Attachment 0022 Appendix K - Lubrication Orders.pdf

MIL-STD-40051-2A

APPENDIX K

LUBRICATION ORDERS

K.1 SCOPE.

K.1.1 Scope. This appendix establishes the technical content requirements for the preparation of stand-alone Lubrication Orders (LOs) for major weapon systems and their related systems, subsystems, equipment, WRAs, and SRAs. This appendix is a mandatory part of this standard.

The information contained herein is intended for compliance. The requirements are applicable for all maintenance levels/classes through overhaul (depot) including DMWRs and NMWRs.

K.2 APPLICABLE DOCUMENTS.

The applicable documents in section 2 apply to this appendix.

K.3 DEFINITIONS.

The definitions in section 3 apply to this appendix.

K.4 GENERAL REQUIREMENTS.

K.4.1 General. The requirements provided in this appendix provide the technical content requirements for the LOs.

K.4.2 Development of lubrication instructions. Lubrication instructions shall be prepared for all equipment, except aircraft, that require lubrication. These lubrication instructions shall be prepared as a stand-alone work card except in the following cases:

a. When specified by the acquiring activity, the lubrication instructions may be included in the PMCS work package or as a lubrication work package. (Refer to E.5.3.4.)

b. When the lubrication procedures are classified, the lubrication instructions shall be included in the PMCS or a lubrication work package that is classified to at least the classification level of the instructions or higher. Classified instructions shall be marked and handled as specified in the current security regulations.

K.4.3 Preparation of digital data for electronic delivery. Data prepared and delivered digitally in accordance with this standard shall be XML tagged using the DTD. Data shall be formatted for presentation using stylesheets in accordance with MIL-STD-2361. Stylesheets may be prepared using XSL or other languages as specified by the acquiring activity. Where possible and when available, Army developed and provided stylesheets shall be used. Refer to 4.6 for information on obtaining or accessing this DTD and stylesheets. XML tags used in the DTD are noted throughout the text of this standard in bracketed, bold characters (e.g., <ginfowp>) as a convenience for the author and to ensure that the tags are used correctly when developing a document instance.

K.4.4 Use of Document Type Definition (DTD)/stylesheet. The DTD referenced in this standard interprets the technical content and structure for the functional requirements contained in this standard. Its use is mandatory. Development of TMs is accomplished through the use of this standard, the DTD, and the guidance contained in MIL-HDBK-1222. Where possible and when available, Army developed and provided stylesheets shall be used. For additional information on the DTD and specific stylesheets, refer to MIL-STD-2361.

K.4.5 Content structure. The examples provided herein are an accurate representation of the content structure requirements contained in this appendix and shall be followed to permit the effective use of the DTD for LOs.

K.4.6 Style and format. This standard provides style and format requirements for the technical content requirements described in this appendix. These requirements are considered mandatory and are intended for compliance.

K.4.7 Work package development. Data developed in accordance with this appendix shall be divided into work packages. For task-related work packages, the tasks shall be in the logical order of the work sequence. These work packages should be stand alone and are broken into the following work package types: general information, operator instructions, troubleshooting procedures, maintenance instructions, parts information, supporting information, destruction of Army materiel to prevent enemy use, preventative maintenance checklist, and LOs. A work package shall contain all information and references required to support the work package type.

K.4.8 Warnings, cautions, and notes. Warnings, cautions, and notes shall be applied in accordance with 4.8.7.

K.4.9 Illustrations. Illustrations may be used in the LO.

K.4.9.1 Single illustrations. Illustrations shall be used to show the location of grease fittings and shall indicate the number of grease points (when applicable). A minimum number of illustrations shall be used. Foldouts shall not be used in lubrication orders.

K.4.9.2 Multiple illustrations. When it is necessary to provide multiple numbers of illustrations to show separate component parts, each illustration shall have an individual title.

K.4.10 Safety devices and interlocks. Information shall be prepared pertaining to the purpose and location of all safety devices and interlocks in conjunction with the pertinent procedures.

K.4.11 Electrostatic Discharge (ESD) sensitive parts. If the equipment contains ESD sensitive parts, components, or circuits, cautions and ESD labels shall be incorporated into the applicable tasks and procedures to ensure ESD sensitive parts are not damaged or degraded during maintenance and operation. (Refer to 4.8.21 for requirements on labeling with ESD.) Actions which could damage ESD sensitive parts, but which are not directly related to handling or operation of ESD sensitive parts, shall not be annotated with the ESD acronym, but shall be preceded by a caution statement.

