Attachment_0039_-_C-7__FUPP_Technical__Inspection_REV_1.pdf
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- W56HZV-18-R-0048
About this file
This technical inspection document outlines inspection requirements and procedures for a C-7 FUPP engine. It details 43 separate inspection points covering the engine, transmission, cooling system, hydraulics, electrical systems, and other components. Inspections are to be performed upon receipt and delivery of the vehicle and include examining components for damage, leaks, loose or missing hardware, and other issues. Technicians must record results, part numbers, measurements, and other requested data. Startup procedures specify checking oil pressure, injection pressures, voltage, and performing cylinder cutoff tests at idle and higher rpm. Operational tests of systems like parking brakes, steering, fans, and hydraulics are also outlined.
The related federal contract opportunity notice indicates the Army intends to solicit proposals for a five-year requirements contract for Stryker vehicle retrofit, reset/refurbishment, and damage repair services. The acquisition will be sole-sourced to General Dynamics as the incumbent. Proposals are due by September 30, 2018. No technical data is currently available. The work will support the Army Materiel Command at the Detroit Arsenal.
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C-7 FUPP Technical Inspection REV 1 Latest Approved
JON:
Hull No.:
Odometer:
Hours:
Lead:
S - Serviceable
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:
Technical Inspection
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 orientation and damage.
e) Ensure proper clearance between the Air Restriction Sensor and the Alternator.
Front Cover, Harmonic Balancer & Pulleys In Out3
a) Inspect for loose or 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.
e) Check Idler Pulley for damage and Bearing for wear.
f) Inspect BeltTensioner Pulley assembly for damaged or missing hardware.
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DISTRIBUTION STATEMENT D.
Distribution authorized to the Department of Defense and U.S. DoD contractors only. (Reason: Export Controlled) (Date of Determination: 1 October 2015). Other requests shall be referred to the Project Manager, Stryker Brigade Combat Team, (PM SBCT), ATTN: SFAE-GCS-SBCT, 6501 E. 11 Mile Road, MS 325, Warren, MI 48397-5000.
WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979 (Title 50, U.S.C., App. 2401 et seq.), as amended.
Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.
Hull No.:
Odometer:
Hours:
Lead:
S - Serviceable
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:
Technical Inspection
AUTO/HULL/TURRET
INSPECTION INSTRUCTIONS
Rounds Fired: (if applicable)
Engine Mounts In Out4
a) Inspect all engine mounting brackets for damage.
b) Ensure rubber mounts are in good condition.
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 signs of damage or wear.
d) Inspect Belt Tensor for damage and serviceability.
Alternator 570 AMP In Out6
a) Record alternator serial number. S/N______________________________
b) Inspect for loose or missing hardware.
c) Inspect Alternator Housing for damage.
d) Inspect Alternator Pulley for damage.
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.
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USE AND DISCLOSURE OF TECHNICAL DATA CONTAINED ON THIS SHEET IS SUBJECT TO ANY RESTRICTION AND
DISTRIBUTION STATEMENT ON THE TITLE PAGE OF THIS DOCUMENT.
Hull No.:
Odometer:
Hours:
Lead:
S - Serviceable
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:
Technical Inspection
AUTO/HULL/TURRET
INSPECTION INSTRUCTIONS
Rounds Fired: (if applicable)
c) Inspect all Clamps and 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.
c) Inspect Oil Cooler Housing for loose or missing hardware.
Exhaust Manifold & Turbo Charger Assembly In Out9
a) Inspect Exhaust Manifold and Turbocharger for loose or missing hardware.
b) Inspect Exhaust Manifold for cracks or damage.
c) Inspect Exhaust Manifold Gaskets for signs of leakage.
d) Check Turbocharger Coolant supply and return tubes for security and signs of leaking.
e) Check Turbocharger Oil supply and return tubes for security and signs of leaking.
f) Inspect Turbocharger Waste Gate Diaphragm and Hose for damage.
g) Remove all Air Transfer Tubes and Exhaust Elbow from Turbocharger and inspect for serviceability.
h) 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 for damage.
c) Inspect Air Filter Housing Seal for damage.
