Attachment 0025 - Draft FMTV Truck De-Processing Checksheet.xlsx

XLSX spreadsheet 117 KB Posted Oct 13, 2016

Attached to: FMTV A2 Production Effort Federal contract opportunity
Solicitation number: W56HZV16R0024
Issued by: Department of the Army Materiel Command Contracting Command Detroit Arsenal

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Attachment 0026 - Draft FMTV Trailer De-Processing Checksheet.xls	XLS spreadsheet	Oct 13, 2016
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	FAMILY OF MEDIUM TACTICAL VEHICLES (FMTV)
	A1P2 DEPROCESSING CHECKLIST
with Oshkosh Wrecker Updates
		BUMPER # _______________
	MAR 2012

NOTE: THE MASTER COPY OF THIS CHECKSHEET IS THE PROPERTY OF MTV
PRODUCT ASSURANCE. CHANGES MUST BE SUBMITTED FOR REVIEW BEFORE
THIS CHECK LIST IS AMENDED OR REVISED
TRUCK: 2 1/2 TON, 4X4, LMTV, A1P2 MODELS
	M1078, M1079

TRUCK: 5 TON, 6X6, MTV, A1P2 MODELS
	VEHICLE MODELS M1083, M1084, M1085, M1086, M1087,
	M1088, M1089, M1148, AND M1157

Serial Number:				Model:
Receipt Miles:				Receipt Date:
Registration Number:				Color:	GREEN CAMO TAN
					(Circle One)
Date of Manufacture/Delivery:		Mfg-dt		Del-dt
Warranty Data:	Start Date			End Date:
Location / Unit:			/
Driver / Inspector:
Road Test Date:		Before Mileage:_____________			After Mileage:___________

Mechanic / Inspector: ______________________________________________
Mechanic's Verification:	Model #	w/o Winch:___________ w/Winch: _________

Complete the entire checklist for model being inspected. Fill in all the above required information as appropriate.

Place a check in the appropriate blocks, i.e., Accept / Reject / Corrected. Also, note all defects and corrections on

the Deficiency Summary Sheet.

NOTE: If a TACOM representative is not on site for deprocessing, please remove cover sheet (with summary sheet)
from the checklist and forward them to:
	US Army Tank-Automotive Command
	ATTN: SFAE-CSS-TV-M
	Warren, MI 48397-5000

March 2012 Revised

DEFICIENCY SUMMARY SHEET
ITEM
NO	CODE	DEFICIENCY	CORRECTIVE ACTION	INITIAL

SERIAL NUMBER: BUMPER NUMBER:

March 2012 Revised Page 2

INITIAL VEHICLE PREPARATION

1. Uncage brakes (if required)

2.	Unbind and open large wooden box in cargo bed.	Change to;
	Carefully unpack individual items and check for damage.
	Install mirrors, side racks and troop seats.

3.	Unbind small wooden crate in cab and carefully unpack the items,
	inventory and check for damage. Ensure large wooden box in cargo bed is secure
	and banded. If unit wants to inspect, open and lay out at time of hand-off

NOTE: BII/COEII will be inventoried after all other deprocessing has been
	completed.

		CLASSIFICATION OF OIL / FLUID LEAKS
CLASS I -	Seepage of fluid not great enough to form drops. Check/clean area where
	necessary and run to determine corrective action.
CLASS II -	Leakage of fluid great enough to form drops but not enough to cause drops
	that fall.
CLASS III -	Leakage of fluid great enough to form drops that fall.

DEFICIENCY CODES

Functional Group Codes:

	Group -01	Engine		Group -16	Springs/Shock Absorb
	Group -03	Fuel System		Group -18	Body and Cab
	Group -04	Exhaust System		Group -20	Hoist, Winch, PTO and Power
	Group -05	Cooling System		Group -22	Body, Chassis and Accesso
	Group -06	Electrical System		Group -24	Hydraulic and Fluid Systems
	Group -07	Transmission		Group -26	Tools and Test Equipment
	Group -08	Transfer, Final Drive		Group -33	Special Purpose Kits
	Group -09	Propeller Shafts		Group -34	Armament, Sighting and FI
	Group -10	Front Axle		Group -39	Searchlight and Electrical Illuminating
	Group -11	Rear Axle		Group -43	Gas, Air, and Vacuum System
	Group -12	Brakes		Group -47	Gages, Mounting, Lines A
	Group -13	Wheels		Group -52	Refrigeration and AC Components
	Group -14	Steering		Group -76	Fire Suppression
	Group -15	Frame		Group -94	Repair Kits
				Group- 95	Bulk Material and Hardware
Second Group Codes:			V - Visual / F - Functional / L - Leak

March 2012 Revised Page 3

PRE-TEST CHECKLIST - ALL MODELS

NOTE: During walk-around inspection, examine vehicle for general appearance. No part shall exhibit any

evidence of damage, mutilation, or poor workmanship. All attachment hardware must be complete and

secured. Paint scratches that do not penetrate the top coat are acceptable.

