Battle Damage Assessment and Repair (BDAR) Procedures 63H34F05 / Version MOSC 01 Oct 2004

SECTION I. All Courses Including This Lesson Task(s) Taught(*) or Supported

ADMINISTRATIVE DATA
Course Number Version Course Title

091-63H30

MOSC

Tracked Vehicle Mechanic(BNCOC)

Task Number

Task Title

INDIVIDUAL 091-63H-3125 (*) 091-63H-3126 (*) 091-63H-3127 (*) 091-63H-3128 (*) 091-63H-3129 (*) Perform Battlefield Damage Assessment and Repair (BDAR) on a Track Vehicle (M113/M88/M993/M48A5) Perform BDAR on Fuel System Perform BDAR on Cooling System Perform BDAR on Electrical Systems Perform BDAR on Power Train/Steering System
Task Title

Reinforced Task(s) Academic Hours

Task Number

The academic hours required to teach this lesson are as follows:

ADT Hours/Methods

Test Test Review Total Hours: Test Lesson Number

1 hr 30 mins / Conference / Discussion 1 hr / Demonstration 7 hrs 20 mins / Practical Exercise (Performance) 0 hrs 0 hrs 10 hrs
Hours Lesson No.

Testing
(to include test review)

1 hr 4 hrs

25 mins 25 mins

63H34F06 version MOSC 63H34F07 version MOSC

Prerequisite Lesson(s) Clearance Access Foreign Disclosure Restrictions

Lesson Number

Lesson Title

None

Security Level: Unclassified Requirements: There are no clearance or access requirements for the lesson. FD5. This product/publication has been reviewed by the product developers in coordination with the CASCOM-TD foreign disclosure authority. This product is releasable to students from all requesting foreign countries without restrictions.

References

Number

Title

Date

Additional Information

FM 9-43-2

TM 9-2350-276-BD

Recovery and Battlefield Damage Assessment and Repair FMFRP 4-34; TO 36-1-181 Operator's, Organizational, Direct Support and General Support, Maintenance Battlefield Damage Assessment and Repair for Combat Vehicles

03 Oct 1995

10 Feb 1984

Student Study Assignments Instructor Requirements Additional Support Personnel Requirements Equipment Required for Instruction

None

Ensure references are set up prior to class. Instructors and Assistant Instructors must hold MOS 63B30
Stu Ratio

Name

Qty

Man Hours

None
Id Name Stu Ratio Instr Ratio

Spt

Qty

Exp

5180-01-502-9507 KIT, ASSESSMENT BATT *ZX7022 Industry Standard Laptop (Toughbook) *ZX7024 Industry Standard Laptop Computer *ZX7043 Projector, Light. High Resolution *ZX9055 Industry Standard Light Pro Screen *ZX9061 Wireless Mouse * Before Id indicates a TADSS

1:16 1:16 1:16 1:16 1:16 1:16

No No No No No No

0 0 0 0 0 0

No No No No No No

Materials Required

Instructor Materials: References listed above 63H34F05, Suppl 1b, 2b, 3b, 4b and 5b Practical Exercise Instructor Guide Student Materials: 63H34F05, Suppl 1a, and 2a, 3a, 4a and 5a Practical Exercise Student Guide Code X vehicles Eye and hearing protection

Classroom, Training Area, and Range Requirements

Field Training Area General Instruction Building

Ammunition Requirements Instructional Guidance

Id

Name

Exp

Stu Ratio

Instr Ratio

Spt Qty

None NOTE: Before presenting this lesson, instructors must thoroughly prepare by studying this lesson and identified reference material.

Proponent Lesson Plan Approvals

Name

Rank

Position

Date

Deilus, John

GS-12

Military Analyst

01 Oct 2004

SECTION II.

INTRODUCTION

Method of Instruction: Conference / Discussion Instructor to Student Ratio is: 1:16 Time of Instruction: 5 mins Media: Large Group Instruction
Motivator

Sometime in the future you may be required to perform repairs on vehicles under combat conditions and may not have the time to do normal repairs. These nonstandard repairs called Battlefield Damage Assessment and repair are designed to rapidly return disabled vehicles to combat by expediently fixing by passing or jury-rigging components. As a maintenance supervisor you may be required to supervise or perform these nonstandard repairs in a combat environment.
NOTE: Inform the students of the following Terminal Learning Objective requirements. At the completion of this lesson, you [the student] will: Action:

Terminal Learning Objective

The student will perform Battle Damage Assessment and Repair (BDAR) on wheeled vehicles. In a field environment, given a BDAR kit, tools, code X equipment and references.

Conditions:

Standards:

IAW applicable technical publications, procedures, and specifications. When this task is complete, the vehicle must be fully mission capable. 1. Complete the solution sheet as the group performs the task. Once the group has correctly performed a step, place a check in the column. 2. Ensure that each student participates. Rotate students so that all members of the group use references, tools, and perform the hands on steps of the task. If time permits, repeat the task with different members performing different steps. 3. Ensure that the group completes each performance step IAW applicable references. 4. If a safety violation occurs, stop the group, correct on the spot and restart the group. 5. If a student misses the practical exercise or a team needs training for longer than the PE allows, then conduct this training IAW TRADOC regulations. 6. Check all work, have students clean work area, and store equipment.

Safety Requirements

1. 2. 3. 4.

Hard hats and work gloves will be worn when repairing equipment Remove all jewelry (watches, rings, ID tags). No horseplay. A haphazard approach to BDAR can lead to death, dismemberment, and damage to equipment.

