Rev 2.
2020
SECTION III. PRESENTATION
A. ENABLING LEARNING OBJECTIVE
ACTION:
Perform Suspension Maintenance on the Stryker DVHA1 Vehicles
CONDITIONS:
Given a Stryker ICVVA1, with necessary technical manual, tools,
basic issue items, equipment, supplies and additional soldiers to
assist as necessary. Task may be performed in either a shop or
field environment.
STANDARDS:
Selected correct technical manual procedures top perform
suspension maintenance on the Stryker DVHA1 Vehicles, without
injury to personnel or damage to equipment.
1. Learning Step / Activity 1. Suspension Description and Function
Method of Instruction: Practical Exercise / Demonstration
Instructor to Student Ratio: 1:4
Time of Instruction: 30 mins
Media: Small Group Instruction (SGI)
Suspension System:
Figure 1
(FLM 91S) 5-5
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1. The suspension system uses eight independent hydropneumatic struts, which provide improved
vehicle stability and traction on all types of terrain and maximize driver, crew and troop comfort.
The suspension system consists of four front hydropneumatic struts (Figure 1, Item 1), four rear
hydropneumatic struts (Figure 1, Item 2), eight wheel drives (Figure 1, Item 5), eight wheel drive
shafts (Figure 1, Item 3), eight brake assemblies (Figure 1, Item 4) and eight wheel rims and tires
(Figure 1, Item 6).
Front Suspension:
Figure 2
1. Each of the four front suspensions uses a hydropneumatic strut (Figure 2, Item 3), steering
knuckle (Figure 2, Item 4) and control arm (Figure 2, Item 5), which allow for approximately 13.4
in. (340mm) of vertical travel and provide rotational movement for steering capabilities. The
hydropneumatic strut consists of nitrogen gas (the spring) over hydraulic fluid (the damper),
separated by a sealed piston.
(FLM 91S) 5-6
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Figure 3
2. The two front hydropneumatic struts (Figure 2, Item 3) on each side of the vehicle are linked
together to form two quadrants (left front and right front) through the nitrogen charge fittings
(Figure 2, Item 1), located on each hydropneumatic strut, and the hydropneumatic manifold
(Figure 2, Item 2), located on the second axle strut tower. This link allows a controlled exchange
of nitrogen between hydropneumatic struts in each quadrant. This link also enables vehicle
weight to be evenly distributed over the first and second axle suspension assemblies which
provides better tire traction and a smoother ride. This allows both hydropneumatic struts a
quadrant to be charged with nitrogen at the same time. The hydropneumatic strut is mounted on
the hull strut tower and on the steering knuckle. The steering knuckle (Figure 3, Item 3) is
supported by the control arm (Figure 3, Item 2), which uses a ball joint (Figure 3, Item 5) and two
bearing assemblies (Figure 3, Item 1) to control rotational and vertical movement of the front
suspension. The steering knuckle provides mounting for the wheel drive (Figure 3, Item 6), brake
assembly (Figure 3, Item 4) and wheel rim and tire (Figure 3, Item 7).
3. The hydropneumatic suspension handles uneven terrain by transferring nitrogen gas back and
forth between the first and second suspension struts (Figure 2, Item 3). This helps to equalize
pressure, absorb impact and maximize tire-to-ground contact.
4. The equalization of pressure, absorption of impact and maximum tire-to-ground contact are
achieved through a series of steps. First, the upward movement of the first axle tire, wheel rim
(Figure 3, Item 7) and steering knuckle (Figure 3, Item 3) causes hydraulic fluid in the first axle
hydropneumatic strut to push against the sealed piston. Movement of the sealed piston is
dampened by the controlled flow of hydraulic fluid (the damper) in both directions. The sealed
piston compresses the nitrogen gas (the spring), causing the transfer of some of the nitrogen gas
through the hydropneumatic manifold (Figure 2, Item 2) into the second axle hydropneumatic
strut. This additional nitrogen gas causes the second axle suspension's sealed piston, hydraulic
fluid, steering knuckle and wheel rim and tire to move downward and provide better tire-to-ground
contact.