K.4.12 Selective application and tailoring. This standard contains some requirements that may not be applicable to the preparation of all TMs. Selective application and tailoring of requirements contained in this standard are the responsibility of the acquiring .activity and shall be accomplished using Appendix A. The applicability of some requirements is also designated by one of the following statements: unless specified otherwise by the acquiring activity; as specified by the acquiring activity; or when specified by the acquiring activity.

K.5 DETAILED REQUIREMENTS.

K.5.1 Lubrication Order (LO) card <lubeorder>.

K.5.1.1 Logbook size lubrication order. LOs shall be prepared in either log book or standard page size. (Refer to Table I.) LO card size C shall be used in conjunction with the operators log book manual. LOs shall not be folded.

K.5.1.2 Lubrication order (LO) number. The LO number shall appear on the first card in accordance with K.5.2.1. The LO number shall appear at the top of all the other cards in the LO.

K.5.1.3 Lubrication order (LO) card numbering. Unless otherwise specified by the acquiring activity, the card number shall be centered at the bottom of the card. Each printed side of a card shall be numbered sequentially. Each side shall reflect the relationship of that side to the total number of printed sides. For example, 1 of 4, 2 of 4, 3 of 4, and 4 of 4. If only one side of a card is printed, it shall be numbered 1 of 1.

K.5.2 Title page (first card) contents <frntcover_abbreviated>. The title page shall contain the LO number, a heading, title, NSN, part number, CAGEC, the EIC, a reference line, reporting errors information, distribution statement/export control warning/destruction notice, and location of the LO statement. Refer to Figure K-1 for an example of a title page (first card).

K.5.2.1 Heading. The heading shall consist of the words "LUBRICATION ORDER," the date printed, the LO number, and a supersession notice (if applicable), formatted as shown in Figure K-1.

K.5.2.2 Title <tmtitle>. The title shall appear below the heading and read the same as the title on the related TM. When more than one piece of equipment is covered by the LO, the title for each shall appear separately.

K.5.2.3 National Stock Number (NSN), part number, Commercial and Government Entity Code (CAGEC), and End Item Code (EIC). The applicable NSNs, part numbers, CAGECs, and EICs for each piece of equipment covered by the LO shall be entered beneath the title(s).

K.5.2.4 Reference line. A reference line consisting of the publication number(s) of the related TMs shall be placed below the title within the applicable area.

K.5.2.5 Reporting errors <reporting>. LO cards shall contain a Reporting Errors and Recommending Improvements Statement.

K.5.2.6 Distribution statement, export control warning, and destruction notice <notices>. A distribution statement and, when required, an export control warning and destruction notice shall be placed on the first card. Requirements for these notices are contained in 5.2.1.1.6 through 5.2.1.1.8 and in DODD 5230.24.

K.5.2.7 Lubrication order (LO) statement <general_purpose_notices>. The following statement shall be included on the title page of the LO:

"A copy of this lubrication order will remain with the equipment at all times;

instructions contained herein are mandatory."

K.5.3 Introduction <intro>. The following statements shall be included in the LO, as applicable.

K.5.3.1 General statement(s)/notes.

K.5.3.1.1 General note placement. General statement(s)/notes shall be placed in the LO that are applicable to the overall understanding of requirements of the LO procedures. These statements/notes should be placed on the first card when possible. If insufficient space is available for these notes on the first card, they shall be placed before the first lubrication procedure.

K.5.3.1.2 General note content. The statement(s) shall include such information as adherence to lubrication intervals, explanation of interval symbols, maintenance levels/classes, exceptional operational requirements, abbreviations, fittings, and parts cleaning. A statement concerning corrosion control shall be used as applicable. The statement shall provide instructions or reference corrosion control requirements provided in the applicable narrative TM. (Refer to Figure K-2 for an example.)

K.5.3.2 Oil filter statement. As applicable, a statement similar to the following shall be included:

"Oil filters shall be serviced/cleaned/changed as applicable, when:

a. They are known to be contaminated, or clogged,

b. Service is recommended by Army Oil Analysis Program (AOAP) laboratory analysis, or

c. At prescribed hardtime intervals."

K.5.3.3 Army Oil Analysis Program (AOAP) statements. One of the following statements shall be included for all equipment falling under the AOAP.

K.5.3.3.1 Army Oil Analysis Program (AOAP) sampling interval statement. A statement similar to the following shall be included:

"Engine oil/transmission oil/hydraulic fluids must be sampled at (insert applicable hour/mileage time frame) as prescribed by (insert DA PAM 750-8 or DA PAM 738- 751).”

K.5.3.3.2 Army Oil Analysis Program (AOAP) not available/non-enrolled statement. When a component/equipment is not enrolled in the AOAP, or oil analysis support is not available, a statement similar to the following shall be used:

"This (enter name of component/equipment) is not enrolled in the Army Oil Analysis Program. HARDTIME INTERVALS APPLY."