Key: A -Accept R - Reject C - Corrected V - Visual / F - Functional / L - Leak

INSPECTION ITEMS:

1. FRONT OF VEHICLE: A R C CODE

a.	Headlights/front marker lights	0609
	(1) Damage	0609
	(2) Security of mounting	0609

b.	Front glad hands	1208
	(1) Hose, lines, and fitting for damage/looseness	1208
	(2) Dust cover for damage/missing chain	1208

c. Windshield for damage 1802

d. Wiper arms and blades 2202

e. Winch roller guides 2001

f. Pneumatic lines properly marked and properly routed to clear radiator 1208

g. A/C lines free of kinks and fitting at bulkhead properly oriented 5200

2. CURB SIDE OF VEHICLE

a.	Front wheel and tire	1311
	(1) 12K Wheel and tire (small hole on wheel next to CTIS fitting)	1311
	(2) C.T.I.S. connected	1311
	(3) ABS wheel sensor connected	1202
	(4) Check brake hydraulic cylinder for proper mounting and leaks	1208

b.	Cab exterior	1801
	(1) Door for ease of operation, fit and sealing	1801
	(2) Window for ease of operation and damage	1801
	(3) Side mirrors for damage and security of mounting	2202

c.	Cab step assembly	1802
	(1) Latch screw and hinges	1802
	(2) Windshield Washer Fluid Level	2202

d.	Cab tilt	1801
	(1) Manual hydraulic pump	2402
	(2) Cab latch engaged and red pin not visible	1801
	(3) Rear leveling cylinder hydraulic lines (no leaks)	1801
	(4) Cab leveling cylinder for proper measurement 1.5 to 2.0 inches	1801

e.	Air transportability
	(1) Kneeling chain assembly	2407
	(2) Hydraulic cylinder	2407
	(3) Air transport control switch	0608

f. Front winch cable guide 2001

g. Heli lift (pins engaged) 1501

h. Tool Box 1808

March 2012 Revised Page 4

PRE-TEST CHECKLIST - ALL MODELS

Key: A -Accept R - Reject C - Corrected V - Visual / F - Functional / L - Leak

CURB SIDE OF VEHICLE (cont.) A R C CODE

i. Engine cold start ether bottle 0311

j. Spare tire/carrier and ratchet 2404

k.	Fuel tank and lines	0306
	(1) Security of mounting	0306
	(2) Fuel line and fittings for damage/looseness	0306

l.	Storage boxes	1810
	(1) Security of mounting	1810
	(2) Hinges for damage	1810
	(3) No water in boxes	1810

m.	Self recovery winch	2001
	(1) Hose, lines and fittings for damage/looseness	2001
	(2) No Leaks	2001

n. Rear self recovery winch cable guide (all except wrecker) 2001

o.	Intermediate/rear wheels and tires	1311
	(1) 12K Wheel and tire (small hole on wheel next to CTIS fitting)	1311
	(2) Inflation valve and cap	1311
	(3) C.T.I.S. connected	1311
	(4) Mud flaps torn/missing/bent hardware	1802
	(5) Fenders for security of mounting/bent/loose bolts	1802
	(6) ABS wheel sensors connected	1202

3. REAR OF VEHICLE

a. Rear Tail light assemblies 0609

b.	Pintle hook (except wrecker)	1503
	(1) Proper operation, lube, freedom of movement, and proper extension	1503

c.	Rear glad hands	1208
	(1) Hose, lines and fittings for damage/looseness	1208
	(2) Dummy couplings for damage/missing chains	1208

d. Trailer light receptacle loose/damaged 0613

e. Lifting shackles missing 1501

f. Rear winch roller guides 2001

4.	ROADSIDE OF VEHICLE
	a.	Intermediate/rear wheels and tires	1311
		(1) 12K Wheel and tire (small hole on wheel next to CTIS fitting)	1311
		(2) Inflation valve and cap	1311
		(3) C.T.I.S. connected	1311
		(4) Mud flaps torn/missing/bent hardware	1802
		(5) Fenders for security of mounting/bent/loose bolts	1802
		(6) ABS wheel sensors connected	1202

b. Side marker lamp 0609

c. Exhaust pipe (clamps not loose) 0401

d. Air dryer 4321

e. Slave receptacle assembly 0612

f. Battery Disconnect System 0612

March 2012 Revised Page 5

PRE-TEST CHECKLIST - ALL MODELS

Key: A -Accept R - Reject C - Corrected V - Visual / F - Functional / L - Leak

ROADSIDE OF VEHICLE (cont) A R C CODE

g.	Battery box	0612
	(1) Latches not damaged	0612
	(2) Battery box roll-out feature for proper operation	0612
	(3) Batteries secured	0612
	(4) Battery cables	0612

h.	Air reservoirs	1208
	(1) Pet cocks for freedom of movement	1208
	(2) Hoses, lines and fittings for damage, looseness, and leaks	1208

i.	Hydraulic reservoir (winch, MHE, LHS, 10T Dump vehicles only)	2408
	(1) Screen	2408
	(2) Fluid Level	2408
	(3) Hydraulic oil filter mounting (no leaks)	2408

j. Heli lift (pins engaged) 1501

k.	Oil fill tubes
	(1) Transmission	0710
	(2) Engine	0106

l.	Radiator coolant surge tank	0501
	(1) Fluid Level	0501

m.	Air cleaner canister assembly	0304
	(1) Intake hood and screen present	0304
	(2) Extractor hose connected	0304
	(3) Canister lid engaged	0304

