Volume No. 1 ARMY TM 9-2320-387-24- 1

AIR FORCE TO 36A12- 1 A-3052- 1

TECHNICAL MANUAL

UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE

FOR

TRUCK, UTIUM: S250 SHELTER CARRIER, 4X4, Ml 113

(2320-01-412-0143) (EIC: 868)

TRUCK, UTlun: UP-ARMORED CARRIER, 4X4, Ml 114

(2320-01-413-3739) (EIC: B6C)

HOW TO USE nil.5 MANUAL

SERVICE AND TROUBlESHOOllNG (UNItI INSlRUCDONS

ENGINE !mlEMS [UNill MAlNlENAME

TRAN!iMwON ANDTRANMIRCASE 5-l wm MAtNlENANQ

FlK4’EUERSHAFB. AXLES, AND SU.%MSlON wNnlM4lNlENANcE

RRAuESYSlEM @NlqMAlNlEw

FRAME (UNbT)MMENANCE

Appmved for public release; dishibuh is unlimited.

HEADQUARTERS, DEPARTMENTS OF THE ARMY AN-b THE AIR FORCE

DECEMBER 1997

ARMY TM 9-2320-387-24-1AIR FORCE TO 36A12-1A-3052-1

TECHNICAL MANUAL HEADQUARTERSNO. 9-2320-387-24-1 DEPARTMENTS OF THE ARMY AND THE AIR FORCE

WASHINGTON, D.C., 31 December 1997TECHNICAL ORDERNO. 36A12-1A-3052-1

TECHNICAL MANUALVOLUME 1 OF 2

UNIT, DIRECT SUPPORT, ANDGENERAL SUPPORT MAINTENANCE

FOR

TRUCK, UTILITY: S250 SHELTER CARRIER, 4X4, M1113

(2320-01-412-0143) (EIC: B6B)

TRUCK, UTILITY: UP-ARMORED CARRIER,4X4, M1114

(2320-01-413-3739) (EIC: B6C)

This manual is published in two parts. TM 9-2320-387-24-1 contains chapters 1 through 9, and TM 9-2320-387-24-2 contains chapters 10 through 33 and appendices A through H.

This manual contains a table of contents and alphabetical index for both volumes 1 and 2.

Change 1 i

Approved for public release; distribution is unlimited.

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTSYou can help improve this publication. If you find any mistakes or if you know of a way to improve theprocedures, please let us know. Submit your DA Form 2028 (Recommended Changes to EquipmentTechnical Publications), through the Internet, on the Army Electronic Product Support (AEPS) website.The Internet address is http://aeps.ria.army.mil. If you need a password, scroll down and click on“ACCESS REQUEST FORM.” The DA Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable usto respond quicker to your comments and better manage the DA Form 2028 program. You may also mail,fax or email your letter or DA Form 2028 direct to: AMSTA-LC-CI Tech Pubs, TACOM-RI, 1 Rock IslandArsenal, Rock Island, IL 61299-7630. The email address is TACOM-TECH-PUBS@ria.army.mil. The faxnumber is DSN 793-0726 or Commercial (309) 782-0726.

TM9-2320-387-24-1

CHAPTER 1

Section I.

II.

III.

CHAPTER 2

Section I.

II.

III.

Iv.

v.

CHAPTER 3

Section I.

II.

III.

Iv.

v.

CHAPTER 4

Section I.

II.

III.

n?

V.

VI.

VOLUME 1 OF 2

1 HOWTOUSETHISMANUAL 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 INTRODUCTION I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information ...........................................

Equipment Description and Data ..................................

Principles of Operation ..........................................

SERVICE AND TROUBLESHOOTING (UNIT) INSTRUCTIONS .........

Repair Parts, Special Tools, Test, Measurement, Diagnostic Equipment (TMDE), and Support Equipment .........................

Service Upon Receipt ...........................................

Preventive Maintenance Checks and Services (PMCS) ...................

General Maintenance Instructions .................................

Electrical/Mechanical Systems Troubleshooting ........................

ENGINE SYSTEMS (UNIT) MAINTENANCE .......................

Lubrication System Maintenance ..................................

Fuel System Maintenance ........................................

Accelerator System Maintenance ..................................

Exhaust System Maintenance .....................................

