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
FlK4EUERSHAFB.
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 9-2320-387-24-1
AIR FORCE TO 36A12-1A-3052-1
TECHNICAL MANUAL HEADQUARTERS
NO. 9-2320-387-24-1 DEPARTMENTS OF THE ARMY AND THE AIR FORCE
WASHINGTON, D.C., 31 December 1997
TECHNICAL ORDER
NO. 36A12-1A-3052-1
TECHNICAL MANUAL
VOLUME 1 OF 2
UNIT, DIRECT SUPPORT, AND
GENERAL 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)
Thi s manual i s publ i shed i n two parts. TM 9-2320-387-24-1 contai ns chapters 1 through 9, and
TM 9-2320-387-24-2 contai ns chapters 10 through 33 and appendi ces A through H.
Thi s manual contai ns a tabl e of contents and al phabeti cal i ndex for both vol umes 1 and 2.
Change 1 i
Approved for public release; distribution is unlimited.
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can hel p i mprove thi s publ i cati on. I f you fi nd any mi stakes or i f you know of a way to i mprove the
procedures, pl ease l et us know. Submi t your DA Form 2028 (Recommended Changes to Equi pment
Techni cal Publ i cati ons), through the I nternet, on the Army El ectroni c Product Support (AEPS) websi te.
The I nternet address i s http://aeps.ri a.army.mi l . I f you need a password, scrol l down and cl i ck on
ACCESS REQUEST FORM. The DA Form 2028 i s l ocated i n the ONLI NE FORMS PROCESSI NG
secti on of the AEPS. Fi l l out the form and cl i ck on SUBMI T. Usi ng thi s form on the AEPS wi l l enabl e us
to respond qui cker to your comments and better manage the DA Form 2028 program. You may al so mai l ,
fax or emai l your l etter or DA Form 2028 di rect to: AMSTA-LC-CI Tech Pubs, TACOM-RI , 1 Rock I sl and
Arsenal , Rock I sl and, I L 61299-7630. The emai l address i s TACOM-TECH-PUBS@ri a.army.mi l . The fax
number i s DSN 793-0726 or Commerci al (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
Secti on I . Engi ne/Crew Compartment Heater Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . 12-1
I I . Communi cati ons Ki ts Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-25
I I I . Wi nch Ki t Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-49
SPECI AL PURPOSE KI TS (UNI T) MAI NTENANCE
CHAPTER 13 . . . . . . . . . . . . . . . . . . . . 13-1
Secti on I . General I nstructi ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
I I . Preparati on for Storage and Shi pment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
PREPARATI ON FOR STORAGE OR SHI PMENT
CHAPTER 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Secti on I . Mechani cal Troubl eshooti ng. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
I I . Ai r Condi ti oni ng Troubl eshooti ng. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
TROUBLESHOOTI NG (DS)/(GS)
CHAPTER 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Secti on I . General Engi ne Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
I I . Engi ne Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-47
ENGI NE (DS) MAI NTENANCE
CHAPTER 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1 FUEL SYSTEM (DS) MAI NTENANCE
CHAPTER 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1 COOLI NG SYSTEM (DS) MAI NTENANCE
Page
TM 9-2320-387-24-1
iv Change 1
CHAPTER 11 . . . . . . . . . . . . . . . . . . . . . . . 11-1
Secti on I . Weapon Carri er Body Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
I I . Shel ter Carri er Body Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-139
I I I . Ai r Condi ti oni ng Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-151
I V. Rear Cargo Door Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-165
SPECI AL PURPOSE BODI ES (UNI T) MAI NTENANCE
VOLUME 2 OF 2
CHAPTER 10 . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Secti on I . Body Mai ntenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
I I . Body Accessori es Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100
BODY AND ACCESSORI ES (UNI T) MAI NTENANCE
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
29-l
30-l
32-1
33-1
34-1
A-l
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 1
INTRODUCTION
Section I. GENERAL INFORMATION
a. Thi s techni cal manual contai ns i nstr ucti ons for uni t, di r ect, and gener al suppor t mai ntenance of
the 4x4, M1113 and M1114 vehi cl es.
b. Model s i ncl uded ar e:
(1) M1113, S250 Shel ter Car r i er
(2) M1114, Up-Ar mor ed
Depar tment of the Ar my for ms and pr ocedur es used for equi pment mai ntenance wi l l be those pr escr i bed
by DA Pam 738-750, The Ar my Mai ntenance Management System (TAMMS).
Refer to TM 750-244-6, Pr ocedur es for Destr ucti on of Ar my Tank-automoti ve Equi pment to Pr event
Enemy Use.
Refer to TM 740-90-1, Admi ni str ati ve Stor age of Equi pment and TM 746-10, Mar ki ng, Packagi ng, and
Shi pment of Suppl i es and Equi pment: Gener al Packagi ng I nstr ucti ons for Fi el d Use.
I f your vehi cl e needs i mprovement, l et us know. Send us an EI R. You, the user, are the onl y one who can tel l
us what you dont l i ke about your equi pment. Let us know why you dont l i ke the desi gn or performance. The
preferred method for submi tti ng QDRs i s through the Army El ectroni c Product Support (AEPS) websi te
under the El ectroni c Defi ci ency Reporti ng System (EDRS). The web address i s: https://aeps.ri a.army.mi l .
Thi s i s a secured si te requi ri ng a password whi ch can be appl i ed for on the front page of the websi te. I f the
above method i s not avai l abl e to you, put i t on an SF 368, Product Qual i ty Defi ci ency Report (PQDR), and
mai l i t to us at: U.S. Army Tank-automoti ve and Armaments Command, ATTN: AMSTA-TR-E/PQDR MS
267, 6501 E. 11 Mi l e Road, Warren, MI 48397-5000. Wel l send you a repl y.
The quar ter l y Equi pment I mpr ovement Repor t and Mai ntenance Di gest, TB 43-0001-62 ser i es,
contai ns val uabl e fi el d i nfor mati on on the equi pment cover ed i n thi s manual . The i nfor mati on i n the
TB 43-0001-62 ser i es i s compi l ed fr om some of the Equi pment I mpr ovement Repor ts that you pr epar ed
on the vehi cl es cover ed i n thi s manual . Many of these ar ti cl es r esul ted fr om comments, suggesti ons,
and i mpr ovement r ecommendati ons that you submi tted to the EI R pr ogr am. The TB 43-0001-62 ser i es
contai ns i nfor mati on on equi pment i mpr ovements, mi nor al ter ati ons, pr oposed Modi fi cati on Wor k Or der s
(MWOs), war r anti es (i f appl i cabl e), acti ons taken on some of your DA For m 2028s (Recommended
Changes to Publ i cati ons), and advance i nfor mati on on pr oposed changes that may affect thi s manual .
The i nfor mati on wi l l hel p you i n doi ng your job better and wi l l hel p i n keepi ng you advi sed of the l atest
changes to thi s manual . Al so r efer to DA Pam 25-30, Consol i dated I ndex of Ar my Publ i cati ons and Bl ank
For ms and appendi x A, Refer ences, of thi s 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 Kontdl
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.
Ml 114
1-3
TM9- 2320- 387- 24- l
l-1 0. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES (Contd)
S250SHELl YERCARRI EkM1113
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.
Ml 113
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