PSPEC_Annex_R_-_Definitions.pdf

UNCLASSIFIED

DRAFT

ANNEX R

DEFINITIONS

TO

PERFORMANCE SPECIFICATION

FOR

FAMILY OF MEDIUM TACTICAL VEHICLES

DOCUMENT CONTROL NUMBER

FMTV PS-R V0

15 APRIL 2016

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

UNCLASSIFIED FMTV PS

Annex R, V0

UNCLASSIFIED Page ii

Revision History

Revision Date Description V0 15 April 2016 Draft release

DRAFT UNCLASSIFIED FMTV PS

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ID FMTV P-Spec Non-Requirements

FMTV-PS-NR-1943 1. DEFINITIONS

FMTV-PS-NR-1944 For the purpose of this specification the following definitions shall apply.

2. Verification Methods

2.1. Analysis (A)

FMTV-PS-NR-2087

An element of verification that utilizes established technical or mathematical models or simulations, algorithms, charts, graphs, circuit diagrams, or other scientific principles and procedures to provide evidence of compliance with Section 3 requirements.

2.2. Certificate (C)

FMTV-PS-NR-2088

Certifications are defined as Contractor-furnished documents certifying conformance with specific Section 3 requirement criteria. Certifications shall be signed by the Contractor’s certifying official or responsible party, and shall include all supporting performance, inspection, and analytical data, as applicable.

Manufacturer’s certifications include factory tests. External certifications shall be from organizations not affiliated with the Contractor. All external certification organizations shall be accredited for testing and certification to the standard or specification referenced in the relevant criteria. Presence of a Certification Mark on the product from such an organization shall be provided IAW regulations and standards. All certifications are external certifications unless specifically identified as a Manufacturer certification.

2.3. Demonstration (D)

FMTV-PS-NR-2089

An element of verification which generally denotes the actual operation, adjustment, or reconfiguration of items to provide evidence that the designed functions were accomplished under specific scenarios. The items may be instrumented and quantitative limits of performance monitored.

2.4. Inspection (I)

FMTV-PS-NR-2090

An element of verification that is generally nondestructive and typically includes the use of sight, hearing, smell, touch, and taste; simple physical manipulation; and mechanical and electrical gauging and measurement.

2.5. Test (T)

FMTV-PS-NR-2091

Testing shall be accomplished through the systematic physical operation of the system, its subsystems or components, under appropriate and specified conditions, with or without instrumentation, and the collection, analysis, and evaluation of resulting data. Testing also includes the act of recording measurements related to the function of the system, its subsystems or components, and verifying interfaces with respect to form, fit, and function.

3. Verification Locations

FMTV-PS-NR-2092 3.1. First Production Vehicle Inspection (FPVI)

3.1.1. In-Process Inspection

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FMTV-PS-NR-2093

During fabrication of the first production vehicle of each variant type, in-process inspections shall be conducted to determine conformance of materials and workmanship to specified requirements. These inspections shall be made at the Contractor’s or Subcontractor’s facilities, prior to the application of primer and paint. Processing and welding procedures, quality system, inspection records, calibration procedures, non-destructive test procedures, and welder certifications will be reviewed and evaluated during the in-process inspections. Another inspection of final paint and final protective coatings shall be conducted and documented.

A “X+” denotation is a Certification Requirement.

FMTV-PS-NR-2094 3.1.2. Completed First Vehicle Inspections

3.1.2.1. Contractor Inspection

FMTV-PS-NR-2095

The first production vehicle of each variant type shall be inspected and road tested by the Contractor at the place of manufacture. The first production vehicle inspection shall include, as a minimum, the inspections referenced in the Performance Specification. The road test shall be conducted with actual or simulated payload, on a smooth relatively level hard-surfaced road, for a distance of not less than 150 miles. Upon completion of testing, the Contractor shall submit the vehicle, and make available all inspection records and certifications, to the responsible Government inspection element at Contractor’s plant, for preliminary inspection. The Government, at its option, may elect to witness, and/or participate (to include vehicle operation/driving), in the Contractor’s inspections and road tests.

3.1.2.2. Repair of Defects

FMTV-PS-NR-2096 Defects found on all production vehicles shall be corrected by the Contractor.

