Training for the Military

HIGH MOBILITY MULTIPURPOSE WHEELED VEHICLE

0665 FIELD SERVICE AND MILITARY TRAINING COURSE CATALOG Aftermarket Fulfillment and Training Center (AFTC) 5448 Dylan Drive, South Bend, Indiana 46628 Contents

General Information 4

Student Registration 5

Payment Information 5

Advanced Mobility / Maintenance / BDAR 6

Field Maintenance Training 8

Sustainment Maintenance Training 10

4L80E Transmission Maintenance Training 12

“ Whether it is ‘training readiness,,’’ combat operations, Air Conditioning Systems Maintenance 14 oror domesticdomestic response to floods and other natural disasters, itit isis thethe soldiersoldier inin hishis oror herher HumveeHumvee thatthat AmeriAmerica sees Alternator / Starter / Electrical Systems Maintenance 16 ccoming to their aide.”

—Major—Major GeneGenerral Courtneeyy CarCarrr,, IIndiana Naationaltional GuaGuarrd Diesel Fuel Injection Pump Maintenance Training 17

Visitor Information 18

2 3

2 Our program development experience has been Training gained throtugh the development of training on a myriad of equipment from the Humvee through Program various tactical bridging equipment, such as the Improved Ribbon Bridge, the Rapidly Emplaced Bridge Development System, all of the MK II series Bridge Erection Boats, as well as MRAP, LTAS Wrecker, water purification and AM General’s Military Training Department fuel distribution systems. is a TRADOC certified world leader in All of our training programs are written to comply with training program development. TRADOC Regulation 350-70.

Our expert program writers and Military Training Department Staff graphic llustrators are highly trained, AM General’s Training Department provides and credentialed professionals. professional training programs at all military skill (echelon) levels for Army systems used in the military inventory. Our technical writers and program to develop professional programs of instruction (POI). Many of our instructors have previous military experience in Army, Navy, and Marine Corps.

Mobile Training Teams

General Information Most of this classroom and technical training also can be provided through Mobile Training Teams, who can be deployed anywhere in the United States and Who needs this training? around the world.

Individuals who are directly or indirectly responsible for operating, servicing, maintaining or conducting training using the High Mobility Multipurpose Wheeled Vehicle (Humvee). To Register for Courses Why your organization should consider this training. For seat availability, student registration, general inquires, regional maps, orinformation regarding In an era of constrained budgets, vehicle operation, servicing, and maintenance are local hotels honoring government Per Diem rates, course availability and major cost drivers, we at AM General believe training is the key to mitigating cost current pricing please contact: drivers through continued and updated knowledge. John Stearns, Nick Messick, Senior Instructor Training Manager What benefits can you expect from this training? [email protected] [email protected] C: (574) 876-1505 C: (574) 876-1007 Operators - will benefit from an increased knowledge of how to properly inspect, O: (574) 247-0371 negotiate extreme terrain, vehicle self-recovery, and understand battle damage assessment techniques for their Humvees. This increased knowledge results in higher Payment Information readiness rates, survivability and safety. MasterCard®, Visa®, American Express®, Discover®, and U.S. Government Credit Cards are accepted.

Maintainers - at all levels Field to Sustainment benefit from an increased understand- ing of detailed automotive principals, troubleshooting, service and repair. Skills learned allow technicians/maintainers to accurately diagnose vehicle systems in a Costs relating to travel, lodging, meals, medical expenses, entertainment, laundry, rental cars, phone and fax services, and other timely and cost e ective manner. related expenses are the responsibility of customers.

4 5 ► ADVANCED MOBILITY / Training Schedule MAINTENANCE / (Classes added upon request) BDAR

Date Class No.

Jan 13-17 OMB000101

Jan 27-31 OMB000102

Feb 10-14 OMB000201

Feb 24-28 OMB000202

Mar 9-13 OMB000301

Mar 23-27 OMB000302

Apr 20-24 OMB000401

Apr 27-1 OMB000402

May 4-8 OMB000501 Advanced Mobility / May 18-22 OMB000502 Jun 8-12 OMB000601

Maintenance / BDAR Jun 22-26 OMB000602 Operator (10) Level Training Jul 6-10 OMB000701 One Week, Forty Hours (5 training days / 8 hours per day) Jul 27-31 OMB000702

The Advanced Mobility Operator Maintenance and Battle Damage Assessment Aug 10-14 OMB000801 Repair Training course is designed for Operators responsible for the preventative maintenance inspections, operation, operator level mainte- Training is conducted at the suggested 3 to 1 student instructor Aug 24-28 OMB000802 nance and battle damage assessment on all Humvee platforms. ratio to ensure maximum hands-on experience. Aug 31-4 OMB000803

