Attachment_0002_-_M160_Acceptance_Test_Procedure_(ATP)_Rev_F.docx

M160 (MV-4B) Acceptance Test Procedure Table of Contents 6/27/2016

01 July 2016

M160 (MV-4B) Acceptance Test Procedure

Revision History Table

RAM results Updates to procedures

E

Purpose This plan was developed to provide complete functional checkout of the M160 (MV-4B) electrical, mechanical, and hydraulic functions. It is intended for use to verify functionality of new systems, systems which have undergone factory modifications, and major subsystem deliveries (i.e. vehicles or hand controllers). Please ensure all data recorded is accurate and legible.

Safety To ensure the safety of the test personnel and any others in the vicinity, the following steps are to be followed:

· Ensure that the operator of the vehicle is a trained M160 (MV-4B) operator.

· The operator’s and technical manuals will be used as references.

· Sufficient range space will be provided, relevant to the functions being tested, to ensure safe operation. When flailing, sufficient standoff distances will be observed.

· M160 (MV-4B) Systems need to be tested with their assigned Operator Control Unit (OCU).

Discrepancies Each step in the procedure will be marked pass/fail and observations noted during the test will be documented under comments. Discrepancies found during acceptance will be documented thoroughly and will be provided in electronic form to the following:

sanjiv.l.dungrani.civ@mail.mil and dwayne.resch@us.army.mil. The description will include the procedure step in which it was observed and the conditions which were observed. Photos, drawings, schematics or any other illustrations which will assist in documenting and describing the failing condition may be included.

SYSTEM: M160 VEH SERIAL No.: ____________________________________ OCU SERIAL No.: ____________________________________ Clearing Tool SERIAL No.: _________________________ Blade SERIAL No.:

Roller SERIAL No.: ____________________________

INSPECTION DATE: _____________ BY: __________________________________

(DCMA Representative)

Procedure

0.1

Confirm presence of Tool Box at time of shipment (ONLY Applicable for NEW Systems).

0.2

Confirm presence of left and right hydraulic fast coupling holder at time of shipment. (Refer to WP 0042; Operator Manual and Attachment R).

(ONLY Applicable for NEW Systems).

0.3.1

· Inventory the following parts:

Confirm presence Blade Basket (1), Blade Knife (1), Blade Handle (2), Blade Handle Pins (2), Blade Handle Pin Bolts (2), Blade Arms Connection with pins and bolts (2), and Blade Handle Square Tubes with pins and bolts (2). (Refer to WP 0048 and WP 0049; Operator Manual and Attachment P).

0.4.1

· Inventory the following parts:

Confirm presence Left and Right Roller Arms Caps (1) for each side, Left and Right Roller Arm Set (1) for each side, and Protective Shield Ensure left and right Protective Shield bolts are there with locking tabs. (Refer to WP 0050; Operator Manual and Attachment Q).

1.2

Inspect vehicle tracks for proper tension (Refer to WP0032; Operator Manual). (Adjustment Refer to WP 0033; Operator Manual).

1.3

Confirm presence of Antenna assemblies and inspect for damage, frayed cables, corrosion, and damage on machine. (Refer to WP 0041; Operator Manual).

1.4

Inspect Engine Air Pre-cleaner for cracks in the housing, Wing nut hand tight and check to ensure all 3 retaining springs are secured and check for cleanliness (Refer to WP 0029; Operator Manual). Clean as required.

1.5

Open all compartmental doors, front & rear hoods ensure seals are presence on front and rear hoods. Raise hydraulic oil cooler ensure all four seals are presence and Hydraulic Oil Cooler Bumper Kit is installed. (Refer to Attachment S).

Secured. (Refer to Attachment T).

indicator (1” above middle mark). Remove cap with filter check for damage, and proper fit. Reinstall cap with filter and Power up machine. Looking at VCP check to confirm proper levels 90% - 110%. Power down machine. *Note: Engine Cold.

check for damage, confirm fuel presence in tank. Looking at VCP check fuel level. *Note:

Fuel level reading must not exceed 25% due to shipping requirements. Do not lock cap.

-20° F with hydrometer. Check overflow hose and cap for damage, reinstall cap.

Operator Manual). Check engine oil filters for leaks.

safety pin lock is functional properly. Close all compartment doors and confirm proper latching of all compartment doors.