n.	Cab tilt	1801
	(1) Cab latch engaged and red pin not visible	1801
	(2) Rear leveling cylinder hydraulic lines (no leaks)	1801
	(3) Cab leveling cylinder for proper measurement 1.5 to 2.0 inches	1801
	(4) Check EHPU fluid level and check for water contamination.	2401
	(5) Check EHPU breather cap in place.	2401

o.	Air transportability	2407
	(1) Kneeling chain assembly	2407
	(2) Hydraulic cylinder	2407

p.	Cab step assembly	1802
	(1) Latch screw and hinges	1802
	(2) Windshield Washer Fluid Level	2202

q.	Cab exterior
	(1) Door for ease of operation, fit and sealing	1802
	(2) Window for ease of operation and damage	1802
	(3) Side mirrors for damage and security of mounting	2202

r.	Front wheel and tire	1311
	(1) 12K Wheel and tire (small hole on wheel next to CTIS fitting)	1311
	(2) C.T.I.S. connected	1311
	(3) ABS wheel sensor connected	1202
	(4) Check brake hydraulic cylinder for proper mounting and leaks	1208

5. BEHIND CAB

a.	Rear Cab Mount Stage 8 Bolts Installed with Locking Feature	1801
b. ABS electronic control module connected		1208
c. Limp home module connected	Load and Battery Control Device (LBCD) for damage and security	0608

March 2012 Revised Page 6

PRE-TEST CHECKLIST - ALL MODELS

Key: A -Accept R - Reject C - Corrected V - Visual / F - Functional / L - Leak

6. ENGINE COMPARTMENT A R C CODE

a. Engine and transmission mounts not broken 0100

b.	Radiator assembly	0501
	(1) Hoses and clamps	0501
	(2) Fan shroud	0502
	(3) Main Serpentine belt	0613

c. Primary transmission oil cooler assembly installed with no leaks 0721

d. Turbocharger connected 0305

e. Alternator functional 0613

f.	Cab tilt cylinder assembly no leaks (both sides)	1801
	(1) Cab Leveling Switch/Sensor (on RH side)	1801

g.	HEUI fuel system and components	0306
	(1) HEUI fuel pump	0306
	(2) HEUI pump oil line	0306
	Check for leaks at operating temperature
	CAUTION: Oil in HEUI system is under extremely high pressure.
	(3) Primary fuel filter	0309
	(4) Fuel water separator	0309

h.	Power steering	1400
	(1) Pump for security and no leaks	1410
	(2) Power steering reservoir fluid level, cap, filter, and dipstick	1413

i.	Air compressor assembly	1209
	(1) No leaks	1209
	(2) Coolant line properly routed	1209
	(3) Air governor for security and line routing.	1209

j.	Air conditioner compressor	5200
	(1) A/C belt alignment acceptable	5200

k.	Steering gear	1407
	(1) Steering column shaft installed correctly	1407
	(2) Steering Gearbox for security and leaks	1407
	(3) Pitman arm and drag link for damage and security	1407

l. Starter Assembly 0603

m. Exhaust Brake Linkage 0401

n. Remote Start Operational 0613 o Both Brake Master Cylinders (check for fluid level and leaks) 1208

7. CAB INTERIOR

a.	Doors, right and left	1801
	(1) Door handles	1801
	(2) Window operation (both panels slide freely and latch functional)("A" Kit)	1802
	(3) Combat latch engagement	1802

b.	Instrument panel	0607
	(1) Gages/indicators	0607
	(2) Control switches and levers	0607

c.	Electrical power distribution panel	0607
	(1) Latching cover	0607
	(2) All connectors secure	0607

d. Central Tire Inflation System (C.T.I.S.) operational 0608

e. Steering wheel assembly 1401

March 2012 Revised Page 7

PRE-TEST CHECKLIST - ALL MODELS

Key: A -Accept R - Reject C - Corrected V - Visual / F - Functional / L - Leak

CAB INTERIOR (cont) A R C CODE

f.	HVAC Unit	5200
	(1) Footwell Vents installed and functional	2207
	(2) PROTECHT Module Functional and Status LED Green (Slow Flashing)	5200
	(3) Heat and Air Conditioning Functional	5200
	(4) Vents Installed and Functional on HVAC Unit	2207
	(5) All fan speeds operational	5200
	(6) Defrost mode operational	5200
	(7) Fresh/Recycle air mode operational	5200

g.	Treadle pedal (brake)	1208
	(1) Treadle valve assembly	1208
	(2) Pneumatic lines installed correctly	1208

h. Accelerator pedal operational 0312

i. Data Bus Connector (J117) dust cover installed 0607

j.	Driver, passenger and center seats	1806
	(1) Seat adjustments	1806
	(2) Seat belts	1806
	(3) Head Protection Pad (Driver and Passenger)	1806

k.	Driver and Co-Driver Communications/Storage Racks	1808	`
	(1) Netting & Fasteners installed and functional	1808	`