3.1.2.3. Vehicle Disposition

FMTV-PS-NR-2097 FPVI vehicles may be selected by the Government as Production Verification Test (PVT) vehicles.

3.1.2.4. Final Approval and Acceptance

FMTV-PS-NR-2098

Final approval and acceptance by the Government, of the first production vehicle of a specific model, will be withheld until the Production Verification testing has been completed, and a final determination has been made regarding conformity of the vehicle to contractual requirements, including, but not limited to, workmanship and materials.

3.1.3. Location

FMTV-PS-NR-2099 FPVI shall be performed at the place of manufacture.

3.2. Production Verification Test (PVT)

FMTV-PS-NR-2101

To determine conformance to Section 3, after completion of the FPVI, production vehicles of each configuration shall be randomly selected by the Government for Government testing. These vehicles shall be subjected to performance, live fire, and RAM testing at a Government selected test site (s).

RAM testing shall consist of a 20,000 mi. test IAW Annex V. In the event the production contract delineates test of less than 20,000 mi., the mileage course mix percentage shall remain the same for the revised mileage. Quantity of test vehicles and configurations to be tested shall be delineated in the production contract. Such tests shall be conducted by the Government at a Government selected test site(s). The vehicles shall be tested with actual or simulated payload. No less than half of the mileage of any PVT will be conducted in Armor Configuration. Quality of test vehicles and configurations to be tested shall be delineated in the production contract.

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NOTE: 90% of the mileage specified for each course shall be performed with payload. The remaining 10% of the mileage shall be performed without payload.

25% of each course shall be run with the vehicles towing a trailer at its GVW, with the exception of the M1148A2, which shall tow the M1147 for no less than 50% of each course. Payloads for the M1088A2 with semitrailer will be determined by the Government as to proper weight distribution and fifth wheel load for 46,000 lb payload. A loaded M871 shall be utilized for performance testing of the M1088A2. The M1089A2 payload (M1083A2 at GVW, front towed) shall be towed for 35% of mileage shown in the Classification of Inspections and Tests.

The Government has the option of performing or not performing any individual test.

FMTV-PS-NR-2102 3.2.1. Reliability Conformance

3.2.1.1. Mean Miles Between Hardware Mission Failures (MMBHMF)

FMTV-PS-NR-2103

A vehicle performance test shall be conducted to verify that the Mean Miles Between Hardware Mission Failure (MMBHMF) requirements, for all body types, as specified in the Main Body, have been attained utilizing test data (e.g., Test Incident Reports (TIR’s)).

3.2.1.2. Maintainability

FMTV-PS-NR-2104

The maintainability design requirements shall be verified, for conformance to the Main Body requirement, during the test operations in an environment which simulates the vehicle’s operational and maintenance conditions. The maintenance ratio (MR) shall be computed, upon completion of the test, utilizing the scheduled and unscheduled man-hour data recorded in the final test report. The MR shall not exceed the values in the Main Body Section 3 requirement.

3.2.1.3. Failure Definition/Scoring Criteria (FD/SC)

FMTV-PS-NR-2105

The Government will unilaterally determine conformance to the Reliability and Maintainability requirements in the Main Body, by scoring failure incidents and severity classification on each vehicle, using the FD/SC designated.

3.2.2. Location

FMTV-PS-NR-2106 PVT shall be performed at a Government Proving Ground.

FMTV-PS-NR-2112 3.3. Final Inspection Record (FIR)

FIR testing may be performed at VCW.

3.3.1. One Hundred Percent (100%) Final Inspection

Each vehicle/trailer produced shall be subjected to a complete final inspection by the Contractor, as described in this section and documented on a Government approved Final Inspection Record (FIR). Verification and inspection of torque, dimensions, routings of hoses and electrical harnesses, and characteristics that are masked by subsequent assembly operations shall be accomplished during in-process assembly and inspection operation. In-process defect prevention techniques shall be implemented to the maximum extent possible to prevent the occurrence of defects during FIR activities. A complete copy of the in-process inspection records and FIR shall be submitted to the Government with each vehicle offered for acceptance. The Contractor is required to perform a verification inspection of the items identified. The type of inspection is dependent on the paragraph referenced. It may be functional, operational, or visual. It is not intended to be a Control Test. Each vehicle shall be inspected by the Contractor for the characteristics/defects listed in the Performance Specification and the FIR, as a minimum. If a characteristic is found defective the Contractor is responsible to provide corrective action, and perform re-inspection prior to offering the vehicle to the Government for final acceptance.