K.5.3.4 Warranty hardtime statement. When applicable, the following statement shall be used:

"For equipment under manufacturer's warranty, hardtime oil service intervals shall be followed. Intervals shall be shortened if lubricants are known to be contaminated or if operation is under adverse conditions such as longer than usual operating hours, extended idling periods, extreme dust, etc."

K.5.4 Lubrication procedures <lubewp>. Lubrication procedures shall be prepared and shall include all applications, procedures, authorized lubricants, intervals, man-hour requirements, lubrication points, and AOAP requirements. Unless otherwise specified by the contracting activity, the lubrication procedures shall be presented in grouped sequence by interval to enable the user to receive, lubricate, and return to an acceptable performance standard all components of the equipment in a minimum amount of time with the skills, tools, test equipment, and spare parts authorized by the LMI or the MAC. Unless otherwise specified by the contracting activity, lubrication procedures shall be based upon the principles of RCM logic.

K.5.4.1 Work package identification information <wpidinfo>. Work package identification information is required for this work package. (Refer to 4.8.9.3.)

K.5.4.2 Work package initial setup <initial_setup>. Initial setup is required for this work package. (Refer to 4.8.9.4.)

K.5.4.3 Maintenance class. The lowest class of maintenance authorized to perform the task shown shall be identified. The applicable maintenance class symbol shall be shown in parentheses after the task. Applicable maintenance classes to be used are provided in Table K-I.

TABLE K-I. Maintenance classes.

Symbol Maintenance Class C Crew

O (aviation only) Aviation Maintenance Company (AMC)

F Maintainer or Aviation Support Battalion (ASB)

H Below Depot L Specialized Repair Activity or

Theater Aviation Support Maintenance Group (TASMG)

D Depot

K.5.4.4 Grouped lubrication points. When grouped lubrication points require the same lubricant at the same interval, the type and number of points shall be identified and described by one of the following methods:

a. Multi-headed, solid-shafted arrows shall point to each of the lubrication points. (Refer to Figure K-3.)

b. Lubrication point notes shall provide instructions for applying lubricants, taking into account the following factors:

(1) Type, grade, availability, and properties of prescribed lubricant.

(2) Expected temperature.

(3) Lubrication gun and tools available to authorized maintenance level.

(4) Types of lubrication fittings.

(5) Possible ill effects of excessive or insufficient lubrication.

Caution shall be stressed where over or under lubrication of a part will damage that part or closely associated parts. Such cautionary notes shall either be included as a portion of the point note or as a special note. (Refer to K.5.8.)

K.5.4.5 Disassembling and hand packing. If applicable, disassembling and hand packing instructions shall be provided for medium- and high-speed antifriction bearings which are sensitive to the amount of lubrication applied and do not have bleed holes or relief valves.

K.5.4.6 Cleaning, disassembling, and reassembling. Cleaning, disassembling, and reassembling instructions that are required before or after lubrication shall be provided. If instructions are extensive and contained in a TM, the TM shall be referenced.

K.5.4.7 Washing and natural drying. If applicable, instructions shall be given for washing and natural drying of finely machined and dirt-sensitive parts before relubricating. Use of compressed air jets or temperatures above 212 degrees Fahrenheit shall not be prescribed.

K.5.4.8 Preservative material. Instructions shall not specify a coating of preservative material, either before or after packing parts that are lubricated with grease; nor shall they specify an application of oil, solvent, or additional grease to a "sealed-for-life" or prepacked antifriction bearing.

K.5.5 Lubricants and military symbols. Unless otherwise specified by the acquiring activity, lubricants shall be identified by standard military symbols, in accordance with MIL-HDBK-113 and MIL-HDBK-275. (Refer to Figure K-3.) The lubricant symbols and interval symbols shall be printed in separate, vertical columns on the inner side of the point names. These columns shall be headed by the words "LUBRICANT" and "INTERVAL." Those lubrication points that are serviced or lubricated by checking the level, replenishing the lubricant, or draining and refilling shall be indicated by the lubricant's symbol at the point on the illustration that is designated for replenishing or refilling. The amount of lubricant required shall be given either in the point note or in the "Capacity" column of the table, if applicable.

K.5.5.1 Lubrication interval symbols. Unless otherwise specified by the acquiring activity, the lubrication interval symbols in Table K-II shall be used:

TABLE K-II. Lubrication intervals.

