Attachment_0038_-_3126_FUPP_Technical_Inspection_Rev_1_(003).pdf

3126 FUPP Technical Inspection REV1 Latest Approved

JON:

Hull No.:

Odometer:

Hours:

Lead:

S - Servicable

A - Adjust

D - Drain/Refill

F - Fluid Leak

R - Repair

V - Service

C - Clean

T - Top up

X - Replace

L - Lube

M - Missing

N - Not Applicable

Status Legend:

STRYKER - TI

AUTO/HULL/TURRET

INSPECTION INSTRUCTIONS

Rounds Fired: (if applicable)

GDLS:

USG:

GDLS:

USG:

GDLS:

USG:

PSD Quality Out Inspection (Last) Incoming Tech Inspection (in) Outgoing Tech Inspection (out)

Signature Date Signature Date Signature Date

Record Engine Serial Number # In Out1

1) Record engine serial number/miles and hours

Air Tubes In Out2

a) Inspect all clamps for serviceability

b) Inspect air cross over tubes for serviceability

c) Inspect all other tubes and adaptor hoses for damage

d) Inspect Air Restriction Sensor for damage and orientation.

e) Ensure proper clearance between the Air Restriction Sensor and the Alternator.

Front Cover, Harmonic Balancer & Pulleys In Out3

a) Inspect for loose and missing hardware b Check for indications of oil leaks.

c) Check for emission sticker on front timing cover, apply if missing.

d) Check harmonic balancer for damage.

f) Check idler pulley for damage and bearing for wear

g) Inspect belt tensioner pulley assembly for damaged or missing hardware.

Front Engine Mountings In Out4

a) Inspect front engine mounts brackets for damage.

b) Ensure rubber mounts are in good condition

Page 1 of 14UNCLASSIFIED SENSITIVE For Official Use Only garciac

15-Jun-11

DISTRIBUTION STATEMENT D: Distribution authorized to the Department of Defense and U.S. DoD contractors only by specific authority of AR 380-5. Effective date of this document is 18 May 2009. Other requests for this document shall be referred to the Project Manager, STRYKER Brigade Combat Team, (PM SBCT), ATTN: SFAE-GCS-SBCT (Security Office), MS 325, Warren, MI 48397-5000.

Hull No.:

Odometer:

Hours:

Lead:

S - Servicable

A - Adjust

D - Drain/Refill

F - Fluid Leak

R - Repair

V - Service

C - Clean

T - Top up

X - Replace

L - Lube

M - Missing

N - Not Applicable

Status Legend:

STRYKER - TI

AUTO/HULL/TURRET

INSPECTION INSTRUCTIONS

Rounds Fired: (if applicable)

c) Inspect for any damaged or missing hardware

Water Pump In Out5

a) Check water pump for signs of leakage

b) Inspect hoses and clamps for damage and leaks

c) Inspect water pump belt for sign of damage or wear.

d) Inspect belt tensor for damage and serviceability

Alternator 280/570 AMP In Out6

Record alternator serial number

a) Inspect for loose or missing hardware

b) Inspect alternator housing for damage

c) Inspect alternator pulley for damage

d) Inspect negative battery cable connection (if equipped with 280 amp alt)

e) Inspect Connectors for damage

f) Inspect alternator brackets for damage

Transmission Cooler In Out7

a) Inspect transmission cooler bracket for loose or missing hardware and damage

b) Inspect transmission cooler for damage or leaks

c) Check all hoses for damage and leaks.

Oil Cooler In Out8

a) Inspect Oil Cooler housing for damage

b) Inspect hoses and seals for damage and leaks

Page 2 of 14UNCLASSIFIED SENSITIVE For Official Use Only garciac

15-Jun-11

Document subject to Distribution Statement D

Hull No.:

Odometer:

Hours:

Lead:

S - Servicable

A - Adjust

D - Drain/Refill

F - Fluid Leak

R - Repair

V - Service

C - Clean

T - Top up

X - Replace

L - Lube

M - Missing

N - Not Applicable

Status Legend:

STRYKER - TI

AUTO/HULL/TURRET

INSPECTION INSTRUCTIONS

Rounds Fired: (if applicable)

