Attachment_0027_-_FSRR_Repair_Tasks.docx

Field Structural Repair Record Page: 2 of 17

Engineering Design and Development

STRYKER PROGRAM

FIELD STRUCTURAL REPAIR RECORD (FSRR)

Hull # Location:

Date (YY/MM/DD) Welder/Inspector:

(yyyy-mm-dd)

All conclusions and findings from this record shall be submitted electronically to Home Office Support Team (HOST) at host@gdls.com.

DISTRIBUTION STATEMENT D: Distribution authorized to the Department of Defense and DoD contractors only, per the STRYKER Security Classification Guide and Program Protection Plan. Date of determination is 27 March 2003. Other requests for this document shall be referred to Project Manager Brigade Combat Team, ATTN: SFAE-GCS-BCT, DSN 786-2000 or Commercial 586-753-2000

PURPOSE AND SCOPE

The purpose of this document is to provide a structured approach to authorizing common Stryker hull field repairs for field welders without the need of Engineering support and to provide a means of documenting the repair.

All findings and repairs on the damaged hull shall be submitted to GDLS-C Home Office Support Team (HOST) for document management. The cover page and section’s 4-8 shall be completed by the Welder/Inspector prior to submitting to HOST.

Note; A separate FSRR shall be submitted to HOST for each different set of weld parameters used per section 7 of this record.

Revision control chart

N/A

Table of Contents

HULL TYPE:

|_| FLAT BOTTOM |_| DOUBLE-V

repaired Damage (AS authorized PER SECTION 9):

Comments: ___________________ location of repaired DAMAGE (AS INDICATED PER SECTION 5):

equipment used in the repair & weld parameters:

Welding Process (GMAW / GTAW / SMAW):

Current Type (DCEP (Reverse Polarity) OR DCEN (Straight Polarity)):

Type / Model of Welding Machine:

Electrode (i.e. E7018): Weld Wire Lot#:

Filler Metal Classification (i.e. ER70S-6): Wire Diameter:

Shielding Gas Composition: Flow Rate (cu.ft./hr):

Position: |_| Flat |_| Horizontal |_| Overhead |_| Vertical Up |_| Vertical Down

Weld Joint Type: |_| Groove (Butt) |_| Lap |_| Corner |_| Tee |_| Other

Welding Parameters; Amperage(A): Wire Feed Speed(in/min): Voltage(V):

Number Of Passes Per Side; Side One: Side Two:

Interpass Cleaning: |_| Wire Brush |_| Grinding |_| None |_| Other

NOTE: Separate FSRR required when using different weld repair parameters.

material used in the repair Parts and Material (used to repair damage in section 5):

Comments:

authorized repairs All items identified in this section are common repairs and are authorized for repair without the need for Engineering support. The authorized hull type, Flat Bottom Hull (FBH) or Double V Hull (DVH), for each authorized item is identified in the description. Submission of a preliminary hull damage assessment is not required to complete the included repairs.

Weld(s)

Repair of small cracks equal to or less than 50mm in accumulated length which are contained within the weld metal only. Cracks which propagate into the heat affected zone (HAZ) or base material shall be dispositioned for engineering assessment.

FBH & DVH

Removal and replacement of common appurtenances as illustrated on drawing 10627790 or LS1080990 (typical examples shown below). Relocation of an appurtenance is not permitted without engineering assessment.

Steering flange crack repair. Repair of small, tight, cracks with a maximum length of 100mm in the factory weld is permitted. Repair is not authorized if there is evidence of a previous repair.

FBH

Removal and replacement of LH and RH steering stops.

Ref Drawing: 10642503 Lower Hull Welded (for ICV).

10627418

Removal and replacement of A-Frame Mounts (ref Fixture M-5686).

Ref Drawing: 10642671 A-Frame Bracket Instl.

10617423 10617558 10655455-011 10617560

10617559 10617558 10617560

10617424 *Note

* Note; Replacement of A-Frame Mounts where the LH#1 steering flange upgrade kit was previously installed, the following part numbers shall be substituted: 10665801-001, 10665800-001, & 10665817-011.FBH

#1 Axle front and rear and #2 axle front A-frame mounts welded to the engine floor only are authorized to be removed and replaced (ref Fixture M-6590).