l. Sun visor installed and hardware not broken 1806

m. Rifle mounts installed and functional 3402

n. All Vehicle Data Plates Installed 2210

o. 12--Volt Indicator 12 VDC convenience outlet 0613

p. Master vehicle Light Switch 0607

q. Battery Disconnect Switch 0607

r. No water leaks. 1801

8. UNDERSIDE OF VEHICLE

a. Engine oil pan/lines 0106

b. Front shock absorbers 1604

c.	Front axle assembly	1000
	(1) Lubricant for proper level	1002
	(2) ABS Modulator Valves	1208
	(3) ABS Wheel Speed Sensors	1202

d. Front suspension 1601

e. Propeller shafts (Front to Transfer, Transfer to Intermediate/Rear Axles) 0900

f.	Transmission and Transfer Case	0710
	(1) Ensure engine flywheel housing vent plug is installed in drain hole	0103

g. PTO assembly (winch, MHE, Dump, LHS, and Wrecker vehicles only) 2004

h. Air tanks 1208

i. Exhaust system 0401

j. CTIS Quick Release Valves 1208

k. Auxiliary transmission oil cooler (MTV variants only) inspect hoses for kinks 0721

l. Intermediate/Rear axle shock absorbers 1604

March 2012 Revised Page 8

PRE-TEST CHECKLIST - ALL MODELS

Key: A -Accept R - Reject C - Corrected V - Visual / F - Functional / L - Leak

UNDERSIDE OF VEHICLE (cont.)		A	R	C	CODE
m.	Intermediate/Rear axle assembly				1000
	(1) Lubricant for proper level				1000
	(2) ABS Modulator Valves				1208
	(3) ABS Wheel Speed Sensors (Rear Axle only)				1202
n.	Intermediate/Rear suspension				1601

	o.	Inspect all Brake Chamber Fittings for leaks. Tank pressure to 120psi
		engine off hold brake pedal down and check for leaks at the fittings.	1200
9.	TRUCK BODIES

a.	FMTV A1P2 Cargo Variants M1078, M1083, M1084, M1085, M1086	1810
	(1) Stowage compartments, cover support rod stow boxes	1810
	(2) Drop sides	1810
	(3) Cargo tie downs	1810
	(4) Side rail vertical posts	1810
	(5) Tailgate	1810
	(6) Troop entry ladder, securing latch	1810
	(7) Material Handling Crane (M1084 and M1086)	2001
	(a) Outrigger cylinders	2001
	(b) Manual pump controls	2001
	(c) Hydraulic control panel	2001
	(d) Boom assembly (inner and outer)	2001
	(e) Control box power (i.e. power display box)	2001
	(f) Ground cable installed to chassis (especially for RSVs - kit on a 1084)	2001
	(g) Check for crane diagnostic codes in accordance with the IETM	2001
	(8) Intercom System between Cab and Cargo area	3307
	(9) Ballast Plate Kit (M1078A1P2 ONLY) CRITICAL SAFETY ITEM	3307

b.	Van (LMTV) M1079A1P2
	(1) Roadside of van	1812
	(a) Power entry panel 110V	1812
	(b) Name plates	1812
	(c) Telephone binding posts	1812
	(d) Windows, screens, and covers	1812
	(e) Marker light	1812
	(2) Rear of van	1812
	(a) Marker lights	1812
	(b) Lifting eyes	1812
	(c) Ladder/Rail assembly	1812
	(d) Rear doors	1812
	(3) Curbside of van	1812
	(a) Marker lights	1812
	(b) Windows, screens, and covers	1812
	(4) Front of van	1812
	(a) Marker lights	1812
	(b) Lifting eyes	1812
	(c) Sling guide assembly	1812
	(d) POD assembly	1812
	(e) Power entry panel 24V	1812
	(5) Interior of van	1812
	(a) Windows	1812
	(b) Sockets 110 volt AC	1812
	(c) Power distribution panel 110V AC	1812
	(d) Power distribution panel 24V AC	1812
	(e) Ventilation fan and filter	1812
	(f) Cab light switch	1812
	(g) Fan switch	1812

March 2012 Revised Page 9

PRE-TEST CHECKLIST - ALL MODELS

Key: A -Accept R - Reject C - Corrected V - Visual / F - Functional / L - Leak

TRUCK BODIES (cont) A R C CODE

Van (LMTV) (cont)
(h) Interior light switch	1812
(i) Door trip switch	1812
(j) Doors	1812
(k) Interior roof lights	1812
(l) Blackout lights	1812