5. Follow all WARNINGS, CAUTIONS AND NOTES listed in the TM. 6. Be careful when handling any training aid. Sharp edges and moving parts can cause injury. 7. When climbing on or around vehicles, always maintain three-points of contact. 8. Know where the fire extinguishers, fire lanes, and fire exits are located. 9. Know fire exit procedures.
Risk Assessment Level Environmental Considerations

Low - It is the instructor's responsibility to conduct a risk assessment prior to instruction using FM 100-14 as guidance. A copy of the risk management work sheet must be present at time of instruction.
NOTE: It is the responsibility of all soldiers and DA civilians to protect the environment from damage.

When working with equipment, in the event of an accidental spill of hydraulic fluid, fuels, oils, solvents, acids, and coolants, the spill must be contained and cleaned up immediately. Floor dry sweep is the most effective material to contain and clean up environmental spills. The student will report the incident to the instructor immediately. The instructor will direct appropriate cleanup actions. All contaminated floor dry materials must be stored in a separate container. The container must be inspected by qualified environmental specialists to determine proper disposal procedures. Additional warnings and cautions concerning environmental hazards will be explained to you at the applicable point in later lessons
Evaluation

Describe how the student must demonstrate accomplishment of the TLO. In lesson 63H34F06, Job Knowledge Test, the student must achieve at least a 70% score and complete the test within one hour. In lesson 63H34F07, Job Performance Test, the student must achieve a GO and complete the test within one hour. We are now ready to begin our discussion on Battle Damage Assessment and Repair (BDAR) Procedures.

Instructional Lead-In

SECTION III.

PRESENTATION

NOTE: A.

Inform the students of the Enabling Learning Objective requirements. ENABLING LEARNING OBJECTIVE
ACTION: CONDITIONS: STANDARDS:

Define BDAR Doctrine In a classroom, given instruction and references. Perform BDAR IAW references listed in this lesson.

1.

Learning Step / Activity 1. Instructor will lead a discussion on BDAR doctrine. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: NOTE: Conference / Discussion 1:16 35 mins Large Group Instruction

Show slides # 1 and 2. a. Introduction (1) The ability to win battle may depend on the capability to repair damaged equipment rapidly. (2) Soldiers throughout history, especially since World War II have used temporary field expedient fixes to keep their vehicle going. (3) The BDAR program will enable us to maintain a vehicle's ability to shoot, move and communicate within its mission requirements with the least possible amount of time spent on repairs.

NOTE:

Show slides # 3 and 4 (refer to FM 9-43-2, pg. 1-3). b. Purpose of BDAR (1) To rapidly return disabled vehicles in a combat environment to the operational commander by expediently fixing, bypassing, or jury-rigging components.

NOTE:

Show Slide # 5 (refer to TM 9-2350-276-BD, pg. 1-1). c. Scope of BDAR (1) The BDAR program was designed with the unit and DS/GS

mechanics in mind. (2) BDAR references are guidelines only, and are not intended to be a complete catalog of all possible emergency repairs.

NOTE:

Show Slide # 6 thru 8 (refer to AR 750-1, pg. 1-4). d. Training (1) Commanders are required to have BDAR trained personnel in their units. (2) BDAR training is applicable to all echelons of maintenance, crew thru general support. (3) IAW AR 750-1, Non-destructive BDAR procedures will be incorporated into peacetime maintenance training.

NOTE:

Show Slide # 9 (refer to TM 9-2350-276-BD, pg. 1-2). e. Application of BDAR (1) BDAR should be used only in a combat environment and only when standard maintenance procedures are impractical. BDAR procedures are not meant to replace standard maintenance procedures. (2) BDAR will be used only at the direction of the commander. (3) BDAR fixes will be repaired by standard maintenance procedures as soon as practical.

NOTE:

Show Slide # 10 and 11 (refer to TM 9-2350-276-BD, pg. 1-2). f. Definitions (1) Battlefield damage: All incidents, which occur on the battlefield that prevent the vehicle from accomplishing its mission. (2) Damage assessment: Procedures to rapidly determine what is damaged, whether it is repairable, what is needed to make the repair, and how long the repair will take. (3) Fully mission capable: The vehicle can perform all its combat missions without endangering the life of the crew. (4) Combat capable: The vehicle meets the minimum functional combat capability requirements. (5) Combat emergency capable: Vehicle meets the needs for specific tactical maneuver or firing missions. (6) Self-recovery capable: Vehicle meets the needs for recovery under self-power. (7) Cannibalization: Any use of repair parts or components obtained from another combat vehicle.

NOTE:

Conduct a check on learning and summarize the learning activity.

CHECK ON LEARNING: Conduct a check on learning and summarize the ELO. B. ENABLING LEARNING OBJECTIVE
ACTION: CONDITIONS: STANDARDS:

Identify BDAR Kits In a classroom environment, given a BDAR kit, with references. IAW applicable references.

1.

Learning Step / Activity 1. Instructor will lead a discussion on the types and components of the Battle Damage repair kits. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: NOTE: NOTE: Conference / Discussion 1:16 35 mins Large Group Instruction

Refer students to FM 9-43-2, appendix A. Show Slides # 12 thru 52 a. Ground BDAR kits (1) M-2/3 Generic BDR kit - Used for Bradley Fighting Vehicle and all other vehicles except the M88 recovery vehicle and the M1 MBT. (2) M-1 BDR kit - Same as the generic kit but has larger hydraulic fittings. (3) M-88 BDR kit - Same as generic kit except for hydraulic fittings. (4) Crew / Operator BDR kit (5) Fuel Cell Repair kit (6) Fuel Line Repair kit (7) Electrical Repair kit b. All BDAR kit are the basically the same except for the hydraulic coupling adapters. There are components in each kit to make repairs in the following areas: (1) (2) (3) Repair fuel leaks Repair coolant leaks Repair oil leaks

(4) (5) (6) c.