This course will ensure operators understand the Humvee’s functions and All segments of training consist of 10% classroom theory and Sep 14-18 OMB000901 capabilities allowing them to safely negotiate extreme o -road conditions 90% hands-on instruction. This training course is one week in Oct 12-16 OMB001001 while maintaining a high level of performance. Utilizing our 320 plus acre length (five training days), eight hours per day. Oct 26-30 OMB001002 proving grounds and testing center located in South Bend, Indiana students are exposed to hills and slopes of sand, mud, rock, and water which simulate Each student will be provided one copy of the Nov 2-6 OMB001101 global areas of operation while practicing multiple vehicle recovery Following OEM training manuals: Nov 16-20 OMB001102 techniques in a real world training environments. • Advanced Mobility Operations Nov 30-4 OMB001103 Battle damage assessment of both mechanical and electrical failures inherent • Component Testing and Troubleshooting Dec 14-18 OMB001201 to battle field operations, teach students safe field expedient procedures for • Battle Damage Assessment and Repair Handbook continued maneuverability. Students are trained within the guidelines of military doctrine utilizing the latest technical manuals and service bulletins combined with in-house manufacturer developed technical training material and operational cut-away training aids. in-house 6 7 ► FIELD Training Schedule MAINTENANCE (Classes added upon request) TRAINING

Date Class No.

Jan 6-17 FM000101

Feb 3-14 FM000201

Mar 2-13 FM000301

Apr 20-1 FM000401

May 4-15 FM000501

Jun 1-12 FM000601

Jul 6-17 FM000701

Aug 3-14 FM000801

Sep 14-25 FM000901 Field Maintenance Training Oct 5-16 FM001001 Nov 30-11 FM001101 Field (20-30) Level Training Two Weeks, Eighty Hours (10 training days / 8 hours per day)

The Field Maintenance Training Course is designed for Technicians / Maintainers responsible for conducting Preventative Maintenance checks, semi and annual services, systems troubleshooting, component replacement and repair at the Field Maintenance Level (formerly Training is conducted at the suggested 8 to 1 student instructor organizational-20 and Direct Support-30 echelons). ratio to ensure maximum hands-on experience.

This comprehensive course emphasizes component theory of operation, All segments of training consist of 10% classroom theory and proper maintenance techniques, use of special tools and shop equipment 90% hands-on instruction. This training course is two weeks in across all Humvee platforms in our state of the art training center located length (ten training days), eight hours per day. in South Bend, Indiana. Each student will be provided one copy of the Students are trained within the guidelines of military doctrine utilizing the following OEM training manuals: latest technical manuals and service bulletins combined with in-house manufacturer developed technical training material and operational • Introduction to Vehicle Systems cut-away training aids. • Introduction to 4L80 E Automatic Transmission • Troubleshooting 4L80E Automatic Transmission • DB2 Fuel Injection Pump System • 6.5L Diesel Engine Systems • Introduction to Air Conditioning • Component Testing & Troubleshooting

8 9 ► SUSTAINMENT Training Schedule MAINTENANCE (Classes added upon request) TRAINING

Date Class No.

Feb 3-14 SM000201

Mar 16-27 SM000301

May 11-22 SM000501

Jun 15-26 SM000601

Jul 13-24 SM000701

Aug 17-28 SM000801

Oct 19-30 SM001001

Dec 7-18 SM001201

Sustainment Maintenance Training

Sustainment(40) Level Training Two Weeks, Eighty Hours (10 training days / 8 hours per day)

The Sustainment Maintenance Training Course is designed for Techni- cians/Maintainers responsible for the rebuilding and repair of the Engine, Training is conducted at the suggested 8 to 1 student instructor Transmission, Transfer Case, Di erential, Geared Hub, and Electrical ratio to ensure maximum hands-on experience. components at the Sustainment Maintenance Level (formerly General Support-40 echelon). All segments of training consist of 10% classroom theory and This comprehensive course emphasizes component theory of operation, 90% hands-on instruction. This training course is two weeks in disassembly, cleaning, inspection, precision measurements, assembly, length (ten training days), eight hours per day. and testing adjustments, of all major vehicle systems and sub systems Each student will be provided one copy of the across all Humvee platforms. following OEM training manuals: In our state of the art training center located in South Bend, Indiana, • Introduction to Vehicle Systems students are trained within the guidelines of military doctrine utilizing the • 6.5L Diesel Engine Systems latest technical manuals and service bulletins combined with in-house • DB2 Fuel Injection Pump System manufacturer developed technical raining material and operational • Introduction to 4L80 E Automatic Transmission cut-away training aids.