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3.3.1.1. Roller Test

The vehicle shall be operated on the roller type fixture for a minimum 3 miles and checked for proper operation of transmission selections through all gears in all-wheel drive mode only. All transmission selections shall be demonstrated during the track test defined below. The vehicle shall be run from 0 through maximum governed speed. The vehicle shall be checked for reverse operation. Before, during and after, all vehicle equipped instrumentation shall be monitored for proper operations and readings. The vehicle shall be stopped and engine idled for not less than 2 minutes after vehicle roller run. While idling, the vehicle shall be subjected to a walk-around inspection. Transmission, engine oil, radiator fluid (if equipped), power steering fluid, and hydraulic brake fluid (if equipped) levels shall be checked and adjusted if necessary before track test.

3.3.1.2. Track/Route (T/R) Test

Subsequent to examinations and corrections of deficiencies found during Roller Test, the vehicle shall be operated for a minimum of 12 miles on a relatively level, hard surfaced test T/R. The T/R test shall be capable of allowing the test vehicles to operate at maximum governed speed. During the T/R test, the Contractor shall verify that the vehicle successfully shifts through all forward transmission shift points. As an option, operation at maximum governed speed may be performed and demonstrated during the roller test. The vehicle shall be operated to verify that the transmission transfer case operates properly.

The vehicle shall also be driven in reverse for a distance of not less than 50 feet. At the completion of accumulated miles, the vehicle shall be stopped and the engine allowed to idle for not less than 5 minutes. At this time a walk-around inspection shall be performed.

3.3.1.3. Examination or Test Failure

If any vehicle fails to pass any examinations or tests specified herein, the Government shall withhold acceptance until the Contractor provides evidence that corrective action has been or is being taken.

3.3.2. Final Inspection of Production Vehicle by Sampling

The Contractor shall not final inspect vehicles on a sampling basis in lieu of final inspection of each end item as described in "One Hundred Percent Final Inspection" unless written authorization is received from the Government procuring activity.

3.3.2.1. Unclassified (Workmanship) Deficiencies

All workmanship deficiencies that have no effect on function, safety, interchangeability, life, vehicle performance or jeopardize mission capability but considered departures from good workmanship, will be documented in writing but will not be used in determining lot acceptance, unless similar deficiencies occur on five consecutive lots. Examples of such deficiencies may include, but are not limited to, foot and or finger prints, trash or debris left over from the manufacturing process, cable wraps not trimmed, rivet stubs and or washers not removed from under the floor mats, etc. All workmanship deficiencies shall be corrected by the Contractor prior to shipment.

3.3.2.1.1. Recurring Unclassified (Workmanship) Deficiencies

Workmanship deficiencies falling within these types of categories, and recurring in five consecutive lots, will be documented in the FIR as a minor defect and remain there until the Contractor passes five consecutive lots without recurrence of such deficiencies.

3.3.2.2. Major Defects

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Any defects which could impact safety, or that will likely result in decreased vehicle performance, mission failure, reduced operational capability, or result in a loss of function to any major component or sub-system (i.e. engine, transmission, steering, hydraulics, brakes, heater, etc.), are considered major defects.

3.3.2.2.1. Recurring Major Defects

A major defect is recurring when the same defect occurs more than once in the same sample, or when a similar defect occurs in two successive samples. A major defect may be considered recurring when the historical inspection records ("P" chart or Government approved equivalent) reflect such a condition.

Recurring major defects shall be cause for the entire lot, or lots, to be inspected for the recurring defects. All defects shall be corrected by the Contractor prior to acceptance by the Government.

3.3.2.3. Minor Defects

Any defects which may result in an inconvenience to the operator or crew, require maintenance or repair at the next convenient stop in operations, are cosmetic in nature but readily visible, exhibit obvious departures from normal and accepted manufacturing practices (i.e. chaffing, loose or missing hardware, easily visible paint defects on class A surfaces, etc.), but which would not likely result in an immediate concern for safety, mission failure, diminished vehicle capability or operational readiness or require immediate maintenance for continued vehicle operation, should be considered minor defects.