c.	Van (MTV) M1087A1P2
	(1) Roadside of van
	(a) Inclinometer	1812
	(b) Name plates	1812
	(c) Windows, screens, and covers	1812
	(d) Marker light and reflectors	1812
	(e) Van door	1812
	(f) Platform support brackets	1812
	(g) BII storage box	1812
	(2) Rear of van
	(a) Lifting eyes	1812
	(b) Ladder/platform/rail and support assembly	1812
	(c) Platform support brackets	1812
	(d) Rear doors	1812
	(e) Folding steps	1812
	(3) Curbside of van
	(a) Marker lights and reflectors	1812
	(b) Vehicle AC IN and OUT receptacle	1812
	(c) Grounding terminal	1812
	(d) 110V AC outlets	1812
	(e) Windows, screens, and covers	1812
	(f) Van door	1812
	(g) Power cable reel assembly	1812
	(h) Power input cable	1812
	(i) Platform support brackets	1812
	(4) Front of van
	(a) Telephone binding posts	1812
	(b) NATO slave receptacle	1812
	(c) 24V "Power In" cannon plug	1812
	(d) Inclinometer	1812
	(e) Ladder/platform stowage bracket mounting/security/complete	1812
	(f) Heater exhaust pipe	1812
	(g) Heater/ECU mounting/security	1812
	(h) Marker lights	1812
	(i) Lifting eyes	1812
	(j) Heater fuel lines	1812
	(5) Interior of van
	(a) Windows	1812
	(b) Sockets 110 volt AC	1812
	(c) Power distribution panel 110V AC	1812
	(d) Ventilation fan and filter	1812

Distribution A - Unlimited; Distribution Approved for Public Release

March 2012 Revised Page 10

PRE-TEST CHECKLIST - ALL MODELS

Key: A -Accept R - Reject C - Corrected V - Visual / F - Functional / L - Leak

TRUCK BODIES (cont) A R C CODE

Van (MTV) (cont)
(e) ECU fan switch	1812
(f) Interior light switches	1812
(g) Blackout trip switches	1812
(h) Doors	1812
(i) White lights	1812
(j) Blackout lights	1812
(k) ECU operation	1812
(l) Heater operation	1812
(m) Tie down rings	1812
(n) Expansible walls and door weather stripping	1812
(6) Operation of expansion sides
(a) Sides open smoothly and evenly	1812

d.	Tractor M1088A1P2
	(1) Fifth wheel	1506
	(a) Release tool	1506
	(2) Approach plate	1506
	(3) Deck plate and fender combination	1802
	(a) Fixed work lamps	0609
	(b) Hose tender and cable supports (pogo stick)	1208
	(c) Air hoses	1208
	(4) Auxiliary transmission oil cooler	0721
	(5) Counterweight CRITICAL SAFETY ITEM	3307
	(a) Alignment pins installed	3307

e.	10 Ton Dump M1157A1P2
	(1) Dump Bed Lockout switch	1810
	(2) Dump UP/DOWN Plunger Switch	1810
	(3) Loadman Operation	4706
	(a) Load pin sensors	4706
	(b) Digital read out monitor in cab	4706
	(4) Tailgate assembly	1810
	(5) Hydraulic reservoir	2408
	(6) Lift cylinders	2407
	(7) Hydraulic lines/hoses	2402
	(8) Dump pivot points	1810
	(9) Dump body operation (cycle up/down 4 times)	1810
	(10) Tailgate Manual Release	1801
	(11) Manual Hydraulic Bypass Valve (functional check)	1810
	(12) Tailgate Release Switch	0607
	(13) PTO Switch	0607
	(14) Maintenance / Safety stands (Dump body in up position)	1810
	(15) Dump Body Indicator (UP/DOWN)	0607

March 2012 Revised Page 11

PRE-TEST CHECKLIST - ALL MODELS

Key: A -Accept R - Reject C - Corrected V - Visual / F - Functional / L - Leak

TRUCK BODIES (cont.) A R C CODE

f.	Wrecker M1089A1P2
	(1) Roadside of wrecker
	(a) Hydraulic tank proper fluid level		2001
	(b) Oxygen & acetylene tank mounts		1501
	(c) HIAB knuckle hook for free movement		2001
	(d) BII/Tools storage boxes hinge, latches, and mounts		1812
	(e) Vise Mount		1812
	(f)	Portable work light outlet	0609
	(g)	Clearance light mounting	0609
	(h)	Main Recovery Winch	2001

(2) Retrieval System M1089A1P2
(a)	Hose manifolds are free of leaks	2001
(b) Wrecker body for damage and security		2001
(c) Clearance and identification lights		0609
(d) Fenders and mudguards		2001
(e) Stiffleg assembly for damage, security, and operation with remote &		2001
	manual control
(f ) Stiffleg locking pin for free movement		2001
(g) Check all cylinders for leaks		2001
(h) Extend & retract lift & tow cylinders with remote & manual control		2001
(i)	Check crossbar for damage & proper amount of grease on ball	2001

(3) Curbside of wrecker
(a) Clearance lights	0609
(b) Portable work light outlet	0609
(d) Access ladder assembly and catwalks installed and free of cracks	1812
(e) Emergency Stop switch	2001
(f) Wrecker control panel cover and storage box	2001
(g) Towing Configuration/Switch ID/Emergency Stop ID plate	2001
(h) Main recovery winch	2001
(i) Wrecker control panel switches and handles	2001
(j) Self recovery winch	2001
(k) Auxiliary transmission oil cooler	0721
(4) Crane assembly
(a) Work Light	2001
(b) Remote control hook up (roadside and curbside)	0613
(c) Manual hand pump	2001
(d) Emergency Stop switches	2001
(e) Crane control boxes - check codes in accordance with the IETM	2001
(f) Outrigger assemblies (roadside and curbside)	2001

March 2012 Revised Page 12

PRE-TEST CHECKLIST - ALL MODELS

Key: A -Accept R - Reject C - Corrected V - Visual / F - Functional / L - Leak

1. SAFETY CHECK BEFORE ROAD TEST A R C CODE

a. All tires properly inflated and free from damage 1311

b. Fuel system free from leaks 0306

c. Check engine oil level/free from leaks 0106

d. Check transmission oil level/free from leaks 0710

e. Check coolant level/system free from leaks 0501

f.	With engine running, verify that the engine oil pressure, voltmeters,	0607
	air pressure gauges, and fuel gauges are operating properly by visually
	inspecting each gage and noting that the indicator is in the proper position.
	Shut engine off and again observe gages to assure they return to their non-
	operating position .