10 11 ► 4L80E Training Schedule TRANSMISSION (Classes added upon request) MAINTENANCE

Date Class No.

Jan 6-9 4L80E000101

Jan 21-24 4L80E000102

Feb 3-6 4L80E000201

Feb 17-20 4L80E000202

Mar 2-5 4L80E000301

Mar 30-2 4L80E000302

Apr 14-17 4L80E000401

May 11-14 4L80E000501

Jun 1-4 4L80E000601 4L80E Transmission Jun 15-18 4L80E000602 Maintenance Training Jun 29-2 4L80E000603 Jul 13-16 4L80E000701 Sustainment(40) Level Training Two Weeks, Eighty Hours (10 training days / 8 hours per day) Aug 17-20 4L80E000801

Aug 31-3 4L80E000802 Four days, 32 hours (8 hours per day) Systems Maintenance Training The Sep 8-11 4L80E000901 4L80E Transmission Maintenance Training course designed for Techni- Training is conducted at the suggested 4 to 1 student cians/ Maintainers who are responsible for inspection, troubleshooting, Sep 21-24 4L80E000902 instructor ratio to ensure maximum hands-on experience. repair, replacement and rebuilding the GTP 4L80E transmission at all Oct 19-22 4L80E001001 maintenance levels (Organizational-20, Direct-30, and General support-40 All segments of training consist of 10% classroom theory and echelons). 90% hands-on instruction. This training course is four days in Nov 2-5 4L80E001101 length (four training days), eight hours per day. This detailed course encompasses transmission theory of operation, Nov 16-19 4L80E001102

electrical, mechanical and hydraulic troubleshooting, disassembly, Dec 7-10 4L80E001201 cleaning, inspection, precision measuring, assembly, and testing for the Each student will be provided one copy of the ollowing OEM training manuals: 4L80E Transmission.

Our facility utilizes field expedient troubleshooting techniques, advanced • Introduction to 4L80 E Automatic Transmission diagnostic equipment, the latest special tools and shop equipment in a • Troubleshooting 4L80E Automatic Transmission state of the art training center located in South Bend, Indiana. Students are • Component Testing & Troubleshooting trained within the guidelines of military doctrine utilizing the latest technical manuals and service bulletins combined

With in-house manufacturer developed technical training materials and operational cut-away training aids. 12 13 ► AIR Training Schedule CONDITIONING (Classes added upon request) SYSTEMS MAINTENANCE

Date Class No.

Jan 6-8 AC000101

Jan 27-29 AC000102

Feb 17-19 AC000201

Mar 16-18 AC000301

Mar 30-1 AC000302

Apr 6-8 AC000401

May 26-28 AC000501

Jun 1-3 AC000601

Jun 15-17 AC000602 Air Conditioning Jun 29-1 AC000603 Jul 20-22 AC000701

Systems Maintenance Aug 3-5 AC000801

Systems Maintenance Training Sep 8-10 AC000901 3 days (24 hours / 8 hours per day) Sep 21-23 AC000902

Sep 28-30 AC000903 The Air Conditioning Systems Training course is designed for Technicians/- Maintainers responsible for electrical troubleshooting, refrigerant Nov 23-25 AC001101 recovery, evacuation, inspection, component replacement, refrigerant Training is conducted at the suggested 8 to 1 student instructor Dec 7-9 AC001201 recharge, leak detection, and testing of Humvee air conditioning systems. ratio to ensure maximum hands-on experience. Dec 21-23 AC001202 This comprehensive course emphasizes the scientific principles of All segments of training consist of 10% classroomtheory and 90% refrigeration, thermal e iciency, electrical control systems and servicing hands-on instruction. procedures. Our facility utilizes advanced diagnostic equipment, the latest special tools and shop equipment in a state of the art training center Each student will be provided one copy located in South Bend, Indiana. of the following OEM training manuals: Students are trained within the guidelines of military doctrine utilizing the • Principles of Air Conditioning latest technical manuals and Service Bulletins combined with in-house manufacturer developed technical training material and operational cut-away training aids.