Exhaust Manifold & Turbo Charger Assembly In Out9

a) Inspect for loose or missing hardware

b) Inspect exhaust manifold for cracks or damage

c) Inspect exhaust manifold gaskets for signs of leakage

d) Check coolant supply and return tubes are tight and are not leaking

e) Inspect waste gate diaphragm and hose for damage

f) Remove all air transfer tubes and exhaust elbow from turbo charger and inspect for serviceability

g) Ensure there is no engine oil in the turbocharger housing assembly

Air Filter Housing Assembly In Out10

a) Inspect air filter housing for loose or missing hardware

b) Inspect air filter housing damage

c) Inspect seal for damage

d) Inspect air filter for serviceablility/clean.

e) Inspect scavenger hose and clamp for damage and serviceability

Engine Oil Pan In Out11

a) Inspect oil pan for any loose or missing hardware

b) Inspect oil pan for leaks and damage

Inlet Heater Assembly & Relay In Out12

a) Inspect the heater assembly and relay for any loose or missing hardware.

b) Inspect cables from the heater assembly to relay for damage and serviceability

Page 3 of 14UNCLASSIFIED SENSITIVE For Official Use Only garciac

Hull No.:

Odometer:

Hours:

Lead:

S - Servicable

A - Adjust

D - Drain/Refill

F - Fluid Leak

R - Repair

V - Service

C - Clean

T - Top up

X - Replace

L - Lube

M - Missing

N - Not Applicable

Status Legend:

STRYKER - TI

AUTO/HULL/TURRET

INSPECTION INSTRUCTIONS

Rounds Fired: (if applicable)

On Board Oil Exchanger In Out13

a) Inspect for loose or missing hardware

b) Inspect electrical connectors

c) Check fuel lines for leaks or damage

e) Inspect oil feed line QD for leaks & damage.

Cylinder Head In Out14

a) Inspect cylinder head assembly for loose or missing hardware

b) Inspect valve cover for damage or leaks

c) Inspect thermostat housing for leaks or damage

d) Check cylinder head gasket for external coolant leaks.

e) Inspect fuel pressure regulator for leaks

f) Inspect injector harness seal at the rear of the cylinder head

g) Inspect engine wiring harness for damage

h) Inspect all sensors for damage and serviceability

i) Inspect oil filler cap

Engine ECM In Out15

a) Inspect engine ECM for missing or loose hardware

Secondary Fuel Filter & Breather Assembly In Out16

a) Check mounts and assembly for loose or missing hardware

b) Check hose for cracks or splits

c) Check fuel filter mounting for leaks

Page 4 of 14UNCLASSIFIED SENSITIVE For Official Use Only garciac

Hull No.:

Odometer:

Hours:

Lead:

S - Servicable

A - Adjust

D - Drain/Refill

F - Fluid Leak

R - Repair

V - Service

C - Clean

T - Top up

X - Replace

L - Lube

M - Missing

N - Not Applicable

Status Legend:

STRYKER - TI

AUTO/HULL/TURRET

INSPECTION INSTRUCTIONS

Rounds Fired: (if applicable)

d) Inspect fuel lines for damage and leaks

HUEI Pump In Out17

a) Inspect HUEI pump for leaks.

b) Inspect fuel transfer pump for damage and leaks.

c) Inspect fuel lines for any leakage.

d) Check IAP valve for serviceability.

Oil Centrifuge In Out18

a) Check for any loose or missing hardware.

b) Check Centrifuge for any signs of leaks.

Oil Pressure Sensor & Switch In Out19

a) Check connections to oil pressure switch

b) Inspect the oil pressure T-fitting for leaks

c) Inspect oil transfer line for damage and leaks

Spin On Oil Filter Housing In Out20

a) Inspect oil filter mounting, ensure there are no leaks

b) Inspect oil sampling port

c) Inspect oil lines

Fuel Water Separator Assembly & Filter In Out21

a) Inspect for loose or missing mounting hardware

b) Check heater assembly for leaks and damage

c) Inspect heater assembly connector (w441 harness for damage)

Page 5 of 14UNCLASSIFIED SENSITIVE For Official Use Only garciac

Hull No.:

Odometer:

Hours:

Lead:

S - Servicable

A - Adjust

D - Drain/Refill

F - Fluid Leak

R - Repair

V - Service

C - Clean

T - Top up

X - Replace

L - Lube

M - Missing

N - Not Applicable

Status Legend:

STRYKER - TI

AUTO/HULL/TURRET

INSPECTION INSTRUCTIONS

Rounds Fired: (if applicable)

d) Inspect filter head assembly for leaks

e) Check operation of the manual fill plunger.

f) Inspect fuel lines and QD for damage and leaks

Air Compressor & Power Steering Pump In Out22

a) Inspect for loose or missing hardware

b) Coolant supply and return hoses for leaks and damage

c) Oil supply and return hoses for leaks or damage

d) Governor and QD for damage and serviceability

e) Outlet fitting for damage

f) Power steering pump housing for damage or leaks

g) Power steering supply hose and fitting for leaks

h) Inspect Power steering return hose for damage

Electrical Harness/Connectors/Cables In Out23

a) Inspect the w441 harness for damage

b) Inspect the w442 harness for damage

c) Inspect the w443 harness for damage

e) Inspect Caterpillar engine harness for damage

f) Verify all connections to engine sensors

Starter In Out24

a) Check for loose or missing hardware

b) Verify cables and connections

Page 6 of 14UNCLASSIFIED SENSITIVE For Official Use Only garciac

Hull No.:

Odometer:

Hours:

Lead:

S - Servicable

A - Adjust

D - Drain/Refill

F - Fluid Leak

R - Repair

V - Service

C - Clean

T - Top up

X - Replace

L - Lube

M - Missing

N - Not Applicable

Status Legend:

STRYKER - TI

AUTO/HULL/TURRET

INSPECTION INSTRUCTIONS

Rounds Fired: (if applicable)

c) Check starter housing for damage

Service checks if applicable In Out25

a) Check coolant for any signs for contamination

b) Check oil for any signs of contamination

Transmission In Out26

Record Transmission Serial Number & TCU Serial Number

a) Ensure Mounting Bolts Are Secure To Engine.

b) Inspect Transmission Oil Pan Gasket for leaks.

c) Inspect drain plug for leaks or damage.

d) Ensure transmission filter housings are not leaking.

e) Inspect transmission dipstick tube for damage or leaks.

f) Ensure the transmission dipstick is not damaged.

g) Inspect both transmission speed sensors are not damaged.

Power Take Off Unit (Aux pump left side) In Out27

a) Inspect mounting flanges for leaks

b) Inspect pump mounting for signs of cracks or damage and leaks

c) Check hoses for leaks

d) Inspect compensator for leaks and damage

e) Inspect remote compensator and manifold block for leaks

f) Inspect remote compensator bracket for cracks

g) Check hydraulic pump for signs of leaks

Page 7 of 14UNCLASSIFIED SENSITIVE For Official Use Only garciac

Hull No.:

Odometer:

Hours:

Lead:

S - Servicable

A - Adjust

D - Drain/Refill

F - Fluid Leak

R - Repair

V - Service

C - Clean

T - Top up

X - Replace

L - Lube

M - Missing

N - Not Applicable

Status Legend:

STRYKER - TI

AUTO/HULL/TURRET

INSPECTION INSTRUCTIONS

Rounds Fired: (if applicable)

Power Take off Unit (Fan Pump right side) In Out28

a) Inspect mounting flanges for leaks

b) Inspect pump mounting for signs of cracks or damage and leaks

c) Check hoses for leaks

Parking Brake Assembly In Out29

a) Inspect Parking Brake Drum For Any Signs Of Damage Or Overheating

b) Inspect Parking Brake Adjustment Rod For Damage

c) Check Parking Brake Actuator For Damage And Ensure Its Secured To The Frame Rail

d) Check Parking Brake Quick Release Valve Hose and QD For Damage

e) Check For Leaks From The Transmission Flange Seal

f) Inspect brake shoes for excessive wear and grooves

g) Inspect park brake assembly for damage

Jack Shaft Assembly In Out30

a) Check For Any Loose Or Missing Hardware

b) Ensure Both U-Joints Move Freely And Check For Serviceablity

c) Inspect Jack Shaft Flanges For Damage

d) Inspect Jack Shaft Support Bracket For Damage

Surge Tank & Radiator Cap In Out31

a) Check surge tank for damage

b) Check hoses for leaks and signs of damage

c) Check sight glass for damage and leaks

Page 8 of 14UNCLASSIFIED SENSITIVE For Official Use Only garciac

Hull No.:

Odometer:

Hours:

Lead:

S - Servicable

A - Adjust

D - Drain/Refill

F - Fluid Leak

R - Repair

V - Service

C - Clean

T - Top up

X - Replace

L - Lube

M - Missing

N - Not Applicable

Status Legend:

STRYKER - TI

AUTO/HULL/TURRET

INSPECTION INSTRUCTIONS

Rounds Fired: (if applicable)

d) Inspect filler neck for damage

e) Pressure test cooling system and check for leaks

f) Check radiator cap for damage

g) Pressure test radiator cap

h) Inspect Over flow bottle and hose for serviabilty

Thermal Control Manifold In Out32

a) Inspect for leaks at fittings

b) Inspect for leaks at the QD

c) Inspect hoses for damage and leaks

d) Check for coolant leaks

Cooling Fan Assembly In Out33

a) Check fan assembly for damage

b) Inspect fan Shroud housing for signs of damage.

c) Inspect fan motor for oil leaks

d) Check fan hydraulic hoses for damage and leaks

Cooling Tower Assembly In Out34

a) Inspect mounts rails for damage or cracks

b) Check mounting isolators for damage

c) Check transfer case cooler and lines for damage and leaks

d) Inspect hydraulic cooler and lines for damage and leaks

e) Inspect fuel cooler and lines for leaks and damage

Page 9 of 14UNCLASSIFIED SENSITIVE For Official Use Only garciac

Hull No.:

Odometer:

Hours:

Lead:

S - Servicable

A - Adjust

D - Drain/Refill

F - Fluid Leak

R - Repair

V - Service

C - Clean

T - Top up

X - Replace

L - Lube

M - Missing

N - Not Applicable

Status Legend:

STRYKER - TI

AUTO/HULL/TURRET

INSPECTION INSTRUCTIONS

Rounds Fired: (if applicable)

f) Inspect air charge cooler for leaks

g) Ensure seals between the air charge cooler and radiator are present

h) Inspect radiator for damage and leaks.

i) Inspect drain cock for leaks or damage

Hydraulic Tank In Out35

a) Ensure the tank is secure to the cooling module

b) Check cap for damage

c) Inspect the strainer and gasket for damage

d) Inspect the hydraulic tank for cracks, dents or damage

e) Inspect sight glass for damage or leaks

f) Ensure all hoses are free from damage or leaks

g) Inspect Qds for serivablity

h) Inspect senosrs for leaks or servicablitly

Air Conditioning In Out36

a) Inspect for loose or missing hardware

b) Inspect a/c compressor 1 & 2 for signs of damage and leaks

c) Inspect a/c condensers for signs of damage or leaks

d) Inspect all hoses for signs of damage proper routing and leaks

e) Check a/c hydraulic motors for leaks

f) Check a/c hydraulic lines for damage or leaks and routing

g) Ensure the a/c motor to compressor couplers are not damage and are serviceable

Page 10 of 14UNCLASSIFIED SENSITIVE For Official Use Only garciac

Hull No.:

Odometer:

Hours:

Lead:

S - Servicable

A - Adjust

D - Drain/Refill

F - Fluid Leak

R - Repair

V - Service

C - Clean

T - Top up

X - Replace

L - Lube

M - Missing

N - Not Applicable

Status Legend:

STRYKER - TI

AUTO/HULL/TURRET

INSPECTION INSTRUCTIONS

Rounds Fired: (if applicable)

h) Inspect a/c 1 & 2 accumulators for damage or signs of leakage

i) Inspect evaporator housing for damage

j) Inspect evaporator housing for blocked drainage

k) Inspect duck bill and hose for damage

l) Inspect evaporators for damage

m) Ensure the air filters are present on the evaporators

n) Check electrical harness on the high & low switches on the rear of A/C compressors 1 & 2