Electrical repairs Fan belt repairs Body repairs

Kits currently in the field are authorized for use, but new kits are no longer available in the supply system. Kits components can be replenished individually.

d. Each unit is expected and encouraged to modify its BDR kits to suit its special operational needs and geographic environment. e. Success rate with the BDR kits and techniques during live fire testing: (1) The purpose of live fire testing is to determine the vulnerability, survivability, and maintainability of new equipment in the U.S. Army. (2) Testing also allows for evaluation of doctrine, publications, and tools. (3) During live fire testing, we found out that by using BDAR we could return up to79% of the M109 Howitzer FOV back into combat. (4) We could return up to 73% of the M1 MBT back to the battlefield. NOTE: Conduct a check on learning and summarize the learning activity.

CHECK ON LEARNING: Conduct a check on learning and summarize the ELO. C. ENABLING LEARNING OBJECTIVE
ACTION: CONDITIONS: STANDARDS:

The student will understand BDAR recording of repairs. In a classroom environment, with references and equipment. IAW applicable references.

1.

Learning Step / Activity 1. Instructor will lead a discussion on the BDAR recording of repairs. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: NOTE: Practical Exercise (Performance) 1:16 20 mins Programmed Instruction

Show slides # 53 thru 57 (refer to FM 9-43-2, pg 6-9). a. Recording BDAR repairs.

(1) BDAR repairs are recorded in order to determine authorized permanent repairs. (2) BDAR forms are: (a) DA Form 2404 / 5988-E - Used to record expedient repairs and operational limitations. (b) DD Form 1577 (or similar tag)- Used to mark a BDR component. (c) DA Form 2407 / 5990-E - Used to job order BDAR repairs above organizational level. (d) System Assessment Summary Form - Used to assist maintenance personnel in assessing battle damaged systems and sub-systems. Form can be found in Chapter 2 of most BD TM's. Form is reproduced locally. (3) Forms must accompany the vehicle throughout the repair process. NOTE: Conduct a check on learning and summarize the learning activity.

CHECK ON LEARNING: Conduct a check on learning and summarize the ELO. D. ENABLING LEARNING OBJECTIVE
ACTION: CONDITIONS: STANDARDS:

Demonstrate BDAR kit uses In a classroom environment, with references and equipment. IAW applicable references.

1.

Learning Step / Activity 1. Demonstrate repairs using a BDAR kit. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Note: Demonstration 1:16 1 hr Small Group Instruction (SGI)

Explain and demonstrate to the students the proper procedures for using the BDAR kit. Emphasize the importance of the safety and environmental aspects when using the BDAR kit.

NOTE:

Conduct a check on learning and summarize the learning activity.

CHECK ON LEARNING: Conduct a check on learning and summarize the ELO.

10

E.

ENABLING LEARNING OBJECTIVE

ACTION: CONDITIONS:

Perform Battlefield Damage Assessment on Fuel System In a field environment, given a BDAR kit, tools, code X equipment and references. IAW applicable TMs.

STANDARDS:

1.

Learning Step / Activity 1. Perform Battle Field Damage Assessment on Fuel System. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: NOTE: NOTE: NOTE: NOTE: NOTE: Practical Exercise (Performance) 1:4 2 hrs Large Group Instruction

Tell students that during the next 2 hour they will complete a practical exercise that is designed to enhance their skills in fuel system BDAR. Conduct the practical exercise IAW 63H34F05, Suppl 1b, Practical Exercise Instructors Guide. Issue students 63H34F05, Suppl 1a, Practical Exercise Students Guide. After the practical exercise, have the students clean the work area. Conduct a check on learning and summarize the enabling learning objective.

NOTE:

Conduct a check on learning and summarize the learning activity.

CHECK ON LEARNING: Conduct a check on learning and summarize the ELO. F. ENABLING LEARNING OBJECTIVE
ACTION: CONDITIONS:

Perform Battlefield Damage Assessment on Electrical System In a field environment, given a BDAR kit, tools, code X equipment and references. IAW applicable TMs.

STANDARDS:

1.

Learning Step / Activity 1. Perform Battle Field Damage Assessment on Electrical System. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Practical Exercise (Performance) 1:4 1 hr 25 mins Large Group Instruction

11

NOTE:

Tell students that during the next 1 hour and 30 minutes they will complete a practical exercise that is designed to enhance their skills in electrical system BDAR. Conduct the practical exercise IAW 63H34F05, Suppl 2b, Practical Exercise Instructors Guide. Issue students 63H34F05, Suppl 2a, Practical Exercise Students Guide. After the practical exercise, have the students clean the work area.

NOTE: NOTE: NOTE: NOTE:

Conduct a check on learning and summarize the learning activity.

CHECK ON LEARNING: Conduct a check on learning and summarize the ELO. G. ENABLING LEARNING OBJECTIVE
ACTION: CONDITIONS:

Perform Battlefield Damage Assessment on Power Train/Steering System In a field environment, given a BDAR kit, tools, code X equipment and references. IAW applicable TMs.

STANDARDS:

1.

Learning Step / Activity 1. Perform Battle Field Damage Assessment on Power Train/Steering System. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: NOTE: NOTE: NOTE: NOTE: NOTE: Practical Exercise (Performance) 1:4 2 hrs Small Group Instruction (SGI)

Tell students that during the next 2 hours they will complete a practical exercise that is designed to enhance their skills in BDAR. Conduct the practical exercise IAW 63H34F05, Suppl 3b, Practical Exercise Instructors Guide. Issue students 63H34F05, Suppl 3a, Practical Exercise Students Guide. After the practical exercise, have the students clean the work area. Conduct a check on learning and summarize the enabling learning objective.