(FLM 91S) 5-7
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5. The upward movement of the second axle suspension's tire, wheel rim (Figure 3, Item 7) and
steering knuckle (Figure 3, Item 3) causes the hydraulic fluid in the second axle hydropneumatic
strut (Figure 2, Item 3) to push against the sealed piston. Movement of the sealed piston is
dampened by the controlled flow of hydraulic fluid (the damper) in both directions. The sealed
piston compresses the nitrogen gas (the spring), causing the transfer of some of the nitrogen gas
through the hydropneumatic manifold (Figure 2, Item 2) into the first axle hydropneumatic strut.
This additional nitrogen gas causes the first axle suspension's sealed piston, hydraulic fluid,
steering knuckle and wheel rim and tire to move downward and provide better tire-to-ground
contact.
Rear Suspension:
Figure 4
1. Each of the four rear suspensions uses a hydropneumatic strut (Figure 4, Item 1), trailing arm
(Figure 4, Item 5) and stabilizer bar (Figure 4, Item 4). The hydropneumatic strut consists of
nitrogen gas (the spring) over hydraulic fluid (the damper), separated by a sealed piston.
(FLM 91S) 5-8
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2. The two rear axle hydropneumatic struts (Figure 4, Item 1) on each side of the vehicle are linked
together to form two quadrants (left rear and right rear) through nitrogen charge fittings (Figure 4,
Item 2), located on each hydropneumatic cylinder, and a hydropneumatic manifold (Figure 4, Item
3), located in the troop compartment. This link allows a controlled flow of nitrogen between
hydropneumatic struts in each quadrant. This link also enables vehicle weight to be evenly
distributed over both suspension assemblies which provides better traction and a smoother ride.
This allows both hydropneumatic struts a quadrant to be charged with nitrogen at the same time.
The hydropneumatic strut is mounted on the trailing arm (Figure 4, Item 5), which provides
mounting for the stabilizer bar (Figure 4, Item 4), wheel drive (Figure 4, Item 8), brake assembly
(Figure 4, Item 6) and wheel rim and tire (Figure 4, Item 7). Each trailing arm is splined to mate
with the splines on each end of the stabilizer bar. This process enables the left and right rear
suspensions to be linked together to counteract inclination of the vehicle during cornering and to
control vertical and horizontal movement of the wheel rim and tire.
3. The hydropneumatic suspension handles uneven terrain by transferring nitrogen gas back and
forth between the third and fourth axle hydropneumatic cylinders. This helps to equalize pressure,
absorb impact and maximize tire-to-ground contact.
4. The equalization of pressure, absorption of impact and maximum tire-to-ground contact are
achieved through a series of steps. First, the upward movement of the third axle tire and wheel
rim (Figure 4, Item 7) causes the trailing arm (Figure 4, Item 5) to pivot upward. The pivoting
action of the trailing arm causes hydraulic fluid in the third axle suspension's hydropneumatic
cylinder to push against the sealed piston. Movement of the sealed piston is dampened by the
controlled flow of hydraulic fluid (the damper) in both directions. The sealed piston compresses
the nitrogen gas (the spring), causing the transfer of some of the nitrogen gas through the
hydropneumatic manifold (Figure 4, Item 3) into the fourth axle suspension's hydropneumatic
strut (Figure 4, Item 1). This additional nitrogen gas causes the fourth axle suspension's sealed
piston, hydraulic fluid, trailing arm and wheel rim and tire to move downward and provide better
tire-to-ground contact.
5. The upward movement of the fourth axle suspension's tire, wheel rim (Figure 4, Item 7) and
trailing arm (Figure 4, Item 5) causes the hydraulic fluid in the fourth axle suspension's
hydropneumatic strut (Figure 4, Item 1) to push against the sealed piston. Movement of the
sealed piston is dampened by the controlled flow of hydraulic fluid (the damper) in both directions.
The sealed piston compresses the nitrogen gas (the spring), through the hydropneumatic
manifold (Figure 4, Item 3) into the third axle suspension's hydropneumatic strut. This additional
nitrogen gas causes the third axle suspension's sealed piston, hydraulic fluid, trailing arm and
wheel rim and tire to move downward and provide better tire-to-ground contact.
