BCIS Initial Draft MFP
20 June 98



4.1 MAINTENANCE PLAN. The BCIS maintenance concept is two-level. Unit and Depot. This concept is supported by a Level of Repair Analysis (LORA). Unit Level (UL) maintenance will be organic to the unit and depot level maintenance is anticipated to be contractor support for the life of the system.

Preventive Maintenance. Crews/Drivers will perform PMCS to include limited system troubleshooting procedures. Typical preventive maintenance tasks are visual inspections of antenna(s) and cables for obvious exterior damage or cable disconnection. Preventive maintenance will include checking the boresight alignment of the interrogator Antenna on the AN/VSX-4 equipped vehicles. Total preventive maintenance time allocation is five minutes as required by the ORD.

Unit Level Maintenance. UL Maintenance actions are limited to troubleshooting the system, fault isolation and removal/replacement of the modular unit and/or cable. Fault isolation is facilitated by BIT. Visual indications on the CEIU tell the operator and/or maintainer that the CEIU or the RT has failed. These two modular components make up 85% of system design and are also the two LRUs with the least reliability. The Mean-Time-Between-Failure (MTBF) is predicted to be 10,601 hours and 19,280 hours respectively. Documentation of these maintenance tasks will be verified in the BCIS TM and the TMs of the "shooter" platforms. Mean-Time-To-Repair (MTTR) at UL is 15 minutes with a maximum of 60 minutes as required by the ORD. See paragraph 4.9 for manpower and personnel requirements.

Depot Level Maintenance. CLS is planned for depot level maintenance. The contractor will repair the LRU by repair/replacement of Shop Replaceable Units (SRUs) and piece parts and return the LRU to wholesale supply stock as directed by the CECOM Item Manager. As part of the CLS contract, the contractor shall document failures and repair actions to identify trends and targets for higher reliability or lower cost parts that will reduce O&S cost by modernizing the LRU components through spares stockage.


4.1.1 Maintenance Reporting Requirements. To be determined.


4.2 WARRANTIES. A warranty is not anticipated as cost effective for BCIS. A warranty determination will be made as part of continuing supportability analysis to be completed prior to Low Rate Initial Production solicitation. The sole source contractor, TRW, is currently developing a warranty offer as part of their production planning.



4.3.1 Special Tools and Tool Sets. Not Applicable.

4.3.2 Common Tools and Tool Sets. Common tools and tool sets are listed in Figure 4-1.
The tool kit required depends on the vehicle type and Military Occupational Specialty (MOS) performing the maintenance action.





 Tool Kits:        
Artillery Mechanics: ORD (Abrams) W32182 5180-00-357-7727

Turret Mechanic (Bradley/BFIST/FISTV) T58051 5180-01-115-5351

Electric Equipment: TK-101/GSQ W37483 5180-00-064-5178

Level, 5 Bubble (Bradley Only)



Common Tools and Tool Sets
Figure 4-1

4.3.3 Special TMDE. Not Applicable. No Special TMDE is required for UL maintenance of BCIS.

4.3.4 Test Program Sets for Special TMDE. Not Applicable

4.3.5 Common TMDE. The only TMDE used during BCIS maintenance is a Multimeter, to troubleshoot cables. This Multimeter is common and is identified below:





Multimeter Digital: AN/PSM-45A M60449 6625-00-265-6000



Common TMDE
Figure 4-2


4.3.6 Test Program Sets for Common TMDE. Not Applicable.

4.3.7 Performance Monitoring and Maintenance Indicators. BCIS design includes Built-in Test (BIT) at the LRU level. BIT is run as a self-test on power up and provides visual fault indications on the CEIU front panel, as well as audible indications via the intercom on "shooter" vehicles. BIT will identify failures of the CEIU and the RT. BIT will also indicate if COMSEC or TOD is lost. BCIS also runs continuous BIT to identify the failures addressed above as they happen.