NOTE:

Conduct a check on learning and summarize the learning activity.

CHECK ON LEARNING: Conduct a check on learning and summarize the ELO.

12

H.

ENABLING LEARNING OBJECTIVE

ACTION: CONDITIONS:

Perform Battlefield Damage Assessment on Hydraulic Power Distribution System In a field environment, given a BDAR kit, tools, code X equipment and references. IAW applicable TMs.

STANDARDS:

1.

Learning Step / Activity 1. Perform Battlefield Damage Assessment on Hydraulic Power Distribution System Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: NOTE: Practical Exercise (Performance) 1:4 1 hr 25 mins Large Group Instruction

Tell students that during the next 1hour and 30 minutes they will complete a practical exercise that is designed to enhance their skills in hydraulic power distribution system BDAR. Conduct the practical exercise IAW 63H34F05, Suppl 4b, Practical Exercise Instructors Guide. Issue students 63H34F05, Suppl 4a, Practical Exercise Students Guide. After the practical exercise, have the students clean the work area.

NOTE: NOTE: NOTE: NOTE:

Conduct a check on learning and summarize the enabling learning objective. NOTE: Conduct a check on learning and summarize the learning activity.

CHECK ON LEARNING: Conduct a check on learning and summarize the ELO.

13

SECTION IV.

SUMMARY Method of Instruction: Conference / Discussion Instructor to Student Ratio is: 1:16 Time of Instruction: 5 mins Media: Large Group Instruction

Check on Learning

Determine if students have learned the material presented by: a. Soliciting student questions and explanations. b. Asking questions and getting answers from the students. NOTE: Show slide # 58. Q. What is the purpose of battle damage assessment and repair (BDAR)? A. To rapidly return disabled equipment to the operational commander by expediently fixing, bypassing, or jury-rigging components. NOTE: Show slide # 59. Q. When can BDAR procedures be implemented? A. Only in an emergency situation, in a battlefield environment and only at the direction of the commander. NOTE: Show slide # 60. Q. What is battlefield damage? A. All incidents, which occur on the battlefield which prevent the vehicle from accomplishing its mission. NOTE: Show slide # 61. Q. What is damage assessment? A. A procedure to rapidly determine what is damaged, whether its repairable, what assets are required to make the repair, who can make the repair, and where the repair should be made. c. Providing immediate feedback in context to material presented and student misunderstanding. correcting

Review / Summarize Lesson

14

SECTION V. Testing Requirements

STUDENT EVALUATION
NOTE: Describe how the student must demonstrate accomplishment of the TLO. Refer student to the Student Evaluation Plan.

Describe how the student must demonstrate accomplishment of the TLO. In lesson 63H34F06, Job Knowledge Test, the student must achieve at least a 70% score and complete the test within one hour. In lesson 63H34F07, Job Performance Test, the student must achieve a GO and complete the test within one hour.

Feedback Requirements

NOTE: Feedback is essential to effective learning. Schedule and provide feedback on the evaluation and any information to help answer students' questions about the test. Provide remedial training as needed.

15

Appendix C - Practical Exercises and Solutions PRACTICAL EXERCISE(S)/SOLUTION(S) FOR LESSON 1: 63H34F05 version MOSC PRACTICAL EXERCISE SHEET 63H34F05 SUPPL 1
Title Lesson Number / Title Introduction Motivator Enabling Learning Objective NOTE: The instructor should inform the students of the following Enabling Learning Objective covered by this practical exercise. (ELO E) At the completion of this lesson, you [the student] will: Action: Perform Battlefield Damage Assessment on Fuel System Conditions: In a field environment, given a BDAR kit, tools, code X equipment Standards: Safety Requirements

Perform BDAR Procedures on Fuel Systems 63H34F05 version MOSC / Battle Damage Assessment and Repair (BDAR) Procedures

and references. IAW applicable TMs.

Hearing protection will be used when equipment is in operation. Safety goggles, should be worn while working under a vehicle. Hard hats will be worn when using an overhead lifting device. Remove all jewelry and I.D. tags before any work is started. Use safety stands while vehicle is in the raised position.

Risk Assessment

Low - It is the instructor's responsibility to conduct a risk assessment prior to instruction using FM 100-14 as guidance. A copy of the risk management work sheet must be present at time of instruction. When working with equipment, in the event of an accidental spill of hydraulic fluid, fuels, oils, solvents, acids, and coolants, the spill must be contained and cleaned up immediately. Floor dry sweep is the most effective material to contain and clean up environmental spills. The student will report the incident to the instructor immediately. The instructor will direct appropriate cleanup actions. All contaminated floor dry materials must be stored in a separate container. The container must be inspected by qualified environmental specialists to determine proper disposal procedures. Additional warnings and cautions concerning environmental hazards will be explained to you at the applicable point in later lessons.