6. The stabilizer bar (Figure 4, Item 4), located at both the third and fourth axle suspension
assemblies, counteracts inclination of the vehicle during cornering. When turning right, the right
side of the vehicle lifts, causing the left trailing arm (Figure 4, Item 5) to pivot upward. The
stabilizer bar applies a downward pressure to the right trailing arm to counteract the upward
movement of the right side of the vehicle. The stabilizer bar has the opposite effect on the left
trailing arm when the vehicle is turning left. A rubber bumper is mounted on the hull and provides
additional damping to prevent the trailing arm from impacting the hull.
(FLM 91S) 5-9
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Height Management
Figure 5
1. The Height Management System (HMS) design allows for the vehicle suspension to be set at its
optimum operating height over a wide range of load and ambient temperature conditions, when
initiated by the operator. This is accomplished by the transfer of nitrogen between the quadrants
and the HMS manifold. In addition, the HMS allows the operator to select suspension settings for
different modes of operation.
2. The HMS has three modes of operation. The nominal mode is used to return the vehicle to
optimum operating height when load and/or temperature conditions vary. The mine ride high
mode raises the vehicle to the highest position to reduce the effects of a mine blast in high-risk
areas. The transport mode is used to bring the vehicle down to an acceptable height for
transportation by aircraft, by sea, by truck or by rail. The Engineer Squad Vehicle (ESV) has its
own operation-specific mode.
(FLM 91S) 5-10
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3. The HMS consists of four height sensors (Figure 5, Item 1), a Height Management Unit (HMU)
(Figure 5, Item 3), an air transport box assembly (Figure 5, Item 4) and a height control manifold
(Figure 5, Item 2), along with several cables, hoses and tubes. The four sensors, located on the
first and third axles, on each side of the vehicle, provide vehicle height information to the HMU .
4. The height control manifold (Figure 5, Item 2) connects to each quadrant (hydropneumatic strut
pair) of the vehicle. It contains a transfer pump and a series of electrically actuated nitrogen
control valves. The nitrogen is stored in five high pressure reservoirs. The HMU (Figure 5, Item 3)
controls suspension height by opening nitrogen control valves to add or remove nitrogen from the
quadrants. When initiated by the operator, the HMU will raise a quadrant, if necessary, by
opening the appropriate valves to connect the quadrant(s) to the high pressure reservoir for a
specified time. To lower a quadrant, the HMU opens the appropriate valves to allow nitrogen from
the struts to be converted back to high pressure nitrogen with a transfer pump powered by the
vehicle hydraulic system. The HMU constantly samples and filters the four height sensors (Figure
5, Item 1). When vehicle leveling is initiated, the HMU adjusts the hydropneumatic struts in each
quadrant to the optimum length as required. For detailed operation of the HMU, refer to Height
Management System Operation
5. The air transport box assembly (Figure 5, Item 4) incorporates a two-position air transport switch,
a capped electrical connector labeled J2 and a non-functional emergency air switch. The air
transport switch has two positions that determine the operating mode of the system. The normal
operating position for this switch is down, which places the system in nominal mode. The up
position is used as an interlock, which allows the transport mode to be initiated. The capped
electrical connector provides a means to calibrate the system.
6. The system-not-available light will flash if there is an operating condition that prevents the system
from working in normal mode, such as vehicle speed, braking, hard cornering or driving over
rough terrain. The HMU contains accelerometers that monitor for these conditions. The system-
not-available light will also flash when in all modes other than the normal mode.
7. The system fault light will flash if there is a failure in the system. The failure could prevent the
system from operating at maximum performance levels or render the system inoperable. The
system will continue to be operational under some failure conditions. The system fault will be
displayed on the Video Display Electronic Terminal (VDET).
8. The low nitrogen light will flash if the nitrogen level in the system falls below a preset level of 2000
psi (13,790 kPa). From initial indication, the reserve capacity may allow continued operation until
corrective maintenance is performed.