3.3.2.3.1. Recurring Minor Defects

A minor defect is recurring if a similar minor defect occurs in four successive samples. Recurring minor defects shall be cause for the entire lot or lots to be inspected for the recurring defects, and correction shall be accomplished prior to acceptance by the Government.

3.3.2.4. Sampling Inspection Failures

If any vehicle fails to pass any examination as specified in Major and Minor Defects or the required tests as specified in the Main Body, the Government reserves the right to withhold acceptance of all vehicles in the lot until the Contractor provides evidence that corrective action has been taken to correct all documented defects and the conditions that caused those defects. On the failure of a lot to pass sampling inspection, the Contractor shall revert to inspection, as defined in "One Hundred Percent Final Inspection", until evidence the Government deems satisfactory has been provided by the Contractor.

3.3.3. Location

FMTV-PS-NR-2113 FIR shall be performed at the place of manufacture.

FMTV-PS-NR-2114 3.4. Control Test (CT)

Control tests for maintaining control of manufacturing operations shall be conducted by the Contractor as specified below.

3.4.1. Frequency

The Government shall select one vehicle or trailer at random for control test from each two (2) week’s production quantity.

3.4.2. 50 mile test

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The test vehicles shall be fully equipped with either actual or simulated payload including the applicable fully loaded trailer and operated for a distance of not less than 50 miles on the relative level, hard-surfaced test track/route. Prior to conducting the CT, the test vehicle shall be subjected to the road test without payload as depicted in "Track/Route Test". The CT shall be performed at the place of manufacture. Prior to conducting the 50 mile CT, each test vehicle shall be inspected to ascertain conformance to the requirements. These tests shall be performed in the presence of a Government representative. The CT shall validate the actual performance requirements.

3.4.3. Test Failure

If the vehicle selected fails to pass any of the CT requirements, the Government reserves the right to stop acceptance examination and testing on subsequent vehicles until such time the condition(s) causing the failure have been investigated for cause and corrected. Any major defects found during, or as a result of the CT, shall be prima facie evidence that vehicles accepted subsequent to the previously acceptable CTs were similarly defective, until the Government is furnished evidence by the Contractor that they are not similarly deficient. Minor defects found during or as a result of the CT shall not result in immediate stoppage of acceptance unless four or more minor defects are documented on one CT vehicle. Such defects on all vehicles shall be corrected by the Contractor at no cost to the Government. Another vehicle with corrective actions implemented shall be subjected to the CT to verify effectiveness of corrective actions.

3.4.4. Location

FMTV-PS-NR-2115 CT shall be performed at the place of manufacture.

FMTV-PS-NR-2116 3.5. Follow-on Production Test (FPT)

To determine conformance to Section 3, the Government may select samples as specified in the contract for FPT. Vehicle(s) shall be subjected to all FPT specified in the Performance Specification and tested for 12,000 miles IAW the course mileage ratios (Annex V). Tests shall be conducted to reveal defects of workmanship or material that may reduce the effective operation of these items in the field, and compare existing quality with previous standards. All tests specified shall be conducted at Government laboratories or test sites designated by the Government. FPT vehicles selected shall not include any vehicles previously control tested. The Government may elect to conduct FPT of less than 12,000 miles.

The Government has the option of performing or not performing any individual test.

3.5.1. Test Deficiencies

FPT vehicle deficiencies during, or as a result of the FPT, may be cause for rejection of subsequent produced vehicles, until the Contractor has provided evidence that corrective action has been taken to eliminate the deficiency. Any deficiency found during, or as a result of the FPT, shall be prima facie evidence that all vehicles currently or subsequently produced are similarly deficient, unless evidence satisfactory to the Contracting Officer is furnished by the Contractor that they are not similarly deficient. The Contractor shall correct such deficiencies on all vehicles at no cost to the Government.

3.5.2. Location

FMTV-PS-NR-2117 FPT shall be performed at a Government Proving Ground.

4. General

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4.1. Vehicle

FMTV-PS-NR-2077 A vehicle is any of the LMTV and MTV truck variants, which does not include trailers.

4.2. Trailer

A trailer is the companion trailer to the FMTV fleet (M1082, M1095, and M1147).

4.3. A-Cab

FMTV-PS-NR-2078 The A-cab is the vehicle cab without armor kits installed.