Ref Drawing: LS1080641 A-Frame Brackets Instl.

LS1081374

LS1080654

LS1081396

DVH

Removal and replacement of Axle #1 and/or Axle #2 differential mounts (ref Fixture M-4776).

Ref Drawing: 10642668 Differential Mounts Instl.

10655859-001 10655859-001 10655859-001 10655859-001

FBH

10655860-001 10655862-001 10655858-001 10655861-001

Removal and replacement of Axle #1 and/or Axle #2 differential mounts welded to the engine floor only (RH vertical leg of the front main tunnel) (ref Fixture M-6535).

Ref Drawing: LS1082421 Driveline Mounting Bracket Asy Instl.

DVH

LS1082694

LS1082425

Removal and replacement of Axle #3 differential mounts (ref Fixture M-4280) and/or Axle #4 differential mounts (ref Fixture M-4786).

Ref Drawing: 10642668 Differential Mounts Instl.

10655861-001 (8x)

Minor (cosmetic) gouges and scratches on all lugs may be sanded smooth and repainted.

Gouge depth to be a maximum of 1/8” (3mm). Repair is not authorized if there is evidence of a previous repair.

Minor (cosmetic) gouges and scratches on all lugs may be sanded smooth and repainted.

Gouge depth to be a maximum of 1/8” (3mm). Repair is not authorized if there is evidence of a previous repair.

Bolt Tack Weld(s)

Tack welds on the rear ramp door hinge bolts (exterior of vehicle). These hinges and the tack welds on the bolt heads may be removed and replaced.

OLD Configuration

NEW Configuration

Rear ramp seal channel is often bent. The seal channel may be bent back to shape (ref pry bar below). Straight edges should be used to ensure the seal channel is as straight as possible post welding.

Rear Ramp Seal Channel Pry Bar

DM-4706

AFES brackets which can be repaired without full removal and replacement is authorized.

AFES brackets may be bent back into shape and cracked weld’s repaired but complete removal and replacement is not authorized. Weld cracks which propagate into the hull structure are not authorized for repair. Example locations of brackets below:

Roof/Rear Wall 10655862-001

10655862-001

Engine Bay / Center Roof

Gouge(s):

Gouges in weld covers may be repaired. A gouge is identified as a blunt groove or surface cavity resulting from material excavation. Weld cover gouges which are allowed to be repaired under this FSRR authority shall be:

A – Gouges 1/8” (3mm) deep up to ¼” (6mm) are to be filled with weld and ground smooth. Gouges with a depth less than 1/8” (3mm) need not be welded and shall be feathered out/ground smooth. Gouges over ¼” (6mm) are not authorized for repair.

Any sharp edges shall be ground smooth.

B – Gouge is confined within weld cover and does not extend into the hull plates.

C – There is no crack associated with the gouge.

D – Gouge area is less than 8 sq inches (5000 sq mm).

Dent(s):

Dents in weld covers, rear floor, LH and RH Sponson, driver’s floor, and engine floor need not be repaired. A dent is identified as a localized deformation of material which violates design profile and does not leave sharp edges.

Interior Weld Covers

Exterior Weld Covers

Damper Stud(s)

Steering Damper Stud may be removed and replaced if damaged.

10628528 Ref Drawing: 10651533 LH Front Floor Plate Assy.

Ref Template APCP1261

10628528 Ref Drawing: 10642513 RH Front Floor Plate Assy.

Ref Template ICVP1132

Steering Damper Studs may be removed and replaced if damaged.

Ref Drawing: LS1080506 Hull Welded.

LS1080780

Ref Fixture M-6286 or Fixture M-6600

LS1081094

Ref Template TPL01839 or Fixture M-6600 conclusion / findings This document is to be submitted in its entirety, no images/pages are to be deleted/removed from this document. The file naming convention of this assessment must be as follows;

· {Hull} - Field Structural Repair Record

Example 1: ICV-0691 – Field Structural Repair Record Example 2: MCV-0225 – Field Structural Repair Record

All conclusions and findings from this record shall be submitted electronically to Home Office Support Team (HOST) at host@gdls.com.

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