(FLM 91S) 5-11
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Wheel Drive, Wheel Drive Brake Assembly, Wheel Drive Shaft, Wheel Rim and Tire:
Figure 7 Figure 8
1. The wheel drive shafts (Figure 7, Item 2) link the differentials to the wheel drives (Figure 7, Item
1), which are the last stage of gearing for the driveline system. Each wheel drive contains a brake
assembly (Figure 7, Item 3) and a planetary gear drive (Figure 7, Item 5), which is supported by
the wheel hub (Figure 7, Item 4). The planetary gear drive has a gear ratio reduction of 4.941:1 to
decrease the speed of the wheel rim (Figure 8, Item 3) and tire (Figure 8, Item 1). Each wheel
drive is oil-bath lubricated with gear oil and incorporates an oil sight glass (Figure 8, Item 6),
which allows the gear oil level to be checked easily. Each wheel drive is vented to an individual
de-aerator tank the vehicle. The de-aerator tanks are part of the driveline system. To allow for
Central Tire Inflation System (CTIS) capabilities, each wheel drive provides a passage for
compressed air to reach the CTIS wheel valve (Figure 8, Item 4) on each wheel rim.
2. Each wheel rim and tire consists of a two-piece wheel rim (Figure 8, Item 3), tire (Figure 8, Item
1), solid rubber run-flat assembly (Figure 8, Item 2) and wheel valve (Figure 8, Item 4). The tire
provides suitable traction on all types of surfaces. The tire's butyl lining allows for patch repair.
The wheel rim has a two-piece configuration that must be separated for tire removal. The step
(Figure 8, Item 5) assists in mounting and dismounting the vehicle. All wheels incorporate a CTIS
guard. The wheel incorporates an inflation valve (Figure 8, Item 7), which allows for manual tire
inflation if the CTIS becomes inoperative. The wheel valve allows compressed air to enter or
escape from the tire when operating the CTIS, but acts as a check valve to prevent air from
escaping from the tire if a CTIS failure occurs.
3. The four differentials provide torsional force through the wheel drive shafts to the eight wheel
drive planetary gear drives (Figure 7, Item 5). Each planetary gear drive reduces the output
speed of the wheel drive shaft which, in turn, increases the output torque at the wheel rim (Figure
8, Item 3) and tire (Figure 8, Item 1). The tire air pressure is maintained and controlled by the
CTIS. The tires can also be manually inflated or deflated through the inflation valve. The solid
rubber run-flat inside the tire allows the vehicle to continue operation if a tire becomes flat.
(FLM 91S) 5-12
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2. Learning Step / Activity 2. Control Arm Assembly Replacement
Method of Instruction: Practical Exercise / Demonstration
Instructor to Student Ratio: 1:4
Time of Instruction: 3 hrs
Media: Small Group Instruction (SGI)
Student Note: Ensure to refer to, TM 9-2355-450-13&P (IETM) to perform the task:
Student Note: Ensure all equipment Pre Conditions have been met before beginning task.
Student Note: Ensure all equipment Follow On’s have been met following completion of task.
Student Note: Ensure to read and comply with all Warnings, Cautions, and Notes while performing the
following task:
Tools and Special Tools Required:
General Mechanic's Tool Kit: Automotive Face Shield
19 mm Hex Bit, 3/4 inch Drive Industrial Rubber Gloves
Socket, Driver Bit, 3/8 inch Drive, Hex, 10mm Single Web Sling
Socket Extension, 1/2 inch Drive, 36 inch Socket Wrench Adapter, 3/8 inch Drive to 1/2
Long inch Drive
Torque Multiplier, 1200 lb-ft, 3 pieces Torque Wrench, 1/2 inch Drive, 30-250 lb-ft
Transmission Lift
1. Equipment Preconditions:
a. Wheels Chocked
b. Vehicle Raised Off Ground
c. Wheel and Tire Assembly Removed
2. Control Arm Assembly Replacement:
1. Select Variant
2. Select MAINTENANCE Procedures
3. Select Maintainer – Maintenance Procedures
4. Select Wheels and Tracks
5. Select SUSPENSION ASSEMBLY
6. Select CONTROL ARM ASSEMBLY REPLACEMENT
7. Complete Task
8. Proceed to FOLLOW ON’S TASKS
3. Follow On’s Conditions:
a. Install Wheel tire Assembly
b. Lower Vehicle
c. Perform Steering System Alignment
d. Remove Wheel Chocks
(FLM 91S) 5-13
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3. Learning Step / Activity 3. Remove / Install Right Front Hydropneumatic Strut
Method of Instruction: Practical Exercise / Demonstration
Instructor to Student Ratio: 1:4
Time of Instruction: 2 hrs
Media: Small Group Instruction (SGI)
Student Note: Ensure to refer to, TM 9-2355-450-13&P (IETM) to perform the task:
Student Note: Ensure all equipment Pre Conditions have been met before beginning task.