Cooling System Maintenance .....................................

ELECTRICAL SYSTEM (UNIT) MAINTENANCE . . . . . . . . . . . . . . . . . . . .

Generating and Protective Control Box System Maintenance ..............

Starter and Starting Control System Maintenance ......................

Instruments, Sending Units, Switches, and Horn Maintenance .............

Transfer Case and Transmission Electrical Maintenance .................

Lighting System Maintenance ....................................

Battery System Maintenance .....................................

Page

vii

1-l

l-1

l-2

l-23

2-1

2-l

2-l

2-2

2-30

2-33

3-l

3-l

3-21

3-81

3-90

3-109

4-l

4-1

4-20

4-29

4-65

4-81

4-107

ii

TM9-2320-387-24-l

Page

CHAPTER 5

Section I.

II.

TRANSMISSION AND TRANSFER CASE (UNIT) MAINTENANCE . . . . . . .

Transmission hlaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer Case Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-l

5-l

5-31

CHAPTER 6

Section I.

II.

III.

PROPELLER SHAFTS, AXLES, AND SUSPENSION (UNIT) MAINTENANCE

Propeller Shafts hlaintenance .....................................

Front and Rear Axles hlaintenance. .................................

Suspension Maintenance .........................................

6-l

6-l

6-12

6-48

CHAPTER 7

I.

II.

1 BRAKE SYSTEM (UNIT) MAINTENANCq. . . . . . . . . . . . . . . . . . . . . . . . . I I

Service Brake System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Dual Service/Parking Brake System Maintenance . . . . . . . . . . . . . . . . . . .

7-l

7-l

7-37

CHAPTER 8

Section I.

II.

WHEELS AND STEERING (UNIT) MAINTENANCE ..................

Wheel and Runflat System Maintenance .............................

Steering Components hlaintenance .................................

8-l

8-l

8-35

CHAPTER 9 1 FRAME (UNIT) hlAINTENANCE I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-l

. . . III

CHAPTER 12 . . . . . . . . . . . . . . . . . . . . . . . 12-1

Section I. Engine/Crew Compartment Heater Maintenance . . . . . . . . . . . . . . . . . . . . . . . 12-1

II. Communications Kits Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-25

III. Winch Kit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-49

SPECIAL PURPOSE KITS (UNIT) MAINTENANCE

CHAPTER 13 . . . . . . . . . . . . . . . . . . . . 13-1

Section I. General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

II. Preparation for Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2

PREPARATION FOR STORAGE OR SHIPMENT

CHAPTER 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

Section I. Mechanical Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

II. Air Conditioning Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15

TROUBLESHOOTING (DS)/(GS)

CHAPTER 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

Section I. General Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

II. Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-47

ENGINE (DS) MAINTENANCE

CHAPTER 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1FUEL SYSTEM (DS) MAINTENANCE

CHAPTER 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1COOLING SYSTEM (DS) MAINTENANCE

Page

TM 9-2320-387-24-1

iv Change 1

CHAPTER 11 . . . . . . . . . . . . . . . . . . . . . . . 11-1

Section I. Weapon Carrier Body Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

II. Shelter Carrier Body Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-139

III. Air Conditioning Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-151

IV. Rear Cargo Door Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-165

SPECIAL PURPOSE BODIES (UNIT) MAINTENANCE

VOLUME 2 OF 2

CHAPTER 10 . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Section I. Body Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1II. Body Accessories Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100

BODY AND ACCESSORIES (UNIT) MAINTENANCE

TM 9-2320-387-24-l

CHAPTER 18 ELECTRICAL SYSTEM (DS) MAINTENANCE . . . . . . . . . . . . .

CHAPTER 19 1 TRANSRIISSION (DS) hlAINTENANCE I. . . . . . . . . . . . . . . . . .

CHAPTER 20 1 TRANSFER CASE CDS) RfAINTENANCE I. . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 21

CHAPTER 22

CHAPTER 23

CHAPTER 24

CHAPTER 25

Section I.

II.

