Tanks are complex weapon systems that require a number of sub-systems and the crew to function properly in order to provide the vehicle with its key characteristics: firepower, protection, mobility and communications. Tank crews vary in size, with 4–5 being the norm for a full-strength crew, but combat and noncombat casualties (as well as disease and sickness in winter months) could reduce crews. It is essential that each member of the crew perform his designated task well for the tank to achieve its full capability. A poorly-trained loader might be the lowest man in the tank crew hierarchy, but his inability to reload main gun rounds quickly in combat could easily lead to his tank losing a gunnery duel against a faster opponent. Likewise, the driver’s ability to maneuver over rough terrain and use cover and concealed approaches is critical for the crew’s survival. In June 1941, most Soviet tank drivers – particularly in battalions equipped with T-34 and KV-1 tanks – had very little practical experience, whereas the majority of German tank drivers had one or more campaigns under their belts. German tank driver training was also very thorough for new recruits, whereas this continued to be a weakness for the Red Army well into 1942.
The foremost fact of life as a tanker is the importance of maintenance and logistics. The track system and roadwheels take a great deal of abuse from large rocks, tree stumps and other assorted battlefield wreckage when the tank moves any significant distance. The track, held together by long pins, wants to fall apart and the crew must constantly monitor it for signs of damage. Most tanks carried a few spare track blocks, but extra track pins to hold them together were often scarce. Good crews check the track and roadwheels at every halt of more than a few minutes and conduct spot-tightening. If they fail to do so, crews can expect to routinely throw track (i.e. the track comes off the roadwheels), which immobilizes the vehicle. In tank platoons and companies, it is imperative that junior leaders force tank crews to conduct routine maintenance – even in extreme cold weather, muddy field conditions and during combat operations. Friction is a tank’s worst enemy and river crossings tend to wash grease out of fittings on the running gear, which can cause roadwheel hubs to burn out if not tended to soon after fording. For example, a T-34 required a minimum of 1kg of grease for each 100km the tank moved on dry surface, but this would need to be replaced sooner if water obstacles were crossed. All tank engines and transmissions leak oil to some degree, particularly as filters and gaskets wear out.
German tank engines often relied on rubber gaskets, which were prone to brittleness in the frigid Russian winters, leading to massive oil leaks if not promptly replaced. Turret systems including hydraulic reservoirs, optics and radios needed to be checked as well and the main gun needed to be bore-sighted again (usually by using string across the muzzle and a snake board target) after any significant move or firing. If the optical telescope and main gun went out of alignment due to hits on the turret or a very bumpy ride, then the tank’s gunner would have a difficult time hitting targets. On a weekly basis, crews needed to check the engine and transmission for wear (often detected by tiny metal shavings in the engine compartment, indicating excessive wear), as well as the batteries, leaf springs or torsion bars and brake systems. Contrary to photos depicting the ‘difficulty’ of panzer crews in cleaning the gun tube with a cleaning rod (a five–ten-minute job), one of the worst tasks was replacing a snapped torsion bar, which necessitated pulling off multiple road wheels and plenty of sledgehammer work to get the broken pieces out (in typical field conditions, a four–six-hour job). If tanks were driven with one broken torsion bar, the shifting weight would likely break the next torsion bar as well. Both sides often pushed their tanks to operate in ‘degraded mode’, with broken or worn parts, but tanks in this condition were often little more than placeholders with decreased combat value. The most important vehicles at the tank battalion level are the recovery vehicles and fuel trucks, which are essential to keeping the unit functional.