DO NOT ROAD TEST TRUCK IF ENGINE OIL PRESSURE OR AIR GAGES ARE NOT OPERATING

g. Check Lighted Indicator Display for any caution/warning light illumination 0607

h. Check CTIS display for proper operating mode 0608

j.	Verify that the steering system is functioning properly by physically checking	Group 14
	steering wheel for side and end play (none permitted). Then rotate steering
	wheel to determine if free play is adequate. Start engine and rotate the
	steering wheel to its maximum. The turning operation must be smooth and
	quiet.

k.	Verify brakes are operating properly.		Group 12
		DO NOT ROAD TEST IF BRAKES ARE NOT FUNCTIONING

l. Light operation 0609

m. Turn signal operation 0609

n. Horn operation 0611

o. Windshield wipers and washer operation 2202

p. Check Low idle (700rpm) and High idle (1350 rpm) switch 0607

2.	ROAD TEST	(MINUMUM 10-15 MILES PER TEST. LET VEHICLE IDLE AFTER TEST AND CHECK 100% FOR
		SEAL LEAKS)

NOTE: Defrost module status light may come on for a brief period when the truck's ignition switch is turned on - applies to A cab and B kit configurations. This is not a defect.

a.	Transmission	Group 07
	(1) Drive, all gears and reverse	0705
	(2) Transmission shifts smoothly	0705
	(3) Inhibitor - Driver shall not be able to shift transmission to reverse in drive
	mode	0705

b.	Brake operation	Group 12
	(1) park brake holds with transmission in gear	1208
	(2) Park brake release operates properly	1208
	(3) Service brake operates properly	1208
	(4) Exhaust brake operates properly	1208

c. Check/Test engine retard switch (warm-up/off/retard). 0610

March 2012 Revised Page 13

ROAD TEST CHECKLIST

Key: A -Accept R - Reject C - Corrected V - Visual / F - Functional / L - Leak

ROAD TEST (cont) A R C CODE

d.	Central Tire Inflation System (CTIS)	Group 06
	(1) Amber overspeed warning light illuminates either in cross country, sand,
	or emergency mode.	0608
	(2) With engine running, select RUN FLAT and check for air leaks.	0608

e. Transmission fluid must be checked with engine running and fluid temperature above 145 degrees F. Fastest way to achieve proper fluid temperature is by driving 8 miles with transmission selector pad showing "6-2" gear. With engine running, pull the dipstick to clean off existing oil, reinsert and pull again to check fill level. Fluid on dip stick must be between the "HOT ADD" and "HOT FULL" marks. If fluid level is high, with engine running, place a tube over the transmission sampling valve and drain until fluid is a the proper level. If fluid is low, with engine still running, add oil slowly to the transmission fill tube 1 pint at a time until fluid is at the proper level. Document any fluid level adjustment - exact amount added or removed. Group 07

3. VEHICLE SYSTEM TESTS

a. With the engine running actuate the start switch (starter should not engage) 0603

b.	With engine shut down connect MSD, 9 pin serial cable, DPA, and J1939
	adapter cable to vehicle diagnostic connector J117. When connected, start
	engine and read diagnostic codes.	Group 26
	(1) Engine Diagnostic Codes	0605
	(2) Transmission Diagnostic Codes	0705
	(3) ABS Diagnostic Codes	1208
	(4) CTIS System Diagnostic codes	0608

c.	Cab tilt and air transportability functional operation	(FUNCTIONAL CHECK 100% ALL VEHICLES)
	(operation thru full range of motion not required)		Group 24
	(1) Cab tilt lower/raise		2401
	(2) Spare tire lower/raise - inspect safety chain stud for tightness		2401
	(3) Suspension lower/raise		2401

d.	Self recovery winch	2001
	Place winch in free spool position, pull approximately ten (10) feet of cable
	from drum, engage PTO and rewind cable.

e.	Material Handling Crane (MTV)	(FUNCTIONAL CHECK 100% ALL VEHICLES)	Group 33
	Material handling equipment (MHE) shall be operated using all controls
	Repeat operation with remote control box		0608