CHAPTER 26

CHAPTER 27

CHAPTER 28 TRANSMISSION (GS) REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 PROPELLER SHAFTS, AXLES, AND SUSPENSION CDS) hfAINTENANCE 21-l I

1 I

1 SERVICE BRAKE SYSTEhl (DS) RIAINTENANCE I. . . . . . . . . . . . . . . . . . . 22-l

1 STEERING SYSTEhl CDS) hlAINTENANCE I. . . . . . . . . . . . . . . . . . . . . . . . 23-l

FRAhIE (DS) MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-l

SPECIAL PURPOSE BODIES CDS) hI.AINTENANCE . .................

Armament Carrier Maintenance ...................................

Air Conditioning Maintenance .....................................

SPECIAL PURPOSE KITS (DS) hfAINTENANCE I. . . . . . . . . . . . . . . . . . . . 26-1

ELECTRICAL SYSTEhf (GS) REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-l

Page

18-l

19-l

20-l

25-l

25-l

25-37

28-l

V

TM 9-2320-387-24-l

CHAPTER 29

CHAPTER 30

CHAPTER 31

CHAPTER 32

CHAPTER 33

CHAPTER 34

APPENDIX A

APPENDIX B

APPENDIX C

APPENDIX D

APPENDIX E

APPENDIX F

APPENDIX G

APPENDIX H

INDEX

1 TRANSFER CASE (GS) REPAIR 1 . . . . . . . . . . .

1 DIFFERENTIAL (GS) REPAIR I. . . . . . . . . . . .

. ,...................

. . . . . . . . . . . . . . . . . . . .

STEERING SYSTEM (GS) REPAIR . . . . . . . . . . . . . . .

1 FRAME (GS) REPAIR I. . . . . . . . . . . . . . . . . . . . . . . . . .

1 BODY(GS) REPAIR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 SUSPENSION (GS) hZAINTENANCE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REFERENCES ................................................

MAINTENANCE ALLOCATION CHART ..............................

EXPENDABLE/DURABLE SUPPLIES AND hIATERIALS LIST ............

ILLUSTRATED LIST OF hI.ANUFACTURED ITEMS ....................

TORQUELIMITS ..............................................

BODY REPAIR MATERIALS. .....................................

MANDATORY REPIACEMEhT PARTS. .............................

WIRING DIAGRAMS AND SCHEMATICS. ...........................

Page

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30-l

32-1

33-1

34-1

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B-l

C-l

D-l

E-l

F-l

G-l

H-l

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDEX 1

vi

TM 9-2320-387-24-1

Change 1 1-1

CHAPTER 1INTRODUCTION

Section I. GENERAL INFORMATION

a. This technical manual contains instructions for unit, direct, and general support maintenance ofthe 4x4, M1113 and M1114 vehicles.

b. Models included are:(1) M1113, S250 Shelter Carrier(2) M1114, Up-Armored

Department of the Army forms and procedures used for equipment maintenance will be those prescribedby DA Pam 738-750, The Army Maintenance Management System (TAMMS).

Refer to TM 750-244-6, Procedures for Destruction of Army Tank-automotive Equipment to PreventEnemy Use.

Refer to TM 740-90-1, Administrative Storage of Equipment and TM 746-10, Marking, Packaging, andShipment of Supplies and Equipment: General Packaging Instructions for Field Use.

If your vehicle needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tellus what you don’t like about your equipment. Let us know why you don’t like the design or performance. Thepreferred method for submitting QDRs is through the Army Electronic Product Support (AEPS) websiteunder the Electronic Deficiency Reporting System (EDRS). The web address is: https://aeps.ria.army.mil.This is a secured site requiring a password which can be applied for on the front page of the website. If theabove method is not available to you, put it on an SF 368, Product Quality Deficiency Report (PQDR), andmail it to us at: U.S. Army Tank-automotive and Armaments Command, ATTN: AMSTA-TR-E/PQDR MS267, 6501 E. 11 Mile Road, Warren, MI 48397-5000. We’ll send you a reply.

The quarterly Equipment Improvement Report and Maintenance Digest, TB 43-0001-62 series, contains valuable field information on the equipment covered in this manual. The information in the TB 43-0001-62 series is compiled from some of the Equipment Improvement Reports that you prepared on the vehicles covered in this manual. Many of these articles resulted from comments, suggestions, and improvement recommendations that you submitted to the EIR program. The TB 43-0001-62 seriescontains information on equipment improvements, minor alterations, proposed Modification Work Orders(MWOs), warranties (if applicable), actions taken on some of your DA Form 2028s (RecommendedChanges to Publications), and advance information on proposed changes that may affect this manual. The information will help you in doing your job better and will help in keeping you advised of the latestchanges to this manual. Also refer to DA Pam 25-30, Consolidated Index of Army Publications and BlankForms and appendix A, References, of this manual.