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Hull No.:
Odometer:
Hours:
Lead:
S - Serviceable
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:
Technical Inspection
AUTO/HULL/TURRET
INSPECTION INSTRUCTIONS
Rounds Fired: (if applicable)
d) Inspect Air Filter for serviceablility/cleanliness.
e) Inspect Scavenger Hose and clamps 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.
c) Inspect Oil Drain Hose for leaks and damage.
Inlet Heater Assembly & Relay In Out12
a) Inspect the Air Heater Assembly and Relay for any loose or missing hardware.
b) Inspect Cables from the Heater Assembly to Relay for damage and serviceability.
On Board Oil Exchanger In Out13
a) Inspect On Board Oil Exchanger for loose or missing hardware.
b) Inspect Electrical Connectors.
c) Check Fuel Lines for leaks or damage.
d) 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.
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Hull No.:
Odometer:
Hours:
Lead:
S - Serviceable
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:
Technical Inspection
AUTO/HULL/TURRET
INSPECTION INSTRUCTIONS
Rounds Fired: (if applicable)
e) Inspect Fuel Pressure Regulator for leaks.
f) Inspect Injector Harness Seal at the rear of the Cylinder Head for security and damage.
g) Inspect Engine Wiring Harness for damage.
h) Inspect all Sensors for damage and serviceability.
i) Inspect Oil Filler Cap for security and damage.
Engine ECM In Out15
a) Inspect Engine ECM for missing or loose hardware.
Secondary Fuel Filter & Breather Assembly In Out16
a) Check Secondary Fuel Filter Mounts and Assembly for loose or missing hardware.
b) Check Hoses for cracks or splits.
c) Check Fuel Filter Mounting for leaks.
d) Inspect Fuel Lines for damage and leaks.
HEUI Pump In Out17
a) Inspect HEUI Pump for leaks.
b) Inspect Fuel Transfer Pump for damage and leaks.
c) Inspect Fuel Lines for any leakage.
d) Check IAP (Injection Actuation Pressure) Control Valve for serviceability.
Oil Centrifuge In Out18
a) Check for any loose or missing hardware.
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Hull No.:
Odometer:
Hours:
Lead:
S - Serviceable
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:
Technical Inspection
AUTO/HULL/TURRET
INSPECTION INSTRUCTIONS
Rounds Fired: (if applicable)
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 for serviceability and signs of leaks.
c) Inspect Oil Lines for abnormal wear and signs of leaks.
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.
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) Inspect Coolant Supply and Return Hoses for leaks and damage.
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Hull No.:
Odometer:
Hours:
Lead:
S - Serviceable
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:
Technical Inspection
AUTO/HULL/TURRET
INSPECTION INSTRUCTIONS
Rounds Fired: (if applicable)
c) Inspect Oil Supply and Return Hoses for leaks or damage.
d) Inspect Governor and QD for damage and serviceability.
e) Inspect Outlet fitting for damage.
f) Inspect Power Steering Pump Housing for damage or leaks.
g) Inspect 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 w551 Harness for damage.
b) Inspect the w552 Harness for damage.
c) Inspect the w553 Harness for damage.
d) Inspect Caterpillar Engine Harness for damage.
e) Verify all connections to Engine Sensors.
Starter In Out24
a) Check for loose or missing hardware.
b) Verify Cables and Connections.
c) Check Starter Housing for damage.
Service checks if applicable In Out25
a) Check Coolant Strength and for any signs for contamination.
b) Check Engine Oil for any signs of contamination.
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Hull No.:
Odometer:
Hours:
Lead:
S - Serviceable
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:
Technical Inspection
AUTO/HULL/TURRET
INSPECTION INSTRUCTIONS
Rounds Fired: (if applicable)
c) Check Transmission Fluid for signs of contamination.
d) Check Hydraulic Fluid for signs of contamination.
