
6100-15/1 Neutralizing and Disposing of Storage Batteries Electrolyte
6850-13/2 Conservation Procedures Antifreeze Solutions
8005-34/18 Prepackaging Inspection for Serviceability Ordnance Materiel (with change 1)
8370-15/1 Identification Marking Small Arms
Navy Publications
Army Publications