Environmental Considerations

D-1

63H34F05 June 04 Suppl, 1a PRACTICAL EXERCISE STUDENTS GUIDE TITLE: Enabling Learning Objective D. Perform Battlefield Damage Assessment on Fuel Systems. ACTION: CONDITION: STANDARD: Safety Requirements 1. 2. 3. 4. 5. 6. 7. 8. 9. Risk Assessment Level Procedure 1. Inspect the fuel tank for damage and write down on DA From 2404 what repairs need to be done. a. Mark the damaged areas using chalk or suitable marking device. (1) Select appropriate items from the BDAR kit to perform the repair. (2) Follow all instructions listed on repair kit and safety warnings b. Test the fuel tank after repair has been completed. (1) Using water to test repair. Fill the tank and check for leaks. (2) Drain water from tank and leave open for water to evaporate. c. Write down all BDAR repairs done to the equipment on a DA 2404. Feedback Group must receive a GO on the Practical Exercise Checklist. If a GO is not received in each area the first time, then the group must correct deficiencies and resubmit their work for approval. Perform BDAR on fuel systems. In a field environment, given a BDAR kit, tools, code X equipment and references. IAW applicable TMs.

Hard hats and work gloves will be worn when repairing equipment Remove all jewelry (watches, rings, ID tags). No horseplay. A haphazard approach to BDAR can lead to death, dismemberment, and damage to equipment. Follow all WARNINGS, CAUTIONS AND NOTES listed in the TM. Be careful when handling any training aid. Sharp edges and moving parts can cause injury. When climbing on or around vehicles, always maintain three-points of contact. Know where the fire extinguishers, fire lanes, and fire exits are located. Know fire exit procedures.

Low. (See Appendix A).

D-2

Feedback Requirements

D-3

SOLUTION FOR PRACTICAL EXERCISE SHEET 63H34F05 SUPPL 1 63H34F05 June 04 Suppl, 1b

PRACTICAL EXERCISE INSTRUCTORS GUIDE TITLE: References Number TM 9-2350-276-BD FM 9-43-2 Enabling Learning Objective D. ACTION: CONDITION: STANDARD: Safety Requirements 1. 2. 3. 4. 5. 6. 7. 8. 9. Risk Assessment Level Environmental Considerations Preparation Title BDAR for Combat vehicle Recovery/BDAR Date Feb 84 Dec 87 Additional Information All All Perform Battlefield Damage Assessment on Fuel Systems.

Perform BDAR on fuel systems. In a field environment, given a BDAR kit, tools, code X equipment and references. IAW applicable TMs.

Hard hats and work gloves will be worn when repairing equipment Remove all jewelry (watches, rings, ID tags). No horseplay. A haphazard approach to BDAR can lead to death, dismemberment, and damage to equipment. Follow all WARNINGS, CAUTIONS AND NOTES listed in the TM. Be careful when handling any training aid. Sharp edges and moving parts can cause injury. When climbing on or around vehicles, always maintain three-points of contact. Know where the fire extinguishers, fire lanes, and fire exits are located. Know fire exit procedures.

Low. (See Appendix A)

Ensure appropriate containers are available to collect any engine fluids; clean all spills immediately. Wash your hands if you come in contact with POL products.

The following will be accomplished before the arrival of students at the Practical Exercise site. 1. 2. Prepare workstation with a damage fuel tank or suitable like item. Ensure all fuel has been drained and purged. Provide each workstation with a BDAR kit.

D-4

NOTE:

Explain to students that the tank has been damaged by small arms fire and needs to be repaired to get the vehicle operation so it can be moved to a safe location to complete the repair in accordance with Technical Manuals (TM). Have the students break down in groups and assign each group a workstation. 1. Have the students inspect the fuel tank. a. Mark the damaged areas using chalk or suitable marking device. (1) Ensure students select appropriate items from the BDAR kit to perform the repair. (2) Ensure students follow all instructions listed on repair kit and safety warnings b. Test the fuel tank after repair has been completed. (1) Using water to test repair. Have the student fill the tank and check for leaks. (2) Drain water from tank and leave open for water to evaporate. c. Write down all BDAR repairs done to the equipment on a DA 2404.

NOTE: Procedure

Feedback

Group must receive a GO on the Practical Exercise Checklist. If a GO is not received in each area the first time, then the group must correct deficiencies and resubmit their work for approval.

D-5

PRACTICAL EXERCISE SHEET 63H34F05 SUPPL 2

Title Lesson Number / Title Introduction Motivator Enabling Learning Objective NOTE: The instructor should inform the students of the following Enabling Learning Objective covered by this practical exercise. (ELO F) At the completion of this lesson, you [the student] will: Action: Perform Battlefield Damage Assessment on Electrical System Conditions: In a field environment, given a BDAR kit, tools, code X equipment Standards: Safety Requirements

Perform BDAR Procedures on Electrical System 63H34F05 version MOSC / Battle Damage Assessment and Repair (BDAR) Procedures

and references. IAW applicable TMs.

Hearing protection will be used when equipment is in operation. Safety goggles, should be worn while working under a vehicle. Hard hats will be worn when using an overhead lifting device. Remove all jewelry and I.D. tags before any work is started. Use safety stands while vehicle is in the raised position.

Risk Assessment

Low - It is the instructor's responsibility to conduct a risk assessment prior to instruction using FM 100-14 as guidance. A copy of the risk management work sheet must be present at time of instruction. When working with equipment, in the event of an accidental spill of hydraulic fluid, fuels, oils, solvents, acids, and coolants, the spill must be contained and cleaned up immediately. Floor dry sweep is the most effective material to contain and clean up environmental spills. The student will report the incident to the instructor immediately. The instructor will direct appropriate cleanup actions. All contaminated floor dry materials must be stored in a separate container. The container must be inspected by qualified environmental specialists to determine proper disposal procedures. Additional warnings and cautions concerning environmental hazards will be explained to you at the applicable point in later lessons.