Symbol Definition D Daily W Weekly M Monthly Q Quarterly S Semiannually A Annually B Biannually H Hours (operated) MI Miles (operated) KM Kilometers (operated) RDS Rounds (fired) OC On Condition

MRA Maintenance Repair Action

K.5.6 Measurements. Unless otherwise specified by the acquiring activity, all measurements expressed in the text, in tables, or in illustrations shall be expressed in both U.S. standard units and metric units. The order shall be in accordance with equipment markings.

K.5.7 Lubricant table. As applicable, a table(s) shall be prepared to provide information needed to select the proper lubricant for various temperature ranges and uses. The size and location of the table(s) shall be tailored to meet layout requirements and shall include as applicable, information on temperature range, lubricant, military symbol, NATO code, specification, NSN, capacity, interval between service, and man-hours required to complete all service by type stated to the nearest tenth for all lubricants prescribed by the LO. (Refer to Figure K-4 for an example.)

K.5.7.1 Notes to tables. As necessary, when specific restrictions, preferred grades, and other conditions exist, notes shall be annotated on tables in accordance with MIL-STD-40051-2. For example: 1/"When MIL-PRF-2104 lubricant is authorized, use 15W-40 (OE/HDO-15/40) when available and the applicable temperature range exists," or 2/"15W-40 oil is not authorized in this particular (enter component name)." Where applicable, the statement "For Arctic Operation, refer to FM 9-207" shall be included as a note.

K.5.8 Special notes.

K.5.8.1 Pertinent lubrication point information. As applicable, additional pertinent lubrication point information shall be incorporated into the LO. When applicable, the LO shall contain a special note referencing, but not repeating, instructions in TMs.

K.5.8.2 Effect of extreme conditions. If applicable, pertinent instructions relevant to the effect of extreme conditions such as temperature, humidity, or altitude on lubrication requirements for the equipment shall be included as a special note.

K.5.9 Lubrication order rear matter <lubeorder_rear>.

K.5.9.1 Reporting errors and recommending improvements DA Form 2028 <da2028>. A DA Form 2028 shall be included as prescribed in 5.2.2.3.

K.5.9.2 Authentication block <authent>. An authentication block, provided by the acquiring activity, shall be included in the LO. Distribution information, as applicable, shall be placed below the authentication block.

K.5.9.3 Back cover <back>. The lubrication order shall contain a back cover as specified in 5.2.2.6.

K.6 NOTES.

The notes in section 6 apply to this appendix.

FIGURE K-1. Example of first card.

LO X-XXXX-XXX-X

LUBRICATION ORDER

OPERATOR’S MANUAL

TITLE

NSN

PART NUMBER

CAGEC

EIC

References: TM X-XXXX-XXX-10, TM X-XXXX-XXX-20, LO X-XXXX-XXX-XX, AND

FM X-XXX

REPORTING OF ERRORS

You can help improve this LO. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms) directly to:

(Insert name and address of proponent.) You may also send your recommended changes via electronic mail or by fax. Our fax number is (insert DSN and commercial number of proponent). Our e-mail address is (insert e-mail address of proponent). A reply will be furnished to you.

SUPERSEDURE NOTICE:

DISTRIBUTION STATEMENT C: Distribution authorized to U.S. government agencies and their contractors. This publication is Administrative-Operational Use required for administrative and operational purposes, as determined on (insert date). Other request for this document must be referred to (insert name and address of proponent.)

WARNING: This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et. seq.) or the Export Administration Act of 1979, as amended, Title 50!, U.S.C., App. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DOD Directive 5230.25.

DESTRUCTION NOTICE: Destroy by any method that will prevent disclosure of the contents or reconstruction of the document.

GENERAL NOTICE: Copy of this lubrication order will remain with the equipment at all times;

instructions contained herein are mandatory.

SERVICE NOMENCLATURE

LO DATE

Card 1 of 16

FIGURE K-2. Example of general statements/notes.

NOTES:

This LO is for crew (C) maintenance. Lube intervals (on-condition or hardtime) are based on normal operation. Lube more during constant use, and less during inactive periods. Use correct grade of lubricant for seasonal temperature expected.

On the picture, a dash line (--) means lube points on both sides.

Clean parts with dry solvent (SD), type II, or equivalent. Use cleaning compound solvent (RBC) on powder-fouled parts. Dry before lubricating. DO NOT use fluid or semi-fluid lubricant on SFD lubricated surface. Wipe surfaces dry.

Before you start your lube service.

ALWAYS NEVER

a. Clean grease fittings before lubrication. a. Use wrong type/grade grease.

b. Use the lubrication order as your guide. b. Use too much lubricant.

FIGURE K-3. Example – identification of lubricant symbol and lubrication points, interval, and note.

FIGURE K-4. Example of lubricant table.