Student Note: Ensure all equipment Follow On’s have been met following completion of task.
Student Note: Ensure to read and comply with all Warnings, Cautions, and Notes while performing the
following task:
Tools and Special Tools Required:
General Mechanic's Tool Kit: Automotive Crowfoot Attachment Set, 3/8 inch Drive
Adapter, 3/4 inch Drive to 1/2 inch Drive Face Shield
Cap and Plug Set Industrial Rubber Gloves
Centering Bolt Socket, Chrome, 1/2 inch Drive, 27 mm
Socket Wrench Ratchet Handle Torque Wrench, 3/4 inch Drive, 90-600 lb-ft
Socket Wrench Ratchet Head, 3/4 inch Drive Torque Wrench, 1/2 inch Drive, 30-250 lb-ft
Suitable Lifting Device Capable of Lifting 717 Torque Wrench, 3/8 inch Drive, 10-100 lb-ft
lb (325 kg
Ultrasonic Leak Detector Wooden Blocks
1. Equipment Preconditions:
a. Wheels Chocked
b. Left Floor Plate (Third from Front) Removed
c. Vehicle Raised Off Ground
d. Wheel and Tire Assembly Removed
e. Inlet Grille Assembly Removed
f. Steering Linkage Tie Rod Removed
g. Front Axle Drive Shaft Assembly Removed
h. Control Arm Removed
2. Right Front Hydropneumatic Strut Replacement:
1. Select Variant
2. Select MAINTENANCE Procedures
3. Select Maintainer – Maintenance Procedures
4. Select Wheels and Tracks
5. Select SUSPENSION ASSEMBLY
6. Select RIGHT FRONT HYDROPNEUMATIC STRUT REPLACEMENT
7. Complete Task
8. Proceed to FOLLOW ON’S TASKS
3. Follow On’s Conditions:
a. Install Inlet Grille Assembly
b. Install Left Floor Plate (3rd from the Front)
c. Remove Wheel Chocks
(FLM 91S) 5-14
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4. Learning Step / Activity 4. Remove / Install Rear Hydropneumatic Strut
Method of Instruction: Practical Exercise / Demonstration
Instructor to Student Ratio: 1:4
Time of Instruction: 2 hrs
Media: Small Group Instruction (SGI)
Student Note: Ensure to refer to, TM 9-2355-450-13&P (IETM) to perform the task:
Student Note: Ensure all equipment Pre Conditions have been met before beginning task.
Student Note: Ensure all equipment Follow On’s have been met following completion of task.
Student Note: Ensure to read and comply with all Warnings, Cautions, and Notes while performing the
following task:
Tools and Special Tools Required:
General Mechanic's Tool Kit: Automotive Crowfoot Attachment Set, 3/8 inch Drive
Adapter, 3/4 inch Drive to 1/2 inch Drive Face Shield
Cap and Plug Set Endless Sling
Face Shield Industrial Rubber Gloves
Mechanical Puller Mechanical Puller Adapter
Socket Wrench Ratchet Head, 3/4 inch Drive Torque Wrench, 1/2 inch Drive, 30-250 lb-ft
Transmission and Differential Lift Torque Wrench, 3/8 inch Drive, 30-200 lb-ft
Ultrasonic Leak Detector
1. Equipment Preconditions:
a. Wheels Chocked
b. Jack Stands Installed
c. Hydropneumatic Strut Guard Removed
d. Wheel and Tire Assembly Removed
2. Rear Hydropneumatic Strut Replacement
1. Select Variant
2. Select MAINTENANCE Procedures
3. Select Maintainer – Maintenance Procedures
4. Select Wheels and Tracks
5. Select SUSPENSION ASSEMBLY
6. Select REAR HYDROPNEUMATIC STRUT REPLACEMENT
7. Complete Task
8. Proceed to FOLLOW ON’S TASKS
3. Follow On’s Conditions:
a. Install Hydropneumatic Strut Guard
b. Remove Jack Stands
c. Remove Wheel Chocks
(FLM 91S) 5-15
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5. Learning Step / Activity 5. Height Management System (HMS) Manifold Replacement
Method of Instruction: Practical Exercise / Demonstration
Instructor to Student Ratio: 1:4
Time of Instruction: 2 hrs
Media: Small Group Instruction (SGI)
Student Note: Ensure to refer to, TM 9-2355-450-13&P (IETM) to perform the task:
Student Note: Ensure all equipment Pre Conditions have been met before beginning task.