Environmental Considerations

D-6

63H34F05 June 04 Suppl, 2a PRACTICAL EXERCISE STUDENTS GUIDE TITLE: Enabling Learning Objective E. Perform Battlefield Damage Assessment on Electrical Systems. ACTION: CONDITION: STANDARD: Safety Requirements 1. 2. 3. 4. 5. 6. 7. 8. 9. Risk Assessment Level Environmental Considerations Procedure 1. Perform BDAR on electrical systems. In a field environment, given a BDAR kit, tools, code X equipment and references. IAW applicable TMs.

Hard hats and work gloves will be worn when repairing equipment Remove all jewelry (watches, rings, ID tags). No horseplay. A haphazard approach to BDAR can lead to death, dismemberment, and damage to equipment. Follow all WARNINGS, CAUTIONS AND NOTES listed in the TM. Be careful when handling any training aid. Sharp edges and moving parts can cause injury. When climbing on or around vehicles, always maintain three-points of contact. Know where the fire extinguishers, fire lanes, and fire exits are located. Know fire exit procedures.

Low. (See Appendix A).

Ensure appropriate containers are available to collect any engine fluids; clean all spills immediately. Wash your hands if you come in contact with POL products. Inspect the wiring harness. a. Mark the damaged areas using chalk or suitable marking device. (1) Select appropriate items from the BDAR kit to perform the repair. (2) Follow all instructions listed on repair kit and safety warnings b. Test the wiring harness after repair has been (1) Using a Multimeter to test repair. Do a continuity check on wires repaired. (2) Use electrical tape to cover any exposed or bare wires. c. Write down all BDAR repairs done to the equipment on a DA 2404.

Feedback

Group must receive a GO on the Practical Exercise Checklist. If a GO is not received in each area the first time, then the group must correct deficiencies and resubmit their work for approval.

D-7

Feedback Requirements

D-8

SOLUTION FOR PRACTICAL EXERCISE SHEET 63H34F05 SUPPL 2 63H34F05 June 04 Suppl, 2b PRACTICAL EXERCISE INSTRUCTORS GUIDE TITLE: References Number TM 9-2350-276-BD FM 9-43-2 Enabling Learning Objective E. ACTION: CONDITION: STANDARD: Safety Requirements 1. 2. 3. 4. 5. 6. 7. 8. 9. Risk Assessment Level Environmental Considerations Preparation Title BDAR for Combat vehicle Recovery/BDAR Date Feb 84 Dec 87 Additional Information All All Perform Battlefield Damage Assessment on Electrical Systems.

Perform BDAR on electrical systems. In a field environment, given a BDAR kit, tools, code X equipment and references. IAW applicable TMs.

Hard hats and work gloves will be worn when repairing equipment Remove all jewelry (watches, rings, ID tags). No horseplay. A haphazard approach to BDAR can lead to death, dismemberment, and damage to equipment. Follow all WARNINGS, CAUTIONS AND NOTES listed in the TM. Be careful when handling any training aid. Sharp edges and moving parts can cause injury. When climbing on or around vehicles, always maintain three-points of contact. Know where the fire extinguishers, fire lanes, and fire exits are located. Know fire exit procedures.

Low. (See Appendix A)

Ensure appropriate containers are available to collect any engine fluids; clean all spills immediately. Wash your hands if you come in contact with POL products.

The following will be accomplished before the arrival of students at the Practical Exercise site. 1. 2. Prepare workstation with a damage wiring harness or suitable like item. Ensure that at least three areas of the harness need repair. Provide each workstation with a BDAR kit.

D-9

NOTE:

Explain to students that the wiring harness has been damaged by fire and needs to be repaired to get the vehicle operation so it can be moved to a safe location to complete the repair in accordance with Technical Manuals (TM). Have the students break down in groups and assign each group a workstation. 1. Have the students inspect the wiring harness. a. Mark the damaged areas using chalk or suitable marking device. (1) Ensure students select appropriate items from the BDAR kit to perform the repair. (2) Ensure students follow all instructions listed on repair kit and safety warnings b. Test the wiring harness after repair has been (1) Using a Multimeter to test repair. Have the student do a continuity check on wires repaired. (2) Have student use electrical tape to cover any exposed or bare wires. c. Write down all BDAR repairs done to the equipment on a DA 2404.

NOTE: Procedure

Feedback

Group must receive a GO on the Practical Exercise Checklist. If a GO is not received in each area the first time, then the group must correct deficiencies and resubmit their work for approval. PRACTICAL EXERCISE SHEET 63H34F05 SUPPL 3

Title Lesson Number / Title Introduction Motivator Enabling Learning Objective

Perform BDAR Procedures on Power Train/Steering System 63H34F05 version MOSC / Battle Damage Assessment and Repair (BDAR) Procedures

NOTE: The instructor should inform the students of the following Enabling Learning Objective covered by this practical exercise. (ELO G) At the completion of this lesson, you [the student] will: Action: Perform Battlefield Damage Assessment on Power Train/Steering Conditions: Standards:

System In a field environment, given a BDAR kit, tools, code X equipment and references. IAW applicable TMs.

Safety Requirements

Hearing protection will be used when equipment is in operation. Safety goggles, should be worn while working under a vehicle. Hard hats will be worn when using an overhead lifting device. Remove all jewelry and I.D. tags before any work is started. Use safety stands while vehicle is in the raised position.