4.4. Armor Configuration

FMTV-PS-NR-2080 Armor Configuration is the vehicle with the B-kit, Underbody Kit, and Objective Gunner Protection Kit (OGPK) installed.

4.5. Armor Kits

The Armor Kits consist of the suite of armor for the FMTV which includes the B-kit, Underbody Kit, and OGPK.

4.6. Payload

FMTV-PS-NR-2075

Payload is defined as any load placed in the vehicle (or trailer). Any trailer tongue load will be included as a part of the payload. Armor kits are not considered part of payload.

For test purposes, the payload shall be uniformly distributed with a center of gravity (CG) 24 inches (61 cm) above the cargo bed.

4.7. LMTV Variants

The LMTV variants consist of both vehicles and trailers. The LMTV vehicle variants are the M1078A2, M1079A2, and M1080A2. The LMTV trailer variant is the M1082.

4.8. MTV Variants

The MTV variants consist of both vehicles and trailers. The MTV vehicle variants are the M1083A2, M1084A2, M1085A2, M1086A2, M1087A2, M1088A2, M1089A2, M1092A2, M1096A2, M1148A2, M1157A2, and M1273A2. The MTV trailers are the M1095 and M1148.

FMTV-PS-NR-1947 4.9. Vehicle Curb Weight (VCW)

FMTV-PS-NR-1948

The VCW is defined as the weight of the empty vehicle or trailer, including integral Materiel Handling Equipment (MHE) and winch (if applicable), full complement of fuel, lubricants, coolants, hydraulic fluid, crew, crew gear and Basic Issue Items (BII).

FMTV-PS-NR-2081 This definition can be either A-cab or Armor Configuration FMTV-PS-NR-1949 4.10. Gross Vehicle Weight (GVW)

FMTV-PS-NR-2082

The GVW is defined as the sum of the vehicle or trailer at VCW and maximum payload. For performance requirements, the GVW of the M1088 and M1089 is equal to VCW.

This definition can be either A-cab or Armor Configuration

FMTV-PS-NR-1961 4.11. Gross Combination Weight (GCW)

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The GCW is defined as the sum of the vehicle at GVW and the designated primary towed loads at GVW as defined below:

a. LMTV vehicle variants and the M1082

b. MTV vehicle variants (except M1088A2 and M1089A2) and the M1095

c. M1088A2 and semi-trailer loads of 63,000 lbs (trailer plus payload) for endurance and mobility; and a fully loaded M871 for performance requirement

d. M1089A2 lift towing the heaviest FMTV A2 in Armor Configuration at GVW from the front

e. M1157A2 at VCW and a Light Equipment Utility Trailer (LEUT) with maximum payload This definition can be either A-cab or Armor Configuration

4.12. Counterweight

FMTV-PS-NR-2079 A weight that is assembled to the rear end of the vehicle (e.g. M1078A2 and M1088A2) to adjust the center of gravity for these vehicles for safe operation.

FMTV-PS-NR-1967 4.13. Vehicle Cone Index (VCI)

FMTV-PS-NR-1968

The minimum soil strength in the critical soil layer in terms of Rating Cone Index (RCI) for fine grained soils, and Cone Index (CI) for coarse grained soils, required for a specific number of passes of a vehicle. VCI1 indicates a single (one) pass.

FMTV-PS-NR-1969 4.14. Remolding Index (RI)

FMTV-PS-NR-1970

A ratio that expresses the proportion of original strength of a medium that will remain under a moving vehicle. The ratio is determined from CI measurements made before and after remolding a 6 inch long sample using special apparatus.

FMTV-PS-NR-1971 4.15. Rating Cone Index (RCI) FMTV-PS-NR-1972 The product of the measured CI and the RI of the same layer.

FMTV-PS-NR-1973 4.16. Cone Index (CI)

FMTV-PS-NR-1974

An index of the shearing resistance of a medium at any depth by a penetrometer. The resistance to penetration by a 30 degrees cone with a 0.5 square inch circular base is expressed in pounds of force on the handle per square inch of the base area. In the basic Waterways Experiment Station (WES) VCI system, the CI is considered as an index only, and no direct meaning is assigned to its dimensions.

FMTV-PS-NR-1975 4.17. Slopes

FMTV-PS-NR-1976 A slope is defined as a sharp transition from one constant grade to another constant grade, which is up to a specified percentage difference in any direction.