Transmission In Out26
a) Record Transmission Serial Number & TCU Serial Number S/N___________________ S/N___________________
b) Ensure Mounting Bolts are secure to Engine.
c) Inspect Transmission Oil Pan Gasket for leaks.
d) Inspect Drain Plug for leaks or damage.
e) Ensure Transmission Filter Housings are not leaking.
f) Inspect Transmission Dipstick Tube for damage or leaks.
g) Ensure the Transmission Dipstick is not damaged.
h) 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.
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Hull No.:
Odometer:
Hours:
Lead:
S - Serviceable
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:
Technical Inspection
AUTO/HULL/TURRET
INSPECTION INSTRUCTIONS
Rounds Fired: (if applicable)
g) Check Hydraulic Pump for signs of leaks.
Power Take off Unit (Fan Pump right side) In Out28
a) Inspect mounting flanges for leaks.
b) Inspect Pump Mount for signs of cracks, leaks or damage.
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 Transmission Flange Sea for leaks.
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.
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Hull No.:
Odometer:
Hours:
Lead:
S - Serviceable
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:
Technical Inspection
AUTO/HULL/TURRET
INSPECTION INSTRUCTIONS
Rounds Fired: (if applicable)
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.
d) Inspect Filler Neck 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 and Rails for damage or cracks.
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Hull No.:
Odometer:
Hours:
Lead:
S - Serviceable
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:
Technical Inspection
AUTO/HULL/TURRET
INSPECTION INSTRUCTIONS
Rounds Fired: (if applicable)
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 Air Charge Cooler for leaks.
f) Ensure Seals between the Air Charge Cooler and Radiator are present.
g) Inspect Radiator for damage and leaks.
h) Inspect Drain Cock for leaks or damage.
Hydraulic Tank In Out35
a) Ensure theTank is secure to the Cooling Module.
b) Check Cap for damage.
c) Inspect the Strainer and Gasket for damage.
d) Inspect the HydraulicTank 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 QD's for serivablity.
h) Inspect Senosrs for leaks or servicablitly.
Air Conditioning In Out36
a) Inspect for loose or missing hardware.
b) Inspect A/C Compressors 1 & 2 for signs of damage and leaks.
Page 11 of 15UNCLASSIFIED SENSITIVE For Official Use Only craigp
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Hull No.:
Odometer:
Hours:
Lead:
S - Serviceable
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:
Technical Inspection
AUTO/HULL/TURRET
INSPECTION INSTRUCTIONS
Rounds Fired: (if applicable)
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) CheckA/C Hydraulic lines for damage or leaks and routing.
g) Ensure the A/C Motor to Compressor Couplers are not damage and are serviceable.
h) Inspect A/C 1 & 2 Accumulators for damage or signs of leakage.
i) Inspect Evaporator Housing for damage.
j) Inspect Evaporator Housing for a blocked drain.
k) Inspect Duck Bill Drain 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 QD's are servicable.
Hydraulic Manifold In Out38
a) Check for missing or loose hardware.
b) Inspect Wiring Harness for damage.
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Hull No.:
Odometer:
Hours:
Lead:
S - Serviceable
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:
Technical Inspection
AUTO/HULL/TURRET
INSPECTION INSTRUCTIONS
Rounds Fired: (if applicable)
c) Check Hydraulic Manifold for leaks.
d) Check all hoses and QD's for leaks. Inspect hoses for proper routing 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.
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 ________________
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Hull No.:
Odometer:
Hours:
Lead:
S - Serviceable
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:
Technical Inspection
AUTO/HULL/TURRET
INSPECTION INSTRUCTIONS
Rounds Fired: (if applicable)
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)
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
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Hull No.:
Odometer:
Hours:
Lead:
S - Serviceable
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:
Technical Inspection
AUTO/HULL/TURRET
INSPECTION INSTRUCTIONS
Rounds Fired: (if applicable)
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
Comments:
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File details come from the government source that posted it. Updated .