4.3.8 Special Purpose Kits. Installation Sets (kits) consisting of mounting hardware and cables specifically designed for BCIS integration with vehicle power, PLGR, intercom, sight units and FBCB2 are uniquely dependent on the vehicle type. The BCIS Installation Sets will be AAL and are listed in Appendix 9.9.

4.3.9 Other Support Equipment. Not Applicable.

4.3.10 Interim Substitute Support Equipment. No interim substitute support equipment is anticipated for BCIS fielding.

4.3.11 Local Fabrication Requirements. There are no local fabrication requirements for BCIS; however, a mounting bracket or attaching hardware may be locally fabricated if cost effective at the unit. These items will not be stocked items.

4.4 SUPPLY SUPPORT. The AN/VSX-4 and AN/VSC-9, Installation Sets, repair parts/assemblies and any required support equipment will be pushed as a BCIS total package for fielding IAW TPF procedures. The BCIS TPF project code has not been established at this time, but is a mandatory entry on requisitions for this materiel fielding. A Materiel Requirements List (MRL) will be developed by PM CI and coordinated with the Gaining Command. MRL development is dependent on the receipt of the Gaining Command's MSP identifying end item requirements. The MRL will identify every item and the quantity to be requisitioned by PM CI and provided as initial issue to the receiving unit, by DODAAC, UIC and project code. Initial issue spares will be computed for all parts coded C (essential) and replaceable at the Unit Level of maintenance. The MRL will also list items and quantities that must be requisitioned by the unit. Standard DOD procedures will be utilized for supply support requisitioning after initial fielding.

4.4.1 Master Support List. Not applicable. A Master Support List is not required because BCIS will be fielded under the TPF concept.

4.4.2 Components of End Item (COEI) List. See Appendix 9.7.

4.4.3 Basic Issue Items (BII) List. See Appendix 9.8.

4.4.4 Additional Authorizations List (AAL). See Appendix 9.9.

4.4.5 Float Quantities. Not applicable. BCIS will have neither an Operational Readiness Float at Ft. Hood, TX, or a Repair Cycle Float located at depot.

4.4.6 Basic Sustainment Materiel (BSM). Petroleum, Oils and Lubricants (POL). Not Applicable. Other Bulk Supplies. BCIS operates with two (2) Lithium batteries,TL-2100-S
(NSN 6135-01-301-8776) to hold COMSEC in memory when the system is turned off. The battery power will also protect BCIS from TOD loss and temporary vehicle power source interruptions. Two batteries will be included with each system when fielded, however the unit must stock this bulk supply for future use. The battery specification indicates battery life is six (6) months. This item requirement will be part of the MRL. Ammunition Requirements. Not Applicable.

4.4.7 Plans for Replaced and Displaced Equipment and Materiel. Not Applicable. BCIS does not replace/displace any equipment and requires no turn-in or redistribution of equipment or materiel. Three components on the M1A1 Abrams in the field will be modified for BCIS operation. They are: (1) Turret Network Box, (2) GPS Lower Panel and (3) Sight Insertion Unit. Modification of these tank components does not displace any equipment on that vehicle. Modifications to these existing components will be accomplished by the Abrams prime contractor during BCIS installation.

4.4.8 Evacuation Procedures. The procedures for evacuation of unserviceable materiel are the US Army Standard. Those procedures include handling and storage of CCI equipment like the BCIS component, CEIU.

4.4.9 Method of Distribution. BCIS will be fielded by the TPF method, Category I, Level II as described in AR 700-142.

- Category I TPF is a materiel system fielding comprised of the system and all Associated Support Items of Equipment (ASIOE) identified in the Basis of Issues Plan (BOIP). It also includes any authorized TMDE, a starter set of TMs, the computed initial issue spare/repair parts, and Installation Sets required for system operation and maintenance.

- Level 2 (High Density Simple system). An end item with little or no ASIOE that will be fielded in high density to a large number of users. This system does not drive additional authorizations of other support equipment in the receiving units.