FMTV-PS-NR-1977 4.18. Rated Engine Power FMTV-PS-NR-1978 The Rated Engine Power is defined as the drawbar pull plus the rolling resistance required to attain the engine's maximum rated RPM.

FMTV-PS-NR-1979 4.19. RESERVED

FMTV-PS-NR-2001 4.20. Like Vehicle

FMTV-PS-NR-2002

A "like vehicle" is defined as another vehicle with the same payload.

a. For MTV vehicles: MTV Series, M939 Series and M809 Series 5-ton trucks

b. For LMTV vehicles: LMTV Series and M35 Series 2-1/2-ton trucks

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4.21. Wall to Wall

FMTV-PS-NR-2083 The distance between walls to allow a vehicle making a uniform turn without touching one of the walls.

4.22. Deadman Type

FMTV-PS-NR-2084 A control, switch or device that automatically returns to the neutral position should the operator inadvertently or intentionally release the control.

FMTV-PS-NR-2085 4.23. Combat Gear

Combat gear is defined as the equipment a soldier wears while in combat. This consists of an advanced combat helmet, protective goggles, load bearing vest with 6x 30 round magazine, improved first aid kit, body armor, M4 carbine with 30 round magazine, uniform (e.g. ACU), protective mask (M40), knee pads, pair of boots, camel back hydration system, and rucksack.

4.24. Certificate of Conformance (CoC)

FMTV-PS-NR-2119

Statement by the Contractor or his Subcontractor that the products or services provided by this shipment or contract meet all the requirements. It is signed and dated by a responsible (accountable) company representative. A statement as to the acceptability of the parts or services supplied by this shipment. It should be specific to a contract or shipment.

4.25. Certificate of Test Data

FMTV-PS-NR-2120

This is a detailed report of test results for chemical, dimensional, mechanical, microscopic, electrical, environmental, electronic, corrosion, life cycle, and or physical testing. The report shall show the:

- signature and statement of the acceptability of the shipment and of the testing results by a responsible company official.

4.26. Damage

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FMTV-PS-NR-2121

A repairable defect or nonconformity, that does not return the material or the part to the same state as a new part. Damage causes physical harm to the material or part and impairs its usefulness, lowers its value, and impairs its normal function.

Possible types of damage are:

• Dents

• Scratches (that exposes the material)

• Corrosion (oxidation)

• Defects of finishes: Blisters, Pores, Coverage voids, Fixture, rack, or hook marks, Bleed-through, Scratches, Cracks, Runs, Sags, Drips, Orange peel, Fish eyes or craters, Solvent popping, Chipping, Blushing, Chalking, Lifting, Peeling, Adhesion and cohesion - lack of, and Pin-holing

4.27. Degradation

FMTV-PS-NR-2122 Damage that will cause the loss in the ability of the system or vehicle to perform its designated objective or mission.

4.28. Deformation

FMTV-PS-NR-2123

A defect that is due to a change in a material or a part that progresses from elastic to plastic and, therefore, represents the permanent irreversible alteration of a material or part. Deformation is considered to be non-repairable without replacement

FMTV-PS-NR-2011 4.29. Fluids FMTV-PS-NR-2016 4.29.1. Fluid Leak Classification

FMTV-PS-NR-2017 Class I - Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops and can be cleaned without recurrence.

FMTV-PS-NR-2018 Class II - Weepage or seepage of fluid great enough to form drops but not enough to cause drops to drip from item being inspected.

FMTV-PS-NR-2019 Class III - Leakage of fluid great enough to form drops that fall from the item being inspected.

FMTV-PS-NR-2020 4.29.1.1. Category of Fluid Leak Defects FMTV-PS-NR-2021 Class I - Observation (no defect for all systems other than the brake system and the fuel system) FMTV-PS-NR-2022 Class II - Minor Defect FMTV-PS-NR-2023 Class III - Major Defect FMTV-PS-NR-2024 4.29.2. Fluid Level Classification

FMTV-PS-NR-2026 Class 1 - Dip stick fluid levels that fall within the crosshatch marks. Sight-glass fluid levels that fall between the upper and lower sight-glass.

FMTV-PS-NR-2027

Class 2 - Dip stick fluid levels that fall above the upper crosshatch mark or below the lower crosshatch mark. Sight-Glass fluid levels that are even with or below the lower sight-glass.