4.	WRECKER SYSTEM TESTS		(FUNCTIONAL CHECK 100% ALL VEHICLES)	Group 20
	a.	Crane operation (Full range)		2001

b. Lift tow device operation (Full range) 2001

c.	Main recovery winches, place winch in free spool position, pull approximately
	fifty (50) feet of cable from drum, engage PTO and rewind cable	2001

d. Repeat above tests using remote control box 2001

e. All Emergency shut down switches 2001

5. 10 TON DUMP SYSTEM TESTS (FUNCTIONAL CHECK 100% ALL VEHICLES) Group 18 a Tailgate Manual Release 1801

b. Dump Body Indicator 1810

c. Safety lock 1810

March 2012 Revised Page 14

LHS

	LHS COMPONENTS TRUCK	Visual /Functional	Pass / Fail		CODE
1	LHS truck BII removed, inventoried and stowed in LHS stowage box.	V	P	F	BII
2	LHS truck storage box to be locked at storage box upper latch.	V / F	P	F	1808
3	LHS truck in cab control box shall be functional within all LHS modes. And PTO engages properly.	V / F	P	F	0613
4	LHS truck lift frame external storage controls shall be functional (refer to lift frame stow and unstow)	V / F	P	F	0613
5	LHS truck hook arm assembly hook shall be in functional position.	V / F	P	F	1501
6	LHS truck hook arm assembly shall be functional and will carry lift frame assembly from front stowed position to rear on the ground.	V / F	P	F	1501
7	LHS truck hook arm assemblies and main cylinders and masts shall be fully functional without leaks, squeals or any other dysfunctions. Main Cylinders will not be scored.	V / F	P	F	2402
8	LHS truck lift frame is shipped in air transport mode and shall be returned to non air transport mode. All components of the function shall be fully functional and properly stowed.	V / F	P	F	1501
9	LHS truck lift frame shall be stowed and unstowed by external LHS lift frame controls and all components including external controls and in cab controls interface, shall be fully functional.	V / F	P	F	1501
10	LHS truck lift frame upper ISO container guides shall be functional.	V / F	P	F	1501
12	LHS truck R and L Rear roller beds shall be fully operational in all LHS modes and all components fully functional to include all locking plates and pins. Rollers shall be functional.	V / F	P	F	1501
13	LHS truck front and rear R and L ISO locks shall be functional and ISO locking anvil turns freely.	V / F	P	F	1501
14	LHS truck auxiliary cooler (located on passenger side, rear of cab) shall be checked that connectors are fully engaged.	V	P	F	0721
15	The LHS truck auxiliary cooler and hoses shall have no leaks.	V	P	F	0721
16	The main LHS hydraulic manifold cover shall be functional.	V / F	P	F	2402
17	The main LHS truck hydraulic manifold shall have no leaks.	V	P	F	2402
18	The main LHS hydraulic manifold truck to truck slave quick release connectors shall have no leaks.	V	P	F	2402
19	LHS truck sliding pintle shall be functional. Locking pin shall be functional and locking pin lynch lock pin shall be functional. Pintle shall be functional.	V / F	P	F	1503
20	All LHS lube points and grease fittings shall be lubed and greased	V	P	F	9501
21	All LHS sensors shall be functional	V / F	P	F	0613
22	All LHS bolts shall not be loose	V	P	F	1501
23	All LHS truck warning and safety notifications shall be present and clearly seen.	V	P	F	2201
24	All LHS locking plates and locking pins shall be functional and	V / F	P	F	1501
	LHS COMPONENTS TRAILER	Visual /Functional	Pass / Fail
1	LHS trailer BII removed, inventoried and stowed in LHS stowage box.	V	P	F	BII
2	LHS trailer storage box to be locked.	V / F	P	F	1808
3	LHS Trailer receives electrical current from LHS truck through IV cable connected to IV cable connector at box and shall function properly.	V / F	P	F	0613
4	LHS trailer lights shall be fully functional, to include: braking, turn signal, side markers. 4-way, night vision and ABS and ABS maintenance tool.	V / F	P	F	0609
5	LHS Trailer receives air from truck.	V / F	P	F	1208
6	LHS trailer suspension air bags shall be fully inflated with no leaks.	V / F	P	F	1208
7	LHS trailer tow bar air bag shall be functional and capable of holding draw bar in suspended position with no leaks.	V / F	P	F	1208
8	LHS trailer air brakes shall be fully functional with no leaks.	V / F	P	F	1208
9	LHS trailer glad hands shall be functional.	V / F	P	F	1208
10	LHS trailer Flat-Rack and CROP din locks shall be fully functional without any obstructions. (mid-frame must be raised)	V / F	P	F	1801
11	LHS trailer mid-frame shall be capable of raising and lowering using crank handle.	V / F	P	F	1801
12	LHS trailer ISO shuttle shall traverse forward and aft using winch, without obstruction. (Mid frame must be in raised position).	V / F	P	F	1801
13	LHS trailer ISO shuttle shall traverse forward and aft using winch, without obstruction. (Mid frame must be in raised position).	V / F	P	F	1801
14	LHS trailer ISO shuttle iso locks shall be functional and ISO lock anvil shall turn freely. Locking pins shall work properly.	V / F	P	F	1801
15	LHS trailer ISO shuttle locking pins shall be functional and properly lock the shuttle.	V / F	P	F	1801
16	LHS trailer ISO shuttle R and L lower side guide pins shall be functional.	V / F	P	F	1801
17	Front LHS trailer ISO locks shall be functional and work freely. ISO lock anvils shall turn freely. Locking pins shall work properly.	V / F	P	F	1801
18	Front LHS trailer ISO guides shall be functional and locking pins and locking plates shall work properly	V / F	P	F	1801
19	Front LHS trailer CROP guides shall be functional.	V / F	P	F	1801
20	LHS trailer tow bar shall function correctly and lunette shall be properly secured.	V / F	P	F	1503
21	LHS trailer front end kneeling function is functioning properly. Front bump stop is functioning properly and locking pins functioning properly.	V / F	P	F	1503
22	LHS trailer stacking brackets are in stowed secured position.	V / F	P	F	1503
23	LHS trailer back-up locking pin should be in stowed position. It is only used when trailer being backed up in straight line.	V / F	P	F	1503
24	LHS trailer tires and spare tire shall be of proper air level.	V / F	P	F	1311
25	LHS trailer brakes shall function properly and be set IAW TM's.	V / F	P	F	1208
26	LHS trailer brake diaphragm caging bolts shall be in proper stowed position on top of diaphragms.	V / F	P	F	1208
27	LHS trailer suspension system shall function properly and be in correct setting IAW TM's.	V / F	P	F	1604
28	All LHS trailer lube points and grease fittings shall be properly lubed and greased.	V / F	P	F	9501
29	All LHS trailer warning and safety notifications shall be present and clearly seen.	V	P	F	2210
30	LHS trailer safety chains shall be crossed between truck and trailer.	V / F	P	F	1503