1.8

Inspect keypad on vehicle VCP for damage and Access Video Control Panel (VCP) General Information check

1.8.5

Verify/program correct tool attachment

Confirm Lower LCD reads at approx 12 sec: Upper line: MV-4, XXX, US ARMY Note XXX is veh. serial no.

Lower Line: “Software V. 2.05”

Upper Line reads: EPROM DATA OK!

Lower Line Reads MIRROR OK!

Upperline: “F1 Tool = 0%” Lower line: flashes between “No Feedback” and “OCU Batt = xx.x V”

2.3.13

Press 'S' button (Attachment refer Button 23) on the lower OCU keyboard to scroll through real-time vehicle status readings. (Refer to Attachment G)

2.4.1

Perform Keypad test (Refer to WP 0005; Operator manual)

2.5.3

Press “M” (Attachment “” button 25) button to get to Drift menu. Press up arrow button (Attachment “G”button 9) until max reading is “>15”. Press down arrow button (Attachment “G” button 10) until Min Reading is “<15”. Return reading to zero.

2.6.1

Press OCU Screen Display “S” settings button on upper OCU keypad once and confirm Menu screen appears and stays up for 10-20 sec. and goes off. (Refer to Attachment H)

(Refer to WP 0005; Operator manual)

Ensure Gear Box Bolt Tabs are mounted *Note: May need to move machine to align fluid check points. Make sure engine is shutdown during check.

(Refer to WP 0004; Operator manual and Attachment I)

Ensure Gear Box Bolt Tabs are mounted *Note: May need to move machine to align fluid check points. Make sure engine is shutdown during check.

(Refer to WP 0004; Operator manual and Attachment I)

Roller, blade, or Plow – 18” to 24” above ground.

Note: Shut down machine.

TABLE 1: Programming Data Chart (refer to Attachment D except as noted)

Machine hardware and OCU Serial Number Information

Blade Attachment Serial # Roller Attachment Serial #

NOTE: Please ensure all Serial Numbers are recorded in the exact format, including all alpha/numeric characters, special characters and spaces, as they are observed on the vehicle, OCU and various components.

Attachment B M160 reference Guide to Acceptance Test Procedure

VCP Keypad Performance Data test

Dated: 1 July 2016

ATP Revision: F ATP Date: 1 July 2016 Exhibit D, Acceptance Test Procedure (ATP) Attachment 0002, Acceptance Test Procedure (ATP) Attachment 0002, Acceptance Test Procedure (ATP)

DRAFT

UNLASSIFIED//FOR OFFICIAL USE ONLY

Subject to Restrictions Listed on Title Page

UNCLASSIFIED//FOR OFFICIAL USE ONLY

Subject to Restrictions Listed on Title Page

Attachment C

Verify/program correct tool attachment

Attachment D

System Self Check

Attachment E

OCU Inventory

July 2016

Attachment F

OCU Inspection

OCU Boot - Up Verification

Attachment H

OCU Upper LCD Checks

Attachment I

After Engine Start POL Gear Box Check

Attachment J

Blade Attachment Inventory

Attachment K

Roller Attachment Inventory

Attachment L

Hydraulic fast coupling holder

Attachment M

Hydraulic Oil Cooler Bumper Kit

Attachment N

MBCU Fasteners

Attachment O

Cooling Fan Housing seals

Spare Parts

Procedure

(ONLY Applicable for NEW Parts).

Attachment A M160 reference Guide to Acceptance Spare Parts Procedure Front Hood P/N 01-01-01

Attachment B

Rear Hood P/N 01-02-01

Attachment C

Front Transverse Hull Support P/N 01-09-04

Attachment D

Rear Transverse Hull Support P/N 01-06-00

Attachment E

Cooling Radiator Set P/N 06-08-00

Hydraulic Oil cooler P/N 05-16-00

Attachment G

Hydraulic Oil cooler P/N 03-12-00-R and 03-12-00-L

Attachment H

Clearing Tool Shaft Housing Cover P/N 03-07-02-02

Attachment I

Small Hydraulic Cylinder P/N 05-18-00

UNCLASSIFIED//FOR OFFICIAL USE ONLY

Subject to restrictions listed on title page.

UNCLASSIFIED//FOR OFFICIAL USE ONLY

Subject to restrictions listed on title page.

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