FMTV-PS-NR-2028 Class 3 - No fluid visible on the dip stick or lower sight-glass.

FMTV-PS-NR-2029 4.29.2.1. Category of Fluid Level Defects FMTV-PS-NR-2030 Class 1 - Observation (No Defect) FMTV-PS-NR-2031 Class 2 - Minor Defect FMTV-PS-NR-2032 Class 3 - Major Defect

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FMTV-PS-NR-2043 4.30. Dressed Engine

FMTV-PS-NR-2044

A dressed engine shall consist of the assembly and all components, brackets, hang-ons and attaching hardware (i.e., air compressor, starter, turbocharger, pulleys etc.) that is common to all vehicle variants (within a family or series of vehicles).

FMTV-PS-NR-2045 4.31. Mission Essential Functions

FMTV-PS-NR-2046

These mission essential functions apply to the LMTV and MTV variants. An incident which would result in the inability to safely perform any one of these mission essential functions to a level no less than that described below will be charged as an operational mission failure.

4.32. Caging

In the event of brake system failure, this is a manual process that allows the brakes to become free so the trailer can be moved. This emergency procedure allows the trailer to be moved if stranded on the travel portion of a road. Normal operation with the brakes caged could result in damage to the vehicle or seriously injury to personnel.

FMTV-PS-NR-2073 4.33. Craning Cycle

FMTV-PS-NR-2074 A craning cycle is defined as a pickup, move, and placement of a load. This shall be either a movement from the bed of the truck to the ground or vice versa.

4.34. Crew Compartment

The crew compartment is the cab of the vehicle only. It does not include any enclosures on the back of the vehicle.

UNCLASSIFIED

CLASSIFICATION OF DEFECTS

MAJOR

Defect No. Defect Characteristic Method of Inspection

Steering mechanism: malfunction, unusual noise, malfunction of pump, gear or other major component resulting in loss or degradation of steering function, or condition that could result in same (i.e. loose pitman arm), Class III leak

Visual, functional

Engine: malfunction resulting in loss of power, stalling, failure to start, or Class III leak, loss of oil pressure, improper installation, loose or missing engine mounting hardware, unusual noise

Visual, functional

103 Transmission: malfunction, unusual noise, improper shifting, Class III leak Visual, functional

104 Drivetrain: transfer case assembly: malfunction, improper clearance, Class III fluid leaks, improper installation

Visual, functional

105 Transfer case assembly: malfunction, improper clearance, improper installation or Class III fluid leaks

Visual, functional

106 Cooling system and component(s): (i.e. radiator, surge tank, water pump):

malfunction, Class III fluid leaks, vehicle overheating

Visual, functional

107 Governor linkage and engine governor: malfunction, improper adjustment Visual, functional

Vehicle electrical charging system and components (alternator, limp home device, reverse polarity protection device): malfunction, voltage within +/-10% of nominal

Visual, functional

Service, parking brakes: malfunction, inability to hold vehicle on required slope, unusual noise, pulling to one-side greater than 42”, air leaks exceeding system pressure drop of 3 psi/min with engine stopped

Visual, functional

110 Tires: damage, improper assembly Visual

Fuel tank and system: welding defects, leakage (Class I, II or III), cracked tank mounting brackets, cracked or clogged fuel/water separator, cleanliness (water in the fuel/water separator is acceptable), interference with surrounding components, malfunction

Visual, functional

Exhaust system: damage, exhaust leaks that could result in unsafe condition, excessive noise, improper installation, improper heat shielding for surrounding components

Visual, functional

113 Suspension system: malfunction, Class III leak Visual, functional 114 Winch and wire rope: malfunction, improper size, damage Visual, functional 115 Instrumentation/gauges/switches: malfunction, location, functional damage Visual, functional 116 Nuclear, biological, chemical: storage mounting provisions missing Visual

Weld defects: welds that are structural shall be inspected IAW the weld standards table found in the main body (Sections “Non-Armor Weld Procedure Qualification” and “Armor and Ballistic Welding”)

Visual, Weld Gages

118 Personnel heater/climate control: malfunction of HVAC Visual, functional

119 Crane/MHE system: malfunction, Class III fluid leaks, contamination, all cylinders rods including wiper seal free of paint, grounding wire attachment