PM CI will have the various contractors ship directly to Ft. Hood where the PM CI Materiel Fielding Team (MFT) will receive and stage all COEI, AAL and bulk supplies at a facility (to be determined) at that fielding location. All equipment and supplies for initial fielding will be pushed to the units based on the BOIP, MSP, AAL and spare requirement computations.



4.5.1 Transportability Guidance and Procedures. The BCIS does not impose transportation restrictions on its host vehicle. Strategic and tactical movement of vehicle-installed BCIS remains unaffected by this fielding. The contractor is permitted to transport BCIS to the fielding location and the wholesale supply depot via the most cost effective means within the guidelines of DA PAM 25-380-2, Security Procedures for Controlled Cryptographic Items, Appendix C, Transportation of Controlled Cryptographic Items. CCI can be transported in four ways: (1) Installed equipment on vehicles, (2) By DOD or contractor Courier, (3) Via registered mail with the US Postal Service, or (4) By commercial carrier, incorporated in the US, and meeting the following standards:

- Provide door-to-door service
- Guarantee delivery in a reasonable number of days
- Has a means of tracking individual packages
- Guarantees the package will be stored in a security cage if not transported directly to the addressee
- Use signature record to reflect chain of custody

Security procedures also govern transportation of the BCIS CCI component (CEIU) from the fielding location to the contractor depot repair facility.

4.5.2 Security-in-Transit. See paragraph 4.5.1 above.



4.6.1 Packaging. The only special packaging requirements for BCIS are for the CCI component. It requires only one wrapper, but the package must be marked "CCI". The CEIU will also be marked "CCI" on the equipment's identification plate.

4.6.2 Handling. The only special handling requirements are for the CCI component. CCI in the logistics channel will be managed under the provisions of AR 710-2, Supply Policy Below the Wholesale Level, and AR 715-50, Requisitioning, Receipt, and Issues System. Asset reporting will be done according to AR 710-3, Asset and Transaction Reporting System. The contractor will ship the CEIU from their COMSEC Custodian to the 4th Infantry Division's COMSEC Custodian with a SF 153, COMSEC Material Report. The Division COMSEC Custodian will issue the CEIU on a temporary hand receipt to PM CI's MFT lead. After installation of the CEIU on a vehicle, the Division COMSEC Custodian will cancel the temporary hand-receipt and issue the CEIU to the appropriate unit. This procedure was coordinated with Communications Security Logistics Activity (CSLA). When the item is handed off to the unit at fielding, serial number tracking on the property book is required.

4.6.3 Storage. Unattended and uninstalled CCI is considered to be in storage when it is in logistics channels. Physical security measures used to protect any unclassified, sensitive or high-value equipment is adequate for CCI protection in storage.



4.7.1 Technical Manuals. BCIS Draft Equipment Publication (DEP)Technical Manual (TM) is entitled Operators Manual, Unit Level Maintenance Manual and Repair Parts and Special Tool Lists. The TM number is DEP TM 11-5898-1554-12&P. The contractor will deliver a final electronic file DEP TM no later than 10 Jan 00 in support of the First Unit Equipped (FUE). Digital delivery at fielding is planned, however the desired media for that delivery must be coordinated with the gaining unit. A hard copy DEP TM can accompany each system at fielding with additional copies for the maintenance libraries, if desired.. The BCIS DEP TM will be in contractor format and will include a System Description Section, an Operating Instructions Section and a Maintenance Instructions Section as well as a RPSTL. TMs for the AN/VSX-4 installed vehicles will be supplemented to include BCIS operation, maintenance and identification of repair parts. These AN/VSX-4 installed host vehicle's TM will be appended with its own unique BCIS integration information for operation and maintenance. An index of all applicable publications will be at Appendix 9.11 of this MFP.

4.7.2 Supply Manuals and Bulletins. To be determined.

4.7.3 Camouflage Pattern Painting Requirements. Not applicable. BCIS requires no camouflage pattern painting.

4.7.4 Instruction Cards and Placards. Not Applicable. These items are not required for BCIS.

4.7.5 Inspection, Test and Calibration Procedures. Calibration requirements and procedures for an oscillator in the RT is yet to be determined.