1-6. EQUIPMENT IMPROVEMENT REPORT AND MAINTENANCE DIGEST (EIR MD)

1-5. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

1-4. PREPARATION FOR STORAGE AND SHIPMENT

1-3. DESTRUCTION OF ARMY EQUIPMENT TO PREVENT ENEMY USE

1-2. MAINTENANCE FORMS, RECORDS, AND REPORTS

1-1. SCOPE

TM 9-2320-387-24-l

1-7. METRIC SYSTEM

The equipment described herein contains metric components and requires metric common and special tools; therefore, metric units in addition to standard units will be used throughout this publication. In addition, a metric conversion table is located on the inside back cover of this publication.

l-8. MANDATORY REPLACEMENT PARTS

The maintenance instructions contained herein make reference to removing and discarding piece parts such as: gaskets, lockwashers, cotter pins, O-rings, seals, etc.; these items should be considered mandatory replacement items and replaced with new parts during assembly/installation.

l-9. BREAK-IN PROCEDURE

Upon receipt of vehicles, or after engine replacement, break-in procedures must be observed during the first 500 miles (804 kilometers) of operation. For break-in procedure, refer to TM 9-2320-387-10.

Section II. EQUIPMENT DESCRIPTION AND DATA

1-l 0. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

The 4x4, Ml113 and Ml114 vehicles are tactical vehicles designed for use over all types of roads, as well as cross-country terrain, in all weather conditions. The vehicles have four driving wheels powered by a V-8, liquid-cooled, turbocharged diesel engine. Four-wheel hydraulic service brakes and a mechanical parking brake are common to all models. Ml113 and Ml114 vehicles are equipped with a pintle hook for towing. Tiedown and lifting eyes are provided for air, rail, or sea shipment.

1-2

TM 9-2320-387-24-l

1 l-1 0. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES Kont’dl 1

UP-ARMORED CARRIER, W/SUPPLEMENTAL ARMOR: Ml 114

PURPOSE: This model is used to transport, mount, and operate the M2 and M60 machine guns and MKl9 automatic grenade launcher with armor protection for crew, weapons components, and ammunition. The Ml114 model may have a optional rear winch which can be used for recovery operations.

Ml114

1-3

TM9-2320-387-24-l

l-1 0. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES (Cont‘d)

S250SHELlYERCARRIEkM1113

PURPOSE: This model is used for securing and transporting the S250 electrical equipment shelter. The Ml113 model may have a optional front winch which can be used for recovery operations.

Ml113

l-4

TM 9-2320-387-24-l

l- 11. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

The exterior components described below are common to all vehicles covered in this manual. Special differences are found in TM 9-2320-387-10 or table l-l, Differences Between Models, in this manual.

0 A

0 B

0 C

0 D

0 E

0 F

0 G

0 H

0 I

0 J

0 K

0 L

AIR CLEANER - Filters air before it enters intake manifold.

ENGINE - Provides power for the vehicle.

TRANSMISSION - Transmits engine power to transfer case at varying speeds.

FUEL TANK - Stores fuel.

GEARED I-IUB - Transfers turning action of halfshafts to wheels for vehicle motion.

PINTLE HOOK - Permits towing of vehicles or equipment.

REAR PROPELLER SHAFT - Transmits power from the transfer case to the rear differential.

TRANSFER CASE - Provides full-time four-wheel drive with three drive ranges.

FRONT PROPELLER SHAFT - Transmits power from the transfer case to the front differential.

MASTER CYLINDER AND HYDRO-BOOSTER - Provides hydraulic pressure and power assist for vehicle stopping power.

DIFFERENTIAL - Transfers turning action of the propeller shaft to the geared hubs through the halfshafts.

WINCH - 9,000 lb electrically powered to provide recovery capability. Located in front of vehicle on Ml113 models (if equipped) and rear of vehicle on Ml114 models (if equipped).

m /

7i-m A

F _- - n n