March 2012 Revised Page &P of &N

B Kit Deprocessing

B-KIT DEPROCESSING CHECKLIST	Functional Group Code: 3307
REVISION 1: OCTOBER 2009

OPAQUE ARMOR PANELS

All panels are present and undamaged.

All ballistic washers are installed.

All mounting hardware is present and torqued (hand check).

Check rear of door gap to be no more than 2.5 mm max.

Door clears fender panel. No interference acceptable.

CAB

All appurtenance plugs on roof and underside of cab are present and undamaged.

TRANSPARENT ARMOR (TA) PANELS

TA panels shall be free of scratches, cracks, delamination or other visual defects and/or damage.

The TA peel-ply sheets are completely adhered to the TA and do not show signs of bubbling or other visual defects.

No gaps are present around the TA panels or the TA cassettes.

All mounting hardware is torqued (hand check).

Front TA panels must have electric defrost connection coupled (inside cab).

Wipers operate through full range of motion.

Wiper arms and blades do not interfere with TA cassette.

DOORS (CHECK BOTH DOORS)

The combat latches must operate smoothly and fully engage the combat latch pads on the cab frame.

The combat latch must engage the detent in the lower combat latch cassette in both the engaged and neutral handle positions.

The upper combat latch must be present and operational.

The combat latches do not contact cab frame when in neutral position.

B-Kit damper must be installed and functional. Must be clearly marked “B-KIT ONLY.” Locking feature must slide and engage freely.

Combat latches engage and disengage using first responder tool.

First Responder Access Portal (FRAP) Cover installed and tight.

B-KIT HATCH

The hatch shall be installed with all required mounting hardware present and torqued (hand check).

The hatch latch shall operate without binding.

The hatch shall open and close smoothly without binding.

The hinges and dampers (including locking feature) shall be operational.

Seal present between hatch and cab.

FUEL TANK FIRE SUPPRESSION (FTFS) KIT	Functional Group Code: 7639
FTFS is installed.
All visible buckles are coupled.
All visible straps are taut.
No tears, abrasions, or other damage present.
No fire suppression powder leaks are evident (Purple K).
Fuel fill neck cover is buckled.
All fuel lines routed beneath the FTFS kit.
Self recovery winch cable is clear of FTFS kit (if applicable).
Fuel tank bracket protection strips installed.

WATER LEAKS

No water leaks are present. Areas to inspect include but are not limited to the following:

Door Seams

Door TA Cassettes

Hatch

Rear B-Kit Backer Panels

Windshield TA Cassettes

Light Bar Pass-Through

Antenna Mount Pass-Through

March 2012 Revised Page &P of &N

Revision Log

DATE	PAGE(s)	REVISION	REASON	MADE BY
Mar-12	8	Added check for twisted trans oil cooler lines	Problem escaped plant	NEI
	14	Added check for tightness of spare tire safety chain stud	Problem escaped plant	NEI
	14	Revised Wrecker checks for Oshkosh configuration	Major changes made to Wrecker retrieval system	NEI
	12	Sections f 1 and f 2 revised/reworded	New wrecker retrieval system on Oshkosh truck and other updates	NEI
	8 and 9	Moved items for better pagination	Ease of use and printing of footers	NEI
	Global	Updated front page and all footers, March 2012 date, "Oshkosh Wrecker"	Made updates	NEI
	1	Added revision notice	Unauthorized changes made	NEI
	8	Fresh/Recycle air mode op	Part of System check	HTSI
	B-Kit	Hatch should open to the front	Problem escaped plant/pic in IETM wrong	HTSI
	3	Functional Group Codes	Corrected	HTSI

File details come from the government source that posted it. Updated Nov 14, 2017.