D-10

Risk Assessment

Low - It is the instructor's responsibility to conduct a risk assessment prior to instruction using FM 100-14 as guidance. A copy of the risk management work sheet must be present at time of instruction. When working with equipment, in the event of an accidental spill of hydraulic fluid, fuels, oils, solvents, acids, and coolants, the spill must be contained and cleaned up immediately. Floor dry sweep is the most effective material to contain and clean up environmental spills. The student will report the incident to the instructor immediately. The instructor will direct appropriate cleanup actions. All contaminated floor dry materials must be stored in a separate container. The container must be inspected by qualified environmental specialists to determine proper disposal procedures. Additional warnings and cautions concerning environmental hazards will be explained to you at the applicable point in later lessons.

Environmental Considerations

D-11

63H34F05 June 04 Suppl, 3a PRACTICAL EXERCISE STUDENTS GUIDE TITLE: Enabling Learning Objective F. Perform Battlefield Damage Assessment on Power Train/Steering Systems. ACTION: CONDITION: STANDARD: Safety Requirements 1. 2. 3. 4. 5. 6. 7. 8. 9. Risk Assessment Level Environmental Considerations Procedure Perform BDAR on power train/steering systems. In a field environment, given a BDAR kit, tools, code X equipment and references. IAW applicable TMs.

Hard hats and work gloves will be worn when repairing equipment Remove all jewelry (watches, rings, ID tags). No horseplay. A haphazard approach to BDAR can lead to death, dismemberment, and damage to equipment. Follow all WARNINGS, CAUTIONS AND NOTES listed in the TM. Be careful when handling any training aid. Sharp edges and moving parts can cause injury. When climbing on or around vehicles, always maintain three-points of contact. Know where the fire extinguishers, fire lanes, and fire exits are located. Know fire exit procedures.

Low. (See Appendix A).

Ensure appropriate containers are available to collect any engine fluids; clean all spills immediately. Wash your hands if you come in contact with POL products.

1. Inspect the Power train/steering systems for damage. a. Mark the damaged areas using chalk or suitable marking device. (1) Select appropriate items from the BDAR kit to perform the repair. (2) Follow all instructions listed on repair kit and safety warnings b. Test the power train/steering systems after repair has been (1) Test the repair that has been done on the Power train/steering systems. Have the student check for safe operation of the system repaired. (2) Operate the equipment. c. Write down all BDAR repairs done to the equipment on a DA 2404.

D-12

Feedback

Group must receive a GO on the Practical Exercise Checklist. If a GO is not received in each area the first time, then the group must correct deficiencies and resubmit their work for approval.

Feedback Requirements

D-13

SOLUTION FOR PRACTICAL EXERCISE SHEET 63H34F05 SUPPL 3 63H34F05 June 04 Suppl, 3b PRACTICAL EXERCISE INSTRUCTORS GUIDE TITLE: References Number TM 9-2350-276-BD FM 9-43-2 Enabling Learning Objective F. ACTION: CONDITION: STANDARD: Safety Requirements 1. 2. 3. 4. 5. 6. 7. 8. 9. Risk Assessment Level Environmental Considerations Preparation Title BDAR for Combat vehicle Recovery/BDAR Date Feb 84 Dec 87 Additional Information All All Perform Battlefield Damage Assessment on Power Train/Steering Systems.

Perform BDAR on Power train/steering systems. In a field environment, given a BDAR kit, tools, code X equipment and references. IAW applicable TMs.

Hard hats and work gloves will be worn when repairing equipment Remove all jewelry (watches, rings, ID tags). No horseplay. A haphazard approach to BDAR can lead to death, dismemberment, and damage to equipment. Follow all WARNINGS, CAUTIONS AND NOTES listed in the TM. Be careful when handling any training aid. Sharp edges and moving parts can cause injury. When climbing on or around vehicles, always maintain three-points of contact. Know where the fire extinguishers, fire lanes, and fire exits are located. Know fire exit procedures.

Low. (See Appendix A)

Ensure appropriate containers are available to collect any engine fluids; clean all spills immediately. Wash your hands if you come in contact with POL products.

The following will be accomplished before the arrival of students at the Practical Exercise site. 1. Prepare workstation with a damage Power train/steering systems or suitable like item. Ensure that at least one area of the system needs repair. 2. Provide each workstation with a BDAR kit.

D-14

NOTE:

Explain to students that the Power train/steering systems has been damaged by indirect fire and needs to be repaired to get the vehicle operation so it can be moved to a safe location to complete the repair in accordance with Technical Manuals (TM). Have the students break down in groups and assign each group a workstation. 1. Have the students inspect the Power train/steering systems. a. Mark the damaged areas using chalk or suitable marking device. (1) Ensure students select appropriate items from the BDAR kit to perform the repair. (2) Ensure students follow all instructions listed on repair kit and safety warnings b. Test the Power train/steering systems after repair has been (1) Test the repair that has been done on the Power train/steering systems. Have the student check for safe operation of the system repaired. (2) Have student operate the equipment. c. Write down all BDAR repairs done to the equipment on a DA 2404.

NOTE: Procedure

Feedback

Group must receive a GO on the Practical Exercise Checklist. If a GO is not received in each area the first time, then the group must correct deficiencies and resubmit their work for approval.

D-15

PRACTICAL EXERCISE SHEET 63H34F05 SUPPL 4

Title Lesson Number / Title Introduction Motivator Enabling Learning Objective NOTE: The instructor should inform the students of the following Enabling Learning Objective covered by this practical exercise. (ELO H) At the completion of this lesson, you [the student] will: Action: Perform Battlefield Damage Assessment on Hydraulic Power Conditions: Standards: Safety Requirements

Perform BDAR Procedures on Hydraulic Distribution Sytems 63H34F05 version MOSC / Battle Damage Assessment and Repair (BDAR) Procedures

Distribution System In a field environment, given a BDAR kit, tools, code X equipment and references. IAW applicable TMs.