Winch Supply Hoses In Out37

a) Inspect Winch Supply hoses for damage and leaks

b) Ensure Winch supply QDs are servicable

Hydraulic Manifold In Out38

a) Check for missing or loose hardware

b) Inspect wiring harness for damage

c) Check hydraulic manifold for leaks

d) Check all hoses for leaks and QDs. Inspect hoses for proper position and Servicability.

e) Inspect HMS solenoid for serviceability

f) Inspect Winch solenoid for serviceability

g) Inspect A/C# 1 solenoid for serviceability

h) Inspect A/C# 2 solenoid for serviceability

i) Inspect the Ramp solenoid for serviceability

j) Check hydraulic manifold bracket for damage or cracks

Page 11 of 14UNCLASSIFIED SENSITIVE For Official Use Only garciac

Hull No.:

Odometer:

Hours:

Lead:

S - Servicable

A - Adjust

D - Drain/Refill

F - Fluid Leak

R - Repair

V - Service

C - Clean

T - Top up

X - Replace

L - Lube

M - Missing

N - Not Applicable

Status Legend:

STRYKER - TI

AUTO/HULL/TURRET

INSPECTION INSTRUCTIONS

Rounds Fired: (if applicable)

Diagnostic Troubleshooting Codes In Out39

a) Record Caterpillar Engine Logged codes or event Codes.

b) Record Allison Transmission Troubleshooting Codes.

Engine Start Up In Out40

FOLLOW INSTRUCTION ACCORDING TO THE ENGINE RUN UP MODUDLE ONLY AND

THE IETM FOR THE FOLLOWING TASKS AND RECORD THE FOLLOWING

INFORMATION.

a) Record engine start up temperature

b) Record engine oil pressure (psi) ____________________

c) Record actuation pressure (psi) _________________________

d) Record Desired actuation pressure (psi) ______________

e) Record Injection Actuation Output ________________

f) Record Charging System voltage _______

Engine Running ( at Operatating Temp) In Out41

a) Engine start up temperature _______________

b) Engine oil pressure ____________ (psi)

c) Injection Actuation pressure ________(psi)

d) Desired Injection actuation pressure ________ (psi)

e) Injection Actuation Output _____________

f) Charging System voltage ______________

g) Perform engine cylinder cut out test at idle (Print out results)

h) Perform engine cylinder cut out test at 1200 rpm (Print out results)

Page 12 of 14UNCLASSIFIED SENSITIVE For Official Use Only garciac

Hull No.:

Odometer:

Hours:

Lead:

S - Servicable

A - Adjust

D - Drain/Refill

F - Fluid Leak

R - Repair

V - Service

C - Clean

T - Top up

X - Replace

L - Lube

M - Missing

N - Not Applicable

Status Legend:

STRYKER - TI

AUTO/HULL/TURRET

INSPECTION INSTRUCTIONS

Rounds Fired: (if applicable)

System Operations Testing In Out42

a) Fast idle operational

b) Parking brake operational

c) Power steering operational 2000 psi @ 700 rpm gpm______

d) Cooling fan operational ______psi @700rpm @________degrees

e) Hydraulic manifold pressure ______psi @700 rpm

f) Ramp open ______psi @ 700 rpm

g) HMS open _______psi @700 rpm

h) A/C#1 open _______psi @700 rpm

i) A/C#2 open _______psi @700 rpm

j) Boost pressure ________psi @2840 top engine limit

k) Set air governor to 135 psi

l) A/C #1 Temp_____________ A/C #2 Temp_________

m) Print Allison Diagnostic Screen

Engine Run Up Close Out In Out43

a) Technician to verify engine ECM parameters and changed vehicle ID

b) Engine passed cylinder cut out test @ 700 and 1200 rpm

c) Engine passed injection actuation pressure test

Page 13 of 14UNCLASSIFIED SENSITIVE For Official Use Only garciac

Hull No.:

Odometer:

Hours:

Lead:

S - Servicable

A - Adjust

D - Drain/Refill

F - Fluid Leak

R - Repair

V - Service

C - Clean

T - Top up

X - Replace

L - Lube

M - Missing

N - Not Applicable

Status Legend:

STRYKER - TI

AUTO/HULL/TURRET

INSPECTION INSTRUCTIONS

Rounds Fired: (if applicable)

Comments:

Page 14 of 14UNCLASSIFIED SENSITIVE For Official Use Only garciac