Visual, functional

120 Wrecker components: malfunction, Class III fluid leaks, contamination Visual, functional 121 Armor Kits fit-up: gap clearances, misalignment, Class III leaks, damage Visual, functional

122 Transparent armor: cracks, scratches or damage IAW ATPD 2352, delamination

123 Fluids: no fluid visible on the dip stick or lower sight-glass Visual 124 Cab tilt system: malfunction, damage, Class III leaks Visual, functional 125 Lights: malfunction Visual, functional

All other defects not specifically listed in the major defects section of this table, but which fall into the major category, based on the definition of a major defect

Visual, functional

CLASSIFICATION OF DEFECTS

MINOR

Defect No. Defect Characteristic Method of

Inspection

Fluids: low or improper fill, dip stick fluid levels that fall above the upper crosshatch mark or below the lower crosshatch mark at engine operating temperature, sight-glass fluid levels that are even with or below the lower sight-glass

Visual

202 Lubricants: component damage from improper lubrication or no lubrication present

Visual

203 Controls/handles/knobs: malfunction, adjustments, loose, missing, or damaged

Visual, functional

204 Steering system: hoses misrouted, loose hardware, Class II leaks, chaffing Visual, functional 205 CTIS: malfunction, improper installation, leaks Visual, Functional 206 Pulleys and fans: misalignment, improper clearance Visual

207 Engine components and subsystems: loose hardware, cables/wires, improperly adjusted, Class II leaks, misalignment, improper clearance

Visual

208 Transmission and related components: brackets, hoses, lines that need adjusting, Class II leaks, dipstick or sampling valve issues, loose bolts

Visual, functional

209 Coolant system components: improper coolant mixture, hoses, lines need adjusting, chaffing

Visual, hydrometer

210 Lubrication system components (engine): damage, Class II fluid leaks, cleanliness

Visual, functional

211 Drivetrain: inoperative grease fittings, Class II differential leaks, vent hoses misrouted/kinked

Visual

212 Body, doors, access covers, tie-downs: improper fit, defective welds, inadequate sealing

Visual, functional

213 Paint application defects: improper color, improperly applied camouflage pattern (if applicable), coverage, cosmetic defects, Stage 1 corrosion

Visual

214 Lube fittings: defective, missing, improperly installed Visual

215 Bolts/nuts/washers/keepers/or other non-critical miscellaneous hardware:

defective, loose, missing or damaged

Visual, torque wrench

216 Cushions/seats and belts: improper fit, tears, or rot, seat belt adjustment and locking

Visual

217 Decals, marking, data and instruction plates: incomplete data, missing, improper location or size

Visual

218 Batteries/battery cover/battery tray: malfunction, cracks, improper installation, operation, Stage I corrosion

Visual, functional

219 Radio brackets/connectors: improper installation Visual 220 Lights: improper installation, cracked lenses Visual, functional

221 Air compressor/pneumatics: improper installation, malfunction, low pressure, and leaks

Visual, functional

222 Windows (A-cab): cracked glass, improper installation, leaks Visual, functional

223 Air transportability: malfunction, leaks-hydraulic/pneumatics, improper installation

Visual, functional

224 Vehicle lifting and tie-down devices: improper fit, loose hardware Visual

Service parking brake: minor air leaks not effecting vehicle braking and can be corrected with minimal effort (i.e. tightening a fitting), hose routing, chaffing

Visual, functional

UNCLASSIFIED

226 Windshield wiper system: inoperative, wiper arms, wiper blades, wiper arm parking location (to be within 5 degrees of normal parking location)

Visual, functional

227 ABS system: ABS indicator light illuminated, malfunction correctable by adjusting or resetting wheel sensor, connector, or clearing history codes

Visual, functional

228 Wire or tubing: defective, improper assembly or installation, improper protection, kinks, improper identification

Visual

Weld defects: weld defects on non-structural materials IAW the weld standards table found in the main body (Sections “Non-Armor Weld Procedure Qualification” and “Armor and Ballistic Welding”)

Visual, weld gages

230 Fire extinguisher mounting provisions: improper installation Visual 231 Corrosion: any visible surface rust Visual 232 Suspension system: Class II leak Visual

233 All other components/characteristics not listed in the minor defects section of this table, but which fall into the minor defect category

Visual , functional