4.7.6 End Item Environmental Effects. BCIS does not affect the environment. BCIS COMSEC memory batteries are Lithium and must be disposed of IAW procedures already in place at Ft. Hood. BCIS packaging will include products for recycling, such as cardboard and PVC pipe.

4.7.7 Modification Work Orders. Not Applicable

4.7.8 Transportability and Transportation Guidance TMs. Not Applicable.

4.7.9 Demilitarization (DMIL) and Explosive Ordnance Demolition (EOD). The National Security Agency (NSA) is the central destruction facility for integrated circuits designated CCI IAW DA PAM 25-380-2. If the CEIU is no longer reparable, the depot maintenance contractor will ship the Circuit Card Assembly (Red Processor) to NSA for destruction. EOD does not apply to BCIS.



4.8.1 Mobile and Fixed Facilities. Fixed facilities are required Jun 00 - Oct 02 at the fielding location for staging, installation and training for BCIS fielding to the 4th Inf Div (-). Storage and Installation Requirements. An estimated 400 square foot room with limited access is required for receiving, storage and staging equipment prior to installation and handoff. Limited access bays for vehicle installation is also required. The estimated number of bays required is no less than two and no more than four. Contractor Installation Team personnel require office spaces (estimate 2) at the installation location. An Installation Schedule will be developed and attached at Appendix 9.15 in the MFP update. Classroom Training Requirements. A classroom to accommodate 15 students and 5 observers is required for Instructor and Key Personnel Training (IKPT) Courses 23 Jun 00 - 1 Aug 00. A classroom to accommodate 30 students and 5 observers will be required from
16 Jan 01 - 15 Oct 02 for New Equipment Training (NET) Courses. The BCIS Net will include both Operator and UL Maintenance Courses. A Training Schedule will be developed and attached at Appendix 9.16 in the MFP update. Field Support Requirements. No mobile or fixed facilities are required for BCIS support after handoff and NET.

4.8.2 Environment Controls. A temperature controlled environment is required for Classroom Training. Not other environment controls apply for the BCIS fixed facilities requirements.

4.8.3 Site Activation and Preparation. Electricity is required in the storage area. All utilities are required for classroom training, in the installation bays and office spaces. A PM CI site survey will determine adequacy of proposed fixed facilities.

4.8.4 Ammunition Storage. Not Applicable. No ammunition is required for BCIS operation.



4.9.1 Manpower and Personnel. Tables of Organization and Equipment (TOEs) and TDAs. TOEs and TDAs of affected units will be automatically revised based on the approved BOIPs (revision DA approved 13 Apr 98). The projected date that the consolidated TOE will be available for the gaining MACOM to prepare an MTOE is to be determined. MTOE must be established no later than Oct 99 to facilitate the FUE. Manpower Requirements. The direct productive annual maintenance manhours (DPAMMH) by MOS for the AN/VSX-4 and AN/VSC-9 are provided in Figure 4-3:















Maintenamce Manpower Requirements
Figure 4-3 Personnel Requirements. Although not specifically required by regulation, MOSs affected by the BCIS fielding are listed in Appendix 9.17. Maintenance personnel requirements identified in Figure 4-4 are for UL maintenance only. The 31U MOS is expected to be the UL maintainer for all "non-shooter" vehicles and can assist the "shooter" vehicle specific UL maintainers if needed. "Shooter" vehicles other than Abrams, Bradley and FISTV families will use 31U repairers.