Hearing protection will be used when equipment is in operation. Safety goggles, should be worn while working under a vehicle. Hard hats will be worn when using an overhead lifting device. Remove all jewelry and I.D. tags before any work is started. Use safety stands while vehicle is in the raised position.

Risk Assessment

Low - It is the instructor's responsibility to conduct a risk assessment prior to instruction using FM 100-14 as guidance. A copy of the risk management work sheet must be present at time of instruction. When working with equipment, in the event of an accidental spill of hydraulic fluid, fuels, oils, solvents, acids, and coolants, the spill must be contained and cleaned up immediately. Floor dry sweep is the most effective material to contain and clean up environmental spills. The student will report the incident to the instructor immediately. The instructor will direct appropriate cleanup actions. All contaminated floor dry materials must be stored in a separate container. The container must be inspected by qualified environmental specialists to determine proper disposal procedures. Additional warnings and cautions concerning environmental hazards will be explained to you at the applicable point in later lessons.

Environmental Considerations

Procedures

D-16

63H34F05 June 04 Suppl, 4a PRACTICAL EXERCISE STUDENTS GUIDE TITLE: Enabling Learning Objective G. Perform Battlefield Damage Assessment on Hydraulic Power Distribution. ACTION: CONDITION: STANDARD: Safety Requirements 1. 2. 3. 4. 5. 6. 7. 8. 9. Risk Assessment Level Environmental Considerations Procedure Perform BDAR on Hydraulic Power Distribution. In a field environment, given a BDAR kit, tools, code X equipment and references. IAW applicable TMs.

Hard hats and work gloves will be worn when repairing equipment Remove all jewelry (watches, rings, ID tags). No horseplay. A haphazard approach to BDAR can lead to death, dismemberment, and damage to equipment. Follow all WARNINGS, CAUTIONS AND NOTES listed in the TM. Be careful when handling any training aid. Sharp edges and moving parts can cause injury. When climbing on or around vehicles, always maintain three-points of contact. Know where the fire extinguishers, fire lanes, and fire exits are located. Know fire exit procedures.

Low. (See Appendix A).

Ensure appropriate containers are available to collect any engine fluids; clean all spills immediately. Wash your hands if you come in contact with POL products.

1. Inspect the Hydraulic Power Distribution. a. Mark the damaged areas using chalk or suitable marking device. (1) Select appropriate items from the BDAR kit to perform the repair. (2) Follow all instructions listed on repair kit and safety warnings b. Test Hydraulic Power Distribution after repair has been (1) Test the repair that has been done on the hydraulic power distribution. Have the student check for safe operation of the system repaired. (2) Operate the equipment. c. Write down all BDAR repairs done to the equipment on a DA 2404.

Feedback

Group must receive a GO on the Practical Exercise Checklist. If a GO is not received in each area the first time, then the group must correct deficiencies and resubmit their work for approval.

D-17

Feedback Requirements

D-18

SOLUTION FOR PRACTICAL EXERCISE SHEET 63H34F05 SUPPL 4 63H34F05 June 04 Suppl, 4b PRACTICAL EXERCISE INSTRUCTORS GUIDE TITLE: References Number TM 9-2350-276-BD FM 9-43-2 Enabling Learning Objective G. ACTION: CONDITION: STANDARD: Safety Requirements 1. 2. 3. 4. 5. 6. 7. 8. 9. Risk Assessment Level Environmental Considerations Preparation Title BDAR for Combat vehicle Recovery/BDAR Date Feb 84 Dec 87 Additional Information All All Perform Battlefield Damage Assessment on Hydraulic Power Distribution.

Perform BDAR on Hydraulic Power Distribution. In a field environment, given a BDAR kit, tools, code X equipment and references. IAW applicable TMs.

Hard hats and work gloves will be worn when repairing equipment Remove all jewelry (watches, rings, ID tags). No horseplay. A haphazard approach to BDAR can lead to death, dismemberment, and damage to equipment. Follow all WARNINGS, CAUTIONS AND NOTES listed in the TM. Be careful when handling any training aid. Sharp edges and moving parts can cause injury. When climbing on or around vehicles, always maintain three-points of contact. Know where the fire extinguishers, fire lanes, and fire exits are located. Know fire exit procedures.

Low. (See Appendix A)

Ensure appropriate containers are available to collect any engine fluids; clean all spills immediately. Wash your hands if you come in contact with POL products.

The following will be accomplished before the arrival of students at the Practical Exercise site. 1. Prepare workstation with a damage hydraulic power distribution systems or suitable like item. Ensure that at least one area of the system needs repair. 2. Provide each workstation with a BDAR kit.

D-19

NOTE:

Explain to students that the Hydraulic Power Distribution has been damaged by indirect fire and needs to be repaired to get the vehicle operation so it can be moved to a safe location to complete the repair in accordance with Technical Manuals (TM). Have the students break down in groups and assign each group a workstation. 1. Have the students inspect the Hydraulic Power Distribution. a. Mark the damaged areas using chalk or suitable marking device. (1) Ensure students select appropriate items from the BDAR kit to perform the repair. (2) Ensure students follow all instructions listed on repair kit and safety warnings b. Test Hydraulic Power Distribution after repair has been (1) Test the repair that has been done on the hydraulic power distribution. Have the student check for safe operation of the system repaired. (2) Have student operate the equipment. c. Write down all BDAR repairs done to the equipment on a DA 2404.

NOTE: Procedure

Feedback

Group must receive a GO on the Practical Exercise Checklist. If a GO is not received in each area the first time, then the group must correct deficiencies and resubmit their work for approval.

D-20