Student Note: Ensure all equipment Follow On’s have been met following completion of task.
Student Note: Ensure to read and comply with all Warnings, Cautions, and Notes while performing the
following task:
Tools and Special Tools Required:
General Mechanic's Tool Kit: Automotive Face Shield
Cap and Plug Set Industrial Rubber Gloves
Lanyard Torque Wrench, 3/8 inch Drive, 30-200 lb-in.
Ultrasonic Leak Detector
1. Equipment Preconditions:
a. Wheels Chocked
b. Battery Ground Disconnected
c. Bulkhead Cover Removed
d. Height Management System Manifold Drained
e. Transfer Case Floor Plate Removed
f. Height Management System Manifold Front Mounting Bracket and Wiring Harness Bracket
Removed
g. Height Management System Manifold Strap Removed
2. Rear Hydropneumatic Strut Replacement
1. Select Variant
2. Select MAINTENANCE Procedures
3. Select Maintainer – Maintenance Procedures
4. Select Wheels and Tracks
5. Select SUSPENSION ASSEMBLY
6. Select HEIGHT MANAGEMENT SYSTEM MANIFOLD REPLACEMENT
7. Complete Task
8. Proceed to FOLLOW ON’S TASKS
3. Follow On’s Conditions:
a. Install Hydropneumatic Strut Guards
b. Install Left Floor Plate (Fourth from Front)
c. Remove Wheel Chocks
(FLM 91S) 5-16
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6. Learning Step / Activity 6. Height Management System (HMS) Charging
Method of Instruction: Practical Exercise / Demonstration
Instructor to Student Ratio: 1:4
Time of Instruction: 2 hrs
Media: Small Group Instruction (SGI)
Student Note: Ensure to refer to, TM 9-2355-450-13&P (IETM) to perform the task:
Student Note: Ensure all equipment Pre Conditions have been met before beginning task.
Student Note: Ensure all equipment Follow On’s have been met following completion of task.
Student Note: Ensure to read and comply with all Warnings, Cautions, and Notes while performing the
following task:
Tools and Special Tools Required:
General Mechanic's Tool Kit: Automotive Nitrogen Charging Kit
Bushing Reducer Nitrogen Tank
Hose Assembly Straight Adapter
Infrared Thermometer
1. Equipment Preconditions:
a. Wheels Chocked
b. Battery Ground Disconnected
c. Bulkhead Cover Removed
d. Height Management System Manifold Drained
e. Transfer Case Floor Plate Removed
f. Height Management System Manifold Front Mounting Bracket and Wiring Harness Bracket
Removed
g. Height Management System Manifold Strap Removed
2. Rear Hydropneumatic Strut Replacement
1. Select Variant
2. Select MAINTENANCE Procedures
3. Select Maintainer – Maintenance Procedures
4. Select Wheels and Tracks
5. Select SUSPENSION ASSEMBLY
6. Select HEIGHT MANAGEMENT SYSTEM CHARGING
7. Complete Task
8. Proceed to FOLLOW ON’S TASKS
3. Follow On’s Conditions:
a. Install Left Floor Plate (Fourth from Front)
b. Remove Wheel Chocks
(FLM 91S) 5-17
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SECTION IV. SUMMARY
Method of Instruction: Conference /Discussion
Instructor to Student Ratio is: 1:4
Time of Instruction: 5 mins
Media: Small Group Instruction (SGI)
Review /
Summarize The information that you have been provided during this lesson will greatly
Lesson benefit you in performing your assigned duties as Stryker DVHA1 Maintainer.
During this lesson you were taught about maintaining the Suspension
Assembly on the Stryker DVHA1. Failure to maintain this equipment safely
could cause serious injury to personnel and/or damage to equipment, and
contribute to failure of the mission.
(FLM 91S) 5-18
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