 Equipment Vehicle Type UL Maintenance MOS Description

AN/VSC-4 Others Signal Support Systems Specialist

   Abrams Family Abrams Tank Turret Mechanic

  Bradley Family & FISTV Bradley Fighting Vehicle Turret Mechanic

AN/VSC-9 All Vehicles Signal Support Specialist


Maintenance Personnel Requirements
Figure 4-4

4.9.2 Training. Training Courses. BCIS Operator and Unit Level Maintenance Courses are identified in the New Equipment Training Plan, Appendix 9.3. PM CI plans to provide contractor instructed IKPT for NET instructor personnel, LARs (to be identified) at the fielding location, Key Training Personnel in the 4th Infantry Division and TRADOC's BCIS proponent personnel in the Jun - Aug 99 timeframe. This IKPT will require one each BCIS installed M1A1 Abrams and M2A2 ODS Bradley. This vehicle requirement causes the IKPT training location and dates to remain nonspecific at this time. Service School Training. BCIS will not impact on institutional training until BCIS is funded for at least a Corps, if not the total army. Current plans do not include institutional training in support of the 4th Infantry Division (-) and the 1st Cavalry Division (-) fieldings. PM CI will provide any school a BCIS overview slide presentation (hard copy) and operational video upon request. Training Site Training. Not Applicable. New Equipment Training. The NET Plan is attached at Appendix 9.3. A NET detailed schedule will be developed and attached at Appendix 9.16 in the MFP update.

Operator Courses: The training plans are to instruct a company-sized unit per class. Operator training will consist of 4 hours classroom instruction followed by a 4-hour practical exercise to include BCIS familiarization (preventive maintenance), initialization and operation in the Motor Pool. For AN/VSX-4 operators an additional four-hour practical exercise is planned using the Close Combat Tactical Trainer (CCTT). Each platoon will spend four hours in this simulated environment for realistic BCIS operational experience.

Unit Level Maintenance Courses: UL maintenance training will be conducted by MOS. Training will consist of 8 hours classroom instruction followed by an 8-hour, on vehicle, practical exercise to include BCIS initialization, troubleshooting and performance of selected maintenance in the Motor Pool. Displaced Equipment Training. Not applicable. Follow-On Equipment Training. The unit will be responsible for sustainment training of NET trained soldiers by using BCIS in all unit exercises. Exercises should include CCTT troop rotations for the M1A1 Abrams and the M2A2 ODS Bradley. PM CI has programmed funding and began coordination with PM, Combat Arms Trainers to incorporate BCIS in the CCTTs located at Ft. Hood prior to fielding. Training Assistance. Training Assistance beyond NET is not planned.



4.10.1 Training Materials. Training Aids. NET Training requires the following training aids provided by the ESSC for classroom instruction:

- Classroom to accommodate 30 Students and 6 Observers
- Tables and Chairs for 30 Students and 6 Observers
- Chalkboard, Chalk and Eraser
- Overhead Projector with Screen
- TV Monitor
- VCR Training Data. The NET Team will provide a sustainment training package to each Battalion Training Officer at the conclusion of his Battalion's NET. The training data will include:

- System Overview slide presentation (hard copy)
- BCIS Operation video
- Pocket-sized, laminated "quick reference" cards for initialization instructions Training Devices. Not applicable for this fielding. If BCIS funding is increased to field III Corps, PM CI will investigate the incorporation of BCIS transponder devices for use in Gunnery. Currently, there are no plans to include BCIS in Gunnery for the 4th Infantry Division (-). Training Equipment. BCIS NET will require training equipment provided by the unit for the practical exercise portion of BCIS training, both Operator and Maintenance. AN/VSX-4 equipped vehicle crew training will require CCTTs to accommodate a company sized unit for 4 hours. The following unit supplied training equipment is required:

- BCIS Equipped Operational Vehicles - 4 (1 Plt) per class
- CVC Helmets with cords - 2 per vehicle
- PLGR with power cable, antenna cable and antenna - 1 Set per vehicle
- AN/CYZ-10 - 1 per vehicle


4.11 COMPUTER RESOURCES SUPPORT. No BCIs computer hardware and software resources support is required after handoff. All support during installation/checkout will be provided by the BCIS Contractor Team. Post deployment software support is the responsibility of PM CI. The BCIS contractor will perform field software updates after handoff, if required, to correct a newly identified deficiency or interface incompatibility. Periodic updates are not required for this system. Simulation, Training and Instrumentation Command (STRICOM) computer resources support for BCIS integrated with CCTT will be required after fielding.

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