14 15 Alternator / Starter / Diesel Fuel Injection Pump Electrical Systems Maintenance Maintenance Training

Systems Maintenance Training (20/30 level) Systems Maintenance Training manufacturer developed technical training 3 days (24 hours / 8 hours per day) 3 days (24 hours / 8 hours per day) material and operational cut-away training aids. Starter & Electrical Systems Training Course operational cut-away training aids. The Diesel Fuel Injection Pump Training is designed for Technicians/Maintainers Training is conducted at the suggested 8 to Training is conducted at the suggested 8 to 1 Course is designed for Technicians/Maintain- responsible for the inspection, diagnosis, 1 student instructor ratio to ensure student instructor ratio to ensure maximum ers responsible for the inspection, repair, replacement and rebuilding of maximum hands-on experience. hands-on experience. electrical components at the field troubleshooting, repair, replacement and rebuilding the entire Humvee diesel fuel All segments of training consist of 10% maintenance level (Formerly Organization- All segments of training consist of 10% injection system. classroom theory and 90% hands-on al-20, Direct Support-30 echelons). classroomtheory and 90% hands-on instruction over 3 training days, eight hours instruction. This detailed course includes theory of This comprehensive course emphasizes per day. component theory of operation, disassem- operation, troubleshooting, disassembly, Each student will be provided one copy bly, cleaning, inspection, precision cleaning, inspection, precision measure- of the following OEM training manuals: Each student will be provided one copy ments, assembly, and testing for the starting, measurements, assembly, and testing of the of the following OEM training manuals: charging, lighting, and glow plug systems. • Component Testing and Troubleshooting DB2 rotary fuel injection pump system and related subsystems. • Component Testing and Troubleshooting In our training center located in South Bend, • Stanadyne DB2 Fuel Injection Pump System Indiana, Students are instructed within the In our state of the art training center located guidelines of and service bulletins combined in South Bend, Indiana, students are trained with in-house manufacturer developed within the guidelines of military doctrine technical military doctrine utilizing the latest utilizing the latest technical manuals and technical manuals training material and Service Bulletins combined with in-house

16 17 Visitor Guide adams road

31 Aftermarket Fulfillment and Training Center Lodging and auten road

iv e Toledo, Ohio d a

brick road d o a Accomodations r o r c r

80 90 ain

ap e Exit 83 r 933 on wo od d r m 23 r g junip e cle i AM General recommends avland road cleveland road cleveland road the following hotels based upon Chicago, Illinois their outstanding accommodations

for our students and their proximity Exit 72 80 90 80 90 Exit 77 80 90 Training Center.

lathrop street douglas road douglas road st. mary’s college d p iv e e

Hilton Garden Inn Staybridge Suites r t

v ort d

b e

e e a f (574) 232-7700 (574) 968-7440 r edis t g on SOUTH BEND s e la ke 331 r o university of s ndix dr i ve 53995 IN-933 52860 IN-933 kingh am p i

a c a e INTERNATIONAL l 23 y r d k

b o notre dame w w South Bend, IN 46637 South Bend, IN 46637 AIRPORT t a y day road Hampton Inn & Suites Inn at St. Mary’s holy c d cross (574) 243-4600 (574) 232-4000 college 7347 Heritage Square Dr. 53993 IN-93 Granger IN 46530 South Bend, IN 46637 angela boulevard

BUS Courtyard by Marriott e Spring Hill Suites f lincolnway w.

(574) 273-9900 Marriott 20 d a d o a r

(574) 271-0832 o

4825 N Main St y r d r al av enu e a t BUS o o 5225 Edison Lakes Pkwy k Mishawaka, IN 46545 r ap e r 20 ap i fir hi c g ma in c Mishawaka IN, 46545 31 BUS BUS 20 20 Mishawaka Manufacturing Campus AM General Corporate Office AM General 2 western avenue sample street Facilities

mishawakaavenue

105 N. Niles Ave. d a

South Bend, IN 46617 o

r lincolnway

t 933 e e r

t BUS s Mishawaka lo we r e v i ay f 20 l 31 933 331

o 23 Manufacturing Campus m

13200 Mckinley Hwy enu e v a n

twyckingham i

Mishawaka IN, 46544 a n rk it

drive a m y g . b s o l ewing avenue 12th

Training dr ag kit oon tr r union y

ail b

Facilities d a Proving Grounds o r and Testing Center us d a lo c

and Training Center o r ir 5448 Dylan Dr. f

South Bend, IN 46628 y t a e t e v e e t r e t r e t s dr i e s r d high w d t a

Proving Grounds 23 s o en r ud e r mi hgian m and Testing Center t r e lm r onwo o e e r 801 W. Chippewa Ave g mi c mi a i b South Bend, IN 46614 ireland road

20 Elkhart, Indiana 31

To ensure you receive the GSA per diem rate when booking reservations be sure to call the hotel’s local number and inform them that you are a customer of AM General. Rates subject to change based on GSA per diem rate changes.

18 19 AM General Military Training

John Stearns, Senior Instructor [email protected] C: (574) 876-1505 O: (574) 247-0371

Nick Messick, Training Manager [email protected] C: (574) 876-1007

A ermarket Fulfillment and Training Center 5448 Dylan Drive, South Bend, IN 46628

Proving Grounds and Testing Center 801 W. Chippewa Ave, South Bend, IN 46614